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
SEPA Development	Proposed
Document for
Effluent Limitations
Guidelines and
Standards for the
Iron and Steel
Manufacturing
Point Source Category
Vol. IV
Hot Forming Subcategory

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DEVELOPMENT DOCUMENT
for
PROPOSED EFFLUENT LIMITATIONS GUIDELINES,
NEW SOURCE PERFORMANCE STANDARDS,
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
and


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HOT FORMING SUBCATEGORY
TABLE OF CONTENTS
SECTION	PAGE
I	PREFACE			1
II	CONCLUSIONS 		3
III	INTRODUCTION	13
General Discussion . 	13
Data Collection Activities 		13
Description of Hot Forming Operations 		14
IV	SUB CATEGORIZATION	89
Introduction		 		89
Factors Considered in Subcategorization 		90
Manufacturing Process and Equipment 		90
Final Products	90
Raw Materials ..... 		92
Wastewater Characteristics and Treatability 		94
Size and Age	95
Geographic Location ...... 	 .....	96
Process Water Usage Rates 		97
V	WATER USE AND WASTEWATER CHARACTERISTICS	119
Introduction 		119
General Discussion 		119
Water Use			119
Waste Characterization 		120
Specific Discussion 		120
Recycle Water Rates .... 		123
Wastewater Characteristics 		124
VI	WASTEWATER POLLUTANTS	137
Introduction			137
Conventional Pollutants 		137
Toxic Pollutants	138

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HOT FORMING SUBCATEGORY
TABLE OF CONTENTS (CONTINUED)
SECTION	PAGE
VII	CONTROL AND TREATMENT TECHNOLOGY 		141
Introduction . 		141
Summary of Treatment Practices Currently Employed . .	141
Control and Treatment Technologies for BAT, BCT,
NSPS, PSES, and PSNS	142
Summary of Analytical Data	143
Plant Visits 				145
VIII	* * * COST, ENERGY,"AND NONWATER QUALITY IMPACTS	219
Introduction 			219
Actual Costs Incurred by the Plants Sampled
for this Study. . .	219
Control and Treatment Technology (C&TT)
Recommended for Use in the Hot Forming
Subcategory	219
Cost, Energy, and Nonwater Quality Impacts 		220
Development of Costs for the Hot Forming
Subcategory . 		220
Hot Forming Treatment Model Concept 		220
Derivation of Co-mingling Factors 		221
Estimated Costs for the Installation of
Pollution Control Technologies 		222
Energy Impacts Due to the Installation of the
Requisite Technology 		22 4
Nonwater Quality Impacts ". 		225
Summary of Impacts		227
* ~ *
IX	EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION* OF BPT TECHNOLOGY,		313
Identification of BPT . 			313
Rationale* for'BPT'		314
Justification of Proposed BPT Effluent Limitations . .	314
•	»	•	j.	,	,
X	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION
OF BAT TECHNOLOGY 		329
Introduction 				329
Identification of BAT		330
Rationale for the Selection of the BAT Alternatives .	331
Selection of a BAT Alternative	333
ii

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HOT FORMING SUBCATEGORY
TABLE OF CONTENTS (CONTINUED)
SECTION	PAGE
XI	BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY ....	359
Introduction			359
Explanation of the BCT Cost Test	359
Development of BCT	359
Development of Proposed BCT Limitations 		360
BCT Cost Summary	360
XII	EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION
OF NEW SOURCE PERFORMANCE STANDARDS 		363
Introduction 		363
Identification of NSPS	363
Rationale for Selection of NSPS	363
Selection of a NSPS Alternative	364
XIII	PRETREATMENT STANDARDS FOR DISCHARGES TO
PUBLICLY OWNED TREATMENT WORKS 		369
Introduction 		369
General Pretreatment Standards 		369
Identification of Pretreatment 		370
Rationale for the Selection of Pretreatment
Technologies 		371
ill

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HOT FORMING SUBCATEGORY
TABLES
NUMBER	TITLE	PAGE
II-l	BPT MODEL FLOWS AND EFFLUENT QUALITY 		7
II-2	PROPOSED BPT EFFLUENT LIMITATIONS 		8
II-3	TREATMENT MODEL FLOWS AND EFFLUENT QUALITY 		9
II-4	PROPOSED EFFLUENT LIMITATIONS AND STANDARDS ....	10
III-1	SUMMARY OF SAMPLED PLANTS - HOT FORMING
SUBCATEGORY		25
III-2	GENERAL SUMMARY TABLE: HOT FORMING - PRIMARY ...	28
III-3	GENERAL SUMMARY TABLE: HOT FORMING - SECTION ...	38
III-4	GENERAL SUMMARY TABLE: HOT FORMING - FLAT
(HOT STRIP AND SHEET) 		57
III-5	GENERAL SUMMARY TABLE: HOT FORMING - FLAT
(CARBON PLATE) 		63
III-6	GENERAL SUMMARY TABLE: HOT FORMING - FLAT
(SPECIALTY PLATE)		66
III-7	GENERAL SUMMARY TABLE: HOT FORMING -
PIPE AND TUBE		67
III-8	DATA BASE SUMMARY: HOT FORMING - PRIMARY		75
III-9	DATA BASE SUMMARY: HOT FORMING - SECTION		76
III-10	DATA BASE SUMMARY: HOT FORMING - FLAT
(HOT STRIP AND SHEET) 			77
III-ll	DATA BASE SUMMARY: HOT FORMING - FLAT (PLATE) ...	78
III-12	DATA BASE SUMMARY: HOT FORMING - PIPE AND TUBE . .	79
IV-1	PLANTS DEMONSTRATING THE ABILITY TO RETROFIT
POLLUTION CONTROL EQUIPMENT - HOT FORMING
SUBCATEGORY	 99
IV-2	GEOGRAPHIC LOCATION OF THE HOT FORMING OPERATIONS
IN THE UNITED STATES	101
V-l	to	SUMMARY OF ANALYTICAL DATA (RAW CONCENTRATION
V-10	VALUES)	126
V-ll	RAW WASTE QUALITY SUMMARY - HOT FORMING
SUBCATEGORY	136
VI-1	PRIORITY POLLUTANTS KNOWN TO BE PRESENT - HOT
FORMING SUBCATEGORY 	 139
VI-2	SELECTED POLLUTANTS - HOT FORMING SUBCATEGORY . . . 140
V

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155
160
173
174
228
237
242
249
253
255
265
291
292
293
295
306
307
309
310
316
317
318
HOT FORMING SUBCATEGORY
TABLES (CONTINUED)
TITLE
LIST OF CONTROL AND TREATMENT TECHNOLOGY (C&TT)
COMPONENTS AND ABBREVIATIONS 	
SUMMARY AND ANALYTICAL DATA (GROSS RAW AND TREATED
VALUES) 	
LONG-TERM DATA ANALYSIS SUMMARY 	
RAW WASTE QUALITY GENERATION RATE SUMMARY TABLE -
TSS AND O&G 	
TREATMENT SYSTEM COSTS REPORTED BY HOT FORMING
OPERATIONS 	
CONTROL AND TREATMENT TECHNOLOGY SUMMARY - PRIMARY,
SECTION AND FLAT OPERATIONS 	
CONTROL AND TREATMENT TECHNOLOGY SUMMARY - HOT
WORKING PIPE AND TUBE OPERATIONS .... 	
LAND REQUREMENT SUMMARY 	
BPT (BAT FEED) CAPITAL AND ANNUAL COST
REQUIREMENT SUMMARY 	
BPT MODEL COST SUMMARIES 	
BAT ALTERNATIVE COST SUMMARIES BY SUBDIVISION
AND MODEL TYPE 	
BAT ALTERNATIVE NO. 1 COST SUMMARY 	
BAT ALTERNATIVE NO. 2 COST SUMMARY 	
BCT COST SUMMARY 	
NSPS MODEL COST SUMMARIES BY SUBDIVISION 	
PRETREATMENT COST REFERENCE TABLE 	
ENERGY REQUIREMENTS AT THE BAT LEVEL OF TREATMENT .
SLUDGE GENERATION AT THE BPT LEVEL OF TREATMENT . .
SLUDGE GENERATION AT THE BAT LEVEL OF TREATMENT . .
RAW WASTE QUALITY SUMMARY 	
BPT EFFLUENT LIMITATIONS - HOT FORMING SUBCATEGORY .
BPT LOAD JUSTIFICATION BY SUBDIVISIONS 	
vi

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HOT FORMING SUBCATEGORY
TABLES (CONTINUED)
NUMBER	TITLE	PAGE
X-l	BAT ALTERNATIVE NO. 1 EFFLUENT LIMITATIONS	334
X-2	BAT ALTERNATIVE NO. 2 EFFLUENT LIMITATIONS	335
X-3	ANALYSIS OF PRIMARY SCALE PIT RECYCLE RATES ....	336
X-4	OVERALL RECYCLE RATE ANALYSIS 		338
X-5	BAT APPLIED FLOW DETERMINATION - PRIMARY OPERATIONS
(BASIC ALLOWANCE)	342
X-6	BAT APPLIED FLOW DETERMINATION - PRIMARY OPERATIONS
(HOT SCARFER) 	344
X-7	BAT APPLIED FLOW DETERMINATION - SECTION OPERATIONS
(CARBON)	345
X-8	BAT APPLIED FLOW DETERMINATION - SECTION OPERATIONS
(SPECIALTY) 	349
X-9	BAT APPLIED FLOW DETERMINATION - FLAT OPERATIONS
(HOT STRIP AND SHEET) 	350
X-10	BAT APPLIED FLOW DETERMINATION - FLAT OPERATIONS
(CARBON PLATE) 		352
X-ll	BAT APPLIED FLOW DETERMINATION - FLAT OPERATIONS
(SPECIALTY PLATE) 		353
X-12	BAT APPLIED FLOW DETERMINATION - HOT WORKING
PIPE AND TUBE	354
X-13	FLOW AND RECYCLE RATE SUMMARY TABLE	355
XI-1	BCT EFFLUENT LIMITATIONS	361
XII-1	NSPS ALTERNATIVE NO. 1 STANDARDS	365
XII-2	NSPS ALTERNATIVE NO. 2 STANDARDS	366
XIII-1	PRETREATMENT STANDARDS 		373
vii

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HOT FORMING SUBCATEGORY
FIGURES
NUMBER	TITLE	PAGE
III-l	PROCESS FLOW DIAGRAM - HOT FORMING (GENERAL) ....	80
III-2	PROCESS FLOW DIAGRAM - HOT FORMING - PRIMARY ....	81
III-3	PROCESS FLOW DIAGRAM - HOT SCARFING OPERATION ...	82
III-4	PROCESS FLOW DIAGRAM - HOT FORMING - SECTION ....	83
III-5	PROCESS FLOW DIAGRAM - HOT FORMING - FLAT
(PLATE OPERATION) 		84
III-6	PROCESS FLOW DIAGRAM - HOT FORMING - FLAT
(HOT STRIP OPERATION)'		85
III-7	PROCESS FLOW DIAGRAM - HOT FORMING - BUTT
WELDED PIPE MILL	86
III-8	PROCESS FLOW DIAGRAM - HOT FORMING - SEAMLESS
TUBE " MILL	87
IV-1	to FLOW VERSUS SIZE ANALYSIS PLOTS - HOT FORMING
IV-8	SUBCATEGORY		102
IV-9 to	FLOW VERSUS AGE ANALYSIS PLOTS - HOT FORMING
IV-16	SUBCATEGORY	110
VII-1 to WASTEWATER TREATMENT SYSTEM WATER FLOW DIAGRAMS -
VII-44	HOT FORMING SAMPLED PLANTS	175
VIII-1	BAT FEED TREATMENT MODEL SUMMARY - HOT
FORMING SUBCATEGORY 	 312
IX-1	BPT TREATMENT MODEL DIAGRAM - PRIMARY, SECTION, AND
FLAT SUBDIVISION	326
IX-2	BPT TREATMENT MODEL DIAGRAM - INTEGRATED PIPE AND
TUBE OPERATIONS 	327
IX-3	BPT TREATMENT MODEL DIAGRAM - ISOLATED PIPE AND
TUBE OPERATIONS	328
X-l	BAT MODEL - ALTERNATIVE NO. 1 - HOT FORMING
SUBCATEGORY		356
X-2	BAT MODEL - ALTERNATIVE NO. 2 - HOT FORMING
SUBCATEGORY	357
XII-1	NSPS MODEL - ALTERNATIVE NO. 1 - HOT FORMING
SUBCATEGORY	367
XII-2	NSPS MODEL - ALTERNATIVE NO. 2 - HOT FORMING
SUBCATEGORY	368
XIII-1	PRETREATMENT MODEL - HOT FORMING SUBCATEGORY .... 374
lx

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HOT FORMING SUBCATEGORY
SECTION I
PREFACE
The USEPA is proposing effluent limitations guidelines and standards
for the steel industry. The proposed regulation contains effluent
limitations 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 Hot Forming 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.

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HOT FORMING SUBCATEGORY
SECTION II
CONCLUSIONS
This report highlights the technical aspects of EPA's study of the hot
forming subcategory. Based on the current study and a review of
previous studies, the Agency has reached the following conclusions:
1.	The Agency has decided to combine all hot forming operations in
one subcategory. The four major subdivisions of the subcategory
- primary, section, flat, and pipe and tube - reflect significant
differences in production process and wastewater flow. All hot
forming wastewaters are basically similar in character.
2.	The Agency is proposing BPT limitations for the hot forming
subcategory that are identical to those promulgated in March,
1976. Those proposed limitations are well demonstrated
throughout the industry.
3.	The proposed BAT, BCT, NSPS, PSES and PSNS limitations and
standards are based upon model plant flow rates (applied and
discharge) determined from the expanded data base of the industry
the Agency obtained as part of this study. While these model
flow rates are different than 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
realistic and appropriate.
4.	During this study, the Agency found that wastewaters from hot
forming operations contain significant levels of conventional and
toxic metal pollutants. Toxic organic pollutants were found at
low levels in some hot forming wastes. As shown below, the
Agency finds that discharges of these pollutants can be
controlled by technologies that are well demonstrated throughout
the hot forming subcategory.
	Effluent Loadings (Tons/Year)
Proposed
Raw Waste Proposed BPT BAT and BCT
Flow, MGD	4,188	2,225	168
TSS	6,017,455	43,860	2,724
Oil and Grease	272,440	24,140	908
Toxic Metals	34,820	1,670	90
The Agency believes that extensive recycle of hot forming
wastewaters considered as components of the BAT, NSPS, and
Pretreatment alternative treatment systems is appropriate to
minimize toxic pollutant discharges from hot forming operations.
3

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5. EPA estimates that the industry will incur the following costs to
comply with the proposed BPT, BCT, BAT, and PSES limitations and
standards for facilities in place as of January 1, 1978.
Costs (Millions of July 1. 1978 Dollars)
TotalIn-placeRequired
Investment
Total
Annual
BPT
BAT
677.0
535.5
541 .7
100.8
135.3
434.7
-103.7
110.8
TOTAL 1212.5
642.5
570.0
7. 1
NOTE: BAT costs are in addition to BPT costs. BCT and PSES
costs are included in the BPT and BAT costs.
It should be noted that the industry profile used for this study
includes many facilities permanently shutdown during the past
four years. Hence, the actual costs to be incurred by the
industry as it stands today will be lower than those shown above
for BPT and BAT.
6.	The Agency developed the estimated investment and annual costs to
achieve the proposed BAT and BCT limitations using a treatment
model concept. This approach recognizes central treatment
practices within the hot forming subcategory and more accurately
depicts the expenditures that will be required to install the
systems being considered. As part of this analysis, the Agency
used co-mingling factors to account for typical cost savings
achieved with central treatment facilities in this subcategory.
7.	The technology identified for the control of conventional
pollutants found in hot forming wastewaters was found to provide
treatment at less cost than comparable POTW treatment. Hence,
the Agency is proposing BCT limitations for all hot forming
operations based upon recycle and filtration. This technology is
fully compatible with the technology used to develop the proposed
BAT limitations.
8.	Proposed New Source Performance Standards and Pretreatment
Standards are based upon the same technologies used to develop
the proposed BAT and BCT limitations.
9.	The Agency has concluded that by proposing effluent limitations
for the same conventional pollutants (BCT) and toxic pollutants
(BAT) for subcategories with compatible wastewaters, central
treatment will be facilitated. For this reason, the Agency is
proposing limitations for toxic metal pollutants in the hot
forming subcategory which are the same as those proposed for
limitations in the steelmaking, vacuum degassing, and continuous
casting subcategories, among others.
4

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10. As shown below (and in Table X-4), the Agency has found several
hot forming operations which achieve zero discharge.
Number of Mills
Subdivision	at Zero Discharge
Primary	3
Section	9
Flat	1*
Pipe and Tube	1
* Plant 0248B is not included in Table X-4 but has reported zero
discharge.
The Agency is soliciting comments on whether zero discharge
limitations and standards should be proposed at the BAT, BCT, and
NSPS levels based upon the demonstrated performance of the above
plants. These plants are achieving zero discharge using BPT,
BAT, and BCT treatment model components. Hence, no additional
costs beyond those required for BPT, BAT, and BCT would be
necessary to achieve zero discharge.
12.	Throughout this report, the Agency has addressed the applicable
remand issues. Conclusions concerning these issues follow.
a.	The age of a plant has little or no effect upon the ease or
cost of retrofitting pollution control equipment.
Therefore, neither relaxed limitations for "older" plants
nor retrofit cost allowances are proposed for hot forming
operations.
b.	The alternative wastewater treatment systems for BAT, BCT,
NSPS, PSES and PSNS involve the use of cooling towers which
will consume about 20 million gallons of water per day (0.5%
of total subcategory water usage). However, the amount of
water consumed as a result of the installation of this
technology is minimal when compared to the total amount of
water used in this subcategory. The Agency concludes that
the effluent reduction benefits associated with compliance
with the proposed limitations justify the minor consumptive
water losses, both on a national basis, and on an "arid" and
"semi-arid" region basis. Plants located in arid and
semi-arid regions have recycle systems for hot forming
wastewaters. Additional details on these and other remand
issues are presented in Volume I and in Section VIII of this
report.
13.	Table II—1 presents the treatment model flow and effluent quality
data used to develop the proposed BPT effluent limitations for
the hot forming subcategory, and Table I1-2 presents these
proposed limitations. Table II-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
5

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PSNS for the hot forming subcategory; Table I1-4 presents these
proposed limitations and standards.
6

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TABLE II-l
BPT TREATMENT MODEL FLOWS AND
EFFLUENT QUALITY-HOT FORMING SUBCATEGORY
Flow
Subdivision	(GPT)
1.	Primary
a.	Carbon w/o scarfers	692
b.	Carbon w/o scarfers	845
c.	Specialty	1220
2.	Section	2626
3.	Flat
a.	Hot Strip and Sheet	4180
b.	Carbon Plate	4000
c.	Specialty Plate	9366
4.	Pipe and Tube	1002
Monthly Average Concentrations (mg/1)^
TSS	0 & G	pH (units)
13	10	6-9
13	10	6-9
13	10	6-9
22	10	6-9
19	10	6-9
10	10	6-9
10	10	6-9
34	10	6-9
(1) Daily maximum effluent concentrations are three times the monthly average concentrations.
7

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TABLE II-2
PROPOSED BPT EFFLUENT LIMITATIONS
HOT FORMING SUBCATEGORY
Subdivi sion
1.	Primary
a.	Carbon w/o scarfers
b.	Carbon w/o scarfers
c.	Specialty
2.	Section
3.	Flat
a.	Hot Strip and Sheet
b.	Carbon Plate
c.	Specialty Plate
4.	Pipe and Tube
Effluent Limitations (kg/kkg of Product)^^
TSS	0 & G	pH (unitsT"
0.0371
0.0453
0.0654
0.242
0.331
0.167
0.376
0.142
0.0288
0.0352
0.0508
0.110
0.174
0.167
0.376
0.042
6-9
6-9
6-9
6-9
6-9
6-9
6-9
6-9
(1) Daily maximim effluent limitations are three times the average limitations.
8

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TABLE II-3
TREATMENT MODEL FLOWS AND EFFLUENT QUALITY
HOT FORMING SUBCATEGORY
Subdivision
BAT
Flow Rates (gal/ton)
BCT
NSPS
PSES
PSNS
1. Primary
a. w/o Scarters
b . w/o Scarfers
90
140
90
140
90
140
90
140
90
140
2.	Section
a.	Carbon
b.	Specialty
3.	Flat
200
200
200
200
200
200
200
200
200
200
a.	Hot Strip & Sheet	260
b.	Carbon Plate	140
c.	Specialty Plate	60
4. Pipe & Tube	220
260
140
60
220
260
140
60
220
260
140
60
220
260
140
60
220
Pollutant
(2)
TSS
0&G
119 Chromium, Total
122 Lead
128 Zinc, Total
pH, units
BAT
0.10
0.10
0.10
Monthly Average Concentrations
BST	NSPS	PSES
(1)
15
10*
6.0 to 9.0
15
10*
0.10	0.10
0.10	0.10
0.10	0.10
6.0 to 9.0
PSNS
0.10
0.10
0.10
(1) Daily maximum concentrations are based upon the monthly average concentrations
multiplied by the following factors:
Pollutants
Factor
(2)
*
TSS	2.67
Chromium, Lead & Zinc 3.00
Concentrations are expressed in mg/1 unless otherwise noted.
Concentrations shown apply to all hot forming subdivisions.
Daily maximum concentration only, as shown.
9

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TABLE II-4
PROPOSED EFFLUENT LIMITATIONS AND STANDARDS
HOT FORMING SUBCATEGORY
Effluent Limitations & Standards (kg/kkg of Product)^^
Pollutants
BAT
BCT

