Development Document for Proposed Effluent limitations Guidelines, New Source Performance Standards, and Pretreatment Standards, for the Iron and Steel Manufacturing Point Source Category


United States
Environmental Protection
Agency
Effluent Guidelines Division
WH-552
Washington, DC 20460
EPA 440/1-80/024-b
December 1980
Water and Waste Management
&EPA Development	Proposed
Document for
Effluent Limitations
Guidelines and
Standards for the
Iron and Steel
Manufacturing
Point Source Category
Vol. V
Scale Removal Subcategory
Acid Pickling Subcategory

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DEVELOPMENT DOCUMENT
for
PROPOSED EFFLUENT LIMITATIONS GUIDELINES,
NEW SOURCE PERFORMANCE STANDARDS,
and
PRETREATMENT STANDARDS
for the
IRON AND STEEL MANUFACTURING
POINT SOURCE CATEGORY
Douglas M. Costle
Administrator
Steven Schatzow
Deputy Assistant Administrator for
Water Regulations and Standards
Jeffery Denit, Acting Director
Effluent Guidelines Division
Ernst P. Hall, P.E.
Chief, Metals & Machinery Branch
Edward L. Dulaney, P.E.
Senior Project Officer
December, 1980
Effluent Guidelines Division
Office of Water and Waste Management
U.S. Environmental Protection Agency
Washington, DC 20460

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SCALE REMOVAL SUBCATEGORY
TABLE OF CONTENTS
SECTION	PAGE
I	PREFACE . . .
II	CONCLUSIONS .
Ill	INTRODUCTION.
General Discussion	
Development of Regulations	
Description of Scale Removal Operations
IV	SUBCATEGORIZATION
Introduction	
Factors Considered in Subdivision
V	WATER USE AND WASTE CHARACTERIZATION.
Introduction	
Description of Scale Removal Operations
and Wastewater Sources	
VI	WASTEWATER POLLUTANTS
Introduction	
Rationale for the Selection of Wastewater
Pollutants 	
VII	CONTROL AND TREATMENT TECHNOLOGY.
Introduction		
Control and Treatment Technologies - Scale Removal.
Summary of Treatment Practices Currently Employed
at Kolene Descaling Operations		
Summary of Treatment Practices Currently Employed
at Hydride Descaling Operations 	
Control and Treatment Technologies Considered
for Toxic Pollutant Removal	. . . . .
Plant Visit Data	-
Plant Visits - Kolene Descaling Operations. . . . ,
Plant Visits - Hydride Descaling Operations . . . ,

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SCALE REMOVAL SUBCATEGORY
TABLE OF CONTENTS (CONTINUED)
SECTION	PAGE
VIII	COST, ENERGY, AND NON-WATER QUALITY IMPACTS 	 7 3
Introduction	73
Actual Costs Incurred by the Operations Sampled
for this Study	73
Control and Treatment Technology	7 3
Cost, Energy, and Nonwater Quality Impacts	74
Estimated Costs for the Installation of
Pollution Control Technologies 		74
Energy Impacts	76
Nonwater Quality Impacts 		78
Summary of Nonwater Quality Impacts 		80
IX	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICA-
TION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE 	 99
Introduction	99
Identification of BPT	99
Rationale for BPT Treatment System	100
Justification of Proposed BPT Effluent Limitations. . 100
X	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICA-
TION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE	105
Introduction	105
Identification of BAT	105
Flows	106
Wastewater Quality	107
Effluent Limitations for BAT Alternatives 	 107
Selection of a BAT Alternative	107
XI	BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
(BCT)	115
Introduction	115
Development of BCT	115
Selection of a BCT Alternative	115
Development of BCT Limitations	116
ii

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SCALE REMOVAL SUBCATEGORY
TABLE OF CONTENTS (CONTINUED)
SECTION	PAGE
XII	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICA-
TION OF NEW SOURCE PERFORMANCE STANDARDS 	 121
Introduction	121
Identification of NSPS	121
Rationale for Selection of NSPS	122
Treatment Scheme	122
Flows	123
Selection of NSPS Alternative	I23
XIII	PRETREATMENT STANDARDS FOR SCALE REMOVAL
OPERATIONS DISCHARGING TO PUBLICLY OWNED
TREATMENT WORKS	I29
Introduction	I29
General Pretreatment Standards	I29
Pretreatment Considerations for Scale Removal . . . .130
Identification of Pretreatment	13 0
Flow Rates	131
Selection of Pretreatment Alternatives	132
iii

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7
8
9
10
14
15
16
17
18
19
27
36
37
41
42
43
44
SCALE REMOVAL SUBCATEGORY
TABLES
TITLE
BPT TREATMENT MODEL FLOW AND EFFLUENT QUALITY -
SCALE REMOVAL SUBCATEGORY	
BPT PROPOSED EFFLUENT LIMITATIONS -
SCALE REMOVAL SUBCATEGORY		 .
TREATMENT MODEL FLOWS AND EFFLUENT QUALITY -
SCALE REMOVAL SUBCATEGORY	
PROPOSED EFFLUENT LIMITATIONS AND STANDARDS -
SCALE REMOVAL SUBCATEGORY	
GENERAL DATA SUMMARY - KOLENE BATCH TYPE . . .
GENERAL DATA SUMMARY - KOLENE CONTINUOUS TYPE.
GENERAL DATA SUMMARY - HYDRIDE BATCH AND
CONTINUOUS OPERATIONS	
SUMMARY OF MILLS SAMPLED DURING THIS STUDY -
SCALE REMOVAL SUBCATEGORY 	
KOLENE SCALE REMOVAL DATA BASE - BATCH AND
CONTINUOUS OPERATIONS	
HYDRIDE SCALE REMOVAL DATA BASE - BATCH
AND CONTINUOUS OPERATIONS 	
EXAMPLES OF SCALE REMOVAL OPERATIONS THAT HAVE
RETROFFITTED TREATMENT 	
CONCENTRATION OF POLLUTANTS IN THE NET RAW
WASTEWATER - KOLENE OPERATIONS 	
CONCENTRATION OF POLLUTANTS IN THE NEW RAW
WASTEWATERS - HYDRIDE OPERATIONS 	
POLLUTANTS KNOWN TO BE PRESENT - KOLENE SCALE
REMOVAL 			
POLLUTANTS KNOWN TO BE PRESENT - HYDRIDE SCALE
REMOVAL
SELECTED POLLUTANTS - KOLENE SCALE REMOVAL . .
SELECTED POLLUTANTS - HYDRIDE SCALE REMOVAL. .
v

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SCALE REMOVAL SUBCATEGORY
TABLES (CONTINUED)
NUMBER
VII-1
VII-2
VI I-3
VII-4
VII-5
VIII-1
VIII-2
VIII-3
VIII-4
VIII-5
VIII-6
VIII-7
VIII-8
VIII-9
VIII-10
VIII-11
VIII-12
VIII-13
VIII-14
VIII-15
IX-1
IX-2
X-l
X-2
X-3
X-4
TITLE	PAGE
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS 	 51
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS -
ORIGINAL GUIDELINES SURVEY - KOLENE 	 56
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS -
POLLUTANT STUDY - KOLENE	58
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS -
ORIGINAL GUIDELINES STUDY - HYDRIDE 	 60
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS -
TOXIC POLLUTANT STUDY - HYDRIDE 	 61
REPORTED EFFLUENT TREATMENT COSTS - KOLENE SCALE
REMOVAL OPERATIONS	81
REPORTED EFFLUENT TREATMENT COSTS - HYDRIDE
SCALE REMOVAL OPERATIONS	82
CONTROL AND TREATMENT TECHNOLOGIES - SCALE REMOVAL
SUBCATEGORY - KOLENE 		83
CONTROL AND TREATMENT TECHNOLOGIES - SCALE REMOVAL
SUBCATEGORY - HYDRIDE 		86
BPT MODEL COST DATA - KOLENE	88
BPT MODEL COST DATA - HYDRIDE	89
BPT CAPITAL COST TABULATION - KOLENE	90
BPT CAPITAL COST TABULATION - HYDRIDE	91
ALTERNATIVE BAT MODEL COST DATA - KOLENE	92
ALTERNATIVE BAT MODEL COST DATA - HYDRIDE	93
RESULTS OF BCT COST TEST - SCALE REMOVAL SUBCATEGORY.	94
ALTERNATIVE NSPS AND PSNS MODEL COST DATA - KOLENE. .	95
ALTERNATIVE NSPS AND PSNS MODEL COST DATA - HYDRIDE .	96
ALTERNATIVE PSES MODEL COST DATA - KOLENE	97
ALTERNATIVE PSES MODEL COST DATA - HYDRIDE	98
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS - SCALE
REMOVAL SUBCATEGORY - KOLENE 	
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS - SCALE
REMOVAL SUBCATEGORY - HYDRIDE 	
BAT EFFLUENT LIMITATIONS GUIDELINES - KOLENE
SCALE REMOVAL		
BAT EFFLUENT LIMITATIONS GUIDELINES - HYDRIDE
SCALE REMOVAL 	
SUMMARY OF FLOW DATA - KOLENE SCALE REMOVAL .
SUMMARY OF FLOW DATA - HYDRIDE SCALE REMOVAL.
vi

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SCALE REMOVAL SUBCATEGORY
TABLES (CONTINUED)
NUMBER	TITLE	PAGE
XI-1	BCT EFFLUENT LIMITATIONS - KOLENE SCALE REMOVAL . . . 117
XI-2	BCT EFFLUENT LIMITATIONS - HYDRIDE SCALE REMOVAL . . 118
XII-1	NEW SOURCE PERFORMANCE STANDARDS - SCALE REMOVAL
SUBCATEGORY - KOLENE	124
XII-2	NEW SOURCE PERFORMANCE STANDARDS - SCALE REMOVAL
SUBCATEGORY - HYDRIDE 	 125
XIII-1	PRETREATMENT EFFLUENT STANDARDS FOR EXISTING
SOURCES - SCALE REMOVAL SUBCATEGORY - KOLENE	 133
XIII-2	PRETREATMENT EFFLUENT STANDARDS FOR EXISTING
SOURCES - SCALE REMOVAL SUBCATEGORY - HYDRIDE . . . .134
XII1-3	PRETREATMENT EFFLUENT STANDARDS FOR NEW SOURCES -
SCALE REMOVAL SUBCATEGORY - KOLENE	135
XII1-4	PRETREATMENT EFFLUENT STANDARDS FOR NEW SOURCES -
SCALE REMOVAL SUBCATEGORY - HYDRIDE 	 136
vii

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SCALE REMOVAL SUBCATEGORY
FIGURES
NUMBER	TITLE	PAGE
III-l	BATCH TYPE OPERATION - KOLENE AND HYDRIDE
SCALE REMOVAL	20
III-3	CONTINUOUS TYPE OPERATION - KOLENE AND HYDRIDE
SCALE REMOVAL	21
IV-1	DISCHARGE FLOW VERSUS PRODUCTION CAPACITY -
KOLENE SCALE REMOVAL	28
IV-2	DISCHARGE FLOW VERSUS PRODUCTION CAPACITY -
HYDRIDE SCALE REMOVAL 	 29
IV-3	DISCHARGE FLOW VERSUS PLANT AGE -
KOLENE SCALE REMOVAL 	 30
IV-4	DISCHARGE FLOW VERSUS PLANT AGE -
HYDRIDE SCALE REMOVAL 	 31
VII-1	WATER FLOW DIAGRAM - PLANT L	63
VII-2	WATER FLOW DIAGRAM - PLANT C	64
VII-3	WATER FLOW DIAGRAM - PLANT Q	65
VII-4	WATER FLOW DIAGRAM - PLANT 131	66
VII-5	WATER FLOW DIAGRAM - PLANT 132	67
VII-6	WATER FLOW DIAGRAM - PLANT 137	68
VII-7	WATER FLOW DIAGRAM - PLANT 138	69
VII-8	WATER FLOW DIAGRAM - PLANT L	70
VII-9	WATER FLOW DIAGRAM - PLANT 139	71
IX-1	BPT MODEL - KOLENE SCALE REMOVAL	103
IX-2	BPT MODEL - HYDRIDE SCALE REMOVAL	104
X—1	BAT MODELS - ALTERNATIVES 1-3 - KOLENE
SCALE REMOVAL	112
X-2	BAT MODELS - ALTERNATIVES 1-3 - HYDRIDE
SCALE REMOVAL	113
XI-1	BCT MODEL - KOLENE SCALE REMOVAL	119
XI-2	BCT MODEL - HYDRIDE SCALE REMOVAL	120
XII-1	NSPS MODEL - ALTERNATIVE 1 - KOLENE SCALE
REMOVAL	126
XII-2	NSPS MODEL - ALTERNATIVE 2 - KOLENE SCALE
REMOVAL		127
XII-3	NSPS MODEL - ALTERNATIVES 1 AND 2 - HYDRIDE
SCALE REMOVAL	128
ix

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SCALE REMOVAL SUBCATEGORY
FIGURES (CONTINUED)
NUMBER	TITLE	PAGE
XIII-1	PSES MODEL - ALTERNATIVE 1 - KOLENE SCALE
REMOVAL	137
XIII-2	PSES MODEL - ALTERNATIVE 2 - KOLENE SCALE
REMOVAL	138
XIII-3	PSES MODELS - ALTERNATIVES 1 AND 2 - HYDRIDE
SCALE REMOVAL	139
XIII-4	PSNS MODEL - ALTERNATIVE 1 - KOLENE SCALE REMOVAL. . 140
XIII-5	PSNS MODEL - ALTERNATIVE 2 - KOLENE SCALE REMOVAL. . 141
XIII-6	PSNS MODEL - ALTERNATIVES 1 AND 2 - HYDRIDE
SCALE REMOVAL	142
X

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ACID PICKLING SUBCATEGORY
TABLE OF CONTENTS
SECTION	PAGE
I	PREFACE	143
II	CONCLUSIONS	14 5
III	INTRODUCTION	157
General Discussion	157
Data Base	157
Description of Pickling Operations	159
Type of Pickling		160
Description of Wastewater Sources 		161
Acid Recovery and Acid Regeneration	163
Pickling of Different Types of Steel
in Combination Acid Pickling Operations 		163
IV	SUBCATEGORIZATION 		199
Factors Considered in Subdivision
and Segmentation	200
V	WATER USE AND WASTE CHARACTERIZATION. 		225
Introduction	225
Acid Pickling	225
VI	SELECTION OF POLLUTANTS	24 5
Conventional 		24 5
Other	246
Toxic 			 	
VII	CONTROL AND TREATMENT TECHNOLOGY	251
Introduction. 			 • •	251
Summary of Treatment Practices Currently Employed . . 251
Treatment of Spent Pickle Liquor	251
Treatment of Fume Scrubber Water	253
General Treatment Configurations for Pickle
Rinsewaters 	 ..... 		254
Control and Treatment Technologies Considered
for Toxic Pollutant Removal 		254
Summary of Analytical Data	256
Summary of Long-Term Analytical Data 		256
Plant Visits				 .	256
xi

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ACID PICKLING SUBCATEGORY
TABLE OF CONTENTS (CONTINUED)
SECTION	PAGE
VIII	COST, ENERGY, AND NONWATER QUALITY IMPACTS 		345
Introduction	345
Actual Costs Incurred by Plants Sampled
for this Study	34 5
Control and Treatment Technologies Recommended
for Use in Acid Pickling	345
Cost, Energy, and Nonwater Quality Impacts	34 6
Summary of Impacts	34 9
IX	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICA-
TION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE 		4 31
Introduction	4 31
Identification of BPT	431
Justification of BPT	432
Total Metals	4 33
X	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICA-
TION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE		445
Introduction	445
Identification of BAT	445
Pollutants Limited at BAT	446
Rationale for BAT	447
Toxic Metal Pollutants 		448
Effluent Limitations for Alternative
Treatment Systems 		44 9
Selection of a BAT Alternative	449
XI	BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY. ...	481
Introduction	481
Methodology	481
BCT Treatment Alternatives 		481
Development of BCT Limitations	481
Proposed BCT Limitations 		482
xii

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ACID PICKLING SUBCATEGORY
TABLE OF CONTENTS (CONTINUED)
SECTION	PAGE
XII	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICA-
TION OF NEW SOURCE PERFORMANCE STANDARDS 		489
Introduction	489
Identification of NSPS	489
Rationale for NSPS	490
Selection of NSPS Alternative	•	490
XIII	PRETREATMENT STANDARDS FOR DISCHARGES TO PUBLICLY
OWNED TREATMENT WORKS	499
Introduction	499
General Pretreatment Standards	499
Categorical Pretreatment Standards	499
Rationale for Selection of Pretreatment Systems . . .	501
Alternative Pretreatment Systems	501
Selection of Pretreatment Alternatives	503
xiii

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ACID PICKLING SUBCATEGORY
TABLES
NUMBER	TITLE	PAGE
II-l	BPT TREATMENT MODEL FLOWS AND EFFLUENT QUALITY ...	148
II-2	PROPOSED BPT EFFLUENT LIMITATIONS	14 9
III-3	TREATMENT MODEL FLOWS AND EFFLUENT QUALITY 		150
II-4	PROPOSED EFFLUENT LIMITATIONS AND STANDARDS	153
III-l	SULFURIC ACID PICKLING SUMMARY TABLE 		164
III-2	HYDROCHLORIC ACID PICKLING SUMMARY TABLE 		171
III-3	COMBINATION ACID PICKLING SUMMARY TABLE	175
III-4	BATCH SULFURIC ACID PICKLING DATA BASE	183
III-5	CONTINUOUS SULFURIC ACID PICKLING DATA BASE	184
III-6	HYDROCHLORIC ACID PICKLING DATA BASE	185
III-7	BATCH COMBINATION ACID PICKLING DATA BASE	186
III-8	CONTINUOUS COMBINATION ACID PICKLING DATA BASE ...	187
III-9	SUMMARY OF SAMPLED PLANTS	188
IV-1	ACID PICKLING OPERATIONS DEMONSTRATING THE
ABILITY TO RETROFIT POLLUTION CONTROL EQUIPMENT. . .	206
IV-2	LOCATION OF ACID PICKLING OPERATIONS 		207
IV-3	AVERAGE PROCESS FLOW VALUES	209
V-l	to	SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS -
V-16	NET RAW CONCENTRATIONS - ACID PICKLING SUBCATEGORY .	228
VI-1	PRIORITY POLLUTANTS KNOWN TO BE PRESENT 		24 8
VI-2	SELECTED POLLUTANTS	*.	249
VII-1	OPERATING MODES, CONTROL AND TREATMENT TECHNOLOGIES
AND DISPOSAL METHODS 		263
VII-2 to	SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS -
VII-14	ACID PICKLING SUBCATEGORY		268
VIII-1	to	EFFLUENT TREATMENT COSTS - ACID PICKLING
VIII-12	SUBCATEGORY	350
VIII-13 to	CONTROL AND TREATMENT TECHNOLOGIES -
VIII-16	ACID PICKLING SUBCATEGORY	362
VIII-17 to
VIII-26	BPT MODEL COST DATA - ACID PICKLING SUBCATEGORY. . .	370
VII1-27 to	BPT CAPITAL COST TABULATIONS - ACID PICKLING
VIII-35	SUBCATEGORY	383
XV

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ACID PICKLING SUBCATEGORY
TABLES (CONTINUED)
NUMBER	TITLE	PAGE
VIII-36	to BAT MODEL COST DATA - ACID PICKLING
VIII-42	SUBCATEGORY 	 394
VIII-43	to RESULTS OF BCT COST TESTS - ACID PICKLING
VIII-46	SUBCATEGORY 	 401
VIII-47	to NSPS, PSES AND PSNS MODEL COST DATA -
VI11-57	ACID PICKLING SUBCATEGORY 	 405
VIII-58	BPT INVESTMENT AND ANNUAL OPERATING COSTS
FOR THE ACID PICKLING SUBCATEGORY	4 25
VIII-59	BAT INVESTMENT AND ANNUAL COSTS FOR THE
ACID PICKLING SUBCATEGORY 	 4 26
VIII-60	ENERGY REQUIREMENTS IN THE ACID PICKLING
SUBCATEGORY	427
VIII-61	SOLID WASTE GENERATION SUMMARY 	 4 28
IX-1	BPT EFFLUENT LIMITATIONS	434
IX-2 to
IX-4	JUSTIFICATION OF BPT EFFLUENT LIMITATIONS	435
X-l	to
X-12	ANALYSIS OF FLOW DATA - ACID PICKLING SUBCATEGORY . . 450
X-13	RAW WASTE LEVEL FLOW JUSTIFICATIONS 	4 71
X-14	ANALYSIS OF FLOW DATA -ABSORBER VENT SCRUBBER .... 472
X-15	DEVELOPMENT OF BAT FLOW RATES	74 3
X-l6	BAT EFFLUENT LIMITATIONS GUIDELINES 	 474
XI-1	BCT EFFLUENT LIMITATIONS GUIDELINES 	 483
XII-1	NEW SOURCE PERFORMANCE STANDARDS	492
XIII-1	PRETREATMENT EFFLUENT STANDARDS (EXISTING
AND NEW SOURCES) 	504
xvi

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ACID PICKLING SUBCATEGORY
FIGURES
NUMBER	TITLE	PAGE
III-l to
III-9	PROCESS FLOW DIAGRAM - ACID PICKLING SUBCATEGORY . . 190
IV-1	to	APPLIED RINSE FLOW VERSUS PRODUCTION -
IV-7	ACID PICKLING SUBCATEGORY	210
IV-8 to	APPLIED RINSE FLOW VERSUS AGE -
IV-14	ACID PICKLING SUBCATEGORY	217
VII-1 to
VII-45	WASTEWATER TREATMENT SYSTEM AND WATER FLOW DIAGRAMS . 299
IX-1 to
IX-5	BPT MODELS - ACID PICKLING SUBCATEGORY	439
X-l	to	BAT TREATMENT ALTERNATIVES - ACID PICKLING
X-4	SUBCATEGORY	477
XI-1	to	BCT TREATMENT ALTERNATIVES - ACID PICKLING
XI-4	SUBCATEGORY	484
XII-1	to	NSPS TREATMENT ALTERNATIVES - ACID PICKLING
XII-4	SUBCATEGORY	494
XIII-1	to	PSES AND PSNS TREATMENT ALTERNATIVES - ACID
XIII-6	PICKLING SUBCATEGORY 	 507
xvii

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SCALE REMOVAL SUBCATEGORY
SECTION I
PREFACE
The USEPA is proposing effluent limitations guidelines and standards
for the steel industry. The proposed regulation contains effluent
limitations guidelines for best practicable control technology (BCT),
and best available technology economically achievable (BAT) as well as
pretreatment standards for new and existing sources (PSNS and PSES)
and new source performance standards (NSPS) under Sections 301, 304,
306, 307 and 501 of the Clean Water Act.
This part of the Development Document highlights the Scale Removal
Subcategory of the Iron and Steel Industry. Volume I of the
Development Document discusses issues pertaining to the industry,
while other volumes relate to the remaining subcategories of the
industry.
l

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SCALE REMOVAL SUBCATEGORY
SECTION II
CONCLUSIONS
This report highlights the technical aspects of EPA's study of the
Scale Removal Subcategory of the Iron and Steel Manufacturing
Category.
Based upon this current study and a review of previous studies, the
Agency has reached the following conclusions:
1.	The Agency is retaining the previous subdivision of the Scale
Removal Subcategory into kolene and hydride scale removal
operations. Studies were conducted to determine if any other
factors warranted further subdivision of the subcategory. None
were found to have a significant effect on subdivision.
2.	The Agency is not proposing a limitation on cyanide for kolene
operations, although the originally promulgated limitations
contained such a limitation. The data gathered for this study do
not indicate that this pollutant is present in the kolene
wastewaters in high quantities. Also, the previously promulgated
regulation contained a limitation for dissolved chromium. The
Agency is now proposing a total chromium limitation in .lieu of
dissolved chromium since total chromium is on the toxic pollutant
list.
3.	EPA estimates that compliance with the proposed BPT and BAT
limitations will result in significant removals of toxic and
other pollutants. A summary of the removal occurring from
compliance with those proposed limitations is shown below.
Kolene Scale Removal
Effluent Discharges (Tons/YearT
Raw	Proposed Proposed
Waste	BPT	BAT
Flow (MGD)
TSS
Toxic Metals
Toxic Organics
Other Pollutants
1.24 1.24
1544.43 32.18
584.70 2.57
0.039 0.039
514.8	0.064
0.79
12.34
0.57
0.025
0.041
3

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	Hydride Scale Removal	
Effluent Discharges (Tons/Year)
Raw	Proposed Proposed
Waste	BPT	BAT
Flow (MGD) 1.44	1.44	0.12
TSS 810.36	40.52	2.02
Toxic Metals 21.02	5.16	0.14
Toxic Organics 1.62	0.41	0.034
Other Pollutants 64.83	1.62	0.027
4. Based upon facilities in place as of January 1, 1978 the Agency
estimates the following costs to the industry will result from
compliance with the proposed BPT and BAT limitations.
	Kolene Scale Removal	
Costs (Millions of July 1.	1978 Dollars)
Investment Costs		Annual
Total In-place Required	Costs
BPT 6.59 3.18 3.41	1.58
BAT 2.66 0.14 2.52	0.48
TOTAL 9.25 3.32 5.93	2.06
	Hydride Scale Removal	
Costs (Millions of July 1,	1978 Dollars)
Investment Costs		Annual
Total In-place Required	Costs
BPT 0.89 0.63 0.26	0.32
BAT 0.56 0.00 0.56	0.10
TOTAL 1.45 0.63 0.82	0.42
5.	The Agency evaluated the "cost-reasonableness" of controlling the
conventional pollutants based upon BCT alternative treatment
systems. The control costs, for kolene operations, are greater
than the costs experienced by publicly owned treatment works
(POTWs). Therefore, the proposed BCT limitations for those
operations are identical to the proposed BPT limitations for
conventional pollutants. The control costs, for hydride
operations, are less than the costs experienced by publicly owned
treatment works (POTWs). Therefore, The Agency is proposing BCT
limitations based upon the BCT model treatment system.
6.	The proposed NSPS and the NSPS model treatment system are similar
to the proposed BAT limitations and the BAT model treatment
system, respectively. However, the discharge flow rates for the
NSPS system are less than the BAT system and the NSPS is based on
that lower flow rates.
4

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7.	EPA is proposing pretreatment standards for new and existing
sources (PSNS and PSES) discharging wastewaters to POTWs. These
standards limit the amount of toxic pollutants which can be
discharged to POTWs. The standards are intended to minimize the
impact from pollutants which could interfere with, pass through,
or are otherwise incompatible with POTW operations. PSNS
standards and technologies are the same as the standards and
technologies for NSPS. PSES technologies are the same as NSPS
technologies, but the flow is retained at the BAT level of
treatment. Conventional pollutants are not included in
pretreatment standards.
8.	Three Phase II remand issues which had a direct bearing on the
scale removal subcategory are addressed in detail in this report.
A summary of these issues is presented below.
a.	The remand required examination of the degree of water
consumption that would result from the installation of the
proposed treatment systems. Since the alternative treatment
systems considered for scale removal operations do not
employ recycle or cooling systems no impact is expected on
water consumption as a result of the applicaton of the
proposed effluent limitations.
b.	The Agency evaluated the adequacy of previous cost estimates
with regard to site-specific factors. An analysis was made
comparing cost estimates based upon model plant
considerations to actual cost data provided for scale
removal operations. However, since wastewaters for all
mills for which data were provided are treated in large
central treatment systems, the Agency found it impossible to
segregate those costs and therefore could not directly
compare those costs on a subcategory basis. Nevertheless,
the adequacy of the cost model to account for site-specific
factors has been verified and is presented in Volume I. The
comparison is made on a central treatment basis.
c.	Neither relaxed effluent limitations nor retrofit cost
allowances are necessary for older scale removal operations.
Analysis indicates that the age of a scale removal operation
has no significant effect upon the ease or cost of
retrofitting pollution control equipment.
9.	Although a significant number of toxic pollutants were found to
be present in the raw wastewater from scale removal operations,
the Agency believes it is not necessary to establish limitations
for each toxic pollutant. Adequate control of those toxic
pollutants not specifically limited is attained by controlling
the pollutants for which limitations are proposed. By limiting
the discharge of these pollutants, effective control is provided
for all toxic pollutants identified in raw wastewaters.
10.	The Agency is proposing NSPS and PSNS based upon model effluent
flows of 200 gal/ton and 50 gal/ton for kolene and hydride
operations, respectively, and is considering promulgating the
5

-------
BAT, BCT, and PSES limitations and standards based on those same
flows as opposed to those contained herein (320 gal/ton and 100
gal/ton for kolene and hydride operations, respectively). The
Agency is soliciting comments on whether model flows of 200
gal/ton and 50 gal/ton are appropriate for kolene and hydride
operations, respectively, at the BAT, BCT and PSES levels.
11. Table II—1 presents the treatment model flow and effluent quality
data used to develop the proposed BPT effluent limitations for
the scale removal subcategory, and Table I1-2 presents these
proposed limitations. Table I1-3 presents the treatment model
flow and effluent quality data used to develop the proposed BAT
and BCT effluent limitations and the proposed NSPS, PSES, and
PSNS for the scale removal subcategory; Table I1-4 presents these
proposed limitations and standards.
6

-------
TABLE II-l
BPT TREATMENT MODEL FLOW AND EFFLUENT QUALITY
SCALE REMOVAL SUBCATEGORY
KOLENE
Pollutant
Monthly Average ^
Concentration (mg/1)
119
Flow, gal/ton
TSS
Chromium, hexavalent
Iron, dissolved
pH, Units
Chromium
500
25
0.05
1.0
6.0 to 9.0
0.5
HYDRIDE
Pollutant
Monthly Average ^
Concentration (mg/1)
119
121
Flow, gal/ton
TSS
Chromium, hexavalent
Iron, dissolved
pH, Unitjs
Chromium
Cyanide
1200
25
0.05
1.0
6.0 to 9.0
0.5
0.25
(1) Daily maximum concentrations are three times the monthly average concentra-
tions presented above.
7

-------
TABLE I1-2
BPT PROPOSED EFFLUENT LIMITATIONS
SCALE REMOVAL SUBCATEGORY
KOLENE
Pollutant
Effluent Limitations.
(kg/kkg of Product)
TSS
Chromium, hexavalent
Iron, dissolved
pH, Units
119 Chromium
0.0521
0.00010
0.0021
6.0 to 9.0
0.0010
HYDRIDE
Pollutant
TSS
Chromium, hexavalent
Iron, dissolved
pH, Units
119 Chromium
121 Cyanide
Effluent Limitations,.
(kg/kkg of Product)
0.125
0.00030
0.0050
6.0 to 9.0
0.0025
0.0013
(1) Daily maximum effluent limitations are three times the monthly average effluent
limitations presented above.
8

-------
TABLE II-3
TREATMENT MODEL FLOWS AND EFFLUENT QUALITY
SCALE REMOVAL SUBCATEGORY
KOLENE
Pollutant
Monthly Average
Concentration (mg/1)
(1)


BAT
BCT
NSPS
PSES
PSNS

Flow, gal/ton
320
500
200
320
200

TSS
-
25
15
-
-

pH, Units
-
6.0 to 9.0
6.0 to 9.0
-
-
119
Chromium
0.10

0.10
0.10
0.10
HYDRIDE






Pollutant

Monthly Average ,
Concentration (mg/1)




BAT
BCT
NSPS
PSES
PSNS

Flow, gal/ton
100
100
50
100
50

TSS
-
15
15
-
-

pH, Units
-

6.0 to 9.0
-
-
119
Chromium
0.10
-
0.10
0.10
0.10
121
Cyanide
0.25
-
0.25
0.25
0.25
122
Lead
0.10
-
0.10
0.10
0.10
(1) Daily maximum concentrations are the above monthly average concentrations
multiplied by the following factors:
Pollutant
Factor
TSS (all except Kolene BCT)
TSS (Kolene BCT)
119 Chromium
121	Cyanide
122	Lead
2.67
3
3
3
3
9

-------
TABLE II-4
PROPOSED EFFLUENT LIMITATIONS AND STANDARDS
SCALE REMOVAL SUBCATEGORY
KOLENE
Pollutant
TSS
pH, Units
119 Chromium
HYDRIDE
Pollutant
TSS
pH, Units
119 Chromium
121	Cyanide
122	Lead
(1) The proposed limitations and standards have been multiplied by 10^ to
obtain the values presented in this table.
Daily maximum effluent limitations and standards are the above
monthly average limitations and standards multiplied by the following
factors:
Pollutant	Factor
TSS (all except Kolene BCT)	2.67
TSS (Kolene BCT)	3
119 Chromium	3
121	Cyanide	3
122	Lead	3
Effluent Limitations (kg/kkg of Product)
BAT	BCT	NSPS	PSES PSNS
5210	1300
6.0 to 9.0 6.0 to 9.0
13	-	8.4	13	8.4
Effluent Limitations (kg/kkg	of Product)	
BAT BCT	NSPS	PSES	PSNS
620	310
6.0 to 9.0 6.0 to 9.0
4.2 -	2.1	4.2	2.1
10 -	5.2	10	5.2
4.2 -	2.1	4.2	2.1
10

-------
SCALE REMOVAL SUBCATEGORY
SECTION III
INTRODUCTION
General Discussion
Scale removal is the operation in which specialty steel products are
processed in molten salt solutions for surface cleaning. Two types of
solutions are used in the scale removal process - kolene and hydride.
As a result of the different characteristics of these solutions, the
Agency is proposing separate limitations for each process.
Pollutants are generated by two sources in the scale removal process;
the bath containing the kolene or hydride solution and the rinse or
quench steps following the scale removal bath. Both sources contain
the same pollutants but at different levels. Since spent descaling
solutions from most plants are hauled off-site for disposal the
proposed limitations are based primarily upon flow and effluent
quality data for the rinse or quench steps. The bath contains a small
volume of solution which is used for a long period of time before
being discarded. This small volume could be gradually bled into a
treatment system, and no extra allowances for this procedure would be
needed. However, this practice is not recommended.
As with many other steel finishing operations, there are two modes of
scale removal operations - batch and continuous. These are detailed
in Figures III—1 and III-2. The pickling step shown after the scale
removal step depicts the typical processing train in a specialty steel
scale removal/pickling line. However, the proposed limitations and
standards developed and proposed herein apply only to the scale
removal portion. The pickling operation is addressed in a separate
subcategory.
Development of Regulations
The regulation governing the scale removal process was previously
promulgated on March 29, 1976, and contained limitations for a number
of pollutants (see Section VI). For this study, the Agency conducted
additional sampling and gathered detailed information from the steel
industry to provide an expanded data base. On the basis of these new
data, the Agency concluded that revisions of the March 29, 1976 BPT
limitations is appropriate.
Responses to the basic data collection portfolios (DCPs) sent to
approximately 85% of the active scale removal operations in the
country are the primary source of new data. DCPs requested
information on process and discharge flow rates, installed treatment
systems, mill capacities and modes of operation. Information for
twenty-four kolene operations and eight hydride operations was
provided in the responses to the DCPs. The data supplied for these
li

-------
mills have been tabulated and summarized in Tables 111 — 1 through
II1-3.
After the DCP responses were reviewed, the Agency sent detailed DCPs
(D-DCPs) to selected mills to gather information on long term effluent
quality, cost information for the installed treatment systems, and on
the scale removal operation. The Agency solicited information for
seven scale removal mills through D-DCPs. The responses to
questionnaires were useful in providing data needed to verify cost
estimates, to consider retrofit costs, and in providing additional
effluent data.
The March 29, 1976 regulation was primarily based upon data obtained
through field sampling at four scale removal operations. During this
study, the Agency conducted sampling at six additional lines to
increase the data base for the previously limited pollutants and to
monitor for the presence of toxic pollutants. A complete list of all
scale removal operations sampled for this study and a basic
description of each is provided in Table III-4. As shown, the Agency
resampled two mills. Data collected at each sampling visit are
presented in this report; however, only the data gathered at the later
visit have been used and for developing limitations. The updated data
base for this subcategory is shown in Tables II1-5 and II1-6.
Description of Scale Removal Operations
A. Kolene Descaling
The kolene process employs highly oxidizing salt baths maintained
at temperatures of 700-900°F. These salts react far more
aggressively with scale than with the base metal and, therefore,
result in a smoother surface than is obtainable with acid
pickling.
The usual kolene process is carried out in the following manner.
The steel product, after annealing, is placed in the kolene bath.
When the product has soaked a sufficient time for necessary
chemical and thermal action it is quenched in a "cold" water
tank. The combination of the chemical action and the sudden
thermal shock and steam formation causes the scale on the surface
to crack so that subsequent pickling operations can be more
effective. Another important function of the quenching operation
is to cool the product. Without adequate cooling, the immersion
of the product into an aggressive acid solution such as nitric
and nitric/hydrofloric will cause overheating of the acid bath
and an undesirable attack on the base alloys.
Kolene baths in the alloy and stainless steel industry are not
separate processes but are operated as an integral part of the
pickling process. More detail on the kolene operation is shown
in Figures III—1 and III-2.
12

-------
B. Hydride Descaling
Sodium hydride descaling depends upon the strong reducing
properties of sodium hydride carried at 1.5 to 2 percent by
weight in a fused caustic soda bath at 700°F. Most scale forming
oxides are reduced to the base metal, and oxides of metals that
form acid radicals are partly reduced. The hydride is formed in
place by the reaction of hydrogen and sodium in open bottom
chambers partially immersed in the bath. Most commercial
operations use ammonia as a source of hydrogen. Hydride
operations, like kolene operations, are operated as an integral
part of the pickling process. More detail on the hydride
operation is illustrated in Figures III—1 and III-2.
13

-------
TABLE III-l
GENERAL DATA SUMMARY
KOLENE - BATCH TYPE
Plant Code Type of Product Plant Age Capacity(TPD)
1947,
020B-01
0601
088A-01
088A-02
176-04
248D
256L
424
430C
440A
776G
776H
856E
Sheet, Plate
Rod, Wire
Tube
Tube
Rod, Wire
Pipe, Tube
Sheet
Plate
Sheet, Plate
Bar, Rod
Bar, Rod, Wire
Sheet
Sheet,Plate
1970
1962
1946
1968
UNK
1962
1960
1962
1958
1960
1960
1956
(1)
99
190
69
36
203
1
NA
54
63
5
13
78
Applied Flow
(GPT)
UNK
380
1774
1553
C46Q
1026
*
[494]
1467
[342]
1283
391
1846
Discharge Flow
(GPT)
91
380
1774
1553
[ 461]
1026
[494]
1467
1283
391
1846
Control and
Treatment Technologies
(2)
CR,NL,FLP,VF,CL,CNT
CR,NC,NA,CNT(12)
CR,E,NL,FLP,CL,T,VF,SS,
CNT(10)
CR,E,NL,FLP,CL,T,VF,SS,
CNT(4)
CNT(17),CL,PSP,NA,CO,CLA,
EB,FLP,NC,NW,CL,SL,SSP,
T,SS,CY
CNT(1),NA,T
CNT( 50 ) , VF, FLP, CR, NL, NC, PSP,
SSP
VF,CR,FLP,NL,NW,NA,CL,SL,T
RET(100)
NW,SL
CNT(55),FLP,NC,FD
CNT(67),NW,CL,T
Not Available
Treatment
Plant Age
1974
1972
1969
1969
1965
1975
1977
1960
UNK
1976
NA
NA
Discharge
To POTW
No
No
No
No
No
No
No
No
Yes
No
No
No
(1)	Mill converted from a hydride operation to a kolene operation. Line initially installed in 1946.
(2)	For definition of codes refer to Table VII-1.
[]	Brackets represent flow data gathered on the sampling visit for this mill.
*:	Confidential data.
TPD:	Tons/Day
GPT:	Gal/Ton

-------
TABLE III-2
GENERAL DATA SUMMARY
KOLENE - CONTINUOUS TYPE




Applied Flow
Discharge Flow
Control and
Treatment Technologies
Treatment
Discharge
Plant Code
Type of Product
Plant Ane
Capacity(TPD)
(GPT)
(GPT)
Plant Age
To P0TW
02 OB-02
Sheet
1957
210
UNK
UNK
CR,NL,FLP,VF,CL,CNT{4.6)
1974
No
060D
Strip
1961
300
UNK
UNK
VF,FLF,NL,CL,CR
1961
No
248B-02
Sheet
1975
NA
UNK
UNK
SCR,NL,Ft.P,CL,T,FP,CNT(18)
1978
No
2560
Strip
1972
*
*
*
VF,FLP,CL,NL,CNT(1)
1978
No
284 A
Strip
1957
138
104
104
CNT<6),CR,NL,FLP,CL,CY
1971
No
432L
Strip
1959
34
UNK
UNK
None
UNK
UNK
528-02
Sheet
1955
153
235
235
CNT,SS,NL
UNK
Yes
528-03
Sheet
1956
54
667
667
CNT,SS,NL
UNK
Yes
528-04
Sheet
1956
90
400
400
CNT,SS,NL
UNK
Yes
528-05
Sheet
1975
210
617
617
CNT,SS,NL
UNK
Yes
68AD
Strip
UNK
69
C 1671
£1673
Not Available
UNK
NA
(1)	For definition of codes refer to Table VII-1.
[]	Brackets represent flow data gathered on the sanpling visit for this mill.
*:	Confidential data.
TPDs	Tons/Day
GPT:	Ga1/Day

-------
TABLE 111-3
GENERAL DATA SUMMARY
HYDRIDE
BATCH AND CONTINUOUS OPERATIONS
Applied Flow Discharge Flow
ON
Plant Code
Type of Product
Plant i
176-01
Bar, Rod, Wire
1941
176-02
Rod, Wire
1950
176-03*
Strip
1963
284B-01
Sheet
1950
256K
Wire
1956
256N
Bar, Billet
1955
684P
Wire
1945
684V
Sheet, Plate
UNK
(1) For
definition of codes
refer
(GPT)
(GFT)
Control and
Treatment Technologies
(1)
173
262
20
NA
165
27
17
UNK
ten:
330
1818
UNK
87
[1.8D
102
UNK
[611]
330
1818
UNK
87
t 1.8]
33
UNK
CNT(17),CR,PSP,NA,CO,CLA,EB,
FLP,NC,NW,CL,SL,SSP,T,SS,
CY
CNT(9),CR,PSP,NA,C0,CLA,EB,
FLP,NC,NW,CL,SL,SSP,T,SS,
CY
CNT(4),CR,PSP,NA,C0,CLA,EB,
FLP,NC,NW,CL,SL,SSP,T,SS,
CY
CNT(18),SCR,NL,FLP,CL,T,FP
CNT(1),FLP,NL,CL
CLA,NA,SL,CNT(66)
Not Available
Not Available
Treatment Discharge
Plant Age To POTW
1965
1965
19 65
1978
1971
1973
NA
NA
No
No
No
No
No
Yes
No
NA
*:	Continuous Mill.
[J	Brackets represent flow data gathered on the sampling visit for this mill.
TPD:	Tons/Day
GPT:	Gal/Ton

-------
TABLE III-4
SUMMARY OF THE MILLS SAMPLED
DURING THIS STUDY
SCALE REMOVAL SUBCATEGORY
Plant
Code
Reference
No.
Type of Operation
Product
Processed
Mill
Age
1960
C
424-01
Kolene - Batch
Plate
L
440A-01
Kolene - Batch
Bar, Rod
1958
Q
684D
Kolene - Continuous
Strip
Unk
L
440A
Hydride - Batch
Unk
Unk
131
424-01
Kolene - Batch
Plate
1960
132
176-04
Kolene - Batch
Rod, Wire
1968
138
440A-01
Kolene - Batch
Bar, Rod
1958
137
432K
Kolene - Continuous
Sheet
1958
132
176-01
Hydride - Batch
Bar, Rod, Wire
1941
139
256N-01
Hydride - Batch
Bar, Billet
1955
17

-------
TABLE II1-5
KOLENE SCALE REMOVAL DATA BASE
BATCH AND CONTINUOUS OPERATIONS
No. of
Operations
oo
Operations Sampled for
Original Study
Operations Sampled for
Toxic Pollutant Study
Total Operations Sampled
Operations to Receive
Detailed DCP
Operations Sampled and/or
Solicited via Detailed DCP
5 incl.
3 above
5
6
11
Operations Responding to DCP's 24
Estimated No. of Operations 28
% of Total
No. of Operations
11
18 incl.
11 above
18
21
39
86
100
Daily Capacity
of Operations
132
515 incl.
132 above
515
571
1086
2069
2434
X of Total
Daily Capacity
21 incl.
5 above
21
23
45
85
100

-------
TABLE II1-6
HYDRIDE SCALE REMOVAL DATA BASE
BATCH AND CONTINUOUS OPERATIONS
No. of
Operations
% of Total
No. of Operations
Daily Capacity
of Operations
% of Total
Daily Capacity
10
Operations Sampled for
Original Study
Operations Sampled for
Toxic Pollutant Study
Total Operations Sampled
Operations to Receive
Detailed DCP
Operations Sampled and/or
Solicited via
Detailed DCP
Operations Responding
to DCP* s
3
1
11
22
33
11
44
89
21
200
221
27
248
664
26
28
3
32
85
Estimated No. of Operations
100
781
100

-------
FUME
SCRUBBER
Water
Supply
Continuous
Discharge
FUME EXHAUST SYSTEM
Rack Conveyor
Descaling and
Pickling Rack-
Fresh Acid
Stea
Water
Supply
-Water
(Constant)
Water
< >
-Water
(Constant)
KOLENE OR HYDRIDE
BATH
DESCALING
QUENCH TANK
PICKLING TANK
DIP RINSE TANK
Spent descaling solution
hauled away
Spent quench water
discharge
c >
Spent acid discharge
Acid rinse water
continuous discharge
c >
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SCALE REMOVAL
KOLENE AND HYDRIDE
BATCH TYPE OPERATION
Dwn. 3/2/79
FIGURE HI-

-------
>u
WATER
SUPPLY
CONTINUOUS DISCHARGE
ACIDIFIED WATER
* WATER SUPPLY
—4 STEAM SUPPLY
¦WATER
KOLENE OR
SPRAY RINSE
DIP RINSE
DIP RINSE
TREATING
PICKLING TANKS
SPRAY RINSE
FURNACE
HYDRIDE
BATH
CONSTANT OVERFLOW
SPENT PICKLING LIQUOR'
SPENT DESCALING
SOLUTION HAULED AWAY
SCALE REMOVAL
WATER DISCHARGE
ACID
RINSE WATER
DISCHARGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SCALE REMOVAL
KOLENE AND HYDRIDE
CONTINUOUS TYPE OPERATION
Dwn.3/2/79


FIGURE m-2

-------
SCALE REMOVAL SUBCATEGORY
SECTION IV
SUBCATEGORIZATION
Introduction
As the two types of scale removal operations are significantly
different, a subdivision of the scale removal subcategory into two
subdivisions is appropriate. Different flow rates and wastewater
characteristics were noted for each of the two operations.
The Agency examined other factors but none indicated that further
subdivision was appropriate. Mill age and size were analyzed to
determine if these had an effect on wastewater quality or quantity,
but no significant impacts were found. In addition, the Agency
considered whether factors including product type and raw materials
had a significant effect but found that further subdivision of the
scale removal subcategory on those bases was not appropriate. Each of
these factors is discussed in greater detail below.
Factors Considered in Subdivision
Manufacturing Process and Equipment
The analysis completed for this study shows that there are significant
differences in kolene and hydride scale removal operations. Effluent
flow rates, wastewater characteristics and other factors resulting
from the process make subdivision of this subcategory on the basis of
the type of descaling operation appropriate.
Final Product
The products that are processed in either hydride or kolene baths
include sheet, strip, rod, wire, tubes and bars. However, final
products do not affect any element to a significant degree and thus do
not affect subdivision. This finding has also been made for other
steel finishing subcategories.
As shown in Table II1-4, numerous products are descaled by operations
sampled for this study. No significant variations were found in
wastewater quality that could be attributed to the product. Also,
similar effluent quality can be attained regardless of the product
descaled. It was also found that applied and discharge flow rates are
not significantly affected by the type of product processed. Flow
rates used to develop the proposed limitations can be achieved for
operations processing all product types studied.
Based, upon the above, further subdivision based upon product type is
not appropriate for scale removal operations.
23

-------
Raw Materials
Only specialty steels are processed in kolene and hydride baths, and
while the elements of the specialty steel (i.e., percentage of Cr or
Ni) may vary, the Agency did not find any significant difference in
flow or wastewater characteristics resulting from the processing of
the various types of specialty steel. Kolene descaling is better
suited for certain types of steels (i.e.,chromium-nickel, high
temperature and nickel product grades) and hydride descaling for other
types such as tool steel and chromium stainless and alloy grades, but
these differences are accounted for under the subdivision into kolene
and hydride operations.
Wastewater Characteristics
Wastewater characteristics and flow rates vary significantly between
the two descaling processes, which make the subdivision into kolene
and hydride descaling appropriate. In addition to different flow
rates, different pollutants are found in the raw wastewaters of the
two processes. Based on these differences, the Agency developed
different alternative treatment systems. The rationale for developing
the alternative treatment systems is explained in Sections VII-XIII.
Wastewater Treatability
Different treatment configurations are required for kolene and hydride
operations. For example, hydride operations discharge quantities of
cyanide that must be treated while the wastewater from kolene
operations do not contain significant amounts of cyanide. Likewise,
kolene operations discharge large amounts of hexavalent chromium while
this pollutant is not normally found at significant levels in
wastewater from hydride operations.
Within each operation, however, no significant differences in
wastewater treatability was found. Pollutants in the wastewater from
the various kolene operations can be reduced to acceptable levels if
adequate treatment is installed. Wastewaters from batch and
continuous operations contain similar levels of pollutants. The same
type of treatment is equally effective for either type. These same
relationships hold true for hydride operations.
For these reasons, the Agency believes that subdivision by the type of
scale removal bath is sufficient to cover the variations in wastewater
treatability.
Size and Age
The Agency considered the impact of size and age on the subdivision of
scale removal operations. Various relationships were analyzed dealing
with possible correlations between the effect of age and size on
wastewater generation, the ability to install treatment, and the
ability to achieve the desired flow rates and proposed effluent
limitations. However, the analysis did not show any significant
relationships which might affect subdivision. Hence, the proposed
limitations and standards apply to lines of all sizes and ages.
24

-------
Size was considered a possible factor for subdivision but from the
analysis of the compiled data, size does not justify further
subdivision. Scale removal operations vary greatly in physical size,
layout and product size. However, these considerations revealed no
relationships to process water usage, discharge rates, effluent
quality or any other pertinent factor. Figures IV-1 and IV-2 are
plots which analyze the possible relationship between discharge flow
and size. On the plots, flow rates used to develop the proposed
limitations are shown to determine if line size is a determining
factor in achieving the proposed limitations. As can be seen in these
plots, the respective flows can be achieved at lines of any size. In
addition, size does not affect wastewater characteristics. Since all
lines are operated in a similar manner, the wastewater characteristics
remain relatively constant regardless of size. The sampling data do
not show any differences in wastewater characteristics between lines
of different size.
It was also found that the size of the line does not affect the
ability to install adequate treatment systems. Large and small lines
have treatment systems that are approximately the same age and which
have similar treatment components. Also, the cost data developed for
this study show treatment can be installed for approximately the same
cost on a $/ton basis.
The relationship between flow and age was analyzed in the same way as
the flow and size relationship. The plots of flow versus age for the
kolene and hydride operations are shown in Figures IV-3 and IV-4. No
relationships between flow and age are evident. Therefore, the Agency
believes that age has no significant impact on discharge flow.
Another element analyzed is the effect of age on the ability, ease and
cost of installing or retrofitting pollution control equipment. Table
IV-1 lists those companies that have retrofitted pollution control
equipment at older lines. The numerous examples effectively
illustrate the ability to retrofit treatment systems to older lines.
The ease and cost of retrofitting pollution controls was evaluated
from the responses to the D-DCPs. Cost data were provided for three
older lines that retrofitted pollution control equipment. No retrofit
costs were reported for two lines and a nine percent retrofit cost was
reported for the third. However, the detailed information to account
for this additional cost which was requested by the Agency was not
provided. As a result, the Agency was not able to assess the
significance of this retrofit cost, or whether it is, in fact, wholly
attributable to retrofitting pollution control equipment. Inasmuch as
the other two facilities reported no retrofit costs, the nine percent
cost reported for the third facility appears to be unique. However,
the Agency does not believe this nine percent retrofit cost is
substantial. Hence, the Agency has not further subdivided the scale
removal subcategory on the basis of costs for retrofitting pollution
control equipment of other mills. It should be noted that scale
removal wastewaters are generally combined with other process
wastewaters and treated in a control treatment plant.
25

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The Agency also analyzed the sampling data collected during this study
to determine if age has a significant effect on wastewater
characteristics or effluent quality. The dates of construction of the
lines sampled varied from 1941 to 1968. No significant differences
were noted between the effluent quality attained at the older lines
versus the newer lines. Acceptable levels of pollutants were being
achieved at lines of all ages where adequate treatment was installed.
Age and size do not affect the ability to achieve the model flow rates
and effluent quality, or to install the appropriate pollution control
technologies. Thus, the Agency concludes that subcategorization based
upon these factors is not appropriate.
Geographic Location
Examination of raw waste characteristics, process water application
rates, discharge rates, effluent quality and other pertinent factors
related to the discharge reveals no general relationship or pattern to
plant location. Scale removal lines are located in only five states,
with about 77% located in Pennsylvania and Ohio.
A few lines are located in what could be considered "semi-arid" or
"arid" regions. For this reason, the consumptive use of water was
considered. However, because the model treatment systems do not
employ recycle or cooling systems consumption of water due to
wastewater treatment is negligible.
Process Water Usage
Water is used in scale removal operations to rinse and cool the
products, following immersion in the kolene or hydride bath. Because
of process requirements and the nature of wastewaters discharged from
the scale removal lines, no recycle systems are installed at any of
the lines surveyed. All process waters are used on a once-through
basis. As a result, the water application and discharge flow rates
are the same.
The observed and reported flow rates from scale removal operations are
highly variable. The Agency, however, believes that this variability
results from excessive use of water. The Agency further believes that
the differences can be minimized through careful control of water
usage. Water should be applied only during the period that product is
being rinsed and cooled; and the application rate should be controlled
to meet strict operational (rinsing and cooling) requirements. Under
these conditions, the Agency believes that the discharge flow rates
from scale removal operations will be similar. As a result, the
Agency concludes that further subdivison on the basis of process water
usage is not warranted.
26

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TABLE IV-1
EXAMPLES OF SCALE REMOVAL
OPERATIONS THAT HAVE
RETROFITTED TREATMENT
Plant
Code
Kolene
601
88A
256L
776G
20B
248B
2560
248A
Hydride
176
248B
256K
256N
Plant
Age
1970
1962
1962
1960
1957
1975
1972
1957
1941
1950
1956
1955
Treatment
Plant Age
1972
1969
1977
1976
1974
1978
1978
1971
1965
1978
1971
1973
27

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1900.00-
FIGURE IV -1
SCALE REMOVAL SUBCATEGORY
KOLENE
i-~
o.
2.
3s
o
1800.00-j
I
1700.00-
i6oaoo-
1500.00-
1400.00-
130000-
I20Q00-
110000-
looaoo-
UJ
cc 900.00-
<
X
m soaoo-
7oaoo-
600.00-
soaoo-
40CL00
300X30-
200A0-
IOQOO
0.00-
X - BATCH
• -CONTINUOUS
*	BPT FLOW BASIS" 320 GPT
o.oo ' 4o.'oo ' aoloo 1 i20joo 1 isdoo 1 200.00 246.00
PRODUCTION CAPACITY (TON/DAY)
28

-------
FIGURE IV-2
SCALE REMOVAL SUBCATEGORY
HYDRIDE
180000-
70000-
180000-
140000-
130000-
£: IIOQOO'
O 100000-
11.
U 90000-
X 80000-
° 70000-
60000-
50000-
20000-
BPT RjOW BASIS* 100 OPT
IOCUOO- -
OlOO
126.00
24000
0.00
•ooo
200.00
PRODUCTION CAPACITY (TON/GAL)
29

-------
180000-
160000-
140000-
120000-
P
0.
2
o 100000
UJ
o
<80000H
z
u
CO
80000-
40000-
20000-
000
FIGURE IV " 3
SCALE REMOVAL SUBCATEGORY
KOLENE
x
X
X BATCH
• CONTINUOUS
BPT FLOW BASIS >320 OPT
1946 1948 I960 1982 1994 1996 1988 I960 1962 1964 1966 1963 1970 1972 1874 1976
PLANT AGE
30

-------
FIGURE IV~4
SCALE REMOVAL SUBCATEGORY
HYDRIDE
isoaoo-
160000
woaoo-
120000-
a.
o
* 90000-
u?
u
§
70000-
o
V)
600.00
400O0-
200,00
ooo-
BPT FLOW BASIS « 100 OPT
1940	1944	1946	198%	1966
PLANT AGE
I960
1964
31

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SCALE REMOVAL SUBCATEGORY
SECTION V
WATER USE AND WASTE CHARACTERIZATION
Introduction
Process water use is a major factor in estimating pollutant loads and
pollutant removal costs. The importance of careful control of process
water usage cannot be overemphasized. Data from sampling surveys and
the DCP responses were used to evaluate process water use and to
obtain total wastewater volumes. Control and treatment technology in
place and operating was identified for each line, and the ultimate
disposal of wastewater was examined. The origins and characteristics
of scale removal operations are reviewed below.
The wastewater characterization for kolene scale removal operations is
based upon data obtained during field sampling programs conducted at
five batch and two continuous kolene scale removal facilities. Two of
the batch facilities and one of the continuous facilities were visited
during the original study. The two batch facilities were visited
again during this study. In these instances, the more recent data are
used for the purpose of wastewater characterization. During this
study sampling was conducted for the previously limited pollutants, as
well as for toxic pollutants.
To provide the data needed to characterize hydride scale removal
operations field sampling programs were conducted at three plants.
One of these plants was visited during the original study. One plant
has both hydride and batch type kolene scale removal operations.
Description of Scale Removal Operations and Wastewater Sources
A. Kolene Descaling
As shown in Figures III-l and III-2, descaling is performed in
both batch and continuous operations and the scale removal
operation is used in conjunction with pickling. However, only
the wastewaters generated in the kolene operation are considered
herein.
Wastewaters are generated at two points in the kolene descaling
operation; the salt bath tank and in the subsequent quench or
rinse steps. The bath is a molten salt solution that contains
high levels of sodium compounds together with other constituents.
The same solution is kept in the bath for a long time and is used
to process a large tonnage of product before being replaced. One
company reported replacing the salt bath in one line only twice
in 17 years.
After the same bath has been used for some time it becomes highly
contaminated with scale from the steel, oils that are burned off
33

-------
in the high temperature bath, metals and other compounds. When a
certain level of contamination is reached, the descaling
properties of the bath diminish to a point where it must either
be replenished or replaced with fresh solutions. Because of the
highly contaminated nature of the salt solution and because of
its relatively small volume, this waste is generally hauled
off-site by private contractors. These salt solutions are
treated at some lines by bleeding a small volume of the wastes
into treatment system over a period of hours or days. The waste
kolene solutions are not disposed of in this manner at any of the
lines sampled for this study.
The other source of wastewater in the kolene operation is the
discharge from the quench or rinse step that follows the scale
removal operation. This discharge is studied herein and all flow
rates and wastewater characteristics referred to in this report
pertain to this source.
After treatment in the heated kolene solution, it is necessary to
rinse the product. Rinsing satisfies four objectives: (1)
removing salt solution "carried over" from the kolene bath; (2)
halting the action of the salt solution on the surface of the
product, (3) inducing a thermal shock which helps "break" the
scale on the surface of the process material; and, (4) cooling
the product to reduce its temperature to a safe level prior to
pickling.
Fresh, cool water is continually added to the tanks, if possible,
to keep the temperature of the water in the rinse tank fairly
constant and relatively clean. Thus, there is usually a
continuous discharge from the quench or rinse tanks. Wastewaters
generated in the quench and rinse steps contain significant
levels of solids, and total and hexavalent chromium and have
elevated pH and temperature levels. The quality of the rinse
water may vary greatly depending on the age of the salt solution
in the kolene bath, the amount of carry-over of solution into the
rinse tank and the amount of product processed. To minimize the
amount of carry-over, the product is usually held over the salt
bath (in batch operations) for some time after it has been
immersed to insure drainage of solution from the process
material.
Flow data and net raw waste loads for the pollutants are
presented in Table V-l for kolene scale removal operations.
Toxic pollutant data are presented only for those pollutants
detected in the raw waste at levels greater than 0.010 mg/1 above
water intake levels. Net concentration data were used to
describe the actual levels of pollutants added in kolene scale
removal operations. However, the proposed limitations were
developed on a gross basis because the effect of pollutants
present in water intake is insignificant
34

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B. Hydride Descaling
As hydride descaling is carried out in the same manner as kolene
scale removal, the general process flow diagrams for scale
removal (Figures III—1 and 2) also apply to hydride operations.
The only significant difference between kolene and hydride
descaling is in the salt solutions used. While the compounds in
the kolene bath act as extremely strong oxidizing agents, the
hydride salt solution depends on the strong reducing properties
of sodium hydride to aid in scale removal. Otherwise, the two
descaling processes are very similar.
Because of the many similarities, the discussion presented above
for the kolene operations also applies to hydride operations. In
fact, the operations are so similar that many lines that
previously used hydride solutions have been converted to kolene
operations with only minor modifications.
Because of the different salt solution used in the hydride
process, the flow and wastewater characteristics are
significantly different from those of the kolene operations. The
flow rate, which averages about 100 gal/ton, is significantly
less than the flow rate for kolene operations. Many of the same
pollutants are found in the wastewaters from both processes, but
generally, they are found at different levels. In addition,
cyanide is sometimes generated in the hydride process while no
significant levels of cyanide were found in the discharges from
the kolene operations. Net raw waste data are presented in Table
V-2 for hydride operations. As previously mentioned, only those
toxic pollutants found at levels greater than 0.010 mg/1 are
included in this table.
35

-------
TABLE V-l
CONCENTRATION OF POLLUTANTS IN NET RAW WASTEWATER^
KOLENE OPERATIONS
u>
cr»
Reference No.
Plant Code
Sample Points
Flow (Gal/Ton)
Type of Mill
Suspended Solids
Chromium, Hexavalent
Dissolved Iron
pH (Units)
023	Chloroform
044	Methylene Chloride
066	Bis-(2-ethylhexyl) phthalate
067	Butyl benzyl phthalate
114	Ant imony
115	Arsenic
118	Cadmium
119	Chromium
120	Copper
122	Lead
123	Mercury
124	Nickel
125	Selenium
127	Thallium
128	Zinc
424-01
131
B-A
494
Batch
119
124
NA
8.2
ND
0.435
ND
NA
0.022
ND
33.7
ND
ND
NA
0.021
NA
NA
176-04
132
H-A
461
Batch
651
261
ND
7.8
0.031
0.231
0.038
0.01
NA
NA
0.01
365
4.73
0.03
NA
37.5
NA
NA
NA
440A-01
138
B-A
342
Batch
191
79.5
7.3
ND
0.115
ND
ND
NA
ND
102
0.03
ND
NA
0.790
NA
NA
ND
432K
137
B-A
280
Cont.
1219
NR
7.3
0.129
0.108
0.012
ND
36.3
0.812
NA
ND
1.08
0.06
0.155
0.087
684D
Q
13-10
108
Cont.
231
424
7.2
NA
NA
NA
NA
NA
NA
0.02
440
0.01
ND
0.03
0.03
ND
NA
Average
(2)
337
482
222
N/A
7.2-8.2
0.0078
0.087
0.151
0.0025
0.054
0.017
0.006
195
1.116
0.008
0.015
7.88
0.027
0.155
0.029
(1)	All values are in mg/1 unless otherwise noted.
(2)	Negative values counted as zero in average.
- :	Negative value.
ND :	Not detected.
NA :	Not analyzed.
N/A:	Not applicable.

-------
TABLE V-2
CONCENTRATIONS OF POLLUTANTS IN THE NET RAW WASTEWATERS ^1^
		HYDRIDE OPERATIONS
Reference No.
176-01
256N-01
440A

Plant Code
132
139
L

Sanple Point(s)
0-A
B-A
(9-11)
A (2)
Average
Flow,
, gal/ton
611
1.8
1200
604

Suspended Solids
465
388
370
408

Dissolved Iron
0.415
36.5
0.36
12.4

pH, units
7.8
8.2
9.5
7.8-9.5
22
Parachlorometacreso1
0.012
ND
NR
*
65
Phenol
ND
0.013
NR
*
66
Bis-(2-ethylhexyl) Phthalate
0.018
0.056
NR
0.037
114
Antimony
NR
0.65
NR
0.65
118
Cadmium
ND
0.11
NR
0.055
119
Chromium
15.3
1.47
ND
5.26
120
Copper
0.65
0.48
ND
0.378
121
Cyanide
ND
ND
0.106
0.0353
122
Lead
0.2
1.05
ND
0.417
124
Nickel
8.68
0.29
ND
2.99
125
Selenium
NR
0.025
ND
0.0125
126
Silver
ND
0.095
NR
0.0475
128
Zinc
0.045
0.18
—
0.075
(1)	All values are in ng/1 unless otherwise noted*
(2)	Negative values counted as zero in average.
* : Value less than 0.01 mg/1
- : Negative value
ND: Not detected
NR: Not reported

-------
SCALE REMOVAL SUBCATEGORY
SECTION VI
WASTEWATER POLLUTANTS
Introduction
A general discussion of the process used in selecting the pollutants
to be limited is included in Section V of Volume I.
Rationale for the Selection of Wastewater Pollutants
Wastewaters are generated in scale removal operations as a result of
the quenching or rinsing of the steel product following its immersion
in the salt bath. These waters become contaminated with both the
materials present on the product surface and any salt solution carried
over from the process. Tables VI-1 and VI-2 list all pollutants found
at concentrations greater than 0.010 mg/1 at any plant, or reported as
being present in the DCP responses for kolene and hydride descaling,
respectively. The Agency believes that the phthalates are artifacts
and thus are not considered representative of scale removal
wastewaters. Tables VI-3 and VI-4 list all pollutants found in an
average concentration (of all sampled plants) greater than 0.010 mg/1
for kolene and hydride descaling, respectively. These pollutants are
considered representative of scale removal wastewaters. In the
original guidelines, the same six pollutants were chosen from these
lists to be limited for both kolene and hydride scale removal
processes. The pollutants ares total suspended solids, dissolved
iron, hexavalent chromium, dissolved chromium, cyanide and pH.
However, additional data gathered during this study indicate changes
are warranted in the selection of pollutants.
Kolene Scale Removal
Cyanide, a pollutant which was originally considered characteristic of
kolene wastewaters, has not been selected as the additional data
gathered during this study indicate that cyanide is not found at
significant levels. Also, instead of developing limitations for
dissolved chromium, the Agency is proposing limitations for total
chromium. This change was brought about mainly due to the designation
of total chromium as a "toxic" pollutant.
Hexavalent and total chromium are included on the list of
characteristic pollutants for kolene scale removal operations as there
are significant levels of these pollutants in kolene scale removal
wastewaters. The presence of chromium (hexavalent and total) and the
other toxic metals in kolene wastewaters is attributable to the
aggressive nature of the salt bath in attacking the product surface.
Chromium is not only released from the product by the kolene, but it
is also an inherent component of the kolene salt bath. The various
metals also comprise a portion of the suspended solids generated in
the process wastewaters. The suspended solids are present in kolene
39

-------
wastewaters primarily due to the pickup of the scale and other
materials on the surface of the product. The limitations for pH
reflect a range within which environmental damage is avoided. in
order to accomplish the desired level of treatment, process
wastewaters require two pH adjustments: one for the hexavalent
chromium treatment process, and the other as a neutralization prior to
discharge.
Hydride Scale Removal
For hydride operations, the Agency is proposing limitations for total
chromium in lieu of hexavalent chromium. Hexavalent chromium was not
found in wastewaters from hydride operations.
Unlike the kolene wastewaters, cyanide is characteristic of hydride
wastewaters. The presence of cyanide is the result of the addition of
a carbon source (such as charcoal) to the hydride salt bath. The
temperature and chemical makeup of the salt bath are such that cyanide
can be generated when the carbon source is added. The industry
reports that under certain operating conditions high levels of cyanide
can be generated in the hydride bath. Hence, alkaline chlorination
has been installed at several hydride plants as treatment for cyanide.
The total suspended solids are primarily comprised of the various
scale and other matter carried over into the rinse/quench tanks by the
product. The selection of pH was necessitated by the need to
neutralize hydride scale removal operation wastewaters.
40

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TABLE VI-1
POLLUTANTS KNOWN TO BE PRESENT
KOLENE SCALE REMOVAL
Total Suspended Solids
PH
Dissolved Iron
Hex. Chromium
023
Chloroform
024
2 - Chlorophenol
030
1,2 - Trans-Dichloroethylene
044
Methylene Chloride
057
2 - Nitrophenol
065
Phenol
066
BIS (2 - Ethylhexyl) Phthalate
068
Di-n-Butyl Phthalate
069
Di-n-Octyl Phthalate
073
Benzo (a) Pyrene
085
Tetrachloroethylene
114
Antimony
115
Ars eni c
117
Beryllium
118
Cadmium
119
Chromium
120
Copper
122
Lead
124
Nickel
125
Selenium
126
Silver
127
Thallium
128
Zinc
41

-------
TABLE VI-2
POLLUTANTS KNOWN TO BE PRESENT
HYDRIDE SCALE REMOVAL
Total Suspended Solids
pH
Dissolved Iron
Hex.	Chromium
022	Parachlorometa Cresol
034	2, 4 - Dimethyl phenol
044	Methylene Chloride
064	Pentachlorophenol
065	Rienol
066	Bis (2 - Ethylhexyl) Fhthalate
068	Di-n-Butyl Phthalate
070	Diethyl Phthalate
071	Dimethyl Phthalate
114	Antimony
118	Cadmium
119	Chromium
120	Copper
121	Cyanide
122	Lead
124	Nickel
125	Selenium
126	Silver
128	Zinc
42

-------
TABLE VI-3
SELECTED POLLUTANTS
KOLENE SCALE REMOVAL
Total Suspended Solids
pH
Dissolved Iron
Hex. Chromium
023 Chloroform
114	Antimony
115	Arsenic
118	Cadmium
119	Chromium
120	Copper
124	Nickel
125	Selenium
127	Thallium
128	Zinc
43

-------
TABLE VI-4
SELECTED POLLUTANTS
HYDRIDE SCALE REMOVAL
Total Suspended Solids
PH
Dissolved Iron
Hex. Chromium
114	Antimony
118	Cadmium
119	Chromium
120	Copper
121	Cyanide
122	Lead
124	Nickel
125	Selenium
126	Silver
128	Zinc
44

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SCALE REMOVAL SUBCATEGORY
SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
Introduction
This section presents the treatment practices currently used within
the scale removal subcategory. Also included are a summary of the
sampling data for kolene and hydride operations and a description of
the treatment practiced at each line. The data show the range of
treatment practiced within this subcategory and the range of effluent
quality achieved with the various treatment systems.
In order to develop the proposed BPT, BAT, BCT, PSES and PSNS effluent
limitations, the Agency examined the levels of treatment that exist
within the subcategory. The different technology levels were then
formulated in an "add-on" fashion to the basic levels of treatment.
Only New Source Performance Standards were not developed in this
manner since NSPS apply to new scale removal operations. The
alternative treatment systems and corresponding effluent
characteristics are presented in Sections IX through XIII.
The Agency developed the proposed effluent limitations and standards
on the basis of a review of effluent data obtained during plant visits
and, in the case of certain advanced technologies, on the proven
capabilities of those systems. Treatment system summaries, schematics
and effluent data fori the visited plants are presented in this
section.	^
Control and Treatment Technologies - Scale Removal
Summary of Treatment Practices
Currently Employed at Kolene Descaling Operations
The wastewater control and treatment technologies currently used at
kolene descaling operations vary considerably. However, similar
components are used to attain reductions in the levels of certain
pollutants. Based upon data from the DCPs and the plant visits, the
following summary of disposal and treatment technologies was developed
for this subcategory.
All treatment systems installed at kolene operations include
physical/chemical controls. Also, over 60% of the operations which
provide treatment use central treatment systems (i.e., other
wastewaters are combined with the descaling wastewaters prior to
treatment). These central treatment systems are generally designed
primarily to reduce the levels of suspended solids and metals and to
neutralize the pH of the discharge. The data for this and other
subcategories were analyzed to determine the effect central treatment
systems on the ability to achieve the proposed limitations and
standards. This analysis found that similar flow rates and effluent
45

-------
levels are achievable with both separate and central treatment systems
and, thus, different limitations and standards are not proposed for
separate and central treatment systems.
Many of the kolene descaling operation treatment facilities provide
sufficient treatment to achieve acceptable effluent quality for
discharge to a receiving stream, while others provide only limited
pretreatment prior to the discharge of wastewaters to a publicly owned
treatment works (POTWs). Additionally, no treatment is proposed for
three kolene descaling operations.
Following is a summary of treatment technologies currently practiced
at kolene descaling operations. The discussion on the technologies,
with the exception of chromium reduction, is equally applicable to
hydride descaling operations.
Chromium Reduction
Chromium is an inherent component of the kolene salt bath. In
addition, chromium contained in the steel is released and discharged
in large quantities in the rinse waters. Most of the chromium present
in the raw wastewaters is in the hexavalent (+6) state. Because of
the toxicity of this pollutant, treatment facilities are provided at
most kolene operations to reduce levels of hexavalent chromium prior
to discharge. The most widely used method to reduce the levels of
Cr(+6) is chemical reduction. The chemical reduction process proceeds
in the following manner. The wastewaters from the quench or rinse
tanks is treated with acid to lower the pH to the range of 2 to 4
standard units, which is the optimum range for the reduction of Cr
(+6) to Cr (+3). A reducing agent such as gaseous sulfur dioxide is
then added and the wastewaters are agitated in a mixing tank. The
combination of the low pH and the action of the reducing agent reduces
the chromium from the hexavalent state to the trivalent state. The
chromium in this form can then be readily precipitated in subsequent
chemical treatment steps with maximum precipitation achieved at a pH
near 8.5
Neutralization
After the chromium is reduced to its trivalent form at a low pH, the
wastewaters at most lines are neutralized to bring the pH above 7
where optimum metal removal will occur in subsequent steps. If
central treatment is practiced, neutralization can sometimes be
achieved by mixing the acidic scale removal wastes with alkaline
wastes from other sources which are compatible for treatment. Wastes
from kolene lines with central treatment systems are neutralized in
this manner. If alkaline waste streams are not available .or if
descaling wastes are treated separately, a neutralizing agent is
needed. Either lime or caustic is used at the kolene lines surveyed.
Enough lime or caustic is added to raise the pH above 7 which is the
optimum range for the precipitation of the metals in the descaling
mills waste stream.
46

-------
Precipitation and Clarification
Chemical additions are made at over 90% of the kolene lines to aid
precipitation, with polymers being the flocculant most often used.
From the chemical addition step, neutralized wastewaters enter
clarification facilities. For kolene operations, three types of
clarification facilities are used; settling lagoons, thickeners and
clarifiers. Clarifiers are in use at 83% of the kolene mills. The
remaining 17% use either thickeners or settling lagoons.
Solid Waste Processing
The final treatment step involves processing suspended solids
collected in the final clarification. Depending on the type of
neutralizing agent used, various types and volumes of sludge are
generated. As much as 10 tons of sludge per day can be generated at a
large kolene descaling operation. Sludge is dewatered by vacuum
filtration or centrifugation with vacuum filtration being the more
common technology.
Summary of Treatment Practices Currently
Employed at Hydride Descaling Operations
As in the case of the kolene descaling operations, wastewaters are
generated in hydride descaling operations as a result of the quenching
or rinsing of the product following the scale removal process.
Because of differences in the wastewaters, the use of different
treatment configurations is necessary. There is very little
hexavalent chromium released in the hydride process, therefore,
chromium reduction treatment steps are not required. However, due to
the nature of the hydride process, there is the potential for the
generation of significant levels of cyanide under certain operating
conditions. As a result, most lines have a cyanide treatment step,
with alkaline chlorination being the most common.
After the cyanide has been destroyed in this pretreatment step,
wastewater treatment is similar to that for kolene operations. The
wastewaters are neutralized with acid to lower the pH, a polymeric
flocculant is added, and then clarification is carried out to remove
the solids and metals precipitated in the process. All hydride
operations that provide treatment and have direct discharges treat
wastewaters in central treatment systems. Also, one line reuses
waters from the central treatment system.
Control and Treatment Technologies
Considered for Toxic Pollutant Removal
The advanced treatment alternatives considered for kolene or hydride
scale removal operations, and a short description of each, are
presented below. These systems have been demonstrated in varying
degrees in the scale removal subcategory and in other industrial
applications on wastewaters with similar characteristics. The
treatment systems are discussed in greater detail in later sections
47

-------
with special emphasis on the applicability to the scale removal
subcategory.
Filtration
This technology is employed to remove the particulate toxic metals
loadings. Filtration can be used as a last major component in a
treatment system or may be used for pretreatment prior to treatment in
another component (such as adsorption on activated carbon). Metals
removal is accomplished by passing the wastewater stream, either under
pressure or by gravity, through a filter media. The filter media,
generally sand, anthracite coal or garnet, permits water passage but
prevents the passage of a major portion of the particles suspended in
the wastewater. The filter media itself can be comprised of a single
type and size, various sizes of the same media, or a mixed media which
contains several types and sizes.
The collected solids are removed from a filter by periodic
backwashings, with the backwash commonly discharged to the treatment
system influent. The backwash procedure involves the pumping of
filter effluent through the filter in a direction opposite that of its
operational flow direction. The backwash process usually begins with
air agitation to both mix and scour the filter media. By returning
the backwash to the system influent (with polymer addition), filtered
solids contained in the backwash are removed by sedimentation in the
treatment system. Filtration is used in many steel industry
applications.
Sulfide Precipitation
Wastewater treatment systems which have a sulfide compound addition
component have been shown to be capable of reducing effluent metals
concentrations below levels usually achieved in lime precipitation
reactions. Some of the metals which can effectively be precipitated
with sulfide are zinc, copper, chromium, nickel, lead and silver which
are all inorganic toxic pollutants. The increased removal
efficiencies can be attributed to the comparative solubilities of
metal sulfides and metal hydroxides. Iron sulfide is often used to
achieve the precipitation because this compound has a solubility which
exceeds that of the heavy metal sulfides to be precipitated and
because this compound does not form excessive levels of sulfide ion
concentrations which could contribute to the formation of hydrogen
sulfide, an objectional gas. The typical sulfide precipitation
systems consists of neutralization, precipitation and a polishing
filter. Refer to Volume I for additional information pertaining to
sulfide treatment.
Vapor Compression Distillation (Evaporation)
Vapor compression distillation is typically used to concentrate a high
dissolved solids wastestream (3,000-10,000 mg/1) to a slurry
consistency (approximately 100,000 mg/1). The slurry discharge can be
dried in a mechanical drier or allowed -to crystallize in a small solar
or steam-heated pond prior to final disposal. The distillate quality
water generated by this system can be recycled back to the scale
48

-------
removal operation thereby eliminating discharges. One desirable
feature of this unit is its relative freedom from scaling. Because of
the unique design of the system, calcium sulfate and silicate crystals
grow in solution as opposed to depositing on heat transfer surfaces.
Economic operation requires a high calcium to sodium ratio (hard
water). Due to economic considerations, only limited application is
made of vapor compression distillation in processing wastewater.
The installation of this type of unit may be the only possible way to
achieve a zero discharge of process water at scale removal operations.
However, energy and cost considerations preclude widespread use of
this technology.
Plant Visit Data
Table VII-1 provides a legend for the various control and treatment
technology abbreviations used in the following tables and in other
tables throughout this report. Table VI1-2 presents a summary of raw
and treated effluent data for kolene operations visited during the
original guidelines survey. Table VII-3 presents a summary of raw and
treated effluent data for kolene operations visited during the toxic
pollutants survey. Tables VII-4 and VII-5 present similar data for
hydride operations.
Plant Visits - Kolene Descaling Operations
The Agency conducted a total of seven field sampling visits at five
kolene descaling operations. Three visits were conducted during the
original study and four visits were conducted during this study. Two
of the originally visited plants were visited again during this study.
A brief description of each wastewater treatment facility follows.
More details are available on the respective wastewater flow diagram
for each plant.
Line L - Figure VII-1
The process rinse water from this batch kolene operation is treated in
a neutralization tank prior to discharge to a municipal treatment
facility.
Line C - Figure VII-2
At the time of the initial survey, no treatment was provided.
Line Q - Figure VII-3
No treatment was provided at the time of the inital survey.
Line 131 - Figure VII-4
Line 131 and line Q described above are the same. Since the time of
the initial survey, a treatment facility has been installed. At the
time of sampling, the treatment system was not yet operating so a
synthetic sample was generated by plant personnel for analysis.
Treatment now installed consists of chromium reduction, neutralization
49

-------
with lime and other wastes, settling in a clarifier and final settling
in a polishing lagoon. Sludges generated in the process are dewatered
with vacuum filters.
Line 132 - Figure VII-5
The wastes from this batch operation are treated in a central
treatment system with wastes from several other sources. Treatment
consists of chromium reduction, neutralization with acid or caustic
depending on the wastes being treated, flocculation with polymer, and
clarification with oil skimming. Sludges are dewatered in cyclones.
Line 137 - Figure VII-6
The continuous kolene operation wastewaters are treated in a central
treatment system. The kolene wastes represent approximately 1.5% of
the total flow to the treatment system. Treatment consists of lime
neutralization and sedimentation in a settling lagoon. The discharge
is directed to a receiving stream.
Line 138 - Figure VII-7
Line 138 is the same mill as Mill L described above. No changes in
treatment were noted between surveys.
Plant Visits - Hydride Descaling Operations
Three field sampling vists were conducted at hydride descaling
operations? one visit during the original study and two visits during
this study. One of the lines visited during this study also had a
kolene descaling operation. A brief description of each wastewater
treatment system follows.
Line L - Figure VII-8
The hydride process rinse waters
treatment system after these wastes
water.
Line 132 - Figure VII-5
are discharged to a municipal
are mixed with other process
The wastewaters from this hydride operations are treated in a central
treatment system with wastewaters from several other sources.
Treatment consists of neutralization with lime or acid depending on
the wastewaters being treated, flocculation and polymer, and
clarification with oil skimming. Sludges are dewatered in cyclones.
Line 139 - Figure VII-9
Hydride descaling wastewaters are treated by alkaline chlorination,
neutralization with acid and settling prior to discharge to a POTW.
50

-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
Symbols
Operating Modea
1.	OT	Once-Through
2.	Rt,a,n	Recycle, where t - type waste
a ¦ stream recycled
n ¦ X recycled
tj U ¦ Untreated
T ¦ Treated
p
Process Wastewater X of
raw waste
flow
F
Flume Only
% of
raw waste
flow
S
Flume and Sprays
X of
raw waste
flow
FC
Final Cooler
X of
FC flow

BC
Barometric Cond.
X of
BC flow

VS
Abs. Vent Scrub.
X of
VS flow

FH
Fume Hood Scrub.
% of
FH flow

REt,n
Reuse, where t "
type



n ¦
X of raw waste
3.
tx U " before treatment
T " after treatment
4. BDn	Blowdown, where n ¦ discharge as X of
raw waste flow
Control Technology
10.
DI
Deionization
11.
SR
Spray/Fog Rinae
12.
CC
Countercurrent Rinse
13.
DR
Drag-out Recovery
Disposal Methods
20.	H	Haul Off-Site
21.	DW	Deep Well Injection
51

-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 2 		.
C.	Disposal Methods (cont.)
22.	Qt,d	Coke Quenching, where t ¦ type
d ¦ discharge as Z
of makeup
t: DW ¦ Dirty Water
CW ¦ Clean Water
23.	EME	Evaporation, Multiple Effect
24.	ES	Evaporation on Slag
25.	EVC	Evaporation, Vapor Compression Distillation
D.	Treatment Technology
30.
SC
Segregated Collection
31.
E
Equalization/Blending
32.
Scr
Screening
33.
OB
Oil Collecting Baffle
34.
SS
Surface Skimming (oil,
35.
PSP
Primary Scale Pit
36.
SSP
Secondary Scale Pit
37.
EB
Emulsion Breaking
38.
A
Acidification
39.
AO
Air Oxidation
40.
GP
Gas Flotation
41.
M
Mixing
42.
Nt
Neutralization, where
t: L ¦ Lime
C - Caustic
A ¦ Acid
W ¦ Wastes
0 - Other, footnote

-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 3		
D.	Treatment Technology (cont.)
43.	FLt	Flocculation, where t ¦ type
t: L • Lime
A ¦ Alum
P ¦ Polymer
M ¦ Magnetic
0 " Other, footnote
44.	CY	Cyclone/Centrifuge/Classifier
44a. DT Drag Tank
45.	CL	Clarifier
46.	T	Thickener
47.	TP	Tube/Plate Settler
48.	SLn	Settling Lagoon, where n - days of retention
time
49.	BL	Bottom Liner
50.	VF	Vacuum Filtration (of e.g., CL, T, or TP
underflows)
51.	Ft,m,h	Filtration, where t ¦ type
m ¦ media
h ¦ head
t	m	h
D ¦ Deep Bed	S - Sand	G ¦ Gravity
F ¦ Flat Bed	0 ¦ Other, P ¦ Pressure
footnote
52.	CLt	Chlorination, where t ¦ type
ts A ¦ Alkaline
B ¦ Breakpoint
53.	CO	Chemical Oxidation (other than CLA or CLB)
53

-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 4	
D.	Treatment Technology (cont.)
54.	BOt	Biological Oxidation, where t ¦ type
t: An * Activated Sludge
n - No. of Stages
T ¦ Trickling Filter
B " Biodisc
0 « Other, footnote
55.	CR	Chemical Reduction (e.g., chromium)
56.	DP	Dephenolizer
57.	ASt	Ammonia Stripping, where t ¦ type
t: F ¦ Free
L ¦ Lime
C ¦ Caustic
58.	APt	Ammonia Product, where t ¦ type
t: S ¦	Sulfate
N ¦	Nitric Acid
A "	Anhydrous
P «	Phosphate
H ¦ Hydroxide
0 ¦	Other, footnote
59.	DSt	Desulfurization, where t * type
t: Q ¦ Qualifying
N ¦ Nonqualifying
60.	CT	Cooling Tower
61.	AR	Acid Regeneration
62.	AU	Acid Recovery and Reuse
63.	ACt	Activated Carbon, where t ¦ type
t: P ¦ Powdered
G ¦ Granular
64.	IX	Ion Exchange
65.	SO	Reverse Osmosis
66.	D	Distillation
54

-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 5
D.	Treatmenj/ Technology (cont.)
67.	AA1	Activated Alumina
68.	OZ	Ozonation
69.	UV	Ultraviolet Radiation
70.	CNTt,n	Central Treatment, where t ¦ type
n ¦ process flow as
Z of total flow
t: 1 ¦ Same Subcats.
2	¦ Similar Subcats.
3	¦ Synergistic Subcats.
4	¦ Cooling Water
5	¦ Incompatible Subcats.
71.	On	Other, where n ¦ Footnote number
72.	SB	Settling Basin
73.	AE	Aeration
74.	PS	Precipitation with Sulfide
55

-------
TABLE VII-2
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES SURVEY
KOLENE
Raw Wastewaters
Reference Code

440A-01

424-01

684D


Plant Code

L

C

Q

11 ^
Saople Point

8

9

13

, V 1 )
Average
Flow
CGPT)

398

494

108

333.3


mg/1
lbs/1000 lbs
mg/1
lbs/1000 lbs
mg/1
lbs/1000 lbs
mg/1
lbs/1000 lbs

Suspended Solids
433
0.72
103
0.21
244
0.11
260
0.35

Chromium Hexavalent
100.0
0.17
ND
ND
424
0.19
174.7
0.12

pH (Units)
12.2
N/A
12.0
N/A
13.1
N/A
12.0-13
.1 N/A
023
Chloroform
NR
NR
NR
NR
NR
NR
NR
NR
114
Antimony
NR
NR
NR
NR
NR
NR
NR
NR
115
Arsenic
NR
NR
NR
NR
NR
NR
NR
NR
118
Cadmium
ND
ND
ND
ND
0.02
Neg.
0.007
Neg.
119
Chromium
115.5
0.19
ND
ND
440
0.20
185.2
0.13
120
Copper
0.01
0.000017
ND
ND
0.03
0.000014
0.013
0.00001
124
Nickel
0.01
0.000017
0.07
0.00014
0.03
0.000014
0.037
0.00006
125
Selenium
ND
ND
ND
ND
ND
ND
ND
ND
127
Thailiun
NR
NR
NR
NR
NR
NR
NR
NR
128
Zinc
0.001
Neg.
0.002
Neg.
0.018
Neg.
0.007
Neg.

-------
TABLE VII-2
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES SURVEY
KOLERE
PAGE 2	
Treated
Effluents
Reference Code	440A-01	424-01	684 D
Flnt Code

L

C

<1
Saaple Point

8

9

13
Flow (CPT)

398

494

108
C&TT


NH.SL
VF,CR,FLP,NL,NW,NA,CL,SL,T
Not
Available


SA
lbs/1000 lbs
mil
lbs/1000 lbs
¦fiZI
lbs/1000 lbs

Suspended Solids
433
0.72
103
0.21
244
0.11

Chroaiw Hexavalent
100.0
0.17
NO
ND
424
0.19

pH (Units)
12.2
N/A
12.0
N/A
13.1
N/A
023
Chlorofor*
NR
RR
NR
NR
NR
NR
114
Antinony
HR
NR
HR
NR
NR
NR
115
Arsenic
NR
HR
NR
NR
NR
NR
US
Cadaiua
NO
HD
HD
ND
0.02
Neg-
119
Chroaitw
115.5
0.19
ffl>
ND
440
0.20
120
Copper
0.01
0.000017
ND
HD
0.03
0.000014
124
Nickel
0.01
0.000017
0.07
0.00014
0.03
0.000014
125
Seleniua
RE
HD
ND
ND
ND
ND
127
Ihalliua
NR
RR
NR
NR
NR
NR
128
Zinc
0.001
Reg.
0.02
Reg.
0.018
Neg.
{1} Values vhicb are listed aa WD are included in calculating averages as zero. Values which are listed as
KR are not included.
H/A :	Hot applicable.
ID :	Not detectable.
R :	Mot reported.
Reg.t	negligible) load ia leas than 0.00001 lbs/1000 lbs.

-------
TABLE VII-3
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
TOXIC POLLUTANT STUDY
KOLENE
Raw Wastewater
Reference Code

424-01

176-04

440A-01

432K




Plant
: Code

131

132

138

137


Overall
Sample Point

B

H

B

B
Average
Average
Flow (GPT)

494

461

342

280

394

368
Mill
Type

Batch

Batch

Batch

Cont.






mg/1
lbs/1000 lbs
mg/1
lbs/1000 lbs
MS/I
lbs/1000 lbs
mg/1
lbs/1000 lbs
mft/l
lbs/1000 lbs
mg/1
lbs/1000 lbs

Suspended Solids
124
0.26
678
1.30
194
0.28
1228
1.43
556
0.82
429.1
0.62

Chromium Hexavalent
124
0.26
262
0.5
79.5
0.13
NR
NR
155.2
0.30
164.9
0.21

pH (Units)
12.6
N/A
12.4
N/A
11.7
N/A
13.0
N/A
11.7-
N/A
11.7-
N/A










13.0

13.1

023
Chloroform
ND
ND
0.041
0.000079
ND
ND
0.015
0.000018
0.014
0.000020
0.014
0.000030
114
Antimony
0.021
0.00004
0.45
0.00087
0.10
0.00014
0.14
0.00016
0.18
0.00030
0.18
0.00035
115
Arsenic
0.03
0.00006
NR
NR
NR
NR
0.019
0.000022
0.027
0.000050
0.030
0.000060
118
Cadmium
0.14
0.00029
0.02
0.000038
0.01
0.000014
0.20
0.00023
0.093
0.00014
0.066
0.00012
119
Chromium
367
0.76
365
0.70
102
0.15
36.7
0.043
217.6
0.41
203.7
0.291
120
Copper
0.133
0.00027
4.75
0.0091
0.05
0.000071
0.88
0.0010
1.45
0.0026
0.84
0.0015
124
Nickel
0.77
0.0016
37.5
0.072
0.86
0.0012
1.67
0.0020
10.03
0.019
5.84
0.011
125
Se len ium
0.027
0.000056
NR
NR
NR
NR
0.069
0.000081
0.038
0.000060
0.024
0.000024
127
Thallium
0.065
0.00013
NR
NR
NR
NR
0.21
0.00024
0.10
0.00016
0.10
0.00013
128
Zinc
0.18
0.00037
0.080
0.00015
0.020
0.000029
0.34
0.00039
0.15
0.00023
0.091
0.00013

-------
TABLE VII-3
SUMMIT OF ANALYTICAL DATA FROM SAMPLED PLANTS
TOXIC POLLUTANT STUDY
KOLENE
PACT 2	 	
Treated
Effluent
Reference Code
Plant Code
Saaple Point
Flow (GPT)
NillfTvpe
C4TT 7
424-01
131
494
Batch
VF,CR,FLP,NL,
NW,KA,CL,SL,T
ZZ(772)
176-04
132
H(90)
X(769)
461
Batch
CNT(17)lCRlPSP,NAt
CO,CLA,EB,FLP,NL
NW,SL,CL,SSP,T,SS,CY
Ul
U>


s/i
lbs/1000 lbs
sZi
lbs/1000

Suspended SoIdis
49.5
0.10
16.5
0.054

Chroaiua Hexava lent
(3)
(4)
0.042
0.53

pH (Units)
9.4
N/A
7.6
N/A
023
Chloroform
0.14
0.00030
*
0.000050
114
Antiaony
0.20
0.00040
NR
NR
115
Arsenic
*
M
NR
NR
118
Cadaiua
0.02
0.000040
*
0.000040
119
Chroaiua
15.0
0.031
0.18
0.026
120
Copper
0.061
0.00012
0.05
0.D0023
124
Hickel
0.28
0.00057
1.35
0.0072
125
Seleniua
ND
m>
*
**
127
Tha11iua
0.050
0.00010
HR
NR
128
Zinc
0.034
0.000070
0.04
**
(1)	Value* listed aa KD are included in average calculations as zero.
(2)	Average of all values froa VI1-2 and VII-3.
(3)	Value* for hex-chroaiua determined to be unreliable.
(4)	Calculations not aade because of unreliable concentration value.
(5)	For CtTT Code definitions, see Table VII-1.
* i	Less than 0.010 ag/1.
** t	Less than 0.00001 lbs/1000 lbs.
I/A*	Rot applicable.
¦ i	Hot reported.
MB I	Mot detected.
440A-01
138
B
342
Batch
NW,SL
ag/1	lbs/1000 lbs
194	0.28
79.5	0.13
11.7	N/A
ND	ND
0.10	0.00014
NR	NR
*	0.000014
102	0.15
0.05	0.000071
0.84	0.0012
MR	HR
NR	NR
0.020 0.000029
432K
137
D
280
Cont.
NL,SL
^t/1
lbs/1000 lbs
91.7
0.11
NR
NR
6.2
N/A
0.065
0.000076
0.038
0.000044
ND
ND
0.20
0.00023
2.67
0.0031
0.15
0.00017
6.00
0.0070
ND
ND
0.05
0.000058
0.26
0.00031
Values listed as NR are not included.

