&EPA
            United States
            Environmental Protection
            Agency
            Water and Waste Management
            Effluent Guidelines Division
            WH-552
            Washington, DC 20460
EPA 440/1-80/070a
April 1980
Development
Document for
Effluent Limitations
Guidelines and
Standards for the
                    Foundries
            (Metal Molding and Casting)

            Point Source Category

-------
                    DRAFT
             DEVELOPMENT DOCUMENT

                     FOR

   PROPOSED EFFLUENT LIMITATIONS GUIDELINES

                     AND

       NEW SOURCE  PERFORMANCE STANDARDS

                   FOR THE

METAL MOLDING AND  CASTING POINT SOURCE CATEGORY
               Douglas  M. Costle
                 Administrator

                Steven  Schatzow
        Deputy Assistant Administrator
       for Water Planning and Standards

              Robert  B. Schaffer
    Director,  Effluent  Guidelines Division

              Ernst P.  Hall, P.E.
       Chief,  Metals  &  Machinery Branch

               John G.  Williams
  Project Officer,  Metal Molding and Casting
                  April  1980
         Effluent Guidelines Division
     Office of Water and Waste Management
     U.S. Environmental  Protection Agency
            Washington,  D.C.  20460

-------
                              TABLE OF CONTENTS


                         METAL MOLDING AND CASTING


Section                            Title                          Page

I-             Conclusions                                         1

II-            Recommendations                                     3

III..           Introduction                                       5
                    Authority                                     5
                    Background                                     5
                    Approach to  Limitations and Standards         7
                    Anticipated  Industry Growth                  15
                    General Description  of Processes              15
IV..             Industry Categorization                           47
                     Introduction                                 47
                     Selected Subcategories                       47
                     Subcategorization Basis                      50
                     Production Normalizing Parameter             58

V.              Water Use and Waste Characterization              61
                     Introduction                                 61
                     Plant Data Collection                        62
                     Profile of Plant Data                        75
                     Specific Subcategory Water Use and Waste     77
                     Characteristics

VI.             Pollutant Parameters                             383
                     Introduction                                383
                     Environmental Impact of Toxic Pollutants    383

VII.            Control and Treatment Technology                 457
                     Introduction                                457
                     Individual Treatment Technologies           457
                     Dissolved Inorganics Removal                457
                     Solids Removal                              474
                     Recovery Techniques                         493
                     Oil  Removal                                502
                     Cyanide Destruction                         513
                     Phenol Destruction                          519


                                     iii

-------
Section                             Title                         Page

VIII.          Cost of Wastewater  Control and Treatment          555
                    Sampled  Plant  Costs                          555
                    Control  and  Treatment Technology             555
                    Components                                    555
                    Basis  of Cost  Estimates                      555
                    BPT and  BAT  Model  Costs                      55 ^

IX.            Effluent Reduction  Attainable Through the
               Application of the  Best Practicable Control
               Technology  Currently Available                    727
                    Introduction                                 727
                    Factors  Considered                           728
                    Approach to  BPT Development                  728
                    Identification of  BPT                        734

X-             Effluent Reduction  Attainable Through the
               Application of the  Best Available Technology
               Economically  Achievable                           757
                    Introduction                                 797
                    Identification of  BAT                        798

XI..            New Source  Performance  Standards                  835
                    Introduction                                 835

               Pretreatment  Standards  for Existing Sources       837
                    Introduction                                 837
                    Pretreatment Options                         837
                    Rationale Used to  Develop Pretreatment       838
                      Technologies
                    Factors  Considered
XIII.           Pretreatment  Standards for New Sources
                                                                 851
                     Introduction                                851
                     Identification of New Source Pretreatment   351
                      Standards
                     Rationale Used to Develop New Source        351
                      Pretreatment Standards

XIV,-            Acknowledgements                                  853

XV.             References                                       855

XVI.            Glossary                                         857
                                     IV

-------
NUMBER
                                    TABLES
                                                        PAGE
                               LIST OF TABLES
NUMBER
III-2

1II-3

III-4

III-5

V-1

V-2

V-3 thru
V-7

V-8 thru
V-10

V-11 thru
V-15

V-16

V-1 7 and
V-18

V-19

V-20


V-21


V-22
                    TABLES                              PAGE

Distribution of Plants ...........................        31

Percentage of Plants With a Process Wastewater. . .        32

Foundry Location by Re gion . ......................        33

Foundry Shipments in the U,. S,.  .... ................        34

Mold Cooling,. ...... ,....,. .........................        46

Penton Foundry Census Information. ......-..-..<...       113

Distribution of Additional 1000 Plant  Surveys....       114

General Summary Tables - Aluminum
Foundries. .... ............. ....... ...... ........... .       115

General Summary Tables - Copper
Foundries.. ................ ................... .....       119

General Summary Tables - Ferrous
Foundries,. ............... ............. ...........       122

General Summary Table - Magnesium Foundries ......       148

General Summary Tables - Zinc
Foundries .......... ,. ....... ,. .....................       149

List of Toxic Pollutants .........................       152

Conventional and Nonconventional  Pollutants
Analyzed. .... ...... ........... ..... . .............       159

Inorganic Toxic Pollutants Selected for
Verification Analysis. . , ..........................       160

Plant Assessment of the Known  or  Believed Presence
of Toxic Pollutants in Foundry Raw Process
Wastewater. ......... ......... , .......................       161

-------
NUMBER
                     TABLES
PAGE
V-23


V-24

V-25


V-26

V-27

V-28



V-29
30  thru
V-34

V-35  thru
V-37

V-38  thru
V-42

V-43  thru
V-44

V-45  and
V-46

VII-1

VII-2

VII-3
 VII-4
 VII-5
Engineering  Assessment of Toxic  Pollutants Likely
to be Present in Foundry Process Wastewater	

Types and Amounts of Binders Used in Foundries...-

Annual Weight of Metal Poured  in Plants With a
Process Wastewater. -,.,.<..-,-<.. - . - .........,..........

Total Process Wastewater Flow,.,.,.,..-.,.,...-.-	

Discharge Mode Profile	

Frequency Distribution of Toxic  Pollutants
Detected in  44 Foundry Raw Process Wastewater
Streams,-,..,.........,..,.,.,...- .,.,-,,..,.,.„,.	.................... .

Organic and  Inorganic Toxic Pollutants  in
Sampled Wastewaters.	

Raw and Treated Waste Loads, Aluminum
Foundries.	

Raw and Treated Waste Loads -  Copper
Foundries	,	

Raw and Treated Waste Loads, Ferrous
Foundries..	

Raw and Treated waste Loads -  Magnesium
Foundries	:...

Raw and Treated Waste Loads -  Zinc
Foundries..	

pH Control  Effects on Metals Removal	

Effectiveness of NaOH for Metals Removal—	

Effectiveness of Lime and NaOH for Metals
Removal,.,.,,.......,.,....... „,.........,.,.,...............	

Hydroxide  Precipitation - Sedimentation
Performance..	

Hydroxide  Precipitation - Additional Parameters..
165

166


167

168

169



170


175


314


326


346


376


379

460

461



462


463

464
                                      VI

-------
NUMBER                               TABLES
VII-6           Precipitation -  Sedimentation -  Filtration
                Performance,  Plant A............... *	
VII-7           Precipitation -  Sedimentation -  Filtration
                Performance,  Plant B,.......,.,...,.,.,..	
VII-8           Selected  Solubilities.......	,..„,.	
VII-9           Sampling  Data From Sulfide Precipitation -
                Sedimentation Systems	
VII-10          Sulfide Precipitation - Sedimentation Perfor-
                mance.. .,..<.......,.„	,	
VII-11          Summary of Treatment Effectiveness. ...*...........
VII-12          Peat Adsorbtion  Performance..,.,.., ..............,.......
VII-13          Performance of Sampled Sedimentation Systems..,.,
VII-14          Membrane  Filtration System Effluent	
VII-15          Ion Exchange Performance.	»	
VII-16          Skimming  Performance...	-
VII-17          Ultrafiltration  Performance.,,	
VII-18          Activated Carbon Performance  (mercury) .............
VII-19          Treatability Rating of Toxic Pollutants
                Utilizing Carbon Adsorption........................
VII-20          Classes of Organic Compounds Adsorbed on
                Carbon.. .....,...... • •....... -.-.. -........................ .......
VH-21          Concentration of Total Cyanide	
Viii-1          Procedure for Determining Industry Wide  Treat-
                ment Costs for Each Process,.................. .........
Viii-2  thru    Foundry Survey,  Model and Statistical
VIII-11        Data,.	....	.......		
VIII-12
thru
Treatment Equipment Requirements of Surveyed
                                                         PAGE

                                                          465

                                                          466
                                                          467

                                                          468

                                                          469
                                                          472
                                                          473
                                                          477
                                                          480
                                                          498
                                                          504
                                                          509
                                                          512

                                                          551

                                                          552
                                                          519

                                                          579

                                                          580
                                      VI1

-------
NUMBEK

VIII-28

VIII-29
thru
VIII-37

VIII-38
thru
VIII-H2

VIII-43
thru
VIII-74

VIII-75
thru
VIII-76

VIII-77
thru
VIII-81

VIII-82
thru
VIII-98

VIII-99
thru
VIII-103

VIII-104
thru
VIII-108

VIII-109
thru
VIII-111

VIII-112
thru
VIII-116

VIII-117
and
VIII-118
                    TABLES
Respondents	


BPT and BAT Model Cost  Data  -  Aluminum
Foundries.........................	


BPT and BAT Model Cost  Data  -  Copper and Copper
Alloy Foundries-	


BPT and BAT Model Cost  Data  -  Ferrous
Foundries.	


BPT and BAT Model Cost  Data  -  Magnesium
Foundries.	


BPT and BAT Model Cost  Data  -  Zinc
Foundries	,	,	


Projected Industry Wide Costs  of  Treatment
Technology Implementation,..,.,,..	



Treatment Costs  of Plants Visited	


Control and Treatment Technologies for
Aluminum Foundries	


Control and Treatment Technologies for
Copper Foundries,.....,...,....,..,..	


Control and Treatment Technologies for Ferrous
Foundries,	...		,	


Control and Treatment Technologies for
Magnesium Foundries.............................
PAGE

 590



 607



 616



 621



 653



 655



 660
 689
 702
 705
 719
                                    Vlll

-------
NUMBER
                                    TABLES
PAGE
VIII-119
thru            Control and Treatment Technologies for  Zinc
VIII-120        Foundries..,.,,,,,,,.,,...,,.,,,. _., ,,.,.	
IX-1 thru
IX-5            BPT Effluent Levels - Aluminum Foundries	
IX-6 thru
IX-8            BPT Effluent Levels - Copper Foundries	
IX-9 thru
IX-13           BPT Effluent Levels - Ferrous Foundries	
IX-1U  thru
IX-15           BPT Effluent Levels - Magnesium Foundries	
IX-16  and
IX-17           BPT Effluent Levels - Zinc Foundries.............
X-1 thru        BAT Alternatives - Effluent Levels -
X-8             Aluminum Foundries.	
X-9             BAT - Effluent Levels - Copper Foundries	
X-10 thru       BAT Alternatives - Effluent Levels -
X-12            Zinc Foundries,	,.	,.	
XVII-1         Metric Unit Conversion Table.	
 721

 763

 773

 779

 789

 793
 812
 828
 830
 861
                                      IX

-------
LIST OF FIGURES
NUMBER
III-1
III-2
III-3
III-4
III-5
III-6
III-7
III-8
III-9
111-10
111-11

V-1 thru
V-6
V-7 thru
V-10
V-11 thru
V-38
V-39
,
V-40

VII-1

VII-2

FIGURES
Cast Metals Production at 5- Year Intervals......




Copper Foundry Process Flow Diagram 	
Ferrous Foundry Process Flow Diagram. 	 ........
Magnesium Foundry Process Flow Diagram 	
Zinc Die Casting Process Flow Diagram.. 	
Iron Foundry Cupola Process Flow Diagram. .......
Iron Foundry Cupola Wet Top Process Flow
Diagram,. ...... 	 	 	 	
Wastewater Treatment System Water Flow Diagrams

Wastewater Treatment System Water Flow Diagrams -
Copper Foundries 	 	 	
Wastewater Treatment System Water Flow Diagams -
Ferrous Foundries 	 	 ,....
Wastewater Treatment System Water Flow Diagram -
Magnesium Foundry. 	 	
Wastewater Treatment System Water Flow Diagrams -
Zinc Foundries,. „...,...,.<.„....., 	 ,...., 	
Comparative solubilities of Metal Hydroxides and
Sulfides as a Function of pR. ......... 	 . 	 	 	
Effluent Zinc Concentrations Versus Minimum
Ef f luen t pH ..... 	 .. 	 ,. 	 	
PAGE
35
36
37
38
39
40
41
42
43
44

45
010
313

324

332

375

377

524

525

-------
NUMBER                               FIGURES                              PAGE

VII-3           Hydroxide Precipitation - Sedimentation
                Effectiveness, Cadmium,.,. ,.,. «. , ,... ....„..,,...,.,. „ -..	        526

VII-4           Hydroxide Precipitation * Sedimentation
                Effectiveness, Chromium..,,.,,.	,.,„,.<.,...	        527

VII-5           Hydroxide Precipitation - Sedimentation
                Ef fectiveness, Copper,.. - , ..<.,.,.,.......,.....,.-.. <•	        528

VII-6           Hydroxide Precipitation - Sedimentation
                Effectiveness, Iron,.,.,.,.,.,,.,.,.,,..,.,...,--«.,.,.,	        529

VII-7           Hydroxide Precipitation - Sedimentation
                Ef fee tiveness, Lead,.,.. , ,,.,.<...,...,.,.,.,.....,.,.,.....,	        530

VII-8           Hydroxide Precipitation - Sedimentation
                Effectiveness, Manganese,.,,,.,., „,.,.,.,.,.,.,,.	        531

VII-9           Hydroxide Precipitation - Sedimentation
                Effectiveness, Nickel.............-.,.......-.	        532

VII-10          Hydroxide Precipitation - Sedimentation
                Ef fee tiveness, Phosphorus,,.	,....        533

VII-11          Hydroxide Precipitation - Sedimentation
                Effectiveness, Zinc................ ^ ...............        534

VII-12          Lead Precipitate  Solubility	<.,..,..,.,.,.,.,	        535

VII-13          Representative Types of Sedimentation	        536

VII-14          Granular Bed Filtration Example	        537

VII-15          Pressure Filtration,.,.	        538

VII-16          Vacuum Filtration.......,.,..,.,........,.,..,	        539

VIl-17          Centrifugation....„„,.......,.......,.	        540

VII-18          Gravity Thickening.,.........,...,.........,..,.,.,,,	        541

VII-19          Sludge Drying Bed.	,.	        542

VII-20          Types  of Evaporation  Equipment	,. .        543

    _21          Ion  Exchange with Regeneration	        544


                                      xi

-------
NUMBER

VII-22

VII-23

VII-24

VII-25

VII-26

VII-27


VII-28

VII-29

IX-1 thru
IX-5

IX-6 thru
IX-8

IX-9 thru
IX-13

IX-14 and
IX-15

IX-16 and
IX-17

X-1 thru
X-8

X-9

X-10 thru
X-12
                     FIGURES

Simplified Reverse Osmosis Schematic...	

Reverse Osmosis Membrane Configuration	

Dissolved Air Flotation....	

Simplified Ultra filtration Flow "Schematic.....

Activated Carbon Adsorbtion Column	

Treatment of Cyanide Wastes by Alkaline
Chlor ination.	

Typical Ozone Plant  for Waste Treatment,.........

Ozonation	


BPT Models, Aluminum Foundries...—	


BPT Models, Copper and  Copper Alloy Foundries.


BPT Models, Ferrous  Foundries.	


BPT Models, Magnesium Foundries		.....


BPT Models, Zinc Foundries.	.............	...


BAT Models, Aluminum Foundries,.	

BAT Model, Copper and Copper Alloy Foundry....


BAT Models, Zinc Foundries.	
gAGE

 545

 546

 547

 548

 549


 550

 553

 554


 762


 772


 778


788


792


811

827


829
                                     XI1

-------
                                 SECTION I

                                CONCLUSIONS

This is a draft development document and is being circulated for review  of
its  technical  merit.   This  draft document is subject to corrections and
revisions as appropriate prior to  its  issuance  as  a  final  development
document at the time of proposed rulemaking.

Treatment  options  for  Best  Available Technology Economically Achievable
(BAT) for the control of toxic  pollutants  have  been  developed  and  are
presented herein together with effluent levels associated with each option.
However,  no  regulatory numbers have been attached to the options.  Before
proposal of effluent limitations and  standards,  the  Agency  will  choose
among  and  between  these options and will set regulatory numbers based on
the final treatment technologies selected.

The metal molding and casting  (foundry) point source category  consists  of
approximately 3600 plants.  Analysis of the available data does not support
the  development  of  a  single  set  of effluent limitations and standards
applicable  to  plants  engaged  in  metal  molding  and  casting.   It  is
concluded,  however,  that  subcategorization based on metal type cast with
limitations and standards for  each subcategory is appropriate.

The most effective basis of subcategorizing the category is by the type  of
metal  cast.  Alloys of these  metal types are also considered as applicable
to the subcategory.  These subcategories are:

                               Aluminum Casting
                               Copper Casting
                               Iron and Steel Casting
                               Magnesium Casting
                               Zinc Casting
                               Lead Casting

The process  wastewater  at  plants  falling  within  the  scope  of  these
subcategories  contains toxic  pollutants, conventional pollutants and other
pollutants.  Many plants are presently  demonstrating  the  feasibility  of
recycling  100 percent of the  process wastewater generated by manufacturing
processes associated with these subcategories.

In addition, many plants have  presently  installed  the  best  practicable
control  technology  currently available   (BPT)  and  the  best  available
technology economically achievable  (BAT) as outlined in this document.

The effluent levels achieved by the application of BPT and BAT are based on
the actual performance of plants in the data or on the performance achieved
by the application of this technology  in   other  industries.   New  source
performance  standards  (NSPS)  are based on  the actual performance of plants

-------
in the data or on the performance  achieved  by  the  application  of  this
technology  in  other industries.  Pretreatment standards for discharges to
publicly owned treatment works (POTW) are based on both BPT and BAT.

-------
                                SECTION II


                              RECOMMENDATIONS
This section will be completed after the  Environmental  Protection  Agency
has  made  a  final  selection  of  treatment  options  and effluent levels
preparatory to proposing a regulation.

-------
                                SECTION III

                               INTRODUCTION

LEGAL AUTHORITY

This report is a technical background document prepared to support effluent
limitations and standards under authority of Sections 301, 304,  306,  307,
308,  and  501 of the Federal Water Pollution Control Act, as amended, (the
Clean Water Act or the Act).  These effluent limitations and standards  are
in  partial  fulfillment  of  the Settlement Agreement in Natural Resources
Defense Council, Inc. v. Train. 8 ERC 2120 (D.D.C. 1976), modified March 9,
1979.  This document also fulfills the requirements of sections 304(b)  and
304(c)  of  the  Act.   These  sections  require  the  Administrator, after
consultation,  with  appropriate  Federal  and  State  agencies  and  other
interested  persons  to  issue information on the processes, procedures, or
operating methods which result in  the  eli-mination  or  reduction  of  the
discharge  of  pollutants  through  the application of the best practicable
control technology currently available (BPT), the best available technology
economically achievable (BAT), and through the implementation of  standards
of  performance  under  section  306  of  this  Act (new source performance
standards, NSPS).

BACKGROUND - The Clean Water Act

The Federal Water Pollution Control Act Amendments of  1972  established  a
comprehensive  program  to restore and maintain the chemical, physical, and
biological integrity of the Nation's waters.  By  July  1,  1977,  existing
industrial  dischargers  were  required  to  achieve  effluent  limitations
requiring the  application  of  the  best  practicable  control  technology
currently available  (BPT), Section 301(b)(1)(A); and by July 1, 1984, these
dischargers  were  required  to  achieve effluent limitations requiring 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 (BAT), Section 301(b)(2)(A).
New  industrial direct dischargers were required to comply with Section  306
new   source   performance   standards   (NSPS),  based  on  best  available
demonstrated technology; and  new  and  existing  sources  which  introduce
pollutants   into  publicly  owned  treatment  works (POTWs) were subject to
pretreatment standards under Sections 307(b) and  (c) of the Act.  While the
requirements for direct dischargers were to  be incorporated  into  National
Pollutant Discharge  Elimination System (NPDES) permits issued under  Section
402  of  the  Act,   pretreatment  standards  were made enforceable directly
against any owner or operator of any  source  which  introduces  pollutants
into POTWs (indirect dischargers).

Although  Section  402(a)(l)  of  the  1972  Act  authorized the setting of
requirements for direct  dischargers  on  a  case-by-case  basis,  Congress
intended  that,  for  the most part, control requirements would be based on

-------
regulations promulgated by the Administrator of EPA.  Section 304(b) of  the
Act  required  the  Administrator  to  promulgate   regulations   providing
guidelines  for  effluent  limitations setting forth the degree of effluent
reduction attainable through the application of  BPT  and  BAT.   Moreover,
Section  306  of  the  Act  required  promulgation of regulations for NSPS,
Sections 304(f), 307(b), and 307(c) required  promulgation  of  regulations
for   pretreatment   standards.   In  addition  to  these  regulations   for
designated industry categories, Section 307(a)  of  the  Act  required   the
Administrator   to   promulgate   effluent   standards  applicable   to   all
dischargers of toxic  pollutants.   Finally,  Section  501(a)  of  the   Act
authorized  the  Administrator  to  prescribe  any  additional  regulations
necessary to carry out his functions under  the Act.

The EPA was unable to promulgate many of these  regulations  by  the dates
contained  in  the  Act.   In  1976,  EPA was sued by several environmental
groups, and in settlement of this lawsuit,  EPA and the plaintiffs  executed
a  Settlement  Agreement,  which was approved by the Court.  This Agreement
required EPA to develop a program and adhere to a schedule for promulgating
for 21 major industries BAT effluent limitations,  pretreatment  standards,
and new source performance standards for 65 priority pollutants and  classes
of pollutants.  See Natural Resources Defense Council, Inc. v. Train, 8  ERC
2120  (D.D.C. 1976), modified March 9, 1979.

On  December 27, 1977, the President signed into law the Clean Water Act of
1977.  Although this law makes several important  changes  in  the   federal
water  pollution  control  program,  its  most  significant  feature is  its
incorporation  into the  Act  of  several  of  the  basic  elements   of   the
Settlement  Agreement  program  for  priority  pollutant control.  Sections
301(b)(2)(A) and 301(b)(2)(C) of the Act now  require  the  achievement   by
July   1,   1984,  of  effluent  limitations  requiring application of  BAT  for
toxic  pollutants, including the  65  priority  pollutants  and  classes   of
pollutants  which  Congress declared toxic  under Section 307(a) of the Act.
Likewise,  EPA's  programs  for  new  source  performance   standards    and
pretreatment   standards  are  now  aimed  principally  at  toxic  pollutant
controls.  Moreover, to strengthen the  toxics  control  program,  Congress
added  Section  304(e) to the Act, authorizing the Administrator to prescribe
best   management  practices   (BMPs)  to  prevent  the  release of toxic  and
hazardous  pollutants from plant site runoff, spillage or leaks,  sludge   or
waste  disposal, and drainage from raw material storage associated with, or
ancillary  to,  the manufacturing or treatment process.

In keeping with its emphasis on toxic pollutants, the Clean  Water   Act   of
1977  also  revised the  control program for non-toxic pollutants.   Instead of
BAT    for   conventional  pollutants  identified  under  Section  304(a)(4)
(including biological  oxygen demand, suspended solids, fecal   coliform   and
pH),   the  new  Section  301(b)(2)(E) requires achievement by July  1,  1984, of
effluent  limitations requiring the application  of  the  best  conventional
pollutant  control  technology   (BCT).  The factors considered in assessing
BCT for an industry include the costs of attaining a reduction in effluents

-------
and the effluent reduction benefits  derived  compared  to  the  costs  and
effluent  reduction benefits from the discharge of publicly owned treatment
works (Section 304(b)(4)(B)).  For non-toxic,  nonconventional  pollutants,
Sections  301(b)(2)(A)   and  (b)(2)(F)  require achievement of BAT effluent
limitations within three years after their establishment or July  1,  1984,
whichever is later, but  not later than July 1, 1987.

APPROACH TO LIMITATIONS  AND STANDARDS DEVELOPMENT

The effluent limitations and standards of performance for the Metal Molding
and Casting Point Source Category were developed using data and information
furnished by the plants  in the category.  For the purpose of this document,
the  Metal Molding and Casting Point Source Category is comprised of plants
in which metal is poured or forced into a mold to form a cast  intermediate
of  final product except, for ingots, pigs, or other  cast shapes related to
primary metal smelting.  During the presentation of information within this
document the word "foundry" will be used  to  identify  plants  engaged  in
casting  activities   as  explained  above.   The use of this word will also
encompass plants engaged in die casting activities.

Initially, all existing  information  on  metal  molding  and  casting  was
collected  from  previous  EPA  studies of foundries, the literature, trade
journals, inquiries to EPA regional and  state  environmental  authorities,
raw  material  and equipment manufacturers and suppliers.  This information
provided direction to the  effort  of  collecting  additional  data  where
needed.

For the purposes of study the category was initially organized into 9 study
subcategories;  aluminium  casting, copper casting, iron and steel casting,
lead casting, magnesium  casting,  nickel  casting,  tin  casting,  titanium
casting and the casting  of zinc.

To  supplement  existing data,  information  requests   (under authority of
Section 308 of the Act)  were transmitted by EPA to a statistically selected
sample of all  known  companies  engaged  in  metal  molding  and  casting.
Responses  to these data requests using a form known as  the data collection
portfolio (dcp) were  profiled to provide  a  complete  description  of  the
category.

In  addition  to  utilizing  existing  data   (including  data from 19 plants
sampled in 1974) and  plant supplied data  (via dcp), a sampling program  was
carried  out  at  23  additional plants.  Five aluminum casting plants; five
copper casting plants; ten iron and steel  casting  plants;  one  magnesium
casting  plant;  and  four zinc casting plants were sampled.  At two plants,
both aluminum and zinc casting analtyical data was obtained.  Each of these
two plants is counted twice  in the above distribution;   once  for  aluminum
casting and once for  casting zinc.

-------
At  the  completion  of  sampling  and  chemical  analysis, all of  the  data
obtained were analyzed to determine, process wastewater characteristics   and
mass  discharge  rates  in  terms of a production normalizing parameter for
each plant sampled.  In addition to  evaluating  pollutant  generation   and
discharges,  the  full range of control and treatment technologies  existing
within the foundry category was then identified.  This was done considering
the pollutants to be treated and  the  chemical,  physical  and   biological
characteristics  of  these  pollutants.   Special attention was paid  to in-
process  technology  such  as  the  recycle  of  process  wastewater,    the
segregation  of  characteristically  different  process wastewaters and the
curtailment of water use.

The information,  as  outlined  above,  was  then  evaluated   in  order  to
determine  what  levels of technology constituted "best practicable control
technology  currently  available"   (BPT),   "best   available    technology
economically  achievable"  (BAT),  "best  demonstrated  control technology,
processes,  operating  methods,  or  other   alternatives"    (BDT),    "best
conventional   pollutant   control   technology"  (BCT),  and  pretreatment
requirements for discharges to POTW's.  In  evaluating  these  technologies
various  factors  were  considered.   These included treatment technologies
from other industries, any pretreatment requirements,  the  total  cost  of
application  of  the  technology  in  relation  to  the   effluent reduction
benefits to be achieved, the age of equipment and facilities  involved,   the
processes  employed,  the engineering aspects of the application  of various
types  of  control  techniques,  process  changes,  and   non-water  quality
environmental impact  (including energy requirements).

Existing Information

Previous   studies  -  Previous federal government contracted  studies  of the
foundry category were examined.  These studies  were prepared  by   Cyrus   Wm.
Rice   Division  of  NUS Corporation under Contract No. 68-01-1507 and A.  T.
Kearney and Company,  Inc. for the National Technical   Information  Service,
U.S.   Department  of  Commerce,  PB-207 148.   Information was  gathered  from
these  studies on types of metals cast, plant size, geographic  distribution,
manufacturing processes, waste treatment  technology, and  raw  and  treated
process wastewater characteristics at specific  plants.

Literature Study - Published  literature in the  form of handbooks, engineer-
 ing  and   technical   texts,   reports,  trade   journals,   technical  papers,
periodicals, and promotional  materials was examined; the  most  informative
sources  are  listed  in Section X V.   The  "Metal Casting  Industry  Directory"
published  by   Foundry  Management  &   Technology   Magazine,    a    Penton
Publication,  provided   information   on   the number, size,  distribution and
other  factors pertaining to plant characteristics.

Regional and State Data  - EPA regional   offices  and  state   environmental
agencies   were   contacted  to obtain  permit and monitoring  data  on  specific
plants.  The EPA's Water Enforcement  Division's "Permits  Compliance System"

-------
was used as another mechanism to identify and gather additional information
on foundries.

Raw Material Manufactures and Suppliers  -  Manufacturers  and  vendors  of
foundry  raw  materials and process chemicals such as core binders and mold
release  agents  were  contacted  for  information   about   the   chemical
compositions  of  their  products.   Since  many  of  these  materials  are
considered proprietary by the  vendor,  generic  information  was  obtained
about  these  products.  From this information, predictions were made as to
the  possible  introduction  of  toxic  pollutants  into  foundry   process
wastewaters  due  to  the  presence  of these materials in the foundry work
area.

Equipment Manufacturers and Suppliers  -  Manufacturers  and  suppliers  of
foundry  process  and  pollution control equipment were contacted to obtain
engineering specifications  and  technical  information  on  foundry  manu-
facturing processes, and air and water pollution control practices.

Profile o_f Plants iji the Metal Molding and Casting Point Source Category

The  profile  is  based  upon the technical data furnished to the Agency by
plants engaged in metal molding and casting operations.  As a result of the
analysis of the information, the nine  original  study  subcategories  have
been  decreased  in  number to the six subcategories addressed in the plant
profile.  The casting of nickel, tin and titanium has been eliminated  from
further  consideration.   The  manufacturing  processes associated with the
casting of these metals and  their  alloys  do  not  result  in  a  process
wastewater.   Analysis  of  lead  casting is still underway.  Plant data is
summarized on Tables V-3 thru V-18 appearing in the back of Section V.

The profile  is organized into the following eight parts, and discussion  of
each part follows.

1.   Wet and dry plant frequency distribution and analysis;

2.   Process wastewater flow profile;

3.   Production profile;

4.   Process wastewater discharge mode profile;

5.   Frequency distribution profile of toxic pollutants;

6.   Production equipment age vs. treatment equipment age;

7.   Analysis of the land available for treatment  equipment   installation;
     and

8.   Description of the foundry category.

-------
Wet and Dry Frequency Distribution and Analysis

Analysis of the available data indicates that an estimated 3636 plants   are
engaged in the manufacture of castings applicable to this category.  Eleven
hundred   thirty-two   plants,   or   approximately   31  percent,  operate
manufacturing processes which result in a process wastewater.  These plants
are considered to be wet  plants.   Of  the  1132  plants  with   a  process
wastewater,  300  plants  discharge process wastewater to navigable waters,
360 plants introduce process wastewater into Publicly Owned  Treatment Works
(POTW), and 472 plants with a process wastewater  do  not  discharge  their
process wastewater.

The distribution of these plants by major metal cast and employee group  are
indicated on Table III-l (appearing in the back of this section), for those
plants  with  a process wastewater and for those plants which do  not have  a
process wastewater.  (Note: for the convenience of the  reader  all  tables
and  figures  have  been  assembled  in the rear of each section.  They  are
presented sequentially as they are referenced in the text).   Those  plants
without  a process wastewater are considered to be dry plants.  TABLE III-l
indicates the following:

Magnesium Casting   :    58 percent of the plants casting magnesium have  a
                         process wastewater.

Iron & Steel Casting:    51 percent of the plants  casting   ferrous  metals
                         have a process wastewater.

Zinc Casting        :    21 percent of  the  plants  casting zinc  have  a
                         process wastewater.

Aluminum Casting    :    17.3 percent of the plants casting  aluminum have  a
                         process wastewater.

Copper Casting      :    11.3 percent of the plants casting  copper  have  a
                         process wastewater.

TABLE   III-l  also  indicates that 69 percent of the plants  in the category
have no process wastewater while 31 percent of the  plants   do  generate  a
process  wastewater as a result of metal molding and casting activities.  A
review of  the number of plants within a metal group which  have   a  process
wastewater   in  relation to the total number of plants in the foundry point
source  category yields the following:

Iron & Steel Casting:    21.9  percent  of  all  plants   in  the   category
                         generate  a  process wastewater  as  a result of  the
                         manufacture of ferrous castings.
                                     10

-------
Aluminum Casting     :    4.6 percent of all plants  in the category generate
                         a  process  wastewater  as   a   result   of   the
                         manufacture of aluminum castings.

Copper Casting       :    2.2 percent of all plants  in the category generate
                         a  process  wastewater  as   a   result   of   the
                         manufacture of copper and  copper alloy castings.

Zinc Casting         :    2.1 percent of all plants  in the category generate
                         a  process  wastewater  as   a   result   of   the
                         manufacture of zinc castings.

Magnesium Casting    :    0.2 percent of all plants  in the category generate
                         a  process  wastewater  as   a   result   of   the
                         manufacture of magnesium castings.

Based on the  information presented in the previous  table, larger plants, as
distinguished  by  number  of  employees, more frequently produce a process
wastewater than smaller plants.  Table III-2 in the back  of  this  section
illustrates   this  trend.   Generally  plants of less than 10 employees £nd
which have a process wastewater are the exception rather than the rule.  An
understanding of the effects of  air  pollution  requirements  and  process
activities  of small plants puts this in better perspective.  The number of
iron and steel foundries with  less than  50  employees  has  been  steadily
decreasing in the  last 20 years.  It appears that this trend will continue.
Those small foundries still in operation are generally job shops and do not
require  large  capacity  production  equipment  and the air pollution from
these shops is small in comparison to  larger  production  foundries.   For
economic  reasons,   baghouses  (as  opposed  to scrubbers which result in a
process wastewater)  are preferred for emissions control.  In addition, most
sand handling activities are by shovel and wheelbarrow and do  not  produce
the  large  volume  of  dusts  associated  with  mechanized  sand  handling
equipment.  Therefore, many of these small foundries have not installed air
pollution control  devices.  In light of this,  few  small  iron  and  steel
foundries  have  a process wastewater.  For those smaller ferrous foundries
with a process wastewater,  an air  pollution  control  device,  a  cupola
scrubber,  is  the  primary process wastewater source.  The trend indicates
that proportionally  more larger plants will be impacted by water  pollution
control limitations  than smaller plants.

Process Wastewater Flow Profile

An  estimated  119  billion gallons of process wastewater results each year
from  the  manufacture  of  castings.   93.2  billion  gallons  of  process
wastewater  or  78 percent is  recycled.  22.5 billion gallons or 19 percent
of the total  process wastewater flow is  discharged to  navigable  waters.
Three  percent  or  3.4 billion gallons are introduced into POTW's.  Of the
93.2 billion  gallons of process wastewater recycled each year, 51.4 billion
is recycled at 100 percent.
                                     11

-------
The subcategories ranked in decreasing volume of  process  wastewater  are:
iron  and steel casting, copper casting, aluminum casting, zinc casting  and
magnesium casting.  Process wastewater discharged to navigable waters  from
plants  engaged in the metal molding and casting of iron and steel accounts
for 77 percent of the total  direct  discharge  volume  for  the  category.
Likewise,  89  percent  of  the total volume of process wastewater which is
introduced into POTWs results from the casting  of  ferrous  metals.   More
specific  details  of  the process wastewater flow profile are presented in
Section V.

Production Profile

For the purposes of this document, the term production is used  to   express
the amount of metal poured and not the weight of finished castings produced
by or shipped from those plants within the foundry point source category.

An  estimated 41 million tons of metal are poured annually in plants with  a
process wastewater resulting from the metal molding and casting   processes.
Nineteen  million  tons  of metal are poured annually in plants discharging
process wastewater directly to navigable waters.  Twelve  million tons   of
metal   is  poured  annually in plants which introduce process wastewater to
POTWs  wastewater.  Ten million tons of metal is poured, or 24  percent   of
the total annual amount of metal poured, in plants which completely  recycle
process  wastewater.   In determining this 10 million ton estimate, only  the
weight  of metal poured  at plants which recycle  100 percent of  the   process
wastewater   from  all   metal  molding and casting processes was considered.
For example,  the weight of metal poured at a plant with one process  at   100
percent  recycle  and  one process discharging to a POTW was included in  the
12 million ton estimate for the POTW discharge  mode.

In addition,  for  those  plants with a process wastewater 65 percent   of   all
the metal melted  is poured in 25 percent of the plants.  Eighty-one  percent
of  the metal poured is ferrous metal and the amount of gray  iron poured is
66 percent of the total weight of all ferrous metal poured.  More specific
information   about the  production profile is presented in Section V  of this
document.

Process Wastewater Discharge Mode Profile

As  previously   indicated,  process  wastewaters  originate   from   various
processes  within  each subcategory.   An  estimated  total of 1,800 metal
molding and  casting processes produce a process wastewater.   A  frequency
distribution of  these wet processes  indicates that process wastewater is
discharged to navigable waters from  28.4 percent of  these  processes,   and
that   process wastewater   is  introduced   into POTW's from 28.7  percent of
these processes.  Process wastewater  is completely recycled   in   783  (43.5
percent)  out of  the  1,800  metal  molding   and casting processes.  More
specific  discharge mode information  is  presented  in  Section  V of  this
document.
                                     12

-------
Frequency Distribution Profile of Toxic Pollutants

Numerous  toxic  pollutants  were  detected in the process wastewaters from
metal molding  and  casting  processes  sampled  during  th  1978  sampling
program.   The  toxic pollutants detected most frequently in concentrations
at or above 0.100 mg/1 include the phenolic compounds and heavy metals.
     2,4,6-trichlorophenol
     2,4-dimethylphenol
     Phenol
     Bis(2-ethylhexyl)
      phthalate
     Cadmium
     Chromium
     Copper
     Lead
     Nickel
     Zinc
was found in 14 percent of the processes sampled
was found in 11 percent of the processes sampled
was found in 23 percent of the processes sampled
was found
was found
was found
was found
was found
was found
was found
in 23 percent of
in 11 percent of
in 9 percent of
in 36 percent of
in 36 percent of
in 16 percent of
in 59 percent of
 the processes
 the processes
the processes
 the processes
 the processes
 the processes
 the processes
 sampled
 sampled
sampled
 sampled
 sampled
 sampled
 sampled
     More specific details of the profile of toxic pollutants are
     presented  in Section V.

Production Equipment Age Versus Treatment Equipment Age

The age of the  foundry has no bearing on the  applicability  of  installing
water  pollution  control equipment.  Some foundries which have operated at
the same address for over 100 years, replaced melting furnaces as  recently
as  five  years ago and sand handling systems as recently as ten years ago.
Process wastewater treatment equipment age varied  from  thirty  years  for
some  equipment items  to  less  than  one year for the more recent system
installations or additions to older treatment systems.

Review of the information appearing on Tables V-3 through V-18 in the  back
of  Section V indicates that 59 percent of the plants in the iron and steel
subcategory have installed process wastewater treatment equipment  five  or
more  years  after  the   installation  of  the  oldest melting furnace.  In
addition, nine  percent of the  plants  have  installed  process  wastewater
treatment  equipment  as  long  as  30  years after the installation of the
oldest melting  furnace.

Information about the other subcategories indicates  that  about  half  the
plants  have  installed   treatment equipment more than five years after the
installation of the melting furnace.

Analysis of Land Available  for   the  Installation  of  Process  Wastewater
Treatment Equipment

Specific  information  assessing  the  amount  of  land  available  for the
installation of process wastewater  treatment  equipment  was  specifically
                                     13

-------
requested  in  the  plant  survey-  The plant data obtained was examined  to
identify plants which may have  a  shortage  of  land  on  which  to  erect
treatment equipment.

Approximately  10  percent  of all the plants responding to this segment  of
the data collection portfolio indicated their  concern  about  the  limited
availability  of  land  adjacent  to  the plant on which to erect treatment
equipment.  This concern  was  expressed  through  their  response  to  the
information   sought   and   through   the   description  of  the  physical
circumstances which may limit the installation of treatment equipment.

Review of the plant data from the  10  percent  of  the  plants  expressing
concern  over  the  limited availability of land indicates that these plants
have already in place some process wastewater equipment similar to the  BPT
and  BAT  treatment  equipment  identified  in this document.  These plants
already employ some form of settling technology and recycle.   Thirty-three
percent  of  these  plants (those plants with information expressing concern
over land  availability)  with  settling  and  recycle  technology  already
installed  have  reported  100 percent recycle of their process wastewater.
No additional treatment  equipment  is  therefore  needed.   The  remaining
plants generally employ extensive recycle.

Based  on  the technical findings, the installation of additional treatment
equipment or the increase of existing recycle rates to 100 percent  recycle
would  not  be  hindered  by  the  limited availability of land reported  by
plants responding to the information request.   In  addition,  though  many
plants  use  settling  ponds  or  lagoons for solids removal, the more space
efficient clarifiers have  been   included  as  part  of  the  BPT  and  BAT
equipment.

Description of the  Foundry Category

The  unique  feature of the foundry industry is the pouring or injecting  of
molten metal into a mold, with the cavity of the mold  representing  within
close  tolerances   the  final  dimensions of the product.  One of the major
advantages of this  process is that intricate metal shapes,  which  are  not
easily  obtainable  by  any  other  method of fabrication, can be produced.
Another advantage is the rapid translation of a  projected  design  into   a
finished  article.   New articles are easily standardized and duplicated  by
the  casting method.

The  foundry  industry ranks sixth  among all manufacturing  industries  based
on   "Value  added   by  Manufacture"  according to data issued by the United
States Department of Commerce in  1970 (Survey of Manufacturers, SIC 29-30).
Presently, this  industry in the United States totals over  3,600  foundries
employing  approximately  400,000  workers  and  producing  over 19 million
tons/year  of  cast products.    Table  111-3   presents   the   geographic
distributions of foundries in the country.
                                     14

-------
ANTICIPATED INDUSTRY GROWTH

Annual castings production has ranged between 15 and 20 million tons during
most  of  the  last 20 years.  Ferrous castings have accounted for about 90
percent of the total tons produced annually since  1956,  with  the  result
that the proportion of total output attributable to nonferrous castings has
remained  close to 10 percent.  Table II1-4 presents information on foundry
shipments in the United States.

Contrasting trends, however, are evident among the ferrous  and  nonferrous
metal  types,  as can be seen  in Figure III-l, which presents production at
5-year intervals over the 1956-76 period.  For example, within the  ferrous
castings  group,  the  trend   of  ductile  iron production has been sharply
upward, while production for gray iron, malleable iron, and steel  in  1976
was  lower  than 20 years earlier.  Similarly, among the nonferrous metals,
aluminum has registered a significant long-term gain,  whereas  the  trends
for the others are relatively  mixed.

Figure  III-2  shows that the  number of smaller iron foundries have dropped
dramatically, while large and  medium  iron  foundries  have  prospered  in
number.   In  addition,  as  noted  in  Figure  III-l  and as observed from
conversations with plant personnel, there  is  a  trend  toward  decreasing
percentage  of  zinc  casting  shipments compared to total foundry shipments
and to aluminum  shipments.    It  appears  that,  generally,  zinc  casting
production would be decreasing in favor of the production of lighter weight
aluminum  castings in the foreseeable future.  However, zinc casting plants
will remain  in operation for some time.

GENERAL DESCRIPTION OF THE METAL MOLDING AND CASTING PROCESSES

The product  flow of the typical foundry operation is shown in Figure II1-3.
In all types of foundries,   raw  materials  are  assembled  and  stored  in
various material bins.

From these bins, a "furnace  charge" is selected by using various amounts of
the  desired  materials.  This material is "charged" into a melting furnace
and through  a heating process, the metal is made molten.

Simultaneously, molds are being prepared.  This process begins by forming  a
pattern  (usually of wood) to the approximate final shape  of  the  product.
This  pattern   is  usually made in two pieces that will eventually match to
form a single piece, although  patterns may be 3 or more pieces.  Each  part
of  the pattern is used to form a cavity in a moist sand media, and the two
portions of  the mold  (called "cope" and "drag")  are  matched  together  to
form  a  complete  cavity  in  the  sand media.  An entrance hole (called  a
"sprue") is  cut to provide the proper paths of  molten  metal  introduction
into  the  cavity.  The mold is then ready to receive the molten metal.  In
die casting  operations the mold cavity is formed  in  metallic  die  blocks
which are locked together to make a complete cavity.
                                     15

-------
The  molten  metal  is  now  "tapped" from the furnace  into  the  ladle.   The
ladle and molds are moved to a pouring area and the metal  is  poured   into
the  molds.   The  molds  are then moved to a cooling area where the molten
metal solidifies into the shape of the pattern.  When sufficiently  cooled,
the  sand is removed by a process known as "shake out." By violent  shaking,
the sand surrounding the metal is  loosened  and  falls  to  the floor  or
conveyor that returns it to the sand storage area.

The  cast  metal  object  (casting) is further processed by  removing excess
metal, and cleaned by various methods that complete the removal  of  the  sand
from its surface.  In the case of die casting, where no sand is   used,   the
cast  object  is  removed  from  the  die  casting  machine  after  cooling
sufficiently to retain its shape.  The casting is either further cooled  by
a  water  bath  or  is allowed to cool by air on a runout or cooling table.
Depending on the final use of  the  casting,  further   processing  by   heat
treatment,   quenching,   machining,  chemical  treatment,   electroplating,
painting or coating may take place.  After inspection,  the casting  is   then
ready for shipping.

Foundry Metal Description

Many of these metals have unique properties that influence the way  they are
melted,  processed  and  affect  the process wastewater characteristics.   A
brief description of these  metals,  foundry  equipment  and processes  is
presented  to identify sources of process wastewater.

Aluminum

Aluminum   is a  light silver-white metal 2.7 times denser than water.   It is
soft  but with good tensil strength.  It melts  at  660°C   (1200°F)  and  is
easily  cast,   extruded, and pressed.  An aluminum structure weighs half as
much  as a  steel  structure of comparable strength.  Until 1886 aluminum   was
a  rarity.  Then  the economic Hall process was developed to extract  metallic
aluminum from its oxide  "alumina." Today aluminum is the second  most widely
used  metal  after iron.  Table  III-4  indicates that in 1977 over 1 million
tons  of aluminum  castings were shipped in the United States. Aluminum   may
be  cast   in  a  variety of ways.  A drawing depicting the process and water
flow  in a  typical aluminum investment operation is presented in  Figure  III-
4.   Figure  111-5  shows the process arrangement and water flow schematic for
a  typical  aluminum die casting operation.

Copper

Copper  is  a  read, ductile nonferrous metal,  second  only  to  aluminum  in
 importance   of   nonferrous  metals.    It  melts  at  1083°C  (1982°F) and has
excellent  corrosion resistance.   It  is the metal that heralded   the Bronze
Age   (3,000  B.C.) and  is occasionally found  in a metallic state in nature.
Brass and  bronze are  the two most  important alloys,  and   are  mixtures  of
copper,  tin,   lead   and  zinc.   Other  copper  alloys  include manganese,
                                     16

-------
aluminum, nickel, silicon, and  beryllium.   Table  III-4  gives  a  recent
history  of  copper  shipment  tonnages.  Copper and its alloys may also be
cast in a variety of ways depicted in  Figure  III-6.   Figure  III-6  also
shows the process and process wastewater flow schematic typical of a copper
casting operation.

Iron and Steel

Iron  is  the world's most widely used metal.  When alloyed with carbon, it
has a wide  range  of  usefull  engineering  properties.   Alloys  of  iron
include:  gray,  ductile, malleable, and steel.  Tonnages shipped are shown
in Table III-4.   Figure  III-7  displays  typical  processes  and  process
wastewater flow schematic for ferrous foundries.

     Gray Iron is the most popular of the cast irons.  It is  characterized
     by  the  presence  of  most  of the contained carbon.as flakes of free
     graphite in the as-cast  iron.   Gray  -iron  is  classified  into  ten
     classes  based  on  the  minimum  tensil  strength of a cast bar.  The
     tensil strength is affected by the amount of free graphite present  as
     well  as  the  size,  shape  and  distribution of the graphite flakes.
     Flake  size,  shape  and  distribution  are  strongly  influenced   by
     metallurgical  factors  in  the melting of the iron and its subsequent
     treatment while molten, and by solidification rates and cooling in the
     mold.

     Ductile Iron (also known as nodular iron, spherulitic iron, etc.)   is
     similar  to  gray iron composition with respect to carbon, silicon and
     iron  content,  and  in  the  type  of  melting  equipment,   handling
     temperatures,   and  general  metallurgy.   The  important  difference
     between ductile and gray iron is the graphite separates  as  spheroids
     or  nodules  (instead of flakes as in gray iron) under the influence of
     a few hundredths of a percent of magnesium in  the  composition.   The
     presence  of minute quantities of sulfur, lead, titanium, and aluminum
     can interfere with and prevent the noduling effect of magnesium.   The
     molten iron for conversion to ductile iron must be purer than for gray
     iron  manufacture.  However, a small quantity of cerium added with the
     magnesium minimizes the effects  of  impurities  that  inhibit  nodule
     formation   and  make it possible to produce ductile iron from the same
     raw materials used for high grade gray  iron manufacture.

     The general procedure for manufacturing ductile  iron  is  similar  to
     that  of  gray  iron, but with more precise control of composition and
     pouring temperature.  Prior to pouring  of metal into the molds  (and in
     some cases  during pouring) the metal is innoculated with  the   correct
     percent  of  magnesium,  usually   in  a   carrier alloy, to promote the
     development of spheroids of graphite on cooling.

     While the development of ductile iron dates back to the 1920's,  it was
     only within  the  last  20  years  that  it  has  become  an   important
                                     17

-------
    engineering  material.   This  can  be  noted  from Table III-4  which shows
    its  increasing  use.

    Malleable  Iron  is  produced  from base metal in a range  of  composition
    of:
               Carbon
               Silicon
               Manganese
               Sulfur
               Phosphorous
               Boron
               Aluminum
2.00
1.00
0.20
0.02
0.01
0.0005
0.0005
to   3.00 percent
to   1.80
to   0.50
to   0.17
to   0.10
to   0.0050
to   0.0150
                         Balance Iron
     Low  tonnage  foundries  use  batch-type furnaces such as electric arc
     induction,   or  reverbatory.    Tapping  temperature  is  1500°C-1600°C
     (2,700  -  2,900°F)   depending  on  the  fluidity  required.   In large
     tonnage shops needing a continuous supply  of  molten  iron,   electric
     furnaces  or  duplexing  systems  are  employed.    Cupola furnaces are
     common in some malleable shops,  especially for the production of  pipe
     fittings.   After  the iron casting solidifies,  the metal is  a brittle
     white iron.   Malleable iron castings are produced from this white iron
     by heat treating processes that convert the  as-cast  structure  to  a
     "temper  carbon"  grain  structure in a matrix of ferrite.   This is an
     annealing process requiring proper furnace temperature/time cycles and
     a controlled atmosphere.

     Steel - The making and pouring of steel for sand castings  is  similar
     to  the casting of steel into ingots.  One major difference from steel
     mill practice is the higher tapping temperature needed to  attain  the
     correct  fluidity  needed  to  pour the steel into molds.  The melting
     furnaces are generally the same as  those  for  steel  mills   but  are
     smaller  for  foundries.  Only a thoroughly "killed" steel  is used for
     foundry products.  Molding practices are similar to gray iron  foundry
     with  the  precautions  required  for  the higher pouring temperatures
     1800°C (3,200°F).  Mold coatings or washes are  used  to  give  better
     finish  and  are  generally  made of more refractory like materials to
     resist metal penetration.

Magnesium

Magnesium is a silver-white metal weighing 108  Ibs/cu  ft.   On  an  equal
weight  basis,  magnesium is equal or stronger than any other common metal.
It can be melted in the same type of furnaces as are used for  aluminum  or
zinc.   However,   due  to  the  nature  of  molten  magnesium, care must be
exercised in selecting refractories and other  materials  that  the  molten
metal may contact.
                                    18

-------
Furnaces  usually  are  stationary or tilting crucible types heated by gas,
oil, or coreless electric induction.  The crucibles are made of low  carbon
steel  with  nickel  and  copper contents below 0.10 percent.  Magnesium is
usually alloyed with aluminum, zinc, manganese, or rare  earth  metals  for
foundry work.

Most  magnesium  is  cast  in sand molds.  The practice for sand casting of
magnesium alloys differs  from  most  other  metals  in  the  precautionary
measures  required  to  prevent  metal-mold  reactions.  Inhibitors such as
sulfur, boric acid, potassium fluoborate  and  ammonium  flurosi-licate  are
mixed  with  the  sand  to  prevent  these  reactions.   Molding  sands for
magnesium alloys must have high permeability to permit free  flow  of  mold
gases to the atmosphere.

Table  II1-4 indicates the growth of magnesium foundry products.  A general
process schematic is shown in Figure II1-8.

Zinc - Zinc is a bluish-white metal with a  hexagonal  close-paced  crystal
structure.   It  is  less  dense than iron and not especially strong.  Zinc
melts at 420°C and boils at  a  temperature  of  907°C.   The  low  melting
temperature  and very small grain size and adequate strength makes zinc and
zinc alloys*well suited for die casting.  Die casting is the  process  most
often used in shaping zinc alloys.  Zinc alloy compositions consist of 0.25
percent  copper,  4  percent  aluminum,  0.005 to .08 percent magnesium and
traces of lead, cadmium, tin and iron with the  remainder  zinc.   Furnaces
used  in  melting  and  alloying  zinc  are  usually the pot type, although
immersion tube and induction furnaces are also used.  A furnace should hold
five to seven times the amount used in one hour.  Good temperature  control
is  a  necessity  for  both  melting  and  holding  furnaces.   Table III-4
indicates the decreasing  shipments  of  zinc  castings.   A  zinc  casting
process schematic is presented in Figure II1-9.

Melting Equipment

A  description of the various melting equipment is presented to clarify the
many  types  of  melting  furnace  scrubbers  which  result  in  a  process
wastewater.

Cupola Furnace

The  cupola furnace is a vertical shaft furnace consisting of a cylindrical
steel shell lined with refractories  and  equipped  with  a  wind  box  and
tuyeres  for  the  admission  of air.  A charging opening is provided at an
upper level for the introduction of  melting  stock  and  fuel.   Near  the
bottom are holes and spouts for removal of molten metal and slag.

Air  for combustion is forced into the cupola through tuyeres located above
the slag well.  The products of combusion, i.e., particles  of  coke,  ash,
metal,  sulfur  dioxide,  carbon  monoxide,  carbon dioxide, etc. and smoke
                                     19

-------
comprise the cupola emissions.  Air pollution  emission  standards  require
that  these  emissions  be  controlled.   Wastewaters are generated in this
process as a result of using water as  the  medium  for  scrubbing  furnace
gases.

The  cupola  has  been the standard melting furnace for gray  iron.  Figures
111-10 and 11 illustrate cupola furnace systems.

Electric Arc Furnaces

An electric arc  furnace  is  essentially  a  refractory  hearth   in  which
material  can be melted by heat from electric arcs.  The molten metal has  a
large surface area in  relation  to  its  depth,  permitting   bulky  charge
material  to  be  handled.   This  large  surface  area  to   depth ratio  is
effective in slag to metal reactions as the slag and metal are at  the  same
temperature.   Arc furnaces generally are not used for nonferrous  metals  as
the high point of the arc tends to vaporize the lower  melting temperature
metals.  Arc furnaces are operated in a batch fashion with tap-to-tap times
of  1-1/2 to 2 hours.  Power,  in the range of 500-600 kwh/ton,  is  introduced
through  three  carbon  electrodes.   These  electrodes are consumed in the
process of passing the electric current through the scrap  and metal  into
the   molten  batch.   They oxidize at a rate of 5 to 8 kg per metric ton  of
steel  (10.5 to 17 Ibs/ton).

The waste products from the process are smoke, slag,  carbon   monoxide  and
dioxide  gases and oxides of  iron emitted as submicron fumes.  Dry type air
pollution control equipment such as baghouses are generally used  to control
electric arc furnace emissions.

Induction Furnaces

Induction melting furnaces  have  been  used  for  many  years to produce
nonferrous  metals.    Innovations  in the power application area  during the
last  20 years have enabled them to compete with cupolas and arc furnaces  in
gray  iron and steel  production.   This  type  of  furnace  has   some  very
desirable features.  There is  little or no contamination of the metal bath,
no  electrodes are necessary,  composition can be accurately controlled, good
stirring   is  inherent  and   while  no  combustion  occurs, the temperature
obtainable  is theoretically unlimited.

There are  two types of  induction furnaces:   (a) coreless, which is a simple
crucible surrounded by  a  water-cooled  copper  coil  carrying alternating
current,   and   (b)  core  or channel,  in which the molten metal is channeled
through one  leg of a transformer core.  The  induction furnace provides good
furnace atmosphere control, since no  fuel  is  introduced  into  the   crucible.
As  long as  clean materials such as castings  and clean metal scrap are used,
no   air pollution  control equipment  is  necessary.   If contaminated scrap  is
charged or  magnesium  is added to manufacture ductile   iron,   air   pollution
control devices are required  to collect the  fumes  that are generated.
                                     20

-------
Reverberatory Furnace

A  reverberatory  furnace operates by radiating heat from the burner flame,
roof, and walls onto the material to be heated.  This type of  furnace  was
developed  particularly for melting solids and for refining and heating the
resulting liquids.  It is generally one of the least expensive  methods  of
melting  since  the  flames  come  into  direct contact with the solids and
molten metal.  A  reverberatory  furnace  usually  consists  of  a  shallow
refractory-lined  hearth  for holding the charged metal.  It is enclosed by
vertical side and end  walls,  and  covered  with  a  low  arched  roof  of
refractories.   Combustion of fuel occurs directly above the charge and the
molten bath.  The wall and roof receive heat from the flame and  combustion
products  and  radiate  heat  to  the molten bath.  Transfer of heat occurs
almost solely  by  radiation.   There  are  many  shapes  of  reverberatory
furnaces;  most  common  type  is  the  open  hearth  style  used  in steel
manufacture.  However, the cost of pollution control equipment, as well  as
inefficiencies in handling the metal have caused this type of furnace to be
obsolete  in  steel  and gray iron manufacture.  Reverberatory furnaces are
widely used  in nonferrous production.

The  products of combustion from reverberatory furnaces are conducted  to  a
stack  and exhausted to the atmosphere.  Contaminants such as smoke, carbon
monoxide and dioxide, sulfur dioxide and metal oxides must be removed  from
the  exhause  stream.   These  become  process  wastewater contaminate when
scrubbers are used.

Crucible Furnace

Crucible furnaces are used to  melt  metals  having  melting  points  below
1900°C   (2,500°F).  They are constructed of a refractory material such as a
clay-graphite mixture or silicon carbide.  They are made in various  shapes
and  sizes.   The  crucible  is  set  on  a  pedestal  and  surrounded by a
refractory shell with a combustion chamber between  the  crucible  and  the
shell.  The  crucible  is usually sealed or shielded from the burner gases to
prevent contamination of the molten metal.

There  are   three  general  types  of  crucible furnaces; tilting, pit, and
stationary.  All  have one or more gas  or  oil  burners  mounted  near  the
bottom  of   the unit.  The crucible  is heated by radiation and contact with
the  hot gases.  The exhaust gases  contain  only  products  of  hydrocarbon
combustion and generally they are not controlled.

Fume Scrubbing Equipment

The  preceding  section  on  the various  types of melting units used  in the
remelting of metal describe the source of  the  fumes,  particulates,   smoke,
and  other   waste  products  that  are   the  major  contaminants  of process
wastewater when scrubbers  are  used  to   control  the  furnace   emissions.
                                     21

-------
Generally,  venturi scrubbers are used to clean these furnace emissions but
other methods are used.

The methods of cleaning the wastewaters produced will be described  in  later
sections of this report.

Fabric Media  (Baghouse)

The collection of particulate matter  is  achieved  by  entrapment   of the
particles  in  the fabric of a filter cloth that is placed  across a flowing
gas stream.  These dust particules are removed from the cloth by shaking  or
back flushing the fabric with air.  Filtration does not remove  gases  from
the  furnace  discharge  gas  stream.   These  gases are:   carbon monoxide,
phenol, carbon dioxide,  hydrogen  chloride,  hydrogen  sulfide,  nitrogen,
ammonia  hydrogen,  and  water  vapor.   Their quantities depend on type  of
fuel, furnace efficiency, and infiltration of  air  into  the   gas   stream.
Filtration  methods have been developed to a high degree of efficiency (97-
99 percent removal of particulate  matter).   These  methods coupled  with
recuperation  of  heat  and ignition of the combustible gases have  received
considerable  attention from industry.

The cloth filter media  (baghouse) has a temperature limit of approximately
250°F.   These gases can be cooled to this temperature by long  runs of duct
work between  the furnace and the baghouse.  The ductwork acts as a  radiator
to  cool  the  gases.   These  systems  are  dry  and  produce  no   process
wastewaters.

Other   installations  have  a  quench  tower  between  the   furnace and the
baghouses or  electrostatic precipitator.  This method cools the hot  gases
by  evaporating  water  sprayed into the quench tower.  This quench chamber
usually is arranged to provide a sharp reversal in the gas  stream direction
and a sudden  reduction  in flow velocity.  These  features   coupled   with   a
cooling   effect  achieved by the evaporation of the water causes the larger
dust particles to be deposited on the chamber floor.  The gas then  flows  to
the filter chamber.  The dust that is deposited is removed  periodically.

In addition to a gas volume reduction, this water spray absorbs many of the
gases listed  above.

Wet Scrubbers

o    Washing  Coolers.  Several general designs of washing coolers are used.
     All  use  some method to secure a long retention time to keep the  gases
     in   contact  with the scrubbing liquor.  In general, they  consist of a
     large cylindrical vessel with the gases entering tangentially   at the
     bottom   and  exiting through the top center.  Several  levels of sprays
     bring the liquor  into contact with the rising gases.    The bottom   is
     usually  conical with a large pipe outlet to return the dirty  liquor  to
     a  settling area.
                                     22

-------
     Another  type  known  as  the bulk bed washer or packed tower contains
     water sprayed gravel beds.  The dusty gas  enters  in  a  downward  or
     tangential direction and has a preliminary dust removal capability due
     to  inertia.   The gases then flow upward through a wetted gravel bed.
     At the upper surface of this bed, the gas velocity causes a  turbulent
     water zone that brings the finest dust particles into contact with the
     water.  The recirculated water is sprayed in above this gravel bed and
     continually  washes  it and is removed at the bottom.  Above the spray
     heads is a droplet catcher that removes the droplets from  the  rising
     gas  stream.   This  method  requires  approximately 10 in. (water) of
     pressure drop and is not effective on particles smaller than 1 micron.

     Figure  I11-10  represents  this  method,  as  well  as  a  method  of
     recovering some of the heat from the gas stream.

     Wet Cap.  The "wet cap" method is  an  early  attempt  to  reduce  the
     particulate  emissions  by  passing  the  waste  gases through a water
     stream or water curtain.  This method operated  with  a  low  pressure
     drop  could  be  added  to existing cupolas with only minor changes to
     equipment and operations.  Figure 111-11 represents this method.

     Venturi Scrubber.  This scrubber consists primarily of a Venturi  tube
     fitted  with  spray  nozzles at the throat.  The dust-laden gases flow
     axially into the throat where they  are  accelerated  to  200  ft/sec.
     Water is sprayed into this throat by a ring of nozzles.  This produces
     a  dense  mist-like water curtain.  The water droplets of this curtain
     combine with the dust particles.   In  the  subsequent  diffuser,  the
     velocity  is  reduced and inertia is used to separate the droplet from
     the gas stream.  Venturi  scrubbers  require  15-100 ' in.  (water)  of
     pressure  drop  across  the  gas  stream.   They are very effective on
     particulate matter in the 1  micron  range  and  readily  adsorb  many
     furnace  gases  in their water streams and thus add many pollutants to
     the process wastewater.

     Venturi scrubbers are operated in conjunction with water settling  and
     recirculating systems as shown in Figures V-13, V-14, and V-15.

Dust Scrubbing Equipment

Foundries  that  use sand as a molding media have the problem of collecting
and controlling the dusts produced in handling and using this sand.   Sand,
as  used   in foundry molding, is mixed with one or more materials that coat
the sand grains and act as a binder to hold the sand into the form  of  the
pattern.   The  binders  are  a  major  source of organic pollutants  in the
foundry.   Fumes and odors are developed in the pouring of  hot  metal  into
molds.   The  cleaning  of  the  casting  to  remove traces of sand,  gates,
runners, heads, mold flashings and mismatch also produces  dust  and  fumes
that are removed from the work place.  Many of these dusts are collected on
fabric media in the "baghouse." In many instances, it is more economical or
                                    23

-------
more  efficient  to remove these airborne particles by entrapping them  in  a
spray or mist.  These types of  "wet collectors" will be  examined  as   they
are currently used in the foundry.

Spray Chambers

The  simplest  type of wet scrubber is a chamber  in which  spray nozzles are
placed.  The gas stream velocity decreases as  it  enters   the  chamber   and
particles  are  wetted  by  the  spray  and settle and are collected at the
bottom of the chamber.

Cyclone-Type Scrubbers

Cyclone-type scrubbers feature  a tangential inlet to  a  cylindrical  body.
Water  is  injected   through  spray nozzles which break the water into  many
droplets that contact the particles and increase  their inertial  action to
cause  them  to  impinge  on the vessel sides  where they are flushed to the
bottom; the clean gas exits through the top.   Baffles in the  exit  collect
and aid in the removal of the water droplets from the gas  stream.

Orifice-Type Scrubbers

Orifice-type  scrubbers  utilize   the velocity of the air  stream to provide
liquid contact.  The  flow of air through  a  restricted  passage  partially
filled  with  water   causes  the dispersion of the water into  many droplets
that  intimately contact and wet the airborne dusts and absorb  some  of   the
gases.  The amount of water in  motion is large and most of the water can be
recirculated without  pumps.

Mechanical-Centrifugal Scrubbers

A  spray  of  water   at the inlet  of a fan becomes a mechanical-centrifugal
collector.  The collection efficiency is  enhanced  by  the entrapment of
dusts  on  the  droplet  surface,  and  impingement  of the droplets on the
rotating blades.  The spray also flushes the blades of the collected dusts.
This  spray will substantially  increase corrosion  and wear  on the fan.

Another  type  of mechanical collector uses a rotating element to generate  a
spray  of water droplets  into a  dust  laden gas  stream.  The wetted particles
flush   to  the  collection  pan where  they   can settle while the water is
recirculated.

Venturi  Scrubbers

Venturi  scrubbers have been described  in the   section  on   melting   furnace
scrubbers.    They   are also used  in  dust collection systems.  In some  cases
 there is  a single  large Venturi in the  dust   laden  air   stream  with   low
pressure   water added at  the Venturi throat.   The extreme  turbulance  breaks
 the water  into  a  fine spray where  it  impacts and  wets  the  dust particles.
                                     24

-------
Other applications are similar to orifice-type scrubbers but with Venturi's
shape replacing the orifices.  These Venturi's are  located  at  the  water
line  and  water is drawn into the Venturi throat where it is broken into a
fine spray by the turbulent air.  The spray droplets wet the dust particles
and are impinged against baffle plates.  Here they drain to  the  reservoir
where the particles settle.

Packed Towers

This  device  is  similar  to  the bulk bed washer described in the melting
scrubber section.  The dust laden  gases  pass  through  a  wetted  bed  of
granular  or  fibrous  collection  material  and liquid is flushed over the
surface of the collection material to keep it wet, clean  and  prevent  re-
entrainment  of the particles.  Collection efficiency depends on the length
of time the gas stream is in contact with  the  collecting  surfaces.   The
collecting  material should have a large ratio of area to weight, and be of
a shape that resists close packing.   Coke,  broken  rock,  glass  spheres,
rashig rings, tellirets, are materials that are often used as tower packing
materials.

A  cone-shaped  bottom  aids   in  removing  settled dust particles from the
liquid.   Recirculation  of  the  liquor  is   usually   practiced.    Mist
eliminators  are  located   in  the  exit  gas-stream  to reduce loss of the
flushing  liquor.

Wet Filters

A wet filter consists of a  spray chamber with filter pads composed of glass
fibers, knitted wire  mesh  or other  fiberous  materials.   The  dust  is
collected  on  the  spray pads by virtue of the dust laden gas stream being
drawn through the pads.  Sprays are directed against the pads to  keep  the
dust  washed  off.   The water drains to a reservoir where it is settled or
clarified and recirculated, or discharged.

Casting Methods

Foundries use several methods  of casting the molten metal  into  its  final
shape.    None  of these methods  involve  intimate contact between the molten
metal and water as  the explosive forces developed by the  rapid  generation
of  steam  when  water  comes   into  contact  with  molten  metal cannot be
controlled.

Sand Casting

o    Green Sand Castings:   This  is the most widely used molding method.   It
     utilizes a mold made of   compressed  moist  sand.   The  term   "green"
     denotes the presence of moisture  in the molding sand and that  the mold
     is   not  dried or baked.   This method  is generally the most expedient,
     but  is generally  not suitable for  large or  very heavy castings.
                                     25

-------
Dry Sand Casting:  Most large and very heavy castings are made in  dry
sand  molds.  The mold surfaces are given a refractory coating and are
dried before the mold is closed for pouring.  This  hardens  the  mold
and  provides the necessary strength to resist large amounts of metal,
but increases the manufacturing time.  Molds which are hardened by the
C022 Process may also be considered in this category.  Such molds  are
not  dried,  but  are  made  from  an  essentially  moisture free sand
mixture, which contains sodium silicate (water glass).   The  mold   is
rapidly  hardened  by  the  reaction  of  carbon  dioxide gas with the
silicate.  The process can also be  used  for  making  cores.   It   is
advantageous  in reducing manufacturing time, but is not practical for
some types of work.

Shell Mold  Castings:   This  method  is  of  recent  development  and
utilizes  the unique process of making molds by forming thin shells  of
a resin-bonded sand over a hot pattern.  It is suitable for small  and
some  medium-sized castings.  Shell molding provides improved accuracy
and surface finish.  It allows for greater detail and less drift  than
is  normally  satisfactory  in  green sand molding.  Metal patterns  of
special construction are necessary.   The  process  is  of  particular
advantage  when  it provides savings in machining and in finishing the
casting.  The shell process has also been very effectively applied   in
making  cores which may be used with any of the molding methods.

Core Mold Casting:  Castings of unusual complexity (such as  the  thin
and  deep  fins  of an air-cooled engine cylinder) may be produced in a
mold made of the type of sand commonly used for cores.  This sand  has
almost  free-flowing  properties when it is packed around the pattern,
and it  will fill crevices and reproduce  detail.   After  baking,  the
mold  becomes  strong  enough  to  resist the forces of flowing molten
metal.  Core sand molds may be used when complexity requires more than
one parting line in a casting.  Core sand sections may be used to form
a complex external portion of a casting in either a green or dry  sand
mold, just as cores are used to form internal surfaces.

Permanent Mold Castings:  Iron castings, within  limits  as  to  size,
complexity,  and properties,  can  be  produced in large numbers from
mechanically  operated  permanent  iron   molds.    This   mechanized,
high-production  process is mainly used for castings of suitable shape,
of  less  than   25  pounds  in  weight,  and  with  3/16" minimum wall
thickness.  Cores are formed with conventional sand or shell cores.

Ceramic Mold Casting:  Certain highly specialized  castings  requiring
an  unusually  fine  finish,  precise detail, and close tolerances are
produced in molds made of fired ceramics.  This is comparable  to  the
plaster-mold  process  which  is  used for nonferrous alloys.  Pattern
equipment  is generally of a "core-box" type, and may be made of  metal
or  plaster.  In some applications, backdraft or undercuts are allowed
by making part of the pattern of a flexible material.  When  the  mold
                                26

-------
     can  be assembled from a number of pieces, castings of several hundred
     Ibs. in weight and several feet in a major dimension can  be  made  to
     relatively close tolerances.

Centrifugal  Casting  the  force  of  gravity, but centrifugal force may be
used.  True centrifugal casting is a means for producing a  cavity  in  the
casting  without the use of a core.  The production of pipe by this process
is well  known,  but  the  method  is  also  used  for  making  many  other
cylindrical castings, from engine cylinder liners to large process rolls.

Investment Casting Operations

Investment  casting  uses  a  mold  that  is  produced  by  surrounding  an
expendable pattern with a ceramic slurry that hardens at room  temperature.
The pattern is usually wax or plastic and is melted or burned out leaving a
cavity, with very close tolerances, in the refractory material.  Investment
casting is also known as the "lost wax" or "precision casting" process.

In  sand  casting,  the  pattern  is usually wood or metal, and it makes an
impression or cavity in the sand.  In investment casting, a  metal  die  is
used  to  produce  the  wax  patterns.  These, in turn, produce the ceramic
mold.  Ceramic cores are used when needed, and these are expendable.

The wax is melted out in an autoclave  where  temperature  can  be  closely
controlled  and  all moisture in the ceramic backup material is eliminated.
Metal is poured into the molds and they are permitted to cool.  The mold is
pushed from its container and the ceramic is broken away.  Final  cleaning,
a  source  of  process  wastewater,  is  by  high  pressure water jets in a
hydroblast cabinet.  The casting is sent to the finishing department  where
heads and gates are removed.

Die Casting

In  most  die  casting  operations  a major source of wastewater is the die
casting machine hydraulic ore leakage, mold cooling water leakage,  casting
quenches,  and  mold  lubercant  spray.   These  waters  collect around the
machine base, and are contaminated by dirt, and oil and grease from various
fittings.
                                             *
In some operations (see Figure II1-3) where  the  casting  quench  tank  is
located  beneath  the  machine,  these  waters  drain into the quench tank.
Other plants segregate the process wastewater streams.

o    Die Lubes

     In die casting, the application of lubricants to the die cavity  is  a
     necessary  and  often  critical process.  Lubricants prevent a casting
     from sticking to the die, and also provide  a  better  finish  to  the
     casting.   The  correct  lubricant  will  permit  metal  to  flow into
                                    27

-------
    cavities that will not otherwise  fill properly.  A  secondary   function
    of a  lubricant  is the cooling of  the die.

    Selection  of   a  lubricant  is  based on  the  melting temperature of the
    metal, operating temperature of the die  surface  and  the   alloy  being
    cast.   No  one lubricant  will   be  suitable   for  all   die  casting
    applications.   Sometimes  two or three different  lubricants are  needed
    to achieve increased productivity.

    When  molten metal contacts an oil type  lubricant some of  the  lubricant
    decomposes  and leaves   a powder of carbonaceous materials on the die
    surface.  This  can be removed from the  die surface  with  an  air  jet.
    When   the  correct   lubricant is  used,  enough of it remains on the die
    for  the production of several more castings.

    Moving die parts, such as ejectors and  cores, must  be treated  with  a
    high   temperature   lubricant  to   prevent  seizure.   Oil suspensions of
    graphite  are  usually used.   Many   of  these   compounds  are  carefully
    developed  for  specific  machines  and represent  a considerable expense.
    The  placement,  recovery  and  reclaimation  of these  materials  is  an
     important  phase of  the die  casting  operation.   Several plants have
    segreated  their waste  streams  and  enacted die   lubercant   recovery
    processes.

Continuous Casting

Billets,   logs or  slabs are continuously  cast  by  pouring at a controlled
rate the  molten metal into one end of  a water cooled mold and withdrawing a
solid  piece from  the other end of the  mold.   The  solidified  metal  may  or
may  not  be immersed into quenching  water.   The cast piece is then cut into
lengths for further  processing.

Continuous casting is used  in operations  where a  slab,  billet, log  or  rod
is  "worked"   to   produce a   final  product.  Large tonnages of metals are
produced  by this  method,  and  the   casting  is  only   an   intermediate  step
between the molten metal  and  the  final product.


Casting Quenches

In  some  instances  certain  metal grain structures that  are obtainable only
through sudden thermal  changes are desired  in a casting.  In  these  cases,
the  operator will quench the casting  in  a  water  bath.   This water bath may
be plain  water  or   may  contain  an   additive  to   promote  some  special
condition.  The additive is  a very minor  part of  the bath.

Casting  quenching  is  practiced  more  frequently   in  nonferrous than in
ferrous foundries.  This is  due to  a   desire  to  cool   and  solidify  the
casting quickly,  more than  to promote  a grain structure change.  Nonferrous
                                    28

-------
foundries  are  predominantly  die casters.  A quench operation immediately
after ejection of a die cast part, will solidify the metal quickly,  reduce
the machine cycle time, and increase production.  Many aluminum die casting
plants  have  replaced the quench with a runout table on which the castings
air cool.  Depending upon the configuration of the casting, zinc  die  cast
material  may  sag and not retain the desired specifications if air cooled.
Therefore, the trend to eliminate  the  quench  and  its  associated  water
pollution problem has not been as prevalent in the zinc die casting area as
in the aluminum die casting area.

Mold Cooling                                                    »

Where  permanent  molds  are  used  in  the  casting  process,  it is often
necessary to force cool the molds with water sprayed or  flushed  over  the
mold.   This water becomes a process wastewater, and contains contaminating
materi-als picked up from the molds.  The centrifugal casting of pipe is  an
example  of  mold cooling.  Only  large foundries are engaged in the casting
method as indicated by Table II1-5.


Slag Quench

Most melting operations produce a slag  or  dross.   This  generally  is  a
mixture  of  non-metallic  fluxes  introduced with the "charge" to act as a
scavanger to remove the impurities from the molten  metal.   This  slag  is
removed  from the molten metal and cooled for disposal, or for reclaiming of
metal.    In ferrous foundries the amount of slag produced requires disposal
on a large scale.  Where the slag is  continuously  produced,  i.e.,  in  a
cupola   operation,  the  slag is  quenched  in a water stream to rapidly cool
and fragmentize  it to an easily handled bulk material.  The quench water is
a process wastewater.

In nonferrous foundries the slags generated are handled without producing a
process  wastewater.

Sand Washing

In the many plants which use sand as a molding media,  the  reclaiming  and
reuse  of  the sand is a major operation.  Three methods of reclaiming sand
are  in general use; dry, wet and  thermal.

The dry  method has several sub-methods that  generally   include  screening,
lump breaking, and cooling before reuse.   These processes usually produce a
dust  from  the  handling  of  the sand, but no process wastewaters results
unless a wet dust collecter  is used.

The wet  method has several variations of making a slurry of sand and water,
agitating or stirring  this slurry to cause the sand grains to scrub against
each other to remove particles of burnt clay, chemical binders, sugar, wood
                                     29

-------
fiber, etc.  that adhere to the sand grains.  The  slurry  is  pumped  to   a
classifier for separation of the fine materials.  The sand  is then dried.

The  thermal  method  involves  heating  the  sand to 1200-1500°F in air  to
remove carbonaceous material.  Some clay may also be removed by abrasion  of
the  sand  grains  as  they  travel  through  the  process.   The   thermal
reclamation process does not produce a process wastewater.

The  wash  water used in wet reclamation contains considerable contaminants
in the form of fine silicate material, spent clay and other pollutants.   To
economize on water use, this water can and has been clarified and  returned
to the salrid washing system.

Several  examples  of water reclamation from wet sand reclamation processes
are found in the data.
Magnesium Grinding Scrubbers

Finely divided particles of magnesium can react violently  in   air.    It   is
mandatory  that  magnesium  dusts  be  wetted  to  prevent  this  reaction.
Therefore, all dusts produced in cleaning, sawing,  grinding   or  machining
are  collected  in  a  scrubber.   The water spray coats the dust laden  gas
stream and wets the magnesium particles eliminating the fire hazard.

Scrubbers on grinding or sawing dusts can be  several  types   as  described
previously.  f  Where   practicable,  the  dusts  from  such  metal  working
operations can be salvaged and remelted.
                                     30

-------
                                                       TABLE III-l
                                              Distribution Of Plants
CO
A1uminum
Copper
Iron and Steel
Magnesium
Zinc

TOTAL
Less than
10 employees
Wet
9
9
1
1
9
Dry
316
217
66
1
74
10-49
empl oyees
Wet
83
14
149
1
35
Dry
401
352
377
3
124
50-249
empl oyees
Wet
55
42
418
5
22
Dry
85
65
269
1
87
Greater than
250 empl oyees
Wet
22
16
229
0
12
Dry
4
0
55
0
7
TOTAL
Wet
169
81
797
7
78
Dry
806
634
767
5
292
                                29
674
282  1257
542   507
279
66
1132  2504

-------
                                     TABLE  III-2
                    Percentage of Plants with Process Wastewater
CO
ro
Aluminum Casting
Copper and Copper
  Alloy Casting
Iron and Steel Casting
Magnesium Casting
Zinc Casting
Les
10


ng


s than
empl oyees
2.77%
3.98%
1.49%
50%
10.84%
10-49
empl oyees
17.15%
3.83%
28.32%
25%
22.0%
50-249
empl oyees
39.28%
39.25%
60.84%
83.33%
20.18%
Greater than
250 employees
84.46%
100%
80.63%
0%
63.16%

-------
                                          Table II1-3

                                 FOUNDRY LOCATION BY REGION
                                   (Number of Foundries)
                                                Major  Metal   Cast
Region
New Eng'land
Mid-Atlantic
Great Lakes
Plains
South Atlantic
£ East South Central
Weat South Central
Mountain
Pacific
Total
Gray
Iron
77
188
386
141
101
89
80
27
	 77
1.166
Ductile
Iron
3
9
20
8
7
13
9
1
n.
81
Steel
23
79
126
31
21
16
38
16
64
414
Malleable
Iron
5
16
29
3
1
1
1
0
_0
56
Aluminum
88
188
471
149
83
42
109
25
231
1,386
Zinc
27
74
141
26
15
7
10
6
=35
341
Copper
Base
85
168
219
54
40
21
46
16
100
749
Magnesium
1
2
7
1
1
0
1
0
_5
18
Other
Metals
28
46
54
7
8
3
6
3
18
173
All
Metals
337
770
1,453
420
277
192
300
94
541
4,384
Source
Penton Publications

-------
Year

'67
 68
 69
 70
 71
 72
 73
 74
 75
 76
 77
 78
                                                   TABLE 111-4

                                      FOUNDRY  SHIPMENTS  IN  THE UNITED STATES

Gra
13,
14,
14,
12,
11,
13,
14,
14,
10,
11,
12,
12,



y Ductile
466
097
679
338
728
494
801
459
621
935
291
524
863
1,
1,
1,
2,
1,
2,
2,
1,
2,
2,
2,
033
254
607
111
835
246
202
824
243
702
868

Malleable
1,131
1,007
1,172
852
884
960
1,031
914
730
846
829
816
Tons
x 10+3
Steel
1
1
1
1
1
1
1
2
1
1
1
1
,857
,730
,897
,724
,583
,609
,894
,090
,937
,803
,718
,862

Al
767
794
849
753
787
926
1,013
869
687
921
1,005
995

Cu
483
396
426
375
352
381
389
337
256
274
289
283

Mji
20
21
21
17
22
21
22.
24.
15.
19.
24.
22.








5
3
7
5
9
4

2n
419
426
439
348
368
400
453
346
286
345
329
274
   Total

Tons x 10

19.0
19.5
20.8
18.0
17.8
19.6
21.8
21.2
16.3
18.4
19.2
19.6
                                                                                                            -6

-------
                         Figure III-l
 20.000 r-
    1956             1961
Sni'RCES: DEPARTMENT OF COMMERCE
1966
                1971
                                1976
         CASTTMETALS PRODUCTION-(THOUSANDS ORTONS) AT 5-YEAR INTERVALS.
         195^1976
                                     35

-------
                                Figure  III-2
  1800
  1600
  1400
  1200
I 1000
Z
   300
   600
   400
   200
                                                SMALL IRON  FOUNDRIES
                                                 (100 or  Last  Employees)
                                                MEDIUM  IRON FOUNDRIES
                                                   (100-500 Employees)
                      LARGE IRON FOUNDRIES
                       (500 or Mora  Employee])
      1960      19«1
SOURCE.  A. T. K««mv;
1963
          1965
                     1967
                               1969
                                         1971
                                                   1973
                                                              1975
                           IRON FOUNDRY TRENDS IN THE UNITED STATES
                                             36

-------
    POUR
     I
   COOLING
     I
   3HAKEOUT
   CASTING
     I
HEADS 8 GATES
  CUT - OFF
     I
  CLEANING
  INSPECTING
     I
  FINISHING
     T
   PRODUCT
 TO INVENTORY
MOLD
CORES
                  H    SAND RECLAIMING
           ENVIRONMENTAL  PROTECTION  AGENCY
                 FOUNDRY INDUSTRY STUDY
                  PRODUCT FLOW DIAGRAM
                I       I        I
FIGURE 3E-3

-------
METAL


POURINO
STATION
CO
co
                                                                CERAMIC
                                                                BACK-UP
                                                                MATERIAL
                                          SOLIDS TO
                                          LANDFILL
                                               WATER
                                                                                                                                   DISCHARGE
                                                               CASTINGS TO
                                                                FINISHING
                                                               DEPARTMENT
SOLIDS TO
LANDFILL
                                                                                                         ENVIRONMENTAL  PROTECTION  AGENCY
                                                                                                              FOUNDRY INDUSTRY STUDY
                                                                                                                INVESTMENT FOUNDRY
                                                                                                              PROCESS FLOW DIAGRAM
                                                                                                                              FIGURE  IH-4

-------
Exhous)
                -Wolcr
                                                                      Pit Costing WoUr
                                                                                                COOLING
                                                                                                 TOWER
                                                                     _.„ ~DIE CASTING
                                                                     RAM 0 MACHINE
  Oil
Disposal
                                                                                                    TRIM
                                                                                                   MACHINE
                                                                                                    Scrap
                                                                                                             To Finithing
                                                                                                             D«parliMnl
                                                                                               ENVIRONMENTAL PROTECTION  AGENCY
                                                                                                    FOUNDRY  INDUSTRY STUDY
                                                                                                    ALUMINUM DIE CASTING
                                                                                                    PROCESS FLOW DIAGRAM
                                                                                                                      FIGURE  Iff- 5

-------
-pa
O
1
iEihautl

FUME * WUU<

Pifl
1 Foundry Scrap
| — "
1
f
. 	 	 MFI TINO FURNACFS
i
... . JUulllpU Unlli)
\ 7
\ 1 III ,WM. _
\ /^ I 1 ll
— ' ^ \ /T ITII I rnMTiMinii': DIRFCT PI

' 	 ^ * MOLDS CASTING CHILL
MOLDS


i
LRMAr
MOLC
/,-,/ 1 * S.
• ' v ' \— F
1 < 1
SHEET. STRIP, BAR. ROD
a WIRE MILLS
(Non- Foundry)


^ WASTE WATER ^ Woslewoter S«w«rt
TREATMENT
1
Recycle
Solids
Oitpotol

Wol«r '
1
IE«hou«t
4 	 ;
JENT 1 SAND
>S DUST * 	 M°LDS
COLLECTOR ,
1 •- •• Callings
<•>— Sond
1
/^SANOV






ENVIRONMENTAL PROTECTION AGENCY
FOUNDRY INDUSTRY STUDY
COPPER S ALLOYS
PROCESS FLOW DIAGRAM
I- Jrifti inF TTT fi


-------
                                                                        Wafer
           Water
Landfit
                                                          HDD BS
                                                                                                  ENVIRONMENTAL PROTECTION AGENCY

                                                                                                       FOUNDRY INDUSTRY STUDY
                                                                                                          FERROUS FOUNDRY
                                                                                                       PROCESS FLOW DIAGRAM
      Discharge or
       Recycle
                                                                                                                        FIGURE Iff 7

-------
-p.
ro


"11
MOLDS

!
                                             Sand Return
                                                                                                           ExhOuit
                                                                                                Waslewoler  Tr«atment
                                                                                                    or  Discharg*
                                                                                                            ENVIRONMENTAL  PROTECTION  AGENCY
                                                                                                                 FOUNDRY  INDUSTRY  STUDY
                                                                                                                   MAGNESIUM FOUNDRY
                                                                                                                  PROCESS FLOW  DIAGRAM

                                                                                                                        I     —[FIGURE

-------
CO
Watttwotv _ . .



•litth
MELTER
| T 0* L«* Sproy

1
I If
c
COOLING
TOWER
1 1 " — — v
' | ' \ Oi« Cooling (NC)
1 , 	 \
% HOLDING |f "!
^ FURNACE 	 |j_ J
4 	 ...j. . f
'/ss///rf////7/M
_ flV__J
1 '
^H

DIE LUBE TANK Li 	
IV)
* •--
* QUENCH
WASTEWATER nrCIIARCC OR
TREATMENT RECYCLE

DISPOSAL LANDFILL
|"l i 	 »OIE CASTING
'IH^M^ACH,^
\ \

TRIM
— 1 Catting ^ )' { ) MACHINE
^-/^ 1
(\^ *
SCRAP
TANK
»TO FINISHING
DEHVRTMENT
ENVIRONMENTAL PROTECTION AGENCY
FOUNDRY INDUSTRY STUDY
ZINC DIE CASTING
PROCESS FLOW DIAGRAM
	 _ 	 „_ ripi inir TIT- 0


-------
                                                               Purge
                                                               Damper
                                                                                               SlocK
                                                                                                                       Bypass
                                                                                                                       Doni pec
STORAGE
BINS
                                                                           COMBUSTION
                                                                            AIR BLOWER
                                                                                             ENVIRONMENTAL  PROTECTION AGENCY
              EXHAUST GASES

              BLAST AIR
FOUNDRY  INDUSTRY STUDY
  IRON FOUNDRY CUPOLA

 PROCESS FlOW DIAGRAM
                                                                                                                   IFIGURE  nr-io

-------
                 -4 gpm/IOOO cfm
                              Verlicol
                              Lift Door
                                                               WET TOP
                                                               DUST COLLECTOR
                                Charge
                                Opening	—••
                                                                              I Blower
           Make-Up
            Waler
DRAG TANK
WET  DUST
REMOVAL
SYSTEM
                                                                                      ENVIRONMENTAL  PROTECTION AGENCY
                                                                                           FOUNDRY  INDUSTRY  STUDY
                                                                                             IRON FOUNDRY CUPOLA

                                                                                           PROCESS FLOW DIAGRAM
                                                                                                             FIGURE  in 11

-------
                                  TABLE II1-5

                                 MOLD COOLING
Plant Code

  4409
  8944
 1M73
 11*580
 11865
 177^6
 1891*7
Emp. Group

    50-249
    >250
    >250
    >250
    >250
    >250
    >250
Metal

Gray
Ductile
Ductile
Ductile
Gray
Gray
Ductile
Product
   Pipe
   Pipe
   Pipe
   Pipe
   Pipe
   Pipe
Casting Process

  71% Centrifugal
  97% Centrifugal
  86% Centrifugal
  100% Centrifugal
  60% Centrifugal
  84% Centrifugal
  100% Centrifugal

-------
                                SECTION IV

                        INDUSTRY SUBCATEGORIZATION

INTRODUCTION

The foundry point  source  category  includes  a  number  of  distinctively
different  kinds  of  foundries  which  cast a variety of metals and employ
various  metal  molding  and  casting  techniques.   Foundries  which  cast
dissimilar  metals, employ different manufacturing processes, some of which
require air pollution control devices,  have  substantially  different  raw
waste characteristics and employ different process wastewater treatment and
control  technologies.   The foundry point source category is therefore not
amenable to a single set of effluent limitations and  standards  applicable
to all foundries.

Instead,  the  foundry  category  is amenable to a subcategorization scheme
which provides for the grouping of foundries  which  cast  similar  metals,
employing  similar  manufacturing  processes,  have  similar sources of air
pollution which require control, and as  a  consequence  have  similar  raw
waste     characteristics.     Appropriate    subcategorization,    through
consideration of the factors  enumerated  in  this  section,  assures  that
plants  grouped  into  a  subcategory  are  sufficiently similar in various
characteristics that a reasonable comparison of similar  plants  and  their
treatment performances can be made.  The subcategorization scheme developed
allows  the  application  of  a  uniform  set  of  effluent limitations and
standards of performance for each subcategory and subcategory segment.

SELECTED SUBCATEGORIES

Based on the findings  detailed  in  this  section  and  supported  by  the
discussions  in Sections III, V, and VII, the subcategories and subcategory
segments of the foundry point source category  established  for  developing
effluent limitations and standards of performance are:

1.   Aluminum Casting
     a.  Investment Casting Process
     b.  Melting Furnace Scrubber Process
     c.  Casting Quench Process
     d.  Die Casting Process
     e.  Die Lube  Process

2.   Copper Casting
     a.  Dust Collection Scrubber Process
     b.  Mold Cooling and Casting Quench Porcess
     c.  Continuous Casting Process
                                     47

-------
3.    Iron and Steel Casting
     a.  Dust Collection Scrubber Process
     b.  Melting Furnace Scrubber Process
     c.  Slag Quenching Process
     d.  Casting Quench and Mold Cooling Process
     e.  Sand Washing Process

4.    Magnesium Casting
     a.  Dust Collection Scrubber Process
     b.  Grinding Scrubber Process

5.    Zinc Casting
     a.  Melting Furnace Scrubber Process
     b.  Casting Quench Process

SUBCATEGORY DEFINITIONS

Aluminum Casting - the remelting of aluminum or an aluminum alloy  to  form  a
cast   intermediate  or final product by pouring or forcing the molten metal
into a mold except for ingots,  pigs,  or  other  cast  shapes  related  to
primary  metal  smelting.   Manufactuirng  processes  associated   with  the
casting of aluminum which result in a process wastewater are:

     a.   Investment Casting Process - The casting of aluminum or   aluminum
     alloys  by  investment  casting  teachniques  involving  mold backup,
     hydroblast cleaning of castings and the collection of dusts   resulting
     from  the hydroblasting of castings and the handling of  the investment
     material.  This operation is also known as the lost wax  process,   lost
     pattern, hot  investment and precision casting.

     b.   Melting  Furnace Scrubber Process - Those  air  pollution control
     operations  which  clean  dusts  and  fumes  resulting   from  a melting
     furnace through the use of water or process wastewater as  a   cleaning
     medium.

     c.   Casting  Quench Process - Those operations in which  a  casting  of
     elevated  temperature  is immersed in a liquid bath for  the purpose of
     rapidly decreasing the temperature of the casting.

     d.   Die Casting  Process  -  These  operations  associated   with  die
     casting  in   which  sources  of  process wastewater are  collected in  a
     common container.  Such sources of  wastewater   include:  die surface
     cooling  sprays,  hydraulic  fluid  leakage,  splash over from casting
     quench, and leakage from non contact cooling water associated with  the
     die  casting  equipment  which  becomes  contaminated  due  to  common
     collection with process wastewaters.

     e.   Die Lube Process - Those operations associated with die casting
     which   involve  the sparying of  a liquid containing mold  release  agents
                                     48

-------
     onto the die  surface  or  die  head  and  the  subsequent  segregated
     collection of the liquid.

Copper  Casting  -  The  remelting of copper to form a cast intermediate or
final product by pouring or forcing the molten metal into a mold except for
ingots, pigs or other  cast  shapes  related  to  primary  metal  smelting.
Manufacturing  processes associated with the casting of copper which result
in a process wastewater are:

     a.   Dust Collection Scrubber Process - Those  air  pollution  control
     operations  which  clean  dusts  resulting from sand preparation, sand
     molding processes, core making  processes,  sand  handling,  and  sand
     transfer  processes,  the  removal of sand from the casting, and other
     sand related  dust  sources  thorugh  the  use  of  water  or  process
     wastewater as a cleaning medium.

     b.   Mold Cooling and Casting Quench Process - Those operations, other
     than processes associated with continuous  casting,  associated   with
     the  application  of  contact cooling water on metalic molds and those
     operations in which a casting is immersed in a liquid  bath,  for  the
     purpose of rapidly decreasing the temperature of the casting.

     c.   Continuous Casting Process - Those operations in which a  casting
     is  produced  by  the  solidification  of  the liquid metal in a water
     cooled metalic mold while passing through the  mold  at  a  controlled
     rate  and  into  a  quench  solution.   Methods  of continuous casting
     considered in this report are: wire bar casting, direct chill casting,
     and continuous casting wheel processes.

Iron and Steel Casting - The remelting of ferrous metals  to  form  a  cast
intermediate  or  finished product by pouring the molten metal into a mold.
Manufacturing processes associated with the casting of iron and steel which
result in a process wastewater are:

     a.   Dust Collection Scrubber Process - Those  air  pollution  control
     operations  which  clean  dusts  resulting from sand preparation, sand
     molding processes, core making processes, sand handling  and  transfer
     processes,  the  removal  of  sand  from  the  casting (including shot
     blasting), and other sand related dust  sources,  and  pouring  floor,
     pouring  ladle, and transfer ladle fumes when collected in an air duct
     system common with sand dusts, through the use  of  water  or  process
     wastewater as a cleaning medium.

     b.   Melting Furnace Scrubber Process - Those  air  pollution  control
     operations  which clean dusts and fumes resulting from melting furnace
     operations, or which clean pouring floor, pouring  ladle  or  transfer
     ladle  dusts and fumes when collected in a air duct system common with
     the melting or holding furnace fumes, thorugh  the  use  of  water  or
     process wastewater as a cleaning medium.
                                     49

-------
     c.    Slag Quench Process - Those operations in which furnace slage  is
     cooled or sluiced through the use of water or process wastewater.

     d.    Casting Quench  and  Mold  Cooling  Process  -  Those  operations
     requiring  the  application  of  cooling water directly on the casting
     mold and those operations in which a casting is immersed in  a  liquid
     bath  for  the  purpose  of  rapidly decreasing the temperature of the
     casting or for imparting desired metallurgical properties.

     e.    Sand Washing Process - Those operations in which  spent  sand  is
     reclaimed for reuse by washing the sand to remove impurities.

Magnesium  Casting - The remelting of magnesium to form a cast intermediate
or final product by pouring or forcing the molten metal into a mold  except
for  ingots,  pigs, or other cast shapes related to primary metal smelting.
Manufacturing processes associated with  the  casting  of  magnesium  which
result in a process wastewater are:

     a.    Dust Collection Scrubber Process - Those  air  pollution  control
     operations  which  clean  dusts  resulting from sand preparation, sand
     molding processes, core making processes, sand handling  and  transfer
     processes,  the  removal  of  sand  from  the  casting, and other sand
     related dust sources through the use of water or process wastewater as
     a cleaning medium.

     b.    Grinding Scurbber Process - Those air pollution control and  fire
     retardant  operations  which  clean and trap magnesium dusts resulting
     from the cleaning, abrading, or grinding of the casting following  its
     removal from the mold medium.

Zinc  Casting  - The remelting of zinc to form a cast intermediate or final
product by pouring or forcing the molten  metal  into  a  mold  except  for
ingots,   pigs, or other cast shapes related to primary metal smelting.  The
manufacturing processes associated with the casting of zinc which result in
a process wastewater are:

     a.    Furnace Scrubber Process - Those air pollution control operations
     which clean dusts and  fumes  resulting  from  a  melting  or  holding
     furnace  through  the use of water or process wastewater as a cleaning
     medium.

     b.    Casting Quench Process - Those operations in  which  castings  at
     elevated temperatures are immersed in a liquid bath for the purpose of
     rapidly decreasing the temperature of the casting.

SUBCATEGORIZATION BASIS

With  respect  to   identifying   the relevent and discrete subcategories and
subcategory segments for the foundry point source category,  the  following
                                    50

-------
factors were considered:

 1.  Type of metal cast
 2.  Manufacturing process
 3.  Air pollution sources
 4.  Water use
 5.  Process wastewater characteristics
 6.  Raw materials
 7.  Process chemicals
 8.  Wastewater treatability
 9.  Plant size
10.  Plant age
11.  geographic location
12.  Non-water quality aspects; solid waste generation and
       disposal, energy requirements

Type  of  metal  cast  and manufacturing process form the framework for the
selected subcategories.  Many of  the  other  factors  provided  additional
support  to  the  subcategorization  scheme.  These other factors including
process  wastewater  characteristics  helped   to   delineate   the   final
subcategories  and  are  reflected  in  the  subcategories  and subcategory
segments developed.

Rationale for Subcateqorization - Factors Considered

Type of Metal Cast

The type of metal cast forms the principle basis for  subcategorization  of
the  foundry  point source category.  Metals differ, among other things, in
physical and chemical properties.  While ferrous metals are all  alloys  of
iron,  non-ferrous  metals  i.e.,  aluminum, copper, lead, magnesium, zinc,
etc. differ among themselves in physical and chemical  aspects  and  differ
substantially from the alloys of iron in many aspects.

In  addition,  these  inherent  differences  in  the  physical and chemical
properties of the various types of metals cast result  in  a  diversity  of
manufacturing  processes,  process  chemical use, sources of air pollution,
water  use,  and  process  wastewater  characteristics.   As  seen  in  the
technical  findings of this study, the type of metal cast affects the kinds
and quantities  of  metal  toxic  pollutants  present  in  foundry  process
wastewater.  Additionally, the type of metal cast indirectly influences the
type  and  quantities  of  organic  toxic  pollutants  present  in  process
wastewaters.  Different casting techniques are used with  different  metals
and  different  casting  techniques  require  the  use of different process
chemicals.  The binders or chemical additives  used  in  sand  casting  are
substantially  different  than those process chemicals used as mold release
agents in die casting operations.
                                    51

-------
As might be reasonable anticipated,  zinc  was  detected   in  much  greater
concentrations  (350  mg/1)  in  the  process  wastewater  from zinc casting
processes than that amount of zinc  (1.3 mg/1) detected  in  process  waste-
waters  from  aluminum  casting  operations.   The  presence  of  lead  was
quantified in the majority of the process wastewater streams  sampled   from
ferrous  casting  processes  while  lead  was  not  detected  in the process
wastewater from zinc casting processes.  In  addition, the  concentration  of
lead was determined to be  greater  (140 mg/1) in the process wastewater  from
ferrous  foundries  than   that  amount determined  (2.0 mg/1)  in the process
wastewater from aluminum casting processes.

Copper was characteristically found in greater concentrations (110 mg/1)  in
the process wastewater from copper  casting processes  than the   amount  of
copper  detected  in  the  process  wastewater from the casting of any other
metal type under study.

Examination of the data indicates  that differences in alloys  of  the   same
base  metal  were  not  of  sufficient magnitude to subcategorize by alloy.
This  is most apparent in the ferrous casting subcategory where  differences
in  raw  waste characteristics, manufacturing processes, process  chemcials,
etc., among gray iron, malleable,  ductile, and  steel  foundries  were  not
substantive to support subcategorization by  alloy.  In addition,  since  many
foundries  cast  a  wide   range  of alloys of a particular base metal,  e.g.
aluminum and zinc, the application  of effluent limitations and standards  to
each  alloy would be impracticle.

Subcategorization based on waste characteristics was considered.   However,
a  review  of  each of the remaining factors reveals that  the type of metal
cast, the manufacturing process and the subsequent  process   chemical   use,
affects  the  process  wastewater   characteristics of plants  in the  foundry
category.  Subcategorization by metal  type,  therefore,   groups  foundries
reasonably well and inherently considers process wastewater characteristics
and other pertinent factors.

 In  addition  to being apparently  technically reasonable,  subcategorization
by  metal type provides a   practicle methodology   for  the application  of
effluent limitations and standards of performance  to specific foundries and
plants   engaged  in metal molding and casting.  It  is easy  to  identify which
subcategory  limitations and standards apply  to  which  plants  since   many
plants   cast  only  one  metal.    In  fact,  many  company names  explicitly
 identify the  type of metal the company casts.

 In  those  instances where a plant casts  more than  one  metal,   the manu-
 facturing   processes,   equipment,   and  pollutant  sources  are   usually
segregated by  metal   type.   A  specific  melting  furnace,   for  example,
exclusively   melts only one metal  to avoid cross contamination  with  another
metal.   Manufacturing  processes are designed to  handle only one metal   type
without  extensive  overhaul  or   rebuilding.    Many of  these manufacturing
processes, die casting  for example, require  the  use of   speciality   process
                                     52

-------
chemicals  designed  for  very  specific applications and fpjr use with very
specific metal types.

As would reasonably be expected, there is a close interrelationship between
type of metal cast (and  the  subcategories  derived  from  them)  and  the
factors  of  manufacturing  processes,  process  chemicals,  raw  material,
process wastewater characteristics, and air pollution source  as  described
below.

Manufacturing Process

Consideration  of  the various manufacturing processes helped to refine the
subcategorization scheme.  Subcategories based on metal type  were  further
segmented  where necessary to allow for dissimilar manufacturing processes.
This would in turn account for differences  in  water  use  and  dissimilar
process wastewater characteristics.

Many  manufacturing  processes  are   unique to the type of metal cast.  The
data  indicate that slag quenching  is  only associated with  the  melting  of
ferrous  metals.   Other  manufacturing  operations vary depending upon the
type of metal being processed.  A  cupula furnance is a unique source of air
pollution with characteristic emissions which are  controlled  by  wet  air
pollution  control  devices and, therefore, a source of process wastewater.
Casting techniques also differ depending upon the metal.  Aluminum and zinc
castings are frequently produced   by  die  casting  methods  while  ferrous
metals are not.

Not   all  manufacturing  processes result  in  a process wastewater.  Con-
sideration of manufacturing process helped  to  distinguish  between  those
processes  which  result  in  a  process wastewater and those which do not.
Examination of the data reveals that  a  manufacturing  process  may  be  a
process  wastewater  source in one of two ways; 1) use of water directly in
the process and 2) through the use of water in  an  air  pollution  control
device   associated   with   the   manufacturing  process.   Discussion  of
subcategorization supported by consideration of  a  air  pollution  control
source is deferred until later.

Manufacturing  processes  which  produce a process wastewater directly are:
for aluminum casting; investment casting process, casting  quench  process,
die   casting  process,  and  die   lube  processes, for copper casting; mold
cooling and casting quench process, and  continuous  casting  process,  for
ferrous  casting;  slag  quenching process, casting quench and mold cooling
process, and  sand  washing  process,  for  zinc  casting;  casting  quench
process.

Though  some  manufacturing processes are significantly different depending
upon  the type of metal, some manufacturing processes similar in design  and
function are associated with the casting of different metals.  For example,
aluminum  and  zinc  castings  may be formed through a similar die casting
                                     53

-------
process.  Where similar manufacturing processes associated  with  different
metals  were  encountered  process  chemical  usage  and process wastewater
characteristics were examined to determine any additional basis of  support
for  a  subcategorization  scheme  based  on  the  type  of  metal cast  and
manufacturing process.

Consideration of the type of metal cast and  the  associated  manufacturing
process helped to identify sources of process wastewater and group the data
by  manufacturing process for further analysis.  In  instances where process
wastewater streams are not the result of direct contact  with  the  process
and  where  different  metals  are processed on similar manufacturing units
other factors were considered as described below.

Air Pollution Sources

Certain manufacturing  processes  are  characteristically  sources  of   air
pollution.   In  many  instances  wet  air  pollution  control  devices  are
associated with these specific operations.

Those manufacturing processes which produce a process  wastewater  via   air
pollution  control  are:   for  aluminum  casting; melting furnace scrubber
process, for copper casting; dust collection scrubber process, for  ferrous
casting;   dust  collection  scrubber  process,  melting  furnace  scrubber
process, for magnesium  casting;  dust  collection   scrubber  process,   and
grinding scrubber process, for zinc casting; furnace scrubber process.

Since   wet  air  pollution  control  equipment  is   unique to certain manu-
facturing  processes,  those  operations  are  differenciated  from   other
manufacturing  operations  and  from  other  process wastewater sources as
previously described.  Consideration of air  pollution  sources  helped   to
further   substantiate   the   manufacturing   process  segments  for  each
subcategory.

Process Water Usage

The decision to use water as part of a manufacturing process or as  an   air
pollution  control  mechanism depends on many factors.  The volume of water
used  is primarily dependent upon the manufacturing process,  air  pollution
control device, the cost and availability of water,  and most significantly,
the plant water management practices.  The effects of manufacturing process
and   air  pollution   control  are implicitly reflected in the subcategories
developed.  Plant water management practices vary from plant to  plant   and
therefore,  for  the  reasons  mentioned above, process water usage was  not
considered to be an appropriate basis for subcategorization.

Process Wastewater Characteristics

While there are  many  inherent  similarities   in  raw  wastewater  charac-
teristics  and  treatability  between  subcategories,  there  are also sig-
                                     54

-------
nificant differences.  As a consequence, this factor was very important  in
supporting the established subcategories as discussed earlier.

The  type  and quantity of pollutants differ in the process wastewater from
similar manufacturing process.  The die casting of  aluminum  and  zinc  is
performed  on  similar  die  cast equipment.  However, zinc was found at 40
times the concentration in zinc casting quench solutions  than  that  which
was  found  in  aluminum  casting  quench  solutions.   More  organic toxic
pollutants were detected at concentrations  above  0.10  mg/1  in  aluminum
casting  quench  solutions  than detected in zinc casting quench solutions.
In addition, to supporting subcategorization by metal  type,  consideration
of wastewater characteristics helped to differentiate similar manufacturing
operations used to process different metals.

Raw Materials

Raw  material  composition  was found to significantly influence wastewater
characteristics.  This effect is predominantly the result of the  the  type
of  metal  being  cast.   The  production  of  a  zinc casting for example,
initially begins with the use of a zinc raw material in the charge  to  the
melting furnace.

Because   of  this,  raw  material  usage  is  implicitly  reflected  in  a
subcategorization scheme based on the type of metal cast.

Process Chemicals

Major process chemicals used  in the manufacture of  castings  fall  into  2
general  classes;  those  associated with sand casting and those associated
with die casting.  This distinction  helped  to  further  substantiate  the
subcategorization  scheme.   Process chemicals associated with sand casting
techniques  include sand and core binders and  related  chemical  additives.
Several  of  these   process chemicals contain toxic pollutants or chemicals
which when exposed   to  hot  metal  temperatures  may  breakdown  to  toxic
pollutant materials.

Analysis  of  plant  data  indicate  the  use  of  a  wide variety of these
materials and at least 14 different chemical types of  sand  additives  are
commercially  available.   Review of the available literature indicates the
possible use of additional sand additives not explicitly identified by  the
plant  survey  data.   In  addition, 142 manufacturers or suppliers of sand
additives or binders were identified in the available literature.   On-site
visits  to  many plants indicated that more than one type of sand additivie
is often used simultaneously within the plant and that changes in  the  use
of the various products available occurs periodically.

Process  chemicals   associated with die casting include die lubricants, die
coatings and quench  solution  additives.   Twenty-eight  manufacturers  or
suppliers of these process chemicals have been identified.  These materials
                                     55

-------
are  used  to  prevent  castings  from adhering to the die and to provide  a
casting with improved surface characteristics.  Frequently  many  different
products  are  tried until a satisfactory lubricant or coating is found.   A
correctly chosen lubricant will allow metal  to  flow  into  cavities   that
otherwise may not be filled.

As  a  result  of  the use of the wide variety of process chemicals  and the
frequent change over of these products,  process  chemicals  used  was   not
found  to  be  useful  as  a  primary basis for subcategorization but was  a
supportive factory in the subcategorization scheme developed.

Process Wastewater Treatability

As  the  process  wastewater  characteristics  differ,   treatment    systems
designed  to  treat specific types of pollutants will differ.  Some  process
wastewaters will be  predominantly  oily  in  nature  while  other   process
wastewater  streams will be free of oil but will contain toxic metals.   The
treatment applications identified at plants during the development of   this
report  encompass systems ranging from no treatment to relatively extensive
treatment.   The  wastewater  treatment  systems  range  from  once-through
systems  discharging  to POTWs or directly discharging to navigable  waters,
to  100 percent recycle systems.  Since process  wastewater  characteristics
differ  among  waste  streams  from  different  manufacturing processes, as
discussed earlier, the different process segments implicitly  consider   the
various  treatment  technologies  and capabilities involved in handling the
different process wastewaters.   Thus,  wastewater  treatability  does   not
substantiate the need for further subcategorization.

