U.S. D[Pf!r!F.»T OF CfiW
                                  N.itwnitl Technical Inf3r;ruticn S^rric?
                                  PB-284 973
The  Use  and  Fate of Lubricants, Oils,
Greases, and  Hydraulic  Fluids  in the
Iron and Steel Industry

Pacific Environmental  Services, !nc, Santa Monica, Calif
Prepared for
Industrial Environmental Research Lab, Research Triangle Park, N C

May 78

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• (Int(1 States I,st .aI Envirnr m ntat P. .’ .irch EP. 60c’ 2 78 1O1
E iiir ;a1 P’otcton 1at, ’ tnry May 19/8
A. r :v • • R sedrch Triangl. 1 C ‘7 / 11
P.B 284 97
EPA • The Use and Fate of
Lubricants, Oils,
Greases, and
Hydraulic Fluids in
the Iron and Steel
Industry
UG 2 S

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                                TECHNICAL REPORT DATA
                             rrtd iittrut Hunt on Ihr rn 
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EPA-600/2-78-1 01
May 1978
The Use and Fate of Lubrican ts, Oils,
Greases, and Hydraulic Fluids
in the Iron and Steel Industry
by
J.C. Serne and K. Wilson
Pacific Environmental Services, Inc.
1930. 14th Street
Santa Monica, California 904.04
Contract No. 68-02-1405
Task No. 9
Program Element No. 1BB61O
EPA Project Officer: Norman Plaks
Industrial Environmental Research Laboratory
Office of Energy. Minerals, and Industry
Researth Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTiON AGENCY
Office of Research nd Development
Washington, DC 20460
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ABSTRACT
This report presents the results of an investigation of the use
and fate of lubricants, oils, greases and hydraulic fluids in
the iron and steel industry. Data from nine integrated steel
plants and two consultants with extensive steel ii .iustry experience
were used to: (1) develop correlations between lubricant usage
rates and steel production capacity and the types of products made;
and (2) prepare total oi , grease and hydraulic fluid material
balances for specific, as well as, .. typlcal” integrated steel
plant. Generalizations were r iade regarding the fate (as air
pollution, water pollution and solid waste) of these oils,
greases and hydraulic fluids. Estimates of the mass air pollution
emissions, the total oil and grease water pollution discharges,
and the quantity of oil and grease being disposed of in landfills
were developed by steel-making area and for a typica ’. integrated
steel plant. Introductory and background information pertaining
to the steel Industry, lubrication practices., steel plant lubri-
cants, and waste oil collection and reclamation methods are also
presented.
Results of the study indicate that for a typical integrated steel
plant, with a raw steel production capacity of 3.6 x 10 kg/yr
(4 x 1o 6 tons/yr), 544,000 kg/mo (1,200,000 lb/mo) of oils, greases
and hydrai 11c fluids are used throughout the plant. Approximately
90% of these lubricants are used in the steel rolling and finishing
operations It was estimated that of the total quantity of oil,
grease and hydraulic fluid used at a typical plant approximately
10% enters the environment as air pollution, 9% as water pollu-
tion and 44% as solid waste.
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TABLE OF CONTENTS
Section Page
ABSTRACT ii
LIST OF TABLES viii
LIST OF FIGURES x
CONVERSION FACTORS xii
INTRODUCTION 1-1
2. PROCESS AND EQUIPMENT DESCRIPTION 2-1
2.1 General Iron and Steel Making and Shaping 2-1
2.1.1 aw Materials 2—1
2.1.2 Pig Iron Manufacture 2-4
2.1.3 Manufacture of Steel 2-5
2.1.4 Steel Processing and Shaping 2-7
2.2 Equipment Utilizing Lubricants, Oils, Greases or
Hydraulic Fluids 2-12
2.2.1 Greases 2-13
2.2.2 Oils 2-16
2.2.3 Hydraulic Fluids 2-17
3. OILS, GREASES AND HYDRAULIC FLUIDS 3-1
3.1 Typical Lubricating Oils Used by Various Steel
Companies 3-1
3.1.1 Classification According to Lubricating
Properties 3-2
3.1.2 Classification According to Chemical
Constitution 3-11
3.2 Additives 3—14
3.3 Toxic Substances 3-18
3.3.1 Toxicities of Lubricant Base Oils 3-18
3.3.2 Toxicities of Lubricant Additives 3-20
3.4 Purchasing Practices 3-22
4. LUBRICATION SYSTEMS AND PRACTICES 4-1
4.1 Lubrication Requirements and Schedules 4-1
4.1.1 Lubrication Surveys 4-1
4.1.2 Classification of Lubricants 4—2
iii
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TAELE OF CONTENTS (continued)
Section Page
4.1.3 Compiling and Updating Lubrication
Charts and Consumption Reports 4-2
4.1.4 Improved Applicat on Methods 4-4
4.l.5 Lubricant Handling and Storage 4-5
4.1.6 New Lubricant Evaluation 4-5
4.1.7 Establishing Maintenance Methods 4-6
4.2 Lubrication Methods and Systems 4-6
4.2.1 Oil Application Methods 4-6
4.2.2 Grease Application Methods 4-10
5. WASTE OIL COLLECTION, RECLAMATION ANt) DISPOSAL 5—1
5.1 Tyr . s of Steel Mill Oily Wastes 5—1
5.2 The Waste Oil and Wastewater Treatment Problem .. 5-3
5.3 Waste Oil Collection and Wastewater Treatment
Equipment 5-5
5.4 Waste Oil Reclamation, Reuse and Disposal 5-9
5.5 Discharge Rates 5—17
5.5.1 National Steel Corporation - Great Lakes
Steel Division 5-18
5.5.2 Ford Motor Company - Rouge Manufacturing
Complex 5-19
5.5.3 United States Steel Corporation - Lorain
Works 5-19
5.5.4 National Steel Corporation - Weirton
Steel Division 5—19
5.5.5 Bethlehem Steel Corporation - Sparrows
Point P1a, t 5-20
5.5.6 NEIC Data Surmiary 5-20
5.5.7 Outfall Data Suniiiary 5—21
6. WASTEWATER SAMPLING AND ANALYSIS 6-1
6.1 Sampling Wastewaters for Oil and Grease 6-1
6.2 Analysis for Oil and Grease 6 —3
7. DATA GATHERING 7-1
7.1 Questionnaire Preparation and Survey Design 7-1
7.2 Contacts and Responses 7—5
iv
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TABLE OF CONTENTS (continued)
Section Page
7.3 Plant Visits and Interviews 7-7
7.4 Second Data Gathering Efforts 7-8
7.5 Consultants 7-9
8. DATA ANALYSIS AND MATERIAL BALANCES 8-1
8.1 Factors Affecting Lubricart Usage and Fate 8-1
8.2 Methodology for Data Analysis 8-2
8.3 United States Steel Corporation .... 8-5
8.3.1 Gary, Indiana 8-5
8.3.2 South Chicago, Illinois 8-10
8.4 Inland Steel Company, East Chicago, Indiana .... 8-13
8.4.1 Lubricant Purchases 8-13
8.4.2 Reclamation and Treatment 8-15
8.4.3 Discharges to Waterways 8-17
8.4.4 Other Losses 8-18
8.4.5 Material Balance 8-21
8.5 Youngstown Sheet and Tube Company, East Chicago,
Indiana 8-21
8.5.1 Lubricant Purchases 8-23
8.5.2 Reclamation an 1 ireatment 8-23
8.5.3 Discharges to Waterways 8-25
8.5.4 Other Losses 8-25
8.5.5 Material Balance 8-27
8.6 Bethlehem Steel Corporation, Sparrows Point,
Maryland 8-28
8.6.1 Lubricant Purchases 8-28
8.6.2 Reclamation and Treatment 8-32
8.6.3 Discharges to Waterways 8-33
8.6.4 Other Losses 8-34
8.6.5 Material Balance 8-36
8.7 Jones and Laughlin Steel Corporation, Aliquippa,
Pennsylvania 8-39
8.7.1 Lubricant Purchases 8-39
8.7.2 R2clamation and Treatment 8-41
8.7.3 Discharges to Waterways 8-43
8.7.4 Other Losses 8-46
8.7.5 Material Balance 8-48
V
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TABLE OF CONTENTS (continued)
Sectic!i Page
8.8 Republic Steel Corporation, South Chicago,
Illinois 8—48
8.8.1 Lubricant Purchases 8-51
8.8.2 Reclamation and Treatment 8-51
8.8.3 Discharges to Waterways 8-51
8.8 4 Other Losses 8-54
8.8.5 Material Balance 8-56
8.9 Interlake, Inc., Riverdale, Illinois 6-b6
8.9.1 Lubricant Purchases 8—56
8.9.2 Reclamation and Treatment 8-60
8.9.3 Discharges to Waterways 8-60
8.9.4 Othe’- Losses 8-61
8.9.5 Mat: ial Balance 8—62
8.10 Kaiser Steel Corporation, Fontana, California .. 8-63
8.10.1 Lubricant Purchases 8-66
8.10.2 Reclamation and Treatment 8—67
8.10.3 Discharges to Waterways 8-68
8.10.4 Other Losses 8-69
8.10.5 Material Balance 8-71
8.11 Lubricant Usage Data Supplied byLykins 8-72
8.12 Lubricant Fate and Material Balance Information
supplied by Jablin 8-61
8. 2 .1 On—Product 8-82
8.12.2 On-Mill Scale 8-86
8.12.3 Left in Containers and Lost in Storage . 8—86
8.12.4 Leaks and Spills onto the Ground/Floors. 8-87
8.12.5 Volatilized, Burned or Consumed 9-87
8.12.6 In Sludges 8-69
8.12.7 In Trash and Debris 8-91
8.12.8 In Wastewater 8-91
8.12.9 Drained, Collected and Skimed 8 9l
8.12.10 Coments on Material Balance Estimate
for Mill A 8-92
9. DATA SUMMARY AND GENERALIZATIONS 9-1
9.1 Usage of Lubricants, Oils, Greases and
Hydraulic Fluids 9-3
0 Usage Versus Steel Mill Production 9-3
vi
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TABLE OF CONTENTS (continued)
Section Page
9.1.2 Usage Versus Product 9-10
9.1.3 Usage in Rolling Operations 9-iS
9.1.4 Usage at a Typical Mill 9-16
9.2 Material Balance Estimates 9-17
9.2.1 Discussion of Loss Terms 9-17
9.2.2 Typical Steel Mill Material Balance 9-22
9.3 Air and Water Pollution Discharges and Solid
Wastes 9-23
9.3.1 Estimation Procedure 9—23
9.3.2 Pollution Estimates 9-26
9.4 Fate of Toxic Substances 9-28
9.4.1 Sulfurized and Phosphorized Fatty Oils .. 9-30
9.4.2 Zinc Dialkyl Dithiophosphate 9-32
9.4.3 Phosphate Ester Hydraulic Fluids 9-32
9.4.4 Othet’ Lubricant Additives 9-33
IC. ECOMMENDATI0NS FOR ADDITIONAL S11JDY 10-1
10.1 011 in Landfilled Sludge and Trash 10-’
10.2 Waste Oil Recovery and Reclamation 10-2
10.] Mill Scale Handling 10-4
10.4 Hydrocarbon Emissions From the Steel Industry .. 10-6
b.c Wastewater Sampling, Analysis and Monitoring for
Tota Oils and Greases 10-7
REFERENCES R—l
APPENDIX A Process Lubrication Areas for an Integrated A-1
Steel Mill
APPENDIX B Oil and Grease in Wastewater Analysis Methods B-l
APPENDIX C A Practical Guide for Lubricating a Fully C-i
Integrated Steel Mill and Lubricant Consumption
Data -- Joseph Lykins
APPENDIX 0 Waste Oil Collection, Reclamation and Disposal D-l
in the Steel Industry -- Richard Jablin
vi i
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LIST OF TABLES
Table Page
1—1. US -1ntegrated Steel Companies and Plant Capacities 1-4
3-1. Typical Lubricating Oils Used by Various Steel
Companies 3-3
3-2. Typical Lubricating Greases and Compounds Used by
Various Steel Companies 3-4
3-3. Lubricant Consolidation Program 3-5
3-4. Index to Standard Specifications for Lubricants .... 3-6
3-5. Base Oil Composition and Dependent Properties 3-12
3-6. Composition Analysis 3-13
3-7. Types of St e1 Mill Lubricants and the Additives
They May Contair 3-16
5-1. PORI Plants 5—14
5-2. Reported Utilization of Waste Oil Refineries 5-16
5-3. NEIC Oil and Grease Discharge Data Sumary 5-22
7-1. Iron and Steel Mills Sent Questionnaires 7-4
8-1. United States Steel Corporation - Gary, Indiana .... 8-6
8-2. Ur ted States Steel Corporation - South Chicago,
Illinois 8—12
8-3. Inland Steel Conipar y - East Chicago, Indiana 8-14
8-4. Annual Usage of Lubricants, Oils, Greases, and
Hydraulic Fluids at Inland Steel - I. H. W. 8-16
8-5. Youngstown Sheet and Tube Company — East Chicago,
Indiana 8-22
8-6. Lubricant Usage 8-24
8-7. Bethlehem Steel Corporation - Sparrows Point, Md.... 8-30
8-8. Average Monthly Consur.iption Data for Bethlehem Steel
Corporation, Sparrows Point, Maryland 8-31
8-9. Estimated Miscellaneous Losses of Maintenance
Lubricants and Hydraulic Fluids - Sparrow Point
Plant 8-37
8—10. Jones And Laughlin Steel Corporation - Aliquippa,
Pennsylvania 8-40
v i i i
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LIST OF TABLES (continued)
Table Page
8—11 tubricant Purchases - 1975 8-42
8-12. Republic Steel Corporation Suth Chicago,IliiflOiS 8-50
8-13 Lubricants, Oils and Greases Used in 1975 8-52
8-14 Interlake, Inc. - Riverdale, Illinois 8-58
8-15 Lubricant.. Usage Data 8-59
8-16 Kaiser Steel Corporaticn - Fontana, Ca1iforn a ... 8-64
8-17 Kaiser Steel Corporation, Fontana Plant. Oils,
Greases and Hydraulic Fluids Purchase Data 8-65
8-18 Estimated Yearly Consumption of Lubricants, Oils,
Greases and Hydraulic Fluids for a Fully Integrated
Steel 1il1 Producing Three Million Net Tons of
Steel Per Year 8-74
8-19 Lykins’ Usage Estimates 8-76
8-20 Comparison of Steel Production at 1 d Lubricant and
Hydraulic Fluid Consumption 8-77
8-21 Rolling Oil and Process Oil Usage Data 8-79
8-22 Total Lubricant, Oil, Grease and Hydraulic
Fluid Consumption 8-80
8-23 Mill A Oil, Grease and H:draulic Fluid Purchase
Data 84
8-24 Sunrary of Mill A Material Balance Values 8-83
9-1 Monthly Oil, Grease and Hydraulic Fluid
Usage Data
9-2 Total Usage and Production Data 9-5
9-3 Usage and Product Data 9-11
9-4 Sumary of Material Balance Loss Terms 9-18
9-5 Fate of Oil on Mill Scales 9-21
9-6 Polluticn Suninary 9-25
9-7 Geographic Distribution of Pollutiol 9-29
9-8 Usage of Sulfurized ai.i Phosphorized Oils as
EP Additives 9-31
i x
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LIST OF FIGURES
ure Page
1-1 Inteqroted Steel Plant Locations 1-2
1-2 Integrated Steel Plant Locdtions (inset) 1-3
2-1 Flow Chart of Steelniaking 2-2
5-1 Flow Diagram Sparrcws Point Operation 5-13
8—1 Lubricant, Oil, Grease and Hydraulic Fluid
Material Bal. nce Esti Iotb 8-3
8-2 Material Balance - United States Steel - Gary ... 8-11
8-3 Mater, i1 Balance — Inland Steel Company, Inliaria
Harbor Works 8-20
8-4 Material Balance - youngstown Sheet and Tube
Company, East Chicago, Indiana 8-29
8-5 Material Balance - Bethlehem Steel Corporation,
Sparrows Point, Maryland 8-38
8-6 Combined lreatm nt of Hot Mill Scale Pit
Discharges 8-44
8-7 Chemical Rinse Treatment Plant 8-45
8-8 Material Balance - Jones and Laughlin Steel
Corporation, Aliquippa, Pennsylvania 8-49
8-9 Material Balance - Republic Steel Corporation,
South Chicago, Illinois 8-57
8-10 Material Balance - Kaiser Steel Corporation,
Fontana 8—73
8-11 Quantity of Coating Oil on Cold Rolled Strip
as a Functioi of Gage 8-85
8-12 Percent Weight Loss After Exposure at
Temperature For 30 Minutes 8-88
x
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LIST OF FIGURES (contlr.ued)
fjgure
8-13. Material Balance - Mill A 8-93
9-1. Total Usage Versus Production Capacity 9-8
9-2. T3taI Usage Versus Production Rate 9-9
Q-3. Oil Usage Rate Versus Product Parameter 9-13
9-4. Total Usage Rate Versus Product Parameter 9-14
9-5. Typical Steel Mill Material Balance 9-24
xi
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CONVERSION FACTORS
Much of the data collected during the performance of this study
were reported in English units. Where possible System Interna-
t1o al (SI) units of measure were used in the text of this report.
When deemed impractical to convert data tables to SI units a con-
version factor is indicated. Following are the factors for con-
version between English and SI units of measure.
1 lb (pound)
1 ton (short ton)
1 ft (foot)
1 in (inch)
1 gal (gallon)
1 MGD (million gallons
per day)
1 GPM (gallon per
minute)
1 psi (pound per square
inch)
1 lb/ton
1 gal/ton
= 1.8°C + 32
= 0.4536 kg (kilogram)
= 0.9072 metric ton (907.2 kg)
= 0.3048 m (meter)
= 2.54 cm (centimeters)
= 3.7853 1 (liter) or m 3 (cubic
meter)
= 0.0438 m 3 /s (cubic i tcrs per
second)
= 6.309 x lO rn 3 /s (cubic meters
per second)
= 6895 Pa (Pascal)
= 0.5 kg/bOO kg
= 4.172 1/1000 kg
xii
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I. INTRODUCTION
Steel is the most widely used single industrial material for the
manufacture of transportation equipment, construction materials,
durable goods, defense hardware and metal containers. The iron and
steel industry is the largest single industry in the United States
and, American steel producers, with an annual production capacity of
approximately 136 million metric tons (150 million tons), consist-
ently rank first or second among world producers. The 1975 produc-
tion level was about 76 percent of the annual production capacity
and represented about 16 percent of the total world steel production. 1
There are over 200 steel producing plants in the U.S. but only about
fifty of these are integrated from the blast furnace through the
rolling mills. In 1915, approximately 90 percent of the total U.S.
annual steel ingot production was produced by fifteen major steel
corporations. Figures 1-1 and 1—2 present the plant locations of
all integrated steel plants in the United States. Table 1-1 lists
all integrated steel plants in the United States and provides pro-
duction capacity data. 2 Only integrated steel companies were sur-
veyed and investigated in this project, and consequently, the ap-
plicability of the project findings to non—integrated and specialty
steel companies is unknown. Non-integrated and specialty steel
companies account for a small fraction (about one—seventh) of the
total American raw steel capacity.
The usage of lubricants, oils, greases and hydraulic fluids in the
iron and steel industry is generally recognized as a potentially
significant source of pollution due to the large quantities that
are used and the numerous applications of these materials in a
typical steel mill. Pacific Enviro”mental Services was contracted
by the Environmental Protection Agency’s Industrial Environmental
Research Laboratory at Research Triangle Park, North Carolina, to
1—1
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re 1-2
UNITED STATES
t P r
are ‘isted in Tabi
1_i
Note :
Figure 1.1. INTEGRATED STEEL PLANT LOCATIflNS
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U
S
wisCONS
Fiqure 1-2. I1TE(F ATED ST [ EL PLI :T LOLAT1)
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C ricanj And Plant Location ________
1. ALAN WOOD STEEL COMPANY
Conshohocken Pennsylvania
2. ARIiCO STEEL CORPOP.ATION
a. Ashland Kentucky
h. HouStOn Texas
c. Middletown Ohio
3. BETHLEHEM STEEL CORPOP.ATION
a Bethlehem Pennsylvania
b. Burns Harbor Indiana
c. Johnstown Pennsylvania
d. Lackawanna New York
e. Sparrows Point Maryland
4. C F I I STEEL CORPORATION
Pueblo Colorado
5. CRUCIBLE. INCORPORATED
Allo> 0 vision
H dland ennsylvan1a
6. CYCLOPS CORPORATION
Portsn uth Ohio
7. FORD P TOR COMPANY
Dearborn Michigan
8. I’LAND STEEL COMPANY
East Chicago Indiana
9. INTERLAKE. INCORPORATED
Chicago Illinois
10. INTERNATIONAL HARVESTER COMPANY
south Chicago Illinois
11. JOP ES AND LAUGHLIN STEEL CORPORATION
a. Aliguippa Pennsylvania
b. Cleveland Ohio
c. Pittsburgh Pennsylvania
See Figures 1-1 and 1-2 for locations
Note: 1 Ton 907.2 kg
Corn !Oy And P1 ant Location
12. KAISER STEEL CORPORATION
Fontana California
13. LONE STAR STEEL COMPANY
Lone Star Texas
14. McLOUTH S1EEL CORPORATION
T ’enton Michigan
15. NATIONAL STEEL CORPORATION
a. Granite City Illinois
b. Eco’se Michigan
c. Weirton West Virginia
16. REPUBLIC STEEL CORPORATION
a. Buffalo New York
b. Canton (Massilon) Ohio
c. Cleveland Ohio
d. Ga sden Alabama
e. South Chicago Illinois
f. Wsrrei (YoungYtown) Ohio
17. SHARON STEEL CORPORATION
Farrell Pennsylvania
18. UNITED SATES STEEL CORPCRATION
a. Braddock Pennsylvania
b. Duquesne Pennsylvania
c. Fairfield Alabama
d. Fairless Hills Pennsylvania
a. Gary Indiana
f. Geneva Utah
g. Homestead Pennsylvania
h. brain Ohio
1. South Chicago Illinois
j. Youngstown Ohio
19. WHEELING—PITTSBURGH STEEL CORPORATION
a. Monessen Pennsylvania
b. Steubenville Ohio
20. YOUNGSTWN SHEET AND TUBE Cc iPANY
a. East Chicago Indiana
b. Brier Hill (Youngstown) Ohio
c. Youngstown Ohio
4,000,C0O
1,500,000
3,400,000
2,500,000
6 , OO.OOO
4.000.000
1.000,000
1,500.000
4,400,000
1,500,000
2.000.000
2,700.000
1,900.000
2,500,000
3.000.000
3,500,000
4,400,000
8,000.000
2,750,000
.000,000
3,000.000
5,250,000
2 .500 .000
1,600,000
2.800.000
- 5.500,000
1.500.000
2.000,000
148,555.000
Table 1-1. USA-IN T( AT STEEL
Raw Steel
Capacity
________ Net Tons
COMPANIES AND PLANT CAPACITIES
Paw Steel
Capacity
Net Tons
1,500,000
2,000,000
1 .500.000
3,800,000
3.600.000
4,500,000
2, 00,000
6.000.000
7,500,000
1,665,000
1 .000.000
1,000.000
3.750,000
8,200,000
900,000
1,200,000
3.840.000
3,100,000
1.800,000
TOTAL
1-4
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inv stigate the use and f te of all lubricai ts , oils, greases and
hydraulic fluids in the i,on and steel industry. Fuel oils, sol-
vents, tars, pitch, transformer oils, wash oils and quench oils
were excluded from the investigation. The objectives of the pro-
gram included the deterr,,ination of (1) the types of lubricants
and hydr 0 ulic fluid.. utilized and their application, (2) the forma-
tion and deposition of air and water contaminants formed by the use
of these lubricants in the various steel production and processing
operations, and (3) current waste oil and grease control, collection,
and reclamation practices. A very ambitious study program was ini-
tiated to accomplish the study objectives via literature search and
review, questionnaires, visits to typical large Integrated steel
plants, and engineering analyses of all available data.
me initial project task was a comprehensive literature search uti-
lizing the resources of several technical libraries, trade journals,
texts, handbooks, technical papers and NTIS microfiche. Background
information was collected on processes and equicment, lubrication
practices and usage, and waste oil collection and reclamation.
Organizations, societies and institutes supported by, knowledgeable
of, or composed of iron and steel personnel were contacted to obtain
information useful for the PES study.
The second major task was to obtain detailed and current data on
steel mill lubrication and waste oil collection and reclamation
from representative integrated iron and steel mills in the United
States. This task involved several contacts and visits to EPA and
state pollution control agencies to obtain pertinent data from
UPDES and other files. In addition, manufacturers and distributors
of oils, greases and hydraulic fluids were contacted and literature
and specifications of lubricants were obtained. This second pro-
ject task was the most time consuming and perhaps the most important.
To obtain data from the steel industry, PES developed an “Iron and
Steel ill Lubrication Questionnaire” and sent it to nine representa-
1-5
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tive integrated mills. Several months of effort and numerous
telephone calls and correspondence with steel mills was required
to secure adequate responses from the industry. Visits were
arranged to discuss the project objectives, review information
and data solicited in the questionnaire, and to obtain additional
information via interviews and facility inspection. Six of the
nine steel plants surveyed allowed PES to visit thcir facilities.
Although information was • eceived from all nine mills, information
and data sufficient to develop oil, grease and hydraulic material
balance estimates were gathered for only seven of the surveyed
teel mills.
Two consultants with considerable experience in the steel industry
were utilized to provide technical support throughout the project.
To supplement the data from the steel mills, PES contacted waste
oil reclaimers that handled waste oils from one or more of the
nine mills being surveyed and requested th to provide relevant
information and data.
The information and data acquired from the literature, steel in-
dustry questionnaires and visits, pollution control agencies waste
oil reclaimers, and the consultants were analyzed and used to de-
velop the material balances and typical values for oil, grease,
and hydraulic fluid usage, as well as conclusions regarding the
fates of these materials at integrated steel mills.
The following report presents the findings and describes the
analyses performed. Sections 2 through 6 provide a general des-
cription of (1) the iron and steel processes and equipment used
for making and shaping steel; (2) lubrication systems and prac-
tices; (3) types and properties of oils, greases and hydraulic
fluids; (4) waste oil collection, reclamation and disposal methods;
and (5) wastewater sampling and an 1ysis procedures for oil and
grease. Sections 7 and 8 present a detailed description of the
1-6
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methodology used for gathering information, and data obtained
from the nine steel i’ills surveyed and the data analyses per-
formed. Section 9 sumarizes the project findings and provides
generalization which can be drawn from the data. The project
conclusions and areas or problems requiring further study are
identified in Section 10. The r2port also 4 ”cludes a list of
references that were used during the course of this project, and
appendices, which provide other data that w2re used in the PES
study.
Throughout the report, as in the steel industry, the terms steel
mill and steel plant are used interchangeably. In actuality,
steel plant is generally composed of steelmaking equipment and
mills for rolling and shaping the steel. Comonly, the term steel
mill is used to refer to the entire steel plant, not just the roll-
ing mills.
1—7
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2. PROCESS AND EQUIPMENT DESCRIPTION
A general knowledge of the processes and equinment utilized in
the making and shaping of iron and steel is needed to understand
and appreciate the quantities and varieties of oils, greases and
hydraulic fluids purchased by the steel industry. This chapter
gives a brief general description of iron and steel making, the
shaping processes involved, and the equipment used. The equip-
ment that utilizes lubricants, oils, greases, or hydraulic fluids
is also identified.
2.1 General Iron and Steel Making and Shaping
The making and shaping of iron and steel is outlined below.
A more detailed description of these processes and equipment is
presented in The Making, Shapinç and Treating of Steel , available
frcm United States Steel Corporation. 3 A simplified flow chart
of steel making is illustrated in Figure 2—1.
2.1.1 Raw Materials
Several basic materials are involved in the production of pig iron
in the blast furnace. These are iron orc, sinter, pellets, mill
scale, scrap metal, coke, limestone and sometimes dolomite.
Iron ore is of varying chemica formulae and metal content. It
..onsists chiefly of oxides such as Fe 2 0 3 or Fe 3 0 4 , and some car-
bonate FeCO 3 . Small amounts of silica, aluminum, calcium,
nesium, phosphorous and other conta& ants are also present.
Upon arriving at the mill, the ore is removed from boats or cars
by an unloader and transferred to the ore storage yard by ore
bridges. From the yard the ore is moved by transfer cars to the
stockhouses at the base of the blast furnace.
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Stntering is one of the methods used to improve or enrich the blast
furnace charge. Ore, as received, may contain considerable quanti-
ties of fines which may credte problems in the blast furnace and
can easfly become lost” in handling and processing operations. To
recover the fines and utilize other metal beariny wastes, sintering
plants are employed. In these plants the following materials are
blended together:
1. Ore fines;
2. Flue dust from blast furnace, basic oxygen furnaces and
other plant operations;
3. Exhaust dust from sintering and air pollution control
units;
4. ‘1111 scales from rolling operation scale pits;
5. Limestone fines;
6. Coke breeze and sometimes powdered coal.
This mixture can be fed directly into the sinter machine or may be
formed with water into small balls or briquets and then charged to
the machine. The mixture is ignited on a traveling grate causing it
to fuse into porous, coherent lumps. The sinter is cooled, broken
into pieces of a desired size, and fed into the blast furnace. Pel-
lets are also used along with sinter. Pellets are made from bene—
ficiated ore that is mixed with a binder, formed in a balling dru n
and then fired so that they have sufficient strength for handling.
Limestone functions in the production of iron as a flux for sequester-
ing impurities In the ore and ccke charged to the blast furnace. From
storage piles in an area adjacent to the iron ore, it is moved to the
stockhouses at the base of the blast furnace and is charged into the
furnace in the same manner as ore or coke.
Metallurgical coke, which acts as the source of heat in the blast
furnace and also as the reducing agent for the iron oxides, is manu-
factured by destructive distillation of crushed bituminous coal in
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specially designed high and narrow coke ovens. Coal is charged
into the top of the ovens by larry cars. It is then heated to
approximately 1100°C (2000°F) for about 15 to 18 hours. White—
hot coke is then “pushedthrough a coke guide into quench cars. The
cars transport the coke to a quenching station w ere it is rapidly
cooled with water to prevent further burning. After quen ing, the
coke is dumped in a storage area. Gases which leaie the coke ovens
are cooled by spraying with flushing liquor. AnTnonia, light oils,
and coal tars are removed from the liquor before the rtripped gas
is sLnt to the plant fuel gas system.
2.1.2 Pig Iron Manufacture
The basic raw materials (iron ore, pellets, sinker, mill scale.
scrap, limestone, and coke) are processed in the blast furnace to
produce an iron with a high carbon content -- pig iron.
The charge is added to the top of the furnace by a skip hoist or
conveyor belt. The skip cars are filled from stockhcuses at the
base of the unit. The charging is done in alternate layers of ore,
coke and limestone to promote even melting. To provile the needed
heat, air to react with the coke is forced by blowers through the
tuyeres arranged around the base of the furnace. The carbon monoxide
from the coke, at the high temperatures, reduces the ore to metallic
iron which runs to the furnace bottom. The lim2store converts to
lime and combines with other elements to accumulate as slag floating
on the heavier iron. The slag is withdrawn from the furnace through
the cinder notch and slag runners into the ladle cars. Molten iron
or hot metal is then ‘ cast’ from the furnace through the tap hol’
into ho metal cars. Blast furrace gas after cleaning is later
used as fuel at the furnace stoves or other points in the plant.
Once the blast furnace has been tapped the molten iron must be
removed. It may be discharged directly into a pig casting machine
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and formed into solid bars or pigs, or it may be placed in a hot
met i car or ladle. The hot metal car or ladle delivers the molten
irer. to a n’ixer or to steel furnaces. In some instances molten
metal is delivered to nearby foundaries for direct use.
The metal mixer serves two main purposes:
1. It keeps the metal molten until ready for further
processing, and
2. It allows xing o’ metal from various blast fur-
nace batches to provide a larger uniform batch.
2.1.3 Ma,ufacture of Steel
In its simplest form, steel is iron refined to contain less than
two percent carbon. The two most doniinant methods in use today
are the basic oxygen and electric arc processes; the open hearth
method is still being used, but it is rapidly being displaced.
The amount of raw steel produced by open hearth furnaces in the
United States has decreased from 84 percent in 1962 to 19 percent
in 1975. The basic oxygen furnace converts molten pig iron and
scrap to st;el by blowing large quantities of oxygen into the
charge to react with the carbon and other impurities. This pro-
cess has a higher production rate than open hearth furnaces. In
the United States, basic oxygen furnace production has increased
from 7 percent of the raw steel produced in 1962 to 62 percent in
1975. Electric furnaces are generally charged with cold scrap and
alloying agents to produce a variety of steels. Heat Is produced
by electricity flowIng through the metal. Domestic steel production
by electric furnaces has increased from 9 percent in 1962 to 19
percent in 1975.
2.1.3.1 Basic Oxygen Process . The basic oxygen process is closely
related to the old Bessemer methcd. The substitution of oxygen for
air is the essential difference. A refractory-lined, pear-shaped
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vessel Is used which can be tilted to either side for tapping and
charging. Scrap and molten metal constitute the ch rçe, with metal
naking up about 70 percent of the mass.
The furnace is tilted before it is charged after which it is re-
turned to an upright position, and a water-cooled oxygen lance is
lowered into the vessel. Oxygen is Injected under pressure and
high velocity and a reaction occurs with the molten metal. The
heat derived is sufficient to continue the refining action. After
about 20 minutes a visual drop in flame occurs signaling the reaction
end point. A sample is taken to check the temperature and composi-
tion. When these are correct the furnace is tilted again and tapped
into a ladle. When the molten metal has been removed, the furnace
is rotated in the opposite direction and the slag dumped. The fur-
nace is then ready for Its next charge.
2.1.3.2 Electric Furnace Process . The electric-arc furnace is a
bowl-shaped vessel mounted on a toothed rocker that can be tilted
for pouring. The top has cylindrical openings, through which three
large electrodes are inserted to conduct electric current.
The furnace charge consists almost entirely of scrap. After
charging, the top is swung into place and the electrodes are lowered
into the furnace. The current is turned on and begln to form a
pool of molten metal on the hearth. The charge then begins to
totally melt from the bottom up by radiation, heat from the arc,
and electrical resistance of the scrap. Impurities combine with
the slag. In some cases an oxygen lance is used to speed the
refining.
When the process is completed the power is shut off, electrodes
raised and tap hole opened. The furnace is then tilted and the
molten metal poured into a ladle. The slag is removed by a
separate ladle, after the steel.
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2.1.3.3 pen Hearth Process . A substantial amount of steel is
still produced by the open hearth process, although it is being
replaced by the basic oxygen and electric arc processes. The
furnace uses are large dish-shaped hearth lined with refractory
material. The raw materials, typically half scrap and half pig
iron, are charged to the furnace from the front. In actual practice
any ratio of hot metal and scrap may be and is often used. Lime-
stone is added to produce a slag as in a blast furnace. First
the limestone is added and then the scrap. Gas or liquid fuel is
burned with air to produce the desired heat. The refining is
hastened by using oxygen lances in some cases. When the proper
temperature is reached the molten iron is added. The heat continues
for up to eight hours and a final temperature of about 1650°C
(3000°F). When ready, the steel is tapped into a ladle a pnured
into ingots or transferred for other purposes. The slag follow3
the steel in 4 o slag cars r ladles. -
2.1.4 Steel Processing and Shaping
By far the greatest portion of metal produced by the various steel-
making processe 3 ultimately reaches the rolLng mills. It is
generally in the form of in9ots. To form ingots, molten metal
is ladl2d from the furnaces into ingot molds resting on cars.
A newer method of forming molten steel is in a continuous caster.
In this process molten sLeel is first poured from a ladle into an
intermediate pouring vessel called a tundish. The tundish is
equipped with nozzles to feed the molds. The mold is made out of
copper and Is internally water cooled. Rolls pull down the
starting bar which assists in pulling the metal through the mold.
The rate is slow enough so that the molten metal continuously
solidifies into the desired form. The finished casting is addi-
tionally cooled by water sprays and is cut into desired lengths.
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Ingots and bars are moved to soaking pits prior to hot rolling in
the primary mills. In these pits the ingots are hee”.ed to a tem-
perature of about 1200°C (2200°F). The steel is then easily rolled
into blooms or slabs.
2.1.4.1 Primary Rolling Mills . The white-hot ingots are taken
from the soaking pits to the primary mills where they are rolled
Into blooms, which have a square cross section, or slabs, which
are of rectangular crcss section.
The blooming mill is equipped with two or three rolls; thus the
nomenclature a “two—high” or “three-high” mill. In a two—high
mill the rolls revolve in opposite directions, gripping the ingot
and pulling it between them while squeezing it Into a thinner,
longer shape. By reversing the direction of the rolls and reducing
clearances between them, the steel can be passed back and forth
until the desired dimensions have been obtained. In the three—
high mill the rolis are not reversed; instead, the metal rests
on tables that can be raised or lowered after each pass to the
level between the two top rolls or the two bottom rolls. When
finished, the bloom, or slab, while still red hot, is carried
on conveyor rolls to a shear and cut to the desired length.
Before further hot working, surface imperfections are removed by
“scarf ing” or burning—off with oxygen lances. After this operation
the slabs are taken to a reheat furnace to bring them back to
suitable rolling temperatures.
2.1.4.2 ! econdary or Finishing Mills . After they are brought
back to rolling temperature, the blooms or slabs are ready to
be finished into a final product. This includes strip, sheet,
plate, bar and rod, tube, rails, structural shapes, and specially
finished steels.
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In the hot strip mill a reheated slab is passed through a two-
high sc ule breaker to remove scale. Next, it enters the roughing
stands composed of four mills with four rolls. While passing
through these mills a large volume of water, steam or air at
high pressure I c blown over the surface to remove scale. The
slab, which is now considerably longer and thinner, is ready for
the finishing stands. Finishing stands may include six or more
mills. They work the strip into a finely finished ribbon of steel.
The finished strip then enters a coiler at about 980°C (1800°F)
which winds it into a bundle ready for shipping.
When thin sheet having good surface and metallurgical properties
are needed, cold reduction stands are used. Mills of from one to
six stands can be used. The stands are carefully synchronized to
absorb slack from strip elongation, and are capable of very fine
roll adjustments.
Sheets that are thicker than 0.584 cm and 20 or more centimeters
(0.230 inches and 8 or more inches) wide are known as plates. Plates
are usually rolled from scarfed heated slabs in two-three- or four-
high mills with four-high reversing mills being the most comon.
Similar procedures as with sheet rolling are followed. After
shearing to size, the plates are cooled and prepered for shipping.
Tubes are rn3de from blooms that are reheated and center-punched
for piercing. At the piercing mill the bloom is gripped by
rotating rolls and a hole is punched through the billet. A rough
pipe with thick walls is produced and sent to the plug mill. The
plug r,ill reduces the wall to the desired gauge while at the same
time lengthening it. Finally, the reeler and sizing rolls make the
pipe round and smooth, and make the walls of uniform thickness. Other
processes roll strip or skelp into cylinders and weld the edge to form
tube and pipe. There are severa’ different types of bar and rod mills.
Each is a hot rolling operation designed to handle the billet or rod as
it is successively reduced in size. Many different arrangements
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of stands are in use and up to twelve may be used in the operations.
Shears cut the final bars and rods into proper lengths, often six to
twelve at a time after which they are either processed further or
bundled for shipment. Structural shapes are produced similarly
using rolls with specific groove designs.
If a precise gauge or very bright surface finish is desired, a final
rolling of thin steel strips or sheets is often carried out in a
Sendzimir mill. This specific cluster mill uses highly finished
work rolls of small diameter, each supported by two series of back-
up rolls. The mill is reversible and the strips are passed back and
forth until the final desired thickness and finish is achieved.
2.1.4.3 Application of Protective Coatings . Correct surface prepa-
ration is the most important requirement for satisfactory application
of protective coatings for steel. Without a properly cleaned surface
the coatings will fail to adhere or to prevent rusting of the steel
base. The coating performance is proportional to the degree of sur-
face preparation. Several methods of surface preparation exist.
Two basic techniques are mechanical and chemical surface preparation.
Solvent cleaning, alkaline cleaning, flame cleaning, blast cleaning
(abrasives), hand or power-tool cleaning and pickling methods are
used. The most comon method for removing scale and rust in large-
scale operations, such as at integrated steel mills, is pickling in
dilute solutions of sulfuric or hydrochloric acid. Nitric and hydro-
fluoric acid mixtures are also used for alloy and specialty steels.
The time of pickling, and concentration and temperature of the solu-
tion, are varied depending upon the type of scale to be removed or
the type of steel being pickled. The metal is exposed to the acid
for as little time as possible to minimize attack on the steel itself.
The acid treatment is followed by a cold water and hot water rinse
then drying. Batchwise or continuous pickling processes are employed.
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After surface cleaning or preparation, protective coatings are ap-
plied. Metallic coatings are most comonly used for steel although
organic coatings are also used. Tin, zinc, and terne metal (lead
plus tin) are typically used while nickel, chromium, cadmium, cop-
per, aluminum, bronze, brass, silver, gold and lead are used to a
lesser extent. Metallic coatings are coimnonly applied to steel
surfaces by electroiytsc or hot dip processes.
Tin plate represents one of the major items produced by the steel
industry in the United States. About 7 percent of the total steel
products shipped are tin plate. The largest use of tin plate is
for containers. The sequence of operations in the manufacture of
tin plate is as follows: slabs are heated and hot-rolled to coil
form in the hot strip mill. The coils are continuously pickled
and taken to cold-reduction mills where they are reduced to ap-
proximately the final desired gage. The cold—reduced steel is
cleaned, annealed, and then temper-rolled or cold-reduced in coil
form in preparation for the tinning operations. There are several
methods of applying tin coatings, but the most common is the elec-
trolytic process. A more uniform coating with less consumption
of tin is achieved by this method. Metal from a coil of steel
which has been hot and cold rolled, pickled, annealed, tempered,
and qiven a final cleaning is passed as the cathode through an
electrolyte composed of tin salts. Blocks of pure tin act as the
anodes. The tin is gradually deposited on the steel. The
plate as it emerges from the plating bath is a dull gray-
white. To cause a bright luster and assure complete
coverage, the coated strip is heated with a resultant uni-
form fusion of the tin coating. After heating it is directly
water quenched and dried. A thin protective oil film is applied
to prevent surface oxidation and to aid in subsequent handling.
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Coatlnj steel with zinc is a very effective and economical means
or providing protection against corrosion. Zinc coatings are
comonly appli3d by dipping or passing the article to be coated
through a molten bath of the metal. This operation Is termed
“galvanizing,” “hot galvanizing” or “hot—dip galvanizing” to dis-
tinguish it from zinc electroplating processes which are termed
“cold” or”electro-galvanizing.” Of all the comon metals used for
protective coating, zinc is the lowest cost per pound. With the
exception of tin, it is used to protect a greater area of steel
than any other coating metal. A continuous (strip) hot—dip gal-
vanizing operation is generally used. The steel in coil form
from the rolling mills Is uncoiled and passed continuously through
the galvanizing equipment. Continuity ‘peration is achieved
by joining the trailing end of one coil to the leading end of the
next.
2.2 Equipment Utilizing Lubricants, Oils, Greases or Hydraulic
Fluids
Lubricant-type materials in the steel industry can generally be
broken down as greases, lubricating oils, process oils and hydrau-
lic fluids. Due to the variety of operations and the amount and
size of equipment used, no other industry employs a more complete
usage of lubricants. High and low temperatures, shock loading,
exposure to water and abrasive materials, are some of the adverse
conditions normally encountered. All types of motors, turbines,
bearings, gears, and drives must be properly lubricated to keep
the machinery functioning.
Greases, oils and t’ydraullc fluids are used in a multitude of pur-
poses and locations in a modern Integrated steel mill. A typical
mill may have over 400,000 lubricatIon points using as many as
150 differIng srPrifications for lubricants. In the sections
which follow, various classes of lubricants are listed together
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with types of equipment to which they are applIed. For more de-
tail in any spec fic area of the mill, Appendix A has a detailed
breakdown by area and application point. A similar but morL de-
tailed steel mill lubrication guide, prepared by Joseph Lykins is,
“A Practical Guide for Lubricating A Fully Integrated Steel Mill”
which is presented in Appendix C.
2.2.1 Greases
Grease is generally used under the following conditions: 1) where
there is no way to retain oil for the parts being lubricated; 2)
when the lubricant must act as a seal to prevent the entrance of
dirt; 3) when a lubricant is seldom added; and 4) where speeds are
low and pressures are high.
TP main use for grease is in the rolling mills. This includes
both primary and secondary operations. The amount of machinery and
extreme operating conditions demand a constant use of grease In
many different situations. Steelmaking operations, as well as the
blast furnace area, also account for a large expenditure of this
lubricant.
Typical greases used In the steel industry can be listed under the
following generic categories:
extreme pressure gre3ce (EP)
molybdenum disulfide grease
roller bearing grease
roll neck grease
extra duty EP grease
high temperature EP grease
mill utility grease
cup grease
block grease
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Extreme Pressure Grease - EP grease is used for normal operating
temperatures of 66 - 93°C,(150 - 200°F) on backup-roll, work-
roll, and table bearings; this includes conditions found on ball,
roller and plain bearings. EP grease is applied in situations
where steel-to-steel contact is involved. One of the largest
uses of EP grease is for various components of the finishing mills.
This includ tensioning and coiler rnandrels, roll bearings and
table bearings. Other uses are for the hot metal and slag cars,
roll bearings on the continuous caster, and on the feeder and
breaker in the sinter plant.
Molybdenum Disulfide Grease - Moly grease l used In slow-speed,
plain-bearing, and sliding-surface applications operated under
marginal lubrication conditions. General plant use of moly grease
is limited. Specific applications are for the blast furnace hoist
cables, BOF trunnion bearings, and open gears on the ore and
limestone handling equipment.
Roller Bearing Grease - Roller bearing grease is a high-temperature
multi-purpose grease used for ball and roller bearing lubrication.
It is coninonly used in conditions covering exposure to water, high
and low temperatures, shearing, oxidation and rust. These condi-
tions are encountered by bearings on electric motors, wheel, gear
shafts, and conveyors. Applications include blast furnace motors,
the tilting mechanism motor on the hot metal mixer, soaking pit
door motors, and sinter machine couplings.
Roll Neck Grease - Roll neck grease is a mild EP grease used in
the presence of large quantities of water. It is used in large
amounts in the blooming mill, billet mill, slabbing mill, bar mill,
and plate mill. It is typically used on the mill screwdown which
is adjusted to control the height of the rollers.
Extra Duty EP Grease - Extra duty EP grease is used in locations
where high operating temperatures are present (93 - 121°C,(200 -
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250°F)) and high pressure metal-to-metal contact is involved. Normal
uses are on backup-roll, work-roll, and table bearings. It is ap-
plied to ball, roll and plain bearings, and for general purpose lub-
rication in the presence of large quantities of water. These con-
ditions are typically found on coke battery latches, bearings and
rods, on the blast furnace distributGr grease seals, and on the
primary mill roll stands, table bearings and mill soindles.
High Temperature EP Grease - This is a high—temperature multi-purpose
grease used as a ball and roller bearing lubricant. It is applied
in a wide range of conditions such as, exposure to water, extreme
temperatures, shearing, oxidation, rust and extreme pressure. These
conditions are usually encountered by motor bearings, wheel bearings,
heavy-duty rnillbearings and pressure systems requiring good mobility
at low temperatures. Coke battery door hinges and latches, blast
furnace torpedo . ars, and electric-arc furnace electrode guL ’es,
drives, and latches are normal locations. The open-hearth fi 1 Aace
uses high temperature lubricants for charging box wheels. Reheating
furnace doors, rollers, and rails also use large quantities of this
grease.
Mill Ut Iity Grease - Mill utility grease is used for operating
conditions found on ball, roller, and plain bearinos, including
roll necks, and general purpose lubrication in the presence of large
quantities of water where adherence to metal is important. A coninon
use for this grease is the coke oven guides where large amounts of
lubricant are needed.
cMpGrease - Cup Grease is used for the hand lubrication of plain
bearings and bushings where the grease feed is controlled by a spring-
load, screw-type, grease cup. Cup grease is widely applied to all
tyPes of small motors and machines in all parts nf the plant.
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Block Grease - Block grease is a water-resistar t hand packed
grease generally applied to rolling—mill necks. Since it is
manually applied, it is generally used in older rolling mills
having a minimum of auton cic feed systems.
2.2.2 Oils
Oils are used in the steel industry for wide variety of purposes.
Very simply, oils are used in all cases where operating conditions
do not dictate the use of a grease.
A basic list of comon oils is given as below:
engine oils
extreme pressure oils (EP)
R & 0 oils
rolling oils
Sendzimir mill rolling oil
protective coating oil
Engine Oils - This category includes, gasoline engine oil, turbine
oil, automatic transmission fluid, circulating oil, and diesel
engine oil. These are all variable viscosity oils used for the
lubrication of plain bearings, slides, machine tool bearings, low
or normal load enclosed gears, and pistons and cylinders in en-
gines. Conii on applications are in automotive engines, diesel
locomotives, turbines, and power transmission systems.
Extreme Pressure (EP) Oils - Extren-.e pressure 0115 are used in
applications involving high pressure metal-to-metal contact. These
lubricants are applied to most gears unless they require grease
lubrication. Examples are water pump gear drivers, blast furnace
and crane reduction drives, rolling mill screw downs and shear
drives, and rolling mill coller and drives.
Rust and Oxidation Inhibited (R&O) Oils - These R&O oils are used
in applications that require oil but do not require EP character-
istics. Frequently they are used in recirculating systems.
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Typical applications are in plain Babbit, Mesta or Morgoil bear-
ings in rolling mills, plain bearings in turbo blowers, air com-
pressors and steam turbines, and in back-up roll bearings.
Rolling Oils - Rolling oils are not usually classified as lubri-
cants, but they are used in large quantities in the cold process-
ing of sheets, plates, strip steei or tin plate to reduce roll
wear and improve the finish of the steel. These oils are spt. ci-
ally formulated for each application and are not at all similar
to lubricating oils. Some steel mills also use rolling oils in
hot rolling operations.
Sendzimir Mill Rollin g Oil - This is a low viscosity, oxidation
and rust resistant oil. It is a well refined oil designed for
use in the Sendzimir Mills, which will serve the dual function of
roll oil and lubricant for mill components. Different types of
oils are used for different steels. Low viscosity mineral oil is
used for heavy gage, fatty polar types for stainless, paraffinic
slushing oils for carbon and silicon, and palm oil for tin plate.
Protective Coating 011 - There are a wide variety of products
that are used to protect finished products against corrosion,
water, and extreme tem ratures. Low ‘,iscosity mineral oils with
polar additives and inhibited petroleum oils are comonly used
for indoor storage. Heavy petroleum or asphaltic coatings and
varnishes are used for outdoor applications.
2.2.3 HydraulIc Fluids
Hyaraulic fluids are generally oil-based products and come in a
slightly lesser variety than lubricating oils and greases. Some
typical products In use ir idude:
inverted emulsions
phosphate ester fluids
water-glycol fluids
2—17
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inhibited hydraulic oil
extra-duty anti-wear hydraulic oil
Inverted Emulsions - Inverted emulsions are stable water-in-oil
emulsions used for fluid power systems that are subject to f re
hazards. They ar not suitable above 66°C (150°F), or above 10
megapascals (1500 psi), or in systems that are prone to shock
loads or high shear stresses. They ere the least exrensive fire
resstant hydraulic fluid. inverted emulsion fluids are used in
coke battery pushers, hot strip mill coil conveyors and the
primary and secondary mill roll balance systems.
Phosphate Ester Fluids - Phosphate ester fluids are also used in
hydraulic systems that are subject to fire hazards. They are
suitable for high-pressure operating systems (to 34 megapascals)
(5000 psi) and high temperatures to 107°C (225°F). They are the
most expensive type of fire resistant hydraulic fluid. A normal
applicatioc is in the hydraulic systems of tractors used in the
removal of pit slag. Optional uses are in the hydraulic systems
on the scdrting machine, soaking pits, rotary furnaces, and askania
regulators.
Water-Glycol Fluids - Water-glycol fluids are also used chiefly
in areas subject to fire hazards. They are not suitable for power
systems operiting above 66°C (150°F) or above 14 megapascals (2000
psi). Typical uses are in the open-hearth dolomite machine, the
electric-arc furnace tilting mechanism and electrode system, and
the continuous caster pinch-roll and cut-off torch systems.
Anti—Wear Hydraulic Oil - Anti-wear hydraulic oils are normally
used in all precision, stationary, hydraulic units, and where
there is no fire hazard.
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3. OILS, GREASES AND HYDRAULIC FLUIDS
The iron and steel industry uses a large number, frequently more
than 100, different lubricants in the makirg, shaping and treating
of steel products. Different lubricants must perform under dif—
erent conditions: at high temperatures, under high pressure, in
the prescnce of water or steam, or they must be fire resistait.
The c nbination of requirements such as these determine the number
and nature of lubricants that must be used. Frequently, the
desired properties .re achieved by using additives and a base
lubricating stock. Approximately half of the lubricants produced
in the United States are used in automobiles 4 and 36 percent in
industrial lubrication. Oil and grease consumption in the steel
industry has been estimated at 378,500,000 liters (100,000,000 gal)
per year which represents 3 to 5 percent of the entire U.S. lubri-
cant production. 4
In this chapter, oils, greases and hydraulic fluids are discussed
according to their chemical composition. The chemical composition
of additives is also discussed and the toxicities of all materials
are reviewed. A brief description of lubricant purchasing practices
is provided at the end of the chapter.
3.1 Classification
Lubricants may be classified n two different ways: l) according
to lubricating characteristics, and (2) according to chemical compo-
sition. The former classification is most often used because it
enables the lubrication engineer or maintenance worker to select
the proper lubricant for the equipment that is being serviced.
The latter classification is more useful in this study because the
disposal, reclamation and toxicity of a lubricant are determined
by its chemical composition rather than by its viscosity, viscosity
index and other physical properties. Both classification schemes
are discussed below.
3-1
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3.1.1 Classification According to Lubricating Properties
A typical classification scheme for steel mill lubricants is shown
in Tables 3- I and 3-2. Forty—two lubricating oil and twenty-three
grease classifications are shown along with the pertinent character-
istics of each. 4 Viscosity, resistance to oxidation, water separa-
tion, detergency, performance at extreme pressures ani temperatures,
and price of the luL’ricant are major factors that define each cate-
gory. Categories are given names such as “circulating eigine oil,
‘hypoid gear oil,” “general purpose grease,” “antiwear hydraulic
oil,” etc. that are helpful in describing families of lubricants.
But within each of these categories several specific lubricants are
usually manufactured in a range of viscosities or other properties.
The same types of lubricants may be available from several manu-
facturers.
The catege ’ies as listed in Tables 3—1 and 3—2 are too general to
be useful to someone who wants to select the correct lubricant for
a particular piece of equipm€ nt or for a purchasing agent who must
replenish stocks of lubricants. For this latter purpose steel mills
have assigned identification numbers or classification numbers that
are used internally as a means of identifying each individual lubri-
cant. Examples of such schemes re given in Tables 3-3 and 3-4.
Table 3—3 shows tP e United States Steel Corporation classification
which uses a three-dI it requirement number to identify each of 101
different lubricants. United States Steel publishes the Lubrication
Engineers Manual 5 that lists the lubricant performance requirements
correspc.nding to each requirement number and gives directions for
performing tests to see if specifications are met. The Kaiser Steel
Corporation lubricant index is also presented in Table 3-4. Kaiser
Steel maintains detailed listings stating the physical properties,
performance requirements, types of containers, and container label-
ing schemes for each of the 93 lubricants in this list. Youngstown
3-2
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Table 3-1. TYPICAL LUBRICATIi .( OILS USED
BY VARIOUS STEEL COMPANIES
Usual dens.ty
I. Ppirrdl. cii i
2. l.ocinc oil--low rosity
2. I--high ,,i ’.cosity
A priros
ri m cOsity
Ian,..
5 )5 it 100 F
l n,lrr IflO
t i . to 4 i)
45012,000
4. bib ,.. Oil Under 500
4. Turbine onil ireubating oil
9. Cireirlsinc enerne oil
7. Circuisring oils
9. Irrck nil t 710 11
9. Frile psr. 1 5 n oil
10. C) utile, c’,l—unfiltercd
I I. C>lundcr rid—Rltered
17. C}lindcr -fllL rir1. compounded
13. C) lindrr— -ursI,trccd, compounded
14. Motor oil—API. MI.
IS. Motor oil—APT. MM
16. Motor oil—API. M
21 T),tr,g .nt diesel rind motor—API, DC
19. Detcrgrnt diesel (APT. D.M)
19. Detergent di .sel (Arl-fis)
20. Critcrpull e. Serre, 3
21. (5usd !o.,motive
22. Way luh,ieanti
23. 1I>drri ulu c.riludcany oils
24. Gear oil
25. 1 1)jiOid gear oil
26. CaT josirral oil
77. Pneiimuir tool oil
2 . I.iclit.doty miner .1 metolwnrkinc fluiiil
29. $Ieiliurn.duty riineru .l nuet..lss-orking
fluid
30. llcae 1 .-duty m rirr . .l metalworkirg
9u id
3!. Conrient.onnl soluble oil
32. )leari .dot> soluble oil
33. Chemical euttini fluid
24. Eztremc.prrnsure gear oil
35. Roll-ne L .prnv oil
36. Open.ge..r lubricant (non-El’)
37. O;iennear lubricrint (El’)
38. Ilydraulic (inverted emulsion)
39. 1l droulic (water glycol.)
40. Itydrsuic (phosphate ester tj(ieri)
41. Artisiar hydraulic oil
42. Nut oils
j T ,nkr 500
Vp to 2(Y)3
O’er $00
80-300
2.000 nd up
2.000 sod up
2.000 isrii up
2.000 and up
1 50/1.250
150/1,2)0
150/1250
1 ).0/ l.250
150/1.230
150/1,250
150/1,250
150/1.000
150/300
500/4.500
500/4,500
150/300
l00/r,00
40 11 )0
100
150/5,00
100/1,500
150/2.330
Various
300/17.000
300/I .000
750 at 210 F up
750 at 210 F up
200/430
150/300
90/250
Under 500
150/1.500
C.en.rsl descriptio
Torbin. quslity
t trim ses Si nluiluty, aster
0 , -Jr. i nhi mNi
Orl ii ii y . 1 .I.ility, writer
selii s rati uin
Ili h osiil.tinn rind rust re.i,* ,nt
water e.e;i?tcatinn, top ijiiality
Second. line turl,ine oil • it, rood
It intl (I nnd • ,lrr.se 1 ,arutiuig
qualities
flood ntsliilitv. w 5ier s .p’trnlui.fl
(most stability. liu l,.i!c .i ,ee water
.c iftratIofl
)isphaltic .,,dusl oil
( )irl , nary rit li,lit ’ — p’sle ‘-iii
Stra ,,bt mineral, Stcafli rei ned
Bright stock
flrirht stock and •ciijlgss tallow
Dark oil and seidle tatiow
Good atshility
Good sl.rsbility
Good .tability
Good stability and detergency
Good stability and detergency
Good stability and detergency
Righ strihility and detergency
E ,IO requirements
Compounded oil with good stick.
slip
Low-s-ocosity compounded oil
with good stick-slip
Non-EI’—SAI denirnatinno
Active n ,rtiweld LI’ for high
loading
AAI( requirements
Vetting ‘Cent and emuls,llcr
laity oil rom iounmjiri
Low suitor, low chlorine corn.
voundinc
Active sulfur. high S. high Cl
eornpouniling
l;iiiul —iitcr. rust inhibitor, low
aetreity
Lmiil-irirr. rust inhit or. S. CI,
or fats added
Synthetic. u,uallv wuiter soluble
hick loail.eare inr r’r 1 u ’srit v,
coo . 1 itiiliility. w i cr s .r mar:rtiOn
Same a, gear oil titus ‘iiJlieoive.
ness in liresenre 01 water
Normal trirutu. shock resistant.
aster resistant
Ailhui’s,ve. lui,h load capacity.
water resistant
Non,etrsrmstine. low cold test,
Fire resistant
Fire resistant, good wear
resists n et
Fire resistant, good wear
rcsi,t:tnCt
Inluitirt,’il oil with anliwear
sdil,t,ves
Good inciting, flOii.guifliflhiig
Iltcnmmen.li’d nr preFerred
application
l’reroiori shop too!.
llruiud oil’rug, onrethrough sight
tr od
II rh In,, huvd raii!iC and r ircu.
lurtin, —i-sterns
Qie:iifl turbines. msrhuin, tools
licrisi .mn In drauluc n’inchinr..
inntnr ‘mimi
irarints. circulating
. 1cm,
l.muckuumr ‘creTe niuCrating
enr oll iris
Ii’ Ii. l r, s rich ,t ins cv stem.
ickum rtIl o ,l.hrri hearing,,
e ,ieln ed earo
an.l flume. ‘hid,
SIu.hiunr. fluishuinc oil (or os stem,
aon.l,l enrIm,,emj. ear lubricant,
rourhi oulint
I ’ .neIosrui i’,’srrnc here good
foal uty i i . ’ red
Steaiii e) under lubr,cstion—orm
rtnrifle
ienm cylinder lubiicat,on—worm
gesrine
Ao’omotive rosin.,. sir compre.-
.o ,r’. light service
Autororutrvr cnenr’. air compre,.
Soc., medium -c es-ice
Aotomom .s’e er,runcs. air compreri.
oar,. ,ev’re strict
l)ie.el antI sutirmotivi engine.,
light serrisce
Diesel and suhomotive engines,
low’S fuel
Diesel and liutoriotive engines.
loch-S luel
Cisterpilir enrine,, h, hs-S fuel
Locomotive service
Slrichiine tool ways
Combination hs’droulie and way
oils—machine tool,
l-:nrlosed ct.trin.
llcavily lu,amicd spiral heed nod
hytioiml cersrine
ltoilr’,sd.c.r journal hieriringi
Pncumatic tool Cylinders
Mill drive,, pinion,, screw,, and
nut,
Itoll-neek bearings, gearing
Open gearing, chain,. skids
hleos’ilc loaded orco ecaring.
drains. etc.
S 1 iei.i t irri h. t> gre of pump
Specited by t) pe of pump
Sp ci8ed by type of pump
Itch. p,i’sniire hydraulic .crvie.
,pecihi—i liy purrifi
lligh’s 1 ri’cd aiit,rirtion hearing,
Noisier of
cci ii I 5 5 i C 5
reporting
U . S
S
5
6
3
. 1
4
2
0
2
2
.3
3
2
2
2
a
3
3
3
2
I
3
4
4
7
2
3
3
2
2
2
4
4
SUS = Saybolt Universal Seconds: Viscosity conversion tables are available in
chemistry or lubrication handbooks.
3-3
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Table 3-2. TYPICAL LUBRICt TING GREI iSES AND
COMPCUNDS USED BY VARIOUS STEEL COMPANIES
P .r i.nent
info, mai ,oa
6000 at 100 F
l.’ .c.otly Cr. DOOP
3 ’tuiIIy Ca soil ’
0.1 si .ro - .ty under
400 S(’
0.1 s ,.rn—.ty OVer
400 S’ . (’
Strin ,nese added
0 .l v .crouty 1.000
at IOU I
0. 1 1.000
•t tOO 1
O Il ooeooty 1.000
at 100 F
O .l s’ .,co .uly ir. o
at 100 F
C’aI um comp.et
lAIum,num romj.lrz
Non-soap jeIhn 1
Non-sost’ ,lI ,ng
Lithium soap
Lithium soap
P.li .ed base
Calcium soap
Calcium soap
Varinus
Various soip tellü .i accntr. plus
e.pholtie o,I
NLGI-4 in !. ‘ 1’0 at 350 F nsp
(no kid or ,i-.pl.I )
NLGI-4 tn ( , at 350 F mp
a .11 lead or
Normal tern;.. water rps .st3nt
Normal temp. sate, ,,i .itsM
(a ‘n r normal temp. aSter
Its Istant. elastomer
anon. rntd,umn ten,I,. water
re. . rt ant
Nnd .osi soar.. ,raph .te. for h,th
Ot .CTftt,flC ICOIP
C. so -. .. leaded. aster
r Cs,*tant
S.m,,, to cup ire.,. heavy
duty. leSo> l.a-c ml. no 1:1’
fl ,np.s,n pont l: .OO F; ri ’.
a le C re.,.t.snt
No d,oi,i .,ic po .nt. water
resistant
Some. but leaded For estrime
pressures
Ili h temp. aster res,.t .snt.
mechanically st.-sl.le
H , h temp. watt, resiatsat. EP
Fibeous. medium tent.. nsid-
t,on 1111,1 .l,,a, stah,l ,tv
S.m..fluid. molt. trim-c. water
rtn.’.tont. LI’
Sem,flo,,l. water resistant. wool
barn borithair
Scmiñuol a,th )o h graphite
and/or (at
100-130 F nip
Prevent leol.aee in A1 ’ I cosine
and tulant Joints, .me. erii.h.te.
etc., 1111cr
Fil,rous, hiith ten,;,. non-water-
resistant
3 to IU ItloS,. in yacinur. soap
creases
Couplines. •erewdowns. cables
floll-neel. ,.t,rie .t.nn for hand-
poetril dt..efl
I Ic .-. ,ts F. 1 ,-I roll i.e. I.,. old
1 .-mI ior .e1 de, n
L, ht lr, .rlr. central greace-cup
lul,rieoi on
.1e,l .orn lo ,.l’. ,encrsl crease.
. mien, lul,ritfltinn
Centroitsed .sstems. whet,
5trlflrmfl ’. dr.,rrd
Roll-or, heir,ni,, cr trahitd
Crease .vsttfra
Itoll-neek i .r .nc- - ayttern crease
—bronie sl,i ,iO ’rr.
Hesv,ly model t .,il, rnlkr or
plssr. heirmn r. v.4 roll-neck
bcnr.ne i
boll-neck bSar .nt-s, WI ?? TOPS
lImb. cnr .t,nuoua operating temp
o .er 250 I’
1I ,rh, rOflt ,OUOu S OperatinC temp
over 250 I-’
Some limit for high loads
Antifrietion and p ain bearinis
(150-250 F)
Same but for hi 1 h lt tds
Antifriction bearings
SI m m 0 machine sears and
tearing.
Journols de-’gned for crease
1 ,.wkin g
Forging compound.
Slushing. rope lubrication, rust
I tr e vfntion
Pipe threads and couplinis
Artilriction hearings. no s-nt??
presence
(iw ,llOt,ag. hi l .ly loaded beat-
some getting
Number or
eoTflt,ftO,C 5
re .ortsng
use
Saybolt Universal Seconds: Viscosity conversion tables are available in chemistry
or lubrication handbooks.
lJsual identity
General requirements
l(ero,nnwnded or p’eferred
application
I. A .phaltic/reaidual I ’ .s-e—El’
2. l Ibel. ircase—non-EP
3. flIock g ,ea ’e—Fr
4. Cup 1 rrase— ’iict ,t duty
6. Cup rease—hcsvy duty
S. Gineral purpoae—stfifl
7. Griphited roll-neck gecase
S. Iligh-temp graph.ted roll- neck grease -
I. Standard El’ roll- , ,eck grease
10. Standard ot,-El’ rell-netk grease
I I Eitreme temp EP
32. bert base
13. Inert bane El’
34. Estra duty
IS. Estra dot0- EP
16. Ball and toOce hearing crease
17. Mmm i niael.,nt lubricant
18. Car jourr.al crease
lb. Drawing and fussag
20. I’etrolatum
21. I’.pe timeend grease
3
3
3
2
I
3
2
7
2
S
3
2
S
3
2
2
2
2
S
3
22. Rofler bearing crease Sodium base
P3. Imloly greass MS, SlIer
3-4
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Table 3-3. LUBRICANT CONSOLIDATION PROGRAM
Bastc Perforrnon’, Classification
The number osigned to these requirerre ’ ts have been estoblished for identif c tion within U. S. Steel
and have no sgniflconce outside of U. S. Steel.
LISS USS
lEO. REQ.
P lO. COMMON IDENTIFICATION NO. COMMON IDENTIFICATION
080 Diesel Fuel 209 Unclassified
081 Diesel Fuel No. 2 — Convertol 210 Compounded Cylinder Oil
085 Coke Plant Wash Oil 211 CylinderOil(Lessthen57. ATO)
110 Engine Oil 219 Oil Unclassified
116 Non-Inhibited Hydraulic Oil 220 Extr.m. Pressure Oil
119 Unciosaifled 221 Hypoid Gear Oil
120 Turbine Oil 222 Extra Duty Gear Oil
122 Ford Type F 225 E.P.Op.nGeorCompound
123 Auto. Tronsrn ssion Fluid, Dearon 226 E. P. Solvent Cut.Bock Open Gear Compound
124 Hydraulic Transmission Fluid, Type C-i 2 227 Dipper Handle Lube
125 Circulating Turbine Oil 229 Unclassified
126 Inhibited Hydraulic Oil 230 Black Oil
129 Uncla sifled 233 AAR Car Oil
130 Circulating Engine Oil 235 Open Gear Compound
133 Elostamer Oil 236 Solvent Cut-Back Open Gear Compound
134 Way Lubricant 239 Unclassified
135 Circulating Oil 299 Special Oil Unclassified
136 Extra Duty CirculatinC Oil 300 Cup G . (100 to 400 SSU @ I OOF)
139 UnclassifIed . 301 Cup Gr. (400 to Cyl. Stock 1 OOF)
140 API Service CA 309 Unclassified
141 API Ser’ic. CA 310 Sodium Base Roller Brg. Grease
142 API Servic. CB 319 Unclassified
143 API S cM cc CC 330 Mixed Base Roller Brg. Grease
144 API S.rvice CC 339 Unclassified
145 API Service CC 340 Graphited Roll Neck Grease
146 Caterpillar Series 3 343 Heavier Than Water Grease
148 Locomotive Diesel Engine Oil 346 Molly Grease
149 UnclassifIed 349 Unclassified
150 Pale Paraffin Slushing Oil 350 Extreme Pressure Grease
151 S.nd:mir Mill Rolling Oil 352 Extra Duty E. P. Grease
152 Comps. ,ided Quenching Oil 355 Extreme Temperature E. P. Grease
153 Compounded Rust Preventative 359 Unclessified
154 Coal Spray Oil 370 High Temperature E. P. Grease
159 Unclassified - 371 Boll & Roller Bearing Greas.
160 Mineral Metalworking 1ud 372 Extreme Temperature Grease
161 Hvy. Duty Miss. Metalworking Fl. 373 Mining Machine I.ubric nt
162 Soluble Metalworking Fluid 374 AAR Journal Roller Bearing Grease
163 Hvy. Duty Sal. Metalworking Fl. 375 Mill Utility Grease
167 Water Hydraulic Additive 379 Unclassified
168 F. R. fluid Invert Emulsion s00 Block Grease
169 Unclassified 405 General Heisting Heavy Gauge Wire tub.
170 P.R. Fluid Phosphate Eater 406 General Hosting Light Gauge Wire tub.
171 F. I. Fluid Glycol-Woter Base 409 Unclassified
174 Henvy Duty Brake Fluid 410 Impregnated Journal Compound
175 Synthetic-Petroleum Hydoulic Fluid 411 Replenishing Lubricant
179 Unclassified 490 Thread Compound — API Modified
190 Insulating Oil 491 Thread Con 1 pound — API Silicone
191 Penetrating Oil 498 Petrolctum
196 Pneumatic Tool Oil 499 Special Grease Unclassified
199 Miscellaneous Oil Unclassified $00 Asphalt Rood Oil, Work Oil, Grade Oil, etc.
200 Cylinder Stock Oil
3-5
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Page 1
Table 3-4. INDEX TO STANDARD SPECIFICATIONS
FOR LUBRICANTS
KSC SPFC NO .
60000
60001
60002
60003
6000’s
60005
60006
60007
60010
60050
60051
60056
TITLE
fIJLTI-PURPOSE E.P. WATER-PROOF HOLY GREASE
MILL GREASE, WASH RESISTANT
MILL GREASE, 1JLTI-PURP0SE
GREASE, BALL ROLLER BEARING, LIGHT
MILL. GREASE, MOLYDISULFIDE
MILL GREASE, HOLY SPII DLE LUBE
MILL GEAR GREASE, FLUID
W.4 TEMP. G . P. GREASE
E.P. WATER-PROOF GREASE
GREASE, BALL £ ROLLER BEARING
GREASE, HIGH TEMPERATURE
GREASE, HIGH TEMPERATURE (PRECISION MACHINERY)
60100
OPEN
GEAR
LUBRICANT,
DILLT ED
60103
OPEN
GEAR
LUBRICANT,
LIGHT
60105
OPEN
GEAR
LUBRICANT,
I €AW
60106
OPEN
GEAR
WBR I CANT,
X-t€AVY
60108
OPEN
GEAR
LUBR I CANT,
ULTP .A—t€AVY
60109
PVL
CHAIN
OIL £ WIRE
ROPE DRESSING
60200 NON-LEAD E.P. li’OUSTRIAL GEAR OIL, LIGHT
60201 NON-LEAD E.P. IM)USTRIAL GEAR OIL, MED ItJl
60202 NON-LEAD E .P. INOUSTR IAL GEAR OIL, P€AVY
60203 NON—LEAD E . P. IM)USTR IAL GEAR OIL, X-HEAVY
6o201i NON—LEAD E.P. INOUSTRIAL GEAR OIL, ULTRA— AVY
60205 NON-LEAD E . P. ThCUSTRIAL GEAR OIL, X—LIGHT
3-6
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INDEX TO STAI OARD SPECIFICATIONS
FOR LUERICANITS PN E 2
KSC SPEC o. TITLE
602119 P’ULTI-PIJRPOSE E.P. G& i OIL SAE-80
60250 MJLTI—PLRPOSE E.P. GEAR OIL SAE—90
60251 tIJLTI—PURPOSE E.P. GEAR OIL SAE—1 1 10
60300 MORGOIL OIL — MEDILI4
60301 MORGOIL OIL — HEAVY
60305 CEARING OIL — HEAVY (MIST)
60360 CYLIM)ER OIL - MEDIUM
601100 HYDRAULIC OIL, A.W. LIGHT
601101 HYDRAULIC OIL, A.W. MEDIUM
60 1 102 HYDRAULIC OIL, ASKANIA
601103 HYDRAULIC OIL A.W. L04 1DIPERATURE
601150 HYDRAULIC FWID — WATER GLYCOL
601160 HYDR. JJLIC FWID — INVERT t1LSION
6O 0O TURBINE OIL, LIGHT
60501 TURBINE OIL, MEDIUM
60502 TURBINE OIL, MEDIUM HEAVY
60503 TURBINE OIL, HEAVY
60550 AIR CCt’4PRESSOR OIL, MEDIUM
60581 MOTOR OIL SAE 10W/30
60582 MOTOR OIL SAE 20W/110
60600 MO1OR OIL, tv, SAE—10s4
60601 MOTOR OIl., 10, SAE—20W/20
60602 MOTOR OIL, 1i , SAE—30
• 3-7
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I TO STAN)P.RD SPECIFICATIONS
FOR LUE’RIC 4TS __ PS*GE 3
C SPEC NO. TITLE
60603 MOTOR OIL, -0, SAE— 1 0
6o6o MOTOR OIL, -0, SAE-50
60605 RAILROAD OIL, SAE Z O
60650 MOTOR OIL, S-’3, SAE—1OW
60651 MOTOR OIL, S— , SAE—20W120
60652 MOTOR OIL, S—3, SAE—30
60653 MOTOR OIL, S—3, SAE— 1 0
60680 AIJTONATIC TRANSMISSION S TCR( JE
CONVERTER FLU ID (DEXRON- II)
60681 AUTCSIAT IC TRANSM I SS I ON FLUID
TYPE F (2—P)
60682 HYDRAULIC TRANSMISSION FLUID—TYPE C-2
60700 Ct.TflIF G OIL, TRANSPARENT
6o O1 .CLJTTII’&Z OIL, DARK
60750 SOLUBLE OIL
60751 SOLUTION OIL, E.P.
60752 WATER-BASE CHEMICAL GRIF’DING COOLANT
6O751 CONVEYOR SPRAY OIL
60755 WATER (TENDABLE SYNTHETIC
RIM)ING COOLANT
60783 HYDRAULIC BRAKE FLUID
60800 JOURNAL OIL, HEAVY
60801 MILL OIL, HEAVY
60802 E.P. WAY OIL, LIGHT
60803 E.P. WAY OIL, HEAVY
6o80 JOURNAL OIL, LIGHT
60809 ROCK DRILL OIL, E.P.
3-8
-------
IFZ)EX TO STAI’DARD SPECIFICATIONS
FOR LUBRICANTS PAGE L
KSC SPEC NO. TITLE
60810 SPDDLE OIL,X-LIG T
60811 SPIrDLE OIL, LIGHT
60850 DIESEL FUEL OIL
60851 DIESEL FUEL LC*4 T PERATURE
60851s GAS, REGULAR
60855 GAS, PREMItJ’1
60856 KEROSE
60857 GAS, UNLEADED REGULAR
6c862 PAIPif THDt.ER
60900 FURNACE SEAL OIL
60901 FURNACE OIL
60902 N(ER FUEL OIL
60903 IPSULATIF’G OIL - IPIIIB lIED
60909 I’CTAL PROTECTIVE OIL
60910 COAL SPRAY OIL
60916 WASH OIL
C STAPZ)ARD NO .
1501 ( (IDATICN NO STABILITY TEST FOR LEADED
GEAR OILS
1502 WATER SEPARATION TEST FOR CIRCULATING OILS
1503 S €AR STABILITY TEST FOR LUBRICATING GREASES
150 1 WATER LEAQt TEST FOR LUBRICATING GREASES
1505 STABILITY TEST FOR DIESEL FUEL
1506 MARKING OF LUBRICANT CONTAINERS ND GENERAL IPFORMAT ION
3-9
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Sheet and Tube uses approximately 120 different lubricants which
are broken down into thirty-six basic specifications and are
obtained from twenty different suppliers. Other steel mills
have similar requirements and procedures.
Although most steel mills have their own classification schemes,
all systems have much in cannon. Lubricants are generally identi- .
fled and classified by similarities in their performance specifica-
tions, chemical or physical properties, or types of service. Indexes
or classification lists are used internally as a means of Identify-
ing lubricants. Code numbers are assigned enabling more efficient
and simplified procurement, storage, handling and record keeping.
Lubricant ap ..lication charts and schedules typically incorporate
the code scheme. The classification of lubricants by code number
enables lubrication englne . rs and plant operators to readily Identi-
fy duplication of brand name products. Records of lubricant pur-
chase and/or application are frequently maintained in computers,
and code numbers are used for these records. Delivery of lubri-
cants In containers color coded and labeled only by the steel
mill’s code number is often required. This procedure may avoid
certain plant operator biases toward a given brand or trade name
product.
Some steel mills may use more types of lubricants than are really
essential, since equivalent results may be obtained with several
different lubricants. Other mills have made efforts to consolidate
and simplify their lubricant usage whenever possible. Making
changes in lubricant recomendations on major producing units is
generally a slow process. The underlying reasons are traditional
conservatism (experimentation and experimental mistakes may be
costly), divided responsibility in some cases (different depart-
ments are often responsible for the selection, purchase and appli-
cation of lubricants), and reluctance to experiment where mill
performance appears to be adequate with the existing lubricant.
3-10
-------
Nevertheless, interest toward consolidation of lubricants has
brought multi-purpose lubricants into favor in most steel mills.
The trend has been towards centralized and automatic lubricant
application systems which, if designed and maintained properly
can simplify lubrication efforts. Although consolidation of
lubricants may result in an upgrading of specifications or
properties, especially where greases are concerned, and a result-
ing higher average cost per gallon or pound of lubricant purchased;
these increased costs are often offset by other savings, such as
reduced lubricant purchase, storage and handling requirements.
3.1.2 Classification According to Chemical Constitution
The average lubrication engineer at a steel mill has little use
for a classification scheme based on the chemical composition of
the lubricant. However, for this study such a scheme is useful
because It relates to the ultimate fate of these lubricants and
to the toxicities of the end products. By far the greatest quanti-
ties of lubricants -- 97% of the worldwide total - - are derived
from petroleum. Petroleum is, of course, a mixture of hundreds
of different hydrocarbons along with small amounts of compounds
that contain nitrogen, sulfur, oxygen and certain metals. Table 3-5
shows how the relative quantities of the various components affect
the properties of the lubricant. 6
The exact composition of the base oil depends on the oil field
where 4 t was produced, but these differences are usually small (see
Table 3_6).6 Base oils are subjected to various refining processes
to alter their properties, usually by removing some minor components
of the base oil. However, all petroleum—based lubricants are suff i-
cently similar with respect to their chemical composition that they
can be treated as a single class for the purpose of this discussion.
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Table 3-5. BASE OIL COMPOSITION AND DEPENDENT PROPERTIES
Component
Properties affected by presence in oil
Hydrocarbons:
such —-
Bulk properties
Viscosity, V.1.
Gravity
Paraffins
Naphthenes
Aromatics
Pour point
Aniline point
Unsulfonated residue
Solvency
Oxidation: Stability and response
to antioxidants
Volatility
Response to V.1. improvers
NonhydrocarbOn:
Oxidation: Stability and response to
antioxidants
Nitrogen compounds
Sulfur compounds
Demulsibility
Lubricity
Oxygen compounds
Organometallic compounds
Solvency
EP properties
Foaming
Rusting
3-12
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Table 3—6. COMPOSITION ANALYSIS
Calif onus Hydro. MC
Type c i compound’ pars nic treMed parsi nle
480 ne trsl 500 neutral 350 neutral
90 V.!. 101 V.!. 97 V.1.
*4U analyü
Percent carbon stoma in eromM o
rinp 5.5 3.5 2
Percent carbon stoma in nsphtbsce
rinp 33 26.5 33
Percent carbon stoma in p.zs n
cbsma 62.5 70 65
Ms spectrometer anslysi* (‘rolums
percent):
Pazs5ns 11.5 14.8 13.9
Cydoparaffice
iriag 19.4 19.6 15.9
2 ria e 113 19.7 18.0
3f 4 ag 15.6 .1L9 14.6
4 p 15.3 8.7 10.5
5 ring 10.6 8.2 11.6
6rinp 0 0 0
Alkylbenasn. 4.8 7.5 5.7
Indsn -te a1ins 2.6 2.3 1.7
Benzodicyc lopern ce 2.7 2.3 2.4
Nsphthslera .7 .6 .3
A c ea aphtb .6 .5 .2
Huereot 0 0 0
Pbenanthna 1.1 1.8 .9
Pyr en 1.1 1.8 .7
hryuenss 2.3 1.8 LI
Benzotb iopbe n .3 0 .2
Thbenioth op en .1 .5 .6
Nspht l obeosot3 iopheu 0 0 0
Paraffin. 11.5 14.8 13.9
Cycloparaffina 72.2 66.1 70.6
(3nnpsndl arpr) (41.6) (28.8) (36.7)
Arom*tic. 16.9 18.8 14.3
(3azomsticrinp larger). (5.1) (5.4) (4.5)
Tb iopb.n. .4 .5 .7
Total ssturat 83.7 80.9 84.5
V.1. = Viscosity Index — an npirlcal number indicating
the rate of change in viscosity of an oil within
a given temperature range.
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A suggested classification scheme based on the chemical compositi n
of the base oil is given beli...:
A. Petroleum—based
B. Non—petroleum based
1. Natural oils
a. Tallow
b. Vegetable oils
2. Synthetic lubricants
a. P’ osphate esters
b. Glycols
c. Others
Most of the natural oils are mixtures of closely related substances,
but for present purposes they can be treated as single classes. The
synthetic lubricants, on the other hand, are usually single chemi-
cal species, and the various subclasses of synthetic lubricants
differ wi$ely from each other.
In a typical steel mill, synthetic lubricar’ts may be used as fire—
resistant hydraulic ‘luids, and natural oils are used in large
quantities as rolling oils at all steel mills that produce sheet
and tin plate. All other lubricants, hydraulic fluids and process
oils used uy a steel mill are petroleum—based products.
3.2 AdditIves
An additive can be defined as a substance that reinforces some de-
sirable property already possessed to some degree by the oil, or
imparts a new and desirable property not originally preseflt.
Although several hundred materials have been developed as additives,
their principal functions can be grouped into eight categories:
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• reduce oxidative degradation of lubricant
• lessen deposition of harmful deposits
• minimize rust and corrosion
• control frictional properties
• rEduce wear
• prevent destructive metal-to-metal contact
• alter viscosity or viscosity lncF x
• reduce tendency to form stable foams
In the trade, a group of descriptive terms is used to identify
additives and approximately describe their use. For example,
antioxidant, corrosion inhibitor, rust inhibitor, extreme pres-
sure (EP) agent, antistain agent, antifoam agent, antiwear agent,
V.!. improver, and detergent are a’l coninonly used terms. Some
additives have more than one function, so it Is not possible to
identify specific additives from these descriptive terms, but
Table 3-7 gives a listing of additives used ir steel w i lubri-
cants and their functions.
Additive formulations are usually patented, and lubricant manu-
facturers consider their particular formulas to be proprietary.
Nevertheless,certaifl general facts are av’ 41 able regarding additive
ccr’oosition and usage. The specific chemical compositions of the
r t widely used additives are given below:
lithiurn-12-hydroxy stearate is used as a thickening agent in most
steel mill greases in quantities averag nq about 6% of the total
weight of the grease. In most steel mills, this additive is used
n greater quantity than any other additive. Molybdenum disulfide
is used in addition to Ilthlum-12-hydroxy stearate In certain greases
for oscillating nechanisms and highly loaded bearings. It is added in
qdantities up to 4 or 5 by weight to form specialty greases that
3-15
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Table 3 - 1. ‘liftS Of 571(1 MILL LI RICMTS Also n€ AOO i (S 1I(V i C ’tAIN
thickener
ant ioiii o ant
corrosion inhibitor
ihickeref
EP agent (optionil)
thickener
graphi t.
Purpost a’ Additive
i rova consIstency
prevent welding and galling
at high pressure
prevent oxidative depredation
•inl .ile rust and corrosion
prevent welding and galling
during hi s pressure, tiow
speed applications
i.prove consistenCY
prevent ogid tive degradatiOn
.ini.it. rust aid corrosion
i rove consistv cy
prevent welding and galling
at high pressure
ieprove consistency
assist is lubrication
permit easy cold weather starting
maintain good lubricant file at
high t erature%
•ini.iz. foening
keep inglnei clean
preven’ oxidative depredation
prevent bearing corrosioS
prevent ludg. accijlation
prevent excessive wear avid
scuffing of valva trai’.
.i.ii.ize ?oau.ng
prevent oxid tiv. depredation
mmmi x, rust and corrosion
prevent rust of metal parts
p -r..nt welding and galling it
high pressure
prevent rust of metal parts
calct a or lithiwe soaps
Sulfur, pho phoru5 ‘ owwis , soaa-
tin,s lead coenound
organic cpis. usually containing
sulfur, olsosoSorus or iiitroge.v
organic cpds. of many kinds
s as for (P grease plus
molyWens disulfid.
calcium or lithI soaps
orqanI cpds. usuilly ontainlnq
sulfur, ph tohoruS or aitrogiø
organic cpds. of many kinds
bentonit,, lithium or alusivam soaps
organic cc ounds containing sulfur
or pIsoipI’arus
c.i’hui soap
graphite
organic p lymers
Orginic polymers
silicone polymers
soaps of alEyl ienate1, sulfinates
and phosphonatei
rganIC cpds. usually c3ntai 5ing
sulfur. phosphorus or nitrOgen
organic cpds. of many kinds
high .clecuiar weIght alkyl
succin*ide’ and thiophosp 5ofiit*S
zinc dialkyldithlopnospiiat.
silicone polymers
orp4niC cpds usually containing
sulfur. phosphorus or nitrogen
organic cpds. of many kinds
sulfanates. weinex. phosphates.
certain acid derivatives
Organic cOIM,00IidS containing sulfur
or phosphorus
sulfonates, ashes, plosphotes.
certain acid derivatives
lomnit of
Steel Mill Lubricants Lubricant Used
Type of Additive
thickn i,r
(P agent
antioxidant
corrosion inhibitor
s as for (P grease
pl i another (P spent
Types of Coavcunds Used
‘I
Os
titrens Prv ssure((P)
i lybdem Disulfida
loller karing
High T .ratare
Cup
Oil’
I spine
tztr . i. Pressisre (If)
lolling Oils
PrOteftiv• Coating
NYDMILIC Rul
Inverted Emalsion
Water-Glycol
Int l-wear
moderate
small
small
very small
small
large
wavy large
variable
moderate
small
moderate
pour depressant
Viscosity Index ieprover
•nti-foas c cund
detergent
antioxidant
corrosion inhibitor
di spersants
(P (anti wear) agent
•ntt-foa. c ound
antioxidant
corrosion Inhikitor
rust inhibitor
Ii agent
no addittves
rust inhibitor
no additiwi
no additives
i as angina *Il without
detergents
(see under ‘(name Oils’ above)
(see snider ‘(ngine Oils’ above)
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constitute 10 to 30% of the total grease consumption In typical
steel mills. Some high temperature greases contain clays such
s bentonite or calcium so ps In place of the lithium—12-hydrOxy
stearate as a thickener. These greases are usually used in small
quantities in various operations associated with iron and steel
production. Greases for extreme pressure applications contain
sulfurized and phosphorized fatty oils in quantities equivalent
to .03% phosphorus and .8% sulfur in the grease. Extreme pressure
greases usually constitute 30 or 40% of the total greases used in
a steel mill.
Zinc dialkyl dithio PhO !( P z )is widely used in oils
as a mild EP additive and corrosion In Ibitor in amounts averag-
ing .8 percent by weight. In most steel mills this additive ranks
second with respect to total quantity used -- outranked only by
ltthium-l2-hydrOXY stearate. It also functions as an antioxidant,
but a small percentage of oils contain 2,6 _ di _ t butYl-4—methYl
phenol (BHT) instead.
Oils for extreme pressure use cortain the same kinds and quantities
of extreme pressure additives that were mentioned in the paragraph
above dealing with greases. Lead naphthena was formerly used as
an extreme pressure additive, but It is being phased out because
of poor stability to heat and oxidation as well as its adverse
environmental impact. Some lead naphthenate gear oils are still In
use in mills where there is reluctance to abandon a lubricant that
has performed satisfactorily in the past, but most lubrication
engineers believe that nonleaded gear oils can be used with equi-
valent or superior results.
Other kinds of additives such as rust inhibitors, V.!. improvers,
antifoam compounds, detergents and dispersants are used in extremely
small quantities In the steel industry. As will be shown In Section 9,
the usage of these minor additives is so small that no material balance
study was done for each of them.
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In general, lubricants, process oils, and hydraulic fluids that are not
petroleum-based do not contain additives. Rolling oils, which are
used in large quantities in cold rolling operations, are derived from
palm oil, tallow or other fatty materials and normally require no addi-
tives. Fire resistant hydraulic fluids of certain types are also used
without additives. Most, but not all, petroleum-based lubricants do
contain additives.
3.3 Toxic Substances
Before an attempt Is made to classify lubricants and their additives
as toxic or nontoxic substances, It is necessary to clarify the
meaning of the term “toxic.” Substances may be harmless or even
beneficial to man and yet be hazardous to fish and other marine
life. Other substances may be harmful when they enter the body
via the respiratory system but harmless when taken In via the gastro-
intestinal tract. Some materials produce acute effects that dis-
appear completely when the exposure ceases, while the effects of
exposure to other materials may require many years to become evident.
For purposes of this discussion, subst nces are classified as toxic
whenever they meet any of the criteria for defining toxicity used by
EPA, the National Institute for Occupational Safety and Health
(OSHA), the Food and Drug Administration and other agencies. The
most useful criteria are those used by EPA for designating hazardous
air pollutants, 8 the OSHA list of cancer-suspect materials, 9 the
EPA list of 306 materIals that may be hazardous In natural waters 1 °
and the list of substances permitted for use as foods, food additives,
drugs, cosmetics or packaging materials according to the federal
Food, Drug and Cosmetic Act.U
3.3.1 Toxicities of Lubricant Base Oils
Most lubricants used in steel mills are petroleum-based and present
the same toxicological problems as petroleum-based materials used
for other purposes. (The toxicities of additives are discussed In
the next section). Extensive Investigations have been conducted
3-18
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on these materials because of their widespread use, and until
recently, they were classified as nontoxic. Fowever, benzene which
is a minor component of petroleum, has now been placed on the EPA
list of hazardous air pollutants. Berizene is a low boiling material
which is present primarily in gasoline and is almost entirely absent
from the higher boiler lubricating oils. It is conceivable that
traces of benzene might be associated with cut-back gear lubricants,
Petroleum-based lubricants are troublesome In the water supply because
they form oil films that are not pleasing aesthetically arid have ad-
verse effects on fish and water fowl. When lubricating oils are
burned or c’..herwise subjected to very high temperatures, they may
emit polynuclear organic compounds such as benz- -pyrene that are
known to be carcinogens. This phenomenon has been demonstrated many
times in studies on oil-fired boilers and similar combustion processes.
In the Iron and steel itsoustry, lubricants may encounter high tempera-
tures at the sinter plant and during heavy duty applications. It is
conceivable that polynuclear organics could be emitted at these loca-
tions.
In this discussion we must also consider the non-petroleum based
lubricants. Vegetable oils and tallow are used in large quantities
as process oils in the steel industry. These materials ie found
in natural meat and vegetable foods and presert no hazards to humans
nor are they listed as hazards in natural waters. They form oil
films when discharged into wastewater with the same adverse effects
as oil films from petroleum products. Glycols that are used In
fire resistant hydraulic fluids do not present any special problems
of toxicity. These same materials are used in much larger quantities
for other applications —— anti-freeze, for example —- and do not
require any special investigation in conjunction with their use in
the steel industry. The toxicities of phosphate esters that are
3-19
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used as fire resistant hydraulic fluids are somewhat uncertain.
Phosphate esters are not specifically included on any of the lists
of toxic substances, but several other phosphorus-containing com-
pounds are included. Further investigation might be appropriate
to determine whether phosphate esters have ever been subjected to
toxicological investigation and found to be harmless or whether
they have never been tested at all. Fortunately, they are used In
small quantities In steel making because of their high cost.
3.3.2 Toxicitles of Lubricant Additives
None of the materials coniiionly used as lubricant additives are
specifically included on any list of toxic substances; however,
this does not mean that they h’ve all been tested and found harm-
less. Many additives are unusual compounds that have no other
uses and may never have come under scrutiny because of their
proprietary nature. Presumably they wiU be included in the
inventory of chemical substances which is currently being compiled
to meet the requirements of the Toxic Substances Control Act, and,
conceivably, some of them could be designated as high-priority test
candidates.
The following list gives lubricant additives, In the approximate
order of usage in a typical steel mill, along with cóninents about
their possible toxicity. Quantitative estimates of usages and the
ultimate fates of these additives are discussed later in Section
9.
.1. Lithlum-12-hYdrOXY stearate — Lithium compounds
are not generally consiff i d toxic nor are stearic
acid derivatives. There Is no reason to assume
that this particular compound is toxic.
2. Molybdenum disulfide - This material has low
o1atility and is Insoluble In water. According
to the Merck Index “limited data suggest a low
order of (human) t o, . :tty.”
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.3. Zinc dialkyl dithiophosphate - Many zinc corn-
pounds are biologically active and are used as
fungicides, antiseptics and astringents. Dlalkyl
dithiophosphates do not appear to have been tested,
or If they have been, the results were not pub-
lish d. This material probably should be Investi-
gated further.
4. Silfurized and Phosphorized fatty oils — These
are proprietary materials of uncertain Co!npo 1tion.
The parent fatty oils are not toxic, but It is
uncertain whether any toxic properties result from
the sulfurizing and phosphorizing treatments.
5. BHT (2,6-di-t-butyl-4-methyl phenol ) - This
material is approved for use as an antioxidant in
food products and is non-toxic to humans.
6. Lead naphthenate - Lead compounds are generally
lassified as poisonous and naphthenlc acid
derivatives are considered hazardous. Fortunately
this additive is being phased out, but it is
unquestionably a toxic material.
A recent publication 12 has called attention to the presence of a
toxic nitrosamine In synthetic cutting fluids that contain triethano-
lamine. Cutting fluids of this type are not used in steel mills
according to the information collected for this study, so these toxic
nitrosamines are not a problem in the steel industry.
Polychlorinated biphenyis (PCB) have been reported in fire resistant
hydraulic fluids that are sent by Republic Steel to a reclaimer
(Radco Industries). These materials are known to be toxic and are
being phased out of all industrial usage. PCBs are not used as
lubricants nor are they purchased by the lubrication departments
of steel mills. They may be used In electrical transformers or other
specialized equipment found at steel mills, but they should not
contaminate lubricants except as a result of infrequent accidental
Incidents.
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3•4 Purchasing Practices
The lubricant purchasing practices followed by the steel mills
surveyed are described in this section. Two different practices
or policies are generally followed with either reported to function
satisfactorily. Many steel mills “buy by requirement,” whereby the
lubrication department selects lubricants and hydraulic fluids which
meet the requirements specified by the equipment manufacturer in the
warranty. In some cases the properties and characteristics are
specified; in other cases a luLrlcant may be identified specifically
by trade name. The lubrication staff Is responsible to see that
the correct product Is selected, purchased and applied properly.
The actual purchasing of lubricants and hydraulic fluids is done
by the purchasing department. Application of the lubricants is
typically done by the plant operators or maintenance department.
The secor.d common method could be called the “buy by specification”
practice. The lubrication department prepares and periodically
updates, to reflect more stringent or changing requirements, a de-
tailed lubricant “specification.” These specifications reflect the
equipient requireme. ts and any additional or modified requirements
determined from operating, maintenance and lubrication experience
and performance. A complete set of specifications for a single
steel miii may include two to four page ‘spec sheets” for over 11)0
oils, greases and hydraulic fluids. Every year or two the steel
mill (via the purchase department and lubrication staff) requests
compet 4 tive bids for the anticipated quantities of lubricants.
Lubricant suppliers may offer an “off-the-shelf” product or a special
product formulated for that particular steel mill. This lubricant
purchasing practice can Involve a major effort by the lubrication
staff. One steel mill surveyed by PES purchases 120 different oils,
greases and hydraulic fluids from more than 20 different lubricant
distributors or manufacturers. As is the case in the previously
described purchasing method, actual eq41 nent lubrication Is
performed by the plant operators or mau tenance department.
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4. LUBRICATION SYSTEMS AND PRACTICES
The lubrication of operating equipment Is an important factor in
maintaining production, reducing delays and down-time, and lowering
maintenance costs. To ensure proper lubrication, the steel indus-
try has almost universally established lubrication departments to
design, coordinate and review the lubrication systems and practices.
In this chapter the responsibilities of the lubrication engineer,
lubrication schedules, and lubricant application methods and sys-
tems are described.
4.1 Lubr cation Requirements and Schedules
To effect proper lubrication each steel mill has a plant lubrica-.
ti i program. This rogram Is nor ’ally coordinated on a plant-
wide basis with each division keeping Its own records and reporting
to the plant lubrication engineer. Certain factors are inherent
in every successful plant lubrication program. Briefly they are:
1. lubrication surveys
2. classification of lu ’ricants
3. compilIng and updating ‘ brication charts and con-
sumption reports
4. Improving application methods
5. lubricant handling and storage
6. evaluation of new products
7. establishing and running a maintenance program
4.1.1 Lubrication Surveys
A lubrication survey is designed to gather detailed information
on current lubrication practices from the entire plant. The
information gathered includes the type of lubricant, the part
lubricated, and the frequency of lubrication. The lubrication
engineer can determine the location and number of lubrication
4-1
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points, method of lubrication, and maintenance responsibility
from an inspection of operating equipment. Operating personnel
are questioned about each unit. If special or abnormal situations
exist the equipment is inspected. A standard form Is used to
document all data and at times is posted or distributed to per—
sonne as lubrication instructions.
4.1.2 Classification of lubricants
Lubricants are most easily classified under a basic performance
classification. By assigning a requirement number to each class
of lubricant, a descriptive means of identifying the lubricant is
established. EacP. requirement number has a coninon identification
which describes the general class of lubricant. In addition, the
general characteristics of the lubricant class are made for each
requirement number. The requirement numbers are sufficiently
extensive to cover all lubricants applied throughout a plant.
The classification of lubricants by requirement numbers enables
the lubricant engineer to readily identify duplication of brand
name products and assists in establishing a consolidated program.
It simplifies the problems of procurement, storage, handling and
application of lubricants.
4.1.3 Compiling and Updating Lubrication Charts and Consumption
Reports
After the plant-wide lubrication survey data is compiled, it is
normally transcribed onto punch cards. This is an efficient con-
trol method to effect proper inspection, lubrication frequency,
quantity, and type of lubricant. All the data pertinent to inspec-
tion and lubrication is recorded on a master control card for each
piece of equipment and component. The cards are distributed
in accordance with the determined chronological frequency to the
specified work area. Simultaneously, printed sumary sheets of
4-2
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all the work performed are issued to supervisors. A master card
is made up for each piece of equipm t and each component part.
It contains all of the information needed to Identify, locate,
inspect, and service a piece of equiprnent. The information is
transferred from the master card to punch cards. The master cards
can then be filed away for reference. Typical data entered on
the punch cards are:
1. type of equipment
2. type of mechanism
3. lube trade name
4. quantity of lube per change
5. frequency of lube or inspection
6. quarter to schedule inspection
7. month of scheduled quarter
8. department responsible for lube
9. equipment number
10. total number of equipment
11. total number of mechanisms
12. n..’móer of lube points
13. frequency of lube change
14. building number
when the plant survey is concluded and all Information has been
coded on punch cards, procurement schedules must be prepared
covering all equipment in the plant. The Information necessary
to prepare these schedules may be taken from the master cards.
An effort is made at all times to keep the number of lubricants
within an operating unit to a minimum. In some instances com-
promises are required which may be more advantageous than attemp-
ting to use the exact lubricant indicated for each bearing or
gear. With the installation of new application devices or change
in lubricant type, the procurement schedules change. The ulti-
mate goal is to have current schedules that indicate the lubricant
inventory and alternatives for the plant.
4-3
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Since each plant spends a substantial amount of money each y ar on
lubricants, consumption reports are necessary for recording and
controlling the use of lubricating materials. Consumption reports
are normafly issued monthly in conjunction with an oil consumption
budget. They help keep plant personrel aware of leakage ai i other
probl ems.
Some oil generally escapes through shaft. seals, but a number of
conditions may develop which will cause excessive oil loss. Among
these are cracked oil reservoirs, oil seal failures, excessive drain-
off from settling tanks, and hidden breaks In pipe lines. As equip-
ment grows older, oil loss Increases. However, a good maintenance
program can reduce the losses. Grease los is less of a problem;
therefore, controlling it is usually somewhat simpler. With grease,
the chief loss takes place when timers on automatic centralized
systems are set incorrectly. This automatically decreases wI n the
correct lubrication frequency is set for the system.
4.1.4 Improved Application Methods
Since most of .,,e present steel facilities were installed some
time and since capacities have increased through the addition
of new operating units, older equipment represents a fertile field
for lubricant savings through Improved application methods. Addi-
tionally, older equipment is often inadequately designed from a
lubrIcation standpoint.
Installing centralized systems on the older equipment reduces
lubrication consumption and increases machine life. Some small
a achine tools, mobile equipment, wire rope, chains, etc. are stUl
lubricated by hand, but they are changing to automatic and central-
system lubrication. Localized lubrication still exists In steel
mills, but only where It cannot be avoided.
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4.1.5 Lubricant Handling and Storage
The large quantities of lubricants used in mlii operations make
storing and handling an important Item from the standpoint of house-
keeping, safety and costs. When lubricants are purchased in drums
they are usually stored In a central area. Whenever possible,
materials handling equipment is provided for the loading and un-
loading of lubricant containers. In central storage, drums are
sorted to await collection by the supplier or a drum handling
concern.
At the consumption site enclosures are provided for the drums and
dispensirg equipment. Covered containers are provided at every
stage of handling to prevent contamination and maintain a clean
and neat plant. To avoid error in use, each container is identi-
fied by requirement number, brand name, suppliers name, batch
number, and other pertinent data as dictated by individual mill
standards.
4.1.6 New Lubricant Evaluation
Once a lubricant has been chosen for a particular application, it
is regularly evaluated against newer products. If a laboratory
is available, the new product is tested; if the results are positive
the new product is installed. There is a field trial period during
which the lubricant’s performance Is recorded and compared to the
former product. The comparison of lubricants for applicability,
performance, and cost, provides a sound basis for choosing the
product that will be used.
4-5
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4.1.7 Establishing Maintenance Methods
From time to time, lubricant samples are tested in the plant labora-
tory. Oils in large circulating systems are especially susceptible
to contaminants such as water, scale, coal dust, iron ore, metal
particles and sludge. If tests show that the oil is reusable, par-
ticles are removed by one of three methods: settling, filtering,
or centrifuging.
Settling lets the liquid stand in a tank allo iing the contaminants
to settle to the bottom. Filtering removes contaminants by pun’ping
the dirty oil through paper, wood pulp, felt or clay filter material.
Centrifuging spins the oil in a container forcing the co .aminants
upward and outward to a point where the water and dirt it ca ries
are expelled. In many cases the oil may have degraded to a point
where these methods are not suitable. In this situation the oil
is replaced.
4.2 Lubrication Methods and Systems
Since steel is such an old inch’stry, there are a variety of lubrica-
tion methods at any given 1 nill. These include manual lubrication,
old hand—operated mechanical devices, reservoirs, circulating and
more modern central application systems. Before a decision can be
made as to the most suitable lubrication method, an initial decision
must be made as to whether the system requires oil or grease. Due
to the basic differences between these lubricants, many choices are
available when choosing an application system.
4.2.1 Oil Application Methods
There are four general categories of oil application methods, namely:
1. once-through oiling
2. oil reservoirs
3. circulating systems
4. methods for special equipment
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There aie varicus nethods used in transferring oil frcri the drum
to the actual lubrication points. A general procedure Is to pump
the oil frcvi drum to supply can to lubrication system (hand oilers,
pump oilers, reservoirs, and force feed systems). The oil Is removed
from the drum by hand, air-operated pump, or by gravity. Reservoirs
of more t: ‘ ten gallons are usually filled directly from the drum.
4.2.1.1 Once Through Oiling . Once-through oiling Is so named
because the oil passes through the bearing only once and is lost for
further use. Methods of this type include hand oiling, drop-feed
oiling, wick-feed oiling aid bottle oiling.
Hand oiling is the direct application of oil to a moving machine
part from a hand oil can. It is often used on older equipment. It
is also used on newer equipment with small bearings involving little
movement. One disadvantage of the method is that an excess amount
of oil i applied which soon runs off, leaving the bearing to
operate with insufficient oil until the next oiling.
When a more uniform supply of oil is required, a drop-feed oiler
may be used. It consists of a shut-off lever, adjustment, oil
chamber, needle valve, and sight glass.
The wic¼-feed oiler consists of an oil reservoir and a wool wick.
The wick draws the oil from the reservoir and feeds It into an
opening In the bearing. The amount of ol’ being delivered to the
bearing can be regulated by changing the size of the wick.
The bottle oiler Coris.sts of an inverted glass bottle mounted above
the bearing and fitted with a sliding pin which rests on the journal.
When the joL’rnal rotates It vibrates the pin. The vibration ini-
tiates a fiow of oil from the bottle to the bearing.
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4.2.1.2 Oil Reservoirs . Reservoir methods use the same 011 repeatedly,
in contrast to the once-through methods. The oil supply Is usually
held in the base of a gear casing or bearing, but different methods
are used to deliver the oil from the reservoir to the moving part,
including ring oiling, chain oiling, oil collars, and splash oiling.
In the ring oiling method, a metallic ring, larger in diameter than
the journal, rides on the journal and turns as the journal rotates.
The ring, dipping into the oil, carries it to the top of the journal
where it flows along and around the journal, providing lubrication
before returning to the reservoir.
Chain oiling is similar to ring oiling except that a small-linked
chain Is substituted for the ring. The chain carries a larger
volume of oil than the ring.
An oil collar may be used to carry oil from the reservoir to
journals turning at high speeds. The collar, fastened to the jour-
nal, dips into the oil reservoir as the journal rotates, carrying
the oil to an overhead scraper which removes and distributes it
along the journal.
A group of b rings and gears enclosed in a single oil-tight casing
usually employs splash oiling for lubrication. In this method,
some moving part Is in direct contact with the oil in the bottom
of the casing. As the moving part turns, it splashes and rarries
the oil up to the other parts within the casing, keeping them well
supplied with lubricant. Splash lubricating is the most reliable
of all reservoir methods.
4.2.1.3 CIrculating Oil Systems . Circulating oil systems make use
of pumps and piping to deliver oil under pressure and often in large
quantities to moving parts. Strainers are used for cleaning the oil
and temperature control equipment is usually present to ensure con-
stant viscosity. Many parts of rolling mills are usua’ly equipped
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with circulating systems. The two primary types of circulating
systems are the gravity feed system and the pressure type.
In the gravity feed system a pump draws the oil from a tank through
a strainer to one of two overhead tanks. From there the oil flows
by gravity through an oil cooler and then through pipes to the
mechanism to be lubrIcated. From the mechanism it drains into the
original tank from which it was pumped to repeat the cycle.
The pressure type of system is comonly used to lubricate heavy
rolling-mill equipment. Oil flows over the gears and through the
bearings into a settling tank. As the oil flows across the tank,
the dirt and water tend to settle to the bottom. The oil Is then
drawn through a filter for additional cleaning. From the filter,
the oil passes through an oil cooler and is delivered under pressure
to the lubrication point. From here it is recycled back to the
settling tank after use.
4.2.1.4 Methods for Special Equipment . The methods described so
far are among those widely used In a steel plant. There are several
other comon oiling devices used on certain types of equipment.
Wool waste or special felt pads are used for lubricating the track-
wheel journal on cranes and railroad cars which are equipped with
half bearings. In this method, woo 1 w? sce is saturated with oil
and packed into the space under and at the sides of the exposed
journal, in direct contact with It. Oil is maintained in the
journal box, and, as the journal turns, it is transferred to the
journal and then to the bearing.
Another oiling method is the oil mist procedure. This method uses
compressed air to atomize the oil from a reservoir and deliver it
as a mist through pipes to the bearings and gears. This method pro-
vides an oil-saturated atmosphere, which lubricates the bearings
while the air passing through, helps carry away heat as well as
prevent dirt from entering.
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In lubricating the piston and cylinder of a steam engine or large
compressor a mechanical force feed lubricator is used. It consists
of an oil reservoir arid several pumping units t at deliver oil In
smaU amounts through pipes to the sides of the cylinders. Force-
feed lubricators are also used for bearings and open gears where
small amounts are needed.
4.2.2 Grease Application Methods
There are, basically, three methods of applying grease:
1. by hand;
2. by hand-operated mechanical devices, which deliver
grease to one point of use at a time; and
3. by centralized grease systei , which supply a
number of points of use from one central reservoir.
Grease is initially dispensed from the drum Into an intermediate
pump, except for reservoirs holding more than 34 kilograms (75
pounds), which receive it directly. A bucket pump may be used to
fill lighter hand guns, or fill the reservoirs of small centralized
systems. At times it is even fed directly to the fittings at the
point of use. For a large number of oearlngs, a larger air—operated
pump may be used.
4.2.2.1 Hand Application . Hand application Is frequently used
during the assembly of a machine. Grease is spread over gears and
bearings to protect them from rust and ensure lubrication when th
machine is started for the first time. In ar.other hand method,
melted grease is poured from a container onto gears or open guide
bearings.
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4.2.2.2 Mechanical Devices . Many types of mechanical applicators
also require manual operation and refilling of grease. Grease cups,
grease fittings, grease guns, bucket pumps, a1r—op, .’ated pumps, and
spray guns are typical examples.
The grease cup is a familiar device for applying grease to bearings.
The ordinary screw-down type ‘;onsists of a small reservoir for
holding the grease and a plate that screws down int the reservoir,
exerting presst re on the grease and forcing It onto the bearing. It
is filled by unscrewing the plate, filling the reservoir with grease,
and replacing the plate.
Grease fittings have replaced grease cups on most steel mill equip-
ment thereby making the use of pressure grease guns possible. Hy—.
draulic fittings are used on most of the smaller machinery. Button—
head fittings are used on heavier mill equipment where severe con-
ditions exist and large volumes of grease are used.
Two types of hand-operated grease guns are comonly used. The
lever gun is used primarily for greasing large pieces of machinery
which use a large volume f grease, and are pressurized up to 69 mega-
pascals (10,000 pounds per square inch). The push gun is generally
used for delivering smaller quantities of grease at lower pressures.
A hand-operated bucket pump, holding about 15 kilograms (35 pounds)
of grease, is used when a greater grease— ’iolding capacity is desired.
It may be used to fill hand guns through loader fittings or to pump
grease directly into bearings hrc”gh grease fittings. The bucket
pump is operated by placing It on the floor and working the handle
to deliver grease through a hose to the bearing. The bearing is
usually equipped with a buttonhead fitting if it is to be lubricated
with a bucket pump.
Air-operated grease pumps are used where a large number of bearings
using a substantial volume of grease are to be lubricated. The pump,
holding about 18 kilograms (40 pounds), Is connected to compressed air and
4-11
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grease is delivered through a hose. At times barrel pumps are used
which are inserted directly Into a grease drum. These are used to
apply grease directly to bearings, portable grease pumps or centre l1zed
systems.
Spray guns use compressed air to spray gear teeth with a film of
grease. Grease Is delivered to the spray gun through a hose from
a barrel pump.
A centralized grease system is the best and most efficient way of
lubricating a large number of bearings on a machine. These systems
consist of a centrally located grease reservoir with a pump and
piping that have grease distribution valves. When the pump is
operated, each bearing receives a predetermined quantity of grease.
The pump is usually operated by compressed air or an electric motor
with a timer that stops and starts the pump at selected Intervals.
One of the several advantages of a centralized system is reduced
leakage and losses and better housekeeping.
4.2.2.3 Centralized Lubrication Systems . A centralized lubrication
system is a method of transmitting and measuring lubricant by means
of a centralized pressure. The system assures a positive delivery
of lubricant under adequate pressure to ensure the maintenance of
a sufficient film betweer moving surfaces. The pressure is developed
by a pump at the lubricant reservoir.
Two basic types of centralized systems are available: the parallel
type and the series types. The primary difference between the two
types is the location of the metering device in relation to the
transmission line. Another difference is in the method used for
returning the piston in the metering device to Its original position.
The parallel-system metering devices are off the main transmission
line. The pump develops a predetermined pressure; individual counters
are used at each metering device to indicate failure of the device
to operate. There are two variations of the parallel type system; the
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single line and the dual line. The single line uses a relief valve
to relieve line pressure and springs tn return the piston for the
next cycle of lubricant discharge. This system has one transmission
line. The dual line has two transmission lines; they are connected
such that pressure can be exerted on either end of the piston In the
metering device. A “reverser” switches the pressure frnm one to the
other, thereby accomplishing piston return and lubricant discharge.
The series-system metering devices are in the main transmission line.
The pump develops the pressure necessary to ove 1 tome line and bearing
resistance. Excessive pressure at the pump indicates the failure of
the metering device to operate. There are two variations of the
series-type system: the manifolded and the reversing. The mani-