-------
TABLE VI1-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
	 HYDRIDE
Raw Wastewater
Reference Code
440A

Plant Code
L

Sample Point
9

Flow (GPT)
1200


mg/1
lbs/lOOO lbb
Suspended Solids
376
1.88
Dissolved Iron
0.36
0.0018
pH (Units)
11.9
N/A
114 Antimony
NR
NR
118 Cadmium
ND
ND
119 Chromium
ND
ND
120 Copper
ND
ND
121 Cyanide
0.11
0.00053
122 Lead
ND
ND
124 Nickel
ND
ND
125 Selenium
ND
ND
126 Silver
NR
NR
128 Zinc
ND
ND
Treated
Effluent
Reference Code
Plant Code
Sample Point
Flow,(GPT)
C&TT
Suspended Solids
Dissolved Iron
pH (Units)
114	Antimony
118	Cadmium
119	Chromium
120	Copper
121	Cyanide
122	Lead
124	Nickel
125	Selenium
126	Silver
128	Zinc
440A
L
9
1200
NW,SL
S&Zl
376
0.36
11.9
NR
ND
ND
ND
0.11
ND
ND
ND
NR
ND
lbs/lOOO lba
1.88
0.0018
N/A
NR
ND
ND
ND
0.00053
ND
ND
ND
NR
ND
(1) For C&TT Code definitions, see Table VII-1.
ND : Not detectable.	6Q
NR : Not reported.
N/A: Not applicable.

-------
TABLE YII-5
SOMttKT Or ANALYTICAL DATA FVOM SAMPLED PLANTS
TOXIC POLURART STUDT
	HTMtlDt	
tarn Haatevater
bftrtnci Coda

176-01

256-01




Plant
: God*

132

139

#11

OveralL,.
Sof la Point

0

¦
Averse*
111

Average
Flow
(err)

615

1.8
308.4




mil
tba/1000 lbs
a/1
lba/1000 lba
a/1
lba/1000 lba
mil
lba/1000 lba

Suir««M Solids
492
1.26
396
0.0029
444
0.63
421.3
1.047

Dissolved Iroa
0.45
0.001
36.5
0.00027
18.5
0.0006'
12.45
0.001

pi (DMit*)
12.4
H/A
11.4
H/A
11.4-12.4
N/A
11.4-12
.4 N/A
114
Antiaony
0.20
0.0005
0.75
0.000005
0.48
0.0003
0.48
0.0003
118
Cadsios
*
**
0.12
0.0000009
0.06
0.0000005
0.04
0.0000003
119
Chroaims
15.3
0.039
1.5
0.00001
8.4
0.039
5.59
0.026
120
Copper
0.67
0.0017
0.52
0.000004
0.59
0.00085
0.40
0.00057
121
Cyanide
Lead
HD
HD
HD
¦D
HD
HD
0.035
0.00018
122
0.2S
0.0006
1.1
0.000008
0.675
0.0003
0.45
0.0002
124
Nickel
8.7
0.022
0.310
0.000002
4.505
0.011
3.003
0.0073
125
Seleniua
m
n
0.035
0.0000002
0.035
0.0000002
0.018
0.0000001
126
Silver
0.02
0.00005
0.115
0.0000009
0.068
0.000025
0.068
0.000025
128
Zinc
0.075
0.00019
0.2
0.0000015
0.14
0.000096
0.092
0.000064

-------
TABU VII-5
SUMMARY OF ANALYTICAL DMA F*OM SAMPLED PLANTS
TOXIC POLLUTANT STUDY
HYDRIDE
PACE 2			
Effluent
Reference Code
Plant Code
Staple Point

176-01
132
0{106> ZZ(772)
Zl769) "w"'
615
CNT(17),C»,PSPfNA,C0
CIA|BI|ntP|MC|W|CL|
SL,SSr,T,SS,CT
f»-l (0.04)
U-i (o.
256-01
139
OA) ~ C-l (A.58) ~ D-l (0.10
-------
PROCESS:
KOLENE SCALE REMOVAL
PLANT:
PRODUCTION:
32.8 metric tons ste«l/day
(36.2 tons steel/day)
CTl
Ul
1.9 l/tflc
(30 gpm)
26.8 lAec
(425 qpm)
KOLENE SCALE
REMOVAL
OTHER PROCESS
WASTEWATER
SANITARY
WASTEWATER
MUNICIPAL
SEWAGE
PLANT
/^SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.2/26/79
FIGURE 3ZE-1
-------
PROCESS: kolene scale removal
PLANT:	c
PRODUCTION: 15.9 metric Ions steel/day
(17.5 tons steel/day)
MUNICIPAL
WATER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn-2/26/79


FIGURE 3ZH-2



KOLENE
QUENCH
TANK
—A"
0.6 l/SEC
(9 GPM)
DISCHARGE
*T0 RIVER
-------
-2&£—•
KOLENE
RINSES
PROCESS:
KOLENE SCALE REMOVAL
PLANT:
PRODUCTION:
60.3 metric tons steel/day
(66.5 tons steel/day)

0.3 l/sec
(5 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM	
Dwa 2/26/79
FIGURE ZEHr3
-------
4*
DISCHARGE
TO CREEK
(I)
NOTE (I) SAMPLE IS A SIMULATED
I
I
J-TERMINAL !
	-f- -fc TREATMENT <4
OTHER PLANT-1 PLANT
WASTES	'	— — —	1
EFFLUENT SAMPLE PREPAREO
BY MILL PERSONNEL AND IS ¦-
ANALOGOUS TO ANTICIPATED
EFFLUENT QUALITY FROM PROPOSED
TREATMENT FACILITIES
PROCESS: SALT BATH SCALE PREPARATION
OR REMOVAL- KOLENE
PLANT:	131
PRODUCTION: 21.97 METRIC TONS STEEL/TURN
(24.22 TONS ST EEL/TURN)
r WASTE 1
J SULFURIC L
J_ACID TANK _j
¦+\
I
I
I
I
	J	
MIXING AND
TRANSFER
BAR MILL PICKLE
LINE RINSES
APR 5 GPM AVG.
, SUMP ,
	X	1
(+¦
*
PLATE MILL PICKLE
LINE RINSES
APR 5 GPM AVG.
TITANIUM GRADES: EACH SHEET PROCESSED
A TOTAL OF FIVE TIMES
PRODUCT
PRODUCT
PRODUCT
DRAGOUT
SPENT RINSE WATER
EXISTING
> DISCHARGE
TO CREEK
0.568 l/SEC. AVG.(MEAS.
{9 GPM) 178 GAL./TON (2
CITY WATER
MAKE-UP
KOLENE DGS
TANK
(T»900°F)
WATER
QUENCH
TANK
LEGEND
SAMPLING POINT
MEAS~ MEASURED FLOW VALUE
	EXISTING FACILITIES
	~ FACILITIES TO BE CONSTRUCTED
NOTE (2) ALTHOUGH RINSE WATERS ARE LEFT
' RUNNING 24 HRS/DAY, PRODUCT IS
PROCESSED ONLY 8 HRS/DAY THEREFORE,
WASTE FLOWS AND LOAD VALUES ARE ALL
BASED UPON 8 HRS/DAY OPERATION.
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SALT BATH SCALE PREPARATION OR REMOVAL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM 	
Dwg.
8/10/77
FIGURE 3Zir-4
-------
MAKE-UP
5.6 i/sec.oq.0 GPM?^
1.1 l/SEC.06.8 GPM)
0.38 I/SEC.(6.I6PM)
0.76 l/SEC.(12 GPM)
0.88 I/SEC.04 GPM)
0.30 l/SEC.(4.8 GPM)
0.95 I/SEC.M5 GPM)
1.3 l/SEC.(20 GPM)
0i20 1/SEC.O.O GPM)
10	0.44 l/SEC.(TO GPM)
11	6.6 I/SEC.Q06 GPM)
12	0.22 l/SEC.(3.5 GPM)
0 2.5 I/SEC.I40 GPM)
r0.2l l/SEC.
(3.3 GPM)
¦POCESS
HOT FORMING, PICKLING, SCALE REMOVAL, WIRE
COATING, ALH&i.rnE CLEANING
plant oei, i22,132,142,152
PRODUCTION M" 65 METRIC T0NS/TURNI72 TONS/TURN)
N(#l a»2 MILLS1-43 METRIC TONS/TURN
(48 TONS / TURN)
N(*4MILL)-64 METRIC T0NS/TURN<70TONS/TURN)
W * 2 BLOCK- 85METRC T0NS/TURNO0 TONS/TURN)
BENCH CLEANING: 76 METRIC T0NS/TURN(84TC)NS/TURf«
X(K0LENE)~65 METRIC TONS/TURN194 TONS/TURN)
X(HYORIDE)-75 METRIC T0NS/TURN(83 TONS/TURN)
D I SC
INSPECTION
HOT MILL
7.2 l/SEC
(114 GPM)
27.7 l/SEC.
(439 GPM)
3.1 l/SEC.
(4 9 GPM)
0.66 l/SEC
(10.5 GPM)
LAMELLA
SEPARATOR
22.3 l/S
n
354 GP
0 l/SEC:
5 GPM)
3.1 l/SEC.-a
(49 GPM) \
MILL
75.7 l/SEC.
(1200 GPM)
20.5 l/SEC
(325 GPM)
SEDIMENTATION
*1 a #2
HOT MILL
UNIT
5.7 l/SEC.
(91 GPM)
18 l/SEC
(28.2 GPM)
FURNACE COOLING WATER
LIFT
STATION
OVERFLOW
LAGOON
KOLENE/HYOROCHUORIC RINSE
OTHER PROCESS
WASTEWATERS
SECONDARY RINSE
HOSE
RINSE
HEX CHROMIUM
TREATMENT
SCRUBBER
27.6 l/SEC
(438 GPM)
SCRUBBER
CENTRAL
TREATMENT
PLANT
ROOF
SCRUBBER
SAMPLE
POINTS
NORTH SCRUBBER
48.5 l/SEC
(769 GPM)
Cu-NoOH
RINSE
48.7 l/SEC
(772 GPM)
ISCHARGE
Cu/CN
TREATMENT
PLATE
RINSE
0.6 l/SEC
(9 GPM)*
15.5 l/SEC.(245 GPM)
ENVIRONMENTAL
PROTECTION AGENCY
LEAD COATING
RINSE
STEEL INDUSTRY STUDY
HOT FORMING. PICKLING, SCALE REMOVAL
WIRE COATING,ALKALINE CLEANING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
HIGH SPEED
DEGREASER
SOOIUM HYDRIDE
QUENCH
RINSE
WATER
SCRUBBER
FUME
DWN.ll/2i/78
FIGURE 3ZH -5
* COMPANY
SUPPLIED (DCP
RESPONSE FLOW RATE
-------

'2 8 3
COLO ANNEAL
AND
PICKLE LINE
(KOLENE)
SOFTENER
PROCESS: X-SCALE REMOVAL-KOLENE SALT BATH
PLANT: 137
PRODUCTION' 54.4 METRIC TONS STEEL/TURN
X-COLD ASP:(60 TONS STEEL/TURN)
(OTHER PROCESS WASTEWATER
JPICKLING-HOT ANNEAL-FUME
) SCRUBBER SYSTEMS" 8 ROLL
/GRINDING SHOP
BRITE ANNEAL
LINE
PENN SALT
ALKALINE
CLEANER
cr>
oo

2.2 l/SEC
(35 GPM)
I.I l/SEC
(IB GPM)
/
EQUALIZATION
LIME
SLURRY
WASTE PICKLE
LIQUORS
139 l/SEC
(2200 GPM)
142 l/SEC
(2250 GPM)
SETTLING LAGOONS (2)
DISCHARGE TO
RECEIVING STREAM
^SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
CONTINUOUS ALKALINE CLEANING a SCALE
REMOVAL - KOLENE SALT BATH
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.4/24/7S
FIGURE 2n-6
-------
CITY WATER
KOLENE
TANK
i_
KOLENE
QUENCH
TANK
t
NEUTRALIZATION
PIT
TO
POTW
PROCESS:
KOLENE DESCALING
PLANT:	138
PRODUCTION: 23.6 METRIC TONS/TURN
(26 TONS/TURN)
-1.2 l/sec.
(18.5 gpm)'"
NOTE
(I) Batch discharge occurs over 8 hours.
A
SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE DESCALING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
?WN. 8/1/78
FIGURE 2H
-------
PROCESS:
HYDRIDE SCALE REMOVAL
PLANT:
PRODUCTION: 19.1 metric tons steel/day
(21.1 tons steel/day)
3.54 l/sec
(53 gpm)
26.8 l/feec
(425 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDRIDE SCALE REMOVAL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
/\SAMPLING POINTS
FIGURE ZEE-8
HYDRIDE SCALE
REMOVAL
SANITARY
WASTEWATER
OTHER PROCESS
WASTEWATER
MUNICIPAL
SEWAGE
PLANT
-------
PROCESS'- SCALE REMOVAL HYDRIDE
PLANT: 139
PRODUCTIONS METRIC TONS/TURN
(10.7 TONS/TURN)
r~
FLUSH
RINSE
AREA
MOLTEN
NoOH/
/NaH
RINSE
NaOH/
/NaH
HNO./HF
LIME
HNO
KMnOi
	J
SPENT
RINSE
40,000 GAL
8750 GAL
SPENT
ACID
SPENT
ACID
12,000 GAL
REACTOR
2200 GAL/DAY
20 GAL/DAY /B
5000 GAL
ACCUMULATOR
(AIR AGITATED)
/v 10 GAL/DAY
SLUDGE
STORAGE
TO CONTRACT
SLUDGE
DISPOSAL
CITY WATER
ENVIRONMENTAL PROTECTION AGENCY
SETTLING TANK
10,000 GAL
STEEL INDUSTRY STUDY
SCALE REMOVAL HYDRIDE
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM	
2150 GAL/DAY
SAMPLING POINT
Dwn.8/1/79
TO POTW
-------
SCALE REMOVAL SUBCATEGORY
SECTION VIII
COST, ENERGY, AND NON-WATER QUALITY IMPACTS
Introduction
This section presents the incremental costs incurred in applying the
different levels of pollution control technology to scale removal
operations. The analysis also describes energy requirements, nonwater
quality impacts, and the techniques, magnitude, and costs associated
with each alternative treatment system for each subdivision.
Actual Costs Incurred by the
Operations Sampled for this Study
The water pollution control costs reported by the industry are
presented in Tables VIII-l and VII1-2. These costs were updated to
July 1978 dollars from current year data. Standard costs of capital
and depreciation percentages were used so that these basic costs would
be comparable. Also, where central treatment systems are in use, the
industry often supplied total cost data for the entire treatment
system. These costs were apportioned as accurately as possible to
isolate costs attributable to the treatment of scale removal
wastewaters.
Because of the extensive use of central treatment for scale removal
wastewaters, the Agency could not directly verify its model-based cost
estimates for for separate treatment of scale removal wastes with cost
data reported by the industry for central treatment systems. However,
the Agency compared its model-based separate treatment costs with
industry costs for several central treatment systems by summing the
model-based separate treatment costs for each subcategory included in
the existing central treatment systems. The results of this
comparison presented in Volume I demonstrate that the Agency's costing
methodology accurately reflects industry costs for central treatment
facilities in general, and for those systems including scale removal
wastewaters in particular. In fact, as shown by the data presented in
Volume I, the Agency's cost estimates for separate treatment for
finishing operation wastewaters are likely to be significantly higher
than the costs which will actually be incurred by industry for central
treatment.
Control and Treatment Technology (C&TT)
Effluent limitations and standards are being proposed for BPT, BAT,
BCT, NSPS, PSES, and PSNS. The alternative treatment systems and
components are presented in Tables VII1-3 and VII1-4. The
technologies described therein represent treatment systems either in
use or available for kolene and hydride scale operations. In addition
73
-------
to listing the treatment methods available, these tables also describe
for each method:
1.	Status and reliability
2.	Problems and limitations
3.	Implementation time
4.	Land requirements
5.	Environmental impacts other than water
6.	Solid water generation
Cost, Energy, and Nonwater Oualitv Impacts
General Introduction
The installation of BPT, BCT, BAT, NSPS, PSES, and PSNS alternative
treatment systems will require additional funding (both investment and
operating) and energy requirements. Also, air pollution, water
consumption and solid waste disposal impacts associated with each
level of treatment are addressed in this section. Costs and energy
requirements were estimated on the basis of the alternative treatment
systems developed in Sections IX through XIII and are presented in the
tables and text of this section.
Estimated Costs for the
Installation of Pollution Control Technologies
A. Costs Required to Achieve the Proposed BPT Limitations
The BPT model costs are presented in Tables VII1-5 and VII1-6.
However, not all plants will incur all these costs, as many are
already operating at or near the BPT level of treatment. To
obtain a more accurate accounting of costs required to comply
with the proposed BPT limitations, a capital cost tabulation was
performed for all scale removal lines. The tabulation presented
in Tables VIII-7 and VIII-8 involve the application of the model
costs to each line in both process subdivisions. These
tabulations summarize the treatment installed at each line and
present the required costs to attain the proposed BPT
limitations.
The Agency estimated capital costs of the proposed BPT for kolene
scale removal are 6.59 million dollars. Of this total, 3.18
million dollars is currently in place. The remaining 3.41
million dollars remains to be installed. The estimated annual
costs for kolene scale removal are 1.83 million dollars. The
estimated capital costs of BPT for the hydride type scale removal
are 0.89 million dollars. Presently, 0.63 million dollars worth
of treatment technology is in place. The remaining 0.26 million
dollars is still required to be installed. The estimated annual
costs for hydride scale removal are 0.32 million dollars.
To develop the above costs, model treatment systems were
developed which are based upon average plant size and the model
flow rates. Plant by plant capital cost estimates were then made
by factoring the production of each plant to the model plant size
74
-------
by the "six-tenth" rule. This method yields cost estimates for
the subcategory which are representative of the actual costs
spent in the industry. Cost comparisons presented in Volume I
verified the accuracy of this costing methodology. Because the
DCP responses listed the treatment components already installed,
costs for "in-place" components were separated from the total
estimated cost.
As a final note, it should be pointed out
were developed assuming all plants would
treatment systems. However, as pointed out
from most operations are treated in central
Treatment in central systems reduces costs
of scale and because duplicate equipment
needed. Hence, actual cost requirements
operations are expected to be less than the
above.
that cost estimates
install separate
earlier, wastewaters
treatment systems,
because of economies
components are not
for scale removal
estimates presented
Costs Required to Achieve the Proposed BAT Limitations
The Agency considered three BAT alternative treatment systems.
The descriptions of rationale for considering, and additional
details regarding the alternatives are provided in Section X.
The additional investment and annual expenditures involved in
applying each of the BAT alternative treatment systems are
presented in Tables VIII-9 and VIII-10. The estimated investment
and annual cost for each model BAT treatment system follow:
Kolene Scale Removal
BAT
Alternative
No. 1
No. 2
No. 3
Investment Costs
In-Place	Required
$140,000
$140,000
0
$ 2,520,000
$ 3,280,000
$38,680,000
Annual
Cost
$ 477,000
$ 621,000
$8,780,000
Hydride Scale Removal
BAT	Investment Costs	Annual
Alternative	In-Place"	Required	Cost
No.1	$	0 $ 564,000	$ 101,000
No.2	$	0 $ 744,000	$ 135,000
No.3	$	0 $5,610,000	$1,020,000
Cost Required to Achieve Proposed BCT Limitations
The BCT cost analysis is presented in Table VIII—11, and
information regarding BCT is provided in Section XI.
The BCT model treatment system considered for kolene operations
fails the cost-reasonableness test. Therefore, the proposed BCT
limitations are the same as the proposed BPT limitations for
conventional pollutants.
75
-------
The BCT model treatment system considered for hydride operations
passes the cost-reasonableness test. The total costs required to
achieve the proposed BCT limitations are included in the costs
required for BAT Alternative No. 1.
D.	Costs Required to Achieve the Proposed NSPS
The Agency considered two alternative treatment systems for scale
removal facilities which are constructed after the proposal of
New Source Performance Standards. The NSPS alternative treatment
systems are similar to the BPT/BAT treatment systems. The NSPS
alternative treatment systems are discussed in Section XII and
treatment model costs for those alternatives are presented in
Tables VIII-12 and VIII- 13.
E.	Costs Required to Achieve the Proposed Pretreatment Standards
Pretreatment standards apply to those existing and new sources
which continue or elect to discharge to POTW systems. Refer to
Section XIII for additional information pertaining to
pretreatment standards. The costs for the pretreatment models
are presented in Tables VIII-12 through VI11-15.
Energy Impacts
Moderate amounts of energy are required by the various levels of
treatment in the scale removal subcategory. The major energy
expenditures for the subcategory occur at the BPT treatment level. It
should be noted that while BAT Alternatives No. 1 and No. 2 require
relatively minor additional energy, BAT Alternative No. 3 requires a
significant amount of electrical energy. The Agency considered this
factor in selecting the BAT model treatment system (see Section X).
A.	Energy Impacts at BPT
The estimated energy requirements are based upon the assumption
that all scale removal operations install treatment systems
similar to that of the treatment model, with flows similar to
those of the model. On this basis, the annual energy usage for
the BPT model treatment system for all kolene scale removal
operations is 1.29 million kilowatt-hours of electricity. The
energy usage for BPT treatment components for all hydride scale
removal operations is 0.26 million kilowatt-hours of electricity.
The total energy needs to comply with the proposed BPT limtations
totals 1.55 million kilowatt-hours. This represents less than
0.01% of the 57 billion kilowatt-hours of electricity used by the
steel industry in 1978.
B.	Energy Impacts at BAT
The estimated energy requirements at the BAT level of treatment
are based upon the same assumptions noted above for BPT.
Following are the estimated energy requirements needed to upgrade
the BPT model treatment system to the three BAT alternative
76
-------
treatment systems, and their relationship to the 1978 industry
power usage:
BAT
Alternative
Kolene
kwh/vaar
% of
No. 1
No. 2
No. 3
Hydride
No. 1
No. 2
No. 3
152,000
228,000
17,556,000
48,000
72,000
672,000
0.00027
0.00040
0.031
0.000084
0.00013
0.0012
The Agency does not consider thaaa requirementa to ba significant
in light of the comparison to total industry usaga and ara
justified by the associated affluant reduction benafita.
Energy Impacts at BCT
No additional energy is raquirad to upgrada tha BPT nodal
treatment aystem to tha BCT laval of traatnant for kolene
operations aa the BPT and BCT limitationa ara idantical.
The estimated energy raquirad to upgrade BPT to the BCT laval of
treatment for hydride operations is included in tha energy
required to upgrade BPT to the BAT level of treatment.
Energy Impacts at NSPS, PSES, and PSNS
Following are the energy requirements for
PSNS treatment models.
tha NSPS, PSES, and
77
-------
Treatment Model
kwh/year
Kolene
NSPS No.1
NSPS No.2
PSES No.1
PSES No.2
PSNS No.1
PSNS No.2
40,000
40,000
68,000
68,000
40,000
40,000
Hydride
NSPS No.1
NSPS No.2
PSES No.1
PSES No.2
PSNS No.1
PSNS No.2
32,000
40,000
32,000
44,000
32,000
40,000
The energy consumption for PSES are included in that for the BPT and
BAT, while only model-based energy consumption is presented for NSPS
and PSNS, respectively.
Nonwater Quality Impacts
In general, the nonwater quality impacts associated with the proposed
treatment technologies are minimal. The three impacts evaluated were
air pollution, solid waste disposal, and water consumption.
A.	Air Pollution
Sulfur dioxide is used to reduce hexavalent chromium in the BPT
and NSPS treatment systems. Excess levels may be discharged to
the atmosphere during treatment. Sulfide addition is
incorporated in the BAT Alternative No. 2 treatment systems. In
the event of treatment process control upsets, the atmospheric
discharge of sulfides could occur. Neither the possible sulfur
dioxide nor the possible sulfide air emissions are considered
significant since only minor emissions are expected.
B.	Solid Waste Disposal
The treatment steps incorporated in the BPT and BAT treatment
systems will remove a significant quantity of the solids
contained in scale removal wastewaters. Following is a summary
of the solid waste generation for all scale removal operations at
the BPT, BAT, and BCT levels of treatment.
78
-------
Solid Waste Generation
Scale Removal Subcategory
Treatment Level 	(Tons/Year)	
Kolene
BPT	1336
BAT No.1	8.6
BAT No.2	8.6
BAT No.3	21.0
Hydride
BPT	64.7
BAT No.1-BCT	1 .4
BAT No.2	1.4
BAT No.3	3.4
As shown above, most suspended solids are generated by the BPT
model treatment system, while the BAT alternative treatment
systems generate relatively minor additional amounts of solid
wastes. Most of the solid wastes require proper disposal. As
the vast majority of these wastes are generated at the BPT level
of treatment and are being disposed of at the present time, the
Agency believes that the solid waste impacts associated with this
proposed regulation are reasonable and justified. A more
detailed discusssion of this issue is contained in Volume I.
Following are the estimated amounts of solid wastes generated by
NSPS and Pretreatment models.
Solid Waste Generation
Scale Removal Subcategory
Treatment Level 	(Tons/Year)	
Kolene
NSPS No.1
54.6
NSPS No.2
54.6
PSES No.1
70.8
PSES No.2
70.8
PSNS No.1
54.6
PSNS No.2
54.6
Hydride

NSPS No.1
1 1 .2
NSPS No.2
1 1.2
PSES No.1
11.0
PSES No.2
11 .0
PSNS No.1
11 .2
PSNS No.2
11.2
The solid wastes generated at the NSPS and Pretreatment levels
are of the same nature as those generated at BPT and BAT levels
79
-------
of treatment and present the same disposal requirements as those
presented for BPT and BAT.
C. Water Consumption
Water will not be consumed at scale removal operations as a
result of compliance with the proposed BPT, BAT, NSPS, PSES, and
PSNS limitations and standards.
Summary of Nonwater Quality Impacts
The Agency concludes that the effluent reduction benefits described
below for the scale removal subcategory justify any adverse impacts
associated with energy consumption, air pollution, solid waste
disposal, or water consumption:
Effluent Discharge (tons/yr)
Raw
Waste
Proposed
Proposed
Kolene
BPT
BAT
Flow, MGD
TSS
Toxic Organics
Toxic Metals
Other Pollutants
1 .24
1544.43
0.039
584.70
514.8
1 .24
32. 18
0. 039
2.57
0.064
0.79
12.34
0. 025
0.57
0.041
Hydride
Flow, MGD
TSS
Toxic Organics
Toxic Metals
Other Pollutants
1.44
810.36
1 . 62
21 . 02
64.83
1 .44
40.52
0.41
5.16
1 .62
0.12
2.02
0.034
0.14
0.027
80
-------
TABLE VIII-1
KBPOBTED EFFLUEHT TBEATHKHT COSTS
KOIJHE SCALE REMOVAL OPERATIONS
CD
Reference Ho.
Plant Type
Initial lweitMt
Auuxt Coats
Coat of Capital
Depreciation
Operation 4 Maintenance
Euergy i Potter
Miscellaneous
TOTAL
J/Ton
9/1000 Cat. Trt.
424-01*
C I 131
VF.CR.FLP.HL.NU,
NA,CL,SL,T
Batch
1,290,000
55,470
129,000
101,780
18,453
304,703
41.9
235.4
176-04*
132
CK,PSP,NA,CO,CLA,
EB.FLP,MC.IM,CL,8L,
SSP,T,SS,CT
Batch
244,145
10,498
24,415
12,446
16,154
63,513
1.37
3.90
440A-01
L t 138
NW,SL
Batch
Hone
227
227
0.010
0.029
776-B
H/A
HW,CT,T
Batch
175,221
7,534
17,522
10,648
2,124
37,828
29.10
2.07
6840
Q*
None
Continuous
Hone
432
137*
NU,NL,SL
Continuoua
14,551
626
1,455
991
3,072
0.045
0.016
(1) For C4TT Cod* definitions, see Table VII-1.
* > Costa attribated to this subcategory.
HAS Hot applicable.
-------
TABLE VIII-2
REPORTED EFFLUENT TREATMENT COSTS
HYDRIDE SCALE REMOVAL OPERATIONS
Reference No.
Plant Code .
C&TT Code
Initial Investment
Annual Costs
Costs of Capital
Depreciation
Operation & Maintenance
Energy & Power
Miscellaneous
TOTAL
$/Ton
$/1000 Gal. Trt.
440A
L*
NW, SL
None
464
464
0.028
0.0232
456N-01
139*
CLA, NA, SL
8,000
344
800
9,730
38.6
10,913
1.09
605.6
176-01
132*
CR,PSP,NA,CO,CLA,
EB,FLP,NC,NW,
CL,SL,SSP,T,SS,CY
20,067
863
2,007
2,550
2,368
7,788
0.340
5.90
(1) For C&TT Code definitions, see Table VII-1.
*: Costs attributable to this subcategory.
82
-------
TABLE VlII-3
CONTROL AND TREATMENT TECHNOLOGIES
SCALE REMOVAL SUBCATEGORY - KOLEHE
Treitaeat and/or
Control Methods Employed
A. Acid Addition - Operation
wastewater ia treated by additiooa
of acid in the aixing tank to lower
pH to the 2-4 range.
B* Sulfur Dioxide Addition -
Bexavalent cbroaiua ia reduced to
the trivalent atate by the addi-
tion of a reducing agent auch aa
eulfur dioxide* This atep ia
used in conjunction with Step A.
C. Oil Skinning - Effluent froa
Step > ia treated with ikiaaer io
pit to reduce oil levels*
Statua and
Reliability
Practiced at the Majority
of mills in this subcategory*
Practiced at the Majority of
¦ills in this aubcategory•
Practiced at a few ailla in
this %ubcategory.
Probleas
and Limitations
Iocrease coat unices
source of acid exists
at plant*
Increased cost aeao~
ciated with cheaical
additioo*
Reaovea priisary
floating oils.
Implemen-
tation	Land
Tiae Requirement!
6 aonths 2$' x 25*
Environaental
Impact Other
Than Water
None
Included No additional None
in Step land required*
A.	Included in
Step A*
onths 50* x 50'
None
00
u>
Solid Waste
Generstion and
Pr iaary
Constituents
None
None
Oil sludge
must be in-
cinerated or
disposed of
in land fill.
D.	Liae Neutralisation - Liae
la added to Step C io order to
raiae the pB in the mixing tank
to the 6-9 range where optiaua
aetal reaoval will occur in aub-
aequent atepa*
E.	Polyaer Addition - Polyaar
ia added to the aaae aixing tank
used in Step D to aid precipi-
tation.
P. Clarification - The
neutralised wastes, froa Step E,
enter a flocculation -
clarifier where
aediaentation occurs*
Widely practiced by
tbia aubcategory*
¦ilia in
Widely practiced in this sub-
category* It ia a reliable
astbod of promoting aettling
characteristics.
Widely practiced in industry
and at the aajority of aills
in this subcategory.
Increaaed cheaical
coata and significant
solida loads generated*
Increased cheaical
coata.
Needa conaidersble
maintenance*
ontha 50- x 50*
None
Included No additional
in D. apace
neceaaary*
15-18
aonths
25* x 25*
None
Produces soae
additional
sludges.
Produces tons
of sludge per
day* Sludge
Bust be dis-
posed of in
landfill.
No aignificant
aaount of sludge
generated.
Sludges that
may contain
aetala are
generated and
aust be disposed
of in a land-
fill.
-------
TABLE VIII-3
CONTROL AND TREATMENT TECHNOLOGIES
SCALE REMOVAL SUBCATEGORY - KOLENE
PAGE 2	
00
Treatment and/or
Control Methods Employed
G. Vacuus Filtration - Used to
dewater the clarifier underflows
(laat atep in BPT).
H. Filtration -
Ibe effluent froa Step F ia
treated with a nixed-media fil-
tration ayateai to proaote aua-
pended solids removal (BAT
Alternative I).
Status and
Reliability
Widely practiced in the
induatry and by the aajority
of ailla in this aubcategory.
Widely practiced in the ateel
industry and at aeveral aiilla
in this subcategory.
I. Sulfide Addition - Prior to
Step H, inatall a aulfide addition
aystea to aid in the precipitation
of solids and aetala (BAT Alter-
native 2).
Problems
and Limitations
Increase capital
and operating costs.
Increased capital
and operating costa.
This aystea, in coojunctioov
with the filtration tanity haa
shown to be an effective aeana
to reduce the levela of heavy
aetata in waatewater streams.
Implemen-
tation	Land
Time Requirements
15-18 30*
months
30*
15-18
months
25*
25*
Additional operating
costs and iocreaaed
aludge production.
Care asiat also be taken
to guard against H^S
gas formation.
6 aootha 25' x 25'
Environaental
Impact Other
Than Water
Sludges require
disposal.
See solid waste
discussion.
See Solid Uaate
Impacts.
Solid Waste
Generation and
Primary
Constituents
Produces ap-
proximately
100 lbs./day
of sludge that
aust be dis-
posed of in
landfill.
Soae addi-
tional sludge
may be generated
when the filters
are backwaslied.
The sludge will
contain aainly
oila and solids/
but may contain
8one metallic
compounds.
There is the
potential for
up to 2,000
additional lbs.
of wet sludge
to be generated
per day due to
the sulfide
addition.
J. Evaporation - A vapor decoa-
preaaioa evaporation aystea ia ia*
stalled in order to concentrate
dissolved solids (BAT
Alternative 3, Step 1 of 2)*
Daaonatrated in the power
generation industry.
Needs considerable
aainteoance. Econoaics
dependent on the inte-
gration of this systen
into the water cycle.
IB
atha 60' s 60'
Uaea approxi-
aately 90 kwh/
1000 gallona of
feed water.
Slurry generated
in thia process
aust be de-
watered. Sludge
generation ia
increaaed
and sludges
asy contain
some metallic
coapounds.
-------
TABU Till-)
OOHTBDL AMD TOAHBHT TCCHNOLOCIES
SCALE HMOVAL SOBCATEGOR - KOLME
PACK 1	
Treataeat aad/or
Coatrol Hethodo
K. Recycle - The liitlUitt
quality	froa (tap K ia
racyclad back to tka kolaaa
proceae (BAT Alternative 3,
Step 2 of 2).
Stataa aad
^liability
Ihla atep reaalte ia a aero
diecbarge of proceae water•
Widely practiced ia the ateel
iaduatry.
00
in
Solid Waste
lapleaan-	Eavironaental Generation and
Problaaa	tation	Land	lapact Other	Primary
d tilitatioaa	Tla» iequiretota Than Water	Conatituenta
12-14
¦ontha
25* a 25'
Hone
None
-------
TABLE VIII-4
CONTROL AND TREATMENT TECHNOLOGIES
SCALE REMOVAL SUBCATEGORY - HYDRIDE
Treatment and/or
Control Method* Employed
A.	Chlorine Addition - Chlorine
or other oxidising agents are
added to the hydride wastewater
to chemically oxidise the cyanides,
B.	Acid Neutralisation - Acid is
added to Step A in order to get
the pH within the 6-9 range where
optima aetal resoval will occur
in subsequent stepe.
Status and
Reliability
Practiced at the majority of
¦ills in this subcategory.
Practiced at the majority of
¦ills in this subcategory.
Problems
and Limitations
Increased chemical
costs.
Increased cheaical
costs.
Implemen-
tation	Land
Time Requirements
6 months 25* * 25'
6 months 50' x 50'
Environmental
Impact Other
Than Water
None
None
Solid tfaste
Generation and
Primary
Constituents
None
None
00
-------
TABLE VII1-4
COtrTROL MID TREATWHT TKCWOLOCIKS
SCALE KEHOVAL 8U1CATEOOR - HTMIDt
PACE 2	
00
Treataent and/or
Control Hethods Eaplortd
Status and
Reliability
Problems
and Liaitatlons
C. Sulfide Addition - A sulfide Ihi« ay (tea, in c oil jane t ion
addition systea la installed prior with the filtration unit, has
to Step F to aid in the precipi-
tation of aolida and aetala
(BAT Alternative 2).
¦. Evaporation - A vapor decoa
preasion evaporation ayatea ia
installed to concentrate dia-
eolved solids (MX Alternative
3, Step 1 of 2).
Addtional operating
costs snd increased
shown to be an effective aeana sludge production,
of reducing the levels of heavy Care anat also be
netala in waatewater streana. taken to guard
againat H,S gaa
foraationT
Deaonstrated in the power
generation industry.
Iaplenen-
tation
Tiaa
6 aonthe
Land
Bequlren
ints
No additional
spsce re-
quired.
Environaentsl
Impact Other
Than Wster
See Solid Haste
lapsets
Heeds considerable
Maintenance. Eco-
noaice dependent on
the integration of this
systea into the eater
cycle.
18 aontha 60' x 60'
Uses approxi-
mate ly 90 Mi/
1000 gallons of
feed ifpter.
Solid Haste
Generation and
Primary
Constituents
Some additional
sludge will be
generated as a
result of the
installation of
this system(
however, be-
cause of the
low flow froa
this process
the sdditional
production
should be less
thsn 1000 lbs/
dsy of wet
sludge.
Slurry generated
in this process
Bust be de-
watered. Sludge
generation ia
increased and
sludges nay
contain some
netsllic
compounds.
I. Recycle - The distillate
quality effluent froa Step I ia
recycled back to the hydride pro-
cess.
This atep results in a aero
discharge of process water.
Hidely practiced ia the ateel
induetry.
15-18
aontha
25' * 25'
None
-------
Subcategory
TABLE VIII-5
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Scale Removal
Kolene
Specialty
Model Size-TPD : 130
Oper. Days/Year: 250
Turns/Day	: 2
C&TT Step
A
B
C
D
E
f(2)
g(2)
Total
_3
Investment $ x 10 _
57
51
39
61
55
114
128
505
Annual Cost $ x 10








Capital
2.4
2.2
1.7
2.6
2.4
4.9
5.5
21.7
Depreciation
5.7
5.1
3.9
6.1
5.5
11.4
12.8
50.5
Operation & Maintenance
2.0
1.8
1.4
2.6
1.9
4.0
4.5
18.2
Sludge Disposal ..
Energy & Power
-
-
-
-
-
-
1.5
1.5
0.1
0.1
0.1
0.2
0.2
0.3
1.2
2.2
Chemical Costs
0.3
6.3
-
0.1
0.5
-
-
7.2
TOTAL
10.5
15.5
7.1
11.6
10.5
20.6
25.5
101.3


Raw
Treated

(3)
uent Quality
Waste
Effluent
Effl
Level
Level

Flow, gal/ton
500
500

Total Susp. Solids
i 1200
25

Hexavalent
400
0.050

Chromium



PH
8-12
6-9
23
Chi orof orm
0.030
0.030
114
Antimony
0.10
0.10
115
Arsenic
0.025
0.025
118
Cadmium
0.010
0.010
119
Chromium
450
0.50
120
Copper
2.0
0.50
124
Nickel
2.0
0.50
125
Selenium
0.060
0.060
127
Thallium
0.20
0.20
128
Zinc
0.10
0.10
(1)	Costs are all power unless noted otherwise.
(2)	Treatment components are used in tandem.
(3)	All values are in mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Acid Addition	E: Polymer Addition
Bs Chemical Reduction	Fs Clarifier
C: Oil Skimming	G: Vacuum Filter
D: Neutralization with Lime
88
-------
TABLE VIII-6
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory: Scale Removal



Model
Size-TPD
200
: Hydride



Oper.
Days/Year
270
: Specialty



Turns/Day
	3
C&TT Step
A
B
C
D«>
e<2)
Total
_3
Investment $ x 10 _
109
74
85
188
126
582
Annual Cost $ x 10






Capital
4.7
3.2
3.7
8.1
5.4
25.1
Deprec iation
10.9
7.4
8.5
18.8
12.6
58.2
Operation & Maintenance
3.8
2.6
3.0
6.6
4.4
20.4
Sludge Disposal^.
-
-
-
-
3.1
3.1
Energy & Power
6.2
0.3
0.3
0.6
.23
3.6
Chemical Costs
2.0
1.9
1.4
-
—
5.3
TOTAL
21.6
15.3
16.9
34.1
27.8
115.7
Effluent Quality
(3)
Raw
Waste
Level
(1)	Costs are all power unless noted otherwise.
(2)	Treatment components are used in tandem.
(3)	All values are in mg/1 unless otherwise noted.
KEY TO C&TT STEPS
Treated
Effluent
Level

Flow, gal/ton
1200
1200

Suspended Solids
500
25

Dissolved Iron
40
1.0

pH, Units
8-12
6-9
114
Ant imony
0.80
0.50
118
Cadmium
0.10
0.10
119
Chromium
5.00
0.50
120
Copper
0.75
0.50
121
Cyanide
1.0
0.25
122
Lead
1.00
0.50
124
Nickel
5.00
0.50
125
Selen ium
0.025
0.025
126
Silver
0.10
0.10
128
Zinc
0.20
0.20
A: Alkaline Chlorination
B: Polymer Addition
C: Neutralization with Acid
D: Thickener
E: Vacuum Filter
89
-------
TABLE VHI-7
Subcategory: Scale Removal
t Kolene
: Specialty
BPT CAPITAL COST TABULATION
BASISt 7/1/78 DOLLARS X 10~3
: FACILITIES 111 PLACE AS OF 1/1/78
Plant
y£>
o
C&TT Step
In
Code
TPD
A
B
C
O
E
F
G
Place
Required
Total
0020 B
309
103
94
72
114
103
188
177
676
175
851
0060D
300
101
9?
71
iTT
TOT
m
T7J
571
264
835
00601
190
77
70
54

~TT
m
157
232
404
636
0088A
105
5?
59
38
So
54
99
92
392
54
446
0176
203
80
n
55
59

155
lTT
661
0
661
0248A
138
W

5*
75
CT
TT5
159
237
287
524
0248D
1

375
2.3
3.7
3.3
5."5
5.7
9.3
18.0
27.3
0432L
34
27
25
19
30
27
"50
47
0
225
225
0440 A
63
39
36
28
44
39
73
68
73
254
327
0528
507
138
127
97
154
138
25J
238
251
894
1145
0684 D
69
42
38
29
ii
42
77
72
0
346
346
0776C
45
8.1
7.4
5.7
9.0
8.1
14.9
13.9
32.0
35.1
67.1
0776H
13
15
14
11
17
"15
15
26
42
84
126
08561
78
45
51
32
50
45
52
77
0
372
372
3176.3*
3412.1*
6588.4*
* Totals do not include confidential plants or dry operations.
Notes Underlined costs represent facilities in place.
KEY TO C&TT STEPS
A: Neutralisation with Acid	D:	Neutralization with Line
B: Cheaical Reduction	E: Polymer Addition
Cs Oil Skiamng	F:	Clarif«r
G:	Vacuum Filter
-------
Subcategory*
1
:
Scale ItMTil
Hydride
Specialty
Plant
Code	TPD
0176	453	91	78
0248B	M	-	~
0256K	165	50	43
0256*	27	17	T¥
0684P	17	IT	11
0684V	HA
Hotel Underlined coat represent facilities in place
KBT TO CtTT STEW
A: Alkaline Chlorination	Ds Thickener
B< Neutralisation with Acid	C: Vacuua Filter
Ct Beutralication with Polyaer
TABLE VIII-8
BPT CAPITAL COST TABULATION
BASIS: 7/1/78 DOLLARS X 10~3
S FACILITIES III PLACE AS OF 1/1/78
CSTT Step
<5
b
E
In
Place
Required
Total
82
96
126
473
0
473
45
53
69
141
119
260
15
T®
23
17
70
87
11
13
18
0
66
66



55T
55?
SS6
-------
U1U VIII-9
ALTMNAT1V1 UT HOBiL COOT MM: U1H 7/1/78 DO CLAM
Subcategory
Scale tamlHtolMl
kick aad Caatiaeaue
Specialty
Medal lix«-T?D
Oper. Days/Year
Turn*/Day
130
m


2


3

I»f 1
-L
J_
tocal
J
K
Total
160
62
140
182
1962
73.7
2035.7
6.0
1.1
6.0
7.8
84.4
3.2
87.6
16.0
4.2
14.0
18.2
196.3
7.4
203.7
6.*
1.6
4.9
6.3
68.7
77.9
146.6
0.2
0.1
0.J
0.3
0.9
23.0
0:i<»
0.9
23.1
•
0.1
-
0.1
-

.
Alternative
C&TT Se«p	_|_
Investment ? x 10"\	140
Annual Cose $ x 10
Capital	6.0
Depreciation	14.0
Operation 6 Haiatemaaaa	*.~
Sludge Dispeeal..
Energy 6 UmtKl'	0.2
Chemical Coat*
Raplaceaanc Part*	- ...	-
TOTAL	23.1 23.1 7.6 23.1 32.7	373.3 88.6(2) 461.9
IAT Feed	MT Ms. 1	IAT Ne. 2	BAT No. 3
Effluent	Iffluent	(ffluent	Effluent
Effluenc Quality	Laval	lave!	Level	Level
Flow, gal/taa	320	320	320	0
Suspended Solids	23	13	13
Hex. Chrsmium	0.03	0.03	0.03
pK, Unit!	6-9	6-9	6-9
023 Chloroform	0.01	0.03	0.03
114 Anciaony	0.10	0.10	0.10
113 Arsenic	0.023	0.023	0.023
118	Cadmium	0.01	0.01	0.01
119	Chromium	0.30	0.10	0.10	-
120	Copper	0.30	0.10	0.10
124 Mick.a I	0.30	0.10	0.10
123 Selenium	0.06	0.06	0.06
127 Thallium	0.20	0.10	0.10
123 Zinc	0.10	0.10	0.10
(1)	Coses are all power ualess otherwise eeted.
(2)	local does not include paver cmc, •« • sndU U MffUad for emitting process wacer power requirements.
(3)	All values are ia ag/l ualaaa Mtantiia eatad.
PT TO CiTT I1PI
H: rilcretiea lyeia*	Ji kafenilaa If—
I: Sulfide AAditiaa	Ki tMT«U
92
-------
TABLE VIII-10
ALBUltATITE BAT MODEL COST DATA: BASIS-7/1/78 BOLLARS
Alterutiw
C4TT Step
ImitMrt f ¦ 10~\
Aoaual CMC I a M~
Capital
Depreciatiaa
Operation 4 Raiataa
Sln*a*
¦aerar I tmrmr
Cfceaical Caata
taplaceaaat Far«a
TOOL
Ifflaeat Q—ltt/'*
liar, aat/daa
fn 11 ii • • MM
OiNdnl Iaaa
»¦. **ta
114	Wlaif
115
119
im
U1
US
1B4
l»
Ul
IM
BAT PaM
Ifflaaat
Laval
100
i5
1
6-9
o.to
0.10
0.50
•.SO
0.25
0.50
0.90
0.02
0.10
O.M
Scale Hem
>val-lydrl4e

Motel
Sise-TTO >
200


Specialty


Oper.
Daya/Tear:
m





Taraa
/Bay I



1


2


3

r
Tatal
c
r
Total
1
t
Total
9*
9*
30
94
124
910.5
10
?34.5
4.0
4.0
1.3
4.0
5.3
39.4
I.I
4#.2
9.2
9.4
3.0
9.4
12.4
91.7
1.1
§3.7
3.3
3.3
1.1
3.3
4.4
32.1
0.7
32.•
0.2
0.2
0.1
0.2
0.3
0.5
2.7
•:.<»
•.5
M

_
0.1
•
0.1
~
-
-
16.9
It.9
5.6
1C.9
22.5
166.4
3.4(I)
169. S

BAT Bo. 1


BAT Ho. 2


UX Be

Effluent


Effluent


IfflM

Level


Level


Level

100


100


•

IS


15


_

0.20


0.20


-

6-9


6-9


-

0.20


0.10


-

0.05


0.05


_

0.10


0.10


-

0.10


0.10


_

0.25


0.25




0.10


0.10


-

0.10


0.10


_

0.020


0.020


_

0.10


0.10




0.10


0.10


-
(1) Ml M* paaaa — laa« atharviaa aotad.
(t) Vital 4m a*t laalaOl pmmr aaat, aa a cradit ia aappliaO for niitiii proceaa water power m»inaiat».
(3) All Mtaaa an ia mg/i aataaa atharviaa natal.
KIT TO C6TT STEPS
Ft riltratlaa Syataa
Ct hIM MJitiaa lyataa
¦< Nylti-atage evaporation ayatea
It Recycle
-------
TABLE VI11-11
RESULTS OF BCT COST TEST
SCALE REMOVAL SUBCATEGORY
A. Kolene
B.
BCT Mod«l:
Hydride
BCT Model:
lbs/year removed ¦ 2086.3
Cost of BCT-1* - $25,100 $/lb - 12.03 FAIL
* Includes the cost of all of the BCT-1 treatment components.
lbs/year removed ¦ 12830.6
Cost of BCT-1* - $16,900 $/lb - 1.32 PASS
* Includes the cost of all of the BCT-1 treatment components.
94
-------
TABLE VIII-12
ALTERWATIVE USPS AMD PSHS WD DEL COST DATA!	BASIS 7/1/78 DOLLARS
Subcategory: Scale Reaoval-Kolene	Model Sise-TPD : 130
t Batch & Continuous	Oper. Days/Tear: 250
: Specialty	Turns/Day : 2
Alternative 1
Alternative 2
C4IT Step
A
¦
C
D
E<«

C
Total
A
D
E^
eIH.

2^
Total
ImitacoC $ x 10
49
47
56
49
4.4
82
110
397.4
49
49
4.4
82
57
110
351.4
Annual Coats $ i 10















Capital
2.1
2.0
2.4
2.1
0.2
3.5
4.7
17.1
2.1
2.1
0.2
3.5
2.5
4.7
15.1
Depreciation
4.9
4.7
5.6
4.9
0.4
8.2
11.0
39.7
4.9
4.9
0.4
8.2
5.7
11.0
35.1
Operation A Maintenance
1.7
1.6
2.0
1.7
0.2
2.9
3.9
13.9
1.7
1.7
0.2
2.9
2.0
3.9
12.3
Sludge Diapoaal .
Energy t Rover11'
-
-
-
-
0.7
0.5
0.1
1.4
-
-
0.7
-
-
0.1
0.8
0.1
0.1
0.1
0.1
-
0.4
0.2
1.0
0.1
0.1
-
0.3
0.3
0.2
1.0
Cbeaical Coat
0.1
2.0
0.1
0.1
-
-
-
2.3
0.1
0.1
-
-
0.1
-
0.3
TOTAL
8.9
10.4
10.2
8.9
1.5
15.5
19.9
75.4
8.9
8.9
1.5
14.9
10.6
19.9
64.6
V0
U1
Effluent Qualit/4'
Feed
Level

Flow, gal/ton
200

Suspended Solida
1480

Hex. Chrosim
500

pB, Unite
8-12
023
Chi or of era
0.04
114
Antisooy
0.10
115
Arsenic
0.030
US
Cadaioi
0.01
119
Chroaitaa
550
120
Copper
2.50
124
Nickel
2.50
126
Seleaitaa
0.06
127
Tballitai
0.25
128
Zinc
0.10
Alt. Ho.l
Effluent
Level
200
15
0.05
6-9
0.03
0.10
0.025
0.01
0.10
0.10
0.10
0.06
0.10
0.10
Alt. No.2
Effluent
Level
200
15
0.05
6-9
0.03
0.10
0.025
0.01
0.10
0.10
0.10
0.06
0.10
0.10
(1)	Coata are all power unless otherwise noted.
(2)(3)	Treatment components are used in tanden.
(4) All value a are in mg/l inlesa otherwise noted.
KEY TO CAIT STEPS
As Acid addition	B: Sulfur Dioxide addition
D: Polymer addition	E: Settling basin
G: Filtration	H: Precipitation with sulfide
C: Liae addition
F: Vacuus Filter
-------
TABLE VIII-13
ALTERNATIVE USPS AND PS US HPDEL COST DATA; BASIS 7/1/78 DOLLARS
Subcategory: Scale Re*ovai-Hydride	Model Size-TPD t 200
: Specialty	Oper. Days/Yeart 270
Turna/Day	: 3
VO
&





Alternative
1


2 -
Alternative 1 plus:
CtTT Step

A
B
C


F
Total
C
Total
(incl. Alt. 1 Coats)
Ineitaat $ i 10 \

43
39
39
3
60
53
237
41
278
Annual Coat $ x 10










Capital

1.8
1.7
1.7
0.1
2.6
2.3
10.2
1.8
12.0
Depreciation

4.3
3.9
3.9
0.3
6.0
5.3
23.7
4.1
27.8
Operation & Maintenance

1.5
1.4
1.4
0.1
2.1
1.9
8.3
1.4
9.7
Sludge Diapoaal .

-
-
-
0.2
0.1
-
0.3
-
0.3
Energy i Power

0.1
0.1
0.1
-
0.3
0.2
0.8
0.2
1.0
Cheaical Coats

0.1
0.1
0.1
-
-
-
0.3
0.5
0.8
TOTAL

7.8
7.2
7.2
0.7
11.1
9.7
43.6
8.0
51.6








Alt. Ho.l

Alt. No.2
Effluent Quality^^
Feed






Effluent

Effluent
Level






Level

Level
Flow, gal/ton
50






50

50
Total Suspended Solida
1000






15

15
Dissolved Iron
80






0.20

0.20
pH, Unite
8-12






6-9

6-9
114 Antiwooy
1.6






0.20

0.10
118 Cadniua
0.20






0.05

0.05
119 ChroaioB
10






0.10

0.10
120 Copper
1.5






0.10

0.10
121 Cyanide
2.0






0.25

0.25
122 lead
2.0






0.10

0.10
124 Rickel
10






0.10

0.10
125 Seleniia
0.05






0.02

0.02
126 Silver
0.20






0.10

0.10
128 Zinc
0.40






0.10

0.10
(1)	Coats are all power unless otherwise noted.
(2)	Treatment coBponenta are used in tandeau
(3)	All values are in ag/1 unless otherwise noted.
KEY TO C4TT STEPS
A:	Alkaline Chlorination	B:	Acid Addition
Cz	Polywer Addition	D:	Settling Basin
E:	Vacuum Filter	P:	Filtration
G:	Precipitation with sulfide
-------
TABLE VIII-14
ALTERNATIVE PSES MODEL COST DATA; BASIS 7/1/78 DOLLARS
Subcategory:
Scale Removal-Kolene
Batch & Continuous
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
130
250
2
Alternative 1	 	Alternative 2
C&TT Step
A
B
C
D

j(2)
G
Total
A
D

/»

g(3)
Total
_3
Investment $ x 10 _3
61
56
68
61
6
105
137
494
61
61
6
105
76
137
446
Annual Cost $ x 10















Capital
2.6
2.4
2.9
2.6
0.3
4.5
5.9
21.2
2.6
2.6
0.3
4.5
3.3
5.9
19.2
Depreciation
6.1
5.6
6.8
6.1
0.6
10.5
13.7
49.4
6.1
6.1
0.6
10.5
7.6
13.7
44.6
Operation & Maintenance
2.1
2.0
2.4
2.1
0.2
3.7
4.8
17.3
2.1
2.1
0.2
3.7
2.6
4.8
15.6
Sludge Disposal
Energy & Power
0.1
0.1
0.2
0.2
0.9
0.9
0.9
0.2
1.8
1.7
0.1
0.2
0.9
0.9
0.9
0.3
0.2
1.8
1.7
Chemical Costs
0.2
4.0
0.1
0.4
-
-
-
4.7
0.2
0.4
-
-
0.1
-
0.7
TOTAL
11.1
14.1
12.4
11.4
2.0
20.5
24.6
96.1
11.1
11.4
2.0
20.5
13.9
24.6
83.6


PSES
PSES No.1
PSES No.2

f J. \
Feed
Effluent
Effluent
Effluent Quality
Level
Level
Level

Flow, gal/ton
320
320
320

Suspended Solids
1200
15
15

Hex. Chromium
400
0.05
0.05

pH, Units
8-12
6-9
6-9
023
Chloroform
0.03
0.03
0.03
114
Antimony
0.10
0.10
0.10
115
Arsenic
0.025
0.025
0.025
118
Cadmium
0.01
0.01
0.01
119
Chromium
450
0.10
0.10
120
Copper
2.00
0.10
0.10
124
Nickel
2.00
0.10
0.10
125
Selen ium
0.06
0.06
0.06
127
Thallium
0.20
0.10
0.10
128
Zinc
0.10
0.10
0.10
(1)	Costs are all power unless otherwise noted.
(2)(3)	Treatment components are used in tandem.
(4) All values are in mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Acid Addition	B:
C: Line Addition	D:
E: Settling Basin	F:
(1 day detention)	G;
H: Precipitation with
Sulfur Dioxide Addition
Polymer Addition
Vacuum Filter
Filtrat ion
-------
TABLE VIII-15
ALTERNATIVE PSKS MODEL COST DATA; BASIS 7/1/78 DOLLARS
Subcategory: Scale Removal-Hydride	Model Siae-TPD : 200
3 Specialty	Oper. Days/Tear: 270
Turns/Day	j J
Alternative 1
C4TT Step
A
B
C


F
Total
-3
Investment $ * 10 ,
56
50
48
4
59
94
311
Annual Cost $ x 10







Capital
2.4
2.1
2.1
0.2
2.5
4.0
13.4
Depreciation
5.6
5.0
4.8
0.4
5.9
9.4
31.1
Operation & Maintenance
2.0
1.7
1.7
0.1
2.0
3.3
10.9
Sludge Diapoaal .
-
-
-
0.2
-
-
0.2
Energy & Power
0.2
0.1
0.1
-
0.2
0.2
0.8
Cheaical Costs
0.2
0.1
0.2
-
-
-
0.5
TOTAL
10.4
9.0
8.9
0.9
10.6
16.9
56.9
2 - Alternative 1 plua:
Total
G	(incl. A-F )
50
2.2
5.0
1.8
0.3
0.1
9.4
361
15.6
36.1
12.7
0.2
1.1
0.6
66.3
00
Effluent Quality^^
Flow, gal/ton
Suapended Solida
Diaaolved Iron
pH (Unita)
114 Antiaony
116 Cadaiua
119	Chroaiu
120	Copper
121	Cyanide
122	Lead
124	Hickel
125	SeleniuM
126	Silver
128	Zinc
PSES
Feed
Level
100
500
40
8-12
0.80
0.10
5.0
0. 75
1.0
1.0
5.0
0.025
0.10
0.20
PSES No.l
Effluent
Level
100
15
0.20
6-9
0.20
0.05
0.10
0.10
0.25
0.10
0.10
0.02
0.10
0.10
PSES No.2
Effluent
Level
100
15
0.20
6-9
0.10
0.05
0.10
0.10
0.25
0.10
0.10
0.02
0.10
0.10
(1)	Coata are all power unless otberviae noted.
(2)	Treatment components are used in tandea.
(3)	All valuea are in ag/1 unless otberviae noted.
RET TO C&TT STEPS
A:	Alkaline Chiorioation B:	Acid Addition
Ct	Polyaer Addition	D:	Settling Basin
E:	Vacuus Filter	F:	Filtration
G:	Precipitation with aulfide
-------
SCALE REMOVAL SUBCATEGORY
SECTION IX
EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION
OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
Introduction
As described below, the proposed best practicable control technology
currently available (BPT) limitations are different than those
promulgated in March 1976 for scale removal operations. The
limitation for dissolved chromium has been replaced by one for total
chromium, and the limitation for cyanide has been deleted for kolene
operations. The March 1976 development document1 describes how the
originally promulgated limitations were developed. The change to
total chromium has been made because this pollutant is now included on
the toxic pollutant list. Cyanide was removed from the list of
limited pollutants for kolene operations because it was not found in
significant quantities. A review of the treatment processes and
effluent limitations associated with the scale removal subcategory
follows.
Identification of BPT
Based upon the information contained in Sections III through VIII of
this report, the proposed BPT limitations for the scale removal
operations are based upon the following treatment technologies.
A.	Kolene Scale Removal
Acidification followed by chemical reduction with sulfur dioxide,
sodium metabisulfate or sodium hydrosulfite. Oil separation or
skimming, neutralization with lime, and chemical precipitation
with polymer followed by settling in a thickener. Sludges are
dewatered in vacuum filters.
B.	Hydride Scale Removal
Chemical oxidation with chlorine, neutralization with acid, and
chemical precipitation with polymer followed by settling in a
thickener. Sludges are dewatered in vacuum filters.
Figures IX-1 and IX-2 depict the treatment systems described above.
XEPA 440/1-76/048-b, Development Document for Effluent Limitations
Guidelines and New Source Performance Standards for the Steelmaking
Segment of the Iron and Steel Manufacturing Point Source Category.
99
-------
The proposed BPT limitations do not require the installation of the
model treatment system. Any treatment system which achieves the
proposed limitations is acceptable. The proposed BPT effluent
limitations, which represent 30-day average values, are presented
below:
Kolene
Total Suspended Solids
Dissolved Iron
Hexavalent Chromium
Chromium (Total)
PH
Hydride
Total Suspended Solids
Dissolved Iron
Hexavalent Chromium
Chromium (Total)
Cyanide (Total)
PH
kq/kkq of Product
0.0521
0.0021
0.00010
0.0010
6.0-9.0
ka/kkq of Product
0.125
0.0050
0.00030
0.0025
0.0013
6.0-9.0
The proposed maximum daily effluent limitations are
average values presented above.
three times the
Rationale for BPT Treatment System
As noted in Section VII, each of the components included in the BPT
model treatment system are in use in a number of scale removal
operations.
Justification of Proposed
BPT Effluent Limitations
Tables IX-1 and IX-2 present sampled plant effluent data which support
the proposed effluent limitations.
100
-------
TABLE IX-1
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS
SCALE REMOVAL SUBCATEGORY
KOLENE
BPT Effluent
Limitations (3/76)
Revised Effluent
Limitations
	Effluent Limitations (kg/kkg)	
TSS D.Iron Hex.Ch. Chromium Cyanide
,(2)
0.0521 0.0021 0.00010 0.0010'
0.0521 0.0021 0.00010 0.0010
(3)
0.00050
NL
_EJL
C&TT Components
(1)
6.0-9.0 CR,SS,NL,FLP,T,VF
6.0-9.0 CR,SS,NL,FLP,T,VF
Actual BPT Loads
Plant Code
131	(0424)
132	(0176)
0.037 NA	**	*	vTO
0.024 0.0012 0.000062 0.00026 >^0
9.4	VF,CR,NL,NW,NA,CL,SL,T
7.6	CNT(17),CR,PSP,NA,C0,CLA
EB,FLP,NC,NW,SL,CL,SSP,T
SS,CY
(1)	For C&TT Code definitions, see Table VII-1.
(2)	Dissolved Chromium limitation.
(3)	119 Chromium (total) limitation.
* :	Limitation not supported.
**:	Unreliable sample analysis.
NA:	Not analyzed.
NL:	No limitation is being proposed.
-------
TABLE IX-2
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS
SCALE REMOVAL SUBCATEGORY
HYDRIDE
BPT Effluent
Limitations (3/76)
Revised Effluent
Limitations
Actual BPT Load8
Plant Code
139 (0256N)
132 (0176)
TSS
0.125
Effluent Limitations (kg/kkg)
D.Iron
0.0050
0.125 0.0050
Hex.Ch. Chromium
0.00030 0.0025
0.00030 0.0025
(2)
(3)
Cyanide
0.0013
0.0013
0.00052 0.0000016 0.00025 0.00036 0.0000027
0.0040 0.00020 0.0000098 0.0000420 0.0000084
_e£_
C&TT Components
(1)
6.0-9.0 CLA,NA,FLP,T,VF
6.0-9.0 CLA,NA,FLP,T,VF
8.2	CLA,NA,SL,CNT(66)
7.6	CNT(17),CK,PSP,NA,CO,
CLA, EB, FLP, NC, NW, CL,
SL,SCP,T,SS,CY
(1)	For C&TT Code definition, see Table VII-1.
(2)	Dissolved Chromium limitation.
(3)	119 Chromium (total) limitation.
-------
ACID
OIL
SULFUR
DIOXIDE
Diachorg* Flow Allowance: 500 GPT
LI ME
FILTRATE
RECYCLE
THICKENER
SOLIDS TO
DISPOSAL
POLYMER
VACUUM
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
BPT MODEL
Dwn.2/27/79
FIGURE TX-
-------
POLYMER
CHLORINE
ACID
o
Dltcharga Flow Allowance: 1200 OPT
J—

THICKENER
VACUUM
FILTER
I
SOLID TO
DISPOSAL
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDRIDE SCALE REMOVAL
BPT MODEL
Dwn.3/3/79
FIGURE IX-2
-------
SCALE REMOVAL SUBCATEGORY
SECTION X
EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION
OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
Introduction
The Best Available Technology Economically Achievable (BAT) Effluent
Limitations are to be attained by July 1/ 1984. BAT is determined by
reviewing subcategory practices and identifying the best economically
achievable control and treatment technologies employed within the
subcategory. In addition, where the technology is readily
transferrable from one subcategory or industry, such technology may be
identified as BAT.
This section identifies the BAT alternative treatment systems
considered for the scale removal subcategory. The rationale for
selecting the BAT alternative treatment systems is presented along
with the proposed BAT limitations.
Identification of BAT
Based upon the information contained in Sections III through VIII, the
Agency developed the following treatment technologies (as add-ons to
the BPT model treatment system) for BAT for kolene and hydride scale
removal operations.
Kolene Scale Removal
1.	BAT Alternative No.l
The BPT effluent would be filtered to remove particulate toxic
metals. The capital and operating costs for this alternative are
presented in Table VIII- 5. The treatment scheme is illustrated
in Figure X-l.
2.	BAT Alternative No.2
The addition of sulfide is used to further reduce the levels of
toxic metal pollutants prior to filtration. The capital and
operating costs for this system are presented in Table VIII-5.
The treatment scheme is illustrated in Figure X-l.
3.	BAT Alternative No.3
An evaporative system was considered to achieve zero discharge
for kolene lines, consisting of a multi-stage evaporator, a
condenser and a centrifuge to dewater the slurry generated in the
process. The distillate produced would be recycled back to the
scale removal operation.
105
-------
The capital and operating costs are presented in Table VII1-5.
The treatment system for this alternative is diagrammed in Figure
X-l .
Hydride Scale Removal
Figure X-2 illustrates the three alternative treatment systems
considered for the hydride scale removal subdivision. These models
are identical to those considered for kolene operations. The
respective investment and operating costs are presented in Table
VIII-6.
The treatment systems shown in Figures X-l and X-2 represent those
technologies in use at one or more plants, or demonstrated in other
wastewater treatment applications, and considered to be capable of
attaining the respective BAT effluent levels.
The BAT limitations for each alternative treatment system are
presented in Tables X-l and X-2 for kolene and hydride operations,
respectively. The selection of pollutants considered for limitation
was based upon the following factors: presence as BPT limited
pollutants; treatability using the technologies presented in the
alternatives; quantity and toxicity in relation to the other process
wastewater pollutants; and finally, the ability to serve as indicators
of both the presence and the removal of other pollutants.
Analytical data indicate that total chromium is found at much higher
levels and in greater quantities than other toxic pollutants found in
kolene wastewaters, and that total chromium, lead and total cyanide
are found at much higher levels and in greater quantities than other
toxic pollutants found in hydride wastewaters. Based upon the above,
the Agency is proposing BAT limitations for total chromium for kolene
operations and limitations for total chromium, lead, and total cyanide
for hydride operations. While other toxic metal pollutants have been
found in scale removal wastewaters, the control of the limited toxic
metals (Tables X-l and X-2) will also result in the control of those
toxic metal pollutants.
Flows
A.	Kolene Scale Removal Operations
Table X-3 summarizes the usable flow data for kolene scale
removal operations. The average of the best discharge flows was
322 gal/ton. The model flow selected by the Agency for BAT was
320 gal/ton. The average discharge flow was calculated using all
available data from plants discharging less than 1000 gal/ton.
The model BAT flow of 320 gal/ton is well demonstrated within
this subcategory.
B.	Hydride Scale Removal Operations
Table X-4 summarizes the usable flow data for hydride scale
removal operations. The average of the best discharge flows was
112 gal/ton. The model flow selected by the Agency for BAT was
106
-------
100 gal/ton. The average discharge flow was calculated using all
available data from plants discharging less than 600 gal/ton.
The recommended flow of 100 gal/ton is well demonstrated within
this subcategory.
Wastewater Qualitv
Following are the average effluent concentrations achievable with each
BAT alternative treatment system (the maximum values are expressed in
parentheses).
Kolene Scale Removal Operations
BAT Alt. BAT Alt. BAT Alt.
Concentration Basis, mq/1	No. 1	No. 2	No. 3
Chromium (Total)	0.10 (0.30) 0.10 (0.30)
Hydride Scale Removal Operations
BAT Alt. BAT Alt. BAT Alt.
Concentration Basis, mq/1	No.1	No.2	No.3
Chromium (Total)	0.10 (0.30) 0.10 (0.30)
Cyanide (Total)	0.25 (0.75) 0.25 (0.75)
Lead (Total)	0.10 (0.30) 0.10 (0.30)
These lists contain all of the toxic pollutants considered for
limitation at BAT. Reference is made to Appendix A of Volume I for
the derivation of the above concentrations.
Effluent Limitations for BAT Alternatives
The effluent limitations for each BAT alternative treatment system
were calculated by multiplying the model effluent flow by the
pollutant concentrations and an appropriate conversion factor. Tables
X-l and X-2 present the effluent limitations developed for each
alternative treatment system.
Selection of a BAT Alternative
The Agency selected BAT Alternative No. 1 as the BAT model treatment
system for both hydride and kolene operations. Filtration is
demonstrated in the Scale Removal Subcategory while sulfide
precipitation and evaporation techniques are not. For this reason the
Agency selected the first alternative as the model treatment systems
upon which the proposed BAT effluent limitations are based.
The proposed BAT effluent limitations are presented in Tables X-l and
X-2.
107
-------
TABLE X-l
BAT EFFLUENT LIMITATIONS GUIDELINES
KOLENE SCALE REMOVAL
BAT Alternative 1*
BAT Alternative 2
BAT Alternative 3
Discharge Flow
(Gal/Ton)
Chromium (Total)
Ave.
Max.
Concentration
Basis (mg/1)
320
0.10
0.30
Effluent
Limitations
(kg/kkg)
0.00013
0.00039
Concentration
Basis (mg/1)
320
0.10
0.30
Effluent
Limitations
(kg/kkg)
0.00013
0.00039
Concentration
Basis (mg/1)
Effluent
Limitations
(kg/kkg)
* : Selected BAT alternative.
-------
Discharge Flow
(Gal/Ton)
Chromium (Total)
Cyanide (Total)
Lead (Total)
TABLE X-2
BAT EFFLUENT LIMITATIONS GUIDELINES
HYDRIDE SCALE REMOVAL
BAT Alternative 1*
Concentration
Basis (mg/1)
100
Effluent
Limitations
(kg/kkg)
BAT Alternative 2
Concentration
Basis (mg/1)
100
Effluent
Limitations
(kg/kkg)
BAT Alternative 3
Concentration
Basis (mg/1)
0
Effluent
Limitations
(kg/kkg)
Ave.
Max.
Ave.
Max.
Ave.
Max.
0.10
0.30
0.25
0. 75
0.10
0.30
0.000042
0.00013
0.00010
0.00030
0.000042
0.00013
0.10
0.30
0.25
0.75
0.10
.0.30
0.000042
0.00013
0.00010
0.00030
0.000042
0.00013
* : Selected BAT alternative.
-------
TABLE X-3
SUMMARY OF FLOW DATA
KOLENE SCALE REMOVAL
plant Code
020B-01
284 A
684D
528-02
432*
440A"*01
0601
776H
528-04
176-04
^24-01
528-05
528-03
248D
776G
430C
088Ar02
088A-01
856E
Plant Type
Recommended Flow Values 320 GPT
Discharge Flow (GPT)
(1)
B
91
C
104
C
167
c
235
c
280
B
342
B
380
B
391
c
400
B
461
B
494
C
617
C
667
B
1026*
B
1283*
B
1467*
B
1533*
B
1774*
B
1846*
Average of all mills|t
Average of the Beat
656 GPT
322 GPT s 320 GPT
Basis
308 Data
308 Data
Sampled Data
308 Data
Sampled Plant
Sampled Plant
308 Data
308 Data
308 Data
Sampled Plant
Sampled Plant
308 Data
308 Data
308 Data
308 Data
308 Data
308 Data
308 Data
308 Data
(1) Data specified as confidential by certain plants were included when calculating averages,
B: Batch
C: Continuous
*: Value not included in Average of the Best
110
-------
TABLE X-4
SUMMARY OF FLOW DATA
HYDRIDE SCALE REMOVAL
Plant Code
256N-01
684P
256K
176-02
176-01
440A
176-03
Average of all mills:
Average of the Best :
Recommended Flow Value: 100 GPT
Discharge Flow (GPT)
1.8
33
87
330
611*
1200*
1818*
(1)
583 GPT
112 BPT 100 GPT
Basis
Sampled Plant
308 Data
308 Data
308 Data
Sampled Plant
Sampled Plant
308 Data
(1) Only continuous plant.
*: Values not included in Average of the Best.
Ill
-------
lacidj
T
PsulfurH
I DIOXIDE |
	1
I
I
[oTl]
—L|-
[lIMeI
T
i
J-
L_?^q. J
l	I
POLYMER.
T~
—I- T"
I f
I
l_ J
k
U-l

THICKENER
T
i
i
VACUUM
FILTER
J
_ _J
T
I
i
SOLIDS
TO
DISPOSAL
Discharge Flow Allowance: 320 GPT
BAT - I
FILTER
BAT -2
SULFIDE
REACTION TANK
BAT-3
EVAPORATION
T~T
CENTRIFUGE
FILTER
•100% RECYCLE
TO PROCESS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE RFMOVAL
BAT TREATMENT MODEL
ALTERNATIVES l'3
Own. 6/16/80
FIGURE X- I
-------
u>
£hl
--ba-
ilor! ne]
r
I
JaCIDj [polymer]
T
I	c*P_ J
I

I	9*9	I
—I
I
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\ ~
S	/
Y
i
i
___ t
VACUUM
L _F1LLE1 J
~
SOLIDS
TO
DISPOSAL
Discharge Flow Allowance: 100 6PT

I
I
BAT-I
t r
FILTER

1 *

BAT-2
r
SULFIDE
urti
REACTION TANK
BAT-3
FILTER






~ 100% RECYCLE
TO PROCESS
CENTRIFUGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDRIDE SCALE REMOVAL
BAT TREATMENT MODEL
ALTERNATIVES I - 3
Dwn.6/16/80
FIGURE 3>2
-------
SCALE REMOVAL SUBCATEGORY
SECTION XI
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY (BCT)
Introduction
The 1977 Amendments added Section 301(b)(4)(E) to the Act,
establishing "best conventional pollutant control technology" (BCT)
for discharges of conventional pollutants from existing industrial
point sources. Conventional pollutants are those defined in Section
304(g)(4) - BOD, TSS, fecal coliform and pH - and any additional
pollutants defined by the Administrator as "conventional." On July
28, 1978, EPA proposed that COD,'oil and grease, and phosphorus be
added to the conventional pollutant list (43 Fed. Reg. 32857). Only
oil and grease was added.
BCT is not an additional limitation, but replaces BAT for the control
of conventional pollutants. BCT requires that limitations for
conventional pollutants be assessed in light of a new
"cost-reasonableness" test, which involves a comparison of the cost
and level of reduction of conventional pollutants from the discharge
of POTWs to the cost and level of reduction of such pollutants from a
class or category of industrial sources. As part of its review of BAT
for certain "secondary" industries, EPA proposed methodoloy for this
cost test. (See 43 Fed. Reg. 37570, August 23, 1978).
Development of BCT
The reference POTW treatment cost for the conventional pollutants is
$1.34/lb. An explanation of this cost is presented in Section X of
Volume I. Figures XI-1 and XI-2 present the scale removal subcategory
BCT alternative treatment systems. As shown, filtration of the BPT
effluent is the BCT alternative treatment system for each descaling
operation. The conventional pollutant treatment costs are summarized
below.
BCT Alternative
Kolene	$12.03/lb
Hydride	$ 1.32/lb
Selection of a BCT Alternative
Kolene Scale Removal Operations
The BCT model treatment system does not pass the BCT cost test.
Therefore, the BCT limitations are the same as the proposed BPT
limitations. Table XI-1 presents the proposed BCT limitations £°r
kolene operations.
115
-------
Hydride Scale Removal Operations
The BCT model treatment system passes the BCT cost test. The model
treatment system employs the same treatment components as BAT
Alternative No. 1. The BCT treatment costs are identical to those
presented in Section VIII for BAT Alternative No. 1. Table XI-2
presents the proposed BCT limitations for hydride operations.
Development of BCT Limitations
The Agency is proposing limitations for suspended solids and pH at
both BPT and BCT. For kolene operations, those limitations are the
same. For the hydride operations, the effluent levels for suspended
solids are based on the BCT treatment system which employs filtration
technology. Refer to the discussion on filtration capabilities in
Volume I for the rationale for the concentration values for TSS used
to develop the proposed BCT limitations. The pH levels proposed at
BCT are the same at those proposed for BPT.
116
-------
TABLE XI-1
BCT EFFLUENT LIMITATIONS
KOLENE SCALE REMOVAL
BCT
Effluent
Limitations (kg/kkg)
Discharge Flow	500
(Gal/ton)
Total Suspended	Avg. 0.0521
Solids	Max. 0.156
pH, Units	6.0-9.0
117
-------
TABLE XI-2
BCT EFFLUENT LIMITATIONS
HYDRIDE SCALE REMOVAL
Discharge Flow
(Gal/ton)
Total Suspended
Solids
pH, Units
BCT
Effluent
Limitations (kg/kkg)
100
Avg. 0.0062
Max. 0.0168
6.0-9.0
118
-------
SULFUR
DIOXIDE
o»o
POLYMER
lime!
~
OkD
Discharge Flow Allowonce
320 6PT
THICKENER



VACUUM
FILTER



FILTER
SOLIDS
TO
DISPOSAL
ENVIRON MENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
BCT TREATMENT MODEL
Own. M/12/80
FIGURE 21- I
-------
ACID
POLYMER
CHLORINE
Discharge Flow Allowance:
100 GPT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDRIDE SCALE REMOVAL
BCT TREATMENT MODEL
Own 11/12/80
FIGURE 21-2
-------
SCALE REMOVAL SUBCATEGORY
SECTION XII
EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF NEW SOURCE PERFORMANCE STANDARDS
Introduction
A new source is defined as any source constructed after the proposal
of New Source Performance Standards (NSPS). NSPS represents the
degree of effluent reduction achievable through the application of the
Best Available Demonstrated Control Technology (BADCT), process,
operating methods, or other alternatives, including, where
practicable, a standard permitting no discharge of pollutants.
For scale removal operations, a "no aqueous discharge of pollutants"
limit is not readily attainable. Due to the nature of the rinsing or
quenching steps, scale removal wastewaters cannot usually be reused or
recycled. Only if scale removal wastewaters are discharged to a large
central treatment system is reuse considered viable. However, this
reuse will not result in zero discharge. This mode of treatment is
not recommended for new source operations. However, substantial flow
and pollutant load reductions are being considered for NSPS.
Identification of NSPS
Kolene Scale Removal Operations
A.	NSPS Alternative No.l
Flows are reduced to the best demonstrated flow rate <200
gal/ton). Acid and sulfur dioxide are added to the waste stream
in order to provide hexavalent chromium reduction. Following
neutralization with lime, the wastewaters are aerated to sparge
any excess sulfur dioxide. Polymer is added prior to
sedimentation in a settling basin, from which surface oils and
scums are skimmed for further disposal. Sludges generated in the
treatment process are dewatered in a vacuum filter. Further
solids removal is then provided in a filtration step. The
capital and operating costs for this alternative are presented in
Table VII1-8. The treatment system is diagrammed in Figure
XII-1.
B.	NSPS Alternative No.2
As outlined in NSPS Alternative No.l, process discharge flows are
reduced to the best demonstrated level. Acid is then added for
the purpose of pH adjustment, followed by the addition of polymer
and sulfide. Sulfide not only helps to precipitate various
metals, but also reduces hexavalent chromium to its trivalent
form. Sedimentation is provided in a settling basin with the
sludges being dewatered in a vacuum filter. Further solids
121
-------
removal is then provided with a filtration step. The capital arid
operating costs for this alternative are presented in Table
VI11-8. The treatment scheme is diagrammed in Figure XII-2.
Hydride Scale Removal Operations
A.	NSPS Alternative No.l
Flows are reduced to the level of the best demonstrated flow rate
(50 gal/ton). Chlorine is added to the alkaline process
wastewaters to destroy (oxidize) the cyanide. Acid is then added
to provide a neutral pH. Polymer is added prior to sedimentation
in a settling basin. The sludges generated in the treatment
process are dewatered in a vacuum filter. Further solids removal
is then provided with a filtration step. The capital and
operating costs for this alternative are presented in Table
VII1-9. The treatment scheme is diagrammed in Figure XII- 3.
B.	NSPS Alternative No.2
The flows are reduced to the same level as in NSPS Alternative
No.l above. Also, as in Alternative No.l, chlorine is added to
destroy any cyanide which may be present. Acid is then added for
the purpose of pH neutralization, followed by the addition of
polymer and sulfide. Sulfide is used to precipitate various
toxic metal pollutants. Sedimentation is provided in a settling
basin with the sludges being dewatered in a vacuum filter.
Further solids removal is then provided with a filtration step.
The capital and operating costs for this alternative are
presented in Table VIII-9. Figure XII-3 diagrams the treatment
system.
Rationale for Selection of NSPS
The NSPS alternative treatment systems for the scale removal
subcategory are similar to the BPT model and BAT alternative treatment
systems described in Sections IX and X. The rationale presented in
these sections is applicable to NSPS.
Both NSPS treatment alternatives for kolene scale removal and hydride
scale removal are addressed below.
Treatment Scheme
As noted in Section X, the use of filtration technology is
demonstrated not only within the steel industry, but also within the
scale removal subcategory. The second alternative for kolene
operations eliminates the addition of sulfur dioxide and lime.
Instead, sulfide is added prior to final filtration. Sulfide not only
helps to precipitate various metals, but under proper conditions also
reduces hexavalent chromium to its trivalent form. The addition of
sulfur dioxide and lime then becomes unnecessary. With the exception
of this sulfide precipitation, the other treatment technologies are
also well demonstrated within the scale removal subcategory. As
discussed in Section X, sulfide precipitation has been successfully
122
-------
applied to the treatment of other metals manufacturing process
wastewaters and is considered suitable for the treatment of the
various steel industry process wastewaters as well. The recommended
treatment technologies are reliable and demonstrated methods of
treatment and are, thus, appropriate for use in NSPS treatment
systems.
The resulting effluent wastewater quality for NSPS alternatives are
presented in Tables XII-1 and XII-2, for kolene and hydride,
respectively. As noted in Section X, the effluent levels were based
upon the capabilities of the various wastewater treatment
technologies. The pollutants listed on Tables XII-1 and XI1-2 include
only those pollutants proposed for limitation at BAT and BCT (refer to
Section X for the factors considered in selecting these pollutants).
Flows
The discharge flows developed for NSPS are 200 gal/ton for kolene
descaling, and 50 gal/ton for hydride descaling. These flow rates are
well demonstrated within the respective scale removal operations.
Selection of NSPS Alternative
The Agency selected NSPS Alternative No.l as the NSPS model treatment
system. NSPS Alternative No. 1 was selected for the same reason noted
in the discussion in Section X regarding the selection of a BAT
Alternative.
123
-------
TABLE XII-1
NEW SOURCE PERFORMANCE STANDARDS
SCALE REMOVAL SUBCATEGORY - KOLENE
NSPS Alternative 1*
NSPS Alternative 2
Discharge Flow
(Gal/Ton)
Total Suspended
Solids
PH
Chromium (Total)
Ave.
Max.
Ave.
Max.
Concentration
Basis (mg/1)
200
15
40
0.10
0.30
6.0-9.0
Effluent
Standards
(kg/kkg)
0.013
0.035
0.000084
0.00025
Concentration
Basis (mg/1)
200
15
40
0.10
0.30
6.0-9.0
Effluent
Standards
(kg/kkg)
0.013
0.035
0.000084
0.00025
* Selected NSPS alternative.
124
-------
TABLE XII-2
NEW SOURCE PERFORMANCE STANDARDS
SCALE REMOVAL SUBCATEGORY - HYDRIDE
NSPS Alternative 1*
NSPS Alternative 2
Discharge Flow
(Gal/Ton)
Total Suspended
Solids
pH
Chromium (Total)
Cyanide (Total)
Lead (Total)
Ave.
Max.
Ave.
Max.
Ave.
Max.
Ave.
Max.
6.0-9.0
Concentration
Basis (mg/1)
50
15
40
0.10
0.30
0.25
0.75
0.10
0.30
Effluent
Standards
(kg/kkg)
0.0031
0.0082
0.000021
0.000063
0.000052
0.00016
0.000021
0.000063
6.0-9.0
Concentration
Basis (mg/1)
50
15
40
0.10
0.30
0.25
0.75
0.10
0.30
Effluent
Standards
(kg/kkg)
0.0031
0.0082
0.000021
0.000063
0.000052
0.00016
0.000021
0.000063
*: Selected NSPS alternative.
125
-------
SULFUR
DIOXIDE
ACID
POLYMER
LIME)
OIL
I
OkD
o»o
Discharge Flow Allowance: 200 GPT
SETTLING
BASIN
VACUUM
FILTER
I

FILTER



SOLIDS
TO
DISPOSAL
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
NSPS MODEL-ALTERNATIVE I
Dwn. 6/16/80
FIGURE 2IL- I
-------
POLYMER
{acid]
_	[oTl]
9 _T,
OkD
o»o
Discharge Flow Allowance: 200 GPT
SETTLING
BASIN
SULFIDE
VACUUM
FILTER
F LTER
SOLIDS
TO
DISPOSAL
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
NSPS MODEL-ALTERNATIVE 2
Dwn.7/17/80
FIGURE XE-2
-------
NJ
00
SETTLING
^ BASIN „
CHLORINE
POLYMER
VACUUM
FILTER
SOLIDS
TO
DISPOSAL
DISCHARGE FLOW ALLOWANCE: 50 GPT
NSPS-I
	FILTER
NSPS-2
SULFIDE
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDRIDE SCALE REMOVAL
NSPS MODEL-ALTERNATIVES I a 2
Jwn. 6/17/80
FIGURE 31-3
-------
SCALE REMOVAL SUBCATEGORY
SECTION XIII
PRETREATMENT STANDARDS FOR SCALE REMOVAL
OPERATIONS DISCHARGING TO PUBLICLY OWNED TREATMENT WORKS
Introduction
This section discusses the alternative control and treatment systems
available for scale removal operations which discharge wastewaters to
publicly owned treatment works (POTWs). Separate consideration is
given to pretreatment of scale removal process wastewaters from
existing sources and from new sources.
The general pretreatment and categorical pretreatment standards
applying to scale removal operations are discussed below.
General Pretreatment Standards
For detailed information on Pretreatment Standards, refer to 43 FR
27736-27773, "General Pretreatment Regulations for Existing and New
Sources of Pollution," (June 26, 1978). In particular, 40 CFR Part
403 describes national standards (prohibited discharges and
categorical standards), revision of categorical standards and POTW
pretreatment programs.
In establishing pretreatment standards for scale removal operations,
the Agency gave primary consideration to the objectives and
requirements of the General Pretreatment Regulations. In addition,
the Agency considered other factors which are specifically applicable
to scale removal operations. These are discussed below.
The General Pretreatment Regulations set forth general discharge
prohibitions that apply to all nondomestic users of a POTW to prevent
pass-through of pollutants, interference with the operation of a POTW,
and municipal sludge contamination. The regulations also establish
administrative mechanisms to ensure application and enforcement of
prohibited discharge limits and categorical pretreatment standards.
In addition, the Regulations contain provisions relating directly to
the determination of and reporting on Pretreatment Standards.
Wastewaters from several scale removal plants are discharged to POTWs.
POTWs are usually not designed to treat the toxic pollutants which are
present in scale removal wastewaters. Instead POTWs are designed to
treat biochemical oxygen demand (BOD), suspended solids (SS), fecal
coliform, bacteria, and pH. Whatever removal is obtained by POTWs for
toxic pollutants is incidental to the POTWs main function of treating
conventional pollutants. Thus, POTWs have historically accepted
extremely large amounts of many pollutants well above their capacity
to treat them adequately. As the issue of municipal sludge use has
become more important, pretreatment standards must address toxic
129
-------
pollutant removal, rather than the transfer of these pollutants to
POTWs where many pollutants concentrate in the sludges.
Due to the presence of toxic pollutants in wastewaters from scale
removal, pretreatment must be provided to ensure that these pollutants
do not interfere with, pass through, or are otherwise incompatible
with POTW operations or cause harm to the treatment plant. In
general, the pretreatment wastewater treatment technologies are the
same as the BAT level treatments. The Agency is not proposing
pretreatment standards for suspended solids because the amounts
present in scale removal wastewaters are compatible with POTW
operations and can be effectively treated at POTWs. Toxic pollutants
are reviewed below.
Pretreatment Considerations for Scale Removal
Toxic Metals
As noted in Volume I, Section V, toxic metals such as chromium and
lead are not destroyed in POTWs, but pass through to the effluent or
are retained in the POTW sludge. They can interfere with POTW
treatment processes and can limit the usefulness of POTW sludge for
application to agricultural croplands. In a study of 240 POTWs, 56
percent of the primary plants allowed more than 80 percent pass
through of chromium, and in a study of 214 POTWs, median pass through
values for lead were over 80 percent for primary plants, and over 60
percent for trickling filter, activated sludge, and biological process
plants. Hence, the proposed pretreatment standards for existing and
new sources are the same as the proposed BAT and NSPS limitations and
standards.
Total Cyanide
As noted in Volume I, cyanide compounds can interfere with the
operation of and pass through POTWs, as well as enhance the toxicity
of metals commonly found in POTW effluents. The mean pass through of
cyanide for fourteen biological plants was found to be 71 percent.
Hence, the Agency concludes that pretreatment standards for existing
and new sources for total cyanide should be equal to the proposed BAT
and NSPS limitations and standards, respectively.
Identification of Pretreatment
Existing Sources
Kolene
A. PSES Alternative No. 1
Acidification followed by chemical reduction with sulfur dioxide.
Oil skimming or separation, neutralization with lime, and
chemical precipitation with polymer followed by settling in a
settling basin. Sludges are then dewatered in vacuum filters.'
An additional filtration system is employed to provide further
reduction in the levels of toxic metal pollutants.
130
-------
B. PSES Alternative No. 2
Acidification followed by chemical reduction with sulfur dioxide;
followed by oil skimming or separation. Chemical precipiation
with polymer followed by setting in a setting basin. Sludges are
dewatered in vacuum filters. Sulfide is added in a reaction
tank followed by an additional filtration system.
Hydride
A.	PSES Alternative No. 1
Chemical oxidation with chlorine, neutralization with acid and
chemical precipitation with polymer followed by settling in a
settling basin. Sludges are dewatered in vacuum filter. An
additional filtration system is employed to provide further
reduction in levels of toxic metal pollutants.
B.	PSES Alternative No. 1
Chemical oxidation with chlorine, neutralization	and chemical
precipitation followed by settling in a settling	basin, sludges
are dewatered in vacuum filters. Sulfide is added	in a reaction
tank followed by an additional filtration system.
Figures XIII-1 through XIII-3 illustrate the model pretreatment
systems for existing sources for kolene and hydride operations, and
Tables XIII-1 and XIII- 2 present the respective PSES standards.
New Sources
The model pretreatment systems for new sources are identical to the
corresponding model PSES systems outlined above. However, the
discharge flows are reduced to the best demonstrated level noted in
Section XII for NSPS. Figures XIII-4 through XIII-6 illustrate the
pretreatment system for new sources for kolene and hydride operations,
and Tables XIII-3 and XIII-4 present the respective PSNS standards.
Flow Rates
A summary of the flow rates considered for PSES and PSNS is presented
below.
131
-------
Kolene
Hydride
PSES 3 20 gal/ton
PSNS 200 gal/ton
100 gal/ton
50 gal/ton
Selection of Pretreatment Alternatives
The Agency selected pretreatment Alternative No. 1 as the PSES, model
treatment system for both kolene and hydride operations. PSES
Alternative No. 1 and PSNS Alternative No. 1 were selected for kolene
operations for the same reason noted in Section XII for the selection
of the NSPS Alternative for kolene operations. PSES Alternative No. 1
and PSNS Alternative No. 1 were selected for hydride operations for
the same reasons noted in Section X regarding the selection of a BAT
alternative.
132
-------
TABLE XIII-1
PRETREATMENT EFFLUENT STANDARDS FOR EXISTING SOURCES
SCALE REMOVAL SUBCATEGORY - KOLENE
PSES Alternative 1*
PSES Alternative 2
Discharge Flow
(Gal/Ton)
Chromium
(Total)
Ave.
Max.
Concentration
Basis (mg/1)
320
0.10
0.30
Effluent
Standards
(kg/kkg)
0.00013
0.00039
Concentration
Basis (mg/1)
320
0.10
0.30
Effluent
Standards
(kg/kkg)
0.00013
0.00039
* Selected PSES alternative,
133
-------
TABLE XII1-2
PRETREATMENT EFFLUENT STANDARDS FOR EXISTING SOURCES
SCALE REMOVAL SUBCATEGORY - HYDRIDE
PSES Alternative 1*
Discharge Flow
Flow (Gal/Ton)
Chromium (Total)
Cyanide (Total)
Lead (Total)
Ave.
Max.
Ave.
Max.
Ave.
Max.
Concentration
Basis (mg/1)
100
0.10
0.30
0.25
0.75
0.10
0.30
Effluent
Standards
(kg/kkg)
0.000042
0.000013
0.00010
0.00030
0.000042
0.00013
PSES Alternative 2	
Effluent
Concentration
Basis (mg/1)
100
0.10
0.30
0.25
0.75
0.10
0.30
Standards
(kg/kkg)
0.000042
0.000013
0.00010
0.00030
0.000042
0.000013
*: Selected PSES Alternative.
134
-------
TABLE XIII-3
PRETREATMENT EFFLUENT STANDARDS FOR NEW SOURCES
SCALE REMOVAL SUBCATEGORY - KOLENE
PSNS Alternative 1*
PSNS Alternative 2
Discharge Flow
(Gal/Ton)
Chromium (Total)
Ave.
Max.
Concentration
Basis (mg/1)
200
0.10
0.30
Effluent
Standards
(kg/kkg)
0.000084
0.00025
Concentration
Basis (mg/1)
200
0.10
0.30
Effluent
Standards
(kg/kkg)
0.000084
0.00025
* Selected PSNS alternative.
135
-------
TABLE XIII-4
PRETREATMENT EFFLUENT STANDARDS FOR NEW SOURCES
SCALE REMOVAL SUBCATEGORY - HYDRIDE
PSNS Alternative 1*
PSNS Alternative 2
Discharge Flow
(Gal/Ton)
Chromium (Total)
Cyanide (Total)
Lead (Total)
Ave.
Max.
Ave.
Max.
Ave.
Max.
Concentration
Basis (mg/1)
50
0.10
0.30
0.25
0. 75
0.10
0.30
Effluent
Standards
(kg/kkg)
0.000021
0.000063
0.000052
0.00016
0.000021
0.000063
Concentration
Basis (mg/1)
50
0.10
0.30
0.25
0.75
0.10
0.30
Effluent
Standards
(kg/kkg)
0.000021
0.000063
0.000052
0.00016
0.000021
0.000063
*: Selected PSNS alternative.
136
-------
| ACIO|
| LIME
POLYMER
SULFUR
DIOXIDE
Dtschorge Flow Allowance: 320 OPT
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
PSES MODEL-ALTERNATIVE I
Own. 6/17/80
figure xn-1
-------
POLYMER
jACIDl
Ok)
1
[ojQ
0
C*0
CD
SETTLING
BASIN
VACUUM
FILTER
I
SOLIDS
TO
DISPOSAL
Discharge Flow Allowance 320 QPT
SULFIDE
FILTER
REACTION TANK
ENVIRONMENTAL PROTECTION A6ENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
PSES MODEL-ALTERNATIVE 2
Dwn.717/80
FIGURE an-2
-------
u>
10
[ACID I
SETTLING
n. BASIN .
CHLORINE
POLYMER
VACUUM
FILTER
SOLIDS
TO
DISPOSAL
DISCHARGE FLOW ALLOWANCE: 100 GPT
PSES-I