Plant  Size

Plant  size  can' be  evaluated  by  two  methods;  number of employees and
production.  After collectively  evaluating   the  production  and  employee
group   information it was observed that the pattern which developed  did not
generally follow the pattern expected,  i.e.,  more   employees   results  in
greater  production.   Nor  was  there an identifiable relationship  between
size and process wastewater characteristics.

 It  was thus determined that employee  size  and  production  rate  have  no
quantifiable  relationship  with  the volume of process wastewaters produced.
No  discernible pattern developed when plant water usage  rates were compared
with plant  production rates and  employee  size.   However,  employee  size
grouping  remained  as  a   consideration  only  as  a means  of  providing
 convenient  BPT and BAT model sizes for further economic  evaluation.

Plant  Age

Some plants which have operated  at the same address for  over   one   hundred
years.   Some  plants  have replaced  melting furnaces  as  recently  as  five
years  ago and sand handling systems as recently as ten years ago.    Process
                                     56

-------
wastewater  treatment  equipment age also varied from thirty years for some
equipment  items  to  less  than  one  year  for  the  most  recent  system
installations or additions to older systems.

Based  on the above observations, and presentation of data in Section V, it
was concluded that age was not an appropriate basis for subcategorization.

Geographic Location

Plants engaged in metal molding and casting  are  located  in  all  of  the
industrial  regions  of  the  United  States.   None  of the available data
indicated that the location of a plant affected the type of metal cast, the
manufacturing process employed or other process wastewater characteristics.
The only pattern noticed is that the plants are generally located near  the
areas  which  will  use  their  products,  whether  they  are used by other
corporate entities or are sold to the  end  users.   Therefore,  geographic
location   was  not  considered  as  an  appropriate  factor  to  establish
subcategories.

Non-Water Quality Aspects: Solid  Waste  Generation  and  Disposal,  Energy
Requirements

These  factors  are  determined by wastewater characteristics and treatment
requirements.   They  are  implicitly  reflected  in  subcategorization  to
achieve   uniform   effluent   performance   capabilities.    The   process
subcategorization scheme chosen establishes groups with similar  wastewater
characteristics  resulting  in  common  solid  waste disposal requirements,
common energy use in waste treatment, and common non-water quality impacts.

Summary

The primary factor affecting  the wastewater characteristics  of  plants  in
the  foundry  point  source   category  is  type  of  metal cast and that an
additionally  important factor, is the type of manufacturing process used to
form  the  desired  casting.   These  two  factors  form  the   basis   for
subcategorization of the foundry point source category.  In addition, other
factors  considered,  such  as  process  chemical  usage, and air pollution
sources helped to support the subcategorization scheme developed.
                                             *
PRODUCTION NORMALIZING PARAMETER

Having selected the appropriate base for subcategorization, the  next  step
is  to  establish  a  quantitative  parameter on which to base limitations.
Since pollutants are measured in concentration  (mg/1), concentration  is the
obvious  first  consideration for   limitations.    However,   while   the
concentration of a pollutant  is an  intensive property of the wastewater,  it
is  not  an   intensive  property  of  pollution.  A plant which dilutes its
wastewater would have an advantage over water conserving plants in  meeting
concentration  limitations.   Thus,  a  plant might be penalized for  having
                                     57

-------
good water conservation practices by a concentration based limitation.    In
order  to  preclude  the  possibility  of  dilution,  the  concentration  of
pollutants in the discharge must be multiplied by the discharge  flow   rate
to  provide  a  mass  discharge  level  for each pollutant.  Since  the  mass
discharge level is  a  result  of  some  level  of  production,  this   mass
discharge level requires still another parameter to account for differences
in the actual production levels from plant to plant.  Such a parameter  must
establish   an   effluent  discharge  rate  relationship  that  changes  in
proportion to the level of production activity.  The following  discussions
deal  with  the  selection of this production normalizing parameter and the
application of this parameter for effluent limitations.

Selection of Production Normalizing Parameter

The  level of production activity in a plant can be  expressed  quantatively
as   the  amount  of metal poured, the amount of process chemicals consumed,
the  weight of castings shipped, or the number of employees.    In  addition,
in   those  instances  where  sand is used as the mold medium,  the amount  of
sand used can be an indicator of production activity.

The  technical findings indicate that the  use  of  two  production   related
parameters   is  appropriate.   These  two  parameters are; 1)  the weight  of
metal poured, and 2) the  weight  of  sand  used  in  molds  and  cores  in
instances where sand is used as the mold medium and where sand is reclaimed
by   washing  methods.   These  two  production  related parameters  are  more
closely  associated with the level of activity relative  to  pollutant   load
than any other potential parameters.

An   outline  of the rationale used in the selection of these two parameters
as well  as the dismissal of the other parameters  considered   is  described
below.

Weight of Metal Poured

The  weight  of metal poured readily lends itself as a reasonable production
normalizing  parameter  for  many  of  the  subcategories  and  subcategory
segments.

In   those  instances  where  a  furnace scrubber is used to control furnace
emmissions,  the  pollutants  become  waterborne  contaminants  during  the
furnace   emmission  cleaning process.  The emmissions are the  result of the
melting  and  heating of the raw materials which make up the furnace   charge.
On   first  consideration,  it  would  appear   to be appropriate to  base the
production   normalizing  parameter  on  furnace   charge.    However,   the
composition  of   the  furnace  charge  varies  from plant to plant.   This  is
particularly prevalent  in the  iron and steel subcategory.   The  ratios  of
coke,  scrap,   iron,  limestone, etc., varies widely among plants to produce
the  same amount of  iron or steel.  Therefore,  it would  be   impractical  to
                                     58

-------
apply  a  production  normalizing  parameter  on  such  a variable basis as
furnace charge.

The use of the weight of metal poured provides  a  consistant  and  uniform
parameter  for  applying  effluent limitations to a wide variety of plants.
In addition to its application to furnace scrubbers, its use with  all  the
other   manufacturing  subcategory  segments,  except  for  those  segments
associated  with  sand  usage,  the  weight  of  metal  poured  provides  a
technically reasonable and uniform basis for applying limitations.

Weight of Sand

In  those instances where sand is used as the mold medium, consideration of
the mechanisms by which pollutants  are  conveyed  from  the  manufacturing
process  to  the process wastewater leads to the selection of the amount of
or  weight  of  sand  as  a  production  normalizing  parameter  for  those
subcategories and subcategory sgements in which sand is used.  Sand used is
the  production  vector  which relates production activity to the amount of
pollutants in the process  wastewater.   Those  subcategories  are:  copper
casting; dust collection scrubber process, ferrous casting; dust collection
and sand washing processes, and magnesium casting; dust collection scrubber
process.

Processes  associate with sand usage, such as mold and core making, casting
shakeout and sand handling equipment, give rise to dusts  and  fumes.   The
contaminated  air   is  cleaned by scrubbers.  Therefore contaminants in the
air are transfered  to the water.  The volume of  air  passing  through  the
scrubbers  remains  at a constant rate while the mass of pollutant material
in the air stream changes with levels of  production  activity,  i.e.,  the
amount  of  sand  in  .use.   To  account  for  these  changes in production
activity, the amount of sand used leads to the selection of weight of  sand
as   a  production  normalizing  parameter  for  dust  collection  scrubber
processes.

In sand washing operations, sand comes into intimate contact with water and
as a result the water is contaminated.  The amount of sand  washed  affects
the process wastewater characteristics and leads to the selection of weight
of  sand  washed as a production normalizing parameter for the sand washing
subcategory segment.

Surface Area of Casting

Surface area was considered a possible production normalizing parameter for
those manufactuirng processes involving quenching  since  pollutants  enter
the  quench  water  through   intimate  contact  with the casting.  However,
surface area of a casting is a randomly changing value dependent  upon  the
variability  of  the  shape  and design of the castings being manufactured.
Therefore,  surface  area  is  not  a  meaningful  production   normalizing
parameter.
                                     59

-------
Number of Employees

AS  previously  indicated,  the  number  of  employees does not necessarily
reflect the production rate at  any  plant.   For  those  reasons  outlined
earlier  number  of employees does not constitute an appropriate production
normalizing parameter.

Weight of Final Product

The weight of final product is a readily available production  record,   but
its  application  as  a  production normalizing parameter has  a significant
drawback.

The weight of the casting  in final product form may vary substantially  from
the castings initial weight when  it  was  poured.   Casting   weight   is  a
maximum  when  the  casting  is  first  formed, i.e.,  immediately  after the
introduction of the molten-metal into the mold.  At this point, the casting
has the gates, sprues, and risers attached and the total weight of all   the
castings  produced  per unit time, closely equates with the total  amount of
metal poured during that unit  of  time,  assuming  negligible metal   loss
through spills, etc.

The  major  reduction  in  weight occurs after the metal molding and casting
and supportive process steps (sand preparation, mold and core  making,   sand
washing,  etc.)  have occured.  This weight reduction  is due to the removal
of the gates, sprues, and  risers.  Weight  loss  can   be  as   little   as  5
percent  or  as  much  as  70  percent  of the initial total casting weight
depending upon the metal cast, the casting shape  and  the  volume of   the
gates, sprues and risers in the mold required to allow adequate flow of the
molten metal into the mold.

Additional  weight changes can occur when metal is removed during  machining
of the casting or when, for example, weight is added during  electroplating
or painting of the casting.

For   the  reasons  stated  above weight, final product  was not  found to  be a
suitable production normalizing parameter.

Process Chemicals Consumed

For the reasons stated in  the discussion  of  the  factors  considered   for
subcategorization, the variability of process chemicals consumed diminishes
 its usefulness as an  appropriate production normalizing parameter.
                                     60

-------
                                 SECTION V

                   WATER USE AND WASTE CHARACTERIZATION

INTRODUCTION

Process  water  usage for all subcategories within the foundry point source
category is a major factor in estimating pollutant loads, and in turn,  the
cost  of  the  removal of the pollutants.  But before a presentation of the
waste  treatment  costs  in  Section  VIII,  a  discussion  of  plant  data
collection, water use and waste characteristics in the foundry point source
category is appropriate.

Published literature, data collection portfolio responses and sampling data
were  analyzed  to characterize water use and process wastewater pollutants
and flows.  This data when analyzed provides information on which  to  base
appropriate effluent limitations and standards.

The  process  wastewater  characterizations  are  based  on analytical data
obtained during the field sampling program.  Raw waste samples  were  taken
downstream  of  manufacturing processes but prior to any process wastewater
treatment.  Metals analysis for both raw and  treated  waste  samples  were
measured as total metal concentrations.

The water use rates discussed henceforth, pertain only to metal molding and
casting  process  wastewaters.   Noncontact  cooling  water  flows  are not
included.   Process  wastewater  is  defined  as  any  water  which  during
manufacturing  or  processing,  comes into direct contract with, or results
from the production or use of  any  raw  materials,  intermediate  product,
finished  product,  by product or waste product.  The process wastewater is
contaminated with  various  pollutants  which  are  characterisitc  of  the
manufacturing  process.   Thus,  process  wastewater from metal molding and
casting processes would  include  process  wastewater  resulting  from  the
remelting  of  the  metal,  the preparation of cores and molds, and related
activities such as sand  transfer,  sand  washing,  etc.,  the  pouring  or
injecting  of metal into the molds, the removal of the metal from the mold,
the removal or cleaning of the mold medium from the mold and the removal of
gates, sprues and risers from the casting.   For  example,  casting  quench
process wastewaters are considered to be metal casting process wastewaters,
however,  process  wastewaters resulting from the plating of these castings
are non-foundry process wastewaters.  Non-contact cooling water is  defined
as that water used for cooling which does not come into direct contact with
any  raw material, intermediate product, waste product or finished product.
However, when non contact cooling water is mixed  with  process  wastewater
either  by  design  or through leaks, spills, etc., the total volume of the
water is considered process wastewater.
                                     61

-------
PLANT DATA COLLECTION

During the early stages of review of  the  foundry  point  source  category
examination  of  existing  information indicated the need for collection of
more extensive plant data.  The collection of plant data through the use of
a mail survey involved several activities; the development  of  a  detailed
request  for  information  in  the form of a data collection portfolio, the
distribution of the survey, logging of the  survey  responses,  examination
and  analysis  of the information received, selection of plants for on-site
sampling of raw and treated process wastewaters and the  implementation  of
sampling programs at selected plant sites.

Development of the Data Collection Portfolio

After  review  and  analysis  of the existing data, a draft data collection
portfolio was developed.  The portfolio was designed to collect information
about  all  types  of  plants  engaged  in  metal  molding   and   casting.
Information  about  plant  size,  age,  historical  production,  number  of
employees, land availability, water  usage,  manufacturing  processes,  raw
material and process chemical usage, air pollution control techniques which
result  in  a  process  wastewater,  wastewater treatment technologies, the
known or believed presence or absence of toxic pollutants  in  the  plant's
raw  and  treated  process  wastewaters,  and  other  pertinent factors was
requested.

During the review of the existing data, 15 trade associations and  interest
groups  associated  with  metal molding and casting activities were identi-
fied.  Representatives of these 15 groups were invited to meet with EPA, to
review the draft data collection portfolio, and to offer comments.

Comments received from these groups were reviewed  and  where  appropriate,
were incorporated into the final data collection portfolio.  In addition to
this  input,  EPA  was in communication with many of the trade associations
throughout the entire program  in  order  to  utilize  their  knowledge  of
foundry practices.

Survey Design

The Penton "Metal Casting Industry Directory" which identifies 4,404 plants
engaged  in  some form of metal molding and casting was used as the primary
basis for  the  survey.   Initially  a  survey  of  all  4,404  plants  was
considered.   However,  the  Penton information, in addition to identifying
company names and addresses, provided sufficient detail about the  type  of
metals  cast,  the number of employees, the capacity of the plant and other
factors to design a statistically based survey which would account for  the
variability  of  plants  within  the  foundry point source category without
surveying the total plant polulation.   Therefore,  a  statistically  based
survey was developed.
                                     62

-------
Analysis  of  existing  data   indicated  that  many  plants  had  installed
treatment  equipment  and   in  process  controls  which  warranted   closer
consideration.   In  addition, a preliminary trend emerged from examination
of process existing information which indicated that  many  of  the  larger
capacity  foundries  had greater volumes of process wastewater than smaller
capacity foundries and that these   larger  plants  had  process  wastewater
treatment  equipment  installed.    The  existing information also indicated
that captive  foundries  were  more likely  to  have  installed  treatment
equipment than foundries engaged in jobbing activities.  The probability of
obtaining  this much needed technical information from many of these plants
would be considerably  enhanced  if the  survey  was  designed  to  obtain
information   from  specific  plants and from specific segments of the plant
population.   This consideration was necessary since the Penton  information
provides  no  indication  of which  plants have implemented in process water
conservation  techniques or  which plants have installed the  best  available
control  technology.   Therefore, after review of the existing information,
71 specific companies with  269 plants were selected  to  receive  the  data
collection portfolio.

In  addition  to  the collection of information from the specific plants of
interest, the collection of information from as broad a spectrum of  plants
as  possible  was  highly desirable.  Therefore, the Penton information was
partitioned into 36 cells,  a matrix of 9 metal types by 4 employee  groups.
The  9  metal types  as  identified by the Penton information are: ductile
iron, gray iron,  malleable  iron,   steel,  brass  and  bronze,  aluminium,
magnesium,  zinc,  and  a   final  group  designated as "other metals".  The
employee groups are: under  10,  10 to 49,  50  to  249,  and  250  or  more
employees.

A  survey  based  on  both  metal type and employee group would provide the
opportunity for technical input  from  many  plants  which  cast  different
metals  and provide a basis for assessing the potential economic impacts of
effluent limitations and standards  on plants of varying employee size.

The Penton information was  partitioned into  36  cells  as  illustrated  on
Table V-l.  The number  in each cell represents the number of plants falling
within  the   cell.  Since a plant may cast more than 1 metal type, the same
plant may occupy more than  1  cell.   This 9x4, matrix  formed  the  basic
survey  framework  from  which additional plants would be selected for the
survey.

After consideration of  the  information available in the  Penton  file,  the
number  of plants engaged in  metal  molding and casting, and review of other
data, information from  an additional 1000 plants was considered  necessary.
A total of 1269 plants were therefore surveyed; approximately 29 percent of
the  total  plant  population   as   identified  by the  Penton foundry census
information.
                                     63

-------
Since 269 specific plants were selected with certainty the  sampling  frame
had  to  be  adjusted  to  eliminate these plants from being counted again.
Certain cell populations have therefore, been  reduced  by  subtraction  of
those 269 plants selected with certainty.

After  deletion  of the 269 plants from the survey frame, one final concern
was factored into the survey framework prior to selection of the  remaining
plants.   To insure that those plants (which appear to be relatively few in
number, i.e., cell population no larger than 70) are not missed when plants
are randomly selected from the Pention  file,  those  plants  falling   into
cells  with  populations  no  larger than 70 were removed from the sampling
frame and also surveyed with certainty.  As a  result,  an  additional  394
plants were surveyed with certainty.

Then  606  additional  plants  were randomly selected via computer from the
Penton file.  As a plant was selected,  it  was  deleted  from  the  survey
frame.   Cell  populations  therefore decreased as each plant was selected.
As the selection process continued some cell populations were  depleted  to
zero.   When  this  occured,  the  remaining  plants  in  the  Penton   file
corresponding to cells with zero populations were not selected.  Table  V-2
displays  the  distribution  by  metal type and employee group of the 1,000
plant selected to receive a survey.  The total number of entries  on  Table
V-2  exceeds  1,000 since entries for plants which cast more than one metal
type appear once for each type of metal cast.  These  plants  were  counted
for each metal type cast.

Plants  randomly  selected  in this manner had equal probabilities of being
selected for inclusion in the survey.  This probability would be later  used
to weight the returned survey data.  The probability that a plant would  be
selected is calculated using the following equation.

     P = (1000 - L) /  (4404 - K - L)

where L  = number of plants occupying cells with populations
            no larger than 70

       K =  number of specific plants surveyed with certainty due
            to the need for technical information

Therefore   P =  (1000 - 394) /  (4404 - 269 -  394)

             P =  0.162

The  weight  assigned  to each plant surveyed with P =  0.162 was therefore,
1/P  or 6.17.  For the  purpose of clarity  in  the   later  discussion  of  how
plant  population  estimates  based  on  the  survey design were made, plants
surveyed with  "p" probability are designeated  as   "P"  plants.   Likewise,
plants   surveyed  with   certainty due to  the need for technical  information
are  designeated  as  "K" plants and plants  surveyed with  corresponding   cell
                                     64

-------
populations no larger than 70 are designated as "L" plants.  In addition to
weighing  the survey response, corrections to the weighing factor were made
to account for plants which failed to respond_to the survey.  Since it  was
anticipated that plants with more employees would have a different response
ratio  (the  number  of  survey responses vs. the number of surveys mailed)
than plants with fewer employees, the correction for non-response was  made
for each employee group and not across all four employee groups.

Distribution of the Plant Survey

Using  a  mailing list of plants developed according to the plant selection
process described above, each  information  request  was  mailed  certified
receipt and contained a statement explaining the recipients legal rights to
protection  of confidential information and EPA's statutory authority under
Section 308 of the Federal Water Pollution  Control  Act  as  amended,  for
requesting  the  needed data.  Data pertinent to the 1976 calendar year was
requested.  In addition, a brief explaination of the  settlement  agreement
background  leading to this request was included and a 30 calendar day time
period for responding to the  information request was indicated.

Distribution of_ Additional Plant Surveys

In addition to the distribution of plant surveys described above, two other
types of plants were mailed data collection portfolios.  These plants  were
identified  from the preliminary data review as engaged in; (1) the casting
of copper or copper alloys as an initial production step in the forming  of
copper  or  copper  alloy  products,  i.e.,  rolling, drawing, extruding of
copper or copper alloys and (2) the casting of lead.  100  percent  of  the
plants  identified  as  falling within these casting areas were mailed data
collection portfolios.  Four  hundred-four surveys were  sent  to  companies
believed  to  have  plants  engaged  in  copper  forming  activities.   Two
hundred-twenty-six surveys were sent to companies believed to  have  plants
engaged in the casting of  lead.

Processing of Survey Responses

Each  response  was processed in the following manner.  Upon receipt of the
data, the responding plant was recorded as having  responded.   Each  plant
was  assigned  a  randomly  generated  plant  code number.  The information
returned was examined for  claims of confidentiality.   Information  claimed-
to  be confidential or proprietary was segregated from that information not
claimed to be confidential and was processed  according  to  the  statutory
requirements for handling  information claimed to be confidential.

Preliminary  information about the response was also logged.  An assessment
of the response was made to determine the water use at the plants.   Plants
in  which  no  water  is used  in the manufacture of castings were considered
"dry".  Plants which only  use water as hon contact cooling water were  also
labeled  as  "dry"  plants.   A  plant  was   considered "dry" when no metal
                                     65

-------
molding and casting process wastewater sources could be  identified   through
examination  of  the  data returned.  Conversely, a plant with  identifiable
process wastewater from manufacturing processes considered by the Agency  as
part of the foundry point source category was labeled as a "wet" plant.

A number of responses were returned with an  indication  that   the   company
either  was  no  longer  in business, the casting manufacturing facility  no
longer existed, or that the company did cast metal, but  it was  not   engaged
in'  commerical activity, i.e. trade school, art studio etc.  Examination  of
the data indicated that these responses  produced  no  process  wastewater.
Therefore,  these  responses  were considered "not a foundry" and logged  as
such.

An  additional  number  of  information  requests  were  returned   with   an
indication from the post office that the material could  not  be  delivered  at
the  address   indicated.  All returned information requests  were considered
"non-deliverable" and a manufacturing plant was considered   not to  be   in
existance at that site.

These   four   designations,   "wet,"  "dry,"  "not  a   foundry"  and non-
deliverable,"  constitute the  initial or primary step in  the  classification
of the data.

Recognizing  the  posibility  that the respondent could  have misinterpreted
what  information was sought,  care was taken in the review  of   plant  data,
particularly   the  data  which  indicated  the  complete recycle of process
wastewater.

 In many instances a respondent indicated in the cover letter that the plant
recycled  all of  its metal molding and casting  process   wastewater.    Other
respondents  furnished  block diagrams or flow schematics which illustrated
 100 percent  recycle of process wastewater.

 Furthermore, process wastewater recycle rates for  specific  metal   molding
 and   casting   processes was requested.  Plants with no discharge of process
wastewater   indicated   100  percent  recycle  of  process  wastewater.    In
 addition,    the   plant  discharge   flow,  treatment  plant  effluent,   and
 disposition  of discharge  (POTW, stream,  river,   lake)   was  requested.    A
plant  operating  at  100 percent recycle of process wastewater would  not have
 a process   wastewater  discharge.   Thus  multiple  items   within  the data
 collection portfolio were used to confirm that,  in fact,  100 percent of  the
 process wastewater was recycled.

 Plant  responses  were than copied and the copy forwarded   to  the  technical
 contractor.

 The   plant   information  was  examined for completeness,  interpretation,  and
 prepared  for computer  entry and analysis by the  technical   contractor.    At
 the   end   of the  30 day response period, a follow up letter  was sent by  EPA
                                     66

-------
to those establishments who had not responded.  Phone calls  were  made  to
plants  which  supplied  confusing  information.   Table  V-3  through V-18
summarizes the plant survey data.

The plant survey information also provided the  identity  of  a  number  of
engineering  firms  who  design and install foundry air and water pollution
control equipment.  Contacts were made  with  some  firms  for  information
regarding  the  technical  aspects of installing, operating and maintaining
such equipment.   Firms  contacted  have  designed  and  installed  process
wastewater  treatment  systems  which operate at 100 percent recycle of all
process wastewater.  In addition, these firms supplied  installation  lists
of   foundries  which  have  installed  pollution  control  equipment.   36
foundries were subsequently contacted by phone and information pertinent to
the operating and maintanence of this equipment was obtained.

Selection of Plants for Sampling

Information contained within the data collection portfolio  served  as  the
primary  basis for selection of plants for engineering and sampling visits.
Specific criteria used to select plants for visits included:

     1.   The type of metal cast;
     2.   The manufacturing processes employed;
     3.   The type  of  air  pollution  control  devices  installed,  i.e.,
*         scrubbers or "dry" type collectors such as bag houses;
     4.   The type of process wastewater treatment equipment in place;
     5.   The in-process control technologies which reduced the  volume  of
          process wastewater; and
     6.   The degree to which  process  wastewater  has  been  recycled  or
          reused.

Sampling Program and Pollutant Analysis

Sampling  programs  were  conducted  at  23  plants  for  analysis of toxic
pollutants and other pollutants.  Prior to any plant visit,  all  available
data, such as plant layouts and diagrams of the plant's production sequence
and  waste  treatment facility were reviewed.  This information was usually
furnished with the data collection portfolio from the responding company.

Generally, two separate visits were made by the EPA project officer and the
contractor to each plant selected as a sampling site.  The first visit,  an
engineering   reconnaissance  visit,  identified  sample  point  locations,
determined the most appropriate flow measurement techniques,  resolved  any
questions  and  enabled  the  sampling  team  leader to become sufficiently
familiar with the plant to conduct a technically  sound  sampling  program.
The  information  collected  during  the  engineering reconnaissance  visit,
together with the previously collected  information  about  the  plant  was
organized  into  a  detailed  sampling  plan.   The plan was then reviewed,
                                     67

-------
approved, and distributed to the sampling team.  During the second  visit  to
the plant, the actual sampling was conducted.

The sampling program  at  each  plant  consisted  of  two  activities;   the
collection of technical information and the collection of water  samples  and
flow  data.   Specific  technical information, such as production rates  and
raw  material  usage,  pertinent  to  the  time  period  of  sampling,   was
collected.   In  addition, inquiries were made as to  the reliability  of  the
treatment  equipment,  routine   maintenance   procedures   and   equipment
replacement i.e., pumps, pipes etc.  Existing or potential problems related
to extensive recycle of process wastewater were also  discussed.  Preventive
maintenance  procedures  associated  with  extensive  recycle  systems,  100
percent  recycle, were also identified.

Additional engineering visits were made at three plants.  No   sampling   was
conducted  at  these plants.  Only technical information was collected.   As
previously indicated, samples were collected at 19 plants during a  previous
EPA study of the foundry point source category.  Therefore, a  total  of   45
plants   have  been  visited,  while  sampling data has been collected at  42
plants.

The plant sampling program was conducted according  to  EPA  screening   and
verification  protocols.   During  screen  sampling   one  or more raw waste
samples   and  the  corresponding  treated  process  wastewater  from   each
manufacturing  process  within  each  subcategory  was analyzed  for all  129*
pollutant parameters finalized by EPA as a result of  the  1976  Settlement
Agreement.   The  total  list of toxic pollutants is  shown on  Table V-19  in
the back of this section.  Additional pollutants, some known to  result from
foundry  processes, were also included in the  analysis.   These  pollutants
are identified on Table V-20.  Some of these additional pollutants, namely,
total  solids,  temperature,  calcium  hardness,  alkalinity,  and  pH were
analyzed so that the Langelier Saturation Index  could  be  determined   for
systems   using  a  high  degree  of  recycle  of  process  wastewater.   The
determination of the  Langelier  Saturation  Index  helped  to  assess   the
impacts   of recycle systems on equipment life, maintenance of  the equipment
and potential problem areas.

Originally, the chemical analysis data obtained from  the screening  sampling
program  together with other supporting data were to be used to  screen   out
those  pollutants  from further consideration that were; 1) not  detected in
the foundry process wastewater streams, 2) detected but  not   quantifiable,
3)   considered   environmentally   insignificant,    and   4)  detected   at
concentrations  lower than the treatment level achievable with  the   specific
treatment methods considered in Section VII.  Environmentally  insignificant
pollutants  include  those  pollutants  found  in only one plant, pollutants
which  are artifacts of  chemicals historically used  in the plant  but  whose
use    has  been   discontinued,   i.e.,  PCB's,  and  pollutants  found   at
concentrations  below a  level of environmental significance.
                                     68

-------
The screening program was designed to screen out specific  pollutants  from
further   analytical   and   regulatory  consideration.   Those  pollutants
remaining after screening would be analyzed  for  during  the  verification
phase of sampling.

However,  the  laboratory  performing  the  analytical  work  was unable to
develop appropriate analytical  methods  designed  to  verify  the  organic
pollutants  selected for verification analysis.  Therefore, all the organic
toxic pollutants were analyzed for during verification.   The  analysis  of
the  toxic metal pollutants though, followed the original sampling strategy
and only the toxic metal pollutants warranting further consideration  after
screen  analysis,  were  analyzed.  The toxic metal pollutants selected for
verification analysis are listed on Table V-21  for  each  subcategory  and
process segment.

Supporting Data

In  addition  to  the  assessment  of  the  screening  analytical data, the
original  strategy  for  determining  toxic  pollutants  for   verification
analysis  called  for  an  analysis  of;  1) the assessment by the surveyed
plants of the known or believed presence of the  toxic  pollutants  in  the
process  wastewater  streams of the plant, and 2) the foundry raw materials
and process chemicals  used  in  the  manufacturing  process.   Table  V-22
present  a summary of the plant responses of the known or believed presence
of the toxic pollutants  in  the  plants  process  wastewater.   Table  V-23
presents  a summary of the toxic pollutants likely to be present in foundry
process wastewaters due  to the raw materials and process chemicals used  or
due  to the manufacturing process employed.  Table V-24 presents the annual
amounts of process chemicals consumed in the form of additives  or  binders
by the surveyed plants.

Published information pertinent to raw materials and process chemicals used
in the casting manufacturing processes indicated the strong likelihood that
many  toxic  pollutants  could  be  present  in these materials.  A generic
review of the raw materials used  in metal  molding  and  casting  processes
follows.

Acrylic  Resins   -  Synthetic  resins  used as sand binders for coremaking.
These resins are  formed  by the polymerization of acrylic acid or one of  its
derivatives  with benzoyl  peroxide  or  a  similar   catalyst.   The  most
frequently  used  starting materials for these resins  include acrylic  acid,
methacrylic  acid or  acrylonitrile.   Since  exposure  of  these   binder
materials to hot  metal temperatures could cause breakdown of these binders,
cyanide might be  generated.

Air Setting Binders - Sand binders which harden by exposure to  air.  Sodium
silicate,  Portland cement and oxychloride are the primary constituents  for
such binders.
                                     69

-------
Magnesia used in the blending of oxychloride can contain small  amounts   of
impurities  such  as  calcium  oxide, calcium hydroxide or calcium silicate
which  increases  the  volume  change  during  the  setting  process,  thus
decreasing mold strength and durability.  To eliminate this  lime effect,  10
percent of finely divided metallic copper is added to the mixture.

Alkyd  Resin  Binders - Cold set resins used in the forming  of cores.  This
type of binder is referred to as a  three  component  system using   alkyd-
isocyanate,  cobalt  naphthenate and diphenyl methane diisocyanate.   Cobalt
naphthenate is the drier and diphenyl methane is the catalyst.  Exposure  of
these binders to hot metal temperatures  could  cause  breakdown  of   these
binder  materials,  and  the  resulting  degradation products might  include
naphthalenes, phenols, and cyanides, in some separate or combined form.
Alloying Materials and Additives - The  following
known to be used in foundry operations.
          Aluminum
          Beryllium
          Bismuth
          Boron
          Cadmium
          Calcium
          Carbon
          Cerium
          Lithium
Magnesium
Manganese
Molybdenum
Nickel
Nitrogen
Oxygen
Phosphorus
Potassium
Selenium
Chloride
Chromium
Cobalt
Columbium
Copper
Hydrogen
Iron
Lead
Silicon
                          list  of  materials  are
Sulfur
Tantalum
Tin
Titanium
Tungsten
Vanadium
Zinc
Zirconium
 Core   Binders  - Bonding  and holding materials used  in  the  formation  of  sand
 cores.   The  three  general  types   consist  of  those that   harden  at   room
 temperature, those that  require baking and the  natural  clays.   Binders  that
 harden  at   room   temperature  include sodium silicate,  Portland cement and
 chemical cements such  as oxychloride.  Binders  that require baking   include
 the   resins,   resin oils,  pitch,  molasses,   cereals,  sulfite liquor and
 proteins.  Fireclay and  bentonite are the clay  binders.

 Sand  Binders - Binder  materials are the same as those  used in  core   making.
 The   percentage  of binder  may  vary  in core and molds  depending  on  sand
 strength required,  extent  of mold distortion from hot  metal and the metal
 surface  finish required.

 Borides   - A class of  boron-containing compounds, primarily calcium  boride,
 used  as  a constituent  in refractory materials.   Metallic   impurities   that
 often accompany   the  use of these materials  include titanium, zirconium,
 hafnium,  vanadium,  niobium,  tantalum,  chromium,  molybdenum,  tungsten,
 thorium, and uranium.

 Catalysts -  Materials  used to  set binder materials  used in  core and  mold
 formation.   Primary  set   catalysts   used   are    phosphoric  acid    and
 toluenesulfonic  acid.   Exposure  of residual catalyst  materials in the  mold
                                     70

-------
to hot metal temperatures could cause chemical breakdown of these materials
with the possible generation of free toluene.

Charcoal - A product of destructive distillation of wood.   Used  for  heat
and  as  a source of carbon in the foundry industry.  Because of the nature
of the destructive distillation process charcoal may contain  residuals  of
toxic  pollutants  such  as  phenol,  benzene,  toluene,  naphthalene,  and
nitrosamines.

Chrome Sand -  (Chrome-Iron Ore) - A dark  material  containing  dark  brown
streaks  with  submetallic  to  metallic  luster.   Usually found as grains
disseminated in perioditite rocks.  Used  in  the preparation of molds.

Chromite Flour -  (See Chrome Sand above)  - Chrome sand ground to  200  mesh
or  finer,  can   be  used  as a filler material for mold coatings for steel
castings.
Cleaning Agents and Degreasers - Ethylene
trichloroethylene.
dichloride,   polychloroethylene,
Coatings  -  Corrosion  Resistant - Generally alkyd - or epoxy resins.  See
Alkyd Resin Binders  and Epoxy Resins.  Applied to metal  molds  to  prevent
surface corrosion.

Foundry  Coke   -  The residue from the destructive distillation of coal.  A
primary ingredient  in the  making of cast  iron in the  cupola.   Because  of
the  nature  of  the destructive distillation process and  impurities  in the
coal, the coke  may  contain residuals of toxic pollutants   such  as  phenol,
benzene, toluene, naphthalene and nitrosamines.

Petroleum Coke  -  Formed by the destructive distillation of petroleum.  Like
foundry  coke,  petroleum  coke can also be used for making cast iron  in the
cupola.
Pitch Coke  -  Formed by  the  destructive  distillation
Used as  a binder  in the sand  molding  process.
           of  petroleum  pitch.
Coolants   -   Water,  oil  and  air.   Their  use  is determined by  the extent  and
rate of cooling  desired.

Core Binder  Accelerators - Used  in conjunction with  Furan resins   to   cause
hardening  of the resin-sand  mixture at room  temperature.  The most commonly
used accelerator is  phosphoric acid.

Core   and  Mold Washes -  A mixture of  various materials, primarily  graphite,
used to obtain a better  finish on castings,   including  smoother   surfaces,
less scabbing and buckling and less metal  penetration.  The filler material
for washes should be refractory  type  composed of  silica flour,  zircon  flour
or chromite  flour.
                                     71

-------
Core  Oils  -  Used  in  oil-sand  cores as a parting agent  to prevent  core
material from  sticking  to  the  cast  metal.   Core  oils   are   generally
classified  as  mineral  oils (refined petroleum oils) and are available  as
proprietary mixtures or can be ordered to specification.  Typical  core  oils
have specific gravities of 0.93 to  0.965  and  contain  a   minimum   of  70
percent nonvolatiles at 350°F.

Die  Coatings  -  Oil  containing  lubricants  or parting compounds  such  as
carbon  tetrachloride,  cyclohexane,   methylene    chloride,   xylene  and
hexamethylenetetramine,  used  to prevent castings  from  adhering  to  the die
and to provide  a  casting  with  a  better  finish.   A correctly   chosen
lubricant  will  allow metal to flow into cavities  that  otherwise cannot  be
filled.

Epoxy Resins - Two component resins used  to  provide  corrosion   resistant
coatings  for  metallic  molds  or castings.  These materials are synthetic
resins obtained by the condensation or polymerization  of  phenol,   acetone
and    epichlorohydrin   (chloropropylene   oxide).    Alkyds,    acrylates,
methacrylates and allyls, hydrocarbon polymers such as  indene,   coumarone
and  styrene,  silicon resins, and natural and synthetic rubbers  all can  be
applied as additives or bases.  Polyamine and  amine  based   compounds  are
normally used as curing agents.  Because of the temperatures to which these
materials  are exposed, and because of the types of materials that are  used
to produce many of the components of these materials, toxic  pollutants  such
as zinc,  nickel,  phenol,  benzene,  toluene,  naphthalene,   and possibly
nitrosamines could be generated.

Furan  Resins  -  A heterocyclic ring compound formed from diene  and cyclic
vinyl ether.  Its main use is as a cold set resin in conjunction  with  acid
accelerators such as phosphoric or toluensulfonic acid for making core  sand
mixtures  that  harden at room temperature.  Toluene could be formed during
thermal degradation of the resins during metal pouring.

Furfuryl Alcohol - A syntehtic resin used to formulate core   binders.   The
amount of furfuryl alcohol used depends on the desired core  strength.

One  method  of  formulating  furfuryl alcohol is by batch hydrogenation  of
furfuryl at elevated  temperature  and  pressure  with   a  copper chromite
catalyst.

Furnace  Charge  - Scrap - Various toxic pollutant  metals may be  present  in
the raw  materials  charged   in  the  melting  furnace.   These   pollutants
originate  from  various  sources  -  iron  ore, pigs, steel or case scrap,
automotive scrap, and  ferroalloys.   These  pollutants  may  be   antimony,
arsenic, chromium, copper, lead, titanium, and zinc.

Gilsonite  -  A material used primarily for sand binders.  It is  one of the
purest natural bitumens  (99.9 percent) and is found in   lead  mines.   Lead
may be present as an  impurity in Gilsonite.
                                     72

-------
Gypsum  Cement - A group of cements consisting primarily of calcium sulfate
and produced by the complete dehydration of gypsum.   It  usually  contains
additives  such  as aluminum sulfate or potassium carbonate.  It is used in
sand binder formulation.

Impregnating Compounds - Materials of low  viscosity  and  surface  tension
used  primarily  for  the sealing of castings.  Polyester resins and sodium
silicate are the two  types  of  material  used.   Phthalic  anhydride  and
diallyl phthalate are used in the formulation of the polyester resins.

Investment  Mold  Materials  -  A broad range of waxes and resins including
vegetable wax, mineral wax,  synthetic  wax,  petroleum  wax,  insect  wax,
rosin,  terpene  resins, coal tar resins, chlorianted elastomer resins, and
polyethylene resins used in the manufacture and use  of  investment  molds.
The presence of coal tar resins in investment mold materials might indicate
the possible presence of toxic pollutants such as phenol, benzene, toluene,
naphthalene,  and  nitrosamines  as  residues  in the resins or as possible
products of degradation of these resins when subjected to heat.

Lignin Binders - Additives incorporated into resin-sand mixtures to improve
surface finish and to eliminate thermal cracking during pouring.  Lignin is
a major polymeric component of woody tissue composed  of  repeating  phenyl
propane  units.  It generally amounts to 20-30 percent of the dry weight of
wood.  Phenol might be  generated  during  thermal  degradation  of  lignin
binders during metal pouring.

Lubricants   -  Calcium  stearate,  zinc  stearate  and  carnauba  wax  are
lubricating agents added to resin sand mixtures to permit easy  release  of
molds from patterns.

Mica  -  A  class  of silicates with widely varying composition used in the
refractory making process.  They are essentially silicates of aluminum  but
are  sometimes  partially  replaced by iron, chromium and an alkali such as
potassium, sodium or lithium.

No Bake Binders - Furan resins and alkyd-isocyanate compounds are  the  two
predominant  no  bake  binders.  Furan resins, as previously mentioned, are
cyclic compounds which use phosphoric acid or toluenesulfonic acid  as  the
setting  agents.   Alkyd-isocyanate  binders  have fewer limitations in use
than furan resins but the  handling  of  cobalt  naphthenate  does  present
problems.

Phenolic  Resins - Phenol formaldehyde resins - A group of synthetic resins
that are probably the most varied and versatile known.  They  are  made  by
reacting   almost   any   phenolic   and   an  aldehyde.   In  some  cases,
hexamethylene-tetramine is added to increase  the  aldehyde  content.   The
resins  formed  are  classified as one and two step resins depending on how
they are formed in the reaction kettle.  Both types of materials  are  used
separately  or  in  combination  in  the  blending  of  commercial  molding
                                     73

-------
materials.  Due to thermal degradation of phenolic resins  that  may  occur
during metal pouring, phenol and formaldehyde may be generated.

Pitch  Binders  -  Thermosetting binders used in coremaking.  Baking of  the
sand-binder   mixture   is   required   for    evaporation-oxidation     and
polymerization to take place.

Quenching  Oil  - Medium to heavy grade mineral oils used  in  the cooling of
metal.  Standard weight or grade of oil would be similar   to  standard   SAE
60.

Riser Compounds - Extra strength binders used to reduce the extent  of riser
erosion.   Such  materials  generally  contain lignin, furfuryl alcohol  and
phosphoric acid.

Rosins, Natural -  (Gum rosin, colophony, pine  resin,  common rosin)  -  A
resin  obtained  as  a residue after the distillation of turpentine  oil from
crude turpentine.  Rosin is primarily an isomeric form of  the anhydride   of
abietic   acid.   It  is  one  of  the  more  common  binders  in the foundry
industry.

Sand Flowability Additives - A mixture of sand, dicalcium  silicate,  water
and  wetting  agents.   This  combination   is based on a process of Russian
origin which achieves a  higher  degree  of  flowability   than  either   the
conventional sand mix or those with organic  additives.

Seacoal - Ground bituminous coal used to help control the  thermal expansion
of  the   mold  and to control the composition of the mold  cavity gas during
pouring.

Urea Formaldehyde Resins -  An   important   class  of  thermosetting resins
identified   as   aminoplastics.    The  parent  raw  materials   (urea   and
formaldehyde) are united with heat and control of pH to form   intermediates
that  are mixed  with  fillers   (cellulose) to produce molding powders  for
patterns.

Wetting Compounds  -  Materials which reduce  the surface tension of solutions
thus allowing uniform contact of solution with the  material   in  question.
Sodium  alkylbenzene sulfonates  comprise   the  principal type of  surface-
active  compounds but there are a vast number of other compounds used.

PROFILE OF  PLANT DATA

Data  collected  from  the previously described sources was  used to  develop  a
technical  profile   of  the plants within the foundry point source category.
The profile  consists of a representative outline of  the plants  within   the
category  and   provides   information  as  to  the  frequency  distribution of
plants,   the  types  of  metals   cast,  employee   groupings,   manufacturing
processes,   air  pollution   sources,  water use,  toxic pollutants, process
                                     74

-------
wastewater  discharge  designation,  and  other  prevalent  factors.    The
profiles   were   briefly  introduced  in  Section  III.   However,  before
presentation of detailed profile data, a discussion of how the profile  was
developed follows.

Industry Profile Development

As  previously  mentioned,  as  the  plant data was received, the plant was
classified as either "wet", "dry", "not a foundry" or "non-deliverable".

Realizing that the plant survey was statistically based,  estimates,  based
on  the  design of the survey and the responses received, were made for the
total plant population.  These estimates were determined in  the  following
manner.

Major  metal  cast  and  employee  group  information  about  those  plants
designated as  "wet"  was  retrieved  from  the  Penton  information  file.
Siminar  information  was  retrieved  for  plants  designated "dry", "not a
foundry", and "non-deliverable".  AS a result, 4 matrices  were  generated.
Each  9x4  matrix  (9 metal types by 4 employee groups) consisted of the
frequency distribution of plants by type of major metal cast  and  employee
size group.  Information about metal cast and number of employees furnished
by  the  plants  was compared to the Penton information and where necessary
adjustments in cell populations were made to reflect the  plant  data.   An
additional  fifth  matrix  was  developed  which  presented  the  frequency
distribution of plants which had not responded after a non response  letter
was mailed.

With  the  information  arrayed  in  this  manner, the percentage of plants
responding to the information request in any cell or across all cells could
be determined.  Of all the plants for which information was  requested,  76
percent  of  the plants responded.  On a subcategory basis, 80.5 percent of
the plants producing ferrous castings responded; 74 percent of  the  plants
producing  copper  castings  responded;  68 percent of the plants producing
aluminum casting responded; 62.5 percent of the plants producing  magnesium
castings  responded;   75.6  percent  of  the plants producing zinc castings
responded; and 76 percent of the plants producing castings of  metal  other
than the metals listed above responded.

Each  of  the  five  matrices  was then further broken down into 3 discrete
subparts which identified plants within the matrix by the way in which  the
plants were surveyed,  i.e., plants previously designated as either K, L, or
P plants.

At this level of detail, the appropriate weights and correction factors for
nonresponse   could    be  applied.   Nonresponse  correction  factors  were
determined for each employee group.  Estimates were then made of the  total
number  of  plants with a metal molding and casting process wastewater, the
                                     75

-------
total number of plants with no process wastewater, and the total number  of
plants not engaged in metal molding and casting.

The next step in the profile development involved the apportionment of data
from  plants  designated  as  "wet"  to the estimated total number of  "wet"
plants.  This apportionment based on the plant data  was  also  applied  to
plants who responded but did not supply complete  information since, as some
plants  indicated,  their  knowledge about their plant production and water
use in the areas of interest to the Agency was limited.

The plant data returned in the  data  collection  portfolios  was  used  to
determine:  the  number  and  types  of processes, i.e.,  furnace scrubbers,
casting quenches, etc., resulting in a process wastewater,  the  frequencey
distribution  of discharge modes, i.e., the number of direct dischargers to
naviagle waters, and the number of indirect dischargers  to  publicly   owned
treatment  works  (POTW), the number of manufacturing processes  in which  100
percent of the process wastewater from  the  process   is recycled.    Again
these  estimates  were  made  for  each  major metal cast and each employee
group.

This weighted plant data was then  apportioned  by  major metal  cast   and
employee  group  over  the  estimated  total  number  of "wet" plants.  In
addition, plant production information and  water  use   data  was  used  to
determine estimates of total plant production and water  use by  subcategory,
employee  group  and manufacturing process.  These estimates were developed
in  the same way as discussed above.  This  information   as  outlined   above
forms  the basis for the industry profile.

Production Profile

Table  V-25   is   constructed to present for each  subcategory: the estimated
weight of metal poured annually, the weight of metal poured  in  plants  which
discharge their process wastewater to navigable waters,  the weight of  metal
poured in plants which discharge their process wastewater to   POTW's,   and
the weight   of   metal  poured  in plants which recycle  100 percent of  their
process wastewater.

Process Wastewater Flow

Estimates by  subcategory of  the  total annual process wastewater flow  within
the foundry point source category are presented on Table V-26.    The   basis
for  these  estimates  are  the process wastewater  flows,  associated with  the
metal  molding and casting  processes, which have been  identified  by   plants
responding  to   the  data  collection  survey.    The   "Applied  Flow"  column
 indicates the volume of process  wastewater which   has   become   contaminated
with  pollutants  as   a  result  of   its  intimate contact with  the process,
products, by-products, waste products,  etc.    The   "Recycle   Flow"   column
 indicates   the   volume of process wastewater which  is  recycled back  to the
process  from  which  it   came.    The   column  marked   "Flow  at   100   percent
                                     76

-------
Recycle"  indicates  the  volume  of process wastewater which is completely
recycled back to the manufacturing process.

Table V-27 summarizes by subcategory the number of processes  according  to
discharge mode, i.e., direct discharge, indirect discharge to POTW's or 100
percent recycle.

Toxic Pollutants

Table  V-28  summarizes  by  subcategory  toxic  pollutants detected in the
untreated process wastewater from 44 metal molding  and  casting  processes
sampled  during  the  sampling program.  This summary table was constructed
from Table V-29.  Table V-29 presents  the toxic  pollutant  data  generated
from  the sampling program.  The concentrations indicated on Table V-29 are
averages based on the data obtained from three sampling days.

SPECIFIC SUBCATEGORY WATER USE AND WASTE CHARACTERISTICS

Aluminum Foundries

An estimated 3.8 billion gallons of process wastewater  results  each  year
from the casting of aluminum.  Fifty-two percent of this water is recycled,
while  39  percent   is  discharged  to navigable waters and nine percent is
discharged to POTWs.  A number of manufacturing  processes  which  generate
process  wastewater  pollutants  are involved in the production of aluminum
castings.

Investment Casting Process:

An estimated 121 million gallons of process wastewater  results  each  year
from  investment  casting  processes.   This  represents 3.1 percent of the
total process  wastewater  flow  at  plants  within  the  aluminum  casting
subcategory.   Eighty-two  percent  of this  121  million  gallon  flow is
discharged to navigable waters while 18 percent is discharged to POTWs.

A general process and water  flow  diagram  of  a  representative  aluminum
investment  casting  operation  was presented in Figure II1-4.  The process
wastewater in this operation results from several processes.  On the  basis
of  plant survey  information, and the  observations made during the sampling
visit, these various processes together are considered to be particular  to
investment  casting  operations.  The  processes are mold backup, hydroblast
(of castings), and dust collection  (used  in conjunction with  hydroblasting
and the handling of  the investment material and castings).

The  major impact on the waste loads results from the use of the investment
material.  The type  of wax  used  in   mold  formation  and  the  hydroblast
process  also   impact  wastewater  quality.  Test data collected during the
visit  to  an   investment  casting  operations  provided  data  about   the
pollutants   from    this   type  of  operation.   All  pollutant  analytical
                                     77

-------
information presented henceforth for investment casting  operations  refers
to  the  pollutants  generated  in  the  combination  of investment casting
processes described above.  Plant survey responses indicated  applied   flow
rates  ranging  from  a  low  of  20,400 1/kkg  (4,900 gal/ton) to a high  of
53,290 1/kkg (12,800 gal/ton).   All  three  plants  listed  on  Table  V-3
discharge 100 percent of their process wastewater.

A  review  of  the three plant respondents employing this process indicated
that the process wastewaters are generated in the same manner and in two  of
the plants, the process wastewaters receive  treatment  via  settling   (the
other  plant's  discharge  is  untreated).   The three plants discharge all
process wastewater flow to either a POTW or  to  navigable  waters  without
recycle.   Table  V-3  describes  treatment systems used with this process.
The most extensive treatment system was installed in 1977  and  this  plant
was  visited  and  analytical  data obtained.  Treatment components at  this
plant include polymer addition to promote floe formation with a  subsequent
settling stage for solids removal.

Plant  4704,  Figure  V-l,  produces process wastewaters from mold back-up,
hydroblast casting cleaning and dust collection are co-treated.  Polymer  is
added to aid settling in a Lamella plate separator.  The Lamella sludge  is
filtered  through  a  paper  filter with the filtrate being returned to the
head of the treatment system.  The treated effluent is  discharged  to  the
river.

Table  V-30  presents  the raw waste load, and the treatment effluent waste
load from this plant.  A quick look synopsis (partial summary) of the   data
presented  on  Table V-30 indicates that the following toxic pollutants are
present in the raw process wastewaters from this manufacturing process.

     Pollutant           Concentration mg/1

     Copper                   0.45
     Zinc                     0.49


Melting Furnace Scrubber Process:

An estimated 1.4 billion gallons of process wastewater  results  each   year
from  melting furnace scrubber operations.  This represents 37.4 percent  of
the total process wastewater flow at plants  within  the  aluminum  casting
subcategory.   65.5  percent  of  this  1.4 billion gallon flow is recycled
while 34 percent is discharged  to  navigable  waters  and  .5  percent  is
discharged to POTWs.

A  general  process  and  water  flow  diagram of a representative aluminum
foundry melting operation and its scrubber system was presented  in  Figure
III-5.
                                    78

-------
The  quality  and  cleanliness  of  the  material  charged  in  the furnace
influences the emissions from the furnace.   Generally,  aluminum  furnaces
which  melt  high  quality  material  do  not require air pollution control
devices.  However, when dirty, oily scrap is used,  the  furnace  emissions
are  often controlled through the use of scrubbers.  The process wastewater
from these  scrubbers  may  be  either  recirculated  within  the  scrubber
equipment  package   (which  includes  a settling chamber) or may flow to an
external treatment system and then recycled back to the scrubber.

Test data from melting  furnace  scrubber  operations  visited  during  the
sampling  program  provided   information  about the pollutants from melting
furnace scrubbers.   Plant survey responses indicated  a  range  of  applied
flow rates from 2,194 1/kkg (527 gal/ton) to 55,290 1/kkg (13,280 gal/ton).
Recycle rates varied from 37  percent to a high of 97.5 percent.

A  review of the five plant respondents using melting furnace gas scrubbing
equipment indicates  that the  process wastewaters are handled in  a  variety
of  ways  although   they  are  generated  in  the  same  manner.  Table V-6
describes the treatment  systems  used  with  this  process.   All  of  the
surveyed  plants employ some  degree of process wastewater recycle, however,
some systems employ  an "internal" (within the scrubber  equipment  package)
recycle  while  other  plants  recycle their process wastewaters externally
after passing through various treatment stages.  Two of the  plants  employ
internal recycle systems with the blowdowns of each system being introduced
untreated  to a POTW.  These  two plants are among the three plants with the
highest  recycle  rates   (95  percent  and  97.5  percent).   The   process
wastewater treatment systems  used at the three remaining plants provide for
recycle  of  externally treated process wastewaters with the blowdown being
discharged to a receiving stream.  The treatment systems  at  these* plants
incorporate  basically  some  type  of  settling  operation, with one plant
providing more extensive treatment.

Plant 17089, Figure  V-2, produces die casting and  casting  quench  process
wastewater  which  are  skimmed  of  oil  and  then co-treated with melting
furnace scrubber process wastewaters.  The treatment consists of  alum  and
polymer  additions   in a flash mix tank followed by clarification, pressure
filtration, recycle, and discharge.  Clarifier underflow is  thickened  and
dewatered in a centrifuge before drying in a basin.  Sixty-seven percent of
the  treated process wastewater is reused in the plant and the remainder is
discharged to a navigable water.

Plant 18139,  Figure V-3   generates  process  wastewater  from  a  Venturi
scrubber  on  the  aluminum  melting  furnaces.   The process wastewater is
recirculated through a settling tank.  Overflow from the settling  tank  is
mixed   with  process wastewaters from the zinc melting furnace and aluminum
and zinc casting quenches.  The mixed process wastewater passes  through   a
settling basin, an oil separator and storage tanks before discharge.
                                     79

-------
Table  V-31  summarizes the raw and treated waste loads observed during  the
sampling program.  A quick look synopsis   (partial  summary)  of   the  data
presented  on  Table V-31 indicates that the following toxic pollutants  are
present in the raw process wastewaters from this manufacturing process.

     Pollutant           Concentration mg/1

     Phenols                  0.84
     Zinc                     0.26

Casting Quench Process:

An estimated 100 million gallons of process wastewater  results  each  year
from  casting quench operations.  This represents 2.62 percent of  the  total
process wastewater flow at plants within the aluminum casting  subcategory.
Sixteen  percent  of   this  100  million   gallon  flow is recycled while 77
percent is discharged  to navigable waters  and 7 percent  is  discharged   to
POTWs.

A  general  process  and  water  flow  diagram of a representative aluminum
foundry casting quench operation is presented in Figure 111-5.  The process
wastewaters  considered  in  association   with  this  operation  are   those
wastewaters  which are discharged from the casting quench tanks.   Raw  waste
loads will depend on the duration of the quenching  cycle,  the  degree   of
quench  recycle,  the  quench solution additives used, and the contamination
of the quench solutions with  wastes  from other  sources  (hydraulic  oil
leaks,  etc.).  The major impact on the raw waste loads, however,  is due to
the  nature of the quenching solution and the contamination  of  the quench
solutions  with  wastes  from other sources.  Test data from casting quench
operations visited during the sampling program provided  information   about
the  pollutants from this process.  Plant survey responses indicated a  range
of   applied  flow  rates  from  79 1/kkg (19 gal/ton) to 28,590 1/kkg  (6,866
gal/ton).  Recycle rates varied from 0 to  100 percent.  In  some   instances
no   applied  flow  could  be  assigned to  a process since the castings were
quenched  in  a tank with no discharge or only  very  infrequent  dumps.    In
these   instances,  the operations were considered to be 100 percent recycle
since the  same quench  solution  is continuosuly reused.

A review  of  the eleven plant   responses   with  casting  quench  operations
indicates  that  all   process   wastewaters are generated in the same manner
although  they are handled in a  variety  of ways.   The  treatment schemes
range   from  untreated discharges  to  POTWs to complete recycle systems.
Refer to  Table V-3 for descriptions of the treatment schemes used   in  this
subcategory  segment.   All  plants use some form of settling stage even if
this is only accomplished in the quench tank itself.  However, the quantity
of castings  quenched,  the process wastewater flow through the quench   tank,
and   the  size of the quench tank are factors which may necessitate the need
for  a separate settling stage to remove solids.
                                     80

-------
Of the eleven plants with casting  quench  operations  indicated  in  their
responses,  two plants employed 100 percent recycle and two plants employed
a 90 percent recycle rate.  The blowdowns of the  two  90  percent  recycle
plants  as  well  as the discharges of three other plants (with no recycle)
are introduced untreated to POTW's.  Of the three direct discharge  plants,
one  has  treatment  via  a  settling  lagoon  and the other two provide no
treatment.  The process wastewaters of one plant are removed by a  contract
hauler.   Settling  is indicated as the only treatment provided for casting
quench process wastewaters.

Plant 10308, Figure V-4, produces zinc die casting quench wastes,  aluminum
die  casting  quench  wastes,  cutting  and  machining  coolant wastes, and
impregnating wastes which are co-treated in a batch-type system.  The  zinc
casting  quench waste is actually the effluent from a system which recycles
the quench tank contents through a settling and skimming operation and back
to  the  quench  tanks.   The  zinc   casting   quench   wastes   represent
approximatley 25 percent of the total treatment volume.  After undergoing a
sulfuric  acid  and  alum  emulsion break, neutralization, flocculation and
solids separation, the treated effluent is  discharged  to  a  land  locked
swamp.

Plant  17089,  Figure  V-2, produces die casting and casting quench process
wastewaters which are skimmed of  oil  and  then  co-treated  with  melting
scrubber  process  wastewaters.  The treatment consists of alum and polymer
additions  in  a  flash  mix  tank  followed  by  clarification,   pressure
filtration,  recycle,  and discharge.  Clarifier underflow is thickened and
dewatered in a centrifuge before drying in a basin.  Sixty-seven percent of
the treated water is reused in the plant and the remainder is discharged.

Plant 18139,  Figure  V-3,  'has  a  number  of  die  casting  machines  and
associated  quench  tanks  which  are  emptied  on  a scheduled basis.  The
schedule results in the  emptying  of  one  300  gallon  quench  tank  each
operational  day.   Each  quench tank is emptied approximately about once a
month.  The quench tank  discharge  mixes  with  melting  furnace  scrubber
discharges,  zinc  casting  quench  tank flows, and other non-foundry flows
prior to settling  and  skimming.   The  treated  process  wastewaters  are
discharged to a POTW.

Table V-32 summarizes the raw and treated waste loads observed at these two
plants  during  the  sampling  program.   A  quick  look  synopsis (partial
summary) of the data presented on Table V-32 indicates that  the  following
toxic  pollutants  are  present  in  the  raw process wastewaters from this
manufacturing process.
                                     81

-------
          Pollutant           Concentrations (mg/1)

          Phenols                  0.84
          Copper                   0.25
          Lead                     0.44
          Zinc                     9.1

Die Casting Process:

An estimated 2.17 billion gallons of process wastewater results  each  year
from  die  casting  operations.   This represents 56.5 percent of the total
process wastewater flow at plants within the aluminum casting  subcategory.
47.5  percent  of  this  2.17 gallon flow is recycled while 38.7 percent  is
discharged to navigable waters and 13.8 percent is discharged to POTWs.

A general process and water  flow  diagram  of  a  representative  aluminum
foundry  die  casting  operation  is depicted in Figure III-5.  The various
sources of wastewaters in the  die  casting  operations  are  contact  mold
cooling  water,  die  surface  cooling  sprays,  casting  machine hydraulic
cooling systems using water, and leakage from  various  noncontact  cooling
systems   which   are   subsequently   contaminated  with  hydraulic  oils,
lubricants, etc.  Depending upon the degree of maintenance performed on the
various die casting systems, the major source of process wastewaters  could
vary from surface cooling sprays in the case of a well maintained operation
to  contaminated leakages in the case of systems which receive only cursory
maintenance.  Preventive maintenance can affect the volume and contaminants
of die casting process wastewater.

Test data obtained from die casting operations visited during the  sampling
program  provided  information  about  the  die  casting  operation process
wastewater characteristics.  Plant 'survey responses indicated  a  range   of
applied  flow  rates  varying  from  370 1/kkg (89 gal/ton) to 60,200 1/kkg
(14,460 gal/ton).  Recycle rates varied from 0 to 90 percent.

Of the eight plant responses identified in this  subcategory  process,  the
process wastewaters are generated by the same basic sources but are handled
in a variety of ways.  Refer to Table V-6 for process wastewater source and
treatment  information.   The  sources  of  process wastewaters are contact
cooling water and  leakages from various  noncontact  water  supplies  which
become process wastewaters as  a result of their contact with  the process  or
with other process wastewaters.

Of  the  eight  plants  with   die  casting  operations  identified  in their
responses, three recycle  systems,  at  37  percent,  79  percent,  and   90
percent,   are   indicated.   Five of these eight plants discharge to POTW's.
One of  these  plants  employs  emulsion  breaking,  skimming,  alum  feed,
flotation  and additional skimming.  Of the remaining four POTW dischargers
two plants provide  no process  wastewater treatment and two  plants  provide
only settling.
                                     82

-------
The  three  plants  discharging  to navigable waters provide more extensive
treatment than the POTW dischargers.

Of the six plants employing  some  type  of  process  wastewater  treatment
system, the following technologies are used:

a.   Settling and skimming (6 plants):  achieves primary solids removal and
     removal of tramp oils.  In some instances, recycle follows.

b.   Emulsion breaking (3 plants):  Using alum or sulfuric  acid  or  both,
     the  emulsified  oils  are  broken  out  of  the emulsion and are then
     removed as scum.

c.   pH adjustment,  flocculation  and  clarification  (2  plants):   lime,
     polymer,  alum  and  other  chemicals  are used to adjust waste pH and
     promote floe formation after which the floe is allowed to settle in  a
     clarifier.   This  step provides for metals removal, some oil removal,
     and enhanced solids removal compared to settling tanks.

Plant 17089, Figure V-2, produces die casting  and  casting  quench  wastes
which  are  skimmed  of  oil  and  then  co-treated  with  melting scrubber
wastewaters.  The treatment consists of alum and  polymer  additions  in  a
flash mix tank followed by clarification, pressure filtration, recycle, and
discharge.   Clarifier underflow is thickened and dewatered in a centrifuge
before drying in a basin.  Sixty-seven percent  of  the  treated  water  is
reused in the plant and the remainder is discharged.

Plant  12040,  Figure  V-5,  produces aluminum and zinc die casting process
wastewaters which are co-treated.  After collection  in  a  receiving  tank
where  oil  is  skimmed,  they  are  batch  treated  by  emulsion breaking,
flocculation and settling before discharge.  The released oil  is  returned
to  the  receiving  tank  for  skimming  and  the settled wastes are vacuum
filtered and dried before being land filled.  Filtrate water is returned to
the receiving tank.

Plant 20147 was also sampled.  Discussion of this plant appears  under  the
discussion of die lubricants.

Table  V-33  summarizes the raw and treated waste loads observed during the
sampling program.  A quick look synopsis  (partial  summary)  of  the  data
presented  on  Table V-33 indicates that the following toxic pollutants are
present in the raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations (mq/1)

          PCB's (1242,
           1254, 1221)             1.4
          Lead                     2.0
          Zinc                     3.7
                                    83

-------
Die Lube Process:

An estimated 14.2 million gallons of process wastewater results  each  year
from  die  lube  operations.   This  represents  0.38  percent of  the  total
process wastewater flow at plants within the aluminum casting  subcategory.
Fifty percent of this 14.2 million gallon flow is recycled while 14  percent
is discharged to navigable waters and 36 percent is discharged to  POTW's.

A  general  process  and water flow diagram of a representative die  casting
operation employing a die lube system was presented in Figure 111-5.

The die lube operation involves the spraying of a lubricating solution onto
the die surface prior to casting.   These  solutions  are  emulsions  which
contain  certain  "casting release" agents which permit the  casting  to fall
away or be removed readily from the dies.  Test data  obtained  during  the
sampling  program provides information about the wastewater  characteristics
of die lube process wastewater.  Plant survey responses indicated  a  range
of  applied  flow  rates varying from a  low of 36 1/kkg (8.79 gal/ton) to  a
high of 270 1/kkg (71.4 gal/ton).  Recycle  rates  varied  from  0  to  100
percent.

A  review  of the four plants with die lube operations, identified in  their
survey responses, indicate that the process wastewaters  are generated   in
the same manner, although the process wastewaters are treated in distinctly
different  ways.   Refer  to  Table  V-7  for  descriptions  of the  various
treatment systems.  A 100 percent recycle system is   in  operation  at  one
plant  and  was  observed  during  a  sampling visit, while  the other  three
plants discharged all die lube process wastewaters.  Waste water   treatment
ranged  from  no  treatment  to  complete   (100 percent) recycle.  The more
extensive treatment systems were installed after 1971.

Of the three  foundries  with  process   wastewater  discharges,  one  plant
provided  no  treatment  prior  to  its  discharge to a POTW, another  plant
discharged the permeate from an ultrafiltration unit  to  a   POTW,  and  the
remaining  plant provided treatment in a central facility prior to a direct
discharge.  This central facility  (die lube flow represented only  7  percent
of   total  central  treatment  facility  flow)  provided  various  chemical
additions,  biological  treatment,  and  clarification.   The   100  percent
recycle plant used skimming, cyclonic separation, and  a  paper  filter   to
treat  its process wastewater and recover die  lubricants.

The  various technologies  in use at the three  plants with process wastewater
 treatment systems are as follows:

a.    Ultrafiltration Unit:  uses hydraulic  pressure to  drive   the  aqueous
      phase  of   the  die   lube  wastes   through  a semi-permeable  membrane.
      Higher molecular weight organics remain  behind   that  membrane.   Some
      lower molecular weight organics pass through with  the aqueous phase.
                                     84

-------
b-   Cyclonic Separator, Skimming, Paper Filter:  this system  is  used  in
     conjunction with a complete recycle operation to provide for suspended
     solids removal, tramp oil removal, and recovery of process chemicals.

c.   Flotation, skimming, addition of ferric  chloride  and  lime,  lagoon,
     trickling  filter,  activated  sludge, and clarifier.  Note:  Die lube
     flow is only seven percent of the total plant process wastewater  flow
     to the treatment system.

Plant  20147,  Figure  V-6,  indicated that the sources of die lube process
wastewaters are:  1) excess die lube sprayed on  the  dies  for  additional
cooling,  2)  leakage  from  die  cooling  (noncontact  cooling water which
becomes mixed with process wastewater, 3)  leakage  from  hydraulic  system
cooling  water  (noncontact  cooling  water  which  passes  through  a heat
exchanger to  cool  the  hydraulic  oil  and  becomes  mixed  with  process
wastewater), and 4) hydraulic oil leakage.

Process  wastewater is controlled in three ways.  On each shift maintenance
personnel inspect each die casting machine  for  leaks.   Where  necessary,
repairs  are  made  during the shift to reduce the process wastewater flow.
Under the die of each machine, a pan collects excess die lube  which  drips
from  the  die.  A portable pump and tank  is wheeled to each machine during
each shift to collect the die lube collected in the pans.  In addition,  on
the  floor  around  each  die  casting  machine  a dam contains the process
wastewater from various  leaks.  Die lubricant which does not collect in the
pan is also contained by the dam.  The process wastewater collected in this
manner flows to storage  tanks through a floor drain.

Stratification of the process wastewater into three layers  occurs  in  the
storage  tanks.   Tramp  oil  floats  to   the  top and is removed by a belt
collector.   The  tramp  oil  is  collected,  stored,  and  removed  by   a
contractor.   The middle layer, comprised  of die lubricant, is removed to a
second tank.  From this  second tank the  die  lubricant  passes  through  a
cyclonic  filter.  The die lubricant removed through the top of the cyclone
passes through a paper filter and then stored until it is reused on the die
casting machines.  The material removed from the bottom of the  cyclone  is
stored until removed by  a contract hauler.

Die  lubricants  collected   in  the pans beneath the dies is removed to the
reconstruction area of the  plant  where   the  used  die  lubricant  passes
through  a  paper filter, is mixed with new lubricant and water to bring it
up to spec, and is stored until needed on  the die casting machines.

Table V-34 summarizes the raw and treated  waste loads observed  during  the
sampling  program.   A   quick  look  synopsis (partial summary) of the data
presented on Table V-34  indicates that the following toxic  pollutants  are
present in the raw process wastewaters from this manufacturing process.
                                     85

-------
          Pollutant                 Concentrations (mg/1)

          2,4,6-Trichlorophenol                1.8
          Parachlorometa cresol               24.0
          2,4-Dichlorophenol                 11.0
          2,4-Dimethylphenol                 11.0
          Chloranthene                       16.0
          Naphthalene                         7.8
          2-Nitrophenol                       3.0
          2,4-Dinitrophenol                  11.0
          4,6-Dinitro-o-cresol                0.74
          Pentachlorophenol                   3.0
          Phenol                             38.0
          Benzo(a)anthracene                 62.0
          Acenaphylene                        4.5
          Fluorene                           20.0
          Pyrene                              1.9
          Copper                              0.91
          Lead                                6.0
          Zinc                                3.05

Copper Foundries

An  estimated  9.2  billion gallons of process wastewater results each year
from the casting of copper and copper alloys.  72.4 percent of  this  water
is recycled,  while 27.46 percent is discharged to navigable waters and 0.14
percent  is  discharge  to POTW's.   11.5 percent of this 9.2 billion gallon
flow is recycled at 100< percent.  Three manufacturing processes  use  water
in the copper casting s'ubcategory.

Dust Collection Process:

An  estimated  615  million gallons of process wastewater results each year
from dust collection operations.  This represents 6.6 percent of the  total
process  wastewater  flow  at plants within the copper casting subcategory.
86.6 percent of this 615 million gallon flow is recycled while 13.4 percent
is discharged to navigable waters.   Estimates, based on  the  plant  survey
responses,  of  the  discharge  flow  to  POTW's could not be made for this
process.  An estimated 86.6 percent of this  615  million  gallon  flow   is
recycled at 100 percent.

A  general  process and water flow diagram of a typical copper foundry dust
collection system is presented  in Figure III-6.

Copper foundry dust collection  operations use scrubbers to remove  airborne
particulates.   The  dust collection systems under consideration herein  are
used to remove the airborn particulates generated as a  result  of  molding
sand  handling  operations,  mold  making and casting shake out.  The major
pollutant load from this process results from the casting sand  itself   and
                                    86

-------
the  binders  and  process  chemicals  used  in  the  molding  and  casting
processes.  Test data from a  representative  dust  collection  system  was
obtained  during  the sampling program.  Plant survey data indicate a range
of applied flow rates varying from 63 1/kkg (15.1 gal/ton) to  8,440  1/kkg
(2,027 gal/ton).  Recycle rates were either 0 or 100 percent.

A  review  of  the  six  plant  responses  with  dust collection operations
indicates that all process wastewaters are generated in the same manner and
are handled in the same manner, i.e., all of the treatment  systems  employ
some  type  of  settling  step.  Refer to Table V-8 for descriptions of the
treatment systems employed in this subcategory segment.  Of the six  plants
using  this process, four plants employ 100 percent recycle systems and two
discharge all dust collector  process  wastewaters.   Of  the  100  percent
recycle  plants,  three  have  "internal"  recycle  systems while one plant
recycles all dust collector process wastewaters through a settling  lagoon.
The  internal  recycle  systems  recirculate  process wastewater within the
scrubber equipment package as designed by the scrubber  manufacturer.   The
two  plants  with discharges provide settling prior to the discharge of all
dust collector process wastewaters to receiving streams.

Settling to  achieve  solids  removal  is  the  only  treatment  technology
identified  in  the survey responses.  Plant 19872, Figure V-7, was sampled
during the sampling program.  This plant uses  a  dust  .collector  scrubber
with an internal recycle rate of 100 percent.  Settled sludge is removed by
a dragout mechanism for disposal.

Plant  9094,  Figure  V-8,  produces process wastewater from three internal
recycle dust collectors.  The process wastewaters are collected and treated
in a series of  three  lagoons  to  provide  solids  removal.   The  lagoon
effluent  is  recycled back to the scrubbers;  Discharge from the ponds was
eliminated in 1977 when the ponds were dammed.  Additional water  from  the
lagoons   is  used  to  sluice  the sludge from the settling chambers of the
three scrubbers to pond number 1.

Table V-35 summarizes the raw and treated waste loads observed  during  the
sampling  program.   A  quick  look  synopsis  (partial summary) of the data
presented on Table V-35 indicates that the following toxic  pollutants  are
present in the raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations  (mq/1)

          Phenol                     0.17
          Cadmium                    1.2
          Chromium                   1.2
          Copper                   330.0
          Lead                     110.0
          Nickel                     3.1
          Zinc                     730.0
                                     87

-------
Mold Cooling and Casting Quench Process:

An  estimated  4.6  billion gallons of process wastewater results each year
from mold cooling  and  casting  quench  operations.   This  represents   50
percent  of  the  total process wastewater flow at plants within the  copper
casting subcategory.  48.75 percent of this  4.6  billion  gallon   flow   is
recycled  while  51  percent  is  discharged  to  navigable waters  and 0.25
percent is discharged to POTW's.

A general process and water flow diagram of a representative copper foundry
dust collection system  is presented in Figure III-6.

Copper casting foundries  generate  process  wastewaters  as   a  result   of
cooling  operations  requiring contact cooling water for molds and  quenches
for castings as they are formed.   The  major  pollutant  load from  these
operations  are  the  particles  of copper and alloying materials which  are
represented as suspended solids.  These particles settle primarily  in   the
cooling  and  quench  tanks  where  periodically the solids are removed  and
reclaimed.  Test data from a representative mold cooling and casting  quench
operation was obtained  during the sampling program.  Plant survey responses
indicated a range of  applied  flow  rates  varying  from  583 1/kkg (140
gal/ton)  to  110,200   1/kkg (26,470 gal/ton).  All plants, except  one,  had
discharge rates of  100  percent of the applied flow.  The  exception,  which
had  the  largest applied flow rate (at least eleven times greater  than  the
next lowest applied flow rate), had a recycle rate of  99.5 percent.

Review of the responses of  the  surveyed  plants  with  mold  cooling   and
casting  quench  operations  indicates  that  all  process  wastewaters  are
generated in the same manner, although the wastes are  handled  in a  variety
of  ways.   Refer   to   Table  V-9 for descriptions of  the treatment systems
employed at these plants.  Process wastewater handling schemes varied from
untreated   discharges   to  POTW's  to  settling  and cooling.    Settling
operations were dated to 1960.

Of  the seven plants identified  in the survey with this process, two  plants
discharge  all of their mold cooling and casting quench process wastewaters
untreated to POTW's, two plants provide settling prior to the  discharge   of
all  of  their  process wastewaters to a receiving stream, and the process
wastewaters of one  plant are treated in a central treatment  facility.    Of
the two  other plants, one had a recycle rate of 99.5 percent (0.5 percent
of  the process wastewater from  the process was discharged to a POTW).   The
response from the remaining plant indicated a recycle  system but sufficient
detail  was  not provided by the plant to determine the recycle rate. This
plant discharges  its process wastewater to navigable waters.   Both  recycle
plants  installed cooling towers in their recycle  loops.  The plant  with  the
undeterminable  recycle discharged  its blowdown to a lagoon  from  where it
was discharged to a receiving stream.
                                     88

-------
Of the five plants using some type of process wastewater treatment  system,
the various technologies employed are as follows:

a.   Settling:  To provide solids removal.

b.   Settling, Recycle and Cooling Tower:  used  in the systems with a  high
     recycle  rate  to  provide  solids  removal and cooling of the process
     wastewater.  Cooling is needed to maintain  the  proper  heat  removal
     capabilities in the system.

     Note:   One plant with mold casting and casting quench discharges to a
     central treatment facility and therefore  was  not  included  in  this
     discussion  since  the process wastewater flow from this metal casting
     process represents  only  0.02  percent  of  total  central  treatment
     process wastewater flow.

Plant  4736,  Figure  V-9 operates a mold cooling and casting quench.  This
process is a 100 percent recycle  with  make-up  via  a  float  valve.   An
auxilliary  holding  tank  is installed to maintain a water balance in this
system.

Table V-36 summarizes the raw and treated waste  load  observed  during  the
sampling  program.   A  quick  look  synopsis (partial summary) of the data
presented on Table XX indicates that the  following  toxic  pollutants  are
present in the raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations (mq/1)

          Copper                   1.1
          Zinc                     3.5

Continuous Casting Process:

An estimated 4 billion gallons of process wastewater results each year from
direct chill casting operations.  This represents 43.4 percent of the total
process  wastewater  flow  at plants within the  copper casting subcategory.
96.8 percent of this 4 billion gallon flow is recycled while 3.1 percent is
discharged to navigable waters and 0.1 percent is discharged to POTW's.  An
estimated 13 percent of this 4 billion  gallon   flow  is  recycled  at  100
percent.

Figure  III-6  presents  a  general  process  and  water  flow diagram of a
representative copper continuous casting operation.

The continuous casting operation wastewaters result from the cooling of the
molds and castings used in and produced on  continuous  casting  equipment.
The  major  pollutant  loads in these process wastewaters are the suspended
solids consisting primarily of copper and  copper  alloy  materials.   Test
data  from  continuous  casting operations was obtained during the sampling
                                     89

-------
program.  Plant survey responses indicated a range of applied  flow  rates  of
5,080 1/kkg (1,220 gal/ton) to  42,600  1/kkg   (10,230  gal/ton).   Recycle
rates varied from 0 to 100 percent.

A  review  of  the  data   indicates  that  eleven  plants responding  to the
information request employ continuous casting operations.   In  all cases the
operations need water for  casting and  mold  cooling  purposes.   Refer   to
Table  V-10  for  descriptions  of  the  treatment  systems  used   in this
subcategory segment.   Process  wastewater  handling  schemes   ranged from
untreated discharges to 100 percent recycle systems.  Of the eleven plants,
seven operate a direct chill casting process casting copper or  copper alloy
logs,  one  plant operates a wire bar casting unit and three plants operate
continuous casting wheels.

Three direct chill casting  plant,  recycle  100  percent  of   the  process
wastewater.   The  three   plants  operating  the  continuous casting  wheels
indicated recycle rates of 100 percent.  The wire bar  casting  plant also
indicated  a  100  percent  recycle rate.  Therefore, of the eleven plants,
seven plants indicated recycle rates of 100 percent.

Two  addition  plants  were  identified  that   employ  continuous   casting
techniques.   One  plant   casts logs while the  other plant casts retangular
slabs.  Of interest in these two plants is that they employ similar  direct
chill   casting  techniques as the other seven  direct chill casting plants,
but  these two plants do not produce a process wastewater.  Only noncontact
cooling  water  is  used.   The difference between these two plants and the
other seven plants  is that these two  plants  have  eliminated  the  quench
water   and therefore the process wastewater source.  The noncontact cooling
water sprayed on the mold  is recirculated, not  allowed to come  into contact
with the casting and is discharged untreated.   Treatment  system  dates   of
installation began  in 1945; the oldest cooling  tower is dated  1965.

Of   the  seven  plants  with  treatment  system information,   the  various
technologies used are as follows:

a.   Settling and Cooling  Tower:   used  to  provide  solids   removal and
     cooling  of  the  wastewater.  Cooling is  needed to remove excess heat
     from the cooling system.

b.   Heat Exchanger and Cooling Tower:  this system provides cooling  of the
     process wastewater while eliminating the water losses  associated with
     the  use of a  cooling tower.  The blowdown from the cooling tower is a
     noncontact  water.    This  system  is  used  in  100  percent  recycle
     operations.

c.   Settling:  to  provide solids  removal on systems discharging at least a
     portion of their process wastewater flow.
                                     90

-------
Plant  6809,  Figure  V-10,  recycles  mold  cooling  and  casting  process
wastewaters  through  a  cooling tower.  Overflow at the hot wells act as a
blowdown  of  process  wastewater  from  the  recirculating  system.   This
blowdown  represents  3  percent  of  the combined process wastewater flow.
These combined process wastewaters are settled and skimmed in a lagoon  and
are then discharged.

Plant  9979  has a direct chill casting operation producing both copper and
aluminum castings.  This 100 percent recycle operation uses a cooling tower
to reduce the wastewater system heat load.  Temperature probes activate the
cooling tower when evaporative  cooling  is  required.   The  recirculating
system  of approximately 25,000 gallons supplies water to: the direct chill
casting molds, the casting quench water, the cooling tower, and  noncontact
cooling  waters  systems within the plant.  The casting molds are cooled by
passing process wastewater through water jackets  around  the  mold.   This
water upon leaving the mold is also sprayed on the casting as it leaves the
mold.   The  addition  of  water  treatment  chemicals  to this 100 percent
recirculation system has  limited  the  scale  buildup  within  the  molds.
Graphite  entering  the  quench  water from the casting applied to the mold
periodically causes a fouling problem but maintenance personnel remedy this
condition.

Table V-37 summarizes the raw and treated waste loads observed  during  the
sampling  program.   A  quick  look  synopsis (partial summary) of the data
presented on Table V-37 indicates that the following toxic  pollutants  are
present in the raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations (mq/1)

          Cadmium                  0.11
          Copper                   2.4
          Zinc                     4.4

Iron and Steel Foundries;

An  estimated  105  billion  gallons of process wastewater result each year
from the casting of ferrous metals.  79 percent of this water  is  recycled
while   18  percent  is  discharged  to  navigable  waters  and 3 percent  is
introduced  into POTW's.  An estimated 47.7  percent  of  this  105  billion
gallon  flow  is recycled at 100 percent.  Five manufacturing processes have
been identified as using water in the iron and steel casting subcategory.

Dust Collection Operations

An estimated  52 billion gallons of process wastewater result each year from
dust collection operations.  This represents approximately  50  percent   of
the  total  process  wastewater  flow  at  plants within the iron and  steel
casting subcategory.  84.2 percent  of  this  52  billion  gallon   flow   is
recycled,  while   14.2  percent is introduced into navigable waters and  1.6
                                     91

-------
percent is discharged to POTW's.   An  estimated  55  percent  of  this   52
billion gallon flow is recycled at 100 percent.

Figure  II1-7  presents  a  general  process  and  water  flow diagram of  a
representative iron and steel foundry dust collection operation.

Ferrous foundry dust collection systems use the various types of   scrubbers
as  described  in  Section  III  to remove airborne gases and particulates.
These dust collection systems are used to remove the airborne  contaminants
generated  as  a  result of sand handling operations, mold and core making,
and mold and casting shakeout.  The major pollutant load results   from   the
casting  sand  itself  and  the  binders  and process chemicals used  in  the
molding and casting processes.  Test data from dust collection systems were
obtained during the sampling  programs  conducted  during  1974  and  1978.
Plant survey responses indicated a range of applied flow rates varying from
171  1/kkg  (41  gal/ton)  to 96,200 1/kkg (23,110 gal/ton).  Recycle rates
varied from 0 to 100 percent.  A number of  the  dust  collection  scrubber
systems  employed  process  wastewater  treatment and handling equipment as
part of the scrubber package.  The process wastewater  is  then  frequently
recycled internally at 100 percent.

A  review  of  the  131  plant  responses  with  dust collection operations
indicates that all process wastewaters are generated in the same manner  and
are treated in essentially the same manner; i.e., all treatment systems  are
primarily settling operations.  Refer to Table V-ll for descriptions  of  the
treatment systems used in this process.  Recycle rates vary from 0 to   100
percent.   Recycle  systems   involved  both "internal" (within the scrubber
equipment  package)  and  "external"  (through  separate  waste  treatment)
recycle of the process wastewaters.

Of  the 131 responses  indicating the presence of dust collection scrubbers,
68 plants indicated that 100  percent of the process  wastewater  associated
with   the  dust  collection   operation is recycled.  Of these 68 plants,  47
plants  indicated  100  percent  "internal"  recycle  within  the  scrubber
equipment  package  and  21 plants indicated 100 percent recycle of process
wastewater with external treatment provided.

Forty-six plants recycle the  dust collection  process  wastewater  at  less
than   100  percent.    Twenty-five  of  these  plants  discharge the recycle
overflow untreated; 17 untreated  discharges  go  to  POTW's,  8   untreated
discharges  go to navigable waters.  The 21 other plants discharged treated
process wastewaters; 8 discharge  to  POTW's,  13  discharge  to   navigable
waters.

Seventeen  plants  discharge  all  of  their process wastewater without  any
recycle;  10 plants provide  treatment  prior  to  direct  discharge;  three
plants  provide  treatment  prior  to  discharge  to  POTW  and  four plant
discharge untreated process wastewater to POTW's.
                                     92

-------
The various treatment technologies indicated in the plant data are:

a.   "Internal" Recycle:  settling for solids removal is provided within  a
     manufacturer's  scrubber  equipment package.  Sludge is removed via an
     endless chain conveyor fitted with scoops to move the sludge from  the
     settling chamber to an appropriate receptor outside the scrubber.

b.   Settling With or  Without  Chemical  Addition  and  Skimming:   solids
     removal  is  accomplished in a variety of ways.  These methods include
     lagoons, clarifiers, tanks, and dragout chambers.   Polymer  or  other
     chemicals  may  be  added  to  enhance  solids  removal.   Skimming is
     provided for surface scum removal.

Plant 55122, Figure V-ll, was sampled during  the  1974  sampling  program.
Dust collector process wastewaters from casting cooling, core room, molding
and  cleaning  departments  are  collected  and recirculated from a central
sump.  Ninety percent of the process wastewater is  recirculated  while  10
percent is discharged to a receiving stream.  A sidestream treatment system
consists  of  a  cyclone separator, with the underflow screen dewatered and
solids disposed to landfill, while the screen drains to the . central  sump.
The  cyclone  overflow  goes  to  a  thickener where polymer is added.  The
thickener underflow is vacuum filtered with solids disposal to landfill and
filtrate returned to the thickener.

Plant 59101, Figure V-12, has a series of 12 bulk bed washer type scrubbers
in the foundry for the cleaning of molding and cleaning dusts.  The process
wastewater from these units is pumped to a collection sump and  then  to  a
lagoon.  No dust scrubber process wastewater is recycled externally.

This  plant  also had a sand washing system to reclaim sand for reuse.  The
process wastewater from this operation also went to the lagoons.

The  lagoons were arranged to give maximum use of the land area.  The  inlet
to   the first lagoon was arranged so that the heavy solids could be removed
readily.  The lagoon overflow is discharged to a receiving stream.

Plant 57775, Figure V-13, has a process wastewater from  a  dust  scrubber.
The  process wastewater flows to a drag tank where solids separation occurs
and  sludge  is removed.  At the time of the plant visit in 1974, 88  percent
of   the  dust collection process wastewater was recycled.  Since that time,
the  dust collection process wastewater has been combined with  the  melting
furnace  scrubber  process  wastewater, recirculation system and 100 percent
recycle of all process wastewater has been achieved.

Plant 53219, Figure V-14, has a scrubber which cleans molding and  cleaning
dusts.   The  process  wastewaters  from  the scrubber drain to a drag  tank
where a flocculant is added, and solids are removed.  Ninety-eight  percent
of   the  process  wastewater is recycled to the collector, and the overlfow
goes to the sanitary sewer.
                                     93

-------
Plant 55217, Figure V-15,  has  a  wet  dust  collector  system.   Scrubber
process  wastewater  flows  to  a  large  lagoon.   From the lagoon process
wastewater is recirculated back to the  dust  collection  scrubbers.   This
recirculation   system   is   common  with  the  melting  furnace  scrubber
recirculation system.  There is no discharge from this common system.   One
hundred percent of all process wastewater is recirculated.

Plant  57100,  Figure  V-16,  has  four  scrubbers to clean dusts from sand
mixing, mold shakeout,  and  shot  blast  cleaning  operations.   They  are
mechanical-centrifugal  type  collectors.  After settling, a portion  of the
water is recycled back to the dust collector.  The remainder is  discharged
to the municipal sanitary treatment plant.

Plant  56771,  Figure V-17, produces dusts from the molding area, core room
shakeout and cleaning areas.   These  dusts  are  cleaned  by  means  of   a
scrubber.   The process wastewater is settled in a drag tank where chemical
additions aid settling.  A portion of the process  wastewater  is  recycled
while  the remaining process wastewater flow was discharged to a POTW prior
to 1974.  Since then the discharge has been eliminated.

Plant  15520, Figure V-18, is a large foundry with a complex water  balance.
Dust collection scrubber process wastewater, slag quench process wastewater
and  sand washing process wastewaters are settled and recycled with make-up
from noncontact cooling water.  As water balance upsets occur, overflow   is
periodically discharged to a POTW.

Plant  20009,  Figure V-19, has four wet dust collectors which are operated
with a overflow to a POTW.  A sand reclaim process washes the sand for sand
recovery.   The waste products are settled in  a  series  of  four  lagoons.
•Settled  sludge from  the ponds is removed to landfill.  Forty percent  of the
lagoon   water  is  discharged  by  overflow to a POTW and 60 percent  of the
process  wastewater flow  is recycled.

Plant  7929,  Figure V-20, has operated nine dust collection scrubbers  at 100
percent  recycle of process wastewater since  1973.   These  nine  scrubbers
remove   airborne  particulates generated in the casting shakeout area, core
room muellers, pouring casting casting cooling  lines,  sand  handling  and
transfer system,  and   the  molding floor and molding line areas.  Western
bentonite clay is used in the foundry sand.   A  two  compartment  settling
concrete tank was installed  in 1973.  Only one settling compartment  is used
at   a  time and  as  necessary  the compartments are switched to allow for
sludge removal.   The  solids  are   landfilled  on  company  property.    An
 inertial grit  separator was installed  in 1978.  Prior to the  installation
of  the grit separator the scrubbers  would become fouled approximately once
per  month.   The fouling  was  believed by plant personnel to be caused  by the
bentonite   clay.   The cleaning of all the scrubbers required a maintenance
effort of three men  for  three 8-hour shifts.   At  the  same  time  of  the
 installation of the  grit separator,  a maintenance program employing  a 1,000
psi  pump   and hand  held cleaning wand was initiated to clean the scrubbers
                                     94

-------
on a routine basis.  All scrubber cleaning is  performed  one  weekend  per
month by one maintenance man and a helper.

Plant  51115,  Figure  V-21,  has  two  interconnected  100 percent recycle
process wastewater systems.  The treatment system was originally  installed
in  1959.   Prior to 1976, process wastewater was discharged to a navigable
water.  In 1976 this discharge was eliminated when 100 percent  recycle  of
the  process  wastewater  was  achieved.  Three scrubbers which clean dusts
from the core room and shakeout area are  in  operation  at  this  foundry.
Process  wastewater  from  the  sand  washer and the dust scrubbers flow by
gravity to a collection tank.  Water  in  the  collection  tank  flows  via
gravity  to  the grit building where alum, polymer, and flocculant aids are
added.  Solids are removed in a drag tank.  Water from the drag tank  flows
to a settling basin where it is pumped as needed to the dust collectors and
sand  washing  equipment.   Problems  were encountered with the 100 percent
recycle system immediately after closing the loop.  These problems were: 1)
the determination of the correct amount of polymer  addition  required  for
optimum  settling  took a number of weeks; 2) during this transition period
plugging of the scrubbers occurred; and 3) a larger than normal  amount  of
mud  collected in the, settling basin.  However, after the correct amount of
polymer addition was determined, and  the  proper  water  balance  achieved
throughout the system, these problems were eliminated.

Plant  50315, Figure V-22, produces process wastewater from scrubbers which
clean dusts from sand molding operations.  The process wastewater drains to
a lagoon for settling.  One hundred percent of this process wastewater  has
been recycled back to the dust collection scrubbers since 1974.

Plant  59212, Figure V-23, produces dust collector, slag quench and melting
scrubber process wastewaters which are collected in a drag tank.   Chemical
additions to aid settling are made and the water is recirculated.

Solids  are  removed  by  the drag conveyor, and overflow water drains to  a
second settling tank.  Two settling  ponds  have  been  added  since  1974.
Water is discharged to a POTW.

Plant  53642,  Figure V-24, has a scrubber system for the cleaning of dusts
collected in the molding, core room, pouring, cooling and  cleaning  areas.
The  process wastewater flows to a primary settling tank and then  is pumped
to a  cyclone separator.  The cyclone underflow flows to  a  classifier  for
dewatering   and removal of solids, with the dewater returned to the primary
tank.

The upflow from the cyclones goes to a second  tank  for  recycle,  with   a
blowdown   (10  percent)  to  a  thickener.   Alum and poly are added at the
thickener.   The underflow goes to a vacuum filter.  The filter cake goes  to
landfill and the filtrate  is returned to  the thickener.

The thickener overflow  is available for reuse or discharge to  the  river.
                                     95

-------
Table V-38 summarizes the net raw waste loads observed during the  sampling
programs.  A quick look synopsis (partial summary) of the data presented  on
Table V-38 indicates that the following toxic pollutants are present  in the
raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations  (mq/1)

          Phenols                  31.3
          2,4-dimethylphenol        1.13
          2,4-dichlorophenol        0.3
          Phenol                    4.77
          Copper                    2.86
          Lead                      2.3
          Zinc                      9.5

Melting  Furnace Scrubber Process:

An  estimated  26.7  billion gallons of process wastewater  result  each year
from melting furnace scrubber operations.  This represents  25   percent   of
the  total  process  wastewater  flow  at  plants within the iron  and steel
casting  subcategory.  80.6 percent of this  26.7  billion   gallon  flow   is
recycled,  while   16.6  percent  is  discharged to navigable waters and 2.8
percent  is discharged to POTW's.  An estimated  11  percent of  this 26.7
billion  gallon flow  is recycled at 100 percent.

A  general  process  and  water  flow  diagram  of a representative ferrous
foundry  melting furnace scrubber operation is presented in  Figure  III-7.

The major pollutant  load is due to the  amount,  type  and  cleanliness   of
scrap  and  metal  used  in  the furnace charge and the various  by-products
associated with the  melting  process.   Test  data  from   melting furnace
scrubber operations  visited during the sampling programs  of 1974 and 1978
provided information about the pollutants from this process.  Plant   survey
responses   indicated  a  range  of  applied   flow rates from 620 1/kkg  (149
gal/ton) to 39,780 1/kkg (9,555 gal/ton).  Recycle rates varied  from  0   to
100 percent.

A  review  of  the  82  plants  responses  with furnace scrubber operations
indicates that the process wastewaters are not only generated in a similar
manner,   but  also  are  treated   in essentially the same manner.  Refer  to
Table  V-12  for descriptions of the treatment  systems used by plants in this
subcategory segment.  Recycle rates may very  from  0  to  100  percent  and
recycle  systems employ both "internal" and "external" treatment  systems.

Of   the  82 plant  responses indicating the use of a melting  furnace scrubber
system forty-five  plants have 100  percent recycle systems.  Of these  forty-
five,  seventeen have "internal" recycle systems  and  twenty-eight provide
external treatment  for the recycled process wastewaters.  Another thirty-
one  plants  employ  recycle systems  with recycle rates  less than  100 percent.
                                     96

-------
Of these thirty-one plants, three plants have internal recycle systems with
untreated  discharges  to  POTW's,  seventeen  plants   discharge   process
wastewaters  from  an  "external"  recycle  treatment system to a receiving
stream, and eleven plants discharge  process  wastewaters  from  "external"
recycle  treatment  systems to POTW's.  One plant treats and discharges all
of its process wastewaters to a POTW, four plants treat and  discharge  all
process  wastewaters to a receiving stream, and one plant discharges all of
its process wastewater without treatment to a POTW.

The various treatment technologies indicated in the plant data are:

a.   Internal Recycle:  these systems provide solids removal via some  type
     of  settling  operaton.  In some instances various chemicals are added
     to provide pH adjustment and enhanced solids removal.

b.   External recycle, settling With or Without Chemical  Addition:   these
     systems  use  lagoons, settling tanks, dragout chambers, or clarifiers
     to accomplish  solids removal.  Various chemicals are  added  for  the
     purposes of pH adjustment and enhanced solids removal.

Note   that both the internal and external treatment systems use essentially
the same treatment process.

Plant  6956,  Figure  V-25,  produces  wastewaters  from  melting   furnace
scrubber, slag quenching, and dust collection operations which are combined
for  treatment.   The  wastewaters  are  first  treated in a clarifier with
polymer added to enhance solids removal and lime added for pH control.  The
clarifier effluent flows to a lagoon fromwhich a  portion  of  the  treated
wastewaters  are  recycled  back  to the three processes listed above.  The
lagoon not  only  provides  system  holding  capacity  but  also  provides
additional solids removal capability.  Clarifier sludge is transported to a
landfill  disposal  site.   A  portion of the wastewater flow is discharged
from the lagoon.  The recycle rate of the combined treatment system  is  95
percent.

Plant  52491,  Figure  V-26,  has  a Venturi scrubber for control of cupola
emissions.  The process wastewater is collected in a  settling  tank  where
caustic  is added.  The overflow  is recycled to the Venturi Scrubber.  This
flow is adjusted to give a slight surplus of return water in  the  settling
tank.   This surplus  is discharged to the city sewer.  The settling tank is
dumped daily to a dewater box.  After additional settling  in  the  dewater
box,   the  water  is  returned  to  the  settling  tank  and the solids are
landfilled.

Plant  57775, Figure V-13,  produces  process  wastewaters  from  a  melting
furnace  scrubber  system  which  are treated in a drag tank by addition of
caustic and polymer.  Solids are  landfilled and the process  wastewater  is
recycled.  At the time of the sampling in  1973, some overflow from the drag
tank   drained  to  the  sanitary  sewer.  However, since collection of plant
                                     97

-------
data in 1973, this plant  has  closed  the  loop  on  the  melting   furnace
scrubber system.  No process wastewater is discharged.

Plant  53219,  Figure  V-14,  has a Venturi scrubber and a separator on  the
cupola.  The separator has a conical bottom  that  collects  heavy   solids.
Caustic  is  added  to  the separator via a pump.  Water is pumped  from  the
separator to the process, and an overflow from the separator discharges   to
the  sanitary  sewer.   The  separator is drained, at the end of  the cupola
run, to a dewatering tank, and the solids are sent to a landfill.

Plant  56789, Figure V-27, operates a cupola Venturi scrubber.  The  scrubber
process  wastewater  drains  to  a  classifier  tank  where   caustic    and
polyelectrolytes are added.  The underflow goes to a drag tank where solids
are  settled  and  removed.   The  drag  tank  overflow  is recycled to  the
classifier and excess is drained to a transfer transfer tank.  Water in  the
overflow transfer tank is pumped to a storage tank.  Caustic  is  added   at
the  overflow  tank  for  corrosion  control.   One  hundred percent of  all
process wastewater from the melting  furnace  scrubber  has  been  recycled
since  1974.

Plant  58589, Figure V-28, has a melting furnace scrubber process  wastewater
which   is collected  in a separator, and then pumped to a large sump.  After
settling overnight,  the sump is syphoned to a second sump.  Water from this
second sump  is recycled to  the quench chamber-scrubber the next day-  This
plant   recycles   100  percent  of  its  melting furnace process wastewater.
Solids were  removed  from the first sump bi-monthly.

Plant   56123,  Figure  V-29,  collects  melting   furnace  scrubber   process
wastewa.ters   in   a   drag  tank  where caustic is  added and heavy  solids  are
removed.

The  overflow from this tank to a filtrate  tank   where  a  portion   of  the
process wastewater  is recycled to the furnace scrubber.  A sidestream from
this filtrate tank passes through cyclone classifiers and then to  pressure
sand filters.  From  the sand filters the treated  process wastewater returns
to  the filtrate  tank.  The filter backwash is  blown down to a  surge tank
and  then to  a floe tank where chemical additions  are made.  The   floe  tank
overflows   to  a  clarifier.   The  clarifier  underflow  is  delivered   to
landfill, and the overflow  is discharged to municipal sanitary sewers.

Plant  55217,  Figure  V-15, produces process  wastewaters  from  the   melting
furnace scrubber on a triplex cupola arrangement.  The process wastewaters
are  collected  in  a slurry tank.  Caustic is added, and the water  is pumped
to  a  large  lagoon that  is  shared with another plants.  One hundred percent
of the process  wastewater   from  the  melting  furnace  scrubber  has  been
recycled since  1974.

Plant   50315,   Figure  V-22,  and  Plant 55217 share settling  lagoons.  The
process wastewater from  the melting furnace scrubbers flows to   the  lagoon
                                     98

-------
and  is recycled from the lagoon to the cupola emission system.  Like plant
55217,  since 1974 100 percent of the process wastewater  from  the  melting
furnace scrubber has been recycled.

Plant  54321,  Figure  V-30,  produces  melting  furnace  scrubber  process
wastewaters and slag quench process wastewaters which are drained to a drag
tank.  A sidestream to a classifier removes solids continuously, as well as
the continuous removal of settled material by the drag conveyor.   Hydrated
lime is added to control corrosion.  Pumps recycle water from the drag tank
to  the  quencher  and  Venturi scrubber on the melting furnace.  Since the
collection of plant data in 1974, this plant has closed  the  loop  on  the
recycle  of process wastewater from the melting furnace scrubber.  There is
no process wastewater discharge from this system.

Plant 56771, Figure V-17, has a system similar  to  plant  54321  with  the
addition  of  an  aftercooler  and a cooling tower.  These two units reduce
stack temperature and carryover.  And like  plant  59321,  this  plant  has
closed  the  loop  on  the  recycle  of process wastewater from the melting
furnace scrubber.

Plant 52881, Figure V-31, has a system that is a duplicate of Plant  54321.
And  like  Plant  54321,  this  plant has closed the loop on the recycle of
furnace scrubber process wastewater.

Plant  59212,  Figure  V-23,  produces  melting  furnace  scrubber  process
wastewaters,   together   with   dust  scrubber  and  slag  quench  process
wastewaters which are collected in a drag tank.  Chemicals are added to the
drag tank to aid settling.   Process  wastewater  from  the  drag  tank  is
recirculated  to  the  mist  eliminator.   Process wastewater from the mist
eliminator is pumped  through  two  cyclones  with  the  clarified  process
wastewater  going  to  the  furnace scrubber and returning through the mist
eliminator to the cyclones.  The cyclone underflow is drained to  the  drag
tank.   Solids  are  removed in the drag tank by a drag conveyor.  Overflow
from the drag tank drains to a second settling  tank.   Process  wastewater
from the second settling tank discharges to a POTW.

Plant 0001, Figure V-32, operates a cupola furnace with an emission control
system similar to plant  7170.  The settled particulates are discharged to  a
landfill  daily.   Settling  is aided by a cyclone, and a classifier in the
system, as  well  as  chemicals  that  are  added  during  operation.   The
particulates  settle  to  the bottom of the cyclone due to inertial action.
These are piped to the classifier where further settlement collects them at
the bottom of the cone.  After the cupola is  shut  down,  this  sludge  is
dumped  to a tote bucket.  The recirculating pumps are operated for a short
period to cool the system and to move any particulates in the  system  into
the  classifier.   After  settling  overnight, the classifier cone is again
dumped to the tote bucket^  This system operates with 100  percent  recycle
of all process wastewater.
                                     99

-------
Plant  00002,  Figure  V-33,  is  similar  to 0001 with an added feature of
energy recuperation before the Ventrui scrubber to reclaim  heat  from  the
furnace  exhaust gas stream.  The Venturi, separator, hydraulic cyclone and
classifier are similar to plant 0001, as well  as  the  operation  methods.
Again, this system recycles 100 percent of the process wastewater.

Plant  15520,  Figure  V-18,  has  a  separate treatment system for melting
furnace scrubber process wastewaters.  The  treatment  system  consists  of
chemical  additions,  clarification  and  vacuum  filtering  of the settled
material.  Clarifier overflow is recycled to a balance tank and then  to the
melting furnace scrubber.  Noncontact cooling water  is used as makeup water
to the melting furnace scrubber recirculating system.

Plant 6956, Figure V-34 produces wastewaters from melting furnace scrubber,
slag quenching, and dust  collection  operations  which  are  combined  for
treatment.   The  wastewaters are first treated in a clarifier with polymer
added to enhance solids  removal  and  lime  added   for  pH  control.   The
clarifier  effluent  flows  to a lagoon from which a portion of the treated
wastewaters are recycled back to the three  processes  listed  above.   The
lagoon  not  only  provides  system  holding  capacity  but  also  provides
additional solids removal capability.  Clarifier sludge is transported to a
landfill disposal site.  A portion of the  wastewater  flow  is  discharged
from  the  lagoon.  The recycle rate of the combined treatment system is 95
percent.

Plant 7170, Figure V-35,  is  small  gray  iron-foundry  which  operates  a
melting   furnace   scrubber   system.    The   melting   furnace  operates
approximately  two hours per  day  during  which  time  all  system  process
wastewaters  are  recycled.   Caustic  and polymer are added to the process
wastewater system following furnace operation and the process wastewater is
allowed  to settle  overnight.   Prior  to  operation  of  the  furnace  the
following  day, the settled solids are drained from  the system to a company
landfill.  One hundred percent of all process wastewaters are  recirculated
in this  system.

Table  V-39  summarizes the raw and treated waste loads observed during the
sampling programs.  A quick look synopsis  (partial   summary)  of  the data
presented  on  Table V-39 indicates that  the following toxic pollutants are
present  in the raw process wastewaters from this manufacturing process.
                                    100

-------
          Pollutant           Concentrations (mq/1)

          Acenaphthylene             0.69
          Antimony                   3.4
          Cadmium                    2.2
          Chromium                   4.6
          Copper                    12.0
          Lead                     140.0
          Selenium                   1.2
          Zinc                     340.0

Slag Quench

An estimated 8.7 billion gallons of process wastewater  results  each  year
from  slag  quenching operations.  This represents 8.5 percent of the total
process wastewater flow at plants within the  slag  quenching  subcategory.
45.4 percent of this 8.7 billion gallon flow is recycled while 52.8 percent
is  discharged to navigable waters and 1.8 percent is discharged to POTW's.
An estimated 19.7 percent of this process wastewater  is  recycled  at  100
percent.

Figure  II1-7  presents  a  general  process  and  water  flow diagram of a
representative ferrous foundry slag quenching operation.

In this operation,  the  slag  removed  during  the  melting  operation  is
quenched in order to cool and thus solidify the slag.  The quenched slag is
subsequently  reirtbved  for  disposal  or  reuse in other applications.  The
pollutants in this  process  wastewater  result  *from  the  slag  quenching
operation.   Test  data  obtained from slag quenching operations during the
1974 and 1978 sampling  programs  provided  indication  of  the  pollutants
expected  in  this  process.   Plant  survey responses indicated a range of
applied flow rates varying from 117 1/kkg  (28  gal/ton)  to  23,860  1/kkg
(5,731 gal/ton).  Recycle rates varied from 0 to 100 percent.

A  review  of  the  63  plants responses with slag quenching operations in-
dicates that the process wastewaters are not only generated  in  a  similar
manner  but also are generally treated in a similar manner.  Refer to Table
V-13 for descriptions of  the  treatment  systems  used  in  this  process.
Degrees  of  process  wastewater treatment vary from no treatment at all to
the recycling of 100  percent  of  all  process  wastewaters.   The  oldest
process wastewater treatment component was installed in 1948.

Of the 63 ferrous foundries with slag quenching operations indicated in the
plant data, twenty-two plants recycle all of their process wastewater while
six  foundries  discharge  all  of their process wastewaters untreated to a
POTW and four plants discharge all of their process  wastewaters  untreated
to  receiving  streams.  Three plants treat and then discharge all of their
process wastewaters to POTW's and ten foundries treat  and  then  discharge
all  of  their  process wastewaters to receiving streams.  Seventeen plants
                                    101

-------
have recycle systems with recycle rates less than 100 percent; 10 of   these
17  facilities  discharge a portion of their wastewater flow to a receiving
stream and seven of these plants discharge a portion  of  their  wastewater
flow  to  a  POTW.   One  plant did not provide sufficient treatment system
information to determine the discharge mode.

Settling with or without chemical addition is the  basic  treatment  system
indicated  in the plant data.  Settling tanks, dragout tanks, or clarifiers
were used as the main means of solids removal.  Various chemicals (polymer,
lime, caustic, etc.) were added to the process wastewaters to aid in solids
removal.

Plant 51026, Figure V-36,  produces  slag  quench,  mold  cooling,  casting
quench,  dust  collecting,  and  sand washing process wastewaters which  are
drained to a series of lagoons, and after 84 hours detention are discharged
to the river.  The first lagoon in the series is periodically dredged  with
the  sludge trucked to a nearby landfill.  During this clean-out operation,
the flow is diverted to a duplicate lagoon.

Plant 54321, Figure V-30, produces  slag  quench  process  wastewaters  and
melting  furnace  scrubber  process wastewaters which are drained to a drag
tank.  A sidestream to a classifier removes solids continuously, as well  as
the continuous removal of settled material by the drag conveyor.   Hydrated
lime  is  added   to  control  corrosion.   Pumps  recycle  all  the process
wastewater from the drag tank to the quencher and Venturi.

Plant 56771, Figure V-17, has a slag  quenching  system  similar  to   plant
54321.  Process wastewater is recycled 100 percent.

Plant  52881, Figure V-31, has a system that is a duplicate of plant 54321.
This system also  recirculates 100 percent of the process wastewater.

Plant 59212, Figure V-23, produces slag quench, dust collector, and melting
furnace scrubber  process wastewaters which are collected in  a  drag   tank.
Chemical  additions  to aid settling are made and the water is recirculated
to the mist eliminator.   Drainage  from  the  mist  eliminator  is  pumped
through  two  cyclones  with  the  clarified water going to the Venturi  and
returning through  the  mist  eliminator  to  the  cyclones.   The  cyclone
underflow  is  drained  to  the  drag tank.  Solids are removed by the drag
conveyor, and overflow water drains to a second settling  tank.   Water   is
discharged to a POTW.

Plant   15520,  Figure  V-18,  produces  slag  quench water, dust collection
scrubber water, and sand washing process wastewaters which are settled  and
recycled  with  makeup  from noncontact cooling water.  Discharge of excess
water  is to a POTW.

Plant  6956, Figure V-34, produces process wastewaters from melting  furnace
scrubber, slag quenching, and dust collection operations which are combined
                                    102

-------
for  treatment.   The  process wastewaters are first treated in a clarifier
with polymer added to enhance solids removal  and  lime  is  added  for  pH
control.   The clarifier effluent flows to a lagoon from which a portion of
the treated wastewaters are recycled back to  the  three  processes  listed
above.   The  lagoon  not  only  provides  system holding capacity but also
provides  additional  solids  removal  capability.   Clarifier  sludge   is
transported  to a landfill disposal site.  A portion of the wastewater flow
is discharged from the lagoon.  The recycle rate of the combined  treatment
system  is 95 percent.


Table   V-40 summarizes the net raw waste loads observed during the sampling
programs.  A quick look synopsis (partial summary) of the data presented on
Table V-40 indicates that the following to^ic pollutants are present in the
raw process wastewaters from this manufacturing process.

          Pollutant                Concentrations (mq/1)

          Cyanide                        0.184
          Phenols                        2.1
          Zinc                           0.67

Casting Quench and Mold Cooling Process:

An estimated 10.7 billion gallons of process wastewater results  each  year
from  casting  quench  and  mold  cooling operations.  This represents 10.4
percent of the total process wastewater flow  at  plants  within  the  slag
quenching  subcategory.   87.9  percent of this 10.7 billion gallon flow is
recycled while 8.4 percent  is  discharged  to  navigable  waters  and  3.7
percent is discharged to POTW's.  An estimated 56.9 percent of this process
wastewater is recycled at 100 percent.