NSPS

PSES
PSNS
la.
Primary w/o Scarfers








TSS
—
563

563

-
-

O&G
-
373*

373*

-
-
119
Chr omium, Tot al
3.75
-

3.75

3.75
3.75
122
Lead
3.75
-

3.75

3.75
3.75
128
Zinc, Total
3.75
-

3.75

3.75
3.75

pH, units
-
6.0 to
9.0
6.0 to
9.0
—
—
lb.
Primary w/o Scarfers








TSS
—
876

876

-
-

O&G
-
584*

584*

-
-
119
Chromium, Total
5.84
-

5.84

5.84
5.84
122
Lead
5.84
-

5.84

5.84
5.84
128
Zinc, Total
5.84
-

5.84

5.84
5.84

pH, units
—
6.0 to
9.0
6.0 to
9.0

—
2a.
Section-Carbon








TSS
—
1250

1250

-
_

O&G
-
834*

834*

-
-
119
Chromium, Total
8.34
-

8.34

8.34
8.34
122
Lead
8.34
-

8.34

8.34
8.34
128
Zinc, Total
8.34
-

8.34

8.34
8.34

pH, units
—
6.0 to
9.0
6.0 to
9.0
—

2b.
Section-Special ty








TSS
-
813

813

-
-

O&G
-
542*

542*

-
-
119
Chromium, Total
5.42
-

5.42

5.42
5.42
122
Lead
5.42
-

5.42

5.42
5.42
128
Zinc, Total
5.42
-

5.42

5.42
5.42

pH, units
-
6.0 to
9.0
6.0 to
9.0
—
—
10

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TABLE II-4
PROPOSED EFFLUENT LIHITATION & STANDARDS
PAGE 2
Pollutants
3a. Flat-Hot Strip & Sheet
TSS
O&G
119 Chromium, Total
122 Lead
128 Zinc, Total
pH, units
3b. Flat-Carbon Plate
Effluent Limitations & Standards (kg/kkg of Product)
(1)
BAT
10.8
10.8
10.8
BCT
1630
1090*
6.0 to 9.0
NSPS
1630
1090*
10.8
10.8
10.8
6.0 to 9.0
PSES
10.8
10.8
10.8
PSNS
10.8
10.8
10.8
TSS
O&G
119 Chromium, Total	5.84
122 Lead	5.84
128 Zinc, Total	5.84
pH, units
3c. Flat-Specialty Plate
TSS
O&G
119 Chromium, Total	2.50
122 Lead	2.50
128 Zinc, Total	2.50
pH, units
4. Pipe & Tube
876	876
584*	584*
5.84
5.84
5.84
6.0 to 9.0 6.0 to 9.0
375	375
250*	250*
2.50
2.50
2.50
6.0 to 9.0 6.0 to 9.0
5.84
5.84
5.84
2.50
2.50
2.50
5.84
5.84
5.84
2.50
2.50
2.50
TSS
0&G
119 Chromium, Total
122 Lead
128 Zinc, Total
pH, units
9.17
9.17
9.17
1380	1380
917*	917*
9.17	9.17
9.17	9.17
9.17	9.17
6.0 to 9.0 6.0 to 9.0
9.17
9.17
9.17
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TABLE II-4
PROPOSED EFFLUENT LIMITATIONS & STANDARDS
PAGE 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 factors:
Pollutants	Factor
TSS	2.67
Chromium, Lead & Zinc 3.00
* Limitations and standards for oil and grease are on a maximum basis only as shown.
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HOT FORMING SUBCATEGORY
SECTION III
INTRODUCTION
General Discussion
Hot forming is the steelmaking process in which hot steel, initially
in solid ingot form or in intermediate shapes, is reduced in
cross-section through a series of forming steps ultimately producing
finished and semi-finished steel products. These products have
numerous cross-sections, lengths and tonnages. While several
different types of hot forming mills are in use today, the hot forming
processes have been grouped into one subcategory with the following
major subdivisions.
Primary Mills
Section Mills
Flat Mills (Plate and Hot Strip & Sheet)
Hot Worked Pipe and Tube Mills
Figure II1-1 illustrates the sequences involved in hot forming
operations.
Process wastewaters originating in the hot forming processes require
treatment prior to discharge to receiving waters. Those wastewaters
contain large amounts of suspended solids, oil and grease, and to a
lesser extent, toxic metal pollutants. Toxic organic pollutants have
been detected in some hot forming wastewaters. This report reviews
wastewater treatment systems used at hot forming operations and
includes model treatment systems and proposed effluent limitations and
standards.
Data Collection Activities
The Agency sampled a total of 76 hot forming operations and obtained
process information and wastewater quality data. The originally
promulgated limitations for hot forming operations were based
primarily upon data obtained through field sampling at 52 mills.
Twenty-nine operations were sampled during the recent toxic pollutant
survey (five operations were resampled). Table III—1 presents basic
descriptions of each mill sampled.
The general methodology and approach for data collection is described
in Volume I. Information regarding applied and discharge flow rates,
treatment systems in use, mill production capacities and modes of
operation were provided by the industry for 485 mills. Tables II1-2
through II1-7 summarize the information received for the respective
hot forming processes.
In an effort to gather additional data, the Agency sent detailed data
collection portfolios (D-DCPs) to thirty-one hot forming operations.
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These questionnaires were designed to gather information on long-term
effluent quality, treatment costs and other operating data.
Tables II1—8 through 111-12 summarize the data base for this report.
Description of Hot Forming Operations
Primary Rolling Mills
The hot forming, primary mill is the initial rolling step used in the
production of a semi-finished product from solid hot steel ingots.
Primary mills produce either blooms, slabs, or billets. Slabs are
oblong shapes with cross-sections varying from 2" to 6" thick and 24"
to 60" wide. Blooms are square or slightly oblong and are generally
in the range of 6" x 6" to 10" x 12". Billets are square products
that are generally less than 6" x 6". The preceding product
dimensions are only reference sizes as many different cross-sections
are produced with primary mills. Blooming, slabbing and billet mills
are generally identified by the number of rolls or by the roll
diameter and length such as a two high reversing mill or a 45" x 90"
slabbing mill. Blooming mills may be coupled with billet mills so
that the semi-finished bloom can immediately be rolled in the billet
mill while it is still hot.
The operation of a typical primary mill operation is described below:
The hot steel ingots are transferred to the primary mills from soaking
pit furnaces which uniformly heat the steel ingots to the desired
rolling temperature, usually 1180 to 1340°C (2,156 to 2,444°F). The
soaking pits also act as storage areas to compensate for production
variations in the flow of steel ingots between the steelmaking
facilities and primary rolling mills. The soaking pit furnaces are
square, rectangular, or circular, fuel fired (i.e., oil, gas)
refractory lined pits constructed with the top of the pits several
feet above ground level. The soaking pits are usually arranged in
rows and are installed in a building adjacent to or within the primary
mill. The ingots are placed into the soaking pits in an upright
position through openings in the top. Removable covers are used to
close the pit openings. The pits are spanned by one or more cranes
equipped with ingot lifting tongs for placing and removing the steel
ingots. The crane removes the properly heated steel ingots and places
them into an electrically driven ingot transfer car which
automatically delivers the ingots to the primary rolling mill.
The mill approach tables transport the ingot to the front table or
roller table in preparation for rolling. Some mills are equipped with
a scale in the ingot receiving table or mill approach tables for
weighing the ingot prior to rolling. Depending upon the type of
primary mill, (i.e., reversing, tandem) the hot ingot is passed
between the mill rolls and reduced in cross-section. In a reversing
mill, the ingot is rolled through the same mill stand a number of
times. A tandem mill is comprised of several mill stands such that
the ingot is continuously rolled forward in one direction. Mill
speeds are generally 200 to 400 feet per minute. During the rolling
cycle, the ingot is transported to and from the mill stands by
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reversing rolls. The rolls are 12 to 21 inches in diameter and are
spaced 2 to 3 feet apart- These roll tables are driven by line
shafts. After the ingot is rolled to the desired size, the end of the
bloom, slab, or billet is cut off or "cropped." A crop shear is also
used to cut long rolled sections into several shorter pieces.
The industry is paying increased attention to the conditioning of
semi-finished products as the demand for high quality steel products
increases. The removal of surface defects from blooms, billets, and
slabs prior to final rolling is a major consideration. Defects such
as rolled seams, light scabs, and checks generally retain their
identity during subsequent forming processes and result in products of
inferior quality. These surface defects may be removed by hand
chipping, machine chipping, scarfing, grinding, milling, and hot steel
scarfing. The various mechanical means of surface preparation are
common to all metal working and machine shop operations. Scarfing is
a process of supplying streams of oxygen as jets to the surface of the
steel product under treatment, while maintaining high surface
temperatures, which results in the rapid oxidation and localized
melting of a thin layer of the metal. The process may be done
manually (involving the continuous motion of an oxyacetylene torch
along the length of the product) but in recent years automatic hot
scarfing has come into wide use. The scarfing machine is located at
the mill run out tables or at the shear approach tables.
The automatic hot scarfing process first uses flames generated by the
burning of oxygen and fuel (either acetylene or natural gas) to
preheat the semifinished product surface to steel melting
temperatures. A continuous stream of pure oxygen is then directed
onto the reheated steel surface and the semifinished product is then
moved at a controlled speed through the scarfing machine. The oxygen
applied to the entire surface of the billet, bloom or slab oxidizes
the steel surface, and removes a surface layer to a predetermined
depth, typically not in excess of 1/8 inch.
The automatic scarfing machine scarfs steels at speeds between 50 to
200 feet per minute. A typical operating cycle for an automatic hot
scarfer is shown below.
a.	Position product
b.	Close scarfing units
around product
c.	Preheat product surface
d.	Scarf (Oxygen on)
e.	Retract scarfing units
Total
7 seconds
3 seconds
5 seconds
30 seconds
5 seconds
50 seconds
The scarfing machine is mounted on a motor driven carriage on rails
and can be moved in and out of the primary rolling mill run out table
line. The removal of the surface metal results in a continuous
production of molten slag. The quantity of slag generated depends
upon the section size and depth of cut and is removed by high pressure
water sprays.
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Scarfing also results in appreciable quantities of smoke. The
quantity and density are dependent upon the type of steel, oxygen
pressure, and the efficiency of slag water jets. Hoods are placed
over the scarfing roll table to collect the fumes which contain solids
consisting mainly of iron oxides with traces of the alloying elements
found in the steel being scarfed. The solids are submicron in size,
and are produced at an approximate rate of 36 grains per pound of
product surface metal removed.
The exhaust gases are comprised mainly of air with some quantities of
CO and CO* (2%). These gases are saturated at a temperature of 60°C
(140°F) when exiting the scarfer hood. Because these gases are
saturated, three types of gas cleaning equipment systems are generally
used:
1.	Wet Precipitator - Intermittent Spray Wash
2.	Wet Precipitator - Continuous Wash
3.	High Energy Venturi Scrubber
The wet precipitator - intermittent spray wash uses a spray water wa^h
on a time cycle to cleanse the fume residue which is collected dry on
the precipitator plates. The wet precipitator - continuous wash uses
a continuous water wash to cleanse the collected fume residue from
precipitator plates. The high energy scrubber requires 45 to 50
(inches water column) pressure drop to clean the gases, and requires
scrubbing water at a rate of 7 to 12 gallons per 1000 cubic feet of
saturated gas exhausted. The effluent wastes from these gas cleaning
systems are generally discharged to the primary mill wastewater
treatment system. At many mills, scarfer wastewaters are recycled
continuously with only a blowdown discharged to the primary mill
treatment system.
Many primary mills are being replaced with continuous casting
operations referred to as billet, bloom or slab casting machines. The
casting machines, in turn, furnish the steel slabs or blooms to the
section mills.
See Figures III-2 and III-3 for primary rolling mill process flow
diagrams.
Section Rolling Mills
The section rolling mill takes the semi-finished product from the
primary mill and produces either an intermediate finished product
called a billet, which is further reduced in other finishing mills, or
rolls the bloom directly to a finished product. Most billets are
rolled directly from the primary mill without reheating furnaces but
some steel plants employ furnaces between the primary and section
mills. The older primary and section mills generally do not have
reheat furnaces since the grades of steel produced do not require the
restricted rolling temperatures as do the newer steel types. New
facilities have the capability to bypass the reheat furnaces depending
upon the grade of steel being rolled.
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Reheating is necessary for section operations whenever the temperature
of the metal being worked falls below that temperature required to
maintain plasticity. Reheating furnaces are either batch or
continuous. Batch furnaces are those in which the charged material
remains in a fixed position on the hearth until heated to rolling
temperature. Continuous furnaces are those in which the charged
material moves through the furnace and is heated to rolling
temperature as it progresses toward the exit. Batch furnaces vary in
size from those with hearths of only a few feet square to those 20 ft
in depth by 50 ft long. Some modern continuous furnaces have hearths
80 to 90 feet long.
Automatic hot scarfing is used at five section mills. The automatic
hot scarfer used for the section mill operations is the same as
described for primary rolling mills.
The intermediate and finished products produced from section mills
include rails, joint bars, I-beams, channels, angles, wide flanged
beams, H-beams, sheet piling, and billets which are further processed
into tube rounds, bar and rod, wire, and numerous, special sections.
Following is a brief description of the various section mills.
Billet Mills
There are several types of billet mills. One is the three high mill
with lifting and tilting tables. This mill consists of three rolls
mounted on a single roll housing stand, one roll above the other.
Billets are rolled in one direction between the bottom and middle
rolls and in the opposite direction between the middle and top rolls.
The lifting and tilting tables move the billets to the two different
pass levels. Mills of this type can produce only a limited number of
product sizes.
Another billet mill design is the cross-country mill which is composed
of several roll stands so arranged that the billet is never in more
than one stand at the same time. The roll stands may be placed side
by side and the billet transferred to the various roll tables. The
direction of rolling can be reversed in each stand. The cross country
billet mill is faster and more flexible than the three high mill and
can roll a complete range of billet sizes.
A third billet mill design is the continuous billet mill in which a
series of roll stands continuously reduce the billet in size, rolling
in only one direction through the mill stands. Continuous billet
mills have high production rates and minimal scrap losses since blooms
of any length can be rolled.
Following the billet mill operation# the product is cut to the desired
finished piece length. The cutting is accomplished by stationary
shears, movable gang shears, flying shears, flame cutting, or saws.
Shears are faster but distort product ends while flying shears are
used on small billets to eliminate long tables and transfers. Saws
and flame cutting eliminate distorted ends but are slower and require
maintenance and expensive fuels.
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The billets are subsequently transferred to bar mills or merchant
mills for processing into finished products. The billets are heated
to rolling temperature in continuous reheat furnaces. The billets are
fed into one end and moved through the furnace by a billet pusher. A
walking beam furnace is sometimes used to eliminate the slide marks on
the underside of the billets. A billet ejector, normally a pusher bar
type, pushes the end billet out of the side of the furnace. A shear
then cuts the heated billets to size or removes bent ends prior to
conveying the billet to the bar mill.
Bar Mills
Modern bar mills are normally arranged in a cross-country design or
continuous design. Both types have in-line roughing stands, however,
the cross-country mill has side by side intermediate and finishing
stands whereas the continuous mill has all stands in-line. The
continuous mill is more efficient for production runs but requires
more space and individual motors on each stand. Descaling and cooling
water sprays are employed at the mill stands with the discharge
draining to trenches under the mill into collection systems.
Various products are rolled in the bar mills such as angles, channels,
flats, other small sections, rebar, window sash, fence posts, rounds,
wire, and flat narrow strips. These products are sheared to proper
length, marked for identification, sometimes straightened, bundled or
coiled, and weighed for shipment or further processing.
Rail Mills
Rails are formed from heated blooms in various mill arrangements, but
the forming generally takes place in three steps or stages. The first
stage is the roughing stage where the bloom is reduced in section and
elongated. High pressure sprays are used at the discharge of the
roughing stands for scale removal. The second, or intermediate stage,
proceeds with the forming of the rail and involves a combination of
slabber, dummy, former, edger, and leader passes, depending upon the
mill layout. The third stage is the finishing pass which then
completes the formation of the desired rail section.
The rails are conveyed from the finishing stand on a runout table to
hot saws which cut the product to the standard 39 ft rail length.
After sawing, the rails are stamped, cambered, and weighed before they
are advanced to cooling beds. Rails intended for railroad service
must be control cooled in containers to prevent the formation of
internal thermal ruptures or cracks. After cooling, the rails are
conveyed to finishing operations which consist of inspection, removal
of saw burrs, straightening, drilling, grinding of ends, leveling,
inspection, classification, and painting.
Rail-Joint Bars
Joint bars are rolled from heated blooms or billets similar to rails.
Additional passes are required if the joint bar has a depending
flange, or long toe. The finishing operation consists of hot-working
and oil-quenching the joint bars. In this operation the product is
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cold sheared to length and then reheated for hot-working which
consists of punching, slotting, straightening, and quenching in an oil
tank.
Structural and Other Section Mills
Structural sections include standard items such as I-beams, channels,
angles, and wide-flange beams, and special sections such as zees,
tees, bulb angles, and car-building center sills. Other sections
include miscellaneous shapes such as sheet piling, tie plates, and
cross ties.
Blooms are heated in a continuous reheat furnace and then conveyed to
the roughing, intermediate, and finishing stands. Passes in actual
use range from fifteen roughing and nine intermediate on sections
requiring heavy overall work, to two fine roughing and three
intermediate on the sections requiring a minimum of work. In all
cases, the intermediate passers are followed by a single finishing
pass. In rolling wide-flange beams it is customary to roll a bloom
which has, as nearly as possible, the same proportions as the finished
beam.
Rolled material from the structural mills is delivered by a roller
table to the hot saw. This equipment consists of a circular saw over
which large quantities of cooling water are passed to maintain the
cutting edges. Cuts are usually made at the hot saw to remove the
crop ends, to part the usable material into lengths that can be
handled for further processing, and to provide short test pieces. The
shapes are then cooled on a cooling bed. After cooling, the shapes
are conveyed to the finishing area where they are straightened, cold
sheared or cold sawed, and inspected prior to separating and
assembling for shipment.
Merchant-bar, rod, and wire mills produce a wide variety of products
in continuous operations ranging from shapes of small size through
bars and rods. Mill designation and product classification are not
very well defined within the industry. In general, the small
cross-sectional area and very long lengths distinguish the products of
these mills. Raw materials for these mills are reheated billets.
Many older mills included hand looping operations in which the
material is passed from stand to stand manually. Newer mills use
mechanical methods of transferring the material from stand to stand.
As with other rolling operations the billet is progressively squeezed
and shaped to the desired product dimensions in a series of rolls.
Water sprays are used throughout the operation to remove scale.
See Figure III-4 for the process flow diagram for section rolling
mills.
Plate Mills
Plates are classified according to size limitations to distinguish
them from sheet, strip, and flat bars. According to this
classification, plates are generally considered to be those flat
hot-rolled finished products that are more than 8 inches wide and
19

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generally 0.23 inches or more thick, or over 48 inches wide and at
least 0.18 inches thick. The sequence of operations for plate mills
is reheating of slabs, descaling, rolling, leveling, cooling and
shearing. Most plate mills use continuous heating furnaces.
Descaling in modern plate mills is accomplished by hydraulic sprays
impinging on both top and bottom surfaces and operating at pressures
up to 1,500 lbs per sq. in. Temperature variation in the plate from
the front to the back is a problem of particular importance in rolling
plates, as is the care that must be exercised in cooling the rolled
product so as to avoid distortion.
The basic operation of a plate mill is the reduction of a heated slab
to the weight and dimensional limitations defining plates. This is
accomplished by heating the slabs, descaling, rolling them to plate,
leveling, or flattening, cooling, and shearing to the desired size.
Slabs are received from slabbing mills or continuous casters and then
stored in slab yards. Slabs are removed from storage by overhead
cranes and placed on a charging table at the entry end of the reheat
furnaces. The slabs are moved through a continuous type reheat
furnace by pushing the last piece charged with a pusher at the
charging entry end of the furnace. The reheat furnace heats the slabs
to a rolling temperature of approximately 1,220°C (2,230°F). As each
cold slab is pushed into the furnace against the line of material
already in the furnace, a heated piece exits the furnace. The heated
slab is discharged from the furnace by gravity upon a roller table
which feeds the mill.
Heated slabs are conveyed on a roller table to a scale-breaker mill
stand. As the slab leaves the scale-breaker, primary descaling is
completed with top and bottom high pressure hydraulic water sprays
operating at 1,000 psi to 1,500 psi. The scale-breaker and water
sprays flush away iron oxide or mill scale which forms on the surface
of the hot slabs. Generally, about 4% of the spray water evaporates
and the balance is discharged through a trench under the mills to a
mill scale and wastewater collection system. Mill scale generation
may amount to 1.5-4% of the steel production. During the rolling
operations, cooling water is sprayed externally over the table and
mill stand rolls. Additional lubrication between product and mill
stand rolls is provided at intervals by sprays of water soluble oil.
The descaled slabs are conveyed on roller tables to the plate mill.
There are various types of plate mills such as three high mills, four
high reversing mills, tandem mills, semi-continuous and continuous
mills. In each of the various plate mills, the heated slab is reduced
to the desired plate size. Cooling water, spray water, and water
soluble oil is sprayed externally over the mill stand rolls.
Hydraulic sprays on both sides of the mill stands, operating at high
pressure, are employed for top and bottom secondary scale removal.
The plates are conveyed on a run-out table to a leveler. A portion of
the run-out table is equipped with a series of cooling sprays. After
leveling, the plates are cooled uniformly to avoid localized stresses
which would set up permanent distortions. After cooling, the plates
are conveyed to end and side shears where they can be cut to proper
20

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size and then transferred to a shipping storage building, or sent to
heat treating furnaces.
More specific details of a plate mill operation are presented in
Figure III-5.
Hot Strip Mill
The continuous wide hot strip mill uses slabs that are reheated to
rolling temperatures (2000-2400°F) in continuous reheat furnaces.
Slabs are provided either from a storage yard or are delivered hot
directly from the slabbing mill, thus bypassing the reheat furnaces.
Slab casting machines are also used to produce slabs. Slabs are
generally provided in sizes of 2 to 7 inches thick, one to five feet
in width and up to twenty feet in length.
The basic operation of a hot strip mill is the reduction of slabs to
flat strip steel in thicknesses of 0,04 inches to 1.25 inches, widths
of 24 inches to 96 inches, and lengths up to 2,000 feet. The modern
hot strip mill produces a product which may be up to 96 inches wide,
although the most common width in newer mills is 80 inches. The
product of the hot strip mill may be sold as produced, processed in
cold reduction mills, and plated or coated.
The continuous wide hot strip mill rolling train consists of a
roughing scale breaker stand, several roughing mill stands, a
finishing scale breaker stand, several finishing mill stands, a
run-out table and coilers. Motor driven roll stands convey the hot
slabs from the reheat furnaces to the mill stands and also from mill
stand to mill stand. if the mill is to produce strip or sheets
greater than the maximum width of available slabs, the first roughing
stand acts as a broadside mill stand in which the width of the slab is
increased in a single pass by cross rolling. Turntables ahead and
following the roughing stand rotate the slab 90° for cross-rolling.
The roughing roll stands are separated from the finishing roll stands
by a holding table while the finishing stands are a closely grouped,
tandem rolling train of scale breakers and finishing mill stands.
High pressure (500-1500 psi) water sprays which are used to remove
scale from the hot slabs are located after the two scalebreaker stands
and the roughing stands. Roll stand spray cooling water is provided
for cooling of each roll in the stands.
Following the last finishing stand, there is usually a flying shear
for cutting the rolled product into sheets. A flying shear moves with
the strip as it cuts the strip into sheets. As the hot strip exits
the last finishing stand it is carried over long tables called run-out
tables. Mill speeds approximate 600 meters/minute (1970 feet/minute).
Two or more coilers, which are located at the end of the run-out
tables, serve to coil the hot strip when continuous long lengths are
required. If sheets are being cut by the flying shear, the coilers do
not operate. Instead, the steel sheets pass over the coilers onto a
sheet piler at the end of the run-out tables.
An alternate arrangement of a hot strip mill uses reversing roughing
stands with tandem continuous finishing roll stands. This arrangement
21

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allows for more passes in one roughing stand, thus decreasing the
length of the mill. However, mill production capacity is less than
the tandem mill arrangement.
A rotary crop shear is located between the roughing and finishing mill
stands so that the front and rear ends of the strip can be squared off
before finishing. Scrap strip steel from the hot strip mill is known
as "cobble."
Strip product is conveyed from the finishing stands to a run-out table
with automatic spray water coolers. The cooling water sprays
continuously cool the product on the run-out tables. Similar to the
wastewater from the mill stands and tables, the spray water drains
through a trench under the mill stands to the wastewater collection
system. The coiled strip product is conveyed to storage for shipping
or further processing.
More specific details of a hot strip mill operation are presented in
Figure III-6.
Combination Sheet. Strip and Plate Mills
Several hot forming-flat rolling mills produce a variety of finished
products including sheet, strip and plate. Product classification is
based upon thickness and width as shown by the following:
Thickness Greater Than
Width	0.05"	0.230"	0.299"
6"-12"	Strip	Plate	Strip
12"-48"	Sheet	Plate	Sheet
Over 48"	Sheet	Plate	Plate
Some mills are capable of producing all of the above products.
Because of the similarities between combination mills and strip mills,
the combination mills have been included in the hot strip data base
for the purpose of developing effluent limitations.
Pipe and Tube Mills - Hot Worked
Butt-Welded Pipe
Welded tubular products are classified as butt-weld. Butt-weld pipe
or tube is made from a hot rolled strip, with square or slightly
beveled edges, called skelp, the width of which corresponds to the
circumference of the pipe, and the gauge to the wall thickness. By
heating skelp to its welding temperature in a reheat furnace and
drawing it through a die or roll pass, the skelp is bent into a
cylindrical shape and its edges pressed firmly together into a
butt-weld, thus forming a pipe. The butt-welding process is used to
manufacture pipe, 1/8 inches to 4 inches in diameter. Skelp is
conveyed from storage and charged into a reheating furnace, welded in
a welding stand, and finished on finishing machines.
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The skelp is charged into a continuous reheat furnace. Modern mills
use skelp strip in coils to feed continuous butt-welding operations.
The skelp is fed into a threading machine which feeds it through the
furnace. Once the leading end is in the forming and welding unit, the
threading rolls release the skelp. The leading end of the next skelp
strip is welded to the trailing arm of the first strip by a flash type
skelp welder, prior to entry into the reheat furnace. The skelp strip
exits from the furnace into a continuous forming and welding mill.
The forming stand rolls then force the skelp into a welding stand,
where the edges are pressed firmly together. The last stands of the
mill contain reducing rolls which provide for reduction of diameter
and a resultant change in wall thickness. A rotary flying saw cuts
the continuous pipe into lengths. The cut lengths are reduced to the
required hot size on a sizing mill. The hot pipe is delivered to a
cooling bed and then passes to a water bosh tank for fast cooling.
Conveyors feed the pipe to straighteners in the finishing bay.
Details of a typical operation are depicted in Figure II1—7.
Seamless Tubular Products
Seamless tubular products are made by two processes; piercing and
cupping. In the piercing process, a solid round bar or billet is
heated, pierced and afterwards shaped to the desired diameter and wall
thickness. This process is used today for most seamless pipe
products. The cupping process is used primarily for the manufacture
of special tubes and gas cylinders. A circular sheet or plate is
forced by successive operations through several pairs of conical dies
until the plate takes the form of a tube, or cylinder with one end
closed. Details of a typical mill are shown in Figure II1—8.
The production of seamless pipe and the mills required for this
operation vary depending on the diameter of the pipe product. The
steps required to produce pipe up to 4 inches in diameter consist of
heating a solid billet, piercing, plug rolling, reeling, reheating and
reducing or sizing. The production of pipe up to 16 inches in
diameter is similar except a second piercing and reheating operation
is required. Pipe up to 26 inches in diameter is produced in a manner
similar to the preceding 16 inch operation except for the addition of
a rotary rolling mill and a third reheating operation.
A solid bar or billet of the proper length and diameter to make the
size and weight of the tube desired is heated to rolling temperature
of approximately 1,230°C (2,250°F). The heated billet is transferred
in a horizontal trough to the piercing mill, which consists of two
contoured horizontal rolls and a piercing mandrel. The roll surfaces
are contoured so that, in the horizontal plane through the centerline
of the pass, the space between the rolls converges toward the delivery
side and then diverges to form the pass outlet. The point of the
centerline of the pass is determined by guides between the rolls.
Between these guides in the pass outlet, a projectile shaped piercing
mandrel is held in position on the end of a water-cooled mandrel
support bar, located on the delivery side of the mill. The heated
billet is drawn over a mandrel, thus forming a hollow shell. As the
billet is drawn and compressed, the spreading of the metal sets up a
lateral tension which may cause its particles to be drawn away from
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the center, and for this reason the nose of the mandrel is at a point
preceding the forming of the cavity to insure a smooth inner surface.
The initial piercing produces a hollow tube with a comparatively heavy
wall. The second piercing mill further reduces the wall thickness and
increases the diameter and length of the piece required in the
production of large diameter product.
In the plug mill, a plug on a support bar is rammed into the end of
the shell, which is then drawn over the plug by revolving rolls,
slightly reducing its wall thickness and increasing its diameter and
length. In the rotary rolling mills, which are used for large
diameter pipe, conical rolls grip and spin the pipe, feeding it
forward over a large tapered mandrel, thereby decreasing the thickness
of the pipe wall and increasing its diameter. The length of the tube
remains essentially unchanged by this operation.
The reeling machine, consisting of rolls and a mandrel similar to the
piercing mill, reduces the thickness of the wall slightly. This
reduction has the effect of burnishing the inside and outside surfaces
of the tube and slightly increasing its diameter. After reeling, the
tube is reheated and conveyed to the sizing rolls, the grooves of
which are slightly smaller than the reeled tube. This reduces the
tube diameter which insures uniform size and roundness throughout its
length. After sizing, the product is straightened, its ends cropped,
inspected, and finished as required for its eventual use.
The properties of hot rolled seamless pipe may be improved by cold
working. One method is the seamless pipe method in which the hot
rolled pipe (after cooling) is conveyed to a cold expander mill. The
hot rolled pipe is dropped into an expander trough, clamped with one
end held firmly against a backstop. A long ram is positioned at the
opposite end of the pipe and an expander plug is forced through the
pipe under extreme pressure. The plug is lubricated through the ram
head with a water soluble oil. After cold expansion, the seamless
pipe enters a rotary straightener after which it is hydrostatically
tested. Cold working the pipe increases its yield strength and
generally improves the product. The cold worked operations are
reviewed in the cold forming subcategory.
24

-------
TABLE III-1
SUMMARY OF SAMPLED PLANTS
HOT FORMING SUBCATEGORY
Plant
Sample	Reference	Type of
Code	Code	Mill
PRIMARY MILLS
E
0020B
Slab
L-2
0060
Slab
A-2
0112B(01 & 02)
Bloom Mills (2)
B-2
0112B-03
Slab
081
0176
Bloom
R
0240A
Bloom
H
0248A
Bloom
D
0248B
Slab
K
0256K
Slab/Bloom
M (1)
082
0432J
Slab/Bloom
0496(140"only)
Slab/Rough Plate
082
0496(140"206" in tandem)
Slab/Rough Plate
Q
0684D
Bloom
C-2&088(Rev is ited)
0684H
Bloom
083
0860H-03
Slab/Bloom
D-2
0946A
Bloom
SECTION MILLS
A-2	0112B	Rail Mill
D-2	0291C	Nos.2,5 and 6 Mills
E-2	0196A(09&10)	Bar Mill & Rod Mill
F-2	0384A-06	12" Bar Mill
G-2	0650A(01&02)	10"&12" Mills
H-2	0432A-04	Rod Mill
1-2	08560	Rod Mill
C	0424(01-03)	Bar Mills(3)
H	0248A	Merchant Mill
K	0256K	Bar Mill
M	0432J	Billet Mill
0 & 081(Reviaited) 0176(01-03)	Bar Mills(3)
083	0860HC02&03)	34" & Rod Mills
087	0432-02	14" Mill
25

-------
TABLE III-l
SUMMARY OF SAMPLED PLANTS
HOT FORMING SUBCATEGORY
PAGE 2		
Plant
Sample	Reference	Type of	Steel
Code	Code	Mill	Type
088	0684H-02	34" Mill	Specialty
088	0684H(01, 03,05,06,07)	36",32",14",10",11" Mills	Carbon
HOT	STRIP & SHEET MILLS
0	0176	#4 Hot Mill	Specialty
E	0020B	HSM	Specialty
D	0248B	HSM	Specialty
J-2	0860B-01	84" HSM	Carbon
L~2	0060	Hot Strip & Sheet Mill	Carbon
M-2	0384A-02	80" HSM	Carbon
N-2	0396D-02	H HSM	Carbon
086	0112D-02	80" HSM	Carbon
087	0432A	44" HSM	Carbon
PLATE MILLS
F	0856H-03	160" Plate Mill	Specialty
K-2	0868B	160" Plate Mill	Carbon
082	0496(01403)	140",112"/120",and	Carbon
140"/206" Mills
082	0496(02&04)	112"/120" and 140" Mills	Specialty
083	0860H-01	30" Plate Mill	Carbon
086	0112D-01	160" Plate Mill	Carbon
PIPE	& TUBE MILLS
E-2 0196A-01	Seamless	Carbon
GG-2 0240B-05	Seamless	Specialty
H-2 0916A	Butt Weld	Carbon
jj-2 0728	Butt Weld	Carbon
26