FILTER



PSES-2
SULFIDE

FILTER
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDRIDE SCALE REMOVAL
P3ES ALTERNATIVES ia2
Own. 6/17/80
FIGURE znr-3
-------
LIME
ACID
OIL
POLYMER
SULFUR
DIOXIDE
O
SETTLING
BASIN
VACUUM
FILTER
T
SOLIDS
TO
DISPOSAL
Discharge Flow Allowance: 200 GPT
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
PSNS MODEL-ALTERNATIVE
Own. 6/18/80
FIGURE Xm-4
-------
POLYMER
Discharge Flow Allowance. 200 0PT
SETTLING
BASIN
VACUUM
FILTER
I
SOLIDS
TO
DISPOSAL
¦SULFIDE
FILTER
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
KOLENE SCALE REMOVAL
PSNS MODEL-ALTERNATIVE 2
Dwn.717/80
FIGURE m-5
-------
ACID
SETTLING
^ BASIN „
SOLIDS
TO
DISPOSAL
POLYMER
CHLORINE
VACUUM
FILTER
Discharge Flow Allowance: 50 GPT
PSNS-I
FILTER
PSNS-2
-SULFIDE
FILTER
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDRIDE SCALE REMOVAL
PSNS MODEL-ALTERNATIVES 182
Own. 6/18/80
FIGURE 3ffl:-6
-------
ACID PICKLING SUBCATEGORY
SECTION I
PREFACE
The USEPA is proposing effluent limitations guidelines and standards
for the steel industry. The proposed regulation contains effluent
limitations guidelines for best practicable control technology
currently available (BPT), best conventional pollutant control
technology (BCT), and best available technology economically
achievable (BAT) as well as pretreatment standards for new and
existing sources (PSNS and PSES) and new source performance standards
(NSPS), under Sections 301, 304, 306, 307 and 501 of the Clean Water
Act.
This part of the Development Document highlights the technical aspects
of EPA's study of the Acid Pickling Subcategory of the Iron and Steel
Industry. Volume I of the Development Document discusses issues
pertaining to the industry in general, while other volumes relate to
the remaining subcategories of the industry.
143
-------
ACID PICKLING SUBCATEGORY
SECTION II
CONCLUSIONS
This volume highlights the technical aspects of EPA's study of the
Acid Pickling Subcategory of the Iron and Steel Manufacturing
Category.
Based upon this current study and a review of previous studies, the
Agency has reached the following conclusions.
1.	The Agency has combined all acid pickling operations into one
subcategory. The three subdivisions of the subcategory
sulfuric, hydrochloric, and combination - reflect significant
differences in wastewater volume. Further segmentation of these
subdivisions reflects differences in production processes.
2.	The Agency is proposing BPT limitations for the acid pickling
subcategory which are identical to those promulgated in March
1976. However, additional BPT limitations are being proposed for
batch sulfuric acid neutralization operations. In the March 1976
regulation, the BPT limitation for all batch sulfuric operations
was zero discharge. Reanalysis of the data for this segment
indicates that batch neutralization and batch acid recovery
operations should be limited separately. The proposed BPT
limitations are well demonstrated throughout the industry.
3.	The proposed BAT, NSPS, PSES, and PSNS limitations and standards
are based upon model plant flow rates (applied and discharge)
determined from the expanded data base which the Agency obtained
as part of this study. While, in some cases, these model flow
rates are different from those used to develop the limitations
promulgated in 1976, they are more representative of the
industry. Thus, the Agency believes industry-wide costs and
effluent limitations based upon these flow data are more accurate
and appropriate.
4.	Sampling and analysis of acid pickling wastewaters revealed
significant concentrations of conventional and toxic metal
pollutants. In addition, toxic organic pollutants were found at
low levels in some acid pickling wastewaters. The Agency
estimates that the following pollution control benefits will
result from compliance with the proposed BPT and BAT limitations.
145
-------
Pollutant
Flow, MGD
TSS
Oil and Grease
Toxic Metals
Toxic Organics
Dissolved Iron
Fluoride
Effluent Discharges (Tons/Year
Raw Waste
172.7
36,211
5, 003
31,918
4.6
544,989
29,345
Proposed BPT
69. 2
819
850
86 . 1
1 . 7
85.0
257
Proposed BAT
15,
551
141
15.
0,
1 8 ,
80,
0
Based upon pollution control facilities in place as of January 1,
1978, the Agency estimates the industry will incur the following
costs in complying with the proposed limitations.
Treatment
Leve1	
BPT
BAT
TOTAL
Costs (Millions of July 1, 1978 Dollars)
Total
309.0
6.16
315.16
Investment
In Place
138.5
138.5
Required
170.5
6.16
176.66
Total
Annual
67. 96
8. 57
76. 53
NOTE: PSES costs are included in those for BPT and BAT.
The Agency evaluated the "cost/reasonableness" of controlling the
conventional pollutants, TSS, oil and grease, and pH. The BCT
model treatment systems, for the hydrochloric acid regeneration
and continuous neutralization segments, have control costs less
than the costs experienced by publicly owned treatment works
(POTWs). Therefore, EPA is proposing BCT limitations for TSS and
oil and grease based upon the application of the BCT model
treatment systems for these two segments of the acid pickling
subcategory. In the sulfuric and combination acid subdivisions
and in the batch neutralization segment of the hydrochloric acid
subdivision, BCT limitations are being proposed at the BPT level,
since the respective BCT model treatment alternatives did not
pass the BCT Cost Test.
7.	NSPS are proposed for acid pickling operations which are
constructed after the proposal of these standards. The proposed
standards are based upon the same or similar technologies used
for BPT and BAT in all subdivisions except for sulfuric acid
pickling. The proposed standard (zero discharge) for these
operations is based upon the acid recovery mode of operation.
8.	EPA is proposing pretreatment standards for new (PSNS) and
existing (PSES) sources which limit the amount of toxic and other
pollutants discharged to POTWs. These standards are intended to
minimize the impact from pollutants which would interfere with,
pass through, or otherwise be incompatible with POTW operations.
These proposed standards are based upon the same or similar
technologies used for BPT and BAT.
146
-------
9.	With regard to the "remand issues," the Agency concludes that the
age of a plant has no significant effect upon the ease or cost of
retrofitting pollution control equipment. Neither relaxed
limitations for older plants nor retrofit cost allowances are
proposed for acid pickling operations. There are no significant
adverse air pollution, solid waste disposal, or water consumption
impacts associated with the proposed limitations and standards.
10.	The proposed effluent limitations and standards are based upon
flow (gal/ton) and pollutant concentrations to yield mass
limitations in kg/kkg (lb/1000 lb) of steel pickled. The Agency
considered using product surface area pickled as a basis for the
limitations and standards, but such data are not readily
available. Hence, the proposed limitations and standards are
based upon production tonnage.
11.	The Agency derived the fume scrubber wasteload contributions on a
water flow per ton of pickled product basis. Since the scrubbers
are open-container air cleaning devices, dependent on the amount
of gases treated, this basis may not be the most representative
for all pickling operations. However, the Agency believes that
the per unit weight of pickled product flow basis is the most
readily acceptable and least cumbersome method of flow
determination for this waste source.
12.	Although the Agency found a significant number of toxic metal
pollutants in acid pickling wastewaters, it is proposing BAT,
NSPS, PSES, and PSNS limitations and standards for three toxic
metals. These pollutants serve as "indicator" pollutants for
those toxic metals which are not directly limited. Chromium,
lead, and zinc are used as indicator pollutants for the sulfuric
and hydrochloric acid subdivisions. Chromium, copper, and nickel
have been selected for the combination acid subdivision.
13.	The Agency used the best demonstrated flows to develop NSPS and
PSNS for the combination acid pickling subdivision. However, the
Agency relied upon average of the best flows in the BAT, BCT, and
PSES model treatment systems for combination acid pickling. The
average of the best flows were also used in the BAT, BCT, NSPS,
PSES, and PSNS model treatment systems for sulfuric acid pickling
and hydrochloric acid pickling. The Agency is soliciting
comments on whether the best demonstrated flows should be used to
develop BAT, BCT, NSPS, PSES, and PSNS effluent limitations and
standards for all pickling subdivisions.
14.	Table II-l presents the treatment model flow and effluent quality
data used to develop the proposed BPT effluent limitations for
the acid pickling subcategory, and Table I1-2 presents these
proposed limitations. Table I1-3 presents the treatment model
flow and effluent quality data used to develop the proposed BAT
and BCT effluent limitations and the proposed NSPS, PSES, and
PSNS for the acid pickling subcategory. Table I1-4 presents
these proposed limitations and standards.
147
-------
TABLE II-l
BPT TREAT*NT MODEL FLOWS AND EFFLUENT QUALITY
ACID PICKLING SUBCATEGORY
Subdivision
Sulfuric Acid
Pollutant
Flew, gal/ton
TSS
Oil & Greasev
Iron, Dissolved
pH, Units
-<2>
Monthly Average Concentrations
(I)
Batch
Acid Recovery
Batch
Neutralisation
360
50
10
1.0
6.0 to 9.0
Continuous
Acid Recovery
Continuous
Neutralisation
With Spent
Pickle Liquor
250
50
10
1.0
6.0 to 9.0
Continuous
Neutralization
Without Spent
Pickle Liquor
225
50
10
1.0
6.0 to 9.0
Batch
Neutralisation
With Scrubber
Batch
Neutralisation
Without Scrubber
Continuous
Neutralisation
With Scrubber
Continuous
Neutralisation
Without Scrubber
Continuous
Acid
Regeneration
With Scrubber
Continuous
Acid
Regeneration
Without Scrubber
Hydrochloric
Acid
gal/ton
(2)
Flow
TSS
Oil & Grease^
Iron, Dissolved
pH, Units
280
50
10
1.0
6.0 to 9.0
230
50
10
1.0
6.0 to 9.0
280
50
10
1.0
6.0 to 9.0
230
50
10
1.0
6.0 to 9.0
450
50
10
1.0
6.0 to 9.0
400
50
10
1.0
6.0 to 9.0
Batch-Other	Batch-Pipe & Tube Continuous
Combination Flow, gal/ton	200	700	1000
Acid TSS ( .	25	25	25
Oil k Crease	10	10	10
119 Chroaiua, Total	0.5	0.5	0.5
Iron, Dissolved	1.0	1.0	1.0
124 Nickel, Total	0.25	0.25	0.25
Fluoride	15	15	15
pH, Units	6.0 to 9.0	6.0 to 9.0	6.0 to 9.0
(1)	Daily aiaxiaua concentrations are three tines the aonthly average concentrations. Also, concentrations are expressed as ag/1 unless
otherwise noted.
(2)	Oil and Grease is limited only when pickling wastewater is treated in combination with cold rolling wastewaters.
(3)	Fluoride is liaited only at those coabination acid pickling operations that use hydrofluoric acid.
-------
TABLE II-2
PROPOSED BPT EFFLUENT
LIMITATIONS-ACID PICKLING SUBCATEGORY
Subdivision
Sulfuric Acid
Pollutanc
(2)
TSS
0&GV
Iron, Dissolved
pH, Units
Batch and
Continuous
Acid Recovery
0
0
0
Effluent Limitations (kg/kkg of Product)
(1)
Batch
NeutTalization
0.0751
0.0150
0.00150
6.0 to 9.0
Continuous
Neutralization
with Spent
Pickle Liquor
0.0521
0.0104
0.00104
6.0 to 9.0
Continuous
Neutralization
without Spent
Pickle Liquor
0.0469
0.00938
0.000938
6.0 to 9.0
Batch
Neutralization
with Scrubber
Batch
Neutralization
without Scrubber
Continuous
Neutralization
with Scrubber
Continuous
Neutralization
without Scrubber
Continuous
Acid
Regeneration
with Scrubber
Continuous
Acid
Regeneration
without Scrubber
H1
ID
Hydrochloric
Acid
TSS( >
0SG
Iron, Dissolved
pH, Units
0.0584
0.0117
0.00117
6.0 to 9.0
0.0480
0.00960
0.000960
6.0 to 9.0
0.0584
0.0117
0.00117
6.0 to 9.0
0.0480
0.00960
0.000960
6.0 to 9.0
0.0938
0.0187
0.00187
6.0 to 9.0
0.0834
0.0166
0. 00166
6.0 to 9.0
Combination
Acid
TSS( )
o«r
119 Chromiui, Total
Iron, Dissolved
124 Nickel, Total
Fluoride
pH, Units
Batch-Other
0.0209
0.00834
0.000417
0.000834
0.000209
0.0125
6.0 to 9.0
Batch
Pipe & Tube
0.0730
0.0292
0.00146
0.00292
0.000730
0.0438
6.0 to 9.0
Continuous
0.104
0.0417
0.00209
0.00417
0.00104
0.0626
6.0 to 9.0
(1)	Daily maxima limitations are three tines the monthly average limitations.
(2)	Oil & Grease is limited only when pickling wastewater is treated in combination with cold rolling wastewater.
(3)	Fluoride is limited only at those combination acid pickling operations that use hydrofluoric acid.
-------
TABLE I1-3
TREATMENT MODEL FLOWS AND EFFLUENT
QUALITY-ACID PICKLING SUBCATEGORY
Subdivision
Sulfuric Acid
Pollutant*
BAT
Monthly Average Concentration*
<1>
BCT
USPS
PSES
PSNS
A. Batch & Continuous
Acid Recovery
b. Batch Neutralization
c. Continuout
Neutralization
Hydrochloric Acid
Flow, gal/ton
Flow, gal/ton	70
ISS(3)
OiClJ;
119 ChroBiun, Total	0.10
122 Lead	0.10
128 Zinc, Total	0.10
pH, Unite
Flow, gel/ton	55
TSS
0&G
119 Chroaium, Total	0.10
122 Lead	0.10
128 Zinc, Total	0.10
pH, Unite
360
50
10
6.0 to 9.0
250
50
10
6.0 to 9.0
(2)
(2)
70
0.10
0.10
0.10
55
0.10
0.10
0.10
(2)
(2)
a. Continuout Acid
Regeneration
Flow, gal/ton
™(3>
04G
119 Chroaiua, Total
122 Laad
128 Zinc, Total
pH, Unite
70
0.10
0.10
0.10
70
15
10*
6.0 to 9.0
70
30
10
0.10
0.10
0.10
6.0 to 9.0
70
0.10
0.10
0.10
70
0.10
0.10
0.10
150
-------
TABLE II-3
TREATMENT MODEL FLOUS AND EFFLUENT
QUALITY-ACID PICKLING SUBCATEGORY
PAGE 2	
Subdivision
b. Batch Neutralization
c. Continuous
Neutralization
Combination Acid
a. Batch
b. Continuous
Pollutant!
Flow, gal/ton
TSSC3)
06G
119 Chromium. Total
122 Lead
128 Zinc, Total
pH, Unit*
Flow, gal/ton
TSS(3>
0&GlJ'
119 Chroaiun, Total
122 Lead
128 Zinc, Total
pB, QniCI
Flow, gal/ton
TSS
04GlJ'
119	Chroaiua, Total
120	Copper, Total
124 Nickel, Total
Fluoride
pH, Unit*
Flow, gal/eon
TSS.
04G
119	Chroaiua, Total
120	Copper, Total
124 Nickel, Total
Fluoride
pH, Unit*
BAT
Monthly Average Concentrations
(1)
BCT
USPS
PSES
PSNS
90
0.10
0.10
0.10
55
0.10
0.10
0.10
105
0.10
0.10
0.20
IS
335
0.10
0.10
0.20
15
560
90

90
90
50
30

-
-
10
10

-
-
-
0.10

0.10
0.10
-
0.10

0.10
0.10
-
0.10

0.10
0.10
6.0 to 9.0
6.0 to
9.0
-
-
55
55

55
55
15
30

-
-
10*
10

-
-
-
0.10

0.10
0.10
-
0.10

0.10
0.10
-
0.10

0.10
0.10
6.0 to 9.0
6.0 to
9.0


(4)
45

105
45
25
30

-
-
10
10

-
-
-
0.10

0.10
0.10
-
0.10

0.10
0.10
-
0.20

0.20
0.20
-
15

-
-
6.0 to 9.0
O
u
O
<0
9.0
-
-
1000
90

333
90
25
30

-
-
10
10

-
-
-
0.10

0.10
0.10
-
0.10

0.10
0.10
-
0.20

0.20
0.20
-
15

-
-
6.0 to 9.0
6.0 to
9.0
-
-
151
-------
TABLE I1-3
TREATMENT MODEL FLOWS AND EFFLUENT
QUALITY-ACID PICKLING SUBCATEGORY
PAGE 3		
(l) Daily maximum concentrations are based upon the monthly average concentrations multiplied by the
following factors:
Factor
2.67
and combination batch and continuous
neutralisation)	3*00
O&G and TSS (NSPS)	2.00
Chromium, Lead and Zinc	3.00
Nickel	2.23
Fluoride	3.00
Also all concentrations are expressed as mg/1 unless otherwise noted.
(2)	No NSPS or PSNS are being proposed for this sefpsent. All new source sulfuric operations will use
acid recovery systems.
(3)	Oil & Grease is limited only when pickling wastewater is treated in combination with cold rolling
wastewater.
(4)	Flow for batch-other operations equals 200 gal/ton. Flow for batch-pipe and tube operations equals
700 gal/ton.
* Daily maximum concentration only, as shown.
Pollutants
TSS (BCT for HC1 continuous
acid regeneration and HCl
continuous neutralization)
O&G and TSS (H.SO^-batch
& continuous neutralization,
HCl batch neutralisation,
152
-------
TABLE H-4
PROPOSED EFFLUENT LIMITATIONS
AND 6TAMDARDS-ACIP PICKLING SUBCATEGORY
Subdivision
1. Sulfuric Acid
Pollutants
Effluent Limitations and Standards (kg/kltg of Product)^
BAT	BCT	NSPS	PSES	PSNS
a.	Batch & Continuous
Acid Recovery
b.	Batch-Neutralization
c. Continuoua
Neutralization
2. Hydrochloric Acid
a. Continuoua Acid
Regeneration
b. Batch-Neutralisation
NA
TS8(3>
O&G
119 Chrooium, Total
1ZZ Lead
1Z8 Zinc, Total
pH, Units
TSS(3)
06C
119 Chroniua, Total
122 Lead
128 Zinc, Total
pH, Units
119 Chroniua, .Total
122 Lead
128 Zinc, Total
pH, Unite
WS(3)
OM
119 Chroniua, Total
122 Lead
128 Zinc, Total
pH, Unit!
ZERO DISCHARGE OF PROCESS GENERATED POLLUTANTS
-
7506
(2)
-
(2)
-
1501

-

2.92
-

2.92

2.92
-

2.92

2.92
-

2.92

-
6.0 to 9.0

-

-
5210
(2)

(2)
-
1040

-

2.30
-

2.30

2.30
-

2.30

2.30
-

2.30

—
6.0 to 9.0



_
438
876
.
.
-
292*
292
-
-
2.92
-
2.92
2.92
2.92
2.92
-
2.92
2.92
2.92
2.92
-
2.92
2.92
2.92
-
6.0 to 9.0
6.0 to 9.0
-
-
-
5840
1130
•
.
-
1170
375
-
-
3.75
-
3.75
3.75
3.75
3.75
-
3.75
3.75
3.75
3.75
-
3.75
3.75
3.75
-
6.0 to 9.0
6.0 to 9.0
-
-
153
-------
TABLE 1X-4
PROPOSED EFFLUENT LIMITATIONS AMD
STANDARDS-ACID PICKLING SUBCATEGORY
PAGE 2	
Subdivision
Pollutant*
Effluent Limitations and Standards (kg/kkg of Product)^*^
BAT	BCT	NSPS	PSES	PSNS
c. Continuous
Neutralization
3. Combination Acid
A. B«tch-N«utralie*Cioa
b« Continuous
Neutralization
TSS(3)
O&G
119 Chromium, Total
122 lud
128 Zinc, local
pH, Unit*
TSS(3)
04G
119	Chromium, Total
120	Copper, Total
124 Nickel, Total
Fluoride
pB, Units
TSS(
119	Chromium, Total
120	Copper, Total
124 Nickel, Total
Fluoride
pH, Units
2.29
2.29
2.29
4.36
4.38
8.76
657
14.4
14.4
28.8
2160
344
229*
6.0 to 9.0
688
229
2.29
2.29
2.29
6.0 to 9.0
2090(7300)^
834(2920>W
6.0 to 9.0
10400
4170
2.29
2.29
2.29
2.29
2.29
2.29
563
-
-
188
-
-
1.88
4.38
1.88
1.88
4.38
1.88
3.75
8.76
3.75
281
-
-
6.0 to 9.0
-
-
1130
-
_
375
-
-
3.75
14.4
3.75
3.75
14.4
3.75
7.51
28.8
7.51
563
-
-
6.0 to 9.0
-
-
154
-------
TABLE II-4
PROPOSED EFFLUENT LIMITATIONS AND
STANDARDS-ACID PICKLING SUBCATEGORY
PACE 3	
(1)	The proposed limitations and standards have been multiplied by 10 to obtain the values presented
in this table. Also, daily maximum limitations and standards are based upon the monthly average
values multiplied by the following faccors:
Pollutants	Factor
TSS (SCT for KC1 eont. acid
regeneration and HC1 continuous
neutralisation.)	2.67
0&G and TSS (H-SO.-bateh and
continuous neutralization, HC1 batch
neutralization, and combination
batch and continuous neutralization)	3.00
O&G and TSS (NSPS)	2.00
Chromium, Lead and Zinc	3.00
Nickel	2.25
Fluoride	3.00
(2)	Ho NSPS or PSNS are being proposed for this segment. All ncu source sulfuric operations will
use acid recovery systems.
(3)	Oil and grease is limited only when pickling wastewater is treated in combination with cold rolling
wastewater.
(4)	Value* listed are for betch-othar operations. Values listed in parentheses are the SCT limits for
batch-pipe and tube operations.
*; Daily maximum limitation only, aa shown.
155
-------
ACID PICKLING SUBCATEGORY
SECTION III
INTRODUCTION
General Discussion
Acid pickling is the steel finishing process in which steel products
are immersed in heated acid solutions to remove surface scale. The
Agency has divided the acid pickling subcategory into three
subdivisions which are based upon the type of pickling acid solutions
used in the process.
1.	Sulfuric Acid Pickling
2.	Hydrochloric Acid Pickling
3.	Combination Acid Pickling
Wastewaters are commonly generated by three sources in the pickling
operation. The largest source is the rinsewater used to clean the
acid solution from the product after it has been immersed in the
pickling solution. The second source is the spent pickling acid
(liquor) which is used to treat the steel product. The spent pickle
liquor is a small volume waste, containing high concentrations of iron
and toxic metal pollutants, which is discharged after it becomes
contaminated by use. Wastewater from wet fume hood scrubbers is the
third source. However, not all plants have wet fume hood scrubbers.
For hydrochloric acid regeneration plants, absorber vent scrubber
wastewater is a source of contamination similar in nature to that of
pickle rinsewaters.
Those wastewaters require treatment prior to discharge to a receiving
stream or to a POTW. This report discusses the wastewater treatment
systems presently used at pickling operations and the proposed
effluent limitations and standards for those discharges.
Data Base
1. Sulfuric Acid Pickling
The effluent limitations originally promulgated in 1976 for
sulfuric acid pickling operations were primarily based upon data
obtained through field sampling at seven continuous and eight
batch sulfuric acid pickling operations. This present study
included field sampling at three continuous and seven batch
sulfuric acid operations, as well as an overall review of the
wastewater treatment systems used at all sulfuric acid pickling
operations surveyed by the DCPs. The Agency received responses
to the DCPs for plants which comprise about 85% of the annual
capacity. A summary of all sulfuric pickling operations
responding to the DCPs is presented in Table 111—1.
157
-------
The Agency, after reviewing and analyzing the DCP responses made
by the industry, forwarded detailed DCPs (D-DCPs) to selected
pickling operations. Those D-DCPs requested cost and monitoring
data from one continuous and 17 batch operations. The operations
included three batch plants which were sampled during the initial
survey.
The expanded data base is presented in Tables 111 — 4 and III-5.
The field sampling covered 13% of the continuous sulfuric acid
pickling plants in operation, which have 21% of the annual
capacity of the industry. The Agency also sampled 9% of the
batch pickling operations, which have 13% of the annual capacity
of the industry.
2.	Hydrochloric Acid Pickling
The effluent limitations originally promulgated in 1976 for
hydrochloric acid pickling operations were primarily based upon
data obtained through field sampling at fourteen operations.
During this study, the Agency conducted field sampling at two of
the same plants and at seven additional operations. In addition,
the Agency reviewed wastewater treatment systems used at all
plants surveyed by DCPs. It also sent D-DCPs to thirteen plants
(two of which had been previously sampled) requesting cost and
analytical information comprising 13% of the industry capacity.
The expanded data base is presented in Table II1-6. The field
sampling covered about 21% of the annual pickling capacity.
Table II1-2 provides a general summary of available data on
hydrochloric acid pickling operations.
3.	Combination Acid Pickling
The originally promulgated limitations for the combination acid
pickling subcategory were primarily based upon data obtained
through field sampling at eight operations. During this current
study, the Agency sampled six additional plants to increase the
existing data base. The Agency conducted sampling at one plant
twice, and the data collected during each visit are presented in
this report. However, only the data gathered during the later
visit have been used in establishing the proposed limitations.
The updated data base for the combination acid pickling
subdivision is shown in Tables III-7 and II1—8.
The Agency received responses to the DCPs from approximately 85%
of the active combination acid pickling operations. Sixty-six
batch and sixty-three continuous operations provided information
in response to the DCPs. The data received from these plants are
summarized in Table II1-3.
The Agency sent D-DCPs to selected combination acid pickling
operations to gather information regarding plant operations and
long-term effluent quality and cost information for wastewater
treatment systems. The Agency received responses from five
combination acid pickling operations.
158
-------
Table III-9 summarizes the pickling operations sampled for this
study and describes those operations.
Description of Pickling Operations
During the forming and finishing operations, the steel product is
exposed to the atmosphere, which causes oxide scale to form on its
surface. This scale must be removed prior to further processing, as
proper surface preparation is the most important requirement for the
satisfactory application of protective coatings to steel, as well as
for cold rolling. Without a properly cleaned surface, even the
coating will fail to adhere. A variety of cleaning methods are used
to insure adequate surface preparation for subsequent coating. In
addition, the steel surface must also be cleaned (by pickling) at
various stages during the production process to insure that oxides
which form on the surface are not worked into the finished product
causing marring, staining, or other surface imperfections.
The traditional method of removing scale is called "acid pickling," or
simply "pickling." Pickling is the process during which surface
oxides (scale) are removed chemically from the surface of the steel
product by immersing it in a heated acid solution. While pickling is
only one of several methods for removing undesirable oxides from the
steel surface, it is the most widely used in the steel industry
because of its comparatively low operating cost and ease of operation.
Carbon steel pickling is almost universally accomplished by using
either hydrochloric acid or sulfuric acid solutions. Pickling
operations for specialty steels include more than one acid.
Typically, nitric and hydrofluoric acids are used together. The acid
combinations vary with the type of material to be pickled. The bath
temperature, use of inhibitors, and agitation also vary depending upon
the material to be pickled. Pickling is accomplished in either batch
or continuous operations.
Temperature, agitation, and acid and iron concentration are important
operating factors in the pickling process.
Temperature
The temperature of the acid bath in which the product is pickled is
critical because it dramatically affects the rate of reaction.
However, the method of heating the acid batch is also important. If
the bath is heated by injecting steam directly into it, it becomes
diluted as the steam condenses into water. To avoid dilution,
internal or external heat exchangers are usually employed. These
devices transfer heat from steam indirectly to the acid batlv thus
avoiding dilution of the bath and reducing the volume of spent acid
requiring treatment or disposal.
Agitation
Agitation is probably the most ignored aid to good pickling. The
speed of the pickling process can be increased significantly by
properly agitating the acid bath, or moving the steel during the
pickling operation. The latter may be accomplished by raising and
159
-------
lowering the bundle of steel in the bath, or by having a conveyor
system keep it moving while passing through the bath. Agitating the
acid bath is a more complex operation.
One method of agitation is a custom designed, air-operated, mechanical
agitation system. An added benefit of this system is that the
evaporation (caused by air agitation) concentrates, rather than
dilutes, the acid bath. The induced evaporation requires that
pickling acids be added to mantain optimum tank level. The acid mists
caused by the agitation system can be collected in a suitable exhaust
system and returned to the pickle tank for reuse.
Acid and Iron Concentration
The concentrations of acid and ferrous salts in the bath are related
directly to the rate of reaction and, subsequently, to the rate of
pickling. Most pickling operations do not have facilities to maintain
consistent acid strengths. As products are processed over a period of
time, the free acid content of the bath progressively diminishes,
which in turn results in increasingly longer pickling times. As the
strength of the acid drops below a certain level, the spent pickle
liquor is dumped. The tanks are replenished with fresh acid and the
cycle begins anew. On the other hand, technology is available to make
such operations more efficient. For example, acid recovery may be
practiced at sulfuric acitf pickle lines. In such an operation, the
acid solution is continually bled from the bath as fresh acid is added
to maintain the bath at a constant strength. The waste acid is then
regenerated and fed back to the bath. The by-product from the acid
recovery process is ferrous sulfate crystals. These crystals can be
sold to pigment manufacturers. They can also be used as fertilizer
supplements or coagulants for water and wastewater treatment.
Type of Picklinq
A.	Batch Pickling
Large, open tanks which vary widely in size, are used for batch
pickling operations. The tanks are used principally for rods,
bars, billets, plate, sheet, strip, wire, and tubing. The tanks
are generally rubber lined and brick sheathed and hold large
volumes of heated acid solution. After continual use, the free
acid content decreases and iron builds up in the acid solution
due to the scale removed. When the pickling process is impaired,
the acid solution is considered spent and is dumped as a batch.
Flow schematics for carbon and specialty batch pickling
operations are shown in Figures III-l and II1-2.
B.	Continuous Pickling
Continuous pickling operations principally use horizontal
pickling tanks. In a few cases, however, vertical spray tanks
are employed. A fresh acid solution is added to the last tank
section and cascades through a series of tanks to an overflow
located in the first tank. The acid solution flows in the
direction opposite to that in which the steel product travels.
160
-------
There are usually at least two acid tanks used in continuous
pickling, with each one divided into four or five compartments.
The fresh acid solution is added to the last tank section and
cascades through the tank to an overflow located in the first
section. Acid flow is opposite to the direction of product
travel. Flow schematics for carbon and specialty continuous acid
pickling operations are shown in Figures III-3 and III-4.
Description of Wastewater Sources
There are three process steps which generate most of the wastewaters
associated with the pickling process.
1.	Pickling - immersion in hot acid solution. The waste is the
spent solution.
2.	Rinsing - removal of pickle liquor from the surface of the
product, using water. The contaminated rinsewater is discharged.
3.	Fume Scrubbing - control of acid vapors and mists by scrubbing
the air and other vapors removed from the immediate area of the
pickling operations by means of an exhaust system. The
contaminated scrubber water is discharged.
Pickling
As discussed previously, the strength of the pickle liquor
progressively diminishes as more and more products are pickled. When
the strength drops below a certain level, the spent pickle liquor is
discarded. Contract hauling is a common disposal method practiced at
many plants. Alternatively, the spent pickle liquor may be treated
along with other wastewaters from the pickling operation, or it may be
recovered (sulfuric and hydrochloric acid) for reuse in the pickling
operation. Spent sulfuric or hydrochloric acid may also be used as a
coagulant in wastewater treatment.
Rinsing
The rinse operation may vary from a one-step dunk or spraying to more
sophisticated multi-stage rinsing with still or running tanks, cascade
rinsing, and countercurrent sprays. The primary purpose of the rinse
is to remove contaminants from the steel product prior to the next
step in the finishing process. In a single step rinsing operation,
the tanks may be replenished and dumped on a periodic basis or fresh
water may be continually added at the end of the tank while wastewater
discharges at the opposite end. Where rinsing is performed in a
series of tanks, the first rinse removes the bulk of the contaminants
from the product, which results in a highly contaminated waste stream.
The subsequent rinse tanks are progressively cleaner. The product
emerges from the final tank £ree of contaminants. Each tank may
discharge separately. However where a series of tanks are installed,
the more common practice would be to.cascade the rinsewaters from the
final to the first tank. Fresh make-up wattor is added to the final
tank, which in turn overflows to the previous tank. The rinsewater
continues in this fashion to the first tank, from which discharge
161
-------
occurs. The volume of rinsewater from cascade rinse systems is
considerably less than the volume from conventional single tank
rinsing.
Most continuous strip pickling operations employ the traditional
approach to rinsing: flooding the strip with hundreds of gallons of
water per minute to wash away the few gallons of acid that are dragged
out of the pickling tanks. In the past, this was a practical approach
to the problem because it effectively cleaned the strip and diluted
the acid content of the rinsewater to a low concentration. The rinse
water was then usually discharged. An alternative to the traditional
method is the cascade rinse system, which is described above. The
dilution rate, from one tank section to the next, follows a geometric
progression, so that the number of stages determines how much clean
water must be fed into the system to achieve a given degree of
rinsing. For instance, a typical, large, high-speed pickle line with
a five-stage system could operate with about 20 gpm makeup. The
treatment of rinse waters at such low rates of flow becomes much
easier. The rinsewaters can be further concentrated and piped to the
waste pickle acid recovery or regeneration system, or they may be used
as makeup for the solution in the pickling tanks. Even if they are to
be treated, the treatment facilities may be sized to economically
handle these wastes, since the volume is much less than that for a
once-through rinse system.
Multi-stage spray rinsing systems can easily be incorporated into new
continuous strip pickling lines, and they can be installed in existing
lines in place of the present rinsing sections, with a minimum of
inconvenience or lost time. These systems can, and have been,
retrofitted to existing pickling operations.
Fume Scrubbing
The generation of acid fumes is prevalent in the pickling process, and
these fumes must be removed in order to provide a safe working
environment. The fumes from many existing exhaust systems ar,e
discharged to the atmosphere, causing air pollution. Either washing
or filtration may be used to remove the acid from the fumes.
Wet scrubbing systems use water to trap and flush away the acid
droplets in the fumes. This practice, however, merely trades air
pollution for water pollution because the acid has contaminated the
scrubber water and will require the same level of treatment as
rinsewaters. Accordingly, some operations use the internal recycle of
wet fume scrubber waters to minimize loads from this source. In
addition, the fume scrubber blowdown may be used as makeup of the cold
rinse sections.
Acid mist filters are specially designed synthetic fibers in a filter
box which is installed in the discharge end of the exhaust system.
This unit filters the acid droplets from the fumes and returns them to
the pickling tanks. The water vapor in the fumes is allowed to pass
through to the atmosphere. The acid mist filter controls air
pollution and simultaneously recovers acid for reuse in the pickle
tank with no discharge of wastewaters.
162
-------
Acid Recovery and Acid Regeneration
Acid recovery and regeneration are used for sulfuric acid and
hydrochloric acid, respectively. Refer to Section VII for detailed
discussions of these processes. Figures II1-5 through II1-9 in this
section illustrate some of the basic processes available at this time.
Although the Agency is unaware of any installation within the United
States, it should be noted that technology for the recovery of nitric
and hydrofluoric acids has apparently been developed. It has been
reported that such a system is successfully operating in the People's
Republic of China.
Pickling of Different Types of Steel
In Combination Acid Pickling Operations
A.	Specialty Steel Pickling
Depending upon the type of steel being processed and the surface
quality desired, different acids and acid combinations are used
in the pickling process. Most of the operations which employ
combination acid pickling are specialty steel lines. In fact,
80% of the lines using combination acid pickling process pickle
specialty steel products.
Sulfuric, hydrochloric, nitric, and hydrofluoric acids are used
in various combinations to pickle the specialty steels. At least
two types of acids are used in the combination acid pickling
process. Most operations use either sulfuric or hydrochloric
acid at the head of the pickle line to soften and loosen the
scale and then use either nitric, hydrofluoric, or a mixture of
the two acids to remove the scale loosened by the first acid
solution. The acid in the first batch is kept at a concentration
of about 10%, if sulfuric acid is used, and 15%, if hydrochloric
acid is used. In addition, the acid bath is heated to
approximately 70°C (160<>F) to increase the action of the pickling
solution. The acids in the second tank are usually kept at lower
concentrations (i.e., 4% HF, 10% HN0S), but at the same
temperature as the first bath.
B.	Carbon Steel Pickling
Several carbon steel operations use a combination acid process;
usually phosphoric acid in combination with either hydrochloric
or sulfuric acid. One operation uses nitric acid in combination
with hydrochloric acid to process wire and rods.
Even though different acid combinations are used to pickle carbon
steel, the Agency found that both the average flow rates and
wastewater characteristics are similar enough to those for
specialty steel operations to allow the development of one set of
proposed limitations. Certain allowances are provided in the
proposed limitations to cover the more significant variations
between the two types of pickling operations.
163
-------
SULFURIC A
Plant
Code
No.
Line
No.
Process
Product
Process
Mode
Capacity
(Tons/Day)
1st
Produ
0020B
01
Sheet,Specialty
Cont.
801
1954
0048B
01(a)
Bar,Wire,Rod
Batch
24 3
1944
004 ac
01(a)
Bar,Wire
Batch
180
1940
004 8D
01(a)
Bar,Wire.
Batch
90
1909

02(a)
Bar,Wire
Batch
18.6
1900
0048F
01(a)
Bar,Wire,Rod
Batch
117
1944
006OC
01(a)
Bar, B loo®, Pipe
Batch
63
1956
0060D
01
Strip,Specialty
Coat.
960
1957

02
Strip,Specialty
Cont.
120
1952

03
Strip,Specialty
Cont.
114
1959
006OG
*
*
*
*
*
006OM
01(a)
Rod,Wire
Batch
816
1970
0060S
*
*
*
*
*
0068
01(a)
Flat Bars,Strip
Batch
93.6
1934
0088A
01(a)
Bars
Batch
744
1942

02
Tubes,Specialty
Batch
243-9
1936

03(a)
Tubes
Batch
519
Unk

04(a)
Tubes, Special ty
Batch
246
1946

05
Tubes,Specialty
Batch
87
1941
0088B
*
*
*
*
*
0088D
01(a)
Bars
Batch
71 7
1952

02
Tubes,Specialty
Batch
51 -9
1969
0112
01
Billets,Specialty Batch
507
1922

02
Flats,Bars,
Batch
53.1
1928


Specialty



01UA
01(a)
Pipes
Batch
237
1929

02(a)
Plate,Sheet
Batch
792
1948

03(a)
Strip
Cont.
1692
1937

04(a)
Strip
Coot.
2496
1957

05(a)
Sheet
Cont.
1797
1945

06(a)
Sheet
Cont •
1875
1951

07(a)
Sheet
Cont.
1875
1951

08(a)
Strip
Cont.
1032
1963

09(a)
Strip
Cont.
Est 840
1966

10(a)
Strip
Cont.
Est 540
1956

11(a)
Strip
Cont.
864
1970

12(a)
Strip
Cont.
Est 540
1957

13(a)
Strip
Cont.
Est 540
1958
TABLE III-X
D PICKLING SUMMARY TABLE

Applied Flow


Discharge Flow

Di s-

(Gal Ions/ton)


(Gal Ions/con)

Treatment
charge
Rinses Scrubber
Cone.
Rinses
Scrubber
Cone.
Components
Mode
539
90
6. 4
539
90
6.4U)
VF,CR,NL,FLP,CL,
Di rect



15.5U)

5.5U)
20.0U)
CNT,OT

15
None
5. 5
None
OT, None
Hauled
58.3
None
20.0
58.3
None
NL,SL,0T
Direct
27.0
None
27.0
27.0
None
27.0
NL,VF,SL,CNT,0T
POTW
10.4
None
10.4
10.4
None
10.4
NL,VF,CNT,0T
POTW
37
None
13
37
None

VF,NL,SL,OT
POTW
Unk
None
8
Unk
None
FLP,SSP,SS,CNT,OT
Di rect
Unk
Unk
Unk
Unk
Unk
Unk
)nl,sl,cnt,ai?
Direct
Unk
Unk
5.0
Unk
Unk
5.0
Di rect
Unk
Unk
Unk
Unk
Unk
Unk
)kt )
* -*
Direct
*
a
*
*
*
2.2(1)
*
17.3
None
2.2
8. 1
None
FDSP,NL,DW,RT
POTW
*
*
~
*
*
*
it
*
769
None
70
>
None
8°1(1)
22.6(1)
OT, None
POTW
<1
None
8.1
None
0T, None
Hauled
49.2
None
22.6
0
None
(^CR, NL, FLP, CL,
Direct
(Unk)
[326]
None

M
None
,(1)
It, VF, SS, E, !
< V
Di rect
(Unk)
117
None
16.3
117
None
CNT,(Line No. j
Direct
132
None
42.1
132
None
102 Sx 03 Recycle/
((04 & 05 0T)	)
Di rect
*
¦k
*
*
*

*
*
4. 7
None
14.2
2.1
None
NL,FLP,CL,SS,VF,
Direct





¦ i . O)
Unk
CNT,0T

277.5
None
Unk
277. 5
None
E,NC,FDSP,OT
Direct
9.7
231
None
None
11.9
22.5
9. 7
231
None
None
li .9
22.5
NL ,0T
Unk
None
Unk
Unk
None
Unk
(S S , SCR, NL
Unk
None
4.5
Unk
None
4 5
)fla,flp,ae
149
Unk
17
149
Unk
17
|SL,T,CY,
136
23
14.4
136
23
14 .4
(CNT.QT
143
Unk
18
143
Unk
18
None
11.5
Unk
29.2
0
0
29.2

127
Unk
8.4
127
0
8.4
fSS,SCR,NL
338
lb. 7
27.y
338
16.7
27.9
\FLA,FLP,A£
423
520.6
30. 9
432
520.6
30.9
JsL.T.CY,
80
None
34.7
80
None
34. 7
-------
TABLE 111-I
SULFURIC ACID PICKLING SUMMARY TABLE
PACE 2		
Plant
Code
Line
Process
Process
Capaci ty
1st Year
No.
Wo.
Product
Node
(Tons/Day)
Production
0112B
01(a)
Billets
Batch
Est 240
1948
0112C
01(a)
Bars,Place,
Batch
261
1926


Auto Sections




02(a)
Square Billets
Batch
1611
1928

03(a)
Square Billets
Batch
942
1930
01120
01(a)
Black Plate
Coat.
1156.2
1966
0112F
01
Billets,Specialty Batch
588
1960

02(a)
Rod,Wire
Batch
238.8
1948
0112G
01(a)
Wire
Batch
39
1929

02(a)
Fasteners
Batch
5.25
1952
01121
01(a)
Fasteners
Batch
3.57
1955

02(a)
Bar,Rod,Plate,
Batch
146.1
1970


Washer




03(a)
Fasteners
Batch
64.8
1922

04(a)
Sluges,Couplings
Batch
44.1
1973

05(a)
Fasteners
Batch
138
1956

06(a)
Rods,Angles
Batch
16.35
1962

07(a)
Wire
Batch
282
1950
0176
01
S tr ipa-Spec i alty
Cont.
10.2
1959
01 %A
*
*
*
*
*
0240A
01
Bars,Billets,
Batch
585
1942


Specialty



0240B
01(a)
Bars,Tubes
Batch
687
1919
0240C
01(a)
Tubes
Batch
102
1973
02484
01
Bars,Specialty
Batch
192
1912

02
Bars,Specialty
Batch
1275
1912

03
Bars,Specialty
Batch
900
1912
0256A
01(a)
Strip
Cont.
414
1941
0256B
01(a)
Strip
Cont'
423.3
1949
0256C
01(a)
Strip
Cont.
1468.8
1955

02(a)
Strip
Cont.
1468.8
1960
0256F
01(a)
Tubes
Batch
75
1953
0256C
01(a)
Tubes
Batch
471
1940
0264
01(a)
Rod
Batch
161.4
1957

Applied Flow


Discharge Flow

Dis-

(GalIons/ton)


(Gallons/ton)

Treatment
charge
Rinses Scrubber
Cone.
Rinses
Scrubber
Cone.
Components
Mode
Unk
None
Unk
Unk
None
U„k(1)
NU,0T
Direct
Unk
None
22. 1
Unk
None
22.1
Cnc,ssp,fdsp"}
Direct
Unk
None
8.9
Unk
None
8.9
JT, SS, CT, A£ j
Direct
Unk
None
9.9
Unk
None
9.9
for J
Direct
Unk
16.2
Unk
Unk
16.2
Unk
Iss,cr,flp,nl[
Direct






UJW, CL, CNT, OTj

5.1
None
5.1
5.1
None
5.1
NC,0T
POTW
3.8
None
3.8
3.8
None
3.8
NU,CNT,0T
POTW
Unk
None
Unk
Unk
None
Unk
fiC,CNT,0T "1
POTW
Unk
None
Unk
Unk
None
Unk
L J
POTW
Unk
None
10.5
Unk
None
10.5
!NL,NW,T,FDSp)
Direct






\sl,ss,cnt,ot/

Unk
None
20. 5
Unk
None
20. 5
|SL,NL,NW>
Direct
Unk
None
14.8
Unk
None
14.81
iCNT,0T J
Direct
Unk
None
25.9
Unk
None
25.9
NL,NW,FDSP
Direct
M
None
33.7

None
33.7
T, SS, SL, A£
Direct
Unk
None
110
Unk
None
110
QiT.OT
Di rect
Unk
None
22.3
Unk
None
0
OT, AU
Direct
847
353
Unk
847
353
Unk
NW, NAL, NC» SL, PSP ,
Direct
85.4
62.9
141
84.4
6.0
10.0
209
425
29.4
29.4
960
107
382
None
None
1059
None
None
None
104
425
None
None
None
None
None
Unk
10.5
3.8
9.4
8.1
10.0
9.7
15
11.0
11.0
4
18.3
17.1
85.4
62.9
100
6.01 w
10.0
209
0
29.4
29.4
960
382
(1)
(1)
(1)
(1)
None
None
41
None
None
None
104
425
None
None
None
None .
None
10.5
3-8U)
g' IC1)
(u
i0*?
9. 7
15
Jll?"
18.3
17.1
(1)
SSP,T,SS,CY,CR,
C0,CLA,EB,FLP,CL,
CNT,0T
*
NL,SSP,0T
NL,NW,T, SS,SL,
AE,VF,CNT,R£
OT,None
OT, None
OT, None
OT, None
NC,0T
NL, OT
OT, None
OT, None
FLL, FLA, FLP, NL,
NAL,CNT,OT
NL,RE,
RT
IX,NAM,ReT
Direct
Direct
Direct
Hauled
Hauled
Hauled
POTW
Direct
Direct
Direct
Direct
Direct
-------
TABLE III-l
SULFURIC ACID PICKLING SIOMAEY TABLE
fACE 3 	
Plant
Code
Bo.
Line
Mo.
Proceaa
Product
Proces*
Hode
Capacity
( Tons/Day)
1st
Produ
0264C
01(a)
Bod
Batch
152.7
1969
0264D
01(a)
Bod
Batch
284.1
1956
0384A
01
Billet*,Bar*,
Batch
261
1939


Specialty




02
Bara,Coila,
Batch
240
1969


Specialty




03(a)
Strip
Coat.
84
1958
0386E
01(a)
Strip
Coat.
900
1953

02(a)
Sheet
Batch
179.1
1970
0432A
01(a)
Strip
Cont.
2088
1947

02(a)
Pipe
Batch
253.5
1930

03(a)
Blow
Batch
801
1927

04(a)
Bar,Bod,Wire
Batch
750
1945
0432B
01(a)
Strip
Coat.
1686
1936
0432E
01(a)
Tube a
Batch
30
1942
0432L
01(a)
Tubea
Coat.
322.8
1949
0432M
01(a)
Strip
Cont.
307.2
1954
046 OA
01(a)
Bod,Wire
Batch
699
1917

02(a)
Bod,Hire
Batch
138
1939

03(a)
Bod,Hire
Batch
444
1958
0460C
01(a)
Bode
Batch
105.3
1965
0460D
01(a)
Rode,Wire
Batch
238.8
1927
0A60E
01(a)
Bod,Hire
Batch
180
1947
0460F
01(a)
Bod,Hire
Batch
27.6
1965
0460G
01(a)
Bod,Hire
Batch
225
1968
0460H
01(a)
Bod
Batch
94.2
1920
0476A
01(a)
Bod,Strip
Batch
69.6
1930

02(a)
Pipe,Tubes
Batch
1800
1930

03(a)
Strip
Coat.
127.2
1948
0492 A
01(a)
Pipe
Batch
186
1962

02(a)
Tube*
Batch
287.7
1970
0528A
01(a)
Strip
Coot.
782.7
1949

02(a)
Strip
Coot.
2577
1954
054ft
01(a)
Tube*
Batch
22.8
1927

02(a)
Tube*
Batch
204.3
1945

03(a)
Tube*
Batch
186
1953

04(a)
Tube*
Batch
51
1966
0548B
01(a)
ripe
Batch
44.4
1947
Applied Flow	Discharge Flow	Dit-
	(Gallona/ton)	 	(Gallons/ton)		Treatment	charge
Bintea Scrubber Cone. Ritiaet Scrubber Cone.	Coaponent*	Hode
589
None
11.8
589
None
446
None
13.6
446
None
1379
None
14.3
1379
None
180
1200
2.5
120
156
4114
None
51.4
4114
None
328
Dry
32
328
Dry
80.4
Dry
44.2
80.4
Dry
115
None
14.4
115
None
Unk
None
26
Unk
None
Unk
None
25.1
Unk
None
(Ink
None
19.2
Unk
None
427
Unk
17
427
Unk
1200
None
3.33
1200
None
1200
None
3.33
1200
None
469
234
7.8
469
234
824
None
25.8
824
None
4174
None
47.8
4174
None
973
None
27.0
973
None
410
None
12.5
410
None
161
None
28.9
181
None
280
None
13.3
280
None
261
None
32.6
261
None
224
None
22.7
224
None
535
306
27.7
535
0
414
None
12.9
424
None
N
None
50.0
[9l]
None
283
226
11.3
283
226
1355
None
32.3
1355
None
2085
None
15.6
2086
None
Unk
Unk
Unk
Unk
Unk
19.6
55.7
14.7
19.6
55.7
853
None
8.9
853
None
961
846
9.0
453
0
960
None
9.0
839
None
965
None
9.1
847
None
649
None
27.0
649
None
11.8
13.6
14.3
2.5
"¦»{{!
•M
" a)
25.1
"(i
17v
3.33(1)
(1)
7.8
28.5
47.8
27.0,
12.5
28.9
(1)
13.3
32.6
22.7,
27.71
12.9 AR
50.0 Alt
11.3 AR
32.3
15h
Unk
14.7
;(D
1)
(1)
8.9
9.0
9.0
9.1
27.0
<1>
NAM,CL,KT
CNT, NAM, CL, ReT
f,PLL,FLA,SS~~)
, CNT, (Line (
-ReT)	/
ine 02-OT) J
DW,SS,SL,CNT
OT
OT
iFT,SS,E,NL,NC~")
 None
(AE,PSP,NL 1

(CNT,OT J
ML,CL,0T
FLP,NL,VF,T,
CL,CNT,OT
FDSP,NL,NC,NA
FLPyOT
NL,CNT,OT
SL,NW,CNT,0T
OT,None
(scr,ss,nl,ae,ot1

|au,cnt,e J
g,SL,0T
_ T	J
'F, FLL, FLP, FDSP
X,NL,Scr,CL,CT
HS,T,SS,SSP,SL
IT, OT
SL
IT, (Lines
11,03,04, OT)
[(Line 02,RT)
CNT,0T
POTW
POTW
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
POTW
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
POTW
POTW
POTW
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
POTW
-------
TABLE III-l
SULFURIC ACID PICKLING SUMMARY TABLE
PACE 4	
Plant






Applied Flow


Discharge Flow

Dis-
Code
Line
Process
Process
Capacity
1st Year

(Gallons/ton)


(Gallons/ton)

Treatmeot
charge
Mo.
Mo.
Product
Mode
(Tons/Day)
Production
Rinses Scrubber
Cone.
Rinses
Scrubber
Cone.
Coaponents
Mode
0580
OK.)
Hire
Batch
0.9
1960
4000
None
16.7
4000
None
16.7
OT, None
POTW

02(a)
Hire
Batch
2.4
1965
1800
None
31.3
1800
None
31.3
OT, None
PQTW

031*)
Wire
Batch
0.6
1965
10000
Hone
20.0
10000
None
20.0
10t )
9.7
OT, None
POTW
0580C
01(a)
Strip
Coot.
45
1955
1184
None
10.4
1184
None
NL,CHT,ReT
POTW
0584 C
01(a)
Sheet,Plate
Batch
462
1920
62.3
None
9.7
62.3
None
SS,$L,CLB,CNT,OT
Direct
0584E
01(a)
Sheet
Coot.
4458
1961
300
74
15.8
300
74
15.7
fFLL,FLP,NL, IX ~j
< CL,$L,CNT, B0,CR,
[Direct








13.5 J



(GF,CO,DW»Eft,SS, OT'

0612
01(a)
Rod
Batch
1137
1960
[122]
None
[123
None
[3.3
NL,CO,FLP,CL,VF, "
FDSP,CNT,ReT,E
Direct
0636
01(a)
Tubes,Bare
Batch
(Ink
1943
Unk
None
Unk
Unk
None
Unk
fCNT.OT )
POTW

02(a)
Tubes,Bars
Batch
Unk
1943
Unk
None
Unk
Unk
None
Unk
I 3
POTW
0640 '
01(a)
Bod
Batch
73*
1917
898
Hone
27.6
89S
None
27.6
NL,CL,T» SL,CNT,0T Direct

02(t)
Wire
Batch
19.8
1953
8291
None
7.6
8291
None
7.6 ^ .
21'?1>
Unk
CNT,0T
Direct
0684C
01(a)
Strip
Cont.
1014
1936
284
142
21.3
284
142
NW,CNT,OT,FHS
Direct
0684D
01
Blooas,Billets,
Batch
Inactive
Unk
Unk
None
Unk
Unk
NOne
fsS,SL,CNT 1
Direct

02
Specialty
Rounds
Batch
Est 348
1924
8.3
Hone
8.9
8.3
None
8 9(1)
[OT J
Direct

03
Bounds,Squarea,
Batch
Est 930
1952
[12.21
None
8.9
[12.2]
None
OT
Direct
0684E
01
Specialty
Blooas,Billeta,
Batch
Est 459
1939
15.7
None
17.5
15.7
None
17.5<»
NA,OT
Direct

02
Specialty
Bars,Specialty
Batch
Eat 123
1939
820
None
17.5
820
None
17 5(1)
17.1U)
SL,SS,CNT,OT
Direct

03
Bars,Coils,
Batch
Est 528
1939
297
None
17.5
297
None
OT, None
Direct

04
Specialty
Bara,Billets,
Batch
Est 525
1942
41
None
17.5
41
None
17.5(1)
SL,SS,CNT,OT
Direct
06S4C
01
Specialty
Billets
Batch
663
1929
54.3
None
3.5
54.3
None
3.5(»
fPSP,NWfNL,FLPt \
Direct











11.9(1)
LSS,CL, VF, CNT, OTy


02(a)
Bars,Shape
Batch
483
1950
74.5
None
11.9
74.5
None
(psPiNw.nl.flp, 2
Direct










25.3'1}
(FLL,CNT, OT J

0864H
01(a)
Bara,Bod
Batch
315.6
1960
913
None
25.3
913
None
CNT,CL,NL,FLL,
FLP,VF,CNT,(Line
Di rect











Unk(1)
01 OT),


02(a)
Bar,Bod,Hire
Batch
320.4
1957
2697
None
Unk
2023
None
(Line 02,RT)
Direct
0684K
*
*
*
*
*
*
*
*
*
*
*
*
*
0684*
*
*
*
*
*
*
*
*
*
*
9 9(1)
(1)
l0-° 1)
2K0ll)
*
*
0634P
01(a)
Bar
Batch
405
1900
11.2
None
9.9
11.2
None
OT, None
Direct

02(a)
Hire
Batch
198
1900
40.3
None
10.0
40.3
None
OT, None
Direct

03(a)
Bara
Batch
43.2
1900
17.4
None
10.0
17.4
None
OT, None
Direct
0684 Q
01(a)
Bara
Batch
372
1930
215
None
24.6
21.5
None
VF, FLL, NL, CL, OT
Direct
0684V
01(a)
Plate
Batch
149.7
Uok
164
None
21.0
164
None
OT, None
Direct
06841
*
*
*
*
*
*
*
*
*
*
*
*
*
-------
TABLE III-l
SOLFtMIC ACID PICKLING SI8MAKY TAILS
PACK 5
riant





Cod.
Line
Pxoceaa
Proceaa
Capacity
lat Tear
Mo.
Ho.
Product
Node
(Ton./Day)
Production
0728
01(a)
Pip*
Batch
75
1951
0760
01(a)
Strip
Coat.
481.8
1958
0776D
e
*
*
*
*
07921
01(a)
Strip
Coot.
480
1966
0792C
01(a)
Strip
Cont.
4860
1968
0796A
•
•
*
*
*
07961
*
*
*
*
*
08S60
01(a)
Strip
Coot.
1626
1938

02(a)
Strip
Coot.

1938

03(a)
Strip
Coot.
2226
1947

OMa)
Strip
Cont •
2344
1971
0856E
01
Strip,Specialty
Coat.
285
1957
0836P
01(a)
Sheet
Cant.
2559
1952

02(a)
Pipe
Batch
222
1953

03(a)
M
Batch
156
1972
08561
01
Bar, Special ty
Batch
300
1970

02(a)
Pipe
Batch
276
1908

03
Ur,S^ecialt]r
Batch
270
1970
0856?
01(a)
Strip
Cont.
771
1940

02(a)
Bod.tlire
Batch
828
1964
08S6Q-
01(a)
Bar,Pipe
Batch
187.5
1947
08561
01(a)
tar
Batch
117
mi
08S6I
01(a)
lod.Wire
Batch
148.2
1917
0856T
01(a)
Slabs
Batch
230.4
1935
08560
01(a)
lod,9telp, Strip
Batch
186
1935


Shad.Plate,Bar




02(a)
Strip
Coot.
339
1950
O860F
01(a)
¦od
Batch
1083
1942
08606
01(a)
tod,Hire
Batch
735
1943
08641
01(a)
Rod,Wire
Batch
651
1940

02(a)
Strip
Coot.
846
1951

03(a)
Strip
Cont.
561
1958

06(a)
Strip
Cont.
759
1964
0868A
01(a)
Kod
Batch
588
1914

02(a)
Strip.Sheet
Cont.
444
1943

03(a)
Strip,Sheet
Coat.
450
1944

06(a)
Strip,Sheet
Cont.
543
1955

05(a)
Strip,Sheet
Coat.
2088
1961
0884C
01(a)
Tubea
Batch
18
1961
Applied Flow
(Gal loo*/Con)
Discharge Flov
(Galloo*/ton)
Binaea
Scrubber
Cone.
¦inses
Scrubber
288
None
7.8
qO)
Nooe
[11. "'
V")
(1)
2-7h)
5.6
23.7
Treataent
Component*
SSP, KL, SL,CTf CUT
VF,AU,CY,CHT
*
AR,AU,VS
FLW,HW,CHT,OT
S, ML, FLP,
,CNT,
12.7
16.6
22.4
9.2
24.8
37.4
27.7
5.0
40.5
36.8
45.6
23.9
25.0
ssp,or
[CR, NL, NW,
-------
TABLE UI-1
SULFURIC ACID PICKLING SUMMARY TABLE
pace 6		_•	
riant
Code
Ho.
Line
¦o.
Process
Product
Proceaa
Node
Capacity
(Tons/Day)
1st Year
Production
0884D
01(a)
Tub**
Batch
18
1969
0884G
01(a)
Tubes
Batch
7.S
1973
0916 A
01(a)
Pip*
Batch
600
1931

02(a)
TUbea
Batch
12
1931
0920D
01(a)
Pipe
Batch
267
1940
0946A
01(a)
Billets
Batch
162.3
Oak

02(a)
Bar,Wire
Batch
219
link

03(a)
Bar
Batch
172.5
1964
0M8A
01(a)
Pipe
Batch
189
1922
o%a>
01(a)
Bar*
Batch
306.3
1947
094 8C
01(a)
Strip
Coot.
699
1930

02(a)
Strip
Coat.
699
1930

03(a)
Sheet
Coat.
1761
1954

04(a)
Strip
Coat.
268S
1965
Applied Plow
(Gallona/too)
Rinses
Scrubber
Cone.
1200
None
16.7
77
None
11.0
165
None
15.0
42
None
18.0
1079
None
33.7
6.4
Hone
10.4
8.6
None
18.8
3.5
None
5.4
3810
¦one
48.9
1081
Hone
Unk
874
None
21.4
i2i
None
21.4

Hone
13.6
161
Naoe
11.3
Discharge Flow	Dia-
(C-allona/ton)		Treatment	charge
Rinses
Scrubber
Cone.
C«aponent9
Mode
1200
None
16.7
NC.SL.OT
Direct
77
None
»<*>
18l,)
33.7^"
10-4<1)
5?4
48.8(1)
VF,CL,HL,0T
Direct
0
None
None
Direct
0
None
None
Direct
1079
None
0T f None
Direct
6.4
None
0TP None
Direct
8.6
None
0T, Hone
Direct
3.5
None
0TV None
Direct
3810
None
(CNT, CO, FLL, FLP"]
Direct


U»k{1)
brF,ci.,or i

1081
None
OT, None
Direct
412
None
10. 7
(WT, FLL,
Direct

None
10.7
JPLP.T.E 1
Direct

None
13.6
1SS,OT,NL [
Direct
161
None
11.3
L J
Direct
-------
TABLE III-l
SULFURIC ACID PICKLING SIMKART TABLE
PAGE 7			
KEY TO ABBREVIATIONS
AD	t	Acid Disposal
ASF	:	Recovery of Acid via Pv*e filters
AH	s	Acid Rinse Hauled
CH	;	Concentrate Hauled
CSD	:	Centrifuge Sludge Dewatering
CSR	3	Contractor Sludge Removal
DC	:	Dechlorination (Sulfur Dioxide)
DU	i	Diiposal Unkoom
EL	:	Equalisation Lagoon
ES	:	Estimated
FIE	;	Ferrous Iron Removal by Air Sparging
FLFC	:	Flocculatioa with Ferric Chloride
FLU	s	Floccalation with Waste®
FLWPL	:	Flocculatioa with Haste Fickle Liquor
LS	i	Luella Separator
M/A	:	Hoc Applicable
HAL	t	Neutralisation with Alum
NAM	s	Neutralisation with Anionia
NU	:	Neutralization with Unknown
NR	;	Hot Reported
M pHS	:	pH Stabilisation
RA	;	Reactor
RB	i	Rinses Untreated
SAFT	l	Sent to Another Plant for Treatment
SP	1	Scale Pit •
SPI	t	Sewage plant
ST	t	Settling Tank
TR	s	Treatment
UA	3	Acid Untreated
UFSP	s	Up Flow Sand Filters with Stew Backwash
UNI	:	Unknown
*	s	Confidential Data
(a)	t	Carbon Steel Hill
t	Nuaber in brackets represents vslues received
in the responses to the detailed queitionnairet.
(1)	s	Indicates wastewater eliminated by contract hauling
NOTE	:	See Table VII-l for other general abbreviation.
[ ]	s	Number in brackets represents values received
in the responses to the detailed questionnaires.
-------
PlttC
Code
Lin*
Proceaa
Process
Capaci t;
Mo.
¦o.
Product
Mode
(Tooa/Oav)
0020C
01
S.Specialty
Cont.
582
0060
01(a)
Strip
Coot.
3900

02(a)
Strip
Cont.
4206
00601
•
*
•
*
0060D
01
Strip-Specialty Goat.
207
0060L
01(a)
Tube
latch
0.375
0068
01(a)
Pence
Cont.
103.8

02(a)
Hire
Cont.
88.8
088A
*
*
*
*
0112S
01(a)
Strip
Coat.
142}

02(a)
Strip
Cont.
2589

03(a)
Strip
Coat.
1578
0112D
01(a)
Strip/Sheet
Coat.
3672

02(a)
Strip/Sheet
Coat.
4788
0112H
01(a)
Hire
Coat.
40.2
0176
01
Hire-Specialty
Batch
15.9
0320
01(a)
Sheet
Cont.
2023.2

03(a)
Sheet
Cont.
1821.6

04(a)
Sheet
Cont.
2990.4
0384A
01(a)
Strip
Coot.
639

01(a)
Strip
Cont.
133.5

03(a)
Strip
Cont.
118.8

04(a)
Strip
Cont
&198]

06(a)
Sheet
Batch
768
0396B
01(a)
Strip
Cont.
126.8

02(a)
Strip
Cont.
226.8

03(a)
Strip
Cont.
226.8

04(a)
Strip
Cont.
226.8

05(a)
Strip
Cont.
226.8
M32C
01(a)
Strip
Cont.
2193

02(a)
Strip
Cont.
2259
04329
01(a)
Strip/Sheet
Cont.
3678
owu
01(a)
Sheet
Cont.
2004.3

02(a)
Sheet
Coat.
792.3
0S26S
01(a)
Strip
Coat.
2196
TAILS 111-2
PICKLING * HYDROCHLORIC ACID - BATCH AND CONTINUOUS
	SUMMARY TABLE	
lat Yeer
Applied Flow
(Gallona/Ton)
Diicbirge Flov
(CallonayTon)
Treatment
Production
Rinaea
Scrubber
Cone.
Av*.
Rinae* Scrubber
Cone.
Av.
Components
Mode
1946
958
7.4

35
_
958
7.4
35
_
CR, NL, FLP, CL, VF
Direct
1969
295
86.8
14.8
-
295
12.9
14.8

rDWtNLfFP,A£ )
Direct
1969
274
8.4

13.7
-
274
12.0
13.7

lFLP,SL,CL,VF j
Direct
*
*
*

*
*
*
*
*
*
*
*
1972
348
696

13.2
-
346
696
13.2
-
NW,NL,SL
Direct
1974
13400
-

4.0
-
13400 -
4*0

NL
POTW
1934
1386
-

5.4
-
693
-
5,4
"
Unknown
P0TU
1947
367
-

8.0
-
70.8
-
8.0
-
Unknown
P0TW
*
*
*

*
*
*
*
*
*
*
*
1936
Unk
202

Unk

Unk
202
Unk
-

Direct
1936
Unk
111

Unk

Uok
111
Unk
"
SSP,AE,FPSP, ~l
Direct
1936
Unk
183

Unk

Unk
183
Unk
- -
^SS,CL J
Direct
1965
Unk
58**
Unk
-
Uok
Unk
Unk
"
'ss,cl,flp,ml,7
Direct
1969
Unk
45**
Unk
-
Unk
Unk
Unk
-
JM,C0,SL J
Direct
1971
Unk
358**
20.9
-
Unk
Uok
20.9
-
NL,FLL,CL,SL
Direct
1961
1811


Unk

1811

Uok

C0,CRfCLA,EBfFLP,
NC(Ktf,KA,CL,SC,
PSP,SSP,TtSS,CY,
CNT
Direct
1936
Unk
214**
6.6
-
Unk
214
6.6
-
r 1
Direct
1939
Unk
210

6.5
-
Unk
210
6.5
-
PSF,CL,SL,SS,NC}
Direct
1967
Unk
144

6.1
-
Uok
144
6.1
-
J
Direct
1932
763
611

13.6
-
763
611
13.6
-
1
Direct
1932
372
298

8.3
-
372
298
8.3
-
SS.SL >
Direct
1951
450
463

7.7
-
450
463
7.7
-
L J
Direct
1958
[37.6]
0-43
7.2
-
[37.6] [3.4J
7.2
-
PSP.SS.CC
Direct
1948
469
169

4.4
-
469
169
4.4
"
SL,PSP,SS
Direct
1967
[40.61
[6.2]

[40.61
-
[40.6
[6.2]
[40.6]
{

POTW
1967
U0.6]
fc.2

[40.6]

[40.6
[6.2]
[40.61

1
P0TW
1967
fc0.6]
fc-2.

[40.6]
-
[40.6
[6.2J
[40.6]
<
CNT,NL,E,CL,VF >
POTW
1967
to.6]
fc.2

(40.61
-
[40.6
[6.2l
[40.6]

(
POTW
1967
fe0.6l
».2

(40.6]
-
(40.6
[6.2]
[40.6]

J
POTW
1952
246
49.
2
15.8
-
246
49.2
15.8
"
VF,FLL,FU>,NW,CL,
Direct
1957
239
47.8
15.3
-
239
47.8
15.3
-
PSPpSS,CT
Direct
1968
596
78.3
8.5
-
596
78.3
8.5
-
FP,DH,FLL,T,FLUFL
Direct
1954
Unk
Unk

9.8
-
Unk
Unk
9.8

U J
POTW
1970
Unk
Unk

7.0
-
Uok
Unk
7.0

POTW
1963
[216]
[6.1]
[81.(0
[176J
[216]
[6.(1
[0]
[l7tj
NC,SL,SS,AR
Direct
-------
TABLE III-2
PICKLING - HYDROCHLORIC ACID - BATCH AND CONTINUOUS
SUMMARY TABLE
PAGE 2		
Plant
Code
No.
Line
No.
Procesa
Product
Proceaa
Mode
Capacity
(Toaa/Day)
1st Year
Production
0580
01(a)
Hire
Cont.
200.1
1960

02(a)
Rod/Wire
Coat.
240
1965

03(a)
Wire
Coat.
300
1965

04(a)
Hire
Coat.
300
1965

05(a)
Wire
Coot.
225
1965

06(a)
Hire
Cont.
240
1970
0580A
01(a)
Hire Cloth
Coat.
1.5
1962

02(a)
Hire Cloth
Coat.
2.16
1962

03(a)
Hire
Batch
3.69
1962
0580B
01(a)
Hire
Coat.
15
1965

02(a)
Hire
Cont.
30
1965

03(a)
Rod/Hire
Cont.
60
1965
0580C
01(a)
Strip/Band
Coat.
3
MR

02(a)
Rod/Hire
Coat.
21
1966

03(a)
Hire
Coat.
15
1957
0580D
01(a)
Rod/Hire
Coat.
60
1965

02(a)
Hire
Coat.
15
1965

03(a)
Hire
Cont.
30
1965
0580E
01(a)
Rod/Hire
Cont.
60
1960

02(a)
Hire
Cont.
30
1930
0580F
01(a)
Rod/Hire
Cont.
60
1965

02(a)
Hire
Cont.
30
1965
0584A
01(a)
Strip
Coat.
2490
1936

02(a)
Strip
Cont.
2409
1936

03(a)
Strip
Cont.
2826
1936

04(a)
Strip
Coat.
2223
1957
0584C
01(a)
Strip
Coat.
3069
1947
0584F
01(a)
Strip
Cont.
2250
1939

02(a)
Strip
Cont.
2730
1956

03(a)
Strip
Cont.
3345
1974
0612
01(a)
Hire
Coat.
66.9
Pre-1950

02(a)
Hire
Coat.
66.9
Pre-1950

03(a)
Hire
Coat.
66.9
Pre-1950

04(a)
Hire
Coat.
66.9
Pre-1950

05(a)
Fence
Cont.
16.2
Pre-1950
0684B
01(a)
Strip
Cont.
1326
1957

02(a)
Strip
Coat.
1407
1961
0684F
01(a)
Sheet/Plate
Coat.
1740
1937

02(a)
Sheet/Plate
Coat.
3084
1969
06841
01(a)
Strip
Coat.
1377
1964
Applied Plow
(Gallons/Ton)
Discharge Plow
(Gallons/Ton)
Rinaea
Scrubber
Cone.
Avs.
Rinses
Scrubber
Cone.
Avs.
1440
_
10.0
-
1440

10.0

360
72
1.8
-
360
72
1.8
-
288
288
3.0
-
288
-
3.0
-
240
-
1.5
-
240
-
1.5
-
1333
-
33.3
-
1333
-
38.3
-
360
360
3.8
-
360
360
3.8
-
6240
-
5.9
-
6240

5.9
-
9333
-
117.5
-
9333
-
U7.5
-
1950
-
38
-
1950
-
38
-
288
2 88
3.0
-
288
288
3.0
-
240
-
1.5
-
240
-
1.5
-
360
120
1.8
-




1440
-
17.5

1440
-
17.5
-
3017
-
13.0
-
3017
-
13.0
-
1152
-
4.4
-
1152
-
4.4
-
360
120
1.8
-
360
120
1.8
-
288
288
3.0

288
288
3.0

240
144
1.5

240
0
1.5

360
-
1.8
-
360
-
1.8
-
240
-
1.5
-
240
-
1.5
-
360
120
1.6
-
360
120
1.8
-
240
144
1.5
-
240
-
1.5
-
217
145**
4.6
-
217
145
4.6
-
224
149**
4.8
-
224
149
4.8
-
191
127**
4.1
-
191
127
4.1
-
243
162**
5.2
-
243
162
5.2
-
225
141
4- 7
-
225
0.8
4.7
-
128
9.6
ri6.g
[23]
128
9.6
[0]
m
316
264
i6.a
[231
316
264
[p]
hi
86
8.6
P6.|
1233
17.2
8.6
toJ
fril
[66]
-
(3-6f
-
[66]
-
[3.£
-
[66]
-
&.61
-
[66]
-
[3. a
-
(66]
-
b.6]
-
fc6]
-
l3.
-------
TABLI III-2
PICXLHC - HTMtOCHLOtlC ACID - BATCH AND COHTINUOUS
snmuT TABU
FACE 3	
Plant
Code
Line
Proceaa
Procaaa
Capacity
lat tear
Ko.
Bo.
Product
Mode
(Tana/Day)
Production
0724A
01(a)
Sheet/Strip
Coot.
360
1949

02(a)
Sheet/Strip/
Cant.
336
1950


Plate




03(a)
Sheet
Cant.
738
1958

04(a)
Sheet
Cant.
1719
1966
0856F
01(a)
Sheet
Cant.
2388
1950
0856P
01(a)
Hire
Cant.
16.86
1917
0856S
01(a)
Hire
Coat.
18.99
1927

02(a)
Wire
Cant.
5.43
1937
0860V
01(a)
Dire
Cant.
69
1942
08641
02(a)
Hire
Cant.
28.2
1943

03(a)
Strip
Coat.
1440
1947

04(a)
Strip
Cant.
1965
1951

05(a)
Pipe
Batch
273
1966
0868A
01(a)
Strip
Cant.
1590
1948
0920A
01(a)
Sheet
Cant.
1761
1930

02(a)
Sbeet
Cant.
1638
1966
0920C
01(a)
Strip
Cant.
2445.9
1953
092OG
01(a)
Strip
Coat.
2133
1958
0948A
01(a)
Strip
Coat.
1428
1935

02(a)
Strip
Coat.
1209
1935
Applied Flow	Discharge Flow
(Cal loni/Ton)		(Call opt/Too)		Treatment	Discharge
Kinaea
Scrubber
Cone.
Ava.
Rinsea
Scrubber
Cone.
Av«.
Coipoocnti
Mode
4160
300
Uok

4160
240
Dak
_
r -)
Direct
120
86
link
-
120
86
Unk


Direct
137
88
Unk
-
137
78
Unk
_
re
Direct
84
17
7.3
-
84
17
7.3
-
_J
Direct
60
66
9.6
-
46
12
9.6
-
CS,NW,HL, FIX,
Direct








SS,CL

15540
15125
5.9
-
15540
0
5.9
-
None
Direct
589
-
0.8
-
589
-
0.8
-
Tnc 1
POTH
1309
-
2.4
-
1309
-
2.4
-
Cc J
POTV
3130
-
2.0
-
188
-
7.0
-
ML,SSP,FPSP,VF,
Direct








CT, FP

766
-
5.3
-
766
-
5.3
-
fsS,NL,FLLt
Direct
400
25
12
-
150
0
12
-
/FLP,CL, NA, (
Direct
330
18
8.8
-
183
0
8.8
-
)PHS (
Direct
1319
132
6.6
-
1055
0
6.6
-
L J
Direct
299
45
25.4
-
299
5.4
25.4
-
FLP, FLWPL, ML, FP
Direct








CL,SLfSS

270
16
18.7
-
245
18
18.7
-
(EB, FLL,CO, IX, ]
Direct
290
13
19.3
-
264
18
19.3
-
CCL, VF J
Direct
258
24
7.4
-
212
25
7.4
-
NL, FLP, SS, VP
Direct
225
-
7.0
-
225
-
7.0
-
CR,NL,FLL,FLP,CL
Direct
61
454
3.7

50
10
3.7
-
CCO,FLL,FLP,CL, "I
Direct
71
536
4.4

60
12
4.4
-
(VF j
Direct
-------
TABU III-2
HYDROCHLORIC ACID PICK.IMG SIMUKT TABLE
PAGE 4 	
KEY TO
ABBREVIATIONS
AD

Acid Disposal
ASF

Recovery of Acid via Fiac Filters
AH

Acid Rinse Hauled
CH

Concentrate Hauled
C8D

Centrifuge Sludge Dewataring
CSR

Contractor Sludge Removal
DC

Dechlorination (Sulfur Dioxide)
DU

Disposal Unknown
RL

Equalisation Lagoon
ES

Estimated
Fit

Ferrous Iron Roioval by Air Sparging
FLFC

Flocculation with Ferric Chloride
FLU

Flocculation with Wastes
FUfPL

Flocculation with Haste Pickle Liquor
LS

Laaella Separator
N/A

Not Applicable
HAL

Neutralisation with Alum
HAH

Neutralization with Amonia
Ntl

Neutralization with Unknown
MR

Not Reported
pHS

pH Stabilisation
RA

Reactor
RU

Rinses Untreated
SAPT

Sent to Another Plant for Treatment
SP

Scale Pit
SPI

Sewage Plant
ST

Settling Tank
TR

Treataent
UA

Acid Untreated
UFSF

Up Flow Sand Filters with Steam Backwash
OHK

Unknown
*

Confidential Data
**

Design Flow
(a)

Carbon Steel Mill
[]

Mueber in brackets represents vslues received

in the responses to the detailed questionnsires
NOTE
:
See Table VII-1 for other general abbreviation.
-------
TABLE III-3
COMBINATION ACID PICKLING, CONTINUOUS AND BATCH TYPE MILLS
SUtMAKY TABLE
vl
Ut
Plant
Code
Mo.
0020B
002OC
002OL
0060
00600
0060E
Line
No.
01
02
03
01
02
03
M
05
06
07
01
02
01
01(a)
02
03
04
05
06
01
Process
Produce
Sheet, Strip, Stelp
wOCCl ,	tp |
a2so4,»o3,ar
Sheet.Strip,
H SO..NNO ,IT
Sfitef,Strip,
ILSO..tmo,w
SReef,Strip,
HNO,,*
Sheet.Strip,
b2so.ibf,imo3
Sneet, Strip,
LSO ,BF,»0
Sheet, Strip,
WO,
slrip'aCt/W
,Sttip
H SO.MO./HF
SvSr>
S trip,SO,
Strip, BjSO^,
Strip^SO^
WO^a "
Strip,BjSO^,
Strip ,UM)3,V
Strip.lLSO,
h*o3,w
Strip, SCI f MP
Process
Capaci ty
1st Year

Applied Flow
(Gallons/ton)


Discharge Flow
(Gallons/ton)
Mode
(Tons/Day)
Production
Rinses Scrubber
Cone.
Rinses
Scrubber
Cone.
Coat .
324
1952
1333
222
15.5
1331
222
15.5
Coat.
210
1957
1029
343
24.7
1029
343
24.7
fetch
99
1947
2182
-
52.1
2182
-
52.1
Coat*
207.6
1951
4127
20.8
Unk
4127
20.8
Unk
Coat.
93.9
1946
6288
1380
Unk
6288
1380
Unk
Coat.
93.8
1946
6288
1380
Unk
6288
1360
Unk
Coot.
58.8
1930
9388
561
Unk
9388
561
Unk
Coat.
100.2
1945
5509
329
Unk
5509
329
Unk
Coat.
68.6
1966
2271
102
Unk
2271
102
Uok
Coat.
262.8
1957
2900
1096
Unk
2900
1096
Unk
Coat.
185.7
1966
1087
272
7.8
1087
272
7.8
Coat.
199.5
1966
1011
253
7.2
1011
253
7.2
Coat.
307.5
1974
Onk
Unk
23.4
Unk
Unk
23.4
Coat.
228
X927
(Ink
1579
Oak
Unk
63
Unk
Coat.
300
1935
Unk
1200
Unk
Onk
48
Unk
Coat.
288
1939
Oak
100
Unk
Unk
Onk
Unk
Coat.
435
1945
link
Unk
Unk
Unk
Unk
Unk
Coat.
300
196L
Unk
50.4
Unk
Unk
Unk
Unk
Coat,
282
1961
Unk
511
Unk
Unk
Unk
Unk
Coat.
0
1973
1690
777
8.2
1690
777
6.2
Treatment
C exponenta
CHT.CR, VF,
FLP,HR,CL
cmt.cr, vf,
FLP,K.,CI,
FHS
CNT,CR,VF,
FLP, HLfCL
€NT,CR,VF,
FLP, NL,Ch
r i
CNT,CR, VF,
IflPjKl.cl j
CNTtCR,VF,
I FLP,NL,CL
CNT,CR, VF,
FLP, NL,CL
CNT,CR, VF,
FU\NL,CL
OIT,CR, FLA,
HL,CL
CNT,CR,FLP,
NL,CL
CUT, Spent
Acid to VF, FLP,
NL,CL,SL
vCNT,NL
jSL.AE
L
CUT, N*,CL,
VF
CNT, NL, SL, AE
CNT, F(Unk)t
FLP,HC,T
Dis-
charge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
-------
TABLE II1-3
COMBINATION ACID PICKLING, CONTINUOUS AND BATCH TYPE HILLS
SUMMARY TABLE
WOt I
Plant
Code
Ho.
Line
Ho.
Proceai
Product
Process
Mode
Capacity
(Tone/Day)
lat Year
Production

02
Strip ,Dnk
Coat.
99.9
1970
00601
0060II
0060P
01
01
01
Rod ,W ire,
ILSO , WO
Plpe.BIO,, W
Pipe, UK)j BP
Batch
Batch
Batch
176.7
9.6
25.5
1946
1970
1969
0068
0088A
01(a)
01
Rod.LSO ,
HC1
Tubes, HlO^ir
Batch
Batch
381
72
1937
1952
0088C
OOS8D
0112A
0112C
0I12B
0176
01(a)
02
-------
HBU III-3
coMUunai icu ficsluk, con unions amd batch ttpb mills
¦HUT T4ILS
PACE 3
flat
Code Liaa	¦ Fmcmi	Proceaa Capacity	lit Tear
l».	fc.	¦ fnfctt	Mode	C Tooa/Pay) Production
03	Strip,!. SO.
¦Oj/V
04	Strip,Hn./Hr,
05	strip,aw3,
06	Vira.HOj.W
07	Strip,Bod,HC1, Re
«Wj,W
9176C 01 Pipe « Me,
no w
01760 01 Tubl(,BH>.,»
02481 02 Strip,
0248I 01 Str?p,«.SO.,
02	S trip,By SO. ,
03	Strip,B_SO,,
¦Wj.ar
0* Strip,R^SO,,
HO., V
05 Strip,*.SO,,
mo ,W*
Strip,LSO
wo,.w
04	Strip,ISO ,
mo w
09	Strip.lLsO.,
HHO,,W
10	StrIp,ILSO.,
WOj.W
06
07
Coat.
90.3
1962
Coot.
19.8
1963
Coat.
18
1963
tatek
•9.4
1964
Batch
202.8
1968
Batcb
22.8
1969
Bjtch
9
1972
Coot.
161.1
1957
Coat.
264.6
1K9
Coot.
93.9
19*9
Coat.
. 227.7
1949
Coat.
169.2
195S
Coot.
246.3
1959
Coat.
153.6
1959
Coot.
78.3
1961
Coot.
98.4
1964
Coat.
321.9
1964
Coot.
222.9
X973

Appl ied Flow


Diacharse Flow

Dis-

(Gallon*/to*)


(Callooa/too)

Treatment
charge
Rieaea Scrubber
Cone.
lioaea
Scrubber
Cooc.
CtafOaeata
Mode
558
3189
Oak
558
80
Dak
CMT,CLA,CR,
Direct






EB.FLP.NC.NU.NA,







CL,Cf

2182
1273
link
2182
364
Unk
CHT,CLA,CR,EB,
Direct






FLP,SC,WL,CL,







I, SS,CY

2000
7000
Unk
2000
400
Unk
CHT,CLA,CR, as,
Direct






FLP, NC,NWtNA.CL, T,







SS.CY

105
6443
tJnk
805
242
Unk
Cin.CLA.CS,
Direct






EP, FLP, NC,1VW, NA,CL,






EB,T, SS.CY

711
3689
Unk
711
284
Unk
cht.cla.cb,
Direct






ES,FLP,NC,NU,1K,







CL.T, SS.CY,

1617
-
41.3
1617
-
41.3
No treatment for
POTW






Kinaea

3200
960
35
3200
960
35
Hone
porw
358
89
1.7
356
89
1.7
CNT,CR, ML,
Direct






FLP,CL,CY

2721
376
13.4
1224
49
13.4
CUT, SOt, NL,
Direct






FLP, CL.T, PP

7668
1702
40.2
3604
230
40.2
CRT, SCR, HL,
Direct






FU ,CL, T, R

3162
702
13.9
1233
95
13.9
arr, sat, nl,
Direct






FLP,Cl,T,FP

4255
766
13.4
1277
0
13.4
an, sat, h.,
Direct






FLP.CL, T, IP

2923
403
10.6
965
53
10.6
art, sat, ml,
Direct






FLP.CL, T, FHS, FP

4688
2344
21.1
1828
188
21.1
an, sat, ml,
Direct






FLP,CL, T, FHS, FP

9195
-
16.5
1563
-
16.5
OCT.Sa.M.,
Direct






FLP,CL, T, FP

7317
-
13.1
1244
-
13.1
CVT.Sat.ML,
Direct






FLP.CL, T,FP

2237
309
8.1
738
40
8.1
r i
Direct






-------
TABLE III-3
COMBINATION ACID PICKLING, CONTINUOUS AND BATCH TYPE MILLS
SUMMARY TABLE
PAGE 4		 		
Plant





Code
Line
Process
Process
Capacity
1st Year
No.
Ho.
Product
Mode
(Tons/Day)
Production
0248C
01
*od,Wire,H_SO.,
Batch
141
1930


HCl.WO., W




02
Rod.Hire.HCl,
Batch
6.6
1930


HMO., V




03
tar,H_S04,
Batch
112.2
IMS
0248D
01
HMO.tW
Pipe,lbbest
Batch
'2.7
1948


HjS04,W03>




02
P i pe , Tube s,
Batch
2.7
1948


^SO^.lWOj,




03
Pipe, Tubes,
Batch
7.8
1958


HgS04,HH03,




04
Pipe, Tubes
Batch
8.7
1974


BjS04,BN03,




OS
Tubes,HjSO.,
Batch
13.5
1970


WO., HF



0248E
01
Tubes,IMO-,HF
Batch
5.2?
1958
0248F
01
Tubes (WO^.tF
Batch
0.84
1966
0256F
01
l^bes , HnSO,,
Batch
30
1953


BHO ,W




02
BsrfmOj,
Batch
0.25
Unk


Muriatic



256L
*
*
*
*
*
2S6N
01
*
*
*
*

02
BarlUNO],
Batch
0.25
Unk


Muriatic



02560
01
Sbeet .Scrip,
Cont,
165.9
1959


h^so4,hho3,




02
Strip.H-SO.,
Cont.
122.4
1960


BHOj.W




03
Strip,H_SO,,
Coot •
185.9
1960


HMO,, Iff




04
Strip,H SO.,
Cont.
102.8
1972


HNOj.W*




Applied How


Discharge Flow

Dis-

(Gallons/ton)


(Gallons/ton)

Treataent
char ge
Rioses Scrubber
Cone.
¦inses
Scrubber
Cone.
Components
Mode
1015
_
2.4
1015
_
2.4
AEf NC,FL, FLP.CL,
Direct






SL, CNT

8889
-
20.8
8889
-
20.8
A£, NC,FL, FLP,CL,
Direct






SL,CNT

2310
-
2.7
1240
-
2.7
AE, NC,FL,FLP.CL,
Direct






SL.CNT

2667
-
87.8
2667
Unk
87.8
r i
Direct






7CNT, T, NL, NC,T, \

2667
-
87.8
2667
Unk
87.8
1 J
Direct
923
-
30.4
923
Unk
30.4
r i
Direct
414
-
149
414
Unk
149
< CNT,T,NL, NC,T, )
' Direct
267
-
119
267
Unk
119
I J
Direct
690
-
2.93
690
_
2.93
CNT
POT VI
2357
Unk
1089
2357
Unk
1089
CNT, NL, SL,
Direct






ML

960
7200
9.5
960
0
9.5
CNT, FLL,
Direct






FLA, FLP, NA, NL,

320
-
-
320
-
-
CNT, NL, NC
POTW
*
*
h
*
*
*
it
*
*
*
*
*
*
*
*
h 1
320
-
-
320
-
-
CNT, NL, NC
POTW
5729
694
11.5
4163
0
11.5
CNT,CL,FLP,
Direct
6588
%l
15.3
5647
0
J5.3
CUT, NL, FLP,
Direct






