EFFLUENT LOADINGS FROM SELECTED INDUSTRIES
INTO THE GREAT LAKES:
IRON AND STEEL PLANTS, PULP AND PAPER MILLS,
CHEMICAL MANUFACTURERS, PETROLEUM
REFINERS, FOUNDRIES, AND ELECTROPLATERS
FINAL REPORT
February 1984
EPA Contract No. 68-01-6700
Wnifescarver Associates Inc.
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EFFLUENT LOADINGS FROM SELECTED INDUSTRIES
INTO THE GREAT LAKES:
IRON AND STEEL PLANTS, PULP AND PAPER MILLS,
CHEMICAL MANUFACTURERS, PETROLEUM
REFINERS, FOUNDRIES, AND ELECTROPLATERS
FINAL REPORT
February 1984
EPA Contract No. 68-01-6700
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ACKNOWLEDGMENT
The authors and the U. S. Environmental Protection Agency would like to
acknowledge the many persons who contributed to the data search, collection, and
verification necessary to comply and present the information in this report.
The authors wish to thank Glenn Pratt of the USEPA-Chicago office for his
direction and assistance. Special acknowledgment is also given to Marvin Rubin
of EPA-EGD, Philip Taylor of EPA-MDSD, and Gary Amendola of EPA-Region V for
their assistance and support.
The acknowledgment of the following persons does not constitute an
endorsement of the report on their part.
USEPA-EGD. Washington. DC
Edward Dulaney
Wendy Smith
Donald Anderson
Elwood Forsht
Richard Kinch
Dennis Ruddy
USEPA-Region V^ Chicago. II
John Gierczah
Jack Newman
Wisconsin DNR, Madison, WI
Carl Blabaum
Kim Nash
Ken Wiesner
Jerry Rodenberg
Thomas Aten
Mike Hammers
Michigan DNR, Lansing, fU
Paul Zugger
Michael Stifler
Frank Horvath
Ralph Resnick
Tim McGarry
Chang Bek
Ohio EPA, Twinsburg and Bowling Green, OH
Robert Phelps
Dennis Lee
Alan Rupp
Marty Hilovsky
William Miller
Bruce Dunlavy
Indiana SHE, Indianapolis, J_N
Larry Kane
Robert Kelsey
Minnesota PCA, Roseville,
Barry Schade
Gary Kimball
International Joint Commission. Windsor. Ontario
William Nye
Pat Murray
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TABLE OF CONTENTS
Page No.
I. INTRODUCTION 1
A. Objective and Scope of Survey 1
B. Industrial Categories 1
C. Drainage Basins 2
D. Effluent Parameters 4
E. Data Bases 5
F. Data Estimation Methods 6
II. SUMMARY OF SURVEY RESULTS 7
A. Effluent Loadings 7
B. Equivalent Concentrations 7
C. Percent Reductions 7
III. IRON AND STEEL MANUFACTURING 11
A. Plants Included in the Survey 11
B. Survey Methods 11
C. Survey Results 14
D. Cost of Effluent Reductions 14
IV. PULP, PAPER, AND PAPERBOARD MANUFACTURING .... 20
A. Mills Included in the Survey 20
B. Survey Methods 20
C. Survey Results 22
D. Cost of Effluent Reductions 22
V. ORGANIC AND INORGANIC CHEMICAL MANUFACTURING . . 30
A. Plants Included in the Survey 30
B. Survey Methods 30
C. Survey Results 31
D. Cost of Effluent Reductions 31
VI. PETROLEUM REFINING 39
A. Refineries included in the Survey 39
B. Survey Methods 39
C. Survey Results 40
D. Cost of Effluent Reductions 40
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TABLE OF CONTENTS (Continued)
Page JYo.
VII. FERROUS AND NONFERROUS FOUNDRIES 45
A. Foundries Included in the Survey 45
B. Survey Methods 45
C. Survey Results 46
D. Cost of Effluent Reductions 46
VII. ELECTROPLATING AND OTHER METAL FINISHING 54
A. Facilities Included in the Survey 54
B. Survey Methods 54
C. Survey Results 54
D. Cost of Effluent Reductions 55
APPENDIX A
Flow Graph and Loading Bar Charts A-l
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TABLES
Table No. Page No_.
No. 1 Effluent Loadings Summary (Ibs/day) 8
No. 2 Equivalent Effluent Concentrations Summary (mg/1) 9
No. 3 Percent Reductions for Loadings and
Concentrations from 1968 to 1982 10
No. 4 Major Iron and Steel Manufacturing Plants
(SIC 3321 - 3317) 12
No. 5 Iron and Steel Discharge Concentrations
for Different Treatment Levels (mg/1) 13
No. 6 Effluent Loadings from Iron and Steel Plants
in 1968 (Ib/day) 15
No. 7 Effluent Loadings from Iron and Steel Plants
in 1976 (Ibs/day) 16
No. 8 Effluent Loadings from Iron and Steel Plants
in 1982 (Ibs/day) 17
No. 9 BPT and BAT Capital Cost Summary for Iron
and Steel Plants in 1978 Dollars (x 1,000) 18
No. 10 Pulp and Paper Mills (SIC 2611 - 2661) 21
No. 11 Effluent Loadings from Pulp and Paper Mills
in 1967 (Ibs/day) 23
No. 12 Effluent Loadings from Pulp and Paper Mills
in 1977 (Ibs/day) 25
No. 13 Effluent Loadings from Pulp and Paper Mills
in 1982 (Ibs/day) 27
No. 14 BPT Capital and Annual Cost Summary for
Pulp and Paper Mills in 1974 Dollars (x 1,000) 29
No. 15 Effluent Loadings from Inorganic and Organic
Chemical Manufacturers in 1968 (Ibs/day) 32
iv
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TABLES (Continued)
Table No. Page No.
No. 16 Effluent Loadings from Inorganic and Organic
Chemical Manufacturers in 1976 (Ibs/day) 34
No. 17 Effluent Loadings From Inorganic and Organic
Chemical Manufacturers in 1982 (Ibs/day) 36
No. 18 BPT Capital and Annual Cost Summary for
Organic and Inorganic Chemical
Manufacturing Plants in 1977 Dollars (x 1,000) 38
No. 19 Effluent Loadings from Petroleum Refineries
in 1968 (Ibs/day) 41
No. 20 Effluent Loadings from Petroleum Refineries
in 1976 (Ibs/day) 42
No. 21 Effluent Loadings from Petroleum Refineries
in 1982 (Ibs/day) 43
No. 22 BAT Capital and Annual Cost Summary for
Petroleum Refineries in 1977 Dollars (x 1,000) 44
No. 23 Effluent Loadings from Foundries in
1968 (Ibs/day) 47
No. 24 Effluent Loadings from Foundries in
1976 (Ibs/day) 49
No. 25 Effluent Loadings from Foundries in
1982 (Ibs/day) 51
No. 26 BPT Capital and Annual Cost Summary for
Foundries in 1978 Dollars (x 1,000) 53
No. 27 Effluent Loadings from Electroplating
Facilities in 1968 (Ibs/day) 56
No. 28 Effluent Loadings for Electroplating
Facilities in 1976 (Ibs/day) 57
No. 29 Effluent Loadings from Electroplating
Facilities in 1982 (Ibs/day) 58
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FIGURES
Page
1. WRC Accounting Units (Basins) 3
VI
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I. INTRODUCTION
A. Objective and Scope of Survey
The objective of this survey is to document the estimated reduction from
1967 to 1982 of certain pollutants of concern in the effluents of selected major
industries that are located in EPA Region V, and discharge either into, or into
tributaries of the Great Lakes. The scope of the survey is limited to only
those industries located in EPA's Region V States (i.e., Michigan, Wisconsin,
Illinois, Indiana, Ohio, and Minnesota] The survey only includes effluents that
discharge directly (i.e., those dischargers with NPDES permits) into Lake
Michigan, Lake Superior, Lake Huron, Lake St. Clair (including the St. Clair and
Detroit Rivers), and the western half of Lake Erie. The survey's purpose is to
support the region's documentation of the progress in reducing industrial waste
loads, to assess the cost to industry, and to determine water quality
improvements. Discharges from Canada and discharges into Lake Ontario and the
eastern half of Lake Erie (i.e., discharges from facilities in New York and
Pennsylvania) were not included in the survey.
Tne sources of data for the survey included (1) EPA Effluent Guidelines
Division (EGD) data bases and Development Documents, (2) EPA Water Planning and
Standards Division Economic Impact Analysis Reports,(3) EPA STORET system data
base, (4) EPA Industrial Facilities Discharge (IFD) files, (5) International
Joint Commission publications, and (6) EPA Region V and State information.
Effluent data were collected for three time periods: 1968, 1976, and 1982. The
treatment costs to industry in achieving these effluent loading reductions are
reported where data were available from EGD sources.
This survey was performed1 in two independent phases. The Phase 1 report
included the two most significant industrial categories; Iron and Steel
Manufacturing, and Pulp, Paper, and Paperboard Manufacturing. Four major
industrial categories identified for study in Phase 2 included (1) Organic and
Inorganic Chemical Manufacturing, (2) Petroleum Refining, (3) Ferrous and
Nonferrous Foundries, and (4) Electroplating. This report presents the results
of the survey for all six industrial categories.
B. Industrial Categories Included in Phase 1 and 2 Surveys
The following six major industries were surveyed as categorized by Standard
Industrial Classification (SIC) codes:
1. Iron and Steel Manufacturing (Phase 1)
SIC 3312 - Blast Furnaces (including coke ovens)
- Steel Works
- Rolling Mills
SIC 3313 - Electrometallurgical Products
SIC 3315 - Steel Wire Drawing
SIC 3316 - Cold Rolled Steel Sheets, Strips, and Bars
SIC 3317 - Steel Pipe and Tubes
-1-
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2. Pulp, Paper, and Paperboard Manufacturing (Phase 1)
SIC 2611 - Pulp Mills
SIC 2621 - Paper Mills (except building paper mills)
SIC 2631 - Paperboard Mills
SIC 2641 - Paper Coating and Glazing Mills
SIC 2661 - Building Paper and Building Board Mills
3. Organic and Inorganic Chemicals (Phase 2)
SIC 2812 - Alkalies and Chlorine
SIC 2813 - Industrial Gases
SIC 2816 - Inorganic Pigments
SIC 2819 - Industrial Inorganic Chemicals
SIC 2865 - Cyclic Crudes, Dyes, and Organic Pigments
SIC 2869 - Industrial Organic Chemicals
4. Petroleum Refining (Phase 2)
SIC 2911 - Petroleum Refineries
5. Ferrous and Nonferrous Foundries (Phase 2)
SIC 3321 - Gray Iron Foundries
SIC 3322 - Malleable Iron Foundries
SIC 3324 - Steel Investment Foundries
SIC 3325 - Steel Foundries
SIC 3361 - Aluminum Foundries
SIC 3362 - Brass, Bronze, and Copper Foundries
SIC 3369 - Nonferrous Foundries
6. Electroplating (Phase 2)
SIC 3471 - Electroplating, Polishing, Anodizing, and Coating
C. Drainage Basins Used in the Survey
Each drainage basin connected to the Great Lakes was categorized using the
U.S. Water Resources Council (WRC) accounting units since these are used in the
EPA STORE! and Industrial Facilities Discharge (IFD) Files. The smaller
cataloguing units were not used since such level of subdivision was not required
in the survey. The effluent loadings from each facility are presented and
totaled to show the pollutant loadings to each of the Great Lakes (excluding
Lake Ontario and the eastern half of Lake Erie). The following WRC accounting
units presented by lake as shown in Figure 1 were used in the survey.
-2-
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Lake Superior Lake Huron
040101 040700
040102 040801
040103 040802
040201
040202 Lake St. Clair (includes
St. Clair and Detroit Rivers)
Lake Michigan
040900
040301
040302 Lake Erie (western half)
040400
040500 041000
040601 041100
D. Effluent Parameters Included in the Survey
This selection of effluent parameters to be considered was dictated mainly
by the extent of the data bases used. For the iron and steel industries,
complete data were generally available for (1) total suspended solids (TSS), (2)
oil and grease, and (3) flow for the entire time period (1967-1982). Adequate
data for comparison were also available for (1) ammonia, (2) cyanide, and (3)
phenols for most of the time period. Data were also available for total metals
and total organic pollutants. These data are adequate for comparison purposes
even though they were derived from calculations based on technical assumptions.
For the pulp and paper industries only data for (1) totul suspended solids
(TSS), (2) biochemical oxygen demand (BOD), and (3) flow were consistently
available. Other data were recorded for (1) zinc, (2) oil and grease, (3)
phenols, (4) sulfate, and (5) phosphate but were not extensive enough for
comparison purposes.
For the chemical manufacturers, data were generally available for (1) flow,
(2) total suspended solids (TSS), (3) biochemical oxygen demand (BOD), (4)
chemical oxygen demand (COD), (5) chloride, (6) ammonia, and (7) total
phosphorus.
For the petroleum refineries, data were generally available for (1) flow,
(2) TSS, (3) BOD, (4) COD, (5) phenols, (6) ammonia, and (7) oil and grease
(O&G).
For both the foundries and electroplaters, some data were available for (1)
flow, (2) TSS, (3) COD, (4) oil and grease, (5) ammonia, (6) total phosphorus,
and (7) total metals.
It should be noted that complete data for all parameters for each facility
were not available for all of facilities within an industrial category.
-4-
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E. Data Bases Used in the Survey
Several computerized data bases and literature references were used in this
survey. The following six data sources were used most extensively for the
collection of information:
1. EPA Effluent Guidelines Division (EGD) data bases and Development
Documents used for technical support for the appropriate effluent
guidelines. Data used include flow, pollutant loadings, plant
production, raw waste loads, effluent limitations, and treatment costs
for the period from 1974 through 1980.
2. EPA Water Planning and Standards Division Economic Analysis Impact
Reports. Main references are the reports Economic Analysis of Proposed
Effluent Limitations and Standards for the Foundry Industry (November
1982), and Economic Analysis of the Proposed Effluent Limitations and
Standards for the Petroleum Refining Industry (November 1982)
3. EPA STORE! System data. Data used include industrial discharge flows
by pipe, pollutant concentrations and loadings, and permit limits for
the period from 1980 through 1982 from discharge monitoring reports
(DMRs).
4. EPA Industrial Facilities Discharge (IFD) files. Data used include
industry identification by WRC accounting units, SIC codes, and States.
5. International Joint Commission (IJC), Great Lakes Regional Office
publications. Main references are the reports Tne Response of the Pulp
and Paper Paper Industry in the Great Lakes Basin to Pollution
Abatement Programs (October 1981); A Review of the Pollution Abatement
Programs Relating to the Petroleum Refinery Industry in the Great Lakes
Basin (November 1982); Inventory of Major Municipal and Industrial
Point Source Discharges in the Great Lakes Basin (July 1979); and
Remedial Programs Subcommittee Report of Great Lakes Water Quality
(July 1978).
6. Data from the States of Indiana, Michigan, Wisconsin, Ohio, and
Minnesota from industrial wastewater surveys, monitoring
investigations, permit applications, and discharge monitoring reports
(DMRs).
In some cases, data for each specific time period (i.e., 1968, 1976, and
1982) were not consistently available, especially for foundries and
electroplaters. Available data were used within a narrow range of years for
each time period. For example, if the earliest data found were for years 1967
through 1971, they were used for the early time period (i.e., designated as
1968). Data for the 1976 mid-point period ranged between 1975 and 1978 and data
for 1982 were from 1981 and 1983 in some cases. For some of the foundries and
electroplating facilities, data were only available for the early period (i.e.,
1968) and the most recent period (i.e., 1982), and not for the mid-1970's.
In many cases data for each time period, especially 1968 and 1976,
represent a single reference point and not a statistically representative daily
-5-
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average derived from a large population. Therefore a great degree of
variability may be found between these data presented and that from other
sources.
F. Data Estimation Methods
Effluent loading data were not available for all of the facilities for all
parameters of interest. For the 1968 period, data for 32 of the total 197
facilities (26 percent) had to be estimated. For the 1976 period, data for 21
of the 184 facilities (11 percent) had to be estimated. In both cases, data for
foundries and electroplaters represent the majority of the unavailable data.
For the 1982 period no data had to be estimated for the 170 facilities and all
values represent actual effluent loadings.
Data were estimated by one of two methods or by comparison of the two
methods as stated below:
1. The mean value for any one parameter in pounds per million gallons
. (Ibs/mg) was calculated from the other facilities' data within the same
industrial category for the same time period. This mean value (e.g.,
171 Ibs of TSS per MG) was then multiplied by the flow in MGD to
estimate parameter loading for each facility which only had flow data.
2. In some cases where data on flow and some of the parameters (i.e., TSS)
were available, values for other parameters were estimated by using the
percent reduction of TSS as the same reduction of other parameters
(i.e., COD). For example, if TSS from 1968 to 1976 showed a 45%
reduction, it was assumed that COD also showed a 45% reduction.
These methods of data estimation may produce slightly inaccurate loading
valves for each time period, especially for 1968, but the percent reductions
should not be affected since the same methods were used for each of the two time
periods of concern (i.e., 1968 and 1976). In all cases, facilities for which
data were estimated are noted in the effluent loading tables.