folded type directs the lubricant flow through Internal porting to
accomplish piston return and lubricant discharge. Optional pressure
indicators and relief fittings may be used on the manifolds. The
reversing system employs a reverser to change the direction of
lubricant flow.
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5. WASTE OIL COLLECTION, RECLAMATION AND DISPOSAL
Oil in steel mill wastewater may be only a faintly discernible slick
or a readily definable floating layer. The oily materials, resulting
from the usage of various oils, greases and hydraulic fluids, may be
chemically emulsified or mechanically dispersed producing various
degrees of turbidity in the water. Some oiiy material may be adsorbed
on floating solids, such as trash and debris, or be entrapped with
solids which settle, such as mill scale. Waste oils and oily solids
in wastewater may be very finely divided or even colloidal in size
with little tendency to ficat to the surface or settle. The variety
of types of oily materials found In steel mill wastewater, as well
as the large wastewater volumes to be treated, make waste oil
collection a difficult task. The chemical and physical properties
of the wastewater itself greatly influence the design nd operation
of waste oil collection systems.
5.1 of Steel Mill Oily Wastes
Two general categories or types of oily wastes are present in steel
mill wastewater streams. The first type, lubricants and cutting oils
(mineral oils), can be sut.divided into two classes: ‘ ,n—emulsifiable
oils such as lubricating oils and greases, and emulsifiable oils such
as soluble oils, rolling oils, cutting ols and drawing compounds.
Emulsifiable oils typically coi i’ fat, soap, or other additives
to enhance their working properties. In general, the non-emulsi-
fiable oils are separated with comparative ease. Emulsifiable
oils, on the other nand, can cause considerable difficulty.
Generally, the older the oil, or the more it is used in recircula-
ting lubrication systems, the more difficult it is to separate.
This is due to the slow oxidation of oils and greases with time
and use, and as a result, the build-up of finely divided solids
and metallic particles which are not completely filtered or centri-
fuged out during re’ycling.
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The second type of oily waste present in steel mill wastewaters are
fats and fatty oils. Tallows, palm oils and animal fats are generally
used in cold rolling mills. These oils are basically triglycerides
with various degrees of chemical unsaturation. They are more readily
emulsified than the mineral oil wastes previously discussed in this
subsection, and, accordingly, are more difficult to collect.
Used hydraulic fluids enter wastc :ater streams as a result of leaks.
Their behavior in waste treatment systems is usually like those oily
materials classified as lubricants.
Some additional understanding of the nature and source of oily wastes
can be reached by considering briefly the steel mill processes or
operations that generate major quantities of these wastes. Most
oily materials in steel mill waste streams are from the various
metal—working or steel-shaping operations. As described in Section
3 a wide variety of oil, greases and hydraulic fluids are utilized to
help shape or form steel, cool equipment or the steel being worked,
or to help operate the machines or mechanisms. The oily materials
may be free or mechanically entrained in the wastewater and easily
separated, or they may be bc ded to solids or emulsified, to be
removed only with difficulty.
Hot-mill effluent water generally contains mostly free or mechanically
entrained oily material, some of which Is bound to scale particles
originating in the rolling operation. Flume water which has been used
to cool the rolls and blow off scale contains some lubricating oils
and hydraulic fluids. In cold strip rolling, the strip is usually
oiled as it leaves the last wash after piciling. This reduces
rusting and acts as a lubricant in the first-stand reduction.
Emulsions of oils (rolling oils or soluble oils as they are often
called) fats, tallows or palm oils are applied in subsequent reductions
to cool the rolls and lubricate the strip and sometimes the roll
bearings.
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The rolling emulsion is often recirculated. The type of rolling
fluid and its composition vary somewhat from mill to mill, depet ding
on the type of mill and the product being made.
Other, generally lesser, sources of oily waste include the oils
contained in rinse waters from cleaning operations used prior to
plating or galvar.izing, and cooling-water waste streams. The
concentration of oils and greases Is usually quite low in these
waste streams, and the volume of water to be treated Is often large,
resulting In a difficult treatment problem.
5.2 The Waste Oil and Wastewater Treatment Problem
A basic principle of waste oil collection and steel mill wastewater
management Is to control or treat oily wastes as close to their
source as practical. Generally, a small volume of concentrated oily
waste Is easier to handle than a large volume of diluted wastewater.
In addition, early waste oil collection or control affords the best
opportunity to segregate for reclamation as a usable product. Tt ’
presence of a single contaminant or several contaminants in a waste
stream may make another stream difficult to treat when the two arc
blended or may eliminate the possibility of recovering and re-
claiming the wa!te oil in a usable form. The presence of emulsifiers,
wetting agents, soaps, defloccuIants, dispersants and finely divided
suspended solI s makes separation of c ily materials from wastewater
more difficult. If dilution and the introduction of these collection
h1nder ng materials can be avoided, the size of wastewater treatment
equipment can often be greatly reduced. In addition, overall waste
oil collection efficiencies can be improv.. d.
Other factors which affect waste oil collectability are temperature
and pH. Usually the higher the temperature of the oil waste, the
easier it Is to separate the oil from the water phase. Often the
oily waste stream is at its highest temperature a’ its source.
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The pH also Influences waste oil collection. A high pH can hinder
separation of oils while a low pH may be helpful or actually required
for effective waste oil col,lection. The presence of acidic waste
streams In steel mills is often used advantageously to enhance waste
oil collection. On the other hand, indiscriminate blending of waste
streams may produce an undesirable pH range for good oil separation.
It may also increase the buffering capacity to the extent that pH
adjustment to within the desired range would be impractical.
Collecting waste oils at their source also serves to simplify final
steel mill wastewater treatine., facilities and may allow for reduct-
icns in treatment facility size and costs. Waste oils recovered
downstream in the wastewater treatment plant are usually contaminated
and require more costly refining or processing before reuse.
Recovery of the heat value of salvaged oil by burning as fuel should
be used as a last resort. Air pollution problems may arise due to
the presence of impurities in the oil if combusted. If the oily
waste cannot be burned, ultimate disposal may be troublesome and
costly. An additional reason for collecting waste oils at their
source is that certain water treating chemicals can lead to oil
and water separation problems.
Good housekeeping and maintenance can help minimize the waste oil
load to be collected and reclaimed at steel mills. One of the
major sources of oil wastes is carelessness in housekeeping and/
or maintenance practices. Operators, in general, tend to use the
most expedient approach to solving production problems often with-
out regard to indirect factors such as wastewater contamination.
The need and Importance of finding and controlling leaks of oils
and hydraulic fluids and containing and properly disposing of oil
spills and oil soaked trash, must be emphasized by plant manage-
ment. Regular inspections should be scheduled and/or leak detection
devices installed to spot leaks. Corrective actions should be
taken as soon as possible. A regular review of th€se housekeeping
5-4
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and leak prvention or control measures should be made for the
purposes of updating, indoctrination and control. The more obvious
leaks can usually be handled on a temporary basis, even if by nothing
more tF,an a bucket and an acceptable place to dump It. Emergency
leak control measures shnuld be undertaken until more permanent repairs
can be made. Major repairs in the lubrication or hydraulic systems
are usually delayed whenever possible, to coincide with a planned
shut-down or turn-around. Good preventive maintenance goes a long
way toward avoiding accidental and costly leaks and loss of lubri-
cants and hydraulic fluids. The benefits of good housekeeping and
mair tenance are two fold. Excessive and costly lubricant and
hydraulic fluid usage is avoided and the waste oil load on the waste-
water treatment facilities is reduced.
5.3 Waste Oil Collection and Wastewater Treatment Equipment
A comprehensive description of all of the various oil-water separa-
tors and a discussion of separator design and sizing practices is
beyond the scope of the PES study. The Manual on Disposal of
Refinery Wastes Volume I, Waste Water Containing Oil, prepared by
the American Petroleum Institute, provides an excellent description
of oil-water separators and wastewater treatment equipment used for
oil removal ) 3 lncluded in the API manual are design nomographs and
illustrations.
The functioning of most oil-water separators depends on the difference
in gravity of the oil and water. The important factors affecting
performance are the velocity of flow through the separator,
settling time and separator design and maintenance. Floating oils
are skinred or drained from the surface of the separator. Several
varieties or methods of skinining or oil removal are utilized.
Gravity separators will not prevent the passage of emulsified oils;
therefore emulsions must be broken if the oil is to b retained in
the separator. Efficient methods for the resolution of emulsions
5—5
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should generally be determined by laboratory test and study prior
to installation or application at steel mills. Emulsion breaking
methods include chemical treatment, the application of h at and the
use of alternating current. Acid addition, demulsifying chemicals
and dehydrating chemicals sometimes are used to assist in emulsion
breaking. Acid addition is contnonly practiced at steel mills since
spent pickle liquo s are generally available.
Scale pits typically provide the first opportunity for oil separa-
tion. Older scale pits often do not provide adequate retention time
or quiesence to achieve effective oil separation. Some type of oil
skimer must be installed and maintained to collect the floating
oils. Although generally not the case, scale pits or separators
should be constructed In two or more parallel channels so that
continuity of operation may be maintained when individual channels
are dredged, repaired, inspected or cleaned.
Separators of even the most modern design cannot be expected to
perform efficiently unless given necessary attention of trained
operators. Separators should be maintained as free of accumulated
oil and sediment as possible, consistent with practical operating
considerations. often waste oils after collection, are fed into
large barrels which if unattended, may overflow resulting in other
oil clean—up problems. Excessive amounts of floating trash and
debris if allowed to build up in scale pits or separators, will
hamper waste oil collection. Cleaning and sediment or mill scale
removal, should be undertaken when the flow of water through the
scale pit or separator channel being cleaned is stopped. Mill
scale, sediments and floating trash may ccntain or be coated with
oil and should therefore be disposed of or stored in a manner which
will not become a source of future surface-water contamination,
such as during a heavy rain. The correct operation and maintenance
of oil-water separators and waste oil collection equipment require
responsible and regular attention of a trained operator.
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As discussed previously in Section 5.2, the most effective waste oil
collection practice is to capture the oil near its source or if pos-
sible, decrease the quantities of oil discharged or leaking from
each source. Since this is not possible, and also because many of
todays steel mills were designed and built prior to the current
emohasis on waste oil recovery and pollution cortrol, a variety of
retrofit oil-water separation and waste oil collection systems are
in use in the steel Industry. Often oil skimers have been retrofit-
ted on to scale pits and operate by ccllectin i floating oils avid
draining the captured oil Into large barrels or waste oil storage
bins. Brill or rope skimers, a comon type used in steel mill
applications, consist of a long loop rope or tubing which floats on
the scale pit or separator water surface. floating oil clings to the
rope which is hauled up continuously by motor and through a rope
scraping mechanism. The collected oil is drained into barrels or
bins which must be replaced or emptied periodically. Rope skimmers
generally yield waste oil containing a relatively low percentage
of water. Floating debris can become entangled In the rope causing
damage to the rope or to skininer itself. Thick oil or oily scum in
scale pits, is sometimes difficult to collect with rope skininers
since the oil clinging to the rope must be lifted, often several
feet, before scraping and collection.
Oil coUecting pipes or troughs are also used on scale pits or oil-
water separators. The trough or pipe with open slots for removing
oil from the water surface is located at water level ahead of an oil-
retention baffle. In the case of oil—collecting pipes, an operator
periodically, upon inspection of the pit or separator, rotates the
slotted pipe allowing floating oil to flow into the pipe and drain
to a waste oil collecting basin or tank. If the water level exceeds
the edge of the o l—collecting trough or if the oil-collecting pipe
is rotated below the water surface, significant quantities of water
will be collected with the waste oil.
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A third method of waste oil collection from scale pits, separators,
or retention ponds involves periodically drawing off floating oil,
with a vacuum truck. Typically this practice is employed when
unusually large waste oil loads are experienced, during major leaks,
spills or upset conditions. The collected waste oil often contains
a large percentage of water which must be removed during reclamation.
Installation and operation of oil skirning or collection devices
on scale pits is the primary approach to waste oil collection.
Wherever quiescent cor itions occur, oils will tend to separate and
an opportunity for collection may arise. Collection of these float-
ing oils reduces the oil load on any downstream control facilities.
Water pollution discharge regulations have resulted in the addition
cf more sophisticated wastewater treatment facilit’ s at domestic
steel mills. Whereas waste oil collection for reclaratlon is often
the objective of oil skinining, especially at scale pits or near the
oil source, water pollution control (i.e., reducing the effluent
oil/grease content, suspended solid content, concentration of toxic
chemicals or pH control) is the goal for the wastewater treat ent
plant.
The continations and types of wastewater treatment equipment Install-
ed at steel mills vary widely and were not extensively researhed
by PER. An effective treatment plant generally Includes one o
more of the following processes to reduce water pollutant discharge
levels to acceptable 1e iels. Emulsion breaking is necessary follow-
ed by collection of the oils which are reed. Chemical flocculation
is coniTlonly practiced to aid in trapping oil particles and removing
them from the water b settling. This treatment is applied only
after most of the oil has been removed from the water by gravity
type separators. Disposal of the oily fioc may constitute a diffi-
cult problem and effective flocculating chemicals may be expensive.
Acid is often added to steel mill wastewater (pickling operations
are generally the acid source) to aid in emulsion breaking. A
properly designed and operated air-or gas-flotation unit also pro-
bides an effective means of removing oil from wastewater.
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flight skinners are sometimes used at the head of wastewater treat-
ment facilities if the oil load Is high. A flight skimer may con-
sist of one or more channels 4 n which flights (wood or metal cross
members) are dragged by chain along the water surface scraDing oily
wastes toward the end of the separator where they are removed. This
type of skimer is effectively used where thick oil scums and foams
are present at the water surface. Such scums are typically caused
by animal fats or tallows in the wa tewater from cold rolling mills.
The ) andling of collected waste tallows, palm oils and fats Is very
messy and difficult since they often do not flow. Reclamation of
animal fats and tallows from steel mill wastewaters Is not generally
practiced. Disposal of the collected fats, oily scum, etc. in a
landfill is comon, although other disposal methods are being sought.
A final opportunity for oil-water separation occurs in he final
treathient lagoons o retention punds. A vacuum truck or a floating
skiming dc. ce can be used if appreciable quantities of oil
accumulate.
5.4 Waste Oil Reclametlon ,Reuse and Dispocal
There is a resurgence in the waste oil re-refining and reclamation
industry, and an increased emphasis on waste oil collection at steel
mills due to the increased Cost of virgin oils, the øesire to conserve
valuable resources and the required reduction in environmental pol-
lution. Frost and Sullivan, 14 in a recent marketing survey on waste
lubricating oil re—refining, predict that the industry’s annual
growth rate from 1975 to IqR5 will be 23 percent. By 1985, 60 per-
cent of all waste oil available will be re-refined, up from the
present level of 9.3 percent. New and improved reclamation and
re—refining processes are being developed and the availability of
companies providing such servic s to the steel industry is increasing.
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Currently, there are about 35 re—refiners In the United States.
It was not within the scope oT this project to Investigate and
review all of the various re—refining processes. Two especially
Informative referen:es, reviewed by PES and used as sources of
background Information for the project, are Waste Oil Recovery and
Disposal 15 ar d Industrial Oily Waste Control.’ 6 The Association
of Petroleum Re—refiners i another reliable source to be contacted
for further information.
The PES study Identified two basic types of waste oil reclaimers
that handled stet l mill waste oils. Waste lubricating oils (pet-
roleum—based oils) collected by skimers or drained from equipment
and accumulated in waste oil containers are pickeci up by offsite,
or, over—the—fence, waste oil reclaimers. These reclaimers generally
collect and pprchase all sorts of waste oil from industrial oils to
cankcase oils. The second general type of reclaimer is typically
located on—site and recovers rolling oils used on cold rolling or
tin mills. Both lubricating oil reclaimers and rolling oil reclaim-
ers are utilized by some steel mills, while other mills rely on only
one type or neither type. A description of the waste oil recovery
and reclamation efforts of the steel mills surveyed by PES is
provided below.
PES surveyed American Recovery Company, Inc. (ARC), a major waste
oil reprocessor. They have a plant in East Chicago, Indiana, that
handles waste oils from three major steel mills In the Chicago/Gary
region, and plant near Sparrows Point, Maryland that processes
waste oils from Bethlehem Steel. Typically, the waste oil collected
at the steel mill contains about 60 percent water and miscellaneous
lm?urlties and 40 percent oil. According to an official at ARC, a very
high recovery efficiency is attained in this reprocessing effort, with
a loss of only about 0.2 percent.* From January 1 to September 30,
1976, the ARC facility in East Chic?go received the following quan-
tities of waste oil (including water) from the companies listed below:
*personal c rnmunicat1on with Loren Hohoy, General Manager, American
Recovery Company, Inc. December 7, 1q76.
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Steel Mills Waste Water and 011*
United States Steel Corporation 9,055,730 1. (2,392,545 gal)
Gary, Indiana
Inland Steel Conpany 4,624,630 1. (1,221,830 cal)
East Chicago, Indiana
Youngstown Sheet and Tube 4,432,610 1. (1,171,100 gal)
East Chicago, Indiana _________________
TOTAL 18, 113,020 1. (4185,475 gal)
*About 7,245, O0 liters of o11(l.914,l O gal)
Source: Letter from Joseph Krieger, Indiana State Board of Health,
December 10, 1976.
The waste oil is normally reprocessed to fuel oil but an attempt
is made, depending on the waste quality, to upgrade to a ro111 ’ig,
pickle or hydra 1ic oil. Most of the waste oil delivered to or
collected by ARC is reclaimed as fuel ofl. Inland Steel and
Youngstown Sheet and Tube buy back quantlt1es of fuel oil approxi-
mately equal to the quantity of waste oil sent to ARC. United
States Steel at Gary does not purchase fuel oil fruu ARC. Recovered
oils which are unsatisfactory for use as lubricants or fuel cii
are often used as road oil.
At Kaiser Steel In Fontana, California, waste oil collected is
picked up by an over-the-fence reclaimer and processed. The
emph is and desire by Kaiser Is to have as much of the waste oil
reclaimed as lubricant. As of mid-1977, approxImately 76,000 lIters
(20,000 gal.) have been successively reclaimed as gear oil. The
quantity of waste oil available for reclamation is about 568,000
1/yr (150,000 gal/yr). Waste oils not suitable for recovery as lubri-
cant are reclaimed as fuel oil. Keeping the lubricating oils segre-
gated from other waste liquids throughout the waste oil collection
and recovery steps is essential to the success of reclaiming lubri-
cants rather than fuel oil.
5—il
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The recovery of rolling oils and fats is practiced at three of
the mills surveyed by PES. PORI, Inc. was identified as the
designer and operator of rolling oil recovery systems at several
steel mills, including the Bethlehem Steel Sparrows Point facility
and the Jones and Laughllr. Aliquippa facility. Figure 5—1 illus-
trates the system insta.led at the Sparrows Point steel mill.
Oily effluent from the cold sheet and tin mills is transferred
by Bethlehem Steel by sewers to surge tanks located at the water
treatment facility. Skimed waste oils are transferred via pipe-
line b PORI to an adjacent waste oil refir.ing facility. The
waste oils are acid neutral :ed, vacuum filtered, washed and
dried, and vacuum distilled. Refined, reclaimed oils are retur,,ed
to the steel mill ahd used in pickling operations as rust pre-
ve, tatives and/or for cold rolling operations as rolling oil. The
tin mill waste oils are segregated and processed separately from
sheet mill waste oils on a batch basis. During 1976 approximately
18.5 x 106 liters (4.9 x 106 gallons) of waste oil (including
entrained water) were processed by PORI at their Sparrows Point
facility. The waste oils from the mills contain about 75 percent
water. Of the 25 percent oil remaining, typically 5 percent are
metals (primarily iron and iron soap) and 1 to 2 percent are dirt
(solids). It was reported that 3.9 x 106 kg/yr (8.7 x io6 ib/yr)
of oil were reclaimed by PORI in 1976 and of this, 2.2 x 106 kg
(4.8 x io6 lb) of reclaimed oil were reused by Bethlehem Steel
at the Sparrows Point facility. The remaining amount of reclaimed
oil is marketed by PORI as fatty acids, fuel and rolling oils.
PORI, Inc. designs and builds waste oil recovery plants which are
either operated for the steel mill by PURl or by the steel mill
personnel. Nine PORI facilities at steel mills are ldent fied
in Table 5-1 along with annual capacities. The PORI facility
recently installed at the Youngstown Sheet and Tube Campbell,
Works Is of particular interest since It:
5-12
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Figure 5 —1. FLOW DIAGRAII SPARROWS POINT OPERATION
U’
-d
‘4
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Table 5—1. PORI PLANTS
Annual Capacfty *
6,500,000 gals. Waste Oil
3,500,000 gals. Waste Oil
1,000,000 gals. Waste Oil
6,500,000 gals. Waste Oil
1,000,000 gals. Waste Oil
1,000,000 gals. Waste 011
PLANTS BUILT BY PORI - - operated by Steel Company personnel
Steel Company Year Built
Steel Company of Canada
Hilton Works, ONT. 1973
Nationdi Steel
Granite City, IL 1974
Youngstown Sheet & Tube
Ycungstown, OH. 1976
*Note: 3.785 liters 1.0 gallon
Annual Capacj
6,500,000 gals. Waste 011
2,500,000 gals. Waste Oil
1,500,000 gals. Waste 011
PLANTS BUILT AND OPERATED BY PORI
Steel Company
Bethlehem Steel
Sparrows Point, MO.
Burns Harbor, IN.
Jones & Laughlin
Aliquippa, PA
National Steel
Weirton, W. VA.
Republic Steel
Hues, OH.
United States Steel
Fairless Hills, PA.
f - f l
—a
Year Built
1950
1972
1953
1963
1969
1975
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1. produces clean water suitable for recycling and/or
discharge;
2. refInes all cold strip mill waste oil for either
reuse or final disposal as fuel;
3. neutralizes acid rinse water.
The PORI facility at the Jones and Laughlin Aliquippa plant
recovers rolling oil from the direct application tin mill.
Recovered oil is returned to the pickling line, and is not reused
as rolling oil. Recli imed water from this PORI system is recir-
culated to the mill. Rolling oil from the cold strip mills at the
Inland Steel Indiana Harbor Works is recovered by Bentex. No
Information on the Bentex facility was obtained.
Table 5-2 sumarlzes the utilization of waste oil recovery practices
at the nine mills surveyed by PES.
In sunlnary, it can be said that if waste oils are collected at
their source and remair s2gregated from other oils and impurities,
It is often possible to reclaim them in the form of a lubricant
or motor oil. Currently, waste oils collected at many steel mills,
are not segregated or are blended with other waste oils prior to
reprocessing. As a result, most recovered waste oils are suitable
only for use as fuel oils. Burning of recovered waste oils with-
out sufficient removal of impurities, simply releases most of the
contaminants into the air. Low quality reprocessed waste oil is
sometimes sprayed or dripped on the coal fed to coke ovens for
bulk density control. Other uses for the lower quality oils
Include road oils and dust suppressants. Sludges and oils not
suitable for reuse must be disposed of in acceptable landfills.
The use of oiiy sludges as an Ingredient in asphalt was noted,
but no details regarding this practice could be found and it is
not known If steel mill waste oils are suitable for this purpose.
The high metals content of steel mill sludge Is reported to make
them unsuitable for use In asphalt.
5-15
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Table 5-2. REPORTED UTILIZATION OF WASTE OIL REFINERIES
Steel Mill and Location Waste 011 Recovery Efforts
Lubricating Oils Rolling Oil
United States Steel Corporation
Gary, Indiana Yes No
South Chicago, Illinois No *
Inland Steel Company
East Chicago, Indiana Yes Yes
Youngstown Sheet and Tube Company
East Chicago, Indiana Yes No
Bethlehem Steel Corporation
Sparrows Point, Maryland Yes Yes
Jones and Laughlin Steel Corporation
Aliquippa, Pennsylvania No Yes
Republir. Steel Ccrporation
South Chicago, IllinoiS No *
Interlake, Inc.
Riverdale, Illinois No No
Kaiser Steel Corporation
Fontana, California Yes No
*Unjted States Steel at South Chicago and Republic Steel do not operate cold rolling or tin
mills and therefore do not use rolling oils or fats.
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Discussions with the steel industry indicate that due to increased
virgin oil and grease costs, and, to some extent, environmental
regulations, more emphasis will be placed on collectin and re-
covering waste oils. Rechmation for lubricating or motor oils
rather than fuel oil is more attractive if waste oil can be collec-
ted at their source and segregated from other wastes.
5.5 DIscharge Rates
Various stz .e water pollution control agencies were rr)ntacted and
outfall data were requested for integrated steel mills. An attempt
was made to determine typical oil and grease concentrations and
mass discharge rates. Recent data are available for steel mills
which have been brought under NPDES permit. NPDES permits generally
require monitoring and reporting of several pollutants discharged
prom each outfall. PES obtained total oil and grease discharge
data for various steel mills in Michigan, Ohio, Indiana, Illinois,
West Virginia and Maryland. Several mills have not yet or have
only recently begun to submit monthly or quarterly outfall reports.
In several cases only concer tration data Is reported; in other
mass discharge rates are reported. If the conduit or outfall flow
rate and oil/grease concentration were both reported, PES calcula-
ted the corr ponding mass discharge rate. It must be pointed out
that total oil and grease sampling methods are generally considered
to be subject to large errors due to difficulties in obtaining
a representative sample (see Section 6.1). In addltthn, the data
are reported on either a net or gross basis. The accuracy of mass
discharge values calculated by multiplying a very high flow rate
(typically in MGD and often estimated, not measured) and a low
concentration (0 to 5 mg/I approaching the limit of detectability
In the analysis method) is questionable.
A wide range of oil and grease discharge rates are reported fri,m
the various steel mifls. Compliance with total oil and grease
5-17
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discharge regulations is maintained at nearly all of the steel
mills for which data could be obtained. A few mills report zero
discharge of oils having completed total wastewater recycling systems.
The oil/grease concentration and mass discharge rate for a parti-
cular outfall at a given steel mill depends on the equIpment dis-
charging to that outfall and the waste oil collection and waste-
water treatment equipment installed. Detennination of the pro-
cesses or equipment served by a glven outfall, was attempted and
is Included with the outfall data. Tabulations of outfall data
were made and brief sumaries of the discharge data are provided
in this section since detailed usage and process data could not
he obtained for these mills. The vast differences in oil and
grease discharges from mill to mill emphasize the need to consider
each steel mill Individually, recognizing the differences ifl pro-
cess and equipment size and design and current waste oil collection
and wastewater treatment practices.
5.5.1 National Steel Corporation - Great Lakes Steel Division
Outfall ddta for the National Steel Corporation, Great Lakes Steel
Division, were obtained from the Michigan Department of Natural
Resources. The Zug Island Plant in Ecorse, Michigan, consists
primarily of coke ovens and blast furnaces. Eight outfalis serve
this facility and the average total daily gross oil aid grease
discharge rate (from May 1975 to April 1976) was 2388 kg/day
(5261 lb/day). The Ecorse Mill Plant, consisting primarily of
rolling mills, Is served by nine nutfalls. During the same time
period, 671 kg/day (1477 lb/day) of total oil and grease was
reported on a net basis. One outfall serves the 80-inch hot
strip mill and had a reported net daily average total oil and
grease discharge rate of 4570 kg/day (10,070 lb/day). The hot
strip mill wastewater contained an average of about 8 mg/i
Freon extractable oil and grease. The Michigan Plant, an armor
plate mill equipped with oil-water separators in the scale pits,
5-18
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discharges to a se!arate outfall. Only 1.4 kg/day (3.1 lb/day) net oil
and grease was reported. If we consider these four sections or
plants as an integrated steel mill, the total oil and grease
discharge rate is approximately 7,672 kg/lay (16,800 lb/day).
5.5.2 Ford Motor Company - Rouge Manufacturing Complex
Outfall data for the period April 21, l97 to April 20, 1976 fcr
the Ford Motor Company, Rouge Manufacturing Complex at Dearborn,
Michigan, was obtained from the Michigan Department of Natural
Resources. Four outfalls serve the plant which consists of coke
ovens, a blast furnace, steel rolling and a foundry. The gross
daily average total oil and grease discharge rate for the entire
plant was reported to be 3430 kg/day (7553 lb/day). Nearly half
of the total oil and grease discharge rate was from the outfall
serving the rolling mills.
5.5.3 United States Steel Corporation - brain Works
U.S. Steel Corporation Operations In Lorain consists of several
cold strip reducing and cold-finishing mills, a rod mill and a
hot-strip mill. Data from the Ohio Environmental Protection
Agency for the period June 1975 to April 1976, IndIcate that the
average total oil dnd grease concentration in the wastewater
discharged from the plant was about 5 mg/i. The daily outfall
flowrate is 11 x 10 1/day (3,000 MGD) and the estimated mass dis-
charge rate of ofi nd grease is 57,800 kg/day (l27,r ’ lb/day).
5.5.4 Natlon l Steel Corporation - Weirton Steel Division
Region III of the EPA provided outfall data for the National
Steel Corporation, Weirton Ste 1 Division in West Virginia. The
Weirton mill is Integrated with over 300 coke ovens, 4 blast
furnaces, 2 BOF’s, 4 slab casters, a blooming mill, a structural
5-19
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mill, and sev rai strip and sheet mills. The reported total plant
oil and grease discharge rate for October 1975 through March 1976,
was approximately 910 kg/day (2,000 lb/day). The average oil and
grease concentration was 1 .7 mg/i.
5.5.5 Bethlehem Steel Corporation — Sparrows Point Plant
The Maryland Department of Water Resources was contacted and
visited to obtain NPDES outfall data for the Bethlehe!n Steel
Corporation plant In Sparrows Point, Maryland. Total oil and
grease discharge data is reported fo.’ three of the seventeen out-
falls serving the steel mill. The NPDES permit limIts the average
and maximum total oil and grease discharge rate on two outfalis,
and specifies limits on oil and grease concentrations for a third
outfall. The two outfalls with mass discharge rate lImits serve
the hot forming, rod mill, wire mill, cold rolling, pickling and
coating processes. From July 1975 to September 1976, the average
daily total oil and grease discharge rate from these two outfalls
was 3,560 kg/day (7,848 lb/day). In all but a few cases the
reported mass discharge rate was below the average discharge
level specified in the NPDES permit.
5.5.6 NEIC Data Sumarv
PES reviewed a set of reports which we prepared by the National
Enforcement Investigations Center (NEIC) that contained oil and
‘ rease data on eight United States Steel Corporation plants 1
the Pittsburgh area. During the time that NEIC was conducting
surveys of these plants most of them were not ooerating at their
normal capacities and outfall flow rates were generally above the
normal levels due to heavy rainfall. The oil and grease discharge
data are briefly summarized in the following paragraphs. For a
more detailed description of the NEIC report findings on oil and
grease discharges, the reader should review the NEIC reports) 7
5-20
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The discharges were very high for the Edgar Thomson and Irvin
plants. The reasons for these high discharge rates could not be
determined from the reports 1 although both plants are very old.
U.S. Steel ha plans to construct new wastewater facilities at the
Edgar Thomson and Irvin plants. The total daily average oi and
grease discharges from various U.S. Steel plants are given in
Table 5-3.
Since most of the oil and grease usage In an Iron and steel complex
is in the steel mIll section, it would be expected that most of
the oil and grease aischarge would be from the fabricating mills.
Oil and crease discharges frum basic iron and steel production
would not be expected to oe very high. But this does no appear
to he the case, as shown on Table 5—3. In the Edgar Thomson and
Duquesne plants, which are basically iron and steel producti.n
plants with very little fabrication, the oil and grease dis’harges
are very high. The reason for this could not be determined from
.he NEIC reports, although both plants are very old and lack ade-
quate oil and grease removal and wattewater treatment facilities.
5.5.7 Outfall Data Surnm y
Several difficulties were encojntered in trying to obtain outfall
data which could be used for making c3rnparisons about oil and
grease discharge rates from steel mills. In many cases,
the steel mills are not yet recorting outfall data because
the NP’)ES permit has not “et t.een issued, is stIll in
adj ication, or is being contested by the .eel mill.
Only steel mills which have been under permit for six months cr
more w ’re potential data sources. Currently th only outfalls
for which oil and grease data are measured and reported are those
which are suspected of potentially si jnificant oil a,id grease
5—21
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Table 5-3. NEIC OIL AND GREASE DISCHARGE DATA SU ?1ARY
.
Name Net/Gross
Total Daily Average Discharge
Of Oil and Grease
Kg Lb
Plant Gross
Gross
Carrie Furnaces Net
Works Net
and Axle Not Kr.own
Gross
9,012
8,556
122
634
67
1,440
19,872
18,823
345
1,395
149
2,770
Total daily average discharge data for the Clairton and National
Plants were not reported in the NEIC reports.
5—22
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disch-ir es. Only oil anti grease concentration data are reported
in sc cral cases. nakin It ir-possible to estimate mass discharge
rates without the corresponding outfall flcw rate. In some cases,
the measured concentration and flow rate data are used to calculate
mass discharge rates, and only the computed mass discharge rate Is
reported.
Daily average total oil and grease discharge rates have been presented
in the previous su’ sc:ti)ns. Total oil and grease concentrations are
measured by Freon extraction methods discussed in Section 6. Generally,
grab samples are taken from one to five times p r month. Flow rate
data Is typically estimated and reported as constant for a given
month. Average and maximum oil and grease concentrations or discharç
rates are reported to either the EPA Regional office or state pollu-
tion control agency if authority to issue NPDES permits has been
delegated. Data is reported on monthly “discharge monitoring
report forms, often submitted at quarterly intervals.
As an example of a typical data request, the Indiana Board of Heaith,
Division of Water Pollution Control, was contacted to obtain outfall
data for oil and grease discharges from the three steel mills in
that State which were included in the PES questionnaire survey. It
was learned that outfall data for United States Steel at Gary was
not available for use by PES. Only concentration dat3 was available
for Inland Steel and Youngstown Sheet and Tube, both in East Chicago.
For these two mills, all outfalls were reporting from 0 to 5 mg/l.
A wide range of discharge rates is reported, differing greatly due
to plant size, age design, the processes served by the outfall,
plant maintenance and lubrication practices, and wastewater treatment
methods. NPDES permits typically require the average oil and grease
concentration for an outfall to be less than 15 mq/l and the maxi—
‘rum concentration per month to not exceed 30 mg/l. In some cases,
5—23
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the averaqe and r xi uri outfall flow rate is combined with the 15
and 30 r’gfl concentration limits and the permit limits are stated
in terr s of mass discharge rates. Currently, some states have
qualified to issue NPDES permits and NPDES permits for the remain-
ing states are being issued by the EPA.
5-24
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6. WASTEWATER SAMPLING AND ANALYSIS
PES Investigated and reviewed the sampling and analysis methods
used for determining the oil and grease content of wastewaters for
two reasons: (1) to appreciate the accuracy and representativeness
of reported outfall data, and (2) to perform a sampling and analy-
sis program If necessary, to obtain data for the PES study. Per—
mission and arrangements could not be obtained to conduct scale
pit and wastewater sampling at any of the nine steel mills surveyed,
but the investigation of sampling and analysis methods did provide
Insight into the problems encountered in developing material balances
for lubricants with discharge rate data. A summary and discussion
of sampling techniques, and analysis methods for detection of oil
and grease in water, are presented in this section of the report.
6.1 Sampling Wastewaters for Oil and Grease
The following three requirements are necessary f r o’taining good
results from any sampling prograru:
1. Insuring that truly represefltative samp e ar’ takei;
2. usIng proper and reproducible san pling techn1o es; and
3. protectIng and pre erving the samples ur.til they are
analyzed.
The first of these requirements, obtaining a representative sample
of the wastestream, may be the source of significant errors,
especially in the case of grab samples. Total oil and grease deter-
minations for steel mill wastewater generally involve periodic and
infrequent (three to five times per mnnth) grab samples to be taken
manually. Waste flows can vary widely, both in magnitude and com-
position, during each day, and within a given wastestream at any
time, the composition can vary due to partial settling of suspended
6—1
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solids or the floating ci light materials, especially oil. Materials
tend to deposit or collect in areas of quiescence or low velocities,
such as near the walls of the flow channe,. To minimize errors
resulting from these factors, samples should be taken from the
wastestream w ’ere the flow is well mixed. Often suitable sampling
points are difficLt o locate or gain access to. If mass discharge
rates are of interest, flow measurements are needed. These must also
be taken with care to ensure representativejness.
Composite sampling is impractical for oil and grease analyses.
Samples must be analyzed separately because grease and oil losses
will occur on sampling equipment a.d containers if compositing 1
attempted. A grab sample, usually a manually collected single por-
tion o’ the wastewater, shows only the concentration of the con-
stituents in the water at the time the sample was taken. The more
variable the flow and composition of the wastestrl?am, or the less
frequent the sampling, the lower the probability s that the grab
sample will be representative of the average wastEstream conditions.
Since composite samples are impractical, and contirnious sampling
would be too costly, Iron and steel mills, are generally required
(undcr the NPDES permit system) to take periodic grab samples fran,
wastewaters for oil and grease analyses.
The methods c analysis for o l and grease n wastewaters (see
Section 6.2) re , 1re a sample volume of approximately one liter
(or one quart). Sampling containers must b glass and thoroughly
cleaned before use. Wide-mouth glass bottles are typically mounted
in a weighted cage or bucket which Is lowered rapidly into the
wastestream. The weighted sample bottle sinks rapidly, collecting
a sample from the wastestream at various depths. Since oils and
greases tend to float in quiescent wastewaters, samples should be
collected in well-mixed turbulent locations, utilizing a rapidly
sinking sample bottle to ensure that the entire sample does not
consist of water from the surface of the wastestream.
6-2
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Once a sample Is collected, It should be marked or tagged for future
identlilcation. Since several piant and wastestream parameters
influence the oil and grease concentration, data related to the
production level, occurrence of oil leaks and spills, wastewater
flow rate, sample location nd time are Important. In practice,
much of this Information is unavailable or otherwise not noted.
It is desirable to run all analytical procedures irnediately after
sample collection. If samples are to be held for more than a few
hours, they should be preserved by adding 5 ml of H 2 S0 4 to lower
the pH below 2.
NPDES data is typically reported on eIther a çjross or net basis.
If intake waters are sampled for oil and grease content, the net
oil and grease concentration of outfalls can be determined. When
interpreting or reviewing wastewater data, attention must be paid
to the b s1s on which it is reported.
6.2 Analysis for Oil and Grease
The methods used for a total oil and grease analysis of wastewaters
are specified in EPA’s Methods for Chemical Analysis of Water and
Wastes. 18 Three different techniques, all utilizing Freon 113 as
a reagent to extract oils and greases, are used, although one of
the methods is not well suited for steel mill wastewater oil and
grease analysis. The two methods comonly used for the measurement
of Freon—extractable matter from wastewater are capable of detecting
total oil and grease concentrations In the range from 5 to 1000 mg/l.
Complete copies of these t methods, Storet Nos. 00550 and 00555,
are Included for reference in Appendix B.
The Soxhlet Extraction Method (Storet No. 00500) Involves filtering
the sample which has been acidified to a low pH (<2) to remove the
oils and greases from solution. Soxhlet extractors are used with
6-3
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Freon, the extract Is evaporated and the residue is weighed. Tests
to determine the precision and accuracy of t’iis method were performed.
When one-liter portions of the sewage were dosed with 14.0 ig of a
mixture of #2 fuel oil and Wesson oil, the recovery was 88 percent,
with a standard deviation of 1.1 mg.
The Separatory Funnel Extraction Method (Storet No. 00556) also
begins with a one-liter, acidified (pH 2) sample. The sample is
serially extracted with Freon in a sep ratory funnel. The solvent
is evaporated from the extract and the residue is weighed. As with
the previous test method, tests to determine the precision and accuracy
of this method were investigated. When one—liter portions of the
sewage were dosed with 14.0 mg of a mixture of #2 fuel oil and
Wesson oil, the recovery was 93 percent with a standard deviation
of 0.9 mg.
Both methods are influenced by the presence of extractable non—oiy
matter which may affect the material measured and the interpretation
of results. As indicated by the precision and accuracy tests, no 4 .
all of the oil or grease is ‘tracted and detected. No data con-
cerning tests performed with industrial wastewater samples dosed
with typical lubricating oils and greases, hydraulic fluids, or
roiling oils and fats was available in the literature. The preci-
sion and recovery of either of these test methods, in steel mill
wastewaters, has not ‘een investigated to date.
There are several devices available for monitoring oil and grease
In wastewater, but they were not currently being used by any of the
steel mills that were visited or contacted In this study. Since
permit systems do not require continuous monitoring, periodic grab
sampling Is conducted once per week, which is less costly. Portable
analyzers and continuous monitoring devices that operate on a variety
of principles, are currently being marketed. These devices have not
been Installed or op2rated on steel mill outfalls, so no discussion
of their usefulness, is presented. Portable monitors are now avail—
able for sampling and ana1ys s of oil and grease contents of
wastewaters.
6-4
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7. DATA GATHERING
This section c rntains a description of the data gathering method-
ology developed and performed by PES. The problems encountered
and measures necessary to overcome these problems are discussed.
1h2 technical consultants providing input to the project are
introduced.
7.1 Questionnaire Preparation and Survey Design
To obtain suflicient data to identify and quantify the use and fate
of oils, greases and hydraulic fluids in the iron and steel indus-
try, PES prepared a questionnaire and planned a survey. During
the initial phase of the project, a literature review, the types
of data needed and a project approach or methodology were Identi-
fied. Since much of the data in the literature was not current and
very little information related to lubricant usage and correspon—
ing waste oil discharge rates and recovery or disposal practices
were available, It was necessary to plan and execute an iron End
steel mill survey. Time and project resource constraints, in ad-
dition to Office of Management and Budget COMB) regulations flmit-
ing the number of questionnaires that can be sent out, fixed the
survey sample size at nine.
A copy of the “Iron and Steel Mill Lubrication Questionnaire” de-
veloped by PES is pr cented on the next page. A great deal of data
and information were requested, and a high degree of detail was
solicited. Since the questionnaire dealt with two major areas (1)
lubricant and hydraulic fluid selection and usage, and (2) waste
oil recovery, wastewater treatment and discharge rates, It was ex-
pected that both lubrication and environmental personnel would
respond to the questionnaire. Although it was expected that few
of the steel mils could or would provide as detailed and complete
a respon3e as was requested by PES, it was anticipated that by
including nine mills in the survey, adequate data for achievement
of the project goals would be obtained for the industry In general.
7-1
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IRON AND STEEL MILL LUBRICATIO j UESTIONNAIRE
Instructions:
Please provide the following information in as much detail and as accurately
as possible.
L st all lubricants, oils, greases and hydraulic fluids used in the steel
mill by trade name and supplier.
Specify where and on which equipment the above is used. (Include material
balances if available.
Specify quantities used and where.
Include any in-house specifications used in ordering lubricants.
Give a description of lubrication program including practices, schedules,
methods and types of systems used. (Include schematics.)
Supply a general flowsheet identifying the waste water collection and treat-
ment system including:
1. Amount of oil and grease treated
2. Collection efficiencies
3. Effluent discharge rates and sources
4. Methods of control
5. Amount reused or recovered
6. Other means of disposal of old lubricants
7. Description of sarrpling program
8. Total waste water flow
9. Modificati’ ns or additions planned for system
7—2
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Preliminary research nt .eeI mill lubricant usage, indicated
that the most significant oil and grease using plant areas or
equipment were the primary and secondary forming and rolling mills.
By definition, the project was to investigate integrated steel
mills. The emphasis was placed on larger steel mills with several
forming and rolling mills because it was expected that they uld be
more likely to have extensi ’e environmental and lubrication depart-
ments and therefore better data and records relevant to the PES study.
To identify candidate steel mills, information obtained during the
literature review were utilized. The prime source of geographical
plant size and descriptive Information was Directory of Iro nd
Steel Works of the United States and Canada published by the Amer-
ican Iron and Steel Institute. The ni ie steel mills listed in
Table 7—1 were chosen for the survey. The plant location and total
number of forming and rolling mills ar. also presented in the table.
7—3
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Table 7-1. IRON AND STEEL MILLS SEI ’.T QUESTIONNAIRES
Jones and Laughlin Steel Corp.
Bethlehem Steel Corp.
Inland Steel Co.
Interlake Steel Co.
Republic Steel Co.
United States Steel Corp.
United States Steel Corp.
Youngstown Sheet and Tube Co.
Aliquippa, Pa.
Sparrows Point, Md.
East Chicago, md.
Riverdale, Ill.
South Chicago, Ill.
Gary, md.
South Chicago, Ill.
East Chicago, md.
12 mills
27 mills
30 mills
16 mills
7 mills
31 mills
10 mills
14 mills
Region III
on V
Kaiser Steel Corp.
Region IX
Fontana, Calif.
16 mills
7-4
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7.2 Contacts and Responses
The process of obtaining data from the nine selected steel mills
began with the identification of key personnel within each steel
mill tc mai’ the data request and coordinate response preparation.
Telephone calls to the nine mills were made, in most cases, to the
director or department head of the environmental control section.
In each case PES and the EPA contract uider which the project was
funded were introduced and a brief de cription was provided of the
nature of the study and types of data being sought. The name,
title and address and telephone number of the steel mill personnel
who would coordinate efforts to prepare the response to the quest-
ionnaire was noted. In most cases it was indicated by the steel
mills that responses could be provided but PES had to make .‘
data request3 in writing.
Questionnaires with covcr letters were mailed to the nine steel
mills during June and July of 1976. The cover letters identified
PES as an EPA—IERL contractor and provided a brief description of
the project approac i and tne study objectives. It was exp2cted
that one or two months would be needed by the steel mills to pre-
pare written responses. After tpproximately one month, follow-ur’
telephone calls were made to the people who had been sent question-
naires to determine the expected completion date and resolve arc’
questions which may have arisen. Several of the nine mi.ls indi-
cated that all requests or data including the PES questionnaire,
had to be reviewed and approved by the legal department, plant man—
agement, or the corporate engineering o fice prior to being released
to PES. It was also indicated that the questionnaire called for a
great deal of information not imediately available or previously
tabulated in the desir9d format. In nearly all cases, input to the
questionnaire response was needed from the lubrication department,
environmer.tal department and plant maintenance or operating
7—5
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d v-’-”it;. Of ’i rchae rP(Or j5 had to be reviewed and tabulation
of Lf ri iit u .a c’ pr ir ..J eso c1ally for N 5. (If relPvant data
were ,revio ;ly ta jl. tei or rr ariz ’d for In-houce or other pir—
poses, P erp c1 to ake use of such data the ehy sinptifying
re cing the demand on the Industry’s time.) Several other
factors were citpd which contributed to the delays and difficulties
in pre’arin qLestion 1aire recL,oncpc. The steel mill contacts
notei that the r’t’unt of infor nation and data reiuested by PES re-
quired a significant e ’enditure of an-’ urs. Environmental ard
1 ”ricatIon çtiff are very busy wit’ responsibilities. For
example, air pollution regulations, particularly for coke oven
emissions, have raised control problems that place major time and
manpower th’mands cn available staff. Pollution control equi ent
design, selection, start—up, operating and testing; studies of in—
plant environmental problems; ai d other commitments to provide var-
ious agencies with emission and discharge data, keep steel mill
environmental staffs very busy. Emission or discharge viclatlons
and other enforcement activities, at both the ,ederal and state
l.veis, have sensitized the steel Industry. An attitude hes devel-
oped that Infornatton provided to po’lution control agencies or
their contractors may te used against them at some later date. The
research oriented role of IERL, and this project in particular,
were emphasised and the desire to prepare an objective and compre-
hensive Investigation were cited as reasons for surveying the
industry for data.
Due to the amount of data requested and the factors discussed in
the preceed1n paragraph, comoletion dates In October or November
(about tn e or four months from the time the PES questionnaires
were mailed) wt. estimated by the nine steel mills. PES decided
to recontact each of the mills periodically (once or twice per month)
—6
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to r ur t’ t t o c stionnaire had not been forgotten nd to
an w ’r r ’stlr.n5 cc c’ in ‘‘ i iea r ’ uest or project ohjecttv s.
Tt e i— ort ’,ce of current industry data to the project called for
efforts to kc er in contact with t e nine steel mills. The project
sc’e 1ule was m 1if1ed to tolerate the data gathering delays and
difficult ips.
7 .1 L l n Visit ar d Tn rvipw
As the initial questionnaire responses were received, it became
clear that the responses generally lacked the degree of detail
desired for the project, particularly for developing material
balance estimates for oils, gre ses, and hydraulic fluids. It was
decided that an attenpt would be made t visit each of the nine
steel mills to inspect facilities and interview personnel knowledge—
abie in lubricant usage and application, wi ste oil recovery and
rech- ation, and wastewater treatment. Telephone calls followed
by written requests for a plant visit were made to the steel mills.
Pennisslon to visit and arrangements to discuss t’ PES project
were finalized for six of the nine steel mills who were sent qucst-
nniaires. One day plant visits and appointments with environmental
and lubric tion department personnel in the following plants were
scheduled during October and November of 1976 with the following
plants:
United States Steel Corporation — Gary, Indiar3
Inland Steel Compan, — East Chicago, Indiana
Int rlake Steel Company — Riverdale, Illinois
Jones and Laughlin Steel Corporation — Aliquippa. Penna.
Beth’ehem Steel Corporation — Sparrows Point, Maryland
Kaiser Steel Corporation — Fontana, California
7—7
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The data provided in the initial written resroflSes were
discussed at the plant visits, and the steel makIng and
shaping equipment, w ste oil recovery practices, and
wastewater treatment facilities were inspected. The scope and
objectives of the project were reviewed and data availability
discussed. If additional useful data was Identified and
d2terrlined to be available, a renuest for such data was made.
Follow-up telephone calls were made after the visits to
expedite these data inputs.
7.4 Second Data Gathering Efforts
Files of data, questionnaire responses, plant visit notes and
telephone contact reports were prepared for each of the nine
steel mills. Significant differences in the depth or degree
of detail were noted between the nine mills surveyed. The
Information and data contained in these files were reviewed
and used to prepare a preliminary data sumary and material
balance estimate for each steel mill. At this time it was
decided that a second data gathering effort was needed to obtain
additional data nef:essary for preparing more complete material
balance estimates. The project was extended to allow aaditlonal
time for recontacting the steel mills.
A list of questions for each of the mills was prepared to obtain
more data. Eight of the steel mills were recontacted by telephone
and notified that additional data and corTiflents on the preliminary
data sunii ary and material balance estimate were being sought.
United States Steel at South Chicago was deleted from further
study because of difficulties in obtaining ciata, and the fact that
a seconc 4 United States Steel plant, the Gary Works, was Included
in the FES survey. The preliminary data sumaries and material
balance estimates, essentially the first draft of the individual
7-8
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steel mill data sur ?ries presented In Section 8, were mailed to
the respective steel mills. Aqain, telephone calls were made to
expedite and discuss the additl3nal data requests. The conii ents
and additional data received from each of the mills was used
to finalize th, data sumaries and material balance estimates
and prepare the material in Section 8 of this report.
To supplement the steel mill data, a survey was made of waste
oil reclaimers that handl9 waste oils from one or more of the
mills under study. PES requested information relating to the
quantity and nature of the steel mill waste oils processed
and general information concerning waste oil reclamation practices.
The data and information from waste oil recl?mation companies
is discussed in SectIon 5, as well as in Section 8, In conjunction
with the appropriate steel mill data.
7.5 Consultants
To issist in the performance of the project and to provide
additional sources of lubricant usage and fate information,
consultants were contracted by PES. During the PES study two
different areas were identified that required technical support
and called for consultants with specialized backgrounds. At
the outset of the project, technical support and a supplementary
data source for the area concerning steel mill lubricant character-
istics and usage was required. It was determined that a
consultant with strong steel industry experience in lubrication
engineering would be beneficial to the project. The P nerican
Iron and Steel Institute (AISI) was contacted to make reconinend—
atlons or provide PES with a list of potential consultants.
As a result of this consultant search, Joseph D. Lykins was
contracted by PES. Mr. Lykins, assisted by Paul D. Metzger,
contributed valuable lubricant usage date to the study. Messrs.
7—9
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Lykins and Metzger are both recently retired from Wheeling—
Pittsburgh Steel Corporation and are currently ac ng as private
consultants to several iron and steel mills and lubricant distrib-
utors. Mr. Lykins served as the Corporate Lubrication Engineer
fcr twenty—five years an tir. Metz r was the Supervisor of Testing
for the Lubric ition Department. Both are long-term active members
and have served on technical subcommittees of the American Society
of Lubricating Engineers (ASLE), the American Society for Testing
and Materials (ASTM)I and the Association of Iron and Steel Engi-
neers (AISE). Mr. Lykins provided PES with typical lubricant usage
data. For fifteen types of lubricants the yearly consumption for
an integrated steel mill producing three million net tons of steel
annually was estimated. A detailed tabulation of lubricant types
and quantities applied monthly for twelve major plant processes or
areas was also prepared for the PES study. The types of bearings
and gears, types of Iubr cants applied and monthly usage data were
tabulated for the various parts or equipment within each mill or
plant area. The input that was received from Mr. Lykins is sum-
marized In Section 8. Additional data provided by Mr. Lykins is
Included in Appendix C as it contains a great deal of valuable
Information.
During the second data gathering eFfort, PES recognized the need
for a second consultant with experience in the steel industry and
a knowledge of the fates of steel mill lubricants. Again the AISI
was contacted for consultant recomendations. Richard Jablin was
selected by PES and contracted to provide information and assistance
In the area of material balance estimation and the fate of steel
mill lubricants. Formerly with the Bethlehem Steel Corporation and
Alan Wood Steel Company, Mr. Jablin served in a number of positions
incluJing Plant Engineer, Manager of Engineering and Construction,
I fector of Environmental Control. Since 1975 he has been self
employed as a consultant to the steel industry and has assisted in
7—10
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several EPA studies. He is a member of the Association of Iron and
Steel engineers (AISE), and is a past Chairman of the Steel Cornittee
of the Air Pollution Control Association (APCA).
Mr. JablIn provided PES with a material balance estima:e for an
unidentified steel mill, Mill A,” and based oi his knwledge of
the industry and material balance data collected by PES, he pre—
pared a material balance estimate for a “typical” steel mill. The
Input provided by Mr. Jablin is summarized in Section 8. A copy
of Mr. Jablin’s Droject input (without appendices) Is provided in
Appendix D.
7—11
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8. DATA ANALYSIS AND MATERIAL BALANCES
A prime objective of the PES survey was to analyze data from the
consultants and from the questionnaires completed by nine steel
mills, and to use this information to develop material balance es-
tiniates identifying the usage and fate of lubricants, oils, greases
and hydraulic fluids. As discussed in the previous chapter, it was
a very difficult and time consuming task to obtain sufficient data.
Several factors influence the quantities an types of oils, greases
and hydraulic fluids that are used. The fate of these lubricants
and hydraulic fluids is also affected by several parameters. Any
comparison or analysis of data from different steel mills must in-
clude a description of these parameters. In this chapter the aval-
able data, methodology for data analysis and naterlal balance esti-
mates for steel mill oils, grea3es and hydraulic fluids is presented.
8.1 Factors Affecting Lubricant Usage and Fate
During the course of gathering data n:; and viiting the steel mills,
several factors were identified which influence lubricant usage
rates and the fates of these lubricants. These factors are discussed
because it is important that the reader understands the limits of
the data and the problems of the material balance development. As
a result of these factors, potentially significant errors are en-
countered In attempts to combine data from different steel mills to
make industry—wide generalizations. It should also be noted that,
for the most part, the steel mills in the study were cooperative,
and the delays or problems in gathering data were often the result
of a lack of data within the steel mills. Generally, sufficient data
to develop material balances for total or specific oils, greases
and hydraulic fluids does not exist. Few, If any, mills have
studied the proble n in detail, although rising lubricant costs
8-1
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are stimulating Interest in Investigations of potential waste oil
recovery schemes and quantities.
The most obvious factors influencing lubricant usage (and their
fate), are the size, design and age of tne steel mill equipment.
A great variety of equipment and major differences in the age and
production capacity exist in the American steel industry. The lubri-
cation practices and application methods also vary quite widely.
These factors, as well as maintenance and housekeeping practices,
Influence the amounts and types of lubricants applied and, to so—....
extent, the fate of these lubricants. Also different amounts of
a variety of steel products are produced at the various steel mills.
Waste oil collection and reclamation efforts differ widely from
one mill to the next. Currently, most steel mills are primarily
trying to prevent excessive oil and grease discharge rates (as
specified in NPDES permits). Other mills are engaged In programs
aimed at recovery and reclamation of waste oil, as well as water
pollution control. Differences In the steel mill organization
schemes and management policies also influence waste oil recovery
practices. l’e responsibilities of the lubrication, cnvironmental,
mathtenance and operating departments vary at the different steel
mills. The sensitivity or awareness of maintenance and operating
personnel can affect the overall steel mill efforts to conserve
and recover lubricants and hydraulic fluids.
8.2 Methodology for Data Analysis
A prime objective of the PES 3tudy was to develop material balances
for oils, greases and hy iraulIc fluids used in the steel Industry.
In the process of gathering dat 1 . and dIscussing the project with
the steel industry, the terms of a general material balance were
identified. As illustrated in Figure 8-1, two input terms, virgin
make—up and reclaimed or recycled lubricants and hydraulic fluids
8-2
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‘i1 ’! ’ T ; si
purchased oilc,
peaces nd
hydraulic fluids
reclaimed &
recycled
----a
i
on trOd’, c
—-- o c ’ ile
on m l’ cc _______ —
N.
- to cuter plirit
left in containers or lost
in storase and handlinq
leaks and cpilis onto c1roun 1.
qene’-illy cleaned up and d’cpo I
volatilized, burned or
consumed n çroress
in sludoes, trash and debris
in waStewaterO
to disposal
discharged to
waterways
Sludge disposal
road oils
C,
5 . )
--4
Figure 8-1. LUBRICAI T, OIL, IREASE A9D HYDRAULIC FLUID ‘IATRrAL B1 LADCE ESTIMATE
-------
enter the material balance. Several output or loss terms are Ident-
ified in the figure, including: lubricant losses on the steel
products shipped from the plant; oils and greases attached to mill
scales which are stockpiled or recycled to lie sinter plant; lubri-
cants, especially greases, left in containers or lost during stor-
age and handling; oils and greases on trash and debris that are
collected and disposed of; leaks and cpills to the ground or floor
which are qenerally cleaned up and dispt.sed of; lubricants volatil—
ized, burned or consumed in various steel making and shaping pro-
cesses; and oils, greases and hydraulic fluids In the wastewater
streams which are lther discharged to waterways or are rerovered
and disposed of or reclaimed. Oils, greases and hydraulic fluids
are also collected, drained directly into either a waste—oil col-
lection bin or tank, or recovered by oil skimers, In scale pits
and wattewater treatment facilities, and treated on or off—site In
waste oil reclamation facilities for use as lubricants, fuels, or
road oils. Reclaimed rolling oils are genera 1 ly equal in quality
to virgin rolling oils and can be recycled effectively. Reclaimed
lubricating oils are generally of lower quality than virgin lubri-
cating oils and are used as fuel or for less demanding lubrication
applications. Oily sludges are generated from wastewater treatment
facilities and waste oil reclamation systems.
Quantifying each of these input and loss terms for each oil, grease
or hydraulic fluid was determined to be an impossible task. A given
lubrt cant may be used in several areas or pieces of equipment and
may appear in several wastewater circuits. The wastewaters from
different areas of the plant ar often combined, resulting In a
blend of oils and greases which cannot be separated and traced
to their sources. The wastewater sampling and analysis methods
that are currently being used only determine the total quantity of
otl and grease. No distinction is made between different oils,
greases and hydraulic fluids. Several of th. output or loss terms,
although recognized by the steel industry, have not been investi
gated to date and quantitative data of any type Is unavailable.
8-4
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With the available data, it was decided that a single material
balance estimate for the total oil, grease and hydraulic fluids
input to the steel mills would be prepared. The questionnaire
responses from the nine steel mills varied significantly in the
degree of detail provided. It was not possible to estimate an over-
all material balance at all of the steel mills due to inadequate or
incomplete data bases. In all cases, sc,me of the materiai balance
loss terms were estimated by PES based on subjective evidence. The
percent of the input unaccounted for is reported for mills that do
not have ‘closed” material balances. The data, estimates and mater-
ial balances for individual steel mills are presented in the remain-
der of this section. The data regarding lubricant usage and ;ates
that the consultants provided is also presented.
8.3 UnIted States Steel Corporation
8.31 Gary, Indiana
A sunir.ary of the major equipment and products associated with the
United States Steel Corporation, Gafy Works, is presented in Table
8-1. The information presented in the table is a sumary o t data
provided In the AISI Directory of Iron and Steel Works . According
to the 1155 Steel Industry in Brie? , the steel production capacity
at the Gary Works is 7.3 x lO kg/yr (8.0 x io6 tons/yr). The ac-
tual production rate was approximately 4.6 x 10 kg/yr (5.1 x io6
tons/yr) during the period for which lubricant usage data were
reported.
8-5
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TABLE 8-1
1 strand — slab
UNITED STATES STEEL CORPORATION - GARY, INDIAHA*
Equipment
584 Core ovens — by-product
11 Blast furnaces
2 BasIc open hearth furnaces
6 BasIc oxygen furnaces
1 ContInuous caster
IYie of Mill Annual Rolling Capaclty
1 Slab 2,820,000
1 BIllet l,20u,000
2 Blooming 1,191,000
1 RaIl
1 Plate
9 Bar
2 Hot strip
3 Sheet - Cold roll
5 Sheet temper
3 Tin—Cold roll
3 Tin temper
31
Capacities of hot strip, cold rolling, cold finish & temper mills
>Capacities of all primary and
Notes
rTquipment and annual rolling capacity data from AISI Directory of Iron and Steel Works
(hO ton 907.2 kg).
** This parameter was computed for later use; correlating lubricant usage and product type.
(See Sect 9.1.2).
20,768,800
secondary mills
5,211,000 Net Tons
15,557,800 Net Tons
NET TONS
12.2188 x 106
*
20.7688 x lO’
c o
682,000
574,000
2,083,000
6,010,000
1,314,800
2,365,900
1,547,400
980,700
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8.3.1.1 Lubricant Purchases . Based on records of actual consump-
tion for the first six months of 1976, the approximate amounts of
lubricating oils, greases and hydraulic fluids are as follows:
Oils 568,000 1/month (150,000 gal/month)
Greases 59,000 kg/month (130,000 lb/mo ,th)
Hydraulic Fluids 76,000 1/month ( 20,000 gal/month)
Assuming an average density of 0.90 kg/l (7.5 lb/gal) for lubri-
cating oils and hydraulic fluids, the total input of oils, greases
and hydraulic fluids was 7,650,000 kg/yr (16,860,000 lb/yr).
Lubricating oils used at the Gary Works are divided thto 25 cat-
egories most of which are used In small volumes. The majority
of the consumption of oil is accounted for by three categories:
gear oil, which is used for lubricating bearings and gear drives;
circulating oil, which is used for lub—icating oil-film back-up
roll bearings; and, circulating turbine oil, which lubricates the
moving parts of turbines, machine tools and hydraulic machines by
means of pressure circulailng pumps.
Greases re similarly divided into 13 categories, with 3 categories
accounting for the bulk of the consui ption. These are: mill util-
ity grease, a general purpose grease used throughou the plant for
bearings and roll necks; high temperatcre grease, similar to the
first category but designed for use in high temperature areas; and,
extreme temperature grease, for still higher temperature appikations.
The hydraulic fluids are divided into nine categories, with the
bulk accounted for by two categories: soluble oils (actually mine-
ral oils with emulsifiers added), used In general metal working
conditions; and, noninhibited hydraulic oil for general use in hy-
draulic systems. A smaller contributor is phosphate ester fluids,
used where fire hazards maj be present.
8-7
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8.3.1.2 Reclamation and Treatment . The oils described above are
mainly consumed in mills which have scale pits, some of which are
equipped to capture and remove floating oils. All the process
waters from the primary mills and bar and structural mills receive
additional final clarification and oil removal in the terminal
lagoons. Process waters from the hot strip mills receive filtra-
tion in addition to primary treatment In scale pits. Process
waters from the finishing mill are treated at the terminal treat-
ment, plant. There, free oil is removed by five API gravity oil
separators operating In parallel. Soluble oil is removed by co-
agulation with waste ‘,ickle liquor and sedimentation in three
fl occul ator-cl an fi ers.
American Recovery Compaiy, Inc. (ARC) has been contracted by Unit-
ed States Steel Corporation to collect waste oil by truck from
eleven collection tanks located at the Gary Works. Data obtained
from the Indiana B ard of Health indicate that approximately
12.074,150 1/yr (3,190,000 cal/yr) of waste oil (containing 60%
1120) is collected by ARC from the Gary Works. It is estimated
that of this quantity, 4,733,150 1/yr (1 ,250,500 gal/yr) of waste
oil are reclaimed as fuel oil and 96,520 1/yr (25,500 gal/yr) of
oily sludges are generated. The quantity of fuel oil reclaimed
represents nearly 55 to 60 percent of the total oil, grease nd
hydraulic fluid input. About one percent of the total input is
accounted for in the sludges from ARC.
!3.3.1.3 Discharges to Waterways . NPDES data were not furnished
for the Gary Works. The net oil and grease load discharged in
wastewaters is estimated by U.S. Steel to be 45,360 kg/month
(100,003 lb/month). The net, rather than gross, amount must be
considered in computing material balances because the one or two
parts per million oil present in the intake water, when multiplied
by the volume, becomes a significant factor i the oil bdlance.
8-8
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c• a ‘ ‘ - --
-‘ .“. rn I I qr r ; that a li d ri
‘‘ ‘ ‘a 1 f:’r r-jct rr ç nicn. or that arø p c r
.‘ur ’ r ”1Hr’ “j flni hir , are re(o njZc r1 as a cipilf1car t
‘i . p lc’cc t r— ’. The q antl y of oils ani qrc’aces
leavir -- the Gary or s on prodicts is estlrnat d by the co .any
at ZL’.7c ) k I.x nth ( 0 ,N’O b/month).
C ils ar. ;reaces i r ill ccil’ s r re pnt another significant — -
tc’r 4 l t 1 c ’ lecs t r-1. The oil cnntrnt pf mill scales fr
cc - ’ rclhng m scale pits is r ’orted to reich u to 25 percent
by wei ht. A Indicated fri tne material balance illuctratlon,
,1ll s.alcs are generally either recycled to a sinter plant for
recovery of the -r eta1 or stockpiled for future recovery due to
air ofl . . .iea control equipment or opacity problems caused by the
oils olati:ed iurlnq cintering. At the Gary works, mill scales
ar currently recycled. The larqer chunks are returned directly
to the blast furnace wh1l the ren ining scale is sent to the
sinter plant. The volatized oils are reported to cause a bluish
phr’e at some sinter plants. The slow moving sinter machine flame
front ‘ ,latizes rather than conibusts the oils contained on the
mill ‘cale. The a!nount of oil contained in mill scale Is estimated
by the mill to 6,800 kg/month (15,000 lb/month).
Sludges that are removed from wastewater treatment facilities at
the Gary Works also contain oils and greases. The çuaitlties of
oil and grease in these sludges are reported to be about 181,000
kg/month (400,000 lb/month).
Other loss torus identified In the oil, grease and hydraulic fluid
material balance, 0 nd for which estimates were provided by the
steel mill. include the:
• ‘r , ’ jntS left In container; or lost during handling and
st riqe, (estirated at 5,900 kg/month (13,000 lb/month)).
8-9
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• oil; and reaces contained o trash and debris wnich re
collected and sent to a solid disposal area; (estimated
at 4.540 kg/month (10,000 lb/month));
• quantities volatilized, burned or other .ise consumed in
use in the various steel riakln 9 and shaping processes,
(esti —ated t 23,600 kg/month (52,000 lb/month));
• leaks and spills which are cleaned up and disp’sed of or
leik into the ground, (estimated at 4,540 kg/,. onth
(10,000 lb/month)).
6.3.1.5 MaterIal Balance . Using the data and estimates presen”d
above, an attempt was made to develop an overall material balance
f3r total oils, greases and hydraulic fluids. The material bal-
ance estimate is Illustrated in Figure 8-2. For conversion of
volume t weight units for oils, a density of 0.9 kg/i (7.5 lb/
gal) was assumed. Shown on the material balance 1l ustrat1on are
lb/month values for several terms and an estimate of the percent
of the total input represented by each loss term. Note that no
data was provided for process or rolling oils and consequently
thes. materials are not included in the input term of the material
balance estimate.
8.3.2 South Chicago 1 Illinois
A sunrnary of the major equipment and products associate i with the
United States Steel Corporation - South Chicago Works is presented
in Table 8-2. The Information presented in the table Is a sumary
of data provided in the AISI Directory of Iron and Steel Works .
According to the IISS Steel Indu try In Brief , the steel produc-
tion capacity at the South Chicago Works is 4.76 x10 9 kg/yr (5.25
x 10 b tons/yr). The actual production rate was approximately
3.4 x IO kg/yr (3.7 x io6 tons/yr) during the period for which
lubricant usag data were reported.
8-10
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( ‘
purchased oils.
greases and
hydraulic fluidS
637,310 kg/mo
(1,405,000 lb/mo)
exclusive of process
and rolling oils
reclaimed &
recycled - I
Unaccounted for: 0.6
22.6 j ki/;
on ro1,CtS (53,000 lb/ ’1O)
[ 3.01
on mill scales to
N_____ ro sinrer mr 15.000 t/:o
5,900 kq/ o il.1 I
left in r.ontainers or lost (13 000 lb 1,o)
hi Stora e and handlthg
_________ 4 .540 kci!rno
leaks and spills onto qro . nd, (10,000 lb/mo)
generally cleaned up and disposed [ 0 ]
_________ 23,590 kq/mo
volatilized. bwned jr (52,000 lb/mo)
181 ,440 kq/mo
in sludqes, trash and debris to diSpOSal (400,000 lb/mo)
(2 .5; )
45,360 kq/mo
in wastewaters d$schird O (100,000 lb/mo)
waterways [ 7.1 ]
6,580 kg/mo
none reported sludge d ’ poSal (15,100 lb/mo)
335,670 kg/mo
(740,000 lb/mo)
[ 52.7 1
luDric ants
-S
drained, collected or skiimied
fu I -a
Figure 8-2. MATERIAL BALANCE - UNITED STATES STEEL C0RP(RATIfl 4, GARY
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Table 8-2. UNITED STATES STEEL CORPORATION — SOUTH CHICAGO, ILLINOIS*
EQUIPMENT
8 B1a t furnaces
3 Basic oxygen furnaces
3 Electric arc furnaces
1 ContInuous caster 4 strand - billet
No. Type of Mill Annual Rolling Capacity
1 Slab 1,870,000 3 343• Ø
2 Blooming 1,473,000
3 Structural 1,343,700
1 Rod 700.000 3 470 9 0
1 Bar 254,000
2 Plate i, l73,2 00
10 6,813,900 Net Tons
Capac1t1es of hot strip, cold rolling, cold finish & temper mills
Capac1ties of all primary and secondary mills
0
6.8139 x
* Equipment ard rolling capacity data from AISI Directory of
Iron and Steol Works (1.0 ton 907.2 kg)
8-12
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8.3.2.1 lubricant Purchases . Based on records of actual con-
sumption for the first six months of 1976, the approximate amounts
of lubricating oils, greases and hydraulic fluids are as follows:
Oils 82,600 1/month ( 21,823 gal/month)
Greases 116,400 kg/month (256,663 lb/month)
Hydraulic Fluids 40,000 1/month ( 10,589 gal/month)
Assuming an average density of 0.90 kg/l (7.5 lb/gal) for lubri-
cating oils and hydraulic fluids, the total input of oils,
greases and hydraulic fluids was 2,720,000 kg/yr (5,997,092 ib/yr).
3.3.2.2 Material Balance . Detailed information on lubricant
usage and fate could not be obtained for the South Chicago Works
so a material balance could not be computed. It is an Integrated
steel mill, and the use of lubricants is similar to the Gary
Works which is also an integrated mill. The South Chicago Works
operates a closed loop recycling water system so no oils or
greases are discharged from the plant.
8.4 Inland Steel Company, East Chicago, Indiana
A swmiary of the major equipment and products associated with the
Inland Steel Company, Indiana Harbor Works, is presented in Table
8-3. The information presented in the table is a sum ry of data
provided in the AISI Directory _ of Iron and Steel Works . Accord-
ing to the IISS Steel Industry in Brief the steel production cap-
acity at this Inland Steel facility Is 7.4 x 10 kg/yr (8.2 x
106 tc ”s/yr). The actual producteun rate during 1975 and 1976,
corresponding to the time period for which lubricant purchase
data were reported, was 6.5 x 1O g y— 7.2 x 13 ous/yr).
8.4.1 Lubricant Purchases
A tabulation of purchase records, reported by major equipment
8-13
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Table 8-3. INLAND STEEL COMPANY - EAST CHICAGO, INDIANA *
Equipment
579 Coke ovens - by-product
8 Blast furnaces.
7 BasIc open hearth furnaces
4 Basic oxygen furnaces
2 Electric arc furnaces
1 Continuous Caster 2 strand — slab 1,300,000
1 ContInuous Caster 4 strand - billet ‘ O,OO0
T OO,00O Net Tons
No. Type of Mill Annual Rolling Capacity
3 Blooming (2 primary, 1 secondary)• 4,150,000
1 Slabbing 3,200,000 8,350,000 Net Tons
1 Billet 1,000,000
4 Bar 1,275,000
1 Structural 550,000
1 Plate 280,000
3 Hot Strip 6,500,000 19,483,000 Net Tons
5 Strip — Cold reducing 5,925,000
8 Coil — Cold finishing 4,18R,000
3 Sheet — Cold finishing 76 ,000_
27,833,000 Net Tons
>. apacities_of hot strip, cold rolling, cold finish & temper mills 17.378 10 : .62
Capacities of all primary and secondary mills 27.833 x 10
*Equipment and annual rolling capacity data from AISI Directory of Iron and Steel Works .
(1.0 ton = 907.2 kg)
-------
area, of rolling oils, lubricants, oils and greases; and hydraulic
fluids is presented In Table 8-4. In 1975 approximately
13,512,003 1 (3,570,000 gal) of oils and greases and 1,890,000 1
(500,000 gal) of hydraulic fluids were purchased for the Indiana
Harbor Works. Approximately the same quantity of oils, greases
and hydraulic fluids was used during 1976. AssumIng an average
den;ity of 0.90 kg/i (7.5 lb/gal) for lubricating oils and hydraul-
ic fluids, the total input of oils, greases and hydraulic fluids
was 13,846,000 kg/yr (30,525,000 lb/vr).
8.4.2 Reclamation and Treatment
Inland Steel reported that in 1975 approximately 2,540,000 1
(670,000 gal) of waste oil collected in scale pits and settling
basins were sent to the American Recovery Company (ARC) waste oil
reclamation plant in East Chicago, Indiana and returned as #6
grade fuel oil. Inland Steei has since began operating a vacuum
tank truck for oil recovery purposes, enabling a greater quantity
of waste oils to be collected. The truck is available twenty-four
hours per day and Is typically used to recover oils which previ-
ously were cleaned up with oil absorbent materials and disposed
of in a landfill. Oil accumulating in the turning basin in the
event of an oil spill at the plant or upstream is vacuumed and
sent to ARC. Oil drained from trucks, locomotives and othe.
plant vehicles is sent to the terminal treatment elant and
then to ARC for reclamation. In )075, O 542,000 1 (1,200,000
gal) of waste oil were collected in scale pits and settling basins
and processed by ARC. Inland Steel purchases the #6 fuel oil
which ARC reclaims. In 1976, the Indiana Harbor Works purchased
approximately 9.1 x 106 1 (2.4 x gal) of fuel oil from ARC
or about twice the amount of waste oils sent to ARC. This is
possible because some other waste oil sources from which ARC re-
claims oil do not purchase the resultant fuel oil. In addition
8-15
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Table 8-4.
ANNUAL USAGE OF LU3RICANTS, OILS, \SES. AND
HYDRAULIC FLUIDS AT INLAND STEEL - c AST ChCAGO, INDIANA
Rolling Oils. Lubricants. Oils
and Greases
Area
Hot Strip Rolling Mills
Coldstrip Rolling Mills
Flat and Shape Mills
Steelmaking
Blast Furnaces
Coke Plants
Used
(2,450,000
( 525,000
( 350,000
( 175,000
( 35,000
( 35,000
(3,570,000
gal)
gal)
gal)
gal)
gal)
gal)
gal)
Hydraulic Fluids
Note: These data were estimated by Inland Steel and are
representative of calendar years 1975 or 1976.
Quantity
9,270,000 1
1,990,000 1
1,320,000 1
662,000 1
132,000 1
132,000 1
TOTAL 13,500,000 1
Area
Steelmaking
Coke Plants
Miscellaneous
1,760,000 1
95,000 1
38,000 1
1,893,000 1
TOTAL
( 465,000
( 25,000
( 10,000
( 500,000
gal)
gal)
gal)
gal)
8-16
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to these waste oil r€covery practices, Bentex, an on-site wa:;te
oil reclaimer, recovered approximately 2 650,000 1 (700,000 ijal)
of rolling oils from the cold strip mills [ 180,000 to 22,300 k!
month (400,000 to 500,000 lb/month)].
To verify and supplement the waste oil recovery data provided by
Inland Steel, data was obtained from the Indiana Board of He lth,
and American Recovery Company was contacted for Information. It
was determined that the waste oils from the Indiana Harbor Works
contain approximately 40 percent oil and 60 percent water. TNo
percent of the oil is not reclaimed and appears as sludge from
the ARC process. The Indiana Board of Health data indicate that
during the first nine months of 1976, 4,625,000 1 (1,221,830 gal)
of waste oil, including water from the Indiana Harbor Wurks, were
handled by ARC. Using this data, it was estimated that an average
of about 181,000 kg/month (400,000 lb/month) of #6 fuel oil and
3,600 kg/month (8,000 lb/month) of oily sludge were produced by
ARC from Indiana Harbor Works waste oils. There appeared to be
some discrepancies in the data or estimates of fuel oil reclaimed
by ARC from Inland Steel waste oils. It was assumed by PES that
the 4,540,000 1/yr (1,200,000 gal/yr) of waste oils, which rere
reported by Inland as processed by ARC, actually Included 60 per-
cent water. WIth this assumption it was calculated that about
136,000 kg/month (300,000 lb/month) of fuel oil was reclaimed from
Inland Steel waste oils. For material balance estimate purposes
it was decided to use values 159,000 kg/month (350,000 lb/month)
of fuel oil and 3,200 kg/month (7,000 lb/month) of oily sludge
from ARC.
8.4.3 Discharges to Waterways
Wastewater recycle systems are operated which reduce the total
volume of discharges to the Indiana Ship Canal and Turning Basin.
8-17
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Since the NPDES permits were applied for In 1971, Inland has
eliminated several outfalls. Currently a total of 14 outfalls
are utilized with total maximum oil and grease discharge or con-
centration limits set on each of these outfalls. At the present
time (1976) approximately 1,400 kg/day (3,100 lb/day) of total
oil and grease are discharged, or about 4% of the total oils and
greases purchased by Inland.
A major wastewater recycle project is planned to recycle all re-
mainht g process waters. After the modifications are completed
the net oil and grease discharges will be further greatly reduced.
8.4.4 Other Losses
Significant quantities of oils and greases leave the steel mill
on the p-oducts. Oils and greases become attached to the steel
during rolling and are also applied Intentionally for rust pre-
vention purposes. Most of the oils and greases which become at-
tached to the steel during rolling are removed by acid washing
and pickling prio to the application of metallic coatings. The
waste pickle liquor or washing fluid which contain these oils are
treated, rc cycled or dIsposed of. At the Indiana Harbor Works
582,000 1/yr (153,700 gal/yr) of slushing and coating oils were
appl1i d during 1976. An oil mist spray system Is employed to
apply these coating o,ls. Excess oil and overspray are collectea
beneath in a trough and recircuLt d, minimizing the oil loss or
waste. A relatively small amount cf excess oil does drip off the
coated p’oducts and on to the floor or ground In product storage
areas. N S assumed that 10 percent of the coating oil is lost
by dri ..paga.
8-18
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Oils and greases on mill scales represent another significant
material balance loss term. The oil content of mill scales from
some scale pits is reported to reach up to 25 percent by weight.
Mill scales typically contain from 0.1 to 2 percent. Data pro-
vided by the Indiana Harbor Works indicate that the average oil
content of mill scales is 0.4 to 0.5 percent. The total quantity
of mill scales collected in scale pits at the Indiana Harbor
Works was reported to be 424 x 106 kg/yr (467,000 tons/yr). It
was estimated that approximately 159,000 kg/month (350,000 lb/
month) of oil is contained on mill scales. The sinter plant at
the Indiana Harbor Works is equipped with two baghouses. To pre-
vent air pollution control equipment problems (bag fouling) or
opacity problems only a small quantity of miY scale is recycled
to the sinter plant. Over 99 percent of the collected mill scales
are screened and .t.ockpiled for future recovery. No hydrocarbon
tests have been performed on the sinter plant stack and no
estimates of the hydrocarbon emission rate were available.
Slu es generated in various areas of the plant such as the clan-
fiers and terminal treatment plant at the Indiana Harbcr Works con-
tain oils arid greases. Data provided by Inland Steel i, dicate that
about 175 x 106 kg/yr (193,000 tons/yr) of sludge on a dry basis
is generated. Sludges are landfilled or stockpiled for future use
at the steel mill. The sludges generally cont iin 60 percent water
and are removed from clarifie s by tank truck and hauled to a land-
fill. The three major sources of sludge and the corresponding oil
contents are as follows:
Quantity Quantity Oil
Sludge of Sludge of Sludge Content
Source ( kg/yr) ( Dry Tons/Yr) ( Percent )
6
Blast furnace 64.9 x 10 71,500 0.
Basic oxygen furnaces 46.7 x 1O 6 51,500 0.01
Terminal treament plant 28.6 x 31,500 3.7
140.2 x 106 154,500
8-19
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INPUT TLRMS
(1JIPUT OR LOS ’ !LRMS
purchased oils,
greases and
hydraulic fluids
1.153,850 kg/mo
(2,543,750 lb/mo)
including process
and rolling oils
reclaimed &
recycled
Unaccounted for: 42.9%
39,240 kg/mo
on produds ( 6,5O0 lb/mo)
[ 3.4 J 157,170 kg/mo
to scale pile (346,500 1 b/r o)
_____ j13.6’ ]
on mill scales to sinter plant (3,500 lb/mo)
1 ,590 kg/mo
[ 0.1 ]
left In containers or lost
In storage and handling
leuks and spills onto ground.
generally cleaned up and disposed
volatilized, burned or
consumed In process
in sludges, trash and debris
4,350 kg/no
(9,600 lb/mo) drippacie + ?
[ 0.4 ]
251 .100 kg/mo
to dIsposal (553,600 lb/mo)
[ 21.8”]
42,800 kg/mo
discharged to ( g4, o0 lb/mo)
waterways [ 3.7 ]
3,180 kg/mo
sludge disposal (7,000 lb/mo)
{0.3 ]
co
0
in wastewaterc
158,760 kg/mo
(350,000 lb/mo) fuel
[ 13.8’ ]
Figure 8-3. fIATERIAL BALANCE - INLA 1D STEEL COMPANY, 1ND1A IA HARBOR WORKS
-------
Coke oven, slab caster and miscellaneous sludges, all containing
low oil contents (assume 0.1 percent), account for the remaining
34.9 x 1O (38,500 dry tons/yr) of sludge. From this information,
it was calculated that 242,000 kg/month (533,600 lb/month) of
oils and greases are contained in sludges. This represents ap-
proximately 21 percent of the total input of oils, greases and
hydraulic fluids.
34.5 Material Balance
Reclaimed oil (as fuel oil), oil and grease in wastewater dis-
charges, oil in sludges and on mill scales, and oil lost on prod-
ucts account for 56.7 percent of the tota 1 oil, greases and
hydraulic fluids used annually by Inland Steel at the Indiana
Harbor Works. Figure 8—3 sumarizes the material balance estimate
and loss term data available for the mill. For the cor,versiOn of
volume to weight units for oils, gredses and hydraulic fluids a
density of 0.9 kg/i (7.5 lb/gal) was assumed. Shown on the mat—
erial balance illustration are usage rate values and the pcrcent
of the total input represented by each loss term for which data
was obtained. No data or estimates were obtained for oils, greases
and hydrdulic fluids left in containers or lost in storage and
handling; or volatilized, burned or consumed in process. These
unknown ter s and the uncertainty of other estimated loss terms
could account for the missing 42.9 percent.
8.5 Youngstown Sheet and Tube Company, East Chicago, Indiana
A suninary of the major equipment and products associated with
the Youngstown Sheet and Tube Compdny, East Chicago plant, is
provided in Table 8-5. The information presented in the table
is a surnary of the data provided in the AISI Directory of Iron
and Steel Works . According to the IISS Steel Industry in Brief
8-21
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Table 8—5. YOUNGSTOWN SHEET AND TUBE COMPANY - EAST CHICAGO, INOIANA*
Equipment
237 Coke ovens - by—product
4 Blast furnaces
8 Basic open hea th furnaces
2 Basic oxygen furnaces
No. Ty eof Mill Annual Rolling Capacity
1 Slab 2,604,000
1 BloomIng 1,200,000 4,512,000 Net Tons
1 Billec 708,000
2 Bar 504,000
1 Hot Strip 3,000,000
2 TIn - Cold redulng 764,000 8 216 000 Net Tons
1 Tin — Cold finishing 408,000
1 Sheet - Cold reducing 900,000
1’ 4 Sheet — Cold finishing 2,640,000
T4 12,728,000 Net Tons
‘ ‘Capac1ties of hot tr1p , cold rolling cold finish & temper mills 7 712
= = .61
Capacittes of all primary and secondary mills 12.728 x io6
*Equjp nt and annual rolling capacity data from AISI Directory of Iron and Steel Works .
(1.0 ton 907.2 kg)
-------
‘ 1:!, i C ri pl t is 5. )
,‘ ,r ‘
L ‘r t r’t uca e a ’, r ’c—tri by —ajor der rt’.ent or plant area,
1r’ “Cr 4 in Fnr lj e h,dr ulft fl j arj
c’i.r 1 r1 c ‘c Q u 4 c ‘c r raw ton of ctpøi prjced
L t rr tim level durir.1 l 7 wa
,‘ — tt’iv 10’- 0 c : - city, t totIl Quantities of lube oils,
h d, ulic (l ’ds a d orea s were esti ’ated as ‘ llow :
lube mi ’s 9l ’, ’ fl /‘onth (241,910 ga1I’ nth)
m roc ’ c ard rollir i oFis 1S2, ’C0 l/rr ,nth ( 40,3 0 qal/ricrth)
‘ , rJ l i c f u ids 433 .400 1 ,‘r nth (115 .820 gal / onth)
GrCiSeS 334.350 i/north (220,410 1 b/r ’ionth)
A c’ino 0.9° km’l (7.5 lb/c al) for oils and hydraulic f1uid , the
total lu ’e oil, process oil, crease and hydraulic fluid input to
the plant is l7,450,CCO im’yr (33,473,000 ib/yr).
The t’ata indicated that the hot strip Mill uses roughly 70 percent
of all lube oils, hydraulic fluids and greases purcP.ased at the
East Chico o plant. Youngstown Sheet and Tube has t roken down the
various lubricants used at the East Chicago facilities Into 36
basic specificatloos. Currently 20 different suppliers provide
;mr t! 130 different products that fall into the basic tatego; ies.
p .5.2 Pc’ci ’atioO and Trt:a c nt
haste oil recovery efforts depend upon the type of oil that Is
,ol1ncted. Different types of rr chanical equip ent are utilized
to rc -cve floating and Insoluble oils. In the case of soluble
solut C5. a cheilcal prctreatnent l ’s generally used, followed by
( ‘; ‘I
,— ‘-
-------
T 1e 5. LUBRIrANT USAC E PER RAW TO 1 OF STEEL PRODUCED
Coke Plant
8 ast Furnace
8.0.F.
Slab.
P1 re
Tin M li i
Sheet
H SM
Ljhricitir flils
——
.007 / .017
.004 I .006
.001 / .002
.075 / .125
.026 I .030
.020 / .030
.020 / .045
. 500 / .600
.001 / .002
.005 / .007
.039 / .045
.010 / .025
.010 / .025
. 250 1 .300
.002 / .009
.024 / .033
.010 / .020
.100 / .115
.060 / .075
.005 / .008
.005 / .008
, _ 4OO / .500
.316 / .406
.361
.606 / .768
.687
Note: in addition, 3,000,000 lb/yr (.545 lb/ton) of rolling nil
and 632,600 lb/yr (.1 5 lb/ton) of coating oils are used.
(1.0 qal/ton 4.172 1/1,000 kg)
(1.0 lb /ton 0.50 kg/i ,000 kg)
t4 ydr u 1 ic Flu ids
.001 / .002
Gr asps
TOTAL
AVERAGE
.653 / .855
‘r4
8-24
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rc’chanical or chemical flocculation before removal. The disposal
of collected waste oils is handled in several ways:
• Waste oils are shipped to outside processors for
cleanup and then used as fuel;
• Some waste oils are recycled in the plant fuel
oil system;
• The company has been experimerting with off-site re-
refining of waste oils for reuse ‘s lubricants.
Data obtained from the Indiana Board of Health and American Recov-
ery Company, Inc. indicate that during 1976 about 5,910,000 1
(1,561,500 gal) of waste oil (containing 60 percent H 2 0) was proc-
essed in ARC’s East Chicago facility. It was estimated that 98
percent of the reclaimed oil [ 2,317,000 1/yr (612,100 gal/yr)) is
returned to Youngstown Sheet and Tube as a fuel oil. The sludge
or waste oil unsuitable for reuse is estimated to be about 2 per-
cent or 47,000 1/yr (12,500 gal/yr).
8.5.3 Discharges to Waterways
The NPDES Permit was reviewed to obtain discharge rate data for the
Youngstow’s Sheet and Tube Company, East Chicago plant. A major
wastewater discnarge modification program Is planned ‘ hich will
eliminate four of the eleven outfalls by December 31, 1978. At
the present time, approximately 5,590 kg/day (12,330 lb/day) of
total oil and grease are discharged into the Indiana Harbor Canal
and Inner Harbor. After the modifications are completed, which
wifl enable the segregation of non-contact cooling waters from
process wastewaters, the total oil and grease discharge rate will
be 1,533 kg/day (3,380 lb/day).
8.5.4 Other Losses
Oils and greases on the products, applied intentionally for rust
prevention or picked up during rolling and finishing, are recognized
8-25
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as a significant matt rial balance loss term. Most oils and
greases which become attached to the steel th.ring rolling are re-
moved by acid washing and pickling prior to the application of
metallic coatings. The waste pickle liquor or washis g fluid
which contain these oils, are treated, recycled or disposed of.
At the Youngstown Sheet and Tube’s East Chicago Plant, 286,950
kg/yr (632,600 ib/yr) oi slushing and coating oils were purchased
during 1976. No data was supplied by the null regarding the fate
of these oils, but other mills have indicated that 90 percent of
the purchased coating oils leave on products and the remaining
10 percent drip off.
Oils and greases on mill scales represent another significant mat-
erial balance loss term. Mili scales are dredged from scale pits
and are either 1) recycled to the sinter plant where the oils and
greases are volatilized by the s ow moving flame front during s1n-
tering; 2) stockpiled for future recovery of the metal values due
to the excessive oil content causing air pollution control equip-
ment oropacity problems; or 3) disposed of in landfills. Mill
scales typica 1y contain 0.1 to 2 percent oil by weight although
mill scales with considerably higher oil contents have been reported.
At the East Chicago plant approximately 90.7 x 106 kg (100,000 tons)
of mill scale are recycled annually through the blast furnace or
the sinter plant. The average oil content of this mill scale is
reported to vary between 0.15 to 0.40 percent. From this data it
was estimated that roughly 20,9C0 kg/month (46,000 lb/month) of
oil is accounted for on recycled mlii scale. It is thought that
mill scales recycled to the sinter plant are volatilized rather
than combusted. No stack test data on hydrocarbon emissions from
the sthter plant are available. An electrostatic precipitator is
installed on the sinter breaker stack. Oils on mill scales recy-
cled to the blast furnaces are thought to be combusted. For
8-26
-------
riaterial balance estimation purposes, it was assumed that half of
these mill scales are sintered and half are recycled directly to
the blast furnace.
An additional 5.4 x kg/yr (6,000 tons/yr) of mill scale is
stockpiled for future use due to excess oil content. This mill
scale has a reported average oil content of 5 to 9 percent. Ap-
proximately 31,750 kg/month (70,000 lb/month) of oil are accounted
for by stockpiled mill scale.
Sludges generated in various areas of the plant can contain signif-
icant quantities of oil. Youngstown Sheet and Tube reported that
approxImately 27.2 x 106 kg/yr (30,000 tons/yr) of sludge are
removed from the wastewater treatment facilities at the East Chi-
cago plant. The average oil content of this sludge is 30 percent.
This sludge, containing 680,000 kg/month (1,500,000 lb/month) of
oil, is disposed of at various off-site landfill locations.
Other loss terms identified in the oil, grease and hydraulic fluid
material balance include:
• amounts left in containers or lost during handling
and storage;
• oils and greases contained on trash and debris which
are collected and sent to a solid disposal area;
• quantities volatilized, burned or otherwise consumed
In use in the various steel making and shaping processes;
• leaks and spills on to the floors or grot’nd
which are cleaned up a :d disposed of.
No data or estimates of these miscellaneous loss terms could be
provided by Youngstown Sheet and Tube.
8.5.5 Material Balance
Using the data presented above, an attempt was made to develop
an overall material balance for total oils, greases and hydraulic
8-27
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fluids. çuantlfylng each of the loss terms Identified in Figure 8-4
is a difficult task. Estimates were made based on data obtained
from several sources, including Youngstown Sheet and Tube Company,
American Recovery Company, Indiana Board of Health, and EPA Region V.
For the conversion of volume to weight units for oils, a density of
0.9 kg/i (7.5 lb/gal) was assumed. Shown on the material balance
Illustration are kg/month values for several terms and the percent
of the total input represented by each loss term. loss estimates
account for 75.9 percent of all purchased lubricants. The remaining
24.1 percent could be accounted for by lubricants left in containers,
spilled onto the ground, volatilized or burned, and by uncertainties
or errors In the estimated loss terms.
8.6 Bethlehem Steel Corporation, Sparrows Point, Maryland
A suninary of the major equipment and products associated with the
Bethlehem Steel Corporation Sparrows Point facility is provided in
Table 8-7. The information presented in the table is a suninary of
the data provided In the AISI Directory of Iron and Steel Works .
According to the IISS Steel Industry in Brief the steel production
capac 4 ty at Sparrows Point is 6.8 x 10 kg/yr (7.5 x 106 tons/yr).
The actual production rate for the first six months of 1976, cor-
responding to the time period for which lubricant usage data were
reported, was approximately 418 x io6 kg/month (461,270 tons/month)
or 5.0 x l0 kg/yr (5.5 x 106 tons/yr).
8.6.1 Lubricant Purchases
Lubricant usage data, reported by major department or plant area,
are prescnted in Table 8-8. A total of 609,000 1/month (161,000
gal/month) of oils and hydraulic fluids, and 149,000 kg/month
(329,000 lb/month) of greases are utilized. Of the 609,000 1/month
(161,000 gal) of oils and hydraulic fluids, 40 percent (242,000
1 (64,000 gal)) are hydraulic fluids and 60 percent (365,600 1
8-28
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INPUT TERMS
cuipul OR EUSS TEkMS
purchased oils.
greases and
hydrauhc fluids
1,454.290 frg/mo
(3,206,100 lb/mo)
including 113,400 kg/mo
(250,000 lb/mo) of roll-
ing oil and 23,910 kg/mo
(52,717 lb/mo) of
coating oils
reclaimed &
recycled
Unaccounted for: 24.1%
21 .550 k j/mo
on products (47,503 lb/u)
[ L5 ] 31,750 kj/iiio
to scale pile (70,000 1 b/no)
on mill scales [ 2.2 ]
to Sinter plant
and blast furnace
left in containers or lost
in Storage and handling
2,350 kq/mo
leaks and spills onto ground,
generally cleaned up and dIsposed (5,200 lb/mo) + ?
[ 0.2%]
volatilized, burned o—
consuesed in process
in sludges, trash and debris
In waStew terS
20,870 kq/mo
(46,000 lb/mo)
[ 1 .4 ]
680,400 kgJrrio
to dIsposal (1 .500.000 lb/mo)
[ 46.8%]
170,100 kg/mo
discharged to (375,000 lb/mo)
waterway $
[ 11.7%]
146,630 kg/mo
1 After December 31, 1918]
lb/mo)
3,630 kg/mo
sludge disposal (8,000 lb/mo)
[ 0.2%]
r..a
‘C,
173,550 kg/mo
(382,600 lb/mo) fuel
[ 11.9%)
Figure 8-4. tIATERIAL BALANCE - YOUNGSTOWN SHEET AND TUBE COMPANI, EAST CHICAGO
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TABLE 8-7. BETHEHEM STEEL CORPORATION - SPARROWS POINT, MARYLAND*
Equipment
757 Coke ovens - by-product
10 Blast furnaces
7 Basic open hearth furnaces
2 BasIc oxygen furnaces
No. Type of Mill Annual Rolling Capac1t
2 Slab 5,320,000
2 Blooming 2,910,000 10,300,000 Net Tons
2 Billet 2,070,000
2 Rod and bar 758,000
2 Plate 1,160,000
2 Hot strip 5,210,000 1
5 Tin — Cold reducing 2,040,000 J P,UU3,0VU Net •ons
2 Sheet — Cold reducIng 1,930,000
4 Sheet — C1d finish — temper 1.360,000
4 TIn - Cold finish - temper 1,425,000
27 24,183,000 Net Tons
CapacitIes of hot strip, cold rolling, cold finish & temper mills 11.965 x io6
________________________________________ = n49
Capacities of all primary and secondary mills 24.183 x 10
*Equlpment and annual rolling capacity data from AISI Directory of Iron and Steel Works .
(1.0 ton 907.2 kg)
-------
Table 8-8. AVERAGE MONTHLY CONSUMPTION DATA FOR
BETHLEHEM STEEL — SPARROWS POINT
Oils and
Plant Area Hydraulic Fluids Greases
Coke Ovens 2,000 3,000
Blast Furnace Section 2,000 13,000
Steelmaking Section 2,000 12,000
Primary Mills 5,000 90,000
Plate Mills 7,000 50,000
Hot Strip Mills 48,000 107,000
Cold Sheet Mills 22,000 10,000
Tin Mills 43,000 24,000
Rod and Wire Mills 12,000 3,000
Pipe Mills 4,000 5,000
Shops, Etc. 14,000 12,000
TOTAL 161,000 Oal.* 329,000 lb.
*Note: 40% HF — 64,400 gals.hydraulic fluids
60% Oils — 96,600 gal, oils
161,000 gals.
It was estimated by PES that 55,000 gal/month of fresh or makeup
rolling oil is used in addition to the oils reported above.
(1.0 gal = 3.785 1)
(1.0 lb = 0.4536 kg)
- 8-31
-------
(96,600 gal)) are oils. Also rolling oil is used which is reclaimed
and recycled. The exact amount of fresh rolling oil makeup is un-
known but approximates 208,000 1/month (55,000 gal/month). Assuming
0.9 kg/1 (7.5 lb/gal) for o 1 ls, the total oil, grease and hydraulic
fluid Input to the plant is 884,000 kg/month (1,949,000 lb/month)
or 10,610,000 kg/yr (23,388,000 ib/yr). Primary and secondary
shaping and rolling mills account for about 0 percent of the oils,
greases and hydraulic fluids used at the Sparrows Point facility.
8.6.2 Reclamation and Treatment
Waste oil recovery efforts includ! the use of several oil skimers
on scale pits, at various lecations along the wastewater canal and
In the Humphreys Creek Wastewater Treatr ent Plant. American Recov-
ery Company, Inc. and PORT, Inc. beth process waste oils for the
Bethlehem Steel plant. ARC converts the waste oil into fuel oil,
and PORT reclaims roiling oil. Cold strip and tin mill rulling sol-
utions are collected and pumped to PORT for reclamation of rolling
oils which are returned for reuse. Approximately 406,000 kg or
452,000 1/month (895,550 lb or 174,641 gal/month) of rolling oils
were applied in the cold strip and tin mills. [ 97,300 kg/month
(214,548 lb/month) applied at the cold strip mill and 496,800 kg/
month (1,095,260 lb/month) applied at the cold tin mill)). From
these data it appears that about 208,000 1/month (55,000 gal/month)
of fresh rolflng oil are required.
Plant waste oil boxes, used for collecting floating waste oils
drained and collected throughout the plant or recovered from the
various scale pits and oil skiim*rs, are accumulated in a central
v st oil pit from which oils are reclaimed by American Recovery
Company (ARC). An average of 122,000 kg or 135,700 1/month
(268,950 lb or 35,860 gal/month) are reclaimed by ARC and returned
as fuel oil to the plant fuel system.
8-32
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Final wastewater treatment at the Huriphreys Creek WWTP includes:
pH cor,trol, aeration, sedimentation, sludge removal, final oil re-
moval (skininers), and.firal aeration before discharge to Bear Creek.
Several opportunities for floating waste oil recovery are provided
at Sparrows Point. Oil ski9lllers have been installed at scale pits
and at fixed floatinq baffles installed in the wastewater canal.
This effectively reduces the total oil and grease load on the Humph-
reys Creek WTP. Within the plant, waste oil containers are used to
handle leaks and spills thus reducing the amount of oils entering
the wastewater system.
8.6.3 Discharges to Waterways
Discharge data for the three outfalls for which total oil and grease
sampling cnd analysis is performed was obtained from the Maryland
Departnent of Water Resources. Grab samples taken once per week at
Outfall 013, which services the hot forming section of the plant,
contained an average o’ 564 kg/day (1244 lb/day). The primary mills
discharging ;nto Outfall 013 have been diverted to the treatment
plant which discharges the Outfall 015. Outfall 014 handles wastes
from the rod mill, wire mills, hot forming, cold rolling, pickling
and coating processes and contains an average of 2995 kg/day (6604
lb/day) (based on monthly data from July 1975 to September 1976.).
Whfle mass emission rate data for Outfall 017 was not available, the
total oil and grease concentration averaged 6.5 mg/i. Gutfall 017
services tne garage and boiler rooms. Based on average flow rate
data, it is estimated that Outfall 017 discharges about 28.5 kg/ day
(62.7 lb/day) of total oil and grease. The total average oil and
grease discharge rate from these three outfalls is 3590 kg/day (7910
lb/day or 237,300 lb/month). A total of 15 outfalls discharge water
from the Beth1 ,iem facility, and the total oil and grease discharge
rate for the entire plant is estimated at about 113,000 to 136,000
kg/month (250,000 to 300,000 lb/month). This represents roughly 13
to 15 percent of the total oils, greases and hydraulic fluids input
to the entire steel “ill.
8-33
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8.6.4 Other Losses
As mentioned previously, significant quantities of oil and grease
leave the steel mill on products. Oil and grease become attached
to the steel during the rolling process and are also applied intent-
lonally for rust prevention. At the Sparrows Point plant Bethlehem
Steel estimates that in the cold-strip mill, 75 percent of the
38,600 /month (10,200 gal/month), or 29,000 1/month (7650 gal/month),
of slushing oils leave on products. The remaining 25 percent Is
lost as drippage. The following estimates of oils and preservatives
were provided for the cold-tin mill:
1/Month ( GaljMonth )
Alkaline lines 3,400 ( 900)
#8 Chrome line 4,350 (1,150)
#6 Cleaning Line 3,000 ( 800)
Halogen Lines (Tin Plating) 6,000 ( 1,750 )
Cold Tin Mill Total 17,400 (4,600)
The total quantity of oils contained on products at Sparrows Point
was estimated to be 46,400 1/month (12,250 gal/month) or 41,675 kg/
month (91,875 lb/month).
MIII scale collected from various scale pits is recycled to the
sinter plant equipped with high energy scrubbers. Oils and greases
contained on the mill scales are volatilized during sintering and
either condensed and captured by the scrubber or are emitted to the
atmosphera. At the Sparrows Point plant, mill scales collected from
various scale pits are sent to temporary storage and subsequently
recycled to the sinter plant. Only the very oily mill scales are
not recycled to the sinter plant. Approximately 13.6 x io6 kg/month
(15,000 tons/month) of mill scale, with an average oil content of
0.15 percent, is sintered. The 20,400 kg/month (45,000 lb/month) of
oil in mill scales is volatilized. Stack test data fror the sinter
plant Indicate that about 20.4 kg/hr (45 lb/hr or 32400 lb/month)
8-34
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of hydrocarbons are emitted. It appears that approximately 72 per-
cent of the hydrocarbons resulting from volatized oIs in mill scale
are emitted to the atmosphere. The remaining 28 percent are either
condensed and captured by the high energy scrubbers or combusted in
the sinter plant.
Sludges generated in various areas of the plant and by the waste oil
reclaimers contain oils and greases. The following sumary of quan-
tities of sludges containing oils was provided by the steel mill:
Humphreys Creek Waste 3
Water Treatment Plant 118 x 10 kg/day 130 T/day
Cold Strip Mill 18 x lO kg/mo 20 T/mo
Cold Tin Mill 27 x. lO kg/mo 30 7/mo
Pipe Mill 9 x 1O 3 kg/mo 1 T/mo
Wire and Rod Mills 9 x lO kg/mo 1 T/mo
PURl 454 x l0 kg/yr 500 T/yr
American Recovery 27 x l0 kg/mo 30 T/mo
It was reported that the oil content of these sludges ranged from
five to twelve percent .ith an average oil content of ten percent.
All sludges are disposed of by landfill. The wastewater treatment
p’ant sludges contain about 353,800 kg/month (780,000 lb/month) of
oil while the other plant sludges accounL for an additional 4,700
kg/month (10,400 lb/month) of oil. The oils in waste oil reclaimer
(PURl and ARC) sludges is estimated to be 6,490 kg/month (14,300 lb/
month). The total quantity of oils in all steel mill and waste oil
reclaimer sludges is 365,000 kg/month (804,700 lb/month).
Other loss terms identified in the oil, grease and hydraulic fluid
material balance include:
• amounts left in containers or lost during handling and
storage;
• Oils and greases contained on trash and debris which are
collected and sent to a solid waste disposal area;
8-35
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o quantities volatized, burned or otherwIse consumcd in use
In the various steel making and shaping processes;
• leaks and spills o the floor or ground which are generally
cleaned up and disposed of.
While data for these various loss terms is not available, Bethlehem
Steel did provide a tabulation by plant area of the percentages of
maintenance oils and hydraulic fluids accounted for by several loss
terms. The tabulation does not include oils applied on products or
rolling oils reclaimed by PORI. For each plant area, such as the
tin mills, Table 8—9 provides an estimation of the distribution of
loss terms or fate of the lubricants and hydraulic fluids used by
the plant area. The last entry, labeled “Plant,” provides a general
or overall accounting of loss terms. The steel mill has indicated
that for the entire plant, approximately sixty pe’cent of the maint-
enance oils and hydraulic fluids are contained in wastewaters or mill
scales. Fifteen percent of the oils and hydraulic fluids are collec-
ted and sent to American Recovery Company. Oils in trash are handlert
as solid waste and account for 15 percent. Of the remaining oils,
three percent Is lost via leaks and spills which are cleaned up and
disposed of, five percent is left in containers, and two percent is
volatized, burned or consumed in process. The lubricants and hydraulic
fluids left in contaii rs rnuy be removed or combusted by a barrel re-
clairn r, returned to the lubricant supplier or discarded with trash.
8.6.5 Material Balance
The data obtained ir response to the PES questionnaire, information
noted during a plant visit, discharge !ata extracted from files at
the Maryland Department of Water Resources and estimates based on
data collected at other steel mills included in the survey were used
to develop a material balance for oils, greases and hydraulic fluids
for the Bethlehem Steel Corp., Sparrows Foint Plant. As illustrated
in Figure 8-5 input and output or loss terIT s are reported on a mass
basis. Also shown on the material balance illustration’ Is the
percent of the total input represented by each loss term.
8-36
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• “ t S flF M, ‘ A’ CE lu3PIcr. 4Ts
•• ‘ -• - r2 ’n- r1 r
V r f ..J

