United State*
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
EPA-600/2-79-002
January 1979
Research and Development
Review of Western
European and Japanese
Iron and  Steel Industry
Exemplary Water
Pollution Control
Technology

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                 RESEARCH REPORTING SERIES


Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination  of  traditional  grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:

    1. Environmental Health Effects Research

    2. Environmental Protection Technology

    3. Ecological Research

    4. Environmental Monitoring

    5. Socioeconomic Environmental  Studies

    6. Scientific and Technical Assessment Reports  (STAR)

    7. Interagency Energy-Environment Research and Development

    8. "Special" Reports

    9. Miscellaneous Reports

This report has been assigned to the  ENVIRONMENTAL PROTECTION TECH-
NOLOGY series.  This series describes research performed to develop and dem-
onstrate instrumentation, equipment,  and methodology to repair or prevent en-
vironmental degradation from point and non-point sources of pollution. This work
provides the new or improved technology required for the control and treatment
of pollution sources to meet environmental quality standards.
                       EPA REVIEW NOTICE
This report has been reviewed by the U.S. Environmental Protection Agency, and
approved for publication. Approval does not signify that the contents necessarily
reflect the views and policy of the Agency, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use

This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.

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                                    EPA-600/2-79-002

                                          January 1979
 Review of Western European and
 Japanese Iron  and  Steel  Industry
Exemplary Water Pollution Control
                Technology
                        by

         H.M. Tockmam, G. Swaminathan, and J.D. Stockham

                  I IT Research Institute
                  10West 35th Street
                  Chicago, Illinois 60616
                 Contract No. 68-02-2617
                     Task No. 2-3
                Program Element No. 1BB610
            EPA Project Officer: John S. Ruppersberger

           Industrial Environmental Research Laboratory
             Office of Energy, Minerals, and Industry
              Research Triangle Park, NC 27711
                     Prepared for

           U.S. ENVIRONMENTAL PROTECTION AGENCY
              Office of Research and Development
                  Washington, DC 20460

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                                 DISCLAIMER'
     This report has been reviewed by the Industrial Environmental Research
Laboratory, U.S, Environmental Protection Agencys and approved for publication,
Approval does not signify that the contents necessarily reflect the views and
policies of the U.S. Environmental Protection Agency, nor does mention of
trade names or commercial products constitute endorsement or recommendation
for use.

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     r     ...                    ABSTRACT
     Lurrent Western European and Japanese water pollution control  technology
an/tilr!n     Steel tndustry was Identified by means of a literature survey
r?,ri*elepu°n? and TELEX communications.  We found that the Japanese favor re-
^'e^nnoTogy whereas Br1tl'sh and Western European steel plants  practice
a variable recycle rate.  Summaries of typical  pollution control  operations
are described and comparative data are provided
                                    11

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                             CONTENTS ,

Abstract..,,.,,,,,,,,,,,.,,.,.	11

                                                                •
Figures                                                        TV

Tables                                                           v

Acknowledgement                                                vi



     1.   Introduction                                           1


     2,   Conclusions                                            3

     3.   Recommendations                                        5

     4,   The Japanese Steel Industry                            6

     5.   The Western European Steel  Industry                  17





Appendix A                                                     26

Appendix B                                                     28
                               fit

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                                  FIGURES


Number

   1  Japanese Investment in  Pollution  Control  Equipment  	   7

   2.  Flow Chart of the Dry Coke Quenching  Process  .,.,,.-••  H

   3.  Flow Chart of the Nippon  Steel  Corp.  Ion  Exchange Process.  ,  ,  13

   4.  Flow Chart of Process:   Coke Oven Liquor  Treatment  ,,,,..-  15

   5.  Flow Chart of the Chemical  Treatment  of Effluent Used
        in Appleby-Frodingham Works	,,...,.,,  22
                                     IV

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                                   TABLES


Number                                                              Page

   1.  Comparison of Techniques .'.._.,	 . _. ,	4
                                                                 t
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                              ACKNOWLEDGMENTS

     He gratefully acknowledge the  following for  their assistance and
cooperation in support of this project:   Dr. K. S.  Goto, Tokyo  Institute
of Technology, Dr.  R.  I.  Cooper,  British  Carbonization Research Association,
Dr. B.  J.  Borne,  Water Pollution  Research Laboratory, Stevenage, Herts, U.K.,
Dr. Dennis Finn,  IIT Research  Institute,  Chicago,  IL, and  Dr. George $t,
Pierre, Professor of Metallurgy,  Ohio  State University, Columbus, OH.

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                                 SECTION 1

                                INTRODUCTION

     In 1971, the International  Iron and Steel  Institute set up a Committee
on Environmental Matters to demonstrate its active support of measures to
conserve and improve the quality of world environmental  conditions,   It did
not attempt to minimize the complexity of the overall  problems faced by the
steel industry.  The institute did believe, however, that acceptable solutions
could be achieved by an exchange of information among industries on  a world-
wide basis, as well as by voluntary cooperation with local control and con-
servation organizations.

     At present, significant problems remain to be solved.  In response to
this, the iron and steel industries of the United States, Japan and  West
Germany have been steadily increasing investments in pollution control.  In
the United States, the steel industry ranks among the leading manufacturers
in capital expenditures for pollution control.   A survey conducted by McGraw--
Hill1, shows th'at between 1971 and 1972, the United States steel industry
spent $400 million on air and water pollution control  -  about 8 percent of the
total spent ty all manufacturing industries.  In 1973, the steel industry's
pollution control expenditure was $276 million or 13,6 percent of the total
expenditures of the steel industry.  By 1976, that figure increased  to an
extimated $517 million spent on pollution control or an  estimated 18.8
percent of total expenditures.

     The figures available for Germany and Japan also indicate a steady
growth in pollution control investment.  Between 1970 and 1974, the  German
investment grew from 7.3 to 12 percent of the total capital investment.
Similarly, the Japanese industry increased its investment from 4 to  20
percent in a matter of 10 years.

     The U.S. iron and steel industry thus compares very favorably with
foreign plants.  Most of the Japanese and Western European plants,  however,
are relatively new, which makes it easier to implement the use of newer
equipment and techniques.

     The objective of this study was to survey foreign techniques in water
pollution control and to identify any advances which might be studied for
transfer to the Unived States iron and steel industry.  Since the limited
fresh water supply in Japan and areas of Western Europe necessitate  a high
degree of water recycle, this survey focused on water pollution control
techniques of iron and steel plants practicing either a  high degree  of water
JIron and Steel International, June, 1974, pp.  228-237

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recycle or exemplary pollution abatement capability,

     In the report, the Japanese iron and steel  plants  are  considered  as  one
group, and the Western European plants as another one.   The guidelines set
by the different countries have been obtained,  and the  actual  performance of
the exemplary plants are compared with these guidelines wherever  possible.
This report also includes conclusions and recommendations which are  concerned
with the applicability of some of these exemplary techniques.  Some  recom-
mendations have been made suggesting improvements in methodology  for col-
lecting information on a project of this nature.

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                                 SECTION 2

                                CONCLUSIONS

     In general, Japanese and British steel plants use more  saline  water  than
their U.S. counterparts, who usually rely on fresh water sources,   from the
available data, Bethlehem SteelKs Sparrows Point is the only American  plant
using seawater.  Since fresh water is cheap and readily available in the  U.S.,
American plants recycle from 15 to 80 percent of the fresh water.   Japanese
plants, however, recycle about 90 percent of the fresh water used, '

     The British steel plants also have a high degree of fresh  water recycling,
2 to 90 percent of the water used from all sources.  Higher  degrees of
recycle are practiced in the inland plants, whereas the smaller figures are
for coastal plants using sea water.  Plants using saline water  recycle only
their fresh water.  The techniques used by the British and other Western
European plants are similar to those of American plants.  For example, the
British Carbonization Research Association has been conducting  research on
the biological'oxidation process for effluent control,

     The Japanese industry uses some relatively modern techniques,  examples
of which are:
     (1)  dry coke quenching,
     (2)  ton exchange resin method for pickling rinse waste water  treatment.

     Based on discussions with our fn-house experts, we conclude that;
     (1)  U.S. iron and steel plants do not practice water recycling to as
          high a degree as the foreign plants, primarily due to the avail-
          ability of cheap and plentiful fresh water in the  U,S,
     (2)  Japanese plants use modern techniques because their plants are
          newer.  U.S. plants could also implement these techniques, given
          sufficient incentive and space.

     Table 1 is provided for comparison of U.S. and foreign  plants,   (More
information is clearly needed from Western European plants.) As can be seen,
the dry coke quenching (DCQ) and the ion exchange processes  are exemplary
techniques used by the Japanese industry.  As can be seen by comparing data
on pollution control investments, the U.S. iron and steel plants rate
favorably with foreign plants.