-6-
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II. SUMMARY OF SURVEY RESULTS
This section presents the results of the survey for all six industrial
categories. Sections 3 through 8 present the detailed results for each facility
for each year. The effluent flows and parameter loadings (daily averages), the
calculated equivalent concentrations in mg/1, and the overall percent reductions
are presented for each year in this section.
A. Effluent Loadings
Table 1 presents the total flow in mgd and effluent loadings in Ibs/day for
11 parameters for each of the six industrial categories for the three periods.
The totals for all six industrial categories are also presented. These totals
should not be considered to include all possible loadings for each of the 11
parameters since data for certain parameters were not available for each
category and therefore are not presented (i.e., shown as blanks in the table).
B. Equivalent Concentrations
Table 2 presents the calculated equivalent effluent concentrations in mg/1
for each industrial category. These concentrations better reflect the history
of regulatory control of effluent discharges since they do not incorporate
effluent reductions due to facility shutdown or production decreases, discharge
to POTW, or non-process discharges caused by economic situations, business
decisions, or other factors. It should be noted that the concentration for one
paramenter, oil and grease, for electroplaters increased from 3.81 mg/1 to 5.58
mg/1.
C. Percent Reductions
Table 3 presents the calculated percent reductions for both effluent
loadings in Ibs/day and equivalent concentrations in mg/1. These percent
reduction values are very similar to values reported by IJC for selected
industries (i.e., iron and steel, pulp and paper, and petroleum refining). It
should be noted that the concentrations for oil and grease show an increase for
the electroplating category as noted in the table.
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TABLE 1: EFFLUENT LOADINGS SUMMARY (Ibs/day)
00
NO. OF
PERIOD PLANTS
IRON AND STEEL
1968
1976
1982
PULP AND PAPER
1967
1977
1982
FLOW
(mgd) CHLORIDE BOD
PLANTS
23 2.694
15 2.418
15 1.641
HILLS
39 295 974.178
39 276 188,520
35 158 63.207
CHEMICAL MANUFACTURERS
1968 38 432 3.325,702 26,445
1976 38 392 2.140,319 15,645
1982 34 328 513.178 6.669
TSS
PHOS.
643,391
213,968
163,895
0&6
174,996
103,009
45,941
METALS
21.288
14.535
9.356
COO
AMMONIA ORGANICS PHENOLS CYANIDE
1
38,048 8,477 16,145
23,635 4,104 4,678
15,574 809 167
4,875
3,660
562
830.654
170.436
72.061
284
50
31
.346
.050
.697
927
915
152
204.628
115.510
42.491
18.393
12,822
3,950
PETROLEUM REFINERIES
1968
1976
1982
16
13
9
456 85,961
258 9.187
156 3.255
61
13
3
.116
.287
.338
16.860
3.700
1.052
187,786
26.452
18.872
13.944 1.878
3,417 64
834 51
FOUNDRIES
1968
1976
1982
56
56
56
88
86
68
52
12
10
.585
.510
.568
373
99
97
6.864
3.235
674
2,133
622
60
60.782
14.182
4.968
9,645
2,501
704
ELECTROPLATERS
ALL
1968
1976
1982
25
23
21
SIX INDUSTRIAL
1968
1976
1982
197
184
170
5.63
3.44
2.97
CATEGORIES
3.971 3.325.702 1,086.584
3,433 2.140,319 213,352
2,354 513,178 73,131
8
1,881
460
281
.988
224
263
.080
.475
,822
184
14
4
1.484
1,028
253
179
149
160
198.899
110.093
47.827
173
28
10
23,594
15.185
9.426
1.064
133
62
454.260
156.277
66,393
26
17
13
80.056 8.477 18,023
42,392 4.104 4.742
21.075 809 218
4,675
3.660
562
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TABLE 2: EQUIVALENT EFFLUENT CONCENTRATIONS SUMMARY (rag/1)
PERIOD
NO. OF
PLANTS
IRON AND STEEL PLANTS
1968 23
1976 15
1982 15
PULP AND PAPER HILLS
1967 39
1977 39
1982 35
FLOW
(mgd)
2.694
2,418
1,641
295
276
158
CHLORIDE BOD TSS
28.64
10.61
11.98
395.96 337.62
81.90 74.04
47.97 54.69
PHOS.
O&G
7.79
5.11
3.36
METALS COD AMMONIA ORGANICS PHENOLS CYANIDE
.95
.72
.68
1.69
1.17
1.14
38 .72 .22
20 .23 .18
06 .01 .04
CHEMICAL MANUFACTURERS
1968
1976
1982
PETROLEUM
1968
1976
1982
FOUNDRIES
1968
1976
1982
38
38
34
REFINERIES
16
13
9
56
56
56
432
392
328
456
258
156
88
86
68
923.07 7.34 78.92
654.68 4.79 15.31
187.60 2.44 11.59
22.60 16.07
4.27 6.18
2.50 2.57
71.65
17.44
18.63
.26
.28
.06
.51
.14
.17
4.43
1.72
.81
9.35
4.51
1.19
56.80
35.33
15.53
49.38
12.29
14.51
2.91 82.82
.87 19.77
.11 8.76
5.11
3.92
1.44
3.67
1.59
.64
13.14
3.49
1.24
.49
.03
.04
ELECTROPLATERS
1968
1976
1982
25
23
21
5.63
3.44
2.97
191.42
7.81
10.62
3.92
.49
.16
3.81
5.19
5.58
3.68 22.66
.98 4.64
.40 2.50
.55
.59
.52
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TABLE 3: PERCENT REDUCTIONS FOR LOADINGS AND
CONCENTRATIONS FROM 1968 TO 1982
IRON AND STEEL PLANTS
Loading
Concentration
PULP AND PAPER HILLS
Loading
Concentration
CHENICAL MANUFACTURERS
Loading
Concentration
PETROLEUM REFINERIES
Loading
Concentration
FOUNDRIES
Loading
Concentration
ELECTROPLATERS
Loading
Concentration
FLOW
(mgd) CHLORIDE BOD
391
46% 94X
871
24X 851 75X
80t 67Z
66Z 96Z
89%
23X
47X
TSS PHOS.
75S
58X
91X
84X
89X 70X
85X 77X
95Z
84X
BOX 74Z
74X 67X
97X 98X
94X 96X
O&G NETALS COD AHHONIA ORGANICS
74X 56X S9X 90X
57X 28X 33X B4X
79X 79X
73X 72X
94Z 90X 94X
82% 71X 83X
90Z 97X 92Z 93%
87X 96X 89X 91X
11% 94X 94% 50X
* 89% 89X 5X
PHENOLS CYANIDE
99X 88X
99X 82%
97X
92X
ALL SIX INDUSTRIAL CATEGORIES
Loading 41Z 85% 93Z 85Z 83Z 76Z 60Z 85Z 74Z 90% 99Z 88Z
(*) denotes negative reductions or percent increase
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III. IRON AND STEEL MANUFACTURING
A. Plants Included in the Survey
Twenty-three (23) major iron and steel manufacturing plants located in
the Region V Great Lakes drainage area were identified. All 23 plants have at
sometime discharged process wastewater directly to the Great Lakes. Of these 23
plants, 4 currently discharge only to municipal wastewater treatment systems
(POTW). Four other plants have shutdown (one since 1976 and three since 1968).
Table 4 lists the 23 major iron and steel manufacturing plants used in
the survey by lake basin. The discharge status for each plant for each time
period (i.e., 1968, 1976, and 1982) is presented.
B. Survey Methods
The Iron and Steel Manufacturing plants were identified from the EPA's IFD
file plant listings and cross-referenced with the EPA EGD plant inventory in the
Final Development Document for Iron and Steel Manufacturing. The IFD file was
found to be more complete since EGD did not include all plants in their
inventory (21 of the 23 plants). Therefore, the list of plants from the IFD
file was used as the basis for identifying plants to include in the survey.
Each plant was identified by SIC code and WRC accounting unit based on
information in the IFD file.
The flow and effluent loading data for each plant for 1968 were derived
from the 1976 EGD data for 8 subcategories as presented in the six volumes of
the Final Development Document. The following steps and assumptions were made
in relating the 1976 data to the 1968 time period.
1. Production data in tons per day (TPD) for 1968 were assumed
to be similar to production data for 1976.
2. Flow values in gallons per ton (GPT) for 1968 were assumed
to be similar to the 1976 time period.
3. Flow rates in MGD were calculated using TPD x GPT/1,000,000 = MGD.
4. The appropriate 1968 treatment level for each plant for each
subcategory was identified.
5. The appropriate discharge concentration (mg/1) for each treatment
level was identified from Table 5.
6. The flow (MGD) multiplied by the concentration (mg/1) times the 8.34
conversion factor equaled loading (Ibs/day).
7. The subcatagory totals for each parameter were then added
together for each plant.
The calculated values were compared with actual loading values from State and
IJC references, where available.
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TABLE 4: MAJOR IRON AND STEEL MANUFACTURING PLANTS (SIC 3312 - 3317)
LAKE SUPERIOR
BASIN 40102
1. U.S. Steel Co
1968
rporation - Duluth, MN Direct
1976
Closed
1982
Closed
LAKE MICHIGAN
BASIN
LAKE ST.
BASIN
40400
1. Environdyne/Vlsconsin Steel Corp. - Chicago, II
2. Interlake/Chicago Furnace - Chicago. IL
3. U.S. Steel Corporation/South Chicago Works -
Chicago, IL
4. Inland Steel - Indiana Harbor - E. Chicago, IN
5. Bethlehem Steel Corporation - Chesterton, IN
6. Jones and Laughlin Steel Corporation -
E. Chicago, IN
7. U.S. Steel Corporation/Gary Works - Gary, IN
8. Republic Steel Corporation - Chicago, IL
9. U.S. Steel Corporation - Uaukegan. IL
10. National Steel Corporation - Portage, IN
CLAIR
40900
1. National (Great Lakes) Steel Corporation -
Ecorse, MI
2. HcLouth Steel Products - Trenton, MI
3. Rouge Steel (Ford) Company - Dearborn, MI
4. HcLouth Steel Products - Gibraltar, MI
5. National (Great Lakes) Steel Corporation -
Zug Island, MI
6. National (Great Lakes) Steel Corporation -
(80* Mill), River Rouge, MI
Direct
Direct
Direct
Oirect/POTW
Direct
Direct/POTW
Direct
Direct
Oirect/POTU
Direct
Direct
Direct
Direct
Direct
Direct
Direct
POTW
POTW
Zero/POTW
Direct/POTW
Direct/Well
Direct/POTW
Direct
POTW
Closed
Direct
Direct
Direct
Direct/POTW
Direct
Direct
Direct
Closed
POTW
Zero/POTW
Direct/POTW
Direct/Well
Direct/POTW
Direct
POTW
Closed
Direct
Direct
Direct
Direct/POTW
Direct
D1rect/POTW
Direct
LAKE ERIE
BASIN 4!
1.
2.
3.
4.
5.
6.
1100
Jones and Laughlin Steel Corporation -
Cleveland, OH
Republic Steel Corporation - Cleveland, OH
U.S. Steel Corporation - Lorain, OH
U.S. Steel Corporation - Cuyahoga, OH
U.S. Steel Corporation/Central Furnace -
Cleveland. OH
Interlace Steel Company - Toledo. OH
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Closed
POTU
Direct
Direct
Direct*
Direct
Closed
POTW
* Coke Plant Closed November 1983
-12-
-------
TABLE 5: Iron and Steel Discharge
Concentrations for Different
Treatment Levels (mg/1)
COKEHAKING
Flow (GPT)
TSS
046
Ammonia
Cyanide
Phenols
Total Organlcs
Total Netals
SINTERING
Flow (GPT)
TSS
O&G
Ammonia
Cyanide
Phenols
Total Organic*
Total Metals
IRON MAKING
Flow (EPT)
TSS
Ammonia
Cyanide
Phenols
Total Organics
Total Netals
STEEL MAKING
BOF
Flow (GPT)
TSS
Total Netals
ARC
Flow (GPT)
TSS
Total Metals
CONTINUOUS CASTING
Flow (GPT)
TSS
O&G
Total Metals
HOT FORMING
Flow (GPT)
TSS
O&G
Total Netals
FINISHING
Dirty
Raw Hater
Waste Quench
162 5
SO SO
75 75
600 600
50 50
300 300
113.6 113.6
2.6 2.6
Once-Through
Clarification
1460
39
7
6
0.2
0.2
0.03
1.22
Once-Through
Clarification
3200
50
20
4
2.3
0.16
15.0
Once-Through
Clarification
50-1100
36-50
1.78-2.24
2100
47
25.97
Once-Through
Clarification
3400
40
10
1.62
Once-Through
Scale Pit
Flows fror
75
25
0.50
BPT
225
100
15
100
16
36
26.75
1.5
BPT
120
39
7
7
0.2
0.2
0.03
1.27
BPT
125
42
60
4
2.3
0.16
15.0
BPT
50-1100
36-38
1.78-1.88
110
47
25.97
BPT
125
25
10
1.62
Once-Through
Clarif icatioi
n Development
40
15
0.148
BAT
153
66
5
7
3
0.02
0.515
0.7
BAT
120
39
7
7
0.2
0.2
0.03
0.455
BAT
70
22
6
0.03
0.01
0.16
0.455
BAT
50-1100
22
0.25
110
22
1.5
BAT
25
25
10
1.31
i BPT BAT
Document
15 15
5 5
0.074 0.074
Average concentrations and discharge flows
for each plant in Development Document.
-13-
-------
The 1976 flow values and effluent loadings were derived from the actual
1976 production levels and effluent loading values for each plant as presented
in the Development Document. The same calculation process was used as described
above but different treatment levels were identified based on Regional and State
information. Calculated values were compared with EGD and State effluent
loading values to verify accuracy where data were available.
The data for the 1982 time period were calculated from the monthly loading
values for each pipe for each plant in the STORET data base. The actual
effluent loading values for each month were averaged over the one year period.
In some cases where only effluent concentration data in mg/1 were recorded,
loadings in Ibs/day were calculated using the average flow rate in mgd with the
following formula:
Average load (Ibs/day) = average concentration (mg/1) x
average flow (mgd) x 8.34
(conversion factor)
The 1982 data is presented without modification (except for gross and
obvious entry errors) from the STORET computer printouts. The 1982 loading
values for total metals and organics were calculated in a similar manner to the
values for 1968 and 1976 since no consistent effluent data for those parameters
were found in the STORET data base.
C. Survey Results
The effluent flow rates and pollutant loadings are presented in tabular
form. Each table represents a separate time period (i.e., 1968, 1976, and 1982)
and presents the data by plant and lake basin. The following parameters are
presented: flow (mgd), TSS, oil and grease, ammonia, total phenolics, total
cyanide, total organics, and total metals (mainly iron).
Table 6 presents the estimated 1968 effluent loadings for 23 plants.
Table 7 presents the actual 1976 effluent loadings data for 15 plants based
on EGD and State information.
Table 8 presents the most recent data from the STORET data base for 15
plants which includes monthly values from 1980 through 1982. Graphs showing
pollutant loadings by time period are included in the Appendix.
D. Cost of Effluent Reductions
The capital costs for each iron and steel manufacturing plant were derived
from the EGD cost summaries for both BPT and BAT levels of effluent reduction.
These costs include cost of in-place facilities and additional required costs as
of July 1, 1981 needed to meet the appropriate effluent limitations for TSS, oil
and grease, phenolics, ammonia, and cyanide and other regulated parameters. The
capital costs do not include annual maintenance costs.
The capital cost summary is presented in Table 9 by WRC accounting unit.