Figure  II1-7  presents  a  general  process  and  water  flow diagram of a
representative ferrous foundry mold cooling and casting quench operation.

In  this  process,   process  wastewaters  are  generated  as  a  result  of
operations  requiring  quenching  and  contact cooling waters.  The various
types of cooling  and quenching operations are listed on the  summary  Table
V-14.   The  mold cooling operations  require contact cooling waters (those
mold  cooling operations  indicated as using noncontact cooling  waters  were
not included on the  summary tables).   Quenching of the castings takes place
either  subsequent to casting or to a heat treatment operation following the
casting operation.   The major impact on the waste loads are the suspended
solids  which consist primarily of scale-like material from the  surface  of
the castings.  Test  data obtained during the 1978 sampling program provided
information about the pollutants from  this process.  Plant survey responses
indicated  a   range  of applied flow rates varying from  17 1/kkg  (4 gal/ton)
to 39,280 1/kkg  (9,434 gal/ton).   Recycle  rates  varied  from  0  to  100
percent.
                                    103

-------
A  review  of  the  44 plant responses with casting quench and mold  cooling
operations indicates that, although the process wastewaters are similar   in
origin,  several  approaches  are  taken  for process wastewater  treatment.
Refer to Table V-14 for descriptions of the treatment systems  employed   in
this  subcategory  segment.   The  degree  of  recycle varies form 0  to  100
percent.  The oldest treatment system dates from 1964.  Of the 44 foundries
with casting quench and mold cooling operations indicated  in  their   data,
eleven  plants  employ  100  percent  recycle  systems  while  seven  plants
discharge all of their process wastewaters to  POTW's  untreated  and nine
plants  discharge  all  of  the  process  wastewaters to a receiving  stream
without treatment.  Six plants provide treatment prior to  discharging  all
of  their  process  wastewaters to receiving streams and one plant provides
treatment for all of its process wastewater prior to discharge to  a   POTW.
Ten  foundries  employ  recycle  systems  with  recycle rates less then  100
percent, with seven of these operations  discharging  a  portion  of   their
process  wastewater  flow  to  a  POTW  and  three operations discharging a
portion of their process wastewater flow to receiving streams.    v

The treatment technologies noted in the plant data are as follows:

a.   Settling:  to provide solids removal.  In some cases recycle follows.

b.   Cooling Tower and Settling:  the cooling tower is used  to  provide a
     means of reducing the heat load on the system.  In some cases settling
     is  incorporated  to provide solids removal as necessary.  The  cooling
     tower system is used generally on the higher recycle rate operations.

Plant  51026, Figure V-36,  produces  casting  quench,  mold  cooling,  slag
quench,  dust collecting, and sand washing wastewaters which are drained to
a series of lagoons, and after 84 hours detention  are  discharged   to  the
river.   The  first  lagoon  in  the series is periodically dreged with  the
sludge trucked to a nearby landfill.  During this clean-out operation,   the
flow is diverted to a duplicate lagoon.

Plant  15654,  Figure V-37, employs a heat treated casting quench operation
involving the complete recycle of all process wastewaters.   The  treatment
system   utilizes  a  settling  channel,  from  which  solids  are   removed
infrequently, and a cooling tower to provide for quench water cooling.

Table V-41 summarizes the raw and treated waste loads observed  during  the
sampling  program.   A  quick  look  synopsis (partial summary) of the data
presented on TAble V-41 indicates that the following toxic  pollutants  are
present in the raw process wastewater from this manufacturing process.

          Pollutant      Concentrations (mq/1)

          Zinc                0.13
                                    104

-------
Sand Washing

An  estimated  6.4  billion gallons of process wastewater results each year
from sand washing operations.  This represents 6.1  percent  of  the  total
process wastewater at plants within the iron and steel casting subcategory.
75.9  percent  of  this  6.9  billion  gallon  flow is recycled, while 12.2
percent is discharged to navigable waters and 11.9 percent is discharged to
POTW's.  Though two plants have been identified which recycle  100  percent
of their process wastewater, one plant did not furnish sufficient detail to
properly  assess  the  flow  data  and  the  other  plant  lies outside the
statistical survey frame.  This plant recirculates (at  100  percent)  45.4
million  gallons  of process wastewater per year in a combined sand washing
and dust collection system.  Seventh-two percent of the process  wastewater
comes from the sand washing operation.

A  general  process and water flow diagram of a representative sand washing
and reclamation system is presented in Figure 111-7.

In this operation, wastewaters are generated as a result of using water  to
wash  the  used  casting  sand.   The waters are used to remove impurities,
primarily "spent" binders and sand, from the  casting  sand  prior  to  its
reuse  in  the molding processes.  The sand and binders become "spent" as a
result of the heat present in the casting  process.   The  major  pollutant
waste  load  is due to the various materials (primarily metals and binders)
washed from the sand.  Test data obtained at sand washing operations during
the  1974  and  1978  sampling  programs  provided  information  about  the
pollutants  from this process.  Plant survey responses indicated an applied
flow rate range of 625 1/kkg  (150 gal/ton) to 12,840 1/kkg (3,085 gal/ton).
Recycle rates varied from 0 to  100  percent.   It  should  be  noted  that
various  pieces  of  settling  and solids removal equipment are used in the
sand washing process to collect and dewater the sand prior  to  its  drying
and  reuse.   This  equipment  is considered to be part of the sand washing
operation rather than a part of the process  wastewater  treatment  system,
and  as  such,  process  wastewater  treatment  equipment is applied to the
discharges from the various pieces of sand washing equipment.

A review of the  10  plant  responses  with  sand  washing  and  reclaiming
operations indicates that the process wastewaters are not only generated in
the same basic manner, but also are treated in essentially similar systems.
Refer  to Table V-15 for descriptions of the treatment systems used in this
process.  These systems vary from 100  percent  discharge  to  100  percent
recycle  systems.   The oldest treatment technology in use was installed in
1950.

Of the 10 foundries with sand washing operations  indicated  in  the  plant
data,  two  plants  (1381 and 5115) recycle all of their process wastewater
while  three  plants  treat  and  then  discharge  all  of  their   process
wastewaters to receiving streams.  Five plants have recycle rates  less than
100  percent,  with  four  plants discharging a portion of their wastewater
                                    105

-------
flow to  POTW's  and  one  plant  discharging  a  portion  of   its   process
wastewater flow to a receiving stream.

Settling is the basic treatment technology observed  in all plant  responses.
Settling  tanks,  clarifiers,  etc.  are  used  in   order to provide solids
removal.  Four of the plants incorporate a polymer feed  in order  to  enhance
solids removal capabilities.

Plant 51473, Figure V-38, has a sand washing process.  The process operates
as follows: The sand from shakeout is conveyed to  a screen.   A magnetic
separator removed all metallic items from the sand.

The  screen oversize (+3/8  in.) went to a mixer vessel where city water was
added.  This was thoroughly agitated, and then pumped  to  a   slurry  tank.
The  slurry  tank  metered  the mix to a dewater table where the solids were
screw conveyed to a rotary  dryer.  The underflow from the dewater table was
pumped  to a settling tank.

The  settling tank is cleaned out  on  a  weekly  schedule  and solids  are
removed to  landfill.  The settled water drains to the river.

Plant   51115,  Figure   V-21,  produces  dust  collection and   sand  washing
wastewaters which are collected, treated with flocculants  and sent  to  a
drag tank.  The sludge  from this settling operation  goes to a  landfill, the
overflow  water   is  drained  to  a  settling pond for additional settling.
Overflow  from  the settling  basin goes to a pump wet  well.  This  is   pumped
to   a   tank  where   it  is pumped (as needed) to the  dust collectors  and the
sand washing equipment.  This is a 100 percent recycle system.

Plant  15520, Figure  V-18, produces sand washing process  wastewaters,  duct
collection   scrubber    process   wastewaters,   and slag  quench   process
wastewaters  which   are settled  and  recycled.   Makeup  water   is   from
noncontact  cooling water.   Overflow  is discharged to a POTW.

Plant   20009,   Figure V-19,  operates a sand  reclaimation process.  The sand
washing process wastewater  is settled in a series of four  lagoons.    Sixty
percent  of   the  process   wastewater  is  recycled  while  40 percent  is
discharged  by  overflow  to a POTW.

Plant  51026,  Figure  V-36, produces   sand  washing,   mold cooling,   casting
quench, slag  quench,  and dust collecting scrubber process wastewaters which
are  drained   to  a   series of  lagoons,  and after 84  hours  detention are
discharged  to  the river. The first  lagoon  in the  series   is   periodically
dreged with the sludge  trucked  to  a  nearby  landfill. During  this clean-out
operation,  the flow  is  diverted  to a duplicate lagoon.

 Plant  59101,   Figure   V-12,  has  a  sand washing system  to reclaim  sand for
 reuse.  The process  wastewater  from  this operation flows to   lagoons.   The
 lagoons  were   arranged to  give  maximum use  of the land  area.   The  inlet to
                                    106

-------
the first lagoon was arranged so that the heavy  solids  could  be  removed
readily.  The lagoon overflow is discharged to a nearby creek.

Table  V-42  summaries  the raw and treated waste loads observed during the
sampling program.  A quick look synopsis  (partial  summary)  of  the  data
presented  on Table 42 indicates that the following priority pollutants are
present in the raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations (mq/1)

          Chromium                 0.23
          Copper                   0.5
          Lead                     2.0
          Phenols                  0.81
          Zinc                     4.4

Magnesium Foundries

An estimated 2.16 million gallons of process wastewater  result  each  year
from  the  casting  of  magnesium.   Two  manufacturing processes have been
identified as using water in the magnesium casting subcategory.

Grinding Scrubber Process:

An estimated 2.15 million gallons of process wastewater results  each  year
from  scrubbers  collecting  dusts from the grinding of magnesium castings.
This represents 99+ percent of the total process wastewater flow at  plants
in the magnesium casting subcategory.

Figure  II1-8  presents  a  general  process  and  water  flow diagram of a
representative magnesium foundry grinding scrubber operation.

Scrubbers are provided on grinding systems in order to  remove  particulate
magnesium  generated  as a result of the grinding operation.  The scrubbing
process not only serves to remove the particulate magnesium as an  airborne
contaminant,  but  also  reduces  the fire hazards which can result from an
accumulation of fine magnesium particles.  Test data  obtained  during  the
sampling  program  provided  information  about  the  pollutants  from this
operation.  Plant survey responses indicated an applied flow rate of  6,660
1/kkg   (1,600  gal/ton)  with one 100 percent recycle operation and one 100
percent discharge operation.

Of the two foundries with a grinding  scrubber  systems  indicated  in  the
plant  data, one plant recycles all of its process wastewater and one plant
discharges all of its process wastewater untreated to a  receiving  stream.
The  recycle  operation employs an "internal" scrubber equipment package to
treat the process wastewater.  Refer to Table V-16 for descriptions of  the
treatment  approaches  used in both the magnesium foundry grinding scrubber
and dust collector systems.
                                   107

-------
Plant 8146, Figure V-39, employs a dust collector scrubber and a  magnesium
grinding  scrubber.   The  process  wastewaters  from  these  scrubbers  are
discharged untreated to a receiving stream.

Table V-43 summarizes the raw and  treated  waste  loads  observed   in   the
sampling  program.   A  quick  look  synopsis (partial summary) of the data
presented on Table V-43 indicates that the following toxic  pollutants   are
present in the raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations (mg/1)

          Lead                     0.13
          Zinc                     1.2

Dust Collection Scrubber Process:

An  estimated  13,200  gallons  per year of process wastewater results each
year from dust collection operations.

Figure  II1-8 presents a  general  process  and  water  flow  diagram of a
representative magnesium foundry dust collection operation.

As described in the previous dust collection system discussion, this system
is  used   to  remove  airborne  particulates  generated as a result  of sand
handling, mold making, and shakeout operations.  The major  pollutant load
results   from  the various process chemicals and binders within the  casting
sand.  One dust collection system was indicated in the plant  survey data.
This operaton had  an applied flow rate of  92 1/kkg (22 gal/ton).

One  foundry  was  indicated in the plant data as utilizing a dust collector
system.   This plant discharges all of its  process wastewater untreated to a
receiving  stream.

Plant 8146, Figure V-39, uses scrubbers to clean sand  handling  dusts   and
dusts   arising  from  the  grinding  of  magnesium  castings.   The  process
wastewater flow is discharged untreated.

This plant was visited during the sampling program and the raw and   treated
waste   loads  observed  during  this visit are summarized  in Table V-44. A
quick look synopsis  (partial summary) of the data presented on  Table V-44
indicates  that   the  following  toxic  pollutants  are  present  in  the  raw
process wastewater from this manufacturing process.

           Pollutant      Concentration  (mg/1)

           Phenols                  1.14
           Zinc                     0.36
                                    108

-------
Zinc Foundries

An estimated 1.07 billion gallons of process wastewater  result  each  year
from  the  casting of zinc.  Sixty percent of this 1.07 billion gallon flow
is recycled, while 37 percent is discharged to navigable waters  and  three
percent  is  discharged  to  POTW's.  Two manufacturing processes have been
identified which use water in the zinc casting subcategory-

Casting Quench Process:

An estimated 383 million gallons of process  wastewater  result  each  year
from  casting  quench  operations.  This represents 36 percent of the total
process wastewater flow at plants  within  the  zinc  casting  subcategory.
Seventy-four  percent  of this process wastewater is recirculated, while 24
percent is discharged to navigable waters and two percent  is discharged  to
POTW's.   An estimated 70 percent of the process wastewater is recirculated
at 100 percent.

General process and water flow diagrams of a representative die casting and
casting quench operation  are  presented  in  Figure  II1-9.   The  process
wastewater  considered  in   this operation is that which is discharged from
the casting quench tanks.

Raw waste loads will vary depending upon  the  duration  of  the  quenching
cycle,  the  degree  of  quenching  recycle,  the  nature  of the quenching
solutions used, the nature  (hardness, corrosivity, etc.) of the raw  makeup
water and the contamination  of the quench wastewater with  wastes from other
sources   (example:  hydraulic  oil  leaks  from  the die casting machines).
However, all process wastewaters sampled contained zinc.   The effluent load
is due to the type and nature of the quenching solutions and  makeup  water
used  in the quenching solutions and due to the contamination resulting from
other  sources.   Test  data from  casting quench operations indicated the
expected higher metal concentrations from the more  corrosive  streams  and
also  the  expected  results of  contamination  from other sources.  Plant
survey responses  indicated applied flow rates ranged from  20 1/kkg to 8,960
1/kkg  (4.8 to 2,152 gal/ton) while effluent  discharge  flow  rates  ranged
from  0 and 8,960 1/kkg to  (0 to 2,152 gal/ton.)  Recycle  rates varied from
0 to  100 percent.

A review of'the plant data within this subcategory segment indicates  that
casting  quench  process  wastewaters  are  handled  in  a variety of ways
although they are generated  in the same manner.   These  treatment  schemes
range from untreated discharges to publicly owned treatment works  (POTW's),
and   contractor  hauling  to complete recycle systems.  Refer to Table V-17
for descriptions of the treatment systems used in this subcategory segment.
Generally, all plants use some form of settling stage even if this is  only
accomplished  in  the quench  tank  itself.  However, the quantity of castings
quenched, the waste flow through the quench  tank,  and  the  size  of  the
quench  tank  are  factors   which  may  necessitate the need for a separate
                                    109

-------
settling stage.  One plant  employing  emulsion  breaking,  pH  adjustment,
flocculation  with  a  variety of chemicals and clarification installed  the
treatment equipment in 1956 while two other emulsion breaking systems  were
installed in 1973 and 1974.

Of  the  twenty  zinc foundries with casting quench operations  indicated in
the plant data, 3 of these plants  indicated  that  they  employed  systems
involving  the  complete   (100  percent)  recycle  of  their casting quench
process wastewaters.  Four other plants utilized systems with varying  rates
of recycle less than 100 percent.   Two  of  these  systems  had  untreated
discharges to POTW's, while the other two provided more extensive treatment
including emulsion breaking, chemical precipitation, and clarification.   On
the  other hand, three of  the twenty plants discharged all of their casting
quench wastewaters untreated to publicly owned  treatment  works  (POTW's).
In  addition,  the  discharges  of two other plants, which amounted to only
periodic quench tank dumps, were discharged untreated  to  the  POTW.    The
wastes of one plant were removed by a contract hauler.

Of  the  eleven  plants  using  some  type  of process wastewater treatment
system, the various technologies used are as follows:

a.   settling and skimming:  achieves primary solids removal and removal  of
     tramp oils.  In some  instances recycle follows.

b.   Emulsion breaking:  using alum and sulfuric acid, the emulsified  oils
     are broken out of the emulsion and are then removed as a scum.

c.   pH adjustment, flocculation and clarification:   lime,  polymer,  alum
     and  other  chemicals are used to adjust pH and promote floe formation
     after which the floe  is allowed to settle in the clarifier.  This step
     provides for heavy metals removal, some oil removal, and    enhanced
     solids removal compared to settling tanks.

Plant  18139,  Figure  V-3,  has  a  number  of  die  casting  machines  and
associated  quench  tanks  which  are  emptied  on  a scheduled basis.   The
schedule results in the  emptying  of  one  300  gallon  quench  tank  each
operational  day.   Each   quench  tank  is emptied about once a month.   The
quench  tank  discharge  mixes  with  melting  furnace   scrubber   process
wastewater, aluminum casting quench tank flows, and other non-foundry  flows
prior  to  settling  and   skimming.   The  treated  process wastewaters  are
discharged to a POTW.  The zinc quench  process  wastewater  makes  up  0.2
percent of the total flow.

Plant  4622,  Figure V-40, produces casting quench process wastewater  which
is hauled away on a contract basis by a reprocessor.  The  oil  and  grease
and  phenol  concentrations  in  the  process  wastewater of this plant  are
substantially higher than  in the other two plants sampled.  The  analytical
information  for this plant is of interest, in that it shows the results of
                                   110

-------
extensive contamination with nonquench wastes  (casting  machine  hydraulic
fluids in particular).

Table  V-45  summarizes  the  raw  and treated waste loads for those plants
visited.  A quick look synopsis (partial summary) of the data presented  on
Table  45  indicates that the following toxic pollutants are present in the
raw process wastewaters from this manufacturing process.

          Pollutant           Concentrations (mq/1)

          4-nitrophenol              1.6
          2,4-dinitrophenol          0.9
          Methylchloride             0.3
          Phenol                     0.46
          Trichloroethylene          0.23
          Zinc                      62.00

Melting Scrubber Process:

An estimated 683 million gallons of process  wastewater  result  each  year
from  melting scrubber operations.  This represents 64 percent of the total
process wastewater flow at plants  within  the  zinc  casting  subcategory.
Ninety-one  percent  of  this  process wastewater is recirculated while six
percent is discharged to POTW's and three percent is recycled 100 percent.

A general process and  water  flow  diagram  of  a  representative  melting
operation scrubber is presented in Figure II1-9.

The  major  effluent  load   is due to the amount and the cleanliness of the
scrap used  in the furnace charge.  The cleanliness of the scrap  influences
the  furnace  emissions.   Generally, zinc melting furnaces which melt high
quality scrap do not  require air pollution control devices.  However,  when
dirty,  oily  scrap   is used, furnace emissions are often controlled by the
use of  scrubbers.  The process  wastewater   from  these  scrubbers  may  be
either  recirculated within the scrubber equipment package (which includes  a
settling  chamber)  or  may  flow  to an external treatment system and then
recycle back to the scrubber.  Test data from this melting furnace scrubber
operation provided information about the pollutants present.  Plant  survey
responses indicated a low applied flow rate,of 22,770 1/kkg  (5,468 gal/ton)
and  a  high  applied flow rate of 102,840 1/kkg  (24,700 gal/ton).  Recycle
rates within the scrubber equipment package  ranged between 85  percent  and
100 percent.

Plant   18139, Figure  V-3, has melting furnace scrubber  systems for both its
aluminum and zinc furnaces.  The quench tank process wastewater mixes  with
melting  furnace  scrubber process wastewater, aluminum casting quench tank
flows,  and  other non-foundry flows prior to  settling   and   skimming.   The
treated process wastewaters  are discharged to a  POTW.   The scrubber process
wastewater  comprises  27 percent of the total treatment  flow.
                                    Ill

-------
Table  V-46  summarizes the raw and treated waste loads observed during the
sampling program.  A quick look synopsis  (partial  summary)  of  the  data
presented  on  Table  V-6 indicates that the following toxic pollutants are
present in the raw process wastewaters from this manufacturing process.

          Pollutant                Concentrations (mg/1)

          Phenols                       36.0
          1,2,4-trichlorobenzene         1.0
          2,4,6-trichlorophenol          1.4
          2,4-dichlorophenol             1.3
          2,4-dimethylphenol            12.1
          Naphthalene                    3.3
          Phenol                        36.0
          Zinc                          19.0
                                   112

-------
                               TABLE V-l
                  Penton Foundry  Census  Information
Ductile Iron
Gray Iron
Malleable Iron
Steel
Brass & Bronze
Aluminum
Magnesium
Zinc
Other Metals
Less than
10 employees
28
149
11
45
533
843
30
225
150
10-49
Employees
127
489
20
177
714
1,016
50
289
158
50-249
Empl oyees
283
579
42
337
277
450
42
175
59
Greater than
250 employees
98
156
37
97
37
75
8
39
9

-------
                                            TABLE V-2
                            DISTRIBUTION OF ADDITIONAL 1000 PLANT SURVEYS
 Ductile Iron
 Gray Iron
 Malleable Iron
 Steel
 Brass & Bronze
 Aluminum
 Magnesium
 Zinc
Other Metals
Less than
10 empl oyees











25
54
11
41
119
167
28
50
32
10-49
empl oyees
26
104
18
30
144
200
46
65
24
50-249
empl oyees
60
103
36
56
69
98
36
43
50
Greater than
250 employees
69
79
22
33
28
52
4
25
8

-------
       Age of
Flint  Oldest
Code   Furnace

5206   196S

6389   NA

4704   1951
    Production
Tons/Yr.

76

12

•430
T/S

0.3

0.05

•0.65
                                                                    TABLE  V-3
                                                             GENERAL SUMMARY TABLES
                                                               ALUMINUM FOUNDRIES
                                                          INVESTMENT CASTING OPERATIONS


Applied Flow

Discharge
Shift
/Day
1
1
1

GPT
12,800
8,000
4,900
Recycle %
	 X POTW
100


1
Direct

100
100
                                                                 Central Treatment
                                                               YesNo  % of total
97
Treatment Technology
Settling
Untreated
Polyner.Lamella Seperator
                                            Treatment
                                            Equipment
                                              Age
                                            NA
   1977
*These figures apparently represent product. Based on visit, the tonnage Is 5.0 tons/day.

 NA - Not available
 17089  1960
>10,000
                                                                    TABLE  V-4
                                                             GENERAL SUMMARY  TABLES
                                                                ALUMINUM MELTING
Applied Flow

Plant
Code
20114
0206
13562
22121
Age of
Oldest
Furnace
1968
1967
1936
1971


Production
Tons/Yr.
9,400
2815.5
13.442
2265.6
T/S
17.8
11.3
18.2
6.47

Shift
/Day
2
1
3
1.25


Discharge
Recycle % % Central Treatment
GPT
2481
NA
527
13,280
I
97.5
>97
37
>95
POTU Direct Yes No X of total
2.5 x
<3 x 3
63 x 1.8
<5 x
                                  2800
                                                                60
                                                     40
70
 Treatment Technology

 Internal recycle-Untreated
 Discharge
 Settling Lagoon
 Settling In lagoon,skimmed
 Untreated-(Contact with
 personnel provides per-
 centages)
 Skim.Alum,Polymer
 Clarlfler, Filter—
                                                                                                                                               Treatment
                                                                                                                                               Equipment
                                                                                                                                                  Age
                                                                                                                                               1969

                                                                                                                                               1975
1973,75,75.75
   1973.1975

-------
                                                                          TABLE   V-5
                                                                   GENERAL SUMMARY TABLES
                                                                   ALUMINUM CASTING QUENCH
Plant
Code
4809
14924
26767
29697
9951
0206
13978
14401
19405
11703
14789
Age of
Oldest
Melter
1963
1946
NA
NA
1976
1967
1969
1949
1960
NA
1952
Production
Tons/Year
40
587.9
1736.7
2,810
1,404
2815.5
6.812
32,500
33,350
3601.2
9,961
T/S
0.15
2.1
3.1
3.75
1.95
11.3
7.76
43.5
42
7.2
13.1

Shift
/Day
1.25
1
2
3
3
1
3
3
3
2
3
Applied Flow
Discharge
Recycle X % Central Treatmen
GPT % POTW Direct Yes No * of To
Tank 100 X
232 100 X
Tank 100
888 100 X
NA 90 10 X
221 100 X 1
NA 100 X
(Minimal Flow)
99.3 90 10 X
19 100 X
NA 100 X
1.45 *hauled
Treatment
t Equipment
tal Treatment Technology Age
No discharge or dump from
tank
Untreated
Tank with an untreated
discharge of 400 gal/yr
Untreated
Untreated
Settling Lagoon 1969
Untreated
Untreated (combined with
die cooling)
Untreated
Untreated (non-continuous)
Commercial waste disposal
10615    1950    602.5

NA - Not available
1.675
1.5
6866
100
company

Untreated

-------
                                                                 TABLE  V-6
                                                           GENERAL SUMMARY TABLES
                                                       ALUMINUM FOUNDRIES - DIE CASTING


Plant
Code
10615

11665


14401


12040


13562


19405

5878
17089

Age of
Oldest
Furnace
pre-1950

1961


1949


1955


1936


1948

HA
1960




Production
Tons/Yr.
602.5

22,692


32,500


32.195


13,442


33.350

18.000
>10,000
T/S
1.675

23.7


43.5


43


18.2


42

22.5
>10
Applied Flow
Discharge

Treatment
Shift Recycle % % Central Treatment Equipment
/Day GPT X POTU Direct Yes No X of total Treatment Technology Age
1-2 2866 100 x
(MOLD COOLING)
3 506 100 x 18
(MOLD COOLING)

3 1655 90 10 x
(DIE SURFACE COOLING)

3 1300 100 x 90
(DIE COOLING, SPRAY.ETC.)

3 14,464 37 63 x 59.6
(DIE COOLING PROCESS MASTEWATER)
•
3 479 100 x
(SURFACE SPRAYS)
3 88.9 100 x
3 1200 79 21 x 30
Untreated

Emulsion break .Skimming 1957
Alum feed
F lot at Ion, Skimming 1974
Combined with quench wastes
In a holding tank-overflow
untreated
Emulsion break, floe with 1952
polymer. float scum.neutrallze
with lime.
Combined with scrubber and 1957
non-contact waters - settling
lagoon and skimming.
Untreated

Settling tank and skimming 1977
Combined with meltlng.oll
                              Die cast and casting quench combined
                                  (Flows From Visit)
(Die Casting Only)
Pressure fliter.Alum,
Polymer. ClaHfler           1975
NA - Not available

-------
         19275  1957      57,442     76.6
         7138   1966      8,697     14
                                                                             TABLE V-7
                                                                      GENERAL SUMMARY  TABLES
                                                            ALUMINUM FOUNDRIES -  DIE LUBE  OPERATIONS


Plant
Code
19405
20147

Age of
Oldest
Furnace
1948
1945




Production
Tons/Yr.
33,350
> 30. 000
T/S
42
>30


Shift
/Day
3
3



GPT
14.3
45.2
Applied Flow
Discharge
Recycle t %
I POTW Direct
100
100


Central Treatment
Yes No t of total
X
X






Treatment Technology

Treatment
Equipment
Age
Untreated
Skim
*r on holding tank
1977
8.7
71.4
      100
100
Cyclone separator,
paoer filter

Floatation (Skimming)        19*57
ferric chloride,lime,lagoon  1971
trickling filter, activated  1977
sludge, clarlfler
Ultraflltratlon unit         1974
(Semi-permeable membrane)
co

-------
                                                                       TABLE V-8
                                                                GENERAL SUMMARY TABLES
                                                          COPPER AND COPPER ALLOY FOUNDRIES
                                                                    DUST COLLECTION


Plant
Code
12322
5946
3884
9094
19872

10011

Age of
Oldest
Furnace
1960
1970
1940
1960
1964
Visited
1940




Production
Tons/Yr.
7580
2330
4978.3
6129.4
7744.1

2127
MTL/SAND
21.9 25.4
10 45
13.98 34
12 256
21.7 333

8.86 40


Shift
/Day
1-1/3
1
1
2
1-1/2

1



GPT
15.1
2027
424
180
NA

HA
Applied Flow
Discharge
Recycle X t Central Treatment
% POTW Direct Yes No X of total
100 x 0.1
100 x
100 x 2.9
100 x 82
100 x

100 x
                                                                                                                    Treatment Technology

                                                                                                                     Settling with non-contact
                                                                                                                     and Metal coating
                                                                                                                     Internal Recycle

                                                                                                                     Settling
                                                                                                                     110 gpt through lagoon

                                                                                                                     Internal Recycle

                                                                                                                     Internal Recycle
Treatment
Equipment
 Age

1960
1972
NA
NA - Not available

-------
                                                                          TABLE  V-9
                                                                   GENERAL SUMMARY TABLES
                                                            COPPER  AND  COPPER ALLOY FOUNDRIES
                                                             MOLD COOLING  AND CASTING QUENCH
Plant
Code
4951
11740
Age of
Oldest
Melter
1963
1953
Production Shift
Tons/Year
27
215
T/S /Day
3
0.43 2

Recj
GPT 5
2300
140
Applied Flow
Discharge Treatment
«:le % % Central Treatment Equipment
i POTW Direct Yes No % of Total Treatment Technology Age
100 X Untreated
100 X 0.02 Settling, emulsion break, 1953
17704    1960    7580           21.9        1  1/3        817


19484    1949    167            .42         1             NA

16446    1972    9969           27.2        2             26,470


38846    1940    5639.8         7.5         3             1,280
99.5
100

0.5
                       100
                       100
                           6.4
                           1.9
skimming, lime, polymer,
ferrous sulfate, clarifier

Settling a non-contact
and metal coating

Untreated
1960
Cooling tower with untreated NA
discharge
Settling Lagoon
1972
NA - Not available

-------
                                                                          TABLE V-10
                                                                   GENERAL SUMMARY TABLES
                                                             COPPER AND COPPER ALLOY FOUNDRIES
                                                               CONTINUOUS CASTING  OPERATION


Plant
Code
40013

t0007




40009
40006
40150



40054
40038
40250



40052

40017


40056


6809

Age of
Oldest
Melter
1970

1961




1966
1971
1975



1965
1967
1969


"
1955

1941


1966


1942
Applied Flow


Production
Tons/Year
2541.46

>50,000




58,822
11.225
18.000



54.500
9440
35.000



75.000

260.800


42.400


> 1*0, 000
TVS
10

>90




87.3
82.5
37



72
49.17
60-70



100

456


56.3


>10

Shift
/Day
1

3




3
1
2



3
1
2



3

3


3


3

Recycle
GPT %
NA 100

2518 100




8247
NA 100
9730 100



4000 98.3
NA 100
10,000 100



7200 94.3

8168 97.5


10,231 100


2593 90
Discharge Treatment
X X Central Treatment Equipment
POTM Direct Yes No % of Total Treatment Technology Age
X Reclrculate through sunp
and cooling tower
X Reclrculate through sump and NA
cooling tower - polymer, caustic
clarlfler. sludge to sand bed.
sump (40,000 gal) drained 4
times a year
100 X Untreated
X
X Closed loop recycle through 1975
heat exchanger - cooling
tower for non-contact supply
to heat exchanger
1.7 X 22.5 Cooling tower on entire flow 1965
X NA
X Closed loop recycle through 1975
heat exchanger - cooling
tower for non-contact supply
to heat exchanger
5.7 X 22.2 Mixed with non-contact for 1941
settling and skim 1945.7
2.8 X 68 Skinning, lime, polymer. 1974
clartfler-acld for final
pH adjustment
X Closed loop recycle through
heat exchanger and cooling
tower
10 X Cooling tower on recycle loop
u4+h lh«*+ »•**! «*«*! *4 r 1 •!! • Ak>4kM _
                                                                                                                                        sumps.
                                                                                                                      flow at hot sump pumped to
                                                                                                                      lagoon and discharged.
NA - Not available

-------
                                                                                TABLE  V-ll
                                                                         GENERAL SUMMARY TABLES
                                                                         DUCTILE IRON  FOUNDRIES
                                                                             OUST COLLECTION
ro
ro


Plant
Code

18888
6450

17018
17370
15372
24595
5941
19733



12393
16502
14809


Age of
Oldest
Furnace
1967
1965
1972

1951
1959
1966
1966
1964
1968



1971
1972
1948







Production
T/S
Ton/Year
1068.9
2000
1419

42,242
19,200
14,500
10.953
17,068
126,000



71,452
42,530
>70.000

.Sand
40
54.1
45

3.15
480
20
408
226.5
3150



1800
228
874

Metal
4.3
8
6

2235
40
19.3
79.9
34.1
293



180
91.6
>100 :

TS/TM
10
4.05
4.5

0.014
12
1
4.8
5.26
11.7



10
2.49
>0.1

Shift
/Day
1
1
1
*
1
2
3
1
2
2



2
2
2


GPT
NA
NA
NA

NA
400
3600
NA
318
283



192
77
4160

Applied Flow
Discharge
Recycle X X
X POTH Direct
100
90 10
90 10

100
93 7
100
100
96 4
84 16



100
100
99.4 0.6



Central Treatment
Yes No X* of Total
X
X
X

X
X
X
X
X
X 75



X
X
X


Treatment
Equipment
Treatment Technology Age
Internal Recycle
2.96 gpt untreated
80 gpt untreated

Internal Recycle
Polymer and settling 1970,74
Through settling tank 1966
Internal
Untreated
With other grinding 1968
scrubbers cyclones, screen-
Ing, polyacr,. thickener.
vacuua filter
Clarlflers 1971
Internal Recycle
Recycle and/or reuse 1948
for Belting, etc. 1968
       16612    1966    >85,000    875
>200  >0.3
                         3946
                                                                                              100
55
Polywr.aliN.settllng,     1977
clarlfler

-------
                                                                               TABLE V-ll  (cont'd)
                                                                        GENERAL SUMMARY TABLES
                                                                        DUCTILE IRON FOUNDRIES
                                                                            DUST COLLECTION
ro
co


Plant
Code
20784

10684
14173
27743


5417
88281
9148

Age of
Oldest
Furnace
1973

1951
1943
1940


1962
1943
1974






Production
T/S
Ton/Year
126,054

213,386
335,000
130.435


7200
18.946
8500
Sand
1550

133
507
2667


12.5
180
1240
Metal
248

335
447
181


14
43
34
TS/TM
5

0.45
1.3
8


1
4
NA
Shift
/Day
2

3
3
3


2
. 2
• 1

GPT
154

1805
61
132


3840
NA
151
Applied Flow
Discharge
Recycle % X
X POTW Direct
1000

NA NA
100
87.4 12.6


100
NA NA
100


Central Treatment
Yes No % of Total Treatment Technology
X 73 Polymer, lagoon, skimming
with slag quench
X 4 Lagoons
X 0.5 Lagoon - REUSED
X Polymer and settling for
discharge and recycle

X Internal Recycle
X 8 gpt untreated
X _ Lagoon

Treatment
Equipment
Age
1973,1975,

1971
1965
1964
1966
1971


1974

-------
       TABLE V-ll (cont'd)
GENERAL SUMMARY TABLES
 GRAY IRON FOUNDRIES
   DUST COLLECTION


Plant
Code

19933

14417
11245

20408
26777
1644
2121
2195
2236
2511
28822
3646
3913
4688
5008


6565
6999

7344
8070
9593
14069


Age of
-Oldest
Furnace

1972

1973
1971

1945
1974
1973
1971
NA
1970
1942
1960
1974
1972
1945
1954


1968
1955

1966
1946
1953
1966


•

-


Production

T/S
Ton/ Year Sand

70.237

33.144
10.000
(Iron)
19.597
27.500
5.500
11.250
3.948
3605
6440
54.644
6263.7
12.670
32.000
22.411


15.275
6910

22.008
14,170
12.126
62.873

128

62.5
111
- ;
150
1800
220
200
160
175
140
1160
350
178
1600
500


Unk
135

365
124
286
1370.5

Metal
290

67.92
13.9
(Iron)
39
120
30
55
16
18
27
114
29.5
52
68
92


69.5
28.8

45
60
55
146.2

TS/TM
0.44

1.06
8

4.5
15
7.3
3.6
-
6
4.66
10.9
11.86
3.4
24
5.43


Unk
4.7

9.75
2
5.2
10.6

Shift
/Day
1

2
3

2
1
1
1
1
1
1
2
1
1
2
1


2
1

2
1
1
2


GPT
164

NA
592

625
200
236
120
165
NA
48
368
43
NA
NA
132


NA
560

270
NA
488
253

Applied Flow
Discharge
Recycle X X
X POTW Direct
100

100
90.2 9.8

100
100
100
100
100
100
100
100
100
100
100
100


100
100

98.2 1.8
NA NA
100
88 12




Treatment
Central Treatment
Yes No X of Total
Equipment
Treatment Technology
Age
Reuse for hydroblast then 1949.1978

X
X

X
X
X
X
X
X
X
X
X
X
X
X


X
X

X
X

X 38

settled
Internal Recycle
58 gpt untreated

Internal recycle
Internal recycle
Internal recycle
Internal recycle
Internal recycle
Internal recycle
Internal recycle
Internal recycle
Untreated
Internal recycle
Internal recycle
Polyaer. Settling- 1968
Reuse In Melting
Scrubber and/or Discharge
Internal recycle
Mix with other Hastes, NA
and reuse
Untreated-Internal recycle
15.5 gpt untreated to POTU
Internal recycle
Lagoon 1977
1946















.1970








.1974


-------
                                                                              TABLE V-ll  (cont'd)
                                                                       GENERAL SUMMARY TABLES
                                                                        GRAY IRON FOUNDRIES
                                                                          DUST COLLECTION
ro
en


Plant
Code
10242
12164
2031

6426

8482
18919

18941
15104

14670
19347



396
17230

Age of
Oldest
. Furnace
NA
1975
1972

Replaced
1970
1957
1942

NA
NA

1975
1939



1949
1968






Production
T/S
Ton/Year
723
4,631
5,222

2,200

24,265
15.882

100,380
325,770

12.678
29.500



7,750
25,011
Sand
10
125
138

40

100
150

125
154

189
350



250
384
Metal
NA
17.8
23

19.4

39.5
61.8

385
514

25.36
64



55
96
TS/TM
5
7.3
6

2.1

1
2.14

0.32
0.3

7.5
5



2.5
4.19
Shift
/Day
1
1
1

1

2
.1

1
1.7

2
2



1
1

GPT
BA
NA
533

NA

446
48

252
935

688
1029



54
139
Applied Flow
Discharge ;.«. >,.
Recycle X X Central Treatment
X POTM Direct Yes No X of Total Treatment Technology
NA NA X Untreated
90 10 X 0.96 gpt untreated
99 1 X 40 Dragout fl Belting
(4 gpt) 6 Lagoon
NA NA X

99 1 X 4.8 gpt to settling
100 X 10 Lime.Acid, Polymer, Clari-
fier.Settling.Skla
66 34 X Untreated
100 X Settling, Polyaer Plate
Separator
99.8 0.2 X Untreated
100 X 48 Clarlfler.Reservolr.Cool-
Ing Tower on Reservoir
Recycle and Reuse •.Melt-
ing and Slag Quench
100 X Internal
100 X Settling and Polymer for

Treatment
Equipment
Aae


1975



1967
1975.1976


1955
1979

1959.1970




1977
                                                                                                                            Reclrculatlon

-------
                                                                               TABLf V-ll (confd)
                                                                        GENERAL SUMMARY TABLES
                                                                         GRAY IRON FOUNDRIES
                                                                           OUST COLLECTION
INi
CTi


Plant
Code
17380

17348
11865
17746
10837

10600

15520
19820
13460

19533
14104

13089
18073
11111

20208
20249
20345
20699

Age of
-Oldest
Furnace
1972

1946
1974
1956
1963

1971

1971
1946
1971

1960
1974
.
1971
1952
1971

1965
1966
1965
1900






Production
T/S
Ton/Year
108.794

132.995
34.662
57,938
243.125

91.956

166.578
57.778
21.600

11.604
374.098

558.391
632.506
121.053

107,041
259.733
188,160
161.819
Sand
130

186
220
1000
8753.5

2344

2430
48
832.5

121.6
240

1333
5238
1368

66.5
1950
1154
623
Metal
241,

294
158.1
131
496.2

194.8

359
123
90

49.4
356

920
962
161.4

208
477
384
133
TS/TM
0.54

0.69
1.39
8
17.6

11.1

6.48
0.75
9.3

2.5
0.5-

1.45
6.1
8.6

0.3
5
3.01
2.75
Shift
/Day
2

2
1
2
2

2

2
2
1

1
3

3
3
3

2
2
2
3

GPT
6780

3740
27
NA
173

NA

96
450
NA

316
NA

68
824
649

NA
1329
NA
NA
Applied Flow
Discharge
Recycle 1 %
% POTW Direct
88 12

100
100
100
100

NA NA
90 10
70
30-Reused
100
100

100
100

100
100
100

100
100
100
NA NA


Central Treatment
Yes No X of Total
X

X 61
X
X
X 89

X

X 85
X
X

X
X

X
X
X

X
X
X
X 8.8



Treatment Technology
Screening, Clarlfler,
Polyaer.Vacuua.Fllter
Lagoons. SklMlng
Internal recycle
Internal recycle
Polymer, Clarlfler, Lagoon
Deep Bed Filter
0.35 gpt untreated

Settling Tank
Internal recycle
POTU discharge untreated
when cleaning units
Internal recycle
Individual settling tanks
for each collector
33. 5X untreated
Settling
Settling


Treataent
Equipment
Me
1972

1958


1967.1977
1978


1949




1976.1969
1958
NA
NA
1967
I
Internal-solids to landfill
Internal -sol Ids to landfill
Internal recycle
Vac. Filter. Pol vmer.Clari-

1977
      20112     1905     187.037   248     159    0.85
91
                                                                                             100
                                                                                                                 5.6
Her. Skimming

Settling.Skimming
                                                                                                                                                       1972

-------
                                                                               TABLE V-ll (conf d)
                                                                        GENERAL SUMMARY TABLES
                                                                         GRAY IRON FOUNDRIES
                                                                           DUST COLLECTION
ro


Plant
Code
1381


1801
58823

3313

3760
5640
S6S8
6265

53772
63773

77775
6680
7322
7*991
7929
94*12
9929

Age of
- Oldest
Furnace
1955


1956
1967

1960

1943
NA
1947
1968

1969
1962

1962
1965
1950
NA
1966
Flows
1969
1977






Production
T/S
Ton/Year
14.200
"

58,280
27.934

78.594

35.609
28.500
8500
81.400

43.281
73.767

37.485
12.999
17.500
11.750
52.500
from visit
114.133
12,950
Sand
300


1095
509

659

2000
2440
412
133

75
175

50
924
280
640
650
1636
325
Metal
59


141.8
58.2

110

150
122
60
133

83.2
113

72
27.4
37.5
24
105
237.8
52.4
TS/TM
3


8.8
9.1

6

13.3
20
6.8
1.18

1.1
1.23

NA
13.7
7.5
23
6
6.87
6
Shift
/Day
1


1 3/4
2

3

1
1
1
3'

2
2

2
2
2
2
2
2
1

GPT
NA


690
830

1318

41
120
161
NA

NA
411

4056
NA
36
NA
570
137
43
Applied Flow
Discharge
Recycle % %
% POTU Direct
100


100
99 1

100

99 1
100
99 1
100

100
100

100
100
100
NA NA
100
85 15
100


Central Treatment
Yes No X of Total
X NA


X
X

X

X
X
X
X

X
X 1

X 25
X
X
X NA
X
X 26
X 29

Treatment
Equipment
Treatment Technology Age
Recycle through alua. NA
polymer .clarlfler.thlck-
ness
Internal
Internal recycle-untreated
blowdowi
Sludge and blowdown to 1974.1976
polymer, lagoon.settllng
Settling In scrubber Itself
Settling NA
Polymer .Caustlc.Thlckener 1970
One system for wltlng.dust,
grinding, blast
Internal recycle
Kith other scrubbers, treated
settled together
Settled with other scrubbers
Internal recycle
Internal recycle
Polymer.Clarlflers 1967
Settling Basin 1973
Polymer, Settling 1976.1974
Sk1m1ng.Caust1c.Ac1d. 1977
     13416    1968    >115,000   4800    >20o  >5
436
100
95
Polymer.Clarlfler,Pressure
Filter for Sludge, and
Emulsion Breaking

Settling Tank. Polymer    1926,1974

-------
                                                                              TABLE V-ll  (cont'd)

                                                                       GENERAL SUMMARY TABLES
                                                                        GRAY IRON FOUNDRIES

                                                                          OUST COLLECTION
ro
oo


Plant
Code
10865
11964


19408

16612

839
27500

Age of
-Oldest
Furnace
1962
1954


1955

1953

1966
1964






Production

Ton/Year
>110,000
>125,000


>95,000

>85,000

133.516
157.912
T/S
Sand
10.526
1052.5


4051.7

1350

1640
2240

Metal
>800
>500


>l»00

>200

213
319.65

TS/TM
>1
>0.5


>2

>0.3

5.8
7
Shift
/Day
3
2


2

2

2
2

6PT
114
1020


752

3619

1014
455
Applied Flow
Discharge
Recycle X X
X POTU Direct
100
77.4 22.6
Recycle
t Reuse
97 3

100

100
100


Central Treataent
Yes No X of Total Treatment TecMolooy
X 83 Lagoon,Polya»r, Cool Ing
Tower.F11ters.Alun
X 30 Settllng.Clarlfler


X 66 VacuuB Filter .Polyaw
Clarlfler
X 55 Polywr.A1uB.Sett ling
Clarlfler
X Internal recycle
X Sett Una. Polyvtr on.

Treatment
EqulpaMt
Aae
1966.1969
1970.1974
1954.1964


1966.1973

1977


1973
                                                                                                                             part only

-------
                                                                               TABLE V-ll
                                                                        GENERAL StfMARY TABLES
                                                                       MALLEABLE IRON FOUNDRIES
                                                                            DUST COLLECTION
ro
vo
Plant
Code
17331
28488
2243
3049
3432
5622
6773
8436
8998
11197
12203
18797
3118
3898
3901
6123
4100
7472
Age of
Oldest
Furnace
1949
1974
1967
1976
1975
1970
1907
1968
1951
1966
1955
1965
1916
1940
1965
1949
1970
1927
Production
Ton/Year
5920
10,619
11,590
11,264.6

8591
4235
13.241
13.539.2
44.299
81.600
207.530
17,402
20.640
30.000
104.356.
12,544
54.660
T/S
Sand
722
250
128
12
343
300
300
160
214.2
875
200
1425
280
400
1500
15 24.8
312
661
Metal
32.7
54.5
32
46.36
45.2
21
20.3
27
23.8
93.5
109
259.4
70
70
200
222.03
42
95
TS/TM
22
4.5
4
0.25
7.6
10
15
5
9
9.36
5.5
5.2
4
7
7.5
.11
6
6

Shift
/Day
1
1
2
1
2
2
1
2
2
2
3
3
1
1 1/2
1
2
1
2

GPT
397
NA
NA
200
NA
NA
48
NA
NA

738
337
100

144
1041
NA
134
Applied Flow
Discharge
Recycle X X
X POTW Direct
100
90 10
100
40 60
100
NA NA
(>95) « 5}
100
100
80 20
100
100
97 3
100
90 10
100
100
100
100-

Central Treatment
Yes No X of Total
X
X
X
X
X
X

X
X
X
X
X 5JT~ 	 	
X
X

X 25


Treatment Technology
Untreated
38.4 gpt dlsch.thru
settling
Internal recycle
Untreated
Internal recycle
0.8 3.2 gpt - polyner.
caustic, filter
Untreated
Line, Aluminum, Polyner
and Dragout
Untreated
Internal recycle
Internal recycle
Clarlfler.Lagoon.Sk Inning
Internal recycle
16.8 gpt untreated
Through Oragout Tank
Settling, Lime, FeCla
Internal recycle
Polymer and Settling
Treatment
Equipment
Age

1972



1975

NA



1976,1977



1973.1975

1970

-------
                                                                                 TABLE  V-ll  (conf d)
                                                                         GENERAL  SUMMARY  TABLES
                                                                        MALLEABLE IRON  FOUNDRIES
                                                                              DUST COLLECTION
Plant
Code
9306
16882
23455
Age of
Oldest
Furnace Ton/Year
1971 13,602
1968 >1 11,000
1946 83539.7
Production
T/S
Sand
319
5767
822
Metal
34
>500
191.2
TS/TM
8.5
>6
5

Shift
/Day
2
3
2

GPT
NA
305
231
Applied Flow
Discharge
Recycle X %
% POTW Direct
100
100
99 1

Central Treatment
Yes No % of Total Treatment Technology
Internal
X 35 Lagoons
Untreated
Treatment
Equipment
Age

1975

OJ
o

-------
                                                                                   TABLE V-ll
                                                                           GENERAL SUMMARY TABLES
                                                                             STEEL FOUNDRIES
                                                                             DUST COLLECTION
OJ
Plant
Code
14761
11635
15873
1835
5333
5560
5643
10225
17015
11598
15654
Age of
Oldest
Furnace
1959
NA
1968
1953
1955
Pre-1943
1962
. 1914
Production

Ton/Year
7024
15,438
5985
4411.5
10,120
2500
9464
37,000
T/S
Sand
50
258.6
182.5
46.5
80
NA
113.2
367
1977 11,700 350
(Apparently new production
1948
1954
15,250
125.000
141.6
80

Metal
14.6
19.53
12.5
10.9
23
10
19.7
44
TS/TM
3
12.21
11.4
3.32
4
NA
5.4
4.17
114.7 4.1
facilities)
31
173.6
3.2
3.75

Shift
/Day
2
3
2
2
2
'l
2
3
2
2
3

6PT
58
223
112.8
392
NA
NA
NA
NA
( 190)
309
NA
130
Applied Flow
Discharge
Recycle X X
X POTW Direct
100
100
100
95 5
100
100
100
100
100
90 10
100

Central Treatment
Yes No X of Total
X
X
X
X
X
X
X
X
X
X
X 2.5
Treatment Technology
Internal recycle
Settling, alum, polymer
clarifier
Internal recycle
Dragout
Internal recycle
Internal recycle
For all purposes It Is
Internal recycle - can
untreated to POTW
Untreated
Internal recycle
Treatment
Equipment
Age

1949
1978

1940


100X
overflow


Internal recycle, untreated
discharge
Settling
1972
                   (Flows from visit)
                   (Processing scrapped molds, etc.)
         10629    1968     10,791
88
23
3.8
164
100
                                                                        0.2         Alum, polymer, clarifier  1977
                                                                                    thickener, skimming

-------
                                                                           TABLE V-12
                                                                    DUCTILE  IRON FOUNDRIES
                                                                   MELTING FURNACE SCRUBBERS
                                                                      Applied Flow
CO
IV)
Plant
Code
14254
14444
15555
7438
18947
12393
10684
14173
30160
8944
9148
14809
16612
Age of
Oldest
Furnace
NA
1970
1962
1954
1974
1976
1951
1943
1972
1956
1974
1964
1966
Production
Tons/Yr.
11,973
70.498
73,968
4410
114,107
71,452
213.386
335,000
26,965
74.200
8500
>70,000
> 85, ooo
T/S
82.6
329
296
21
423
180
335
447
115
327
34
>100
>200
Shift
/Day
1
1
1
1
2
2
3
3
1
1
1
2
2
Discharge
Recycle X X Central Treatment
GPT X POTH Direct Yes No X of total
5230 >80 <20 X
978 43 57 X 43
819 70 30 X 60
2000 100 X
149 100 X
2400 100 X 82
5731 100 X
3812 100 X
626 100
201 40 60 X 3
1524 100 X 22
2100 99.4 0.6 X 57
2035 100 X 42
Skinning
Vac. Filter.Lime,Polyner     1978
Settling (Internal re-
cycle of 64X)
Internal Recycle
Gas Quench Syste* -
which reusers what Is left
after evaporation for slag
quench
Polyicr.C1ar1f1er            1971
Screening. Vac.Filter        1971
Polymer, Clarlfler.
Thickener, Sk1«, Lagoon
Llme.Polyner.Settllng Tank.  1977.1978
Lagoon
Lagoon
Settl1ng,Ac1d.Sk1m*1ng       1970
Lagoon                       1974
Lagoons                      1948,1968
AHm.Polywer,Clarlfler       1966

-------
                                                                             TABLE  V-12  (conf d)
                                                                       GENERAL  SUMMARY TABLES
                                                                            GRAY  IRON
                                                                     MELTING FURNACE SCRUBBERS
                                                                         Applied Flow
co
CO
Plant
Code
2031
2418
3868
6426
7170
8092
9925
0000
14670
19347
0396
17230
23454
1942
2121
2195
2884
3399
Age of
Oldest
Furnace
1972
1930
1946
1970
1952
1924
1938
1948
1975
1939
1949
1968
1960
1972
1971
NA
1960
1976
Production
Tons/Yr.
5222
1300
1723.5
2200
200
1775
1000
3724
12,678
29,500
7,750
25.011
3684
32,385
11,250
3,948
54,644
2700
1/5
23
5.2
8
19.4
4
15
4
16
25.4
64
55
91.6
14.6
115.7
55
16
114
11
Shift
/Day
1
1
1
1
1
1
1
1
2
2
1
1
1
l(10hr)
1
1
2
1
GPT
4876
NA
3000
3943
2880
NA
2700
450
5906
6000
2600
4913
9555
1556
2182
9000
3032
NA
Recycli
99
400
99+
100
100
100
50
100
99
100
100
100
96+
100
95
100
100
100
Discharge
e % X Central Treatment
POTU Direct Yes No 1 of total
10 X 60
X
X
X
X
X
50 X
X
1 - X
X 25
X
t> T' " r x
^ 3* X
X
5 X 40
X
X

                             Treatment
                             Equipment
Treatment Technology          Age

Settling. Lagoon             1973
Settling with dragout        1978
Cyclone, Classifier. L1«e    1974
Scale Pit                    1971
Settling. Urn. fo\ymr      1977
No discharge-to leach field
Scale Pit                    1972
Settling. L1«e. Caustic      1978
Settling with dragout        1973
Clarify. Lagoon. Caustic     1959
Internal Recycle
Settling. Caustic.Polyaer    1977
Polyner                      1970
Settllng.Polywr.Caustlc     1972
Settled.Caustlc              1971
Settled (Internal)           1970
Internal Recycle
Internal Recycle

-------
11964  1963
>112,000   >350
19408  1955      315,707   607
16612  1952      >85,000   >200
5691   1964      >65,000   >100
6956   1959     >119,000   >200
               FLOWS FROM VISIT
                                                                   TABLE V-12 (cont'd)
                                                            GENERAL SUMMARY TABLES
                                                                  GRAY IRON
                                                          MELTING FURNACE SCRUBBERS
                                                              Applied Flow
Plant
Code
1801
58823
3313
5533
5640
5658
6213
6265
53772
63773
7*991
77775
17746
19533
13416
10865
Age of
Oldest
Furnace
1956
1967
1973
1960
NA
1947
1948
1968
1969
1974
NA
1963
1956
1960
1968
1965
Production
Tons/Yr.
58.280
27,934
78,594
57,123
28,500
8500
24,820
81,400
43,281
73,767
11,750
37,485
57,938
11,604
>100,000
> 50, 000
!£
141.8
58.2
110
115
122
60
52
113
83.2
113
24
72
131
49
>300
>250
Shift
/Day
1.75
2
3
2
1
1
2
3
2
2
2
2
2
1
2
3
GPT
2031
7093
1903
3130
2295
1440
2538
5522
NA
3186
500
7222
649
3673
4400
1632
Recycle
t
100
100
81
40
100
100
100
100
NA
100
-
100
100
70
98+
100
Discharge
1 % Central Treatment
POTW Direct Yes No % of total
X
X
19 X 75
60 X
X
X
X
X NA
NA X
X
100 X 12
X
X
30 X 20
1+ X
X 10
Treatment Technology
Internal Recycle
Internal Recycle
Settling. Lagoon, Polymer
Settling, Lagoon
Settling Tank
Dragout and unk.
Settling Tank
NA
Untreated discharge fron
Internal Recycle
Internal Recycle

Internal Recycle
Settled
Settling for discharge
Settling tank.thlckner
Caustic, Polywr.SMm
Settling with dragout lagoon
Treatment
Equipment
Age


1974
1974
NA
NA
1963
1968


1967

1970
NA
1975
,1966.1969
                          2
                          2
                          2
                          3
1041

2141
960
286
1900
95

100

100
95
                                                                                  0.7
100
                   52
Polymer,Llme.Alum,Press.     1970,1974
Filter                       1978
Classlfler-blowdown co-treat-1965
ed In clarlfler
Settling                     NA
Settle,Clarify.Polymer       1966
Settling,Tank.Lagoon         1964
Clarify,L1we,Polymer,Lagoon  1974

-------
                                                                            TABLE V-12 (cont'd)
                                                                     GENERAL SUMMARY  TABLES
                                                                    MALLEABLE IRON FOUNDRIES
                                                                    MELTING FURNACE SCRUBBERS

                                                                       Applied FlOM
Plant
Code
7472
8436
23455
3898
Age of
Oldest
Furnace
1927
1973
1974
1940
Production
Tons/Yr.
54.660
>8,000
>*0,000
>15,000
T/S
95
>20
>180
> 50
Shift
/Day
2
2
2
1-1/2
GPT
2284
NA
3163
2400
Discharge
Recycle % t
% POTW Direct
100
100
99.7 0.3
97 3
Central Treatment
Yes No X of total
X 69
X NA
X
X 97
         3901   1976      30.000     200
1350
100
                                                                                                                         Treatment Technology
                                                                                                                         Lagoon

                                                                                                                         Alim.Llw.Polywr
                                                                                                                         Dragout,Sludge to Holding
                                                                                                                         Pond
Internal Recycle

Polyner.Settllng Pits.
Lagoon

Settling
                                                                                           Treatment
                                                                                           Equipment
                                                                                             Age
                                                                                           1967

                                                                                           1968
1971


MA
GO
in

-------
CO
en
                                                                            TABLE  V-12  (cont'd)
                                                                     GENERAL SUMMARY TABLES
                                                                           GRAY  IRON
                                                                   MELTING FURNACE SCRUBBERS
                                                                       Applied Flow
Plant
Code
3646
3913
4577
4955
5008
5584
6343
8828
9183
9441
9593
2236
14069
17746
15520
19820
18073
0749
20249
20345
1381
Age of
Oldest
Furnace
1974
1972
1936
1952
1954
1970
1962
1955
1964
1967
1953
1970
1966
1956
1971
1946
1952
1975
1974
1965
1955
Production
Tons/Yr.
6263.7
12,670
16,800
6,003
22,411
15,742
37,790
4996.4
7,646
31.421
12,126
3,605
62,873
57,938
166,578
57,778
632,506
86,421
259,733
188,160
14,200
T/S
29.5
52
70
25
92
67.3
72.7
22.6
63.7
65.5
55
18
2
131
359
123
962
157
477
384
59
Shift
/Day
1
1
1
1
1
1
2
1
1
2
1
1
2052
2
2
2
3
2.37
2
2
1
GPT
6834
3323
3000
300
2217
NA
4952
139
1883
536
1676
3653
88
649
401
6572
2694
2599
1610
425
NA
Recycle
X
86
100
99.9
100
99
100
100

100
NA
100
100
-
100
95
100
100
90
NA
77
100
Discharge
X X Central Treatment
POTW Direct Yes No X of total
14 X
X
0.1 - X
X
1 - X
X
X
100 - X

NA X
X
X
12 X 33
X
5 - X
X NA
X NA
10 X 40
NA X
23 X 43
X NA
Treatment Technology
Settled
Settled (Internal Recycle)
Settled, Caustic. Polymer
Untreated
Scale Pits (2) Settling Tank
Polymer
Settling with dragout Caus-
tic, Polymer
Internal Recycle
Untreated
Settling, Caustic
Lagoon Settling
Internal Recycle
Settled
Lagoon
Internal Recycle
Clarify ,Sk1m, Alum, Polymer
Settl 1 ng , Lagoon. Settl 1 ng
Settled, Lagoon
Settling, Polymer, Lime .Clari-
fy Lagoon
Untreated
ClaHfler
Clar1f1er,Alum,Th1ckner,
Treatment
Equipment
Age
1974

1971
1976
1964
1971


1974
1972

1970
1946,1974
1977

1971
1976
1952
1973
1965
NA
                                                                                                                           Polymer

-------
OJ
                                                                          TABLE  V-13
                                                                   GENERAL SUMMARY TABLES
                                                                   DUCTILE IRON FOUNDRIES
                                                                        SLAG QUENCH
Age of
Plant Oldest
Code Furnace
17018 NA
14444 1970
15555 1962
24595 1966
18947 NA
10684 1951
14173 1943
16666 1966
20784 1977
30160 NA
14809 1964
16612 1966
20784
27743 1956
Applied Flow
Production
Tons/Yr.
42.242
70,498
73,968
10,953
114.107
213.386
335.000
109.187
126.054
26.965
1.226.942
>85,000
126.054
130.435
1/5
223.5
329
296
79.9
423
335
447
237
248
115
2606
>20C
248
181
Shift
/Day
1
1
1
1
2
3
3
2
2
1
2
2

3
GPT
HA
540
997
935
236
5731
805
60.8
58*1
NA
1234
1943
581
NA
Recycle
X
100
100
100

90

100
100
39

99.4


NA
Discharge
X % Central Treatment
POTH Direct Yes No X of total
X
X
X
100 X
10 X 10
100 X
X
X
61 X
100 X
0.6 X 29
100 X NA

NA X
                                                                                                                        Treatment Technology
                             Treatment
                             Equipment
                               Age
Settling Tank                NA
Settling.Reused for quencher NA
Settling.Reused In scrubber  1978
Untreated                    NA
Settllng.Acld.Lagoon         NA
Settling Pond,Chior1nation   NA
Settl1ng.Polymer.L1me        1972
Settling                     NA
Settl1ng,Polymer.Lagoon      1973
skim
Settling Pond                NA
SettlIng.SettlIng Pond       1948.1968
Settling Pond.Alum.Polymer   1966
Clarlfler
                                                                                                                        NA

-------
                                                                            TABLE  V-13 (cont'd)
                                                                     GENERAL SUMMARY TABLES
                                                                       GRAY  IRON FOUNDRIES
                                                                          SLAG QUENCH
00
oo
Plant
Code
2031
18919
19347
1942
2121
2195
3646
4577
4688
6565
8070
8663
8828
9441
2236
14069
17348
Age of
Oldest
Furnace
1972
1964
1974
1972
1971
NA
1974
1936
1945
1968
1946
1972
1955
1978
1974
1966
1946
Applied Flow
Production
Tons/Yr.
5,222
15,882
29,500
32,385
11,250
3948
6263.7
16,800
32,000
15,275
14,170
11,177
4996
31,421
3605
62,873
132,995
T/S
23
61.8
64
115.7
55
16
29.5
70
68
69.5
60
31
22.6
65.5
18
146
294
Shift
- /Day
1
1
2
1
1
1
1
1
2
1
1
2
1
2
1
2
2
Recycle
GPT %
274
777 100
1500 100
1287 100
873 95
1650
1007
NA(Tank) 100
1162
NA 100
16
NA 100
160 57
1088
NA(Tank) 100
378 90
327
Discharge
! % % Central Treatment
POTW Direct Yes No X of total
100 X 75
(LAGOON)
X
X 16
X
5 X
100 - X
100 - X
X
100 X
X
100 - X
X
43 - X
100 X
X
10 X 5.8
100 X 10
Treatment Technology
Lagoon

Settling Tank
Clarifier,Lagoon,Cool ing
Tower
Settled', Caustic. Polymer
Settled, Caustic added
untreated
Settled
Settled (Tank)
Untreated
Settled
Untreated
Settled with Dragout
NA
Lagoon
none(tank w/makeup)
Lagoon, Skimmer
                                                                                                                         Screen,Clarifier,Polymer,
                                                                                                                         Vac.Filter, Skim
                                                                                                                                                      Treatment
                                                                                                                                                      Equipment
                                                                                                                                                        Age
                                                                                                                                                      1975
                                                                                                                                                      NA
                                                                                                                                                      1959,1970

                                                                                                                                                      1972
                                                                                                                                                      1971

                                                                                                                                                      1974
                                                                                                                                                      NA

                                                                                                                                                      NA
                                                                                                                                                      NA
                                                                                                                                                      1955
1946,1974
1977
1958

-------
GO
vo
                                                                           TABLE  V-13 (cont'd)
                                                                    GENERAL SUMMARY  TABLES
                                                                     GRAY  IRON FOUNDRIES
                                                                         SLAG QUENCH
                                                                        Applied Flow
Plant
Code
11865
.-%uV'
17746
19820
0749
20249
20345
20699
20112
27500
1801
3313
5533
5658
6213
63778
63779
7322
7499
Age of
Oldest
Furnace
1974
1956
1946
1975
1974
1965
1954
1966
1964
1956
1973
1960
1967
1948
1971
1974
1975
NA
Production
Tons/Yr.
34.622
57,938
57,778
86.421
259.733
188,160
161.819
187,039
157,912
58,280
78.594
57,123
8,500
24,820
43,291
73,767
17,500
11,750
I£
158
131
123
157
477
384
230
211
319.65
141.8
110
115
60
52
83.2
113
37.5
24
Shift
/Day
NA
2
2
2.37
2
2
3
3
2
1 3/4
3
2
1
2
2
2
2
2
Discharge
6PT
607
229
468
183
NA
300
620
895
1652
28
436
2713
240
3173
NA
NA
256
600
Recycle *
X POTW
100
Recycled &
Reused
80
Reused
100
90 10
NA NA
62 38
90
-
100
-
-
40
100
-
100
100
100
100
X Central Treatment
Direct Yes No X of total
X NA
20 X 30
X 6
X
X
X 15
10 X 3
100 X 47
X
100 X
100 X
60 X 56
X
100 X
X
X
X 10
X 15
                                                                                                                           Treatment  Technology
                                                                                                                             Treatment
                                                                                                                             Equipment
                                                                                                                               Age
                                                                                                                           Settle w/DO.CIarlfy.Polymer   1976
                                                                                                                           Deep Bed Sand Filter
                                                                                                Clarlfy.Polywr.Deep Bed     1976
                                                                                                Filter .Cool Ing Totter
                                                                                                Settled.Lagoon               1976
                                                                                                Settling P1t,Alum.Po1ymer    1974
                                                                                                Untreated
                                                                                                Clarlfler                    NA
                                                                                                Sk1m,Clar1fy.Polymer,Vac.     1977
                                                                                                Filter
                                                                                                Lagoon, ski*                 1972
                                                                                                Settling with Dragout        1969
                                                                                                Settling with Dragout        NA
                                                                                                Untreated
                                                                                                Settling, Scale Pit,         1972.1951
                                                                                                Lagoons (2)
                                                                                                Settling with Dragout        NA
                                                                                                Settling with Dragout        NA
                                                                                                NA                           NA
                                                                                                Untreated
                                                                                                Lagoon. Polymer. Alum        1976
                                                                                                Settling. Clarlfler          1967
                                                                                                Thickner. Polymer
          9440   1977
114.133   237.8
                                                            1067
70
30
30
Settling, Polymer. Lagoon    1974.1976

-------
        TABLE V-13 (cont'd)
 GENERAL SUMMARY TABLES
MALLEABLE IRON FOUNDRIES
       SLAG QUENCH

   Applied Flow
Plant
Code
4222
5538
6773
7472
23455
3901
Age of
Oldest
Furnace
NA
NA
1964
1927
1974
1976
Production
Tons/Yr.
80,435
2100
4235
54,660
83,539
30,000
T/S
40.2
9.5
20.3
95
191.2
2000
Shift
/Day
1
1
1
2
2
1
GPT
NA
378.9
259
1026
753
1350
Discharge
Recycle i X Central Treatment
% POTW Direct Ves No % of total
50 50 X
100 X
100 X
100 X 31
100 X
100 X
Treatment Technology
Untreated
Untreated
Untreated'
Settling Lagoon
Untreated
Settling with dragout
Treatment
Equipment
Age



1967

NA

-------
                                                                   TABLE V-14
                                                            GENERAL  SUMMARY TABLES
                                                            DUCTILE  IRON FOUNDRIES
                                                 CASTING QUENCH AND MOLD COOLING OPERATIONS

                                                              Applied Flow
Plant
Code
17081
1444
15555
19733
14580
18947
16502
14173
Age of
Oldest Production
Furnace tons/Yr. T/S
1951 >15.000 >10
(Mold Cooling and Pipe)
1970 > 56, 000 >300
Pipe Quenching. Mold Cooling
1962 > 51, 000 >250
Pipe Quenching, Mold Cooling
1968 126.000 293
Casting Cooling
1973 >100,000 >150
Mold Cooling and Pipe Quench
1974 >97,000 >200
Mold Cooling and Pipe Quench
1972 42.530 91.6
1943 335.000 447
Shift
/Day
1
1
1
2
2
2
2
3
GPT
NA
350
190
328
4377
9434
157
*NA
Discharge
Recycle X X
X POTW Direct
NA NA
64 36
Reused
14 86
Reused
100
85 15
100
100
100
Central Treatment
Yes
X
X
X
X
X


X
No X of total
48
21
46
*
5
60
X
X
NA
         Casting Quench and Mold Cooling
8944
1956      74.200
  Mold Cooling
327
1376
                                                                80
20
23
                                                                                                                 Treatment Technology
                                                                                                                                      Treatment
                                                                                                                                      Equipment
                                                                                                                                        Age
                                                                                                                 Settling, Acid (36 gpt DIs-  1965.1972
                                                                                                                 charge

                                                                                                                 Lime. Polymer. ClaHfler,    1974
                                                                                                                 Skin

                                                                                                                 Vac.Fllter. Lime, Polymer    1978
                                                                                                                 Settling

                                                                                                                 Polymer, Thlckner. VAc.      1968
                                                                                                                 Filter

                                                                                                                 Settling and Skimming, re-   1970
                                                                                                                 cycle In spray basin          -f

                                                                                                                 Recycle through spray basin  NA
Untreated to landfill

Settling Lagoon for re-      1965
circulation

Settling Lagoon. Acid.       1970
Skimming

-------
ro
                                                                           TABLE V-14 (cont'd)
                                                                    GENERAL SUMMARY TABLES
                                                                     GRAY IRON FOUNDRIES
                                                         CASTING QUENCH AND HOLD COOLING OPERATIONS

                                                                      Applied Flow
Age of
Plant Oldest Production
Code Furnace Tons/Yr. T/S
15104 NA 325,770 514
Hold cooling, cleaning, and Quencl
17289 1962 9719.7 11.39
Centrifugal Casting
20408 1945 19,597 39
Casting Quench
3068 NA 214,373 355
Flask cooling and ladle cleaning
11865 1974 > 32. 000 >145
Hold Cooling and Washdown
17746 1956 >i»7,000 >121
Hold cooling and washdown
20112 1905 187.037 210
Pipe casting machines
3069 NA 129,399 412
Shift
/Day
1.7
ling
3
2
2
1
2
3
1
GPT
NA
588
NA
}23
266
534
120
55
Discharge
Recycle % t Central Treatment
t POTU Direct Yes No X of total
100 X
100 X
100 X
100 X
100 X 35
80 20 X 70
100 X 6.S
100 X
                                                                                                                         Treatment  Technology
                                                                                                                         Untreated
                                                                                                                         Untreated
                                                                                                                         In Tanks
                                                                                                                         Polymer,  Clarlfler
                                                                                                                         Polymer,  clarlfler
Treatment
Equipment
  Age
1978
1976
               Flask  cooling and  ladle cleaning
                                                                                                                         Polymer,  clarlfler.  cooling   1976.1977
                                                                                                                         Settling lagoon,  skim        1972
                                                                                                                         Skimming                     1977

-------
                                                                          TABLE V-14 (cont'd)
                                                                   MALLEABLE IRON FOUNDRIES
                                                        CASTING QUENCH AND MOLD COOLING OPERATIONS
                                                    	Applied MOM    	
         Age of                                                                     DischargeTreatment
Plant    Oldest        Production	  Shift                  Recycle        X^~Z   Central  Treatment                                Equipment
Code     Melter  Tons/Year      T7?         /Day         GPT          X         POTW      Direct  Yes  No   X of Total  Treatment Technology           Age

6123     1949    104,356        222.03      2            113                              100         X    2.5         Settling                    1973
                 Cooling/Tumbling Mill

-------
                TABLE V-14 (cont'd)
         GENERAL SUMMARY TABLES
            STEEL FOUNDRIES
CASTING QUENCH AND MOLD COOLING OPERATIONS

           Applied Flow
Plant
Code
11643
20000
20002
20011
20719
21175
2495
7898
8768
10225
17015
11598
15654
16934
17017
Age of
Oldest
Furnace
1970
1957
1964
1961
1942
1948
NA
1967
NA
1914
1977
1948
1954
1943
1952
Production
Tonr/Yr. T/S
41,478 70
Casting Quench
66,144 95.44
Quenching
62,331.2 90
Quenching
75,346 107.3
Quenching
4108 11.3
Quenching
4450 12.4
Quench
600 2.5
Quench
397 0.8
Casting Quench
6754 13.3
Casting Quench
37,000 44
Casting Quench
11,700 114.7
Roll Quench Tank
15,250 31
Quenching
125,000 173.6
Quench from heat treat
20,599 38.2
Quench
66,117 88.1
Casting Quench
Shift
/Day
3
3
3
3
1.5
1
1
2
2
3
2
2
3
2
3
GPT
8229
1320
1493
2237
NA
NA
4
125
75
NA
NA
145
5100
52
11.4
Discharge
Recycle X % Central Treatment
% POTW Direct Yes No % of total
100 X
99.8 0.2 X 34
99.8 0.2 X 29
99.8 0.2 X 42
100 X
100 X
100 X
100 X
100 X
75 25 X
100 X
100 X
100 X
100 X
76 24 X
(Reused)
Treatment Technology
Dragout and Recycle
Cooling Tower
Cooling Tower
Cooling Tower
Tank
10,000 Gal Tank -
Dump once a year to POTW
Untreated to Pond
Untreated
Untreated to dry well
Cooling Tower
Tank
Untreated discharge from
tank
Cooling tower, settling
Untreated
Untreated
Treatment
Equipment
Age
1970
NA
NA
NA





NA


1972



-------
-Pi
en
                                                                              TABLE V-14  (cont'd)
                                                                      GENERAL  SUMMARY  TABLES
                                                                         STEEL FOUNDRIES
                                                             CASTING QUENCH AND MOLD COOLING OPERATIONS

                                                                        Applied Flow
Plant
Code
10388
20003
20007
20009
24566
28634
1665
1834
4880
7882
Age of
Oldest
Furnace
1968
1943
1969
1969
1971
1951
1976
1957
1965
1942
Production
Tons/Vr. T/S
33.192 46.3
Casting Quench
19.210.7 39.9
Quenching
46.778 192
Casting Quench
72.341 105
Casting Quench
38.106 82.48
Casting Quench
15.796 30.37
Casting Quench
9151.6 15.2
Quench
38.700 42.6
Casting Quench
24.995 49.5
Heat Treat Quench
5467 10.9
Casting Quench
Shift
/Dajr
3
2
1
3
2
2
2
3
2
2
GPT
583
1170
55
NA
1164
1391
291
76
199
5505
Discharge
Recycle % t Central Treatment
% POTW Direct Yes No X of total
100 X
100 X
100 X NA
<100 X
100 X NA
100 X
100 X
100 X
100 X
100 X
Treatment Technology
Untreated
Untreated
Clarifler
Drain tank once • year
or less
Settling Lagoon and recycled
or reused
Untreated
Untreated
Untreated
Untreated
Untreated
Treatment
Equipment
Age


NA

NA






-------
        TABLE V-15
 GENERAL SUMMARY TABLES
   GRAY IRON FOUNDRIES
SAND WASHING AND RECLAIM


Plant
Code
17348
15520


20699

1381

Age of
Oldest
Melter
1946
1971

Flows from
1954

1955


Metal
Tons/Year
132,995
166,578

visit
161,819

14,200



Metal
294
359


133

59

T/S
Reclaimed
Sand
120
2404


25

75


Shift
/Day
2
2


2

1
Applied Flow
Discharge
GPT Recycle % %
Rec. Sand X POTW Direct
3040 100
198 81 91


1402 100

NA 100


Central Treatment
Yes No X of total Treatment Technology
X 32 Settling Lagoon
X Settling tanks, classifier
vacuum filter

X 6.6 Polvmer.clarlfler.sklm.
vacuum filter
X NA Sett ling, classifier.

Treatment
Equipment
Age
1969
.1971


1977

NA
centrlfuge.clarlfler, polymer
11964

7902
1965 >1

1975
12,000

17,143
>350

77
903

40
I

1
3085 77.5 22.5

NA NA NA
X 41 Settling tanks, claHfler
alum, polymer
X Incomplete data
1954.1964



-------
        TABLE V-15 (cont'd)
 GENERAL SUMMARY TABLES
     STEEL FOUNDRIES
SAND MASHING AND RECLAIM


Plant
Code
20007

20009

24566

Age of
Oldest
Me Her
1969

1969

1971

Production
Metal
Tons/Year T/S
46,778 192

72,341 105
Flows from visit
38,106 82.5



Applied Flow
(Tons/Shift)
Reclaimed
Sand
285 '

83

50
Shift
/Day
1

3

2

GPT
NA

1565

1461
Recycle
X
NA
(>90)
56



Discharge
X X
POTW Direct
NA

44

100


Central
Yes No
X

X

X


Treatment
X of Total
NA

80

96



Treatment Technology
Clarifier

Settling Lagoons

Polymer, calcium

Treatment
Equipment
Age
NA

1950

1975
                                                           chloride,  settling
                                                           lagoon

-------
                                                                              TABLE V-16
                                                                       GENERAL SUMMARY TABLES
                                                                         MAGNESIUM FOUNDRIES


Plant
Code

5244
8146


8146


Age of
Applied Flow

Oldest Production
Me Her Tons/Year
GRINDING SCRUBBERS
1975 49.7
1940 's 192
Flow from visit
DUST COLLECTORS
1940's 49.7
Flow from visit
T/S

0.2
0.82


100 T/S
of sand

Shift
/Day

1
1


1


Recycle
GPT X

NA 100
1600


22

Discharge
X X Central Treatment
POTW Direct Yes No * of Total Treatment Technology

X Internal recycle
100 X Untreated


100 X Untreated

Treatment
Equipment
Age







CO

-------
                                                                      TABLE V-17
                                                               GENERAL SUMMARY TABLES
                                                            ZINC FOUNDRY CASTING QUENCH
Plant
Code
4525
12060
2589
5091
5947
9707
10640
18139
13524
18463
21207
4622
5117
Age of
Oldest
Furnace
1959
1967
1970
1956
1970
1956
1965
1952
1956
NA
1965
1956
1940
Production
Tons/Yr. T/S
330 1.4
>1,000 >U
500 1
360 0.75
3600 14
586 1.4
>5.500 >12
>10.000 >10
>25,000 >30
>7,000 >15
1421.5 3.17
10,671 22.2
>10,000 >16
Shift
/Day
1
1 1/2
2
2
1
1 1/2
2
3
3
2
2
2
3

GPT
NA
32.7
500
533
NA
NA
857
4.8
66.7
2152
772
93
546
Applied Flow
Discharge
Recycle % % Central Treatment
% POTU Direct Yes No X of total
100
100 X 0.01
100
100
100
80 20 X NA
100 X 5
100 X 0.2
100 X NA
100 X X 35
NA NA
100
30 70 X 8
                                                                                                                    Treatment Technology

                                                                                                                    Untreated

                                                                                                                    Polymer. Clarlfler

                                                                                                                    Untreated

                                                                                                                    Untreated

                                                                                                                    Tanks,  also circulated for cooling

                                                                                                                    Reservoir, untreated discharge

                                                                                                                    EB for  casting quench and melting
                                                                                                                    followed by flocculatlon with lime.
                                                                                                                    alun, polymer and  Iron sulfate;
                                                                                                                    neutralization with line, acid and
                                                                                                                    wastes, clarlfler  and thickener

                                                                                                                    Settling and skimming

                                                                                                                    Emulsion break; flocculatlon
                                                                                                                    with alum and polymer; flotation;
                                                                                                                    neutralization with caustic;
                                                                                                                    settling tanks, skinning

                                                                                                                    Flocculatlon with  line and polymer;
                                                                                                                    flotation; neutralization with caustic.
                                                                                                                    line, and other wastes; lagoons

                                                                                                                    Untreated - A portion Is recycled
                                                                                                                    through a filter

                                                                                                                    Wastes  are removed by a reprocessor

                                                                                                                    Emulsion break; vacuum filter;
                                                                                                                    flocculatlon with  lime and polymer;
                                                                                                                    neutralization with lime; clarlfler,
                                                                                                                    thickener; skimming
NA - Not available

-------
                                                                           TABLE V-17  (cont'd)
                                                                    GENERAL  SUMMARY  TABLES
                                                                 ZINC FOUNDRY  CASTING  QUENCH
                                                                        Applied Flow
en
o
Plant
Code
6606
9105
10308
10475
1334
1707
Age of
Oldest
Furnace
1946
UNK
1954
1955
1964
1975
Production
Tons/Yr. T/S
6000 6.41
8030.3 10.3
>5.000 >7
>6,000, >10
6,000 15
2,500 3.4
Shift
/Day
3
3
3
2
2
3
GPT
NA
NA
NA
NA
"NA
706
Discharge
Recycle % % Central Treatment
% POTW Direct Yes No % of total
X
X
NA NA X 25
(28gpt)
100
100 X NA
100 X 5
          8724   1952
2,268     2.9
5.5
100
0.01
Treatment Technology

Uses • quench tank which
Is periodically drained

Uses a quench tank which 1$ drained
once a year

Recycled through settling and
skinning - Emulsion break; floccu-
latlon with alim, caustic and polymer
neutralization with caustic;
flotation; sklnalng

Not Available

Nixed with mold cooling In a reservoir

Pressure filter; flocculatlon with
neutralization with line;
settling; sklmlng

So small a part of total treatment
flow, treatment process not
representative
       NA - Not available

-------
  18139  1952     >10,000     >10
  13524  1956    >25,000     >30
  10475  1955      11.000    25
                                                                     TABLE V-18
                                                              GENERAL SUMMARY TABLES
                                                         ZINC FOUNDRY MELTING OPERATIONS

                                                                Applied Flow
Plant
Code
4622
10640
Age of
Oldest
Furnace
1956
1965
Production
Tons/Yr.
10,671
>S,500
_[/S
22.2
Shift
/Day
2
2
GPT
NA
24,700
Recycle
I
100
(Internal)
98.3
(Internal)
Discharge
X
POTM

X
Direct
1.7
(41l9Pt)
Central Treatment
Yes No X of
X 2.4
total
3       5468
3       NA
2       NA
 85        15

(Internal)


 >90       <10
 (est.)    (556gpt)
 (Internal)
 >90       <10
 test.)    (102gpt)
 (Internal)
27
(816gpt)
10
                                                                                                                  Treatment Technology
Envision break for casting
quench and Melting - flocculatlon
with line, aliM, poly«er and Iron
sulfate; neutralization with line.
acid and wastes; clarlfler and
thickener

Settling and sklnrtng;
Emulsion breaking, line, polymer,
clarlfler, pressure filter Installed

Emlslon break; flocculatlon with
alum and polymer; flotation;
neutralization with caustic;
settling; skinning

Untreated
NA > Not available

-------
                             TABLE
                              V-19
                     LIST OF TOXIC POLLUTANTS
Compound Name                                          Mole Wt.
1.  *acenaphthene                                      154
2.  *acrolein                                             56
3.  *acrylonitrile                                       53
4.  *benzene                                             78
5.  *benzidine                                         184
6.  *carbon tetrachloride (tetrachloromethane)         155
    •Chlorinated benzenes (other than dichlorofaenzer.es)
7.      chlorobenzene                                   113
•8.      1,2,4-trichIorobenzen'e                          182
9.  '    hexachlorobenzene                               285
    *Chlorinated ethanes (including 1,2-dichloroethane,
    1,1,1-trichloroethane and hexachloroethane)
10. 1,2-dichloroethane                                   99
11. 1,1,1-trichloroethane                              135
12. hexachloroethane                                   237
13. 1,1-dichloroethane                                   99
14. 1,1,2-trichloroethane                              134
15. l,*l,2,2-tetrachloroethane                          168
16. chloroethane
    *Chloroalkyl ethers (chloromethyl, chloroethyl)
    and mixed  ethers)
•Specific  compounds and chemical classes as listed  in the
  Consent Decree.
                              152

-------
17.   bis(chloromethyl)ether
18.   bis  (2-chloroethyl) attar                           137
19-   2-ehloroethyl vinyl attar  (mixed)
    •Chlorinated naphthalene
20.   2-chloronaphthalene                                 162
    •Chlorinated phenols  (other than those listed
     elsewhere; includes trichlorophenols and
     chlorinated cresols)
21.    2,4,6-trichlorophenol                              202
22.    parachlorometa cresol
23. *chloroform  (trichloromethane)                        121
24. *2-chlorcphenol                                       130
    *Dichloroben2enes
25.   1,2-dichlorobenzene                                 150
26.   1,3-dichlorobenzene                                 150
27.   1,4-dichlorobenzene                                 150
    *Dichloroben2idine
28.   3,3'-dichlorobenzidine
    *pichloroethylenes (1,1-dichloroethylene and
     1,2-dichloroethylene)
29.   1,1-dichloroethylene                                96
30.   1,2-trans-dichloroethylene
31. *2,4-dichlorophenol                                   166
    *Piehloroprogane and diehloropropene
32.   1,2-dichloropropane  -                               113
•Specific compounds and chemical classes are listed in the
 Consent Decree.   *
                            153

-------
33.     1,2-dichloro?ropylene (1,3-dichlorcpropene)
34. *2,4-dimethylphenol '                                  122
    *Dinitrotoluene
35.   2,4-diaitrotoluene                                  182
36.   2,6-dinitrotoluene                                  182
37. *l,2-diphenylhydrazine
38. *ethylben2ene
39. *fluoranthene
    *Ealoethers  (other than those listed elsewhere)
40.   4-chlorophenyl phenyl ether
41.   4-bromophenyl phenyl ether
42.   bis  (2-chioroisopropyl) ether
43.   bis  (2-chloroe-thoxy) methane
    .*Halomethanes  (other than'those listed elsewhere)
44.   methylene chloride  (dichlorernethane)                 87
45.   methyl chloride  (chloromethane)                      50
46.   methylbromide  (bromomethane)                         95
47.   bromoform  (tribromomethane)                         253
43.   dichlorobromomethane                                164
49.   trichlorofluoromethane                              139
50.   dichlorodifluoromethane                             121
51.   chlorodibromomethane                                209
52. *bexachlorobutadiene
53. *hexachlorocyclooentadiene
•Specific compounds and chemical classes are  listed  in  the
 Consent Decree.
                            154

-------
54. *isophorone                                          138
55. 'naphthalene                                         128
56. ^nitrobenzene                                        123
    *Nitrophenols (including 2,4-dinitrophenol and
     31,nitrocresol)
57.   2-nitrophenol                                      139
58.   4-nitrophenol
59.   *2,4-dinitrophenol                                 184
60.   4,6-dinitro-c-cresol
    *Nitrosamines
61.   fr-nitrosodiaethylamine                              74
62.   N-nitrosodiphenylamine                             198
63.   N-nitrosodi-n-propylamine
64. *pentachlorophenol                                   267
65. *phenol                                               94
    *Phthalate esters
66.   bis  (2-ethylhexyl) phtnalate
67.   butyl benzyl phthalate                             310
68.   di-n-butyl phthalate
69.   di-n-cctyl phthalate
70.   diethyl phthalate
71.   dimethyl phthalate
    *Polynuelear aromatic hydrocarbons
72.   benzo(a)anthracene  (1/2-benzathracene)             243
•Specific compounds and chemical classes are listed in the
 Consent Decree.
                             155

-------
73.   benzo(a)pyreae  (3,4-benzcpyrene)
74.   3,4-ber.zofluoranth.ane
75.   benao(k)fluoranthane  (11,12-benzofluoranthene)
76.   chrysene                                            223
77.   acenaphthylene
78.   anthracene                                          I*78
79.   benzo(ghi)perylene  (1,12-benzoperylene)
80.   fluorene
31.   phenathrene
82.   dibenzo(a,h)anthracene  (1,2,5,6-diienzanthracene)
83.   indeno(1,2,3-cd)?yrene  (2,3-o-phenylenepyrene)
84.   pyrene
85. *tetrachloroethylene                                  168
86. *toluene                                               92
83. *trichloroethylene                                    132
88. *vinyl chloride  (chloroethylene)                       63
    Pesticides and Metabolites
39.   *aldrin                                             363
90.   *dieldrin                                           383
91.   *chlordane  (technical mixture  & metabolites)        410
    *DDT and metabolites
92.   4,4'-DDT
93.   4,4'«DDE  (p,p'-DDX)
*Specific compounds  and chemical  classes  are  listed in the
 Consent Decree.
                              156

-------
94.   4,4'-DDD  (p,p'-TDE)
    *endosulfan and metabolites
95.   a-endosulfan-Alpha
96.   b-endosulfan-Beta
97.   endosulfan sulfate
    *endrin and metabolites
98.   endrin                                             381
99.   endrin aldehyde
    *heptachlor and metabolites
100.   heptachlor                                        376
101.   heptachlor epoxide                                394
    *hexachlorocyclohexane  (all isomers)
102.   a-BEC-Alpha
103.   b-BEC-Beta
104.   r-BEC  (lindane)-Gamma
105.   g-BEC-Delta
                                        •
    *polychlorinated biphenyls  (PCB's)
106.   PC3-1242 (Arochlor 1242)
107.   PC3-1254 (Arochlor 1254)
108.   PCB-1221 (Arochlor 1221)
109.   PCB-1232 (Arochlor 1232)
110.   PC3-124S (Arochlor 1248)
111.   PCB-1260 (Arochlor 1260)
112.   PC3-1016 (Arochlor 1016)
*Soeci£ic compounds and chemical classes are listed in the
 Consent Decree.
                               157

-------
113. *Toxaphene
114.  *Antimony  (Total)
115.  *Arseaic  (Total)
116.  'Asbestos  (Fibrous)
117. ' *BeryIlium  (Total)
118.  *Cacmium  (Total)
119.  *Chromium  (Total)
120.  *Copper  (Total)
121.  *Cyanide  (Total)
122.  *Lead  (Total)
123.  *Mercury  (Total)
124.  *Nickel  (Total)
12S.  *Seleniunt  (Total)
126.  *Silver  (Total)
127.  'Thallium  (Total)
128.  *2inc  (Total)
129.  **2,3,7,8  - tetrachlorodibenzo-p-dioxin (TCDD)
130.  Xylene
 •Specific compounds  and  chemical classes are listed in the
  Consent Decree.
**This compound  was specifically listed in the Consent Decree
  because of its  extreme  toxicity.
                             158

-------
                                         TABLE V-20
                    Conventional  and Nonconventlonal  Pollutants Analyzed
en
10
Acidity, free
Acidity, total
Alkalinity (Methyl Orange)
Alkalinity (Phenolphthalein)
Alumi num
Ammonia
Calcium
Carbon, Organic
Chi oride
Cyanate
Fluoride
Hardness
Iron
Magnesi urn
Manganese
Nitrogen
Oil and Grease
pH
Potassium
Silica, Soluble
Sodi urn
Solids, Dissolved
Solids, Suspended
Solids, Volatile
Sulfate
Sulfide
Temperature
Thiocyanate
Tin

-------
                                                                              TABLE V-21
                                                   INORGANIC TOXIC POLLUTANTS SELECTED FOR VERIFICATION ANALYSIS
                                                                                                CN
                                                           Sb    Aa   Be    Cd    Cr   Cu     (Total)    £b    Hg   IU    Se   Aj   Tl^    Zn
CTl
O
Aluaunuai Foundries

  Investment Casting Operation*
  Melting Furnace Scrubbers
  Canting Quench Operations
  Die Casting Operations
  Die Lube Operation*

Copper and Copper Alloy Foundriea

  Duct Collection Systi>n>»
  Hold Cooling and Canting Quench
  Continuous Caating Operation*

Ferroua Foundriea

  D»'*t Collection Systems
  Melting Furnace Scrubbera
  Slug Quenching
  Canting Quench and Hold Cooling
  Sand Washing

Magngaiuaj Foundrie*

  Grinding Scrubber Systems
  Duat Collection Systrsts

Zinc Foundries
  Casting Quench Operation*
  Melting Furnace Scrubbera
X

X
X
X
•a
X X
h X
X
X X X X X
X X X X X
X X
ig X XX X X
X X X X X


X
X
X





X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X


X
X





X
X
X
X
XXX
X
XXX
X
X
X
X
X

-------
                              TABLE V-22

     PLANT  ASSESSMENT OF  THE  KNOWN  OR  BELIEVED  PRESENCE
   OF  TOXIC  POLLUTANTS  IN FOUNDRY RAW  PROCESS WASTEWATER
                   SUBCATEGORY:  ALUMINUM CASTING

                           ALL PROCESSES
POLLUTANT
                                     KNOWN
                                     TO BE
                                    PRESENT
      Hexachloroethane
      2-chloronaphthal ene
      2,4-dichlorophenol
      Phenol
      Heptachlor epoxide
      (BHC-hexachlorocyclohexane)
      Delta-BHC
      (PCB-polychlorinated blphenyls)
      PCB-1248 (Arochlor  1248)
      Beryl 1i an
      Cadmiun
      Chromium
      Copper
      Lead
102 -
020 •
031 -
065 -
101 •

105 -

110
117
118
119
120
122
124 - Nickel
128 - Zinc
BELIEVED
  TO BE
 PRESENT

    1
    1
    1
              SUBCATEGORY:   COPPER ft COPPER  ALLOY CASTING

                            ALL PROCESSES
POLLUTANT

114 - Antimony
119 - Chromium
120 - Copper
122 - Lead
124 - Nickel
                                      KNOWN
                                      TO BE
                                     PRESENT
BELIEVED
  TO BE
 PRESENT

    1
    1
    2
    2
    1
                                      161

-------
                     TABLE  V-22 (Cont'd.)


  PLANT ASSESSMENT  OF THE  KNOWN  OR  BELIEVED  PRESENCE
OF  TOXIC POLLUTANTS IN  FOUNDRY RAW  PROCESS WASTEWATER
                            SUBCATEGORY:  IRON &  STEEL

                             PROCESS:  DUST COLLECTION
       POLLUTANT

       004  - Benzene
       007  - Chlorobenzene
       008  - 1,2,4-trichlorobenzene
       009  - Hexachlorobenzene
       021  - 2,4,6-trichlorophenol
       024  - 2-chlorophenol
       025  - 1,2-diChlorobenzene
       026  - 1,3-diChlorobenzene
       027  - 1,4-dichlorobenzene
       031  - 2,4-dichlorophenol
       034  - 2,4-dimethylphenol
       035  - 2,4-dinitrotoluene
       036  - 2,6-dinitrotoluene
       038  - Ethyl benzene
       052  - Hexachlorobutadiene
       055  - Naphthalene
       064  - Pentachlorophenol
       065  - Phenol
       086  - Toluene
       114  - Antimony
       118  - Cadmium
       119  - Chromium
       120  - Copper
       121  - Cyanide
       122  - Lead
       124  - Nickel
       125  - Selenium
       126  - Silver
       127  - Thallium
       128  - Zinc
 KNOWN
 TO BE
PRESENT

  1
  30

   1
   2
  11
  12

  10
   9

   2
   1
  10
BELIEVED
 TO BE
PRESENT

   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
  15
   2
   1
                             SUBCATEGORY:   IRON & STEEL

                                 PROCESS:   MELTING
       POLLUTANT
  KNOWN
  TO BE
  PRESENT
       065 - Phenol                        2
       105 - Delta-BHC
            (PCB-polychlorinated biphenyls) 1
       114 - Antimony                      2
       115 - Arsenic                       2
       118 - Cadmium                       4
       119 - Chromium                      9
       120 - Copper                        9
       121 - Cyanide                       2
       122 - Lead                         10
       123 - Mercyry                       3
       124 - Nickel                       10
       125 - Selenium                      4
       126 - Silver                        4
       127 - Thallium                      1
       128 - Zinc                         14
BELIEVED
  TO BE
PRESENT
                                      162

-------
                    TABLE  V-22  (Cont'd.)


   PLANT  ASSESSMENT  OF THE KNOWN OR  BELIEVED  PRESENCE
OF  TOXIC  POLLUTANTS IN  FOUNDRY  RAW  PROCESS WASTEWATER
                        SUBCATEGORY:  IRON 8 STEEL CASTING

                             PROCESS:  SLAG QUENCHING
       POLLUTANT

       ! !$ _ Antimony
       118 - Cadmium
       119 - Chromiun
       120 - Copper
       122 - Lead
       123 - Mercury
       124 - Nickel
       125 - Selenium
       126 - Silver
       127 - Thallium
       128 - Zinc
 KNOWN
 TO BE
PRESENT

   1
   4
   6
   6
   6
   2
   4
   1
   3
   1
   7
BELIEVED
  TO BE
 PRESENT
                         SUBCATEGORY:  IRON & STEEL CASTING

                               PROCESS:   SAND HASHING
        POLLUTANT

        065 - Phenol
        122 • Lead
        124 - Nickel
        128 - Zinc
  KNOWN
  TO BE
  PRESENT

     1
     1
     1
     1
                                                     BELIEVED
                                                       TO BE
                                                      PRESENT
                                     163

-------
                    TABLE V-22 (Cont'd.)


  PLANT ASSESSMENT  OF THE  KNOWN OR  BELIEVED  PRESENCE
OF  TOXIC  POLLUTANTS IN FOUNDRY  RAW  PROCESS WASTEWATER
                          SUBCATEGORY: ZINC  CASTING

                               ALL PROCESSES
     POLLUTANT

     -55 -  Naphthalene
     065 -  Phenol
     073 -  Benzo(a)pyrene (3,4-benzopyrene)
     114 -  Antimony
     115 -  Arsenic
     117 -  Beryllium
     118 -  Cadmium
     120 -  Copper
     121 -  Cyanide
     124 -  Nickel
     128 -  Zinc
    KNOWN
    TO BE
    PRESENT
BELIEVED
  TO  BE
PRESENT

   1
   1
   1
                         SUBCATEGORY:  MAGNESIUM CASTING

                                ALL PROCESSES
      POLLUTANT

      117 - Beryllium
      120 - Copper
      124 - Nickel
      128 - Zinc
 KNOWN
 TO BE
PRESENT

   1
   1
   1
   1
                                                    BELIEVED
                                                     TO  BE
                                                    PRESENT
                                    164

-------
                                             TABLE  23
                        ENGINEERING ASSESSMENT OF  TOXIC  POLLUTANTS
                   LIKELY  TO  BE  PRESENT  IN FOUNDRY PROCESS WASTEWATERS
SUBCATEGORY:   ALUMINUM  CASTING

ALL PROCESSES

004   Benzene
006   Carbon tetrachloried (tetrachloromethane)
044   Methylene chloride (dichloromethane)
061   N-nitrosodimethylamine
062   N-nitrosodiphenylamine
063   N-nitrosodi-n-propylamine
065   Phenol
086   Toluene
124   Nickel
125 . Selenium
128 - Zinc
                                SUBCATEGORY:   COPPER  CASTING
.ALL
114 •
117 •
119 •
120 -
122 •
124 •
128 •
PROCESSES
• Antimony
• Beryllium
• Chromium
• Copper
• Lead
• Nickel
• Zinc
 SUBCATEGORY:  IRON & STEEL

 PROCESS:  DUST COLLECTION

  003  - Acrylonitrile
 004  - Benzene
 055  - Naphthalene
 061  - N-nitrosodimethylamine
 062  - N-nitrosodiphenylamine
 063  - N-nitrosodi-n-propylamine
 065  - Phenol
 086  - Toluene
  119  - Chromium
 120  - Copper
 121  - Cyanide
 122  - Lead
 124  - Nickel
 125  - Selenium
 128  - Zinc
SUBCATEGORY:   IRON  &  STEEL

PROCESS:   MELTING

004 - Benzene
055 - Naphthalene
061 - n-nitrosodimethylamine
062 - N-nitrosodiphenylamine
063   N-nitrosodi-n-propylamine
065   Phenol
•086   Toluene
118   Cadmium
119   Chromium
120 - Copper
122 - Lead
124 - Nickel
125 - Selenium
128 - Zinc
        SUBCATEGORY:   IRON « STEEL CASTING

        PROCESS:  SLAG QUENCHING

        055 - Naphthalene
        061 - N-nitrosodimethylamine
        062 - N-nitrosodiphenylamine
        063 - N-nitrosodi-n-propylamine
        065 - Phenol
        086 - Toluene
        118 - Cadmium
        119 - Chromium
        120 - Copper
        122 - Lead
        124 - Nickel
        125 - Selenium
        128 - Zinc
  SUBCATEGORY:   IRON I STEEL

  PROCESS:  SAND WASHING

  003   Acrylonitrile
  004   Benzene
  055   Naphthalene
  061   N-nitrosodimethylamine
  062   N-nitrosodiphenylamine
  063 - N-nitrosodi-n-propylam1n
  065 - Phenol
  086 - Toluene
  119 - Chromium
  120 - Copper
  121 . Cyanide
  122 - Lead
  124 - Nickel
  125 - Selenium
  128 * Zinc
SUBCATEGORY:  MAGNESIUM  CASTING   SUBCATEGORY:  ZINC  CASTING
 ALL PROCESSES
 065 - Phenol
ALL PROCESSES
004
006
044
061
062
063
065
086
124
128 - Zinc
Benzene
Carbon tetrachloride  (tetrachloromethane
Methylene chlorice  (dichloromethane)
N-nitrosodimehtylamine
N-nitrosodiphenyl amine
N-nitrosodi-n-propylamine
Phenol
Toluene
Nickel
                                                        165

-------
                                                                  TABLE  V-24

                                                          Types and Amounts of Binders
                                                               Used In Foundries
                                                                   Pounds per Year
                   Binder
                         Aluminum  Copper
                      Iron
  Steel    Magnesium Z1nc
Total
en
01
Linseed Oil
Alkyd Oil
Urea Formaldehyde
Furan:  No Bake
Furan:  Hot Bake
Oil Urethane
Furnace Bake
Sulfonlc Acids
Phenolic Urethane
Cold Box
Cold Box Isocynates
Silicate
Collolded Silica
Hot Box
No Bake
co2 Process
Air Setting Process
           40.447   10.504,383
 28.800     7,160    3.942,725
555.000   164.236   22,183.186
           48.285    3,614,239
            7.631    1,907,936
                       580.308

                       737,617
  2,132   162,415   18.209,723

  1,243         -    4,752,151
493.284     4.662      575.749
521,700         -       21.700
 75.480   173.915   79.006.515
           15.318    5.238.642
668.775    44.400    1.471.304
  872.015        -      - 21.416.845 11.5
  676.145        -      -  4.654,830  2.5
  426.406        -      - 23.328.828 12.5
1.277,424        -      -  4.939.948  2.7
4,262,400        -      -  6,177,967  3.3
                             580,308  0.3

   72,150        -      -    739.767  0.4
5.350.200        -      - 23.724.470 12.8

                        -  4.753.394  2.6
  921.780        -      -  1.995.475  1.1
   75,036        -      -    618.436  0.3
  567,594        -      - 79,823.504 42.9
3.120,183   17,100  3.330  8,424.543  4.5
2.649,667   16,000      -  4.850.146  2.6
                  Total
                                                                                                   86.029,470  99.9

-------
                                        TABLE V-25

                        Annual Weight of Metal Poured  in Plants
                               With A Process Wastewater
                                 Million Tons Per Year
                               Total
                             Weight of
                             Metal Poured
            Weight of
            Metal Poured
            In Plants With
            Direct Discharge
              Weight of
              Metal  Poured
              In Plants Dis-
               Weight of
               Metal Poured
               In Plants With
              charging to POTW's  100% Recycle
O)
         Aluminum Casting
1.781
0.891
0.700
0.190
         Copper and Copper
           Alloy Casting        5.431
                  2.548
                   2.666
                  0.217
         Iron & Steel Casting  33.002
                 15.474
                   8.372
                  9.156
         Magnesium Casting      0.0008
                  0.00075
                                     0.00005
         Zinc Casting
0.381
0.063
0.172
0.146

-------
                                       TABLE V-26

                             Total  Process  Wastewater  Flow
                                Mil 1 ion Gal Ions  Per  Year

                                                 Flow  Discharged         Flow         Flow  At
                             Applied    Recycle     To Navigable        Discharged       100%
                              Fl ow       Flow         Waters	      to  POTW s       Recycle
oo
         Aluminum Casting      3,826     1,993
         Copper and Copper
           Al1oy Casting
                       1,499
  9,233    6,685       2,535
  334
   12.7
   108
   883
         Iron & Steel
           Casting
105,031   83,667      18,291
3,073
50,120
         Magnesium Casting      2.16
                           2.16
         Zinc Casting
  1,067      906       1,334
   26.5
   267

-------
CTl
10
Aluminum Casting



Copper and Copper

  Alloy Casting



Iron & Steel Casting



Magnesium Casting



Zinc Casting



TOTAL
                                       TABLE V-27



                                Discharge Mode Profile



                                 Direct         Discharge      100%

                                 Discharge      to POTWs      Recycle   TOTAL
                                     76
                                     35
                                    381
                                     12
108
 24
325
                                    511
                                                   59
516
 21      205
 35
94
690     1396
                         13
                36      102
783     1800

-------
                                                         TABLE V-28

                                               FREQUENCY DISTRIBUTION OF TOXIC
                                POLLUTANTS DETECTED IN 44 FOUNDRY RAW PROCESS WASTEWATER STREAMS
     POLLUTANT

001   Acenaphthene
002   Acroleln
003   Acrylonitrile
004   Benzene
005   Benzidlne
006   Carbon tetrachloride
       (tetrachloromethane)
007   Chlorobenzene
008   1,2,4-trlchlorobenzene
009   Hexachlorobenzene
010   1,2-dichloroethane
Oil   1,1,1-trlchlorethane
012   Hexachloroethane
013   1,1-dichloroethane
014   1,1,2-trichloroethane
015   1,1,2,2-tetrachloroethane
016   Chloroethane
017   Bis (chloromethyl) ether
018   B1s (2-chloroethyl) ether
019   2-chloroethyl vinyl ether
       (mixed)
020   2-chloronaphthalene
021   2,4,6-trichlorophenol
022   Parachlorometa cresol
023   Chloroform (trichloro-
       me thane)
024   2-chlorophenol
025   1,2-dichlorobenzene
026   1,3-dichlorobenzene
027   1,4-dichlorobenzene
028   3,3-dichlorobenzidine
029   1,1-dichloroethylene
030   1,2-trans-dichloroethylene
031   2,4-dichlorophenol
Concentration  Concentration
 <0.01 rng/1  >0.01 mg/1
    13
     0
     0
    20
     1

    15
     3
     1
     2
     4
     9
     1
     1
     3
     1
     0
     0
     2

     0
     0
    14
    13

    10
     9
     1
     1
     1
     0
     0
     2
    14
 7
 0
 0
 5
 1

 5
 1
 2
 0
 1
 7
 0
 0
 1
 1
 0
 0
 0

 0
 0
11
 9

 8
 6
 0
 0
 0
 0
 0
 2
 9
 Concentration
^ 0.1  mg/1

    0
    0
    0
    1
    1

    1
    1
    1
    0
    1
    3
    0
    0
    0
    0
    0
    0
    0

    0
    0
    6
    4

    3
    2
    0
    0
    0
    0
    0
    0
    5
                                    Concentration  Concentration
                                   ^fl.Q mg/1      ^H.O mg/1
0
0
0
0
0

0
0
1
0
0
1
0
0
0
0
0
0
0

0
0
1
0

0
0
0
0
0
0
0
0
3
0
0
0
0
0

0
0
0
0
0
1
0
0
0
0
0
0
0

0
0
0
0

0
0
0
0
0
0
0
0
0

-------
                                                    TABLE V-28  (Cont'd.)

                                               FREQUENCY DISTRIBUTION OF TOXIC
                               POLLUTANTS DETECTED IN  44 FOUNDTY RAW PROCESS WASTEWATER STREAMS
     POLLUTANT

032   1,2-dtchloropropane
033   1,2-dlchloropropylene
       (1,3-dlchloropropene)
034   2,4-d1metnylphenol
035   2,4-d1n1trotoluene
036   2,6-d1n1trotoluene
037   l,2-d1phenylhydraz1ne
038   Ethylbenzene
039   Fluoranthene
040   4-chlorophenyl phenyl ether
041   4-bromophenyl phenyl ether
042   61s(2-ch1oro1sopropy1) ether
043   B1s(2-chloroethoxy) methane
044   Methylene chloride
       (dlchloromethane)
045   Methyl chloride
       (dlchloromethane)
046   Methyl bromide
       (bronomethane)
047   Bromoform (trlbromo-
       •ethane)
048   Olchlorobromomethane
049   Trlchlorofluoromethane
050   Dlchlorodlfluoromethane
051   Chiorodibronomethane
052   Hexachlorobutadi ene
053   HexachToromyclopenta-
       dlene
054   Isophorone
055   Naphthalene
056   Nitrobenzene
057   2-nltrophenol
058   4-nltrophenol
059   2,4-dlnltrophenol
Concentration  Concentration
 <0.01 mg/1  >0.01 mg/1
     0
    21
     4
     6
     2
     8
    20
     0
     0
     0
     2

    13
     0
     1
     6
     0
     0
     1
     0

     1
     2
    15
     4
    11
     6
    11
 0
16
 2
 2
 0
 3
 8
 0
 0
 0
 1

 8
 0
                Concentration
               >0.1  mg/1
                   0
                   0
                   0
                   0
                   0
                   0

                   0
                   0
                   2
                   0
                   1
                   1
                   2
 Concentration
>1.0 mg/1
0
2
0
0
0
0
0
0
0
0
0

1
0
0
0
0
0
0
0

0
0
1
0
0
1
0
            Concentration
                 mg/1
                   0
                   0
                   0
                   0
                   0
                   0
                   0
                   0
                   0
                   0
                   0

                   0
                   0
                   0
                   0
                   0
                   0
                   0
                   0

                   0
                   0
                   0
                   0
                   0
                   0
                   0

-------
                                                     TABLE  V-28  (Cont'd.)

                                               FREQUENCY DISTRIBUTION OF TOXIC

                                POLLUTANTS DETECTED IN 44 FOUNDRY RAW PROCESS WASTEMATER STREAMS
                                       Concentration  Concentration     Concentration       Concentration  Concentration
     POLLUTANT                          <0.01 rng/1  ^.Q.Ol mg/1       > o.l mg/1         ^.1.0 rng/1    >10.0 mg/1

060   4,6-dinltro-o-cresol                 11            6                 0                   0              0
061   N-n1trosod1methylamine                00                 0                   00
062   N-nitrosodiphenylamine                53                 1                   10
063   N-nltrosodi-n-propylamine             32                 1                   00
064   Pentachlorophenol                    13            7                 3                   1              0
065   Phenol                               20           17                10                   63
066   B1s(2-ethylhexyl)phthalate           23           20                10                   51
067   Butyl benzyl phthalate               18           12                 3                   00
068   D1-N-Butyl Phthalate                 23           12                 3                   11
069   01-n-octyl phthalate                  93                 4                   10
070   Dlethyl Phthalate                    17            9                 2                   00
071   Dimethyl phthalate                   12            8                 2                   10
072   1,2-benzanthracene
       (benzo(a)anthracene)                 96                 2                   22
073   Benzo(a)pyrene (3,4-benzo-
       pyrene)                              83                 0                   00
074   3,4-Benzofluoranthene
       (benzo(b)fluoranthene)               42                 0                   00
075   11,12-benzofluoranthene
       (benzo(b)fluoranthene)               30                 0                   00
076   Chrysene                             11            7                 3                   2              2
077   Acenaphthylene                       14            6                 0                   00
078   Anthracene                           15            8                 3                   00
079   1,12-benzoperylene
       (benzo(ghi)perylene)                 00                 0                   00
080   Fluorene                             17            9                 3                   00
081   Phenanthrene                         16            9                 3                   00
082   1,2,5,6-dibenzanthracene
       (dibenzo(,h)anthracene)              00                 0                   00
083   Indeno(l,2,3-cd) pyrene
       (2,3-o-pheynylene pyrene)            11                 0                   00
084   Pyrene                               22            8                 2                   10
085   Tetrachloroethylene                   98                 4                   00
086   Toluene                              15            5                 1                   00

-------
                      TABLE V-28 (Cont'd.)