     It is not feasible in this survey to perform an economic analysis of the
applicability:of transferring foreign techniques.  In order  to  generate
specific data it would be necessary to do an in-depth study  on  a case  by  case
basis.   This type of analysis was beyond the scope of this survey report.

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                                                 TABLE 1
METHOD
                              U.S,A,
           COMPARISON OF TECHNIQUES

                    JAPAN           BRITAIN
                                                                              W, GERMANY
1. Use of seawater
2. Degree of freshwater
     recycle
3. Physical  treatment
     (settling, filtration,
      etc.)

4. Ultrahigh Rate filtration

5. Dry Coke  Quenching
   process
Used at Bethlehem
Steel's Sparrows
Point Plant
                              Not in use
6. Ion Exchange Process for   Not in use
     the Pickle Liquor Wastes
7. Biological  Oxidation
     Process

8. Pollution Control
     Investment (% of
     Capital Investment)
                              -18.1
V
**N.A.
***
        Technique currently in use
        Information not available
        Estimate
                                                   /
                              A very wide range,  around
                              depending on the    90%
                              age of the plant
                              and location
                                                  16-20%
                                                                               N,A,  **
                                                                   around      N.A.
                                                                   90%
                                                                    N.A.         N.A.

                                                                   Not in use   N.A.
                                                                   In the be-   N.A.
                                                                   ginning
                                                                   stages
                                                                    N.A,
                                                                                     ***
                                                                                             ITALY
                                                                                            N.A.
                                                                                             N.A.
                                                                                             N.A.

                                                                                             N.A.


                                                                                             N.A.
                                                                LA.

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                                 SECTION 3

                              RECOMMENDATIONS

     Further research into foreign iron and steel  pollution control  should
be conducted.  In order to evaluate the feasibility of technology transfer
and to verify the specific operational state-of-the-art in Europe and Japan,
more in-depth, operational information on a wide range of steel  plants is
required.  There is also more information available than this survey covered.
For example, new guidelines are currently being formulated by government and
industrial committees.  This information, combined with specifics obtained
through site visits, should result in a more accurate prediction of the
utility of technology transfer of foreign water recycle and pollution con-
trol techniques.

     A general study of steel plant parameters correlated with effluent
levels would answer some applicability questions.   Ranges of plant size,
age, output, and water source characteristics could be matched to ranges
of pollution capability, yielding data helpful in  technology transfer analysis,
It must be noted that recycle and pollution control systems are designed on
a case by case basis.  Thus, before a new pollution control system can be
recommended, a case by case analysis of the above  variables should be per-
formed .

     We would also suggest that distance and language barriers could be
eliminated by on-site activity.  Delays in translating questions and re-
ceiving information would thus be minimized.  On-site interviews might also
alleviate some of the hesitation of steel companies to discuss their pol-
lution control data.  An intergovernmental agreement or project might also
facilitate access to these plants.

     Another area of research would be in-depth studies of individual ex-
emplary plants.  Exemplary plants with the newest, model equipment can be
either those recently constructed, such as Nippon  Kokan Corporation's
Ogishima plant or older plants with recent pollution control retrofit.

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                                 SECTION 4

                        THE JAPANESE STEEL INDUSTRY

     The Japanese iron and steel industry is one of the more sophisticated
 in the world.  The Japanese have built many modern steelmaking facilities
 during the last decade.  With every year, regulations for environmental
 control in Japan have become progressively stricter.  The Japanese industry
 currently spends 16 to 20 percent of its capital investment on pollution
 control2.  As can be seen from Figure 1, the proportion of pollution control
 investment has increased from 4 to 20 percent in a span of 10 years3.  This
 20 percent compares with a 18.8 percent for the United States and about 12
 percent for West Germany.

     According to Mr. Minora Mizuno (General Manager, Environmental Control
 Department, Nippon Kokan Corporation), the following are recent developments
 in water pollution control in Japan1*:
     (a)  Over 90 percent of the water used at the Japanese Steel Works
          is recovered.
     (b)  Coke Oven Gas Cooling H20 is treated by the activated Sludge Process,
          Aerobic bacteria remove the ammonia and phenol.

OPERATING DATA FOR  A  JAPANESE  IRON  AND STEEL  PLANT

     We shall  examine more closely  the operation  statistics of an  exemplary
Japanese iron and steel  plant5,  which  has  invested  about 20 percent of  its
capital in  pollution  control  equipment.   The  plant  has  one blast  furnace  with
a capacity of 4«3 x 106 Kg of pig  iron per day and  two  basic  oxygen furnaces
that each process 0«25 x 106  Kg. of steel  each.   Seawater is  used  as  a  coolant
for the plant's electric power station.   When the water leaves the system,
there is no further contamination  except thermal.   This water must be returned
to the sea  with a maximum temperature  of 38 C.   This  is a difficult standard
to meet during the  summer.  No information has been provided  on corrosion
levels or corrosion inhibiting techniques  used by the industry.   This seawater
should be treated before use as  a  coolant.  Some of the commonly  used tech-
niques are:
^Chemical and Engineering News,  July 28,  1975,  pp.  10-11.
 Transactions of the Iron and Steel  Institute of Japan,  Figure 12, Vol.  17
 No, 8, 1977, pp, 441.
 Steel Times, May, 1973, pp, 388,
Unpublished information provided  by Dr.  K.S. Goto, Tokyo  Institute of Tech

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     billion Ym
         3
         •r,
                           (Snrvrv t»\ tho Mim^trv of InlrriKiliitital I riuli- ;tnd

                                 I           '            i
                    1967
1976
Figure  1.Investment in Japans  steel industry for  pollution

          control  equipment.                  ,       „„_,_,  ft.
Trans  Iron & Steel  Institute  of Japan,Vol  17,No 8,1977,p441
Reprinted with  permission

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     1.   Ion Exchange
     2.   Electrodialysis
     3.   Reverse Osmosis

     The daily intake of process water is 1-3 x  109  Kg.  of which  1*27  x  109  Kg.
or 97.8 percent is recycled.   30 x 106 Kg. (_2,2  percent) is consumed on  a
daily basis in this plant.

     The plant has four water storage pools and  nine units of wastewater
treatment systems, of which two use the activated sludge process  with  acti-
vated carbon.

     Table 2 compares the operating characteristics  of this plant with
Japanese regulation values.  As can be seen, operating values are uniformly
better than the regulation value.  The regulation values give us  an idea of
the Japanese effluent guidelines.

     The data in Table 2 were obtained with considerable effort as Japanese
steel plants are very secretive about their operating values.  It is our
feeling that further efforts  should be made to obtain the operating data of
all exemplary plants, as well as the transfer of technology from  this  plant
to the United States.

     Some of the pollution control efforts of Nippon Kokan Corporation (NKK)
and Nippon Steel Corporation  (NSC) were exemplary.   NKK's efforts are  briefly
described as we]! as several  specific techniques used by NKK and  NSC.

THE NIPPON KOKAN CORPORATION  (NKK)

     NKK, the second largest  steel corporation in Japan, spent about $163
million for pollution control between 1971 and 19746.  It is now  calculated
that steelmaking pollution costs are about $6,00 per 1000 ;KgJ ingot. NKKKs
Ogishima project, scheduled for completion by the end of 1978, has been
heralded as the most modern plant in the world7.  Its operating values are
similar to those shown in Table 2.  The Keihin works is  currently being
phased out and is being replaced by the Ogishima plant.   The first phase is
already operational.

The Fuluyama and Keihin Works

     The water treatment equipment at Fukuyama incorporates design technology
obtained from the United States:
     0    The cascade method  of recirculation, which separates the water
          according to its quality.
     •    Ultra-high-rate filtration for treating direct contact  water at
          hot and cold strip  mills.

     The plants at Fukuyama and Keihin have very high water recirculation


6Iron and Steel International, June 1974, pp. 205-227.
7Iron and Steel International, Vol. 50, No. 2, April, 1977, pp. 75.

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                                                TABLE 2
COMPOSITIONS OF
(Average Values of
CONSTITUENT
pH
COD (rag/1)
TSS
Oils (mg/1)
Soluble Iron
Soluble Mange
BOF DUST
WATER
A
8,0- 8.
4
14 -15
<3
(mg/1) 0.70
mese <0.02
CATCHER
B
3 5,8- 8,6
<2Q
<30
<3
3
1
Operation
SPRAYWATER
CONTINUOUS
SLABS
A
8,2- 8,3
WATER AFTER TREATMENT
Data Over a Period of 4 Months).
OF COKE OVEN WATER ROLLING MILL WATER
CASTING (ACTIVATED SLUDGE)
B A B A B
5.8- 8.6 6S6- 7,1 5^8- 8,6 7,6- 7.7 5,8- 8.6
4-5 <2Q 9 -31 30 4 <20
<5 <30 5 -12 30 5^8 <3Q
<3
<0,02
<0.02
<3 <3 <3 <3 <3
3 „ - 
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rates:  88 percent at the Keihin and 93 percent at the Fukuyama Works.   Part
of the water for cleaning blast furnace gas is circulated through a thickener
to trap suspended solids and is then reused.   Another part is used for  cooling
the blast furnace slag.  Pollutants in coke oven waste ammonia liquor such as
phenol and cyanides are removed by an activated sludge process.  At Fukuyama,
a 2400 m3/day treatment plant was installed at the cost of about $3 million,
In order to eliminate any coloration which might be present,  NKK utilizes a^
treatment plant, wherein coagulation, sedimentation, and filtration activities
take place.