7 J - - -
RL ct f(Jt. ( P
Stee1’ ik ‘
Prr ary gills
Mate Uj1
Hct “tr’ l1
Cold S!eet M ill
Ith Mills
Rice Mill
Rod and Wire Mill
1 )
- is
- 10 25
51 20 20
70 12 15
90 5 3
50 25 20
60 20 15
20 40 30
85 7 5
10 35 45
20 1C
15 5
15 5
5 4
- 3
— 2
• 5
- 5
5 5
- 3
5 5
tate 3ories 1 3 4 5
1. In Waste Water and Mill Scale-
2. Waste 011 to rerican Pecovery—
3. In Trash; 1 ind1ed as Solid Waste
4. leaks and Spills (cleaned up & disposed)-
5. left Zn Cuntjiners
6. Vo1atize i, L urncd. Etc.
S
45
Plant 60 15 15 3 5 2
C
6
8-37
-------
T [ R
urcP ased il .
et 4
P jdriu ç flwU
TOTAl. 884,070 kg/mo
(1,949,000 lb/mo)
TMs Includes
187,110 kg/mo
(412,500 lb/mo)
of ro lflng oils
rec1a mtd I
recycled
41 ,65 kq/mc
or $utS ,825 lblrncr)
(4.7 J
to r I
on iU s a es
‘ . 0 5Ir ,tav
4.2 2CQ k’ / o
th C x t.*rpr% or lost (97 450 lb’mo)
In itora e and lond1 lag
26.520 kq/rno
leaks ard ptfl Onto gfO4J t• (Sd 1/0 lb/mo)
generally cleaned p and d 4d
17.6 0 kq!r
wolatlll:ed. b sraed or (38,980 1b/rn . ))
cos sumed In YO(eSS (2 ]
ta slI4dgeS, trash and debr $
5.500 kg/1E
+ ( l ’ . .l25 lb/rno
20 .410 kP/!no
(4 .O O
r . 1
Qf tnis, 5.720 k I
rn.) (t2,€00 lt !Te))
is ccmbtfte 1 or
c .I2turedl
124 .740 kq!i’o
(275,000 lb/rno
l4. t1
132,610 kg/mO
(292,350 lb/mo)
(1 5 ) 35a ,530 kg/mo
to ulsposal 4. (790,400 iD/mo)
[ 40 .6 ]
dis har d to
.a t.CWEJS
Iludge disposal
6,430 kg/me
(14,300 l /mno)
C0.7t]
in asteøaters
122,000 kg/i io
(268,950 lb/mo) ‘ ael
(13. .8 )
Figure 8 -5. MATERIAL BAtANCE - BETHLEHEM STEEL CORPORATION, SPARROWS POINT
-------
PES and Bethlehem Steel estimates were used to complete the balance.
The loss terms or categories for which Bethlehem Steel provided es-
tim tes were not the same as in the PES material balance estimate.
For cxa ple, oil losses in wastewater and mill scales are estimated
as one term by the steel mill. The waste oil to ARC term agrees with
infor- aticn ‘vaiIable to PES. The oil In trash quantity reported by
the steel mill apparently does not include oily sludges. Process
and rolling oils were tiot incluoed in the Bethlehem Steel estimates.
Nevertheless, the estimates provided for losses as icaks and spills,
in trash, left in containers, and volatized or burned in process ap-
pear reasonable and were used by PES in the material balance estimate
provided in Figure 8—5. Totalling the loss term percentages calcu-
lated by PES, and including the four percentages estimated by the
steel mill, a value 0 f 102.2 percent Is obtained. Unce ta!nty In
calculated loss terms, such as oil in sludges, wastewater or on mill
scales, could easily account for the apparent 2.2 percent error.
5 ,7 Jones and 1au Hn Steel Corporation 1 Aliguippa, Pennsylvania
A summary of the major equipment and products associated with the
Jones and Laughlin Steel Corporation, Altquippa Works, is presented
in Table 8-10. The information presented in the table is a summary
of data provided in the AISI Directory of Iron and Steel Works .
According to the IISS Steel 1ndust y in Brief the total steel pro-
duction capacity at Aliquippa is 3.48 x 10 kg/yr (3.84 x io6 tons,’
yr). The actual production rate during 1975, corresponding to the
time period for which lubricant usage data were reported, was
1.8 x 10 kg/yr (2 x io6 tons/yr).
8.7.1 Lubricant Purchases
A list of lubricants, oils, greases 1 hydraulic fluids and protective
:oatings, including quantities purchased for use at the Aliquippa
8-39
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TABLE 8- O. JONES P140 LAUGHLIN STEEL CORP. — ALIQUIPP . PENNSYLYN4IA
Equipment
271 Coke ovens by-product
5 Blast furnaces
3 Basic oxygen ftirnace’
1 Continuous caster — 6 strands - billets
No. Type of Mill Annual Rolling Capacity
1 Blooming 2,115,000
2 BIllets & sheet bars 1,810,000 4,488,400 Net Tons
1 Round 563,400
1 Bar 409,000
1 Rod 433,000 3 705 200 N T
1 Hot strip 1,536,003 P et OflS
5 Sheet or tin 1,327,200
12 8,193,600 Net Tons
‘ 5 apac1t1es of hot strip, cold rolling, cold finish & temper mills
,Capac1t1es of all primary and secondary mills
2.8632 x l0 ’
b a 35
8.1936 x 10
*Equlpmant and annual rolling capacity data from AISI
Directory of Iron and Steel Works .
(1.0 ton a 907.2 kg)
8.4t)
-------
Works in 1975 is presented in Table 8-11. These materials are used
throughout the plant. Thç usage data provided by the mill did not
appear to Include rolling oil. PES estimated that 37,850 1/month
(10,000 gal/month) of rolling oil Is used at Aliquippa. The total
plant usage amounts to approximately 5,408,000 kg/yr (or 11,922,000
Ib/yr) with the purchases of the three major users of lubricants
within the Aliquippa Works reported as follows:
Annual
Lubricant
Purchases Usage Rate in
In Thousands of kg/1000 kg lb/ton
&eoartment kg lb of Steel Processed
Strip Mill 460 (1,016) 0.55 (1.11 )
Rod and Wire 435 ( 960) 0.98 (1.97 )
Tin Plate 751 (1,656) 0.37* (0.74*)
*Nota: The usage rate value for the Tin Plate Department is
based cn multiple processing steps, Including pickling,
cold ro1lin annealing and tin plating. A given piece
of steel product may be subject to more than one
processing step.
8.7.2 Reclamation and Treatment
Oils, lubricants and fluids used in vehicles and tractors at the
steel mill are genera11 ’ drained and collected. R’latively small
quantities would be expected to be consumed (volatized) in use,
oxidized or leak to the floor or ground. Annual purchases of these
materials total 67,750 1 (17,900 gal) or 60,900 kg (134,250 Ib).
For material balance development purposes it was estimated that
approximately 80 percent of these lubricants are drained and col-
lected for reclamation or disposal. Half of the remaining 20 per-
cent was assumed to be consumed or lost in use, with the remainIng
amount leaking from the vehicles or lost during changing.
8-41
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Table 8—fl. LUBRICANT PURCHASES - 1975
Oils
Lubricating Oils 275,000 gal.
Motor 011 15,000 gal.
Dexron, Brake Fluid & Penetrating Oil 1,800 gal.
Transmission Lubes 1,100 gal.
Soluble Oils 61,000 gal.
Cutting Oils 153,000 gal.
Pipe Coating Oils 154,000 gal.
RistPreventat lves 18,200 gal.
Slushlng Oils 5,200 gal.
684,300 gal.
Greases
Wire Drawing Compounds 16,000 lb.
A.P.I. Modified Thread Compounds 97,000 lb.
E.P. Gear Lubricants 90C 000 lb.
Greasss 2,700,000 lb.
Casting Lube 9,200 lb.
3,722,200 lb.
Hydraulic Fluids
Hydraulic Oils 220,000 gal.
Fire Resistant ‘luids 69,000 gal.
289.000 gal.
Note: PES estimated that in addition to the above oils,
10,000 gal/month of rolling oil is used.
(1.0 gal 3.765 1 and 1.0 lb 0.4536 kg)
8-42
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It was reported that a study will be made to determine if waste oil
collected in scale pits and various oil skinning locations can be
reclaimed and returned as fuel or lubricating oil. Currently 45,420
1/month (12,000 gal/month) of hydraulic and lubricating oils are col-
lected and centrifuged for r use in certain tin, rod and welded tube
mill areas. Approximately ‘,140 1/month (300 gal/month) from the
machine shop steam cleaning operation is collected and forwarded to
an oil reclaimer. The five-stand tandem cold mill utilizes a recycle
water system. Fats skimed from tanks in this system are delivered
to an oil recovery unit which produces oil which is recycled to the
pickle line oiler and also oil that is sent to an outside purchaser
(a waste oil scavenger).
According to information provided by PORI, recovery equipment to re-
claim rolling fats was installed and is operated on a fee basis by
PORI on the 5-stand tin mill (direct application lubrication). The
oil recovery system was designed to handle a water flow of 760 1/mm
(200 GPM) and recover 68,000 kg/month (150,000 lb/month) of rolling
oils. The PORI system is capable of returning 27,000 kg/month
(60,000 lb/month) to the mill. The water is recirculated to the tin
mill with a blowdown to the chemical rinse treatment plant. Reclaimed
rolling oils are used In the pickle l 4 ne oiler.
8.7.3 Discharges to Waterways
Wastewater treatment is performed in two separate systems illus-
trated, in Figures 8-6 and 8.7. One treatment system (see Figure
8—6) is currently treating wastewaters from the 35.6 cm (14-inch)
mill, hot-strip mill and welded-tube mill. Future plans for this
system call for handling wastewaters from the bar, billet and
blooming mills and seamless and round mills. Oil skinners to
remove floating oil have been installed at the clarifiers and
8-43
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AU UIPPA WORKS
COM $NED TREATMENT OF HOT MILL SCALE PIT DISCHARGES
EnvIro m.ntoI Control Division
Nov.mb.r 8, 1976
Bx& 44 ”
Biflet Blooming
MIII MIII
1
I I
S S
_ _ .1 — — _ J —
1’
———_ Future
Figure 8-6. COMBINED TREATMENT OF HOT MILL SCALE PIT DISCHARGES
AUQUIPPA WORKS
-------
AUQUIPPA WORKS
CHEMICAL RINSE TREATMENT PLANT
Environmental Control Dlvhlon
November 8, 1976
U i
4000 GPM
Figure 8-7.
CHEMICAL RINSE TREATMENT PLANT
-------
certain scale pits. The second tr . atment system (Figure 8-7) is
a che iiical rinse treatment plant to treat discharges from var 4 ous
finishing mill areas. Included are rinse water from pickling
units, blowdown from the tandem cold 1 n111 recycle system, caustic
cleaning line discharges, tin line rinse waters and miscellaneous
sump discharges. Much of the oil collected in this system is dis-
posed of with the sludge from the plant.
NPDES Discharge Monitoring Reports (DMR’:) for 1976 were obtained
from EPA Region I II and reviewed to determine the average daily net
oil and grease discharge rate. For tne outfalls for which oil and
grease discharges are reported, the total net daily average oil and
grease discharge was l478/ /day (3258 lb/day) or approximately
44,400 1/month (97800 lb/month).
8.7.4 Other Losses
Significant quantities of oil and grease have the plant on product
intentionally or otherwise. The type of lubricants likely to be
found on the product include:
pipe coating oils 582,900 1/yr (154,000 gal/yr)
cutting oils 579,000 1/yr (153,000 gal/yr)
thread compounds 44,000 kg/yr ( 97,000 ib/yr)
rust preventatives 68,900 1/yr ( 18,200 ga’I/yr)
slushing oils 19,700 1/yr ( 5,200 gal/yr)
For material balance estimation it was assumed that 90 percent of
these materials leave the plant on the product. The remaining
amount would be expected to appear as leaks, be lost in use, or
attached to cutting fines.
Mill scales generaui contain a significant qu ntity of oil and grease.
These mill scales are currently recycled to the sinter plant where a
large portion of the oils and greases are volatized and either
8-46
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condensed and captured by the air oollution control equipment or
discharged to the atmosphere. Multiclones are installed and opera-
ted to clean the slnter plant waste gas stream and wet scrubbers
clean emissions from other sinter plant sources. Most of the vola-
tized hydrocarbons resultIng from the recycling of mill scales con-
taming oil are thought to pass through the control devices to the
atmosphere. It was reported that 9.1 x io6 kg/month (10,000 tons/
month) of mill scales are generated at the Aliquippa Works. Mill
scale data from other steel mills indicate that the oil content typ-
ically ranges from 0.1 to 2.0 percent. Assuming an average oil con-
tent of 1 percent, it Is st1mated that 90,700 kg/month (200,000
lb/month) of oils are contained on mill scales. It is thought that
most of the oil is volatized and emitted to the atmosphere.
Sludges removed at the wastewater treatment facilities contain oils
and greases. It was reported that 3.2 x io6 kg/month (3,500 tons!
month) of sludges are removed from the wastewater treatment facili-
ties. For material balance development purposes it was assumed,
based on data from other steel mills, that the oil content of these
sludges is approximately 5 to 10 percent of 159,000 to 318,000 kg/
month (350,000 to 700,000 lb/month) of oil. The sludges from the
treatment plant which receive scale pit discharges are sold and the
remaining sludges are disposed of by landfill methods. The average
value, 238,000 kg/month (525,000 lb/month), was used in the material
balance estimate.
Other loss terms identified in the oil, grease and hydraulic fluid
material balance include:
• amounts left in containers or lost during handling and
storage;
• oils and greases contained on trash and debris which are
collected and sent to a solid waste disposal area;
• quantities volatized, burned or other.4ise consumed in
use in the various steel making and shaping processes;
8-47
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• Leaks and spills on to the floor or ground which are
generally cleaned up and disposed of.
8.7.5 Material Balance
Using the data presented above, an attempt was made to develop an
overall material balanc2 for total oils, greases and hydraulic fluids.
The material balance estimate is illustrated in Figure 8-8. or
the conversion of volume to weight units for oils, a density of 0.9
kg/i (7.5 lb/gal) was assumed. Shown on the material balance illus-
tration are kg/month values for several terms and an estimate of the
percent of the total input represEnted by each loss term. The esti-
mated loss terms account for 102 percent of all lubricant purchases.
Estimates of the other loss terms (the four terms called out with
bullets above) are not included but are expected to account for
roughly 10% of the total input. Oils drained, collected and proc-
essed by the waste cii scavenger are also not shown on the material
balance estimate Illustration. It app rs, based on data from other
mills, that the oil on products aid in sludges terms are over esti-
mated. The uncertainty in these and the other oss terms could
result in the material balance errors.
8.8 Republic Ste Corporation, South Chicago, Illinois
A sumary of the major equipment and products associated with the
Republic Steel Corporation, South Chicago Works, is provided in Table
8-12. The Information presented in the table is a sumary of data
provided in the AISI Directory of Iron and Steel Works . According
to the IISS Steel Industry in Brief the steel production capacity at
the South Chicago facility is 1.8 x 10 kg/yr (2.0 x io6 tons/yr).
During 1975, the year for which lubricant usage data was reported,
actual steel production was approximately 1.4 x 10 kg/yr (1.5 x 106
tons/yr).
8-48
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INPUT TLRM .
(IJTPIJI Oil LQ T1i i4
TOTAL 4E0,650 kg/mo
(993,490 lb/mo)
purchased oils,
greases and
hydraulic fluids
416,630 kg/mo
(918,493 lb/mo) plus
ôfl estimated
34,020 kg/mo
(75,000 lb/mo) of
rolling oils
reclaimed &
recycled
s le pile zero
0,720 kq/mn
to sinter plant (200 ,01jJ 1 bjr:o)
?0. 1:]
238,140 kg/mo
to dl.pulal (525 000 lb mo)
[ 52.8 ]
44,360 kg/ T;o
discharged (97 ,R0O 1b/n )
waterways
[ 9.8
sludge disposil ?
87,600 kg/mo
n prodJ ts (193,125 lb/no)
fl).4 ]
on mill sc le —
— left In Contdir,ers o lost
in storage ar.ii handling
leaks end spills onto orcund,
generally c’.eaned p and disposed
solat lized. burned or
consumed in process
n sludges, trash and debris
in wasteWaterS
(reclaimed rolling oil
uced on pickle line)
a
? fuel
Figure 8-8. MATERIAL BALANCE - JONES AND LAUGHLIN STEfl C0RP0 ATI0N, ALIQUIPPA
-------
TABLE 8-12. REPUBLIC STEEL ORPOR.ATION — SOUTH CHICAGO, ILLINOIS*
Equipment
75 Coke ovens by-product
1 Blast furnace
4 Basic open hearth furnaces
3 Electric arc furnaces
Type of Mill Annual Rolling Ccapacity
1 Bloo’ning 1,860,000
1 Billet 300.000
1 ainet & bar 1,027,000
3 Bar 1,365,000
1 Rod 165,000
7 4,708,000 Net Tons
“ 5 Capacities of hot strip, cold rolling, cold finish & temper mills
‘VCapacities of all primary and secondary mills
6 =0
4.708 x 10
*Equip1 nt and annual rolling cepacity data from AISI Directory
of Iron and Steel Works (1.0 ton = 907.2 kg)
8-50
-------
9 1 “r’- r ’ r)r - -1 .;
ç i1c , anri hy ra jlic fluid; purcP ased during 975
3r4 5’1 in Ti ’Te -l3 t’i c uantity rchasPd and use. A to-
“ ((7Q. ) ib) of grease and 1,742,000 1 or 1,566,000
( 3,19? ‘ l or 3 ,4S1 ,44tJ Ib) of oils and hydraulic fluid; were
rc2; rted. Of t l,74,TI) 1 (460,19? gal) of oils and hydraulic
f ij, rt- xi—ately l.C€4, 0 1 (281,055 gal) (6l ) were oils and
1 (1 Q,l37 qal) (3 ) were hydraulic fluid;. It was reprrted
t - durin 19 5 126,500 1 (33,425 gal) of fi,e—resistant hydraulic
flu h were used. This represents nearly 20 pcrcent of the total
quantity nf hydraulic fluids used at the South Chicago Works. A
total of a rroximately 1,874,000 kg (4,131,000 lb) of oil;, grease;
and hydraulic fluids w e r ’jr hased in 1975 for use at the South
C caqo Works.
8.8.2 Recla nati n and Trtr’. nt
Waste oil recovery and reclamation practices at the South Chicago
Works include the reclamation of fire resistant hydraulic fluid; by
Radco Industries. No other waste oil recovery or reclamation prac-
tices were reported. P4o information regarling sludges generated by
Radco Industries was available. However, It is thought that li..tle,
if any, sludge Is forried. Radco Industries provides fire resistant
hydraulic fluid recovery services to the steel and other Industries.
(Kcess PCB s are incinerated and a reusable hydraulic fl’ 1d Is
retureed to the steel ni H.
8.8.3 DIscharges to Waterways
Data f r 1975 reported by Republic Steel Corporation for three out-
fall; Indicate that about 200 kg/day (443 lb/day or 161,635 ib/yr)
of he’iar,” soluble materials are discP arqed frm the South Chicago
9-5 1
-------
Tat 1, 8 -13. LUB 1c:’ i5, O!t.5 & GPEASFS IJSEP I 1 1975
a
_____ ______________________ CAlF RY
C,4. *y o4 IZ

