national enforcement investigations center
denver federal center bldg 51 b()xJS227  denver, LO 8022S
                             SUMMARY
                      PRETREATMENT CRITERIA
                  Taken from Pretreatment Standards
                   for Existing  and New Sources
             and from Various EPA Limitations-Guidelines
                       Development Documents
                    [Current as  of March 1977]
                                               EPA-330/1-77-010
                              us. environmental protection agency
                                           office of enforcement

-------
       ENVIRONMENTAL PROTECTION AGENCY
           OFFICE OF ENFORCEMENT
             EPA-330/1-77-010
                  SUMMARY

          PRETREATMENT CRITERIA

     Taken from Pretreatment Standards
       for Existing and-New  Sources
and from Various EPA Limitations-Guidelines
           Development Documents

        [Current as of March 1977]
                 July  1977
National  Enforcement  Investigations Center

             Denver,  Colorado

-------
                              CONTENTS
Port
405    D.AIRY PRODUCTS INDUSTRY	   1
406    GRAIN MILLING INDUSTRY . 	 	   5
407    CANNED AND PRESERVED FRUITS AND VEGETABLES INDUSTRY. ...   9
408    CANNED AND PRESERVED SEAFOOD PROCESSING INDUSTRY 	  12
409    BEET SUGAR PROCESSING	16
409    CANE SUGAR REFINING	17
409    RAW CANE PROCESSING	19
410    TEXTILES MANUFACTURING 	  21
411    CEMENT MANUFACTURING INDUSTRY	25
412    FEEDLOTS INDUSTRY	27
413    ELECTROPLATING AND METAL FINISHING INDUSTRY	29
414    ORGANIC CHEMICALS MANUFACTURING INDUSTRY 	  39
415    INORGANIC CHEMICALS MANUFACTURING INDUSTRY 	  48
416    PLASTICS AND SYNTHETICS MATERIALS MANUFACTURING
          INDUSTRY  . .  . '.	66
417    SOAP AND DETERGENT MANUFACTURING	72
418    FERTILIZER MANUFACTURING INDUSTRY	78
419    PETROLEUM REFINING INDUSTRY	87
420    IRON AND STEEL MAKING SEGMENT OF IRON AND STEEL
          INDUSTRY	91
420    HOT FORMING, COLD FINISHING AND SPECIALTY STEEL
          SEGMENT OF IRON AND STEEL INDUSTRY	97
421    ALUMINUM, COPPER, LEAD AND ZINC SEGMENT OF THE
          NON-FERROUS METALS MANUFACTURING INDUSTRY 	 106
422    PHOSPHATE MANUFACTURING INDUSTRY 	 118
423    STEAM ELECTRIC POWER GENERATING INDUSTRY 	 126
424    FERROALLOYS MANUFACTURING INDUSTRY 	 133
425    LEATHER TANNING AND FINISHING INDUSTRY 	 140
426    (INSULATION) FIBERGLASS MANUFACTURING	146
426    FLAT GLASS, PRESSED GLASS AND BLOWN GLASS MANUFACTURING.  . 148
427    ASBESTOS PRODUCTS MANUFACTURING INDUSTRY 	 153
428    RUBBER PROCESSING INDUSTRY 	 157
429    TIMBER PRODUCTS INDUSTRY 	 163
430    UNBLEACHED KRAFT AND SEMICHEMICAL PULP/PAPER MILLS  .... 171
430    BLEACHED KRAFT, GROUNDWOOD, SULFITE,  SODA,  DEINK AND
          NON-INTEGRATED PULP/PAPER MILLS 	 174
431    BUILDING PAPER AND ROOFING FELT MANUFACTURING	179
432    RED MEAT SEGMENT OF THE MEAT PRODUCTS INDUSTRY	181
432    PROCESSOR SEGMENT OF MEAT PRODUCTS INDUSTRY	184
432    RENDERING SEGMENT OF THE MEAT PRODUCTS INDUSTRY	187
432    POULTRY SEGMENT OF THE MEAT PRODUCTS  INDUSTRY	189
434    COAL MINING INDUSTRY	192
435    OFFSHORE AND ONSHORE OIL AND GAS EXTRACTION INDUSTRY ... 194
436    MINERAL MINING AND PROCESSING INDUSTRY 	 199
439    PHARMACEUTICAL MANUFACTURING	-	203
440    ORE MINING AND DRESSING INDUSTRY	205
443    PAVING AND ROOFING (TARS AND ASPHALT) MATERIALS
          INDUSTRY  .	208
446    PAINT FORMULATING  	 210
447    INK FORMULATING	212
454    GUM AND WOOD CHEMICALS MANUFACTURING	214
455    PESTICIDE CHEMICALS MANUFACTURING  	 216
457    EXPLOSIVES MANUFACTURING 	 219
458    CARBON BLACK MANUFACTURING 	  	 221
459    PHOTOGRAPHIC PROCESSING  	 223
460    HOSPITALS	226

-------
                               FOREWORD

Pretreatment standards and criteria are expected to undergo considerable
change in the future and those who deal with pretreatment issues should
strive to keep informed of all updatings.

This Pretreatment Report has been prepared to satisfy, at least in part,
a pressing need for information on pretreatment of industrial  wastes --
that is, treatment before these wastes are properly received into
municipal collection and disposal systems.  This information has been
widely requested.  In connection with ongoing technical  support activities
on pretreatment, the Environmental Protection Agency (EPA)  National
Enforcement Investigations Center (NEIC), Denver, Colorado  has compiled
and summarized available data on pretreatment principally as found in
the Code of Federal Regulations, Title 40 - Protection of the  Environment,
Subchapter N - Effluent Guidelines and Standards, Parts  405-460.  This,
in turn, was supplemented by various available USEPA Effluent  Limitations
Guidelines Development Documents prepared from 1973 through the present.

This Pretreatment Report covers 42 different industries, which are
represented by 50 sections.  Each section is divided into various
subparts consisting of:  Subcategorization and Description  of  the
Industry; Nature of the Problem; Waste Parameters of Concern;  Preliminary
                                   *
Limitations for Discharge to POTW's ; and Prescribed Pretreatment Measures.
Detailed industry description is provided for two reasons:   1) to
summarize this information in a single EPA report; and 2) since NEIC in
June 1977 published another document summarizing Limitations Guidelines
for Existing Sources and New Sources across the same industry  classifications,
a thorough industry description will enable easier and more complete use
of the June 1977 publication.
   Publicly Owned Treatment Works

-------
In the Federal Register of February 2, 1977, the USEPA gave notice of
intentions to issue regulations setting up mechanisms and procedures for
controlling the introduction of industrial wastes into POTW's.   The
preamble to these general pretreatment regulations would set forth EPA's
overall policy for the establishment and enforcement of pretreatment
regulations.  Four options were proposed giving various approaches to
establishing and enforcing pretreatment requirements.  These options
differed mainly in terms of the degree to which industrial users of
POTW's would be controlled by Federally promulgated technology-based
standards vs. locally developed and applied pretreatment limits.  The
options also vary in terms of the particular government body (i.e.
Federal, State or local) charged with primary responsibility for en-
forcement of applicable requirements.  These options are very briefly
delineated below.  It is intended that one of these options will be
selected in the near future as part of a National Pretreatment Strategy.

     Option I - Local enforcement, monitoring and reporting would be
               heavily emphasized.  Local agencies would be expected
               to require compliance with Federal technology-based
               standards or alternative standards where variances are
               approved.

     Option II - Local enforcement of technology standards integrated with
               locally-derived water quality based pretreatment limits
               in lieu of Federal standards.

     Option III - Local enforcement but with Federal technology-based
               standards for the more hazardous pollutants and  the more
               significant industries discharging these pollutants.
               Local standards would apply in all other cases.

     Option IV - The regulatory program would rely heavily upon the
               USEPA and the NPDES States, and Federal  technology-based
               pretreatment standards would be issued.

-------
In connection with the above notice, the USEPA in January 1977 released
a three-volume document titled "Federal  Guidelines and State and Local
Pretreatment Programs," EPA Report MCD-43.   The report provides introduction
to the pretreatment problems and information on management of a control
program, legal aspects of a control program, monitoring, pollutants
which interfere with POTW's, and removal and pass-through of pollutants
in POTW's.  Volumes II and III comprise a series of useful technical
appendices.

This report is a compilation of draft, interim, interim final, and final
regulations,  and information from the various Development Documents  and
other sources, current through March 1977.   Where pretreatment regulations
have been superseded, remanded or revoked,  these changes are indicated.
However, all changes in the Code of Federal  Regulations may not have
been incorporated in this report; therefore, such accuracy is not
claimed.  Much of the information contained  herein is of guidance nature
only.  It is recommended this Report be used as a summary, or desk
reference.  The Federal Register should be  consulted for official
application of pretreatment limitations.

-------
                        DAIRY PRODUCTS INDUSTRY
                             (40, 41, 42)
                              [Part  405]

SUBCATEGORIZATION OF THE INDUSTRY

The Dairy Products Industry is divided into twelve Subcategories as
defined below:

     A - Receiving Stations
     B - Fluid Products
     C - Cultured Products
     D - Butter
     E - Cottage Cheese and Cultured Cream Cheese
     F - Natural and Processed Cheese
     G --Fluid Mix for Ice Cream and Other Frozen Desserts
     H - Ice Cream, Frozen Desserts, Novelties and Other Dairy Desserts
     I - Condensed Milk
     J - Dry Milk
     K - Condensed Whey
     L - Dry Whey
Subcategory A, Receiving Stations.   Establishments engaged in the as-
sembly and reshipment of bulk milk for the use of manufacturing or pro-
cessing plants.  Receiving stations have been further subdivided into
establishments receiving more than 150,000 Ib. milk daily vs. those re-
ceiving less than 150,000 Ib. milk daily.

Subcategory B, Fluid Products.  Manufacture of market milk,  flavored
milk (chocolate and others), and cream (of various fat concentrations,
plain and whipped).  Fluid product plants  have been further  subdivided
into establishments receiving more than -  and less than - 250,000 Ib.
milk equivalent daily.

Subcategory C, Cultured Products.  Manufacture of cultured products,
including cultured skim milk, yogurt, sour cream, and dips of various
types, including cultured cream cheese dip.  Cultured product plants
have been further subdivided into establishments receiving more than -
and less than - 60,000 Ib. milk equivalent daily.

Subcategory D, Butter.  Manufacture of butter, either by the churning
or continuous process.  Butter plants have been further subdivided into
establishments processing more than - and  less than - 175,000 Ib milk
equivalent daily.

-------
Subcategory E. Cottage Cheese and Cultured Cream Cheese.   Manufacture
of cottage cheese curd and cultured cream cheese (soft),  as opposed
to rennet curd natural and processed cheese.   Cottage cheese plants have
been subdivided into establishments processing more than  - and less
than - 25,000 Ib. milk equivalent daily.

Subcategory F, Natural and Processed Cheese.   Manufacture of natural
cheese (hard curd) and processed cheese.These plants have been sub-
divided into establishments processing more than - and less than -
100,000 Ib. milk equivalent daily.

Subcategory G, Fluid Mix For Ice Cream and Other Frozen Desserts.   These
products are manufactured for later freezing  in other plants.   The fluid
mix plants have been subdivided into establishments receiving  more than -
and less than - 85,000 Ib. milk equivalent daily.

Subcategory H, Ice Cream, Frozen Desserts, etc.  Manufacture of ice
cream, ice milk, sherbet,  water ices, stick  confections, frozen novelties
products, frozen desserts, melonne, puddings  and other dairy product-base
desserts.  Ice cream and associated plants have been subdivided into  es-
tablishments receiving more than - and less than - 85,000 Ib.  milk equiva-
lent daily,

Subcategory I, Condensed Milk.   Manufacture of condensed  whole milk,  con-
densed skim milk, sweetened condensed milk and condensed  buttermilk.
Condensed milk plants have been subdivided into establishments condensing
more than - and less than - 100,000 Ib milk equivalent daily.   For the
smaller size plants, the limitations documents indicate that once-through
barometric condenser waters may be discharged untreated if the composite
NET entrainment is less than 15 mg/1 BOD,- for any single  day,  and  less
than 10 mg/1 BODj- as an average for 30 consecutive days.

Subcategory J, Dry Milk.  Manufacture of  dry  whole milk,  dry skim  milk,
and dry buttermilk.  Milk drying plants have  been subdivided into  es-
tablishments receiving more than - and less than - 145,000 Ib. milk
equivalent daily.

Subcategory K, Condensed Whey.   Manufacture of condensed  whey  and  con-
densed acid whey.  Whey condensing plants have been subdivided into
establishments receiving more than - and  less than - 300,000 Ib.  fluid
raw whey daily.  For the smaller size plants  the limitations documents
indicate that once-through barometric condenser waters may be  discharged
untreated if the composite NET entrainment is less than 15 mg/1  B005  for
any single day, and less than 10 mg/1 BODj- as an average  for 30 consecutive
days.                                    b

-------
Subcategory L, Dry Whey.  Manufacture of dry sweet whey and dry acid
whey.  Whey drying plants have been subdivided into establishments re-
ceiving more than - and less than - 57,000 Ib of 40 percent dry solids
daily.
NATURE OF PROBLEM

In 1970, there were approximately 5,500 dairy plants in the United
States.  Many are multi-product facilities.  Pollutants in wastewaters
from dairy product plants represent materials lost through processing
of raw materials into finished products, and materials lost from an-
cillary operations.  The former consists of milk, milk products and
non-dairy ingredients such as sugar, fruit, nuts, etc.  The latter con-
sists of cleaners and sanitizers, lubricants, sanitary wastes, etc.
Dairy plant wastes with the possible exception of certain lubricants,
cleaners, sanitizers and concentrated wheys are relatively degradable
in biological waste treatment systems.  Refractive materials are generally
present in fairly low concentrations.
PARAMETERS OF CONCERN

               BOD                      Phosphorus
               COD                      Nitrogen
               TSS                      Chlorides
               pH                       Temperature

The majority of phosphorous is contributed by wasted detergents.   Some
cleaning solutions may be recycled.  Quaternary ammonium compounds used
for sanitizing and certain detergents can be a source of nitrogen in
dairy wastewaters.  Principal  sources of chloride include brine leaked
from refrigerator systems and chlorine-based sanitizers.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED
PRETREATMENT MEASURES

Np_ specific pretreatment limitations have been developed for Existing
and/or New dairy product establishments.  It has been determined that
dairy plant discharges are treatable and can be handled by biological
treatment provided that suitable design and capacity have been incor-
porated into the POTW.  Equalization of dairy wastes may be necessary
in some cases.  Difficulties may be experienced in attaining normal
treatment efficiencies when the BOD load attributable to whey exceed
10 percent of the total POTW load received.  This is especially true
without proper wastes equalization.  Consequently, under given situa-
tions, whey may not be a compatible pollutant at the POTW.

-------
The best approach by dairy plants to reduce excessive surcharges and
waste load to the POTW is to practice good in-plant controls and re-
cycling of cooling waters.  If the local authority requires pretreat-
ment, this may take the form of anaerobic digestion, high-rate bio-
logical systems, stabilization ponds, aerated ponds, or chemical treat-
ment.  Anaerobic digestion may be applicable to small plants discharg-
ing low volume wastes.  If dairy wastes comprise a significant portion
of the total load to the POTW, it may be necessary to completely sep-
arate the whey to avoid upset of the treatment works.

Grease, fats and oils in dairy wastes generally do not pose a large
problem to the municipality.  Large quantities of floating fats and
grease from dairy effluents could, however, adhere or cling to sewer
lines and in some cases, clog sewerage systems.

-------
                        GRAIN MILLING INDUSTRY
                 (96, 97, 98, 99, 100, 101, 102, 103)
                              [Part 406]
SUBCATEGORIZATION OF THE INDUSTRY

The Grain Milling Industry is divided into 10 Subcategories.  Six Sub-
categories are devoted to!grain processing including corn, wheat and
rice.  The remaining four;subcategories cover the production of animal
feeds, breakfast cereals,.and wheat starch.  These subcategories are
described in further detail  below.

     A - Corn Wet Milling!

     B - Corn Dry Milling:
     C - Normal Wheat Flour Milling

     D - Bulgur Wheat Flour Milling
     E - Normal Rice Milling
     F - Parboiled Rice Processing

     G - Animal Feeds

     H - Hot (Breakfast) Cereals

     I - Ready-to-eat (Breakfast) Cereals
     J - Wheat Starch and .Gluten

Subcategory A, Corn Wet Milling.  Processing includes the dry cleaning
of the shelled corn, followed by softening of the kernels in the steep-
ing operations, followed by wet milling.   The latter serves to separate
the germ, starch, gluten and hulls.  Further wet processing can;be used
to produce corn oil, regular modified starches, corn syrup, dextrose
and animal feed.

Subcategory B. Corn Dry Milling.  Differs substantially from corn wet
milling.  After the corn is washed, only dry processing is used ;to pro-
duce corn meal, grits, flour, oil and animal feed.

Subcategory C, Normal Wheat Flour Milling.  Preparation of wheat into
ground:flour or granular product is fundamentally a dry milling process,
which distinguishes it from the production of bulgar flour.  After clean-
ing with water or air, moisture is added in a tempering process with no
water discharged, followed  by dry milling.  Dry milling in this case
separates the germ and bran from the flour.

-------
Subcategory D, Bui gar Wheat Flour Milling.  Differs from normal wheat
flour milling in that the wheat is parboiled, and then dried before
milling.

Subcategory E, Normal Rice Milling.   In contrast to corn and wheat,  the
product of rice processing is the whole grain rather than the flour  or
meal.  Rough rice is cleaned and then milled to remove hulls, bran and
germ.  The latter may be sold separately or combined into animal mill
feed.  The polished rice is eventually enriched with vitamins and min-
erals before packaging.

Subcategory F, Parboiled Rice Processing.  Parboiling differs from normal
rice processing only in the soaking and cooking operations known as  par-
boiling.

Subcategory G, Animal Feeds.  Animal  feeds (formula feed concentrate)
are manufactured primarily using grain and grain by-products, which  may
be supplemented by proteins, Pharmaceuticals, vitamins or mineral
additives.

Subcategory H, Hot Cereals.  The production of various breakfast cereals
from grains, principally wheat and oats, and requiring cooking prior to
normal human consumption.

Subcategory I. Ready-To-Eat Cereal.  The processing of various grains
and other materials (whole grain wheat, rice, corn grits, oat flour,
sugar and minor ingredients) to produce various breakfast cereals nor-
mally available for human consumption without cooking.

Subcategory J, Wheat Starch and Gluten.  Wheat flour is used as a raw
material for production of wheat starch and gluten (protein) components
through conventional processes of physical separation and subsequent
refinement.
NATURE OF PROBLEM

The industry incorporates the three main grains of corn, wheat and rice.
Finished products from the milling of the different grains are quite
distinct.  Corn milling products range from corn meal and grits to starch
and syrup.  Wheat milling principally produces flour for baking and
other purposes, and the specialty product of bulgar wheat.  Rice milling
yields ordinary and parboiled rice for human consumption.

The animal feed, breakfast cereal, and wheat starch industries all uti-
lize products from basic grain processing mills for raw materials.
Grain and grain milling by-products are the chief ingredients in animal
feed.  The manufacture of breakfast cereals utilize both milled and whole

-------
grain, particularly corn, wheat, oats and rice.  Wheat starch manufac-
turing employs wheat flour as its raw material.  Of all cereal grain
produced  in the U.S., only about 15% is used as food for human consump-
tion.  The vast majority of the grain harvested is used to feed poultry
and livestock.  "Complete feeds" have been replaced by "feed concen-
trates."  The farmer mixes his own grain with the feed concentrates.
Also, many manufacturers of drugs and feed ingredients have developed
combinations of drugs and vitamins known as "premixes" to which protein
and grain are added.

Corn wet  milling uses more water and generates more waste water than
any other grain milling process.  Major waste streams include:  con-
densates  from steep water evaporation, cooling water from once-through
barometric condensers, waste water from modified starch production,
and waste water from activated carbon and ion exchange units and evapor-
ation of  syrup in the syrup refining operations.  Raw waste waters from
wet corn  milling plants may range from 1 to 30 MGD.  The BODg of these
wastes averages 415 lbs/1,000 Standard Bushels.  The term Standard
Bushel means a bushel of shelled corn weighing 56 Ibs.

A large percentage of grain mills discharge to POTW's.  Regarding
starch and gluten mills in particular, these effluents may require
.special pretreatment in order to reduce waste strength prior to entering
the municipal system.
 PARAMETERS OF  IMPORTANCE

               BOD                 TDS

               COD                 Phosphorous
               TSS                 Total Nitrogen

               pH                  Temperature


 PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED
 TREATMENT MEASURES

 Except for excessive  peak discharges of Corn Wet Milling wastes into
 POTW's, which  may need to be closely controlled, the Federal Regulations
 and accompanying EPA  Development Documents for Grain Mills describe
 these wastes as compatible with POTW's. Np_ pretreatment limitations
 have been placed upon Existing mills within Subcategories A through F,
 and both Existing and New mills within Subcategories G through J.
 Pretreatment limitations for New Sources within Subcategories A through
 F are not completely  defined.  However, they would likely approximate

-------
limitations given for Existing Sources in these same Subcategories,
which means the absence of any limitations.  The one possible exception
is given as follows.

For Subcategory A, Corn Wet Milling.   New Sources, redefined in response
to the Federal Court remand of May 5, 1975.

     "Process waste water shall not be discharged to a POTW at a flow
     rate or pollutant mass laoding rate which is excessive over any
     time period during the peak load at a POTW.  Excessive (peak)
     discharges are defined as those  in which the flow of BODr or TSS
     exceed the respective values of  P from the following formula,
     which is based upon dry weather  conditions:

                         P = K (Q + R) - S
     Where:

     P = Maximum allowable Peak waste load for the New Corn Wet Milling
         Source to be discharged to the POTW (gallons per hour for  flow,
         and Ibs per day for BODr and TSS)
     Q = Average existing waste load  to POTW
     R = Average waste load for the New Corn Wet Milling Source to  be
         discharged to the POTW
     S = Existing peak load of POTW
     K = 2, except when ratio of S/Q  >1.5 in which case K = 3

-------
          CANNED AND PRESERVED FRUITS AND VEGETABLES INDUSTRY
                     (10, 30, 132, 133,  134,  135)
                              [Part  407]

SUBCATEGORIZATION OF THE INDUSTRY

The industry has been divided into eight subcategories  but  some  of  the
subcategories comprise a great number of commodities as described below:

     A - Apple Juice
   .  B - Apple Products
     C - Citrus Products
     D - Frozen Potato Products
     E - Dehydrated Potato Products
     F - Canned and Preserved Fruits, in turn including:

          Apricots            Grape  Juice-Canning       Pineapple
          Caneberries         Grape  Juice-Pressing      Plums
          Cherries-Sweet      Olives                   Raisins
          Cherries-Sour       Peaches                  Strawberries
          Cherries-Brined     Pears                     Tomatoes
          Cranberries         Pickles-Fresh Pack
          Dried Fruit         Pickles-Process Pack
                              Pickles-Salt Stations

     G -  Canned and Preserved Vegetables, in turn  including:

          Beets               Dehydrated Vegetables     Sauerkraut-Canning
          Broccoli            Dry Beans                 Sauerkraut-Cutting
          Carrots             Lima Beans               Snap Beans
          Corn-Canned         Mushrooms                 Spinach
          Corn-Frozen         Onions-Creamed            Squash
          Dehydrated Onion'    Peas                     Potatoes
               and Garlic

     H -  Canned and Miscellaneous Specialties,  in  turn including:

          Added Ingredients   Ethnic Foods
          Baby Food           Jams and Jellies
          Chips-Corn          Mayonnaise and  Dressings
          Chips-Potato        Soups
          Chips-Tortilla      Tomato-Starch-Cheese  Canned Specialties


NATURE OF PROBLEM

In 1971, 164 apple processing plants were identified and located among
28 States.  Citrus is the largest fruit  crop  in  the  U.S.  Some 97 citrus

-------
 10
plants were identified in 14 States, primarily Florida,  Californa,  Texas
and Arizona.  In 1972, there were 112 canned and frozen  potato processing
plants in 31 States.  Of all potatoes processed, frozen  french fries
account for 45 percent, dehydrated potatoes about 20 percent,  potato
chips 30 percent, and canned potatoes the remaining 5 percent.

Excluding apples, citrus and potatoes, the industry operated more than
2,000 plants in 1967.  Approximately 30 million tons of  fruits and
vegetables are processed annually.  It is estimated around 55  percent
of the processing plants discharge their liquid wastes to municipal
sewers, 33 percent have land disposal, and 12 percent discharge to
navigable waterways.

Although effluents from this industry are generally considered compatible
with well designed and operated biological POTW's, judgement must be
made as to the type and degree of pretreatment necessary to protect
the POTW.  Citrus wastes containing citrus oil may be biologically
treated but only with difficulty.  The oil also creates  sludges that
are difficult to dewater.  Fruit and vegetable wastes have the poten-
ial to adversely affect POTW's in many ways:

     Flow Volume:  The industry is frequently characterized by high volumes
     of waste discharged seasonally, also having high hourly fluctuation
     in flow.  Flow equalization may be necessary.  Installation of cool-
     ing towers may serve to reduce high-volume cooling  water  discharges.

     Organic Strength:  Wastes are oftentimes high in BOD but  are
     compatible to POTW's provided that the municipal system has
     sufficient capacity to handle the combined municipal and  industrial
     waste loads.  In troublesome cases, pretreatment may be necessary
     by the industrial plant to reduce organic loads.

     Oil and Grease:  Certain sectors of the industry discharge high
     concentrations of oil and grease.  Regulation may be required  to
     protect the collection system from stoppages and to safeguard  the
     treatment works.

     Dissolved Solids:  Appreciable concentration of chlorides and
     other inorganic solids may be experienced by the POTW receiving
     certain subcategory wastes.  These constituents will pass through
     the POTW and this condition may determine whether the municipality
     should accept the subject wastes.

-------
                                                                        11
PARAMETERS OF CONCERN

          pH, Acidity, Alkalinity       COD
          BOD                           Nitrogen, including Ammonia N
          TSS                           Phosphorous
          Oil/Grease                    IDS
          Fecal Coliforms               Temperature
          Chlorides                     Peticides

     pH:  Low pH levels can be experienced during slicing, grinding and
     macerating operations.  Wastewater from steam-peeled carrots and
     blanched prunes is acidic enough in some cases to require lime
     treatment before final release.  Conversely lye peeling waste may re-
     quire neutralization with acid prior to final discharge.

     IDS. Chlorides:  High chlorides in wastewaters from pickle,
     sauerkraut, olive and other brine processing plants may be of
     significance when biological treatment is utilized.  Although
     aerobic biological systems may possibly adapt to high chlorides,
     concentrations should be constrained to a fairly narrow range,
     either by in-plant control of brine wastes or by flow equaliza-
     tion.  Shock loads to the biological system, can substantially
     reduce treatment efficiency.

     Other Pollutants:  Agricultural chemicals and pesticides are
     found in wastewaters from fruit and vegetables processing plants
     primarily in the initial washings of raw commodities.  However,
     they should not constitute significant pollutants.


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

No specific limitations have been prescribed to date.


PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

No across-the-board unit operations are defined, although screening,
flow equalization, grease removal, and possible pH control, may be
implied for a number of fruit and vegetable processing plants.

Especially with citrus and potato wastewaters, three streams have been
found detrimental  to POTW's having secondary treatment including:
spent caustic solutions from peeling operations; d'limonene from citrus
peel processing operations; and oils from frying operations.  Adequate
control methods should be used to minimize effects of these particular wastes

-------
12
           CANNED AND PRESERVED SEAFOOD PROCESSING INDUSTRY
                        (30, 104, 105,  106,  107)
                                [Part 408]
SUBC'ATEGORIZATION OF THE INDUSTRY
The Canned and Preserved Seafood Industry has been divided into 33 Sub-
categories.  The various subcategories  cover processing of catfish,
crab, shrimp, tana, fish meal, salmon,  bottom fish, clam,  oyster,  sar-
dine, scallop, herring fillet and abalone commodities.   These 33 sub-
categories are tabulated and described  below.
     A - Farm-Raised Catfish
     B - Conventional Blue Crab Processing
     C - Mechanized Blue Crab Processing
     D - Non-Remote Alaskan Crab Meat  Processing
     E - Remote Alaskan Crab Meat Processing
     F - Non-Remote Alaskan Whole Crab  and Crab Section Processing
     G - Remote Alaskan Whole Crab and  Crab Section Processing
     H - Dungeness and Tanner Crab Processing in  the Continguous States
     I - Non-Remote Alaskan Shrimp Processing
     J - Remote Alaskan Shrimp Processing
     K - Northern Shrimp Processing in  the Continguous  States
     L - Southern Non-Breaded Shrimp Processing in the  Continguous States
     M - Breaded Shrimp Processing in  the Continguous States
     N - Tuna Processing
     0 - Fish Meal Processing
     P - Alaskan Hand-Butchered Salmon  Processing
     Q - Alaskan Mechanized Salmon Processing
     R - West Coast Hand-Butchered Salmon Processing
     S - West Coast Mechanized Salmon  Processing
     T - Alaskan Bottom Fish Processing
     U - Non-Alaskan Conventional Bottom Fish Processing
     V - Non-Alaskan Mechanized Bottom  Fish  Processing
     W - Hand-Shucked Clam Processing

-------
                                                                        13
     X - Mechanized Clam Processing

     Y - Pacific Coast Hand-Shucked Oyster Processing

     Z - Atlantic and Gulf Coast Hand-Shucked Oyster Processing

     AA - Steamed and Canned Oyster Processing

     AB - Sardine Processing

     AC - Alaskan Scallop Processing
     AD - Non-Alaskan Scallop Processing

     AE - Alaskan Herring Fillet Processing

     AF - Non-Alaskan Herring Fillet Processing
     AG - Abalone Processing

Subcategory A, Farm-Raised Catfish.  Applicable to facilities processing
more than 3,000 Ibs raw material/day on any day during the calendar
year, and all New sources.

Subcategory B, Conventional Blue Crab.  Manual picking or separation
of crab meat from the shell.  Applicable to facilities processing more
than 3,000 Ib raw material/day on any day during the calendar year, and
all New sources.

Subcategory C, Mechanized Blue Crab.  Processing of blue crab in which
mechanical picking or separation of crab meat from the shell  is utilized.

Subcategories D and E, Non-Remote and Remote Alaskan Crab Meat.  The pro-
cessing of dungeness, tanner and King crab meat both in Subcategories
D and E.  Non-remote refers to population or processing centers in
Alaska including but not limited to Anchorage, Cordova, Juneau,
Ketchikan, Kodiak and Petersburg.

Subcategories F and G, Non-Remote and Remote Alaskan Whole Crab Sections.
The processing of dungeness, tanner and King whole crab and crab sections
both in Subcategories F and G.

Subcategories I and J, Non-Remote and Remote Alaskan Shrimp Processing.
Self explanatory.

Subcategory K, Northern Shrimp Processing in Continguous States.
Applicable to the States of Washington, Oregon, California, Maine, New
Hampshire and Massachusetts and to plants processing more than 2,000 Ib
raw material/day on any day during a calendar year, and all New sources.

-------
 14
Subcategory L, Southern Non-breaded Shrimp Processing in Contlnguous
States.  Applicable to States of North and South Carolina, Georgia,
Florida, Alabama, Mississippi, Louisiana and Texas, and to plants
processing more than 2,000 Ib raw material/day on any day during a
calendar year, and all New sources.

Subcategory M, Breaded Shrimp Processing in Continguous States.  Appli-
cable to plants processing more than 2,000 Ib raw material/day on any
day during a calendar year, and all New sources.

Subcategory 0, Fish Meal Processing.  Processing of menhaden on the Gulf
and Atlantic coasts and processing of anchovy on the West Coast into
fish meal, oil, and solubles.

Subcategory U, Non-Alaskan Conventional Bottom Fish Processing.  Appli-
cable to processing of bottom fish outside of Alaska in which unit
operations are carried out predominately through manual methods.
However, the use of scaling machines and/or skinning machines are con-
sidered normal in this Subcategory.  Commercially.processed species of
bottom fish include flounder, ocean perch, haddock, cod, sea catfish,
sole, halibut and rockfish.  Subcategory U applies to plants proces-
sing more than 4,000 Ib raw material/day on any day during the calendar
year, and all New sources.

Subcategory V, Non-Alaskan Mechanized Bottom Fish Processing.  Refers
to processing of bottom fish such as whiting and croaker.

Subcategory W, Hand-Shucked Clam Processing.  Applies to plants proces-
sing more than 4,000 Ib raw material/day on any day during the calendar
year, and all New sources.

Subcategory Y, Pacific Coast Hand-Shucked Oyster Processing.  Applicable
to plants processing more than 1,000 Ib of product (oyster meat after
shucking)/day on any day during the calendar year, and all New sources.

Subcategory Z, and Gulf Coast Hand-Shucked Oyster Processing.  Same size
plant as defined for Subcategory Y.

Subcategory AA, Steamed and Canned Oyster Processing.  Applies to plants
processing mechanically shucked oysters.

Subcategory AB, Sardine Processing.  Applies to canning of sardines or
sea herring for sardines but the Subcategory does not cover the relatively
new steaking operations in which cutting machines are used for preparing
fish steaks.

Definitions of Subcategories not specifically cited above, are thought
to be self-explanatory.
self-

-------
                                                                          15
NATURE OF THE PROBLEM

Quantities of waste discharged from seafood processing plants can range
from 30 to 80% or more of the weight of raw material.  In many cases,
there is little or no pretreatment of seafood processing wastes, before
final discharge.  Generally, major waste sources in a seafood processing
plant include: receiving, pre-processing, evisceration, pre-cooling,
picking and cleaning, shucking, preserving, canning, freezing, plant
cleanup and byproduct operations.
PARAMETERS OF IMPORTANCE

          BOD

          COD

          Settleable Solids

          TSS

          Oil/Grease

          pH
TKN, Ammonia and Nitrate N

Phosphorous

Coliform Bacteria

Chlorides

Temperature
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED
TREATMENT MEASURES

No constituents in the waste discharges from seafood processing plants
have been found in the concentrations measured, to interfere with, pass
through, or otherwise be incompatible with well-designed and well-operated
biological POTW's.  It is however, suggested that these effluents  should
be passed through primary treatment in order to remove settleable  solids
and excessive oils and greases.  Sodium chloride levels may also be suf-
ficiently high to warrant dilution.

The Federal Regulations for Seafood Processing have determined that
Existing Sources within all 33 Subcategories be allowed entry into
municipal POTW's without pretreatment limitations.  Similar definition
is given for New Sources within Subcategories 0 through AG.  Pretreat-
ment for New Sources in Subcategories A through N appears to be the
same as for Existing Sources in these same Subcategories, which is
determined to be "None" although primary treatment is preferred.

-------
16
                         BEET SUGAR PROCESSING
                             (30, 59, 60)
                              [Part 409]

SUBCATEGORIZATION OF THE INDUSTRY

The Beet Sugar Processing Industry is defined as a single Subpart, i.e.
Subcategory A of the overall sugar processing industry.   However, this
Subcategory has been divided into different BPT and BAT effluent limi-
tations based upon the size of plant, availability of land for waste
disposal and other criteria.  Beet sugar processing plants convert raw
sugar beets into refined crystalline and liquid refined sugar.
NATURE OF THE PROBLEM

Fifty-three beet sugar processing factories were identified during the
EPA Guidelines study of the early 1970's.  Twelve of these plants were
reported to be achieving zero waste discharge.   Major waste streams
include flume water, lime mud slurry, diffuser water, cleaning wastes
and barometric condenser waters.  Only a few sugar beet mills are
connected to municipal sewers and waste treatment systems.
PARAMETERS OF CONCERN

          BOD                           COD
          TSS                           Total  and Fecal  Coliforms
          pH                            IDS
          Temperature                   Nitrogen, especially  Ammonia
                                        Phosphorous
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTVJ AND PRESCRIBED TREATMENT
MEASURES

The Federal Register documents appropriate to Existing and New sugar
beet mills have described resulting effluents as essentially compatible
to receiving POTW's.  No limitations have been given.   It has been
determined that pretreatment is not necessary and beet sugar process
wastes may thereupon be discharged directly to a POTW.

However it is noted in the 1960's, cases of municipal  plant failures or
at least significant deterioration were recorded when  relatively large
quantities of beet sugar wastes were received into the municipal
system.  The POTW must be both properly designed and operated to handle
large BOD and TSS loads from the sugar mill, especially heavy overloads.
Pretreatment would seem highly desirable when the sugar mill is large
in comparison to the municipal STP.

-------
                                                                        17
                          CANE SUGAR REFINING
                             (56, 57, 58)
                              [Part 409]

SUBCATEGORIZATION OF THE INDUSTRY

The Cane Sugar Refining segment of the overall sugar processing industry
is divided into two Subcategories as shown below:

     Subcategory B - Crystalline Cane Sugar Refining, converting
     raw cane sugar into crystalline refined sugar.

     Subcategory C - Liquid Cane Sugar Refining, converting raw
     cane sugar into liquid refined sugar.
NATURE OF THE PROBLEM
Twenty nine domestic sugar cane refineries were identified including
plants on the mainland United States, in Hawaii and Puerto Rico.   EPA
studies in the early 1970's indicated that three refineries at that
time were achieving zero discharge of pollutants to navigable waters
by means of land retention; two refineries were discharging all  process
wastes to municipal treatment systems; and 10 additional  refineries were
releasing all wastes except barometric condenser waters to municipal
systems.  The remaining 14 plants partially treat their waste waters.

Principal water streams from cane sugar refineries include barometric
condenser cooling waters, filter cake slurry, char wash water, floor
wash waters, carbon slurries, truck and car washes, and ion exchange
regeneration water.  The filter cake stream may be handled separately
in either a dry or slurry form.  Both the removal of solid materials
from the incoming raw cane sugar and the biological treatment of  sugar
cane refining wastes generate appreciable quantities of solid wastes
which must be disposed of at the plant site or to landfill.
PARAMETERS OF CONCERN
          BOD                           COD
          TSS                           Total  and Fecal  Coliforms
          pH                            IDS
          Temperature                   Nitrogen, especially Ammonia
                                        Phosphorous

-------
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
MEASURES

Regulations contained in the Federal  Register of March 20,  1974 have
described crystalline and liquid cane sugar refineries as discharging
compatible pollutants to POTW's.  It is cautioned, however  that the
filter cake slurry waste stream with its extremely high concentrations
of BOD and TSS could in some cases interfere with the operation of
publicly-owned treatment works.  These situations should be controlled
by the operator of the POTW.  If necessary, such highly-concentrated
wastes may be dry-handled and disposed of as solid waste.  Process
wastes from Subcategory B and C plants have been determined to  be
more or less amenable to treatment when directly released to a  POTW.

-------
                                                                          19
                       RAW CANE SUGAR PROCESSING
                               (54, 55)
                               [Part 409]

SUBCATEGORIZATION OF THE INDUSTRY

The raw cane sugar processing segment of the sugar processing industry
has been divided into five Subcategories as follows:

     Subcategory D - Louisiana raw cane plants which convert sugar
     cane into a raw cane sugar.

     Subcategory E - Florida and Texas raw cane sugar processing plants.

     Subcategory F - Hilo-Hamakua Coast raw cane plants on the Island
     of Hawaii.

     Subcategory G - Hawaiian raw cane plants not included in Sub-
     category F.

     Subcategory H - Puerto Rico raw cane plants.


NATURE OF THE PROBLEM

Raw sugar cane is grown in four states of the U. S.  including Florida,
Louisiana, Texas and Hawaii, and also in the Commonwealth of Puerto
Rico.  There were a total  of 70 to 75 raw sugar cane factories operating
in the above areas in 1973-1974.

Waste water streams from raw cane sugar processing factories include
barometric condenser waters, filter cake slurry, ash slurries, floor
washes, excess condensates, chemical cleaning and wash waters from
evaporators and vacuum pans, and cane wash waters.  Contact and non-
contact cooling waters represent additional waste streams together
with boiler blowdowns.  Pollutants which enter into  the effluent streams
comprise:  1) dissolved matter including sugar from  the washing of sugar
cane, entrainment of sugar into the vapors of the evaporators and
vacuum pans which are condensed into the barometric  waters, and spills
which are integrated into floor washings; 2) solid materials arising
from trash and extraneous matter brought into the factory with the raw
cane.  Solids enter into the cane wash water stream  during the washing
of the cane; into the filter cake slurry during clarification and
filtration of the juice; and into the ash slurry stream if bagasse is
burned and wet scrubbing is employed.

-------
20
PARAMETERS OF CONCERN
          BOD                           COD
          TSS                           Total and Fecal  Coliforms
          pH                            TDS
          Temperature                   Nitrogen, especially Ammonia
                                        Phosphorous
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTM AND PRESCRIBED TREATMENT
MEASURES

The EPA Development Document of February 1975 for the Raw Cane Sugar
Industry claims that effluents from cane sugar factories contain no
constituents that are known to be incompatible with a well-designed
and well-operated municipal waste water treatment plant, nor any
pollutants that would pass through a POTW.  In general,  however,
municipal treatment plants are not available to the raw  cane industry
because the latter are predominately located in highly rural areas.

Quantity of solids in the waste waters discharged by a cane sugar
factory could be substantial.  A judgment may be necessary as to the
amount of solids allowed to enter a municipal treatment  system.
Existing municipal load and total design capacity of the POTW must be
considered.  If it is determined that pretreatment for solids removal
is necessary, primary settling should be provided at the cane sugar
factory.

-------
                                                                          21
                        TEXTILES MANUFACTURING
                             (27, 28, 136)
                               [Part 410]

SUBCATEGORIZATION OF THE INDUSTRY

The textiles industry is divided into seven main subcategories described
below together with additional waste load allowances for simple and complex
manufacturing operations that may be applicable for certain plants in
Subcategories D, E, and F.  Further load allowances are given for "com-
mission finishing."  Commission finishing refers to the finishing of
textile materials, 50% or more of which are owned by others, in mills
that are 51% or more independent.  These mills must generally process
20% or more of their commissioned production through batch, non-con-
tinuous processing in contrast to the usual continuous processing.

          A -  Wool Scouring
          B -  Wool Finishing
          C -  Dry Processing, includes greige mills, coated fabrics,
               laminated fabrics, tire cord fabric felts, carpet
               tufting and carpet backing.
          D -  Woven Fabric Finishing
          E -  Knit Fabric Finishing
          F -  Carpet Mills
          G -  Stock and Yarn Dyeing and Finishing
NATURE OF PROBLEM

Of approximately 7,100 mills, knitting mills are the largest group num-
bering about 2,700, but there are also about 1,000 weaving mills of
various types, and over 1,000 plants which process miscellaneous textile
goods.  "Wet" process plants probably account for less than 700 mills in
the industry.

PARAMETERS OF CONCERN
          BOD                 TDS
          TSS                 Ammonia and total  nitrogen
          COD                 Phosphates
          Oil and grease      Color
          pH, acidity,        Temperature
            alkalinity        Heavy metals including
          Fecal  Coliforms       copper,  zinc,  mercury
          Chromium            Toxic organic chemicals
          Qnl-Firla             Dkian/O e-
Sulfide             Phenols

-------
 22
Color is found throughout the textile industry.   Some colors are water
soluble but others are not, such as those caused by dispersed dyes.   Bio-
degradability is variable.  Many hues are used in dyeing and these appear
in the wastewaters.  A common waste color is gray or black.

Chromium is widely used as an oxidant in the form of sodium  dichromate in
vat and sulfur dyes and as an oxidant for wool dyes.  Substitutes are
available but chromium is still  widely used.  Chromium is the most signi-
ficant heavy metal in the industry.  Others are employed selectively.

Other Heavy Metals include copper salts used in some dyeing  operations,
which can be harmful to biological  treatment systems.  Zinc  nitrate is
used as a catalyst for durable press goods.  Mercury may be  present
but generally in relatively small quantities.

Phenols are widely used as carriers in dyeing polyesters;>and:.blerids.
Some natural materials such as lignins removed in scouring and some dye
compositions may analyze as phenols.

Sulfides originate from sodium sulfide incorporated in one or more
types of dye, and from other sulfur-containing chemicals.

Toxic Organics may be present.  One such compound was Dieldrin,  a
moth proofing agent used in carpets but reported as no longer employed.
Some carriers, particularly the  chlorinated benzenes are considered
toxic, and should not be used in textile manufacturing.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW
The Federal Register, Part 410 specifies that Pretreatment Standards for
New Sources shall for incompatible pollutants be equivalent to the
standards of performance for New Sources (numerical  limits same as
BPT).  Additionally, Pretreatment for Existing Sources shall,  for in-
compatible pollutants, be equivalent to BPT limitations.

The Development Document of January 1974 for Textiles cites as follows
	"The constituents of the wastewater from plants within the textile
industry have been found which would interfere with, pass through, or
otherwise be incompatible with a well designed and operated publicly
owned activated sludge or trickling filter wastewater treatment plant.
Wastewater constituents include grease from wool scouring operations,
latex from carpet mills and heavy metals such as chromium used in dyes.
Adequate control  methods can and should be used to keep significant
quantities of these materials out of the wastewater.  Dye substitutes
are available for many dyes containing heavy metals."

-------
                                                                         23
Based upon the above, 40 CFR, Part 410 stipulates that COD, total
chromium, phenol, sulfide and oil and grease are waste pollutants  which
would interfere with the operation of POTW's, pass through such works
untreated or inadequately treated or otherwise be incompatible with such
treatment works.  After careful consideration, it was the opinion  of the
EPA for existing sources that pretreatment should reduce COD, total
chromium, phenol, sulfide and oil and grease to the levels required by
BPCTCA.

For Subcategory A, Existing and New Sources:
     Parameter
     Avg.  30 Days                Max.  Day
(lb/1,000 Ib product)1    (lb/1,000  Ib  product)1
Oil /Grease
Total Chromium
Phenol
Sulfide
COD
• 3.6
0.05
0.05
0.10
69.0
7.2
0.10
0.10
0.20
138.0
For Subcategory B, Existing and New Sources:
     Total Chromium
     Phenol
     Sulfide
     COD
        0.07
        0.07
        0.14
        81.5
0.14
0.14
0.28
163.0
For Subcategory C, Existing and New Sources:
     Parameter
      Avg.  30 Days                Max.  Day
(lb/1,000 Ib product)2    (lb/1,000  Ib  product)2
     COD
        1.4
2.8
For Subcategory D, Existing and New Sources:
     Total Chromium
     Phenol
     Sulfide
     COD
        0.05
        0.05
        0.10
        30.0
0.10
0.10
0.20
60.0
     But if "simple" manufacturing operations  are employed  (desizing,
     fiber preparation and dyeing), COD limitations  shall be  incrementally
1  Ibs.  product received into mill
2  Ibs.  final product

-------
 24
increased by 10 and 20 lb/1,000 Ib for 30 consecutive day and  max..day
conditions, and if "complex" manufacturing operations are employed
(simple operations plus printing, waterproofing or applying  stain
resistant or other fabric finishes), the above COD limitations shall  be
increased by 20 and 40 lb/1,000 Ib, respectively.


For Subcategory F, Existing and New Sources:

                            Avg. 30 Days               Max.  Day
     Parameter         (lb/1,000 Ib product)2  (lb/1,000 Ib  product)2

     Total Chromium           0.02                     0.04
     Phenol                   0.02                     0.04
     Sulfide                  0.04                     0.08
     COD ,                    35.1                     70.2

     But if "complex" manufacturing operations are employed  at the  carpet
     mill, COD limitations shall be increased by 10 and 20 lb/1,000 Ib
     for 30 consecutive day and max. day conditions respectively over
     the above COD levels.
For Subcategory G, Existing and New Sources:

     Total Chromium           0.06                     0.12
     Phenol                   0.06                     0.12
     Sulfide                  0.12                     0.24
     COD                      42.3                     84.6
PRESCRIBED TREATMENT FOR DISCHARGE TO POTW

No specific treatment practices have been cited,  although  pretreatment
for incompatibles for existing sources is "equivalent"  to  BPCTA, which
in turn generally consists of screening,  primary  treatment and  secondary
biological treatment.  In-plant controls  and  recovery would partially
substitute for treatment.   Pretreatment limitations  for New Sources on
incompatibles approximates that for Existing  Sources.
*Lbs final product.

-------
                                                                        25
                     CEMENT MANUFACTURING INDUSTRY
                             (77, 78, 79)
                               [Part  411]
SUBCATEGORIZATION OF THE INDUSTRY

The Cement Manufacturing Industry is divided into three Subcategories.
Two of the Subcategories involve manufacturing, and the third Subcate-
gory is for plant area runoff.  These are described below:

          A - Nonlcaching Subcategory
          B - Leaching Subcategory
          C - Materials Storage Piles Runoff Subcategory

     Subcategory A, Nonleaching Activities.   Process in which several
     mineral ingredients (limestone or other natural sources of calcium
     carbonate, silica, alumina, iron and gypsum) are used  in the
     manufacturing of cement.  Plants in this Subcategory do not contact
     kiln dust with water in the process, and water is not  used in wet
     scrubbers to control kiln stack emissions.

     Subcategory B, Leaching Activities.  Processes in which several
     mineral ingredients are used in the manufacture of cement.  Plants
     in this Subcategory contact kiln dust with water as an integral
     part of the process and/or water is used in wet scrubbers to con-
     trol kiln stack emissions.

     Subcategory B, Materials Storage Piles  Runoff.  Discharges result-
     ing from runoff over materials storage piles.   Stored  materials
     include raw products, intermediate products, finished  products and
     waste materials associated with the manufacture of cement under
     either Subcategory A or B.
NATURE OF THE PROBLEM

The cement manufacturing industry produces various types  of Portland
cement to meet given specifications.   In the early 1970's,  there were  51
companies with 166 cement plants in operation in the U.S. and  Puerto
Rico.  Cement is manufactured by the continuous  process,  normally
interrupted only to reline the kilns.   Three major steps  in the produc-
tion process include:  1)  the grinding and blending of raw materials;
2)  clinker production; and 3) finish  grinding.

Normal ingredients for cement include  lime (calcium oxide), silica,
alumina, and iron.  Lime is usually the largest  single  ingredient.

-------
26
 Materials such as sand,  clay,  shale,  iron  ore  and  blast  furnace  slag
 are subsequently added.   At "wet"  cement plants, materials  are ground
 with water and fed to the kiln in  a  slurry.  At  "dry"  cement  plants,
 raw materials are dried, ground, and  fed to  the  kiln  in  a dry state.
 The ground raw materials fed to the  kiln are heated to around 1600°C
 to form "clinker."  The  clinker along with added gypsum  are ground  to
 a fine powder representing the final  product ready for shipment  or  use.
 Dust collection is achieved by means  of  cyclones,  electrostatic  preci-
 pitators, bag filters and/or wet scrubbers.
 PARAMETERS OF CONCERN

           pH, alkalinity                Turbidity
           TSS                           Aluminum
           TDS                           Iron
           Potassium                     Calcium
           Sulfate                       Magnesium
           Temperature                   Sodium
                                         Chlorides
 PRELIMINARY LIMITATIONS  FOR DISCHARGE  TO  POTW AND  PRESCRIBED TREATMENT
 MEASURES'

 The Development Document of August  1973 indicates  in  general that POTW's
 are not available to cement plants  due to a  lack of sewerage facilities.
 If municipal  connection  is  possible, the  major  troublesome  pollutant
 would most likely be high TDS  in  the waste waters.  It may  be necessary
 to determine the maximum allowable  load of dissolved  solids to a particular
 POTW.

 The Federal  Register of  February  20, 1974 indicates existing cement
 manufacturing plants do  not require specific pretreatment,  nor removal
 of particular pollutants before entering  a POTW.

-------
                                                                             27
                           FEEDLOTS INDUSTRY
                               (52, 53)
                              [Part 412]

SUBCATEGORIZATION OF THE INDUSTRY

The Feedlots Industry is divided into two main subcategories, as
described below:

     Subcategory A. All Feedlots Except Ducks. This subpart applies to
     the following types of feedlots:   beef cattle-open lots; beef
     cattle-housed lots; dairy cattle-stall barn (with milk room);
     dairy-free stall barn (with milking center); dairy cowyards (with
     milking center); swine-open dirt or pasture lots; swine-housed,
     slotted floor; swine-solid concrete floor, open or housed lot;
     sheep-open lots; sheep-housed lots; horses-stables (race tracks);
     chickens-broilers housed; chickens-layers (egg production),
     housed; chickens-layer breeding or replacement stock, housed;
     turkeys-open lots; turkeys-housed.  Furthermore, limitations shall
     apply only to feedlot operations  equal to or larger than the
     capacities presented below:

          1,000 slaughter steers  and heifers; 700 mature dairy
          cattle; 2,500 swine weighing over 55 pounds; 10,000
          sheep; 55,000 turkeys;  100,000 laying hens or broilers
          when facility has unlimited  continuous flow watering
          systems; 30,000 laying  hens  or broilers when facility
          has liquid manure handling system;  500 horses; and
          1,000 animal  units  from a combination of slaughter
          steers and heifers, mature dairy cattle,  swine over
          55 pounds and sheep.

     Subcategory B, Ducks.  This  subpart applies to duck feedlots
     equal  to or larger than  5,000 ducks and  covers both dry lot
     and wet lot operations.

     Excluded from these limitations guidelines are facilities used to
      aise pets, small  game and wild game.
PARAMETERS OF CONCERN

          BOD                           Total  Solids
          TSS                           Color
          pH                            Turbidity
          TDS                           Odor
          Temperature                   Nitrogen, especially  Ammonia  N
          Fecal  Coliforms               Phosphorous

-------
  28
 PRELIMINARY  LIMITATIONS  FOR DISCHARGE  TO  PQTVI AND  PRESCRIBED TREATMENT
 MEASURES

 The Federal  Register of  February  14, 1974 describes  Subcategory A feed-
 lots as generating  waste materials  characterized by  solids, organic
 materials, andnutrients.  In rare cases these feedlots may have a storm
 water discharge or  overflows from a livestock watering system to a
 POTW.  Such  effluents could contain high  concentrations of pollutants
,in runoff.   Watering system releases would have low  waste concentra-
 tions.   Suitable capacity can be  provided in the municipal treatment
 works to satisfactorily  handle intermittent, concentrated storm dis-
 charges or continuous, low concentration  livestock drinking water
 overflows.

 Wastes  from  Subcategory  B establishments  also contain considerable
 solids, organic materials and nutrients.   However, the concentration
 of these pollutants is generally  low and  the discharge considerably
 diluted.

      It has  been determined that  wastes from Subcategory A and B feed-
 lots are amenable to treatment in POTW's  and may be  discharged to such
 works without need  for pretreatment.   Consequently np_ pretreatment
 limitations  have been developed for this  industry.