     Water discharged in the cold strip mill  is treated by dissolved air
flotation with coagulating agents.  Water from surface treating processes is
discharged after reduction, neutralization, and sedimentation.

     Water containing high concentrations of hydrochloric acid is first
treated to recover the acid and then reused.   A 60 x 103 Kg/day capacity
drying plant is maintained at the Keihin Works, where sludge  is neutralized,
dehydrated, and then dried in a rotary kiln for recovering iron materials.

     At the Keihin Works, a $1.0 million incineration plant processes oily
sludge and waste at a rate of about 800 x 103  Kg/month.  The  oil separated
from the waste is used for fuel.  At the Fukuyama Works, a $1.5 million
incineration plant processes oily wastes and  other refuse at  a capacity of
4-2 x 106 Kg/month.

SPECIFIC PROCESSES USED BY THE JAPANESE IRON  AND STEEL INDUSTRY

     The Japanese steel industry utilizes some new and exemplary techniques
for controlling its water pollution, such as  dry coke quenching and ion
exchange treatment of pickle liquor water.

Dcy Coke Quenching (DCQ)

     The dry coke quenching process is a novel  technique devised by Russian
scientists and perfected by the Japanese (initially by the Nippon Steel
Corporation).  It has not yet been implemented in any American plant.

     The process has the following advantages:
          it is a closed system.
          it eliminates the use of water
          it saves energy.
          it reduces pollution.
          it yields a better quality coke (no  impurities and  a better
          crystalline structure).

     In DCQ, hot coke pushed out from the ovens is  quenched with recirculatino
inert gas instead of water.  Figure 2 represents the flow chart for the DCO
process.  Red hot coke is carried to the top  of a quenching chamber and
dumped into its pre-chamber.  It gradually descends  from the  pre-chamber to
the cooling chamber, where inert gas absorbs:  heat  from the coke   The  cooled
coke is then discharged from the bottom of the  quenching chamber'   The  gas
                                     10.

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                 Coke
              rox. I.IHIU'C
          Cooling Chamber
                                                                                            Cyclone
FIGURE 2    DRY COKE QUENCHING PROCESS
            Transactions  Iron & Steel  Institute of  Japan, July, 1977, Reprinted with permission.

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heated to temperatures of about 800 C,  Is  led to a  waste  heat boiler,  after
its dust has been removed, to produce the  stream for heat recovery,'8   The
cooled gas is sent back to the cooling  chamber for  circulation.   NKK currently
has 5 DCQ units, each with a  quenching  capacity of  about  70 x 103 Kg/hr.

Ion Exchange Resin Method for Pickling  Rinse Mater  Treatment

     The pickling process is  a very important step  in an  integrated steel
plant.  Some 50 percent of the products produced in an integrated steel
works undergoes acid pickling.9  Water  is  used both for diluting the sulfuric
or hydrochloric acid in the acid bath and  for washing to  steel  in the  rinse
tank.  This accounts for a large quantity  of water  which  should  be treated.

     The usual  method for treating this wastewater is by neutralization  and
settling.  This procedure, however, produces a large amount of sludge  re-
quiring costly disposal and treatment.   NSC, in joint research with Mit-
subishi Chemical Industries Limited, has developed  a new  process which
employs direct ion exchange for the effective treatment of rinse wastewater
generated by acid pickling. While already  an exemplary Japanese  technique,
it has not yet been implemented by any  American plant.

     Figure 3 is the flow diagram for the  NSC ion exchange process.  It  is
much simpler than conventional processes and offers several  advantages.   The
influent water to the ion exchange process contains 50-200 ppm Fe2  ions
and 100-500 ppm Cl" ions.  This rinse wastewater i$ directly introduced  into
the cation exchange resin column to remove the Fe2   ions  and subsequently
into the anion exchange resin column to remove Cl"  ions and obtain pure  water.
This pure water is then recycled as rinse  water.

     The cation exchange resin is regenerated with  highly concentrated hydro-
chloric acid and the regenerant waste solution is used as a  supply of  supple-
mentary pickling acid.  The anion exchange resin is regenerated  with caustic
soda and its regenerant waste solution  is  used as a fume  scrubbed absorption
solution for hydrochloric acid pickling or as an alkaline deoiling solution
preceding the pickling process.  Both washing and backwashing water for
resin regeneration are taken  from the effluent (treated water);  the water
is mixed with rinse wastewater for ion  exchange treatment.

     The process features are:
     •    The process is closed:   no water is being discharged from the
          system and chemicals and agents  are effectively economized.
     •    The process does not produce  any secondary waste  such  as sludge.
     •    Because the process  supplies  its own pure water as it  treats
          wastewater, water supply and  drainage costs  are lower  than those
          of conventional  throwaway systems.

8Transactions of the Iron and  Steel  Institute of Japan, Vol. 17, No. 8,  1977
 pp.  437-438                                                       '   '      '
9Private communication from Nippon Steel Corporation.   Brochure  from NSC's
Plant and Machinery Division,  Engineering  Divisions Group on Nippon Steel's
Ion Exchange Resin Method for  Pickling  Rinse Wastewater Treatment.
                                    12

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Steel Product-
Pickling Tank
(acid bath)
Rinse  Tank
                                          Storage Tank
                                          (pH control)
               To Pickling Tank •*	/Cation  Ex-
                                          change Column
                          HCI	l
                              (regeneration)
         To Fume Scrubber
    , etc. ••	f Anion Ex-
             	jchange ColumnJ
                          NaOH
                             (regeneration)
^Pickled Steel
'Product
                                                                Effluent Tank
                      FIGURE 3,   NIPPON STEEL CORPORATION ION EXCHANGE PROCESS

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     c    The process operates  automatically,  reducing  labor  requirements.
     e    Because water is  recycled,  effective water  resource utilization
          is assured.
     e    In conventional  processes,  rinse  water  is heated  before  rinsing
          begins.  In this  new  process,  water  heating energy  requirements
          are reduced.
     •    The process obtains pure  water as its effluent  and  recycles  it
          as rinse water,  which in  turn  improves  rinsing  efficiency.

     Nippon Steel Corporation treats  rinse  wastewater from  the acid  pickling
section of its Kimitsu Works  by ion exchange for  purposes of  environmental
protection, water resource  economization, and  cost reduction.   The commercial
plant began operations in  1975.

     The following are the  operating  data from the Kimitsu  Works of  Nippon
Steel Corporation:

     Influent flow rate                 60  m3/hr  (max.)
     Influent properties                Fe  <200 ppm
                                        Cl  <500 ppm
     Effluent properties                Fe  <0.1 ppm
                                        Cl  <1.0 ppm
                                        Electric  conductivity
                                         <20ymho/cm
     Resin volume                       Cation Exchange Resin
                                         2.7m3x3
                                        Anion  Exchange  Resin
                                         5.1m3x2
     Operation practice                 2 lines alternate operation
                                        Full automatic  operation

     NSC claims that despite  varying  influent  properties, the effluent quality
is extremely good and stable:
     Fe <0.1 ppm
     Cl <1.0 ppm
and  pH ~7 (electric conductivity lower  than lOymho/cm.

     The effluent is repeatedly recycled as rinse water and its clarity
results in improved rinsing as  compared  to  conventional filtered water.