-------
TABLE III-l
SUMMARY OF SAMPLED PLANTS
HOT FORMING SUBCATEGORY
PAGE 3
Sample
Code
Plant
Reference
Code
KK-2
087
088
0256G
0432A-01
0684H
Type of
Mill
Butt Weld
Butt Weld
Seamless
Steel
?ype
Carbon
Carbon
Carbon
(1) Plant 082 consists of a 206" and a 140" set of mill stands which are part of the same
line, and can work as a single unit or as separate mills. The line was sampled while
operating in two different configurations as shown. This same complex also functions
as a Hot Forming - Flat/Plate Mill.
27

-------
TAILS III-2
IY TULI
¦ot rominc-mmsT
ri«t
Cod* Frodnct
00201 Slabs
0Q6Q Slake
00601 tlsbl
01
00601 Slooas
02
0060D 11mm,
Slat a
Age -	Production
Steel 1st Taar Ca^cit;
Tin ot Prod. TdBl/DiT
SS I
(lects
C.S.
C.S.
1940
C.S. 1969
IM)
o*i
19*4
llect. J91fl
Steal
1910
406}
•537
SMS
1453
226B
Tteafeat Components
	flaw la Callons/Toa	 Procees	Ceatral
Applied h«ca»» Discharge Ttaitwrt Traafsat
1594
2024
(1012)
II
II
1594
1012
II
II
1S94
210
II
11
254	254
TOP
psr.ss.
II
II
PSP
CMT.riX,
PLF,CL,
CT,»r
II
U
SSP.PLL,
rLA.CL
SL
Operating Diachir|l Machine
Moda	Mode	Scarfing
BSP,SS.SC	01
¦IIP-50
IET-10
ITP-39.6
10-0.4
ITP(IMK)
UT(OMK)
ITP(MK)
UT(W)
ITP-99
SD-1
DiracC
Diract
Direct
Ho
Tas
Indirect Ho
Indirect
No
0060P Slake 4
01 lie
C.S. 1962
0060F IIoom
02
0060C	ftl<
00601	llooae
006*	Blooaa
0088A Iloose
OOUD	llooae
0112 11.
01
C.S.
C.S.
SS
C.S.
SS
¦SLA
C.S.
1944
19S4
1941
1905
M
1942
Q95|
1959
1907
6195
2070
2S6S
495
1407
ISO
2058
1966
2045	232.4
II
4S95
(1004)
3782
It
Zero
6339
IS
II
4A93
3782
11
Zero
II
60S
II
Zero
41.3	41.3
II
PSP.SSP,
SC.SL
SS
II
PSP.SL
SS.SCS
PSP
II
II
psr.ssp,
ss
SSP.CT,
SS
11
HL.PLP,
CL.SS.Vf
CUT
FDS
IUP-S9
ITP-IMK
SD-UM
UMI
SUP-66
ID-14
STP-100
H/A
IUP-99
ID-1
OT
Direct
Diract
Direct
Zero
Discharge
ITr(INK) HOT
H/A
Direct
Diract
Yes
Tea
Yes
No
Yes
Ho
Yes
No

-------
TAIL* III-2
CSMBAL SUNUIT tUU
BOT P0BMN6-PBIHABT
MM 2		
l|i -	Production
Plaat	Steal	lat Taar Capacity
Coda	Prodact	Tr»a	of Prod. Toaa/DaT
0112	BIoom	C.S.	1907	*13
02
0112	BIoom	C.I.	1917
03
0112	BIoom,	MS LA	1914	B70
04	Slaba
0II2A	Slaba 4	C.S. I92«	4641
01	BIoom	[mij
0I12A	Slaba	C.S. 1930	6B61
02
0I12A	Slaba	C.S. 19)7	10,033
03
0112B	BIoom C.S. 19H	1971
01	£195?)
01I2B	BIoom C.S. 192S	3963
02
0112B	Slaba	C.S. 19*1	10,974
03
0112D	Slaba	C.S. 1969	11,619
01121 BIoom C.S. 1914	4515
[1954]
0II2P Slaba 4 C.S. 1947	IS57
Bio
How la Cal loaa/Tog
Treatment Coawwiti
		 Proceaa	Central
Applied Proceaa Dlachirta Treafent Treafent
Operating Diacharga Machine
Hode	Mode	Scarfing
U
IB
11
PSP.SSP,
SS
CUT
PM
OT
Ho
NOT IB OPERATION
U
1179
»
559
II
559
PSP
PSP.SSP
SS.CP
ros
BUP(IMK)
BTP(UMK)
BD(UNK)
BB-47
BUP-53
Direct	Ye*
Direct	Tea
336
2296
336
574
336
574
PSP.SSP
SS
PSP,SS,
SCB
CUT
r
CMT.NL,
PLA.PLP,
SL
RBT-100
IUP-75
BD-25
Indirect Tea
Direct
Yes
IB
IB
IB
PSP
BTP(UNK) Direct
No
IB
IB
IB
IB
IB
IB
IB
IB
IB
PSP
PSP
PSP.SSP,
SS
PBS
T
PDS(UMK)
CNT.PLP,
W..CL,
SL
BTP(UNK) Direct
BTP(UNK) Direct
BTP(UNK) Direct
Tea
Tea
Yea
IB
IB
IB
IB
IB
PSP.SS
PSP.SS
art
SSP.SL
CUT
CL.SSP.CT
BUP(UNK) Direct
BUP(UMC) Direct
BTP(OMC)
No
Yea

-------
TABLE II1-2
CENEtAL SUMMIT TABLE
HOT POMtlNC-PtlHAKY
FACE 3
Plant
Code Product
0112G Slab* t
Bio
0176
Blooae
0188 A BIoom
01881 Blooaw
CI96A Kail
01 Mill
Age -
Steal lat Tear
iTPt	of feed.
C.S.
C.8.
C.S.
1958
1959
19*0
Q*1
Production
Capacity
Flow in C«Uona/To«
Treatment Coayoneate
Proceaa	Central
Tone/Par Applied Procaaa Piacbarte Treatment Treata»nt
1575	It	It	It	PSP.SS
1917/18 28S
[mg
825
804
It
1011
5585
3656
1011
SMS
3656
35.S
5S85
18*6
PSP
PSP.SS
PSP
CUT
SSP
TF,CL,CT
SSP.FDS
SSP.CT
Operating Diacharge Machine
Wade	Mode	Scarfim
KTP(IMK) Direct
ITP-96
>0-*
OT
ITP-49.5
1ET-49.5
BD-1
Direct
Direct
Direct
Mo
No
No
u>
o
0196A Slaba *
02 llooaa
0240A llooaa
0248A llooaa
02481 Slab
024SC S loose
0256C Slaba
0256K
0120
01
11
HSU
AT
ss
ss
C.S.
1942
0953
d912
"fl
1960
1962
I9S2
Ql966]
**	1973
Alloy 1936
2322
2433
1500
415
2S26
*#
1500
It
It
473S	473S
7776	7776
2186	2186
It
459
It
It
It
II
146
It
It
PSP
PSP
PSP
PSP
PSP
PSP
SSP
SL.ES
SCI,
SSP.SS
SSP,
SCB.FLP
CL,S8,CT
A.NC.PLF
FLP
CL
SL.SS
SS
NC,CC,CL
SL
UHK
8TP-90.3
8D-9.7
tTP-98.8
BD-1.2
OT
Direct
Direct
Direct
1TP-93.3 Direct
BD-6.7
tTF(UNK) Direct
Direct
Yea
Ye*
Yea
No
No
No

-------
VMM III-t
mat raMue-rtmun
na m	
4ga -	fntetlw
Plaat ItMl 1 at Ttat Capacity	fla
Coda yttfcet Tw« ri Prod. Tom/Ih
•32* (tab*	C.S. ItH	NN	2175
•t
IMU	Slaba ft	C.S. 1*1?	3SM	MU
ii	binm	[i»jg
•NU	IImm ft	C.S. • 191ft	MM	M13
M	IU*i	QmI
&k
IMU Slab*	C.S. JtM	SSIS	1919
N
DM* Slab	C.S. M»	Mil	IB
•3MI NliM C.S. IMI	Ml*	«M5
Strip
U>
H	MM Slab,	SS	1971	«»	SW
MMC Plata	SS	19ftl
•1 Mil
MMC Shaat	C.S. I9M	11*	MU
tl Bar Mill	Q*S#
M3ZA BIoom C.S. 1909	SIM	IK
1909
095j
M32S SIMM I C.S. 1952	570J	IS
Slab*
M3IC Slab*	C.S. I9SI	10,119	1945
0*3
» ta CallaM/Toa	 Procaaa	Central	Operating Diacharga Nachiaa
ProcaM MkImw TraatMat XraatMat	Ho4«	HoJa	Scarfiat
IS00	315	rsr	K.SS,	BBP-S3	Diract	Ta*
OC.CL.	BO-11
SL
MS)	MS3	rsr	SSP.SS	or	Diract	He
SL
MIS	MIS	rsr	SI	or	Diract	*«•
SS
1919	1919	rsr	SS,	or	Diract	Taa
SL
u	at	rsr.ss	tsrcsnt) Mintt mo
sst(«k) to roni
Mt)	IN)	rsr	SL	STP-SI.9 Diract	Ho
sn-M
•0-9.1
SM	M0	ns	BTT-S0	Diract	Ho
SL,CT	w-n
rsr.ss.ssr
M0	MS	sat, BIO	or	Diract	Ho
¦L.PLL.CL
nr, ss.cla
SL
lftH	IUI	SCB.BOA,	or	Diract	So
¦L.nx.n*.
CL.SS.OLA,
SL
II	II	rsr	rLT.FLM,	or	Diract	Y*a
CL.M.SCB,
W
IS	IB	rsr.ss	-	or	Diract	»«
1003	151	rsr.ss	vr.ru.,*xr,	Diract
MI.CL,	BO-7.7
ct	inm.i

-------
TABLE 111-2
CENEBAL 8UHHAKT TABLE
BOT FOBMINC-PBIMAET
PAGE 1	
Plant
Code
Product
0432J llooa
Slab
0440A Slab,
Itooa
A«« -
Steel lat Tear
Type of Prod.
SS
SS
0448A llooa* t C.S.
01 Slab*
1950

Production
Capacit;
Ton«/Dar
1089
387
19M
	Plow* la Callona/Too	
Applied Proceaa Diicharge
»	It	1*
21,163 0	0
IB
IB
IB
M4M Slab*
02
C.S.
1858
6636
IB
IB
IB
0460A Blooaa
C.S.
u>
to
0476A Blooaa * C.S.
Slab*
0492A Slab
0496
Slab* A
llooaa
C.S.
C.S.
052SA BIoom 6 C.S.
Slaba
1917
D'5
-------
TABU Ul-2
GWEBAL SUMMIT TABLE
HOT POtMlNC-PBlHAKY
pagb 6
Plant
Code	Product
0612	Slabs «
01	Blooas
Age -	Production
Steal lat tear Capacity
tTp< of Prod.
C.S. 1952
Tons/DaT
3312
0612 Slab* A
02 Bio
C.8.
1*7*
2631
MAO 81
0652A Blooaa
C.8.
C.S.
d»ali
1906
a«a
1*76
795
0672B Bis
06SAA Slake A
Bio
OMAB llooas
06MD Btooa
06*4« Blab,
C.S.
C.S.
1952
Alto; 1915
Steel
At loy
Stool
©
*53
MSI
*905
2520
0684P Slabs A
01 Bio
C.S.
19)7
1752
06*4P
01
Slabs
C.B.
1956
7110
06*46
Slaka A
Bio
C.S.
rf«J
2208
Plows ta Callo««/To»	
AppliedProcess Discharge
3913	3913
A332	1265
1087	10*7
6517	1272
7S
4926	4926	9*.S
1265
10*7
1272
Treefent Cowo«wt«
Process	Ceatral
Treatment
PSP
PSP
PSP
PSP
742
742	742
PSP
P8P,SS
Treafent
SSP,
SL.CT,
SCB.SS.PDS
SSP,
SL.CT,
SCR,SS,FDS
PDS.SL
TLX,FLA,
HL,NC,
8SP,8S,CT
Operating Discharge Machine
Mode	Mode	Scarfing
BTP-98
MT-2
OT
BUP-80
80-20
Indirect
OT
Direct
rOTW
Direct
Ho
BTP-98	Indirect Ho
BRT-2
BUP-70.8 Direct	No
BD-29.2
No
Ho
Ho
734	114	734
HOT IB oroATioa
PSP,SSP,
SS
SL.SS
OT
Direct
Ho
)»	*57
•57
6164	6164	6114
(2466)
PSP,SSP,
ss.ruc,
CL.CT
PSP
SSP.S8,
SCR.PIX.PLP
VIC.PDS
W
OT
BD-99.2
BTP-0.8
Direct
Direct
No
Yes
1985	196)
1965
2400	2048	1839
PSP
PSP
SSP.SC*
ru.,rir,nc,
ros.vr
SSP,SCI,
FIX, PL?,
FLC.CL,
PDS.VT
BTP-O.S
BD-99.2
RUP-14.7
BD-76.6
BET-8.7
Direct
Direct
Vea
Yes

-------
TAIL! II1-2
NOT roUtIRC-Pt IHMT
Ma 7	
rlaat
Cote
06MB
060*1 S
«RW
oJact
aba t
OIH Mr
07964 **
NMf Slake
Steal
Tw«
c.s.
c.s.
tat Taar
ol f»o4.
19*1
1930
aba t C.I. 1157
C.». ••
~	192*
c.s. ifsa
hofatioa
Capacity
Tona/Par
)SU
5517
*151
fl
•eelisi
Mil
(057)
679
41(2
12,*12
1927
NM Slaba,
01 Oloeaa, 6
talea
NMI
11 II
00540 Slaba
03
0056Q lleov
01
0050Q llooaa
02
C.O.
C.S.
C.S.
MSM Slaba I C.S.
C.S.
C.S.
NMI Slaba t C.S.
0056T Slaba t C.S.
01 Sloooa
ItM
1926
IN*
19*9
1*00
0»3
1907
1*59
1072
10)0
1910
7905
1195
mo
5191
*059
272S
2707
727
373*
II
U
2712
1281
a la 6aHoaa/To»
Treat—at Coapooeate
Pcocaaa	Ceatral
ftocaaa Diecharae Traafaat
1*02 96	rsr
079
007
MO
007
rsr
rsr,nr
Traafaat
CL,
no
ssr,
ss.so*.
W.SL
Operating Diacbarge Machlna
Hoda	Scarfing
Taa.
Woda
HT-94.7
10-5.3
¦0-52.9
RIT-47.1
mr-79.z
SO-20.0
row
Direct
Oirect
Taa
1370
2725
1)70
272J
rsr
rsr
«*.
nr.oos,
0L,sr
ssr.ss
r-25
-75
at
Direct
Oirect
Taa
2707
27S7
ssr.ss
OT
Oiract
727
727
rsr
OT
Oiract
Tea
1907
I*
U
27S2
1281
1907
II
II
27S2
1281
rsr
rsr
rsr
rsr,ss,
rsr,ssr.ss
ss,
SL
SL
SS
SL
SS
cvr-*7
IO-S3
OT
OT
OT
OT
Oirect
Direct
Direct
Direct
Direct
Tea
Ho
Tea

-------
TABLE 111-2
GENERAL SUtMABY TABLE
HOT FOUtlNC-NUHMT
PACE 8
Flant
Co4«
0856T
02
06601
01
0880B
02
08601
03
OHM
04
OOMB
05
088011
01
Product
Slab*
Slab*,
Bio
Slab* i
Billet*
¦laba,
Blooaa
8 Ukeela
¦laba t
Bio
Slaba
Slaba 4
Bio
Stael
Ttp«
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
Age -
let Year
of Prod.
1909
1909
'1909
1918
1911
i9sa
19)1
Production
Capacity
Toot/Pat
2893
2404
M92
1280
2S29
11,US
2981
OUOH Slaba	C.S. 1931
02
•490
0S8OI Slaba,
03 Blooaa
C.S.
1959
3441
OHM	Slaba i
01	SIoom
0844A	Blooaa
02

C.S.
1978
879S
2373
0884C Blooaa
C.S.
1928
450
Applied
298
1915
3484
Fiona in Callona/Ton
Proceaa
298
1903
3439
Di*chane
298
1903
3439
Treafent CMponwti
Proceaa	Central
Treafent Treafent
Scale
Bucket
rsp.ssr
psr
SL,
ss
SL,
ss
Operating
Mode
OT
BEU-0.6
BD-99.3
BEU-0.7
BD-99.3
Discharge
Hode
Direct
Direct
Direct
Machine
Scarfing
No
Ye*
Yea
HOT M OPERATION
3587	3587
1095	1092
8747	*747
3587
1092
234
1888	188«	85
5859	5859	203
1272	318	318
2124	303	127
1280	1280	93
PSP
PSP
rsr
PSP
PSP.SS
PSP
PSP
PSP.SS
SL
SS
SL
ss
CL.CT
VF.FU.,
FLA, SCR,
SSP.SS.T
CL.CT.VP,
FLL.FLA,
SCB.SSP,
88,T
CL.CT,
•f.fll.
FLA,SCt,
SSP.SS.T
CL.SS,
SL
SL,
88,CT,
CLA.EB.FLP
OT
BEU-0.2
BD-99.S
BTP-94.8
BO-J.4
BTP-96.5
BD-3.5
BUP-75
REU-25
BUP-85.7
RET-8.9
BD-5.4
RTP-92.7
BD-7.3
Direct
Direct
POTW
BTP-96.5 POTW
BD-3.5
Ho
Ye*
No
Ho
POTW
Indirect
Direct
Direct
No
No
No

-------
1ASLK 111-1
GENUAL SIMtUI TABLE
HOT FORMIHG-MIMAIY
PACE 9
Plant
Code
0868A
01
O068A
02
Product
Slab* 4
¦ la
Slab* 4
¦ lo
Steal
Type
C.S.
C.S.
A(e -
Iat Tear
oi Prod.
1902
1919
2340
Plow* in Gallon*/Too
Production
Capacity		 •	w vhm—# 	
Tone/Day	Applied	Proceaa Diacharte
1000	1234	1236 1234
414
414
599
086SA Slaba
03
C.S.
1939
4492
1S«4
945
917
0920A Slab*
C.S.
192S
5361
3443
33S4
510
0920S Slaba 4 C.S. 1908
0920N Slaba
C.S.
fi95j|
1932
5325
4543
2382
4309
740
4309
740
S07
0940 lobar
0944A Sic
094(4 Slaba,
Slaba 4
¦ Ifl
09488
094SC	Slaba 4
01	Slooaa
094SC	Slaba
02
C.S.
C.S.
C.S.
C.S.
c.a.
c.s.
ft
1914
if#
1929
til
133
3064
3909
3930
4441
7923
1047
1330
34*1
(2374)
1905
710
3908
(600)
1067
1409
1271
190S
710
3908
1409
U7t
1905
710
3908
Treatment Component*
Proce**	Central
Treat pent Treatment
Operating
Mode
Discharge Machine
Mode	Scarfing
PSP
PSP
PSP
PSP,SSP
r
SSP,
SS,SL
SL,
SSP.SS
SL,
SSP.SS
OT
STP-2.4
MT-S4.1
SD-11.5
•TP-2.6
MT-42.7
•0-5.9
•UP-48.8
BTP-87.6
SD-12.4
Direct
No
Direct and Mo
Indirect
Direct and Mo
Indirect
Direct
PSP.SSP
P
PSP,SS
KUP-48
SD-32
ITP-88.2
ID-11.8
Direct
Mo
Ye*
PSP
PSP
PSP
SSP.PDS,
PLP.T
MIP-100
RUP-9
HET-91
•UP-43.5
SD-36.S
Zero
Discharge
Mo
Indirect Tea
Direct	Te*
PSP
Direct
Ho
PSP
PSP
SSP,
SL.SS
SSP,
SL,SS
OT
OT
Direct
Direct
Ho
Tea

-------
TABLE III-2
GENERAL SOMAKV TABLE
HOT FORMING-PRIMARY
PAGE 10	
KEY TO SYMBOLS fc ABBREVIATIOHS
Steel Type
AT :	Alloy Tool
C.S. :	Carbon Steel
Elect.:	Electrical Steel
HSLA :	High Strength, Low Alloy
SS <	Stainless Steel
UHK :	Data not provided by coapany
Treatment Components
For a description of the treataent coaponent codes, see Table VII-1.
Operating Mode (Number following abbreviation indicates Z of
applied rate in each case)
BD : Slowdown
OT : Once-Through
RET: Reused on operations other than hot forcing following treataent
REO: Reused on operations other than hot foraing without treataent
RTF: Recycled to hot foraing operations following treataent
RDF: Recycled to hot foraing operations without treataent
Discharge Mode
U)
-j
Direct	:
Indirect	:
FOTW	:
Indirect	to POTW:
Discharged froa process to receiving stress.
Sensed in mm other process, then eventually discharged to receiving stress.
Discharged froa process to publicly owned treataent works.
Reused in aoae other process, then eventually discharged to publicly owned treataent works.
Peteraination of Capacity Value
The capacity values for priaary operations (and the other hot foraing operations) were calculated
by taking the average 1976 production per turn and aultiplying by three.
* :	Dry operation
** :	Confidential Data
IS :	Inadequate Reaponse
() :	Portion of applied flow attributable to aachine scarfing
[1 l	Tear of aoat recent aajor rebuild
H/A:	Hot applicable

-------
TAILS III-)
¦dt ramac skctio#
SWWAW MIU
1|( Prodwctioa	Treefaat Coaaoaeate
Plaat

Steel
let JT.
Capacity
Flaw (Callaai
¦/To.)
Proceaa
Caatral
Operating
Discharge
Co*
hofatl
1VHI
at Prod.
Toa/Dav
AhIM Preceaa
Diicbtrt*
TrtstMat
Tteataeat
Mode
Mode
0060C
M* Cotkic
CS60,
1913
1320
0HK MK
UMK
nr
Cn(UMK)
stp(imk)
Diract
01

LAM





(OMO.SSP
St, FLP
ret(wk)
HKVNO

0060C
louada
CS60,
1*13
1017
IMC M
UK
nr
arr(ow)
RTP(INK)
Direct
02

1AM





(imOssp,
SS, FLP
UT(UNK)
SIX UMK)

0060C
¦aoaAa
-CMS,
1*13
462
mac mm
UMK
ptr
CHT(2)
STP(MK)
Direct
03

U»





(DWOSSP,
SS, FLP
RET (DM)
MKUMK)

oo6or
l-kui,U|lti
CS40,
mi
903
at vm
mm
Mr
CMT(2>
STP(OMC)
Diract
01
kMli,natM<
Cclfcr Blades
LAM
ASS SO





(MK)SSF,
SS,SCR
SL(PK)
UT(UNK)
¦tKDMC)

0060F
l-Seaa*,Chaaaal
CS70,
1942
•It
M 1MK
UNK
PSP
C*T(2)
¦TP(UMK)
Diract
02
Aagla, kaoi,
Flat tar,labar
Sfl|M Sectioa
CraAar Slate
U10
ABS20





(unOssp,
SCS, S3
SL(WK)
SET(ONK)
¦D(DMK)

0060P
Bound -
CMS,
1946
2070
BMK IMK
UMK
PSP
CMT(2)
ITT (IMK)
Direct
01

LAIS
ABS40





(IWK)SSP,
SCS.SS.SL
(aw)
nT(UNK)
BD(OMC)

0060F
ftooad. Saaaca
CS5S,
1950
2070
UNK IMK
UMK
PSP
CNT(2),
RTF(UNK)
Direct
M
•too*
LAIS
ATS30





(UMC)SSP,
scs.ss,
¦ET(UNK)
SD(OMK)

0060F
HP-Sea—
CSM,
1971
1224
[llS7t] [49SS}

PSP,SSP
sl(unO
CMT(4)(6J)
MIP(56.S)
Direct
05

LA 20


88
FDSP
CL, VP
SL(DMK)
STF(43)
WHO.5)

0060C
a*
•a
aa
M
M **
**
PSP
CNT(2)(26.6>
RUP(6.3)
Direct
01






SSP
SCS.SS,
SL(UIK)
¦Ell(SO.t)
SD(43.1)

0060C
a*
M
aa
a*
** **
**
PSP
CHT(2)(9.S)

OT
02






ss
SC*,SS,SL
(UMK)

Direct
0060G
**
**
aa
+*
M H
**
FSF,
arr(2)(8.s)
REUT(16)
Direct
03






SSP
SS
sct.ss,
SL
-------
TAIL! III-J
HOT FOBM1MC SECTION
SUHHAtY TABU
fACE 1	



Age
Product loi
n«ot

Steel
let yt.
Capacity
Code
Products
Typea
of Frod.
Ton/Bar
0060B
¦minds, Bebar
CSI00
1929
1071
01
StriM Tec



00601
Bounds, Squarea
SS100
1956
176
01
Flat lira



00601
Bounds
SS100
1946
138
02




0060ft
ln|l( t Bounds,
C3100
1920
537
01
Flat Bare,Bebar




Fence-Sign Fast



0060
Obi Bevel.Strip
CS100
1901
78
01
1 Bands Cotton Tiea


0068
Bounds,Squares
CS100
190}
270
02
Flat Bar,Strip



0068
Channel,Angle
CSI00
1916
144
01
Square,Flat Bar




Beber



0068
Channel,Aagle
CS100
1956
in
M
Bqueree,Flat Bar




Bebar



0068
Bods
CS100
1968
399
OS
00681
Angle,Channel
C8100
1976
fri1"

Bound,Square




Flat, Bebar



0088A
M-foata , Rouada
CS3I,
1942
531


LA49.SS9




CHHU


00888
Bo ends
CS33,
1962
885


LAS6




0SI1





Treatment
Conponents


Applied
Flow (Calloaa/Too)
Process
Central
Operating
Discharge
Froceas
Discharge
Treatment
Treataent
Node
Mode
3025
2057
121
psr.ss
CMT(1)(6.}>
BUP32,KTP64
Direct




SS.SCB,
BD4





SL(UK)


10,636
10,256
0
FSF.SB
CUT (UK)
BTF<23)
Zero



(25)SSF,
BUF(75)
Discharge




8S,CT


13,040
13,043
0
FSF,SS
CMT(OK)
BTT(IOO)
Zero


(25)SSF,

Dischsrge




SS,CT


8,045
8,045
34.9
FSF
CHT(UK)
BTF(99.6)
Direct



(UK)SSF,
80(0.4)





8S,CT


UMK
OK
UK


at
FOTH
UK
•K
IIK
FSF.SS

OT
FOTH
M
OK
UK
FSF

or
FOTW
OK
OK
UK
FSF

BUF-(UK)
FOTU





¦D(UK)

OK
OK
UK
P8P.SS

kUP(UK)
POTU





BD(UK)

Bo,386]
Bo.mI
Co]
FSF

BUF(IOO)
Zero



Discharge
561
561
561
FSF

OT
Direct
9,836
9,836
73.2
FSF.SSF
C*T<2)39
BTF(99.2)
Direct


HL,FLF,
1D(0.8)





CL,SS,TF



-------
TABU II1-3
HOT FORMING SECTION
SUMMARY TA1LC
PAGE 3	



Age
Production
Plant

Steal
lat jr.
Capacity
Code
Producta
I»na
of Prod.
Ton/tar
0112
I-Beaaa,WF-Beaae
CS79,
1907
2709
01

