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
-------
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.
-------
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
-------
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.
-------
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
-------
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
-------
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
-------
TABLES
Number Page
1. Comparison of Techniques .'.._., . _. , 4
t
-------
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
-------
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.
-------
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.
-------
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
-------
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
-------
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 „ -
-------
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.
-------
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.
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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.
43. "A Study of the Economic Impact on the Steel Industry of the Costs of
Meeting Federal Air and Water Pollution Abatement Requirements," Part
1 - Executive Summary, NTIS: PB-211-917, July 1972.
44. "Thrybergh Bar Mill: a Technical Survey," Iron and Steel International,
Special Issue, June 1976.
45. "Structure and Production of Austria's Iron and Steel Industry," Iron
and Steel International, April 1974.
46. "Treatment of Waste Water - Waste Oil Mixture," U.S. Dept. of Interior
Federal Water Pollution Control Administration, '
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,"
Iron and Steel, April 1973.
49. "What Will Real: Cleanup Costs Be?" Envir. Sci. and Tech., Vol. 10, No. 1,
January 1976.
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
Activated Sludge Process," Water Research, Vol. 1, No. 8/9, August/
September 1967.
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,"
Industrial Wastes, November/December 1976.
55. Borne, B.J., "Industrial Effluent Treatment: Physico-Chemical and
Biochemical Options," Effl. and Water Treatment Journal, Vol, 16, No. 10,
October 1976.
56. Carotti, A., Thomas, J.C., "How the Army Does a Bang-Up Job of Treating
Effluent," Env. S.ci and Tech., Vol. 10, No. 8, August 1976.
57. Caruso, S.C., McMichael, F.C., Samples,, W.R., "AISI Water Resources
Fellowship Review," AlSI-Pittsburgh Regional Technical Meeting of
America, 1971.
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
Wastes," Industrial Wastes, November/December 1976.
60. Cheremisinoff, P.N., Ciancia, J., Perna, A.J., "Treating Metal Finishing
Wastes," Industrial Wastes, January/February 1977.
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.
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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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