               FREQUENCY DISTRIBUTION OF TOXIC
POLLUTANTS DETECTED IN 4* FOUNDRY RAW PROCESS HASTEHATER STREAMS
     POLLUTANT

087   THchloroethylene
088   Vinyl chloride (chloroethylene)
089   Aldrln
090   Dleldrln
091   Chlordane (technical mixture
       and metabolites)
092   4,4-DDT
093   4,4-DDE (p.p-DDX)
094   4,4-DDD (p,p-TDE)
095   Alpha-endosulfan
096   Beta-endosulfan
097   Endosulfan sulfate
098   Endrln
099   Endrln aldehyde
100   Heptachlor
101   Heptachlor epoxlde
       ( BHC-hexachl orocyc 1 o-
        hexane)
103   Alpha-BHC
103   Beta-BHC
104   Ganma-BHC (llndane)
105   Delta-BHC (PCB-poly-
       chlorinated blphenyls)
106   PCB-1242 (Arochlor 1242)
107   PCB-1254 (Arochlor 1254)
108   PCB-1221 {Arochlor 1221)
109   PCB-1232 (Arochlor 1232)
110   PCB-1248 (Arochlor 1248)
111   PCB-1260 (Arochlor 1260)
112   PCB-1016 (Arochlor 1016)
113   Toxaphene
114   Antimony
115   Arsenic
116   Asbestos
Concentration  Concentration
 <0.01 mg/1   S?0.01 mg/1
13
 0
 7
13

 7
15
14
 7
 9
 6
 6
 6
13
 7
 5
 8
 7
15

 7
16
16
16
17
17
17
17
 1
 7
 6
              0
              1
              2
              1

              5
              8
              8
              8
             10
             10
             10
             10
              0
              5
              3
Concentration
  0.1 mg/1

   2
   0
   0
   0

   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0

   0
   4
   4
   4
   4
   4
   4
   4
   0
   3
   2
                                                            Concentration  Concentration
                                                           ^1.0 mg/1    ^10.0 mg/1
                                                        0
                                                        0
                                                        0
                                                        0

                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0

                                                        0
                                                        2
                                                        2
                                                        2
                                                        0
                                                        0
                                                        0
                                                        0
                                                        0
                                                        2
                                                        2
                                                                              0
                                                                              0
                                                                              0
                                                                              0

                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0

                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0
                                                                              0

-------
                                                     TABLE  V-Z8  (Conf d.)

                                               FREQUENCY DISTRIBUTION OF TOXIC
                               POLLUTANTS  DETECTED IN 44 FOUNDRY RAH PROCESS WASTEWATER  STREAMS
                                       Concentration  Concentration      Concentration        Concentration   Concentration
     POLLUTANT                          <0.01 mg/1   >0.01 rng/1        ^0.1  mg/1         >1.0 mg/1    ^10.8 tng/1

117   Beryllium                            10            1                 0                   00
118   Cadmium                               75                 5                   10
119   Chromium                             14            8                 4                   20
120   Copper                               23           21                16                   52
121   Cyanide, Total                       24           11                 1                   0              0
122   Lead                                 28           22                16                  10              7
123   Mercury                              23            0                 0                   00
124   Nickel                               21           16                 7                   00
125   Selenium                              63                 2                   10
126   Silver                                31                 0                   00
127   Thallium                              21                 1                   10
126   Silver                                00                 0                   00
128   Zinc                                 30           28                26                  21             12
129   2,3,7,8-tetrachloro-
       dibenzo-p-diox1n (TCDD)              00                 0                   00

-------
                                                             TABLE V-29


                                       PRIORITY FObUITANTS IN AUMINUN POUMWT 1NVKSTMNT CA8TIHB OPEMTIfHIS
                                                	  IAI.I, euwKHrwTiotis IN
                                                                                            Page 1
01
POLLUTANT PARAMETER

1. •cen.phlhene
2. •croleln
3. Hcrflonltrtl*
' • Dcvtxdtc
5. Itencidln*
6 . Carbon Tetrachlorlde
7 . Oil orobenzene


9. Iteiacblnrobenxene
10. 1,2-Dlchloroettuine
11. l.I.I-Trlchloroetham
12. HeiaehtoroeUiiiim
1). 1.1-OlchlaroethMie
1*. 1.1.2-Trlcblaraethnim
19. l.l.2.?OT>i
IB. blB-(?-chlor
-------
                              TABLE  V-29
                                                                                    Paqe 2
PRIORITY POI.UITAtrrS  IN AUIMINUN FOUNDRY INVESTMENT CASTING OPERATIONS
                     (ALL OUtK.-RHTKATIOUS IM Mli/U
R POLLUTANT PARAMETER

JS* _2r0»loro«l»rll flnjl Eltwr
20. 2-Chlorofuphthalena
21. 2.4,6-Trlclilorophenol
22. Parach 1 or«iet aci*€ao 1
2J. Oilorofoni
2<. 2-Chlnm|4ienol
25. l,2-Dlc!iloroli«nrefi«
24. 1, J.-Dldilorotwnzwie
27. l,V-l>lrhloi'Oli«nzen«
28. J,3-nichtnrobenzldene
29. 1,1-blchlnroethrlene
30. l,?-Tran.im
47(
R.>w












»


O.HO5


4
Tic.il f*l



•
O.02O










»



RAW



















Treated



















RAW



















Trented



















t>M



















Treat nt



















Raw



















Tteatod



















Rim



















Treat e
-------
                             TABLE V-29
                                                                                  pan* 1.
MUOHITY POI.IJHTAWrS IN MUMIHUN rOUHDKV INVESTMENT CASTING OPERATIONS
                     (ALL (XWL-KHTHATIOHS IN MH/I.I        	
POLLUTANT PARAHETER
37. 1 ,3-Dlphenylhya'raEfine
18. eUivlbenteim
j». n.^ru.Lh**.
§l«_^-Proiaophcnii Flicnr! JEthei

elher
*J. bls-(2»otiloroetlN»r/)aethi
M. NehtfleiM Chloride
45. Nethfl Chloride
W. Nethfl Brodldo
•T. BrOKfoni


M. Trlchlorofluoroawthane
58 _ DlrhlnrodirinnroMethiiw
51. ChlorodlbroiKMet.ha.ne
V.. HeiaohlorobnUdlow
5J. Heiachloro
-------
                                                                                TABLE  V-29
                                                                                                                                     Page  4
                                                   PRIORITY  POLLUTANTS IN AUININUN POUNDRT INVESTMENT CASTING OPERATIONS
                                                                        (AM. (VNCEHTflATinNR IN H:/l.)
--J
oo
A. POLLUTANT PARAMETER'

5».J.«r*o™«
•K. B.phlh.1^.
96. Nltrahmum*
ST. 2-NltroDhenol
58. 4-Hltroohetiol

60. 4l6-Dtnltry-o.9reM|
61. M-nltroaodla»thrUa)lne
62. H-nltroaotHrhenrlaitlnfl
63. N-nitro90ti
64. FentachloroflieiKil
65. Phenol
66, t>ls-(2-elbrll«ri DphUia
67. Butrl.Benzjrl PbLhaiata_

69. Pl-a-ootTl Tbthalata
JO. Dlethrl ftiltalate
71. Pl.etbrl fhlbaUta „ .

RAW



•


.


e
•

at
.
0.006
0.004
.


Treated

A








'

O.012
.
.


O.blJ

Raw



















Treated



















Maw



















Treated



















Raw



















Treated



















Raw



















Treated



















Raw



















•heated


















Nil. of
Mtore,
Raw



1






1


I
1
1
1

rlmi«A
Foimd
Tieatetl

1








1

1
1
1


1

-------
                                                                                TABLE  V-29
                                                                                                                                    Page 5
                                                  PRIORITY roi.l*rtKN"S IN AUMItKM rOUMURV INVESTMENT CASTING OPP.RMTIONS
                                                                       (KM. i-owem-HATiims IN H:/I.)
10
% POLLUTANT PARAMETER

_72._ Benzn(a)aallwiemw
TJ. Hnrn (p) pjnwiui
_Il._J»A-JlaitoriiMiranLliena.
.J5_. Jhozo(k)tliMKiDUieoe
. 76. Chrraene
77. Ncenanhthrlena
7B._Anthr«cen«
_T9- Denzo(a.H.I)rerylen&_
BO. Fluorena
81. rhenMthreiw
82. Dlbfflto(a.h)*nthriccne
83. lnd«H>(lt2,3.cd)j>rren«
8*. Pfrene
85. Tetrndiloroetlijrlene
86. Toluene
87. Trlchloruethylene
88. flnyl Chloride
89. Aldrln
470
K>iw





0.002
< •

<•
<•


0.024
0.010
•
0.116'J


\
tro.il 
-------
                                                                                    TABLE  V-29
                                                                                                                                        Page 6
                                                     PRIORITY POLUJTMfTS  IH M/M1NUN FOUNORT INVESTMENT CMTING OPERATIONS
                                                                          (M.I. Cut*'RNTRAT IONS IN MI/1.)
00
o
ft POLLUTANT PARAMETER

90. Dleldrln

92. t.f-UDT

9». i.«'-DDn(P.I"-TDEJ
95. 2-Grak>suiran-Mpha
96. b-Cndosul fan-Beta
97. Endos.il fa.. Sulfate
98. Eiidrln
99. Emir In Aldehyde
100. Ifeptachlnr
101. Heptavhlor Epoxtde
102. a-MrC-alpha
103. b-NIC-beti
10*. r-n«KMLInd»ne>0«i.a
105. g-IKIC-OelU
106. Pcn-l*2< 1
10T. PCB-125* I
108. PCB-1221 J
470

"




..

••






••


O.OOJ

4


..
t •
..


••



..
..

• •
••


* *












































Rax



'
















Tteated




















Haw




















Treated




















Rax




















Treated




















Rax













^






Treateil



















M>. of
R.ix
1




1








1


1

Plant*
F
-------
                                                                                    TABLE  V-29
                                                       PRIORITY POUJUT
                                                                          IN MMNIMIM rOIMIRV INVESTMENT CASTING OPKHAT IfJNS
                                                                           (KM. ClrlllTirMlATICIIM  IN H:/|.|
O5
POLLUTANT PARAMETER


J0», fCB-l?J2 1
no. rcn-izw |
III. KB-1260 1
112. fCB-1016 J
111. To««|4ien«
l?9. 2,1.7,8-TetradilafO'
dllmizo-r-dloiln (TCM»
IJO. Irlnie









471
Max


B.UIO















14
Tii-aled


• •





• •










HAM



















Tienl.nl



















Mm



















Trailed



















NM



















Trrflted


















^
Haw



















Trcateil



















H*w



















Treat eil


















Mt. nl
MM-K
*M


1















I'laiiln
1 rnml
TlRftlnil


1





1




-





-------
                                                                                   TABLE  V-29


                                               IMOKT.ANIC  PRIORITY POLLUTANTS IN AUIHINIIH FOUNDRY INVESTMENT CASTING WASTEHATBRS



                                                               	(ALL COHCENTRlmONS 1M HC/LJ	
oo
ro
POLLUTANT PARAMETER .
Aabustoa
UiruMiiM
Copper
Cyanide (Total )
Lead
Mercury
Nickel
Seleiliun
Zitic
i

1




4704
Nnv

O.020
0.4S
-(0)
O.OS
O.OOU2
O.OU5
0
0.49









0.030
0.083
0.007
*
•
•
«
0.1





.











































































































Maw
















Treated

















DM
















Treateil

















RAW


	












Treat*



	
	









-------
                                                                                     TABLE  V-29
                                                                                                                                           Page' I
                                                         PRIORITY POLLUTANTS M.IJHIMUH FOUNDRIES - WKLTING FlIRNIVTE SCfHinBRRS
                                                                            (M.I. Cdwr.irntnriiins in M:/I.)
oo
CO
POLLUTANT PARAMETER
1 • KcCIMpnlhOffW
2. Rcrololn
3. Herylonllrlle
4. Benzene
5. B*ntitlMin
1). 1. 1-Ulcti lor cw than*
1*. l.l,?-Trl«-hloro«ttiaiw
15. l,l,?.20Tetr«chloroetlwi
16. ChllM.hri
18. li|s-(?-chlri»-rM?thfl). nf Planfn
Miorff FoiifMt
Raw



2

1










	
Treated
2


2

1










	

-------
                                                                                     TABLE  V-29
                                                                                                                                            Paqe  2
                                                         PRIORITY POIAJUTANTS KUIMtNUH rOUNDRIR - MPLTIHG FURH/VCE SCRUBBERS
                                                                             (ALL nitKt.1fTRATfCltlS IN MI/I.)
00
POLLUTANT PARAMETER

JJ. _2-Chlorocthrl flnyl Ether
20. 2-Chloronaplittialene
21. 2.4.6-Trlchlorophenol
22. PsrachlcM-aetacresol
23. Chlororom
24. 2-Chloroplienol
29. 1,2-Dldilorobcnzene
26. 1,3,-Dlchlorobenzene
?T. 1,^-Dlcliloi-obanr.ene
28. 3,3-Dlehlnrobenzldcne
29. l.l-0lchlm-o*th|r)efi«
3O. 1.2-Tmnndlnhlnroethylmw
31. 2,«-Dlrhlnroptx>nol
32. 1 ,?-Oldilot orropnne
3J. l,2-0lnliloroprnp)rlene
31. 2,<-DlMlhrl H^nol
35. 2,<-Dlnltrotolu«im
36. 2,6-DlnllrololuciM
171
RAW


0.039


•






0.022


0.011


)89
Tt *?a( oil


O.O52

0.12
•






0.012


O.O06


18
n*»w


0.014
*








*


•


'39
Tieateil


O.OO6

O.O16







*


«



Row



















Trent ert



















DM

















































































































.




(*>. of
Wit1 re
Raw


2
1

1






2


2


rlmitn
FOIHH!
Trcrt(t'«)


2


1






2


2



-------
                                                                                     TABLE  V-29
                                                                                                                                          Pmge  J
                                                        PRIORITY POMMTMITS MJUMINUH miNORICS - MRWIMB FlIRNHCr SCRUBBERS

                                                                           I M.I. CclHCBKrilATIOMS IN Mi/1,)
oo
tn
POLLUTANT PARAMETER
37. l,?-Ulphwif IhTdrazene
_J«._etbil benzene
._ 39- _ f 1 uoraoltwmr
_ to. JrCbloroubenrl -HwnTLEUK
91. *-Qr(NM>fil>ctijrl fhanjl Ethci
»?_. b!a-(?-pilorot9gpr9p»U
ether
43. bla-(2~chloroethoi{)*ethi
M. IMitflene Chloride
*5. Hethrl Chlorlita
V>. Hi- thy 1 Brmlde
<7 . BroMarani
48. DlehlorohrmMMethnne
49. TrlchlornriiKH-CNKltane
50. DIchlarodiriiiariMWtlwiw
91. Clilorodlbfo«i>«»eth>in0
5?. He««chlorobuUdlene
53- llv inch Inrncycl open l«dlen«
17089
HAW


r



ne










TiMled








0.019



O.Ull





18139
RUM


•












•


Treated


•





*



•


•



Raw


















Treated



















Raw


















Treated



















Raw


















Treated



















Raw


















Tieated


















Nu. of Planta
Mhote Punnd
Raw


1












1


Tiealerf


1





2



1


1



-------
                                                                                            TABLE  V-29



                                                             rRKWlTT  I'OI.IJITANTS AMJMlMIM rOUNTIRlKS - HKI.TING PINNACE  STKIIUHKK9

                                                                                  •M.I. miK-KirritATimif: IM K;/I.|
Page
co
CTi
POLLUTANT PARAMETER

1» 1 4VH-..
Vi tophi !•*!»««

57. ?-NUroulienol
58, 1-BHi i/i. Itwnol
.66. bi0-<2-«lbyllicirl)phUu
_ .*7, Plltyl Uciizjl Fbtlialata
*?! filTl-0
0.41

O.O2O

•

181


•




•




0.011
II. 20
4
.
•
11.014
•
39


.




•




O.OOl
0.21
.
*

11.1124
•
































































































































































' •*.. of
Mli»j r a
Hnw

1

1

1
2



1


1
2
2
1
1
I'laiiti
FOMII'I
Ti cat p.l

1

1

1
2



1
2
2 -
1
2

2
1

-------
                                                                                  TABLE V-29
                                                      FRIOR1TY POLLUTANTS M.UHIWIH FOUNDRIES - MPI.T1HU FURNACE SCKIIDHERS

                                                                          (AM. COMI-EIITRATIOHS IN r»!/l.»
00
—I
POLLUTANT PARAMETER -

.72. BenznU)anthraccna. 	
_73~- Benzn. (a)-pyrene
-Jl. J.*-Bentorioocaiithn»__
J5» ..Dnuo(k)tliKir*DltKD« 	
|6. Oirvaetw
77 1 Mcrvwplilhr lene
7*. «nthr»cene
JS-. 0onzo(Q.n. I )r«rrlcoe
•0. riuoreiM
Si. Plienanthreiw
8?. Dlbenxo(*,h)llnthr»cen«
83. ImteiraU^J-ctltarreiM
8*. Prr«ne
K. Tatrachloroelhf lene
86. Toluene
87. Trlchloroetnrlom
88. Vlnrl Chlnrlde
89. «l
-------
                                                                                TABLE  V-29
                                                       PRIORITY POLLUTANTS  ALUMINUM rOMNDRIKS - MKLTIWR FtlRNACF SCRUBBKRS

                                                                         (ALL ttmCKMTRATKINfl IN MC/I.)
                                                                                                                                      Page  6
oo
oo
POLLUTANT PARAMETER

40. nirl.h-ln
Ql. Phlrwreton^
92. *,«<-UOT
91. ^.V-DOEir.P'-TDE)
s^.M'-MHKW-TDE)
f>. 2-Kndo3uir«n-»lplia
96. b-biJosuiran-Beta
9T. Endonulfan Stilfale
98. Endrln
99. Bndrin MdrliMe
100. Heptaclilor
101. Hvptachlor Epoxld<>
102. a-MIC-DliilM
10). b-B1IC-b«t«
10%. r-DIIC-(l.ln,l»n
-------
                                                                                    TABLE V-29
                                                                                                                                                1
                                                        PRIORITY POLIJUTMfTii AUJHimm FOUNDRIES - MPI.TTNR rUMIACE SCRIIIHirRS

                                                                           (ALL CDNCRNTRATKIII3 IN HC/I.)
00
IO
POLLUTANT PARAMETER -


lOJ^-fCBTigJ? _ _. J.
110. KB-I2W 1
111. KB- 1260 t
112. fCB-1016 J
113- Toniiphnie
129. 2.1,7. S-Tetrachloro-
d!linito-r-dlo«ln (TCBO)
190. lylene









17C
MAM


0.011















189
Trnalcil


0.008















18
Rjw


• •















39
Treated



















Kaw



















Treated



















Paw



















Tifiited



















RAW



















Treated



















Raw



















Treated












v





M>. fit
Mmr«
Raw


2















r Pl.mlfi
I r.niiKl
Ticated


1
















-------
                                      TABLE  V-29

INORCMIIC PRIORITY Itll.MrTAHTS IN MJMINUH FOUNDRY HELTINR FURNACE SCRIWBER HASTKWATKR
                 	(M.L COHL-Btn-RBTIOMS IM MU/M	
POLLUTANT PARAMETER-

A9bento9
L> an lik.- (Tut.il)
Lam)
Mercury
Nl.kol
SelRfiliB
Klnc



•





170
Maw

0.002
O
O
O
O
0.09









89
Treated

O.IK) 2
•
O.OOOJ
•
•
0.056









18
Maw

<>.OI«
O
O.OO09

0
O.I









39
Treated

0.1114
ft
O.OOO9
•
o. 01 >on
O.OfeS










Raw

















Treated

















Haw

















Troateil

















Raw

















Treotnl

















Rnw













^



Ttealeit

















R.w

















TienliH













-



-------
TABLE  V-29  '
                                                                                  Page 1
PRIORITY POI.UITAN1S ALUMINUM KXINPKIES   CUSTINT! QUENCH OPERATIONS
                   (AM. (.ONI KNTHATHINS IN Hi/I.)
POLLUTANT PARAMETER
1 . acenaphlhene
2. ftcroleln
9. Hrrrlonltrlle
t. Benzene
5. Bpnziillmi
6. Carbon Tetranhlorlite
7. Oilorobenzaw
8. 1,2,4-TrlchlM'olwnzetw
9. He»rlilnrobenzene
10. 1 ,2-Dlchlnrmthane
II. 1,1,1-TrlchloroeilMira
12. HeiachloroellMfM
13. I.l-Dlchloroethmw
It. 1,1,2-Trlrhloroethane
15. l.lfZ.roTvtrAchloroflthaf
16. Chlnrnellnm*
17. Mfl-(diluro •Bth»l)»lt.pi
18. li|a-(2-nliloro<>Ui|rl)etlH>i
10308}
Rnw



0.030

•



•




n 0.018



Treated



O.HS














17089
R.iw



•














Ttonled



A






*







18139
Maw



0.014

•












Tt eat oil



*















DM


















Trrateil


















»
Raw


















Tteatrd



















Raw


















Treated














•



tkv. of rimilfl
Hlicte FrmiHl
M.iw



3

2



1




I



Treated



J


i


1








-------
                                                                                         TABLE  V-29
Paqo 2
                                                                  PRIOMTt POI.LUTMITS MJJMINIM POUNUOIKS CUSTIN*; OIIRNCII OPKRM'I'IMS
                                                                                (M.I.  oil* KtrrHATKitin IH w:/i.)
ro
POLLUTANT PARAMETER

J9. 2-thloroelhfl »injl Ether
20^ j-C*)toruna>>hlh«lene
21. 2,^,6-Trlchloroplicnol
22, tarachlooetacreaol
23- CtiloroforB)
2». 2-Uiloro|4icnol
25. l,2-blch)oroUenr.me
26. 1, J,-l>lrtiIorolx-nzen«
27. 1,4-DlchlofotMnzene
28. 3,3-DlclilorohCTlll«ne
30. 1,2-Trwi.iillchloroolliylene
31. 2.«-l>IHiloroph*nol
32. l,2-Dli:hlwo|>i'o|)an«
33. 1 ,2-tllrtiloropi opyletK-
3*. 2,4-DlMlhyl Fttrnol
35. 2,«-l>lnltrotolii«n«
3*. 2,ft-Dlnltrotol«pn«
103
R


U.JOO

0.017













08





1.4













17(



0.3B
0.032
0.10
0.053






0.72


O.OV1


)89



O.30

0.42
*






o.oie


O.O7S


181



0.2OO
0.283











O.O60


39



O.087

0.012










O.OO2










































'















































































1*1. Of
MtM-t*
R.iw


1
2

1






1


2


rl mil *t
t'fHMid
Tl<-illr-il


2

3
1






1
_

2



-------
                                                                   TABLE  V-29
                                               I.RIOR.TT
10
CO
ft. POLLUTANT PARAMETER

HI. 1.2-Dlphenylhydrar.ww
JB. Etlurlbentene

_JJU_|-ailoroBljeii»l_rbeiul..EUi'
91. *rPniMoplienil rtnail Ethci

ether
*}. bla-(2-chloroetlMMr)MtlK
M. Hehlylene Chloride
«9. HP thy 1 Chloride
•6. Methyl Brimtde
*7. Hfflanfora)
*B. DldilorobroiHMethiiM
«9. TrlchlororiuoroMthane
y) _ Dlchlorodiriuoroawthane
51. ChlorodllmMuaKthnne
92. llexachlorobiitcdlene
53- lleiaohlorucirclofimladleiia
103C
K.m

O.078
*
r



ne
U.I1I7


•
•





)8
Treat «l








9.6









1701
Haw

*
O.U02









'1.002





39
Treated


.





0.061



0.011





18139
Ran


0.209
















Tinated


0.48





0.007










Raw



















Treated



















Raw



















Treated



















Raw



















Treated














*



ft>». nl
Hltorc
Raw

2
1








1
2





l-lmla
rcHMMl
Tieaterf


2





J



1






-------
                             TABLE  V-29
PRIORITY I'OLIJrrHNT.S AUIMINUH  fOONORIES CASTING 0IIEHCPI OPERATIONS
                   (M.I, COWEIfNUM'IIWS IH H./l.t
POLLUTANT PARAMTTro

*A - iMflhni-fin^
55. Naphtha 1 Mia
56. HILrnlMiMtKf
57. Z-NltruDheoul
.Sai.^-lfJtroHienol.
59..*.6-Pln>Vr«mi«irol
. .M-.?.6-Plnllrfc9-Qr«wl_
61. M-nllroaodlirclhTlaalne
6?. H-nltroaodlplmnTlulna
63. N-nltrosodl-N-propylaBli
6* . rmilarlilorophenol
65. Phenol
. 6>. bla-<2-etbyJlmxrljphLha
__ §7. 9utyl Denzil fhlliaJate
68, BI-H-Mulil Plilhalate
69. IU-n-.~,lTl FliLhalala .
70. Dlethjrl Phlhalate
. -71. Pl»eth»l Pbtbalale
103
H,!W



0.029





e


.ti051
O.OJ1
*


0.015
08
Trc.il oil












0.017

O.0035

O.O.M
J.2
17C
R/iw

0.011

O.O33


0.061




1.1
0.6»

0.12

O.091

)8g
Trcftlcd





•
O.O12




O.O57
2.2

0.01')



181
Rao





0.117
0.07O




O.049
6.70
0.049
O.OS6



59







«




O.OO4
0.71
0.029
0.25

•


















































































RAV



















Tlcaleil


















Iki. »r
W|H»r«9
Rnw

1

2


2




2
3
2
3


1
I- 1 n»« *
FO«IIM|
Tical »•«!





1
2




2
3
1
3

2
1

-------
                                                                                        TABLE  V-29
                                                            PRIORITY  POI.IJUTAHTS MJM1MIH fOtlNDRlES CHSTII*: QUF.NCII OPFRATKHIS
                                                                               (M.I. ltlWFtflHATI"NS IN Hi/1.)
                                                                                                                                                rag, 5
vo
en
POLLUTANT PARAMETER

-72.. BoiznCalantbracrae .
-33. Benza (•) pyr«M
-I9._3.4-BenzoUiimDthefKL__
+ 75. . Qenzolk ) CluacaoUieiw
76. Otrracfw .
IT. ftcetMDhthilena
JB. «nlhr»c«iie
.JS- PenzQ(Q.ll.l)rerrlcne
90. Fluoreno , ,
81. PhenonthreiM
82. Dlbcnzo(a,h)«nlhrKcme
fl]. lMl«io(lL2,3-cd)pjrrene
8». ryren*
85. Tatrachloroethflcne
86. Toluene
87. Trlehlorvelhjrlena
88. Vinyl Chloride
89. AlOrln
1030
Raw

•






•



•
0.121
•
O.O2II


8
Tl nnteil













1.0
•



170
Raw
<13



<13







•

•
•


89
Treated
•




0.024






•
O.OG1

*

*•
181
Raw





0.047






0.25B

*
•


39
Treat ert





•




' * ;

0.44
0.1J
•
•
-


Raw



















Ttpatcil


















'
Raw



















Treatril



















Rnw



















Treateil














-



Mi. ol
WlH>r«
Maw
1
1


1



2



]

3
3


Plant*
rnuml
Tinatnl
1




2






2

2
2

1

-------
                                                                                     TABLE  V-29
rage' e
                                                            PRIORITY roLLUTAHTS ALUMINUM FOUNDRIES CASTING QUENCH OPERATIONS
                                                                             (M.I. (DW tllTHAI IIXIS IN H:/|.)
CT>
POLLUTANT PARAMETER

90. Dl*litrln
91. fTM'wn'l^n*
42. *I«'.DDT
9V M'-WEir.r'-TDE)
9*. J.^'-MHMr.F'-TDE)
95. ?-Endosul fun-Alpha
96. b-Cndoauiran-BelH
97. Fjxfosuirim Sulfate
96. Fo.li- In
99. Kn.li In Alitehyle
100. llrplachlor
101. lleplachlor Epoilda
102. a-miC-«lplm
10). b-DIK:-li«la
lot. r-DHC-(LlndHne)GaiM
105. K-NIC-Dnlta
106. ITH-I»2« "I
107. TCB-i?5» 1
10B. PTB-1221 J
1030
PAW

*•
• •

• •
*•
• •
* *


• •

**
**



*•

9
Tl onl otl

• •


*•

• *
• •









* *

170
RAW


• *
O.O1O








• •

* *


1.4

89
Trf»*l«»«!

• •










• •

• •
* *

0.11

18139
Raw
• •

• •

• •



• *
• *

• •
«•

*•


*•


Trfat^il
• •













«*





Raw




















Treat e«l



















•
Raw




















Trcatcil




















Raw




















Treated














-




ito. «r
HlH-»<
R.iw
1
1
2
I
2
I
1
1
I
1
1
1
3
1
2


3

Hunt*
KfHIlnl
Tical<->l
I
1


1

I
1




1

?.
I

2


-------
                                                                                  TABLE  V-29
                                                                                                                                       Page 7
                                                      PHIOR1TT POLMrTMITS  MJUMINUH nXINnniKS CASTING pUENTH OPERATIONS
                                                                         (ALL Cot*'MnilAT IONS IN HI/I.)
^Q     	_ _T
POLLUTANT PARAMETER.

we. rcB-1221
109. PCB-1332 7
110. PCB-12M |
111. PCB-1260 \
112. K8-I016 J
113. Toxaphene
129. 2.J.7.a-Tetrachlnro-
dlhcnxo-f-dloxln (TCOO)
130. lyleiie




-•




10
M.iw


• •















308
Tioal nj


















170
Mow


0.8J















89
T[«atod


O.OBO















1813
Raw


• •





0.01S









9
Treated



















Paw



















Treated


















»
Raw



















Treali>il



















Raw



















Treated


















Mi. of
MlK-te
Raw


J





1









ri.nii*
FnufMl
TlKalol


1
















-------
                                                                                   TABLE  V-29
                                           INOKC-.AN1C PRIORITY POLLUTANTS  IN ALUMINUM ruUNDRY CASTING QUENCH OPKRATION WASTKHATERS
                                                              	(ALL COtH-BNTRBTlOtlS IN Htt/L)	
CO
POLLUTANT PARAMETER

ftcbevtoa
OiroKluB
CY.uilrte (Total)
Lead
H-Tcurf
Nickel
Selentim
Zinc

,

•




103
Rao



0.4

0.01
•
8.8








08
Treated

*
O.OO59
•
O.OOO2
0.12
•
0.96








1708
Raw


O.O04




0.64








9
Treated

•
O.OO4
»
U.OO02
»
*
0.64








1813
Raw


O.OOB

O.OOO1


0.28








9
Treated

•
O.OO79
•
O.OOOJ
•
O.O095
O.I6









Raw

















Treated
















	 • —
Raw

















Treated

















Raw

















Treated

















RAW

















TienKM













-



-------
                          TABLE V-29
                                                                               rage  1
PRIORITY
                   IH MIIN1WM rAUM>*T DIR CMTIW! OPRHATIONS
                  (M.I. awErn-RM-iiiiis IN
POLLUTANT PARAMETER

I. Heen.rt.then.
2. ftcrolelH
3. "crjrlonltrtl.
"• BMixcitQ
5. Bmzidlnn
6. Carbon Telrachlorlde
7 . Oil orotaf izene
9. I,2,t-Trlchlornbenzene
9. Noiachlorobenzene
10. 1,2-DlchloroetlMn.
II. I.l.l-Trlchloraethan.
1?. Heiarhloraethan.
13. 1.1-niHiloroelhane
1*. 1.1.7-TrlnlilaraellMiM
15. 1.1.2.20T>-traelilaroetlH»
16. nilaraethnm*
IT. Mn-Jrtiloro •eth-D-llM-i
in. h|a-<2-cMoroellirl>el.lie,
170f
Raw



.










e



19
Treated



.






.







120*
Haw
O.2II


.

.











o.ww
lO
Treated
.


.

.




O.OS1








Haw



















Treated



















Haw



















Troateil



















Haw



















Treated



















Raw



















Treated


















Ito. nl
«her«
•aw
1


2

1











1
Plant*
Found
Tro*l*.|
1


2

1




2








-------
                                                                                      TABLE  V-29
                                                                                                                                            rage 2
                                                          PRIOR ITT FOLI.UTAHTS IN AUmiMIM FOUNDRY  Die CASTING OPERATIONS

                                                                             (M.I. COtHT.HTRATIl'H1:  Ifl
ro
o
o
'POLLUTANT PARAMETER
J9i 2_-ailqroolhjl Ilnjrl rthor
20. 2-CMorooaphllialene
21. 2.*.6-Trlchloroprienol
22. Paradilorawtacreral
23. Clilorofo™
2*. 2-ChIoro|ili«iol
25. 1,2-IHchlorobvncene
it. l,3,-l>lolilorob*ni*rw
27. 1,4-Dlchlorobcnzene
2B. J,J-l>lrhlo.-ohonr.lden«
?9. 1,1-Dlchlomethrlene
JO. t,?-Tranan«
36. 2,6-ninltrotolunne
17089
Raw


O.J8
U.OJ2
0.1O
U.OS3






0.72


0.091


Tic.ltpil


O.JO

0.42
•






0.018


11.025


12040
fl.1V



0.11
0.004







*


0.041


TicAteil



O.OA2
O.OO7






•
•


•



Maw


















Treated











	






Pa*


















Trealeil


















*
Raw


















Treated



















Raw


















Treat *<\


















Nit. of Manif*
Micro Fomxl
Maw


1
2
2
1






2


2


Ttnal rfl


1
t
2
1





1
2
.

2



-------
                                                                                TABLE  V-29
                                                      PRIORITY POLUJTANTS IN AMMINUM rout»nr  Die CASTING OPERATIONS
                                                                       (AM. nwuKimvmoN!; IN ML:/I.(	
                                                                                                                                  Page' I
ro
o
POLLUTANT PARAMETER

37. 1 ,2-Dlphenf Ihydrarme
38. Blhrlhenzene
39. riuwaoLhene .
_4lk IrCbJorviilwafl-flKiuUEllii
91..*-Prgwwheafl-nienil Ether
W.-M*-(?TC|ilor«j9Vprpp»ll .
elher
43. bl3-(?-ehloroethoiy)Mth
M. HehtjleiM Chloride
»5. Nethrl Chloride
M. Hethfl DicMlde
»7. BroBorora
kH ••! • ».

»9. TrlchloruriiiorcMKlhmie


51. ChlnrodlbroMMthane
W. neiTClilorobuUdlene
5). Il
-------
                          TABLE V-29
I'HIOHITT POUirrhHTS IN MJMIWIN rOIINOHT OIK COSTING OfLHATHWS
                 IM.t. niucKUTHATiniis in MN/I.I

POLLUTANT PARAMETER

W- l***|4*ortm«



^ ^ outoeaol
59- *.*-PlnHroHwnol
60. 4.6-ninllro-o-creaol

62. •-filtroMMfli'tenrtiMliMi
6]. M-nltro90rl»1r
64. reiilachloroftftenol
6V llMfiol
66 bl»-<2 tb Ibni 11 ihtit*
67 > Putrl Dcuzjl riiUialat«
68, D|-H-0iiifl HilhalaLa
69 "l-a-j»:l il FlillMlala
70. DlelbjrL PhtlwJala
	 71. OjaclhrL ruibalata ...

17C
H.iw

0.011

0.1J


0.061


e

1.1
.O.6H

0.12

O.O*JI


)89
Tinatcil





.
0.012




0.057
2.2

n.ni'j




12
ll.w

0.16







O.OI4

0.016
5.5
0.64
0.074

0.7)
.

040
Trcnlrd

0.001









•
0.012
.
O.OO1

.



Kw












•







Tre«»«.l




















B«-




















TreAtcil




















Biw




















Tiratr.l




















Mm













.






T.Mlf.l



















Nil. "f
R.iw

2

1

1
1


1

2
2
1
2

2
1

l-l.mtn
t'lNHMl
Ti«alf.l

1



1
1




2
2
1
2

1


-------
                                                                               TABLE  V-29
                                                       PRIORITY rCLtUTMTfS IN MJUHIMM rOUHOKT DIB CKSTlWi OPERATIONS

                                                                       (AM. fOWrm-HM-IOHS IH
ro
o
co
POLLUTANT PARAMETER
72. •««.<» t«.ll~.~_T
TJ. Rfmxo (a) pyr«M
_M »_ 3. IrBcnioriuoranLtieae- 	
15, Bn*p(k)riiM>ravtl)en4
76. ChrtaeiM
77. •eeiMDhlliflena

.7.9: r»enro«3.M.l)reryl«na_
BO. FluorffM
•I. Itienantlirene
82. 01benzo(«.hMnthrac«iM
SJ. Indenod^^-iMDnrrma
•*. Prrnie
85. Tetrachlorn«lhjrlene
86. Toluene
87. TrldtloroetlyleiM
88. tlnyl Chloride
89. Aldrln
17089
Haw

-------
                                                                                    TABLE  V-29
                                                          PRIORITY POLUJTftNTS IN ALUHINDM. rOOMDRY DIE CASTING OPERATIONS

                                                                            (AM. cum-KinwvTiim.s IN M:/I.|
ro
o
-p.
POLLUTANT PARAMETER
90. Dtelrtrln
91. Chln-n>l»n»
92^ ^.I'-DOI
Jl^iJ'-BOEtP^'-TPE)
9*. M'-WtKP.r'-TUE)
f). 2-EndoauirBn-Mpha
96. b-endoaul fan-Beta
97. Enrtoauiran Sulfale
98. Endi-ln
99. Endt-ln aldeliyde
100. Hrptachlor
1OI. Heptachlor Epoildi*
102. a-nilC. Alpha
103. b-MIC-bela
ion. r-MK-(Lln
-------
                                                                                   TABLE  V-29
                                                                                                                                        tmge 1
                                                        PRIORITY POMAITMfTS IN MjUHIMM FOUNDRY DIB CASTING OPERATIONS
                                                                              uwrrjcTRATicms IN *;/i.)
INS
O
tn
POLLUTANT PARAMETER


109. PCB-I23Z ")
110. rcR-12«8 |
111. PCB-1260 \
112. fCB-1016 J
11]. Toiapliene
129. 2,3,T,8-Tetr«chloro-
dlboizo-r-dloiln (TCDO)
130. Xylene



(





17
Raw


0.83















089
Ti nalnl


0.080















120'
Maw








0.075









(0
Treated








0.007










Rao



















Treated



















Raw



















Treated



















HAH



















Tr**ale(i



















Maw



















Treated


















HII. ol
MKT<
Raw


1





1









r rt. int*
i Found
Treated


1





I










-------
                                                                                   TABLE  V-29


                                               INURCANIC PRIORITY POI.MITAtrrS IH MDNIMUH raWDHT BIB CASTING OPERATION KASTEHATERS


                                                               	(ALL COMCPfnUtTIOHS  IH  MU/I.)          _
POLLUTANT PARAMETER

Aabestua
Chroalin
cyanide (Total)
Lead
Mercury
Nickel
SelrnluB
Zinc:








170
Hm


O.OO4




O.64








89
TreAlrd

•
O.004
*
U.OOO2
•
*
0.64








12
Raw

<0.1
0.005
O.2
•
'O.O9

-------
                                                                              TABLE  V-29
Page 1
                                                      PRIORITT Pni.MITAN
                                                                                              JIBE OPRRATTONS
ro
O
—I
POLLUTANT PARAMETER
1 . Acmiaiihthene
2. ftcroleln
J. Acrflmltrllv
4. Benzene
5. Dencidlmi
6. Carbon Tetraohlorlde
T. Chlorubenzeiw
6. 1,2,4-Trlchlorobenzmie
9. HemchlarabenzeiM
10. 1 ,2-Dldilaroethane
II. 1,1,1-Trldilaroetham
1?. Menaehluroclhurw
11. 1,1-KlchloroffllMioe
I*. I,l.?-Trlctiloro«llwii«
15. l.l,?.20Ti>tr«ehloraeUMi
16. Chlarnetlnne
IT. Mn-fHiloru »eth«l Mhtw
ID. ht!i-(2-nfiloro>illqrl)etlwi
201«i7
K.iw
o^M. .

O.084

0.47H
0.24S


0.17]
is.esn

o.o»

n



Tn-«l«l



0.050

0.055
0.465



2. ISO


O.OO7
O.O18




Rnv


















Trealcil



















Haw


















Treated



















RM


















Trf*Al:eil



















Rao


















Treated



















Mm


















Treated


















Ni>. of Ptntil*
Miere t'onn-t
Han
I


1

1
1


1
1

1





Trralnl



1

1
1



1


1
1




-------
                                                                                      TABLE V-29
Pa<)e 2
                                                              PHIOHITT foUJITIMfTS IN AUIHIMM  KUIMOBY OIK IJII1B OTtHATIONS

                                                                              (M.I. coiirKMTiiftTHHi:; JH H:/M	
ro
o
co
POLLUTANT PARAMETER
JJ,. ,2-l?|lqi-o«llif!. fln|J. Ether
JO, 2-Cli|ufOfM|iliUialene
21. 2.».6-Trl.-hloro|4i«H.l
22. FarachlonMlanreaol
2). Clilot-nrni-a
2*. 2-Chl<«tiHimal
25. 1,2-DlchtorotMftznM
26. l,3.-l)lrhlo«-oh«oir»e
27. 1.4-DlchlnrobMizena
28. l.l-|ilrhlmut>nizldfHM
29. I,l-Dlr4ilnro«thrlene
30. 1.2-Tr.iHnilli-hlufnelhf leiMi
Jl. ?.<-lllchlorO|4w>ool
J2. 1.2-IHclilm-oproiwn*
1). 1,2-OIHiluf opropylmm
)N. 2,4-Dlwtthyl Ptwfiol
J5. 2.4-ninUrolnliMM
J6. 2.«-|t|iiltrutolii«n«
201^7
Haw


O.JSJ

(L«lt (Ml
O.OC*>

_Q.J?5_













M.IW


















Ticnlrd



















RAW


.















Ticalcil



















Haw


















Treat i>. ol
Wliorfl
M.iw


1

1







>





fl.mln
KIHIIM!
Tl f.il •-!


1

	 	










- •--

-------
                                                                                        TABLE  V-29
                                                             I'KIOHITV 1'OI.I.IITANTli  III  MJIM1NUH KOUNI.HY OIK IJIHK KI'KIDVTKPNS
                                                                              (AM. nitiTHHYimTloM:;  IN n:/i.)
ro
O
POLLUTANT PARAMETER
17 . 1 ,2-lil|>li«'tiylliyi1rar.eiie
.3?. ElliyJIwiizraie
. J'J. FluuranUiciit!
. W. .IrUilocuvliciiyl Tlienyl Elh<
. 11. 4-BrMuvlietiyl rimiiyl tllici
IL. tiin>(?-Clil. Melhyl <:iil<4-tilc
^1 1 (.'li|€ii-o«lll*n.i«»iiwl.liMli»'
'ii* . llf.R.i'Ji 1 «.|-O|H||.;I>| 1 *ff|p
it. II i.i. hi in yi li.p ulallHiin
20
K..W
r . .
ne
2.41D
-
1*7.
Tti'.it vil

M.II'Jl




l.-ill

..
Haw

• 	










Irvat vil
	
	 .












R.iw
	
	 _













Tn;.it«.'il
	
	














Haw


	














Tir.ilfil















	

— -- --














-

Tic-alixl


















fljw

	















	

	















IV.. ..I
B-.w

	


— 	 	

1

	






IM.nifl
I'trtiiifl
Tlf.ll I'll

1


	

1
. 	







-------
                   TABLE  V-29
                                                                                r.v|i. 4
I...I.IJHTAHTS IN  M.1IMIIIIIH  FmillllHY DIH MIHK I >PKKAT II .1) ;
         (M.l. I'Di* i in PA I n ni:;  ill H:/I.)
POLLUTANT PARAMETER


V>. ll.-<|,lillnleiie
56. HI lrob.-Mzi.iie

'j». 1-NJtrupliciiul
'». 1.6-OliillruHignol
dO. 1,6-IMnUi-o-o-cie»ol
61 . N-rillronipMHvtlirlamliie
62. H-nItro.iodl|iheny lamlne
6j. N-iiltro.ipJI-N-|>r<>|.rl.tnli
61. P,.|ita..-lilor«,<,«i,0l
d'j. I'ln-nol
06. b)3-(3-clliylhri,l)pl,IJ,a
6/. Mulyl Uunzyl riil.h.il.il G
6*. Hl-H-Hul»l 1'lithalaLc
(•'>. IU-ii-«»-lYl Hilhiilate
70. UlUhyl 1'hll.al.iLe
n. DJnclhTl I'htliQUle
t










" • •'" '
l.i.i)
21,
II) 1
iLe

'.- . H.

D.I. Illl
.f .»).'•)
!01'i7












M
"'•'">

•». ji.

In.1.









































































































































































































HIi.-.O










i
i
i
1

i

i
r
l-l.llll-l
1.. .111.1












1
'

I

I


-------
                          TABLE  V-29
rtiioRiTi poiLUTMm IH ALUMINUM rouNnnr OIB iimv OPERATIONS
                 (M.I, uitreirriiATiiiNS  IN MT./I.I
                                                                                Paqe 5
POLLUTANT PARAMETER

72. HM»»(» )pnthr*'^nt .
7}- lUnui (• ) fff^nf

15, Bra*olkmuoc«nllienfl_
76. Chr*9em
ro
78. Anthracene
79. 0enr.o(ti.H l)Perylaie_
80, riiiorcne
81. rbmtmthrene
82. DlbenzoU.hMnthracene
83. lnrteno(l,2,J-cd)pyrene
8*. Pjrene
85. Tetrachloroetliylene
86. Toluene
87. Trlditoroethjrlene
H8. flnrl Clilorlda
89. HMrln
201
RAW






<0.«67

_SvQ«
<0.4G7



0.157
O.SJ7
0.277

"
U7
Ttralctl
7.JJ




0.50O
O.23

10,0
<].2J


1.21
0.211
0.177
0.118

*

Raw



















Treated



















Mnw



















Trcatod



















Ran



















Tieateil



















Raw



















Trcatpcl



















Raw



















Treated













.




•*>. of
Mlmci
Rnw






1

1
1



1
1
1

1
rlnnrn
Found
Tiealwl
1




1
1

1
1


1
1
1
1

1

-------
                         TABLE  V-29
                                                                                Page 6
I-RIORITT roi.WTAMTS  IN AUMtNIIM, rODNJWY Ttlf HIDE OPERATIONS
                (AM. CUNCKNTHATIIINR IN K:/|,|
POLLUTANT PARAMETER

.90. Dleldrln

, 12. 1^1' -MIT

91. I.I'-IHJOCP.P'-TOK)
95. ?-Endo9uUan-Alpha
96. b-Endosuiran-Bela
97. Ei¥lo9uir«n Sulfate
98. Endrln
99. Endi-ln Aldehyde
100. HepUohlor
101. flnplachlor Rpoilde
102. a-miC-Alpha
103. b-WIC-bela
101. r-RIKMUwlaneXIaBM
105. g-HIC-Df-llfi
106. rcB-ii?i 1
107. p«:B-i?5i J
.... 	 1
108. PTB-1221 J
20
Haw
..
o.oia
.'
•

« *






0.026
O.07O
O.O07
"

O.8D7

1
-------
                                                                                  TABLE V-29
                                                                                                                                      Paq« 7
                                                         PRIORITY rol.lM1-ANTS IN MJUNtMM rOUHDMT DIB UJBE OPERATIONS
                                                                        IM.t ciiMCKNTRATmtis IN H:/I,»
ro
i—•
CO
POLLUTANT PARAMETER

108. KB-1221
109. rcii-i2« )
110. PCB-12M |
in. rcn-i26o \
112. FCB-1016 J
113. ToHfilieiM
1?9. 2.1.7.8-Tatrachlora-
(Ithcnzo-P-dloiln (TCIIO)
130. lylem






-


20
N.1M


O.STO





47. 0









<»7
Treat ml


0.4B1





11.8










Rtlw



















Tienleil



















Row



















Treat- ml



















I>M



















Treat pit



















M.1H



















T text nil


















Miw














	


Treated














	


Mi. of
Mnrf
H.IV


1





1





	


PI MllS
r-niHKl
Treatml


1





1





	



-------
                                TABLE V-29
ION 1C PRIORITY  FOUJITANTS  IN BUIMINUH FOUNURf DIE I.IIIIB DERATION HASTKHATERS
            	(fiU, COHCRm-nATIONS  IN HO/I.}	
POLLUTANT PARAMETER
Asbeatoa
CliroMliM
Cyanide (Total)
Lvad
Mercury
Nickel
SeleiiliM
Zllic








2011(7
Raw

*
O.O08
2.0
•
•
•
1.6








Treated

»
0.01
2.1
•
•
•
1.5









Raw
















Treated

















Raw
















Treated

















Raw
















Treated

















Raw
















Treated

















Row




	







—


T rented

















HAW
















Ttentw

















-------
                                                                                  TABLE  V-29



                                                         PRIORITY POLLUTANTS IN COPPER toUHDRY'DUST CniJfX'TIOH SVST0IS

                                                                         (ALL CUMrFNTHATIOHS IN »!/!.(
ro
i—•
en
POLLUTANT PARAMETER

1 . Acenaphthene
2. Acroleln
3. ftcrylonllrlle
*. Benzene
5. frmzidln*
6. Carbon Tetrachlorlde
T . Chlorvbenzene
8. 1,2,4-Trlchlnrolnnzene
9. Heiachtnrobenzene
1O. 1.2-Olcblaraethane
11. 1,1.1-TrlchloroethaiM
1?. neMacbloroethan*
11. l.l-Dlchloroethane
l«. l.t.Z-Trlirhlaroethane
19. l.l.Z.ZUTetradiloitMtlMi
In. niloroetlmw
IT. Mn-lchloro •eth«IMI»i
18. bla-(2-ehloroetlijl)ethei
9W
Rnw
O.OOS


•
.









e



4
Tl IMtRft
«


















M.tw



















Treated



















Maw



















Treated



















Haw



















Treated



















Maw



















Treated



















Maw



















Treated

















!
N». ol
HtM-Ifl
Maw
1


1
1













FuiNld
Trfal.ed
1


















-------
                                                                                  TABLE  V-29
                                                                                                                               Pa,).- 2
                                                        PRIORITY  POI.UUTKNTS IN COPPER FOUNDRY DUST COUfCTION SVSTIMS
                                                                          (ALL fUNceMTRATKIMS IN f»:/l.l
ro
POLLUTANT PARAMETER

19. 2-Chloroethfl flnyl Ether
20. 2-Chloronaptiltialem
21. 2.t.6-Trlchloro|ilienol
22. FaraehlofBelacreaol
23. Chloroform
2«. 2-Chlorophenol
25. 1,2-llldilnrobenzefW
26. 1 ,3»-0leh1orobenzen«
27. 1,4-Dlchloi-obenxene
28. 3(3*Dldilorobenclderw
29. 1,1-Dlehloroethf Icne
30 . 1 , ?-Tmna<1 1 ch liiroelhjf 1 ene
31. 2,4-Klchlnroplrenol
32. 1 t2>Dldilm'Opro|>ana
33. l,2-Dlrliloroprop7lene
3». ?.»-OI«ellifl Phenol
35. 7,4-Dtnltrotoltren*
36. 7,6-PlnllrololuerM
'JO'
Ra«


.
.











O.OJ6

O.OO4
»4
i
Tlf.lliMl



.
.














P.n*



















Treated



















RAW



















Trcat.ed



















I'M






































•















































































Wlmre
RAW


_JL
1











j

1
F«1!!!r
Ti(*«ilr«|



1















-------
                                                                                  TABLE  V-29
                                                                                                                                 Paqe 1
                                                        PRIOR ITT POI.IWTAKTS IN COPPRN FOUNOHT OUST COI.I.KLTIOM SYSTEMS
                                                                          IM.L cimi'BHTtu>TniM!» IN M:/I.)
ro
»-•
—i
POLLUTANT PARAMETER

37. 1,2-Dlphenylhydratera
JB. Ethrlbeiizene
59. FIlinpMiLhniM
ML JrCblorDcbenrl_Cbeiul_CUt<
tl. il-BrvMiihenvl riKnyl EllMi
«2, b»?-(?-Cbl W Ql9oprp«fl)
ether
»3. bl9-(2-cfiloroelho«T)«>th.
44. Hehtylow Chloride
45. Methyl Cltlorlde
»6. Hethyl Drcwlde
47. DrtMnrora
48. DI«hlorobr«aclilai-ocyrlo|ient>dl«M
9OT
H[«
K.W
t

A















1
Plantn
round
Tr«.il IH!
1

4





1











-------
                                                                                   TABLE  V-29
                                                                                                                                           Page 4
                                                          PRIORITY POLUT1MITS IM COPPER rOUNURY DOST OOI.LJX-TION SYSTEMS

                                                                           (M.I. (.•UHCKNTH/lTHItiniN W:/l.)
ro
H->
CO
POLLUTANT PARAMETER


56. MUrob.,1,™.
57, 2-Nltropheaol
58. t-Nllropbeuol
59. k.6-Dlnltroulienol

61. N-nltroaodlMlhilamlije
62. N-nltroaodlphenrlaailne
6]. M-nllro9ndl-ll-prop]rla*ti
6*. Pentad) loropheno I
65. PlKMiol
-*.-"-«— »Ua»i*:
68. BI-N-Butyl Pl.thnl.t.
69 l>l-n-"oi »1 rblbalate 	
70^ Dletbyl Phlhalale
. 71. Pl»cthrl.rhtbalale
9O91


O.O11

.
.




e
_fl Q1J>_
0 . 02^
0.011
0.18
0.001
.
O.OOf,
O.O10





0,^06
0.004





.
O.017
.
0.011

0.011















































































Paw



















































































































Ho. of rlniils
Wlmre FOUIH!
Raw

1

1
1





1
1
1
1
1
1
1
1
Treat o
-------
                                                                                TABLE  V-29
                                                                                                                                  faqe 5
                                                       PHIOK1TT rOLUITANTS  IN COPKM FOUHTOIY DUST COLI^TTIOH SYSTEMS
                                                                       (M.I. OmrEHTHATIOHS IN
ro
POLLUTANT PARAMETER

_72.. l)rani(«)antJmaan*-
T)- Brnrn (•) pymt*
.7*. Itt-PnptoflnnrvtUpnm,
75. Benxo(k)rliKir»nthene
76. Chi-*a«M
77. AomMpMhflale
7B. Rnthraacne
_Ki.B(B.h)«nthr>oeiM
83. Iml«no(l.?.l-cd)prrene
84 . tjrtnf
8$. Tetrachlaroelhylene
86. TolimM
87. Trlrhlanmthrleira
88. rinjrl Chloride
89. Ulilrln
901
Km

-------
                                                                                        TABLE V-29
                                                                                                                                             Page 6
                                                             PRIORITY POLLUTANTS IN COPPER FOUHOKT DOST COI.LKCJTION SVSTKMS

                                                                               (INLI, CONCFtrrHATHIN.'; IN H:/l.)    	
ro
o
POLLUTANT PARAMETER
90. Dlftldrln

92. «,*t-UOT

9*. •.V-UOU(P.P>-TDE)

96. b-Rndoaal fan-Beta
97. findoauiran Sulfale
98. Endrin
99. Endrin Aldehyde
100. Heptachlnr
101. Heptachlnr Epoilde
102. a-WIC-Alpha
10}. t-UIIC-hela
10*. r-IMIC-(l.liRtKne)G»MU
105. ft-MIC-Del la
106. PCB-1«2< 1
107. PCU-125* I
9O94
Raw
0
	
..





O.OU4
*•






Tlcal^d
*•









*•

..
..
..
A *

ft ft

Raw












*





109. lftt-IZ21 J
Treated




















Raw



















Treated



















|i*»*














































































Raw










	







Treated



















Nri. of rlnnll
Mint a F«MIIH|
Rnw
1


1





1

1







Treatotl
1









1

1
1
1
1

1


-------
                                                                                      TABLE  V-29
                                                                                                                                              Pagn f
                                                            PRIORITY POLIJITANT9 IN COPPER rOIINDRT OUST COI,I£CTION SYSTWS
                                                                             (M.L CUHTRNTIIATtOtl!) IN HI/1.}
r\s       _-'-
POLLUTANT PARAMETER

100. res-rat
109. PCB-I2J2 I
110. FCB-12U |
111. PCB-1260 1
112. n:B-ioi6 J
11]. To«a|iliene
129. 2.3,7, a-Tetrnrhlora-
dllxnzo-r-dloiln (TCDO)
130. Xylen*









9I»I
Ha»



















Treated


*•
















R*iw



















Treated



















Raw



















Treated



















Rax



















Treated



















Rax



















Tr«*ateil



















Rax



















Treated


















*>». of
Hlicrii
R.1W


















Plant-n
fnnwl
Tceatml


1










-





-------
                                                                                   TABLE  V-29
                                          INOHT.ANIC PRIORITY POLLUTANTS IN COTPKH AND COPPER ALLOT FOUNDRY DUST COLLECTOR HASTEWATERS
                                                              	(m.L COtfcEMTBimOMa IN HU/M	
ro
POLLUTANT PARAMETER
Asbestos
Cartelw*
ChruiMiim
Coivet
Cyanide (Total)
Lead
Ptorcury
Nickel
Sclcnlw
Zinc






9094


0.10

110
0.041
28

0.72

130








*
*
0.16
O.OOI
0.081
O.O005
•
•
0.45










































Raw
















Treated

















Rao
















Treated

















Raw
















Treated

















Raw













	 _~

Treated

















Raw
















TteatPi













-



-------
                                                                                     TABLE  V-29
                                                                                                                                            Page 1
                                         PRIOR ITT PUI.UITMfTS IN COPPEft AND COPPKM ALUW FOUHDRY MOLD COOLING AND CASTING gllKMCII OPERATIONS


                                                                            (M.I. mMfEMTMATIIHia  III MVP  	
r\>
CO
POLLUTANT PARAMETER

1 . Hcenaphlhene
2. ftcroleln
3. »crylonHrll«
4. Dentine
5. BenzidliM
6. Carbon Tetrachlortde
T. Chlorobenzene
8. I.Z.t-Trlchlorobenxene
9. NeiraehlarobenzeiM
10. 1,2-DlrhloroetlMiie
11. 1,1,1-Trlchloroethan*
1?. h>xachloroethane
13. 1 , 1-Dlchloroethane
14. 1,1.2-TrlRhloroethwM
15. l.l.?.20Tetr«cfiloroethii.
16. rtiloraeltaiM*
IT. Mn-ldilorx. Beth'! M.hri
Ifl. b1n-(Z-chloroelliyl)ellwi
earn
M.iw
•




0.011




O.OJ7



I!




Treatntl










0.044








Maw



















Treated



















Maw



















Tie* tori



















Ma-



















Ticateil



















Maw



















Treat rH



















Raw



















Tiealed


















Mi. »(
Mllflf
Raw
1


1

1




1







Hanta
FoiHMl *
Trn.ilml



1






1








-------
                                                                                  TABLE V-29
                                                                                                                                        E 2
                                       PR.ORITY Poi.um.rrs IH COTPER  MD COPPB. »LLOY  FOUNDRY *>u> com.mi «ND C*STIHG QOPNCH OPERATIONS

                                                                         (ALL (_1>W Km-RATKlMS  IN MC/I.)
ro
ro
POLLUTANT PARAMETER
19, 2-Chloroethrl tlnjl Ether
20. 2-Ciiloronaplilhalene
21. 2,^.6-Trlchlorophrnol
22. ParachlofB«tacreaol
23. Chlororom
2*. 2-Chloro|*«»ol
25. It2-Dlchlorobcnzen«
26. 1,1,-Dlchlorolwnzen*
27. 1 ,<-Dlctilorob«nzffne
28. 3,3-DlchlnrotaenzlilefM
29. 1,1-Dlchloroelhrlena
JO. l,2-Trann. of l-lalitn
Wlir*r<9 ^«>IIIH|
R.iw


















Troat r
-------
                                                                                   TABLE V-29
                                                                                                                                          Pane I
                                        PMIUIIITT rOLIUTANTS IN OOt»E* ANO COPPER MAO* FaMPIIT HMD COOLING Mill CASTING QUEHCII OPKRATIONS


                                                                           (AM. UmCKNTRATIOMS IN Hi:/1.)
ro
ro
en
POLLUTANT PARAMETER
3T. l,2-Mphenjlh»«lr«i«ne
18. Elhrlbenzrm
J». Plun.-Mlh»«
9V. _l-Chlorontioiiil_niBn»l_CU«
il. *rProwwbeiurl fbcaxl Ethei
42. bt3-f2_-Chl«TQi90pCQPrU
ether
•3. bls-t?-chlor«ethoi]r)»eth.
M. Hehtytem Chloride
%5. Methyl Chloride
46. Nellyl BroBlde
47. Brotmror*
»• -. ^«

*9. Trlchlorariuonwethme
50. UlehlorodiriuaroMethtine
51. Chlorodlhi o»jaett»oe
57. Hesaclilorotiatjnllvtie
5). Iteiai4ilaificfnln|ientadlen*
6HIW
Haw


•
r



ne



•






Tifvttetl


•





O.030










Haw


















Treatml



















*JM


















Trnnted



















Raw


















Treated



















B.1W


















Treated



















Raw


















Treateil














•»



»>. of riant*
Mmc* round
Maw


1








1






Treated


1





1






	


-------
                                                                                     TABLE  V-29
                                                                                                                                           Paqe 4
                                         PRIORITY POLUITftNTS IN COT»PH KHO COPPER M.LOY FOUNDRY MOID COOLING  M*> CASTING gilENCII OPERATIONS
                                                                            (AM, (tJMi'ENTitATiiiNs IN w:/i.)
ro
ro
en
       I	
POLLUTANT PARAMETER

54. l9nphAfl*Offt*
SS. Mxphllulon*
56. HI Lnit».nTJl«wi
57. 2-RllroDhenol
58. ^-Hltroph*nol
59. 4.6-Dlnltronhenol
_60. *,6.01nUrs-9-cc9MJL
61. D-nltro9odllne
62. H-nltroaodlphenrlaalM
6). H-filtroaodl-N-proprlauli
64. fentachlorophenol
65. Phenol
_66. bla-(Z-«tbrlheiyl)phUu
6T..Pulvl DeozrUtitbaUte
M^Dl-^Rvifl ruthalBLa .
69- ni-ctootil Fbllwlate
70. lUettvl ItittalaLe
-71,-PlBetbrl fbUwlate
680
K.iw
•




•
•


•
0.017
•
>(*
•

•
•
O.015
9
Treated












0.17
•
O.U19

0.014
0.093

Raw



















Treated



















Raw



















Treated



















Raw















































































Raw



















Tiealed














-



M>>. of
Mlinie
R.lw
1




1
1



1
1

1

1
1
1
PI mil ^
r'OMINl
Tin.it 0.1
1











1
1
1

1
1

-------
                                                                                 TABLE  V-29



                                       PRIORITY POI.UUTMIT5  IH COPPER MID COPPER M.UJT rouNDNT HOLD COOLING wm cwmtr; OIIENCM OPERATIONS

                                                                         (M.I. CUtHTHTBATIOMi IH NS/I.I 	
Paqe
ro
ro
POLLUTANT PARAMETER
"
72. BrmnUhmlhracMM
73- *«•«? (•) pfrvna
_tt._J.I-Daizoriuarantbeaa__.
^li _BraseU)riuwantlMnft__
76. Chrira«M. .,
77. •eciMDhthvlen*
78. Untlmcene
J?:-Penro(»l.H.I)ferrloM___
60. riuorme
01. flwiiMithrffn . .. .
82. Dlbencod.hlHiitliraaefM
•3^ J"«?«»>
Tipatpil

•


0.019
0.019






•
0.093

0.05*



Haw



















Treated



















RAW



















Treated



















Rao



















Treated



















Raw


















»
Trratpil



















R.IW



















Treated














^



N». nl
Mmre
Raw

1


1
1


1



1
1
1
1


Plant*
FfXMKl
Treat oil

1


1
1






1
1

1



-------
                                                                                   TABLE  V-29
                                        PRIORITY I-OLUITANTS IN COPPER AMD COPPER ALLOT rouNtmr HOIB COOLING AND CASTING UMKNCH OPERATIONS

                                                                          (AI.I. CONrENTRATKINS IN H:/|.|      	
ro
ro
oo
POLLUTANT PARAMETER

90. Dlaldrln
Ql . Chlnp*'^*'uf
42. «,«'.MiT
Jl. «.*'-Dl»E(r.r'-TOE)
9«, ^.^'-OOOCP.P'-TUE)
95. Z-Endosulfan-Alpha
96. b-Endosul Tan-Beta
9T. Endosuirm Sulfate
90. Endrln
99. Emlrln dldehjrdo
100. llcptaehlor
101. Hriitachlor Cpolldo
107. •-niK-«lplw
10 J. b-n»C-li«ta
10H. r.MK-(l.lmt«ne)Ri»M
lift. g-mC-PelU
106. rCft-ll?t "I
107. PCB-1?5* J
108. PCR-I72I \
6BO9
Rax

• •

• •



• •
.
• •
• •
• •
0
• •
• •





Ti vntcil




















Raw




















Treated




















Raw




















Troated




















Raw




















Treated




















Rnw




















Treated




















Raw














~





Treat-.fltl



















Ho. of
Micro
Raw

1

I



1

1
1
1
I
1
1




Pl.int*
Ftniiid
Tteatnl




















-------
                                                                                 TABLE V-29




                                       PRIORITY POUJrTANTS IN CUPPER AMI COPPER ALLOY rtWMWIT MOLD COOLING AND CASTING OUKNCH OPERATIONS

                                                                         (AIX UHk.-rtrrRATKlNS IN Ni/l.)
ro
ro
POLLUTANT PARAMETER.


109. rCR-1232 1
110. KB-1248 |
111. K0-1260 1
11?. PCB-1016 J
113. Tonifteiw
129. ?,J.7,«-Tetr«chloro-
dlbcnio-r-dloxln (TCIlD)
190. Ijrlene









68U
Hn«




•
• *












9
Treat cil



















Kw>



















Treated



















Mm



















Treated














•*'




»••



















Treated



















Raw



















Tr«nte
-------
                                                                                  TABLE  V-29


                                INORGANIC PRIORITY  POI.I.UTANTS IN COITER ANI> COFFER ALJAY  FOUNDRY HOLD COOLING ANI> CASTING QUENCH WASTKWATERS


                                                             	    (ALL COMCBHTRftTIONS IB HC/I.)	
rxi
oo
o
POLLUTANT PARAMETER
Asbestos
Catkiiu«
|t|>er
Cyanl
-------
                                                                                     TABLE V-29
••9. I
                                                                     PRIORITY POLLUTANTS IN COPTER MO COPPER AI.UMT

                                                                        POtMlRY CONTINUOUS CASTIIW (XTRATIOHS
                                                                            (AM. com Kwnu\Ti(»is IN H:/I.|
ro
GJ
POLLUTANT PARAMETER

1. fteemphthen.
2. Acrolotn
3. Acryluiiltrlle
4. Benzene
. V Benxidlim
(. Carbon Tetrachlorlde
T. Chlorobenzena
6. 1,2,4-Trlchlorobemene
9. Henichlorobenieiw
10. 1.2-Dlchloroethane
11. 1.1,1-Trlehloroettana
12. Hennhloraettana
13. I.l-Dlrtiloroeth»n«
11. 1.1.7-Trlchlorwthane
15. l.l.2.20Tetr«cbloroetni«
|6. ClilororthaiM
IT. Mfl-(uhloro •alli'D'l.lm
Ifl. Ma-(2-chloroetlijl)etlNH
997
Mm

r












e



9
Trent cd
•
1

















KftW



















Treated



















HIM



















Treated



















KM



















TrD*tp
-------
                                                                                     TABLE  V-29
                                                                    PRIORITY POLLUTANTS IH COPPER AND COPPER ALU>Y

                                                                       FOUNDRY CONTINUOUS CASTING OPERATIONS

                                                                           (ALL cuNTFirniATioN!: IN M:/D
ro
co
ro
POLLUTANT PARAMETER
J9,__?-Ct!}qro«|.hfl_»lnjJ _Ether
20. 2-Chloronitplithaleiie
21. 2.*,6-Trlchlorophenol
22. rarachlor«etacr«9ol
23. ChloroCorw
24. 2-ChloroplMnol
25. 1,2-DlchlorotamCHW
26. 1,3,-UlnhIur ibenzeiM
27. 1,4-DlclilorolMwizefW
28. 3.).Dldilurobenzlden«
29. l.l-DlcMnro«lh]rlene
30. l,?-Trannx*


















Trcnl pr« f'oiltttl
R.1W















1


Troal rd




1














-------
                                                                                    TABLE V-29
                                                                    PRIORITY  FUIJJVTMITS IN COPPBR AND COPPI* M.M>»
                                                                              CONTINUOUS CASTING OPERATIONS
                                                                           (M.I. CIWCKMTRATMIN!: IN Hi/I.}
Page 1
ro
POLLUTANT PARAMETER

37. 1 ,?-DI|4ienylhydriizeiM
38. EUnlbentene
, J9 FpimnnthM^
M. JrOaoroiilimilJlieiui_CUK
ll> «-DrMQCheiiyl rtKQil_eUKi
•?*- bl9Tl2-C1»I«:«j9PPC9PlU
ether
*3. bI«-(2-chloroetho«r)»»th.
4*. Nchtylene Clilarlde
*5. Methyl Chloride
46. Nelhfl Bnmtde
47 . Brogwfor*
n. DIchlarohruwMettaiM
kn » i«j.t n *k

50 _ DIchlaroiliriaariMethMM
51 ChlaradlbraMawtlwne
•#. l^inclilni-obuLiiillPTMi
53- llexatthlarnci'clofwfiliidleiM
99
H.w



r



ne
-Hi)










79
Treated


•





0.015











Raw




















Trent eil




















Haw




















Treated




















HM




















Treated



















»
R.w




















Tipnteil




















RM




















Treated



















Nn. of
Minre
R.-W








1










rlantii
Fotiml
Trent <«l


1





1











-------
               TABLE  V-29
                                                                            Paq« 4
PRIORITY POLLUTANTS IN COPPER AND COPPER ALUH

   roilNpKT CONTINUOUS CASTING OPERATIONS
       (M.l. COWRHTRATIIIIIR  IN H./l.)
POLLUTANT PARAMETER

-5JL Isnphorooe _
55. tonhUialme
56. HltmbMiriww,
_57_^ 2-Hltrool.cnol
5*. .KrHltrvptaenol.
59- *»'-uinHroDlteriQi_

61. N-nllroaodliiethjIaBlm
62. N-nltroaodlphenjlaHlna
63. N-nllrosodl-N-pi-opflAKh
64. Pentachlarophenol
6%. nwnol
66, bJ»-t-n-~;lU FliUialaLe.
70. Olellurl-ltiUalaLa
71. ni»elhrl fbtbalate
95
Raw









,


»U_
o. we




79
Tlp.ilccl
•
•










0.315

O.030

•
*

RAW



















Trnal-ed



















ft AW



















Treated



















RAW



















Treated


















*
Raw



















Treated



















Maw



















Treated


















MM. of
Hlirrc*
Kiw













1




S"
Ti.-.iled
1
1










1

1

1
1

-------
               TABLE V-29
PRIORITY  POLLUTANTS IN COPPER AND COPPRH ALLOY
   FOUNI1RY CONTINUOUS CASTING OPERATIONS
       (ALL CUNCBNTRATIONS IN N:/|.)
POLLUTAMT PARAMETER
72. *»•»'>(• )rDthrav*na
_I3.. Denzn. (a) pyrciM
_7).. 3.i-0eDzariuor*nttaM__
^75^ . JewolkJ riirar«oLban__
76. Chriscne
71. KcciUDhUiTlena
79, «nthr»cen«
_7»- Penwi
-------
                                                                                   TABLE  V-29

                                                                    PRIORITY PULLUTMTTS IN COPPER AND COPPFR M,l/l»
                                                                       FOUNDRY CONTINUOUS CAST 1 HO OPERATIONS

                                                                          (MM. CONCENTRATIONS IN MC/l.t
ro
UJ
          1OB.  PCB-IZ2I
POLLUTANT PARAMETER
40 Dl.ldPln
91 Chlnmd.n.
92. *,«'-nr>T
„ JJ^ M'-WECtP'-THM
9^. «.»'-POO{r.P1-TOE)
9%. 2-Eodosuiran-Mpha
96. b-Cmtoaul Can-Beta
97. Endo.iuirm SulfaU
90. Ehdrln
99 • Endr in N Iclcnyo*!
100. Hcplaohlnr
101. Ik-pinch lor Epoild*
107. a-miC-«lpha
10]. b-IWr-beta
104. r-MH;-(l.|nd.in«)GMM
105. g-MIC-belU
106. Kit- 1«2» ~l
1O7. PrR-|25t )
1
9979
Raw



••










"
•'


Tlealwl
• A
• *
"



•«
"


"

"
"



"

RAW


















Treated



















Raw


















Treated



















Haw


















Ti eatod



















Raw


















Treato<1



















Raw


















Treated


















Mi. of I'lnnll
Wlicre Fmiiul
Row



1










1
1


Tiealfl
1
1
1



1
1

~r—
1
i
i



•

-------
                                                                                       TABLE  V-29
                                                                      PRIORITY POLUFTAKTS IN caert* AMI COPI-EH M.IX>»
                                                                         rOUHIIftV CUWTIMKHH CASTING OPERATIONS
                                                                             (ALL CUM.-KimUkTIUHS IN Mi/I.)   	
ro
POLLUTANT PARAMETER


, 10». KD-1232 1
110. KB-12W |
111. tCB- 1260 \
11?. KB-1016 J
11). Toiarhene
I?9. ?.3.T,«-T«tr«chloro-
dlbcnzo-r-dloiln (TCDO)
1)0. lylem









99
Urn


















79
Tmtol


••
















Now



















Treated



















Mw



















Treated



















Pa<



















Trrated


















	 •»-
Haw



















Treated



















Hun



















Treate.1


















Nn. ol
Mmrq
Haw


















rl.ml-l
rmml
Treat
-------
                                                                                    TABLE V-29

                                                                INORGANIC  PRIORITY POI.LirTANTS IN COPPER AND COPPER AI.I.OY

                                                                  FOUNDRY  C-ONTINIKXIS CASTING OPERATION WASTCWATBRS

                                                               	(ALL CONCENTRATIONS IN HC./l.t	
POLLUTANT PARAMETER
AlbeatO*
Caitalun
Copper
Cyanide (Total)
l««l
Mercury
Nickel
Sel«nlui
Zliic



•



9979
Raw




0.07



2.7







Treated

o.nl
O.OOI
O.I 3
*
*
•
4.4




'



Raw












•



Treated

















Raw
















Treated

















Raw
















Treated
















.
Raw
















Treated

















Raw
















Treated

















Raw
















Treatn


	









	

ro
oo
00

-------
                                                                        TABLE  V-29
                                                                                                                           Paqe i
                                                        PRIORITY POMJUTMTTS - remwus rouwwr-wisT

                                                                    (AM. oiKinmMTifwn IH
ro
CO
POLLUTANT PARAMETER
1. Aennaptilhene
2. ftoroleln
3. Aerylonltrlle
4* B0flKCIM
5. Bmcidlne
«. Cnrbon Tetridilarlde
T. ChlarobenxaM
8 . 1.2, *-Tr lehlorabenzene
9. fteiitchlorobeniene
10. 1.2-DlchlaraethiiM
11. 1,1.1-Trlehlaroethana
12. HeuctiloroettMiM
13. 1,1-Dldilorcwthane
11. 1,1,2-Trlchloroethane
15. 1.1.2,?OTetmchloro«ltwi
16. Chlaroelhiine
IT. Mn-idiloro >oUi*l )~lhr,
IB. bla-(?-ohlormthfl)«ttwi
15520
R.TW







O.OOT






e



Tioalcd
0.010


•
I
i




«

j





6950
Raw
0.02


•

A




0.037


•




Treated
•


•






•







7929
Haw
0.036


-|0>

-<0)




O.O2







Tioated
•


•

•













*•-


















TtPHlc.l


















r
Raw


















Ti eal o J



















RUM


















Treated


















Ho. of Plimln
Hlmrit Fniiml
M.1W





2

1





1




Tro.il <<
-------
                                                                                TABLE  V-29
                                                                                                                                        Page 1
                                                             PRIORITY POLLUTANTS - FERROUS FOUNDRY OUST COIJJUCTORS

                                                                          (M.I. COMCEHTIWTICINS IN MS/1.)
ro
-p»
o
POLLUTANT PARAMETER
JJi..J-Chl«?rS«thjL»lnil Ether
.2JL 2.-Chlorpn«i*thaleiw
21. 2,*.6-Trlchloro|>h«nol
22. rar«chloriKtiicr«aol
23. Chlororom
2<. 2-Chloro|4>«noI
25. 1,2-DluhlorobcnzefW
26. 1,3,-Dlchlorobenzene
27. l,Q-Dlchlnrob«fizen«
28. J,J-Olchlorobfmrl
-------
                                                                                TABLE  V-29
Page 3
                                                            PRIORITY poujjTMirs - FERROUS rniNORr WIST roi.UK.Tons
                                                                         (RI.L COMl'EtrrRATIOMii IN KV
ro
POLLUTANT PARAMETER-
37. 1,2-DlphenjrlhydrazefM
J8. EthrlbeniciM
. 39. FliiorM)t-iM>«if*
_JO.-lrCblQ»>Bben>lJ3nfiiLEtb<
11^^-llroiKWheiul Cbcnxl EtlMi
*2, bls-I?-Ct»lorsl90propjlL
ether
43. bl9-(2-ctiloroeUK»r)iKth;
M. Hehtylene Chloride
45. Methyl Chloride
46. Melhfl nrmlde
47 . Broanrora
kfl ni I 1
^o , uidii*it vuruanHpuBina
•9. TrlchlarnriiiaroMlhmw
50. Dldilorodiriunrwwthmn
51. Clilofodlbf-ooonelhane
•>?. lleiai'hlorobutadlene
53. Hr« round
ftitw
2
2





2










Ttented
2
1
]





J










-------
                   TABLE V-29
                                                                         Page 4
PPIOHITT POIJJUTAWTS - FERROUS fOHNDRY  DUST COM.RCTOHS
             (M.I.  cotKTmwmoNS IN w;/i.)
POLLUTANT PARAMETER
11 Janphorone
_ 55. Naphtha J cite
5t« Jtltrubenznna.
,. 51. 2-NltronlMHiol
58. *-Nllro|jlK-nol
59. 4.6~DlnltroDhenol

61. N-nllroaortlanthilMilne
62. N-nllroaodlj4iefr2lMlnq_
(3. H-nltrosoUI-N-propjlaarti
6*. Penlachloropltwiol
65. Phenol
_67..ftitjJ..Beniyl CbUulata_
68i_B|-N'Butjri rtithalala
f-9. i>l-n=nnj.Tl rbtlulate

.71. OJ«elhrl thllMUte . .
15520
tl.iw



-------
                                                                   TABLE V-29
1*9. »
                                                          poLumwn - PBMOUB mmuinr MIST COLUCTMS

                                                          	 (KM. UMrnmWTIfMS IN HVl.l	
ro
-P»
co
POLLUTANT PARAMETER
.-72»_Bauui(a)anlnrac«a*
TJ- HM«A (•) pr~~
_U^JJLrBenzoriinranttem_ .
75 • •ejiM(l)r|TwHiline
76 r Chf-paem
77. Acenaohthrlena
78. Anthracene
_!•• «enza
-------
                TABLE  V-29
                                                                           Tage 6
PRIORITY POUWTMITS - PKRROUS fOUNDRY WIST COI.IJSCTORS
             (M.I, afflTENTRATHIte;  IM
POLLUTANT PARAMETER

9O. Dlftlrirln
91- '>il«X'«*«n'1
92. »,»'-Dt)T
, «. «.V-DDE(P.P'-TDE)
9*. ^'-DBIXP.P'-TDE)
. 2-KMoauiran-«lpta
96. b-Endoaul Tan-Beta
97. EMoauiran Sulfite
90. Bmtrln
99. Endrln *lptachlor
101. Heptachlor Kpollde
10?. a-MIC-«lpha
103. b-B«C-h«ta
104. r-INIC-
-------
                                                                             TABLE V-29

                                                            PR ion ITT pot.iirrwfra - PRRROUS rounoir» OUST COMDCTORS
                                                                  	  (M.L CIHlrEHTRATHIIIS  IN Ni/l.)  	  	
                                                                                                                                     Page 7
ro     _J5L-.
POLLUTANT PARAMETER -


iw. PCB-UK |
110. PCB-I2M j
111. rCB-1260 \
112. PCB-1016 ^
11). Toiaphene
129. 7,3,7.»-Tetr«chloro-
dlbenzo-r-dloiln (TCDD)
1)0. Irleiw









15520
N.1V


••
















Tn-nleil


• •















6956
How
















4


Treat oil


••





•









7»»
Raw



















Treated


• •
















Paw



















Treated


















»
Raw



















Treated



















•mr



















Tieated


















H». nl
Mlmr«
Maw


















PlmiH
KOIHHl
Tiealml


1





1





-




-------
                                                                               TABLE V-29


                                           INORCAIIIC PHIOfllTY POLLUTANTS IN F'ERHMIS FOUNDRY  MIST COM ACTION SYSTEM

                                                           	(ALL. com.-EHmATiuto IM MO/I.)	
ro
-^
CT>
POLLUTANT PAF-.vMETER
Antlatmr
Arsenic
Asbestos''"
Morrlllu*
C^tail am
• 3u u»l am
Coiiwr
Cyxnlile (Total)
Le«J
Hurcuiy
Nl.k.-l ,
Si.'lt-iilw
2liH.- '
|
r
i



59101
ftM






0.0)7









Tieatpd


•



0.019

O.OOO2







/ 536^2
Haw





0.14

0.14

0.1]

O.O97




reacted





•

o.nso
o.uio
*

0.09




50315
*•«


•


0.11



O.IO

1.9




Treated


4


0.021
0.02]
0.46
0.007
•

I.B




59212
Raw






0.069









Trnated






NA

NA







1 5520
Nnw
0.07 "
	 	

O.OO7
0.09
».0(i7~
0.0]








Treated
•

b

'
»
0.074
O.OI
n.ool
0.02
•
0.37




695*
HAW
1 . IH)»



i.oi
>. 1
>.Z1
>.2
I.OOOOJ


).59




Treat™
0.05
•

6.01
070003 	
674-9 	
0.0059
O.OO06
n.oi
*
O.023





-------
                                                                                    TABLE  V-29


                                                 INORGANIC PRIORITY  POUJJTWtTS IN FERROUS FOUNDRY DOST CCM.I.BCTION 3YSTKH WASTKWATKRS


                                                              	(M.L qmCENTRATIOHS IB MB/I.)	
ro
-p»
—i
POLLUTANT PARAMETER

Kntiaonr
Arsenic
AabMtoS
Bervlliw
Cadalw
CIlKMlin
Coivvr
Cyanide (Totalt
Ledd
Hotcury ,
Nickel i
SrlonliOT
Zinc



71
Rnt
U.OI


*

•
O.OJ
0.047
U.OJ7

0.01
•




129
Treated
•
•

*
•
•
0.14
0.014
0.20
O.OOO7
O.O4
•
0.16




Maw

















Treated

















Maw

















Treated

















Maw

















Treated

















Haw

















Treated





.











Maw













_



Treated

















*aw

















TreatiN













-



-------
                                                                                       TABLE  V-29
                                                       PR ION ITT I-OLLUTANTS IN FRRHOUS toUNtiRf MEI/TUIC FURNACE SCRUBBER OPEKATIONS

                                                                              (M.I. <1M4rt:NTRATION3 IN W:/l.|
ro
•t»
oo
POLLUTANT PARAMETER
1. Amnaphlhene
2. kcfoleln
3. Acrjlonltrlle
*. Benzene
5. Benzidlne
6. Carbon Tetrachlorlde
T. Chlorobmzcne
6. 1,2,%-Trlchlorobenzene
9. Hcxachlorobenzene
IO. 1,2-Dlchloroethdn*
11. 1,1,1-Trlchloroethane
1?. Itenachloroethane
13. 1,1-Dlchloroethane
1». 1,1,2-Trlrtiloroelliane
n. t,l,2.20Tetrachluro«trwi
16. Oiloronl hniw
IT. l>ln-0»
•


0.007

•
•



0.02)






*
Treatr.l
•


*






*







»
Rav


















Treated



















Raw


















Treated


















Nn. of Plmitx
Mliere Fmiiftl
Raw




1

2

1
1








Treal<»«l
2

1
2
1
1

1

1
2


1



.1 .

-------
                                                                              TABLE  V-29



                                                       •OUJUTAHT9 IN rtnanus rnimoM Hetrim niMMCic SCPUWIKK OPKRATIOMS

                                                                     IAI.I. OJWWITHATUIIIS IN N:/U 	
•a*, a
ro
-p.
10
POLLUTANT PARAMETER
Jl, . Z-PllPWlhfl «_•>»}. Blhrr
Mi.. .?rC!ll9rai»pHM«l*»» .
Jl. 2,»>-Trlc«iloro|*enol
22. farachla-Bctscreaal
2|. Chlarorara
24. 2-Chlar»|ilicnol
». 1.2-DlahlarolwnxaM
2*. 1.1,-UlRhlM-ubenira*
27. l.»-tHchlorob«iozei««
2*. J.J-DlctilnrobenzldWM
29. I.l-Ulchlor«ithflen«
30. 1,2-TrwtfMllchlaroellvletM
Jl. 2,«-Uli!lilfira|ilie«ol
J2 . 1 , 2-DI rh 1 or«H'rofwiiie
JJ. l.?-Dlrlilfwn|M-aprl«iM
}k. 2.*-fii«elbri flHmol
35. 2,4-HlnltivtaliMM
36. ?,6.|ilnUralolwiiM
ooot
















O.IW4
	
Trp.itfil
rw
HA
HA
H»
m
HA
HA
HA
HA
MA
MA
MA
MA
MA
MA
MA
MA
0002
















•


Treated
MA
MA
HA
MA
HA
MA
MA
MA
HA
HA
HA
MA
HA
NA
MA
MA
HA
15220
HUM












J1.1US 	




Trnatfld

<0.140
O.072
0.061
0.026
0.085






J.IHQ , ,

0.40
-IBJQ1-

Maw


















Treatfd



















__•«!• 	

















Tr««tefl









	







Ha. of I'lMilM
Mhn>« fimml
•aw



	






1
-*—



1
Ttenlvd

1
1
t
j
2









I
1
1

-------
                                                                                   TABLE V-29
                                                                                                                                         Paqti 3
                                                    PRIORITY POLUrTAKTS IN FERROUS FOUMORT MBI.TINR fURNACK SCRUHHKR OTKRATIONS

                                                                           (M.I. CDNCeNTMATIUNS IN Mi/1,1
en
o
POLLUTANT PARAMETER
37. I.Z-Dlphenflhrdrar.en*
30. Ethrlb«nzen«
39, F p. mri.nl V>-
__Uj JL-CbloroiAetiil _BKfl»l_EUK
(1. l-Bmortieofl FtreniXJUbe/
«?. bl3-(?-Chlorol90Droi>Tl)
ether
*3. bl8-(2-chloroelhoijr)«ieth.
M. Nehtjlen* Chloride
ft. Hethjrl Clilorlde
46. Hethjrl Brould*
*7. Dromror*
*8. DIohlorobrcMKMiethanv
49. Trlchlorofluoro«»aettloroflfclop«Titadlefl«
0001



0.049
r



tie










TrpAlcil
NA
HA
NA
NA
NA
NA
NA
NA
NA
HA
NA
NA
NA
NA
NA
NA
NA
NA
0002



01,036








.






Treated
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
15220
Raw

*
<0.39





0.02










•
«
<0.097


0.003


O.036









6906


•
0.026





•












•





0.013























































































l*>. of l-l.inli
Wltor4 KotHHl


2
4
















1
2
2


A


2





-




-------
                                                                                     TABLE V-29

                                                    MUOWITY  PUUJITANT8 IN FERROUS rOUHDHY  HELTINO rtlHNACK SCRIIIIHKR OI'KIIATKMS
                                                                           (M.I. umrMfUiATliHi!!  IM n:/l.(        	
r\3	rrj_zt.—-
POLLUTANT PARAMETER
5* JaniihoraM
. !A..lla|ihUialeiM .. .. .
56..Hltrut>uiunci. .
57. Z-MLroubeiiol
. 5». 4-Nltroubcfiul

60. «,»-l»ln|lnt9-sr«9l
61. N-nllrosodlBethvlaBliM
62. N-nllroMHll|>lietif laailn;
6). H-nltrosodl-N-p-oprUejIi
64. renlairliloro|4ieiKiI
65. Itienul
66. l>J9-(2-elliylheiyl)|>l>U>a
.«. fcilyl .Benzyl .niLlialate.
68. Qj-N-pvlyl riilliaUla
69 l>l-a-=$iQt.vl FliUiAlfltfl
70. Ulellvl fhltalale

ooc









e
O.J40
O.Of.l
»B«17
0.049
O.021
O.I 111


11
Ti oal cil
NA
NA
NA
HA
HA
NA
HA
NA
NA
IIA
NA
HA
NA
NA
NA
HA
NA
NA
0002





0.051
0.044






0.14
0.072
0.021



Treated
IIA
HA
HA
NA
NA
NA
NA
NA
NA
IIA
NA
NA
NA
IIA
HA
NA
NA
HA
15220
Maw



-------
                                                                                   TABLE V-29
                                                    PRIORITY POLUrTANTS  IN FERROUS FOUNDRY MELTING FURNACE SCRUBBER OPERATIONS

                                                                          (ALL UIHrENTRATHWS IN Mi/l.»
                                                                                                                                       Page 5
ro
tn
ro
POLLUTANT PARAMETER
12. RMMinfa )•«• brazen*
73- Itonro (») pyr**"*
7^. V<-B«ninfliinr«nt.h»tui
J5, _Braso(k)fJjiocuabene__
76. CtirraeiM
77. Acvnaplilhflene
70 • Anlhncene
79- P^nio(iJ.II,I)Ferylene
80. Film-em
Bl. Ptmianlhreiw
8?. Dlbenzo(a.hl*nlhr«ceiM
6). lntf«io( l,?,3-cd)prren«
8*. rrrem>
85. Telrachloroethjlene
86. Tolumw
87. Trlchloroethjrlmte
88. Tlnyl Chlorldfl
89. Ulrtrln
0001









— —


0.04





Tioaleil
NA
MA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0002







iO.OJl


•cO.OJl


0.074





Tienled
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
15220
Row
O.OO9



O.OO4
0

0.021
«
O.OO6
O.OO6
0.021
0.016
50.067

0.014
<0.067


0.027
QJU6. 	
0.026


Treateil





•
f

•
<•

*
	 BJU6_
0.014
0.018


•
Raw


















Tientr.l



















Raw


















TrAat«il


















Mi. of rlnntH
Hl*«*i«> FOIHM!
RAW
2
1
1
1
2
3

2
3


4

t
3

1
Ti entnl
1




2
2

2
2


2
.-JZ. 	 z.
2
2

1

-------
                                                                                   TABLE V-29



                                                    PRIORITY POLUJTANTS  IN FKRROUS FOUNDRY MELTING FIIRNACK SCRUWIER OPERATIONS
                                                                           (M.I. C»>K'E>ITI»\TIOMS IN Hi/1.)     	
rv>
en
OJ
POLLUTANT PARAMETER

. 90. niM^ii,
91- Chlnr«it»i»
92. «,«>-n>T
.^j^j^'-Jweip.r'-TDe)
9». »..V-W)D>. or
Nliotfl
Haw
3




2

1
1
J





1



Plant 4
P
-------
                               TABLE V-29
PRIORITY POLUITANTS IM rFRHODS FOOflDRY MELTING FURNACE SCRUBBER OPERATIONS
                       (M.I, CONCENTRATIONS IN Hi/1.)
POLLUTANT PARAMETER

109, PCD- 1232
110. PCB-1218
111. PCB-1260
112. PCD-1016 -*
113. To«»phene
129. ?,3.7.B-Tetraehloro-
dlhcnzo-P-dloln (TCDD)
1JO. Xylen«









0(


O.O2O















301
Ttcal 04!
NA
NA
NA
NA
NA
NA
NA
NA
NA







	
0002



















Tlenled
NA
NA
NA
NA
HA
NA
NA
NA
NA









15220
Haw


0.27















Treated


O.046





•









69Sft
KM


O.023















TrMtecl


«•





•























































































lt>. of rl.niln
MlmlA FiftllMl



4





2









TlCittt^l


2





2




.





-------
                                                                                   TABLE  V-29


                                             INORGANIC PRIORITY POLI.UTAHTS  IH PEMHOUS POUNDIIV MEI.TIMO FURNACE sctnnmrx MASTKHATERS


                                                             	(Obi. COMCeHTBATIOHS IH MB/I.)	
ro
in
in
POLLUTANT PARAMETER
AiitlBony
ftraenic
Asbestos
Beryl Hun
Cadntw
Cliroolim
Cn|i)>er
Cyanide (Total)
Lt-ad
Hercury
Hlckel
Soleiiliat
Silver
Tlialliui
Zliic
Hiwber X).1OO mg/t
58589
Max



•


0.17

40
O.OO7S
O.O6



8.5
)
. Treated



•


0.10
O.OO6
2.2
0.0025
0.1)5



O.76
1
56123
Maw



•


2.S
O.OOO1
54
0.0040




I6O
J
Treated



•


0.01
0.047
0.91
0.0041
0.01



1.5
2
55217
taw



•


0.37
;
9.O

0.090



22
}
Treated



•


0.01
0.0073
0.50
0. 00007
•



1.4
2
50315
Raw



•


4.4

29
0.006
0.91



87
4
Trflflted



•


0.09
•
1.4
O.OOJ
•



4.4
2
0001
Raw
2.4
1.2

0.016
0.62
4.6
12

25

0.55
O.22
O.OOS
3.8
no
10
nated
rut
HA

HA
NA
HA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0002
Raw
1.4
1.5

-(0)
2.2
4.2
5.5
O.O79
~19

0.43
1.2
O.O7

190
9
Trenr«»
NA
in

HA
NA
HA
NA
NA
HA
NA
NA
NA
NA
NA
NA
NA

-------
                                                                                      TABLE  V-29


                                              INORUANIC miORITY POLLUTANTS  IN FKRROUS FOUNDRY HALTING FURNACE Sl'RIIBBEP •-V-.STFWATBR

                                                                	(ALL COt rtMTRAT tOMS IN HC/M	
POLLUTANT PARAMETER

AntlHLMiy
Arsenic
Asbestos
fleryl 1 it*t
Cjcl-li-
I'lirowluH
Cufifwr
Cyanl.tr (Total)
Lead
Horrtiry
Nickel |
SelctiluM
Silver
Ttialllw
Zinc
Niotx>r JO.IOU mt/\
152
Raw
O.8
0.16


O.74
0.4)
3.4
n.i)47
100
0.0011
0.11

0.03
•
150
B
10
Treated
0.4
0.03

•
O.R4
•
O.22
0.164
8.5
O.OO11
0.13
4
*
•
190
7
695
Raw
O.9
'


0.63
O.20
1.7

140
O.OOO3
0.04


*
170
f>
6
Treated
0.4
*

•
O.O2
0.06
O.I
O.OB9
0.87
O.OOO4
O.04
*
•
*
1.7
4

Raw

















Treated

















Raw

















Treated

















Raw

















Treated

















Row















-

Treated

















Urn

















Tieatm
















r-o
on
CT)

-------
                                                                          TABLE  V-29


                                                     PRIORITY POLLUTANTS IN PRMOIIS rouMDMT su«! gop.MciiiHO OFRMTIOHS

                                                                      IM.L cum'BMnuvrtims IH M:/I.)
•age 1
ro
tn
—i
POLLUTANT PARAMETER
M • ACCIMpltUMflC
2. toroleln
3. terrlonltrlle
*. Benzene
5. Ifenzirtltt
6. CcrlMii Tetrachlorlde
T. Chlorobentene
8. 1 .Z.H-TrlGblarobenxeM

10. 1.2-DlchlorooUniM
11. 1.1.1-TrlchloroettaM
12. IteiaehluroathnM
13. 1.1-DlehtaroethaM
1*. 1,1,2-TrlchlaroethMM
15. l.l,?,20TatrachloroethM
16. Cblnroettom!
IT. Mn-Jcliloro wtlvl )»t.hn
Id. bl9-(2-ekloroellqrl)ethei
15520
Urn
0.02


0.10

0.02




O.O6


0.02
1



Ti natixl
0.027


0.06






(I.O4







69S4
RAW
•




•




•







Tieated
*


•






u.uuo








Kw


















Treated



















MM


















Treateil


















.
Him


















Treated



















HIM














™



Ttaatwl


















Ifc*. of Plitntii
Mll«l« Fnund
fa*
2




2




2


I




Treat ml
2


2






2


„





-------
                                                                                TABLE V-29
                                                                                                                                         Page 2
                                                         PRIORITY POUJITMrrS IN FERROUS FOUNDRY SIAG QUKNC1IINR OPERATIOHS

                                                                           (M.I. OmcFHTRATIUNS IN Hi/1.)
ro
en
oo
POLLUTANT PARAMETER

19. 2-Oiloroethfl »ln»l Ether
20. 2-Chloronaphllialene
21. 2,4.6-Trlcliloroplienol
22. Paraclil«-»flacr«9ol
23. Clilcnofor*
24. 2-Chloro|*ienol
25. 1,2-Dlchlorobenzene
26. l,3.-Dlclilarobenzene
27. l.4-l>lchlorohenzene
26. 3l3-Dlchlnrobenzlro|»ropane
33. l,2-Olrhloro|M-op)flene
3*. 2,»-DI«w»tlijri Ptn-nol
35. 2,1-Dlnltrotolii>Tie
36. 2,6-Dlnllrololuem
1552
RAW


o.oa
0.12
o.oa
0.02






0.02


o.or,


D
Tl n,ij *M!


0.051

0.21
O.O4






O.O1


0.04


69 5<
R.i-





.









0.011


I
Tieated




.
•









0.016



Raw



















Treated



















Pa*



















Treated



















Raw



















Treato.1



















Rnw



















Treated


















Mi. of
Mm re
H.IW


1
1

2






1


2


rlniirn
Trnar.^1


1

2
2






1
-

2



-------
                                                                                  TABLE  V-29
                                                                                                                                            Pago J
                                                           PHIORlTf POLUITANT3 IN FRHHOIIS FOUNDRY SLAG OtlKHCIIINT. OI'KRATIOtlS
                                                                             (M.I. row:KIITPATIONS IN rt:/M
ro
en
10
POLLUTANT PARAMETER -

3T. l,2-IM|iheiirlhydri«T.one
J«. Blliflbcnzcne
39. riunpT»'hr>">
tt. _l-Cliloroi!tienrUh«niLEUx
Si. ilrRiiMKwheinl tlNorl Elhei
*.?,_ bla -J?-C!llQr«J»oprgpj:lJi
ether
43. bta-(2-chloroeUK»jr)MUv
M. Hehtfleiia. Chloride
*•>. Methyl Chloride
«6. Heihyl Bromide
*7. DroonforB
48. D 1 Hi 1 oroN-onoaet Imna
49. Trldilnroriuoron«lhiine
50 _ Dlohlorodiriiioroaetliana
51 Chlorodlbromwthiine
0?. llexacliloroliutadlene
53. lk>iiaclilorocyclo|Miitadlene
155
H.w


0.051
r



ne
0.47



0.037





20
Tvriiteil


0.072





o.n



0.021





69S6
Raw


•





0.001










Treated
•

•





0.012










Km



















Treated



















HIM



















Treated



















Haf



















Treat*il



















Raw















-



Treated


















M>. nl
MlK>r«
H.IW


2





2



1





flMiln
finuut
TlP.llnl
1

2





2



1






-------
r>o
01
o
                                                                                    TABLE V-29



                                                            HHIOIIITY  POI.IJITAHTS IN rEKHOUS ffldNOHY SIM fMKHCIIIMG OrtHATIDHU

                                                                                (M.I. CONrKCTHATIIlNS  IN Hi/I.I
Pd-je 4

POLLUTANT PARAMETER -



57. ?-Nllroulienol

W. 4.6-l>lnlLroi4i«iol

61. H-nllro3uill««lh}lHaliHi
12. N'lillroaodliilwnf laailn;
63. N-ultro:iodl -W-pi'i>|,jf laali
64. fuiilanliluroHicnnl
. 6f, Kulrl Benzyl FlitlialaU .
60. H|-K-Hyl,l rtiUulale
(•1 lil-it-»:|»l llilhalalD
. 70. Wcllifl llillialaLe
. .71. l>l»elli)rl FbUulale . ..
15520
H.I-

a. 02

O.O4

O.O2
0.112

1.4
e
O.O21
0.1
1.2
0.02
0.11

O.OJ'J

noat.,.1

.O.Oi . -
O.04


O.O4

0.18

0.027
O . Ollf)
o.orw
O.O27
O.O7D

O.O2

6'^
H.IK
.
^
.





.



-(01
-KM



0.024
56

A
0.002






.



0.011
A
•

O.OIH
.

B..-















	
Trisatoil















	

Haw


















Tr <•;>(<•.»



















R«l
1
2

J


1

2

1

2
•2 -
2

.1 	 .

-------
                                                                                TABLE V-29
                                                       PRHWITV PoturrAHTs IN rRHMiis roUNMir SUMS uowrinnr; CIFRKATIUHS
                                                                          (MM, UWKWTRATKIMS JM HVl.)
                                                               ..-_.- -—_ - _..__—, • •—— -•• I. i M--^roff-f ifc. L ar — •  -— - - • • -  — -••-
ro
POLLUTANT PARAMETER
72. Pmu)(a)«DtlM^c*n«
73. Beoso.IaJ.pyrciM ..
_7)._3.irBeasonuaraoLbeM__.
. K,. Jciizo(k)riuarHillwM
76. Chr|raMM
77. AeeiwDblhvlcn*
. 70. Anlhrcccn* .
_Ii:-B«n*o(O.H. Drerrlcna 	
BO. FlunreM
81. rtmianthrena
82. Dlbenzo<«.h)tbithmeene
83. lndenoMMM|
Rnw
1




2


2









Treated
1




2
1

2
1


1
2
2
2



-------
                                                                             TABLE  V-29
                                                                                                                                        Page 6
                                                       PRIORITY POLLUTANTS  IN fKRROUS FOUNDRY SLAR OUEIICIIING OPERATIONS

                                                                         (M.I. CUMTEKTRATIIINn IN KI/U
ro
01
rso
POLLUTANT PARAMETER
tO Dlolilrln
91. riilfvnitan*
92. •.,*'-DOT
_ 91. «.<--PPE(P.r'-Tl)E)
9<, ^'-DWHP.P'-TtiE)
95. 2-F4*lo3ulran-»lp)»
96. b-Endoauiran-Reta
97. Kodosullan Sulfate
96. Endi-In
99. Endrln Aldehyde
1OO. Iteptachlnr
101. lloptichlnr Epoilde
102. a-MIC-Alpha
1O3. b-W(C-bcla
10*. r-IMIC-(l.lnilnne)na«*a
I'l*;. p.-miC-DelU
106. rcB-i«?* ~t
iof. rcB-i25"i (
10B. K-B-I27I J
15520
Raw
0.02

0.02
0.02





O.02
0.02


O.02
0.02
O.O2

O.U2
Tl rnlfMl


0.02






0.02




O.O2
O.O2

O.02
69 56
R.i*
• *




• •
• •












Treal.ed

• »
« •

• •





0.02
«•
«*
0.01
* *





Rnw



















Tieated



















Haw



















TrcM Ofl


















f
nnw



















Treated




















Raw



















Trent e»l



















Nn. of IMnnlff
Hltoift rtnillil
R.iw
2

1

1
1








1



Tieal oil
1
2

1




1
1
1
1
1
2
1




-------
                                                                             TABLE V-29
                                                       PRIORITY POUUTMITS  IM rERROUS FOUNDRY SlAG yiKHCHlHT. OPERATIONS

                                                                         IAI.L UmCKHrHATIIINS IN
ro
en
co
POLLUTANT PARAMETER

109, KV-123? 1
no. rcB-»M |
15520
Hm


[ 0.02
111. fCB-1260 \|
112. rcn-ioi*
11]. Tourhnw
129. ?.J.T.«-Tetr»chlor«-
«lbenso-r-
-------
                                                                                    TABLE  V-29
                                                 ININHiKNIC PRIORITY POIXirTAIfrS IN FERROUS FOUNDRY SIAO OURHC1IIKG tWSTKWATRRS
                                                               	(M.L COMCKMTRMTIOlig III Bti/L)	
POLLUTANT PARAMETER
ftsbeato*
Cadailtn
ChroolUB
roM«tr
Cyanide (Total)
Lead
Hrrcury
Nickel
Selenlun
Zinc
•
1




51026
Raw






O.OOIS









. Treated




0.019

O.O006









15520
Maw
-
0.2
0.7O
0.3S '

6.1
O.CI021
0.04

25






Treated
-
•
•
*

O.S9
O.OO2
0.099
•
8.0






6956
Maw
-

O.O4

0.094
0.32
O.OO02
O.O6








Treated
-
•
•
0.007
O.JI
O.OO77
O.OO04
o.an
*
0.012







Maw
















Treated
















•
Maw
















Treated

















Maw
















Treated

















M.1H
















Tcentw
















CTl

-------
                                                                               TABLE V-29
                                                                                                                                           Pag*  1
                                                          PRIORITY rOUJUTANTS  IN FERROUS POUHDRY CASTING (JIIKHCH OPERATIONS

                                                                           (M.I, COWTHTHATIONS  111 Hi/1.)
no
01
POLLUTANT PARAMETER

1. feen.rf.lteM
2. Aoroleln
3. Acrrlonltrlle
». Benzene
5. Benzidlim
«. C«rl«n Tetrachlorlde
7. ChlorobenznM
8. 1,2,4-TrlchlnrolMnzeiM
9. Heiiaclilarobenzxiw
10. 1,2-Dlctiloroettuno
11. 1,1.1-TrlehlaroethaiM
12. Hexachloroethmw
13. 1,1-DlchloroethaiM
l«. 1.1.2-TrlGhlnroettafM
15. l,l,2,?OT«lr«chlor«'lhai
|6. rhloroRthniK
IT. Mn-teliloro Mlh<> 1 )M.lm
18. l.l»-(?-chloro«lhf Dellwi
156
R.w





•




•



t



&
floated



•

•




A







•
II«M



















Treated



















Maw



















Treated



















PM





.













Treated



















Raw



















Treated



















Rao



















Treat «l


















Nn. nf
Micre
RM





1




1







Flmlfl
PfMlml
Treated



1

1




1


-





-------
                                                                                  TABLE  V-29
Page 2
                                                           PRIORITY POUJITANTS IH KERROdS rtXINDRt CASTING (HIKNCII OI'UIATIOIIS

                                                                              (Al.l, CUM•ENTRATIONS IN «./!.(
ro
O1
POLLUTANT PARAMETER

19. 2-Chloro«lhjl Tlnrl Kther
2O. 2-ChlorotiRf>hlhalene
21. ?.*,6-Trlchlorophritol
22. Parachlof-aetacrcanl
23. ChlorororM
24. Z-Chloroplienol
25. 1,2-Dlchlnrobencene
26. 1,3,-Ulrhlorobcnzem
27. 1,4-DlchlorotanzeiM
28. J,3-Oldilorobeozlileti«
29. l,l-Dlchlorl
32. 1,2-Dloliloroprofwrw
33. l,2-Dldilorn|>rop|rlene
3<. 2,t-DlBi>lhyl P»M>nol
¥>. 2,^-Dlnltrotolucna
36. ?,6-l>lnltrutoliH>ne
156
Raw


•









•





5*
Treat f* «l

•
•

•
•





•
*


•



R.iw



















Treated



















RAW



















Treated



















n«-



















Treated





/












r
H.I-



















Trentct]



















Raw



















Tre»te.1


















Nil. rif
MI»T«
Raw


1









1





I'lantn
Koiin.l
Troat c*l

1
1

1
1





1
1

-
I



-------
                                                                            TABLE V-29
                                                                                                                                    Page 3
                                                      PRIORITY nn.urrRNTs IN FERROUS raiNDRT CASTING OHKHUH IN OPERATIONS
                                                                        (AM. COWMfnWTIOIIS IN M:/l.)
ro     	
POLLUTANT PARAMETER
37. 1,2-Dlphcnjrlhrlriicnw
38. ethtlbenzene
jo.. Flwatt.'H'iMi
_ iD^L-ChlaroiilieiiilJCbeoil^Uv
_J1. ^DnMoriiaul rtwoil.ethei
*?, bl?-{?-P>«?r«l?PprS!PjU
•tlwi-
*3. bla-(2~dilaroethaK2)iH>th!
M. (Mitflene Chloride
«5. Helhyl Chloride
«6. Helhjrl Braalde
47. Brtuwfom
»B. nichlorobfoww-tlMiw
«9. TrlchlororiiioroBelhane
50 _ DIchloi-odiriunroBKlliane
51 ChlorodlhroHnKthane
58. Heiachloi-obiitJidlene
53. HexacttlorncjrclnfMmtadteiM
1565"»
M.1V



p



ne




•





Ti «•.!» vd


•





•










RAH


















Treated











«







ROM


















Treated



















RM


















Treat eil


















*
Rav


















Treated



















Raw
	
















Treated


















Mi. of Plants
MH>r« Punnd
Raw












1





Tiealwl


1





1





-




-------
                                                                              TABLE  V-29
Pai|« 4
                                                        PRIORITY POLLUTANTS 1H TEKROUS FWWtHT CASTING

                                                                          (M.I. UNKT.NTHATION3  IN Hi/ 1.)
                                                                                                            OTKRATIONS
ro
CTi
co
POLLUTANT PARAMETER
«;*. Iwtpiipfniui
SS. H.l|lliLhal«ui
30. Nltrobenznw
57. 2-Nltroohanol
58 , S-Bi IroplicnoL
59. *.6-DlnltrODh«nol
_ 60. «,6-Dlnllro-g-crf»ol_
61. N-nltrosalne
6?. N-nltroaodlption/laalne
6J. W-nltrosodl-H-propjr laali
64. rrntnchloroptMHiol
65. Ilicnol
. W . ,ble-<2-clh>lbfli»l)phtha
.67, Pulfl. Denzsl -FltUtalattt.
. M. B»rstpvi»i_n,iial«ta
.69.. Ulrik^-trl.nilhalatfc.
70. Plelhyl Phltalit*
71. Plpclbrl FbtbaUte _
ISfeS'*
H.iw





»



e


aU

•



Ticnlril
•
•










O.027

«

«


n.iw


















TioAtei]



















RAW


















Troatcrl



















Ra««





































•













































_-_.