100 Lbs. $i 9 Pi tr . use and lnfrequint
relubricatlon on qrindir s and
c
furnice areas, 14 hot saws
i
and 10 rod mill.
C0 O*i 31
1Y Ti Anti-we4r hydraulic o lon —
grInders, bar class’fler and
HF
a’a’ ‘‘ “r - c’ ‘
‘ •. l
* .( .
Arcr, 1,”msnt M3 ‘l S Ir I
hj i
7 iTa l s tr - ‘tivø aca e_oi _
j
‘ . ‘. s le • .t 4I
iI .v .ral r .c .sjr1. .1canr
74, 1O1 a1s. i1 Mlii Ct oifsystems.
11 $111 pInion drIve o’I
y
p

• 0 150) OH
• ‘ ZSOO 011

iiy . t il
-
c i r
•
SySte’s,
10.150 Gals. )
7 0 Gal*. ) Used plant wide for general
18,110 baIt. ) lube applIcations.
CI’S )
0
3 aTs. j Ceeral e PYd?auHC oil In
2 Gals. ) T$( ad 11’ $111.
HF
•6C .is. s;c7ct iri -gos1 System
In 11 Mill Fin1sP I!2.
Z5 .500 Gals. A - it ndMorqoi1 System
In ir Mill RO hlr,
3,OSOGaIs. jlt ’b*leejuT nt.
8,& O Gals. 3 cranbclle all,
0
CItgo iry1W T
iGCitq oCiI
* tor C-! . W- O CItp Oil
{liOt r Cit Fi id
eir Itigo tP9

v. oVap(ost ”pnta I1
onoco Miigr.r 1 1W Oil
o
o
1O ’ ’? ali Stri sk s
1 17
10.4OO kIt. 1P M l1 (stI System and
P’jQ 1 !!,!’ l•.
5 ,1E O_G a1s tight ‘ d uS cutting perat lens
I 3? Calt. Gear r!ducprOiT.
2 O ) ?aIs. CeTThr systcms in Primary $
Tut Mills.
o
n
p
1 T..i t l .i 011 -
Ji fain r..se
Càa T.teriaI •T7 .w OH

flC o G . 1 14p.irr tt te.
3,910 Lbs Llectr$cwotor r ,.,e
n
c
440 a1s. MeIiT5 iop cranes. StrIpper
- cranes.
o
rrfai 727- ’Ofl
4.180 Gals. b tSi j cranes, stripper and
so.blvjplt cranes.
o
T ’TaT -T(rpjie
Tqal 1 a). ’V rpasp
o’ r
ki .’ ‘;T G’rs e
y Ci •‘ ‘a 3 $ T r,a e -
L,iTc$ rijc G ’rsse
t Majic u’sg Is 0*1