LA 21


0112
I-Beaaa.WF-Beana
CS89
1917
1086
02

LAI 1


0112
Billeta
CSS5
I9SS
3771
03

LAIS


0112
Rounda
ATS 100
1915
19$
04




0112
Billata
CSS,LA80
1916
B«!
OS

ATS1S


0112
I-Bean,Channel
CS86,
1917
SS2
06
Zee, Angle
LAM


0112
Roaftdl, S^utrci
SSI,
1963
138
07
Hexagon,Plat Bar
Octagon
ATS98


0112
Angla
CS87,
1919
642
oa

LAI 3


0112
Rounda,Squarea
ATS 100
1917
17.4
09
Hexagon,Flat tar
Octagon



0112
UF-Beaae,t-Beaae
CSSS
1968
2301
10
Channel, Bulb
Angle,Ship Channel
LAIS


01I2A
Billeta
CSIOO
1918
3735
01




0112A
Debar
CS100
1937
1101
02




01I2A
Rounds, Rod
CS100
1968
1455
03




Tie»t«trt Componenta
	flow (Callona/Ton)	 Procese Central Operttin| Discharge
Applied Procaas Diacharge Treatment Treafapt	Mode	Mode
IMC
IMC
IMC
PSP
OT
Direct
INK
IMC
IMC
PSP
OT
Direct
IMC
UMC
UMC
PSP
OT
Direct
IMC
IMC
UMC
PSP
OT
Direct
IMC
IMC
IMC
PSP
or
Direct
IMC
UMC
IMC
PSP
OT
Direct
33,391
33,391
3673
PSP,
ss
KTF(89)
BD(ll)
Direct
UMC
IMC
UNK
PSP
OT
Direct
IMC
IMC
UMC
PSP
OT
Direct
OM
UMC
UMC
PSP,
ss
OT
Direct
4627
IMC
IMC
4627
IMC
DMC
771
3662
3959
PSP
PSP
PSP,
SS
RTP(83.3)
BDU6.7)
RUP(UNIC)
BD(UMK)
RUP(UMC)
BD(UMC)
Direct
Direct
Direct

-------
TABLE III-J
HOT FORMING SBCTIOM
SUMMIT TABLE
PACT A	



Age
Production



Treataent
Component*


Plant

Steel
lat jrr.
Capacity

Flow (Gallons/Ton)
Froceaa
Central
Operating
Discharge
Code
Froducta
Typea
CSIOO
of Frod.
Ton/Day
Applied
Froceaa
Diacharxe
Treataent
Treataent
Mode
Hode
0112B
WF-Beaaa
1926
3321
UNK
UNK
UNK
PSF
CHT(l)
RET(UNK)
Direct
01








(UMt)T,
BD(UNK)









PDSCUNK)


0112B
I -Bean, Channe 1,
CS85
1926
1461
UNK
UNK
UNK
PSP
CNT(l)
RET(UNK)
Direct
02
Zee,Sheet Piling
Angle,BuIdozer
Track Shoe
LAIS






(UNK),T,
FDS(UNK)
BD(UNK)

0112B
Billeta, Kail
CSBO
1928
1563
INK
UNK
UNK
FSF
CNT(l)
RET(UNK)
Direct
03
Round
LA20






(UNK),T,
FDS.(UNK)
BD(UNK)

0112B
Billeta
CSBO
1930
2538
UNK
IMC
UNK
FSF
CNT(l)
BET(UNK)
Direct
OA

LA20






(UNK) ,T,
FDS(UNK)
BD(UNK)

0112B
Rounda, Flat
CS76
1940
711
UNK
UNK
UNK
PSP
CHTtl)
(TP(UNK)
Direct
OS
Bar,Hinge Bar,
Leaf Spring
LA2A





«
(UMO.T,
FDS(UNK)
RET(UNK)
ID(UNK)

0112B
Bound, Flat Bar
CS7A
19A6
900
UNK
UNK
UNK
PSP
CNT(l)
RTP(UNK)
Direct
06
Debar
LA26






(«UK),T,
FOS(UNK)
RET(UNK)

0112B
Bound, Flat Bar
CS76
1976
444
UNK
UNK
UNK
PSP
CHT(l)
RTF(UNK)
Direct
07

LA2A






(UNK) ,T,
FDS(UNK)
RET(UNK)
BD(UIK)

01I2C
Wheel Blanke
CS87
1920
180
UNK
UNK
UNK
PSP
CMT(UNK)
OT
Direct
01

ASI3






SSP,SS,T,
FDS(UNK)


0112C
HI. Uheela
CS99
1920
375
UNK
UNK
UNK
PSP
CNT(UNK),
OT
Direct
02

ASI






SSF,SS,T,
FDS(UNK)


0112C
Billeta, Round
CS92
1940
1728
UNK
UNK
UNK
PSP
CNT(2)
OT
Direct
03
Slab
ASB






(UNK)SSP.SS
T,CT,A,NC,
FDS(UHK)


0112C
Bound*
CS92
1950
849
UNK
UNK
UNK
PSP
CNT(UNK)
OT
Direct
OA

ASS






SSP,SS,T,
FDS(UNK)


0112C
Billeta
CSS 7
19S2
3234
IINK
UNK
UNK
PSP
CNT(2>
OT
Direct
OS

AS 13






(UNO.SSP.SS











T,CT,APNC,FDS










(UNK)


0II2C
Round Corner
CS95
1918
10S
UNK
UNK
UNK
PSP
CNT(2)
OT
Direct
06
Square*,Tie Clip*
ASS






(UNK),SSP,SS
t

Bearing Segaenta	T,CT,A,NC,FDS
(UNK)

-------
TAILS III-J
HOT roniK SECTION
SUMMARY TABUS
PACE 5



Age
Production

Treataeut Coaponeota


Plant

Steel
lat jr.
Capacity
Plow (Callona/Ton)
Proceaa
Central
Operating
Diacharge
Code
Product!
Typee
of Prod.
Ton/Day
Applied Proceaa Discharge
Treataeut
Treatment
Mode
Node
0112C
Bulb Angle, Rjil
CS89
1926
648
UMC UNK UNK
PSP
CNT(2)
OT
Direct
07
Round, Sfitn ,FUt
ASH




(UMK),SSP



Bar,Tee BartHine





SS.T.A, NC,



Tiea,Rin Sect too





FDS(UNK)



Brake Ben








OI12C
Round t Square
CSBS
1926
849
UMK ONK UNK
PSP
CNT(2)
or
Direct
08
Hexagon, Plat Bar
AS12




(UMC)SSP,









SS,T,A,NC









FDS(UNK)


0112C
Plat Bar.Auto
CS91
1926
204
UMK UMK UNK
PSP
CNT<2)
OT
Direct
09
Leaf Sprg Band
AS9




(UNK)SSP.SS,



Tie Clip,Bail





T,A,NC,FDS



Anchor





(UNK)


0112C
Round , Square,
CS81
1963
999
UMK UMK UNK
PSP
CNT(2)
OT
Direct
10
Hexagon,Specia1
AS19




(UNK)SSP,



Shapea





SS,T,A,NC,









FDS(UNK)


0I12E
Billeta, Rail
CSI0O
1914
3705
UNK UNK UNK
PSP
CNT(2)
OT
Direct
01






(UMOSSP.SS,









03,SL(UNK)


0112E
Billeta, Round*
CS97.2
1918
1200
UNK UMK VM
PSP
CNT(2)
RUP(UNK)
Direct
02
Plat Bar,Hiae.
LAI.A




(UNK)SS,
BO(UKK)



BS1.4




03,SL(UNK>


0112E
Rebar
CS100
I960
2259
IMC UNK UNK
PSP
CNT(2>
RUP(UNK)
Direct
03






(UNK)SS,
BD(UNK)








SL(UNK)


01I2F
I-Reaa, Channel
CS79
1922
567
UNK one UNK
PSP
CNT(2)
RTP(UNC)
Direct
01
Anglea,Round*
LA 21




(UNK)SSP,
REP(UNK)


Square,fiat Bar





SS,CL,CT
BIX UNK)

0112F
Round, Square
CS97
1948
669
UNK UNK UNK
PSP
CNT(2)
RTP(UNK)
Direct
02
Hexagon, Plat
LAI




(UNK)SSP,
REP(UMK)


Bar, Babar





SS.CL.CT
BD(UNC)

0112C
1-Beaa, Channel
H/A
1914
417
I
1
1
rsp
CNT(2)
RTP(UNK)
Direct
01
Zee, Angle , Round




ss
(UNK)SSP
REP(UMK)


Flat Bar





SS
BD(IINK)

01I2C
1-Beaa,Channe1,
N/A
1958
675
UNK UMK UNK
PSP
CNT(2>
RTP(UNK)
Direct
02
Angle, Round,




ss
(UNK)SSP
REP(UNK)


Square,Flat





SS
BD(UNK)


Bar .Rebar








01121
Bound*,Square a
CS92
1926
711
i
i
i
PSP,SS,

RUP(UNK)
Direct

Flat Bara
LAS



P.SS.E,

RIKUNK)







CT.FDS









(UNK)



0I12J
I-Bean,Channel
CS95
1924
378
UNK UNK UNK
PSP
CNT(l)
RTP(UNK)
Direct
01
Angle,Square,
LAS




(UNK)SSP.SS
REP(UNK)


Flat Bara,Billet





CT,SL(UNK)
BO(UMC)


-------
TABU II1-3
HOT FORMING SECTION
SUMMIT TABU
PACE t	
it*
U)
Plant

Steal
Code
Product*
Typea
0112J
I-Beaa, Channel,
CSI00
02
Angle,Plat Bar


Jail Bar

0112J
Channel, Angle
CS100
03
Rot Strip

01MB
Channel,Angle
CS96
01
Round,Square,Plat
LA4

Bar, Rebar

0136B
Channel,Angle
CS94
02
Bound,Square,Plat
LA4

Bar,Rebar

0134C
Rebar,Plat Bar
CSI00
0176
Bound.Square,Has,
»/A
01
Plat Bar,Octagon
All

Plutaa
Special
0176
Round*, Square, Hex,
B/A
02
Plat Bar,Octagon
All


Special
0176
Bound,Square,Be*
H/A
03
Plat Bar.Plutea
All


Special
0176
Mire
¦/A
04

All


Special
OlftftB
Bound, Bebar
CS100
•IftftC
Bound, Bebar
CS100
0196A
*•
+*
01


0196A
**
**
02


0196A
**
**
03


let jrr.
of Prod.
1924
1915
190ft
1967
1913
1910
1927
192ft
1953
1940
1954
Production
Capacity
flow (Callono/Ton)
Ton/Pay Applied frocaaa Diacbarae
339	am	UMK	IMK
177
321	1)72
(Cloaed 11/77)
354
411
30.2
10.5
7ft
16ft
004
462
11,859
6190
M,2ft5
4911
£3,700
725ft
74SO
•372	100
52,943 C"3
ll,ft59
6190
3657
74B0
Sftl
223
34,285 1234
4911	172
([3,700] 636)
145
140
Treatment Componenta
Proceaa Central
Treafent Treatment
Operating
Hode
Diacharge
Hode
PSP CNT(l)
(UNK)SSP.SS,
CT,SL(UMK)
PSP CKT(I)
(imOSSP.SS
CT,SL(0MO
PSP
SSP
PSP
SSP
PSP,SSP
SS,CT,02
PSP CRT(2>(14)
SSP.SS.T.CT
MP CNT(2)(26)
SSP.SS.T.CT
psp arr(2)(28)
SSP.SS.T.CT
PSP CMT(2)(I8)
SSP.SS.CL,
CT,T
PSP,SSP
CT.SS
PSP.SSP
SS,SL(UMC)
** **
•a •*
** **
RTP(UNK)	Direct
RET(ONC)
RD(UIRO
BTP(UMC)	Direct
RET(IMK)
BD(UNK)
RTP(98.8)	POTV
¦D<1.2)
RTP(99.5)	POTW
BD(O.S)
BTP(95.1)	POTV
BD(4.9)
¦TP(96.4)	Direct
BD(3.6)
RTP(96.4)	Direct
>0(3.6)
BTP(96.5)	Direct
BD(3.5)
RTP(94.0)	Direct
BD(6.0)
RTP(9S)	Direct
BD(2)
RTP(98.1)	Direct
BD(1.9)
**	tot
M	M

-------
TABLE III-3
MR rOWING SECTION
SUMMIT TAILS
wa t	
l|t	froAictioa
riMt

Staal
lat jr.
Capacity
Co<«
rr«*»cta
Tt—a
ot hod.
Toa/Bav
01 MA
M
M
—
**
04




0196A
M
M
—
M
OS




0196A
**
**
•»
**
Ot




01 HA
*•
M
**
**
07




0I96A
**
•*
**
**
00




0916A
M
**
**
**
09




0194A
Mr
**
*•
**
10




0I9AA
**
**
**
*»
11




0240A

CS2S
194J
94*
01

LA7S


0240A

CS2S
1941
474
02
fc>,n
Froctii Diacharit
Treebmt OmvombIi
Froceii Central
IrtttMftt TctataeM
Optr«tin|
N>4t
Ditchert*
ttxte
**
** #*
**
**
**
**
**
** **
**
**
*•
**
•*
** **
+*
*#
**
**
**
*• **
**
**
**
**
**
M M
**
**
**
**
**
** **
**
**
**
**
**
** *+
4*
**
**
**
**
** •*
**
*•
**
**
tJMK
BNK DHK
fSP
CWT(I)
OT
Direct


tor
(UMK)SS,SL





(UMK)


DM
UMK UMK
rsr
CNT(I)
OT
Direct


8SP
(UNK)SS,8L





(UMK)


+*
+* •*
rsr,ML,

OT
Direct


rtp.ct



**
** **
rsp

uir(ioo)
Zero





Discharge
**
•* **
PSP

RUP(IOO)
Zero





Discharge
**
** •*
PSP

RUP(IOO)
Zero
Discharge

-------
TABLE IU-1
mot romiMc tecTioM
SUMMIT TAILS
PACE 8	



*8®
Frodnctioa



TreataaoC Coapoaeata


riaat

Steel
1st yr.
Capac Ujr
Mow
(Ctlloae/Toa)
Proceas
Central
Operating
Diachargi
Co4e
hoAicti
Tvpea
of Pco4.
Toa/Day
IhIM
Proceea
Diacharie
Treatment
Trcataant
Moda
Hade
llUt

CS20
1925
7.2
4114
4114
4114
PSP,

err
Direct
• 1

ATSJ
OS75





ssr.ss



0288A
Riaga
CS30
1919
11.8
2)27
2527
2527
MP,

OT
Direct
01
ATS 5,





SSP.SS





OS65








02 Ma
•ia«e
CS30
19)7
22.2
2159
2359
2359
MP,

OT
Direct
0]

882,0868





ssr,ss



02MA
tint*
CS20
1941
11.19
1136
1136
3136
PSP,

or
Direct
M
SSI,ATSI,
0878





8SP.SS



0288A
¦lata
GSM
1967
20.5
1995
1995
1995
PSP

OT
Direct
05

882,ATSI,
0840





ss



02MA

CS50
1940
4.0
7014
7014
7014
PSP

OT
Direct
06
osso





8SP,S8



02MA
bIM ¦.ft.Mtaala
CSI00
1919
313.4
3I«
316
316
PSP,

OS
Direct
•I







SSP.SS



02MA

cm
1919
96.8
1)28
1328
1328
PSP,

OT
Direct
08
OSS





SSP




-------
TABLE III-3
HOT FORMING SECTION
SUMtARV TABLE
FACE 9	




*«•
Production



Treataent
1
i
a
•


Flant

Steal
1st yr.
Capacity
Flow (Callona/1
'on)
Proceta
Central
Operating
Diacharge
Code
Products
Typee
of Frod.
Ton/Day
Applied
Proce**
Diacharae
Treatment
Treatnent
Hode
Hade
out
Round, Icktr
CSIOO
1959
446
9044
9044
S698
PSP
CRT(3)(36)
SS,CT,SL
(UNK)F(04>
RTP(37)
BD<63)
Indirect
0316A
Billeta,Rebar
CS100
1970
620
7S43
7S43
0
PSP,
SSP,SS

RUP(IOO)
Zero
Discharge
03I6R
Round¦ Rebar
CSIOO
1961
423
10,383
10,383
0
PSP,
SSP.SL
(UHK)

RTP(IOO)
Zero
Discharge
03 liC
Round. Rebar
CS100
1976
Started
9/76
IMC
UHK
IKK
PSP

IMK
UHK
0320
Billet*
ABS100
1936
1500
UHK
KMC
IINK
PSP
CNT(2)
OT
Direct
01








(UMC)SCR,NC











SS,CL,SL(URK>

0320
Billet*
ASS 100
1936
1428
MR
OMt
UHK
PSP
CNT(2)
OT
Direct
02









-------
TABLE IH-3
ROT FOBM1MC MCTIM
SUMAH TABU
FACE 10	
¦fe.
-~J
nut
Code
0396D
0424
01
0424
02
0424
03
0432A
01
0432A
02
0432A
03
0432A
04
04320
01
0432*
02
0432J
0440A
0448A
01
044BA
02
ttoAnU
Billets
Billete,Aagle
Bound,Stuart,Be*
Flat Bar
Aagla, Kauai,
tfuntln,Nit' '
Bar
Aa| le, Roub^ ,
Square,las,Flat
lod
Billete,Bounds,
Square,Bex,Bebar
lound , Squa re , Ilex
Flat Bar,Bebar,
Octagon
tillete
Aa| le , Bound , Be*
Square,Flat Bar
tebar
Billete,WF.I-
Beaa, Chame 1, II-
Sectioa,Angle,
Mate,Mine Arcb
Chanae1,Bound
Bebar, Miac.
Steel
Tim
CS100
ATS20
ATS 20
ATS 20
Bar, Billet	CS40
Other Shapea	LA20
VF,I-Beaa,Channel CS60
Aa^le,Flat Bar LA40
Jr.Chaaael,Truck
Biae
CS70
LA 30
CSI00
CS95
LAS
CS95
LA4.3
SS0.3
0810,
SS90
SSIOO
CSM
LAI
C89B
AS2
*8«	Production
1st jr. Capacity
of Frod. Ton/Per Applied
1939	2031	0
44
Flow (Gellows/Ton)
1942
1946
1920
1910
1925
1927
1932
1931
1933
1930
1928
1944
1943
23
23
2709
1167
1303
1234
1179
1000
HA
43
1068
383
7281
UMK
IMK
URK
(INK
3200
UMK
UW
Process Discharge
0	0
Treatacat Coaponeats
Frocess Central Operating
Treafeat Trestaent	Mode
7283
IMK
3200
UMK
6024
11,707	11,707 10634
10,337	10,337 9388
[6340]	[*3*o| (*3*6)
UMK
UNK
UNK
3200
UNK
UNK
FSF
nr
PSF
FSF
FSF
FSF
FSF
SSF,
CY.07
FSF
S8
PSF
SS
FSF
FSF
PSF
PSF
SSF
cirr(i)(i6>,
SS,SSP,CT,
8L(MBC)FDS
(UMK)
CNT(I>(9>
SS,SSF,CT,
SL(UM0FD8
(UMK)
cm(i)(8),
SS,8SF,CT,
SL(UNK)FDS
(UMK)
BTF(I7)
BIK83)
BTP(9)
BD(91)
*TF(9)
BIK91)
arr(i)
(UMK)8CB,CL
FLL.VF.SS,
FLH
CMT(3)(18)
SSP
CHT(2)
(UNK)CL,CT,
SL(UMK)
CNT(2)
(UW)CL,CT,
8L(UfS()
OT
OT
OT
OT
OT
OT
OT
BUF(UMK)
¦TP ( UMK )
BET(UMK)
BlXUNK)
BUP(UMK)
BTP(UMK)
BET(UMK)
BD(UMK)
Discharge
Hade
HA
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
FOTW
POTW
Direct
Direct

-------
TABLE II1-3
HOT FOftHINC SECTION
SUMMIT TABLE
PAGE 11
Plant
Code
Product*
Steel
Typea
*««
I*t yr.
of Prod.
Production
Capacity
Ton/Day
Flow (Gallone/Ton)
Applied Proceaa Discharge
Trc«twat
Process
Treatment
Components
Central
Treataent
Operating
Mode
Diacharge
Node
0460A
Hire
CS100
1920
897
4816
4415
0
PSP
CNT(2)(19)
BTP(100)
Zero
01







SSP
8CR,SS,T,

Di*ch*rge









SL(UNK)


04 60 A
Wire
CSI00
1958
702
7744
7385
0
PSP
CKT(2)(25)
BTP(100)
Zero
02







SS
T,SCR,

Diacharge









SL(UNK)


0460B
Channel, Angle,
CSI00
1969
441
32,686
327
327
PSP

BUP(99)
POTV

Square, Round, Tee-,






SSP,

BD(1)


Flat Bar






SS



0468B
Fence Poet,Flanged CS106
1968
1294
7,811
7,789
89
PSP.CT

BTP(98.9)
Direct

Channe1,Hire,Bebar






SSP.FLP
t
BD(l.l)









PF(UNK)



0468F
Hire, Bod, Bebar
CSI00
1976
312
29,463
29,465
9841
PSP,
CNT(3)(69.5)
BTP(66.6)
Direct








SSP,
SS,CT,SL
BD(33.4)









SS
(lltBC)


04 76A
Angle,Bound,Square
CS90
1915
190
16,719
16,293
10,786
PSP
CNT(2)(37),
BTP(33.8)
Direct
01
Flat Bar, Bebar
LAIO






SCB,FLP,NL,
80(66.2)










CL.SS.CY,











£L
-------
TABU III-3
HOT FOBHING SBCTIOH
SUNttKT TABU
fACE 12	
Plant
Coda
Product*
Steal
Type a
l*t jrr.
of Prod.
Product ion
Capacity
Ton/Bar
Plow (Gallon*/Ton)
Applied Proce** Di (charge
Treataeot Coapomnt*
Process Central
Treataeot Treatment
Operating
Hade
Discharge
Mode
0640
Bod Mill,Bound
CS100
1953
903
3352
3352
3352
PSP
CMT(2)(40)
OT
Direct

¦ebar







SL(UMt)FDS











(UNK)


0640A
Boond,Befcar
CS100
195*
203
11,449
11,449
345
PSP
CWT(2)(14),
BTP<97)
P01W
01







SSP
SS,SL
BTP(97.6)
POTH
02
Bound ,Plat Bar






SSP.SS

BD(2.4)

0652A
22"Stri>ctaral,
CS86
1904
243
7111
7111
7111
PSP,

at
Direct
01
I-lcu,CkaaMl
LAM





CS.SSP



06S2A
1-Beaa, Channel
CS86
1907
345
6261
6261
6261
PSP,

or
Direct
02
Angle
LAU





SS.SSP



0672A
I-Beaa,Chaaael
CSM
1951
817
5418
5418
563
PSP,SS
CBT(2)(45)
BTP(89.6)
Direct
01
Angle,Plat Bar
LAU





SSP.SS
BS,T,6L(lMO
¦0(10.4)


Babar ,Mn i-Baaaa










0672A
Bound,Plat Bar
GtlOO
1930
328
10,967
10,967
1151
PSP.SS
CBT(2)(37)
BTP(89.S)
Direct
02
Jail Bar.Oay






SSP.SS
SS.T.SL(UMK)
BD(10.5)

0672B
l-iua,auMi 1
CS40
1907
270
4880
4747
0
PSP

BTP(IOO)
Zero
01
Ba i 1, Spec. Sec t ion
UN





SSP


Di (charge
0672B
I-Bean,Chanaa1
CS40
1918
462
5922
5610
0
PSP

BTP(IOO)
Zero
02
Bulk Angle,Sp«c.
LAM








Di (charge
06MA
•illata
CS95
1911
2112
1705
1705
1705
PSP,

at
Direct
01

US





ss



06MA
tatoaatin Part*
CS100
1911
573
10,052
10,052
10,052
PSP

or
Direct
02
•creper Bladaa










06MA
m
Billets
CS100
1923
2052

DISMANTLED





Vi
06MD
Billata
CS15
19IS
1929
1493
1493
1493
PSP
CMT(2)( 33)
OT
Direct
01

IMi






K.SL(UHK)


06MB
Bit lata. Bound
CS1S
1920
1626
1689
1689
1689
PSP
CHT(2)
OT
Direct
02
Plat Bar
SS2.AS83






(UNK)SS.SL











(urn)


06MD
Bound,Square,Bex
SUI
1920
51
owe
INK
IM
PSP
CKT(2)
OT
Direct
03
Plat Bar,Octagon
AS52






(UNK)SS.SL


((INK)

-------
TABU III-3
HOT FORMING SECTION
suwun TABU
Ma n	
Flant
Code	Product*
0664K	Bound,Square
01
0684K	louod , Stuart
02	Hex, Octagon
0684F	Billets
01
0684P Bound.Square
02	Flat Bar
0684F Bound .Square
03	Flat lar,Bebar
0684C Billets
01
0664C Bound t Square
02	Flat Bar
0684G Square .Flat Bar
03	Bebar, Other
06MC	Bound,Square
04	Flet Bar, Bebar
06MB	Billet*
01
06MB	Bound, Square
02
0684H	Bound, Square
03	Flet Bar
0684B	Squares
M
Age Product ion
Steel let jr. Capacity
Types of Frod. Ton/Par
CS22	1920	IIBS
8X1,AS77
CS19 1961	MM
SS6
as75
CS98	1916	1338
LAI
CS92 1927	763
LAS
CS98	1927	754
LA2
CS63	1916	900
ATS37
CSSI 1918	1131
ATS19
C353	1918	S73
ATM 7
CS6I	1920	237
ATS 39
CS70	1943	2898
AS 30
CS33	19)8	17S8
AS67
CS63	1943	2898
AS37
CS83	1947	1314
AS13
Flow (Gallons/Ton)
Process
Centre 1
Operating
Discharge
Applied
Process
Discharce
Trsatnent
Treatment
Mode
Hade
3087
3087
1440
PSP
arr(2)(43)
SS,CL,CT,FL
(OMOSL(UMC)
BTP(S3.3)
BIM46.7)
Direct
Bill
8371
4003
PSP,
SS
arr(2)(53),
SS,CL,CT,FL
(OIK)SL(UMK)
*TP(53.3)
•D(46.7)
Direct
3767
3767
3767
PSP,
CNT(1)(I4)
OT
Direct



SS
SS,VF,FLL,FLP




SSP
FL06,SCB,CL
PB6(UMR)


8282
mat
IMK
PSP
CNT(1)(17)
or
Direct



SS
6S,VF,F1X,FLP




SSP
P106.SCB,CL,
FOS(UMK)


8190
BMC
OMK
PSP
CNT(2)(8)
OT
Direct



SS,
CL,VF,SCB,FLL,




ssp,
FLP,FL06,PDS





SS
(UMK)


2240
2240
2043
PSP
CMT(2)(1S)
MH,FU.,HL,
rL06.Vr.CL
FLP.SS
KEU(B.S)
1D(91.2)
Direct
4774
4774
4774
PSP
SS
CKT(l)(31)
SSP.SS
OT
Direct
3026
3026
3026
PSP,
CNT(I)(27.2)
SSP,ss
OT
Direct
9722
9722
9722
PSP
CKT(1)(21.8)
OT
Direct
L««9
[«iq|
@
PSP
SSP,
CNT(IXIS)
FLP.SS,FLL,
1TP<99.7)
POTV
DmJ
M
M
SS
PSP
SSP
CL,T,CT
arrdxis)
FLP.SS.FLL
RTP(99.7)
POTV
C»*D
M
~
SS
PSP
CL.CT.T
ctrr(i)(7)
1TP{99.7)
POTW