Data were available for only 17 plants in the Great Lakes area from the EGD cost
-14-
-------
TABLE 6: EFFLUENT LOADINGS FROH IRON AND STEEL PLANTS IN 1968 (Ibs/day)
LAKE SUPERIOR
Basin 40102
LAKE MICHIGAN
Basin 40400
FACILITY NAME
U.S. Steel Corporation - Duluth, UN
SUBTOTAL
Environdyne/Wisconsln Steel - Chicago, IL
Interlake/Chicago Furnance - Chicago, IL
U.S. Steel/Chicago Works - Chicago, IL
Inland Steel - Indiana Harbor, IN
Bethlehem Steel - Chesterton, IN
Jones and La ugh 11 n Steel - E. Chicago, IN
U.S. Steel/Gary Works - Gary, IN
Republic Steel - Chicago, IL
U.S. Steel Corporation - Waukegan, IL
National Steel Corp. - Portage, IN
FLOW
(ragd)
.34
.34
18.10
3.17
28.01
975.60
141.06
324.90
766.60
.88
30.32
25.59
TSS
142
142
9,870
1,302
13,796
127.363
17,649
74,347
237.578
450
9,771
4,356
046
212
212
2,824
1.002
2,237
37.194
5,882
15.715
62,103
163
3.624
1,245
Ammonia
1,698
1,698
1,824
8,148
178
3,562
154
969
377
10
34
28
Cyanide
142
142
214
706
36
372
31
181
399
16
7
6
Phenols
849
849
2,410
3,981
21
639
176
191
91
92
38
32
Total
Organic*
321
321
231
1,500
1
904
582
92
1,432
1
125
106
Total
Metals
7
7
506
207
1.415
6,021
87
1,436
3.660
62
306
259
SUBTOTAL
2,314.23 496,482 131,989 15,284 1,968 7.671 4,974 13.959
LAKE ST. CLAIR
Basin 40900
National Steel Co. - Ecorse, HI
National Steel Co. - Zug Island, HI
National Steel Co. - River Rouge, HI
McLouth Steel - Trenton, HI
McLouth Steel - Gibraltar. HI
Ford Hotor Company - Dearborn, HI
50.13
22.44
58.19
50.39
7.35
81.59
9,407
9,358
36.398
17,757
1,929
18,461
3,135
526
12,133
4,798
630
4.060
55
7,809
64
55
12
3,299
11
1,072
15
11
4
619
63
2.517
72
63
11
626
207
825
240
1
30
288
46
2,720
243
598
243
1.790
SUBTOTAL
270.09 93,310 25,282 11,294 1,732 3,352
LAKE ERIE
1,591 5,640
Basin 41100 Jones and Laughlin Steel - Cleveland, OH
Republic Steel - Cleveland, OH
Interlake Steel - Toledo, OH
U.S. Steel Corporation - Loraln, OH
U.S. Steel Corporation - Cuyahoga, OH
U.S. Steel Corporation - Cleveland, OH
SUBTOTAL
1968 TOTAL
8.82
54.42
1.57
33.i>9
8.27
2.40
109.27
2,693.93
5,113
32,942
697
12.669
1,035
1,001
53,457
643,391
1,449
10.396
613
4.321
345
389
17,513
174.996
203
1,782
5,017
2,360
10
400
9,772
38,048
41
241
432
210
29
80
1,033
4,875
23
592
2.464
1,138
10
46
4.273
16,145
2
196
929
427
34
3
1.591
8.477
309
804
107
157
5
300
1.682
21.288
-------
TABLE 7: EFFLUENT LOADINGS FROM IRON AND STEEL PLANTS IN 1976 (Ibs/day)
LAKE MICHIGAN
Basin 40400
LAKE ST. CLAIR
Basin 40900
LAKE ERIE
Basin 41100
FACILITY NAME
Inland Steel - Indiana Harbor. IN
Bethlehem Steel - Chesterton, IN
Jones and La ugh 11 n Steel - E. Chicago, IN
U.S. Steel/Gary Works - Gary, IN
National Steel Corp. - Portage, [N
SUBTOTAL
National Steel Co. - Ecorse. HI
National Steel Co. - Zug Island, HI
National Steel Co. - River Rouge, HI
McLouth Steel - Trenton, HI
McLouth Steel - Gibraltar, HI
Ford Motor Company - Dearborn, HI
SUBTOTAL
Jones and Laughlln Steel - Cleveland, OH
Republic Steel - Cleveland. OH
U.S. Steel Corporation - Loraln, OH
U.S. Steel Corporation - Cuyahoga, OH
SUBTOTAL
1976 TOTAL
FLOW
(mgd)
990.75
145.56
274.24
607.66
25.59
2,043.80
50.13
22.44
58.19
50.39
7.35
80.38
268.88
8.82
54.42
33.69
8.27
105.20
2. 417. 88
TSS
38.390
18,553
36,231
36,682
2,505
132,361
9,407
9.358
10,919
17.757
643
18,232
66.316
1.553
8,149
4,554
1,035
15,291
213.968
OSG
11,622
5,954
11,545
51,239
251
80,611
3,135
526
3,640
4,798
210
4,169
16.478
1,843
2,104
1,628
345
5,920
103,009
Ammonia
2,869
222
2.408
2.156
24
7,679
47
7.809
55
55
8
2,290
10.264
610
2,696
2,360
26
5,692
23,635
Cyanide
1,211
13
293
110
4
1.631
8
1.072
9
11
2
458
1,560
41
210
210
8
469
3,660
Phenols
166
8
166
26
15
381
28
2,517
33
63
5
263
2.909
23
211
1,138
16
1,388
4.678
Total
Organ ics
904
2
93
1,432
52
2.483
102
825
118
1
15
18
1.079
2
95
427
18
542
4.104
Total
Hetals
6.021
149
663
1,169
184
8.186
46
2.720
54
598
123
1,779
5.320
284
626
114
5
1.029
14,535
-------
TABLE 8: EFFLUENT LOADINGS FROM IRON AND STEEL PLANTS IN 1982 (Ibs/day)
LAKE MICHIGAN FACILITY NAME
FLOW Total Total
(mgd) TSS 046 Ammonia Cyanide Phenols Organics Metals
Basin 40400 Inland Steel - Indiana Harbor. IN 318.04 40,227 3.845 561 53 36 23 2.196
Bethlehem Steel - Chesterton, IN 145.56 32.470 1,853 856 35 12 1 141
Jones and Laughlin Steel - E. Chicago. IN 195.11 9.388 2,519 1.675 112 9 6 658
U.S. Steel/Gary Works - Gary, IN 597.j9 12,385 22,468 803 7 20 126 678
National Steel Corp. - Portage, IN 25.59 1.501 65 22 4 3 17 134
SUBTOTAL
1,281.99
95,971 30,750 3,917
211
80
173 3,807
LAKE ST. CLAIR
-vJ
Basin 40900
National Steel Co. - Ecorse, HI
National Steel Co. - Zug Island. HI
National Steel Co. - River Rouge, HI
NcLouth Steel - Trenton, HI
HcLouth Steel - Gibraltar, HI
Ford Motor Company - Dearborn, HI
27.09
32.16
58.19
50.39
.53
80.38
1,465
9.007
10,919
11,906
66
17,315
535
2.697
3,640
1.426
71
1,426
27
175
59
55
5
2,290
3
6
20
17
0
19
3
1
6
6
0
6
18
29
39
1
0
18
25
2.707
54
598
5
1,718
SUBTOTAL
248.74 50,678 9,795 2,611
65
22
105 5,107
LAKE ERIE
Basin 41100
Jones and Laughlln Steel - Cleveland, OH
Republic Steel - Cleveland, OH
U.S. Steel Corporation - Lorain, OH
U.S. Steel Corporation - Cuyahoga, OH
8.82
54.42
33.69
12.86
4,943
3,982
5.018
3,303
633
1.839
2.684
240
415
6,467
2,034
130
3
269
9
5
3
55
6
1
2
95
426
8
284
18
114
26
SUBTOTAL
1982 TOTAL
109.79
17,246 5.396 9,046
1,640.52 163,895 45,941 15,574
286
562
65
167
531 442
809 9,356
-------
TABLE 9: BPT and BAT Capital Cost Summary
for Iron and Steel Plants in
1978 dollars (x 1,000)
Lake Michigan
Basin 40400 BPT
BAT
Lake St. Clair
Basin 40900 BPT
BAT
Lake Erie
Basin 41100 BPT
BAT
Subtotal BPT
BAT
TOTAL
AVERAGE
No. of
Plants
8
8
4
3
5
5
17
16
17
Inplace
Costs
205,416
3,802
59,589
1,465
67,233
4,439
332,238
9,706
341,944
20,114
Required
Costs
12,115
8,365
25,367
1,735
13,595
3,038
51,077
13,138
64,215
3,777
Total
Costs
217,531
12,167
84,956
3,200
80,8^8
7,477
383,315
22,844
406,159
23,892
-18-
-------
summaries. Costs are presented in 1978 dollars and it is estimated that at the
present time the required costs have been expended to achieve BPT and BAT
requirements.
-19-
-------
IV PULP, PAPER, AND PAPERBOARD MANUFACTURING
A. Mills Included in the Survey
Thirty-nine (39) major pulp, paper, and paperboard mills located in the
Region V Great Lakes drainage area were identified. All of these 39 mills have
at sometime discharged process wastewater directly to the Great Lakes. Of these
39 mills, two currently discharge to municipal wastewater treatment systems
(POTW). One mill shutdown in 1982 while one mill has zero discharge. The
remaining 35 mills currently discharge process wastewater directly to the Great
Lakes drainage area.
Table 10 lists the 39 major pulp and paper mills identified by lake basin
used in the survey. Each mill's discharge status is also presented for each of
the three time periods (i.e., 1967, 1977, and 1982). The years 1967 and 1977
were used since more complete data were available as compared to 1968 and 1976.
B. Survey Methods
The pulp and paper mills that discharge directly to the Great Lakes area
were identified from the EPA IFD file cross-referenced with the EPA EGO
inventory used in the Final Development Document for the Pulp and Paper
Industry. In addition, Appendix IV of the IJC report on the Pulp and Paper
Industry, the STORET system, and State files were reviewed to obtain the list of
39 mills. Each mill was identified by SIC code and WRC accounting unit based on
information in the IFD file.
The TSS and BOD effluent loading data from the EGO inventory and the IJC
report for 1977 period were compared. In all cases for the 25 mills for which
both sources had data, the values were within 10 percent. Values from neither
source were consistently higher or lower. Therefore, the highest value from
either source was used as the 1977 loading value for that particular mill. Flow
data were not included in the IJC report, so all flow values were taken from the
EGD information. Flows were calculated by multiplying the daily production rate
(tons per day or TPD) by the appropriate flow factor (kgal/ton). Loading values
from these sources were verified with State information. In all cases,
excellent correlation was found among all references.
The effluent loading data for 1967 were derived from the 1977 data. The
discharge trends as reported by IJC in Tables 2 and 3 of the Pulp and Paper
Industry report were used as the basis for the 1967 loadings. Each mill in each
State (i.e., Michigan, Wisconsin, and Ohio) was assumed to be discharging TSS
and BOD loads at the same ratio in 1967 on a statewide basis. For example,
Table 2 of the IJC report shows that in 1967, 4.68 times as many TSS were being
discharged by mills in Michigan than in 1977 (100.2 megagrams per day divided by
21.4 megagrams per day). It was therefore assumed that all mills in Michigan
were discharging 4.68 times as many TSS in 1967 as they were in 1977.
These factors were calculated for each State for both TSS and BOD and applied to
the 1977 data to derive the 1967 data. All loading values for 1967 were
verified against State data, where available, and adjustments were made if
necessary. Data for two unidentified mills in Minnesota obtained from the IJC
Remedial Programs Subcommittee Report were added to the totals for 1967 and
1977. No mills in Minnesota currently discharge to the Great Lakes.
-20-
-------
LAKE SUPERIOR
TABLE 10: PULP AND PAPER HILLS (SIC 2611 - 2661)
1967
1977
1982
BASIN 40103
1. James River/Dixie Northern, Inc. - Ashland. UI
2. Superior Fiber Products - Superior, WI
BASIN 40201
1. Champion International Corp. - Ontonagon, HI
BASIN 40202
1. Klmberly Clark Corp. - Hun1s1ng, HI
LAKE MICHIGAN
BASIN 40301
1. Head Corporation - Escanaba, HI
2. Scott Paper Co. - Harinette, HI
3. Scott Paper Co. - Oconto Falls, WI
4. Badger Paper Hill - Peshtigo, UI
5. Heneminee Paper Co. - Heneralnee, HI
6. Niagara Paper Co. - Niagara, UI
7. George Whiting Paper Co. - Nenasha, WI
BASIN 40302
1. Thilmany (Haimnermill) Paper Co. - Kaukauna, UI
2. Green Bay Packaging Co. - Green Bay, HI
3. Consolidated Papers Co. - Appleton, UI
4. Fort Howard Paper Co. - Green Bay.UI
5. Hidtec Paper Co. - Kimberly, UI
6. Kerwln [Riverside) Paper Co. - Appleton, UI
7. Kimberly Clark Corp. - Neenah, UI
8. Appleton Papers Co. - Combined Locks. WI
9. Bergstrom Paper Co. - Neenah, UI
10. James River/Dixie Northern, Inc. -
Green Bay, UI
11. Shawano Paper Mill - Shawano, UI
12. Nicolet Paper Co. - DePere, UI
13. Wisconsin Tissue Hill - Henasha. UI
14. Proctor a Gamble (Charmin) Co. -
Green Bay, WI
BASIN 40500
1. Henasha Corporation - Otsego, HI
2. Hatervliet Paper Co. - Hatervliet, HI
3. French Paper Co. Niles, HI
4. Simplicity Pattern Co. - Niles, HI
5. Plainwell Paper Co. - Plainwell, HI
BASIN 40601
1. Packaging Corporation of America -
Filer City, HI
2. Nanistlque Pulp and Paper Co. -
Hamstique, HI
LAKE HURON
BASIN 40700
1. Fletcher Paper Co. - Alpena, HI
2. Proctor and Gamble Co. - Cheboygan, HI
3. Abitibi Corporation - Alpena. HI
LAKE ST. CLAIR
BASIN 40900
1. Dunn Paper Co. - Port Huron, HI
2. Port Huron Paper Co. - Port Huron, HI
LAKE ERIE
BASIN 41000
1. Simplex Industries - Palmyra, HI
BASIN 41100
1. Chase Bag Co. - Chagrin Falls, OH
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct/POTU
Direct
Direct
Direct
Direct/POTU
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct/POTW
POTW
Direct
POTW
Direct
Direct
Closed
Direct
Direct
Direct
Direct
Direct
Direct
Direct/POTW
Direct
Direct
Direct
Direct/POTW
Direct
Zero
Direct
Direct
Direct
Direct
Direct
Direct/POTU
Direct
Direct
Direct
Direct
Direct
Direct
-21-
-------
The flow and effluent loading data for the 1982 time period were
calculated from the loading and flow data by pipe found in the STORET data base.
The actual effluent loading values for each month were averaged over the one
year period. In some cases where only average effluent concentration data in
mg/1 were recorded, loadings in Ibs/day were calculated using the average flow
rate in mgd with the following formula:
Average load (Ibs/day) = average concentration (mg/1) x
average flow (mgd) x
8.34 (conversion factor)
All loading values calculated from the STORET data base were verified and
modified, if necessary, with data obtained from the appropriate States. In
cases where major inconsistencies were noted, values from the State references
were used.
C. Survey Results
The effluent flow rates and pollutant loadings are presented in tabular
form. Each table represents a separate time period (i.e., 1967, 1977, and 1982)
and presents data by mill and lake basin. The following parameters are
presented: flow (mgd), TSS, and BOD. Data for oil and grease, phosphate,
sulfate, and phenolics from several references were also found for a few mills
but are not presented.
Table 11 presents the estimated 1967 effluent loadings of TSS and BOD and
flow for 39 mills based on discharge trends reported by IJC and State information,
Table 12 presents the actual 1977 effluent loadings for TSS and BOD and
flow for 39 mills based on IJC, E6D and State information.
Table 13 presents the actual 1982 effluent loadings for TSS and BOD and
flow for 35 mills based on current STORET data verified with State information.
Graphs showing effluent loadings by time period are included in the Appendix.
D. Cost of Effluent Reductions
The capital and annual costs for pulp and paper mills were derived from
the EGD cost estimates developed for each mill to meet BPT levels of effluent
reduction. The capital costs represent the cost to industry to install complete
BPT systems which are required to meet BPT limits. The annual costs represent
the yearly cost of operation, maintenance, and depreciation.
The costs for the pulp and paper mills are presented in Table 14 by lake
basin. Data were available for only 27 of the 39 mills in the survey. Costs
are presented in 1974 dollars and do not include cost incurred by mills with BPT
treatment systems already in place at that time.
If the average costs per mill are applied to all 35 mills, a total capital
cost of 270 million dollars and annual costs of 85 million dollars is estimated
for pulp and paper mills to achieve BPT levels of effluent reduction.