-------
                                                                         29
              ELECTROPLATING AND METAL FINISHING INDUSTRY
                         (18, 19, 20, 21, 129)
                               [Part 413]

SUBCATEGORIZATION OF THE INDUSTRY

The Electroplating and Metal Finishing Industry consists of six subcate-
gories.  Subcategories A, B, C include plants having essentially
electroplating operations in contrast to Subcategories D, E, F plants
conducting metal finishing operations.

     A)   Electroplating of Common Metals Subcategory.  Electroplating
     of ferrous, non-ferrous and plastic base materials by copper,
     nickel, chromium, zinc, cadmium, tin, lead, aluminum and iron.

     B) '  Electroplating of Precious Metals Subcategory.  Electroplating
     of ferrous or non-ferrous base materials by gold, silver, indiums
     palladium, platinum, rhodium, ruthenium.

     C)   Electroplating of Specialty Metals Subcategory (Reserved).
     Intended to apply to electroplating by beryllium, magnesium,
     calcium, tellurium, rhenium, cobalt and mercury.

     D)   Amodizing Subcategory.  A protective film is deposited onto
     ferrous or non-ferrous objects, usually aluminum, the latter
     acting as an anode.

     E)   Coatings Subcategory.  A protective coating is applied to
     ferrous or non-ferrous objects by chromating, phosphating or
     immersion plating.

     F)   Chemical Etching and Milling Subcategory.  Ferrous or non-
     ferrous materials receive etching or chemical milling, and in  this
     process some portion of the base material is dissolved or removed.
NATURE OF PROBLEM

Metallic coatings are applied to surfaces by electrodeposition by both
independent (job) platers and captive operations associated with  product
fabrication and assembly.  Approximately 20,000 Companies are engaged
in metal finishing.  Approximately 3,500 of these shops provide only
plating services.  (Subcategories A, B,  C).

An electroplating process includes cleaning, electroplating, rinsing,
and drying.  Cleaning generally consists of two or more steps required
for removing grease, oil, soil and oxide films from the base metal  surface

-------
 30
and providing good electroplate adhesion.  Cleaning will usually involve
a minimum of alkaline solution treatment followed by acid solution treat-
ment, and then rinsing.  In electroplating, metal ions in either acid,
alkaline or neutral solutions are reduced onto cathode surfaces, which
are the work pieces being plated.  Hundreds of different electroplating
solutions have been developed commercially, but only two or three types
are utilized widely for copper, zinc and cadmium.  Cyanide solutions are
common for copper, zinc and cadmium.  However non-cyanide alkaline solu-
tions containing pyrophosphate or other chelating agents have been
developed for zinc and copper.  Acid sulfate solutions are also used
for zinc, copper and a number of other metals.  Rack plating is utilized
for perhaps 90% of the surface area processed commercially.

Metal Finishing Operations (Subcategortes D, E, F) are conducted by both
independent (job) platers and captive operations associated with product
metal finishing;.  Of the 15,000 to 20,000 companies involved in metal
finishing, about 1,000 of these conduct processes covered by regulations
for Subcategories D, E, and F.
PARAMETERS OF CONCERN

For Subcategp.ry A, Electroplating With Common Metals.:

          Coipper                             Tin
          Nickel                             Iron
          Chromium, hexavalent and total     IDS
          Zinc                               COD
          Cyanide, amenable to chlorine      BOD
            oxidation                        Oil/Grease
          Cyanide, total                     Turbidity
          TSS                                CosTor
          pH, acidity, alkalinity            Temperature
          F T u o n d'e                           A1 um.t n urn
          Phosphate                          Nitrate and: Ammonia N
          Cadmium
          Lead

For Subcategory B,. Electroplating. With Precious Metals:

          Silver                             Paladium
          Gold                               Platinum
          Indium                             Rhodium
          Osmium                             Ruthenium'

-------
                                                                         31
Subcategories C through F.   Parameters same as above.


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

I).  For Subcategory A, Electroplating With Common Metals,  the limita-
tions for Existing Sources  are more or less the same as  BPT;  and  for
New Sources, they are equivalent to BAT.

     a)  For Existing Sources -

                              Avq.  30 DayMax. Day
     Parameter             (mg/nr/operation)       (mg/m2/operation)
Copper
Nickel
Chromium, total
Chromium, hexavalent
Zinc
Cyanide, total
Cyanide, amenable to
oxidation
Fluoride
Cadmium
Lead
Iron
Tin
Phosphorous
TSS
PH
80
80
80
8
80
80

8
3200
48
80
160
160
160
3200
6.0 to 9.5
160
160
160
16
160
160

16
6400
96
160
320
320
320
6400

     b)    But for Small  Existing  Sources,  defined as  having  less than
     11  employees with a discharge  less  than  2,061 gals/hour, and a
     production rate less than  4.9  m2/hr/employee, the following limi-
     tations shall  apply in  lieu  of the  above limitations  -

     Cyanide, amenable
          to oxidation             8                        16
     Cyanide, total                 80                        160
     pH                                  6.0 to 9.0

     c)    Definitions for Existing  and New Sources -

               The term  "m2", shall  mean the  area acted upon by the
               coating process  expressed in square meters.

               The  term,  "operation," shall mean any  step  in the coating
               process which is followed by a rinse,  and in which a
               protective film  is deposited on the basic material.

-------
32
    Additional definitions of "Operation," for Existing and New Sources
    are as follows:

          .   • The post plating steps of chromating, if followed by a
              rinse, phosphating and coloring, may be included under
              the term "operation" for the purpose of calculating
              effluent discharges, provided that such steps are an
              integral part of the plating line.

              Stripping, where followed by a rinse and conducted in
              conjunction with electroplating for the purpose of
              salvaging improperly plated parts, may be included
              under the term "operation" for the purpose of calculat-
              ing effluent discharges.

              Electroless plating on non-metallic materials for the
              purpose of providing a conductive surface on the base
              material, preceding the actual electroplating step,
              forming an integral step in the plating line and followed
              by a rinse may be included under the term "operation"
              for the purpose of calculating effluent discharges.

    d)   For New Sources -

                                 Avg. 30 DayMax. Day
    Parameter                   (mg/m2/operation)        (mg/m2 operation)

    Copper                        40                       80
    Nickel                        40                       80
    Chromium, total               40                       80
    Chromium, hexavent            4                        8
    Zinc                          40                       80
    Cyanide, total                40                       80
    Cyanide, amenable
      to oxidation                4                        8
    Fluoride                      1,600                    3,200
    Cadmium                       24                       48
    Lead                          40                       80
    Iron                          80                       160
    Tin                           80                       160
    Phosphorous                   80                       160
    TSS                           1,600                    3,200
    pH                                   6.0 to 9.5

-------
                                                                          33
II).  For Subcategory B, Electroplating  With  Precious  Metals,  the
limitations for Existing Sources are more or  less  the  same  as  BPT;  and
for New Sources, they are equivalent to  BAT.

     a)   'For Existing Sources -

                                  Avg. 30 DayMax. Day
     Parameter    .             (mg/nr/operation)        (mg/m2/operation)
Silver
Gold
Cyanide, amenable
to oxidation
Cyanide, total
Chromium, total
Chromium, hexavalent
Iridium
Osm'ium
Palladium
Platinum
Rhodium
Ruthenium
Phosphorous
TSS
PH
8
8

8
80
80
8
8
8
8
8
8
8
160
3,200
6.0 to 9.5
16
16

16
160
160
16
16
16
16
16
16
16
320
6,400

     b)    Additional  definitions  of  "Operation" for Existing and New
     Sources are as  follows:

               Stripping  (see  definition under Subcategory A).

               Electroless  plating (see definition under Subcategory A)

     c)    For New Sources -

     Silver                       4                        8
     Gold                          4                        8
     Cyanide, amenable
          to oxidation             4                        8
     Cyanide, total                40                       80
     Chromium,  total               40                       80
     Chromium,  haxavalent          4                        8
     Iridium                      4                        8
     Osmium                       4                        8
     Palladium                     4                        8.
     Platinum                     4                        8

-------
 34
     Rhodium                       4                        8
     Ruthenium                     4                        8
     Phosphorous                   80                       160
     TSS                           1,600                    3,200
     pH                                      6.0 to  9.5
III).  For Subcategory D,  Anodizing,  the limitations  for  Existing
Sources are more or less the same as  BPT;  and  for  New Sources,  they
are equivalent to BAT.

     a)   For Existing Sources -


                                   Avq.  30 DayMax. Day
     Parameter                  (mg/m2operation)        (mg/m2/operation)


     Copper                        45                      90
     Nickel                        45                      90
     Chromium, total                45                      90
     Chromium, haxavalent           4.5                      9
     Zinc                          45                      90
     Cyanide, total                45                      90
     Cyanide, amenable
          to oxidation             4.5                      9
     Fluoride                      1,800                   3,600
     Cadmium                       27                      54
     Iron                          90                      180
     Tin                           90                      180
     Phosphorous                   90                      180
     TSS                           1,800                   3,600
     pH                                     6.0 to 9.5

     b)   But for Small  Existing Sources,  defined  as  having less than
     11 employees with a discharge less  than 2,061 gals/hour, and a
     production rate  less  than 4.9 m2/hr/employee, the following limi-
     tations shall  apply in  lieu of the  above  limitations  -

     Cyanide, amenable
          to oxidation             4.5                      9
     Cyanide, total                45                      90
     pH                                     6.0 to 9.0

     c)   Additional  definitions of Operations for Existing and New
     Sources are as follows:

-------
                                                                         35
               Post plating steps (see definition under Subcategory A)

               Stripping (see definition under Subcategory A).

               Electroless plating (see definition under Subcategory A).

     d)   For New Sources -

                                   Avg. 30 DayMax.  Day
     Parameter                 (mg/m2/operation)        (rng/m2/operation)

     Copper                        23                       45
     Nickel                        23                       45
     Chromium, total        '      23                       45
     Chromium, hexavalent          2.3                      4.5
     Zinc                          23                       45
     Cyanide, total                 23                       45
     Cyanide, amenable to
          oxidation                 2.3                      45.
     Fluoride                      900                      1,800
     Cadmium                       14                       27
     Iron                          45                       90
     Tin                           45                       90
     Phosphorous                   45       •                90
     TSS                           900                      1,800
     pH                                      6.0  to  9.5
IV). For Subcategory E, Coatings,  the limitations  for  Existing  Sources
are more or less the same as BPT;  and for New Sources,  they  are equiva-
lent to BAT.

     a)   For Existing Sources -

     Copper                        40                       80
     Nickel                        40                       80
     Chromium, total               40                       80
     Chromium, hexavalent          4                         8
     Zinc                          40                       80
     Cyanide, total                 40                       80
     Cyanide, amenable to
          oxidation                 4                         8
     Fluoride                      1,800                     3,600
     Cadmium                       24                       48
     Iron                          80                       160
     Tin                           80                       160
     Phosphorous                   80                       160
     TSS                           1,800                     3,600
     pH                                      6.0 to 9.5

-------
 36
     b)   But for Small  Existing Sources,  defined as having  less  than
     11 employees with a discharge less than 2,061  gals/hour,  and a
     production rate less than 4.9 m2/hr/employee,  the following  limi-
     tations shall apply in lieu of the above limitations  -

                                   Avg. 30 Day:Max.  Day
     Parameter                  (mg/rrr/aperation)      (mg/m2/operation)


     Cyanide, amenable
          to oxidation             4                        8
     Cyanide, total                 40                       80
     pH                                      6.0 to 9.0

     c)   Additional definitions of "Operation"  for Existing and  New
     Sources are as follows:

               Post plating steps (see definition under Subcategory A).

               Stripping (see definition under Subcategory A).

               Electroless plating (see definition  under Subcategory A).

     d)   For New Sources -

     Copper                        20                       40
     Nickel                        20                       40
     Chromium, total               20                       40
     Chromium, hexavalent          2                        4
     Zinc                          20                       40
     Cyanide, total                 20                       40
     Cyanide, amenable to
          oxidation                2                        4
     Fluoride                      900                      1,800
     Cadmium                       12                       24
     Iron                          40                       80
     Tin                           40                       80
     Phosphorous                   40                       80
     TSS                           900                      1,800
     pH                                      6.0 to 9.5
V).  For Subcategory F, Chemical  Etching and Milling,  the limitations
for Existing Sources are more or  less the same as BPT;  and for New
Sources they are equivalent to BAT.

-------
                                                                    37
a)   For Existing Sources -
                         Avg. 30 Day              Max. Day
Parameter              (mg/m2/operation)      (mg/m2/operation)
Copper                        60                       120
Nickel                        60                       120
Chromium, total               60                       120
Chromium, hexavalent          6                        12
Zinc                          60                       120
Cyanide, total                60                       120
Cyanide, amenable
     to oxidation             9                        18
Fluoride                      2,400                    4,800
Cadmium                       36                       72
Iron                          120                      240
Tin                           120                      240
Phosphorous                   120                      240
TSS                           2,400                    4.800
pH                                      6.0 to 9.5
b)   But for Small Existing Sources, defined as having less than
11 employees with a discharge less than 2,061  gals/hour,  and a
production rate less than 4.9 m2/hr/employee,  the following limi-
tations shall apply in lieu of the above limitations -

Cyanide, amenable
     to oxidation             4.5                      9
Cyanide, total                45                       90
pH                                      6.0 to 9.0

c)   Additional definitions of "Operation" for Existing and New
Sources are as follows:

          Post plating steps (see definition under Subcategory A)

          Stripping (see definition under Subcategory A).

          Electrolysis plating on non-metallic materials  for the
     purpose of providing a conductive surface on the base  mate-
     rial, preceeding the actual  electroplating step, forming an
     integral step in the plating line and followed by a  rinse
     may be included under the term "operation" for the purpose
     of calculating effluent discharges.

-------
  38
     d)   For New Sources -
                                  Avg. 30 Day              Max. Day
     Parameter	(mg/mVoperation)	(mg/m2/operation)

     Copper                        30                       60
     Nickel                        30                       60
     Chromium, total               30                       60
     Chromium, hexavalent          3                        6
     Zinc                          30                       60
     Cyanide, total                30                       60
     Cyanide, amenable
          to chlorination          5                        9
     Fluoride                      1,200                    2,400
     Cadmium                       18                       36
     Iron                          60                       120
     Tin                           60                       120
     Phosphorous                   60                       120
     TSS                           1,200                    2,400
     pH                                      6.0 to 9.5
PRESCRIBED TREATMENT FOR DISCHARGE TO POTW

BPT and Pretreatment for Existing Sources emphasize both end-of-line
chemical waste treatment and in-process controls.   Chemical  treatment
includes segregation of the acid and alkali  waste  streams,  the chromium
stream, and the cyanide stream; cyanide destruction by oxidation;  reduc-
tion of haxavalent chromium to the trivalent form; neutralization; and
co-precipitation of metals as hydroxides or  hydrated oxides  together
with settling to remove TSS prior to final discharge.   In plant controls
include reduction of dragout of concentrated solutions, use  of reclaim
tanks, still rinses, overall water conservation, and other feasible
recovery techniques.

BAT and Pretreatment for New Sources emphasize end-of-line chemical
waste treatment coupled with Best in-process controls, especially  to
conserve rinse waters.
SUSPENSION AND REVOCATION OF ELECTROPLATING EFFLUENT REGULATIONS AND
GUIDELINES

On December 3, 1976, the Federal  Register announced that certain effluent
guidelines and standards for the  Electroplating and Metal  Finishing
Industry previously published on  March 28, 1974 and April  24,  1975,
merited reconsideration.  Thereby, certain sections of 40 CFR  Part
413 were temporarily suspended or revoked.  It appears most if not
all of the pretreatment limitations may be in suspended status pending
promulgation of new pretreatment  regulations expected around mid-1977.

-------
                                                                        39
                ORGANIC CHEMICALS MANUFACTURING INDUSTRY
                        (61, 62, 63, 64, 65 66)
                               [Part 414]

SUBCATEGORIZATION OF THE INDUSTRY

The Organic Chemicals Manufacturing Industry has been divided into four
main Subcategories described below as containing a total of 67 product/
process segments.  Each of these Subcategories contains Phase I and
Phase II organic chemicals, the compounds varying considerably in
pollution consequence.

Subcategory A - Nonaqueous processes.

Subcategory B - Processes with process water contact only as steam
                diluent quench or vent gas absorbent.

Subcategory C - Aqueous liquid phase reaction systems.

Subcategory D - Batch and semicontinuous processes.


Subcategory A, Nonaqueous Processes.  These processes have minimum con-
tact between water and reactants or products.  Water is not required as
a reactant or diluent, and is not formed as a reaction  product.

Subcategory A, Phase I, Major Products and Processes:

             Product	Process	

          Cyclohexane              Hydrogenation of  benzene

          Vinyl Chloride           Addition of hydrochloric acid
                                     to acetylene

          BTX Aromatics            Hydrotreatment of pyrolysis gasoline

          BTX Aromatics            Solvent extraction from reformate

Subcategory A, Phase II, Major Products and Processes:

          BTX                      Fractional distillation

          Cumene                   Alkylation of benzene with propylene

          p-xylene                 Isomerization, crystallization and
                                     filtration of mixed xylenes

-------
 40
Subcategory B, Processes with Process Mater Contact as Steam Diluent
or Absorbent.  Process water usage is in the form of dilution steam,
direct contact quench, or as an absorbent for reactor effluent gases.
Reactions are all vapor phase and carried out over solid catalysts.
Most processes have an absorber coupled with steam stripping of chemi-
cals for purification and recycle.
Subcategory B, Phase I, Major Products and Processes.
                 Product                     Process
          Ethylene and Propylene

          Butadiene
          Butadiene
          Butadiene
          Methanol
          Acetone
          Acetaldehyde
          Vinyl Acetate
          Acetylene
          Ethylene Oxide
          Formaldehyde
          Ethylene Dichloride
          Vinyl Chloride
          Styrene
          Methyl Amines
          Ethyl Benzene
Pyrolysis of naptha or liquid
  petroleum gas
Co-product of ethylene
Oxidative dehydrogenation of butylene
Dehydrogenation of n-butane
Steam reforming of natural gas
Dehydrogenation of isopropanol
Oxidation dehydrogenation of ethanol
Synthesis of ethylene and acetic atid
Partial oxidation of methane
Catalytic oxidation of ethylene
Oxidation of methanol
Direct chlorination of ethylene
Cracking of ethylene dichloride
Dehydrogenation of ethyl  benzene
Addition of ammonia to methanol
Alkylation of benzene with ethylene
For purposes of effluent limitations, Subcategory B, Phase I,  has been
further subdivided into two classes of products i.e., B 1, with lower
allowable waste loads, and B 2 products with higher allowable  waste
loads.  The B 1 products include Ethylene and Propylene; Butadiene
(as a co-product of ethylene); Acetone; Ethyl Benzene; Ethylene
Dichloride; Ethylene Oxide; Formaldehyde; Methanol; Methyl Amines;
Vinyl Acetate; and Vinyl Chloride.   The B 2 products include:   Acetalde-
hyde; Acetylene; Butadiene (by the dehydrogenation and oxidative -
dehydrogenation of butylene); and Styrene.

-------
                                                                         41
Subcategory B, Phase II, Major Products and Processes.
        	Product	Process	
         • Adiponitrile             Chlorination of butadiene
          Benzole Acid and         Catalytic oxidation of toluene
            Benzaldehyde             with air
          Chloromethanes           Chlorination of methyl chloride and
                                     methane mixture
          Diphenylamine            Deamination of aniline
          Hexamethylenediamine     Hydrogenation of adiponitrile
          Hexamethylenediamine     Ammonolysis of 1,6-hexanediol
          Maleic Anhydride         Oxidation of benzene with hydro-
                                     chloric acid
          Methyl Ethyl  Ketone      Dehydrogenation of sec-butyl  alcohol
          Phthalic Anhydride       Oxidation of o-xylene
Subcategory C, Aqueous Liquid Phase Reaction Systems.  These systems
comprise liquid phase reactions where the catalyst is generally in
aqueous media such as dissolved or emulsified mineral salt, or acid
and caustic solutions.   Continuous regeneration of catalyst systems
requires extensive water use.  Substantial  removal of spent inorganic
salt by-products may also be necessary.
Subcategory C, Phase I, Major Products and  Processes.
        	Product	Process	
          Phenol and Acetone       Cumene oxidation and cleavage
          Oxo Chemicals            Carbonylation and condensation
          Acetaldehyde             Oxidation of ethylene with air
                                     and/or oxygen
          Acetic Acid              Oxidation of acetaldehyde
          Methyl Methacrylate      Acetone  cyanohydrin process
          Ethylene Glycol          Hydration of ethylene oxide
          Acrylic Acid              Synthesis with carbon monoxide
                                     and acetylene
          Acrylates                Esterification of acrylic.acid
          Terephthalic  Acid (TPA)  Nitric acid oxidation of p-xylene
                                     (Catalytic)
          Terephthalic  Acid (TPA)  Catalytic oxidation of p-xylene

-------
 42
               Product
                  Process
     Polymer Grade TPA

     Dimethyl Terephthalate
     p-Cresol
     Aniline
     BisphenoT A
     Caprolactam
     Tetraethyl Lead

     Coal Tar Products
     Coal Tar Products
Purification of crude terephthalic
  acid
Esterification of terephthalic acid
Sulfonation of toluene
Hydrogenation of nitrobenzene
Condensation of phenol and acetone
Oxidation of cyclohexanone
Addition of ethyl  chloride to
  lead amalgam
Coal tar distillation
Pitch forming
For purposes of effluent limitations, Subcategory C, Phase I was further
subdivided into four classes of products, i.e., Cl  through C4, with in-
creasing allowable waste loads when progressing from C 1  through C 4.   The
C 1 products include Acetic Acid; Acrylic Acid; Coal Tar  Products (dis-
tillation); Ethylene Glycol; Terephthalic Acid (oxidation of p-xylene);
and Polymer Grade Terephthalic Acid.  The C 2 products include:
Acetaldehyde (oxidation of ethylene with oxygen); Caprolactam; Coal Tar
(pitch forming); Phenol and Acetone; and Oxo Chemicals.   The C 3 Products
include Acetaldehyde (oxidation of ethylene with air); Aniline; Bis-
phenol A; and Dimethyl  terephthalate.  The C 4 Products  include:
Acrylates; p-Cresol; Methyl Methacrylate; Terephthalic acid (nitric acid
process); and Tetraethyl lead.
Subcategory C, Phase II, Major Products and Processes.
               Product                          Process
          Ethyl acetate

          Acrylonitrile
          p-AminophenoT
          Calcium stearate
          Hydrazine solutions
          Isobutylene

          Isopropanol
          Sec-butyl alcohol
     Esterification of ethyl alcohol
       with acetic acid
     Ammoxidation of propylene
     Catalytic reduction of nitrobenzene
     Neutralization of stearic acid
     The Raschig process
     Extraction from a mixture of
       C 4 hydrocarbons
     Hydrolysis of propylene carbohydrates
     Sulfonation and hydrolysis of
       mixed butylenes

-------
                                                                         43
Subcategory D, Batch and Semi-Continuous Processes.  Processes are
carried out in reaction kettles equipped with agitators, scrapers,
reflux condensers, etc., depending upon the nature of the operation.
Many reactions are liquid phase with aqueous catalyst systems.  Re-
actants are transferred to batch reactors by gravity flow, pumping or
pressurization with air or inert gas.  Much of the material handling
is manual, and there is limited use of automatic process control.
Filter presses and centrifuges are commonly used to separate solid
products from liquid.  Where drying is required, air or vacuum ovens
are used.  Cleaning of noncontinuous production equipment constitutes
a major source of process waste water.

Subcategory D, Phase II, Major Products and Processes.

     	Product	Process	

     Citronellol and Gernaiol      Citronella oil  distillation

     lonone and Methylionone       Condensation and cyclization of citral
     Methyl Salicylate             Esterification  of salicylic acid with
                                     methanol
     o-Nitroaniline                Ammonolysis of  o-nitrochlorobenzene

     p-Nitroaniline                Ammonolysis of  p-nitrochlorobenzene
     Plasticizers                  Condensation of phthalic anhydride

     Tannic Acid                   Extraction of natural vegetable
                                     matter


NATURE OF PROBLEM

The Organic Chemicals Industry is a highly complex and integrated in-
dustry in which there are approximately 454 Companies and 665 plants
manufacturing several thousand products.  Synthetic organic chemicals
are derivative products of petroleum, natural gas  and coal, which have
undergone at least one chemical conversion.  The organic chemicals
industry was initially dependent upon coal as the  sole source of raw
materials.  However, over the last two decades the industry has moved
rapidly from coal to petroleum-based feedstocks.  In recognition of the
change in raw materials, the term "petrochemical"  has come into common
usage.  This term commonly refers to all organic chemical products
derived from petroleum fractions and byproducts, or materials derived  .
from natural gas constituents.

The organic chemicals manufacturing category consists of approximately
260 product commodities listed under SIC Code 2865 - Cyclic Inter-
mediates, Dyes, Organic Pigments and Coal Tar Crudes; and under SIC

-------
44
Code 2869 - Industrial  Organic Chemicals not elsewhere identified.
From this list, 40 major product/process segments were selected and
incorporated into Phase I.  The Phase I product/process segments re-
present approximately 75% of the production capacity in the organic
chemicals industry.  Subsequently, data were developed on 27 additional
product/process segments which became known as the Phase II Study.
Guideline limitations on other product/process segments will be de-
veloped in the future.

In the Phase II Organic Chemicals area, high concentrations of Cyanide
which could be inhibitory to biological systems were observed particu-
larly in the waste streams from the manufacture of hexamethylenediamine,
adiponitrile and acryonitrile.  Heavy metals in significant concentra-
tions were found in the waste streams from the following Phase II
product-process segments:

          Adiponitrile             Cu, Fe, Cr

          Chloromethanes           Fe, Cr

          Hexamethylenediamine     Zn

          Maleic Anhydride         Cd

          Hydrazine                Cd

          Plasticizers             Cu

These metals could interfere with biological treatment systems when
present in significant concentrations.
PARAMETERS OF CONCERN

          BOD                           Iron

          COD, TOC                      TDS

          TSS              '             Sulfate

          Oil/grease                    Sulfides

          Phenols                       Chlorides

          pH, acidity, alkalinity       Hardness

          Cyanide                       Phosphorous

          Ammonia N                     Calcium

          Total Kjeldahl N              Magnesium

          Heavy Metals including        Color
            Zinc, Copper, Lead,
            Chromium, Cadmium,          Chlorinated hydrocarbons
            Cobalt, Nickel,
            Vanadium                    Toxicity

-------
                                                                         45
 PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTM AND PRESCRIBED
 TREATMENT MEASURES

 The USEPA published regulations on Organic Chemicals Guidelines Limi-
 tations, especially those covering the Phase II chemicals describe
 effluents from these manufacturing plants as containing many hazardous
 substances over and above the organic byproducts specifically cited in
 the regulations.  As more data becomes available on the severity of risk
 resulting from exposure to the pollutants in organic plant chemical
.waste streams, additional substances and product lines will  be covered
 by effluent limitations guidelines.

 Cyanide and copper were considered to be among the more deleterious sub-
 stances referred to in the published Federal Register regulations of
 January 5, 1976.  Besides toxicity of individual pollutants, the waste
 streams from organic chemical  plants contain substances that create
 multiple stress on fish and other aquatic life.  These wastes also in-
 troduce combinations of metals and chemicals into raw water  supplies
 used for drinking water, the synergistic effects of which have received
 relatively little attention.  The hazards which attach to organic chemi-
 cal effluents are increased by the clustering of these plants on major
 rivers and waterways used as drinking water sources as well  as major
 recreational  areas.

 The prevelance of organic chemicals as products, byproducts, inter-
 mediate chemicals and raw materials in the nation's waters,  is con-
 sidered by many to be a significant threat to human health.   Certain
 organic chemicals, covered both by Phase I and II regulations, if
 present in significant quantity are acutely toxic to people  and to
 aquatic life, cause cancer in  test animals and man, bring about first-
 generation birth deformities,  or alter genetic patterns.   A  majority
 of these organic compounds are also listed in the DHEW's  Toxic Substances
 List of 1974.

 Many synthetic organic chemicals found in drinking water  supplies of the
 U.S.  have resulted in concern  that the organic problem may have in-
 itially been  grossly underestimated.   The House of Representatives
 Committee on  Interstate and Foreign Commerce recently declared that	
 "more than 12,000 chemical  compounds  are now being used commercially,
 not counting  additional  variants and  fractions.   About 500 new chemi-
 cals  are added each year.   Many of these will  find their  way into the
 Nation's drinking water supplies."

 EPA has conducted recent surveys of contamination of drinking  water by
 organic chemicals.   At least 187 organic compounds have been found
 present in one or more randomly selected water supplies.   Many of these
 compounds are suspect carcinogens.  This list  will  undoubtedly grow as
 work  continues in the analysis  of drinking water and  as analytical

-------
46
techniques are improved for the concentration, separation, identifi-
cation and measurement of organic compounds in drinking water.   With few
exceptions, all the organic compounds found in drinking water have
also been found in the effluents of organic chemical  plants under Phases
I and II regulations.  Many synthetic organics have their origin only
in the discharges of organic chemical plants.

Examples are given below of products incorporated into Phase II guide-
lines limitations which have troublesome public health implications:

Cumene, p-Xylene and Adiponitrile - contained  in DHEW Toxic Substances
List of 1974.
Benzoic Acid - also on the TSL, and besides having high acute toxicity,
causes skin effects.

Maleic Anhydride - cited as a carcinogen.

Phthalic Anhydride and Acrylonitrile - on  the  TSL; occupational exposure
standards have been established.

Hydrazine - causes neoplastic effects, i.e., growth of different or ab-
normal tissues or a tumor.

Isopropanol, Butyl Alcohol, Citronellol, lonone, Methyl Salicylate and
Nitroaniline - are all toxic and on the TSL.

Tannic Acid - has neoplastic properties.

The EPA Development Documents on Organic Chemicals published in December
1973 and November 1975 made a significant  distinction between manufac-
turing plants in Subcategories A and B vs. those in Subcategories C and
D.  The former group are considered likely to  contain appreciable am-
ounts of free and emulsified oils of petroleum origin in the waste-
waters, whereas wastes of the latter grouping  more probably will contain
significant quantities of heavy metals.  Fatty acid wastewaters from the
manufacture of products in Subcategory D may contain free and emulsified
oils primarily of animal and vegetable origin.

The manufacture of acrylonitrile (included in  Subcategory C) produces a
highly toxic wastewater which is very difficult to treat biologically
unless pretreatment is provided for cyanide.  Cyanide levels have been
reported in the range of 500 to 1,800 mg/1.  These wastes are usually
segregated from other process effluents and disposed of by incineration
or other acceptable means.  They are generally not discharged to muni-
cipal collection systems.  Recommended pretreatment schemes given below
assume the exclusion of acrylonitrile wastes from the POTW.

Oil separation may be required when the oil content (petroleum-based),
of a wastewater exceeds 100 mg/1.  Animal  and  vegetable oils in fatty
acid wastewaters should also be segregated in  order to minimize solids
separation problems at the municipal works.

-------
                                                                          47
Heavy metals, if present in harmful quantities in organic chemicals
manufacturing wastes, may require pretreatment via chemical precipi-
tation to remove and/or lower these toxic materials.

Pretreatment unit operations will generally consist of a minimum of
equalization, neutralization, oil separation, and possibly phenols
and/or metals reduction.

  With Suspended Growth     With Fixed Growth      Physical-Chemical
   Biological System        Biological System           System

           For Subcategory A and B Plants Discharging to POTW

Oil Separation and       Oil Separation and      Oil Separation and
   Equalization             Equalization            Equalization

+ Neutralization and     + Neutralization and    + Neutralization and
Chemical Precipitation   Chemical Precipitation  Chemical Precipitation

           For Subcategory C and D Plants Discharging to POTW
Equalization + Neutral-  Equalization +          Equalization +
 ization + Chemical         Neutralization          Neutralization
   Precipitation

The Federal Register of April 25, 1974 established that wastewaters from
Subcategory A, B and C industries may be discharged to POTW's pending
the above statements, except for the Subcategory C plants manufacturing
Phenol and Acetone via the Cumene process, Bisphenol A, and p-Cresol
manufacturing.  Phenols are determined to be detrimental to POTW's if
these systems are not acclimated to phenolic loads.  Pretreatment for
existing sources are defined as more or less equivalent to BPCTCA levels
and that for New Sources equivalent to NSPS levels as shown below:

Pretreatment for Existing and New Sources:
                         Avg. 30 Day                      Max. Day
 Parameter       (lb/1,000 Ib final product)    (lb/1,000 Ib final product)

 Phenol                   0.020                            0.045
REMAND/REVOCATION OF EFFLUENT GUIDELINES LIMITATIONS

In accordance with a decision of the U.S. Court of Appeals for the
Fourth District arrived at on February 10, 1976, the USEPA has revoked
all of 40 CFR, Part 414 promulgated on April 25, 1974 (i.e. Phase I)
except that portion of butadiene; and also all of 40 CFR, Part 414 pro-
mulgated and proposed on January 5, 1976 (i.e. Phase II).  The Agency
intends to repromulgate the Regulations as soon as possible, using a
more adequate base.  Regardless of the revocation, the discussion given
above on pretreatment should continue to be largely applicable.

-------
   48
              INORGANIC CHEMICALS MANUFACTURING INDUSTRY
                     (46, 47,  48, 49,  50,  51,  130)
                               [Part 415]

SUBCATEGORIZATION OF THE INDUSTRY

The Inorganic Chemicals Manufacturing  Industry as  defined  to  date  by
the USEPA consists of 63 Subcategories covering 74 different  inorganic
chemical  products.  These are  described below:

          A -  Aluminum Chloride.Production
          B -  Aluminum Sulfate
          C -  Calcium Carbide
          D -  Calcium Chloride
          E -  Calcium Oxide and  Calcium Hydroxide
          F -  Chlorine and Sodium or  Potassium Hydroxide
          G -  Hydrochloric Acid
          H -  Hydrofluoric Acid
          I -  Hydrogen Peroxide
          J -  Nitric Acid
          K -  Potassium Metal Production
          L -  Potassium Dichromate
          M -  Potassium Sulfate
          N -  Sodium Bicarbonate
          0 -  Sodium Carbonate
          P -  Sodium Chloride
          Q -  Sodium Dichromate  and Sodium Sulfate
          R -  Sodium Metal
          S -  Sodium Silicate
          T -  Sodium Sulfite
          U -  Sulfuric Acid
          V -  Titanium Dioxide
          W -  Aluminum Fluoride
          X -  Ammonium Chloride
          Y -  Ammonium Hydroxide (reserved)
          Z -  Barium Carbonate (reserved)
         AA -  Borax Production
         AB -  Boric Acid
         AC -  Bromine
         AD -  Calcium Carbonate
         AE -  Calcium Hydroxide
         AF -  Carbon Dioxide  Production (reserved)
         AG -  Carbon Monoxide and Byproduct Hydrogen
         AH -  Chrome Pigments
         AI -  Chromic Acid
         AJ -  Copper Sulfate
         AK -  Cuprous Oxide (reserved)
         AL -  Ferric Chloride

-------
                                                                           49
          AM - Ferrous Sulfate (reserved)
          AN - Fluoride Production
          AO - Hydrogen
        •  AP - Hydrogen Cyanide
          AQ - Iodine
          AR - Lead Monoxide
          AS - Lithium Carbonate
          AT - Manganese Sulfate (reserved)
          AU - Nickel Sulfate
          AV - Strong Nitric Acid (reserved)
          AW - Oxygen and Nitrogen production
          AX - Potassium Chloride
          AY -. Potassium Iodide
          AZ - Potassium Permanganate (reserved)
          BA - Silver Nitrate
          BB - Sodium Bisulfite (reserved)
          BC - Sodium Fluoride
          BD - Sodium Hydrosulfide (reserved)
          BE - Sodium Hydrosulfite (reserved)
          BF - Sodium Silicofluoride
          BG-_ Sodium Thiosulfate (reserved)
          BH - Stannic Oxide
          BI - Sulfur Dioxide Production (reserved)
          BJ - Zinc Oxide (reserved)
          BK - Zinc Sulfate

Subcategory A, Aluminum Chloride.  Formed by reaction of gaseous
chlorine with molten aluminum.

Subcategory B, Aluminum Sulfate.  Formed by reaction of bauxite ore
with sulfuric acid.

Subcategory C, Calcium Carbide.  Reaction of calcium oxide with carbon
in uncovered high-temperature furnaces.

Subcategory D, Calcium Chloride.  Produced by the brine extraction
process.

Subcategory E, Calcium Oxide and Calcium Hydroxide.  Made from calcin-
ing various types of limestone in continuous vertical or rotating  kilns,

Subcategory F, Chlorine and Sodium or Potassium Hydroxide.  Chlorine
is produced by the electrolysis of sodium or potassium brines.   Sodium
hydroxide and potassium hydroxides are byproducts.   Chlorine is formed
by one of two methods:  the mercury cell  process and the diaphram  cell
process.

Subcategory G. Hydrochloric Acid.  Manufacturing utilizes the direct
reaction of chlorine with hydrogen, or hydrochloric acid is obtained
as a byproduct of organic chlorination reactions.

-------
  50
Subcategory H, Hydrofluoric Acid.  Hydrofluoric acid is produced by the
reaction of fluorospar with sulfuric acid in a furnace.

Subcategory I, Hydrogen Peroxide.  Manufactured by three processes:
1) the electrolytic process; 2) oxidation of alkyl hydroanthraquinones;
and 3) as a byproduct in making acetone from isopropyl  alcohol.
Limitations guidelines are applicable only for the first two processes.

Subcategory J, Nitric Acid.  Produced by the catalytic oxidation of
ammonia to nitrogen dioxide which in turn is reacted with water vapor
under pressure to obtain nitric acid.

Subcategory K, Potassium Metal.  Results from the reaction of potassium
chloride with sodium vapors.

Subcategory L, Potassium Pi chromate.  Results from the reaction of
sodium dichromate dihydrate solution with potassium chloride.

Subcategory M. Potassium Sulfate.  A naturally-occurring potassium
magnesium sulfate ore is reacted with potassium chloride to yield
potassium sulfate.

Subcategory N, Sodium Bicarbonate.   Sodium carbonate is reacted with
water and carbon dioxide under pressure to yield sodium bicarbonate.

Subcategory 0, Sodium Carbonate (Soda Ash).   Produced by the Solvay
process, or by the mining of trona  (sodium sesquicarbonate).  The
Solvay process reacts ammonia and carbon dioxide in a brine solution
to yield sodium bicarbonate.  Heating converts the bicarbonate to
carbonate.   Ammonia can be recovered by adding slaked lime to the
used liquor.

Subcategory P, Sodium Chloride.  Produced by solution brine mining;
by solar evaporation of sea water;  or by conventional mining of rock
salt.   Effluent limitations apply only to the first two processes.

Subcategory Q, Sodium Dichromate and Sodium Sulfate.   These chemicals
are prepared by calcining chrome ore, sodium carbonate  and lime, which
is followed by leaching with water.

Subcategory R, Sodium Metal.  The metal  is generated during the
electrolysis of fused sodium chloride, i.e.  the Downs cell  process.

Subcategory S, Sodium Silicate.  Soda ash or anhydrous  sodium hydroxide
is reacted  with silica to yield sodium silicate.

Subcategory T, Sodium Sulfite.   The reaction of sulfur  dioxide with
soda ash.

-------
                                                                           51
Subcategory U, Sulfuric Acid.  The sulfur burning contact process is
used in both single and'double adsorption plants.  The effluent limi-
tations are not applicable to plants burning sulfides, or recovering
sulfuric acid from waste streams of other processes such as oil refining
or metallurgical operations.

Subcategory V, Titanium Dioxide.  Produced by the sulfate process and
by the chloride process.  The effluent limitations are not applicable
to processes in which benefication of raw ilmenite ore and chlorination
are inseparably combined in the same process step.

Subcategory W, Aluminum Fluoride.  Formed by the reaction of hydrated
alumina with hydrogen fluoride.

Subcategory X, Alumimum Chloride.  Guidelines cover the formation of
aluminum chloride by reacting anhydrous ammonia with hydrogen chloride
gas; or by extracting aluminum chloride from waste mother liquors using
the Solvay process in producing sodium carbonate.

Subcategory AA, Borax.  Produced by mining and extraction from borax
ore, and also by the Trona process.

Subcategory AB, Boric Acid.  Made by reacting borax and sulfuric acid.
Boric acid is also produced by the Trona process utilizing liquid-
liquid solvent extraction-evaporative crystallization operations.

Subcategory AC, Bromine.  May be produced by the Trona process, or by
extraction from well brines.

Subcategory AD, Calcium Carbonate.  Produced by various processes.
One process involves reaction of slaked lime with carbon dioxide.
Other methods react selected waste streams from the Solvay process
used to manufacture sodium carbonate.

Subcategory AE, Calcium Hydroxide.  Reaction of calcium oxide with
water.

Subcategory AG, Carbon Monoxide and Byproduct Hydrogen. Methane, air
and water are catalytically reacted to form a mixture of carbon monox-
ide, carbon dioxide, and hydrogen.  The carbon monoxide and hydrogen
are separated and purified.

Subcategory AH, Chrome Pigments and Iron Blues.   A number of pigments
are included in the chrome pigments Subcategory.  Iron blues are
formed by reaction of ferrous sulfate with sodium ferrocyanide in the
presence of ammonium sulfate.  Chrome pigment wastewaters usually con-
tain chromium, lead, zinc, iron, cyanide, dissolved sodium salts and
acetates.

-------
    52
 Subcategory AI, Chromic Acid.  Waste liquors from sodium dichromate
 manufacturing are reacted with sulfuric acid to yield chromic acid.

 Subcategory AJ, Copper Sulfate.  Copper sulfate can be produced from
 a pure copper raw material or from impure copper sources.  A pure
 copper raw material is reacted with sulfuric acid, air and water.  A
 waste stream from a copper refinery may also be fed to an oxidizer
 tank and reacted with copper shot, steam and air to yield copper sul-
• fate.

 Subcategory AL, Ferric Chloride.   Produced from waste pickle liquor
 by reacting with iron, chlorine and sometimes hydrochloric acid.

 Subcategory AN, Fluoride.  Formed from the electrolysis of hydrogen
 fluoride.  The reaction either involves direct electrolysis of liquid
 hydrofluoric acid, or an electrolysis of fused salts containing potas-
 sium acid fluoride.

 Subcategory AO. Hydrogen.  Generally obtained from the refining and
 purification of crude hydrogen obtained as refinery byproduct gas.

 Subcategory AP, Hydrogen Cyanide.  Manufactured by the Andrussow
 process and also derived as a byproduct of acrylonitrile manufacturing.
 Hydrogen cyanide receives refining and purification in both processes.

 Subcategory AQ, Iodine. Obtained  from brine solutions containing
 iodide.

 Subcategory AR. Lead Monoxide.  Produced by the thermal  oxidation of
 lead.

 Subcategory AS, Lithium Carbonate.  Manufactured by the Trona process
 and/or from spodumene ore.The latter involves reacting the ore  with
 sulfuric acid.   In the Trona process, a solid residue is reclaimed
 from potassium chloride and bromine production.   This residue is  with-
 drawn as dilithium sodium phosphate which in turn is reacted with
 sulfuric acid yielding lithium sulfate.   Lithium sulfate is reacted
 with sodium carbonate to give the desired end product.

 Subcategory All, Nickel Sulfate.   Produced from pure nickel, from  nickel
 oxide and from impure nickel  substances.   The pure metal  or pure  oxide
 is  digested in  sulfuric acid.   When impure nickel  is used,  the  sulfuric
 acid reaction solution must be treated with oxidizers to remove impuri-
 ties.

 Subcategory AW. Oxygen and  Nitrogen.   Process involves  distillation of
 liquefied air.   Air is compressed, cooled and then separated into nitro-
 gen and oxygen  by distillation.

-------
                                                                           53
 Subcategory AX, Potassium Chloride.  Produced by the Trona process and/
 or  by extraction from sylvite ore which is a potassium chloride-sodium
 chloride mineral.  In the Trona process, a brine solution is concentrated
 and potassium chloride recovered.  When sylvite ore is used, it is ground and
 converted into a brine solution from which potassium chloride is reclaimed.

 Subcategory AY, Potassium Iodide.  Potassium hydroxide is reacted with
 iodine.

 Subcategory BA, Silver Nitrate.  Silver is dissolved in nitric acid.

 Subcategory BC, Sodium Fluoride.  Two processes are used.  Anhydrous
 hydrofluoric acid is reacted with sodium carbonate and sodium fluoride
 eventually recovered.  Also, sodium silicofluoride can be reacted with
 sodium hydroxide and sodium fluoride separated and purified.

 Subcategory BF, Sodium Silicofluoride.  Fluorosilicic acid is reacted
 with sodium chloride.  Sodium silicofluoride is alternately manufactured
 by  reacting impure phosphoric acid containing fluorides with sodium
 carbonate.

 Subcategory BH, Stannic Oxide.  Two processes are available.  In a dry
 process, metallic tin is thermally reacted with oxygen.  In the second
 process, tin is recovered from scrap materials and subsequently oxidized.

 Subcategory BK. Zinc Sulfate.  Sulfuric acid is reacted with crude zinc-
 containing materials.


 NATURE OF THE PROBLEM

 In many inorganic chemical  manufacturing processes, wet scrubbers are
 used to control air pollution.  The scrubbing solution is generally
 treated and may be reused.   Operations for treating process wastewater
 in the inorganic chemicals  manufacturing industry include settling,
 filtration, chemical  coagulation, ion exchange,  carbon adsorption and
 evaporation.   Some treatment processes may generate large volumes of
 sludge in turn creating a substantial  solid waste problem.   Landfill
or lagoon sites of adequate size and good  design may be essential.


PARAMETERS OF CONCERN

Primary Parameters include:

        •  pH,  Acidity,  Alkalinity            Cadmium
          COO,  TOC                           Iron
          TSS                                Lead
          Chromium                           Mercury
          Arsenic                            Cyanide
          Fluoride

-------
   54
Parameters of slightly less importance:

          Oil/Grease
          Boron
          IDS
          Ammonia N
          Nitrate and Nitrite N
          Fluoride
          Chloride
          Sulfate
          Sulfite
          Phosphate
          Phenols
          Silicates
          Barium
Chlorinated Hydrocarbons
Cyclic Hydrocarbons
Temperature
Aluminum
Selenium
Copper
Manganese
Molybdenum
Nickel
Tin
Titanium
Vanadium
Zinc
Silver
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
MEASURES

For Subcategories A through U,  Pretreatment for Existing  Sources  has
been established equivalent to  BPCTCA limitations and  Pretreatment  for
New Sources has been made equivalent to New Source Performance  Standards,
It is further indicated where the effluent limitation  guidelines  based
on BPCTCA are not defined for incompatible pollutants  (such  as  TDS),  no
pretreatment will be required for such incompatible pollutant unless
persuant to 40 CFR 128, the wastes interfere with the  operation or  per-
formance of the POTW, or pretreatment is required by local or
law.  As best as can be determined,  pretreatment criteria are those
shown below:

For Subcategory A, Existing and New Sources of Aluminum Chloride
Production

No discharge allowed.

For Subcategory B, Existing and New Sources of Aluminum Sulfate
Production.

Essentially no discharge except for low frequency runoff. No limita-
tions are given for incompatibles.

For Subcategory C. Existing and New Sources of Calcium Carbide
Production.

No discharge.

-------
                                                                            55
For Subcategory D, Existing Sources of Calcium Chloride Production.
Discharge allowed.  No limitations given for incompatible pollutants.
For Subcategory D, New Sources of Calcium Chlorj'de Production.
No discharge.
For Subcategory E, Existing and New Sources of Calcium Oxide and
Calcium Hydroxide Production.
See explanation under Subcategory B.
                                                        e
For Subcategory F, Existing Chlorine Production Source, Mercury Cell
Process.

                              Avg. 30 DayMax Day
     Parameter	(1b/1000 1b final  product)(1b/1 OOP 1b final product)
     Mercury                       .00014                   .00028
For Subcategory F, Existing Chlorine Production Source, Diaphram
Process.
     Lead                          .0025                    .005
For Subcategory F, New Chlorine Production  Source,  Mercury Cell  Process.
     Mercury                       .00007                   .00014
For Subcategory F, New Chlorine Production  Source,  Diaphram Process.
     Lead                          .00004                   .00008
For Subcategory G. Existing and New Sources of Hydrochloric Acid
Production.
No discharge.
For Subcategory H, Existing Sources of Hydrofluoric Acid  Production.
     Fluoride                      .18 and  up to            .36 (and up
                                      30 mg/1)                   to 60 mg/1)

-------
  56
For Subcategory H, New Sources of Hydrofluoric Acid Production.
                                   Avg. 30 Day              Max Day
     Parameter  .           (lb/1000 Ib final product)(lb/1000 Ib final product)
     Fluoride                      0.12 and up to           0.24 (and up
                                        25 nig/1)                to 50 mg/1)
For Subcategory I, Existing Sources of Hydrogen Peroxide Production by
Oxidation of Alkyl Hydroanthraquinones.
     TOC                           0.22                     0.44
For Subcategory I, Existing Sources of Hydrogen Peroxide Production by
Electrolytic Process.
     Cyanide, amenable             .0002                    .0004
          to chlorine
          oxidation
For Subcategory I, New Sources of Hydrogen Peroxide Production by
Oxidation of Alkyl Hydroanthraquinones.
No discharge.
For Subcategory I, New Sources of Hydrogen Peroxide Production by
Electrolytic Process.
See explanation under Subcategory B.
For Subcategory J, Existing and New Sources of Nitric Acid Production.
No discharge.
For Subcategory K, Existing and New Sources of Potassium Metal
Production.
No discharge.
For Subcategory L, Existing and New Sources of Potassium Dichromate
Production.
No discharge.'
For Subcategory M, Existing and New Sources of Potassium Sulfate
Production.
See explanation under Subcategory B.

-------
                                                                        57
For Subcategory N, Existing and New Sources of Sodium Bicarbonate
Production..
No discharge.
For Subcategory 0, Existing Sources of Sodium Carbonate Production.
Discharge allowed.  No limitations given for incompatibles.
For Subcategory 0. New Sources of Sodium Carbonate Production.
No discharge.
For Subcategory P, Existing Sources of Sodium Chloride Production.
Discharge allowed.  No limitations given for incompatibles.
For Subcategory P. New Sources of Sodium Chloride Production.
No discharge.
For Subcategory Q, Existing and New Sources of Sodium Dichromate and
Sodium Sulfate Production.
                         Avg. 30 DayMax Day
     Parameter     (lb/1000 Ib final product) (lb/1000 Ib final  product)
     Chromium, hexavalent    .0005                      .009
          chromium, total    .0044                      .0088
For Subcategory R, Existing Sources of Sodium Metal  Production.
Discharge allowed.  No limitations given for incompatibles.
For Subcategory R, New Sources of Sodium Metal  Production.
See explanation under Subcategory B.
For Subcategory S. Existing Sources of Sodium Silicate Production.
Discharge allowed.  No limitations given for incompatibles.
For Subcategory S, New Sources of Sodium Silicate Production.
See explanation under Subcategory B.

-------
   58
For Subcategory T, Existing Sources of Sodium Sulfite Production.

                              Avg.  30 DayMax Day
     Parameter      (lb/1000 Ib final product)(lb/1000 Ib final  product)
     COD                      1.7                      3.4

For Subcategory T, New Sources of Sodium Sulfite Production.
No discharge.
For Subcategory U, Existing and New Sources of Sufuric Acid Production.
No discharge.
For Subcategory V. Existing Sources of Titanium Dioxide Production  by
the Chloride Process.
     Iron                     0.36                     0.72
For Subcategory V, Existing Sources of Titanium Dioxide Production  by
the Sulfate Process.
     Iron                     1.7                      3.4
For Subcategory V, New Sources of Titanium Dioxide Production  by the
Chloride Process.
     Iron                     0.18                     0.36
For Subcategory V, New Sources of Titanium Dioxide Production  by the
Sulfate Process.
     Iron                     0.42                     0.84
For Subcategory W, Existing Sources of Aluminum Fluoride.
     Aluminum                 0.17                     0.34
     Fluoride                 0.34                     0.68
For Subcategory W. New Sources of Aluminum Fluoride.
     Aluminum                 0.017                    0.034
     Fluoride                 0.034                    0.068
For Subcategory X, Existing and New Sources of  Ammonium Chloride.
     Ammonia N                0.5                      1.0

-------
                                                                         59
For Subcategory AA, Existing and New Sources of Borax Production.

               Parameter                Pretreatment Standard

               Boron as B                    1 mg/1
               Arsenic as As                 1 mg/1

Residual brine and depleted liquors may be returned to the body of
water from which the process brines were originally withdrawn.

For Subcategory AB, Existing and New Sources of Boric Acid Production
by Trona Process.

               Arsenic as As                 0.5 mg/1
               Boron as B                    1.0 mg/1

Residual brine and depleted liquors may be returned to the body of
water from which the process brines were originally withdrawn.

For Subcategory AB, Existing and New Sources of Boric Acid Production
From Ore Mined Borax.
                              Avg. 30 Day               Max.  Day
     Parameter        (IbjflOOO Ib. final product) (lb/1000 Ib final  product)


     Arsenic                  .0014                         .0028

For Subcategory AC, Existing and New Sources of Bromine Production.

               Parameter                Pretreatment Standard

               Free Bromine (molecular)           0.1 mg/1

Residual brine and depleted liquors may be returned to the body of
of water from which the process brines were originally withdrawn.

For Subcategory AD, Existing and New Sources of Calcium Carbonate
Production.

No Limitations.

For Subcategory AE, Existing and New Sources of Calcium Hydroxide.

No Limitations.

-------
 60
For Subcategory AG, Existing Sources of Carbon Monoxide and Byproduct
Hydrogen Production.
                                Avg. 30 Day            Max. Day
     Parameter    (lb/1000 Ib final product)(lb/1000 Ib final  product)

     COD                           0.25                     0.5


For Subcategory AG, New Sources of Carbon Monoxide and Byproduct
Hydrogen Production
     COD                           0.125                    0.25


For Subcategory AH, Existing Sources of Chrome Pigments Production.
     Chromium, total               0.034                    0.10
     Chromium, hexavalent          0.0034                   0.01
     Lead                          0.14                     0.42
     Zinc At                       0.27                     0.72
     Cyanide Att                   0.0034                   0.01
     Cyanide                       0.034                    0.10
     Iron                          0.27                     0.72


For Subcategory AH. New Sources of Chrome Pigments Production.
     Chromium, total               0.017                    0.051
     Chromium, hexavalent          0.0017                   0.0051
     Lead                          0.033                    0.099
     Zinc At               •        0.67                     0.20
     Cyanide Att                   0.0017                   0.0051
     Cyanide                       0.017                    0.051
     Iron                          0.067                    0.20


For Subcategory AI, Existing and New Sources of Chromic Acid Production,
                                            Pretreatment
     Parameter                                Standard

     Total Chromium                            0.5 mg/1
 t  Zinc limitatation is based on production of Zinc yellow.
tt  Cyanides amenable to chlorination.