	 — -


-






















>»>. of I'l.illlfl
Mi'*re t'«>iiiKl






1








1




1
1










1

1

1


-------
                                                                                TABLE  V-29
Page S
                                                        PRIORITY POLUITANTS IH FERROUS FOUNDRY CASTim QUENCH OPKMTIONS

                                                                          (M.I. l.tlWKMTRflTKItlS IH Mi/1.)
1N3

vo
POLLUTANT PARAMETER

72. Ben74>(a)antJirMMM.
1). Itonnt (•) pjrr«M
_II. B.L-BoitoriiKK-uiLtetM
75. Bcnxofklflunmithenq
76. Chr«9«M
77. AceiWDhthrlane
78. Unthraocm
19- Ihmcala.H.Drerrlaie
•0. FlaorfM
•l, rhmmthreiM
62. Dlbenxo(a.h)«ntlmiceiM
83. lnd«to(l.Z.J-od)pfr«M
8«. rrreiw
83. Tetr«chlomethylen«
86. Toluene
87. TrlchloroetlqrleiM
88. flnyl Clilarlde
89. *l5«t
TlCAtKll

A


*







•
•

•

• •

H.1V



















Treated



















Urn



















Treated



















HIM



















Treated


















.
Maw



















Trmioil



















Maw



















Treat eil


















Iki. of
MK»lfl
•JW
I

















rinnrn
F
-------
                                                                             TABLE  V-29


                                                     PRIORITY POLLUTANTS IH FERROUS rcJINOHT  CRSTTIW OIIFNCII OPERATIONS

                                                                        (M.I. CUWKm-RATKIN!.  IN
Paqe 6
ro
-~i
o
POLLUTANT PARAMETER

40. 0l«lrirln

, 92. •.••-DOT
91. *.«'-DOe(P.P'-TDE)
9», •.»'-UDHP.PV-TDE)
95. 2-Endosuiran-dlpha
96. b-Endosul fan-Beta
9T. Endoaulran Sulfale
96. Ehdrln
99. EiKlrln Aldehyde
100. lleptachlor
101. llnptanhlor EpoKlde
107. a-miT-«lpha
101. b-Dltr-tota
10«. r-BIIC.(Llndan«)Oi
-------
                                                                           TABLE  V-29

                                                    PRIORITY  POLUrTANTS IN FERROUS FOUNDRY CASTING QUENCH OPERATIONS
                                                                       (ALL cimrKwrnATiiitis IN
                                                                                                                                    tmqe 7
rv>
POLLUTANT PARAMETER


_JOJ. rCB-1232 |
no. rcB-izu 1
111. PCB-I?60 ^
112. PCB-1016 J
11). ToMphene
129. ?,3.7.a-Tetrachloro-
dlbcnzo-r-dloxln (TCDD)
130. lylme









1?
Kmi


















.&
TinAtPil


*•





•










RAM



















Trealp. of
MicfC
MM


















PlMltfl
K'HHHl
TceAtei!


1





1










-------
                                                                                  TABLE V-29


                                       IMORIJANIC PRIORITY  POLLUTMTTS  IM FERROUS FOUNDRY CASTING pUENCII AND MO1J) COOUNG HASTKWATERS


                                                             	(ALL COtlLT.rfrRATlOM5 IH IHi/L)  	
ro
^j
ro
POLLUTANT PARAMETER

Ant Iwjiiy
Arsenic
Asbeatos
Borrlllun
CajMliH
Chroolun
C»H>cr
Cyanide (Total)
Lead
Mercut y
Nickel
Selcnlui
Silver
TtiallluH
Zinc

15
Raw






O.O2
O.OO3








651!
Treated
«
*

•
*
•
O.O5
O.OO2
0.06
o.onos
•
*
•
*
0.14


Raw

















Treated

















Maw

















Treated

















Raw

















Treated
















.
Raw

















Treated

















Raw

















Treated

















R.1W

















Trcatni














-


-------
                                                                               TABLE V-29
                                                         PRIORITY POLUITMITS IN PBRROUS POUtflW SUM) MASHING OPRMTKIHS

                                                                          (M.I. CUnVKMTIMTKJUS IH
ro
—i
co
POLLUTANT PARAMETER
... _f i . **«n«|ilitlwn«
?. ftorolaln
3. HrrylowllrllB
4. Benzene
5. Bmxidlnn
6. Carbon Tetrachlorlde
T. Chloronenzefw
8. 1,2,4-Trlehlorabanzena
9. lto(Mdilorobeniaw
10. l.a.Dlchloroetliane
11. 1,1,1-TrlchloroettaiM
1?. HeMchlaroethnm
13. I,l-Dlctiloroeth»n«
M. l,l.?-Trlclilaroetlune
15. l,l.?,?OT«lr«ohloi-o«thiii
16. ChloroethaM
IT. Mn-IHiloio Mth«l )<-t.hei
|1. bla-(?-chlnrnethrI>etliei
15520
Maw

	
•

•








8



Treated
*






•


•







20009
KMW
0.01









•







Trenteil
O.OSJ


•






*








Mm


















Treated



















Pw


















Treateil
















	
«
Haw

















TreaLeil



















Hun


















Treat mA


















Nn. of Plnnlii
Mhrre rowtl
Hav





1












Troalnl
2


1



1


2








-------
                                                                               TABLE  V-29
                                                                                                                                         Paqe  2
                                                         PRIORITY rui MITHNTS IN FERROUS FOUNDRY SAND WASHING OPERATIONS
                                                                           (M.I. COIITKNTHATIKNS III HU/I.I
ro
POLLUTANT PARAMETER
_1J. 2-ChloroethTl Vinyl Ether
JO, J-CI)loronaplitha)ene
21. ?,<,6-Trlchlo.ojJ»ienol
22. Parnchloraetacreaol
23- Ch lorn fora
2^. 2*Chlorophenol
n. 1,2-Olchlorobenzme
?*. l,3«-Ulchlorobenzene
27. 1,^-Dlchlorobenzi-n*
?8. 3,3-DlchlorotMmcldene
29. 1,1-Dlchlnroethjrlena
30. l,?-Tranndlrhloro*lhrlen«
31. 2,^-Dlclilcn-optienol
32. 1,2-Dlrtiloropropaim
33- t,2-Dlchllnllrntolurm
15520
Ha«



•











•
•
•
Tl ('ill IMl

•
A

*
*






*


•


20009
R/IW












*




-------
                                                                            TABLE V-29
                                                        PRIORITY POLLUTANTS TH PKRROUS' POUNDM SAND WASHING OPERATIONS

                                                                        (AM. CUNTKHTRATKIH!) IH Mi/I.)
ro
—i
en
POLLUTANT PARAMETER
37. l,?-Dtphrn»lhydr«x«n«
». BlhTlbcnt«MJ
JO P|i»r.nLh«u>
_J9. JrOblarprtieiurl -ttemLEUu
11. «-PrMmAeiul.nien>l_EUKi
^. bla-(?-Ctilorol90Drof>tl>
ether
43. bl9-(2-cbloroellioi]r)«etlK
M. Hehtflene Chloride
<5. Hclhfl Oilorlde
W. Methyl DroMlde
*T. BronurofB
»B. ninhlorobrtMmwthMW
49. Trldilm-oriuorovethMM
i>l J.I ~tlrt ____«k.

51. ChlorcxIllirfMaKthane
5?. He«MlilarohuU
-------
                                                                             TABLE V-29
Paqc 4
                                                       PRIORITY POLHITAKTS IN FERHOUS FOUNDSr SAM) MASKING OH1HATIOMS

                                                                        (ALL (XHH KMTH/\TI(IMS IN K;/l.(
ro
~j
01
POLLUTANT PARAMETER
^. Iffofhornw
SS, M.|Alh.lM.
56* JllLrolMsn««««
. 57. 2-Mltroohenol
58. t-Nlti-oDlHmol
59. t.6-Dlnltronhenol
&°- li'-Pinllrs-e^sr^aol
61. N-nUroaodlKlhrlanlrM
67. N-nltroaodlphenrlaiiln«
6). N-nllrosoiH-M-proprlaBli
64. Pentachlorophenot
60. Phenol
	 ft . . tilar (2-eLbjrlhRifJJphlha:
67,_Pul»l Baizjil PbthaJata
68. DI-H-DuLtl PhthalaL*
69. Pl-fto.:lTl rtithalate
70. lUethfl PliU«Lite
JJ. Plaelhyl rbttuUte 	
15520
K.1H



•

	
•


e
•

aB*°°5





TI0.1(.M|

«
*


•
*



•
*
O.OI1
*
•

*
O.O10
20009
HAW




«
o.ooo





0.50
O.OO4
•
O.OOfl

O.003
O.OO)
Treated

0.021


•






0.67
0.071
O.OO7
O.O28

U.016
O.CM7

Raw


















Treateil



















DHW


















Trcrtleil



















R.w


















Tre»l*J



















Rfiw


















Treat »rt















-


Ni>. of I'i.intn
wlinio FfMiiifl
R.w



1
1

1





2
1




Tieal nV

2
1

1
1
1



1
2
2
2
2

2
2

-------
                                                                            TABLE V-29
                                                                                                                                      Paqo  5
                                                      PRIORITY FOIXUTAHTS IN FERROUS FOUNDRY SAND MUSHING OPERATIONS
                                                                       (M.I. aWCRHTIIATKINS IN HU/I.)  	
          POLLUTANT PARAMETER
     _72^fienzo(aJanlbracena-
     _ M.. 3. ^T
ro
•^j
-j
     Jo,. FlwreiN
     _82.  Dlben»o(«.h)«nthr«c«iie
       63.  lmleno( 1.2. }-cd )prren«
      86. Tolue-rw
     _B7. TrlohloroflUijrl
      88. Vinyl Chloride
      89.
15520
20
TicalfM)
•
•


•
•
<0.004



-------
                                                                            TABLE V-29



                                                      PRIORITY POLLUTANTS  IN FERROUS FOUNDRY  SAND HASHING OPERATIONS

                                                                       (AM. CUMTENTItATIOnS IN MC/I.)
Page 6
ro
-~j
oo
POLLUTANT PARAMETER
90 ni-tdrln
„ ChInmrt.M
92. *,1'-DDT
9J. ^'-DUetP.P'-TPE)
9*. I.V-DWKP.P'-TUE)
95. 2-Endo9uiran-Alph>
96. b-Endoaulfan-Bela
97. Endoauiren .lulfate
98. Emtrln
99. Endrln Aldehrde
100. Heptaclilor
101. ItepLachlor Epoilde
10?. a-RIIC-«lpha
103. b-BIIC-bnla
101. r-B1IC-(l.lnrtnne)rai»i
1O5. g-BIIC-DelU
106. ltn-lli'1 1
107. PCB-l?Ti1 |
ion. Pcn-1221 \
15520
IIJ1X



,
••


**
"










Ti onl ,.,!
• ft
A •
• *


"


• *
**
* *
ft*
* •
* *
*•

.-
20009
Raw
* *


















Tro.ited


« *
* *



•*
• *

• *
*•
••
••
*•
••

**


Rnw



















Tie.iteil



















R«x





































.











































	






























.^ 	


No. of Pl.ititn
Wtmte FIMJIH!














	 	




I
1
2
2


1
1
1
1
2
2
2
2
2
2

1


-------
                                                                        TABLE V-29
                                                    PRIORITY POLUrrANM IH FERROUS FOOHOUT SMffi WASHING OPERATIONS

                                                                    I M.I. cuwemiutTicms IN MB/I.)	
PO
>^i
10
POLLUTANT PARAMETER

109. rce-121? 1
110. PCB-I2W
111. rce-i26o
112. rcn-ioie
111. Tomipheo*
129. 2,J.7,
-------
                                                                                TABLE  V-29

                                                    PRIORITY PoijAfT/vHTs IN rwwoiis rrjunwiT KANO

                                                                       (M,I, cot*ciamu>Ttotis lit
ro
oo
o
POLLUTANT PARAMETER
Kntluwny
Ar**"nlr
Aithrstos lz*
B^ryl Miiw
r«lHliM
Chrom 1 tun
ropfwr
Cyan Mo (Totnl)
If**
H"rcury
Hlckol .
S«l»nfiM '
7.1nr



59101
Rnw



•



O.07fi

O.OOOOI






Treated



»



0.014

O.OOO3

^




51"»73
Maw



•


0.5O

Z.O
O.OOIfi
o.?o

4.1



Treated



»


o.so
O.OO3
l.ft
O.O03O
O.IB

3.J



51026
Km



•





O.OO1S






Treated







O.O'IB

O.OOI






15520
Pnw
0.3
o.noi
-




O.OO5
O.I
n.oool
«





Tr«"tcd
•
«
-
•
•
•
O.O7
0.02S
O.OR
O.OOI 3
•
ft
12



20009
Raw

O.O7
-


0.7
O.3
O.O1O

O.OO04
O.O10





Tieolr-
•
o.ol
-
•
n.oi
ii. 1
0.33
o.ot
0.43
o.ooo«
0.07B
•
O.73




-------
                                                                                 TABLE V-29
                                                     PRIOIUTT roi.timwTS IM Hir.MtsjOH rouNnnr
                                                                        IAI.I, CVNTMrrnATHINS  IM
                                                                                                   srwwnF.n
ro
00
POLLUTANT PARAMETER
£• RC^fW|HllllBIM^
Z. ftcroleln
3. ftcrrlonllrllo
4. Bmicene
5. Bon»i«11n»
6. Carbon TetracMorlda
T. rhlarobenzene
B. 1,2,4-TrlehlarolmnzMie
9. llpiiaehlarobenxnw
10. 1 ,?-Dlctllnrwthniw
II. l.t.t-Trlphlaroettane
17. HemirlilarfWtlmM
13. 1,1-Dlrhloro-thniM
1*. 1,1 ,?-Trlr*iloro«"lhi«n«»
15. l,l,2f?OT<)triicfilor*>eUMr
16. Chloroothnfw
IT. hl»-(rflloro «l!Hr.|)Mho,
Id. Mn-(?-rhloro«thyl)eth»i
814
MilW








•


•


i»



Ti nnl.pil
NA
HA
m
HA
HK
HA
HK
NA
HA
NA
NA
NA
NA
NA
NA
NA
NA
NA

RJW


















TlMl«wl



















Maw


















Trcnted





.













Fn-


















Trrntwl


















.
HUM


















Tr<«iit<>d



















Mm














	 _


Tr<«»l
-------
                                                                                          TABLE  V-29
                                                                   roi.iJirrArrrs IN MAGNFSIUH FOUWPHT GRINKIHT;

                                                                                (M.I. «X»WKWrnRTIOMS IN
                                                                                                                      OTOIATIOWS
ro
oo
ro
POLLUTANT PARAMETER

J9. 2-Chloro«lhTl Tlnjl Eth»r
20. Z-thlortnuiplithalFne
SI. 2,*,6-Trlchloror«wm>l
22. t«r»chlonret»cr^»o!
2J. Chlort>ror»
2*. 2-Chlorophcnol
25. 1 ,2-Dlchlorob*lr»>lorob»nr,»»H?
27. l,<-Dlchlorob«i7.ri»«
?'• 3,J-Olphloroh«iil<1tm«
79. !,1-I»lpll1oro<"l.hTlnw
JO. I.Z-Trnnrnltrhloro^lhylen*
31. ?,^-Dlchlornph«iol
32. 1 ,7-OI'-hloropmp>tn<"
33- 1,2-OlrhloropropylMH!
3^. ?,»-ni«-t.hyl Ptwnol
35. ?,<-ninltrotoliMn»«
36. 2,6-flnltrotoln"!!*
BUf
Dm






«













NA
NA
NA
NA
NA
NA
NA
MA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA

















































































n.i-



















Trrnlr.l


















-
Pnw



















TrMtrvl



















Bow














.



                                                                                                                                                                     ft*, rtf


                                                                                                                                                                      Wltf»r»»
                                                                                                                                                                             Fotltwl



                                                                                                                                                                             Ti r.il r*«l

-------
                                                                                  TABLE  V-29
                                                     rmoi»m roLumurn;  IN MARHRMIIN FOUNDHT GRiNniw:
                                                                         IAI.I. ciiNcRrrrnATKiNn in N:/I.|
ro
oo
CO
POLLUTANT PARAMETER
37. l.?-Dlpheny]hjrdrnzrne
38. Elhylbenzme

lO^JrChlflTonhcnilJPhenjUllii
	 91. t-BroBODheiul Fhenrl Ctbei
42. bIa-(?-Oilorpl90propjl)
ether
*3. bt9-(*-chl<>roethoiy)ii«UK
"*. ffphtylme Chloride
*5. Methyl Chloride
^v. Nel.hfl Brtwlde
*T. frnmofiyrm
•0. nirtilorohl imoa'thung
»9. TrlchlorortuoTo^lhnira
SO. OlrhlorodiriunrfHmMiHiw
51. ChloroHlliioimaii'tliatm
5P. lleii«*hlnfnliutjiifl«m«
53. n-Mrhlnrocrclopmbidl''!!*
R146
Row


0
r



ne
o.o«









Trp/il-,1
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
HA
NA
NA
HA

Rnw


















Treated



















Mnw


















Treated



















RIM


















Trrnle.1


















•
Mm










a^-







Trrnred



















Mnr.<>il


















t».. of i-l.inl->
Maw


1





1









Tteaf.!



















-------
                                                                                  TABLE  V-29
                                                     PRIORITY rot.urrANTS IN M ACHES urn rowNDRT nntNiiTMn prminnFR orFRATJONS
                                                                         (AM. cwiiwniATioNS IN M:/U
ro
00
POLLUTANT PARAMETER

^_i^hoponln«
6). H-nttromxII-N-propyliiMli
6*. rentachlorofihenol
65. rtM-nol
66. blD-(2-etbyJhnxyJJphtha
67, Outrl BenzTl Fhttwl»te_
68, ni-R-ButyUChlhalala
69. 01-n-nrlil fhthalile
JQ. Dlctb»LPhth«late
71, Dlnethrl HitlnUle
SI'










e


0.051
xLm
0
0



ir>

NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA

















































































Fw



















Trnn»«-,1


















,
Rnw



















Trp«»-«»i1



















Unw



















Tr*».tl ^il


















ik>. »r
Wlini«
Raw












1
I
1



rl ,tni n
Fofitnl
Tfnl »»
-------
                                                                                   TABLE  V-29
                                                     PRIORITY POI.UITANTS TN HAKNFSTIM raiNWRT OMNPIW;  WRIinnRR CIPF.RATtnllS
                                                                          (M.I, umcnrrnATiiiNS IN M:/M
ro
00
en
POLLUTANT PARAMETER

T2._Dffnrji(»)antt»-»cgn«
_73._0enr.o-(fi).pyn»ni» . .
_7^. 1.1-lk!nioriiiamntheim__
. J5, JtenxoOi ) fluoraithene
76. ChrT9«M

19. Rnthracem
.J9j.l»nnJ!o(fl.n. I tfrrflGnn
T80. Fltnrene
81. Phenanthren*
82. Dlbmc»U.b)«nlhrie«n«
8J. Inrt»no(I,r,3-cfw
88. *lnjrl ^l














-




-------
                                                                                      TABLE  V-29
                                                       PRIORITY roi.uiTAirrs TN MAGNESIUM m)HORT ORtNorw; w:nmit»rn
                                                                             (M.I. COHfHITRATIlHI!!  IN «:/!,)
POLLUTANT PARAMETER-

OU(P,P'-TDEJ
95. Z-Endoauiran-Mpha
96. b-Krnlos«iran-B«t«
97. Bn»fo9ulr«n Sulfat«
96. Endrtn
99. Eiwfrln *!<1»]Ui
106. pcn-i«?< 1
107. PO»-I?5* 1
ni
R.1V
..

.,

* •
• A



*•


..




..
if.
Trr.llr.l
NA
NA
NA
HA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA

Itw



















Trenlcd



















Rnw



















Trpsfw|



















H/T»






































f















































































tin. «r

i

i

1
1



^


l




1
Jiv















-



ro
co
01

-------
                                                                                        TABLE V-29
                                                         PRIORITY POI.UITftNTS IH HHlNfSJHH FOHNPRT nP.lNDING STOTIRnKR OPFRATIOIIS
                                                                               (M.l. fOWEWTIIATMllin III !«:/!.I
PO
CO
--J
POLLUTANT PARAMETER


109. PCB-1232
no. rco-uw
111. rCH-ITMI
11?. rcn-ioie -J
113. Toimphene
1?9. 2,J,T,H-Tetr»phlort>-
. nf
WlK-r*
n.i»


1





1









rl-inlt
^»MMItl
Tt »tnl *•*!















•



-------
                                 TABLE V-29
tnnnM. COMCnmWrlWW IM MB/I.)	
POLLUTANT PARAMETER

A-.be.to,
Copr-r
Cyanide (Total)
l«ad
H-rr,.ry
Selenlw.
Zinc
ro
00


1

•


m
Km

0.06

O.Ofl


1.2









»f>
Treated

NA
NA
NA
NA
NA
NA










Rao

















Treated

















Raw

















Treated

















Raw

















Trrtnl.ed
















.
Rav

















Trrafd

















Rav














^


Treat etl

















Rm*

















Ttenl^














-
_

-------
                                                                                  TABLE  V-29
PRIORITY rol.MTANTS IN
                     (M.i.
                                                                                       rf»INn*t mi!7T «rOf.t.RT|OH orrRATICNS
                                                                                             S IN
I\S
CO
IO
POLLUTANT PARAMETER

1 • Ac9mpti1.twfiv
2. •protein
3. •crrlonUrll«
"• W**tlX*?IIP
S. BensMInn
6. Cwrbon Telr«chlorl<1<"
T. ChlorobmznM
8. Il?l^-Trlnhlorab*n7.rn«
^. npvnctilorolMnx'wc
10. 1,7-PlrblortM-thanr
11.- 1,1,1-TrlchIm-o-thJ.iw
1?. Ni>nieMnro<>thnn<*
13. 1,1-nichlortmthmw
1*. l.l.?-Trlehlorllvim>
15. l,l,?,?WTetmchIom*ll»i
]K. Cliinrtlmie
IT. Mn-I«-(?-i!lilnnicth7l)<>lh»i
n\«
K.1H
n.nii


•










R



r,
Tl f»nl oil
Hl\
N/V
HA
UK
NA
IW
MK
NA
NA
NA
NA
HA
NA
NA
NA
NA
NA
NA

R.iw



















Tr«»tpd



















HIM



















Treatmt



















PlM



















Trp.ilvl


















.
KHW



















Tr>-lll«l



















Han>



















Tr»»lp«l


















N... of
Wwr«
l>aw
,


1














ri.-mi^
»'m>n.l
Tr-.il-.!














-




-------
                                                                                         TABLE  V-29
                                                                                                                                          »i* 2
                                                            PRIORITY  POLt-UTAWTS  IN MAGtlKSTJH rotlHORT WIST COU.FCTICW OPERATIONS

                                                                                 (AM. «x»NrrNTiiATi'iN5:  in n:/i.)
ro
10
o
POLLUTANT PARAMETER
19. 2-CMoroethyl flnyl Ether
20. 2>C!ilnronnphthalm«
21. 2,*,6-TrlchloroplmKFl
22. rarachloi •eturreaol
23. Chlortifor*
2*. 2-Chlorophcnol
25- 1,?-DlchlorobrnT.»m»
c6. l,3t-0lphlort>h«ii«i»
27. l,*-f»lchlorol>««n7.rti«
2". 3,3-'lt<'hI'Tob»nz1*"f>«
29. l,l-nirhlnrn»thr]rap
3O. I,7-Tr»nndlchlororopro|>jin<"
33. lt?-OI"hloropropf l«w
3«. 2,<-DI»wlhrl Phwiol
35. ?,^-nin1trntolii*«*»
36. ?,f.-Dlnltrololti»iw
0146
B.TW







•
•





— --


Ttf-.llfMl
HA
NA
NA
KA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
HA

n.iw


















Trpnled



















Raw


















Trentwl



















P.v


















Ttr.il n*l







































	

































.





















N». nf I'l.inl^
WHT** f'lHiiiil
n.iw







1
1









Tr-.ll »v|















-



-------
                                                                                     TABLE V-29
                                                        PRIORITY OTI.MITMIT* tH HAGNKSNIH rmnmur WIST cm.Mrrinn OPERA-I-TOMS
                                                                            (AM. fMM.r.NTItnTKItK IN N:/l,)
ro
<£>
POLLUTANT PARAMETER

3T. 1,2-Dlphenylhydrmtene
38. Ethylbeitzone


_Jl._«-"ro»w*wl nwnxl _Elh«i
*Z. bl9-(2-Chlorolaoproorl)
ether
»3. bls-(?-chloro«lhoxT)M>th.-
«. MHitrlene Chloride
*5. Methyl Chloride
DA. Methyl Oroaldo
4 T . Bronorom
*B. IHcMm-otii umm'l.tmn*
*9. Tr Ich lorof luoi-oiBithaiHi
5fl _ Dlchlorodiriuoronrt.hntm
51. ChlorofllbrpPnwtlHnq
5P. lk»xnvhlorohut*dl
-------
                                                                                      TABLE V-29
                                                         rnuwiTY rin.uiTANTS  IN HAGNKSIIIN rouNnpT WIST COU.FCTION OPERATIONS

                                                                             (IILK COWrNTHATKItK! IM Ht:/l.)
ro
to
ro
POLLUTANT PARAMETER

•>(- I*nflh«i-nn.
. ft. Naphtha 1 rne
TA . . Hi InibflnzmwL _
57. 2-NllroDltcnol
5"- *-»llrvr»ienol
59. ',6-Dlnltrortienol
60. 4p6-Dlnttro-9-cr«9o|
61. M-nttrosodliiplhrliiiiliTC
6?. M-nltroaodlphenylmilne
63. N-nUrosodl-H-propjInnl
6^. r. «r
WlHM ••


1

1






1

1

t

_JL

M.inlv
Klnlll.1















_




-------
                                                                                    TABLE  V-29
                                                                 roi.urriuiTS IN NAGHRSHM mnmnr OUST COM.HTION orn»ATioHS
                                                                            (AM. i.iiwMmiATiiiws IN M:/I.|
ro
vo
co
POLLUTANT PARAMETER

-J2._Brn7j>(»)»nthric*n«
_7_3._ Hmn>. In) .pyrem .
J'., J.^-Brniortuornnth«im__
-J5._Bro»o*t<*il












i" •' •"






Ms-



















TreatrH


















V
Knv



















Trvnto'l



















MAW















™



Trait erf


















It., of
WlK»r*
Mnw I




1
1
1

1



1

1



                                                                                                                                                                Ttr.nl "tl

-------
                                                                                     TABLE  V-29
                                                                                                                                 pig** 6
                                                         pptoniTT roujiTANTs in MAOHTSIUM FOUHDRT WIST COU.PCTION
                                                                            (M.I. COW TOT-RAT MlNS IN N:/|.)
ro
<£>
-P.
POLLUTANT PARAMETER
. 50. Dleldrln _
91. rhlnrnrtanlt
92. M'-WT
93. «.«'-DOK(P.P'-TOE)

95. 2-F.n!»iiran-ftlptM
96. b-&Hto»u>rwi-n«tji
97. Rhdoanirm Soir»le
98. Enrtrln
99 . &HIf" 1 o A liffffiyiw
100. n>ptjinhlnr
1O|. llcpln<-hlor Rpo
-------
                                                                                    TABLE  V-29
                                                                roLMmurrs IN Mivwrsum rniimuT OUST cnu^rrinH ornvmoHK

                                                                           (M.I, UIWr.Hr|IATI<>HS IN t*!/M      	
rsa
VO
tn
POLLUTANT PARAMETER

09. rcB-17?l
IW. rcV-1232
no. rcn-izM
111. ro>-i2«o
112. fCH-1016
1IJ. To«Mph«tM>
129. 2.5.7. B-Tetrachloro-
(Hhmzo-r-dloxln (TCPO)
130. lylme









(III
Mnw








•









6
Ti ml.ml
NA
HA
rm
NA
HA
NA
NA

NA










Haw



















Treated



















Urn



















Treated









,









"a-



















Treated


















•>
Haw



















Tr«-«tr«l



















HIM



















Ttealf~l


















N.I. 0
Kl»-r.
Hi»








1









                                                                                                                                                         Ivrr roitml
                                                                                                                                                              Tre.il "
-------
                        TABLE  V-29
rmoniTT foi,urrANTS m HV»RSIUM roumwY WIST roi.i.rcroR HASTEHMTRS
               (I\LL cofteEin-iumoMS in m;/i.) __
POLLUTANT PARAMETER -

tabosto*
Corpsr
CTanld« (Total)
l«ad
Hprcnry
S^lvnluo
7.lnc









RM
Ra*

O.O2

O.O3












f.
Tr*»l«tJ

HA
MA
MA
NA
NA
NA










Kaw

















Tteatnl

















Kim

















Treated
.
















M«w

















Tt«tat«I

















naw

















Tr«at«tl

















Mow

















Treat -.1

















Itnw

















Tt»»tr«














-


-------
                                                                                      TABLE V-29
                                                          ORGANIC PRIORITY  POI.I«TAKrrf(lN 7.1NC FOONDHV CASTIMR

                                                                                 (ALI. CONCENTRATIONS 111 HG/I.)
                                                                                                                   OTFRRTICHS
ro
iO
POLLUTANT PARAMETER
I AceMphtha*
i. Aeroleln
3. IcrylonUrll*
^» IWfflXCfW
5. BnniWliw
6. Ortmn Tetracdlorlda
T. Chlorabenxeim
•. 1,2,4-Trlehlarobmsem
y • ftoXM*!*! KOTO DCtlXCffM
10. 1,7-Olchlorwittaiw
11. 1,1,1-Trlchlorw.thntw
1?. Be»i»phloro<"thinm
13. 1,1-Dlnhtorocttaim
I«. 1,1,7-TrlHilaroellmiNi
' 15. 1,1,2,2 TelrKchlorw-lhsi
16. OilnrimMMiw
IT. MM-(cblara Mth>1)«lhm
18. bjB-iZ-chloroethflM.hri
10308
R.-~














i|



Trcnlcil


















18139
Mm
•

















Treated
*


















Dm


















Treated


















HI
tan



0.130

0.019




0.14*








Tre*t*il
NA
"4_
HA
MA
NA
NA
NA
NA
NA
HA
NA
NA
NA
NA
NA
NA
«
HAW


















Treated



















Km


















Treated


















Mn. of rimit^
Mw*t«* Pfmnif
MAW


















TrpMt rd
1









i
	 _

-




-------
                    TABLE  V-29




PP1PHITY rOU-UTMITS tN  ZIW FOUHrmY rUBTTNT.

            (ALL CONCENTRATIONS IH HC/L)
                                                                                                             OTFBAT1ONS
ro
10
oo
POLLUTANT PARAMETER
19. 2-Chloroelh»l Tlnjl Ether
20. Z-Chlot-nnnphlhaleno
21. 2,^,6-Trlchlorophenol
22. rBTBcblotTwtacreBol
23. Chlorofom
2*. 2-Chloroph«fK»l
n. l,2-01chloroh«nxen«
26. l,J,-niohlort>b«nxw»e
27. 1 . ^-Dlchlof ob^nignc
29. 3,3-nichlorob*nilil««»
29. l,l-Dlchlonwlhyl«i«
JO. l,?-Tmnfr<1lrhlir<7
-------
                                                                                   TABLE V-29
                                                         OflRANIC  mtOnlTY rOI.MITMITS IN ZINC ftUfNORV CASTtfK!

                                                                                 (ALL CTNCBHTMTIONS IN n:/L>
                                                                                                                 HFKWTfOMI
ro
10
POLLUTANT PARAMETER

3T. 1,2-Dlphniylhyilnizeim
3B. EUurlbeitMM
M FlunRmthOTi
_J9, JbCblocvrtMiulJEboiiUMii

5i. Chlorodllii ciimni>thiin«
V-- RnnchlorolNiljiillxHi
53- B*«»cWorocyclop«iUrtl^«
103C
Nnw


*
r



nfl
0.011










8
Tr-nl^.1








o.ro










181
Km


0.014
















39
Tr.ntM


0.01)





*











Rmr




















Tr«*t«I



















«77
K*.








0.290











Trmtnl
NA
HA
HA
NA
NA
NA
NA
NA
NA
NA
NA
NA

NA
NA
NA
NA
NA
NA

Raw




















TICK tod




















**•
















-



TmtM



















till. Of
N*v


2
















riml.n
Tronlnl


|





2











-------
                                                                                      TABLE  V-29

                                                        OPCANJC  PRIORITY POI.U/TRWTS IN 7.TNC FOUNDRY CAKT1MC yiFNTII OTFIWTKlHS
                                                                                      (AM, CONCENTRATIONS IN MT/I.)
             POLLUTANT PARAMETER-
CO
o
o
               ^JlltrobenznnR	
        __5L_Z=JUlronhenol_
        	58,_».-)Uicortien
-------
                                                                                      TABLE V-29
                                                          ORGANIC PRIORITY roUJUTAKTS 111 7.1HC FOOWIH1Y OWTIIIR OlIFMCII OPKHATIOHS

                                                                                      (All. COHCF.HTHATIOHS III HC/I.)   	
OJ
o
POLLUTANT PARAMETER

72. BrnmU >•">>•«"••>•
	 7J^ l*rww (•) pyr»iMi
7<. _3L_1-BenzQ£luoraothr.iw__^
_ 15.. B«uo( k)riuarant>*f|« .
76. CtirTaene
_77- •cen»ohth»l«n«
„?•. AnthraceiM
.79. Rmxofa.H.IlPerrlMHi ..

01. nienanthreiw
•2. Dlbenito(i,h)lnthr«cen«
8J. Inl«iM>(1.2.J-ed)prrfliw
8*. ryrem
95' Tetmchloroetbylen*
66. Toluene
•7. Trlctiloroetlqrlefw
M. Vlnrl Chloride
89. ftlnrln
10308
R.IW





*


*



•






Trrnlrrl






<•


« •








1813
Raw












•




•»
9
Tr*nt.fHl












0.020
0.031





Rnv



















TreRted


















Aft?
|im













O.IJI
0.027
0.230


I
Tr««ate
-------
                                                                                 TABLE  V-29
                                                               PBiomTT POMOTANTS  IN Tim ZINC ruwnnv cAr.Tinr: yiirwn orrwmoNS

                                                                             (ALL CONCENTRATIONS IN HC/1.)	
CO
o
ro
POLLUTANT PARAMETER

T
93. ».v-DOEfr.r-m)
9*. M'-DWXF.r-TDE)
95. J-Endomilfwi-Alpha
96 . b-Fndonul fan-Beta
97. Emfoauiran Sulfata
96. Enrtrln
99. Enrtrln dldHiyrt*
100. Rrptachlor
101. neptnchlnr Rpotlite
10?. n-WIC-AlpM
103. b-RIIC-twU
I0<. r-HK-dlnafimflOmmm
105. n-miC-D-Iln
106. PCB-I»?»
107. PCT-175*
1
IVnw

**
**
**
**
**
*•

**
**




**



0308
Tr«»nt»vl

*4

**
**

**











181
RMW


**
**






**
**
**
**
**
**
r **
[with ion
59
TfMted










**


**
«*

1 **
|wlth ion

flm*



















Trc«t**l

















Hlth 10P
4f>?
H*w

**
**
**

**
#*
**



**
**

#*

/
j 0.043
7
Trpntrrt
NA

NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
.
HUM



















Trenlril



















HAW



















Treated
















/
101
l»». of
wtif r"
Pnv

1
I
1
1
1
1

1
I
1
1
1
1
I
,
1
1 .
f'l.1fll ft
Ffdiml
Tt<»rtl.r»fl

1


1

1

1
1


1
1
1 -

I
1 •

-------
                                                                                      TABLE  V-29
                                                                PRT'lBITV roi.HITAMTS  1M THK J!INC FOUNDRY

                                                                                   (ALL CnNcr.MT»ATION(l IX
                                                                                                              : 'JHF.HI1I orKHRTir»IS
O
CO
POLLUTANT PARAMETER

109. fCB-1221
109. FCIU1Z32 -
110. PCO-1Z*8
111. rCB-1260
11?. PCB-1016
11 J. Tiriaphene
129. 2,3.T.B-Tetn«chlorfl-
<1ltwnzo-P-dlo«tn (TCDI>)
130. Xjltne









10
Mm


















}08
Trrnt^il






































181
RAM


**









*





39
Trentmt



















Mm



















Treated


















462
Duo


JJ.054















1
Tr«>.tt^l
NA
MA
MA
MA
MA
NA
MA
HA










^
Mm



















Tri«»t«vl



















M«m



















Tr^»l-rt


















N». of
M1mr«
n.iw


I.















ri.tHi*i
KmttMt
Tre.tl.**«t


0











-




-------
                                                                                   TABLE V-29
                                                  INORGANIC PRIORITY
                                                                            B IN 7inc FOUNDRY CASTING PIIFIKII

                                                                         (M,L concrMTRftTioBfl IN nn/i.)
CO
o
POLLUTANT PARAMETER

ft^hcstr»«
Clirnwliim
Con»*r
Cynnl'lp (Totnl)
|<^Ad
Herc»iry
Nickel
?Vl?nliM
Zinc







10
n««

*
0.15
O
•
O
O.OJ
0
350







308
Ttc»t«^l

•
O.O5
O.OO4
•
n.nooi
0.12
ft
36







1
Haw

•
n
O.OO9
*
O.OOOJ
o
o
3.7







8139
Trented

•
O.O79
O.0079
ft
O.OOO9
•
0.0095
2. 1








Mm

















Trpnted
















*r,7
Raw



n.i»9
•



62







;
Tiwiited
NA
HA
tin
NA
NA
NA
NA
NA
MA








Raw

















TrpntoO

















F.iw

















Tr«nle
-------
                                                                                TABLE V-29
                                                               PBIDRTTT rwtMmins ulr.iHc mmm nw.Tt*: riimiwR
                                                                          (ALL COHCKKTRATIOM3 Ml HG/M
CO
o
in
POLLUTANT PARAMETER
I. Hcmphll^ne
2. ftcrolfttn
J. Rcrrlmltrll*
4. Henxm?
5. Bntcirfliw
6. dirlmn T*tr«chlortthmN>
n. l,l.?,70T«triKlilor"lh«
1H. lilB.(2-clilaroeUirl)vtlwi
18139
RAW
O.OJ7


*

•

1.0






"I



Tl "ill 


















Trt*nl-.*i1




	












»
Itmt


















Tt<»ii»r<1



















HIM















•


Treated


















IM. of rtmti
Mirr* Tnntvt
It-m
1


1

1

1





	



Trml "1
1


1















-------
                                                                                          TABLE  V-29


                                                             ORT.HNTC PBIOBITT.. POLIiUTANTS  IH 7.INT FrKIHDRr MELTIMi". FIJRHW.T  SCRtlBflERS
                                                                        	(ALL CONCENTBATIOHS IN MC/L	
OJ
O
CT>
POLLUTANT PARAMETER

M^_ 2-Cbloro«th»l »lnyl Ether
20. 2-Chloronaphth«lene
21. 2.4,6-Trlchloroptienol
22. Pirachlorvetacraaol
23. ChloroTorB
2^. 2-Chlorophenol
25. l,2-Dlchlorob<"ni€n«
2S. 1, J^-IMchlorolWTizpn*
2T. 1 . '-PlchJ m-oh"nr.»o«
28. 3l3-l'l'*l'<''''*'*n*l
31. 2,*-Dlchloroplwi»ol
3?. l,2-Dlchloroprt>iu»n<»
33- l,7-l>lohloro|»rop)rlrn«
3*. 2,<-ni«»thyl Itwnol
35. 2,*-Olnltrotolu»ne
36. ?,6-Dlnltrotolii*m
181
Raw


1.4
0.071

"






1.3


12
<0.nl7
AO.037
39
T» r.^t»»tl


0.6O

•







0.22


0.19
•^0.017
•a1, ol 7

R.1-



















Tre»»««
-------
                                                                                TABLE V-29
                                                       OHOMIIC pRicmm PCH.UITMITS IN sine ronnwr HKI.TINO niRwcK scwmneRS

                                                                             , CONCENTRATIONS 1M MG/I.I	
CO
o
—1
POLLUTANT PARAMETER
JT. 1 ,2-Dlphenylhydrir.ene
38. Ethylbcnzeira
JO. riimranLliMO
_JO,_lrCblor«iihenilJQMDrl-EUH
_Jl. *rBraxwhetuljrbcnfiJEUKi
«2. bla-UrClilorQlsoiM-jmr.U
ether
»J. bla-(?-ohloro«tho«T)iMttlv
M. Hehlrlene Chloride
*5. Hethjl Chloride
•6. Methyl BroBlite
*T. Bronofor*


M. Trlchlororiirarow>thiine
50. DIchlorodiriunramthMne
• 51. OilorodltiroxoMnthHne
V. H*XKchlorolwU»dl1


















MP. of PL-Mil <<
H|K
-------
                                                                                   TABLE  V-29
                                                                PRIORrrr roLumrrrs IN ZINC njmiunr HO/TINT: rimwrK SCRIIBPF.RS
                                                                  	(MJ. CONCENTRATIONS IN MG/I.)	
fnr," 4
CO
o
CO
POLLUTANT PARAMETER

S%. t«f.phoron»
Vtn Ibphthfllmt
56. MIM-ntMir.iiM
	 5T,. 2-RltroDhenal
56. 4-Hltrophenol
59 .^ * . 6-Dlnl tronhenol
W. ».6-DInHro-o-cre»ol
61. R-nltrmodlBethTlsuliM
62. R-nltrosodlptonrliBlnv
63. R-nltro8odl-M-propfla«li
64. Pentnehloroptienol
65. rh«nol
66, .bl9-(2-athylhRiyUphUu
67, _ ftitrl Beniy l_nitlnl«ta
68. Bl-M-Butfl Phthalata
69. l'1-n-ootil Fbthalata
	 10.. Dlelhrl fhttalflta
	 11.. PlMtbrl.AtlMUte. ..
181
RAW

3.3
O.O60






9

JO
»te.
O.OBO
•

0.11
o.iwm
39
Trewtml

•









2.}
5.5
O.O49
n.oTO

O.1H
n.u

RAH



















Trentet!



















Rm












•






Trrntwl



















RUM



















Trpatod



















Raw



















Trp»t«J



















Row















-



Treated


















fk>. nl
Mhr>r«
R.fw

1
1








1
1
1
1

1
1
rlniifw
Pntm*l
Tt«?»lr.l

1









1
1
1
1

1
„ 1_ 	

-------
                                                                               TABLE V-29
                                                                  rRionirr POI-UWWCTS IN r,inc FnwimT HF.I.TJHR nmwicB
                                                                        (M.L COHCENTIUVrlOHS IN MU/U	
CO
o
POLLUTANT PARAMETER '

_ 72. •MHM>» )«nHif «rTB»
_73..Bmiiu>- (nj.fif raM
	 J^._a.L-*anoriuoc«nthen«___
TL Jet«olk) auocantben«^__
7*. Chr*aeiM
77. HeeiwDhthTlem
7>. Anthriceiw
T9. VenzatQ.H.Iirerrleoa 	
80. Fluorem
91, PlieiiMithreiM
62. Dlbenro(i.h)*nthrieeira
83. Ind>>no(l.?.3-cd)p7r«ne
•W. Fyrene
85. T«traohloro«thjlcn«
86. Tolu*fie
87. Trlehloroothrlmw
88. Vinyl Chlorltfa
89. Klilrln
18
RUM
•



•
0.04]
SO.Oflft

O.04B
in.nefi


•

•
•


139
Tri*Mnl





+






0.017
*
•
•



Raw












«






Trrntml



















Hnv



















Treated



















Kx*



















TrMlcd



















Raw



















Tr^ntcd



















HIM















-



Treated


















»•. »r
Mi»r«
•av
1



1
I
I

1, „
1


1

1
1


rlimt-i
Fount
TlVfflrtt





1






JL
1
1
1



-------
                                                                                    TABLE  V-29
                                                        ORGANIC rHIDRtTY IMlt.t.UTANTS IN ZINC FrY  MKI.TIM; FURNACE

                                                                  	(ALL CONCENTRATIONS  IN  M«/L)	
CO
1—"
o
POLLUTANT PARAMETER
40. Dlnlilrlit
Ql- CMT^tann
12. ».*'-DOT
93. ».<'-POE(f.r'-TOg)
9*. M'-DWUP.P'-TDe)
95. ?-Endosul Tan-Alpha
96. t>-Cn«5o»ul Tan-Beta
97. Endosulfsn SulTat*
98. Endrln
99. Endrln DHpfiyde
100. n^ptachlor
101. B«?pi.»rhlor RfKnlde
1O7. •-miC-«lphii
103. b-mtC-hpta
101. r-ntir.(l.fn
-------
OW.RMIC
           TABLE  V-29

POWITMITS  IN 7,tMC r«IHOHY MKLTIMT,
   (MJ. COMCKHTPATIOtlS IN MG/U
POLLUTANT PARAMETER-

108. PCB-1221
109 1 PCB-1232 . 1
no. rco-i?w |
111. FCH-1260 \
112. FCB-1016 ^
113- Toufihviie
129. 2.3,7. 8-Tetmchloro-
dlbn»o-r-dl. of
MH>r«
Maw


» ...





t









1-l.inti
rnnmt
Ttnal «l














_




-------
                                                                                      TABLE  V-29


                                                             PRIORITY rotiJiTMiTS  IN 7i»c FOUNDRY HELTtur; OTEPATIOH


                                                                            IMA CPHt.KMI BATIOHS IM H(;/l»|
oo
I—I
ro
POLLUTANT PARAMETER

Mnhaotoa
ChrowltiiB
Cori-r
Cy>nl<1<>(Tutnl)
L»ad
Mercury
Nickel
Selenium
Zinc







11
Haw

•

O.OOB
•
O.OOOJ


19







)139
Trc«tpi1


O.OOO57
O.O071
•
O.OOO5
•
o.ww
11








Raw

















Troatcd

















Maw

















Treated

















Rnw

















Tr«»nl*
-------
                                                                                           PROCESS;
                                                                                           PLANT:
INVESTMENT FOUNDRY
(ALUMINUM)
4704
                                                                                           PRODUCTION:  5.0 TONS/DAY
                                                                                                       (4.54 METRIC TONS/DAY)
                                                                                                         SOLIDS  TO
                                                                                                         LANDFILL
                                                                                       ^SAMPLE POINTS
TO RIVER
 50 GPM
(3.2 I/sec)
                                                                                               ENVIRONMENTAL  PROTECTION  AGENCY
                                                                                                    FOUNDRY INDUSTRY  STUDY
                                                                                                WASTEWATER TREATMENT  SYSTEM
                                                                                                      WATER FLOW DIAGRAM
                                                                                                                     FIGURE  V-l

-------
                              TABLE  V-30

                     CHARACTERISTICS OF ALUMINUM
                INVESTMENT CASTING PROCESS WASTEWATER
          Plant 4704

          Production:     5 Tons Per Day
               Flow :     20,380 1/kkg
                         4,900 Gallons Per Ton

Pollutant                     Raw                 Treated
                         mg/1       Ib/ton    mg/1       Ib/ton

Total  Suspended Solids   930       38        83        3.2
Oil & Grease              18        0.74     10        0.38
Aluminum                   2.1      0.84      0.2       0.008
Carbon Tetrachloride       0.026    0.001     0.01     0.0004
1,1,1-Trichloroethane      0.14     0.006     0.046    0.0019
Methyl Chloride            0.040    0.002     0.034    0.0014
Trichloroethylene          0.069    0.003     0.078    0.0032

Copper                     0.45     0.018     0.083    0.0034
Zinc                       0.49     0.020     0.1       0.0041

pH                            6.6-7.5             7.1
                              314

-------
10
i-»
en
                                                                                      PROCESS: ALUMINUM
                                                                                      PLANT:  17089
                                                                                      PRODUCTION:
                                                                                                >110 METRIC TONS/DAY
                                                                                                > 100 TONS /DAY
                           10.853 JLfSGC.
                           (172 GPM)
                                                             52.244 i/SEC
                                                             (SM GPM)
                 DIE CAST
                    AND
                  QUENCH
                                    ALUM I POLY
                                    PecDlFBED
                                   FURNACE
                                   SCRUBBER
                                                      FLASH
                                                      MIX
                                                      TANK
          OIL
        SEPARATORS
            42.78* J/SIC.
IS.7S4J/SEC.  fe78GPM)
                                          DEWATEH-
                                                                                                       OVERFLOW
                                                                                                       IO.S98J/SEC
                                                                                                           GPM)
 CITY
WATER
             PISTON
              HEAT
            EXCHANGE*
                                                                   i>TO  LANDFILL
                               I/SEC
                           (70 GPM)
       NORTH CHLORINI BOOTH,
       HCAT EICHAN6ER5 FOR
       HRA. WAI MCLT OVT AREA
                                          SLUDGE SETTLING
                                                                             /^-SAMPLING  POINT
                                                                             IS.44i/etC.
                                                                            »4S GPM)
                                                                               ENVIRONMENTAL PROTECTION AGENCY
                                                                                             FOUNDRY INDUSTRY STUDY
                                                                                       WASTEWATER  TREATMENT SYSTEM
                                                                                             WATER FLOW DIAGRAM
                                                                    »OUTFALL
                                                                      O02
             NORTH SETTLING POND

                               OUTFALL OOI
                                                                                                    FIGURE V-2

-------
            ASSEMBLY AREA  OCA/MS
            NQN PDUMCCy

            WASTE TEEATMEffT AQgA
                           PROCESS'- ZNC  A  ALUMNUM FOlfCRf


                           PLANT:  13139

                           PRODUCTION2 Aluminum >30  tontAkn
                                               t>27  mtlric lom^oy)
                                        Zinc     >50 font/day
                                               (>l»5 metric tomboy)
      REOCLE TANfc
 K',
-Si
 *3

 $5
 » x*
r
-------
                                           TABLE V-31

                             CHARACTERISTICS OF ALUMINUM MELTING
                             FURNACE SCRUBBER PROCESS WASTEWATER
                           Plant 17089
               Plant 18139
t*J



Pollutants

Total
Suspended Solids
Oil & Grease
Aluminum
Ammonia
Cyanide
Manganese
Phenols
Sulfide
Copper
Lead
Nickel
Zinc
Production
Flow

Raw
JOS/1

48
13
4.7
4.7
0.004
0.06
0.840




0.26
: >110 tons per day
: >8,000 1/kkg
>1,923 gallons per ton
Treated
Ib/ton mg/1 Ib/ton

9
2
0.4

0.002

0.14




0.056
Production: >30
tons per
day
Flow : >3,000 1/kkg
>72]
Raw
mg/1 1 b/ton

9
3
0.4
0.4
0.015
0.02
0.032

0.04


0.11
gallons
per to:
Treated
mg/1

7
2.9
5
0.6
0.014
0.002
0.0044

0.057


0.065
Ib/ton













                                7.4
7.1
8.1
8.0

-------
CO
I—•
CO
                                                                                                           ALUMINUM AND ZINC
                                                                                                              DIE  CASTING
                                                                                                              10308
                                                                                                PRODUCTION' ALUMINUM > 20 TONS/DAY
                                                                                                                    P18 METRIC TONS/MY
                                                                                                            Zlne
                                                                                                                       TO CONTRACT
                                                                                                                       HAULER
                                                                                SULFUR 1C ACID
                                                                                   OIL SOLO TO
                                                                                   CONTRACT HAULER_JEJOSJ!NGJ
RECOVERED
ALUM
                                                                                RECOVERED
                                                                                ALUM
                                                                                                              PROPRIETARY
                                                                                                               COP^POUNOS
                                                                           RECOVEREC
                                                                             ALUM
                                                                             TANK
                                                                                                         GLYCOL, ETC. FOR
                                                                                                         REUSE
                                                                                                         IN PLACE FOR FUTURE USE
              PROPRIETARY
              IODINE
              COMPOUND
                                                                                 ENVIRONMENTAL PROTECTION AGENCY
   FOUNDRY INDUSTRY STUDY
WASTEWATER TREATMENT SYSTEM
    WATER FLOW  DIAGRAM    !
       TO
       LOCKED
       SWAMP
                INSPECTION  TANK

-------
Pollutants
Total
                                                         TABLE  V-32

                                            CHARACTERISTICS OF ALUMINUM CASTING
                                                 QUENCH PROCESS UASTEMATER
                   Plant 10308

                   Production:
                       Flow :
            >20 tons  per day
            >100 1/kkg
            >24 gallons per ton
     Raw
•g/1      Ib/ton
     Treated
mg/1      Ib/ton
                   Plant 17089

                   Product Ion
                       Flow
Raw1
 >110 tons per day
 >2,000  1/kkg
 >480 gallons per ton

            Treated
/ton   Kg/1      Ib/ton
                                 Plant 18139

                                 Production:
                                      Flow  :
Raw
 >30 tons per day
 >10 1/kkg
 >2 gallons per  ton

           Treated
ton   •g/1      Ib/ton



co
(0








Suspended Solids
Oil * Grease
AluMlniw
Aimnla
Cyanide
Iron
Manganese
Phenols
SulHde
Copper
Lead
Zinc
PH
58
139
5.3

0.01
4.7
0.56
0.066
37
0.07
0.44
9.1
8.6
4.9
7.1
3.5

0.00059
3.8
0.2
0.23

0.03

0.96
9.1
48
13
4.7
4.7
0.004

0.06
0.840



0.26
7.4
9
2
0.4

0.002


0.14



0.056
7.1
941
155
1.4
0.2


0.09
0.081
2.4
0.25

0.29
5.8
710
170
10
0.25


0.08
0.011
1.6
0.28

0.16
8.0
              Casting process wastewater pollutants

-------
_1
ALUMINUM
01

E CASTING
PLANT
ZINC
DIE CASTING
PLANT
1
| 47 GPM
A (3.0 l/s.c) ,
14 GPM
(0.68 1
PROCESS'-      ALUMINUM a ZINC DIE  CASTING

PLANT:        12040
PRODUCTION ALUMINUM  90.8 TONS/DAY
                     (46.1 METRIC TOMS/DAY)
           ZINC     11.45 TONS/DAY
	(10.39 METRIC TONS/DAY)
                                                                                                         Off
                                                                                                         TO RECEIVING
                                                                                                         TANK
                                                                                               RIVEH
              FILTRATE   |5-9 GPM
               PUMP     1(0.37 l/»«c)
                                                                                   ENVIRONMENTAL PROTECTION AGENCY
                                                                                        FOUNDRY INDUSTRY STUDY
                                                                                    WASTEWATER TREATMENT  SYSTEM
                                                                                          WATER FLOW DIAGRAM
                                                                                                          FIGURE  V-5

-------
                                                                   TABLE V-33
INS
                                                         CHARACTERISTICS OF  ALUMINUM
                                                        DIE CASTING PROCESS  HASTEWATER
                           Plant 17089
                           Production:
                                Flow :
       Pollutants
                           mg/1
Raw1
Total
Suspended Solids
Oil ft Grease
Aluminum
Ammonia
Cyanide
Iron
Manganese
Phenols
Sulflde
2 ,4-Trlchl orophenol
Chloroform
2 ,4-01 chl orophenol
2 ,4-Dlmethyl phenol
2-N1trophenol
2,4-Dlnltrophenol
Pentachl orophenol
Phenol
PCB 1242"!
PCS 1254V
PCB 122LX
PCB 12321
PCB 12481
PCB 1260f
PCB 1016J
Copper
Lead
Zinc
pH

110
504
0.9
0.1
0.007

0.04
3.25
0.5
0.5
0.267
0.71
0.1



1.14
1.4


0.87



0.84
7.4
 >110 tons per day
 >2,000 1/kkg
 >480 gallons per ton

            Treated
ton   mg/1       Ib/ton
                                               8.0
                                              10
                                               0.04

                                               0.004
                0.64
                0.4
                0.3
                0.42
                0.018
                0.025
                                               0.057

                                               0.11



                                               0.08
                                              0.64
                                                   7.1
       1
         Includes Casting Quench process wastewater pollutants

       2 Also contains die lube process wastewater pollutants
                                  Plant 12040
                                  Production:
                                       Flow :
                                  mg/1
Raw
     Treated
mg/1      Ib/ton
                                  Plant 20147
                                  Production:
                                       Flow :
Raw
535
707
3.1
0.5
0.007
1.0

0.087
36





5.9
7.8
0.034
0.0055
0.00008
0.011

0.00096
0.4





9.9
12
8.0
0.37
0.0023
0.04

0.069






0.11
0.13
0.088
0.0041
0.000026
0.0004

0.00076






1.739
5.619
10.43
18.6
0.01

0.014
66.3
2.3
17
2.3
1.8
4.8
43
                                    1.0     0.011
                                    3.7     0.041
                                       7.2
                                              0.15     0.0016
                                              0.04     0.0004
                                                  9.1
                                      0.49
                                      2.01
                                      1.63
                                       6.9
 >120 tons per day
 >40 1/kkg
 >9 gallons per ton

           Treated  (recovery process)
ton   mg/1      Ib/ton
                                                                                     3,072
                                                                                    26,757
                                                                                        16
                                                                                        16.76
                                                                                         0.046

                                                                                         0.5
                                                                                        82.13
                                                                                                93
                                                                                                15
                                                                                                14
                                                                                                19
                                            0.61
                                            2.95
                                            2.13

-------
OJ
ro
ro
                                IYDRAULIC OIL
                               COOLING WATER!
                                  SYSTEM
                   LEAKAGE
                   0 GPMIO I/SEC)
                     DIE  CASTING
                      MACHINES

                      \  PAN    /
       LEAKAGE
       0 GPM (O I/SEC)
                                                                                             PROCESSi    ALUMINUM DIE CAST
                                                                                             PLANT"      20147
                                                                                             PRODUCT ION:
                                                                                                   >108 METRIC TONS/DAY
                                                                                                    <>120 ONS/OAY)
DIE  LUBE WASTES
                  COLLECTION
                  SYSTEM
        CYCLONIC
\   / SEPERATOR
                                                                                                     PORTABLE TANKS TOi
                                                                                                     ©DELIVER DIE LUBES TO
                                                                                                         MACHINES
                                                                                                     (f) PICKUP AND TRANSPORT^
                                                                                                         DIE LUBE  WASTES
                                                                                                         FROM  MACHINE PANS
                                                                CITY WATER
                                                                0 GPM (0 I/SEC)
                                                                                                ENVIRONMENTAL PROTECTION AGENCY
                                                                                                    FOUNDRY INDUSTRY STUDY
                                                                                                 WASTEWATER TREATMENT  SYSTEM
                                                                                                      WATER FLOW DIAGRAM
                                                                                                                     FIGURE v-6

-------
                                   TABLE V-34

                          CHARACTERISTICS OF ALUMINUM
                          DIE LUBE PROCESS WASTEWATER
               Plant 20147

               Production:
                    Flow :
>120  Tons  Per Day
>20 1/kkg
>4 Gallons Per  Ton
Pollutant
Total Suspended Solids
Oil & Grease

A1 uminum
Ammonia
Cyanide
Magnesium
Phenols
Sulflde

2,4,6-Trlchlorophenol

Parachlorometa
  Creso]

2,4-Dlchlorophenol
2,4-Dimethylphenol
Chioranthene
Naphthalene
2-N1trophenol
2,4-Dinltrophenol
4,6-D1n1tro-o-cresol
Pentachlorophenol
Phenol
Benzo(a)anthracene
Acenaphylene
Fluorene
Pyrene

Copper
Lead
Zinc

PH
 mg/1

 2,700
 43,300

     23.
     24.
           Raw
                                             Ib/ton
      0.038
      0.22
    106.4
      1.8
     24

     11
     11
     16
      7.8
      3.0
     11
       .74
      3.0
     38
     62
      4.5
     20
      1.9

       .91
      6.0
      3.05
mg/1

3,072
26,757
     Treated
(recovery process)
 Ib/ton
    16
    16.76
     0.046
     0.5
    82.13
     5.2


     6


    57
    93
    15
    13
    14
    19
     0.61
     2.95
     2.13
           7.0
                                         323

-------
                                                                                          PROCESS:
                                                                                          PLANT:
                                                                                          PROCXJCTION;
 BRONZE FOUNDRY

 OUST COLLECTION
 19872
49 TONS/DAY
M0.8  METRIC TONS/DAY)
                                                                 CLEAN AIR
CO
ro
           OUST LADEN
                  AIR
               CITY WATER
        LEVEL CONTROL VALVE
                                                                                                                  TO LANDFILL
                                                                                             ENVIRONMENTAL  PROTECTION AGENCY
                                                                                                  FOUNDRY  INDUSTRY  STUDY

                                                                                                WASTEWATER TREATMENT SYSTEM
                                                                                                     WATER FLOW DIAGRAM
                                                                                                                    IGURE V-7

-------
^3 QPM
2.7 VMC
 33
          OUST COUKTM
           SdfUBBCK
              A*/
r,
-&—*
TRouqH
                                  USCD 4
                                  SAND
3PM
f/*ee

<
(
1
KUTAL
RECLAIM

               KCCLMMLD
               MfTAL
                               PROCCU s   COPPCM ALLOY TOUNDRY
                               PLANT:      tO»4
                               PROOUCTK)M<  64 MTrfclC TOM8|0*kY
                                          II TONS/DKY
              LAQOON  Nt I
LAOOON Nff t
          yjsraniKnx
           BCKUBBCK
            H* a.
                                                             55 QPM
                                      OQPM
                                      o f/<«c
  0.4/A.C
                                                                                          u
                                             LAQOON Nfl
                                 SAMPLWW POINT
                                                                                 ENVIRONMENTAL  PROTECTION AGENCY
                                                                                      FOUNDRY INDUSTRY STUDY
                                                                                  WASTE WATER TREATMENT SYSTEM
                                                                                       WATER FLOW  DIAGRAM
                                                                                                      FIGURE v'8

-------
                                                    TABLE V-35

                               CHARACTERISTICS  OF  COPPER  AND COPPER ALLOY
                                    DUST SCRUBBER  PROCESS WASTEWATER
                                    Plant  19872
                                                             Plant 9094
00
                Pollutants
Total
Suspended Solids
Oil & Grease

Ammonia
Cyanide
Manganese
Phenols
Sulfide

2,4,6-Tri chl orophenol
Parachlorometa cresol

2,4-Dimethylphenol
2-Nitrophenol
Phenol
Arsenic
Cadmium
Chromium
Copper
Lead
Nickel
Zinc

PH
Production:
Flow :

Raw1
mg/1







1
1










45 tons per day
Not Determinate
(internal recycle)
Treated
mg/1
710
55
75
0.344
11
2.6
15
.021
.041
0.084
0.079
0.170

1.2
1.2
52
16
3.1
1,200
Production
Flow

Raw
mg/1
1,600
21
3
0.087
1.9
1.7






0.12
0.25

330
110
3.1
730
71.4
tons per day (sand)
: 4,021 1/kkg
970
gallons
per ton (sand)
Treated
Ib/ton
21
0.17
0.03
0.00070
0.015
0.014






0.00096
0.0020

2.7
0.87
0.025
5.9
mg/1
2
0.4
0.2
0.001
0.1










0.16
0.081

0.45
Ib/ton
0.002
0.0005
0.0002
0.000001
0.00011










0.00017
0.000088

0.00049
                                                               7.4
7.2
7.7
                 Raw process wastewater  inaccessable  for sampling

-------
                        WELL
                       WATER
                                                                                             PROCESS!    BRASS. £ COPPER. FOUNDRY

                                                                                             PLAMTI     47J«

                                                                                             PRODUCTIONt»02 MCTWIG
                                                                                                      112   TONS/DAY
CO
ro
                      MAKE-UP
RECYCLE
SUMP
                                                                                            A
                                                   SAMPLING POINT
                                                                                                 ENVIRONMENTAL PROTECTION  AGENCY
                                                                                                      FOUNDRY INDUSTRY STUDY
                                                                                                  WASTEWATER TREATMENT SYSTEM
                                                                                                       WATER  FLOW DIAGRAM
                                                                                            UWN6-ZO-TI
                                                                                                                      FIGURE  v-9

-------
                          TABLE V-36

           CHARACTERISTICS OF COPPER & COPPER ALLOY
              CASTING QUENCH PROCESS WASTEWATER
          Plant 4736

          Production:
               Flow :
112 Tons Per Day
Undeterminable (100% Recycle)
Pollutant
Total Suspended Solids
Oil & Grease

Ammonia
Cyanide
Manganese
Phenols
Sulfide

Copper
Raw1
mg/1
Treated
 mg/1

16
                0.009
               <0.3

                1.1
Zinc

PH
                3.5

                8.1
1
  Raw and treated (settled) process wastewater continuously mixed
                          328

-------
                   MOLTEN
                   METAL
MOLTCN
 METAL
                                           DIRECT
                                            CHILL
                                           MOLDS
                    M.XI/MC.J2290PM)

                  MAKE-UP FROM  TREATED

                  WELL  WATER SYSTEM
PROCESS: MASS • COPPER FOUNDRY
PLANT: «»ot
PRODUCTION: >5oo METRIC TONS/OAT
            >550 TONS/DAY
co
ro
<£>
                                                                                                              979 t/SEC
                                                                                                               (23 GPM)
                                                                                         MOM - FOUNDRY  PLOWS
           ISO//SEC
     4—(2036GHM)
                                             A
                                                                                           SAMPLMO POINT
                                                                                          ENVIRONMENTAL  PROTECTION AGENCY
                                                                                              FOUNDRY INDUSTRY  STUDY
                                                                                          WASTE WATER TREATMENT SYSTEM

                                                                                              WATER FLOW DIAGRAM
                                                                                                                 FIGURE v-io

-------
                          TABLE V-37

           CHARACTERISTICS OF COPPER
            CONTINUOUS CASTING PROCESS WASTEWATER
          Plant  6809

          Production:
              Flow  :
    >500  tons  per day
    >600  1/kkg
    >120  gallons per ton
Pollutant
Total
Suspended Solids
Oil & Grease
     Raw
mg/1       Ib/ton
56
40
     Treated
mg/1       Ib/ton
20
 6.2
Cyanide
Manganese
Phenols
Sulfide
Arsenic
Cadmi um
Copper
 0.004
 0.09
 0.006
 1.3
 0.010
 0.11
 0.36
 0.002
 0.087
 0.004

 0.01
 0.04
 0.11
Zinc

PH
 2.1
     8.3
 1.4
     7.9
                        330

-------
                                TABLE.V-37  Cont.

                   CHARACTERISTICS OF COPPER
                     CONTINUOUS CASTING PROCESS WASTEWATER
               Plant 9979

               Production:
                    Flow :
Pollutant
Total Suspended Solids
Oil & Grease
9.3 Tons Per Day
8,710 1/kkg
2,100 Gallons Per Ton
mg/1

33
10
          Raw
                                           1
Ib/ton

0.0026
0.0008
                                                            mg/1
                    Treated'
Ib/ton
Manganese
Phenols
Sulfide

Copper
Lead
Zinc

PH
 0.035
 0.005
 0.35

 2.4
 0.13
 4.4
0.000004
0.0000004
0.00003

0.00018
0.00001
0.0003
     8.0
  Raw and treated waste continuously mixed during casting.   Treatment
  consists of only settling.  Process wastewater is recycled 100%.
                                   331

-------
OJ
GO
                                                                          PROCESS: FERROUS FOUNDRY (GRAY IRON)
                                                                          PLANT'  55122
                                                                          PRODUCTION:
                                                                             DUST COLLECTION' 7732 Metric Tons/Day
                                                                                            (8947 Tom/Day)
                               ELECTRIC
                            FURNACE  SHOP
                                                      MISC. DRAINS
                                                      8 COOLING
                                                        WATERS
                        (Non-Contact Cooling Water)
                            AT-lfC (20"F)
                        (5> 97 8 lAec (1550 gpm)
CASTING. COOLING ft
CORE ROOM AREAS
                                FUGITIVE
                              EMMISSION
                                 DUST
                             COLLECTORS
                          Rearculated
                          Dusl Cdlecled
                          Wat ir
                                                                                                       Oitchoroe lo
                                                                                                      Sanitary S«w«r
                                                                                                       SAMPLING  POINT
                                                   Ctean    „ .
                                                   Sid.     Solldl lo
                                                           Disposol
                                                                                                          ENVIRONMENTAL  PROTECTION AGENCY
                              164.1  l/iec
                              (2600 gpm)
                                                                                    FOUNDRY  INDUSTRY  STUDY
                                                                                 WASTEWATER TREATMENT  SYSTEM
                                                                                       WATER FLOW DIAGRAM
                                                RECIRCULATING WATER SUMP
                                                                                                                                 FIGURE  V-ll

-------
       136 I/SEC
       (2150 GPM)
    /-NUN
   /  COi

r/A-
                    NON-CONTACT
                    COOLING  WATER
                                          -MAKE-UP  FLOW
                                           AS REQUIRED
          63 I/SEC
          (IOOO GPM)
                                               35 I/SEC
                                              (55O GPM)
Co
CO
00
                                                                   -44 I/SEC
                                                                   (700 GPM)
'PROCESS;
PLANT:
PRODUCTION!
  DUST COLLECTION
                                                                                                           FERROUS FOUNDRY (GRAY  IRON)
                                                                                                           59101
                                                                                                SAND WASHING
6367 METRIC TONS/DAY
(70fcO TONS/DAY)
160 METRIC  TONS/DAY
(176 TONS/DAY)
                                                      MOLDING  S CLEANING
                                                       DUST  COLLECTORS
                                                      (12 INTERNAL RECIRC.
                                                        PACKAGE UNITS
                                                                                 LAGOON  *l
                                                                                          LAGOON *2
                                                                                                                     DISCHARGE
                                                                                                                        CREEK
                                                                                                                     107 I/SEC
                                                                                                                    (I70O GPM)
                                                                                                                POINT
                      l
               SAND  TO  REUSE
               IO  METRIC TONS/MR
                (II TONS/HR)
                                                  SUMP
                                                                                                 ENVIRONMENTAL  PROTECTION  AGENCY
                                                                                          FOUNDRY INDUSTRY STUDY
                                                                                      WASTEWATER TREATMENT  SYSTEM
                                                                                            WATER FLOW DIAGRAM
                                                                                                                        FIGURE  V-12

-------
                                                                                            Evoporotive
                                                                                              Lois
                                                  -Got Slr«om
                                                     Flow
PROCESS   FERROUS FOUNDRY (GRAY IRON)
PLANT1   57775
PRODUCTION;
  DUST COLLECTION:  34.9 Mtlric Tont/Doy
                    (38.5 Tont/Doy)
  MELTING: 23 Metric  Tom/Doy
           (23 Toot/Day)
00
00
                                                                        COLLECTION
                                                                            BOX
                                                                                  Solids to
                                                                                  Disposal
                                                                                 601 kg/day
                                                                                (1300 Ibi/doy)
          9.47 l/««c
          (150 gpm)
                                                                                         063 I/MC
                                                                                         (10 gpm)
                                 Solids to
                                  Disposal
                                673 kg/day
                               (1482 Ibs/doy)
                                                                                                               ENVIRONMENTAL  PROTECTION  AGENCY
           FOUNDRY  INDUSTRY  STUDY
       WASTEWATER  TREATMENT  SYSTEM
             WATER FLOW DIAGRAM
                                                                                                                                       FIGURE   V-13

-------
                                      NoOH
                                     X
PROCESS'  FERROUS FOUNDRY (GRAY IRON)
PLANT,   ,53219
PRODUCTION'
  OUST COLLECTION' 59 Molrie Toot /Day
                   (65 Tons/Day)
  MELTING: IZ.r Metric Tone/Day
           (14  Torn/Day)
         1.9 I/MC
         (90 gpm)
CO
CO
en
       City Water
         Supply
                              Solid* to
                              Disposal •*
                                                                 Discharge to
                                                                 Sanitary  Sawer
                                                                                                                    FOUNDRY INDUSTRY  STUDY
                                                                                                                 WASTEWATER TREATMENT SYSTEM
                                                                                                                       WATER  FLOW DIAGRAM
                                                                                                                   I         I         E
                             IGURE  V-14

-------
CO
CO
en
                                                                                                     PROCESS' FERROUS FOUNDRY(GRAY IRON)
                                                                                                     PLANT'   55217

                                                                                                     PRODUCTION •
                                                                                                       DUST  COLLECTION: 1897 Metric Tom/Day
                                                                                                                        (2091  Tom/Day)
                                                                                                       MELTING: 197 Metric Toot/Day
                                                                                                               (217 Tone/Day)
                                                                                                                              Evaporative
                                                                                                                                Los*
                   From Wet Wen
                   Ptant HHH-2B
                       Plant Water
                         Supply
                                                                                                                                Make-Up Water
                                                                                                                                a* Required
                                                                                                                       MOLDING AND
                                                                                                                        CLEANING
                                                                                                                     DUST  COLLECTORS
         OO
         SLAG CAR
      NOTE'
        Zero discharge  to receiving
        stream from plant HHH-2A  8
        HHH- 28
ENVIRONMENTAL  PROTECTION  AGENCY

    FOUNDRY INDUSTRY STUDY
 WASTEWATER TREATMENT SYSTEM
       WATER  FLOW DIAGRAM
   I	L_t
                                                                                                                                  IGURE V-15

-------
Co
Co
        .-   .2 I/SEC
        \ (5O GPM)
                                                       DISCHARGE  TO SANITARY
                                                       SEWER 2.7 I/SEC  (42 GPM)
                                                                                                  PHOCtSS:  FERROUS FOUNDRY (GRAY IRON)
                                                                                                  PLANT:    57100
                                                                                                  PRODUCTION:
                                                                                                    DUST  COLLECTION   1814 METRIC TONS/DAY
                                                                                                                      (20OO TONS/DAY)
                                                                                                    MELTING
                3\9 METRIC TONS/DAY
                (352 TONS/DAY)


X









                                                                                                                                DUST
                                                                                                                                 TO
                                                                                                                              DISPOSAL
                                                                                                   /\  SAMPLING POINT

                                                                                                   	»> EXHAUST GAS FLOW
                                                                      1.6 I/SEC.
                                                                      (25 GPM)     TO
                                                                               SANITARY
                                                                                SEWER
ENVIRONMENTAL  PROTECTION  AGENCY
      FOUNDRY INDUSTRY STUDY
   WASTEWATER TREATMENT SYSTEM
         WATER FLOW  DIAGRAM
                                                                                                          I        I        I
                       FIGURE V-16

-------
CO
CO
oo
                     MAKE-UP
                       WATER
                COOLING
                 TOWER
            COOLING WATER
             (CITY WATER)
                    I
                                              SLOWDOWN
            CUPOL A
    0 UENCHER
           WET  SLAG
           OUE NCHING
      MAKE-UP WATER
         (CITY WATER)
     SOLIDS TO
     DISPOSAL
                                                          VE N TURI
                                                             I
                                                                                            PROCESS:
                                                                         FERROUS FOUNDRY (GRAY  IRON)
                                      PLANT:      56771
                                      PRODUCTION:
                                       OUST COLLECTION

                                       MELTING
                       2277 METRIC TONS/DAY
                       (25IO TONS/DAY)
                       175 METRIC TONS/DAY
                       (193 TONS/DAY)
                                                                              AFTER  COOLER
                                                 SEPARA TOR
         H
                                                 SECONDARY
                                                 CLARIFIER
                                                    TANK
                                         HYORATED
                                          LIME
                            T
                         SOLIDS  TO
                         DISPOSAL
DRAG
        TANK
                                                       15.8  I/SEC
(250 GPM)
 75.7  I/SEC
                                                      WASTE  GAS
                                                        TO  STACK
                                                                      DUST
                                                                   COLLECTOR
                                                                     SYSTEM
                                                            MAKE-UP
                                                             WATER
                                                                                                            DRAG   TANK
                                                                                               SOLIDS
                                                                                               DISPOSAL
A
                                                                                    DISCHARGE  "TO
                                                                                    SANITARY  SEWER-
                                                                                      3.28 I/SEC
                                                                                       (52 GPM)
                                                            CAMPLE POINT
                                                       (I2OO  GI'M)
                                          -3.8  I/SEC
                                          (60  GPM)
                              DISCHARGE ELIMINATED AFTER  1974
                                                                                                ENVIRONMENTAL  PROTECTION  AGENCY
                                                                       FOUNDRY INDUSTRY STUDY
                                                                    WASTEWATER TREATMENT  SYSTEM
                                                                          WATER FLOW DIAGRAM
                                                                                         IGURE  v-17

-------
                                                                                                          GRAY IRON FOUNDRY
                                                                                                          15520
                                                                      20.2  /SEC. ADO
                  CUPOLA
                    GAS
                 SCRUBBCR
                                     CUPOLA
                                      GAS
                                    SCRUBBER
                                                                                                CITY WATER
                                                                                                EMERGENCY MAKE-UP
                                                                VACUUM
                                                                FILTER
                                                                                                               MOLDING TANKS
                                                                              TO LANDFILL
                                                                              19 TONS/DAY
                           BALANCE
                           TANK   A
                                                320 GPM
                                                20.2 I/SEC.
                                                              SPLITTER
                                                                BOX
                                                                                                                              -uncontrollec
                                                                                                                      moke vp to slog dnraler
                                                                                                                      274 GPM    """'••
                                                                                                                      17.31/SEC.
                                                                                                                               •
                                                                                 438 0PM
                                                                                 27.6 I/SEC.
                                   SECONDARY
                                  CLASSIFIER
                                        290 GPM
                                        19.8 I/SEC.
     SAND TO
     SYSTEM
                                                SETTLING  TANK *l
                                                SETTLING  TANK #2

-------
CO
-ti
o
EVAPORATIVE LOSSES 23 GPM
t i i L& (13 I/SEC)
CITY ^ ^ , k ^ t - , ^
(103 I/SEC) T Y Y
VAcuuta
FILTER" KILN DUST KILN CHnoMiTt
^ . " ^~ xV SCRUBBER COOLIR SCRUBBER
f ^ \% ^~~~~~~ ' " ' * i *
" FTI ,. .. 1
^ ' J. . -. .1 4.CHJ/SEC.
T, ^ LJ> ^/aec ^ ,, — (O4GPM)
SAND SAND A "^ C24 GPM) " ^ ^
1 WASHtR LSI |^T^ fc Pi - ' PI ^ A 1
WATER "i n n T i* /ft 	
1411
Q ~n •/ — —
N<5 DUST M«JDUiT N» IA DUST Nf t DUST '""/•»« rpi!rt
COLLECTOR COLLECTOR COLLECTOR COLLECTOR l ^ &PM'

xO. 55 QPM 1 ( rJO-ZSGFM
i ' ^ > .+18.05 GPM) ^ r ., , . T0

r\ /
POND N« *

A SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
FOUNDRY INDUSTRY 6TUDY
WASTE WATER TREATMENT STUDY
WATER FLOW DIAGRAM
1E7I/"*I inf~ V 1 O
-•— r lv?Ur\t * A"
	

-------
                                                                           PROCESS:  GRAY  IRON  FOUNDRY
                                                                           PLANT i  7929
                                                                           PRODUCTION:    *2 METRIC  TONS/DAT
                                                                                         123 TONS/DOT
                                                                                                       RECYCLE
                                                                                                        PUMP
                                                                                                           MAIfE-UP
                                                                                                           WATER
                                                                            ENVIRONMENTAL  PROTECTION  AGENCY
                                                                             FOUNDRY  INDUSTRY  STUDY
                                                                             WVSTEWATER  TREATMENT SYSTEM
                                                                             WATER  FLOW  DIAGRAM
                                                       /\ SAMPLING  POINT
OWST  6CRUBBERS
                                                                                                    FIGURE V-20

-------

diy j
Woler •—
j .
QUENCH ^
1 TANK
ELECTRIC 1
FURNACES «••{

p_______-__^
I— V- L V^-l f fS COMPRESSOR
C *, t; r T-

r \* •• • • ^
l-ci J-ci J a £
~i r n r=""~ i ^ ^
III ^ r^^ i r-
- ' c
1 CHILLER 1 r™iin "•-•-- —
i 	 	 y
»I
Q68 Ifsec- ^ 1
(100 gpm) r 	 ' 	 1
T-2
n H
* t
Emergency
Discturge to
Swuiury Sewer 8 1
(14
POLYME
. 1.
Wed
Wuler
I.L
a, :..: 	
DRAG TANK

r ^ ^
i • * #
T-3 \KAfi en/ DUST
^ — i ^ x — } Y**"3* ^^/
^. J ' ' *^ ir / \ / COLLE'CTOR
K - 1 |* M 7,31' " " ' '
0 gpm) ill \
1 (60 gpm)
COLLECTION
n
TANK
	 1 	 J
-^
- i — T n 1
(__ 	 '°
TI --- --1 - :c^
\^_ - — ^ i^ -i
SETTLING BASIN SUMP
— ^^
I
I
I
i— .

PHOCCSS' FERROUS FOUNDHY (STEEL)
PLANT' 51115
PRODUCTION'
DUST COLLECT ION'- SIT Metric Tont/Doy
(68O Tont/Day)
MELTING1 128 Metric Tons/Day
(Ml Toni/Doy)
SAND WASHING1 OS Metric Ton* /Day
(96 Tons /Day)
P-l
1 1 We"
City
Woler
I' '1
SANITARY :
I BOILERS
FACILITIES



/\ SAMPLING POINT
r r
j
Diicharg* to
Sanitary Sewer
ENVIRONMENTAL PROTECTION AGENCY
FOUNDRY
WASTEWATER
WATER


INDUSTRY STUDY
TREATMENT SYSTEM
FLOW DIAGRAM
i-i/^i ioi~ ir T i
1 IbUHL V /I

-------
U                                                                EVAPORATION
                                                                   LOSS
                                                                                     PROCESS:   FERROUS FOUNDRY (GRAY IRON)
                                                                                     PLANT:    50315
                                                                                     PRODUCTION*
                                                                                      DUST COLLECTION 980 METRIC TONS/DAY
                                                                                                     (64O TONS/DAY)
                                                                                      MELTINO        123. METRIC TONS/DAY
                                                                                                     u >
                              OAS
                         STREAM FLOW
                  36 TONS/DAY)
    QUENCH
     RINGS
                                                                                                              QUENCH
                                                                                                               RINGS
                                                            3.2 I/SEC
                                                            (50 0PM)
                           15.0 I/SEC
                           (247 0PM)
THIS PART  OF
PLANT  SHUTDOWN
             0.31 I/SEC
             (100 0PM)
                                                                                                            03.1 I/SEC
                                                                                                            (IOOO GPM)
                                                                                   17.7  I/SEC
                                                                                   (201  0PM)
                                                            14.9  I/SEC
                                                            (237 GPM)
               MOLDING A
               CLEANING
              OUST COLLECTOR
                                            NORTH  LAGOON
                                                                                                             03.1 I/SEC
                                                                                                             (IOOO GPM)
                                                                                  FROM PLANT
                                                                                   55217
                                                                                       ENVIRONMENTAL  PROTECTION  AGENCY
                                            SOUTH  LAGOON
 PLANT
 WATER
SUPPLY
5.7 I/SEC
(9O GPM)
 TO PLANT
    56123
                  1.9 I/SEC
                (347 0PM)
                                   NOTE:
                                     NO DISCHARGE TO RECEIVING
                                   STREAM FROM PLANT 55217        /^SAMPLING POINT
                                   AND smi s
         FOUNDRY INDUSTRY STUDY
     WASTEWATER TREATMENT SYSTEM
           WATER FLOW DIAGRAM
                                                                                           i
                          IGURE V-22

-------
          *
-City Wol*r Supply
CO
                    1
PROCESS1 FERROUS FOUNDRY (STEEL)
PLANT:   . 59212
PRODUCTION i
  DUST COLLECTION: 2612 Metric Ton*/Doy
                  (288O Ton*/ Day)
SOFTENERS OISPERSANT
B
^•M
ochwai
Mok«-
Woler
*
!

"P
CAUSTIC




COOLING ^^
TOWFR _
~
1 ' film i All ift
IjlOWOOWfl

1
/
/
J


DUST
COLLECTOR
1\
DRAG TANK
t-

solid* 10 •
)i*po*al T
K>82
I/tec
r:

j


Mti_iiM /j\
_|—

f '
o
?
o
ri m
^
1



^

•—WET SLAG
QUENCHING CYCLONE
_ SEPARATORS

	 u.9o wtcto opm)

[COAGULANT ACID " 	 3.2 i/»«e(9o gpm)
. \

P — 	 r— 34./ U*«c(990 gpm)
i i f /
— ... I - /\ /
                                                       DRAG, TANK
                                                                                      • Solid* to
                                                                                       Ditposal
                                  04O l/»«c(6.3 gpm)-
                                                    I
                                                  r
                                                      0.40 l/«*c (6.3 gpm)
                                                                                        ^SAMPLING POINT
                                                SETTLING
                                                  TANK
                                                                         A
                                                                  Solid* to
                                                                  Diipoial
                                                                                      Discharge la
                                                                                     Sanitary Sewer
                                                                                                              ENVIRONMENTAL  PROTECTION AGENCY
                                                                                                   FOUNDRY INDUSTRY STUDY
                                                                                                WASTEWATER TREATMENT SYSTEM
                                                                                                     WATER FLOW  DIAGRAM
                                                                                                 i         i         i
                             FIGURE  V-23

-------
            14.9 I/SEC	
       WET  DUST
       COLLECTOR
      WET  DUST
      COLLECTOR
             113.6  I/SEC
             08OO GPM)
                                  LIME
(230 GPM)
NON -CONTACT
COOLING WATER


.
                        PROCESS:    FERROUS FOUNDRY (GRAY  IRON)
                        PLANT:      53642
                        PRODUCTION:
                          OUST COLLECTION  109 METRIC TONS/DAY
                                          (120 TONS/DAY)
-113.6 I/SEC
 (I6OO   6PM)
                        154.B I/SEC
                       (2453  6PM)
SETTLING
CHAMBERS
^.SOLIDS tO
  DISPOSAL
 1.36 METRIC TONS/HR
 ( 1.5 TONS/HR)
                                                DISCHARGE TO
                                                SEWER  OR
                                                  REUSE
                                                           POINT
                                                                                 ENVIRONMENTAL  PROTECTION  AGENCY
                                                                                       FOUNDRY INDUSTRY STUDY
                                                                                    WASTEWATER TREATMENT SYSTEM
                                                                                          WATER FLOW  DIAGRAM
                                                                                                        FIGURE V-24

-------
                                                                         TABLE  V-38

                                                             CHARACTERISTICS OF FERROUS FOUNDRY
                                                              OUST SCRUBBER PROCESS WASTEWATER
                     Plant 57100
                                                                         Plant 15520
                                   Plant 6956
CO
-E=>
cr>
              Pollutants
Total
Suspended Solids
Oil & Grease

Ammonia
Cyanide
Iron
Manganese
Phenols
Sulflde

2,4-Dimethylphenol
Naphthalene
Phenol

Copper
Lead
Thai Hum
Zinc
Production: 500 tons per day (sand) Production: 3,700 tons per day (sand) Production: 230 tons per day (sand
Flow : 1,000 1/kkg Flow : 400 1/kkg Flow : 7,080 1/kkg
240 gallons per ton (sand) 96 gallons per ton (sand) 1,700 gallons per ton
Raw
mg/1
5,380
150
7.2
0.02
101
0.8
3.87







Treated1
Ib/ton
10.7
0.29
0.014
0.00004
0.202
0.0016
0.0077







mg/1
12,880
138
6.2
0.02
0.3
<0.8
4.12







Ib/ton
5.15
0.055
0.0025
0.000008
0.00011
0.00032
0.0016







Raw2
mg/1
440
11
16
0.007
21
0.68
0.29



0.11



Ib/ton
0.35
0.009
0.013
0.000005
0.017
0.00054
0.00023



0.000092



Treated
mg/1
41
2.7
17
0.074
3.4
1.4
0.23



0.02



Ib/ton
0.032
0.0022
0.014
0.000059
0.0027
0.0011
0.00019



0.00001



Raw
119/1
4,550
7
25
0.296
52
19
31.3
1.13
0.10
4.77

0.58
1.0
1.4
Treated
Ib/ton
65.2
0.087
0.35
0.004
0.74
0.27
0.43
0.02
0.001
0.065

0.008
0.01
0.02
mg/1
70
3
7.3
0.5
0.28
0.11
2.4
0.19
0.03
0.062

0.0060

0.024
1 b/ton
0.87
0.03
0.09
0.006
0.002
0.001
0.03
0.002
0.00013
0.00086

0.00007!

0.00031
                                      7.5
                                             7.6
7.1
7.3
             1
               Based on a treatment system effluent flow of 48 gallons per ton
              .Determined from two dust scrubber process wastewater streams

-------
                                                           TABLE V-38

                                                CHARACTERISTICS OF FERROUS FOUNDRY
                                                 DUST SCRUBBER PROCESS WASTEUATER
                    Plant 7929

                    Production:
                         Flow :
               123 tons per day (sand)
               11,979 1/kkg
               2,881 gallons per ton (sand)
Pollutants
Total
Suspended Solids
Oil 4 Grease
     Raw
mg/1      Ib/ton
               Treated
          mg/1       Ib/ton
1,496
17.96
599
14.4
Ammonia
Cyanide
Iron
Manganese
co Phenols
^ Sulfide
2,4-Dichl orophenol
Phenol
Arsenic
Copper
Lead
Nickel
Zinc
pH
49.4
0.0061

0.515
9.68
4.7
0.30
2.3
0.01
0.17
0.24

0.345
7.4
1.19
0.00015

0.0124
0.233
0.11
0.007
0.05
0.0002
0.004
0.0057

0.001

53
0.014

0.35
0.76
1.6
0.048
0.033
0.01
0.003
0.2
.

7.6
1.13
0.00034

0.0084
0.018
0.039
0.001
0.0008
0.0002
0.14
0.0048



                                                                     Plant 58122

                                                                     Production:
                                                                          Flow :
                                                                          8,547 tons per day (sand)
                                                                          1,214 1/kkg
                                                                          296 gallons per ton (sand)
                                                                Raw
                                                           mg/1      Ib/ton
                                                                          Treated
                                                                     mg/1      Ib/tpn
4,762
20.45
1,200
11.5
11.58
4.97
2.92
0.028
4,505
19.35
670
4.8
10.95
0.047
1.62
0.012
                                                                                                              0.0024
                                                                                                       2.86   0.069
                                                                                                       0.57
                                                                                                       0.7

                                                                                                        7.7
                                                                                          0.0014
                                                                                          0.0017
                                                                                                              0.0024
                                                                                                       1.6    0.004
                                                                                             0.39
                                                                                             0.49

                                                                                              7.7
                                                                                          0.00095
                                                                                          0.0012
  Raw process wastewater Inaccessible for sampling

-------
                                                                TABLE V-38  Cont.

                                                          CHARACTERISTICS OF FERROUS FOUNDRY
                                                           DUST SCRUBBER PROCESS WASTEWATER
Co
-fe
CO
           Pollutants
Total
Suspended Solids
Oil i Grease

Ammonia
Cyanide
Iron
Manganese
Phenols
Sulflde

Copper
Lead
Nickel
Zinc

PH
                               Plant 59101

                               Production:
                                    Flow :
                                                            Plant  53642

                                   176 tons per day (sand)   Production:
                                   3.790 1/kkg                  Flow  :
                                   110 gallons per ton (sand)
                                                           Plant 50315

                                   120 tons per day (sand)  Production:
                                   5,830 1/kkg                   Flow :
                                   1,440 gallons per ton (sand)
                               mg/1
                         Raw
     Treated             Raw
mg/1       Ib/ton    mg/1
               Treated             Raw
Ib/ton    mg/1       Ib/ton    mg/1
 1,207 tons per day (sand)
 5,000 1/kkg
 547 gallons per ton (sand)

           Treated
on    mg/1       Ib/ton
4,107
21
2.3
0.042
77
32
1.14




7.6
3.37
0.019
0.0021
0.000038
0.070
0.029
0.0010





4.6
11.6
0.57
0.019
0.29
0.392
0.0002




8.1
0.0042 20,032 240.4
0.011
0.00052
0.000018
0.00026
0.00036
0.0000002





55


793
42
1.98
0.94
0.71
0.70
1.3
7.8
0.66


9.52
0.504
0.024
0.011
0.0085
0.0084
0.016

46
6


1.7
.14
4.12
<.02
0.05
<.02
.09
8.7
0.06 1
0.008


0.002
0.00018
0.0055
<0. 000026
0.00006
<0. 000026
0.0001

1,650
17
2.5
0.016
232
7.7
0.15
0.25
2.38

9.5
8.6
16.4
0.17
0.02
0.00016
1.15
0.076
0.0015
0.003
0.023

0.694

64
2.7
2.16
0.023
4.5
2.06
0.15
0.021
0.5

1.8
8.5
0.64
0.027
0.022
0.00022
0.045
0.021
0.0014
0.00021
0.0046

0.018


-------
                         TABLE V-38 Cont.

                 CHARACTERISTICS OF FERROUS FOUNDRY
                  DUST SCRUBBER PROCESS WASTEWATER
             Plant 2009

             Production:
                  Flow :
   Pollutant
   Total Suspended Solids
   Oil & Grease

   Ammonia
   Cyanide
   Iron
   Manganese
   Phenols
   Sulfide

   Lead

   Zinc

   PH
433 Tons Per Day (Sand)
260.6 1/kkg
62.7 Gallons Per Ton (Sand)
     Raw
mg/1      Ib/ton
             Treated1
        mg/1       Ib/ton
10,910
     4
2.850
0.002
     1      0.0005
     0.037  0.000019
2.0
4.77
1.2
0.49
0.32
7.8
0.0010
0.00249
0.00063
0.00026
0.00017

Dust Scrubber process wastewater not treated before
introduction to POTW
                                      349

-------
                                                                       TABLE  V-38 Cont.

                                                               CHARACTERISTICS OF  FERROUS FOUNDRY
                                                                DUST SCRUBBER PROCESS WASTEWATER
OJ
CJl
O
                                   Plant 53219

                                   Production:
                                        Flow :
                                                            Plant  59212

                                   65 tons per day (sand)    Production:
                                   91 1/kkg                     Flow  :
                                   22 gallons per ton (sand)
                Pollutants
Total
Suspended Solids
Oil & Grease

Anmonia
Cyanide
Iron
Manganese
Phenols
Sulfide

Copper
Lead
Nickel
Zinc

pH
                         Raw1
                                   mg/1
     Treated
mg/1       Ib/ton    mg/1
Raw
                         Plant 55217

2,880 tons per day (sand) Production:
21 1/kkg                      Flow :
5 gallons per ton (sand)

          Treated2            Raw
     rng/1      Ib/ton    mg/1       1b/
82
2
3.95

0.026
0.17
0.64
5.8
0.06
0.1
0.05
0,15
0.015 20,795
0.00036
0.00072

0.0000047
0.00003
0.00011
0.001
0.00001
0.00002
0.000009
0.000027
14.5
51
0.07
710
8
2.17
3.2




0.866
0.0006
0.002
0.000003
0.03
0.00033
0.00009
0.00013




41
1.7
61.6
0.126
6.6
31
0.534
4.1




0.00017
0.00007
0.0026
0.000005
0.00027
0.0013
0.00002
0.00017




 2,091 tons per day (sand)
 1,312 1/kkg
 316 gallons per ton (sand)

           Treated
on    mg/1       Ib/ton
                                                                                                                       Analytical data not available

                                                                                                                       This 1s a 100% recycle system
                                                            7.4
                         7.3
                    6.8
                 Raw process wastewater inaccessible for sampling

                 Includes process wastewater pollutants from other foundry processes

-------
                                                                                    PROCESS'
                                                                                    PLANT:
                                                                                    PRODUCTION: >400 TONS/DAY
                                                                                               (>360METRIC TONS/DAY)
                                                                                FERROUS FOUNDRY
                                                                                6966
         SLUDGE
       SLOWDOWN
                    496PM
    ^» wm  s^^***.
   AZ.J vaxxY     \
  4^—fcLARrCRJ
              A
                     19960PM
                     000.8
UNDERGROUND^
SPRINGS
 II 0PM
(0.69
RUNOFF
 WATER
                                                               42 0PM
                                                              (2.6 I/SEC)
                POND
         &
                                                                               I5T3 0PM
                                                                    I/SEC)
                                   78
                                  (4.9 I/SEC)
                              OUTFALL
                                                                                        ENVIRONMENTAL PROTECTION AGENCY
                                                                              FOUNDRY INDUSTRY STUDY
                                                                          WASTEWATER TREATMENT SYSTEM
                                                                               WATER FLOW DIAGRAM
                                                                                                             FIGURE  V-25

-------
                                                                         Got Sfrvom
           Well Wottr
               Supply
CO
on
ro
                                                                                                          PROCESS'  FERROUS  FOUNDRY(GRAY  IRON)
                                                                                                          PLANT;    52491
                                                                                                          PRODUCTION:
                                                                                                             MELTING-- 8 M«tric TOM/Day
                                                                                                                      (9 Toni/Day)
                                                                                                                                         Evaporative
                                                                                                                                            Lots
          0.348
          (3.31 gpm)
                                                                                                                   FAN
                                        Minimal Ditcharg*
                                          By Evaporation
                                                                                                             SAMPLING POINT
                                • Discharge to
                                 Sanitary  Sewer
T Sol ids to
 Disposal

O45 Metric Tom/Day
11000 Lb«/Doy)
                                                                                                                ENVIRONMENTAL PROTECTION AGENCY
    FOUNDRY INDUSTRY STUDY
WASTEWATER TREATMENT  SYSTEM
      WATER FLOW DIAGRAM
                                                                                                                  1         I          I
                      FIGURE  V-26

-------
CO
in
Co
                                                                                                             FERROUS FOUNDRY (GRAY IRON)
                                                                                                             56789
                                                                                      PROCESS:
                                                                                      PLANT:
                                                                                                 PRODUCTION:
                                                                                                  MELTING
                                                                                                  67  METRIC TONS/DAY
                                                                                                  (74 TONS/DAY)
                                                                                       EVAPORATIVE LOSS
                                            GAS STREAM
                                               FLOW
                                                                                                                   STORAGE
                                                                                                                    TANK
                                                                                                                   56775 I
               QUENCH
                RINGS
                                                                                                               CITY WATER
                                                                                                                SUPPLY
                                                                               MAKE-UP
                                                                                 WATER
             6.31  I/SEC
             (IOO  GPM)
                                                                       4.4 I/SEC
                                                                      (70 GPM)
 23.7
(375 GPM)
                                                        MIXING
                                                        TANK
                                                                                            2.87  I/SEC
                                                                                            (45.5  GPM)
                                                                                                                           MIXING
                                                                                                                           TANK
                                                                                      1.3 I/SEC
                                                                                     (2O GPM) 1
                                                                                                         OVERFLOW
                                                                                                         TRANSFER
                                                                                                           TANK
                                                                          RECYCLED
                                                                            FLOW
                                                       .42  I/SEC
                                                      (22.5 GPM)
                                                                                                            SAMPLE POINT
                                                                               .14 I/SEC
                                                                              (18  GPM)   /3\
                                                                                         KNVIRONMENTAL  PROTECTION  AGENCY
                                                                                                          FOUNDRY INDUSTRY STUDY
                                                                                                       WASTEWATER TREATMENT SYSTEM
                                                                                                            WATER FLOW DIAGRAM
SOLIDS  TO
 DISPOSAL
                                      COLLECTION
                                         BOX
                                                                          0.28 I/SEC
                                                                          (4.5 GPM)
                                                                                                                           FIGURE  V-27

-------
           CITY   WATER
             SUPPLY
                                             3.2  I/SEC
                                             (50 GPM)
CO
en
                                                                                            PROCESS:    FERROUS FOUNDRY (GRAY IRON)
                                                                                            PLANT:      58589
                                                                                            PRODUCTION:     90  Tons/  Day

CUPOLA

t
	 • 	 ^


1 I
QUENCH
CHAMBER
i

i
n

— y"
L-GAS S
1 ' 1

VENTURI

TREAM

                                               FLOW
                            SOLIDS TO  DISPOSAL
                            1.36  METRIC TONS/DAY
                              (1.5   TONS/DAY)
                                                6.31  I/SEC
                                               (100 GPM)
ONE DAY RETENTION
   EACH  SUMP
 (109.765  I
  29.000 GAL)
                                                                         SOLIDS REMOVAL
                                                                          BI-MONTHLY
                                                            /\ SAMPLE POINT
                                                                                                ENVIRONMENTAL PROTECTION  AGENCY
                                                                                                      FOUNDRY INDUSTRY STUDY
                                                                                                   WASTEWATER TREATMENT SYSTEM
                                                                                                        WATER FLOW DIAGRAM
                                      1        I         I
                                                                                                                      FIGURE V-28

-------
                                                                                                  FERROUS FOUNDRY (GRAY IRON)

                                                                                                  56123
PLANT
WATER
SUPPLY
                    EVAPORATIVE
                     »5 I/SEC
                     (150 GPM)
S.2  I/SEC
(50 0PM)
                                                                                                  178 METRIC TONS/DAY
                                                                                                  (196 TONS/DAY)
                                                               3.2 VSEC
                                                               (50 GPM)
 O.63 I/SEC
  (10  GPM)
                                                                                     YDE-CRITTERS!
                                                                      C2.7 I/SEC
                                                                      (360 GPM)
1.3 I/SEC
(20 GPM)
                                                                                                               0.63 l/SEC-v,
                                                                                                               (10 GPMJ ^
                                                 WATER SEALS
                                                   MISC. DRAINAGE
                                             63.1 I/SEC
                                             (IOOO  GPM)
                                                                                              FOUNDRY INDUSTRY STUDY
                                                                                           WASTEWATER TREATMENT SYSTEM
                                                                                                 WATER FLOW DIAGRAM
    DISCHARGE
  TO SANITARY^
    SEWER
                                                                                                                FIGURE V-29

-------
    A
      ^COOLING WATER
       (CITY WATER)
                                                                                               PROCESS;    FERROUS FOUNDRY (GRAY IRON)
                                                                                               PLANT;     54321
                                                                                               PRODI ICTION:
                                                                                                    MELTING   9S METRIC TONS/DAY
                                                                                                              (IO5  TONS/DAY)
 CUPOLA
                                                QUENCHER
WET SLAG
QUENCHING
CO
01
o-i
                                                     VENTURI
                                                          I
                                                                         SEPARATOR
                                              MAKE UP WATER
                                              (CITY WATER)
      34.5 I/SEC
       (546 GPM)

COMPRESSOR —
COOLING
WATER
(CITY WATER)
                                                                                  I
                                                         I
                                                                  15.8 I/SEC
                                                                  (25O GPM)
                                                        SECONDARY
                                                        CLARIFIER
                                                          TANK
                                                             ,- SOLIDS TO
                                                               DISPOSAL
                                         ORAG  TANK
-?
                                                                                                                         WASTE GAS
                                                                                                                         TO STACK
                                                                                          75.7 I/SEC
                                                                                          (25O GPM)
                                                                                           ^-
                                                                                             HYDRATED LIME
                                                                                             A
                                                                                                                      SAMPLING POINT
                                                 TiSOLIDS  TO  DISPOSAL
                                                        ^-DISCHARGE
                                                          ELIMINATED
                                                                             ENVIRONMENTAL  PROTECTION  AGENCY
                                                                                                        FOUNDRY INDUSTRY STUDY
                                                                                                    WASTEWATER TREATMENT  SYSTEM
                                                                                                           WATER FLOW DIAGRAM
                                                                                 I        I        I
                                                                                                                          -IGURE  V-3Q

-------
rCooling Wot*
                   (City WoUf)
                                                                                             PROCESS: FERROUS FOUNDRY (GRAY  IRON)
                                                                                             PLANT:    52881
                                                                                             PRODUCTION:
                                                                                                MELTIN& 78 Metric  Tons/Day
                                                                                                        (86  Tons/Day)
                                                          SECONDARY
                                                         CLARIFIER
                                                            TANK
Make-up Wot«r
(City Wat«r>
From Plant
N< XX2A
           1
Ditchorg*
Eliminated
                                                                                                    L—Waste Go* to Stack
                              A
                                                                                                 SAMPLING  POINT
                                                                                                  ENVIRONMENTAL PROTECTION AGENCY
                                                                                                       FOUNDRY  INDUSTRY STUDY

                                                                                                    WASTEWATER  TREATMENT SYSTEM
                                                                                                         WATER  FLOW DIAGRAM
                                                                                                                         FIGURE  V-31

-------
                                                          EVAPORATION
                                                           2O- 35 GPM
OJ
in
oo
      CUPOLA
PROCESS;    FERROUS FOUNDRY


PLANT:      00001


PRODUCTION:  20 TONS/DAY
            16  METRIC TONS/DAY
                                                                                          CAUSTIC
                                                                                          ADDITION
                                                               TOTE BUCKET
                                                                 160 IbiYDAY
                                                                                   •LANDFILL
                                                                                              ENVIRONMENTAL PROTECTION AGENCY
                                                                                                    FOUNDRY INDUSTRY STUDY

                                                                                                  WASTEWATER TREATMENT SYSTEM

                                                                                                       WATER FLOW DIAGRAM
                         FIGURE V-32

-------
                                                                                              PROCESS:    FERROUS FOUNDRY

                                                                                              PLANT:      00002

                                                                                              PRODUCTION; 40 TON/DAY
                                                                                                         36.4 METRIC TON/DAY
to
CJl
vo
                 CHARGE
                                                                                                EVAPORATION
                                                                                                   74 GPM
                                                                                                   STACK
                                                                                                  DEMISTER
                                        TO LANDFILL
                                                                                                ENVIRONMENTAL  PROTECTION  AGENCY
                                                                                                      FOUNDRY INDUSTRY STUDY

                                                                                                   WASTEWATER  TREATMENT SYSTEM

                                                                                                        WATER FLOW DIAGRAM
                                                                                                                      FIGURE V-33

-------
                   tOB 0PM
V
WATER
199 OPM
,(0.4 I/SEC
9-



ke.3 I/SEC)
I
*EVAPORAT
A
(9.0 I/SCO
NCC HEAT
EXCHANGER

x900 OPM (97.2 I/SEC)
1 1 n
ION VI 1
CUPOLA SLAG
scRueeeR QUENCH

i
DUST
COLLECTORS
A 040 OPM A 994 OPM A 279 OPM
/L^(99.4 I/SEC1 *>^- (24.9 I/SEC) A^(I7.2 I/SEC)
90.0 OPM t


90 OPM
(\9 U9ECI
DOME
                                                                      PROCESS*    FERROUS  FOUNDRY
                                                                      PLANT:     MM
                                                                      PRODUCTION: >400 TON9JMY
                                                                                 >360 METRIC TONS/DAY)
oo
en
o
                                            30 0PM U.9 I/SEC)
                                        ,W4I 0PM
                                        103.8 I/SEC)
                              CLj
                                                                 I
                                              SEPTIC
                                              SYSTEM
                             19980PM
                             •004 V9ECJ
        UNDEfNNOUND
        9PRIN03
 It 0PM
(0.691/ScT
                                                    RUNOFF
                                                    WATER
                                                                                                 PLASTIC
                                                                                                  OEPT
                                                                                                  N.C.C.
                                                42 9PM
                                               (2.6 .I/SEC)
POND
                                                                                        1979 0PM
                                               (992 V3EC)
                                              OPM
                                          (4.9 I/SEC)
                                      OUTFALL
                                                                                                 ENVIRONMENTAL PROTECTION AOENCY
                                                                               FOUNDRY INDUSTRY STUDY
                                                                           WASTEWATER TREATMENT SYSTEM
                                                                                WATER FLOW DIAGRAM
                                                                                                                      FIGURE V-34

-------
    5 6PM (O.32 I/IMC)  LOSSES
                                                                       PROCESS'

                                                                       PLANT:


                                                                       PRODUCTION:
                                                   GRAY IRON FOUNDRY
                                                   MELTING SCRUBBER

                                                   TITO
                                                   4 TONS/DAY
                                                   (9.6 METRIC TONS/DAY)
FAN-*
SCREEN
 OVER
 INTAKE
 BOX
                                                                                                (I)-POLYMER
                                                                                                (21-FLOCCULANT
                                                                                                (3)-NoOH
i CITY WATER
      9 0PM
      (0.32 I/MC»
                       SLUDGE
                         TO
                      LANDFILL
                       2IO GAL/DAY
                      (795  I/DAY)
                                                                           ENVIRONMENTAL  PROTECTION AGENCY
                                              FOUNDRY INDUSTRY STUDY

                                           WASTEWATER TREATMENT SYSTEM

                                                WATER FLOW DIAGRAM
                                                                                                 FIGURE V-35

-------
                                                                             TABLE V-39

                                                                  CHARACTERISTICS OF FERROUS FOUNDRY
                                                             MELTING FURNACE SCRUBBER  PROCESS WASTEWATER
                                       Plant 15520
Co
                   Pollutants
Total
Suspended Solids
Oil 8 Grease

Annonla
Cyanide
Iron
Manganese
Phenols
Sulflde

Acenaphthylene
Phenol
Copper
Lead
Nickel
Zinc

pH
Production: 620 tons per day Product 1i
Flow
: 2,
078 1/kkg
500 gallons
Raw
mg/1
1,162
90
100
0.23
110
91
15.8
18
0.155
2.7
110
340
6.9

per ton
Treated
Ib/ton
4.8
0.37
0.41
0.00095
0.45
0.38
0.065
0.074
0.0064
0.011
0.45
1.4

mg/1
71
21
92
0.18
8.5
46
12.4
8.6


8.5
190
6.
Ib/ton
0.29
0.087
0.38
0.00076
0.035
0.19
0.051
0.036


0.035
0.78
9
Flot

Raw
mg/1
573
21
11
0.053
57
18
2.52
0.8
0.69
0.69
140
170
6.3
                                                           Plant 6956                              Plant 58589

                                                           Production:  >400  tons  per day       Production:
                                                                       7-3,000 1/kkg                 Flow  :
                                                                       ?720  gallons per  ton

                                                                                   Treated
                                                                       fton    mg/1       Ib/ton
                                                                                                                                   90 tons per day
                                                                                                                                   4,988 1/kkg
                                                                                                                                   1 20  gallons per ton
     Raw
ing/1      Ib/ton
     Treated
•tg/1      Ib/ton
                                                                                                 10
                                                                                                 10

                                                                                                  5.2
                                                                                                  0.089
                                                                                                  0.22
                                                                                                  0.87
                                                                                                  0.93
                                                                                                   0.87

                                                                                                   1.7

                                                                                                      8.4                 3.7
458
4
2.1
0.010
110
16
0.187
1.3
0.46
40
0.06
8.8
4.58
0.04
0.021
0.0001
1.1
0.16
0.0019
0.013
0.0046
0.4
0.0006
0.088
56
3
2.4
0.006
7.9
1.7
0.356
2.5
0.10
2.2
0.05
0.76
0.56
0.030
0.024
0.00006
0.079
0.017
0.0036
0.025
0.001
0.022
0.0005
0.0076
                         11.0

-------
                                                                      TABLE V-39  (Cont'd.)

                                                                  CHARACTERISTICS OF FERROUS FOUNDRY
                                                             MELTING FURNACE SCRUBBER PROCESS WASTEWATER
                                                                              Plant 56123

                                                                              Production:
                                                                                   Flow :
               196 tons per day
               8,330 1/kkg
               2,000 gallons per ton
                    Plant SS217

                    Production:
                         Flow :
               217 tons per day
               2.993 1/kkg
               720 gallons  per ton
CO
CT>
CO
                   Pollutants
                   Total
                   Suspended Solids
                   Oil & Grease

                   Ammonia
                   Cyanide
                   Iron
                   Manganese
                   Phenols
                   Sulflde

                   Copper
                   Lead
                   Nickel
                   Zinc

                   pH
     Raw
mg/1      1 b/ton
     Treated
mg/1      1 b/ton
     Raw
mg/1      1 b/ton
     Treated
ma/1      1b/ton
8,350
36
2.1
0.02
428
356

2.6
11.2
274
0.6
1,372
139.7
0.602
0.035
0.0003
7.16
5.96

0.04
0.187
4.59
0.01
22.96
13
3.5
1.2
0.042
1.11
2.2

2.3
0.03
0.93
0.015
3.5
0.000053
0.0014
0.00049
0.000017
0.00045
0.00089

0.00093
0.000012
0.00038
0.000006
0.0014
788
7.5
3.15
0.024
35
23
0.449
2.15
0.5
11.5
0.09
30
4.73
0.045
0.011
0.0001
0.21
0.138
0.003
0.013
0.003
0.15
0.0003
JO. 18
7.2
0.27
0.39
0.0073
0.32
1.5
0.099

0.0097
0.5

1.4
0.095
0.0036
0.0026
0.000097
0.0042
0.019
0.0013

0.00013
0.0066

0.018
     7.6
     9.4
     7.4
     8.8

-------
                                                                      TABLE V-39  (Cont'd.)