The Treatment of Coke Oven Liquor5

     The flow chart for this  process  in  shown  in  Figure 4.  About  80-90xl03Kg/
hr of coke oven liquor leaves the coke oven.   The concentration of ammonia
in this stream is about 6000-9000 mg  NH3/liter of solution.   Coke  oven liquor
is first sent to a tar decanter, where the  tar is removed.  The liquor is
then sent through coke filters  to the ammonia-water tank.   The ammonia
content is reduced to about 500-1100  mg/liter.  The rest  of the ammonia is
removed by steam stripping.  This process involves stripping  the NH3 by steam
under slightly alkaline conditions  (pH = 8).   The process stream is  then
neutralized by HaSO^.  The COD  of this steam is about 3000  mg/liter    The
                                     14

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en
           From
           Coke Oven
Neutralizer
    A
Coke  Filter
                               Air
                                      Mixer
                                                                                           Water

                                                                                        Steam
                                                                v~.   --
                                                              r©-l
                                                           *>  * \
                                                                                        NH3
                                                                                        Is  Taken Out
              Kl
              O
                      Return  Of A  Part Of Sludge
                      Activated
                                       V 1 V
Sludge Pool

                         Excess Sludge
                                                              Coagulator (FeCl3, PAC, Ect.)
                                                              •         o
    Coagulation  And
   Descending  Of  S.S.
                                                            Siudge



1
t
^

c
.
                                                              Treated
                                                               Water
                                                                                            Filter
                                                Phosphite
                                                  Tank
                                                                      Active
                                                                      Cartoon
                                                                                                      Treated  Water
                                                                                                     (To Be Recycled!
                                  FIGURE 4.   FLOW SHEET OF WATER  TREATMENT FROM COKE OVEN

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 is sent to the activated sludge pool  where the organics  are decomposed by the
 bacteria at 20-30 C.   The product stream from the activated sludge pool^pro-
 ceeds to the thickener where ferric chloride (FeCl3)  and other coagulating
 agents are added, reducing the COD of duct stream from this step to 90 mg/
 liter.  From this point, the product stream flows through sand filters to
 remove any suspended  solids and through an activated  carbon tower to remove
 any color.

      The activated sludge process involves an aerobic reaction in the presence
 of bacteria.  The organic contaminants contained in the  wasteware are
 biochemically oxidized by the activities of the aerobicr  bacteria in an aera-
 tion chamber.  Bacteria thus flocculated are sedimented  and separated out as
 sludge leaving treated water.

      To ensure a proper balance in the treatment process, a sludge disposal
 unit is usually annexed to the system to eliminate a  part of the organic
 phase which increased as a result of bacterial  multiplication.10  A portion
 of the sludge is recycled to maintain some bacterial  activity.

      The following operations data were obtained for  a sludge disposal unit^:

                               Initial              Final

           COD                 3000 rog/1           13  rag/1
           NH3               6000-9000 mg/1        0  mg/1

      The composition  of the effluent stream from the  process is as follows:

           TSS = 5-12  mg/1
           pH = 6.6 to 7.1
           N-Hexane =  <3 mg/1
           Phenol = <0.05 mg/1

      This process is  usually split into two parts AB  and BC, as represented
 in the flow chart. The second part of BC removes color.   Most Japanese
 plants using the process implement only the first part,  AB.   Since all the
 water recovered is used for process purposes, color would not cause problems.
1"Brochure of Japan Gasoline Company (JGC Corporation),  a  specialized
plant engineering company.                                  K
                                     16

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                                 SECTION 5

                    THE WESTERN EUROPEAN STEEL INDUSTRY

     The iron and steel Industry in the United Kingdom, West Germany, Italy,
and Spain, and Belgium was examined.

The British Steel Industry

     The British Steel Corporation CBSC) is the largest iron and steel  manu-
facturer in the United Kingdom.  For a BSC plant which produces 15-9xl09Kg/yr
of pig iron and 24-2xl09Kg/yr of crude steel, the water intake is 2-43xl03m /
day.lf

     Table 3 shows the distribution of water intake on a percentage basis.12

     Where industries are located close to the coast, the tidal waters  (non-
fresh water) can be used.  Fresh water, which is comparatively .scarce,  is
recycled and reused to a great extent.  The degree of recycling varies  from
2.6 percent for plants using tidal water to 97.8 percent for plants at  inland
works.  The various effluent control techniques used for different process
streams are discussed in the following section.11

Coke Ovens and Byproducts Wastes

     The disposal of these wastes, particularly the spent ammoniacal  liquor,
is a very difficult problem.   These effluents amount to about 6500 ppm  of
coal carbonized and contain substantial amounts of toxic compounds such as
phenols, thiocyanates, thiosulfates, chlorides, and fixed ammonia.  Table
4 gives the approximate composition of spent ammoniacal liquor obtained in
BSC plants.
"Speight, G.E., Davis, C.M., "A Review of Water Supplies and Effluent Dis-
posal," unpublished works, private communication from Dr. R.L. Cooper of the
British Carbonization Research Association (BCRA).  This work is based on a
survey of water usage of BSC, 1968-69.
12Cook, G.W., "Conservation of Water by Reuse at the Appleby-Frodingham
Steel  Works, Scunthorpe," Iron and Steel International, October, 1974, pp.
393-402, Table on p. 394.
                                     17

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                                  TABLE 3

DISTRIBUTION OF WATER INTAKE - BSC (Appleby Frodinqham) FOR THE YEAR ENDING
                    MARCH, 1976 - (FORECASTED ESTIMATET2            ~

     PROCESS                           % OF TOTAL MATER INTAKE

     Sinter Plants                                9.3

     Blast Furnace Cooling                       10.2

     Blast Furnace Gas Cleaning                   6.4

     Blast Furnace Blowing                       10.8

     Coke Ovens                                  14.7

     Steelmaking - BOF                            6.2

     Continuous Casting                           4.2

     Rolling Mills                                6.6

     Electrical Power Generation                  5.1

     Steam Raising                               12.0

     Domestic Purposes                            4.2

     Slag Quenching                               4,4

     Miscellaneous Users                          j>.9

                                                100.0%
  Reprinted with permission
12Iron and Steel International,  October,  1974,  pp.  394
                                    18

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                                  TABLE 4

             APPROXIMATE COMPOSITION OF SPENT AMMONIACAL LIQUOR
            	IN BRITISH STEEL CORPORATION PLANTS
                     CONSTITUENT                 ppm

                     Total Phenols              1500
                     Thiocyanate                 250
                     Thiosulphate                350
                     Chloride                   3000
                     Ammonia (.Free)              250
                     Ammonia (Fixed)            1200
The biological oxidation process (activated sludge) is quite frequently used
for the disposal of these effluents.  Under favorable conditions—no  heavy
influx, no sudden variations in temperature, a very large retention time--
the process completely eliminates phenols and over 70 percent of the  thio-
cyanate and thiosulphate present.  However, the standard activated sludge
treatment process does not affect the fixed ammonia content.  Thus, further
treatment is necessary if the standard activated sludge treatment process
is used.

Blast Furnace Gas Mashing Maters

     The amount of solids collected in wash water (suspended solids)  can be
as high as 4000 ppm.  These solids are usually separated as sludges after
settlement and thickening.

     The presence of cyanides and zinc, which are evolved from the blast
furnace and are collected in the washing waters, poses additional  problems.
The level of these pollutants are so high that this water cannot be discharged.
The water is utilized in some BSC plants, however, for evaporative reuse
such as slag quenching or sinter cooling.

Fume Cleaning from Oxygen Steelmaking

     The amount of fume from such oxygen steelmaking processes as the LD
converted, Kaldo, rotor, and electric arc processes is substantial —
32-5 - 43-4 x 10~3Kg/Kg of steel, and the concentration of solids in  the
washing water is often up to about 10,000 ppm.  Recirculatory systems with
sedimentation and filtration units for the separation of the iron oxide
sludges are normally employed.

Hot Rolling

     The main contaminants here are mill scale, oils, greases, and sludges.
Circulatory systems are used with scale pits, settling ponds, and oil skimming
facilities for the coarser materials and clarification and filtration units
for final cleansing of water before reuse.  Some of the BSC plants use a
                                     19

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purge discharge which controls build-up of dissolved salts in the circulating
water.

Acid Pickling Solutions

     These pose a very difficult effluent problem.   Neutralization of the
sulfuric acid solutions with lime had been practiced, but this is an expensive
process, and it is difficult to dispose of the sludge produced.  Hence, acid
recovery and regeneration processes have been given more importance.  Several
forms of acid recovery processes, based on the precipitation of ferrous
sulfate heptahydrate or monohydrate with consequent enrichment of the acid
content of the remaining liquor have been practiced.

     Although sulfuric acid pickling is still being widely practiced, the
trend in the British steel industry has been towards hydrochloric acid
pickling combined with regeneration of the acid from the spent liquor.  BSC
has one of these plants currently under operation,  and quite a few more are
under construction.

Cold Rolling

     The wastes from cold rolling are contaminated  with rolling oils, deter-
gents, and metallic particles.  The effluents are initially skimmed and
settled.  The stream leaving this step is acidified with spent pickle liquor
or an acidic rinse water to break down the emulsions.  The free oil is then
skimmed off and,the remaining liquor neutralized and clarified.