CL

1064
268
7.5
796
0
7.5
CNT, NL, FLP,
Direct






CL

6051
1532
17.0
4443
0
17,0
CNT, NL, FLP,
Direct






CL

-------
TAB LI 111-3
DOMINATION ACID PICKLING, CONTINUOUS AND BATCH TYPE HILLS
SUMMIT TABLE
PAGE S
Plant
Code
No.
02 MA
0424
04)00
0432K
0432K
0432L
0440A
Lin*
No.
01
01
02
01
01
02
03
04
01
01
02
Proceai
Product
Proceta
Sheet.Plate,
h^so4,m»3,
Plate,H, SO.,
IMOj.W
^r.H-SO. ,
HNO^t V *
Plate,IL SO
HMO j, HP
Tubea,»0W
Sheet,IL SO,,
nK>.,V
Sheet,H_SO.,
NNO-.W
Sheet,H_SO,,
BNO..V-1
Strip,WO.., V
Bar,NCl,BROj
Rod,Hire,BC1,
HNOj.HF
0476A 01(a) Kod;nCl,li2S04
latch
Batch
Batch
Batch
latch
Coot.
Coat.
Coot.
Coot.
Batch
Batch
Batch
Capacity
( Tboa/Day)
177
IBS. 7
24.9
60
IS
229.8
341.4
187.5
33.6
161.7
75
386
lat Tear
Production
1946
1960
1968
1962(1977)
1969
1958
1966
1958
1959
19S8
19S8
1940
0496
0S48A
0548B
0580
0S8OG
0636
0640B
02
03
01 Plate,n03,W
01(a) PipefTtofcel
HSO HNO,
htpo
01 T3beft,aK>-,V
01(a) Rod,BCl.MO.
01(a) Bod,Hire,N.SO.
BCl
01 Tubea.lLSO,,
»0,,HP
Tubia.WO.,,1*
Tubes .HMof, HP
01(a) Kod.Uire.^SO^
t
BCl
Batch
Batch
Batch
Batch
Batch
Batch
Batch
Batch
Batch
411
63
1.8
45
161.1
HA
HA
171
1964
1957
1947
1965
1950
1943
1%3
1968
1950
Applied Flow
(Gallon*/ton)
Binaea	Scrubbed Cone.
325	163	3.0
93	-	10.8
463	-	45.7
288	1200	72
3168	864	2.2
Unk	94	(Ink
Unk	63	Unk
Unk	115	Unk
5571	-	18
178	-	6.9
384	-	11
932	-	31.1
736	701	9
2286	Unk	0.633
3871	-	16.1
667	Unk	1.0
143	Unk	1.25
Unk	-	Unk
Unk	-	Unk
Unk	-	Unk
1011	Unk	33.3
Diacharge Plow
(Galloot/ton)
Binaea	Scrubber* Cone.
325	163	3.0
93	-	10.8
463	-	45.7
288	1200	72
3168	864	2.2
457	94	Unk
457	63	Unk
Unk	115	Unk
5571	-	18
178	-	6.9
384	-	11
932	-	31.1
736	2.4	9
2286	Unk	0.633
3871	-	16.1
667	Unk	1.0
143	Unk	1.25
Unk	-	Unk
Unk	-	Unk
Unk	-	Unk
1011	Unk	33.3
Treatment
Components
Dis-
charge
*Mode
CKT,CR,SL,
Direct
NL,FLP,CL,CY,
ce

99
CNT, PLP, tL,
Direct
CL,NC.NW,

SL.B

CNT.FLP.H.,
Direct
CL,NC,NH,

SL

CHT,B0A( O.CLN,
Direct
PLL, FLP, NL, SC8,

SS,PSP,SSP,CL,SL

Hone
POTW
CNT,NL, SL
Direct
CNT, ML, SL
Direct
CNT, ML, SL
Direct
None
POTW
fatT.NL, 1
POTW
MUySL, )

L J
POTW
CNT, SCR,
Direct
SS, NL, AE, FLP,CL,

CY

CNT, IC,
Direct
SL

CMT, NC
Direct
SL

NL.CNT
POTW
None
POTW
None
POTW
CNT
POTW
CNT
POTW
CNT
POTW
FLP,NC,CLt T,CNT
POTW
-------
TABLE III-3
COMBINATION ACID PICKLING, CONTINUOUS AND BATCH TYPE MILLS
SUMMARY TABLE
PACE 6
00
o
Plant

Code
Line
No.
No.
0648
01(a)
0684 D
01

02

03

04

OS

06

07

08

09

10

11

12

13
06841
*
0644 P
01
-------
TABLE III-3
COMBINATION ACID PICKLING, CONTINUOUS AND BATCH TYPE MILLS
SUMMARY TABLE
PAGE 7			
Plant





Code
Line
Procea a
Proceaa
Capacity
1st Year
No.
Ho.
Product
Mode
(Tona/Day)
Production
0776J
01
Hire,BN03,ir,
Batch
8.1
1975


Muriatic



0792A
01(a)
Rod,Wire,
Batch
54
1925


H, SO..HC1



0796A
*

*
*
*
0856E
01
Sheet, Plate, mOJt
Batch
78
1957
0856H
01
BP
Plate ,W03,W
Batch
125.4
1968
0860B
01
Strip,H-SO.,
Cont.
390
1942(1957)


WO., HF



0860F
01(a)
Mire.H.SO. ,
Coat.
45
1962


HCl



0884 E
01
Tubea,W,BI03
Batch
24
1968
0884F
01
Tubea,aH>a,W
Batch
4.5
1970
0900
01
mo3,EF
Cont.
182
link
0948F
01(a)
Pipe,H_ SO,,
Cont •
81.9
1959


WO]




Applied Flow


Discharge Flow

Dis-

(Gallons/ton)


(Gallons/ton)

Treatment
charge
Rinaes Scrubber
Cone.
Rinses
Scrubber
Cone.
Canponents
Mode
360
Unk
-
360
Unk
-
CNT, NL
Direct
180
-
4
180
-
4
None
POTW
*
*
* «
*
*
*
*
*
922
-
123
922
-
123
CUT, NL,
Direct






SL

338
39.4
13.4
338
39.4
13.4
CUT, ML,
Direct






PSP,SSP,SS

2585
738
14.8
2585
736
14.8
CNT, SS
Direct
0
11,520
864
0
640
864
CNT,
Direct






SSP, FP, SC,







T,VF, HA,







CT, DU

[650]
[5400]
6.3
[650]
[10]
6.3
CNT, NL, PSP, E, FLP
POTW





SSP

<1
-
<1
0
-
<1
None
Direct
[1888]
&57]
Unk
[91 a
[157]
Unk
CR, NL, E, SS, CL,







T, SC

176
882
Unk
176
0
Unk
None
Direct
-------
IA1LB III-3
OOmiMTIOK ACID PICKLIHC SIMttHT TABUS
PAGE »	
KEY TO ABBREVIATIONS
ARF
S
Recovery of Acid vie Fuse Filters
CSO
I
Centrifuge Sludge Dewatering
DC
»
Dechlorination (Sulfur Dioxide)
FIR
I
Ferroua Iron Removal by Air Sparging
FiFC
I
Flocculation with Ferric Chloride
FLU
I
Flocculation with Vaatea
FUfPL
•
Flocculation with Haste Fickle Liquor
IP
:
Pressure Filtration
LS
:
Lasella Separator
HAL
:
Neutralization with Al»
NAM
;
Neutralization with Aanonia
NU
J
Neutralisation with Unknown
ML
:
Not Reported
pas
;
pH Stabilization
SAPT
:
Sent to Another Plant for Treatment
UNK
«
Unknown
*
.
Confidential Data
(a)
;
Carbon Steel Mill
[J
:
Number in brackets represents values received

in the reapoaaes to the detailed questionnaire*
NOTE
s
See Table VII-1 for other geoeral abbreviation.
-------
TABLE III-4
BATCH SULFURIC ACID PICKLING DATA BASE
No. of	X of Total	Daily Capacity of	Z of Total
Operations No. of Operations	Operations (Tons)	Daily Capacity
Operations sampled for original study 8	4.7	3 , 62 5	7.9
Operations sampled for toxic pollutant study 8	4.7	2,256	4.9
Total nunber of operations sampled 16	9.4	5,881	12.8
Operations selected for the detailed DCP 17 incl.	10.0 incl	5 , 629 incl.	12.3
3 above	1.8 above	3,345 above	7.3
Operations sampled and/or solicited via
detailed DCP 30	17.6	8,165	17.8
Operations responding to basic DCP 136	80.0	38,966	85.0
Estimated total number of batch
sulfuric acid picklers 170	100.0	45,850	100.0
-------
TABLE III-5
CONTINUOUS SULFURIC ACID PICKLING DATA BASE
No. of
Operations
Z of Total	Daily Capacity of % of Total
No. of Operations	Operations (Tons) Daily Capacity
Operations sampled for original study	7
Operations sampled for toxic pollutant study	3
Total nunber of operations	10
Operations selected for the detailed DCP	1
Operations sampled and/or solicited via
detailed DCP
Operations responding to basic DCP
Estimated total number of continuous
sulfuric acid picklers
11
55
78
9.0
3.8
12.8
1.3
14.1
70.5
100.0
13,118
3,652
16,760
127
16,887
68, 604
80,700
16.3
4.5
20.8
0.2
20.9
85.0
100.0
-------
TABLE J11-6
HYDROCHLORIC ACID PICKLING DATA BASE
Operations sampled for original study
Operations sampled for toxic pollutant study
Total number of operations sampled
Operations selected for the detailed DCP
Operations saapled and/or solicited via
detailed DCP
Operations responding to basic DCP
Estimated total number of hydrochloric acid
pic kl era
No. of
Operations
14*
9 incl.
2 above
20
13 incl.
2 above
31
98
115
Z of Total
No. of Operations
10.4
7.8 incl.
1.7 above
17.4
11.3 incl.
1.7 above
27.0
85.2
100
Daily Capacity of Z of Total
Operations (Tons) Daily Capacity
19,110
6,864
1,197 above
24,777
14,785 incl.
2,196 aobve
37,366
100,155
117,140
16.3
5.9 incl.
1.0 above
21.2
12.6 incl.
1. 9 above
31.9
85.5
100
*: Two of these plants are Canadian and will not be included in any percentage or capacity figures.
-------
TABLE III-7
COMBINATION ACID PICKLING DATA BASE
BATCH TYPE OPERATIONS
Operations sampled for original study
Operations sampled for toxic pollutant study
Total number of operations sampled
Operations selected for the detailed DCP
Operations sampled and/or solicited via
detailed DCP
Operations responding to basic DCP
Estimated total number of batch type
combination acid picklers
No. of
Operations
4
5
9
5 i ncl.
2 above
14
66
78
X of Total
No. of Operations
5.1
6.4
11.5
6.4 incl.
2.6 above
17.9
85
100.0
Daily Capacity of Z of Total
Operations (Tons) Daily Capacity
472.8
313.8
786.6
1,133.6* incl.
89.4 above
1,830 .8
7,657*
9,008*
5.2
3.5
8.7
12.6 incl.
1.0 above
20.3
85
100.0
*: Confidential mills' capacity not included in this total.
-------
TABLE III-8
COMBINATION ACID PICKLING DATA BASE
CONTINUOUS TYPE OPERATIONS
Operations sanpled for original study
Operations sampled for toxic pollutant study
Total number of operations sampled
Operations selected for the detailed DCP
Operations sampled and/or solicited via
detailed DCP
Operations responding to basic DCP
Estimated nuaber of continuous type
combination acid picklers
No. of
Operations
1 incl.
1 above
4
0
4
63
74
Z of Total
No. of Operations
5.4
1.4
1.4
5.4
0
5.4
85
100.0
Daily Capacity of 7. of Total
Operations (Tons) Daily Capacity
503.1
183 incl.
183 above
503.1
0
503.1
9,557
11,243
4.5
1.6	incl.
1.6 above
4.5
0
4.5
85
100.0
-------
TABLE III-9
SUMMARY OF SAMPLED OPERATIONS
ACID PICKLING OPERATIONS
SULFURIC ACID
Sample

Type
Code
Reference Code
of Operation
I-2A
0856P
Beech
I-2B
0856P
Batch
0-2
0590
Batch
P-2
0312
Batch
Q-2
0894
Batch
R-2
0240B
Batch
S-2
02S6C
Batch
090
0476A
Batch
091
0612
Batch
092
0088A
Batch
096
01121
Batch
098
0684D
Batch
R
0240A
Batch
H-2A
0432A
Continuoua
H-2B
0432A
Continuoua
QQ-2
0584E
Continuous
SS-2
0112A
Continuous
TT-2
0856 D
Continuous
WW-2
0868A
Continuous
T-2
0792B
Continuous
094A
0948 C
Continuous
094B
0948C
Continuous
097
0760
Continuous
Process Product
Steel Type
Rod and Hire

Carbon
Rod and Wire

Carbon
Wire

Carbon
Bars, Shapes,
and Tubing
Carbon
Rod and Wire

Carbon
Tube

Carbon
Pipe and Tube

Carbon
Pipe and Tube

Carbon
Rod and Bar

Carbon
Pipe and Tube

Carbon
Fasteners and
Special Shapes
Carbon
Bars, Rods and Special Shapes
Specialty
Billets and Bara
Specialty
Strip

Carbon
Strip

Carbon
Sheet

Carbon
Sheet and Strip
Carbon
Strip

Carbon
Strip and Sheet
Carbon
Strip

Carbon
Sheet

Carbon
Strip

Carbon
Strip

Carbon
188
-------
TABLE 111-9
SUMMARY OF SAMPLED OPERATIONS
ACID PICKLING OPERATIONS
PAGE 2	
HYDROCHLORIC ACID




Sample

Type


Code
Reference Code
of Operation
Process Product
Steel Tvoe
1-2
0856P
Continuous
Wire and Rod
Carbon
U-2
0480A
Batch
Rod
Carbon
V-2
0936
Batch
Rod and Wire
Carbon
W-2
*
Continuous
Strip
Carbon
X-2
0060B
Continuous
Strip
Carbon
Y-2
*
Continuous
Strip
Carbon
2-2
0396D
Continuous
Strip
Carbon
AA-2
0384A
Continuous
Strip
Carbon
BB-2
0060
Continuous
Strip
Carbon
091
0612
Continuous
Wire
Carbon
093
0396D
Continuous
Scrip
Carbon
095
0584F
Continuous
Strip
Carbon
099
0528B
Continuous
Strip
Carbon
100
0384A
Continuous
Strip
Carbon
COMBINATION ACID
CD
Sample
Code
A»>
D
I
0
121
U
123
124
C
F
L
122
125
Reference Code
0900
248 B
432K-02
176
0900
0748
88A
88D
424-01
856H
440A-01
176
884E
Type
of Operation
Continuous
Continuous
Continuou*
Continuous
Continuou*
B«tch
Batch
Batch
Batch
Batch
Batch
Batch
Batch
Process Product
Sheet and Strip
Strip
Sheet
Strip
Sheet and Strip
Pipe and Tube
Tubes
Tubes
Plate, Bar
Plate
Bar
Rod, Wire,
Tubea
Shapes
Steel Type
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Specialty
Acids Used
In Process
HF/HNO.
H.SO,,HNO,,HF
H,S07,HN0,,HF
Unk, HNO-7HF
HF/HNO,
Unk
HNO,,HF
HNof/HF
H-SO. ,HN0,/HF
KSOT.HNOj/HF
HCIjHNO^
hci,hno::,hno3/hf,
HC1/HNO-
HF/HN03
(1) Operations A and 121 are the seae operation chat was visited on tvo different occasions.
* Plants W-2 and Y-2 are located outside of the United States, and have not been assigned
a reference code number.
189
-------
FUME
SCRUBBER
WATER SUPPLY
CONTINUOUS DISCHARGE
ACIDIFIED WATER
FUME EXHAUST SYSTEM
Rack conveyor
-FRESH ACID
,	STEAM
WATER SUPPLY
WATER
-WATER
(CONSTANT)
Pickling rack
PICKLING TANK
DIP RINSE TANK
N.C.
PERIODIC OVERFLOW
DISCHARGE-	
SPENT ACIO (DUMP) DISCHARGE <>
¦ACID RINSE WATER
CONTINUOUS DISCHARGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
BATCH PICKLING
SULFURIC 8 HYDROCHLORIC ACID
PROCESS FLOW DIAGRAM
Don. 3/27/79
FIGURE m-i
-------
*©
Continuous Discharge
Acidified Water
Water
Supply
Rack Conveyor
Pickling Rack
Fresh
Acid
_rh_
Fresh
Acid
Steam Supply
Water Supply
RINSE
TANK
RINSE
TANK
PICKLE TANK
PICKLE TANK
Pickle Rinse Water
ENVIRONMENTAL PROTECTION AGENCY
Spent Pickle Liquor
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
BATCH TYPE OPERATION
Own. 4/10/7 9
FIGURE m-2
-------
to
Water Supply
FUME
SCRUBBER
Continuous Discharge
Acidified Water
FUME EXHAUST SYSTEM
Steam Supply
Steam
-Steam
(Constant
feed rate)
, j Steam
(Constont
feed rate)
, j- Steam
(Constant
feed rate)
Water Supply
Water
Steam
-Water
(Constant feed rate)
-Steam
(Constant feed rate)
TANK N* I
TANK N* 2
TANK N! 3
TANK N* 4
SPRAY RINSE
DIP RINSE
PICKLING TANKS
Constant OwrflMifCoHMil
Of Spent Pickle Liquor
Containing Steam Condensate.
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
CONTINUOUS STRIP PICKLING
SULFURIC 8 HYDROCHLORIC ACID
PROCESS FLOW DIAGRAM
Acid Rinse
Water Discharge
Dwn. 8/27/73
Rev.2 2/24/76
FIGURE H-3
Re*. I 2/19/76
-------
WATER
SUPPLY
CONTINUOUS DISCHARGE
ACIDIFIED WATER
FRESH
ACID
FRESH
ACID
{STEAM
WATER ,
J V
/ V
SUPPLY
SPRAY
RINSE
DIP
RINSE
SPRAY
RINSE
DIP
RINSE
ACID TANK
ACID TANK
PICKLE RINSE
WATER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
CONTINUOUS TYPE OPERATION
SPENT PICKLE LIQUOR
-------
To
Atmosphere
Condenser
Cooling Woter-»
I0-|2.8"C~I2.6 lAec
Air
PRE-COOLER
-Water
INDENSERS
/HIGH PRESSURE
VACUUM EJECTORS
(Steam)
CENTRIFUGE
THICKENER
17.2* C
Water
Discharge
Liquor
Solids
VACUUM
CRYSTALLIZERS
(Air agitated &
continuosly operated)
150* F)
Crystals
CENTRIFUGAL PUMP
(Vacuum)
Recovered Acid
SPENT ACID
STORAGE TANKS
RECOVERED ACID
STORAGE TANKS
FERROUS SULFATE
HEPTAHYDRATE CRYSTALS
PICKLING TANKS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID RECOVERY
PROCESS FLOW DIAGRAM
TYPE I
Dwa 5/13/74 Re*2"2/26/76
FIGURE IE-5
-------
n r
V
COOLING a
AGITATION
CRYSTALLIZER
CRYSTAL
COLLECTOR
RECOVERED
ACIO TANK
HEAT a
AGITATION
FERROUS
SULFATE
HEPTAHYDRATE
U"
-ACID MIST FILTER
Roof Line

d Return
I f^n|
Purchased
Acid
Acidified Rinse Water
Push-Pull Fume
Exhoust System
Air
¦J
HEAT 8 	
AGITATION	, sT<^
Spent Pickle Liquor i \j) )
PICKLING TANK
Recovered Acid
Water
COMBINATION DIP
a SPRAY RINSE TANK
ACIO RECOVERY UNIT
BATCH PICKLING LINE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID RECOVERY
PROCESS FLOW DIAGRAM
TYPE H
Dot. 5/11/74
** I2/2C/76
Rat2-2/2y76
FIGURE n-6
-------
SPENT
ACID
REACTOR
OXIDE
BURNER
CONTROL
UNIT
VENT
CYCLONE
HOPPER
RECOVERED
HYDROCHLORIC
ACIO
WATER
INLET
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HCI REGENERATION TYPE I
PROCESS FLOW DIAGRAM
Dwq. 5/4/74HW.2/26/76
lm.Z/ZO/76	
[figure m-7
-------
WASTE
FAN
WASTE PICKLE
LIQUOR
CYCLONE
1 r*7 VENTURI SCRUBBER
WATER
INLET
FLUID-BED
REACTOR
SEPARATOR
ABSORBER
REGENERATED
ACID
AIR
FUEL
BLOWER
ENVIRONMENTAL PROTECTION AGENCY
O3
PELLETS
STEEL INDUSTRY STUDY
HCI REGENERATION
TYPE II FLUID BED ROASTER
PROCESS FLOW DIAGRAM
)waS/4/74 fr*2/26/76
FIGURE m-8
-------
WATER
INLET
WASTE
PICKLE-
LIQUOR
TAIL GAS
SCRUBBER
STORAGE
TANK
SCRUBBER
WASTEWATER
HYDROLYZER
EVAPORATOR
H'
ID
GO
OXIOIZER
SETTLING
TANK
JZL
SLURRY
TANK
REGENERATED ACID
FILTER
CONVEYOR
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HCI REGENERATION
TYPE III WET CHEMICAL PROCESS
PROCESS PLOW DIAGRAM
FIGURE m-9
-------
ACID PICKLING SUBCATEGORY
SECTION IV
SUBCATEGORIZATION
The Agency considered several factors to determine whether further
subdivision of the pickling process is appropriate. The applicability
of these factors to the pickling process and the rationale for the
proposed subdivision of the acid pickling subcategory are presented
below.
In the originally promulgated regulation, the Agency subdivided the
pickling process into three subgroups. That division has been
retained. However, each subdivision has been segmented further, as
shown below.
Segmentation
	( 1976 Regulations)
Sulfuric Acid
a.	Batch Operations -
Acid Recovery
b.	Continuous Operations
Neutralization
c.	Continuous Operations
Acid Recovery
Hydrochloric Acid
a.	Neutralization
b.	Acid Regeneration
Combination Acid
a.	Batch Operations -
Pipe and Tube
b.	Batch Operations - Other
c.	Continuous Operations
Revised
Segmentation
Sulfuric Acid
a.	Batch Operations -
Neutralization
b.	Batch Operations -
Acid Recovery
c.	Continuous Operations
Neutralization
d.	Continuous Operations
Acid Recovery
%
Hydrochloric Acid
a.
b.
c.
Batch Operations -
Neutralization
Continuous Operations
Neutralization
Continuous Operations
Acid Regeneration
Combination Acid
a.	Batch Operations
b.	Continuous Operations
For all acid pickling operations, one common element which affects the
segmentation of the process is the type of pickling carried out (i.e.,
whether the operation is batch or continuous). Because of the
different operating practices and products processed by these two
operations, applied and discharge flow rates are different.
199
-------
The treatability of the wastewater generated in the sulfuric acid and
hydrochloric acid subdivisions also affects segmentation. Acid
recovery processes make zero discharge from sulfuric acid pickling
operations possible, while neutralization of wastewaters and acid
regeneration of hydrochloric acid still require a discharge of
wastewater pollutants. Therefore, further segmentation is needed to
accommodate the treatment options.
The Agency also examined other elements, but found that the discharge
flow rate was the only other element which has a significant effect
upon segmentation. The Agency analyzed line age and size to determine
if those factors had an effect upon wastewater quality or quantity,
but found no signficant relationship. Also, the Agency considered
such factors as product type, raw material, and wastewater
characteristics, but found that none of these factors warrant further
subdivision or segmentation. While water use was found to have an
effect upon specific effluent limitations, this variation did not
require further segmentation. Each of these elements is discussed in
greater detail below.
Factors Considered in Subdivision and Segmentation
Manufacturing Process and Equipment
Within the acid pickling subcategory, the processes employed and the
equipment used are basically the same throughout the industry. The
Agency found only two signficant differences in acid pickling
operations that could possibly affect subdivision. The first involves
the manner in which the pickling process is carried out. While some
operations pickle products in a batch fashion, other operations use a
continuous process to pickle products such as strip or sheet,
resulting in significantly different flow rates. The justification
for segmentation based on the batch or continuous mode of operation is
discussed below under the heading "Process Water Usage."
The second difference is in equipment employed at acid pickling
operations. Fume scrubber systems which collect and scrub the fumes
generated in the pickling process are used at some lines. Most types
of scrubbers generate considerable quantities of wastewater and
consequently increase the pollutant load in the discharge from the
pickling process. The proposed BAT, NSPS, PSES, and PSNS limitations
and standards have been developed based upon the assumption that all
acid pickling operations use fume scrubbers.
Final Products
An analysis was done to determine whether the products being processed
affected the pickling process, wastewater characteristics, or other
significant factors. For this analysis, the Agency evaluated only
rinsewater quality, since rinsewater is the only wastewater source,
which could significantly be affected by variations in the product
and, thereby, affect segmentation. The spent pickle liquor and fume
scrubber characteristics are relatively constant for each subdivision,
even for operations which process a wide variety of products.
200
-------
A.	Sulfuric Acid Pickling Operations
Sulfuric acid pickling operations process a wide variety of
products, some as final products and others for further
processing (i.e., cold reduction, coating, oiling, or painting).
The most common steel shapes processed by sulfuric acid pickling
are: strip/sheet/plate; bar/wire/rod; and pipe/tubs. The
strip/sheet/plate grouping comprises 92.5% of the continuous
sulfuric acid pickling operations, while the bar/wire/rod and
pipe/tube groups make up 92.5% of all batch operations.
Sampling data do not indicate any significant differences in
rinsewater characteristics between the three types of products
being pickled in sulfuric acid solutions. In addition, the basic
pickling process is similar for these configurations. Therefore,
the Agency believes that no further segmentation of this
subdivision is warranted on the basis of final products.
B.	Hydrochloric Acid Pickling
The most common steel products processed by hydrochloric acid
pickling are: strip/sheet; pipe/tube; and wire/rod/fence.
Strip/sheet may, in turn, be formed into various shapes, such as
auto parts, architectural components, containers, gutters, and
channels. The seven batch hydrochloric acid picklers in
operation process all three types of product groupings. The
continuous hydrochloric acid pickling segment consists of the
strip/sheet and wire/rod/fence product lines.
Sampling data do not indicate any significant differences in the
qualities of the rinsewaters generated for the three types of
products. In addition, the basic pickling process is similar for
these configurations. Therefore, the Agency believes that no
further segmentation of the hydrochloric acid subdivision is
warranted on the basis of final products.
C.	Combination Acid Pickling
As in the other subdivisions, the products processed in
combination acid pickling operations are strip/sheet, pipe/tube>
and bar/wire products. Strip/sheet products comprise 92.4% of
the continuous operations. In contrast, batch operations consist
mainly of bar/wire and pipe/tube products (81.3%). As in the
other two acid pickling subdivisions, no significant differences
were found in either the rinsewater quality or pickling process
characteristics associated with the pickling of the three types
of products. Therefore, the Agency believes that no further
segmentation on the basis of final products is warranted in the
combination acid pickling subdivision.
201
-------
Raw Materials
A.	Type of Acid Used
The most signficant raw material - the acid used for pickling -
forms the basis for subdividing the pickling subcategory into
sulfuric, hydrochloric, and combination acid subdivisions. The
choice of the acid(s) to be used in the process is usually
dictated by the types of steel to be pickled and the desired
surface characteristics after pickling. Sulfuric acid penetrates
the oxide layer and reacts with the base metal to form hydrogen,
which aids in removing the oxide scale. The scale eventually
dissolves in the acid bath forming ferrous sulfate. Hydrochloric
acid reacts directly with the oxide scale, forming soluble
ferrous and ferric chloride. Generally, combination acid
pickling is the preferred process for alloy, stainless, and other
specialty steels. In addition to the iron salts which result
from pickling, other metals found in the steel are dissolved in
the acid bath. These are discussed in Section VI.
B.	Type of Steel Pickled
The other significant raw materials are the carbon steel and
specialty steel products being pickled. For the sake of this
discussion, any operation which processes 50% or more carbon
steel is called a "carbon steel operation", and any which
processes less than 50% carbon steel is called a "specialty
steel" operation. While the Agency found that the type of steel
being processed might affect the way in which a pickling line is
operated, it also found that the type of steel does not
significantly affect the eventual wastewater pickling quantity.
About 5.2% of the sulfuric acid pickling operations and only 2.9%
of the hydrochloric acid operations pickle specialty steel
products. While raw wastewaters from pickling specialty steels
contain more toxic metal pollutants than do wastewaters from
pickling carbon steel, nearly all specialty steels undergo
combination acid pickling. Thus, the difference in wastewater
quality between carbon and specialty steels is accounted for by
the basic subdivision of the acid pickling subcategory into
sulfuric, hydrochloric, and combination acid subdivisions. For
these reasons, the Agency concluded that it is not necessary to
segment or subdivide further, based upon the type of raw material
used (i.e., the type of steel processed).
The type of steel pickled is often the determining factor for the
types of acids used. For specialty steel operations, a much
broader range of acids is used (hydrochloric, sulfuric, nitric,
and hydrofluoric acids). Although the exact order of pickling
and the types of acids used vary from plant to plant, most
operations use hydrochloric or sulfuric acids at the head of the
pickling lines and finish with a mixture of nitric and
hydrofluoric acids.
Most carbon steel operations use hydrochloric and sulfuric acid
pickling lines. Nitric acid is used at one carbon steel line,
202
-------
and hydrofluoric acid is not used at any line processing carbon
steel. Hence, the high levels of fluorides and nitrates found in
the discharges from specialty steel operations are not found in
discharges from carbon steel lines. This was taken into
consideration by the Agency in developing the proposed
limitations.
The Agency also analyzed the effect of raw materials on applied
and discharge flow rates. The Agency initially thought that
specialty steel operations might require additional water in the
process because of the more stringent product quality
requirements. However, this did not turn out to be the case.
Wastewater Characteristics
As noted above, wastewaters from acid pickling operations originate
from rinsewater, fume scrubbers, and spent acid solutions. Rinsewater
flow is often the highest flow among the three sources and contains
suspended solids and dissolved metals, and normally has a very low pH.
Fume scrubber wastewaters are similar to rinsewaters in character.
Flow rates through the scrubbers vary considerably, but discharge
flows can be reduced to 10-50 gals/ton of steel processed if recycle
is practiced. Fume scrubber blowdowns from sulfuric and hydrochloric
acid pickling operations may be completely reused as makeup to cascade
rinse systems. The third source, the spent pickle liquor (SPL) is
lower in volume than the other sources but is highly contaminated.
Because of the small volume and high pollutant levels, this waste is
often hauled off-site for disposal. As would be expected, the
wastewater characteristics of the combined discharge from pickling
lines depends greatly on whether or not fume hood scrubbers are
installed and whether or not the SPL is hauled off-site.
Another factor affecting wastewater characteristics is the type of
acid used in the pickling process. As noted earlier, various acid
combinations are used depending on the type of product being processed
and the type of finish desired. The number of acids used ranges from
one to four.
Wastewaters from each pickling subdivision can be treated by
neutralization and settling. However, the materials remaining in
solution are different for each subdivision. Sulfuric acid will, form
relatively insoluble calcium sulfate precipitates which contribute
significantly to the sludge loads, while hydrochloric acid yields
soluble calcium chlorides with less of an impact on sludge generation.
Dissolved solids are likely to be higher for hydrochloric acid
wastewaters after treatment with lime, soda ash, or caustic soda.
Fluorides are only discharged in significant quantities when
hydrofluoric acids are used. Accordingly, allowances have been made
in the proposed limitations for the use of hydrofluoric acid. The
variations in waste character are the primary reasons for the division
of pickling operations by acid type.
203
-------
Wastewater Treatability
The Agency analyzed the treatability of wastewaters from the different
acid pickling operations. Based upon the data developed during plant
visits and the data supplied in DCP responses pertaining to treatment
systems, the only signficant differences in wastewater treatability
for acid pickling operations are in the sulfuric and hydrochloric
pickling subdivisions, where acid recovery, regeneration, and
neutralization are practiced. Because these methods differ
significantly in discharge flow rates, pollutant loads, and typical
treatment systems, the Agency concluded that segmentation on this
basis is appropriate.
Size and Age
The Agency evaluated whether either the size or age of pickling
operations are signficant factors which warrant further subdivision or
segmentation of the acid pickling subcategory.
Figures IV-1 and IV-2 are plots of applied rinsewater flow (gal/ton),
vs. production (tons/year) for sulfuric acid batch and continuous
operations, respectively. The points on these plots are widely
scattered, indicating no correlation between size and applied
rinsewater flow, which is a major factor in pickling treatment system
design. Figures IV-3 to IV-5, and Figures IV-6 and IV-7 present
similar data for the hydrochloric acid and combination acid pickling
subdivisions, respectively. Those data again demonstrate no
correlation between size and applied rinsewater flow. Hence, there is
no basis to further subdivide or segment pickling operations on the
basis of size.
The question of age was addressed in two ways. First, plots of
applied rinsewater flow (gal/ton) vs. age (first year of production)
similar to those noted above were made. These data (Figures IV-8 to
IV-14) show no correlation between the age of any type of pickling
operation and the respective applied rinsewater flows. Secondly, the
ability, ease, and cost of retrofitting pollution control facilities
was evaluated. Table IV-1 lists the older pickling operations which
have been retrofitted with pollution control facilities. The fact
that treatment facilities have been retrofitted on those older lines,
and that similar effluent loads are discharged from these treatment
facilities, demonstrates the feasibility of retrofitting pollution
control equipment to plants of all ages. As part of its data
gathering efforts, the Agency also obtained actual costs incurred by
the industry to install retrofitted treatment facilities, specifically
including any costs due solely to retrofitting. In general, the
industry reported either no specific retrofit costs or relatively
small retrofit costs. Retrofit costs of about 14% of total treatment
system costs were reported for one sulfuric acid pickling line. Based
upon these data, the Agency concludes that the costs of retrofitting
pollution control facilities on pickling lines are not substantial,
and that no further subdivision or segmentation of the acid pickling
subcategory on the basis of age is necessary.
204
-------
Geographic Location
An examination of the raw waste characteristics, process water,
application rates, discharge rates, effluent quality, and other
factors relating to plant location revealed no general relationship or
pattern. Sulfuric acid pickling operations are located in 20 states.
Hydrochloric acid operations are in 13 states, and combination acid
pickling operations are in 15 states. Most of these lines are located
in the major steel producing areas of Pennsylvania and Ohio. Table
IV-2 is a summary of the location of all acid pickling operations
responding to the DCPs.
A small percentage of pickling plants are located in what could be
considered "semi-arid" or "arid" regions. However, since no cooling
systems are required to attain the proposed limitations and standards,
consumption of water by these operations will be nil. Additional
details on this issue are presented in Section VIII.
Process Water Usage
Table IV-3 presents average applied rinsewater flow rates for all
batch and continuous pickling operations. The data presented in this
table illustrate the basic differences between batch and continuous
operations within each subdivision. Also presented in Table IV-3 are
spent pickle liquor and fume scrubber flows. Both applied and
discharge flows are presented for fume scrubbers to demonstrate the
extent of recycle applied to these waters.
Based upon these data, the Agency decided to retain allowances for
spent pickle liquor for sulfuric acid pickling and for fume scrubbers
for hydrochloric acid pickling at the BPT level, and to incorporate
all of these flows at the BAT level.
205
-------
TABLE IV-1
ACID PICKLING OPERATIONS
DEMONSTRATING THE ABILITY
TO RETROFIT POLLUTION CONTROL EQUIPMENT
Reference	Operation	Treatment
Subcategory		Code	Age (Year)	Age (Year)
Sulfuric Acid Pickling 0020B	1954	1974
0048F	1944	1969
0060D	1957	1968
0060M	1970	1977
0088A	1936	1969
0088D	1962	1971
0112	1922	1977
0112C	1926	1977
0256F	1953	1 975
0384 A	1958	1964
And Others
Hydrochloric Acid Pickling 0020C	1946	1977
0112B	1936	1 971
0176	1961	1956
0320	1936	1955
0384A	1932	1 970
0396D	1967	1969
0432C	1952	1964
0448A	1954	1 970
0580A	1962	1 967
And Others
Combination Acid Pickling 0020B	1947	1974
0088A	1952	1969
0112A	1926	1977
0112H	1940	1 951
0256F	1953	1 975
0284 A	1957	1 971
0584D	1940	1970
0860 F	1962	1977
And Others
206
-------
TABLE IV-2
LOCATION OF ACID PICKLING OPERATIONS
SULFURIC ACID PICKLING
Total
Location
Numbers
% of Total
Pennsylvania
52
27.2
Ohio
36
18.8
Illinois
17
8.9
Indiana
14
7.3
Maryland
14
7.3
California
11
5.8
Connecticut
8
4.2
Michigan
8
4.2
3.7
Texas
7
Alabama
6
3.1
New York
4
2.1
Missouri
3
1.6
Washington
3
1.6
Kentucky
2
1.0
Georgia
1
0.5
Colorado
1
0.5
Florida
1
0.5
Mississippi
1
0.5
New Jersey
1
0.5
West Virginia
1
0.5
Number of States » 20
191
100%
HYDROCHLORIC ACID PICKLING
Location
Ohio
Pennsylvania
Michigan
Illinois
California
Kentucky
Indi ana
Alabama
West Virginia
New Jersey
Georgia
New York
Connecticut
Number of States * 13
207
Total

Nunbers
Z of Total
16
16.3
14
14.3
14
14.3
13
13.3
8
8.2
7
7.1
7
7.1
5
5.1
3
3.1
3
3.1
3
3.1
3
3.1
2
2.0
98
100Z
-------
TABLE IV-2
LOCATION OF ACID PICKLING OPERATIONS
PAGE 2
COMBINATION ACID PICKLING
Total
Location	Numbers	2 of Total
Pennsylvania	69	53.5
Ohio	18	14.0
Wisconsin	7	5.4
Maryland	6	4.7
New York	4	3.1
Indi ana	4	3.1
California	4	3.1
Massachusetts	3	2.2
Illinois	3	2.2
Delaware	2	1.6
Texas	2	1.6
New Jersey	2	1.6
Georgia	2	1.6
Michigan	2	1.6
Florida	1	0.8
Number of States - 15	129	100Z
208
-------
TABLE IV-3
AVERAGE PROCESS FLOW VALUES
(CAL/TaO—ACID PICKLIHC 3OBCATEGORY
Applied
Sp«nt Pickle
Sulfuric Acid Pickling	Liquor
Batch Neutralixatioa	15.6
Batch Acid Recovery	IS.6
Continuous Neutralisation	19.9
Continuous Acid Recovery	19.9
Hydrochloric Acid Picklim
Batch Neutralixatioa	7.2
Continuous Neutralixatioa	8.4
Continuous Acid Regeneration	8.4
Combination Acid pickling
Batch	14.1
Conti nuous	14.2
Applied	Discharged
Applied	F«ne Hood	Fine Hood
Rinse	Scrubber	Scrubber
327	708	10.3
327	708	10.3
213	126	0
213	126	0
538	ISO	0
295	176	6.2
29}	176	6.2
317	1136	2.0
1809	716	47.8
These flow values represent averages of the best flow values.
209.
-------
FIGURE IV- I
SULFURIC ACID PICKLING - BATCH
APPLIED RINSE FLOW ( GAL /TON )
vs. PRODUCTION (TONS/TURN)
g
i.
c*
10
7
°	XX
!0
2	3
£2	*	"x
N.	*
¦J	Q
<	O	XX
O	*
X
X
R. X
UJ »-
m	x
Q o	* x
Uj i0
—	X
CL	X
£1.
<
KJ	v
Sj * * *
x *
* X
*
XX	*
Xx X X '
* X	*V x 54
	1		r3	1	-7—	1	1	1	1
.00	12.90	25.00	ST. 50	30.00	62.50	73.00	87.30	100.00
PRODUCTION (TONS/TURN) X 10"'
210
-------
s
FIGURE IV ~ 2
SULFURIC ACID PICKLING - CONTINUOUS
APPLIED RINSE FLOW ( GAL /TON )
vs. PRODUCTION (TONS/TURN)
X
*	X
X
*5<	X
X
XX	X
X
*	* X X
-X-X	1		1—	—J-		1	1	1	1
.BO	60.44	120.57 180.31 240.28 300.19. 560.12 420.06 460.00
PRODUCTION (T0N5/TURN1 X 10"'
211
-------
FIGURE IV - 3
HYDROCHLORIC ACID PICKLING - BATCH
APPLIED RINSE FLOW ( GAL/TON )
vs. PRODUCTION (TONS/TURN)
8
S«4
2 «
o.
p
<
2B
o
U/ 2.
§§
-J
Q.
QL
<
' I" .
53.23
"I	
168. £7

• II
r
66.34
"T	
99.48
"I	
132.96
198.75
zs\.m
568.00
PRODUCTION (TONS/TURNJ
212
-------
s
J
si!
W 5-
o
x _
5
z &
g
V '
i 9
o
o «
-»5
*7
Ui
(0
2
5 £
O R.
LU
~
a.
< 3
it
FIGURE IV- 4
HYDROCHLORIC ACID PICKLING - CONTINUOUS
APPLIED RINSE FLOW ( 6AL./T0N )
vs. PRODUCTION (TONS/TURN)
*
*	x
3 »	w * x3* .»» »*	* 	*	X
"* r i i i » i	J i 		 	 1
.01 17.a* SB.63 98.44 7I.U 81.07	I06.BB 124.60 , 141.80
PRODUCTION (TONS/TURN) X ICT1
213
-------
s
2-k
FIGURE IV- 5
HYDROCHLORIC ACID PICKLING - ALL PLANTS
APPLIED RINSE FLOW ( GAL./TON )
vs. PRODUCTION (TONS/TURN)
i;*%x
o
3-JC
*	r ^ **—* -3** * * * t *	1—		^
.01	|7.«* ».63 85.44 71.16 49.07 I06.SS »«*.» 14%. 50
PRODUCTION (TONS/DAY)X 10"'
214
-------
U-S *
k
>«> v *
ir» ,C
FIGURE IV - 6
COMBINATION ACID PICKLING - BATCH
APPLIED RINSE FLOW ( GAL /TON )
vs. PRODUCTION (TONS/TURN)

X
X
& * **	X
„ x*
;£t * *£	x
	1	1	1	1	II	I	I
.00	ia.78 37.80 tt.28 78.00 «.7B	If«.» I5L2S 100.
PRODUCTION/CAPACITY ( TONS / DAY) X ICT1
215
-------
FIGURE IV-' 7
COMBINATION ACID PICKLING - CONTINUOUS
APPLIED RINSE FLOW ( GAL /TON )
vs. PRODUCTION (TONS/TURN)
vi
o *-
zR
_1
<
*
o
-J
SS
taJ .
Z **
o
jt' *'*¦
a. w
CL
<.
2
X xx
X X
X
X
X
X
>5*
X
X
X
*
xx *
X X X X *
**x
*	X
x», * *
*	,	J	1	1	J	1	1	1
.00	18.78 57. BO W>.» 7S.00 93.78	Il«.» 191.29 100
PRODUCTION ( TONS / DAYJ X IO-'
216
-------
s
©
FIGURE IV- 8
SULFURIC ACID PICKLING - BATCH
APPLIED RINSE FLOW ( GAL /TON) vs.
AGE (FIRST YEAR OF PRODUCTION )
X
X
X	X
X
X
X x
X *
3t	X
*	X
*	X
*	* X *
* »
X	*
*	X *	V*	*
*	X	v
X	X	X
X „	*	**
X	x	X	X	X	*	*
_—| 		 —''11 11 i ;,n					i	—t" ' 1 1 11	1:
1900.00 f9IO.tt f431.28 nSt.OT 1942.80 1963.I* 19*3.78 (974.37 f9«.0<
AGE (FIRST YEAR OF PRODUCTION)
217
-------
FIGURE IV - 9
SULFURIC ACID PICKLING - CONTINUOUS
APPLIED RINSE FLOW ( SAL /TON )
AGE (FIRST YEAR OF PRODUCTION)
X
X
X
X
T
T
1900.00 1907.50 1918.00 I9**.S0 1930,00 1937,30
AGE (FIRST YEAR OF PRODUCTION)
1948.00
1932.30
"1
1960.00
218
-------
FIGURE IV- 10
HYDROCHLORIC ACID PICKLING - ALL PLANTS
APPLIED RINSE FLOW ( GAL /TON ) vs.
AGE ( FIRST YEAR OF PRODUCTION)
cu
8
*
8_
a
b'S*.
z _
n
<
wR
uj-
«sJ
z."
83
CL
<
» *
* 1	1	1 ' t	i	1	i	|
1949.00 I44f.lt J 985.39 1987.57 1961.80 I9M.M 1969.78 1973.07 1978.00
AGE (FIRST YEAR OF PRODUCTION)
219
-------
figure IV" II
HYDROCHLORIC ACID PICKLING - CONTINUOUS
APPLIED RINSE FLOW ( GAL /TON )
AGE (FIRST YEAR OF PRODUCTION)
CM
i
O
x ®.
O
H
3?
< ®.
O **
oS
sl<.
UJ
cr>
z
£S
O n-
UJ
3
a.
a. 4
< *»
;
X
*	X
x *-*$** n -*** ** ***** gx x
1	:	1	1—		1—	1	1	1	1
1910.00 I9IB.7B 1937.90 I9».W 194B.OO 1993.75 1962.50 1971.23 I
AGE. (FIRST YEAS OF PRODUCTION)
220
-------
FIGURE IV- 12
HYDROCHLORIC ACID PICKLING - ALL PLANTS
APPLIED RINSE FLOW ( GAL /TON )
AGE (FIRST YEAR OF PRODUCTION )
S
J
£_
B
rs
CVJ —'
I
o
X -
— o
Z &
e
*9
® &
o
ills
&
uj w
to
z
£
N
Q".
UJ S»-
Ij
OL
a.
-------
FIGURE IV- 13
COMBINATION ACID PICKLING - BATCH
APPLIED RINSE FLOW ( GAL /TON )
AGE (FIRST YEAR OF PRODUCTION )
N
n
B"
CM »
o P-
2 £
o ¦?
h- s-
v
<
O O
- . 0
©•
.J
u_
w 3
s ri-
ce '
a	* *
UJ
. P	x
frf **
< *
x
X
" " * *
-, llj I.*
*2—y »a
i	i	I	1	J		—1 " '< i	1
.00 law. 12 1911.28 1914.37 1987.80 1980.42 19*3.78 [V7&.S7 1990.00
AGE (FIRST YEAR OF PRODUCTION)
222
-------

3h
FIGURE IV- 14
COMBINATION ACID PICKLING - CONTINUOUS
APPLIED RINSE FLOW ( GAL/TON) vs.
AGE (FIRST YEAR OF PRODUCTION )
x*
*
X
X
X
X
X	x
X
X
X
*
X	*
3 X * 3
* X
* X
* * X
X
	—,	<	1	I	J M—I	i	1
1930.00 !9*7.W> 1958.00 19-tt.SO (989.08 I987.W 1948.00 1971.80 1980.00
AGE 
-------
ACID PICKLING SUBCATEGORY
SECTION V
WATER USE AND WASTE CHARACTERIZATION
Introduction
Process water usage within the steel industry is a major factor in
determining pollutant loads and estimating the cost of wastewater
treatment. The Agency used the data from the sampling inspections and
responses to the DCPs to evaluate process water usage within this
subcategory, and to obtain total wastewater volumes. The Agency
identified, for each line, existing control and treatment technology
and the method of wastewater disposal.
This section characterizes the wastewaters from acid pickling
operations and reviews the actual operation of the pickling process.
The waste characterization is based upon data obtained from two
sampling programs. During the first sampling program, the Agency
investigated the levels of the previously limited pollutants. During
the second program, additional monitoring was conducted for toxic
pollutants. When an operation was visited twice, only the more recent
data were used to characterize wastes from that operation.
Only process wastewaters are considered herein. Noncontact cooling or
nonprocess waters are not limited by the proposed regulation. Process
wastewater is that water which comes into contact with the process,
product, by-product, or raw materials, thus becoming contaminated with
various pollutants characteristic of the process. Noncontact cooling
water is defined as that water which does not directly contact
processes, products, raw materials, or by-products. Nonprocess
cooling water is defined as that water which is used for nonprocess
operations, i.e., utilities and maintenance.
Acid Pickling
As shown in Section III, acid pickling is performed either on a batch
or continuous basis. Wastewaters are discharged from three sources in
the acid pickling process: from the tanks containing the pickle
liquor, from the rinsing step(s) following the pickling tank, and from
the fume scrubber systems if wet scrubbers are used. Each of these
sources is described separately below.
1. Pickle Rinsewater - Batch and Continuous
The first wastewater source is the rinsing operation following
the pickling step. Depending upon whether or not the operation
is batch or continuous, varying amounts of water are used and
discharged. However, regardless of the type of operation, the
rinsewaters constitute higher flows than the other sources and
contribute much of the pollutant load to the treatment system.
225
-------
There can be one or more rinse steps depending upon the pickling
operation. A considerable number of lines include a single tank
in which the product is rinsed after pickling. However, many
lines include multi-step rinsing processes which consist of dip
tanks, spray chambers, or other rinsing components. The exact
arrangement of the rinses depends greatly upon the degree of
rinsing and cooling required.
Rinsewater discharge flows can be minimized with cascade or
countercurrent rinse systems. The water flow to the rinse tanks
is reduced and cascades from one tank to the next. The fresh
water makeup enters the final tank and then discharges from the
first rinse tank. The product to be pickled travels in the
opposite direction to the water flow and thus is rinsed with
successively cleaner water. These systems reduce water flow,
concentrate the pollutants in the last rinsing chamber, and
achieve more thorough rinsing. Although cascade rinsing is
ideally suited to continuous operations, it is also used for
batch operations.
The rinsewater flow and the wastewater characteristics can vary
considerably depending upon such factors as the number of rinsing
steps used and the type of rinsing (i.e., flow-through versus
standing; cascade versus conventional), and other factors. The
Agency considered these variations in developing these proposed
limitations.
Flow data and net concentrations for pollutants found in the
rinsewater at batch and continuous lines surveyed for this study
are summarized in Tables V-l, V-3, V-6, V-8, V-12, and V-15. Net
concentrations are presented to describe the actual levels of
pollutants contributed by acid pickling operations. Averages are
also listed to show a typical level of pollutants found in
discharges from batch and continuous operations.
B. Spent Pickle Liquor
The second source of wastewater in acid pickling operations is
spent pickle liquor (SPL) bath, which contains a pickling
solution composed of acids or various acid mixtures depending on
the type of steel being pickled (i.e., carbon versus specialty),
or, on the type of finish desired. Regardless of the type of
acid used, however, spent pickle liquors are highly contaminated.
The same pickling solution is generally used for several days or
weeks to process large tonnages of steel products. The contents
of the bath are replaced when the acid loses its strength to the
point, where extended pickling times are required or product
quality diminishes.
The quality of the SPL can vary greatly, depending on the age of
the solution. The wastewater characteristics for the sampled SPL
sources are summarized in Tables V-2, V-4, V-7, V-9, V-13, and
V-l6. If no flow data are presented in these tables for a
particular plant, there was no flow from the tanks when the
sampling was conducted. Because spent pickle liquor is highly
226
-------
contaminated and low in volume, contract hauling off-site is a
common disposal method. Lines that do not have SPL hauled,
gradually bleed the liquor into treatment systems for disposal,
or recover or regenerate it.
The solutions in the acid tanks are heated to increase the
chemical action of the pickling solutions. As a result, the
temperatures of the wastes being discharged from the bath can be
as high as 93.3°C (200°F).
C.	Fume Scrubber Water
The third potential source of wastewater in the acid pickling
process is the wet fume scrubber. Wet systems are used to
collect and scrub fumes generated in the pickling process. Other
types of fume treatments that do not require water are in use at
several acid pickling operations. An example of this type of
system is the acid demi&ter used at one of the sampled sulfuric
acid pickling operations.
Considerable quantities of pollutants are discharged from the
fume scrubbing system, as the water scrubs the contaminants
carried from the process in the fumes. The concentrations of
pollutants discharged from the scrubbers vary considerably and
depend upon such factors as the amount of fumes generated in the
process, the water usage in the scrubber, and the degree of
recycle. The level of pollutants found at the 12 fume scrubber
systems sampled are summarized in Tables V-5, V-10, and V-14.
As discussed in later sections, the applied flow to the scrubber
system can, however, vary considerably. These flow rates can be
reduced significantly by recycling of the scrubber water. Many
of the lines with recycle systems on fume scrubbers discharge
less than 10 gal/ton. As noted earlier, these blowdowns may be
completely reused as rinsewater makeup at sulfuric and
hydrochloric acid lines.
D.	Absorber Vent Scrubber Water
The regeneration mode of treating spent hydrochloric acid
pickling solutions can generate an additional wastewater source.
Wet absorber vent scrubbers are used to collect and scrub fumes
generated by the acid regeneration process. The concentrations
of pollutants discharged from the scrubbers vary considerably and
depend upon such factors as the amount of fumes generated in the
process, the water usage in the scrubber, and the degree of
recycle. Table V-ll summarizes analytical data from absorber
vent scrubbers.
The applied flow to the scrubber systems may vary. However,
these flow rates may be reduced through recycle. Absorber
scrubber recycle systems have demonstrated a discharge of 25
gal/ton. These blowdowns may be reused as rinsewater in
hydrochloric acid lines.
227
-------
tabu: v-i
SWWAHT OF AKALYTICAL UU FROM SMUD FLAHTS
BATCH SULFURIC ACID FICXLIHG
MET RAW RIHSE WASTEWATER - eOHCBHTEATIOH (¦g/1)
Raw Wastewater
Plant Code
Reference do.
Saaple Point*
Flow (gal/toil)
Parameters
090	091
0476A	061Z
C-(*H)	F-A
91	122
092
00B8A
F-D-C-A
326
096
01121
D-A
604
I-ZA
0856F
7-6
207
1-2B
0856P
3-6
465
0-2
OS 90
1-2
18.0
R-2
0240B
2-7-6
30.8
S-2
02566
3-4-2
198
I
0240A
11-1
30
Average
164
NJ
tvj
CO

Diaaolved Iron
391
2350
51.7
97
2900
350
3.6
43,000
6500
3500
1850
596
8990
5430

Oil and Grease
22
15
42.8
12
-
4.3
8.4
12
11
0.6
4.5
21
1.3
11.9

Suspended Solids
-
-
361
126
19
70
21
18
749
20
370
159
1.3
147

P«
1.7-2.5
1.8
5.9-6.9
3.2-3.7
1.8
2.4-2.6
2.9-6.4
<1.0
1.3-1.6
1.9
2.0
2.2
1.6
<1.0-6.9
22
Parachl orcweta-
cresol
HD
0.020
HD
HD
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.004
44
Methylene Chloride
HD
m>
0.040
HD
HD
ML
HA
HA
HA
HA
HA
HA
HA
0.008
51
Chi orodibroao-
aethane
HO
HD
0.070
HD
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.014
57
2-Hitrophenol
0.022
m>
HD
HD
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.004
60
4,6-Dini tro~o-
creaol
m
0.095
HD
HD
HD
HA
HA
m
HA
HA
HA
HA
M
0.019
66
Bi»(2-ethylhe*3rl)
phthalate
0.078
0.025
2.03
0.042
HD
HA
M
HA
HA
HA
HA
HA
HA
0.44
67
Butyl benqrl
0.011
0.034
HD
0.011
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.011

ph thai ate













0.011
68
St-rhit}l
pbthalate
n>
n>
0.055
HD
HD
KA
M
HA
HA
HA
HA
HA
HA
70
Diethyl phthalate
0.065
HD
HD
HD
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.013
71
Dinetbyl phthai ate
0.085
HD
HD
HD
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.017
85
Ttetrachloroethylane
0.012
HO
HD
HD
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.002
US
Arsenic
HA
m
0.08
HA
0.33
HA
HA
HA
HA
HA
HA
HA
HA
0.021
118
Cafeitaa
-
-
-
-
0.13
HA
M
HA
HA
HA
HA
HA
HA
0.026
119
Orosiai
0.36
3.8
16.3
0.090
2.4
HA
M
HA
HA
HA
HA
HA
HA
4.59
120
Copper
0.33
0.61
0.M
0.07
3.7
HA
HA
HA
HA
HA
HA
HA
HA
1.09
121
Cyanides
Wad
HO
HD
0.075
HD
HD
HA
HA
HA
HA
HA
HA
HA
HA
0.015
m
-
0.13
HD
0.18
1.89
HA
HA
HA
HA
HA
HA
HA
HA
0.44
124
nickel
0.42
0.79
1.4
0.080
3.7
HA
1M
HA
HA
HA
HA
HA
HA
1.30
126
Silver
m
HD
HD
HD
0.020
HA
HA
HA
HA
HA
HA
HA
HA
0.004
128
Zinc
59
27
1.14
15
-
HA
HA
HA
HA
HA
HA
HA
HA
20.6
HDi Hot detected (included in average).
Ms Mot analysed.
- I let calcalatiooa yielded negative values.
-------
TABLE V-2
SnOKKX OF AMLVTICAL DATA FK>M SMTU» PLAHTS
MICH. SULFURIC ACID PICKLMG
WET RAW SPEW OOMCEHrRATBS - CfCHBMn«l (»g/l)
Raw
Wastewater






Plant Code
091
092'
P-2
Q-2
R-2

Reference No.
0612
0088A
0312
0894
0240B
Aieragi
Sanple Points
R-A
C-A
3
1
6

Flow (gal/com)
3.5
14.6
17.6
24.3
10.5
14.1
Par aneter







Dissolved Iron
63,000
38,500
46,800
61,900
67,800
55,600

Oil and Grease
8
14
29
14
HA
16.25

Suspended Solids
2363
305
26
142
70
581.2

PH
<1.0
<1.0
1.4
<1
2.0
<1.0-2.
11
1,1,1,-Trichloroethane
0.010
HD
HA
NA
NA
0.005
23
Chi or of am
0.010
HD
MA
NA
NA
0.005
44
Methylene Chloride
ND
0.042
MA
NA
M
0.021
66
Bi»(2-ethylhexyl )ph thai ate
0.78
0.015
NA
NA
NA
0.40
68
Di-n-butyl phthalate
HD
0.045
HA
NA
HA
0.022
71
Dinethyl phthalate
m>
0.150
HA
NA
NA
0.075
85
Tet rachl oroethylene
0.010
HD
HA
NA
HA
0.005
86
Toluene
0.010
HD
HA
NA
HA
0.005
87
Trichloorethylene
0.010
HD
HA
NA
HA
0.005
118
Cadaiun
0.25
0.26
NA
NA
HA
0.026
119
Chroaiua
269
205
HA
NA
HA
237
120
Copper
2.6
4.7
HA
HA
HA
3.7
122
lead
1.5
-
HA
HA
HA
0.75
124
¦ickel
23
27
HA
HA
HA
25
126
Silwr
0.59
0.43
HA
NA
HA
0.52
128
Zinc
16
133
NA
NA
HA
75
Dt lot detected!.
Mi Hot analysed.
- I Met calculations jtilM negative result*.
-------
TABU V-3
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
CORTIHDODS SOLFtftIC ACID PICKLING
NET RINSE WASTEWATERS - COH CENT RATIONS (mg/l)
Raw Wastewater
Plant Code
094(Sheet)
094(Strip)
097
H-2
T-2
QQ-2
SS-2
TT-2
WW-2

Reference No.
0948C
094 8C
0760
0432A
0792 B
0584 E
0112A
0856D
0868A
Averaj
Sasple Point
C-A
D-A
(B+C)-A
3+4-1
1-2
5-1
2-10
1-2-3
1-3
Flow (gal/ton)
303
422
11.6
115
21.6
167
202
134
284
184
Partaeter











Dissolved Iron
40
98
36
28.7
1833
64.7
63
81.9
357
289

Oil aid Grease
9
7
3.3
6.2
5
-
2
2.4
1.6
4.1

Suspended Solids
38
29
334
-
49
34.5
76
7.0
6.1
63.7

pa
3.2-5.7
2.2-2.3
NA
1.9-6.4
1.6
2.7
2
1.8
1.7
1.6-6.
4
Benzene
*
ND
ND
NA
NA
NA
NA
NA
NA
*
44
Methylene
0.145
ND
ND
NA
NA
NA
NA
NA
NA
0.048

Chloride










70
Diethyl
ND
0.029
ND
NA
NA
NA
NA
NA
NA
0.010

phthalate










71
Din ethyl
ND
*
0.015
NA
NA
NA
NA
NA
NA
0.008

phthalate










115
Arsenic
-
-
1.0
NA
NA
NA
NA
NA
NA
0.33
118
Cathiua
-
0.080
0.1
NA
NA
NA
NA
NA
NA
0.060
119
Chtosiw
-
0.040
2.91
NA
NA
NA
NA
NA
NA
0.98
120
Copper
0.045
0.13
10.4
NA
NA
NA
NA
NA
NA
3.52
122
Lead
0.03
-
0.240
NA
n
NA
NA
NA
NA
0.090
124
Nickel
-
-
4.62
NA
NA
NA
NA
NA
NA
1.54
126
Silver
ND
ND
0.847
NA
NA
NA
NA
NA
NA
0.28
128
Zinc
-
0.040
0.20
NA
NA
NA
NA
NA
NA
0.080
* : Concentration leas than 0.010 mg/l.
NDt Hot detected.
11: Not analysed.
- : Net calculations yielded negative results.
-------
TABLE V-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
COHTIHUOUS SULFURIC ACID PICKLING
WET HAW SPENT CONCENTRATES - CONCENTRATION («g/l)
Raw Hastenater








Plant Code
097
B-2
T-2
QQ-2
SS-2
TT-2
WW-2

Reference No.
0760
0432A
0792B
0584 E
0112A
0856D
0868A
Average
Sanple Points
E-C
2
-
2
1
4
2

Flow (gal/ton)
7.2
14.7
14.6
23.6
10.9
23
44.7
19.8
Far as e£ era








Dissolved Iron
38,750
47,900
34,000
48,300
48,000
70,800
19,000
43,800
Oil and Crease
35
HA
18
8.5
9.5
18.5
10
16.6
Suspended Solid*
236
18,000
65
128
200
222
91
2706
1*
<1.0
<1.0
<1.0
<1.0
<1.0
<1.0
<1.0
<1.0
44 Methylene Chloride
0.055
NA
NA
NA
NA
NA
NA
0.055
115 Arsenic
0.20
HA
NA
NA
NA
NA
NA
0.20
118 Cadaias
0.41
NA
NA
NA
NA
NA
NA
0.41
119 Chrosiai
26
NA
NA
NA
NA
NA
NA
26
122 Lead
1.19
NA
NA
NA
NA
NA
NA
1.19
124 Nickel
14.4
NA
NA
NA
NA
NA
NA
14.4
126 Silver
0.?8
NA
NA
NA
HA
NA
NA
0.28
128 Zinc
2.5
NA
NA
NA
NA
NA
NA
2.5
Ml Rot analysed.
ID: Not delated.
- i No Maple at*
noaber designated.
-------
TABLE V-5
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
CONTINUOUS SULFURIC ACID PICKLING
NET RAW FDME HOOP SCRUBBER WASTEWATERS - CONCENTRATION (ag/1)
Row Wastewater
Plant Code
Reference No.
Saaple Points
Flow (gal/ton)
Parameters
QQ-2
0584 E
3
2
SS-2
0112 A
3*4+5
22.6
TT-2
0856D
2
2.3
Average
9.0
Dissolved Iron
Oil and Grease
Suspended Solids
PB
305
2.5
2.5
1.4
0.55
2.0
7.5
1.9
88.7
9.0
198
1.7
131.4
4.5
69
1.4-1.9
-------
TABLE V-6
SUMMARY OF ANALYTICAL MIA FROM SAMPLED PLANTS
BATCH HYDROCHLORIC ACID PICKLING
NET HAW RINSE WASTEWATERS - CONCENTRATION (mg/1)
Raw Wastewater
Plant Code
Reference Ho.
Saple Point
Flow (gal/ton
Par meters
V-2
0936
1+6-5
167.2
U-2
04 80 A
1-2
92.9
Average
130.0
KJ
U
w
Dissolved Iron
Saapended Solids
Oil and Grease
pH (Units)
270
0
1.5
2.5-3.4
190
0
3
1.8
230
0
2.3
1.8-3.4
-------
TABUS V-7
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
BATCH HYDROCHLORIC ACID PICKLING
NET RAW SPENT CONCENTRATES CONCENTRATION (mg/1)
Raw Wastewater
Plant Code
Reference No.
Saaple Point
Flow (gal/ton)
Parameters
V-2
0936
(7*8)
3.86
U-2
0480A
3
6.45
Average
5.16
KJ
Ul
Dissolved Iron
Suspended Solids
Oil and Grease
pH
107,000
140
HA
<1
77,000
40
NA
<1
92,000
90
NA
<1
-------
IAS LIE V-8
SUMMIT OF AHALTTICAL DATA FROM SAW LED P LASTS
OOKTIHOOUS HYDROCHLORIC ACID PICXLIHG
NET HAW MUSE WASTEWATERS - COBCE Iff RATIOS Oag/1)
Raw iMtwata
Plant Code
1-2
W-2
JE-2
1-2
Z-2
AA-2
BE-2
091
093
095
099
100(a)
100(b)

teCerocc Ho.
08S6F
M
00601
**
03960
0384 A
0060
0612
0396D
0584F
052 88
0384A
0384 A

Saaple Point*
4-6
7-3
3-7
5-4
1-4
2-1
5-2
B-G-F-A-L
B-A
G-A
C-F
C-A
B-A
Average
riw (gal/toa)
220
227.5
663
87.3
166
5.85
211
328
203
16.9
45.4
289
3.3
188
Puacten

.













Dissolved Iron
7
136
193
218
11,300
13,700
1100
_
2,530
2,325
1,379
35
2,185
2,700

Suspended Solids
96
17
-
1.5
72
8
37
-
206
-
16
34
0
37.5

Oil aid Grease
3.9
S
HA
-
9
28
59
-
147
0
9.1
3.0
0
20.3

pB, Units
4.5-5.0
2.9-3.8
2.2-2.6
1.7
1.1
1.1
1.5-1.7
2.9-3.8
1.0
1.4-1.7
1.9-2.8
4.2
2
<1.0-5.0
23
Chi or of oral
HA
HA
HA
HA
HA
HA
NA
-
*
0.020
HD
*
•
0.007
39
Fluoraathene
HA
HA
HA
HA
HA
HA
HA
*
0.060
HD
RD
*
HD
0.013
44
Methylene Chloride
HA
HA
HA
HA
HA
HA
HA
-
-
1.20
*
-
-
0.20
60
4,6-ftini tro-o-cresol
HA
HA
HA
NA
NA
HA
NA
0.013
m>
HD
HD
RD
HD
0.002
65
Phenol
HA
HA
HA
HA
HA
HA
HA
*
TO
•
HD
•
-
0.005
66
8is(2-ethylhexyl)
HA
n
NA
HA
NA
HA
HA
-
4.705
*
-
-
0.050
0.79

phthai ate














67
Butyl be nay 1 phthal ate
HA
HA
HA
HA
HA
HA
m
-
0.025
HD
HD
HD
*
0.006
68
Di-n-butyl phthal ate
HA
HA
HA
HA
HA
HA
HA
-
0.112
•
*
*
*
0.025
70
Diethyl phthalate
HA
HA
HA
HA
HA
HA
HA
-
HD
HD
HD
*
HD
0.002
71
Diaethyl phthalate
HA
HA
NA
HA
KA
M
MA
*
0.055
HD
HD
HD
HD
0.011
85
Tetrachloroethylene
HA
HA
HA
HA
HA
HA
HA
•
0.040
0.019
HD
HD
HD
0.012
87
Trichloroettaylene
HA
HA
HA
HA
HA
HA
NA
0.057
HD
HD
HD
HD
HD
0.010
114
AxMtinony
HA
HA
HA
HA
HA
HA
HA
HA
HA
0.181
HA
*
0.19
0.124
115
Arsenic
HA
HA
HA
HA
HA
MA
MA
M
-
0.225
0.25
HA
HA
0.23
118
Cadnin
HA
HA
HA
HA
HA
MA
MA
-
HD
HD
*
*
0.010
0.005
119
OrniiB Total
HA
MA
M
HA
HA
HA
HA
-
0.79
-
0.34
•
0.57
0.28
120
Copper
m
MA
HA
M
HA
MA
MA
-
0.67
0.68
0.61
0.06
1.6
0-60
122
toad
HA
HA
HA
HA
HA
MA
MA
-
0.43
HD
HD
*
0.14
0.10
124
Nickel
HA
HA
HA
HA
HA
HA
HA
-
0.48
0.733
0.63
*
1.28
0.52
128
Zinc
HA
HA
M
HA
HA
HA
HA
160
1.41
0.416
0.13
0.14
0.38
27.1
* t Calculation yielded values leas than 0.010 mfjl.
**! riant hu m refereace airtic.
(a) bndiiiii acid riaae
(k) Cascade riaae
nh Mot detected
¦i lot aul/nd
- > Calculation yielded a negative value
-------
TABLE \H
SUMMUtY Of AHALTTICAL DATA »»! SANPUD FLAHTS
OOHTIHODOS RMOCBLflUC ACID riGKLIHC
HBT U» WW CMamflB - OCBCEimMnOH <¦»/!)
>¦* Haatevater










Plant Code
1-2
W-2
2—2
AA-2
091
093
095
099
100

Reference Ho.
0856P
-
03960
03WA
0612
0396D
0584 F
0528B
0384A
Average
Staple Points
8-6
1-3
3-4
3-1
L-A
Kl)-A
B-A
B-A
K-A
Flow
Flow (gal/ton)
220
11.9
41.4
3.26
18.1
203
49.7
81.7
4.6
70.4
Par Meters











Dissolved Iron
7.1
137,700
44,300
116,000
56,000
3950
8,000
75,500
18,000
51,050

Suspended Sol ids
54
97
120
40
3,026
240
74.0
42.0
316
445

Oil and Grease
HA
S.l
0
0
4.0
237
4.0
11.0
5.0
33.3

pH, Units
4.5-5.0
0.6-0.7
<1
<1
<1
1.0
1.3-3.0
<1
<1
0.6-3.0
23
Chlorof oca
HA
M
HA
HA
*
•
0.101
*
O.OU
0.022
44
Methylene Chloride
HA
HA
HA
HA
*
RD
2.333
0.014
0.409
0.55
65
fhenol
HA
HA
M
HA
HD
RD
0.013
HD
ND
0.003
66
Bia(2 ethylheiyl)
M
HA
HA
HA
*
HO
0.017
1.550
0.155
0.344

phthalate










67
Butyl bensyl phthalate
HA
M
m
HA
ND
RD
HD
o.ou
0.045
O.OU
68
Di-n-bu tyl phthalate
HA
HA
HA
HA
RD
RD
HD
0.033
HD
0.007
85
Tetrachloroethylene
HA
HA
HA
HA
RD
RD
0.031
HD
HD
0.006
87
Triehl or ©ethylene
mk
HA
HA
HA
0.028
HD
HD
HD
HD
0.006
114
Antinomy
HA
HA
HA
HA
HA
HA
0.187
HA
4.1
2.14
115
Arsenic
HA
HA
HA
HA
HA
0.05
0.025
0.39
HA
0.155
118
CaifaiuB
HA
M
HA
HA
0.028
0.02
HD
0.26
0.28
0.12
119
Chroaiua Total
HA
MA
HA
HA
37.0
0.84
1.505
17.0
8.7
13.0
120
Copper
HA
HA
HA
HA
22.0
0.67
2.42
19.0
11.0
11.0
122
Lead
HA
m
HA
HA
1550
0.43
HD
*
2.1
311
124
Mickel
M
IM
HA
HA
22.0
0.48
2.505
13.0
13.0
10.2
128
Zinc
HA
HA
HA
HA
61.0
1.5
2.505
4.20
4.50
14.7
* : Calculation yielded nnlc* lees than 0.010 ag/1.
Ms Rot analyzed.
HDs Hot detected.
-------
TABLE V-10
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLAHTS
COHTIHOOUS HYDROCHLORIC ACID PICKLIHC
BCT BAH FPUS HOOD SCRUBBER WASTEWATERS - COHCBHTMTIOH fag/1)
Raw Wastewater
Plant Code	W-2	7-2	093	095
Reference No.	**	**	03960	0584F
Swple Points	6-4	4-6	J-A	GA2-G
Flow (gal/ton)	45.5	39.7	31.1	0.39
Parameters
880	662
2098
325	43.8
1.6	1.2
HD	0.017
*	0.332
HD	HD
*
							—	...	0.325	HD
U)	69 Di-n-octyl phthalate	HA	HA	0.358	0.055
o	114 Antisony	HA	HA	HA	0.106
0	0.039
0.24
0.76	0.267
0.35
0.20
1.6	0.159

Dissolved Iron
23.9
3.7

Suspended Solids
3.0
1.7

Oil and Crease
5.3
-

pH (Units)
2.8-3.7
1.8-1.9
6
Carbon Tetrachloride
HA
MA
23
Chi orofocw
HA
HA
64
PeatMcbl orofbenol
M
HA
66
Bis(2 ethylhexyl)phthaiate
HA
HA
67
Butyl benayl phthalate
HA
NA
69
Di-n-octyl phthalate
HA
HA
114
Antisooy
Ift
MA
115
Arsenic
HA
HA
119
Qsoain
HA
HA
120
C°Pper
HA
MA
122
Lead
HA
HA
124
Hickel
HA
HA
128
Zinc
M
M
099
100

052 SB
0384 A
Average
F-A
J-H

6.1
3.4
21.0
45
1025
440
6
9
353
4
-
63.0
<1.0
1.0-1.2
<1.0-3.7
HD
HD
0.004
*
*
0.091
0.043
HD
0.011
0.320
-
0.083
0.026
*
0.090
0.01
*
0.109
MA
0.1
0.103
0.070
HA
0.036
0.09
0.15
0.12
0.10
0.1
0.31
-
-
0.009
o.oeo
0.1
0.095
0.009
0.07
0.460
* s Calculation yielded a value less than 0.010 mg/1.
Hs Hoc analysed.
- s Calculation yielded a negative result.
HD: Mot detected.
**:. Plants have no assigned reference mnber.
-------
TABLE V-ll
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
OMIIHUOUS HYDROCHLORIC ACID PICKLING
HKT HAW ABSOBBER VEWT SCRUBBER WASTEWATERS - COHCEOTRATIOH (mg/l)
R*w Wastewater
to
cj
CD
Plant Code
W-2
X-2
Reference No.
**
0060B
S««ple Points
5
2-1
Flew (gal/ton)
98.6
200
Pari
¦¦eters



Dissolved Iron
15
63.5

Suspended Solids
129
70

Oil and Grease
2.2
-

pH (Dnits)
3.7-7.6
6.9-7.1
30
1, 2-Transdichloroethylene
NA
NA
44
Methylene Chloride
NA
NA
66
Bis(2-ethylbexy 1)ph thalste
NA
NA
69
Di-n-octyl phthalate
NA
NA
71
Diaethyl phthalate
NA
NA
85
Tet rachloroethy1ene
NA
NA
114
Antimony
NA
NA
115
Arsenic
NA
NA
119
Chroaiua
NA
NA
120
Copper
NA
NA
122
Lead
NA
NA
124
Nickel
NA
NA
128
Zinc
NA
NA
T-?(a)
**
1-6
288
85
7.0-7.1
NA
na
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
T-2(b)
**
2-6
336
0.41
1.5
1.7
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
095
099

0584F
052 8B
Average
C-A
E-A

69
170
197
3658
150
650
65
51
67
-
-
0.4
1.7-2.1
<1.0-2.3
1.7-7.6
0.109
ND
0.055
1.070
0.031
0.55
0.046
0.012
0.029
0.021
ND
0.011
0.030
ND
0.015
0.011
ND
0.006
0.209
NA
0.209
0.017
*
0.014
-
0.98
0.49
1.27
0.436
0.85
-
0.10
0.05
0. 790
0.64
0.72
1.09
0.71
0.90
*: Calculation yielded a value less than 0.010 ag/1.
Calculation yielded a negative result.
(a)	Acid regeneration unit with cyclone,
(b)	Acid regeneration unit with electrostatic precipitator.
NA: Not analysed.
ND: Not detected.
**: Plant has no assigned reference awber.
-------
TABU V-12
SUMMARY OF ANALYTICAL DATA FBOM SA»LED PLANTS
BATCH COMBINATION ACID PICKLING
MET BAH RINSE WASTEWATERS - COHCKHTRATIOH (ng/1)
Raw Wastewater
Plant Code
C
F
L
D
123
124
125

Reference Mo.
0424-01
0856H
0440 A-01
0748
0088A
00 (USD
0S84B

S«aple Poiota
2 City
1-9
10-Hell
1-8
D-A
B-A
C-A
Average
Hater

Hater





Flow (gal/ton)
91
279
140
677
310
1,176
650
475
Parameters

Suspended Solids
404
—
165
_
35
1
1
86.6

Oil and Grease
-
0.1
0.9
2.2
2
9
3.0
2.5

Fluoride
635
173
0.33
500
MA
24.0
49.9
230.4

Dissolved Iron
717
60.3
133
1,080
46
10
5.0
293

pi, Units
0.4-0.8
2.6-2.9
2.8-3.0
1.9
2.6-2.7
2.7
3.5-3.6
0.4-3.6
23
Chloroform
MA
NA
NA
NA
-
-
0.047
0.016
44
Methylene Chloride
MA
NA
NA
MA
-
0.040
0.028
0.023
66
Bis(2 ethylhexyl)phthai ate MA
MA
NA
NA
0.266
0.138

0.135
0.048
67
Butyl benxyl phthai ate
MA
NA
NA
NA
*
•k
0.125
68
Di-n-butyl-ph thai ate
MA
NA
NA
NA
*
*
*
~
85
Tet r achl oroet hy 1 ene
DA
MA
NA
NA

—
*
0.01
115
Arsenic
MA
NA
NA
NA
0.01
0.01
0.01
119
Cbroaion
111
13.4
24.4
152
2.9
25.9
1.07
47.2
120
Copper
4.6
-
0.8
1.38
0.24
*
0.05
31.01
121
Cyanide
0.12
0.12
NA
NA
-
*
-
0.050
122
Lead
-
-
-
-
0.10
0.05
0.05
0.030
124
Mickel
156
9.4
12.5
70
7.4
27
0.54
40.4
128
Zinc
0.87
0.05
0.02
5.1
0.06
0.03
-
0.88
HD l Mot detected.
Unk: Unknown.
H : Mot analysed.
* t Concentration less than 0.010 ag/1.
- t Calculations yields a negative value.
-------
TABLE V-13
SDMNttT OF ANALYTICAL DATA FROM SAMPLED PLANTS
BATCH COMBINATION ACID PICKLING
met iaw sfgirr cobcbmtratk - ccwcEHrRATioii (ng/i)
Raw Wastewater










Plant Code
C(l)
C(2)
E
F
L
M
S
T
0

Reference Mo.
0424
0424
0201
0856H
0440A
0432J
00601
link
0748

Saaple Points
11
12
14
11
5
15
7
9
2

Flow (gal/ton)
-
-
-
-
-
-
-
-
-

Pari
¦seter











Dissolved
13,200
13,200
15,700
34,300
1.2
NA
8,240
34,500
30,400
18,693

Iron











Fluoride
1,700
7
18
7,000
232
17,000
380
MA
NA
3, 762

Nitrate
DA
MA
16,000
8,800
NA
1,481
NA
NA
NA
8,760

Oil and Grease 0.2
0.2
0.4
HA
NA
NA
NA
NA
NA
0.4

Suspended
224
44
114
100
123
60
236
NA
16
115

Solids











pH, Units
1.2
0.3
0.8
2.2
NA
1.2
0.8
0.9
2.3
0.3-2.3
118
Cadaiua
0.09
0.118
0.06
0.22
NA
0.32
0.17
0.3
0.35
0.20
119
Chroaiun
2,090
1360
2,426
6,800
NA
6,720
1,424
5,040
7,000
3,651
120
Copper
114
6.79
78
54
NA
640
52
632
144
19
122
Lead
*
*
5.7
2.64
NA
NA
1.28
7.1
1.2
2.56
124
Nickel
2,832
1786
2,123
4,200
NA
5,980
1,552
17,200
9,040
5,589
128
Zinc
0.97
2.15
1.6
85
MA
7.2
1.6
32
5.8
17.0
(1)	Pickle line utilised HHO.-flF acid*.
(2)	Pickle line utilised H^SO^ acid
RD :	Rot detected.
HA :	Hot analysed.
Onk:	Unknown.
* :	Concentration is less than 0.010 ag/1
-------
TABU V-14
SUMHARY OF ANALYTICAL DATA FROM SAMPLED PLAITS
BATCH row HAT ION ACID PICKLIHG
1 SAW PQjg aOOD SOtBWgK WASTEWATERS - CCHCBWTKATIOH (¦g/1)
Iw Wastewater
(o
ft
M
Plant Code
leference Ho.
Saiple Poiata
Flow (gal/ton)
Recycle Syatea It
Parameter
¦tailed
F
856H
2-9
50.4
Ho
125
884E
B-A
10.0
Tea
Average
30.2

Suspended Solida
-
23.0
11.5

Oil and Grease
0.2
23.0
11.6

Fluoride
1,802
5,500
3,650

Dinolwd Iron
45.7
503
274.4

pH, Units
1.5-2.0
2.9
1.5-2,
1
Aeenapthene
MA
0.017
0.017
21
2,4, 6-Trichl orophenol
HA
0.023
0.023
22
Parachloromtacresol
HA
RD
HD
31
2, 4-Dichl orophenol
MA
0.022
0.022
3*
2, 4-D methyl phenol
MA
0.045
0.045
39
Fluoranthene
HA
*
*
44
Methylene Chloride
HA
*
*
67
Butyl benzyl ph thai ate
HA
0.027
0.027
M
Di-o-butyl ph thai ate
HA
0.135
0.135
69
Di-n-octyl ph thai ate
HA
0.080
0.080
70
Diethyl phthalate
HA
*
*
71
Dinethyl phthalate
HA
0.076
0.076
115
Araenic
HA
0.57
0.57
119
Chroaion
2.42
69
35.7
120
Copper
0.07
1.8
0.94
121
Cyanide
*
0.10
0.088
122
Lead
MA
0.04
0.04
124
Michel
3.3
47
25.2
128
Zinc
0.30
1.5
0.90
At	lot analysed.
IDs	lot detected.
- t	Calculation# yielded a negative result.
* l	Calculations yielded a value leaa than 0.01 mgf\.
-------
TABLE V-15
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
CONTINUOUS COMBINATION ACID PICKLING
NET RAW RINSE WASTEWATERS - CONCENTRATION (mg/1)
Raw Wastewater
to
to
Reference No.
Plant Code
Sample Points
Flow (gal/ton)
Parameter
Suspended Solids
Oil and Grease
Fluoride
Dissolved Iron
pH, Units
Benzene
Chi oroform
Methylene Chloride
Bis(2 ethylhexyl)phthalate
Tet r achloroethylene
Antimony
4
23
44
66
85
114
115
119
120
124
128
Arsenic
Chromium
Copper
Nickel
Zinc
Nitrates
248B
D
4-1
1,016
10
76.5
103.5
3.8
HA
NA
NA
NA
NA
NA
NA
16.0
0.11
9.2
11.0
432K-02
I
4-1
1,814
553
0.6
31.4
59.2
3.2-7.2
NA
NA
NA
NA
NA
NA
NA
17.1
0.14
5.98
0.747
14.4
176-03
0
29-32
974
76
9.5
15.4
1.71
5.4-8.2
NA
NA
NA
NA
NA
NA
NA
0.48
0.040
2.14
0.070
20.3
0900
121
B-A
2, 754
2
169.0
148
2.4-2.7
0.028
0.184
0.501
0.017
0.030
0.060
0.012
32.2
0.528
19.4
0.317
NA
Average
1,640
160
3.0
73.1
78.1
2.4-8.2
0.028
0.184
0.501
0.017
0.030
0.060
0.012
16.4
0.205
9.18
0.284
15.1
NA: Not analyzed.
- : Calculations yielded a negative number.
-------
TABLE 7-16
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
COrrINITIOS COMBINATION ACID PICKLING
NET RAW SPEW COHCEOTEATIS - CONCENTRATION tmg/1)
Iwlaitmtit
Plant Cod*
A
0(1)
0(2)
I
0(1)
0(2)

llfnnct Ho.
0900
248B
2488
Q432K
0176
0176
Avaraga
Saapla Point
12
14
13
12
23
26
Flow (gal/ton)
NA
NA
NA
4.2
NA
NA
4.2
Paraaatara







Oil and Graaaa
2.6
2.2
2.0
7.1
NA
NA
3.5
Suapandad Solida
196
318
196
109
NA
KA
205
Diiaolvad Iron
989
74 , 700
36,900
20.6
16,200
6,960
22,595
Fluorida
15,000
2.5
6.4
26,000
NA
NA
10,253
pH, Onita
0.7
2.2
2.1
1.1
2.0
0.9
0.7-2.2
US Cadaiua
0.03
0.08
0.07
0.1
0.05
0.02
0.06
119 Chroaiua
2,400
6,242
3,481
4,284
2,361
1,248
3,336
120 Coppar
36
80
28
37
416
16
102
122 Uad
1.3
1.4
1.4
MA
1.2
0.6
1.2
124 Hickal
2,300
4,680
1,952
2,031
4,914
3,822
3,283
128 Zinc
1.4
6.4
4.0
1.1
10.8
0.76
4.1
Hitrata
463
NA
226
3,550
NA
NA
1,413
NAi Hot availabla
243
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ACID PICKLING SUBCATEGORY
SECTION VI
SELECTION OF POLLUTANTS
The final selection of pollutants for the acid pickling subcategory
was based on the analysis of wastewater samples collected during this
study. A number of pollutants originally limited by the 1976
regulation were selected, because they characterize the wastes from
the pickling operation. The pollutants limited by this proposed
regulation include those listed in the 1976 regulation plus certain
toxic pollutants found during extensive monitoring conducted for this
study. This section describes the pollutants considered for
regulation, presents the rationale for selecting those pollutants, and
the process sources of those pollutants.
Pollutant Selection
Conventional Pollutants
In the original regulation, three conventional pollutants were limited
for all types of acid pickling operations: total suspended solids,
oil and grease, and pH. However, the limitations for the oil and
grease were applicable only when pickling wastes were treated jointly
with cold roiling wastes. Wastewater characteristics for batch and
continuous operations are similar, such that the same limited
pollutants can apply to both types of operations in each acid
subdivision.
Based upon the information gathered during this study, the Agency
decided to retain oil and grease on the list of limited pollutants in
certain instances. Cold rolling wastes and pickling wastes are often
co-treated to take advantage of emulsion breaking properties of the
acid wastes. Since this is a common practice, and since the pickling
wastewaters can contain moderate amounts of oils, an allowance for oil
and grease is included in the proposed limitations.
High levels of suspended solids and low pH are also characteristic of
acid pickling operations. Solids are generated in the pickling
process and are carried away in either the rinse or fume scrubber
waters or in the spent pickle liquor bath. In addition, pH was also
limited in the original regulation for this subcategory and will
continue to be regulated by the proposed limitations. The pH of the
raw wastes from acid pickling lines is always acidic, with typical
values ranging from <1 to 4 standard units. Wastewaters with low pH
values can have detrimental effects if discharged without treatment.
Neutralization is required to bring the pH to within the regulated
levels of 6.0-9.0 standard units.
245
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Other Pollutants
In the original regulation, several nonconventional nontoxic
pollutants were limited. Dissolved iron was limited for all three
acid pickling operations. In addition, dissolved chromium, fluoride,
and dissolved nickel were all limited for combination acid pickling
operations. (The fluoride limitation applied only to those mills
using hydrofluoric acid). Limitations for these four pollutants are
being retained in the present regulation. However, chromium and
nickel are now limited on a total rather than a dissolved basis at
BAT, NSPS, PSES, and PSNS. The Agency made this change to more
accurately reflect the true pollutant load characteristics of these
wastewaters.
Toxic Pollutants
Besides the pollutants limited during the first phase of this study,
the Agency found that toxic pollutants are present at significant
levels in the discharges from acid pickling operations. During the
second phase of sampling, the Agency conducted additional monitoring
for the pollutants limited in the 1976 regulation, toxic pollutants,
and other pollutants. Based upon this sampling and responses provided
by the industry, the Agency developed a list which summarizes toxic
pollutants known to be present in the wastewater. (Table VI-1).
The Agency tabulated and calculated a composite concentration value
for each pollutant in the raw wastewater. A net value was used to
describe the contribution of pollutants from the pickling process. If
a pollutant was found in the raw wastewater at an average
concentration (net) of 0.010 mg/1 or greater, it was considered to be
characteristic of acid pickling wastewater and is addressed
accordingly throughout this report. Also shown in Table VI-2 are the
other pollutants for which limitations are being considered.
Several organic pollutants were detected at concentrations greater
than 0.010 mg/1 but are not listed in Table VI-2. These pollutants
were omitted because it is believed that their presence is not due to
acid pickling operations. Methylene chloride was omitted because it
is a solvent commonly used as a cleaning agent in the laboratory, and
its presence is ascribed to this practice and not to acid pickling
operations. Also, some phthalate compounds were detected at levels
greater than 0.010 mg/1, but they are not believed to be
representative of acid pickling wastes. Evidence developed during the
sampling inspections indicates that the presence of phthalates was
probably related to plasticizers in the tubing used in collecting the
samples. Only two toxic organic pollutants, namely, chloroform in
hydrochloric acid pickling and benzene in combination acid pickling,
are listed. These are common solvents that may occur in the pickling
process under certain operating circumstances, or may originate from
oils present on the steel product which is pickled.
As noted in Table VI-2, many toxic metal pollutants were detected at
concentrations greater than 0.010 mg/1. These pollutants, as with the
pollutants limited in the 1976 regulation, are present in the
wastewater because of the extreme chemical action that occurs during
246
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the pickling process. The acids remove the surface scale from the
steel products which contain the toxic metals. While these pollutants
may vary in concentration from line to line, they are characteristic
of the process. The Agency is proposing BAT, NSPS, PSES, and PSNS
limitations and standards for these toxic pollutants, together with
the previously limited pollutants.
247
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TABLE VI-1
PRIORITY POLLUTANTS KNOWN TO BE PRESENT
IN ACID PICKLING OPERATIONS
Sulfuric	Hydrochloric	Combination
Acid Pickling	Acid Pickling	Acid Pickling
004
Benzene
-
-
X
021
2,4,6-Trichlorophenol
-
-
X
023
Chloroform
- .
X
X
031
2 f4-Dichl orophenol
-
-
X
039
Fluoranthene
-
X
-
044
Methylene Chloride
X
X
X
051
Chi arodibromomethane
X
-
-
066
Bis(2-ethylhexyl)phthalate
X
X
X
067
Butyl benzyl phthaiate
X
X
X
068
Di-n-butyl phthalate
X
X
X
069
Di-n-octyl phthalate
-
X
X
070
Diethyl phthalate
X