                                                                    CHARACTERISTICS OF FERROUS FOUNDRY
                                                               MELTING FURNACE  SCRUBBER PROCESS WASTEWATER
CO
                    Pollutants
Total
Suspended Solids
Oil & Grease

Ammonia
Cyanide
Iron
Manganese
Phenols
Sulfide

Copper
Lead
Nickel
Z1nc

PH
                                        Plant 56789

                                        Production:
                                             Flow :
                                        •52/1
                         Raw
                                   74 tons per day
                                   375 gallons per minute
     Treated
mg/1       Ib/ton
                    Plant 53219

                    Production:
                         Flow :
                                                           mg/1
Raw
 14 tons per day
 1,426 1/kkg
 393 gallons per  ton

           Treated
on    rog/1      Ib/ton
                                   Plant  54321

                                   Production:
                                       Flow  :
                                             Non-representative  process
                                             wastewater samples  taken

                                             This plant recycles
                                             100% of the melting
                                             furnace scrubber
                                             process wastewater
                                  mg/1
Raw1
 105 tons per day
 20.798 1/kkg
 4,992 gallons per ton

           Treated2
on    mg/1       Ib/ton
1.800
2
7.3
0.0035
76
75
0.301
5.25
2.5
41
0.17
100
5.14
0.0057
0.021
0.00001
0.217
0.214
0.00086
0.015
0.0071
0.117
0.00049
0.286
22
3.5
0.5
2.0
0.38
0.005

0.0086
0.0014
0.0002
0.0008
0.00015
0.000002

                                                                                                        4.3
                                                                                                                                                9.1
                      Raw process wastewater inaccesible for sampling
                      Includes  slag  quenching  process wastewater pollutants

-------
                                                           TABLE  V-39  (Cont'd.)

                                                        CHARACTERISTICS OF FERROUS FOUNDRY
                                                   MELTING FURNACE  SCRUBBER PROCESS HASTEWATER
                            Plant 50315
Plant 0001
CO

cn
        Pollutants
        Total
        Suspended Solids
        Oil & Grease

        Anmonla
        Cyanide
        Iron
        Manganese
        Phenol s
        Sulflde

        Antimony
        Cadmium
        Copper
        Lead
        Nickel
        Zinc

        PH
Production: 136 tons per day Production:
Flow

Raw
mg/1
4,307
0.77
3.82
0.05
523.2
67.8
4.76
4.37
27.64
0.95
94.4
*
: 4,
1.

Ib/ton
41.3
0.007
0.366
0.0004
5.01
0.38
0.04
0.04
0.26
0.009
0.90

780 1/kkg Flow :
150 gallons per ton
Treated Raw
mg/1 Ib/ton mg/1 J_
40 0.84
0.03 0.00063
0.5 0.010

4.8 0.1
2.53 0.053

0.09 0.0019
1.4 0.030

4.35 0.091
8
               20 tons  per day
               46 1/kkg
               11 gallons  per ton

                        Treated
              on    mg/1      Ib/ton
                    8,900
                        5
0.08
0.0004
          Plant 0002

          Production:
               Flow :
                                                                                                                          40 tons per day

                                                                                                                               1.4 gallons per ton
               Raw1
          mg/1       Ib/ton
                        1.8   0.00016

                      870    6.080
                      420    0.038
                        0.002 0.0000007
                       35    0.0032
                        2.4
                        0.82
                       12
                       25
                        0.75
                      130

                         6.4
0.00022
.000075
0.0011
0.0023
0.00007
0.012
     Treated
mg/1      1 b/ton
6.800
   10
0.081
0.0001
                                  2.3   0.000022
                                  0.080 0.0000016
                                180    0.0021
                                240    0.0029
                                  0.43 0.000005
                                 26    0.00055
    3.4
    2.2
    5.5
   19
    0.46
  190

     8.8
0.000040
0.000026
0.000066
0.00023
0.0000075
0.0023
          Raw process wastewater Inacceslble for sampling

-------
CO
01
CTi
                                      Plant  56771
                                                                    TABLE  V-39  (Cont'd.j

                                                                 CHARACTERISTICS  OF FERROUS FOUNDRY
                                                            MELTING FURNACE  SCRUBBER PROCESS WASTEWATER
                                                           Plant 52881
               Plant 52491
                  Pollutants
                  Total
                  Suspended Solids
                  Oil  &  Grease

                  Ammonia
                  Cyanide
                  Iron
                  Manganese
                  Phenols
                  Sulfide
Production:
Flow :

Raw1
mg/1 _M>








105 tons per day
1,238 1/kkg
298 gallons per ton
Treated2
/ton mg/1 Ib/ton
527 1.30
26 0.064
4.6 0.011

32 0.079
32.5 0.080
0.71 0.0117

Production: 86 tons per day
Flow : 26,438 1/kkg
6,361 gallons per ton
Raw1 Treated2
mg/1 Ib/ton mg/1 Ib/ton
28 1.48
3.0 0.159
1.23 0.065
.16 0.0085
2.95 0.156
0.37 0.196
0.004 0.0002

Production: 9 tons per day
Flow : 636 1/kkg
153 gallons per ton
Raw1 Treated
mg/1 Ib/ton mg/1 Ib/ton
1,262 1.60
9 0.0114
2.6 0.003

453 0.577
119.9 0.153
0.02 0.00003
49 0.06
PH
                                                              6.9
9.2
                                       8.1
                    Raw process  wastewater  inaccesible for sampling
                    Includes  slag quenching process wastewater pollutants

-------
OTHER
 USES
                         PLANT WATER SUPPLY
                         2.649.OOO I/DAY (7OO.OOO GAL/DAY)
                                                 *ETAL
               6.31 I/SEC
              /(lOO GPM)
                                      MAKE-UP WATER
                                                  SUMP
                   'PIG  MACHINE
MAKE-UP
                  JWATEJ^L
    J.I3 I/SEC
    (5O GPM)
                                                   32.9 I/SEC
                                                   (521 GPM)
                                                    BAG HOUSE
PIPE
MACHINE
                                                                                    FERROUS FOUNDRY (GRAY  IRON)
                                                                                    51026
PROCESS:
f'LANT:
PRODUCTION:
   DUST COLLECTION 240 METRIC TONS/DAY
                   (263 TONS/DAY)
                    45 METRIC TONS/DAY
                   (5O TONS/DAY)
                   4O8 METRIC TONS/DAY
                   (45O TONS/DAY)
                                                                                           SAND WASHING
                                                                                                                         BLOWER
                                                       /-I3.8 I/SEC
                                                      / (220 GPM)
                                                                                   r_
                                                                                        SAND WASHING
                                                                                            SYSTEM
                                                                      19 I/SEC
                                                                      (301 GPM)
                                                                                                                          MAKE-UP
                                                                                                                          WATER
                   (I GPM)7f

                          (SOLIDS!
                                                                                                                         POINTS
     392 I/SEC
                                                     ,^
                                                    /
                                                                        (.179.330 I/DAY
                                                                        (311.580 GPM)
\	X
12 HR. LAGOON
                                                  72 HR. LAGOON
                            12 HR. LAGOON
                                                             t
                                                           TO RIVER
   ENVIRONMENTAL  PROTECTION  AGENCY
          FOUNDRY INDUSTRY STUDY
      WASTEWATER TREATMENT SYSTEM
            WATER FLOW DIAGRAM
                                                                                                                  FIGURE V-36

-------
CO
CTl
00
        Pollutants
        Total
        Suspended Solids
        Oil & Grease

        Ammonia
        Cyanide
        Iron
        Manganese
        Phenols
        Sulflde
Zinc

pH
                            Plant 51026
                                                                    TABLE  V-40

                                                        CHARACTERISTICS  OF FERROUS FOUNDRY
                                                        SLAG QUENCHING PROCESS WASTEWATERS
                                                            Plant  15520
Plant 6956
Production: 450
Flow : 998
240
Raw
mg/1
48
1.7
0.186
0.010
1.5
0.16
0.014
0.13

7.8
tons per day
1/kkg
gallons per ton
Treated1
Ib/ton
0.083
0.0037
0.0004
0.000017
0.0026
0.00027
0.000024
0.00023


mg/1
7.2
0.89
0.258
0.019
0.342
0.077
0.015


7.6
Ib/ton
0.013
0.0015
0.00045
0.000033
0.00060
0.00013
0.00002



Production: 620
Flow : 411
99
Raw
mg/1
*
200


51
25
2.1
10

7.3
tons per day
1/kkg
gallons per ton
Treated2
Ib/ton
*
0.1


0.042
0.021
0.0018
0.01


Production: >400 tons per day
Flow : >3,000 1/kkg
>720 gallons per ton
Raw
mg/1 Ib/ton mg/1
* *
39 0


7.2 0
11 0
1.7 0
2 0

7.4

.016


.060
.0092
.0017
.002


89
5
10
0.184
6.1
1.1
0.379

0.67
7.2
Treated1
Ib/ton
0.64
0.04
0.072
0.0013
0.049
0.0079
0.0027

0.0048

mg/1
2
2
9.0
0.29
0.032
0.072
0.07

0.011
8.4
Ib/ton
0.01
0.01
0.062
0.0020
0.00022
0.00049
0.00048

0.000017

        1 2
         •  Slag Quenching process  wastewater 1s  jointly-treated with  other foundry process wastewaters.  Treated process wastewater
            characteristics for slag  quenching determined by  apportioning mass loadings
        * Mass balance results  In a  negative  value

-------
                    PRODUCT

                       t
          1    I
 25 GPM    f    i
(1.6 I/SEC)
PRODUCT — — - -|
                                      EVAPORATION
                                     25 6PM (1.6 I/SEC)
                                                                      PROCESS:
                                                                      PLANT:
                                                                          STEEL FOUNDRY
                                                                          15654
                                                             PRODUCTION!    216 TOMS/DAY (196 KKO/DAY)
                                                                SAND DRYER: eo TONS/SHIFTS KKG/SHIFT)
                       I  780 0PM
                      A (49.2 I/SEC I
                    755 0PM
                    (47.6 I/SEC)
                                            TOWER
                                   UT*   —-AU
           CASTING
            WHEEL
          COOLING
            WATER
            SYSTEM
              22 GPM
             (1.4 I/SEC)
                              21 GPM
                              0.3 I/SEC)
                                                  EVAPORATIVE LOSSES I GPM (O.I I/SEC)

                                                  SAND DRYER SCRUBBER
                                                                         ENVIRONMENTAL PROTECTION  AGENCY
                                                                             FOUNDRY INDUSTRY STUDY
                                                                          WASTEWATER TREATMENT SYSTEM
                                                                              WATER FLOW DIAGRAM
                                                                                            -[FIGURE  v-37

-------
                                                                        TABLE  V-41

                                                             CHARACTERISTICS OF  FERROUS FOUNDRY
                                                              CASTING QUENCH AND MOLD COOLING
                                                                    PROCESS HASTEWATERS
                                 Plant 15654
                                                           Plant 51026
                                                      Plant 51026
to
VJ
O
              Pollutants
Total
Suspended Solids
Oil A Grease

Ammonia
Cyanide
Iron
Manganese
Phenols
Sulflde

Lead
Zinc

PH
Production: 220 tons per
Flow : 21,200 1/kkg
5,100 gallons
Raw
mg/1
147
9
0.13
0.005
7.3
0.08
0.01

0.06
0.13
day
per ton
Treated
Ib/ton
6.3
0.4
0.0055
0.0002
0.31
0.003
0.0004

0.003
0.0055
mg/1
62
9
0.11
0.002
6.7
0.06
0.01

0.06
0'.14
Ib/ton
2.6
0.4
0.0046
0.00008
0.28
0.002
0.0004

0.002
0.0058
Production: 450 tons per
Flow : 14 1/kkg
3.3 gallons
Pig Machine
Raw
mg/1
496
1.7
0.33

8.0
0.41

6.25


Ib/ton
0.014
0.000046
0.000009

0.00022
0.000011

0.000173


day
per ton
Treated1
mg/1
16
2
0.14

1.55
0.07

<.02


Ib/ton
0.0004
0.00005
0.000004

0.00004
0.000002

<0. 0000005


Production: 450 tons per day
Flow : 977 1/kkg
235 gallons per ton
Pipe Machine
Raw
mg/1
166
22.7
0.117

16.3
0.11

0.25


Treated1
Ib/ton
0.32
0.05
0.00023

0.032
0.0002

0.0004


mg/1
16
2
0.14

1.55
0.07

<.OZ


Ib/ton
0.03
0.0039
0.0003

0.0030
0.00013

0.00004


                                      8.6
8.6
11.1
7.6
7.2
7.6
               Treated Jointly

-------
                                                                 PROCESS:   FERROUS FOUNDRY (STEEL)
                                                                 PLANT:     51473
                                                                 PRODUCTION:
                                                                   SAND WASHING   29  METRIC TONS/DAY
                        5.7 I/SEC
                        (90 6PM)
                           (32 TONS/DAY)
CITY WATER
  SUPPLY
                                                                                  SLURRY
                                                                                  TANK
                                                       EVAPORATIVE  LOSS
                                                             0.63 I/SEC
                                                             (IO GPM)
                                                                                             OE WATERING
                                                                                               TABLE
                                                                         5  I/SEC
                                                                         (80  GPM)
                                      3.6 METRIC TONS/DAY
                                      (4 TONS/DAY)
          14.5 METRIC  TONS/DAY
           ( 16 TONS/DAY)
                                                                                              DISCHARGE TO
                                                                                                  RIVER
                                                                                           5 I/SEC (80 GPM)
SOLIDS TO
 DISPOSAL
                                                                     tNVIRONMENTAL
                                        RETURN TO
                                      SAND SYSTEM
                                    18.1 METRIC TONS/DAY
                                      (20 TONS/DAY)
                      FOUNDRY INDUSTRY STUDY
                  WASTEWATER TREATMENT SYSTEM
                        WATER FLOW DIAGRAM
                                                                                            FIGURE  v-38

-------
                                                  TABLE V-42

                                      CHARACTERISTICS  OF FERROUS  FOUNDRY
                                        SANDWASHING PROCESS WASTEWATERS
00
—J
ro
             Pollutants
Total
Suspended Solids
Oil & Grease

Ammonia
Cyanide
Iron
Manganese
Phenols

Sulfide
Arsenic
Cadmium
Chromium
Copper
Lead
Nickel
Zinc
                                 Plant 15520

                                 Production:

                                      Flow :
                                   3,600 tons of sand
                                        per day
                                   831 1/kkg
                                   200 gallons per ton
                         Raw
                    mg/1      Ib/ton
     Treated
mg/1       Ib/ton
 230 tons of sand
      per day
 6,640 1/kkg
 1,600 gallons per ton

           Treated
an    mg/1       Ib/ton
810
2.7
8.6
0.031

0.98
0.036





0.24

0.08
9.7
0.032
0.10
0.00037

0.012
0.00044





0.0029

0.001
172
4
8.3
0.025

0.82
0.022







0.55
2.1
0.05
0.10
0.00030

0.0098
0.00026







0.0066
3,300
3
0.3
0.070
80
1.6
0.93
7.0
0.03
0.01
0.23
0.50
0.37
0.12
0.67
43.48
0.043
0.0043
0.00091
1.043
0.0213
0.012
0.0913
0.00039
0.00013
0.0030
0.0065
0.0048
0.00156
0.00869
830
7
0.17
0.01
18
1.2
0.67
6.7
0.014
0.01
0.1
0.33
0.93
0.028
0.73
10.8
0.09
0.0022
0.00017
0.24
0.015
0.0086
0.0086
0.00018
0.00013
0.0013
0.0043
0.0056
0.00036
0.00956
            pH
                         7.3
     8.8
           6.9

-------
                                                                           TABLE  V-42

                                                                CHARACTERISTICS OF  FJRROUS  FOUNDRY
                                                                 SANDUASHING PROCESS WASTEHATERS
CO
                 Pollutants
Total
Suspended Solids
Oil & Grease

Anmonia
Cyanide
Iron
Manganese
Phenols

Copper
Lead
Nickel
Zinc

PH
                 1
Plant 59101
Production: 176 tons of sand
per day
Flow : 26,525 1/kkg
6,382 gallons per ton
Raw
mg/1
5,933
14
4.0
0.031
61
1.8
0.591




7.5
Treated1
Ib/ton
473.2
1.12
0.319
0.0025
4.86
0.144
0.047





mg/1
6.6
7.8
0.99
0.014
0.23
0.022
0.021




8.1
Ib/ton
0.53
0.621
0.079
0.0011
0.018
0.0018
0.0016





;s wastewater 1s jointly treated with
Plant 51473
Production: 32 tons of sand
per day
Flow : 4,987 1/kkg
1,200 gallons per ton
Raw
mg/i
8.200
21
0.21
0.013
380
3.6
0.81
0.5
2.0
0.20
4.4
6.3
Treated
Ib/ton
82
0.21
0.0021
0.000013
3.8
0.036
0.00081
0.0050
0.020
0.0020
0.044

mg/1
1.100
19
0.25
0.003
260
2.8
0.068
0.5
1.6
0.18
3.3

Ib/ton
11
0.19
0.0025
0.000003
2.6
0.028
0.00069
0.005
0.016
0.0018
0.033

Plant 51026
Production: 50 tons of sand
per day
Flow : 2.872 1/kkg
691 gallons per ton
Raw
sail . .
226
3.6
0.299
0.010
22
0.14
0.008




7.9
dust collection process wastewaters. Treated process
Treated1
Ib/ton
10.4
0.166
0.014
0.00046
1.01
0.0064
0.0004





•g/J.
34
1.5
0.33
0.018
5.0
0.20
0.007




7.5
Ib/ton
1.6
0.072
0.016
0.00088
0.24
0.0096
0.00032





wastewater
                   characteristics for sandwashIng determined by apportioning mass loadings

-------
                                  TABLE V-42

                       CHARACTERISTICS OF FERROUS FOUNDRY
                        SANDWASHING PROCESS WASTEWATERS
               Plant 51115

               Production:
                    Flow  :
Pollutant
Phenols
Arsenic
Chromium
Copper
Lead
Nickel
Zinc
96 Tons Of Sand Per Day
6,640 1/kkg
1,600 Gallons Per Ton
0.26
0.35
1.4
1.72
1.60
1.40
4.26
          Raw
Ib/ton

0.0035
0.00^7
0.0186
0.023
0.021
0.019
0.568
                                                            mg/1
                    Treated
<0.81
<0.02
<0.01
  ,005
  ,02
 0.05
<0.00013
<0.00026

-------
             JB&
                                                                      PROCESS.'MAGNESIUM FOUNDRY
                                                                      PLANT:  8146
                                                                      PRODUCTION: 0.745  METRIC TON^)AY
                                                                                  0.82 TONS/DAY
CO
-4
           MMCC-UP
                                                 3ETTUMQ AMD
                                                 DRAG TANK
                                                (4.5 GPM)
                                                                 TO
                                                               OUTFALL
                                                                                                          0.174^/SEC.
                                                                                                          (2.75 GPM)
                                                                                                 TO
                                                                                                 OUTFALL
                A
SAMPLING  POIMr
                                                                                            ENVIRONMENTAL  PROTECTION AGENCY
                                                                              FOUNOfW  INDUSTRY  STUDY
                                                                          WASTEVWER  TREATMENT  SYSTEM
                                                                              WATER   R-CW  DIAGRAM
                                                                                                                  FIGURE V-39

-------
                                 TABLE  V-43

                    CHARACTERISTICS OF MAGNESIUM CASTING
                    GRINDING SCRUBBER PROCESS WASTEWATER
             Plant 8146

             Production:
                  Flow :
   Pollutant
   Total  Suspended Solids
   Oil  & Grease

   Ammonia
   Cyanide
   Manganese
   Phenols
   Sulfide

   Copper
   Lead

   Zinc

   PH
0.82 Tons Per Day
6,692 1/kkg
1,610 Gallons Per Ton

     Raw                 Treated (internal to scrubber)
mg/1      Ib/ton    mg/1       Ib/ton
36
4
0.1
0.003
0.3
0.017
0.08
0.13
0.49
0.05
0.001
0.00004
0.004
0.00023
0.001
0.0018
                     1.2      0.016

                         9.8
Raw process wastewater inaccessible for sampling
                                376

-------
                                   TABLE V-44

                      CHARACTERISTICS OF MAGNESIUM CASTING
                        DUST SCRUBBER PROCESS WASTEWATER
               Plant 8146

               Production:
                    Flow :
     Pollutant
     Total  Suspended Solids
     Oil  & Grease

     Ammonia
     Cyanide
     Manganese
     Phenols
     Sulflde

     Phenol
                            100 Tons Per Day (Sand)
                            90 1/kkg
                            21.6 Gallons Per Ton

                                 Raw                 Treated (Internal to scrubber)
                            mg/1      Ib/ton    tng/1      Ib/ton
26
10
1.8
0.004
0.07
1.14
13
0.0047
0.0018
0.00032
0.0000007
0.000013
0.00021
0.0023
                                                 0.13
0.000023
1
   Lead

   Zinc

   PH


Raw process wastewater Inaccessible for sampling
                                                   0.08     0.000014

                                                   0.36     0.000065

                                                       7.6
                                          377

-------
                                                                                              PROCESS'


                                                                                              PLANT"
                                                         ZINC DIE CASTING


                                                         4622
                                                                                              PRODUCTION'   METAL USED 16.8 TONS/DAY
                                                                                                                     (15.2 METRIC TONS/CAY)
                                  .RAW WATER
                           ZINC DIE CASTING
                           QUENCHING OPERATIONS


WAS
EWATCR 3TO
TANKS
)AGE
U)
-J
oo
                               TO CONTRACT.
                               HAULER    ^
323 GAL/SHIFT
I.O9 GPM
(O.OT I/SEC)
                                                                                                 ENVIRONMENTAL PROTECTION AGENCY
                                                                                                       FOUNDRY INDUSTRY STUDY
                                                                                                   WASTEWATER TREATMENT  SYSTEM
                                                                                                        WATER FLOW DIAGRAM
                                                                                                                        FIGURE  V-40

-------
                 TABLE  V-45

CHARACTERISTICS OF ZINC CASTING
   QUENCH PROCESS WASTEWATER
Plant 10308
               Plant 18139
Production: 28 tons per day
Flow : 116 1/kkg
28 gallons per ton
Pollutants
Total
Suspended Solids
Oil & Grease
Ammonia
Cyanide
Iron
Manganese
Phenols
2 ,4-Dlmetnyl phenol
4-N1trophenol
2,4-Dlnltrophenol
Copper
Nickel
Zinc
Raw
94
81
0.008
6.6
.46
0.111
0.12
1.6
0.9
0.16
0.04
350
Ib/ton
0.022
0.019
0.000002
0.0016
0.011
0.000026
0.000028
0.00038
0.00021
0'. 000038
0.000009
0.08
Treated
mg/1 Ib/ton
8.0
4.2
0.0048
5.2
0.026
0.38

0.05
36
0.0019
0.0010
0.000001
0.0012
0.000006
0.000089

0.00001
0.0086
Production:
Flow :
Raw
mg/1 lb/
40
24
0.010
0.07
0.061

0.07
3.7
>50 tons per day
>10 1/kkg
>2 gallons per ton
Treated
ton mg/1 1 b/ton
32
29
0.07

0.07
2.3
     5.7
9.1
7.4
8.0

-------
                                     TABLE V-45

                    CHARACTERISTICS OF ZINC CASTING
                       QUENCH PROCESS WASTEWATER
                    Plant 4622
                                    Plant 12040
Production:
Flow :





CO
oo
o



Pollutants

Total
Suspended Solids
Oil & Grease
Ammonia
Cyanide
Iron
Manganese
Phenols
Raw
mg/1

3,800
17,100
2.
0.
6.
0.
1.
16.8 tons per day Production:
386.5 1/kkg Flow :
93 gallons per ton
Treated1
Ib/ton mg/1



4
020
9
17
42

3
13
0
0
0
0
0

.0

.0019
.000016
.0054
.00013
.0011
Ib/ton mg/1

685
1,290
3
0
1

0
Raw
11.45 tons per day
1,800 1/kkg
Treated
Ib/ton



.3
.008
.2

.11

10
20
0
0
0

0



.050
.0001
.018

.0017
mg/1

13
21
0.4
0.002
0.03

0.083
Ib/ton

0.2
0.33
0.0061
0.00003
0.0005

0.0013
Methyl chloride
Phenol
Tetrachloroethyl ene
Trichloroethylene
 0.3   0.00023
 0.46  0.00036
 0.142 0.00011
 0.23  0.00018
Lead
Nickel
Zinc

PH
62

 7.4
0.048
0.35   0.0053    0.2      0.0031

2.9    0.044     0.02     0.004
  No treatment provided.  Process wastewater is contract hauled.

-------
                          TABLE V-46

           CHARACTERISTICS OF ZINC MELTING FURNACE
                 SCRUBBER PROCESS WASTEWATER
          Plant 18139

          Production:   >50   Tons Per Day
               Flow  :   XL20 gallons per ton

Pollutant                     Raw                 Treated
                         mg/1      Ib/ton    mg/1      Ib/ton

Total Suspended Solids   428                 310
Oil & Grease             758                 860

Ammonia
Cyanide                    0.009               0.0073
Manganese                  0.05                0.05
Phenols                   90.6                14
1,2,4-Trichlorobenzene     1.0
2,4,6-Trlchlorophenol      1.4                 0.6
2,4-Dlchlorophenol         1.3                 0.22
2,4-Dimethylphenol        12.1                 0.49
Naphthalene                3.3                 2.3
Phenol                    36.0

Copper               •      0.08
Lead                       0.08

Zinc                      19                  11

pH                            4.7                 8.0

-------
                                SECTION VI

                           POLLUTANT PARAMETERS


INTRODUCTION

The  major  process  wastewater  parameters  of  significance  for  foundry
operations were determined on the basis of analytical review and experience
with the foundry industry.  Certain distinct parameters are associated with
various foundry processes.

Raw  wastewater  and  treated  effluent  characteristics  were described in
further detail in Section V.  Toxic pollutants and  conventional  and  non-
conventional pollutants in the raw and treated process wastewaters from the
various metal molding and casting  processes are discussed below.

ENVIRONMENTAL IMPACT OF TOXIC POLLUTANTS

Acenaphthene(1).  Acenaphthene (1,2-dihydroacenaphthylene, or 1,8-ethylene-
naphthalene)  is  a  polynuclear  aromatic hydrocarbon (PAH) with molecular
weight of 154 and a formula of C12H10.  The structure is

Acenaphthene occurs in coal tar produced during high temperature coking  of
coal.   It  has  been  detected  in  cigarette  smoke  and gasoline exhaust
condensates.

The pure compound is a white crystalline solid at room temperature  with  a
melting  range  of  95  to  97°C and a boiling range of 278 to 280 °C.  Its
vapor pressure at room temperature is less than  0.02 mm Hg.   Acenaphthene
is  slightly  soluble in water (100 mg/1), but even more soluble in organic
solvents such as ethanol, toluene, and  chloroform.   Acenaphthene  can  be
oxidized  by  oxygen  or ozone in the presence of certain catalysts.  It is
stable under laboratory conditions.

Acenaphthene is used as a dye intermediate,  in  the  manufacture  of  some
plastics, and as an insecticide and fungicide.

So  little  research  has been performed on acenaphthene that its mammalian
and  human  health  effects  are  virtually  unknown.   The  water  quality
criterian  of  0.02 mg/1  is  recommended to prevent the adverse effects on
humans due to the organoleptic properties of acenaphthene in water.

No detailed study of acenaphthene behavior in POTW is available.   However,
it  has  been  demonstrated  that  none  of the organic priority pollutants
studied so far can be broken down  by  biological  treatment  processes  as
readily  as  fatty acids, carbohydrates, or proteins.  Many of the priority
pollutants have been investigated, at least in laboratory scale  studies, at
concentrations higher than  those expected to be contained by most municipal
                                   383

-------
wastewaters.  General observations relating molecular  structure to ease  of
degradation have been developed for all of the organic priority pollutants.

The  conclusion  reached  by  study  of the limited  data  is  that biological
treatment produces little or no degradation of acenaphthene.    No  evidence
is available for drawing conclusions about its possible toxic or inhibitory
effect on POTW operation.

Its  water  solubility  would allow acenaphthene present  in  the influent to
pass through a POTW  into the effluent.  The hydrocarbon character  of  this
compound  makes  it  sufficiently hydrophobic  that  adsorption onto suspended
solids and retention in the sludge may also   be  a  significant  route  for
removal of acenaphthene from the POTW.

Acenaphthene  has  been demonstrated to affect the growth of plants through
improper nuclear division and polypoidal  chromosome  number.    Howerver,   it
is   not  expected   that  land  application   of  sewage  sludge  containing
acenaphthene at the  low concentrations which  are to  be expected in  a  POTW
sludge  would  result  in  any  adverse affects on animals ingesting plants
grown in such soil.

Benzene  (4) .  Benzene  (C6H6) is a clear,  colorless,  liquid obtained  mainly
from   petroleum  feedstocks  by  several  different  processes.   Some  is
recovered from light oil obtained from coal carbonization gases.  It  boils
at  80C  and  has  a  vapor  pressure of  100  mm Hg at  26°C.   It is slightly
soluble  in water  (1.8  g/1 at 25°C) and it disolves in  hydrocarbon solvents.
Annual U.S. production is three to four million tons.

Most of  the benzene  used in the U.S. goes into chemical manufacture.  About
half of  that is converted to ethylbenzene which is used  to   make  styrene.
Some benzene is used in motor fuels.

Benzene  is harmful to  human health according  to numerous  published studies.
Most  studies  relate  effects  of  inhaled   benzene vapors.   These effects
include  nausea, loss of muscle coordination,  and   excitement,  followed  by
depression and coma.  Death is usually the result  of respiratory or cardiac
failure.   Two  specific  blood  disorders are related to benzene exposure.
One of these, acute  myelogenous leukemia, represents a carcinogenic  effect
of  benzene.   However,  most  human  exposure data  is based on exposure in
occupationed settings  and benzene carcinogenisis is  not  considered  to  be
firmly established.

Oral administration  of benzene to laboratory  animals produced leukopenia, a
reduction   in number of  leukocytes  in the blood.   Subcutaneous injection of
benzene-oil solutions  has produced suggestive, but not conclusive, evidence
of benzene  carcinogenisis.

Benzene  demonstrated  teratogenic  effects   in  laboratory   animals,   and
mutagenic effects  in humans and other animals.
                                    384

-------
For  maximum  protection  of  human  health from the potential carcinogenic
effects of exposure to benzene through ingestion of water and  contaminated
aquatic organisms, the ambient water concentration is zero.  Concentrations
of benzene estimated to result in additional lifetime cancer risk at levels
of  10-7,  10-«,  and  10-*  are 0.00015 mg/1, 0.0015 mg/1, and 0.015 mg/1,
respectively.

Some studies have been reported regarding the behavior of benzene in  POTW.
Biochemical   oxidation   of   benzene   under  laboratory  conditions,  at
concentrations of 3 to 10  mg/1,  produced  24,  27,  24,  and  29  percent
degradation  in  5,  10,  15, and 20 days, respectively, using unacclimated
seed cultures in fresh water.  Degradation of 58, 67, 76,  and  80  percent
was  produced  in  the  same  time  periods using acclimated seed cultures.
Other studies produced similar results.  Based on these  data  and  general
conclusions  relating  molecular  structure to biochemical oxidation, it is
expected that biological treatment in POTW will remove benzene readily from
the water.  Other reports indicate that most benzene  entering  a  POTW  is
removed  to  the  sludge  and that influent concentrations of 1 g/1 inhibit
sludge digestion.  There  is  no  information  about  possible  effects  of
benzene on crops grown in soils amended with sludge containing benzene.

Carbon   Tetrachloride  (6).   Carbon  tetrachloride  (CC14),  also  called
tetrachloromethane,  is  a  colorless  liquid  produced  primarily  by  the
chlorination  of hydrocarbons - particularly methane.  Carbon tetrachloride
boils at 77°C and has a vapor pressure of 90 mm Hg at 20°C.  It is slightly
soluble in water  (0.8 gm/1 at 25°C) and soluble in many  organic  solvents.
Approximately one-third of a million tons is produced annually in the U.S.

Carbon  tetrachloride,  which  was  displaced by perchloroethylene as a dry
cleaning agent in the 1930's, is used principally as  an  intermediate  for
production  of chlorofluoromethanes for refrigerants, aerosols, and blowing
agents.  It is also used as a grain fumigant.

Carbon tetrachloride  produces  a  variety  of  toxic  effects  in  humans.
Ingestion  of  relatively  large quantities - greater than five grams - has
frequently proved fatal.  Symptoms are  burning  sensation  in  the  mouth,
esophagus  and  stomach,  followed  by  abdominal  pains, nausea, diarrhea,
dizziness,  abnormal  pulse,  and  coma.   When  death   does   not   occur
immediately,  liver  and  kidney  damage  are  usually  found.  Symptoms of
chronic poisoning are not as well defined.  General fatigue, headache,  and
anxiety  have  been  observed,  accompanied  by  digestive tract and kidney
discomfort or pain.

Data concerning teratagenicity and mutagenicity of carbon tetrachloride are
scarce  and  inconclusive.   However,   carbon   tetrachloride   has   been
demonstrated  to  be carcinogenic in laboratory animals.  The liver was the
target organ.
                                   385

-------
For the maximum protection of human health from the potential   carcinogenic
effects  of exposure to carbon tetrachloride through ingestion  of  water  and
contaminated aquatic,organisms, the ambient water  concentration   is   zero.
Concentrations  of  carbon  tetrachloride estimated to result in additional
lifetime cancer risk at risk levels of 10~7, 10-*, and   10~5  are   0.000026
mg/1, 0.00026 mg/1, and 0.0026 mg/1, respectively.

Data  on  the  behavior  of carbon tetrachloride in POTW are not available.
Many of the organic priority pollutants have been  investigated, at least in
laboratory-scale studies, at concentrations higher than  those   expected   to
be  found  in  most  municipal wastewaters.  General observations  have been
developed relating molecular structure to ease of  degradation   for all   of
the  organic  priority  pollutants.  The conclusion reached by  study  of  the
limited data is that biological treatment produces  a  moderate degree   of
removal  of  carbon  tetrachloride  in  POTW.   No  information was   found
regarding the possible interference of carbon tetrachloride with   treatment
processes.   Based on the water solubility of carbon tetrachloride, and  the
vapor pressure of this compound, it is expected that some of the undegraded
carbon tetrachloride will pass through to the POTW effluent and some will
be volatilized in aerobic processes.
 Chlorobenzene   (7).   Chlorobenzene  (C6H5C1), also called monochlorobenzene
 is  a  clear,  colorless,  liquid manufactured by the liquid phase  chlorination
 of  benzene over a  catalyst.  It boils at 132C and has a vapor   pressure   of
 12.5  mm Hg at  25°C.   It  is almost  insoluble  in water  (0.5 g/1 at  30°C),  but
 dissolves  in  hydrocarbon solvents.  U.S. annual production  is  near  150,000
 tons.

 Principal uses of  Chlorobenzene are  as a solvent and  as an  intermediate  for
 dyes  and pesticides.  Formerly it  was  used  as  an   intermediate for   DDT
 production,  but   elimination of production  of that compound reduced annual
 U.S.  production requirements for Chlorobenzene by half.

 Data  on the  threat to human health posed by  Chlorobenzene   are   limited   in
 number.   Laboratory  animals  administered  large  doses   of Chlorobenzene
 subcutaneously, died  as  a result of  central  nervous system  depression.    At
 slightly  lower  dose  rates,  animals  died of  liver  or  kidney  damage.
 Metabolic disturbances  occurred also.  At even lower  dose rates  of   orally
 administered  Chlorobenzene similar  effects  were observed,  but  some  animals
 survived  longer than  at  higher dose  rates.   No studies have  been reported
 regarding    evaluation   of  the  teratogenic,  mutagenic,   or   carcinogenic
 potential of Chlorobenzene.

 For the prevention of adverse effects due to the organoleptic properties of
 Chlorobenzene  in water  the recommended criterian is 0.020 mg/1.
                                    386

-------
Only limited data are available on which  to  base  conclusions  about  the
behavior  of  chlorobenzene in POTW.  Laboratory studies of the biochemical
oxidation of chlorobenzene have been carried out at concentrations  greater
than  those  expected  to  normally  be  present in POTW influent.  Results
showed the extent of degradation to be 25, 28, and 44 percent after 5,  10,
and  20  days,  respectively.    In  another,  similar study using a phenol-
adapted culture 4 percent degradation was observed after  3  hours  with  a
solution  containing  80  mg/1.    On the basis of these results and general
conclusions about the relationship of molecular  structure  to  biochemical
oxidation, it is concluded that chlorobenzene will be removed to a moderate
degree  by  biological  treatment in POTW.  A substantial percentage of the
chlorobenzene remaining intact is expected to volatilize from the  POTW  in
aeration  processes.   The  estimated  half-life  of chlorobenzene in water
based on water solubility, vapor  pressure  and  molecular  weight  is  5.8
hours.

1,2,4-Trichlorobenzene (8).  1,2,4-Trichlorobenzene (C«H3C13, 1,2,4-TCB) is
a  liquid  at  room temperature, solidifying to a crystalline solid at 17°C
and boiling at 214°C.  It is  produced  by  liquid  phase  chlorination  of
benzene  in  the  presence of a catalyst.  Its vapor pressure is 4 mm Hg at
25°C.  1,2,4-TCB is insoluble in water and  soluble  in  organic  solvents.
Annual  U.S.  production is in the range of 15,000 tons.  1,2,4-TCB is used
in limited quantities as a solvent and as a  dye  carrier  in  the  textile
industry.   It  is also used as a heat transfer medium and as a transformer
fluid.   The  compound  can  be  selectively  chlorinated  to   1,2,4,5
tetrachlorobenzene using iodine plus antimony trichloride as catalyst.


No  reports  were  available  regarding  the  toxic effects of 1,2,4-TCB on
humans.  Limited data from studies of effects  in  laboratory  animals  fed
1,2,4-TCB  indicate  depression  of  activity  at  low  doses  and predeath
extension convulsions at lethal doses.  Metabolic  disturbances  and  liver
changes  were  also  observed.   Studies  for  the  purpose  of determining
teratogenic or mutagenic properties of 1,2,4-TCB have not  been  conducted.
No   studies   have   been  made  of  carcinogenic  behavior  of  1,2,4-TCB
administered orally.

For the prevention of adverse effects due to the organoleptic properties of
1,2,4-trichlorobenzene in water, the water quality criterion is 0.013 mg/1.

Data on the behavior of 1,2,4-TCB in POTW are not available.  However, this
compound has been investigated in a laboratory scale study  of  biochemical
oxidation  at  concentrations higher than those expected to be contained by
most municipal wastewaters.  Degradations of 0, 87, and  100  percent  were
observed  after  5,  10, and 20 days, respectively.  Using this observation
and  general  observations  relating  molecular  structure   to   ease   of
degradation  for all of the organic priority pollutants, the conclusion was
reached that biological treatment produces a  high  degree  of  removal  in
POTW.
                                   387

-------
l,l,l-Trichloroethane(ll).    1,1,1-Trichloroethane    is   one   of  the  two
possible trichlorethanes.  It is manufactured  by  hydrochlorinating  vinyl
chloride  to  1,1-dichloroethane  which   is then chlorinated to the desired
product.  1,1,1-Trichloroethane is a  liquid  at  room   temperature  with  a
vapor  pressure  of  96   mm  Hg  at   20°C and a boiling point  of 74°C.  Its
formula is CC13CH3.  It  is slightly soluble in water  (0.48 g/1) and is very
soluble in organic solvents.  U.S.  annual production  is  greater than  one-
third of a million tons.

1,1,1-Trichloroethane   is used  as   an   industrial  solvent and degreasing
agent.

Most human toxicity data for 1,1,1-trichloroethane  relates to  inhalation
and  dermal   exposure   routes.   Limited  data are available for determining
toxicity of ingested 1,1,1-trichloroethane, and those  data are all for  the
compound  itself  not   solutions in water.  No data are available regarding
its toxicity  to fish and aquatic organisms.  For the   protection  of  human
health  from  the toxic  properties of  1,1,1-trichloroethane ingested through
the consumption of water and fish, the  ambient  water criterion  is  15.7
mg/1.  The criterion is based on bioassy  for possible  carcinogenicity.

No  detailed  study of  1,1,1-trichloroethane behavior  in  POTW  is available.
However, it has  been   demonstrated   that  none  of  the   organic  priority
pollutants  of  this  type  can  be   broken  down  by   biological treatment
processes as  readily as fatty acids,  carbohydrates, or proteins.

Biochemical oxidation of many of the  organic priority  pollutants  has  been
investigated,   at  least  in  laboratory  scale  studies,  at concentrations
higher  than  commonly    expected    in    municipal   wastewater.     General
observations  relating  molecular structure to ease of  degradation have been
developed for all of these pollutants.  The conclusion reached by study  of
the limited data is that biological  treatment produces a  moderate degree of
degradation of  1,1,1-trichloroethane.  No evidence is  available for drawing
conclusions   about  its possible   toxic or   inhibitory  effect  on  POTW
operation.  However, for degradation  to occur a fairly constant  input  of
the compound  would be necessary.

Its  water  solubility   would   allow   1,1,1-trichloroethane, present in the
influent and  not biodegradable, to pass through a POTW into the  effluent.
One factor which has received some attention, but no detailed  study, is the
volatilization  of  the lower molecular weight organics  from POTW.   If 1,1,1-
trichloroethane is  not  biodegraded,  it  will volatilize during aeration
processes  in  the POTW.

Hexachloroethane    (12).   Hexachloroethane    (CC13CC13),  also    called
perchloroethane is a white crystalline solid with a  camphor-like odor.  It
is manufactured from tetrachloroethylene, and  is a minor   product  in  many
industrial  chlorination  processes   designed   to produce lower chlorinated
hydrocarbons.   Hexachloroethane sublimes  at  185°C and  has a vapor  pressure
                                    388

-------
of  about 0.2 mm Hg at 20°C.   It is insoluble in water (50 mg/1 at 22C) and
soluble in some organic solvents.

Hexachloroethane can be used in lubricants designed  to  withstand  extreme
pressure.   It  is  used  as  a  plasticizer for cellulose esters, and as a
pesticide.  It is also used as a retarding agent  in  fermentation,  as  an
accelerator in the rubber industry, and in pyrotechnic and smoke devices.

Hexachloroethane  is  considered  to  be  toxic  to humans by ingestion and
inhalation.  In laboratory  animals  liver  and  kidney  damage  have  been
observed.   Symptoms  in  humans  exposed to hexachloroethane vapor include
severe  eye  irritation  and  vision  impairment.   Based  on  studies   on
laboratory animals, hexachloroethane is considered to be carcinogenic.

For  the maximum protection of human health from the potential carcinogenic
effects of exposure to hexachloroethane  through  ingestion  of  water  and
contaminated  aquatic  organisms,   the ambient water concentration is zero.
Concentrations  of  hexachloroethane  estimated  to  result  in  additional
lifetime  cancer risks at levels of 10~7, 10~«, and 10~5 are 0.000059 mg/1,
0.00059 mg/1, and 0.0059 mg/1, respectively.

Data on the behavior of hexachloroethane in POTW are not  available.   Many
of  the  organic  priority  pollutants  have been investigated, at least in
laboratory scale studies, at concentrations higher than those  expected  to
be contained by most municipal wastewaters.  General observations have been
developed  relating  molecular  structure to ease of degradation for all of
the organic priority pollutants.  The conclusion reached by  study  of  the
limited  data is that biological treatment produces little or no removal of
hexachloroethane in POTW.  The lack of water solubility  and  the  expected
affinity  of  hexachloroethane  for solid particles lead to the expectation
that this compound will be removed to the sludge in POTW.   No  information
was  found regarding possible uptake of hexachloroethane by plants grown on
soils amended with hexachloroethane-bearing sludge.

l,l-Dichloroethane(13).    1,1-Dichloroethane,   also   called   ethylidene
dichloride  and  ethylidene  chloride is a colorless liquid manufactured by
reacting  hydrogen  chloride  with  vinyl  chloride  in  1,1-dichloroethane
solution   in  the  presence  of  a catalyst.  However, it is reportedly not
manufactured commercially in the U.S.  1,1-dichloroethane boils at 57°C and
has a vapor pressure of 182 mm Hg at 20°C.  It  is slightly soluble in  water
(5.5 g/1 at 20°C) and  very soluble in organic solvents.

1,1-Dichloroethane is  used as an extractant for  heat-sensitive  substances
and as a solvent for rubber and silicone grease.

1,1-Dichloroethane  is  less toxic than  its isomer  (1,2-dichloroethane) but
its  use  as  an  anesthetic  has  been  discontinued  because  of    marked
excitationof  the  heart.   It  causes central  nervous system depression  in
                                   389

-------
humans.  There are insufficient data to derive water quality   criteria  for
1,1-dichloroethane.

Data on the behavior of 1,1-dichloroethane  in POTW  are  not  available.   Many
of  the  organic  priority  pollutants  have been investigated,  at least in
laboratory scale studies, at concentrations higher  than those   expected  to
be contained by most municipal wastewaters.  General observations  have been
developed  relating  molecular  structure to ease of degradation for all of
the organic priority pollutants.  The conclusion reached by study  of  the
limted  data  is that biological treatment produces only a  moderate removal
of 1,1-dichloroethane in POTW by degradation.

The high vapor pressure of 1,1-dichloroethane  is   expected to result  in
volatilization of some of the compound from aerobic processes  in POTW.   Its
water solubility will result in some of the 1,1-dichloroethane which enters
the POTW leaving in the effluent from the POTW.

1,1,2-Trichloroethane(14).    1,1,2-Trichloroethane  is one   of   the  two
possible trichloroethanes and is sometimes  called  ethane  trichloride  or
vinyl  trichloride.   It  is  used  as a solvent for fats,  oils, waxes,  and
resins, in the manufacture of 1,1-dichloroethylene, and as  an   intermediate
in organic synthesis.

1,1,2-Trichloroethane is a clear, colorless liquid  at room  temperature with
a  vapor  pressure of 16.7 mm Hg at 20°C, and a boiling point  of 113°C.   It
is insoluble in water and very soluble in organic solvents.  The formula is
CHC12CH2C1.

Human toxicity data  for  1,1,2-trichloroethane  does   not  appear  in  the
literature.    The  compound  does  produce  liver  and'  kidney damage  in
laboratory animals after  intraperitoneal  administration.   No literature
data   was  found  concerning  teratogenicity  or   mutagenicity of  1,1,2-
trichloroethane.  However, mice treated with  1,1,2-trichloroethane  showed
increased incidence of hepatocellular carcinoma.  Although  bioconcentration
factors  are  not  available  for  1,1,2-trichloroethane in fish  and  other
freshwater aquatic organisms, it is concluded on the basis  of  octanol-water
partition coefficients that bioconcentration does occur.

For the maximum protection of human health from the potential   carcinogenic
effects of exposure to 1,1,2-trichloroethane through ingestion of  water and
contaminated  aquatic  organisms,  the ambient water concentration is  zero.
Concentrations of this compound estimated to result in  additional   lifetime
cancer  risks  at  risk   levels  of 10~7, 10-«, and 10~5 are 0.000027  mg/1,
0.00027 mg/1, and 0.0027 mg/1, respectively.

No detailed study of 1,1,2-trichloroethane behavior in  POTW is available.
However,  it  is  reported  that  small  amounts are formed by chlorination
processes and that this compound presists in the environment (greater   than
two  years)  and  it  is  not  biologically degraded.   This information not
                                    390

-------
completely consistant  with  the  conclusions  based  on  laboratory  scale
biochemical  oxidation studies and relating molecular structure to ease the
degradation.   That study concluded that biological treatment in  POTW  will
produce moderate removal of 1,1,2-trichloroethane.

The  lack  of  water  solubility and the relatively high vapor pressure may
lead to removal of this compound from POTW by volatilization.

2-Chloronaphthalene (20).   2-Chloronaphthalene (C10H7C1)  is  a  crytalline
solid  melting  at  61°C.    It is obtained as coproduct (9 percent) with 1-
chloronaphthalene  after  fractional  distillation  of  the  crude  product
obtained  from the catalysed chlorination of molten naphthalene.  Nearly 25
tons of monochloronaphthalene is produced annually  in  the  U.S.   The  2-
chloro  isomer  is readily made in the pure state from 2-naphthylamine.  2-
Chloronaphthalene is insoluble in water and soluble in organic solvents.

No information was found in the literature on uses for 2-chloronaphthalene.

No information  was  found  in  the  literature  on  toxic  effects  of  2-
chloronaphthalene on humans or other animals.

Data  on  the  behavior  of  2-chloronaphthalene in POTW are not available.
Many of the organic priority pollutants have been investigated, at least in
laboratory-scale studies,  at concentrations higher than those  expected  to
be contained by most municipal wastewaters.  General observations have been
developed  relating  molecular  structure to ease of degradation for all of
the organic priority pollutants.  The conclusion reached by  study  of  the
limited  data  is  that  biological treatment produces a moderate degree of
removal of 2-chloronaphthalene in POTW.  The lack of water  solubility  and
the  expected  affinity  of 2-chloronaphthalene for solid particles lead to
the expectation that this compound will be removed to the sludge  in  POTW.
No  information  was found regarding possible uptake of 2-chloronaphthalene
by plants grown on soils amended with 2-chloronaphthalene-bearing sludge.

2,4,6-Trichlorophenol  (21).  2,4,6-Trichlorophenol (C13C6H2OH,  abbreviated
here  to  2,4,6  TCP)  is a colorless crystalline solid at room temperature.
It is prepared by the direct chlorination of phenol.   2,4,6-TCP  melts  at
68°C and is slightly soluble in water (0.8 gm/1 at 25°C).  This phenol does
not  produce  a color with 4-aminoantipyrene, therefore does not contribute
to the non-conventional pollutant parameter "Total Phenols."  No data  were
found on production volumes.

2,4,6-TCP  is used as a fungicide, bactericide, glue and wood preservative,
and for antimildew treatment.  It is  also  used  for  the  manufacture  of
2,3,4,6-tetrachlorophenol and pentachlorophenol.

No  data  were  found  on  human toxicity effects of 2,4,6-TCP.  Reports of
studies  with  laboratory  animals   indicate   that   2,4,6-TCP   produced
convulsions when injected interperitoneally.  Body temperature was elevated
                                   391

-------
also.   The compound also produced inhibition of ATP production  in isolated
rat liver mitochondria, increased mutation rate  in one  strain  of  bacteria,
and  produced  a genetic change in rats.  No studies on teratogenicity were
found.  Results of a test of carcinoginicity were inconclusive.

For the prevention of adverse effects due to the organoleptic  properties of
2,4,6-trichlorophenol in water, the water quality criterion  is 0.100 mg/1.

Although no data were found regarding the behavior of   2,4,6-TCP  in  POTW,
studies  of  the  biochemical oxidation of the compound have been made in a
laboratory scale at concentrations higher than those normally   expected  in
municipal  wastewaters.   Biochemical  oxidation  of  2,4,6-TCP  at 100 mg/1
produced 23 percent degradation  using  a  phenol-adapted  acclimated  seed
culture.   Based  on  these  results,  biological  treatment  in  a POTW is
expected to produce  a  moderate  degree  of  degradation.   Another  study
indicates  that 2,4,6-TCP may be produced in POTW by chlorination of phenol
during normal chlorination treatment.

Para-chloro-meta-cresol  (22).    Para-chloro-meta-cresol    (C1C7H6OH)   is
thought  to be 4-chloro-3-methyl-phenol (4-chloro-meta-cresol,  or 2 chloro-
5-hydroxy-toluene), but is also used by some authorities  to  refer  to  6-
chloro-3-methyl-phenol     (6-chloro-meta-cresol,   or    4-chloro-3-hydroxy-
toluene), depending on whether the chlorine is considered  to be  para to the
methyl or to the hydroxy group.  It is assumed for  the purposes  of  this
document  that  the  subject  compound is 2-chloro-5-hydroxy-toluene.  This
compound is a colorless  crystalline  solid  melting  at  66-68°C.   It  is
slightly soluble in water  (3.8 gm/1) and soluble in organic  solvents.  This
phenol  reacts  with  4-aminoantipyrene  to  give  a  colored   product  and
therefore  contributes  to   the   non-conventional   pollutant    parameter
designated  "Total  Phenols."  No  information   on manufacturing methods or
volumes produced was found.

Para-chloro-meta cresol  (abbreviated  here  as  PCMC)   is  marketed  as a
microbicide,  and was proposed as an antiseptic  and disinfectant, more than
forty years ago.  It is used in glues, gums, paints,  inks,  textiles,  and
leather  goods.   PCMC  was  found  in raw wastewaters  from  the  die casting
quench operation from one  subcategory of foundary operations.

Although  no  human  toxicity  data  are  available  for  PCMC  studies  on
laboratory  animals  have  demonstrated  that  this  compound  is toxic when
administered subcutaneously and  intravenously.   Death was  preceeded  by
severe  muscle  tremors.   At  high dosages kidney damage  occurred.  On the
other hand, an unspecified isomer of chlorocresol, presumed  to be PCMC,  is
used at  a  concentration  of  0.15  percent to preserve  mucous heparin, a
natural product administered intervenously as an anticoagulant.   The report
does not  indicate  the  total  amount  of  PCMC typically  received.   No
information was found regarding possible teratogenicity, or  carcinoqenicity
of  PCMC.
                                    392

-------
Two  reports  indicate  that  PCMC  undergoes  degradation  in  biochemical
oxidation treatments carried out at concentrations higher than are expected
to  be  encountered  in  POTW  influents.   One  study  showed  59  percent
degradation  in 3.5 hours when a phenol-adapted acclimated seed culture was
used with a solution of 60 mg/1 PCMC.  The other study showed  100  percent
degradation  of  a  20  mg/1  solution  of  PCMC in two weeks in an aerobic
activated sludge test  system.   No  degradation  of  PCMC  occurred  under
anaerobic conditions.

Chloroform(23).  Chloroform is a colorless liquid manufactured commercially
by  chlorination  of  methane.   Careful  control  of  conditions maximizes
chloroform production, but other products must  be  separated.   Chloroform
boils  at  61°C  and  has  a  vapor  pressure  of 200 mm Hg at 25°C.  It is
slightly soluble in water (8.22 g/1 at 20°C) and readily soluble in organic
solvents.

Chloroform  is  used  as  a  solvent  and  to   manufacture   refrigerents,
Pharmaceuticals,  plastics,  and  anesthetics.   It  is  seldom  used as an
anesthetic.

Toxic effects of  chloroform  on  humans  include  central  nervous  system
depression,  gastrointestinal  irritation,  liver  and  kidney  damage  and
possible cardiac sensitization  to  adrenalin.   Carcinogenicity  has  been
demonstrated for chloroform on laboratory animals.

For  the maximum protection of human health from the potential carcinogenic
effects  of  exposure  to  chloroform  through  ingest ion  of   water   and
contaminated  aquatic  organisms,  the ambient water concentration is zero.
Concentrations of chloroform estimated to  result  in  additional  lifetime
cancer  risks  at  the  levels  of 10-7, 10~6, and 10~5 were 0.000021 mg/1,
0.00021 mg/1, and 0.0021 mg/1, respectively.

No data are available regarding the  behavior  of  chloroform  in  a  POTW.
However,  the  biochemical  oxidation  of  this compound was studied in one
laboratory scale study at concentrations higher than these expected  to  be
contained  by  most  municipal  wastewaters.   After  5, 10, and 20 days no
degradation of chloroform was observed.  The  conclusion  reached  is  that
biological  treatment  produces  little  or  no  removal  by degradation of
chloroform in POTW.

The  high  vapor  pressure  of  chloroform  is  expected   to   result   in
volatilization  of  the  compound  from  aerobic  treatment  steps in POTW.
Remaining chloroform is expected to pass through into the POTW effluent.

2-Chlorophenol  (24).   2-Chlorophenol   (C1C«H4OH),  also   called   ortho-
chlorophenol,  is  a  colorless liquid at room temperature, manufactured by
direct chlorination of phenol followed by distillation to separate it  from
the  other  principal  product,  4-chlorophenol.  2-Chlorophenol solidifies
below 7°C and boils at 176°C.  It is soluble in water (28.5 gm/1  at  20°C)
                                   393

-------
and  soluble  in  several  types  of organic solvents.  This phenol  gives a
strong color with 4-aninoantipyrene and therefore contributes  to   the   non-
conventional  pollutant  parameter  "Total  Phenols." Production  statistics
could not be  found.   2-Chlorophenol  is  used  almost  exclusively  as   a
chemical  intermediate in the production of pesticdes and dyes.   Production
of some phenolic resins uses 2-chlorophenol.

Very few data are available on which to determine the toxic effects  of  2-
chlorophenol  on  humans.  The compound is more toxic to laboratory  mammals
when  administered  orally  than  when   administered   subcataneously   or
intravenously.   This affect is attributed to the fact that the compound  is
almost completely in the un-ionized state at the low pH of the stomach and
hence  is  more  readily  absorbed  into  the  body.   Initial symptoms are
restlessness and increased respiration rate, followed by motor weakness and
convulsions induced by noise or touch.   Coma  follows.   Following  lethal
doses, kidney, liver, and intestinal damage were observed.  No studies were
found which addressed the teratogenicity or mutagenicity of 2-chlorophenol.
Studies  of  2-chlorophenol as a promoter of carcinogenic activity of  other
carcinogens were conducted by dermal application.  Results do  not  bear   a
determinable relationship to results of oral administration studies.

For  the prevention of adverse effects due to the organoleptic  properties  of
2-chlorophenol in water, the criterion is 0.0003 mg/1.

Data on the behavior of  2-chlorophenol in POTW are not available.  However,
laboratory  scale studies have been conducted at concentrations higher than
those expected to be found in municipal  wastewaters.   At  1  mg/1  of  2-
chlorophenol,  an  acclimated  culture  produced 100 percent degradation  by
biochemical oxidation after 15 days.  Another study showed 45, 70,   and  79
percent  degradation  by  biochemical  oxidation  after 5, 10, and 20  days,
respectively.  The conclusion reached by the study of these  limited  data,
and  general  observations  on  all  organic  priority  pollutants relating
molecular  structure  to  ease  of  biochemical  oxidation,  is    that   2-
chlorophenol  is  removed  to  a  high  degree  or completely  by  biological
treatment  in POTW.  Undegraded 2-chlorophenol is expected to   pass  through
POTW   into  the  effluent  because  of  the  water  solubility-   Some  2-
chlorophenol  is also expected to be generated by chlorination  treatments  of
POTW effluents containing phenol.

1,3-Dichlorobenzene  (26).  1,3-Dichlorobenzene  (C6H4C12), also called  meta-
dichlorobenzene,  is a colorless liquid at room  temperature  obtained  as   a
minor   product   in  the  production of the ortho-and para  isomers by liquid
phase chlorination  of   monochlorobenzene.   1,3-Dichlorobenzene   boils  at
172°C   and  has   a  vapor  pressure  of  2  mm  Hg at  25°C.  The compound  is
slightly soluble  in water  (0.123 g/1  at  25°C)  and   is  soluble  in   many
organic  solvents   and   in fats.  Commercial production of this compound  is
limited.  No statistics  were  found.   1,3-Dichlorobenzene  is used  as   a
fumigant and  insecticide.
                                    394

-------
Very few  studies have been made of the toxic effects of 1,3-dichlorobenzene
on  humans.    A substantial amount of data has been generated regarding the
toxic effects  of the other two dichlorobenzene isomers.   In  two  studies,
laboratory  animals fed the 1,3-isomer developed a metabolic disorder of the
liver.    No data are available regarding the teratogenicity, mutagenicity,
or carcinogenicity of 1,3-dichlorobenzene.  However, in one survey of  data
on dichlorobenzenes, it was concluded that there is a sufficient collection
of  varied  data to suggest a prudent regard of these compounds as suspected
carcinogens even though no strong direct evidence  for  that  property  was
found.
                                 /

For the protection of human health from toxic properties of dichlorobenzene
ingested   through  water  and  through  contaminated aquatic organisms, the
ambient  water  criterion  is   determined   to   be   0.230   mg/1   total
dichlorobenzenes (all isomers combined).

Data  on   the   behavior  of  1,3-dichlorobenzene in POTW are not available.
Many of the organic priority pollutants have been investigated, at least in
laboratory  scale studies, at concentrations higher than those  expected  to
be contained in most municipal wastewaters.  General observations have been
developed  relating  molecular  structure to ease of degradation for all of
the organic priority pollutants.  The conclusion reached by  study  of  the
limited  data   is  that  biological treatment produces a moderate degree of
removal of  1,3-dichlorobenzene in POTW.  No information was found regarding
the possible interference of 1,3-dichlorobenzene with treatment  processes.
Based  on  the limited water solubility and moderate vapor pressure of this
compound  it is expected that undegraded 1,3-dichlorobenzene  will  leave  a
POTW  in   the   effluent,   and  by  volatilization m during aerobic treatment
processes.

l,l-Dichloroethylene(29).   1,1-Dichloroethylene  (1,1-DCE),  also   called
vinylidene   chloride,   is   a  clear  colorless  liquid  manufactured  by
dehydrochlorination of  1,1,2-trichloroethane.   1,1-DCE  has  the  formula
CC12CH2.   It has a boiling paint of 32°C, and a vapor pressure of 591 mm Hg
at 25°C.   1,1-DCE is slightly soluble in water (2.5 mg/1) and is soluble in
many  organic   solvents.    U.S. production is in the range of a hundreds of
thousands of tons annually.

1,1-DCE is used as a chemical intermediate and for  copolymer  coatings  or
films.  It may enter the wastewater of an industrial facility as the result
of  decomposition of 1,1,1-trichloroethylene used in degreasing operations,
or by migration from vinylidene chloride copolymers exposed to the  process
water.

Human  toxicity  of  1,1-DCE  has  not  been  demonstrated, however it is a
suspected human carcinogen.  Mammalian toxicity studies have focused on the
liver and kidney damage produced by  1,1-DCE.   Various  changes  occur  in
those organs in rats and mice ingesting 1,1-DCE.
                                   395

-------
For  the maximum protection of human health from the potential  carcinogenic
effects of exposure to 1,1-dichloroethylene through ingestion of  water  and
contaminated  aquatic  organisms,  the ambient water concentration  is zero.
The concentration of 1,1-DCE estimated to result in an additional  lifetime
cancer risk of 1 in 100,000 is 0.0013 mg/1.

Under  laboratory conditions, dichloroethylenes have been  shown to  be toxic
to fish.  The primary effect of acute toxicity of  the dichloroethylenes  is
depression  of  the  central  nervous  system.  The octanol/water partition
coefficident of 1,1-DCE  indicates  it should not accumulate significantly in
animals.

The behavior of 1,1-DCE  in POTW has not been studied.   However,  its  very
high  vapor  pressure  is  expected  to  result  in  release of significant
percentages of this material to the atmosphere in  any  treatment  involving
aeration.   Degradation  of  dichloroethylene  in  air is reported to  occur,
with a half-life of 8 weeks.

Biochemical oxidation of many of the organic priority pollutants  has  been
investigated   in  laboratory-scale  studies  at  concentrations higher than
would normally be expected in municipal wastewaters.  General   observations
relating molecular structure to ease of degradation have been developed for
all  of  these  pollutants.  The conclusion reached by study of the limited
data is that biological  treatment  produces little  or no degradation of 1,1-
dichloroethylene.  No evidence is  available for drawing  conclusions   about
the  possible  toxic  or   inhibitory  effect  of 1,1-DCE on POTW  operation.
Because of water solubility.- 1,1-DCE which is not  volatilized   or  degraded
is  expected   to  pass through POTW.  Very little  1,1-DCE  is expected to be
found  in sludge from POTW.

1,2-trans-Dichloroethylene(30).  1,1-trans-Dichloroethylene (trans-1,2-DCE)
is a clear, colorless liquid with  the formula CHC1CHC1.    Trans-1,2-DCE  is
produced   in mixture with  the cis-isomer by chlorination of acetylene.   The
cis-isomer has distinctly  different physical properties.   Industrially,  the
mixture  is used rather than the  separate  isomers.   Trans-1,2-DCE  has  a
boiling point  of 48°C, and a vapor pressure of 324 mm Hg at 25°C.

The  principal  use  of   1,2-dichloroethylene  (mixed isomers) is  to produce
vinyl  chloride.  It  is used  as  a lead  scavenger  in  gasoline,   general
solvent,   and  for synthesis of various other organic chemicals.  When it is
used as a  solvent trans-1,2-DCE can enter wastewater streams.

Although   trans-1,2-DCE   is  thought  to  produce  fatty   degeneration   of
mammalian   liver,  there are insufficient data on  which to base any ambient
water  criterion.

In the  one reported  toxicity test  of trans-1,2-DCE on  aquatic  life,  the
compound   appeared   to be  about half as toxic  as the other dichloroethylene
 (1,1-DCE)  on the priority  pollutants list.
                                    396

-------
The  behavior of  trans-1,2-DCE  in  POTW has not been studied.   However,  its
high vapor  pressure   is   expected  to  result  in  release of significant
percentage of  this  compound to the atmosphere in  any  treatment  involving
aeration.   Degradation of the   dichloroethylenes  in  air is reported to
occur, with a  half-life of  8 weeks.

Biochemical oxidation  of many  of  the organic priority pollutants  has  been
investigated   in  laboratory  scale  studies  at concentrations higher than
would normally be  expected  in  municipal wastewater.   General  observations
relating molecular  structure to ease of degradation have been developed for
all   of  these  pollutants.   The  conclusion  reached  by the study of the
limited  data  is   that biochemical  oxidation  produces  little   or   no
degradation  of   1,2-trans-dichloroethylene.   No evidence is available for
drawing conclusions about  the  possible toxic or inhibitory effect  of  1,2-
trans-dichloroethylene  on   POTW   operation.   It  is expected that its low
molecular weight and degree of water solubility will result  in  trans-1,2-
DCE  passing   through   a  POTW  to  the  effluent  if it is not degraded or
volatilized.   Very little  trans-1,2-DCE is expected to be found  in  sludge
from POTW.

2,4-Dichlorophenol   (31).    2,4-Dichlorophenol  (C12C6H3OH) is a colorless,
crystalline solid manufactured  by  chlorination  of  phenol  dissolved  in
liquid  sulfur  dioxide or by chlorination of molten phenol (a lower yield
method.   2,4-Dichlorophenol  (2,4-DCP)  melts  at  45°C  and  has  a  vapor
pressure  of   less  than  1 mm Hg at 25°C (vapor pressure equals 1 mm Hg at
530C).  2,4-DCP  is slightly soluble in water (4.6 g/1 at 20°C) and  soluble
in   many  organic  solvents.    2,4-DCP  reacts  to  give  a  strong  color
development with 4-aminoantipyrene and therefore contributes  to  the  non-
conventional   pollutant designated "Total Phenols." Annual U.S. production
of 2,4-DCP'is  about 25,000 tons.

The principal  use of 2,4-DCP is  for  manufacture  of  the  herbicide  2,4-
dichloro-phenoxyacetic acid (2,4-D) and other pesticides.

Few  data exist  on which to base an evaluation of the toxic effects of 2,4-
DCP on  humans.  Symptoms exhibited  by  laboratory  animals  injected  with
fatal  doses  of  2,4-DCP included loss of muscle tone followed by rapid then
slow breathing.    Ir\  vitro  experiments  reveal  inhibition  of  oxidative
phosphorylation   (a  primary  metabolic  function)  by 2,4-DCP in rat liver
mitochandria  and rat  brain  homogenates.   No  studies  were  found  which
addressed   the  teratogenicity, or the mutagenicity in mammals, of 2,4-DCP.
The  only   studies  of  carcinogenic  properties  of  2,4-DCP  used  dermal
application   which  has  no established relationship to oral administration
results.

For the prevention of  adverse effects due to the organoleptic properties of
2,4-dichlorophenol in  water, the criterion  is 0.0005 mg/1.
                                   397

-------
Data on the behavior of  2,4-dichlorophenol   in   POTW   are  not  available.
However,  laboratory  scale  studies  have been  conducted  at concentrations
higher  than  those  expected  to  be  found   in  municipal   wastewaters.
Biochemical  oxidation  produced degradation  of  70,72,  and 72 percent after
5,10 and 20 days, respectively, in one study.  In another   study  using  an
acclimated phenol-adapted culture 30 percent  degradation was measured after
3.5  hours.   Based  on  these  limited  data,   and on  general observations
relating molecular  structure  to  ease  of   biological  oxidation,   it  is
concluded  that  2,4-DCP  is  removed  to  a   high  degree or completely by
biological treatment in POTW.   Undegraded  2,4-DCP  is  expected  to  pass
through  POTW  to  the  effluent.   Some  2,4-DCP may  be  formed in POTW by
chlorination of effluents containing phenol.

2,4-Dimethylphenol(34).  2,4-Dimethylphenol   (2,4-DMP),  also  called  2,4-
xylenol,  is a colorless, crystalline solid at room temperature (25°C),  but
melts at 27 to 28°C.  2,4-DMP is slightly soluble in water and,  as  a  weak
acid,   is soluble in alkaline solutions.  Its  vapor pressure is less than 1
mm Hg at room temperature.

2,4-DMP is a natural product, occurring in coal  and petroleum sources.    It
is  used  commercially  as  a  intermediate   for manufacture of pesticides,
dystuffs, plastics and resins, and surfactants.   It is  found in  the  water
runoff  from asphalt surfaces.  It can find its way into the wastewater of a
manufacturing plant from any of several adventitious sources.

Analytical   procedures   specific  to  this   compound  are  used  for  its
identification and quantification in wastewaters.  This compound  does  not
contribute to "Total Phenol" determined by the 4-aminoantipyrene method.

Three   methylphenol  isomers  (cresols)  and  six  dimethylphenol  isomers
(xylenols)  generally  occur  together  in  natural  products,    industrial
processes,  commercial  products, and phenolic wastes.  Therefore, data are
not available for human exposure to 2,4-DMP alone.  In  addition  to  this,
most mammalian tests for toxicity of individual  dimethylphenol isomers have
been conducted with isomers other than 2,4-DMP-

In  general,  the  mixtures  of  phenol, methylphenols, and dimethylphenols
contain compounds which produced acute  poisoning in   laboratory  animals.
Symptoms  were  difficult  breathing, rapid muscular spasms,  disturbance of
motor coordination, and assymetrical body position.   In   a  1977  National
Academy of Science publication the conclusion  was reached  that,  "In view of
the   relative  paucity  of  data  on  the  mutagenicity,   carcinogenicity,
teratogenicity-  and  long  term  oral  toxicity of  2,4    dimethylphenol,
estimates  of  the effects of chronic oral exposure at  low levels cannot be
made with any confidence."  No ambient water  quality criterion can  be  set
at this time.  In order to protect public health, exposure to this compound
should  be minimized as soon as possible.
                                   398

-------
Toxicity   data   for  fish and freshwater aquatic life are limited.  However,
in reported  studies  of  2,4-dimethylphenol at concentrations as  high  as  2
mg/1  no adverse  effects were observed.

The  behavior  of  2,4-DMP in POTW has not been studied.  As a weak acid its
behavior  may be  somewhat dependent on the pH of the influent to  the  POTW.
However,   over   the   normal   limited  range of POTW pH, little effect of pH
would be  expected.

Biological degradability of  2,4-DMP as determined in one study, showed 94.5
percent removal  based on chemical oxygen demand (COD).   Thus,  substantial
removal   is  expected  for  this  compound.   Another study determined that
persistance  of 2,4-DMP in the environment is low, thus any of the  compound
which remained   in  the sludge or passed through the POTW into the effluent
would be  degraded  within moderate length of time (estimated as 2 months  in
the report)-

2,4-Dinitrotoluene  (35).   2,4-Dinitrotoluene  [(N02)2C6H3CH,],  a  yellow
crystalline  compound, is manufactured as a coproduct with the 2,6 isomer by
nitration of nitrotoluene.    It  melts  at  71°C.    2,4-Dinitrotoluene  is
insoluble  in  water  (0.27  g/1 at 22°C) and soluble in a number of organic
solvents. Production data for the 2,4-isomer alone are not available.  The
2,4-and  2,6-isomers  are manufactured in an 80:20 or 65:35 ratio,  depending
on  the   process  used.   Annual  U.S.   commercial   production is about 150
thousand  tons of the two isomers.  Unspecified amounts are produced by  the
U.S.   government and further nitrated to trinitrotoluene (TNT) for military
use.

The major use of the dinitrotoluene mixture is for  production  of  toluene
diisocyanate used  to  make polyuethanes.  Another use is in production of
dyestuffs.

The  toxic  effect   of   2,4-dinitrotoluene   in   humans   is   primarily
methemoglobinemia   (a  blood  condition  hindering  oxygen transport by the
blood).   Symptoms  depend on severity of the disease, but include  cyanosis,
dizziness,  pain  in  joints,  headache,  and  loss  of appetite in workers
inhaling   the  compound.   Laboratory  animals  fed  oral  doses  of   2,4-
dinitrotoluene exhibited many of the same symptoms.  Aside from the effects
in red blood cells,  effects are observed in the nervous system and testes.

Chronic   exposure   to  2,4-dinitrotoluene  may  produce  liver  damage  and
reversible anemia.  No data were found on teratogenicity of this  compound.
Mutagenic  data   are limited and are regarded as confusing.  Data resulting
from studies of  carcinogenicity of 2,4-dinitrotoluene point to a  need  for
further  testing  for  this property.

For  the  maximum protection of human health from the potential carcinogenic
effects  of exposure  to 2,4-dinitrotoluene through ingestion  of  water  and
contaminated aquatic  organisms,  the ambient water concentration is zero.
                                   399

-------
Concentrations of 2,4-dinitrotoluene  estimated  to  result   in   additional
lifetime  cancer  risk  at  risk  levels of 10~7,  10-*,  and  10~5  are 0.0074
mg/1, 0.074 mg/1, and 0.740 mg/1, respectively.

Data on the behavior of  2,4-dinitrotoluene  in  POTW  are   not   available.
However,  biochemical  oxidation of 2,4-dinitrophenol was  investigated on a
laboratory scale.   At  100  mg/1  of  2,4-dinitrophenol,  a  concentration
considerably   higher   than   that   expected   in  municipal  wastewaters,
biochemical oxidation by an  acclimated,  phenol   -  adapted  seed  culture
produced  52  percent  degradation  in  three hours.  Based  on this  limited
information and general observations relating molecular  structure to  ease
of  degradation  for  all the organic priority pollutants, it  was concluded
that biological treatment in POTW  removes  2,4-dinitrotoluene  to  a  high
degree  or  completely.   No  information  is  available regarding possible
interference by 2,4-dinitrotoluene in POTW treatment processes,  or  on  the
possible  detrimental  effect  on  sludge used to  amend  soils  in  which food
crops are grown.

2,6-Dinitrotoluene   (36).    2,6-Dinitrotoluene    [(N02)gC^HyCHy]    is   a
crystalline  solid  produced  as  a  coproduct  with  2,4-dinitrotoluene by
nitration of nitrotoluene.  It  melts  at  66C.    No  solubility   or  vapor
pressure data are given in the literature, but this compound is  expected to
be   insoluble  just  as the 2,4-dinitrotoluene isomer is (0.27 g/1 at 22C).
Production data for the 2,6-isomer are not available.  The   2,4-   and  2,6-
isomers  are  manufactured  in  an  80:20  or  65:35 ratio depending on the
process used.  Annual U.S. commercial production is about  150  thousand tons
of   the  two  isomers.   Unspecified  amounts  are  produced  by   the  U.S.
government and further nitrated to trinitrotoluene  (TNT) for military use.

The  major  use  of the dinitrotoluene mixture is  for production  of  toluene
diisocyanate used to make polyurethanes.  Another  use is in  production  of
dyestuffs.

No   toxicity  data  are available in the literature for  2,6-dinitrotoluene.
The  2,4-isomer is toxic and is classed as a  potential   carcinogen  on  the
basis  of  tumerogenic  effects and other considerations.  No  water  quality
criterion has been established for 2,6-dinitrotoluene.

Data on the behavior of  2,6-dinitrotoluene  in  POTW  are   not   available.
Biochemical  oxidation of many of the organic priority pollutants have been
investigated, at least  in  laboratory  scale  studies,  at   concentrations
higher  than  those expected to be contained by  most municipal wastewaters.
General observations have been developed relating  molecular  structure  to
ease   of  degradation  for  all  the  organic   priority  pollutants.   The
conclusion reached  by  study  of  the  limited  data  is  that   biological
treatment  produces a moderate degree of removal of 2,6-dinitrotoluene.  No
information   is  available  regarding   possible    interferance    by   2,6-
dinitrotoluene   in  POTW  processes,  or the possible detrimental effect on
sludge used to amend soils in which crops are grown.
                                    400

-------
Ethylbenzene(38).    Ethylbenzene   is   a   colorless,   flammable   liquid
manufactured commercially from benzene and ethylene.  Approximately half of
the  benzene  used  in  the U.S.  goes into the manufacture of more than three
million tons of  ethylbenzene annually.  Ethylbenzene boils at 136°C and has
a vapor pressure of  7  mm Hg at 20°C.    It  is  slightly  soluble  in  water
(0.14 g/1 at 15°C)  and is very soluble in organic solvents.

About 98  percent   of  the ethylbenzene produced in the U.S. goes into the
production of styrene,  much of which  is used in the plastics and  synthetic
rubber industries.    Ethylbenzene is a consitutent of xylene mixtures used
as diluents  in the  paint industry,   agricultural  insecticide  sprays, • and
gasoline blends.

Although  humans are   exposed to ethylbenzene from a variety of sources in
the environment, little information on effects of ethylbenzene  in  man  or
animals is available.   Inhalation can irritate eyes, affect the respiratory
tract, or cause vertigo.  In laboratory animals ethylbenzene exhibited low
toxicity.  There are no data available on teratogenicity, mutagenicity,  or
carcinogenicity  of  ethylbenzene.

Criteria  are  based  on data derived from inhalation exposure limits.  For
the protection of human health from the toxic  properties  of  ethylbenzene
ingested  through   water  and  contaminated  aquatic organisms, the ambient
water quality criterion is 1.1 mg/1.

The behavior of  ethylbenzene in  POTW  has  not  been  studied  in  detail.
Laboratory   scale   studies  of the biochemical oxidation of ethylbenzene at
concentrations   greater  than  would  normally  be   found   in   municipal
wastewaters  have demonstrated varying degrees of degradation.  In one study
with phenol-acclimated seed cultures 27 percent degradation was observed in
a   half  day  at   250 mg/1  ethylbezene.   Another  study  at  unspecified
conditions showed 32,  38, and 45 percent degradation after 5,  10,  and  20
days, respectively.   Based  on  these  results  and  general observations
relating molecular  structure to ease  of  degradation,  the  conclusion  is
reached  that  biological  treatment  produces  only  a moderate removal of
ethylbenzene in  POTW by degradation.

Other studies suggest  that most of the  ethylbenzene  entering  a  POTW  is
removed  from the aqueous stream to the sludge.  The ethylbenzene contained
in the sludge removed  from the POTW may volatilize.

Fluoranthene(39).    Fluoranthene  (1,2-benzacenaphthene)   is  one  of   the
compounds  called   polynuclear  aromatic hydrocarbons (PAH).  A pale yellow
solid at room temperature, it melts at 111°C and  has  a   negligible  vapor
pressure  at 25°C.    Water  solubility  is  low (0.2 mg/1).  Its molecular
formula  is Ci6H10.

Fluoranthene,  along  with  many  other  PAH's,  is  found  throughout  the
environment.    It   is   produced  by  pyrolytic  processing  of  organic raw
                                   401

-------
materials,  such  as  coal  and  petroleum,  at   high   temperature  (coking
processes).   It  occurs  naturally  as  a  product  of plant biosyntheses.
Cigarette smoke contains fluoranthene.  Although  it  is  not used as the pure
compound  in industry, it has been found at relatively higher concentrations
(0.002 mg/1) than most other PAH's in at  least   one industrial  effluent.
Furthermore,  in  a  1977  EPA  survey  to  determine levels of PAH in U.S.
drinking  water supplies, none of the 110 samples  analyzed  showed  any  PAH
other than fluoranthene.

Experiments  with  laboratory animals indicate that  fluoranthene presents a
relatively low degree of toxic potential  from  acute   exposure,  including
oral  administration.   Where  death  occured,  no  information was reported
concerning target organs or specific cause of death.

There is  no epidemiological evidence to prove  that  PAH  in  general,  and
fluoranthene,  in  particular, present in drinking water are related to the
development of  cancer.   The  only  studies  directed   toward  determining
carcinogenicity of fluoranthene have been skin tests on laboratory animals.
Results of these tests show that fluoranthene has no activity as a complete
carcinogen   (i.e.,   an  agent which produces cancer  when applied by itself,
but exhibits significant cocarcinogenicity (i.e.,   in   combination  with  a
carcinogen,  it increases the carcinogenic activity).

Based  on the  limited  animal  study  data,  and  following an established
procedure, the ambient water quality  criterion   for fluoranthene,  alone,
 (not  in   combination  with other PAH) is determined to be 200 mg/1 for the
protection of human  health from its toxic properties.

There* are no data on the chronic  effects  of  fluoranthene  on  freshwater
organisms.    One    saltwater   invertebrate   shows chronic  toxicity  at
concentrations below 0.016 mg/1.  For  some  freshwater  fish  species  the
concentrations  producing acute toxicity are substantially higher, but data
are very  limited.

Results of studies of the behavior of fluoranthene  in   conventional  sewage
treatment processes found  in  POTW  have  been  published.   Removal  of
fluoranthene during  primary sedimentation was found  to  be 62 to 66  percent
 (from  an  initial   value  of  0.00323  to  0.0435  mg/1 to a final value of
0.00122 to  0.0146 mg/1), and the removal was 91 to  99 percent (final values
of 0.00028  to 0.00026 mg/1) after biological  purification  with  activated
sludge processes.

A review was made  of data on biochemical oxidation of many of the organic
priority   pollutants investigated    in    laboratory   scale   studies   at
concentrations   higher  than  would  normally  be   expected  in  municipal
wastewater.  General observations relating molecular structure to  ease  of
degradation   have   been  developed   for   all  of  these  pollutants.   The
conclusion  reached   by  study  of  the  limited   data   is  that  biological
treatment  produces  little  or  no   degradation  of  fluoranthene.  The same
                                    402

-------
study however  concludes that  fluoranthene  would  be  readily  removed  by
filtration   and   oil  water separation and other methods which rely on water
insolubility,  or  adsorption on other  particulate  surfaces.   This  latter
conclusion   is supported by the previously cited study showing significant
removal  by  primary sedimentation.

No studies  were found to give data on either the possible  interference  of
fluoranthene  with  POTW  operation,  or the persistance of fluoranthene in
sludges  on  POTW effluent  waters.    Several  studies  have  documented  the
ubiquity of  fluoranthene  in  the  environment  and  it cannot be readily
determined  if  this results from persistance of  anthropogenic  fluoranthene
or  the   replacement   of degraded fluoranthene by natural processes such as
biosynthesis in plants.

Methylene Chloride(44).  Methylene chloride,  also  called  dichloromethane
(CH2C12),   is  a colorless liquid manufactured by chlorination of methane or
methyl chloride followed by separation from the higher chlorinated methanes
formed as coproducts.  Methylene chloride boils at 40°C, and  has  a  vapor
pressure of 362  mm Hg at 20°C.  It is slightly soluble in water (20 g/1 at
20°C), and  very soluble in organic solvents.   U.S.  annual  production  is
about  250,000  tons.

Methylene  chloride  is  a common industrial solvent found in insecticides,
metal  cleaners, paint, and paint and varnish removers.

Methylene chloride is not generally regarded as  highly  toxic  to  humans.
Most human  toxicity data are for exposure by inhalation.  Inhaled methylene
chloride acts as  a  central  nervous  system  depressant.  There is also
evidence that  the compound causes heart  failure  when  large  amounts  are
inhaled.

Methylene  chloride  does  produce  mutation  in tests for this effect.  In
addition a  bioassay recognized for its extermely high sensitivity to strong
and weak carcinogens produced results which  were  marginally  significant.
Thus potential carcinogenic effects of methylene chloride are not confirmed
or  denied,  but   are  under continuous study.  Difficulty in conduting and
interpreting the   test  results  from  the  low  boiling  point  (40°C)  of
methylene  chloride  which  increases  the  difficulty  of  maintaining the
compound in growth media during incubation at 37°C; and from the difficulty
of removing all  impurities, some of which might themselves be carcinogenic.

For the  protection of human health from the toxic properties  of  methylene
chloride  ingested  through  water  and contaminated aquatic organisms, the
ambient  water  criterion is 0.002 mg/1.

The behavior of methylene chloride in POTW has  not  been  studied  in  any
detail.   However, the biochemical oxidation of this compound was studied in
one  laboratory scale study at concentrations higher than those expected to
be contained by most municipal wastewaters.  After five days no degradation
                                   403

-------
of methylene  chloride  was  observed.   The  conclusion   reached  is  that
biological  treatment  produces  litte  or  no  removal   by   degradation of
methylene chloride in POTW.

The high vapor pressure of methylene chloride   is  expected   to   result  in
volatilization  of  the  compound from aerobic  treatment  steps  in POTW.  It
has been reported that methylene chloride inhibits  anerobic  processes  in
POTW.   Methylene  chloride that is not volatilized in the POTW  is expected
to pass through into the effluent.

Isophorone(54).  Isophorone is an industrial chemical produced at  a  level
of  tens  of millions of pounds annually in the U.S.  The chemical name for
isophorone  is 3,5,5-trimethyl-2-cyclohexen-l-one and  it is also  known  as
trimethyl   cyclohexanone  and isoacetophorone.  The formula is C6H5(CH3)30.
Normally, it is produced as the  gamma  isomer;  technical grades  contain
about  3  percent  of the beta isomer  (3,5-5-trimethyl-3-cyclohexen-l-one).
The pure gamma isomer is a water-white liquid,  with  vapor   pressure  less
than 1 mm Hg at room temperature, and a boiling point of  215.2°C.   It has a
camphor- or peppermint-like odor and yellows upon standing.   It  is slightly
soluble  (12 mg/1) in water and dissolves in fats and  oils.

Isophorone  is  synthesized  from  acetone  and is   used commercially as a
solvent or  cosolvent for finishes, lacquers, polyvinyl  and   nitrocellulose
resins, pesticides, herbicides, fats, oils, and gums.  It is  also used as a
chemical feedstock.

Because  isophorone is an  industrially used solvent,  most toxicity data are
for  inhalation exposure.  Oral administration to laboratory animals in  two
different   studies revealed no acute or chronic effects during  90 days, and
no hematological or pathological abnormalities  were reported.    Apparently,
no studies  have been completed on the carcinogenicity of  isophorone.

Isophorone  does undergo bioconcentration in the lipids of aquatic organisms
and  fish.

Based  on subacute data, the ambient water quality criterion  for isophorone
ingested through consumption of water and fish  is set at  460  mg/1  for  the
protection  of human health from its toxic properties.

Studies  of the effects of isophorone on fish  and aquatic organisms reveal
relatively  low toxicity, compared to some other priority  pollutants.

The  behavior of isophorone in POTW has  not  been  studied.   However,  the
biochemical oxidation  of many of the organic  priority pollutants has been
investigated  in laboratory-scale  studies  at   concentrations  higher  than
would  normally  be expected in municipal wastewater.  General  observations
relating molecular structure to ease of degradation have  been developed for
all  of these pollutants.   The  conclusion  reached  by  the   study  of  the
limited  data   is  that  biochemical   treatment  in   POTW produces moderate
                                    404

-------
removal of  isophorone.   This  conclusion is consistant with the findings  of
an  experimental  study   of microbiological degradation of isophorone which
showed about  45  percent biooxidation  in  15  to  20  days  in  domestic
wastewater,  but  only   9 percent  in salt water.   No data were found on the
persistence of  isophorone in  sewage sludge.

Naphthalene(55).   Naphthalene  is  an  aromatic   hydrocarbon   with   two
orthocondensed  benzene  rings and  a molecular formula of Ci0H8.  As such it
is properly classed  as a  polynuclear  aromatic  hydrocarbon   (PAH).   Pure
naphthalene is a white  crystalline solid melting at 80°C.  For a solid, it
has a relatively high vapor pressure (0.05 mm Hg  at  20°C),  and  moderate
water  solubility   (19   mg/1   at  20°C).    Naphthalene is the most abundant
single component of  coal tar.   Production is more than a third of a million
tons annually in the U.S. About three fourths of the production is used as
feedstock  for   phthalic   anhydride  manufacture.    Most  of  the  remaining
production goes   into   manufacture of insecticide, dystuffs, pigments, and
Pharmaceuticals.  Chlorinated and  partially hydrogenated  naphthalenes  are
used  in   some  solvent   mixtures.   Naphthalene  is  also  used  as a moth
repellent.

Napthalene, ingested  by humans,  has  reportedly  caused   vision   loss
(cataracts),  hemolytic   anemia,  and  occasionally,  renal disease.  These
effects of naphthalene  ingestion are confirmed  by  studies  on  laboratory
animals.    No   carcinogenicity  studies  are available which can be used to
demonstrate carcinogenic activity  for  naphthalene.   Naphthalene   does
bioconcentrate  in  aquatic organisms.

For the protection  of  human  health from the toxic properties of naphthalene
ingested   through   water  and  through  contaminated aquatic organisms, the
ambient water criterion  is determined to be 143 mg/1.

Only a  limited  number  of studies  have  been  conducted  to  determine  the
effects   of naphthalene on  aquatic organisms.  The data from  those studies
show only moderate  toxicity.

Naphthalene has been detected in sewage plant effluents  at  concentrations
up to  22  »«g/l  in studies carried out by the U.S. EPA.  Influent levels were
not reported.   The  behavior of naphthalene in POTW has not  been studied.
However,  recent studies  have determined that naphthalene will  accumulate in
sediments at 100 times the concentration in overlying water.   These results
suggest that naphthalene will be readily removed by primary  and  secondary
settling  in POTW,  if it  is not biologically degraded.

Biochemical oxidation  of many of the organic priority pollutants has been
investigated  in laboratory-scale  studies  at  concentrations  higher  than
would   normally be expected in municipal wastewater.  General observations
relating  molecular  structure to ease of degradation have been  developed for
all of  these pollutants.  The conclusion reached by study   of  the  limited
data is that biological  treatment produces a high removal by degradation of
                                   405

-------
naphthalene.   One  recent  study has shown that microorganisms can degrade
naphthalene, first to a dihydro compound, and ultimately  to carbon  dioxide
and water.

Nitrobenzene (56) .   Nitrobenzene (C6H5NOZ), also called nitrobenzol and oil
of mirbane, is a pale yellow, oily  liquid, manufactured by  reacting benzene
with  nitric acid and sulfuric acid.  Nitrobenzene  boils  at 210°C and has a
vapor pressure of 0.34 mm Hg at 25°C.   It is slightly  soluble in water (1.9
g/1 at 20°C), and is miscible with  most  organic  solvents.    Estimates  of
annual U.S. production vary widely, ranging from 100 to 350 thousand tons.

Almost the entire volume of nitrobenzene produced  (97  percent)  is converted
to  aniline, which is used in dyes, rubber, and medicinals.   Other uses for
nitrobenzene include: solvent for organic synthesis, metal   polishes,   shoe
polish, and perfume.

The toxic effects of ingested or inhaled nitrobenzene  in  humans are related
to  its  action  in  blood:   methemoglobinemia and cyanosis.   Nitrobenzene
administered orally to laboratory animals  caused   degeneration  of  heart,
kidney,  and  liver  tissue;  paralysis;  and death.   Nitrobenzene has also
exhibited teratogenicity in laboratory  animals, but studies  conducted  to
determine  mutagenicity  or  carcinogenicity did not reveal  either of  these
properties.

For the prevention of adverse effects due to the organoleptic properties of
nitrobenzene in water, the criterion is 0.030 mg/1.

Data on the behavior of nitrobenzene in POTW are not   available.    However,
laboratory  scale studies have been conducted at concentrations higher than
those expected to be found in municipal wastewaters.   Biochemical oxidation
produced no degradation after 5, 10, and 20  days.   A second  study   also
reported no degradation after 28 hours, using an acclimated,  phenol-adapted
seed  culture  with nitrobenzene at 100 mg/1.  Based on these limited  data,
and on  general  observations  relating  molecular  structure  to  ease  of
biological  oxidation,  it  is  concluded  that  little   or  no  removal of
nitrobenzene occurs during biological treatment in  POTW.    The  low  water
solubility  and  low vapor pressure of  nitrobenzene lead  to the expectation
that nitrobenzene will  be  removed from  POTW  in the  effluent  and  by
volatilization during aerobic treatment.

2-Nitrophenol    (57).    2-Nitrophenol   (N02C6H4OH),  also  called  ortho-
nitrophenol, is a light yellow crystalline solid, manufactured commercially
by hydrolysis of 2-chloro-nitrobenzene  with aqueous sodium   hydroxide.   2-
Nitrophenol  melts at 45°C and has  a vapor pressure of 1  mm Hg at 49°C.  2-
Nitrophenol is slightly soluble in  water (2.1 g/1 at 20°C)  and  soluble  in
organic  solvents.   This  phenol   does  not  react to give a color with 4-
aminoantipyrene, and therefore does not contribute  to  the  non-conventional
pollutant  parameter  "Total  Phenols."  U.S.  annual  production  is   five
thousand to eight thousand tons.
                                    406

-------
The principle  use  of  ortho-nitrophenol is to synthesize  ortho-aminophenol,
ortho-nitroanisole, and other dyestuff intermediates.

The  toxic  effects   of  2-nitrophenol  on humans have not been extensively
studied.  Data from   experiments  with  laboratory  animals  indicate  that
exposure  to   this compound causes kidney and liver damage.  Other studies
indicate  that  the  compound acts directly on cell  membranes,  and  inhibits
certain   enzyme systems  iri  vitro.    No  information  regarding potential
teratogencity  was  found.  Available data indicate that this  compound  does
not pose  a  mutagenic  hazard to humans.  Very limited data for 2-nitrophenol
do not reveal  potential carcinogenic effects.

No  U.S.  standards for exposure to 2-nitrophenol in ambient water have been
set.

Data on the behavior  of 2-nitrophenol in POTW were not available.  However,
laboratory-scale studies have been conducted at concentrations higher  than
those expected to be found in municipal wastewater.  Biochemical oxidation
using adapted  cultures frois various sources produced 95 percent degradation
in three  to six days  in one study.  Similar results were reported for other
studies.  Based on   these  data,   and  an  general  observations  relating
molecular  structure   to ease of biological oxidation, it is concluded that
complete  or nearly complete removal of 2-nitrophenol occurs during

4-Nitrophenol   (58).    4-Nitrophenol   (N02C6H4OH),   also   called   para-
nitrophenol,   is  a   colorless  to yellowish crystalline solid manufactured
commercially by hydrolysis of  4-chloro-nitrobenzene  with  aqueous  sodium
hydroxide.   4-nitrophenol  melts at 114°C.  Vapor pressure is not cited  in
the usual sources.  4-Nitrophenol is slightly soluble in water (15  g/1   at
25°C) -and  soluble in organic solvents.  This phenol does not react to give
a color with 4-aminoantipyrene, and therefore does not  contribute  to  the
non-conventional   pollutant   parameter   "Total  Phenols."   U.S.  annual
production  is  about  20,000 tons.

Para nitrophenol is  used to prepare phenetidine, acetaphenetidine, azo  and
sulfur dyes, photochemicals, and pesticides.

The  toxic  effects   of  4-nitrophenol  on humans have not been extensively
studied.  Data from  experiments  with  laboratory  animals  indicate  that
exposure  to   this  compound  results  in  methemoglobinemia  (a  metabolic
disorder  of blood),   shortness  of  breath,  and  stimulation  followed   by
depression. Other studies indicate that the compound acts directly on cell
membranes,  and  inhibits  certain enzyme systems in vitro.  No  information
regarding potential  teratogenicity was found.  Available data indicate that
this compound  does not pose a mutagenic hazard  to  humans.   Very  limited
data  for  4-nitrophenol  do  not  reveal  potential  carcinogenic effects,
although  the compound has been selected by the  national  cancer  institute
for testing under  the Carcinogenic Bioassay Program.
                                   407

-------
No  U.S. standards for exposure to 4-nitrophenol  in ambient  water have been
established.

Data on the behavior of 4-nitrophenol in POTW are not  available.    However,
laboratory-scale  studies have been conducted at  concentrations higher than
those expected to be found in municipal wastewater.  Biochemical   oxidation
using   adapated   cultures   from  various  sources   produced  95  percent
degradation in three to six  days  in  one  study.   Similar  results  were
reported   for  other  studies.   Based  on  these  data,  and  on  general
observations relating molecular structure to ease of biological  oxidation,
it  is  concluded that complete or nearly complete removal of  4-nitrophenol
occurs during biological treatment in POTW.

2,4-Dinitrophenol  (59) .   2,4-Dinitrophenol    [(N02)2C«H3OH],    a   yellow
crystalline  solid,  is  manufactured  commercially  by   hydrolysis of 2,4-
dinitro-1-chlorobenzene with sodium hydroxide.   2,4-Dinitrophenol  sublimes
at  114°C.   Vapor  pressure is not cited in usual sources.   It is slightly
soluble in water  (7.9 g/1 at 25°C) and soluble  in organic solvents.    This
phenol  does  not  react  with  4-aminoanitipyrene  and   therefore does not
contribute to the non-conventional  pollutant   parameter   "Total   Phenols."
U.S.  annual production is about 500 tons.

2,4-Dinitrophenol   is   used   to   manufacture   sulfur   and  azo  dyes,
photochemicals, explosives, and pesticides.

The toxic effects of 2,4-dinitrophenol in humans  is generally  attributed to
their ability to  uncouple oxidative phosphorylation.   In  brief, this  means
that   sufficient   2,4-dinitrophenol  short-circuits  cell^ metabolism  by
preventing utilization of energy provided by  respiration and  glycolosis.
Specific  symptoms  are gastrointestinal disturbances, weakness,  dizziness,
headache, and loss of weight.  More acute poisoning  includes symptons  such
as:   burning  thirst,  agitation, irregular breathing, and  abnormally high
fever.   This  compound  also  inhibits  other   enzyme systems;   and  acts
directly on the cell membrane, inhibiting chloride permeability.   Ingestion
of  2,4-dinitrophenol also causes cataracts  in humans.

Based  on available data it appears unlikely that 2,4-dinitrophenol poses a
teratogenic hazard to humans.  Results of studies of mutagenic activity  of
this  compound  are inconclusive as far as  humans are  concerned.   Available
data  suggest  that  2,4-dinitrophenol   does    not    posses   carcinogenic
properties.

To  protect  human  health  from  the  adverse  effects of 2,4-dinitrophenol
ingested  in contaminated  water  and  fish,  the suggested   water  quality
criterion is 0.0686 mg/1

Data  on  the  behavior  of  2,4-dinitrophenol   in   POTW  are not available.
However,  laboratory scale studies have  been  conducted   at   concentrations
higher    than   those   expected  to  be  found  in  municipal  wastewater.
                                    408

-------
Biochemical oxidation  using   a  phenol-adapted  seed  culture  produced  92
percent  degradation  in  3.5  hours.   Similar results were reported for other
studies.  Based   on   these  data,   and  on  general  observations  relating
molecular  structure   to ease of biological oxidation, it is concluded that
complete or nearly complete  removal  of  2,4-dinitrophenol   occurs  during
biological treatment  in  POTW.

N-nitrosodiphenylamine  (62).    N-nitrosodiphenylamine  [(C6H5)2NNO],  also
called nitrous diphenylamide,  is a  yellow crystalline solid manufactured by
nitrosation of diphenylamine.   It melts at 66C and is insoluble  in  water,
but  soluble    in    several  organic  solvents  other  than  hydrocarbons.
Production in the U.S. has approached 1500 tons per year.  The compound  is
used as a retarder  for  rubber vulcanization and as a pesticide for control
of scorch  (a fungus  disease  of plants).

N-nitroso  compounds  are  acutely toxic to every animal  species  tested  and
are  also  poisonous   to  humans.   N-nitrosodiphenylamine toxicity in adult
rats lies  in the midrange of the values for 60 N-nitroso compounds  tested.
Liver damage is  the  principal toxic effect.  N-nitrosodiphenylamine, unlike
many  other  N-nitrosoamines,  does  not .show   mutagenic  activity.   N-
nitrosodiphenylamine has been reported by several investigations to be non-
carcinogenic.  However,  the  compound is capable  of  trans-nitrosation  and
could thereby convert other  amines  to carcinogenic N-nitrosoamines.  Sixty-
seven of  87  N-nitrosoamines  studied  were reported to have carcinogenic
activity.   No   water quality  criterion  have  been   proposed   for   N-
nitrosodiphenylamine.

No  data   are  avaiable  on the behavior of N-nitrosodiyphenylamine in POTW.
Biochemical oxidation of many of the organic priority pollutants have  been
investigated,  at  least  in  laboratory  scale  studies, at concentrations
higher than those expected to be contained in most  municipal  wastewaters.
General  observations  have  been developed relating molecular structure to
ease of   degradation  for  all  the  organic  priority  pollutants.    The
conclusion reached   by   study  of   the  limited  data  is  that biological
treatment  produces  little or no removal of N-nitrosodiphenylamine in  POTW.
No   information   is  available  regarding  possible  interference  by  N-
nitrosodiphenylamine in  POTW processes,  or  on  the  possible  detrimental
effect on  sludge used to amend soils in which crops are grown.  However, no
interference   or   detrimental  effects  are  expected  because  N-nitroso
compounds  are widely distributed in the soil and water environment, at  low
concentrations,    as   a   result  of  microbial  action  on  nitrates  and
nitrosatable compounds.

Pentachlorophenol(64).  Pentachlorophenol  (C«C15OH) is a white  crystalline
solid produced commercially by chlorination of phenol or polychlorophenols.
U.S. annual  production  is  in  excess of 20,000 tons.  Pentachlorophenol
melts at   190°C   and    is   slightly   soluble   in   water    (14 mg/1).
Pentachlorophenol is not detected by the 4-amino antipyrene method.
                                   409

-------
Pentachlorophenol   is   a  bactericide  and   fungacide   and  is  used  for
preservation of wood and wood products.  It is  competative  with creosote in
that application.  It is also used as a preservative   in  glues,  starches,
and photographic papers.  It is an effective algicide  and herbicide.

Although  data  are  available  on  the  human   toxicity  effects of  penta-
chlorophenol, interpretation of data is frequently  uncertain.   Occupational
exposure observations  must  be  examined  carefully   because   exposure  to
pentachlorophenol  is  frequently  accompained   by  exposure  to other wood
preservatives.   Additionally,  experimental    results   and   occupational
exposure observations must be examined carefully to make  sure  that observed
effects  are  produced  by  the pentachlorophenol itself  and not by the by-
products which usually contaminate pentachlorophenol.

Acute and chronic toxic effects of pentachlorophenol in humans are similar;
muscle weakness, headache, loss of appetite, abdominal pain,   weight   loss,
and  irritation of skin, eyes, and respiratory  tract.  Available literature
indicates that pentachlorophenol does not  accumulate in body tissues  to any
significant extent.  Studies on laboratory animals  of  distribution  of  the
compound  in body tissues showed the highest levels of pentachlorophenol in
liver, kidney, and intestine, while the lowest  levels  were  in   brain,   fat,
muscle, and bone.

Toxic effects of pentachlorophenol in aquatic  organisms are much greater at
pH  of  6  where  this weak acid is predominantly in the  undissociated form
than at pH of 9 where the ionic form predominates.   Similar  results   were
observed in mammals where oral lethal doses of  pentachlorophenol were  lower
when  the  compound  was  administered  in hydrocarbon solvents (un-ionized
form) than when  it was administered as the sodium salt  (ionized  form)  in
water.

There  appear  to be no significant teratogenic,  mutagenic,  or carcinogenic
effects of pentachlorophenol.

For the protection of human health from  the   toxic properties  of  penta-
chlorophenol  ingested  through  water  and  through   contaminated  aquatic
organisms, the ambient water quality criterion  is determined  to  be   0.140
mg/1.

Only limited data are available for reaching conclusions  about the behavior
of  pentachlorophenol   in  POTW.   Pentachlorophenol   has been found  in the
influent to POTW.  In a study of one POTW  the  mean  removal  was  59  percent
over  a 7 day period.  Trickling filters removed 44 percent of the influent
pentachlorophenol, suggesting that biological  degradation occurs.  The same
report compared  removal of pentachlorophenol of  the   same   plant  and  two
additional  POTW  on a  later date and obtained values  of  4.4,  19.5 and 28.6
percent removal, the last value being for  the  plant which  was  59  percent
removal    in    the    original   study.    Influent    concentrations   of
pentachloropehnol ranged  from  0.0014  to 0.0046  mg/1.   Other  studies,
                                    410

-------
inducing   the   general   review  of  data  relating  molecular  structure to
biological  oxidation,  indicate that pentachlorophenol  is  not  removed  by
biological   treatment  processes in POTW.  Anaerobic digestion processes are
inhibited  by 0.4  mg/1  pentachlorophenol.

The low water  solubility and low volatility of  pentachlorophenol  lead  to
the  expectation   that   most  of the compund will remain in the sludge in a
POTW.  The effect on plants grown on land treated with pentachlorophenol
containing  sludge  is   unpredicatable.    Laboratory  studies show that his
compound affects  crop  germination at 5.4 mg/1.  However, phot©decomposition
of pentachlorophenol occurs  in  sunlight.   The  effects  of  the  various
breakdown   products which  may  remain  in  the  soil was not found in the
literature.

Phenol(65).  Phenol, also called hydroxybenzene and  carbolic  acid,  is  a
clear,  colorless,  hygroscopic,  deliquescent,  crystalline  solid at room
temperature.  Its melting point is 43°C and  its  vapor  pressure  at  room
temperature is  0.35  mm Hg.  It is very soluble in water (67 gm/1 at 16°C)
and can be dissolved in benzene, oils,  and petroleum solids.   Its  formula
is C6H5OH.

Although a small  percent of the annual  production of phenol is derived from
coal   tar  as  a  naturally  occuring   product,  most  of  the  phenol  is
synthesized.  Two of the methods  are  fusion  of  benzene  sulfonate  with
sodium hydroxide,  and  oxidation  of   cumene  followed  by clevage with a
catalyst.   Annual production in the U.S. is in excess of one million  tons.
Phenol   is  generated   during  distillation of wood and the microbiological
decomposition  of  organic matter in the  mammalian intestinal tract.

Phenol  is  used as a disinfectant, in the manufacture of resins,  dyestuffs,
and  Pharmaceuticals,   and* in  the  photo processing industry.  Phenol was
detected on only  one day in one coil coating raw waste  stream  out  of  14
days  of   sampling  and  analysis  at  11  coil  coating  plants.   In this
discussion,  phenol is  the specific compound which is separated by methylene
chloride extraction of an acidified sample and identified and quantified by
GC/MS.  Phenol also contributes to the  "Total Phenols", discussed elsewhere
which are  determined by the 4-AAP colorinmetric method.

Phenol  exhibits acute  and  sub-acute  toxicity  in  humans  and  laboratory
animals.    Acute   oral  doses of phenol in humans cause sudden collapse and
unconsciousness by its action on the central nervous system.  Death  occurs
by  respiratory  arrest.   Sub-acute  oral  doses  in  mammals  are rapidly
absorbed then  quickly  distributed to various organs, then cleared from  the
body  by   urinary excretion and metabolism.  Long term exposure by drinking
phenol  contaminated  water  has  resulted  in  statistically   significant
increase   in  reported  cases  of diarrhea, mouth sores, and burning of the
mouth.   In laboratory  animals long term oral administration at  low  levels
produced   slight   liver and kidney damage.  No reports were found regarding
                                   411

-------
carcinogenicity of phenol administered orally - all  carcinogenicity studies
were skin tests.

For the protection of human health from phenol ingested  through  water  and
through  contaminated  aquatic  organisms the concentration  in water should
not exceed 3.4 mg/1.

Fish and other aquatic organisms demonstrated a wide range of  sensitivities
to phenol concentration.  However, acute toxicity  values were   at  moderate
levels when compared to other organic priority pollutants.

Data  have  been  developed  on  the behavior of phenol  in POTW.   Phenol is
biodegradable by biota present in POTW.  The ability of   a   POTW   to  treat
phenol-bearing  influents  depends  upon  acclimation of the  biota and the
constancy of the phenol concentration.  It appears that  an induction period
is required to build up the  population  gf  organisms   which   can  degrade
phenol.   Too large a concentration will result in upset or  pass  through in
the POTW, but the specific level causing upset  depends   on  the   immediate
past  history  of  phenol concentrations in the influent.  Phenol levels as
high as 200 mg/1 have been treated with 95 percent  removal  in  POTW,   but
more  or  less  continuous  presence of phenol is  necessary  to maintain the
population of microorganisms that degrade phenol.

Phenol which is not degraded is expected to pass thorugh the  POTW  because
of  its very high water solubility.  However, in POTW where  chlorination is
practiced for disinfection of the POTW effluent, chlorination  of  phenol may
occur.  The products of that reaction may be priority pollutants.

The EPA has developed data on influent and effluent  concentrations of total
phenols in a study of 103 POTW.  However, the analytical procedure was  the
4-AAP  method  mentioned  earlier and not the GC/MS  method specifically for
phenol.  Discussion of the study,  which  of  course includes phenol,  is
presented under the pollutant heading "Total Phenols."

Phthalate Esters  (66-71).   Phthalic acid, or 1,2-benzenedicarboxylic acid,
is one  of  three  isomeric  benzenedicarboxylic   acids   produced   by  the
chemical industry.  The other two isomeric forms are called  isophthalic and
terephathalic acids.  The formula for all three acids is C6H4(COOH)2.  Some
esters  of  phthalic acid are designated as priority pollutants.   They will
be discussed as  a  group  here,  and  specific  properties  of  individual
phthalate esters will be discussed afterwards.

Phthalic  acid  esters  are  manufactured  in the  U.S. at an annual rate in
excess of 1 billion pounds.  They are used as plasticizers -  primarily  in
the  production  of  polyvinyl chloride (PVC) resins.  The most widely used
phthalate plasticizer is bis  (2-ethylhexyl) phthalate (66)   which  accounts
for  nearly  one  third  of the phthalate esters produced.   This  particular
ester  is commonly referred to as dioctyl phthalate (DOP) and should not  be
confused with one of the less used esters, di-n-octyl phthalate (69), which
                                    412

-------
is  also  used  as a plastcizer.   In addition to these two isomeric dioctyl
phthalates, four other  esters,  also used  primarily  as  plasticizers,  are
designated  as priority pollutants.   They are:  butyl benzyl phthalate  (67),
di-n-butyl phthalate  (68),  diethyl phthalate (70), and  dimethyl  phthalate
(71).

Industrially, phthalate esters  are prepared from phthalic anhydride and the
specific  alcohol to form the ester.  Some evidence is available suggesting
that phthalic acid esters also  may be  synthesized  by  certain  plant  and
animal  tissues.  The extent to  which this occurs in nature is not known.

Phthalate  esters  used as plasticizers can be present in concentrations up
to 60 percent of the total weight of the PVC plastic.  The  plasticizer  is
not  linked  by  primary  chemical  bonds  to the PVC resin.  Rather,  it is
locked  into the structure of intermeshing polymer molecules and held by van
der Waals forces.  The  result is that the plasticizer is easily  extracted.
Plasticizers  are responsible for the odor associated with new plastic toys
or flexible sheet that  has been contained in a sealed package.

Although  the phthalate  esters are not soluble or  are  only  very  slightly
soluble  in water, they do migrate into aqueous solutions placed in contact
with the  plastic.  Thus industrial facilities with tank linings,  wire  and
cable  coverings,  tubing,  and  sheet  flooring  of  PVC  are  expected to
discharge some phthalate esters in their raw waste.  In addition  to   their
use  as  plasticizers,   phthalate  esters  are used in lubricating oils and
pesticide carriers.   These also can contribute to industrial  discharge  of
phthalate esters.

From  the accumulated   data on acute toxicity in animals, phthalate esters
may be  considered as  having a rather low order of toxicity.  Human toxicity
data are  limited.   It  is thought that the toxic effects of  the  esters  is
most  likely  due   to   one  of   the  metabolic  products, in particular the
monoester.  Oral acute   toxicity  in  animals  is  greater  for  the   lower
molecular weight esters than for the higher molecular weight esters.