-------
                                                                           61
For Subcategory AJ, Existing and New Sources of Copper Sulfate Produc-
tion Using Pure Copper Raw Material
                              Avg. 30 Day              Max. Day
     Parameter        (lb/1000 1b. final product)(lb/1000 Ib. final product)


     Copper                   0.0002                    0.0006


For Subcategory AJ, Existing Sources of Copper Sulfate Production
from Impure Copper.

     Copper                   0.001                     0.003
     Nickel                   0.002                     0.006
     Selenium                 0.0005                    0.0015

For Subcategory AJ, New Sources of Copper Sulfate Production from
Impure Copper.

     Copper                   0.00046                   0.0014
     Nickel                   0.00046                   0.0014
     Selenium                 0.00023                   0.00069

For Subcategory AK, Existing and New Sources of Ferric Chloride
Production.
                                             Pretreatment
          Parameter                            Standard


          Iron                                  4 mg/1

For Subcategory AN, Existing and New Sources of Fluorine Production,

          Fluoride                              20 mg/1

For Subcategory AO, Existing and New Sources of Hydrogen Production.

          Oil/Grease                            100 mg/1

-------
   62
For Subcategory AP, Existing Sources of Hydrogen Cyanide Production
by Andrussow Process.
                              Avg.  30 Day              Max.  Day
     Parameter         (lb/1000 Ib. final product)(lb/1000 Ib.  final  product)


     Cyanide                  0.025                       0.05
     Cyanide, amenable to     0.0025                      0.005
          chlorine oxidation
     Ammonia as N	0.18	0.36	

For Subcategory AP, Existing Sources of Hydrogen Cyanide Production
from Acrylonitrile Wastes.
               Parameter                      Pretreatment
               	Standard

               Cyanide                          0.5 mg/1
               Cyanide, amenable to             0.05 mg/1
                    chlorine oxidation	

For Subcategory AP, New Sources of Hydrogen Cyanide Production by
Andrussow Process.
                              Avg.  30 Day              Max.  Day
     Parameter         (lb/1000 Ib.  final product)(lb/1000 Ib.  final  product)


     Cyanide                  0.0023                      0.0046
     Cyanide, amenable to     0.00023                     0.00046
          chlorine oxidation
     Ammonia as N             0.016                        0.032


For Subcategory AP, New Sources of Hydrogen Cyanide Production  from
Acrylonitrile Wastes.
                                             Pretreatment
               Parameter	Standard

               Cyanide                         0.5 mg/1
               Cyanide, amenable to            0.05 mg/1
                    chlorine oxidation
               Ammonia as N                    30.0 mg/1

-------
                                                                           63
For Subcategory AQ, Existing and New Sources of Iodine Production.

No Limitations.

For Subcategory AR, Existing and New Sources of Lead Monoxide Production.
                              Avg. 30 Day              Max. Day
     Parameter       (lb/1000 Ib. final product)(lb/1000 Ib. final product)

     Lead                     0.015                    0.030

For Subcategory AS, Existing and New Sources of Lithium Carbonate
Production.

No Limitations.

For Subcategory AU, Existing and New Sources of Nickel  Sulfate Produc-
tion from Pure Materials.
                                             Pretreatment
                   Parameter	Standard

                    Nickel                      2 mg/1

For Subcategory AU, Existing and New Sources of Nickel  Sulfate Produc-
tion from Impure Raw Materials.

                              Avg. 30 Day              Max.  Day
     Parameter        (lb/1000 Ib. final  product)(lb/1000 Ib.  final  product)

     Nickel                   0.002                    0.006

For Subcategory AW, Existing and New Sources of Oxygen  and Nitrogen
Production.
                                             Pretreatment
                    Parameter	Standard

                    Oil/Grease                  100 mg/1


For Subcategory AX, Existing and New Sources of Potassium Chloride
Production.

No Limitations.

-------
    64
For Subcategory AY, Existing Sources of Potassium Iodide Production.
                              Avg. 30 Day              Max. Day
     Parameter        (lb/1000 Ib. final product)(lb/1000 Ib. final product)


     Sulfide                  0.005                      0.015
     Iron                     0.005                      0.015
     Barium                   0.003                      0.009


For Subcategory AY, New Sources of Potassium Iodide Production.

     Sulfide                  0.0036                     0.0069
     Iron                     0.0036                     0.0069
     Barium                   0.0023                     0.011

For Subcategory BA, Existing Sources of Silver Nitrate Production.

     Silver                   0.003                      0.009

For Subcategory BA, New Sources of Silver Nitrate Production.

     Silver                   0.0015                     0.0045

For Subcategory BC, Existing and New Sources of Sodium Fluoride
Production.
                                             Pretreatment
               Parameter	Standard

               Fluoride                        20/mg/l

For Subcategory BF. Existing and New Sources of Silicofluoride
Production.
                              Avg.  30 Day              Max.  Day
     Parameter      (lb/1000 Ib.  final  product)(lb/1000 Ib.  final  product)

     Fluoride                 0.25                        0.50
For Subcategory BG, Existing and New Sources of Stannic Oxide Production.

No Liimttatiions.

-------
                                                                           65
For Subcategory BK, Existing and New Sources of Zinc Sulfate Production.
                                             Pretreatment
               Parameter	Standard

               Cadmium                         1.0 mg/1
REMAND AND REVOCATION OF INORGANIC CHEMICALS MANUFACTURING EFFLUENT
REGULATIONS AND GUIDELINES
n November 23, 1976, the Federal  Register announced that certain
effluent guidelines and standards for the Inorganic Chemicals  Produc-
tion Industry merited reconsideration and/or change.   Thereby,  certain
sections of 40 CFR Part 415 were  withdrawn or temporarily suspended.
Regarding pretreatment standards, the following revisions were  made
effective by the USEPA.

     A.  Pretreatment Standards for Existing Sources.

     Subcategories W - Aluminum Fluoride; AH-Chrome Pigments;  AP-
     Hydrogen Cyanide; and BF-Sodium Silicofluoride have been withdrawn,

     B.  Pretreatment Standards for New Sources.

     Subcategories G-Hydrochloric Acid; H-Hydrofluoric Acid;  I-Hydrogen
     Peroxide; J-Nitric Acid;  0-Sodium Carbonate;  R-Sodium Metal;  S-
     Sodium Silicate; U-Sulfuric  Acid; V-Titanium  Dioxide;  W-Aluminum
     Fluoride; AH-Chrome Pigments; AP-Hydrogen Cyanide; and BF-Sodium
     Silicofluoride have either been remanded and/or revoked.

-------
 66
       PLASTICS AND SYNTHETICS MATERIALS MANUFACTURING INDUSTRY
                  (156, 157, 158, 159, 160, 161, 162)
                              [Part 416]
SUBCATEGORIZATION OF THE INDUSTRY

The Plastics and Synthetics Manufacturing Industry involves a diverse
series of processing and products as described below.  Twenty-one
subcategories have been established to date by the USEPA with additional
subcategories scheduled for adoption in the future.  The 21 subcategories
are described below:

     A - Polyvinyl Chloride Manufacturing
     B - Polyvinyl Acetate
     C - Polystyrene
     D - Polypropylene
     E - Polyethylene
     F - Cellophane
     G - Rayon
     H - Acrylonitrile - Butadiene - Styrene (ABS) and Styrene -
          Acrylonitrile (SAN) Resin Copolymers
     I - Polyester
     0 - Nylon 66
     K - Nylon 6
     L - Cellulose Acetate
     M - Acrylics
     N - Ethylene - Vinyl  Acetate Copolymers
     0 - Polytetrafluoroethylene
     P - Polypropylene Fiber
     Q - Alkyds and Unsaturated Polyester Resins
     R - Cellulose Nitrate
     S - Polyamide (Nylon 6/12)
     T - Polyester Resins (Thermoplastic)
     U - Silicones

Subcategory A, Polyvinyl Chloride.  Includes plants employing poly-
merization reaction of vinyl chloride by bulk polymerization, suspension
polymerization, or emulsion polymerization.

Subcategory B. Polyvinyl Acetate.  Polymerization of polyvinyl acetate
and associated processes.

Subcategory C, Polystyrene.  Refers to plants utilizing the polymeriza-
tion reaction of Styrene by suspension polymerization or by bulk poly-
merization, and the processing associated with polystyrene manufacturing.

-------
                                                                          67
Subcategory D, Polypropylene.  Applies to the polymerization reaction
of polypropylene and processes associated with the manufacture of poly-
propylene.

Subcategory E, Polyethylene.  Includes plants producing low-density
polyethylene by the polymerization of ethylene; and the manufacture
of high-density polyethylene by the polymerization of ethylene by the
solvent process or by the polyform process.

Subcategory F, Cellophane.  The processing of wood pulp to produce
cellophane together with associated manufacturing.

Subcategory G, Rayon.  The processing of wood pulp to produce rayon and
associated manufacturing.

Subcategory H, Acrylonitrile-Butadiene-Styrene (ABS) and Styrene-
Acrylonitrile (SAN) Resin Copo1ymers"i  Includes plants utilizing
polymerization of acrylonitrite, butadiene and styrene, together
with the various associated processing to make ABS and SAN resins.

Subcategory I, Polyesters.  Refers to plants utilizing polymerization
of dihydric alcohol and terephthalic acid or dimethyl terephthalate,
and subsequent processing for the manufacture of polyester fibers.

Subcategory J, Nylon 66.  Polymerization of hexamethylene diamine
and adipic acid together with associated processing for the manufacture
of nylon 66 resin and/or the fiber.

Subcategory K, Nylon 6.  Refers to the polymerization of caprolactum
and the various associated processing used to make nylon 6 resin
and/or the fiber.

Subcategory L, Cellulose Acetate.  Processing of wood pulp with acetic
acid and acetic anhydride, together with the various associated process-
ing for the manufacture of cellulose acetate fibers and/or the resins.

Subcategory M, Acrylics.  Polymerization of acrylonitrile and the
copolymerization of acrylonitrile and vinylidene chloride and/or
vinyl chloride to make acrylic resins and fibers.

Subcategory N, Ethylene-Vinyl Acetate.  Reaction of vinyl acetate and
ethylene monomers by polymerization in order to produce ethylene vinyl
acetate copolymers.

Subcategory 0, Polytetrafluoroethylene.  The manufacture of granular
and fine powder grades of polytetrafluoroethylene together with the
production of the monomer from the precursor, chlorodifluoromethane.

-------
 68
Subcategory P, Polypropylene Fibers.  Applies to plants manufacturing
polypropylene fibers from polypropylene.

Subcategory Q. Alkyds and Unsaturated Polyester Resins.  Involves
complex polymerization processing.

Subcategory R, Cellulose Nitrated  Fibrous cellulose is reacted with a
mixture of sulfuric and nitric acids to manufacture cellulose nitrate.

Subcategory S, Polyamide (Nylon 6/12).  Production of Nylon 6/12.

Subcategory T. Polyester Resins (Thermoplastic).  The manufacturing of
saturated polyester polymers based on poly (ethylene terephthalate) and
poly (butylene terephthalate), together with associated processing.

Subcategory U, Silicones.  Applicable to plants manufacturing silicone
fluids, greases, emulsions, rubber and resins.
NATURE OF PROBLEM

The plastics and synthetics industry is more or less comprised of
three segments:  manufacture of raw materials or monomers; conversion
of monomers into resin or plastic material; and the conversion of this
plastic material into plastic items such as toys, synthetic fibers,
packaging film, adhesives, paints, etc.  The effluent guidelines for
the plastics and synthetics industry mainly cover the manufacturing
of the plastic or synthetic resins.  However, they also include the
production of synthetic fibers such as nylon, polyester, and acrylic
fibers; and man-made cellulosic fibers including rayon and cellulose
film, namely cellophane.  The synthetic fibers have been growing in
importance whereas the cellulosic fibers are declining in use.

In the plastics and synthetics industry, the major oil companies and
others have integrated from oil and monomer raw material production
into resin manufacture.  A number of chemical companies have also
integrated back to raw materials and forward into end products.  In
many cases, a given facility will produce monomer, polymers and the
end products.  The large volume commodity resins, generally comprise
part of a petrochemical complex which may include production of the
monomer (such as ethylene), and the production of end products (such
as film).  Because of dependency on petroleum and gas feedstocks,
many petrochemical plants are located on the Gulf coast.  The petro-
chemical complexes may ship their intermediate products to resin and
plastic manufacturers located closer to the market areas.

Polymerization in very simplistic terms, involves the splitting of a
double carbon bond hydrocarbon monomer and rearrangement to form a

-------
                                                                         69
long-chain polymer compound with normal  carbon bond linking.   Catalysts
and modifiers are employed to initiate and control  the polymerization
reaction.  Upon leaving the reactor, the polymer contains unreacted
monomer and various contaminants and byproducts.  The latter  are vacuum
distilled, condensed, recovered and/or sent to the sewer.  Processes
for removal and/or recovery of catalyst may generate significant process
wastes.

Subcategories A Through M.  Cellophane involves viscose preparation
from wood pulp and alkali cellulose., film casting and coating.   In
rayon manufacturing, the processes basically comprise viscose prepara-
tion from wood pulp and fiber spinning.   Polyester fiber is made from
the molten fiber passed through a spinerette and then cooled, and
formed into staples or coils.  Nylon fibers are manufactured  in the
form of staple bales, continuous yarn or textile filaments.  Acrylic
fibers are made through both wet and dry spinning methods and shipped
in staple form.

Subcategories N Through U.  Ethylene-vinyl acetate copolymers are often
made in facilities manufacturing polyethylene.  In the final  process
step, the EVA pellets are remelted9 combined with additives and
repelletized.  Many of the uses of the EVA final product involve
direct contact with food.  Polytetrafluoroethylene is the most important
of the fluorocarbon polymers,, and is polymerized from the monomer,
tetrafluoroethylene.  The monomer is generated via a continuous process
based on pyrolysis of chlorodifluoromethene.  In polypropylene fiber
manufacture, polypropylene flake is colored, melted and extruded as
pellets.  The pellets are passed through a spinerette, cooled and
drawn and converted into monofilaments,  fibers or film.  Polypropylene
fiber is employed in carpets and for various textile needs.  The
alkyd and unsaturated polyester resins differ principally in  that for
the alkyds the acid component is supplied by long chain unsaturated
acids vs. phtholic and maleic anhydrides used in the unsaturated poly-
esters.  Alkyd resins are mainly used in paint formulations and molding
compounds.  The unsaturated polyester resins are mainly used  in the
manufacture of plastic reinforced with glass and metallic fibers, etc.
Cellulose nitrate or nitrocellulose generates wastewater containing
acids and alcohols lost from processing.  Nylon 6/12 (DuPont) resins
are produced in somewhat similar fashion as Nylon 66 above except that
sebacic acid is used rather than adipic acid.  The Thermoplastic
saturated polyester resins mostly used for molding materials, are
formed from polymerization using ethylene glycol and either dimethyl
terephthalate (DMT) or terephthalic acid (TPA).  Silicones encompass
a wide variety of products with complex processing.  Typical  opera-
tions at a single silicone plant may include production of methyl
chloride, varied methyl chlorosilanes and other chlorosilanes,  the
hydrolysis of dimethyl dlchlorosilane,  a range of silicone resins,
elastomer products, and specialties comprising surfactants, coupling

-------
 70
agents, fluorosilicones, etc.  Solvents, acids, heavy metals, and
fluorides may be generated in silicone manufacturing wastewaters.

Available data show that treated effluents from plastics and synthetics
manufacturing plants generally have relatively high COD/BOD ratios
denoting large amounts of refractory residual remaining after conven-
tional treatment.  This seems to be especially true of acrylic plants
and treatment of waste from this type of manufacturing represents one
of the most difficult situations in the industry.  Waste equalization
appears to be a prerequisite for satisfactory treatment of plastics
and synthetics manufacturing effluents.


PARAMETERS OF CONCERN

     Primary parameters include:

          BOD                           Zinc
          COD                           Phenolic compounds
          TSS                           Chromium
          pH, Alkalinity, Acidity

     Other important parameters comprise:

          Iron                          Nitrogenous compounds
          Aluminum                      IDS
          Nickel                         Oil/Grease
          Vanadium                      Color
          Titanium                      Turbidity
          Molybdenum                    Phosphates
          Cobalt                        Sulfides
          Copper                        Magnesium
          Cadmium                       Antimony
          Cyanide                       Temperature
          Mercury                       Manganese
          Fluorides                     Polychlorinated organics
          Lead                          Toxic compounds


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTV1

For Subcategories A Through F.  i.e.  Polyvinyl Chloride, Polyvinyl
Acetate,  Polystyrene,  Polypropylene, Polyethylene and Cellophane
Manufacturing, Existing Sources.  No limitations presently prescribed
for process wastes to  POTW's.

For Subcategories G Through M,  i.e.  Rayon,  ABS and SAN Resin Copolymers,
Polyester, Nylon 66, Nylon 6.  Cellulose Acetate and Acrylics, Existing
Sources.'Limitations  not yet established  for these Subcategories.

-------
                                                                           71
For Subcategon'es N and 0, i.e. EVA Copolymers and Polytetrafluoroethy-
lene, Existing Sources.No limitations presently prescribed for process
wastes to POTW's.

For Subcategory P, Polypropylene Fibers, Existing Sources.   No limita-
tions prescribed except for oil and grease with a Pretreatment Standard
of 100 mg/1.

For Subcategory Q Through T, i.e. Alkyds and Unsaturated Polyester
Resins, Cellulose Nitrate, Nylon 6/12 and Polyester (Thermoplastic)
Resins, Existing Sources.  No limitations presently prescribed for
process wastes to POTW's.

For Subcategory U, Silicones, Existing Sources.  No limitations
prescribed except for Copper with a Pretreatment Standard of 1  mg/1.

For Subcategon'es A Through U, i.e. All  Subcategdries.  New  Sources.
Limitations not yet established.
REVOCATION AND SUSPENSION OF REGULATIONS FOR THE  PLASTICS  AND  SYNTHETIC
MANUFACTURING INDUSTRY

The 40 CFR Part 416, Federal Resister publication of May 19, 1975
suspended the entire Acrylics Subcategory (Subcategory M)  together
with applicable limitations.  On March 10,  1976,  the U.S.  Court  of
Appeals for the 4th Circuit further remanded Subcategories A through
M and the effluent limitations guidelines and the new source performance
standards to the EPA for reconsideration.  Doubt  was also  cast on
Subcategories N through U, and their associated effluent limitations
guidelines and new source performance standards.   Proposed pretreatment
standards for existing sources in alj_ established Subcategories  were
similarly determined to be rescinded.

-------
 72
                   SOAP AND DETERGENT MANUFACTURING
                           (29, 30, 31, 32)
                              [Part 417]
SUBCATEGORIZATION OF THE INDUSTRY
The Soap and Detergent Manufacturing Industry is divided into 19 Sub-
categories.  Subcategories A - H are essentially soap and soap product
manufacture, and Subcategories I through S are detergent product man-
ufacture.
     A - Soap Manufacturing by Batch Kettle
     B - Fatty Acid Manufacturing by Fat Splitting
     C - Soap Manufacturing by Fatty Acid Neutralization
     D - Glycerine Concentration
     E - Glycerine Distillation
     F - Manufacture of Soap Flakes and Powders
     G - Manufacture of Bar Soaps
     H - Manufacture of Liquid Soaps
     I - Oleum Sulfonation and Sulfation
     J - Air/S03 Sulfation and Sulfonation
     K - SO., Solvent and Vacuum Sulfonation
     L - Sulfamic Acid Sulfation
     M - Chlorosulfonic Acid Sulfation
     N - Neutralization of Sulfuric Acid Esters and Sulfonic Acids
     0 - Manufacture of Spray Dried Detergents
     P - Manufacture of Liquid Detergents
     Q - Manufacturing of Detergents by Dry Blending
     R - Manufacturing of Drum Dried Detergents
     S - Manufacture of Detergent Bars and Cakes

-------
                                                                        73
PARAMETERS OF CONCERN

               BOD                           IDS

               COD                           Nitrogen
               TSS                           Phosphorous

               Surfactants (NBAS)            Boron

               Oil/Grease                    Sodium Salts
               pH, Acidity, Alkalinity       Sulfate

               Zinc                          Barium


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

In early guidelines documents, COD, oil and grease and surfacants were
described as incompatible pollutants to POTW's.  This was subsequently
changed with oil and grease and surfactants said to be removed through
adequately designed and operated POTW's.  COD pretreatment limitations
were deleted for some subcategories and retained for others.  Whereas
surfactants and other compounds expressed as COD in most subcategories
were determined to be relatively biodegradable, concern was especially
raised over wastes from the production of industrial and institutional
detergents.  The latter materials are highly refractive and may thusly
adversely affect POTW's through bacteriostatic or bacteriocidal effects,
or pass through POTW's without significant reduction.  Consequently,
COD pretreatment limitations were retained for spray dried and liquid
detergent, and dry blending and drum-dried detergent manufacturing.

For Subcategories A through N and Subcategory S, Existing and New
Sources:

Wastewaters are considered to contain no incompatibles and therefore may
be discharged to POTW's without pretreatment.  No pretreatment limi-
tations are given.

For Subcategory 0, Spray Dried Detergents, Existing Sources:

COD - Where more than 25 percent of the annual production is represented
      by final products having a COD: BODr ratio greater than 4, the
      allowable COD discharge shall be restricted to 2.5 lb/1,000 Ib
      anhydrous product for that portion of the production representing
      final products with a COD:  BODr ratio equal to or greater than 4.
      For that portion of the production representing final products
      with a COD:  BODr ratio less than 4, the incremental COD discharge
      shall be restricted to 8.0 lb/1,000 Ib anhydrous product.

-------
 74
For Subcategory 0,  Spray Dried Detergents,  New Sources:

COD - Where waste streams have a COD:   BOD7 ratio of 10  or less,  or the
      streams have a COD content of 2.4 lb/1,000 Ib anhydrous  product
      or less, no pretreatment limitations  are given.

      Where waste streams have a COD:   BOD7 ratio greater than 10 and a
      COD content of more than 2.4 lb/1,000 Ib anhydrous product, COD
      pretreatment limits are:

     1)   With normal operation of spray drying towers:
            Avg.  30 Day
           (lb/1,000 Ib
         anhydrous product)
                                           Max.  Day
                                         (lb/1,000 Ib
                                       anhydrous product)
                0.04
                                              0.08
      2)
          For air quality restricted operation of spray drying tower,
          but only when high rate of wet scrubbing is  necessary which
          produces more waste than can be recycled to  process :
                0.25
                                              0.50
      3)
          For fast turnaround operation of a spray tower when the number
          of turnarounds over any 30 day period exceeds 6,  the maximum
          daily allowable waste load shall  be sum of 1) or  2) directly
          above plus the appropriate value of 0.07 lb/1,000 Ib anhydrous
          product.  Also, the avg.  30 day allowable load shall  be the
          number of turnarounds in  excess of 6 multiplied by 0.07
          lb/1,000 Ib anhydrous product and prorated to 30  days plus
          the value contained in either 1)  or 2)  above.

For Subcategory P. Manufacture of Liquid Detergents. Existing Sources:

COD - Where more than 25 percent of the annual  production is represented
      by final  products having a COD:  BOD5 ratio greater than 4, the
      allowable COD discharge shall  be restricted to 1.0 lb/1,000 Ib
      anhydrous product for that portion of the production  representing
      final product with a COD:  BOD,- ratio equal to or greater than  4.
      For that portion of the production representing final  products
      with a COD:   BODg ratio less  than 4,  the incremental  COD discharge
      shall be restricted to 4.0 lb/1,000 Ib anhydrous  product.

For Subcategory P, Manufacture of Liquid Detergents, New Sources:

COD - Where waste  streams have a COD:  BODy ratio of 10 or  less or
      the streams  have a COD content of 1.1 lb/1,000 Ib anhydrous pro-
      duct or less, no pretreatment limitations are given.

-------
                                                                        75
COD - Where waste streams have a COD:   BOD ratio greater than 10 and a
      COD content of more than 1.1  lb/1,000 Ib anhydrous product, COD
      pretreatment limits are:

      1)  With normal liquid detergent operations:

                  Avg 30 Day                      Max.  Day
                 (lb/1,000 Ib                   (lb/1,000 Ib
               anhydrous product)              anhydrous product)

                      0.22                          0.44

 2)  For fast turnaround operation  of automated fill  lines,  when
     the number of turnarounds exceeds 8 over any 30 day period, the
     maximum daily allowable waste  loads shall be the sum of   1)
     directly above plus the appropriate value of 0.07  lb/1,000 Ib
     anhydrous product.   Also, the  avg.  30 day allowable load shall
     be the number of turnarounds  in excess of 8 multiplied  by
     0.07 lb/1,000 Ib anhydrous products and prorated to 30  days plus
     the value contained in 1) above.

For Subcategory Q, Manufacture of  Detergents by Dry Blending, Existing
Sources:

COD - Where more than 25 percent of the  annual production is represented
      by final products  having a COD:   BOD,- ratio  greater than 4, the
      allowable COD discharge shall be restricted to 0.25 lb/1,000 Ib
      anhydrous product  for that portion of the production representing
      final products with a COD:  BODr ratio equal  to or greater than 4.
      For that portion of the production representing final  products
      with a COD:  BODr  ratio less  than  4, the incremental COD discharge
      shall be restricted to 0.50  lb/1,000 Ib anhydrous product.

For Subcategory Q, Manufacture of  Detergents by Dry Blending, New Sources:

COD - Where waste streams have a COD:   BOD7 ratio of 10 or less or the
      streams have a COD content of 0.26 lb/1,000 Ib anhydrous product
      or less, no pretreatment limitations are given.

      Where waste streams have a COD:   BOD-, ratio of 10 or more and  a
      COD content of more than 0.26 lb/1,000 Ib anhydrous product, COD
      pretreatment limits are:

                 Avg 30  Day                      Max. Day
                (lb/1,000 Ib                   (lb/1,000 Ib
              anhydrous  product)             anhydrous  product)

                    0.07                           0.14

-------
 76
For Subcategory R, Manufacture of Drum Dried Detergents, Existing Sources:

COD - Where more than 25 percent of the annual production is represented
      by final products having a COD:  BOD5 ratio greater than 4, the
      allowable COD discharge shall be restricted to 0.15 lb/1,000 Ib
      anhydrous product for that portion of the production representing
      final products with a COD:  BOD,- ratio equal to or greater than 4.
      For that portion of the production representing final  products with
      a COD:  BOD5 ratio less than 4, the incremental COD discharge shall
      be restricted to 0.30 lb/1,000 Ib anhydrous product.

For Subcategory R, Manufacture of Drum Dried Detergents, New Sources:

COD - Where waste streams have a COD:  BOD^ ratio of 10 or less or the
      streams have a COD content of 0.20 lb/1,000 Ib anhydrous product
      or less, no pretreatment limitations are given.

      Where waste streams have a COD:  BOD^ ratio of 10 or more and a
      COD content of more than 0.20 Ib/I500o Ib anhydrous product, COD
      pretreatment limits are:

                 Avg. 30 Day                  Max. Day
                (Tb/1,000 Ib               (lb/1,000 Ib
              anhydrous product)        anhydrous product)
                      0.05                      0.10


PRESCRIBED TREATMENT FOR DISCHARGE TO POTW

No specific pretreatment systems have been defined for soap and detergent
plants discharging to municipal sewers.  However, the EPA Development
Document on Soap and Detergent Manufacturing emphasizes caution with
respect to fats and oils from both soap and detergent plants.  Other
areas of caution include the manufacture of industrial cleaners and po-
tentially high zinc levels in wastes throughout the industry.

Fats and oils in wastes from soap plants, if excessive, should be passed
through gravity-type separators or well-designed fat traps.  This type of
pretreatment should remove at least 9Q% of the free oils which are re-
ported as the main source of problems in both municipal sewers and
treatment plants.  Fats and oils from detergent plants behave more like
hydrocarbons encountered in the organic chemical industry rather than
the natural fats.  Detergent-type fats are consequently less biodegradable.

Zinc concentrations greater than 5 mg/1 can exert adverse effect upon
biological POTW's.  Should zinc problems arise, alkaline precipitation
pretreatment may be employed.  Certain industrial cleaners contain

-------
                                                                        77
phosphoric acid, hydrofluoric acid and certain organics such as the
chlorinated benzenes.  Release of phosphates and fluorides may possibly
be controlled by in-house measures.  Chlorinated organics should be
restricted and/or controlled to a very close degree because of toxicity
to man and deleterious effects to waste treatment plants and receiving
waters.

The Federal Register of February 20, 1975 discusses pretreatment to
reduce COD loads from New Sources in the Soap and Detergent Industry.
Such measures may include installation of on-site storage to eventually
facilitate recycling of wastewater and materials back into the process.
Reasonable use of in-plant controls, especially when formulations con-
tain large amounts of refractory organic materials, will further reduce
COD loads to prescribed levels.

-------
 78
                   FERTILIZER MANUFACTURING INDUSTRY
      (182, 183, 184, 185, 186,  187,  188,  189,  190,  191,  192,  196)
                              [Part 418]

SUBCATEGORIZATION OF THE INDUSTRY

The fertilizer industry has been divided into seven  distinctly different
subcategories which have different pollutants,  waste treatment tech-
nologies and waste management problems.   These  subcategories are described
below:

A - Phosphate Subcategory.  Applicable to plants manufacturing sulfuric
acid by sulfur burning, and the  manufacture of  wet process phosphoric
acid, normal superphosphate, triple superphosphate and ammonium phos-
phate.  The manufacture of phosphoric acid includes  phosphate  rock
grinding, acid attack of phosphate rock, phosphoric  acid  concentration,  .
and phosphoric acid clarification.  All  of these operations usually
occur in a single complex separate from nitrogen fertilizer products.

B - Ammonia Subcategory.  Applicable to plants  manufacturing (anhydrous)
ammonia.  Ammonia is manufactured by high temperature - high pressure
gaseous reactions.  Adequate treatment of the primary waste constituent,
ammonia, can only be accomplished by treatment  separate from other
operations in a nitrogen fertilizer complex, i.e.  ammonia stripping, and
hence these activities are classed in a single  Subcategory.

C - Urea Subcategory.  Applicable to plants manufacturing urea.  The
synthesis of urea is characterized by high pressure  gaseous reactions.

D - Ammonium Nitrate Subcategory.  Applicable to plants manufacturing
(anhydrous) ammonium nitrate!Liquid ammonia and nitric  acid  are mixed
in a low pressure vessel and subsequently water is removed by  flash
vaporization.

E - Nitric Acid Subcateqory.  Applicable to plants producing nitric acid
used as an intermediate for the  manufacture of  fertilizer or for other
intermediates.  Nitric acid is essentially produced  via the oxidation of
ammonia at elevated temperatures.

F - Ammonium Sulfate Subcategory.  Applicable to plants producing ammo-
nium sulfate by the "Synthetic"  process and by  coke  oven  byproduct  re-
covery.  This Subcategory does not^apply to ammonium sulfate as a by-
product of caprolactum manufacturing.  In the synthetic process, virgin
ammonia and sulfuric acid are directly combined.  Coke oven ammonium
sulfate is produced from ammonia reclaimed from the  coking of coal  by
absorption with sulfuric acid.

-------
                                                                        79
G - Mixed and Blend Fertilizer Production Subcategory.  Applicable to
plants  producing mixed fertilizer and blend fertilizer.   "Mixed fer-
tilizer" manufacturing refers to a process which mixes wet and/or dry
straight fertilizer materials, mixed fertilizer materials, fillers and
additives progressing through chemical reactions to give  a certain
formulation.  "Blend fertilizer" manufacturing refers to  a process which
mixes dry, straight and mixed fertilizer materials to a given N-P-K
formulation.
NATURE OF PROBLEM

The Fertilizer Industry manufactures three types of nutrient products:
1) the nitrogen fertilizers including ammonia, urea, ammonium nitrate
and ammonium sulfate;  2) the phosphate fertilizers including phosphoric
acid, normal superphosphate and triplephosphate; and  3) combination
fertilizer comprising the ammonium phosphates, "Mixed" fertilizers, and
"Blend" fertilizers.

In the Phosphate Subcategory, processing requires large amounts of
cooling waters.  Leaks in heat exchange equipment cause escape of sul-
furic acid.  Waste pollutants from phosphates and sulfuric acid manu-
facturing include low pH, phosphorous, fluorides, cadmium, arsenic,
vanadium and uranium.  Cadmium is a major pollutant found in raw waste-
waters from phosphate Subcategory plants.  Phosphoric acid used for
fertilizers is produced by adding a strong acid, usually sulfuric, to
phosphate ores.  The ore is not pure and abundant fluorides and trace
amounts of cadmium, arsenic, vanadium and uranium will be leached out by
the acid.  Fluorine is volatized in processing and collected via water
scrubbers.  Large amounts of byproduct gypsum formed in the reaction are
sluiced to gypsum ponds.  The wastewaters from  the scrubbers are usually
sent to this same pond.  When phosphoric acid is concentrated, impurities
will be volatilized and collected within the barometric condenser waters.
Escaping gases from the production of superphosphates and ammonium
phosphates are treated by wet scrubbers. Phosphorous and fluorides are
present in these waters.  Ammonia is found in ammonium phosphate scrubber
waters.

In the Ammonia Subcateqory, nitrogen waste will be present as ammonia.
Highly varying pH levels and oil  and grease are important pollutants.
The principal process wastewater results from the condensation of excess
steam used in the primary reformer.  Ammonia in the condensate origi-
nates from recycle of purge gas,  from feed air containing ammonia, and
from ammonia inadvertantly formed in the shift converter.  Because
cryogenic equipment is used, condensate about the pipes, etc., can
absorb ammonia from leaks in seals.  Ammonia also emanates from absorp-
tion in cooling towers of various ammonia emissions.  Oil and grease are
mainly derived as drippings from pumps and high-pressure compressors.

-------
 80
 in the Urea Subcategory,  nitrogen  waste  is  characterized  by  ammonia  and
 organic nitrogen mixed with  urea.   Highly varying  pH  levels  are  also
 experienced.   Following high-pressure  gaseous  reactions,  the pressure  is
 reduced and ammonia,  carbon  dioxide and  ammonium carbamate are flashed
 from the ur.ea product.  These  flashed  gases receive water scrubbing.
 This scrub liquor together with  condensates from the  urea concentration
 step, result in a waste containing urea,  ammonium  carbamate, ammonia and
 carbon dioxide.  Prill tower operations  are responsible for  increased
 loads of ammonia and  urea.  Fine dust  from  prill towers and/or urea  pan
.granulators will enter the liquid  waste  collection systems via rain
 water and wash waters.

 In the Ammonium Nitrate Subcategory, nitrogen  waste is characterized by
 ammonia and nitrates.   Flash vaporization of water from the  dilute
 nitric acid is a major process wastewater.   The nitric acid-ammonia
 reaction is highly exothermic, and large  quantities of water with am-
 monia, nitric acid, nitrates and nitrogen dioxide  are evaporated.  Air
 scrubbing transfers these pollutants to  the water  phase.  As for urea,
 prilling of ammonium  nitrate causes a  fine  dust which can enter  the
 liquid waste collection systems  via wash  waters and rain  waters.

 In the Nitric Acid Subcategory.  nitrogen  waste is  characterized  mainly
 by nitrates.   The oxidation  of ammonia at elevated temperatures  gen-
 erates little or no process  wastewaters.  Leaks and spills are reported
 as the only sources of pollution from  nitric acid  manufacturing.

 In the Ammonium Sulfate Subcategory, major  waste sources  include con-
 taminated water, closed loop tower waters,  crystal wash waters,  pro-
 cess condensates, spills  and leaks, and miscellaneous.  Contaminated
 waters mostly refer to barometric  condenser waters coming off the sa-
 turator-crystallizers  and excess waters withdrawn  from the plant re-
 circulated water system(s).

 Mixed and Blend Fertilizer processing  is  represented  by a significantly
 large number of establishments in  the  U.S.   Waste  streams can include
 contaminated  water, process  waters, spills  and leaks, and miscellaneous.
 Contaminated  water in  most cases will  encompass liquors from the wet
 scrubbing of drier and/or ammoniator exhaust gases.   Contaminated water
 is usually bled out of the closed  loop recirculation  system  serving  the
 scrubbers.

 In summary,  principal  wastewaters  in fertilizer production are from
 manufacturing operations  including product  washdown and purification,
 closed loop tower blowdowns, process condensates,  wet scrubbing  ef-
 fluents, spills and leaks, and various runoff.

-------
                                                                         81
PARAMETERS OF CONCERN
          pH, Acidity, Alkalinity       IDS
          Ammonia Nitrogen              Phosphorous, phosphates
          Organic Nitrogen              Sulfates
          Nitrates, Nitrites            Cadmium
          Fluorides                     Arsenic
          COD                           Vanadium
          TSS                           Uranium
          Hardness                      Radium-226
          Oil and Grease                Temperature
                                        Phenols
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

For Subcategory A, Phosphate Production. Existing Sources

Pretreatment limitations have been equated to BPT limitations which are
described below.

I.  Process wastewaters are prohibited from discharge.  However for
(process) wastewaters from a calcium sulfate storage pile runoff fa-
cility operated separately or in combination with a water recirculation
system, there shall be no discharge except when there is an excess over
and above a surge capacity equal to the runoff from a 10-year, 24-hour
rainfall event; or_ when extremely unusual precipitation events cause the
water level to rise into the surge capacity in which case the wastewater
must be treated and discharged whenever the water level equals or exceeds
the mid-point of the surge capacity.

     The following concentrations shall be adhered to for excess storage
pond waters:
Pollutant
Total Phosphorus
Fluoride
TSS
PH
Avg. 30 Day
mg/1
as P 35
25
50
6.0 to 9.5
Max. Daily
mg/1
105
75
150
But the above TSS limits may be waived when process waters are chem-
ically treated and then settled in order to meet the other pollutant
limits.

II.  "Contaminated non-process wastewaters" are defined as:  "any water
including precipitation runoff which, during manufacturing or process-
ing, comes into incidental contact with any raw material, intermediate
product, finished product, byproduct or waste product by means of:  1)

-------
82
precipitation runoff;  2) accidental  spills;  3) accidental  leaks caused
by the failure of process equipment and which are repaired or the dis-
charge of pollutants therefrom contained or terminated within the short-
est reasonable time which shall not exceed 24 hours after discovery or
when discovery should reasonably have been made, whichever is earliest;
and 4) discharges from safety showers and related personal safety
equipment, and from equipment washings for the purpose of safe entry,
inspection and maintenance;  provided that all reasonable measures have
been taken to prevent, reduce, eliminate and control to the maximum
extent feasible such contact, and provided further that all  reasonable
measures have been taken that will  mitigate the effects of such contact
once it has occurred."  For these contaminated non-process waters, the
following concentrations shall be adhered to:
Pollutant
Total Phosphorus as P
Fluoride
PH
Avg. 30 Day
mg/1
30
25
6.0 to 9.5
Max. Daily
mg/1
105
75
For Subcategory A, Phosphate Production, New Sources

There shall be no discharge of process wastewater pollutants.


For Subcategory B, Ammonia Production, Existing Sources

Pretreatment limitations have been equated to BPT limitations which are
described below.

                           Avg. 30 Day            Max.  Daily
   Pollutant      lb/1,000 Ib anh. ammonia  1b/l,000 Ib anh. ammonia

 Ammonia as N                0.0625                 0.1875
 pH                                   6.0 to 9.0


For Subcategory B, Ammonia Production, New Sources

Pretreatment limitations have not yet been specified.


For Subcategory C, Urea Production, Existing Sources

Pretreatment limitations have been equated to BPT limitations which are
described below.  Limitations are applicable to the manufacture of urea.
Discharge from shipping losses and precipitation runoff are excluded.

-------
                                                                         83
 I.   Manufacturing  operations  in which urea  is  "prilled" or granulated.

                         Avg.  30 Day                  Max. Daily
   Pollutant          lb/1,000  Ib urea product    lb/1,000 Ib urea product


 Ammonia  as N                   0.46                     0.92
 Organic  nitrogen as  N          0.55                     1.03
 pH                                    6.0 to 9.0
 II.   Manufacturing  operations  in which urea is produced as a solution
 product.

                         Avg.  30 Day                  Max. Daily
   Pollutant          lb/1,000 Ib urea product    lb/1,000 Ib urea product

 Ammonia as N                 0.43                       0.85
 Organic nitrogen  as N        0.27                       0.50
                                     6.0 to 9.0
 For  Subcategory C. Urea  Production, New Sources

 Pretreatment  limitations have not yet been specified.


 For  Subcategory D, Ammonium Nitrate Production, Existing Sources

 Pretreatment  limitations have been equated to BPT limitations which are
 described  below.  Limitations are applicable to the manufacture of
 ammonium nitrate.  Discharges from shipping losses and precipitation
 runoff are excluded.

                         Avg. 30 Day                  Max. Daily
   Pollutant        lb/1,000 Ib ammomium nitrate  lb/1,000 Ib ammonium nitrate

 Ammonia as N                0.35                         0.66
 Nitrate as N                0.36                         0.66
 pH                                    6.0 to 9.0


 For  Subcategory D, Ammonium Nitrate Production. New Sources

 Pretreatment  limitations have not yet been specified.


 For  Subcategory E, Nitric Acid, Existing Sources

 Pretreatment  limitations have been equated to BPT limitations which
are described below.   Limitations  are  applicable to  the manufacture

-------
 84
of nitric acid in concentrations up to 68%.   Discharge from shipping
losses are excluded.  In the regulations,  certain terms are defined.
"Shipping losses" refer to the discharges  from loading tank cars or
tank trucks; discharges from cleaning tank cars or tank trucks;  and
discharges from air pollution control scrubbers designed to control
emissions from loading or cleaning tank cars or tank trucks.   The
term "shipped liquid ammonia" refers to liquid ammonia commercially
shipped for which the Department of Transportation requires 0.2%
minimum water content.  The term "non-contact cooling water"  shall
mean water which is used in a cooling system designed so as to main-
tain constant separation of the cooling medium from all contact  with
process chemicals but which may on the occasion of corrosion, cooling
system leakage or similar cooling system failure contain small amounts
of process chemicals,...."


I.  Nitric acid production in which all raw material ammonia is  in
the gaseous form.

                        Avg. 30 Day                      Max. Daily
 Pollutant        lb/1,000 Ib nitric acid  on     lb/1,000 Ib nitric acid on
                    the basis of 100% HN00         the basis of  100% HNO-
Ammonia as N
Nitrite as N
PH
0.0007
0.044
6.0 to 9.0
0.007
0.33
II.  Nitric Acid production in which all raw material  ammonia is in the
shipped liquid form.

                        Avg. 30 Day                      Max. Daily
  Pollutant   lb/1,000 Ib nitric acid on      lb/1,000 Ib nitric acid on
               the basis of 100% HN00           the basis of 100% HNO-
Ammonia as N
Nitrate as N
PH
0.0008
0.044
6.0 to 9.0
0.08
0.33
III.  Non-Contact Cooling Water Limitations.

                 Parameter                     Limitation

                   pH                           6.0 to 9.0

-------
                                                                         85
For Subcateqory E, Nitric Acid, New Sources.

Limitations are applicable to the manufacture of nitric acid in con-
centrations, up to 68%.   Discharges from shipping losses are excluded.


I.  Nitric Acid production in which all raw material  ammonia is in the
gaseous form.

                         Avg. 30 Day                  Max.  Daily
  Pollutant      lb/1,000 Ib nitric acid on  lb/1,000 Ib nitric acid on
                   the basis of 100% HN03      the basis of 100% HN03


 Ammonia as N            0.00045                      0.0045
 Nitrate as N            0.023                     -   0.17
II.  Nitric acid production in which all  raw material  ammonia is in the
shipped liquid form.

                         Avg.  30 Day                  Max.  Daily
   Pollutant     lb/1,000 Ib nitric acid  on   lb/1,000 Ib nitric acid on
                  the basis of 100% HN03        the basis of 100% HN03

  Ammonia as N           0.008                        0.08
  Nitrate as N           0.023                        0.17
III.  Non-contact cooling water limitations.

          Parameter                    Limitation
             pH                        6.0 to 9.0


For Subcategory F, Ammonium Sulfate Manufacturing, Existing and New Sources

          Pollutant                 Pretreatment Standard

          Ammonia as N                  30 mg/1
          pH, BOD, TSS                 No limitations


For Subcategory G, Mixed and Blend Fertilizer Production, Existing and
New Sources

          Pollutant                 Pretreatment Standard

          Ammonia as N                  30 mg/1
          Total Phosphorous as P        35 mg/1
          pH, BOD, TSS, Nitrates        No limitations

-------
 86
In summary, the waste waters from fertilizer plants, if passed to con-
ventional secondary treatment municipal  plants may not be amenable to
reduction of wastwater pollutants, and furthermore, could cause severe
adverse impact on proper functioning of the POTW.   Accordingly, pre-
treatment criteria especially for ammonia nitrogen, should be relatively
stringent.
SUSPENSION AND REVOCATION OF CERTAIN FERTILIZER EFFLUENT REGULATIONS
AND GUIDELINES

On June 23, 1975, the Federal  Register effectively suspended the whole
of Subcategory D (Ammonium Nitrate) effluent limitations and regulations
including pretreatment stipulations.

The Federal Register publication of March 25, 1977 made subsequent
changes on pretreatment limitations for the Fertilizer Industry.  Spe-
cifically, for Subcategories A and E, respectively, the Phosphate and
Nitric Acid Subcategories, pH limits were revoked for Existing and for
New Sources.  It was determined that maintaining pH levels in the 6-9
range from the subject plants was not completely reasonable.

-------
                                                                     87
                      PETROLEUM REFINING INDUSTRY
                         (197, 198, 199, 200)
                               [Part 419]

SUBCATEGORIZATION OF THE INDUSTRY

The Petroleum Refining Industry has been divided into six major sub-
categories described as follows:

A - Topping Subcategory.  Applies to facilities which produce petroleum
products by topping and catalytic reforming whether or not the facility
includes other processes in addition to topping and catalytic reforming.
This subcategory is not applicable to facilities having thermal pro-
cesses such as coking, visbreaking, and catalytic cracking operations.

Specialized definitions are given for "runoff", "ballast", "feedstock",
"once-through cooling water", and units of measurement shown below.
These definitions are important in terms of additional waste load allo-
cations permitted under BPT, BAT and New Source regulations.

Runoff - refers to the flow of storm water.

Ballast - refers to the flow of wastes from a ship, which are treated
at the refinery.
Feedstock - refers to the crude oil and natural gas liquids fed to the
topping units.

Once-through Cooling Waters - refers to discharges that are used for the
purpose of heat removal and that do not come into direct contact with
any raw material, intermediate, or finished product.
M gal. - shall mean one thousand gallons; M bbl. shall mean one thousand
barrels.  One barrel is equivalent to 42 gallons.

B - Cracking Subcategory.  Applies to facilities which produce petroleum
products by topping and cracking, whether or not the facility includes
any other processes in addition to topping and cracking.  This sub-
category is not applicable to facilities having processes specified
under Subcategories C, D or E.

Specified definitions are the same as for Subcategory A plants.

C - Petrochemical Subcategory.  Applies to facilities which produce
petroleum products by topping, cracking and petrochemical operations,
whether or not the facility includes any processes in addition to
topping, cracking and petrochemical operations.  This subcategory is not
applicable to facilities having processes specified under Subcategories D
and E.  Specialized definitions are the same as for Subcategory A plants

-------
 88
to which is added the term "petrochemical operations."  Petrochemical
operations are defined as the production of second generation petro-
chemicals, i.e., alcohols, ketones, cumene, styrene, etc., or first
generation petrochemicals and isomerization products, i.e. BTX, olefins,
cyclohexane, etc., when 15 percent or more of refinery production com-
prises first generation petrochemicals and isomerization products.

D - Lube Subcategory.  Applies to facilities which produce petroleum
products by topping, cracking and lube oil manufacturing processes,
whether or not the facility includes any processes in addition to top-
ping, cracking and lube oil manufacturing.  This subcategory is not
applicable to facilities having processes specified under Subcategories
C and D.  Specialized definitions are the same as for Subcategory A
plants.

E - Integrated Subcategory.  Applies to facilities which produce petro-
leum products by topping, cracking and lube oil manufacturing processes,
and petrochemical operations, whether or not the facility includes any
process in addition to topping, cracking, lube oil manufacturing pro-
cesses and petrochemical operations.  Specialized definitions are the
same as for Subcategory C plants.

In terms of providing general understanding of petroleum refining pro-
cessing, the following description of processes may be helpful:

Distillation - separates hydrocarbon molecules by differences in their
               physical properties, i.e., boiling points.

Cracking - the breaking down of high molecular weight hydrocarbons to
           lower weight hydrocarbons.

Polymerization and Alkylation - the rebuilding of hydrocarbon molecules.

Isomerization and Reforming - the rearranging of molecular structures.

Solvent Refining - the separation of hydrocarbon molecules by differences
                   in solubility in other compounds.

Desalting and Hydrotreating - the removal of impurities occurring in
                              the feedstocks.

Miscellaneous Operations - these include the removal of impurities from
                           finished products by various treating and
                           finishing processes, et. al.

-------
                                                                   89
NATURE OF PROBLEM

As of January 1973, a total of 247 operating petroleum refineries were
reported in the United States having a combined crude oil processing
capacity of 14 million barrels/day.  Individual plants ranged in capacity
from 200 to 434,000 barrels/day.  Because of crude supply limitations,
most new refinery capacity is being designed to handle higher sulfur
crudes.  This trend leads to increased sour water stripping, desalting,
more sour heavy bottoms, and greater efforts to reduce sour gas emis-
sions and general problems of corrosion through the refinery.

Ammonia, sulfide and phenol at a refinery originate from sour water
waste streams.  Sour waters are produced when steam is used as a strip-
ping medium in the various cracking processes at a refinery.

Oil and grease may be generated by a wide variety of operations at a
refinery, including pad washings, tank bottom washings, and contaminated
storm runoff.

Chromium is primarily associated with cooling tower blowdown when chro-
mium compounds are employed as corrosion inhibitors in the refinery
cooling water systems.
PARAMETERS OF CONCERN

          BOD                           Zinc
          COD                           IDS

          Oil/Grease                    TSS
          Sulfides                      TOC

          Ammonia N                     Temperature
          pH, Acidity, Alkalinity       Chlorides
          Phenols                       Fluorides
          Chromium, total  and           Phosphates
           hexavent                     »..    ,, .  ,
                                        Other Metals

-------
.90
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
MEASURES

Pretreatment Standards for Existing Plants Within Subcategories A
Through E~(That for New Sources have not yet been clearly defined).

          Parameter                Daily Max. Value
          Ammonia as N                 100 mg/1
          Oil/Grease                   100 mg/1

          pH                    Shall not be lower than 5.0 in order
                                to minimize corrosive structural damage,
                                unless the POTW is specifically designed
                                to accommodate the given conditions.
It is recognized at relatively low concentrations in biological treat-
ment, ammonia may serve usefully as a nutrient.  At excessively high
levels however, ammonia will inhibit the biological process and pass
through the POTW untreated.

Phenolic compounds are said to be biodegradable by acclimated biota.
Many POTW's can accept phenol-containing industrial wastes without
upset.  In cases where a POTW cannot handle phenolic wastes of a spe-
cific refinery, a maximum daily phenol limitation of 0.35 mg/1 has been
developed as guidance.

Chromium pretreatment limits have not been established.  However, when
chromium is' judged to cause detrimental effect upon POTW's a daily max-
imum total chromium limit of 1.0 mg/1 can be attained and is cited as
guidance.  It is suggested that cooling tower blowdown be segregated,
and hexavalent chromium be reduced to trivalent chromium using sulfur
dioxide, followed by waste settling.

SuIfides in refinery wastewaters can interfere with successful operation
of POTW's and cause corrosion in concrete waste conveyance pipelines.
When sulfides are judged to cause significant detrimental effect upon
POTW's, a daily maximum sulfide limit of 3.0 mg/1 can be attained and is
cited as guidance to POTW's.

It is reported that pretreatment limitations for the Petroleum Refining
Industry will generally require implementation of control and pretreat-
ment technology similar to that practiced by direct dischargers in the
industry.  This includes sour water strippers for removing ammonia from
sour water waste streams; and dissolved air flotation (DAF) units or
equivalent methods, in addition to API separators, for removing oil and
grease content.  Also, sufficient waste equalization should be strongly
considered in all pretreatment systems.

-------
                                                                       91
       IRON AND STEEL MAKING SEGMENT OF IRON AND STEEL INDUSTRY
                          (12, 208, 209,  210)
                               [Part 420]

SUBCATEGORIZATION OF THE INDUSTRY

Twelve Subcategories described as Subcategories A through L have been
defined for the Iron and Steel Making Segment of the Iron and Steel
Industry.  Fourteen other Subcategories are included under the Hot
Forming and Cold Finishing Segment of the Iron and Steel  Industry which
are described in another section of this  report.   It is noted that
Subcategories G, K and L and their accompanying pretreatment limita-
tions below encompass alloy and stainless steel in addition to customary
carbon steel.

     A)   Byproduct Coke subcategory
     B)   Beehive Coke subcategory
     C)   Sintering subcategory
     D)   Blast Furnace (Iron) subcategory
     E)   Blast Furnace (Ferromanganese)  subcategory
     F)   Basic Oxygen Furnace (semi-wet  air pollution controls)
          subcategory
     G)   Basic oxygen Furnace (wet air pollution controls)  subcategory
     H)   Open Hearth Furnace subcategory
     I)   Electric Arc Furnace (semi-wet  air pollution controls)
          subcategory
     J)   Electric Arc Furnace (wet air pollution controls)  subcategory
     K)   Vacuum Degassing subcategory
     L)   Continuous Casting and Pressure Slab Molding subcategory

     Subcategory A. Byproduct Coke -   Coke making operations  conducted
     by the heating of coal  in slot-type  ovens in the absence of  air
     to produce coke.

     Subcategory B, Beehive  Coke - Coke making operations  conducted
     by the heating of coal  with the  admission of air in  controlled
     amounts.   Beehive coking operations  do not have accompanying
     byproduct plants.