-22-
-------
TABLE 11: EFFLUENT LOADINGS FROM PULP AND PAPER HILLS IN 1967 (Ibs/day)
LAKE SUPERIOR
Basin 40103
Basin 40201
Basin 40202
LAKE MICHIGAN
Basin 40301
Basin 40302
Basin 40500
Basin 40601
FACILITY NAME
James River/Dixie Northern, Inc. - Ashland, UI
Superior Fiber Products - Superior, UI
Champion International Corp. - Ontonagon, HI
Kimberly Clark Corporation - Munising, Ml
TWO HILLS IN MINNESOTA
SUBTOTAL
Head Corporation - Escanaba. HI
Scott Paper Company - Harinette, WI
Scott Paper Company - Oconto Falls, WI
Badger Paper Hill - Peshtigo. UI
Meneminee Paper Co. - Heneminee, HI
Niagara Paper Co. - Niagara, UI
George Whiting Paper Co. - Henasha, UI
Thilmany (Hammermill) Paper Company -
Kaukauna. UI
Green Bay Packaging - Green Bay, UI
Consolidated Papers - Appleton, UI
Fort Howard Paper Company - Green Bay, UI
Hldtec Paper Co. - Kimberly, UI
Kerwin (Riverside) Paper Co. - Appleton, UI
Kimberly Clark Corp. - Neenah, UI
Appleton Papers Co. - Combined Locks, UI
Bergstrom Paper Co. - Neenah, UI
James River/Dixie Northern - Green Bay, UI
Shawano Paper Hills - Shawano, UI
Nicolet Paper Co. - DePere, UI
Wisconsin Tissue Hills - Henasha. UI
Proctor ft Gamble (Charmin) Co.- Green Bay, UI
Henasha Corp. - Kalamazoo, MI
Uatervliet Paper Co. - Uatervliet. HI
French Paper Co. - Niles, HI
Simplicity Pattern Co. - Niles, HI
Plainwell Paper Co. - Plainwell, HI
Packaging Corp. of America - Filer City, MI
Hanistique Pulp and Paper - Hanistique, HI
FLOU
(mgd)
7.54
1.31
11.65
1.27
76.48
98.25
35.53
3.94
10.89
5.96
3.55
6.20
.35
2.57
1.60
8.73
11.72
6.97
2.23
6.40
6.40
4.50
4.50
4.22
3.06
1.80
14.82
2.56
3.60
1.67
1.23
3.89
6.80
9.98
TSS
3,818
6,361
106,422
1.441
98,334
216,376
211.598
10,890
6,314
13.200
2.471
28.545
1,509
30.855
2.880
27,555
27.005
14,955
6.953
5.068
11,055
21,968
23,265
2,172
6.930
6.105
24,334
6.767
2.883
1.338
309
7.015
8.532
16.268
BOD
3.764
15.065
48.138
2,534
319.229
388,730
68,790
12,750
52,527
18.850
13,094
23,164
521
16,636
9.649
36.496
31.105
8,231
1.593
10,771
16,320
20,101
57,895
1.514
13.688
7.630
45,892
9,861
5.914
2.957
2,112
10,138
4,646
21.965
SUBTOTAL
175.66 528.738 524,810
-23-
-------
TABLE 11: EFFLUENT LOADINGS FROM PULP AND PAPER HILLS IN 1967 (Ibs/day)
(Continued)
LAKE HURON
Basin 40700
LAKE ST. CLAIR
Basin 40900
LAKE ERIE
Basin 41000
Basin 41100
FACILITY NAHE
Fletcher Paper Co. - Alpena, HI
Proctor and Gamble Co. - Cheboygan, HI
Abitibl Corporation - Alpena, HI
SUBTOTAL
Dunn Paper Co. - Port Huron, HI
Port Huron Paper Co. - Port Huron, HI
SUBTOTAL
Simplex Industries - Palmyra, HI
Chase Bag Co. - Chagrin Falls, OH
FLOW
(mgd)
.80
2.49
3.30
6.59
3.80
9.24
13.04
.31
1.51
TSS
1,919
721
72,000
74,640
6,469
3,412
9.881
140
880
BOD
3,802
12.672
31.700
48.174
2.852
5,702
8.554
170
3.740
SUBTOTAL 1.82 1,020 3,910
1967 TOTAL 295.36 830.654 974.178
-24-
-------
TABLE 12: EFFLUENT LOADINGS FROM PULP AND PAPER HILLS IN 1977 (Ibs/day)
LAKE SUPERIOR
Basin 40103
Basin 40201
Basin 40202
LAKE MICHIGAN
Basin 40301
Basin 40302
Basin 40500
Basin 40601
FACILITY NAHE
James River/Dixie Northern, Inc.- Ashland, UI
Superior Fiber Products - Superior, UI
Champion International Corp. - Ontonagon, HI
Kimberly Clark Corporation - Humsing, HI
TWO HILLS IN HINNESOTA
SUBTOTAL
Head Corporation - Escanaba. HI
Scott Paper Company - Hannette, UI
Scott Paper Company - Oconto Falls, WI
Badger Paper Hill - Peshtigo, UI
Heneminee Paper Co. - Heneminee, HI
Niagara Paper Co. - Niagara, UI
George Uhitlng Paper Co. - Henasha, UI
Thilmany (Hammermill) Paper Company -
Kaukauna. UI
Green Bay Packaging - Green Bay. UI
Consolidated Papers - Appleton, UI
Fort Howard Paper Company - Green Bay, UI ,
Hidtec Paper Co. - Kimberly, UI
Kerwin (Riverside) Paper Co. - Appleton, UI
Kimberly Clark Corp. - Neenah. UI
Appleton Papers Co. - Combined Locks, UI
Bergstrom Paper Co. - Neenah, UI
James River/Dixie Northern - Green Bay, UI
Shawano Paper Hills - Shawano, UI
Nicolet Paper Co. - DePere, UI
Uisconsin Tissue Hills - Henasha, UI
Proctor a Gamble (Charmin) Co.- Green Bay, UI
Henasha Corp. - Kalamazoo, HI
Uatervliet Paper Co. - Uatervliet. HI
French Paper Co. - Niles, HI
Simplicity Pattern Co. - Niles, HI
Plalnwell Paper Co. - Plainwell, HI
Packaging Corp. of America - Filer City, HI
Hanistique Pulp and Paper - Hanistlque, HI
FLOU
(mgd)
7.54
1.31
12.35
1.27
56.71
79.18
42.64
3.94
10.89
5.96
3.55
6.20
.16
2.57
1.60
8.73
11.72
6.97
2.33
6.40
6.40
4.50
4.50
4.22
3.06
1.80
14.82
.93
3.60
.45
.19
3.89
6.00
8.82
TSS
797
249
7.062
30B
51,410
59,826
17.187
1,107
5,433
392
528
6.138
143
10,389
102
865
11.066
6,054
480
279
3,047
13,719
2,377
245
675
235
3.567
2,728
616
286
66
1.499
1.823
3.476
BOD
743
1,545
4,378
264
57,458
64,388
5.500
1.254
41.557
447
1.364
9,756
201
6,413
607
4,976
5,730
7,155
447
166
4,150
8,527
5,725
875
1,193
173
1,927
2.173
616
308
220
1.056
484
2,288
SUBTOTAL
176.84
94.522 115.288
-25-
-------
TABLE 12: EFFLUENT LOADINGS FROM PULP AND PAPER HILLS IN 1977 (Ibs/day)
(Continued)
LAKE HURON
Basin 40700
LAKE ST. CLAIR
Basin 40900
LAKE ERIE
Basin 41000
Basin 41100
FACILITY NAHE
Fletcher Paper Co. - Alpena, MI
Proctor and Gamble Co. - Cheboygan, HI
Abitibi Corporation - Alpena, HI
SUBTOTAL
Dunn Paper Co. - Port Huron, HI
Port Huron Paper Co. - Port Huron, MI
SUBTOTAL
Simplex Industries - Palmyra, MI
Chase Bag Co. - Chagrin Falls. OH
FLOW
(mgd)
.80
2.49
3.30
6.59
2.17
9.24
11.41
.19
1.51
TSS
410
154
13,992
14,556
572
729
1.301
55
176
BOD
396
1.320
5,676
7,392
396
594
990
88
374
SUBTOTAL 1.70 231 462
1977 TOTAL 275.72 170,436 188.520
-26-
-------
TABLE 13: EFFLUENT LOADINGS FROM PULP AND PAPER HILLS IN 1982 (Ibs/day)
LAKE SUPERIOR
Basin 40103
Basin 40201
Basin 40202
FACILITY NAME
James River/Dixie Northern, Inc. - Ashland. WI
Superior Fiber Products - Superior. WI
Champion International Corp. - Ontonagon, HI
Kimberly Clark Corporation - Hunising. HI
FLOW
(mgd)
8.60
1.30
11.75
3.82
TSS
1,357
36
10.350
192
BOD
1.635
538
11.240
237
SUBTOTAL
25.47 11,935 13,650
LAKE MICHIGAN
Basin 40301
Basin 40302
Basin 40500
Basin 40601
Head Corporation - Escanaba. HI
Scott Paper Company - Harinette, WI
Scott Paper Company - Oconto Falls, WI
Badger Paper Mill - Peshtigo, WI
Niagara Paper Company - Niagara, WI
George Whiting Paper Co. - Henasha, WI
Thilmany (Hammermill) Paper Company -
Kaukauna. Wl
Green Bay Packaging - Green Bay, WI
Consolidated Papers - Appleton. Wl
Fort Howard Paper Company - Green Bay, WI
Hidtec Paper Co. - Kimberly, WI
Kerwin (Riverside) Paper Co. - Appleton. WI
Kimberly Clark Corp. - Neenah. WI
Appleton Papers Co. - Combined Locks, WI
Bergstrom Paper Co. - Neenah, WI
James River/Dixie Northern, Inc.- Green Bay, WI
Shawano Paper Hills - Shawano. WI
Nicolet Paper Co. - DePere. WI
Wisconsin Tissue Hills - Henasha, WI
Proctor 8 Gamble (Charmin) Co. - Green Bay, WI
Henasha Corp. - Kalamazoo, HI
French Paper Co. - Niles, HI
Simplicity Pattern Co. - Niles, HI
Plainwell Paper Co. - Plainwell, HI
Packaging Corp. of America - Filer City, HI
Hanistique Pulp and Paper Co.- Hanistique, HI
30.63
3.69
1.41
3.61
5.60
(Discharge to
2.57
1.65
(Closed 1982)
11.72
6.97
1.75
3.26
4.70
4.44
8.62
1.90
3.57
1.85
3.19
.39
.66
.28
2.67
5.30
5.16
6,600
1.682
371
3.000
1.841
POTW)
3.901
430
7.B21
1,771
1.725
331
1.907
2,174
2,460
248
863
819
3.430
23
384
66
2.319
2.150
692
7.573
1.288
813
2.406
2.760
1.941
1.022
7,724
2,065
1.562
286
860
2.660
5,986
1.139
1.424
564
941
46
287
220
1.703
540
277
SUBTOTAL
115.59 47.008 46.087
-27-
-------
TABLE 13: EFFLUENT LOADINGS FROH PULP AND PAPER HILLS IN 1982 (Ibs/day)
(Continued)
LAKE HURON
Basin 40700
LAKE ST. CLAIR
Basin 40900
LAKE ERIE
Basin 41000
Basin 41100
FACILITY NAME
Fletcher Paper Co. - Alpena, HI
Proctor and Gamble Co. - Cheboygan, HI
Abitibi Corporation - Alpena, HI
SUBTOTAL
Dunn Paper Co. - Port Huron, HI
Port Huron Paper Co. - Port Huron, HI
SUBTOTAL
Simplex Industries - Palmyra, HI
Chase Bag Co. - Chagrin Falls, OH
FLOW
(mgd)
.51
1.72
3.20
5.43
2.60
7.53
10.13
.16
.77
TSS
120
110
11,500
11.730
660
639
1,299
67
22
BOD
456
97
1,400
1,953
396
977
1,373
90
54
SUBTOTAL
.95
89
144
1982 TOTAL
157.57 72,061 63,207
-28-
-------
TABLE 14: BPT Capital and Annual Cost Summary
for Pulp and Paper Mills in 1974
dollars (x 1,000)
No. of Capital Annual
Mills Costs Costs
Lake Superior
Basin 40103 1 5,100 1,545
Lake Michigan
Basin 40301 5 52,150 15,900
Basin 40302 10 101,835 32,150
Basin 40500 4 13,870 4,920
Basin 40601 2 16,700 6,250
Total 21 184,555 59,220
Lake Huron
Basin 40700 1 2,950 830
Lake St. Clair
Basin 40900
Lake Erie
Basin 41000
Basin 41100
Total
TOTAL
AVERAGE
2
1
1
2
27
11,700
1,850
2,170
4,020
208,325
7,716
3,010
660
770
1,430
66,035
2,446
-29-
-------
V. ORGANIC AND INORGANIC CHEMICAL MANUFACTURING
A. Plants Included in the Survey
Thirty-eight (38) major organic and inorganic chemical manufacturing plants
located in the Region V Great Lakes drainage area were identified. All 38
plants have at some time discharged process wastewater directly to the Great
Lakes drainage area. Of these 38 plants, two (2) have shutdown since
1976 and two (2) no longer discharge process wastewater. Ten (10) of the
plants are classified as organic chemical manufacturers whereas 28
plants are classified as inorganic chemical manufacturers according to
the SIC codes in the IFD file.
B. Survey Methods
The chemical manufacturing plants were identified from the EPA's IFD file
plant listings and cross-referenced with the appropriate State inventories. The
IFD file was found to be fairly complete. The EGD inventory did not include
many plants (only 7 of the 38 plants). Therefore, the list of plants from the
IFD file verified with State data was used as the basis for identifying plants
to include in the survey. Each plant was identified by SIC code, WRC accounting
unit, and lake basin based on information in the IFD file.
The flow and effluent loading data for each plant for the 1968 time period
were derived from State files and IJC references. State monitoring reports,
early permits applications, and discharge monitoring reports (DMRs) were
reviewed for appropriate data. Data was either reproduced or transcribed
directly from the State files as appropriate. Verification and collection of
data not obtained from visits to the State offices was performed by telephone.
Flow values and effluent loadings for each plant for the 1976 time period
were also collected from the appropriate State offices and verified with EGD and
IJC data where available.
The data for the 1982 time period were calculated from the monthly loading
values for each pipe for each plant in the STORET data base. The actual
effluent loading values for each month were averaged over the entire one year
period. In some cases where only effluent concentration data in mg/1 were
recorded, loadings in Ibs/day were calculated using the average flow rate in mgd
with the following formula:
Average load (Ibs/day) = average concentration (mg/1) x
average flow (mgd) x 8.34
(conversion factor)
The 1982 data is presented without modification from the STORET computer
printouts. The flow rates include all discharges that are monitored on a
routine basis. These discharges contain wastewater other than process
wastewater, such as storm runoff, cooling water, etc. No method of calculating
only process wastewater flow was identified. Therefore, some flow values for
1982 may be higher than actual process wastewater discharge rates (as presented
-30-
-------
for 1968 and 1976). Most data points including flow obtained from the STORE!
system were verified with existing State data in files or by telephone contact
and modified, if appropriate.
C. Survey Results
The effluent flow rates and pollutant loadings are presented in tabular
form. Each table represents a separate time period (i.e., 1968, 1976, and 1982)
and presents the data by plant and lake basin. The following parameters are
presented: flow (mgd), TSS, BOD, COD, ammonia, chloride, and total phosphorus.
Table 15 presents the 1968 effluent loadings for 38 plants based on State
and IOC information. Data for six (6) plants were estimated as noted in the
table.
Table 16 presents the 1976 effluent loadings data for 38 plants based on
State, EGO, and IJC information.
Table 17 presents the most recent data from the STORET data base for 34
plants which includes monthly average values from 1982 verified with State
information. Graphs showing effluent loadings by time period are included in
the Appendix.
D. Cost of Effluent Reductions
The average capital costs and annual costs for the organic and inorganic
chemical manufacturing plants were derived from the EGO model plant cost
summaries for BPT and BAT (BPT only for organic chemical plants) levels of
effluent reduction. The model plant cost summaries are found in the final
Inorganic Chemical Development Document (EPA 440/1-82/00) and the proposed
Organic Chemical Development Document (EPA 440/1-83/009-b). These costs include
the capital cost of installing treatment facilities needed to meet the
appropriate BPT and BAT effluent limitations, as well as the annual operation,
maintenance, and amortization costs. Since specific EGD cost data was available
for only two of the inorganic chemical manufacturers and none of the organic
chemical manufacturers, the average costs per plant were calculated using the
following assumptions: (1) all 10 inorganic chemical subcategories were
assumed to be represented equally within the 28 inorganic chemical
manufacturers, and (2) the types of organic chemical manufacturers were
distributed among the 10 organic manufacturing plants in a similar manner to
those inventoried by EGD. The gross cost summary is presented in Table 18 by
lake basin for both organic and inorganic manufacturers. Costs are presented in
1977 dollars.
-31-
-------
TABLE 15: EFFLUENT LOADINGS FROM INORGANIC AND
ORGANIC CHEMICAL MANUFACTURERS IN 1968
(Ibs/day)
LAKE MICHIGAN
Basin 40301
Basin 40400
Basin 40500
Basin 40601
FACILITY NAME
Ansul Co. - Marlnette. WI
Fromm Laboratories, Inc. - Graf ton, WI
Union Carbide Corp. - Gary, IN
DuPont Co. - E. Chicago. IN
Hansen's Laboratory - Milwaukee, WI
Hexcel Corporation - Zealand, HI (EST.)
BASF Uyandotte (Pigment) - Holland, MI
Dow Chemical Co. - Ludtngton, MI
Morton Chemical Co. - Manistee, MI
Hooker Chemical Co. - Montague, HI
Martin Marietta Corp. - Manistee. MI
FLOW
(mgd)
.85
.01
46.30
1.90
.05
.16
.53
28.60
.85
16.70
.51
TSS
148
7
682
1,009
6
118
219
114,500
7,514
5,980
2
COD
1.477
4
' 18,011
739
12
62
1.450
12,750
331
4.007
17
Ammonia
23
0
1,250
51
1
4
4
6,279
73
34
14
Chloride
1.422
70
322.665
13.241
12
558
3,694
1.331.100
49,374
220.806
48
Phosphorus
2.0
.0
92.6
3.8
2.0
.3
4.8
57.0
2.0
18.0
.3
BOD
1,042
0
3,929
46
0
4
704
686
20
136
5
I
to
ro
LAKE HURON
SUBTOTAL 96.46 130,185 38,860 7.733 1,942,990
SUBTOTAL 91.40 10,369 3,788
73 118,956
182.8 6,572
Basin 40802
Dow Chemical Co.