      Table 5 gives the maximum permitted effluent levels of toxic constituents
from  blast furnace gas cleaning water recycling systems.  The data is from
the Appleby-Frodingham works of the British Steel  Corporation.13

                                  TABLE 5

BLAST FURNACE GAS CLEANING SYSTEMS - MAXIMUM CONCENTRATION  OF TOXIC CONSTITU-
	ENTS IN TREATED EFFLUENT WATER13	

     CONSTITUENT                        MAXIMUM CONCENTRATION - Mg/1

     Suspended solids                              30.0
     Dissolved solids as fluoride                  25.0
     Dissolved zinc or lead                         1.0
     Free cyanide                                   0.1
  Reprinted with permission.
13Cook, G.W., "Conservation of Water by Reuse at the Appleby-Frodingham Steel
Works, Scunthorpe," Iron and Steel  International, October'  1974  pn  401
Table on 401.                                                  '        " f
                                     20

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The Appleby-Frodingham Works of British Steel Corporation

     The Appleby-Frodingham Works in Scunthrope is considered to be a world
leader in steelmaking efficiency,ll*  The extent of water reuse here has been
steadily increasing.  Between 1972 and 1976 the total consumption expressed
as Kg of water/Kg of steel has decreased from 4,94 to 2,74,  During the same
period, the steel output has increased from 1.44 x 109 Kg to 4^50 x 109 Kg.
The Appleby-Frodingham Works uses pnysical, chemical, and biological methods
of treatment either separately or in conjunction with each other.

Physical Treatment—

     The water from the primary scale settling pits is lead to four rectangu-
lar clarifiers, each equipped with a traveling bridge scraper, and then to
12 horizontal sand pressure filters.  The filters, designed for high specific
filtration rates of 14.8 to 16.0 m3/m2/hr, operate and clean automatically.
The suspended solids content of the water is reduced to not more than 5 ppm.
The filtered water is cooled to below 29°C in a three-cell open evaporative
cooling tower before being recirculated.

Chemical Treatment--

     The water used for blast furnace gas cleaning is treated by a chemical
process.  This stream contains not only dust particles, but also contaminants
such as zinc, lead, cyanide, and fluoride.  Table 6 gives an analysis of the
recirculating water in the blast furnace gas cleaning system.  Figure 5 shows
the flow diagram of this chemical process.

                                  TABLE 6

ANALYSIS OF RECIRCULATING WATER IN BLAST FURNACE GAS CLEANING SYSTEM AT
       .	APPLEBY-FRODINGHAM13	


     CONSTITUENT                             VALUE

     pH                                        8.4
     Suspended solids                         30.0 mg/1
     Dissolved fluoride                       85.0 mg/1
     Dissolved zinc                           10.0 mg/1
     Dissolved lead                            4.0 mg/1
     Free cyanide                             10.0 mg/1
From Iron and Steel International, October 1974, pp, 401, Table 4
,,  Reprinted with permission                       -, ,   „ „   -,  ,..
""Appleby and Frodingham from the 1860's to the 1970's," Steel  Times, Vol
203, No. 6, June, 1975, pp. 407-498.
                                     21

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                                                                                                   Sulphuric
                                                                                                     Acid
l\3
                                                       Reaction/
                                                       Sedimentation
                                                       Tank
Sludge
Disposal
                                                                                                       Treated
                                                                                                       Effluent
                                                                                                        Discharge
              Figure 5.Effluent treatment process  for removal of lead,zinc,flouride and free cyanides
               Steel Times,June 1975,p496
              Reprinted with permission

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     Lime is added to the incoming liquor to raise its pH to between 11,a and
12.2.  This alkaline condition is necessary for the oxidation of the cyanide
and the precipitation of the zinc, lead, and most of the fluoride.  Chlorine
is injected as the liquor enters a 'circulator1 reaction/sedimentation tank
which is designed to give intimate mixing of the chemicals with the liquor
and allow adequate time for subsequent settling of the precipitates.  The
precipitated solids are withdrawn as a sludge which is returned to the blast
furnace gas cleaning slurry lagoon.  The clarified water from the circulator
is fed through pressure sand filters to a neutralization tank where sulfuric
acid is added to restore the pH value to between 5 and 9.  The lime silo,
acid storage tank, filter wash water tank, and controls permit the plant to
be self-contained and automatic in its operation.  The effluents leaving
this process meet the standards shown in Table 5.

Biological Treatment—

     Appleby-Frodingham Works uses a central plant for the biological treat-
ment of the effluent from three coke oven plants and two tar distillation
plants.  The effluents, totalling an average of 3-075 m3/min, are collected
in a reservoir with a capacity of 3180 m3 located at the treatment plant.
This liquor is diluted by adding a maximum of 0-71 m3/min of 'clean1 drainage.

     The mixed liquor from the reservoir is fed into nine aeration cells,
each fitted with a surface aerator.  For the purpose of sludge recirculation
and  solids removal, the nine cells are operated as three stream flows to a
separate clarifier so that under normal operation, biological sludge is
returned only to those cells serving the particular clarifier,

     The supernatant liquor from the clarifiers flows by gravity to a tidal
storage reservoir of 3200 m3 capacity before discharge.

The  Other Western European Works

     Information as detailed as that obtained from Japan and Britain was
not  accessible from other Western European countries.  The problems were
primarily caused by a language barrier, plus a hesitancy of plant officials
to discuss the possibility of pollution.  The information presented here is
essentially from published literature available in the English language.

West.Germany

     German pollution control investments have been climbing sharply in the
last few years.  Between 1961 and 1970, 7.3 percent of total capital invest-
ment of the German steel, industry was allocated to pollution control.  Figures
for  1973 indicate the pollution control investment to be around 12 percent.
Between 1969 and 1971, the amount expended by the steel and metal working
industry for investment maintenance and research represented in the aggregate
34.4 percent of all monies spent by German industry on pollution control.15

15Theegarter, H.F., Von Hartman, R.K,, "Hoesch Huttenwerke's Hot Strip Mill
Water Supply System," Iron and Steel Engineer, August, 1973, pp. 67-74.
                                     23

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      The  data  In  Table  7  represent West  German  effluent  guidelines  as  of 1973.

                                  TABLE  7

     	PERMISSIBLE IMPURITIES  IN  INDUSTRIAL WASTE HATER15	


           Temperature °C                        30
           Settling materials, ppm                1.0
           Acidity, pH                            6.5-9,5
           Total Chromium  ppm                     4.0
           Copper, ppm                            3.0
           Nickel, ppm                            5,0
           Zinc, ppm                              5.0
           Total iron, ppm                       No limitations if  no  problems
                                                 with treatment are to be
                                                 expected.
           Cyanides, ppm                          1.0
           Oil, ppm                               0.0
   Reprinted with  permission
 i:>Iron and Steel  Engineer, August, 1973, pp.67.
 It  is understood that the German authorities are currently setting up even
 more stringent guidelines.  Unfortunately, despite repeated requests, we
 were unable to get any specific information on the newer guidelines.
      Like the Japanese and British plants, the Italsider plant at Taranto,
 Italy, also uses a large amount of sea water.  The plant treats coke oven
 liquor by means of ammonia stripping and the biological  oxidation process.
 Is also uses an interesting technique:  inflatable collars are fastened
 across the water outlet channel to remove oil films.16
     The Spanish pollution control guidelines date back to 1961   At the
integrated plant at Sagunto considered, great attention is paid'to keeoina
pollution to a minimum.                                               H  y

     It is interesting to note that although some research and development
is carried out, reliance on foreign 'know-how* is still  strong.17
16VandenBerge, H., "Analysis,  Measurement  and  Control  at  Italsider
Iron and Steel International,  Vol  49  .  No,  5,  October,  1976   on  W   ™
 Ward, R A.C    The Rise of the Spanish Ste.el  Industry!"  ffen and Steel
International, Vol 47,  No.  5,  October,  1976, pp. 353-360.
                                     24

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Belgium

     Belgium's water pollution control guidelines date back to legislation  of
March, 1971, with revisions in August, 1974 and August, 1976,   The  following
effluent guidelines for ferrous metal industries represent maximum  additions
which can be made to existing levels In the source waters,  The specific
guidelines of August 3, 1976, affected steel plants, cast iron foundries, hot
rolling, and similar speciality works that were out of compliance:

     1.   Five  C5) day Basic Oxygen Demand tBOD), 2Q°C; less than 3Q mg/1.
     2.   Temperature limits, "slag granulating" as a separate discharge,
          less  than 35°C.
     3.   For hot rolling and speciality steel works, limits for separate
          discharge only:
          a)    petroleum ether extraction:  20 mg/1
          b)    apolarity solids by carbon tetrachloride extraction,
                cold water:  15 mg/1

     Further guidelines revisions cited in August, 1976  give the following
maximums:

     1.   Cyanide  Coxidized by chlorination)               0.5 mg/1
     2.   Chemical Oxigen Demand  (COD)                   500.0 mg/1
     3..  Fluoride  (F  )                                   10,0 mg/1
     4.   Sulfates  (SOj                                2000,0 mg/1
     5.   Total Zinc                                       5.0 mg/1
     6.   Total  lead                                       1.0 mg/1
     7.   Diluted  iron                                     2.0 mg/1
     8.   Diluted manganese                                1.0 mg/1