-
071
Dimethyl phthalate
X
-
-
085
Tetrachloroethylene
-
X
X
087
Tri chl oroethylene
-
X
-
114
Antimony
-
X
X
115
Arsenic
X
X
X
118
Cadmium
X
X
X
119
Chromium
X
X
X
120
Copper
X
X
X
121
Cyanide, Total
X
-
X
122
Lead
X
X
X
124
Nickel
X
X
X
126
Silver
X
-
-
128
Zinc
X
X
X
Xt Parameter known to be present in at least one of the waste sources.
Parameter not found.
-------
TABLE VI-2
SELECTED POLLUTANTS - ACID PICKLING OPERATIONS
' Dissolved Itoo
Fluoride
Oil and Grease
Suspended Solids
PH.
4 Benzene
23 Chlorofom
114	Antiaony
115	Arsenic
118	Cadniua
119	Cbroniua
120	Copper
122 Lead
124 Nickel
126 Silver
128 Zinc
Sulfuric
Acid Pickling
X
X
X
X
X
X
X
X
X
X
X
Hydrochloric
Acid Pickling
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Combination
Acid Pickling
X
X
X
X
X
X
X
X
X
X
X
X
X: Par meter selected.
Parameter not selected.
-------
ACID PICKLING SUBCATEGORY
SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
Introduction
This section reviews existing wastewater treatment practices for the
acid pickling subcategory and lists those technologies which were
considered by the Agency in developing this proposed regulation. The
sampling data gathered at the acid pickling operations visited during
this study and a description of the treatment practiced at each are
also presented.
As a first step, it was necessary for the Agency to determine the
level of existing wastewater treatment in the acid pickling
subcategory. The Agency then developed BPT, BAT, BCT, PSES, and PSNS
alternative treatment systems in an "add-on" fashion to this base
level. The NSPS alternative treatment systems, however, were not
developed in this manner. Since NSPS applies to new acid pickling
operations, the Agency did not consider the "add-on" approach. The
alternative treatment systems (levels of treatment) and their
corresponding effluent characteristics are summarized in Sections IX
through XIII.
Summary of Treatment Practices Currently Employed
Because there is the potential for three different wastewater sources,
the treatment systems used on each source are discussed in detail
below, prior to a discusion of the general treatment scheme.
Treatment of Spent Pickle Liquor
Spent pickle liquor is presently classified as a hazardous waste under
the Resource Conservation and Recovery Act (RCRA). Special attention
must be given to this waste to insure that it is either properly
disposed of, or that it is treated sufficiently prior to discharge.
There are several different methods for handling spent acid
concentrates (spent pickle liquor). These methods include disposal,
treatment, or recovery/regeneration processes.
A. Disposal Methods
The disposal methods, which include contract hauling and deep
well injection, are not ideal solutions for handling the spent
acid concentrates. Hauling, and deep well injection move the
wastes from one place to another, and therefore, only relocate
the pollution. However, if properly performed any adverse
environmental effects can be minimized to levels comparable to
treatment of these wastes. Contract hauling is a commonly used
251
-------
method in the industry. Several plants dispose of their spent
pickle liquor by deep well injection.
B. Treatment Processes
Treatment processes include chemical neutralization and
precipitation. Detailed discussions of these processes follow.
Treatment may be performed separately or jointly with the other
wastewaters from the pickling operation. These methods are
commonly employed throughout the industry.
The ideal method for handling spent pickle liquor is to recycle
the wastes through recovery/regeneration processes. These
processes minimize handling costs and either reduce or eliminate
the discharge of pollutants. In addition, the pickling operation
itself may be made more efficient, since the acid bath can be
kept at a relatively constant, strength.
The Agency has identified the following recovery and regeneration
systems which are presently operated in this country. These
systems are available and have been proven effective at many
pickling operations.
1.	Sulfuric Acid Recovery
The most common treatment method for recovering valuable
products from spent sulfuric acid is acid recovery by
removing ferrous sulfate through crystallization. Spent
pickle liquor, which is high in iron content, is pumped into
a crystallizer, where the iron is precipitated (under
refrigeration or vacuum) as ferrous sulfate heptahydrate
crystals. As the crystals are formed, water is removed and
the free acid content of the solution increases to a level
where it is reusable in the pickling operation. The
crystals are separated from solution, and the recovered acid
is pumped back to the pickling tank. The by-product ferrous
sulfate heptahydrate is commercially marketable. The
crystals are dried, bagged, and marketed, or sold in bulk
quantities. Ferrous sulfate, commonly referred to as
"copperas," is used in appreciable quantities in numerous
industries, including the manufacture of inks, dyes, paints,
and fertilizers. It is also used as a coagulant in water
and wastewater treatment. See Figures II1-5 and II1-6 for
the two types of available recovery operations. As an added
note, recovery processes, which produce ferrous sulfate
monohydrate crystals as a by-product are also available.
This process is usually carried out at elevated
temperatures.
2.	Hydrochloric Acid Regeneration
The only commercially proven technology to regenerate spent
hydrochloric acid is through thermal decomposition. The
spent pickle liquor contains free hydrochloric acid, ferrous
chloride, and water. The liquor is heated to remove some of
252
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the water through evaporation and to concentrate the
solution. The concentrated solution is then further heated
to 925° to 1,050°C (l,700o to 1,920°F). At this
temperature, water is completely evaporated and the ferrous
chloride decomposes into iron oxide (ferric oxide, Fe203)
and hydrogen chloride (HC1) gas. The iron oxide is
separated and removed from the system. The hydrogen
chloride gas is reabsorbed in water (sometimes rinsewater or
scrubber water is used), to produce hydrochloric acid
solution (generally from 15% to 21% HC1) which is reused in
the pickling operation. There are several types of these
"roaster" processes in operation. The basic difference
between the processes is the design and operation of the
roaster/reactor and the recovery equipment. Each design,
however, has its own distinct advantages and disadvantages
(see Figures 111—7 through III-9).
Combination Acid Pickling
The Agency is unaware of any operating nitric or
hydrofluoric acid recovery process operating in this
country. It has been reported that such a system is
installed and successfully operating in the People's
Republic of China. However, due to the lack of operating
and performance data, the Agency is not basing any of its
proposed limitations or standards on this technology.
A summary of the treatment practices in each subdivision
disposal of spent pickle wastes is listed below;
for the
Acid
Subdivision
Sulfuric
Hydrochloric
Combination
Central
Treatment
38.3%
13.7%
46.0%
Acid
Recovery
2.6%
8.4%
0%
Contract
Hauling
44.5%
53.7%
44.0%
Deep
Well
5.2%
12.6%
0%
POTW
Discharge
9.4%
11.6%
10.0%
Treatment of Fume Scrubber Water
Many pickling lines include wet scrubber systems to control the
emission of fumes from the operation. Water is used to scrub the
fumes and thus becomes contaminated with the same type of pollutants
which are discharged from the other waste sources. The flow rates
from the scrubbers can be very large, and if not controlled, will
result in the discharge of large pollutant loads.
One means to control the amount of pollutants generated from this
source is to install recycle systems. Recycle rates of 100% have been
reported for many operations and many others have installed systems
which have recycle rates ranging between 90-95% of the total
wastewater flow.
High recycle rates are achievable, because corrosion does not present
a problem. The scrubbers are normally made of fiberglass, which is
not affected by the low pH of this waste source. Therefore, the
253
-------
degree of recycle is limited by the buildup of dissolved solids in the
recycle loop. Those operations that do not recycle this waste source
discharge these wastes to POTWs or to receiving streams after varying
degrees of treatment. The treatment components used by the lines that
discharge wastes from their scrubber systems are described below.
General Treatment Configuration for Pickle Rinsewaters
Most of the operations that treat pickle rinsewaters prior to
discharge do so in central treatment systems. Some of the wastewaters
that are often combined with the pickling wastes are cold rolling
wastewaters and wastewaters from alkaline cleaning or kolene and
hydride descaling operations. The pickling wastewaters are often
combined with cold rolling wastewaters, because the acid in the
pickling wastewaters helps break oil emulsions in cold rolling
wastewaters. Pickling wastewaters are often treated together with
alkaline wastewaters so that they neutralize each other. This can
greatly reduce the costs for chemicals necessary for neutralization.
In any event, most existing treatment systems have components which
accomplish the following: neutralize the acid in the wastes;
precipitate dissolved metals out of solution; promote flocculation of
solids and metals; and provide sufficient sedimentation for the solids
and precipitated metals. Also, some systems include a step which
dewaters any sludge generated in the treatment process.
Control and Treatment Technologies
Considered for Toxic Pollutant Removal
As the Agency found toxic metal pollutants in significant levels in
the discharges from acid pickling operations, it evaluated treatment
systems which are designed primarily to remove these pollutants.
The advanced alternative treatment systems considered by the Agency
for acid pickling operations are described below. These systems have
been demonstrated in varying degrees in the pickling subcategory and
in other industrial applications for wastes with characteristics
similar to those of acid pickling.
A. Lime Precipitation
Chemical treatment of acid pickling wastewaters is well
demonstrated at many plants with lime and polymer flocculation.
Lime precipitation is an effective method of removing toxic metal
pollutants from the wastewater. Lime precipitation involves the
addition of lime, either in the dry or hydrated slurry form, to
the wastewater in a mixing tank followed by sedimentation or
filtration. The metal precipitates are in the hydroxide form.
Lime is commonly used to neutralize acidic wastes because of
economic considerations. Other chemicals such as caustic are
considerably more expensive, but in certain applications offer
advantages over lime. Good removal efficiencies of metals with
lime precipitation have been found in this subcategory. Low
effluent levels have also been demonstrated in other steelmaking
subcategories that employ lime precipitation.
254
-------
A final consideration relating to lime precipitation systems is
the solid waste generation resulting from its use. The large
amounts of sludges which are generated due to the lime addition
are generally disposed of by landfilling. The disposal of
such sludges may pose an operating problem and result in
increased costs, depending on the availability of landfill sites.
The amount of sludge produced during treatment of pickling
wastewaters can be minimized by the design of the treatment
process. In conventional treatment processes the entire volume
of sludge produced is discharged for handling and disposal. In
the modified system a portion of the sludge is recycled to the
head of the treatment plant to act as seed for the treatment
process. The sludges produced in this modified approach are
considerably denser than the sludge produced by the conventional
process. The sludge volume can be reduced by a factor of 30.
B.	Sulfide Precipitation
The addition of sulfide compounds to the wastewaters is capable
of reducing metals concentrations below the levels usually
achieved in lime precipitation reactions. Some of the metals
which can effectively be precipitated with sulfide are zinc,
copper, nickel, lead, and silver, which are all toxic metal
pollutants. The increased removal efficiencies can be attributed
to the comparative solubilities of metallic sulfides with
metallic hydroxides.
Iron sulfide is used to achieve precipitation, because this
compound has a solubility which exceeds that of the heavy metal
sulfides to be precipitated. Also, this compound does not form
excessive levels of sulfide ion concentrations, which could
contribute to the formation of hydrogen sulfide, an objectionable
gas. The typical sulfide precipitation system consists of
neutralization, precipitation, and filtration.
There are several problems associated with the sulfide
precipitation system which must be taken into consideration: (1)
high sludge production (unless the sulfide addition follows a
preliminary hydroxide precipitation step); and (2) higher costs
than for the standard hydroxide precipitation system, because
neutralization of the wastewater prior to sulfide treatment is
necessary.
C.	Vapor Compression Distillation (Evaporation)
Vapor compression distillation is typically used to concentrate a
high dissolved solids waste stream (3,000 - 10,000 mg/1) to a
slurry consistency (approximately 100,000 mg/1). The slurry
discharge can be dried in a mechanical drier or allowed to
crystallize in a small solar or steam-heated pond prior to final
disposal. The distillate quality water generated by this system
can be recycled back to an acid pickling operation thereby
eliminating all discharges. _ One desirable feature of
this system is its relative freedom from scaling. Because of the
255
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unique design of the system, calcium sulfate and silicate
crystals grow in solution as opposed to depositing on heat
transfer surfaces. Economic operation of this system requires a
high calcium to sodium ratio (hard water).
The installation of this system may be the only possible way to
achieve a zero discharge of process water at all acid pickling
operations. However, the high cost and energy intensive nature
of this system precludes its widespread use.
Summary of Analytical Data
Raw wastewater and effluent analytical data for the acid pickling
operations which were visited are presented by subdivision in Tables
VII-2 through VII-14. Table VII-1 provides a key for the control and
treatment technology abbreviations used in the tables throughout this
report. The concentration values presented in the tables represent,
except where footnoted, averages of gross measured values. In some
cases these data were obtained from central treatment systems. Spent
concentrations, fume scrubber wastewaters, and absorber vent scrubber
wastewaters are listed in the raw form only; no effluent values are
given. In several instances, the effluent waste loads (lbs/1000 lbs)
for certain central treatment operations indicated on the analytical
data tables represent apportioned loads. In these central treatment
systems, the percentage contribution of an individual operation to the
total treatment system influent load is determined and subsequently
applied to the total effluent load. This procedure was repeated for
each pollutant. By using this procedure, the Agency assessed the
effects of treatment on the waste loads of an individual process which
discharges to a central treatment facility. Following the
determination of the raw and effluent waste loads, the pollutant load
reductions accomplished by each operation for each pollutant were then
determined.
Summary of Long-Term Analytical Data
As a supplement to the sampled plant analytical data, long-term
effluent analytical data from operations responding to the D-DCPs are
presented in Volume I.
Plant Visits
Brief descriptions of the visited plants follow. Treatment system
flow schematics are provided at the end of this section.
Plant A - See Plant 121
Plant C - Figure VII-1 (Combination)
This plant recently completed the installation of a new central
treatment facility. At the time of this sampling inspection, the
rinsewaters from bar and plate pickling lines were combined prior to
entering an equalization tank. From the equalization tank the wastes
were transferred to a mixing tank, where lime and coagulant aids were
added. The neutralized wastes then were settled in a sedimentation
256
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tank. The discharge was sent to a receiving stream. The spent pickle
liquors from the bar and plate lines are discharged to a holding tank,
and then are hauled away by a private contractor.
Plant D - Figure VII-2 (Combination)
At the time of the sampling trip, the acid rinses generated by this
continuous strip pickling process were discharged to a receiving
stream without treatment. However, a central treatment system that
treats the wastewaters from this combination acid pickling line was
completed in 1978 and is now in operation.
Plant F - Figure VII-3 (Combination)
This plant had two sources of wastes: pickle rinsewater and fume
scrubber water, that were combined prior to entering an equalization
tank. After equalization, lime is added and the pickling wastes are
combined with rolling mill wastes in a scale pit. From the scale pit,
the combined wastewater undergoes settling in a settling basin. The
spent pickle liquor at this operation is hauled away to a company
owned disposal site.
Plant H-2 z Figure VII-4 (Sulfuric)
Dunk rinses are cascaded to minimize flow; spray and other rinses
blended with other plant wastewaters for treatment by gas flotation,
neutralization with lime or caustic, flocculation with polymers,
clarifier, with thickening and vacuum filtration of clarifier
underflows. Concentrations are contract hauled off-site.
Plant Z. Figure VI1-5 (Combination)
This plant employs lime neutralization of the spent pickling
solutions,mixing with the acid rinses, and sedimentation in a lagoon
to treat this wastewater generated by the strip pickling process.
Plant 1-2 - Figure VII-6 (Sulfuric)
Waste pickle liquor is hauled away by a private contractor. All
rinses are combined with other plant wastes in a terminal lagoon and
discharged to a canal.
Plant 1-2 z Figure VII-6 (Hydrochloric)
This plant dilutes pickle liquor and rinses together with other plant
wastes in a terminal lagoon and then discharges to a canal.
Plant L - Figure VII-7 (Combination)
This plant employs municipal co-treatment to treat process rinsewaters
generated by the batch bar pickling operation. Waste pickle liquors
are treated at the plant employing lime neutralization.
257
-------
Plant 0 - Figure VII-8 (Combination)
This plant treats its pickle rinsewaters in a central treatment system
with wastes from other processes. The pickling wastes comprise 50% of
the total flow to the central treatment system. Central treatment
consists of equalization, sodium hydroxide neutralization, aeration,
and clarification. Sludges are dewatered in a sludge lagoon. Spent
pickle liquors at this operation are hauled off-site by a private
contractor.
Plant 0-2 - Figure VII-9 (Sulfuric)
This plant employs batch evaporative crystallization of spent sulfuric
acid. Acid is recovered by the production of ferrous sulfate
heptahydrate. Rinses are recycled to process as makeup to pickle
tank. Zero discharge is achieved.
Plant P-2 z Figures VII-10 and VII-11 (Sulfuric)
This plant employs batch pickle liquor regeneration by vacuum
crystallization. Rinses are metered to the sewer.
Plant Q-2 - Figure VII-12 (Sulfuric)
This plant practices batch pickle acid recovery through the cooling of
spent pickle liquor and crystallization of ferrous sulfate
heptahydrate. Rinses and mists from the filter are recycled back to
the pickle tank. Zero discharge is achieved.
Plant R - Figure VI1-13 (Sulfuric)
This plant uses lime neutralization and sludge lagooning to treat
spent concentrates and rinses from batch specialty steel pickling
operations. There is no discharge from the sludge lagoon.
Plant R-2 - Figure VII-14 (Sulfuric)
Pickle liquor and rinses are combined in an equalization tank; mixed
and treated with acetylene sludge; lagooned; and discharged to a
receiving stream.
Plant 5-2 - Figure VII-15 (Sulfuric)
Concentrated pickle liquor is contract hauled. Standing rinse is
reused as makeup to the pickle tank. Running rinse is treated with
lime and lagooned. The lagoon overflow is recycled, and the sludge is
contract hauled.
Plant T-2 - Figure VII-16 (Sulfuric)
Sulfuric acid is recovered from spent pickle liquor by evaporative
concentration. Rinses are cascaded and used as pickle tank makeup.
Steam condensate is used as a final product rinse.
258
-------
Plant U - Figure VII-17 (Combination)
This plant employs batch lime neutralization of the acid rinses after
combining the rinses with wastes from a degreasing line. This
operation also neutralizes its spent pickle liquor prior to
evaporating this waste stream to extinction. The effluent from the
batch treatment system is discharged to a receiving stream.
Plant U-2 - Figure VI1-18 (Hydrochloric)
The waste pickle liquors and rinsewaters	from the batch pickling
operations are neutralized in a batch	treatment tank by sodium
carbonate prior to discharge to a municipal	sewerage system.
Plant V-2 - Figure VII-19 (Hydrochloric)
The spent pickle liquor from the batch pickling operations is contract
hauled. Rinses are neutralized with sodium hydroxide prior to
discharge to a municipal sewerage system.
Plant W-2 - Figure VI1-20 (Hydrochloric)
Waste pickle liquor is treated by pyrolytic regeneration of
hydrochloric acid. Rinses and fume hood scrubber wastes are diluted
and metered to a sewer. Absorber vent scrubber wastes are neutralized
with caustic solution prior to discharge to a receiving stream.
Plant X-2 - Figures VII-21 and VII-22 (Hydrochloric)
This plant practices spent acid recovery by hydrochloric acid
regeneration. Rinses are diluted and discharged to a receiving
stream. Absorber vent scrubber wastes are treated in a clarifier
along with other plant wastes.
Plant Y-2 z Figures VII-23 and VII-24 (Hydrochloric)
Spent pickle acid is recovered by pyrolytic regeneration of
hydrochloric acid. Rinses and absorber vent scrubber wastes are
diluted and discharged to a receiving stream.
Plant Z-2 - Figure VII-25 (Hydrochloric)
Refer to Plant 093.
Plant AA-2 - Figure VII-26 (Hydrochloric)
Refer to Plant 100
Plant BB-2 - Figure VII-27 (Hydrochloric)
Concentrated pickle liquor is disposed of by off-site contract hauling
to a regeneration system owned by the same company or in an on-site
deep well. Rinses are equalized; mixed with cold rolling wastewaters;
neutralized; aerated; treated with polymers; clarified; lagooned; and
259
-------
discharged to a receiving stream. Sludge from the clarifiers is
dewatered by vacuum filters prior to transport to a dump.
Plant QQ-2 - Figure VI1-28 (Sulfuric)
Spent concentrates and fume scrubber system blowdowns are partially
cascaded, blended with other plant wastewaters and treated by chromium
reduction; emulsion breaking; polymer addition; neutralization with
lime; clarification; and, discharge through a settling lagoon with
surface skimming for oil removal.
Plant SS-2 - Figure VII-29 (Sulfuric)
Spent concentrates are collected, equalized, and discharged to a deep
well. Fume hood scrubber blowdowns and rinsewaters are combined with
all other plant wastes; blended; skimmed; neutralized with lime;
aerated; flocculated with polymers; and, transferred to a settling
lagoon; from which sludges are treated by cyclones and thickeners.
Plant TT-2 - Figure VII-30 (Sulfuric)
Waste pickle liquors are collected, neutralized, and transferred to
off-site evaporation ponds. Rinses are cascaded, blended with fume
scrubber blowdowns, and discharged without treatment. A treatment
facility is under construction.
Plant WW-2 - Figure VII-31 (Sulfuric)
Spent concentrates are filtered and injected into deep wells.
Rinsewaters are blended with other plant wastewaters, flocculated with
polymers and alum, neutralized with lime, clarified, skimmed and
discharged through a terminal settling lagoon.
Plant 090 - Figure VII-32 (Sulfuric)
Plant treats rinses from batch pipe and tube pickling in a central
treatment facility that includes equalization, oil skimming, aeration,
neutralization with lime, polymer addition, clarification, and
finally, discahrge to a receiving stream. Spent concentrates are
recovered by a vacuum crystallization acid recovery system.
Plant 091 - Figure VI1-33 (Sulfuric)
Concentrates from a batch rod pickling operation are hauled off-site
for disposal. Rinses are blended and equalized with hydrochloric acid
pickling and galvanizing wastewaters; aerated; neutralized with lime;
clarified; and, filtered prior to discharge.
Plant 091 - Figure VII-33 (Hydrochloric)
Spent pickle liquor and rinses are neutralized with lime, oxidized,
clarified, and filtered through pressure sand filters prior to
discharge to a receiving stream. Clarifier sludge is dewatered by
vacuum filters prior to disposal.
260
-------
Plant 092 - Figure VI1-34 (Sulfuric and Hydrochloric)
Refer to Plant 123.
Plant 093 - Figure VI1-35 (Hydrochloric)
Spent pickle liquor and rinses are mixed with galvanizing and cold
rolling wastewaters, neutralized and clarified with polymer addition
prior to discharge to a municipal sewerage system. Sludges from the
clarifier are dewatered by vacuum filtration prior to transport to a
landfil1.
Plant 094 - Figure VI1-36 (Sulfuric)
Spent concentrates hauled off-site; rinses combined with all other
finishing mill wastewaters, equalized, skimmed, treated with lime and
polymer, clarified via thickener. Centrifugation of underflows and
discharge of treated effluents.
Plant 095 - Figures VI1-37 and VII-38 (Hydrochloric)
This plant practices spent acid recovery by hydrochloric acid
regeneration. Some rinsewater is recycled to fume hood scrubbers and
absorber vent scrubbers. Remaining rinsewater and scrubber wastes are
sent to waste lagoons.
Plant 096 - Figure VII-39 (Sulfuric)
Batch fastener pickler wastes are blended with galvanizing,
aluminizing, and electroplating wastes; aerated and neutralized with
lime; thickened; and, filtered. Filtrates are discharged to a holding
lagoon for plant-wide reuse or discharge.
Plant 097 - Figure VI1-40 (Sulfuric)
Spent concentrates are recovered by a two-stage evaporation and
crystallization recovery system designed to produce dry copperas.
Cold water rinses are used as pickle tank makeup, while hot rinses are
discharged to a POTW for further treatment.
Plant 098 - Figure VII-41 (Sulfuric)
Three lines pickle bar, wire, and special shapes. Rinses are
concentrated and dumped to pickle tanks as makeup. Acid vapors are
collected by a demister and recycled to pickle tanks. All sumps and
foundation drains are collected and transferred to storage. All
liquid wastes are contract hauled off-site.
Plant 099 - Figure-42 (Hydrochloric)
The spent pickle liquor is recovered by acid regeneration. Rinses and
fume scrubber wastes are mixed with other plant wastes, neutralized
and settled in ponds prior to discharge to a receiving stream.
261
-------
Plant 100 - Figure VII-43 (Hydrochloric)
This plant has cascade rinse systems with the rinsewater used as
makeup to a fume scrubber. Spent pickle liquor and fume scrubber
wastes are combined with cold rolling wastewaters and disposed of by
deep well injection.
Plant 121 and A - Figure VI1-44 (Combination)
This operation was visited on two occasions for this study. The first
time the operation was designated as Plant A, and for the second
sampling trip the operation was designated as Plant 121. The pickle
rinse and fume scrubber waters are combined with other small volume
waste flows before entering a central treatment system. The pickling
wastes comprise approximately 75% of the total wastewater flow
entering the central treatment system.
The combined wastes are treated by equalization, neutralizaton and
clarification. The underflow from the clarifiers goes to thickeners
and centrifuges. The overflow from the clarifiers goes to a polishing
tank from which approximately 50% of the treated water is discharged
to a receiving stream. The waste pickle liquor is hauled off-site by
private contractors.
Plant 122 (Combination)
Due to various technical difficulties not known during sampling, the
data from this plant are unacceptable. Therefore, they were
disregarded.
Plant 123 - Figure VII-34 (Combination)
The rinsewaters from this combination acid pickling operation (sample
point D) are combined with other pickling and hot mill wastes prior to
entering a central treatment system. The combined waste stream then
undergoes equalization, neutralization with lime, flocculation with
polymers, and clarification. Sludges produced are dewatered in vacuum
filters. Spent acid solutions are hauled off-site by private
contractors.
Plant 125 - Figure VII-45 (Combination)
This operation treats its pickle rinse and fume hood scrubber blowdown
water in a three-compartment lime neutralization pit prior to
discharging these wastes to a POTW.
262
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
Symbols
Operating Modes

1. 0T
Once-Through

2. Rt,s,n
Recycle, where t
* type waste

s
* stream recycled

n
* Z recycled

t:
: U = Untreated


T ¦ Treated

s
n
P
Process Wastewater Z of
raw waste flow
F
Flume Only Z of
raw waste flow
S
Flume and Sprays Z of
raw waste flow
FC
Final Cooler Z of
FC flow
BC
Barometric Cond. Z of
BC flow
VS
Abs. Vent Scrub. ! of
VS flow
FH
Fume Hood Scrub. Z of
FH flow
3. REt,n
Reuse, where t ¦
type

n ¦
Z of raw waste flow

t:
U ¦ before treatment


T ¦ after treatment
4. BDn
Blowdown, where n ¦ discharge as % of


raw waste flow
Control Technology

10. DI
Deionization

11. SR
Spray/Fog Rinse

12. CC
Countercurrent Rinse
13. DR
Drag-out Recovery
Disposal Methods
20.	H
21.	DW
Haul Off-Site
Deep Well Injection
263
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 2	
C.	Disposal Methods (cont.)
22. 
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 3
D.	Treatment Technology (cont.)
43.	FLt	Flocculation, where t = type
t: L = Lime
A = Alum
P = Polymer
M * Magnetic
0 = Other, footnote
44.	CY	Cyclone/Centrifuge/Classifier
44a. DT Drag Tank
45.	CL	Clarifier
46.	T	Thickener
47.	TP	Tube/Plate Settler
48.	SLn	Settling Lagoon, where n = days of retention
time
49.	BL	Bottom Liner
50.	VF	Vacuum Filtration (of e.g., CL, T, or TP
underflows)
51.	Ft,m,h	Filtration, where t ¦ type
m * media
h ¦ head
	t	m	h	
D ¦ Deep Bed	S ¦ Sand	G ¦ Gravity
F ¦ Flat Bed	0 ¦ Other, P ¦ Pressure
footnote
52.	CLt	Chlorination, where t » type
t: A ¦ Alkaline
B ¦ Breakpoint
53.	CO	Chemical Oxidation (other than CLA or CLB)
265
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 4		
D.	Treatment Technology (cont.)
54. BOt	Biological Oxidation, where t = type
t = type

t: An ¦
Activated Sludge
n =
No. of Stages
T -
Trickling Filter
B «
Biodisc
0 -
Other, footnote
55.	CR	Chemical Reduction (e.g., chromium)
56.	DP	Dephenolizer
57.	ASt	Ammonia Stripping, where t * type
t: F = Free
L * Lime
C * Caustic
58.	APt	Ammonia Product, where t ¦ type
t: S ¦ Sulfate
N ¦ Nitric Acid
A * Anhydrous
P * Phosphate
H ¦ Hydroxide
0 ¦ Other, footnote
59.	DSt	Desulfurization, where t ¦ type
t: Q = Qualifying
N ¦ Nonqualifying
60.	CT	Cooling Tower
61.	AR	Acid Regeneration
62.	AU	Acid Recovery and Reuse
63.	ACt	Activated Carbon, where t ¦ type
t: P * Powdered
G " Granular
64.	IX	Ion Exchange
65.	RO	Reverse Osmosis
66.	D	Distillation 266
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 5
D. Treatment	Technology (cont.)
67.	AA1	Activated Alumina
68.	OZ	Ozonation
69.	UV	Ultraviolet Radiation
70. CNTt,n	Central Treatment, where t ¦ type
n ¦ process flow as
Z of total flow
t: 1	"	Same Subcats.
2	¦	Similar Subcats.
3	¦	Synergistic Subcats.
4	¦	Cooling Water
5	*	Incompatible Subcats.
71.	On	Other, where n ¦ Footnote number
72.	SB	Settling Basin
73.	AE	Aeration
74.	PS	Precipitation with Sulfide
267
-------
TABLE VII-Z
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - BATCH PROCESS
GROSS RAN AMD EFFLUENT WASTEWATERS - CONCENTRATIONS AND LOADS
Saw Waatewater










Plant
: Coda

I-2( 1)

I-2( 2)

0-2

P-2

0-2
Raferance No.

0856P

08S6P

0590

0312

0894
Sanpla Point a

7

3

1

1

3
Flow
(gal/ton)

207

465

18

16.9

8.0
Paraaatara

Iba/iuuu iba
all
lb*/1000 lbf
J!SZi
lt»/1000 lba
ag/1
lbs/1000 lba agjl"
lba/1000 lba

Dissolved
350
0.302
36
0.070
43,000 3.23
6,500 0.459
3,500 0.117

Iron



0.12
18






Suspended
113
0.0977
65
0.0014
749
0.0528
20
0.00067

Solida



0.028







Oil and
4.3
0.0037
14,4
12
0.00091
11
0.00078
0.6
0.00002

Crease











pH, Unica
2.4-2.
,6 -
2.9-6
.4 -
<1.0
-
1.J-!
L.6 -
1.9
-
11S
Arsenic
NA
NA
NA
NA
NA
MA
NA
MA
NA
NA
118
Cadaiua
NA
NA
NA
MA
MA
NA
NA
NA
NA
NA
119
Chroaiun
NA
MA
NA
NA
MA
MA
NA
NA
NA
NA
120
Copper
NA
NA
NA
NA
NA
KA
NA
NA
NA
NA
122
Lead
NA
NA.
NA
NA
MA
NA
NA
HA
NA
NA
124
Nickel
NA
NA
NA
NA
NA
MA
NA
MA
NA
NA
128
Zinc
NA
NA
NA
NA
MA
HA
NA
MA
NA
NA
Sffluenea










Treatment Tech.

SL

SL

AO

Nona

AD
Plant
: Coda

I—2< I)

1-2(2)

0-2

P-2

Q-2
Reference No.

0856P

085 6P

0590

0312

0894
Saapl
.a Points
7/(7+3 *2 <4) 5
3/<7+3*2-t4) 5

.

1


Streams Traatad

Rinses

Rinaaa
Rinaaa
i Concencraces

Rinaaa
Rinaaa
: & Concentrates
Flow (gal/ton)

207

465

0

16.9

0
Par an
latere
at/l
Iba/lUOO lba
V1
Ibe/1000 lba
¦ag/1
iwiKwr lba
qg/l
lba/iOOO
lba ag/l
lba/1000 lba'

Diaaolvad
0.03
0.0018
0.03
0.00041







Iron











Suapcndad
39
0.023
39
0.029

Zaro

Diract

Zaro

Solida











Oil and
Cresse
14
0.0068
14
0.0516

Diacharga

Diacharga

Diacharga

pB, Units
6.7
-
6.7
-



to


115
Arsanic
NA
NA
NA
NA



POTW


118
Cadaiua
NA
NA
NA
NA






119
Chroaiun
NA
NA
HA
NA






120
Coppar
NA
NA
NA
NA






122
Laad
HA
NA
MA
NA






124
Nickel
MA
NA
MA
MA






128
Zinc
NA
NA
NA
MA






268
-------
TABLE VII-2
SUMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - BATCH PROCESS
GROSS SAW AND EFFLUENT WASTEWATER - CONCENTRATIONS AND LOADS
PACE 2
Raw tfaatevater
Plant Cod*

R-2

S-2

R

090

091
Reference No.

0240B

0256G

0240A

04 76A
0612
Sanple Pointa

2-7-6

3-4

11

C

r
Flov (gal/ton)

30.8

198

30

91

122
Parametera
¦§yi
lbe/1000 lba mgiI
Iba/iuoo lba
¦K/l lba/1000 lba
Si!!
lba/1000 lb*
a|/l
lba/1000 lba
Diaaolvad
1850
0.238
596
0.491
(990 1.126
393
0.150
2350
1.20
Iron










Suspended
3688
0.474
159
0.131
1.
3 0.00016
10
0.0038
96
0.0092
Solida










Oil and
665
0.0855
21
0.017
1.
3 0.00016
26
0.0099
It
0.049
Greaaa










pB, Onita
2.0
-
2.2
-
1.
6
1.7-2
.5 -
1.8
-
115 Araenic
NA
NA
NA
NA
NA
NA
MA
NA
M
NA
118 Cadmium
NA
NA
NA
NA
NA
NA
*
Neg
0.020
0.000010
119 Chromium
NA
NA
NA
NA
NA
NA
0.37
0.00014
3.8
0.0019
120 Copper
NA
1H
NA
NA
NA
1U
0.39
0.00015
0.63
0.00032
122 Lead
NA
NA
NA
NA
NA
NA
•
Neg
0.21
0.00011
124 Nickel
NA
NA
NA
NA
m
IU
0.44
0.00017
0.80
0.00041
128 Zinc
NA
na
NA
HA
NA
HA
59
0.022
27
0.014
Effluenta










Treatment Tach.

SL, E

None

SL,RL
E, AE, NLfCL, FLP
R, M., CL.m
Plant Code

R-2

S-2

R

090

091
Reference No.

0240B

0256G

0240A

0476A
0612
Saapl a Point a

(2-7-6)/(2«9) 3

-

-
(C/E)G
F/(#+C*D»B) H
Streama Treated

Kinaaa

Rioaea
Rlnaea t Concentrate*
Rin*e* Rin**a
t Concencrac*
Flo* (gal/ton)

30.8

o

0

9.1

122
Paraaetera
mg/1
lb*/100Q lba
¦g/l
lba/1000 lba
ac/1 lba/1000 lba
aii
lba/1000 lba
¦|/1
Ibe/IQOO lb*
Diaaolvad
0.04
Reg
Ccaplete

Ccaplete
0.050
0.00012
0.37
0.0086
Iron










Suapended
82
0.000057
Recycle
bfouokast
4
0.000066
11
0.00066
Soli da










Oil and
9
Reg
Operation

via
U
0.0040
4
0.0038
Graeae










pR, Onita
11.4
-



Lagoon*
6.6-9.
.0
8.3-8
.5
115 Araenic
NA
NA




NA
NA
NA
NA
113 Cadaiia
NA
NA




*
Reg
0.020 0.000085
119 ChroniuB
NA
NA




•
Reg
0.04
0.00059
120 Coppar
NA
NA




0.030
0.000030
0.03
0.00110
122 Laad
NA
NA




*
Meg
0.19
0.000010
124 Nickel
NA
MA




0.030
0.000034
0.03
0.00026
128 Zinc
NA
NA




0.060
0.00030
0.13
0.000070
269
-------
TABLE VII-2
SOIMAK? OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - BATCH PROCESS
GROSS RAH AMD EFFLUENT WASTEWATER - CONCENTRATIONS AND LOADS
PACE 3 			 ¦	
Raw Wastewater
Plane Code
Reference No.
Saaple Poinea
092
0088A
F-D
326
096
01121
0
604
098
0684 D
I
12.2
Average
248
Par Meters
ag/1
"Ibe/1000"Iba
Wf/l
lbe/1000 Iba
¦t/r
-TE./1000"TT).
¦$/l
—ISsTTOM' Iba

Diaaolved
51.7
O.0704
97
0.24
2900
0.15
5432
0.603

Iron









Suapended
361
0.492
127
0.320
32
0.00020
418
0.131

Solida









Oil and
42.8
0.0582
16
0,040
4
0.0016
64.3
0.022

Grease









pH, Unite
5.9-6.9
-
3.2-3.7
-
1.8
-
1.0-6,
,4 -
115
Arsenic
0.39
0.00053
HA
HA
0.34
0.000017
0.37
0.00027
118
Cadaium
3.96
0.0054
*
Me(
0.14
Nag
0.83
0.0011
119
Chromium
16.3
0.022
0.100
0.00025
4.8
0.00024
5.07
0.0049
120
Copper
0.74
0.0010
0.200
0.00050
4.1
0.00021
1.21
0.00044
122
Lead
ND
HD
0.019
0.00048
2.06
0.00011
0.49
0.00014
124
Nickel
1.4
0.0019
0.090
0.00023
7.5
0.00038
2.05
0.00062
128
Zinc
3.9
0.0053
15
0.038
1.3
0.000066
21.2
0.016
Effluent!
Treatment Tech.
Plane Code
Reference No.
Saaple Poinea
Streaae Treated
EICR,NL,PLP,CL, T,VF
092
0O88A
(F-0)/(r*C*H) I
Rinaea
326
AE, NL.CL.F,
096
01121
D
-------
TABLE VII-2
SUM4ARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - BATCH PROCESS
GROSS RAW AND EFFLUENT WASTEWATER - CONCENTRATIONS AND LOADS
PAGE 4		
FOOTNOTES
NA : Not analyzed.
ND : Not detected.
Neg: Calculated vaateload <0.000010 lba/1000 lb».
* : Concentration* <0.010 ag/1.
Negative reaulta were obtained when contributing acreama arc aubtracted frov the atream.
TreaOaent Tech. Code
AE	:	Aeration
AU	I	Acid recovery
CC	:	Countercurrent rinae
CR	:	Chemical reduction
E	¦	Equalisation
F	i	Filtration
FLP	:	Flocculation with polymer
FDBSi	Filtration - Deep Bad Sand
NA	Not analysed
NL	:	Neutralization with Lime
CL	:	Sedimentation via clarifier
SL	:	Sedimentation via lagoon
T	:	Sedimentation via thickener
VF	:	Vacutaa filtration
(1) No. 4 pickling operation
(2} No. 3 pickling operation
271
-------
TABLE VII-3
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - BATCH PROCESS
GROSS RAH SPENT CONCENTRATES - CONCENTRATIONS AND LOADS
Raw Wastewater
P-2
R-2
091
092
Kj
to
Reference Ho.

0312

0894

0240 B

0612

0088A


Sanple Points

3

1

6

R

C

Average
Flow (gal/ton)

17.6

24.3

10.5

3.5

14.6

14.1
Paraieters
¦g/1
lbs/lOM lbs
¦g/1
lbs/1000 lbs
-g/1
^bs/1000 lbs
¦g/1
lbs/1000 lbs
¦g/ 1
lbs/1000 lbs
¦g/1
lbs/1600

Dissolved
46,800
2.93
61,900
6.27
67,800 2.97
63,000
0.921
38,500 2.38
55,600 3.09

Iron













Suspended
26.0
0.00016
1420
0.144
70
0.0031
2520
0.837
306
0.187
868
0.234

Solids













Oil & Grease
HA
0.00018
14
0.0014
NA
NA
11
0.00016
17
0.0010
15.3
0.00069

pH
1.4
-
<1
-
2.0
-
<1
-
<1
-
<1-2.
0
115
Arsenic
HA
NA
MA
MA
NA
NA
NA
NA
0.17
0.000010
0.17
0.000010
118
Cadtaiua
HA
MA
NA
HA
NA
NA
0.26
Neg.
0.28
0.000017
0.27
Neg.
119
ChroaiuB
!U
ha
MA
NA
NA
NA
269
0.00393
205
0.0725
237
0.0082
120
Copper
HA
MA
MA
HA
NA
NA
2.6
0.000038
4.7
0.00029
3.7
0.00016
122
Lead
NA
NA
MA
MA
NA
RA
1.6
0.000023
•
Neg.
0.81
0.000012
124
Mickel
DA
MA
NA
HA
NA
HA
23
0.00034
27.0
0.0016
25
0.00097
128
Zinc
NA
MA
HA
MA
RA
NA
16
0.00023
133
0.0087
74.5
0.0042
RA Mot analysed
Meg.: Hasteload leas than 0.000010 lha/1000 lbs
* : Concentration is less than 0.010 ag/l
-------
TABU WI-4
SOHMUY OP ANALYTICAL DATA FROM UWUD PLAHTS
SUtrOtlC ACID PICXLHG - OOHTIRUODS PBOCESS
qtOSS 1AH AMP EFFLBBHT WASTEVATgtS - COWCEHmTIOWS AND LOADS
taw Waetevater
Plant Code
Reference Bo.
Saaple Pointa
Floe ((al/taa)

H-2<»
0432A
3
103

H-2<»
0432A
4
11.5	

T-2
0792 B
1
21.6

QQ-2
05848
5
167

SS-2
0112A
2
202
Para
act era
sll
Ibe/tOOO lba
5^1
lba/1000- lba
ad
lba/MHJU lba
a11
lba/1000 lba
3d
lba/1000 lba

Diaeolved
55
0.024
0.02
¦eg.
1833
0.165
83
0.058
63
0.053

Iron











Seapeaded
28
0.012
20
0.00096
49
0.0044
35
0.024
76
0.064

Solida











Oil aad
11
0.0047
11
0.00053
5.0
0.00045
2
0.0014
2
0.002

Creaae











pi, Oaite
1.9
-
6.4
-
1.6
-
2.7
-
2
-
115
Araeaic
HA
HA
HA
HA
HA
HA
HA
HA
HA
HA
US
Cadaliaa
HA
HA
HA
HA
HA
HA
HA
HA
HA
HA
119
Chroaiua
HA
HA
HA
HA
HA
HA
HA
HA
HA
HA
120
Copper
M
HA
HA
HA
HA
HA
HA
HA
HA
HA
122
Lead
H
HA
HA
HA
HA
M
HA
HA
HA
HA
124
Hckel
M
M
HA
HA
HA
HA
HA
HA
HA
HA
128
Ziac
HA
HA
HA
HA
HA
HA
HA
HA
HA
HA
to
CJ
Ifflnwti
Treitant Tech.
Plant Code
Reference Re.
8«apl e Points
Streaae Treated
Flo. (gal/toe)
Par act era
FLL, HL, riP.CL.T, VP
H-2
0432A
¦izr
tinaea
- 103
Ibe/IOM lba
FLL,N.,fLf^L,T,VF
M32A
tinaea
11.5
^71	lbe/lOW lba
T-2!
0792It
tinaea
C*,CC,n, M..CL, SL
W-2
0584 E
5/(6+2) 7
Concentrate! 1 tinaea
0	167
¦t/1 lbe/tOWTTEr ^7T—Ibe/IMO lb.
hl, a, ne, t, sl, ss
SS-2
0112A
1/(1*1*7) 9
Rinaea 4 Fiaae
Hood Scrubber
202
¦g/i iba/nnw~rtr

Diiiolved



0.04
Neg.
0.04
0.0003

Iroa








Suspended
Direct
Direct
Complete
1
0.00015
43
0.014

Sol Ida
Discharge
Discharge






Oil fc
to
to
Recycle
3
0.000056
6
0.00021

Grease
Teniae!
Tendnal






pB, Unit*
Treats ent
Treatment
System
7.5
-
7.7
-
115
Arsenic
Where
Where

NA
NA
NA
HA
118
Cadaitn
No Saiples
Ho S«ples

NA
NA
NA
NA
119
Chroaiusi
Were
Were

NA
NA
NA
NA
120
Copper
Taken
Taken

NA
NA
NA
NA
122
Lead



NA
NA
NA
NA
124
Nickel



NA
NA
NA
NA
128
Ziac



NA
NA
NA
NA
-------
TABLE VII-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAU AND EFFLUENT WASTEWATERS - CONCENTRATIONS AND LOADS
PAGE 2
Raw Wastewater











Plant Code
TT-2

WW-2

o*<3>

094 <*>

097


Reference No.
0856D

0868A

0948C

0948C

0760


Saaple Points
1

1

C

D

E+B

Average
Flew (gal/ton)
134

284

303

422

11.1

166
Parameters
mg/i lbs/1 000 lbs
mg/1
lbs/1 WO lbs
¦g/1
lbs/1000 lbs
¦g/1
lbs/1000 lbs
¦8/1
lbs/1000 lbs
¦g/i
lbs/1000 lbs
Dissolved
81.9 0.0458
357
0.423
40
0.051
98
0.17
29, 780 1.38
6071
0.414
Iron











Suspended
7.0 0.003 9
6.1
0.0072
38
0.048
37
0.065
501
0.0232
118
0.029
Solids











Oil and
2.4 0.0013
1.6
0.0019
9
0.011
14
0.025
33.4
0.00155
12.1
0.0082
Grease











pHt Units
1.8
1.7
-
3.2-
-
2.2-
-
NA
-
1.7-
-




5.7

2.3



5.7

115 Arsenic
NA NA
NA
NA
*
0.000013
*
0.000018
0.17
Neg.
0.064
0.000010
118 Cadmium
NA NA
NA
NA
*
0.000013
*
0.000018
0.302
0.000014
0.107
0.000014
119 Chroaita
NA NA
NA
NA
*
0.000013
0.05
0.000088
2.0
0.000093
0.687
0.000005
120 Copper
NA NA
NA
NA
0.055
0.000070
0.14
0.00025
2.4
0.000111
0.865
0.00014
122 Lead
NA NA
NA
NA
0.04
0.000051
*
0.000018
1.0
0.000048
0.35
0.000039
124 Nickel
NA NA
NA
NA
0.06
0.000076
0.011
0.000019
13.8
0.00064
4.62
0.00025
128 Zinc
NA NA
NA
NA
0.04
0.000051
0.09
0.00010
1.8
0.000085
0.64
0.000099
Effluents











Treatment Tech.
Evaporation Pond
FLP, FLA, H,CL, SS, SL
E, S
!S,TI(Hf,NL
E, FLP, SS*\T, NL Evaporatiw
n,Crys talligation

Plant Code
T-2

WW-2

094137

094

097


Reference No.
0856D

0868A

0948C

0948C

0760


Sample Points
-

(1/4)5

(C/G)H

(D/G)H

F*G


Streams Treated
Rinses, 4 Ftme Rood

Rinses

Rinses

Rinses

Rinses



Scrubbers










Flow (gal/too)
134

28t

303

422

11.0


Parameters
wfj 1 lbs/1000 lbs
¦s/1
lbs/1000 lbs
¦g/1
lbs/1000 lbs

lbs/1000 lbs
«g/1
lbs/1000 lbs


Dissolved
Di rect
0.17
0.0007
0.050
0.000040
0.050
0.0003
465
0.0834


Iron
Discharge










Suspended
to
15
0.0006
6
0.00047
6
0.0013
7.5
0.00131


Solids
Receiving










Oil and
Stream
8.5
0.00007
6
0.00047
6
0.00091
9.3
0.0017


Grease











pR, Units

8.0
-
7.6-
-
7.6-
-
NA
-






7.8

7.8





115 Arsenic

NA
NA
*
0.000013
~
0.000018
0.010
Neg.


118 Cadtaium

NA
NA
*
0.000013
*
0.000018
0.012
Neg.


119 Chromiiai

NA
NA
0.020
0.000013
0.020
0.000053
ND
ND


120 Copper

NA
NA
*
ND
*
0.000018
0.139
0.000025


122 Lead

NA
HA
*
0.000051
*
0.000018
0.040
Neg.


124 Nickel

NA
NA
0.040
0.000051
0.040
0.000018
0.094
0.000017


128 Zinc

NA
NA
0.070
0.000020
0.070
0.000062
0.059
0.000011


-------
TABLE VII-4
SUMfAR OF ANALYTICAL DATA FROM SAMPLED PUNTS
SULFURIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAH AMD EFFUJBRT WASTEWATERS - CONCENTRATIONS AMD LOAD6
PAGE 3		
FOOniOTES
(1)	Spray tine
(2)	Cascade tine
(3)	Sheet Pickling Operation
(4)	Strip Pickling Operation
Treatment Tech Code
AE t Aeration
CC t Counter cur rent rinse
CR : Cheaical reduction
E I Equalization
EB t Eaulaion breaking
FLA: Flocculation with ilia
FLL: Flocullation with lime
MD	Rot detected
RA :	Rot analysed
Reg.:	Waateload is less than 0.000010 lbs/1000 lbs
* I	Concentration is less than 0.010 mg/1.
FLPi Flocculation with polymer
Hi t Neutralization with liae
CL s Sedimentation via clarifier
SS:	Skiaing
SL :	Sedimentation via lagoon
T i	Sedimentation via thickener
VF i	Vacuum filtration
-------
TABLE VII-5
Raw Wastewater
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAW SPENT CONCENTRATES * CONCENTRATIONS AND LOADS
Plant Code

H-2

T-2*
QQ-2

SS-2

TT-2
Reference No.

0432A

0792B
0584 E

0112A

0856D
Sampling Points

2


2


1

4
Flow
(gsl/ton)

14. 7

14.6
23.
,6

10.9

23
Paraaet ers
sig/1 lbs/1000 lbs
mg/l lb./1000 lbs
mg/l
lbs/1000 lbs
mg/ 1 lbs/1000 lb*
mg/l
lbs/1000 lbs

Dissolved
47,
900 2.93
34,
000 2.07,
48, 300
4.76
48,
000 2.18
70,800 6.8

Iron











Suspended
17,
000 1.04
65
0.0040
128
0.126
200
0. 0091
222
0.0213

Solids











Oil &
NA
NA
18
0.0011
8.5
0.008
9.5
0.00043
18.5
0.00178

Grease











pH
<1
-
<1
-
<1
-
<1
-
<1
-
115
Arsenic
MA
NA
NA
NA
NA
NA
NA
NA
NA
NA
116
Cadmium
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
119
Chroqium
HA
NA
NA
NA
NA
NA
NA
NA
NA
MA
120
Copper
NA
NA
MA
NA
NA
NA
NA
NA
NA
NA
122
Lead
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
124
Nickel
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
128
Zinc
NA
NA
HA
NA
NA
NA
NA
NA
NA
NA
Raw Wastewater
Plant Code
Reference No.
Sanpling Points
Flow (gal/ton)
WW-2
0868A
2
44. 7
097
0760
E
7.2
Average Flow
19.8
Parameters
mg/ 1
lbs/1000
lbs mg/l
lbs/1000 lbs
Average Average
mg/l lbs/1000 lbs

Dissolved
19,000
3.55
46,000
1.4
44,860
3.4

Iron







Suspended
91
0.0170
320
0.0096
2,575
0.175

Solids







Oil I
10
0.00187
46
0.0014
18
0.0012

Grease







pH
<1
-
<1
-
<1
-
115
Arsenic
NA
NA
0.18
Nag
0.18
Nag
118
Cadmium
NA
NA
0.46
0.000014
0.46
0.000014
119
Chromium
NA
NA
30.0
0.00090
30.0
0.00090
120
Copper
NA
NA
3.0
0.000090
3.0
0.000090
122
Lead
NA
NA
1.6
0.000048
1.6
0.000048
124
Nickel
NA
NA
21
0.00063
21
0.00067
128
Zinc
NA
NA
2.8
0.000084
2.8
0.000084
NA : Not analyzed.
Neg: Wasteload value is less than 0.000010 lbs/1000 lbs.
* : Acid Recovery plant with zero discharge.
276
-------
TABLE VII-6
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
SULFURIC ACID PICKLING - CONTINUOUS PROCESS
GROSS SAW FUME HOOD SCRUBBER WASTEWATER - CONCENTRATIONS AND LOADS
Raw Wastewater
Plant
Code

QQ-2

SS-2

TT-2


Reference No.

0584 E

0112A

856D


Staple Points

3

3-»4+5

2
Average Flow
Flow (gal/ton)

2

22.6

2.3

9.0








Average
Average
Par®
leter
¦g/1
lbs/1000 lbs
mg/1
lbs/1000 lbs
mg/1
lbs/1000 lbs
mg/1
lbs/1000 lbs

Dissolved Iron
305
0.00255
0.55
0.000052
88.7
0.000852
131
0.00115

Suspended
2.5
0.000021
7.5
0.0007)
198
0.00190
69.3
0.00088

Solids









Oil and Grease
2.5
0.000021
2
0.0019
9.0
0.000086
4.5
0.000099

pH, Units
1.4
-
1.9
-
1.7
-
1.4-1.9
-
US
Arsenic
NA
NA
NA
NA
NA
NA
NA
NA
118
CaAiiiza
NA
NA
NA
NA
NA
NA
NA
NA
119
Chroaiw
NA
NA
NA
NA
NA
NA
NA
NA
120
Copper
NA
NA
NA
NA
NA
NA
NA
NA
122
Lead
NA
NA
NA
NA
NA
NA
NA
NA
124
Nickel
NA
NA
NA
NA
NA
NA
NA
NA
128
Zinc
NA
NA
NA
NA
NA
NA
NA
NA
HA: Mot analyzed
-------
TABLE VII-7
SUMMARY OF ANALYTCIAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - BATCH PROCESS
CROSS RAW AND EFFLUENT WASTEWATERS - COR CENT RAT IONS AND LOADS
Raw Wastewater
Plant Code
Reference No.
Sanpling Points
Flow (gal/ton)

U-2
0480A
1
92.9

V-2
0936
1+6
167.2

Aver age
130,1
Parameters
¦g/1
lbs/1000 lbs
iag/1
lbs/I000 lbs
r j/1
lbs/lQOft lbs

Dissolved Iron
190
0.074
270
0.188
230
0.131

Suspended Solids
0
0
0
0
0
0

Oil and Grease
3
0.0012
1.5
0.0010
2.3
0.0011

pH, Units
1.8
-
2.5-3.4
-
l.fc-3.4
-
23
Chloroform
NA
NA
NA
NA
NA
NA
114
Antimony
NA
NA
NA
NA
HA
NA
115
Arsenic
NA
NA
NA
NA
NA
NA
118
Cadaiui
NA
NA'
NA
NA
NA
NA
119
Cfaroniun
NA
NA
NA
NA
NA
NA
120
Copper
NA
NA
NA
NA
NA
NA
122
Lead
NA
NA
NA
NA
NA
NA
124
Nickel
NA
NA
NA
NA
NA
NA
126
Silver
NA
NA
NA
NA
NA
NA
128
Zinc
RA
NA
HA
NA
NA
NA
-------
TABLE VII-7
SCMfARf OF AKALYTCIAL MTA FROM SAMPLED P LASTS
HTDBOCKjOKIC ACID PICKLING - BATCH PROCESS
GROSS RAW AND EFFLUBKT WASTEWATERS - COHCEKTRATIOSS AND LOADS
PAGE 2
fo
VD
Effluents



Treataent Technology

N.<»

Plant Code

0-2

Reference No.

04 80 A

Ssapling Points

-

Streaas Treated

Rinses

Flow (gal/too)

92.9

Parameters
¦g/1
lbs/1000 lbs
mg/1
Dissolved Iron
0.50
0.00020
261
Suspended Solids
385
0.149
195
Oil and Grease
5
0.00191
13
pH, Units
8.5
-
3.4*+. 5
23 Chi or of or*
NA
na
NA
114 Antiaooy
MA
NA
NA
115 Arsenic
NA
NA
NA
119 Chroaiua
NA
NA
NA
120 Copper
NA
NA
NA
122 Lead
NA
NA
NA
124 Nickel
NA
NA
NA
126 Silver
NA
NA
Mi
128 Zinc
MA
NA
NA
MA: Mot analysed.
(1) Neutralised with Soda Aah.
AB.NC
V-2
0936
4
Rinses
167.2
	iWlOM
0.182
0.136
0.009
NA
NA
NA
NA
NA
NA
NA
NA
NA
-------
TABLE VII-8
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - BATCH PROCESS
GROSS RAW SPENT CONCENTRATES - CONCENTRATIONS AND LOADS
Raw Wastewater
Plant Code
Reference No.
Sampling Points
Flow (gal/ton)
Parameters
ng/1
U-2
0480A
3
6.45
V-2
0936
7-m
3.86
lbs/1000 lbs
mg/1
lbs/1000 lbs
Average Flow
5.16
Average
mg/1
Average
lbs/1000 lbs

Dissolved Iron
77,000
2.06
107,000
1.72
92,000
1.89

Suspended Solids
40
0.0108
140
0.0022
90
0.0065

Oil and Grease
NA
NA
NA
NA
NA
NA

pH, Units
<1
-
<1
-
<1
-
23
Chlorofora
NA
NA
NA
NA
NA
NA
114
Antimony
NA
NA
NA
NA
NA
NA
115
Arsenic
NA
NA
NA
NA
NA
NA
118
Cadmium
NA
NA
NA
NA
NA
NA
119
Chromium
NA
NA
NA
NA
NA
NA
120
Copper
NA
NA
NA
NA
NA
NA
122
Lead
NA
NA
NA
NA
NA
NA
124
Nickel
NA
NA
NA
NA
NA
NA
126
Silver
NA
NA
NA
NA
NA
NA
128
Zinc
NA
NA
NA
NA
NA
NA
M: Not analyzed.
-------
TABLE VI1-9
SUMMARY OP ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAH i EFFLUENT WASTEWATERS - CONCENTRATIONS AND LOADS
Rao Wastewater











Plant Code

1-2

W-2


X-2

Y-2

Z-2
Reference Ho.

08S6P

**


006OB

**

0396D
S«plin| Points

4

7


3

5

1
Flow
(gal/ton)

220

228


663

87.3

166


«k/i
lbs/lOOOlbs
¦g/l
lbs/lOOOlbs
¦g/1
lbs/lOOOlbs
V1
lbs/lOOOlbs
¦g/1
Iba/lOOOlbs

Dia. Iron
7
0.0064
136

0.129
193
0.054
220
0.0802
11300
7.83

Sua. Solids
96
0.088
20

0.019
9
0.025
7
0.0026
72
0.050

Oil 4 Create
3.9
0.0036
14.8

0.014
ND
NO
3
0.0011
9
0.006

pH, Units
4.5-5.0
-
2.9-3.8

-
2.2-
¦2.6
1.7
-
1.1
-
023
Chloroform
HA
NA
NA

NA
NA
NA
HA
NA
NA
NA
114
Antiaoay
MA
NA
NA

NA
NA
NA
HA
NA
NA
NA
US
Arsenic
HA
HA
NA

MA
NA
NA
HA
NA
NA
NA
118
Cadniua
MA
NA
NA

NA
NA
NA
HA
NA
NA
NA
119
Chrosri.ua
¦A
NA
NA

NA
NA
NA
HA
HA
NA
NA
120
Copper
NA
NA
NA

MA
NA
NA
HA
NA
NA
NA
122
Lead
NA
NA
HA

NA
NA
NA
HA
NA
NA-
NA
124
Nickel
NA
NA
NA

NA
NA
NA
NA
NA
NA
NA
126
Silver
NA
NA
MA

NA
NA
NA
NA
NA
NA
NA
128
Zinc
NA
NA
NA

NA
NA
HA
NA
NA
NA
NA
**! Plant ha* ao reference auaber.
-------
TABLE VII-9
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAW & EFFLUENT WASTEWATERS - CONCENTRATIONS AND LOADS
PAGE 2		
Effluents
Treatment Tech.

SL
None
Plant Code

1-2
W-2
Reference No.

08S6P
-
Stapling Points

5
None
Streams Treated

Rinses
None
Flow
(gal/ton)

220
228


mg/1
lbs/lOOOlbs
mg/1 lbs/lOOOlbs

Dis. Iron
0.03
(1)


Sus. Solids
41
(1)
Discharge

Oil & Grease
14
(1)
to POTW

pH, Units
6.7
~
without
treatment
023
Chloroform
NA
NA

114
Antimony
NA
NA

115
Arsenic
NA
NA

118
Cadmium
NA
NA

119
Chromiua
KA
NA

120
Copper
NA
NA

122
Lead
NA
NA

124
Nickel
KA
NA

126
Silver
NA
NA

128
Zinc
NA
NA

None
None
X-2
Y-2
0060B
-
None
None
None
None
663
87.3
E, CL, NL, VF
Z-2
0396D
2
Rinses & Concentrates
166
lbs/10001ba mg/1 lbs/lOOOlbs mg/1 lbs/lOOOlbs
Direct
Discharge
wi thout
treatment
Discharge
to POTW
without
treatment
0.23
0.000162
36
0.0249
1
0.00069
8.1-8.6
-
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
-------
TABLE VII-9
SUMMIY OF ANALYTICAL DATA ttOH SAMPLED PLANTS
HTDCOCHLOK1C ACID PICKLING - COCTINUOOS PBOCESS
GKOSS IAW t EFFLDEKT RUSE WASTEWATERS - CONCBNTIATI0NS AND LOUS
PACE 3	 			 	
Iw Waatevatar
to
09
CJ
Plaat Code
Kef are nee Bo.
Sapling Point*
AA-2
0384A
2
S.8S
M-2
0060
5
211
091
0612
K-F
328
093
0396D
UJ
234
095(2)
0584F
G+GA2+GA3



Iba/lOOOlba
¦g/1
Iba/lOOOlba
¦»/!
Iba/lOOOlba

Ibs/lOOOlbs
¦R/l
Ibs/lOOOlbs

Dia. Icon
14000
0.342
1100
0.969
~
+
3539
3.46
1591
0.164

Sua. Solida
21
0.00051
37
0.033
120
0.102
491
0.480
46.7
0.048

Oil 4 Grease
40
0.00098
59
0.052
~
+
249
0.243
2.8
0.00029

pi, Units
1.1
-
1.5-1.7
-
2.9-3.9
-
1.0
-
1.4-1.7
-
023
Chlorofora
HA
NA
NA
NA
~
+
*
NeS
0.03
Neg
114
Antiaony
NA
HA
NA
NA
ND
ND
NA
NA
0.13
0.000014
115
Arsenic
HA
HA
NA
NA
HO
ND
0.045
0.000044
0.16
0.000016
118
Cadaiiai
NA
NA
NA
NA
*
Neg
*
NeS
0.14
0.000014
119
Chroaiua
NA
NA
NA
NA
-
-
0.79
0.00075
0.035
Neg
120
Copper
NA
NA
NA
NA
0.20
0.00017
0.69
0.00067
0.633
0.000065
122
Lead
NA
NA
NA
HA
23.7
0.020
0.43
0.00041
0.42
0.000052
124
Nickel
HA
NA
NA
NA
0.126
0.00011
0.48
0.00043
0.035
Neg
126
Silver
NA
NA
NA
NA
NA
NA
0.027
0.000026
0.17
0.000018
128
Zinc
NA
NA
NA
NA
162
0.137
1.52
0.00149
0.42
0.000043
-------
TABLE VII-9
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS SAW & EFFLUENT WASTEWATERS CONCENTRATIONS AND LOADS
PAGE 4 	
Effluent
NJ
03
Treatment Tech.
None
AE,FLP,CL,VF,SL,E
NL,
,FDS,VF,CL
NL, CL, VF, E
None
Plant Code
AA-2
BB-2

091

093
095
Reference No.
0384A
0060

0612

396D
0584F
Sampling Points
None
6(3)

(B-G-F) „
(J+B)





(B+E+C+D)
(D+B+F+J+E)
None
Streams Treated
None
Rinses

Rinses &
Rinses & Fume





Concentrations
Hood
Scrubber
None
Flow
(gal/ton)
5.85
211

328

234
24.7


¦g/1 lbs/lOOOlbs
mg/1 lbs/lOOOlbs
mg/1
lbs/10001bs
mg/1
lbs/lOOOlbs
mg/1 lbs/lOOOlbs

Dis. Iron
Disposed
0.004 (1)
0.365
0.00030
5.1
0.00073


Sus. Solids
via deep
2 (1)
11
0.0111
43.0
0.0156
Discharge to

Oil & Grease
wel 1
3 (1)
4
0.00076
5.5
0.0085
waste lagoons

pH, Units
injection
8.3-8.9
8.4
-
9.1
-
with no








treatment
023
Chlorofora

NA NA
*
+
~
Neg

114
Antimony

NA NA
NA
NA
NA
NA

115
Arsenic

NA NA
NA
NA
*
0.000011

118
Cadmium

NA NA
0.02
0.000055
0.02
0.000053

119
Chromium

NA NA
0.04
Neg
0.075
0.0010

120
Copper

NA NA
0.03
0.000075
0.17
0.000092

122
Lead

NA NA
0.19
0.0016
0.58
0.000030

124
Nickel

NA NA
0.03
0.000066
0.27
0.00017

126
Silver

NA NA
0.03
0.000080
0.09
0.000071

128
Zinc

NA NA
0.03
0.00041
0.25
0.000023

-------
TABLE VII-9
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAH & EFFLUENT WASTEWATERS CONCENTRATIONS AND LOADS
PACE 5		
Raw Wastewater




Plant Code

099

100
Reference No.

0528B

0384F
Saapling Points

C+E

C
Flow
(gal/ton)

215.6

37.6


mg/1
lbs/lOOOlbs
mg/1
lbs/lOOOlbs

Dis. Iron
409
0.37
35.0
0.0055

Sus. Solids
56.8
0.051
54.0
0.0085

Oil & Grease
7.8
0.0070
8.0
0.0013

pH, Units
NA
-
4.2
-
023
Chloroform
*
Neg
0.011
Neg
114
Antimony
NA
NA
0.10
0.000016
115
Arsenic
0.063
0.000056
NA
NA
118
Cadmium
*
Neg
*
Neg
119
Chromium
0.85
0.00076
0.030
Neg
120
Copper
0.47
0.00043
0.060
Neg
122
Lead
0.10
0.000090
0.050
Neg
124
Nickel
0.64
0.00057
0.020
Neg
126
Silver
0.02
0.000018
0.020
Neg
128
Zinc
0.60
0.00054
0.14
0.000016
Average
mg/1 lbs/lOOOlbs
2710
1.15
92.8
0.078
33.1
0.0274
1.1-5.0
-
0.012
Neg
0.076
0.000010
0.067
0.000029
0.034
0.000003
0.341
0.00030
0.41
0.000267
4.94
0.0041
0.26
0.00022
0.059
0.000016
32.9
0.028
-------
TABLE VII-9
SWMARY OF ANALYTICAL DATA FBOM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS TROCESS
GROSS RAW & EFFLUENT WASTEWATERS CONCENTRATIONS AND LOADS
PACE 6	
Effluent*
K)
CO

Treatment Tech
Plant Code
Reference No.
Sampling Points
Streams Treated
Flow (gal/ton)
Di». Iron
Sua. Solids
Oil i Grease
pB, Units
023 Chlorofoza
114 Antiaony
US Arsenic
118	Cadaius
119	Cbroaiua
120	Copper
122 Lead
124 Nickel
126 Silver
128 Zinc
AR.NL.SL
099
0528B
«>E> G
(C+E+D+N) "
Rinses, Fiae Hood
Scrubber & Adsorber
Vent Scrubber
215.6
¦k/1 ¦ lbs/lOOOlbs ag/1
0.19
11.0
15.5
7.0
¦D
HA
*
*
0.03
0.025
0.10
0.03
0.02
0.02
0.00024
0.0128
0.0144
ND
HA
0.000013
0.000013
0.000015
0.000071
Reg
Reg
0.000023
0.000011
CL
100
0384A
(C/G) I
Rinses
37.6
15.7
20.0
3.0
8.2
0.024
0.10
HA
*
0.03
0.02
0.05
0.035
0.02
0.47
lb»/10001bs
0.0177
0.0021
0.000077
Neg
Neg
MA
Neg
Neg
Neg
Neg
Neg
Neg
0.000013
-------
TABLE VII-9
SIMIARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS BAH & EFFLUENT WASTEWATERS CONCENTRATIONS AND LOADS
PAGE 7		
FOOTNOTES
(1)	No wasteload calculations possible due to contribution froa unknown streaaa.
(2)	Untreated wastewater to waste lagoon not included in average.
(3)	Includes tandea cold aill waste.
HA :	Not analyzed
ND :	Not detected
+ :	Quantities determined by subtracting other atreaas yields negative values.
* :	Concentration is less than 0.010 ag/1.
Neg:	Wasteload is less than 0.000010 lb/1000 lbs.
Treatment Tech. Code
AE :	Aeration
AR :	Acid regeneration
E	Equalization
FDS:	Filtration deep bed sand
Flf:	Flocculatioa with polyaer
ML:	Neutralization with liae
CI:	Sedimentation via clarifier
SL:	Sedimentation via lagoon
VF:	Vacuua filtration
to
00
-------
TABU VII-10
SUMMIT or ANALYTICAL DATA FUN 8AWLKD PLAKTS
HTDtOC&LOMC ACID PICKLIHC - OMTHODOS PROCESS
CROSS RAW SPCIfT CCHC8 ITT RATES - COHCK WIATIOWS AUD LOADS
Km Haitevttir
Pint Code -
Reference Ho.
Sampling Points
Plow (gal/ton)
~^rr
1-2
0856P
220
Iba/lOOOlba
"mHT
W-2
**
1
11.9
	lbs/lOMlbs
"57T"
z-i
0396D
DNK
41.4
1 bt/100011m
SE7T"
AA-2
0384A
3
3.26
Iba/lMOlba
091
0612
L
18.1
¦gA lbg/lOOOlbg

Dissolved
7.1
0.0065
137700
13.7
44300
15.3
116000
3.14
56000
4.24

Iron











Suspended
54
0.049
97
0.0096
120
0.0414
40
0.0011
3026
0.229

Solids











Oil & Grease
HA
HA
5.1
0.00050
1
0.00035
20
0.00055
4.0
0.00030

pH, Doits
4.5-5.0
-
0. 6-0.7
-
<1
-
<1
-
<1
-
23
Chi or of on
NA
NA
NA
NA
NA
NA
NA
NA
*
Neg
114
Antiaooy
M
HA
NA
NA
HA
NA
NA
NA
NA
NA
115
Arsenic
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
118
Csdaita
NA
NA
NA
NA
NA
NA
NA
NA
0.28
0.000021
119
Cfaroain
HA
NA
NA
NA
NA
NA
NA
NA
37
0.0028
120
Copper
LMd
na
NA
NA
NA
NA
NA
NA
NA
22
0.0017
122
Hk
NA
HA
NA
HA
NA
NA
NA
1550
1.17
124
Nickel
HA
HA
NA
NA
NA
NA
NA
NA
22
0.0017
126
8ilver
HA
HA
NA
NA
NA
NA
NA
NA
0. 30
0.000023
12$
Zinc
M
NA
HA
NA
HA
NA
NA
NA
61
0.0046
-------
TABLE VII-10
BOMAHT or ANALTT1GAL DATA FBOM SAMPLED FLAWS
HTMOC&OUC ACID FICKLOK - COMTINDOUS P BO CESS
GROSS IAW SFUT OMICSHriATES
PAGE 2
law lutenater
Flat Cod*

093

095

hftrnct Bo.

0396D

0584T

Sampling Mat)

Ml)

>

Flan
' (*«l/too)

203

49.7



mt/l
llM/lOO01b*
¦f/1 .
lIX/lOOUltM
•f*

Diaiolwd
3950
3.35
8000
1.66
75,500

Iran






Suap*ad*d
240
0.203
74
0.015
42

Solid*






Oil 8 Gran*
237
0.201
4
0.00083
11

pa, Ooita
1.0
-
1.3-3.0
-
<1
23
Chi or of oca
*

0.101
0.000021
•
114
Aatiaony
m.
m.
0.187
0.000039
HA
IIS
Ananic
0.05
0.000042
0.025
—s
0.40
118
Cateiw
0.02
0.000017
¦D
ID
0.31
119
Oraia
0.84
0.00071
1.50
0.000031
18
120
Cofp*r
0.67
0.00057
2.42
0.00050
28
122
L**d
0.43
0.00036
¦D
K>
*
124
¦ickal
0.48
0.00041
2.50
0.00052
13
126
Silver
0.03
0.000025
n>
ID
0.31
128
Xiae
l.S
0.0013
2.50
0.00052
4.2
(1)>	CaUal rimm k coraatrttM
¦D I	lot datcctad
RA t	lot
¦a«i	latdori is laa¦ that 0.000010 lba/10001kw
*	I	Coacatritia 1* 1*m than 0.010 ag/1
~	t	C«oaot b* ml«it«d
** i	pint r*f*r*nc* cod* not uaifMl,
049
05281
*
81.7
lWlMOlhi
^7T
100
0384 A
k
4.65
"TGTTWBIK"
~ML
iu/lfl001b«-
15.8
18000 0.349
56723
7.50
0.014
316
0.00613
445
0.0631
0.0038
5
0.000097
35.9
0.0259
-
<1.0
-
<1-5.0
-
«•!
0.011
"*S
0.028

m
4.2
0.000082
2.19
0.00006)
0.00014
m.
¦A
0.158
0.000061
0.00011
0.28
¦ec
0.178
0.000030
0.0061
8.7
0.00017
13.2
0.00202
0.0096
11
0.00021
12.8
0.0025
"«
2.1
0.000041
310.5
0.234
0.0044
13
0.00025
10.2
0.0015
0.00011
0.39
He*
0.21
0.000032
0.0014
4.6
0.000089
14.8
0.00158
-------
TABU VII-U
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID FICKLIHC - CONTINUOUS PROCESS
GROSS RAH FUME HOOD SOtUBBLER WASTEWATERS - CONCENTRATIONS AMD LOADS
Ran Wastewater










Plant Code

M

M

0396D

0584F

0528B
Reference Code

W-2

Y-2

093

095

099
Saspling Points

6

4

J

GA

F
Flow
(gal/ton)

45.5

39.7

31.1
0.386

6.1


mgj 1
lbs/lOOOlbs
¦8/1
lbs/lOOOlbs
¦g/1
lbs/10001 bs
¦8/1
lbs/10001bs
¦8/1
lbs/10001bs

Dissolved
23.9
0.0045
3.8
0.00063
880
3.55
733
0.00118
45
0.00115

Iron











Suspended
3.0
0.00055
6.7
0.00111
2132
8.61
21
0.000034
22
0.00056

Solids











Oil 1 Creese
5.3
0.0010
2
0.00033
330
1.33
46
0.000074
14
0.00036

pH, Units
2.8-3.7
-
1.8-1.
9
1.6
-
1.2
-
<1
-
23
Chi or of on
HA
NA
NA
NA
*
0.000040
0.369
Reg
*
Neg
114
Antimony
NA
NA
NA
NA
NA
NA
0.117
Heg
NA
NA
115
Arsenic
HA
NA
NA
NA
*
0.000040:
0.047
Neg
0.08
Neg
118
Cedkiia
NA
NA
MA
NA
*
0.000040
0.20
Meg
*
Heg
119
Chrflaiia
NA
NA
NA
NA
0.29
0.00117
0.35
Neg
0.09
Keg
120
Copper
NA
NA
NA
NA
0. 76
0.0031
0.503
Neg
0.10
Heg
122
Lead
NA
NA
NA
NA
0.35
0.0014
0.60
Neg
0.10
Heg
124
Nickel
NA
NA
NA
NA
0.20
0.00081
0.50
Heg
0.08
Heg
126
Silver
NA
NA
NA
NA
*
0.000040
0.25
Neg
0.02
Neg
128
Zinc
NA
NA
NA
NA
1.7
0.0069
0.35
Heg
0.11
Heg
-------
TABLE VII-11
SUMIARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAH FUME HOOD SCRUBBER WASTEWATERS - CONCENTRATIONS AND LOADS
PAGE 2
Raw Wastewater
Plant Code
Reference Code
Sampling Points
Flow (gal/ton):
ag/ 1
0384 A
100
J
3.37
lbs/lOOOlbs
mg/ 1
Average
21.0 	
lbs/1000lbs
to
¦JD

Dissolved
3210
0 . 0452
816
0. 600

I ron





Suspended
29
0. 00041
369
1.44

Solids





Oil & Grease
3
0.000042
66
0. 222

pH, Units
1.0-1.2
-
<1-3. 7
-
23
Chioroform
~
Neg
0. 100
0.000010
114
Antimony
0. 6
Neg
0.359
Neg
115
Arsenic
NA
NA
0.046
0.000020
118
Cadmium
0. 015
Neg
0.059
0.00010
119
Chromium
0. 72
0.000010
0.36
0.00030
120
Copper
1.7
0.000024
0. 77
0.00078
122
Lead
0.08
Neg
0.28
0.00035
124
Nickel
1.4
0.000020
0.55
0.00021
126
Silver
0.20
Neg
0. 12
0.000010
128
Zinc
0.45
Neg
0.65
0. 001 7
+ :	Value determined by subtracting other contributing streams yielded a negative value.
NA :	Not analyzed.
* :	Concentration is less than 0.010 mg/1.
Neg:	Wasteload is less than 0.000010 lbs/lOOOlbs.
** :	Plant has no assigned reference number.
-------
TABLE VII-12
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAW ABSORBER VENT SCRUBBER WASTEWATERS - CPU CERT RATIOKS AND LOADS
fo
id
NJ
Raw Wastewater










Plant Code

W-2

X-2

Y-2( 1)

Y-2( 2)

095
Reference No.

**

0060B

**

**

0584 F
Saapling Points

2

2

1

2

C
Flow
(gal/ton)

98.6

220

288

336

69


¦g/l
lbs/lOOOlbs
ng/ 1
lbs/lOOOlbs
®g/l
lbs/lOOOlbs
mg/ 1
lbs/lOOOlbs
®g / 1
lbs/10001bs

Dissolved
15
0.0062
63.5
0.072
+
+
0.41
0.00058
3670
1.06

Iron











Suspended
129
0.053
70
0.079
85
0.102
1.5
0.0021
194
0.0559

Solids











Oil & Grease
2.2
0.0009
+
+
~
+
•f
+
3
0.00086

pH, Units
3.7-7.6
-
6.9-7.1
-
7.0-7.1
-
1.7
-
1.7-2.1
-
23
Chi orof on
NA
NA
NA
NA
NA
NA
NA
NA
0.026
Neg
114
Antimony
KA
NA
NA
NA
NA
NA
NA
NA
0.22
0.000063
US
Arsenic
NA
NA
NA
NA
NA
NA
NA
NA
0.025
Neg
118
Cadaiut
NA
NA
NA
NA
NA
NA
NA
NA
0.02
Neg
119
Chroaita
NA
NA
NA
NA
NA
NA
NA
NA
0.58
0.000167
120
Copper
NA
NA
NA
NA
NA
NA
NA
NA
1.503
0.000423
122
Lead
NA
HA
NA
NA
NA
NA
NA
NA
0.60
0.00017
124
Nickel
NA
NA
NA
NA
NA
NA
NA
NA
0.790
0.00023
126
Silver
NA
NA
NA
NA
NA
NA
NA
NA
0.25
0.000072
128
Zinc
NA
NA
NA
NA
NA
NA
NA
NA
1.277
0.000368
-------
TABLE V11-12
SUMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HYDROCHLORIC ACID PICKLING - CONTINUOUS PROCESS
GROSS RAH ABSORBER VENT SCRUBBER WASTEWATERS
PAGE 2
Raw Wastewater
Plant Code
Reference No.
Sampling Points
Flow (gal/ton)
099
0582B
F+E
176
Average
465
N>
ID
W


mg/1
lbs/lOOOlbs
mg/1
lbs/lMdlbs

Dissolved
150
0.11
650
0.207

Iron





Suspended
67
0.0492
91
0.0566

Solids





Oil & Grease
7
0.0051
2
0.0011

pH, Units
<1.0-2.3
-
<1.0-7.6
-
23
Chloroform
*
Neg
0.018
Neg
114
Antimony
NA
NA
0.22
0.000063
115
Arsenic
*
Neg
0.018
Neg
118
Cadmiua
*
Neg
0.015
Neg
119
Chromium
0.98
0.00072
0.78
0.00043
120
Copper
0.436
0.00032
0.97
0.00037
122
Lead
0.10
0.000073
0.35
0.00012
124
Nickel
0.64
0.00047
0.72
0.00034
126
Silver
*
Neg
0.13
0.000036
128
Zinc
0.73
0.00054
1.00
0.00044
(1):	Acid regeneration unit with cyclone.
(2):	Acid regeneration unit with electrostatic precipator.
Neg:	Wasteload is less than 0.000010 lbs/1000 lbs.
NA :	Not analyzed.
* :	Concentration is less than 0.010 mg/1.
+ :	Value obtained by substracting other contributing streams yielded a negative value.
** :	Plant has no assigned reference number
-------
TABLE VII-13
SUMMAM OF ANALYTICAL DATA FROM SAMPLED PLANTS
COMBINATION ACID PICKLING - BATCH PROCESS
GROSS RAW AMD EFFLUENT WASTEWATERS - CCMCEOTRATIOHS AND LOADS
Raw Wastewater
Reference No.

0748

0424

0836H

0440A
Plant Cod*

U

C

F

L
Sample Point

1

2

1

10
Plow (gal/too)

677

91

279

140
Parameter*
¦gA
lbe/1000 lbs
Bg/1
lbs/1000 lba
all
1be/1000 lbs

lbs/1000 lbs
Suspended
4
0.0113
106
0.0402
8
0.0093
179
0.105
Solida








Oil and Create
3
0.0085
5
0.0019
0.7
0.0008
1.9
0.0011
Fluoride
soo
1.41
1,725
0.655
174
0.203
1.4
0.00082
Diaaolved Iron
1,080
3.05
216
0.082
61
0.07
135
0.0788
pH, Uniti
1.9
-
0.4-0.
8 -
2.6-2.
,9 -
2.8-3
.8 -
US Arsenic
NA
NA
NA
HA
NA
NA
NA
NA
119 Chroaim
132
0.429
137
0.032
13.4
0.0156
24.4
0.0142
120 Copper
1.38
0.0038
9.3
0.0036
0.06
0.000070
0.8
0.0005
122 Lead
*
Nag
NA
NA
*
Nag
*
Nag
124 Nickel
70
0.198
241
0.0915
9.4
0.0109
12.5
0.0073
128 Zinc
5.6
0.0158
0.87
0.003
0.07
0.000081
0.08
0.000047
Effluent








Plane Code

0

C

r(l>

L
Reference No.

-

0424

0856H

0440A
Sasple Point•

4

4

4

1
stream! Treated
Kins**
i Concentrates

linees
Kinses 6 Fuae Hood Scrub.

Xinaea
Treatment Tech.

KL, SL

(, NL, PSP

1,NL, SL

NW
Flew (gal/ton)

677

91

279

140
Par Meters
¦g/i
' TGs/IMO lbs
ail
lbs/1000 lb*
a/1
lba/1000 lba

lbt/1000 lb*
Suspended
12
0.0339
31
0.0118
430
0.50
119
0.0695
Solida








Oil and Graaae
1.0
0.0028
0.3
0.0001
1.6
0.0019
3.0
0.00175
Fluoride
12
0.0339
133
0.0303
68.7
0.0799
1.4
0.000817
Dissolved Iron
0.02
0.000037
8.3
0.0032
41.1
0.0478
0.1
0.000058
pH, Units
10.4
-
3.0
-
3.8
-
5.8
-
113 Arsenic
NA
NA
NA
HA
NA
NA
NA
NA
119 Chroaiua
0.04
0.0001
1.3
0.0003
7.3
0.0085
0.61
0.000356
120 Copper
0.03
0.00008)
0.0«
0.000030
0.07
0.000081
0.01
0.0000058
122 Lead
NA
NA
NA
HA
NA
NA
NA
NA
124 Nickel
0.02
0.000037
2.3
0.0093
6.7
0.0078
0.16
0.000356
128 Zinc
0.03
0.000085
0.033
0.000013
0.14
0.0016
0.01
Nag
294
-------
TABLE VII-13
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PUNTS
COMBINATION ACID PICKLING - BATCH PROCESS
GROSS WASTEWATER - CONCENTRATIONS AND LOADS
PACE 2
Raw Haacevater
Reference No.

0088A

0088D

0884 E


Plant Code

123

124

125


Sample Point

D

B

C

Average
Fltw (gal/ton)

310

1176

650

475
Parameters
mg/ 1
lba/1000 lba
tag) 1
lba/1000 lba

lba/1000 lba
mg/ 1
lba/1000 lba
Suspended
36
0.0459
2
0.0098
3
0.0081
48.3
0.0319
Solid!








Oil and Graaae
5
0.00646
11
0.054
6
0.0163
4.6
0.0124
Fluoride
NA
NA
25
0.12
32
0.141
428
0.439
Diaaolved Iron
46
0. 0595
10
0.049
5
0.0136
222
0.486
pH, Units
2.6-2.7
-
2.7
-
3.5-3.
.6 -
1.9-3.
6 -
11S Araenic
0.01
0.000013
0.01
0.000049
0.01
0.000027


119 Chromitan
3.21
0.0042
6.2
0.0304
1.1
0.00298
48.1
0.078
120 Copper
0.26
0.000336
0.02
0.000098
0.08
0.000230
1.28
0.0011
122 Lead
0.10
0.000129
0.05
0.000245
0.05
0.000135
0.067
0.00017
124 Nickel
7.6
0.0099
27
0.132
0.56
0.00153
52.5
0.064
128 Zinc
0.08
0.000110
0.05
0.000245
0.02
0.000054
0.97
0.0024
Effluent
Plane Code
Reference No.
Sample Point a
Streama TreaCed
Treatment Tech.
Flow (gal/too)
123
0088A
(D/F+OH)xI
Rinaea 4 Concentrates
E| M«| FLPtCL
310
124
0088D
C
Rinaea
E,NC,FtsP
1176
125
0884 E
(C/C+F»D)*E
Rinaea i Fuse Rood
Scrubbera & Concen.
E, NL, FLP, PSP
650
Par meters
¦g/1
lba/1000 lba
mg/ 1
lba/1000 lba
¦J/J.
lba/1000 lba'
Suapended
28.5
0.00646
65
0.314
527
0.694
Solida






Oil and Creaae
8.50
0.00
5
0.0245
24
0.0434
Fluoride
NA
NA
10
0.0490
94.J
0.260
Diaaolved Iron
0.445
0.00129
ND
KD
0.04
0.00
pH, Units
7.9
-
11.9
-
11.9
-
115 Araenic
*
0.00
*
0.000049
*
0.000027
119 Chromiim
0.355
Neg
1.9
0.00932
10.6
0.0352
120 Copper
0.030
0.000026
0.03
0.000147
0.185
0.000542
122 Lead
0.100
+
0.050
0.000245
0.125
+
124 Nickel
0.325
0.000776
8
0.0392
6.79
0.0217
128 Zinc
0.115
Neg
0.495
0.00243
0.140
~
295
-------
TABU VXI-13
8CMUKY OF ANALYTICAL DATA FROM SAMPLED PLANTS
COMBINATION ACID PICKLING - BATCH PROCESS
RINSE WASTEWATER - CONCENTRATIONS AND LOADS
PAGE 3
FOOTNOTES
(1) Sample taken prior Co final tattling.
NA : Not analyzed.
ND : Not datectad.
Neg: Waateload is leaa than 0.000010 lba/1000 lbe
+ : Unable to calculate.
* : Concentration ia leaa Chan 0.010 Bg/1.
Treatment Tech. Code
E	Equalization
FDSP: Deep bed eand preaaure filtration
FLT : Flocculation with polyner
NC t	Neutralisation with cauatic
NL I	Neutraliiation with live
MW I	Neutrelixation with waste*
FSF s	Friaarjr scale pit
SC I	Sedimentation via clarifier
SL <	Sediaeat ation via lagoon
296
-------
TABLE VII-14
Saw Waat.load
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PUNTS
COMBINATION ACID PICKLING - CONTINUOUS PROCESS
GROSS RAW AMD EFFLUENT WASTEWATERS - CONCENTRATIONS AND LOADS
Plant Co
-------
TABLE VII-14
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
COMBINATION ACID PICKLING - CONTINUOUS PROCESS
RINSE WASTEWATER - CONCENTRATIONS AND LOADS
PACE 2	___ 	
Raw Wastewater
Flint Code

121



Reference No.

0900



Sanple Point*

B


Average
Flow (gal/ton)

2754



Pnaetert
mg/1

lbs/1000 lbs
mg/1
lbs/1000 lbs
Dissolved Iron
148

1.70
152.9
0. 968
Suspended Solids
14.3

0.164
180.8
1.26
Oil and Grease
6.3

0.0724
8.3
0.055
Fluoride
180

2.07
69.2
0.647
pH, Unit.
2.4-2.7

-
2.4-8.0
-
4 Benzene
0.049

0.00567
0.049
0.000567
119 Chromium
33.4

0. 383
24.9
0.264
120 Copper
0.59

0.00678
0.27
0.0027
124 Nickel
20

0.230
14.9
0.104
128 Zinc
0. 33

0.0038
0.39
0.0033
Effluent*
Plant Code
Reference No.
Sample Point*
Systens Treated
Treatment Technology
Flow (gal/ton)
Par am et era	
Dissolved Iron
Suspended Solids
Oil and Grease
Fluoride
pH, Units
4 Benzene
119	Copper
120	Chromium
124 Nickel
126 Zinc
121
0900
4
Rinses, FHS and Concentrates
E, CLyCR
1338
¦K/*
	-lbsTTOBff lb.
0.26
0.00145
8
0.0446
4.3
0.0247
9.5
0.0544
7.9
NA
0.033
0.000186
0.074
0.000413
0. 90
0.00503
0.37
0.00205
0.07
0.000391
NA: Not analysed.
NDi Not detected.
Treatment Tech* Code
CR : Chemical reduction
E : Equalisation
FLP: Flocculation with polymer
NL : Neutalisation with liae
CL : Sedimentation via clarifier
SL :	Sedimentation via lagoons
T : Sedimentation via thickener
298
-------
K)
VO

C
BAR MILL
PICKLING
0.19 Itoc
(3 gpm)
PLATE MILL
PICKLING
EQUALIZ-
ATION
TANK
—
0.378 l/»ec
(6 gpm)
0.19 l/*ec
(3 gpm)
W. P. L.
HOLDING TANK
-v Z&H2S04
J A
hno3-hf
oo
rfoi
A
SAMPLING POINTS
DISPOSAL BY PRIVATE
CONTRACTOR
PROCESS: COMBINATION ACIO PICKLING -
BATCH
PLANT: C
PROOUCTION: plate: 79.4 METRIC TONS/TURN
87.5 TONS/TURN
BAR: 6.6 METRIC TONS/TURN
7.3 TONS/TURN
LIME
SLURRY
TANK
MIXING
TANK
SEDIMENTATION
TANK
0.378 1/sftC
(6 gpm)
SLUDGE
REMOVAL
DISCHARGE
COAGULANT
AIDS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING - BATCH
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn. 4/9T9
FIGURE 1ZII-
-------
PICKLING
LINES
PROCESS
WATER
WASTE PICKLING
LldUOR TANKS
PROCESS: COMBINATION ACID PICKLING -
CONTINUOUS
PLANT: 0
PRODUCTION:
A__
42 30 l/sec
(1016 gal/ton)
DISCHARGE
TO RIVER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING'CONTINUOUS
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 4/9/79
FIGURE 3ZH-2
-------
PROCESS'
COMBINATION ACID PICKLING
BATCH
PLANT:
PRODUCTION: 43.5 METRIC TONS STEEL/TURN
(48 TONS STEEL/TURN)
FEED
(9.3 gpm)
PLATE MILL
PICKLING
SCALE
LI ME
NEUTRALIZATION
EQUALIZATION
.0.6 l/sac
(8.6 gpm)
NITRIC-HYDROFLUORIC
ACID WASTE PICKLE
LIQUOR
SULFURIC
ACID
WASTE
PICKLE
LIQUOR
SETTLING
BASIN
oo o=^
HAULED TO COMPANY
DISPOSAL SITE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING - BATCH
WASTEWATER TREATMENT SYSTEM
	WATER FLOW DIAGRAM
Dwn. 4/9/79
-------
INDUSTRIAL
SUPPLY WATER
PROCESS: PICKLING-H2S04-CONTINUOUS STRIP
CONCENTRATES 6. RINSES
PLANT:h-2
PRODUCTION^
625 METRIC TONS/TURN
(689 TONS/TURN)
-10.4 l/sec
1165 gpm)
FRESH
ACID
PRODUCTION FLOW


k k A 
-------
process: combination acid pickling-
CONTINUOUS
PLANT: I
PRODUCTION: 257.3 METRIC TONS STEEL/TURN
1283 TONS STEEL/TURN)
OTHER
PROCESS RINSES
31 gpm
PICKLING RINSES
1070 gpm
SPENT
PICKLING
LIQUOR
69.4 I/sec
(1100 gpm)
FEED PUMP
2.5 gpm
TRANSFER
PUMP
HOLDING
TANK
BATCH
NEUTRALIZATION
TANKS
(2)
DISCHARGE
TO RIVER
SETTLING LAGOONS 12)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICK LING - CONTINUOUS
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
LIME
SLURRY
STORAGE
CONTINUOUS
STRIP
PICKLING
PROCESS
-------
w
o
it.
MILL SERVICE
WATER
A
— 353 l/SEC
(5600 6PM)
*4 PICKLE LINE -
3.97 l/SEC
(63 6PM)
FRESH t^S04
-337 l/SEC
IU5347 6PM)
SCALE
PICKLE
TANKS
(*4 a
PR0CESS: hot forming-section
PICKLING H2S04-HCL
HOT COATING GALVANIZING
PLANT1 l"2
PR0DUCTI0N;464 METRIC TONS(5l2 T0N3/TURN ROD
278 METRIC TONS(306T0NS)/TURN
H2S04 PICKLING
22 METRIC TONS (24 TONS)/TURN
HCL PICKLING S GALVANIZING
¦5 PICKLE LINE
9.84 l/SEC
(136 GPM)
FUME HOOD
I NO SCRUBBING)
P. 9
SPRAY
RINSE
OEEP
RINSE
337 l/SEC,
(5347 6PM)
SPENT ACID
TO CONTRACTED
DISPOSAL
WATER SPRAYS
l/SEC
GPM)
HCL

RUNNING

HOT

HOT
PICKLE

RINSE

STANDING

DIP
TANK



RINSE

GALV.
13.8 l/SEC
(219 GPM)
0.7 t/SEC
'(II GPM)
TERMINAL SETTLING LAGOON
46,2000,000 I
(12,200,000 GAL.)
¦~ 350 l/SEC (5556 GPM)
TO RECEIVING STREAM
/V SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINED WRE, ROO, PICKLING 8 WERE GALVANIZING LINES
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DWG.6-24-''dfte#.2 2S&76
RDM 110
1
FIGURE 3ZE-6
-------
PROCESS: COMBINATION ACID PICKLING'BATCH
PLANT:
PRODUCTION: 39.1 METRIC TONS STEEL/TURN
(43.1 TONS STEEL/TURN)
1.56 IA«C
(25 gpm)
WASTE PICKLING
SOLUTION TO LIME
NEUTRALIZATION
PLANT
26.8 l/tec
(423 gpm)
i
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING-BATCH
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
SAMPLING POINTS
Dwn. 4/9/79
BAR MILL
BATCH
PICKLING
SANITARY
WASTEWATER
OTHER PROCESS
WASTEWATER
MUNICIPAL
SEWAGE
PLANT
-------
		 i/sec
C (763 gpm)
48.1 l/sec.
(763 gpm)
OO CH
OTHER PROCESS
WASTEWATER
EQUALIZATION
AND
AERATION
CONTINUOUS
STRIP
PICKLING
WASTE PICKLING
LIQUOR
PROCESS"- COMBINATION ACID PICKLIN6-
CONTINUOUS
PLANT'- 0
PRODUCTION: 40.5 METRIC TONS STEEL/TURN
(44.6 TONS STEEL/TURN)
COAGULANT
AID
OTHER PROCESS
WASTEWATER
SODIUM
HYDROXIDE
NEUTRALIZATION
c
DUAL
RECTANGULAR

'J
CLARIFIER
a.