Orally  administered phthalate esters generally produced enlargeing of  liver
and  kidney,  and atrophy of testes in laboratory animals.  Specific esters
produced  enlargement  of heart and brain, spleenitis,  and  degeneration  of
central nervous  system  tissue.

Subacute  doses  administered  orally  to  laboratory animals produced some
decrease  in  growth  and  degeneration of  the  testes.   Chronic  studies   in
animals  showed  similar  effects  to  those  found  in  acute and subacute
studies,  but  to  a much  lower degree.  The same organs  were  enlarged,  but
pathological  changes  were not usually detected.

A  recent study of   several  phthalic  esters produced suggestive  but not
conclusive evidence  that dimethyl and  diethyl  phthalates  have  a   cancer
liability.  Only four  of the six priority pollutant esters were included  in
                                   413

-------
the  study.   Phthalate  esters  do  biconcentrate   in   fish.   The factors,
weighted for relative  consumption  of  various  aquatic  and   marine  food
groups,  are  used  to  calculate  ambient water quality  criteria for four
phthalate esters.  The  values  are  included  in  the   discussion  of  the
specific esters.

Studies  of  toxicity  of  phthalate  esters   in  freshwater and  salt water
organisms are scarce.   A  chronic  toxicity   test   with  bis(2-ethylhexyl)
phthalate  showed  that  significant  reproductive impairment  occurred at 3
mg/1 in the  freshwater  crustacean,  Daphnia  magna.    In acute  toxicity
studies,  saltwater fish and organisms showed  sensitivity  differences of up
to eight-fold to butyl benzyl,  diethyl,  and  dimethyl  phthalates.    This
suggests that each ester must be evaluated individually  for toxic effects.

The  behavior  of  phthalate esters in POTW has not  been studied.   However,
the biochemical oxidation of many of the organic  priority pollutants  has
been investigated in laboratory-scale studies  at concentrations higher than
would  normally be expected in municipal wastewater.  Three of  the phthalate
esters  were studied.  Bis(2-ethylhexyl) phthalate was found to be degraded
slightly or not at all and its removal by biological treatment  in a POTW is
expected to be slight or zero.  Di-n-butyl phthalate and diethyl   phthalate
were   degraded  to  a  moderate  degree  and   their  removal   by  biological
treatment  in a POTW is expected to occur to a  moderate degree.  Using these
data and  other  observations  relating  molecular   structure   to  ease  of
biochemical  degradation  of  other  organic pollutants, the conclusion was
reached that butyl benzyl phthalate and dimethyl phthalate would  be removed
in a POTW  to a moderate degree by biological treatment.  On the same basis,
it was concluded that di-n-octyl phthalate would be  removed   to   a  slight
degree or  not at all.

No  information  was  found on possible interference with  POTW  operation or
the possible  effects  on  sludge  by  the  phthalate  esters.    The  water
insoluble  phthalate  esters - butylbenzyl and di-n-octyl  phthalate - would
tend to remain  in  sludge,  whereas  the  other  four   priority   pollutant
phthalate  esters  with water solubilities ranging from  50 mg/1 to 4.5 mg/1
would  probably pass through into the POTW effluent.

Bis (2-ethylhexyl) phthalate(66).  In addition to the general   remarks  and
discussion  on  phthalate esters, specific information on  bis(2-ethylhexyl)
phthalate  is provided.  Little information is  available  about  the  physical
properties of bis(2-ethylhexyl) phthalate.  It is a  liquid boiling at 387°C
at 5mm Hg  and is insoluble in water.  Its formula is C6H4(COOC8H17)2.   This
priority   pollutant  constitutes  about  one   third  of  the phthalate ester
production in the U.S.  It is commonly referred to as dioctyl  phthalate,  or
DOP, in the plastics  industry  where  it  is  the   most  extensively  used
compound   for  the  plasticization  of  polyvinyl  chloride   (PVC).   Bis(2-
ethylhexyl) phthalate has been approved by the FDA for use in   plastics  in
contact  with  food.   Therefore,  it may be found in wastewaters coming in
contact with discarded plastic food wrappers as well as  the PVC  films  and
                                    414

-------
shapes  normally  found   in   industrial  plants.   This priority pollutant is
also a commonly used  organic  diffusion  pump  oil  where  its  low  vapor
pressure is an advantage.

For  the  protection  of   human  health  from the toxic properties of bis(2-
ethylhexyl) phthalate  ingested  through  water   and  through  contaminated
aquatic  organisms, the ambient water quality criterion is determined to be
10 mg/1.

Although the behavior of  bis(2-ethylhexyl)  phthalate in POTW has  not  been
studied,  biochemical oxidation of  this  priority pollutant has been studied
on a laboratory scale at   concentrations  higher  than  would  normally  be
expected  in  municipal   wastewater.    In  fresh  water with a non-acclimated
seed culture no biochemical  oxidation was  observed  after  5,  10,  and  20
days.   However,  with  an  acclimated  seed  culture, biological oxidation
occurred to the extents of 13,  0,  6,  and 23 of theoretical after 5, 10,  15
and  20 days, respectively.   Bis(2-ethylhexyl) phthalate concentrations were
3 to  10 mg/1.   Little   or  no  removal  of bis(2-ethylhexyl) phthalate by
biological treatment  in POTW is expected.

Butyl benzyl phthalate(67).    In  addition  to  the  general  remarks   and
discussion  on  phthalate  esters,   specific  information  on  butyl benzyl
phthalate is provided.  No information was found on the physical properties
of this compound.

Butyl benzyl phthalate  is used as  a  plasticizer  for  PVC.   Two  special
applications  differentiate it from other  phthalate esters.  It is approved
by the U.S. FDA for food  contact in wrappers and containers; and it is  the
industry  standard for plasticization of vinyl flooring because it provides
stain resistance.

No ambient water quality  criterion is proposed for butyl benzyl phthalate.

Butylbenzylphthalate  removal in POTW by biological treatment in a  POTW  is
expected to occur to  a moderate degree.

Di-n-butyl  phthalate  (68).   In  addition  to  the  general  remarks  and
discussion  on  phthalate  esters,   specific  information   on   di-n-butyl
phthalate   (DBP)  is  provided.   DBP is a colorless, oily liquid, boiling at
340°C.  Its water solubility at room temperature is reported to be 0.4  g/1
and   4.5g/l   in  two different  chemistry  handbooks.   The  formula  for
DBP, C6H4(COOC4H,)2  is  the same as for its isomer,  di-isobutyl  phthalate.
DCP  production  is   one   to  two  percent  of  total  U.S. phthalate ester
production.

Dibutyl phthalate is  used  to  a  limited  extent  as  a  plasticizer  for
polyvinylchloride   (PVC).  It is not approved for contact with food.  It is
used in liquid lipsticks  and as a diluent for polysulfide dental  impression
materials.  DBP is used as a plasticizer for nitrocellulose  in  making  gun
                                   415

-------
powder,  and  as a fuel in solid propellants  for  rockets.   Further uses are
insecticides,  safety  glass  manufacture,  textile    lubricating   agents,
printing inks, adhesives, paper coatings and  resin solvents.

For  protection  of  human  health  from  the  toxic   properties of dibutyl
phthalate  ingested  through  water  and    through    contaminated   aquatic
organisms, the ambient water quality criterion  is determined  to be 5 mg/1.

Although the behavior of di-n-butyl phthalate in  POTW has  not been studied,
biochemical  oxidation  of  this  priority  pollutant has  been studied on a
laboratory scale at concentrations higher than  would  normally  be  expected
in  municipal  wastewater.  Biochemical oxidation of  35, 43,  and 45 percent
of  theoretical  oxidation  were  obtained  after 5,   10,  and  20   days,
respectively.- using sewage microorganisms as  an unacclimated  seed culture.

Biological   treatment in POTW is expected to  remove di-n-butyl phthalate to
a moderate degree.

Di-n-octyl phthalate(69).   In  addition  to   the  general   remarks   and
discussion   on   phthalate  esters,  specific  information  on  di-n-octyl
phthalate  is provided.  Di-n-octyl phthalate  is not to be  confused with the
isomeric bis(2-ethylhexyl) phthalate which  is commonly referred to  in  the
plastics   industry as OOP-  Di-n-octyl phthalate  is a liquid  which boils at
220°C  at 5 mm Hg.  It is  insoluble in  water.   Its   molecular  formula  is
C6H4(COOCBH17)2.   Its  production  constitutes  about  one  percent of all
phthalate  ester production in the U.S.

Industrially, di-n-octyl phthalate is used  to plasticize polyvinyl chloride
(PVC)  resins.

No  ambient water quality  criterion is proposed for di-n-octyl phthalate.

Biological treatment in  POTW  is expected to lead  to little or no removal of
di-n-octyl phthalate.

Diethyl phthalate  (70).   In addition to the general remarks and  discussion
on  phthalate esters, specific  information on  diethyl  phthalate is provided.
Diethyl  phthalate,  or  DEP,  is a colorless liquid boiling at 296°C, and is
insoluble  in water.  Its molecular formula  is  C«H4(COOC2H5)2.   Production
of  diethyl   phthalate   constitutes  about   1.5  percent of phthalate ester
production in the U.S.

Diethyl phthalate  is approved  for use  in plastic   food  containers  by  the
U.S.  FDA.  In addition  to  its  use as a polyvinylchloride (PVC) plasticizer,
DEP  is   used   to  plasticize   cellulose  nitrate for gun  powder, to dilute
polysulfide  dental  impression materials, and  as an  accelerator  for  dying
triacetate  fibers.   An   additional use which would  contribute to its wide
distribution in  the environment  is as  an approved special  denaturant  for
ethyl   alcohol.   The   alcohol-containing   products   for  which  DEP  is an
                                    416

-------
approved denaturant  include  a  wide range of personal  care  items  such  as
bath  preparations,   bay   rum,   colognes,   hair preparations, face and hand
creams, perfumes   and  toilet   soaps.    Additionally,  this  denaturant  is
approved   for    use   in    biocides,   cleaning  solutions,  disinfectants,
insecticides, fungicides,  and  room deodorants which have ethyl  alcohol  as
part  of  the   formulation.    It  is  expected,  therefore, that people and
buildings would have some  surface loading of this priority pollutant  which
would find its  way into raw  wastewaters.

For the  protection  of   human health from the toxic properties of diethyl
phthalate  ingested   through  water  and   through   contaminated   aquatic
organisms,   the  ambient   water  quality  criterion  is determined to be 60
mg/1.

Although the behavior of diethylphthalate in POTW  has  not  been  studied,
biochemical  oxidation of  this  priority  pollutant has been studied on a
laboratory scale  at  concentrations higher than would normally  be  expected
in  municipal   wastewater.  Biochemical oxidation of 79, 84, and 89 percent
of theoretical  was   observed   after  5,  5,  and  20  days,  respectively.
Biological   treatment  in   POTW is expected to lead to a moderate degree of
removal of diethylphthalate.

Dimethyl phthalate (71).   In addition to the general remarks and discussion
on phthalate esters, specific  information on dimethyl  phthalate  (BMP)  is
provided.    DMP  has  the  lowest molecular weight of the phthalate esters -
N.W. =  194 compared  to M.W.  of 391 for bis(2-ethylhexyl)phthalate.  DMP has
a boiling point of 282°C.   It  is a colorless liquid, soluble  in  water  to
the extent of 5 mg/1.  Its molecular formula is C6H4(COOCH,)2.

Dimethyl  phthalate   production  in  the  U.S. is just under one percent of
total phthalate ester  production.   DMP  is  used  to  some  extent  as  a
plasticizer  in  cellulosics.    However,  its principle specific use is for
dispersion of polyvinylidene fluoride (PVDF).  PVDF is  resistant  to  most
chemicals    and  finds use as  electrical  insulation,  chemical  process
equipment  (particularly pipe), and as a base  for  long-life  finishes  for
exterior  metal  siding.    Coil  coating  techniques are used to apply PVDF
dispersions  to  aluminum or galvanized steel siding.

For the protection of human health from the toxic  properties  of  dimethyl
phthalate    ingested   through   water  and  through  contaminated  aquatic
organisms, the  ambient water quality criterion  is  determined  to  be  160
mg/1.

Biological   treatment in POTW's is expected to provide a moderate degree of
removal of dimethyl  phthalate.

Polynuclear  Aromatic  Hydrocarbons(72-84).    The   polynuclear   aromatic
hydrocarbons  (PAH)selected   as  priority  pollutants  are  a group of 13
compounds consisting of substituted and unsubstituted  polycyclic  aromatic
                                   417

-------
rings.   The  general class of PAH includes hetrocyclics, but none of  those
were selected as priority pollutants.  PAH are  formed  as  the   result  of
incomplete  combustion  when organic compounds are burned with insufficient
oxygen.  PAH are found in coke oven  emissions,  vehicular  emissions,   and
volatile products of oil and gas burning.  The compounds chosen as priority
pollutants  are  listed  with  their  structural  formula and melting  point
(m.p.).  All are insoluble in water.

     72   Benzo(a)anthrancene (1,2-benzanthracene)

                                 m.p. 162°C

     73   Benzo(a)pyrene (3,4-benzopyrene)

                                 m.p. 176°C

     74   3,4-Benzofluoranthene

                                 m.p. 1680C

     75   Benzo(k)fluoranthene (11,12-benzofluoranthene)

                                 m.p. 217°C

     76   Chrysene (1,2-benzphenanthrene)

                                 m.p. 255°C

     77   Acenaphthylene
               HC=Ch
                                 m.p. 92°C

     78   Anthracene

                                 m.p. 216°C

     79   Benzo(ghi)perylene  (1,12-benzoperylene)

                                 m.p. not reported



     80   Fluorene (alpha-diphenylenemethane)

                                 m.p. 116°C

      81   Phenanthrene

                                 m.p. 101°C
                                   418

-------
    82   Dibenzo(a,h)anthracene  (1,2,5,6-dibenzoanthracene)

                                m.p. 269°C



    83   Indeno(l,2,3-cd)pyrene  (2,3-o-phenyleneperylene)

                                m.p. not  available

    84   Pyrene

                                m.p. 156°C
Some of these priority  pollutants  have   commercial   or  industrial  uses.
Benzo( a)anthracene,       benzo(a)pyrene,        chrysene,        anthracene,
dibenzo(a,h)anthracene, and pyrene are  all  used  as antioxidants.   Chrysene,
acenaphthylene, anthracene, fluorene, phenanthrene,  and pyrene are all used
for  synthesis   of   dyestuffs   or    other   organic   chemicals.    3,4-
Benzofluoranthrene,  benzo(k)fluoranthene,  benzo(ghi)perylene,   and indeno
(1,2,3-cd)pyrene have no known industrial  uses,  according to the results of
a recent literature search.

Several of the PAH priority pollutants  are found in smoked meats, in  smoke
flavoring  mixtures,  in  vegetable oils,  and  in coffee.  They are found in
soils and sediments in river beds.  Consequently,  they are  also  found  in
many drinking water supplies.  The wide distribution of these pollutants in
complex mixtures with the many other  PAHs  which  have not been designated as
priority   pollutants  results   in  exposures  by  humans  that  cannot  be
associated with specific individual compounds.

The screening and verification analysis procedures  used  for  the  organic
priority  pollutants  are based  on gas  chromatography (GO.   Three pairs of
the PAH have identical  elution   times  on the   column  specified  in  the
protocol,   which   means   that  the  parameters  of  the  pair  are  not
differentiated.  For these three pairs  [anthracene  (78)  -  phenanthrene
(81);   3,4-benzofluoranthene    (74)    -    benzo(k)fluoranthene  (75);  and
benzo(a)anthracene  (72) - chrysene  (76)] results are obtained and  reported
as "either-or."  Either  both   are   present   in the combined concentration
reported, or one is present in the concentration reported.  When detections
below reportable limits are recorded  no further  analysis is required.   For
samples  where  the  concentrations   of coeluting pairs have a significant
value, additional analyses are conducted,  using  different  procedures  that
resolve the particular pair.

There  are no studies to document the possible carcinogenic risks to humans
by direct ingestion.  Air pollution studies  indicate  an  excess  of  lung
                                   419

-------
cancer  mortality  among workers exposed  to  large  amounts of PAH containing
materials such as coal gas, tars, and   coke-oven   emissions.   However,  no
definite  proof  exists  that  the   PAH  present   in   these  materials  are
responsible for the cancers observed.

Animal studies have demonstrated the toxicity  of PAH   by  oral  and  dermal
administration.  The carcinogenicity of PAH  has been  traced to formation of
PAH  metabolites  which,   in  turn,  lead to  tumor formation.  Because the
levels of PAH which induce cancer are  very low, little work has  been  done
on  other  health hazards  resulting  from  exposure.  It has been established
in animal studies that tissue damage and  systemic  toxicity can result  from
exposure to non-carcinogenic PAH compounds.

Because there were no studies available regarding  chronic oral exposures to
PAH  mixtures,  proposed   water quality criteria were derived using data on
exposure to a single compound.  Two  studies  were   selected,  one  involving
benzo(a)pyrene   ingestion   and   one   involving   dibenzo(a,h)anthracene
ingestion.  Both are known animal carcinogens.

For the maximum protection of human  health from the potential  carcinogenic
effects  of  exposure  to  polynuclear aromatic hydrocarbons (PAH) through
ingestion of water and contaminated  aquatic  organisms,   the  ambient  water
concentration   is  zero.   Concentrations of  PAH estimated  to result in
additional risk of 1 in  100,000 were derived by the EPA and the  Agency  is
considering  setting  criteria at an interim target risk level in the range
of 10~5, 10-*,  or 10~7   with  corresponding  criteria  of  0.0000097  mg/1,
0.00000097 mg/1, and 0.000000097 mg/1,  respectively.

No  standard  toxicity tests have been reported for freshwater or saltwater
organisms and any of the  13 PAH discussed here.

The behavior of PAH in POTW has received  only  a limited  amount  of  study.
It  is  reported  that   up to  90   percent  of PAH entering a POTW will be
retained  in  the  sludge  generated  by  conventional   sewage   treatment
processes.   Some  of  the PAH  can inhibit bacterial growth when they are
present at concentrations  as low as  0.018 mg/1.    Biological  treatment  in
activated  sludge  units   has  been  shown   to reduce the concentration of
phenanthrene  and  anthracene  to  some  extent.   However,  a   study   of
biochemcial   oxidation   of  fluorene   on a ' laboratory  scale  showed  no
degradation after 5, 10,  and 20 days.   On the basis  of  that  study  and
studies  of  other  organic  priority  pollutants,  some general observations
were made relating molecular  structure  to  ease  of  degradation.   Those
observations   lead  to the conclusion  that the 13  PAH selected to represent
that group as priority pollutants will be removed  only slightly or  not  at
all  by  biological  treatment  methods  in  POTW.    Based  on  their water
insolubility and tendency  to attach  to sediment particles very little  pass
through of PAH  to POTW effluent  is expected.
                                    420

-------
No  data   are   available  at  this  time  to  support any conclusions about
contamination  of  land by PAH on  which  sewage  sludge  containing  PAH   is
spread.

Tetrachloroethylene(85).    Tetrachloroethylene   (CC12CC12),  also  called
perchloroethylene and PCE, is  a  colorless  nonflammable  liquid  produced
mainly by  two methods  - chlorination and pyrolysis of ethane and propane,
and oxychlorination of  dichloroethane.   U.S.  annual  production  exceeds
300,000   tons.    PCE boils at 121°C and has a vapor pressure of  19 mm Hg  at
20°C.   It is insoluble in water but soluble in organic solvents.

Approximately  two-thirds of the U.S. production of  PCE  is  used  for  dry
cleaning.   Textile  processing  and  metal  degreasing,  in  equal amounts
consume about  one-quarter of the U.S. production.

The principal  toxic effect of PCE  on  humans  is  central  nervous  system
depression  when   the  compound is inhaled.  Headache, fatigue,  sleepiness,
dizziness and  sensations of intoxication are reported.  Severity of effects
increases   with    vapor   concentration.    High    integrated    exposure
(concentration  times  duration)  produces  kidney  and liver damage.  Very
limited data on PCE ingested by laboratory animals  indicate  liver  damage
occurs when PCE  is administered by that route.  PCE tends to distribute  to
fat in mammalian  bodies.

One report found  in the literature suggests, but does  not  conclude,  that
PCE  is teratogenic.  PCE has been demonstrated to be a liver carcinogen  in
B6C3-F1 mice.

For the maximum protection of human health from the potential  carcinogenic
effects  of  exposure to tetrachloroethylene through ingestion of water and
contaminated aquatic organisms, the ambient water  concentration is  zero.
Concentrations  of  tetrachloroethylene  estimated  to result in additional
lifetime  cancer risk levels of 10~7, 10~«,  and  10~5  are  0.000020  mg/1,
0.00020 mg/1,  and 0.0020 mg/1, respectively.

No  data   were  found  regarding  the  behavior of PCE in POTW.   Many of the
organic priority pollutants have been  investigated, at least in  laboratory
scale studies, at concentrations higher  than those expected to be contained
by  most   municipal  wastewaters.  General observations have been developed
relating  molecular structure to ease of  degradation for all of the  organic
priority  pollutants.   The conclusions  reached by the study of  the limited
data is that biological treatment produces a moderate  removal   of  PCE   in
POTW  by  degradation.   No  information was  found  to   indicate that PCE
accumulates in the sludge, but some PCE  is expected  to  be  adsorbed  onto
settling   particles.   Some  PCE  is   expected to be volatilized in aerobic
treatment processes and little, if any,  is expected to  pass  through   into
the effluent from the POTW.
                                   421

-------
Toluene(86).   Toluene  is  a  clear,  colorless  liquid with  a  benzene like
odor.  It is a naturally occuring compound derived primarily  from  petroleum
or petrochemical processes.  Some toluene is obtained from  the   manufacture
of   metallurgical   coke.    Toluene   is  also  referred  to   as  totuol,
methylbenzene, methacide, and phenymethane.  It is an aromatic   hydrocarbon
with the formula C6H5CH3.  It boils at 111°C and  has a vapor  pressure  of  30
mm  Hg  at  room temperature.  The water solubility of toluene  is  535  mg/1,
and it is miscible with a variety of organic solvents.   Annual  production
of   toluene   in   the  U.S.  is  greater  than  2  million  metric  tons.
Approximately two-thirds of the toluene is converted  to  benzene   and the
remaining  30  percent  is  divided  approximately  equally  into   chemical
manufacture, and use as a paint solvent and aviation gasoline additive.   An
estimated 5,000 metric tons is discharged to the  environment  annually  as   a
constituent in wastewater.

Most  data  on  the effects of toluene in human and other mammals  have been
based on inhalation exposure or dermal contact studies.  There  appear  to  be
no reports of oral administration of toluene to   human  subjects.    A   long
term  toxicity  study on female rats revealed no  adverse effects on growth,
mortality, appearance and behavior, organ to body weight ratios, blood-urea
nitrogen levels, bone marrow counts, peripheral blood counts, or morphology
of major organs.  The effects of inhaled toluene  on  the   central   nervous
system,  both  at  high and low concentrations, have been studied  in humans
and  animals.   However,  ingested  toluene  is   expected   to  be    handled
differently  by  the body because it is absorbed  more slowly  and must  first
pass through the liver before reaching  the  nervous  system.    Toluene   is
extensively  and  rapidly  metabolized  in the liver.  One  of the  principal
metabolic products of toluene is benzoic acid, which itself seems   to   have
little potential to produce tissue injury.

Toluene  does  not  appear  to be teratogenic in  laboratory animals or man.
Nor  is there any conclusive evidence that toluene  is  mutagenic.    Toluene
has  not  been  demonstrated to be positive in any iji vitro mutagenicity  or
carcinogenicity bioassay system, nor to be carcinogenic in  animals  or  man.

Toluene has been found in fish caught in harbor waters in the  vicinity   of
petroleum and petrochemical plants.  Bioconcentration studies have  not been
conducted,  but  bioconcentration factors have been calculated  on  the  basis
of the octanol-water partition coefficient.

For  the protection of human health from the  toxic  properties   of   toluene
ingested  through  water  and  through  contaminated aquatic  organisms, the
ambient water criterion is determined to be 12.4  mg/1.

Acute toxicity tests have been conducted with  toluene  and  a   variety   of
freshwater  fish and Daphnia maqna.  The latter appears to  be significantly
more resistant than fish.  No test  results  have been  reported   for the
chronic effects of toluene on freshwater fish or  invertebrate species.
                                   422

-------
No  detailed  study of toluene behavior in POTW is available.  However,  the
biochemical   oxidation  of  many  of  the  priority  pollutants  has   been
investigated  in  laboratory  scale  studies at concentrations greater than
those expected to be contained by most municipal wastewaters.   At  toluene
concentrations  ranging  from 3 to 250 mg/1 biochemical oxidation proceeded
to fifty percent of theroetical or greater.  The time period varied from a
few  hours  to  20  days  depending  on whether or not the seed culture  was
acclimated.   Phenol adapted acclimated seed cultures gave  the  most  rapid
and  extensive  biochemical  oxidation.  The conclusion reached by study of
the limited  data is that biological treatment produces moderate removal  of
toluene  in   POTW.   The  volatility and relatively low water solubility of
toluene lead  to  the  expectation  that  aeration  processes  will  remove
significant  quantities of toluene from the POTW.

Trichloroethylene(87).   Trichloroethylene (1,1,2-trichloroethylene or TCE)
is a clear colorless liquid boiling at 87°C.  It has a vapor pressure of 77
mm Hg at room temperature and is slightly soluble in water (1 gm/1).   U.S.
production  is  greater  than  0.25  million  metric  tons annually.  It is
produced from tetrachloroethane by treatment with lime in the  presence  of
water.

TCE  is used for vapor phase degreasing of metal parts, cleaning and drying
electronic components, as a solvent  for  paints,  as  a  refrigerant,   for
extraction  of oils, fats, and waxes, and for dry cleaning.  Its widespread
use and relatively high volability result  in  detectable  levels  in  many
parts of the environment.

Data on the effects produced by ingested TCE are limted.  Most studies have
been  directed  at inhalation exposure.  Nervous system disorders and liver
damage are frequent results of inhalation  exposure.   In  the  short  term
exposures, TCE acts as a central nervous system depressant - it was used as
an anesthetic before its other long term effects were defined.

TCE  has been shown to induce transformation in a highly sensitive iin vitro
Fischer rat embryo  cell  system  (F1706)  that  is  used  for  identifying
carcinogens.   Severe  and  persintant  toxicity  to the liver was recently
demonstrated when TCE was shown to produce carcinoma of the liver in  mouse
strain  B6C3F1.   One systematic study of TCE exposure and the incidence of
human cancer was based on 518 men exposed to  TCE.   The  authors  of  that
study  concluded  that although the cancer risk to man cannot be ruled out,
exposure to low levels of TCE probably does  not present a very serious  and
general cancer hazard.

TCE is bioconcentrated in aquatic species, making the consumption  of  such
species by humans a significant source of TCE.  For the protection of human
health   from   the   potential   carcinogenic   effects   of  exposure  to
trichloroethylene through  ingestion  of  water  and  contaminated  aquatic
organisms,  the  ambient  water  concentration  is zero.  Concentrations of
                                   423

-------
trichloroethylene estimated to result in additional  lifetime  cancer risk of
1 in 100,000 corresponds to an ambient water concentration  of 0.00021 mg/1.

Only a very limited amount of data on the  effects   of   TCE  on   freshwater
aquatic life are available.  One species of fish  (fathead minnows)  showed a
loss  of  equilibrium  at  concentrations  below  those  resulting in lethal
effects.

The behavior of trichloroethylene in POTW has not been   studied.    However,
in  laboratory  scale  studies  of  organic  priority  pollutants,   TCE was
subjected to biochemical oxidation conditions.  After 5, 10,  and  20 days no
biochemical oxidation occurred.  On the basis of  this   study and   general
observations  relating  molecular  structure  to  ease   of  degradation, the
conclusion  is reached that TCE  would  undergo  no   removal  by   biological
treatment in a POTW.  The volatility and relatively  low  water solubility of
TCE  is expected to result in volatilization of some of  the TCE  in  aeration
steps in a  POTW.

Polychlorinated    Biphenyls    (106-112).     Polychlorinated   biphenyls
 (C12H,0nCln,H10-nCln where n can range from 1 to  10), designated  PCB's, are
chlorinated derivatives of biphenyls.  The commerical products are complex
mixtures of chlorobiphenyls, but are no longer produced  in  the   U.S.    The
mixtures    produced   formerly   were   characterized    by  the   percentage
chlorination.  Direct chlorination of biphenyl was used  to  produce  mixtures
containing  from 21 to 70 percent chlorine.  Six of these mixtures have been
selected as priority pollutants:

                                 Percent        Distilation    Pour      25°C Wat
Priority Pollutant No.  Name     Chlorine       Range (°C)     Point (°C)  Solubili

        106           Arochlor 1242    42         325-366        -19         240
        107               "     1254    54         365-390         10         12
        108                    1221  20.5-21.5    275-320          1        >200
        109               "     1232  31.4-32.5    290-325        -35.5
        110               "     1248    48         340-375        -7          54
        111               "     1260    60         385-420         31         2.7
        112               "     1016    41         323-356        -         225-25

 The Arochlors 1221, 1232,  1016, 1242, and 1248 are colorless  oily  liquids;
 1254   is  a viscous  liquid;   1260   is a sticky  resin at room temperature.
 Total  annual U.S. production of PCBs  averaged about  20,000  tons   in  1972-
 1974.

 Prior   to   1971,  PCB's  were  used  in  several   applications   including
plasticizers, heat transfer  liquids,  hydraulic fluids,   lubricants,  vacuum
 pump   and   compressor  fluids;  and   capacitor and transformer oils.  After
 1970, when  PCB use was restricted to  closed systems, the  latter   two  uses
 were the only commercial applications.
                                    424

-------
The  toxic   effects   of PCBs ingested by humans have been reported to range
from acne-like  skin  eruptions and pigmentation of the skin to  numbness  of
limbs,   hearing and  vision problems,  and spasms.  Interpretation of results
is complicated  by the fact  that  the  very  highly  toxic  polychlorinated
dibenzofurans    (PCDFs)   are   found  in  many  commerical  PCB  mixtures.
Photochemical   and  thermal  decomposition   appear   to   accelerate   the
transformation   of PCBs to PCDFs.  Thus the specific effects of PCBs may be
masked  by the effects of PCDFs.   However, if PCDFs are  frequently  present
to  some  extent  in  any  PCB  mixture, then their effects may be properly
included in the effects of PCB mixtures.

Studies of  effects of PCBs in laboratory animals indicate  that  liver  and
kidney   damage,  large weight losses, eye discharges, and interference with
some metabolic  processes occur frequently.  Teratogenic effects of PCBs  in
laboratory  animals   have been observed, but are rare.  Growth retardations
during  gestation, and reproductive failure are more common effects observed
in studies of PCB teratogencity.  Carcinogenic effects of  PCBs  have  been
studied  in  laboratory  animals  with  results  interpreted  as  positive.
Specific reference has been made to liver cancer in rats in the  discussion
of water quality criterion formulation.

For  the maximum protection of human health from the potential carcinogenic
effects of exposure  to PCBs through ingestion  of  water  and  contaminated
aquatic   organisms,  the  ambient  water  concentration  should  be  zero.
Concentrations  of PCBs estimated to result in  additional  lifetime  cancer
risk  at  risk   levels  of  10-*,  10-*,  and  10-«  are 0.0000000026 mg/1,
0.000000026 mg/1, and 0.00000026 mg/1, respectively.

The behavior of PCBs in POTW has received limited study.  Most PCBs will be
removed with sludge.  One study  showed  removals  of  82  to  89  percent,
depending  on  suspended  solid  removal.   The  PCBs adsorb onto suspended
sediments and other  particulates.  In laboratory-scale experiments with PCB
1221, 81 percent was removed by degradation in an activated  sludge  system
in  47   hours.   Biodegradation can form polychlorinated dibenzofurans which
are more toxic  than  PCBs (as noted earlier).  PCBs at concentrations of 0.1
to 1,000 mg/1  inhibit or enhance bacterial growth rates, depending  on  the
bacterial  culture and the percentage chlorine in the PCB.  Thus, activated
sludge  may be inhibited by PCBs.  Based on studies  of  bioaccumulation  of
PCBs  in  food  crops grown on soils amended with PCB-containing sludge, the
U.S.  FDA has recommend a limit of 10 mg PCB/kg dry weight of  sludge  used
for application to soils bearing food crops.

Antimony(114).   Antimony (chemical name - stibium, symbol Sb) classified as
a  non-metal or metalloid, is a silvery white , brittle, crystalline solid.
Antimony is found in small ore bodies throughout the world.  Principal ores
are oxides of mixed  antimony valences, and an oxysulfide ore.  Complex ores
with metals are important because  the  antimony  is  recovered  as  a  by-
product.   Antimony   melts at 631°C, and is a poor conductor of electricity
and heat.
                                   425

-------
Annual U.S. consumption of primary antimony ranges  from   10,000  to  20,000
tons.   About  half  is consumed  in metal products  - mostly  antimonial lead
for lead acid storage batteries,  and about half  in  non -  metal  products.   A
principal compound is antimony trioxide which  is  used as  a flame  retardant
in  fabrics, and as an opacifier  in glass, ceramincs, and enamels.   Several
antimony compounds are used as catalysts  in organic chemicals synthesis,  as
fluorinating agents (the antimony fluoride), as pigments, and in fireworks.
Semiconductor applications are economically significant.

Essentially no information on antimony -  induced  human health  effects  has
been  derived  from community epidemiolocy studies.  The  available data are
in literature relating effects observed with therapeutic  or  medicinal  uses
of  antimony  compounds and industrial exposure studies.  Large therapeutic
doses of antimonial compounds, usually used to treat schistisomiasis,  have
caused  severe nausea, vomiting,  convulsions,  irregular heart action, liver
damage, and skin rashes.  Studies of acute  industrial  antimony  poisoning
have  revealed  loss  of  appetitie,  diarrhea,   headache, and  dizziness  in
addition to the symptoms found in studies of therapeutic  doses  of antimony.

For  the protection of human health from the toxic  properties  of  antimony
ingested   through  water  and  through  contaminated  aquatic organisms the
ambient water criterion is determined to  be 0.145 mg/1.

Very  little information is available regarding the  behavior  of  antimony  in
POTW.   The limited solubility of most antimony compounds expected in POTW,
i.e.  the oxides and sulfides, suggests that at least part of  the  antimony
entering   a  POTW  will  be  precipitated and  incorporated into the sludge.
However, some antimony  is expected to remain dissolved and pass through the
POTW into  the effluent.  Antimony compounds remaining  in  the  sludge  under
anaerobic  conditions may be connected to  stibine  (SbH3),  a very soluble and
very  toxic compound.  There are  no data  to show  antimony inhibits any POTW
processes.  Antimony is not known to be essential to the  growth of  plants,
and  has been reported to be moderately toxic.  Therefore, sludge containing
large amounts  of antimony could be detrimental  to plants if it is applied
in  large amounts to cropland.

Arsenic(115).  Arsenic  (chemical  symbol As), is  classified as  a  non-metal
or   metalloid.   Elemental arsenic normally exists  in  the alpha-crystalline
metallic form which is steel gray and brittle', and  in  the beta   form  which
is   dark gray and amorphous.  Arsenic sublimes at 615°C.  Arsenic is widely
distributed throughout  the world  in a large number  of  minerals.   The  most
important  commercial source of arsenic is as a by-product from treatment  of
copper,  lead,  cobalt,  and gold ores.   Arsenic  is usually  marketed as the
trioxide (As203).  Annual U.S. production of the  trioxide approaches 40,000
tons.

The  principal use of arsenic  is  in agricultural  chemicals (herbicides)  for
controlling  weeds  in  cotton fields.  Arsenicals have various applications
                                    426

-------
in medicinal  and   veterinary  use,   as   wood   preservatives,   and   in
semiconductors.

The  effects  of  arsenic   in  humans  were known by the ancient Greeks and
Romans.  The principal  toxic  effects  are  gastrointestinal  disturbances.
Breakdown  of  red  blood cells occurs.   Symptoms of acute poisoning include
vomiting, diarrhea,  abdominal pain,   lassitude,  dizziness,  and  headache.
Longer   exposure  produced dry,  falling hair,  brittle, loose nails, eczema;
and exfoliation.  Arsenicals also exhibit teratogenic and mutagenic effects
in humans.  Oral  administration of arsenic compounds  has  been  associated
clinically  with  skin  cancer  for  nearly  a  hundred  years.  Since 1888
numerous studies  have linked  occupational  exposure  to,  and  therapeutic
administration  of   arsenic compounds to increased incidence of respiratory
and skin cancer.

For the  maximum protection of human health from the potential  carcinogenic
effects  of exposure to arsenic through ingestion of water and contaminated
aquatic  organisms,  the  ambient water concentration is zero.  Concentrations
of arsenic estimated to result in additional lifetime cancer risk levels of
10~7, 10-*, and 10~s are 0.0000002 mg/1, 0.000002 mg/1, and  0.00002  mg/1,
respectively.

A  few  studies   have   been made regarding the behavior of arsenic in POTW.
One EPA  survey of 9 POTW   reported  influent  concentrations  ranging  from
0.0005  to  0.693 mg/1; effluents  from 3 POTW having biological treatment
contained 0.0004  -  0.01 mg/1; 2 POTW showed arsenic removal efficiencies of
50 and  71  percent in biological  treatment.   Inhibition  of  treatment
processes  by sodium arsenate is reported to occur at 0.1 mg/1 in activated
sludge,  and 1.6 mg/1 in anaerobic digestion processes.   In  another  study
based on data from  60 POTW, arsenic in sludge ranged from 1.6 to 65.6 mg/kg
and  the median  value  was 7.8 mg/kg.  Arsenic in sludge spread on cropland
may be taken up by  plants  grown on that land.   Edible paints  can  take  up
arsenic, but normally their growth is inhibited before the paints are ready
for harvest.

Beryllium(117).   Beryllium  is  a  dark  gray  metal of the alkaline earth
family.  It is relatively  rare, but because of its unique properties  finds
widespread use as an alloying element especially for hardening copper which
is used in  springs,  electrical contacts, and non-sparking tools.  World
production is reported  to  be in the range of 250 tons  annually.   However,
much   more   reaches   the  environment  as  emissions  from  coal  burning
operations.  Analysis of coal indicates an  average  beryllium  content  of
3 ppm and 0.1 to  1.0 percent in coal ash or fly ash.

The   principal   ores   are   beryl    (3BeO«Al203»6Si02)  and  bertrandite
[Be4Si207(OH)2].  Only  two industrial facilities produce beryllium  in  the
U.S.   because of limited  demand and the and highly toxic character.  About
two-thirds of the annual production goes into alloys, 20 percent into  heat
sinks, and 10 percent  into beryllium oxide  (BeO) ceramic products.
                                   427

-------
Beryllium has a specific gravity of  1.846 making  it  the lightest metal with
a  high  melting  point  (1350C).  Beryllium  alloys are corrosion resistant,
but the metal corrodes   in  aqueous   environment.    Most  common  beryllium
compounds are soluble in water, at least to  the extent necessary to produce
a toxic concentration of beryllium ions.

Most  data  on  toxicity  of beryllium  is for  inhalation of beryllium oxide
dust.  Some studies on orally administered beryllium in laboratory  animals
have  been  reported.    Despite  the large  number   of studies implicating
beryllium as a carcinogen, there is  no  recorded instance  of  cancer  being
produced  by  ingestion.   However,  a recently convened panel  of uninvolved
experts concluded that epidemiologic evidence  is  suggestive that  beryllium
is a carcinogen in man.

In  the  aquatic  environment  beryllium  is  acutely toxic to fish at con-
centrations as low as 0.087 mg/1,  and  chronically   toxic  to  an  aquatic
organism  at  0.003 mg/1.   Water  softness  has a large effect on beryllium
toxicity to fish.  In soft water, beryllium  is   reportedly  100  times  as
toxic as in hard water.

For  the maximum protection of human health  from  the potential carcinogenic
effects  of  exposure  to  beryllium through  ingestion   of    water   and
contaminated  aquatic  organisms.  The  ambient water concentration is zero.
Concentrations of beryllium estimated  to  result in  additional  lifetime
cancer  risk  levels of  10~7, 10~«,  and 10~5 are  0.00000087 mg/1, 0.0000087
mg/1, and 0.000087 mg/1, respectively.

Information on the behavior  of  beryllium   in POTW  is  scarce.   Because
beryllium  hydroxide  is  insoluble   in water, most  beryllium  entering POTW
will probably be  in the  form of suspended solids.  As a result most of  the
beryllium  will  settle  and be removed  with  sludge.   However,  beryllium has
been shown to  inhibit   several  enzyme systems,  to  interfere  with  DNA
metabolism  in  liver,   and to induce chromsomal  and mitotic abnormalities.
This interference in  cellular  processes  may extend  to  interfere  with
bioloigcal treatment processes.  The concentration and effects of beryllium
in sludge which could be applied to  cropland has  not been studied.

Cadmium(118).  Cadmium is  a relatively  rare  metallic element that is seldom
found   in  sufficient  quantities   in  a  pure state  to warrant mining or
extraction from the earth's surface.  It  is  found in trace amounts of about
1 ppm throughout  the earth's crust.   Cadmium is,  however,  a  valuable  by-
product of zinc production.

Cadmium  is  used  primarily  as an  electroplated metal, and is found as an
impurity in the secondary  refining of  zinc,  lead,   and  copper.   Cadmium
appears  at  a  significant  level   in  raw wastewaters from only one of the
three subcategories of coil coating  - galvanized. The presence of  cadmium
in the wastewater is attributed to  its  presence as an impurity in zinc used
                                    428

-------
to  produce   galvanized  coil  stock.    Some  of the zinc is removed by the
cleaning  and  conversion coating steps.

Cadmium is an extremely dangerous cumulative toxicant, causing  progressive
chronic  poisoning  in  mammals,   fish,   and probably other organisms.  The
metal  is  not  excreted.

Toxic  effects of cadmium on man have  been  reported  from  throughout  the
world.    Cadmium  may  be  a  factor  in  the  development  of  such  human
pathological  conditions as kidney disease, testicular tumors, hypertension,
arteriosclerosis,  growth  inhibition,   chronic  disease  of  old  age,  and
cancer.  Cadmium  is normally ingested by humans through food and water as
well as  by   breathing  air  contaminated  by  cadmium  dust.   Cadmium  is
cumulative   in the liver, kidney, pancreas, and thyroid of humans and other
animals.  A  severe bone and kidney syndrome known as itai-itai disease  has
been  documented in Japan as caused by cadmium ingestion via drinking water
and contaminated irrigation water.  Ingestion of as  little  as  0.6 mg/day
has  produced the disease.  Cadmium acts synergistically with other metals.
Copper and  zinc substantially increase its toxicity.

Cadmium is  concentrated by marine organisms, particularly  molluscs,  which
accumulate    cadmium   in   calcareous  tissues  and  in  the  viscera.   A
concentration factor of 1000 for cadmium in fish muscle has been  reported,
as  have concentration factors of 3000 in marine plants and up to 29,600 in
certain marine animals.  The eggs and larvae of fish  are  apparently  more
sensitive  than  adult fish to poisoning by cadmium, and crustaceans appear
to be more  sensitive than fish eggs and larvae.

For the protection of human health from the  toxic  properties  of  cadmium
ingested  through  water  and  through  contaminated aquatic organisms, the
ambient water criterion is determined to be 0.010 mg/1.

Cadmium is  not destroyed when it is introduced into a POTW, and will either
pass through to the POTW effluent or be incorporated into the POTW  sludge.
In addition,  it can interfere with the POTW treatment process.

In a study  of 189 POTW, 75 percent of the primary plants, 57 percent of the
trickling  filter  plants, 66 percent of the activated sludge plants and 62
percent of  the biological plants allowed over 90 percent  of  the   influent
cadmium  to  pass  thorugh  to  the  POTW effluent.  Only 2 of the  189 POTW
allowed less than 20 percent pass-through, and none less  than  10  percent
pass-through.   POTW effluent concentrations ranged from 0.001 to 1.97 mg/1
(mean 0.028  mg/1, standard deviation 0.167 mg/1).

Cadmium not  passed through the POTW will be retained  in the sludge  where  it
is likely to build up in concentration.  Cadmium  contamination  of  sewage
sludge  limits  its  use on land since it  increases the level of cadmium  in
the soil.  Data show that cadmium can be  incorporated into crops, including
vegetables  and grains, from contaminated soils.  Since the crops themselves
                                   429

-------
show no adverse effects from soils with levels   up   to   100  mg/kg  cadmium,
these  contaminated  crops could have a significant  impact on human health.
Two Federal agencies have already recognized the potential   adverse  human
health  effects posed by the use of sludge on cropland.   The FDA recommends
that sludge containing over 30 mg/kg of  cadmium should not  be  used  on
agricultural  land.   Sewage  sludge contains 3  to 300 mg/kg (dry basis)  of
cadmium mean = 10 mg/kg; median  =  16 mg/kg.    The   USDA also  recommends
placing  limits  on  the  total  cadmium from sludge that may be applied  to
land.

Chromium(119).  Chromium is an elemental metal usually found as a  chromite
(FeOCr203).   The  metal  is  normally produced by  reducing the oxide with
aluminum.  A significant proportion of the chromium  used is  in the form  of
compounds  such  as  sodium dichromate (Na2Cr04), and chromic acid (Cr03)  -
both are hexavalent chromium compounds.

Chromium and its  compounds  are  used  extensively   in   the  coil  coating
industry.   As  the  metal,  it  is  found as an alloying component of many
steels.

The two chromium forms most frequently found in  industry wastewaters are
hexavalent  and  trivalent chromium.  Hexavalaent chromium is the form used
for metal treatments.  Some of it is reduced to  trivalent chromium as  part
of the process reaction.  The raw wastewater containing  both valence states
is  usually  treated  first  to  reduce  remaining   hexavalent to trivalent
chromium, and second to precipitate the trivalent form   as   the  hydroxide.
The hexavalent form is not removed by lime treatment.

Chromium,  in  its  various  valence  states,  is hazardous  to man.  It can
produce lung tumors when inhaled, and induces skin   sensitizations.   Large
doses  of  chromates have corrosive effects on the intestinal tract and can
cause  inflammation of the kidneys.  Hexavalent chromium  is   a  known  human
carcinogen.   Levels  of chromate ions that show no  effect in man appear  to
be so  low as to prohibit determination, to date.

The toxicity of chromium salts to fish and other aquatic life varies widely
with the species, temperature, pH, valence of the chromium,  and synergistic
or antagonistic effects, especially the effect of water  hardness.   Studies
have shown that trivalent chromium is more toxic to  fish of  some types than
is  hexavalent  chromium.   Hexavalent  chromium retards growth of one fish
species at 0.0002 mg/1.  Fish food  organisms  and   other lower  forms  of
aquatic   life  are  extremely  sensitive  to  chromium.   Therefore,  both
hexavalent and trivalent chromium must be considered harmful to  particular
fish or organisms.

For  the  protection  of human health from the toxic properties of chromium
(except  hexavalent  chromium)  ingested  through  water and  contaminated
aquatic organisms, the recommended water qualtiy criterion is 0.050 mg/1.
                                    430

-------
For  the  maximum protection of human health from the potential carcinogenic
effects of  exposure to hexavalent chromium through ingestion of  water  and
contaminated aquatic organisms,  the ambient water concentration is zero.

Chromium   is  not  destroyed  when  treated by POTW (although the oxidation
state may change),  and will either pass through to the POTW effluent or  be
incorporated  into  the  POTW sludge.  Both oxidation states can cause POTW
treatment inhibition and  can  also  limit  the  usefuleness  of  municipal
sludge.

Influent   concentrations  of chromium to POTW facilities have been observed
by EPA to range from 0.005 to 14.0 mg/1, with  a  median  concentration  of
0.1 mg/1.  The efficiencies for removal of chromium by the activated sludge
process  can  vary  greatly,  depending  on  chromium  concentration in the
influent, and  other  operating  conditions  at  the  POTW.   Chelation  of
chromium   by  organic  matter  and  dissolution  due  to  the  presence  of
carbonates can cause deviations from the predicted  behavior  in  treatment
systems.

The  systematic presence of chromium compounds will halt nitrification in a
POTW for  short periods, and most of the chromium will be  retained  in  the
sludge  solids.   Hexavalent  chromium has been reported to severely affect
the nitrification process, but trivalent chromium has litte or no  toxicity
to  activated sludge, except at high concentrations.  The presence of iron,
copper,  and low pH will increase the toxicity of  chromium  in  a  POTW  by
releasing  the  chromium  into solution to be ingested by microorganisms in
the POTW.

The amount of chromium which passes through to the POTW effluent depends on
the type'of treatment processes used by the POTW.  In a study of 240 POTW's
56 percent of the primary plants allowed more than 80 percent pass  through
to  POTW  effluent.   More advanced treatment results in less pass-through.
POTW effluent concentrations ranged from 0.003 to 3.2 mg/1  total  chromium
(mean  =   0.197,  standard  deviation = 0.48),  and  from 0.002 to 0.1 mg/1
hexavalent chromium  (mean = 0.017, standard deviation = 0.020).

Chromium not passed through the POTW will be retained in the sludge,  where
it  is likely to build up in concentration.  Sludge concentrations of total
chromium of over 20,000 mg/kg (dry basis) have been observed.  Disposal  of
sludges  containing  very  high  concentrations  of  trivalent chromium can
potentially cause problems in uncontrollable landfills.   Incineration,  or
similar  destructive  oxidation  processes  can produce hexavalent chromium
from lower valance states.  Hexavalent chromium is potentially  more  toxic
than  trivalent  chromium.   In  cases  where  high  rates of chrome sludge
application on land are used, distinct growth inhibition and  plant  tissue
uptake have been noted.

Pretreatment  of  discharges  substantially  reduces  the  concentration of
chromium in sludge.  In Buffalo, New York, pretreatment  of  electroplating
                                   431

-------
waste resulted in a decrease  in chromium  concentrations in POTW sludge from
2,510  to  1,040 mg/kg.   A   similar   reduction   occurred  in Grand Rapids,
Michigan, POTW where the chromium concentration  in  sludge  decreased  from
11,000 to 2,700 mg/kg when pretreatment was  made a requirement.

Copper(120).  Copper is a metallic element that  sometimes is found free, as
the  native  metal,  and  is  also found in minerals such as cuprite (Cu20),
malechite  [CuC03»Cu(OH)2], azurite  [2CuC03»Cu(OH)2],  chalcopyrite (CuFeS2),
and bornite  (Cu5FeS4).  Copper is obtained from   these  ores  by  smelting,
leaching,  and  electrolysis.   It  is used  in  the  plating, electrical,
plumbing, and heating equipment industries,  as well as in insecticides  and
fungicides.   In  the  coil   coating   industry  copper can be attributed to
various  contaminant sources.

Traces of  copper are found in all forms of plant and animal life,  and  the
metal  is  an  essential  trace  element  for nutrition.   Copper  is  not
considered to be a cumulative systemic poison for humans as it  is  readily
excreted  by the  body, but  it can cause symptoms of gastroenteritis, with
nausea and  intestinal  irritations, at  relatively low dosages.  The limiting
factor in  domestic water  supplies  is taste.   To  prevent  this  adverse
organoleptic effect  of  copper  in   water, a criterion of 1 mg/1 has been
established.

The  toxicity of copper to aquatic organisms  varies significantly, not  only
with  the   species, but  also  with the  physical and chemical characteristics
of  the   water,  including  temperature,   hardness,  turbidity,  and  carbon
dioxide  content.   In   hard  water,   the toxicity  of copper salts may be
reduced  by  the  precipitation  of  copper   carbonate  or  other  insoluble
compounds.   The sulfates of  copper and zinc, and of copper and calcium are
synergistic  in their  toxic effect on  fish.

Relatively high concentrations of copper  may be  tolerated by adult fish for
short periods of time; the critical effect of copper  appears  to  be  its
higher   toxicity   to   young   or   juvenile fish.  Concentrations of 0.02 to
0.031 mg/1  have proved fatal  to some  common  fish species.  In  general  the
salmonoids  are  very  sensitive  and   the   sunfishes are less sensitive to
copper.

The recommended criterion to  protect  saltwater aquatic life is 0.00097 mg/1
as  a 24-hour average,  and 0.018 mg/1  maximum concentration.

Copper salts cause  undesirable color  reactions in  the  food   industry  and
cause  pitting  when   deposited   on   some other  metals such as aluminum and
galvanized steel.

 Irrigation water containing more  than minute quantities of  copper  can  be
detrimental  to  certain crops.    Copper appears  in  all  soils, and its
concentration ranges  from   10 to   80 ppm.     In   soils,  copper  occurs  in
association with  hydrous oxides  of manganese and iron, and also as soluble
                                    432

-------
and insoluble complexes with organic matter.  Copper is  essential  to  the
life  of   plants,   and the normal range of concentration in plant tissue  is
from 5 to  20  ppm.   Copper concentrations in plants normally do not build  up
to high levels when toxicity occurs.  For example,  the  concentrations   of
copper  in snapbean  leaves  and  pods  was  less  than  50  and 20 mg/kg,
respectively,  under conditions  of  severe  copper  toxicity.   Even  under
conditions of copper toxicity, most of the excess copper accumulates in the
roots; very little is moved to the aerial part of the plant.

Copper  is not  destroyed  when  treated  by  a POTW, and will either pass
through to the POTW effluent or be retained in the  POTW  sludge.   It  can
interfere  with the POTW treatment processes and can limit the usefulness  of
municipal  sludge.

The  influent  concentration of copper to POTW facilities has been observed
by the EPA to range from 0.01 to 1.97 mg/1, with a median concentration   of
0.12 mg/1.   The  copper that is removed from the influent stream of a POTW
is adsorbed on the sludge or appears in the sludge as the hydroxide of  the
metal.  Bench scale pilot studies have shown that from about 25 percent  to
75 percent of the copper  passing  through  the  activated  sludge  process
remains  in  solution  in  the  final  effluent.  Four-hour slug dosages  of
copper sulfate in concentrations exceeding 50 mg/1 were  reported  to  have
severe  effects  on  the removal efficiency of an unacclimated system, with
the system returning to normal in about 100 hours.  Slug dosages of  copper
in  the  form  of  copper  cyanide  were  observed to have much more severe
effects on the activated sludge system, but the total  system  returned   to
normal in  24  hours.

In  a recent  study of 268 POTW, the median pass-through was over 80 percent
for primary plants and 40 to 50 percent  for  trickling  filter,  activated
sludge,  and   biological treatment plants.  POTW effluent concentrations  of
copper ranged from  0.003  to  1.8 mg/1  (mean  0.126,  standard  deviation
0.242).

Copper  which does not pass through the POTW will be retained in the sludge
where it will build up in concentration.  The presence of excessive  levels
of  copper in sludge may limit its use on cropland.  Sewage sludge contains
up to 16,000  mg/kg of copper, with 730 mg/kg  as  the  mean  value.   These
concentrations are significantly greater than those normally found in soil,
which  usually  range from 18 to 80 mg/kg.  Experimental data indicate that
when dried sludge is spread over tillable land, the copper tends to  remain
in  place down to the depth of tillage, except for copper which  is taken  up
by plants grown in the soil.   Recent  investigation  has  shown  that  the
extractable  copper  content  of  sludge-treated  soil decreased with time,
which suggests a reversion of copper to less soluble forms was occurring.

Cyanide(121).  Cyanide compounds  are  widely  used  in  the  coil  coating
industry.     The  major  use  of  cyanide   ions   in  the  industry  is  for
accelerating action of chromating solutions.
                                   433

-------
Cyanides are among the  most  toxic  of  pollutants   commonly  observed  in
industrial  wastewaters.  Introduction of  cyanide  into industrial processes
is usually by dissolution of potassium   cyanide   (KCN)  or  sodium  cyanide
(NaCN)  in process waters.  However, hydrogen  cyanide (HCN)  formed when the
above salts are dissolved in water,  is probably   the  most  acutely  lethal
compound.

The  relationship  of  pH to hydrogen cyanide formation is  very important.
As pH is lowered to below 7, more than 99  percent  of the cyanide is present
as HCN and less than 1 percent as cyanide  ions.   Thus, at neutral pH,   that
of most living organisms, the more toxic form  of  cyanide prevails.

Cyanide ions combine with numerous heavy metal ions  to form  complexes.   The
complexes  are  in equilibrium with  HCN.   Thus, the  stability of the metal-
cyanide complex and the pH determine the concentration of HCN.    Stability
of  the  metal-cyanide anion complexes is  extremely  variable.  Those formed
with zinc, copper, and cadmium are not stable  -   they  rapidly  dissociate,
with  production  of  HCN,  in  near neutral  or  acid waters.  Some of the
complexes are extremely stable.  Cobaltocyanide is very resistant  to  acid
distillation  in  the  laboratory.   Iron cyanide  complexes are also stable,
but undergo photodecomposition to  give  HCN   upon  exposure  to  sunlight.
Synergistic  effects have been demonstrated for the  metal cyanide complexes
making zinc, copper,  and  cadmiun,  cyanides  more   toxic  than  an  equal
concentration of sodium cyanide.

The  toxic  mechanism  of  cyanide   is   essentially  an inhibition of oxygen
metabolism, i.e., rendering the tissues  incapable  of  exchanging  oxygen.
The  cyanogen compounds are true noncummulative protoplasmic poisons.   They
arrest the activity of all forms of  animal life.    Cyanide   shows  a  very
specific  type of toxic action.  It  inhibits the  cytochrome  oxidase system.
This system is the one which facilitates  electron  transfer  from  reduced
metabolites  to  molecular oxygen.   The  human  body can convert cyanide to a
non-toxic thiocyanate and  elminiate it.   However,  if  the  quantity of
cyanide  ingested  is  too  great  at  one time,  the inhibition of oxygen
utilization proves  fatal  before  the   detoxifying   reaction  reduces  the
cyanide concentration to a safe level.

Cyanides  are  more  toxic to fish than  to lower  forms of aquatic organisms
such as midge larvae, crustaceans, and mussels.    Toxicity  to  fish  is a
function  of chemical form and concentration,  and  is influenced by the rate
of metabolism (temperature), the level of  dissolved   oxygen,  and  pH.    In
laboratory  studies  free  cyanide   concentrations  ranging   from  0.05 to
0.15 mg/1 have been proven to be fatal to  sensitive  fish species  including
trout,  bluegill,  and  fathead minnows.   Levels  above 0.2 mg/1 are rapidly
fatal to most fish species.  Long term sublethal  concentrations of  cyanide
as  low  as  0.01 mg/1  have  been   shown   to  affect the ability of fish to
function normally, e.g., reproduce,  grow,  and  swim.
                                    434

-------
For the  protection of human health from the  toxic  properties  of  cyanide
ingested  through  water  and  through  contaminated aquatic organisms, the
ambient  water quality criterion is determined to be 0.200 mg/1.

Presistance of cyanide in water is highly variable  and  depends  upon  the
chemical  form  of  cyanide in the water, the concentration of cyanide, and
the nature of other constituents.    Cyanide  may  be  destroyed  by  strong
oxidizing  agents  such as permanganate and chlorine.  Chlorine is commonly
used to  oxidize strong cyanide solutions.  Carbon dioxide and nitrogen  are
the  products  of complete oxidation.  But if the reaction is not complete,
the very toxic compound, cyanogen chloride, may  remain  in  the  treatment
system   and   subsequently   be  released  to  the  environment.   Partial
chlorination may  occur  as  part  of  a  POTW  treatment,  or  during  the
disinfection treatment of surface water for drinking water preparation.

Cyanides can interfere with treatment processes in POTW, or pass through to
ambient   waters.   At  low  concentrations  and with acclimated microflora,
cyanide  may be  decomposed  by  microorganisms  in  anaerobic  and  aerobic
environments  or waste treatment systems.  However, data indicate that much
of the cyanide introduced passes through to the POTW  effluent.   The  mean
pass-through  of 14 biological plants was 71 percent.  In a recent study of
41  POTW  the  effluent  concentrations  ranged  from  0.002  to   100 mg/1
(mean =  2.518,  standard  deviation - 15.6).   Cyanide  also  enhances  the
toxicity of metals commonly found in POTW effluents, including the priority
pollutants cadmium, zinc, and copper.

Data for Grand Rapids, Michigan, showed a significant  decline  in  cyanide
concentrations downstream from the POTW after pretreatment regulations were
put  in  force.   Concentrations  fell  from 0.66 mg/1 before, to 0.01 mg/1
after pretreatment was required.

Lead (122).  Lead is a soft,  malleable  ductible,  blueish-gray,  metallic
element,  usually  obtained  from  the  mineral galena (lead sulfide, PbS),
anglesite (lead sulfate, PbS04),  or  cerussite  (lead  carbonate,  PbC03).
Because  it  is  usually  associated with minerals of zinc, silver, copper,
gold, cadmium, antimony, and  arsenic,  special  purification  methods  are
frequently  used  before  and  after  extraction  of the metal from the ore
concentrate by smelting.

Lead is widely used for  its  corrosion  resistance,  sound  and  vibration
absorption, low melting point (solders), and relatively high imperviousness
to various forms of radiation.  Small amounts of copper, antimony and other
metals  can be alloyed with lead to achieve greater hardness, stiffness, or
corrosion resistance than is afforded by the pure  metal.   Lead  compounds
are  used  in glazes and paints.  About one third of U.S.  lead consumption
goes into storage batteries.  About half of U.S. lead consumption  is  from
secondary  lead  recovery.  U.S. consumption of lead is in the range of one
million  tons annually.
                                   435

-------
Lead ingested by humans produces  a   variety   of   toxic  effects  including
impaired   reproductive   ability,    disturbances    in   blood   chemistry,
neurological  disorders, kidney damage,  and adverse cardiovascular effects.
Exposure to lead in the diet results  in  permanent  increase in  lead  levels
in  the  body.   Most  of  the  lead   entering the body eventually becomes
localized in the bones where it  accumulates.   Lead  is  a  carcinogen  or
cocarcinogen  in some species of experimental  animals.   Lead is teratogenic
in experimental animals.  Mutangenicity  data are not available for lead.

For the protection of human  health   from  the toxic  properties  of  lead
ingested  through  water  and  through  contaminated  aquatic organisms the
ambient water criterion is 0.050 mg/1.

Lead is not destroyed in POTW, but  is passed through  to  the  effluent  or
retained in the POTW sludge; it can  interfere  with POTW treatment processes
and can limit the usefulness of POTW  sludge for application to agricultural
croplands.   Threshold concentration  for inhibition of the activated sludge
process is 0.1 mg/1, and for the nitrification process is 0.5 mg/1.    In   a
study  of  214  POTW,  median  pass  through values were over 80 percent for
primary plants and over 60 percent  for trickling filter,  activated  sludge,
and biological process plants.  Lead  concentration in POTW effluents ranged
from 0.003 to 1.8 mg/1  (means = 0.106 mg/1, standard deviation = 0.222).

Application of lead-containing sludge to cropland  should not lead to uptake
by  crops  under most conditions because normally  lead is strongly bound  by
soil.  However, under the unusual conditions of low pH (less than 5.5)   and
low  concentrations  of labile phosphorus, lead solubility is increased and
plants can accumulate lead.

Mercury.  Mercury  (123) is an elemental  metal  rarely found in nature as the
free metal.  Mercury is unique among  metals as it  remains a liquid down  to
about  39  degrees  below  zero.    It is relatively inert chemically and  is
insoluable in water.  The principal  ore  is cinnabar (HgjS).

Mercury is used industrially as the  metal and   as   mercurous  and  mercuric
salts  and  compounds.   Mercury  is   used  in several types of batteries.
Mercury released to the aqueous environment is subject to biomethylation   -
conversion to the extremely toxic methyl mercury.

Mercury  can  be   introduced  into   the  body   through  the  skin  and  the
respiratory system as the elemental  vapor.  Mercuric salts are highly toxic
to humans and can be absorbed through the  gastrointestinal  tract.    Fatal
doses  can  vary from 1 to 30 grams.   Chronic  toxicity of methyl mercury  is
evidenced primarily by  neurological  symptoms.   Some  mercuric  salts  cause
death  by kidney failure.

Mercuric  salts  are  extremely  toxic  to  fish   and  other  aquatic life.
Mercuric chloride  is more lethal than copper,   hexavalent  chromium,  zinc,
nickel,  and  lead towards fish and  aquatic life.   In the food cycle, algae
                                    436

-------
containing mercury up to 100 times the concentration in the surrounding sea
water are eaten  by fish which further concentrate the  mercury.   Predators
that eat the  fish  in turn concentrate the mercury even further.

For the  protection  of  human health from the toxic properties of mercury
ingested through water  and  through  contaminated  aquatic  organisms  the
ambient water criterion is determined to be 0.0002 mg/1.

Mercury  is   not  destroyed  when  treated  by a POTW, and will either pass
through to the POTW effluent or be incorporated into the POTW  sludge.   At
low concentrations  it  may  reduce POTW removal efficiencies, and at high
concentrations it  may upset the POTW operation.

The influent  concentrations of mercury to POTW have been  observed  by  the
EPA to  range  from  0.0002 to 0.24 mg/1,  with  a median concentration of
0.001 mg/1.   Mercury has been reported in the literature to have inhibiting
effects upon  an  activated sludge POTW at levels as  low  as  0.1 mg/1.   At
5 mg/1  of  mercury,  losses  of COD removal efficiency of 14 to 40 percent
have been reported, while at 10 mg/1 loss of removal of 59 percent has been
reported.  Upset of an activated sludge POTW is reported in the  literature
to  occur  near   200 mg/1.   The  anaerobic  digestion process is much less
affected by  the  presence of mercury, with inhibitory effects being reported
at 1365 mg/1.

In a study of 22 POTW having secondary treatment, the range of  removal  of
mercury  from  the  influent  to  the POTW ranged from 4 to 99 percent with
median  removal of  41 percent.  Thus significant pass through of mercury may
occur.

In sludges,  mercury content may be high if industrial  sources  of  mercury
contamination are present.  Little is known about the form in which mercury
occurs  in  sludge.   Mercury may undergo biological methylation  in sediments,
but no  methylation has been observed in soils, mud, or sewage sludge.

The  mercury content of soils not receiving additions of POTW sewage  sludge
lie in  the  range from 0.01 to 0.5 mg/kg.  In soils receiving  POTW  sludges
for  protracted  periods, the concentration of mercury has been observed to
approach  1.0  mg/kg.  In the soil, mercury enters into  reactions  with  the
exchange   complex  of  clay  and  organic fractions, forming both ionic and
covalent  bonds.   Chemical and microbiological degradation of mercurials can
take place  side by side in the soil, and the products - ionic or  molecular
- are  retained by organic matter and clay or may be volatilized if gaseous.
Because of  the high affinity between mercury and the  solid soil surfaces,
mercury  persists in the upper layer of soil.

Mercury  can  enter plants through the roots, it can readily  move  to  other
parts  of  the plant, and it has been reported to cause injury to plants.   In
many  plants mercury concentrations range from 0.01 to 0.20 mg/kg, but when
plants  are  supplied with high levels of mercury, these  concentrations  can
                                   437

-------
exceed  0.5 mg/kg.  Bioconcentration occurs  in  animals ingesting mercury in
food.

Nickel(124).   Nickel is seldom found in nature  as  the pure elemental metal.
It is a reltively plentiful element and is   widely  distributed  throughout
the  earth's  crust.   It  occurs  in  marine organisms and is found in the
oceans.  The chief commercial ores for nickel are  pentlandite [(Fe,Ni),SB],
and a lateritic ore consisting of hydrated nickel-iron-magnesium silicate.

Nickel has many and varied uses.  It is used in alloys  and  as  the  pure
metal.   Nickel  salts are used for electroplating baths.   The coil coating
industry uses  nickel  compounds  as  accelerators  in  certain  conversion
coating solutions.  Nickel is also found as  a contaminant  in mineral acids.
It  occurs  in significant concentrations in the wastewaters from all three
subcategories of coil coating.

The toxicity of nickel to man is thought  to be   very  low,  and  systemic
poisoning  of human beings by nickel or nickel  salts is almost unknown.   In
non-human mammals nickel acts to inhibit insulin release,   depress  growth,
and  reduce  cholesterol.   A high incidence of cancer of  the lung and nose
has been reported in humans engaged in the refining of nickel.

Nickel salts can kill fish at very low concentrations.   However,  nickel  has
been found to be less toxic to some  fish  than copper,   zinc,   and  iron.
Nickel  is present in coastal and open ocean water at concentrations in  the
range of 0.0001 to 0.006 mg/1 although the most common values are  0.002 -
0.003 mg/1.   Marine  animals  contain  up   to  0.4 mg/1   and marine plants
contain up to 3 mg/1.  Higher nickel concentrations have been  reported   to
cause  reduction  in  photosynthetic  activity  of  the  giant kelp.  A  low
concentration was found to kill oyster eggs.

For the protection of human health based on  the toxic properties of  nickel
ingested  through  water  and  through  contaminated aquatic organisms,  the
ambient water criterion is determined to be  0.133  mg/1.

Nickel is not destroyed when treated  in  a   POTW,  but  will  either  pass
through  to  the  POTW  effluent or be retained in the POTW sludge.  It  can
interfere with POTW treatment processes and  can also limit  the  usefulness
of municipal sludge.

Nickel  salts have caused inhibition of the  biochemical oxidation of sewage
in a POTW.  In a pilot plant, slug doses of   nickel  significantly  reduced
normal  treatment  efficiencies  for  a few  hours, but the plant acclimated
itself somewhat to the slug dosage and appeared to achieve normal treatment
efficiencies within 40 hours.  It has  been   reported  that  the  anaerobic
digestion process is inhibited only by high  concentrations of nickel, while
a low concentration of nickel inhibits the nitrification process.
                                    438

-------
The   influent   concentration of  nickel to POTW facilities has been observed
by the EPA  to  range  from 0.01 to 3.19 mg/1,  with a median of 0.33 mg/1.  In
a study of  190 POTW,  nickel  pass-through was greater than 90 percent for 82
percent of  the primary plants.   Median pass-through for  trickling  filter,
activated   sludge,   and  biological  process  plants  was  greater  than 80
percent.    POTW  effuent  concentrations  ranged  from  0.002  to   40 mg/1
(mean - 0.410,  standard deviation - 3.279).

Nickel  not passed   through the POTW will be incorporated into the sludge.
In a recent two-year study of eight cities,  four of the cities  had  median
nickel  concentrations  of  over  350 mg/kg, and two were over 1,000 mg/kg.
The  maximum nickel concentration observed was 4,010 mg/kg.

Nickel  is found in nearly all soils, plants, and  waters.   Nickel  has  no
known essential function in  plants.  In soils, nickel typically is found in
the   range  from 10 to 100 mg/kg.  Various environmental exposures to nickel
appear  to correlate   with  increased  incidence  of  tumors  in  man.   For
example,  cancer  in  the maxillary  antrum of snuff users may result from
using plant material grown on soil high in nickel.

Nickel  toxicity may  develop  in plants from application of sewage sludge  on
acid soils.    Nickel has caused reduction of yields for a variety of crops
including oats,  mustard,  turnips,  and  cabbage.   In  one  study  nickel
decreased the  yields of oats significantly at 100 mg/kg.

Whether nickel  exerts  a  toxic  effect on plants depends on several soil
factors, the amount  of nickel applied, and the contents of other metals  in
the   sludge.    Unlike  copper  and  zinc,  which  are  more  available from
inorganic sources than from  sludge, nickel uptake by  plants  seems  to  be
promoted by the presence of  the organic matter in sludge.  Soil treatments,
such as  liming  reduce  the  solubility of nickel.  Toxicity of nickel to
plants  is enhanced  in acidic soils.

Selenium(125).  Selenium (chemical symbol Se)  is  a  non-metallic  element
existing  in several allotropic forms.  Gray selenium, which has a metallic
appearance, is the  stable form at ordinary temperatures and melts at 220°C.
Selenium  is a  major  component of 38 minerals and a minor  component  of  37
others  found in various parts of the world.   Most selenium is obtained as  a
by-product   of  precious  metals recovery from electrolytic copper refinery
slimes.  U.S.  annual production at one time reached one million pounds.
                          9
Principal uses of selenium are in semi-conductors, pigments, decoloring  of
glass,   zerography,   and metallurgy.  It also is used to produce ruby glass
used in signal lights.  Several selenium compounds are important  oxidizing
agents  in the  synthesis of organic chemicals and drug products.

While  results  of   some  studies suggest that selenium may be an essential
element in  human nutrition,  the toxic effects of  selenium  in  humans  are
well established.    Lassitude,   loss  of  hair,  discoloration and  loss of
                                   439

-------
fingernails are symptoms  of  selenium  poisoning.    In   a  fatal  case  of
ingestion  of a larger dose of selenium acid, peripheral  vascular collapse,
pulumonary edema, and  coma  occurred.   Selenium   produces  mutagenic  and
teratogenic  effects,  but  it  has  not  been   established  as  exhibiting
carcinogenic activity-

For the protection of human health from the  toxic   properties  of  selenium
ingested  through  water  and  through  contaminated  aquatic organisms,  the
ambient water criterion is determind to be 0.010 mg/1.

Very few data are available regarding the behavior  of   selenium  in  POTW.
One EPA survey of 103 POTW revealed one POTW using  biological treatment and
having  selenium  in the  influent.  Influent concentration was 0.0025 mg/1,
effluent concentration was 0.0016 mg/1 giving a  removal  of 37 percent.    It
is  not known to be  inhibitory to POTW processes.   In another study, sludge
from POTW in 16 cities was found to contain  from 1.8  to  8.7 mg/kg selenium,
compared to 0.01 to  2 mg/kg in untreated  soil.   These   concentrations  of
selenium  in sludge present a potential hazard for  humans or other mammuals
eating crops grown on soil treated with selenium containing sludge.

Silver(126).  Silver is a soft, lustrous, white  metal that is insoluble  in
water  and  alkali.   In  nature,  silver  is  found  in  the elemental state
(native silver) and  combined in ores such as argentite  (Ag2S),  horn  silver
(AgCl),  proustite   (Ag3AsS3),  and  pyrargyrite (Ag3SbS3y.   Silver is used
extensively in several industries, among them electroplating.

Metallic silver  is not considered to be toxic, but  most  of  its  salts  are
toxic  to  a  large  number  of  organisms.  Upon ingestion by humans,  many
silver salts are absorbed  in  the  circulatory  system   and  deposited  in
various  body tissues, resulting in generalized  or  sometimes localized gray
pigmentation of  the  skin  and mucous membranes know  as argyria.   There is no
known method for removing silver from the tissues once  it is deposited,  and
the effect  is cumulative.

Silver is recognized as a bactericide and doses  from  0.000001  to  0.0005
mg/1  have  been  reported as sufficient to  sterilize water.  The criterion
for ambient water to protect human health  from  the  toxic  properties  of
silver ingested  through water and through contaminated  aquatic organisms is
0.010 mg/1.

The  chronic  toxic  effects  of silver on the aquatic  environment have not
been given  as much   attention  as  many  other   heavy  metals.    Data  from
existing  literature  support the fact that  silver  is very toxic to aquatic
organisms.  Despite  the fact that silver is  nearly  the  most  toxic  of  the
heavy  metals,   there are insufficient data  to adequately evaluate even the
effects of  hardness  on silver toxicity.  There are  no data available on the
toxicity of different forms of silver.
                                    440

-------
There  is  no  available literature on the incidental  removal  of  silver  by
POTW.   An   incidental   removal   of  about  50  percent is assumed as being
representative.   This is the highest  average  incidental  removal  of  any
metal   for   which data  are available.   (Copper has been indicated to have a
median incidental removal rate of 49 percent).

Bioaccumulation  and concentration of silver from sewage sludge has not been
studied to any great degree.  There is some indication that silver could be
bioaccumulated in mushrooms to the  extent  that  there  could  be  adverse
physiological  effects   on  humans  if  they  consumed  large  quantites of
mushrooms grown  in silver enriched soil.   The effect, however,  would  tend
to be  unpleasnat rather than fatal.

There  is  little  summary data available on the quantity of silver discharged
to  POTW. Presumably there would be a tendency to limit its discharge from
a manufacturing  facility because of its high intrinsic value.

Thallium  (127).   Thallium (Tl) is a soft,  silver-white,  dense,  malleable
metal. Five major minerals contain 15 to 85 percent thallium, but they are
not  of  commerical  importance because the metal is produced in sufficient
quantity  as  a  by-product of lead-zinc smelting of sulfide  ores.   Thallium
melts   at  304°C.   U.S. annual production of thallium and its compounds is
estimated to be  1500 Ib.

Industrial  uses  of thallium include the manufacture of  alloys,  electronic
devices  and  special  glass.   Thallium  catalysts are used for industrial
organic syntheses.

Acute  thallium   poisoning   in  * humans   has   been   widely   described.
Gastrointestinal  pains  and diarrhea are followed by abnormal sensation in
the legs  and arms, dizziness,  and,  later,  loss  of  hair.   The  central
nervous  system   is also affected.  Somnolence, delerium or coma may occur.
Studies on  the teratogenicity of thallium appear inconclusive;  no  studies
on  mutagenicity were found; and no published reports on carcinogenicity of
thallium  were  found.

For the protection of human health from the toxic  properties  of  thallium
ingested   through  water  and  contaminated  aquatic organisms, the ambient
water criterion  is 0.004 mg/1.

No reports  were  found regarding the behavior of thallium in POTW.  It  will
not  be  degraded,  therefore  it  must  pass through to the effluent or be
removed  with   the  sludge.   However  since  the  sulfide   (T1S)  is  very
insoluble,   if  appreciable  sulfide  is  present dissolved thallium  in the
influent  to  POTW may be precipitated into the sludge.   Subsequent  use  of
sludge bearing thallium compounds as a soil amendment to crop bearing soils
may  result  in uptake of this element by food plants.  Several  leafy  garden
crops  (cabbage,   lettuce,  leek,  and  endive)  exhibit  relatively   higher
concentrations of thallium than other foods such as meat.
                                   441

-------
Zinc(128).    Zinc  occurs  abundantly  in  the  earth's crust,  concentrated in
ores.  It is readily refined  into  the  pure,   stable,   silvery-white  metal.
In  addition  to its use in alloys,  zinc  is used  as a protective coating on
steel.  It is applied by hot  dipping (i.e.  dipping  the  steel  in  molten
zinc)  or by electroplating.  The  resulting galvanized steel is used as one
of the basis materials for coil  coating.   Zinc   salts  are   also  used  in
conversion coatings in the coil  coating industry.

Zinc  can have an adverse effect on  man and animals at high  concentrations.
Zinc at concentrations in excess of   5 mg/1   causes  an  undesirable  taste
which  persists  through  conventional treatment.    For  the prevention of
adverse effects due to these  organoleptic properties of  zinc,   5 mg/1  was
adopted for the ambient water criterion.

Toxic  concentrations  of  zinc  compounds cause  adverse  changes  in the
morphology and physiology of  fish.   Lethal concentrations in the  range  of
0.1 mg/1  have been reported.  Acutely toxic  concentrations  induce cellular
breakdown of the gills, and possibly the  clogging of the gills with mucous.
Chronically  toxic  concentrations  of   zinc   compounds   cause   general
enfeeblement and widespread histological  changes  to many organs, but not to
gills.   Abnormal swimming behavior  has been  reported at 0.04 mg/1.  Growth
and maturation are retarded by zinc.   It  has  been observed that the effects
of zinc poisoning may not become apparent immediately,  so that fish removed
from  zinc-contaminated water  may die as long  as  48  hours after removal.

In general, salmonoids are most  sensitive to  elemental zinc  in soft  water;
the   rainbow  trout   is  the  most  sensitive  in  hard  waters.  A complex
relationship   exists   between    zinc   concentration,   dissolved    zinc
concentration,  pH,   temperature,  and calcium and  magnesium concentration.
Prediction of harmful effects has  been less than   reliable  and  controlled
studies have not been extensively  documented.

The   major  concern   with zinc compounds  in marine  waters is not with acute
lethal effects, but rather with  the   long-term  sublethal  effects  of  the
metallic compounds and complexrs.  Zinc accumulates in some  marine species,
and   marine animals contain zinc in  the range of  6  to 1500 mg/kg.  From the
point of view of acute lethal effects, invertebrate marine animals seem  to
be the most sensitive organism tested.

Toxicities  of  zinc  in  nutrient  solutions  have been demonstrated for a
number of plants.  A  variety of  fresh   water   plants  tested  manifested
harmful  symptoms at  concentrations  of 10 mg/1.   Zinc sulfate has also been
found to be lethal to many plants  and it  could impair agricultural uses  of
the  water.

Zinc  is not destroyed when treated by POTW, but  will either  pass through to
the  POTW effluent or  be retained in  the POTW  sludge.   It can interfere with
treatment  processes  in  the POTW   and   can also limit the usefuleness of
municipal sludge.
                                    442

-------
In slug doses,  and  particularly in the presence of copper,  dissolved  zinc
can  interfere   with  or seriously disrupt the operation of POTW biological
processes  by  reducing overall removal efficiencies, largely as a result  of
the toxicity  of the metal to biological organisms.  However, zinc solids in
the  form   of  hydroxides  or  sulfides  do  not  appear  to interfere with
biological treatment processes, on  the  basis  of  available  data.   Such
solids accumulate in the sludge.

The influent  concentrations of zinc to POTW facilities has been observed by
the  EPA   to  range from 0.017 to 3.91 mg/1, with a median concentration of
0.33 mg/1. Primary treatment is not efficient in removing  zinc;  however,
the microbial floe  of secondary treatment readily adsorbs zinc.

In  a study  of  258  POTW,  the  median pass-through values were 70 to 88
percent for primary plants, 50 to  60  percent  for  trickling  filter  and
biological process plants, and 30-40 percent for activated process plants.
POTW effluent concentrations of zinc ranged from 0.003 to 3.6 mg/1 (mean  =
0.330, standard deviation = 0.464).

The  zinc   which  does not pass through the POTW is retained in the sludge.
The presence  of zinc in sludge may  limit  its  use  on  cropland.   Sewage
sludge contains  72  to over 30,000 mg/kg of zinc, with 3,366 mg/kg as the
mean value.  These concentrations  are  significantly  greater  than  those
normally   found  in  soil,  which  range from 0 to 195 mg/kg, with 94 mg/kg
being a common  level.  Therefore, application of sewage sludge to soil will
generally  increase the concentration of zinc in  the  soil.   Zinc  can  be
toxic  to   plants,   depending  upon  soil  pH.  Lettuce, tomatoes, turnips,
mustard,  kale,  and beets are especially sensitive to zinc contamination.

Aluminum.   Aluminum is a non-conventional pollutant.  It is a silvery white
metal,  very abundant in the earths crust (8.1  percent),  but  never  found
free  in   nature.   Its  principal  ore  is  bauxite.   Alumina   (A1203) is
extracted  from  the bauxite and dissolved in molten cryolite.   Aluminum  is
produced  by electrolysis of this melt.

Aluminum    is   light,  malleable,  ductile,  possesses  high  thermal  and
electrical conductivity, and is non-magnetic.  It can be  formed,  machined
or  cast.    Although aluminum is very reactive, it forms a protective oxide
film on  the surface which prevents corrosion  under  many  conditions.   In
contact   with  other  metals in presence of moisture the protective film is
destroyed  and voluminous white corrosion products form.  Strong   acids  and
strong alkali  also break down the protective film.  Aluminum  is  one of the
principal  basis metals used in the coil coating industry.

Aluminum  is non-toxic and   its  salts  are  used  as  coagulants   in  water
treatment.   Although  some aluminum salts are soluble, alkaline  conditions
cause precipitation of the aluminum as a hydroxide.
                                   443

-------
Aluminum is commonly used  in   cooking   utensils.    There  are  no  reported
adverse physiological effects  on man from  low concentrations of aluminum in
drinking water.

Aluminum  does  not  have   any adverse effects   on  POTW operation at any
concentrations normally  encountered.

Ammonia.  Ammonia  (chemical formula NH3) is  a  non-conventional  pollutant.
It   is   a   colorless  gas   with  a   very   pungent  odor,   detectable  at
concentrations of  20 ppm in air by the  nose,  and  is very soluble  in  water
(570 gm/1  at  25°C).    Ammonia  is  produced  industrially  in  very large
quantities (nearly 20 millions tons annually in the U.S.).  It is converted
to ammonium compounds or shipped   in  the   liquid  form  (it  liquifies  at
-33°C).   Ammonia  also results from natural  processes.   Bacterial action on
nitrates or nitrites, as well  as dead plant  and animal   tissue  and  animal
wastes  produces   ammonia.   Typical  domestic  wastewaters  contain  12 to
50 mg/1 ammonia.

The principal use  of ammonia and its  compounds  is  as  fertilizer.    High
amounts  are  introduced  into soils and the water runoff from agricultural
land by this use.   Smaller quantities of ammonia  are used as a refrigerant.
Aqueous ammonia  (2 to 5  percent solution)  is widely  used  as  a  household
cleaner.  Ammonium compounds find  a variety  of uses in  various industries.

Ammonia is toxic to humans by  inhalation of  the gas or  ingestion of aqueous
solutions.   The ionized form  (NH4+) is less toxic than the unionized form.
Ingestion of as  little as  one  ounce of  household  ammonia has been  reported
as  a   fatal dose.  Whether inhaled or  ingested,  ammonia acts distructively
on mucous membrane with  resulting  loss  of  function.  Aside from  breaks  in
liquid  ammonia  refrigeration equipment,   industrial   hazard from ammonia
"exists  where solutions of  ammonium compounds may  be accidently treated with
a strong alkali, releasing ammonia gas. As  little as  150 ppm  ammonia  in
air is  reported  to cause laryngeal spasm,  and inhalation of 5000 ppm in air
is considered sufficient to result in death.

The  behavior of ammonia in POTW is well documented because it is a natural
component of  domestic   wastewaters.    Only   very  high  concentrations  of
ammonia  compounds  could overload   POTW.  ,  One  study  has  shown  that
concentrations   of unionized   ammonia   greater   than   90 mg/1   reduce
gasification   in   anaerobic digesters   and  concentrations of 140 mg/1 stop
digestion competely.  Corrosion of copper  piping and excessive  consumption
of  chlorine   also result  from high ammonia concentrations.  Interference
with aerobic nitrification processes can occur when large concentrations of
ammonia suppress dissolved oxygen.  Nitrites are then produced  instead  of
nitrates.   Elevated  nitrite  concentrations in drinking water are known to
cause  infant methemoglobinemia.

Barium.  Barium  is a  non-conventional pollutant.   It is an  alkaline  earth
metal   which   in   the pure state  is soft and silvery white.  It reacts with
                                    444

-------
moisture  in  the  air,  and reacts vigorously with water, releasing  hydrogen.
The principal   ore  is  barite  (BaS04)  although  witherite  (BaC03) was a
commerical   ore   at  one  time.   Many  barium  compounds  have, commerical
applications.    However,  drilling  muds  consume  90 percent  of all barite
produced.  For manufacture of the other chemicals barite  is   converted  to
barium  sulfide   first.   The  aqueous  barium  sulfide  is then treated to
produce the  desired product.   Barite itself and some other insoluble barium
compounds are used as fillers and pigments in paints.  Barium  carbonate  is
the most important  commerical  barium  compound  except  for the natural
sulfate.  The carbonate is used in the brick, ceramic,  oil-well  drilling,
photographic, glass,  and chemical manufacturing industries.

Barium  compounds such as the acetate, chloride, hydroxide, and nitrate are
water soluble;  the arsenate,  chromate, fluoride, oxalate, and  sulfate  are
insoluble.   Those salts soluble in water and acid, including  the carbonate
and sulfide  are  toxic to humans.  Barium sulfate is so insoluble that it is
non-toxic and  is used in X-ray medical diagnosis of  the  digestive  tract.
For  that purpose the sulfate must pass rigorous tests to assure absence of
water or  acid soluble barium.

Lethal  adult doses of most soluble barium salts are in the range of 1 to 15
g.  The barium  ion stimulates muscular tissue and causes  a  depression  in
serum  potassium.   Symptoms of acute barium poisioning include salivation,
vomiting, abdominal pain and diarrhea;  slow  and  often  irregular  pulse;
hypertension;   heart  disturbances;  tinnitus,  vertigo;  muscle  twitching
progressing  to  convulsions or paralysis;  dilated  pupils,  confusion;  and
somnolence.    Death  may occur from respiratory failure due to paralysis of
the respiratory muscles, or from cardiac arrest or fibrillation.

Raw wastewaters from  most  industrial  facilities  are  unlikely  to  bear
concentrations  of soluble barium which would pose a threat to  human health.
The  general  presence  of  small  concentrations  of  sulfate ion in many
wastewaters  is  expected to be sufficient to convert the barium to the  non-
toxic barium sulfate.

No  data  were  found relating to the behavior of barium in POTW.  However,
the insolubility of barium sulfate and the presence  of  sulfates  in  most
municipal  wastewaters  is expected to lead to removal of soluble barium by
precipitation  follwed by settling out with the other suspended solids.    It
is  reported  that  the  typical  mineral  pickup  from  domestic water use
increases the  sulfate concentration of 15 to 30 mg/1.   If  it is  assumed
that sulfate concentration exists in POTW, and the sulfate  is  not destroyed
or  precipitated  by  another metal ion, the dissolved barium  concentration
would not exceed 0.1 mg/1 at neutral pH in a POTW.

Boron.   Boron  is a non-conventional pollutant.  Elemental   boron  does  not
occur in  nature and in  the highly refined form  (99.9999 percent purity) has
only  limited   use.   The  compounds  of  boron  are  the   only  form   used
extensively  in industrial application.  The boron  minerals  of  commerical
                                   445

-------
significance  in the U.S. are tincal  (also called  borax,  Na2O2B203«10H20),
kernite (Na2O2B203»4H20), as well as colemanite,  ulexite,   and  probertite
which  are  hydrated  oxides  of  boron and calcium,  or  boron,  calcium, and
sodium.

Uses of boric acid and the various sodium, potassium,  ammonium, and calcium
borates include manufacture of adhesives, corrosion  inhibitors,  electrical
insulation,  fertilizers,  fire  retardants,  insecticides,  photography, and
vitreous enamels, frits and glazes.  Boric acid  itself is also   used  as a
mild antiseptic.

Conflicting  reports  about  the toxicity of  boric acid  and borax in humans
have been published.  On one hand, reports are available of high  doses  of
borax  administred  for  neutron  capture  therapy for brain tumors without
adverse effects.  On the other hand, reports  have  been repeatedly made  for
a hundred years, of human fatalities resulting from  theraputic  misadventure
and accidental poisoning by boric acid and borax.

Acute  poisoning  causes  nausea,  vomiting,  diarrhea,  muscle  twitches and
convulsions, and bright  red  skin  rashes.   Lethal   dose  for  adults  is
considered  to  be  15  to  20 g.  In addition to  ingestion,  application of
boric  acid to large areas of bruised skin have been  reported to lead to the
above  symptoms and fatality.  Raw wastewater  from  most industrial processes
are unlikely to bear concentrations of boron  compounds sufficiently high to
be a human health hazard.

No data were found  relating  to  behavior  of   boron compounds  in  POTW.
However,   it   has  been  reported  that  boron  compounds  are  toxic  to
microorganisms and that their presence must be taken  into consideration  in
design of biological treatment plants.  Concentrations causing  interference
were   not reported, but the same source reports  that  typical mineral pickup
from domestic water use contributes 0.1 to 0.4 mg/1  boron  in  the  seweage
system.   Thus  interfering  concentrations   are  probably greater than 0.4
mg/1.

Cobalt.  Cobalt is a non-conventional pollutant.   It  is   a  brittle,  hard,
magnetic,  gray  metal  with  a reddish tinge.   Cobalt ores are usually the
sulfide  or  arsenide   [smaltite-(Co,Ni)As2;   cobaltite-CoAsS]   and   are
sparingly  distributed  in the earth's crust.  Cobalt  is  usually produced as
a by-product of mining  copper, nickel, arsenic,  iron,  mangense, or  silver.
Because  of  the variety of ores and  the very low  concentrations of cobalt,
recovery of the metal is accomplished by several different processes.  Most
consumption of cobalt is for alloys.  Over two-thirds of  U.S.  production
goes to heat resistant, magnetic, and wear resistant  alloys.   Chemicals and
color  pigments make up  most of the rest of consumption.

Cobalt and many of its alloys are not corrosion resistant, therefore minor
corrosion of any of the tool alloys or  electrical  resistance  alloys  can
contribute   to   its   presence  in  raw  wastewater  from  a  variety  of
                                    446

-------
manufacturing  facilities.   Additionally,  the use of cobalt soaps as  dryers
to  accelerate curing  of  unsaturated oils used in coatings may be a general
source of  small  quantities of the metal.   Several cobalt pigments are  used
in paints  to produce yellows or blues.

Cobalt   is an  essential   nutrient  for   humans  and other mammals, and  is
present  at a fairly constant level of about 1.2 mg in the adult human body.
Mammals  tolerate low levels of ingested water-soluble cobalt salts  without
any  toxic symptoms;   safe dosage levels in man have been stated to be 2-7
mg/kg body weight per  day.  A goitrogenic  effect  in  humans  is  observed
after the systemic   administration of 3-4 mg cobalt as cobaltous chloride
daily for  three weeks.   Fatal heart disease among heavy beer  drinkers  was
attributed to  the  cardiotoxic action of cobalt salts which were formerly
used as  additives to improve foaming.  The  carcinogenicity  of  cobalt   in
rats has   been verified,  however, there is no evidence for the involvement
of dietary cobalt in carcinogenisis in mammals.

There are  no data available on the behavior of cobalt in POTW.   There  are
no  data  to   lead to  an expectation of adverse effects of cobalt on POTW
operation  or the utility of sludge from POTW for crop application.   Cobalt
which enters   POTW  is  expected  to  pass  through to the effluent unless
sufficient sulfide ion is present, or generated in anaerobic  processes   in
the POTW to cause precipitation of the very insoluble cobalt sulfide.

Fluoride.   Fluoride ion  (F~) is a non-conventional pollutant.  Fluorine  is
an extremely reactive,  pale yellow,  gas  which  is  never  found  free   in
nature.    Compounds  of fluorine - fluorides - are found widely distributed
in nature. The principal minerals containing fluorine are fluorspar (CaF2)
and cryolite  (Na3AlF6).  Although  fluorine  is  produced  commercially   in
small quantities  by   electrolysis  of  potassium  bifluoride in anhydrous
hydrogen fluoride, the  elemental  form   bears  little  relation  to  the
combined  ion.   'Total  production  of  fluoride  chemicals  in the U.S.  is
difficult  to estimate  because of  the  varied  uses.   Large  volume  usage
compounds   are:   Calcium fluoride (est.  1,500,000 tons in U.S.) and sodium
fluoroaluminate (est.  100,000 tons in U.S.).  Some fluoride  compounds  and
their uses are:  sodium  fluoroaluminate  - aluminum production; calcium
fluoride - steelmaking, hydrofluoric acid production, enamel, iron foundry;
boron trifluoride -    organic   synthesis;   antimony   pentafluoride
fluorocarbon   production;  fluoboric acid and fluoborates - electroplating;
perehloryl fluoride  (C103F) - rocket fuel  oxidizer;  hydrogen  fluoride
organic   fluoride  manufacture,  pickling  acid  in  stainless steelmaking,
manufacture of alumium fluoride; sulfur hexafluoride -  insulator  in  high
voltage   transformers;   polytetrafluoroethylene  -  inert  plastic.  Sodium
fluoride is used at a  concentration of about 1 ppm in many public  drinking
water supplies to prevent both decay in children.

The  toxic effects  of  fluoride on humans include severe gastroenteritis,
vomiting diarrhea, spasms, weakness,  thirst,  failing  pulse  and  delayed
blood coagulation.    Most  observations  of  toxic  effects  are  made   on
                                   447

-------
individuals  who  intentionally  or  accidentally   ingest  sodium  fluoride
intended  for  use  as rate poison or  insecticide.   Lethal  doses for adults
are estimated to be as low as 2.5 g.   At  1.5 ppm  in drinking water, motling
of tooth enamel is reported, and 14 ppm,  consumed over  a period  of  years,
may lead to deposition of calcium fluoride  in  bone  and  tendons.

Very  few  data  are  available on the behavior of  fluoride in POTW.  Under
usual operating  conditions  in  POTW,  fluorides   pass  through  into  the
effluent.   Very  little  of the fluoride entering  conventional primary and
secondary treatment processes is removed.   In  one study of   POTW  influents
conducted  by  the  U.S. EPA, nine POTW reported  concentrations of fluoride
ranging from 0.7 mg/1 to 1.2 mg/1, which  is the  range  of  concentrations
used for fluoridated drinking water.

Iron.   Iron is a non-conventional polluant.   It  is an  abundant metal found
at many places in the earth's crust.   The most common  iron  ore is  hematite
(Fe203)  from which iron is obtained by reduction with  carbon.   Other forms
of commercial ores are magnetite (Fe304)  and taconite  (FeSiO).    Pure  iron
is  not often found in commercial use, but  it  is  usually alloyed with other
metals and minerals.  The most common  of  these is carbon.

Iron is the basic element in the production of steel.   Iron with carbon  is
used  for  casting of major parts of machines  and it can be machined, cast,
formed, and welded.  Ferrous iron is used in paints,  while  powdered  iron
can  be  sintered  and  used in powder metallurgy-   Iron compounds are also
used to precipitate other metals and undesirable minerals  from  industrial
wastewater streams.

Corrosion  products  of iron in water  cause staining of porcelain fixtures,
and ferric iron combines with tannin to produce a dark  violet  color.   The
presence of excessive iron in water discourages cows from drinking and thus
reduces milk production.  High concentrations  of  ferric and ferrous ions in
water  kill  most  fish introduced to  the solution  within a few hours.  The
killing action is attributed to coatings  of iron  hydroxide  precipitates  on
the  gills.   Iron  oxidizing  bacteria   are dependent  on iron in water for
growth.  These bacteria form slimes that  can affect the aesthetic values of
bodies of water and cause stoppage of  flows in pipes.

Iron is an essential nutrient and micro-nutrient  for all forms  of  growth.
Drinking  water  standards   in  the U.S.  set a limit of 0.3 mg/1 of iron in
domestic water supplies based on aesthetic  and organoleptic  properties  of
iron in water.

High  concentrations  of iron do not pass through a POTW into the effluent.
In some POTW iron salts are  added to coagulate precipitates  and  suspended
sediments into a sludge.  In an EPA study of POTW the  concentration of iron
in   the  effluent  of  22   biological POTW   meeting   secondary  treatment
performance levels ranged from 0.048 to 0.569  mg/1  with a median  value  of
                                    448

-------
0.25  mg/1.  This represented  removals of 76 to 97 percent with a median of
87  percent removal.

Iron  in sewage sludge  spread on  land used for agricultural purposes is  not
expcected to have a detrimental  effect on crops grown on the land.

Manganese.   Manganese is  a non-conventional pollutant.  It is a gray-white
metal resembling iron,  but more  brittle.   The pure metal does not occur  in
nature,   but  must  be  produced  by  reduction  of  the oxide with sodium,
magnesium, or  aluminum,   or   by  electrolysis.   The  principal  ores  are
pyrolusite   (Mn02) and psilomelane (a complex mixture of Mn02 and oxides of
potassium, barium and  other alkali and alkaline earth metals).  The largest
percentage of manganese used  in  the U.S.  is in ferro-manganese  alloys.   A
small amount goes into dry batteries and  chemicals.

Manganese is  not  often  present  in  natural  surface waters because its
hydroxides and carbonates  are  only sparingly soluble.

Mangenese is undesirable in   domestic  water  supplies  because  it  causes
unpleasant   tastes,  deposits  on food during cooking, stains and discolors
laundry   and  plumbing  fixtures,  and   fosters   the   growth   of   some
microorganisms in reservoirs,  filters, and distribution systems.

Small concentratons   of  0.2  to  0.3 mg/1 manganese may cause building of
heavy encrustations  in piping.  Excessive manganese is also undesirable  in
water   for  use  in   many  industries,  including  textiles,  dying,  food
processing,  distilling, brewing, ice, and paper.

The recommended  limitations  for  manganese in drinking water in the U.S.  is
0.05 mg/1;   The  limit  appears to be based on aesthetic and economic factors
rather   than physiological hazards.  Most investigators regard manganese to
be of no toxicological significance in drinking water at concentrations not
causing  unpleasant  tastes.  However, cases of manganese poisoning have been
reported in  the  literature.    A   small  outbreak  of  encephalitis  -  like
disease,  with early  symptoms  of  lethergy and edema, was traced to manganese
in  the   drinking   water  in  a village near Tokyo.  Three persons died as a
result of poisoning  by well  water contaminated by  manganese  derived  from
dry-cell batteris buried nearby.  Excess manganese in the drinking water is
also believed   to   be  the  cause of a rare disease endemic in Northeastern
China.

No data  were found  regarding  the behavior of manganese in  POTW.   However,
one  source  reports   that  typical  mineral pickup from domestic water use
results  in an  increase in manganese concentration of 0.2 to 0.4 mg/1   in  a
municipal sewage   system.   Therefore, it  is expected that interference in
POTW,  if it  occurs,  would  not  be  noted  until  manganese   concentrations
exceeded 0.4 mg/1.
                                   449

-------
Phenols(Total).  "Total Phenols"  is a non-conventional  pollutant parameter.
Total phenols is the result of analysis  using  the  4-AAP (4-aminoantipyrene)
method.   This  analytical  procedure  measures  the  color  development of
reaction products between 4-AAP and some phenols.   The  results are reported
as phenol.  Thus "total phenol" is not total phenols because  many  phenols
(notably  nitrophenols)  do  not  react.   Also, since  each reacting phenol
contributes to the color development to  a different degree, and each phenol
has a molecular weight  different  from  others  and  from  phenol  itself,
analyses  of  several  mixtures   containing the  same total concentration in
mg/1 of several phenols  will  give  different  numbers  depending  on  the
proportions in the particular mixture.

Despite  these  limitations  of   the  analytical method,  total phenols is a
useful parameter when the mix of  phenols is   relatively   constant  and  an
inexpensive monitoring method is  desired.  In  any  given plant or even in an
industry  subcategory, monitoring of "total phenols" provides an indication
of the concentration of this group of priority pollutants as well as  those
phenols  not  selected as priority pollutants.   A  further advantage is that
the method is widely used in water quality determinations.

In an EPA survey of 103 POTW the  concentration of   "total  phenols"  ranged
grom 0.0001 mg/1 to 0.176 mg/1 in the influent,  with a  median concentration
of  0.016 mg/1.  Analysis of effluents from 22 of  these same POTW which had
biological treatment meeting secondary treatment performance levels  showed
"total  phenols"  concentrations  ranging  from  0  mg/1  to 0.203 mg/1 with a
median of 0.007.  Removals were 64 to 100  percent  with   a  median  of  78
percent.

It  must  be  recognized, however, that six of  the  eleven  priority pollutant
phenols could be present  in  high  concentrations  and  not  be  detected.
Conversely, it is possible, but not probable,  to have'a high "total phenol"
concentration  without  any  phenol itself or  any  of the  ten other priority
pollutant phenols present.  A characterization of  the phenol mixture to  be
monitored  to establish constancy of composition will allow "total phenols"
to be  used with confidence.

Phosphorus.   Phosphorus, a conventional  pollutant, is a general  term  used
to  designate  the  various  anions  containing  pentavalent phosphorus and
oxygen - orthophsophate  [(PO*)-3],  metaphosphate   [(P03)-],  pyrophosphate
 [(P0207-4],   hypophosphate  T(P206)-4].   The  element phosphorous exists in
several allotropic  forms  -  red,  white  or  yellow,  and  black.   White
phosphorus  reacts  with  oxygen  in air, igniting  spontaneously.  It is not
found  free in nature, but  is  widely  distributed  in  nature.   The  most
important commercial sources of phosphate are  the  apatites [3Ca3(P04)2»CaF2
and  3Ca3(P04)2»CaCl2].   Phosphates  also  occur  in bone and other tissue.
Phosphates are essential for plant and animal  life.   Several  millions  of
tons   of  phosphates  are mined and converted  for  use each year in the U.S.
The major form produced  is phosphoric acid.    The   acid  is  then  used  to
produce other phosphate chemicals.
                                    450

-------
The  largest use for phosphates  is  fertilizer.   Most of the U.S. production
of phosphoric acid goes  into  that   application.    Phosphates  are  used  in
cleaning  preparations   for .household  and  industrial applications and as
corrosion inhibitors in  boiler feed water and cooling towers.

Phosphates are not controlled because of toxic effects on man.   Phosphates
are  controlled because they promote growth of algae and other plant life in
aquatic  environments.    Such growth  becomes  unsightly  first, and if it
florishes, eventually dies, and  adds to the BOD.  The result can be a  dead
body of  water.   No standards  or  criteria appear to have been established
for  U.S. surface waters.

Phosphorus is one of the concerns   of  any  POTW,  because  phosphates  are
introduced into domestic wastewaters from human body wastes and food wastes
as  well  as  household   detergents.   About  ten percent of the phosphorus
entering POTW is insoluble and  is  removed by primary settling.   Biological
treatment  removes  very  little  of  the  remaining phosphate.  Removal is
accomplished by forming  an insoluble precipitate  which  will  settle  out.
Alum,   lime,  and  ferric chloride  or  sulfate are commonly used for this
purpose.  The point of addition  of  chemicals for phosphate removal requires
careful evaluation because pH adjustment may be required, and material  and
capital costs differ with different removal schemes.  The phosphate content
of the  effluent also varies according to the scheme used.  There is concern
about   the effect of phosphate  contained in sludge used for soil amendment.
Phosphate is a principal ingredient of fertilizers.

Strontium.  Strontium, a non-conventional pollutant, is a hard silver-white
alkaline earth metal.  The metal reacts readily with water and moisture  in
the air.   It  does not occur  as  the free metal in nature.  Principal ores
are strontianite  (SrCO?) and  celestite (SrS04).   The metal is produced from
the oxide by heating with aluminum, but no commerical  uses  for  the  pure
metal are known.

Small percentages of strontium  are alloyed with the lead used to cast grids
for some  maintenance   free   lead acid batteries.  Strontium compounds are
used in limited quantites in  special  applications.   Strontium  hydroxide
[Sr(OH)2]  import thermal and mechanical stability and moisture resistance.
The hydroxide   is  also   used  in   preparation  of  stabilizers  for  vinyl
plastics.  Several strontium  compounds are used in pyrotechnics.

Very few data are available regarding toxic effects of strontium in humans.
Some studies indicate  that strontium may be essential to growth in mammals.
Large   amounts  of  strontium  compounds orally administered, have retarded
growth  and caused rickets in  laboratory animals.  Strontium   is  considered
to  be  nontoxic or of  very low  toxicity in humans.  Specific  involvement of
strontium toxicity in  enzyme  or  biochemical systems is not known.

No reports were found  regarding  behavior of strontium in POTW.  At the  low
concentrations  of  strontium  to  be expected under normal conditions, the
                                   451

-------
strontium is expected to  pass  through   into   the  POTW  effluent  in  the
dissolved state.

Sulfides

Sulfides  are  oxidizable  and  therefore  can  exert  an oxygen demand on the
receiving stream.  Their presence  in amounts which consume oxygen at a rate
exceeding the oxygen uptake of  the  stream  can   produce  a  condition  of
insufficient dissolved oxygen in the receiving water.   Sulfides also impart
an  unpleasant  taste  and odor to the water and  can render the water unfit
for other uses.

Sulfides are constituents of many  industrial   wastes  such  as  those  from
tanneries,  paper  mills, chemical plants, and gas works; but they are also
generated in sewage and some natural waters by the anaerobic  decomposition
or organic matter.  When added to  water,  soluble  sulfide salts such as Na2S
dissociate  into  sulfide ions which,  in  turn,  react with the hydrogen ions
in the water to form HS - or H2S,  the proportion  of  each depending upon the
resulting pH value.  Thus, when reference  is made to sulfides in water, the
reader should bear in mind that the sulfide is probably in the form  of  HS
or H2S.

Owing to the unpleasant taste and  odor which results when sulfides occur in
water,  it  is  unlikely  that any person  or animals will consume a harmful
dose.  The thresholds of tast and  small were reported to  be  0.2  mg/1  of
sulfides  in  pulpmill  wastes.    For  industrial uses, however, even small
traces  of  sulfides  are  often   detrimental.    Sulfides  are  of   little
importance in  irrigation waters.

The toxicity of solutions of sulfides  toward fish increases as the pH value
is  lowered, i.e., the H2S or HS- rather than the  sulfide ion, appears to be
the principle  toxic agent.  In water containing 3.2  mg/1 of sodium sulfide,
trout  overturned  in two hours at pH  9.0,  in  ten minutes at pH 7.8, and in
four minutes at pH 6.0.  Inorganic sulfides have   proved  to  be  fatal  to
sensitive  fish such as trout at concentrations between 0.5 and 1.0 mg/1 as
sulfide, even  in neutral and somewhat  alkaline solutions.

Titanium.  Titanium is a non-conventional  pollutant.    It  is  a  lustrous
white metal occuring as the oxide  in  ilmenite  (FeO«Ti02) and rutile (Ti02).
The metal is used in heat-resistant, high-strength,  light-weight alloys for
aircraft  and  missiles.  It  is also used in surgical appliances because of
its high strength and light weight.  Titanium  dioxide is  used  extensively
as  a white pigment in paints, ceramics, and plastics.

Toxicity  data  on  titanium  are  not  abundant.   Because  of the lack of
definitive data titanium  compounds  are   generally   considered  non-toxic.
Large  oral doses of titanium dioxide  (Ti02) and  thiotitanic acid (H4TiS03)
were tolerated  by  rabbits   for   several  days  with  no  toxic  symptoms.
However,  impaired  reproductive   capacity was observed in rats fed 5 mg/1
                                    452

-------
titanium  as  titanate in drinking water.   There was also a reduction in  the
male/female   ratio  and  in  the  number  of animals surviving to the third
generation.   Titanium compounds are  reported  to  inhibit  several  enzyme
systems and  to  be carcinogenic.

The behavior of titanium in POTW has not been studied.  On the basis of the
insolubility of  the titanium oxides in water, it is expected that most of
the titanium entering the POTW will be removed by settling and will  remain
in  the sludge.  No data were found regarding possible effects on plants as
a  result of  spreading  titanium  -  containing  sludge  on  agricultural
cropland.

Total Organic Carbon.  Total Organic Carbon (TOO is an alternative measure
of  the   amount  of organic matter in a wastewater.  Other measures are BOD
and COD.   TOC is rapid and can be determined on a small quantity of sample.
The sample is injected into a high temperature furnace and oxidized in  the
presence   of a catalyst.  Carbon dioxide is analysed instrumentally.  Some
resistant compounds  will  not  be  oxidized.   Potentially,  each  organic
priority   pollutant makes a specific contribution to TOC.  Some however are
not oxidized under the analytical conditions.  Many other organic compounds
also contribute to TOC.

Typical  TOC  values for untreated domestic wastewater are 80 to 290 mg/1.

There is  no  specific toxic effect associated with  TOC  because  everything
from  fecal   coliform  bacteria, to oil and grease, to phthalate esters are
included  to  some extent in this parameter.

Behavior  of  TOC in POTW must be determined by  the  individual  components.
Removal   of   TOC  by primary settling and biological treatment in POTW will
vary from almost zero to almost complete.  Effect of TOC on crops grown  in
sludge-amended  soil must be evaluated by looking at what went into the TOC.

Oil  and   Grease.   Oil  and  grease  are  taken  together as one pollutant
parameter.  This is a conventional polluant and some of its components are:

1.   Light Hydrocarbons - These  include  light  fuels  such  as  gasoline,
     kerosene,  and jet fuel, and miscellaneous solvents used for industrial
     processing,  degreasing,  or cleaning purposes.  The presence of these
     light hydrocarbons may make the removal of other  heavier  oil  wastes
     more difficult.

2.   Heavy Hydrocarbons, Fuels, and Tars - These include  the  crude  oils,
     diesel  oils, #6 fuel oil, residual oils, slop oils, and in some cases,
     asphalt and road tar.

3.   Lubricants and Cutting Fluids - These generally fall into two classes:
     non-emulsifiable  oils  such  as   lubricating  oils  and  greases  and
     emulsifiable  oils  such  as water soluble oils, rolling oils,  cutting
                                   453

-------
     oils, and drawing compounds.  Emulsifiable oils  may  contain  fat  soap
     or various other additives.