     These  standards were proposed  for a five year  period, to 1981; they were
 published September  29,  1976,  in  the  Belgrisch Staatsblad  (the Belgian
 Monitor), a government  publication.
                                      25

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were:
                           APPENDIX A

                      SOURCES OF  INFORMATION

Data for this  project  were obtained by:

1.   Manual  searches  in  libraries,
2.   Computerized  searches,
3.   Telephone interview and TELEX,

The data bases that were searched through  our  Computer  Search  Center


APTIC:    A comprehensive resource on  all  aspects  of air pollution,
          its  effects, prevention, and control.
BIOSIS PREVIEWS:  Citations  on  all  aspects of  the  biosciences  and
          medical  research,
CA CONDENSATES:  Literature  on  chemistry,  chemical  engineering, and
          chemical aspects  of  the life sciences.
CHEMICAL INDUSTRY NOTES (CIN):   Articles from  over 75 worldwide^business-
          oriented periodicals  which  cover the chemical processing
          industries.
COMPENDEX;  Worldwide coverage of approximately 3,500 journals, publica-
          tions of engineering societies,  proceedings of conferences,
          and selected government reports  and  books.
ENVIROLINE:   Indexing and abstracting coverage of more  than 5,000 inter-
          national primary and secondary source publications reporting
          on  all aspects of the environment.
ISMEC:    Abstracts of significant articles in mechanical engineering
          from approximately 250 journals  throughout the world.
METADEX  (Metals Abstracts/Alloys Index):  International literature on
          the science and practice of metallurgy produced by the
          American Soqiety for Metals (ASM) and the Metals Society
           (London).
NT 1S:     Government-sponsored research, development, and engineering
          plus analyses prepared by federal agencies, their contractors,
          or  grantees.
POLLUTION ABSTRACTS:  Environmentally-related literature on pollution,
          its sources and control.
SCISEARCH:  Multidisciplinary index to the literature of science and
          technology, containing 90 percent of the world's significant
          scientific  and technical literature.
SSIE  (Smithsonian  Science Information Exchange):  Abstracts and  project
          descriptions on ongoing research in all areas of research.
                                     26

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The following is a list of organizations contacted:

0    Centre for Technical and Scientific Information and Documentation
     (TNO), Delft, Netherlands
     United Kingdom Chemical Information Service
     Danmarks Tekniske Bibliotek, Denmark
     Royal Institute of Technology Library, Sweden
     The Japan Information Center of Science and Technology, Japan
     Kinokuniya Book-Store Company, Tokyo
     Iron and Steel Federation of Japan -;>
     International Iron and Steel Institute, Belgium
     Umweltbundesamt (Federal Environmental Agency.), Berlin, W.Germany
     Netherlands Consul General, Chicago,  IL, U,S;A,
     German Consul General, Chicago, IL, U.S.A. •
     Italian Trade Commissioner, Chicago,  IL.U.S.A^
     Chamber of Commerce, Luxemburg City,  Luxemburg
     Swedish Counsul General, Chicago, IL  U.S.A.
     J.G.C. Corporation, Tokyo, Japan
     Nippon Steel Corporation, Tokyo, Japan
     Nippon Kokan Corporation, Kawasaki, Japan
     Krupp Industires and Steel Works, Essen, Germany
     Emission Technical  Institute, Baden-Baden, W. Germany
     Water Pollution Research Lab., Stevenage, Herts, England
     British Steel Corporation, Middlesbourgh, Cleveland, United Kingdom
     British Carbonization Research Assn., Wingerworth, Chesterfield,
     Derbyshire, United  Kingdom
     The Metals Society, London, United Kingdom
     Alkalide Inspectorate, United Kingdom
     Hydrotechnics, Inc., New York, NY, U.S.A.
     Engineering Science, Inc., Austin, TX, U.S,A.
     Department of the Environment, Water  Directorate, London, United
     Kingdom
     Aquatechnics, Chicago, IL.U.S.A.
     Gurnham Associates, Chicago, IL, U.S.A.
c    Stanley Consultants, Muscatine, IA, U.S.A
•    Hydro Science, Inc., Westward, NJ, U.S.A.

Sites  visited:

*    Inland Steel, East  Chicago, IN, U.S.A.
»    Hydrotechnics, Inc., New York, NY, U.S,A.
t    Belgium Consulate,  Chicago, IL, U.S.A.

A  general  bibliography is found in Appendix B.
                                27

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                                 APPENDIX B

                             GENERAL BIBLIOGRAPHY

 1.    "Acid Regeneration Goes Remote," 33 Mazazine, March 1973,

 2.    "Activated  Carbon Makes Water Clean,'* Envir. Set. and Tech., Vol, 10,
      No.  10,  October 1976,

 3.    "Anchor  and the Environment," Iron and Steel, Special Issue, April 1974.

 4.    "Appleby and Frodingham from the 1860s to the 1970s," Steel Times,
      Vol. 203, No.  6,  June  1975.

 5.    "Armco Takes Forefront in  Battle Against Air and Water  Pollution,"
      33 Magazine, June 1973.

 6.    NEIC - "Characterization and Evaluation of Wastewater Sources,"  U.S.
      Steel Corp., Irvin  Plant,  Pittsburgh, PA, Aug. 18-28, 1975, December
      1975.

 7.    NEIC - "Characterization and Evaluation of Wastewater Sources,"  U.S.
      Steel Corp., Homestead Wheel and Axle Plant, McKees Rocks, PA, August
      21-28, 1975, January 1976.

 8.    "Current Abstracts," Envir. Sci and Tech,, Vol, 10, No,  3, March 1976.

 9.    "Current Abstracts," Envir. Sci and Tech.* Vol 10, No,  10, October 1976,

10.    "Detoxifying Industrial Wastewaters," PAT Report-Env, Sci and Tech.,
      Vol. 10, No. 2,  February 1976.

11.    "Economic Growth with Environmental Quality," Envir. Sci. and Tech.,
      Vol. 11, No. 2,  February 1977.

12.    "Economic Impart  of Pollution Control Regulations on Steel Plants in
      the Makoning River  Valley," NTIS:  U.S. Depart, of Commerce-
      PB-256-228, April 28,  1976.

13.    "Environmental  Considerations of Selected Energy Conserving Manufactur-
      ing Process Options,"  Vol.  Ill, Iron and Steel Industry Report,
      EPA-600/7-76-034C,  December 1976.

14.    "Environmental  Control  in  the Steel Industry," Iron and Steel Inter-
      national , June 1974.
                                     28

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15.  "Environmentalists,,They Have a Little List," ,Envir. Sci. and Tech.,
     Vol. 11, No. 4, April 1977.

16.  List of End of Chapter References from an EPA Publication on Iron and
     Steel Manufacture.

17.  "Flame Spraying Reduces Pump Leakage at Wastewater Treatment Plant,"
     Welding Journal, November 1976.

18.  "DevelopmentJtoc_ument for  Interim  Final Effluent Limitations Guidelines
     and  Proposed New Source Performance Standards for the Forming, Finishing
     and  Specialty Steel.  Vol  II., Segments of the Iron and Steel Manufactur-
     ing  Point Source Category,"  EPA 440/1-76-048-6, Group I, Phase II.

19.  "Development Document for Advanced Notice of  Proposed Rule Making for
     Effluent Limitations  Guidelines and New Source Performance Standards
     for  the Hot Forming and Cold Finishing Segment of the Iron and Steel
     Manufacturing  Point Source  Category," EPA-440/1-75/048, Group I, Phase
     II,  March 1976.

20.  "German Pollution  Control,"  Envir. Sci & Tech., Vol. 11, No. 2,
     February 1977.

21.  "How to Keep Track of Key Developments in Metal Technology," Copy of
     Metals  Information Services, 1977.

22.  "Japanese  Industry Boosts Pollution Spending," Chemical and Engineering
     News,  July  28,  1975,  pp.  10-11.

23.  "Japanese  Steelmakers Make Progress in Fighting Pollution," 33 Magazine,
     February  1977.

24.  "Kaiser Steel  Corp.,  and  Water  Qualiiy," Report

25.  "The Krakatau  Steel Project:   Saga  of an Indonesian  Steel Rolling Plant,"
      Iron and  Steel  International, Vol. 50,  No.  2,  April  1977.

26.   "Major Techniques, Equipment and  Facilities Adopted  and  Designed  into
     the Keihin  Works  and the  Fukuyama Works  of Nippon  Kokan NKK,"  Iron and
     Steel  International,  Vol. 47,  No. 2,  June  1974.