Bay Chemical Co.
- Midland,
- Bay City
MI
. MI
(EST.)
90.40
1.00
9,633
736
3,399
389
46
27
111,987
6.969
13.9
2.0
444
24
15.9
468
LAKE ST.CLAIR
Basin 40900
Diamond Crystal Salt Co.- St.Clalr, MI
Monsanto Corporation - Trenton. HI
Pennwalt Corporation - Wyandotte, MI
BASF Wyandotte Corp. (North) - Wyandotte
BASF Wyandotte Corp. (South) - Wyandotte
(EST.)
, NI
, MI
11.00
22.98
28.76
69.90
9.62
8,096
4.408
4.715
23.160
31.747
4
8
25
41
60
.279
.939
,280
.193
.974
297
211
2.992
3.137
260
226
7
8
240
55
.850
.283
.779
,589
.743
22.0
345.0
58.0
86.0
67.0
264
552
2.110
6.563
1,387
SUBTOTAL 142.26 72,126 140.665 6,897 539,244
578.0 10,876
-------
TABLE 15: EFFLUENT LOADINGS FROM INORGANIC AND
ORGANIC CHEMICAL MANUFACTURERS IN 1968
(Continued)
I
co
CO
LAKE ERIE FACILITY NAME
Basin 41000 Stauffer Chemical Co. - Weston, HI
Air Products and Chemicals - N. Baltimore. OH
Vlstron Corporation - Lima. OH
USCO Services (Unlroyal) - Port Clinton, OH
Basin 41100 RMI Company (Na a Cl Plant) - Ashtabula, OH
RMI Company (Metals Plant) - Ashtabula. OH
01 In Corporation - Ashtabula, OH
General T1re and Rubber Co. - Ashtabula, OH
SCM Corporation (Plant 11) - Ashtabula, OH
SCM Corporation (Plant 12) - Ashtabula, OH
Diamond Shamrock Corp.- Pa1nesv1lle, OH
LCP Chemical (IMC Chemical) - Ashtabula, OH
Diamond Shamrock Corp.- Ashtabula, OH (EST.)
Glyco Chemicals, Inc. - Pa1n?sv1lle, OH
Zlrcoa Products/Corning Glass - Solon, OH
Lubrlzol Corp. - W1ckl1ffe, OH
Hall Chemical Co. - Uickllffe, OH (EST.)
Dupont Company - Cleveland, OH
Harshaw Chemical Co. - Cleveland, OH
SOS Biotech Inc. - Concord, OH (EST.)
SUBTOTAL
1968 TOTAL
FLOW
(mgd)
.23
.05
2.87
.45
3.82
1.44
.40
.41
1.22
1.74
79.80
2.91
.83
1.53
.11
.13
.18
1.20
1.50
.90
101.72
431.84
TSS
165
13
250
119
2,500
204
240
68
98
325
63,929
243
611
1.400
62
235
132
340
70
662
71,666
284,346
COO
510
18
2.000
175
1,321
305
4,345
252
514
703
7,991
128
323
596
686
48
70
240
740
350
21,315
204,628
Ammonia
6
1
1.530
6
92
1
11
21
33
24
1.345
8
22
41
3
4
5
250
263
24
3.690
18.393
Chloride
1,630
0
10,000
3,136
23,672
2.100
26,957
644
10.110
10,269
592,679
2,301
5,784
10.663
5,452
905
1,250
3,500
7,188
6,272
724.512
3.325,702
Phosphorus
9.2
1.0
6.9
.7
6.8
2.5
.8
4.0
2.4
9.4
91.0
.6
1.7
3.1
3.3
.0
.4
2.4
2.5
1.8
150.5
927.2
BOD
346
5
7
309
82
12
10
34
29
308
1.915
8
26
5.300
7
6
0
7
96
22
8.529
26.445
-------
TABLE 16: EFFLUENT LOADINGS FROM INORGANIC AND
ORGANIC CHEMICAL MANUFACTURERS IN 1976
(Ibs/day)
LAKE MICHIGAN
Basin 40301
Basin 40400
Basin 40500
Basin 40601
FACILITY NAME
Ansul Co. Marlnette, WI
Froimn Laboratories, Inc. - Graf ton, WI
Union Carbide Corp. - Gary, IN
DuPont Co. - E. Chicago. IN
Hansen's Laboratory - Milwaukee, WI
Hexcel Corporation - Zeeland, HI
BASF Wyandotte Corp. (Pigment) - Holland. MI
Dow Chemical Co. - Ludlngton. HI
Norton Chemical Co. - Manistee, MI
Hooker Chemical Co. - Montague, MI
Martin Marietta Corp. - Hams tee, MI
FLOW
(mgd)
.70
.00
115.20
5.02
.05
.13
.81
28.60
.71
9.36
.71
TSS
154
6
11,290
602
5
10
195
935
26
598
260
COD
592
17
23.270
1.224
10
90
2,123
104
143
1,997
278
Ammonia
1
2
2.152
1.303
1
1
943
35
1
280
75
Chloride
1.915
6
40,018
2.505
12
689
880
110,420
37,400
43.735
280.000
Phosphorus
1.7
.1
172.8
4.0
2.0
.1
1.6
10.2
1.0
14.0
1.0
BOD
67
2
2.760
40
9
4
536
6
15
4
21
I
OJ
r
LAKE HURON
SUBTOTAL 161.29
14,081 29,848 4,794
517,580
SUBTOTAL 91.35
785
800
24
7,282
LAKE ST.CLAIR
SUBTOTAL 117.88
29.749 76,722 7.157 1.513.158
208.4
2.8
3,464
Basin 40802
Oow Chemical
Bay Chemical
Co.
Co.
- Midland,
- Bay City
HI
. MI
90.40
.95
579
206
606
194
23
1
6,731
551
.9
1.9
154
56
210
Basin 40900
Diamond Crystal Salt Co.- St. Clalr. Ml
Monsanto Corporation - Trenton, MI
Pennwalt Corporation - Wyandotte, HI
BASF Wyandotte Corp. (North) - Wyandotte,
BASF Wyandotte Corp. (South) - Wyandotte,
MI
MI
11
13
29
40
23
.00
.08
.80
.30
.70
5,950
763
6,659
8,506
7,871
3,145
1,547
25.280
45,772
978
218
175
2.99Z
3.737
35
226
5
1,075
204
,850
.672
742
.520
.374
16.2
436.3
44.7
80.5
45.8
194
94
2,110
6.563
1,387
623.5 10,348
-------
TABLE 16: EFFLUENT LOADINGS FROM INORGANIC AND
ORGANIC CHEMICAL MANUFACTURERS IN 1976
(Continued)
CO
en
LAKE ERIE
Basin 41000
Basin 41100
FACILITY NAME
Stauffer Chemical Co. - Weston. HI
Air Products and Chemicals - N. Baltimore, OH
Vlstron Corporation - Lima, OH
USCO Services (Unlroyal) - Port Clinton. OH
RHI Company (Na & Cl Plant) - Ashtabula. OH
RNI Company (Metals Plant) - Asntabula, OH
01 1n Corporation - Ashtabula, OH
General Tire and Rubber Co. - Ashtabula, OH
SCM Corporation (Plant »1) - Ashtabula. OH
SCM Corporation (Plant 12) - Ashtabula, OH
Diamond Shamrock Corp.- Palnesvllle, OH
LCP Chemical (IHC Chemical) - Ashtabula, OH
Diamond Shamrock Corp.- Ashtabula, OH
Glyco Chemicals, Inc. - Painesvllle, OH
21rcoa Products/Corning Glass - Solon, OH
Lubrlzol Corp. - Ulckliffe, OH
Hall Chemical Co. - Wickllffe. OH
Dupont Company - Cleveland. OH
Harshaw Chemical Co. - Cleveland, OH
SOS Biotech Inc. - Concord, OH
SUBTOTAL
1976 TOTAL
FLOW
(mgd)
.14
.05
2.32
1.40
3.82
.04
.45
.29
.80
2.36
.17
3.95
.83
.29
.05
.16
.18
1.37
2.10
.90
21.67
392 . 20
TSS
41
13
193
36
2.500
2
57
27
34
1,674
13
21
55
256
33
25
15
102
233
105
5,435
50,050
COO
208
18
1,544
53
772
9
91
159
242
3.621
34
11
29
113
11
48
8
170
68
931
8,140
115,510
Ammonia
2
1
278
64
90
1
10
99
11
33
5
1
2
8
1
3
3
75
161
1
847
12.822
Chloride
904
0
7.720
949
20.254
212
2,386
322
5.707
52,828
901
288
526
1.538
1,877
96
142
1.361
3,293
995
102.299
2,140,319
Phosphorus
2.3
1.0
38.1
7.6
5.7
.0
.1
.4
1.5
3.5
9.2
5.9
1.2
.4
.1
.0
.0
2.0
.2
1.4
80.6
915.2
BOO
98
4
39
15
18
2
12
14
67
71
1
8
4
1.004
9
6
5
2
19
225
1,623
15.645
-------
TABLE 17: EFFLUENT LOADINGS FROM INORGANIC AND
ORGANIC CHENICAL MANUFACTURERS IN 1982
(Ibs/day)
i
CJ
LAKE MICHIGAN
Basin 40301
Basin 40400
Basin 40500
Basin 40601
FACILITY NAME
Ansul Co. - Harlnette, UI
Fromm Laboratories Inc. - Grafton, WI
Union Carbide Corp. - Gary, IN
DuPont Co. - E. Chicago. IN
Hansen's Laboratory - Milwaukee, WI
Hexcel Corporation - Zeeland, HI
BASF Wyandotte Corp. (Pigment) - Holland, MI
DOM Chemical Co. - Ludlngton, MI
Norton Chemical Co. - Manlstee. HI
Martin Marietta Corp. - Manlstee, MI
Hooker Chemical Co. - Montague, MI
FLOW
(mgd)
.95
.01
115.00
4.45
.17
.25
.60
12.87
.52
2.14
4.70
TSS
27
1
7,820
195
0
4
104
62
12
243
82
COD
7
4
3.565
138
2
32
1,080
399
16
232
274
Ammonia
.0
.6
920.0
32.5
.0
.1
14.8
21.2
1.1
60.3
38.4
Chloride
160
27
7,216
349
0
245
7,497
12.304
15,262
167,139
5,997
Phosphorus
.3
.3
23.0
.2
.1
.1
1.3
2.6
.5
.5
1.9
BOD
52
2
1.610
13
6
2
24
a
10
20
3
SUBTOTAL 141.65
8,550 5,749 1.089.0
216,196
30.7
1,750
LAKE HURON
Basin 40802
Dow Chemical
Bay Chemical
Co.
Co.
- Midland,
- Bay City
HI
, HI
54.92
2.73
2,121
265
2,220
747
84.5
4.5
24,657
0
3.3
1.4
885
50
SUBTOTAL 57.65 2,386 2.967
89.0
24.657
4.7
935
LAKE ST.CLAIR
Basin 40900 Diamond Crystal Salt Co.- St. Clalr. MI
Monsanto Corporation - Trenton, MI
Pennwalt Corporation - Wyandotte, MI
BASF Wyandotte Corp. (North) - Wyandotte,
BASF Wyandotte Corp. (South) - Wyandotte,
MI
HI
(Stor
16
30
7
50
m Runoff Only)
.73
.52
.44
.11
4
3,072
1,570
7,263
1.336
11,662
8,450
6.456
441
1,760
5
121
.0
.0
.1
.6
3
102
139
,489
342
,835
,175
38.9
20.6
14.9
24.5
120
478
1.426
1,720
SUBTOTAL 104.80 11.909 27,904 2.327.7 245.841
98.9 3,744
-------
TABLE 17: EFFLUENT LOADINGS FROM INORGANIC AND
ORGANIC CHEMICAL MANUFACTURERS IN 1982
(Continued)
i
co
LAKE ERIE
Basin 41000
Basin 41100
FACILITY NAME
Stauffer Chemical Co. - Weston, HI
Air Products and Chemicals - N. Baltimore, OH
USCO Services (Unlroyal) - Port Clinton, OH
Vlstron Corporation - Lima, OH
RNI Company (Na 4 Cl Plant) - Ashtabula, OH
Diamond Shamrock Corp.- Ashtabula, OH
Diamond Shamrock Corp.- Palnesville, OH
Dupont Company - Cleveland, OH
General Tire and Rubber Co. - Ashtabula, OH
Glyco Chemicals. Inc. - Palnesville, OH
Hall Chemical Co. - Wlckllffe. OH
Harshaw Chemical Co. - Cleveland. OH
LCP Chemical (IMC Chemical) - Ashtabula, OH
Lubrlzol Corp. - Wlckllffe, OH
Olln Corporation - Ashtabula, OH
RHI Company (Metals Plant) - Ashtabula. OH
SCn Corporation (Plant 11) - Ashtabula, OH
SCM Corporation (Plant 12) - Ashtabula, OH
SOS Biotech Inc. - Concord, OH
Zircoa Products/Corning Glass - Solon, OH
SUBTOTAL
1982 TOTAL
FLOW
(mgd)
.05
.03
.14
2.40
10.00
.17
(Closed
.82
.38
TSS
8
1
8
328
1,357
13
1977)
75
32
COD
2
5
5
125
310
6
170
44
Ammonia
.4
.2
1.2
188.0
80.0
1.4
65.0
3.0
(No Process Discharge)
.18
1.43
3.95
.16
(Closed
.04
1.07
2.43
.45
.05
23.75
327.85
18
92
21
25
1981)
2
89
6,728 4
23
33
8,852 5
31,697 42
6
68
12
48
9
36
,828
186
11
.871
,491
1.4
71.0
1.0
2.2
.3
8.6
19.4
.5
1.0
444.6
3,950.3
Chloride
48
0
134
2.294
9.560
163
1,361
364
132
1,367
267
80
38
1,023
8.323
430
900
26,484
513.178
Phosphorus
.0
.0
.9
2.4
5.0
.2
.8
.4
.0
.2
3.9
.0
.0
1.1
2.4
.5
.0
17.8
152.1
BOD
1
1
7
6
10
2
2
12
3
19
9
6
2
16
43
92
9
240
6.669
-------
TABLE 18: BPT Capital and Annual Cost Summary
for Organic and Inorganic Chemical
Manufacturing Plants in 1977 dollars
(x 1.000)
ORGANIC CHEMICAL MANUFACTURERS
INORGANIC CHEMICAL MANUFACTURERS
Lake Michigan
Basin 40400
Basin 40500
TntAl
Lake St. Clair
Lake Erie
Basin 41000
Basin 41100
TntAl
TOTAL
AVERAGE
No. Of
Plants
1
2
>
1
4
10
Capital
Costs
716
1.436
2T>7
1 4BK
795
2.872
3CC7
7,305
731
Annual
Costs
178
335
11 \
wfi
185
669
OCA
1.693
169
Lake Michigan
Basin 40301
Basin 40400
Total
Basin 40802
Lake St. Clair
Basin 40900
1 abA Cr IP
Basin 41000
Basin 41100
Total
TOTAL
AVERAGE
No. of
Plants
1
3
8
2
3
3
12
IS
28
Capital
Costs
461
4.964
,013
9,438
913
3.930
1.542
18.499
20,041
34.322
1,226
Annual
Costs
273
2.626
.696
5.595
541
2.432
925
12.529
13,454
22.022
787
-38-
-------
VI. PETROLEUM REFINING
A. Refineries Included in the Survey
Sixteen (16) major petroleum refineries located in the Region V Great Lakes
drainage area were identified. All 16 refineries have at some time discharged
process wastewater directly to the Great Lakes drainage basin. Of these 16
refineries, five (5) have shutdown since 1972, one (1) has not discharged
process wastewater since 1974, and one (1) currently dischrges to a POTW. There
are currently nine (9) refineries discharging process wastewater to the Great
Lakes drainage basin.
B. Survey Methods
The petroleum refineries were identified from the EPA's IFD file plant
listings and cross-referenced with the EPA EGD plant inventory in the Final
Development Document for petroleum refining. The IFD file was found to be more
complete since EGD did not include all refineries in their inventory (11 of the
16 refineries). Therefore, the list of refineries from the IFD file was used as
the basis for identifying plants to include in the survey. The list was
verified with IJC reports on petroleum refineries and State information. Each
refinery was identified by WRC accounting unit and lake basin based on
information in the IFD file.
The flow and effluent loading data for each refinery for 1968 were derived
from State files and IJC references. State monitoring reports, early permit
applications, and discharge monitoring reports (DMRs) were reviewed for
appropriate data. Data was either reproduced or transcribed directly from State
files as appropriate.
Flow values and effluent loadings for the 1976 time period were also
collected from the appropriate State offices for each refinery. Collected data
were compared with EGD and IJC effluent loading values to verify accuracy where
data was available.