SS
FDS(lfNK)CL


3792
3792
193
PSP
SSP
CNT(1)(13)
VF.PLL.FLP.
CL,T,SS.CT.
FDS(UNX)
RTP(94.9)
SD(S.l)
Direct

-------
TABLE III-3
HOT FORMING SECTION
SUMMIT TABLE
FACE I*	
*8*	Production
Flaot

Steel
let ft.
Capacity
Code
Froducte
T»pea
of Frod.
Ton/Day
oiMa
Bound*,Square,
CS68
1967
1707
OS
¦»,Flat Bar
LA 2, AS 30


06MB
louod , Hex v kbit
CSS2
1958
996
06

ATSI.AS17


0684N
Rouad,HeK,Rebar
cut
ONE
432
07

AS13


0776G
Billet*,Bound
CS2.SS1I
Fre-1950
66
01
Square
LA9.MS5




ATS73,


0776c
Bound,Square
CS2.SS11
Fre-1950
17
02
¦•a .Flat Bar
LA9.KS5




ATS73


0776C
Squat* ,Hcb,
CS2.SS11
Fre-1950
6
03
Flat Bara
LA9.HSS




ATS73


0776C
Combination
CS2.SS1I
Fre-1950
25
04
Mill, Boo ads
U9.HS3




ATS73


0776N
Flat Bara
ATS 100
1902
37
01




0796A
**
M
**
**
01




0796A
•*
M
**
**
02




0796A
**
M
**
t*
03




0796A
**
**
M
**
04




0004B
Seaaleaa Bing*
CS7S
1890
ISO
01

8SLA25


0004B
Seaaleaa Binga
CS60
1948
342
02

BSLA40


0036A
Flat Bar(Special*
CS79
1903
471
01

LA14.AS7


0036A
Channel, Zee,
CS67
1905
525
02
Bulb Angle,Angle
LA31.ASI.
8

How (Cation/Ton)
Applied
M
393)
9067
*
Proc
-------
TABLE II1-3
HOT FORMING SECTION
SUMMI TABU
FACE >5	
*«« Production
Plant

ft««l
1st jr.
Capnc itj
Code
Product a
Types
•f Prod.
Ton/Day
0856A
1-Beaa,Channel
CS89
1907
396
0)
Angle
LAU,ATS0.
.2

08S6A
l-Beaa,Chaanal
CS96,
1910
444
M
K-ka«,Tct, Niac
LA3.5




AS0.3


08S6F
Blooas 6 Skelp
C8100
1952
6867
01




0856P
Billete,Bound
C8100
1952
6867
02
Skelp



08S6P
•illeta
C8100
1952
5232
03




08S6F
ta|l«,loMl
C8I00
1953
1057
M
Plat Bar.Bebar



0856P
Bod
CS100
1969
2133
OS




08561
UF-laaa.M-f il«
CS86,
1927
1683
01

LAU


08568
I-Seas.Channel
CS72,
1926
1338
•2
Zee,Sheet Piling
LA23



Mac. Atfta



0856C
Circular Sect.
CS100
1918
123
01
Forging



0856K
Ax lee
CS100
1966
255
02




0856K
WlMll
C898
1971
732
03

AS2


08S6N
lo«ndt B*War
CS65,
1970
3348
01

ATS17,H811



BALS.BS2


08S6I
¦•bar
C865,
1970
1722
02

ATS17.MS11



8ALS,B8Z


How (6allona/Ton)	
Awlt«4 Process Di«char«c
nc	mat	nt
UMK	UMK	UHK
1258	1258	419
•52	9S2	476
DMC	MK	UMK
12,2)8	12,238	6804
8101	8101	8101
1515	ISIS	ISIS
1906	1906	1906
61	61	61
198	198	198
1770	1770	1770
3226	3226	3226
6272	6272	6272
Tr»«tft Coapooeota
rroctit Central Operating Discharge
Tr««t—t Tr««t—nt	Hodt	Hod*
PSP

OT
Direct
PSP

or
Direct
PSP
CHT(2)(3),
BUP(66.7>
Direct
ss
BOAl.PLP,
BIK33.3)


cr.sMtwK)


PSP
CMT(2)(3)t
BUP(50)
Direct
88
BOAl.PLP
BIK50)


CP,SL(IHK)


PSP
orr(2>(6),
BUP(50)
Direct
SS
BOAl.PLP,
B0(50)


CP.SL(UMC)


PSP
CNT(2>(8)
BUP(44.4)
Direct
ss
BOAl.PLP,
BD(SS.6)


Cf,SL(UMK)


PSP
CMT(2)(97)
or
Direct

S8,SL(UHK)


PSP
CVT<2>(25)
OT
Direct
ss



PSP
CMT(2)(10)
OT
Direct
ss



PSP

OT
Direct
ss



PSP
CaT(2)(4),
OT
Direct
ss
CL.PLP


PSP
arr<2)<95)
OT
Direct
ss
CL.PLP


PSP
CIIT(2)(50)
OT
Direct
ss
SL(UMK)


PSP
arr(2)(50)
OT
Direct
ss
SL(UMK)



-------
UIU III-)
¦or romiac stctim
MMunr TABU
PACT I*	




Productioa

riant

Oteel
let jr.
Capac icy
Pl«
Coda
Prodacta
Trpaa
of Prod.
Too/Day
A»»l1*4
MStr
Wi
C099
I9SS
123)
S6S«


LAI



NWq
Mi
COOO,
1932
2979
no
01

LAM



NMT
Boaad,flqaara
COM
1900
1029
S3S
01

0040



NJM
Miie.Huptl
C0100
I92S
204
14,OM
01





NMI
Hiac. Shapea
C0100
1920
090
0099
02





00360
Aagta,Plat Oar,
COOS
1910
370
S030
03
Balf Boaad,Other
LAS



00MI
riac Oar aad
C0100
1910
22S
12,200
M
Other Skafas




00S6O
ffnn,IUif,
cooo
1931
093
012S
0)
BaaadgBpriag Otecl
LA20




Plat Bar,B*har,




00400
Otkcc OiafM
Oillata.Baaai
COM
1971
2132
3309
01
Oqaara, Flat Oar
LAI .AOS



ooooo
1-Oaaa, Cfcaaae 1
COM
1909
S36
5909
02
Zae.Dalh tall*,
LAI,




Aa(la (facial
AOS



ooooo
I-Oaaa, Cfcaaae1
COM
1910
400
0S22
0)
Tta,htk Aagla
LAI




Oqaare
AOS



oocoo
Oar
COM
BOB
1135
2003
M

LAI, AOS



ooooo
iMtlailaJbl
COM
1911
429
9399
OS
Oar,0pec.Beetioa
LAI .AOS



ooooo
Oalh Aagle
COM
1911

IBU
00
Oqaare, Plat,Opec.
LAI, AOS



**
£
j
|
Procaaa
Treataeat
Caatral
TraatMOt
Oparat ing
Node

Procaaa
Diacharte
Hade
5454
5456
POP
C*T(2)(06)
OT
Diract



BOP,00


OMK
BMC
iSP
CNT(2)(UMC)
or
Direct


OOP
OO.SL(UHK)


S3S
535
POP

or
Diract
14,094
14,OM
POP
cn(2)(s)
OT
Diract



OOP,00


0099
0699
POP
cot(2)(0)
OT
Diract



OOP,00


SO 30
5630
POP
cn(2)(3.o)
OT
Direct



OOP,00


12,200
12,200
POP
CMT(2)(S)
or
Diract



OOP.OO


0123
012S
POP
CMI(2)(10)
OT
Diract



OOP.OO


3309
3309
POP
an(2)(6.7)
or
Diract


00
00,8L(UHK)


5909
3909
POP
cn(2>(3)
OT
Diract


00
00,0L(0MK)


0322
6S22
POP
CHT(2)(3)
OT
Diract


00
SL(ONt) ,0S


2003
2663
POP
C*T(2)(3)
OT
Direct



OO.SL(IMK)


9399
9399
POP
art(2>(4)
OT
Direct



00,SL(I1IK)






or
Direct

-------
TABU III-3
¦or routine section
rawn TABLE
PACT 17	
Age	Production
Plant

Stent
let yr.
Capacity
Code
Producta
Tmi
of Prod.
Ton/Day
06601
Round(Square
lit*
1911
IDLE
07
Bex(R«bar,Spec.



08MB
Round,Rebar
CS94
1919
492
08

LSI,ASS


0660B
Channel,Angla
CS94
1927
474
09
Plat Bar,Strip
LSI,ASS


0860B
Round, Plat Bar
CS94
UNK
892
10
Rebar,Spec.Sect;-
LAI,ASS


0860B
Hil1(Round tFlat
CS94
1972
1464
11
Bar,Rebar
LAI,ASS


0860P
Hire Rod.
CS97
1936
726
01

LA3


0860F
Hire Rod!
CS94
1943
1167
02

LA6


06608
HP-Beaa
CS80
1931
2616
01

LAW


08601
Hf-Bcaat 1-lua
CS8S
19S9
1380
02
Channel,Sheet
LAIS



Piling,Angle




Zee



06608
Rod, Coila
CS99
1974
20S8
03

ATS I


0864A
Billeta.HF-
CS94
UMC
2040

6 I-Beaa,Chanffte 1
LA6



Zee,Angel



0864B
Round
CS100
1941
1161
0664C
Billeta, Channel
CS7S
1916
4S0
01
Ang 1«,Round,Flat
LAS,ATS20



Bar,Bebar



0864C
Channel, Angle
CS7S
1916
360
02
Round,Flat Bar
US



Rebar
ATS20


How (Callona/Ton)
Applied frocw Discharge
Treatment Conpooente
Proceae Central Operating
Treat—nt Treafent	Hode
Discharge
Mode
11,993
11,993
11,993
PSP
7S90
7S90
7590
PSP
12,751
12,751
12,751
PSP
6880
6880
6880
PSP
7934
7934
793
PSP
SS
4936
7794
4934
7794
494
218
[469§	[469^ [ieq]
[6930]	[693^ [3j
PSP
ss
PSP
38
PSP
SS
PSF,SSP
SS.CT,
e.FSP,
*r.T
CNT(2)(5.6)
SS,SL(UMO
CNT(2)(3.4)
SS.SLdlNK)
CITT(2)(I0.8)
SS,8L(UNK)
CHT<2)(9.6)
SS.SMUNK)
orr(i)(25)
ssp,T,*r,p,
NA.NL.CT
fds(umc)
CNT<2)(25)
ssp,t,vf,p
NA.NL.CT,
fds(uw)
CHT(2)(IS.7)
SSP,SS,SCR,
fll,fla,vf
CL,T
CHT(2)<22.7)
SSP f SS,SCR
fll,fla,vf
CL.CT.T
or
at
OT
or
RTP(90)
»D( 10)
RTP(90)
>D(10)
RTF(97.2)
BD(2.8)
RTF(96)
>D(4.0)
«TP(99.5)
»D<0.5)
10,729
10,729
933
PSP
CMT(2)(83)
RUP(78.9)




SS,CL
RTP(12.3)




SL(IHK)
BD(8.7)
9054
9054
245
PSP
CNT(2)(1.6)
RUF(97.3)




NL,FLL,FLP
BD<2.7)




CL,HA,SS,T

3840
3840
280
PSP
CHT(2)(29)
RTF(92.7)



SS
SSP,SS,CT,
BD(7.3)




SL(UNK)

10,000
10,000
730
PSP
arr(2){6i)
RTP(92.7)



SS
SSP,CT,S8
BD<7.3)




SL(UMK)

Direct
Direct
Direct
Direct
Direct
POTW
Indirect
Direct
Direct
Direct
Direct

-------
TAILS III-l
HOT FORMING SECTION
SUMMRT TAILS
pace 18	
Plant
Code
Product*
Steel
Types
««•
let jr.
of Prod.
Production
Capacity
Ton/Day
Aral lad
0868A
Bails
CSI00
1908
1902
1020
01





0868A
Hill,Billeta,
CS9S
1912
2307
709
02
Bloons
LAS



0868A
I-Beaa,Channe 1
C39S
1919
1386
1647
03
Bulb Angle,Angle-
US



0868A
I. It. Axel
CS100
1923
249
3909
04





0868A
Bound,Square
CS98
1924
537
963
OS
Flat Bar,Bebar
LA2



0868A
Billets
CS9S
192S

IDLE
06

LAS



09208
Bound.Square
CSIOO
1908
1806
1037
01





09208
Bounds
CS100
1910
S16
1674
02





0946A
Bound(Square
CS77,
1907
759
7S89
01
Flat Bar,Spec.
LA2 3



0944A
Bound,Square
CS2S,
1926
906
8742
02
Flat Bar,Disc.
LACS



0946A
Bound, Square
CS80
1961
•31
7798
03
Hex
LA 20



09488
Bounds
CSS*
1914
768
262S


LA44



0948P
Bound,Square
CS60
191S
424
UMK
01
Hex, Bebar
LAI0,KAL30


0948P
Zee,Angle,Bound
CS60
1916
583
mm
02
Square,Bes,Bebar
LA8.BAL32



0948F

CS96
1933
29
3750
03

CB4



¦ (Callooe/Ton)
Process
1020
709
1647
3909
~63
Discharge
1020
709
224
532
111
Treittnt Cowtntnf
Process Central
Treatment Treatnent
Operat tng
Mode
OT
PSr CKT(2)(23)
SSP.SS,
SL(IIHK)
PSP CNT(2)(23.S) OT
SS,SSP,
SL(UNK)
PSr CKT<2)(3.«) RTP(86.4)
SSP.SS,	»D(13.6)
SL(UNK)
PSP CMT<2)(1.6) BTP(86.4)
SS.SL(UMK) BD(13.6)
PSP CHT(2)(0.8S) RTP(86.4)
SSP.SS,
Discharge
Mode
Direct
Direct
Indirect
Indirect
Indirect
SL(UNK)
BD( 13.6)
1037
421
PSP
arr(2>(i3)
RTP(59.4)
Direct



SSP
80(40.6)

1674
1674
PSP

OT
Direct
7589
1009
PSP
CWT(2>(22)
RTP<86.7)
Direct



SSP.PDSP
BD(13.3)

8742
1609
PSP
CHT(2)(30)
RTPI81.6)
Direct



SSP,T,FLP
BD(18.4)




FDSP


7798
328
PSP

8TP(95.8)
POTW


ss

BO(4.2)

2625
2625
PSP

OT
Direct
UMK
OMK
PSP

OT
Direct


ss



UMK
UMK
PSP

OT
Direct


SS



3750
3750
PSP

OT
Direct

-------
TABU III-J
MOT FOBMIK 8BCTIM
SUMMIT TAILS
fACE »	
rOOTWOTES
(1) 1977 value
* i Pry Opaiitln
**« Confidential Data
[Ji Data listed ia bracket* na received ia tha nipomii to tka detailed fitationn«ire«
w dariai taafllai viiits
Steel Tw«i
Alloy Steel
Boron Staal
Alloy Bar Staal
Free Machining
Kclulphur i red and Leaded
Vanadiua Grade Steal
Managing Steel
Ul

Additional Footnotee
01i	Decant Tank
02i	Inclined Flata Separator
Oil	Battling Baaia
OA:	Coatinuoue Cloth Filter
Oil	Settling Tank
Ml	Floccttlatioa v/Ferric Chloride
cs
1
Carbon Steel
AS 1
LA
I
Low Alloy Steal
BS 1
ss
I
Stainleas Steel
ABSt
QUI
ll
Chroae/Nuldeoua Beat laaiatant
FMSi
OS
1
Other Steal Not Identified
BALI
ATS
I
Alloy Toot Steel
VCSl
ES
I
Electrical Steal
MS 1
For a definitioa of other CtTT Codea, »ee Table VII-1.

-------
Age
Plant

Steel
lat Tear
Coda
Product
Tzbl.
of Prod.
0020B
Plate,
SS-40
1953

Rot Strip
ES-60

0060
Hoc Strip
CS-95
1968

LA-5
(1971)
00608
Hot Strip
CS-98.4
1953

LA-1.6
(1967)
00600
Hot Strip
CS-5.1
1958


S8-22.4



ES-72.5

0112A-03
Hot Strip,
CS-IOO
1937

Skeip

(1960)
0112-04
Plata,Sheet,
CS-95
1947

Hot Strip,
LA-5


Skalp


0112B
Plate,Hot
CS-99.9
1936

Strip,Sheat
LA-0.1
(1957)
Oil2D-02
Plate,
CS-98.6
1966

Sheat
LA-1.4

0176
Hot Strip
SS«ES
1953


100

0248B
Plate,Hot
CS-10
1960

Strip,Slabs
SS-90

Production
Capacity
(Tons/Day)
2,550
10,032
4,790
2,520
4,978
7,891
7, MS
12,744
240
1,500
TABLE II1-4
CEHEKAL SUMMIT TABLE
HOT FORMING I FLAT-HOT SKIP AMD SHEET
Flow (Cation/Ton)
Applied Proce»« Di»char«e
Treatment CoKooenta
Proceaa	Central	Operating
Treatment Treatment	hode
5,421	5,421
UMK
7,143 7,143
5,619	584
uwc
UMK
5,421
UMK
4,911	1,405	1,405
584
UNK
9,630 9,630	693
7,680	7,680	92
PSP
[8,297] D.936J |j5l]	PSP.SS
PSP,SSP,88
PSP
PSPfCT
PSP.CT
PSP
[5,713 Cs,710 D.»H reP
PSP
PSP,SSP
S8P,CL,
PDS(UMK)
CMT2-82.6,
FU.,FL0(1),
CL,VP, CT
CNT2(UMK),HL,
FIP,CL,VF,CT
CMT2(UIK>,
FU.,FLP,FL
(01),CL,SL
(UNK),CT
CHT2(UN*),SS,
Scr.AE, ML,
PU.PLP.SL
S(UNC),T
CMT2-61.3,
CL.FLP.HL,
Mf,Cltf SL(UNK)
CNT2-13.SSP,
T,SS,CY,CL
PLP,Scr,TP,
CT, SS
Discharge
Hode
Direct
BUP-4,RTP-94, Direct
803
KTP(UMK),RET Direct
(UNK),ED(UNK)
ITP(UNK),
RET(UNK),
BD(UNK)
KUP-71.4,
80-28.6
RUP-89.6,
B0-10.4
RTP((UMOf
BD(UNK)
OT
KTP-92.8,
BD-7.2
KTP-98.8,
8D-1.2
Direct
Direct
Direct
Direct

-------
TABU III-*
emui SUMMIT TABU
k>t roniirn plat-mot stbip amd smet
fAGt 1	
Pleat
Cod*
Product
lt«l
TfP»
Asa -
lit Tear
of Prod.
Prodwctioa
Capacity
(Tooa/Da?)
Iwliti
0254C
Rat Scrip
CS-86.13
SS-S.43
BS-S.4
1932
{1947)
2,328
UMK
0254L-03
0236L-04
CONFIDENTIAL DATA



0320-02
Sheet
CS-100
1974
8,232
9,931
0384A-02
Hot Strip
CS-94.2
LA-2.9
ra-o.*
1943
<1947)
12,291
10,193
0384A-03
Mat*,
Strip, Sheet
CS-83.9
LA-14.1
1932
(193t)
3,444
17,511
0384A-04
Plata,Strip,
Meat
CS-9S.8
LA-1.2
I93S
<1940)
3,400
S, 373
03>M>-01
Hot Strip
CS-100
1927
231
24,933
0394D-02
But Strip
CS-100
1940
1,438
7,033
0424-02
Plata,
Sbaat
CS-100
1930
20.1
714
0432A
¦at Strip,
Skalp
CS-90
LA-S
BS-3
1937
3,400
-
0432B
Plata,
tot Strip
CS-90
SS-10
1937
3,942
UMK
Flow (Cjllop/Ton)	
Procaaa	tliclutM
OMC	UNK
6,73?	6,737
7,380	7,380
17,ill	17,311
•,373	8,573
24,933	om
7,033	UK
71*	71C
UK	DNK
OK	UNK
Traataeat Coapoaeata
Proceaa Central
Treatment Traataeat
Operating
Node
Oi (charge
Node
PSP
CNT2(UMK),SL
,SS
BTP(UMK),
BD(UMK)
Direct
PSP.SS
OIT2-52.7,
MC.SC, CL,
¦tflM)
BUP-32.3,
¦0-47.7
Oi rect
PSP.SS
PLL.PLP.FLA,
ruKD.ss.cL
BDP-27.4,
¦0-72.4
Direct
PSP
om-31.8,
SS.SMUM)
OT
Direct
PSP
CNT2-23,
SL(UHK),SS
OT
Birect
PSP
CNTI(IJNK),
StfUMO.SS
R TP (IMC),
¦O(ONC)
POTH
PSP,CT,FDSP,
CL.VP
CNT2
-------
TABU III-4
CBMBAL gOHUR TABLE
¦OT rOBUNCi FIAT-IDT STRIP AMD SHBBT
PACE 3			
Ul
VD
Plaat
Product
0432C
0448A-01 Plate,
Skelp
0492A Skelp
0328A Hot Strip
0584B
OSMG lot Strip
Steel
lilt.
Plata,Bat CS-92
Strip,Skelp SS-4
LA-4
CS-96
AS-*
0448-02 rlate.Bot	CS-95
Strip,Sheet	AS-3
Skelp
0476A Plata,Sheet	CS-SO
Hot Strip,	LA-JO
Skelp, Sar
CS-100
CS-M
SS-3
LA-3
Plate,	CS-SO
Bit Strip LA-20
CS-80
LA-20
0S84P
Hot Strip CS-100
Age -	Production
let Teer	Capacity 	Flow 
-------
TABU 111-4
C EM UAL SUMAH TABU
IDT romiNG: FLAT-TOT STBIP AMD SHEET
PACE 4		
CTi
O
Plant
Code
06MB
Product
Steel
Type
Plate,Bot CS-84
Strip,Sheet, SS-5
Skelp	LA-2
AT-1
BS-t
0684P-02 Plate, Sheet, CS-94
Skelp	SS-1
LA-4
06841-01 Hot Strip CS-96
LA-4
06M»-02 Sheet
07761-02 Sheet
SS-100
88-10
LA-IS
AT-75
OIMD lot Strip cs-as
U-ll
ES-4
SS-100
0856B Plata,
Sheet
0854F-02 Skelp
CS-100
Age - Production
let Teer Capacity 	
of Prod. (Tone/Pat) Applied Proceaa Diacharce
Plow (Gallon/Ton)
1961
(1964)
6,396	[+,50j) (4.S0S| [i.46^
1971 8,221
1957 3,429
(1964)
1916	20.7
1902 IB
(1962)
1938 8,445
(1961)
1927 28
0S56F-01 Rot Strip CS-100 I9S2 9,168
1953 3,042
9,347	7,578	327
5,802	5,802	5,288
8,803*	8,803*	403*
6,400	6,400	6,400
4,450	4,450	4,450
0MC	UMK	UNK
5,497	4,238	4,238
2,840 947
947
Treafent CoDoaeotl
Proceaa Central	Operating
Treatment Treafent	Mode
PSP.SLdlM), -	BTP-67.5,
CT	BO-32.5
PSP
PSP,SS,
SLtUMC)
PSP
PSP
PSP
CMT2-56.0, BUP-1S.9,
Scr.FLL.PLP, BTP-77.6
FLO
-------
TABLE III-*
CEMEBAL SUMIAIR TABU
HOT VOIMlllCl FLAT-HOT STBIP AW SUET
FACE 5		
riant

Steel
Ate -
let Tear
Production
Capacity

flow (Gallon/Ton)
Treatment
Process
Cosoonents
Central
Operating
Dischai
Code
Product
Tlf
CS-100
of Prod.
(Tons/Day)
Applied
Process
Discharge
Trestsent
Trestaent
Node
Hode
06 SiP
Hot Strip
1929
253
5,125
5,125
5,125
PSP.SS
CHT2-96,
SSP,SS
OT
Direct
06360-01
Hot Strip,
Skelp,B«r
CS-100
1929
556
11,277
11,277
11,277
PSP
CMT2-11.3,
SSP.SS
OT
Direct
08560-02
Hot Strip,
Specials
CS-100
1916
iso
22,944
22,944
22,944
PSP
CMT2-6.9.
SSP.SS
OT
Direct
oe»o~o3
Hot Strip
cs-u
LA-5
1920
639
6,400
6,400
6,400
PSP
CHT2-7.3,
SSP.SS
OT
Direct
0*560-0*
Plata,Sot
Strip,Skelp,
Bar
CS-100
1926
91S
4,647
4,647
4,647
PSP
CHT2-7.9,
SSP.SS
OT
Direct
06569-05
Plata,Hot
Strip,Sheet,
Ikalp
CS-S5
LA-IS
1935
2,907
11,609
11,609
11,609
PSP
CNT2-61.4,
SSP.SS
OT
Direct
0660B-01
Hot Strip
CS-96.5
SS-2
LA-l.S
1967
12,206
6,446
7,S10
7,S10
PSP.SS
CMT1-79.6,
SSP.SS,PDSP,
t.vf
MIP-ll.l,
BD-86.9
Direct
0660B-02
Hot Strip
CS-100
1936
<1976)
5,895
5,594
5,594
5,594
PSP.SS
CNT1-20.2,
SSP.SS,
PDSP,T,VP
OT
Direct
0B6*A
Plate,Hot
Strip,Sheet
C6-94.6
LA-5.2
1946
(1971)
6,016
4,666
4,666
4,666
PSP
CHT2-50.4,
CL.SS,
SL(UNK)
RET-56.7.
BO-41.3
Direct
0668A-02
Hot Strip
CS-100
1929
177
21,356
18,443
1,815
PSP
CHT2-5.4,
SSP,SS,
SL(UIK)
KUP-13.6,
BTP-77.9,
BO-8.5
Direct
0M8A-03
Hot Strip
CS-99
U-l
1937
(1969)
4,65*
2,905
2,90S
334
PSP
CMT2-23.3,
SSP.SS,
SL(UMK)
BTF-88.5,
BO-11.5
Direct

-------
TAIL! 1II-4
CBBUl SOMAKT UIU
bt romiHo piat-hot mir u> sun
paci t 			
Plant

Steel
Age -
let Tear
Production
Capacity

Flow (Callon/Ton)
Treatment
Process
Coapooeats
Centrsl
Operating
Discharge
Code
Product
TtM
of Prod.
(Tons/Day)
Applied
Process
Mscbaree
Treataent
Treataent
Mode
Made
0920C
lot Strip
CS-99.5
LA-0.2S
¦C8-0.2S
1953
<»H4>
3,300
7,767
5,150
3,150
PSP.88,
SSP.SS
-
¦OP-33.7,
¦0-66.3
Direct
0920M
Hot Strip
CS-96
LA-4
196*
7,9 91
[3,198]
[l.M 2]
0,892]
P8P.SS,
pump
-
(jUIP-40.8,
¦D-59.2J
Direct
0948A
Plate,Hot
Strip,Sheet,
Skelp
CS-S9
LA-10
ES-1
1935
(1960)
7,584
6,076
6,076
6,076
PSP,SS
•
OT
Direct
0948C
Plats,Hot
Strip,Sheet,
Skelp
CS-95
LA-5
1968
8,724
6,602
6,602
6,602
PSP.SS
OT2-97.6,
PDSP.CL,
PUX1),SS
¦ET-100
Indirect
•l Includes flows froa oac plat* ¦III.
( ) Dates in parentheses represent year* In «4>ich the mill neat through a aajor Bonification.
n Data lilted in bracket* was received la the response to the detailed questionnaires or during sanpling visits.
m TO CfcTT STEPS
AS I	Alloy Steel
CB t	Csrboe Steel
¦CSi	Ugh Carboa Steel
SS I	Staialess Steel
Por definitions of C4TT
AT I	Alloy Tool
ES I	Electrical Steel
LA I	Low Alloy
SASi	Super Alloy Steel
see Tsble VII-1.