     Subcategory C. Sintering -  A sinter plant conducts  heating  of
     iron bearing wastes (mill scale  and  dust from blast  and  steel
     making furnaces) together with fine  iron ore,  limestone  and  coke-
     fines in an ignition furnace in  order to produce a special
     agglomerate or sinter.   This latter  is charged into  the  blast
     furnace.

-------
92
    Subcategory D, Blast Furnace (Iron) - Comprises the making of iron
    in which iron ore is reduced to molten iron within a blast furnace.

    Subcategory E, Blast Furnace (Ferromanganese) - Iron/manganese
    ores are reduced to molten ferromanganese in a blast furnace.
    Ferromanganese differs from Subcategory D (Iron blast furnace)
    in requiring higher operating temperatures in the blast furnace,
    which  in turn is said to produce higher concentration of pollutant
    parameters, notably cyanides, in the gas washing waters.

    Subcategory F. Basic Oxygen Furnace (with semi-wet air pollution
    controls) - Carbon steel is manufactured in a basic oxygen furnace
    equipped with a semi-wet dust collection system.  With the semi-
    wet system a spark box or a spray chamber using slightly more
    water  than can be evaporated is used to condition the gases for
    further cleaning, producing a highly contaminated but relatively
    small  volume of waste water.

    Subcategory G, Basic Oxygen Furnace (with wet air pollution con-
    trols) - Carbon steel is manufactured in a basic oxygen furnace
    equipped with a wet dust collection system.  With the wet system
    high energy scrubbers or wet gas washers are used to cool and to
    condition furnace gases, producing much larger volumes of
    moderately-contaminated waste waters than are found for the
    semi-wet systems.

    Subcategory H, Open Hearth Furnace - Carbon steel is manufactured
    in an  open hearth furnace equipped with wet dust collection systems.

    Subcategory I, Electric Arc Furnace (with semi-wet air pollution
    controls) - Carbon steel is manufactured in electric arc furnaces
    equipped with semi-wet dust collection systems.  With the semi-wet
    system, a spark box or a spray chamber using slightly more water
    than can be evaporated is used to condition the gases for further
    cleaning in a precipitator or baghouse.  A relatively small
    volume of contaminated waste water may be produced, depending
    upon the degree of excess spray water employed.

    Subcategory J, Electric Arc Furnace (with wet air pollution controls
    Carbon steel is manufactured in electric arc furnaces equipped with
    wet furnace off-gas dust collection.  With the wet system, high
    energy scrubbers or wet gas washers are used to cool and to condi-
    tion furnace gases, producing much larger volumes of moderately-
    contaminated waste waters than are found for the semi-wet systems.
     Subcategory  K. Vacuum Degassing -  Degassing operations comprise
     application  of a vacuum to molten steel to further refine the
     steel  product.  Degassing removes hydrogen, carbon and oxygen and

-------
                                                                       93
     any other volatile alloys from the steel, along with minute
     particles of iron oxide.  These gases together with exhaust
     steam, are condensed by direct contact with cooling water,
     producing a contaminated waste water.

     Subcategory L, Continuous Casting and Pressure Slab Molding -
     The continuous formation of a primary steel shape (such as a
     slab, billet or bloom) from molten steel by casting through a
     water cooled mold.  Most of the water serving the continous
     casting operations is used for mold and machine cooling.  The
     latter represent noncontact systems on closed recycle with no
     contamination.  Dirty process waters originate from open spray
     methods.  Pressure slab molding is the casting of a slab in a
     mold by a bottom pouring method.
NATURE OF PROBLEM

Approximately 92 percent of the 1972 total U.S. annual  steel  ingot
production was produced by 15 major steel corporations.   This also
represented 22.5 percent of the world total of 625 million ingot tons
of steel produced in 1972.  Steel production in 1969 was a record
141 million ingot tons.  In 1972, approximately 65 million tons of
coke, 83 million tons of iron, and 134 million tons of steel, were
manufactured.

Three series of operations are involved in the production of  steel.
Coal is first converted to pure carbon, coke.   Secondly, coke is
combined with iron ore and limestone in a blast furnace to produce
iron.  Thirdly, iron is purified into steel in either an open hearth,
basic oxygen, or electric arc furnace.  Further refinements include
degassing, etc.  Steel not cast into ingot molds can be cast  in a
process called continuous casting.  The sintering plant as part of
the present day integrated steel mill has the  main function of agglo-
merating and recycling (waste) fines back to the blast furnace.

Characteristics of wastes from the various Subcategories and  the
identified sources of pollutants are described as follows:

     A)   By Product Coking - Major pollutants include  ammonia,  BOD,
     cyanides, phenols, oils and grease,  sulfides, TSS  (and varying pH).
     Major waste sources comprise excess  ammonia liquor  resulting from
     the condensation of moisture originally present in  the raw coal
     before coking; wastes from the light oil  recovery  system; overflows
     from the final cooler recycle system; condensates  from desulfurizers;
     effluents from baro-meter condensers; and indirect  cooling  waters.
     Additional waste sources may include coke wharf drainage, quench
     water overflow, and coal pile runoffs. Beyond conventional  waste
     treatments, additional technology for reducing waste at  by-product
     coke plants includes steam stripping of ammonia liquor,  depheno-
     lization, and desulfurization.

-------
94
   B)   Beehive Coke - Important pollutant parameters are ammonia,
   BOD, cyanides, phenols, TSS and heat.   In comparison to byproduct
   coking, wastewater quantities from beehive coking are considerably
   lower since the bulk of the volatile waste components (unfortu-
   nately) are allowed to escape to the atmosphere.   Process water
   contacts the coke materials during the quenching  operation carry-
   ing along fine particles of coke and dissolving various residues
   from the product.

   c)   Sintering - Significant pollutants include TSS, oil  and grease,
   sulfides and fluorides.  Sinter plants built in the 1950's are
   more likely to have wet scrubbers vs.  plants constructed more
   recently.  Main pollutants associated with a wet  system are TSS
   washed out of the process gases; oils and greases from mill scale
   which are vaporized during sintering then scrubbed out; sulfides
   from coke fines; and fluorides from fluorspar and limestone
   found in flue dusts from the steelmaking processes.   The pollu-
   tants will vary depending upon the various blends of iron bearing
   dust and mill scale, coke fines and limestone constituting a
   typical sinter burden.

   D)   Blast Furnace (Iron) - Major pollutants are  TSS, cyanides,
   phenols, ammonia, sulfides (and varying pH).  Main waste sources
   include the waters used for contact tooling of blast furnace gases
   and the scrub waters used to wash blast furnace gases free of fine
   particulates so as to permit their use as a fuel.  TSS, in the waste
   waters originate with these fines from the gases.  Cyanides, phenols
   and ammonia originate with the coke material charged to the blast
   furnace especially if the coke had been quenched  with contaminated
   waters.  Sulfides are produced as hydrogen sulfide gas caused by
   the reducing atmosphere in the blast furnace.   Fluorides  occur in
   the gas streams from the decomposition of raw materials charged to
   the furnace which are easily transferred to the gas  washer waters.

   E)   Blast Furnace (Ferromanganese) -  Pollutants  include TSS,
   cyanides^ phenols, ammonia, sulfides,  manganese (and varying pH).
   The two main waste sources are the waters used for cooling the
   blast furnace gases, and the waters for scrubbing the gases free
   of fine particulates to permit their use as fuel.  TSS in the
   waste waters originate with these particulates which are  relatively
   high in manganese.  Cyanides, phenols  and ammonia originate from
   the coke material charged to the furnace.  Sulfides  are produced
   as hydrogen sulfide gas caused by the  reducing atmosphere in the
   blast furnace.

-------
                                                                   95
     F)   Basic Oxygen Furnace (semi-wet air pollution controls)
     Pollutant parameters principally comprise TSS and fluorides,
     both of which are scrubbed out of the BOF gas streams  during
     water contact.  Varying pH may also constitute a problem.

     G)   Basic Oxygen Furnace (wet air pollution  controls)  -  Pollutants
     and waste sources are the same as described above for  Subcategory  F.

     H)   Open Hearth Furnace - Known pollutants include TSS,  fluorides,
     zinc, nitrates, and varying pH.   These contaminants are scrubbed
     out of the furnace gas streams during water contact.

     I)   Electric Arc Furnace (semi-wet air pollution controls)
     Important pollutants are TSS,  zinc and fluorides, all  of  which
     are scrubbed out of the furnace  gas streams during water  contact.

     J)   Electric Arc Furnace (wet air pollution  controls)  -  Pollu-
     tants and waste sources are the  same as described above for
     Subcategory I.

     K)   Vacuum Degassing - Known  significant constituents  in  the
     waste waters comprise TSS, zinc, manganese, lead, nitrates  (and
     varying pH).  These contaminants originate from the water  scrub-
     bing of the gases under vacuum.

     L)   Continuous Casting and Pressure Slab Molding - Major
     pollutants include TSS, oil and  grease (and varying pH).   These
     contaminants are derived from  the contact cooling of the  cast
     materials and the washing and  cleaning of the molds.
PARAMETERS OF CONCERN

          pH, Acidity, Alkalinity*           TDS
          Ammonia*                           Turbidity
          BOD*                               Beryllium
          Cyanide, total*                    Chlorides
          Oil/Grease*                        COD
          Phenols*                           Color
          Sulfides*                          Heat
          TSS*                               Mercury
          Manganese*                         TKN
          Fluorides*                         Sulfates
          Zinc*                              Thiocyanates
          Nitrates*                          TOC
          Lead*                              Sodium
          Aluminum                           Potassium
          Hardness                           Phosphorous
             Most significant pollutants.

-------
  96
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
MEASURES

For Subcategories A through L, Existing and New Sources.

No specific limitations have been prescribed to date for  Existing and
New sources in the Iron and Steel Industry connected to POTW's.   How-
ever, the Federal regulations and the EPA Development Document for the
Iron and Steel Making Segment of the Iron and Steel  Industry describe
wastewaters from Subcategories A through L as containing  high concen-
trate of ammonia, oil/grease, cyanide, sulfides, phenols, fluorides,
nitrates, lead, zinc and manganese all of which could interfere with
the successful operation of POTW's, pass through such works  untreated
or inadequately treated, or otherwise be incompatible with the POTW.
Therefore, such process waste waters should receive  special  considera-
tion by the operator of the POTW, and are subject to future  regulation.

-------
                                                                      97
            HOT FORMING, COLD FINISHING AND SPECIALTY STEEL
                  SEGMENT OF IRON AND STEEL INDUSTRY
                          (11, 12, 206, 207)
                              [Part 420]

SUBCATEGORIZATION OF THE INDUSTRY

Fourteen Subcategories described as Subcategories M through Z have
been defined for the Hot Forming and Cold Finishing Segment of the
Iron and Steel Industry.  The first twelve Subcategories,  i.e. Sub-
categories A through L have been previously incorporated under the
Steel Making Segment of the Iron and Steel Industry.  Pretreatment
limitations for the Steelmaking Segment are given in another section
of this report.  The Subcategories and limitations below cover both
carbon steel and specialty steel hot forming and cold finishing
operations.

          M)   Hot Forming, Primary
          N)   Hot Forming, Section
          0)   Hot Forming, Flat
          P)   Pipes and Tubes
          Q)   Pickling, Sulfuric Acid, Batch and Continuous
          R)   Pickling, Hydrochloric Acid, Batch and Continuous
          S)   Cold Rolling
          T)   Hot Coating, Galvanizing
          U)   Hot Coating, Terne
          V)   Miscellaneous Runoffs
          W)   Combination Acid Pickling, Batch and Continuous
          X)   Scale Removal, Kolene and Hydride
          Y)   Wire Pickling and Coating
          Z)   Continuous Alkaline Cleaning

Subcategory M, Hot Forming, Primary -  Operations involving reduction
of hot steel ingots into slabs and blooms by rolling and associated
processes.

Subcategory N, Hot Forming, Section - Operations involving  reduction
of hot steel blooms into various shapes and sizes of products including
billets, bars, rods and sections.

Subcategory 0, Hot Forming, Flat -  Operations involving the reduction
of hot steel slabs into plates, strips and sheet steel  or skelp.

Subcategory P, Pipes and Tubes - Operations producing welded or seam-
less pipe or tube, either by welding hot or cold skelp,  or  by piercing
hot blooms.

-------
98
 Subcategory Q,  Pickling,  Sulfuric  Acid  Batch  and  Continuous  - Operations
 involving the immersion of rods, wire,  strip  or similar  steel products
 in a sulfuric acid bath and subsequent  rinsing.

 Subcategory R,  Pickling,  Hydrochloric Acid  Batch  and  Continuous  -
 Operations involving  the  immersion of rods, wires,  strip or  similar
 steel  products  in a hydrochloric acid bath  with rinsing  and  associated
 absorber vent and fume hood scrubbers.

 Subcategory S,  Cold Rolling -  Operations  involving  the size  reduction
 and improvement in surface or  mechanical  properties of unheated  steel
 with associated rolling and cooling oils  and  solutions.

 Subcategory T,.  Hot Coat,  Galvanizing -  Operations involving  the  immer-
 sion of steel  strip or pipe in a bath of  molten zinc; and associated
 processes.

 Subcategory U,  Hot Coat,  Terne - Operations involving the immersion of
 steel  in a bath of molten lead and tin, and associated processes.

 Subcategory V,  Miscellanous Runoffs - Runoff  from coal,  limestone, and
 ore storage piles and discharges from castings and  slagging  operations.

 Subcategory W,  Combination Acid Pickling, Batch and Continuous -
 The pickling of specialy  steel  in  a nitric  acid and hydrofluoric acid
 bath,  with or without a sulfuric acid or  hydrochloric acid bath  used
 in-line with the nitric-hydrofluoric acid bath.  After immersion in
 the acid bath(s), the steel  is rinsed.

 Subeategory X,  Scale  Removal,  Kolene and  Hydride - The removal of
 scale  from alloy or stainless  steel by  immersion  in a bath of a molten
 salt such as kolene or hydride.

 Subcategory Y,  Wire Pickling and Coating  - The pickling of alloy or
 stainless steel  wire  and  the coating of the wire  (with copper or
 another metal)  to assist  in further drawing of the wire.

 Subcategory Z.  Continuous Alkaline Cleaning - The removal of rolling
 oil  or other material  from alloy or stainless steel in a continuous
 process involving the electrolysis of the steel in an alkaline solution.


 NATURE OF PROBLEM

 Hot steel  working differs considerably  from cold finishing operations.
 Essentially hot working of steel involves the deformation of steel at
 elevated temperatures of  2150°F to 2450°F whereas cold finishing
 processes are carried out at far lower  temperatures, i.e. less than
 1000°F.   Hot forming  operations rquire  relatively large pieces of

-------
                                                                       99
machinery and auxiliary equipment.  Generally cold finishing processes
deal with much small steel sizes and do not utilize relatively large
equipment.  Cold finishing processes are used to impart certain surface
characteristics to the steel products.  Similarly, pickling and coating
are surface preparation procedures and do not involve any of the princi-
pal forming or shaping operations.

Pickling processes clean the metal surface by chemical means, i.e.  with
acids.  Coating operations serve to cover the surface of the steel  with
another metal in order to impart special surface characteristics such
as corrosion resistance.  Pickling and coating processes may be either
batch or continuous type.  The principal coating materials include  tin,
chromium, copper, lead and zinc.

Principal wastewater characteristics include oil and grease and TSS
from hot forming and cold rolling processes; and tin, lead, chromium,
copper and zinc from coating operations.  Certain operations particularly
steelmaking, pickling and hot coating processes require the use of
wet gas cleaning equipment which create unique liquid scrubbing effluents.

Characteristics of wastes from the various subcategories and the iden-
tified sources of pollutants are described as follows:

     M)   Hot Forming, Primary - TSS, oil and grease are derived from
     washing scale from the surface of the steel with water.  Water
     is also used to transport scale through the flumes below the mill
     lines.  The oils and greases principally originate from hydraulic
     and lubricating systems.  Additional wastewaters are generated
     from scarfing operations which include the flush water to remove
     the hot scale from the product generated by the scarfer; sprays
     to protect against heat and flying scale particles; and wet
     scrubbing effluents for removal of fume and smoke generated by
     scarfing.

     N)  Hot Forming, Section - TSS, oil and grease principally coming
     from washing scale off the surface of steel with water, and other
     water used to transport scale through the flumes beneath the mill
     lines.

     0)  Hot Forming, Flat -  TSS, oil and grease principally coming
     from washing scale off the surface of steel with water, water
     used to transport scale through the flumes beneath the mill  lines,
     and other water for cooling the strip on the runout table.

     P)  Pipes and Tubes - TSS, oil and grease contained in roll  spray
     cooling waters, cooling bed and spray quench waters.

-------
100
      Q)   Pickling, Sulfuric Acid,  Batch  and  Continuous  -  TSS, dissolved
      iron and low pH's associated  with spent,  concentrated waste pickle
      liquor and dilute solutions from the  dunk and  spray  rinsing of
      pickled.products.  Wastewaters  are  also generated  by fume scrubbers,

      R)   Pickling, Hydrochloric Acid, Batch  and Continuous - TSS,
      dissolved iron and low pH's associated  with the  same type of pick-
      ling operations as for Subcategory  Q.   The operations of hydro-
      chloric acid regeneration plants represents an additional potential
      waste source.

      S)   Cold Rolling - TSS,  oil and grease  caused  by the dumping of
      spent rolling solutions  used  to provide cooling  and  lubrication
      to  the rolls and the  products.  These wastes contain oil and
      grease in the form of water soluble oils  as well as  tramp oils
      from mill  equipment lubricating systems.

      T)   Hot Coatings, Galvanizing - TSS, oil  and grease, zinc,
      chromium and varying  pH  in wastes from  cleaning, chemical
      treatment and acid, alkaline or neutral rinses applied to
      the products before and  after coating together with  spent
      baths and other solutions from  the  coating  operations.  Wet
      fume hood scrubbers may  also be present generating a waste
      scrubbing effluent.

      U)   Hot Coatings, Terne  - TSS,  oil  and  grease, lead, tin and
      varying pH levels resulting from various  cleaning or coating
      rinses utilized on the products before  and  after coating.
      Wet fume  hood scrubbers  may also be present generating addi-
      tional  waterborne waste.

      V)   Miscellaneous Runoffs, Storage  Piles,  Casting and Slagging -
      TSS is reported as the main pollutant.

      W)   Combination Acid  Pickling,  Batch and  Continous -  TSS,
      chromium,  iron, fluorides and nickel associated with spent
      concentrated waste pickle liquors and dilute solutions from
      the dunk  and spray rinsing of pickled products.  Wastewaters
      are also  generated by fume scrubbers.

      X)   Scale  Removal,  Kolene and Hydride - TSS, chromium, iron,
      cyanide (and possible pH problems)  resulting from the removal
      of  scale  by  molten salt  baths and ensuing  dunk or spray
      rinsing.

      Y)   Wire  Pickling and Coating - TSS, chromium, iron, cyanide,
      fluorides,  nickel, copper, and  low  pH's resulting from pickling
      and coating  operations.  Wastewaters may  consist of  spent con-
      centrated  solutions and  dilute  rinses.

-------
                                                                      101
     Z)   Continuous Alkaline Cleaning - TSS, chromium, iron, nickel
     and high pH's resulting from the cleaning of alloy or stainless
     steel strip for the removal of oils and greases.  Wastes may consist
     of spent concentrated solutions and dilute rinses.
PARAMETERS OF CONCERN
          pH, Acidity, Alkalinity
          Alumi num
          Ammonia N
          Beryllium
          BOD
          Cadmium
          Calcium
          Chlorides
          Chromium, hexavalent
               and total
          Cobalt
          Color
          COD
          Copper
          Cyanide, free and
               total
          Flow
          Fluoride
          Hardness
          Iron, dissolved, ferrous
               and total
          Lead
Magnesium
Manganese
Mercury
Molybdenum
Nickel
Nitrogen
Odor
Oil and Grease
Phenols
Phosphates
Selenium
Sulfates
Sulfide
Sulfite
IDS
Temperature
Thiosulfate
Tin
Titanium
TOC
TSS
Tungsten
Turbidity
Zinc
Zirconium
PRELIMINARY LIMITATIONS AND PRESCRIBED PRETREATMENT FOR DISCHARGE TO
POTW

In the EPA Development Document for the Hot Rolling and Cold Finishing
Segment of the Iron and Steel Industry, it is reported that pickle
liquor generally can be discharged to public sewers but only in limited
quantities.  Furthermore these liquors should be at least partially
neutralized with soda ash, caustic soda or ammonia prior to release.
In certain cases, such discharges could impose unnecessarily excessive
loads upon the municipal system.   Recovery of byproducts is possible
by the industry.

Proposed pretreatment regulations for existing and new sources  in the
iron and steel industry are given in the Federal  Register,  40 CFR,
dated March 29, 1976 as follows:

-------
102
     M)   Hot Forming,  Primary  Subcategory
          For Existing  and  New  Sources:   Oil/Grease  -  100 mg/1.

     N)   Hot Forming,  Section  Subcategory
          For Existing  and  New  Sources:   Oil/Grease  -  100 mg/1.

     0)   Hot Forming,  Flat Subcategory
          For Existing  and  New  Sources:   Oil/Grease  -  100 mg/1.

     P)   Pipe and Tube Subcategory
          For Existing  and  New  Sources:   Oil/Grease  -  100 mg/1.

     Q)   Pickling, Sulfuric Acid  Subcategory
          For Existing  and  New  Sources:   Dissolved iron  - 50 mg/1.
                                         Oil/Grease  -  100 mg/1

     R)   Pickling, Hydrochloric Acid  Subcategory
          For Existing  and  New  Sources:   Dissolved iron  - 50 mg/1.
                                         Oil/Grease  -  100 mg/1

     S)   Cold' Rolling  Subcategory
          For Existing  and  New  Sources:   Dissolved iron  - 50 mg/1.
                                         Oil/Grease  -  1.00 mg/1.

     T)   Hot Coating,  Galvanizing Subcategory
          For Existing  Sources:
                           Avg.                        Max. Day
     Pollutant   tlb/1000 Ib.  final  product)  (lb/1000 Ib. final product


     Zinc                 .0125                          .0375
     Chromium.             .0075                          .0225
     Oil/Grease           100  mg/1                       100 mg/1

          For plants  with wet  fume  hood  scrubbing, add the following
          limitations to  existing sources:

     Zinc                 .0125                          .0375
     Chromium             .0075                          .0225

          For New Sources:

     Zinc                 .0050                          .0150
     Chromium             .0005                          .0015
     Oil/Grease           100  mg/1                       100 mg/1

-------
                                                                  103
 For  plants with wet fume hood scrubbing, add the following
 limitations  to new sources.
                    Avg. 30 Day                   Max. Day
 Pollutant    (lb/1000 Ib. final product) (lb/1000 Ib. final product)
Zinc
Chromium
.0050
.0005
.0150
.0015
U)   Hot Coating, Terne Subcategory
     For Existing Sources:

Tin                  .01250                       .03750
Lead                 .00125                       .00375
Oil/Grease           100 mg/1                     100 mg/1

     For Plants with wet fume hood scrubbing as part of the coating
     operation, add the following limitations to existing sources.

Tin                  .01250                       .03750
Lead                 .00125                       .00375

     For New Sources:

Tin                  .00500                       .01500
Lead                 .00063                       .00189
Oil/Grease           100 mg/1                     100 mg/1

For Plants with wet fume hood scrubbing as part of the coating
operation, add the following limitations to new sources.

Tin                  .00500                       .01500
Lead                 .00063                       .00189

V)   Miscellaneous Runoffs Subcategory
     For Existing and New Sources:  Oil/Grease - 100 mg/1

W)   Combination Acid Pickling,  Batch and Continuous Subcategory.
     For Continuous Operations,  Existing and New Sources:

     Diss. Chromium  .0021                        .0063
     Diss. Nickel     .0010                        .0030
     Diss. Iron      50 mg/1                      50 mg/1
     Oil/Grease      100 mg/1                     100 mg/1

-------
104
     For Batch Pipe and Tube Operations, Existing- and New Sources:
                         Avg. 30 Day                   Max.  Day
     Pollutant  (lb/1000 Ib. final  product)   (lb/1000 Ib.  final  product)
Diss. Chromium
Diss. Nickel
Diss. Iron
Oil /Grease
.0015
.0007
50 mg/1
100 mg/1
.0045
.0021
50 mg/1
100 mg/1
     For Other Batch Operations,  Existing and New Sources:

     Diss. Chromium      .0004                         .0012
     Diss. Nickel         .0002                         .0006
     Diss. Iron          50 mg/1                        50 mg/1
     Oil/Grease          TOO mg/1                       100  mg/1-

For Subcategory W  the term "product"  refers  to the steel material  that
is pickled in a combination of nitric and hydrofluoric  acid.

     X)   Scale Removal,  Kolene and Hydride  Subcategory For Ketone,
          Existing and New Sources:

     Cyanide             .0005                         .0015
     Diss. Chromium      .0010                         .0030
     Diss. Iron          50 mg/1                        50 mg/1
     Oil/Grease          100 mg/1                       100  mg/1

          For Hydride, Existing and New Sources:

     Cyanide             .0013                         .0039
     Diss. Chromium      .0025                         .0075  .
     Diss. Iron          50 mg/1                        50 mg/1
     Oil/Grease          10D mg/1                       100  mg/1

     Y)   Wire Pickling and Coating Subcategory

          For Existing and New Sources:

     Diss. Nickel         .0010                         .0030
     Diss. Copper         .0010                         .0030
     Diss. Chromium      .0021                          .0063
     Cyanide             .0010                         .0030
     Diss. Iron          50 mg/1                        50 mg/1.
     Oil/Grease          100 mg/1                       100  mg/1

     Z)   Continuous Alkaline Cleaning. Subcategory

-------
         For Existing and New Sources:
                                                                105
                    Avg.  30 Day
Pollutant  (lb/1000 Ib.  final  product)
          Max.  Day
(lb/1000 Ib.  final  product)
Diss. Chromium
Diss. Nickel
Diss. Iron
Oil /Grease
.00010
.00005
50 mg/1
100 mg/1
.00030
.00015
50 mg/1
100 mg/1

-------
106
              ALUMINUM, COPPER, LEAD AND ZINC SEGMENT OF THE
                 NON-FERROUS METALS MANUFACTURING INDUSTRY
          (145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155)
                                [Part 421]

  SUBCATEGORIZATION OF THE INDUSTRY

  The Aluminum, Copper, Lead and Zinc Segment of the Non-Ferrous Metals
  Manufacturing Industry has been divided into 8 Subcategories as
  described below:

       A)   Bauxite (Aluminum) Refining Subcategory
       B)   Primary Aluminum Smelting Subcategory
       C)   Secondary Aluminum Smelting Subcategory
       D)   Primary Copper Smelting Subcategory
       E)   Primary Copper Refining Subcategory
       F)   Secondary Copper Subcategory
       G)   Primary Lead Subcategory
       H)   Primary Zinc Subcategory

  Subcategory A, Bauxite Refining.  Bauxite refining is the process of
  extracting alumina from aluminum ore (bauxite) by the Bayer process
  or by combination processes.  The Bayer process dissolves the alumina
  in a caustic solution to form sodium aluminate.  The sodium aluminate
  is precipitated as aluminum hydroxide.  The precipitate is filtered and
  dried and becomes purified "alumina," the raw material for the produc-
  tion of aluminum metal.

  Subcategory B, Primary Aluminum Smelting.  Primary aluminum smelting
  involves the electrolytic reduction of purified "alumina" to produce
  aluminum metal utilizing the Hall-Heroult process.  Alumina is dissolved
  in a solution or bath of molten cryolite and other fluoride salts.
  The bath is kept molten in a carbon crucible.  The crucible further
  serves as the cathode and a carbon block (or blocks) inserted into the
  bath serves as the anode.  Electrolysis decomposes the alumina into
  aluminum and oxygen.  The aluminum sinks to the bottom of the crucible
  and is captured.  A primary aluminum facility typically consists of a
  reduction cell operation, an anode formation plant, and an aluminum
  casting house.

  Subcategory C, Secondary Aluminum Smelting.  Secondary aluminum smelting
  is the process of remelting, purifying and recovering aluminum-bearing
  scrap to produce an aluminum alloy of marketable specifications.  A
  variety of products are manufactured.  Secondary aluminum smelters
  recycle a moderately priced metal which otherwise would become a solid
  waste.  Secondary aluminum smelters receive two types of scrap raw

-------
                                                                    107
material:  1) solids and 2) residues.   The first of these includes metal
borings and turnings, new clippings and forgings5 old castings and sheet
and aluminum containing iron.  Residues comprise two subtypes:  dross
and skimmings from melting operations  at foundries9 fabricators and the
primary aluminum industry; and secondly, slags formed during secondary
smelting operations.  "Demagging," which is the removal  of excess mag-
nesium from the melt, represents an important operation  in secondary
aluminum smelters.  Demagging is accomplished by passing chlorine
through the melt with the formation of magnesium chloride, or by mixing
aluminum fluoride with the melt resulting in the formation of magnesium
fluoride.  Heavy fuming occurs with demagging, and extensive air scrub-
bing operations are generally available.

Subcategory D, Primary Copper Smelting.  Includes all primary copper
smelting facilities and accompanying copper refineries,  if such opera-
tions may exist on-site.  The basic process used by the  primary copper
industry, is pyrometallurgical.   The primary smelter receives the
copper concentrates and subjects the concentrates to roasting, smelting,
and converting.  Blister copper is produced.  Blister copper is normally
purified by fire-refining, a pyrometallurgical operation.  If additional
purification is necessary, an electrolytic process is used.  The final
product is cathode copper.  Byproducts consisting of gold, silver, etc.
which are actually contaminents of blister copper, are collected as
"slimes" during electrolytic refining  and subsequently recovered.
Roasting serves to reduce sulfur and other impurities in the feed.
Smelting is carried out in a reverberatory furnace or an electric fur-
nace.  The smelter provides for collection of a molten copper-iron-
sulfide material called "matte," suitable for subsequent treatment in
converters.  In this process, slag is  separated and discarded.  Matte
is converted to blister copper with air blowing in large, horizontal,
cylindrical furnaces.  Converter slag  is removed and the crude copper
containing varying amounts of heavy metals, arsenic and  sulfur is
ready for refining.

Subcategory E, Primary Copper Refining.  Includes all primary copper
refineries which are not operated on-site with a primary copper smelter.
The blister copper described above is  further refined into either fire-
refined copper or anode copper.   Impurities are removed, more slag
produced and cuprous oxide formed.  Deoxidation is accomplished by
coke addition and other means.  This is usually followed by electrolytic
refining.  In the latter process, copper is separated from its impuri-
ties by electrolytic dissolution at the anode, and deposition as the
pure metal, at the cathode.  Non-copper values accumulated in the
"slimes" and in the solution electrolyte, are eventually recovered.

Subcategory F, Secondary Copper Facilities.  Covers plants primarily
engaged in the recovery of copper from new and used scrap and from
residues gathered from melting operations.  These residues comprise
spills, slags, skimmings, etc.  This Subcategory includes establishments

-------
108
melting and refining copper alloys obtained from secondary brass and/or
secondary bronze scrap sources.  Also included are establishments melting
and refining copper-bearing scrap to recover principally pure (unalloyed)
copper.  "Primary" copper may occasionally be processed.  Major operations
comprise presmelting, melting, smelting, refining and alloying.  Products
consist of blister copper, brass or bronze ingots, fire-refined copper
ingots, and electrolytically refined and cast high-grade copper commo-
dities.

Subcategory G, Primary Lead Facilities.  Includes plants primarily engaged
in smelting lead from ores, and refining lead by any process.  Primary
lead in the U.S. is recovered entirely from sulfide ores, which are
associated with other metals chiefly zinc, copper and silver.  The
primary lead facility receives the ore concentrate which is blended with
flux and other materials, and then provides sintering, blast furnace
smelting and refining operations to remove (and in some cases to recover)
metallic impurities.  Sintering serves to reduce the sulfur oxide content
of the charge, to eliminate other undesirable impurities, and to produce
an even size feed for the blast furnace.  The furnace separates consti-
tuents into the desirable molten metal and slag.  Dressing is usually
the first step in the refining of the lead bullion as received from the
blast furnace.  Dressing is performed in heated kettles and promotes
removal-of copper.  The bullion then passes through "softening" accom-
plished by oxidative slagging or oxidation in a reverberatory furnace.
Generally two stages of slag are obtained.  Softened lead is further
subject to desilverizing and dibismuthizing.  The Parke process uses
zinc metal for purposes of combining with gold and silver, which are
recovered.  Zinc is sequentially removed by vacuum dezincing.  Debis-
muthizing consists of adding calcium and magnesium to form a calcium-
magnesium-bismuth crust which is later processed and recovered.  Final
refining involves addition of sodium hydroxide and/or sodium nitrate
to the lead to effect removal of residual zinc, antimony and arsenic.

Subcategory H, Primary Zinc Facilities.  Includes plants primarily
engaged in smelting zinc from ores, and/or refining zinc by any process.
The primary zinc industry in the U.S. includes both electrolytic and
pyrometallurgical retort plants.  Zinc smelters receive sulfide con-
centrates which are blended and roasted.  Roasting serves to remove
sulfur, and also eliminates some of the other impurities from the zinc
concentrates including lead, mercury and cadmium.  Roaster off-gases
are passed to sulfuric acid manufacturing.  For purposes of a uniform
feed, the roasting product is sintered, with off-gases treated for
particulate control.  Large amounts of lead and cadmium are eliminated
in sintering, and the dust is recylced or recovered for cadmium and lead
values.  In pyrolytic reduction, the zinc oxide content is reduced in
the furnace and all gases exhausted.  These gases contain metallic zinc
vapor and carbon monoxide.  The zinc vapor is specially condensed and
recovered.  Residues are recycled and/or recovered for zinc or other

-------
                                                                       109
metal values.  In electrolytic zinc production, the zinc concentrate is
acid washed to remove unwanted magnesium sulfate and the roasted product
is finely ground.  This material is then leached with a sulfuric acid
solution serving as an electrolyte.  The purpose is to dissolve as
much zinc as possible and precipitate iron and accompanying impurities.
The pregnant solution is purified largely by addition of zinc dust
which precipitates copper, cadmium, cobalt, nickel, etc. by replacement.
All residuals are recovered.  The electrolytic room receives the zinc
laden electrolyte.  Zinc is deposited onto aluminum cathodes and eventually
stripped off.  The final zinc products include various grades of slab zinc,
zinc oxide, and zinc dust.                         :                     .
NATURE OF PROBLEM

Major waste sources from the aluminum, copper, lead, and zinc subcate-
gories of the Non-Ferrous Metals manufacturing industry are described
as follows:

     Bauxite Refining.  Bauxite refining produces about equal amounts
     of alumina and red mud waste and the latter represents an important
     solid waste disposal problem.  Other wastes comprise spent liquor,
     condensates, barometric condenser and miscellaneous cooling waters.

     Primary Aluminum Smelting.  The majority of waste from primary
     aluminum smelting originates from wet scrubbing devices for con-
     trolling air emissions.  Resulting scrub liquors contain acids,
     hydrocarbon tars and oils, sulfur oxides, alumina, chlorides and
     fluorides.  Other wastes include cooling waters from casting,
     rectifiers, and fabrication.

     Secondary Aluminum Smelting.  Waste waters are generated princi-
     pally from the cooling of molten aluminum alloy, the wet scrub-
     bing of fumes during magnesium removal, and the wet milling of
     residues such as dross and slag.  High TDS and TSS content of the
     waste are generally attributable to the wet milling of residues.

     Primary Copper Smelting.  Smelting furnace slag represents a major
     solid waste disposal problem at copper smelters.  Sulfur oxide
     emissions are treated by air pollution control devices which in
     turn produce significant liquid waste.  Air particulate control
     and treatment are also important at primary copper smelters.
     Other wastes originate from slag granulation, acid plant blowdown,
     and from fire-refined copper.

     Primary Copper Refining.  Many of the same types of waste originate
     from primary copper refining as found in primary copper smelting,
     but in lesser degree.  Specific waste sources include disposal of
     spent electrolyte, electrolytic refinery washing, and slimes recovery,

-------
no
       Secondary Copper.  Waste waster is generated principally from six
       operations:  cooling of molten unalloyed or alloyed copper,  slag
       quenching and granulation, slag milling and classification,  fur-
       nace exhaust scrubbing, electrolytic refining,  and equipment cooling.

       Primary Lead Smelting and Refining.  Major waste waters from pri-
       mary lead establishments include waterborne effluent from a  variety
       of air cleaning/scrubbing devices, spent streams from blast  furnace
       slag and slag granulation circuits, acid plant  blowdowns, and
       various cooling waters.

       Primary Zinc Smelting and Refining.  Process wastes from zinc
       establishments include scrub waters from the cleaning of roaster
       off-gases, acid plant blowdowns, bleed streams  from reduction
       furnace gas cleaning operations, metal casting  cooling, excess
       liquors from cadmium recovery, preleaching of zinc concentrates,
       electrolytic purification washwater and spills,  boiler blowdowns,
       scrub waters from auxiliary wet air pollution devices, and a
       variety of "non-contact" cooling waters.

  The non-ferrous metals manufacturing industry is characterized by
  comparatively large plants but relatively limited in  number.  As  of  the
  early 1970's, the following plants were identified for the domestic
  industry:  9 bauxite refineries; 31 aluminum reduction plants; 85 plants
  producing secondary aluminum metal; 22 plants or properties engaged  in
  primary smelting and refining of copper; 50 plants classified as  secondary
  copper smelters; 7 plants or properties engaged in lead smelting  and/ or
  refining; and 6 primary zinc establishments.   In the  zinc sector  the
  pyrometallurgical plants because of significant air pollution problems
  and high corrective costs, are considered more vulnerable to future
  shutdown.
  PARAMETERS OF CONCERN

       Bauxite Refining:         pH, Alkalinity       COD
                                IDS                  Oil/Grease
                                TSS                  Color
                                Temperature          Turbidity
                                Sulfates             Trace Metals

       Primary Aluminum          pH                   COD
       Smelting:                 Fluorides            Chlorides
                                TSS                  Sulfates
                                Oil/Grease           Temperature
                                Cyanide              Trace Metals  (includes
                                TDS                  zinc, copper  and nickel)

-------
                                                                 in
Secondary Aluminum       pH                  IDS
Smelting:                TSS                 Chlorides
                         Oil/Grease          Magnesium
                         COD                 Cyanide
                         Fluorides           Nickel
                         Ammonia nitrogen    Zinc
                         Aluminum            Cadmium
                         Copper              Lead
                         Sodium

     pH:  Raw wastewater from demagging fume scrubbers is very
     acidic, with a pH range of 1.0 to 2.5.   Metal  cooling waters
     are less acidic with a pH range of 4.5-6.5.  Residue milling
     wastewaters in contrast generally have  a pH of 8.0-9.5.

     Oil/Grease:  Significantly exceed 100 mg/1  in  some metal
     cooling waters.

     TSS:  High levels of TSS are found in some  wastewaters from
     metal cooling and especially, residue milling.   Excessive
     TSS may cause blockage of sewer lines.

     Aluminum:  May be present in very high  levels  up to 200 mg/1
     or more, in raw demagging fume scrub wastewaters and residue
     milling wastewaters.  Aluminum is present primarily in parti-
     culate form, and therefore relatively settleable.

     Ammonia:  May be present in certain residue milling waste
     waters in concentrations of several hundred mg/1.  Ammonia
     was determined to be "generally" amenable to biological
     treatment by the POTW, if present in "limited"  quantities.

     Copper:  Found in residue milling wastewaters.   Studies
     show about 75% of the incoming copper may be removed by a
     POTW and eventually concentrated in treatment  plant
     sludges.

Primary Copper           pH, Acidity,        Sulfates
Smelting and                Alkalinity       Chlorides
Refining:                TSS                 COD
                         Oil/Grease          Cyanide
                         Arsenic             Temperature
                         Cadmium             Nickel
                         Copper              Silver
                         Lead                Cobalt
                         Selenium            Iron
                         Zinc                Antimony
                         TDS                 Tin
                         Aluminum            Mercury
                         Chromium

-------
112
    Secondary Copper:         pH                   Cadmium
                             TSS                  Nickel
                             Oil/Grease          Selenium
                             Ammonia  nitrogen     Silver
                             Copper              Tin
                             Zinc                Cobalt
                             Aluminum            Magnesium
                             Iron                Antimony
                             Lead                Boron
                             COD                  Fluorides
                                                 Chromium

         Copper;   Most heavy metals including  copper, are reported
         as generally not susceptible to  treatment by biological
         means at POTW's.  Past studies show approximately  half of
         the incoming copper will pass through the POTW, and  the
         other half is concentrated in treatment plant sludges.   Copper
         •is reported capable of causing toxic  interference  with
         biological treatment with consequent  reduction  in  waste
         removal  efficiencies.  Copper in sludges may restrict reuse
         and disposal  of these sludges.

         Zinc:  Dissolved zinc is generally considered as not being
         susceptible to biological treatment by POTW's.   In slug
         doses and in the presence of copper,  zinc can be toxic to
         biological treatment with consequent  reduction  in  waste
         removal  efficiency.  Zinc accumulating in treatment  plant
         sludges  does not seem to restrict the reuse and/or disposal
         of these sludges.

         Lead:  This metal is considered  as generally not susceptible
         to biological treatment  by POTW's. Significant quantities
         of lead  are said to pass through the  POTW while the  remainder
         of the lead is carried down  with the  sludges.   Lead  toxicity
         can lower removal efficiencies of the biological treatment
         plant.  Lead accumulation in sludges  may serve  to  restrict
         the reuse and/or normal  disposal of these sludges.

         Cadmium;  Represents a dangerous cumulative toxicant to
         animals  and humans, with possible mutagenic or  tetratogenic
         properties, and with marked  acute and chronic effects.   Cad-
         mium acts synergistically with other  metals including copper
         and zinc.  Cadmium is reported as generally not susceptible
         to biological treatment  by POTW's. Significant quantities
         of cadmium may pass through  the  POTW, and the remainder
         concentrates in treatment plant  sludges.  Cadmium  toxicity
         can significantly reduce biological treatment plant  waste
         removal  efficiencies.  Cadmium accumulation in  sludges can
         restrict the reuse and disposal  of these sludges.

-------
                                                                 113
Primary Lead Smelting
and Refining:
Primary Zinc Manu-
facture:
pH             Various metals including
TSS            aluminum, antimony, cobalt
Cadmium        copper, chromium, iron,
Lead           magnesium, nickel, silver,
Zinc           selenium and tin.
Mercury
IDS            Other possible pollutants
Sulfates       of concern include arsenic,
               cyanide, fluorides, bismuth,
               oil/grease, chlorides,
               temperature and phosphates

pH             IDS
TSS            Sulfates
Arsenic        Chlorides
Cadmium        Phosphates
Mercury
Selenium       Various metals including
Zinc           aluminum, magnesium,
Lead           antimony, chromium,
Copper         cobalt, iron, nickel,
               silver and tin.

               Other including cyanide,
               temperature, etc.
PRETREATMENT LIMITATIONS FOR PI CHARGE TO POTVI

The Federal Register publications and supporting Development Documents
for the Non-Ferrous Metals Manufacturing industry indicate the follow-
ing pretreatment limitations:

Bauxite Refining, Subcategory A, Existing Sources (New Sources not
yet  clearly defined).

     N£ discharge of process wastes to POTW except for possible over-
     flow from impoundment ponds during months of excess precipitation.

Primary Aluminum Refining, Subcategory B, Existing Sources (New
Sources not yet clearly defined).
     Process waste water shall conform to the following values:

-------
114
                              Avg. 30 Day              Max. Day
     Parameter           (lb/1000 Ib product)t    (lb/1000 Ib product)t

     Fluorides                   1.0                     2.0
     TSS                         1.5                     3.0
     pH                          Allowable range of 6.0 to 9.0
Secondary Aluminum Smelting, Subcategory C, Existing Sources (New
Sources not yet clearly defined)!

     For Metal Cooling Waste water:

     Parameter	Avg. 30 Day	Max. Day

     Oil/Grease                 -                      100 mg/1
     pH                            Not less than 5.0


     For Fume Scrubbing Waste Water from Demagging operations:

     Parameter	

     PH                         Allowable range of 5.0 to 10.0

     For Residue Milling Waste Water:

     Parameter	Avg. 30 Day	Max. Day

     Ammonia                  50 mg/1                  100 mg/1
     pH                            Not less than 5.0

Primary Copper Smelting, Subcategory D, Existing and New Sources.

     Parameter	Pretreatment Standard

     Arsenic                                 10.0 mg/1
     Copper                                  0.25 mg/1
     Lead                                    0.5 mg/1
     Cadmium                                 0.5 mg/1
     Selenium                                5.0 mg/1
     Zinc                                    5.0 mg/1
   Hoi aliarn-num metal produced.

-------
                                                                    115
Primary Copper Refining, Subcategory E, Existing and New Sources.
Parameter
Oil /Grease
Arsenic
Zinc
Selenium
Copper
Secondary CojDper
Sources not yet
Avg. 30 Day
(lb/1000 Ib product)tt
0.02
0.02
0.01
0.01
0.0005
Manufacturing, Subcategory F,
clearly defined) .
Max. Day
(lb/1000 Ib p»
0.04
0.04
0.02
0.02
0.001
Existing Sources

*oduct)t

(New

The limitations below apply to all process wastes from secondary copper
mills:

     Parameter	Avg. 30 Day	Max. Day

     Copper                     0.5 mg/1               1.0 mg/1
     Cadmium                    0.2 mg/1               0.4 mg/1
     Oil/Grease                    -                   100 mg/1
     pH                              Not less than 5.0

Primary Lead Facilities, Subcategory G, Existing and New Sources.
                              Avg. 30 Day              Max. Day
     Parameter	(lb/1000 Ib product)ttt  (lb/1000 Ib product)ttt

     Cadmium                    0.0004                 0.0008
     Lead                       0.0004                 0.0008
     Zinc                       0.004                  0.008
 tt  Electrolytically refined copper.
ttt  Lead bullion.

-------
  VT6
      Primary Zinc Facilities, Subcategory H. Existing and New Sources.
           •                   Avg. 30 Day              Max. Day
     Parameter           Ob/1000 lb product)ttft (lb/1000 lb product)ttt
Arsenic
Cadmium
Selenium
Zinc
8.0 x 10 - 4
0.004
0.04
0.04
1.6 x 10
0.008
0.08
0.08
_3



PRESCRIBED TREATMENT MEASURES OR EQUIVALENT

Specifically for Secondary Aluminum, Subcategory C Facilities:

     Metal Cooling Haste Waters:  Treatment is required to remove
     excessive oil and grease and TSS before release to a POTW.
     Grease traps and specialized skimming equipment are identi-
     fi cable technology for reduction of oil and grease.  Adjust-
     ment of pH may be necessary.

     Demagging Fume Scrubber Waste Water:  Aluminum is the prime
     parameter of concern in these spent waters.  Identified pre-
     treatment technology for these effluents include pH adjustment
     and/or neutralization,, floceulation and settling prior to release
     to the POTW'..  In lieu of POTW discharge, complete recycle of
     this wastewater is considered feasible and may be less, expensive.

     Residue Milling Waste Water.  Identified pretreatment technology
     for the spent waters is settling, although pH adjustment and
     floccolation may also be necessary.

Specifically for Secondary Copper, Subeategory F Facilities:

     Overall Pretreatment:  Identified technology is chemical treat-
     ment consisting of controlled precipitation followed by settling.
     Skimming is advocated where necessary to control  oil and grease
     levels.  Mercury-laden wastes are subject to treatment with
     sodium sulfide, the pollutant; removed by precipitation and
     filtering.  Neutralization with lime to a pH of 8 to 11; will
     reduce concentrations of most metals and with proper settling,
     will also reduce TSS.  Each metal has an optimum pH for chemical
tttf  Zina metal...

-------
                                                                  117
precipitation.  Metals such as lead, cadmium and mercury may show
lesser degrees of removal when the pH is above pH 7.  Treatment
will likely require pH adjustment representing a compromise
between .the maximum removal of copper and zinc, and that suited
for maximum removal of cadmium, lead, antimony, tin, etc.  Recycle
and reuse of process waste water streams should be carefully
considered.

Metal Cooling Waste Haters:  Neutralization may not be necessary
for these waters.  Pretreatment if needed will involve adjustment
of pH to between 8 and 10, followed by settling.  Sludge removal
is probable when charcoal cover is employed in the metal cooling
and quenching process.  Waste discharges to the POTW can be
reduced or eliminated by recycling process waters.

Slag Quenching/Granulation Waste Haters and Furnace Exhaust
Scrub Waters:  Pretreatment comprises pH adjustment and/or
neutralization, followed by waste settling.  Waste streams may
be treated separately or combined.

Electrolytic Refining Operations Waste Water.  Identified
technology consists of removal or copper by cementation with
iron, followed by lime neutralization and solids settling
prior to release to the POTW.  Special treatment for mercury
may be additionally required.

-------
1:18
                   PHOSPHATE MANUFACTURING INDUSTRY
                    (176, 177, T78, 179, 180, 1:81)
                              [Part 422]

SUBCATEGORIZATION OF THE INDUSTRY

The Phosphate Manufacturing Industry has been divided into six major
subcategories.  It is defined separate from the Fertilizer Industry
although intermediate products are transferred between the two
industries.  The first three subcategories are based upon use of phosphate
ores and "dry process" phosphoric acid whereas the last three subcate-
gories are based upon phosphate ores and/or "wet process" phosphoric
acid.  The six subcategories are:

     A)   Phosphorous Production
     B)   Phosphorous Consuming
     C)   Phosphate Manufacturing
     D)   Defluorinated Phosphate Rock
     E)   Defluorinated Phosphoric Acid
     F)   Sodium Phosphates

Subcategory A.  Phosphorous Production.  Refers to the smelting and
reduction of phosphate ore to produce phosphorous and ferrophosphorous.
Copious amounts of water are used for cooling and granulating slag, and
for condensing phosphorous vapors from the furnace.

Subcategory B.  Phosphorous Consuming.  Elemental phosphorous is used
for the manufacture of various phosphorous compounds by the "dry
process".  Products include phosphoric acid, phosphorous pentoxide,
phosphorous pentasulfide, phosphorous trichloride and phosphorous
oxychloride.  Liquid phosphorous is burned, and the ?2^5 vapors are
quenched and hydrolyzed.  Phosphoric acid mist is collected.

Subcategory C.  Phosphate Production.  Phospates including sodium,
tripolyphosphate, animal feed grade calcium phosphate, and human food
grade calcium phosphate are manufactured from dry process phosphoric
acid.  For sodium tripolyphosphate, the acid is neutralized with
caustic soda and soda ash producing a mixture of mono and di-sodium
phosphates.  The mixture is dried and calcined to yield the tripoly-
phosphate.  The calcium phosphates are similarly made by the neutrali-
zation of phosphoric acid with lime giving mono, di-, or tricalcium
phosphate.

Subcategory D.  Defluorinated Phosphate Rock.  Applies to plants
practicing defluorination of phosphate rock by high temperature treat-
ment together with wet process phosphoric acid, silica and other reagents.

-------
                                                                       119
Subcategory D, E and F plants use phosphate rock and importantly "wet
process" phosphoric acid as starting raw materials.  The distinction
between "dry" and "wet" processes is provided under Nature of Problem
in this report.

Phosphate rock can be processed to provide animal feed supplements,
mainly the essential of calcium and phosphorous incorporated into
animal foodstuffs.  However the 3-4 percent fluorine content in this
rock is too high for animal usage.  Accordingly various proprietory
processes were developed to defluorinate phosphate rock, as incorporated
into Subcategory D plants.

Subcategory E.  Defluorinated Phosphoric Acid.  Two processes are
available.  The first of these involves the concentration of "wet
process" phosphoric acid from a 52-54% P205 level up to a 68-72% P205
strength, i.e. superphosphoric acid.  When water is evaporated from
the acid, fluorine is removed generally to a sufficient degree to
permit its use in the manufacture of animal feed supplements.  The
second method of acid defluorination relies upon an additive incor-
porated into the acid which facilitates fluorine removal by aeration.
Defluorinated phosphoric acid may be mixed with limestone to produce
dicalcium phosphate for animal feed supplement use.  Otherwise, it is
used for liquid fertilizer production.  Superphosphoric acid is also
an intermediate used in the production of dry mixed fertilizer.

Subcategory F.  Sodium Phosphates.  These high quality salts usually
employ "wet process" phosphoric acid as a starting material, which
has been derived from calcined phosphate rock.  A series of operations .
are employed for the removal of flurosilicates, arsenic, sulfates, iron,
aluminum and residual fluorine from the acid.   The acid is eventually
converted to a salt laden, neutralized solution.  Precipitated
impurities can be recovered for incorporation into fertilizer.  The
solution is subjected to evaporation which serves to crystallize out
monosodium phosphate.  Other end products include sodium meta phosphate,
disodium phosphate and tri-sodium phosphate.

NATURE OF PROBLEM

Background.

The Phosphate Manufacturing Industry may be descriptively defined as
the non-fertilizer phosphorous industry.  The industry is almost
entirely based upon the production of elemental phosphorous from mined
phosphate rock.  Phosphate rock in the U.S. is situated in the Tennessee,
Idaho-Montana and Florida areas.  The first line product derived from
phosphate rock is elemental phosphorous with ferrophosphorous as a by-
product.  (Subcategory A plants).  A large portion of the elemental
phosphorous is used to manufacture high-grade phosphoric acid by the
"dry" process (as opposed to the "wet" process which converts phosphate

-------
120
 rock directly into phosphoric acid; this lower grade wet process acid
 is largely used in the fertilizer industry).  The remainder of elemental
 phosphorous is either marketed directly or converted to chemicals such
 as phosphorous pentoxide, phosphorous pentasulfide, phosphorous trich-
 loride and phosphorous oxychloride (Subcategory B plants).   The latter
 are used chiefly for synthesis in the organic chemicals industry.

 Phosphoric acid is directly marketed to the food industry or to the
 fertilizer industry, or otherwise is used for the manufacture of two
 classes of phosphates:  1) the water soluble phosphates for detergents
 and water treatment such as sodium tripolyphosphate; and 2) the water
 soluble calcium phosphates used for addition to animal  feeds and human
 foods (Subcategory C plants).

 Plants in Subcategories D, E and F, i.e., Defluorinated Phosphate Rock,
 Defluorinated Phosphoric Acid, and high-quality Sodium  Phosphates use
 phosphate rock and "wet process" phosphoric acid as starting raw mate-
 rials. These products find their way into animal feeds  as nutritive
 supplements, are used as fertilizer intermediates and for other needs.

 Water Sources and Pollutional Characteristics.

 In Phosphorous Production plants a grossly impure raw material  is
 employed.Consequently the wastes and byproducts generated are far
 greater in quantity than the primary products recovered.  The remainder
 of the industry starts with relatively pure materials and generates
 less unit wastes.