PitTra ’pi
G
1)5 1i , s, P Tr P ’rp ad “111 tvanrs.
5,3 -5 Gals 5a In p it bT ns
4$ 11 Lts. r...rsI_Purjc ,.
5i bs , 14 M$T a..4 l ,. ,e Will-General.
Ore J ch br ? i ’d W 1i,t
1 Gals.
UOO0tbs lu ’ e kiil - rial OurpOS e
C)
C
c
G
p
8-52
-------
T t r L)3 (cr”rtinued) OILS & G EASEO I
IN 1975
A-i , - Cil 1,100 Gals. ) Light machine oils u 4
A-3 . ic ( l 8,440 Gals, plant wide.
A-f ‘i.’ ‘c llq’q Gals. )
cir 17 ,N a 1YaC Tre oils used
.i• ‘‘ 330 Gals. ) plan wide._____________________
‘ . (r r 1 ir( T _1 ,4N_tejI )0r TflTo te
k, uc,1i “i ‘ ‘ c resse Tb, T0 Lbs. luue P1flTan i Blast Turnace
erer ,pu ’ voSe
ir M.’ i 0 Pt’q r.ase 0 docksTan T1 ’ e
cold w th r rease.
* .p 1, . (rpm 4 ’ lp s Tu D 11l9ereraT use
fl ‘ 4 ( u 35( bs. ]
‘ 3 iC Grease 3,(} ) lbs Cranes.
• r r oil,
Ia S!. c i l — 37, ,C’ (ialG aroflfoi Tr1mar)&
Mill.
7 ’ T —— i 1fls. iceSh po11.
{ rr t:r * :.oT iV ,f .aTs.
ç ;rije’i aco on Z,0 Ga’s. Waste heat bT wers and
Boiler Hr uSC blowers.
‘aco 1 uid 3, 30 Gals. Mobile equipment transmission
0
n
c
C
0
0
o
fluid.
Oi ,39 1 Gals. BaiTer House and waste
heat blow,r .
o
g * 4JA • TeIco Oil
Ilyd Rando C •ifIB Teia o Oil
12,114
7,718
Gals.
Gals.
1
) General DUrPOSC hydraulic oil.
d - 7r)G ls. 10” MIl! [ scania system . —
O Tc.,cc r. r’jdT reasP .4 Cranes.
7 x Tc.atn Cvater Ce ’ . Grease 4 .ct) lbs. )
X leisco Crater C pl. Grease 2.730 Lbs. ) Open gear ‘ipplications.
•sz leaao rl id Grease 4 0 lbs. J Plant wide use. C
Te*:lad •? Te.aco Grease 2,400 lbs. )
• ‘ ) Prt o sGrøase - 4,920 lbs. )
c,alnn. • “ ‘I ‘-case l 1 4ft 1bs. G ner jp se - plant wide .
hcu ’n. *11’t Lut’r1CE t _ 4l 5. & nera1plant use .
oughto- a e # O Lubricant 14,8tO GiTs. Water glycoFfluid for 36 HF
and 34 Mill area.
‘ 6?) Gals. Fire re T intThr Coke Plant,
_____ - blast rurnace and Melt_Shop. HF
T j .’l i ;i cT1 tar tb Tcant ‘T a’ls. Strip er crarT flFe resistant
Piyd. fluid. HF
i • ‘ . ‘t T 1 . T1 7 ‘ThiTs r i ecIs t jd flul d _______________
)ydr i . t.lt. M .nsanto Lubr . 3.160 ali. Hyd fluI , srailous ap 1Tca- HF —
tion . ______________________________
- — 4q T ’ [ bs. PIa hf ’en iT.
-ic e I ,1 &7 Gress,___3’S, 0 LbS. Grcase se. C —
I’ b% • ..
7S .I ’0 Lbs. Co l1nq beds.
• Ic oil. MT
ç,.... .4 ” if_____ 1 D1s.1ubC! illT _ ! %dr UTiC ol .
0 P’)I( ’l ,1rauT - -- Fire resistant hydri TIc —
2° III or ( _____________________ 4,5 O0 Gals. fluid for Llpctrlc Furnace .
l ot,: 0- t’il C— Crease HF- Hydraulic Fluid
(1.0 gal 3.785 land i.O lb B 0.4536 kg)
iyr [
*
list__________________ — CAI IGaRY
HF
C
8-53
-------
Works. A total oil and grease dischdrge rate estimate was also made
by ‘ s ng MPE ES Perr it Application Information. If all four outfalls
were discharpnq wastewaters (only three are reported to have a net
total oil and grease disch irge),.with the average net oil and grease
content and at the a erage flow rate indicated in the permit appli-
cation 1 the total oil and grease discharge would be 360 kg/day (792
lb/day or 289,080 lb/yr). This would represent about 7 percent of
th a4l , greases a d hydraulic fluids used in the plant.
8.8.4 Other (.ocses
Significant quantities of oils and greases are applied to steel
products intentionally cr during processing. The quantity of lubri-
cants and rust preventatives leaving the Republic Steel, South Chi-
cago plant on products could not be determined because no data was
available from the steel mill It is expected that a significantly
lower quantity of oil leaves the South Chicago Works on products,
compared to other steel mills in the study, since only bar, rod,
tube and wire products are shipped. Large quantities of coating and
slushing oils are generally associated with rolled strip, sheet or
coiled steel products. From data and estimates of quantities of
oils on products provided by other steel mills, it is thought that
approximately 5 percent of the total oil and grease input to the
South Chicago Works leaves on products.
Mill scales collected In the various scale pits also contain oils
and greases. Oil contents of mill scale as high as 25 percent by
weight have been reported for some rollir.g mills, although an oil
content ranging fron 0.1 to 2.0% Is typical. Mill scales are gener-
ally either stockpiled (often because of excessive oil content which
would result in air pollution control equipment or opacity problems)
or recycled to a sinter plant or directly to the melt shop. Republic
Stee repcrted that at the South Chicago Works approxImately 7.26
8-54
-------
kg/month (8,000 tons/month) of scale is removed from scale pits.
All mill scale is returned directly to the melt shop for use in the
steel n aking process. No oil content data was available from Repub-
lic Steel. For material balance estimation purposes, it was assumed
that the average oil content of these mill scales was 0.2 percent.
A relatively low oil content value was chosen in consider. t1on of
the types of mills oper tea. Therefore, approximately 14,500 kg/
month (32,000 lb/moith) of oils are contained on mill scales and
subsequently corr.busted or volatized in the melt shop. No data on
the quant.Ity of hydrocarbons emitted to the atmosphere by volatiza-
tion of these ils was available. It is thought that nearly all
of the oil on mill scules fed to the melt shop is combusted.
Sludges and filter cake containing oils and greases generated in
wastewater treatment facilities represent a potentially significant
loss term. Ihe quantity of filter cake generated at the South Chi-
cago Works wastewat.er treatment plant was reported to be 10.2 x io6
kg/yr (11,295 tons/yr) during 1976. The cii content of this filter
cake was uiiknown. Sludges and filter cake are reportedly stockpiled
by Ret:’ubllc Steel. Assuming an average oil content of ten percent,
which Is typical for rilter cake and sludges generated at other steel
mills, it was estimated that 85,400 kg/month (188,250 lb/month) of
oil is lost in this manner.
Other loss terms identified in the oil, grease and hydraulic fluid
material balance Include:
• amounts left in containers or lost during handling and
storage;
• oils and greases contained or trash and debris which are
collected and sent to a solid waste disposal area;
• quantities volatized, burned o. otherwise consumed in use
in the various steel making and shaping processes;
• leaks and sp 11s on to the floor or ground which are
cleaned up and disposed of.
8-55
-------
No data was available from Rerjbllc Steel regarding these various
loss terms.
8.8.5 Material Balance
Using the data and estimates presented above, an attempt was made
to develop an overall material balance for total oils, greases and
hydraulic fluids. The material balance estimate is Illustrated in
Figure 8-9. For the conversion of volume to weight units for oils,
a density of 0.9 kg/i (7.5 lb/gal) was assumed. Shown on the mater-
ial balance illustration are kg/month values and the percent of the
total input represented by each loss term for which data was obtained.
PES was able to account for 76 percent of the total oil, grease and
hydraulic fluid input to the Sout . Chicago plant. The four miscel-
laneous loss terms, noted above with bullets, are thought to account
for roughly 10 to 20 percent of the total input. Uncertainty in the
estimated loss terms; such as oil on product, on mill scale or on
sludges, may account for the remainder of the input.
8.9 Interlake, inc., Riverdale, Illinois
A surnary of the major equipment and products associated with the
Interlake, Inc., Riverdale facility, is provided in Table 8-14. The
information presented in the table is a sunv ary of the data provided
in the AISI Directory of Iron and Steel Works . According to the
IISS Steel Industry in Brief the steel production capacity at the
Riverdale Plant is 0.8 x 10 kg/yr (0.9 x io6 tons/yr). Durin i 1975
the actual production is estimated to be 0.5 x kg/yr (0.6 x o6
ton s/yr).
8.9.1 lubricant Purchases
lubricant usage data reported by ‘iajor plant area is presented in
Table 8-15. A total of g2,700 kg/yr (204,340 Ib/yr) of grease,
8-56
-------
lNi uT TIkMS
(IJIPUI OR LOY. 1i M
purchased O IlS,
gr ase . and
hydraulic fluids
l56 l50 kg/mo
(344,250 lb/mo)
reclaimed I
recycled
7,900 kg/no
ruiutS (17,200 lb/no)
[ 5 i
111 1
one CaeS
left in containers or lost
in storage md h ndl ing
leaks and spills onto ground,
generally cleaned up jod disPosed
volatilized, burned or
consumed in process
in sludges, trash and debris
in waStewat !S
to scale pile zero
toicelt shop
14,520 kq! ro
(32,0 O lb/mo)
[ 9.3 : i
85,3g0 kg/mo
to disposal (188,250 lb/mo)
[ 54.7 )
10,930 kg/mo
discharged tO( 24 (JgQ lb/mo)
waterways [ 7.O ]
sludge disposal
Unaccounted for: 24%
I I
None reported fuel
Figure 8-9.
MATERIAL BALANCE - REPUBLIC STEEL CORPORATION, SOUTH CHICAGO
-------
TABLE 8-14. INTERLAKE, INC. - RIVERDALE, ILLINOIS*
Eqjiipment
2 Basic oxygen process furnaces
No. Type of Mill Annual Rollinq Capacity
1 Primary 737,000
1 Billet 580.000f 1,317,000 Net Tons
2 Hot strip 744,000
5 Strip — cold reducing 254,600
1 1,258,800 Net Tons
6 Strip - cold finishing 243,000
1 Strip — cold sizing 6,900
2,575,800 NET TONS
V -
>Capacities of hot strip, cold rolling, cold finish & temper mills
Capacities of all primary and secondary mills
1.2588 io 6
____________ = .49
2.5758 x lO
*Equjpment and annual rolling capacity data from AISI Directory
of Iron and Steel Works
1.0 ton = 907.2 kg.
8-58
-------
T?ble 8-15. LUBRICANT USAGE DATA
__________ Greases ____
1,800 gal/yr
43,000 gal/yr
100,000 gal/yr
138,000 gal/yr
+ 6,000 gal/yr
rolling oil
115,000 gal/yr
Greases 204,340
Lube Oils 397,800
Rolling Oils 6,000
(1.0 gal = 3.785 1)
(1.0 lb = 0.4536 kg)
Department
Melt Shop (2 BOF’s)
Primary Mills
Hot Scrip Mills - 2
Cold Pulls —
Pickling Line
Oils
11,000
89,000
5,860
98,000
lb/yr
lb/yr
lb/yr
lb/yr
480 lb/yr
Total
Note:
lb/yr
gal/yr
gal/yr
8-59
-------
150,600 1/yr (397,800 gal/yr) of lube oils and 22,700 1/yr (6,000
gal/yr) of rolling oils are utilized. Assuming 0.9 kg/i (7.5 lb/gal)
for the lube and rolling oils, the total oil and grease input to
the plant is 1,466,000 kg/yr (3,232,800 ib/yr). No information is
available on purchases of hydraulic fluids and process oils.
8.9.2 Reclamation and Treatment
Waste oil recovery efforts include collecting oils from the cold
mills and pickup by a waste oil scavenger. A 10 percent oil in
water emulsion is recirculated in the mills. When the emulsion
reaches 6 percent oil in water it is disposed of by cracking the
emulsion with waste pickle liquor. The recovered waste oil is ap-
plied to in-plant dirt roads to suppress dust. Consideration is
being givet to sending this waste oil to the coke ovens here it
can be used to replace straw oil which is currently used as a bulk
density control for coal being coked.
Consideration IS being given to phasing out the belt skinners
installed on scale pits and replacing them with more effective
Lockheed “Clean Sweeps.”
8.9.3 DischargeS to Waten ays
The water system at the Riverdale plant includes total separation
of process water, which is recycled xcept for a small amount of
blowdown, and cooling and torn water, which is discharged to the
Little Calumet River.
Three wastewater t’ eatment facilities are operated. They are the:
1. basic oxygen furnace clarifier sy3tem
2. sand filtration system on the #4 hot-strip mill
3. Neutralization-oxidatiOn system for treating spent acids
( ‘ aste pickle liquor).
8-60
-------
The sand fi1 ration system is of interest to this study because it
is designed to treat and recycle all contact process water used on
the #4 hot-strip mill. The system’s major components are six sand
filters each rated at 9,500 1/mm (2500 gal/mm), a backwash surge
tank, a 12m (40-ft) diameter by 3.6m (12-ft) side wall depth clari-
fier, a 3m (10 ft) by 3m (10 ft) vacuum filter with ancillary equip-
ment, and a recycle pump house. Suspended solids and oils are
removed by the system. Operational data are as follows:
Influent to System Effluer.t from System
Flow 37,850 1pm (10,000 gpm) 37,850 1pm (10,000 gpm)
Suspended
Solids 250 ppm 30 ppm
Oil 50 ppm 15 ppm
From the influent and effluent data it wa.. estimated that 1900 kg/
day (4200 lb/day) of oil is captured in the sand filters. It was
reported that an off-site waste oil reprocessor reclaims this oil
as a motor oil. No information could be provided on the oil
discharges from the process water recycle system blow own .
8.9.4 Other Losses
Mill scales collected in the two hot-strip mills and the primary
mill szale pits are recycled to a sinter plant. Oils and greases
contained on the mill scale are volatized during sintering.
A wet precipitator is installed and operated on the sinter plant.
The volatized oils and greases cause a bluish haze, possibly due to
the condensible hydrocarbons. Source test data, described during
an interview with Fred Krikau, Dl ctor of Environmental Control at
the Interlake Riverdale plant, indicate that about 37 kg/hr (81
lb/hr) of total hydrocarbons are present in the sinter olant
stack gas prior to the wet precipitator. The wet precipitator
8-61
-------
outlet gases contain 1.8 kg/hr (4 lb/hr) of total hydrocarbons.
Research into de-olling mill scale with solveits proved ineffec-
tive because the solvents actually added to the hydrocarbon air
pollution problr i.
Significant quantities cf oils anc 4 greases are applied to steel
products intentionally or during processing. No estimate was pro-
vid d of the quantity of oils and arease leaving the Interlake
plant on products. Also 1 Pstii ate was provided for the oil and
grease content of sludqes removed at the wastewater treatment
facilities.
Other loss teni s identified in the cil, grease and hydraulic fluid
material balance include:
• amounts left in containers or lost during handling and
Storage;
• oils and greases contained on trash and debris which are
collected and sent to a solid waste disposal area;
• quantities volatized, burned or otherwise consumed in use
in the various steel making and shaping processes;
• leaks and spills which are cleaned up and disposed of or
leak intc the ground.
8.9.5 Material Balance - Detailed inforn ation on lubricant usage
and fate could not be obtained for the Riverdale facility and a
complete material balance estimate could not be prepared. Available
material balance information is sumarized below. Of the total
input of 122,200 kg/month (269,400 lb/month), approximately 23 per-
cent is contained on mill scales. It was estimated from limited
sinter plant source test data that 1330 kg/month (2880 lb/month)
(1.1 percent of the total steel mill oil and grease input) is emitted
from the sinter plant stack. Approximately 26,450 kg/month (58,320
lb/month) of oil (21.6 percent of the total input) is captured by
the wet precipitator.
8-62
-------
The sand filtration system on the #4 hot-strip mill Is estimated
to collect 57,000 kg/month (126,000 lb/month) 46.8 percent of
he total input) of oil and grease, whicn Is reclaimed as motor
oil by an off—site reprocessor.
The remaining 30 percent of the oils and greases that are inputted
to the plant are unaccounted for. Wastewater discharges are expected
to account for a portion of the oil and grease input. The quantity
of oils and greases on products, left in containers or lost in
handling and storage, on trash and debris to solid waste disposal,
and volatized or consumed in process are e”pected to account for
the remainder.
8.10 Kaiser St c’ Corporation, Fontana, California
A sumary of the major equipment and products associated with the
Kaiser Steel Corporation plant in Fontana, California, is provided
In Table 8-16. The information presented in the table is a suni nary
of the data provided in the AISI Directory of Iron and
and Steel Works . The production capacity of the Fontana
plant is approximately 3.3 x 10 kg/yr (3.6 x tons/yr). Six
of the open hearth furnaces are being decomissioned and Kaiser is
currently replacing this steelmaking capacity with two new basic
oxygen furnaces. Two open hearth furnaces will be retained for
handling scrap. The actual production rate for 1975 and 1976 was
reported to be about 70 percent of capacity or 2.3 x i0 kg/yr
2.5 x 10° tons/yr).
8-63
-------
Table 8—16. KAISER STEEL CORPORATION - FONTANA, CALIFORNIA
EQIJI PP4ENT
315 Coke ovens - by-product
4 Blast furnaces
8 Basic open hearth furnaces**
3 L—D oxygen pror’ ss furnaces
No. Type of Mill Annual Rolling Capacity
1 Blooming 4,368,000 Net Tons
1 Plate 824,000
1 Structural 457,000
1 Merchant skeip 333000
1 Hot-strIp 1,500,000 6,019,000 Net Tons
2 ReversIng 316,000
2 Cola reducing 820,000
3 Skin pass 571,000
3 Temper 1,198,000
TO,387,000 Net Tons
Capacities of hot strip, cold rolling, cold finish & temper mills 4 405 io6
= _______ =.42
Capac1ties of all primary and secondary mills 10.387 106
!qulpment and annual rolling capacity data from AISI Directory of Iron and Steel Works
(1.0 ton 907.2 kg).
**1 200 metric ton/heat (225 ton/heat) basic oxygen furnaces (BOF) will replace six of the
npen hearth furnaces (OH). Two open hearth furnaces will be maintained and used for scrap
steel processing. The blooming mill, structural mill and r ierchant-skelp mill will be
deconinlssioned in late 1S17.
-------
-. t. . S !1. C I 4, F &MA PLAMT
S. IC 1t’I S r DATA
— cu4ntity urC i
___- j_Ga ion;
All rr’.i c l,4 5 , 31
f’’.’’ c r rci;ps A Chain Oils lO,4 l P
‘i-ar Oils 4 4,”A1
Circ1 t1’ Oils P. MIst 011; 455,705
H 1ra ic (‘11; 18 0 .242
Turbine & Air Cor re’sor 011; 24,915
t ’ a1iroai A Traris ’ 1%cion
5O,53
& Gririin Oi’s
A C’ rcjnds P. Soluble Hydraulic
1,962 92,5)1
Miscel1 reous Products 7.170 54,847
rr ,cess Oils & Met 1
‘rot ctIv Coatinos 2,175
Rollins 01’s & Fas l,56O, 00
TOTALS 3,032,540 lb 1,355,134 gal.
nn Palser Steel Corporatioi purchase records for V ie
ç’øriod of July 1, 1975 tr June ?J, 1976. Fu 1;, solvents
ai coke plait wash and spray oils are not included. Th.se
u ’3S data jnclucj.’ materials purc iased for and conui J
b. the Mctal Prolicts Division.
(1. ) 931 3.7851 and 1.0 lb • 0.4536 kg)
8- 5
-------
I ;r
e L ri ’’- ’ rt’ ’n P’ø V cer Stc’e Corporation plant in
pr. 1ie1 a vrrw l 1 ta aLi i’n )f tP. types and
t1t’r . of at” oils. re s , and hydraulic purchased
iur ” the third ar d fcurth quarters of l 75 and th. first ard sec-
ond Q aters of 1976. The appflc tion or usale of the lubrlc*nt;
anj dr3ij c fli’ tl as well as the tyv° an ;ize of container in
t”e ‘ater al was rurha; d, was rpp rtØl. ;he purchase records
are very detailed an inc1ud specialty products purchased in small
Qut tiCS . It is t’ o ht that the Fontana plant data are more cor p-
retsive than that obtaind frt other steel mifls in the survey,
and, as a rrs’ t, the total quantity of lubricants and hydraulic
flu 4 c nay a ’pear lar ier than w u1d he the case if determined or es-
tnatetl In a rarner i 1lar to some of the other mills. The lubri-
cant r’tj-chase provi4 d ty Kaiser Steel includes some materials p 4 r -
( a ”d for and consumed by the Metal Products Division, a satellite
orerat cn located adjo ent to the Fontana steel mill. The Metal
rrc ucts Pivision, which Inclu % light steel, structural steel and
pLate steel fabrication fac’lities. are est mated to consume roughly
S to 10 percent of the lubrlc nt Stocks purchased by the Fontan
plant. Mote also that purchase records during a one year period may
differ from the actual quantity of lubricants or hydraulic fluids
used.
1 t’riant usage data which are suor arized by general type of oil,
r’rease or P’yilraullc fluid are presented In Table 8-li. A total of
310,400 1/yr (l,174,8Q2 qal/yr) of lubricating and process oil was
purchased during the one )ear period from July 1, 1975 to June 30.
197*). In addition, about 707,000 kg/yr (1,560,000 Ib/yr) of roll-
ing oil and fats was bought. The total quantity of grease purchased
aurin that time period was 668,000 kg/yr (1,472,504 lb/ye).
-------
w ’ i t ;artity o ,:1raulic fluids rurchas i wa 6R2,000 1/yr
qi1f r). Ac ’in 1 ar avpr dv’ city f o.co kgIl (7.5
l! ’ al) fc r oils ar’ hydraulic fluids, the total avera e quantity
o oils (lnçlu.jin rotHnq oils) grease; and hydraulic f1uid used
was a roxirna1 e1y 4 9.Cc’0 /- ,nth (1,101 ,c 00 lb/r nth).
P 2 “ d Tr ’ i’nt
Wac•o il røccvery r’ tc inc ud th. jse of oil sk1-rv’r on sor ’e
ccal psts ani a fl irk tank in the wastewater treat nt plant.
Th luhrh.ation t ’ a t -* nt has been investigating the potential for
rec1 i’ nq tP e e haste oil; ;hi,,ried in the plant and returning them
as ‘:ear oil or neral purpose mill oils. To date an over-the-fence
reUa’- r h ; successfully returned about 76,000 liters (20,000 gal)
of ‘ar oil reclairied from waste oils collected it the Fontana Plant.
Th rocla?nation of waste oils as fuel oils Is an additional altern-
ative. This practice has also been ei’vloyed by Kaiser Steel. Cur-
rent elan ; are for the continued and Increased u; o outside waste
oil rpclair rs to return valuable lubricants to the mill from
coflected waste oils.
Kaiser Steel is also investigating ways of enhancing waste oil re-
covery capabilities by installi ’g additional oil skimers and seg-
regating waste oils and collecting then’ at their sources. This
will simplify reclar at 4 on e’forts and maximize the return as lubri-
iants rather than fuel oil. A use or rerlalmer for fats and oily
scus collec ted at the treatr ent plant float-sink tank is also
urder investigation by raiser Steel.
-67
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• -a” f tr ints and cut down on the rr ultlr j
c l lc’ . ct, the rication partr nt has taken and is cons d-
v —h’r ‘ r’ -a; ‘es. Th rc’duce the freqiency of leaks, the
l 1 l v c r hot strip mill are being rebuilt. 1 fl—
.‘ ‘ l ‘tvr syst&i’ and maintenance practices are alto being
•ve” 4 . T c istir ho strip mill lubrication system for the
are’ e ni1 replaced by a ,nore effective mist oil
1. •onv:r o t ” i-ct strip mill lubrication system Is
O ‘erc.nt cor p’ ”e at thiS time. This two-step approach,
‘at e’ red . ng l. br cant usaç and losses while increasing waste
cii oi’ection ca ibilities, is being pursued by the 1ubricatio,
‘artr c as time and funds permit.
m 3
tr ..sa e a ’ 1 tr 3t ’ct at tPe Fontana plant is unioue and calls
a t ricf descri t1on. Their wate’ syStem is recognized as havlnç
tiqPte t water re:irculation systems currently oper ’ting at an
• fc ’a ’d irol anci te”l plant; they have nearly zero water dis-
b3rqe. The ieneraI concept applied at Kaiser Steel for water u age,
r .’rcula’ on and waste treatment is that water passes through e num-
‘ i t. nc in erie , with the blowdown of one system becoming
? cf the fc”ilow’rg system. The systems are sequenced In
“d.’r ‘ Jai’y re airf”’cnts , with the first system having the high-
• t q li y aid the )a t system the poorest. The point is reached
w tt ’r ouahty et rioration Is such that it can no longer be
a;ed in any syster’ and t, en it is disposed of in final uses, such as
claj . ‘n hing, s ntCr cooling. BOF hood sprays, etc. A small quan-
¶ y of cxc s watt r i discharged to the non-reclaimable waste water
1 ’ ’e r’. na ed by tne local municipality which treats It and ultimately
d1sr ar1es it to the occan. Oils not captured by oil skimers which
re3ch the waste water tre3tlnent plant are removed by float/sink
8-68
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sc ’arator anti clarif er. Sin most waters are recyc1 d and event-
uaPy evaporate as quench sprays, very little oil is discharged
fror ’ the lentana plant in wastewater. rinal use waters are reported
t3 contain an average of about 200 rng/l of oil. At an estimated
averac e flow of 1500 1 PM (40C GPM) to absolute termlr.al uses, it
was estimated that 13,000 kg/month (28,B0O lb/month) of oil are
conta red in quench waters. W5en these waters ave sprayed on slag,
OF hoods, or used for siitor co 1iny the oils are volatized and
lost to the atmosphere.
NPDES data indicate that cnly after significant periods of rain are
oils discharged in run-off. It was estimated that about 6800 kilo-
ra (15,000 lb) of oil were discharged during periods of run-off
curing 1976. A limit of 15 mg/1 of oil in the run-off Is permitted.
A detention pond designed to haidle the 10-year Intensity ralnfcll
is being installed to eliminate most water discharges resulting
from ra nfall. The pond will be equipped with an oil skin rer for
recovery of the oils contained in captured run-off.
8.10.4 Other losses
Mill scales collected in the various scale pits also contain oils
and greases. Data provided by Environmental Quality Control Depart-
ment at the Fontana plant, concerning a 1971 study of mill scale
quantities, was used to estimate the amounts of oil In mill scale
and their fate. Oily mill scales are currently stockpiled for fu-
ture recovery due to potential air pollution co’ trol equipment and
opacity probl .. ms which ‘qould result from the volatlzed oils.
The sir.ter plant is equipped with a baghouse for air pollution con-
trol. Fouling of the bags or opacity problems are encountered if
mill scales are cinter’ 4 . large differences in the oil content of
trill scales collectc . in various scale pits was noted in the 1971
8-69
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study. For exa p e, tt e oil content of mill scales taken from t ot-
strip mill scale pits ranged from 0.4 to 23.5 percent, averaging 5
to 1 ) percent by weight. Slab mU), blooming mill, continuous weld
pipe mill, merchant mill and structural mill scales all contain
‘less than 1 percent oil. From the data and discussions with Kaiser
Steel personnel, It was estimated that a total of 171,100 kg/month
(377,200 lb/month) of oil are contained on mill scales. All of this
oil is contained on mill scales which are stockpiled. Preliminary
investigations have been made by Kaiser Steel into alternative meth-
ods of removing and handling mill scales from the scale pits. One
possible approach is to hydraulically pump the mill scales to a
central mill scale treatment facility wt ere the oils would be removed
with a solvent. This system would enable the recycle of mill scales.
after drying, directly to the blast furnace. The feasibility of
recovering the oils from the mill scales am 1 reclaiming then as a
fuel might also be achieved.
Significant quantities of oils and greases are thought to leave a
steel mill on the products. Oils and greases become attached to
the steel during rolling. These oils are generally removed prior
to the application of metallic coatings, such as tin plate and gal-
vanizing, and are carried away in wash and pickle liquors. Oils
are applied to some products intentionally for rust prevention pur-
poses. The only jnfonnatlon concerning this practice at the Kaiser
plant indicates that about 34,000 to 38,000 liters (9,000 to 10,000
gal) of metal protective oils were applied during the period of
which lubricant data was provided. The actual quantity of oils and
greases contained on products is thought to be larger than this
value. Oils finding their way onto products, such as pipe products,
during production often result in a residual quantity which leaves
the plant. Applied and residual oils bn products are estimated to
be about 56,800 I/yr (15,000 gal/yr) or nearly 4,540 kg/month
(10,000 lb/month).
8-70
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Slui es ger’rated in various areas of the plant and by the waste
oil reclaimer handling Fontana plant waste oils contain o11 and
greases. Sludges from the wastewater treatment plant are being
mixed with the coking coal and being charged to the coke ovens.
This practice is expect d o continue until an alternative use or
recovery method is found. The quantity of sludges and oil content
of these sludges was not reported by K aiser Steel. Data at other
steel mills indicate that oil contents of 5 to 10 percent are typ-
ical and therefore the oil in sludge loss term can represent a con-
siderable portion of the total quantity of lubricants and hydraulic
fluids used at the steel mill.
Other loss terms identified in the oil, grease and hydraulic fluid
material balance include:
• amounts left in containers or lost during storage and
handling;
• quantities volatized, burned or otherwise consumed in use
in the various steel making and shaping processes;
• leaks and spills on the floor or ground which are generally
cleaned up and disposed of.
Quantitative data for these miscellaneous loss terms Is very diffi-
cult, If not impossible, to obtain and could not be provided by the
steel mill. It was estimated that as much as 10 percent of some
greases are left in containers and lost. A lower quantity of oils
would be expected to be lost In containers. Efforts to reduce the
frequency of leaks and spills are continually practiced at the Fon-
tana plant, as described previously. It Is estimated that about
20 percent of all oils, greases and hydraulic fluids are lost via
these three miscellaneous terms.
8.10.5 Material Balance
A material balance estimate for the Fontana plant was developed from
the data obtained In response to a PES questionnaire, Information
8-71
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note i durinq plant visists and telephone discussions, discharge data
ebtained fror, EPA Region IX PDES files, and knowledge of the fate
of lubricants gained from other steel mills. This material balance
is presented in Figure 8-10 with k j/rionth and relative percentages
of the total input .epresented by each loss term. A value of 0.9
g/1 (7.5 1b/g l) was used to convert volume to weight units for oil.
The data and estimates provided by Kaiser Steel are Indicated In
Fi jre 8-10. PES estimated other values based on Information and
conclusions drawn from other mills. The Kaiser Steel data estimates
account for about 45 percent of the total input. The quant ty of
oils, greases and hydraulic fluids that are unaccounted for were
distributed by PES as follows:
• in slLdges, trash and debris, 35 percent;
• left in containers or lost in storage and handling, 5 percent;
• leaks and spills on the floor or ground which are generally
cieaned up and disposed of, 5 percent;
• volatized, burned or consumed in use 10 percent.
Of the 3 percent in sludges, trash and debris, some are lisposed
of in landfill, ,h1le sludges from the wastewater treatment plant
are dripped on the coal belts feeding the coke ovens. These oils
are burned In the coke ovens.
8.11 lubricant Usage Data Supplied by lykins
Joseph t.ykins provided u a on lubricant usage in a variety of formats.
Based on his e*perience in the steel Industry and as a consulting
steel mill lubrication engineer, Lykins provided PES with four Items
regarding lubricant usage. The yearly consumption of various types
of lubricants, oils, greases and hydraulic fluids were estimated for
a fully Integrated steel mill producing tnree n,illlon net tons of
steel per year, (see Table 8-18). UsIng a value of 0.9 kg/I
8-72
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1PUT YCMMS JJVPUT OR lOSS T NIqS
4,540 kg/mo
on pro4ucts (10,000 lb/mo)
171,10 (1 kg/ ro
= to scale pile (377,?’O 1 /’o)
on mi ii scaJes [ 343 1
to sintir plant Zero
_________ 24,950 kg/mo
left In containers or lost (55,000 1 b /mo)
purc c ei 3 11s, f in storage and handlir,
greases end
hydraulic fluids I [ 5
_________ 24,950 kg/mo
498,960 kg/mo leaks and spills onto ground, (55,000 lb/mo)
(1,100,000 lb/mo) generally cle*n*d up and disposed [ st )
including
rolling oils
49,900 kg/mo
volatilized, burned or (110,000 lb/mo) 174640 kg/mo 13,060 kg/mo
consumed In process
[ 10%] (385,000 lb/mo) (28,800 lb/mo)
_________ [ 35 ] [ 2.6%)
reclaimed &
in sludjes, trash and debris ‘ - to disposal
recycled El
rminal water uses
___________ _______ stewater te ___________________
__________ ______ discharged to 570 kg/rr
in wastewaters
we te rway S
(storm runoff) (1,250 lb/mo
[ 0.l )
_________ 42,530 kg/mo
drained, collected or skinined -.
(93 7 0 lb/mo)
_________ t8. %J
L — 5,670 kg/mo reclaimed
______________________ ________________________ Ste oil
(12,500 lb/mo) lubrIcJvtT _recianaT } sludge disposal
36,860 kg/mo __________
(81,250 lb/mo) fuel -
[ 7.4 ]
FigLr’ 8-Ic. MATERIAL BALANCE - KAISER STEEL C0RP0RJ\T10 , FONTANA
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Table 8-18
Estimated Yearly Consumption of Lubricants,
Oils, Greases and Hydraulic Fluids for a Fully
Integrated Steel Mill Producing Three Million
Net Tons of Steel per Year.
Oils
EP Gear Oils 434,000 lb
Rust & Oxidation Inhibited Oils 205,000 gal
Black Oils 6,000 gal
Red Engine Oils 11,000 gal
Motor Oils 100,000 gal
Water Soluble Oils (neat) 120,000 gil
Rolling Oils 6,700,000 lb
Hydraulic Fluids
Anti-wear Hydraulic Oils 270,000 gal
Inverted Emulsions 165,000 gal
Water - Glycol 140,000 gal
Phosphate Ester Type 35,000 gal
Greases
Black lithium & Aluminum Complex Greases 1,400000 lb
Premium Ball & 1 o11er Bear1 q Grease 25,C’)O lb
Specialty Greases 50,000 lb
(1.0 gal = 3. !5 I and 1.0 lb = 0.4536 kg)
8-74
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(7.5 lb/gal) to convert the quantities expressed as liters (gallons)
to kilograms (pounds), it is estimated that total of 7,484,000 kg/
yr (16,499,000 ib/yr) cf oils, greases and hydraulic fluids are re-
quired by an integratea steel mill of the specified capacity. A
total oil, grease and hydraulic fluid usage rate of 2.75 kg/1000 kg
(5.5 lb/tun) of steel produced was calculated from Lykins’ esti Tlate.
Table 3-19 sumarizes the individual usage of oils, greases and hy-
draulic fluids per quantity of steel produced per month.
Lykins also provided usage and production rate data for typical
rolling and finishing operations. The total quantity of lubricants
consumed and correspond. ig production ‘ate data for 1975 were used
to calculate the kg/l000 kg (lb/ton) usage factor for several mills
or processes. Thesc data are presented in Table 8-20, which includes
only lubricating oils, greases an ‘iydraulic fluids. Usage rates
of rolling oils and process oils ar tabulated in Table 8—21. The
total quantity of lubricants, oils, greases and hydraulic fluids,
including rolling and process oils, is 8,430 kg (18,584,845 ib), as
surnarized in Table 8-22. This usage rate corresponds to a total
steel production rate of 2.97 x l0 kg/yr (3,277,000 tons/yr). A
value of 2.83 kg/l000 kg (5.67 lb/ton) is obtained by dividing the
usage data by the production rate. This value is i the clc’se
agreement with the 2.75 kg/l000 kg (5.5 lb/ton) value estimated
with the data in Table 8.19.
In .1dition to the usage and consumption data, and estimates revi-
ously presented and discussed in this section, Mr. Lykins supplied
PES with a “Practical Guide for LLbricating a Fu ly Integrated Steel
Mill.” A copy of this guide is included as Appendix C of this re-
port. For the major steel mill equipment and processes, the types
of lubricants and their properties are specified. This information
is useful for identifying typical lubricant applications in an
integrated steel mill.
8-75
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Table 8—19
Lykin’s Usage Estimates*
Usage per Ton of Steel Usage per Month
Oils (Includes lubricatIng 0.464 gaif 116,100 gal
and process o 1 s
Hydraulic Fluids 0.203 gal/I 50,833 gai
Greases 0.492 lb/I 122,917 lb
* 7.5 lb/gal used to convert gallons to pounds.
(0.9 kg/l used to convert liters to kilograms)
(1 gal/ton = 4.172 1/1000 kg)
(1 lb/ton = O.5O ) kg/l000 kg)
8-76
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TABLE 8-20
C P, 2ISflNOFSTEEL P DUCT1ON AND LIJORIC,\NT AND HYDRAULIC FLUID CONSUMPTION
80U Hot StrIp Mill
Rated Capacity 353 Tons/Hr. 2,620,000 Tons/Year
1975 Production 330 Tons/Hr. 1,980,800 Tons
Lubricant Consumption (1975) 3,400,800 Lbs.
Lbs. Lubricant/Ton S ee1 Rolled 1.72
4511 Blooming oe Slabbiriqt ijj
Rated Capacity 2:0 Tons/Hr. 1,600,000 Tons/Year
1975 Production 195 Tor ,s/Hr. l,200,00Ci Tons
44” Blooming Or Slabbing Mill
Rated Capacity 200 Tons/Hr. 1,493,000 Tons/Year
1975 Production 165 Tons/Hr. 835,000 Tons/Year
1975 Total Production 44 & 45 ’ Mills 2,035,000 Tons
Lubricant Consumption (1975) 3,914,820 Lbs.
Lbs. Lubricant/Ton Steel Rolled 1.9
Cold Strip Picklers
Rated Capacity 220/Hr. 1,647,360 Ii’ns/Year
1975 Production 1,510,000 Tons
Lubricant Consumption (1975) 760,000 Lbs.
Lbs. Lubricant/Ton Ste& Pickled 0.5
5 Stand Tandem Mill—Tin Plate
Rated Capacity 100 Tons/Hr. 748,803 Tons/Year
1975 Production 660 OO0 Tons
Lubricant Consumption (1975) 787,500 Lbs.
Lbs. Lubricant/Ton Steel Rolled 1.2
4 Stand Tandem Sheet Mill
Rated Capacity 90 T,Dns/Hr. 674,000 Tons/Year
1975 Production 576,000 Tons
Lubricant Consumption (1975) 686,400 Lbs.
Lbs. Lubricant/Ton Steel Rolled 1.19
Electrolytic Washers
Rated Capacity 100 Tons/Hr. 749,000 Tons/Year
1975 Production 638,000 Tons
Lubricant Consumption (1975) 6,525 Lbs.
Lbs. Lubricant/TCfl Steel Washed 0.01
8-77
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Table 8-20 (continued)
Electrolytic Tin Lines
Rated Capacity
1975 Production
Lubricant Consui ption (1975)
Lbs. lubricant/Ton Steel Tinned
261 ,36G Tons/Year
257,000 Tons
l6,O0 Lbs.
0.062
1975 Production
lubricant Consumption (1975)
Lbs. Lubrlcan /Ton Hot Metal
Seamless Pipe Mill
Rated Capacity 56 Tons/Hr.
1975 Production
Lubricant Consumption (1975)
Lbs. L’ibrlc Int/Tcn P pe
Buttweld Pipe Mills
Rated Capacity 45 Tons/Hr.
1975 Productior
Lubricant ConsumptIon (1975)
Lbs. Lubricant/Ton Pipe
3,277,000 Tons
580,000 Lbs.
0.13
420,000 Tons/Year
315,500 Tons
178,000 Lbs.
0.6
Blast Furnaces, Basic Oxygen Furndces
nd Auxillaries
337,000 Tons Year
285,000 Tons
144,300 Lbs.
0.51
(1.” lb = 0.4535 kg and 1.0 ton = 907.2 kg)
8- 8
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Table 8-21. ROLLING OIL AND PROCESS OIL USAGE DATA
Rolling Oils
Tin Plate Mflls Including Picklers - D A Mills*
Production Pounds of
__________ Roll 011 Used lbs. Oil/Ton Steel
660,000 Tons 4,950,000 Lbs. 7.5 lbs/Ton
Sheet Mills Including Picklers D A Mills
Production Pounds of
__________ Roll Oil Used lbs. Oil/Ton Steel
576,000 Tons 1,750,000 Lbs. 3.04 lbs/Ton
Threading Our
seamless Pipe Mills
Production Pounds of
__________ Threading Oil Used Lbs. Oil/Ton Pipe
315,000 Tons 540,000 lbs 1.71 Lbs/Ton
Buttweld Pipe Mills
Production Pounds of
__________ Threading Oil Used lbs. Oil/Ton Pipe
212,165 Tons 360,000 lbs 1.71 Lbs/Ton
Coating Oils
Production Pounds of Oil Lbs. Oil/Ton Steel
274,000 Tons 328,800 Lbs 1.2 Lbs/Ton
*D.A. = Direct Application type lubrication system
(1.0 lb = 0.4536 kg)
(1.0 ton = 907.2 kg)
(1.0 lb/ton = 0.5 kg/lOGO kg)
8-79
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Table 8-22
Total Lubricant, Oil, Grease and Hydraulic Fluid Consumption
Consumption
3,400,800 lb
3,914,820 lb
760,000 lb
787,500 lb
4,950,000 lb
686,400 lb
1,750,000 lb
6,525 lb
16,000 lb
580,000 lb
178,000 lb
540,000 lb
182,000 lb
360,000 ii’
144,000 lb
328,800 lb
18,584,845 lb
*Note: The steel production rate corresponding
to these consumption data was 3,277,000
tons/yr.
(1.0 lb = 0.4536 kg)
(1.0 ton = 907.2 kg)
Department*
80” Hot Strip Mill
44” & 45” Blot’mlng or Slabbing Mills
Continuous Picklers
Tin Plate Mills Including Picklers
Rolling Oil
Sheet Mills Including Picklers
Rolling Oil
Electrolytic Washers
Electrolytic Tin Lines
elast Furnaces, BOF’s, and Auxiliaries
Seamless Pipe Mills
Threac!lng Oil
Buttweld Pipe Mills
Threadin j Oil
Continuous Galvanizing Line
Coating 011
8-80
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Appendix C also includes a lengthy listing of parts and equ1pmE t
that are lubricated, the types of bearings or gears, the ‘.ypes )f
lubricants used, and monthly lubricant consumption rates. The ap-
proximate monthly consumption of lubricating oils and greases and
hydraulic fluids are identified by their application. A sumary
tabulation of these detailed consumption estimates was prepared by
PES and follows Lykins’ input in the appendix. Subtotals of total
lubricant, oil, grease and hydraulic fluid usage were calculated
for the iron and steel making processes as well as for the steel
shaping and finishing processes. Based on these calculations, it
appears that approximately 90 percent of all the lubricants, oils,
greases and hydraulic fluids consumed man integrated steel mill
are used in the shaping and finishing operations. Conversely, about
10 percent of these materials are used in the steel making and
auxiliary processes.
In sumary, Joseph Lykins provided PES primarily with consumption
(usage) and application data. He was not responsible for providing
detailed or comprehensive data on, or estimates of, lubricant fate.
His data, in conjunction with that gathered by PES, are basically
representative of an integrated steel mill although usage data varies
greatly from one steel mill to another. A typical steel mill is
also difficult to depict due to the variability in equipment design
and maintenance, the type and size of mills, and the types of prod-
ucts produced. Finally, the usage data that was provided by the
nine steel mills included in the study, were not sufficiently de-
tailed, or in a format to be compared with the data from Mr. Lykins.
8.12 lubricant Fate and .laterial Balance Information Supplied by
Jablin
Richard Jablin was contracted by PES to provide technical assistance
and information regarding the fate Df steel mill lubricants and the
material balance estimates. Based on hs extensive experience in
the steel industry and as a consulting engineer to EPA and industry
8-81
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sponsored studies of the steel Industry, Jablin prepared a report
for PES which is incluc ed as Appendix D. Backgrund information
relevant to the PES study were supplied as well as material balance
data and estimates for an unidentified steel mill, libeled “Mill A.’
In addition, Jablin prepared a material balance estimate for a “typ-
ical” steel mill based on his experience and data, and the material
balance d3ta collected from the nine steel mills by PES. This “typ-
ical” steel mill material balance is presented and discussed In
Section 9.
The total input of oils, greases and hydraulic fluids for Mill A,
based on purchase records, are sumdrized In Table 8-23. A suninary
f the material balance estimate output terms Is presented in Table
8-24. In making his analysis of Mill A, a small Integrated steel
mill, Jablin attempte to approach each loss term estimate from more
than one viewpoint. For example, to estimate the quantity of oil
on products the theoretical amount was calculated based on references
to oil film thickness and the average gage of steel product rolled.
A second method of estimating the quantity of oil on products leaving
the plant was based on the quantity of coating oils applied minus
the estimated amounts lost due to drippage and volatized during ap-
plication. From the estimates of individual loss terms Jablin de-
veloped an overall best” estimate taking into account all available
data and including field observation and engineering judgment. The
estimation method and logic regarding each loss term are suim arized
in the following pages of this section.
8.12.1 On-Product
Two approaches to estimating the amount of oil on-product were pro-
vided by Jablin. A graph relating the amount o’ coating oil on-
product per quantity of cold rolled strip for an oil film thickness
of 0.00025 cm (0.0001 inch) was utilized. The curve, included here
8-82
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Table 8-23. MILL A OIL, GREASE AND HYDRAULIC FLUID PURCHASE DATA
Hydraulic Oils
Bulk Grease
Gear Oils
Coating Oils
Rolling Oils
Miscellaneous Greases
Miscellaneous Oils
Motor Oils
TOTAL*
284,000 gal/yr
253,000 lb/yr
115,000 gal/yr
58,000 gal/yr
31,000 gal/yr
20,000 lb/yr
7,000 gal/yr
5,000 gal/yr
534,125 gal/yr
Output Term
Drained, collected
In sludges
Wastewater discharge
Volatized
On-Products
On-Mill scale
Trash and debris
Leaks and spills
Left in containers
TOTAL
TOTAL
Input :
(1.0 gal = 3.785 1)
*Note: Jablin converted grease data to gallons using a factor 01
8 lb/gal. His matertal balance estimate for “Mill A” is
in gallon units.
(1.0 lb = 0.4536 kg)
(1.0 gal = 3.785 1)
Table 8-24. SU 4ARY OF MILL A MATERIAL BALANCE VALUES
Quantity
( gal/yr )
250,500
57,800
57,300
51 ,595
40,740
36,800
19,825
7,000
1 ,382
Percent
of Input
46.9%
10.8%
10.7%
9.7%
7.6%
6.9%
3.7%
1 .3%
3%
519,342 97.9%
534,125
Unaccounted for: 2.1%
8-83
-------
a Figure 8-11, is independent of sheet width or coil size. From a
breakdown of Mill A cold gages produced in 1976 it was calculated
that the averag3 gage was about 0.13 cm (0.050 inch). Jablin esti-
mated the oil film thickness on Mill A cold rolled product to be
0.00064 cm (0.00025 inch). At 0.13 cm (0.050 inch) gage Figure 8-11
indicates a 0.50 1 (0.12 gal) of coatir g oil per 1000 kg (ton) of
product. Since an oil film thicI’ ne s of 2.3 tImes that for which
the curve was drawn was considered typical, Jablfn concluded that
the oil on-product loss term was 1.3 1 (0.30 gal) of coating oil per
1000 kg (ton) of cold rolled sheet product. Approximately 1.2 x 108
kg (131,600 tons) of cold rolled product were made, resulting in a
total oil on-product quantity of about 150,000 liters (39,500 gal)
per year.
The second method of estimating the oil on-product loss term utilized
the coating oil purchase data and estimates of the amounts of coat-
ing oil lost due to drippage and volatization. A total of 220,000
1/yr (58,000 gal/yr) of coating oils were applied. Of this amount,
it was estimated that 22% was volatized when applied. The basis for
this assumption concerning volatized coating oil is discussed in
SubsectIon 8.12.5. An additional 19% of the remaining coating oil
was estimated to be lost due to drippage from the product. The oil
on-product calculation Is as follows:
Total coating oil usage = 58,000 gal/yr (131,600 tons of product)
[ 220,000 l/yr)
Volatile loss 22% x 58,000 gal/yr = 12,760 gal/yr [ 43,300 1/yr)
Dripp ge off product after application = 10% = 4,500 gal/yr
(17,000 1/yr)
Remaining on-product as shipped = 40,740 gal/yr (.31 gal/ton)
[ 154,200 l/yr
The two methods of estimating oil on-product leaving the plant both
yield a value of about 151,000 1/yr (40,000 gal/yr). For the Mill A
8-84
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0 0.05 0.10
Gage (cm)
0.15 0.20 0.25
4.0
3.5
C
0
4.3
0’
C,
2.5
3.0
0
2.O
0
S.-
w
4.3
1.5:
1.0
0.5
Note :
Steel Density 502 lb/ft 3
Oil Density = 7.78 ib/qal
= 58.3 lb/ft 3
Independent of Sheet
Width or Coil Size
0 .01 .02 .03 .04 .05 .06 .07 .08 .09 .10
Ga je (inch)
Fiqure 8-11. Quantity of Coatinq Oil on Cold Rolled Strip as a Function of Gaqe
-------
material balance estimate Jablin used the 154,200 1/yr [ 40,740 gall
yr (.31 gal/ton)] value which ac ounts for abut 7.6% of the total
input.
8.12.2 On-Mill 5 c e
The range of oil content in mfll scale from data reported by various
steel mills is areat. The bulk of the data obtained in the PES study
and reported in the literature indicate a typical oil content of
mill scale in the .2 to 1.0% range. At Mill A an average oil content
of 0.4% by we 4 ght was cited by Jablin. From this value and mill scale
quantity data a total of 139,000 1/yr (36,800 gal/yr) of oil on-mill
sca 1 e was calculated and ente”ed into the material balance estimate.
At Mill A mill scale is recycled to a sinter plant equiçped with a
scrubber for air pollution control. The scrubber reportedly captures
about 8% [ 11,100 1/yr (2,940 gal/yr)] of the oil volatized from the
mill scale. The remaining mill scale oil is volatized and discharged
to the atmosphere via the sinter plant stack, or in part is combusted
in the sinter machine.
a.12.3 Left in Containers and Lost in Storage
To estimate the amount of oils and greases left in containers or lost
in storage Jablin applied the following logic. From field examina-
tion it was estimated that approximately 10% of the greases are left
In the containers or drums. About 2% of the greases delivered and
used in bulk system are lost in this manner. About 0.1% of the pur-
chased oils are left in containers such as drums and bulktanks.
These quantities may be combusted with the drums if the drums are
scrapped or cleaned by a drum reclainer. To some extent oils and
greases left in containers may drip to the ground and be cleaned up
and disposed of wit! other solid wastes. The total quantity of oils
and greases lost via this term is as follows:
8-86
-------
oil: .1% x 500,000 gal/yr = 500 gal/yr L1890 1/yr]
drum grease. 10% x 2,500 gal/yr = 250 gal/yr [ 950 l/yr)
bulk grease: 2 x 31,625 gal/yr = 632 gal/yr [ 2390 1/yr]
TOTAL 1,382 gal/yr [ 5230 1/yr]
8.12.4 Leaks and Spills onto the Ground or Floo
This item will vary depending on oil .andling facilities, operating
practices and preventive maintenance procedures. From experience
at Mill A, an average of about 3 major spills occur on the ground
in a year with several more or less regular minor spills in addition.
The total loss from these leaks and spills is estimated at 18,900
1/yr (5,000 gal/yr). In addition, an estimated 7,570 1/yr (2,000
gal/yr) results from drippage 0 ff coated procLct. This oil will
eventually find its way into scud waste being cleaned up by slag
for the most part. The total in this category is therefore 26,500
1/yr (7,000 gal/yr).
8.12.5 Volatized, Burned or Consumed
Laboratory tests were made by Jablin for the purposes of the project
to determine the volatization loss of various types of oils, greases
and hydraulic fluids. These laboratory test data are plotted in
Figure 8-12 which was used to determine the percent weight loss of
four types of oils and grease at the appropriate temperature. The
four items tested represent 85% of the oils, greases and hydraulic
fluids used in Mill A. They also represent the great bulk of the
oils which are exposed to elevated temperatures. To translate these
tests into an estimate o volatile loss requires estimating the
“average” temperature to which the materials are exposed. These
estimates are as follows:
8-87
-------
—Coating Oil
—Rolling Oil
—Hydraulic Oil
— Grease
KEY
X Coating 011
(.1 Hydraulic Fluid
A Rolling Oil
0 Grease
350 400 450
TEMPERATURE, °K
5
U,
0
0
22%
Co
11
4
3
2
1
0—
300
1 0
(200°F)
(250°F)
Figure 8-12. Per ent Weight Loss After Exposure dt Temperature for 30 Minutes
-------
Grease 120°C (250°F) 10% loss
Coating 011 95°C (200SF) 22% loss
Hydraulic Oil 95°C (200°F) 11% loss
Rolling Oil 120CC (250°F) 13.5% loss
Applying these percentage losses to the purchased quantities of
oils, greases and hydraulic fluids for Mill A:
Grease 10% loss for 273,000 lb or 34,100 gal/yr = 3,410 gal/yr
(12,900 1/yr)
Coating oil 22% loss for 58,000 gal/yr = 12,760 ja1/yr
(48,300 1/yr)
Hydraulic oil 11% loss for 284,000 gal/yr = 31,240 gal/yr
(118,000 1/yr)
Rolling oil 13.5% ioss for 31,000 gal/yr = 4,185 gal/yr
(15,800 1/yr)
TOTAL VOLATILE LOSS 51 ,595 gal/yr
(195,000 1/yr)
Obviously some items would be volatized to a greater degree because
of 2xposure to nigh temperatures, such as table roll bearings, hot
metal crane lubrication, etc. In other cases, the temperature would
be less such as motor room bearings, hydraulic coil handling equip-
ment, etc. The above is presented as a reasonable overall estimate.
8.12.6 In Sludges
Blast furnace and sinter plant scrubber wastewaters are treated by
a clarifier before aischarge. Oil concentration data for the waste-
water entering and leaving the clarifier, along with the average
wastewater flow rate, were used to calculate the quantity of oil in
sludges resulting from iron and steelrnaking operations. This cal-
culation was performed as follows:
8-89
-------
Oil into clarifier: 8 mg/liter
Oil out of clarifier: 1 mg/liter
Average wastewater flow rate: 9,840 1pm (2,600 gpm)
(8 mg/liter - I mg/liter) (9,840 1pm 60mm 2 a ) =
99 kg/day (218 lb/day) 110 1/day (29 gal/day).
Based on 355 operating days per year the total quantity of oil on
ironmaklng sludges is approximately 39,000 1/yr (1O,3C’) gal/yr).
Two methods of calculating the quantity of oil on sludges from the
rolling operatins were employed bj Jablin. The rollina mill waste-
waters are treated by skimers and a clarifier before being discharged.
Concentrator sludge and clarifier urderfiow solids are generated at
a rate of 3.25 kg/1000 kg (6.5 lb/ingot ton). At a production rate
of 650 x io6 kg/yr (716,000 net ingot tons/yr), 208 x 106 kg/yr
(2,290 tons/yr) of sludge and solids are generated. Analysis of
concentrator sludge and clarifier underflow solids indicate that
about 7% of the material by weight is carbon. Assuming that 90% of
the oil is accounted for by carbon, and a 0.9 kg/l (7.5 lb/gal) oil
density, a total of 180,000 1/yr (47,500 gal/yr) of oil are contained
in the sludge from the rolling operations. An alterrate method of
calculating the oil content of rolling operation sludge was provided
by Jablin. The clarifier underflow contains 2,096 mg/liter of oil
and is withdrawn at a rate of 189 1pm (50 gpm). Multiplying these
terms and converting to kg/day (lb/day) units yields a value of
570 (1.258). Based on 300 days/yr 0.9 kg/i and (7.5 lb/gal), a
total of approximately 190,000 1/yr (50,300 gal/yr) are calculated
(the typical operating rate of the clarifier).
Depending on the method used for calculating the oils in rolling
operation sludge, a range from 219,000 to 229,000 1/yr (57,800 to
60,600 gal/yr) of oil in all plant sludges is obtained. A value of
219,000 1/yr (57,800 gal/yr) was selected by Jablin for use in the
material balance estimate. This represents about 10.8% of the total
oil, grease and hydraulic fluid input.
8-90
-------
8.12.7 Ii Trash and flebris
Trash and debris were calculated to contain a total of 79,000 1/yr
(20,825 gal/yr) of oil. This value was determined using the
following estimates and assumptions:
Oil absorbent: 142,000 lb/yr @ 20% by weight oil = 3,800
gal/yr (14,400 1/yr);
Rags: 77,000 lb/yr @ 10 by weight oil = 1,025 gal/yr (3,900
1/yr)
Miscellaneous debris*: 3,000 tons/yr 0 2% by weight oil =
16,000 gal/yr (60,600 1/yr)
Total: 20,825 gal/yr (78,900 1/yr)
8.12.8 In Wastewater
IWOES discharge monitoring records were used to calculate the oil
content of wastewaters from Mill A. The discharge ‘from steel works
average 5 mg/liter of oil and 11,400 1pm (3,000 gpm). Multiplying
the oil concentration and flow rate data, converting units and sum-
ming the discharges, Jablin determined that approximately 217,000
1/yr (57,300 gal/yr) of oil was discharged in wastewaters, based on
a 300 &y/yr operating schedule for the wastewater treatment facilities.
8.12.9 Drained, Collected and Skin ed
The following data and estimates were provided concerning quantities
of oil drained, collected and skimed at Mill A:
Reclaimed oils by direct collection: 122,000 1/yr (32,150 gal/yr)
(actual)
Reclaimed by cracking-water treatment: 583,000 1/yr (154,150 gall
yr) (actual)
Skiniiied and retained on lagotn: 243,000 1/yr (64,200 gal/yr) (es-
timated)
TOTAL: 948,000 1/yr (250,500 gal/yr)
*From floors, ,achine shops, degreasing, dirt, scrap metal, etc.
8-91
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Reclaimed oil at Mill A is used exclusively for fuel. It Is mixed
with 16 fuel 311 in the soaking p t oil tanks. Slulges from the
reclaiming operation are estimated at 0.1%.
8.12.10 Conrents on Material Balance Estimate for Mill A
As shown In T3ble 8-24, 97. % of the oils, greases and hydraulic
fluids purchased by Mill A are accounted for by the material balance
loss terms. The 2.1% unaccounted for is not considered significant
in light of the accuracy of the data and estimation methods. The
unaccounted for 42,400 1/yr (11,200 gal/yr) is prob3bly due to a
slight error in all of the component figures and does not represent
a major missing loss term. The weakest estimate, according to
Jablin, is the loss via leaks or spills to the ground and general
clean-up. Variations in reclaimed oil data, wastewater discharges
and mill scale oil content values could also easily account for the
2.1%. Figure 8-13 illustrates the Mill A material balance estimate
provided by Jablin.
8-92
-------
INPUT TtWMS
(AITPUI i Ii LO t F M
purchased oils,
greases and
hydraulic fluids
2,021,770 1/yr
(534,125 gal/yr)
reclaimed &
recycled
12q,1Fj) 1/yr
(3: ,1iy) c;a’/yr)
[ 6.3
11,130 1/ir
(2,941 qal/yr)
[ 3.6 1
293,810 1/yr
(77,625 gal/yr)
[ 14.51
21f,880 1/yr
L___ discharged to (57,300 gal/yr)
waterw. yS (10.7%]
948,140 1/yr
(250,500 gal,’yr)
[ 46.91
154,200 1 /yr
on prodiit (40,740 q i 1 /yr)
[ 7.6 1
to s aIe pile Zero
— on mill scales
(36,800 gal/yr)”\. volatized and eiritteil
to sinter plant
[ 6.9 ]
captured by scrubber
left tn containers or lost
in storage and naridi leg
5,230 1/yr (1 382 qal/yr)
[ 0.3 1 26,500 1/yr
———-—- leak, and spills onto ground, (7,000 qal/yr)
generally cleaned up and dispc ed [ 1.3 ]
________ 195,290 i/yr
colatilized. burned or (51 ,595 qal,’yr)
consumed ii process
[ 9.7 ]
218,770 1/y (57,800 qal/yr)
in sludges. tiesh and debris
[ 10.81 __________
in wastewâterS _______ wastewater
treatment
75,040 l’yr
—•- t o *jspi sal
(19,825 ga1Iyr
--
drained, collected or skinoned -
Unaccounted for: 2.1%
0 1/yr rerlaimed
(0 gal/yr) luDricants
waste oil 950 1/yr
sludge disposal (250 qal/yr)
reclamet ion
[ 0.1%1
947,200 1/yr
(250,250 gal/yr)fuel a
[ 4b.8 )
Figure 8-13. MATERIAL BALANCE - MILL A
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9. DATA SU ARY AND GENERALIZATIONS
A sumary of the data obtained from the nine steel mills and the
consultants is presented in this section along with generalizations
concerning steel mill lubricant usage, material balance estimates
and the fate of toxic substances. An effort has been made to pre-
sent estimates for a typical integrated steel mill. Also, estimates
are provided of total lubricant, oil, grease and hydraulic fluid
usage by the steel industry in the United States and the resulting
quantities of air and water pollution. A geographical breakdown of
air and water pollution discharge estimates, .‘esulting from the usage
of lubricants, oil, greases and hydraulic fluids by steel mills, is
included.
Only integrated steel mills were surveyed in the study. The appli-
cability to non-integrated and specialty steel mills of the generaliza-
tions derived from the PES data base were not tested or investigated.
Since 9O of the lubricants, oils, greases and hydraulic fluids used
in the Integrated steel plants is used in the shaping and rolling
steps, one would expect similar usage rates for non-integrated or spec-
ialty steel plants engaged in these shaping and rolling operations.
However, no data was obtained to substantiate this hypothesis. The
differences in the types and sizes of equipment, as well as the
types and quantities of products associated with non-integrated and
specialty steel mills may significantly influence the quantity and
types of lubricants and hydraulic fluids used. Differences in
wastewater treatment facilities and waste oil recovery efforts, along
with the factors influencing usage, could limit the similarities
between non—integrated or specialty steel plants and integrated
steel plants.
The integrated steel plant production capacity information contained
in Tdble 1-1 (presented in Section 1) indicate that the average
9-1
-------
plant capacity is 2.9 x 10 kg/yr (3.2 x 106 tons/yr). The average
production capacity of independent an specialty steel plants is
roughly an order of magnitude smaller than for integrated steel
plants. Independent and speci . lty steel plants account for only
about 15 to 20% of the total raw steel production capacity in the
United States.
The representativeness of the nine integrated steel mills surveyed
by PES was also considered. The total raw steel production capacity
of the nine surveyed mills is 41 x 10 kg/yr (45.2 x io6 tons/yr)
or nearly 30% of the total capacity of all domestic integrated steel
mills. The average raw steel production of the nine plants studied
by PES is about 4.5 x 10 kg/yr (5 x i0 6 tons/yr) compared to 2.9 x
10 kg/yr (3.2 x i0 6 tons/yr) average for all integrated plants. A
representative sampling of the types of shaping or rolling mills and
steelmaking equipment was obtained by including nine different steel
mills. The variety of products and differences in the relative
quantities of these products at the nine steel mills are thought to
be typical.
Estimatec and generalizations have been made by PES for a “typical”
steel mill. It must be pointed out that no two integrated steel
mills are alike and describing in detail the equipment, lubricating
practices and air or water pollution discharges at a “typical” steel
mill would be difficult. Whenever data and circumstances permit,
the lubricant usage and resulting air and water pollution discharges
should be studied on a case by case basis. The generalizations and
estimates made by PES are intended to be used as a starting point
or basis from which to begin more detailed investigations. The
generalizations and estimates for the “typical” mill and for the
steel industry in general are intended to Illustrate the magnitude
and relative importance of the various items investigated.
9-2
-------
9.1 Usage of lubricants, Oils, Greases and Hydraulic Fluids
The usage data obtained from the nine mills and the consultants are
suninarized in this section. As mentioned in previous sections of
the report, several factors influence the types and usage rates of
lubricants, oil, greases and hydraulic fluids at an integrated steel
mill. Two key parameters, steel production rate and the type of
products made, have been considered by PES.
9.1.1 Usage Versus Steel Mill Production
A suninary of monthly oil, grease and hydraulic fluid usage data are
presented in Table 9 -1. For each of the nine steel mills, the usage
data, broken down by oils, greases and hydraulic fluids are tabulated
along with the steel production capacity and number of rolling mills
at each plant. Also included are usage data provided by Lykins.
Pertinent remarks concerning the usage data appear in the last column.
The data in Table 9-1 along with the data concerning production rate
and type of products made were analyzed in a variety of ways. Least
squares correlations were made and correlation coefficients calcu.
lated for several combinations of the parameters in an effort to
verify relationships between the usage of lubricants, oils, greases
and hydraulic fluids and production capacity, production rate and
finally type of product made. In all cases the inclusion of con-
sultants’ data had little influence on the calculated correlation
coefficients indicating that the data provided by these consultants
was consistent with the data obtained by PES directly from the steel
industry. Since this was found to be the case, Lykins’ usage data
and Jablin’s data for Mill A are included in the correlations.
The total monthly usage c.f all lubricants, oils, greases and hydrau-
lic fluids was correlated to both the plant capacity and production
rate. These parameters are tabulated in Table 9-2. Note that the
9-3
-------
T able 9-I. i NTHLY OIL. GACASL MO HTDRA(LIC FtUID USAGE IEiTA
Inland Steel Co.pafly
Last Chicago. Indiana
253,690 1 140,699 kg 91,154 1
12 (67.025 gal.) (310,183 lb, ) (.24.063 gil.)
88,640 1 25 687 kg 56,510 1
1 (23.420 gal.) (56!.630 lb (14.930 gal.)
127,365 1 7,725 kg
16 (33.650 gil.) ( 11.030 lb.) No Data
436,830 1 55 661 kg 56 850 1
16 (115.410 gal.) ( 1 /2.110 lb.) (15.b20 gil.)
439,440 1 55 155 kg .192.403 1
—— 116.100 gal. l2 ,9l7 lb. (50.833 gal.)
No iata for process or
rolling oils.
No data for pr asS sils.
No hot strip or cold
rolling ullls.
Rolling oils, lubricants
end greases reported as
one value.
Value for 0 11i includes
40,360 g .n1 of rolling
and coiting oils.
Value for ‘Qils Includes
55,000 gal of rolling
oils.
Value for Oils’ inclwdts
10,000 gal of rolling
oils.
No hot strip or cold
rolling .1115.
No data for process oils
or hydrauliC fluids.
Satellite operations use
5 to 10% of these stocks
STIlL HILL N W LOCATION
United States Steel Corporation
ary, Indiana
South Chicago, Illinois
APPROIIPIAT( STEEL
P9ORJCT IQ(I
CAPACITT( 1)
kg/yr Tons/Tear
1.3 * 10 (8.0 * 106)
4.8 a 10 ( .25 *106)
7.4 a l0 (8.2 x l0 )
N1I4& N
OF
HILLS 12 O .LS GRTASES
567,750 1 58,968 ka
31 (150,000 gal.) (130 .0C C lb.)
400 79 1 116,422 kg
10 (l0. 89 gil.) (256.663 lb.)
‘F
HYDRA Ii. IC
fl.UIDS
75,700 1
(20.000 gal.)
82 600 1
2l .k23 gal.)
Toungitowa Sheet and Tube Co.peny
Lest Chicago. Indiana 5.0 a
kthl.h Steel Corporation
Sparrows Point. Paryland 6.8 a 10
1 126,038 1 157,710 1
30 1297.500 gal.) ( 41 .667 gal.)
(Oils and greases reported
as one value)
1,068,390 1 99,9’8 kg 438,380 1
14 (282.270 gal.) (220.410 lb.) (pS.d20 gal.)
573,690 1 143,234 kg 243,150 1
21 (151.600 gal.) ( 329.Othl lb.) (64.400 gal.)
.3onas and Leurhl in Steel Corporation
Al iquippa, Pennsylvania
Republic Steel Corporation
South Chicago. Illinois
I tarlake, Inc.
Riverdale, Illinois
Liiier Steel Corposetton
Fontane, Cilifornia
Lst.I.ate Provided by Lytins
(5.5 *106)
(7.5 *106)
3.64 106)
(2.0 *106)
(0.3 *106)
(3.6 a l0 )
3.0 a 106)
3.5 a l0
1.8 a lO
0.6 a 10
3.3 *
2.7 a lO
iteel production capacity data was taken fr the IISS Steel Industry in Brief . Nost steel iills reported that production levels corresponding to
the period for which lubricant usage dita were reported were approximate’y 70% of capacity.
t The Ni ber of roiling •Ills listed r*presents the total priaary and finish shaping and rolling nills as reported in the AISI Directory of iron end
5teel Works or by the steil •ill during the PES survey.
3 Youmjpstanin Sheet and Tube reported usage rates per raw ton of iteel produced, P13 assii.ed tnst the plant was operated at 10% of the reported capacity
li,t*d in the 1155 Sceel Industry In Brief .
-------
Table 9-2. TOTAL USAGE AND PRODUCTION DATA
Steel Mill Total Oil, Grease & Production Capacity Production Rate
Hydraulic Fluid Usage
Units kg/mo (lb/mo) 10 kg/yr (106 tons/yr) 10 kg/yr (106 tons/yr)
USSC - ry 637,310 (l,4O ,OOo) 7.3 (8.0 ) 4.6 (5.1
USSC — South Chicago 226,688 ( 499,753) 4.8 (5.25) 3.3 (3.675)
Inland Steel 1,153,845 (2,543,750) 7.4 (8.2 ) 6.5 (7.2
Youngstown Sheet & Tube l,4 4,29O (3,206,100) 5.0 (5.5 ) 3.5 (3.85 )
Bethlehem Steel 884,066 (1,949,000) 6.8 (7.5 ) 5.0 (5.5
Jones & Laughlin 450,648 ( 993,493) 3.5 (3.84) 1.8 (2.0 )
Republic Steel 156,152 C 344,250) 1.8 (2.0 ) 1.4 (1.5 )
Interlake 122 ,’OO ( 269,400) 0.8 (0.9 ) 0.57 (0.63 )
Kaiser Steel 499,384 (1,100,935) 3.3 (3.6 ) 2.3 (2.5 )
Lykins Data 623,661 (1,374.915) 2.7 (3.0 ) 1.9 (2.1 )
* Note: When actual production rates were unavailable a 70% production level was assumed.
-------
usage data have been converted to mass units, using a 0.9 kg/i (7.5
lb/gal) factor, and all oils, greases and hydraulic fluids are in-
cluded in the figures presented in the second column of the table.
The raw steel production capacity of each mill is shown in the third
column, while actual production rates are found in the last column.
Plots of total usage versus production capacity and also production
rate are provided in Figures 9-1 and 9-2. Also shown in each of
these figures are the least squares line, correlation coefficient
and regression equation. In both cases, statistically, there appears
to be a strong correlation and the confidence limit on the correla-
tion coefficient lies between 95 and 98%.
A few conmients must be made regarding the data used to develop these
correlations. As noted in the remarks column of Table 9-1, the usage
data provided by some of the steel mills does not include process or
rolling oils. In one case hydraulic fluid usage data were not avail-
able. Satellite operations at another mill used some of the lubri-
cant stocks, resulting in a higher than actual usage value. The
effect of these differences in the usage data is to add to the
uncertainty or error inherent in the correlations.
Both production capacity and actual production rate were correlated
to allow use of the PES findings with either type of data. For ex-
ample the total quantity of oils, greases and hydraulic fluids used
by the steel industry in 1975 have been estimated using AISI produc-
tion rate data for that year. The total usage of oils, greases and
hydraulic fluids was also calculated using JISS production capacity
data. These calculations are provided on the next page.
According to these calculations, it is estimated that about 23 x
io6 kg/month (50 x 106 lb/month) of oils, greases and hydraulic fluids
are used by the domestic integrated steel mills. Stated another way,
about 300 x 106 1/yr (80 x 106 gal/yr) of lubricants and hydraulic
fluids are used by integrated steel mills.
9-6
-------
CALCULArI0Ns OF TOTAL LUBRICANT USAGE
Usage vs Production Rate
Y 320,000X + 278,900
For all 47 integrated steel mills and a total actual pro-
duction in 1975 of 116.64;’ x 106 tons/yr (AISI):
Y = 320,000 X + 47 278,900
= 37,325,440 + 13,108,300 = 50,433,740 lb/month
or approximately 50 x l0 lb/month [ 23 x 106 kcj/month)
Usage vs Production Capacity
Y = 246,400X + 190,900
For all 47 integrated steel mills and a total production
capacity of 148.555 x 106 tons/yr:
Y = 246,400 X + 4?• 190,900
= 36,603,950 + 8,972,300 = 45,576,250 lb/month
r approximately 46 x io6 lb/month [ 21 x io6 kg/month)
Note: V = aX + b for X 1 , X 2 , X 3 X 1 X
n n
= a X+n•b
1=1 i=l
9-7
-------
1
U
0
=
•0
a)
In
I .
In
0
In
4J
C
I D
U
I.
-J
0
C.,
‘C
U I
I D
4.,
0
I-
-C
4. )
C
0
E
0
C
><
3.0
2.0
1.0
0.8
0.6
0.4
0.2
0
0
1’ .1
T 1 L : J1
i I ± 1ij __
- i - - - - - N & -
I TTT
L_4
TL IiI 4It IlLi I1I
USSC:GARY
- a t u res Line
:1 y46, ()rJ +190,900
-— - - 4 H___ =0 j53=1O 95 t98%
-__ I -
• V I__ - _CHICAGO O.2
EPu LIc - . . . . . 4
i_
/ JNTFF L __ —--- --

r: F TTT T tn 0
4-,
2 3 4 5 6 7 8
X10 6 Tons/yr
Raw Steel Production Capacity
Figure 9-1. TOTAL USAGE VS. PROCUCTJON CAPACITY
9-s
9 10
-------
X 1O kg/yr
Figure 9-2. TOTAL USAGE VS. PRODUCTION RME
_: ii
——
•1
I S
I I
4 5
6
7
-— .-- J
U
L
L C
4 - I
C
E
-
C
• 0
‘p
‘C
‘-I
-a
0
C-
0
3.0
2.0
1 .0
0.8
0.6.
0.2
0
IL
/O 4 --_-