-------
TABLE III-5
Plant
Cod#	Product
OO&OP-OI	Plate
0060F-0!	Plat*
0II2A-01	Plata
0112A-02	Plata
0U2G-01	Plata
0112C-02	Plat*
OII2D-01	Plate
0384A-0I	Plate
GENERAL SUMAH TABLE
HOT nmiKs PLAT-PLATE (CABBOH)
Age - Productioa
Steal	tat Tear Capacity 	Floy (gallon/Toe)	
Trpt	of Prod. (loni/Pitl Applied Procaaa Diacharte
CS-73 1962	2,1 IS	3,976 3,976	UK
LA-16
AS-II
CS-73 1950	1,410	UK	UK	UK
LA-16
AS-1I
CS-100 1920	1,056	2,*55 2,4SJ	2,455
(1964)
CS-98 1931	2,592	2,778 2,778	2,778
TS-2	(1957)
CS-82.7 1902	834	UK	UK	UK
AS-17.3 (1954)
CS-69.7 1906 471	UK
AS-30.3 (1961)
CS-70 1964 3,360	UK	T3"32*!
LA-15
AS-15
CS-74.7
LA-25.3
1913
(1951)
972
7,867
7,867
7,867
Treafent Cowwaenta
Proceaa
Treatment
Central
Treatment
Operating
Mode
Diacharge
Mode
PSP
CHT2(UK),
SSP.Scr,
SL(IHK), SS
kTP(UHK),
KET(OMC),
BD(UHK)
Direct
PSP
CHT2(Ut*),
SSP.SLtUMK),
Scr.SS
BTP(UK),
KET(INK)
BO(UNK)
Direct
psr,ss
am(uiK)
SS.Scr.AE,
ML,FLA,FLP,
8L(UIK>,CT,T
OT
Direct
PSP.8S
am(uK),
Scr,AE,NL,SS,
PLA,PLP,SL
(UK),CT,T
OT
Direct
PSP
CMT2(UIK),
MC,AE,SSP,SS,
T.PDS(UIK),
CT
OT
Direct
PSP
am (uw),
MC,AI,SSP,SS,
T,PDS(IHK),
CT
OT
Direct
PSP,SS
CMT2-12.2,
SS,CL,FLP,
HL.NU.CR,
SIX UNO
KUP(UNK)
IO(UKK>
Direct
PSP.SSP,
SS
CMT2-93,
SL(IIIK),SS
OT
Direct

-------
TABLE III-S
CENERAL SUMtARY TABLE
HOT FORMING: FLAT-PLATE (CARBON)
PAGE 2	 	
Plant
Code
Product
0496
112"/120" Plate
0496
140"
Plate
06841-02 Plate
Steel
Typ«
Carbon
Carbon
CS-76
LA-24
Flow (Callon/Ton)
Age - Production
lat Tear Capacity			
of Prod. (Tona/Day)	Applied frocaaa
1,740	869	869
1,830	118	118
1967	1,629	7,558	7,558
1904
(1943)
1959
(1968)
Diatharte
869
118
6,889
0856H-01	Plate
0856H-02	Plate
0856N-03	Plate
0860B-03	Plate
0860H-01	Plate
CS-72.1
LA-27.9
CS-87.4
LA-12.1
AT-0.5
CS-73.5
SS-1.5
LA-13.5
AT-11.5
CS-67
AS-33
1898
1936
1944
1962
CS-50 1907
LA-42	(1973)
AT-8
984
3,939
2,916
3,162
648
117	117
117
5,473	5,473	5,473
3,652 3,652	3,652
2,550 2,550	2,550
[9,82l] [9,820 C*U
Treatment Component!
Proceaa	Central
Treafent Treafent
Operating
Mode
Diacharge
Mode
PSP,SSP, CNT1-28,	OT	Direct
SS	FLF,DR,FDMC
PSP.SSP, CNT1-4,	OT	Direct
88	FLP,DR,FDMG
PSP	CNT2-13.9, RTP-8.9,	Direct
SSP,SS,	BD-91.1
B0A(l),NU,
SL(UMK),SS
PSP.SSP, -	OT	Direct
S3
PSP	-	OT	Direct
PSP.SS	-	OT	Direct
PSP.SF	CHT2-7.5, OT	Direct
SL(UNK),
SS
PSP.SS	CNT2-5.3, RTP-96.3, POTV
Scr,CL,CT, BD-3.7
T,FLL,VF,FLA
SSP.SS

-------
TABLE II1-5
CEHERAL SUMMIT TABLC
HOT FORMlNCs PLAT-PLATE (CAMON)
FACE 3	
Plant
Code
Product
086BA-01 Plate
0868B
Plate
Steel
Typ»
0860H-02 Plate,	CS-60
Floor Plate LA-40
CS-SO
LA-20
CS-85
LA-10
AT-S
Age -
1st Tear
of Prod.
1931
1919
(1942)
1970
Production
Capacity
(Tona/Day)
2,886
1,800
3,894
Applied
5,489
3,922
4,992
Flow (CatIon/Ton)
Proceaa
5,489
3,922
4,992
Pi ¦chares
154
451
185
Treatment Coapoaenta
Proceaa	Central
Treatment
PSP.8S
psr
PSF.SS
Dteafeat
CNT2-14.7,
Scr.SfiP, S8
CL,T,CT,FLL,
Vr.FLA
CNT2-11.7,
SLdllK),
88,SAP
CHT2-99.3,
FLP,A,88,
ssr.suum),
F(unc)(UNK)r
Operating
Mode
8TP-97.2,
¦0-2.8
(TP-88.5,
80-11.5
8TP-96.3,
IMLoaaea-
3.7
Discharge
Mode
POTU
Direct
Direct
O1	( ) Datea in parentheeea repreaent years in which the at 11 vent through a aajor aodif{cation.
^	[] Data liated in bracketa waa received in the reaponaea to the deteiled queationnairea or during aaupling viaita.
KET TO CfcTT STEPS
AS t	Alloy Steel	AT I	Alloy Tool
CS :	Carbon Steel	U s	Low Alloy
SS 1	Specialty Steel	SASt	Super Alloy Steel
T8 t	Titeniun Steel
HOT*: for definition* of CATT code* aee Table VU-I.

-------
TABLE II1-6
CEMOtAL SIMIAIT TABLE
hot tantaci hat-tlate (specialtO
cn
Plant
Code
04%
(112"/
120")
0496

-------
TAILS III-J
GENERAL SUMMIT TAILS
HOT WOKMC PIPS MID TOM
A«e -	Production
Plaat	Steel	tat Tur Capacity		How (Callon/Toa)	
Code Product	Tr»e	of Prod.	(Toni/»w)	Applied hweii Dlacharte
006OC lualeu CS - tO
01	Pip*	HSLA - 40 1913	906	UNK	OK	M
OOMC Seaaleaa CHJ
02	Hp*	HSLA-55 1913 406	IMK	OIK	IMS
0060F hct 
-------
TAILS IU-7
CEHEKAL SUHHABT TAILS
hot wohumc nn ahd tuib
fAGE 2	

Plant

Steal
lat Tear
Coda
Product
Typ*
of Prod.
0088A
Seaaleee
CS-7

03
Tube
HSLA-93
1932
0088C
Seaaleae
CS-60

01
Tube
MSLA-40
1910
0088C
Seaaleaa
CS-60

02
Tube
BSLA-40
1937
0112A
¦utt Held


01
Pip.
CS-100
1939
0112A
¦utt Held
CS-100
1940
02
Pipe


Production
Capacity	Flow (Callon/Too)	
(Tona/Pa?)	Applied frocaM	Placharae
171	2712	2712	2712
283.1	3552	3)52	1369
268.3	6436	6436	2481
366	IM	ONK	UIK
744	URK	IMC	OIK
0196A
Seaaleae
Tube
CS-95
¦SLA-5	1933 "	12,794 12,794 4,572
Treatment Coapooentt
Proceaa Ontral
Treatment • Traafent
Operating Discharge
Mode	Hode
OT
PSP,SSP,"J CUT 2-33.7, RTP-61.4,
S3	I GF.CT	ID-38.6
rsr.ssp,
IS
psp.ss am(oiK), ot
Scr,RL,
A, FLA,FLP,
SLOMD.SS,
T,CT
PSP.SS	CMT2(UMK), OT
Sct.HL,A,
PU.FLP,
SL(UHK),SS,
T,CT
PSP.SS	CMT2-32.9, ID-35.7
SSP.SS,	ITP-64.3
SL(OMC),
CL.rD8P.CT
Direct
Direct
Direct
Direct
Direct

-------
TABLE III-7
cnmm. Hmur tabu
»t vow img pipb am tvbb
PAGB 3	
Plant
Code
Product
Ac* - Productioo
Steel	lit Tear Capacity 		.
trM	of Prod. (Iwii/Pw) Awll«< ProcaeaHacharte
Plow (Calloo/Toe)
0240S
OS
Beealeae
Pipe
C8-J4
U-M
l«»
213
0"§	L»il
02M6 Butt UtU
Pipe
CS-97
¦SLA-3
I9M
S<4
[51§ M [«3
0396E
Butt Held CS-80
Pipe	AS-20
1947
AM
A50
41
0432A Butt Held
01	Pipe aad
Welded Tube
CS-100 1957 6M	[mm) [mS^	[som|
CT1

0432A Butt Held
02	Pipe and CS-100
Uelded Tube
1958
I029.«
0432A Seaaleee CS-70
01	Pipe	RSLA-JO
1927
828
OIK
OMK
Treatweat Cougoaeef
Proceaa	Caatral
Treatment Treafeat
Operating
Hode
Discharge
Hode
PSP.Oil	SL(HIK)	BTP-87.5, Direct
Seperator	BD-12.J
PSP.SSP, -	0T	Direct
SS
CMT2-1.B	ITP-91,
SL(UMt)	BD-9.0	Direct
PSP.SS	orr 2(11.6) OT	Direct
PLP.PUI,
CL,tS,Scr,
*T
PSP.SS	art Hum), OT	Direct
PLP.PLM,
CL.SS.Scr,
VP
PSP	-	OT	Direct

-------
TABLE II1-7
CENERAL SUMMIT TABLE
HOT HOMING FIFE AMD TUBE
FACE 4	
Plant
Code
Product
Steel
Age - Product ion
lit Tear Capacity
How (Callon/Toa)
Tr»itw»t Coeoonenf
Froceaa	Central
		Oftittlq Diicturge
of Prod. (Tone/Par) Applied Fr«c«w Placharee Treataent Treatment	Mode	Mode
0432A Seaaleaa
M	Pipe and CS-70
Tube	HSLA-30
1926
516
PSF
OT
Direct
0448A Butt Weld CS-100
Fipe
1946	*56.3
FSP.SS	CUT 2(UNK), KUP(UNK),
CL,SL(UMK), KTF(UMK),
CT	ID(IMK)
Direct
-J
O
04764 Butt Held C8-100
Pipe
1930	361.6	4672	667
687
0492A Seaaleaa
OS	Tube
0546
Seaaleaa
TUB*
CS-5
RSLA-95
CS-90
AS-10
1975	156
1945 196.6
10154	10154	6237
4573	915
915
FSF
PSP.SSP,
88
TOP
OIT2-9.9,
Ser, SS.NL,
CT.PLF.CL
CHT2-1.4,
SL(DMK),
SS
MIP-78.7,
10-19.1,
Utaaee 2.2
KTP-18.9,
KET-81.1
CMT2-27.1, tUP-80,
ML.SLdINC), BO-20
CP,FLL, MA
Di rect
Indirect mo
diacharge froa
total ajratea
Direct
0546A Seaaleaa
01	Pipe
CS-70
LA-30
1960 126
6000	8000	1794
PSF.SSF,
SS
CHT2-77.8,
Spray
Cooling
BTF-77.6
BET-22.3
BD-0.1
Direct

-------
TAILS I1I-7
GCHEKAL SUMMCT IUU
IDT WOCXIHC riK AMD TDM
MCE 5		
Plaat
Co4«
MWt
02
Pro*»ct
tanl
-------
TABLE 1X1-7
GENERAL SUMMARY TABLE
HOT WORKING PIPE AND TUBE
PAGE 6	
Age - Production
Plant	Steel	lit Tear Capacity 	Plow (Gallon/Ton)	
Code Product	Type	of Prod. (Tom/Day) Applied Proceaa Diacharge
07 96A *	*	*	*	*	a	a
03
0796B *	*	a	*	*	a	a
0856C Seaadeaa CS-90	1972	36	16,000 100	100
Pipe	HSLA-'
AS-9
0856P Butt Held
01	Pipe	CS-100	1953	663
7,111 3,556	3,556
08S6F Butt Weld
-J	02	Pipe	CS-100	1963	957
M
0856N Seaaleea
01	Pipe	CS-100	1928	1011	3418	3418	3418
Treatment Component!
Proceaa	Central	Operating Diacbarge
Treatment Treatment	Mode	Mode
PSP	-	BUP-99.4, Direct
BD-0.6
CHTI-6.7, BUP-50	Direct
PSP	GP,SSP>FLP, BO-50
BOA(l),
EL(UMC),SS
PSP
CUT 2-9.4, OT
SL(UHK),SS
Direct

-------
TABLE 111-7
GBROtAL SUMUH TABU
HOT WORKING PIPE A» TU»S
PACE 7		
- Productioa
Plant	Steal	lat Tear Capacity
Coda Product	Type	of Prod. (Tooe/DaT)
NSH	Saaalaaa	CS-65
02	Pipe	HSLA-15 1930 1500
OSSU	haaltai	CS-90	1949 9S1
0)	Pip*	BSLA-10
0856M	Butt He 14
M	Pip*	CS-100	I960	888
08S6Q	Seaaleaa
01	Pipa	C8-100	1930 927
OSMQ	Saaalaaa
02	Plpa	CS-100	1930 1365
0916A	Butt Weld
01	Pipa	CS-100	1931	600
Treafent Coapoaaata
	Plow (Callon/Toa)	Procaaa	Central	Operating Diacharge
Applied Proctn Diacharae Treafent Treafent	Mode	Mode
3MB
X4I
3648
CNT2-10.7, OT
SL(UMK),
>8
Direct
3083
3083
308]
PSP
CUT 2-5.9,
8L(0tK>,
SB
OT
Direct
3730	3730	3730
PSP
car 2-6.S, OT
sl(umk),
88
Direct
PSP.SSP
CUT 2(UMK), OT
SL(UMC),SS
Direct
OMR	OHK	UMK
PSP.SSP
CUT 2(UMK), OT
SL (OIK),
88
Direct
276}	2765	276}
PSP,88,
FD(UHK) P,
SL(UIK)
OT
Direct

-------
TABLE III-7
CDKML SUMHART TABLE
ROT WORK INC PIPE AMD TUBE
PACE »	
AS*
Production
-~J
Plant

Steel
let Tear
Capacity

Plow (Catlon/T<
»)
Code
Product
Type
of Prod.
(Tooe/Dar)
Applied
Proceaa
Diacharee
0920C
Seaaleaa
CS-85





01
Tuba
HSLA-15
1934
229.5
4706
4235
4235
0920C
Seaaleaa
CS-85





02
Tube
HSLA-15
1943
373.2
5788
5209
5209
0920C
Seealeea
CS-85


Hot ia Operation la 1976
03
Tube
BSLA-15
1924
111.3
BA
BA
BA
0948A
Seaalaea
cs-to





01
Tube
HSLA-40
1924
615



0948A
Seaaleaa
cs-;o


6207
6207
6207
02
Tube
BSLA-30
1926
777



094SA
Butt We 14
CS-97





03
Pipe
AT-J
19)9
468
3077
3077
3077
0948C
Seaaleaa
CS-60





01
Pip*
¦SLA-20
1957
444
21.40}
21,405
21,405
094SC
Batt Held
CS-90





02
Pip*
AT-10
19 SO
SOI
6611
6611
6611
*1 OaafifcMUl Information
NOTE: For the defiaitioa of the treatment coaponeat lyvboll, refer to Tabl* fll-l.
Tteataent CowoBMti
Procen	Central
Treatncnt Treatment
Operating Discharge
Mode	Made
PSP
CUT 2-19.7, OT
BC,SSP,	(loeeea)
Si
Direct
PSP
CUT 2-39.5, OT
NC,SSP,SS (loaaea)
Direct
PSP
CUT 2-19.7, OT
HC.SSP,SS (loeeea)
Di rec t
PSP
CUT 1-60, OT
SSP.SS
PSP
OT
Direct
P8P.SS
OT
Direct
PSP.SSP,
ss.Fosr
OT
Direct

-------
TABLE III-8
HOT FORMING-PRIMARY
CARBON AND SPECIALTY STEELS
DATA BASE
Operations Sampled for
Original Study
Operations Sampled for
Toxic Pollutant Study
Total Operations Sampled
Operations Selected
for D-DCP
Operations Sampled and/or
Solicited via D-DCP
Operations Responding
to DCP
Estimated Number of Hot
Forming-Primary Operations
No. of
Operations
13
5, inc1.
1	above
17
9, inc1.
2	above
24
111
(2)
% of
Total No. of
Operations
10.0
3.9
0.8
13.1
6.9
1.5
18.5
85
(3)
Daily Capacity
of Operations
	(Tons)
48,084
14,673 incl.
5,565 above
57,192
44,685
12,063
89,814
(1)
130
100
423,332
460,000
Total Daily
Capac ity
10.4
3.2
1.2
12.4
9.7
2.6
19.5
92.0
100
(1)	1976 capacities were used for the values in this column.
(2)	Responses were received from 114 operations, three of which were reported to be idle. Data is included in
the totals from five operations which requested confidential treatment.
(3)	Responses were solicited and received from approximately 85% of all active Hot Forming - Primary operations.

-------
TABLE III-9
HOT FORMING SECTION
CARBON AND SPECIALTY STEELS
DATA BASE
-j
o>
Operations sampled for
original guidelines study
Operations sampled for
toxic pollutant study
Total operations sampled
Operations selected for
detailed DCP
Operations sampled and/or
solicited via detailed DCP
Operations responding to
basic DCP
Estimated number of hot
forming section operations
No.
of
Operations
25
13 inc1.
4 above
34
10 incl.
1 above
43
240
(2)
% of
Total No.
of Operations
8.9
4.6 incl.
1.4	above
12.1
3.5	inc1.
0.4 above
15.2
85
(3)
282
100
Daily Capacity
of Operations
	(Tons)
21,309
15,581 incl,
287 above
36,603
9464 incl.
2058 above
44,009
236,809
278,599
(1)
% of Total
Daily
Capacity
7.6
5.6 incl.
0.1 above
13.1
3.4 incl.
0.7 above
15.8
85
100
(1)	1976 capacities were used for the values in this column.
(2)	Responses from 242 operations were received; however, two of those operations were reported
to be idle. This number includes confidential operations.
(3)	It has been estimated that responses have been received from 85% of the active section operations
in the United States.

-------
TABLE 111-10
HOT FORMING FLAT
HOT STRIP AND SHEET
CARBON AND SPECIALTY STEELS
DATA BASE
Operations sampled for
original guidelines study
Operations sampled for
toxic pollutant study
Total operations sampled
Operations selected for
detailed DCP
Operations sampled and/or
solicited via detailed DCP
Operations responding to
basic DCP
Estimated number of hot
forming flat operations
No.
of
Operations
7 incl.
2 above
14
55
(2)
65
% of
Total No.
of Operations
10.8
3.1
13.8
10.8 incl.
3.1 above
21.5
85(3)
100.0
Daily Capacity
of Operations
	(Tons)	
40,455
17,694
58,149
48,795 incl.
10,272 above
96,672
260,324
306,264
% of Total
Daily
Capacity
13.2
5.8
19.0
15.9 incl.
3.4 above
31.6
85.0
100.0
(1)	1976 capacities were used for the values in this column.
(2)	Responses from 57 operations were received, however, 2 of these operations were reported
to be idle. This number includes confidential plants.
(3)	It has been estimated that responses have been received from approximately 85Z of the active flat operations
in the United States.

-------
TABLE I11-11
HOT FORMING FLAT
PLATE
CARBON AND SPECIALTY STEELS
DATA BASE
No.
of
Operations
Operations sampled for
original guidelines study
Operations sampled for
toxic pollutant study
Total operations sampled
Operations selected for
detailed DCP
Operations sampled and/or
solicited via detailed DCP
Operations responding to
bas ic DCP
Estimated number of hot
forming flat operations
9
2
11
27
32
% of
Total No.
of Operations
6.3
21.9
28.1
6.3
34.4
85(2)
100.0
Daily Capacity
of Operations
	(Tons)
6810
15,948
22,758
2537
25,295
35,414
41,664
(1)
% of Total
Daily
Capacity
16.3
38.3
54.6
6.1
60.7
85.0
100.0
(1)	1976 capacities were used for the values in this column.
(2)	It has been estimated that responses have been received from approximately 85% of the active flat operations
in the United States.

-------
TABLE III-l2
HOT WORKING PIPE AND TUBE
CARBON AND SPECIALTY STEELS
DATA BASE
Number
of
Operations
% of Total
Number of
Operations
Daily Capacity
of Operations
(Tons)
% of Total
Daily
Capacity
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
10 detailed DCP
Operations responding to the
basic DCP
Estimated number of hot working pipe
and tube operations
5
2
7
3
,(D
52
(2)
8.2
3.3
11.5
4.9
(1)
61
13.1
85(3)
100
2,439
1,239
3,678
816
4,041
26,202(4)
30,826
7.9
4.0
11.9
2.6
13.1
85
100
(1)	Two operations were sampled AND surveyed via detailed questionnaire.
(2)	Includes two operations reported as idle.
(3)	It has been estimated that responses were received from eighty-five percent of
the hot working pipe and tube operations in the United States.
(4)	This number does not include data from the two operations reported as idle.

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BUTT WELD
PIPE
PLATE
PRODUCTS
HOT BANO(SKELP)
SLABS
HOT ROLLED FLAT
PRODUCT" SHEET. STRIP
SEAMLESS PIPE
INGOTS
SEAMLESS
PIPE PRODUCTS
LAR6E	1
STRUCTURAL PRODUCTS
BLOCMS
U HOT ROLLED
BAR PRODUCTS
HOT ROLLEO BARS
BILLETS
CAST STEEL
INTERMEDIATES
.FINISHED FORGED
PRODUCTS
ROD (INTERMEDIATE)
HOT ROLLED
ROD PRODUCTS
SPECIAL
SHAPES
EXTRUDED
PRODUCTS
ENVIRONMENTAL PROTECTION AGENCY
FORGED STEEL PRODUCTS
STEEL INDUSTRY STUDY
HOT FORMING
PROCESS FLOW DIAGRAM
[FIGURE UI-I
MACHINING
FORGING
MACHINING
EXTRUSIONS
PLATE
MILLS
ROD
MILLS
SEAMLESS
PIPE MILLS
FORGING
SLAB
MILLS
BILLET
MILLS
BAR
MILLS
SMALL ,
STRUCTURAL
MILLS
BUTT WELD
PIPE
Ml LLS
LARGE
STRUCTURAL
MILLS
HOT
STR IP
Ml LLS

-------
BLOOMING a SLABBING MIL PRODUCTION
(Based on ingot steel input & neglecting mill
production efficiency & down time)
a)	Ingots to blooms or slabs -75%-85%.
b)	I ingot ton of finished product requires
I.2S ingot ton input at 80% efficiency
c.)	1*4*/• row waste load as mill scale 8
8 - 10 % os crop ends.
d.)	Scarfing will reduce production output
by an additional 2~2Vk% over(b)Q(c).
High pressure descaling
jet water 1000 lo 2000 piig
Soaking pit furnace
burners, gas, oil find
etc 756,000 kgcal/hr
(3.000,000 btu/hr)
burners 30"40 lorn
capacity per month per tq. ft.
of floor area lor heating
" infl0,*7 i
both tides of milt for
reverting
Mill tland low pretsure
cooling water
SOAKING
PIT
CRANES
Hat Steel
II77*C to 1343'C
(2I50*F lo 2450*0
4-50 ton tile mot
INGOT WEIGH SCALE
B TURNTABLE
Rotted Product
boowoo1
oooooooo
MILL TABLE ROLLS
SPRAY WATER COOLED
EXTERNALLY
INGOT BUGGY TRANSFER
TO HOT ROLUNG MH.L
SCARFER HOOD
See Fig IS - S for
tcorler procen flows
To storage yard
To plate mill
To hoi strip mill _
Slabs-
Spray
Water
MILL TABLE
RUN-OUT ROLLS
o6ouho
-------
03
(O
~¦Exhaust
(30,000 to 170.000 elm)
830k>4,8l4 cu. mAnin
Total-100%
-4360 l/kkfl
(1090 gal/Ion of «tMl scarfing)
4,967 l/kkg-
(1,100 gal/Ion)
Fan	Slack
WET PRECIPITATOR SYSTEM
21 l/kkg (9 gal/Ion) lor
Inlermitlanl wash
209 l/kkg (90 gol/lon) (or
Continous wash
SCALE
PIT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUOY
HOT FORMING-PRIMARY MILLS
AUTOMATIC HOT SCARFER
PROCESS FLOW DIAGRAM
FIGURE ET-3

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RAIL <
STRUCTURAL
BLOOM STORAGE YARD
-MILL
ROLL COOLING
ROLL C00LIM6
DESCALING SPRAYS
STORAGE
HEAVY BEAM
I Q00QQ
0O0000 00000
c , STRAI6HTEMER
> AMD
SHIPMENT
MILL
©©©
CONTINUOUS
CAST BLOOMS
STRUCTURAL SECTIONS
HEAVY HEXAGONS
AKIQLE5
MEDIUM WEI6MT
STRUCTURAL
TEES
HEAVY ROUNDS
BEAMS
Miy.
WATER
TRAMP OILS
MILL SCALE PINES
WATER
ROLL COOLING
TRAMP OILS
REHEAT
HOT BLOOM
COILS OR ROD
TABLE ROLLS
FROM BLOOMING
MILL DIRECTLY
SHIPMENT
TO BILLET MILL
CONTINUOUS
BILLET MILL
WATER ROD MILL
TRAMP OILS 4
MILLSCALE FIHES ft
SHEAR
ROtL COOLING
NARROW STRIP
STORAGE
COILER
WATER
AND
roToToIoToToToM
TU000000 I I
VIBRATOR
FOR CURLING STRIP
MILL SCALE
SHIPMENT
TRAMP OILS < GREASES
CONTINUOUS
NARROW
STRIP MILL-
WATER
TRAMP OILS
MILL SCALE FINES
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
SECTION MILLS
PROCESS FLOV/ DIAGRAM
DM6 i-IV»
FIGURE IH-4

-------
COICfc OVEN GAtt.NATURAL
GAS OR OIL FIRED
FURNACE BURNEB.&
KtftLMPftR METO >C TON
(300.000 TO 4SOO000 BTU/
CONTINUOUS
SLAB MILL
aUBBlNa MILL
SfcEr PBOCfcSS PLOW DIAGRAM FIGURE: JU-2-
83340 K«fAL/HftTO l.gQ. loo
MR PER 1H&OTT0N)-
C-22SOT) 14-G.K.ftTO 73Mil
60 m HEARTH AREA (SO