 Electrostatic precipitators collect a dust that contains about 50 percent
 phosphorous pentoxide, with other solids.  The calciner and wet furnace
 fume scrubber produce a highly acidic "phossy" liquid effluent containing
 sulfur dioxide, iron oxides and phosphates, sulfates and fluorides.  A
 sludge originates in the phosphorous condenser sump. This  is a mixture
 of dispersed phosphorous and other solids that are scrubbed from the
 air.  This colloidal type waste is extremely harmful to aquatic organisms.
 A slag quenching liquor stream is also present containing high TSS and
 TDS, mainly sulfates and fluorides.

 In Phosphorous Consumption plants, air pollution abatement systems
 serving casting of phosphorous pentasulfide, product purification resi-
 dues, tail gas seals, vessel cleaning, and leaks and spills represent
 major waste sources.  Chlorination is employed in production of
 phosphorous trichloride and phosphorous oxychloride which leads to the
 formation of hydrochloric acid and a difficult waste water problem.

 In Phosphate Production plants, effluents are derived from wet scrubbers,
 spray and dust deposits, clarified waste water from centrifuges and
 filtrate fractions.  A defluorination process in food grade phosphate
 production contributes large amount of TSS.  The raw wastes from phos-
 phate production contain fluoride, calcium and sodium compounds, arsenic

-------
                                                                     121
compounds, phosphorous, phosphoric acid, sulfurous acid, sulfuric acid,
hydrochloric acid, TSS, chromates, IDS and ammonia.  Large amounts of
cooling waters are used by these plants, and heat is a general problem
in the discharges.  Some western ores contain considerable cadmium.
This element does not normally appear in the phosphate manufacturing
discharges.  Vanadium and radium occur in some ores and are potential
pollutants.

In Defluorinated Phosphate Rock production, serious waste water prob-
lems result from wet phosphoric acid production which is the same case
for the production of defluorinated phosphoric acid and sodium phosphate
salts i.e. Subcategories E and F.  These wastes include large amounts
of sulfuric acid derived from stack or tail gas scrubbing, filtration,
solids washing and acid manufacturing.  Also included are large quan-
tities of solid wastes from various manufacturing together with signi-
ficant amounts of gypsum and phosphate rock debris.  The major wastes
from plants processing defluorinated phosphate rock are the scrub effluents
from cleaning gaseous effluents.

In Defluorinated Phosphoric Acid production, major wastes are the scrub
effluents from wet air pollution control devices and the condensates
from the acid concentration process.  Other waste sources include
spills, pump seal leaks, etc.  The condensates contain phosphoric acid,
fluorides, etc.

In Sodium Phosphates production, wastes result from various salting out
processes and the solids removed via precipitation means.  Phosphoric
acid by the "wet process" produces a type of waste already described
above.  Other waste sources include pump and seal leaks, spills,  etc.


Solid wastes control is very important in the phosphate industry.
The waste waters and the treatment processes generate considerable
volumes of hydrated fluorsilicaceous and silicaceous materials.
These hydrated solid wastes form relatively unstable landfill deposits.
In order to ensure long term protection of the environment from what-
ever hazardous and harmful  constituents may be present, special pre-
cautions must be exercized over waste disposal  sites.  The landfills
should be selected and designed to prevent horizontal and vertical
migration of these critical constituents to ground and surface waters.
Also, the location of solid hazardous materials disposal sites should
be permanently and legally recorded.
PARAMETERS OF CONCERN

     pH, Alkalinity, Acidity
     TSS
     TDS
     Phosphates, phosphites
Sulfates, sulfites
Fluorides, fluorosilicates
Arsenic
Vanadium

-------
122
      PHr.0s4Jho.rQ.u5 „ e^emejiitad; phosphorous; Rad!i;ujn^22j5;
      Chlorides                          Uranium;
      Cadmium                            liron
      Aluminum:                           Ca.lcium.
      Temperature                        COD

 Radium-226 is one of the most hazardous radioisotopes of the uranium
 decay series, when present in. water.  The human body preferentially
 utilizes radium, over? calcium when present in food or drink.  Plants
 and animals concentrate radium,, leading to a multiplier effect upon
 the food chain.
 PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

 For Subcategory A.  Phosphorous Production:, Existing Sources.

 Limitations have been* equated to BPT limits; which are:

                                Avg. 30 Day          Max. Day
      Pollutant	(lb/1.000 Ib. product}(lb/l.QOO Ib Ib product)

        TSS                      0.5                    1.0s
        Total  Phosphorous        0.15                   0.30
        Fluorides                0.05                   0.10
        Elemental Phosphorous        No detectable quantity
                                         6.0 to 9.0

 For Subcategory A,  Phosphorous Production, New Sources.

 Limitations have not yet been defined.
 For Subcategory B,  Phosphorous Consuming, Phosphoric Acid, Phosphorous
 Pentoxide and Phosphorous Pentasulfide Manufacturing, Existing Sources.

 No discharge of process waste water pollutants is allowed.

 For Subcategory B,  Phosphorous Consuming. Phosphorous Trichloride
 Manufacturing, Existing Sources.

 Have been equated to BPT limitations which are:

        TSS                      0.7                    1.4
        Total Phosphorous        0.8                    1.6
        Arsenic                  0.00005                0.0001
        Elemental  Phosphorous        No detectable quantity
        pH                                 6.0 to 9.0

-------
                                                                     123
For Subcategory B, Phosphorous Consuming, Phosphorous Oxychloride
Manufacturing, Existing Sources.

Have been equaled to BPT limits, which are:

     TSS                           0.15                     0.30
     Total Phosphorous             0.17                     0.34
     pH                                   6.0 to 9.0

For Subcategory B, Phosphorous Consuming. All New Sources.

Limitations have not yet been defined.

For Subcategory C, Phosphate Manufacturing, Existing Sources.

Have been equated to BPT limits, which are:

     TSS                           0.06                     0.12
     Total Phosphorous             0.03                     0.06
     pH                                   6.0 to 9.0

For Subcategory C, Phosphate Manufacturing, New Sources.

Limitations have not yet been defined.

For Subcategory D, Defluorinated Phosphate Rock, Existing Sources.
                                   Avg.  30 Day         Max.  Day
     Pollutant                       mg/1                 mg/1

     BOD, TSS, pH                  No limitations    No limitations
     Total Phosphorous                 35                  70
     Fluorides                         15                  30
Volume restrictions are implied on wastewaters to be released  to a POTW
but these limitations are not clearly defined.  Previously this  limita-
tion was described as an excess flow from an impoundment capable of
holding a 10 year, 24 hour rainfall  event or the difference between
precipitation into the impoundment and evaporation from the pond water
surface area.  However the latter definition has since been changed.

For Subcategory D, Defluorinated Phosphate Rock, New Sources.

     BOD, TSS, pH                  No limitations    No limitations
     Total Phosphorous                 35                 70
     Fluorides                         15                 30

-------
124
The volume of allowable process waste water is defined in the same
manner as given above for existing sources of Defluorinated Phosphate
Rock.

For Subcategory E, Defluorinated Phosphoric Acid, Existing Sources.
                              Avg. 30 Day                Max. Day
     Pollutant                  (mg/1)                    (mg/1)

     BOD, TSS, pH             No limitations           No limitations
     Total Phosphorous             35                       70
     Fluorides                     15                       30

The volume of allowable process waste water is defined in the same
manner as given above for existing sources of Defluorinated Phosphate
Rock.

For Subcategory E, Defluorinated Phosphoric Acid, New Sources.

    .BOD, TSS, pH             No limitations           No limitations
     Total Phosphorous             35                       70
     Fluorides                     15                       30

The volume of allowable process waste water is defined in the same
manner as given above for existing sources of Defluorinated Phosphate
Rock.

For Subcategory F, Sodium Phosphates, Existing Sources.
                                   Avg. 30 Day         Max. Day
     Pollutant                (lb/1,000 Ib. product)(lb.1,000 Ib product)

     BOD, TSS, pH                  No limitations      No limitations
     Total Phosphorous                0.40                  0.80
     Fluorides                        0.15                  0.30

For Subcategory F, Sodium Phosphates, New Sources.

     BOD, TSS, PH                 No limitations       No limitations
     Total Phosphorous                0.40                  0.80
     Fluorides                        0.15                  0.30

PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

With regard to f 1ow rate to a POTW, it has been recommeded that each
plant  in the phosphate industry be required to determine impact of its

-------
                                                                     125
flow upon the hydraulic capacity of the POTW collection and treatment
system should the POTW be used by the industry.  This analysis should
include effects of a time-varying flowrate.

With respect to TSS, high concentrations of inorganic solids could
overload primary sludge collectors, the primary sludge pumps, the
sludge thickeners, dewatering operations, and the sludge disposal
system.  Furthermore these solids would provide no food for the micro-
flora in secondary treatment and also reduce the activity of the biomass.
It is recommended that the maximum concentration of suspended inorganic
solids be held to 250 mg/1.

For Metals, it is noted that elemental phosphorous in phossy waters
and enriched arsenic compounds are potential substances discharged
to POTW's.  There is special need to pretreat waste waters for removal
of these materials.   It is recommended that pretreatment standards
provide for zero discharge of metals or harmful materials to POTW's.

Dissolved Phosphates would affect sludge operations in POTW's.  Gravity
thickened sludges are generally conditioned with various chemicals.
However, phosphates would react with these chemicals and be precipitated,
detracting from the efficiency of these agents in properly conditioning
the sludges.  In the case of tertiary treatment at a POTW, phosphates
are generally removed by using lime, ferric chloride or alum.  Phosphate
industry discharges would cause greatly increased chemical dosages and
seriously impact upon the sludge handling capacity of the POTW.  It is
recommended that the maximum permissable phosphate concentration (as
P04) to a POTW be held to 30 mg/1.

-------
  126
               STEAM ELECTRIC POWER GENERATING INDUSTRY
                       (201,  202,  203,  204,  205)
                              [Part 423]

SUBCATEGORIZATION OF THE INDUSTRY

The Steam Electric Power Generating Industry has  been divided into
four main subcategories as described in the  following paragraphs.

     A)   Generating Unit Subcategory.

     A generating unit operated by an establishment primarily engaged
     in generating electricity for distribution and sale  which results
     primarily from a process utilizing fossil-type fuel  (coal,  oil  or
     gas) or nuclear fuel  in  conjunction with a thermal cycle employ-
     ing the steam water system as the  thermodynamic medium.   The
     term "generating unit" however shall  not include those  units
     defined below as either  "small" or "old."

          Small  Unit shall mean any generating unit (except  one  defined
          as being old)  having less than 25  megawatts rated  net  generat-
          ing capacity or any unit which is  part  of an electric  utilities
          system with a total  net  generating capacity of  less than  150
          megawatts.

          Old Unit shall  mean any  generating unit of greater, than 500
          megawatts rated net generating capacity place in service  on
          or before January 1, 1970, or any  generating unit  of less
          than 500 megawatts  rated net  generating capacity placed in
          service on or before January  1,  1974.

     B)  Small Unit Subcategory

     A small unit operated by an establishment primarily  engaged in
     generating  electricity for distribution and  sale which  results
     primarily from a process  utilizing fossil-type fuel  (coal,  oil
     or gas) or  nuclear fuel  in conjunction  with  a thermal cycle
     employing the steam water system as the thermodynamic medium.
     For further definition of Small  Unit  see Subcategory A  directly
     above.

     C)  Old Unit Subcategory

     An old  unit operated  by  an establishment primarily engaged  in
     generating  electricity for distribution and  sale which  generally
     results primarily from a  process utilizing fossil-type  fuel (coal,
     oil  or  gas)  or nuclear fuel in conjunction with a thermal cycle

-------
                                                                        127
     employing the steam water system as the thermodynamic medium.
     For further definition of Old Unit see Subcategory A above.

     D)  Area Runoff Subcategory

     This Subcategory applies to discharges from material  storage
     runoff and construction runoff which are used in or are derived
     from generating units covered under Subcategories A,  B and C.
     Special definitions for this Subcategory are given below.

          Material storage runoff shall  mean the rainfall  runoff from
          or through any coal, ash or other material  storage pile.

          Construction runoff shall mean the rainfall  runoff from any
          construction activity and any earth surface disturbed by  such
          activity from the start of construction until  the completion
          of construction and the disturbed earth is  returned to a
          vegetative or other cover state commensurate with the intended
          land use.

Other definitions appropriate to all subcategories are included below:

          Slowdown shall mean the minimum discharge of recirculating
          water for the purpose of getting rid of materials contained
          in these waters, the further buildup of which would cause
          concentrations in amounts exceeding limits  established by
          best engineering practices.

          Sufficient land shall  mean 1,100 square feet or  more  of
          land per megawatt of nameplate generating capacity.

          Low Volume Waste Sources shall  mean wastewater from diverse
          sources except those for which specific limitations  have
          been otherwise established.  Low volume waste sources include
          but are not limited to waters  from wet scrubber  air pollution
          control systems, ion exchange  water treatment systems,  water
          treatment evaporator blowdown,  laboratory and sampling
          streams, floor drainage, cooling tower basin cleaning wastes,
          and blowdown from recirculating house service water systems.

          Ash transport water shall mean water employed in hydraulic
          transport of either fly ash or bottom ash.

          Metal  cleaning wastes  shall mean any cleaning compounds,  rinse
          waters, or any other waterborne residues derived from cleaning
          any metal process equipment including, but  not limited  to
          boiler tube cleaning,  boiler fireside cleaning and air  preheater
          cleaning.

-------
  128
          Once-through cool ing water shall mean water passed through
          the main cooling condensers in one or two passes for the
          purpose of removing waste heat from the generating unit.

          Recirculated cooling water shall mean water passed through
          the main condensers for the purpose of removing waste heat
          from the generating unit, passed through a cooling device,
          other than a cooling pond or a cooling lake, for the purpose
          of removing such heat from the water and then passed again,
          except for blowdown, through the main condenser.

          Cooling pond shall mean any man-made water impoundment which
          does not impede the flow of a navigable stream and which is
          used to remove waste heat from heated condenser water prior
          to returning the recirculated cooling water to the main
          condenser.

          Cooling lake shall mean any man-made water impoundment which
          impedes the flow of a navigable stream and which is used to
          remove waste heat from heated condenser water prior to recir-
          culating the water to the main condenser.
NATURE OF PROBLEM

Steam-electric power plants burn fuel to produce heat to generate
steam, which in turn drives turbine generators for the production
of electrical energy.  The spent, expanded steam is condensed to water
by transferring the unusable waste heat to a cooling water circuit(s).
The condensed steam becomes high quality water which is returned to the
powerplant boiler ready for reuse.  The rejected heat is wasted to the
environment.

Steam electric powerplant (.stations) consist of one or more generating
units.  Typically, a generating unit consists of a discrete boiler,
turbine-generator, and a condenser system.  However some units employ
multiple boilers associated with multiple turbine-generators.  Fuel
storage and handling, water treatment facitilies, and miscellaneous
components may be part of a discrete generating unit, or may service
more than one generating unit.

Generally, the newer, larger, more efficient generating units are
assigned base-load service; and the older, smaller, less efficient
generating units are used for meeting peak demands.  The type of
service (whether base load, etc) and the remaining service life
characteristics of the unit are important factors affecting ability
in meeting effluent reductions relative to the quantities of heat
generated.

-------
                                                                        129
The  Federal Power Commission describes base-load, intermediate,
and  peaking units as follows.  Base-load units are designed to run more
or less continuously near full capacity except for periodic maintenance
shutdowns.  Peaking generating units are designed to provide electricity
principally during periods of maximum system demand and operate only a
few  hours a day.  Units employed for intermediate service range between
the  extremes of base-load and peaking service and are designed to respond
readily to swings in system demand, or cycling.  Net generation at
any  unit is less than the gross generation because electricity is
used by the power plant itself.

Nuclear power generation units are almost always used for base-load
service in spite of the significantly larger quantities of waste
heat discarded to cooling water compared to otherwise similar fossil-
fuel base-load units.

Base-load units represent approximately 70 percent of the total U.S.
installed capacity of steam-electric powerplants; cycling about 25
percent;.and peaking units about 5 percent.  However when viewed in
terms of the total U.S. steam electric energy actually produced, the
base-load units account for approximatly 90 percent of the real
energy (and spent heat) generated; cycling units about 10 percent;
and  peaking units less than 1 percent.

Steam electric powerplants discharge around 50 trillion gallons of
waste water per year, which amounts to about 15% of the total  flow
of waters in U. S. rivers and streams.  Almost all  of these waters
contain heat and in come cases, chemicals added by the powerplants.

The  general types of wastewater streams from powerplants include:   1)
cooling system waste waters; 2) metal  cleaning wastes; 3) boiler
blowdowns; 4) ash transport waters; and 5)  various  low volume  wastes.
These are described below:

Condenser cooling systems at power plants are classified either as
once-through or recirculating.   In once-through cooling systems,
biocides such as chlorine or hypochlorites  are generally added to
the  system to minimize biological  growth within the condenser(s)  and
are  therefore likely discharged.   In recirculating  cooling systems
the waters will contain:  a)  chemical additives to control growth  of
organisms (chlorine, hypochlorites, organic chromates, etc); chemical
additives to inhibit corrosion  (organic phosphates,  chromates, zinc
salts, etc); and materials present in  the intake waters (but at much
higher concentration due  to evaporative losses).

Metal cleaning wastes are derived  from the  cleaning  of metal process
equipment.   Such equipment includes boiler  tubes, boiler fireside
and air preheaters.   Pollutants in these wastes include oil and grease,
iror. copper, nickel, zinc,  TSS, and chromium.

-------
  130
Boiler blowd'own wastes usually demonstrate high pWi and high IDS.
Phosphates used for the precipitation of calcium and magnesium salts
are generally found in boiler blowdown.

When coal and oil  are burned, ash residues are created.   These ashes may
be transported by water to a settling pond or basin.  Some or all  of the
water from the pond or basin may be dis-charged.  Ash handling wastes
derived from coal-fired plants may contain TSS, iron, aluminum, mercury,
and oil and grease.  Oil-fired plants can additionaly produce vanadium.

Low volume wastes  include ion exchange water treatment,  water treat-
ment evaporative blowdown, laboratory and sampling streams, floor
drainage, cooling  tower basin cleaning, ash pollution device effluent,
and other aqueous  power plant wastes not previously cited.  These
wastes contain primarily TSS and oil and grease.

Area runoff can contain TSS and oil and grease.  Runoff from coal
piles may also contain iron, high or low pH. values, copper, zinc and
manganese.

The Steam Electric Power Industry is comprised of approximately 1,300
plants throughout the continguous U.S.  Some 98 plants or 7.7 percent,
are said to discharge wastewaters to POTW's.  Steam Electric plants
tied into POTW's are smaller on the average than plants discharging
to surface streams.  These plants averaged 150 MW vs. about 400 MW for
the entire Stream Electric Industry.  Plants connected to POTW's are
also older than plants discharging to surface streams.  No nuclear
powered plants are believed to be connected to POTW's.
PARAMETERS OF CONCERN,
          pH, Acidity, Alkalinity*
          Algicides
          Aluminum
          Ammonia W
          BOD
          Boron
          Bromide
          COD
          Chlorides
          Copper*
          Debris
          Fecal Coliforms
          Fluorides
          Chlorine-free available and
               total, residual*
          Heat*
TDS
Magnesium
Manganese
Mercury
Nitrate N:
Oil/Grease*
Phenols
Selenium
Sulfates
Sulfites
Surfactants
Total chromium*

Hardness
Phosphorous
TSS*
Turbidity
*  Most significant pollutant parameters.

-------
                                                                        131
                Iron                          Vanadium
                Lead                          Zinc*
                Nickel*

 PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
 MEASURES

 The USEPA Draft Supplement for Pretreatment to the Development Docu-
 ment for the Steam Electric Power Generating Industry tentatively
 concluded that  power plants discharging to POTW's are capable of pre-
 treating effluents equivalent to BPCTCA.  However, a survey of current
 industry practices indicated that most plants provide little pretreat-
 ment of their chemical-type wastewaters.

 The USEPA has determined that control of copper, nickel  and zinc
 associated with metal cleaning wastes at a power plant are required.
 Additionally, control of oil and grease from the plant's combined dis-
 charge to the POTW is required.  The metals were found incompatible
 because they can interfere with proper operation of the POTW; they
may not be adequately treated; and threats are posed both to the
 receiving waters and to vegetation and crops grown on soil treated
with sludges from the POTW.  A pretreatment standard of 1 mg/1  copper
was established because this level can be attained by BPT technology
 (lime precipitation).  Limits for nickel and zinc were not imposed
because they are indirectly controlled through the regulation of
copper.  When copper may not be present in significant quantity but
nickel and zinc are found in high levels, it may be necessary for the
POTW to regulate the latter metals to concentrations achievable by
lime precipitation.  Discharge of oil/grease of petroleum origin
exceeding 100 mg/1  from a power plant could interfere with the  POTW
or be inadequately treated.  Power plants can comply with the oil/
grease standard of 100 mg/1 by using good housekeeping procedures
and by other methods.

Pretreatment Standards for Existing Sources Within Subcategories A, B,
and C (New Source Limitations not yet clearly defined).

          Parameter                               Limitation

     Copper in metal  cleaning wastes    1  mg/1  Quantity  of copper
                                        allowed = flow of metal
                                        cleaning  wastes  x 1  mg/1.
     Oil/Grease in  combined discharge   100 mg/1; Quantity of oil/
                                        grease allowed to POTW  =
                                        combined  flow x  100 mg/1
     PCB's                               Prohibited
     pH                                 pH  shall  not be  less than
                                        5.0,  unless  the  POTW is
                                        designed  to  accomodate
                                        this  condition.

-------
   132
Pretreatment Standards for Existing Sources Mi thin Subcategory D.
(New Source Limitations not yet clearly defined).

          Parameter                          Limitation

          pH                            pH shall not be less than 5.0
                                        unless the POTW is designed
                                        to accomodate this condition

Treatment can lower the oil/grease content to 20 mg/1 or below by
using properly-designed oil skimmers.  The pretreatment standard of
100 mg/1 for oil and grease should be easily attainable by good
housekeeping practices.  Treatment of metal cleaning wastes to achieve
the pretreatment standard of 1.0 mg/1 copper would consist of oil and
grease skimming, waste equalization, lime addition to attain a pH
level of about 9, followed by settling.  This treatment sequence
should also significantly reduce nickel, zinc and choromate pollutant
loads.  Disposal of chemical sludges from the treatment works must be
conducted so as to ensure long-term protection of the environment
especially adjacent surface and ground waters.  The recommended pre-
treatment technology for power facilities further includes in-plant
measures to recycle and reuse waste waters at the industrial site.

-------
                                                                      133
                  FERROALLOYS MANUFACTURING INDUSTRY
                    (165, 166, 167, 168, 169, 170)
                               [Part 424]

SUBCATEGORIZATION OF THE INDUSTRY

The Ferroalloy Industry is divided into seven subcategories predicated
upon type of melting furnace used, air pollution control devices
available, and specific ferroalloy or metal produced.  These are:

     A -  Open Electric Furnaces with wet air pollution control
          devices subcategory

     B -  Covered Electric Furnaces and other smelting operations
          with wet air pollution control devices subcategory

     C -  Slag Processing subcategory

     D -  Covered Calcium Carbide Furnaces with wet air pollution
          control devices subcategory

     E -  Other Calcium Carbide Furnaces subcategory

     F -  Electrolytic Manganese Products subcategory

     G -  Electrolytic Chromium subcategory

Further description of major processing operations within each sub-
category is provided below:

Subcategory A.  Applies to the smelting of ferroalloys in open electric
furnaces with wet air pollution control devices.  Includes electric
furnaces of such construction or configuration that the furnace  off-gases
are burned above the furnace charge level  by air drawn into the  system.
After combustion, the gases  are cleaned via a wet air pollution  control
device, such as a scrubber,  an ESP with water, or other aqueous  sprays,
etc.  This subcategory does  not include electric furnaces which  are
covered, closed, sealed or semi-covered, or where the off-gases  are not
burned prior to collection.

Subcategory B.  Applies to covered electric furnaces or other smelting
operations not defined elsewhere under the ferroalloy industry,  and
having wet air pollution control  devices.   Included are those furnaces
of such construction or configuration and known as covered, closed,

-------
134
sealed, semi-covered or semi-closed, and in which the furnace off-gases
are not combusted prior to collection and cleaning.  The off-gases after
collection are cleaned in a wet scrubber, wet baghouse etc.   This
subcategory includes non-electric furnace smelting operations such as
exothermic, smelting, ferromangenese, etc., equipped with wet air pollu-
tion control devices.  Furnaces which utilize dry dust collection
techniques are not included.

Subcategory C.  In slag conversion, either the "concentration" or the
"shotting" process is used.  In the first process, the slag  floats to
the surface of the water, and the metal particles which are  eventually
recovered, sink to the bottom.  The concentration process is generally
employed on ferrochromium slags.  The shotting practice involves the
granulation of molten slag in water and is usually employed  with ferro-
manganese slags.

Subcategory D.  Applies to the production of calcium carbide in covered
electric furnaces which employ wet air pollution control devices.  In-
cludes electric furnaces of such construction or configuration and known
as covered, closed, sealed, semi-covered or semi-closed, and in which
the furnace off-gases are not combusted prior to collection  and cleaning.
The off-gases once collected are cleaned in a wet scrubber,  wet baghouse,
etc.  This subcategory excludes furnaces which utilize dry dust col-
lection techniques such as dry baghouses, etc.

Subcategory E.  Applies to the production of calcium carbide in covered
furnaces which do not utilize wet air pollution controls. Covered
calcium carbide furnaces with wet air pollution controls are regulated
under Subcategory D above.  Open or uncovered calcium carbide furnaces
are regulated under 40 CFR, Part 415, the Inorganic Chemicals Industry.

Subcategory F.  Applies to the manufacture of electrolytic manganese
products such as electrolytic manganese metal or electrolytic manganese
dioxide.  The processing involves leaching the metal from the ores,
purification of the leach solution, plating of the product and final
product preparation.  Ammonia is used in the production of both electro-
lytic manganese and chromium, but not manganese dioxide.

Subcategory G.  Applies to the manufacture of chromium metal by the el-
ectrolytic process.  However, this subcategory is not applicable to the
manufacture of chromium metal by aluminothermic or other methods.
NATURE OF THE PROBLEM

Farroalloys are used for deoxidation,  alloying and graphitization of
steel and cast iron.  In the nonferrous metal  industry,  silicon is used
primarily as an alloying agent for copper,  aluminum,  magnesium and
nickel.  Manganese is the most widely  used  element in ferroalloys

-------
                                                                      135
followed by silicon and chromium.  Other elements include molybdenum,
tungsten, titanium, zirconium, vanadium, boron and columbium.  The U.S.
is almost entirely dependent upon commercial sources of manganese,
chromium and other ores from outside the country.  Ores are crushed
prior to entry into the melt furnaces.

There are four major methods used to produce ferroalloy and high-purity
metallic additives for steel making which are:  1) the blast furnace;
2) the electric furnace;  3) the alumino or silicothermic process;  and
4) electrolytic deposition.  Electric smelting furnaces produce most
of the ferroalloy tonnage.  The major ferroalloys produced are silicon
alloys e.g. ferrosilicon; chromium alloys e.g. high carbon ferro-
chromium; and manganese alloys, e.g. standard ferromanganese.  Air pol-
lution control devices are in widespread use in the industry including
baghouses, wet scrubbers, and electrostatic precipitators.  Accordingly,
the largest source of water-borne pollutants other than thermal in the
industry is the use of wet methods for air pollution control.  There are
some 40 plants in the U.S. which produce ferroalloys, chromium, manga-
nese and other additive metals.

Calcium carbide is manufactured by thermal reduction of lime and coke
in an electric furnace.  Emissions from calcium carbide furnaces have
a major impact upon water pollution in plants using wet air pollution
controls.  Manganese metal and chromium metal are manufactured electro-
lytically from ores, ferroalloy slag or ferroalloys.

Major waste sources and pollutants within the seven subcategories of
the Ferroalloy Manufacturing Industry are summarized as follows:

Subcategory A.  Open Electric Furnaces with wet air pollution control
devices.  Wet air cleaning collects particulates from furnace gases
either by gas scrubbing, or by water sprays prior to electrostatic pre-
cipitators.  The particulates are generally oxides of the material
being smelted.  With this type of furnace, most cyanide and phenol
is destroyed in the combustion of the off-gases.  The wastewaters con-
tain large amounts of TSS and smaller amounts of manganese and chromium.
Yet smaller quantities of phenol and oil are generally found in these
effluents.

Subcategory B.  Covered Electric Furnaces and other smelting operations
with wet air pollution control devices.  Wastes are similar to those
for Subcategory A but since in covered smelting furnaces the off-gases
are not combusted, this results in cyanide and phenol being present in
rather significant quantities in the scrubber wastewaters.

Subcategory C.  Slag Processing.  The most important pollutant may be TSS
with manganese and chromium present in lesser amounts.

Subcategory D.  Covered Calcium Carbide Furnaces with wet air pollution
control  devices.   The off-gases from covered calcium carbide furnaces

-------
136
usually contain about 70% carbon monoxide and lesser amounts of cyanides.
Calcium carbide manufacturing and scrubbing wastes contain predominately
TSS with cyanides also present.  These wastes usually are of high pH.

Subcategory .E.  Other Calcium Carbide Furnaces.  Air pollution control
by plants in this subcategory may be by baghouses in conjunction with
evaporative cooling, or is non-existent.  Therefore, little water pol-
lution potential is usually present.

Subcategory F.  Electrolytic Manganese.  The main pollutants in waste-
waters from the manufacture of electrolytic ferroalloys are TSS and
ammonia.  Manganese is found to some extent in the spent waters from
all electrolytic products.  Electrolytic manganese plants appear to
have two main waste streams.  The first is a highly concentrated effluent
referred to as strong electrolytic manganese waste derived from the hy-
draulic transport of filter residues to tailings ponds and which also
carries small quantities of electrolyte solution (spilled or dumped).
These wastes may contain several thousand mg/1 TSS, manganese and
ammonia, and may also have low pH.  The second stream is referred to
as the weak electrolytic manganese waste derived from product washing
and other.  This waste may contain a few hundred mg/1 of TSS, manganese
and ammonia.

Subcategory G.  Electrolytic Chromium.   Resulting wastes may contain
several thousand mg/1 of chromium, TSS  and ammonia and have a low pH.
Manganese can also be present in appreciable quantities.
PARAMETERS OF CONCERN

     pH, alkalinity, acidity       Oil  and Grease
     Temperature                   Phenols
     TSS                           Phosphates
     Total Chromium                Iron
     Hexavalent Chromium           Zinc
     Cyanides                      Aluminum
     Manganese                     Lead
     TDS                           Color
     Ammonia-N                     Calcium, Sodium,
     Turbidity                       Potassium,  Silica
LIMITATIONS FOR DISCHARGE TO POTW
     Pretreatment limitations for existing and new sources  in the
Ferroalloy Manufacturing Industry have been proposed as  follows:

-------
                                                                      137
For Subcategory A, Open Electric Furnaces With Wet Air Cleaning,
Existing Sources

Have been equated to BPT limits which are:

                                Avg. 30 Days                 Max.  Day
Pollutant               (Ib/Megawatt hrs. energy       (Ib/Megawatt hrs.  energy
                          consumed in furnace)           consumed  in furnace)
TSS
Chromium, total
Chromium, hexavalent
Manganese, total
PH
0.352
0.007
0.0007
0.070
6.0 to 9.0
0.703
0.014
0.0014
0.141

For Subcategory A. Open Electric Furnaces With Met Air Cleaning, New Sources

Limitations have not yet been defined.


For Subcategory B, Covered Electric Furnaces and Other Smelting With
Wet Air Cleaning, Existing Sources

Have been equated to BPT limits which are:

TSS                              0.461                          0.922
Chromium, total                  0.009                          0.018
Chromium, hexavalent             0.0009                         0.0018
Manganese, total                 0.092                          0.184
Cyanide, total                   0.005                          0.009
Phenols                          0.009                          0.013
pH                                        6.0 to 9.0

Provided however, that for non-electric furnace smelting operations, the
permitted limits shall read as Ib/ton of products rather than  Ib/Mwh, and
the limits except for pH,  shall be three times the numerical values  given
in the above table.
For Subcategory B, Covered Electric Furnaces and Other Smelting  With Met
Air Cleaning, New Sources.

Limitations have not yet been defined.

-------
 138
For Subcategory C, Slag Processing, Existing Sources.

Have been equated to BPT limits which are:

                               Avg. 30 Days                      Max.  Day
  Pollutant                 (lb/ton processed)              (lb/ton processed)

 TSS                             2.659                           5.319
 Chromium, total                 0.053                           0.106
 Manganese, total                0.532                           1.064
 pH                                        6.0  to 9.0


For Subcategory C, Slag Processing, New Sources.

Limitations have not yet been defined.


For Subcategory D, Covered Calcium Carbide  Furnaces With Wet Air Cleaning,
Existing and New Sources.

                                                Pretreatment
               Pollutant                          Standard

               TSS, pH                          No limitations
               Cyanide                            0.5  mg/1


For Subcategory E, Other Calcium Furnaces,  Existing and New Sources.

No limitations.
For Subcategory F, Electrolytic Manganese Products,  specifically the
production of manganese. Existing and New Sources^

                               Avg.  30 Days                    Max.  Day
Pollutant                 (lb/1,000  lb product)          (lb/1,000 Ib product)

Manganese                       1.356                         2.711
Ammonia-N                       20.334                        40.667
TSS, pH                     No limitations                 No  limitations

-------
                                                                     139
For Subcategory F, Electrolytic Manganese Products, specifically the
production of manganese dioxide, Existing and New Sources.

                                   Avg. 30 Days             Max. Day
Pollutant                     (lb/1000 Ib. product) (lb/1000 Ib. product)


Manganese                            0.352                  0.705
Ammonia-N                            5.287                  10.574
TSS, pH                            No limitations        No limitations
For Subcategory G, Electrolytic Chromium, Existing and New Sources.

                                   Avg. 30 Days             Max.  Day
Pollutant                     (lb/1000 Ib. product) (lb/1000 Ib.  product)
Manganese
Chromium
Ammonia-N
TSS, pH
1.055
0.053
5.276
No limitations
2.111
0.106
10.553
No limitations
PRESCRIBED TREATMENT MEASURES OR EQUIVALENT

Although np_ pretreatment schemes have been described or formulated,  it
is noted that certain BPT methods may be applicable for ferroalloy com-
panies discharging to POTW's.  The latter may include neutralization,
physical-chemical treatment for removal  of metals and TSS,  settling,
sand or multi-media filtration, cyanide  destruction by alkaline  chlori-
nation or other oxidation, breakpoint chlorination for phenols reduction,
overall biologial treatment, and possible ammonia treatment by steam
stripping or breakpoint chlorination.

-------
140
                LEATHER TANNING AND FINISHING INDUSTRY
                          (25, 26, 211, 212)
                               [Part 425]

SUBCATEGQRIZATION OF THE INDUSTRY

The'Leather Tanning and Finishing Industry has been divided into seven
Subcategories described below:

     A - Hair - pulp - chrome tan
     B - Hair - save - chrome tan
     C - Hair - save - nonchrome tan
     D - Retan only
     E - No beamhouse tannery
     F - Thru-the-blue
     G - Shearlings tannery

Specialized definitions used in subcategorization are provided as
follows:

Hide shall mean any animal pelt or skin received by a tannery as raw
material.

Finish means the final steps performed on a tanned hide including but not
limited to retan, bleach, color and fatliquor.

Hair Pulp shall mean the removal of bair by means of chemical dissolution.

Hair Save shall mean the physical or mechanical  removal of hair which
has not been chemically dissolved.

Chrome Tan means the process of converting hide into leather using a
chromium agent.

Vegetable Tan means the process of converting hide into leather using
chemicals either derived from vegetable matter or equivalent synthesized
chemicals.

Split means the nongrain part of a hide which results from a cut parallel
to its surface.

Beamhouse is that portion of the tannery where the hides are washed,
limed, fleshed, and unhaired when necessary, preparatory to the tanning
process.

Tanyard or Tanhoiise is that portion of the tannery in which bating,
pickling, and tanning are performed on the hides or skins.

Fatliquoring is a process by which oils and related fatty substances
replace natural oils lost in the beamhouse and tanyard processes.  Fat-
liquoring regulates the softness and pliability of the leather.'

-------
                                                                       141
Further description of plants within the various Subcategories is given
as follows:

Subcategory A, Hair - pulp - chrome.  Include tanneries that primarily
process raw or cured cattle or other hides into finished leather, chemi-
cally dissolving the hide hair, and using chrome tanning and usually
wet and dry finishing.

Subcategory B, Hair - save - chrome.  Includes tanneries that primarily
process raw or cured cattle or other hides into finished leather,
loosening and removing at least a portion of the hide hair as a solid,
and using chrome tanning and usually wet and dry finishing.

Subcategory C, Hair - save - nonchrome.   Includes tanneries that pri-
marily process raw or cured cattle or other hides into finished leather
usually hair save, using less than 20% chrome tanning, using instead
vegetable, alum, syntans, oils or other methods for tanning, and usually
wet and dry finishing.

Subcategory D, Retan only.  Includes tanneries that primarily process
previously tanned hides and/or skins (including splits) into finished
leather, the major wet process consisting of retanning, coloring and
fatliquoring.

Subcategory E, No beamhouse.  Includes tanneries that primarily process
hides and/or skins, with the hair previously removed, into finished
leather using either chrome or nonchrome tanning methods.   Materials
primarily include pickled sheepskin and cattlehides and pigskins.

Subcategory F, Thru-the-blue.  Includes tanneries that primarily process
raw or cured cattle or other hides through-the-blue tanned state only,
with no retanning or finishing operations, using chrome tanning.

Subcategory G, Shearling.  Includes tanneries that primarily process
raw or cured sheep or sheep-like skins, with the wool or hair retained
on the hides, into finished leather using chrome or nonchrome tanning;
or a wool pullery, a plant which processes hair-on raw or cured sheep or
sheep-like skin by first removing the wool and then pickling the skin
for use by a sheepskin tannery (i.e. Subcategory E).
NATURE OF PROBLEM

There are approximately 200 to 210 tanneries (wet process)  in operation
at present time across the U.S.  Another 225 to 260 firms are engaged
in finishing operations (mostly dry operations) for the leather tanned
at some other location.  Cattle hides represent about 20 percent of the
total estimated pounds of hides tanned in this country.  Other types of
hides include sheep, lamb, pigskin, horse, goat, etc.  Currently, waste

-------
142
from around 90 percent of the tanneries, constituting about 80% of the
production, is discharged to municipal  sewers.   Tannery wastes can ex-
hibit high strength, i.e. 2,000 to 3,000 mg/1  TSS,  up to 850 mg/1  oil
and grease, and sulfides up to 250 mg/1.

Leather tanning and finishing wastewaters contain hair, hide scraps,
pieces of flesh, blood, manure, dirt,  lime,  surface active agents,
tannins, dyes, solvents, etc.  These wastes  are generally characterized
as having appreciable amounts of TSS,  TDS, BOD, COD, oil and grease,
total chromium, sulfides, total kjeldahl nitrogen,  ammonia nitrogen,
chlorides, alkalinity, heat, fecal coliforms,  and possible pH problems.
Major wastewater sources in a leather  tanning  and finishing plant in-
clude: washing and soaking, degreasing, unhairing,  bating, pickling,
tanning, retanning, coloring, fatliquoring,  drying, and finishing opera-
tions.  Finishing may generate various wastewaters  such as wet scrubbing
of buffing dust and spray booth washdowns.

Washing and soaking create spent waste streams  containing dirt, manure,
salts and other foreign materials.  Degreasing  (usually only for sheep-
skins and pigskins) contributes animal  fats  and associated waste ma-
terials from the skins, plus spent detergents  or solvents.  With solvent
degreasing, most plants utilize a solvent recovery  system.  Detergents
used will be dependent upon the type of hide or skin to be degreased.

Unhairing is performed by either the "hair save" or the "hair pulp"
method.  Hair save refers to mechanical removal of  chemically-loosened
hair.  This hair is mostly disposed of to landfill  although some may
enter the plant sewer.  In the hair pulp method, the hair is dissolved
completely.  The latter method is the  most important waste source of
proteinaceous organic and inorganic lime-type  pollutants, characterized
by wastewaters of high pH and containing substantial amounts of BOD,
TSS, sulfides, alkalinity and nitrogen.  Beamhouse  processes whicb_in-
clude washing through unhairing operations,  typically generate u'p to
75 percent of the waste load expected  at a complete tannery.

Bating produces inorganic calcium salts, proteinaceous hair and waste
hide substances together with large amounts  of ammonia nitrogen.
Pickling operations are responsible for low  pH  wastes which also contain
large amounts of salts.

Tanning is accomplished primarily using trivalent chromium salts or
tannins in extracts derived from special forms  of tree bark.  Spent
chrome tanning liquors will contain high concentrations of trivalent
chromium in low pH waters together with BOD, TSS and heat.  Slowdown
associated with vegetable tanning is highly  colored and contains sub-
stantial amounts of BOD, COD and TDS.

-------
                                                                       143
Retarding, coloring, and fatliquoring contribute additional  trivalent
chromium, vegetable tannins, synthetic tannins, natural and synthetic
oils and spent acid dyes found in relatively large wastewater volumes.
These wastes have moderate-to-low amounts of BOD and TSS, moderate
levels of COD, and may contain significant color and heat.

Drying and the various finishing operations (such as pasting, frame
washing, rewet conditioning, vacuum dryer cooling, wet scrubbing of
buffing dust, spray booth washdowns, etc.) generally cause relatively
small volumes of low strength wastewaters.

It is reported in POTW's properly designed to handle leather tanning and
finishing wastewaters that BOD, TSS, sulfides, oil/grease and chromium
loads from the tanning industry should be compatible pollutants.
Almost all POTW's receiving major amounts of leather tanning and fin-
ishing wastes where sulfide problems could become severe, have imple-
mented special measures primarily to control pH fluctuations.  Sulfides
are thought to be readily ozidized in secondary-type POTW's.  Various
municipal sewer ordinances include provisions to limit sulfide inputs to
the sewer.  However, where sulfide problems have occurred, they have
been quite severe.  Documentation is available regarding sewer crown
corrosion, odors, asphyxiation and death of municipal workers, and el-
ectrical and mechanical equipment corrosion both within sewer collection
systems and treatment works.  High surges of oxygen demand are caused
by rapid oxidation of sulfides in the system.  Ammom'a nitrogen is also
a problem associated with leather tanning wastes.  Treatment alternatives
for reducing ammonia include beamhouse stream segregation and precipi-
tation of proteins (from pulped hair) after the sulfides have been oxi-
dized, and the possible substitution of ammonia in the bating process.

Specific effects upon POTW'S include the large pieces of scrap hide,
leather trimmings, hair and other screenable solids which can clog
pipes, pumps and equipment.  Industrial batch processes can produce
wide fluctuation in hydraulic, organic and pH loadings to the POTW.
Unhairing wastewaters containing sulfides can cause odor, corrosion
and hazardous gases.  Disposal of POTW sludges containing undue amounts
of chromium may be of special concern.  Ammonia nitrogen may pass through
a POTW.  Pretreatment of leather tanning wastes for sulfides, chromium
and/or ammonia may well be indicated in specific cases.
PARAMETERS OF CONCERN
               BOD
               Total Chromium
               Oil/grease
               TSS
               Sulfide
               Chlorides
               pH, Acidity and
                Alkalinity
COD
Kjeldahl and Total Nitrogen
Ammonia Nitrogen
Fecal Coliforms
Color
Phenols pH, Acidity and
TDS

-------
144
Total Chromium.  Most leather in the U.S.  is tanned with chromium salts,
Evidence indicates that chromium in both the trivalent and hexavalent
forms is harmful, and thusly total  chromium is measured.

Sulfide.  Sulfide compounds are used extensively in the beamhouse for
the unhairing process and consequently are commonly found in  tannery
effluents.  A significant portion of the alkaline sulfides contained in
tannery wastewaters can be converted to hydrogen sulfide at pH's  below
8.5 to 9.0, resulting in release of this gas.   The gas is not only
Odorous but is also oxidized to sulfuric acid, causing sewer  "crown"
corrosion.  At high concentrations, this gas can be lethal, and is a
significant hazard in sewer maintenance.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTU

For Subcategory A, Hair Pulp, Chrome Tan, limitations for existing
plants; (limits for New plants have not yet been clearly defined).

                    Parameter             Pretreatment Standard


                     pH                Acceptable range of 7 to 10

For Subcategory B, Hair Save, Chrome Tan, limitations for Existing
plants; (limits for New plants have not yet been clearly defined).

                     pH                Acceptable range of 7 to 10

For Subcategory C, Hair Save, Non-chrome Tan, limitations for Existing
plants; (limits for New plants have not yet been clearly defined).

                     pH                Acceptable range of 7 to 10

For Subcategory D, Retan, limitations for Existing plants; (limits for
New plants have not yet been clearly defined).

                     pH                Acceptable range of 6 to 10

For Subcategory E, No Beamhouse, Subcategory, limitations for Existing
plants; (limits for New plants have not yet been clearly defined).

                     pH                Acceptable range of 6 to 10
For Subcategory F, Through-The-Blue, Subcategory, limitations for Ex-
isting plants; (limits for New plants have not yet been clearly defined)

                     pH                Acceptable range of 7 to 10

-------
                                                                      145
For Subcategory G, Shearling Subcategory, limitations for Existing
plants; (limits for New plants have not yet been clearly defined).

                    Parameter            Pretreatment Standard


                      pH              Acceptable range of 6 to 10


PRESCRIBED TREATMENT FOR DISCHARGE TO POTW

Undue amounts of sulfide and chromium may be responsible for serious
problems at POTW's but adequate POTW control methods are reported
available to minimize effects.  Non-contact cooling waters can be
recycled.  Spent unhairing, chrome tanning and vegetable tanning
liquors can be recovered and reused as makeup.  Other cases involve
protein recovery from beamhouse wastewaters, and chromium recovery
from tanyard wastewaters.  Substitution for ammonia in the bating
process can significantly reduce the amount of dissolved ammonia in
tannery wastewaters.

Chromium removal may be necessary by the tannery prior to the municipal
system where stringent water quality limits have been imposed on the
POTW or where the POTW utilizes a sludge destruction process such as
incineration, pyrolysis or wet oxidation which most likely generate
hexavalent chromium which in turn cannot be properly disposed of be-
cause of lack of appropriately controlled landfill  sites.  Sulfide
removal may be necessary by the tannery prior to the municipal system
when there may be appreciable HLS gas evolution in the sewers, or
when the municipality has experienced a history of severe odor and
corrosion problems in spite of various control procedures.   The Federal
regulations of March 23, 1977 indicate where important operational
or sludge disposal problems occur or stringent water quality standards
are prevailing, the local authority should be invoked to require pre-
treatment.

Basic pretreatment at leather tanning facilities may include waste
equalization, effective fine screening and close pH control.  Tanneries
employ waste holding, carbonation, screening, settling,  lagoons, etc.
One study has recommended pretreatment consisting of waste equalization,
carbonation with flue gas, followed by settling with removal of settle-
able solids.  Chemical  treatment includes use of alum, lime, iron salts
or polymers, pH adjustment followed by necessary sludge  handling and
disposal.

-------
  146
                 (INSULATION) FIBERGLASS MANUFACTURING
                               (94, 95)
                             [Part 426]

SUBCATEGORIZATION OF THE INDUSTRY

Fiberglass Manufacturing has been defined as Subcategory A of the overall
Glass Manufacturing Industry.  The process is one in which glass is made
either directly or indirectly,  continuously fiberized, and chemically
bonded with phenolic resins into a wool-like final  product.  Insulation
fiberglass or thermal insulation fiberglass includes but is not limited
to noise insulation products, air filters, and bulk wool products.  These
operations are referred to as a primary process as  contrasted to secondary.
processes e.g. where waste textile fiberglass is processed into an insula-
tion product.  The term insluation fiberglass is synonymous to the descrip-
tions-glass wool, fibrous glass, and construction fiberglass.
NATURE OF PROBLEM

Insulation fiberglass is manufactured by only three companies in the
U.S.  A total of 19 plants has been identified.   One waste stream of
particular concern is cullet cooling water.   Cullet water is necessary
in order to solidify molten glass from a furnace whenever the glass
spinning portion of the operation is interrupted or discontinued.
Cullet water can contain high levels of TSS  ranging from a few hundred
mg/1 to tens of thousands of mg/1 even after settling.
PARAMETERS OF CONCERN

          BOD                                Ammonia
          COD                                Color
          Phenols                            Turbidity
          TSS                                Oil/Grease
          TDS                                Temperature
          pH                                 Dyes
                                             Toxicity

Phenols.  Basic constituents of the binder in fiberglass are phenol,
formaldehyde, urea and ammonia which react to form various mono and
poly methylol phenols.  Free phenols will  occur in any water having
contact with uncured resin.   Phenols levels range from 4 mg/1  in once-
through process waters to several  hundered mg/1 in recycled waters.

COD.  Fiberglass manufacturing raw waste streams  may contain COD's
ranging from 3,300 to 44,000 mg/1.

-------
                                                                       147
Dissolved Solids. IDS concentrations can be increased significantly
from chain washing and wet scrubbing of air streams.  Net increases
of 200 mg/1 IDS are reported.  Gross concentrations of up to 40,000
mg/1 IDS have also been observed.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
MEASURES

The Development Document for Fiberglass Manufacturing indicates process
waste waters can contain high concentrations of phenols, formaldehyde
and other hazardous materials which interfere with the operation of
POTW's, pass through these works untreated or inadequately treated, or
otherwise are incompatible with the treatment works.  Accordingly, it
has been determined that fiberglass process waste waters from existing
sources shall receive pretreatment to the level required by BPCTCA, and
new sources shall receive pretreatment to the level  required by New
Source Performance Standards.  However, both BPCTCA and NSPS call  for
np_ discharge of process wastes.  Two exceptions to the above pretreat-
ment requirements are cullet waters from both existing and new sources;
and wastewaters resulting from "advanced air emission control  devices"
at existing plants, when such waters cannot be consumed in the process.

Under BPCTCA limitations for advanced air emission control devices, the
following allowances are specified:
                                   Avg. 30 Day         Max Day
     Parameter             (lb/1000 Ib final  product)(lb/1000 Ib.  final  product)
Phenol
COD
BOD*
TSS*
pH*
0.0003
0.165
0.012
0.015
Range of 6 to 9
0.0006
0.330
0.024
0.030
0.030
Cullet water is defined as water necessary to solidify molten glass
coming off the furnace when the glass spinning portion of the operation
may be discontinued for some reason.  Cullet waters may contain large
quantities of finely divided silica particles in suspension together
with heat, but this waste has been determined to be amenable for
acceptance into POTW's.
   Are likely considered compatible pollutants for POTW purposes.

-------
148
          FLAT GLASS, PRESSED GLASS AND BLOWN GLASS MANUFACTURING
                        (88, 89, 90, 91, 92 and 93)
                               [Part 426]

 SUBCATEGORATION OF THE INDUSTRY

 The Glass Manufacturing Industry is divided into 13 subcategories.
 Fiberglass  manufacturing, which is Subcategory A of the glass industry,
 has been given elsewhere in this report.  The remaining 12 Subcategories
 are discussed below.  Subcategories B through E deal with primary glass
 manufacturing.  Subcategories F and G deal with automobile window glass
 fabrication.  Subcategories H through M cover a wide range of pressed
 and blown glass prbducts.

      B - Sheet Glass Manufacturing
      C - Rolled Glass Manufacturing
      D - Plate Glass Manufacturing
      E - Float Glass Manufacturing
      F - Automotive Glass Tempering
      G - Automotive Glass Laminating
      H - Glass Container Manufacturing
      I - Machine Pressed and Blown Glass Manufacturing (Reserved)
      J - Glass Tubing (Danner) Manufacturing
      K - Television Picture Tube Envelope Manufacturing
      L - Incandescent Lamp Envelope Manufacturing
      M - Hand Pressed and Blown Glass Manufacturing
 Subcategory B, Sheet Glass.  Manufactured from sand, soda ash, limestone,
 dolomite, cullet, etc., these raw materials being mixed and melted in a
 furnace.  The material is drawn vertically from a melting tank to form
 sheet glass.

 Subcategory C, Rolled Glass.  The same raw materials as used in Sub-
 category B are mixed, melted in a furnace and cooled by rollers to form
 rolled glass.

 Subcategory D, Plate Glass.  The same raw materials as used in Sub-
 category B are mixed, melted in a furnace, pressed between rollers, and
 subsequently ground and polished to form plate glass.

 Subcategory E, Float Glass.  Equivalent to plate glass manufacture except
 a molten tin bath is used after the melting furnace and no grinding or
 polishing is required.

 Subcategory F. Automotive Glass Tempering.  Mostly float glass is used,
 which is cut, ground, polished, bended and tempered to produce front and
 back windows for automobiles.

-------
                                                                       149
Subcategory G, Automobile Glass Lamination.  Deals with the fabrication
of auto windshields.  Fabrication consists of inserting a vinyl  plastic
sheet between two layers of glass, immersing in an oil bath, and washing,
cutting and seaming.

Subcategory H, Glass Containers.  Includes plants which melt raw materials
at their facility and mechanically process the resulting glass into glass
containers.

Subcategory I, Machine Pressed and Blown Glass.  Includes plants which
melt raw materials at their facility and mechanically process the result-
ing glass into pressed or blown glass products.

Subcategory J, Glass Tubing (Danner).  Includes plants which melt raw
materials at their facility and produce glass tubing as the final product.

Subcategory K, Television Picture Tube Envelopes.  Includes plants which
melt raw materials at their facility and produce TV tube envelopes as
the final product.

Subcategory L, Incandescent Lamp Envelopes.  Includes plants which melt
raw materials at their facility and produce incandescent lamp envelopes.
Also includes plants which frost the envelopes by etching with hydro-
fluoric acid.

Subcategory M, Hand Pressed and Blown Glass.  Includes plants which melt
raw materials at their facility and hand process the resulting glass into
pressed or blown glass products.
NATURE OF THE PROBLEM

Flat Glass (Subcategories B through G)

There are a total of 36 plants owned by 11  Companies which manufacture
flat glass and fabricate automobile window glass in the U.S.  (Sub-
categories B through G).  Major operations in primary glass manufacturing
consist of batching raw materials, melting, forming, annealing,  grinding
and polishing, washing and cooling.  Major operations in automobile  win-
dow glass fabrication include windshield laminating and solid tempering.

Pressed and Blown Glass (Subcategories H through M).