^-2.2 l/sec
c (35 gpm )
,11.8 l/sec
< ' (IB7 gpm)
74.9 l/sec
(1187 gpm)
1

TO RIVER




A SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING'CONTINUOUS
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
3wn. 4/9/79


FlfilJRF "VTT-fl



-------
h2o vapor
CRYSTALLIZED
TANK
20«C I
FRESH H,SO. ACID
PICKLE TANK
TO* C 060* F)
18% ACID
18,900 LITERS
(SlOOO GALLONS)
SEPARATOR
TANK
FERROUS
SULFATE
HEPTAHYDRATE
CRYSTALS
RECOVERY
ACID
13%
PROCESS: PICKLING H2SO4-BATCH-CONCENTRATED
a RINSE; PK3KLIN6-SULFURIC ACID
RECOVERY
plant: 0-2
PRODUCTION: 60 METRIC TONS STEEL/TURN
(67 TONS STEEL/TURN)
CITY WATER
LIME
DIP
SPRAY
RINSE
STANDING
RINSE

ENVIRONMENTAL PROTECTION AGENCY

STEEL INOUSTRY STUDY
SULFURIC ACID PICKLING AND ACID
RECOVERY OPERATION
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM

Own.6/5/75 |Rev. 2/26/76
FIGURE 3ZH-9

Re*6/20'76l 1
-------
PROCESS: PICKLING H^O^-BATCH-CONCENTRATEE
a RINSE,PICKLING SULFURIC ACID
RECOVERY
plant: P-2
production: 43 METRIC tons of steel/turn
(47 TONS OF STEEL/TURN)
recovery and
FRESH ACID	VSfy.
batch charge
(SEE FIS. an-II)
SULFURIC
ACID PICKLE
TANK
processing sequence:
(T) product to rinse
(4) TO ROD DRAWING
(?) PRODUCT TO DRAINAGE
(2) PRODUCT TO LIME COAT
WATER
HOSE
		fc-.
1, r
	»-
RINSE

AND

DRAINAGE

TANK
MILK OF LIME
TANK
/\0.I6 l/SEC
(2.5 GPM)
BATCH DUMP
208,200 l/MO.
(55,000 GAL/MOJ
SPENT
PICKLE
LIQUOR
STORAGE
-A-
TO SEWER
TO REGENERATION
PLANT (SEE FIG. 3EI-II)
A
SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
BATCH H2S04 PICKLING AND ACID RECOVERY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
|Pwn.7/l6/lgg
FIGURE 3ZII-I0
-------
u>
o
vo
COOLING
WATBQ
-&r
5AICLZLE:«	
TANi^e>
{see R&. szn-io
P&COVEgErD
ACID
COOLINS WAT&E
TO &E-VVEQ
A-
5AHPU M6 POI NT^
ENVIRONMENTAL PROTECTION AGE A/CV
STEEL INOUSTffV STUDY
SU l—F-U R I C ACID R&COVERY
W^TEWAT&R. TCtATMEiNT SYST&M
VVATC-K PLOW DIA&RAM
UV(. I fr.-7'j
Rl-V.l VH Hr
Pl V'/ 'L U- Tte
Pi&uRE 2E-II
-------
PROCESS' PlCKLIMG. SO A - BM"CLW
C0K1CEKSTR/WE.S £ RIWSES;
PICkLIKJG SULFURIC ACID
RECOVERY
PLAUT ' Q-?_
PKODUtTlOW : 36 METRIC TOU&/TUC,\i
(40 TOM s/TURN)
ACID M 1ST
,-SPEUT PIC.K.LE LIQUOR
COOL TO IO*~ C (^50°F^
ACID RETURN
UUE.
CRYSTALL'.ZER
MAK.6.-UP WATER
(CITY WATEf*-)
PURCHASED
FRESH AC.IO
ACIDIFIED RlWSE.
WATER	,
AVG, FLOW
0.03S X/SEC.
(O.SCi &PM1)
COLLECTOR
AIR
///////,' /
PUSH/PULL
" ~ ~ FUMt CONTROL
HEAT TO GS.5°C
(l500F)
Alft AaiTATIOto
W
PICK.LIKJCj takji^
RE-COVERED
5ULFUR\C ACID
FHP,RO'JS SULFATE
HE.PTAHY PRATE. /
CAPACITY: ZCmSOO jC
(T.060GAL.)
SPRAY WH5£t
DIP TANK.
RECOVERED ACtO
A SNMPLIWO POIMTS
EUVIB.ONMEMTNL PtaoTI^CTlQ>J ft6£KlLY
Steel ihpustrv stu&v
SULFURIC ACID ptCK-LWIG ^RE-COVG-RV
BATCH OP6RAT IOK)
W#V6TEWATEB. TREATMF.NT SYSTEM
WATER FLOW DIAGRAM
owe. t-<-75
R.EV.2 Hi-fi

figure m-i
Vt0-7<


-------
PROCESS: BATCH PICKLING (SULFURIC ACID)
PLANT: R
PRODUCTION:301 METRIC TONS STEEL/TURN
(332 TONS STEEL/TURN)
RIVER A
WATER
SLUDGE LAGOON
/{^SUPERNATE
A SAMPLING POINTS

ENVIRONMENTAL PROTECTION AGENCY

STEEL INDUSTRY STUDY
SULFURIC ACID BATCH PICKLING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM

Own. 3/28/79


FIGURE 331-13




WASTE
PICKLE
LIQUOR
BATCH
PICKLING
¦1.3 l/sec.
(21 gpm)
LIME
NEUTRALIZATION

-------
ACID Rl NSE. WATE.R
O.SS &/SEC.. 04-GPM)
ALKALI ME RIKJSE WATER
OA2. -£/SE0.£G,.G> GPM)
SPE.MT PIC.K.LE. LIQUOR.
0^4 JL! SE.C. C3.& GPM)
-A:—¦
SPEtsIT ALK.A.HKJE CLEAKJERS
IKIT6RMITTEWT FLOW
O.OZ^/SEC.fO.SGPM)
¦A-—*
PROCESS- PICKLIWG HjSO^.-BATCH
CONCENTRATES K Rll-JSES
PLAMT : P.- Z.
PRODUCTION: 300 METRIC TOWS OF STEEL/
TUjeA/(33l TONS OF STEEL/
	TU&N)	
EQUAL.IXATIOM TAKJK.
ACETYLENE SLUDGE
STORAGE
I.Gl/SEC
(25 4PM)
(a) SETTLIKJG
LAGOONS
f
I.G,i»/SEC.
(tESPM)
TO RECEIVING STREAM
Ml V ING TAK1VC
^/N^SAMPLIKJG POIWTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY .
H^SO* PICK.LIWG LIKJE
WASTEWATER TRE AT ME, KIT SYSTEM
WATER PLOW DIAGRAM
DWG 6-C.-7S
Rtv t iv>m
FIGURE 3ZH-I4
-------
PROCESS: PICKLING-H2504-BATCH RINjSE
PLANT t 5-2
PRODUCTION: 77 METRIC TONS OF STEEI/TJCM
(as tonsofsteel/t^aO
Z.-Zizl SEC
(35GPM)
MAKE-UP WATER
tr DlCHROMATE SPlLL/VGE
^ FROM HOT DIP
BATCH
MAKE-UP
ADDITIONS
HzSQ4
batch
pch
TREATMENT
PRE-HOTDIP
GALVANIZING
STANDING
RUNNING
RINSE
RlMSfc
PlCKLE
TANK
SUMP
PUMP

2/ZlijSEC
(356PM)
ACID PROOF BRICK
ALLTANKS
CONTRACT DISPOSAL.
LIME
STORAGE
MfXER
LAGOON
SLUDGE TO
ENVIRONMENTAL PROTECTION AGENCY
CONTRACT DISPOSAL
(WEEKLY)
STEEL INDUSTRY STUDY
batch HzSOij pickling,
wastewater treatment system
WATER FLrVv DIAGRAM
A = SAMPLING POINTS
k» /? i yt if
figure xn-15
t Jt If
-------
PROCESS : PIOO.IN6K, SO4 CONTINUOUS-
CONCENTRATED AND RINSES
PICKUNG-5ULPUQIC ACID PtCOVERY
TO ATMOSPWEQEr
PLANT:
O. 2a.iL/5EC. M?P VAPQg-
C 4.5 &PM W2O VAPOa)
ITMO'aPH&R
PPODUCTIOn- "/ METBlC 'QMS c3P
6T&E-L- /TUZN
HOP TON'S? OP eTE:fc"L_/
TUEN )
KJOoi
(&OOOGAL.)
=P»CKLIN& TAN Id.
RIN&E TANK.
TAMK
COMPENSATE- BIN5E WAT Eg
o/2a£/s&c. ( spm-mot)
SPENT P1CU.L& LIPUOC
Q.2&1/SEC. (4.5 6 PM)
METEBeD PLOW
RlNSt
/2\ CITY WAT&CZ.
(USED TO &&N£Q A.TE.
TAKlId
Q£.covee£.o acid
STOQA&& TAN IC
STEAM
CONOE.NS&T&
2e>£/S6C
PROM
CON OH ION I NIG
~ NIT
TAN 16
2-2 TOO X.
CA S 6PM MOT)
(&OOOSAL.)
NEW AC I O
TAMI^.
NON -CONTACT
COOLiM T TO
ENVIRONMENTAL PROTECTION AGENCY
^ TO CBVaTALLl^&g. TAN U. OF ACID BECOVEPY LI Ml
ACID COMC. iS-^O^ BY
STEEl INDUSTRY STUDY
CONTINUOUS STRIP* PI C KL.I W6
WASTE: rt&TErR TREATMENT SYSTEM
WAT£R P-LOW QI6&0AM
ErVAPORATI V
COKiC&KjTCATlOM
A=samplins points
W6.3/6-74.
m.i m-x
FIOUftB Sir 16
IfiY, I 2 201k
-------
OJ
H*
Ln
PROCESS". COMBINATION ACID PICKLING BATCH
PLANT:	U
PRODUCTION: 10.4 METRIC TONS STEEL/TURN
(11.5 TONS STEEL/TURN)
EMERGENCY RECIRCULATION
LIME
L ME
LIME
(AS NEEDED
(AS NEEDED)
(MANUALLY)
rt?
PICKLING
PROCESS
(PIPE AND
TUBE)
DISCHARGE
TO CREEK
BATCH DUMPED
PICKLING
RINSES
BATCH NEUTRALIZATION SYSTEM
LIME
DEGREASER
RINSE
WATER
SPENT PICKLE
LIQUOR
MIXING
PUMP
SOLIDS TO LANDFILL
NEUTRALIZATION
TANK
ENVIRONMENTAL PROTECTION AGENCY
VACUUM DRUM
FILTER
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING - BATCH
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
STEAM
F
Dwn. 4/5/79
IGURE 3ZTE-I7
EVAPORATION TANK
-------
WIRE PICKLE OPERATION
CITY WATER
process: pickling-hcl-batch
CONCENTRATED a RINSE
PLANT: U-2
PRODUCTION: 9 METRIC TONS OF STEEL/TURN
(10 TONS OF STEEL/TURN)
757 l/DAY
1200 GAL./DAY)

z
z








o
UJ 9
UJ


c*>
©
UJ
©

*-
t- *-
1-
©
z

z
Z

uj
Z>
<5 <
<
UJ
J
v>
CO
<
UJ
a:
©
UJ
o
<

I
I
JL
SODIUM CARBONATE
NEUTRALIZATION
BATCH
TREATMENT TANK
SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HCI PICKLING LINE
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
pwn. 6/6/75 Rev. 2* 2/26/7S
Rw. 1-2/21
FIGURE 3ZXT-18
-------
process: pickling hci-batch
CONCENTRATED 8 RINSE
PLANT:	V-2
PRODUCTION: 72 METRIC TONS OF STEEL/TURN
I79 TONS OF STEEL/TURN)
FIXED
SPRAYS
ACCUMULATOR
1.64 l/SEC,
(26 6PM)
CITY WATER
ACCUMULATOR
HOSE
HOSE
EAST
BATCH PICKLE
CAR 3
RINSE
DRAIN
AREA
LIME B BORAX



SPARE
LIME
LIME
BORAX


BIN
CONTRACT OISPOSAL
OFF-SITE
0.82 l/SEC
(13 6PM)
FIXED SPRAYS
CENTRAL
BATCH PICKLE]
CAR 2
(NOT IN USE)
RINSE
WEST
BATCH PICKLE
CAR 4
NaOH
STORAGE
0.82 l/SEC.
(13 GPM)
"X
0.82 l/SEC.
/ (13 GPM)
CONTRACT
OFF-SITE
DISPOSAL
METROPOLITANS*
SANITARY DISTRICT
4.73 l/SEC
(75 GPM)
	 OTHER FLOOR DRAINS
rNON CONTACT COOLING
FROM HOT COATING LINE
NEUTRALIZATION TANK
BATCH TREATMENT
A SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
Own. 6/6/75
STEEL INDUSTRY STUDY
HCI PICKLING LINE
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Rev. 2/27/76'
R«». 2/20/76
FIGURE 301-19
-------
process:
PICKLING-HCrCONCENTRATED AND
RINSE, PICKLING-HCI REGENERATION
TYPE: PYROLYTIC HCI REGENERATION
PLANT*. W-2
PRODUCTION: |,I48 METRIC TONS/TURN
(1,266 TONS/TURN)
HCI PICKLING AREA
FUMES
EXHAUST
37.9 l/SEC
1600 GPM)R|NSE water
	 MAKE-UP
(SERVICE WATER
SUPPLY)
PICKLED
STRIP STEEL
7.57 l/SEC.
(120 GPM) SCRUBBER
	 SPRAY WATER
PICKLE LINE FUME COLLECTION HOOD
STRIP
STEEL
RINSING
SECTION
PICKLING SECTION
(POTABLE SUPPLY)
FRESH
PICKLE
LIQUOR
STORAGE
ACID
MAKE-UP
WATER
RINSE
FUME
SCRUBBER
TO SEWER
EFFLUENT
37.9 l/SEC
(600 GPM)
SPENT
PICKLE
LIQUOR
STORAGE
FUME SCRUBBER
EFFLUENT
SPENT
PICKLE LIQUOR
SCRUBBER
SPRAY WATER
FRESH WATER MAKE-
UP TO VENTURI
(POTABLE SUPPLY)
HCI-HoO VAPORS
7.57 l/SEC
I (120 GPM)
(SERVICE WATER SUPPLY)
HCI-HaQ VAPOR
FRESH MAKE-UP
WATER TO ABSORBER
(POTABLE SUPPLY)
SCRUBBER
GASES
HCI-H-0 VAPORS
CARRYOVER
/k 16.4 l/SEC
^<260 GPM)
2.0 l/SEC
(31.5 GPM)
CYCLONE
DUST
COLLECTOR
ABSORBER
EXHAUST
SCRUBBER
HCI
ABSORBER
PYROLYTIC
REACTOR
HCrHgO
VAPORS
INLINE CAUSTIC
SOLUTION FEED
IRON OXIDE
DUST
AI6.4 l/SEC
(260 GPM)
NEUTRALIZED
SCRUBBER EFFLUENT
VENTURI \/
NATURAL GAS
AIR
PREHEATED
SPENT
PICKLE
LIQUOR
RON OXIDE PELLETS
REGENERATED
2.0 l/SEC.
(31.5 GPM)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
CONTINOUS HCI PICKLING AND RECOVERY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
A SAMPLING POINT
Dwn.6/6/75
JZH-20
FIGURE
R«v. 2/24/76
-------
LaJ
H
lO
PROCESS: COVC ROLUNG ¦ RE.C\RCULM\ON
HCU- CONTINUOUS CONCENTRATED
PlCKLINt,- VACL- fvOD RtiE-NtSKTvON
PLANT: X-Z
PRODUCTION:	(COLD RQL\.ED^

(P^CKLlNtS)
4GO NSETR.\CTON^ OF "STE-tL \TJ^r\
ISD1 TONS C>* mZl.\_jTU£V^
C\AR\F\EK5
H UNITS)
TO VA.CV)\)W
RE^ERVOtR
(lAUVIW EC ?,OPPlV)
F\CTE^-,tL<>.VJOCVU.
CITY
^\NS>E 3i.5(/ser
NC COOLING
¦=*.5 l/SE-C
C\5a 4PM)
WM CR
(50O&PN\)
U£KTINS VIEAtA
3.2 ft/SEC.
(bOSPM)
CONTINOOO&
HC>- PlCKUN
KMLLWMER
•>, SETTLED WfftK
TOERED VJME.R
T/VNDE^
COLD
NULL
PlCKUER
NON-CONTKCT
Cool\nG
5 rinse
WATERS
4&T S| "SEC
f^oo gpia)
S.hAP. UNfc
TO	V\\\-L
44.ZIISUS3
(loo 6PC'
C LAiRI F>ER
•5£TT\.CR
i5i" lac
AWoc,PtA)j
EFFUOtW
rbv - Q.LT£R
*OD
Rt&EHEW'.TVCiN
PL&.MT
VVAVTE 0\L
(f LOTMlON TANK)
\REtaV\ENT
Ofe3  points
«.v.t 1Z.S7G>
tSVOCk (o- <© 13
F\GOfcfc 3ZEE-2I
Rfcvt ?2oTfe
-------
process; pickling-hydrochloric
ACID REGENERATION
plant:
X - 2
production: 4I METRIC tons of HCt/TURN
(46 TONS OF HCl/TURN)
WASTE ACID (FROM 3 LINES)
1.56 l/SEC (25 GPM)
CYCLONE
WATER
VAPOR
STORAGE
TANKS
STORAGE
TANKS
STACK
ACID
COOLER
PACKING
EXHAUST
FANS
47.3 l/SEC'1
(750 GPM)
ACID WASTE
ROASTER
"''A'.
/,////////,

CRUSHER
PUMP
RECUPERATOR
FUME
SCRUBBER
~
Tor
OXIDE BIN
BLOWER
,2 47.3 l/SEC.
T'(750 GPM)
TO CLARIFIER
REGENERATED ACID
REGENERATED
ACID
A SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HCI REGENERATION
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
3wn.6/V74
RW. 2/28/76

FIGURE VE-ZZ
fl»v. 2/20/76


-------
PROCESS! PICKUN6-HCI-PINS&
TYPE: CONTINUOUS
PLANT-
PRODUCTION:	WETRICTONSOFSTEEL/>Z*W
(<£,OCc TONS OF STEEL/ TUEM)
SERVICE WATER
3.I//SEC
(SOQPM)
HEATED BAYWATEP
3.8 II SEC	1
(£0 GPMN,	f
DIRECTION OF STRIP TRAVEL
RINSE TANK
n«z rinse tank
KJ03 RINSE TANK
OVERFLOW
OVERFLOW
TO SEWER
¦TO BE DIVERTED TOHCl PLANT
AND USED IN ABSORBER TO
GENERATE ACID, ELIMINATING
RINSE WATER DISCHARGE FROM
K|S 3 PICKLE LINE
ENVIRONMENTAL PROTECTION AGENCY
A- SAMPLING, POINTS
STEEL INDUSTRY STUDY
HCI PICKLE LINE
"WASTEWATER TREATMEMT SYSTEM
WATER FLOW DIAGRAM
FIGURE 301-23
TOWER FUME
SCRUBBER
N«3
CONTINUOUS
PlCKLER
-------
OJ
to
to
PROCESS: HCI RELGCUE-RATIOkJ
TYPE. '• SPW./VV R.O\STEP.
PLO.MT ' Y* H.
PRODUCTION : /3<£/ METRIC TOKSS/TU£M
(ISOO TOVOS/T U£M)
(SERVES 3P>CK.unG OPERATIONS)
RE.GEKgttATE.tt
AciD
STORAGE TANK
PIC.VCLE-
LIQOOF^
S TO RAG E_ TAVUC
REGENERATED
A. dp
STORAGE TAHK.
P'C-*t-E.
LIQUO R
STORAGE TM^K.
< 1.3 21/SEC. FEED
(aiGPM)E-ACH *
3Z.-l/see feed
•	
BAOV.WASH WMER^
COKJCEKJTRATED RltJSE WATER
TO BE. UsE-OikJIOEW*. FUTURE
WATER
ACID
AC-ID
COOLER.
> »
CI CUOMt
WATER
ABSORRW
AtSORBte
PRECIPITATOR.
A - B
ROASTERS
(iDEkmCM-)
tlA/SEC.
Asogpm}
(I UNIT)
FUME.
FUME.
CLEANER.
{eOOGPM)
(2 UNITS)
OXIDE.
VlBRATIMG
HPPPEB
VI BRAT IMG
HoPPEia.
TANK. CAR
OXIDE. COMvE-tOR
Ox\OE. CONVE.YOR
EXHAUST FAWS
E.KHAUST FAMS
EWVIKOME.IOTAL PRQTEC.TIOW A,C,EtOC^
STEEL IkJCSUSTRY STUDY
WCL RE&EMER.ATIOM
WASTEWATER TR.H.AT NvE_>OT SYSTEM
WATER Flow DIAGRAM
«se ^/sec
I /i4oo GPM)
* INCLUDES NOM-CONiAC
WM£V)
' ' / IN'.
^SAMPClUG POIklTS
REV? ixi-n
DWG 5-1 ITU
FIGURE HH-24
REV. I Z-T-^U
-------
WATER
ACID (HCl)-
5TEEL STRIP-
K:
PICKLERS
7t
WASTE PICKLE7 i.
LIQUOR ^
TANK
lO.lllSEC.
\ (l&OSPM)
2.511 SEC ¦
(40GPM)
r*Kl9 17
AIR
g-*
/\-- SAMPLING POINTS
CLARIFIER
VACUUM
FILTER
SERVICE
WATER
PROCESS: PICKLING HCI CONTINUOUS
COVENTRATED 4 RINSE
PLANT: 2-Z
PRODUCTION! 453 TONS OF5TEEL/TU/Su)
MM/iVr a>
RINSETANKS
'^RINSES
tj-K 2/SEC
(I20GPM)
UPCOILER
POLYELECTROLVTE
- lO.tfi/SELC
(IfcOGPM)
TO
SANITARY
SEWER
ENVIRONMENTAL PROTECTION AGENCY
STEtL INDUSTRY STUDY
HCI PICKLING LINE
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DWa 75
REV-1 2-lc5
P£.v ? 1-71 K
FIGURE. EH- 25
-------
PROCESS: PICKLING-HCI CONTINUOUS
CONCENTRATED < PlNSE
PLANT: AA 2
PRODUCTION- Bit METRIC TONS OF STEEL/""!'.
( 1C.O TOWS OF STEEL/ TURn)
ZZH.OL
CfeOOGMS}
1981.11
(5Z5GAL5)
1197.8 1
(415 GALS )
1892.51
(50OGALS.)
2116.41
(575 GALS)
2081.81
(550 GALS)
HCI PICKLING
0.14 C./5EC
(l 1.1 6PM)
STEEL STRIP
MAKE-UP WATER
0.73-0.1fci|5EC.
(l 1.5- IZGPM)
SPENT —
PICKLE
LIQUOR
0.4IAISEC
(&-5GPM)
T0
DEEP WELL
DISPOSAL
A-
SAMPLING points
ENVIRON mental protection A6E.NCV
STEEL industry study
HCI PICKLING LIME
WASTEWATER TREATMENT SYSTEM
WATER FLOW OlAtaBAM
Xi <- 6 1 S
Rtv i 2 20 ~/i
Rtv 1 2 nv.
FIGURE 3ZE-26
-------
4&jG/S£C. (ia>o gpm)
WfcLL WAT&g
3.6^/seC.
(ao 6pw)
CONTINUOUS STRIP
,i i 4J1	—
PICl^L&K.t) UN£5)
AOD RlMSfc WTO
5UK6ETAW5(2)
5 STD TANDEM
COLD MILL.
COLD MILL BINSc
SPENT EMULSION
WTC.SUH6ETAKJTO
TANK&  t COLD COLLINJ&
B&CI BCULATlOKl;
PICI^LI NI&-UC.I —CONTl NUOUS
RlNSEr
RLANJT : BB-Z
PRODUCTION : (.COLD COLL I Kltj) :
!&>33 METRIC TOnI'sOF STL /T. C'J
QeOI TOK>^> OP STfcfcV..T_ C
(PICtUNO) :
ZZZS METCICTOHSQEgTL -
( Z4£3 TONS OF ST&£L/rtC )
¦TO MCI gfcCOVEB.V AT AN OPP-SlT^ LOCATION.
~OR DISPOSAL-AT AN ON-SlTfc DEEP YV6-LL.
n3.feOO.QOO I ( 30,000,000 tiUSV)DIA
vi&KM'iatt-wF
TO gfcCEIVING
STEEAM

Kbfth)C65,)DIA.
VACUUM PI CT ErE-bC*)
RECIRCULATED SLUDGE:
4 ,T 'O1
VACUUM El LTErCb (Z)
/\= SAMPLING pqimts
ENVIRoriM EbJTAL PROTECTION A&EMCV
©Tee-L industry study
COLO ROLLINC> £ HC( PICKL.ING,
WASTE HVATBP TREATMENT SYSTEM
watec. plow diaqcam
m Qr
-------
PROCESS1 PICKLING H 2S04 "CONT I NUOUS
CONCENTRATES & RINSES
PLANT:QQ-2
PRODUCTION- 922 METRIC TONS/TURN
(1016 TONS/TURN)
FUME HOOD
PRODUCTION
FLOW	
r*	FRESH H2SO4
rorpio
Ul
to
-------
ROLLIMG> SOl-UTIOM
CO l_D
ROLLING
PROCESS
PROCESS. PICKLING-H-j SO* COKJT
C-OMCEWTRATES AND
RIW5ES
PLAUT SS-2.
PRODUCT iokj
7<7a METRIC TOUS/7"6'-£'A'
800 TOWSITUSN
-za. i/SEC
\ (itGRMV





COLD
HOT






WATER
WATER
RECOIL
T-l
T-Z
T-3
T- A
T-S




RINSE
RINSE
STATION





-3&9«/SEC"5a8i/SEC
(4000 GPM" 3,0OO
gpm)
OTHER PLAK1T
•WASTE PICKLE. LIQUOR
I. 2C. -fi/SEC..
(fcO GPM)
WASTE WATER
Z3-a^/SEC
(37 7 5 GPM)
2E to receiving stream
-DISCHARGE to
R.E.CE-IVIK1G STREAM
307 o-e/sec.
(^sso&pm)
A'
SAMPLING POINT
EkJVIROUMEMTAL PROTECTION AGENCY
STEEL IkJDUSTKY STUDY
COMTIUUOUS N;SO+ PICKLIU&
AUD COLD ROLLING
WASTE WATER TREATMENT SYSTEM
water flow diagram
DWG H-II-7S
R6.V.1 ?-t87<
figure HI-29
-------
INDUSTRIAL
WATER SUPPLY
FUME SCRUBBER HOODING
PROCESS^ PICKLING-H2S04-CONTINUOUS
CONCENTRATES -RINSES
PL ANT: TT-2
PRODUCTION 947 METRIC TONS/TURN
(1044 TONS/TURN)
FRESH
h2so4
COLD RINSE WATER
HOT RINSE WATER
Q
V

PRODUCTION _ FLOW
f 1 *
PRE-PICKLING
COOLING WATER
STATION

h2so4
1
COLD WATER 1 HOT WATER
RINSE 1 RINSE
1
1
RECOIL
STATION
Q
rr
Looping car

>-3.16 I/tec I
(50 gpm) I
A
3.16 lAec-
(50 gpm)
- 0.316 l/sec
(5 gpm)
FUME SCRUBBER
EFFLUENT
y\.
-17.6 t/sec (279 gpm)
COMBINED RINSE WATER
-21.1 l/sec(334 gpm)
-Transfer by tank car
To-
other
ACID WASTE"

WASTE PICKLE LIQUOR
NEUTRALIZATION
SYSTEM



EVAPORATION PONDS
COMBINED WITH OTHER
PLANT WASTEWATER AND
DISCHARGED DIRECTLY TO
RIVER
SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
CONTINUOUS SULFURIC PICKLING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn. 3/29/79
FIGURE 3ZH-30
-------
PROCESS: PICKLING H2S04 CONTINUOUS
CONCENTRATES 8 RINSES
PLANT: WW"2
PRODUCTION^ 584 METRIC TONS/TURN
(644 TONS/TURN)
INDUSTRIAL WATER SUPPLY
PRODUCTION
FLOW
3.79 l/sec
60 gpm
24.0 l/sec
(380 gpm)
OTHER PLANT
WASTEWATER
A SAMPLING POINT
I 75 l/sec—
(2778 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
CONTINUOUS SULFURIC PICKLING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DISCHARGE TO
RECEIVING STREAM
Dwn. 3/29/79
FIGURE 2TT-3I
FILTRATION
SYSTEM
DEEP WELL
INJECTION
TERMINAL
TREATMENT
PLANT
LOOPING
PIT
COLD WATER
RINSE
HOT WATER
RINSE
RECOIL
STATION
-------
SULFURIC ACID PICKLIN6
BATCH PIPE AND TUBE
090
PROCESS1
TUBE MILL
PLANT-.
production: 37 metric tons/turn
(41 TONS/TURN)
O.oez 9/SEC
1.3			
O.OZS f/SEC
< >—o.^t q pm
RINSE
TANK
CROWN
SYSTEM RINSE
RINSE
TANK
RINSE
TANK
0.6 V/SEC
9 G,PM
EQUALIZATION
AND OIL
SKIMMINQ .
RINSE AREA
SUMP
EMERQENCV
IMPOUNDMENT
TO LAGOON
AERATION
COOLING
BOSH
CHEMICAL
addition 4
MIXING
1ARI FIERI
PAR5HALL
FLUME
OTHER PLANT SOURCES
/37 i/SEC
2.170 qPM
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING-BATCH GALVANIZING
WASTEWATER TREATMENT
WATER FLOW DIAGRAM
/\SAMPLING POINT
OWN. 11/16/78
FIGURE m-32
-------
NON-CONTACT CDOUNC- h70
ChilLER CInOEnSaTE
Discharge jnlv OPERA1ES
At 60°p>
PROCESS Uj-SULFURIC ACID PICKLING
BATCH - ROD
plant: 091
PRODUCTION: Q-250 METRIC TONS/TURN
<284 TONS/TURN)
MAKE-UP
Zinc ammonia
CRvStalS
MA Hi
uHTOMATE
RINSE
TANK
•VA X
F L U*
REEIERS
K'NSt
TANK
TANK
TANK
bath
ROD Mi:
1-NK
UN*
RECiCiE 4
TO MILL
CiVEk
4 PICKLING ( GALVANIZING LINE
CiN BASEMENT)
Kj atmosphere
MAKE-Uf
k
X
amPER water
Lift STATION
U*4 Of T
MECVCIE I RivER WATER
PUMP HOUSE
DISCHARGE TO
RiVf R
FLU* I
k doling
galv
2inC
BATH
RINSE
rinse
MAX
reelers
RINSE
ALIU
TANK
TANK
TANK
"GO MILL
TANK
CCnTiNuOUS
&LEE3
no 3 picklingigalvanizing line
(uRQUNO FLOOR)
make-up
rS
PRESSURE
SANO FILTERS
CPE RATING
I STANDbV
30*%l
124 t Of**
FROM LEAD
ANfCALING
CL ARIFIERS
iPRAt #11


furnace
LIME FEEO
slurrv
galv
riNC
BATH
ChnQMATE
RINSE
TANK
LOOLIN^
RINSE
TANK
flu*
fANK
RINSE
TANK
REELERS
f
0 r^Tt
VACUUM DRUM
FttTER
1555<^«
CAM
2 GPM
(GftOUNO FLOOR)
WATER TREATMENT PtANI
SPHtfcfc
MAKE-UP
REACTION
TANK
iOXlOATlON
TANKS
BOILER
LFT STATION
IBLCMOOWN)
0 2a
5ALV
ZINC
Bath
IUU.ING
RINSE
TANK
chrcmaje
RINSE
TANK
RINSE
TANK
RtNSE
TANK
WAX
TANK
h?SC4
RtNSE
A TA*K

4 VS	l?2 * GPW
n*i picklingi galvanizing line
(G#?0U*0 FtOOP)
VANI2ING
(NO ACID)
lORAuE
I
SAMPLING POINT
bBlS i
10 H GPM
A
LIFT STATION
ENVIRONMENTAL PROTECTION AGENCY
MARSHALL
i )96//V«c i24"4 cpm
0 b CPM
Hy.1 TANKS OUMPEb
EVEttV FRlOAV NI^Hf
~%C ME1ERE0 'MO
TREATMENT SYSTEM
(¦ »N«SwEO MCNOAT
MORNING
MAIN LIF T blAllON
STEEL INDUSTRY STUDT
HQ-NEUTRALIZATION— CONTINUOUS GALVANIZING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
E2Kyj£]
I
FIGURE 3ZH-33
-------
RINSE.
COLO
RINSE
RINSE
J/&£C

0.16JI/SIC
[if.fSPM)
HOT
RINSE
NON-CONMCT
COOLING V/ATEX
RINSE
^2-S7 A/S£C
(GrPM^ i
HOT MILL
WASTEWATER
W.-*-
(2-2-
J/SEc.
C,PM)
¦its—~
UPSETTER
i
1
t
HOT
MILL
SUMP
m zinc.
(312 G,PK\)
-£-~fcx—>1
I'ROCt ss: SULFURIC ACID PICKLING-BATCH
HYDROCHLORIC ACID PICKLING-BATCH TUBE
COMBINATION ACID PICKLING-BATCH
plant: 092 a 123
PRODUCTION:COMBINATION ACID PICKLING
20 METRIC TONS/TURN (22 TONS/TURN)
SULFURIC ACID PICKLING
157 METRIC T0NS/TURNII73 TONS/TURN)
HYDROCHLORIC ACID PICKLING
154 METRIC TONS/TURN (173 TONS/TURN)
SPENT PICKLE
LIQUOR
EXTRUSION


BLDQ.





EXTRUSION
AREA
SUMP
EXTRUSION


&L0<*.





EXTRUSION


BLDG,.


Id-lJ/sec.
(Z97 GfM)

A
MAKE UP WATER (CITY WATER) GOES TO VARIOUS LINES
COLO

FINISHING,

area
L
SUMP

CENTRAL
TREATMENT
PLANT
46.Z. Jt/se-C.
(732- OjPM)
——~
A;
SAMPLING POINT
(IZS G,PfA)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID-COMBINATION ACID PICKLING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DWN.il/2l/7E
FIGURE 3ZH-34
-------
PROCESS: i< tickling iici neutralization
093
PRODUCTION; R- 34 3 METRIC TONS/TURN
(378 TONS/TURN)
RIVER
WATER
1.55 l/SEC.
(24.5 6PM)
11.64
l/SEC
(184.5
GPM)
STEAM
CONTINUOUS
HCL
PICKLING LINES
^ 10.1 l/SEC.
(160 GPM) i "
0 l/SEC.
(0 GPM)	<'
(5 LINES)
SPENT
MILK OF LIME
PICKLE
REACTOR
STORAGE
LIQUOR
PURCHASED
TANK
TANK
HOLOING
H2S04 TUB
PICKLER LIQUOR
TRUCKED FROM
ANOTHER PLANT
MILK OF LIME
TANK

NO TRUCK LOADS
DURING SAMPLING
0. 41 l/SEC.
O l/SEC.
(0 GPM>-
17.42 l/sec
(276 GPM)
SUMP
DISTRICT
RUN
CLA RIFIER
ENVIRONMENTAL PROTECTION AGENCY
-------
PROCESS' CONTINUOUS H2S04 PICKLING
PLANT: 094
SERVICE WATER
MIL LS
LIME FEED
PRODUCTION: 955 METRIC TONS/TURN
(1053 TONS/TURN)
POLYMER
L I M t
FEED
FEED
PRIMARY
TANK # I
263.5 l/SEC
4176 GPM)
00
PRIMARY
SCALPING
TANK #
LIME FEED
PRIMARY
MIX
TANK # 2
PARSHALL
TANK
FLUME

PRIMARY
SCALPING
TANK «2
SCUM
BOX
TANK
FLOCCUL
24.29 l/SEC
(385 GPM)
CL ARIF
OIL
SKIM
TANK
Sludge
A LIFT
STATION
WEL L
THICKENER
SLUDGE
PUMPS
0.947 l/SEC
(15 GPM)

u> tc
116
l/SEC
(1847 GPMI
Filtrate
OIL
SEPARATION
TANK
OIL
STORAGE
TANK
ELECTROLYTIC
PLATING LINES
LIFT
STATION
CENTRIFUGES
SLUDGE
CONVEYOR
CONTRACT
HAULER TO
LANDFILL
N" I TIN MILL
3 STAND C.R.S.M
CONTRACT
HAULER
UO
LIFT
STATION
ENVIRONMENTAL PROTECTION AGENCY
N " 2
PICKLER
LIFT
STATION
STEEL
NOUSTRY
STUDY
CONTINUOUS H2S04- CONTINUOUS GALVANIZING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
25.75
(406
l/SEC
GPM)
N I
PICKLER
DWN 8/3/78
SAMPLING POINT
FIGURE 3ZH-36
-------
FILJERED
MAKEUP
WATER
// 1	:! . \>A'/ A'. /. )us ;,^i P/'KL/Htj-
PLANT'.
PRODUCT /ON: /5.-90ZMETK/C TCWS S.T££jrj.kLM
(ViS TONS STE£l/TU£K>)
FRESH ACID
MAKEup
RI NSE
section
PICKLING
SECTION
PRODUCT
EMERGENCY
overflow
PRODUCT
TO HC/
REGENERATION
PLANT	*
SpENT ACID
TANK
cj>-(iaGPM)
i. i tysEc.
AC ID
INSTRUMENT-
ATION
spm>(D
L/SEC.
TWO
FUME
SCRUBBERS
SCRUBBER
MAKEUP
NOT IN USE
<0.50 G PM)(1)
0.05 '-/SEC.
-SCRUBBER
BLOWDOWN
*r\-

(O.G6GPMJ0)
O.04 L/SEC-
A-
-#|8ASEMEAIT/\
SUMP
AREA
DRAINS
-(52.25 GpMjO)
3,30 l/SEC.
ARB A
DKAINS
NOTE (DMEaSUREO FLOW
VALUES.
TO WASTE
LAGOONS
A
SAMPLING POINT
environmental protection ASENCY
STEEL INDUSTRY STUDY
CONTINUOUS HCt PICKL.INQ-RINSES
WASTEWATER TREATMENT SYSTEM
Water Flow t>iAC*RArv\
DWN:fr2l-77
FIGURE MT-37
-------
L-HC! PICkLZ LIQUOR
vt-^EHt/cATioN (meat PROCESS)
PiMT' oisa
f 'H'ODUC TlON: 8-&Z0 METZIC TONS ST£Ll/TIMN
i.G9S TDHS STEELL/tu£N)
HOT GASES
4.5 ^/?6C.
(11 6PM.)
WASTE PICKLE
FROM SJ0RA6E
7ANKS
MOT SASES
LIQUOR
HOT GASES
FUEL OIL
PZE-E-VAPORAJOZ
AIR
-SOME RINSE
WATER FROM
PICKUNQ LINES.
BALANCE TO
LAG>OOHS ^
FILTERED
MAKEUP WATER
IRON OXIDE
FRESH PICKLE
LIQUOR TO
STORAGE TANKS
WASfE S
ENVIRONMENTAL PROTECTION AQENCY
SCRUBBER WASTES FROM
OTHER THREE TRAINS
STEEL INDUSTRY STUDY
CONTINUOUS HCI PICKLING AND RECOVERY
WASTEWATER TREATMENT SYS TEW
WATER plow diaqrana
FIGURE 3ZH-38
(Si
-------
PROCESS-. CrSIILFUKIC ACID PICKLING
BATCH FASTENERS
SOUTH Dt^REASLR
A L HAL INC RINSES
096
PLANT:
PRODUCTION: Q-42 METRIC TONS/TURN
(46 TONS/TURN)
NORTH AND SOUTH
qALVAhllZER rinses
EL EC. TKOLYTIC
RINSES
RAMSOHOrr WASHER, j.
furnaces, £rc.
IO MILL,
HOT FORMING)
ETC.
C T.
COIL ORAWIN$, £ TC-
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
ACID PICKLING, GALVANIZING, ALKALINE CLEANING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
TO STREAM ANo/oR
RECYCLE
DWN.11/27/78
FIGURE3ZII-3S
LACfOON
DEEP
BED
FILTERS
-------
No I TANK 10,SOO gal A /0 H2S04
No. 2. TANK 10,500 gal 7-l2°,fc h^SQ,
No. 3 TANK 10,500 gal \b-Z\% H2S04
OPERATING TEMPERATURE flO*
PROCESS: o-sulfuric ACID PICKLING
CONTINUOUS STRIP
FROM WELL WATER SUPPLY
PLANT".
0.22 S/SEC
(3.7 
-------
CJ
u>
KD
PROCESS-
Q BATCH SULFURIC ACID PICKLING
BAR, WIRE a SPECIAL SHAPES
recovered
AClOJMkSH
AC 10 VAPOR DE MISTER
PLANT:
PRODUCTION:
VAPOR
EXHAUST
188 METRIC TONS/TURN
(207 TONS/TURN)
steam
I heating
ACID
VAPOR
DEMISTER
VAPOR
PICKLE
TANK
H2S04
3000 GAl
PlCKlt
TANK
H2SO4
3000 GAl.
RINSE
TANK
PICKLE
TANK
H2S04
J000 GAL
LJMt
TANK
4000 GAL
WATER
STORAGE
3800 GAL
STEAM HEAI
FOUNDATION DRAINS
TANK
MAKEUP WATER
W PICKLING
INOlRECT
HEAT
EXCHANGERS
"-fe
RINSE WATER
TRANSFER PUMP
MAKEUP WATER
BOOSTER PUMP
FEED WATER
SUMP PUMPS
AC 10 VAPOR OEMISTCR
AIR SPARGING
BLOWERS
T*T77
AIR CURTAIN
FAN
PLANT BAR PICKLING
RECOVERED AC»D WASH
S-tMiaKft IuWn
t—i SPENT ACiO PUMP
STEAM
HEAT
C0N0FN5«t
RtTlUN
OCfcNSA'E
RETURN
pickle
TANK
H2SO4
PICKLE j
TANK I
HgSO^ I
WPOR EXHAUST FAN
STEAM HCAI
PICKLE
TANK
H7SO4
PCKLE
TANK
H2SQ!
BONDER
LUBE
TANK
RINSE
TANK
3HOSPHAIE
TANK
FOMWa
CRAWS
INOlRECT
aJR
SPARGING i»
BLOWER
RINSE WATER
TRANSFER pump

x^aiR SPARGING rv
[jg BlOWERSCTVP)
Alio VAr'iN OE MISTER
AlR CURIAM
FAN
RECOVERED AC©
SPENT AC»0
PUMP
PLANT N® I WIRE COIL PICKLING
TSjOOO GALLON
STORAGE TANK
SPENT ACID
LIQUORS
MWE-lP ViAIER
STEAM
CONTRACT*
HAULER
effluent
SUMP
A IK CUXTAIN
FANS
PICKLE
TANK
LIME
TANK
RINSE
TANK
PCKLE
TANK
^HjSO,
A-SAMPL1NG POINT
PLANT N»l
SPECIAL
LL	,h2so4 r*
SHAPE	j
iTFAM 10 f€Al ~'	'**¦%. Z! J- = W~~
FOUNDATION DRAINS
ENVIRONMENTAL PROTECTION AGENCY
Pickling steam 10 ^cai
kJCHANGER Atft
curtain
FAN
STEEL INDUSTRY STUDY
BATCH SULFURIC ACID PICKLING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
^ RINSE water
TRANSFER PUMP
^»AIR SPARGING
a eiowERs---s
SPENT ACIO
PUMP
DWNB/ll/78
FIGURE "VTT-41
-------
u>
O
HCI Continuous Strip
Pickling Line
PICKLE
LINE
/C\RINSE
WATER
Non- Contact
Cooling Waters
from Mills
FUME
DISCHARGE
HCI

SPENT

PICKLE
L
LIQUOR

-Recovered HCI
-A-
HCI REGENERATION
PLANT
PROCESS: R-CONTINUCUS IICI PICKLING/
ACID REGENERATION
PLANT 099
PRODUCTION : R-384METRIC TONS/TURN
(423 TONS/TURN)
-FeCI j
(Sold)
BOI LER
a HOUSE
/h\sump
CENTRAL MIXING
MANHOLE
PARSHALL
FLUME
DRAIN
N* 4
SETTLING
POND AND/OR
EMERGENCY
POND
Ns I POND
PUMP
STATION
SETTLING
POND
SECONDARY
NEUTRAL
SUMP
N? 3

Ns 2
SETTLING

SETTLING
POND

POND
To Mills-^-
-Z^s	
RAW RIVER
WATER
PRIMARY
NEUTRAL
SUMP
,CONDENSER
^RUBBER
DISCHARGE
TANDEM
MILL
POND
PUMP
DISCH.
,
k
TANDEM
MILL
SETTLING
POND

SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDf
CONTINUOUS HCL PICKLING/ACID REGENERATION
WASTEWATER TREATMENT Sn'STEM
WATER FLOW DIAGRAM
DWN.7/26/78
FIGURE 2EM2
-------
PNOCLSS: l< IIt I Al io PICKLING
PLANT: 100
production:
*1 Normalizing Line- 362 Metric Tons/Turn
(399 Tons/Turn)
6.82 l/sec
(108 gpm) PICKLE ACID
RAW WATER 20% HCl
0.375 lAec
(5.94 gpm)
*4 Pickling Line
2761 Metric Tons/Turn
(3066 Tons/Turn
A RAW WATER
(23.8 gpm)
1.5 l/fcec
I NORMALIZING
LINE
ACID RINSE
WET
LOOPING
PIT
UJIu
A PICKLING LINE
HCl CASCAOE RINSE
TANDEM
(21.5 gpm
36
lAec
CASCAOE
RINSE
1.87 l/sec
(29.7 gpm)
FUME
SCRUBBER
!
(4) FLOCCULATING
(21,129 gpm)
1,333 l/sec
CL/vRIFtERS
CLAR F ER
DISTRIBUTION
SOT HSM
SCALE
PIT 4-B
BOX
1,310 l/sec
e(X767gpnd
STRIP
DISTRIBUTION
BOX
B MIXING
CHAMBER
ACID
SUMP
OUTFALL
TO LAKE
"3 COLD
STRIP MILL
PRETREATMENT
FACILITIES
(SCALPING PITS)
D.I.W.
WET WELL
3 CSM
EAST
—rhr*
(362 gpm)
22.84 l/sec
362 gpm)
22B4 Ifoc
•5 PICKLE
LINE
2
COLDMILL
SPENT ACID
*3
COLDMILL
SPENT ACID
/\ SAMPLING POINT
	 > PRODUCT FLOW
ONLY
AC D
*3 COLDMILlI A(82.6 qpmtj
ACID WASTES) 521 l/sec
80 TANDEM
PUMP
ENVIRONMENTAL PROTECTION AGENCY
HOUSE
SPENT ACID STORAGE TANKS
STEEL INDUSTRY STUDY
COLO ROLLING - ACID PICKLING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
*3 COLD ROLLED STRIP MILL
DEEP WELL
ACID INJECTION
"4 S ^5 PICKLING LINES
56" a 80" TANDEM MILLS
DWN.6/27/78
FIGURE 2)1-431
-------
OJ
to
City water
Make-up
Recycle
(I80gpm)'''
11.'4 l/sec
RECYCLE
SURGE
TANK /!t\
KOLENE
RINSE
TANK
JN

• »
o£
w

WASTE
PICKLE
LIQUOR
TANK
BRIGHT
ANNEAL
LINE
1*1
(90 gpm)
5.7 l/»ec."
(240 gpm)
15.1 I/sec."
ANNEAL
AND
PICK LING
LIQUORS

—Watte pickling
liquor
PICKLE TANK
FUME
SCRUBBERS
Slowdown
to creek
COOLING
TOWER
COLD
REDUCTION
MILL
"A	
N» 3 STRIP
GRINDER
DECREASE
2
22.1 lAec.
(350 gpm)
SOLIDS
REMOVAL
FILTERS
PROCESS- COMBINATION ACID PICKLING-CONTINUOUS
PLANT= 121 a A
PRODUCTION1 55 METRIC TONS STEEL PICKLED/TURN
(61 TONS STEEL/TURN)
To creek
(170 gpm)
10.7 l/»ec. avg.
POLISHING
TANK
T
A
-~ Oil removal
(Contract disposal)
COOLING
TOWER
:r*
¦600 gpd
BOILERS
Sodium metabisulfate
feed (not in use)
-Btowdown
ACID
WASTES
SUMP
Overflow-
EQUALIZATION
TANK
NEUTRALIZA" ION
] TANK
Oil removal
(To contract
disposal)
Underflow—^
TWO
REACTOR/
CLARIFIERS
AIR
COMPRESSOR
COOLING
WATER
THICKENER
(20 gpm)"'
1.3 l/eec.
Disposal by
private contractor

TOWER

COOLING
TOWERS
i
k


i
>

COLD

REDUCTION

MILLS

Underflow-
Underflow
TWO
CENTRIFUGES
-^Slowdown
to creek
NOTES: (I) Company supplied
design flow data
(2) Weir measurements
I
Centrifugate -
SOLIDS
REMOVAL
FILTERS
A
SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING'CONTINUOUS
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.6/21/77
FIGURE 3ZH-44
-------
PROCESS: COMB. ACID PICKLING - BATCH
PLANT:
PRODUCTION -3.6 METRIC TONS/TURN
(4 TONS/TURN)
81,800 l/DAY
(21,600 GPD)
/lai l/DAT
(40 GPD)
LIME
9840 l/DAY
(2600 GPD)
v 12,100 l/DAY
(3,200 GPD)
2,120 l/DAY
(360 GPD)
12100 l/DAY
(3200 GPD)
151 l/DAY
(40 GPD)
DISCHARGE
TO POTW
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMB. ACID PICKLING - BATCH
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
FIGURE 521-45
SCRUBBER
BAR WASH
WATER
TUBE WASH
WATER
PICKLING OPERATION
THREE STAGE OVERFLOW
NEUTRALIZATION PIT
-------
ACID PICKLING SUBCATEGORY
SECTION VIII
COST, ENERGY, AND NONWATER QUALITY IMPACTS
Introduction
This section addresses the cost, energy, and nonwater quality impacts
of applying the different levels of pollution control to acid pickling
operations. Topics of discussion include actual treatment costs
incurred by plants sampled, the alternative treatment systems
considered for use in the pickling subcategory, and the cost, energy,
and other nonwater quality impacts associated with the application of
the BPT, BAT, BCT, NSPS, and Pretreatment alternative treatment
systems. In addition, the BCT cost comparison and the consumptive use
of water are addressed.
Actual Costs Incurred by Plants Sampled for This Study
The water pollution control costs for the acid pickling operations
sampled during this study are presented in Tables VI11—1 through
VI11-12. The costs were derived from data supplied by the industry at
the time of sampling or from data submitted in response to the D-DCPs.
The costs have been adjusted to July 1978 dollars. Where central
treatment systems are present, the industry often supplied total cost
data for the entire treatment system. These costs were analyzed and
apportioned to determine costs attributable to acid pickling wastes.
In some instances, standard cost of capital and depreciation factors
were applied to the reported costs to determine those portions of the
annual costs of operation. In the remaining instances, those costs
were provided by the plants.
Control and Treatment Technologies
Recommended for Use in Acid Pickling
The treatment components and systems incorporated in the BPT and BAT
alternative treatment systems are presented in Tables VIII-13 through
VIII-16. The following items are described for each treatment step.
1.	Treatment and/or control methods employed
2.	Status and reliability
3.	Problems and limitations
4.	Implementation time
5.	Land requirements
6.	Environmental impacts other than water
7.	Solid waste generation and primary constituents
It should be noted that the use of these control and treatment
technology components will not be required by the final regulation.
Any treatment system which achieves the proposed effluent limitations
is adequate.
345
-------
Cost, Energy, and Nonwater Quality Impacts
General Introduction
The Agency estimated cost and energy requirements on the basis of the
alternative treatment systems developed in Sections IX through XIII of
this report.
Estimated Costs for the
Installation of Pollution Control Technologies
A. Costs Required to Achieve the Proposed BPT Limitations
The Agency has made estimates of the expenditures needed to bring
acid pickling facilities from current treatment levels to a level
from which BAT technology can be installed. This level is
referred to as the "BAT Feed Level." These costs were considered
as "BPT Required" costs for purposes of the economic impact
analysis of the industry. To develop the costs required to
achieve this level, a cost summary based upon a treatment model
concept has been established. As explained above, this model
concept recognizes the types of treatment systems presently
installed and includes the types of components that the plants
will install in the future.
In order to develop BPT compliance costs, it was necessary to
develop BPT models sized to represent the average pickling plants
in the United States. Separate model sizes were developed for
batch and continuous operations in each acid pickling
subdivision. The model sizes (tons/day) were developed on the
bases of the average production capacities of each type of acid
pickling operation. The components incorporated in the various
treatment models are also representative of actual acid pickling
operations.
Using the rationale explained above, a plant by plant inventory
was conducted for each acid pickling segment to determine the
number of plants in each model configuration. Using updated flow
rates (see Section X) and the model sizes described previously,
unit costs for each treatment component were developed. Total
costs were then calculated by applying the treatment component
model costs, adjusted for size, to each acid pickling site. BPT
Capital Cost Tabulations are presented for all acid pickling
lines in Tables VIII-27 through VIII-35 . The estimated capital
costs of BPT technology in this subcategory are $309 million
{July 1978 dollars). Of this total, equipment valued at $138.5
million is currently in place at various pickling facilities as
of January 1978. The remaining $170.5 million remains to be
expended for additional treatment equipment. The estimated
annual operating costs for all acid pickling operations are
approximately $68 million. Tables VIII-17 through VIII-26
present BPT model capital and annual costs and effluent flows and
concentrations for each acid pickling subdivision. Table VIII-58
details the capital and operating costs at BPT for all segments
of the acid pickling subcategory.
346
-------
B.	Costs Required to Achieve the BAT Limitations
The Agency considered three BAT alternative treatment systems for
all acid pickling segments except for sulfuric acid recovery.
These operations achieve zero discharge at BPT. Therefore, no
additional treatment components are necessary at the BAT level.
For all other segments of the acid pickling subcategory, BAT
Alternative No. 1 consists of a cascade rinse system. BAT
Alternative No. 2 adds sulfide precipitation and a filtration
system to the BAT 1 component. BAT Alternative No. 3 achieves
zero discharge through a cascade rinse system, evaporation, and
100% recycle. Additional details and rationale for these
alternatives are provided in Section X. The additional capital
and operating costs at BAT for operations in the various acid
pickling segments appear in Tables VIII-36 through VIII-42.
Table VIII-59 details the capital and operating costs for the
three BAT alternatives for all segments of the acid pickling
subcategory.
C.	Costs Required to Achieve BCT Limitations
The BCT cost analyses for the various acid pickling segments are
presented in Tables VIII-43 through Vlll-46, while additional
information regarding BCT is provided in Section XI.
D.	Costs Required to Achieve NSPS
Two different NSPS alternatives are being considered for
hydrochloric and combination acid pickling operations and one for
sulfuric acid pickling. New facilities constructed after the
proposal of this regulation will be required to meet NSPS. Model
costs have been developed for the NSPS alternative treatment
systems. These costs are shown in Tables VII1-47 through VII1-53
for pickling operations.
E.	Costs Required to Achieve Pretreatment Standards
Pretreatment Standards apply to those existing (PSES) and new
{PSNS) sources which continue or elect to discharge to POTW
systems. Tables VII1-54 through VII1-57 present the costs of the
pretreatment alternative systems developed for each segment of
the acid pickling subcategory.
Energy Impacts
Moderate amounts of energy are required for the various levels of
treatment in the acid pickling subcategory. Major energy expenditures
for the subcategory occur at the BPT treatment level. BAT
Alternatives No. 1 and 2 require little or no additional energy.
However, BAT Alternative No. 3 is extremely energy intensive. The
hydrochloric acid regeneration segment is the only one where BAT No. 3
energy costs are not greater than BPT energy costs. This is due to
the acid regeneration system which requires additional energy. The
sulfuric acid recovery models only incur energy costs at BPT, since
the system achieves zero discharge at this level of treatment.
347
-------
A.	Energy Impacts at BPT
The estimated energy requirements are based upon the assumption
that all acid pickling operations will install treatment systems
similar to the alternative treatment systems which have flows
similar to those of the models discussed in Section IX. On this
basis, the estimated annual energy usage at the "BAT Feed Level"
for all pickling operations is 423 million kilowatt hours of
electricity. This estimate represents about 0.7 percent of the
57 billion kilowatt hours used by the steel industry in 1978.
Refer to Table VI11-60 for a detailed analysis of the BPT energy
requirements for the acid pickling segments.
B.	Energy Impacts at BAT
The estimated energy requirements for the BAT treatment
alternatives are based upon the same assumptions noted above for
BPT. The estimated energy requirements needed to upgrade
facilities to the three BAT alternatives appear in Table VIIl-60
for the segments of the acid pickling subcategory.
C.	Energy Impacts at BCT
The estimated energy requirements for the BCT level of treatment
in the acid pickling subcategory appear in Table VIII-60.
D.	Energy Impacts at NSPS, PSES, and PSNS
The energy requirements for the NSPS, PSES, and PSNS treatment
models appear in Table VIII-60. Only model-based estimates are
presented for NSPS and PSNS as estimates of future additions of
capacity were not made as part of this study. The energy
consumption associated with PSES is included in the totals for
BPT and BAT.
Nonwater Quality Impacts
In general, there are minimal nonwater quality impacts associated with
the alternative treatment systems. Air pollution, solid waste
disposal, and water consumption impacts were considered.
A. Air Pollution
Sulfide addition is incorporated in the BAT, NSPS, PSES
alternative treatment systems and PSNS Alternative No. 2. In the
event of treatment process control upsets, the atmospheric
discharge of sulfides could occur. However, the use of FeS
rather than H2S is recommended to avoid this problem. No other
air pollution impacts will result from the installation of any of
the treatment components considered. Sulfide addition is not the
selected alternative.
348
-------
B.	Solid Waste Disposal
Considerable amounts of solid wastes will be generated at the BPT
level of treatment, consisting primarily of metal hydroxide
sludges that result from the lime neutralization step. Very
little additional sludge will be generated as a result of
installation of the BAT components. The amounts of dry solids
that can be expected for operations in the various pickling
segments appear in Table VII1-61.
C.	Water Consumption
The Agency does not expect that a significant amount of water
will be consumed as a result of the installation of BPT
technology in the acid pickling subcategory. The model treatment
system includes recycle for fume scrubber streams. Some water
may be consumed in these systems; however, the amount is expected
to be minimal. No cooling devices are envisioned for these
recycle systems, so evaporation will not be a problem. Hence, no
significant water consumption is expected for this subcategory at
the BPT level. No appreciable amounts of water are expected to
be consumed at any other treatment level in the acid pickling
subcategory.
Summary of Impacts
In summary, the Agency concludes that the pollutant reduction benefits
described below for the acid pickling subcategory justify any adverse
energy and nonwater quality environmental impacts.
Effluent Discharges (Tons/Year)
Pollutant
Raw Waste
Proposed BPT	Proposed BAT
Flow (MGD)
TSS
Oil & Grease
Fluoride
Toxic Metals
Toxic Organics
Dissolved Iron
172.7
69. 2
15.0
551
36,211
5,003
29,345
31,918
3,819
850
257
141
80.8
15.5
0.3
18.3
4.6
544,989
86. 1
1 .7
85.0
NOTE: PSES discharges are included in those for BPT and BAT.
349
-------
TABLE VIII-1
EFFLUENT TREATMJNT COST
SULFURIC ACID PICKLING - BATCH SPENT OONCEOT RATES
(All costs are expressed in July 1978 dollars)
Plant Code
1-2
0-2
P-2
Q-2
R-2
R
Reference No
0856P
0590
0312
0894
0240 B
0240A
Initial Investment
1,203,800
413,800
322,490
512,960
469, 360
280,000
Annual Cost






Cost of Capital
51,760
17,790
13,870
22,060
20,180
12,040
Depreciation
120,380
41,380
32,250
51,300
46,940
28,000
Operation & maintenance
49, 910
2,320
-
19,910
27,820
-
Energy and Power
25,710
-
101, 730
24,880
61,030
59,660
co Other
CT1
484,000
-39,230
-34,170
-102,110
35,120
-
TOTAL
731,760
22,260
113,680
16,040
191,090
99,700
$/Ton
2.81
0.56
3.11
0.51
0.58
0.38
Plant Code
090
091
096
098
Reference No
0476A
0612
01121
0684D
Initial Investment
448,550
394,800
817,600
NR
AnnualCost



Hauling
Cost of Capital
19,290
16,980
35,160
C08tS
Depreciation
44,860
39,480
81,760
estimated
Operation & Maintenance
34,940
34,380
34,230
at
Energy and Power
6,860
22,800
2,900
210,000/yr
Other
-11,830
3,600
3,730
—
TOTAL
94,120
106,440
157,780
210,000
$/Ton
4.92
0.52
17.46
1.41
NR: Ho response
-------
TABLE VIII-2
EFFLUENT TREATMENT COST
SULFURIC ACID PICKLING-BATCH RINSEWATER
(All costs are expressed in July 1978 dollars)
Plant Code
1-2 (1)
1-2 (2)
R-2
S-2
Reference No.
0856P
0856P
0240 B
0256G
Initial Investment
83,920
20 9,800
64,000
16,730
Annual Cost




Cost of Capital
3,610
9,020
2, 750
720
Depreciation
8,390
20,980
6,400
1,670
Operation and




Maintenance
820
2,060
3,790
4,380
Energy and Power
10
30
8,320
3,100
Other
780
1,990
4,790
90,060
TOTAL
13,610
34,080
26, 050
99,930
$/Ton	0.19	0.18	0.079	1.06
Plant Code	R
Reference No	0240A
Initial Investment	144,240
Annual Cost
Cost of Capital	6,200
Depreciation	14,420
Operation and
Maintenance
Energy and Power	29,830
Other
TOTAL	50,450
$/Ton	0.19
090	0 91	096
0476A	0612	01121
178,080	794,540
7,660	34,179	70,700
17,810	79,450	164,410
7,420	69,200	68,450
5 , 380	45 , 890	5 , 800
1,160	7,250	7,450
39,410	235,960	316,810
2.06	1.15	35.06
(1)	Spray rinse
(2)	Cascade rinse
351
-------
TABLE VIII-3
EFFLUENT TREATICNT COST
SULFURIC ACID PICKLING - CONTINUOUS SPENT CONCENTRATES
(All costs are expressed in July 1978 dollars)
Plant Code
H-2
T-2
QQ-2
TT-2
WW-2
Reference No
0432A
0792B
0584 E
0856D
0868A
Initial Investment
Hauling
679,000
1,534,500
3,017,400
3,650,000
Annual Cost
costs




Cost of Capital
estimated at
29, 200
65,980
129, 750
156,950
Depreciation
$264,000/yr
67,900
153,450
301,750
365,000
Operation & Maintenance

-
65 , 940
464 , 050
313,260
Energy and Power

30,350
12,410
888 , 840
4,000
Other

-31,930
28,860
767,320
1,677,630
TOTAL
264,000
95,520
326,640
2,551,700
1,677,630
§/Ton
0.43
1.41
0.23
1.53
1.63
-------
TABU VIII-4
EFFLUENT TKIAXWNT COST
sulfuric AcxDria^no-OMTimniiB uisnun
(All
eoata ara axpreaaed in July 1978 dollara)

Plat Cod*
H-2
QQ-2
88-2
WW-2
Refaranc* No.
0432A
05848
0112A
0868A
Initial Imitant
297,630
2,087,240
144,450
716,170
Annual Coat




Coat of Capital
12,800
89,7S0
6,210
30,800
Depreciation
29,760
208,720
14,430
71,620
Oparation and




Maintenance
14,9*0
163,160
13,570
55,990
Energy and Paver
9,370
1S4,300
10,790
7,670
Othar
1,330
-
3,290
34,460
TOTAL
68,400
613,930
48,310
200,540
~ /Ton
0.11
0.43
0.078
0.29
353
-------
TABLE VIII-5
EFFLUENT TREATMENT COST
SULFURIC ACID PICKLING-CONTINUOUS FUME HOOD SCRUBBERS
(All costs are expressed in July 1978 dollars)
Plant Code
QQ-2
SS-2
WW-2
Reference No.
0584 E
0112 A
0868A
Initial Investment
25,350
14,310
71,620
Annual Cost



Cost of Capital
1,090
615
3,080
Depreciation
2,540
1,430
7,160
Operation and



Maintenance
1,980
1,350
5,600
Energy and Power
1,710
1,070
770
Other
-
330
3,450
TOTAL
7,320
4,795
20,060
$/Ton
0.0052
0.0078
0.029
354
-------
TABLE VIII-6
EFFLUENT TREATMENT COST
SULFURIC ACID PICKLING-BATCH AND
CONTINUOUS ACID RECOVERY PLANT WASTEWATER
(All costs are expressed in July 1978 dollars)
Plant Code	090
Reference No.	0476A
Initial Investment	1,630
Annual Cost
Cost of Capital	70
Depreciation .	160
Operation and Maintenance	70
Energy and Power	50
Other	10
TOTAL	360
$/Ton	0.019
355
-------
TABLE VIII-7
EFFLUENT TREATMENT COST
HYDROCHLORIC ACID PICKLING-BATCH SPENT CONCENTRATES
(All costs are expressed in July 1978 dollars)
Plant Code
Reference No
U-2
0480A
V-2
0936
Initial Investment
Annual Cost
Cost of Capital
Depreciation
Operation and Maintenance
Energy and Power	-
Other	5860	7848
TOTAL
5860
7848
$/Ton
0.675
0.112
356
-------
TABLE VIII-S
EFFLUENT TREATMENT COST
HYDROCHLORIC ACID PICKLING-BATCH RINSEWATER
(All costs are expressed in July 1978 dollars)
Plant Code	U-2
Reference No.	0480A
Initial Investment
Annual Cost
Cost of Capital
Depreciation
Operation and Maintenance
Energy and Power
Other	27311
TOTAL	27311
$/Ton	3.143
2180
1591
3771
0.054
357
-------
TABLE VIII-9
EFFLUENT TREATMENT COST
HYDROCHLORIC ACID PICKLING-CONTINOOUS SPENT CONCENTRATES
(All costs are expressed in July 1978)
Plant Code
Reference No.
Initial Investment
Annual Cost
Cost of Capital
Depreciation
Operation and
Maintenance
Energy and Power
Other
TOTAL
$/Ton
X-2
0060B
2,928,397
122 , 992
292 , 840
387,555
-1,397 , 605
-594 , 217
-1.046
Z-2
0396D
1,645,754
69,122
164,576
679, 595
913,292
2.021
BB-2
0060
1,717,169
72,120
171,718
101,850
33,333
379,021
0.166
091
0612
56,101
2,412
5,610
4,470
1,936
14,428
0.164
Plant Code
Reference No
Initial Investment
Annual Cost
Cost of Capital
Depreciation
Operation and
Maintenance
Energy and Power
Other
TOTAL
$/Ton
093
03 96A
1,645,754
69,122
164,576
679,595
913,292
2.021
095
0584 F
10,632,692
1,249,341
106,327
1,357,196
958,643
349,193
4,020, 700
099(1)
0528B
44,090
1,896
4,409
9,952
-24
437
16,670
0.030
(1) Includes only the costs of treating fune hood scrubbers.
358
-------
TABLE VIII-10
EFFLIKRT TREAT«KT COST
HYDRO CHLORIC ACID PICKLIHC - COHTIHUOUS RIHSEHATER
(All coats are expressed in July 1978 dollars)
Plant Code
1-2
Z-2
AA-2( 1)
BB-2
091
093
099
Reference Ho.
0856P
0396D
0384 A
0060
0612
0396D
0528B
Initial Investment
14,951
86,619
394 , 950
5,647,341
399,528
86,619
815,271
Annual Cost







Cost of Capital
628
3,638
16,589
237,189
39,953
8,661
81,527
Depreciation
1,495
8,661
39,495
564,733
19,300
-
21,493
Operation & Maintenance
145
-
120,966
366,104
13,786
35,768
-455
Energy and Power
-
35,768
4,543
304,612
12,532
-
162,543
Other
143

-
-
17,180
3,638
35,057
TOTAL
2,411
48,067
181,593
1,442,638
102,751
48,067
308,236
Sfton
0.560
0.106
0.215
0.633
1.166
0.106
0.556
(1) Applies to plant 100 in toxic pollutant study.
-------
TABU VIII-11
EFFLUENT TREATWNT COST
COMBINATION ACID PICTLINC-BATCH OPIBATICHS
(All costs are expressed in July 1978 dollars)
Plant Code
D
C
F
L
124
125
**
/ 1 \
Reference No.
0060D
0424
0856H
0440A
0088D
0884E
112H
Initial Investment
169,387
140,462
508,760
None
40,574
18,310
283,611
Annual Cost







Coat of Capital
7,284
6,077
21,877
-
1,745
' 787
12,195
Depreciation
16,938
14,135
50 , 876
-
4,057
1,831
28, 361
Operation and,.
Maintenance
Energy and Power







11,613
4,081
33
21,014
20,830
11,279
24,711
—
-
-
-
-
-
-
Other

1,006
9,335
5,088
-

-
TOTAL
33,836
33,042
82,140
26,102
26,632
13,897
65,267
$/too
19.91
0.95
4.69
0.83
6.40
2.89
1.22
(1):	Cost data was received in the response to the detailed questionnaire.
(2)i	Energy and power costs are included in operation and maintenance.
** : No plant code assigned.
-------
TABU VIII-12
EFFLIKNT TREATMENT COST
OOHBimTIOH ACID PICKLIHG-COHTINUOUS OPERATICHS
(All coats are expressed in July 1978 dollars)
Plant Code
D
I
0
121
Reference No.
0248 A & B
0432K
0176
0900
Initial Investment
_
546,051
674,735
1,100,683
Annual Coat




Cost of Capital
-
23,259
29,014
47,329
Depreciation
-
54,605
67,474
110,068
Operation & Maintenance (1)
-
17,696
39, 741
49, 986
Energy and Power (1)
-
-
-
-
Other
-
90,692
49,686
29,212
TOTAL
-
186,474
187,974
239,265
$/Ton
0.35
0.54
3.68
2.56
(1) Energy & power costs are included in operation and maintenance
-------
TABLE VIII-13
CONTROL AND TREATMENT TECHNOLOGIES
ACID PICKLING SUBCATEGORY
Sulfuric Acid - Batch and Continuous Acid Recovery
Treatment and/or
Control Methods Employed
A. Spent acid storage
B. Acid recovery syste
Status and
Reliability
Widely practiced.
Excellent, yielding no
aqueous discharge. Currently
in use at several pickling
plants.
Probl ess
and Limitations
None if storage tank
is constructed
properly.
High initial capital
cost is eventually
balanced by recovery
of usable products.
High energy requirement.
Impl men-
tation	Land
Time Requirements
6 months 20* x 20'
24 months 200'x200'
Envi ronment al
Impact Other
Than Water
None
Ferrous sulfate
heptahydrate
Solid Haste
Generation and
Primary
Consti tuents
None
Generates large
amounts of
is highly soluble FeSO.^H^O
so it cannot be crystals,
landfilled.
-------
TABLE V1II-14
CONTROL AMD TREAT«lfT TECHNOLOGIES
ACID PICKLIHG SUBCATEGORY
Sulfuric Acid - Batch and Continuous Neutralization
Treatment and/or
Control Met ho da Employed
A. Spent acid equalization
B. FHS recycle blowdown
goes to further treataent.
C. Equalisation
D. neutralization
with liae to raise pH to 6-9.
E. Flocculation with
polyaer to aid flocculation.
P. Aerati<
G. Settling Basin
(last step of BPT).
Stat us and
Reliability
Widely practiced.
Practiced at aany
operations in the
subcategory.
Practiced at aany operations.
Oil separator not needed
unless cold aill wastes are
jointly treated.
Practiced at a aajority of
operations.
Widely practiced.
Reliable when attention is
given to operation and
aai ntenance.
Practiced at aany
operations in the
subcategory.
Problems
and Liaitations
Hone if storage tank
is constructed
properly.
Requires sufficient
blowdown to reduce
possibility of dissolved
solids build up and
plugging.
Basin aust be sized
sufficiently to
accoaaodate batch
duap and other
irregular flows.
Increased cheaical
cost. Considerable
amounts of solids are
generated which aust
be recovered.
Iapleaen-
t at ion	Land
Tiae	Requireaents
6 aonths	20' x 20'
Increased che
costs.
lical
HigJ) capital costs.
Sludges hard to
dewater.
Accuaulated solids
aust be periodically
reaoved.
2 aonths 25* x 251
3 aonths 50'x50'
3 aonths 50'x50'
6 aonths 2S'x2S'
9-12
months
6 aonths
200' x 200'
Envi ron ent al
Impact Other
Than Water
None
None
None
See solid waste
impacts.
None
Potential for
fine generation
Solid Waste
Generation and
Primary
Constituents
None
None
Any oils collected
aust be landfilled
or incinerated.
Lime addition
increases the aaount
of sludge which aust
be landfilled.
No significant
aaount of sludge
generated.
Increased metallic
precipitates.
Accuaulated solids Sludges aust be
must be disposed landfilled.
of properly.
-------
TABLE VIII-14
CONTROL AND TREATMENT TECHNOLOGIES
ACID PICKLING SUBCATEGORY
PACK 2		
Treatment and/ or
Control Methods Employed
BAT Alternatives
H.	Cascade rinse iy»t« to
reduce riiaewater discharge
(end of BAT Alternative 1).
I.	To H, add sulfide
precipitation to fon
^	Metallic precipitates.
J. Filtration of overflew
(end of BAT Alternative 2)
K. To H, add an evaporation
system.
Status and
Reliability
Practiced at niaerous
operations in other
subcategories.
Used in various industrial
wastewater treatment
operations for toxic metal
removal.
Practiced at ninerous
operations.
Demonstrated in the power
generation industry.
L. Recycle distillate quality	Demonstrated in the power
effluent back to process (end	generation industry,
of BAT Alternative 3).
Problems
and Limitations
Implemen-
tation	Land
Time Requi regents
Envi ronmental
Impact Other
Than Hater
Sol id Waste
Generation and
Primary
Constituents
Requires coordination
with rinsewater flow
ratios.
Care must be exercised
in the handling of the
feed solution. The
treatment process
control is required to
prevent odor problems.
Hydraulic overloads
must be controlled.
Reeds maintenance.
Economics depend on
integration of this
system into the water
cycle.
6-12
months
50'x100'
6 months 20'x20*
15-18
months
25' x 25*
6 months 60 'x60 '
None
Precipitates need
proper disposal.
9ulfide odors
can resul t from
improper control.
Backwash solids
must be properly
disposed.
None
Precipi tates
be filtered.
¦us t
The backwash solids
are removed by
vacuum filtration.
Uses approximately Slurry generated
90 kwh/100	must be dewatered.
gallons of feed- Sludge generated
water.	is decreased.
None
2 months 25'x25'
None
None
-------
TABLE VIII-15
CONTROL AND TREATICMT TECHNOLOGIES
	 ACID PICKLING SUBCATEGORY	
Hydrochloric Acid - Batch and Continuous
Treatnent and/or
Control Methods Employed
A. Spent acid storage
B.	Install acid regeneration
systea (this step is applicable
only to continuous acid
regeneration process).
C.	FHS Recycle - blowdown
goes to futher treatment.
D. Equalization
E. Add line to raise the pfl
to 6-9 in mixing tank.
Status and
Reliability
Practiced at many
operations in the
subcategory.
Good with proper attention
to operation.
Practiced at many operations
in the subcategory.
Practiced at many operations
in the subcategory.
Problems
and Limitations
None, if storage
tank is constructed
properly.
Requires coordination. 6-12
months
Implesen-
tation	Land
Time Re qui rement s
6 months 20' x 20'
Requires sufficient
blowdown to reduce
possibility of dissolved
solids buildup and
plugging.
Equalization basin
must be sufficiently
large to accommodate
batch dusp or other
irregular flow.
Practiced at a majority of	Increased chemical
operations in this subcategory, costs. Considerable
amounts of solids are
generated which must
be treated.
200'xAOO'
2 months 25'x25'
3 months S0'x50'
3 months 50'x50'
Environmental
Impact Other
Than Water
None
Energy intensive
None
None
See sol id was te
impacts.
Solid Uaste
Generation and
Primary
Constituents
None
Sludges must be
disposed of in
a landfill.
None
If any oils are
collected, they
must be incinerated
or landfilled.
Addition of lime
increases amount
of sludges generated
Sludges must be
landfilled.
-------
TABLE VIII-15
CONTROL AND TREATMENT TECHNOLOGIES
ACID PICKLING SUBCATEGORY
PAGE 2
Treatment and/or
Control Methods Employed
F. Polymer addition
to aid f locculation.
G. Aeration
H. Thickener
^	I. Vacum Filter to thickener
CT	underflow (last step in BPT).
BAT Alternatives
J. Cascade rinse systea to
reduce rinsevater discharge
(end of BAT Alternative 1).
K. To J, add sulfide
precipitation systea.
L. Filtration of overflow
(end of BAT Alternative 2).
H. To Jv install vapor
compression/ evaporation
systea.
Status and
Reliability
Widely practiced.
Reliable method of
promoting settling.
Good when given attention to
operation and maintenance*
Practiced by many operations
Practiced at many operations
Practiced at numerous
operations.
Used in various industry
treatment opertions for
purpose of toxic metals
removal •
Practiced at maerous
operations
Demonstrated in power
generation industry.
Problems
and Limitations
Increased chemical
costs.
Implemen-
tation	Land
Time Requirements
6 months 20'x20'
Environmental
Impact Other
Than Water
None
Solid Waste
Generation and
Primary
Cons ti tuents
No significant
amounts generated.
High capital costs.	9-12
Sludges hard to	months
dewater •
200 'x200'
Potential for	Increased metallic
fuse generation. precipitates.
Needs considerable
maintenance.
6 months 150'xl25'
Produces sludge.
Sludges must be
landfilled.
Increased capital and 15-18 25'x25'
operating costs.	months
Dewatered sludge Solids produced
requires disposal, must be landfilled.
Requires coordination 6-12
with rinsewater flow months
ratios.
50*xl00*
None
None
Care is to be exer-
cised in handling of
feed solution. Careful
treatment process
control required to
prevent odor problems.
Hydraulic overloads 15-18
must be controlled.	months
6 months 20'x20'
Needs maintenance.
Economics dependent
on integration of this
system into water cycle.
25 * x 25'
6 months 60*x60'
Precipitates
requires proper
disposal. Odors
can result if
treatment process
is not controlled,
Backwash solids
must be properly
disposed.
Precipitates must
be filtered.
Backwash solids are
removed by vacuus
filtration.
Uses approximately Slurry generated
90 kwh/1000	must be dewatered.
gallons of feed-
water•
-------
TABLE VIII-15
CONTROL AND TREATMENT TECHNOLOGIES
ACID PICKLING SUBCATEGORY
PAGE 3
Treatment and/or
Control Methods Employed
N. Recycle distillate
to process (end of BAT
Alternative 3).
Status and
Reliability
Widely practiced in the
power generation industry.
Solid Haste
Implemen-	Environmental	Generation and
Problems	tat ion	Land	Impact Other	Primary
and Limitations	Time Requirements Than Water	Constituents
Hone	12-14 25'x25'	None	None
months
-------
TABU VIII-16
CONTROL AMD TREAT WITT TECHNOLOGIES
ACID PICKLING SUPCATEGORY
Combination Acid - Batch and Continuous
U)
o>
00
Treatment and/or
Control Methods Employed
A* Recycle FHS vaateiiter
with a blowdown
going to further treatment.
B. Equalisation with oil
separation.
C. Neutralisation with lime
to raise pH to 6-9.
D. Plocculaticn with polymer
to aid flocculationa.
E. Clarifier
F.	Vacuus Piltration
of clarifier underflow
(last step of BPT) .
BAT Alternatives
G.	Cascade rinse tyatcs
to reduce rinsewattr discharge
(end of BAT Alterntivn 1).
Status and
Reliability
Practiced at many
of the operations in the
subcategory.
Practiced at mmy operations.
Oil separator not needed
unless cold mill wastes are
jointly treated.
Practiced at a majority
of operations.
Widely practiced.
Practiced at nany operatic
Practiced at nany operatic
Practiced at msserous
operations in other
subcategories.
Probl ena
and Lisa tat ions
Requires sufficient
blowdown to reduce
to possibility of
dissolved solids buildup
and plugging.
Bssin aust be sized
sufficiently large
to accomodate batch
diap and other
irregular flows.
Increased cheaical
coat. Considerable
aaounts of solids are
generated which aust
be trested.
Implemeo-
tation	Land
Tiae	Requirements
2 months	25'*25'
3 months 50'xSO1
Increased cheaical
coats.
Need considersble
aai ntenance.
Increased capital
and operating costs.
Requires coordination
with rinsewater flow
ratios.
3 months	50'xSO1
6 months	25,x25*
6 months	150axl25'
6 aonths	25'x25*
Environmental
Impact Other
Than Water
None
None
See solid
waste iapacts.
Solid Waste
Generation and
Primary
Constituents
None
Produces
sludge.
Dewatered sludge
will require
disposal •
6-12
aonths
50'xl00'
None
Any oils collected
must be landfilled
or incinerated.
Lime addition
increases the
amount of sludge
which must be
landfilled.
No significant
mount of sludges
generated.
Sludges must
be landfilled.
Solids oust be
disposed via
landfill.
None
-------
TABLE VIII-16
COHTBOL AMD THEATMEKT TECHNOLOGIES
ACID PICKLWC SCBCATEGC*?
PAGE 2	
Treataent and/ or
Control Method* Employed
H. To G, add sulfide
precipitation to font Metallic
precipitates.
Status and
Reliability
Used in various industrial
wastewater treatment
operations for toxic aetal
reaoval.
1. Filtration of overflow	Practiced at nu
(end of BAT Alternative 2).	operations.
J. To G, install vapor	Deaonat rated in the power
compression/evaporation	generation industry,
¦ystaa.
K. Recycle distillate
quality effluent back to
process (end of BAT Alternate
3).
Widely practiced
in the power generation
industry.
Probl ail
and Limitations
Care Bust be exercised
in the handling of the
feed solution. The
treatsient process
control is required to
prevent odor problea.
Hydraulic overloads
¦ust be controlled.
Needa maintenance.
Economics depend on
integration of this
systea in the water
cycle.
lapl Caen-
tat ion	Land
Tiae Requirement»
6 aontha 20 '*201
Environmental
Impact Other
Than Hater
Precipitates
need proper dis-
posal. Sulfide
odors can result
frow improper
control.
Solid Haste
Generation and
Primary
Constituents
Precipitates Bust
be filtered.
15-18 25' x 25'
aonths
6 aonths 60'x60'
Backwash solids
Bust be properly
disposed.
Uses approxi-
aately 90 kwh/
1000 gallona of
f eedwater.
The backwash solids
are removed by vacua
filtration.
Slurry generated
must be dewatered.
Sludge generated
is decreased.
None
2 aonths Z5'x25'
Hone
None
-------
TABLE VIII-17
BPT MODEL COST PATAs BASIS 7/1/78 POPLARS
Subcategory: Pickling-Sulfwic Acid Models Size-TPD:	500
: Batch Oper. Days/Year :	T5ff
: Neutralization Turns/Day :	3
C&TT Step
A
B
C
D
E
Total
-3
Investment $ * 10 ,
119
128
381
99
60
787
Annual Cost $ x 10






Capi tal
5.1
5.5
16.4
4.3
2.6
33.8
Depreciation
11.9
12.8
38.1
9.9
6.0
78.7
Operation & Maintenance
4.2
4.5
13.3
3.5
2.1
27.5
Sludge Disposal..
Energy & Power
~
0. 9
-------
TA11X VIII-18
BPT HO DEL COST DATA I BASIS 7/1/76 DOLLARS
Subcategoryi
rickllnt-Sulfurie Acid
Batch
Acid Recovery
Carbon I Specialty
Hodeli SiM'TPDr $00
Opar. Daya/Keer t JOT
Turna/Day	I J
ClrTT Stop
-3
,-3
Inveatment 5 * 10
Annual Coat $ x 10
Capital
Depreciation
Operation & Maintenance
Cryatal Diapoaal
Energy i Power
TOTAL
US
S.l
11.»
4.3
11.1
3430
147.}
343.0
120.1
St.2
114.3
781.1
Total
3549
152.6
334.9
124.2
56.2
114.3
802.3
Leaa Credit
Net Total
(1)
21.1
4$. 3
735.6
45. J
756.8
f 2)
Effluent Quality
Flow, gal/ton
Total Suapendad Solida
Oil and Greaae
Diaaolved Iron
pHr Unit*
115 Ananic
U8 Cadaiua
11 9 Chroaitaa
120 Copper
122 Lead
124 Nickel
128 Zinc
BPT
Iffluent
Laval
(1)	Credit for acid recovery.
(2)	All values are in «g/l unla«» otharviia noted.
nx TO C*TT I TIP I
Ai Spaat Acid Storage Syateei
>l Acid Recovery SyaCea
371
-------
TABLE VIII-19
BPT MODEL COST PATAi BASIS 7/1/78 DOLLARS
Subcategory:
Fickling-Sulfuric Acid
Continuous
Heutraliution
Carbon & Specialty
Model: Size-TPD:
Oper, Day*/Year :
Turns/Day	:
1980
"555
C&TT Step
-3
„-3
Investment $ i 10
Annual Coat $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy & Power
Chemical Coat*
TOTAL
228
9.8
22.8
8.0
40.6
171
7.3
17.1
6.0
2.4
2.0
32.4
(2)
I
(2)
c
D
E
Total
757
149
116
1421
32.5
6.4
5.0
61.0
75.7
14.9
11.6
142.1
26.5
5.2
4.1
49.8
-
-
15.5
15.5
19.2
0.5
-
19.7
97.8
9.8
-
109.6
251.7
36.8
36.2
397.7
u>
K>	BPT
...	Effluent
Effluent Quality	Level
Flow, gal/ton	250
Total Suspended Solids	50
Oil and Grease	10
Dissolved Iron	1.0
pH, Units	6-9
IIS Arsenic	0.10
118	Cadaiw	0.10
119	ChroisiuB	0.10
120	Copper	0.10
122 Lead	0.10
124 Nickel	0.20
128 Zinc	0.10
(1)	Costs are all power unless otherwise noted.
(2)	Total cost does not include power, because a credit is supplied for existing process water requirements.
(3)	All values are in »g/l unless otherwise noted.
KEY TO C&TT STEPS
A: Spent Acid Equalization	D: Polymer Addition, Aeration
B: FHS Recycle	E: Setting Basin
C: Equalization and Lime Addition
-------
TABLE VIII-20
BPT H)DEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory:
Pickling-Sulfuric Acid
Continuous
Acid Recovery
Carbon & Specialty
Model: Size-TPD: 1980
Oper. Days/Tear : 260
Turns/Day	: J
C&TT Step
.-3
Imeataeat $ * 10
Annual Coat $ z 10 J
Capital
Depreciation
Operation & Maintenance
Cryatal Disposal
Energy & Power
OJ
TOTAL
Less Credits
Ret Total
(1)
Total
264
11.3
26.4
9.2
46.9
46.9
4034
173.5
403.4
141.2
128.7
123.B
970.6
260.6
710.0
4298
184.8
429.8
150.4
128.7
123.8
1017.5
260.6
756.9
BPT
i.t	Effluent
Effluent Quality	Level
Plow, gal/ton	0
Total Suspended Solids
Oil and Crease
Dissolved Iroa
pB, Units
115 Arsenic
118	Cadaiuai
119	Chroaiui
120	Copper
122 Lead
124 Bickel
128 Zinc
(1)	Credit for acid recovery.
(2)	All values are in «g/l unless otherwise noted.
KEY TO C&TT STEPS
A: Spent Acid Storage Systeu
It Acid Recovery Systea
-------
TABLE VII1-21
CtTT Step
Inwataent $ x 10-'
Annual Cost 9 x 10
Capital
Depreciation
Operation & Maintenance
Sludge Diapoaal
Energy k Power
Cheaical Coat a
TOTAL
u>
Efflweat Quality*4*
Flo*, gal/too
Total Suapended Solid*
Oil and Cimm
Dissolved Iron
|«, Oaita
23 CU«nC«m
114	Antimony
115	Annie
lit CaAaioa
119	Cknaia
120	Copper
122	Lead
124	Hickal
126	Silver
128	Zinc
BPTHDDBLC06TDAIA: BASIS 7/I/?8 DOLLARS
Subcategory! Pickling-Hydrochloric Acid
» Batch-Heutralieation
( Carbon & Specialty
Model Sise-IFD I 190
Oper. Days/Tear: 260
Turns/Day	I 2
n<3>
.(3)
Total
55
76
186
47
26
51
123
138
702
2.4
3.3
8.0
2.0
1.1
2.2
5.3
5.9
30.2
5.5
7.6
18.6
4.7
2.6
5.1
12.3
13.8
70.2
1.9
2.7
6.5
1.6
0.9
1.8
4.3
4.8
24.6
_

-
-
-
-
-
7.6
7.6
-
0.6
1.9
0.3
0.2
0.5
0. 1
1.3
4.5
-
-
-
11.0
2.1
-
-
-
13.1
9.8
13.6<»
35.0
19.6
6.9
9.6
22.2
33.4
150.2
BPT
Effluent
Level
280
50
10
1.0
6-9
0.01
0.10
0.10
0.10
0.10
0.10
0.10
0.20
0.10
0.10
-------
TABU VtII-21
BPT IODE1, OOST DATA: BASIS 7/1/78 DOLLARS
PICKLHG-HYDBOCHXKIC ACID
BJSrCBHKDTBALn«riai
MBS 2		
(1)	Coats are all power unless otherwise noted.
(2)	Total cost does not inelode power, because a credit is applied for existing process water requirements.
(3)	Treatment components are used in tandem.
(4)	All values are in sg/1 unless otherwise noted.
KIT TO C4TT STEPS
CJ
-J
Ln
At	Spent Acid Equalisation
B:	FHS Recycle
C:	Equalization
D:	List Addition
B:	Polymer Addition
F*	Aeration
6:	Thickener
Hi	Vacuum Filter
-------
TABU VII1-22
HPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory: Pickling-Hydrochloric Acid	Model Size-TPD :
: Continuous-Neutralisation	Oper. Days/Tear:
i Carbon t>' Specialty	Turns/Day	:
C4TT Step
A -
B
C
D
K
F
g(3>
_H("
Investment $ x 10 ' ,
198
191
885
185
59
150
416
506
Annual Coat $ x 10








Capital
8.5
8.2
38.1
8.0
2.6
6.4
17.9
21.8
Depreciation
19.8
19.1
88.5
18.5
5.9
15.0
41.6
50.6
Operation fc Maintenance
6.9
6.7
31.0
6.5
2.1
5.2
14.6
17.7
Sludge Disposal
-
(?)
-
-
-
-
-
159.1
Energy i Power
-
10.5IZ'
2.0
0.6
2.1
1.4
15.6
15.6
Cheaical Coats
-
-
-
126.8
21.3
—
—
-
TOTAL
35.2
34.0<»
159.6
160.4
34.0
28.0
89.7
264.8
-------
U1U *111-22
BFT MOOS I. COST DATA: BASIS 7/1/78 DOLLARS
ncKLiaG-irn»ocax«ic acid
OOKTIBUOUS-WUTtALIZATIC*
PACE 2		
(1)	Coat* are all power unless otherwise noted.
(2)	Total coat doea not include power, because a credit i» applied for exiating process water requirements.
(3)	Treatment ctspoanti are wed is twta.
(*) All ssloes are in ag/1 m las a otherwise noted.
KEY TO CATT CTKFS
W
-J
At	Spent Acid Equalisation
Bt	M Icejcle
Ci	Bfoalisatioa
Di	Lis* Additioo
K:	Poljaer Addition
Ft	Aeration
Ci	Thickener
H<	Vacnoa Filter
-------
TABLE VIII-23
BPT MODKL COST DATA; BASIS 7fl /?8 POfclARS

Subcategory: Pickling-Hydrocfcloric Acid

Model Sixe-TPD ;
2760




: Continuoos-Acid Regeneration
Oper. Days/Year:
"317




: Carbon & Specialty

Turns/Day
•
—



C&TT Step
A
¦¦ » ¦¦
C
D
E
F ¦¦¦
G
h<3)
_i(3>
Total
Investment J r 10
198
4420
191
963
98
59
182
494
241
6846
Annual Cost $ * 10










Capital
8.5
190.0
8.2
41.4
4.2
2.5
7.8
21.2
10.4
294 .2
Depreciation
19.8
442.0
19.1
96.3
9.8
5.9
18.2
49.4
24.1
684.6
Operation 6 Maintenance
6.9
154.7
6.7
33.7^
3.4
2.1
6.4
17.3
8.4
239.6
Sludge Disposal. .
-
-
" (2)
-
-
-
-
-
18.1
18.1
Energy fc Power11'
-
307.3
10.5
41.9
1.0
0.6
2.8
1.4
4.9
359.9
Chemical Costs
-
-
-
-
27.4
29.2
-
-
-
56.6
TOTAL
35.2
1094.0
34.0*2>
213.3
45.8
40.3
35.2
89.3
65.9
1653.0
Less Credits










Acid Recover;

2304.6







2304.6
Iron Oxide Recovery

1543.6







1543.6
Ret Annual Coat
35.2
-2754.2
34.0(2)
213.3
45.8
40.3
35.2
89.3
65.9
-2195.2
BPT
...	Effluent
Effluent Quality	Level
Flow, gal/ton	450
Total Suspended Solid*	50
Oil and Grease	10
Dissolved Iron	1.0
pB, Knits	6-9
23 Chi or of or*	0.01
114	Antinoay	0.10
115	Arsenic	0.10
118	Cadkiw	0.10
119	Chroaiua	0.10
120	Copper	0.10
122 Lead	0.10
124 Rickel	0.20
126 Silver	0.10
128 Zinc	0.10
-------
TABLE VIII-ZJ
¦FT MDKL COST DATA! BASIS 7/1/79 DOLLARS
FICKLnC-flTMOCHARIC ACID
cohtiwoos-acid bgbkmxioh
PACK 2
(1)	Coats are all power unless otherwise noted.
(2)	Total cott does we include power, because a credit is applied for existing process water requirements.
(3)	Treatment coaponents are used in tandea.
(4)	All values are in ag/I unless otherwise noted.
KIT TO C4TT STEPS
A:	Speat Acid Storage System
It	Acid Regeneration
C:	FHS Recycle
D:	Equalisation
I!	Line Addition
Fl	Polyaer Addition
Gi	Aeration
Hi	Thickener
11	Vacuus Filter
-------
TABUS VIII-24
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory: Pickling - Combination Acid
; Batch-Other
: Carbon-Speciality
Model Size-TPD : 200
Oper. Days/Year: IftO
Turn*/Day	: 2
C&TT Step
.-3
Investment $ x 10 ,
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal,.
Energy 4 Power
Chemical Costs
TOTAL
A
B
C
D
E( 3)
F( 3)
Total
52
88
92
40
85
162
519
2.2
3.8
3.9
1.7
3.7
7.0
22.3
5.2
8.8
9.2
4.0
8.5
16.2
51.9
1.8
3.1
3.2
1.4
3.0
5.7
18.2
0.6(2)
0.2
0.3
0.2
0.2
2.1
1.3
2.1
2.2