The data for the 1982 time period were calculated from the monthly loading
values for each pipe for each plant in the STORET data base. The actual
effluent loading values for each month were averaged over the entire one year
period. In some cases where only effluent concentration data in mg/1 were
recorded, loadings in Ibs/day were calculated using the average flow rate in mgd
with the following formula:
Average load (Ibs/day) = average concentration (mg/1) x
average flow (mgd) x 8.34
(conversion factor)
The 1982 data are presented without modification (except for obvious entry
errors) from the STORET computer printouts. Data points obtained from the
STORET system were verified with State and IJC data where available.
-39-
-------
C. Survey Results
The effluent flow rates and pollutant loadings are presented in tabular
form. Each table represents a separate time period (i.e., 1968, 1976, and 1982)
and presents the data by refinery and lake basin. The following parameters are
presented: flow (mgd), TSS, oil and grease, ammonia, total phenolics, BOO, and
COD.
Table 19 presents the 1968 effluent loadings for 16 refineries based
on State and IJC information.
Table 20 presents the 1976 effluent loadings data for 13 refineries based
on EGO, IJC, and State information.
Table 21 presents the most recent data from the STORET data base for 9
refineries which includes monthly values for 1982 verified with State and IJC
information. Graphs showing effluent loadings by time period are included in the
appendix.
D. Cost of Effluent Reductions
The capital and annual costs for 11 of the 16 refineries were derived from
the EPA Economic Impact Analysis of Effluent Limitations and Standards for the
Petroleum Refining Industry (EPA-440/2-82-007). These costs include the capital
cost of required treatment facilities and annual costs needed to meet the
appropriate BAT effluent limitations. Annual costs include operation, maintenance,
and amortization costs.
The cost summary is presented in Table 22 by WRC accounting unit and lake
basin. Costs are presented in 1977 dollars.
-40-
-------
TABLE 19: EFFLUENT LOADINGS FROM PETROLEUM
REFINERIES IN 1968 (Ibs/day)
LAKE SUPERIOR
Basin 40102
Basin 40103
LAKE MICHIGAN
Basin 40400
Basin 40500
LAKE HURON
Basin 40801
Basin 40802
LAKE ERIE
Basin 41000
FACILITY NAME
Phillips Petroleum Co.- Cloquet, HN (EST.)
Murphy Oil Co. - Superior, HI
SUBTOTAL
Energy Cooperative - E.Chicago. IN (EST.)
American Oil Co. - Whiting, IN
Cities Services Oil Co. - E. Chicago, IN
Mobil Oil Co. - E. Chicago. IN
Sinclair Oil Co. - E. Chicago, IN
Lakeside Refining Co. - Kalamazoo, MI
Crystal Refinery - Carson City, MI (EST.)
SUBTOTAL
Osceola Refining Co. - losco. MI
Total Petroleum. Inc. - Alma. HI
Dow Bay Refinery - Bay City. HI
SUBTOTAL
Standard Oil Company - Lima. OH
Standard Oil Company - Toledo, OH
Sun Oil Company - Toledo, OH
Gulf Oil Co. - Toledo, OH
FLOW
(mgd)
1.71
.68
2.39
3.60
127.10
63.00
2.70
3.90
.59
.84
201.73
.30
.58
155.71
156.59
3.17
35.30
1.91
54.50
TSS
35
113
148
26
4,200
5,741
1,244
1,230
103
506
13,050
42
121
21.027
21,190
2.508
18.800
2,220
3,200
BOD
50
595
645
2.051
18.452
3,872
1.897
4,419
36
907
31.634
52
96
15,231
15,379
4.733
23,500
2.470
7.600
COD
70
3.390
3,460
5.660
20.918
23,774
1.019
1,472
243
3,786
56.872
173
787
59.935
60,895
28.934
20.300
5.065
12,260
Ammonia
22
340
362
478
2,688
398
106
520
5
298
4,493
6
198
1,230
1.434
6,544
706
190
215
0&6
15
164
179
377
5,271
2,252
492
1.700
75
103
10.270
6
5
4.018
4,029
288
600
492
1,002
Phenols
2.2
680.5
682.7
103.6
175.1
82.0
89.0
111.0
2.4
21.9
585.0
1.4
96.0
461.0
558.4
.7
42.0
6.8
2.0
SUBTOTAL 94.88 26.728 38.303 66.559 7,655 2.382 51.5
1968 TOTAL 455.59 61.116 85,961 187,786 13,944 16,860 1,877.6
-41-
-------
TABLE 20: EFFLUENT LOADINGS FROM PETROLEUM
REFINERIES IN 1976 (Ibs/day)
LAKE SUPERIOR
Basin 40102
Basin 40103
LAKE MICHIGAN
Basin 40400
Basin 40500
LAKE HURON
Basin 40801
Basin 40B02
LAKE ERIE
Basin 41000
FACILITY NAME
Phillips Petroleum Co. - Cloquet, HN
Murphy 011 Co. - Superior. HI
SUBTOTAL
Energy Cooperative, Inc.- E. Chicago, IN
American Oil Co. - Whiting. IN
C.F. Petroleum (Sinclair) - E. Chicago. IN
Cities Services Oil Co. - E. Chicago, IN
Mobil Oil Co. - E. Chicago, IN
Lakeside Refining Co. - Ka lama zoo, HI
Crystal Refinery - Carson City, MI (EST.)
SUBTOTAL
Osceola Refining Co. - losco, MI
Total Petroleum, Inc. - Alma, MI
Dow Bay Refinery - Bay City, MI
SUBTOTAL
Standard Oil Company - Lima, OH
Standard Oil Company - Toledo, OH
Sun Oil Company - Toledo, OH
Gulf Oil Co. - Toledo, OH
SUBTOTAL
1976 TOTAL
FLOU
(mgd) TSS
1.71 40
.17 48
1.88 88
3.60 10
129.90 1.609
4.76 1.091
BOD
28
49
77
355
1.340
560
COD
55
322
377
1,396
5.160
1,797
Ammonia
7
22
29
109
730
728
OSG
15
15
30
169
1.980
344
Phenols
.2
.2
.4
16.1
27.2
8.0
(No Process Discharge)
(Closed 1972)
1.08 24
.84 195
140.18 2.929
.16 9
.34 21
(Closed 1976)
.50 30
4.36 1.340
46.00 7,407
2.32 1.134
63.20 359
115.88 10.240
258.44 13,287
39
157
2.451
6
24
30
1.668
3.683
1.009
269
6.629
9,187
165
934
9.452
46
158
204
2.602
9.816
3,356
645
16.419
26,452
1
68
1.636
4
2
6
667
755
131
193
1,746
3,417
53
46
2.592
0
10
10
205
500
321
42
1.068
3,700
.3
3.4
55.0
.1
.2
.3
.5
4.0
1.5
2.0
8.0
63.7
-42-
-------
TABLE 21: EFFLUENT LOADINGS FROM PETROLEUM
REFINERIES IN 1982 (Ibs/day)
LAKE SUPERIOR
Basin 40102
Basin 40103
LAKE HI CHI 6 AN
Basin 40400
Basin 40500
LAKE HURON
Basin 40801
Basin 40802
LAKE ERIE
Basin 41000
FACILITY NAHE
Phillips Petroleum Co.- Cloquet. HN
Hurphy Oil Co. - Superior, WI
SUBTOTAL
Energy Cooperative, Inc.- E. Chicago, IN
American Oil Co. - Whiting. IN
C.F. Petroleum - E. Chicago, IN
Lakeside Refining Co. - Kalamazoo, HI
Crystal Refinery - Carson City, HI
SUBTOTAL
Osceola Refining Co. - losco. HI
Total Petroleum, Inc. - Alma, HI
SUBTOTAL
Standard Oil Company - Lima, OH
Standard Oil Company - Toledo. OH
Sun Oil Company - Toledo, OH
Gulf Oil Co. - Toledo. OH
FLOW
(mgd)
(Closed 1979)
.25
.25
.77
114.80
(Closed 1977)
1.26
(Discharge to
116.83
.11
.50
.61
5.10 1.
30.59 1.
2.60
(Closed 1981)
TSS
52
52
75
506
21
POTH)
602
7
74
80
076
275
253
BOO
86
86
162
444
34
640
7
158
165
1,176
765
423
COD
417
417
637
3,680
132
4.449
12
233
245
1.876
10.970
915
Ammonia
35
35
12
212
0
224
2
5
7
463
36
69
OS6
55
55
13
254
41
308
1
19
21
238
350
80
Phenols
3.7
3.7
5.2
1.0
.2
6.4
.0
.5
.5
34.9
4.0
1.4
SUBTOTAL
38.29 2,604 2,364 13.761
568 668 40.3
1982 TOTAL 155.98 3.338 3.255 18,872
834 1.052 50.9
-43-
-------
TABLE 22: BAT Capital and Annual Cost
Summary for Petroleum Refineries
in 1977 Dollars (x 1,000)
Lake Superior
Basin 40103
No. of
Refineries
Capital
Costs
145
Annual
Costs
47
Lake Michigan
Basin 40400
Basin 40500
2
1
2,995
130
433
40
Total
3,125
473
Lake Huron
Basin 40801
Basin 40802
1*
160
330
50
103
Total
490
153
Lake Erie
Basin 41000
Total
TOTAL
AVERAGE
Note:
2
3
5
11
152
972
1,124
4,884
444
419
388
807
1,480
135
Costs reflect two levels of treatment.
Level 1 is flow reduction to 73% of model flow
plus equalization and filtration. Level 2
is all of Level 1 plus activated carbon or
rotating biological contactors (RBCs). All
costs are for Level 1 treatment except those
noted by an asterisk (*).
-44-
-------
VII. FERROUS AND NONFERROUS FOUNDRIES
A. Foundries Included in the Survey
Fifty-six (56) ferrous and nonferrous foundries in the Region V Great Lakes
drainage area were identified. All 56 plants currently discharge process
wastewater directly to the Great Lakes drainage basin. For the purposes of this
survey, ferrous foundries include foundries which cast gray iron, malleable
iron, and steel. Non-ferrous foundries include foundries which cast aluminum,
copper, brass, zinc, magnesium, titanium, lead, and bronze.
B. Survey Methods
The foundries were identified from EPA's IFD file plant listings and cross-
referenced with the EPA EGD plant inventory and State information. The IFD file
was found to be more complete since EGD did not include all foundries in their
inventory (23 of the 56 plants). Therefore, the list of foundries from the IFD
file was used as the basis for identifying foundries to include in the survey.
Each foundry was identified by SIC code, WRC accounting unit, and lake basin
based on information in the IFD file.
The flow and effluent loading data for each foundry for 1968 were collected
from State files which included monitoring surveys, early permit applications,
and discharge monitoring reports (DMRs) where available. In many cases, no data
for 1968 were found for foundries. This lack of data is noted on the table
where appropriate. Data had to be estimated for 35 of the 56 foundries for the
1968 time period.
Flow values and effluent loadings for the 1976 time period were also
obtained from State information for each foundry. State data were verified with
EGD foundry inventory data where available. Data had to be estimated for 10 of
the 56 foundries.
The data for the 1982 time period were calculated from the monthly loading
values for each pipe for each foundry in the STORET data base. The actual
effluent loading values for those parameters monitored were averaged over the
entire one year period. In some cases where only effluent concentration data in
mg/1 were recorded, loadings in Ibs/day were calculated using the average flow
rate in mgd with the following formula:
Average load (Ibs/day) = average concentration (mg/1) x
average flow (mgd) x 8.34
(conversion factor)
The 1982 data are presented without modification from the STORET computer
printouts. STORET data were verified with State information, where available.
-45-
-------
C. Survey Results
The effluent flow rates and pollutant loadings are presented in tabular
form. Each table represents a separate time period (i.e., 1968, 1976, and 1982)
and presents the data by foundry and lake basin. The following parameters are
presented: flow (mgd), TSS, oil and grease, ammonia, total phosphorus, COD, and
total metals. Total metals includes iron, copper, nickel, zinc, total chromium,
lead, and cadmium.
Table 23 presents the estimated 1968 effluent loadings for 56 foundries
based on State information.
Table 24 presents the 1976 effluent loadings data for 56 foundries based on
EGD and State information.
Table 25 presents the most recent data from the STORET data base for 56
foundries which includes average monthly values from 1982 verified with State
information. Graphs showing effluent reductions by time period are included in
the Appendix.
D. Cost of Effluent Reductions
The capital and annual costs for foundries were derived from the EGD cost
summaries for the BPT levels of effluent reduction. These costs include capital
and annual costs of treatment facilities needed to meet the appropriate BPT
effluent limitations. The annual costs include operation, maintenance, and
amortization costs. These cost estimates were derived from average costs for
each type of foundry (e.g., gray iron and copper) as presented in the report
Economic Analysis of Proposed Effluent Limitations and Standards for
the Foundry Industry (EPA-44072-82-016)
The cost summary for the foundries is presented in Table 26 by lake basin
and WRC accounting unit. Costs are presented in 1978 dollars.
-46-
-------
TABLE 23: EFFLUENT LOADINGS FROM
FOUNDRIES IN 1968 (Ibs/day)
LAKE MICHIGAN
Basin 40301
Basin 40302
Basin 40400
Basin 40500
Basin 40601
FACILITY NAME
Brilllon Iron Works - BHlllon, WI
Gllson Bros. Co. - Plymouth. WI (EST.)
Medalist State Foundry - Cedar Grove. WI (EST.)
Tecumseh Products Co. - Sheboygan, WI (EST.)
Waupaca Foundry (11) - Waupaca. WI
Neenah Brass & Al Foundry - Neenah, WI
Neenah Foundry (Plant 12) - Neenah. WI (EST.)
NcQuay - Perfex, Inc. - Berlin, WI
Universal Foundry Co. - Oshkosh, WI
American Steel Foundries - E. Chicago. IN
Ampco Metal Division - Milwaukee, WI
Badger Die Casting Corp. - Milwaukee. WI
Blaw-Knox S Mill Machines - E. Chicago. IN
Brlggs & Stratton Corp - W. All1s. WI
Dayton Malleable Inc. - Cedarburg. WI
Federal Malleable Co. - W. Allls, WI
Grey Iron Foundry - W. Allls, WI
Howmet Corporation - Milwaukee, WI
Milwaukee Malleable A Grey Iron - Milwaukee, WI
Motor Casting Co. (Pit 11) - W. Allls, WI
Motor Casting Co. (Pit 12) - Milwaukee, WI
Pelton Cast Steel Co. - Milwaukee, WI
Stroh Die Casting Corporation - Milwaukee. WI
Wehr Steel Co. - W. Allls. WI
ESTIMATED LOADINGS FOR 17 FOUNDRIES
Attwood Corp. - Lowell, MI
Auto Specialties - St. Joseph, MI
Bonn Aluminum and Brass - Holland, HI
Brooks Foundry - Albion, HI (EST.)
Campbell, Wyant. & Cannon - S. Haven. MI (EST.)
Du-Well Products, Inc. - Bangor, HI
Dynac Corp. - St. Joseph, HI
Hoover Ball 4 Bearing Co. - Adrian, HI
Hoover Universal, Inc. - Charlotte, HI
Hoover NSK Bearing Co. - Ann Arbor, HI (EST.)
New Products Corp. - Benton Harbor, MI
Nelson Metal Products - Grandvllle, HI
Reynolds Metals - Grand Rapids. HI
Sundstrand Heat Transfer - Dowaglac, HI
Campbell, Wyant, * Cannon - Huskegon, MI (EST.)
East Jordan Iron Works, Inc. - E. Jordan, HI
Great Lakes Casting Corp. - Ludlngton.MI (EST.)
Sealed Power Co. - Huskegon Hgts, HI (EST.)
Westran Corp. - Muskegon, MI (EST.)
FLOW
(mgd)
.12
.05
.08
.02
.14
.45
.75
NO
ND
.50
ND
ND
.43
ND
ND
ND
NO
ND
ND
ND
ND
ND
ND
ND
3.66
.18
.71
.16
.22
.08
.20
.16
.38
.16
.05
.08
.79
.46
.31
.92
1.82
.03
1.14
.58
TSS
68
19
3
63
615
1.485
2,563
ND
NO
ND
ND
ND
ND
ND
NO
ND
ND
ND
NO
ND
ND
ND
ND
ND
2,188
22
154
50
125
45
123
81
10
345
28
45
32
0
176
523
947
17
648
329
COD
71
32
49
8
83
266
212
NO
NO
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
2,286
107
510
120
130
368
233
38
31
95
30
47
387
32
51
545
259
18
675
343
Ammonia
13.3
6.2
9.7
.8
15.5
49.9
28.6
ND
ND
ND
ND
ND
ND
ND
NO
ND
ND
ND
ND
ND
ND
ND
ND
ND
428.0
.0
78.9
66.2
24.4
8.9
22.2
.0
.2
17.8
5.6
8.9
.0
.1
34.4
102.2
202.1
3.3
126.6
64.4
Phosphorus
.4
.5
1.8
.5
2.0
4.1
3.3
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
28.0
1.4
1.9
.8
.9
17.8
14.0
.1
2.1
1.8
1.6
.3
.1
.2
3.2
2.0
.0
.3
100.5
1.2
OSG
5
13
2
2
131
238
238
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
972
10
30
7
1
41
10
24
6
10
40
60
273
20
13
41
31
2
60
20
Total
Hetals
2.78
.25
.04
.06
2.73
166.71
201.80
ND
NO
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
1,025.00
15.15
.04
.18
6.33
12.25
63.60
.37
4.00
.84
.18
.14
.87
.06
3.27
115.58
19.20
1.00
15.29
.08
SUBTOTAL
13.88 10.704 7.027 1.318.1 190.7 2.299 1.657.80
-------
TABLE 23: EFFLUENT LOADINGS FROM
FOUNDRIES IN 1968 (Ibs/day)
(Continued)
I
*»
oo
LAKE HURON
Basin 40802
LAKE ST.CLAIR
Basin 40900
LAKE ERIE
Basin 41000
Basin 41100
FACILITY NAME
GHC - Chevrolet Motors - Bay CUy. HI
Eaton Corporation - Vassar, HI
GNC-Chevrolet Metal Castlngs-Saglnaw,
NPW Haven Foundry, Inc. - New Haven,
GHC - Central Foundry - Pontlac, HI
(EST.)