Various plants identified by the USEPA for the manufacture of Pressed
and Blown Glass in the U.S. and Puerto Rico include as follows:
Glass Container plants - 30 Companies having 140 plants; Machine Pressed
and Blown Glassware - 50 plants; Glass Tubing - 30 plants; TV Picture
Tube Envelope plants - 10 establishments;  Incandescent Lamp Envelope
facilities - 18; Hand Pressed and Blown Glassware -  approximately 50

-------
plants.  Major operations in the pressed and blown glass industry in-
clude: weighing an.d< mixing of raw, materials, melting, of raw materials,
forming of moltet glass, annealing of formed glass products, and special
ftm string operations.
PARAMETERS OF CONCERN

               BOD*                 Lead
               COD                 Ammonia
               TSS                 IDS
               Oil/grease          Phosphorus
               pH", acidity,        Temperature
                 a1ka1i n i ty        Turbi d i ty
               Fluoride
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTVI AND PRESCRIBED TREATMENT
MEASURES
Flat Glass (Subcategories B through G)

The Federal regulations indicate for Existing Sources in the Flat Glass
Subcategories, that the wastewaters generally contain pollutants com-
patible with POTW's.  The one exception is Subcategory G, i.e., Automo-
tive Glass Lamination, which generates a wastewater high in oil.  Raw
wastes from the laminating process typically contain 1,000 to 2,000 mg/1
of oil.  The proposed regulations of February 14, 1974, require that
BPCTCA limitations for oil/grease be attained as shown below.  This is
necessary because of the known detrimental effect of high concentration
of oil on biological treatment systems, and the inability of POTW's to
adequately remove oil.

For Subcategory G, Automotive Glass Lamination:

                          Avg. 30 Day                   Max. Day
  Parameter      (lb/1,000 ft2 final  product) (Ib 1,000 ft? final product)

  Oil/Grease                 0.36                        0.36
Pressed and Blown Glass (Subcategories H through M)

The Federal regulations for Existing Sources in the Pressed and Blown
Glass Subcategories have established limitations for mineral-type oils
and fluoride in certain Subcategories, and also indicate concern over
lead and ammonia loads.

-------
                                                                       151
Animal and vegetable oils were reported as adequately removed by POTW's,
whereas mineral oils are much more persistent and may pass through POTW's
untreated.  Consequently, only mineral-type oils have been limited.
The criteria have been developed in terms of mg/1 and also on the basis
of Ibs. of "furnace pull" which means the amount of molten glass drawn
from the molten furnace(s).


For Subcategory H, Glass Container Manufacturing, Existing Sources:

               Parameter                Daily Max.

               Oil (Mineral)            100 mg/1

For Subcategory H, Glass Container Manufacturing, New Sources:

                    Avg. 30 Day                   Max. Day
Parameter    (lb/1,000 Ib furnace pull)   (lb/1,000 Ib furnace  pull)

Oil (mineral)          0.03                          0.06


For Subcategories I  and J - No limitations.


For Subcategory K, TV Picture Tube Envelope Manufacturing, Existing Sources

Fluoride               0.07                          0.14
Oil(mineral)             -                            100 mg/1


For Subcategory K, TV Picture Tube Envelope Manufacturing, New  Sources:

Oil (mineral)          0.13                          0.26
Fluoride               0.06                          0.12
For Subcategory L, Incandescent Lamp Envelope Manufacturing,  Forming
Operations, Existing Sources:

               Parameter                Daily Max.

               Oil (mineral)             100 mg/1
For Subcategory L, Incandescent Lamp Envelope Manufacturing,  Forming
Operations, New Sources:

-------
152
                            Avg. 30- Day                  Max.. Day
Parameter           (lb/1,000 Ib furnace pull)'    (lb/T',000 Ib furnace pull)

Oil (mineral);                0.115                         0.230


For Subcategory L, Incandescent Lamp Envelope Manufacturing, Finishing
Operations, Existing Sources:

                            Avg. 30 Day                  Max., Day
Parameter         (lb/1.,000 Ib product frosted)(lb/l ,000 Ib. product, frosted)

Fluorfde                    0.115                           0.230
Oil (mineral)                 -                             100 mg/1


For Subcategory L, Incandescent Lamp Envelope Manufacturing, Finishing
Operations, New Sources:
Fluorfde                    0.052                           0.104
Oil (mineral),                 -                             TOO mg/1


For Subcategory M, Hand. Pressed and; Blown: Glass Manufacturing, Existing
Sources:

No Limitations
For Subcategory M, Hand Pressed and Blown Glass Manufacturing; produces
hand pressed or blown leaded glassware and employs HF acid finishing,
New Sources:

                             Avg. 30 Day             Max. Day
Parameter                       mg/T                   mg/1

Fluoride                     13.0                           26.0
For Subcategory M, Hand Pressed and Blown Glass Manufacturing; produces
non-leaded hand pressed or blown glassware and employs HF acid finishing,
New Sources:

Fluoride -                    13.0                           26.0
For Subcategory M, Hand Pressed and Blown Glass Manufacturing; produces
leaded or non-leaded pressed or blown glassware and does not use HF acid
finishing, New Sources:

No Limitations..

-------
                                                                    153
                           ASBESTOS PRODUCTS
                        MANUFACTURING INDUSTRY
                         (83, 84, 85, 86, 87)
                              [Part 427]

SUBCATEGORIZATION OF THE INDUSTRY

The Asbestos Manufacturing Industry has been divided into eleven Subcat-
egories.  The first seven Subcategories represent industrial  activities
under the Building, Construction and  Paper Segment of the Industry,  and
the last four Subcategories represent processes incorporated  under the
Textile, Friction Materials and Sealing Devices Segment of the Asbestos
Industry.  These Subcategories are described below:

     A - Asbestos Cement Pipe

     B - Asbestos Cement Sheet
     C - Asbestos Paper (Starch Binder)
     D - Asbestos Paper (Elastomeric  Binder)

     E - Asbestos Millboard
     F - Asbestos Roofing

     G - Asbestos Floor Tile

     H - Coating or Finishing of Asbestos Textiles
     I - Solvent Recovery
     J - Vapor Absorption

     K - Wet Dust Collection

Subcategory A, Asbestos-Cement Pipe.   Asbestos, Portland cement, silica
and other ingredients are mixed and blended for the fabrication of as-
bestos-cement pipe.

Subcategory B, Asbestos - Cement Sheet.  Asbestos, Portland cement,
silica and other ingredients are mixed and blended in the manufacture
of asbestos-cement sheets.  Asbestos-Cement sheet laboratory  tops are
excluded from this Subcategory.

Subcategory C, Asbestos Paper, Starch Binder.   Asbestos, starch binders
and other materials are used in the manufacture of starch binder type-
asbestos paper.

Subcategory D. Asbestos Paper, Elastomeric Binder.  Asbestos, elasto-
meric binders, and other materials are used in the manufacture of elasto-
meric binder type-asbestos paper.

-------
1,54.
Subcategflry E, Asbestos Millboard.  Asbestos in combination, with; other
materials such as cement, starch, clay, lime and mineral wool are
used to produce asbestos millboard.

Subcategory F, Asbestos Roofing.  Asbestos paper is saturated with as-
phalt or coal tar followed by various surface treatments in order to
manufacture asbestos roofing products.

Subcategory 6. Asbestos Floor Tile.  Asbestos, polyvinyl chloride resin,
chemical stabilizers, limestone and other fillers are mixed for the
manufacture of asbestos floor tile.

Subcategory H, Coating or Finishiing of Asbestos Textiles.  The process
of coating or impregnating asbestos textiles with selected materials
to obtain desired finished products or to eliminate the problem of air-
borne particles in the further handling, of the textiles.

Subcate.gory I, Solve.nt Recovery,.  In some textiles coating and friction
materials; operatiioris,, the solvents driven1 off in drying! ovens are. cap-
tured by adsorption onto activated carbon.  The solvents are then steam-
stripped; off the carbon and recovered by decanting or further distilling.

Subcatej.ory J, Vapor Absorption.  In some textiles drying operations, the
so 1 vent I dr i ven of fa re removed from the exhaust, gases by absorption in
wet scrubbers.  Solvents are not recovered and they are discharged with
the s,c rubber waters.

Subcategory K, Wet Dust Collection.  Finishing; operations associated with
friction, materials., e.gj;,, grinding and, drilling, can generate excess
airborne.' parti culates;.  Wet scrubbing: results in additional raw waste
loads.
NATURE OF THE PROBLEM

Building. Construction and Paper Segment of Asbestos Manufacturing

In the 1970's, this portion of the Asbestos Manufacturing, industry was
identified as consisting of 51 plant operations under 12 different com-
panies.  Asbestos is normally combined with other materials to yield
manufactured products, and consequently loses its identity.  Asbestos
is actually a group name that refers to several serpentine minerals
having different chemical composition, but similar characteristics.
The most widely used variety is chrysotile.  Asbestos fibers are graded
on the basis of length, with the longest grade priced 10 to 20 times
higher than the shorter grades.  The shorter grades are normally used
in the products described herein.  Overall, asbestos^eement products
and. pipes consume about 70% of all asbestos mined.

-------
                                                                      155
At many asbestos product plants, there is considerable manufacture of
non-asbestos products.  For example, organic cellulose fiber paper
is commonly made at asbestos plants.  Organic cellulose manufacturing
effluents often have high waste strength and may be more difficult to
treat than asbestos-type wastes.

Increased concern with the health effects of asbestos fibers in the air
has brought about changes that have in turn impacted upon water pollu-
tion.  For example, dry processes have been converted over to wet pro-
cesses, and there is increased use of water sprays to minimize dust from
mining operations and slag piles.  Much research has been carried out on
the health effects of asbestos fibers in air.  Conversely, there has
been little study on the effects of fibers in water until the recent
findings of asbestos-like material in the drinking water supply of the
city of Duluth, Minnesota.

Textile, Friction Materials and Sealing Devices Segment of Asbestos
Manufacturing.

This portion of the asbestos industry essentially deals with the manu-
facture of asbestos textile products including yarn, cord, rope, thread,
tape, wicks and various fabrics; friction materials including brake
linings, clutch facings, etc.; and asbestos-containing gaskets, pack-
ings, seals, washers, etc.  In many plants producing the above products,
little or no water is used in manufacturing, and liquid wastes are not
generated.  Wastewaters from Coating, Solvent Recovery and Vapor Absorp-
tion type plants contain a variety of synthetic organic resins, elasto-
mers and/or solvents.  The wastes from wet dust collectors are char-
acterized by high levels of suspended solids.
PARAMETERS OF CONCERN

          BOD                      Oil  and Grease
          COD, TOC                 Nitrogen

          TSS                      Phosphorous
          pH, alkalinity           Color
           acidity

          Temperature              Heavy Metals including:  Cadmium,
                                    Chromium,  Copper,  Mercury,  Zinc,
          Phenols                   Nickel, Barium

          Solvents                 Asbestos

                                   Toxicity

-------
156
 PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED
 TREATMENT MEASURES

 The various Federal documents on effluent limitations/guidelines have
 not developed specific pretreatment limitations to date on asbestos
 manufacturing effluents.  Although these effluents may contain complex
 organics together with appreciable amounts of suspended solids and
 asbestos, the streams are reported as compatible with municipal systems
 and many industrial plants are discharging to POTW's with little or no
 pretreatment.

-------
                                                                      157
                      RUBBER PROCESSING INDUSTRY
                    (108, 109, 110, 111, 112, 113)
                              [Part 428]

SUBCATEGORIZATION OF THE INDUSTRY

The Rubber Industry has been divided into 11 Subcategories.  Subcate-
gories B, C, D include the (primary) synthetic rubber production
plants.  Subcategories E, F and G comprise molded, extruded and fabri-
cated rubber plants; Subcategories H and I - reclaimed rubber plants;
and Subcategories J and K - latex rubber operations.  The various sub-
categories are described below:

     A - Tire and Inner Tube Plants
     B - Emulsion Crumb Rubber

     C - Solution Crumb Rubber
     D - Latex Rubber

     E - Small-Sized General Molded, Extruded, and Fabricated
         Rubber Plants
     F - Medium-Sized General  Molded, Extruded, and Fabricated
         Rubber Plants
     G - Large-Sized General Molded, Extruded, and Fabricated
         Rubber Plants

     H - Wet Digestion Reclaimed Rubber

     I - Pan, Dry Digestion, and Mechanical  Reclaimed Rubber

     J - Latex - Dipped, Latex Extruded, and Latex Molded Rubber
     K - Latex Foam

Subcategory A, Tire and Inner Tube Plants.  Production of pneumatic tires
and inner tubes.

Subcategory B, Emulsion Crumb Rubber.  The manufacture of emulsion crumb
rubber* other than acrylonitrile butadiene rubber.  Emulsion polymeri-
zation is the traditional process for the production of synthetic rubber
crumb.  To an aqueous medium are added the ingredients of the reaction,
emulsifiers, catalysts, activators, etc.  The emulsified product is then
coagulated with a combination  of electrolyte and acid to form the
rubber crumb.

-------
158
Sutxcategpry C., 'Solution Cnumfa Rubber.  Solution  pol;ymeTi,zation  Is ;a
nona'queous process for "the .production of synthet-tc 'rubber  crumb.
Poljmerization (occurs in an organic  solvent 'and  the  crumb  rubber sub-
sequently coagulates by the addition of hot water and  agitation.

Subcategory D, Latex Rubber.  Similar to emulsion crumb  rubber  produc-
tion with the exception .of the coagulation, crumb rinsing,  and  dewater-
ing steps.  Unlike crumb rubber production, short production  runs are
.common.

Subcategory E, Small-Sized General 'Molded, Extruded, and Fabricated
Rubber Plants.  Refers to the production of molded,  extruded  and
fabricated rubber items, foam rubber .backing,  rubber cement-dipped
goods and retreaded'ttres in plants  processing less  than 8,200  Ib/day
raw materials,.

Subcategory F., Medium-Sized General Molded, Extruded,  and  Fabricated
Rubber Plants.  Production of similar products as described for Sub-
category E in plants processing -between 8,200  :and 23,000 Ib/day raw
materials.

Subcategory G, Large-Sized General Molded, Extruded, and Fabricated
Rubber Plants.  Production of similar products as described for Sub-
category E, i:n plants processing greater than  23,000 l:b/:day raw materials,

Subcategory H-, Wet Digestion Reclaimed Rubber.   Rubber scrap  is broken
down into small particles for defibering in .a  digestor.  Defibering
agents and plasticizing oils are added to facilitate chemical degra-
dation of the fibers.

Subcategory I, Pan., !Dry Digestion, and Mechanical Reclaimed Rubber.
Mechanical means of defibering are used in place of  chemical  defibering
employed by Subcategory H plants, thus avoiding  defibering chemicals
and dissolved fibers in the waste waters.

Subcategory J, Latex-.Dipped, Latex Extruded and  Latex  Molded  Rubber.
Latex is used as a raw material in the production of latex thread, and
latex-dipped or molded items.

Subcategory K, Latex Foam.  The production of  latex  foam.


NATURE OF PROBLEM

Major waste sources from tire and tube plants  (Subcategory A) include
tire .and inner tube production materials which come  into contact with
process-waters and raw materials storage areas coming  in contact with
storm water.  Major waste waters from synthetic  rubber plants (Sub-
categories B, C, D) originate from reaction vessel cleaning in  the
emulsion processes, crumb washing and dewatering, and  plant washdown.

-------
                                                                      159
Major waste sources from general molded, extruded and fabricated rubber
plants (Subcategories E, F, G) include waste process solutions, wash-
downs, runoff from outdoor storage sites, spills/leaks of organic sol-
vents and lubricating oils, and vulcanizer condensates.  Excess lead
can originate from lead-sheathing operations and excess COD from cloth-
wrapped curing.

Major waste waters from reclaimed rubber operations (Subcategories H and
I) include waste process solutions, washdowns, outdoor runoff, spills
and leaks, discharge from air pollution control devices, and dewatering
liquor from the wet digestion process.

Waste waters from latex rubber operations (Subcategories J and K) ori-
ginate as product wash and rinse waters, spills, leakage, washdown and
runoff.  Chromium is present in spent waters from latex-dipped and
latex-molded rubber facilities.  Zinc is contributed by latex foam
facilities.
PARAMETERS OF IMPORTANCE

          BOD                           Lead

          COD                           Chromium

          TSS                           Zinc

          Oil and Grease                Other Metals

          Surfactants                   IDS

          pH, acidity, alkalinity       Temperature

                                        Color
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
MEASURES

The Federal Regulations have determined for Subcategory A Rubber
Processing Plants, that process waste waters are amenable for discharge
to POTW's without any pretreatment.   Waste waters from Subcategory B
through K Plants are reported compatible to POTW's, with exceptions
in pretreatment criteria as defined  below:

For Subcategory A, Tire and Inner Tube Plants, Existing and New Sources.
No Limitations

-------
160
For Subcategory B, Emulsion Crumb Rubber, Applicable to Existing Sources,
and apparently also to New Sources.

                         Avg. 30 Day                      Max. Day
Parameter     •   (lb/1,000 Ib final product)    (lb/1.,000 Ib final product)

   COD                       8.0                           12.0
For Subcategory C, Solution Crumb Rubber, Applicable to Existing Sources
and apparently also to New Sources.

   COD                       3.94                          5.91
For Subcategory D, Latex Rubber, Applicable to Existing Sources, and
apparently also to New Sources.
   COD                       6.85                          10.27
For Subcategories E, F and G, i.e. General Molded, Extruded, and Fab-
ricated Rubber Plants, Applicable to Existing and New Sources.

                         Avg. 30 Day                      Max. Day
Parameter        (lb/1,000 Ib raw materials)    (lb/1,000 Ib raw materials)

Oil/Grease                   -                             100 mg/1
Lead*                     0.0007                           0.0017
For Subcategory H, Wet Digestion Reclaimed Rubber, Existing and New
Sources.

                         Avg. 30 Day                      Max. Day
Parameter        (lb/1,000 Ib final product)    (lb/1,000 Ib final product)

 Oil/Grease              '     -                            100 mg/1

 COD                         6.11                          14.70
For Subcategory I, Pan, Dry Digestion, and Mechanical Reclaimed Rubber,
Existing and New Sources.

 Oil/Grease                    -                           100 mg/1

 COD                          2,8                           6.7  -
 *  Attributable to lead-*sheathed hose production, wastes from which
    are discharged to a POTW.

-------
                                                                     161
For Subcategory J, Latex-Dipped, Latex-Extruded, and Latex-Molded
Rubber, Existing and New Sources.

                         Avg. 30 Day                      Max. Day
Parameter  '      (lb/1,000 Ib raw materials)   (lb/1,000 Ib raw materials)
Oil /Grease
*
Chromium
0.0036
100 mg/1
0.0086
For Subcategory K, Latex Foam, Existing and New Sources.

 Zinc                        0.024                         0.058
The EPA Development Documents on the Rubber Processing Industry indicate
the following pretreatment measures are desired for rubber processing
waste waters before release to a POTM:

Tire and Inner Tube Plants (Subcategory A).  Process wastes should re-
ceive separation of oils and solids in an API gravity separator together
with flow equalization in order to prevent shock loads of oil, TSS, or
batch dumps of dipping solutions from upsetting the POTW.

Synthetic Rubber Plants (Subcategories B, C, D).  Emulsion crumb and
solution crumb slurry overflow waste waters should  be passed through
crumb pits to remove floatable rubber crumb.  Few POTW's have primary
settling equipment adequate to handle large quantities of agglomerated
rubber crumb solids.  Waste waters from emulsion crumb and latex pro-
duction facilities are invariably laden with uncoagulated latex solids.
Since POTW's generally do not have coagulation capabilities, these
waste waters should be at least chemically coagulated with a "sinking
agent" and clarified.  The following pretreatment measures apply res-
pectively to Subcategory B, C and D rubber plants.

Emulsion Crumb Plants.  Gravity separation of crumb fines in crumb pits,
chemical coagulation and clarification of latex-laden waste waters, and
neutralization or equalization of utility wastes.

Solution Crumb Plants.  Gravity separation of crumb fines in crumb
pits, and neutralization or equalization of utility wastes.

Latex Plants.  Chemical coagulation of latex-laden waste waters, and
neutralization or equalization of utility wastes.
   Attributable to plants employing the chromic acid form-cleaning
   operation, the wastes from which are discharged to a POTW.

-------
162
General Molded, Extruded and Fabricated Rubber Products (Subcategories
E, F, G).  Process wastes should be passed through an API Separator for
separation of. oils and solids, together with an equalization basin to
prevent shock loads of oil, TSS or batch dumps of dipping solutions,
etc., from upsetting the POTW.  In addition, waste waters containing
excess lead must be treated prior to release to the POTW.

Met Digestion Reclaimed Rubber (Subcategory H).  Process wastes should
be treated for separation of oils and solids followed by use of equali-
zation.  An API separator is appropriate for oil removal if the waters
do not contain digested fibrous materials.  If the fiber is digested
along with the rubber scrap, an abundance of fibrous material will be
present, which is difficult to settle.  An oversize settling lagoon may
be adequate prior to discharge to a POTW.

Pan, Mechanical and Dry Digestion Operations (Subcategory I).  Oil and
solids removal together with flow equalization.

Latex Products (Subcategories J and K).  Coagulation and clarification
of solids-laden wastes followed by chemical precipitation for Chromium
and Zinc, if found necessary.

-------
                                                                     163
                       TIMBER PRODUCTS INDUSTRY
         (2, 114, 115, 116, 117, 118, 119, 120, 121, 122, 127)
                             [Part 429]

SUBCATEGORIZATION OF THE INDUSTRY

The Timber Products Industry has been divided into 19 subcategories.
Subcategories A through H comprise the Plywood, Hardboard and Wood
Preserving Segment of the industry;  Subcategories I through 0 - the  Wet
Storage, Sawmills, Particleboard and Insulation Board aspects of the
industry; and Subcategories P through S include furniture and fixture
manufacturing operations and plants.  These subcategories are further
described below.

     A - Barking Operations
     B - Veneer Manufacture
     C - Plywood
     D - Hardwood - Dry Processing
     E - Hardwood - Wet Processing
     F - Wood Preserving
     G - Wood Preserving - Steam
     H - Wood Preserving - Boultonizing
     I - Wet Storage
     J - Log Washing
     K - Sawmills and Planing Mills
     L - Finishing
     M - Particleboard Manufacturing
     N - Insulation Board Manufacturing
     0 - Insulation Board Manufacturing with Steaming
         or Hardboard Production
     P - Wood Furniture and Fixture Production without Wash
         Spray Booth(s) or Laundry Facilities
     Q - Wood Furniture and Fixture Production without Wash
         Spray Booth(s) but with Laundry Facilities
     R - Wood Furniture and Fixture Production with Water
         Wash Spray Booth(s) but without Laundry Facilities
     S - Wood Furniture and Fixture Production with Water Wash
         Spray Booth(s) and with Laundry Facilities

Subcategory A, Barking.  Operations for removal of bark from logs. Bark-
ing is accomplished by mechanical abrasion or by hydraulic force.   Ma-
terial removed by barking is generally used as a feed material to  other
plants in the Timber Processing Industry.

Subcategory B, Veneer.  Operations converting barked logs or heavy tim-
ber into thinner sections of wood known as veneer.

Subcategory C. Plywood.  Layers of veneer  are laminated to produce fin-
ished plywood.  Plywood manufacturing is mostly "dry" except that  water
is used in cleaning the glue application equipment.

-------
164
 Subcategory D. Hardwood Dry Processing.  Manufacturing operations assoc-
 iated with finished hardboard made from chips, dust, logs, etc., using
 the dry_ matting process in forming the board mat.

 Subcategory E, Hardwood Wet Processing.  Manufacturing operations asso-
 ciated with finished hardboard made from chips, dust, logs, etc., using
 the wet matting process in forming the board mat.  Fibers are diluted
 from 40 percent to less than 1.5 percent prior to mat formation.

 Subcategory F, Wood Preserving.  Wood preserving plants in which steam-
 ing or boultonizing is not the predominant method of conditioning,
 waterborne salts are used in pressure and non-pressure processes, and
 preserving methods are of the non-pressure type.

 Subcategory G, Mood Preserving-Steam.  Processes that use direct steam
 impingment on the wood as the predominant method of conditioning.

 Subcategory H, Wood Preserving-Boultonizing.  Wood preserving methods
 utilizing the Boulton process for conditioning stock.

 Subcategory I, Wet Storage.  Includes: 1) the holding of unprocessed
 wood, i.e., logs or roundwood with bark; 2) the holding of barked logs
 in self-contained bodies of water (mill ponds or log ponds); or 3)
 land storage of logs with water being sprayed on the wood (wet decking).

 Subcategory J, Log Washing.  Logs are passed through pressure sprays,
 the water serving to remove foreign material from the surface of the log
 before further processing.

 Subcategory K, Sawmills and Planing Mills.  Includes one or more of
 the following operations:  log washing, bark removal other than hy-
 draulic barking, sawing, resawing, edging, trimming, planing, and/or
 machining.

 Subcategory L, Finishing.  Consist of operations following edging and
 trimming, which include drying, planing, dipping, staining and coating,
 moisture proofing, fabrication, and by-product utilization.

 Subcategory M, Particleboard Manufacturing.  Particleboard refers to
 board products that are composed of distinct particles of wood or other
 lignocellulosic materials not reduced to fibers which are subsequently
 bonded together with an organic or inorganic binder.

 Subcategory N, Insulation Bond Manufacturing.  Production of insulation
 board where the wood material is not subject to a pressure created by the
 steam.  Excluded is the manufacture of insulation board from bagasse.

-------
                                                                     165
 Subcategory 0, Insulation Board Manufacturing Hith Steaming or Hardboard
Production.  Production of insulation board at facilities which either
steam condition the raw material before refining, or produce hardboard
at the same facility.  Excluded is the manufacture of insulation board
from bagasse.

Subcategory P, Hood Furniture and Fixture Production Without Water Hash
Spray Booth(s) or Laundry Facilities.  Applies to manufacture of wood fur-
niture and fixtures at establishments that: 1) do not utilize wash spray
booths to collect and contain the overspray from spray applications of
finishing materials; and 2) do not maintain on-site laundry facilities
for the fabrics utilized in various finishing operations.

Subcategory Q, Wood Furniture and Fixture Production Without Water Hash
Spray Booth(s) but Hith Laundry Facilities.Applies to manufacture of
wood furniture and fixtures at establishments that: 1) do not utilize
wash spray booths to collect the overspray from spray applications of
finishing materials; but 2) maintain on-site laundry facilities for the
fabrics utilized in various finishing operations.

Subcategory R, Hood Furniture and Fixture Production Hith Water Hash
Spray Booth(s) but Hithout Laundry Facilities.Applies to manufacture
of wood furniture and fixtures at establishments that: 1) utilize water
wash spray booths to collect and contain overspray from spray applica-
tions of finishing materials; but 2) do not maintain on-site laundry fa-
cilities for the fabrics utilized in various finishing operations.

Subcategory S, Hood Furniture and Fixture Production Hith Hater Hash
Spray Booth(s) and Hith Laundry Facilities.Applies to manufacture of
wood furniture and fixtures at establishments that:  1) utilize water
wash spray booths to collect and contain overspray from spray application
of finishing materials; and 2) maintain on-site laundry facilities for
the fabrics utilized in various finishing operations.
NATURE OF PROBLEM

Plywood, Hardboard and Hood Preserving Subcategories (A through H).
Comprise establishments thought to be the most significant sources of
water pollution problems across the timber products industry.  As of
around 1970, there were 340 plywood plants in the U.S.  and about 160
veneer plants.  In 1973, there were 27 known hardwood manufacturing
facilities of which 17 represented variations of the dry process and
10 utilized variations of the wet process.  Het or dry refers to the
formation or felting of fibers to form a mat which is eventually formed
into sheets or boards.  The main difference is essentially that dry
process fibers are suspended in air rather than in water.  Hood preser-
ving subjects round and saw cut wood products to a chemical  injection
process which imports fungistatic, insecticidal, and fire-resistance

-------
166
 properties to the  wood.   In  1971,  a  total of  390 wood  preserving  plants
 were recorded.   Common  preservatives are  creosote,  pentachloro-phenol
 and special  formulations  of  water  soluble inorganic chemicals  including
 copper,  chromium and  arsenic.   Fire  retardants  are  generally formulations
 of borates,  phosphates  and ammonium  compounds.  In  veneer  and  plywood
 mills, major waste sources are  log conditioning, cleaning  of veneer
 dryers,  washing  of glue appertanances and cooling needs. Major waste
 sources  from hardwood mills  comprise log  washing, chip washing, fiber
 preparation, mat formation and  pressing,  resin  system, caul washing,
 housekeeping and humidification.   Wood preserving effluents typically
 have high phenolics,  COD  and oils  including the emulsified form together
 with low pH.

 Wet Storage, Sawmill, Particleboard  and Insulation  Board Subcategories
 (I through 0).Represent a  diverse  group of  establishments.Subcate-
 gories  I and J  include  the handling  and storage of  logs.   Sawmills and
 planing  mills (Subcategory K) produce lumber  products  from logs.  Additional
 operations falling under  Subcategory K comprise fabrication using adhesives
 to join  wood members, machining, etc.   Finishing operations covered
 under Subcategory  L include  drying,  dipping,  staining  and  coating, and
 by-product conversion.  Particleboard made by Subcategory  M plants,  is
 divided  into low,  medium  and high  density particleboard.   Insulation
 board made by Subcategory N  and 0  plants, principally  include  building
 board,  insulating  roof  deck, roof  insulation, ceiling  tile, lay-in-
 panels,  sheathings and  sound deadening insulation board.   In 1967, a
 total of 10,270  sawmills  and planing mills in the U.S. was estimated.
 It was also reported  that there were 76 particleboard  plants and  18
 large-sized insulation  board plants  in the U.S.

 Wood Furniture  and Fixture Subcategories  (P through S).  Consist  of
 approximately 7,000 establishments which  are  highly diversified.  More
 than 90  percent  of these  plants have less than  100  employees and  are
 primarily located  in  North Carolina, the  middle Atlantic,  southern
 Atlantic, the east northcentral States, and California. Raw materials
 include  lumber,  veneer, plywood, hardwood and particle-board.  Wood  is
 dried, machined  and bent  to  desired  shape.  Parts are  assembled generally
 using glue.   Finishing  operations  include bleaching, staining, filling,
 sealing, topcoating,  wood graining etc. Wood  finishing materials  are
 applied  by brush or roller,  but most often are  sprayed onto the wood
 utilizing dry booths  or water wash spray booths.  In the dry booth,  air
 is withdrawn and passed through one  or more filters or paint arresters.
 Especially in larger  furniture  factories, laundry facilities for  the
 rags used in various  finishing  operations, are  common.  Major  sources of
 wastewater include the  water wash  spray booths, laundry facilities and
 glue applicators which  may require cleaning.  Miscellaneous sources
 comprise bleaching, bending  operations, and air pollution  control devices.
 Generally, wastewaters  from  wood finishing plants are  high in  pH  because
 alkaline surfactant agents are  used  to disperse the finishing  materials.
 Strong detergents  emanate from  laundry facilities.   These  wastes  may
 demonstrate relatively  low biodegradability.

-------
                                                                     167
PARAMETERS OF CONCERN
          BOD                           Temperature
          COD                           TDS
          Phenols                       Phosphorous
          Oil/Grease                    Ammonia Nitrogen
          pH                            Fluorides
          TSS                           Boron
          Zinc                          Arsenic
          Copper                        Pentachlorophenol
          Chromium                      Color
          Mercury

Specifically for the Wood Preserving Segment of the Timber Products
Industry (Subcategories F, G, H) the following parameters  are of
special importance:

     pH:  The pH level  of wood preserving waste waters from creosote
     and pentachlorophenol treatments generally varies from 4 to 6
     but may be lower than 4.0.

     Phenols:  Phenolics in waste waters originate from contact with
     creosote, pentachlorophenol-petroleum solutions, and  from products
     treated with these preservatives.   Principal phenolics present in
     the waste waters include para-, meta- and ortho-creosols, and
     various derivatives of these compounds.  Phenolics concentrations
     in the waste waters range from 1 mg/1 up to 600 mg/1  or higher.
     Phenolics are "presumed" to be readily degraded by acclimated
     bacteria in biological POTW's.

     Pentachlorophenol:  PCP is soluble in water up to around 15-20
     mg/1, but frequently exceeds these levels in wood preserving
     wastes.  The fate  of pentachlorophenol in POTW's has  not yet
     been precisely determined.

     Oil/Grease:  Prevalent in both creosote and pentachlorophenol-
     petroleum solutions.  May occur either in free or emulsified form
     in associated wastewaters.  Oil/grease concentrations may range
     from less than 100 mg/1 to much in excess of 1,000 mg/1  after
     primary oil separation.

     Copper, Chromium,  Arsenic and Zinc:  Constitute active ingredients
     in wood preserving fire retardant formulations.   In addition,
     chromium and zinc  are incorporated into fire retardant formu-
     lations.

     Boron:  Boric acid and sodium tetraborate constitute  ingredients
     in commercial fire retardant mixtures used by the wood preserving
     industry.

-------
168
      Fluorides:  Occur as sodium or potassium fluoride, the latter an
      active constituent in one type of wood preserving solution.  After
      lime treatment, fluorides in wastewater may still be present in
      the range of 10 to 20 mg/1.

      Nitrogen and Phosphates:  Both ammonium compounds and phosphates
      are ingredients in fire retardants.  Ammonia N and phosphates have
      been measured in concentrations up to 25 mg/1 in the waste waters
      originating from wood preserving plants employing fire retardants.
 PRELIMINARY PRETREATMENT LIMITATIONS FOR DISCHARGE TO POTW
 Subcategories A through E Including Barking, Veneer. Plywood and
 Hardwood Processing.  (New Source limitations are not yet clearly
 defined).For Existing Sources, the Federal Regulations have determined
 that waste waters from plants in the above subcategories are compatible
 and may be introduced into POTW's without the need for pretreatment.
 However, the pH of waste entering POTW's shall not be less than 5.0
 unless the POTW is specifically designed to accomodate these pollutants.

 Subcategories F. G, H, the Wood Preserving Subcategories.  Proposed
 Federal Regulations of April 18, 1974 indicate that wastewaters from
 wood preserving plants may contain pollutants such as heavy metals,
 phenols and/or oil and grease that could interfere with the operation of
 POTW's, pass through such works untreated or inadequately treated, or
 otherwise be incompatible with such works.  Accordingly, for Subcategory
 F, i.e. Wood Preserving, it was specified that there shall be np_ dis-
 charge or process waste pollutants.  For Subcategories G and H, the
 following limitations are given and the pH of wastes to the POTW, is
 to be controlled at 5.0 or above.

      Subcategory G, Wood Preserving - Steam, Existing Sources.
Parameter
Oil /Grease
Copper
Chromium
Arsenic
Max. Day
(mg/1)
100
5
4
4
Max. Day
(grams/m3 production)
20.5
0.62
0.41
0.41
      Subcategory H, Wood Preserving - Boultonizing, Existing Sources.
      Oil/Grease
      Copper
      Chromium
      Arsenic
100
  5
  4
  4
20.5
0.62
0.41
0.41

-------
                                                                      169
A Draft Report on Pretreatment for the Timber Products Industry
prepared by the EPA in August 1976 did not prescribe specific limi-
tations but indicated that pollutant levels after recommended pre-
treatment should conform to the following values:

     For Wood Preserving Subcategory Plants.  Oil separation in
     combination with flocculation-filtration or decantation should
     provide:

                    Concn. Limit, mg/1       Mass Limit, g/cu.m. Product

     Oil/Grease          80                            14.43
     Pentachlorophenol   10                            1.80
     Copper              2.2                           0.40
     Chromium            2.6                           0.43
     Arsenic             4.1                           0.74
     Zinc                4.4                           0.79
     Boron               0.9                 "         0.17
     For Hood Preserving - Steam Subcategory Plants.  Oil separation
     followed by a flocculation-filtration system should provide:

          Oil/Grease - less than 80 mg/1, and possibly 10 mg/1.
          Pentachlorophenol - apparently 10 to 20 mg/1.
          Copper - apparently 2.2 mg/1
          Chromium - 2.6 mg/1
          Arsenic - 4.1 mg/1

     For Wood Preserving - Boultonizing Subcategory Plants.  Oil separa-  .
     tion in combination with flocculation-filtration or decantation,
     shall provide concentration and mass limits similar to  those above
     for Wood Preserving Subcategory Plants.

Subcategories I through 0, Wet Storage, Log Hashing, Sawmills and Planing
Mills, Finishing, Particleboard Manufacturing, Insulation Board
Manufacturing (New Source limitations are not yet clearly defined).
For Existing Sources, the Federal Regulations have determined that waste
waters from plants in Subcategories I through 0 are compatible for
acceptance into POTW's, and therefore no pretreatment limitations have
been specified.  However the pH of wastes entering the POTW  shall not be
less than 5.0 unless the POTW is designed to accomodate such pollutants.

Subcategories P through S, Wood Furniture and Fixture Production.  (New
Source limitations are not yet clearly defined).  For Existing Sources,
the Federal Regulations have determined that waste waters from Sub-
categories P through S are compatible for acceptance into POTW's, and
therefore no pretreatment limitations have been specified. However,  the
pH of wastes entering POTW's shall not be less than 5.0 unless the POTW
is specifically designed to accomodate these pollutants.

-------
170
 PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

 Specifically for the Wood Preserving Segment of the Timber Products
 Industry (i.e. Subcategories F, G, H), all or a portion of the follow-
 ing treatment and control technologies and procedures have been tenta-
 tively recommended by the EPA:

           Oil separation and the use of flocculation-filtration.
           Segregation of waste streams, water conservation measures,
           elimination of leaks, flow equalization and recovery
           systems when applicable.
           Biological treatment has been identified but is unlikely as
           pretreatment.
           Importantly, it is noted that the Wood Preserving Subcategory
           i.e. Subcategory F, was described as capable of achieving np_
           discharge of process waste water to a POTW.

-------
                                                                       171
          UNBLEACHED KRAFT AND SEMICHEMICAL PULP/PAPER MILLS
                         (30, 142, 143,  144)
                              [Part 430]

SUBCATEGORIZATION OF THE INDUSTRY

Five Subcategories have been established for the Unbleached Kraft and
Semi chemical Mill Segment of the Pulp,  Paper arid Paperboard Industry as
follows:

          A -  Unbleached Kraft Mills
          B -  Sodium-Based Neutral Sulfite Semi-Chemical  Mills
          C -  Ammonia-Base Neutral Sulfite Semi-Chemical  Mills
          D -  Unbleached Kraft, Neutral  Sulfite Semi-Chemical
               (Cross Recovery) Mills.
          E -  Paperboard From Waste Paper Mills

Further description of processes employed within Subcategories A
through E is provided below:

     A)   Unbleached Kraft Subcategory.   Includes mills producing pulp
          and paper by the unbleached kraft process.   Wood, the  fiber raw
          material of unbleached Kraft  pulp, enters  the pulp mill  as
          logs or chips.  Bark is removed from the logs either by a
          wet or dry process.  The chips  are carried  to a  digester,  a
          large steel pressure vessel  heated by steam  to approximately
          150°C.  The chips are cooked  in either a batch or continuous
          operation to dissolve lignin  and separate  the cellulose fibers.
          The cooking liquor is a mixture of sodium  hydroxide and
          sodium sulfite, which because  of high costs,  makes necessary
          a chemical recovery system.   The pulp with  spent cooking
          liquor is transferred to a brown-stock chest and then  to
          vacuum drum washers or continuous diffusers  which separate
          the pulp from the spent cook  liquors.   Paper is  made by
          depositing from a dilute water  suspension of pulp, a layer
          of fiber onto a fine screen which permits  the water to drain
          through but which retains the  fiber layer.   This layer is
          removed from the wire, pressed  and dried.  Unbleached  kraft
          pulp is principally used for  the manufacture of  linerboard
          and grocery sacks.

     B)   Sodium-Based Neutral Sulfite  Semi-Chemical Subcategory.
          Includes the production of pulp and paper by a neutral  sul-
          fite cooking liquor having a  sodium base.  NSSC  mills  may
          purchase their cook chemicals,  but more commonly they  pre-
          pare the cook liquors on the  premises  by burning sulfur and
          absorbing it in soda ash or ammonia.   Chemical recovery in
          the sodium-base NSSC process is considerably  more difficult

-------
  172
          than for the Kraft process.  Most mills simply evaporate and
          burn the spent cook liquor without recovery, but a few large
          sodium-base NSSC mills do have chemical recovery systems.  No
          successful system has been developed for chemical recovery in
          the ammonia-based NSSC mills (Subcategory C below), and the
          spent liquors may be incinerated.  The principal product from
          Subcategory B mills is corrugated paperboard.

     C)   Ammonia-Base Neutral Sulfite Semi-Chemical Subcategory.
          Includes the production of pulp and paper by a neutral sul-
          fite cooking liquor having an ammonia base.

     D)   Unbleached Kraft. Neutral Sulfite Semi-Chemical (Cross
          Recovery) Subcategory.Includes the production of pulp and
          paper in combined unbleached Kraft and neutral sulfite semi-
          chemical (NSSC) mills and where the sodium-based NSSC spent
          liquors can be disposed of to the Kraft chemical recovery
          system.

     E)   Paperboard From Waste Paper Subcategor.y.  Paperboard products
          such as corrugated boxes, box board, newspapers, etc. can be
          manufactured from a wide variety of waste paper.  In these
          mills, waste paper represents 80 percent or more of the
          fibrous materials incoming to the facility.  Waste paper is
          converted to secondary fiber waste paper by adding sufficient
          water to dilute the materials to about 4-6 percent solids
          and charging with chemicals to permit a controlled feed rate
          to the pulper along with steam.  The paper is ripped, shredded
          and finally defibered.  The stock is then passed through
          centrifugal cleaners and a thickener.  Reject material is
          dewatered for disposal, and the stock sent to the refiners
          which serve the paper machines.

NATURE OF PROBLEM

Major waste producing sectors include wood preparation, the pulping
processes, and the paper machines.  Waste sources comprise wet barking,
pulp washing waters, various condensate streams in cooling and pulping,
chemical recovery operations and paper production waters.

In the pulp and paper industry, the dewatering and disposal of sludges
represents a major problem with high attendant costs.  These sludges in
past decades were primarily placed into holding basins from which free
water was decanted.  When a basin was full, it was simply abandoned, or
if sufficient drying occurred, the cake was excavated and deposited onto
marginal land.  More advanced practices for better handling paper and
pulp mill sludges are now employed extensively through the industry.
Hopefully, these excess sludges will not enter into POTW's.

-------
                                                                       173
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTM AND PRESCRIBED TREATMENT
MEASURES

The subject of pretreatment, for both Existing and New Sources of
unbleached Kraft and semichemical pulp and paper mills has been
addressed in the Federal Register publications of January 15, 1974
and May 29, 1974.  However up through the present no specific limita-
tions nor recommended pretreatment methods have been advanced for pulp
and paper mill wastes in the unbleached and semichemical  segment of
the industry.  Process waste water may be introduced into publicly-
owned treatment works pending future recommendations on pretreatment.

-------
174
         BLEACHED KRAFT, GROUNDWOOD,  SULFITE,  SODA,  DEINK  AND
                    NON-INTEGRATED PULP/PAPER  MILLS
                          (13,  14, 131,  141)
                             [Part 430]

SUBCATEGORIZATION OF THE INDUSTRY

Sixteen subcategories have been established  for the  Bleached Kraft,
Groundwood, Sulfite, Soda, Deink and  Non-Integrated  Mill Segment  of  the
Pulp, Paper and Paperboard Industry as follows:

     F)  Bleached Kraft Dissolving Pulp
     G)  Bleached Kraft Market  Pulp
     H)  Bleached Kraft, Paperboard,  Coarse  and Tissue Papers  (BCT)
     I)  Bleached Kraft, Fine Paper
     J)  Papergrade Sulfite (Blow Pit Wash)
     K)  Dissolving Sulfite Pulp
     L)  Groundwoodv Chemi-Mechanical (Fine  Papers,  Newsprint  and
         Molded Fiber Products)
     M)  Groundwood, Thermo-Mechanical (Fine Papers, Newsprint and
         Tissue Papers)
     N)  Groundwood, Coarse, Molded Fiber and  Newsprint (CMN)
     0)  Groundwood, Fine Papers
     P)  Soda Mills
     Q)  Deink Mills
     R)  Non-Integrated Fine Papers
     S)  Non-Integrated Tissue  Papers
     T)  Non-Integrated Tissue  Papers From Waste Paper
     U)  Papergrade Sulfite (Drum Wash)

Further description of mills within the various subcategories  is  pro-
vided below:

     F)  Bleached Kraft Dissolving Pulp Subcategory.  Includes mills
which make a bleached pulp by a "full cook"  process  using  a strong
alkaline sodium hydroxide and sodium  sulfide cooking liquor.   A "pre-
cook" operation termed pre-hydrolysis is employed.   The principal pro-
duct is a highly-bleached and purified dissolving pulp destined for
rayon manufacture or for other  needs  requiring a high alpha cellulose
content.

     G)  Bleached Kraft, Market Pulp  Subcategory.  Includes mills which
make a bleached pulp by a "full cook" process  using  a strong alkaline
sodium hydroxide and sodium sulfite cooking  liquor.   Final product  is
a papergrade market pulp.

     H)  BCT Bleached Kraft Subcategory.  Includes  the integrated pro-
duction of bleached kraft pulp  and paper. Bleached  kraft  is made in

-------
                                                                 175
a  "full cook" process with a strong alkaline sodium hydroxide and
sodium sulfide cooking liquor.

      I)  Bleached Kraft, Fine Papers Subcategory.  The integrated pro-
duction of bleached kraft pulp and fine paper.  Bleached kraft is made in
a  "full cook" process with a strong alkaline sodium hydroxide and sodium
sulfide cooking liquor.  Fine papers comprise business, writing and printing
papers.

      J)  Papergrade Sulfite (Blow Pit Wash) Subcategory.  The integrated
production of sulfite pulp and paper.  Sulfite pulp is made in a "full
cook" process using an acidic cook liquor of sulfites of calcium, mag-
nesium, ammonia, or sodium.  Following cooking, the spent cooking liquor
is separated from the pulp in blow pits.  Principal products are tissue
papers, newspaper, fine papers, and market pulp.

      K)  Dissolving Sulfite Pulp Subcategory.  Includes mills making a
highly bleached and purified pulp from softwoods by a "full cook" pro-
cess  involving strong solutions of sulfites of calcium, magnesium,
ammonia, or sodium.  These pulps are used principally for the manufacture
of rayon and other products requiring the virtual absence of lignin.

      L)  Groundwood, Chemi-Mechanical Subcategory.  The integrated pro-
duction of chemical-mechanical groundwood pulp and paper.  A chemical
cooking liquor is employed in a partial cook of the wood followed by
mechanical defibration.  Principal products are fine papers, newsprint
and molded fiber items.

     M)  Groundwood, Thermo-Mechanical  Subcategory.  The production of
thermo-mechanical groundwood pulp and paper.  Groundwood is made by a
brief cook utilizing steam with or without cooking chemicals such as
sodium sulfite, which is followed by mechanical defibration.  Principal
products are market pulp, fine papers,  newsprint, and tissue papers.

     N)  Groundwood, CMN Papers Subcategory.  The integrated production
of groundwood pulp and paper.   The pulp is made utilizing only mechani-
cal defibration.  Principal products are coarse papers, molded fiber
items, and newsprint.

     0)  Groundwood, Fine Papers Subcategory.  The integrated production
of groundwood pulp and fine papers.   The pulp is made utilizing only
mechanical defibration.  Principal products are fine papers comprising
business, writing and printing papers.

     P)  Soda Subcategory.   The integrated production of bleached soda
pulp and paper.  The pulp is made by a  "full cook" process  with a
strong alkaline sodium hydroxide cooking liquor.  Principal  products
are fine papers comprising printing, writing and business papers,
together with market pulp.

-------
176
     Q)  Deink Subcategory.  The integrated production of deinked pulp
and paper.  Deinked pulp is generally made from waste papers using an
alkaline treatment procedure to remove contaminants such as ink and
coating pigments.  Principal products besides pulp are printing,
writing and business papers, tissue papers, and newsprint.

     R)  Non-Integrated Fine Papers Subcategory.  Includes mills which
produce fine papers from wood pulp or deinked pulp prepared off-site.
Principal products are printing, writing, business and technical papers.

     S)  Non-Integrated Tissue Papers Subcategory.  Includes mills which
produce tissue papers from wood pulp or deinked pulp prepared off-site.
Principal products are facial and toilet papers, glassine, paper dia-
pers, and paper towels.

     T)  Non-Integrated Tissue Papers From Waste Paper Subcategory.
Includes mills which produce tissue papers from waste papers without de-
inking.  Principal products are facial and toilet papers, glassine,
paper diapers and paper towels.

     U)  Papergrade Sulfite (Drum) Hash) Subcategory.  Integrated pro-
duction of sulfite pulp and paper.  The sulfite pulp is made in a
"full cook" process employing an acidic cooking liquor of sulfites of
calcium, magnesium, ammonia or sodium.  The spent cooking liquor is
then washed from the pulp on vacuum or pressure drums.  Also included
are belt extraction systems for pulp washing.  Principal products are
tissue papers, fine papers and newspapers, together with market pulp.
PARAMETERS OF CONCERN

          pH, Acidity, Alkalinity       Settleable Solids
          BOD                           Turbidity
          TSS             •              COD

          Color                         Resin Acids
          Ammonia N                     Polychlorinated Biphenyls
          Zinc                          Coliform Organisms
          Temperature                   Mercury


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

Proposed pretreatment regulations for existing and new sources' in  the
pulp, paper and paperboard industry, Subcategories F through U,  were
published in the Federal Register of February 19, 1976 and subsequently
modified in a recent publication of January 6, 1977.

-------
                                                                  177
Subcategory F - Bleached Kraft, Dissolving Pulp.
     For existing and new Sources:  No limitations.
Subcategory G - Bleached Kraft Market Pulp.
     For existing and new Sources:  No limitations.
Subcategory H - Bleached Kraft, Paperboard, Coarse, Tissue Paper.
     For existing and new Sources:  No limitations.
Subcategory I - Bleached Kraft, fine Papers.
     For existing and new Sources:  No limitations.
Subcategory J - Papergrade Sulfite.
     For existing and new Sources:  Limitations not yet established.   -
Subcategory K - Dissolving Sulfite Pulp.
     For existing and new Sources:  No limitations.
Subcategory L - Groundwood, Chemi-Mechanical.
     For existing Sources where Zinc Hydroxide used as bleaching agent:
                              Zinc,  lb/1,000  Ib product
                              Avg. 30 Day  -   .06
                              Max. Day     -   .12
     For new Sources where Zinc Hydroxide used as bleaching  agent:
                              Avg. 30 Day  -   .048
                              Max. Day     -   .095
Subcategory M - Groundwood, Thermo-Mechanical.
     For existing Sources,  where Zinc Hydroxide used as bleaching agent:
                               Zinc, lb/1,000  Ib. product
                              Avg. 30 Day  -   .05
                              Max. Day     -   .105
     For new Sources, where Zinc Hydroxide used as bleaching agent:
                              Avg. 30 Day  -   .0455
                              Max. Day     -   .090

-------
178
Subcategory N - Groundwood, Coarse, Molded Fiber, Newsprint.
     For existing Sources, where Zinc Hydroxide used as bleaching agent:
                              Zinc, 1b/1.000 Ib.  product
                              Avg. 30 Day  -  .05
                              Max. Day     -  .105
     For new Sources, where Zinc Hydroxide used as bleaching  agent:
                              Avg. 30 Day  -  .0455
                              Max Day      -  .090
Subcategory 0 - Groundwood, Fine Papers.
     For existing Sources, where Zinc Hydroxide used as bleaching agent:
                              Zinc, lb/1,000 Ib.  product
                              Avg. 30 Day   -   .048
                              Max. Day      -   .095
     For new Sources, where Zinc Hydroxide used as bleaching  agent:
                              Zinc, lb/1.000 Ib.  product
                              Avg. 30 Day   -   .044
                              Max. Day          .090
Subcategory P - Soda Mills.
     For existing and new Sources:  No Limitations.
Subcategory Q - Deink Mills.
     For existing and new Sources:  No Limitations.
Subcategory R - Non-Integrated Fine Papers.
     For existing and new Sources:  No Limitations.
Subcategory S - Non-Integrated Tissue Papers.
     For existing and new Sources:  No Limitations.
Subcategory T - Non-Integrated Tissue Papers from Waste Paper.
     For existing and new Sources:  No Limitations.
Subcategory U - Papergrade Sulfite (Drum  Wash).
     For existing and new Sources:  Limitations  not yet established.

-------
                                                                     179
             BUILDING PAPER AND ROOFING FELT MANUFACTURING
                             (80, 81, 82)
                               [Part  431]

SUBCATEGORIZATION OF THE INDUSTRY
Building Paper and Roofing Felt Manufacturing is considered to be part
of the overall Building Paper and Buiilders Board Industry.  To date,
only Subcategory A has been defined by the EPA guidelines limitations,
also known as the Builders Paper and Roofing Felt Subcategory.

NATURE OF PROBLEM

Builders Paper and Roofing Felt mills produce the heavy papers used in
the construction industry made from cellulose fibers in turn derived
from waste paper, wood flour and sawdust, wood chips and rags.  Bleaching
and chemical pulping are not employed by these mills.

Builders papers are generally characterized as saturating papers, floor-
ing paper, and deadening papers used by the construction and automotive
industries.  They differ from the roofing felts in thickness and possible
chemical additives to the builders papers.

Dry roofing felt is a strong, highly absorbent material used as backing
and support for subsequent bituminous coating.  These coatings serve to
waterproof the final  product.

Waste loads from Builders Paper and Roofing Felt mills originate princi-
pally from the stock preparation and board manufacturing processes.  Loss
of fiber and miscellaneous materials occur from both the "white water"
and stock cleaning rejects which are continuously discharged.   Cleaning
losses are also encountered.  Additional  waste sources may include cool-
ing and quenching the coatings on roofing felts.   Mica, talc or similar
solids can be lost to the waste streams.

     Fifty-six mills  which produce saturated papers and/or coating or
dry roofing felt were identified in the industry.  The majority of the
mills are located in  or near metropolitan areas.   It was found that  up
to 75 percent of the  mills have access to municipal  sewers and POTW's.