-
7.5
0.8
—
-
8.3
92(2)
15.9
24.1
8.1
15.4
32.3
105.0
Effluent,.
Quality
Fl
B: Equalization and oil separation E:
Cj Neutralisation with lime	PJ
Flocculation with polymer
Clarifier
Vacuus Filter
380
-------
TABLE VIII-25
BPT MODEL COST DATA: BASIS 7/1/78 DOT.t.abs
Subcategory: Pickling - Combination Acid Model Size-TPD s	200
: Batch-Pip# & Tube Oper. Daya/Year:	260
s Carbon-Speciality Turn*/Day i	—2
C&TT Steo
A
B
C
D
E(3)
F( 3)
Total
Investment ? x 10 .
52
208
109
56
154
192
771
Annual Coat $ x 10





Capi tal
2.2
8.9
4.7
2.4
6.6
8.2
33.0
77.1
26.9
4.9
2.6
Depreciation
5.2
20.8
10.9
5.6
15.4
19.2
Operation & Maintenance
1.8
7.3
3.8
1.9
5.4
6.7
Sludge Disposal,.
Energy & Power
0.6(2)
0.1
0.4
0.2
0.2
4.9
1.7
Chemical Coats
-
••
9.3
2.7
-

12.0
TOTAL
92(2)
37.1
29.1
12.8
27.6
40.7
156.5
Effluent
Level
700
Flow, gal/ton
Total Suspended Solids
Oil 4 Grease	"
Fluoride	«
Disaolved Iron	,
PH, Unit*
11S Arsenic
119	Chromium	®*J®
120	Copper	J*»
122 Lead	®-J®
124 Nickel	®*J®
128 Zinc	®'"
0.10
(1)	Coats are all power unleaa otherwise noted.
(2)	raquiranantf0' iBCUd*	b*C*U" * Cr,dU U «»FPUM for existing process water
(3)	Treatment components are used in tandem.
(4)	All values are in og/1 unleaa otherwise noted.
U1 TO C4TT STEPS
As FHS Recycle
B: Equalisation and Oil Separation
C> Neutralisation with Lime
D» Flocculation with Polymer
*« Clarifier
Pi Vacuum Pilter
381
-------
Subcategory
TABLE VIII-26
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Pickling - Combination Acid
Continuous
Carbon-Speciality
Modal Size-TPD : 500
Oper. Days/Year: 320
Turns/Day	: 3
C&TT Step
A
B
C
D
E(3)
F( 3)
Total
_3
Investment $ x 10 ,
83
239
166
77
245
216
1116
Annual Cost $ x 10







Capital
3.6
14.1
7.1
3.3
10.5
9.3
47.9
Depreciation
8.3
32.9
16.6
7.7
24.5
21.6
111.6
Operation & Maintenance
2.9
11.5
5.8
2.7
8.6
7.6
39.1
Sludge Disposal.v
Energy & Power
Ji'2'
0.3
1.0
0.9
1.4
6.2
6.3
6.2
9.9
Chemical Costs
-
-
32.0
12.1
—
—
8.3
TOTAL
u.»(2)
58.8
62.5
26.7
45.0
51.0
258.8
BPT
Effluent,v	Effluent
Quality	Level
Flow, gal/ton	1000
Total Suspended Solids	25
Oil & Grease	10
Fluoride	15
Dissolved Iron	1<0
pH, Units	6-9
4 Benzene	0.05
115 Arsenic	0.10
119	Chromium	0.50
120	Copper	0.10
122 Lead	0.10
124 Nickel	0.25'
128 Zinc	0.10
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power, because a credit is supplied for existing process water
requirements.
(3)	Treatment components are uaed in tandem.
(4)	All values are in mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: FHS Recycle	Ds
B: Equalization and oil separation E:
Ci Neutralization with lime	Ft
Floceulation with polymer
Clarifier
Vacuum Filter
382
-------
TABLE VI1I-27
BPT CAPITAL COST TABULATION
BASIS)
7/1/78 DOLLAKS x 10
FACILITIES IN PLACE AS OF 1/1/78
9ubcat«goryi Pickling-Sulfuric Acid
i Batch Mautraliiatioo
i Carbon 4 Speciality
CfcTT 8 tap
Plant


Code
TPD
A
0048?
117
50
0060H
816
160
0088A
1594
535
0088D
769
154
0112
560
157
0112A
1029
183
0112C
2886
340
0112?
827
161
0112G
44
w
01121
287
83
0240A
58)
131
0240B
687
144
0256?
90
42
02560
471
TT5
0432A
1805
257
0460A
1281
209
0460C
105
47
04600
239
TP
0460E
180
64
0460?
28
21
0460C
225
74
0476A
250
78
0492A
474
115
0612
1137
195




Id


B
c
p
B
Plica
Required
Total
53
159
41
25
237
91
328
T7l
5TT
133
w
922
133
1055
m
m
198
TTo
238
1338
1576
166
493
106-22
78
997
22
1019
TT7
5OT
106
u
0
842
842
197
587
153
93
1030
183
1213
366
IT371
m
Tfi
1629
623
2252
T7T
5T5~
134
TT
334
730
1064
to-
89
23
14
30
154
184
st
273
71
43
408
156
564
TO)
m
109
U
625
240
865
T5F
m
120
71
689
264
953
sr
T35
35
2T
280
0
280
113
3OT
W
W
664
96
760
m
8!?
214
TTo
1700
0
1700
in
57ff
m
106
1175
209
1384
vr
IT?
J5T
25"
270
39
309
52
25*
64
3*
430
76
506
vs
JBlf
W
IS
69
357
426
TS
68
18
u
23
118
141
7?
2-36
61
37
352
135
487
m
25T
65
55
440
78
518
154
m
W
vs
551
211
762
¦m

162
W
1093
195
1288
383
-------
TABU VIII-27
1PT CAPITAL COST TABULATION .
BASISt 7/1/78 DOLUM *10
t facii.itus iii rues as or 1/1/78
PACE 2		
C4TT8t«p
Plant






In


Coda
TPD
A -
B ¦
¦ c ¦
D

Placo
Inquired
Total
0640
758
153
164
489
127
77
730
280
1010
0684G
1143
1»
m
626
163
w
1098
195
1293
0684Q
372
100
VST
m
5T
3ff
659
0
659
0728
75
3r
JfT
lib
31
to
220
32
252
0SS6P
378
TBI
1BS
3IT
84
3T
481
185
666
0856S
222
73
7T
33*
61
17
151
332
483
08360
is*
ff
rt
110
55
33
71
364
435
0860F
1083
189
TOs
606
137
99
904
346
1230
0860C
733
150
ttt
m
123
7S
842
150
992
08648
651
139
IOT
440
TIT
7ff
782
139
921
0868A
373
129
TVS
517
VST
BT
617
236
853
0884C
18
16
ir
5r
13
r
17
89
106
0884D
18
16
17
52
13
8
17
89
106
08846
8
10
IT
32
8
5
43
18
61
0948A
189
66
7T
3T3
35
35
438
0
438
2*, 185* 10,334* 34,738*
•Total inclodaa confidential pianta.
HOTBl
Underlined coat* repreeent fecil Itiee in-plece, where two fijuree eppeer in tin	column,
the underlined portion it it>-plaea( the now non-underlined portion rnaeioe to be inetailed.
BY T0-C6TT STIPS
At Spent Acid equalisation
Bi FBI lacjrcle
Ct Iqualiaation and Liaa Addition
Di Poljnanr Addition, Aeration
It Settling Baain
384
-------
TABLE VIII-28
BPT CAPITAL COST TABULATION
_3
Subcategory: Pickling - Sulfuric Acid Basiss 7/1/78 Dollars x 10
: Batch Acid Recovery	: Facilities In Place as of 1/1/78
: Carbon & Specialty
C&TT Step
Code
TPD
A
B
In Place
Requi red
Total
0048B
450
112
2499
0
2,611
2, 611
0060C
63
34
768
34
768
802
0068
94
5ZT
977
44
977
1,021
0112B
240
77
1714
0
1,791
1,791
01121
282
84
1888
188 8
84
1,972
0240C
102
46
H5K
0
1,026
1,026
0384A
501
119
2665
0
2,784
2,784
0432E
30
22
492
22
492
514
0432 L
323
5T
2048
91
2,048
2,139
0460H
94
Vi
977
0
1,021
1,021
0584C
462
113
2539
113
2,539
2,652
0684 D
1400
m
4937
221
4,937
5,158
0684 E
1650
557
5449
243
5,449
5,692
0684 H
636
157
3075
137
3,075
3,212
0684 P
603
151
2979
133
2, 979
3,112
0684 V
150
"3*
1293
0
1,351
1,351
0856N
846
163
3650
163
3,650
3,813
0856P
1599
m
5347
239
5,347
5,586
0856Q
15
15
325
15
325
340
0856R
351
W
2153
96
2,153
2,249
085 6 T
258
w
1790
80
1,790
1,870
0916A
612
13*
3005
134
3,005
3,139
0920D
267
SI
1827
82
1,827
1,909
0948B
306

1983
89
1,983
2,072
3824*
60,969*
64,793*
NOTE! Underlined costs represent facilities in place. Where two figures appear in the
same column, the underlined portion is in place; the non-underlined portion remains
to be installed.
*: Totals include confidential plants.
KEY TO C&TT STEPS
A: Spent Acid Storage System
B: Acid Recovery System
385
-------
TABU VIII-29
BPT CAPITAL COST TABULATION
Subcategoryt Pickling - Sulfuric Acid B««ia:
S Continuou* Neutralisation	:
; Carbon 6 Specialty
7/1/78 Dollar* x lO-3
Facilities In Place aa of 1/1/78
Plant Code
TPD


C4TT Stepa


A
B
C
D
E
0012 A
11,031
638
479
2121
418
326
0020B
801
132
"9?
"TOT
"87
"58
0060D
1,194
157
iir
490
97
75
0112D
1,156
165
T25
558
108
8?
0176
60
28
TT
"W
"15
T3T
0256A
414
8*
87
2 98
58
55
0256B
423
9T
88
300
59
46
0432A
2,088
235
m
781
154
120
0432B
1,686
TOT
rsr
687
T3T
106
0476A
127

~3J
146
29 ,
22
0528A
2, 577
266
2ro
187
17*
lis
058OC
45
~7T
18
78
12
15
0584 E
4,458
37IT
m
1232
243
189
0684 C
1,014
152
m
~!5T
TOT
^8
0792C
486
Tff

.326
64
50
08560
9,650
588
427
1957
38?
3or
0856r
2,560
265
199
883
174
136
0856V
339

"57
262
52

0846B
2,166
240
1ST
799
158
123
0868A
3,525
322
m
15TO
ITT
TO
0948C
5,844
436
337
1449
387
222
In Place
3,344
826
676
864
174
1S6
68
1,466
362
230
266
41
1,942
266
514
0
1,483
59
1,260
1,686
2,284
17,967
Eeqiilted
638
0
244
163
0
399
495
0
929
44
1,397
105
370
685
98
3,674
174
433
240
322
436
10,848
Total
3,982
826
920
1,029
174
555
563
1,466
1,291
274
1,663
146
2,312
951
612
3, 674
1,657
492
1,500
2,008
2,720
28,815
SOTEl Underlined catta repreaent facilitiea in place, tfhere two figure* appear in the aaae column, the underlined
portion i* in place; the non-underlined portion meina to be inatalled.
KEY TO C&TT STEPS
Ai	Spent Acid Equalization
Br	FHS Racyclt
Ct	equalisation & Lis* Addition
Dj	polya«r Addition, Atratioa
It	Settling Bttin
386
-------
TABLE VIII-30
BPT CAPITAL COST TABULATION
Subcategory: Pickling - Sulfuric Acid
: Continuous Acid Recovery
: Carbon & Specialty
Basis: 7/1/78 Dollars x lO-3
: Facilities In Place as of 1/1/78
Plant
C&TT Step
Code
TPD
A
B
In Place
Required
Total
0384A
84
40
794
0
834
834
0432M
307
86
1727
86
1727
1813
0580
4

128
0
134
134
0760
482
113
2264
0
2377
2377
0792 B
480
113
2258
2258
113
2371
0856E
297
84
T55T
0
1777
1777




2344
6962
9306
MOTE: Underlined costs represent facilities in place. Where two figures appear in the
same column, the underlined portion is in place; the non-underlined portion remains
to be installed.
KEY TO C&TT STEPS
A: Spent Acid Storage System
B: Acid Recovery System
387
-------
TABLE VIII-31
BPT CAPITAL COST TABULATION
_3
Subcategory: Pickling - Hydrochloric Acid	Basis: 7/1/78 Dollars x 10
: Batch Neutralization	: Facilities In Place as of 1/1/78
: Carbon i Specialty
Plant		C&TT Step
Code
TPD
A
B
C .
D
E
F
G
H
In Place
Required
Total
0060L
0.4
1
2
9
2
I
2
5
7
2
27
29
0176
16
12
17
85
19
12
19
50
63
98
179
277
0384A
768
127
176
865
197
118
199
506
640
506
2322
2828
0580A
4
5
7
37
8
5
8
22
27
42
77
119
0864B
273
68
94
465
106
63
107
272
344
642
877
1519
1290*	3482*	4772*
*: Totals do not include confidential plants.
NOTE: Underlined costs represent facilities in place. Where two figures appear in the same column, the underlined
portion is in place; the non-underlined portion remains to be installed.
KEY TO C&TT STEPS
A:	Spent Acid Equalization
B:	FHS Recycle
C:	Equalization
D:	Lime Addition
E:	Polymer Addition
F:	Aeration
G:	Thickener
H:	Vacuum Filter
-------
TABIE VlII-32
BPT CAPITAL COST TABULATION
Subcategory:	Pickling - Hydrochloric Acid	B fit: 7/1/78 Dollar* x 10~*
!	Continuoua	: Facilities In Place aa of 1/1/78
:	Neutralixation
I	Carbon & Specialty
Plant



Coda
TPD
A
& "
• - ¦
¦
_

0020C
582
78
75
0060
8107
378
355
0060D
207
42
~~us
0112B
5592
302
297
01120
8517
389
375
0112H
40
16
15
0320
7075
348
337
0384A
3708
236
TTJ
0396D
1134
116
112
0432C
4452
264
75X
0432D
3678
235
277
0448A
2797
200
T5I
0580 A
4
4
4
0580C
18
10
9
0S80D
105
28
27
0580 E
90
25
25
0580 F
90
25
24
0584A
9948
427
412
0612
234
45
43
0684 F
4824
277
2S7
0856F
2388
182
175
0856S
24
11
IT
0860F
69
22
21
0864B
3492
228
ITS
0868A
1590
142
T37
09Z0A
3399
224
717
0920C
2446
184
178
092 0G
2133
170
T55
094 SA
2637
193
w
	 C&TT Step			
C	D	E	F	0	H	In Place	Required	Total
348	73	23	59	163	1 99	940	78	1,018
lW9	353	lTT	iBS	7BT	955	4,566	378	4,944
TIT	TT	H	TI	1	1JT	2U	281	547
1357	287	90	22 9	635	773	2,279	1,676	3,955
TTOJ	364	116	295	SI*	995	1,298	3,795	5,093
70	~T5	5	12	"3T	40	150	56	206
1557 325	10?	255	737	890	3,318	1,238	4,536
tots m	nr	m	m	604	497	2^94	3091
519	108	35	88	357	297	998	521	1,519
1177 244	2	2	2	67A	2>512	93a	3,450
TP5T	720	70	178	594	601	2,020	1,056	3,076
"S5I	186	W	T5T	ST5	510	186	2,424	2,610
18	T	1	3	8	10	34	18	52
53	9	3	7	2ff	25	9	117	126
124	2j	8	21	59	71	265	99	364
TTJ	3T	ff	17	53	65	24	307	331
113	25	8	19	53	65	24	307	331
1910	399	127	324	898	1092	1,424	4,165	5,589
201	H	^	115	160	588
1377	259	37	2TC	587	707	2,637	984	3,621
®	^	HE	464	1)729	646	1,375
TT	Tt	"J	-»	TJC	29	11	138	149
97	6	16	45	55	238	44	282
i22	52	SBT	2,172	811	2«983
125	rrr	®	w	363	1,355	505	1,860
lBBJ	TVS	67	TTff	V7T	373	1,321	1,613	2,934
2|2	In	2	|li	H	HI	2,225	184	2,409
12	15	£	12	S	*3*	1.616	604	2,220
861	ISO	57	146	405	492	1,835	193	2,028
36,377	25,930	62,307
NOTE) Underlined coat* repreaent tacllitiea in place. Vhiti two Ilgurea appear in the aaae coliaan, the underlined
portion ia in place) the now-underlined portion raaaina to be inatalled.
KEY TO CtTt STOPS
Ai	Spent Acid Equalization
B:	FH8 Recycle
Ci	Equalixation
Di	Line Addition
E:	Polymer Addition
Fi	Aeration
Gi	Thickener
Hi	Vacuua Filter
389
-------
TABLE VII1-33
BPT CAPITAL COST TABULATIOH
Subcategory: Pickling - Hydrochloric Acid	Basia: 7/1/78 Dollars x 10
:	Continuous	: Facilities In Place as of 1/1/78
t	Regeneration
:	Carbon 6 Specialty
Plant	¦	 ¦ CtrrStcpa
Code
TPD
A
B
t
D
E
F-
6
H
V
In Place
Required
Total
0068
193
40
896
39
195
20
12
37
100
49
0
1,388
1,388
0384A
2808
200
4466
193
973
99
60
184
500
244
500
6,419
6,919
05288
2196
173
3854
167
839
85
51
159
5JT
210
4,370
1,599
5,969
0580
125
31

30
150
15
9
28
17
38
0
1,068
1,068
0580B
105
28
622
27
135
14
8
26
69
34
0
963
963
0584C
3066
211
4708
203
1026
104
63
194
526
257
526
6,766
7,292
0584 F
8325
384
8572
370
1868
190
114
353
955
467
9,530
3,746
13,276
0684B
2733
197
5155"
190
957
97
59
181
m
240
491
6,315
6,806
06841
1377
130
2912
126
635
65
39
120
355
159
3,302
1,209
4, 511
0856P
17
9
209
9
45
~5
3
9
~T5
11
0
323
323
18,719* 29,796* 48,515*
*: Totals do not include confidential plants.
ROTE: Underlined costs represent facilities in place. Where two figures appear in the awe col tain, the underlined
portion is in place; the non-underlined portion mains to be installed.
EET TO CtIT STEPS
At	Spent Acid Storage
8:	Acid Regeneration Systea
Ct	FKS Recycle
D:	Equalisation
E:	Lime Addition
Ft	Polyaer Addition
Ct	Aeration
H:	Thickener
It	Vacuus Filter
-------
TABLE VtII-34
EPT CAPITAL COST TABULATION
BASIS: 7/1/78 DOLLARS x 10~3
: FACILITIES IN PUCE AS OF 1/1/78
Subcategory: Combination Acid Pickling
; Batch
: Carbon & Speciality
C&TT Step
Plant







In


Coda
TPD
A
B
-C-
D ~
8
P
Place
Requi red
Total
0020B
99
-
113
70
35
89
103
410
0
419
00601
117
-
TOT
W
ro
176
T55
259
322
581
0060 S
10
-
rr
TS
9
22
26
46
57
103
0060P
26
-
w
3T
16
40
46
121
62
183
0068
381
~
253
T57
79
T?9
232
0
920
920
0088A
72
-
93
58
29
73
85
338
0
338
0088C
546
-
m
TO
m
257
258
0
1142
1142
0088 D
52
-
77
48
24
60
70
125
154
279
0112A
1044
-
153
2SS
145
364
425
1685
0
1685
0112C
882
.
5T?
25ff
T3T
32?
335
1007
515
1522
0112H
552
-
m
TS5
99
259
290
761
389
1150
0176
728
113
m
231
117
235
342
1471
0
1471
0176C
23

vr
T9~
rr
rr
53"
0
171
171
01760
9
8
27
17
8
21
25
0
106
106
0248C
260
61
201
125
63
158
184
0
792
792
0248D
37
19
62
39
20
49
57
88
158
246
0248E
5
6
19
T7
6
13
17
0
75
75
0248?
1
2
7
4
2
6
7
10
18
28
0256P
30
17
55
%
17
53
50
166
50
216
0256H
0.3

r
T"
r
r
3
5
7
12
0256L
84
31
102

32
Bb
176
%
T75
127
VSl
0284A
177
48
160
95
35
146
275
354
629
0424
211
-
177
TTo
35
TO
163
343
303
646
0432E
15
11
vr
23"
IT
29
33
0
143
143
0440A
237
-
190
118
60
150
174
0
692
692
0476A
386
-
235
158
80
201
234
928
0
928
0496
411
80
m
165
53
20?
253
718
326
1044
0548A
63
-
86
17
33"
27
58"
79
207
106
313
05488
42
-
51
21
33
62
42
203
245
0580
45
-
70
55
22
55
64
0
255
255
0636
-
-
-
-
-
-
-
_
-
-
0684 P
96
19
145
90
46
115
133
0
548
548
0684 0
194
-
169
105
53
133
155
0
615
615
0684 V
194
51
169
105
53
133
155
0
666
666
391
-------
TABLE VIII-34
BPT CAPITAL 038T TABULATION ,
BASIS: 7 /I /7B DOLLARS * 10
: FACILITIES IS PLACE AS OP 1/1/78
PACE 2 	
C1TT Stap
Plant







In


Coda
IPC
A
¦ B ¦¦
0
D —

F
Placa
Kaqui rad
Total
0728
75
-
93
39
30
73
88
0
347
347
0776F
26
-
30
31
16
40
46
97
86
183
07760
3
-
T9
17
r
15
17
52
17
69
0776H
13
-
3J
JT
TO
TX
31
47
74
121
0776J
8
-
25
TS
8
OT
23
40
51
91
0792A
34
•
7f
V9
23
62
72
0
286
2S6
0856E
78
-
98
61
31
77
90
159
198
357
0856H
123
39
no
*r
41
102
119
313
199
512
0884 E
24
13
SB"
w
15
W-
44
45
145
190
0884 F
5
-
19
17
6
13
17
0
69
69
*ruTO~
~TOE"
•21586
*Total includes confidential plant*.
HOTS:
Underlined coat* represent facilities in-pi oca, what* two figures appesr in the saae colutn,
the underlined portion i» itr-placst tha new non-underlined portion raaaint to b* installed.
m to ott saps
At FH8 Xaeyela	D: Poljner Addition
Bt Equalisation with oil separation It Clarifier
Ci Lisa Addition	Pi Vacuus Filter
392
-------
TABLE VIII-35
BPT CAPITAL COST TABDLAIIOII
„-3
BASIS)
I
7/1/78 DOLLARS X 10
FACILITIES IN PLACE AS OP 1/1/78
Subcategory: Combination Acid Pickling
: Batch
< Carbon A Speciality
C6TT Stap
Plant
Coda
002 OB
0020C
0020L
0060
0060D
0060E
0112A
0112C
0176
0248B
02560
0284A
0432K
0432L
0648
0684 D
0860B
0860F
0948F
In
WD
534
906
386
308
1,833
100
96
131
128
1,877
577
161
739
34
129
1,083
390
45
82
• A"
B
C
. P
E
F
Placa
Raquired
Total
69
508
228
108
357
312
1,513
69
1,582
95
597
3T7
T59
5W
5T9
2, 078
95
2,173
57
517
TOT
8r
I9T
537
1,245
57
1,302
49
353"
m
n
T%
235
1,087
49
1,136
145
T7564
577
577
757
535
2,433
881
3,314
T5~
TBS
HI-
40
nr
114
254
325
579
25
181
ST
3?
157
111
543
25
568
29
OT
w
57
T35
T35
316
364
680
29
in
95
46
151
132
669
0
669
157
TvT79

270
TVS
663
3,362
0
3,362
rr
3*r-
m
TT3
375
317
798
859
1,657
35
247
ITT
33"
T75
152
585
186
771
85
vn
m
m
441
385
722
1,231
1,953
13
97
53"
21
sr
60
0
302
302
29
216
97
46
152
133
97
576
673
105
776
358
165
54
477
545
1,871
2,416
57
420
189
89
295
258
0
1,308
1,308
16
115
52
25
81
71
319
41
360
22
1ST
75
35
TO
TO
22
491
513
IP.M8 17735"
25,318
NOTE!
Underlined coat* repreaent faeilitiaa in-place, where two figurea appaar in tha aaaa colunn,
tha undarlinad portion 1* in-plac«| tha new non-underlined portion raaaina to ba inatalled.
KEY TO Oil STEP 8
Al FIB Recycle	oi	Polymer Addition
Bt Equalisation with oil aaparation	Et	Clarifier
Cs Lisa Addition	ft	Vacuus Viltar
393
-------
TABLE VIII-36
BAT MODEL COST DATA! BASH 7/1/78 DOLLARS
Subcategory: Picklinf-Sulfuric Acid
: Batch
i Neutralisation
Modal Siae-TPD I 500
Oper. Days/Year t IOT
Turns/Day	i 3
Alternete 1
C&TT Step
G
Total
T	
	j	
ToEat
" J" ' ~
—r~
Total



1 1
	

	

Investment $ x 10 -
114
114
34
lit
226
1256
66
1436
Annual Coat $ x 10








Capital
4.9
4.9
1.5
5.1
11.4
54.0
2.8
61.7
Depreciation
11.4
11.4
3.4
11.8
26.6
125.6
6.6
143.6
Operation & Maintenance
4.0
4.0
1.2
4.1
7.3
44.0
2.3
50.3
Sludge Ditpoaal
•
-
-
-
-
1.8
-
1.8
Energy & Power
-
-
0.2
1.8
2.0
23.8
0.2
24.0
Replacement Parta
15.2
15.2
-
-
15.2
-
-
15.2
Chemical Coata
-
-
0.7
-
0.7
-
-
-
TOTAL
35.5
35.5
7.0
22.8
65.3
249.2
11.9
296.6
Effluent Quality'1}
BAT
Feed
Level

Flow, gal/ton
360

Suspended Solids
30

Oil & Graaae
10

Dissolved Iron
1.0

pK, Units
6-9
115
Arsenic
0.10
118
Cadmium
0.10
119
Chromium
0.10
120
Copper
0.10
122
Lead
0.10
124
Hiclcel
0.20
128
Zinc
0.10
(1)
All values are in ng/1 unless
70
30
10
1.0
6-9
0.10
0.10
0.10
0.10
0.10
0.20
0.10
70
15
s.o
1.0
6-9
0.10
0.10
0.10
0.10
0.10
0.10
0.10
KEY TO C4TT STEPS
Gi Caacada tin**
H. Sulfide Precipitation
Is Filtration
JI Evaporation Sy«ta
Ki Recycle 1001
394
-------
TABU VIII-37
BAT HODP. COST PAIAl BASIS 7/1/78 DOLLARS
Subcategory:
Pickling-Sulfuric Acid
Continuoua
Heutralixatiaa
Carbon & Specialty
Modal Siw-TPD i 1980
Opar. Daya/Yaar i "TOT
Turna/Day	J 3
Alternate 1
3-Alternate 1
C&TT Stap
"'33
InvifCaaat 9 x 10
Annual Coat $ x 10
Capital
Dapraci eti on
Operation i Maintenance
Sludga DUpo«al.,
Energy & fewar
Replacement Pacta
Chemical Coat
TOTAL
Effluent Quality'^
BAT
Feed
Laval

Vlou, gal/ton
250

Sua pe tided Soli da
30

Oil £ Graaae
10

Diaaolved Iron
1.0

PH
6-9
115
Araanic
0.10
118
Cedntiun
0.10
119
Chroniun
0.10
120
Coppar
0.10
122
Lead
0.10
124
Hickal
0.20
128
Zinc
0.10
""c
Total
x—
. ^ .
Total
J
K
Total
323
323
64
137
544
234.6
83
2752
13.9
13.9
2.8
6.7
23.4
100.9
3.6
118.4
32.3
32.3
6.4
15.7
54.4
234.6
8.3
275.2
11.3
11.3
2.2
5.5
19.0
82.1
2.9
96.3
-
-
-
-
-
4.3
-
4.3
-
-
0.3
2.2
2.5
58.2
0.3
58.5
42.8
42.8
-
-
42.8
-
-
42.8
-
—
1.4
-
1.4
-
-
-
100.3
100.3
13.1
30.1
143.5
480.1
15.1
595.5

55


55


0

30


15


.

10


5.0


-

1.0


1.0


-

6-9


6-9


-

0.10


0.10


-

0.10


0.10


.

0.10


0.10


-

0.10


0.10


-

0.10


0.10


_

0.20


0.10


.

0.10


0.10


-
(1) All valuaa ara in mg/1 unleae otherwiae noted.
«Y TO CtTT STEPS
as Caacade Rinae	j; Evaporation Syat«
Bt Sulfide Precipitation K: Recycle 100%
It 1 titration
395
-------
TABLE VIII-38
BAT HODEL COST DATA! BASIS 7/1/78 DOLLARS
Subcategory! Pickling-Hydrochloric Acid	Modal Size-TPD I 190
t Batch Neutralisation	Oper. Days/Yaar : TTO
I Carbon t Specialty	Turin/Day	i 2
2 Alternate 1 plua:
3 Alternate 1 pluai
CftTT Step
Inveataant $ x 10
-3
,-3
Annual Coat $ x 10
Capital
Depreciation
Operation t Maintenance
Sludge Diapoaal.t
Energy * Power11'
keplacaent Parta
Cheaical Coeta
TOTAL
Effluent Quality*4'
BAT
feed
Level

flow, gal/ton
560

Suapended Solida
30

Oil t Creeae
10

Diaaolved Iron
1.0

pB, Onita
6-9
23
Chlorofon
0.01
114
Antiaony
0.10
115
Araenic
0.10
US
Cadaiua
0.10
119
Chroaiua
0.10
120
Copper
0.10
122
Lead
0.10
124
Nickel
0.20
126
Silvar
0.10
128
Zinc
0.10
I
Total

K(1>
Total
iiii
M(l>
local
"






63
63
29
72
164
1292
58
U13
2.7
2.7
1.2
3.1
7.1
55.6
2.5
60.7
6.3
6.3
2.9
7.2
16.4
129.2
5.8
141.3
2.2
2.2
1.0
2.5
5.7
45.2
2.0
49.5

_
0.1
0.2
0.3
12.1
0.2<2>
12.1
8.3
8.3
-
-
8.3
-
-
S.3
-
-
0.2
-
0.2
-

-
19.5
19.5
5.4
13.0
38.0
242.1
10.3(2)
271.9

90


90


0

30


15


«•

10


5.0


_

1.0


1.0


•

6-9


6-9


•

0.01


0.01


.

0.10


0.10


_

0.10


0.10




0.10


0.10




0.10


0.10


•

0.10


0.10


•

0.10


0.10




0.20


0.10


•

0.10


0.10




0.10


0.10


•
(1)	Treatment componenta are uaed in tandea.
(2)	Total coat doea not include power, because a credit ia applied tor exiating proceaa water requirement!.
(3)	All valuta are in a(/l ualeaa otherwiaa noted.
KIT TO C4TT STEPS
II Caacade tinea	J> Sulfide Precipitation
Ki Filtration	Li Evaporation Syatan
Ki tecyele
396
-------
TABU VIII-39
BAT MODEL COST BAKU BASIS 7/1/78 DOLLARS
Subcategory! Pickling-Hydrochloric Acid Modal Size-TPD I 2760
1 Continuoua Neutralization	Oper. Daya/Year I 312
» Carbon & Specialty	Turna/Day	t 3
2 Alternate 1 pluai
3 Altarnata 1 pluai
C&TT Step
I
Total
£1

Total
slii

Total
Inveataant, $ x 10~?
293
293
24
153
470
2003
33
2329
Annual Coat t * 10~








Capital
12.6
12.6
1.0
6.6
20.2
86.1
1.4
100.1
Depreciation
29.3
29.3
2.4
15.3
47.0
200.3
3.3
232.9
Operation i Maintenance
10.3
10.3
0.8
5.4
16.3
70.1
1.2
81.5
Sludge Diapoaal,.
Energy t Power

.
0.1
0.6
0.7
122.6
1>>
123.6
Replacement Parti
38.9
38.9
-
-
38.9
-
-
38.9
Cheaical Coata
**
*"
1.0
-
1.0
-
•
-
TOTAL
91.1
91.1
5.3
27.9
124.3 •
479.1
6.9<2)
577.0
Effluent Quality'4^
BAT
Peed
Lave!

Plow, gal/ton
320

Suapended Sot Ida
30

Oil & Creaaa
10

Diaaolved Iron
1.0

pHi Oniti
6-9
23
Chi orof on
0.01
114
Antiaony
0.10
115
Araenic
0.10
118
Cadaiua
0.10
119
Chroaiiai
0.10
120
Copper
0.10
122
Lead
0.10
124
Hickel
0.20
126
Silver
0.10
128
Zinc
0.10
35
30
10
1.0
6-9
0.01
0.10
0.10
0.10
0.10
0.10
0.10
0.20
0.10
0.10
35
13
5.0
1.0
«-»
0.01
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
(1)	Treataant coaponanta are uaed in tandea.
(2)	Total coat doea not include povtr, becauaa a credit i« applied for (xiating procaaa water requiraaenta.
(3)	All valuaa are in ag/1 unle»» otherviae noted.
til TO CtTT STEP8
Ii Caacade tinaa	Jt Sulfide Precipitation
K: Filtration	Li Evaporation
Ml Recycle
397
-------
TABLE VIII-40
BAT MP DEL COST DATA! BA8I3 7/1/78 DOLLARS
Subcategory! Pickling-Hydrochloric Acid	Model Siie-TPD : 2760
i Continuoua-Acid Neutralization Oper, Daya/Year : 312
I Carbon & Specialty	Turns/Day	i 3
2 Alternate 1 pluai
3 Alternate 1 pluai
-3
-3
C&TT Step
Inveatment, | i 10
Annual Coat j i 10
Capital
Depreciation
Operation 6 Maintenance
Sludge Diapoaal.s
Energy & power
Replacement Parte
Chemical Coeta
TOTAL
(4)
Effluent Quality
BAT
Feed
Level

Flow, gal/ton
430

Suapended Solid*
30

Oil fc Greaae
10

Diaaolved Iron
1.0

pB, Unit*
6-9
23
Chloroform
0.01
114
Antimony
0.10
US
Araenic
0.10
118
Cadmium
0.10
119
Chromiia
0.10
120
Coppar
0.10
122
Lead
0.10
124
Wickal
0.20
126
Silver
0.10
128
Zinc
0.10
I
Total
Jlii

Total

Mu>
Total
339
339
31
192
562
2398
40
2877
14.6
14.6
1.3
8.3
24.2
115.7
1.7
123.7
33.9
33.9
3.1
19.2
56.2
249.8
4.0
287.7
11.9
11.9
1.1
6.7
19.7
87.4
1.4
100.7
_
_
0.2
1.0
1.2
191.3
1.8<2)
191.3
45.0
43.0
-
-
45.0
-
-
45*0
-
-
1.3
-
l.S
-
-
-
105.4
105.4
7.2
35.2
147.8
644.2
7.1
748.4

70


70


0

30


15


•

10


5.0


-

1.0


1.0


•

6-9


6-9


-

0.01


0.01


•

0.10


0.10


•

0.10


0.10


-

0.10


0.10


-

0.10


0.10


-

0.10


0.10


-

0.10


0.10


•

0.20


0.10


-

0.10


0.10


•

0.10


0.10


-
(1)	Treatment component* are uaed in tandem.
(2)	Total coat do** not include power, becauae a credit ia applied for axiating procaaa water requirementa.
(3)	All value* are in ag/1 unleia otherwiie noted.
PT TO C&TT STEPS
Ii Caacade Rinae
K> Filtration
Hi Recycle
Ji Sulfide Precipitation
Lt Evaporation
398
-------
TABU VIII-41
IAI HODEL COST DATA; BASH 7/1/76 DOLLARS
Subcategory! Combination Acid Pickling	Modal Siae-TPD	: 200
I Batch	Oper. Days/Year : 260
I Carbon A Specialty	Turn»/Day	i 	2
CATT Stap
-3
-3
Inveataent, $ x 10
Annual Coit 9 x 10
Capital
Depreciation
Oparation A Maintenance
Sludge Diapoaal,.
Enargy A Power
Chemical Coata
Replaceable Coata
TOTAL
1

2-Altarnate 1
plua:
3-Alternate 1
plus:
c
Total
H
1
Total
J
K
To tal
69
69
23
97
191
1467
24
1559
3.0
3.0
1.1
4.2
8.2
63.1
1.0
67.0
6.9
6.9
2.5
9.7
19.1
146.7
2.4
155.9
2. A
2.*
0.9
3.4
6.7
51.3
0.8
54.6
-
-
0.1
0.2
0.3
13.7
0.2<2)
13.8
9.1
9.1
0.1
-
9.1
-
-
-

-
-
-
1.5
-

9.1
21 .A
21.A
A.7
17.5
43.5
274.8
4.2<2>
300.4

BAT



Effluent Quality'3'
Feed



Laval



Flow, gal/ton
545
10}
105
0
Suapended Solida
30
10
15
-
Oil A Create
2.0
2.0
2.0
-
Fluoride
15
15
15
-
Diaaolvad Iron
1.0
1.0
1.0
-
pH, Unite
4-9
6-9
6-9
-
120 Coppe r
0.10
0.10
0.10
-
119 Chroaiiia
0.10
0.10
0.10
-
124 Nickel
0.20
0.20
0.10
-
115 Araenic
0.10
0.10
0.10
-
122 Lead
0.10
0.10
0.10
-
128 Zinc
0.10
0.10
0.10
-
(1)	Coata are all power unleea otherviaa notad.
(2)	Total coat doea not include power, bacauae a credit ia applied for exiating proceea water requireaenta.
(3)	All valuaa are in ag/1 unlaaa otherwiaa noted.
REV TO art STEPS
Gi Caacade kinaa	Jj Evaporation
Hi Sulfide Precipitation Ri Recycle
li filtration
399
-------
TABLE VIII-42
BAT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory: Combination Acid Pickling	Model Size-TPD : 500
: Continuous	Oper. Days/Year : 320
: Carbon & Specialty	Turns/Day	: 3



1
2-Alternate 1
plus:
3-Alternate 1
plus:
C&TT Step

G

Total
H
t
Total
J
K
To tal
-3
Investment, $ x iO -

142

142
41
191
374
2473
38
2653
Annual Cox $ x 10










Capital

6.
.1
6.1
1.8
8.2
16.1
106.3
1.6
1K.0
Depreciation

14,
.2
14.2
4.1
19.1
37.4
247.3
3.8
265.3
Operation 6 Maintenance

5.
,0
5.0
1.4
6.7
13.1
86.6
1.3
92.9
Sludge Disposal.,

-

-
-
-
-
-
(?)
-
Energy i Power

-

-
0.2
0.9
1.1
122.3
0.7UJ
122.3
Chemical Coat*

-

-
0.9
-
0.9
-
-
-
Replacement Parts

18.
8
18.8
-
-
18.8
-
-
18.8
TOTAL

44,
.1
44.1
8.4
34.9
87.4
562 5
6.7<2>
613.3

BAT









Effluent Quality''*'
Peed
Level









Flow, gal/ton
1865


335


335


0
Suspended Solids
30


30


15


-
Oil & Grease
2.0


2.0


2.0


-
Fluoride
15


15


15


-
Dissolved Iron
1.0


1.0


1.0


-
pH, Units
6-9


6-9


6-9


-
4 Benzene
0.05


0.05


0.025


-
115 Arsenic
0.10


o. «¦


0.10


-
119 Chromium
0.10


0.10


0.10


-
120 Copper
0.10


0.10


0.10


-
122 Lead
0.10


0.10


0.10


-
124 Nickel
0.20


0.20


0.10



128 Zinc
0.10


0.10


0.10



(1)	Coats are all power unless otherwise noted.
(2)	Total coat does not include power, because a credit is applied for existing process water requirements*
(3)	All values are in ng/l unless otherwise noted.
KEY TO C&TT STEPS
G: Cascade Rinse	J: Evaporation
Us Sulfide Precipitation K: Recycle
It Filtration
400
-------
TABLE VIII-43
RESULTS OF BCT COST TEST
SULFURIC ACID PICKLING SUBCATEGORY
(Neutralization Systems Only)
A. Batch Type
BCT-1: lbs/year removed ¦ 29,383
Cost of BCT-1* » $35,500	$/lb -1.74	FAIL
*Include8 the cost of all BAT components
BCT-2: lbs/year removed ¦ 21,901
Cost of BCT-2* - $58,300	$/lb » 2.66 FAIL
*Includes the cost of all BAT	components except ———
sulfide precipitation.
B. Conti nuous Type
BCT-1s lbs/year removed » 48,485
Cost of BCT-1* ¦ $100,300	$/lb - 2.07	FAIL
~Includes the cost of all BAT components.	'
BCT-2 lbs/year removed ¦ 53,256
Cost of BCT-2* - $130,400	$/lb - 2.45 FAIL
~Includes the cost of all BAT	components except ——
sulfide precipitation.
401
-------
TABLE VIII-44
RESULTS OP BCT COST TEST
HYDROCHLORIC ACID PICKLING SUBCATEGORY
(Neutralization Systems)
A. Batch Type
BCT-1: lbs/year removed =5,420
Cost of BCT-1* » $19,500	$/lb =3.60	FAIL
~Includes the cost of all BAT components
BCT-2S lbs/year removed ¦ 6,160
Cost of BCT-2* - $32,500	$/lb ¦ 5.28	FAIL
~Includes the cost of all BAT components except
the sulfide precipitation.
B. Continuous Type
BCT-1: lbs/year removed » 126,460
Cost of BCT-1* - $ 91,100 $/lb - 0.72	PASS
~Includes the cost of all BAT components
BCT-2 lbs/year removed » 134,268
Cost of BCT-2* - $119,000 $/lb -0.88	PASS
~Includes the cost of all BAT components except
the sulfide precipitation.
402
-------
TABLE VII1-45
RESULTS OF BCT COST TEST
HYDROCHLORIC ACID PICKLING SUBCATEGORY
(Acid Regeneration System Continuous Pickling Lines Only)
A. Bat ch Type
BCT-1: lbs/year removed ¦ 173,819
Cost of BCT-1* - $105,400 $/lb -0.61	PASS
~Includes the cost of all BAT components
BCF-2 lbs/year removed » 183 , 707
Cost of BCT-2* - $140,600 $/lb -0.76	PASS
~Includes the cost of all BAT components except
the sulfide precipitation.
403
-------
TABLE VIII-46
RESULTS OF BCT COST TEST
SULFURIC ACID PICKLING SUBDIVISION
A. Batch Type
BCT-1: lbs/year removed = 8,804
Cost of BCT-1* - $21,400	$/lb « 2.43	FAIL
~Includes the cost of all BAT components
BCT-2: lbs/year removed * 9,714
Cost of BCT-2* - $38,900	$/lb - 4.00	FAIL
*Include8 the cost of all BAT components except
sulfide precipitation.
B. Conti nuous Type
BCT-1: lbs/year removed » 28,556
Cost of BCT-1* - $44,100	$/lb - 1.54	FAIL
*Include8 the cost of all BAT components.
BCT-2 lbs/year removed ¦ 37,630
Cost of BCT-2* - $79,000	$/lb - 2.10	FAIL
~Includes the cost of all BAT components except
sulfide precipitation.
404
-------
TABLE VIII-47
USPS MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory: Pickling-Sulfuric Acid Model Size-TPD : 500
: Batch Oper. Days/Year: 260
: Carbon & Specialty	Turns/Day	: 	3
cvrr step



A
B
Total
Investment $ x 10 -



119
1457
1576
Annual Cose $ x 10






Capital



5.1
62.7
67.8
Depreciation



11 .9
145.7
157.6
Operation & Maintenance



4.2
51.0
55.2
Crystal Disposal



-
27.8
23.8
Energy & Power



-
48.5
48.5
TOTAL



21.2
331.7
352.9
Less Credit






Acid Recovery



-
19.3
19.3
NET ANNUAL COST



21.2
312.4
333.6


Raw Waste Levels


NSPS
Effluent Quality^
Cone
Rinse
FHS
Total'
Total
Effluent
Level
Flow, gal/ton
20
330
710
1060
70
0
Suspended Solids
870
420
70
195
2940
-
Oil & Grease
150
65
4.5
26
395
-
Dissolved Iron
56,000
54,000
130
2800
42,800
-
pK, Units
<1-2
1-&
1.4-1.9
<1-6
<1-6
-
115 Arsenic
0.20
0.40
-
0.40
2.5
-
118 Cadniun
0.80
0.80
-
0.80
4.0
-
119 Chromiisn
240
5.1
-
18.5
95
•
120 Copper
3.7
1.2
-
1.3
6.7
-
122 Lead
0.80
0.30
-
0.50
1.4
-
124 Nickel
25
2.0
-
3.3
17
-
128 Zinc
75
21
-
24
120
-
(1)	Step A costs and loada attributable to apent concentrates only.
(2)	All values are in ag/1 unless otherwise noted.
(3)	Concentrationa and flow values represent cosiposite averages of concentrates, rinses, end FHS streams.
(4)	Concentrations and Clow values represent composite averages of concentrates, rinses after cascade
rinse, and FHS blovdown streets.
KEY TO C4TT STEPS
A: Spent Acid Storage Systsn B: Acid Recovery System
405
-------
TABLE VIII-48
USPS MODEL COST DAIAi BASIS 7/1/78 DOLLARS
Subcategory:
Pickling-Sulfuric Acid
Continuous
Carbon & Specialty
Model Si»e-TPD
Oper. Daya/Year
Turns/Day
1980
260
3
C&TT step



A<»
B
Total
-3
Investment $ * 10 ,



264
4034
4298
Annual Cost $ x 10






Capital



11.3
173.5
184.8
Depreciation



26.4
403.4
429.8
Operation i Maintenance



9.2
141.2
150.4
Crystal Disposal



-
128.7
128.7
Energy & Power



-
123.8
123.8
TOTAL



46.9
970.6
1017.5
Less Credit






Acid Recovery



-
260.6
260.6
NET ANNUAL COST



46.9
710.0
756.9



Raw Waste Levels


NSPS
Effluent Quality'2'
Cone
Rinse
FHS
Total(3)
Total(4)
Ef£lu«ut
Ltvel
Flow, gal/ton
20
220
130
370
55
0
Suspended Solids
2600
120
70
236
1590
-
Oil & Greaae
18
12
4.5
10
65
-
Diseolved Iron
45,000
6100
130
6100
41,100
-
pH, Units
<1
2-6
1.4-1.9
<1-6
<1-6
-
US Arsenic
0.20
0.07
-
0.10
0.35
-
118 Cadmium
0.50
0.10
-
0.10
0.60
-
119 Chromium
30
0.70
-
3.1
14
-
120 Copper
3.0
0.90
-
l.l
4.7
-
122 Lead
1.6
0.35
-
0.45
2.0
-
124 Nickel
21
4.6
-
6.0
26
-
128 Zinc
3.0
0.65
-
0.85
3.7
-
CI) Step A costs and loads attributable to spent concentrates only.
(2)	All values are in mg/1 unless otherwise noted.
(3)	Concentrations and flow values represent composite averages of concentratea, rinses, and FHS strea
(4)	Concentrations and flow values represent composite averages of concentrates, rinses after cascade
rinse, end FHS blovdown stream.
KEY TO CiTT STEPS
Ai Spent Acid Storage System	B: Acid Recovery System
406
-------
TABLE VII1-49
MSPS, PSES AMD PSNS MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory: Hydrochloric Acid Pickling Model Site-TPD : 190
: Batch Neutralization Oper. Days/Year: 260
: Carbon and Specialty	Turns/Day	: 	2
O
TOTAL
Alternative No. 1
Alternative No. 2
9.8
13.6
(2)
24.6
10.7
30.2
10.8 4.9
12.9 18.0
136.1








H(l)
ill!



Total
C6TT Steps
A
B
C
D
E
F
G
Total
Unci. A-J)
Investment $ x 10 ^
55
76
79
60
116
57
26
72
91
63 2
29
72
733
Annual Cost $ x 10













Capital
2.4
3.3
3.4
2.6
5.0
2.5
1.1
3.1
3.9
27.2
1.2
3.1
31.5
Depreciation
5.5
7.6
7.9
6.0
11.6
5.7
2.6
7.2
9.1
63.2
2.9
7.2
73.3
Operation and Maintenance
1.9
2.7
2.8
2.1
4.1
2.0
0.9
2.5
3.2
22.1
1.0
2.5
25.6
Sludge Disposal
-
(?\
-
-
-
-
-
-
1.7
1 7
-
-
17
Energy and Power
-
0.6
-
-
0.4
0.3
0.3
0.1
0.1
1.2
0.1
0.2
1.5
Cheaical Costs
-
-
-
-
9.1
0.3
-
-
-
10.2
0.2
-
L0.4
Replacement Parts
-
-
10.5
-
-
-
-
-
-
10.5
-
-
10.5
5.4 13.0 1154.5
-------
TABLE V1I1-49
NSPS, PSES AND PSNS MODEL COST DATA: BASIS 7/1/78 DOLLARS
hydrochloric acid pickling
PAGE 2
Effluent Quality
(3)
Cone
Raw Haste Level
Rinse FHS
Total
(4)
Total
(5)
Alt. Ho. 1
Effluent Level
PSES No. 1
Effluent Level
O
CD

Flow, gal/ton
10
540
150
700
90
90
90

Total Suspended Solids
450
90
370
155
1200
30
15

Oil & Grease
44
33
66
40
310
10
5.0

Dissolved Iron
57,000
2700
820
3100
24,000
1.0
1.0

pH (Units)
<1-5
1-5
<1-3.7
<1-5
<1-5
6-9
6-9
23
Chloroform
0.03
0.01
0.10
0.03
0.25
0.01
0.01
114
Antimony
2.2
0.01
0.40
0.10
1.0
0.10
0.10
115
Arsenic
0.20
0.09
0.05
0.10
0.65
0.10
0.10
118
Cadnium
0.20
0.04
0.06
0.10
0.35
0.10
0.10
119
Chromium
13
0.35
0.35
0.50
4.1
0.10
0.10
120
Copper
13
0.60
0.80
0.80
6.4
0.10
0.10
122
Lead
310
18
0.30
18.35
145
0.10
0.10
124
Nickel
10
0.50
0.55
0.60
5.0
0.20
0.10
126
Silver
0.20
0.06
0.10
0.10
0.55
0.10
0.10
128
Zinc
15
146
0.65
113
880
0.10
0.10
(1)	Treatment components are used in tandem.
(2)	Total cost does not include power, because a credit is applied for existing process water requirements.
(3)	All values are in ng/1 unless otherwise noted.
(4)	All values are once-through concentrations.
(5> Concentrations and flow values represent composite averages of concentrates, rinses after cascade
rinse, and FHS blowdown stream.
KEY TO C&TT STEPS
A:	Spent Acid Equalization System
B:	FHS Recycle
C:	Cascade Rinse
D:	Equalization
E:	Lime Addition
F:	Polymer Addition
G: Aeration
H:	Clarifier
I: Vacuum Filter
J: Sulfide Precipitation
K: Filtration
-------
TABU VIII-50
USPS, PSES AHD P3NS MODEL COST DATA:	BASIS 7/1/78 DOLLARS
Subcategory: Hydrochloric Acid Pickling	Model Sise-TPD : 2760
: Continuous-Neutraliration	Oper. Days/Tear: 312
t Carbon and Specialty	Turns/Day : 3
Alternative No. l	Alternative No. 2
C&TT Steps
A
B
C
D
E
F
<5
HW
I<3)
Total

k(3>
Total
(Incl. A-l)
_3
Investment $ * 10
154
191
394
349
86
47
81
204
258
1764
24
153
1941
Annual Coat $ x 10













Capital
6.6
8.2
16.9
15.0
3.7
2.0
3.5
8.8
11.1
75.8
1.0
6.6
83.4
Depreciation
15.4
19.1
39.4
34.9
8.6
4.7
8.1
20.4
25.8
176.4
2.4
15.3
194.1
Operation and Maintenance
5.4
6.7
13.8
12.2
3.0
1.6
2.8
7.1
9.0
61.6
0.8
5.4
67.8
Sludge Disposal ...
Energy and Power
-
" (2)
-
-
-
-
-
-
94.2
94.2
-
-
94.2
-
10.5* Z'
-
0.9
5.8
1.1
0.7
7.6
7.6
23.7
0.1
0.6
24.4
Qieaical Coat*
-
-
-
-
77.0
12.6
-
-
-
89.6
1.0
-
90.6
Replacement Part a
-
~ {2}
52.3
-
-
-
-
-
-
52.3
-
-
52.3
TOTAL
27.4
34.0
122.4
63.0
98.1
22.0
15.1
43.9
147.7
573.6
5.3
27.9
606.8
4*
O
U>
-------
TABLE VIII-50
NSPS, PSES AND PSNS MODEL QOST DATA: BASIS 7/1/78 DOLLARS
HYDROCHLORIC ACID PICKLING
PAGE 2		
Raw Waste level
O
(4)
Effluent Quality
Cone
Rinse
FHSU)
Total
Total

Flow, gal/ton
10
300
180
490
55

Total Suspended Solids
450
90
370
200
1780

Oil & Grease
44
33
66
45
400

Dissolved Iron
57,000
2700
870
3100
28,000

pH, Units
<1-5
1-5
<1-3.7
<1-5
<1-5
23
Chi or of orm
0.03
0.01
0.10
0.04
0.40
114
Antimony
2.2
0.01
0.40
0.20
1.8
115
Arsenic
0.20
0.09
0.05
0.10
0.70
118
Cadmium
0.20
0.04
0.06
0.10
0.45
119
Chromium
13
0.35
0.35
0.60
5.4
120
Copper
13
0.60
0.80
1.0
8.3
122
Lead
310
18
0.30
17.5
155
124
Nickel
10
0.50
0.55
0.70
6.4
126
Silver
0.20
0.06
0.10
0.10
0.70
128
Zinc
15
146
0.65
90
800
Alt. Ho. 1
Effluent Level
55
30
10
1.0
6-9
0.01
0.10
0.10
0.10
0.10
0.10
0.10
0.20
0.10
0.10
(1)	Treatment components are used in tandem.
(2)	Total cost does not include power, because a credit is applied for existing process water needs.
(3)	All values are in mg/1 unless otherwise noted.
(4)	All values are once-through concentrations.
(5)	Concentrations and flow values represent coaposite averages of concentrates, rinses after cascade
rinse, and fuse hood scrubber blow down stream.
Alt. No. 2
Effluent Level
55
15
5.0
1.0
6-9
0.01
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
1ST TO C6TT STEPS
A:	Spent Acid Equalization System
B:	FHS Recycle
C:	Caacade Rinse
Dt	Equalisation
E:	Lime Addition
F:	Polymer Addition
G:	Aeration
H: Clarifier
I: Vacuum Filter
J: Sulfide Precipitation
Ks	Filtration
-------
TABLE VIII-51
USPS, PSES AHD P3HS MODEL COST OAIA:	BASIS 7/1/76 DOLLARS
Subcategory: Hydrochloric Acid Pickling	Model Sire-TPD :
: Continuous-Acid Regeneration	Oper. Days/Tear;
: Carbon and Specialty	Turns/Day :
Alternative Not 1
Alternative No. 2
C4TT Step
A
B
C
D
E
r
G
H<1)
i—
Total
Investment $ * 10 'j
198
4814
191
406
77
46
94
237
300
6363
Annual Cost $ * 10










Capital
8.5
207.0
8.2
17.5
3.3
2.0
4.0
10.2
12.9
273.6
Depreciation
19.8
481.4
19.1
40.6
7.7
4.6
9.4
23.7
30.0
636.3
Operation and Maintenance
6.9
168.5
6.7
14.2
2.7
1.6
3.3
8.3
10.5
227.7
Sludge Disposal ...
Energy and Power
-
-
" M)
-
-
-
-
-
109.5
109.5
-
307.3
10.5"'
1.0
5.5
1.0
0.9
8.8
8.9
333.4
Cbeaical Costs
-
-
-
-
72.0
12.0
-
-
-
84.0
Replacement Parts
-
52.3
-
-
-
-
-
-
-
52.3
TOTAL
35.2
1216.5
34.0<2)
73.3
91.2
21.2
17.6
51.0
171.8
1716.8
Less Credits










Acid Recovery

2304.6







2304.6
Iron Oxide Recovery

1543.6

73.3
91.2
21.2
17.6
51.0
171.8
1543.6
Met Annual Cost
35.2
-2631.7
34.0






-2131.4
(l) ^U)
192
J	
31
1.3
3.1
1.1
0.2
1.5
7.2
8.3
19.2
6.7
1.0
Total
(Incl. A-I)
6586
283.2
658.6
230.5
109.5
334.6
85.5
52.3
7.2 35.2 1754.2
2304.6
35.2 1543.6
-2094.0
-------
TABLE VIII-51
USPS, PSES AMD PSNS MODEL COST DATA: BASIS 7/1/78 DOLLARS
HYDROCHLORIC ACID PICKLING
PAGE 2
Waste Level
...	Alt. No. 1	Alt. »o. 2
Effluent Quality
Cone
Rinse
FHS
AVS
Total -
Total
Effluent Level
Effluent Level

Flow, gal/ton
10
300
180
120
610
70
70
70

Total Suspended Solids
450
90
370
90
180
1560
30
15

Oil & Grease
44
33
66
2
37
320
10
5.0

Dissolved Iron
57,000
2700
820
650
2630
23,000
1.0
1.0

pH (Units)
<1-5
1-5
<1-3.7
<1-7.6
<1-7.6
<1-7.6
6-9
6-9
23
Chi orof on
0.03
0.01
0.10
0.02
0.04
0.35
0.01
0.01
114
Antiaony
2.2
0.01
0.40
0.20
0.20
1.7
0.10
0.10
115
Arsenic
0.20
0.09
0.05
0.02
0.10
0.60
0.10
0.10
118
CaAaiun
0.20
0.04
0.06
-
0.10
0.35
0.10
0.10
119
Chroai.ua
13
0.35
0. 35
0.02
0.50
4.3
0.10
0.10
120
Copper
13
0.60
0.80
0.80
0.90
7.9
0.10
0.10
122
Lead
310
18
0.30
1.0
14
125
0.10
0.10
1Z4
Nickel
10
0.50
0.55
0.35
0.65
5.6
0.20
0.10
126
Silver
0.20
0.06
0.10
0.10
0.10
0.70
0.10
0.10
128
Zinc
15
146
0.65
1.0
73
630
0.10
0.10
(1)	Treat*ent coaponents are used in tandem.
(2)	Total coat does not include power, because a credit is applied for existing process water needs.
(3)	All values are in ag/1 unless otherwise noted.
(4)	All values are once-through concentrations.
(5)	Concentrations and flow values represent composite averages of concentrates, rinses after cascade
rinse, and f we hood scrubber blow down streams.
KEY TO C6TT STEPS
A:
Spent Acid Equalisation Systea
F:
Polyaer Addition
B:
Acid Regeneration Systea
G:
Aeration
C:
FHS Recycle, Cascade Rinse
H:
Clarifier
D:
Equalisation
I:
Vacuus Filter
E:
Liae Addition
J:
Sulfide Precipitation


Ks
Filtration
-------
TABLE VIII-52
USPS Ir fSH3 Maoa. CQST DAIAiBASIS 7/1/78 DOLLARS
Subcategory: Combination Acid Pickling	Model Sise-TPD : 200
: Batch	Oper. Days/Tear: 260
: Carbon-Specialty	Turns/Day : 2
Alternative Ho. 1	Alternative Ho. 2
CSTT Steps
A
B
C-
D
E

•J?
Total
H
I
Total (Includes A-G)
Invests ant $ x 10
63
82
41
79
39
49
62
415
34
84
533
Annual Coat $ x 10











Capital
2.7
3.5
1.8
3.4
1.7
2.1
2.7
17.8
1.5
3.6
22.9
Depreciation
6.3
8.2
4.1
7.9
3.9
4.9
6.2
41.5
3.4
8.4
53.3
Operation and Maintenance
2.2
2.9
1.4
2.8
1.4
1.7
2.2
14.5
1.2
2.9
18.7
Sludge Disposal ...
Energy and Power
~ (2)
-
-
-
-
-
1.2
1.2
-
-
1.2
0. 7
-
-
0.3
0.2
0.1
0.1
0.7
0.1
0.1
0.9
Chenical Costs
-
-
-
6.2
0.2
-
-
6.4
0.1
-
6.5
Kepiacenent Parts
-
10.8
-
-
-
-
-
10.8
-
-
10.8
TOTAL
11.2(2)
25.4
7.3
20.6
7.4
8.8
12.4
92.9
6.3
15.0
114.3
-------
TABUS VIII-52
USPS 4 PSNS MODEL COST DATA: BASIS 7/1/78 DOLLARS
ODMBIMATIOH ACID PICKLING
PAGE 2
Raw Haste Level
4*
Effluent Quality**-
Cone
Rinse
FHS(*>
Flow, gal/ton
15
200
1140
Suspended Solids
130
50
25
Oil ( Grease
0.40
4.6
0.30
Dissolved Iron
19,000
230
50
Fluoride
3900
430
1800
pH, Units
<1-2.3
2-4
1.5-2.0
115 Arsenic
-
0.10
-
119 Chroaitas
4300
48
2.4
120 Copper
230
1.3
-
122 Lead
2.7
0.07
-
124 Nickel
5800
53
3.3
128 Zinc
1.7
1.0
0.30
Total(5) Total(6>
1355
30
1.0
290
1620
<1—4
0.10
55
17
0.25
75
0.60
45
900
28
8620
48,800
<1-4
0.10
1700
82
1.2
2250
18
Alt. Ho. 1
Effluent Level
45
30
10
1.0
15
6-9
0.10
0.10
0.10
0.10
0.20
0.10
(1)	Treatment components are used in tandesu
(2)	Total cost does not include power, because a credit is applied for existing process water needs.
(3)	All values are in «g/l unless otherwise noted.
(4)	All values are once-through concentrations.
(5)	All values are once-through concentrations.
(6)	Concentrations and flow values represent concentrates, rinses after cascade
rinse, and foe hood acrubber blow down streaas.
Alt. No. 2
Effluent Level
45
15
5.0
1.0
45
6-9
0.10
0.10
0.10
0.10
0.10
0.10
KEY TO C4TT STEPS
A:	FIB Recycle
Bt	Cascade Rinse
C:	Equalization Tank
Ds	lis* Addi ti on
E:	Polyner Addition
F:	Clarifier
G:	Vacuus Filter
H:	Sulfide Precipitation
I:	Filtration
-------
TABLE VIII-53
NSPSVPSNS MODEL COST DATA: BASIS 7/1/78 DOLLARS
CATT Steps
Investment $ x
Annual Cost $ x
10
10
3
-3
Replacement Parts
TOTAL
Subcategory
Combination Acid Pickling
Continuous
Carbon-Specialty
Model Siee-TPD : 500
Oper. Days/Year: 320
Turns/Day	: ?
Alternative No. 1
Alternative No. 2
A
59
B
142
C
96
D
102
E
52
F_
84
(3)
G_
81
(3)
Total
616
H
34
I
107
18.8
10.5(2) 44.1
17.1
26.9
10.7
18.8
15.2 16.3 140.9 6.6
19.3
Total (Includes A-G)
757
Capital
2.5
6.1
4.1
4.4
2.2
3.6
3.5
26.5
1.5
4.6
32.6
Depreciation
5.9
14.2
9.6
10.2
5.2
8.4
8.1
61.6
3.4
10.7
75.7
Operation and Maintenance
2.1
5.0
3.4
3.6
1.8
2.9
2.8
21.6
1.2
3.7
26.5
Sludge Disposal ...
Energy and Power
l.I(2)
-
-
-
-
-
1.3
1.3
-

1.3
-
-
0.5
0.3
0.3
0.6
1.7
0.2
0.3
2.2
Cheaical Costs
-
-
-
8.2
1.2
-
-
9.4
0.3
-
9.7
18.8
166.8
-------
TABLE VtlI-53
USPS 4 PSNS HODKL COST DATA: BASIS 7/1/78 DOLLAKS
OOMBIMXIOR ACID PICKLIHG
PAGE 2
Raw Waste Level*
Alt. Ho. 1	Alt. Mo. 2
Effluent Quality^	Cone	Rimt	FHS^^	Total^ Total^Effluent Level	Effluent Level
Flow, gal/ton	15	500	720	1235	90	90	90
Suspended Solids	200	180	25	90	1230	30	15
Oil & Grease	3.5	3.3	0.30	1.6	21	10	5.0
Dissolved Iron	23,000	155	2.4	345	4700	1.0	1.0
Fluoride	10,000	69	50	180	2450	15	15
pH (Onits)	1.5	2.5-8	1.5-2.0 1.5-8	1.5-8	6-9	6-9
4 Benzene	-	0.05	**	0.05	0.05	0.05	0.025
115 Arsenic	-	0.01 -	0.01	0.01	0.01	0.01
119	Chroaiua	3300	25	8.3	55	755	0.10	0.10
120	Copper	100	0.27	0.07	1.4	19	0.10	0.10
122 Lead	1.2	- -	1.2	1.2	0.10	0.10
124 Bickel	3300	15	1800	1100	15,000	0.20	0.10
128 Zinc	4.1	0.40	0.30	0.40	5.3	0.10	0.10
** Value is less than 0.010 ag/1.
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power, because a credit is supplied for existing process water requirements.
(3)	Treatment components are used in tandes.
(4)	All values are are in ag/1 unless otherwise noted.
(5)	All values are once-through concentrations.
(6)	Concentrations and flow values represent composite averages of concentrates, rinses after cascade
rinse, and fuse hood scrubber blow down strew.
KEY TO C6TT STEPS
A:	FBS Recycle
Bt	Cascade Rinse
Cl	Equalisation Tank
D:	Liae Addition
E:	Polyaer Addition
F:	Clarifier
G:	Vacuus Filter
H:	Sulfide Precipitation
I:	Filter
-------
TABLE VIII-54
tSBS MODEL COST DATA; BASIS 7/t/7B DOLLARS
Subcategory:
Pickling-Sulfuric Acid
Batch
Neutralization
Model Size-TPD :
Oper. Days/Year:
Turns/Day	:
500
m
Alternative No. 1
Alternative Ho. 2

CSTT Steps
A
B
C
D
E
r
<£1

Total

11
Total	
(Incl. A-B)
Investment $ x 10 '-
119
128
114
41
36
74
90
60
662
34
118
814
Annual Cost 9 x 10












Capi tal
5.1
5.5
4.9
1.8
1.5
3.2
3.9
2.6
28.5
1.5
5.1
35.0
Depreciation
11.9
12.8
11.4
4.1
3.6
7.4
9.0
6.0
66.2
3.4
11.8
81.4
Operation and Maintenance
4.2
4.5
4.0
1.4
1.3
2.6
3.2
2.1
23.2
1.2
4.1
28.5
Sludge Disposal , .
Energy and Power
-
"(7>
-
-
-
-
-
4.1
4.1
-
-
4.1
-
0.9 '
-
0.2
0.4
0.2
0.2
1.1
2.1
0.2
1.8
4.1
Cheaical Costs
-
1.2
-
-
16.2
2.6
-
-
20.0
0.7
-
20.7
Replaceaeot Parts
-
-
15.2
-
-
-
-
-
15.2
-
-
15.2
TOTAL
21.2
24.0(2)
35.5
7.5
23.0
16.0
16.3
15.9
159.3
7.0
22.8
189.0
-------
TABLE VIII-54
PSES MODEL COST DATA: BASIS 7/1/78 DOLLARS
PICKLING-SULFORIC ACID
PAGE 2
Raw Waste Level
Effluent Quality*
Cone
Rinse
FHS
Total
Total(

Flow, gal/ton
20
330
710
1060
70

Suspended Solids
870
420
70
195
2940

Oil & Grease
150
65
4.5
26
400

Dissolved Iron
56,000
5400
130
2800
42,800

pH, Units
<1
1-6
1.4-1.9
<1-6
1-6
115
Arsenic
0.20
0.40
-
0.40
1.9
118
Cadaiua
0.80
0.80
-
0.80
4.0
119
Chromium
240
5.1
-
18.5
93
120
Copper
3.7
1.2
-
1.3
6.7
122
Lead
0.80
0.30
-
0. 50
1.6
124
Nickel
25
2.0
-
3.3
16.5
128
Zinc
75
21
-
24
120
PSES No. 1
Effluent Level
70
30
10
1.0
6-9
0.10
0.10
0.10
0.10
0.10
0.20
0.10
PSES No. 2
Effluent Level
70
15
5.0
1.0
6-9
0.10
0.10
0.10
0.10
0.10
0.10
0.10
(1) Treatment components are used in tandem.
CO	(2) Total cost does not include power, because a credit is supplied for existing process water needs.
(3)	All values are in mg/1 unless otherwise noted.
(4)	All values are once-through concentrations.
(5)	Concentrations and flow values represent concentrates, rinses after cascade
rinse, and fuse hood scrubber blcwdovn streams.
KE* TO C&TT STEPS
A:	Spent Acid Equalization Systc
B:	FHS Recycle
C:	Cascade Rinse
D:	Equalization
E:	Line Addition
F:	Polymer Addition, Aeration
G:	Clarifier
H:	Vacuum Pilter
I:	Sulfide Precipitation
J:	Filter
-------
TABLE VIII-55
PSES MODEL COST DATA: BASIS 7/1/78 DOLLARS
yo
Subcategory:	Pickling-Sulfuric Acid
: Continuous
:	Neutralization
:	Carbon & Speciality
Model Size-TPD :
Oper. Days/Year:
Turns/Day	s
C4TT Stepa
Iineilaeat $ i 10 ^
Annual Cost $ * 10
Capital
Depreciation
Operation and Maintenance
Sludge Disposal
Energy and Power1
Cheaical Coats
Replacement Parts
TOTAL
.(1)
Alternative Ho. 1
A
264
11.3
26.4
9.2
B
171
7.3
17.1
6.0
2.4
2.0
(2)
46.9 32.4
(2)
C
323
13.9
32.3
11.3
42.8
100.3
D
287
12.3
28.7
10.0
0.3
E
68
2.9
6.8
2.4
1.6
104.4
P
105
4.5
10.5
3.7
0.4
10.4
51.3 118.1
(1)
C	
167
7.2
16.7
5.8
1.0
29.5 30.7
213
9.2
21.3
7.5
15.3
5.1
58.4
1980
—J
Total
1598
68.6
159.8
55.9
15.3
8.4
116.8
42.8
I
64
(1)
2.8
6.4
2.2
0.3
1.4
467.6 13.1
Alternative
j(P
157
6.7
15.7
5.5
2.2
30.1
Ho. 2
Total
(Incl. A-H)
1819
78.1
181.9
63.6
15.3
10.9
118.2
42.8
510.8
-------
TABU VIII-55
PS8S MODEL COST MTA: KASIS 7/1/78 DOLLARS
flCKLIKC-SOLFOSIC ACID
PAGE 2
Itr Vntc Level
Effluent Quality'3'
Cone
time
res
Total

Flow, gal/too
20
220
130
370

Suspended Solids
2600
120
70
236

Oil 4 Grease
18
12
4.5
10

Diaaolved Iron
45,000
6100
130
6100

pH, Unit*
<1
2-6
1.4-1.7
<1-6
US
Araenic
0.20
0.07
-
0.10
118
Cadaiua
0.50
0.10
-
0.10
119
Chroaiw
30
0.70
-
3.1
120
Copper
3.0
0.90
-
1.1
122
Lead
1.6
0.35
-
0.45
124
Rickel
21
4.6
-
6.0
128
Zinc
3.0
0.65
-
0.85
/C\
FSES Mo. 1
FSES Ho. 2
Total '
Effluent Level
Effluent Level
55
55
55
1590
30
15
65
10
5.0
41,000
1.0
1.0
<1-6
6-3
6-9
0.35
0.10
0.10
0.60
0.10
0.10
14
0.10
0.10
4.7
0.10
0.10
2.0
0.10
0.10
26
0.20
0.10
3.7
0.10
0.10
O
(1)	Treataent coaponenta are used in tandea.
(2)	Total coat does not include power, becauae a credit ia supplied for exiating process water needs.
(3)	All value* are in ag/1 unless otherwise noted.
(4)	All value* are once-through concentration*.
(5)	Concentration* and flow value* represent concentrate*, rinses after cascade
rinse, and fuse hood scrubber blowdovn itreaa*.
EET TO CMT STEPS
Ai	Spent Acid Equalisation Syatea
Bi	ns ftecycle
Ci	Caacade Kinae
D:	Bqual isation
Et	Liae Addition
F:	Foljnaer Addition, Aeration
G:	Clarifier
Bt	Vacuus Filter
It	Sulfide Precipitation
Jt	Filter
-------
TABLE VIII-56
PSES HP DEL POST DATA: BASIS 7/1/76 DOLLARS
Subcategory: Combination Acid Pickling	Model Size-TPD : 200
: Batch	Oper. Days/Year: 260
: Carbon and Specialty	Turns/Day	: 2
Alternative Ho. 1 	 2-Steps A to E of Alt. 1 plus:
C4TT Step*
A
B
C
D
E

£1
Total
H


Total
_3
Investment $ x 10 ^
63
69
68
85
39
69
79
472
23
25
97
469
Annual Coat $ s 10












Capital
2.7
3.0
2.9
3.7
1.7
3.0
3.4
20.3
1.0
1.1
4.2
20.2
Depreciation
6.3
6.9
6.8
8.5
3.9
6.9
7.9
47.2
2.3
2.5
9.7
46.9
Operation and Maintenance
2.2
2.4
2.4
3.0
1.4
2.4
2.8
16.5
0.8
0.9
3.4
16.4
Sludge Disposal ,
Energy and Power

-
-
-
-
-
1.7
1.7
1.7
-
-
1.7
0. 7
-
0.2
0.3
0.1
0.2
0.3
1.8
-
0.1
0.2
1.6
Cheaical Coats
-
-
-
6.1
0.5
-
-
6.6
-
0.1
-
6.6
Keplaeeaent Parts
-
9.1
-
-
-
-
-
9.1
-
-
-
9.1
TOTAL
11.2<2>
21.4
12.3
21.6
7.6
12.5
16.1
103.2
4.1
4.7
17.5
102.5
-------
TABU VIII-56
PSES MODEL COST DATA: BASIS 7/1/78 DOLLARS
OOHBIKATIOH ACID PICKLIHG
PAGE 2	- ¦¦


lw Waste Level


Effluent Quality*3*
Cone
Rinae
FHS
Total
Total((
Flow, gal/ton
15
520
1140
1675
105
Total Suspended Solida
130
50
25
34
540
Oil 6 Greaae
0.40
4.6
0.30
1.6
26
Dissolved Iron
19,000
230
50
275
4400
Fluoride
3900
430
1800
1400
22,200
pH (Units)
<1-2.3
2-4
1.5-2.0
<1-4
<1-4
115 Arsenic
-
0.10
-
0.10
0.10
119 Chroaiia
4300
48
2.4
55
880
120 Copper
230
1.3
-
7.7
39
122 Lead
2.7
0.07
-
0.10
0.75
124 Rickel
5800
53
3.3
71
1130
128 Zinc
17
1.0
0.30
0.70
U
PSES Ho. 1
Effluent Level
105
30
10
1.0
15
6-9
0.10
0.10
0.10
0.10
0.20
0.10
PSES No. 2
Effluent Level
105
15
5.0
1.0
15
6-9
0.10
0.10
0.10
0.10
0.10
0.10
		'
to
10 (1) All coats are power unleaa otherwise noted.
(2)	Total coat doea not include power, becauae a credit ia applied for exiating proceaa water requirenenta.
(3)	Treatment components are used in tandea.
(4)	All valuea are in ag/1 unlea a otherwiae noted.
(5)	Valuea are ooce-through concentrations.
(6)	Concentration and flow values represent composite averages of concentrate, rinse after cascade rinse,
and fuse hood acrubber blowdown atreaaa.
KET T0C4TT STEPS
At
FHS Recycle
Ft
Clarifier
Bl
C as cade Rime
Cs
Vacuua Filter
CI
Equalisation
H:
Settling Baain
Dt
Liae Addition
It
Sulfide Precipitation
Ei
Polyaer Addition
J:
Fil ter
-------
TABLE VII1-5 7
PSES MODEL COST DATA; BASIS 7/1/78 DOLLARS
Subcategory: Combination Acid Pickling Model Sire-TPD :	506
: Continuous Oper. Days/Tear:	320
: Carbon and Specialty Turns/Day :	3
N)
OJ
C&TT Steps
_3
Investment $ x 10
Annual Coat $ * 10
Capi tal
Depreciation
Operation and Maintenance
Sludge Disposal
Energy and Powerx
Cheaical Coata
Replacement Parta
TOTAL
.CD



Alternative Ho.
1


2-Steps A to E
of Ait. :
I plus:
A
B
C
D
E
f(3)

Total
H
l(3)
j(3)
Total
69
142
225
160
SB
135
203
982
105
41
191
981
2.5
6.1
9.7
6.9
2.5
5.8
8.7
42.2
4.5
1.8
8.2
42.2
5.9
14.2
22.5
16.0
5.8
13.5
20.3
98.2
10.5
4.1
19.1
98.1
2.1
5.0
7.9
5.6
2.0
4.7
7.1
34.4 ,
3.7
1.4
6.7
34.4
-
-
-
-
-
-
4.4
4.4
-
-
-
-
1.4(2)
-
0.3
1.0
0.7
0.4
4.2
6.6
-
0.2
0.9
3.1
-
-
-
27.2
4.1
-
-
31.3
-
0.9
-
32.2
-
18.8
-
-
-
-
-
18.8
-
-
-
18.8
10.5(2)
44.1
40.4
56.7
15.1
24.4
44.7
235.9
18.7
8.4
34.9
228.8
-------
TABLE VIII-57
PSES MODEL 00ST DATA: BASIS 7/1/78 DOLLARS
OOMBItUXlOH ACID PICKLING
PAGE 2


Raw Waste Level

Effluent Quality*4'
Cone
Rinse
fhs(4)
Total(5)
Flow, gal/ton
15
1800
720
2535
Total Suspended Solids
200
180
25
135
Oil & Grease
3.5
3.3
0.30
2.4
Dissolved Iron
23,000
155
2.4
250
Fluoride
10,000
69
50
122
pH, Units
1-5
2.5-8
1.5-2.0
1.5-8
004 Benzene
-
0.05
**
0.05
115 Arsenic
-
0.01
-
0.01
119 Chroaiua
3300
25
8.3
40
120 Copper
100
0.27
0.07
0.80
122 Lead
1.2
-
-
1.2
124 Nickel
3300
15
1800
540
128 Zinc
4.1
0.40
0.30
0.40
PSES No. 1	PSES No. 2
Total	Effluent Level	Effluent Level
335
335
335
1030
30
15
18.5
10
5.0
1870
1.0
1.0
930
15
15
1.5-8
6-9
6-9
0.05
0.05
0.025
0.01
0.01
0.01
300
0.10
0.10
6.1
0.10
0.10
1.2
0.10
0.10
4100
0.20
0.10
3.0
0.10
0.10
(1)	Costs are all power unless otherwise noted.
(2)	Total coat doe* not include power, because a credit ia applied for existing process water needs.
(3)	Treataent components are used in tandaa.
(4)	All values are in ag/1 unless otherwise noted.
(5)	All values are once-through concentrations.
(6)	Concentrations and flow values represent coaposite averages of concentrates, rinses after cascade
rinse, and fiae hood scrubber blowdown streaas.
KEY TO CSTT STEPS
A:	FHS Recycle	F:
B:	Cascade Rinse	G:
Ci	Equalisation	H:
D:	Liae Addition	I:
El	Poljraer Addition	J:
Clarifier
Vacuua Filter
Settling Basin
Sulfide Precipitation
Filter
-------
TABLE VIII-58
BPT INVESTMENT AND ANNUAL COSTS FOR THE
ACID PICKLING SUBCATEGORY
Subdivision
Sulfuric
Segment
Batch Neutralization
Batch Acid Recovery
Continuous Neutralization
Continuous Acid Recovery
24.18
3.82
17.97
2.34
48.31
BPT Costs ($ x 10"6)
Investment
In Place Required Total
10.55
60.97
10.85
6.96
89.33
34.73
64.79
28.82
9.30
137.64
Total
Annual
10.32
17.63
7.56
12.70
48.21
Hydrochloric
Batch Neutralization*
Continuous Neutralization
Continuous Acid Regeneration*
1.29
36.38
18.72
63.47
3.48
25.98
29.80
60.94
4.77
62.31
48.52
124.41
1.75
25.11
-19.80
7.06
Combination
Batch
Continuous
10.10
16.59
26.69
11.48
8.73
20.21
21.58
25.32
46.90
7.00
5.89
12.89
Total of Subcategory
138.47
170.48
308.95
68.16
* : The costs of confidential plants are not included in the investment cost totals for this
segment.
Note: All investment cost totals presented in this table include the costs of confidential
plants unless otherwise noted.
425
-------
TABLE VIII-59
BAT INVESTMENT AND ANNUAL COSTS FOR THE
ACID PICKLING SUBCATEGORY
BAT Cos ts ($ x 10
Total Investment
Subdivision 5tg»tiit
Sulfuric
Hydrochloric
Combination
BAT^I BAFI BAT1?
BAT-1
Total Annual
BAT-2
ife.
to
BAT-3
Batch Neutralization
6.73
15.69
84. 72
2.09
3.84
17.50
Continuous Neutralization
6.14
10.34
52.29
1.91
2.73
11.31

17787
ism
137.61
4. 00
6.51
28.81
Batch Neutralization
0.44
1.15
9.89
0.14
0.27
1.90
Continuous Neutralization
9.08
14.57
72.20
2.82
3.85
17.89
Continuous Acid Neutralization
3.05
5.06
25.89
0.95
1.33
6. 74

12.57
20.78
107.56
TT5T
TT5F
26.53
Batch
3.45
9.55
77.95
1.07
2.18
15.02
Continuous
2.70
7^11
50.41
0.84
1.66
11.65

6.15
16.66
128.36
rrsr
"JT85"
26.67
Total of Subcategory
31.59
63.47
373.35
9.82
15.86
82.01
Hotel Sulfuric acid recovery operations achieve zero discharge at BPT, therefore no additional
cost* are incurred at BAT.
-------
TABLE VIII-60
g«R0Y mqPIREHBWTS IK THE ACID PICKLIH6 3UBCATBC0RT
Subdj-riai oo Seynit
Sulfuric
A
KJ
vj
Hydrochloric
Combination
Batch neutralisation
Batch Acid Recovery
Continuous Neutralization
Continuous Acid Recovery
Batch Neutralization '
Continuous neutralisation
Continuous Acid Regeneration
Batch
Continuous
TPT
16.99
117.65
14.97
84; 34
233.95
2.44
46.25
129^56
178.25
4.60
-6i08
-nrw
Subcategory Basis
BAT-1
6AT-2 BAT-3
Energy Requirements (kw-hr/year) x 10
Treatment Model Basis
4.72
1.90
6.62
0.08
0.87
0.43
T73JS
0.60
0.84
T7W
56.64
44.46
101.10
3.39
153.26
68;87
775751
27.60
92i95
150.55
ET
0.02
0.04
H5PS-1
MSPS-2 PSES-i PSES-2 PSNS-i
1.94
4.95
0.05
0.95
13.34
0.03
0iO7
(1)
(2)
R/A
N/A
0.06
0.98
13.38
0.04
0i«9
0.08
0.43
0.05
0.95
13.34
0.16
0.53
0.06
0.98
13.38
0.06
0.12
1.94
4.95
0.05
0.95
13.34
0.03
0i07
(1)
(2)
PSH5-1
H/A
N/A
0.06
0.98
13.38
0.04
0.09
Total Cor Subcategory
422.88
9.44
447.17
1	J	The energy requiresents listed refers to all batch sulfuric operations.
2	<	The energy requirements listed refers to all continuous sulfuric operations.
¦/At	Hot applicable.
Bote: .BAT and BCT energy rcqnirenentf listed represent those energy units required in addition to BPT.
-------
TABLE VIII-61
SOLID HASTE GENERATION SUMMARY(1)
ACID PICKLING SUBCATEGORY
Subdivision	lb«/ ton^	lbs/day^
Sulfuric Acid
Batch Acid ftecovary
BPT	4 9..54	24,770
Batch Neutralisation
BPT	40.02	20,010
BAT 1*	0.206	103.2
BAT 2*	0.220	109.9
BAT 3 *	0.234	116.8
Continuous Acid Raeovary
BPT	36.611	72,490
Continuous Neutralisation
BPT	29.252	5 7 , 919
BAT 1*	0.141	278.9
BAT 2*	0.151	299.5
BAX 3*	0.162	321.2
Hydrochloric Acid
Batch Neutralisation
BPT	28.196	5 35 .7
BAT 1*	0.330	62.62
BAT 2*	0.347	65.87
BAT 3*	0.365	69.30
Continuous Neutralisation
BPT	20.245	55,875
BAT 1*	0.187	51 5 .9
BAT 2*	0.197	544.8
BAX 3*	0.208	575.2
Continuous Acid Rscovmry
BPT	12.357	34,106
BAT 1*	0.253	697.5
BAT 2 *	0.266	734.2
BAT 3 *	0.280	773.0
428
-------
TABLE VIII-61 m
SOLID HASTE GENERATION SUMMARY
ACID PICKLING SUBCATEGORY
PAGE 2 		
Subdivision	lbe/ton^	lb*/day^
Cq»binatiot> Acid
Batch
BPT	7.419	1,484
BAT 1*	0.147	29.33
BAT 2*	0.160	31.99
BAT 3 *	0.182	36.33
Continuou*
BPT	8.671	4335
BAT 1*	0.510	255.0
BAT 2 *	0.552	276.2
BAT 3*	0.622	310.8
(1)	Include* tolidi and octal calculated on a dry baaia.
(2)	Pound* of *olid watt* par ton of production baaad on traataant modal.
(3)	Pound* of solid vaatt par day baaad on traataant nodal,
*i	Load* ovar and above BPT level*.
429
-------
ACID PICKLING SUBCATEGORY
SECTION IX
EFFLUENT QUALITY ATTAINABLE THROUGH
THE APPLICATION OF THE BEST PRACTICABLE
CONTROL TECHNOLOGY CURRENTLY AVAILABLE
Introduction
The Agency is proposing BPT limitations which are the same as those
originally promulgated in 1976. Additional limitations are being
proposed in the sulfuric acid subdivision for batch neutralization
operations. The 1976 regulation limited all batch sulfuric operations
at zero discharge. However, reanalysis of the data for this segment
indicates batch neutralization and batch acid recovery operations
should be limited separately. A review of the treatment processes and
effluent limitations associated with the acid pickling subcategory
follows.
Identification of BPT
The BPT model treatment systems described in this section are
identical to the systems used to develop the originally promulgated
BPT limitations. There are three basic modes of treatment in use in
the acid pickling subcategory. A description of each treatment mode
follows.
1.	Neutralization
Neutralization of acid pickling wastewaters is currently carried
out for sulfuric, hydrochloric, and combination acid pickling
operations. The basic treatment system combines spent pickle
liquor (which has been equalized), rinsewater, and fume scrubber
blowdown in a second equalization basin. An oil separator is
included in the combination acid pickling model. Lime and
polymer are then added to the wastewaters in a mixing tank. The
lime neutralizes the acidic waste, while the polymer serves as a
flocculant. In the sulfuric and hydrochloric acid pickling BPT
model treatment systems, aeration is also provided at this point.
The pollutants which have been separated out must be removed.
The sulfuric acid pickling model includes a settling basin to
accomplish this. Separation is achieved with a thickener and
vacuum filter in the hydrochloric acid pickling subdivision,
while a clarifier and a vacuum filter are used in the combination
acid pickling subdivision. The filtrates from the vacuum filters
are returned to the respective thickener and clarifier inlets.
2.	Acid Recovery
Acid recovery is practiced in the sulfuric acid pickling
subdivision. A spent acid storage system and the acid recovery
system, including storage for the recovered acid and by-product,
431
-------
are the only components necessary for acid recovery. This method
crystallizes the iron salts out of the pickling wastewater. The
sulfuric acid which remains is then strengthened to its original
concentration, so that it may be reused. This treatment model
achieves zero discharge.
3. Acid Regeneration
Acid regeneration is practiced in the hydrochloric acid pickling
subdivision as an alternative to neutralizing the spent pickle
liquor. In this method, the spent pickle liquor is regenerated.
Ferrous chloride is hydrolyzed to an iron oxide by-product and
HC1 gas. The gas is then absorbed to reform hydrochloric acid.
This process can generate absorber vent scrubber wastewater,
which is combined with the rinsewater and fume scrubber blowdown.
The three sources of wastewater are then neutralized as described
previously.
The BPT model treatment systems described above are illustrated
in Figures IX-1 through IX-5. As noted in Section VII, each
component included in the model treatment systems is in use at a
number of acid pickling operations.
The proposed BPT limitations do not require the use of the model
treatment systems presented in this section. Any systems which
achieve the limitations are acceptable. The proposed BPT
effluent limitations, which represent 30-day average values are
presented in Table IX-1. The proposed maximum daily effluent
limitations are three times the average values.
Justification of BPT
Tables IX-2 through IX-4 present the justification of the BPT effluent
limitations originally promulgated in March 1976. All of these
limitations are being reproposed. In addition, new limitations are
proposed in the sulfuric acid subdivision for batch neutralization
operations. The 1976 BPT limitation for all batch sulfuric operations
was zero discharge. However, only acid recovery operations achieve
zero discharge. Therefore, a neutralization model treatment system
was developed reflecting treatment components, flows, and pollutant
concentrations of those sulfuric batch neutralization plants currently
in operation. Refer to Tables X-l and X-2 for the derivations of the
flow values used to specify the sulfuric acid batch neutralization
model.
Tables IX-2 through IX-4 present sampled plant effluent data which
support the proposed BPT limitations. All of the plants listed
achieve one or more of the effluent limitations, except for Plant
AA-2, in the hydrochloric subdivision. No specific chemical treatment
is practiced at this plant, because all effluents are disposed of by
deep well injection. Data from the other sampled plants demonstrate
that the proposed BPT effluent limitations are achievable.
432
-------
Total Metals
In the combination acid pickling subdivision, limitations for chromium
and nickel were promulgated on a dissolved basis in 1976. The Agency
is presently proposing limitations for these toxic metal pollutants on
a total metal basis. The total metal more accurately reflects the
true pollutant load characteristics of this waste source. In
addition, total chromium and total nickel are included in the toxic
pollutant list. No change in the limitations for these.metals is
being proposed, since the proposed limitations for the total metals
are justified in this subcategory. Fluoride is also limited at BPT in
the combination acid pickling subdivision. However, these limitations
only apply when hydrofluoric acid is used in the pickling process.
433
-------
TABLE IX-1
BPT EPFLOENT LIMITATIONS - ACID PICKLING SUBCATEGORY
Operation
SULFURIC ACID
Batch Neutralizacion
Batch Acid Recovery
Continuous Neutralization
(with spent pickle liquor)
Continuous Neutralization
(without spent pickle liquor)
Continuous Acid Recovery
Discherge
Flow
Basis (GPT)
360
250
225
OU anf j
TSS	Grease
Dissolved
Iron
Chromitxn
Fluoride'2' Nickel
0.0751 0.0150	0.00150
No discharge of process wastewater pollutants
0.0521
0.0104
0.00104
0.0469 0.00938	0.000938
No discharge of process wastewater pollutants
BYDROCH.ORIC ACID
Batch Neutralization
with scrubber
280
0.0584
0.0117
0.00117
-
-
Batch Neutralization






without scrubber
230
0.0480
0.00960
0.000960
-
-
Continuous Neutralization






vith scrubber
280
0.0584
0.0117
0.00117
-
-
Continuous Neutralization






without scrubber
230
0.0480
0.00960
0.000960
-
-
Continuous Acid Regeneration






vith scrubber
450
0.0938
0.0187
0.00187
-
-
Continuous Acid Regeneration






without scrubber
400
0.0834
0.0166
0.00166
-
-
COMBINATION ACID






Batch Pipe and Tube
700
0 . 0730
0.0292
0.00292
0.00146
0.0438
Batch Otber
200
0.0209
0.00834
0. 000834
0.000417
0.0125
Continuous
1000
0.104
0.0417
0.00417
0.00209
0.0626
0.000730
0.000209
0.00104
(1)	Thia load is allowed only when theae wastes are treeted in combination with
cold rolling Bill wastes.
(2)	Thia loed is allowed only when hydrofluoric acid is used.
434
-------
TABLE IX-2
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS
SULFURIC ACID PICKLING SUBDIVISION
Effluent Limitations (kg/kkg)
Proposed BPT Effluent Limitation!
Batch-All Operations
Continuous-Neutralization
(with (pent pickle liquor)
(without spent pickle liquor)
Continuous-Acid Recovery
TSS
0.0521
0.0469
04C
(1)
0.0104
0.00938
Dissolved
Iron
0.00104
0.000938
pH (Units)
6-9
6-9
C4TT
Actual Effluent Loads
Batch-Neutralization
I-2a (08560)
I-2b (08560)
R-2 (0240B)
S-2 (0256C)
090	(0476A)
091	(0612)
096 (01121)
(4)
0.023
0.029
0.000057
0
0.000066
0.00066
0.0028
0.0068
*
Meg
0
0.00400
0.00060
0.0026
0.0018
0.00041
Neg
0
0.00012
0.00093
0.003
6.7
6.7
6.6-9.0
7.5-8.3
7.3
SL,NL
SL.NL
SL,E
100X Recycle
E,A,NL,SC,Ski,FLP
E,CRCC,NL,FLP,T,VF
A,NL,F,T
Batch-Acid Recovery
0-2 (0590)
Q-2 (0894)
Continuous-Neutralization
QQ-2 (0584E)J?
SS-2 (0112A)
TT-2 (0856D)},;1
WW-2 (0868A)
094 (0948C) Strip
094 (0948C) Sheet
097 (0760)
Continuous-Acid Recovery
T-2 (0792B)
0.00015
0.014
0.0039
0.00060
0.00047
0.0013
0.00131
0.000056
0.00022
0.00130
0.000070
0.0004
0.00091
0.0017
Neg
0.00034
*
0.00070
0.000040
0.00013
7.5
7.7
*
8.0
7.6-7.8
7.6-7.8
AR
CRCC,EB,NL,SC,SL
NL,A,T,SL,Ski,FLP
Evaporation Pood
FLP,NL,SC,SL,FLA,Ski
e,NL,Ski,FU>,T
E,NL,FLP,T,Ski
Evaporation and
Crystallization
435
-------
TABLE IX-2
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS
SULFURIC ACID PICKLING SUBDIVISION
PAGE 2 		
FOOTNOTES
(1)	Load permitted only for joint treatment with cold rolling wastewaters.
(2)	Plants with scrubbers
(3)	Plant uses evaporation pond with no discharge. Quality shown is feed to pond.
(4)	Plant neutralizes rinses, settles out solids in a lagoon, and recycles all treated wastewaters.
(5)	Plant neutralizes rinses and spent concentrates, and impounds the sludges, with no discharge.
* : Limitation not supported
Neg: Load less than 0.000010 lb/1000 lbs
c&rr codes
A :	Aeration
CRCCt	Chemical reduction chromium conversion
E :	Equalization
EB :	Emulsion breaking
F :	Filtration
FLA :	Flocculation with alum
FLPi	Flocculation with polymer
NL ;	Neutralization with lime
SC :	Sedimentation via clarifier
SKi:	Skimming
SL ;	Settling lagoon
T :	Sedimentation via thickener
436
-------
TABLE IX-3
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS
HYDROCHLORIC ACID PICKLING SUBDIVISION
Effluent Limitation* (kg/Wkg)
TSS
O&G
(1)
Dissolved
Iron
pH (Units)
C&TT
BPT Effluent Limitations (3/76)
B*tch and Continuous Neutralization
with scrubbers	0.0584
without scrubbers	0.0480
Continuous Acid Regeneration
with scrubbers	0.0938
without scrubbers	0.0834
0.0117
0.00960
0.0187
0.0166
0.00117
0.000960
0.00187
0.00166
6-9
6-9
6-9
6-9
Actual Effluent Loada
Batch Neutralization
U-2 (0480AK>
V-2 (0936)
0.136
0.00194
0.009
0.00020
*
8.5
NL
NC
Continuous Neutralization
z-2 (0396D)1;'!;,;
AA-2 (0384A)1*"-"
091 (0612)
093 (0396D)^?
100 ( 0384A)
Continuous Acid Regeneration
x-2 (oo^gyr ;
V-2 (-) . .
95 (0584F)
99 (0S28B)
(2)
0.024
*
0.0111
0.0156
0.0021
0.025
0.0026
0.0048
0.0128
0.00069
*
0.00076
0.0088
0.000077
ND
0.0011
0.00029
0.0144
0.000162
*
0.00030
0.00073
*
*
*
0.00024
8.1-8.6
*
8.4
9.1
8.Z
*
*
*
7.0
E,NL,VF,SC
None
NL,FDS,VF,SC
NL,VF,E,SC
SC
AR
Alt
AR, NL, SL
(1)	Load permitted only for joint treatment with cold rolling wastes.
(2)	Plants with scrubbers.
(3)	Plants discharged to deep well. Later visit (see Plant 100) gives current data on
present treatnene syscsn.
(4)	Plant discharges to a P0TW.
NA: Not applicable.
* ! Limitation not supported.
C4TT CODE
AH
E
FDS
NC
Acid regeneration
Equalization
Filtration-deep bed send
Neutralization with cauatic
NL I Neutralization with line
SC : Sedimentation via clarifier
SL :	Sedimentation via lagoon
VT ¦ Vacuus filtration
437
-------
TABLE IX-4
Actual BPT Loads
Proposed
BPT Effluent
Limitations
Proposed
BPT Effluent
Limitations
JUSTIFICATION OF BPT EFFLUENT LIMITATIONS
COMBINATION ACID PICKLING SUBDIVISION
Proposed
BPT Effluent
Limitations
TSS
O&C
(I)
Dissolved
Iron
Effluent Limitations (kg/kkg)
Chromium
(2)
Fluoride	Nickel
C&TT
Batch-Pipe & Tube
0.0730
0.0292
0.00292
0.00146
0.0438
0.0007 30
U (Unk)
123 (088A)
0.0339
0.00646
0.0028
ND
0.000057
0.00128
0.0001
ND
0.0339
NR
0.00005 NL.SL
0.000776 E,NL,FLP,CL
Batch-Other
Actual BPT Loads
C (0424)
0.0209
0.0118
0.00834
0.00010
0.000834
0.000417
0.0125
0.000209
E, NL,PSP
Continuous
0. L04
0.00417
0.00209
0.0626
0.00104
Actual BPT Loads
O (0176)
121 (Unk)
0.0824
0.0446
0.00196
0.0247
0.00785
0.00145
0.0544
E,NL,FLP,SC,T
E,SC,CR
U) Load pexmitted only when joint treatment vith cold rolling wastewaters it practiced.
(2) Load permitted only when hydrofluoric acid is used.
* t Limitation not supported. Where inadequate treatment was denonstratad within the subcategory,
limitations will be justified by transfer of technology.
NR: Not repotted.
ND; Not detected.
c&rr code
E :	Equalization
CR ;	Chemical reduction
FLP:	Flocculation with polymer
NL :	Neutralization with lime
PSP: Primary scale pit
SC : Sedimentation via clarifier
T : Sedimentation via thickener
438
-------
W
VO
Spent
Pickle
Liquor
FUME HOOD
SCRUBBER
BLOWDOWNS