27.   "1976 AISE Annual  Convention,"  Iron and  Steel Engineer,  September 1976.

28.   "Nippon Steel  Closes the  Loop on Acid Rinse Water,"  Back Cover  of Iron
      and Steel  International,  Vol.  50, No. 4,  August  1977.

29.   "The Ogishima  Project:   Japan's Newest Integrated  Works  Goes  Into Action,"
      Iron and  Steel  International,  Vol.  50,  No.  2, April  1977.

30.   "The Ogishima  Project - Steelmaking at NKK*s New Keihin  Works," Iron
     and Steel  International,  Vol  50,  No.  2,  June 1977.
                                      29

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31.  "Polish/U.S.  Symposium on Wastewater Treatment and Sludge Disposal,"
     Cincinnati, OH,  February 10-20,  1976, Vol.  II. NTIS:   PB-261-422.

32.  "Pollution Control  at Inland,  a  Long, Hard  and Costly Climb,"  33 Magazine,
     June 1974.

33.  "Pollution Control  is a Growth Industry,"  Consulting  Services, etc.,
     Enviro- Sci and  Tech., Vol.  10,  No.  11,  October 1976.

34.  "Pollution Control, 3:  Water,"  33 Magazine,  January  1976.

35.  PAT Report:  "Putting Powdered Carbon in Wastewater Treatment," Envir.
     Sci and Tech., Vol. 11, No.  9, September 1977.

36.  Report to the Congress by the  National  Commission on  Water  Quality,
     March 18, 1976.

37.  References from  British Carbonization Research Association.

38.  "Ruling Questions 'Scrubber1 Standard,"  Industry Week,  Vol. 195, No, 3,
     November 7, 1977.

39.  "Steel Mill Wastes are Recycled  in a Novel  Way at Kawasaki  Steel Corp.
     (Japan)," Envir Sci. and Tech.,  Current  Section, Vol. II, No.  3, March
     1977.
               i
40.  "Steel Industry's Efforts for  a  Better Environment in Japan,"  Steel
     Times, Vol. 201, No. 5, May 1973.

41.  "The Steel Industry in Japan and Great Britain:  Some Questions and
     Answers," Transactions of the  Iron and Steel  Institute of Japan, Vol.16,
     No. 3, 1976.

42.  PAT Report:  "Steel Industry Sludge  is Being  Reused," Envir. Sci and
     Tech., Vol. 9, No.  7, July 1975.

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46.  "Treatment of Waste Water - Waste  Oil Mixture," U.S.  Dept.  of  Interior
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47.  "Water Pollutant or Reusable Resource?"  Envir. Sci and  Tech, May 1970.
                                     30

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48.   "The West  German Steel  Industry - Its Position,  Problems, and  Prospects,"
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49.   "What Will Real: Cleanup Costs Be?" Envir. Sci. and Tech., Vol. 10, No. 1,
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50.   Adams, C.E. Jr., Eckenfelder, W,W. Jr.,  "Nitrification Design Approach
      for High Strength Ammonia Wastewaters,"  JWPCF, Vol. 49, No. 3, May 1977,

51.   Ashmore, A.6., Catchpole, J.R., Cooper,  R.L., "The Biological Treatment
      of Carbonization Effluents - I.  Investigation Into Treatment by the
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52.   Barker, J.E., Melyer, S.F., Snook, R.D., "Limestone Treatment of Rinse
      Waters from Hydrochloric Acid Pickling of Steel," proceedings of the
      26th Industrial Waste Conference, May 4-6, 1971, Eng. Bulletin of
      Purdue University.

53.   Barton, P, Vatanatham, T,, "Kinetics of  Limestone Neutralization  of
      Acid Waters," Env. Sci and Tech., Vol. 10, No. 3, March 1976.

54.   Bell, J.P., "Closed Loop Water Recycling System Solves Waste Problem,"
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55.   Borne, B.J., "Industrial Effluent Treatment:  Physico-Chemical  and
      Biochemical Options," Effl. and Water Treatment Journal,  Vol,  16, No. 10,
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56.   Carotti, A., Thomas, J.C., "How the Army Does a Bang-Up Job  of Treating
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57.   Caruso, S.C., McMichael, F.C., Samples,, W.R., "AISI  Water  Resources
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58.   Catchpole, J.R., Cooper, R.L., "The Biological Treatment of  Carboniza-
     tion Effluents-Ill.  New Advances in the Biochemical  Oxidation  of
      Liquid Wastes," Water Research, Vol. 6, No.  12,  December 1972.

59.  Cheremisinoff, P.N., Ciancia, J., Perna, A.J., "Treating Metal  Finishing
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60.  Cheremisinoff, P.N., Ciancia, J., Perna, A.J., "Treating Metal  Finishing
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61.  Cook, G.W., "Conservation of Water By Reuse  at the Appleby-Frodingham
     Steelwords, Scunthorpe," Iron and Steel  International,  October  1974.

62.  Davis,  E.M.,  Petros, J.L.,  Powers,  E.L., "Organic Biodegradation in
     Hypersaline Wastewater," Industrial  Wastes,  January/February 1977.
                                     31

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63.  Davis, J.C., "Activated Carbon:   Prime  Choice  to  Boost  Secondary Treat-
     ment," Chemical  Engineering,  April  11,  1977.

64.  Dean, J.G., Bosqui, F.L.,  Lanouette,  K.H.,  "Removing  Heavy Metal  From
     Waste Water," Env.  Sci  and Tech.,  Vol.  6, No.  6,  June 1972.

65.  DeFalco, A.J., "Biological Treatment  of Coke Waste  Waters,"  Iron and
     Steel Engineer,  June 1975.

66.  Dulaney, E.L., "Development Document  for Effluent Limitations  Guidelines
     and New Source Performance Standards  for the Steel  Making  Segment of  the
     Iron and Steel Manufacturing  Point Source Category,",EPA,  June 1974,
     NTIS, PB-238-837.

67.  Dulaney, E.L., "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,"
     NTIS, PB-238-837,  EPA,  June 1974.

68.  Dunlap, R.W., McMichael, F.C., "...Reducing Coke  Plant  Effluent," Env.
     Sci and Tech., Vol. 10, No. 7, July 1976.

69.  Elliott, A.C., "Regeneration  of  Steelworks  Hydrochloric Acid Pickle
     Liquor," Effluent  and Water Treatment Journal, Vol. 16, No.  3, March
     1976.

70.  Entwistle, J.E., "The Electrolytic Processing  of  Cyanide Wastes," Ef-
     fluent and Water Treatment Journal, Vol.  16, No.  3, March  1976.

71.  Gelb, B.A., "The Cost of Complying with Federal Water Pollution  Law,"
     Industrial Water Engineering,  December  1975/January 1976.

72.  Gravens, C.W., "Growth  of  Japanese Steelmaking and  Its  Impace  in World
     Markets," AISI Meeting, Pittsburgh, PA, November  12,  1970.

73.  Hall, N., "Technical Developments  in  1975," Metal Finishing, February
     1976.

74.  Hall, N., "Technical Development in 1976," Metal  Finishing,  February
     1977.

75.  Ikehata, T., "Treatment of Waste Oil  at the Keihin  Works,  Nippon Kokan,"
     Iron and Steel Engineer, February 1975.

76.  James, L.D., "Economics,"  JWPCF, Vol. 59, No.  6,  pp.  1537-46,  June 1977.

77.  Kincannon, D.F., Gaudy, A.F.  Jr.,  "Some Effects of  High Salt Concentra-
     tions on Activated  Sludge," JWPCF, Vol. 38, No. 7,  July 1966.

78.  Kitagawa, T., Nishikawa, Y.,  Frankenfeld, J.R., Hi, N.N.,  "Wastewater
     Treatment by Liquid Membrane  Process,"  Env. Sci and Tech   Vol   11
     No. 6, June 1977.


                                     32

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79.  Klemetson, S.L., "Biological Filters," JWPCF, Vol. 48, No.  6,  pp.  1001-
     1005, June 1977.

80.  Kohlmann, H.J., "Integrated Steel Plant Pollution Study for Zero Water
     and Minimum Air Discharge," prepared for EPA by Hydrotechnic Corp.
     (5 parts).

81.  Kono, T., "Consumption and Conservation of Energy in the Japanese  Steel
     Industry," Iron and Steel International, April 1977.

82.  Kotch, J.A., Labee, C.J., "Development and Expansion Plants for the
     Steel Industry Overseas," Iron ,>and :8;teel Engineer, October 1975.

83.  Kwasnoski, D., "Water-Pollution Control in an Integrated Steel pi ant,"
     Int. Metallurgical Reviews, Vol.'20, pp. 137-142, 1975.

84.  Land, J.E., et al, "Nature and Stability of Complex Mercury Compounds  in
     Surface and Ground Waters," NTIS, PB-226-226, September 1973.