PARAMETERS OF CONCERN

          BOD                           Turbidity TSS
          TSS                           Color
          pH                            Nitrogen  and Phosphorous
          Settleable  Solids             Polychlorinated Biphenyls
          Oil/Grease

-------
 180
PQLYCHLORINATED BIPHENYJ.S (PCB's) are chemically and thermally-stable
compounds contained in waste papers,  Recycled office papers appear to
be a main source of PCB's although recycled paperboard also shows evi-
dence of PCB's.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTVI AND PRESCRIBED TREATMENT
MEASURES.- No specific limitations have been developed to date in the
Federal regulations for the discharge of builders paper and roofing
felt wastewaters to municipal collection and treatment systems.  The
pollutants in these waste waters are considered to be chiefly organic
materials and solids, and generally compatable to municipal treatment.

-------
                                                                   181
            RED MEAT SEGMENT OF THE MEAT .PRODUCTS INDUSTRY
                       (171, 172, 173,  174,  175)
                              [Part 432]

SUBCATEGORIZATION OF THE INDUSTRY

The overall Meat Products Industry has  been  divided into 15 subcate-
gories including subcategories A through D covering the Red Meat
Segment of the industry; subcategories  E through  I  described as  the
Processor Segment of the industry; subcategory J  representing the
Rendering Segment; and subcategories K  through 0  the Poultry Processing
Segment of the industry.  These are tabulated as  follows:

     A)   Simple Slaughterhouse
     B)   Complex Slaughterhouse
     C)   Low Processing Packinghouse
     D)   High Processing Packinghouse
     E)   Small Processor
     F)   Meat Cutter
     G)   Sausage and Luncheon Meats Processor
     H)   Ham Processor
     I)   Canned Meats Processor
     J)   Renderer
     K)   Chicken Processor
     L)   Turkey Processor
     M)   Fowl Processor
     N)   Duck Processor
     0)   Further Processing Subcategory

The Red Meat Segment of the industry consisting of  four distinct sub-
categories is described below:

     Subcategory A, Simple Slaughterhouses.   A slaughterhouse is
     defined as a plant that slaughters animals and has as  its main
     product fresh meat in whole, half, or quarter  carcasses or
     smaller cut meats.  A "simple slaughterhouse"  refers to a
     slaughterhouse which accomplishes  very  limited by-product
     processing, if any, such as rendering,  paunch  and  viscera
     handling, blood, hide or hair processing.

     Subcategory B, Complex Slaughterhouses.   A slaughterhouse that
     performs extensive byproduct processing, generally including
     at least three operations such as  rendering, paunch and viscera
     handling, blood, hide or hair processing.

-------
182
      Subcategory C,  Low-Processing Packinghouses.  A packinghouse is
      defined  as  a plant  that  both slaughters animals and subsequently
      processes carcasses into cured, smoked, canned or other prepared
      meat products.  A "low processing" packinghouse refers to a
      packinghouse that processes no more  than  the  total animals killed
      at that  particular  plant, and normally processes less than the
      total  kill.

      Subcategory D.  High-Processing Packinghouses.  A packinghouse
      which processes both animals slaughtered  at the site and addi-
      tional carcasses from outside sources.
 NATURE OF PROBLEM

 Plants in the meat products  industry range from establishments that
 carry out only  one operation,  such as  slaughtering,  to full-line
 plants that not only  slaughter,  but also conduct processing to vary-
 ing levels, i.e. conversion  of meat products  into sausages, cured
 hams, smoked products,  etc.  Slaughtered animal types include cattle,
 calves, hogs and sheep.  As  of March 1973, 5990 meat slaughtering
 plants were recorded  in the  U.S.  Fifteen percent of the plants in
 the industry account  for 90  percent or more of the total production.
 In 1966, about  70  percent  of all waste water  in the  meat packing
 industry was discharged to municipal sewers.  Waste  waters from meat
 slaughtering, packinghouses  and  associated facilities such as stock-
 yards, rendering and  feed  manufacturing plants contain organic matter,
 grease, TSS and inorganic  materials such as phosphates and salts.
 These materials enter sewers and streams as manure,  curing and pickling
 solutions, caustic or alkaline detergents, et. al.
 PARAMETERS  OF CONCERN

                pH                       Ammonia N
                BOD                     TKN
                COD                     Nitrates,  nitrites
                TSS                     Phosphorous
                TDS                     Chlorides
                TVS                     Temperature
                Oil  and Grease
                Total and  Fecal  Coliforms

-------
                                                                        183
 PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

The 40 CFR Part 432 Federal Regulations for both existing and new
sources in the meat products industry have not formulated pretreatment
limitations, and thusly, these wastes may be discharged to POTW's.
PRESCRIBED PRETREATMENT FOR DISCHARGE TO POTW

The Development Document of October 1973 on the Meat Products Industry
together with the Federal Register publications on meat industry wastes
describe the subject effluents as containing no constituents which
would interfere with, pass through, or otherwise be incompatible with
well-designed and operated POTW's.  However, suggestions have been
made that these effluents before reaching the POTW should receive in-
plant recovery for the removal of grease and gross solids.   Grease can
be a valuable by-product when collected and sent to rendering.   Greases
are collected via catch basins, grease traps or dissolved air flotation
units.  Solids are removed by settling or via screens-static, vibrating
or rotating and generally self-cleaning types.   Waste equalization
is desirable.  In-plant controls should emphasize the following practices:

          Prevent waste materials from interfacing with water streams.
          Covering and dry cleaning of livestock holding pens,  careful
          control over drinking water troughs,  and separate disposal
          of pen manure etc.  to agricultural fields.
          Separate collection and recovery of blood wastes.
          Separate handling and disposal  of paunch materials.
          Precluding viscera  wastes from entering plant sewers.
          Installation of troughs under the killing room to keep blood,
          trimmings, bone dust and miscellaneous off the floors.
          Wastewater from rendering should be condensed and/or  evaporated
          for sale or disposal as "stickwater."  Tankwater,  greases
          and cracklings should receive high priority for recovery.
          Overflows from hide curring vats or raceways should receive
          close control.
          Hog scald tanks contain strong  wastes which should be
          collected, treated, and if possible,  reused.
          Consideration should be given to special  handling  of  spent
          pickling and curing liquors which contain high levels  of
          salt and in many cases, also have high sugar content.
          Many possibilities  of water reuse and water reduction  inside
          the meat processing plant have  been demonstrated  and warrant
          serious attention for implementation.

-------
184
               PROCESSOR SEGMENT OF MEAT PRODUCTS INDUSTRY
                                (16, 17)
                               [Part 432]

 SUBCATEGORIZATION OF THE INDUSTRY

 The Meat Products Industry consists of 15 Subcategories.   The  Processor
 Segment described herein includes five Subcategories,  i.e.  E through  I.
 The slaughtering of animals, rendering and poultry processing  are
 covered elsewhere in this report.

 Meat processing plants included in this segment of the industry  are
 plants which manufacture prepared meats and meat products  from purchased
 carcasses, meat cuts and other materials, and perform  np_ slaughtering
 at the same plant site.  Processing plants that produce 6,000  Ibs. or
 less of finished product per day are categorized as Small  Processors.
 Remaining plants are described as large processors and are further
 divided into four Subcategories, i.e. F through I.  Canned pet foods
 are not included in the meat processing industry.

      Subcategory E.  Small Processors.  Refers to the  production of
      finished meat products such as fresh meat cuts, smoked products,
      canned products, hams, sausages, luncheon meats or similar  products
      by a small processor.  A small processor is further defined as an
      operation that produces 6,000 Ib/day or less of finished  products.

      Subcategory F.  Meat Cutters.  Refers to the fabrication  or manu-
      facture of fresh meat cuts such as steaks, roasts, chops, etc. by
      a meat cutter.  A meat cutter is further defined  as an operation
      which fabricates, cuts or otherwise produces fresh meat cuts and
      other finished products from livestock carcasses, at  rates  greater
      than 6,000 Ib/day.

      Subcategory 6, Sausage and Luncheon Meat Processors.   Applies to
      the manufacture of fresh meat cuts, sausage,  bologna  and  other
      luncheon meats by a sausage and luncheon meat processor.  A
      sausage and luncheon meat processor is defined as an  operation
      which cuts fresh meats, grinds, mixes, seasons, smokes or other-
      wise produces finished products as sausage, bologna,  and  luncheon
      meats at rates greater than 6,000 Ib/day.

      Subcategory H.  Ham Processors.  Applies to the manufacture of hams
      alone or in combination with other finished products  by a.ham
      processor.  A ham processor is defined as an operation which manu-
      facturers finished products at rates greater than 6,000 Ib/day.

-------
                                                                 185
Subcategory I.  Canned Meat Processor.  Applies to the manufacture of
canned meats alone or in combination with other finished products by a
canned meats processor.  A canned meat processor is defined as an opera-
tion manufacturing canned meats such as stew, sandwich spreads or other
finished products at rates greater than 6,000 Ib/day.
NATURE OF PROBLEM

A total of 1374 meat processing plants were included in the 1967 Census
of Manufacturers in the U. S.  An additional 168 meat processing plants
were reported under Federal inspection up through June 30, 1973.  The
small processing plant handling less than 6,000 Ibs finished product
per day, is estimated to account for 85 to 90 percent of the total
number of plants, but only produces 10 to 15% of total meat processed
across this Segment of the industry.  In 1967, it was estimated about
70% of all meat packing and processing wastewaters found their way into
municipal sewers.  By 1972, 80% or more of the meat processing plants
were said to be discharging to municipal sewers.

Typical operations and major water sources inside a meat processing
installation include:  meat materials preparation, pickling, product
cooking and cooling, and canning.
PARAMETERS OF CONCERN
          pH, acidity, alkalinity
          BOD
          COD
          TSS
          TDS
          TVS
          Oil and Grease
Nitrogen including Ammonia N,
  TKN, nitrates and nitrites
Phosphorous
Chlorides
Temperature
Fecal coliforms
Ammonia Nitrogen is but one of many forms of nitrogen-type pollutants
present in meat processing wastewaters.   Anaerobic decomposition of
protein, which is essentially organic nitrogen,  leads to the formation
of ammonia.  Thusly, anaerobic waste treatment lagoons or digesters can
produce high levels of ammonia.  Septic  or anaerobic conditions  in
traps, holding chambers, etc. also leads to ammonia formation in waste-
water.  Another source of ammonia is leakage from ammonia refrigeration
systems, thought to be fairly common in  meat processing plants.

Nitrates and nitrites are the result of  the oxidation of ammonia and
organic nitrogen.  Nitrates and nitrites are also ingredients in curing
and pickling solutions and in processed  meat formulations.

-------
186
Chlorides originate from meat processing plants as salt from animal
tissues, pickling and curing solutions,  cleaning chemicals,  blowdown
waters and the salt sprinkled on processing plant floors to  prevent
slipping.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

The 40 CFR, Part 432 Regulations of January 3,  1975 give no specific
limitations for existing and new meat processing installations  dis-
charging wastes to municipal sewers.
PRESCRIBED TREATMENT FOR DISCHARGE TO POTVJ

The Development Document of August 1974 on Meat Processor Plant waste-
waters describes these effluents as containing no constituents  which
would interfere with, pass through, or otherwise be incompatible with
well-designed and operated POTW's.  It is however reported that this
wastewater should pass through materials recovery operations  in order
to remove settleable solids and a majority of the grease.   Materials
recovery is accomplished by in-plant control  measures  and primary treat-
ment.  It is possible that grease remaining in the partially-treated
effluent to a POTW can cause difficulties at the POTW.   A concentration
of 100 mg/1 oil and grease is usually cited as the upper limit  to the
POTW.  An air flotation system may be required in addition to catch
basins.  If the BOD strength of wastes going to the POTW must be
reduced further, anaerobic contact, aerated lagoons and other methods,
may be considered for pretreatment.

In-Plant Control methods at Meat Processor Plants generally include
collection of spent pickling and curing solutions, various water
conservation practices and modification of plant cleanup procedures
including dry squeegeeing or scraping of affected surfaces, proper
use of drain basins, minimization of water and detergents, and  automa-
tion of conveyors, piping and other equipment.  Primary treatment
consists of one or more operations of waste flow equalization,
screening, catch basins, and dissolved air flotation.

-------
                                                                    187
            RENDERING SEGMENT OF THE MEAT PRODUCTS INDUSTRY
                             (15, 16, 171)
                              [Part 432]

SUBCATEGORIZATION OF THE INDUSTRY

Rendering has been defined as Subcategory J of the overall Meat Products
Industry.  This segment of the industry considers only independent
rendering plants which collect animal byproducts such as bone, offal,
fat and dead animals from slaughterhouses, processing plants, butcher
shops, restaurants, feed lots, ranches, and process these materials
into end products such as fats, oils, and solid proteinaceous meal.
Heat melts the fat out of tissues, coagulates all proteins and evaporates
material moisture.  The end products may be either edible or inedible.
Plants processing fish byproducts are not included in this study.
An independent rendering plant may also cure hides as an ancillary
operation.

The term "renderer" is specifically defined as an independent or off-
site rendering operation, conducted separately from a slaughterhouse,
packinghouse, or poultry processing plant, which manufactures at rates
greater than 75,000 pounds of raw material per day.  Raw material
includes meat meal, tankage, animal oils, grease and tallow, but excludes
marine oils, fish meal and fish oils.  The term "tankage" shall  mean
dried animal by-product residues used in feedstuffs.  The term "tallow"
shall mean a material made from beef cattle or sheep fat that has  a
melting point of 40°C or higher.
NATURE OF PROBLEM

Of about 450 renderers encompassed by this study,  approximately one-half
discharge to municipal sewers; one-quarter achieve zero discharge  of
pollutants; and one-quarter directly discharge to  surface waterways.
PARAMETERS OF CONCERN

          pH. Acidity, Alkalinity       Ammonia N
          BOD        -                   TKN
          COD                           Nitrates, Nitrites
          TSS                           Phosphorous
          TDS                           Chlorides
          TVS                           Total  and fecal  coliforms
          Oil and Grease                Temperature

-------
Oil and Grease is a major pollutant in waste streams from rendering
plants.  Sources of grease are primarily the spillage of processed
tallow and associated materials and the cleanup of equipment, floors,
barrels and trucks.  Grease forms unsightly films on water, interferes
with aquatic life, clogs sewers, disturbs biological treatment processes,
and can become a fire hazard.  Levels of grease in raw waste will
average around 1600-1700 mg/1.

Ammonia and Kjeldahl Nitrogen pollution loads are highly affected by
.blood losses from raw material drainage and blood and feather opera-
tions, and the degree of liquid entrainment in the cooking vapors.
Typical raw waste TKN concentrations will range from 50 to 800 mg/1.

Chlorides in rendering plant wastes originate as salts from animal
tissues, hide curing operations and blood.  Chlorides are much higher
in plants processing hides and sewering the blood wastes.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

The 40 CFR, Part 432 Regulations of January 3, 1975 provide np_ specific
limitations for existing and new rendering sources which discharge wastes
to municipal sewers.
PRESCRIBED PRETREATMENT FOR DISCHARGE TO POTW

The Development Document of August 1974 on Rendering Plant wastewaters
describes those effluents as containing no constituents which would
interfere with, pass through, or otherwise be incompatible with well-
designed and operated POTW's.  It is however reported that this waste-
water should pass through materials recovery in order to remove
settleable solids and a majority of the grease.  Materials recovery is
accomplished by in-plant measures and primary treatment.  It is possible
that grease remaining in the partially-treated effluent to the POTW
can cause difficulty at the POTW.  Trickling filters appear to be
particularly sensitive.  A concentration of 100 mg/1 oil and grease is
usually cited as the upper limit to the POTW.  An air flotation system
may be required of the renderer in addition to catch basins.  If the
BOD strength of wastes going to the POTW must be reduced, anaerobic
contact, aerated lagoons and other methods, may be considered for pre-
treatment.

In-Plant Control methods at rendering plants include special handling
of condensables and high-strength liquid wastes, truck and barrel
washings, odor control and plant cleanup and spills.  Primary treatment
would consist of one or more methods of waste flow equalization,
screening, use of catch basins and dissolved air flotation.

-------
                                                                     189
             POULTRY SEGMENT OF THE MEAT PRODUCTS INDUSTRY
                               (22, 23)
                               [Part 432]

SUBCATEGORIZATION OF THE  INDUSTRY

For  the  Poultry  Industry, five sub-classes are proposed:


     Subcategory K.  Chicken Processor.  A chicken dressing plant that
     primarily slaughters broilers.  The plant may also cut up, further
     process and/or render at the same plant site.

     Subcategory L.  Turker Processor.  A turkey dressing plant that
     primarily slaughters turkeys.  The plant may also cut up and
     further process concurrently or seasonally and/or render at the
     same plant site.

     Subcategory M.  Fowl Processor.  A fowl dressing plant that
     primarily slaughters light or heavy fowl, i.e.  mature chickens.
     The plant may also cut up, further process and/or render at the
     same plant site.  Geese and capon dressing plants are included
     in this Subcategory.

     Subcategory N.  Duck Processor.  A duck processing plant that
     primarily slaughters ducks.   The plant may also cut up, further
     process and render at the same plant site.

     Subcategory 0.  Further Processing.   A poultry plant that conducts
     only "further processing" with any type of bird, but has no onsite
     slaughtering.  Cooking is involved in all "further processing"
     plants.  Various ingredients are mixed with the poultry meat and
     the numerous products .are formed, cooked (into  cut, ground, chopped
     breaded, etc.), packaged, and usually frozen.  Plants that process
     eggs or manufacture such products as canned soups and TV dinners
     are excluded from the above  subcategories.


NATURE OF PROBLEM

Principal waste sources within poultry processing are killing, breeding,
scalding, defeathering, evisceration,  chilling, further processing,
rendering,  and various condenser  operations.

Wastewaters from poultry processing plants  contain organic matter,
grease, TSS, inorganics such as phosphates,  nitrates and nitrites,  and

-------
190
 coliform bacteria.  Waste materials consist of meat and fatty tissue,
 offal, feathers, body fluids from the birds, blood, loss of materials
 from processing, preservatives,  lost product ingredients and caustic or
 alkaline detergents.

 The end products of slaughtering and eviscerating operations are  ice
 packed or chilled ready-to-cook  broilers and chickens,  fresh or frozen
 fowl, turkeys, etc.  Small  game  are also processed by the industry.
 "Further processing" leads to a  variety of cooked, canned and processed
 poultry meat items such as pre-cooked breaded parts, roasts, rolls,
 patties, meat slices in gravy, canned boned chicken and various sausages,

 In 1973, there were 248 Federally-inspected poultry plants that only
 conducted slaughtering, 288 that processed only,  and 144 plants that
 both slaughtered and processed.
 PARAMETERS OF CONCERN

           BOD                           Ammonia  N
           COD                           TKN
           TSS                           Nitrates,  nitrites
           IDS                           Phosphorous
           TVS                           Chlorides
           Oil and Grease                pH
           Total  and Fecal  Coliforms      Temperature

 Grease is a major pollutant in raw wastes from poultry processing
 establishments.   Grease forms  unsightly films  and  layers  on  water,
 interfers with aquatic life,  clogs sewers,  disturbs  biological  processes
 in POTW's, and can also become a  fire hazard.  The concentration of
 grease in poultry processing  raw  waste waters  ranges from 100  to 400
 mg/1.   Grease can foul municipal  treatment  facilities especially trick-
 ling filters, and seriously reduce their effectiveness.   Thus,  grease
 may be of great concern to municipal  treatment plants.

 Phosphorous in raw poultry wastewaters originates  from bone  meal in
 cutting, detergents used in cleanup,  food additives, and  from  boiler
 water additives.
 LIMITATIONS FOR DISCHARGE TO POTVJ

 No specific limitations have been prescribed up to  this  time.   Main
 pollutant parameters that were considered  for limitation include  BOD,
 TSS, Oil  and Grease, Fecal  Coliforms  and pH.

-------
                                                                     191
PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

No constituents have been found in poultry processing wastewaters
which would interfere with, pass through, or otherwise be incompatible
with a well-designed and operated biological-type POTW's.  The poultry
processing effluent before reaching the municipal sewer, should how-
ever be passed through byproduct recovery and in-plant primary treat-
ment at the poultry plant in order to remove settleable solids and the
majority of the grease.  It is possible that greases remaining in the
poultry plant effluent can cause difficulty at the POTVJ.  Trickling
fitters appear especially sensitive.  A concentration of 100 mg/1 oil
and grease is usually cited as the upper limitation for acceptance
by a POTW.  Achieving this level may require an effective air flotation
system in addition to catch basins.  If the waste strength measured as
BODg must be further reduced, biological unit operations including
anairobic contact, trickling filtration or aerated lagoons, can be
used for pretreatment.

In-Plant Controls and byproduct recovery include one or more of the
following practices.

          Control and minimize water usage throughout the plant.
          Stun birds during killing so as to reduce carcass movement
          during bleeding.
          Confine bleeding, provide sufficient bleed time and recover
          all  collectable blood.
          Consider reuse of chiller water for makeup to the scalder.
          Consider dry offal handling in lieu of waste fluming.
          Closely monitor screening systems used for offal  and feathers,
          and deploy backup screens if at all possible.
          Separate and treat offal  truck drainage before sewering.
          Use dry cleanup prior to floor and equipment washdown.   This
          is particularly important in bleeding and cutting areas.
          Minimize chemicals and detergents used in cleaning.
          All  spent raw materials should be routed to rendering rather
          than to plant sewers.
          Segregate all overflows from the cooking sector for grease
          and solids recovery and/or treatment.
          Offal  and feathers in respective flow-away systems to be
          properly screened, collected and taken to rendering.

In-Plant primary treatment and byproduct recovery should consist  of
the following:   flow equalization,  effective screening, use of catch
basins and if necessary, dissolved air flotation and electrocoagulation.

-------
192
                          COAL MINING INDUSTRY
                            (73, 74, 75, 76)
                                [Part 434]

 SUBCATEGORIZATION OF THE INDUSTRY

 The Coal Mining Industry is divided into coal production and coal prep-
 aration.  Mining creates both acid and alkaline drainage.  Preparation
 involves preparation plant waste water and area wastewater around the
 plant.  The industry has been divided into four subcategories as shown
 below:

      A - Coal preparation plant

      B - Coal storage, refuse storage and coal preparation plant
          ancillary area

      C - Acid or ferruginous mine drainage

      D - Alkaline mine drainage


 NATURE OF THE PROBLEM

 The Federal Regulations contained in the Federal Register, Part 434 are
 applicable to discharges resulting from the cleaning or beneficiation
 of coal of any rank including but not limited to bituminous, lignite and
 anthracite.

 In coal preparation plants process methods generally require an alkaline
 media for efficient and economical operation.  Therefore, process water
 does not dissolve significant quantities of constituents found in raw
 coal.  Coal preparation plants generate TSS as a principal pollutant.
 Coal storage, refuse storage and coal preparation ancillary areas have
 wastes generally similar to drainage at the mine served by the prepara-
 tion plant.  Coal mining produces drainage which may vary in character
 from grossly polluted to drinking water quality.  Two main types of mine
 drainage are found:  1) acid or ferruginous-high in acid and iron and
 with varying concentrations of aluminum, manganese, nickel and zinc,
 and usually requiring neutralization and settling; and  2) alkaline -
 possibly requiring settling.   Water enters mines via precipitation,
 ground water infiltration and runoff, where it may become polluted by
 contact with materials in the coal, the overburden material, or the
 mine bottom.

-------
                                                                 193
PARAMETERS OF CONCERN

               pH, acidity, alkalinity       IDS
               Iron, dissolved and total     Sulfate

               Manganese                     Fluoride

               Aluminum                      Strontium
               Nickel                        Ammonia N

               Zinc                          TSS


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED
TREATMENT MEASURES

Wastewaters from the Coal Mining Industry are not characteristic of
wastes considered amenable to treatment by biological means.  Coal
mining wastes are generally not compatible with sanitary sewage because
of their potential acidic nature, metals content, and large volume
rates.  However, certain metallic salts such as aluminum sulfate and
ferrous salts may be considered beneficial and are used in wastewater
treatment as coagulants.  It has been shown under controlled conditions
that acid mine drainage and municipal wastes may be handled by joint
treatment.

The Federal Regulations on Existing Sources of Coal Mining indicates
these wastewaters, if necessary, may possibly be accepted into POTW's.
However, the operator of a POTW is cautioned that certain constituents
in coal mining wastewaters may interfere with the treatment works or
can pass through the treatment works inadequately treated.  Therefore,
these waste waters should receive special  consideration by the operator
of the POTW and the wastes may be subject to further regulations.

For New Sources of Coal Mining, special  pretreatment limitations have
been prescribed for Subcategory A,  coal  preparation plants, and for
Subcategory B, coal storage, refuse storage and coal  preparation plant
ancillary areas as shown below:


     Subcategory A - Max.  daily of 50 mg/1 dissolved iron
     Subcategory B - Max.  daily of 50 mg/1 dissolved iron

-------
 194
         OFFSHORE AND ONSHORE OIL AND GAS EXTRACTION INDUSTRY
                         (137, 138, 139, 140)
                              [Part 435]

SUBCATEGORIZATION OF THE INDUSTRY

The Oil and Gas Extraction Industry has been divided into six subcate-
gories, the first two relating to Offshore installations and other four
to Onshore installations.  Major pollutants are derived from the pro-
duction of crude petroleum and natural gas, drilling of oil  and gas
wells, and oil and gas field exploration services.   The six  subcate-
gories comprise:

     A - Near Offshore Subcategory
     B - Far Offshore Subcategory
     C - Onshore Subcategory
     D - Coastal Subcategory
     E - Beneficial Use Subcategory
     F - Stripper Subcategory

Subcategory A - Near Offshore Facilities.  Includes offshore structures
within State waters engaged in the production, field exploration, drill-
ing, well completion and well treatment of oil and  gas.

Subcategory B - Far Offshore Facilities.  Includes  offshore  structures
within Federal waters engaged in the production, field exploration,
drilling, well completion and well treatment of oil and gas.

Subcategory C - Onshore Facilities.  Includes onshore structures engaged
in the production, field exploration, drilling, well completion and well
treatment of oil and gas, but is not applicable to  those onshore facili-
ties defined in Subcategories D, E and F. "Onshore" means all land and
water areas landward from the inner boundary of the territorial seas,
including the Great Lakes.

Subcategory D - Coastal Works.  Includes coastal facilities  engaged in
the production, field exploration, drilling, well completion and well
treatment of oil and gas.  The term "coastal" is interpreted as com-
prising all land and water areas landward from the  inner boundary of
the territorial seas, and bounded on the inland side by a line defined
by the inner boundary of the territorial seas as defined above eastward
of the point defined by 89° 45'  W. Longitude and 29° 46' N Latitude and
continuing as follows west of that point:

-------
                                                                   195
           Direction to West Longitude   Direction to North Latitude

                    West, 89° 48'            North, 29° 50'
                    West, 90° 12'            North, 30° 06'
                    West, 90° 20'            South, 29° 35'
                    West, 90° 35'            South, 29° 30'
                    West, 90° 43'            South, 29° 25'
                    West, 90° 57'            North, 29° 32'
                    West, 91° 02'            North, 29° 40'
                    West, 91° 14'            South, 29° 32'
                    West, 91° 27'            North, 29° 37'
                    West, 91° 33'            North, 29° 46'
                    West, 91° 46'            North, 29° 50'
                    West, 91° 50'            North, 29° 55'
                    West, 91° 56'            South, 29° 50'
                    West, 92° 10'            South, 29° 44'
                    West, 92° 55'            North, 29° 46'
                    West, 93° 15'            North, 30° 14'
                    West, 93° 49'            South, 30° 07'
                    West, 94° 03'            South, 30° 03'
                    West, 94° 10'            South, 30° 00'
                    West, 94° 20'            South, 29° 53'
                    West, 95° 00'            South, 29° 35'
                    West, 95° 13'            South, 29° 28'
                    East, 95° 08'            South, 29° 15'
                    West, 95° 11'            South, 29° 08'
                    West, 95° 22'            South, 29° 56'
                    West, 95° 30'            South, 28° 55'
                    West, 95° 33'            South, 28° 49'
                    West, 95° 40'            South, 28° 47'
                    West, 96° 42'            South, 28° 41'
                    East, 96° 40'            South, 28° 28'
                    West, 96° 54'            South, 28° 20'
                    West, 97° 03'            South, 28° 13'
                    West, 97° 15'            South, 27° 58'
                    West, 97° 40'            South, 27° 45'
                    West, 97° 46'            South, 27° 28'
                    West, 97° 51'            South, 27° 22'
                    East, 97° 46'            South, 27° 14'
                    East, 97° 30'            South, 26° 30'
                    East, .97° 26'            South, 26° IT

East to 97° 19' W. Longitude and Southward to the U.S.-Mexican  border.
Along all boundaries of the territorial  seas except the Gulf of Mexico,
the term "coastal" is not defined.

Subcategory E - Beneficial Use.   This subcategory is  applicable to
onshore facilities for which produced water has  a beneficial  use when
discharged to navigable waters.   These facilities are engaged in the
production, drilling, well completion and  well treatment of oil  and gas.

-------
  196
Subcategory F - Stripper Works.  This subcategory is applicable to
onshore facilities which produce less than 10 barrels per calendar
day of crude oil and one operating at the maximum feasible rate of
production in accordance with recognized conservation practices.
These facilities are engaged in the production and well treatment of
oil and gas.
NATURE OF PROBLEM  .

There are some half million producing oil wells onshore generating
produced water in excess of 10 BGD.  Approximately 17,000 wells have
been drilled offshore in U.S. waters and there are around 11,000
operations producing both oil and gas.  Offshore leasing, exploration
and development will  expand rapidly over the future, and offshore
production will constitute an increasing proportion of the domestically-
produced supplies of gas and oil.

Wastes associated with offshore and onshore oil and gas extraction
facilities result from the discharge of produced water, deck drainage,
drilling muds, drill  cuttings, well treatment, sanitary and domestic
needs and produced sands.  Produced waters are those wastes generated
when the natural oil-water or gas-water interfaces within the oil-gas
bearing formations are disrupted.  Deck drainage includes waste from
platform washings, deck washings, and runoff from curbs, gutters, and
drains including drip pans and work areas.  Drilling muds are materials
used to maintain hydrostatic pressure in the well, lubricate the drill-
ing bit, remove drill cuttings from the well, or to stabilize the walls
of the well  during drilling and workover.  Drill cuttings contain metals
and mineral  particles from drilling into subsurface geologic formations.
Drill cuttings are brought to the surface of the well with drilling
muds and are then separated from the muds.  Well treatment wastes arise
from acidizing and hydraulic facturing to improve oil recovery.  Sani-
tary and domestic wastes originate from toilets, showers, etc.  Produced
sands consist of slurried particles from hydraulic fracturing and the
accumulated formation sands generated during production.
PARAMETERS OF CONCERN

          Oil/Grease
          Fecal Coliforms
          Floating solids
          Chlorine residual
          BOD
          TOC
Heavy metals (arsenic,
     chromium, copper, lead
     nickel, silver and zinc)
TDS
Chlorides
Oxygen demand
Phenolics
Toxicants

-------
                                                                    197
Major  pollutants  expected  in oil and gas extraction industry wastewaters
include oil  and grease, residual chlorine, and floating solids.  Water
insoluble  hydrocarbons and free floating and emulsified oils in the
wastewaters  can affect aquatic flora and fauna by interfering with
oxygen transfer,  coating bottom life and food, damaging the plumage of
water  fowl and animals, and causing taste and toxicity problems.  Resi-
dual chlorine is  important in controlling fecal coliform bacteria in
sanitary wastes from offshore and onshore facilities.  Floating solids
derive in  most part from domestic and sanitary wastes.  Pollutants
may settle or float, and can lead to objectionable odors.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

For Subcategories A and B, Offshore Facilities. Oil and gas extraction
facilities in the offshore subcategories have the option of piping
their wastes to onshore treatment facilities.  This method could be
preferra-ble to treatment at the offshore works.

Subcategories A and B, Offshore Facilities, Both Existing and New
Sources:
Oil /Grease
Waste Source
Produced water

Deck drainage

Drilling muds

Drill cuttings

Well treatment

Produced sand

Sanitary wastes*

Domestic wastes*

Avg. 30 Day
(mg/1)
No waste
discharge
No waste
discharge
No waste
discharge
No waste
discharge
No waste
discharge
No waste
discharge
No limitations

No limitations

Max. Day
(mg/1)
No waste
discharge
No waste
discharge
No waste
discharge
No waste
discharge
No waste
discharge
No waste
discharge
No limita-
tions
No limita-
tions
Residual Chlorine
Max. Day
(mg/1)
No waste discharge

No waste discharge

No waste discharge

No waste discharge

No waste discharge

No waste discharge

No limitations

No limitations

*  There shall be no float-ing solids as a result of discharge of these
wastes.

-------
198
      For Subcategories C,  D,  E,  F,  Onshore Facilities.   Limitations  have
      been proposed only for New  Sources  as shown  below:

                         BOD       -      No limitations
                         TSS       -      No limitations
                         pH        -      No limitations
                         Oil/Grease      100 mg/1

-------
                                                                     199
                MINERAL MINING AND PROCESSING INDUSTRY
                       (67, 68, 69, 70, 71, 72)
                               [Part 436]
SUBCATEGORIZATION OF THE INDUSTRY
The Mineral Mining and Processing Industry has been divied into 38
discrete Subcategories which are described below.   Differences in raw
materials, processing, and the use of wet air pollution control devices
have largely determined subcategorization.  Effluent limitations have
been developed to date for 21  of the 38 Subcategories.
     A - Dimension Stone (Reserved)
     B - Crushed Stone
     C - Construction Sand and Gravel
     D - Industrial  Sand
     E - Gypsum
     F - Asphaltic Minerals
     G - Asbestos and Wollastonite
     H - Lightweight Aggregates (Reserved)
     I - Mica and Sericite (Reserved)
     J - Barite
     K - Fluorospar
     L - Salines from Brine Lakes
     M - Borax
     N - Potash
     0 - Sodium Sulfate
     P - Trona (Reserved)
     Q - Rock Salt (Reserved)
     R - Phosphate Rock
     S - Frasch Sulfur
     T - Mineral Pigments  (Reserved)
     U - Lithium (Reserved)
     V - Bentonite
     W - Magnesite

-------
200
      X - Datqmite
      Y - Jade
      Z - Novaculite
      AA - Fire Clay (Reserved)
      AB - Attapulgite and Montmorillonite (Reserved)
      AC - Kyanite (Reserved)
      AD - Shale and Common Clay (Reserved)
      AE - Aplite (Reserved)
      AF - Tripoli
      AG - Kaolin (Reserved)
      AH - Ball Clay (Reserved)
      AI - Feldspar (Reserved)
      AJ - Talc, Steatite, Soapstone and Pyrophyllite  (Reserved)
      AK - Garnet (Reserved)
      AL - Graphite

 NATURE OF THE PROBLEM
 More than 11,000 establishments have been identified  as included within
 the Mineral  Mining and Process  Industry in  the U.S.   The large majority
 of these plants are contained within the Crushed Stone and Construction
 Sand and Gravel Subcategories  (i.e., Subcategories B  and C).
 At the mine, sources of waste  pollutants include surface runoff  of rain-
 water into the mine and mine water treatment systems, ground  water seep-
 age and infiltration into the mine, and water used to transport  the ore
 to the processing plant.
 At the process plant, sources of waste include transport water,  ore and
 product wash water, dust suppression water, classification water, heavy
 media separation water, flotation water, solution water, air  emissions
 control equipment water, and equipment and  floor washdown water.
 BPCTCA regulations for many of  the mineral  mining and process subcat-
 egories specify that no discharge conditions are to be achieved  at
 least for the process water originating from the process plant.   Ex-
 emptions could be allowed during times of extreme runoff.

-------
                                                                     201
PARAMETERS OF CONCERN

     pH, acidity, alkalinity    Asbestos
     TSS                        BOD
     Iron                       Oil and Grease

     IDS                        Phosphates
     Sulfide                    Ra-226 (Phosphate Rock Subcategory)

     Turbidity                  Chlorides
     Sulfate                    Possibility of trace constituents
                                (including antimony, arsenic, barium,
     Fluoride                   boron, cadmium, chromium, copper, cyanide,
                                mercury, nickel, manganese, lead, selenium,
     Temperature                tin and zinc)


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED
TREATMENT MEASURES

For Pretreatment of Existing Sources in the Mineral Mining and Processing
Industry and subsequent waste discharge to POTW's, the Federal Register
has declared that these process wastes are generally amenable to munici-
pal treatment and there is little or no requirement for pretreatment.
However, the operator of a POTW is cautioned that some of the consti-
tuents of the process waste waters may interfere with the treatment
works or pass through the treatment works inadequately treated.   These
process wastes may warrant special consideration by the POTW and could
be the subject of future regulations.

For Pretreatment of New Sources in the Mineral  Mining and Processing
Industry and subsequent discharge to POTW's, regulations are the same
as for existing sources above with apparent change only in Subcategory D,
Industrial  Sand, and in Subcategory AL, Graphite as shown below.

Limitations for Subcategory D, Industrial  Sand  Production:


                           Avg. 30 Day                   Max. Day
 Parameter            (lb/1,000 Ib product)        (lb/1,000 Ib  product)

Total fluoride               0.003                         0.006
Limitations for Subcategory AL, Graphite Production:

          Parameter             Pretreatment Standard
        Dissolved Iron               50 mg/1

-------
202
 The EPA Development  Documents  of  October  1975  and June  1976  for  the
 Mineral  Mining and Processing  Industry recommend the  following pretreat-
 ment measures:

 1)    No pretreatment necessary for compatible  pollutants.

 2)    Pollutants such as  COD, TOC, phosphorous  and phosphorous compounds,
      nitrogen  and nitrogen  compounds, and oils and  greases do not  re-
      quire removal provided the POTW is designed to remove these pollu-
      tants and will  accept  them.  Otherwise, pretreatment for Existing
      Sources  should  be  set  at  the BPCTCA  levels, and  pretreatment  for
      New Sources should  be  established at New  Source  Performance
      Standards levels.   Incompatible pollutants and suspended materials
      laden with hazardous pollutants are  subject to these same limi-
      tations.

-------
                                                                   203
                     PHARMACEUTICAL MANUFACTURING
                             (1, 126, 163)
                               [Part  439]

SUBCATEGORIZATION OF THE INDUSTRY

The Pharmaceuticals Manufacturing Industry has been divided into five
subcategories as shown below:

          A - Manufacture of Fermentation Products
          B - Biological and Natural  Extraction Products C - Chemical
          Synthesis Products D - Mixing/Compounding and Formulating E
          Research Activities
NATURE OF PROBLEM

Available reports indicate that pollutants of special significance in
the pharmaceutical industry, in addition to BOD, COD, TOC and TSS
include mercury, cyanide, ammonia nitrogen, organic nitrogen and total
phosphorous.

Mercury salts are used to produce medicinal products and disinfectants.
Cyanides are primarily used as catalysts in chemical synthesis processes.
Mercury and cyanide can exert toxic impact upon biological treatment
works.  High concentrations of organic and inorganic nitrogen have been
observed in raw waste waters of the pharmaceutical  industry.  High
total phosphorous concentrations are apparent in the raw wastes from
some fermentation and chemical synthesis product plants.

Waste waters from some chemical synthesis and fermentation operations
contain metals such as copper, nickel, mercury, cyanides, etc. together
with anti-bacterial constituents, which can seriously affect biological
treatment processes.  A biological treatment works  can be deactivated if
these pollutants are present in significant quantities.  Equalization of
pretreated process wastes is likely necessary before release to a POTW.


PARAMETERS OF CONCERN

          BOD                                TSS
          COD                                pH
          TOC                                Cyanides
          Metals (Fe, Cu, Ni, Hg,            Phenolics
               Ag and others)                Oil  and Grease
          Ammonia N                          Chlorinated hydrocarbons
          Organia N                          TDS
          Phosphates                         Bioassay (testing)

-------
204
 LIMITATIONS FOR DISCHARGE

 No specific limitations established! at, tins time.
 PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

 Equalization is generally required for pharmaceutical process wastes.
 Excess solvents in waste waters may be (partly) removed by gravity
 separation and skimming.  Neutralization may be required for waste
 waters from specific pharmaceutical manufacturing.  Odor controls are
 also possible.

 For Fermentation and Chemical Synthesis-Type Plants.   Pretreatment
 processes could consist of equalization, neutralization, solvent
 separation, chemical precipatation for metals removal, and possible
 cyanide oxidation.

 For Extraction Product, Pharmaceutical Formulation and Research.-Type
 Installations.  Pretreatment could consist of waste equalization and
 neutralization.

 It is further noted for purposes of calculating Raw Waste Loads appli-
 cable to NPDES discharges to receiving streams - the regulations specify
 that separable mycelia and solvents shall be excluded from these raw
 waste Toads.  Removal, disposal and reuse practices include physical
 separation and removal of separable mycelia, recovery of solvents from
 waste streams, incineration of concentrated solvent waste streams
 (including tar still bottoms), and fermentation broth concentrated and
 disposed of in some acceptable manner other than to the treatment system.
 Whereas these regulations do not preclude discharge of the above wastes
 to a POTW, they do strongly suggest the described practices are the most
 effective means of significantly reducing raw wastes whether to a POTW
 or to an industrial treatment works.

-------
                                                                  205
                   ORE MINING AND DRESSING INDUSTRY
                               (33, 34)
                               [Part 440]

SUBCATEGORIZATION OF THE INDUSTRY

The Ore Mining and Dressing Industry is divided into seven major sub-
categories based upon the particular metal ore produced or processed.
These seven subcategories have been further arrayed into 22 subdivi-
sions.  The seven subcategories are described as follows:

     A - Iron Ore Subcategory

     B - Base and Precious Metals Subcategory

     C - Bauxite Ore Subcategory

     D - Ferroalloy Ores Subcategory

     E - Uranium, Radium and Vanadium Subcategory

     F - Mercury Ore Subcategory

     G - Titanium Ore Subcategory

Subcategory A, Iron Ore.  Includes: 1) mines producing iron ore re-
gardless of the type of or mode of occurrence; 2) mills beneficiating
iron ores by physical and chemical separation or by physical  means only;
and 3) mills beneficiating iron ores by magnetic and physical  separation.

Subcategory B, Base and Precious Metals.  Includes: 1) mines  producing
copper bearing ores, lead ores, zinc ores, gold ores or silver bearing
ores; 2) mills which employ the froth-flotation process for treating
the above ores; 3) mines/mills which employ dump, heap, in-situ leach
or vat-leach processing for extracting copper from ores; 4) mills which
extract gold or copper by the cyanide process only; 5) mills  which
extract gold or silver by the amalgamation process alone; and 6) mines/
mills beneficiating gold, silver, tin or platinum ores by gravity sep-
aration.

Subcategory C, Bauxite Ore.   Applies to mines producing bauxite/aluminum
ores.

Subcategory D, Ferroalloy Ores.  Includes: 1) mines producing at least
5,000 metric tons of ferroalloy ores annually; 2) mines/mills producing
less than 5,000 metric tons of ferroalloy ores yearly by methods other
than ore leaching; 3) mills producing at least 5,000 metric tons of
ferroalloy ores yearly by purely physical  means; 4) mills producing at
least 5,000 metric tons of ferroalloy ores yearly by froth flotation;
and 5) mills processing ferroalloy ores by leaching and associated

-------
206
 chemical beneficiation.   Ferroalloy metals include:   chromium,  cobalt,
 columbium, tantalum, manganese, molybdenum,  nickel,  tungsten and va-
 nadium.

 Subcategory E, Uranium,  Radium Vanadium.   Includes:  1)  mines producing
 uranium, radium and vanadium ores; and 2)  mills using acid,  alkaline
 or combination leach processing for the extraction of uranium,  radium
 and vanadium values.

 Subcategory F, Mercury Ores.  Includes: 1) mines producing mercury ores;
 and 2) mills beneficiating mercury ores by gravity separtion or froth-
 flotation methods.

 Subcategory G, Titanium Ores.   Includes:  1)  mines producing  titanium
 ores from lode deposits; 2) mills beneficiating titanium ores by elec-
 trostatic methods, magnetic and physical  methods, or flotation  methods;
 and 3) mines engaged in dredge mining of deposits containing rutile,
 ilemite, leucoxene, monazite,  zircon, and other heavy metals, together
 with the milling procedures employed in conjunction  with dredge mining.
 NATURE OF PROBLEM

 Major pollutants of ore mine drainage and mill  process wastewaters
 comprise a variety of common and heavy metals in the solubilized
 form, suspended and dissolved solids, radionuclides, organic and in-
 organic matter, and reagents used in the milling process.

 Process wastes from ore mining and milling include ore transport waters,
 ore and product washes, dust suppression waters, grinding  and classifi-
 cation wastes, heavy media separation waters, and equipment and floor
 washes.  Additional streams consist of boiler blowdown and contact and
 non-contact cooling waters.  Raw waste loadings from ore mining and
 milling are unrelated, or only indirectly related to production quanti-
 ties, and consequently, effluent limitations are expressed in terms of
 concentration rather than units of production.
 PARAMETERS OF CONCERN

           pH, Acidity,
           TSS
           Oil/Grease
           COD
           Cyanide
           Ammonia N
           Aluminum
           Antimony
Alkalinity
Iron
Lead
Manganese
Mercury
Molybdenum
Nickel
Vanadium
Zinc

-------
                                                                207
          Arsenic                  Radionuclides, especially Ra-226
          Beryllium                Uranium
          Cadmium                  Asbestos
          Chromium                 Flotation reagents having
          Copper                    potential toxicity
          Fluorides

Other potential or probable parameters include:

          Barium                   Carbonates
          Boron                    Nitrate, Nitrite
          Calcium                  Selenium
          Magnesium                Silicate
          Potassium                Tin
          Strontium                Zirconium
          Sodium                   IDS
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED
TREATMENT MEASURES

The EPA Development Document of October 1975 and effluent limitations
guidelines consider TSS as an incompatible pollutant to a POTW when pre-
sent in high concentrations.  Most wastewaters in this industry require
settling in order to reduce the TSS to a level of around 500 mg/1 where
they may be normally accepted by a POTW.  Phosphorous and nitrogen com-
pounds and fats and greases are thought to be compatible with properly
designed and operated POTW's.  Otherwise, these pollutants should be
pretreated to equivalent BPCTCA discharge levels.  Hazardous pollutants
such as cyanides, chromates, heavy metals etc. which may interfere with
biological unit operations at POTW's would require pretreatment to
equivalent BPCTCA levels.  Waste equalization was recommended by the
Development Document.  Chemical  treatment, settling and pH control might
also constitute required pretreatment ahead of the POTW.

The Federal Register of November 6, 1975 on Ore Mining and Dressing
wastes, although providing JTO_ specific limitations for Existing and
New plants in the industry, nevertheless indicated that certain pol-
lutants in process waste discharges may interfere with the POTW or
pass through the treatment works inadequately treated.  Therefore,
these process waters should receive special consideration by the POTW,
and may be the subject of further regulations.

-------
208
        PAVING AND ROOFING (TARS AND ASPHALT)  MATERIALS INDUSTRY
                              (43, 44,  .45)
                               [Part 443]

 SUBCATEGORiZATION OF THE INDUSTRY

 The Paving and Roofing Materials Industry  is  divided into  four  Sub-
 categories which are described below:

      A - Asphalt Emulsions
      B - Asphalt Concrete
      C - Asphalt Roofing
      D - Linoleum and Printed Asphalt  Felt

 Subcategory A includes plants engaged  in production  of oxidized
 asphalt for use in both roofing and paving material.   Oxidizing
 consists of blowing hot air through asphalt.   The oxidized asphalt
 is stored as paving asphalt or as roofing  and paving emulsions.

 Subcategory B includes plants producing asphalt  concrete which  is
 asphalt mixed with crushed rock or gravel, and used  for paving  such
 as blacktop.

 Subcategory C includes plants producing roofing  felts,  impregnated
 roofing felts, shingles, tar papers, impregnated siding* canal  liners,
 expansion joints, roofing cements, etc.  The  process consists of
 saturating and coating an organic felt with asphalt.   The  coated felt
 may be subsequently covered with crushed rock.

 Subcategory D includes plants producing linoleum and printed asphalt
 felt floor coverings.   The process consists of painting or embossing
 a design on a saturated felt backing.
 NATURE OF THE PROBLEM
 Approximately 5,100 plants  have  been  identified  in  the  paving and
 roofing materials industry, most of which  are  contained in Subcategory
 B,  i.e. Asphalt Concrete.

 Major Waste sources from paving  and roofing materials plants include
 various codling waters  both contact and  non-contact; plant area
 runoff; concentrated slurries  from air pollution  control equipment;
 product cooling waters  which may contain the majority of pollutant
 loads; dried paints and inks;  and cleaning waters resulting from the
 washdown of floor,  equipment and work areas.   Typical waste streams
 from this industry  contain  organic and inorganic  solids (predominately

-------
                                                                 209
the latter), suspended and settleable matter, oils and greases principally
petroleum-derived, and some potentially harmful solvents.  Suggestions
have been made that the potentially harmful nature of industry waste-
waters resulting from contact with asphalt, tars and similar materials
should possibly lead to zero discharge limitations across the industry.
PARAMETERS OF CONCERN

          BOD                           IDS
          COD or TOC                    Nitrogen
          TSS                           Phosphorous
          Oil/Grease                    Phenols
          pH    '                        Heavy Metals
          Temperature                   Turbidity

Suspended solids in paving and roofing plant wastewaters were found to
range from less than 10 mg/1 up to 35,000 mg/1.  Generally, when carbon-
ate rocks are used as raw material by the plant, a higher level of TSS
occurs.  A lower level occurs with igneous rock.  Paving and roofing
plants have reported trace amounts of one or more of the following
metals in their effluents:  cadmium, chromium, copper, iron, lead,
nickel, zinc and aluminum.  Arsenic and cyanide can originate from
stone or rock used by the plants, or from other sources.
PRELIMINARY LIMITATIONS FOR DISCHARGE TO PQTW AND PRESCRIBED PRETREATMENT
MEASURES

The Development Document for Paving and Roofing indicates that waste-
water from asphalt concrete plants may contain large amounts of suspended
sand and gravel which can cause or contribute to sewer line obstruction.

The Federal Register regulations have established a maximum limit of
100 mg/1 oil/grease in the discharge from both existing and new paving
and roofing establishments entering municipal sewer systems.  This
limitation is applicable to plants in all four subcategories of the
industry.  No other pretreatment limitations have been developed to
date.

Depending upon specific pretreatment needs dictated mostly by Regional
and local authorities, paving and roofing materials plants should strongly
consider good in-plant controls and water recycle augmented by oil
skimming, primary settling, filtration and sludge handling and disposal.
Other pretreatment may also be necessary.

-------
 210
                           PAINT FORMULATING
                             (35, 36,  37)
                               [Part 446]

SUBCATEGORIZATION OF THE INDUSTRY

The Paint Formulating Industry was described by the EPA Development
Document of February 1975 on Paints and Inks and by the Federal
Register of February 26, 1975 as consisting of two subcategories
including:  A) Oil-Based Paints and  B) Water-Based Paints.   This was
subsequently modified by the Federal  Register of July 28,  1975 which
gave Final Limitations for only a single Subcategory titled  "Oil Base
Solvent Wash Paint."  Solvent wash paints represent a subpart of the
original Oil-Base Paints Subcategory.

The industry produces paints, varnishes and lacquers, which  consist of
film-forming binders (resins or drying oils) dissolved in  volatile
solvents or dispersed in water.  In addition, all  paint and  most lacquers
contain pigments and extenders (calcium carbonate, clays and silicates).
The industry also produces side products such as putty, caulking com-
pounds, sealants, paint and varnish removers and thinners.   Al-based
paints include all of the above items  that use oil as the  major  carrier.
Water-based paints include all of the  above items  that use water as the
major carrier vehicle.
NATURE OF PROBLEM

Approximately 1,630 plants are represented in the paint formulating
industry of which less than 200 are reported to be discharging to sur-
face receiving waters.  The remainder either discharge to municipal
sewers or have no waste discharge.   Sources of wastes are principally
cleaning and milling equipment, cleanup of product and raw material
spills and leaks from product transfer equipment.  Treatment of paint
manufacturing wastes leads to accumulation of solid wastes and liquid
concentrates.  Some of these concentrated materials may be hazardous
and require special handling and disposal.  Landfill  sites receiving
these hazardous wastes should be selected and maintained so as to prevent
horizontal and vertical migration of contaminants into ground water.

-------
                                                                   211
PARAMETERS OF CONCERN
          pH, acidity, alkalinity       Chromium
          BOD                           Boron
          COD                           Cadmium
          TSS                           Iron
          Oil/Grease                    Titanium
          Mercury                       Bactericides, fungicides
          Lead                          Special additives
          Copper                        Solvents
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTH AND PRESCRIBED PRETREATMENT
MEASURES

The Development Document of February 1975 reported that wastewater from
the manufacture of oil-base paints entering most municipal sewer systems
are fairly well controlled.  The wastes from water-base paint formulators
have generally been accepted by municipalities and a majority of paint
plants are connected to municipal sewers.  Metals in paint wastes
generally become part of the suspended solids.  The organics in water-
base paint wastes are said to be relatively biodegradable.

Many paint plants discharging to municipal systems employ waste settling
as pretreatment.  Physical-chemical methods may be used by other plants
to meet state and local pretreatment limitations.  These methods may
consist of holding, chemical coagulation and settling.

The Federal Register of February 26, 1975 proposed zero discharge of
process wastes from new paint installations to the POTW unless the
municipality can guarantee removal of incompatible pollutants.  The
Federal Register of July 28, 1975 gave Final limitations for only the
specialized oil-base solvent wash paint plants.  It indicated for both
existing and new sources that there shall be np_ discharge of process
water pollutants to the POTW.   Final pretreatment limitations for other
types of paint plants await future publication.

-------
212
                              INK FORMULATING
                               (35, 38, 39)
                                [Part 447]

  SUBCATEGORIZATION OF THE INDUSTRY

  The Ink Formulating Industry is divided into Oil-Base and Water-Base
  inks as described in the EPA Development Document of February 1975.
  Accordingly, the Federal Register of February 26, 1975 divided the
  industry into two proposed subcategories of  A) Oil-Based Inks; and
  B)  Water-Based Inks.  This was subsequently modified by the Federal
  Register of July 28, 1975 which gave Final Limitations for a single
  subcategory titled "Oil Base Solvent Wash Ink."  Solvent wash plants
  represent a subpart of the original Oil-Base Inks Subcategory.