RATCH OR CONTINUOUS
SLAB. REUSaT FURNACES
SLABS MEATED TPtft32*C
TO ISO LB7FT.*HEARTH ABU
t 2.7Z METPIC TQM3/
HB. CAPACITY(*aOO
TON/MB. CAPACITY
DIRECT TO
6S.CONOARV FINISHING
i,
CA"bTlNG> MACHINE
PRODUCT
SLAB STOttACafc YARD
FLAME CUT
no5
UIQU PflESfeUttfc
/SOO-IBOO Pfel)
M^CMINa WATER
HIGH PRESSURE
DESCALING WTB.
TWK.PLMK
—PLATE COOLING
WATEtt 5MSAV&
E-NTRY SIDE OP
FINISHING STAND —
DESCALING WATEO
SPRAYS HIGH DBE4S
Nt Ai 41 bt OF-
LOW PgfcSfcUQE
POLL COOLING
WATER.
CUE)
UGUER.
00000
0006606
oocrou
ROLL'S
COOUN6
5ES
EDGt~ END
rough i no
PI WISHING
STORAGE- \
SMIPPrNG
1 METRIC TON (LIMOOT TON)
FtNtSH&D POODUCT
MEAT
TREATMENT
ANNEALING, NORHALlZI NG ,
STRftfeS BELIEVIN<5.
TEMPERING. QUENCHING,
IE-
RECYCLED COOLING WATER FOR
FURNACE; WATEg COOLED SKIDS
aag7 TO I249Q l/METRIC TOM f»ftOOUCT
(TOOO TO aOQO GALS./TON PRODUCT)
PLATE- MILL. PRODUCTION
MILL STD.
MILL.
STAND
MILL
STAND
I
I
~
I
I
*
SUEAP. LINES
va* to iva"
THICK. PLATED
ROTARY SHEARS
FOR CUTTING
CIRCULAR PLATE*
STORAGE- ~ SHIPPING
t EFFICIENCY OF MILL BASED OH
INPUT~ OUTPUT AND
MILL DOWNTIME
	KIEQL&CTI NG»
~ EFF\CIeTnCY)
WAT Erg JPAMPOIL,
GEEAS&S * MILL6CALE-
t
a) SLABS TO
to)
	PLATE: •
AVE:QAg»e
ie> '/o - aa %
c.)
I METRIC TON Flts/ISHErP PRODUCT
REQUIPE^ l.aiS METRIC TON INPUT.
(I TM6QT TON FINISHED PRODUCT,
OEQUlgE-a I.ZOS INGOT TON INPUT)
t raw WAST& \ ran as Mill
SCALE/TON OP PGOOUCT
±.SVo AS SHEAtt&D EDGES k END
SCPAP/TON OP PRODUCT
NOTEri MILL SCALE -flOK* AVS/M6TRIC TDM PttOOUCT
fffILL 5CALE IQ>0LBS AVfi/TON PBODUCTJ
FxaOi-4l^o,BALANCE4%.HISC.
ELEMENTAL COMPOUNDS PJt-jOs
EO&£ < END SHEAP SCRAP
ftt.7 AVG. Oao IB AVG )
BICYCLE TO MOT
METAL FACILITIES
SCRAP
E.IN
WATER » 4%. EVAPORATION RATE
		 G.Uol Tofc.lW/HgTElC
TON PBODlCT (I5QQ TO
AOQO G /> L/TON POODUCT)
Ol
.*ZS 1^4 -.5>Rft/ METRIC TON PRODUCT
.E>lbS. - I Lt^/TON PgQDUCT	
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
MOT f=ORMIN&
PLATE MILLS
PROce-aa p-low Diagram
PLATE- MILL.
n^xnrss
FiG.ua £ m-5

-------
COKE OVtN 
&jAQK*tU-M TO l,3SOtl00
CONTINUOUS
OST1N6 MACHINE
SLA& W.VL
01 DECT TO
ilabbins mill
Stt PgOCE35 PLOW OlfrSQAM FIGUttfc m-2
K»XH-/Ut PEa. HBTPIG TON
[800.000 -4-j»OPOO B.TU/ Uft
per ivkjot tom)—
TT
CONTINUOUS SLAB
REHEAT FURNACES
SLABS H&ATEO TDtim^te
(?M60»P) lA&fcft TO 732tf|
FLYING SHEAR.
curTINS plat
SHEETS TO LENGTHS
(.SMEAR MOVEb w/atBIP)
/Sn iff HEABTH AREAlSO
TO ISO LBS/FT."* MEAgTH
ftgfeA.)
tm. METRIC TOHfe/ue.CAP.
i soqtons/hb.capacit'V)
RECYCLE COQLIKKa WATfcg.
toe furna.ce waiter.
ceoufco silio^
>M1 TO I149P 1/HETBIC
TOM PRODUCT
fioooTo aooo sal ~
TON PPOOUCT)
HOT STRIP MILL PRODUCTION
NCV OP MILL BASED OH
(EPFICIEI
inpvtI
OUTPUT AND
KILL DOWNTIME: * EFFICIENCY
8l) SLABS TO MOT STPIP
AveoA&6 agy«»
b) 1 METRIC TON HWISHED PRODUCT
REQUIRES Lia& HETBICjrON INPUT
U IH6PT TQN" ftNTiH&O PRQQUCf
REQUIRES l.tfA INGOT TOM INPUTJ
£.) i RAM* WASTE LOAD Aft MILL-
~ 6CALE/TON PBOOUCT.
fTSlL AA feCttAfr	
SECONDARY FINISHING
i
SLAB STORAGE fABD
STRIP COOLING
ROLLCOOUNG WATER. (.TYP)

ROLL COOLING
WATER
MI6M PRESS. dcscalihg
WATER (gOOO Pat) —7
HKaU PQ.IVUMS. OESCALINg WATiR
tSOO-lSOO PSI) ITYP)
6116k
SHEETS
TO HOT
ooooooot)
, IABUL
OOOOO
OOO

TUBM
T*BLfc
BUM-OUT
I TABLE.
BROADSIDE
MILL.
PINISHIN6
STANDS
crop
SMEAR
i
STCtL 9C8AP
a
<£lw'fiiy
TON PRODUCT)
DOWN
SOU.EQ
&TAND5
4-MIGH
|F ffTRip IS
WIDER TMAM
HIGH
AVAILABLE
ie
SLABS AR
REQUIRED
TRAMP Oil.
ICI6NCV1
(NO MILL SCALE. O PINI6MINS STAN OS 1
MOTE 1 MIUL g>CALfe - BO \L1 AV&/METPIC. TON PPOOUCT
( IfeO LBS. AVS./TON PRODUCT)
FaO -&&*» . Fa.*04	BALANCE: 4*b
MiSCTECmi^AU ^OM^UKIP
wAT&a. - a% evaporation rate
	2.7.Q4Q A/METRIC
TON PRODUCT
L METRIC TON
(I INGOT TON)
FINISHED
PRODUCT
PBOCESSfcQ
~ TO PLAT
CUT SHEETS
TO COLO MILL6
BSQO GAL /TON PRODUCT8 )
MOT 5TC3IP (Vlll_l_
ENVmONMENTAL PROTECTION AGBNC.V
STE
LINDUSTRY STUOV
WOT FORMING
HOT STRIP MILL
PROCB59 FLOW OIA3RAM

pi&u/?fc nr-6

-------
NON CONTACT
COOLING WATER
BUNDLED SKELP
CUT TO LENGTH
ROLL
LEVELER
CRANE
RECUPERATORS
HEATING
FURNACE
nwiMii
COILED
SKELP
COILED
NARROW
STRIP
UNCOILERS
FLASH
WELDER
FORMING
&WELDING
MILL
HOT
SAW
NON CONTACT
COOLING WATER
TO PLANT
SEWERS
NON CONTACT
COOLING WATER
t
WATER
BOSH
COOLING
BED
—c,
COOLING
BED
~TO STORAGE
DESCALER
a SIZING
MILL
WATER TO SCALE PIT
OR PLANT SEWERS
SCALE
PIT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
BUTT WELDED PIPE MILL
PROCESS FLOW DIAGRAM
3/13/
FIGURE M- 7

-------
MILL SPRAY
COOLING
WATER
NON - CONTACT
COOLING
WATER
ROUND
BILLETS
REHEAT
FURNACE
MANDREL
COOLING
WATER

Tf?
tw—
PIERCING
MILL WATER
COOLED
MANDREL
TUBE
REHEAT
FURNACE
TO PLANT
SEWER
MANDREL
COOLING
WATER
COOLING
WATER
ft ftj1) g)
SIZING MILL
WATER COOLED
MANDREL
a.
HEAT
TREATING
FURNACE
TUBE
COOLING
SPRAY
HDR'S
CUTTING
MILL
TO
STORAGE
8 SHIPMENT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUOY
SEAMLESS TUBE MILL
PROCESS FLOW DIAGRAM

1
1
FIGURE HI-8

-------
88

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HOT FORMING SUBCATEGORY
SECTION IV
SUBCATEGORIZATION
Introduction
The proposed BPT limitations for hot forming operations are the same
as those previously promulgated in 1976. However, the Agency
developed the proposed BAT, BCT, PSES, PSNS, and NSPS limitations and
standards on the expanded data base obtained as a result of this
current study.
The division of hot forming into the four subcategories under the
originally promulgated limitations has been changed. Hot forming
operations have now been combined into one subcategory which has been
divided into four major subdivisions which match the old
subcategorization scheme. These subdivisions have been segmented
further to recognize variations in flow between the different types of
hot forming operations. A comparison of the 1976 segmentation with
the revised subcategorization is shown below:
Segmentation
(1976 Regulation)
Hot Forming-Primary
a.	Carbon operations
w/o scarfers
b.	Carbon operations
w/scarfers
c.	Specialty operations
Hot Forming-Section
a. Carbon & Specialty
operations
Hot Forming-Flat
a.	Hot Strip & Sheet
operations
b.	Carbon Plate operations
c.	Specialty Plate operations
Pipe & Tube (Hot Working)
a. Carbon & Specialty
operations
Revised
Segmentation
Hot Forming-Primary
a.
b.
Carbon & Specialty
operations w/o scarfers
Carbon & Specialty
operations w/scarfers
Hot Forming-Section
a.	Carbon operations
b.	Specialty operations
Hot Forming-Flat
a.	Hot Strip & Sheet
operations
b.	Carbon Plate
operations
c.	Specialty Plate
operations
Pipe & Tube (Hot Working)
a. Carbon & Specialty
operations
89

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Segments within the four subdivisions are based primarily upon
differences in flow rates (applied, process, and discharge).
Although the Agency considered other factors, it found that flow rates
and mill configuration were the most important factors in the
segmentation of the four basic hot forming subdivisions. The Agency
analyzed mill age and size to determine if these factors had a
significant effect on either wastewater quality or quantity, or costs,
but found no significant relationship. Also, such factors as product
type, raw material, wastewater characteristics and treatability were
considered. However, the analysis demonstrated that none of these
factors are significant in terms of the segmentation developed. Each
of these elements is discussed in greater detail below.
Factors Considered in Subcateqorization
Manufacturing Process and Equipment
The manufacturing and production processes associated with the forming
of a variety of steel products served as the principal basis for
defining the hot forming subcategory. As explained in Section III,
each hot forming operation is different. The process flow diagrams
presented in Section III clearly illustrate these differences which
result in different process water usage for the four types of hot
forming operations. The Agency found that the different flow rates,
more than any other factor, were the most significant in establishing
the subdivision contained herein. The flow rates associated with hot
forming operations are discussed in greater detail later in this
section.
Besides the range of production equipment used at the different types
of hot forming operations, the Agency also analyzed the possible
variations within each type of operation. For example, there are
numerous section operations (i.e., tandem, cross-country). The Agency
examined data for these different mill configurations to determine if
variations in flow, wastewater characteristics, or other elements
existed which would make further subdivision appropriate. However,
the Agency determined that the basic subdivision outlined above is
affected by differences in equipment only for primary mills, some of
which have machine scarfing equipment that generate additional
wastewater volumes and pollutants. Hence, an additional effluent
limitation allocation is being proposed for those primary mills with
machine scarfing equipment.
Final Products
Hot forming operations produce products of widely different size and
shape. The revised subcategorization contains four groups which
primarily reflect the different products being processed. However,
within any one hot forming subdivision, the product type may affect
the segmentation of that subdivision. For this reason, the data for
each type of hot forming operation were analyzed for variations due to
final product considerations. The Agency found that only the flat
subdivision required further segmentation because of the type of
product processed. There are no product differences that
90

-------
significantly affect the ability to achieve the proposed effluent
limitations or standards in the other hot forming subdivisions.
Additional details on this factor are presented below.
Primary Mills
In primary operations, two basic final products are processed from the
hot steel ingots; slabs and blooms. Most mills (58%) produce either
blooms or slabs; however, approximately 35% of the primary mills
produce both blooms and slabs. The remaining primary mills (7%)
produce products other than slabs or blooms, such as bars or plate.
The data for all primary mills indicate that no significant
differences exist among the product types. Water use rates are
similar and the Agency found no difference in the technical
feasibility of achieving the proposed limitations. For these reasons,
the Agency concluded that further subdivision of primary operations
based upon product type is not appropriate.
Section Mills
In section hot forming operations, a wide variety of products are
produced, ranging from angles to railroad wheels to billets. The
responses to the DCPs show that more than 40 different products are
produced in the section mills in the United States. At about 30% of
the mills, a single product is produced. However, at the remaining
mills, more than one product is processed, with some mills producing
up to ten products. This great diversity complicated the Agency's
analysis of the effect of final products on subcategorization.
However, data for the mills producing different products indicate
there are no significant variations, thus, no further subdivision was
made.
To determine if flow variations exist between the different products,
the flow data for the mills were separated into eight product
classifications. For example, all types of beam mills were put into
the beam category and all the different types of bar mills were
classified as bar mills. This grouping of similar product types
consolidated the data base and simplified the flow analysis. The
Agency then conducted statistical analyses on these groupings to
compare the applied and discharge flow rates on a gallon/ton basis.
The Agency concluded that the data for all mills are within the same
statistical population. The Agency did not find any significant
variations which would indicate that any one type of section mill
requires more (or less) water or that wastewaters from any one type
could not be recycled to the degree necessary to achieve the proposed
limitations. For these reasons, the Agency concluded that further
segmentation of the section mill subdivision based upon final product
considerations was not appropriate.
Flat Mills
The three types of flat mills operating in the United States today are
hot strip and sheet mills (HSM), plate mills, and combination mills
which produce both plate and hot strip. Of the 80 flat mills, 29 are
91

-------
hot strip mills, 25 are plate mills, and the remaining 26 are
combination mills. For this analysis, strip mills, sheet mills, and
skelp mills were grouped together under the strip mill designation
because of similarities in mill configurations and flow rates.
As with other hot forming operations, different types of flat mills
produce similar quality effluents. There were slight differences in
the concentrations of the pollutants limited in 1976 (total suspended
solids (TSS), oil and grease (O&G), and pH) among the different types
of flat mills, but the Agency believes that the differences are not
significant enough to warrant further segmentation. More details on
wastewater characteristics are provided later in this section.
When the Agency analyzed flow rates for flat operations, it found
significant variations which affected the segmentation of the flat
subdivision. Hot strip and sheet mills and combination mills were
compared, but it was found that both types of mills use similar
applied flows and can achieve- similar discharge flows. Therefore
combinations mills were combined with hot strip and sheet mills for
the purpose of developing effluent limitations. However, the Agency
found significant differences between plate and hot strip mills, with
hot strip mills using up to 4900 gallons/ton more applied flow than
some plate mills. This wide variation led the Agency to further
segment the flat subdivision into plate and hot strip mills.
Pipe and Tube Mills
There are two hot working pipe and tube products: butt welded and
seamless. The Agency compared data for these pipe and tube mills and
found no significant differences between them. Wastewater quality and
quantities are similar for both types of mills and the Agency believes
the proposed limitations can be achieved at each. Hence, no
segmentation of the pipe and tube subdivision is needed.
Raw Materials
Raw materials for hot forming operations include steels of various
material specifications. A basic split was made between carbon steel
and specialty steel mills. For purposes of this section, any mill
rolling less than 50% carbon steel is called a "specialty steel*
operation. Of the 485 hot forming operations responding to the DCPs
96 (19.8%) are specialty steel operations. While the sampling data do
not show a significant difference in treated wastewater quality
between carbon and specialty operations, the Agency found significant
differences in flow rates in some hot forming subdivisions. The
differences between the carbon and specialty mills in each hot forming
subdivision are examined below.
Primary Mills
Data for primary mills show that raw materials affect only model plant
size. There are no significant differences in the wastewater
characteristics between the two types of mills. In addition, the
Agency found no significant differences in flow between carbon and
specialty operations. The average applied flow for carbon mili8
92

-------
without scarfers is 2250 gallons/ton, and for specialty mills without
scarfers, 2625 gallons/ton. A model applied flow of 2300 gallons/ton
was selected for primary operations. The achievability of this model
flow is demonstrated by both carbon and specialty operations.
The average production capacity of carbon operations is about 6620
tons/day while that of the specialty operations is about 1440
tons/day. Because of this difference, the Agency prepared separate
cost estimates for the carbon and specialty treatment models.
Section Mills
The Agency analyzed carbon and specialty section mills in the same
fashion as the primary operations. It found differences in flow rates
(5100 gal/ton vs 3200 gal/ton) and model sizes (2920 tons/day vs 1475
tons/day) between carbon and specialty operations which led to further
segmentation and separate costing. It did not find any significant
differences in wastewater characteristics of the section mills using
different raw materials.
Flat Mills
For flat operations, the raw material analysis led to the
determination that separate limitations are appropriate for carbon and
specialty plate operations due to differences in flow rates (applied
and discharge). The Agency found no difference between the carbon and
specialty hot strip operations. Also, as for primary and section
operations, separate costing was completed for carbon and specialty
plate operations.
Carbon plate mills use 1900 gallons/ton more applied flow than the
specialty mills (3400 gal/ton vs 1500 gal/ton). For this reason, the
Agency is proposing separate limitations for the two types of plate
mills.
Flow rates for carbon and specialty hot strip and sheet mills are not
significantly different (6380 gal/ton vs 6710 gal/ton). The Agency
selected an applied flow basis of 6400 gallons/ton for developing the
proposed BAT, BCT, NSPS, PSNS, and PSES limitations and standards for
the hot strip and sheet mills. The achievability of this flow rate is
well demonstrated by both carbon and specialty operations.
As with the primary and section operations, a difference in the sizes
of specialty and carbon plate mills required separate cost
development. For the plate mills, the average size of carbon mills is
3480 tons/day and for specialty mills, 1060 tons/day. For hot strip
mills, there is no significant difference in size between carbon and
specialty operations. In fact, both carbon and specialty products are
often rolled on the same mill. For these reasons, all hot strip
operations were costed together.
Pipe & Tube Mills
The only significant difference between carbon and specialty pipe and
tube operations is in size. Wastewater quality and quantity are
93

-------
similar. Carbon operations have an average applied flow of 5490
gallons/ton and the specialty operations have an average applied flow
of 5790 gallons/ton. A flow basis of 5520 gallons/ton is being used
to develop the proposed limitations for the carbon and specialty
operations. The achievability of the flow is demonstrated by both
types of mills.
Production rates are more than twice as great for carbon mills as for
specialty mills (970 tons/day versus 480 tons/day). This significant
difference in size led to separate costing of the treatment systems.
Wastewater Characteristics and Treatabilitv
The wastewater characteristics of the hot forming operations depend
upon scale formation and the oil usage within the mill. Although
there are differences in pollutant concentrations generated by
different hot forming operations, the Agency concluded that it was not
appropriate to subdivide the hot forming subdivisions on this basis as
described below.
Suspended solids and oil and grease are the conventional pollutants
found in hot forming operation wastewaters. Toxic metal pollutants
are also present in lesser concentrations due to the use of alloying
agents in the steel. The Agency estimated from scale generation rates
that the raw waste concentrations of suspended solids vary from 390
mg/1 for specialty plate operations to 7,590 mg/1 for carbon primary
operations with scarfers. It also estimated from oil usage rates that
the oil concentrations in hot forming operation wastewaters range from
15 to 160 mg/1. The Agency estimated the raw waste concentrations for
suspended solids and oils because consistent and reliable samples of
raw wastewaters were difficult to obtain. At most mills, the Agency
sampled the primary scale pit effluent and based its estimates on
those data.
As noted above, there is a significant variation in raw wastewater
concentrations from hot forming operations. However, these
differences are reduced after primary scale pit treatment as shown
below:
Concentration Range of Pollutants(mg/1)
Discharge from Primary
Raw Wastewaters 	Scale Pits	
Total Susp. Solids	3?2""I*n9°	15-42
Oil & Grease	15-160
_. . i.u. Anpnr*\/ concluded thflt it is not ncccss&ry to
differentiate between the types of hot forming operations because of
wastewater characteristics.
•	in wastewater quality between carbon and specialty
Possible	analyzed. However, no significant variations
operations	of tJe specialty mills did have higher levels
were found. While some o some carbon mills also had comparably high
!eve^1CIn anj ^ent ?oxic metals from both carbon and specialty
94

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mills can be reduced to similar levels with the same type of
treatment. On this basis, the Agency concluded that no further
subcategorization on this basis is warranted.
Similar treatment components are used at all mills and a consistent
range of effluent quality is demonstrated. Wastewaters from most
mills in each of the hot forming subdivisions are treated in central
treatment systems (combining different hot forming wastewaters prior
to treatment). Typical treatment components include sedimentation,
clarification, or filtration systems, often in combination. Extensive
recycle systems are also employed at many plant sites. Flocculation
with polymers or other flocculant aid is often used in conjunction
with sedimentation. Because of the similarities in treatability of
hot forming wastewaters, no further subdivision based upon this factor
is appropriate.
Size and Age
The Agency also analyzed possible correlations relating the effects of
age and size upon such elements as wastewater flow, wastewater
characteristics and the ability to retrofit treatment equipment to
existing facilities. However, it found no relationships which
warranted further division.
As discussed earlier in this section, size has an impact on costing of
the treatment models for specialty and carbon plants. This is the
only apparent impact that size has on the hot forming subdivisions.
Hot forming operations vary greatly in physical size, . layout, and
product size. However, an analysis of those factors revealed no
significant relationships between process water usage, discharge flow
rates, effluent quality, or any other pertinent factor. Figures IV-1
through IV-8 show there are no relationships between discharge flow
(gal/ton) and size (tons/day). Since mills are generally operated in
a similar manner, the resulting wastewater characteristics are similar
regardless of size. The sampling data do not show any significant
difference in wastewater characteristics among different sized mills.
The Agency also found that the size of a particular hot forming
operation does not affect the ability to install adequate treatment
systems. Large and small mills have treatment systems that are
approximately the same age and which have similar treatment
components. Also, the cost data supplied by the industry show that
the costs to install treatment (on a $/ton basis) are more
significantly affected by the type of treatment installed. It was
found that the costs on a $/ton basis vary slightly based on the size
of the mill. However, these variations are accounted for by
developing costs for average sized model mill and by developing costs
separately for carbon and specialty plants, where necessary.
One additional factor influenced by size is the choice of effluent
disposal methods. As noted in most iron and steel subcategories, more
of the smaller operations discharge to POTWs than larger mills. For
example, in the hot forming section subdivision (the other hot
forming subdivisions show the same trend) the average size of the
mills with direct discharges is approximately 1000 tons/day. However,
95

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the average size of the mills discharging to POTWs is 580 tons/day.
This is because the smaller mills have smaller total wastewater
volumes which enable them to discharge more readily to POTW systems.
The larger mills, even with good water conservation practices, release
larger volumes of wastewater which make it too costly or physically
impossible to discharge to POTWs.
The relationship between flow rates and age was analyzed in the same
fashion. The plots of discharge flow (gallons/ton) versus age (first
year of operation) are shown in Figures IV-9 through IV-16. As with
the flow versus size plots, no relationship between flow and age is
evident. Therefore, the Agency has concluded that the age of a mill
has no significant affect on discharge flow.
The Agency also analyzed the effect of age on the ability, ease, and
cost of installing or retrofitting pollution control equipment. Table
IV-1 lists older hot forming operations that have been retrofitted
with pollution control equipment. The numerous examples illustrate
quite effectively that pollution control equipment has been
retrofitted on older mills.
The Agency also demonstrated that treatment systems could be
retrofitted on older mills at about the same costs as for newer mills.
The responses to the D-DCPs and past cost studies were used in this
demonstration. Almost all D-DCP responses indicate no retrofit costs
were associated with the installation of treatment systems, or, that
retrofit costs could not be distinguished from treatment costs.
Retrofit costs, typically less than 5% of the total installation cost,
were reported for some mills. Retrofit costs were also analyzed by
comparing detailed cost estimates completed for retrofitted plants
(with no consideration for age) with the actual cost of installation
for these systems. This analysis also showed that no significant
costs are associated with the installation of treatment facilities
onto "older" plants. Hence, the Agency concluded that about the same
costs for pollution control are necessary for "older" and "newer"
plants.
The sampling data collected during this study were analyzed to
determine if age has a significant effect on wastewater
characteristics or effluent quality. The ages (first year of
production) of the operations sampled varied from 1904 to 1974. No
significant differences were noted in effluent quality from older
mills versus newer mills. In fact, the mill that was built in 1904
had one of the newest and most sophisticated treatment systems. in
any event, comparable levels of discharge were being achieved at mills
of all ages where adequate treatment was installed.
Hence, the Agency concluded that age and size do not affect the
ability to achieve the proposed effluent limitations.
Geographic Location
The Agency examined the raw waste characteristics, process water
application rates, discharge rates, effluent quality and other factors
pertaining to plant location and found no general relationship or
96

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pattern. Hot forming operations are located in 22 states across the
country. Most of these operations are located in the major steel
producing areas of Indiana, Illinois, Pennsylvania and Ohio. Table
IV-2 summarizes the location of hot forming operations for which DCPs
were received.
Approximately 11.5% of the mills are located in what could be
considered "arid" or "semi-arid" regions. Because cooling towers are
included in BAT, BCT, NSPS, PSES, and PSNS alternative treatment
systems, a small amount of water will be consumed as a result of the
installation of the model treatment technologies. The Agency analyzed
water consumption for hot forming operations and determined the amount
to be small. For this reason, subdivision is not necessary because of
water consumption or geographic location considerations. Additional
details on this issue are presented in Section VIII.
Process Water Usage
As discussed earlier, the Agency found significant variations in both
the applied and discharge flows of the various hot forming
subdivisions. This factor, in combination with those described
previously, led the Agency to revise the segmentation contained
herein.
To analyze the flow data, applied flow rates were first developed for
each subdivision and each potential segment of that subdivision.
Production weighted average flows were used for this analysis. These
flow value derivations are shown in Section X for each hot forming
subdivision. Statistical analyses were completed on these applied
flows to verify previous segmentation and to develop new segments
where necessary.
After applied flow rates were developed, the Agency determined recycle
rates for each category. These recycle rates were used with the
applied flow to calculate the appropriate discharge flows used to
develop the proposed BAT, BCT, NSPS, PSES, and PSNS limitations and
standards. A summary of the hot forming applied flows, recycle rates
and resultant discharge flows is shown below;
Category
PRIMARY
Applied
Flow
(Gal/ton)
Discharge
Recycle Rates(%) Flow
RUP RTP Total (Gal/ton)
a. Carbon & 2300
Spec.
wo/scarf.
50 46 96
90
b. Carbon & 3400
Spec,
w/scarf.
50 46 96
140
97