.- :. .: H
±H±
: 4
— --
- -j
H
-

• .-•i
I 1
I____
I
I : (
Y-3 o,book+z ‘00 1
-
7 r0 682 fi—lO •9 S t o
J
:T C TA t i f
/ ic L . .
o_1! 1 E LA E
.i
4- 1
0
E
0
cD
‘ C
0 1 2 3 4 5 6 7 8 9 10
X10 6 Tons/yr
Raw Steel Production Rate
9-;
-------
The reader Imist be cautioned that estimating total oil, grease and
hydraulic fluid usage using the PES correlations can provide only
an order of magnitude value. As improved equipineit lubrication,
wastewater treatment and waste oil recovery practices are adopted
by the steel mills (and such changes are taking place currently)
the regression coefficients will change.
A second potential use for the calculated correlations would be for
estimating the expected usage at a mill not studied by PES, using
either production capacity or actual production rate data. Again
major differences in equipment design and lubrication practice, as
well as other factors influencing lubricant usage, could result in
a much different actual usage value. New steel mills which can be
expected to have much improved lubrication systems, wastewater treat-
ment facilities and waste oil recovery efforts could be expected to
differ significantly from the correlation. The use of the calculated
correlations with either production capacity or actual production
rate data would be appropriate if actual oil, grease, and hydraulic
fluid data were not available. As will be demonstrated next, other
factors besides production rate influence lubricant usage.
9.1.2 Usage Versus Product Type
An analysis of the correlation between lubricant usage and type of
product made was performed. The total oil, grease and hydraulic
fluid usage data for each of the nine steel mills were divided by
the corresponding production rate data to obtain a kg/bOO kg (lb/
ton) usage rate. Similarly the usage data for just oils (Including
lubricating, process and rol 1 ing oils) were converted to a 1/1000
kg (gal/ton) term. The kg/1000 kg and 1/1000 kg (lb/tun and gall
ton) usage rates are tabulated in the third and fourth columns of
Table 9-3. The secona column contains a parameter calculated by
PES based on the rolling capacities of the various mills within
9-10
-------
Table 9-3. USAGE AND PRODUCT DATA
Steel Mill Product Parameter Total Oil, Grease & Hydraulic Fluid Usage Total Oil Usag
USSC, Gary 59 1.653 (3.306) 1.473 (0.353)
USSC, South Chicago 0 0.816 (1.632) 0.146 (0.035)
Inland Steel 62 2.120 (4.240) 2.069 (0.496)
Youngstown Sheet & Tube 61 4.997 (9.993) 3.671 (0.830)
Bethieheni Steel 49 2.126 (4.252) 1.381 (0.3 l)
Jonas & LaughlIn 35 2.981 (5.961) 1.677 (0.402)
Republic Steel 0 1.371 (2.754) 0.780 (0.187)
Interlake 49 2.566 (5.131) 2.674 (0.641)
Kaiser Steel 39 2.642 (5.284) 2.311 (0.554)
Mill A 42 2.815 (5.630) 2.920 (0.700)
Units kg/bOO kg (lb/ton) 1/1000 kg (gal/ton)
-------
each st’ el mill. Th AISI Directory of Iron and Steel orks for
1975 providcd t ’e source of rolling capacities. Ic obtain a relative
percentage of rolled strip and coil products, the sum of all hot
strip, cold rolling, cold ‘inishing and temper mill capacities at
each plant was divided by the su of all shaping, rolling and fin-
ishing mill capacities. The parameter is expressed as a percentage.
The calculation of the product parameter is included in Section 8,
at the bottom of the equiprne,it sumary table provided for each of
the nine sLetl nills. The two plants with no mills capable of pro-
ducing strip or coil steel are assigned a product parameter of zero.
The plants with large capaciti.2s to roll hot strip or cold rolled
products have product parameters of around 60%. Sufficient input
was provided by Jablin to include Mill A in this correlation.
The product parameter calculated using the capacity of mills may not
agree precisely with the actual percentage of stip and coil products
made at each still mill. It is at least an indicator of the prod-
ucts made at the various plants. Due to a lack of actual product
data the product parameter was used to correlate lubricant usage.
Pots o. the usage data versus product parameter are provided in
Fig ires -3 and 9-4. Also shown on each of these figures are the
least sq1.ares line, correlation coefficient and regression equation.
The correlation betweefl total oil, grease and hydraulic fluid usage
per production rate and the product parameter has a correlation co-
efficient with a confidence limit of between 90 and 95%. The cor-
relation between the usage rate of oil per production rate and the
product paran’cter appears stronger. The confidence level for the
correlation coefficient in this case is 98%. Again the reader is
reminded that the remarks irniicated in Table 9-1 concerning the
usage data will affect the correlat.OnS. The lack of process or
rolling oil data; and for one mill, hydraulic fluids, causes these
usage terms to be lower than the actual case. On the other hand
9-12
-------
Percent
Product Parameter
Figure 9-3. OIL USAGE RATE VS. PRODUCT PARAMETER
9-13
ic. —— - — - -
_4n
- . . . — .1- . - I - *
T’
__ : :i :_ - t ____
- -—--—- . --—.-- ----.- - — — —
T I- It 1 ri i - - I 1 t - III
- t - - -
__ ___ 1 I
____ LIL1 ±J±! >/: I
0.9
0.8
0.7
0.6
0.5.
0.4
0.3
0.2
U
0
L
0 .
a)
0)
L’)
‘V
I—
0
0
L
C-
1
“I
0)
U
0
C-
‘V
C
0
C
‘V
U
L
-I
I .-
0
0)
‘V
0)
‘V
UI
‘V
4 -’
C
C
0
4 - ’
4-’-----
Ti±: : - A-
:INLA’ U
J_ .
1Le4St!Sq ar4s 1..lnq
1 M783 J 8i

49 LiI:iJ
5- I
- 4
.
:r . 1 i ii ii 1 ii iii ti — — --- -
0
0
20 30 40 50 60
70
-------
Percent
Product Parameter
Figure 9-4. TOTAL USAGE RATE VS. PRODUCT PARAMETER
0
.0
4 )
U
C
0
a)
4)
4.)
1
Va
0
C
0
I-
4)
0.
U-
U
V a
=
•0
0 )
tO
a)
0
4)
C
tO
U
I-
-J
0
a. ’
4. )
tO
4)
Va
tO
4-)
0
9-14
-------
the use of a portion of Kaiser’s lubricant stocks by a satellite
operation results in a higher than actual usage rate. The oil usage
rate for Inland Steel includes greases while the oil usage rate for
Mill A includes hydraulic fluids. It is impossible to determine the
magnitude of the error resulting from these discrepancies in the
usage data. The regression equations are thought to be accurate for
order of magnitude calculations.
9.1.3 Usage In Rolling Operations
Three steel mills surveyed provided lubricant and hydraulic fluid
usage data by plant area, enabling an analysis 0 f the relative amount
used in the rolling operations. The hypothesis at the project outset
was that the rolling operations were the major users of lubricants.
On this assumption an effort was made to include in the study inte-
grated steel mills which have relatively large nuwbers of rolling
mills. A test of this hypothesis was called for.
The percentage of the total lubricants, oils, greases and hydraulic
fluids ued in the rolling operations at the three steel mills pro-
viding adequate data for such an analysis are listed below:
Bethlehem Steel 90%
Inland Steel 82%
Youngstown Sheet and Tube 98%
In addition to the percentages calculated by PES from steel mill u-
sage data, Jablin reported that 90% of all lubricants, oils, greases
and hydraulic fluids used at Mill A were associated with the rolling
operations. Thes data for four integrated steel mills indicate
that an average of about 90% of all lubricants, oils, greases and
hydraulic fluids are used in the rolling operations. The ironrnaking,
steelmaking and auxiliary processes account for the remaining 10%.
The other steel mills did not report usage data in a form that could
be used to calculate th! usage by the rolling operations.
9-15
-------
9.1.4 Usage at a Typical Mill
The lubricant, oil, grease and hydraulic fluid usage data obtained
from steel mills and the consultants have been sumarized and cor-
related to different parameters in this section. As a final exercise
usage calculations for a typical mill were performed. An integrated
steel mill with annual production capacity of 3.6 x 10 kg/yr (4.0
x 10 tons) was selected. Integrated steel plant capacities range
from about 0.8 x lO to 7.4 x l0 kg/yr (0.9 x to 8.2 x 106
tons/yr) and averaae around 2.9 x lO kg/yr (3.2 x io6 tons/yr). A
list containing integrated steel plants is provided in Section 1.
A produ .tion capacity of 3.6 x lO kg/yr (4 x 106 tons/yr) was con-
sidered to be typical by PES and the consultants.
Using the usage versus production capacity regression equation de-
scribed in subsection 9.1.1 a total lubricant, oil, grease and hy-
draulic fluid usage rate per month was calculated to be 533,660 kg/
month (1,176,500 lb/month) or roughly 0.54 x 106 kg/month (1.2 x
io6 lb/month). Considering the accuracy of the correlation and due
to variations in actual usage caused by the several factors influen-
cing usage rates, this calculated value is thought to be a range of
about +20%. No evaluation of error or uncertainty was possible due
to the nature of the data.
If we assume that the typical steel mill is composed of various
shaping, rolling and finishing mills such that a product parameter
of 40% results, an oil usage rate (lubricating, process and rolling
oils) of 1.9 1/1000 kg (0.46 gal/ton) of steel production is cal-
culated using the appropriate PES correlation. Similarly a total
luLuicant, oil, grease and hydraulic fluid usage rate of 2.4 kg/
1000 kg (4.8 lb/ton) of steel production Is calculated. Applying
the calculated 2.4 kg/l000 kg (4.8 lb/ton) usage rate to the 3.6 x
10 kg/yr (4.0 x 1O 6 ton/yr) typical steel mill and assuming a 70%
production level, a total usage of about 6.1 x 10 kg/yr or 0.5 x
io 6 kg/month (13.4 x 106 lb/yr or 1.1 x 106 lb/month) is obtained.
9-16
-------
The regression equations determined from the steel mill data can be
used to estimate approximate lubricant usage rates for integrated
steel mills knowing the raw steel production capacity. The findings
and regression equations presented in this section are, in effect,
empirical relationships. The main intent of the study was not to
develop a method of e timating steel mill lubricant usage per se
but such a procedure was needed to carry out the extrapolation of
material balance loss term data to other integrated steel mills and
the industry in general.
9.2 Material Balance Estimates
A sunn ary of the material balance data and the generalizations re-
garding typical steel mill loss terms are presented in this section.
Material balance estimates for eight integrated steel mills (seven
mills surveyed by PES and Mill A) provided the basis for calculating
average loss terms. Table 9-4 sunlnarizes the loss term data, ex-
pressed as percentages of the total lubricant, oil, grease and hy-
draulic fluid input to each steel mill. From the available data the
average value and range of values of each loss term were computed.
The last column of Table 9-4 indicates the value selected as repre-
sentative of a typical steel mill. In light of the wide range of
values encountered and the recognized uncertainty in the data, whole
number values were chosen for the typical mill.
9.2.1 DiscussIon of Loss Terms
The variability of the loss terms at different steel mills is thought
to be caused by two factors. Errors or uncertainty in the data may
result In a portion of the data spread; however, the principal cause
of loss term variability can be attributed to differences in equip-
ment and practices affecting the usage and fate of lubricants. In
addition, the loss terms are interrelated at a given steel mill.
The variability of data for eacP loss term is coninentedon in the
following paragraphs.
9—17
-------
Table 9-4. SU 44ARY OF MATERIAL BALANCE LOSS TERI’6
LOSS TEI 4S
USCC - GARY
INLAND
YS & 1.
BETH 1HEM
J & t.
REPUBLIC
KAISER
MILL A
AVERAGE
RANGE
“TYPICAL MILL”
On Products
On MIII Scales
Dlschdrged to Waterways
In Sludge, Trash & Debris
ToRec aimers
Left In .ontainers
leaks & Spills
Volatilized or Consumed
3.6
LI
7.1
28.5
53.8
0.9
0.7
3.7
3.4
3.7
3.7
21.8
14.1
?
0.4+ ?
7
1.5
3,6
11.7
46.8
12.1
?
0.2+ ?
7
4.7
.2.3
14.1
55.6
14.5
5.0
3.7
2.0
19.4
20.1
9.8
52.8
0
?
?
?
5.0
9.3
7.0
54.7
0
7
7
?
0.9
34.3
0.1
35.0
8.5
5.0
5.0
12.6
7.6
6.9
10.7
14.5
46.9
0.3
1.3
9.7
5.8
11.4
8.0
38.7
18.7
2.8
1.9
7.0
0.9 - 19.4
1.1 - 34.3
0.1 - 14.1
14.5 - 55.6
0.53.8
0.3- 5.0
0.2 - 5.0
2.0 - 12.6
6
11
8
39
19
3
2
7
Total:
Unaccounted for:
99.4
0.6
57.1
42.9
75.9
24.1
101.9
-
102.1
—
7 .O
24.0
101.4
-
97.9
2.1
9

Notes: 1. All numbers represent percentage of total lubricant, oil, grease and hydraulic fluid input to the steel mill.
2. Whole number values were selected for the “typical mill”, reflecting the accuracy of available data and estimates.
-------
Oil and grease in wastewater discharges account from about zero to f If-
teen percent of the total steel mill lubricant input. The wastewater
treatment facilities and water use systems determine the amount of
oil and grease discharged. For example, at Kaiser Steel where a
nearly complete water recycle system is operated, the loss of oil to
waterways Is very low. In areas where water is more available and
water use systems are not designed for recycle, the discharge of
wastewaters containing oil is more significant. As improved waste-
water treatment facilities and water recycle systems are installed,
the percentage of oil discharged to waterways will decrease. Event-
ually zero discharge of wastewater may be required of all steel
mills. The achievement of zero discharge is stated as a goal in
P1 92-500, the Federal Water Pollution Control Act. Better waste-
water treatment facilities, while decreasing the “discharged to
waterways” loss term, will result in a higher “in sludge, trash and
debris” loss term. Current practice typically ca1ls for disposal of
sludges and trash, along with the oil they contain, in a landfill.
From the data it appears that about 15 to 55 percent of the oil,
grease and hydraulic fluid purchased by steel mills are contained
in sludge and trash in landfills. No data was obtained regarding
the ultimate fate of oil in landfills.
Good wastewater treatment facilities are also related to waste oil
recovery and reclamation practices. Current waste oil recovery and
reclamation efforts vary widely in the steel Industry. From zero
to about half of the total oil, grease and hydraulic fluid input to
steel mills is reportedly being collected and sent to reclaimers.
The growing emphasis on waste oil recovery will increase the “to
reclaimers” loss term while reducing the oil and grease wastewater
discharge load. Recovered waste oils are mostly reclaimed as fuel
oil and burned, although efforts to reclaim more valuable lubricants
are increasing. The potential air pollution problems resulting from
combustion of fuels reclaimcd from steel mill waste oils was not
evaluated during the project.
9-19
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The thre loss terms, “discharged to waterways;” “in sludge, trash
and debrisY’ and “to reclaimers” are trongly interrelated for a
given mill. Together they account for from 43.6 to ‘ ‘.l p.-.cent of
the total lubricant input. On the average these three loss terms
represent about 65 percent of the material balance.
The next most significant loss term is the quantity on mill scales.
As indicated in Table 9-4 an average of about 11 percent of the oil,
grease and hydraulic fluid input to a steel mill ends up on mill
scales. The fate of oil on mill scales is determined by the method
of handling the scales. Mill scales are either stockpiled o recy-
cled to a sinter plant or the melt shop. Oil Ofl stockpiled mill
scale is thought to remain attached to the metal fines, although it
is expected that some of the oil may partially be washed off by
storm run-off. No data or information could be obtained regarding
the fate of oil in scale piles. The oil in recycled mill scale is
volatized or combusted depending on flame temperatures. It is thought
that the oil on mill scale returned directly to the melt shop is
combusted while oil on scale sent to the sinter plant is volatized.
The type of air pollution control equipment installed on the sinter
plant affects the ability of the sinter plant to handle mill scale
with attached oil and also the amount of hydrocarbons emitted to the
atmosphere. The fate of oil on mill scales for the eight steel mills
is shown in Table 9-5. Of the total steel mill lubricant input about
11 percent is attached to mill scales. By fate, six percent qoes
to the scale pile and 5 percent is contained on recycled mill scale.
Future recovery of oiiy mill scale is under study by the steel indus-
try. When a technically and economically feasible method of removing
the attached oil is developed, the fate of oil on mill scale will
change. Much less mill scale (and attached oil) will be stockpiled
and possibly more oil will be recovered. Changes in siriter plant
air pollution control equipment will also affect the quantity of
hydrocarbons emitted and captured at the sinter plant.
9-20
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Table 9—5. FATE OF OIL Oti MILL SCALES
Steel Mill Total To Scale Pile To Sinter Plant/Melt Shop
IJSSC - Gary 1.1 0 1.1 emitted
Inland 13.7 13.6 0.1 emItted
emitted
YS & 1 3.6 2.2 1.4 or burned
1.7 emitted
Bethlehem 2.3 0 0.6 captured
J & 1 20.1 0 20.1 emitted
Republic 9.3 0 9.3 combusted
KaIser 34.3 34.3 0 -
6.3 emitted
Mill A 6.9 0 6.9 0.6 captt red
Avtage 11.4 6.3 5.1
Note: All numbers represent the percentage of the total
lubricant, oii, grease aid hydraulic fluid input to the
steel mill.
9-21
-------
The amount of oil volatized or consumed in process or use at steel
mills account for an average of seven percent. This term varied
from 2 to 12.6 percent for the eight mills investigated. Two oppor-
tunities are provided for volatizing oil, grease and hydraulic fluid.
The use of oil and grease in equipment or application on product at
high temperature (above 66°C [ 150°F]) results in some loss. A second
opportunity for volatizing oil occurs when water containing oil is
used to cool or quench metal, slag or equipment. As mentioned pre-
viously, the required shift to complete wast water recycle at steel
mills will result in great r quantities of volat zed oil. At Kaiser
where nearly complete water recycling is practiced, the volatized
loss teri is 12.6 percent.
Oil on products accounts for a six percent loss term. This fate or
loss term is affected primarily by the type of product made and is
essential since rust prevention or protection is required for some
types of product.
The amount of oil, grease and hydraulic fluid left in containers or
lost in storage and handling represents about three percent of the
lubricant input. It is thought that little can be done to alter
this, although the increasing cost of lubricants will stimulate more
efficient handling. The fate of oil, grease and hydraulic fluid
left in containers is not known specifically for each mill.
Leaks and spills which are generally cleaned up and disposed of ac-
count for an estimated two percent of the total input. This will
vary with equipment age and maintenance. As lubricant costs increase
and requirements for better leak and spill prevention efforts are
adopted by th9 operating and r iaintenance personnel, this loss term
may decrease.
9.2.2 Typical Steel Mill Material Balance
The loss term percentag !s for a typical steel mill, shown in the
last column of Table 9-4, were applied to the total oil, grease
9-22
-------
and hydraulic fluid usage rate estimated previously for a 3.6 x 10
kg/yr (4 x 106 ton/yr) capacity plant. As computed in section 9.1.4,
this total usage rate is about 544,000 kg/month (1,200,000 lb/month).
Multiplying this usage rate by the loss term percentages, a material
balance e timate was derived for a typical mill. Figure 9-5 illus-
trates the calculated material balance. The fate ot oils sent to
reclaimers (21%) was assumed to be distributed as follows:
fuel 15%
reclaimed lubricant 5%
sludge from the reclamation process 1%
9.3 Air and Water Pollution Discharges and Solid Wastes
Using the typical lubricant usage rate and loss term percentages
determined during the study, estimates were made of the quantities
of air and water pollution discharges and solid wastes resulting
from the use of oils, greases and hydraulic fluids in the steel in-
dustry. These estimates for a typical steel mill, and the entire
domestic steel industry, are described in this section. The assump-
tions and logic used to develop the air, water and solid waste pol-
lution loads or contributions are identified, also. The pollution
estimates were computed to determine the magnitude and relative
importance of potential environmental problems stenining from the
use of lubricants by the steel Industry.
9.3. 1 Estimation Procedure
The first step in preparing estimates of the quantities of air and
water pollution and solid wastes was to relate the loss terms to the
air, water and solid waste pollution categories. For each loss term,
the contribution (as a percentage of the total steel mill lubricant
input) to either air pollution, water pollution or solid waste was
assumed. Table 9-6 suninarizes the results of this process. The de-
cision or assignment of the loss term percentage to a type of
9-23
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INPUT TERMS
cJJTPUT OR LOSS TERMS
purchased oils.
greases and
hydraulic fluids
544,000 kg/mo
(1,200,000 lb/mo)
reclaimed &
recycled
6
on products 36,640 kg/mo
(7L,000 lb/mo)
on mill scales to
left in containers or lost
in storage and ha ’liflq 16,320 kg/mO
(36,000 lb/mo)
leaks and spills onto ground. 2%
gencrally cleaned uP and disposed 10,880 kg/mo
(24,000 lb/mo)
volatilized, burned or 7
consumed n procesS 38,080 kg/mo
(84,000 lb/mo)
debris
6
to scale pile 36,640 kg/me
(72,000 lb/mo)
5%
sinter plant 27,200 kg/mo
(60,00U lb/mo)
39%
to Isposa1 212,160 kg/mo
(468,00J lb/mo)
discharged to 8 %
waterwayS 43,520 kg’mo
96,000 lb /mo)
sludge disposal
1. ’
5440 kg/mo
(12,000 lb/mo)
Unaccounted for: 5%
N)
in sludleS, trash ‘nd
in wastewaters
12%
65,250 kg/mo
(144,000 lb/mo)
fuel
Figure 9—5. TYPICAL STEEL MILL MATERIAL BALANCE
-------
Table 9-6. POLLUTION SIM4ARY
No resulting pollution.
Of the 6% of oil In stockoiled mill scab 1% is washed
off and becomes water poilution and 1% Is permanently
“stored.”
Of the 5% of oil in recycled mill scale 4% is volatil-
Ized and the renainder is combusted or Captured.
Loss Term
Percent
Air Pollution
Water Pollution
Solid Waste
Assisnpt ions
8
‘.0
U ’
On Products
On Mill Sc’les
Discharged to Waterways
In Sludge, Trash & Debris
To Reclaimers
Left in Containers
Leaks & Spills
Volatilized or Consijned
6
11”
8
39
19
3
2
7
4
6
39
2
The fate of oil in landfills was not considereJ.
One percent si dye from the reclamation process.
potential air pollution from fuel combustion was
considered.
One percent is in containers whicn are discarded
a landfill.
All leaks and spills are cleaned up and disposed
of in landfills.
One percent is combusted.
The
not
in
Total
g
. 10
9
44
32 aoes not result in air or water pollution or
solid waste and 5% is unaccounted for.
-------
po lution was stra1 htforward in some cases. For example the oil
and qre3se discharged to waterways is obviously a source of water
pollution. In other cases, such as oil and grease left in containers
or lost in handling or storage, assumptions had to be made with
litt e information upon which to base them. The goal was to identify
the potential pollution sources and the relative magnitude for a
typical steel mill. The assunption made by PES are noted in the
last column of Table -6.
A total of 10 percent of the oils, greases and hydraulic fluids re-
suit in air pollution, 9 percent co itribute to water pollution, and
44 percent become solid waste. The remaining 32 percent does not
result in a pollution or solid waste problem. Five percent is unac-
counted for. The nature of the loss term data and the number of
assum ’tions needed to arrive at these pollution percentages limit
the confidence that can be placed on their accuracy or correctness.
It is thought that realistically a range of values should be stated.
The percentage of the total oil, grease and hydraulic fluid input
to a typical integrated steel mill which enters the environment can
be sumarized as follows:
Air pollution 5 to 15
Water pollution 5 to 15 %
Solid waste 30 to 60 %
9.3.2 Pollution Estimates
The pollution percentages were applied to the lubricant usage rate
for a typical inegrated steel plant [ 3.6 x 10 kg/yr (4 x 106 tons/
yr)] raw steel production during 1975. At a typical steel mill,
544,000 kg/month (1,200,000 lb/month) of oil, grease and hydraulic
fluid is used resulting in roughly 54,400 kg/month (120,000 lb/month)
of air pollution, 43,520 kg/month (96,000 lb/month) of water pol-
lution and 239,500 kg/r onth (528,000 lb/month) of solid waste.
These calculations are shown on the next page.
9-26
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Polluti’n Estin ate for a Typical Integrated Steel Mill
(3.6 x 10 kg/yr (4 x io6 tons/yr) raw steel production capacity)
Total oil, grease and hydraulic fluid input =
544,000 kg/mo (1,200,000 lb/mo)
Air Pollution :
10% x 544,000 kg/mo (1,200,000 lb/mo) = 54,000 kg/mo
(120,000 lb/mo)
5 to 15% = 27,200 to 81,600 ‘g/mo
(60,000 to 180,000 lb/mo)
Water Pollution :
9% x 544,000 kg/ no (1,200,000 lb/mo) = 43,520 kg/mo
(96,000 ‘tb/mo)
5 to 15% = 27,200 to 81,600 kg/mo
(60,000 to 180,000 lb/mo)
Solid Waste :
44 x 544,000 kg/mo (1,200,000 lb/mo) = 348,160 kg/mo
(528,000 lb/mo)
30 to 60% = 163,200 to 326,400 kg/mo
(360,000 to 720,000 lb/mo)
9-27
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The total usage of od, grease and hydraulic fluid by integrated
steel mills was estimated to be about 23 x 100 kg/month or 300x
106 1/yr (50 x 1O 6 lb/month or 80 x io6 gal/yr) (see p. 9-6). Mul-
tiplying this usage rate by the pollution percentages it is estimated
that 2.3 x io6 kg/mo (5 x 106 lb/mo) of air pollution, 2.1 x io6 kg/
mo (&5x 106 lb/mo) of water pollution and 10 x 106 kg/mo (22 x 106
lb/mo) of solid waste is generated.
As a final exercise, the geographical distribution of the ir and
water pollution discharges and solid waste was computed using raw
steel production data tabulated by states in the AISI Annual Statist-
ical Report 1975 . These estimates are suninarized in Table 9-7.
9,4 Fate of Toxic Substances
As discussed In Chapter 3 of this report, most of the materials used
as lubricants and hydraulic fluids are derived from petroleum by
various refining processes. These base oils are Identical to those
used in the automotive industry and almost all other lubricants,
except for extremely high performance applications. Base oils are
generally considered to be non-toxic to humans because they have
been used extensively in the automotive service industry without
adverse effects. They do have adverse effects on marine life and
water fowl, and water pollution discharges are monitored to see that
allowable lImits are not exceeded. At high temperatures or during
comoustion, toxic polynuclear organic compounds may be formed from
base oils. The sinter plant Is an obvious location where this
might cccur. It is impossible to estimate the magnitude of these
emissions without actual test data, but they will be found as a
trace compound of the suspended particulate matter coming from the
sinter plant.
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Table 9 -7. GEOGRAPHICAL DISTRIBUTION OF POtLUTION
Percent
1975 of
Raw Total
Steel Steel Air Water Solid
States EPA Region Production Production Pollution Pollution Waste
Pennsylvania III 23.370 22.1 501.228 451,098 2.205.403
(25,161) (1.105.000) ( 994.500) ( 4.862.000)
Indiana V 17.969 17.0 385.560 347,000 1.696.464
(19.807) ( 850,000) ( 765,000) ( 3,740,000)
Ohio V 17.799 16.8 381,024 342,916 1.676.506
(19.620) C 840,000) ( 756.000) ( 3,696,000)
Illinois V 8.666 8.2 185,976 167,376 818,294
9.552) C 410,000) ( 369.000) C 1.804.000)
Michigan V 8.249 7.8 176,904 159,210 778,378
C 9.093) C 390,000) C 351,000) ( 1,716,000)
New York II 3,085 2.9 65,772 59,194 289.397
3.401) ( 145,000) ( 130,500) ( 638,000)
California IX 3,040 2.9 65,772 59.195 289,397
3 .351) ( 145,000) ( 130,500) ( 638,000)
Kentucky IV 1.888 1.8 40.824 36,740 179.626
2.081) ( 90,000) ( 81,000) C 396,000
Minnesota, Missouri, Oklahoma, V. VI, VII 4.898 4.6 104,328 93,894 459,043
Texas, Nebraska, Iowa C 5.399) C 230.000) ( 207.000) ( 1,0l2 00O)
Rhode Island. Connecticut. New Jersey I, II, 111 4.621 4.4 99.792 89,811 439,085
Delaware, Maryland ( 5.094) ( 220.000) C 198,000) C 968 000)
Virginia, West Virginia. Georgia, Florida III, IV, VI 4.360 4.1 92,g88 83,688 409,147
North Carolina. South Carolina, Louisiana ( 4.795) C 205,000) ( 184.500) C 902,000)
Arizona, Colorado, Utah VIII, IX, X 3.974 3.8 86.184 77,564 319,210
Washington. Oregon, Hawaii C 4.380) C 190,000) C 171.000) ( 836.000)
Alabama, Tennessee, Mississippi, Arkansas IV, VI 3.908 3.7 83,916 75,523 369,230
4.308) ( 185,000) ( 166,500) ( 814,000 )
105.818 100% 2,268.000 2,041,200 9,979.200
x l0 kg/yr kg/mo kg/mo kg/mu
(116.642) (5,000,000) (4,500,000) (22,000.000)
x10 6 ton/yr lb/mo lb/mo lb/mo
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The rest of this discussion deals with the fate of toxic compounds
that are present in the original lubricants and pass through the
chain of use without undergoing any profound chemical transforma-
tions. Lubricant additives and fire-resistant hydraulic fluids
are the main substances under consideration here. Additives are
used to impart specific lubrication properties for particular
applications and, as a result, are not found distributed uniformly
throughout the steel mill. It is of interest, therefore, to
attempt to determine whether these additives find their way to the
scale pits, solid waste disposal, wastewater or other of the final
destinations of steel mill lubricants, and to estimate the quantity
of each additive that is involved.
9.4.1 Sulfurized and Phosphorized Fatty Oils
Sulfurized and phosphorized fatty oils are used as EP additives in
gear oils and greases in quantities equivalent to ,024 — .03% phos-
phorus and .7 - .9% sulfur. These EP lubricants are used primarily
in hot and cold forming operations, and to a lesser extent in iron
and steel pr’ duction. Sufficient information was supplied by Kaiser
and Republic, ar ’ by a consultant (Lykins) to permit rough estima-
tions of the quantities of additives used in the mills and their
ultimate fates. Table 9-8 shows these estimates.
The total yearly usage of these additives is small -— less than 295
kg (650 ib) (as P) of phosphorized fatty oils and less than 8,795 kg
(19,390 lb)(as S) of sulfurized fatty oils for the mills listed.
The bulk of the material probably is found in sludges and other solid
waste, a lesser amount on mill scale, and still smaller amounts in
wastewater and In volatiles from the scale pile. Since the toxicity
of these substances has not been reported, it is not possible to
estimate the risks associated with their handling and disposal.
9-30
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Table 9-8. USAGE OF SULFIJRIZED AND PHOSPHORIZED OILS AS EP ADDITIVES
Iron and Steel Production
Kaiser
Republic
Lyki ns
P lubricant usage
Total yearly EP additive use (as S
Total yearly EP additive use (as P
Probable fate
0.009 kg/bOO kg
( .018 lb/ton)
149 kg (328 lb)
5 kg (11 ib)
solid waste
or volatilized
very little
very little
very little
solid waste
or volatilized
0.055 kg/1000 kg
.109 lb/ton)
653 kg (1,440 ib)
22 kg (48 lb)
solid waste
or volatilized
Hot Forming
EP lubricant usage
Total yearly EP additive use as S)
Total yearly EP additive use as P)
Probable fate
.342 kg/bOO kg
( .683 lb/ton)
5,625 kg (12,400 ib)
187 kg (413 ib)
mill scale
and sludge
.281 kg/l000 kg
( .562 lb/ton)
2,753 kg (6,070 ib)
92 kg (202 lb)
mill scale,
sludge and waste
water
.313 kg/bOO kg
( .626 lb/ton)
6,124 kg (13,500 ib)
205 kg (451 lb)
mill scale,
sludge and waste
water
Cold Rolling
EP lubricant usage
Total yearly EP additive use (as S)
Total yearly EP additive use (as P)
Probable fate
Other
.160 kg/1000 kg
( .319 lb/ton)
2,626 kg (5,790 ib)
88 kg (193 ib)
solid waste
no cold rolling
no cold rolling
no cold rolling
no cold rolling
.031 kg/bOO kg
( .062 lb/ton)
.103 kg/bOO kg
.206 lb/ton)
2,018 kg (4,450 lb)
67 kg (148 lb)
sludge,
solid waste
.124 kg/bOO kg
.248 lb/ton)
EP lubricant usage
-0-
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9.4.2 Zinc Dialkyl Dithiophosphate
Zinc dialkyl dithiophosphate is used In many lubricants and t\ydraulic
fluids, and, as a result, is found throughout the steei mill. Total
quantities used of this additive are given below:
Kaiser Republic Lykins
Quantity of lubricant
per ton of steel 0.938 kg 0.621 kg 0.460 kg
produced (2.068 ib) (1.369 ib) (1.015 ib)
Total yearly use of 18,100 kg 7,080 kg 10,500 kg
zinc dithiophosphate (40,000 ib) (15,600 1b) (23,100 lb)
Probable fate all locations all locations all locations
This additive is used in larger quantities than the EP additives
discussed in Section 9.4.1, but they are still relatively small
amounts. Most of the U.S. production of zinc dialkyl dithiophosphate
is used in motor oils, so any hazards associated with its use in the
steel industry would be encountered to a much greater extent in the
automotive service industry.
9.4.3 Phosphate Ester Hydraulic Fluids
Phosphate ester hydraulic fluids are used by some steel mills in
applications that req aire fire resistant fluids. These materials
are more expensive than other fire resistant hydraulic fluids,, so
there is an incentive to use cheaper substitutes whenever possible.
Kaiser reported no use of phosphate ester fluids, but Republic in-
dicated purchase of 625 liters (165 gallons) of some hydraulic fluid
that was categorized as “other 11 and which we have assumed to be a
phosphate ester type since all other categories were identified.
In the list of lubricants recomended by Lykins for an integrated
steel mill, 4,540 kg/yr (10,000 1b/yr) of phosphate ester hydraulic
9-32
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fluid was suggested. These fluids are used in hydraulic systems for
coke ovens, furnaces and hot forming mills. Spills account’ for most
losses of hydraulic fluids, and material from these spills probably
Is cleaned up and combined with other trash which goes to solid waste
disposal. At the present time it is not known whether these materials
are leached by rain and event ally find their way into the waterways.
9.4.4 Other Lubricant Additives
Other lubritant additives are assumed to be non-toxic as expidined
in Section 3.3 and have been omitted from this discussion. Lead
naphthenate is a toxic additive, but It has not been Included in
the discussion because it is being phased out of use and soon will
not be used at all.
9-33
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10. RECOMflENDATIONS FOR ADDITIONAL STUDY
During the course of the project several areas were identified as
potential topics for additional study. This section provides a
brief outline or description of potential study topics for use by
EPA.
10.1 011 In Landfilled Sludge and Trash
It was determined that a large percentage of the oil, grease and
hydraulic fluid used by the steel industry is contained in sludges,
trash and debris which are generally disposed of in landfills.
The ultimate fate of this oil and grease and the potential environ-
mental problems associated with oily materials in landfills are
unknown. It is suspected that storm or rain w3ter will carry off
at least a portion of the oil contained in landfills. Estimates
for the entire steel industry indicate about 10 x io6 kg/month
(22 x i0 6 lb/month or 132,000 tons/yr) of oil and grease are placed
in landfills. An effort to verify this estimate, as well as to
determine ways of reducing the quantity of oils landfilled, could
be performed for the steel industry. The feasibility of recover-
ing sor ie oils or recycling certain oily sludges should be Included
in the study.
The first project step would be to verify and possibly improve the
accu ’acy of the quantity of oil in landfilled sludge and trash.
A literature search is called for, but it Is expected that indus-
try contact will be required to obtain the necessary Information.
Telephone contacts followed by a survey by questionnaire of nine
steel mills will be performed. The questionnaire should include
questions concerning the quantity and types of landfilled sludge
and trash, oil contents, and method of transport and disposal.
The fate of oil in landfills will have t3 be determined by using
10-1
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a test program. Plant visits should be made to inspect landfill
facilities and to obtain samples of oily sludge and trash. Samples
of storm-runoff at representative steel plant landfills mast be taken
to determine the oil concentration in discharges and the chemical
and toxic properties. Local rainfall patterns must be considered in
the study of runoff oil contents. The relative amount of oil washed
or carried away by the runoff should be determined experimentally
and in the field.
Included in the investigation of oil in landfilled sludge and trash
should be review of available control and oil recovery methods.
Methods of recovering the oil from sludge prior to disposal in land-
fills or of capturing oil in landfill runoff will be reviewed. Tech-
niques to prevent oil from escaping the landfill and entering the
environment should be investigated for oil that cannot be recovered.
10.2 %aste Oil Recovery and Reclamation
The second largest loss term identified in the study was oils reclaimed
as fuel or lubricants. A few waste oil reclaimers were contacted and
data regarding specific steel mill waste oils was collected. The
increasing cost of virgin lubricants combined with more stringent
wastewater discharge requirements is stimulating improved waste oil
collection and recovery efforts by the steel industry. Rapid growth
In the waste oil recovery and reclamation industry is predicted, in
part, as a result of these efforts. The steel industry should be en-
couraged and possibly assisted in their attempts to increase waste
oil collection and reclamation practices. Improved waste oil collec-
tion methods and practices are needed at some steel mills. An in-
vestigation of the most effective waste oil collection equipment and
practices could be of use by the steel industry. The benefits and
economics of recovering steel mill waste oil for reclamation as both
fuel and lubricants should be reviewed. Environmental problems as-
sociated with the waste oil reclamation industry could also be in-
vestigated and a more comprehensive survey of waste oil reclaimers
10-2
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;ould be conducted. Air and water pollution and solid waste problems
resulting from waste oil reclamation may increase as increasing
quantities of waste oil are handled. As part of the waste oil rec-
lamation inve3tigatiOfl a review should be made of potential air
pollution or equipment operating problems due to the combustion of
reclaimed fuel containin met ls and other impurities.
To obtain information and data necessary to evaluate steel plant
waste oil recovery and reclamation the literature should be reviewed
and both the steel industry anc waste oil reclamation industry should
be contacted. The literature search and review, performed at the
beginning .Df the study, will provide background information and a
guide to specific topics to be investigated in greater detail. Much
information concerning waste oil reclamation efforts is available in
recent literatut e.
Steel plants identified in the literatt’re and previous industry stud-
ies as practicing good waste oil recovery and reclamation habits
should be contacted for information. Waste oil reclamation processes
and capabilities should also be reviewed by dircct industry contact.
A questionnaire for the steel industry, and a second questionnaire
for the waste oil reclamation industry, should be prepared and mailed
to the respective industries. Prior to mailing the questionnaire,
telephone contacts should be made to identify knowledgeable and co-
operative industry people. Plant visits to both steel mills and
waste oil reclaimers are needed to collect data, inspect equipment,
discuss operating practices and obtain a first-hand understanding
of waste oil recovery and reclamation capabilities and problems.
Emphasis should be placed on the air and water pollution and solid
waste problems resulting froiii waste oil reclamation. Methods of re-
ducing or controlling pollution discharges should be identified and
described. The benefits and drawbacks of recovering and reclaiming
steel p’ant waste oil from an environmental standpoint should be
evaluated.
10-3
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10.3 Mill Scale Handling
Mill scales are known to contain significant quantities of oil.
The collection, handling and treatment of i,iil scales in the steel
industry, and the resulting environmental effects deserve additional
study. Currently a wide variety of systems and practices are used by
the industry for handling mill scales. Mill scale Is produced in
large quantities during rolling operations. At one steel mill pro-
ducing 2.3 x 10 kg/yr (2.5 x io6 tons/yr) of raw steel, It is re-
ported that approximately 113 x 106 kg/yr (125,000 tons/yr) of mill
scale is generated. Mill scale, depending on the type of rolling
mill and lubrication practices, can contain up to about 20 percent
by weight oil. Typically oil contents of 0.1 to 1.0 percent are
reported. Oily mill scale is undesirable for recycling to most
sinter plants because of air pollution problems caused by volatized
oil. It appears that the slow moving flame front encountered in
sinter machines volatizes rather than combusts the oil. The con-
centration and nature of the hydrocarbons emitted as a result of
sintered mill scale is currently unknown. Volatized oil can ad-
versely affect air pollution control device performance and cause
opacity problems and emission violations. Several steel mills cur-
rently stockpile for future recovery mill scales containing excess-
ive amounts of oil. The amount of oil in mill scale that the sinter
plant can handle varies from one steel mill to the next, depending
primarily on the type of Installed air pollution control equipment.
The use of certain types of control devices, such as baghouses,
precludes recycling mill scale containing significant amounts of
oil..
An investigation of the entire oily mill scale problem is needed.
Rates and quantities of mill scale generated by the various roll-
ing mills and the oil content of these scales should be studied
in more detail. The effect of improved scale pit design, incor-
10-4
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porating oil recovery equipment, should be dctermined. Current
practices employed by the steel mills for collecting and stock-
piling or recycling mill scale need further investigation.
Several factors must be evaluated as they are interrelated. For
example, once oily mill scale is formed it becomes a potential
problem. When stockpiled, oil picked up by surface runoff can
become a water pollution problem. This potential water pollution
problem requires additional study. When recycled to the sinter
plant, air pollution (hydrocarbon emissions) becomes a problem.
The overall impact resulting from either practice should be
evaluated. A program to resolve one aspect of the problem while
overlooking other aspects is unsatisfactory from both an environ-
mental and industry point of view.
The steel industry is currently investigating methods of reclaiming
the iron from oily mill scale. One approach involves washing the
mill scale with solvent to remove the oil. Consideration of oil
recovery is only secondary. Another approach involves adding
chemicals to the scale pits to reduce the oil content of mill
scales. Segregation of the very oily mill scales is currently
practiced at some steel mills. Modification or replacement of
sinter plant control equipment is considered at other plants.
The potential environmental impacts of adapting these various
alternatives should be determined.
A literature and industry survey is needed to obtain additional
data regarding the quantities of mill scale produced. Current
and planned methods of handling and recycling mill scale should
be studied. Following a literature review, a program utilizing
questionnaires sent to steel companies is needed. The removal
of oil prior to sintering should be considered as well as sinter
plant add-on control equipment capable of removing both parti-
culates and the volatized oils introduced by the mill scale.
10-5
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10.4 Hydrocarbon Emissions from the Steel Industry
Hydrocarbon emissions from the steel Industry nec-i o b studied
in greater detail. The dccuracy of the loss te.ms related to
volatized oil Is questionnable and other potential hydrocarbon
emission sources may exist at steel mills. It was estimated In
Section 9.3 that 2.3 x io6 kg/month (5 x io lb/month or 30,000
tons/yr) of hydrocarbons are emitted by the steel ln’1stry as a
result of volatized lubricants. Also, most steel prcduction
occurs In areas with recognized air quality problems. The con-
tribution of steel industry hydrocarbon emissions to oxi nt for-
mation should be determined. The quantity of hyd,ocarbons
emitted should be verified, and the nature of these hydrocarbon
emissions should be determined. The increased emphasis or snift
to wastew t ’ recycle could lead to greater hydrocarbon emissions
by the steel industry. Projections should be made of future hydro-
carbon emissions resulting from zero wastewater discharge require-
ments. Air pollution control devices capable of reducing hydro-
carbon emissions from sinter plants handling mill scale need to
be identified, also.
A review Is needed of available literature and previous EPA studies
related to hydrocarbcn emissions from the steel Industry. The
relative magnitude of steel plant hydrocarbon emissions in air
sheds with recognized hydrocarbon/oxidant air quality problems
should be determined. To evaluate the mag’ itude of steel plant
hydrocarbon emissions, emissi3n factors for the equipment or
processes responsible for these emissions is needed. Currently
AP-42 Compilation of Air Pollution Emission Factors does not
include any hydrocarbon emission factors for the iron and steel
Industry. The fact that potentially significant hydrocarbon
emissions are encountered in the steel industry and nearly all
steel plants are located tn or near large population centers
10-6
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necessitates an evaluation of steel mill hydrocarbon emissions.
A more accurate esti-r ate or data rec ard1 1 ig steel plant hydrocar-
bon emissions or usable iron and steel industry hydrocarbon
emission factors would be very useful to federal, state and local
air quality plannina agencies.
A review and evaluation of available hydrocdrbon emission control
technology is need2d. The performance and costs of such control
equir ent should be determined. The ability of a control syste i
capable of minimizing air pollution emissions without resulting
in additional water pollution or solid waste disposal problems
should be evaluated. Control equipment vendors and users should
be contacted for design, operatir.g and cost data. Growth pre-
dictions for the iron and steel industry, combined with the use
of improved control technology and practices should be used to
project future steel industry hydrocarbon emissions.
As part of the steel industry hydrocarbon emissions evaluation
reconrendations for a source testing program could be developed
and available steel mill hydrccarbon source test data compiled
and sumarized.
10.5 Wastewater Sampling, Analysis and Monitoring for Total Oil
and Grease
The representativeness of wastewater samples for total oil and
grease determinaton is questioned by both water pollution control
agency and industry representatives. The selection of the samp-
ling site and design of the sampling apparatus can strongly affect
the sample obtained. The sampling difficulties are primarily
caused by the tendency of oils and greases to float and hence be
nonuniformly distributed In the wastewater stream. Current
sampling practices rely on rapidly sinking a wide mouth glass jar
to obtain a representative sample. Uniform sampling apparatus
design has not teen encouraged and a determination of the influence
of apparatus design has not been performed.
10-7
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Total oil and gr ase analysis procedures also need to be evaluated.
The two most co ron methods (Storet Nos. 00550 and 00556) utilize
Freon 113 as a reagent to extract oils and grea3es. One methcd
invoves the use of Soxhiet extractors to remove the oils and
greases while the ot er method employs large separatory funnels.
Both methods are reported to be capable of measuring total oil and
grease concentrations in the range from 5 to 1000 mg/i. The pre-
cision end accuracy of the two analysis methods were determined by
dosing a one liter portion of sewage with 14.0 mg of a mixture of
#2 fuel oil and Wesson Oil. No data concerning tests performed
with Industrial wastewater samples dosed with typical lubricating
oils and greases, hydraulic fluids, or rolling oils and fats was
available. In addition, most steel mill waste samples are reported
to contain from 0 to 5 mg/i of total oil and grease; below the
recomended range of detection of the two analysis methods.
An investigation of wastewater sampling, analysis and monitoring
methods fortotal oil and grease content should consist primarily
of an experimental program. A steel plant must be located where
a field sampling program can be carried out. At a given waste-
water discharge (or in-plant wastewater stream) sampling location
a determination must be made of the precision (the degree of
agreement of repeated measurements of the same property) of the
grab sampling method. Ar effort to develop a repeatable sampling
procedure and apparatus must be made. The influence of sample
apparatus parameters, such as the sinker weight and diameter
and size of sample Jar mouth, and wastewater stream parameters,
such as depth and stream velocity, must be evaluated. Once a
repeatable sampling apparatus is developed a study to evaluate
the representat,lyeness of the grab sample to the actual waste-
water stream should be determined. Also, an evaluation Is needed
of the frequency of grab sampling necessary to determine average
wastewater oil and grease content. Often only one or two grab
sample5 are taken per month.
10-8
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A laboratory progra to determine the accuracy and precision of
the analysis methcds (Stori. t Nos. 00550 and 00556) is also needed.
Oil free industrial wastewater samples should be dosed with known
quantities of typical lubricating oils and grease and then analyzed.
Since st2el plant wastewater discharges often contain from 0 to 5
mq/i of total Oil . n( i ase the accuracy of the two analyses
methods within tiii r ’t should be evaluated.
several continuous nonitoring an portable sampling devices have
been developed recently fo total oil and grease measurement.
Currently, little information is available concerning the appli-
cation of these devices on Industrial wastewater streams. An
investigation of ws tewdter oil a:id grease sampling and analysis
procedures and methods, should include a review of the currently
available continuous or portable monitors. Designers and vendors
of onito ing and sampling devices should be contacted and re-
quested tc provide specifications for ‘available devices and lists
of where such devices have been installed. Calls to users of such
equipment should be made to verify performance.
10-9
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REFERENCES
1. M erican Iron and Steel Institute, Annual Statistical Report
1975 , AISI, Washington, D.C. 1976.
2. Institute for Iron and Steel Studies, Steel Industry In Brief ,
IISS, Green Brook, New Jersey, l 76 .
3. H.E. McGannon, ed., The Making, Shaping and Treating of Steel,
Ninth Edition, united States Steel Corporation, Pitts&iirgh,
1971.
4. AE. Chichelli, “The Steel Industry,” In Standard Handbook of
Lubrication Enqj ering , ed. by J.J. O’Connor, New York,
McGraw-Hill Book Company, 1968.
5. J.S. Aarons, and C.A. B 11ey, eds.,, The Lubrication Engineers
Manual , First Edition, United Sta.tes Steel Corporation,
Pittsburgh, 1971.
6. U.S. National Aeronautics and Space Administration, Scientific
and Technical Information Office, “Mineral Oils,” by N.W.
Furby in Interdisciplinary Approach to Liquid Lubricant
Techno1o9 TProceedings of a NASA-sponsored symposium,
January 11—13, 192, Cleveland Ohio), ed by P.M. Kw
National Technical Information Service, 1973), pp. 57-100
N74—12219— 12230.
7. Texaco Inc., Steel Mill Lubrication , New York. 1973.
8. 40 CFR (Code of Federal Regulations) 61; 38 F.R. (Federal
Register) 8820 April 6, 1973, et seq.
9. 29 CFR l fl0.93; 39 rR 23540, June 27, 1976.
10. 40 FR 59960, December 30, 1975.
11. 42 FR 14302-14669, March, 15, 1977.
12. Fan, Isal, et al, “N Nitroso-di—ethanol-amine in Synthetic
Cutting Fluids: A Part—Per-Hundred Impurity,” Science
196: 70—71, 1977.
13. Pjnerican Petroleum Institute, Manual on Disposal of Refinery
Wastes , Volume 1, Waste Water Containing Oils, API,
Sixth EditIon, 1959.
14. Frost & Sullivan, Inc., An Abstract of The Waste Lubricating
Oil Re—Refining & Associated Plant Equipments Markets ,
New York, N.Y. December 1975.
R-1
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REFERENCES (continued)
15. V.S. Kimball, Waste Oil Recovery and Disposal , Noyes Data
Corporation, N w Jersey, 1975.
16. American Petroleum Institute and the American Society of
Lubrication Engineers, Industrial Oily Waste Control ,
(A collection of nine papers), 1971 .
17. U.S. EPA, Office of Enforcement, National Enforcement
Investigations Center, Denver, and Region Ill Phila-
delphia, December 1975. (8 reports) “Characterization
and Evaluation of Wastewater Sources United States
Steel Corporation
Edgar Thomson Plant EPA-330/2-75-Oll
Irvin Plant EPA—330/2-75- 0l2
Homestead Wheel and Axle Plant EPA-330/2-76- 0l9
Homestead Carrie Furnaces Plant EPA-330/2-76-020
Homestead Main Works EPA-33012—76- 022
Duquesne Plant EPA-33 0/2-76-024
Clairton Works EPA—330/2-76- 025
National Plant EPA-330/2-76 - 026
18. U.S. EPA, Office of Technology Transfer, Manual of Methods for
Analysis of Water and Wastes. EPA—265/6—74—003, 1974 .
19. American Iron and Steel Institute, Directory of Iron and Steel
Works of the United States and Canada , Thirty—Third Edition,
AISI, Washington, D.C. 1975 .
The following references, although not cited in the text, were
reviewedand cnntain relevant information.
U.S. EPA, Effluent Guidelines Division, Development Document for
Interim Final Effluent Limitations Guidelines and
Proposed New Source Performance Standards for the
Forming Finishing and Specialty Steel Segments of the
Iron an Steel Manufacturing Point Source Category,
Volumes I and II, EPA-440/1-76/C48-b, March 1976 .
U.S. EPA, Effluent Guidelines Division, Development Document
for Effluent Limitations Guidelines aii New Source
Performance Standards for the Steel Making Segment
of the Iron and Steel Manufacturing Point Source
Cat g y, EPA-440/1-74-024a, June 1974 .
R-2
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REFERENCES (continued)
U.S. EPA, Office of Technology Transfer, Handbook for Monitoring
Industrial Wastew3tcr , August 1973.
1. Pasztor and S.B. Floyd, Jr., Managing and Disposing of Residues
from Environmental Control Facilities In the Steel
Industry , (Pra.ft Report for EPA) Dravo Corporation,
Pittsburgh, June 1976.
Federal Water Pollution Control i\dniinistration, The Cost of Clean
Water, olun’e III , Industrial Waste Profiles No. 1,
Blast Furnace and Steel Mills , NTIS PB 218 215,
S ptember 1967.
Environmental Health Center, Rollin 9 Mills: An Industrial Waste
Guide to Steel Roiling Mills , NTIS PB 217 706, October
1951.
Environmental Health Center, Industrial Waste Survey Report: Beth-
lehem Steel Company, Lackawanna, New York , NTIS PB
217 073, December 1949.
J. Szekely, The Steel rndustry and the Environment , Proceedings of
the Second CC Furnas Memorial Conference, edited by
Marcel Dekker, Inc., New York, 1973.
1. “Treatment of Cold-Mill Wastewaters by Ultrahigh-
Rate Filtration’. C. R. Symons, p 100 - 116.
2. “A Survey of Wastewater Treatment Techniques for
Steel Mill Effluents”, 1. J. Centi, p 168-198.
Iron and Steel Institute, Management of Water in the Iron and Steel
Industry , Proceedings, May 1970.
1. R. W. Gronbech, “Water Systems for Cooling and
Cleaning in Rolling Mills.”
Institute of Mechanical Engineers, Proceedings 1964-65. Volume 179
1. S. F. Chishoim, ‘Some Factors Governing the Choice
of Rolling Lubricants.”
2. J. H. Harris, et. al., “Pursuit of the Ideal in
Lubricating Grease for Steel Works.”
R- 3
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REFERENCES (continued)
3. A. E. Annable and H. Stafford, “The Classification
of Lubricants for a Group of integrated Steel Works.”
4. H. P. Jost, “The Planning and Organization of Lubri-
cation for a New Integrated Iron and Steel Works.”
E. R. Booser, “When to Grease Bearings.” Machine Design, p 70-73,
August 21, 1975.
R-4
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APPENDIX A
Process Lubrication Areas For An
Integrated Steel Mill
A-i
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PROCESS LUBRICATION AREAS FOR AN INTEGRATED STEEL MILL
1. ORE AND LIMESTONE HANDLING EQUIPMENT
Car Dumpc rs, Conveyors, Bridge Bearings, Track Wheel Journal Box Roller
Bearings - General Purpose EP Grease.
Open Gears - Graphite or Molybdenum Disulfide Grease.
Cables, Closed Gears - Mild EP Oil.
Electric Motors, Roller Bearings - Rust and Oxidation Inhibited Bearing
Greases.
2. COKE BATTERIES AND COAL HAHDLING EQUIPMENT
Larry and Quench Car Bearings — Oxidation Resistant Grease.
Conveyor Idler, Coke Guides - General Purpose Grease.
Reduction, Worm & Enclosed Spur Gears - Mild EP Gear Oil.
Coal Elevator, Charger - EP Gear Oil.
Door Hinges, Latches - High Temperature EP Grease.
Hydraulic Pusher - Fire Resistant Hydraulic Fluid.
Locomotive - Diesel EMD Oil.
Rollers, Bearings, Rods - Extra OLty Lithium EP Grease.
3. BLAST FURNACE
Skip Hoist Sheaves, Skip Car Wheels - NGLI #2 EP Grease.
Hoist Cables - Graphite or Molybdenum Disulfide Grease.
Electric Motors - Rust and Oxidation Inhibited Ball and Roller Bearing Grease.
Reduction Gears - Mild EP Oil.
Furnace Bells - NGLI #1 EP Grease.
Hot Metal and Slag Cars - General Purpose EP Grease.
Distributor Grease Seals - Extra Duty Lithium EP Grease.
Torpedo Cars - High Temperature EP Grease.
A-2
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4. COKE BY-PRODUCT PLANT
Fans, Blowers - Rust and Oxidation Inhibited Turbine Oil.
5. METAL MIXER
Tilting Mechanism Motor - Bearing Grease.
Worm Gears, Tilting Screw Gears — Mild EP Oil.
6. STEEL FURNACES
A. Basic Oxygen Process
Gear Train - Mild EP Gear Oil.
Trunnion Bearings - Extreme Temperature Grease or Molybdenom Disulfide
Greases.
Tilting Mechanism - Low Viscosity EP Oil.
B. Electric Arc Furnace
Tilting Mechanism, Electrodes - Fire Resistant Hydraulic Fluids, i.e.
(Water-in-Oil Emulsions, Water—Glycol Fluids, Phosphate Ester Fluids,
Phosphate Ester-Mireral Oil Fluids, & Halogenated Fluids), All Invert
Emulsions.
Tilting Gears - Mild tP Gear Oil.
Electrode Guides, Drive and Clutches - High Temperature EP Grease.
C. Open Hearth Furnace
Charging Machine Ram Induction Gears - Mild EP Oil.
Ran Motors, Electric Motors - Ball Grease.
Charging Box Wheels - High Temperature EP Grease.
Door Lifter Worm Gears - Mild EP Gear Oil.
Fan Bearings - High Viscosity Turbine Oil.
7. CONTINUOUS CASTING
Mold Coating - Rape Seed Oil.
Casting Unit Gears - Mild EP Oil.
A— 3
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7. CONT!NUOUS CASTING (Con’t)
Roll Bearings — General Purpose ER Grease.
Pinch Roll & Cut Off Torch Systems - Fire Resistant Hydraulic Fluids (Oil-
In-Water Emulsions or Glycol Fluids).
8. SCARFER
Rollers and Bearings — High Viscosity Mineral Oil or Medium Viscosity Spray Oil.
Hydraulic System - Phosphate Esters.
9. REHEAT FURNACES
Doors, Rollers, Rails - Temperature Resistant jthium or Lime Base #2 ER Grease.
10. SOAKING PITS
Crane Reduction Gears - Mild EP Gear Oil.
Electric Motor Roller Bearings - Ruse and Oxidation Inhibited Grease.
Door Equipment - Phosphate Ester Hydraulic Fluids.
Wheel Bearings - Extreme Temperature Grease.
11. PRIMARY ROILING PAILLS (Bloom, Slabs & Billets)
Roll Stands, Mill Table Bearings, Mill Spindles - Water and Shear Resistant
ER Grease.
Screw Down - Medium Viscosity Mild EP Oil, low Viscosity Roll Neck Grease.
Pinion Stands, Table Gears - Low Viscosity EP Oil.
Roll Balance System - Fire Resistant Hydraulic Oil, Invert Emulsions.
•Roll Neck Bearings - Medium Viscosity Spray Oil.
12. SECONDARY ROLLING MILLS (Rail, Structural, Plate, Merchant Bar, Hot Strip—
i eet, Strip, Tin Plate , Rod, Wire, Tube.)
Tensioning and Co ler Reel Mandrels, Roll Bearings, Table Roll Bearing -
General Purpose ER Grease.
A-4
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12. SECONDARY ROILING MILLS (Con’t)
Back Up Roll Neck Bearings — Mineral Oil With Water Separation Properties.
Drives - Mild EP Gear Oil.
Screwdown - Medium Viscosity Mild EP Gear Oil, Low Viscosity, Roll Neck Grease.
Pinion Stand Bearings and Gears — Medium Viscosity EP Oil.
Roll 3alance System - Fire Resistant Inhibited Hydraulic 01
Coller Drive - Mild EP Gear Oil.
Mandrel Components - General Purpose EP Grease.
13. SINTERING AND PEILETIZING PLANT
Chains, Wire Ropes, Gear Cases, Reducers — Mild EP Oil.
Retarder Bearing, Breaker Shaft, Drive Shaft, Conveyors, Feeding Machines -
General Purpose EP Grease.
Couplings - General EP or Adhesive Sodium Base Greases.
Pallet Wheel Bearings, Rails, Sinter Screen Bearings - Extreme Temperature
Greases.
Ore Crushers, Balling Machine - Mild EP Oil With Thermal and Oxidation
Inhititors.
Seals - #2 lithium Base EP Greases, and Asphaltic Compounds at High Temperatures.
14. AIR AND WATER CIRCULATION
Turbo Fans, Turbines - Paraffinic Rust and Oxidation Inhibited Oils.
Steam Engines - Mineral Cylinder Oil.
Pump Gear Drives - Mild EP 011.
Electric Motors - Rust and Oxidation Inhibited Grease or Oil.(l5O-300 SUS).
Water Pump Bearings - Water Resistant Greases or High Quality Mineral Oil.
15. PICKLING AND GALVANIZING
Rolls, Reels - High Viscosity Mineral Oils.
Uncoilers - low Viscosity Mineral Oil Hydraulic Fluid.
A- S
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I . ANNEALING LINES
Continuous Lines - Low Viscosity EP Misting Oils.
Batch Lines - High Temperature EP Grease.
17. SENDZIMIR ROLLING
Fine Finishes, Heavy Gage Steel - Low Viscosity Mineral 011 (70-150 SUS).
Stainless Steel, Sheet & Plate - Fatty Polar Type Oils.
Carbon & Silicon Steels - Soluble Oil Emulsions, Paraffinic Slushing Oils.
Tin Plate - Palm Oil or Palm Oil Blends.
18. STORA ç.
Protective Coatings -
Indoor - Low Viscosity Mineral Oil in Some Cases With Polar Additives,
Inhibited Petroleum Oils.
Outdoor - Heavy Petroleum or Asphaltic Coatings, Petroleum, Varnish Coating.
A-6
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APPENDIX B
011 and Grease in Wastewater Analysis Methods
B-i
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Oil. ANI) (;Kl ASI. Total, RccovcraNe
(Soxhict 1 tra tiOn)
STOREiT NO. 0O5 O
Sct pc .inJ Arrlicaiion
Ii This method includes the measurement of Freon extractable matter from surface
ani saline water. industrial and domestic wastes. It is applicable to the
determination of relatively non-volatile hydrocarbons. vegetabh oils, animal fats.
waxes, soaps. p eases and related matters.
.2 The method is not applicable to measurement of light hydrocarbons that
vol tihze at temperatures below 70°C. Petroleum fuels from gasoline through 2
fuel oil are completely or substantially lost in the solvent removal operation.
1 .3 The method c ers the range from 5 to 1000 mg/I of extractable matenal.
2. summary of Method
2. I The sample is acidified to a low pH (<2) to remove the oils and greases from
solution. After they are isolated by filtratior , they are extracted with Freon using
a $ ‘oxhlet extraction. The solvent is evaporated from the extract and the residue
weighed.
3. DefInitions
3.1 The definit.on of grease and oil is based on the procedure used. The source of the
oil and/or grease, and the presence of extractable non-oily matter will influence
the material measured and interpretation of results.
4. Sampling and Storage
4.1 A representative I liter sample should be collected in a wide-mouth giass bottle. If
analysis is to be delayed for more than a few hours, the sample is preserved by the
addition of S ml H 2 SO 4 or HCI (6.1) at the time of .ullection.
4., Because losses of grease will occur on sampling equipment, the collection of a
composite sample is impractical. Individual portions collected at prescribed time
intervals must be analyzed separately to obtain the average concentration over an
extended period.
5. Apparatus
5.1 Extraction apparatus consisting of:
5.1.1 Soxhlet extractor, medium size (Corning No. 3740 or equivalent).
5.1.2 Soxhlet thimbles, to lit in Soxhlet extractor. (5.l.l).
5.1.3 Flask. 125 ml (Coming No. 4100 or equivalent).
8-2
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51.4 Condenser. Allihn t ulh) type, to fit extractor.
5.1.5 Flectric heating rn ntk.
5.2 Vacuum pump, or other source of vacuum.
5.3 Buchner funnel. 12cm.
5.4 Filter paper, Whatman No. 40. 11 cm.
5.5 Muslin cloth dscs, 11 cm (muslin cloth available at sewing centers). The muslin
iiscs are cut to the size of the filter paper and pre-extracted with Freon before
use.
6 Reagents
6. 1 Sulfunc acid. I I. Mix eijual volumes of conc. H SO 4 md distilled water. (Conc.
hydrochloric acid may bc su” stituted directly for conc. sulfuric for this reagent.)
6.2 Freon 113. h.p. 48°C. l,I.2-trichloro-L2.2-trifluorocthane. At this time, reagent
grade Freon is not commercially available. Freon 113 is available from F. I.
DuPont de Nemours, Inc., and its distributors in 5•gallon cans. it is best handled
by filtering one gallon quantities through paper into glass containers, and
maintaining a regular progr ’ r i of solvent blank monitoring.
6.3 Diatomaceous- silica filter aid sespension. 10 g/l in distilled water.
NOTE. Hyflo Super-Cd (Johns-Manville Corp.) or equivalent is used in the
preparation of the filter aid suspension.
7. Procedure
7.1 In the following procedure, all steps must be rigidly adhered to if consistent
results are to be obtained.
7.2 Mark the sample bottle at the water mcniscus for later determination of sample
volume. If the sample w is not acidified at the time of collection, add 5 ml sulfuric
acid or hydrochloric acid (6.1) to the sample bottle. After mixing the sample,
check the pH by touching pHsensitive paper to the cap to insure that the pH is 2
or lower. Add more acid if necessary.
7.3 Prepare a filter consisting of a muslin cloth disc overlaid with filter paper. Place
the assembled filter in the Buchner funnel and wet the filter, pressing down the
edges to secure a seal. With vacuum on, put 100 ml of the filter aid susp *sion
through the fIlter and then wash with three 100 ml volumes of distilled water.
Continue the vacuum until no more water passes through the filter.
7.4 Filter the acidified sample through the prepared fii’er pad under vacuum and
continue the vacuum until no more water passes through the filter.
7.5 Using forceps, transfer the filter paper and all solid material on the muslin to a
watch glass. Wipe the inside and cap of the amp3e bottle and the inside of the
B—3
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Buchner funnel with pic!es of filter paper soaked in Freon to remove all oil film.
Fold the pieces of filter paper and fit them into an extraction thimble. Wipe the
watch gla!s in a similar manner and add the filter paper and all solid matter to the
thimble.
7.6 Fill the thimble with small glass beads or glass wool, and dry in an oven at 103°C
for exactly 30 minutes.
7.7 Weigh the distilling flask (pre-dried in oven at 103°C and stored in desiccator),
add the Freon, and connect to the Soxhiet apparatus in which the extraction
thimble has been placed. Extract at the rate of 20 cycles per hour for four hours.
The four hours is timed from the first cycle.
7.8 Evaporate the solvent from the extraction flask in a water bath at 70°C. Dry by
placing the flask Ofl 3 covered 80°C water bath for I S minutes. Draw air through
the flask by means of an applied vacuum for 1 minute.
7.9 Cool the flask in desiccator for 30 minutes and weigh.
& Calculation
R-B
8.1 mg/ltotalgrease=
where:
R = residue, gross weight of extraction flask minus the tare weight, in milligrams.
B = blank determination, residue of equivalent volume of extraction solvcnt, in
milligrams.
V = volume of sample, determined by refilling sample bottle to calibration line
and correcting for acid addition if necessary, in liters.
9. Precision and Accuracy
9.1 The three oil and grease methods in this manual were tested by a single laboratory
(MDQARL) on a sewage. This method determined the oil and grease level in the
sewage to be 14.8 mg/I. When I liter portions of the sewage were dosed with 14.0
mg of a mixture of #2 fuel oil and Wesson oil, the recovery was 88% with a
standard deviation of 1.1 mg.
Bibliography
Standard Methods for the Examination of Water and Wastewater, 13th Edition. p 409,
Method 209A (1971).
2. Hatfield, W. D., and Symons, C. E., “The Determination of Grease in Sewage”, Sewage
Works 3., 17. 16 (1945).
3. Blum, K. A., and Taras, M. 3., “Determination of Emulsifying Oil in Industrial
Wastewater”, JWPCF Research Suppi 40. R404 (1968).
B-4
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Oft AND GRL. SE. Total. Recoverable
(Separatory Funnel Extraction)
STORET NO. 00556
Scope and Application
1. I This method includes the measurement of Freon extractable matter from surface
and saline waters. industrial and domestic wastes. It is applicable to the
determination of relatively non-volatile hydrocarbons, vegetable oils, animal fats.
waxes. soaps, greases and related matter.
1.2 The method is not applicable to measurement of light hydro arhons that
volatilitc at t rnpcrarures bclow 70°C. Petroteum fuels from gasoline through 2
fuel oils are completely or substantially lost in the solvent removal operation.
1.3 Some crude oils and heavy fuel oils contain a si ificant percentage of
residue-type materials that are not soluble in Freon. Accordingly, recoveries of
these materials will be low.
1.4 The method covers the range from 3 to 1000 mg/I of extractable material.
2. Summary of Method
2.1 The sample is acidified to a low pH (<2) and serially extracted with Freon in a
separatory funnel. The solvent is evaporated from the extract and the residue
weighed.
3. Defmitions
3.1 The definition of grease and oil is based on tl procedure used. The source of the
oil and/or grease, and the presence of extractable non-ody matter will influence
the material measured and interpretation of results.
4. Sampling and Storage
4.1 A representative sample of 1 liter ol me should be collected in a glass bottle. If
analysis is to be delayed for more than a few hours, the sample is preserved by the
addition of 5 ml H,S0 4 or HCi (6.1 at the time of coIlect on.
4.2 Because losses of grease will occur on sampling equipment, the collection of a
composite sample is impractical. Individual portmns collected at prescribed time
intervals must be analyzed separately to obtain the average concentration over an
cx tended neriod.
5. Apparatus
5.1 Separatory funnel. 2000 ml, with Teflon 3 opcock.
5.2 Vacuum pump, or other source of vacuum.
R- S
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5.3 Flask, distilling, 1 25 ml (Coming No. 4100 or equivalent).
5.4 Filter paper, Whatman No. 40, II cm.
6. Reagents
6.1 Sulfuric acid, Ii. Mix equal volumcs of conc. H 2 S0 4 and distilled water. (Conc.
hydrochloric acid may be substituted directly for conc. sulfuric for this reagent).
6.2 Freon 113, b.p. 48°C, l,1,2-trichloro-1,2,2-trifluoroethane. At this time, reagent
grade Freon is not commercially available. Freon 113 is available from E. 1.
DuPont de Nemours, Inc. and its distributors, in 5-gallon cans. it is best handled
by filtering one gaUon quantities through paper into glasi containers, and
maintaining a regular program of solvent blank monitoring.
6.3 Sodium sulfate, anhydrous crystal.
Procedure
7.1 Mark the sample bottle at tht. water meniscus for later determination of sample
volume. If the sample was not acidified at time of collection, add 5 ml sulfuric
acid or hydrochloric acid (6.1) to the sample bottle. After mixing the sample,
check the pH by touching pH-sensitive paper to the cap to insure that the pH is 2
or lower. Add more acid if necessary.
7.2 Pour the sample into a separatory funnel.
7.3 Add 30 ml Freon (6.2) to the sample bottle and rotate the bottle to rinse the
sides. Transfer the solvent into t e separatory funnel. Extract by shaking
vigorously for 2 minutes. Allow the layers to separate.
7.4 Tare a dislilhing flask (pre-dritd in an oven at 103°C and stored in a desiccator),
and filter the solvent layer into the flask through a funnel containing solvent
moistened filter paper.
NOTE: An emulsion that fails to dissipate can be broken by pouring about I g
sodium sulfate (6.3) into the filter paper cone and draining the emulsion through
the salt. Additional 1 g portions can be added to the cone as required.
7.5 Repeat (7.3 and 7.4) twice more, with additional portions of fresh solvent,
combrning all solvent in the distilling flask.
7.6 Rinse the tip of the separatory funnel, the filter paper, and then the funnel with a
total of 10-20 ml Freon and collect the rinsings in the flask.
7.7 Evaporate the solvent from the extraction flask in a water bath at 70°C. Dry by
placing the flask on a covered 80°C water bath for 15 minutes. Draw air through
the flask by means of an applied vacuum for 1 minute.
7.8 Cool in desiccator for 30 minutes and weigh.
B- 6
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Calculation
R—B
8.1 mgjltotaloilandgrease
where:
R = residue. gross weight of extraction flask minus the tare weight. in milligrams.
B = blank determInation, residue of equivalent volume of extraction solvent. in
milligrams.
V = volume of sample, determined by refilling sample bottle to calibration line
and correcting for acid addition if necessary, in liters.
9. Precision and Accuracy
9.1 The three oil nd grease methods in this manual were tested by a single laboratory
(MDQARL) on a sewage. This method determined the oil and grease level in the
sewage to be 12.6 mg/I. When I liter portions of the sewage were dosed with 14.0
mg of a mixture of #2 fuel oil and Wesson oil, the recovery was 93% with a
standard deviation of 0.9 mg.
Bibliography
Standard Methods for the Examination of Water and Wastewater, 13th Edition. p 254,
Method 137(1971).
2. Blum, K. A., and Taras, M. J.. “Determination of Emulsifying Oil in indu ’ ial
Wastewater”, JWPCF Research Suppl. 40. R404 (1968).
B-i
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APPENDIX C
A Practical Guide for Lubricating a Fully
Integrated Steel Mill
Detailed Oil, Grease and Hydraulic Fluid Usdge Data
By Plant Area and Application
(page C-13)
?onthly Lubricant Usage Data Sumary
(page C-25)
Provided by
Joseph Lykins
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A PRACTICAL GUIDE FC LUbIUCATL G
A FULLY 1T; x;iArED.,T: L NILL
By
Joseph I). Lyl:ins
A. Auxiliary uuir wnt
1. Electric F otor BearinCo
Oil Lubricated Rust : Oxidation Inhibited ils
Grease Lubricated 1reriit .’n Lual ty iali & 1 oller
Bearing Greases
2. Air Coc preSsorS Rust & Cxidation Inhibitel Oils
3 Water I unps
Gear Drives 1009 Z U (215.8 cSt) Vis.
100 k’. Sul/rhos Er Gear Oil
Bearings
Oil Lubricated Rust & Oxidation Inhibited Oils
Grease Lubricated
4, Steam Turbines
Direct Connected
Bearings & Govenors 150 SSU (31.9 cSt) or 0 215 SSU
(46.2 cSt) Vis. @ 100 F. O Oil
Geared Turbines
Bearings & Gears 315 SSIJ (68.0 cSt) or 65 SSU
(100.4 cStc) Vis. @ 100 .1.
R&O Oil
5. Blowing Engines
Steam Engines
Saturated & Superheated
Steam System 4659 SSIJ (1003.9 cSt) Vis. 0
100 F., I•lin. VI-80, Cylinder
oil + 4—6% Acidless Tallow
Compounding
Non-Condensing
Steam System 2150 SSU (464.3 cSt) Vis.
o 100° ?., Mm. VI-80, Cylinder
Oil + 8—10 Acidlcss Tallow
and Degras Com 1 oundiflg
6. Turbo-Blowers SAE 40 or 50 lID Motor Oil
C- 2
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7 • M j 11 5
Cranj:cane - SA 4L or 50 }ID Iotor 011
En, ine T rt 150 SSU (31.q c t) an 315 SU
(f .o e ;t) Vis. (‘ 100 F.
Red in 0 l
B. P)ri t Thr c s
1 • B€ i1 J)istribut’r,
Skir i i:t, S ir’ Cars,
arid r..r-l rcase Luhric ti n ——-— ithcr of the fo] jo :j r;—
Lithiu n 12—!iydro :y Stearat
LI i o .1
L1unir u C’rr t lx i }?
Calciui Co .lcx 1 o.1
Lentone I
2. uctjyn Gr’ars ( oirt) 2150 U ( C4.3 C .) Vis.
( 100° . Sul/ihos L1 Gear Oil.
3• \:1 Horc- Follow .ir’ Ro;
ji coIr nt ndations
4. Hot F tal & Sian Car WheCiF ————-— Th’ntone Groa , r
2150 SL (464,3 eSt) Vis.
100 J . Sul/rhoo .i’ GearOil,
where oil is requirod.
5. Cou ’ling s Sodium Base Greace
C. Iin/ t rft and Ore
; iiJ I ,. o iir .nt
1. hoIsts
Electric rotor Hearings
Oil Lubricated R&0 inhibited Oils
Grease Lubricated Premium Quality Ball Roller
Bearing Grease
Worn and Helical Gears 2152 SSI.j (464, .St) Vis.
100 F. Sul/ihos thGear Oil
Open Gear Solvent Cut-Back Gear Shield
B . .se Oil Vis. 210° ?. of
5oOo/io oo SSU (1o72.o/21 4.3
cSt Denerding on amBient
temperature condit5r ns
Wire Rope Follow :iire Rope Hfg.
Recormnendat ions.
Journal Hoxes (Track hcels) — “Sta—Pax” With Oil, or
‘Woel Yarn l stic”
General Grcase Lubrication —— Either of the follow1n 1 :—
Lith. 12—i.yd. St arate j.’).l o
Aluminum Com -lcx L1’
Calcium Ccm 1tx k’
Calcium i j)
C- 3
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D. Sinter1ni and Pelletizin
1. Enclo ;cd Gear Drives 2150 51 (464.3ost)
or 7000 0 (1511.2 cSt;
Yin. iLU F. Su1/!ho
1 T Gear Ci] Depending
on tyTw of gears and
ambient .ec eratur .
2. General Grease Lubrication Either f th f 1’ g: —
Lith. 12—il(d. 0tcar to .
Aluminum Ucmolex
Calciur Com lex J
Calcium k
3. Chairu; P Gear Ci )
4. Centralized Gr a e Sy tern Same 2. above.
5. Bull, Retarder and Breaker Cams
Gear Cases 2150 SOU (( ,4.3 c.t)
Vis. 100 F. Sul/khcs
Gear oil
6. Shaker Sczcen Conveyor
Pinion Gears and Bearingn 715 SO1J (1’ 4.4 cSt) Vir.
1C0 ’x. E.I Gear Lii
Bearings (l ist Lubricated) 1000 U (215.8 c. .t) V. .r.
100 F. ±2 :ist 011
7. Sinter Cooler
Speed Reducers and Gear Cases 150r —2150 SSU (323.8—
464.3 c3tj Vis. @ 100°F.
EP Gear Oil
8. Fan Bearings 715 S U (154.4 cStj Yin.
100 i. R&-0 Oil
B. Coke Oven Equipment
1. Electric Motor Bearings —-. Premium uality ball &
Roller Bearing Greace
2. Air Compressors R&0 Inhibited Oil
3. Reduction Drives 1500—2150 SSU (323.8—
464.3 cSt) ( 100°F.
EP Gear Oil
4. General Grease Lubrication Either of the foll(,wing:-
Lith. 12—Jyd. Stearate i
Aluminum Corn lex £P
Calcium Cozu’lex £F
Calcium
5. Chains 315 SSU ( 80.1 cSt)
100 F. El’ Gear Oil
6. Coke Quenching Car Wheels “Sta—Pax” or “wool 1arn
Elastic” with £P Oil
7. Coal Elevator and Charger
Woria Gears 2150 — 15O 3 U (464.3 —
C—4 8O . 1 e ;t) pp (;e ’r i.1
-------
8. Coi r CV n J ‘} er nd P’or 1 achinvn
D r Latc r — flc ntor .( Grra e 10. 1
: draulics _ Water Glycol or lnv. rt d
Emulslon , Dependir.: on
the type or pumn in servic’
F. hci. r1 C rs
1 • Wh :e1 b . arinrs
Antifrictiui iearthrE Lentone Cr: rc . Ne.1, or
2150 L (‘ 4 .3 c t) Vi .
( 100:. Su1/jho
w1rre ‘,jl ir rer.ujr d.
i) 7in i’t J “Eta-3ax” r
i.idStlC t ’ ‘ •:jtn 03 l
U. L
1. W ’ o e’r Either cl tb f l1o .irr:_
Lith. 12—i:y . Steai it : i
Aluminum Car. lc x
Calcium Lo:. jlex LP
Calcium Er
2. Tiltinr Yech n rn
Lotor ear r
Grea -e Lu’ ricated Tremiuo i o lcr Gin. Grcase
Cu Lubricated 315—7 O U (68.U—151.u cGt)
100 ?. R 0 011
Worm Gear Dr ves 2100 SU (455.4 cSt) Vis.
@ 100 1. - Compounded
Cylindcr Gil or Sul/Ihos iG
Gear Oil
Cpen Gear Solvent Cut—Rack Gear Gil.
. C ’ n rth - ui-z nt
1. TracI: Wheels Either of the following:—
Lith. 12 -Hyd. Stearate EP
Aluminum Complex P
Calcium Comclex P
2. In ucr -D aft Fans Calcium liP
700 SSU (151.0 cSt. 1 Vis.
‘ 100°r. R&0 Oil
Electric Lotor Erg. iiigh Temp. Premium Roller
Bearing Grease
3. Door Lifting Drives
rotor Lrgs. Premium Roller Brg. Grease
Worm Gear Drives 2150 OSU (464.3 cSt.j Vis.
100°F. Sul/Ihos i P Gear
Oil, or Corn;,ounded Cylinder
Oil
Enelo :d C- aro 2150 3513 (464.3 CSt.) Vis.
c-s ( l00 0 J. SuJ/l’hos. G ar Oil
-------
,. So k1ng 1itts
1, Pit Covers
Enclosed ars 215c ‘StJ (464.3 eSt.) Vis.
IOOUF. Sul/rhos El’ Gear Oil
Open Gears Solvent Cut-back Gear Shield
2. Liftir. I chani
‘heel Bcarisfs Eift.cr of the followir. :—
Lith. 12—}iyci. Stc rate .P
Alw Jni,m Cor ) .: r1’
Caic’ Comr l•
Cal. E l ’
j. : ‘ic _ ç 7r n ur e (h( ’ )
le otriting, Ch inr ,and Dus pir..r Eachine
Tilting ch nis Gear Train— 700 S U (151,0 cs.) Vis.
100° . Sul/ hn r r Grar Oil
Trunlon Brg. Antifriction ——— i ith r of the foliowinC:
Lith. 12 —}iyd. t”arate EY
Aluminum Com:;lcx EP
Calcium Complex El’
Calcium El’
&ntone El’
Charging achine Either of the fo)lowinr;—
rhoc hate ister Ilyd. Fluid
Water Glycol Lyd. Fluid
Inverted nulsion }iyd. i’i jd,
deDending on the type of
pump in service.
2. Oxygen Lance
Hoist Bearings High Temperature Grease
Either of the followinC:—
Be ntone
Aiwninuin Complex
Calcium Comrlox
Lithium Com;lex
5. Enclosed Gears 21 .) SsU (464.3 cSt.) Vis. @
1GO ’F. Sul/Phos P ( ear 011
4. Oren Gears Solvent Cut-Back Gear Shield
5. General rease Lubrication Either of thy followinf :—
Lith.12-l yd. Stearatc El’
Aluminum Conriex
Calcium Conilex El’
Calcium El’
C-6
-------
K. p-v-ic Cxyr cn ‘ottc m Lio rn rrocer3
Lubricitien i the same a
that fo” bO r’ Furi tce, exc r t
that nc) OxyCen L; ncc is r uircd
L. Ar—mn Cxy ’. ( carhc’nizat3. n 1 r;CE’SS “A(D”
1. Ti.ti v ;: Lanir 1050 SU (226.7 cbt.) Vis.
1( 0°F. i 0 Oil or where
requireJ, j,050 2 U (226.7 Ct.)
Vis. 1Cr” F. Sul/ hc’s f
Gear Oil
2. rur i: Larir L Ei er of the foil :ing:
12—Lyd. t rate
Al : ini’ n Com 1(X
Calciui Corn ieX
Calci n El’
Bcntonc
? i. l ctric }\‘rnace Process
1. l ctroth s
Tiltinr I 1 chan sm Gear Train ———— 1050 SSU (226.7 cSt.) Vis.
100°F. Sul/Ithos l Gear Cii
Gui.d ..:’, Swing sheaves, Cylinder
1 ’nd 0 c. ’rir, a r Gene r .i
Gr ,-asc uhrication Either of the following:—
Lith. 12—Eyd. Stearate i.P
Aluminum CornrieX
Calcium Cor ’ lex El’
Calcium E )
Bentonc
2. Swin i Roof an i’urnace Tilting
1 ydrauliC System Phosphate Ester Hyd. Fluid
Water Ulycol hyd. luid
Inverted Emulsion Eyd. Fluid
depending on the tyje pumn
in service.
3. Door Eoist
Worm Gear Reducer 215 SSU (4b4.3 cSt.) VIS.
100 F. 3ul /Phos El’ Gear OU
4. Air Con ressor B&0 Oil.
N. Electric Puriace Anti—T-olutiofl Equipment
1. Ash system
B1ow r 715,SSIJ (154.4 cSt.j Vis
100 F. 1t20 Oil
Rotary l’ eds (Gear :otors) 315 9 5SU (t 8.O cSt.j Vis. C
100 . . R 0 Oil
ylexibl Coupiir. s Lith. %2-4yd. Stearate El’ or
Sodium P Grease o. 1 Con ;i tcflCY
C- 7
-------
I ,. (Cc ,ntjnuedj
2. Lime and ether Additives to Slag
Dcspenstng Motors —. - —— — —— — ——— — —. -—215 0 SSu (4o.2 cSt.j Vis 0
LOu F. i cO Oil
Netering Mot 0 r Ge ir n’ducers &
Blo* rs ———
3, Water l flteis
Worn Gear Drives 215 S 1J (464.3 eft.) Vis
1OO . ul/Phos ;: ear 01].
4. Exhaw t and Represeuring lane
Greasc Lubricateø i’earings,
Premiu” all & E ’ar-
Grease, -r for 1.uhricatc
Bearirru, 715 S (154.4 c t.,
_____________ Vie C. luO°F. R .O Ci i.
1. GeP.r Privca ————— 1500 2150 SSU ( ; .& & 46i.
eSt.) ‘.‘is 0 1( O°.f. Sul/Phoo
NP Gear Oil
— —————— — Either f the Foiio ’ing:—
Lith. ?—H.yd. St : ate P
Aluwit rn Cointlex EP
Calci c omt lex EP
Caleiir EP
Bento;ie
all 1o.1 Consistiscy Grease
Phosnhate Ester I1y . i luid
Water (lyco]. Hyd. i•lUjd
Inverted anulsio’ Lyd. Fluid
depend inc on thc tyi e pun p
in service.
Blooming I Slabbing Mills, Hot Strip Mills, Cold Reduction
Mills, emper Itilla, Bar I Rod 1 .illa, Structural Shape Nille,
and KRI1 Nul].a all use the same or similar type equ rnent anc.
therefore are classed under this general ‘cading, without
distinction.
1. Plain, Oil Film Type, Roll Neck
Bearings
Note:— These bearinrs are
uselly of the high tin base
babbit or easarcaloyM bearing
metal type and are lubricated ___
by circulating oil systems.
Due to the large quantity of
water involved, the oil used
must have good demulaibility
ch racterietice as measured by
the ASTh D—2711 test for
demulsi!4lity of oils.
715 t (154.4 cSt.j Vis c’
100° ?. R&o Oil
W,tor and Pan Bearings
0. C’ i. nuous C 4
2. Roll Bcaringe
3. Hydraulic Systems -
P. P 13 ing Mill nuj e
RIO Oils having the following
Viscosities 0 100°1. dependinr
on the loads, soeeds, and mill
temperatures involved :—
SSU — eSt .
7W );4,4
1000 215.8
.1250 2 o9.9
1500 323.0
1750 377.0
2150 464.3
2450 528.9
-------
• —