4.   Vegetable and Animal Fats and Oils - These  originate  primarily  from
     processing of foods and natural products.

These  compounds  can  settle  or  float and may exist  as solids or liquids
depending upon factors such as  method  of  use,  production  process,   and
temperature of wastewater.

Oils  and  grease even in small quantities cause troublesome taste and  odor
problems.  Scum lines from these agents are  produced  on  water  treatment
basin  walls  and  other  containers.   Fish  and  water  fowl are adversely
affected by oils in their habitat.  Oil emulsions may adhere to  the gills
of  fish  causing  suffocation,  and  the  flesh  of  fish  is tainted  when
microorganisms that were exposed to waste oil are eaten.   Deposition of oil
in the bottom sediments of  water  can  serve  to  inhibit  normal  benthic
growth.  Oil and grease exhibit an oxygen demand.

Many  of  the organic priority pollutants will be found distributed between
the oily phase and  the  aqueous  phase  in  industrial  wastewaters.    The
presence  of phenols, PCBs, PAHs, and almost any other  organic pollutant in
the  oil  and  grease  make  characterization  of  this  parameter   almost
impossible.   However, all of these other organics add  to the objectionable
nature of the oil and grease.

Levels of oil and grease which are toxic to aquatic organisms vary greatly,
depending on the type and the species susceptibility.   However,  it has  been
reported that crude oil in concentrations'as low as 0.3 mg/1  is  extremely
toxic  to  fresh-water  fish.   It  has  been recommended that public water
supply sources be essentially free from oil and grease.

Oil and grease in quantities of 100 1/sq km show  up  as   a  sheen  on   the
surface  of  a  body  of  water.   The presence of oil  slicks decreases the
aesthetic value of a waterway.

Oil and grease is compatible  with  a  POTW  activated  sludge  process  in
limited quantity.  However, slug loadings or high concentrations of oil and
grease  interfere  with  biological  treatment  processes.    The  oils  coat
surfaces and solid particles, preventing access of oxygen,  and  sealing  in
some  microorganisms.   Land  spreading  of  POTW sludge  containing oil and
grease uncontaminated by toxic pollutants is not expected to  affect crops
grown on the treated land, or animals eating those crops.

p_H.   Although  not  a  specific pollutant, pH is related to the acidity or
alkalinity of a wastewater stream.   It  is  not,  however,  a  measure  of
either.  The term pH is used to describe the hydrogen ion concentration (or
activity)  present  in a given solution.  Values for  pH range from 0 to 14,
and  these  numbers  are  the  negative  logarithms   of  the  hydrogen   ion
                                    454

-------
concentrations.  A pH of  7  indicates  neutrality.   Solutions with a pH above
7  are  alkaline,  while  those  solutions with a pH below 7 are acidic.  The
relationship of pH and  acidity  and  alkalinity is not necessarily linear  or
direct.   Knowledge  of  the  water  pH  is useful in determining necessary
measures for corroison  control,  sanitation, and disinfection.  Its value is
also necessary in the treatment  of  industrial  wastewaters  to  determine
amounts  of  chemcials  required  to  remove pollutants and to measure their
effectiveness.  Removal  of  pollutants,  especially  dissolved  solids  is
affected by the pH of the wastewater.

Waters  with  a  pH  below  6.0  are   corrosive  to water works structures,
distribution lines,  and  household  plumbing  fixtures  and  can  thus  add
constituents  to  drinking  water  such as iron,  copper, zinc, cadmium, and
lead.  The hydrogen  ion concentration can affect the taste of the water and
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 7.0.  This is significant  for providng safe drinking water.

Extremes of pH or rapid pH  changes  can  exert  stress  conditions  or  kill
aquatic  life  outright. .  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.
For example, metallocyanide  complexes  can  increase  a  thousand-fold  in
toxicity with a drop of 1.5 pH  units.

Because  of  the universal  nature of  pH and its effect on water quality and
treatment, it is selected as  a  pollutant parameter for all subcategories in
the coil coating industry.  A  neutral  pH  range  (approximately  6-9)  is
generally   desired   because  either  extreme  beyond  this  range  has  a
deleterious effect on receiving waters or the  pollutant  nature  of  other
wastewater constituents.

Pretreatment  for  regulation of pH is covered by the "General Pretreatment
Regulations for Exisiting and  New  Sources  of  Pollution,"  40 CFR 403.5.
This  section  prohibits  the discharge to a POTW of "pollutants which will
cause corrosive structural  damage to  the POTW but  in  no  case  discharges
with  pH  lower  than   5.0  unless  the  works  is  specially  designed  to
accommodate such discharges."

Total Suspended Solids(TSS).  Suspended solids  include  both  organic  and
inorganic materials. The inorganic compounds include sand, silt, and clay.
The organic  fraction   includes  such  materials  as grease, oil, tar, and
animal and vegetable waste  products.   These solids may settle out  rapidly,
and bottom  deposits   are  often  a   mixture of both organic and inorganic
solids.  Solids may  be  suspended in water for a time and then settle to the
bed of the stream or lake.  These solids discharged with man's  wastes  may
be  inert,   slowly   biodegradable   materials,  or  rapidly  decomposable
substances.  While in suspension, suspended solids increase  the  turbidity
                                   455

-------
of  the  water,  reduce  light  penetration,   and impair the photosynthetic
activity of aquatic plants.

Supended solids in water interfere with many  industrial processes and cause
foaming in boilers and incrustastions  on  equipment exposed to  such  water,
especially as the temperature rises.   They  are undesirable in process water
used in the manufacture of steel, in the  textile industry, in laundries,  in
dyeing, and in cooling systems.

Solids  in  suspension  are aesthetically displeasing.   When they settle  to
form sludge deposits on the stream or  lake  bed,  they are often damaging  to
the  life in the water.  Solids, when  transformed to sludge deposit, amy  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 nature,  solids use
a  portion  or  all of the dissolved oxygen available in the area.   Organic
materials also serve as  a  food  source  for  sludgeworms  and  associated
organisms.

Disregarding  any  toxic  effect  attributable to substances leached out  by
water, suspended solids may kill fish  and  shellfish  by  causing  abrasive
injuries  and  by  clogging  the  gills and respiratory passages of various
aquatic fauna.  Indirectly, suspended  solids  are inimical to  aquatic  life
because   they  screen  out  light,  and  they  promote  and  maintain the
development of noxious conditions through oxygen depletion.   This  results
in  the  killing  of  fish  and fish food organisms.  Suspended solids also
reduce the recreational value of the water.

Total suspended solids is a traditional pollutant which is compatible  with
a ' well-run  POTW.   This  pollutant with the exception of those components
which  are  described  elsewhere  in   this  section,  e.g.,   heavy   metal
components,  does  not  interfere  with   the  operation  of a POTW.  However,
since a considerable portion of the innocuous TSS may be inseparably  bound
to  the  constituents  which  do  interfere with POTW operation, or produce
unusable sludge, or subsequently  dissolve  to  produce  unacceptable  POTW
effluent, TSS may be considered a toxic waste hazard.
                                    456

-------
                                SECTION VII

                    CONTROL  AND TREATMENT TECHNOLOGY


INTRODUCTION

This section describes  the  treatment techniques currently used or available
to remove  or  recover  wastewater  pollutants normally generated by metal
molding and casting  processes.    Included  are  discussions  of  individual
treatment technologies  and  in-plant technologies.

INDIVIDUAL TREATMENT TECHNOLOGIES

Individual recovery  and treatment technologies are described which are used
or are  suitable  for use in  treating wastewater discharges from foundries.
The technology descriptions are grouped by primary application  under  five
headings:    Dissolved    Inorganics   Removal,   Solids  Removal,  Recovery
Techniques,  Oil   Removal  and   Cyanide  and  Phenol   Destruction.    Each
description    includes    a    functional   description  and  discussions  of
application  and   performance,   advantages  and  limitations,   operational
factors   of   reliability,  maintainability,  solid  waste  aspects,  and
demonstration  status.    The  treatment  processes  described  include  both
technologies   presently  demonstrated  within  the  foundry  manufacturing
category, and  technologies  demonstrated in treatment of similar  wastes  in
other  industries.

Even   though   some  of   the  techniques  are  used  in more than one of the
classifications, they are only  described once.

DISSOLVED INORGANICS REMOVAL
                              t
Foundry process wastewater  streams characteristically  contain  significant
levels of  toxic  metals.  Copper, lead, nickel, and zinc and are found in
wastewater streams at substantial concentrations.

In general, these  pollutants  are  removed  by  chemical  precipitation  and
clarification  or  filtration.    Most of them may be effectively removed by
precipitation  of metal  hydroxides or  carbonates  by  reaction  with  lime,
sodium hydroxide,  or   sodium   carbonate.  For some, improved removals are
provided by the use  of  sodium sulfide, ferrous sulfide, or sodium bisulfide
to precipitate the pollutants as sulfide  compounds  with  exceedingly  low
solubilities.


    CHEMICAL  PRECIPITATION

Dissolved   toxic    metal   ions  and  certain  anions  may  be  chemically
precipitated so that they may  be  removed  by  physical  means  such  as
                                   457

-------
sedimentation,   filtration,   or  centrifugation.    Several   reagents  are
commonly used to effect this precipitation.

1)   Alkaline compounds such as lime or sodium  hydroxide   may  be  used  to
     precipitate many toxics metal ions as metal  hydroxides.   Lime also may
     precipitate phosphates as insoluble calcium  phosphate and fluorides as
     calcium fluoride.

2)   Both soluble sulfides such as hydrogen sulfide  or  sodium  sulfide  and
     insoluble  sulfides such as ferrous sulfide  may be used  to precipitate
     many heavy metal ions as insoluble metal sulfides.

3)   Ferrous sulfate, zinc sulfate or both (as  is required) may be used  to
     precipitate cyanide as a ferro or zinc ferricyanide  complex.

4)   Carbonate precipitates may be used to remove metals  either  by  direct
     precipitation  using  a carbonate reagent  such  as  calcium carbonate or
     by converting hydroxides into carbonates using  carbon dioxide.

These  treatment chemicals may be added to a flash mixer or rapid mix  tank,
to a presettling tank, or directly to a clarifier or other settling device.
Because metal hydroxides tend to be colloidal in  nature,  coagulating agents
may  also  be  added  to  facilitate  settling.   After  the solids have been
removed, final pH adjustment may be required to reduce  the high pH  created
by the alkaline treatment chemicals.

Chemical  precipitation  as a mechanism for removing metals from wastewater
is a complex process made up of at least two steps - precipitation  of  the
unwanted metals and removal of the precipitate.   Some small amount of metal
will   remain dissolved in the wastewater after  complete precipitation.  The
amount of residual dissolved metal depends on the treatment chemicals  used
and  related  factors.   The  effectiveness  of this method of removing any
specific metal depends on the fraction of the specific  metal  in  the  raw
waste   (and  hence  in  the precipitate) and the  effectiveness of suspended
solids removal.

Application and Performance

Chemical precipitation is used in foundries for precipitation of  dissolved
metals.   It  can  be  utilized  to  permit  removal of  metal ions such as
aluminum, antimony, arsenic, beryllium, cadmium,  chromium, cobalt,  copper,
iron,   lead,  manganese, mercury, molybdenum, tin and zinc.   The process is
also applicable to any substance that can be transformed  into an  insoluble
form such as  fluorides, phosphates, soaps, sulfides  and others.  Because it
is  simple  and  effective  chemical  precipitation  is  extensively used for
industrial waste treatment.

The performance of chemical precipitation  depends  on  several  variables.
The most important factors affecting precipitation effectiveness are:
                                    458

-------
    1.   Maintenance  of  an  alkaline  pH   throughout   the  precipitation
         reaction and subsequent settling.

    2.   Addition of a sufficient excess of  treatment  ions  to  drive  the
         precipitation reaction to  completion.

    3.   Addition of an adequate supply of sacrifical  ions (such  as  iron
         or  aluminum)  to  ensure  precipitation   and  removal of specific
         target ions.

    4.   Effective  removal  of  precipitated   solids    (see   appropriate
         technologies discussed under "Solids Removal").

Control  of_  pH.   Irrespective  of  the solids removal  technology employed,
proper control of pH is absolutely essential  for favorable  performance  of
precipitation-sedimentation  technologies.    This is clearly illustrated by
solubility curves for selected metals  hydroxides  and   sulfides  shown  in
Figure  VII-1,  and  by plotting effluent zinc concentrations against pH as
shown  in Figure VI1-2.  It is partially illustrated by  data obtained from 3
consecutive days of sampling at  one metal   processing   plant  (47432)  as
displayed in Table VII-1.
                                   459

-------
                                TABLE VII-1
                    pH Control Effect on Metals Removal

               Day 1               Day 2               Day  3
          In	Out       In	Out        In	Out

pH Range  2.4-3.4   8.5-8.7   1.0-3.0   5.0-6.0    2.0-5.0   6.5-8.1

(mg/1)

TSS        39        8         16        19         16         7

Copper     312      0.22       120      5.12        107      0.66

Zinc       250      0.31      32.5      25.0       43.8      0.66

This  treatment system utilizes lime precipitation (pH adjustment) followed
by coagulant addition and sedimentation.  Samples  were   taken  before  (in)
and  after  (out)  the  treatment system.  The best treatment or  removal of
copper and zinc was achieved on day one when the pH  was maintained  at  a
satisfactory level.  The poorest treatment was found on  the second day when
the  pH  slipped  to an unacceptably low level and intermediate values were
were achieved on the third day when pH values were less  than  desirable but
in between the first and second days.

Sodium  hydroxide  is  used  by  a  plant  (plant   439)  with metal  process
wastewater  pollutants  for  pH  adjustment  and   chemical    precipitation,
followed by settling (sedimentation and a polishing lagoon) of  precipitated
solids.   Samples  were  taken  prior to caustic addition and following the
polishing lagoon.  Flow through the system is approximately 6,000 gal/hr.
                                   460

-------
                                TABLE VI1-2
                Effectiveness of  NaOH for Metals Removal

              Day  1                Day 2               Day 3
          In	Out        Iji	Out       In	Out

pH Range   2.1-2.9   9.0-9.3    2.0-2.4   8.7-9.1   2.0-2.4   8.6-9.1
(mg/1)
Cr
Cu
Fe
Pb
Mn
Ni
Zn
TSS
0.097
0.063
9.24
1.0
0.11
0.077
.054

0.0
0.018
0.76
0.11
0.06
0.011
0.0
13
0.057
0.078
15.5
1.36
0.12
0.036
0.12

0.005
0.014
0.92
0.13
0.044
0.009
0.0
11
0.068
0.053
9.41
1.45
0.11
0.069
0.19

0.005
0.019
0.95
0.11
0.044
0.011
0.037
11
These data indicate that the system was operated efficiently.  Effluent  pH
was  controlled  within the range of 8.6-9.3, and, while raw waste loadings
were not unusually high,  most  heavy  metals  were  removed  to  very   low
concentrations.

Lime  and  sodium hydroxide are sometimes used to precipitate metals.  Data
developed data from plant 40063, a  facility  with  wastewater  similar  to
foundry   wastewaters,    exemplify   efficient   operation  of  a  chemical
precipitation and settling system.  Sampling data from this  system,  which
consists of the addition of lime and sodium hydroxide for pH adjustment  and
chemical    precipitation,   polyelectrolyte   flocculant   addition,    and
sedimentation.  Samples were taken of the raw waste influent to the  system
and  of  the  clarifier effluent.  Flow through the system is approximately
5,000 gal/hr.
                                   461

-------
                                TABLE VI1-3
             Effectiveness of Lime and NaOH for Metals  Removal

               Day 1               Day 2                Day  3
          In	Out       In	Out       In	Out

pH Range  9.2-9.6   8.3-9.8   9.2       7.6-8.1   9.6       7.8-8.2
(mg/1)

Al        37.3      0.35      38.1      0.35      29.9      0.35

Cu        0.65      0.003     0.63      0.003     0.72      0.003

Fe        137       0.49      110       0.57      208       0.58

Mn        175       0.12      205       0.012     245       0.12

Ni        6.86      0.0       5.84      0.0       5.63      0.0

Se        28.6      0.0       30.2      0.0       27.4      0.0

Ti        143       0.0       125       0.0       115       0.0

Zn        18.5      0.027     16.2      0.044     17.0      0.01

TSS       4390      9         3595      13        2805      13


At this plant, effluent TSS  levels were below  15 mg/1 on  each day,   despite
average  raw  waste  TSS concentrations of over 3500 mg/1.  Effluent pH was
maintained at approximately  8,  lime addition was sufficient to   precipitate
the   dissolved  metal  ions,  and  the  flocculant  addition  and  clarifier
retention served  to effectively remove the precipitated solids.

Precipitation-Sedimentation  Performance

Sampling data was analyzed from over thirty industrial  plants  successfully
employing  chemical  precipitation  as  a  waste treatment  technology.   The
plants  included in this analysis all employ  pH  adjustment  and  hydroxide
precipitation  using lime or caustic, followed by settling  (tank,  lagoon or
clarifier) for solids  removal.  Most also add  a  coagulant  or  flocculant
prior  to  solids removal.   No  sample analysis were included  where effluent
TSS  levels exceeded 50 mg/1  or  the effluent pH fell below  7.0.   This   was
done to exclude  any data which represented clearly inadequate  operation of
the  treatment system.  These data are derived  from a variety  of  industrial
manufacturing  operations  which  have  wastewater  relatively   similar  to
foundry process wastewater.   Plots were made   of  the   available  data   for
eight  metal  pollutants  showing  effluent  concentration  vs.  raw waste
concentration  (Figures VII-3 -  VII-11) for  each  parameter.    Table VII-4
                                    462

-------
summarizes   data   shown  in  Figures  VI1-3  -  VII-11, tabulating for each
pollutant of interest to the number of data points, maximum observed  value
and  average  of   observed values.   Generally accepted design values  (GADV)
for these metals  are also shown in Table VI1-4.

                        TABLE VI1-4
Hydroxide Precipitation - Sedimentation Performance
Specific    No.  data
metal	    points
                      Observed Values
                 Maximum	     Average
                             GADV
Cd
Cr
Cu
Fe
Pb
Mn
Ni
P
Zn
 7
29
24

35
20
14
21
28
0.10
0.5
  50
  00
1,
1
0.13
0.50
  00
  50
2,
5,
2.00
0.03
0.15
0.30
0.35
0.02
0.15
0.50
1.20
0.30
2
3
0.02
0.2
0,
0,
0.02
0.3
0.2

0.5
A number of other pollutant parameters were considered with regard  to   the
performance  of  hydroxide precipitation-sedimentation treatment systems in
removing them from industrial wastewater.  Sampling data for most of  these
parameters  is  scarce, so published sources were largely consulted for  the
determination of  average  and  24-hour  maximum  concentrations.   Sources
consulted  include  text books, periodicals and EPA publications as well as
applicable sampling data.

The available data indicate that the concentrations shown  in  Table  VI1-5
are reliably attainable with hydroxide precipitation and sedimentation.
                                   463

-------
                                TABLE VII-5
             Hydroxide Precipitation-Sedimentation  Performance
                           ADDITIONAL PARAMETERS

Parameter         Average              24-Hour Maximum
(mg/1)

Fluoride            15                        30
Aluminum            0.2                       0.55
Antimony            0.05                      0.5
Arsenic             0.05                      0.5
Beryllium           0.3                       1.0
Cobalt              0.07                      0.5
Mercury             0.03                      0.1
Selenium            0.01                      0.1
Titanium            0.01                      0.1

Precipitation-Sedimentation-Filtration Performance

Long  term  data  were  analyzed  from  two plants  which  have  well  operated
precipitation-sedimentation   treatment   followed    by    filtrates.     The
wastewaters  from both plants contain pollutants from metals processing  and
finishing  operations  (multi-category).   Both  plants   reduce  hexavalent
chromium  before  neutralizing  and  precipitating  metals with   lime.   A
clarifier is used to remove much of the solids load and a  filter  used  to
"polish"  or  complete  removal of suspended  solids.  Plant A  uses  pressure
filtration while Plant B uses a rapid sand filter.

Raw waste data was collected only occasionally at each facility and the  raw
waste data is presented as an indication of the nature  of the  wastewater
treated.   Data  from  plant A was received as a statistical summary and is
presented as received.  Raw laboratory data was collected at   plant  B  and
reviewed  for  spurious points and discrepencies.   To eliminate unexplained
spurious points the data was averaged and points falling  outside  3  standard
deviations above the mean were purged.  (As a matter  of   information,  this
procedure  purged  16  days  data because of  spurious nickel values,  22  for
iron, 1 for zinc and 12 for chrominum, out of a data  base of about 1400
points).  After purging the data was reanalyzed and is presented  below.
                                    464

-------
                    TABLE VII-6
PRECIPITATION-SEDIMENTATION-FILTRATION PERFORMANCE
                      Plant A
Parameters No Pts
For 1979-Treated
Cu
Ni
Cr
Zn
Fe
For 1978-Treated
Cu
Ni
Cr
Zn
Fe
Raw Waste
Cu
Ni
Cr
Zn
Fe
Range mq/1
Mean +,
std . dev .
Mean + 2
std. dev.
Wastewater
12
47
47
47

0.
0.
0.
0.

01
08
015
08

- 0.
- 0.
- 0.
- 0.

03
64
13
53

0.
0.
0.
0.

019
22
045
17

+0.
+ 0.
To.
+ 0.

006
13
029
09

0.
0.
0.
0.

03
48
10
35

Wastewater
28
47
47
47
21

5
5
5
5
5
0.
0.
0.
0.
0.

0.
1.
32.
33.
10.
005
10
01
08
26

08
65
0
2
0
- 0.
- 0.
- 0.
- 2.
- 1.

- 0
- 20
- 72
- 32
- 95
055
92
07
35
1

.45
.0
.0
.0
.0
0.
0.
0.
0.
0.






016
20
06
23
49






+0.
+ 0.
+ 0.
+ 0.
+ 0.






010
14
10
34
18






0.
0.
0.
0.
0.






04
48
26
91
85






                       465

-------
                                TABLE VI1-7
            PRECIPITATION-SEDIMENTATION-FILTRATION  PERFORMANCE
                                  Plant B

                                        Mean  +.       Mean + 2
Parameters     No Pts.    Range mg/1    std.  dev.     std.  dev.
For 1979-Treated Wastewater

     Cu        176       0.0   - 0.22   0.024 +0.021    0.07
     Ni        175       0.01  - 1.49   0.219 +.0.234    0.69
     Cr        175       0.0   - 0.40   0.068 +0.075    0.22
     Zn        175       0.01  - 0.66   0.054 +.0.064    0.18
     Fe        174       0.01  - 2.40   0.303 +0.398    1.10
     TSS         2       1.00-1.00

For 1978-Treated Wastewater

     Cu        143       0.0   - 0.23   0.017 +0.020    0.06
     Ni        143       0.0   - 1.03   0.147 +0.142    0.43
     Cr        144       0.0   - 0.70   0.059 +0.088    0.24
     Zn        131       0.0   - 0.24   0.037 +0.034    0.11
     Fe        144       0.0   - 1.76   0.200 +0.223    0.47

Total  1974-1979-Treated Wastewater

     Cu       1290       0.0   - 0.23   0.011 +0.016    0.04
     Ni       1287       0.0   - 1.88   0.184 +0.211    0.60
     Cr       1288       0.0   - 0.56   0.038 +.0.055    0.15
     Zn       1273       0.0   - 0.66   0.035 +0.045    0.13
     Fe       1287       0.0   - 3.15   0.402 +.0.509    1.42

Raw Waste

     Cu          3       0.09  - 0.27   0.17
     Ni          3       1.61  - 4.89   3.33
     Cr          3       2.80  - 9.15   5.90
     Zn          2       2.35  - 3.39
     Fe          3       3.13  -35.9   22.4
     TSS         2       177   - 446

This   data  are  presented to demonstrate  the performance of precipitation-
sedimentation-filtration technology  (also  known  as  lime   and   settle  with
filter technology) under actual operating  conditions  and  over  a long period
of time.

It should be noted that the iron content of the  raw waste of both plants is
high.  This results  in coprecipitation of  toxic  metals  with iron,  a process
sometimes  called ferrite precipitation.   Ferrite precipitation using high-
calcium lime for pH  control yields the results shown  above.   Contact  with
                                    466

-------
plant   operating    personnel   indicates   that  this  chemical   treatment
combination   (sometimes  with  polymer  assisted   coagulation)    generally
produces   better and more consistant metals removal than other combinations
of sacrifical  metal  ions and alkalis.

Sulfide precipitation is sometimes used to precipitate metals resulting   in
Improved   metals   removals.    Most  metal  sulfides  are less soluable than
hydroxides and the precipitates are frequently more dependably removed from
water.  Solubilities for selected metal hydroxide,  carbonate  and sulfide
precipitates    are   shown   in  Table  VI1-8.   Sulfide  precipitation   is
particularly  effective in removing  specific  metals  such  as  silver   and
mercury.    Sampling  data  from  three  industrial  plants  using sulfide
precipitation are  presented in Table VI1-9.

                                TABLE VI1-8
           THEORETICAL SOLUBILITIES OF HYDROXIDES AND SULFIDES
                       OF HEAVY METALS IN PURE WATER
Metal

Cadmium (Cd++)
Chromium (Cr+++0
Cobalt (CC++)
Copper (Cu++)
Iron (Fe++)
Lead (Pb++)
Manganese (Mn++)
Mercury (Hg++)
Nickel '(Ni++)
Silver (Ag+)
Tin (Sn++)
Zinc (An++)
           Solubility of metal ion, mq/1
 As hydroxide        Carbonate      As sulfide
   6.7 x 10-10
No precipitate
   1.0 x 10-"
   5.8 x 10-»»
   3.4 x 10-s
   3.8 x 10-»
   2.1 x 10-'
   9.0 x 10-20
   6.9 x!0-«
   7.4 x lO-12
   3.8 x 10-»
   2.3 x lO-7
 2.3 x
 8.4 x 10-4
 2.2 x 10-»
 2.2 x lO-2
 8.9 x 10-»
 2.1
 1.2
 3.9 x 10-*
 6.9 x 10-'
13.3
 1.1 x 10-*
 1.1
                                   467

-------
                         TABLE VI1-9
                 SAMPLING DATA FROM SULFIDE
            PRECIPITATION-SEDIMENTATION SYSTEMS
Treatment



pH
(mg/1)

Cr + 6

Cr

Cu

Fe

Ni

Zn
   Lime,  FeS,  Poly-
   electrolyte,
   Settle,  Filter
   In
5.0-6.8
   0.52
   39.5
  Out
8-9
   25.6   <0.014

   32.3   <0.04
0.10
<0.07
            Lime,  FeS, Poly-
            electrolyte,
            Settle,  Filter
In
  Out
7.7
7.38
0.022  <0.020

2.4    <0.1



108     0.6

0.68    <0.1

33.9    <0.1
                    NaOH, Ferric
                    Chloride, NaS,
                    Clarify  (1 stage)
In
Out
                                11.45   <.005

                                18.35   <.005

                                0.029   0.003
           0.060
        0.009
 In all cases except  iron, effluent concentrations  are  below 0.1  mg/1  and'in
 many cases below 0.01 mg/1 for the three plants  studied.

 Sampling data from   several  chlorine-caustic  manufacturing  plants   using
 sulfide  precipitation  demonstrate effluent mercury concentrations varying
 between 0.009 and  0.03  mg/1.   As   can   be   seen  in  Figure  VII-1,  the
 solubilities  of  PbS  and Ag2S  are lower  at alkaline  pH levels  than  either
 the corresponding hydroxides or  other sulfide  compounds.   This implies that
 removal performance  for lead and silver sulfides should be comparable to or
 better than that shown for the metals listed' in  Table   VI1-5.  Bench   scale
 tests  on  several   types  of  metal  finishing and manufacturing wastewater
 indicate that metals removal to  levels of  less than 0.05 mg/1  and  in  some
 cases  less than 0.01 mg/1 are common  in systems  using  sulfide  precipitation
 followed  by  clarification.  Some of the  bench  scale  data, particularly  in
 the case of lead,  does  not  support such  low  effluent  concentrations.
 However,  lead  is   consistently removed to  very low  levels (less than 0.02
 mg/1)  in  systems   using  hydroxide   and    carbonate    precipitation   and
 sedimentation.
                                    468

-------
Of  particular  interest  is  the  ability of sulfide to precipitate hexavalent
chromium  (Cr+6) without  prior reduction  to  the  tri-valent  state  as  is
required   in  the  hydroxide  process.   When ferrous sulfide is used as the
precipitant,  iron and  sulfide act  as reducing  agents  for  the  hexavalent
chromium  according to  the reaction:

     Cr203+ 2FeS + 7H20     2Fe(OH)3  + 2Cr(OH)3 + 2S + 20H

In  this  reaction the  sludge produced consists mainly of ferric hydroxides,
chromic hydroxides and various  metallic  sulfides.   Some  excess  hydroxyl
ions  are generated   in this   process,   possibly requiring a downward re-
adjustment of pH.

Based on  the  available  data,   the  minimum  reliably  attainable  effluent
concentrations  for sulfide  precipitation-sedimentation systems are given in
Table VII-10.   These values are  used to calculate performance predictions
of sulfide precipitation-sedimentation systems.

                         TABLE  VII-10
      SULFIDE PRECIPITATION-SEDIMENTATION PERFORMANCE

          Parameter                Treated Effluent
                                       (mg/1)

               Cd                      0.01
               CrT                     0.05
               Cu                      0.05
               Pb                      0.01
               Hg                      0.03
               Ni                      0.05
               Ag                      0.05
               Zn                      0.01

Carbonate precipitation  is  sometimes used to precipitate metals, especially
where precipitated metals values are to be recovered.   The  solubility  of
most  metal   carbonates   is  intermediate  between  hydroxide  and  sulfide
soluabilities and carbonates  form easily filtered precipitates.

Carbonate ions  appear  to be particularly useful in precipitating  lead  and
antimony.  Sodium   carbonate  has been observed being added at treatment to
improve   lead  precipitation.    The  lead  hydroxide  and  lead   carbonate
solubility curves displayed in  Figure VII-12 explain this phenomena.

Advantages and  Limitations

Chemical  precipitation has  proven to be an effective technique for removing
many  pollutants  from  industrial  wastewater.   It  operates  at  ambient
conditions and  is well suited  to automatic control.  The  use  of  chemical
precipitation  may   be limited  because of interference of chelating agents,
                                   469

-------
because of the chemical interference possible  when  mixing  wastewaters  and
treatment  chemicals,  or  because  of   the potentially hazardous situation
involved with the storage and handling of  those  chemicals.   Lime is usually
added as a slurry when used in hydroxide precipitation.   The slurry must be
kept well mixed and the addition  lines  periodically  checked  to  prevent
blocking  of  the  lines, which may result from  a buildup of solids.  Also,
hydroxide precipitation usually makes recovery of the  precipitated  metals
difficult, because of the heterogeneous  nature of most  hydroxide sludges.

The major advantage of the sulfide precipitation process is that because of
the  extremely  low  solubility  of  most  metal sulfides, very high metal
removal efficiencies can be achieved.  Also, the sulfide  process  has  the
ability  to  remove chromates and dichromates  without preliminary reduction
of the chromium to its trivalent state.  In addition,  it  will  precipitate
metals  complexed with most complex ing agents.   However,  care must be taken
to maintain the pH of the solution at approximately 10  in order to  prevent
the  generation of toxic hydrogen sulfide  gas.   For this reason ventilation
of the treatment tanks may be a necessary  precaution in most installations.
The use of ferrous sulfide reduces or virtually  eliminates the  problem  of
hydrogen  sulfide  evolution.   As  with  hydroxide  precipitation,  excess
sulfide ion  must  be  present  to  drive  the  precipitation  reaction  to
completion.   Since  the sulfide ion itself is toxic, sulfide addition must
be carefully controlled to  maximize  heavy  metals  precipitation  with a
minimum  of  excess  sulfide  to avoid the necessity of post treatment.  At
very high excess  sulfide  levels  and   high   pH,   soluble  mercury-sulfide
compounds may also be formed.  Where excess sulfide is  present, aeration of
the  effluent  stream  can  aid  in  oxidizing residual sulfide to the less
harmful sodium sulfate (Na2S04).  The cost of  sulfide precipitants is  high
in comparison with hydroxide precipitants, and disposal of metallic sulfide
sludges  may  pose  problems.   An  essential  element  in effective sulfide
precipitation is the removal of precipitated solids from the wastewater and
proper disposal in an appropriate site.  Sulfide precipitation  will  also
generate a higher volume of sludge, than hydroxide  precipitation, resulting
in  higher  disposal  and  dewatering  costs.  This is  especially true when
ferrous sulfide is used as the precipitant.

Sulfide precipitation may be used as a polishing treatment after  hydroxide
precipitation-sedimentation.   This treatment  configuration may provide the
better treatment effectiveness of sulfide  precipitation  while  minimizing
the  variability  caused by changes in raw waste and reducing the amount of
sulfide precipitant required.

Operational Factors

Reliability;  The reliability of alkaline  chemical  precipitation  is  high,
although proper monitoring, control, and pretreatment to remove interfering
substances  is  required.   Sulfide  precipitation   systems provide similar
reliability.
                                    470

-------
Maintainability;   The  major  maintenance needs involve  periodic  upkeep  of
monitoring  equipment,   automatic  feeding equipment, mixing equipment, and
other  hardware.  Removal of  accumulated sludge is necessary  for  efficient
operation of precipitation-sedimentation systems.

Solid  Waste  Aspects;    Solids  which  precipitate  out  are  removed in a
subsequent  treatment   step.    Ultimately,  the  solids  must  be  properly
disposed.

Demonstration Status

Chemical  precipitation  of   metal  hydroxides is a classic waste treatment
technology  used  by most  industrial  waste  treatment  systems.   Chemical
precipitation  of   metals  in the carbonate form alone has been found to be
feasible and, is used  in commercial application to permit  metals  recovery
and water  reuse.   Full scale commercial sulfide precipitation units are in
operation at numerous  installations.  As noted  earlier,  sedimentation  to
remove precipitates is discussed separately.

Chemical Precipitation System Effectiveness

Data  have  been  presented   showing  the  effectiveness  of precipitation-
sedimentation -  (lime  and  settle),  precipitation-sedimentation-filtration
(lime,  settle    and    filter)   technology   and  sulfide  precipitation-
sedimentation technology.  These data are summarized in Table  VII-11.   In
making  this  summary   the larger of average or design values were selected
from Table  VI1-4 as the average performance of lime and settle  technology.
In summarizing  lime,  settle and filter data in Tables VII-6 and 7, the data
were  considered  as   5 separate data sets and the largest mean and largest
mean plus two standard deviation for each pollutant are used as the average
and maximum respectively.  Observed copper values  have  been  replaced  by
values  calculated  from  lime  and  settle  data  on the basis of measured
precipitate removal because raw waste copper values may  have  been  unduly
low.
                                   471

-------
                               TABLE VII-11

                    Summary of Treatment Effectiveness
Pollutant
Parameter
114  SB
115  As
117  Be

118  Cd
119  Cr
120  Cu

122  Pb
123  Hg
124  Ni

125  Se
126  Ag
127  Th

128  Zn

     Al
     Co
     F
     Fe
     Ti
Hydroxide
Precipitation
Sedimentation
Avq.

0.05
0.05
0.3

0.03
0.2
0.3

0.02
0.03
0.5

0.1
0.5

0.2
0.07
15
0.5
0.01
Max.

0.5
0.5
1.0

0.10
0.5
1.5

0.13
0.1
2.0

1.0
2.0

0.55
0.5
30
1.5
0.1
         Hydroxide
         Precipitation
         Sedimentation
         Filtration
0.07
0.22

0.02

0.22
0.25
0.5
                                                  Max.
0.30
0.70

0.1

0.70
1.0
1.5
                 Sulfide
                 Precipitation
                 Filtration

                     Avg.
0.01
0.05
0.05

0.01
0.03
0.05
                                         0.05
0.01
     PEAT ADSORPTION

Peat  moss   is  a  complex  natural  organic material containing  lignin and
cellulose as major constituents.  These constituents, particularly   lignin,
bear  polar  functional groups, such as alcohols, aldehydes,  ketones,  acids,
phenolic hydroxides, and ethers, that can be involved in  chemical   bonding.
Because  of  the  polar nature of the material,  its adsorption  of dissolved
solids such  as transition metals and polar organic molecules is quite high.
These properties have  led  to  the  use  of  peat  as  an   agent   for the
purification of industrial wastewater.
                                   472

-------
Peat  adsorption   is   a   "polishing"  process  which  can  achieve very  low
effluent concentrations  for  several pollutants.  If the  concentrations  of
pollutants  are   above 10 mg/1,  then peat adsorption must be preceded by pH
adjustment  for   metals    precipitation   and   subsequent   clarification.
Pretreatment  is also  required for chromium wastes using ferric chloride  and
sodium  sulfide.    The wastewater is then pumped into a large metal chamber
called a kier which contains a layer of peat through which the waste stream
passes.  The  water flows to  a second  kier  for  further  adsorption.    The
wastewater  is  then   ready  for  discharge.  This system may be automated or
manually operated.

Application and Performance

Peat  adsorption can be used  in foundries for removal of residual  dissolved
metals from clarifier effluent.   Peat moss may be used to treat wastewaters
containing  heavy  metals such   as  mercury,  cadmium, zinc, copper, iron,
nickel, chromium, and lead,  as  well  as  organic  matter  such  as  oil,
detergents,   and  dyes.  Peat adsorption is currently used commercially at  a
textile plant, a  newsprint facility, and a metal reclamation operation.

The following table contains performance figures obtained from pilot  plant
studies.   Peat   adsorption  was  preceded by pH adjustment for precipitation
and by clarification.

                               Table VII-12
                        Peat Adsorption Performance

Pollutant                    :iri                          Out
(mg/1)

   Cr+6               35,000.0                          0.04
   Cu                   250.0                          0.24
   CN                    36.0                          0.7
   Pb                    20.0                          0.025
   Hg                     1.0                          0.02
   Ni                     2.5                          0.07
   Ag                     1.0                          0.05
   Sb                     2.5                          0.9
   Zn                     1.5                          0.25

In addition,  pilot plant studies have shown that chelated metal wastes,  as
well  as   the chelating  agents themselves, are removed by contact with peat
moss.

Advantages and Limitations

The major  advantages  of   the  system  include  its  ability  to  yield   low
pollutant  concentrations,  its  broad  scope  in   terms  of the pollutants
                                   473

-------
eliminated, and its capacity to  accept   wide   variations  of  waste  water
composition.

However,  the  cost  of purchasing, storing, and disposing of the peat moss
could limit the use of this system.  The  necessity for regular  replacement
of the peat may lead to high operation and  maintenance costs.  Also, the pH
adjustment  must  be  altered  according  to   the  composition of the waste
stream.

Operational Factors

Reliability; The question  of  long  term  reliability  is  not  yet  fully
answered.   Although  the  manufacturer   reports it to be a highly reliable
system, operating experience is needed to verify the claim.

Maintainability;  The peat moss used in   this   process  soon  exhausts  its
capacity to adsorb pollutants.  At that time,  the kiers must be opened,  the
peat  removed,  and  fresh  peat placed inside.   Although this procedure is
easily  and quickly accomplished, it must  be done at regular  intervals,   or
the system's efficiency drops drastically.

Solid   Waste  Aspects;  After removal from  the kier,  the spent peat must be
eliminated.  If incineration is used, precautions should be taken to insure
that those pollutants removed from the water are not released again in  the
combustion  process.   Presence of sulfides in the spent peat, for example,
will give  rise to sulfur dioxide in the fumes  from burning.   The  presence
of  significant quantities of toxic heavy metals in foundry wastewater will
in general preclude  incineration of peat  used  in treating these wastes.

Demonstration Status

Only three commercial adsorption systems  are currently in use in the United
States  at  a  textile  manufacturer,  a  newsprint  facility,  and  a  metal
reclamation  firm.   No  data  have  been  reported showing the use of peat
adsorption  in battery manufacturing plants.

     SOLIDS REMOVAL

Solids  removal from  wastewater is heeded  both'for sludges formed during the
manufacturing  process  and  for  precipitates  formed  in  previous  waste
treatment.  Dewatering techniques for clarifier underflow (sludge) may also
be regarded as solids removal.   (As a point of clarity the term settling is
used   to   mean  any  process  in which solids are separated from liquid using
the force  of gravity, usually following Stokes law in a  stagnant  or  slow
moving   containment;  sedimentation is used to denote mechanically assisted
settling;  filtration  is the  separation of solids by allowing the liquid  to
pass   through  a  media  which  withholds  solids; and clarification is the
removal of  solids using any  mechanism).
                                    474

-------
Clarification  by means  of  simple settling is the most common technique  for
removal  of  solids.    Filtration  is another commonly used means of solids
removal.  Membrane  filtration,  which can be used in place of  a  clarifier,
is  a  more  recently   developed  technique.   Granular  bed  filtration is
frequently used  to further  reduce  solids  concentrations  in  clarifier
effluent.    Skimming,   ultrafiltration and flotation, which can also remove
certain  solid  materials,   are  discussed  under  Oil  Removal  and  reverse
osmosis  is discussed under Dissolved Inorganics Removal.

Sludge   containing  precipitated  metal  salts  results  from  wastewater
clarification.  This sludge typically contains two to four percent  solids.
It  is   sometimes directed to a gravity thickener, which doubles the solids
content.  The  thickened sludge is then either distributed on outdoor sludge
drying beds  or is mechanically dewatered.  Vacuum filtration is  the  usual
means  of  mechanical dewatering, but pressure filtration or centrifugation
are also used.

There are alternatives  to  handling large quantities  of  hazardous  sludge.
Process  chemical recovery, described later in this section, is the soundest
alternative  from an environmental standpoint and often makes good economic
sense.   This approach can   drastically  reduce  the  need  for  end-of-pipe
treatment  and the concommitant formation of sludge.  Many establishments,
especially   smaller ones,  have  their  sludge  removed  by   a   licensed
contractor.    Some   establishments adjust pH to precipitate metals and then
avoid sludge disposal costs by discharging the wastewater directly  to  the
sanitary sewer  without  settling.   This  practice,  which  transfers the
problem  to  the  POTW,  hardly  ever  constitutes  adequate  pretreatment.
Another  possibility  that  has  received  recent attention is formation of
single-metal sludges by integrated treatment followed by redissolution  and
use of  the  resulting solution in the process, electrolytic recovery of the
metal, or by sale of the contained metal salt as a byproduct.

    SETTLING

Settling (sedimentation) is a process which removes solid particles from  a
liquid   matrix by   gravitational  force.   The  operation  is  effected by
reducing the velocity of the feed stream in a large volume tank  or  lagoon
so  that gravitational  settling can occur.  Figure VII-13 shows two typical
sedimentation  devices.

Sedimentation  is often  preceded by chemical  precipitation  which  converts
dissolved  pollutants   to  solid  form  and  by  coagulation which enhances
settling by  coagulating suspended precipitates into larger, faster settling
particles.   Figure  VII-13  depicts  representative  types  of  sedimentation
units.

If  no   chemical pretreatment is used, the wastewater is fed into a tank or
lagoon where it loses velocity and the  suspended  solids  are  allowed  to
settle   out.   Long retention  times  are generally required.  Accumulated
                                   475

-------
sludge can be collected either  periodically   or  continuously  and  either
manually  or mechanically.  But because  simple sedimentation may require an
excessively large catchment, and  because  high  retention  times  (days  as
compared   with   hours)   are  usually   required  to  yield  high  removal
efficiencies,  addition  of  settling  aids   such  as  alum  or   polymeric
flocculants is often economically attractive.

In  practice,  chemical  precipitation   often  precedes  clarification, and
inorganic coagulants or polyelectrolytic flocculants are usually  added  as
well.   Common coagulants  include sodium sulfate,  sodium aluminate,  ferrous
or ferric sulfate, and ferric chloride.   Organic polyelectrolytes  vary  in
structure,  but  all  usually  form   larger   floccules than coagulants used
alone.

Following this pretreatment, the  wastewater  can be fed into a holding  tank
or   lagoon  for  settling, but is more often  piped into a clarifier for the
same  purpose.   A  clarifier  reduces   the   space  requirements,   reduces
retention  time, and increases the solids removal efficiency.  Conventional
clarifiers generally consist of a circular   or  rectangular  tank  with  a
mechanical  sludge collecting device or  with  a sloping funnel-shaped bottom
designed for sludge collection.   In  advanced   clarifiers  inclined  plates,
slanted  tubes,  or a lamellar network may be included within the clarifier
tank  in order  to increase  the effective  settling area, increasing clarifier
capacity.  A fraction of the sludge  stream is  often  recirculated  to  the
clarifier inlet, promoting formation of  a denser sludge.

Application and Performance

Sedimentation  and clarification  are used in  the foundry category to remove
metals.  Sedimentation  can be used to remove  most  suspended  solids  in  a
particular  waste  stream;  thus   it  is used extensively by many different
industrial waste treatment facilities.   Because most metal  ion  pollutants
are   readily converted  to  solid metal  hydroxide precipitates, sedimentation
is of particular use in  those industries associated with metal  production,
metal  finishing,   metal working,  and  any  other  industry  with  high
concentrations of metal  ions in their wastes.  In addition to toxic metals,
suitably precipitated materials effectively   removed  by  settling  include
aluminum,    iron,   manganese,  cobalt,   antimony,  beryllium,  molybdenum,
fluoride, and  phosphate.

A properly operating sedimentation system is capable of  efficient  removal
of   suspended  solids,   precipitated metal hydroxides, and metal pollutants
and  other impurities from  wastewater.    The  performance  of  the  process
depends on a variety of  factors,  including the density and particle size of
the   solids, the effective charge on the suspended particles, and the types
of chemicals used  in pretreatment.  It has been  found  that  the  site  of
flocculant   or    coagulant   addition   may  significantly   influence  the
effectiveness  of clarification.   If  the  flocculant is subjected  to too much
mixing  before  entering  the clarifier,  the complexes may be sheared and  the
                                    476

-------
settling  effectiveness  diminished.   At the same time, the flocculant must
have sufficient mixing  and reaction time in order for effective set-up  and
settling  to occur.   From conversations with plant personnel, it seems that
the line or trough  leading into the clarifier is often the  most  efficient
site   for  flocculant  addition.    The  performance of simple settling is a
function of the retention time, particle size and density, and the  surface
area of the basin.
The  data  displayed  in  Table  VI1-13
efficiencies  in  settling systems.
                             indicate   suspended  solids removal
                        TABLE VI1-13
        PERFORMANCE OF SAMPLED SEDIMENTATION SYSTEMS
PLANT ID
01057
09025

11058
12075
19019
33617

40063
44062
46050
SETTLING
DEVICE
SUSPENDED SOLIDS CONCENTRATION  (mg/1)
Day 1	     Day 2          Day 3
                         In
                        Out   In
                     Out  In
                         Out
Lagoon         54
Clarifier    1100
Settling Ponds
Clarifier     451
Settling Pond 284
Settling Tank 170
Clarifier &
Lagoon
Clarifier    4390
Clarifier     182
Settling Tank 295
        6
        9

       17
        6
        1
        9
       13
       10
  56
1900
 242
  50
1662

3595
 118
  42
 6
12
10
 1
16

12
14
10
  50
1620
 502

1298

2805
174
153
 5
 5
14

 4

13
23
 8
The mean effluent TSS concentreation obtained by the plants shown in  Table
VII-11  is  10.1   gm/1.    Influent  concentrations  averaged 838 mg/1.  The
maximum effluent  TSS value reported in the sampling data used in Table VII-
11 is 23 mg/1.  These plants all use alkaline pH adjustment to  precipitate
metal hydroxides, and most add a coagulant or flocculant prior to settling.
Based  on these data, a 30 day average of 15 mg/1 TSS and a 24 hour maximum
of 30 mg/1  TSS  are  considered  to  be  reliably  attainable  values  for
sedimentation technology.

Advantages and Limitations

The  major  advantage  of  simple settling is the simplicity of the process
itself - the gravitational settling of solid particulate waste in a holding
tank or lagoon.  The major problem with simple settling involves  the  long
retention  times   necessary to achieve complete settling, especially  if the
specific gravity  of the suspended matter is close to that of  water.   Some
materials cannot  be practically removed by simple sedimentation alone.
                                   477

-------
Sedimentation  is effective in removing slow  settling  suspended matter in a
shorter time and in less  space  than  a   simple   settling  system.   Also,
effluent  quality is often better from a  clarifier.  The cost of installing
and maintaining a clarifier is, however,   substantially  greater  than  the
costs associated with simple settling.

Inclined  plate,  slant tube, and lamella settlers have even higher removal
efficiencies than conventional clarifiers,  and  greater capacities per  unit
area  are  possible.   Installed  costs   for  these advanced clarification
systems are claimed to be one half the  cost  of   conventional  systems  of
similar capacity.

Operational Factors

Reliability;   Settling  can  be  a highly reliable technology for removing
suspended solids.  Sufficient retention time  and  regular sludge removal are
important factors  affecting  the  reliability  of  all  settling  systems.
Proper  control  of  pH adjustment, chemical  precipitation and coagulant or
flocculant addition are additional factors affecting settling  efficiencies
in systems  (frequently clarifiers) where  these  methods are used.

Those  advanced  clarifiers  using  slanted  tubes,  inclined  plates,  or a
lamellar network may  require  pre-screening  of   the   waste  in  order  to
eliminate  any  fibrous  materials which  could  potentially clog the system.
Some installations are especially vulnerable  to shock  loadings, as by storm
water runoff, but proper system design will prevent this.

Maintainability:  When clarifiers are used, the associated system  utilized
for  chemical  pretreatment  and  sludge   dragout  must  be maintained on a
regular basis.  Routine maintenance of mechanical parts is also  necessary.
If  lagoons  are  used,  little maintenance is  required other than periodic
sludge removal.

Demonstration Status

Sedimentation represents the  typical  method  of  solids  removal  and  is
employed   extensively   in   industrial   waste  treatment.   The  advanced
clarifiers  are  just  beginning  to  appear  in   significant  numbers   in
commercial  applications.   Sedimentation  or clarification is used in many
foundries.

     FILTRATION

Filtration  is the process of passing wastewater through some type of filter
medium for  the purpose of removing solids from  the  waste  stream.   Cloth,
paper,  plastic,  glass fiber and other materials may  be used as the filter
medium upon which solids will collect as  water  passes  through to the  other
side.   Membrane  filtration,  granular   bed  filtration,   ultrafiltration,
                                    478

-------
pressure  filtration,   and   vacuum  filtration  are   specific   filtration
techniques.

Application and Performance

Filtration  is  a  highly  versatile  technology which is applied to a wide
range of purposes from  dewatering highly  concentrated  sludge  streams   to
removing   residual   suspended   solids   from  clarifier  effluent.   The
capabilities and performance of the technology are  governed  primarily   b/
the design  parameters of the specific filtration unit and particularly  by
the filter medium chosen.

Advantages and Limitations

Advantages of filtration  include  simplicity  of  operation,  low  capital
costs,  and  wide  applicability to different types of waste streams.  Many
filters can be backwashed  and reused.   This process may require  additional
equipment such as pumps, backwash storage tanks, etc.  A major disadvantage
is  that  fouling of  the filters can allow large amounts of contaminants  to
pass through the filter with the liquid portion.

Operational Factors

Reliability;  Reliability  should be high assuming  proper  maintenance  and
correct  selection  of   the   filter medium to match the nature of the waste
stream.

Maintainabi1ity;  Filters  must be cleaned or changed regularly, or whenever
solids buildup becomes  significant.

Solid Waste Aspects;  Solids which are periodically cleaned from the filter
media must be properly  disposed.

Demonstration Status

Filtration is in use  at a  number of foundries as  well  as  in  many  other
industries.   It   is  a  fully  proven  technology for removing solids from
industrial waste streams.    The  extent  of  present  practice  and  proven
capability   for   wastewater  treatment  varies  for  specific  filtration
techniques.

    MEMBRANE FILTRATION

Membrane filtration  is  a treatment  technology  for  removing  precipitated
metals  from  a  wastewater  stream.  It must therefore be preceded by those
treatment  techniques  which will properly prepare the wastewater for  solids
removal.    Typically,   a   membrane  filtration  unit  is  preceded  by   pH
adjustment or sulfide addition for  precipitation  of  the  metals.   These
steps  are followed by  the addition of a proprietary chemical reagent which
                                   479

-------
causes the precipitate to be non-gelatinous, easily  dewatered,   and  highly
stable.   The  resulting  mixture  of  pretreated  wastewater and reagent is
continuously  recirculated  through  a  filter  module   and  back  into   a
recirculation  tank.   The filter module contains  tubular  membranes.   While
the reagent-metal hydroxide precipitate mixture flows through the inside of
the tubes, the water and any dissolved salts permeate the   membrane.    When
the  recirculating  slurry  reaches  a  concentration   of   10 to 15 percent
solids, it is pumped out of the system as sludge.

Application and Performance

Membrane filtration appears to be applicable to any  wastewater   or  process
water  containing  metal  ions which can be precipitated using  hydroxide or
carbonate precipitation.  It could function as the primary treatment  system
but might find application as a polishing  treatment  (after  precipitation
and  settling)  to  ensure  continued  compliance  with metals  limitations.
Membrane filtration systems are  being  used   in   a  number  of  industrial
applications,  particularly  in  the  metal finishing area.   They have also
been used for heavy metals removal in the metal  fabrication  industry  and
the paper industry.

The  permeate  is  claimed  by  one  manufacturer  to contain less than the
effluent concentrations shown in the following  table,   regardless  of  the
influent  concentrations.   These claims have  been largely substantiated by
the analysis of water samples at various plants in various industries.

In   the   performance   predictions   for   this    technology,   pollutant
concentrations  are  reduced  to the levels shown  below unless  lower  levels
are present  in the  influent stream.

                                  Table VII-14

                              MEMBRANE FILTER  EFFLUENT
Specific      Manufacturing      Plant 19066       Plant 31022
Metal         Guarantee          In     Out         Ln    Out     Predicted
                                                                  Performance

Al                  0.5          —    —         	    	
Cr,  (+6)            0.02         0.46   0.01        5.25   <0.005
Cr   (T)             0.03         4.13   0.018     98.4    0.057       0.05
Cu                  0.1         18.8    0.043       8.00   0.222       0.20
Fe                  0.1       288      0.3       21.1    0.263       0.30
Pb                  0.05         0.652  0.01        0.288 0.01       0.05
CN                  0.02        <0.005 <0.005     <0.005 <0.005       0.02
Ni                  0.1          9.56   0.017    194      0.352       0.40
Zn                  0.1          2.09   0.046       5.00   0.051       0.10
TSS                 	       632      0.1       13.0    8.0       10.0
                                    480

-------
Advantages and Limitations

A major advantage of  the membrane filtration system is  that  installations
can utilize  most of  the conventional  end-of-pipe systems that may already
be in place.  Removal  efficiencies are  claimed to be excellent,  even  with
sudden  variation  of  pollutant  input rates.  However, the effectiveness of
the membrane filtration system can be limited by clogging of  the  filters.
Because  a  change   in the   pH  of the  waste stream greatly intensifies the
clogging problem, the  pH  must   be  carefully  monitored  and  controlled.
Clogging  can  force   the  shutdown  of  the  system and may interfere with
production.  In  addition, the utilization of this system may be limited  by
its relatively high  capital  cost.

Operational Factors

Reliability;   Membrane  filtration  has  been  shown to be a very reliable
system, provided that  the pH  is  strictly  controlled.   Improper  pH  can
result  in  the  clogging of  the  membrane.  Also, surges in the flow rate of
the waste stream must  be controlled in  order to prevent solids from passing
through the filter and into  the  effluent.

Maintainability; The membrane filters  must  be  regularly  monitored,  and
cleaned  or  replaced  as  necessary.   Depending on the composition of the
waste stream and its flow rate,  frequent cleaning of  the  filters  may  be
required.   Flushing  with   hydrochloric  acid  for 6-24 hours will usually
suffice.  In addition, the routine maintenance of pumps, valves, and  other
plumbing is required.

Solid  Waste  Aspects;  When  the recirculating reagent-precipitate slurry
reaches 10  to 15 percent solids, it is  pumped out of the  system.   It  can
then be  disposed   of directly  or  it  can-undergo a dewatering process.
Because this sludge  contains toxic metals, it must be properly disposed.

Demonstration Status

There are more  than  25 membrane filtration  systems  presently  in  use  on
metal finishing  and  similar  wastewaters.  Bench scale and pilot studies are
being  run   in   an   attempt  to expand the list of pollutants for which this
system  is known  to be effective.

    GRANULAR BED FILTRATION

Filtration  occurs  in nature  as the surface ground waters  are  cleansed  by
sand.   Silica   sand,   anthracite  coal, and garnet are common filter media
used in water treatment plants.   These are  usually  supported  by  gravel.
The media  may  be  used  singly or in combination.  The multi-media filters
may be arranged  to   maintain  relatively  distinct   layers  by  virtue  of
balancing   the   forces of   gravity,  flow,  and bouyancy on the individual
                                   481

-------
particles.  This is accomplished  by  selecting appropriate filter flow rates
(gpm/sq-ft), media grain size, and density.

Granular bed filters may be  classified  in terms of filtration rate,  filter
media,  flow  pattern,  or   method   of   pressurization.    Traditional  rate
classifications are slow sand, rapid sand,  and high rate mixed  media.   In
the  slow  sand  filter,  flux  or hydraulic loading is  relatively low, and
removal of collected solids  to clean the  filter  is  therefore  relatively
infrequent.   The  filter   is  often cleaned by scraping off the inlet face
(top) of the sand bed.  In  the higher rate filters,  cleaning  is  frequent
and   is  accomplished   by a  periodic backwash, opposite  to the direction of
normal flow.

A filter may use a single medium  such as sand or  diatomaceous  earth,  but
dual  and  mixed   (multiple)  media   filters  allow  higher  flow rates and
efficiencies.  The dual media filter usually consists of a fine bed of sand
under a coarser bed of  anthracite coal.   The coarse coal  removes  most  of
the  influent solids, while  the fine  sand performs a polishing function.  At
the   end of the backwash, the fine sand settles to the bottom because it is
denser than the coal, and the filter is ready for  normal  operation.   The
mixed  media  filter operates on  the same principle, with the finer,  denser
media at the bottom and the  coarser,  less dense  media  at  the  top.   The
usual  arrangement is garnet at the  bottom (outlet end)  of the bed, sand in
the  middle, and anthracite  coal at the  top.   Some mixing  of  these  layers
occurs and  is,  in  fact, desirable.

The  flow pattern  is usually  top-to-bottom,  but other patterns are sometimes
used.   Upflow  filters are sometimes  used, and in a horizontal filter the
flow is horizontal.   In a biflow  filter, the influent enters both  the  top
and   the   bottom  and exits  laterally.  The advantage of  an upflow filter is
that with  an upflow backwash the  particles of a single  filter  medium  are
distributed  and   maintained  in  the desired coarse-to-fine (bottom-to-top)
arrangement.  The  disadvantage is that  the bed tends to   become  fluidized,
which ruins  filtration  efficiency-   The  biflow design is an attempt to
overcome  this problem.

The  classic  granular   bed   filter   operates  by  gravity  flow.   However,
pressure   filters  are  fairly  widely   used.   They  permit  higher solids
loadings  before cleaning and are  advantageous when the filter effluent must
be pressurized  for further  downstream  treatment.   In  addition,  pressure
filter systems  are often less  costly for low to moderate flow rates.

Figure  VII-14  depicts a  high rate, dual media, gravity downflow granular
bed  filter, with  self-stored backwash.    Both  filtrate   and  backwash  are
piped around   the bed  in an arrangement that permits gravity upflow of the
backwash,  with  the stored filtrate serving as backwash.    Addition  of  the
indicated   coagulant  and   polyelectrolyte usually results in a substantial
improvement  in  filter performance.
                                    482

-------
Auxiliary filter cleaning  is  sometimes employed in the upper few inches  of
filter  beds.   This   is   conventionally referred to as surface wash and is
accomplished by water  jets just  below  the  surface  of  the  expanded  bed
during  the  backwash  cycle.   These jets enhance the scouring action in the
bed by increasing the  agitation.

An important feature for   successful   filtration  and  backwashing  is  the
underdrain.   This  is the  support  structure for the bed.  The underdrain
provides an area for collection  of  the filtered water without clogging from
either  the  filtered   solids or  the  media  grains.   In  addition,  the
underdrain  prevents   loss of  the  media  with  the water, and during the
backwash cycle it provides even  flow  distribution over the bed.  Failure to
dissipate the velocity head during  the filter or backwash cycle will result
in bed upset and the need  for major repairs.

Several standard approaches  are employed  for  filter  underdrains.   The
simplest  one  consists of a  parallel porous pipe imbedded under a layer of
coarse gravel and manifolded  to  a header pipe for effluent removal.   Other
approaches  to  the  underdrain  system are known as the Leopold and Wheeler
filter bottoms.  Both  of these  incorporate  false  concrete  bottoms  with
specific  porosity  configurations   to  provide  drainage and velocity head
dissipation.

Filter system operation may be manual or automatic.   The  filter  backwash
cycle may be on a timed basis,  a pressure drop basis with a terminal value
which triggers  backwash,   or a solids  carryover  basis  from  turbidity
monitoring   of  the   outlet   stream.   All  of  these  schemes  have  been
successfully used.

In wastewater treatment plants granular bed filters are often employed  for
polishing   following   clarification,   sedimentation,  or  other  similar
operations.  Granular  bed  filtration  thus  has  potential  application  to
nearly  all  industrial plants.   Chemical  additives  which  enhance  the
upstream treatment equipment  may or may not be compatible with  or  enhance
the   filtration  process.   Normal operating flow rates for various types of
filters are as follows:

     Slow Sand                       2.04 - 5.30 1/sq m-hr
     Rapid Sand                     40.74 - 51.48 1/sq m-hr
     High Rate Mixed Media         81.48 - 122.22 1/sq m-hr

Suspended solids are commonly removed from wastewater streams by  filtering
through  a  deep  0.3-0.9  m (1-3 feet) granular filter bed.  The porous bed
formed by the granular media  can be  designed  to  remove  practically  all
suspended particles.   Even colloidal  suspensions (roughly 1 to 100 microns)
are   adsorbed  on  the surface   of  the media grains as they pass in close
proximity in the narrow bed passages.
                                   483

-------
Properly operating filters following  some  pretreatment to reduce  suspended
solids  below  200  mg/1  should  produce  water  with less than 10 mg/1 TSS.
plant 33056 following hydroxide  precipitation   and  settling  reduced  the
effuent TSS concentrations from 20 mg/1  to 8  mg/1.

Advantages and Limitations

The principal advantages of granular  bed filtration are its low initial and
operating  costs,  reduced  land requirements over  other methods to achieve
the same level of solids removal, and elimination   of  chemical  additions
which  add  to   the  discharge  stream.    However,   the  filter may require
pretreatment  if  the  solids   level   is   high   (over  100  mg/1).   Operator
training  must   be  somewhat  extensive  due  to  the controls and periodic
backwashing involved,  and  backwash  must be   stored  and  dewatered  for
economical disposal.

Operational Factors

Reliability;     The   recent    improvements   in   filter  technology  have
significantly improved filtration reliability-   Control  systems,  improved
designs,  and  good  operating  procedures have  made  filtration a highly
reliable method  of water treatment.

Maintainability:  Deep bed filters may be  operated  with  either  manual  or
automatic  backwash.   In  either case,  they  must be periodically inspected
for media attrition, partial  plugging, and leakage.   Where  backwashing  is
not  used,  collected solids  must be  removed  by  shoveling, and filter media
must be at least partially replaced.

Solid Waste Aspects;  Filter  backwash is   generally  recycled  within  the
wastewater  treatment  system,  so that  the solids  ultimately appear in the
clarifier sludge stream  for  subsequent  dewatering.   Alternatively,  the
backwash  stream may be dewatered directly or,  if there is no backwash, the
collected solids may be disposed of  in a suitable landfill.  In  either  of
these  situations  there   is  a  solids  disposal problem similar to that of
clarifiers.

Demonstration Status

Deep bed filters are in common  use in municipal   treatment  plants.   Their
use  in  polishing   industrial  clarifier   effluent  is increasing, and the
technology is proven and conventional.   Deep  bed  multi-media  filters  are
used in several  foundries.

     PRESSURE FILTRATION

Pressure  filtration   is   achieved   by   pumping  the liquid through a filter
material which  is  impenetrable  to the solid phase.   The  positive  pressure
exerted  by   the feed pumps or  other  mechanical  means provides the pressure
                                    484

-------
differential   which   is  the  principal  driving  force.    Figure   VII-15
represents  the operation of one type of pressure filter.

A  typical  pressure  filtration unit consists of a number of plates or trays
which  are held rigidly in a frame  to  ensure  alignment  and  are  pressed
together  between a fixed end and a traveling end.  On the surface of each
plate  is mounted a filter made of cloth or a  synthetic  fiber.   The  feed
stream  is  pumped into the unit and passes through holes in the trays along
the length  of  the press until the cavities or chambers  between  the  trays
are completely filled.  The solids are then entrapped, and a cake begins to
form  on  the  surface of the filter material.  The water passes through the
fibers,  and the solids are retained.

At the bottom  of the trays are drainage ports.  The filtrate   is  collected
and discharged to a  common drain.  As the filter medium becomes coated with
sludge,  the  flow of filtrate through the filter drops sharply, indicating
that the capacity of the filter has been exhausted.  The unit  must then  be
cleaned of the  sludge.   After the cleaning or replacement  of the filter
media, the  unit is again ready for operation.

Application and Performance

Because dewatering  is  such  a  common  operation  in  treatment  systems,
pressure filtration  is  a technique which can be found in many industries
concerned with removing solids from their waste stream.

In a typical pressure filter, chemically preconditioned sludge detained  in
the  unit   for  one   to  three  hours  under pressures varying from 5 to 13
atmospheres exhibited final solids content between 25 and 50 percent.

Advantages  and Limitations

The pressures  which  may be applied to a sludge  for  removal   of  water  by
filter presses that  are currently available range from 5 to 13 atmospheres.
As  a  result,  pressure  filtration  may  reduce  the  amount of chemical
pretreatment required for sludge dewatering sludge, retained in the form of
the filter  cake, has a higher percentage of solids  than  a  centrifuge  or
vacuum  filter  yield.   Thus,  it  can be easily accommodated by materials
handling systems.

As a primary solids  removal technique, pressure  filtration  requires   less
space  than  clarification  and  is well suited to streams with high solids
loadings.   The sludge produced may be disposed without further dewatering,
but  the  amount  of  sludge  is  increased  by  the  use of filter precoat
materials  (usually diatomaceous earth).  Also, cloth pressure  filters often
do not achieve as high a degree of effluent clarification as clarifiers  or
granular media filters.
                                   485

-------
Two disadvantages associated with pressure filtration  in  the past have been
the  short life of the filter cloths and  lack  of  automation.   New synthetic
fibers have largely offset the first of these  problems.   Also,   units  with
automatic feeding and pressing cycles are now  available.

For  larger operations, the relatively high  space requirements,  as compared
to those of a centrifuge, could be prohibitive in some situations.

Operational Factors

Reliability;  Assuming proper pretreatment,  design,  and  control,   pressure
filtration is a highly dependable system.

Maintainability;   Maintenance consists of periodic  cleaning or  replacement
of the filter media, drainage grids,  drainage piping,   filter   pans,   and
other  parts  of  the  system.   If  the  removal of the  sludge  cake is not
automated, additional time is required for this operation.

Solid Waste Aspects:  Because it is generally  drier  than  other  types  of
sludges,  the  filter  sludge  cake  can  be  handled   with  relative ease.
Disposal of the accumulated sludge  may   be  accomplished  by any  of   the
accepted procedures such  as landfill depending on its  chemical composition.
The  levels  of  toxic  metals  present   in  sludge  from  treating foundry
wastewater necessitate proper disposal.

Demonstration Status

Pressure filtration  is   a  commonly  used   technology that  is  currently
utilized in a great many  commercial applications.

     VACUUM FILTRATION

In  wastewater  treatment plants, sludge  dewatering  by vacuum filtration is
an operation that is generally accomplished  on cylindrical  drum  filters.
These  drums  have  a  filter  medium which  may be cloth  made of natural or
synthetic fibers, coil  springs,  or  a   wire-mesh  fabric.   The  drum  is
suspended above and dips  into a vat of sludge.  As the drum rotates slowly,
part  of  its  circumference  is  subject  to  an  internal vacuum that draws
sludge to the filter medium.  Water is drawn through the  porous  filter  cake
to a discharge port, and  the dewatered sludge,  loosened by compressed  air,
is  scraped  from  the  filter  mesh.   Because the  dewatering of sludge on
vacuum filters is relativley expensive per kilogram  of water  removed,   the
liquid sludge is frequently thickened prior  to processing.   A vacuum filter
is shown in Figure VII-16.

Application and Performance

Vacuum  filters  are frequently used both  in municipal treatment plants and
in a wide variety of industries.  They are most   commonly  used   in  larger
                                    486

-------
facilities,  which   may   have  a  thickener to double the solids content of
clarifier sludge  before  vacuum filtering.

The  function of vacuum filtration is to reduce the water content of sludge,
so that the solids  content  increases from  about  5  percent  to  about  30
percent.

Advantages and Limitations

Although  the  initial   cost  and area requirement of the vacuum filtration
system are higher than those of a centrifuge, the operating cost is   lower,
and   no special provisions  for sound and vibration protection need be made.
The  dewatered sludge from this process is in the form of a moist  cake  and
can  be conveniently handled.

Operational Factors

Reliability;   Vacuum filter  systems  have  been  proven reliable at many
industrial and municipal treatment facilities.   At  present,  the  largest
municipal  installation is at the West Southwest waste water treatment plant
of  Chicago,   Illinois,   where  96  large  filters  were installed in 1925,
functioned approximately 25 years,  and  then  were  replaced  with   larger
units.  Original  vacuum  filters at Minneapolis-St. Paul, Minnesota now have
over  28  years   of  continuous  service,   and  Chicago has some units with
similar or greater  service life.

Maintainabi1ity;  Maintenance consists of the cleaning  or  replacement  of
the   filter  media, drainage grids, drainage piping, filter pans, and other
parts of  the equipment.   Experience in a number  of  vacuum  filter  plants
indicates  that   maintenance  consumes approximately 5 to 15 percent of the
total time.  If  carbonate buildup or other problems are  unusually  severe,
maintenance  time  may   be  as  high as 20 percent.  For this reason, it is
desirable  in the  selection of vacuum filters to provide one or  more  spare
units.

If intermittent  operation is to be employed, the filter equipment should be
drained   and  washed  each time it is taken out of service and an allowance
for  wash   time   should   be  made  in  the  selection  of  sludge  filtering
schedules.

Solid Waste Aspects; Vacuum filters generate a solid cake which is usually
trucked   directly  to landfill.  All of the metals extracted from the plant
wastewater are concentrated in  the  filter  cake  as  hydroxides,  oxides,
sulfides, or other  salts.

Demonstration Status

Vacuum  filtration   has   been  widely  used  for many years.  It is a fully
proven, conventional technology for sludge dewatering.
                                   487

-------
     CENTRIFUGATION

Centrifugation is the application of centrifugal  force to  separate  solids
and  liquids  in  a  liquid-solid mixture  or  to effect concentration of the
solids.  The application of centrifugal  force is  effective because  of  the
density  differential  normally  found between the  insoluble solids and the
liquid in which they  are  contained.    As a waste   treatment  procedure,
centrifugation is applied to dewatering  of sludges.   One type of centrifuge
is shown in Figure VII-17.

There  are  three  common  types  of  centrifuges:    the  disc, basket, and
conveyor type.  All three operate by removing solids  under the influence of
centrifugal force.  The fundamental difference between the three  types  is
the method by which solids are collected in and discharged from the bowl.

In  the  disc  centrifuge,  the  sludge  feed is  distributed between narrow
channels  that  are  present  as  spaces  between  stacked  conical  discs.
Suspended particles are collected and discharged  continuously through small
orifices in the bowl wall.  The clarified  effluent  is discharged through an
overflow weir.

A  second  type  of centrifuge which is  useful in dewatering sludges is the
basket centrifuge.  In this type of centrifuge, sludge feed  is  introduced
at  the  bottom  of  the  basket, and solids  collect  at the bowl wall while
clarified effluent overflows the lip ring  at  the  top.    Since  the  basket
centrifuge  does  not  have provision for  continuous  discharge of collected
cake, operation requires  interruption of the  feed for cake discharge for a
minute or two in a 10 to  30 minute overall cycle.

The  third  type  of  centrifuge  commonly used in  sludge dewatering is the
conveyor type.  Sludge is  fed  through  a stationary  feed  pipe  into a
rotating  bowl in which the solids are settled out  against the bowl wall by
centrifugal force.  From  the bowl wall,  they  are  moved by a  screw  to  the
end  of  the  machine,  at  which  point  whey are discharged.  The liquid
effluent is discharged through ports after passing  the length of  the  bowl
under centrifugal force.

Application And Performance

Virtually  all of those industrial waste treatment  systems producing sludge
can utilize centrifugation to  dewater   it.   Centrifugation  is  currently
being used by a wide range of industrial concerns.

The  performance of sludge dewatering by centrifugation depends on the feed
rate, the rotational velocity of the drum, and the  sludge  composition  and
concentration.  Assuming  proper design and operation, the solids content of
the sludge can be increased to 20-35 percent.
                                    488

-------
Advantages And Limitations

Sludge  dewatering   centrifuges  have minimal space requirements and show a
high  degree of effluent  clarification.   The operation is simple, clean, and
relatively  inexpensive.    The  area  required  for  a  centrifuge   system
installation   is   less   than  that  required  for a filter system or sludge
drying  bed of  equal  capacity,  and the initial cost is lower.

Centrifuges have  a  high  power  cost that partially offsets the  low  initial
cost.   Special   consideration  must  also  be  given  to  providing sturdy
foundations and soundproofing  because  of  the  vibration  and  noise  that
result  from   centrifuge operation.   Adequate electrical power must also be
provided  since large motors are required.  The major difficulty encountered
in the  operation  of  centrifuges has been the disposal  of  the  concentrate
which is  relatively  high in suspended,  non-settling solids.

Operational Factors

Reliability;   Its   reliability is high, assuming proper control of factors
such  as sludge feed, consistency, and temperature.   Pretreatment  such  as
grit   removal  and   coagulant   addition  may  be  necessary.   Pretreatment
requirements will vary  depending on the composition of the  sludge  and  on
the type  of centrifuge  employed.

Maintainability;    Maintenance  consists of periodic lubrication, cleaning,
and inspection.   The frequency and degree  of  inspection  required  varies
depending on  the type  of sludge solids being dewatered and the maintenance
service conditions.   If  the sludge is abrasive, it is recommended that  the
first inspection  of  the rotating assembly be made after approximately 1,000
hours  of operation.  If the  sludge is not abrasive or corrosive, then the
initial inspection might be  delayed.   Centrifuges  not  equipped  with  a
continuous  sludge  discharge   system require periodic shutdowns for manual
sludge cake removal.

Solid Waste Aspects;  Sludge dewatered in the centrifugation process may be
disposed  of by landfill.  The  clarified effluent  (centrate),  if  high  in
dissolved or  suspended  solids,  may  require  further treatment prior to
discharge.

Demonstration  Status

Centrifugation is currently used in a great many commercial applications to
dewater sludge.   Work is underway to improve the efficiency,   increase  the
capacity, and  lower the costs  associated with centrifugation.

     GRAVITY SLUDGE THICKENING

In  the  gravity   thickening  process,   dilute sludge is fed from a primary
settling  tank  or  clarifier to  a thickening tank.   Rakes  stir  the  sludge
                                   489

-------
gently  to  densify  it  and  to push  it to a  central  collection well.   The
supernatant is returned to the primary settling  tank.   The thickened sludge
that collects on the bottom of the tank is pumped  to   dewatering  equipment
or  hauled  away.   Figure  VI1-18  shows  the  construction  of  a gravity
thickener.

Application and Performance

Thickeners are generally used in facilities  where the  sludge  is  to  be
further dewatered by a compact mechanical device such  as  a vacuum filter or
centrifuge.   Doubling  the  solids  content in  the thickener  substantially
reduces capital and operating cost of  the subsequent dewatering device   and
also  reduces  cost  for hauling.  The process is  potentially  applicable to
almost any industrial plant.

Organic sludges from sedimentation units  of   one  to   two  percent  solids
concentration  can  usually  be  gravity  thickened  to six to ten percent;
chemical  sludges can be thickened to four to six percent.

Advantages and Limitations

The principal advantage of a gravity sludge thickening process is  that  it
facilitates   further   sludge   dewatering.   Other   advantages  are  high
reliability and minimum maintenance requirements.

Limitations of the sludge thickening process are  its   sensitivity  to   the
flow  rate  through the thickener and  the sludge removal  rate.   These rates
must be low enough not to disturb the  thickened  sludge.

Operational Factors

Reliability;  Reliability is high assuming proper  design  and operation.   A
gravity   thickener  is  designed  on   the basis  of square feet per pound of
solids per day,  in which the required  surface  area is  related  to the solids
entering  and  leaving  the  unit.   Thickener   area requirements  are  also
expressed in  terms  of mass loading, grams of  solids per square meter per
day  (Ibs/sq ft/day).

Maintainability;   Twice  a  year,  a  thickener  must be  shut  down   for
lubrication   of  the  drive mechanisms.  Occasionally,  water must be pumped
back through  the system in order to clear sludge pipes.

Solid Waste Aspects;  Thickened sludge from a  gravity thickening  process
will usually  require further dewatering prior  to disposal, incineration,  or
drying.   The  clear  effluent  may  be  recirculated  in  part,  or it may be
subjected to  further treatment prior to discharge.
                                    490

-------
Demonstration Status

Gravity sludge thickeners  are  used  throughout  industry  to  reduce  water
content  to  a  level where  the sludge may be efficiently handled.  Further
dewatering is usually practiced to minimize costs of hauling the sludge   to
approved landfill areas.

    SLUDGE BED DRYING

As a waste treatment procedure,  sludge bed drying is employed to reduce the
water  content of a variety  of sludges to the point where they are amenable
to mechanical collection and  removal  to  landfill.   These  beds  usually
consist  of  15  to  45 cm (6  to 18 in.)  of sand over a 30 cm (12 in.) deep
gravel drain system made up  of 3 to 6 mm  (1/8 to  1/4  in.)  graded  gravel
overlying  drain  tiles.   Figure VII-19  shows the construction of a drying
bed.

Drying beds are usually divided  into  sectional  areas  approximately  7.5
meters (25 ft) wide x 30 to  60 meters (100 to 200 ft) long.  The partitions
may be earth embankments, but more often are made of planks and supporting
grooved posts.

To apply liquid sludge to  the  sand bed, a  closed  conduit  or  a  pressure
pipeline  with  valved  outlets at each sand bed section is often employed.
Another method  of  application  is  by  means  of  an  open  channel  with
appropriately  placed  side  openings  which are controlled by slide gates.
With either type of delivery system,  a  concrete  splash  slab  should   be
provided  to  receive  the  falling  sludge and prevent erosion of the sand
surface.

Where  it is necessary to dewater sludge continuously  throughout  the  year
regardless  of  the  weather,   sludge beds may be covered with a fiberglass
reinforced plastic or other  roof.  Covered drying  beds  permit  a  greater
volume of sludge drying per  year in most  climates because of the protection
afforded  from  rain  or   snow  and  because  of  more efficient control  of
temperature.  Depending on the climate, a combination of open and  enclosed
beds will provide maximum  utilization of  the sludge bed drying facilities.

Application and Performance

Sludge  drying  beds  are   a means of dewatering sludge from clarifiers and
thickeners.   They  are  widely  used  both  in  municipal  and  industrial
treatment facilities.

Dewatering  of  sludge on  sand beds occurs by two mechanisms: filtration  of
water  through the bed and  evaporation of  water as a result of radiation and
convection.  Filtration  is generally complete in one to two  days  and  may
result  in  solids concentrations as high as 15 to 20 percent.  The rate  of
filtration depends on the  drainability of the sludge.
                                   491

-------
The rate of air drying  of  sludge   is  related   to   temperature,   relative
humidity, and air velocity.  Evaporation will proceed at a constant rate to
a  critical  moisture  content,  then  at  a falling  rate to an equilibrium
moisture content.  The average evaporation rate  for a sludge  is  about  75
percent of that from a free water surface.

Advantages and Limitations

The  main  advantage  of  sand  drying  beds  over  other  types  of sludge
dewatering is the relatively   low   cost  of  construction,   operation,   and
maintenance.

Its disadvantages are the large area of land required and long drying times
that depend, to a great extent, on  climate and weather.

Operational Factors

Reliability:   High  assuming  favorable  climactic   conditions, proper bed
design and care to avoid  excessive or  unequal sludge  application.    If
climatic  conditions in a given area are not favorable for adequate drying,
a  cover may be necessary.

Maintainability;  Maintenance  consists basically of periodic removal of the
dried sludge.  Sand removed from the drying bed  with   the  sludge  must  be
replaced  and the sand layer resurfaced.

The  resurfacing  of  sludge   beds   is the major expense item in sludge bed
maintenance, but  there  are   other areas  which may  require  attention.
Underdrains  occasionally become clogged and have to  be cleaned.  Valves or
sludge gates that control the  flow  of sludge  to the  beds  must  be  kept
watertight.    Provision  for drainage of lines  in winter should be provided
to prevent damage from freezing.  The partitions between  beds  should  be
tight  so that  sludge will not flow from one  compartment to another.   The
outer walls or banks around the beds should also be watertight.

Solid Waste Aspects:  The full sludge drying bed must either  be  abandoned
or  the   collected  solids  must  be removed   to a  landfill.  These solids
contain  whatever metals or other materials were  settled in  the  clarifier.
Metals   will   be  present  as  hydroxides, oxides, sulfides, or other salts.
They have the  potential   for   leaching  and  contaminating  ground  water,
whatever   the   location  of the semidried solids. Thus the abandoned bed or
 landfill   should   include  provision for   runoff  control   and   leachate
monitoring.

Demonstration  Status

Sludge   beds   have  been   in   common use   in  both  municipal and industrial
 facilities  for many  years.    However,   protection   of  ground  water  from
 contamination  is  not always adequate.
                                    492

-------
RECOVERY TECHNIQUES

Recovery  of   process  chemicals  is  currently  used  in lead-acid, nickel
cadmium, and  silver  zinc battery manufacturing plants.  Recovery techniques
to be  discussed   are  evaporation,   ion  exchange,  reverse  osmosis,  and
insoluble   starch   xanthate.    Insoluble  starch xanthate is included under
recovery techniques  because it is used for rinse water recovery in  its only
observed commercial  application.  The description  is  abbreviated  because
the technique does  not  have  widespread  use.   Although settling is an
important technique  for materials recovery, it is discussed near the end of
this section,  under  In-Plant  Technology.

    EVAPORATION

Evaporation is a   concentration  process.   Water  is  evaporated  from  a
solution, increasing the concentration of solute in the remaining solution.
If  the  resulting  water  vapor  is  condensed  back  to liquid water, the
evaporation-condensation process is called distillation.   However,  to  be
consistent  with industry terminology, evaporation is used in this report to
describe  both processes.   Both  atmospheric  and  vacuum evaporation are
commonly used in  industry today.  Specific evaporation techniques are shown
in Figure VII-20  and discussed below.

Atmospheric evaporation could be accomplished simply by boiling the liquid.
However, to aid evaporation,  heated liquid is  sprayed  on  an  evaporation
surface, and air  is blown over the surface and subsequently released to the
atmosphere.   Thus,  evaporation occurs by humidification of the air stream,
similar  to  a  drying  process.   Equipment  for  carrying  out  atmospheric
evaporation  is  quite similar for most applications.  The major element is
generally   a  packed  column  with  an  accumulator  bottom.    Accumulated
wastewater  is pumped from the base of the column, through a heat exchanger,
and  back  into the top of the column, where it is sprayed into the  packing.
At the same time,  air drawn upward through the packing by a fan  is heated
as  it  contacts   the  hot  liquid.   The  liquid  partially  vaporizes and
humidifies  the air stream.  The fan then blows the hot, humid  air  to  the
outside  atmosphere.   A  scrubber  is often unnecessary because the packed
column itself acts as a scrubber.

Another  form of atmospheric evaporator also works on the air humidification
principle,  but the evaporated water is recovered for reuse by condensation.
These air  humidification techniques operate well below the boiling  point of
water and  can utilize waste process heat to supply the energy required.

In vacuum  evaporation, the evaporation pressure  is  lowered  to  cause  the
liquid to  boil at reduced temperature.  All of the water vapor  is condensed
and,  to  maintain  the  vacuum  condition,  noncondensible  gases   (air  in
particular) are removed by a vacuum pump.  Vacuum evaporation may be  either
single or  double effect.  In double effect evaporation, two evaporators are
used,  and  the water vapor from the first evaporator  (which may  be heated  by
                                   493

-------
steam) is used to supply heat to  the second   evaporator.    As  it  supplies
heat,  the  water vapor from the  first  evaporator condenses.   Approximately
equal quantities of wastewater are  evaporated  in  each   unit;  thus,  the
double  effect  system  evaporates  twice  the amount of water that a single
effect system does, at nearly the same cost  in  energy  but  with  added
capital   cost   and   complexity.    The    double   effect   technique  is
thermodynamically possible because the  second evaporator  is  maintained  at
lower   pressure    (higher   vacuum)    and,   therefore,  lower  evaporation
temperature.  Another  means  of  increasing  energy  efficiency  is  vapor
recompression (thermal or mechanical),  which enables heat to be transferred
from  the  condensing  water  vapor  to the  evaporating wastewater.   Vacuum
evaporation equipment may be classified as submerged tube or climbing  film
evaporation units.

In  the  most  commonly  used  submerged  tube  evaporator, the heating and
condensing coil are contained in  a single  vessel to  reduce  capital  cost.
The   vacuum  in  the  vessel  is  maintained by an eductor-type pump, which
creates the required vacuum by the flow of   the  condenser  cooling  water
through  a  venturi.   Waste water accumulates in the bottom of the vessel,
and  it is evaporated by means of  submerged   steam  coils.    The  resulting
water vapor condenses as it contacts the condensing coils in the top of the
vessel.   The  condensate  then   drips   off   the  condensing  coils  into a
collection trough that carries   it  out of   the  vessel.   Concentrate  is
removed from the bottom of the vessel.

The   major  elements  of  the  climbing film evaporator are the evaporator,
separator, condenser, and vacuum  pump.   Waste water  is  "drawn"  into  the
system  by  the vacuum so that a  constant  liquid level is maintained in the
separator.  Liquid  enters the steam-jacketed evaporator tubes, and part  of
it  evaporates  so  that a mixture of vapor and liquid enters the separator.
The design of the   separator  is  such   that  the  liquid  is  continuously
circulated  from  the  separator  to the evaporator.  The  vapor entering the
separator flows out through a mesh entrainment separator  to the  condenser,
where it  is  condensed as it flows down  through the condenser tubes.  The
condensate, along with any entrained air,  is pumped out of  the  bottom  of
the   condenser  by  a liquid ring vacuum pump.   The liquid seal provided by
the  condensate keeps the vacuum  in the  system from being  broken.

Application and Performance

Both  atmospheric and vacuum evaporation are  used in many  industrial plants,
mainly for the concentration and  recovery  of process  solutions.   Many  of
these evaporators  also  recover water for rinsing.  Evaporation has also
been  applied to recovery of phosphate metal  cleaning solutions.

In   theory,  evaporation  should  yield a  concentrate  and  a   deionized
condensate.    Actually,   carry-over   has  resulted  in  condensate  metal
concentrations as high as 10 mg/1, although  the usual level is less than  3
mg/1,  pure  enough for most final rinses.  The condensate may also contain
                                    494

-------
organic  brighteners and antifoaming agents.  These can be removed  with  an
activated   carbon  bed,   if necessary.  Samples from one plant showed 1,900
mg/1  zinc  in  the feed,  4,570 mg/1 in the concentrate, and 0.4 mg/1  in  the
condensate.    Another plant had 416 mg/1 copper in the feed and 21,800 mg/1
in the concentrate.   Chromium analysis for that plant indicated 5,060  mg/1
in  the  feed  and 27,500 mg/1 in the concentrate.  Evaporators are available
in a range of capacities,  typically from 15 to 75 gph, and may be  used  in
parallel arrangements for  processing of higher flow rates.

Advantages and Limitations

Advantages of  the  evaporation  process are that it permits recovery of a
wide  variety  of  process  chemicals,  and  it  is  often  applicable   to
concentration  or  removal of compounds which cannot be accomplished by any
other means.   The  major  disadvantage  is  that  the  evaporation  process
consumes  relatively  large amounts of energy for the evaporation of water.
However, the  recovery of waste heat from many industrial  processes  (e.g.,
diesel generators,  incinerators, boilers and furnaces) should be considered
as  a source  of  this  heat  for a totally integrated evaporation system.
Also, in some cases solar  heating could be  inexpensively  and  effectively
applied  to  evaporation units.  For some applications, pretreatment may be
required to remove solids  or bacteria which tend to cause  fouling  in  the
condenser   or  evaporator.  The buildup of scale on the evaporator surfaces
reduces  the heat transfer  efficiency and may present a maintenance  problem
or increase operating cost.  However, it has been demonstrated that fouling
of  the  heat  transfer  surfaces  can  be avoided or minimized for certain
dissolved  solids by maintaining a seed slurry which  provides  preferential
sites for  precipitate deposition.  In addition, low temperature differences
in  the  evaporator  will   eliminate  nucleate  boiling and supersaturation
effects.  Steam distillable impurities in the process  stream  are  carried
over with  the product water and must be handled by pre or post treatment.

Operational Factors

Reliability;    Proper  maintenance will ensure a high degree of reliability
for the  system.  Without such attention, rapid fouling or deterioration  of
vacuum seals  may occur, especially when handling corrosive liquids.

Maintainability;   Operating  parameters  can  be automatically controlled.
Pretreatment  may be required, as well as periodic cleaning of  the  system.
Regular  replacement of seals, especially in a corrosive environment, may be
necessary.

Solid Waste   Aspects;   With  only  a few exceptions, the process does not
generate appreciable quantities of solid waste.
                                   495

-------
Demonstration Status

Evaporation  is  a  fully  developed,   commercially  available   wastewater
treatment  system.    It  is used extensively  to recover plating chemicals in
the electroplating industry and  a  pilot  scale  unit  has  been  used  in
connection  with  phosphating  of   aluminum.    Proven performance in silver
recovery indicates that  evaporation could  be a useful  treatment  operation
for the photographic  industry, as well  as  for metal finishing.

ION EXCHANGE

Ion  exchange   is  a  process in which  ions,  held by electrostatic forces to
charged functional groups on the surface of  the  ion  exchange  resin,  are
exchanged  for  ions  of  similar charge  from  the solution in which the resin
is immersed.  This is classified as a  sorption process because the exchange
occurs on the surface of the resin, and the  exchanging ion must  undergo  a
phase   transfer   from   solution  phase  to  solid  phase.    Thus,  ionic
contaminants in a waste  stream can  be  exchanged for the  harmless  ions  of
the resin.

Although  the   precise  technique   may  vary  slightly according to the ap-
plication  involved,   a  generalized   process  description  follows.    The
wastewater  stream  being  treated  passes  through  a filter to remove any
solids, then flows through  a  cation   exchanger  which  contains  the  ion
exchange  resin.   Here,  metallic  impurities  such  as  copper, iron, and
trivalent chromium are retained.  The  stream then passes through the  anion
exchanger  and  its associated resin.   Hexavalent chromium, for example, is
retained  in this stage.  If one pass does  not reduce the contaminant levels
sufficiently, the stream may then enter another series of exchangers.  Many
ion exchange systems  are equipped with  more  than one set of exchangers  for
this reason.

The  other  major  portion  of  the ion   exchange process concerns the re-
generation of the resin, which now  holds those impurities retained from the
waste stream.   An ion exchange unit with in-place regeneration is shown  in
Figure  VI1-21.   Metal  ions such  as  nickel are removed by an acid, cation
exchange  resin, which is regenerated with  hydrochloric  or  sulfuric  acid,
replacing  the  metal  ion  with one or more hydrogen ions.  Anions such as
dichromate  are removed by  a  basic, anion  exchange  resin,  which  is
regenerated  with  sodium  hydroxide,   replacing the anion with one or more
hydroxyl  ions.  The   three  principal   methods  employed  by  industry  for
regenerating the spent resin are:

A)   Replacement Service;  A regeneration  service replaces the spent  resin
     with  regenerated  resin,  and regenerates the spent resin at its own
     facility.  The service then has the problem of treating and  disposing
     of the spent regenerant.
                                    496

-------
B)    In-Place Regeneration;   Some establishments may find it less expensive
     to do  their  own  regeneration.   The spent resin column is shut down for
     perhaps an hour,  and the spent resin is regenerated.  This results  in
     one  or  more  waste  streams  which must be treated in an appropriate
     manner.  Regeneration is performed as the resins require  it,  usually
     every  few months.

C)    Cyclic Regeneration;  In this process,  the regeneration of  the  spent
     resins takes  place within the ion exchange unit itself in alternating
     cycles with  the  ion removal  process.   A  regeneration  frequency  of
     twice  an  hour   is  typical.    This  very  short  cycle  time permits
     operation with  a  very  small  quantity  of  resin  and  with  fairly
     concentrated  solutions,  resulting  in a very compact system.  Again,
     this process varies according to  application,  but  the  regeneration
     cycle  generally  begins  with  caustic being pumped through the anion
     exchanger, carrying out hexavalent chromium, for  example,  as  sodium
     dichromate.  The sodium dichromate stream then passes through a cation
     exchanger,   converting  the  sodium dichromate to chromic acid.  After
     concentration  by evaporation or other means, the chromic acid  can  be
     returned  to  the  process  line.    Meanwhile, the cation exchanger is
     regenerated  with sulfuric acid,  resulting  in  a  waste  acid  stream
     containing   the   metallic  impurities  removed  earlier.  Flushing the
     exchangers with  water completes the cycle.  Thus,  the  wastewater  is
     purified  and,  in  this  example, chromic acid is recovered.  The ion
     exchangers,  with newly regenerated resin, then enter the  ion  removal
     cycle  again.

Application and Performance

The  list  of  pollutants  for  which  the  ion  exchange system has proven
effective includes  aluminum, arsenic,  cadmium,  chromium  (hexavalent  and
trivalent), copper, cyanide, gold, iron, lead, manganese, nickel, selenium,
silver,   tin,  zinc, and more.  Thus, it can be applied to a wide variety of
industrial  concerns.   Because of the  heavy  concentrations  of  metals  in
their  wastewater,   the  metal finishing industries utilize ion exchange in
several  ways.  As an   end-of-pipe  treatment,  ion  exchange  is  certainly
feasible,  but   its  greatest  value  is  in  recovery applications.  It is
commonly used  as  an integrated treatment to recover rinse water and process
chemicals.  Some  electroplating facilities use ion exchange to  concentrate
and purify  plating  baths.

Ion  exchange   is  highly  efficient at recovering metal bearing solutions.
Recovery of chromium, nickel, phosphate solution, and  sulfuric  acid  from
anodizing  is  commercial.   A  chromic  acid  recovery  efficiency of 99.5
percent  has been  demonstrated.  Typical  data  for  purification  of  rinse
water  have  been reported as shown on the following page.  Sampling at one
battery  plant  characterized  influent  and  effluent  streams  for  an  ion
exchange  unit  on   a silver bearing waste.  This system was in start-up at
                                   497

-------
the  time  of  sampling,  however,  and   was   not   found  to  be  operating
effectively.


                               Table VII-15
                          Ion Exchange  Performance
Parameter
     Plant A
                     Plant B
All Values mg/1

Al
Cd
Cr + 3
Cr + 6
Cu
CN
Au
Fe
Pb
Mn
Ni
Ag
S04
Sn
Zn
Prior To
Purifi-
cation

  5.6
  5.7
  3.1
  7.1
  4.5
  9.8

  7.4

  4.4
  6.2
  1.5

  1.7
 14.8
After
Purifi-
cation

 0.20
 0.00
 0.01
 0.01
 0.09
 0.04

 0.01

 0.00
 0.00
 0.00

 0.00
 0.40
Prior To
 Purifi-
 cation
 After
Purifi-
cation
  43.0
   3.40
   2.30

   1.70

   1.60
   9.10
 210.00
   1.10
  0.10
  0.09
  0.10

  0.01

  0.01
  0.01
  2.00
  0.10
Advantages and  Limitations
 Ion   exchange   is   a   versatile   technology  applicable  to  a  great  many
 situations.    This  flexibility,   along   with  its   compact   nature   and
 performance,   makes  ion   exchange  a very effective method of waste water
 treatment.  However,  the  resins  in these systems can prove to be a limiting
 factor.   The thermal  limits  of the anion resins,  generally  placed  in  the
 vicinity  of 60  C,  could  prevent  its use in certain situations.  Similarly,
 nitric  acid, chromic  acid, and hydrogen  peroxide can all damage the  resins
 as    will   iron,   manganese,  and  copper  when  present  with  sufficient
 concentrations  of  dissolved  oxygen.    Removal  of  a  particular   trace
 contaminant  may be   uneconomical  because  of the presence of other ionic
 species that are preferentially  removed.  The regeneration  of  the  resins
 presents  its   own  problems.  The cost of the regenerative chemicals can be
 high.   In addition, the waste streams originating  from  the  regeneration
 process  are   extremely   high   in pollutant concentrations, although low in
 volume.   These must be further processed for proper disposal.
                                    498

-------
Operational  Factors

Reliability;   With the exception of occasional clogging or fouling  of  the
resins,  ion  exchange has been shown to be a highly dependable technology.

Maintainability;    Only the normal maintenance of pumps, valves, piping and
other hardware used in the regeneration process is usually encountered.

Solid Waste  Aspects;   Few,  if  any,  solids  accumulate  within  the  ion
exchangers,   and  those  which  do  appear  are removed by the regeneration
process.   Proper prior treatment and planning can eliminate  solid  buildup
problems  altogether.    The  brine  resulting  from regeneration of the ion
exchange resin most  usually  must  be  treated  to  remove  metals  before
discharge.   This can generate solid waste.

Demonstration Status

All  of   the  applications  mentioned  in  this  document are available for
commercial use, and industry sources estimate the number of units currently
in the field at well  over  120.   The  research  and  development  in  ion
exchange is  focusing on improving the quality and efficiency of the resins,
rather  than  new  applications.   Work  is also being done on a continuous
regeneration  process  whereby  the  resins  are  contained  on  a   fluid-.
transfusible  belt.   The belt passes through a compartmented tank with ion
exchange, washing, and regeneration sections.   The  resins  are  therefore
continually  used and regenerated.  No such system, however, has been repor-
ted to be beyond the pilot stage.

REVERSE OSMOSIS

The  process  of  osmosis  involves  the  passage  of  a  liquid  through a
semipermeable membrane from a  dilute  to  a  more  concentrated  solution.
Reverse  osmosis  (RO)  is an operation in which pressure is applied to the
more concentrated solution, forcing the permeate  to  diffuse  through  the
membrane and into the more dilute solution.  This filtering action produces
a  concentrate  and  a  permeate  on  opposite  sides of the membrane.  The
concentrate  can then  be  further  treated  or  returned  to  the  original
operation  for  continued use, while the permeate water can be recycled for
use as clean water.  Figure VI1-22 depicts a reverse osmosis system.

As illustrated in Figure VII-23, there are three basic configurations  used
in  commercially  available  RO modules:  tubular, spiral-wound, and hollow
fiber.  All  of these operate on the principle described  above,  the  major
difference being their mechanical and structural design characteristics.

The tubular  membrane module utilizes a porous tube with a cellulose acetate
membrane-lining.   A common tubular module consists of a length of 2.5 cm  (1
inch)  diameter  tube  wound on a supporting spool and encased in a plastic
shroud.   Feed water is driven into the tube under pressures varying from  40
                                   499

-------
- 55 atm (600-800 psi).  The permeate passes  through  the walls of the  tube
and  is collected in a manifold while the concentrate is drained off at the
end of the tube.  A less widely used tubular  RO  module uses  a straight tube
contained in a housing, under the same operating conditions.

Spiral-wound membranes consist of a porous backing  sandwiched  between  two
cellulose acetate membrane sheets and bonded  along  three edges.   The fourth
edge of the composite sheet is attached  to a  large  permeate  collector tube.
A  spacer  screen  is  then  placed on top of the membrane sandwich and the
entire stack is  rolled  around  the  centrally   located tubular  permeate
collector.  The rolled up package is inserted into  a  pipe able to withstand
the  high  operating  pressures employed in this process, up to 55 atm (800
psi) with the spiral-wound module.   When  the  system  is   operating,  the
pressurized  product  water  permeates   the   membrane and flows through the
backing material to the central collector tube.   The  concentrate is drained
off at the end of the container pipe and can   be reprocessed  or  sent  to
further treatment facilities.

The hollow fiber membrane configuration  is made  up  of a bundle of polyamide
fibers of approximately 0.0075 cm (0.003 in.)  OD and  0.0043  cm (0.0017 in.)
ID.   A commonly used hollow fiber module contains  several hundred thousand
of the fibers placed in a long tube, wrapped   around   a  flow  screen,  and
rolled  into a spiral.  The fibers are bent in a U-shape and their ends are
supported by an epoxy bond.  The hollow  fiber unit  is operated under 27 atm
 (400 psi), the feed water being dispersed from the  center   of  the  module
through  a porous distributor tube.  Permeate flows through  the membrane to
the fibers hollow interiors and is collected  at  the ends of  the fibers.

The hollow fiber and spiral-wound modules have a distinct   advantage  over
the  tubular  system   in  that  they are able to load a very large membrane
surface area into a relatively small volume.   However,  these  two  membrane
types  are  much more susceptible to fouling  than the tubular system, which
has a  larger flow channel.  This  characteristic also  makes  the  tubular
membrane  much  easier to clean and regenerate than either the spiral-wound
or hollow fiber  modules.   One  manufacturer claims  that   their  helical
tubular  module  can  be  physically  wiped   clean  by passing a soft porous
polyurethane plug under pressure through the  module.

Application and Performance

 In a number of metal processing plants,  the overflow  from the  first  rinse
 in  a  countercurrent setup  is directed  to a  reverse  osmosis unit, where it
 is separated into two streams.  The concentrated stream  contains  dragged
out  chemicals  and  is returned to the bath to replace the  loss of solution
due to evaporation and dragout.  The dilute stream  (the permeate) is routed
to the last rinse tank to provide water  for   the rinsing operation.   The
rinse  flows from the last tank to the first tank and  the cycle is complete.
                                    500

-------
The  closed-loop system  described above may be supplemented by the addition
of a vacuum evaporator after  the RO unit in order  to  further  reduce  the
volume  of  reverse   osmosis   concentrate.    The  evaporated  vapor  can be
condensed and returned to  the last  rinse  tank  or  sent  on  for  further
treatment.

The  largest application has  been for the recovery of nickel solutions.  It
has been shown  that  RO can generally be applied to most  acid  metal  baths
with  a high degree  of performance, providing that the membrane unit is not
overtaxed.  The limitations most critical here are the allowable  pH  range
and maximum operating pressure for each particular configuration.  Adequate
prefiltration   is  also  essential.   Only three membrane types are readily
available in commercial  RO units, and their overwhelming use has  been  for
the  recovery   of  various  acid metal baths.  For the purpose of calculating
performance predictions  of this technology, a rejection ratio of 98 percent
is assumed for  dissolved salts, with 95 percent permeate recovery.

Advantages and  Limitations

The major advantage  of reverse osmosis for handling  process  effluents  is
its  ability  to  concentrate  dilute  solutions  for recovery of salts and
chemicals with  low power requirements.  No latent heat of  vaporization  or
fusion  is  required for effecting separations; the main energy requirement
is for a high pressure pump.   It requires relatively little floor space for
compact, high capacity units, and it exhibits good recovery  and  rejection
rates  for  a   number of   typical  process solutions.  A limitation of the
reverse osmosis process  for treatment of process effluents is  its  limited
temperature  range  for  satisfactory  operation.   For  cellulose  acetate
systems, the  preferred   limits  are  18  to  30°C  (65  to  85°F);  higher
temperatures  will  increase   the  rate  of  membrane hydrolysis and reduce
system life, while lower temperatures will result in decreased fluxes  with
no damage  to   the   membrane.   Another  limitation is inability to handle
certain solutions.  Strong oxidizing agents, strongly acidic or basic solu-
tions, solvents,  and other organic compounds can cause dissolution  of  the
membrane.   Poor  rejection  of  some  compounds  such  as  borates and low
molecular weight organics  is  another  problem.   Fouling  of  membranes  by
slightly  soluble  components  in solution or colloids has caused failures,
and fouling of  membranes by feed  waters  with  high  levels  of  suspended
solids  can  be  a  problem.    A  final limitation is inability to treat or
achieve  high   concentration   with  some  solutions.    Some   concentrated
solutions  may   have  initial osmotic pressures which are so high that they
either exceed available  operating pressures or are uneconomical to treat.
                              •
Operational Factors

Reliability;  Very good  reliability is  achieved  so  long  as  the  proper
precautions  are  taken  to minimize the chances of fouling or degrading the
membrane.  Sufficient testing of the waste stream prior to  application  of
                                   501

-------
an  RO  system  will  provide the  information  needed to insure a successful
application.

Maintainability;  Membrane life  is estimated to fall between 6 months and 3
years, depending on the use of the  system.    Down  time  for  flushing  or
cleaning  is  on  the  order  of   2  hours  as  often  as once each week; a
substantial portion of maintenance time   must   be  spent  on  cleaning  any
prefilters  installed ahead of the  reverse osmosis unit.

Solid  Waste  Aspects;    In  a   closed   loop system utilizing RO there is a
constant recycle of concentrate  and  a   minimal  amount  of  solid  waste.
Prefiltration eliminates  many solids before they reach the module and helps
keep the buildup to a minimum.   These solids require proper disposal.

Demonstration Status

There  are  presently  at least   one  hundred  reverse osmosis waste water
applications in a variety of industries.  In addition to these,  there  are
thirty  to  forty units being used  to provide pure process water for several
industries.

Despite the many types and configurations of membranes,   only  the  spiral-
wound  cellulose  acetate membrane has had widespread success in commercial
applications.

INSOLUBLE STARCH XANTHATE

Insoluble starch xanthate is essentially an ion  exchange  medium  used  to
remove  dissolved  heavy  metals  from wastewater.  The water may then either
be reused  (recovery application) or discharged  (end-of-pipe  application).
In  a  commercial  electroplating  operation, starch xanthate is coated on a
filter  medium.   Rinse   water   containing  dragged  out  heavy  metals  is
circulated  through  the  filters  and then reused for rinsing.  The starch-
heavy metal complex is disposed  of and replaced  periodically.   Laboratory
tests  indicate  that recovery of  metals from  the complex is feasible, with
regeneration  of  the  starch  xanthate.   Besides  electroplating,  starch
xanthate   is  potentially applicable to coil  coating, porcelain enameling,
battery manufacturing, copper fabrication, and any other industrial  plants
where  dilute  metal  wastewater streams are generated.   Its present use is
limited to  one electroplating plant.

OIL REMOVAL

Use  of  a  mechanical  skimming   device is   the  standard  technique  for
separating  oils  from  industrial wastewater.  The source of these oils is
generally cutting fluids, lubricants, and preservative  coatings  used  in
metal  fabrication operations.   Coalescing  is  another method which has been
demonstrated for use in oil removal.   Ultrafiltration  and  flotation  are
used to achieve especially low oil concentrations or to remove mechanically
                                    502

-------
emulsified  oils   from  wastewater.   Carbon adsorption can be used to remove
residual oil  and  grease which may be present as  trace  organic  compounds.
Oils  may  also   be   incidentally  removed  through  other  waste treatment
processes such as clarification.

     SKIMMING

Pollutants with a specific gravity less than water will often float  remove
these floating wastes.   Skimming  normally takes place in a tank designed to
allow  the  floating  debris  to   rise and remain on the surface, while the
liquid  flows  to an outlet  located  below  the  floating  layer.   Skimming
devices are therefore suited to the removal of non-emulsified oils from raw
waste  streams.   Common skimming  mechanisms include the rotating drum type,
which picks up oil from the surface of the water as it rotates.   A  doctor
blade scrapes oil from  the drum and collects it in a trough for disposal or
reuse.   The  water   portion  is   allowed  to flow under the rotating drum.
Occasionally, an  underflow baffle is installed after the drum; this has the
advantage of  retaining  any floating oil which  escapes  the  drum  skimmer.
The  belt  type   skimmer is pulled vertically through the water, collecting
oil which  is  scraped  off from the surface and collected in a drum.  Gravity
separators, such  as the API type, utilize overflow and underflow baffles to
3kim a  floating oil layer from the surface of the wastewater.  An overflow-
underflow baffle  allows a small amount of wastewater (the oil  portion)  to
flow over into a trough for disposition or reuse while the majority of the
water flows underneath  the baffle.   This is followed by an overflow baffle,
which is set  at a height relative to the first baffle such  that  only  the
oil  bearing  portion  will  flow over the first baffle during normal plant
operation.  A diffusion device, such as a vertical  slot  baffle,  aids  in
creating a   uniform   flow  through  the  system and increasing oil removal
efficiency.

Application and Performance

Lubricants for drive  mechanisms and other machinery  contacted  by  process
water  is  a  principal source of oil.  Skimming is applicable to any waste
stream  containing pollutants which float to the surface.   It  is  commonly
used  to  remove   free   oil,  grease, and soaps.  Skimming is often used in
conjunction with  air  flotation or clarification in order  to  increase  its
effectiveness.

The  removal  efficiency of a skimmer is partly a function of the retention
time of the water in  the tank.  Larger, more buoyant particles require  less
retention  time  than  smaller particles.  Thus, the efficiency  also  depends
on  the composition   of  the waste stream.  The retention time required to
allow phase separation  and subsequent skimming varies from 1 to 15 minutes,
depending  on  the  wastewater characteristics.

API or  other  gravity-type separators tend to be more suitable for use where
the amount of surface  oil  flowing  through  the  system  is  consistently
                                   503

-------
significant.   Drum  and belt type  skimmers  are  applicable to waste streams
which evidence smaller amounts of floating oil and where surges of floating
oil are not a problem.  Using an API  separator system in conjunction with a
drum type skimmer would be a very effective   method  of  removing  floating
contaminants  from  non-emulsified  oily  waste streams.   Sampling data shown
below illustrate the capabilities of  the technology  with  both  extremely
high and moderate oil  influent levels.

                               Table  VII-16
                           Skimming Performance

                              Oil & Grease    Oil & Grease
                                 mg/1            mg/1
Plant     Skimmer Type        I_n              Out

06058        API              224,669         17.9
06058        Belt             19.4            8.3

Based  on   data from  installations  in  a  variety  of manufacturing plants,  it
is determined that effluent oil  levels may be reliably  reduced  below  10
mg/1  with  moderate   influent concentrations.   Very high concentrations  of
oil such as the 22 percent shown above may require two  step  treatment  to
achieve this level.

Advantages  and Limitations

Skimming  as  a  pretreatment  is   effective in  removing naturally floating
waste material.  It also  improves the performance of subsequent  downstream
treatments.

Many  pollutants,  particularly  dispersed or emulsified oil, will not float
"naturally" but require additional  treatments.   Therefore,  skimming  alone
may not remove all the pollutants capable of being removed by air flotation
or other more sophisticated technologies.

Reliability;   Because of  its  simplicity, skimming  is  a very reliable
technique.

Maintainability;  The  skimming   mechanism requires  periodic  lubrication,
adjustment, and replacement of worn parts.

Solid  Waste Aspects;  The collected  layer of debris must be disposed of  by
contractor  removal,  landfill, or  incineration.    Because  relatively  large
quantities  of  water  are present  in the collected wastes, incineration  is
not always  a viable disposal method.
                                    504

-------
Demonstration Status

Skimming  is a common  operation utilized  extensively  by  industrial  waste
treatment systems.

     COALESCING

The  basic  principle of coalescence involves the preferential wetting of a
coalescing medium  by  oil droplets which accumulate on the medium  and  then
rise  to  the  surface  of  the  solution  as  they  combine to form larger
particles.  The  most  important  requiremen