85.  Leitz, F.B.,  "Electrodialysis for Industrial Water Cleanup," Env.  Sci
     and Tech., Vol. 10, No. 2, February 1976.

86.  Latterf, W.J., Miller, K,, Riecke, C.A., "Sidor's Scale Handling and
     Water Treatment Plant," Iron and Steel Engineer, May 1975,

87.  Mace, G.R.,, "In-Plant Wastewater Treatment Can Ease Soaring Water  Costs,"
     Energy Management Guidebook, 1977.

88.  McManus, G.J., "Heat of Pollution Drive Hits the Coke Oven," Iron  Age,
     June 29, 1972.

89.  Martin, J.R., "Future Trends in Water  Treatment  in the Steel Industry,"
     Steel Times Annual Review, 1975.

90.  Myatt, R.T., Aston, R.J., Johnson, K.S., "The Treatment of Blast Furnace
     Gas Washing Effluent," Iron and Steel  International, Vol. 46, No,  5,
     October 1973.

91.  Nebolsine, R., "Present Practice and  New Concepts for Handling Effluents
     from Hot Rolling Mills,"  Iron and Steel Engineer, August 1970.

92.  Nebolsine, R., Pouschine, I. Jr., "Federal Water Pollution  Control Bill
     and the Steel Industry,"  Iron and Steel Engineer, December  1972.

93.  Ogawa, H., Ono, M., "Purification Plant for  Coke Oven  Gas at Ohita Works,
     Nippon Steel Corp.," Chemical Abstracts, Vol. 79, p.  292,  1973.

94.  Patterson, J.W., "Illinois Institute  for Environmental  Quality, IIEQ
     Document 76/22, Project 20.070A.

95.  Patterson, J.W., Cheng, M.N., "Steel  Industry Waste,"  JWPCF, June  1973.
                                      33

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 96.  Patterson,  J.W.,  Cheng,  M.H.,  "Steel  Industry Wastes,"  JWPCF,  June  1974.

 97.  Pearce,  A.S.,  Punt,  S,E.,  "Biological  Treatment  of  Liquid  Toxic  Wastes,"
     Part 1,  Effluent  and Water Treatment  Journal, Vol.  15,  No.  1,  January
     1975.

 98.  Pifer, H.W., Smith,  D.A.,  et al,  "Economic  Analysis of  Proposed  and
     Interim Final  Effluent Guidelines,"  EPA-230/1-76-048, Integrated Iron
     and Steel  Industry,  March  1976.

 99.  Pyke, R.A., "Air, Water, and Inland  Steel."

100.  Rankin,  L.V.,  "A  No-Nonsense Introduction to  Big Steel's Most  Misunder-
     stood Resource,"  The ABC's of  Water  Treatment:  Part 1, 33 Magazine,
     January 1976.

101.  Reicher, H., "Closed Loop  Regeneration of Waste  Pickle  Liquor,"  Iron  and
     Steel Engineer, May  1975.

102.  Reznek, S.R.,  "The National  Commission on Water  Quality Study  of the
     Impacts of Public Law 92-500 on  Industry,"  Industrial Water Engineering,
     February/March 1976.

103.  Richards, R.A.C., "The Rise of the Spanish  Steel  Industry," Iron and
     Steel International, Vol.  49,  No,  5,  October  1976.

104.  Saunders, F.M., "Activated Sludge,"  JWPCF,  Vol.  49, No. 6,  pp. 1005-
     1016, June 1977.

105.  Schmidt, C., Stone,  R., "A Survey of Industrial  Waste Treatment  Costs
     and Charges,"  Proceedings  of the  23rd Industrial  Waste  Conference,  May
     7-9, 1968, Engineering Bulletin  of Purdue University.

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     trial wastewaters by basic processes), Env, Sci  and Tech.,  Vol.  10,
     No. 2, February 1976.

107.  Schroeder, J.E.,  Naso, A.C., "A  New  Method  of Treating  Coke Plant Waste
     Water," Iron and  Steel Engineer,  December 1976.

108.  Skovronek, H.W.,  "Environmental  Considerations of Selected  Energy Con-
     serving Manufacturing Process  Options:  Vol.  Ill, Iron  and  Steel Industry
     Report," NTIS: PB-264-269, prepared  for Industrial  Environmental
     Research Lab,  Cincinnati,  OH,  by  Arthur D.  Little Inc., Cambridge,  MA,
     December 1976.

109.  Smith, D.W., "Steel  Industry Wastes,"  JWPCF,  June 1976.

110.  Smith, D.W., "Steel  Industry Wastes,"  JWPCF,  June 1977.

111.  Smith, N.B., "Paper  on Cyanide Removal."
                                     34

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112. Smith, S.E., "Steel Industry Wastes," JWPCF, June 1970.

113. Symons, C.R., "Treatment of Cold-Mill Wastewater by Ultra-High-Rate  Fil-
     tration," JWPCF, November 1971.

114. Tabata, S., "Problems and Actual Situation of the Japanese Iron  and
     Steel Industry," Iron and Steel, June 1972.

115. Temmel, F.M., "Treatment of Acid and Metal-Bearing Wastewaters by  the
     High-Density Sludge Process," AISI, San Francisco Regional  Technical
     Meeting of America.

116. Theegarten, H.F., von Hartman, R.K., "Hoesch Huttenwerke's Hot Strip
     Mill Water Supply System," Iron and Steel Engineer, August 1973.

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     Works," Iron and Steel Engineer, August 1972.

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     dustry," NTIS:   AD-742-381, January 1971.

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     Vol. 14, pp. 331-343, 1972.
                                     35

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     Other Information Sources (Publicity Brochures, etc.)
128. "The Combat Against Surface Water Pollution in the Netherlands," Brochure
     from Netherlands.
129. "Environment Protection Act, Marine Dumping Protection Act with Commen-
     taries," Brochure from Sweden, Information to United Nations Conference
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130. "The Fukuyama Filters," Brochure from Hydrotechnic Corp.
131. "Management of Land and Water Resources,"  Brochure from Sweden,
     Information to the United Nations Conference on the Human Environment.
132. "Nippon Steel's Ion Exchange Resin Method  for Pickling Rinse Water
     Treatment," Brochure from Nippon Steel  Corp, (Japan).
133. "Solution of the Water Problem at Taranto  (Italy)  Steel  Plant," from
     Hydrotechnic Corp.
134. "Ultra-High Rate Filtration, A New Technique for Purifications  and Reuse
     of Water," from Hydrotechnic Corp.
135. "Water for a Growing Giant - Nippon Kokan's Fukuyama Works," from
     Hydrotechnic Corp.
136. "Water Treatment," brochure from JGC Corp., (Japan).
                                    36

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                                                   completing)
 EPA-600/2-79-002
                                                      3. RECIPIENT'S ACCESSION NO.
Review of Western European and Japanese Iron and
 Steel Industry Exemplary Water Pollution Control
             B. REPORT DATE
              January 1979
             6. PERFORMING ORGANIZATION CODE
H.M.Tockmam, G.Swaminathan, and  J.D.Stockham
                                                      8. PERFORMING ORGANIZATION REPORT NO.
         G ORGANIZATION NAME AND ADDRESS
HT Research Institute
10 West 35th Street
  hicago,  Illinois  60616
             10. PROGRAM ELEMENT NO.

             1BB610
             11. CONTRACT/GRANT NO.

             68-02-2617, Task 2-3
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
             13. TYPE OF REPORT AND PERIOD COVERED
             Final;  8/77 - 1/78
             14. SPONSORING AGENCY CODE
               EPA/600/13
15.SUPPLEMENTARY NOTES IERL-RTP project officer is John S.  Ruppersberger,  MD-62,
919/541-2733.                                            H        &
16. ABSTRACT
          The report gives results of a literature survey of current Western Euro-
pean and Japanese water pollution control technology in the iron and steel industry.
Further information was obtained through personel communication.  Recycle tech-
nology was identified as being practiced to a high degree by the Japanese. A variable
recycle rate was found to be practiced at British and Western European steel plants.
Summaries of typical pollution control operations  are described and comparative
date are provided.
17.
                             KEY WORDS AND DOCUMENT ANALYSIS
a.
                DESCRIPTORS
                                          b.lDENTIFIERS/OPEN ENDED TERMS
                          c. COSATI Field/Group
Water Pollution
Iron and Steel Industry
Industrial Processes
Water Reclamation
  Water Pollution Control
  Stationary Sources
  Europe
  Japan
13B
11F
13H
18. DISTRIBUTION STATEMENT

 Unlimited
  19. SECURITY CLASS (1
  Unclassified
                                                            eport)
 44
  20. SECURITY CLASS (Thispage)
  Unclassified
                          22. PRICE
EPA Form 2220-1 (9-73)
37

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