r;ri d(C€’ntra 1jz ij Sjntc ) —
::
‘ r urr : / r
• I t ’ r r’ ( ,
Z i . , 1? and
Z1 ’ 1’ “ ir rn
re .: LuLr catrd —
7, F ri- C ’ r & :4r’ r Roil
rither of th
Lath. 12—i : .rt r “
Al urur li x
c 1( •’:’ -. t; . : L :(
Ceiu L
er tor c
LI c : :‘c. :.‘ ( ‘i-- I
cnr.tainr .r
otn x
rrc ar ft-’:e —
friction _yp4
olv t Cui— k ar
1 i or 7 . /‘. .,.
(1511, , /?1•; .’4 C. t.) Vi::
( 1 . il
Cocbi atj f
(as ab v) fl’
Water
pCC 1 ! G • • c :—
• n :;rf j r • —
Lith.12—r ,:. •.:t’C, ,
AJ . :au’, ‘-—;:; c —
tain . .r .; 3-. . ., .
Di—sulf d • 1 ra ait
and irn 5 c] ciJ
Polyn r.;
215C . —3150 it ( c 4;;_.
eSt.) Vjr •(OF t 1/ .r’
1’ Gear CU, or ec iva) r.t
Leade’ G ar C i i
Su1/ -.os .L J 1;rar CU,
v1rc nity d : i :it
Gear Siz • r ri, n d
Cper itir 1 g ‘‘ : . rature
V c C. (,i F.
_s; —
1 0O
1500 323.b
2150 4u4 ,3
‘ .. ic; ‘‘c a1 ,1 .i t Cii
‘. • :onne ri,i p
. :: d
L rat’ . . ’ n1ra1i rd ycte”j —
rry L’ ric t”d
• .. i
€: :T. FI .:in ,
ar ar :: ii
Uold,
6. crrw D :’ , ! ill Scrc & ts
C-9
-------
P. (C ntir.ued)
8. Mii i Table Gears — 15( 0—215t. Z5U ( 23. —464,3
cSt.) Vis 1001.
Sul/l’hos G’-ar Oil
9. Roll C rin R rs
Skid i r e8 WIGI o. Gr’ase ccr—
taming 3—5 . 1.olybdnan
10. 1:y raulic Accumulat re Di u1ridr
Gr ar hited Gr.’ 3e
Roil 1ance Sy ’tem
iiuid 5 luh)’: Oil in ter,
nr .n lnvert”d ul i’ n
Huid
11. General Grease Lubrication £fther cf ti’ oll v i:
Litj .1 — .y . :;tf rhtf’ LJJ
Aluninum Co .r x
C lciu Cr r ’1.ex
Calcium
Q. enzi ir clucteri_?11]a
1. Co ion Lubricant for Roll bearings,
lntern l trs, ax Rolling Cii (for
the reduction of Strip)
j i j il Ty”e -- - -
br ? rmai S ecds & Pressures — 105 S 1J (71.7 eSt.) Viz
r 100 r., r then c
- pale Oil
Par High Srceds & Pressures —— 105 S U (21.7 eSt.) Vis
I 0’., I.z ththeniC
}ale Cii ) ; Degraz and
th a’ditivc-z
Soluble Gil ryp }!eavy Duty, ro1rurn
Sulfr n tr ‘y’ ’ Svl hlr
01].. C’ ccntr tion of
Cii in ‘ .at .r is dep ndeflt
on the -ill I quirer1cfltS.
2. Reduction Gears — ————— — — —-— 2150 3U ( t64.3 cSt.) Vis
0 1 D() 1,., Sul/ihos £.P
Gear Oil
3. flydraulic Systea —————— —— Anti-wear i:ydraulic Oil.
Th dictated oy the F” P
in service
4. Bearings
Grease Lubricated — Either of th’ fo)lo :ifl’
Lith.12 —Hyd. tcarat r,k
tlu.ninum C!rn ltx
Calcium Cor.lcx
Mist Oil Lubricated 2150 SSU (464.3 cSt.) Vj B
C ’ li.O° t oi 1
c-jo
-------
I —-
•.i:t1 ’ 1 . i ;n —
s • t t : .‘. 11:
• 1
t LI
c
C’i1r r c-Ct y
t ar . c . “it’ rt’
c du i
r.d . .‘r i d ::
, r ry, : , :rf’1- •r.
Vi: . 1 , .:
rtn ;j;iiCati’ fl
-‘ 1 5
1(. .
715 1 1•
21’.
- .
21t .
iT- r Utry 1rc 2t
af . hettcr
•...t .o.;
..T cc i
a r- :‘ b1 r ”
nDn_r”’ . .r iT.C ty-
fr’:- ’.-y :y,P:tro1
Su f , oIu 1•
} avi a Vis of . -
(d ’ . i —7 ..5 cSt. )
in t . t fo’ :’.
jt. .’, ‘ )
wil) i ; ‘r. o:i tL
Cr (A it fl )
! * Lt i ici e
a VU: ctf 5O— ’\ : :
(5: _7 .5 cSt.)
n W, Li :’:r;
, bi c1du , :
cc-t n i: ri Ic tti .
rn’ nt ; , ifi’:r: .r
-1 r
-J. -
ly r J:
r l’
t, c - ..
— -‘;:: (: i-jt . ...-
. -
:: .i::., or •
I r trj 1r- .
-
U. ’ ri i1! U’.
i. .: ; v -’it
br . - I : r afld •
• “i ‘tiCs.
Ir - 1 .- ry Irr . ‘
r .t ’ r’ t:’. - -,
- c L l U
( -. . ‘. LAflJ .flC
a’ d i :v
• . • j:.- :u:-
-c: j ’tt. —
0
• a i.1( 1
C— 11
-------
2. Tandem nub (Continued)
Tin Plate —— Blends of Tallow, Stearic
Acid and/or other Lubricity
Agent& and for certain
application requirements,
ulsifiers are added.
Note:— For both Black Plate and Tin
Plate rolling, the lubricant
is arplied to the strip by
oithcr a Direct Application
or a Recirculating System.
in the Direct Apouication
System, the lubricant and water
are mechaniaafly mixed and the
resulting mixture is used only
once. In the Recirculating
Syatezn the lubricant is emulsified
iiith water and the resulting emulsion
tB used over and over again.
C- f l
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DETAILED OIL, GREASE AND HYDRAULIC FLUID USAGE DATA
BY PLANT AREA AND APPLICATION
Provided by Joseph D. Lykins
C-13
-------
AIR, WATE , GAS Fz—FPC’U’ S, AND POW P ‘IP r
Parts & Equipment Type Bearings Type of Lubricant Gal, or Lb.
Lubricated or Gears Used Per Nonth
Blowing ines
Stearn Cylinders
Compounded Cylinder
Cil,2150 S U (464.3 .
cSt.)I 1LO 7.,6—8;
Corn; ound ing
-
o
i
a
General Lubrication
300 SSU ( 4.b OSt .)
Vis 0 1 0 i., zted
1LOO
Gal.
Engine Oil
Air ur b b1cwers
Gas ‘ngines
Crank Case and
Cylinders —
gine Parts
Beavy Duty Detergent
F:otor Cii SA 4L—50
325
G
al.
Gal.
30C SSU ( 4.b cSt.)
Via e 100 r., Red
Engine Oil
35C
Air Ccmpressars
Crank Case
315 SSU ( 8.0 cSt.)
Via 0 100 r.,ii &O
arhthenic i ase uli
500
Gal.
Cylinders
315 SSu ( 8.0 cSt.)
Vis luO 1,,
riaryirhosphate
ester type oil
250
Gal.
ater k’uzps
Gear Drives
700 SSU (a51 .0 cSt.)
Vis C 100 z., L
Sul/Phos Gear Oil
16CC
Lbs.
Bearings
Oil Lubricated
25u—700 550 (53.8-
15180 cSt) Vis U
100 1., 1(&O Oil
1 O
Gal.
Grease Lubricated
NIGI No. 2, Lith.
12-Hyd.Stearate
Grease
4C0
Lbs.
Stean urbines
Bearings &
150—300 550 (31.9—
t irect Connected
Govenor
64. cStj Vis 0
100 i. ,R&O Oil
6t.0
Gal.
Steam Turbin s
Geared
Bearings &
Gears
300—465 550 (64.6—
lOO 4 cSt) Via 0
100 1., R&O Oil
3’Q
Gal.
—
C-14
-------
art V :ui ” flt
1 ricatcd
Type Br rings
or Ge; ro
Type of Lubricant
Used
Gal.or Lbr.
Per Yonth
Bearings
eli Lubricated
150—300 SSU (31.9—
64. cSt) Vis
1(J F., F 0 Ci i
NIGI No.2, Lith.
12—Hyd. St€ arate
Gre as e
Coke Cv n
Cok- vrn : oors
nydraul ics
Door Sz rews
ater— lycol rR
r.ydraulic Fluid
? I No.1, Bentone
Grease
£75 Gal.
500 Lbs.
General Lubricati’fl
Centralized ljrease
Sys tern.
Blast Va1vu , Plain
and Antifr:ctl fl
earings
Plain AntifriCti fl
earir gs, Sl des,etC.
NIA,! r o.l, Lith.
1 2—hyd . Ste arate
Grease
lectriC Motors
Orrase lubricated
80 Gal.
12 0 Lbs.
Coke Lven, ;eneral
Grrase I’ brica 4 i”n
I;I I ;o.l, Lith.
12—hdy. St arate
Grease
1200 jus.
Skip h st
5 BLAST FU’ ACES
Plain & Antifriction
bearings
&teei Cablee
.
NWI No.1, Lith.
12—hyd. Stearate
Grease
00
Lbs.
Solvent Cut-Back
Gear Shield, or
Nfgr’s. ?ecorn cn—
dation
25
Lbs.
Lar e Srall Bell
Eea Bearings
Plain Bearings and
bell Seals
LDI No.1, Lith.
12—}iyd. Stearate
Grease
200
Lbs.
teductior. Drives
Bev’ l & Snur
clsed G€ars
1050 SSU 226.7 cStj
Vis 100 r.,SU1/}hOS
.T Gear Oil
100
Gal.
Worrn iear Drives
2150 SSU 464.3 cSt.)
Vis ‘ 100 F.,SUi/PhOS
EP Gear Oil
15
al.
140 Lbs.
C- is
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BCu? STEEL FURNACES
Farts & Equipment Type Bearings Type of Lubricant Gal.or Lbs.
Lubricated or Gears Used Per Month
runion Bearings
Antifriction Type 2150 SSU 464.3 cSt.)
Vis 100 F.,Sul/Phos
EP Gear 01].
800
Lbs.
Ieco Charging
ach1nea
}iydraulic Systems 300 SSU (64.6 cSt.)
Via C 100°F.,
R hyd. Fitid,
Phosthate Ester Type
300
Gal.
?? Car Jau nal
Bearings
Antifricti’,n Type NIGI No.2, AAR
Aoproved Grease
1200
Lbs.
Gøneral r ase
Lubricati ’n
flairi : Antifriction 1101 No.1.,Llth.
earinga 12.nyd. Stearate
Grease
2300
Lbs.
S rEEL 1 ILL AUXILIARIES
Air Co nress rs
Gears Cylinders 150 SSU ( 1.9 CSt.)
Via C 100 1. ,R t) oil
2000
Gal.
Sh- ’ s