CASCADE
RINSE


PICKLE
TANK(S)
-Cool to
I0#C(50»F)
CRYSTA
LLIZER
c>o
CRYSTAL
COLLECTOR

RECOVERED
ACID TANK
Recovered Acid


FERROUS SULFATE
HEPTAHYORATE CRYSTALS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING
CONTINUOUS B BATCH ACID RECOVERY
8PT MODEL
D*m.6/l2/80
FIGURE IX" I
-------
EQUALIZATION
TANK
LIME
PICKLE
RINSE
WATER
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
FUME HOOD
SCRUBBER
SLOWDOWN
POLYMER
-t
•TO DISCHARGE
SETTLING
BASIN
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING
BATCH a CONTINUOUS NEUTRALIZATION
BPT MODEL
Dwn.6/13/80
FIGURE JK-2
-------
EQUALIZATION
TANK
.ACID TO
REUSE
ABSORBER
VENT SCRUBBER
(ONCE-THROUGH)
ACID
REGENERATION
UNIT(S)
PICKLE
RINSE
WATER
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
FUME HOOD
SCRUBBER
SLOWDOWN
THICKENER
AIR
LIME
POLYMER
VACUUM
FILTER
•TO DISCHARGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
CONTINUOUS ACID REGENERATION
BPT MODEL
Dwn. 6/17/80
FIGURE IX-3
-------
lp»
NJ
To
Discharge
THICKENER
EQUALIZATION
TANK
AIR
LIME
POLYMER
VACUUM
FILTER
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK	
PICKLE
RINSE
WATER
FUME HOOD
SCRUBBER
SLOWDOWN
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
BATCH 8 CONTINUOUS NEUTRALIZATION
BPT MODEL
Dwn.6/16/80
FIGURE I£-4
-------
OIL
^•TO DISCHARGE
CLARIFIER
EQUALIZATION
TANK
LIME
POLYMER
VACUUM
FILTER
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
FUME HOOD
SCRUBBER
BLOWDCMN
PICKLE
RINSE
WATER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
BATCH 8 CONTINUOUS NEUTRALIZATION
	BPT MODEL 	
Own.&'ie/BO


FIGURE IX-5



-------
ACID PICKLING SUBCATEGORY
SECTION X
EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION
OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
Introduction
The Best Available Technology Economically Achievable (BAT) effluent
limitations are to be attained by July 1, 1984. BAT is determined by
reviewing subcategory practices and identifying the best economically
achievable control and treatment technologies employed within the
subcategory. In addition, where a technology is readily transferable
from one subcategory or industry, such technology may be identified as
BAT.
This section identifies the model BAT flow rates, three BAT
alternative treatment systems, and the resulting effluent levels
considered for the acid pickling subcategory. In addition, the
rationale for the Agency's selection of the alternative treatment
systems, applied and discharge flow rates, and effluent pollutant
concentrations are presented. Finally, this section addresses the
Agency's selection of a BAT model treatment system to serve as the
basis for the proposed BAT limitations.
Identification of BAT
Based upon information contained in Sections III through VIII of this
report, the Agency developed the following three alternative treatment
systems (as add-ons to the BPT treatment system models) for the acid
pickling subcategory. These three alternatives are applicable to all
pickling operations except for those practicing sulfuric acid
recovery. The acid recovery operations attain zero discharge at BPT.
Therefore, no further treatment is necessary beyond BPT.
BAT Alternative No. 1_
The first BAT alternative treatment system reduces the flow being
discharged from the rinse operations through the application of a
cascade or countercurrent rinse system. The fume scrubber blowdown
may be eliminated by feeding it to the cascade rinse system. Zero
discharge of fume scrubber wastewaters could also be achieved by 100%
recycle. At the present time, plants in the sulfuric and hydrochloric
acid subdivisions have demonstrated zero discharge of fume scrubber
waters through blowdown to the cascade rinse system. Other plants
have achieved zero discharge by using mist filters in lieu of wet
scrubbers.
BAT Alternative No. 2
The second BAT alternative treatment system employs the same cascade
rinse system presented in the description of Alternative No. 1. In
445
-------
addition, toxic metals removals are improved by the installation of a
sulfide precipitation system followed by a filter. The filter removes
suspended solids in the wastewater and the toxic metals entrained in
the suspended solids,
BAT Alternative No. 3
The third BAT alternative treatment system also employs the cascade
rinse system described in Alternative No. 1. In addition, this
alternative achieves zero discharge of the entire wastewater flow.
Evaporation, with the use of a multi-stage evaporator, a condenser,
and a centrifuge to dewater the slurries generated, are included to
achieve zero discharge. The distillate quality water, which is
produced by this system, is recycled back to the acid pickling
operation.
Figures X-l through X-4 illustrate the BAT alternative treatment
systems described previously for the acid pickling subcategory. The
treatment technologies shown represent those technologies in use at
one or more plants, or demonstrated in other wastewater treatment
applications, and considered to be capable of attaining the respective
BAT effluent levels.
Pollutants Limited at BAT
The BAT effluent limitations for each alternative treatment system are
presented in Table X-l6. The pollutants listed in this table
represent a condensation of the list of selected pollutants presented
in Section VI. The Agency selected pollutants for limitation based
upon the following factors: treatability using the technologies
presented in the alternative treatment systems, and the ability to
serve as indicators of both the presence and the removal of other
pollutants.
Analytical data indicate that chromium, lead, and zinc predominate in
sulfuric and hydrochloric acid pickling wastewaters. Chromium,
copper, and nickel are found at much higher levels and in much greater
quantities than other toxic pollutants in combination acid pickling
wastewaters. Based upon these observations, the Agency has selected
chromium, lead, and zinc for sulfuric and hydrochloric operations and
chromium, copper, and nickel for combination operations, as the toxic
pollutants to be limited at BAT. Other toxic metals could be found in
acid pickling wastewaters; however, control of the toxic metals listed
in Table X- 16 will also result in comparable control of the other
toxic metals. Toxic organics have also been found in acid pickling
wastewaters at very low levels. However, the cascade rinse system,
which is part of all three BAT alternative treatment systems, will
provide significant reductions in toxic organic pollutant loads, as
well as in toxic metal pollutant loads, by reducing the discharge
volume.
In addition to the toxic metals listed above, fluoride is also limited
at BAT in the combination acid subdivision. However, these
limitations only apply when hydrofluoric acid is used in the pickling
process.
446
-------
Rationale for BAT
The following discussion presents the rationale for the selection of
the BAT model treatment systems and for the determination of the flow
rates and effluent concentrations of the critical pollutants.
Treatment Scheme
The cascade rinse system included in the first BAT alternative
treatment system is commonly used by plants in the acid pickling
subcategory. The 85% recycle rate used to develop BAT model flows has
been demonstrated by two acid pickling plants. In addition, zero
discharge from the fume scrubber recycle system has been demonstrated
by plants in the sulfuric and hydrochloric acid pickling subdivisions.
Zero discharge is being achieved by reuse of the fume scrubber
blowdown in the rinsing operation, and by total recycle (100%) of the
fume scrubber wastewater system.
The sulfide precipitation system incorporated in the second BAT
alternative treatment system is not presently demonstrated in this
subcategory. However, its effectiveness in removing toxic metals from
wastewaters has been demonstrated in studies involving wastewaters
from other metals manufacturing operations. Filtration, used to
remove solids and metals precipitated with sulfide, has also been
proven in other subcategories.
The evaporation technology included in the third BAT alternative
treatment system is extremely costly and energy intensive in
comparison to the other BAT alternative treatment systems.
BAT Flow Rates
The best applied flows were averaged for each acid pickling segment
for the purposes of sizing and costing treatment systems and
establishing effluent limitations. These averages of concentrate,
rinse, fume scrubber, and absorber vent scrubber (if applicable)
streams for the various acid pickling segments appear in Tables X-l
through X-l4. The flow rates for this subcategory were developed as
explained below.
Raw Wastewater Flow Values
The BAT raw flow rates were determined by summing the appropriate
concentrate, rinse, fume scrubber, and absorber vent scrubber (if
applicable) flows.
Bat Feed Flow Values
The BAT feed flow rates were determined by summing the appropriate
concentrate, rinse, fume scrubber blowdown, and absorber vent scrubber
(if applicable) flows. The best discharge fume scrubber values were
averaged to determine fume scrubber blowdowns. All acid pickling
segments, except for combination continuous, demonstrated 10 gal/ton
of fume scrubber blowdown. Combination continuous operations
demonstrated 50 gal/ton of fume scrubber blowdown.
447
-------
BAT Model Flow Values
The model BAT flows were determined by summing the appropriate
concentrate, cascade rinse blowdown, fume scrubber blowdown, and
absorber vent scrubber blowdown (if applicable) flows. Data from two
pickling operations (0584F and 0384A) demonstrate rinse flow
reductions with cascade rinse systems in excess of 85%.
Based on these data, model BAT feed rinse flows were reduced by 85% at
the BAT level. Several hydrochloric acid regeneration operations have
demonstrated 80% recycle of absorber vent scrubber (AVS) streams.
Based on these data, BAT feed AVS flows were reduced to 20% of the
original value, at the BAT level. In addition, the fume scrubber flow
was reduced to zero at BAT for sulfuric and hydrochloric operations.
This reduction was based upon the sulfuric and hydrochloric operations
which have demonstrated the ability to blow down any remaining fume
scrubber flow to the cascade rinse system. This type of reduction has
not been demonstrated at combination acid plants. The fume scrubber
flow could also be reduced by 100% recycle of the fume scrubber
wastewaters as reported for many plants.
Refer to Table X-15 for the development of model BAT flow rates.
Wastewater Quality
The average effluent concentrations incorporated in each BAT
alternative treatment system follow (the maximum values are enclosed
in parentheses):
Pollutant, mq/1	BAT-1	BAT-2	BAT-3
Fluoride1	15 (45)	15 (45)
Chromium2	0.10(0.30)	0.10(0.30)
Copper3	0.10(0.30)	0.10(0.30)
Lead4	0.10(0.30)	0.10(0.30)
Nickel3	0.20(0.45)	0.10(0.30)
Zinc4	0.10(0.30)	0.10(0.30)
IFluoride is limited in the combination acid subdivision only when
hydrofluoric acid is used.
2Chromium is limited in all three acid pickling subdivisions.
3Copper and nickel are limited in the combination acid pickling
subdivision only.
4Lead and zinc are limited in the sulfuric acid and hydrochloric acid
pickling subdivisions only.
Toxic Metal Pollutants
A. BAT Alternative No. 1
The cascade rinse system in this alternative achieves a
substantial flow reduction which results in a comparable
pollutant load reduction. The pollutant concentrations in the
remaining flow are dependent upon the preceding treatment
components. Thickeners, clarifiers, or settling basins with
448
-------
chemical addition are incorporated at the BPT level of treatment.
Short-term data involving these treatment components, in pickling
and other related subcategories, were reviewed to determine the
toxic metal removal capabilities of these wastewater treatment
components. Reference is made to Volume I, Appendix A, for the
derivation of 30-day average and daily maximum performance
standards for Alternative No. 1.
B.	BAT Alternative No. 2
As noted previously in this section, BAT Alternative No. 2
incorporates a sulfide precipitation and filtration system in
addition to the cascade rinse system in Alternative No. 1. As
sulfide precipitation technology has not been demonstrated in
this subcategory, the capabilities of this technology have been
transferred from other metals manufacturing wastewater treatment
applications. The toxic metals effluent levels which can be
achieved with this treatment technology were developed on the
basis of the data review presented in Volume I. The data
indicate that average toxic metals effluent concentrations of
0.10 mg/1 can be attained with this treatment technology.
C.	BAT Alternative No. 3
The evaporation system incorporated in BAT Alternative No. 3
achieves zero discharge of process wastewater pollutants.
Effluent Limitations for Alternative Treatment Systems
The effluent limitations for the BAT alternative treatment systems
were calculated by multiplying the model effluent flow incorporated in
each alternative treatment system and the corresponding concentration
of metals with appropriate conversion factors. Table X-16 presents
the effluent limitations developed for each alternative treatment
system in each segment of the subcategory.
Selection of a BAT Alternative
The Agency has selected BAT Alternative No. 1 as the model treatment
system upon which the proposed BAT limitations are based. Cascade
rinse systems are well demonstrated in the acid pickling subcategory,
while sulfide precipitation and evaporation techniques are not. For
this reason, the first alternative was selected as the BAT model
treatment system. The proposed BAT effluent limitations are presented
in Table X-16 under the Alternative No. 1 heading.
449
-------
TABLE X-l
ANALYSIS OF FLOW DATA
SULFURIC ACID PICKLING-BATCH
APPLIED FLOW RATE (GPT)
Plant Code
Concentrates
Rinses
Basis
0088A-1
8.1
<1
DCP
0946A-3
5.4
3.5
DCP
0088D-1
14.2
4.7
DCP
0248A-2
8.1
6.0
DCP
0946A-1
10.4
6.4
DCP
0894
24.3
8.0
Sampled
0684D-2
8.9
8.3
DCP
0946A-2
18.8
8.6
DCP
0112-1
11.9
9.7
DCP
0248A-3
10.0
10.0
DCP
0048D-2
10.4
10.4
DCP
0684P-1
9.9
11.2
DCP
0048B
5.5
15 .
DCP
0684E-1
17.5
15.7
DCP
0312
17.6
16.9
Sampled
0060M
2.2
17.3
DCP
0684P-3
10.0
17.4
DCP
0590
Unk
18.0
Sampled
0048D-1
27.0
27.0
DCP
0048F
13
37
DCP
0684P-2
10.0
40.3
DCP
0684E-4
17.5
41
DCP
0916A-2
18.0
42
DCP
0088A-2
22.6
49.2
DCP
0684G-1
3.5
54.3
DCP
0856T
5.6
55.8
DCP
0048B
20.0
58.3
DCP
0856U
23.7
62
DCP
0584C
9.7
62.3
DCP
0240B
10.5
62.9
DCP
0684G-2
11.9
74.5
DCP
0884G
11.0
77.0
DCP
0684D-3
8.9
77.4
DCP
0248A-1
9.4
84.4
DCP
0240A
Unk
85.4
DCP
047 6A
Unk
91
Sampled
0492A
3.5
91
Sampled
0256G
18.3
107
DCP
0088A-4
16.3
117
DCP
0612
14.6
122
Sampled
450
-------
TABLE X-l
ANALYSIS OF FLOW DATA
SULFURIC ACID PICKLING-BATCH
APPLIED FLOW RATE (GPT)
PAGE TWO		
Plant Code	Concentrates	Rinses	Basis
0088A-5
42.1
132
DCP
0856S
2.76
134
DCP
0240C
3.8
141
DCP
0856N-3
11.7
160
DCP
0684V
21.0
164
DCP
0916A-7
15.0
165
DCP
0384A-2
2.5
180
DCP
0460D
28.9
181
DCP
0856N-2
21.7
209
DCP
0684Q
24.6
215
DCP
0460G
22.7
224
DCP
0112-2
22.5
231
DCP
0460F
32.6
261
DCP
0088A-3
14.6
272
DCP
0460B
13.3
280
DCP
0728
7.8
288
DCP
0684E-3
17.5
297
DCP
0856F-3
7.7
346
DCP
0868A-1
5.0
349
DCP
0264
17.1
382
DCP
0864B-1
9.2
398
DCP
0884C
25.0
400
DCP
0460C
12.5
410
DCP
0856N-1
20
432
DCP
0264D
13.6
446
DCP
0860F
16.6
465
DCP
0856Q
15
480
DCP
0460H
27.7
535
DCP
0264C
11.8
589
DCP
0548B
27.0
649
DCP
0856P-2
13.5
696
DCP
0068
70 **
769
DCP
0684E-2
17.5
820
DCP
0460A-1
25.8
824
DCP
0548-1
8.9
853
DCP
0860G
22.4
o52
DCP
0640-1
27.6
898
DCP
0684H-1
25.3
913
DCP
0256F
4
960
DCP
0548-3
9.0
960
DCP
0548-2
9.0
961
DCP
451
-------
TABLE X-l
ANALYSIS OF FLOW DATA
SULFURIC ACID PICKLING-BATCH
APPLIED FLOW RATE (GPT)
PAGE THREE
Plant Code
Concentrates
Rinses
Basis
0548-4
0460A-3
0920D
0948B
0856F-2
0884D
0384A-1
0088D-2
0948A
0460A-2
0640-2
0060C
0112A-2
0112C-1
0112C-2
0112C-3
0112F-1
0112F-2
01121-1
01121-2
01121-3
01121-4
01121-5
01121-6
01121-7
0432A-2
0432A-3
0432A-4
0856R
9.1
27.0
33.7
Unk
4.1
16.7
14.3
Unk
48.9**
47.8**
7.6
8
4.5
22.1
8.9
9.9
5.1
3.8
10.5
20.5
14.8
25.9
33.7
110 **
22.3
26
25.1
19.2
8.5
965
973
1079
1081
1126
1200
1379
2775**
3810**
4174**
8291**
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
Unk
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
Unk: Unknown
- : Not present
** : Not used in "Average of the Best" Calculation
APPLIED FLOW RATE AVERAGES
Concentrates
Average of all sources 17.4 GPT
"Average of the best" 15.6 GPT
Rinses
Average of all sources 537 GPT
"Average of the best" 327 GPT
Note: The above averages	include confidential data
452
-------
TABLE X-2
ANALYSIS OF FLOW DATA
SULFURIC ACID PICKLING-BATCH
Plant
Code
Applied Flow Rate (GPT)
Scrubbers
Discharge Flow Rate (GPT)
Scrubbers
Basis
0460H
306
0
DCP
0856N-3
534
133**
DCP
0548-2
846
0
DCP
0856N-1
960
240**
DCP
0240C
1000
41
DCP
0384A-2
1200
156**
DCP
0856F-3
2677**
185**
DCP
0856F-2
7518**
162**
DCP
** » Not
used in "Average of the best
" calculation

APPLIED
FLOW RATE AVERAGES


Scrubbers
Average of all sources 1684 GPT
"Average of the best"	708 GPT
DISCHARGE FLOW RATE AVERAGES (Of those plants practicing flow reduction)
Scrubbers
Average of all sources 102 GPT
"Average of the best" 10.3 GPT
Note: The above averages include confidential data.
453
-------
TABLE X-3
ANALYSIS OF FLOW DATA
SULFURIC ACID PICKLING-CONTINUOUS
Applied Flow Rate (GPT)
Plant Code
Concentrates
Rinses
0856P
27.5
1.95
0760
7.2
11.1
0112A-6
29.2
11.5
0528A-2
14.7
19.6
0256C-1
11.0
29.4
0256C-2
11.0
29.4
0856F
18.0
54
0112A-12
34.7
80
0112A-13
34.7
80
0112A-10
34.7
86
0868A-3
36.8
96
0432A-1
14.4
115
0122A-7
8.4
127
0792C
39.0
127
0856D-3
13.0
129
0868A-4
45.6
133
0112A-4
14.4
136
0112A-5
18
143
0856D-2
11.5
143
0112A-3
17
149
0948C-4
11.3
161
0868A-2
40.5
162
0112A-11
11.7
170
0864B-2
24.8
170
0864B-4
27.7
190
0256A
9.7
209
0856D-4
10.2
225
0864B-3
37.4
257
0684C
21.3
284
0584E
15.8
300
0948C-1
21.4
303
0856D-1
15.9
310
0396E-1
Unk
328
0112A-8
27.9
338
0868A-5
23.9
345
0948C-2
21.4
422
0112A-9
30.9
423
0256B
15
425
0432B
17
427
0856U-2
12.7
467
Basis
DCP
Sampled Data
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
Sampled Data
DCP
DCP
DCP
DCP
Sampled Data
DCP
DCP
DCP
DCP
454
-------
TABLE X-3
ANALYSIS OF FLOW DATA
SULFURIC ACID PICKLING-CONTINUOUS
PAGE TWO		

Applied Flow Rate
(GPT)

Plant Code
Concentrates
Rinses
Basis
0432M
7.8
469
DCP
0948C-3
13.6
532
DCP
0020B
6.4
539
DCP
0856E
21.4
758**
DCP
0176
Unk
847**
DCP
0580C
10.4
1184**
DCP
0432L
3.3
1200**
DCP
0580-2
31.3
1800**
DCP
0580-1
16.7
4000**
DCP
0384A-3
51.4**
4141**
DCP
0580-3
20.0
10,000**
DCP
0060D-2
5.0
Unk
DCP
0112D
Unk
Unk
DCP
0528A-1
Unk
Unk
DCP
**: Not used in "Average of the best" calculation
APPLIED FLOW RATE AVERAGES
Concentrates
Average of all sources 20.5 GPT
"Average of best"	19.9 GPT
Rinses
Average of all sources 649 GPT
"Average of best"	213 GPT
455
-------
TABLE X-4
ANALYSIS OF FLOW DATA
SULFURIC ACID PICKLING-CONTINUOUS
Plant Applied Flow Rate(GPT)
Code Scrubbers
Discharge Flow Rate(GPT)
Scrubbers
Basis
0112A-11
16.7
16.7
DCP
0856D-4
20.5
20.5
DCP
0112A-4
23
23
DCP
0856D-1
44
44
DCP
0528A-2
55.9
55.9
DCP
0856F
62
11.3**
DCP
0020B
90
90
DCP
0856D-3
97
97
DCP
0256A
104
104
DCP
856D-2
143
143
DCP
0856P
232
232
DCP
0432M
234
234
DCP
0792C
237
0
DCP
0856E
253
253
DCP
0684C
284
284
DCP
0256B
425**
425
DCP
0868A-3
448**
0
DCP
0868A-4
597**
0
DCP
0176
750**
750
DCP
0868A-2
908**
0
DCP
0060D-2
Unk
Unk
DCP
0112A-3
Unk
Unk
DCP
0112A-5
Unk
Unk
DCP
0112A-6
Unk
Unk
DCP
0112A-7
Unk
Unk
DCP
0112A-8
Unk
Unk
DCP
0112A-9
Unk
Unk
DCP
0112D
Unk
Unk
DCP
0432B
Unk
Unk
DCP
0528A-1
Unk
Unk
DCP
0584E
Unk
Unk
DCP
0868A-5
Unk
Unk
DCP
Unk: Unknown



**: Not used in
"Average of best"
calculation

APPLIED FLOW RATE
AVERAGE


Scrubbers
Average of all sources 251 GPT
"Average of best"	126 GPT
DISCHARGE FLOW RATE AVERAGE (all plants practicing flow reduction)
Scrubbers
Average of all sources 2.3 GPT
"Average of best"	0 GPT
456
-------
TABLE X-5
ANALYSIS OF FLOW DATA
HYDROCHLORIC ACID PICKLING-BATCH
Applied Flow Rate (GPT)
Plant Code
Concentrates
Rinses
Bas is
048OA
6.5
92.9
Sampled
0936
3.9
167
Sampled
0384A-6
4.4
469
DCP
0864B
6.6
1319
DCP
0176
Unk
1811**
DCP
0580A-3
38.0**
1950**
DCP
0060L
4.0
13,400**
DCP
Unk: Unknown
**: Not used in "Average of best" calculation
APPLIED FLOW RATE AVERAGES
Concentrates
Average of all sources 11.6 GPT
"Average of best"	7.2 GPT
Rinses
Average of all sources 2481 GPT
"Average of best"	538 GPT
457
-------
TABLE X-6
ANALYSIS OF FLOW DATA
HYDROCHLORIC ACID PICKLING-RATCH
Plant
Code
Applied Flow Rate (GPT) Discharge Flow Rate (GPT)
Scrubbers
Scrubbers
Basis
0864B
0384A-6
132
169
0
169
DCP
DCP
Unk: Unknown
Not present
**: Not used in "Average of best" calculation
APPLIED FLOW RATE AVERAGES
Scrubbers
Average of all sources 399 GPT
"Average of best"	150 GPT
DISCHARGE FLOW RATE AVERAGES (of those plants practicing flow reduction)
Scrubbers
Average of all sources 0 GPT
Note: The above averages inlcude confidential data.
458
-------
TABLE X-7
ANALYSIS OF FLOW DATA
HYDROCHLORIC-ACID PICKLING-COHTINUOUS

Applied- Flow Rate
«JPT>

Plant € ode
Concentrates
Rinses
Baai«
0612-5
<1
0
DCP
03 84-4
7.2
7.7
DCP
085 6 F
9.6
60
DCP
0948A-1
3.7
61
DCP
0948A-2
4.4
71
DCP
0724A-4
7.3
84
DCP
Y-2
Unk
87.3
Sampled Data
0684 B-2
12.3
102
DCP
0684B-l
8.7
109
DCP
0724A-3
Unk
137
DCP
0584 A-3
4.1
191
DCP
0528B
81.7**
216
Sampled Data
0584 A-1
4.6
217
DCP
0584 A-2
4.8
224
DCP
0584 C
4. 7
225
DCP
0920G
7.0
225
DCP
W-2
11.9
228
Sampled' Data
03 96D
203**
234
Sampled Data
0432C-2
15.3
239
DCP
0580-4
1.5
240
DCP
0580B-2
1.5
240
DCP
0580D-3
1.5
240
DCP
0580E-2
1.5
240
DCP
0580F-2
1.5
240
DCP
0584 A-A
5.2
243
DCP
0920C
7.4
258
DCP
0920A-1
18.7
270
DCP
0060-2
13. 7
274
DCP
0580-3
3.0
288
DCP
0580B-l
3.0
288
DCP
0580D-2
3.0
288
DCP
0920A-2
19.3
290
DCP
0060-1
14.8
295
DCP
0868A
25.4
299
DCP
0684 F-2
8.2
305
DCP
0612
18.1
328
Sampled Data
0864 B-4
8.8
330
DCP
0580-2
1.8
360
DCP
0580-6
3.8
360
DCP
0580B-3
1.8
360
DCP
0580 D-l
1.8
360
DCP
459
-------
TABLE X-7
ANALYSIS OF FLOW DATA
HYDROCHLORIC ACID PICKLING-CONTINUOUS
PAGE TWO
Applied Flow Rate- (OPT)
Plant Code
Concentrates
Rinses
Basi
0580E-1
1.8
360
DCP
0580F-l
1.8
360
DCP
0068-2
8.0
367
DCP
0384 -2
8.3
372
DCP
0864 B-3
12.0
400
DCP
0384-3
7.7
450
DCP
0864B-l
2.5
487
DCP
0684 F-l
7.3
500
DCP
0684 F-3
8.1
503
DCP
0856S-1
0.8
589
DCP
0432D
8.5
596
DCP
0384-1
13.6
763
DCP
0864B-2
5.3
766
DCP
0020C
35
958
DCP
0580 C-3
4.4
1152**
DCP
0724A-2
Unk
1200**
DCP
0856S-2
2.4
1309**
DCP
0580-5
33.3
1333**
DCP
0580-1
10.0
1440**
DCP
0580C-l
17.5
1440**
DCP
0068-1
13.2
2087**
DCP
0860F-1
7.0
3130**
DCP
0724A-1
Unk
4160**
DCP
0860F-2
12.8
5760**
DCP
0860F-3
12.8
5760**
DCP
0580C-2
13.0
6034**
DCP
0580 A-1
5.9
6240**
DCP
0580 A-2
117.5**
9333**
DCP
085 6 P
5.9
15,540**
DCP
0112B-1
Unk
Unk
DCP
0112 B-2
Unk
Unk
DCP
0112 B-3
Unk
Unk
DCP
0112D-1
Unk
Unk
DCP
0112D-2
Unk
Unk
DCP
0112H
20.9
Unk
DCP
0320-1
6.6
Unk
DCP
0320-2
5.1
Unk
DCP
0320-3
6.5
Unk
DCP
0320-4
6.1
Unk
DCP
0448A-1
9.8
Unk
DCP
0448A-2
7.0
Unk
DCP
460
-------
TABLE X-7
ANALYSIS OF FLOW DATA
HYDROCHLORIC ACID PICKLING-CONTINUODS
PAGE TIBIEE
Unk: Unknown
**! Data not included in "Average of the best" calculati
APPLIED FLOW RATE AVERAGES
Concentrates
Average of all sources 14.0 GPT
"Average of best"	8.4 GPT
Note: The above averages include confidential dta.
Rinses
Average of all sources
"Average of best"
1150 GPT
295 GPT
461
-------
TABLE X-8
ANALYSIS OF FLOW DATA
HYDROCHLORIC ACID PICKLING-CONTINUOUS
Plant
Applied Flow Rate (GPT)
Discharge Flow Rate (GPT)

Code
Scrubbers
Scrubbers
Basis
0020C
7.4
7.4
DCP
0384-4
7.7
7.7
DCP
0920A-1
16
16
DCP
0724A-4
17
17
DCP
0864B-4
18
0
DCP
0920A-2
18
18
DCP
0920C
24
24
DCP
0864B-3
25
0
DCP
0112D-2
45
Unk
DCP
0868A
45
0
DCP
0432C-2
47.8
47.8
DCP
0432C-1
49.2
49.2
DCP
0112D-1
58
Unk
DCP
0856F
66
12
DCP
0580-2
72
72
DCP
0432D
78.3
78.3
DCP
0528B
78.7
6.1
Sampled Data
0060-2
80.4
12.0
DCP
0724A-2
86
86
DCP
0060-1
86.8
12.9
DCP
0724A-3
88
78**
DCP
0684F-2
93
12
DCP
0684B-2
102
0
DCP
0112B-2
111
Unk
DCP
0580B-3
120
120
DCP
0580D-1
120
120
DCP
0580F-1
120
120
DCP
0584A-3
127
127
DCP
0584C
141
0.8
DCP
0580D-3
144
0
DCP
0580F-2
144
0
DCP
0320-4
144
144
DCP
0584A-1
145
145
DCP
0584A-2
149
149
DCP
0584A-4
162
162
DCP
0684F-1
166
21
DCP
0112B-3
183
Unk
DCP
0112B-1
202
Unk
DCP
0320-3
210
210
DCP
0320-1
214
214
DCP
462
-------
TABLE X-8
ANALYSIS OF FLOW DATA
HYDROCHLORIC ACID PICKLING-CONTINUOUS
PAGE TWO
Plant
Applied Flow Rate (GPT)
Discharge Flow Rate (GPT)

Code
Scrubbers
Scrubbers
Basis
0684B-1
217
217
DCP
0684F-3
251
251
DCP
0320-2
277
277
DCP
0580D-2
288
288
DCP
0580-3
288
288
DCP
0580B-1
288
288
DCP
0384-2
298
298
DCP
0724A-1
300
240**
DCP
0112H
358
Unk
DCP
0580-6
360
360
DCP
0948A-1
454
10
DCP
0384-3
463
463
DCP
0948A-2
536
12
DCP
0384-1
611
611
DCP
0060D
696
696
DCP
0856P
15,125**
0
DCP
0396D
Unk
31.1
Sampled Data
0448A-1
Unk
Unk
DCP
0448A-2
Unk
Unk
DCP
W-2
Unk
45.5
Sampled Data
Y-2
Unk
39.7
Sampled Data
**: Data not included in "Average of the best" calculation
APPLIED FLOW RATE AVERAGES
Scrubbers
Average of all data 430 GPT
"Average of the best" 176 GPT
DISCHARGE FLOW RATE AVERAGES (includes only those plants which recycle)
Scrubbers
Average of all data 29.0 GPT
"Average of the best" 6.2 GPT
Note: The above averages include confidential data.
463
-------
TABLE X-9
ANALYSIS OF FLOW DATA
COMBINATION ACID PICKLING-BATCH

Applied Flow Rate
(GPT)

Plant Code
Concentrates
Rinses
Basis
0884F
<1
<1
DCP
0684P-1
12.0
38
DCP
0424-1
10.8
93
DCP
0060N
46.9
109
DCP
0684P-2
14.0
133.6
DCP
0684P-3
14.0
135.5
DCP
0580G
1.3
143
DCP
0068
27.6
162
DCP
0776F
1.2
169
DCP
0440A-1
6.9
178
DCP
0088A
4.1
310
Sampled
0256N-2
11
320
DCP
0284A
3.0
325
DCP
0856H
13.4
338
DCP
0776J
11.6
360
DCP
0440A-2
11
384
DCP
0796A
12.0
386
DCP
0684V
5.8
409
DCP
0424-2
45.7
463
DCP
00601
Unk
611
DCP
0176-1
Unk
633
DCP
0580
1.0
640
DCP
0884E
6.3
650
Sampled
0748
Unk
677
Sampled
0176-7
Unk
711
DCP
0496
9.0
736
DCP
0088-1
6.6
791
DCP
0088-2
6.6
791
DCP
0176-6
Unk
805
DCP
0856E
12.3
922
DCP
0476A
31
932
DCP
0256F
9.5
960
DCP
0248C-1
2.4
1015
DCP
0176-2
Unk
1043
DCP
0776G
18.7
1050
DCP
0088D
Unk
1176
Sampled
0176C
41.3
1617**
DCP
0020B-3
52.1
2182**
DCP
0248C-3
2.7
2310**
DCP
0792A
4.0
2667**
DCP
0548A
0.6
2743**
DCP
464
-------
TABLE X-9
ANALYSIS OF FLOW DATA
COMBINATION ACID PICKLING-BATCH
PAGE TWO

Applied Flow Rate
(GPT)
Plant Code
Concentrates
Rinses*
0176D
35
3200**
0776H
42.7
3303**
0548B
16.1
3871**
0248C-2
20.8
8889**
0060P
8.2
Unk
0112A-1
3.9
Unk
0112C
16.3
Unk
0112H
6.5
Unk
Basis
DCP
DCP
DCP
DCP
DCP
DCP
DCP
DCP
Unk: Unknown
Not Present
**: Not used in "Average of the best" calculation
APPLIED FLOW RATE AVERAGES
Concentrates
Average of all sources	14.1 GPT
"Average of best"	14.1 GPT
Rinses
Average of all sources	1169 GPT
"Average of best"	517 GPT
Note: The above averages include confidential data.
465
-------
TABLE X-10
ANALYSIS OF FLOW DATA
COMBINATION ACID PICKLING-BATCH
Plant
Code
Applied Flow Rate (GPT) Discharge Flow Rate (GPT)
Scrubbers
Scrubbers
Basis
0856H
0284A
0432E
0176D
0176-2
0884E
0176-1
0176-7
0176-6
0256F
39.4
163
864
960
2087
2700
417**
6.3
330**
284**
242**
0
39.4
163
864
960
DCP
DCP
DCP
DCP
DCP
Sampled Data
3550**
5689**
6443**
7200**
DCP
DCP
DCP
DCP
- = Not present
** = Not used in "Average of the best" calculation
APPLIED FLOW RATE AVERAGES
Scrubbers
Average of all sources 3344 GPT
"Average of the best" 1136 GPT
DISCHARGE FLOW RATE AVERAGES (Of those plants practicing flow reduction)
Scrubbers
Average of all sources 160 GPT
"Average of the best" 2.0 GPT
Note: The above averages include confidential data.
466
-------
TABLE X-ll
ANALYSIS OF FLOW DATA
COMBINATION ACID PICKLING-CONTINOOUS

Applied Flow Rate
(GPT)

Plant Code
Concentrates
Rinses
Basis
0948F
Unk
176
DCP
0284A-3
1.9
313
DCP
0284A-2
1.7
358
DCP
0432K-1
1.6
457
DCP
0176-3
Unk
558
DCP
0020L-2
7.2
1011
DCP
0020B-2
24.7
1029
DCP
02560-3
7.5
1064
DCP
0020L-1
7.8
1087
DCP
0684D-7
11.2
1255
DCP
0020B-1
15.5
1333
DCP
0684D-14
12.8
1383
DCP
0684D-6
16.8
1387
DCP
0060E-1
8.2
1690
DCP
0684D-12
18.8
1714
DCP
0724A-1
Unk
1846
DCP
0684D-2
Unk
1867
DCP
0176-5
Unk
2000
DCP
0684D-3
23.4
2044
DCP
0648
15
2097
DCP
0684D-5
24.9
2100
DCP
0176-4
Unk
2182
DCP
0684D-11
22.4
2222
DCP
0248B-9
8.1
2237
DCP
0020C-6
Unk
2271
DCP
0684D-1
22.2
2291
DCP
0684D-10
7.6
2713
DCP
0248B-1
13.4
2721
DCP
0900
Unk
2754
Sampled Data
0020C-8
Unk
2900
DCP
0248B-5
10.6
2923
DCP
0684D-9
25.7
3120
DCP
0248B-3
13.9
3162
DCP
0248B-10
11.7
3230
DCP
0020C-1
Unk
4127**
DCP
0684D-4
Unk
4246**
DCP
0248B-4
13.4
4255**
DCP
0684D-8
18.4
4457**
DCP
0248B-6
21.1
4688**
DCP
0724A-2
Unk
4966**
DCP
0020C-5
Unk
5509**
DCP
467
-------
TABLE X-ll
ANALYSIS OF FLOW DATA
COMBINATION ACID PICKLING-CONTINUOUS
PAGE TWO		

Applied Flow Rate
(GPT)

Plant Code
Concentrates
Rinses
Bas:
0432L
18
5571**
DCP
02560-1
11.5
5729**
DCP
02560-4
17.0
6051**
DCP
0020C-2
Unk
6288**
DCP
0020C-3
Unk
6288**
DCP
02560-2
15.3
6588**
DCP
0248B-8
13.1
7317**
DCP
0248B-2
40.2
7668**
DCP
0112G-2
6.0
7706**
DCP
0248B-7
16.5
9195**
DCP
0020C-4
Unk
9388**
DCP
0860F
Unk
22,400**
DCP
0060
23.4
Unk
DCP
0060D-1
Unk
Unk
DCP
0060D-2
Unk
Unk
DCP
0060D-3
Unk
Unk
DCP
0060D-4
Unk
Unk
DCP
0060D-5
Unk
Unk
DCP
0060D-6
Unk
Unk
DCP
0060E-2
2.5
Unk
DCP
0112A-2
18.8
Unk
DCP
0112C-3
6.0
Unk
DCP
0112C-4
6.0
Unk
DCP
0432K-2
Unk
Unk
DCP
0432K-3
Unk
Unk
DCP
0432K-4
Unk
Unk
DCP
Unk: Unknown
**s Not used in "Average of the best" calculation
APPLIED FLOW RATE AVERAGES
Concentrates
Average of all sources 14.2 GPT
"Average of best"	14.2 GPT
Rinses
Average of all sources 3677 GPT
"Average of best"	1809 GPT
463
-------
TABLE X-12
ANALYSIS OF FLOW DATA
COMBINATION ACID PICKLING-CONTINUOUS
Plant
Code
Applied Flow Rate (GPT)
	 Scrubbers	
Discharge Flow Rate (GPT)
	 Scrubbers	
Bas:
0020C-1
20.8
20.8
DCP
0060D-5
50.4
Unk
DCP
0432K-3
63
63
DCP
02 84A-2
89
89
DCP
0432K-2
94
94
DCP
0060D-3
100
Unk
DCP
0020C-6
102
102
DCP
0284A-3
104
104
DCP
0432K-4
115
115
DCP
0020B-1
102
102
DCP
0020L-2
253
253
DCP
02560-3
268
0
DCP
0020L-1
272
272
DCP
0248B-9
309
40
DCP
0020C-5
329
329
DCP
072 4A-2
331
331
DCP
0020B-2
343
343
DCP
0248B-1
376
49
DCP
0648
400
0
DCP
0248B-5
403
53
DCP
0248B-10
446
58
DCP
0060D-6
511
Unk
DCP
0020C-4
561
561
DCP
02560-1
697
0
DCP
0248B-3
703
95
DCP
0112A-2
750
750
DCP
0248B-4
766
0
DCP
0060E-1
777
777
DCP
0948F
882
0
DCP
02560-2
941
0
DCP
0020C-8
1096
1096
DCP
0060D-2
1200
48
DCP
0176-4
1273
364**
DCP
0020C-2
1380
1380
DCP
0020C-3
1380
1380
DCP
0060E-2
1381
1381
DCP
02560-4
1532
0
DCP
0060D-1
1579
63
DCP
0248B-2
1702
230**
DCP
0248B-6
2344
188**
DCP
0176-3
3189
80
DCP
0176-5
7000**
400**
DCP
469
-------
TABLE X-12
ANALYSIS OF FLOW DATA
COMBINATION ACID PICKLING-CONTINUOUS
PAGE TWO	
Plant	Applied Flow Rate (GPT) Discharge Flow Rate (GPT)
Code		Scrubbers	 	Scrubbers	 Basis
0860F	11,520**	640**	DCP
0060	Unk	Unk	DCP
0060D-4	Unk	Unk	DCP
0724A-1	Unk	Unk	DCP
**: Not used in "Average of the best" calculation
APPLIED FLOW RATE AVERAGES
Concentrates
Average of all sources 1113 GPT
"Average of best"	716 GPT
DISCHARGE FLOW RATE AVERAGES (All plants practicing flow reduction)
Scrubbers
Average of all sources 115 GPT
"Average of best"	47.8 GPT
470
-------
TABLE X-13
vj
I—1
Subdivision
Sulfuric Acid
-Batch
Sulfuric Acid
-Cont inuous
Hydrochloric Acid
-Batch
Hydrochloric Acid
-Continuous
Combination Acid
-Batch
Combination Acid
-Continuous
RAW WASTE LEVEL FLOW JUSTIFICATION
ACID PICKLING
Actual Applied Flow Rate (GPT)
Concentrates	Rinses Scrubbers
15.6
19.9
7.2
8.4
14.1
14.2
327
213
538
295
517
1809
708
126
150
176
1136
716
Listed Values (GPT)
Concentrates
20
20
10
10
15
15
Rinses
330
200
540
300
520
1800
Scrubbers
710
130
150
180
1140
720
-------
TABLE X-14
ANALYSIS OF FLOW DATA
ABSORBER VENT SCRUBBER
Plant
Flow Rate (GPT)

Code
Scrubber
Basis
0584F
69
Sampled
W-2
98.6
Sampled
0528B
176
Samp led
0684F
376**
DCP
Y-2
624**
Sampled
**: Not used in "Average of the best" calculations.
SCRUBBER FLOW RATE AVERAGES
Average of all sources 269 GPT
"Average of the best" 115 GPT
472
-------
TABLE X-15
DEVELOPMENT OF BAT FLOW RATES

Treatment

Flow
(GPT)


Process
Level
Cone.
Rinse
FHS
AVS
Total
Sulfuric Acid







1. Batch
Raw

20
330
710

1060
Neutralization
BAT
Feed
20
330
10

360

BAT

20
50
0

70
2. Batch Acid
Raw

20
330
710

1060
Recovery
BAT
Feed
-
-
-

0

BAT

—



0
3. Continuous
Raw

20
220
130

370
Neutralization
BAT
Feed
20
220
10

250

BAT

20
35
0

55
4. Continuous Acid
Raw

20
220
130

370
Recovery
BAT
Feed
-
-
-

0

BAT

—
—
—

0
Hydrochloric Acid







1. Batch
Raw

10
540
150

700
Neutralization
BAT
Feed
10
540
10

560

BAT

10
80
0

90
2. Continuous
Raw

10
300
180

490
Neutralization
BAT
Feed
10
300
10

320

BAT

10
45
0

55
3. Continuous Acid
RAW

10
300
180
120
610
Regeneration
BAT
Feed
0
300
10
120
430

BAT

0
45
0
25
70
Combination Acid







1. Batch
Raw

15
520
1140

1675

BAT
Feed
15
520
10

545

BAT

15
80
10

105
2. Continuous
Raw

15
1800
720

2535

BAT
Feed
15
1800
50

1865

BAT

15
270
50

335
Cone: Concentrate
FHSs Fume Hood Scrubber
AVS: Absorber Vent Scrubber
473
-------
TABLE X-16
BAT EFFLUENT LIMITATIONS
ACID PICKLING SUBCATEGORY
Subdivision
Sulfuric
Process
BAT
Alternative
1 Batch -
Neutralization 1*
Discharge
Flow (GPT)
70
70

2.	Batch Acid
Recovery
3.	Continuous -
Neutralization
BPT
1*
55
55
Pollutants
Concentration
Basis (mg/1)
Effluent
Limitations (lbs/1000 lbs)

AVE.
MAX.
AVE
MAX
Chromium
0.10
0.30
0.0000292
0.0000876
Lead
0.10
0.30
0.0000292
0.0000876
Zinc
0.10
0.30
0.0000292
0.0000876
Chromium
0.10
0.30
0.0000292
0.0000876
Lead
0.10
0.30
0.0000292
0.0000876
Zinc
0.10
0.30
0.0000292
0.0000876
Chromium
_
_
-
_
Lead
-
-
-

Zinc
-
-
-
-
Chromium
0.10
0.30
0.0000230
0.0000690
Lead
0.10
0.30
0.0000230
0.0000690
Zinc
0.10
0.30
0.0000230
0.0000690
Chrom iura
0.10
0.30
0.0000230
0.0000690
Lead
0.10
0.30
0.0000230
0.0000690
Zinc
0.10
0.30
0.0000230
0.0000690
Chromium
-
-
-
-
Lead
-
-
-
-
Zinc
-
-
-
-
4. Continuous Acid BPT
Recovery
0
-------
TABLE X-16
BAT EFFLUENT LIMITATIONS
ACID PICKLING SUBCATEGORY
PAGE 2
BAT
Subdivision	Process	Alternative
Hydrochloric 1. Batch
Neutralization 1*
2
J)	2. Continuous	1*
Neutralisation
1
3. Continuous
Regeneration	1*
2
3
Discharge
Flow (CPT)
90
90
0
55
55
0
70
70
0
Concentration	Effluent
Pollutants Basis (ag/1) Liaitations (lbs/1000 lba)
AVE. MAX. AVE	MAX
Chroaiun	0.10	0.30
Lead	0.10	0.30
Zinc	0.10	0.30
Chroaiua	0.10	0.30
Lead	0.10	0.30
Zinc	0.10	0.30
0.0000375	0.000113
0.0000375	0.000113
0.0000375	0.000113
0.0000375	0.000113
0.0000375	0.000113
0.0000375	0.000113
Chroaiua
Lead
Zinc
Chroaiua
0.10
0.30
0.0000229
0.0000688
Lead
0.10
0.30
0.0000229
0.0000688
Zinc
0.10
0.30
0.0000229
0.0000688
Chroaiua
0.10
0.30
0.0600229
0.0000688
Lead
0.10
0.30
0.0000229
0.0000688
Zinc
0.10
0.30
0.0000229
0.0000688
Chroaiua
-
_
-
_
Lead
-
-
-

Zinc
-
-
-

Chroaiua 0.10 0.30 0.0000292 0.0000876
Lead	0.10 0.30 0.0000292 0.0000876
Zinc	0.10 0.30 0.0000292 0.0000876
Chroaiua
Lead
Zinc
0.10
0.10
0.10
0.30
0.30
0.30
0.0000292
0.0000292
0.0000292
0.0000876
0.0000876
0.0000876
Chroaiua
Lead
Zinc
-------
TABLE X-16
BAT EFFLUENT LIMITATIONS
ACID PICKLING SUBCATEGORY
PAGE 3	
BAT	Di acharge
Subdivision Procen Alternative	Flow (GPT)
Combination 1. Batch 1*	105
2	105
3	0
2. Continuous 1*	345
2	345
3	0
Concentration	Effluent
Pollutants Basis (¦»/!) Limitations (lbs/1000 lbs)
AVE. MAX. AVE	MAX
Fluoride
15
45
0.00657
0.0197
Chroaiua
0.10
0.30
0.0000438
0.000131
Copper
0.10
0.30
0.0000438
0.000131
Nickel
0.20
0.45
0.0000876
0.000197
Fluoride
15
45
0.006571
0.0197
Chroaiua
0.10
0.30
0.0000438
0.000131
Copper
0.10
0.30
0.0000438
0.000131
Nickel
0.10
0.30
0.0000438
0.000131
Fluoride

-
-
-
Chroniua
-
-
-
-
Copper
-
-
-
-
Nickel
-
-
-
-
Fluoride
15
45
0.0216
0.0647
Chroaiua
0.10
0.30
0.000144
0.000432
Copper
0.10
0«30
0.000144
0.000432
Nickel
0.20
0.45
0.000288
0.000648
Fluoride
15
45
0.0216
0.0647
Chromium
0.10
0.30
0.000144
0.000432
Copper
0.10
0.30
0.000144
0.000432
Nickel
0.10
0.30
0.000144
0.000432
Fluoride
-
-
-
-
Chroaiua
-
-
-
-
Copper
-
-
-
-
Nickel
-
-
-
-
* : BAT Alternative selected.
Note: The fluoride load in codbination acid pickling is allotted only when hydrofluoric acid is used.
-------
rSPENT PICKLE1
I LIQUOR L_.
i EQUALIZATION i
1	TANK	|
[" FUME HOOO~1
SCRUBBER
' SLOWDOWN 1
u		,
CASCADE
RINSE
L-«J-
LLIMEri r-, !
" i '''J
rPOLYMElTj
s^;
EQUALIZATION
TANK
T	
I
aIr
BAT-I
BAT "2
SETTLING
SULFIDE
BAS N
FILTER
BAT" 3
EVAPORATION
100% RECYCLE
TO PROCESS
ENTRIFUGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING
BATCH 8 CONTINUOUS NEUTRALIZATION
BAT TREATMENT ALTERNATIVES
[Vm. 6/16/80
FIGURE X-l
-------
BAT-I
-J
CO
CASCADE
RINSE
SYSTEM
I
FUME HOOD
SCRUBBER
BLOWDOWN
ISPENT PiCKLEl
I LIQUOR I
EQUALIZATION
I TANK
	1
r
±
ACID
EQUALIZATION
TANK
rJ-	
ABSORBER
¦^—^^REGENERATION I	»|VENT SCRUBBER)
UNIT(S)
|_ SLOWDOWN	|
r
i
L
» POLYMER
V	
"T
r-i
L THICKENER
BAT-2
SULFIDE
J	, I
VACUUM 	f
•^FILTER |
AIR
FILTER
REACTION TANK
BAT-3
EVAPORATION
100% RECYCLE
TO PROCESS
CENTRIFUGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
CONTINUOUS ACID REGENERATION
BAT TREATMENT ALTERNATIVES
Dwn.6/17/80
FIGURE X-2
-------
[spent pickle]
LIQUOR |	»,
I EQUALIZATION I	,
I TANK J	I
r FUME HOOD |
SCRUBBER I
; SLOWDOWN |
"X"
CASCADE
RINSE
EQUALIZATION
TANK
BAT-1
POLYMER |
1	
in
	
I
I
I
r-l	1
j VACUUM ^
| FILTER |
I THICKENER



V
		J
BAT-2
SULFIDE
REACTION TANK
BAT-3
100%
^RECYCLE
TO PROCESS
¦^•CENTRIFUGE
FILTER
EVAPORATION
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
BATCH a CONTINUOUS NEUTRALIZATION
BAT TREATMENT ALTERNATIVES
Own. 6/16/80
FIGURE X-3
-------
J" FUME HOOD ~1
SCRUBBER 	
I	BLOWDOWH J
[spent-pickTe"]
I LIQUOR I	
I EQUALIZATION I
L TANK j
-i
I
I
[oip
i
oo
o
EQUALIZATION
TANK
BAT-I
LIMEJ J" p0LYMER 1
"T L.	J
CLARIFIER
BAT-2
SULFIDE
1	
VACUUM I
FILTER J
FILTER
REACTION TANK
BAT-3
EVAPORATION
100% RECYCLE
TO PROCESS
•"CENTRIFUGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
BATCH 8 CONTINUOUS NEUTALIZATION
BAT TREATMENT ALTERNATIVES
Dwa 6/18/80
FIGURE x-4
-------
ACID PICKLING SUBCATEGORY
SECTION XI
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
Introduction
The 1977 Amendments added Section 301(b)(4)(E) to the Act,
establishing "best conventional pollutant control technology" (BCT)
for discharges of conventional pollutants from existing industrial
point sources. Conventional pollutants are those defined in Section
304(b)(4) - BOD, TSS, fecal coliform and pH - and any additional
pollutants defined by the Administrator as "conventional." On July
28, 1978, EPA proposed that COD, oil and grease, and phosphorus be
added to the conventional pollutant list (43 Fed. Reg. 32857). Only
oil and grease was added.
BCT is not an additional limitation, but replaces BAT for the control
of conventional pollutants. BCT requires that limitations for
conventional pollutants be assessed in light of a new
"cost-reasonableness" test, which involves a comparison of the cost
and level of reduction of conventional pollutants from the discharge
of POTWs to the cost and level of reduction of such pollutants from a
class or category of industrial sources. As part of its review of BAT
for certain "secondary" industries, EPA proposed methodology for this
cost test. (See 43 Fed. Reg. 37570, August 23, 1978).
Methodology
Reference is made to Volume I for a review of the BCT methodology.
BCT Treatment Alternatives
BCT treatment has not been considered for those sulfuric acid plants
practicing acid recovery. Zero discharge is attained at BPT by this
model. Therefore, further reduction of conventional pollutants is not
necessary. The proposed BCT limitations for sulfuric acid recovery
plants are the same as the proposed BPT limitations.
BCT Alternative No. T_
The BCT alternative treatment systems developed for the other
operations in the acid pickling subcategory are add-ons to the
respective BPT model treatment systems. The first BCT alternative is
identical to the BAT-1 developed in each subdivision. A cascade rinse
system is incorporated in this alternative to reduce the rinse flow
entering the treatment system. In the hydrochloric and sulfuric acid
subdivisions, the fume scrubber blowdown is fed to the cascade rinse
system. However, zero discharge from fume scrubbers at combination
acid pickling operations has not been demonstrated. Therefore, in the
combination acid pickling model, fume scrubber blowdown is not fed to
the cascade rinse system at the BCT level of treatment.
481
-------
BCT Alternative No. 2
The second BCT alternative treatment system passes the discharge flow
from the BCT-1 treatment system through a filter. Filtration
technology provides for additional removal of conventional pollutants
than that accomplished by sedimentation. The BCT alternative
treatment systems are depicted in Figures XI — 1 through XI-4.
Development of BCT Limitations
The reference POTW treatment cost for the conventional pollutants is
$1.34/lb (July 1, 1978). (See Section X of Volume I). The BCT cost
test is detailed in Section VIII with the results listed in Tables
VIII-43 through VIII-46 . A pass/fail summary of the BCT cost test
for the acid pickling subcategory follows:
BCT Cost Test
Results for the
BCT Alternatives
Subdivision	1	2
Sulfuric Acid - Batch	Fail	Fail
Neutralization
- Continuous	Fail	Fail
Neutralization
Hydrochloric Acid
-	Acid Regneration	Pass	Pass*
-	Batch	Fail	Fail
Neutralization
-	Continuous	Pass	Pass*
Neutralization
Combination Acid
-	Batch	Fail	Fail
-	Continuous	Fail	Fail
~Selected as the BCT Alternative
The Agency is proposing BCT limitations for suspended solids, oil	and
grease, and pH. However, the oil and grease limitations	are
applicable only when acid pickling wastewaters are treated	in
combination with cold rolling wastewaters. Reference is made to
Appendix A of Volume I for the derivation of performance standards	for
suspended solids and oil and grease.
Proposed BCT Limitations
The proposed BCT limitations are presented in Table XI-1. Proposed
BCT limitations for those segments of the acid pickling subcategory
which did not pass the BCT Cost Test are the same as the proposed BPT
limitations. The proposed BCT limitations were calculated by
multiplying the effluent flow incorporated in the chosen treatment
model and the corresponding concentrations of suspended solids and oil
and grease, with appropriate conversion factors.
482
-------
TABLE XI-1
03
GO
BCT EFFLUENT LIMITATIONS GUIDELINES
ACID PICKLING SUBCATEGORY
Subdivision
Sulfuric Acid Pickling
1. Batch Neutralization
Total Suspended Solids
(lbs/1000 lbs)
Ave.
0.0751
2. Continuous Neutralization
(with spent pickle liquor) 0.0521
(without spent pickle liquor)0.0469
Hydrochloric Acid Pickling
1.
Batch Neutralization
(with scrubber)
(without scrubber)
0.0584
0.0480
2.	Continuous Neutralization	0.00344
3.	Continuous Acid Regeneration	0.00438
Combination Acid Pickling
1.	Batch (Pipe and Tube)	0.0730
2.	Batch (Other)	0.0209
3.	Continuous	0.104
Max.
0.225
0.156
0.141
0.175
0.144
0.00917
0.0117
0.219
0.0627
0.312
Oil and Grease
(1)
(lbs/1000 lbs)
Ave.
0.0150
0.0104
0.00933
0.0117
0.00960
0.0292
0.00834
0.0417
Max.
0.0450
0.0312
0.0282
0.0351
0.0288
0.00229
0.00292
0.0876
0.0249
0.125
Model
Selected
BPT
BPT
BPT
BPT
BPT
BCT-2
BCT-2
BPT
BPT
BPT
(1) This load is allowed only when these wastes are treated in combination with
cold rolling mill wastes.
Note: pH is also limited in this subcategory at BCT to the range 6.0 to 9.0 standard units.
-------
["spent PICKLE 1
1 LIQUOR 1
I
I
L .
EQUALIZATION
TANK
I FUME HOOO I
SCRUBBER I
BLOWDOWN I
I
I
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1
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TANK j
Jll.
i
I C»kO
f"""
i
I
AIR
I
I
_ J
BCT-I
\.	;
SETTLING BASIN
BCT" 2
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING
BATCH S CONTINUOUS NEUTRALIZATION
BCT TREATMENT ALTERNATIVES
Own. 11/25/80
FIGURE XI-
-------
4*-
00
Ul
BCT"
CASCAOE
RINSE
SYSTEM
FUME HOOD 1
SCRUBBER I
SLOWDOWN j
TSPENT PICKLE 1
I LIQUOR 1
, EQUALIZATION |
L TANK j
[lime1.
T
I
. POLYMER
1
EQUALIZATION
TANK J
+ -+4
I I
I
V
i-u,~

T

THICKENER J
I
I
AIR
T
i
ACID
TO +
REUSE
^ ACID ^
•H REGENERATION t- •
^ UNIT(S> J
|	¦*	1
'ABSORBER VENT1
H SCRUBBER |
BLOWDOWN j
I , VACUUM
U -1	^
^FILTER
V
I
I
BCT- 2
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
CONTINUOUS ACID REGENERATION
BCT TREATMENT ALTERNATIVES
0wn.il/25/80
FIGURE XT-2
-------
00
-------
T FUME HOOO 1
l SCRUBBER
BLOWDOWN I
rsPent~pickle 1
LIQUOR I
EQUALIZATION
I
I
I	
TANK
CASCADE
RINSE
OIL
T
t
l
jlime;
i
i
^polymer]
I
r
l-T	^
I EQUALIZATION
i TANK
BCT- I
I	'
I -Je->
i	zrL"	i
! I
CLARIFIER s*
VACUUM ~j |
L FILTER J*
r
i
i
BCT "2
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
BATCH a CONTINUOUS NEUTRALIZATION
BCT TREATMENT ALTERNATIVES
Dwn.M/26/80


FIGURE 21-4



-------
ACID PICKLING SUBCATEGORY
SECTION XII
EFFLUENT QUALITY ATTAINABLE THROUGH
THE APPLICATION OF NEW SOURCE PERFORMANCE STANDARDS
Introduction
A new source is defined as any source constructed after the proposal
of New Source Performance Standards (NSPS). The effluent standards,
which must be achieved by new sources, are to specify the degree of
effluent reduction achievable through the application of the Best
Available Demonstrated Control Technology (BADCT), including, where
applicable, a standard permitting no discharge of pollutants. This
section identifies the treatment alternatives considered by the Agency
for NSPS and the resulting effluent standards for acid pickling
operations. In addition, the rationale for selecting the NSPS
treatment models, flow values, and proposed effluent standards are
discussed.
Identification of NSPS
Acid Recovery
NSPS for continuous and batch sulfuric acid pickling operations are
proposed at zero discharge. The alternative treatment systems which
achieve this level of reduction are identical to the continuous and
batch acid recovery BPT model treatment systems for sulfuric acid
pickling operations. Refer to Figure XII-1.
Two NSPS alternative treatment systems have been developed for
hydrochloric and combination acid pickling operations. Descriptions
of these alternatives follow. Refer to Figures XII-2 through XII-4
for illustrations of these model treatment systems.
NSPS Alternative No. ]_
The first NSPS alternative treatment systems are similar to the BPT
and BAT-1 treatment systems developed for the hydrochloric and
combination acid pickling subdivisions. For the batch and continuous
neutralization models in the hydrochloric acid subdivision, the NSPS-1
treatment system consists of spent acid equalization; fume scrubber
recycle with subsequent blowdown to the cascade rinse system;
equalization of spent pickle liquor and cascade rinsewaters;
neutralization with lime; flocculation with polymer; aeration;
clarification; and vacuum filtration of the clarifier underflow. The
batch and continuous neutralization model in the combination acid
pickling subdivision is identical to the corresponding model for
hydrochloric operations, except that aeration is not a treatment
system component. The NSPS-1 treatment system developed for
continuous hydrochloric acid regeneration operations incorporates all
of the treatment components just discussed. In addition, an acid
489
-------
regeneration unit and absorber vent scrubber recycle system are
included in the treatment system prior to the equalization unit.
NSPS Alternative No. 2
The second NSPS alternative treatment systems are similar to the
corresponding BPT and BAT-2 treatment systems developed for the
hydrochloric and combination acid pickling subdivisions. For the
batch and continuous neutralization models, in both subdivisions,
NSPS-2 treats the NSPS-1 system discharge by sulfide precipitation and
filtration. The NSPS-2 model developed for continuous hydrochloric
acid regeneration operations incorporates the NSPS-1 treatment systems
developed for these operations. In addition, the discharges from the
NSPS-1 systems are treated with sulfide and then filtered.
Rationale for NSPS
Alternative Treatment Systems
The NSPS alternative treatment systems developed for the acid pickling
subcategory are similar to the BPT, BAT-1, and BAT-2 treatment systems
described in Sections IX and X. Therefore, the rationale presented in
those sections is applicable to NSPS.
Flows
The applied and discharge flows developed for the zero discharge
sulfuric acid recovery model at NSPS are identical to the correspondng
model BPT flow values. Refer to Section IX. The applied and
discharge flows developed for the other NSPS treatment systems are
identical to the BAT-1 and BAT-2 raw and effluent flows developed for
operations in the hydrochloric acid subdivision. Refer to Section X
for the development of these flow values. In the combination acid
pickling subdivision, the raw concentrate and fume hood scrubber flows
are identical to those developed at BAT (see Section X). However, the
raw rinse flows have been lowered from those used in the BAT model.
In the batch NSPS system, the raw rinse flow is 200 GPT as compared to
520 GPT at BAT. In the continuous NSPS system, the raw rinse flow is
500 GPT in comparison with the value of 1800 GPT incorporated in the
BAT system. Applied flows for combination acid pickling operations
were lowered to the Best Demonstrated Flows for NSPS. Flows for
sulfuric and hydrochloric acid plants were not lowered at NSPS.
However, the Agency is soliciting comments on the use of best
demonstrated flows for NSPS in these subdivisions.
Selection of NSPS Alternative
The acid recovery model, which achieves zero discharge, has been
chosen for batch and continuous sulfuric acid pickling operations.
NSPS Alternative No. 1 has been selected as the model treatment system
upon which the proposed NSPS effluent standards are based for all
hydrochloric and combination acid pickling operations. The Agency
selected the first alternative rather than the second, because the
sulfide precipitation technology included in the second alternative
has not been demostrated in this subcategory.
490
-------
The proposed NSPS effluent standards are presented in Table XII-1.
The NSPS model treatment systems are designated by asterisks.
491
-------
TABLE XI1-1
NEW 90URCE PERFORMANCE STANDARDS
ACID PICKLING SUBCATEGORY
Subdivision
Sulfuric
Hydrochloric
ID
K>




Concentration Basis
Effluent Standards


Discharge

lmg/1)

(lb/1000 lb
Process
NSPS Alternative
Flow (GPT)
Pollutant
Ave.
Max.

Ave.
Max.
Batch
1*
0






Continuous
1*
0






Batch
1*
90
TSS
30
60

0.0113
0.0225
Neutralization


O&G
10
20

0.00375
0.00750



Chromium
0.10
0.30

0.0000375
0.000113



Lead
0.10
0.30

0.0000375
0.000113



Zinc
0.10
0.30

0.0000375
0.000113



pH, Units

6.0 to
9.0



2
90
TSS
15
40

0.00563
0.0150



OSG
-
10

-
0.00375



Chr onion
0.10
0.30

0.0000375
0.000113



Lead
0.10
0.30

0.0000375
0.000113



Zinc
0.1O
0.30

0.0000375
0.000113



pH, Units

6.0 to
9.0


Continuous
1*
55
TSS
30
60

0.00688
0.0138
Neutral!xation


OtrG
10
20

0.00229
0.00458



Chromium
0.10
0.30

0.0000229
0.00006B7



Lead
0.10
0.30

0.0000229
0.0000687



Zinc
0.10
0.30

0.0000229
0.0000687



pH, Units

6.0 to
9.0



2
55
TSS
15
40

0.00344
0.00917



O&G
-
10

-
0.00229



Chroaiian
0.10
0.30

0.0000229
0.0000687



Lead
0.10
0.30

0.0000229
0.0000687



Zinc
0.10
0.30

0.0000229
0.0000687



pH, Units

6.0 to
9.0


Continuous
1*
70
TSS
30
60

0.00876
0.0175
Acid


OtG
10
20

0.00292
0.00584
Regeneration


Chrcmlum
0.10
0.30

0.0000292
0.0000876



Lead
0.10
0.30

0.0000292
0.0000876



Zinc
0.10
0.30

0.0000292
0.0000876



pH, Units

6.0 to
9.0


-------
TABLE XII-1
NEW SOURCE PERFORMANCE STANDARDS
ACID PICKLING SUBCATEGORY
PAGE TWO	
Concentration Basis Effluent Standards
Subdivision
Process
USPS Alternative
Discharge
Flow (GPT)
70
Combination
Batch
45
10
u>
45
Continuous
1«
90
90
Pollutant
Ave.
Max.

Ave.
Max.
TSS
15
40

0.00438
0.0117
OtG
-
10

-
0.00292
Chroaiua
0.10
0.30

0.0000292
0.0000876
Lead
0.10
0.30

0.0000292
0.0000876
Zinc
0.10
0.30

0.0000292
0.0000876
pH, Units

6.0 to
9.0


TSS
30
60

0.00563
0.0113
OtG
10
20

0.00188
0.00376
Fluoride
15
45

0.00281
0.00844
ChroHiia*
0.10
0.30

0.0000188
0.0000564
Copper
0.10
0.30

0.0000188
0.0000564
Nickel
0.20
0.45

0.0000375
0.0000844
pH, Units

6.0 to
9.0


TSS
15
40

0.00281
0.00751
OtG
-
10

-
0.00188
Fluoride
15
45

0.00281
0.00844
Chroaiua
0.10
0.30

0.0000188
0.0000564
Copper
0.10
0.30

0.0000188
0.0000564
Nickel
0.10
0.30

0.0000188
0.0000564
pH, Units

6.0 to
9.0


TSS
30
60

0.0113
0.0225
OtG
10
20

0.00375
0.00750
Fluoride
15
45

0.00563
0.0169
Chroaiua
0.10
0.30

0.0000375
0.000113
Copper
0.10
0.30

0.0000375
0.000113
Nickel
0.20
0.45

0.0000751
0.000169
pH, Units

6.0 to
9.0


TSS
15
40

0.00563
0.0150
OtG
-
10

-
0.00375
Fluoride
15
45

0.00563
0.0169
Chroaiua
0.10
0.30

0.0000375
0.000113
Copper
0.10
0.30

0.0000375
0.000113
Nickel
0.10
0.30

0.0000375
0.000113
pH, Units

6.0 to
9.0


*t Alternative selected.
Hotei The fluoride load Is allowed only when hydrofluoric acid is used.
-------
Spent
Pfckle
Liquor
CRYSTA LLIZER
FUME HOOD
SCRUBBER
BLOWDOWNS
CRYSTAL
COLLECTOR

CASCADE
RINSE
PICKLE
TANK(S)
RECOVERED
ACID TANK
FERROUS SULFATE
HEPTAHYDRATE CRYSTALS
Recovered Acid
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING
CONTINUOUS 8 BATCH OPERATIONS
NSPS TREATMENT MODEL
Dwn.6/12/80
FIGIJRF "XTT-I
-------
CASCADE

RINSE

SYSTEM

FUME HOOD
SCRUBBER
BLOWDOWN
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
REUSE
ACID
REGENERATION
UNIT(S)
POLYMER
NSPS- I
CLARIFIER
NSPS"2
EQUALIZATION
TANK
SULFIDE
VACUUM
FILTER
REACTION TANK
FILTER
ABSORBER
VENT
SCRUBBER
BLOWDOWN
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
CONTINUOUS ACID REGENERATION
NSPS TREATMENT ALTERNATIVES
Dwn.6/18/80
FIGURE 211-2
-------
EQUALIZATION
TANK
FUME HOOD
SCRUBBER
SLOWDOWN
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
CASCADE
RINSE
SYSTEM
LIME
NSPS ~I
NSPS-2
CLARIFIER
SULFIDE
AIR
REACTION TANK
POLYMER
VACUUM
FILTER
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
BATCH S CONTINUOUS NEUTRALIZATION
NSPS TREATMENT ALTERNATIVES
Dwn. 6/18/80
FIGURE XK-3
-------
|LIMEl | POLYMER
EQUALIZATION
TANK
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
CASCADE
RINSE
FUME HOOD
SCRUBBER
SLOWDOWN
NSPS"I
CLARIFIER
NSPS"2
SULFIDE
VACUUM
FILTER
REACTION TANK
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
BATCH a CONTINUOUS NEUTRALIZATION
NSPS TREATMENT ALTERNATIVES
Own, 11/21/80
FIGURE UL-4
-------
ACID PICKLING SUBCATEGORY
SECTION XIII
PRETREATMENT STANDARDS FOR DISCHARGES
TO PUBLICLY OWNED TREATMENT WORKS
Introduction
This section discusses the alternative control and treatment systems
available for acid pickling operations which discharge wastewaters to
publicly owned treatment works (POTWs). The main factors considered
in the pretreatment standards are: (1) the need to ensure that the
acid pickling wastewaters are treated sufficiently to avoid
overloading POTW systems, and (2) that provisions for toxic pollutant
removal are incorporated such that these pollutants do not interfere
with or pass through the POTW, or are not otherwise incompatible with
POTW operations.
The Agency developed separate pretreatment systems for existing (PSES)
and new (PSNS) operations in the sulfuric and combination acid
pickling subdivisions. However, in the hydrochloric acid pickling
subdivision, PSES and PSNS systems are identical.
General Pretreatment Regulations, 40 CFR Part 403, are applicable to
all acid pickling sources. A discussion of the general pretreatment
and categorical pretreatment standards applying to acid pickling
operations follow.
General Pretreatment Standards
For detailed information concerning Pretreatment Standards, refer to
43 FR 27736-27773, "General Pretreatment Regulations for Existing and
New Sources of Pollution," (June 26, 1978). In particular, 40 CFR
Part 403 describes national standards (prohibited discharges and
categorical standards), revision of categorical standards through
removal allowances, and POTW pretreatment programs.
The General Pretreatment Regulations set forth general discharge
prohibitions that apply to all non-domestic users of POTWs to prevent
pass through of pollutants, interference with the operation of POTWs,
and municipal sludge contamination. The regulations also establish
administrative mechanisms to ensure application and enforcement of
prohibited discharge limits and categorical pretreatment standards.
In addition, the Regulations contain provisions relating directly to
the determination of and reporting on Pretreatment Standards.
Categorical Pretreatment Standards
In establishing pretreatment standards for acid pickling operations,
the Agency gave primary consideration to the objectives and
requirements of the General Pretreatment Regulations. In addition,
499
-------
the Agency considered other factors specifically appl icable to acid
pickling operations.
Although wastewaters from a significant number of pickling operations
are discharged to POTWs, the POTWs are not designed to treat toxic
metal pollutants present in pickling wastewaters. Instead, POTWs are
designed to treat biochemical oxygen demand (BOD) / total suspended solids
(TSS), fecal coliform bacteria,"and pH. Toxic metal removal by POTWs
is incidental to the POTW's main function of treating conventional
pollutants. POTWs have historically accepted many pollutants in
amounts well above their capacity to treat them adequately. The
problems of municipal sludge disposal are becoming increasingly
difficult to resolve. Pretreatment standards must address toxic
pollutant removal. This will greatly reduce the transfer of these
pollutants to POTWs where they concentrate in the sludges.
Due to the presence of toxic metal pollutants in pickling wastewaters,
extensive pretreatment must be provided to ensure that these
pollutants do not interfere with or pass through the POTWs, or are not
otherwise incompatible with POTW operations or cause harm to the
treatment plant. In general, the alternative treatment systems are
comparable to the BAT alternative treatment systems. Pretreatment
standards for suspended solids and oil and grease are not proposed.
These pollutants, in the amounts present in acid pickling BPT
effluents, are compatible with POTW operations and can be effectively
treated at POTWs.
Various studies1 have demonstrated that the toxic metal pollutants
found in wastewaters at levels comparable to those present in pickling
wastewaters inhibit the biological treatment process. The
pretreatment systems ensure that the toxic metal pollutants present in
the pickling wastewater discharges of these segments will not
adversely affect the treatment process.
Other studies2 involving the electroplating industry (with similar
levels of the same toxic metals) indicated that from fifty percent to
ninety percent of the toxic metal pollutants entering a POTW will pass
through the system. The possiblity therefore exists that a POTW could
discharge undesirable levels of toxic metal pollutants when accepting
industrial process wastewaters.
The toxic metal pollutants which do not pass through a POTW are
concentrated in the POTW sludges. Generally, land application is the
most advantageous, yet least expensive, method of POTW sludge disposal
as the sludge can be used to replace soil nutrients. However,
excessive amounts of toxic metal pollutants in the sludges could
lEPA-430/9-76-017a, Construction Grants Program Information; Federal
Guidelines, State and Local Pretreatment Programs
2Federal Register; Friday, September 7, 1979; Part IV, Environmental
Protection Agency; Effluent Guidelines and Standards; Electroplating
Point Source Category; ' Pretreatment Standards for Existing
Sources-Pages 52597-52601.
500
-------
inhibit plant growth, thus rendering the sludge unfit for use as a
soil nutrient supplement. In addition, these metals could enter
either the plant or animal food chain or could leach into the
groundwater. For the above reasons, the Agency believes that the
control of toxic metal pollutant discharges to POTWs is essential.
Rationale for Selection of Pretreatment Systems
Treatment Models
The PSES and PSNS systems developed for the acid pickling subcategory
are similar to BPT, BAT-1, and BAT-2 treatment systems described in
Sections IX and X. Therefore, the rationale presented in those
sections is applicable to PSES and PSNS.
Flows
The applied and discharge flows developed for the PSES and PSNS
systems are identical to the BAT-1 and BAT-2 raw and effluent flows
for hydrochloric neutralization operations and hydrochloric acid
regeneration operations. The applied and discharge flows developed
for sulfuric acid recovery operations at PSES and PSNS are identical
to the corresponding BPT flows, as are the PSNS flows for sulfuric
neutralization operations. PSES flows for sulfuric neutralization
operations refect BAT flow values. Refer to Sections IX and X for the
development of these flow values.
In the combination acid pickling subdivision, the applied and
discharge flow values developed for the PSES alternatives are
identical to the corresponding BAT-1 and BAT-2 applied and discharge
flow values. Refer to Section X. However, the flow values developed
for the PSNS alternative system are identical to the corresponding
NSPS applied and discharge flow values. Refer to Section XII for the
development of these flow values.
Alternative Pretreatment Systems
A. Sulfuric Acid Pickling
1. PSES
The PSES system developed for sulfuric acid recovery
operations is identical to the model BPT treatment system.
Refer to Figure XIII-1. The two PSES systems developed for
sulfuric acid neutralization operations are similar to the
corresponding BPT, BAT-1, and BAT-2 treatment systems. PSES
Alternative No. 1 consists of spent acid equalization; fume
scrubber recycle with subsequent blowdown to the cascade
rinse system; equalization of spent pickle liquor and
cascade rinsewaters; neutralization with lime; flocculation
with polymer; aeration; clarification; and, vacuum
filtration of the clarifier underflow. The filtrate from
the vacuum filters is returned to the clarifier inlet. The
clarifier overflow is then discharged to the POTW. PSES
Alternative No. 2 incorporates all of the Alternative No. 1
501
-------
treatment components just discussed. In addition, the
clarifier overflow is treated with sulfide in a reaction
tank. The solids precipitated by the sulfide are removed by
filters and the filter effluent is then discharged to a
POTW. Figure XIII-2 depicts the treatment models just
described.
2. PSNS
The PSNS treatment model developed for all sulfuric acid
pickling operations is identical to the NSPS model treatment
system for sulfuric operations. This treatment system
achieves zero discharge. Refer to Figure X111 — 1.
B.	Hydrochloric Acid Pickling
1.	Acid Regeneration
The PSES/PSNS systems developed for hydrochloric acid
regeneration operations include all of the PSES-1 and PSES-2
system components developed for sulfuric acid neutralization
operations. In addition, an acid regeneration unit and
absorber vent scrubber recycle system are included prior to
the equalization unit in each treatment system. Refer to
Figure XIII-3.
2.	Neutralization
The PSES/PSNS treatment systems developed for hydrochloric
acid neutralization operations are identical to the
corresponding PSES Alternatives No. 1 and 2 developed for
sulfuric acid neutralization operations. Refer to Figure
XII1-4.
C.	Combination Acid Pickling
1. PSES
The two PSES systems developed for combination acid
neutralization operations both include fume hood scrubber
recycle; cascade rinse; equalization of spent pickle liquor,
fume hood scrubber blowdown, and cascade rinse system;
neutralization with lime, and flocculation with polymer. At
this point, the PSES Alternative No. 1 treatment system flow
passes through a clarifier. The clarifier underflow is
vacuum filtered with the filtrate returned to the clarifier
inlet. The clarifier overflow then enters the POTW. In the
PSES Alternative No. 2 treatment system, the wastewater
which has been neutralized with lime and flocculated with
polymer then passes to a settling basin. Sludge is removed
periodically, and after sufficient retention time, the
wastewater is treated with sulfide in a reaction tank. The
solids which have been precipitated are removed by filters.
The filter effluent then passes to the POTW. Figure XIII-5
depicts the treatment systems just described.
502
-------
2. PSNS
The PSNS systems developed for combination acid
neutralization operations incorporate all of the PSES-1 and
PSES-2 treatment components developed for sulfuric aci4
neutralization operations, with the exception of aeration.
Refer to Figure XIII-6.
Selection for Pretreatment Alternatives
The acid recovery system, which achieves zero discharge, has been
developed for new batch and continuous sulfuric acid pickling
operations (PSNS). This system also applies to existing batch and
continuous sulfuric acid recovery operations.
The PSES-1 alternative has been selected as the model treatment systen
upon which the proposed PSES effluent standards are based for sulfuric
and hydrochloric neutralization operations and hydrochloric aci4
regeneration operations. The PSNS models for the two types of
hydrochloric acid pickling operations are identical to the
corresponding PSES models.
The first PSES and PSNS alternatives have also been selected as the
model treatment systems upon which the proposed PSES and PSNS effluent
standards are based for combination neutralization operations. The
Agency selected the first alternatives for operations in all three
subdivisions, because the sulfide precipitation technology
incorporated in the second alternatives has not been demonstrated in
this subcategory.
The proposed PSES and PSNS effluent standards are presented in Table
XIII—1. The selected PSES and PSNS alternatives are designated by
asterisks. No effluent standards are proposed for suspended solids
and oil and grease, as these are conventional pollutants which can be
effectively treated in a POTW.
503
-------
TABLE XIII-1
PRBIHEMMENT OTLDENT STANDARDS (EXISTING AND NEW SOURCES)
	ACID PICKLING SUBCATEGORY	
Subdivision Process
Sulfuric
Batch
Pretreataent
Alternative
PSES-1*
Flow
Baaia (GPT) Pollutants
Concentration
Basis (nq/1)
Ave. Max.
Effluent Standards
(lbs/1000 lbs)
Ave.
PSES-2
70
70
U1
o
Hydrochloric
Batch
Neutralization
Chroaiua
Lead
Zinc
pa (Units)
Chroaiua
Lead
0.10
0.10
0.10
0.10
0.10
0.30	0.0000292
0.30	0.0000292
0.30	0.0000292
6.0 to 9.0
0.30
0.30
0.0000292
0.0000292


Zinc
pH (Units)
0.10
0.30
6.0 -
9.0
0.0000292
PSNS*
0

-
-

-
PSES-1*
55
Chroaiua
Lead
Zinc
pH (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000229
0.0000229
0.0000229
PSES-2
55
Chroniua
Lead
Zinc
pB (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000229
0.0000229
0.0000229
PSNS*
0

-
-

-
PSES/PSNS-1*
90
Chroaiua
Lead
Zinc
pH (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000375
0.0000375
0.0000375
PSES/PSNS-2
90
Chroaiua
Lead
Zinc
pB (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000375
0.0000375
0.0000375
Max.
0.0000876
0.0000676
0.0000876
0.0000876
0.0000876
0.0000876
0.0000688
0.0000688
0.0000688
0.0000688
0.0000686
0.0000686
0.000113
0.000113
0.000113
0.000113
0.000113
0.000113
-------
TABLE XIII-1
PRE TREATMENT EFFLUEHT STANDARDS (EXISTING AND NEW SOURCES)
ACID PICKLING SUBCATEGORY
PAGE TWO
Subdivision Process
Pretreataent
A1 tentative
Flow
Basis (GPT)
Conti nuoui
Neutralization
PSES/PSNS-1*
55
PSES/PSNS-2
55
Coati ntious
Acid
Regeneration
PSES/PSNS-1*
70
m
O
cn
PSES/PSNS-2
70
Cfiabination
Batch
PSES-1*
105
PSKS-2
105
PSNS-1*
45
PSNS-2
45

Concentration
Basis (mg/1)

Effluent Standards
(lbs/1000 lbs)
Pollutants
Ave;
Max.

Ave.
Max.
Chroaita
Lead
Zinc
pH (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000229
0.0000229
0.0000229
0.0000687
0.0000687
0.0000687
Chroaiua
Lead
Zinc
pH (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000229
0.0000229
0.0000229
0.0000687
0.0000687
0.0000687
Chroaiua
Lead
Zinc
pH (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000292
0.0000292
0.0000292
0.0000876
0.0000876
0.0000876
Chroaiua
Lead
Zinc
pR (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000292
0.0000292
0.0000292
0.0000876
0.0000876
0.0000876
Chroaiua
Copper
Nickel
p>H (Units)
0.10
0.10
0.20
0.30
0.30
0.45
6.0 -
9.0
0.0000438
0.0000438
0.0000876
0.000131
0.000131
0.000197
Chroaiua
Copper
Nickel
pH (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000438
0.0000438
0.0000438
0.000131
0.000131
0.000131
Chroaiua
Copper
Nickel
pH (Units)
0.10
0.10
0.20
0.30
0.30
0.45
6.0 -
9.0
0.0000188
0.0000188
0.0000375
0.0000563
0.0000563
0.0000844
Chroaiua
Copper
Nickel
pH (Units)
0.10
0.10
0.10
0.30
0.30
0.30
6.0 -
9.0
0.0000188
0.0000188
0.0000188
0.0000563
0.0000563
0.0000563
-------
TABLE XIII-1
PRETREATMENT EFFLUENT STANDARDS (EXISTING AND NEW SOURCES)
ACID PICKLING SUBCATEGORY
PAGE THREE	
Pretreatnent	Flow
Subdivision Process	Alternative	Baals (GPT)
Continuous	PSES-1*	345
PSES-2	345
PSNS-1*	90
Ul
o
PSNS-2	90
*i Alternative selected
Concentration

Basis
to/1).
Pollutants
Ave.
Max.
Chroaiua
0.10
0.30
Copper
0.10
0.30
Nickel
0.20
0.45
pa (Units)

6.0 -
Chroalua
0.10
0.30
Copper
0.10
0.30
Nickel
0.10
0.30
pfl (Units)

6.0 -
Chroaiua
0.10
0.30
Copper
0.10
0.30
Nickel
0.20
0.45
pH (Units)

6.0 -
Chroaiua
0.10
0.30
Copper
0.10
0.30
Nickel
0.10
0.30
pB (Units)

6.0 -
Effluent Standards
(lbs/1000 lbs)
9.0
9.0
Ave.
0.000144
0.000144
0.000288
0.000144
0.000144
0.000144
0.0000375
0.0000375
0.0000751
0.0000375
0.0000375
0.0000375
Max.
0.000431
0.000431
0.000647
0.000431
0.000431
0.000431
0.000113
0.000113
0.000169
0.000113
0.000113
0.000113
-------
FUME HOOD
SCRUBBER
SLOWDOWNS
CASCADE
RINSE
PICKLE
TANK(S>
-Cool to I0"C(50° F)
CRYSTA LLIZER
o»o
CRYSTAL
COLLECTOR
tfMtlWIftlfil.
RtCOVERED
ACID TANK
—/ FERROUS SULFATE
/ MEPTAHYDRATE CRYSTALS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING
CONTINUOUS 8 BATCH OPERATIONS
PSNS TREATMENT MODEL
Dwa II/22/BO
FIGURE 2DI-
-------
U1
o
oo
PSES-)
PSES-2
CLARIFIER
SULFIDE
EQUALIZATION
TANK
AIR
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SULFURIC ACID PICKLING
BATCH ft CONTINUOUS NEUTRALIZATION
PSES TREATMENT ALTERNATIVES
LIME
POLYMER
VACUUM
FILTER
FILTER
FUME HOOD
SCRUBBER
BLOWDOWN
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
CASCADE
RINSE
-------
EQUALIZATION
TANK
ACID TO
REUSE
CASCADE
RINSE
SYSTEM
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
FUME HOOD
SCRUBBER
SLOWDOWN
ACID
REGENERATION
ABSORBER
VENT SCRUBBER
SLOWDOWN
LIME
POLYMER
PSES/PSNS - I
PSES/PSNS-2
CLARIFIER
SULFIDE
FILTER
AIR
VACUUM
FILTER
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HYDROCHLORIC ACID PICKLING
CONTINUOUS ACID REGENERATION
PSES/PSNS TREATMENT ALTERNATIVES
Dwn.6/20/8C
FIGURE Xm-3
-------
-^HJYTiCKOT
LIQUOR
EQUALIZATION
TANK
I LIMEl | POLYMER
FUME HOOD
\1
SCRUBBER

SLOWDOWN


CASCADE
RINSE


EQUALIZAT ON
TANK
AIR
CLARIFIER
VACUUM
FILTER
PSES/PSNS ~ I
PSES/PSNS'2
	SULFIDE
FILTER
REACTION TANK
ENVIRONMENTAL PROTECTION A6ENCY
STEEL INDUSTRY STUDY
HYOROCHLORIC ACID PICKLING
BATCH a CONTINUOUS NEUTRALIZATION
PSES/PSNS TREATMENT ALTERNATIVES
On* II/22/8C
FIGURE 201-4
-------
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
FUME HOOD
SCRUBBER
BLOWDOWN
| POLYMER
1

EQUALIZATION
TANK
CASCADE
RINSE
PSES- I
CLARIFIER
VACUUM
FILTER
PSES * 2
SULFIDE
FILTER
SETTLING BASIN
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
BATCH a CONTINUOUS NEUTRALIZATION
PSES TREATMENT ALTERNATIVES
Dwn. 11/24/80
FIGURE 2m-5
-------
LIME] 1 POLYMER
EQUALIZATION
TANK
SPENT PICKLE
LIQUOR
EQUALIZATION
TANK
FUME HOOD
SCRUBBER
BLOW DOWN
CASCADE
RINSE
PSNS " I
CLARIFIER
VACUUM
FILTER
PSNS ~ 2
SULFIDE
FILTER
REACTION TANK
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINATION ACID PICKLING
BATCH 8 CONTINUOUS NEUTRALIZATION
PSNS TREATMENT ALTERNATIVES
Dwn.il/25/60
FIGURE ZEI-6
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