(EST.)
HI
SUBTOTAL
MI (EST.)
(EST.)
SUBTOTAL
Webster Manufacturing Co. - Tiffin. OH (EST.)
Bonn Aluminum and Brass - Butler, IN
Kitchen Quip. Inc. - Waterloo, IN
Hoover Ball & Bearing Co.- Saline. HI
Brush Wellman Co. - El more, OH
Chrysler Corp./Amplex - Van Wert, OH
Chase Brass & Copper - Montpeller, OH
Chase Brass & Copper - Euclid, OH
(EST.)
(EST.)
SUBTOTAL
1968 TOTAL
FLOW
(mgd)
11.20
.69
28.00
39.89
18.96
6.70
25.66
.02
.05
.02
.46
3.23
.43
.15
4.20
8.56
87.99
TSS
6,362
392
16,599
23.353
10.769
3,806
14.575
345
28
12
203
1.642
142
636
945
3.953
52.585
COD
6.632
409
8,248
15,289
11,227
3,967
15,194
12
30
12
586
18.818
85
89
3,640
23,272
60.782
Ammon 1 a
1.244
76
358
1.678
2.106
744
2.850
3
6
2
51
3.204
47
16
466
3,798
9.644
.0
.0
.0
.0
.0
.0
.0
.6
.0
.2
.8
.0
.8
.6
.5
.5
.6
Phosphorus
56
1
41
98
38
27
66
1
3
8
1
17
373
.6
.2
.0
.8
.9
.5
.4
.9
.7
.3
.2
.4
.8
.8
.1
.2
.0
OSG
495
41
1,238
1.774
829
1,550
2.379
3
2
1
127
84
5
4
185
411
6.864
Total
Metals
55.70
6.94
47.20
109.84
200.02
70.69
270.71
.21
.17
1.00
46.87
.45
8.19
.36
37.24
94.49
2.132.84
-------
TABLE 24: EFFLUENT LOADINGS FROH
FOUNDRIES IN 1976 (Ibs/day)
vo
I
LAKE MICHIGAN
Basin 40301
Basin 40302
Basin 40400
Basin 40500
Basin 40601
FACILITY NAHE
Br 11 lion Iron Works - Br1ll1on. WI
Gllson Bros. Co. - Plymouth. WI
Medalist State Foundry - Cedar Grove, WI
Tecumseh Products Co. - Sheboygan, WI
Waupaca Foundry (11) - Waupaca, WI
McQuay - Perfex, Inc. - Berlin, WI
Neenah Brass & Al Foundry - Neenah, WI
Neenah Foundry (Plant 12) - Neenah, WI
Universal Foundry Co. - Oshkosh, WI
American Steel Foundries - E.Chicago. IN (EST.)
Ampco Netal Division - Milwaukee, WI
Badger Die Casting Corp. - Milwaukee, WI
Blaw-Knox a Hill Machines - E. Chicago, IN (EST.)
Brlggs 1 Stratton Corp W. All1s, WI
Dayton Malleable Inc. - Cedarburg, WI
Federal Malleable Co. - W. All Is, WI
Grey Iron Foundry - W. AlUs, WI
Howmet Corporation - Milwaukee, WI
Milwaukee Malleable a Grey Works - Milwaukee ,WI
Motor Casting Co. (Pit 11) - W. Allls, WI
Motor Casting Co. (Pit 12) - Milwaukee, WI
Pelton Cast Steel Co. - Milwaukee, WI
Stroh Die Casting Corporation - Milwaukee, WI
Wehr Corporation - W. Allls. WI
Attwood Corp. - Lowell, HI
Auto Specialties - St. Joseph, HI
Bohn Aluminum and Brass - Holland, MI
Brooks Foundry - Albion, MI (EST.)
Campbell, Wyant, a Cannon - S. Haven, MI
Du-Well Products. Inc. - Bangor. MI
Dynac Corp. - St. Joseph, MI (EST.)
Hoover Ball a Bearing Co. - Adrian. MI (EST.)
Hoover Universal, Inc. - Charlotte, MI
Hoover NSK Bearing Co. - Ann Arbor, HI
New Products Corp. - Benton Harbor, MI
Nelson Metal Products - Grandvllle. MI
Reynolds Metals - Grand Rapids, HI (EST.)
Sundstrand Heat Transfer - Dowaglac, HI
Campbell, Wyant, & Cannon - Huskegon, MI
East Jordan Iron Works, Inc. - E. Jordan, HI
Great Lakes Casting Corp. - Ludlngton.MI
Sealed Power Co. - Muskegon Hgts, HI
Westran Corp. - Huskegon, MI
FLOW
(mgd)
.12
.00
.06
.10
.16
.06
.50
.75
.44
.14
.15
.04
.57
1.30
.00
.00
.11
.58
.07
.16
.04
.00
.02
.08
.16
1.64
.16
.22
.08
.33
.16
.38
.16
.05
.07
.03
.46
.31
.92
1.82
.03
1.14
.58
TSS
13
8
0
26
15
49
744
1,284
34
24
6
1
97
476
5
2
11
15
9
40
1
26
1
4
57
165
27
38
28
43
28
65
29
12
12
34
79
24
330
170
3
47
42
COD Ammonia Phosphorus 086
18
8
12
2
29
9
144
115
94
2
23
6
87
237
3
4
17
88
5
24
6
12
3
44
99
243
24
33
368
50
24
58
42
3
18
185
70
151
25
277
14
675
66
.1
.2
.2
.2
.3
1.7
6.8
3.9
.0
3.9
.4
.2
15.9
9.1
.0
.0
.0
1.7
.1
.3
.1
.3
.0
.0
20.7
66.2
4.5
6.2
10.4
.9
4.4
10.6
.2
.2
1.3
.0
12.9
.3
.5
50.9
.2
2.3
.9
.1
3.4
.1
.0
.0
.1
.0
.8
.5
.1
.1
.0
.6
.1
.1
.9
.1
.6
.0
.1
.0
.0
.0
.1
.6
2.2
.2
.2
4.6
3.5
.1
.4
2.8
.4
.3
.0
.5
.8
.5
2.3
.0
32.3
.3
2
7
1
2
2
22
0
20
5
4
4
1
7
48
1
2
6
13
4
2
1
3
5
11
14
74
4
10
24
6
14
10
6
2
3
161
12
8
24
18
0
41
15
Total
Hetals
.00
.14
.02
.01
1.31
.29
29.95
95.80
.00
.70
.63
.03
2.BS
108.63
.22
.08
2.04
.07
.10
.06
.06
3.76
.05
.28
14.02
32.20
.02
1.10
3.00
5.81
.80
1.90
.40
.09
.07
1.33
2.30
1.55
54.78
9.10
.00
7.25
.04
SUBTOTAL 14.16 4,122 3,417 238.8
59.8
618 382.84
-------
TABLE 24: EFFLUENT LOADINGS FROM
FOUNDRIES IN 1976 (Ibs/day)
(Continued)
i
s
LAKE HURON
Basin 40802
LAKE ST.CLAIR
Basin 40900
LAKE ERIE
Basin 41000
Basin 41100
FACILITY NAME
6MC- Chevrolet Motors D1v.- Bay City. HI
Eaton Corporation - Vassar, HI
GNC-Chevrolet Metal Castlngs-Saglnaw, HI
SUBTOTAL
New Haven Foundry, Inc. - New Haven. HI
6MC - Central Foundry - Pont lac, MI
SUBTOTAL
Webster Manufacturing Co. - Tiffin, OH
Bonn Aluminum and Brass - Butler, IN (EST.)
Kitchen Quip, Inc. - Waterloo, IN (EST.)
Hoover Ball & Bearing Co.- Saline. MI
Brush We 11 man Co. - El more, OH
Chrysler Corp./Amplex - Van Wert, OH
Chase Brass S Copper - Montpeller. OH (EST.)
Chase Brass A Copper - Euclid, OH (EST.)
SUBTOTAL
1976 TOTAL
FLOW
(mgd)
11.20
.69
28.00
39.89
18.96
6.70
25.66
.02
.05
.02
.12
1.88
.17
.15
4.20
6.61
86.32
TSS
670
360
2,719
3.749
949
1,485
2.434
345
9
3
30
1.066
8
26
719
2.206
12.510
COD
1,089
31
4,400
5,520
3.162
1.018
4,180
8
8
4
70
2B6
26
25
638
1.065
14,182
Ammonia
62.8
.6
370.0
433.4
189.7
471.0
660.7
2.6
1.4
.8
.5
1.044.0
.4
1.2
117.0
1.167.9
2,500.8
Phosphorus
13.8
.3
4.7
18.8 I
9.5
6.7
16.2 1
.0
.0
.0
.8
2.1
.2
.2
1.0
4.3
99.1 3
086
291
24
728
,043
493
912
.405
2
1
0
2
49
3
4
109
170
.235
Total
Metals
26.40
3.29
58.00
87.69
94.80
33.50
128.30
.10
.80
.00
2.10
1.57
.00
.75
17.65
22.97
621.81
-------
TABLE 25: EFFLUENT LOADINGS FROM
FOUNDRIES IN 1982 (Ibs/day)
en
t*
i
LAKE MICHIGAN
Basin 40301
Basin 40302
Basin 40400
Basin 40500
Basin 40601
FACILITY NAME
BHlHon Iron Works - Brllllon, VI
611 son Bros. Co. - Plymouth, WI
Medalist State Foundry - Cedar Grove, UI
Tecumseh Products Co. - Sheboygan, WI
Waupaca Foundry (fl) - Waupaca, WI
McQuay - Perfex. Inc. - Berlin, WI
Neenah Brass ft A] Foundry - Neenah, WI
Neenah Foundry (Plant 12) - Neenah, WI
Universal Foundry Co. - Neenah, WI
American Steel Foundries - E. Chicago, IN
Ampco Metal Division - Milwaukee, WI
Badger Die Casting Corp. - Milwaukee, WI
Blaw-Knox ft Mill Machines - E. Chicago, IN
Brlggs a Stratton Corp - W. All Is. WI
Dayton Malleable Inc. - Cedarburg, WI
Federal Malleable Co. - W. AlUs, WI
Grey Iron Foundry - W. AlHs, WI
Howmet Corporation - Milwaukee, WI
Milwaukee Malleable ft Grey Iron - Milwaukee, WI
Motor Casting Co. (Pit 11) - W. AlHs, WI
Motor Casting Co. (Pit 12) - Milwaukee. WI
Pelton Cast Steel Co. - Milwaukee, WI
Stroh Die Casting Corporation - Milwaukee, WI
Wehr Steel Co. - W. AlHs, WI
Attwood Corp. - Lowell, HI
Auto Specialties - St. Joseph, HI
Bonn Aluminum and Brass - Holland, HI
Brooks Foundry - Albion. HI
Campbell, Wyant, ft Cannon - S. Haven, MI
Du-Well Products, Inc. - Bangor, MI
Dynac Corp. - ST. Joseph, MI
Hoover Ball ft Bearing Co.- Adrian, HI
Hoover Universal, Inc. - Charlotte, MI
Hoover NSK Bearing Co. - Ann Arbor, MI
New Products Corp. - Benton Harbor, MI
Nelson Metal Products - Grandvllle, MI
Reynolds Metals - Grand Rapids, MI
Sundstrand Heat Transfer - Dowagiac. HI
Campbell, Wyant, ft Cannon - Muskegon, HI
East Jordan Iron Works, Inc. - E. Jordan, HI
Great Lakes Casting Corp. - Ludlngton.HI
Sealed Power Co. - Huskegon, MI
Westran Corp. - Muskegon, MI
FLOW
(mgd)
.32
.02
.06
.09
.38
.21
.05
.02
.39
.14
.13
.02
.57
.00
.01
.01
.18
.44
.27
.09
.03
.00
.01
.02
.16
.78
.42
.22
.08
.16
.02
.24
.16
.04
.07
.78
.46
.46
.25
1.90
.08
.07
.13
TSS
0
2
0
2
138
10
6
3
25
3
13
1
75
12
9
82
6
9
1
18
2
0
0
27
21
45
10
4
2
0
1
8
26
1
9
103
51
61
44
106
10
9
7
COD Ammonia Phosphorus
7
1
2
3
15
7
2
1
19
5
5
1
20
15
5
22
21
20
9
185
27
86
7
5
44
1
55
55
6
2
27
12
16
29
67
2
66
5
1.4
.2
.5
.6
1.6
1.6
.3
.2
2.1
1.1
1.0
.0
4.1
.0
1.0
4.7
1.0
4.0
.2
.4
.1
.1
.0
.1
10.3
24.0
.0
.0
.0
.2
.0
.6
.3
.5
.1
1.8
.5
.4
.1
14.4
.2
.7
.9
.3
8.4
.1
.1
.7
.3
.0
.0
.4
.2
.3
.0
.5
.0
.2
5.6
.1
.5
.0
.2
.0
.0
.1
.0
.3
.6
.3
.1
.0
.5
.0
.6
.6
.0
.0
.7
.5
.8
.0
1.6
.0
.2
.1
O&G
11
1
7
4
7
47
0
0
192
2
1
1
7
1
11
2
4
9
0
0
5
0
2
14
1
25
1
1
0
1
1
5
1
0
1
1
2
32
1
5
1
3
2
Total
Hetals
2.77
.09
.01
.01
3.38
.84
.21
.00
3.11
.04
.02
.00
4.80
12.80
.02
.21
1.18
.19
.00
4.25
.12
.02
.04
.02
1.02
3.26
.07
.55
.03
.48
.00
.36
.36
.08
.03
.33
.15
.44
2.02
.64
.51
.44
.04
SUBTOTAL
9.94
963
885
81.3
24.8 412
44.92
-------
TABLE 25: EFFLUENT LOADINGS FROM
FOUNDRIES IN 1982 (Ibs/day)
(Continued)
LAKE HURON
Basin 40803
FACILITY NAME
GHC- Chevrolet Motors Division
Eaton Corporation - Vassar, HI
GNC - Chevrolet Metal Castings
- Bay City, MI
- Saginaw, MI
FLOW
(mgd)
10.70
.21
28.87
TSS
3.359
7
5,292
COD Ammonia Phosphorus
2,420
8
1.010
37.4
1.6
396.9
44.0
.2
11.0
DIG
40
2
107
Total
Netals
4.40
.07
2.67
SUBTOTAL
39.78 8.658 3.438 435.9
55.2
149
7.14
LAKE ST.CLAIR
01
ro
Basin 40900
LAKE ST.CLAIR
Basin 41000
Basin 41100
New Haven Foundry, Inc. - New Haven, HI
GNC - Central Foundry - Pontlac, HI
SUBTOTAL
Webster Manufacturing Co. - Tiffin, OH
Bohn Aluminum and Brass - Butler, IN
Kitchen Quip, Inc. - Waterloo. IN
Hoover Ball ft Bearing Co.- Saline, HI
Chase Brass 1 Copper - Hontpeller, OH
Chrysler Corp./Amplex - Van Wert, OH
Brush Well man Co. - El more, OH
Chase Brass 1 Copper - Euclid, OH
SUBTOTAL
1982 TOTAL
15.80
.77
16.57
.04
.05
.02
.16
.15
.55
.13
.50
1.60
67.89
640
102
742
2
2
2
23
13
75
23
66
206
10,568
553
27
580
1
2
1
14
5
19
5
18
65
4,968
171.0
5.9
176.9
.3
.4
.1
1.7
1.1
1.1
1.4
3.8
9.9
704.0
13.3
.6
13.9
.0
.1
.6
.2
.1
.5
.2
.9
2.6
96.5
58
26
64
0
0
1
2
3
7
2
14
29
674
5.37
.26
5.63
.01
.08
.17
.37
.32
.18
.29
1.37
2.79
60.48
-------
TABLE 26: BPT Capital and Annual Cost Summary
for Foundries in 1978 Dollars
(x 1,000)
No. of
Foundries
Lake Michigan
Basin 40301
Basin 40302
Basin 40400
Basin 40500
Basin 40601
5
4
15
14
5
Capital
Costs
658.6
533.7
2,511.2
1,545.7
607.1
Annual
Costs
136.6
116.9
471.1
491.4
220.8
Total 43 5,856.3 1,436.8
Lake Huron
Basin 40802 3 401.9 84.0
Lake St. Clair
Basin 40900 2 259.0 57.0
Lake Erie
Basin 41000
Basin 41100
Total
TOTAL
7
1
8
56
765.7
142.9
908.6
7,425.8
221.9
27.0
248.9
1,826.7
AVERAGE " 132.6 32.6
-53-
-------
VIII. ELECTROPLATING AND OTHER METAL FINISHING
A. Plants Included in the Survey
Twenty-five (25) electroplating and other metal finishing facilities
located in the Region V Great Lakes drainage area were identified. All 25
facilities have discharged process wastewater directly to the Great Lakes
drainage basin. One facility has not discharged process wastewater since 1968.