Roll Grinders Soluble Oil
5 00
Gal.
General Lubrication
Grease NI I No.1, Lith.
I 2—r yd. Stearate
16L0
Lbs.
011 150 ssu ( 1.9 cSt. 1
Spjndles 100 F.,R O Oil
300
Gal.
Reduction Gear 750 SSU ( 61.8 cSt.)
Drives Via C 100 P., Sul/Phas
EP Gear Oil
600
Gal.
Cranes Electric Motor NIGI No.2,Preinium
Bearings B i11 & Roller 3000 Lbs.
Bearing Grease
Wheel Bearings and
(‘eneral
! TLGI No.1, Lith.
12—1 yd. Stearate 6o00 Lbs.
Grease
Gear V’0O SSU 215.a cSt.)
Via I lOu 1., Sul/Phos 950 Ga
EP Gear Oil
2150 SSU 464.3 cSt, 1
Via 0 1OC 1., Sul/Phos 1300 Ga .
EP Gear Oil
C-16
-------
nt Ty: P : :e rin Type of Lubricant a1 .cr Lbs.
Lubric- tLd or dears Used }€r .onth.
:j1l A’: r:acb. E vci Je rs anc 1. ded •‘siduai Type -
Thhlrs ings gear Cii 11u,U Lbs.
: t i: : lator 3p r, Y xr-i b ne, 2150 3U 4.2cSt.) —
rivrs an .or e rs Vis. 1O .. F., 3ui/Ir os
:J ar Ui
or, 14 i 0 lbs.
L id p t}.r te Type
G ar Cii of th’ s : i
Viscosity
:: - — l v 5 iCti fl for :• r it ul—
r ; (;.. c’:c ul— tor :rive (; :‘ e ) ?1 Lb:.
ati .r 1 Iy t Y)
I a rYS : it Learir.s Li C ,:‘ ase (Caici
with Lr nz’ S - ents Tha— with A - itic 2. , i
F siduuri as€ Cii
? t fricic’n S rn’ as f-r lani-ul—
L r inns r1anh ator :rives (Abcve) 5 L s.
L’ibr cateci)
Cj-’iir.r Beveled jears arid i ad’ d rtesidual ype
fla n Lc rin s C,ear Cii, - - Lb’
(1C , cSt..j Vis. ‘“‘
ic o
iil Scr w Dc.-n Steel ofl Lt’. l,Lcrew NL I I c.1, Lith.
nd ut C c ntralizt d 12—Lyd. Stearate 5000 Lbs.
Lubricator hi Gr ase
Wo rn Drives 2250’ SSU ( o4. cOt.)
Vis. 100 !. ,Sl/h’s b.C0 Lbs.
EF dear Oil
:a ’ - :rive 1 ..tor flain arinns, o ssu cSt.)
i.’arinrs iIiri Cued V.s. ( 10 - P., 55-5 ,al.
F vO Cii
, - ralLubricatin, Plain ntifrict inn Ii i o.1, Lith.
12—Lvu. tearate 26, L0 Lbs.
Orc ase
SIi -rr r:iss }lain Sli:r’er bLOl No.1, lAth.
ross Lca i:.gs 12—Eyd. Stearate
Orcase + 5’ I• iy. 410 Lbs.
Disuifide, and
High J :)iecular
;eight P-clyrners
.nxii iary . Antifniction :IGI No.2, lith.
—:-:yd. Stearat ’ 12L0 Lbs.
Grease
-------
80” E(YT STRIP MILL
Parts & BquiDment
Lubricated
Type Bearings
or Gears
Type of Lubricant
used
Galor Lbs.
Per Month
eli Lubrication
System “1”,Serving
Miii Tables between
and including Mill
Ar rroach Table to
Cror Shear
ull Lubricatl n
System “2” Serving
Scr ’w owns, ;ill
rrive , and Pinion
Stands br l
Vertjc i dvers and
E er rives El & E2
Spur - Bevel
Gears
Screw, Spur, Bevel,
and worm Drives
2150 SSU ( 64.3 cSt.)
Yis. 100 r.,Sul/Phos
EP Gear Oil, or Lead
aphthanate Type Gear
Oil of the same Vis.
Same as for
System “1”
i OO Gal.
2000 Gal.
Cii Lu ’ricat ion System
n3n,3 j g Screwdowns,
Mill )rives and Union
Stands for R3,R4,& R5,
aid drers 5.
uii Luhricati ,n System
4 ” Serving Rotary Crcp
S ar Drives, Finishing
Scale Br”aicer Drives and
Six () Finishing Mill
Drives.
Screw, Siur, Bevel,
and o rm Gears
Bevel, Spur, and
} erringbone Gear
Drives
Same as for
System “1” & “2”
1500 SSU ( 23.& cSt.)
Vis. @ 100 .F.,Sul/Inos
P Gear Oil, or Lead
laphthanate :ype Gear
Oil 0 f the same Vis.
2000 Gal.
150u Gal.
Oil Lubrication System
“8 ” Serving Roughing
Train M.G. Synchronous
Motor and ain Drive
Motor Bearings
Oil Lut icat ion System
Serving on Finishing
Train.
Bevel Gears, and
Screws
Same as for
System 4” 1500 Gal.
Cii Lu1’ricati”n System
“5”,S rving Scr wdowns,
Pinion Stands Fl thru P7
011 Lubrieatirri System
“6”,Serving Stands Ri,
Plain Babbit
2100 SSt’ ( 53.4 cSt.)
Via. 0 100 z.,RtO Oil,
n2,R3,R4,R5, 1,F2,r3,
Bearings of
or Straight Mineral
o000
Gal.
and 14, and back—Up
the Mesta or
Oil having good
doll Bearings.
Morgoil Type
D mulsibility
Ci i Lubrication System
“7” Serving Stands 15,
r€, and F? .8ac —up
Plain abUt
Bearings of
the Mesta or
1 i00 SSU (g15.8 cSt.i
Vis. ICO F.,R&O
or Straight Minera’
i 00
Gal
.
Roll Bearings
Norgoil Type
Oil having good Dem.
Plain Babbit
Bearings
315 SSU (6 .o CSt.j
Vis. lOOP.,
kt&0 Oil
Plain Babbit
Bearings
100 Gal.
Same a for
System “6”
‘ ,
i
C-18
-------
E0” :oT sTi IF MILL
(0 ritinued)
Parts & iuirnent Type Bearings Type Lubricant Gal.or Lbs.
Lubricated or Gears Used r I onth
lectric Notor hearings
a d Air Corrre ’sors
(General)
Plain and Spur
Gears and
Clinders
150 SSU (3 .9 cSt.J
Vis. 1O0 1.,h 0 Cii 66u Gal.
! eheat Ft rnace Fan
i’arin s
Plain and
kntifricti n
100 SSU (2 .b CSt.)
Vis. 1 0 .,Rou Oil 1 U Gal.
}ece11 tne uS rg.
Lu rica i n
Plain and
kntifrictic’n
2 SSu (4 .C eSt.) G .
Vis. Oil b 5 a
.il ‘ist Systern
B iload Switches
and Yisc. Lbr c ti fl
ef Fig aohines
Foil Shor
Ci a ning Solvent -
Plain and
ti ricti n
10CC SZU (,15.S cSt.) 200 al
Vis.3 100 . ,List Cii
Plain Br r.
and rive Chains
1010 . SU 215.8 cSt.)
Vis. 100 F., Black
Cii for ‘;inter, and 150 Ual.
2500 SSU S39.7 cSt.)
Vis.’ 10C F., Elack
Oil for Suimner 30u Ual.
Eearin r and
}arts
Stoddard Srlv€nt /1 /1 /
Nm. Flash — 100 F.
Down Ci,ilers, Side
Gui’ es,Foll Ealance,
and Entry &uides
Lc.oper Controls and
Coil and rs
Eydraulie
Systems
400/500 SSU (8 .2/10b.0
cSt.) Vis.@1e0 ., -
lnvertvd ulsion ut., Ua
F ydrauijc Fluid
Eydraulic
Systems
Blended Phosphate
ster, FR i ydraulic 350 Gal.
Fluid
Gfncral i.ubricati n,
Work c Table Roll
Pearings, Slides &
Ways
Plain and
Antirniction
.
NLGI No.1, Lith.
1?— yd. St arate 35,030 Lbs.
P Grease
Eløctric Noto? Errs.
an Cram Lubricatic n
Antifricticn
NL I No.?, lith.
12—iyd. Stearate 1630 lbs.
EP Grease
Spindle Frasses and NLGI No.1, Lith.
G ared CDunhings 12—hyd. Stearate
- EF Grease plus
3—5 :olyb5enuin
Disulfide, i 3500 Lbs.
Graphite, and
r:i -h I olecular
Weight Polymers
C- 19
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4 ‘‘ :- CCLP ‘ILL
larts & Bqui ent yp Bearings ‘y Lubricant Gal.or Lbs.
Lubricated or Gears Used er I’onth
sack—up Roll : sta, flain 1000/2150 SSL (215.E/
B ’ arings Bcarin s 4 4 cSt.) Vis
i , or
Etraitt A•.ir ral C li ¼J¼J
virir : e ul—
sibility.
Tinicn ? educt1on Spur, and 15CC SSC cSt.)
Gear Drives L rrin bone Vis. 100 F. ,Sul/in s i.
G ars Gear Cii
Screw ow Scre . v or— 60 C St st.;
jears 1 C:.,L€ad 1
arr ki nate :y- ° ‘
ar uil
i ton Iu ’s,Valves, yärauiics Leavy juty sluble
nd CyLnders Cii (neat)
Eotors an fl2i, 1 s:u ( .€ cit.) c ‘al
.G. Sets Vis. 100 r., .L ii -
Work R ’ ll earinrs, An ’tifriction 1G1 I . 1, Lith.
and eneral rease and }lairi ar n s 12—Eyd. St€arat 2 0 Lbs.
Lubricati n EP Grease
I(ollinr C’il 50 Iatty Cii
50 rinerai oil
Cr. CV NS & LAs: fl ?NACc S
Grease Lubrication Antifricticn and 11G1 N .1, 11th.
(genralj ham Bearings 12—i yd. Stfarate 4030 Lbs.
EP Grease
Furnace Linkage Antifrictionan i M I c.1,Bentone LbS
flain Bearings G asc
Cr ke Oven Door :ydr u1ics 2 0 SS ( 3, ) CSt.j
Pushers Vis. iCo 1 ., ater/ 24’ ,al
Glycci tT l-.ydraulic
hula
urbo Blowers Plain ea”ir.cs ico SSU ( 1. çSt.)
Vis.’ 1CC F., Prern. 300 Gal.
Quality R&u 011
C- 20
-------
a t T C; : Ui . flt
Lubr ca ed
k xil : r1es
Type Lubricant
Used
lc,0 SSU (31.9 cst.)
hate E,ster FR
hydraulic Fluid
too ssu (2o.b cSt.)
Vis. lOO l . , iC Oil
Gal.or Lbs.
Per onth
1300 Gal.
Th 1 1’ -‘t rC l — E L 4 ____ C al
Car J urral bros.
lain
:i .. ss cSt.)
Vi .( ? 100 r., 1ack il
A tifrictir fl ILGI I .2,Soda/Lic1e -
12 Lb. .
Base Grea
G n. ra1 Gr a e
li ’-ica i n
.kntifricti and
flain B arincs
Inverted ulsion,
FR iydrauiic Fluid
KIG c.1 , Lith.
—Eyd. Stcarate
Grease
cc .. cv: ;s ‘t ;.T 3
r&ttnu d)
Type “arings
or GEars
Air Co ’res crS
A kania Contr’ls
110 Gal.
‘dash (‘ii (Coal .
B j1kirc l)
250 Gal.
Waste Cii (Spent
Notor Cii, etc.)
,al.
se ls hydraulics
cTl I3iiS_F1GFLR S
50o Gal.
Coil Cc ting Oi1
G ar Trives
2150 SSL p64.3 CSt.j
Vis. 100 r.,3ui/lhCC
Gear oil
lOOu
2430
Gal.
Lbs.
General Grease
LubriCati fl
NIAI1 1 o.1, lith.
12—riyd. St-arat
Er grease
Rust protectiVe
Cil 3 (hot band
Shi mentF)
100 SSU (20.6 cSt.)
Vis. 100 F., Pro-
rrietarY : roducts
1500
Gal.
Lbs.
ROllinT Cils
Fully fatty Oils
4L0 Lbs.
-------
a &
i t-rs and
F G Sets
NLGI N -_i, 11th.
12— vd. teardte
;F r a e -lus
3—5 i ,lybder ui!
Disulfide, 1
ra ite, and
Eirth ? lecular
Weight P ly ers
150 SSU ( 1.9 cSt. 1
Vis. 1(..0 Cii
cSt.)
oil
A tifriction
Bea’ring
N1 I Nc.2, Lith.
12—Fyd. Stearat
.P Grcas
9O allow,
5; Stearic Acid,
5;- Cxidation
mb it it ‘ rs,
..rul5ifiers, etc.
5 S ND.A:.D : Cc: YILL
Tin Plate fl- - uct
rarts & Equi ment Tytw arings Type lubricant Gal.or Lbs.
Lubricated or Gears Used Per nth
Coil Cars, Coil Lifts,
jurnarounds, Up”n rs, iiydraulics Inverted zri ulsion
Roll sacks. —______ ri-. r:y’ rai lic Huid
Back—ur Roll 1 e ta 1:ain
earings stands:—
Nu.1, 2, &: 3 2150 SSu Ct.)
Vis.c 1 :., R . ii
,7 .1 uak.
tavin p’ocd .i- u1—
sib il I ty
1 cc s u (215.z cSt.)
Vis. 1 Cu
havinp- L u1—
sibil ity.
educti-n ar Stands:— 2150 SS 4ó .3 cat.,
‘ rives o. 1, 2, 3 Vis. 1 3 .,Sul/3hos ‘0 al.
EP Gear Oil
i,5 j: i.
C ut l ings
No. a,
seared
1000 . Si ct.)
Vjs. 1CG F.,S l/Thn ’
j ear Cii
)G .,ai.
ham earings
i,200 Lbs.
15C .al.
Rolling Ci i
c jFtl.
4 C Lbs.
5€ ’0,OC0 Lbs’.
C-2 .
-------
A A k.
irt :‘ i
:ir sTr
Ty’ -r’ ri ;rs
OT u’arr
yp 1’dr cant
U ed
Gal.rr Lh .
k’r :orth.
C : ct2nn ear
rives
.-ct’jc t ’r
r ch Bri’ ’
u 11
Iick1in Thnk:—
Cv’rhead C’ nduct’t and
BDttr L ’- rer ko11s
}latinr Tank:—
C z ad
y ’ .-n i u , 3L. ( 4 .6 c..t. j
Vir.( 00 i., Anti—
.rar iycrauIiC Oil
1 LEOTR0LYTIC TIN LINES
Thternal jears
Antifriction
Bear in rs
Ant ‘ict1”fl
B’-arings
210.. SOC (453.4 c t.)
Vis. 1LO F. ,Jui/ hos
Er Gear Ci i
NLG1 .o.?, lith.
1 2—}:yd. arat
. . F Grea ’
SL._
12—Lyc . t’arat’
-I GrCas’
‘ur, ,: *e1Ical
€‘irr and .ays
5 ‘ . .A JI1
203 Lbo.
Fall e11 r
‘a ri rr .,
knt:fricti n and
iain cAariflf $
ri’, S:’ars,ard
i .i:rs
i ydraul ics
75 Lb .
7L .t .
5 3 a1.
300 :su (t- .o cOt.;
Vis.( k’ ti—
Wear }t L, hydraulic
Oil
51 ; es, and knt:fr cti’n and 10I ,Litr .
e2 Oiinr Flairi Eea”in s 12— y . Otearat’ 2 L Lbs.
F Grease
Internal iears
i5 c, 0s12 est.)
Vis. 100 r. ,Sui/ r.r’s 27 3 Lbs.
LF Gear eu
0O SSU e3.)
1:0 .,Sul/ihos T5 C Lbs.
Gear Oil
1OI N’.l, Lith.
7—J yu. Stearat’ 50 Lbs.
Ti G’ ase
700 SEC (1.0 cSt.)
Vis. 1C0 F., ..r
T iist Oil
Gal.
C— 23
-------
Fi. c: jrric TIN LI’S
(C’nt lnued)
u1- ent y’€ arIngs Ty ’e Lubricant Gal.Gr
i.i ’ricit j or G-ars Ls d let’ I.o’
icvrirr I — i ; rn,m ir, 1C O (215.8 cZt.j
:‘y — - : oU .A ; -1---r.t cr.wr,, 1C F., u1/J}cs O
and 1niv’rt’al :r!v- 1? G’ar 611
AorTr G• ars 2156 (464.3 c t .j
1..iO ‘., uu/j ’tios 3 ia )
Gear Ci i
F.1.V. nxt :rives 710 CSU (151.C eat.)
Vi 3.r’ 1CO 7., ’.i/;n i: ;
‘3 • ‘ar C li
ir.’ral rea r 14L61 !o.1,Lit .
1 ’ricati i 12— yd.Stearat 12 U lbs
F 6rrase
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MONTHLY LUBRICANT USAGE DATA SU? V1ARY
(Prepared by PES based on preceeding lykins’ tabulation)
Air, Water Gas By-Products and Power Equipment
lubricating oust 4,105 gal
1,600 lb
greases 3,600 lb
hydraulic fluids 675 gal
Blast Furnaces
lubricating oils 115 gal
greases 2,450 lb
hydraulic fluids 0 gal
BOF Steel Furnaces
lubricating oils* 0 gal
800 lb
greases 3,200 lb
hydraulic fluids 300 gal
Steel Mill Auxiliaries
lubricating oils 5,150 gal
greases 10,600 lb
hydraulic fluids 0 gal
process oils (soluble oil roll grinders) 5,000 gal
Coke Ovens & Blast FurnL:es
lubricating oils 2,950 gal
greases 6,400 lb
hydraulic fluids 2,570 gal
C- 25
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80” Hot Strip Mill
lubricating oils
. cdS S
hydraulic fluids
12,323
2,400
26,250
3,545
5,000
550
269
62,610
0
gal
lb
lb
gal
gal
gal
lb
lb
gal
17,715 gal
40,iflO lb
9,350 gal
4 Stand Tanden Cold Sheet Mill
lubricating oils
greases
hydraulic fluids
rolling oils
6,900 gal
3,200 lb
6,000 gal
180,000 lb
1,000
2,800
3,500
90,000
1,500
gal
lb
gal
lb
gal
fSubtotal or Above DePartznents}
lubricatIng oils*
greases
hydraulir fluids
process oils
44’ & 45” Blooming Mills
lubricating olls*
greases
hydraulic fluids
Continuous Picklers
lubricating oils
greases
hydraulic fluic’s
rolling oils
rust preventatives
C-26
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5 Stand Tanden Cold Tin Mill
lubricating oils 5,750 gal
greases 1,650 lb
hydraulic fluids 3,000 gal
rolling oils 560,000 lb
Electrolytic Washers
lubricating OilS* 0 gal
2,000 lb
greases 775 lb
hydraulic fluids 500 gal
Electrolytic Tin Linc s
lubricating OilS* 200 gal
7,40 ) lb
greaSes 3,450 lb
hydraL 1ic fluids 500 gal
[ Sub Total for Rolling & Finishing 0 erationsJ
lubricating oils* 32,115 gal
278,900 lb
greases 114,585 lb
hydraulic fluids 22,850 gal
rolling olh 830,000 lb
rust preventatives 1,5)0 gal
C- 27
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TOTAL USAGE
lubricating olls* 44,435 gal
281 ,iOO lb
greases 140,835 lb
hydraulic fluids 26,395 gal
rolling oils 830,000 lb
røcess oils 6,500 gal
77,330 gal x 7.5 ib/qal = 579,975 lb
1,252,135 lb
Total L8 2JiQ_1 /montb
* Note: gear oil quantities are reported in both gallon and pound
units.
C- 28
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APPENDIX D
Waste Oil Collection, Reclamation and Disposal
in the Steel Industry
Provided by
Richard Jab1i
D- 1
-------
, WASTE OIL _ COLLECTIO? RECUIM’ TION AND DISPOSAL IN THE
STEEL INDUSTRY
.1 - Types nf Steel M l ii Oily Wastea
II - The Waste Oil and Was ewater Treatment Problem
III - Waste Ott Collectton and Wastewater Treatment Equipment
IV - Waite Oil Reclamation, Reuse and Disposal
V - Discharge Rates - The Material Balance
VI - A i)etatled Analysis of an Example Mill
VII - The Typical Mill
VIII - Bibliography
APPENDIX A - Report of leak control in a cold roiling mill
B - upportive datd from AISI
C - Submitted Data Sheets
D- 2
-------
LIST OP TABI2 CRAP 4S & FIGURES
TABLE I - Analysis of Tramp Oil recovered by cracking
It — Losses by oil leaks as a function of use of leek
I II — Comparative data on oil and grease from previous studies
IV — Type of Rolling Facilities for Steel Mills studied
V - Oil and Crease consumption for Steel Hills studied
VI - Breakdown of strip gage for Hill A
VII - Weight los, of oil and grease at elevated temperature
VIII - Oil Balance Comparison of Reporting Mill.
GRAPH I - Relation between oil conswsption and type of product
II — Coating oil aa a function of gage for strip product
III — Volatilizatio to.. of oil and greases as a function
of tenperature
PICERE 1 — Oil Balance for Mill A acrop.s rolling taills
II - Oil Balance for Hill A across blast furnece-sinter plant
III - Oil Balance for Mill A across total plant
TV - Oil Baler’e for “Typical” Mill
D-3
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Types of Steel Mill Oily Wastes
The t pical integrated steel mill (ices a large variety of hydrau’ic, ubrica—
tion and rolling oils as well as greases. These are used in the following
general classifications:
- Hydraulic oil for shoiring, and coil handling equipment
— tubricatit’n of rolling mill gear , bearings, etc.
Rolling oil tor cooling and lubricating strip during cold rolling
- Ctankcase oil for mobile equipment and railroad equtpmern.
Rust preventative oiling of finished products
- Miscellaneous lubrication and hydraulic applications in the primary areas,
i.e., iron and stee!making
The oily wastes generated fall into four broad categories:
- Weter discharges cont?tning relatively small amounts of e l (‘ .-tO0 ppm),
mill contact cooling water
Soluble oil water solutions, primarily from cold rolling (—2-67. oil)
- Contaminated or used oil, being essentially 1007. oil
— Solid wastes contaminated with oil and greases, including roll scale, oil
clean—up, debris. etc.
To make any meaningful assessment, the individual processes must be considered
separately becauce the types of lubricants and quantities used vary widely
between processes. In this repcrt we will consider the following processes:
— Primary, Slabbing and Structural Hills
- Continuo’is Casters
— Plate Mills
- jot Strip Mills
- Tandem Mills
— Pickling Line’
- Temper iills
— in Plate Mi’ ls
- Galvanizing Lines
- Terne Coating Lines
- Coke Ovens
- Blast Furnace
- Basic Oxygen Steelmaking
D-4
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hOT F0r i1Nc QrLL I.i2i .
Wastewater result from the hot forming operation because of the large amount
of direct cor 1 act cooling and descaling waters required between the hot steel
and the rolling mill equipment. Approximately 4/. of the water sprayed on the
steel evaporat and the balance is discharged beneath the rolling mill equipment
to trenches calLed flumes.
When the hot ted, product is being rolled, iron oxide scale keeps fotming on the
surface of the hot steel and this scale is coi inuously removed by direct contact
high pressure (1,000 - 2,000 psig) spray water before each roll pass of the product.
Low pressure spray cooling water is also used to keep the mill stand and table
rolls cool as the hot steel passes over or in between them.
The wastewaters from descaling and mill equipm nt cooling are generally discharged
via flumes or trenches to inground concrete settling chambers called scale pits
where the heavier iron oxide particles are settled out. These scale pits gener-
ally contain underflcw weirs with launders to trap oils and greases picked up
by the cooling waters. The waste oils are removed from the water surfaces by
belt, rope, or other type of floating oil skimmers, and pumped to large capacity
waste oil storage tanks where contract haulers periodically remove the accumulated
oils. The scale is c1a.in d nut by mechanical means such as clam shell buckets,
drag link conveyors, etc.
The wastewaters discharged from scale pits are eithcr discharged to plant ;ewers
or are recycled back Po the mills. The suspended solids content in overflows
is generally 100 to 200 mg/L, but these wastewaters can be further treated by
means of filtration or thickeners with chemical coagulation.
Due to the many different types of hydraulic and lubrication systems required to
meintain the rolling mill equipment, the direct contact cooling and descaling
waters pick up oil and greases when being sprayed over the mill equipment. Also,
water soluble oil solutions are sometimes used for mill roll spray coolant watets.
ROT F0R14 G - PR1M R L
Ejoomt.jg and Slabbing t.tills
The blooming and slabbing mills have generally four mein plant water systems.
a. Descaling water sprays
b. Table roll cooling sprays
c. Scarfer water spray System
d. Mill stand cooling sprays
All the water cooling and dcscaling systems are generally a once-through water
system discharged into a scale pit where the scale is settled outs oil is trapped
by means of weirs and the overflow water is pumped to a sewer. Some mills do
not have scale pits but use mechanical means such as drag scrapers or clam buckets
for the scale removal while the water is collected in a sump and pumped to a central
plant water treatment systell.
D- 5
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1101 F C SECT1(I 1
Section mills gencr lly have w3ter cv tems st i1lar to primary mills as
discussed . bove. The wastewaters p.-oduccd are primarily the result of reheat
furnace non-cortac cochng waters, mill e uipmcnt cooling waters, an high
presstire prav .ater dv. caling systems. The furnace cooling waters are generally
once-th” u h and disch.irged to plant sewers.
The mill eqtipment cooling and high pressure descaling vater are disc’ arged
via flumes and trenches to scale p ’ s where the heavier solids are settled out.
Oils and greases pic eJ up by the cooling watere are trapped in the scale pits by
means of underfiow weirs and launders.
The oils are removed from th surface of scale pit waters by means of belt, rope
or floating type oil skimmers, and pumped to iaig capacity oil Storage tanks
iihere contract haulers perio ically remove the accumulated oils. The scale
pit overflow waters are generally discharged to plant sewers, but sometimes
recycled back to the mills as sluicing or flushing waters in flumes and trenches.
Some mills use mechanical scraper or drag line buckets to remove the heavier
iron oxide scale beneath the the mill stands aad stock pile the scale for recycl-
ing in mills. The waters are still flushed into scale pits or settling chambers
fur final sedimentation and skimeing of waste oils and grease
PLATE MILLS
The plate mills have generally four types of mill water systems:
a. Descaling water sprays — Direct Contact
b. Table roil and pUt.? cooling water sprays - Direct Contact
c. lUll stand roll cooling sprays Direct Contact
d. Reheat slab furnace skid cooling water - NonContact
The slab reheat furnace non-contact cooling wtters can either be once-through or
recycled water systei is depending upon mill wa t er availabili -y. Flows u to
315 1/sec (5,000 gm) are required to cool th furnace skids but discharged waters
are non-contact cooling nd will only pick up heat. The descaling sprays, table
roll, and plate co,lin sprays and mill stand rolling cooling sprays are generally
once —through systems where the waters are discharged to flumes or sumps her ath
the plate mill stands. The scale and oil-’earing waters are flushed into scale
pits where the majority (up to 907.) of scale is settled out, oil is removed by
means of weirs and s.U rsners ana scale p .t overflow water is discharged to sewers.
Removal of scaie is generally through mechanical means such as cranes with clam
buckets or drag scraper conveyors befleath the mill stands.
D-6
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C V % ‘ y V —
*. * —
r- . b t trtr’ ‘ t Al ha ’ gr rally !iv tvø of mill water systeris
a. Slab ‘“-.‘ t ‘ o co’it .at r - N ’n-Crntact
b. ich r dca1tr *tc’r — pirect Contact
C. . r re roil cnc’l nt ter — Direc! Contact
. Table r’ll •n ‘iear cooling waters - Direct Contact
e. Stttp c ’r*y coclins waters Diret Contact
1L. lih r ’heat f rr ice n nco i ct cooling water descaling c rav , chearing
cc’ .’lg. ciIe and otlbearing waters are as described abo’.-e for plate mills.
The ctri c ’rav cc’ l1nc waters are sprayed to cool the strip after it has been
rolled on tt’e I ml mill fi;’isMn ,tards. Th! water syStsm rly be orcethrc jzh
if go d i1lttv witer t available, but hecauc of the great quantities required,
(up to 4, . OO liec (7O .0 ’O gp& on new hot strip culls) recyc’e systems are
tnqtalled. Arrrc d - te1y 8 of the strip cooling waters evapo4te and the balance
1. either discharged to sewers or recycled. The suspended s ’liIs in overflow
waters is generally 100 to 200 rig/b.
T’ 1iLL1.
ripe and tube nills can be classed into three types of hot forring production
.thc’ds: Butt welded pipe; El.etricrosistance weld tubing. and Seamless tubes.
The butt welded pipe nilli generally have three types of water systems.
1. Non-contact co ltn atcrs in skeip heating furnaces — water cooled skids,
water cooled welding bell, etc.
2. Roll ccoling spray waters.
3. Pipe cooling bed water bosh.
The skeip heating furnace non-contact cooling waters can either be orrethrou?h or
recycled water systems depending upC. mill water availability. The effluent waters
ai.o non-contact cooling waters and will only increase in heat content.
The roll cooling spray waters are g’nerally once—through water systems where the
,calc and oi1—h. aring waters are discharged to flumes or trenches beneath the pipe
nh roll st* ds and in turn riushed into scale pits where scale is settled out
and oils removed by means of weirs and skimers. Removal of scale is generi’ly
through mechanical means such as drag scrcper convevOrS, clam buckets hung on over
head crane,, etc. About 4 ‘f the spray waters evapcate ard the balance is dis
charged to the scale pit’.
The p1w c oltng bed water bosh s sometimes used to provide adaqua ’e cooling
-apacity without ecc stvely ng pipe cooling beds. The waterS are generally OflCe
thrcsign .;ystem ‘rovidin dtrect control cooln and waters are discharged into the
roll coo’’q wa r sy3tcms.
7
-------
7 j Lj (cont tnued)
The electrIc-resistance . ‘‘lded tubing nuts have only two tyPes of water system,,
I. ? ‘n-c .ict c o1ii sa r’r for r tp -’ent wd’lders, etc.
7. utter soluble oil pay co lfng systems.
EIectri .- c i tancc woldrd tubing is forrind by cold rolling and then Is heated
by the electtic wol er as th. tube seam 1 ; welded. The tube is cooled by pass-
ing threug a spray of water soluble oils. These waters are generally reiycl.
• It*ws and make—sip is required.
The seamless tube mills generally have thrce t pes of water systems:
1. N(’n—contact cooling waters — reheat furnaces, water cooled, piercing mandrel,,
etc.
2. Roll spray coolant waters
3. Spray water quench
The non-contact cooling waters for furnaces r piercing (tube shaping) mandrels
can either be once-through or recycled depenIin upon mill water availability.
The r,oncontact effluent waters will only increase to temperature.
The roll spray coolant waters are generally once-through systems where the spray
vste is discharged to scale pits via flumes and trenches beneath the tube mill
•tands. Scale is settled out end oil is trapped and removed by means of wei s
and skjrsners.
The spray quench water system is used to produce higher strength tubes than juSt
hot working the tubing. The tubing is que-ched, rehe.te , and quenched by means
of st.r srays. These waters are once-through systems.
The primary function of a pickling facility is to chemically remove iron scale
from steel. The amount of iron removed depends upon the typ’ of steel being
pickled and the specific condition of the product. As an example, heavy and
bulky steel shapes, such as billets, bars, etc., may experience an trom weight loI1
(due to pickling) of l14 . This would amount to 5 lb F. loss per ton bein* pickled
Steel strip or sheet is more typically l/2Z (10 lb Fe per ton pickled). Rod (for
manufacture of wire) ranges from l/2 . to 2Z (10 lb to 40 lb per ton). The three
majur Vastevater sources associated with, pickling are inseparabl, from the prOC ’
They include:
J ’nt Pickle LI tjor , The pickling solution becomes progressively saturated vtth
ferrous salts. Ihen the ferrous solt cor.tent reaches a certain level, the acid
becomes Ineifect lye and has to be dumped.
D- 8
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Z1c ’J’ (cc.ntinued)
Ftn e V tcr . Rinse uater is p .ckle liquor in dilute form. Disposal of
large quantities of rinse t ater poses a difficult and serious problem.
cid yapor snd ?ii’ts . The emission of pungent and corrosive mist and vapo ’
from the pickling t3nks presents serious hazards, both indoors from a health
•r d maintenance standpoint and outdoors as air pollution.
In addition to the free acid and ferrous salt content, the spent liquor could atsr
contain relatively small ai ounts of other metal sulfates, chlorides, lubricants,
in hibitors, hydrocarbons, and other impurities.
Rl S E A TERS
After pickling is achieved in the acid bath, the material is subjected to a water
rinse to remove the acid/iron solution prior to further processing. The tradi
tional method of rinsing calls for high volumes of fresh water simply to wash the
pickled product by flushing. Pickling facilities vary; however, typical rinse
water volumes range from 1.5 to 65 1/sec (25 to 1,000 gal/minute) flow rate. The
larjer continuous strip pickling lineo use 6 to 65 1/sec (100 to 1,000 gpm), most
often closer to 20—25 I/see (300-400 gpm). Batch type pickling facilities average
about 1.5-20 1/sec (25 to 300 gpm).
COLD ROLLINC PERATIONS
The major water use on cold reduction mills is for cooling the roll; and the
material being rolled. This is accomplished by using a flooded lubrication system
to supply both lubrication and cooling. A water—oil emulsion is sprayed directly
on the material and rolls as the material enters the rolls. Each stand has its own
sprays and where recycle is used, its own recycle system. Past: practice has been
th. direct severing of t e emulsion. However, the high cost of rolling oils and
the expense of complying with pollution control regulations are modifying this
practice, and recycle and recovery systems are currently in cosrion use.
The water used in a cold rolling mill must be a fairly good quality water, free
of suspended matter. High quality rolling oils are added to form the emulsion.
Since the material being rolled is clean and free from rust, and since no scale
is generated during the rolling, oil and temperature are the basic pollutants in
this discharge.
Those ,ills still using once—through solution systems have installed oil recovery
plants. The recovered oil is returned for processing or otherwise disposed of.
Those mills operating recirculatiOfl systems on all mill stands have no continuous
discharge of wastewaterS. However, meansmust be provided for the treatment or
disposal of ba ch discharges of spent rolling solutions. The majority of plants
operate as combinations ‘ f bath systems, and will have significant volumes of
continuously running wastwater$.
D-9
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Lr LLIN CJ 1 ! (cntinued)
P’ gariles; of what ystems are used, miscellaneous oil leaks and spills can occur.
One Rre.1 csoci ’t d with the cold rolling operation but separate from the rolling
mill itseir is th’ r’ainten3nce and roll finishing shop. Or-hearing astewater
ortg1nattn [ i I ece are.,s is a major contributor ta wastevater discharges from
a told rolli mill using total recirculatton on all stands. Oil and “ater leaks
in the oil basement also contribute heavily to this problem.
Considerable heat is generated during heavy ruductions at high speed on the various
types of mills. Not orly is the temperature of the product raised but also the
temperature of the rolls. This heat is removed from the mill via a flooded lubri
cation sy tem. A water—oil emulsion is sprayed on the material as it enters the
i-oils. This emulsion drains off between stands and each stand has its own spray
system. In the older mills this emulsion was used once and severed without any
treatment.
Modern Continuous cold reduction mills recycle the oil emulsion in the flooded
lubrication system. Each stand has its own collection tank and pump to return
the emulsion to the sprays. A five stand tandem mill would have five recycle
systems, one for each stand. With this arrangement, it is possible to renew one
tank of emulsion at a time, or all at once. It is also possible to use different
oil emulsions in each tank if the product being rolled so requires. Mills using
these recycle systems have no direct discharge to the sever. However, they do
have the problem of disposal of large batch dumps of spent rolling emulsions.
Mills using once—through systems usually install treatment plants and palm oil
recovery systems to reclaim these oils for reprocessing and reuse. In this process
various techniques are used to break the emulsion to separate the oil frcm the
water. The water is discharged while the oil i.. returned to a processor for up
griding and resale. The cost of palm oil and the treatment cost for its recovery
brought about the development of the recycle system.
The high cost of rolling oil has discouraged mills from using the once-through
system, hence it is the oil cost and not pollution control that dictates the type
of sy3tem to be installed in mills. The recycle system eliminates the continuous
discharge of oil emulsions fr n cold rolling mills.
HOt C TINc OPER) T1ONS
Wastewaters generated by the various hot coating techniques practiced in the iron
and steel industry fall into three categories:
1. Continuously running rinse waters, vhi:h may include rinses following alkaline
and acid cleaning operations; rinses following chemical treatment and surface
passivatjon operations; fipil rinses; and running wastewater flows horn fume
scrubbing systems associated with air pollution control devices.
0-10
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HOT C( \TI G OrER \fl :$ (ccntinued)
2. Intermittent disch3rges, which may include spent baths from alkaline and acid
cleaning operations; flux baths; chemical treati ’ent solutions; and ion exchange
regenerant vastewater, being citht r t covered or regenerated as part of the
coating operations, or sold to outside contractors for processing and recovery.
3. Non-contact cooling waters associated with the hot coating processes may include
furn.ace cooling wdter and molten metal pot cooling water.
pa lyanjziti
The continuously running rirse waters generated in gaLvanizing may include alkaline
cleaning rinses; sulfuric or hydrochloric acid rinses; and chromate or phosphate
treatment final rinses. Combined total flow rates may range from 10 to 150 1/sec
(158—2,380 gpm), depending upcn whether the non-contact cooling waters are included
or not. The wastewaters may contain suspended and dissolved matter, sulfates,
chlorides, phosphates, silicates, zinc, chror,ium, and oily matter in concentrations
rainging fran traces to high levels, dependIng on galvanizing line operating
conditions. Intermittent overflows of concentrated alkaline or acid cleaning
solutions and flux tank solutions may occtr, contributing to the load normally
running continuously. These can be minimized, by close attention to maintenance
and operating conditions and through provision of dragout recovery units where
possible. Spent pickle liquor is normally collected separately for disposal or
treatment. Typical non-contact cooling water sources from galvanizing lines include
zinc pot cooling and, from the so-called “furnace lines,” indirect furnace cooling
waters.
Terne Coating
The contir uous’ z.unning rinses from the terne coating operation may include rinses
following imersion in alkaline or mineral spirit d reasing solutions; and sulfurii
or hydrochlrric acid rinses. Total flows may range from 10 to 60 1/sec (l58950gpr
depending upon whether the non-contact cooling waters are included or not. This
vastewater may contain suspended end dissolved matter, oily matter, sulfates,
chlorides, iron, lead, and tin in concentrations which depend on line operating
conditions. Intermittent discharges are limited tc dragout or spills from cleaning
and pickling tanks. Spent p”ckle liquors are normally collected separately for dis-
posal or treatment. The non-contact cooling water originates due to the necessity
for con ’ inuously cooling the molten terne pot.
D- 11
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II - The Wacte 01.1 and W stewater ircairnent Problem
The Incentive for control of ‘. aste oil is two—fold. All steel mills are
subject to sore lImitation on oIl and greases (more properly hexane extract—
ables) permitted in discharged wastewater. This is typically 10-15 mg/L.
Although the EPA Effluent Gul lelines provide total weight limitations in
terms of kg/kkg production, in most cases it will be found that the concentra-
tion limitation is more restrictive. A second major incentive is control of
lubrication costs. Typical general duty mill, grease costs about 2O /pound
and rotting and hydraulic oils about 7 Oc/gallon. The recovery of these
materials can be a significant cost—saving. At this point in time, most
mills find it economical to recover oil for combustion use rather than actual
reclamation for reuse as a lubricant. One exception t this Is the routine
filtering and centrifuging in some cases of cold mill soluble rolling oil.
This is done routinely using systems integral to the mill.
Despite the incentive, oil control is still a major oroblem for many mills,
especially older mills with sewer systems installed prior to the awareness
of water pollution control. The use of oils and greases is so pervasive
that control requires a comprehensive effort of both equipment and operating
practices.
Before proceeding, ft is well to review briefly the environmental impact of
oil and grease discharges in general.( 1 )
Concentrations of oil and grease which adversely affect aquatic organisms
are difficult to determine because of the numerous compounds comprising oil
and grease. For example, the major components of crude oil can be categorized
as aliphatic normal hydrocarbons, cyclic paraffin hydrocarbons, aromatic
hydrocarbons, naptheno-aromatjc hydrocarbons, resins, asphaltenes, hetero—
atomic compounds, and metallic compounds.( 2 ) The aromatic hydrocarbons
appeac to be the major acutely toxic group of compounds. In a review of
toxicity tests for oily substances the National Academy of Science (3)
concluded that tests conducted provide a broad range of results which does not
permit rigorous evaluation. Reasons for the variability result from differ-
ences in petroieum products tested, non-vniform testing procedures, and specieb
differences. Much of the research has been done with pure compounds which
exist only in low percentages in many petroleum products and crude oils. With
these limitations in mind a brief review is given of toxic concentrations of
oil and grease.
(1) These coawnents ate abstracted from “Evaluation of the Effects of the Iron
and Steel rhase II Effluent Guidelines on Energy Use in the Hot Forming
Sub Categories”.
(2) Bestougeuf, H.A., “Petroleum Hydrocarbons,” in Fundamental Aspects of
Petroleum Ceoi hemistr 1 , B. Nogy and U. Colombo, eds. Elseuter Pi,blishing
Company, New York, New York, 1967, pp. 109-175.
(3) Environmental Studies Board, National Academy oi Sciences, National
Academy of Engineering, waterpuality Criteria 1972 , A Report of the
Coi miittee on Water fluality Criteria, Washington, D.C., 1972,
EPA.Re.73.033, March 1973.
D- 12
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H — The ‘ _ Qil and astcwater !ic.1tjren _Prc blen (continued)
Free oil and enulsions may adhere to gills of fish causing aephyxiat ion and
coat aquatic plants. (3) Oils may also become sedimented resulting in adverse
effects on bottom dwelling organisms. Also, organisms may ingest oils result-
ing in bioaccumuL tion.
Bioaccumulation of petroleum products presents two important public health
pretiloms: (4 tainting of edible, aquatic species and the possibility of edible
organisms incorporat ng the high boiling, carcinogenic polycyçlic aromatics
in their tissues. Crude oil at concentrations of 0.01 mg/i. has caused oil
taming in oysters. (5) Marine organisms have been shown to incorporate
potentially carcinogenic compounds into their body fat where the compounds
remain unchanged.(6 , 7)
Oil pollutants incorporated in sediments may remain toxic for long perio .
This cccurs when oils become incorpo a ed below the aerobic surface layer
where bacterial degradation is slow.’ 3 ’ No.2 fuel oil incorporated into
marine sediments persisted for over a year and began spreading in the form
of oil-laden sediments to more distant areas. (6, 7)
Variations in toxicity with various petroleum products can be illustrated
by results of bioassay test on the american shad (alosa sapidissima). Con-
centrations which resulted in 50 percent mortality of the test fish within
a 48-hour period (4°-hour LC Q) were 91 ppm gasoline 167 ppm diesel fuel and
2417 ppm bunker oil. (8) An example of a sublethal concentration is a kerosene
concentration of 0.001 to 0.006 mg/L which caused a reduction in the chemo
tactic perception of food by the snail, Nassarius obsoletus.( 9 )
(3) Environmental Studies Board, National Academy of Sciences, National
Academy of Engineering, Water Quality Criteria 1972 , A Report of the
Conriittee on water Quality Criteria, Washington, D.C., 1972,
EPA.Re.7 1 .033, March 1973
(A) Qtiality Criteria for water , U.S. Environmental Protection Agency, Draft
Report, 1976.
(5) Smith, N.A., Oil Pollution and Marine Eco1o y . Plenum Press, New York,
260 p.
(6) fllummer, 3., “Oil Contamination and the Living Resources of the Sea,
No. R1 in Report of the FAO Technical Conference on 1arine Pollution
and its l ffects on Living Resources and Fishing , FAO Fisheries Report 99.
(7) Tagatz, M.E., “Reduced Oxygen Tolerance and Toxicity of petroleum Products
to juvenile American Shad.” Chesapeake Science , Vol. 7, No. 12, 1961,
pp. 65-71.
(8) Jacobson, S.M. and Boylan, G.B., “Etfect of Seawater Soluble Fraction
of Kerosene Ofl ChemOtaxis in a Marine Snale, Nassarius obsoletus,
“ Nature , Vol. 241, 1973, p. 21 -s.
D- 13
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II. The Waste Oil and Wastewater Treatment Problem (continued)
The brief review of effects of petroleum products on aquatic life illustrates
tb difficulty of estiblishing a criterU for oil and grease. However, in a
rt rent dr.ift of rlteria a concentration of not more than 0.01 ppm was
recommended as an upper allowable level for petroleum products in general.( 6 )
A discussion of this c riteria within the draft document recognized that sub-
lethal effects may occur at lover concentrations of some products and that
levels higher tnan 0.01 mg/I. may have no tovtc effects in other instances.
Since not all cils can be emulsified the use of any general criteria expressed
in terms of concentration is questionable.
We shalt not consider in this report any air pollution imp?ct of either
volatilization of oil and greases or the coubustion of oil after recovery.
There are air pollution effects but they are considered insignificant relative
to fuel oil combustion in a steel mill. Several reports (53,54) discusS the
evolution of hydrocarbons from sintering mill scale. Table I shows an
analysis of tramp oil (primarily soluble rolling oil) recovered by chemical
cracking using demulsifiers and heating. Although various metals are present,
this oil is mixed with regular fuel oil and diluted to an insignificant per-
centage.
The method to measure “oil and grease” is very non-specific since no solvent
is available that will selectively extract only “oil and grease” from a
wastevater sample. Thus, the solvent can extract other components present
in a sample which will then be measured as “oil and grease.” Some orgenics
present in water may be formed through natural processes such as the deconi ,OSi
tion of plankton or other forms of aquatic life. These will also be measured
as “oil and grease.” After standing, solvents can form oxidation products
which leave a gummy residue on evaporation. This residue will then be
measured as “oil and grease”. Also, emulsions can form on extraction which
contribute to erroneous results.
In carrying out this analytical procedure, the solvent is removed by evapora-
tion alter extraction to leave a residue, which is then weighed. However,
it is extremely difficult to accurately determine the point when all of the
solvent has been removed and only extracted material remains. This can be
a serious source o error s nd ca vary considerably with the analyst carrying
out this procedure.
Precision data are not reported for this method. However, the precision and
accuracy must be poor because of t ie serious limitations of this procedure
noted above. If the quantity of oil or grease is extremely small, the
technical skill of the analyst may be the most import3nt factor in the
accuracy of the analysis. This implies that values cbtained by two analysts
on the same sample can be significantly different.
Also, it is difficult to obtain a representative sanple for analysis, since
“oil or grease” can be present in water as an emulsion, as floating substance
(film) and in solution in the water. It is impossible to evaluate an oil
film on the surface of an effluent stream in relation to the volume of water,
or to measure its total film area and thickness.
D- 14
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II. The Waste Oil and Wasrewater treatment Probleii (continued)
The control of waste oil and wastewater can be considered from four separate
standpoints:
- Control of usage including leak control
- Recovery of oil directly through skimming, draining, etc.
- Wastewater capture and treatment
- Changes in equipment design and lubrication science to n, 4 ni.::ze usage
and contamination of water
Hydraulic oil leaks can be a surprisingly large percentage of total consump-
tion. The oil which leaks will represent an increased load to the ‘4ater
treatment plant and may or may not impair water quality depending on the
capacity and efficacy of the treatment system. Leakage will also result in
higher discharges in clean—up residue and may result in direct ground con-
tamination or direct discharge to waterways where it finds its way into
non-contact cooling water sewers which do not go through water treatment.
The report included as Appendix A gives an indication of the complexity of
the leak potential in a small cold rolling complex (150,000 NT/year). The
program described in this report reduced hydraulic oil consumption from
32,000 gal/morath to 15,000 gal/month.
This is an extrerre cave where equipment had been allowed to deteriorate and
operating prac jce was indifferent. Reports from other mills, however, show
that some degree of leakage is inevitable. A well maintained cold mill would
appear to have a minimum leak rate of 27.. A typical leak rate for a cold
mill is consider.?d to be 1O . Table 11 excerpted from reference 37 provides
further insight zn the impact of leaks.
The recovery of oil by skimming or draining equipment is the first line of
recovery and among the simplest of technologies. This is limited to insoluble
floating oils, i.e., hydraulic oils and motor oils. Skimming is accomplished
at various bcations in the process stream. It can be done at recovery sumps
directly under the rolling mills, at scale pits serving hot rolling mills, at
quiescent basins preceding clarification, on the surface of clarifiers or
lagoons serving as primary or secondary treatment. The equipment used is
described in Chapter III.
Direct recovery or draining is, of course, limited to oils contained in hold-
ing chambers of various sorts, the typical case being crankcase oils and
reservoir oils for compressors. Very high (857 ) recovery rates are possible
in this case, but poor or sloppy practice could result in direct ground drain-
age or sewer drainage.
Wastewaters contamin;ted with small amounts (100 rng/L) of oil and grease are
difficult to treat if primary skimming and isolation of oil—water rolling
emulsions are not done beforehand. Many typical treatment systems are descri-
bed in the bibliography and summarized in Chapter III.
D- 15
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TABLE I
* Analysis of Tramp Oil Recovered By Cracking
BTU 19,000 BTU/lb
API Gravity - 21.4
Density — 7.7 lb/gal
Si - 8Bppin
Fe 700 ppm
Pb 36ppm
Al - S5ppm
Cu - 3Oppm
Pin - 4ppm
Mg - Ippm
Ni - 6ppm
Ca - lOppm
Na - 2ppm
S .257.
* Aver ge of four samples
D- 16
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i.\r r i i
LOSSES l Y OIL LEAKS
LFAK.x:I:
One drop in 10 sec
On dr ’ 1 ’ in 5 sec
One drop N r Sec
Thrte dropc per sec
Stream 6re k into drops
Loss iN 1 t)Ai
Va I uc °
Doll ars
0.05
0.10
0.55
1.85
12.20
- LOSS i : I flflN1
Doll ars
1.65
3.90
16.90
56.40
360.25
LOSS IN 1 ILAR
Va1lne’
Do liars
19.8
39.60
204.60
621 .50
4323.Oo
ror ..i:rroy ir ate l v 11/64 in. dii.
on 50 p r c a1
‘ -hased on 55 gal bbl
One drop in 10 sec = 200 makeup per year
One drop in 5 sec 400T, .iIzeup per year
One drop in 100 sec = 20 . makeup per year
( .i lions
0.112
0. 225
1-i /8
3-3/ . 4
24
0. 12
0.62
2.05
13.1
Iare1s -. o
0.72
1.46
7.44
22.60
157.2
0-17
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ii - Th j te flit and astcwater Ll itj ent Problem (continued)
A final area of con ideration Is the reduction in oil and grease usage.
Leak control h already been discussed but other opportunities exist.
it seems unlikely that significant reduction will be made in the near
future hut the following references in the bibliogr.iphy suggest interesting
arrrnaches t minirnizing oil and grease usage and concomnitant water con-
tamination: (6) (9 (17) (19) (21) (22) (27) (30) (44) (45) (48).
Consumption of oils and greases varies greatly by steel mill. Using approxi-
mite data only, the grease usage varies from .28 to 1.86 lbs/ingot ton.
Total oil usage varies from .11 to Lii gal/ingot ton. Those mills producing
heavy product will generally have higher grease and lower oil consumption and
mills r roducing light product will have higher oil consumption.
In Chapter V we will examine the fate of these quantities in detail.
I II — Waste Oil Collection and Wastewater Treatment Equipment
It is difficult to sutrinarize briefly the many variations In specific treat-
ment vstems, and for this reason, we have attached an extensive bibliography
on the subject. in general, however, there are seven major types of systems:
i Recirculation and filtering of cold mill soluble oil at mill.
2. Scale pit skimming following by clarification and secondary skimming.
3. clarification can be supplamtedor supplemented by deep bed filtering.
4. Soluble oil cracking systems employing chemical treatment and heating.
5. Centrali2cd collection of wastewaters with lagooning either by itself
r a’ter clarification.
6. Centralized tramp oil reclamation.
7. Plant—wide cojlcctjn o waste nils separate from water systems.
D-18
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IV - Waste Oil Reclamation, Reuse Disposal
The recovery of waste oils comprises basically three methods:
I - Skimming of floating oils from wastevater followed by a gravity
or chemical separation procedure depender : on the purity of
skimming.
2 — Direct recovery of oils from mill sumps, compressors, fans, crank—
cases, etc.
3 - Chemical cracking of soluble oil—water emulsions
The recovery systems in any given mill may be separate or combined in a
terminal treatment plant. Several of the references provided in the
bibliography discuss a variety of recovery schemes.
Review of the literature indicates that the bulk of recovered oil is used
as fuel and not reclaimed for reuse as a lubricant or hydraulic fluid.
The reason for this is that in most systems, there is conta .iination of
various oils and separation into specific fractions is not economically
feasible. Furthermore, many of the waste oils will have ost their
original properties through oxidation and contami ation. On-site
recirculating systems installed integral to cold rolling mills and palm
oil recovery plants are a notable exception to this.
D- 19
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V Dtschar e Rates. The Material Balance
Table III shows a comparison of various sources for oil consumption per ton of
product for various subc.itegories. There are some high discrepancies revealed
between these values. Even estimates by EPA vary widely in what is essentially
the same report, i.e., the EPT background document. Column I and S should equal
column 2 but in sane cases are way off. This discrepancy is not understr.od but
is probably due to flow rate data variations.
Available data from reporting mills has been used to get an indication of which
of the values in the table are correct. The values from coltmin 5 have been used
in the calculation. The “oil removed” value in column S is after scale pit and
therefore should correspond roughly to the total of oils in waste water dt charge,
sludges, and sktmntng. The calculations are necessarily rough because specific
product data is not available and rolling capacity data must be used. Also, the
specific nature of the mills is not known, e.g., whether hot strt mills use roll-
ling oil or cold mills use recirculation.
Inland: ths. Oil Based on Column 5 EPA Values
Primary RoIling 8.3 x io6 tons x .76 lbs. oil/ton 6.31 x 106
Plate Ro’ling .3 x 106 tons x 3.10 “ “ .93 x 1O
Hot Strip 6.5 x io6 tons x 4.65 “ “ — 30.23 x 106
Cold Reduction 5.9 x io6 tons x .13 “ “ .77 x 10
Lbs. Oil Totil — 38.24 x 106
This total is multiplied by the ratio of actual production to capacity. In
some cases, this will be an estinate of 70,.. In this case, 38.26 x 7.3/8.2
34.03
Reported Data From Inland (1)
In sludges, trash & debris - .534 lbs./mon. x 10
Discharged to water - .668
Drained, collected, skinined - , 4
1.632 lbs.tmonth
19.58 x 10 ibs./year
This is fot the entire plant and to get an estimate for rollirg only, we take
907. of this value which equals 17.6 x 106 lbs.
OR 2.4 lbs./in t ton
FractIon of actual to calculated 17.6 /34.03 — .50
(1) The submitted data shows 6 x i06 lbs. oil as reclaimed cold mill lubricant, it
is assumed here that this is reclaimed dircctly and does not constftute raw
load to wastewater.
0-20
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I
:1I :t y ! ‘ C’TY fl S t’ act taI rr t o
r’fl’tor, — t ,4Lr ’r) lbs.

e — I 3 l,Cfl )
— u
• I.,,..
TOTAL 2 ,f.()
At tMs value is ‘,4 3,OO0 or 3.4 ‘ingot ton
Fraction “ ‘ ‘i.il t caiculated — 2 6l3,0UO/2,957,O00 . 2
jr .I,irlv t r ,.,ther riills with sufficient .ata, have:
l’ri irv Rolling
Lute R ’1ling
Hot StrIp — 13.95 x 13 “
c’ld P eduction . 22 x l0
• TOTAL 17.59 x 106
? ‘iltiplvin by .7 to correct capacity to production yields 12.31 x 106
Fcon Reported Pata:
— 1.5 x 106 lbs/mon.
— 375x10 6
- . 1 0xl0 ’
TOTAL 2.265 x 106 lbs. oil/mon.
Y’zltiplvtn by •0 to correct fr entire plant to rolling only and multiplying
by 2 to c ’nvert to yearly basis yields 24.46 x 100 or 6.35 #/ingot ton
ct • n
r
t o ‘.t
c
x
x
x .13
1 —
:i ’ .c’-, tt.I .4 -’ris
t ’ t
L •’ Ito ‘ irct
4.5 x io6 t. T’! x .76 —
3.0 x l0 tons x 4.65
1.66 x 10 ’ tons x .22
3.42 x 106 lbs. ru year
in sludges, trash and debris
In disch.irge to .1ter’ iy
rrat ed, collected . skimed
Fraction of ictual to calculated — 6.46 / 12.31 — 1.99
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Caculstlor . for Kaiser for table on page 19
PrS.ary RollIng *4.) x x .76 lb.. oil/year • 3.27 x
P1st. roll*ng, 1.6 io6 x 3.1 “ • 500
tt l. ! truct
Ei elp
Hot Strip 1.5 x 10 w’ 7.00
Cold R. duction . to 6 .13 “ • .10
Lb.. Oil Total • 15.37 x io 6
Multiplying by 2.4/3.6 (a tua1 prod/capacity) a 10.24 106 lbs otl(yesr
Prc Reported Dsta**
In sludges, trash 6 debris — .0144 x to 6 lbs/mon.
n di.charge to waterway — .0012 x 106 1bs./s on.
Drained, coile ted 6 skiviried - .0075 x io6 lta./mon.
Total .023 x io6 lbs.Imon.
Multiplying by .9 and 12 (see p. 18) yields .25 x i0 6 lbs./year
2s io6
#oil/thgot ton — 2.4 x .10
Ratio actual oil from rolling operation to EPA guideline
calculated; i.e., ACTUAL/CALCULATED (p.19)
. 25 x 10 li.024
10.24 a ii
Rots:
These values are out of proportion to other sitlis because th. values for
sludge., waterways, etc., reported by Kaiser are extraordinarily low
(and probably wrong)
* Iron Table I ot Kaiser submission
** From balance diagram in Kaiser suba’ission
D- 22
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Calcu1 . tions for Gary for table on page 19
Frit ary Rolling 5.2 x io6 x .76 lb.. oil/year 3.95 x 106
Plate Rolling 1.25 x io6 x 3.1 “ — 3.88
(mci rail) 6
Hot Strip 6.0 x 10 4.65 “ “ 27.90
Cold Reduction 2.85 x 10 x .13 “ .37
TOTAL - 36,1
Multiplying 5.1/8.0 (actual prod/capacity) — 23 x io6 lbs. oil/year
From Reported Data
In sludgds, trash & debris — .01 x io6 lbs/mon.
Waterway discharge - .10 x 106 bs./mon.
Drained, collected & skicined — 1.155 x 10 lbs./v on .
Total - 1.265 x io6 lbs. ./mcn.
Multiplying by .9 and 12 (see page 18) yIelds — 13.66 lbs oil/year x io6
#oil/ingot ton 13.66 x io6 2.7
5.1 x 10 b
Ratio actual/caic. (page 19) 13.66 x lo 6 .59
23.0 x 106
Data for Gary for Craph I
7. of product as sheet and strip 607. (Table 1 of Gary submission)
Oil gal/ton - .40 2.040,000
5,100,000
Grease lbs./ton - .31 130,000 x 12
5,100,000
Total gal/ton — .44
Total lbs./tou 3.31
Note: This plots out very nicely on Graph I
D-23
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Following this calculation for other mills, we end up . tth the following table:
Ratio
OtlfInsot Ion Actual/Calculated
Inland 2.4 .50
Mill A 3.4 .82 (known tobe onhigh eldebecause of excess
youngstown 6.4 1.99 leakage)
J&L 3.4 1.20
kaiser .1 .02
Republic 1.5 .30
Eethlehem 2.t
USS Gary Li _ .i2
Avg. (Exci. Kaiser) 3.2 .85
On the average, t terefore, there is an indication that the values from cnlumn 5 of
Table lU are overstated. This is necessarily a very rough perspective because of
the limited detail of the data, but it appears that the EPA values are overstated
for rrit rv and plate mj!ls and understated for strip mil’s. clearly the variation
amongst mills is very great and greater detail cd mill specifics would e necessary
to examine this question more closely.
In m.iking the oil balarce, which is our ir- ediate interest, the foregoing is of limited
value, but it does indicate that the use of effluent guideline data is not a parti-
cularly good source of data for i.alance purposes.
It is apparent that the product mix of a steel mill will greatly influence the oil
balance with respect to total consumption and the percentage of oil in various
categories.
Using the data in Table TV, we have constructed craph 1. Naturally, there is great
variation due to d tferent practices amnng mills, but the graph illustrates that oil
and grease consu..aption tends to increase for steel mills have a higher percentage of
light product rol’ing, I.e., hot strip and cold rolling. Mills producing predominat’tly
heavy product tenJ to have lower consumption. The reason, of course, is that the u e
of oils especially is higher on strip mills than on plate and structural mills. Certain
mills show up with exceptionally high or low consumption in this comparison. Further
ex mtnation of this fact cannot be done without more detailed data. It is known that
Mill A had excessive oil leak. ge during the period. One aight assume that the other
m411 with high usage, Youngstown, may have a similar problem.
It is apparent, that differences in product, treatment facilities, and oil practice
will produce variations in the relative percentages of oil and grease reporting to
scale, vastevatr, sludges, etc. From the literatuie for example, some hot mills
employ rolling oil and some do not. Some cold rolling mills use recirculation and
others do net. Lubrication systems are obvious .y mrch more efficient on the newer
rolling ,ni1 s of all types. Revie-. of mill descrip. On as presented in the biblio-
graphy will prowide a general understanding of these factors.
D- 24
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1-, ‘
cOHr\R TIvF: D\TA ON OIL ANT) CREASE
cO J ION J2J J1 CD DATA
(IN LBS./TON)
EPA EPA r w (2) EPA (3) AISI (4)
PROCESS BPT LOAD STUDY R/’W LOAD RE>IOVED
CC CAST .016 .13 .14 - — . 12
PRIM. -CAR .058 .02 - .64 .09 .99 .76
PRIM. ALY .102 .03 - .60 - - 1.10
PRIM. SECT .219 .02 - .91 29.8 2.54 3.56
PlATE .334 .14 -1.25 .95 3.78 3.10
HOT STRIP .349 .65 - 3.78 4.65
PLATE -ALLOY .752 .3 -5.5 - - —
PIPE & TUBE .084 0 -2.9 1.4 - 2 6
COLD MILL:
RECIRC .002 - - .13
coMnc.. .033 .09 -10.5 .67 1.17
DIRECT .083 L .1 - 1.59
GALVANIZE .075 0 - .2 .13 .35
TERNE .075 .04 — .05 - .35
(1) Fcderal Register, March 29, 1976
(2) Calculated from EPA sampling, from EPA/176/048b Group I, Phase II, Development
Document for Interim Final Effluent Limitation Guidelines - Forming, Finishing
and Specialty Steel, Vol. 1
(3) 12010 DT Q 02/72 Combined Steel Mill and Municipal Wastewaters Treatment
(4) Comments f AISI to EPA on Guidelines for BPT (See Appendix B)
(5) Same as 2, Vol. II calculated using flow/ton and concentration
D-25
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V 1 LE _ 11
t of Total Rollin Capacity
Hot
Product aa (1) Strip Cold 2 Total (3
Cc D’ny Sheet Strip Prir ary plate Skeip Red. ( Tons x
uSS Gary 60 33.8 12.0 3.3 34.5 16.4 17.4
‘SS South 0 69.0 14.C 17.0 0 0 6.8
Inlond 89 38.9 5.6 1.2 28.4 25.9 22.9
Yo’i g$t n (Chgo) 94 46.6 5.2 0 31.0 172 9.7
Beth. (Sp. Pt.) 86 48.1 3.5 5.5 24.3 18.6 21.4
.161. Aliquippa 77 54.8 10.3 0 18.7 16.2 o.2
Rep. So. Chgo. 0 45.9 54.1 0 0 0 4.7
lnt.rlak.-(Riv’d) •N.A. 57.1 0 0 32.0 10.9 2.3
%atser 73 56.0 0 9.6 24.9 9.5 8.6
Hill “A” 45 50.0 0 19.0 16.0 15.0 2.4
SOURCE: Data sheets submitted by companies except for IJSS South and Interlake iverda1e
which are from 1974 Edition of the AISI Directory Iron & Steel Works
(1) Includes slab, bloom, billet, rail and structural
(2) Excludes Finishing mills
(3) Total excludes Finishing mills, expressed as io6 tons annual capacity.
Value in parentheses includes Finishing mills
D- 26
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TABLE V
OIL AND GREASE CONSL’NPTI
PER TON CF INGOTS (1)
Oil Gcease Total Total
1/TOn Lbs/Ton Cal/Ton Gal/Ton
uss Gary .40 .31 — .44 - 3.3__
USS South .11 .84 .22 1.6
inland .56 .56 4.’
Youngst fl (Chgo) 2 Lii .69 1.20 9.0
seth. (Sp. Pt.) .47 .72 .56 4.3
J&L A1 quippa .69 1.86 .72 5.5
Rep. So. Chgo. .31 .45 .37 2.8
interlake (Riv’d) .64 .32 .68 5.1
Kaiser .56 .61 .6 6.8
Miii “A” .70 .38 .75 5.6
Average .54 .69 .09 .61 4.6
(1) Production rate for 1975 for jnland and Kaiser was obtained from jron Ag , April 25,
1977. ProductiOn for other mills was taken from data submitted by them, and i.-i
some cases is estimated as 707. of capacity. These data are derived from data sheets
submitted for each company or from the summary data sheet for those companies not
submitting detail sheets. The high grease value for .J&L is believed tO be a matter
of categorizing, possible differences among company interpretations of oil and
grease may exist elsewhere &n the data and therefore the total is believed to be
more representative for comparison purposes.
(2) Note that there was a mistake in the Youngstown detail data sheet in reversing hydrau
uic fluid and grease. This created an erroneous input wei;ht on the balance diagrao.
D- 27
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VI - A Detailed Ana’ysis of An Example Mill
In naking a detailed analysis of a typica rmall integrated mill, an
attempt has been made to approach each estimate from more than one
viewpoint.
For oil on product, for example, we can consider the theoretical amount
based on references to film thickness of oil films and average sage.
We can also consider consumption, recognizing that leakage and other
losses are contained in total consumption. We can get some idea from
the effluent of secondary processing lines such as galvanizing where
the oiled product is cleaned before coating. Given various types of
estimates, a final Judgement must be made to givt the “best” estimate.
Thraughout the oil balance, all available oata Ir.cluding field observa-
tion and estimating has been used to derive a composite balance con-
sisting of all the various “best” estimates.
The following calculations and Figures 1, II and lit portray the balance
for this mill. The unaccounted for portion is 27. and is not considered
significant in light of the accuracy of the data. This is probably
due to a slight error in all the component figures and does not represent
a major missing source. The weakest estimate is in the loss to ground
leaks, contaminated grease, general clean—up, etc. This value probably
is underestimated in the balance. Variations in reclaimed oil data,
wastewater and mill scale could also easily account for 27..
D-28
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Determination of Oil Balance - Mill A
The input of oils F;reaaes and hydraulic fluids are obtained from purchasing record..
Greases converted to gallors using a factor of 8 lbs./gallon. These records givi
the following:
Pulk Crease - 253,000 lbs. or 31,625 gal.
Coating Oil - 58,000 gal.
Hydraulic Oil- 284,000 gal.
Rolling 01’. - 31,000 gal.
Gear Oil - 115,000 gal.
MiacellaneOua oils - 7,000 gal.
Motor Ofls - 5,000 gal.
?tiscellPaneous Greases - 20,000 lbs.or 22500 gal
TOTAL 534,125 gal.
Output
On Products
Several approaches were used to frame a suitable value for this item. The
Inland data gives a value of .04 gal/ton, representing the low side. The
3 & L data (I) gives a value of .30 gal/ton.
Prom table III, the galvanizing guidelines give a value of 0-.43 gal/ton.
Assuming this conies from cleaning oil off strip, it represents another
estimate of oil on sheet product.
Prom Graph II, using an average gage of .050 and a fluid film thickness of
.C0025, we get a theoretical value of .3 gal/ton for sheet product.
Table VII shows the average gage for Mill A product is about .050.
Mill A actual constssption of coating oil was .44 gal/ton product during the
period under study.
Obviously, the type of product will influence this value, with generally
low (say .04 - .10 gal/ton) values for heavy product, and say .3 - .5
gal/ton for strip product. The 3 & L value indicates the same range for
pipe product.
For Mill A, the calculation is as follows:
Cons iiPtiOn — 58,000 gal & 133,000 tons product
Volatile loss — 227. (see discussion below) — 12,760 gal/year
Assume 107. drippage off product after application — 6,500 gal
Remaining on product as shipped — 40,740 gal (.31 gal/ton)
On Mill Scale
The range of oil content in mill scale from the reported data is great. Values
up to 257. are reported, but the weight of data indicstes a much lower value:
(I) 3aeed on gal/ton prodtiet, assuming product weight is 7O of ingot weight
D-29
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Inland data — .4 - .57, oil (128 #.cale/ton ingot.)
Mill A Value — .2 - .57, oil (103 #scale/ton ingot.)
J 6 L (ref 54, Table II) .17,
Armco (ref 43, P 6) - .3 - .57.
Youngstown data - .15 - .47 .
For Mill A, the average is .47. x 103 #.cale/ton ingots — 36,800 gal/year
Left on Containers and lost in storag !
Pro. a reference on cleaning oil tankers (Ref. not avail),- .17, of oil left in
containers such as drums and bulk tanks.
From examination in field, it is believed that relatively good estimates for
grease left in containers is 107. in the case of drums and 27. for bulk grease
systems. These quantities may be conbusted with the drums if the drums are
scrapped or cleaned by a drum reclaimer, and to some extent drop off to the
ground and become part of solid waste.
oil: .17. x 500,000 — 500 gal
drum grease: 107, x 2,500 — 250 gal
bulk grease: 27. x 31,625 al
TOTAL 1,882 gal/year
Leak. and Spills onto ground
This item will be variable depend big on oil handling facilities, operating
practices and preventive maintenance procedures. Fro. experience at Hill A,
an average of about 3 major spills occur on the ground in a year with several
more or less regular minor spills in addition. The total loss from these
leaks and ptlls is estimated at 5,000 galfyear. In addition, we have the
estimated 2,000 gal/year from drippage off coated product. This oil will
eventually find its way into solid waste being cleaned up by slag for the atost
part. Total in this category is therefore 7,000 galfyear.
“ olatiltsed lurvied or Consumed
Table VIII illustrc.te: the renulte of labcratory tests made to determine the
volitaliration loss of various types ot oils and hydraulic fluids. The four
items tested repreae’t 857. ef the oils, greases and hydraulic fluids used in
Mill A. They also re resent the great bulk of the oils which .re exposed
to elevated temperatures. To translate these tests into an estimate of volatile
loss requires estimating the “average” temperature to which the materials are
exposed. These estimates are as follows:
Crease - 250°? 7. loss (from Graph III) — 107.
Coating Oil - 200° F 7. loss (from Graph III) — 227.
Hydraulic Ott - 200° F 7, loss (from Graph III) — 117.
Rolling Oil - 250° 1 7. loss (from Graph III) 13.57,
D- 30
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Applying these percentage lost.. to the quantil iea of oil for Hill A we have:
Grease 107. volatile loss for 273,000 lbs. or 34,100 gal at 8 lb/gal
loss 3,410 gal
Coating oil 227. loss for 58,000 gal loss — 12,760 gal
Hydraulic oil 117. loss for 284,000 gal 31,240 gal
Rolling oil 13.5 7. loss for 31,000 gal 4.185 gal
TOTAL VOLATILE WSS 51,5v gal
Obviously some items would be voLatilized to a greater degree because of
exposure to high temperatures, such as table roll bearings, hot metal crane
lubrication, etc. fr other cases, the temperature would be less such as
motor room bearings, hydraulic coil handling equipment, etc. The above is
presented as a reasonable overall estimate.
D- 31
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In Sludges. T.! 1sh & Debri
Calculatt’n of Oil in Sludz. ! — Ro11in
Method 1:
Confcntrator sludge & clarifier underfl i solid3 — 6.4# ingot ton
At 716,000 rr ingots/ye*r — 6.4 x 716,000 + 2,000 2,285 tons/year
At 77. C in sludge — 160 tons carbon
178 tons oil Q 907. C
Method _ 2 :
Underf low is 2,096 mg/I. oil and flow is 50 gpm
2096 x 50 x .012 x 300 days.yr + 2000 — 178.7 tons oil/year
Good estimate of oil in sludge therefore is 178 tons/year ± 57.
or 47,500 gals/year (7.97. oil in sludge)
SEE FIGURE 1
Calculation of Oil in Slud2e - Ironmekin
Oil into clarifier — 8 rag/I.
Oil out of clarifier— 1 mg/I.
7 mg/I. x 2600 gpm x .012 — 218 lb/day — 27.3 gal/day (355 days/year)
10300 gal/year
SEE FIGURE .1
Trash and Debris
Oil absorbent 142,000 lbs. 0 207. by weight oil 3,800 gal/year
Rags 77,000 lbs. Q 107. by weight oil 1,025 gal/year
Miscellaneous debris from floors, machine shop, degreasing, dirt, scrap metal, etc.
3,000 tons/year at 27. oil (estimated) — 15,000 gal/year
TOTAL — 19,825 gal/year
In Wastewater
Steel Works 3,000 gpm at 5 mg/I. 23 gal/day (fr 0 raNPDES discharge monitoring)
Other 37,300 gpra at 3 mg/I. — 168 gal/day
TOTAL 57,300 gal/year (300 days/year)
Drained, Collected & Skim 4
Recla Tned oils — direct collection - — 32,150 gal. (actual weights)
Reclaimed by cracking -water treatment - 154,150 gal.
Skiussed & retained cn lagoon for future reclaim — 64.200 p al . (estimated)
TOTAL - 250,500 gal.
The reclaimed oil is used exclusively for fuel, being mixed with #6 fuel oil in the
soaking pit oil tanks. Sludge from the reclaim operation is .17. or 186 gal.
D-32
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Suttr rizing the balance for Mill A, ye have:
7.67.
6.91.
.47.
1. 3
9.77.
10.87.
3.77.
10.77.
46.97.
98. Y7.
On Products
40,740
gal/year
On Mill Scale
36,800
“
Left in Containers
1,882
tI
Leak. & Spills
7,000
“
Volatilized
51,595
“
I.i Sludges
57,800
“
Trash & Debris
—
19,825
“
%4 stewater Discharge
—
57,300
‘
Drain d, Collected
-
250,500
“
T’YrAL
519,842
TcIrAL
-
534,125
Urwccounted foc
— 2.07.
D- 33
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Table VI
MIlL “A’ COLD R011. GAGC RF fl 1J 1976
Ran e Tons ____ _•
.017 — .025 11,393 97. .021
.0251- .035 29,988 23 .030
.0351— .045 28,172 217. •0
.0451— .055 21,416 167. . OYJ
.0551— .06S 18,h23 l4/. .060
.0651- .07i 2,699 27. .070
.0751— .100 5,190 47. .087
.100 — .140 14,600 117. .120
TOThL 131,611 avg. gage .032
No tin plate production
D- 34
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T.bl. Jil
tcr TA E V!T WT WSS 2M
P, TC Y TESTS
T ° Je1 t 1r .. sUet 3Oetnot.s
Cress. 2O P 6.1L
27t° P l4.
Coating Oil iy u F 22.9Z
279° V 54.lt
) ydraul(C 0(1 2030 P 11.47.
293° F 34.77.
Rol1in 0(1 203° F 3.17.
2930 ‘ 35.77.
D- 35
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// ON EN L A - R L 1. //i’ - ,4/ -I “3
TQ
//i 4 /JNG.d7T 2AI
T //E’
t4ecc /P1we d. 1 c..rrecp. d ..xaLtJy 1-. i-A& i /jve: / /Ae s.! 1 ’ ce v #
-tAt, ‘e s rr’ia.I,*,e_J .to pr d .*is. S ‘7 ,OOD sn. ot
SLuP TO Scs.#O N4,f.!
OD2.
(ii PI.It fth/l 11J
-------
c/G .11 - ilL A vce ON etA ST J URNA CE A ND /r/7 t
&ef1’k1 replirt • 1 a’t.fes 7 ? •f 4r £,j
2.. 7. Litter s (%ftJ •p• citptwre4 b s r&,Ier
a’1’,4. A dara. herein 1 ow .o?t tre.J Se-’ kL p (378o/4 7’103
flute theie V !ues JO 1 QI c srrespitJ e*’atctly 1o tJ’se. ( re.
L c 41 i . #) t P3Qt .4J(r ac D pfodM tIoI! of 7a0,ooo
Oil 7 6 P Md/4
lmj.l /inf/y 4r.
rect’ .
(Z600e
37,100
(ZOO r ’ •
i /L)
-J
q ‘io
EwT ,,.j *I/ 5 r bQseJ 9 ” 7 O,OOO *04f In et$
* The
-------
OIL. G 4 4 iA ,iC
INPLø’T r6 # 5 ot .’7frur a rc c
Z.7 7. (oR
p I rc 6Z
s Ie
,
i/t H/7 t :i:.c; 0 ‘ P
. - - ‘ cô ’ ’ “
n it r v.je
. p,/ S *‘i
ese.aiI j ,ed a d Jscp sed /.3
=
— , . y ’l ii, eJ 4’wc”CS ‘p.
i.i c .’! ‘ 7/.
— - 4 H /id; . c(/r4:A d .J 1))
Ic 7 37 ” _________
S
1
P idAs m 4 /A wacte4l4te,c /
* i4 m .y..icd ____________
1)e .f J
4 I 1 J 1
‘ .‘ “‘
•/
/ç
-------
FIGURE IV.
OIL BALANCE OF TYPICAL’ MILL
.Lr*.s &
S — t. L 5
D- 39
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TAPLE Vii
Analysis of the other mills reporting in this study cannot be made as vigorously
because the data is not as detailed. Based on the data re orted, we have
Table Viii.
Addltton 1 approxir tions riust be made to develop an overall ba1anc for a
typical nut, recognizing that there is no such thing in reality.
For this exercise, the following approximations are used:
ate ory approximation Resultant 7 .
Product Average of (l),(3),(4),(6),(7), (8) in Table VI I I 7•9Z
Scale Average of (1),(3),(6),(6),(7), (8) In Table VIII 6.77.
Lost Average of (3) and (7),(8) inTabte viii 2.17.
Leaks Average of (l),(3),(6),(7),(8) in Table VIII l. l
Volatile (7) adjusted to total 100 inTable viii
Sluc ges (39.9k-Average of all b t (2). These three are con-
(12.7) bined as total, the specific breakdoi.rn is a 72 9
Collected (20.3)L_ function of water treatment facilities. J
TOTAL 100.04
This result is shown pictorially in Figure IV.
These percentages can be translated into pounds er ingot ton or total gallons
using the average of 4.6 pounds per ton from TaFle V. Assume a mill of 4 x 106
ingot ton capacity.
Gallons fin nt Ton
4 On Produet 193,800 .36
TYPICAL -4 On Scale 164,400 .31
hILL Volatiltzed 228,100 .43
2 453,300 gaLlons 6 .- Lost in Storage 51,500 .10
or 4 x 10 TOns -, Leaks&SpLlls 27,000 .05
4.6 S/ton Annual 4 Sludgns, Trash 978,900 1.84
Capacity -4 Discharged 311,500 .58’
____________ - Collected 498,000 .93
* Compare this value to column 1 (EPT guidelines) of Table III.
D-40
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TAT LE VIII Coe rariaon of 011 Dalance For Reporting MUle
___._____L.f Ic a In ur (SeeAp pcndjx C for d tasheets )
1n1 nd Z 1 er cth1ehen ’ j b1ic Mill “A ” USS ( arv
(1) (2) (3) (4) (5) (6) (7) (8)
F oduct 3.4 .06 4.7 22.6 — 5 7.6 3 3.6
Scale 12.9 38.9 2.3 10.5 4.0 9.3 6.9 1.1
Loct - - 5.0 - - - •4 .9
Leaks .4 — 3.0 .1 - 1.3 .7
V 1ati1e — — 2.0 .2 — 9.7 3.7
SIuJge ,Debr1s 19.7 1.5 55 55 51.7 .54.7 14.5 29.2
atcr 24.6 .1 14 10.2 12.9 7.0 10.7 7.1
Cr1lect d 16.0 0 16.7 13.4 - 46.9 53.7
t ni cc oun ted 23 .0 59.5 — .7 1.6 18.0 24.0 2.0 0
(1) See data sheets in Appcr’dix C for full title of categories.
0-4 1
-------
:T
— . ...4 . — — - -
• I I
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r’-°” r pQs..’I\E. AT__tPftT”
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H - --
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_ RAP1I - %
• F 30
OIL.
YQfl iiiLlC. OIL
I /3. 7 - -
____ -- ____ _____—- __________ x.._c ArJNt 1L
rj-.1-4 1 R vgjc F LI’D
• 6-RQL.LI Ji OIL
300 .350 ‘ C o 45C -
- - b teTh -. - I -, -
I L_. • ____ __ __ I L. I
-------
\‘lI I — 1IL1 P’r11Y
1. Removing Oil Frcm Plant Effluents, J.G. Rabosky, Colgon Corp., Plant Engineerin ,
May 4, 1972, p. 84-85.
2. 1rterf cial Fr’rerties On OilyWater Clarification, G.P. Canevari, Eeso Research
and Engineering, Florham Park, N.J.
3. Oil In Water Emulsion Breaking Tochnif ” < Nalco Chemical Co.
14. 31trafiltraticn Removal of Soluble 011, R.P. Nordstrom, Jr., Abcor, 1 c.
Pollution En ireerin , October, 1974, p. 46—47.
5. Ultrafiltration of Soluble Oil Wastes, Goldsmith et al Journal WPCF, Vol.46 #9,
September, 1974, p. 2183-2192.
6. Water gased Hydraulics Proved OK ut Is Not Always Worth The Effort, anon., Product
Engh’er n , February, 19Th, p. 21-22.
7. Cold Rolling Lubrication Technoto;y, M. Shamaiengar, Iron& Steel Engineer Yearbook , 1967,
p. 381387 .
8. Water Pollution Control Program At Armco’s Middlet n Works, R.J. Thompson,
jron and Steel En ireer . August, 1972, p. 43—48.
9. Solid Lubricants, A Survey ?ASASP—5059 (01) 1972. (Not Attached)
10. From Sand To Steel, The Burns Harbor Story, C. Labee, pn and Stee1 _ F.nc ineer ,
October, 1971.
11. Combined Steel Mill and Municipal Wastewaters Treatment U.S. EPA Water Pollution
Control Research Series 12010 IYIQ, February, 1972. (Not Attached)
12. Development Document EPA 440/1—76/048-b Iron and Steel Manufacturing Effluent Guide-
lines - Forming, }inishing and Specialty Steel, Volumes 1 & II. (Not Attached)
13. Va te Oil Treatment -Ultrafiltration At Allegheny Ludlum, Lisanti & Heiwick, Water
Pollution Control Association of Pa. 1as az e , March—April, 1977, p. 4 — 5 .
14. Testing Cold Rolling Lubricants In The Laboratory, R.A. Dickinson, United States Steel.
Iron and Steel Engineer yearbook . 1968, p. 749-760.
IS. Rolling Oil Practice For Tandem Cold Mills and Double Re’Iuced Tin Plate, T.J. Bishop,
Iron and Steel En Jneer yearbook . 19b8, p. 747749.
16. Rec ery of Waste Oil Using FloatingType Skii ers, H.E. Ilillyard, Iron and Steel
Eigineer yearbook , 1968, p. 519—522.
17. OnceAyedr Crane Lubrication, PAUl S. Hoffman, Lron and Steel Ergineet yearbok , 1968,
p. 383390.
18. Planning For Contro’ of Stream Pollution At J&L’s Hennepin Works, j.A. Maru zeWSki etal
Jron_and_ eet En Jr ’cer arhp , 1968, p. 313—318.
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19. Evaluation of Solid Lubric ants, Oil and Grease, H.T. Azzam, ! ron and Steel En ine r
yearbook, l9 8, p. 299-306.
20. Operation of Waste Water Syste i At Inland’s 80 In. Hot Strip Mill, R.C. Wey-er,
Iron and ctecl n in”er ye*rb.’ c’k , 1968, p. 183-193.
21. Lubrication of Gear-Type Fle.dble Sptndles, J.J. Winkler, Iron and Steel Enzineer
yearbook 1966, p. 222-226.
22. lmprc’vet nts To OiIFilm Bearing Lubrtcanta At Kaiser Steel, D. Domonoske, Iron and
Steel Engineer yeirhook , 1966, p. 901-917.
23. Recycled W .ter Systems For Steel Mills, G.A. Bowman and R.B. Houston, Iron and Steel
En&tneer earoook . 1966, p. 860-869.
24. Liquid Density Cage For Determining Rolling Oil In Cold Mill Coolant, Free man ot al,
Iron and Stool E inoer yoarbook , 1966, p. 730—702.
25. The Operation of Pressure Type Sand Filters For Hot Mill Waste Waters, C. Broman,
Chtca o Regional Technical eettnt AISI . 1970.
26. The 80 Inch Hot Strip Mill At Great Lakes, T.J. Lea, Iron and Steel Ene ineer . April,
1969, p. 8 e-93.
27. Hydrodynar ic and Hydrostatic Lubricating Systems For Oil Film Roll Neck Bearings,
S.S. Richley, Iron and Steel Engineer , May, 1971, p. 55—59.
28. Waste Water rentrol At Midwest Steel’s New Finishing Mill, C.D. Hartman et al, Iron
and Stecl Enc in2er . 1963, pp. 736746.
29. World’s First 6-Stand Tandem Cold Mill For Reduction of T a Plate Products, N.W. Tucker
Iron and Steel Eneineer yearbook . 1963, p. 697—700.
30. Oil Mist Lubrication On Roll Neck Bearings, K. Frazier, Sr., Iron and Steel Eneineer
yearbook , 1963, p. 576-580.
31. .J&t’s 3 Stand Cold Reducing Mill For Thin Tin Plate, R.W. Barnitz et .1, Iron and
Steel Eneine r Yearbook , 1963, p. 265-273.
32. Physical 6 Chemical Properties of Complex Soap Greases, A.P. Polishuk, Sun Oil Company,
Marcus Hook, Pa.
33. Alkaline Treatment System Reduces Pollution Problems, P.R. Erickson, Industrial tJa tes .
Mar/Apr 1977, p.24-25
34. Closed-Loop System Separates Oil From Prewash Overflow, D. Erwin, Pdustrtal Wastes ,
Mar/Apr, 1977, p.2627.
35. Treatment of Waste Ott: Wastewater Mixtures, i.E. Barker et at, Chemical Enetneerinz
Progress Symposium Series . Water 1970, p.423427.
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36. Ir itrtnt of Waste Oil at the Ke!hin W’rks — Nippon Kokan, T. Ikehata, iron and Steel
Ergin c , Febrt:lry 1975, p.65 10 .
37. In Plant Handlinc to Control Waste Oils, Nnbil
33. Lh ic ti n in the Coot nuo,is Casting Process, W.G. Ritter, Iron and Ste ’l En ineer
yeatbc ’k, 1967, p.IS .—lS 9 . -
36. gums W rb’r aste Treatrcn planning for a New Steel Mill, R.N. Leidner, Iron j
StlEn ir’ er l967 p. 3 A 4 8
40. Hi h Terperture Rolling Oils Aid Hot Rolling, M.R. Edmundson, Iron and ctcel Enc ineer ,
Oct. 1970, o.b66 .
41. A New igh-Temperature Lubricant Fcr Hot Rolling, A.R. GIOhUS, Lt’° and Steel Engir’eer ,
Aug. l°70, p. 9 ) 4 .
42. Present Practice and New Concepts For Handling Effluents From Hot Rolling Mills,
R. Nebolsine, iron and Steel Enzineer , Aug. 1970. p.8592
43. Inereasine Hot Strip Mill Roll ‘ Life By Spray Lubrica ton, R.S. Ht ;t tter Iron and
Steel Engineer , Oct. 1973, p. 66 — 70 .
43. 011 MiSt Lubrication-A Method TO Design Out Maintenance, E. ,u1ker, Iron and Steel
Enz.ireer , Oct. 1974, p. 473 O.
45. Recent Developments in the Design & Application of Centralized Crease Lubrication Syste-
E.J. Gesdorf, Iron and cteel Engineer , Aug. 1974, p.65 -7 0 .
46. FrictiOn Ifl the Hot Rolling of Steel Strip. W.L. Roberts, Iron and Steel Engineer .
July, 1974, p. 56-62.
47. Studies in Roll Lubrication — Shape Mills, A.E. Cichelli, lr a and Steel Engine. ,
June 1974, p.S6— 6 2 .
48. Misty: The Design of a Modern Mist ‘Lubricant, T.C. Wilson, Iron and Steel Engineer ,
Jan. 1974, p. 9 5- 98 .
1.9. HIgh Speed Rolling On 5—Stand Tandem Cold Mill, H. Nakata et al, n and Steel Engineer .
Nov. 1971, p. 3 —S 9 .
50. In’and’s 5—Stand 80 In Tandem Cold Mill, E.W. James et al, Iron and Steel Engire r ,
Nov. 1972, p. 33 - 38 .
51. Planning your Caster, its Water and Pollution Control Facilities, C.N. Krueger,
and Steel En ineer , June 1971, p. 62 - 70
52. Lubrication Practices at 8urns Harbor 80 In. Hot Strip Mill, D.K. Gilrsore, Iron and Steel
Engineer, June 1971, p.6 2 ’lO.
53. A Characterization of Air Pollutants From Sintering Plant tnduc d Draft Stacks, G.E.
}Ltnning and F.E. Rover, ArmeO Steel.
54. Report To Jones & ‘ Lauc hlin Steel on the Analysis of 0rg iic Emissions From a S inter
Plant - carnegi ‘ ‘ellon t niver ..ty Report.
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