  The industry produces oil and water-base printing inks.  The major
  components include drying oils, resins, varnish,  pigments and many
  specialty additives.  Oil-base inks use oil or solvent as the major
  carrier.  Water-base inks use water as the major carrier vehicle.
  NATURE OF PROBLEM

  Less than 50 ink formulating plants discharge wastewater to surface
  receiving streams.  The number of ink plants discharging to POTW's
  are thought to be far greater.  A significant number of establishments
  are believed to approach zero discharge of process wastes.   Sources
  of wastes are principally cleaning and milling equipment, cleanup of
  product and raw material spills, and leaks from product transfer equip-
  ment.  Treatment of paint manufacturing wastes leads to accumulation
  of solid wastes and liquid concentrates.  Some of these concentrated
  materials may be hazardous and require special handling and disposal.
  Landfill sites receiving these hazardous wastes should be selected
  and maintained in such a manner as to prevent horizontal and vertical
  migration of contaminants into ground water.
  PARAMETERS OF CONCERN
            pH, acidity, alkalinity       Chromium
            BOD                           Boron
            COD                           Cadmium
            TSS                           Iron
            Oil/Grease                    Titanium
            Mercury                       Bactericides, fungicides
            Lead                          Special additives
            Copper                        Solvents

-------
                                                                213
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW AND PRESCRIBED TREATMENT
MEASURES

The Development Document of February 1975 reported that wastewater from
the manufacture of oil-base inks entering most municipal sewer systems
are controlled in reasonable degree.  The wastes from water-base ink
formulators have generally been accepted by municipalities and the
large majority of ink plants are connected to municipal sewers.  Metals
in ink wastes generally become part of the suspended solids.  The
organics in water-base ink wastes are said to be relatively biodegradable.

Many ink plants discharging to municipal systems employ waste settling
as pretreatment.  Physical-chemical methods may be used by other plants
to meet state and local pretreatment limitations.  These methods may
consist of holding, chemical coagulation and settling.

The Federal Register of February 26, 1975 proposed zero discharge of
process wastes from new ink formulating plants to the POTW unless the
municipality can guarantee removal of incompatible pollutants.  The
Federal Register of July 28, 1975 gave Final Limitations for only the
specialized oil base solvent wash ink plants.  It indicated for both
existing and new sources that there shall be ru3 discharge of process
waste pollutants to the POTW.  Final pretreatment limitations for other
types of ink plants await future publication.

-------
 214
                 GUM AND WOOD CHEMICALS MANUFACTURING
                               (6, 193)
                              [Part  454]

 SUBCATEGORIZATION OF THE INDUSTRY

 Six  types of manufacturing plants have been defined as shown below:

          A - Char and charcoal briquets
          B - Gum rosin and turpentine
          C - Wood rosin, turpentine and pine oil
          D - Tall oil rosin, pitch and fatty acids
          E - Essential oils
          F - Rosin based derivatives

 NATURE OF PROBLEM

 Waste sources in the gum and wood chemicals manufacturing industry
 include watery wastes from reactors, filtration systems, decanting
 systems, distillation vacuum exhaust scrubbers, caustic scrubbers,
 process equipment cleaning, production area washdowns, refinery area
 washdowns, formulation equipment cleanups, and washdowns of spills.

     Gum and wood chemicals wastewaters may be characterized as having
 high concentrations of soluble oxygen-demanding materials, are generally
 acidic and deficient in nitrogen and phosphorous.  Significant levels of
 zinc are noted in the effluents of plants within Subcategories B and F.
 Appreciable oil and grease are seen in the discharges of plants in
 Subcategories B, D and F.  Separable oils should be removed from these
 process streams by skimming prior to being received into municipal
 sewers.  Phenol is a significant waste parameter for installations in
 Subcategory F and possibly those in Subcategory D.

 Certain substances may be present in gum and wood chemical wastewaters
 exerting inhibitory effects upon subsequent biological treatment.  Because
 of high soluble oxygen demand, gum and wood chemical wastes may require
 increased oxygen transfer, solids handling and disposal capacity at the
 POTW.  Otherwise, the industrial  plant may need to provide biological
 pretreatment to supplement the POTW.   In all cases the manufacturer
 should provide sufficient waste equalization and neutraliza-tion to
minimize adverse impacts upon the POTW.


 PARAMETERS OF CONCERN

          pH, Acidity, Alkalinity       Temperature
          BOD                           Nitrogen compounds
          COD                    ~      Phosphorous

-------
                                                                    215
          TOC                           Zinc
          TSS                           Sulfates
          IDS                           Phenols
          Oil/Grease                    Pesticides
                                        Toxicity
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW.
No specific limitations given to date.
PRECRIBED PRETREATMENT MEASURES OR EQUIVALENT

Pretreatment unit operations which may be necessary by gum and wood
chemicals manufacturing plants prior to discharge to a POTW include:

     For Subcategory B, D, F Plants - Oil separation plus  equalization
     plus neutralization plus chemical  precipitation (depending upon
     metal content)

     For Subcategory C, E Plants - Equalization plus neutralization.

-------
  216
                   PESTICIDE CHEMICALS MANUFACTURING
                          (8, 123, 124, 125)
                                [Part 455]

SUBCATEGORIZATION OF THE INDUSTRY

Five types of pesticides manufacturing establishments have been defined
as shown below, Subcategory A-D Plants are involved in the direct manu-
facture of the active ingredient.  Subcategory E comprises plants that
formulate, blend, and package pesticides.

          A -  Alogenated organics pesticides
          B -  Organo - phosphorous pesticides
          C -  Organo - nitrogen pesticides
          D -  Metallo - organic pesticides
          E -  Pesticide formulators and packagers
NATURE OF PROBLEM
Pesticides can affect the aquatic environment and water quality in many
ways.  A number of pesticides will degrade very slowly and consequently,
are extremely persistent.  Other pesticides will degrade rapidly, some
into products that are more toxic than the parent compound, and some to
harmless products.  A significant number of pesticides have high poten-
tial for bioaccumulation and biomagnification in the food chain, thereby
posing a serious threat to many organisms, including man.

The chlorinated organic pesticides represent a large group of chemicals
having wide use, stability in the environment, toxicity to wildlife and
nontarget organisms, and adverse physiological effects upon humans.
This group of pesticides readily accumulates in aquatic organisms and
man.  They are stored in fatty tissues and not readily metabolized.

The organo-phosphorous pesticides will more rapidly hydrolyze or break
down into less toxic compounds as compared to the halogenated compounds.
This group exhibits a wide range of toxicity, some having high mammilian
toxicity.  Accumulation of these pesticides results in a dysfunction of
the cholinesterase of the nervous system when ingested in small amounts
over a long period of time.

The organo-nitrogen pesticides are generally less persistent in the
environment than the halogenated organic pesticides.  This group has
a wide range of toxicity.  The carbamates are especially toxic-to
mammals by acting on the nervous system in the same manner as the
organo-chlorine pesticides.

-------
                                                                   217
Metallo-organic pesticides include the arsenicals, mercury compounds,
and those containing zinc, manganese, tin, cadmium, lead and other
metals.  Toxicity of these compounds is highly variable.  Arsenic is
notorious for its toxicity to humans.  Mercuro-organic compounds are
significantly toxic and demonstrate biomagnification.

The organic pesticides cited above are notquately measured by the
conventional waste parameters of BOD, COD, TOC, etc.  Pesticides are
frequently toxic to organisms utilized in the BOD analysis.  Their
reponse to the COD and TOC tests is not well known.  Levels of critical
pesticide pollution may in certain cases be below the detection limit
of available analytical methods.
PARAMETERS OF CONCERN

          pH, Acidity,
               Alkalinity          Ammonia N
          BOD                      TKN
          COD                      Total phosphates
          TOC/TOD                  Cyanide
          TSS                      Sulfide
          TDS                      Metals including Zinc, Copper,
          Oil and Grease                Arsenic, Manganese, Tin
          Chlorides                     Cadmium, Chromium, Lead,
          Phenols                       Mercury, Nickel
          Pesticides*
     Typical halogenated organic pesticides include:  PCNB, Terrazole
     Toxaphene,  DCPA,  Chlorothalonil,  Chlorobenzilate, 2-4D, 2-4D-5T,
     POP,  Endrin,  Heptachlor, MCPA,  DDT.   Typical organo-phosphorous
     pesticides  include:  Coumaphos, Disolfoton,  Azinphosmethyl,
     Mathamidophos,  Fensulfothion,  Fenthio, Demeton, Methyl Dementon,
     Monitor,  Diazinon,  Methyl Parathion,  Ethyl Parathion,  Dursban,
     Crufornate,  Eonnels  Aspon, Rabon}  Vapona.

     Typical organo-nitrogen pesticides include:   Benefin,  Trifluralin,
     Isopropalin,  Oryzalin,  Pipron,  Tebuthurion,  Atrazine,  Metribuzin,
     Benzazimide,  Simazine,  Propazine,  Ametrynes  Prometryne, Sinutryne,
     Sumitol,  Terbetryne,  Prometone, Cybnazine,  Dinoseb,  Alachlor,
     Propochlor, Bromacil,  Diuron, Aldicarb.

     Typical metallo-organic pesticides include:   DSMA, MSMA,  PMAS  Copper
     8 Quinolate,  CMP, Zineb, Tricyclohexyltin Hydroxide,  Triphenyltin
     Hydroxide,  Tributyltin Oxide, Maneb.

-------
 218
The BOD test is reported as sensitive to toxic materials.  Therefore,
if toxic materials are present in a pesticides manufacturing waste-
water, the BOD value could be erroneous.  This situation can be remedied
by conducting a microorganism toxicity test, i.e., serially diluting the
wastewater sample until the BOD value attains a plateau indicating that
the waste is at a low enough concentration to no longer inhibit biologi-
cal activity.

LIMITATIONS FOR DISCHARGE TO POTVJ

No specific limitations established at this time.
PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

Even though the EPA Effluent Guidelines Division study cites many
pesticide plants discharging to POTW's, no description is given in the
August 1976 Draft Development Document of pretreatment limitations
and controls before release of pesticide wastes  to a POTW.   Such
technology will presumably be delineated in future publications.

-------
                                                               219
                       EXPLOSIVES MANUFACTURING
                               (7, 194)
                              [Part 457]

SUBCATEGORIZATION OF THE INDUSTRY

Four types of explosives manufacturing plants have been identified as
shown below.  It must be recognized however that the Federal  Register,
Part 457, has so far only recognized plants in Subcategories  A and C.

     A - Production of explosives, e.g., dynamite, nitroglycerin, RDX,
         HMX, TNT.
     B - Production of propel 1 ants
     C - Load, assemble and pack operations
     D - Production of initiating compounds

NATURE OF PROBLEM

Of special significance is the problem of trace amounts of the explo-
sive products themselves.  Explosives such as nitroglycerin,  TNT, RDX
and HMX have high potential hazard, toxicity or inhibitory impact upon
biological life.  Some investigators have shown nitroglycerin to be
amenable to biological treatment whereas others have had little success
with biological  treatment.

Process wastewaters from explosives manufacturing contains high levels
of soluble oxygen-demanding materials, TSS, nitrates, sulfates, organic
nitrogen, carbon, trace metals and trace quantities of explosives.

Metals such as lead and mercury can be discharged in significant amounts
as to disrupt biological  activity.  Lead concentrations of 200 mg/1  have
been found in explosive wastes, which would require physical/chemical
precipitation as a pretreatment measure.

Trace explosives present in wastewaters being discharged to a POTW can
lead to serious  problems for the POTW because of the toxicity and
hazardous nature of the industrial waste.
PARAMETERS OF CONCERN

          pH, Acidity, Alkalinity       Nitrogen compounds  including
          BOD                                TKN, ammonia,  nitrates
          COD                           Sulfates
          TOC                           Lead
          TSS                           Mercury
          TDS                           Other metals
          Oil/Grease                    Trace explosives
          Color                         Toxicity

-------
220
 PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW.

 Since oil/grease  in high concentrations can be disruptive to POTW's
 under certain circumstances, a pretreatment limit of 100 mg/1 oil and
 grease  has been established for both existing and new installations in
 the explosives industry.
 PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

 It  is recommended that explosives manufacturing wastewaters be treated
 on  site.  If municipal treatment is employed, pretreatment must remove
 potentially hazardous explosives wastes.

 Discharge of explosives manufacturing wastes to POTW's is not common.
 High sulfates can disrupt a biological secondary treatment system
 thereby requiring calcination as necessary pretreatment.  Wastes high
 in  TNT may require activated carbon absorption prior to municipal sew-
 erage to remove the dissolved explosives and its isomers together with
 associated toxicity.  High concentration of nitrocellulose suspended
 solids are disruptive to biological systems, but can be economically
 removed by centrifuging.  Heavy metals concentrations potentially toxic
 to  microorganisms and the activated sludge process can be reduced by
 physical/chemical pretreatment.  Oil and grease can be reduced to 100
 mg/1 or lower by skimming or equivalent means.

 Pretreatment for minimizing toxicity and safety hazards with explosives
 wastes, may consist of a minimum of waste equalization, chemical preci-
 pitation of metallics, and neutralization.

-------
                                                                  221
                       CARBON' BLACK MANUFACTURING
                                  (213)
                               [Part 458]
SUBCATEGORIZATION OF THE INDUSTRY

The Carbon Black Industry has been divided into four subcategories which
are described below:

          A - Carbon black furnace process.
          B - Carbon black thermal process.
          C - Carbon black channel process.
          D - Carbon black lamp process.
NATURE OF THE PROBLEM

Wastewater sources from carbon black manufacturing include scrubber
waters, process equipment cleanouts, production area washdowns, spill
washdowns, and laundry operations.

Under best practicable control technology, carbon black furnace and
thermal process plants (Subcategories A and B) are reported capable of
achieving no discharge of process wastewater pollutants by virtue of
recycling these wastes to the quench step.  Channel  and lamp black
process plants (Subcategories C and D) are reported  to be dry opera-
tions also resulting in no discharge of process wastewater pollutants.
PARAMETERS OF CONCERN

          pH, Acidity, Alkalinity       Iron
          TSS                           Copper
          TDS             ,              Manganese


PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTH AND PRESCRIBED
TREATMENT MEASURES

For Subcategory A, furnace process, New sources (Limitations for Existing
sources not yet defined).

               Parameter                Pretreatment Standards

               BOD5, TSS                  No limitations

               Oil/grease                  100 mg/1

-------
 222




For Subcategory B, thermal  process,  New sources (limitations for Existing
sources not yet defined).

               Parameter                Pretreatment Standard

               BOD5, TSS                  No limitations

               Oil/grease                  100 mg/1

For Subcategory C, channel  process,  New sources (limitations for Existing
sources not yet defined).

               BOD5, TSS                  No limitations

               Oil/grease                  100 mg/1

For Subcategory D, lamp process, New sources (limitations  for Existing
sources not yet defined).

               BOD5, TSS                  No limitations

               Oil/grease                  100 mg/1

In-process controls are important for minimizing waste loads from the
carbon black industry.  Good practices include minimizing  and containing
spills and leaks, segregating waste  streams, water  conservation and reuse,
wastewater equalization and good housekeeping, and  process operation and
equipment maintenance.

New carbon black plants can minimize future waste abatement costs by
including:

     1.  dikes, emergency  holding ponds, catch basins and  other contain-
         ment for leaks, spills and  washdowns.

     2.  piping, trenches,  sewers, sumps and other  isolation facilities
         to keep leaks, spills and process waters separated from cooling
         and sanitary waters.

     3.  non-contact condensers for  cooling waters.

     4.  efficient reuse,  recycling  and recovery of all  possible raw
         materials and byproducts.
     5.  closed cycle water utilization whenever possible.

-------
                                                                223
                       PHOTOGRAPHIC PROCESSING
                               (9, 164)
                              [PART 459]
SUBCATEGORIZATION OF THE  INDUSTRY

The photographic processing industry was not subcategorized because the
pollutant loads per unit  of production were found to fall in a relative-
ly narrow range.  The photographic industry as presently defined by the
EPA does not include the  manufacture of photographic film, photographic
plates and photographic paper.
NATURE OF PROBLEM

There are around 12,500 photographic processing plants in the U. S., of
which about 3,000 are amateur operations; 3,000 are "captive" labs
serving business and industrial firms; 650 are major labs specializing
in work for professional and industrial photographers; and the remaining
plants are portrait and commercial studios.  Major sources of waste-
water in the photographic processing industry are photoprocessing
solution overflows and wash waters.  It is estimated that 95 percent
of all photographic processing establishments after varying degrees of
in-plant pollution abatement discharge their effluents to municipal
sewarage.  Certain pollutants such as silver and cyanide, which can
exert toxic effects upon POTW's together with non-biodegradable materials
may be contained in these releases.  Therefore, in-plant measures or
pretreatment to reduce these contaminants to levels acceptable to local
authorities must be practiced.  The yearly discharge of cyanide salts
from photographic sources has been estimated at over 5 million pounds.

Silver and ferrocyanide represent the prevalent incompatible pollutants.
The developer solutions, couplers and fixers become a problem if dumped
in a slug to the POTW.   Discharge of these materials mostly occurs
during emergencies, periodic shutdowns, contamination, or exhaustion of
solutions.  The most practical pretreatment of incompatible pollutants
involves regeneration and reuse of processing solutions.   Both silver
and ferrocyanide can be recovered and reused.  To prevent shock loads
to the municipal system, waste equalization and/or holding is advised.

-------
 224
PARAMETERS OF CONCERN

          pH, Acidity, Alkalinity       Boron
          BOD/COD/TOC                   Cadmium
          TSS                           Chromium
          Phenols                       Cyanide
          IDS                           Ferrocyanide
          Phosphorous           ,        Silver
          Nitrogen Compounds            Thiosulfate
          Sulfates                      Temperature

Wastewaters generated by the photographic processing industry are
characterized as containing high concentrations of BOD, COD, TOC,
silver and cyani.de in various forms.

The Ferrocyanide ion in the photographic industry originates from the
bleach used in some color processes, i.e., ferrocyanide bleach.  Ferro-
cyanide is one of the most objectionable pollutants from photographic
processing.  The complexed ion is potentially harmful because it is
converted to free, highly-toxic CN in the presence of sunlight.  It
degrades only slowly in POTW's.  The ferro and ferrocyanide complexes
impose a distinct threat to the environment.  Fortunately, methods to
recover or minimize these compounds are currently being employed by
the industry.

       Silver is a prevalent heavy metal in photographic processing
wastewaters.  It is mostly derived from either the fix or bleach-fix
bath overflow.  At this stage, silver is usually in a soluble complex
form, e.g., silver thiosulfate, which is somewhat less toxic than ionic
silver.  While silver itself is not considered to be toxic, many of its
salts are poisonous.  Toxicity of silver to POTW's seems to be dependent
upon the free filver ion concentration.
PRELIMINARY LIMITATIONS FOR DICHARGE TO POTW

Existing sewer ordinances generally specify that cyanide discharges be
maintained in the range of 0.0 to 10.1 mg/1.  Pretreatment standards for
New sources within the photographic processing industry are given below:

     Pollutant                30 Day Avg. Limit        Max. Day Limit
                            (lb/1000 ft2, product)   (Ib/IQOO ft2 product)

     Silver                        .00034                   .00067
     Total Cyanide                 .00170                   .00340
     pH                                         6 to 9

-------
                                                                    225
PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

Besides in-plant controls, pretreatment for New sources would include
cyanide destruction, dual-media filtration and ion exchange.

       General pretreatment unit operations which may be necessary by
photographic processing plants prior to discharge to a suspended growth
biological system, a fixed growth biological system, or to a  physical -
chemical system of a municipal POTW would consist of equalization,  .
physical methods and chemical precipitation plus solids separation.

The following in-plant controls are recommended:

     1)   Silver can be recovered by any of four available methods:
          metallic replacement, electrolytic plating, ion exchange
          and chemical precipitation.

     2)   Regeneration of ferrocyanide bleach can be accomplished by
          oxidation with persulfate or ozone.

     3)   Developer solutions can be cleaned for reuse by ion exchange,
          or precipitation and extraction.

     4)   Physical wastewater carryover between the process steps can
          be reduced by mechanical  means of using squeegees.

-------
226
                                HOSPITALS
                                (5,  195)
                               [Part 460]
 NATURE OF PROBLEM
 Approximately 92 percent of the more than 7,000 hospitals in the U.S.
 discharge their effluents to municipal  sewerage.

 Sanitary wastes usually comprise a significant portion of total  hospital
 discharges.  Major sources of wastes include patient rooms, laundries,
 cafeterias, surgical  suites, laboratories and X-ray departments.  Be-
 sides the usual waste parameters, hospital  effluents may contain mercury,
 silver, barium, beryllium, boron, and a wide range of solvents.   Various
 anti-bacterial  constituents, e.g., disinfectants,  may exert toxic im-
 pacts upon subsequent biological waste treatment works.   Radionuclides
 can be released within patient excrement.  One radioisotope having wide-
 spread use is Iodine-131.  The above-cited waste pollutants should be
 recovered by in-house techniques in order to eliminate them from the
 raw waste load.  Radioactive wastes should be temporarily stored until
 certified safe release to the environment is possible.  Hospitals dis-
 charging to municipal sewer facilities may expect  additional pretreat-
 ment standards in the future.
 PARAMETERS OF CONCERN

 Compatible Pollutants

 BOD, TSS, pH and fecal  coliform bacteria are defined as compatible
 pollutants along with other pollutants which POTW's are designed to
 remove.

 Incompatible Pollutants

 Silver, mercury and boron together with other parameters are considered
 incompatible pollutants in  hospital  wastes and are subject to removal
 by in-process modification  or end-of-pipe treatment methods.

      PH, Acidity, Alkalinity            Ammonia N

      BOD                                Barium

      COD                                Beryllium

      TOC                                Mercury

      TSS                                Silver

      TDS                                Radioactivity

      Oil/grease                         Fecal  Col iforms

-------
                                                                 227
PRELIMINARY LIMITATIONS FOR DISCHARGE TO POTW

Pretreatment standards for New Sources specify a limit of 100 mg/1 oil
and grease in the discharges to a POTW.
IN-PLANT CONTROLS

The following in-plant controls are recommended methods of dealing with
hospital wastes:

1)   X-ray units should utilize the boron-free fixer.

2)   Stand-by controls should be installed on X-ray processing units
     to decrease water consumption by the processer.  Water flows should
     be reduced to the maximum practicable extent consistent with obtain-
     ing a good final radiograph.

3)   Silver discharge from X-ray processing should be controlled by a
     silver recovery system or return of the spent developer to the
     manufacturer.

4)   Hospital personnel should be acutely aware of mercury pollution
     and disposal problems.

5)   All radioactive waste should be contained and held pending safe
     disposal.
PRESCRIBED PRETREATMENT MEASURES OR EQUIVALENT

Pretreatment unit operations which may be necessary by hospitals prior
to waste discharge to a suspended growth biological system, or fixed
growth biological system, or to a physical-chemical system of a muni-
cipal POTW are outlined below:

Suspended Growth Biological System:  Chemical precipitation (for metals)
plus solids separation.

Fixed Growth Biological System:  Chemical precipitation (for metals)
plus solids separation.

Physical-Chemical System:  Chemical precipitation (for metals) plus
solids separation and oil and grease skimming.

-------
                              REFERENCES
1.   "Development Document for Interim Final  Effluent Limitations
     Guidelines and Proposed New Source Performance Standards for the
     Pharmaceutical Manufacturing Point Source Category," Effluent
     Guidelines Division, USEPA, September, 1976.

2.   "Draft Supplement for Pretreatment to the Development Document for
     the Timber Products Processing Point Source Category," Effluent
     Guidelines Division, USEPA, August, 1976.

3.   "Supplemental for Pretreatment to the Development Document for the
     Secondary Aluminum Segment of the Non-Ferrous Metals Manufacturing
     Point Source Category," Effluent Guidelines Division, USEPA,
     August 1976.

4.   "Supplemental for Pretreatment to the Development Document for the
     Secondary Copper Segment of the Non-Ferrous Metals Manufacturing
     Point Source Category," Effluent Guidelines Division, USEPA, August
     1976.

5.   "Development Document for Interim Final  Effluent Limitations Guide-
     lines, and Proposed New Source Performance Standards for the Hospital
     Point Source Category," Effluent Guidelines Division, USEPA, April
     1976.

6.   "Development Document for Interim Final  Effluent Limitations Guide-
     lines, and Proposed New Source Performance Standards for the Gum
     and Wood Chemicals Manufacturing Point Source Category," Effluent
     Guidelines Division, USEPA, April 1976.

7.   "Development Document for Interim Final  Effluent Limitations
     Guidelines, and Proposed New Source Performance Standards for the
     Explosives Manufacturing Point Source Category," Effluent Guide-
     lines Division, USEPA, March 1976.

8.   "Draft Development Document for Interim Final Effluent Limitations
     Guidelines and Proposed New Source Performance Standards for the
     Pesticides Industry Segment of the Miscellaneous Chemicals Industry,"
     Effluent Guidelines Division, USEPA, August 1976.

9.   "Development Document for Interim Final  Effluent Limitations Guide-
     lines and Proposed New Source Performance Standards for the Photo-
     graphic Processing Subcategory of the Photographic Point Source
     Category," Effluent Guidelines Division, USEPA, July 1976. '

-------
10.  "Development Document for Interim Final  and  Proposed Effluent
     Limitations Guidelines and New Source  Performance Standards for the
     Fruits, Vegetables and Specialties Segment of  the Canned and Preserved
     Fruits and Vegetables Point Source Category,"  Effluent Guidelines
     Division, USEPA,  October 1975.

11.  "Development Document for Interim Final  Effluent Limitations
     Guidelines and Proposed New Source Performance Standards for the
     Forming, Finishing and Specialty Steel  Segments of  the Iron and
     Steel  Manufacturing Point Source Category, Volumes  I and II,"
     Effluent Guidelines Division,  USEPA, March,  1976.

12.  40 CFR Part 420,  41 FR 12990-13030, Mar.  29, 1976.

13.  40 CFR Part 430,  41 FR 7662-7770, Feb.  19, 1976.

14.  "Development Document for Interim Final  and  Proposed Effluent
     Limitations Guidelines and Proposed New Source Performance Standards
     for the Bleached  Kraft, Groundwood, Sulfite, Soda,  Deink and Non-
     Integrated Paper  Mills Segment of the  Pulp,  Paper and Paperboard
     Industry, Volumes I and II," Effluent  Guidelines Division, USEPA,
     January 1976.

15.  "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for the Renderer Segment of
     the Meat Products Point Source Category," Effluent  Guidelines
     Division, USEPA,  August 1974.

16.  40 CFR Part 432,  Proposed Rules, 40 FR 902-914, Jan. 3, 1975.

17.  "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for the Processor Segment of
     the Meat Products Point Source Category," Effluent  Guidelines
     Division, USEPA,  August 1974.

18.  "Development Document for Effluent Limitations Guidelines, and New
     Source Performance Standards for the Copper, Nickel, Chromium and
     Zinc Segment of the Electroplating Point Source Category," Effluent
     Guidelines Division, USEPA, March 1974.

19.  "Development Document for Interim Final  Effluent Limitations Guidelines
     and Proposed New  Source Performance Standards  for the Common and
     Precious Metals Segment of the Electroplating  Point Source Category,"
     Effluent Guidelines Division,  USEPA, April 1975.

20.  "Development Document for Interim Final  Effluent Limitations Guide-
     lines and Proposed New Source  Performance Standards for the Metal
     Finishing Segment of the Electroplating  Point  Source Category,"
     Effluent Guidelines Division,  USEPA, April 1975.

-------
21.  40 CFR Part 413,  40 FR  18130-18148, Apr.  24, 1975.

22.  "Development Document for  Proposed Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Poultry Segment of the
     Meat Product and  Rendering Process Point  Source Category," Effluent
     Guidelines Division, USEPA, April 1975.

23.  40 CFR Part 432,  Proposed  Rules  40 FR 18150-18161, April 24, 1975.

24.  40 CFR Part 128,  38 FR  30982-30984, Nov.  8, 1973.

25.  "Development Document for  Proposed Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Leather Tanning and
     Finishing Point Source  Category," Effluent Guidelines Division,
     USEPA, November 1973.

26.  40 CFR Part 425,  39 FR  12958-12969, Apr.  9, 1974.

27.  "Development Document for  Proposed Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Textile Mills Point
     Source Category," Effluent Guidelines Division, USEPA, January
     1974.

28.  40 CFR Part 410,  39 FR  24736-24752, July  5, 1974.

29.  "Development Document for  Proposed Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Soap and Detergent
     Manufacturing Point Source Category," Effluent Guidelines Division,
     USEPA, December 1973.

30.  40 CFR, Chapter I, Subchapter  N, 40 FR 6432-6447, Feb. 11, 1975.

31.  40 CFR Part 417,  39 FR  13370-13397, Apr.  12, 1974.

32.  40 CFR Part 417,  40 FR  7580-7583, Feb.  20, 1975.

33.  "Development Document for  Interim Final and Proposed Effluent
     Limitations Guidelines  and New Source Performance Standards for the
     Ore Mining and Dressing Industry, Volumes I and II," Effluent
     Guidelines Division, USEPA, October 1975.

34.  40 CFR Part 440,  40 FR  51722-51748, Nov.  6, 1975.

35.  "Development Document for  Proposed Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Paint Formulating and
     the Ink Formulating Point  Source Categories," Effluent Guidelines
     Division, USEPA,  February, 1975.

36.  40 CFR Part 446,  Proposed  Rules, 40 FR 8302, Feb. 26, 1975.

37.  40 CFR Part 446,  40 FR  31724-31726 and 31729-31730, July 28, 1975.

-------
38.  40 CFR Part 447, Proposed Rules,  40  FR  8307,  Feb.  26,  1975.

39.  40 CFR Part 447, 40 FR 31726-31728 and  31730-31731,  July 28, 1975.

40.  "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Dairy Products Process-
     ing Point Source Category," Effluent Guidelines  Division,  USEPA,
     January 1974.

41.  40 CFR Part 405, Proposed Rules,  38  FR  34954-34967,  Dec. 20, 1973.

42.  40 CFR Part 405, 39 FR pp. 18594-18612, May  28,  1974.

43.  "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Paving  and Roofing
     Materials (Tars and Asphalt)  Point Source Category," Effluent
     Guidelines Division, USEPA,- December 1974.

44.  40 CFR Part 443, Proposed Rules,  40  FR  2352-2358,  Jan. 10, 1975.

45.  40 CFR Part 443, 40 FR 31190-31197,  July  24,  1975.

46.  "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Major Inorganic
     Products Segment of the Inorganic Chemicals  Manufacturing  Point
     Source Category," Effluent Guidelines Division,  USEPA, August  1973.

47.  "Development Document for Interim Final Effluent Limitations Guide-
     lines and Proposed New Source Performance Standards  for the Signifi-
     cant Inorganic Products Segment of the  Inorganic Chemicals Manufactur-
     ing Point Source Category," Effluent Guidelines  Division,  USEPA,
     May 1975.

48.  40 CFR Part 415, Proposed Rules,  36  FR  28174-28194,  Oct. 11, 1973.

49.  40 CFR Part 415, 39 FR 9612-9639, March 12,  1974.

50.  40 CFR Part 415, Proposed Rules,  40  FR  1712-1714,  Jan. 9,  1975.

51.  40 CFR Part 415, Proposed Rules,  40  FR  22402-22445,  May 22, 1975.

52.  "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Feedlots  Point Source
     Category," Effluent Guidelines Division,  USEPA,  August 1973.

53.  40 CFR Part 412, 39 FR 5704-5710, Feb.  14, 1974.

54.  "Development Document for Interim Final Effluent Limitations Guide-
     lines and Proposed New Source Performance Standards  for the Raw
     Cane Sugar Processing Segment of  the Sugar Processing  Point Source
     Category," Effluent Guidelines Division,  USEPA,  February 1975.

-------
55.  40 CFR Part 409, Interim Final  and  Proposed  Rules, 40  FR 8498-85:11,
     Feb. 27, 1975.

56.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source  Performance Standards  for  the Cane Sugar Refining
     Segment of the  Sugar Processing Point Source Category," Effluent
     Guidelines Division, USEPA, December  1973.

57.  40 CFR Part 409, Proposed Rules, 38 FR 33846-33851,  Dec. 7,  1973.

58.  40 CFR Part 409, 39 FR 10522-10528, March 20, 1974.

59.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source  Performance Standards  for  the Beet Sugar Segment of
     the Sugar Processing Point Source Category," Effluent  Guidelines
     Division, USEPA, August 1973.

60.  40 CFR Part 409, 39 FR 4034-4038, Jan.  31, 1974.

61.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source  Performance Standards  for  the Major Organic  Products
     Segment of the  Organic Chemicals Manufacturing Point Source  Category,"
     Effluent Guidelines Division,  USEPA,  December 1973.

62.  "Development Document for Interim Final  Effluent  Limitations
     Guidelines and  New Source Performance Standards for  the Significant
     Organic Products Segment of the Organic Chemical  Manufacturing
     Point Source Category," Effluent Guidelines  Division,  USEPA,
     December 1975.

63.  40 CFR Part 414, Proposed Rules, 38 FR 34706-34716,  Dec. 17, 1973.

64.  40 CFR Part 414, 39 FR 14676-14685, April 25, 1974.

65.  40 CFR Part 414, 41 FR 902-928, Jan.  5, 1976.

66.  40 CFR Part 414, 41 FR 13936,  April 1, 1976.

67.  "Development Document for Interim Final  Effluent  Limitations Guide-
     lines and New Source Performance Standards for the Minerals  for the
     Construction Industry, Volume  I, Mineral  Mining and  Processing
     Industry Point  Source Category," Effluent Guidelines Division,
     USEPA, October  1975.

68.  "Development Document for Interim Final  Effluent  Limitations Guide-
     lines and New Source Performance Standards for the Minerals  for the
     Chemical and Fertilizer Industries, Volume  II, Mineral Mining and
     Processing Industry Point Source Category,"  Effluent Guidelines
     Division, USEPA, October 1975.

-------
 69.  "Development Document for Interim Final  Effluent Limitations  Guide-
      lines and New Source Performance Standards for the  Clay,  Ceramic,
      Refractory and Miscellaneous Minerals,  Volume  III,  Mineral  Mining
      and Processing Industry Point Source Category," Effluent  Guidelines
      Division, USEPA, October 1975.

 70.  "Development Document for Interim Final  Effluent Limitations  Guide-
      lines and New Source Performance Standards for the  Mineral  Mining
      and Processing Industry Point Source Category," Effluent  Guidelines
      Division, USEPA, June 1976.

.71.  40 CFR Part 436, 40 FR 48652-48668,  Oct.  16,  1975.

 72.  40 CFR Part 436, 41 FR 23552-23573,  June  10,  1976.

 73.  "Development Document for Interim Final  Effluent Limitations
      Guidelines and New Source Performance Standards for the Coal  Mining
      Point Source Category," Effluent Guidelines Division,  USEPA,  October
      1975.

 74.  "Development Document for Interim Final  Effluent Limitations  Guide-
      lines and New Source Performance Standards for the  Coal Mining
      Point Source Category," Effluent Guidelines Division,  USEPA,  May
      1976.

 75.  40 CFR Part 434, Interim Final and Proposed Rules,  40  FR  48830-48839,
      Oct. 17, 1975.

 76.  40 CFR Part 434, 41 FR 19832-19843,  May 13, 1976.

 77.  "Development Document for Proposed Effluent Limitations Guidelines
      and New Source Performance Standards for  the  Cement Manufacturing
      Point Source Category," Effluent Guidelines Division,  USEPA,  August
      1973.

 78.  40 CFR Part 411, Proposed Rules, 38  FR  24462-24466, Sept, 7,  1973.

 79.  40 CFR Part 411, 39 FR 6590-6596, Feb.  20, 1974.

 80.  "Development Document for Proposed Limitations Guidelines and New
      Source Performance Standards for the Builders  Paper and Roofing
      Felt Segment of the Builders Paper and  Board  Mills  Point  Source
      Category," Effluent Guidelines Division,  USEPA.,. Janaury 1974.

 81.  40 CFR Part 431, Proposed Rules, 39  FR  1818-1821, Jan. 14,  1974.

 82.  40 CFR Part 431, 39 FR 16578-16583,  May 9, 1974.

 83.  "Development Document for Proposed Effluent Limitations Guidelines
      and New Source Performance Standards for  the  Building, Construction
      and Paper Segment of the Asbestos Manufacturing Point  Source
      Category," Effluent Guidelines Division,  USEPA, October 1973.

-------
84.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source Performance Standards  for  the Textile,  Friction
     Materials and Sealing Devices  Segment of  the Asbestos  Manufacturing
     Point Source Category, Effluent Guidelines Division, USEPA, August
     1974.

85.  40 CFR Part 427, 39 FR 7526-7535, Feb.  26, 1974.

86.  40 CFR Part 427, Proposed Rules, 39 FR 31592-31599, Aug.  29,  1974.

87.  40 CFR Part 427, Proposed Rules, 40 FR 1874-1880,  Jan. 9,  1975.

88.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source Performance Standards  for  the Flat  Glass Segment of
     the Glass Manufacturing Point  Source  Category,"  Effluent  Guidelines
     Division, USEPA, October 1973.

89.  40 CFR Part 426, Proposed Rules, 38 CF 28902-28910, Oct.  17,  1973.

90.  40 CFR Part 426, 39 FR 5712-5722, Feb.  14, 1974.

91.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source Performance Standards  for  the Pressed and  Blown
     Glass Segment of the Glass Manufacturing  Point Source  Category,"
     Effluent Guidelines Division,  USEPA,  August  1974.

92.  40 CFR Part 426, Proposed Rules, 39 FR 30282-30295, Aug.  21,  1974.

93.  40 CFR Part 426, 40 FR 2952-2965, Jan.  16, 1975.

94.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source Performance Standards  for  the Insulation Fiberglass
     Manufacturing Segment of the Glass  Manufacturing Point Source
     Category," Effluent Guidelines Division,  USEPA,  July 1973.

95.  40 CFR Part 426, 39 FR 2564-2568, Jan.  22, 1974.

96.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source Performance Standards  for  the Grain Processing
     Segment of the Grain Mills Point Source Category," Effluent Guide-
     lines Division, USEPA, December 1973.

97.  "Development Document for Proposed  Effluent  Limitations Guidelines
     and New Source Performance Standards  for  the Animal Feed,  Breakfast
     Cereal, and Wheat Starch Segment of the Grain Mills Point Source
     Category," Effluent Guidelines Division,  USEPA,  September 1974.

98.  "Supplement to Development Document for Effluent Limitations  Guide-
     lines and New Source Performance Standards for the Corn Wet Milling
     Subcategory, Grain Processing  Segment of  the Grain Mills  Point
     Source Category," Effluent Guidelines Division,  USEPA, August 1975.

-------
99.  40 CFR Part 406,  Proposed  Rules,  38  FR  33438-33445, Dec. 4, 1973.

100. 40 CFR Part 406,  39 FR 10512-10520,  March 20, 1974.

101. 40 CFR Part 406,  Final  and Proposed  Rules, 40 FR 916-922, Jan. 3, 1975.

102. 40 CFR Part 406,  Proposed  Rules,  40  FR  37052-37054, Aug. 25, 1975.

103. 40 CFR Part 406,  40 FR 52014-52019,  Nov. 7,  1975.

104. "Development Document for  Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for the Catfish, Crab, Shrimp
     and Tuna Segment  of the Canned  and Preserved Seafood Processing
     Point Source Category," Effluent  Guidelines  Division, USEPA, January
     1974.

105. "Development Document for  Interim Final Effluent Limitations Guide-
     lines and Proposed New Source Performance Standards for the Fish
     Heal, Salmon, Bottom Fish, Sardine,  Herring, Clam, Oyster, Scallop,
     and Abalone Segment of the Canned and Preserved Seafood Processing
     Point Source Category," Effluent  Guidelines  Division, USEPA, January
     1975.

106. 40 CFR Part 408,  39 FR 23134-23156,  June 26, 1974.

107. 40 CFR Part 408,  40 FR 55770-55801,  Dec. 1,  1975.

108. "Development Document for  Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for the Tire and Synthetic
     Segment of the Rubber Processing  Point  Source Category," Effluent
     Guidelines Division, USEPA, September 1973.

109. "Development Document for  Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for the Fabricated and Reclaimed
     Rubber Segment of the Rubber Processing Point Source Category,"
     Effluent Guidelines Division, USEPA, August, 1974.

110. 40 CFR Part 428,  Proposed  Rules,  FR  28219-28228, Oct. 11, 1973.

111. 40 CFR Part 428,  39 FR 6660-6667, Feb.  21, 1974.

112. 40 CFR Part 428,  39 FR 30632-30645,  Aug. 23, 1974.

113. 40 CFR Part 428,  Interim Final  and Proposed  Rules, 40 FR 2334-2349,
     Jan. 10, 1975.

114. "Development Document for  Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for the Plywood, Hardboard,
     and Wood Preserving Segment of  the Timber Products Processing Point
     Source Category," Effluent Guidelines Division, USEPA, December,
     1973.

-------
115. "Development Document for Proposed  Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Wet Storage, Sawmills,
     Particleboard, and Insulation  Board Segment of the Timber Products
     Processing Point Source Category,"  Effluent Guidelines Division,
     USEPA, August 1974.
116. "Development Document for Proposed  Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Wood Furniture and
     Fixture Manufacturing Segment  of  the  Timber Products Processing
     Point Source Category," Effluent  Guidelines Division, USEPA, November
     1974.
117. 40 CFR Part 429, Proposed Rules,  39 FR 938-949, Jan. 3, 1974.
118. 40 CFR Part 429, 39  FR 13942-13954, April 18, 1974.
119. 40 CFR Part'429, Proposed Rules,  FR 30892-30903, Aug. 26, 1974.
120. 40 CFR Part 429, 40  FR 2804-2810, Jan. 16, 1975.
121. 40 CFR Part 429, Proposed Rules,  39 FR 40236-40242, Nov. 14, 1974.
122. 40 CFR Part 429, 40  FR 23824-23830, June  2, 1975.
123. "Development Document for Interim Final Effluent Limitations Guide-
     lines for the Pesticides Chemicals Manufacturing Point Source
     Category," Effluent  Guidelines Division,  USEPA, November 1976.
124. 40 CFR Part 455, 41  FR 48088-48096, Nov.  1, 1976.
125. 40 CFR Part 455, 41  FR 54181,  Dec.  13, 1976.
126. 40 CFR Part 439, 41  FR 50676-50686, Nov.  17, 1976.
127. 40 CFR Part 429, 41  FR 53930-53938, Dec.  9, 1976.
128. 40 CFR Part 421, 41  FR 54850-54854, Dec.  15, 1976.
129. 40 CFR Part 413, 41  FR 53018-53019  and 53070, Dec. 3, 1976.
130. 40 CFR Part 415, 41  FR 51598-51603  and 51621, Nov. 23, 1976.
131. 40 CFR Part 430, 42  FR 1398-1426, Jan. 6, 1977.
132. "Development Document for Proposed  Effluent Limitations Guidelines
     and New Source Performance Standards  for  the Citrus, Apple and
     Potato Segment of the Canned and  Preserved Fruits and Vegetables
     Processing Point Source Category,"  USEPA, Effluent Guidelines
     Division, Washington, D.C., November  1973.

-------
133. 40 CFR Part 407, 39 FR 10862-10870,  March  21,  1974.

134. 40 CFR Part 407, Interim Final  and Proposed  Rules, 40  FR 40222-49265,
     October 21, 1975.

135. 40 CFR Part 407, 41 FR 16272-16286,  April  16,  1976.

136. 40 CFR Part 410, 39 FR 30134-30135,  August 21,  1974.

137. "Development Document for Interim Final  Effluent  Limitations  Guide-
     lines and New Source Performance Standards for  the Offshore Segment
     of the Oil and Gas Extraction Point  Source Category,"  USEPA,
     Effluent Guidelines Division, September,  1975.

138. 40 CFR Part 435, 40 FR 42543-42551 and  42572-42577, Sept.  15,  1975.

139. "Development Document for Interim Final  Effluent  Limitations  Guide-
     lines and Proposed New Source Performance  Standards for the Oil and
     Gas Extraction Point Source Category,"  USEPA,  Effluent Guidelines
     Division, September 1976.

140. 40 CFR Part 435, Interim Final  and Proposed  Rules, 41  FR 44942-44952.

141. 40 CFR Part 430, 41 FR 27741-27744,  July  6,  1976.

142. "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Unbleached Kraft  and
     Semi-Chemical  Pulp Segment of the Pulp,  Paper,  and Paperboard  Mills
     Point Source Category," USEPA,  Effluent  Guidelines Division,  January
     1974.

143. 40 CFR Part 430, Proposed Rules, 39  FR  1908-1916, Jan. 15, 1974.

144. 40 CFR Part 430, Proposed Rules, 39  FR  18742-18754, May 29, 1974.

145. "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Bauxite Refining
     Subcategory of the Aluminum Segment  of  the Non-Ferrous Metals
     Manufacturing Point Source Category," USEPA, Effluent  Guidelines
     Division, October 1973.

146. "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Primary Aluminum
     Smelting Subcategory of the Aluminum Segment of the Non-Ferrous
     Metals Manufacturing Point Source Category," USEPA, Effluent  Guide-
     lines Division, October 1973.

147. "Development Document for Proposed Effluent  Limitations Guidelines
     and New Source Performance Standards for  the Secondary Aluminum
     Smelting Subcategory of the Aluminum Segment of the Non-Ferrous
     Metals Manufacturing Point Source Category," USEPA, Effluent  Guide-
     lines Division, October 1973.

-------
148.  "Development Document  for  Interim  Final Effluent Limitations Guide-
     lines and Proposed  New Source  Performance Standards for the Primary
     Copper Smelting Subcategory  and  the  Primary Copper Refining Sub-
     category of the Copper Segment of  the  Non-Ferrous Metals Manufactur-
     ing Point Source Category,"  USEPA, Effluent Guidelines Division,
     February 1975.

149.  "Development Document  for  Interim  Final Effluent Limitations Guide-
     lines and Proposed  New Source  Performance Standards for the Secondary
     Copper Subcategory  of  the  Copper Segment of the Non-Ferrous Metals
     Manufacturing Point Source Category,"  USEPA, Effluent Guidelines
     Division, February  1975.

150.  "Development Document  for  Interim  Final Effluent Limitations
     Guidelines and Proposed New  Source Performance Standards for the
     Lead Segment of the Non-Ferrous  Metals Manufacturing Point Source
     Category," USEPA, Effluent Guidelines  Division, February 1975.

151.  "Development Document  for  Interim  Final Effluent Limitations
     Guidelines and Proposed New  Source Performance Standards for the
     Zinc Segment of the Non-Ferrous  Metals Manufacturing Point Source
     Category, USEPA, Effluent  Guidelines Division, February 1975.

152.  40 CFR Part 421, Proposed  Rules, 38  FR 33170-33183, Nov. 30, 1973.

153.  40 CFR Part 421, 39 FR 12822-12830,  April 8, 1974.

154.  40 CFR Part 421, 40 FR 8514-8535,  Feb. 27, 1975.

155.  40 CFR Part 421, 40 FR 24539-24540,  June 9, 1975.

156.  "Development Document  for  Proposed Effluent Limitations Guidelines
     and New Source Performance Standards for the Synthetic Resins
     Segment of the Plastics and  Synthetic  Materials Manufacturing Point
     Source Category," USEPA, Effluent  Guidelines Division, August 1973.

157.  "Addendum to Development Document  for  Proposed Effluent Limitations
     Guidelines and Mew  Source  Performance  Standards for the Synthetic
     Resins Segment of the  Plastics and Synthetics Materials Manufactur-
     ing Point Source Category,"  USEPA, Effluent Guidelines Division,
     September 1974.

158.  "Development Document  for  Effluent Limitations Guidelines and New
     Source Performance  Standards for the Synthetic Polymers Segment of
     the Plastics and Synthetic Materials Manufacturing Point Source
     Category," USEPA, Effluent Guidelines  Division, January 1975.

159.  40 CFR Part 416, 39 FR 12502-12525,  April 5, 1974.

-------
160. 40 CFR Part 416,  Final  and  Proposed  Rules, 40 FR 3718-3732, Jan. 23,
     1975.
161. 40 CFR Part 416,  Final  and  Proposed  Rules 40 FR 21731-21732 and
     1740-21741, May 19,  1975.
162. 40 CFR Part 416,  41  FR  32587-32589 and 32613, Aug. 4, 1976.
163. 40 CFR Part 439,  42  FR  6813-6814, FEb. 4, 1977.
164. 40 CFR Part 459,  41  FR  29078-29082,  July 14, 1976.
165. 40 CFR Part 424,  Proposed Rules, 38  FR 29008-29018, Oct. 18, 1973.
166. 40 CFR Part 424,  39  FR  6806-6814, Feb. 22, 1974.
167. 40 CFR Part 424,  Interim Final  and Proposed Rules 40 FR 8030-8041,
     Feb. 4, 1975..
168. "Development Document for Proposed Effluent Limitations Guidelines
     and New Source  Performance  Standards for the Smelting and Slag
     Processing Segment of the Ferroalloy Manufacturing Point Source
     Category," USEPA, Effluent  Guidelines Division, August 1973.
169. "Development Document for Interim Final Effluent Limitations Guide-
     lines and Proposed New  Source  Performance Standards for the Calcium
     Carbide Segment of the  Ferroalloy Manufacturing Point Source Category,"
     USEPA, Effluent Guidelines  Division, February 1975.
170. "Development Document for Interim Final Effluent Limitations Guide-
     lines and Proposed Mew  Source  Performance Standards for the Electro-
     lytic Ferroalloys Segment of the Ferroalloy Manufacturing Point
     Source Category," USEPA, Effluent Guidelines Division, February
     1975.
171. 40 CFR Part 432,  Proposed Rules 39 FR 31486-31497, Aug. 28, 1974.
172. 40 CFR Part 432,  Proposed Rules 38 FR 29858-29868, Oct. 29, 1973.
173. 40 CFR Part 432,  39  FR  7894-7908, Feb. 28, 1974.
174. 40 CFR Part 432,  Proposed Rules 40 FR 902-914, Jan. 3, 1975.
175. "Development Document for Proposed Effluent Limitations Guidelines
     and New Source  Performance  Standards for the Red Meat Processing
     Segment of the  Meat  Product and Rendering Processing Point Source
     Category," USEPA, Effluent  Guidelines Division, October 1973.
176. 40 CFR Part 422,  Proposed Rules, 39  FR 24470-24476, Sept. 7, 1973,
177. 40 CFR Part 422,  39  FR  6580-6588, FEb. 20, 1974.

-------
178. "Development Document for  Proposed  Effluent Limitations Guidelines
     and New Source Performance Standards for the Phosphorous Derived
     Chemicals Segment of the Phosphate  Manufacturing Point Source
     Category," USEPA, Effluent Guidelines  Division, August 1973.

179. 40 CFR, Part 422, Interim  Final  and Proposed Rules, 40 FR 4102-4113,
     Jan. 27, .1975.

180. 40 CFR Part 422, 41  FR 25974-25979, June 23, 1976.

181. "Development Document for  Interim Final Effluent Limitations Guide-
  .   lines and Proposed New Source  Performance Standards for the Other
     Non-Fertilizer Phosphate Chemicals  Segment of the Phosphate Manufactur-
     ing Point Source Category,"  USEPA,  Effluent Guidelines Division,
     January 1975.

182. 40 CFR Part 418, 39 FR 12832-12844, April 8, 1974.

183. 40 CFR Part 418, 40 FR 2650-2655, Jan. 14, 1975.

184. 40 CFR Part 418, 40 FR 26275,  June  23, 1975.

185. 40 CFR Part 418, Proposed  Rules, 40 FR 33052-33054, Aug. 6, 1975.

186. 40 CFR Part 418, 41  FR 20582-20585, May 19, 1976.

187. 40 CFR Part 418, 40 FR 36337-36339, Aug. 20, 1975.

188. 40 CFR Part 418, Proposed  Rules, 41 FR 29429-29432, July 16, 1976.

189. 40 CFR Part 418, 41  FR 2386-2388, Jan. 16, 1976.

190. 40 CFR Part 418, Proposed  Rules, FR 33852-33860, Dec. 7, 1973.

191. "Development Document for  Proposed  Effluent Limitations Guidelines
     and New Source Performance Standards for the Formulated Fertilizer
     Segment of the Fertilizer  Manufacturing Point Source Category,"
     USEPA, Effluent Guidelines Division, September 1974.

192. "Development Document for  Proposed  Effluent Limitations Guidelines
     and New Source Performance Standards for the Basic Fertilizer
     Chemicals Segment of the Fertilizer Manufacturing Point Source
     Category," USEPA, Effluent Guidelines  Division.

193. 40 CFR Part 454, 41  FR 20506-20519, May 18, 1976.

194. 40 CFR Part 457, 41  FR 10180-10188, March 9, 1976.

195. 40 CFR Part 460, 41  FR 18779-18780, May 6, 1976.

196. 40 CFR Part 418, 42 FR 16140-16141, March 25, 1977.

-------
197.  40 CFR Part 419, 42 FR 15684-15690,  March  23,  1977.

198.  40 CFR Part 419, 40 FR 21939-21954,  May 20,  1975.

199.  40 CFR Part 419, 39 FR 16560-16575,  May 9,  1975.

200.  "Development Document for Proposed Effluent  Limitations Guidelines
      and New Source Performance Standards for the Petroleum Refining
      Point Source Category," USEPA,  Effluent Guidelines  Division,
      Washington, D.C., December 1973.

201.  40 CFR Part 423, 39 FR 36186-36211,  Oct. 8,  1974.

202.  40 CFR Part 423, Proposed Rules,  39  FR  8294-8307, March 4, 1974.

203.  "Development Document for Proposed Effluent  Limitations Guidelines
      and New Source Performance Standards for the Steam  Electric Power
      Generating Point Source Category," USEPA,  Effluent  Guidelines
      Division, March 1974.

204.  "Supplement for Pretreatment to the  Development Document for the
      Steam Electric Power Generating Point Source Category," USEPA,
      Effluent Guidelines Division, November  1976.

205.  40 CFR Part 423, 42 FR 15690-15696,  March  23,  1977.

206.  40 CFR Part 420, 41 FR 12990-13030,  March  29,  1976.

207.  40 CFR Part 420, Interim Final  and Proposed  Rules,  41 FR 2218-
      32219 and 32242, Aug.  2, 1976.

208.  40 CFR Part 420, 39 FR 24114-24133,  June 28, 1974.

209.  40 CFR Part 420, 39 FR 6484-6505,  Feb.  19, 1974.

210.  "Development Document for Proposed Effluent  Limitations Guidelines
      and New Source Performance Standards for the Steel  Making Segment
      of the Iron and Steel  Manufacturing  Point  Source Category," USEPA,
      Effluent Guidelines Division, February  1974.

211.  40 CFR Part 425, 42 FR 15696-15704,  March-23,-  1977.

212.  "Supplement for Pretreatment to the  Development Document for the
      Leather Tanning and Finishing Point  Source .Category," USEPA, Effluent
      Guidelines Division, November 1976.

213.  40 CFR Part 458, 41 FR 20496-20504,  May 18,  1976.

-------