One facility has discharged process wastewater to a POTW since 1975. Two other
facilities have closed since 1980. These 25 facilities include electroplating,
anodizing, coating, and polishing facilities.
B. Survey Methods
The electroplating facilities were identified from EPA's IFD file plant
listings and cross-referenced with the EPA EGO plant inventory and State
information. The IFD file was found to be more complete since EGD did not
include all facilities in their inventory (only 7 of the 25 plants). Therefore,
the list of plants from the IFD file was used as the basis for identifying
plants to include in the survey. Each plant was identified by SIC code, WRC
accounting unit and lake basin based on information in the IFD file.
The flow and effluent loading data for each facility for 1968 were
collected from State files which include monitoring surveys, permit
applications, and discharge monitoring reports (DMRs). Data had to be estimated
for 8 of the 25 facilities.
Flow values and effluent loadings for the 1976 period were also collected
from State files and values were compared with EGD effluent loading values to
verify accuracy where data were available. Data had to be estimated for 10 of
the 25 facilities.
The data for the 1982 time period were calculated from the monthly loading
values for each pipe for each plant in the STORET data base which was verified
with State information. The actual effluent loading values for each month were
averaged over the entire one year period. In some cases where only effluent
concentration data in mg/1 were recorded, loadings in Ibs/day were calculated
using the average flow rate in mgd with the following formula:
Average load (Ibs/day) = average concentration (mg/1) x
average flow (mgd) x 8.34
(conversion factor)
C. Survey Results
The effluent flow rates and pollutant loadings are presented in tabular
form. Each table represents a separate time period (i.e., 1968, 1976, and 1982)
and presents the data by plant and lake basin. The following parameters are
presented: flow (mgd), TSS, oil and grease, ammonia, COD, total phosphorus, and
total metals. Total metals includes copper, total chromium, zinc, nickel, lead,
and aluminum.
-54-
-------
Table 27 presents the 1968 effluent loadings for 25 facilities based on
State information.
Table 28 presents the 1976 effluent loadings data for 23 plants based on
State and E6D information.
Table 29 presents the most recent data from the STORET data base for 21
plants which includes monthly values from 1982 verified with State information.
Graphs showing effluent reduction by time period are included in the Appendix.
D. Cost of Effluent Reductions
The capital and annual costs for each electroplating facility cannot be
derived from the E6D cost summaries without detailed information on specific
plant operations and wastewater treatment requirements for each facility.
Generally capital costs for a mid-sized electroplating facility (i.e., flow
rate of .15 MGD) using batch process operations would be approximately $184,000
which includes sludge handling costs. Annual costs average about $78,000
including sludge handling costs. Using these gross figures a total capital cost
of $3,864,000 and annual costs of $1,638,000 for the 21 facilities would be
required to meet BPT limitations.
-55-
-------
TABLE 27: EFFLUENT LOADINGS FROM ELECTROPLATING
FACILITIES IN 1968 (Ibs/day)
LAKE MICHIGAN
Basin 40400
Basin 40500
FACILITY NAME
S.K. Williams Co. - Wauwatosa. WI
Bronson Plating Co. - Bronson, HI
Home Plating Co. - Sturgie, HI
Indian Head Co. - fielding, HI
Keene Products. Inc. - Elkhart, IN
Portage Metal Finishing - 3 Rivers, HI
Michigan Tube Co. - Eau Clalve, MI
Lear Slegler Co. Inc. - Hendon, MI
Valley Industries, Inc. - Qulncy, HI
(EST.)
(EST.)
(EST.)
(EST.)
FLOW
(mad)
.27
.13
.02
1.14
.03
.05
.05
.12
.05
TSS
13
11
1
271
7
12
8
8
12
COD
51
22
2
217
6
10
10
17
10
O&G Ammonia Phosphorus
9
4
1
36
1
2
2
4
2
.1
.0
.0
7.5
.0
.0
.0
6.0
.0
.8
.0
.5
25.8
.7
1.0
.1
1.0
1.0
Total
Metals
1.24
2.64
.06
37.70
.99
1.65
1.49
.62
1.65
SUBTOTAL
1.86
343
344
61
13.6
31.0 48.04
LAKE ST.CLAIR
I
in
T
Basin 40900
LAKE ERIE
Basin 41000
Belleville Plating Co. - Belleville, HI
Bechtel -Mclaughlin - Sandusky, OH
Edgerton Metal Products - Edgerton, OH
Farley Industries - Toledo, OH
Hayes-Albion Corp. - Bryan, OH
ITT Aerospace Optical - Ft.Uayne, IN
National Machinery Co. - Tiffin, OH
(EST.)
SUBTOTAL
(EST.)
Ohio Decorative Products, Inc.-Spencervllle.OH
Basin 41100
Ohio Electro Polishing Co. - Venedocia,
Stanadyne Corp. - Garrett, IN
Weatherhead - Antwerp, OH
True Temper Corp. - Geneva, OH
Bedford Anodizing - Walton Hills, OH
Standadyne Corporation - ElyMa, OH
Valley Hold and Iron - Hubbard, OH
TRW, Inc. - Cuyahoga, OH
OH
(EST.)
(EST.)
SUBTOTAL
1968 TOTAL
.19
.19
.10
.15
.35
.07
.30
.09
.05
.02
.38
.56
.82
.01
.58
.00
.10
3.58
5.63
45
45
32
42
72
3
71
7
48
5
90
6,297
1,778
3
138
2
12
8,599
8,988
36
36
19
29
40
5
57
25
97
4
72
25
104
2
111
1
93
683
1,064
6
6
3
5
17
2
10
3
2
9
12
3
26
0
18
0
3
112
179
.1
.1
.0
.1
1.1
.0
.1
.0
5.0
.0
2.2
.3
1.2
.0
.3
.0
1.5
11.8
25.5
4.3
4.3
17.7
3.4
2.7
2.4
6.8
.1
68.6
.5
8.6
.1
23.1
.2
13.1
.0
1.2
148.4
183.6
6.28
6.28
4.76
.07
4.00
2.30
9.92
2.97
11.47
.15
1.60
18.51
58.00
.33
.93
.07
3.31
118.39
172.71
-------
TABLE 28: EFFLUENT LOADINGS FOR ELECTROPLATING
FACILITIES IN 1976 (Ibs/day)
LAKE MICHIGAN FACILITY NAME
FLOW
(mgd)
Basin 40400 S.K. Williams Co. - Wauwatosa. VI (Discharge
Basin 40500 Bronson Plating Co. - Bronson, MI
Home Plating Co. - Sturgls, HI
Indian Head Co. - Beldlng, MI
Keenr Products, Inc. - Elkhart. IN (EST.)
Portage Metal Finishing - 3 Rivers, MI
Michigan Tube Co. - Eau Claire, MI
Lear Slegler Co. Inc. - Mendon, HI
Valley Industries, Inc. - Qulncy, HI (EST.)
.13
.02
1.14
.03
.00
.00
.12
.05
TSS
to POTW)
5
1
14
2
0
0
24
3
COO
8
0
28
1
1
3
44
1
O&G Ammonia Phosphorus
5
8
19
1
0
0
29
Z
.4
.1
3.5
.1
.0
.4
5.0
.2
.3
.0
2.9
.1
.0
.0
6.0
.1
Total
Netals
.85
.15
6.75
.18
.02
.02
2.05
.29
SUBTOTAL
1.48
49
86
64
9.7
9.4 10.31
LAKE ST.CLAIR
l
01
Basin 40900
Belleville Plating Co. - Belleville. HI
.19
SUBTOTAL .19
LAKE ERIE
Basin 41000
Bechtel - He La ugh Hn - Sandusky, OH
Edgerton Metal Products - Edgprton, OH
Farley Industries - Toledo, OH
Hayes-Albion Corp. - Bryan, OH
ITT Aerospace Optical - Ft. Wayne, IN
(EST.
(EST.
.12
.02
(No Process
.07
.30
Ohio Decorative Products, Inc. -Spencervl lie, OH .03
Basin 41100
Ohio Electro Polishing Co. - Venedoda,
National Machinery Co. - Tiffin, OH
Stanadyne Corp. - Garrett, IN
Weatherhead - Antwerp, OH
True Temper Corp. - Geneva, OH
Valley Hold and Iron - Hubbard. OH
Bedford Anodizing - Walton Hills, OH
TRW, Inc. - Cuyanoga, OH
Stanadyne Corp. - Elyria, OH
OH
(EST.
(EST.
(EST.
(EST.
EST.
(EST.
.03
.08
.38
.28
.36
.00
.01
.10
.58
SUBTOTAL 1.77
1976
TOTAL 3.44
2
2
10
10
Discharge)
5
20
2
5
5
35
23
50
0
1
7
68
173
3
3
3
0
2
7
1
2
2
9
7
9
0
0
2
14
44
224 133
7
7
5
1
3
11
1
0
3
14
1
35
0
0
4
22
78
149
.0
.0
.4
.0
.2
.9
2.0
.1
.2
1.2
.8
1.1
.0
.0
.3
1.8
7.2
16.9
.0
.0
.3
.1
.2
.8
.1
.1
.2
1.2
.7
.9
.0
.1
.3
1.5
5.0
14.4
.09
.09
7.02
1.24
.41
1.76
.87
.04
.47
2.23
1.02
2.12
.01
.06
.59
3.41
17.84
28.24
-------
TABLE 29: EFFLUENT LOADINGS FROH ELECTROPLATING
FACILITIES IN 1982 (Ibs/day)
LAKE MICHIGAN FACILITY NAME
Basin 40400 S.K. Williams Co. - Uauwatosa. WI
Basin 40500 Bronson Plating Co. - Bronson, HI
Home Plating Co. - Sturgls, HI
Indian Head Co. - Beldlng, HI
Keene Products, Inc. - Elkhart. IN
Portage Metal Finishing - 3 Rivers, HI
Michigan Tube Co. - Eau Claire, HI
Lear Slegler Co. Inc. - Hendon, HI
Valley Industries, Inc. - Quincy, MI
FLOW
(mgd)
(Discharge
.32
.09
.53
.03
.01
.00
.31
.05
TSS
to POTW)
55
32
14
2
14
0
5
3
COO
42
2
13
1
16
1
86
1
O&G Ammonia Phosphorus
33
1
28
1
0
0
12
2
4.4
.3
1.5
.1
.0
.0
1.1
.4
.0
1.0
.4
.0
1.2
.0
.1
.0
Total
Hetals
2.07
.20
1.16
.32
1.36
.02
1.75
.11
SUBTOTAL
1.33
126
161
77
7.8
LAKE ST.CLAIR
I
171
00
2.7
6.98
Basin 40900
LAKE ERIE
Basin 41000
Basin 41100
Belleville Plating Co. - Belleville, HI
SUBTOTAL
Farley Industries - Toledo, OH
National Machinery Co. - Tiffin, OH
Edgerton Metal Products - Edgerton, OH
Weatherhead - Antwerp, OH
Bechtel - He La ugh Hn - Sandusky, OH
Hayes-Albion Corp. - Bryan, OH
ITT Aerospace Optical - Ft. Wayne, IN
Ohio Decorative Products, Inc. -Spencervllle, OH
Stanadyne Corp - Garret t, IN
Ohio Electro Polishing Co. - Venedoda, OH
Bedford Anodizing - Walton Hills, OH
Valley Hold and Iron - Hubbard. OH
True Temper Corp. - Geneva, OH
TRW, Inc. - Cleveland, OH
Stanadyne Corp. - Elyrla, OH
.06
.06
1
1
(No Process Discharge)
.08 2
.02
.31
.13
(Closed
.06
.05
.03
.03
.01
.00
(Closed
.74
.20
1
16
13
1980)
2
2
1
2
4
0
1982)
91
30
1
1
23
0
41
3
2
1
1
1
0
0
18
6
2
2
2
1
39
5
1
1
0
0
0
0
27
7
.2
.2
.2
.0
.9
.4
.2
.2
.1
.1
.0
.0
2.0
.7
.0
.0
.1
.0
.3
.1
.0
.2
.0
.0
.0
.0
.6
.2
.13
.13
.10
.09
.60
.28
.10
.11
.07
.06
.02
.00
1.61
.82
SUBTOTAL 1.58 137 0 80 4.5 1.3 3.30
1982 TOTAL 2.97 263 162 160 12.5 3.9 10.41
-------
APPENDIX A
Flow Graph and Bar Charts Illustrating Effluent
Flow and Loadings from the
Six Industrial Categories
Graph No. Page No.
1. Effluent Flow for all Six Industrial Categories A-2
2. Effluent Loadings for Chloride, TSS, BOD, and COD
for all Six Industrial Categories A-3
3. Effluent Loadings for 0 & G, Ammonia, Total Metals,
Phenols, Total Organics, Cyanide, and Phosphorus
for all Six Industrial Categories A-4
4. Effluent Loadings for Iron and Steel Plants A-5
5. Effluent Loadings for Pulp and Paper Mills A-6
6. Effluent Loadings for Chemical Manufacturers A-7
7. Effluent Loadings for Petroleum Refineries A-8
8. Effluent Loadings for Foundries A-9
9. Effluent Loadings for Electroplaters A-10
A-l
-------
FLOW
Iron and Steel
2100-
1600-
1100
1968
1976
1982
FLOW
Q
O
500-
400 i
300
200-
100-
Pulp and Paper
Chemicals
Refineries
Foundries
Electroplaters
1968
1976
1982
A-2
-------
EFFLUENT LOADINGS
All Six Industries
3,500,0001
o
Chloride
TSS BOD
Parameter
1968
1976
1982
A-3
-------
D
-a
-------
o
o
800.000 i
BOO.OOO -
tn
JD
co 400,000 -
200,000 -
EFFLUENT LOADINGS
Iron and Steel
TSS O&G
Parameter
1968
1976
-a
en
.Q
OT
O
EFFLUENT LOADINGS
Iron and Steel
2B.OOO -
28,500 -
19,000-
9,500 -
//////////////////////////////A
Xs
s
Ammonia Metals Phenols Organlcs
Parameter
Cyanide
1968
1976
1982
A-5
-------
X
D
u
\
W
.0
w
en
c
^
T>
0
0
1,000,000-1
800,000 -
600,000
400,000 -
200,000
EFFLUENT LOADINGS
Pulp and Paper
BOD TSS
Parameter
1968
1976
1982
A-6
-------
CO
JO
CO
C7»
c
'o
o
o
750,000 -i
600,000 -
450,000 -
300,000 -
150,000-
EFFLUENT LOADINGS
Chemicals
1968 - 3,325,702
1976 - 2,140,319
1968
1976
1982
Chloride
TSS
Parameter
COD
tO
JO
CO
CP
c
'~o
o
o
27,000 -1
21.600-
16.200-
10,800-
5.4OO -
EFFLUENT LOADINGS
Chemicals
1968
1976
1982
BOD
Ammonia
Parameter
Phosphorus
A-7
-------
o
o
CO
CQ
o
o
o
100,
80,000
60.000 -
40,000
20,000
EFFLUENT LOADINGS
Refineries
187,786
COD
BOD
Parameter
TSS
1968
1976
1982
o
CO
^'
CO
-o
O
O
17.000-
13,600-
10,200-
6,800 -
3.400 -
EFFLUENT LOADINGS
Refineries
O&G
Ammonia
Parameter
Phenols
1968
1976
1982
A-8
-------
O
TJ
CO
_o
tO
o>
c
"-o
O
o
in
_O
CO
o
O
EFFLUENT LOADINGS
Foundries
65.000 -i
52,000 -
39,000 -
26,000 -
13,000
COD TSS
Parameter
7,000 -,
5,600 -
4,200 -
2.800 -
1,400 -
EFFLUENT LOADINGS
Foundries
9,645
1968
1976
19B2
1968
1976
1982
Ammonia O6cG Metals Phosphorus
Parameter
A-9
-------
EFFLUENT LOADINGS
Electroplaters
1,988 1,064
3UU-
XJ /\rt
400-
o
T>
\
0)
£ 300-
v'
en
.E 200
T>
0
0
100-
0-
^
\.
s
A
1
s
TT
y
y
y
y
y
y
y
y
y
y
y
V
//
s
V
N
A
I
N
i
H ra TO
$ \tfh\
^ \ \
y \ \y// \
y \ \y/, \
yn \ \y% \
yy \ \y% \
x/ \ \y/s \?
OV 07i_ V07 0^
1 1 1 1
^1 1968
* * ^
^ 1976
^ 1982
-
I i
M Q ,/i O IA <
f? ° o * * z
H o ? o i^ o
Parameter
A-10
------- |