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SECTION
a. Carbon
5100
50
46
96
200
b. Specialty
3200
50
46
96
130
FLAT





a. Hot Strip
6400
30
66
96
260
b. Carb.Plate
3400
30
66
96
140
c. Spec.Plate
1500
30
66
96
60
PIPE & TUBE





a. Carbon &
5520
50
46
96
220
Spec.
Additional details on these flow rates and recycle rates are presented
in Section X.
98

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TABLE IV-1
EXAMPLES OF PLANTS THAT HAVE
DEMONSTRATED THE ABILITY TO RETROFIT
POLLUTION CONTROL EQUIPMENT
HOT FORMING SUBCATEGORY
Subdivision
A. Primary
Plant
Reference
Code
0020B
006 OD
00601
0088D
0112
0112A
0112B
0176
0188A
0188B
0248C
0320
Plane Age
(year)
1948
1910
1941
1959
1907
1930
1928
1917
1959
1940
1962
1936
Treatment Age
(year)
1971
1959
1958
1971
1979
1970
1970
1965
1970
1946
1975
1952
Section
006 OC
006OF
00601
006OK
0088D
0112
0112A
0112F
0136B
0316
1913
1942
1956
1920
1962
1907
1937
1922
1908
1959
1920-1975
1965
1958
1955
1971
1943-1979
1971-1978
1947-1978
1959-1969
1966
C. Flat
1 - Plate
0112C
0424
0448A
0496
0860B
1902
1970
1943
1918
1936
1964
1971-1978
1948
1948-1977
1967
99

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TABLE IV-1
EXAMPLES OF PLANTS THAT HAVE
DEMONSTRATED THE ABILITY TO RETROFIT
POLLUTION CONTROL EQUIPMENT
HOT FORMING SUBCATEGORY
PAGE 2		
Subdivision
2 - Hot Strip
& Sheet
D. Pipe & Tube
Plant

sference
Plant Age
Code
(year)
0020B
1953
0396D
1960
0432A
1957
04 76A
1915
0684F
1937
0856D
1938
0856P
1929
0060C
1913
006OF
1950
006 OR
1930
0432A
1957
0476A
1930
0548A
1945
0728
1929
0856N
1930
0856Q
1930
0916A
1931
0920C
1934
0948A
1926
Treatment Age
(year)
1971
1970
1974
1977
1969
1980
1966
1948
1971
1961
1974
1977
1969
1952
1961
1963
1971
1970
1966
100

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TABLE IV-2
GEOGRAPHIC LOCATION OF HOT FORMING OPERATIONS

Pr imary
Section
Flat
Pipe & Tube

% of
State
Mills
Mills
Mills
Mills
Total
Total
Pennsylvania
32
79
27
20
158
32.6
Ohio
17
29
15
14
75
15.5
Illinois
11
30
6
11
58
12.0
Ind iana
13
19
10
11
53
10.9
Texas
4
6
4
6
20
4.1
Cali fornia
5
9
2
1
19
3.9
Alabama
3
9
5
0
17
3.5
New York
4
10
1
0
15
3.1
Maryland
4
5
3
2
14
2.9
Colorado
1
11
0
1
12
2.5
Michigan
4
3
2
0
9
2.0
West Virginia
2
3
1
0
6
1.2
Georgia
0
6
0
0
6
1.2
Kentucky
3
0
1
1
5
1.0
Utah
2
1
1
0
4
0.8
Missouri
0
0
4
0
4
0.8
Washington
1
2
0
0
3
0.6
Flor ida
0
3
0
0
3
0.6
Ok iahoma
0
1
0
0
1
0.2
N. Carolina
0
1
0
0
1
0.2
S. Carolina
0
1
0
0
1
0.2
Connec ticut
0
1
0
0
1
0.2
# of States =
22



485
100
101

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8
O
S-i
8
10
FIGURE 1ST-1
FLOW vs SIZE ANALYSIS
HOT FORMING - PRIMARY (MILLS WITHOUT SCARFERS)
x
28
8
&
08
«*»
^8
N
3e
o
_i
«»-o
oS
q:-'
:n
o
(O
58
R
X
x
K
X
X	X
X
J*
X
r X
X	X K
X
X
* X
X
X
,* * x *x x*	X
1—*—I	1	1	1	1	1	1
-.00 18.00 50.00 40.00 60.00 75.00 90.00 . 100.00 U0.
h4h-
size tTONsmn	iioxf

-------
s
2-
8
fi-
ve
—8
S-
8
8-
FIGURE ISL-Z
FLOW vs SIZE ANALYSIS
HOT FORMING - PRIMARY (MILLS WITH 5CARFERS)
O
U>
Z
s*
z
o
«8
2 •
SH
uj8
oJ.
««
x
o
m
58
X w	X
_T_X	1	,	
16.18	32. BO 48.78
SIZE (TONS/DAY)
~l	1	
68.00 81.*8
n	1	1
97.80 . I19.70 130.00
MOXf
.00
V

-------
FIGURE nr-3
FLOW vs SIZE ANALYSIS
HOT FORMING - SECTION (CARBON MILLS)
8
©
2-i
S
i-
08
«n""
z
o
o
lUtf*
oBJ
«E~
X
o
tn
08
x
X
* *
^x*
X XX X
s'iA" V
X
X
" *f"KT V *
& ~- - \j
-------
FIGURE EL-4
FLOW vs SIZE ANALYSIS
HOT FORMING - SECTION (SPECIALTY MILLS)
8
8
8
S.
x
^8
©
*
8
z
OO
tr®
m3
z
o
«8
9c
o
-8.
Ss
or
o
m
Qo
<*
<
*
w X
X X
8
	M-j	N	1	«-|	1	»| X	M	1	X	j	j
0.00	31.26	62.60 99.78	126.00 166.26 IB7.60 , 2IBl76 260
SIZE (TONS/DAY)	(IOXl
X

-------
FIGURE 121-5
FLOW vs SIZE ANALYSIS
HOT FORMING - FLAT (HOT STRIP I SHEET MILLS)
8
O
3-.
x
8 x
X
os
'8_
8
o
08
tn~
z
o
38
3:
o
S3
¦c
X
o

-------
8
9
R
A-
X
8
3-
FI6URE Iff "6
FLOW vs SIZE ANALYSIS
HOT FORMING - FLAT (CARBON PLATE MILLS)
o
p.
Z
o
%
o
°S»-
ncM
-<
x
o
«n
08
X
X
~1	I	I
87.00	178.00 CM. SO
SIZE IT0N5/DAYI
1	
457.00
"1
700.00
0.00
X
900.00
020.00 ,
(I OX/
frit, oo

-------
8
8-
o
10
3
x
28
FIGURE ISO- 7
FLOW vs SIZE ANALYSIS
HOT FORMING - FLAT (SPECIALTY PLATE MILLS)
O
00
S
Sl-
18
KiJ
m~
z
o
Of}
o
uj8
-<
in
o
«r>
og
_j	1	1	j	,	1	1	1
<9.00 00.00 70.00 100.00 120.00 100.00 , 170.00 200.00
SIZE (T0NS/DAYI	UOXl
.00
X

-------
FIGURE Iff "8
FLOW vs SIZE ANALYSIS
HOT WORKING PIPE & TUBE
x
X
K
X
X
* -	*	* X
I# X	X
X	X
X
X
X
ft.	X
X
x,*	„ „
i	1	r
.00	K.OO BO.00 70.00	100.00 UB.00
SIZE (TONS/DAY)
X
1	1	1
IBO. 00 , 170.00 200.00
11 oxl

-------
8
In
8
8
x
28
8
s
§8
s
•a
z
o
3*8
*"8
08.
a.—
*t
x
o
«o
58
HOT FORMING
FIGURE nz:-9
FLOW vs AGE ANALYSIS
- PRIMARY (MILLS WITHOUT SCARFERS)
X
X
X
* X	X
* X
Xxx*
1090.00
T

1
n	~-i—	1	-i	*—r
1901.20 1912.00 1915.78 1955.00 1946.28 1907.00 1969.78 960.00
AOE (FIRST YEAR OF PRODUCTIONI

-------
FIGURE 12-10
FLOW vs AGE ANALYSIS
HOT FORMING - PRIMARY (MILLS WITH 5CARFERS)
8-
8
*-
x
8
i-
z
zs
^2-
K
o*	*
ssU
uj«
odl	*
K	x	x	X	X K
X	X
* *
X
X	X *
X	X
X	*
T	I	1	1	*T	1	1
1900.00 mo. 00 1730. 00 1930.00 1940. 00 1900. 00 1960.00 1970. 00 1900.00
AOE (FIRST YEAR OF PRODUCTION)

-------
8
O
2-
M
2


8
8
$-1
oS
«n«*
z
o
-Jo
2«
w
h-o
oS
£K~
•4
X
o
«n
oS
O
o
NOT
FIGURE EE ~11
FLOW vs AGE ANALYSIS
FORMING - SECTION (CARBON MILLS)
A w
X
a
XX
XX X
J07B,
X
T
xX>f
* N
)0C
tU . Ittx—ft—yK &x flip ¦><»$« h* >y>H« hx
00 iem.lt 1901.25 1914.37 1917. DO
AOE (FIRST YEAR OF PRODUCTION!
1940.62
1905.76
1966.87
1980.00

-------
FIGURE ISC - I?
FLOW vs AGE ANALYSIS
HOT FORMING - SECTION (SPECIALTY MILLS)
8
S
S
8.
x
—8
R-
£8
•o '
-«8
sh
o
uiS
S8
x
o
m
5g
8
i
x
X X

1695.00
X
-|-H	1 H H	pH	1	H—H	H-Mj	a	1	
1900.61 1916. Z0 1976.87 1937.BO 1948.1« 1968.70 1969.37
AOE (FIRST YEAR OF PRODUCTION!
1980.00

-------
8
©
3-i
s
. •
©
N'
HOT
FIGURE nr-13
FLOW vs AGE ANALYSIS
FORMING - FLAT (HOT STRIP & SHEET MILLS)
X
28
"8.
8
S.
§8
¥t-
-J
_J
28
.8
oj.
ce*
«rf
£
o
aO
58
8-
8_
x
x
1890.00
X
~l	1	1	1	1	
1900.M 1916.» 1926.67 1957. BO 1948. I*
AGE (FIRST YEAR OF PRODUCTION)
x *
x	
"T
1908.70
X x
I	
1969.57
1
1960.00

-------
FIGURE BC-14
FLOW vs AGE ANALYSIS
HOT FORMINO - FLAT (CARBON PLATE MILLS)
Ui
8
O.
R
P»-
x
8
3
z
oo
t" •
•n"
z
2d-l
o
«uj
<(
r
o
m
08
	1	1	1	1	1	
1890.00 1908. M I9I6.M 1926.87 I997.B0 1948. IX
AGE (FIRST YEAR OF PRODUCTION)
x
T	
1908.79
1	
1969.97
"1
1980.00

-------
8
HOT
FIGURE HZ-15
FLOW vs AGE ANALYSIS
FORMING - FLAT (SPECIALTY PLATE MILLS)
ON
s
i
x
28
S
Si.
©8
Ki.
*»-
z
o
"5
o«S
X
o
n
oS
•
6-
1090.00
X
-I	1	1	1	1	
1900. tt 1916. Z8 1926.87 1957. BO I948.l«
AOE IFIRST YEAR OF PRODUCTION)
1980.78
_1	
1969.97
I
1900.00

-------
8
8h
8
x
28
8
08
oS
toj8
K"
a:
u
«o
oS
&
FIGURE 12-16
FLOW vs AGE ANALYSIS
HOT WORKING PIPE & TUBE
8
*x x x
MX
1900.00
X
1	1	"T	1	" I *	1	
1910.00 1920.00 1950.00 1940.00 ITOO.00 1960.00
AGE (FIRST YEAR OF PRODUCTION!
1970.00
~i
1900.00

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HOT FORMING SUBCATEGORY
SECTION V
WATER USE AND WASTE CHARACTERIZATION
Introduction
This section describes the water systems in use in the hot forming
subcategory and the types of wastewaters originating from each of the
rolling mill processes. The description of the water systems is
limited to those water systems which come into contact with pollutants
generated by the processes, and excludes noncontact cooling water
systems. Waste characterization for hot forming mills is based upon
monitoring data obtained during field sampling surveys, data supplied
directly by the industry, and upon EPA data.
General Discussion
Water Use
Hot forming wastewaters are comprised of direct contact cooling and
descaling waters. Roll cooling water is used to flush the work rolls
of the mill stands to prevent surface cracking of the steel rolls due
to sudden temperature changes. When not rolling the hot steel, the
rolls, are kept turning to prevent uneven cooling within the steel
rolls. Approximately 4% of the water sprayed on the hot steel
evaporates and the balance is discharged beneath the rolling mill to
trenches called flumes.
When the hot steel product is being rolled, iron oxide scale (called
mill scale) forms on the surface of the hot steel. The scale is
removed by direct contact high pressure (1,000-2,000 psig) sprays
which release water before each roll pass of the product. Low
pressure spray cooling water is also used to keep the mill stand rolls
and the table rolls cool as the hot steel passes over or in between
them.
Wastewaters from descaling, rolls, hot shear equipment cooling, roll
tables, and flume flushing, are generally discharged through flumes or
trenches to inground concrete settling chambers called scale pits
where the heavier solid particles settle out. Scale pits often
contain underflow weirs with launders to trap oils and greases picked
up by the process waters. The waste oils are removed from the water
surfaces by belts, ropes, or other types of floating oil skimmers, and
then discharged to waste oil storage tanks. Contract haulers
periodically remove the accumulated oils. The scale is cleaned by
clam shell buckets or scale pit drag link conveyors. Waste oils are
generated at an average rate of 0.1 to 0.2 gallons per ton of steel
produced at each rolling mill operation (i.e., primary, section,
etc.). Major sources of oils at many mills are the oil cellars where
recirculated oils are conditioned, i.e. separated from entrained
water. The discharge from these pits often contains high quantities
119

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of oil and is usually directed to the scale pits. Other major sources
of oil include leaks from lubricating and hydraulic systems. The
scale pit overflows are generally not directly discharged, but are
usually routed to wastewater treatment plants for additional
treatment. Many rolling mills recycle part of the scale pit effluent
back to the rolling mill for use in flume flushing.
Waste Characterization
Scale and oil and grease are the conventional waste products from
rolling mill operations. As the hot steel is being rolled in the mill
stands, the steel surface oxidizes and is continuously scaling and
chipping off. The scale particles range in size from submicron to
several millimeters. The particles are 70-75% iron and consist of
ferrous oxide (FeO), and ferric oxide (Fe203). Overhead cranes
equipped with clam buckets are generally used to clean the scale pits.
Scale pit effluents are discharged to plant sewers or are partially
recycled back to the mills. The -suspended solids content in scale pit
overflows can be as high as 50 to 300 mg/1. These wastewaters can be
further treated by means of clarification, filtration, and recycle.
Oils from the scale pit effluents are generally in the range of 15 to
45 mg/1. Oils are found in rolling mill wastewaters as a result of
oil conditioning, oil spills, line ruptures, and excessive dripping of
lubricants. Also, appreciable quantities of spent oils and greases
are contributed to the wastewaters when equipment is washed down.
Concentrations as high as 150 mg/1 may be reached during line
ruptures.
The discharges from the different types of hot forming operations are
similar with respect to suspended solids, oil and grease, and pH.
However, the quantity of solids and applied water rates in gallons per
ton vary among rolling mills.
Toxic metal pollutants have been detected in the wastewaters from the
rolling mills. The appearance of toxic metals such as chromium,
copper, lead, nickel, and zinc result from the use of these metals in
steelmaking and alloying and possibly in lubricants used at certain
mills. Relatively few toxic organic pollutants were detected in
wastewaters from the hot forming mills sampled. This subject is more
completely discussed in Section VI.
Specific Discussion
Water Use
1. Primary Rolling Mills
The blooming or slabbing rolling mills generally have six main
contact water systems.
120

-------
a.	High pressure descaling spray water
b.	Mill stand roll and roll table spray cooling water
c.	Hot shear spray cooling water
d.	Flume flushing
e.	Hot scarfer spray flushing and cooling system
f.	Hot scarfer wet gas cleaning system
The first four sources are common to all hot forming operations
and were briefly discussed above. The last two sources - hot
scarfer water system and hot scarfer gas scrubber systems are
described below.
Automatic Hot Scarfers
The use of automatic hot scarfing machines for surface finishing
results in the generation of fumes, smoke, and slag. The
scarfing operation results in a continuous production of molten
slag ahead of the reaction zone. This slag is directed to a slag
pit or trench beneath the scarfer machine and high pressure water
is used to break up and flush the slag generated by the scarfing
process. Exposed equipment in the vicinity of the scarfing
reaction is also sprayed to protect it from heat and flying slag
particles. High pressure water (150 psig) is used for flushing
the slag from the steel surface while low pressure water (40
psig) is used for the spray cooling water.
Wastewaters from the automatic scarfer spray water systems are
generally routed into a scale pit where the heavy slag particles
settle out. The scale pit overflow is discharged to plant
sewers. Often these spray waters are discharged into the same
primary scale pit as the mill equipment cooling and descaling
waters.
The high pressure spray water granulates the slag and protects
the scarfer pinch rolls from slag splatter. The slag produced
weighs approximately 180 lbs/ft® dry and 198 lbs/ft3 wet. The
slag particles vary in size from smaller than 100 mesh to less
than 1/2 inch in size with most (75%) in the 40 to 60 mesh range.
The chemical composition of slag is approximately:
The total iron content in scarfer slag is about 84%.
The quantity of slag produced by the scarfing process ranges from
2% to 4% of the tonnage scarfed whereas the quantity of mill
scale produced by the primary mills ranges from 1-1/2 to 3% of
the tonnage rolled by the mill.
Metallic Iron (Fe)
Ferrous Oxide (FeO)
Ferric Oxide (Fe203)
Balance (Si02/ Mn, C, etc.)
44%
33%
21%
2%
100%
121

-------
As noted earlier, the hot scarfing process results in appreciable
quantities of fume and smoke. Additional wastewater results when
wet type dust collectors are used to clean the exhaust gases from
the scarfer. Dry collectors are not normally used because the
exhaust gases are saturated. Discharge waters may be acidic if
resulphurized steels are being scarfed. The discharge rate
varies with the type of gas cleaning system used. The high
energy Venturi requires a 1500-2000 gpm water rate. Wet
continuous precipitators use about 200 gpm, while intermittent
spray wash precipitators use approximately 300 gpm for a 30
second spray every half hour cycle.
Section Rolling Mills
Section rolling mills generally have four main mill contact water
systems:
a.	High pressure descaling spray water
b.	Mill stand roll and roll table spray cooling water
c.	Hot shear spray cooling water
d.	Flume flushing
The combined discharge from these four sources is the wastewater
source regulated by the proposed limitations.
Flat Mills
a.	Plate Mills
Plate rolling mills have three contact water systems:
(1)	Descaling water sprays
(2)	Mill stand roll and roll table water sprays
(3)	Flume flushing
The combined discharge from these three sources is the
wastewater source regulated by the proposed limitations.
b.	Hot Strip and Sheet Mills
Hot strip rolling mills generally have six mill contact
water systems:
(1)	Flume flushing water
(2)	High pressure descaling water
(3)	Low pressure roll coolant water
(4)	Table roll and shear cooling waters
(5)	Product cooling including runout tables
(6)	Coiler cooling water
Large quantities of cooling waters are applied to cool the
strip on the runout table after it has been rolled on the
final mill finishing stands. This water is relatively clean
and is often recycled because of its large volume.
Approximately 8% of the strip cooling waters evaporate and
122

-------
the balance is either recycled or further treated with the
other wastewaters.
The mill scale from the finishing roll stands is much finer
and is retained on a 325 mesh screen. Hot strip and
combination mills require greater cooling water rates due to
cooling tables and laminar water spray cooling. Laminar
flow is a method of non-turbulent water flow over the entire
surface of the strip to effect uniform surface cooling and
prevent strip distortion.
The combined discharge from the six sources mentioned above
is the wastewater source addressed in the proposed
limitations.
4. Pipe and Tube (Hot Working)
Wastewaters are generated in the hot working operation as a
result of the large amounts of direct contact cooling and
descaling waters required by the hot steel and the piercing, plug
and reeler mill equipment.
The butt welded pipe mills generally have two types of contact
wastewater systems.
a.	Roll cooling spray waters
b.	Pipe cooling bed water bosh
The pipe cooling bed water bosh is sometimes used to provide
adequate cooling capacity without the use of excessively long
pipe cooling beds. These wastewaters provide direct contact
cooling and are generally discharged to the roll cooling
wastewater system.
The seamless tube mills generally use two types of contact water
systems:
a.	Roll spray coolant waters
b.	Spray water quench
The spray quench water system is used to produce higher strength
pipe and tube than that achievable by only hot working the pipe
and tube. The product is quenched, reheated, and quenched again
by means of water sprays. These wastewaters are handled in a
manner similar to that of the roll cooling wastewaters.
Recycle Water Rates
To reduce the large volumes of wastewater discharged from hot forming
operations, recycle systems are installed at most mills. These
systems recirculate either treated or partially treated process water
back to the mill which reduces service (makeup) water requirements and
discharge flow.
123

-------
The degree of recycle that can be practiced at hot forming operations
is controlled primarily by product quality and temperature
requirements of the process water. The water must be fairly cool
because one of the principal uses of process water is to cool the
rolling stands. Recirculation of hot forming wastes is considered
recycled, if the water is recirculated to a hot forming operation. If
the water is recirculated to a process other than hot forming, (i.e.,
BOF, Blast Furnace) it is considered to be reused and is eventually
counted as part of the discharge flow from the hot forming mill.
Based on these determinations, the Agency analyzed the recycle rates
in hot forming operations. Recycle of scale pit process water and
recycle of treated process water were considered separately. A
detailed listing of recycle percentages is given in Section X;
however, a summary of these data is provided below.
* Average recycle rate of water from primary scale pits for flume
flushing or similar process uses, for mills with recycle systems.
** Overall recycle equals the total recycle practiced at mills with
recycle systems. As noted above, many mills have higher recycle
rates.
Overall process water recycle rates for the better treatment systems
exceed 96% for each hot forming subdivision. Several mills have, in
fact, reported achieving no discharge.
Wastewater Characteristics
Tables V-l through V-10 summarize the raw waste concentrations
discharged from the hot forming operations sampled for this study.
Data are divided into those obtained during the original guidelines
study and those obtained during the toxic pollutant study because of
the diverse nature of the sampling conducted during the two studies.
For the original study, only metals and limited pollutants were
analyzed. However, for the toxic pollutant study, toxic metals and
toxic organic pollutants were studied in addition to the previously
limited pollutants.
Wastewater quality presented in Tables V-l to V-10 represent the
contribution of hot forming operations to the wastewaters.
Concentrations were calculated by subtracting all "background" amounts
of each pollutant from the individual total pollutant amounts present
in the wastewaters. This includes pollutants in the intake water and
also pollutants in recycle loops, if any recycle was practiced. Only
those pollutants present in the raw wastewaters at levels equal to or
Average Recycle
Rate of Scale Pit
Process Water*(%)
Average Overall
Process Water
Recycle Rate**(%)
Primary Operations
Section Operations
Flat Operations
Pipe and Tube Operations
53.3
53.7
29.5
77.0
74.4
84.6
71 .2
73.5
124

-------
greater than 0.010 mg/1 are included in the raw waste concentration
list. Those data indicate that toxic metals are found in wastewaters
from both carbon and specialty operations. Toxic organic compounds
were also detected at both types of mills. Table V-11 summarizes the
raw waste concentration data for hot forming operations. With the
high rate recycle systems considered at the BAT, BCT, NSPS, PSES, and
PSNS levels, the impact of small volumes of makeup water on treated
effluent quality is not significant. Hence, the proposed effluent
limitations were developed on a gross basis.
125

-------
TABLE V-l
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES SURVEY
	HOT FORMING-PRIMARY
Net Concentration of Pollutants in Raw Wastewaters
to
CTv
Reference Code
Plant Code
Sample Points
0112B-01,02
A~2 (2)
4~{3+U
890
0112B-03
B-2
3"3?3)
510
0684H
C-2
1-?3
780
0946A
D-2
(l+2)-(6+7)
700
0060
610
)
(3)
0248B
s33>
0020B
E
6-10
2740
0248A
H
9-14
2480
(3)
0256K
K
12-7
5600
0432J
M
4350
0684D
Q (2)
4-ir-"
3420
0240A
R
6-1
4780
Suspended Solids
78
56
21
37
15
78
80
127
*
Data
No
47
74
Oil & Grease
12
150
1.5
14.2
8
49
26
1.0


10.8
2.4
pH (Units)
7.6
8.0-8.3
7.9-8.1
7.8-8.2
7.6-8.1
2.5-6.4
7.0-7.2
6.3
Not
Separate
7.2-7.6
7.4-7
Chromium
NA
NA
NA
NA
NA
NA

*
Availab le
Sample
*
*
Co ppe r
NA
NA
NA
NA
NA
NA
*
0.02


*
0.01
Lead
NA
NA
NA
NA
NA
NA
0.03
0.03

of
0.03
0.03
Mercury
-
0.0003
0
0.0010
0
NA
NA
NA


NA
NA
Nicki: 1
NA
NA
NA
NA
NA
NA
0.18
ft

Primary
0.06
0.07
Zinc
NA
NA
NA
NA
NA
NA
-
*


0.04
0
Average
2280
61
27
2.5 to 8.3
*
0.01
0.03
*
0.08
0.01
(1)	All values are in ng/1 unless otherwise noted.
(2)	Sample includes wastewater from hot forming operations other than primary.
(3)	Includes flow from machine scarfing operation.
* :	Net concentration is less than 0.010 mg/1
:	Calculation yielded negative result
0 :	Zero value (included in average)
NA :	Not Analyzed
NOTE:	Negative values (-) are counted as zero in calculating averages.

-------
TABLE V-2
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
TOXIC POLLUTANT SURVEY
	HOT FORMING-PRIMARY	
Net Concentration of Pollutants in Raw Wastewaters^^
Reference Code
Plant Code
Sanple Points
Flow (gal/ton):
0496
082-140"
(Gj+Hj)-A
170
(3)
0496
082-140'7206"
(j2+h2)-a
460
(3)
0860H
083
E-(A+B)
320
0684H
088
(B+C)-(Q)
1700(3)
0176
081
B-D
760
Average
680
Overall
Average
1810
(2)
Suspended Solids
Oil & Crease
pH (Units)
81
63
7.7-7.9
52
4.
2.6-8.9
235
25
7.0-7.1
20
0.5
7.9
15
157
7.9-8.1
61
50
2.6-8.9
68
35
2.5 to 8.9
Cadmiuai
Chroaium
Copper
Cyanide
Lead
Nickel
Silver
Zinc
0.02
0.15
0.35
0.53
0.02
0.04
0.02
0.26
0.05
0.18
0.02
0.06
0.49
0.06
0.09
0.02
0.032
0.04
0.21
0.002
0.25
0.11
0.02
0.02
0.09
0.44
0.002
0.68
0.21
0.02
0.05
0.03
0.31
*
0.28
0.22
0.02
0.04
0.02
0.18
~
0.18
0.16
0.02
0.032
to
-¦J
Chlorofora
Methylene Chloride
Bis-(2-ethyl hexyl) phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Tetrachloroethylene
0.002
0.149
0.002
0.018
0.002
0.007
0.1
0.013
0.01
0.007
0.27
0.003
0.005
0.005
0.020
0.071
0.063
0.020
0.071
0.063
(1)	All values are in ag/1 unless otherwise noted.
(2)	Average of all values froa Table V-l and V-2.
(3)	Includes flow froa machine scarfing operation.
:	Calculation yielded negative result
* :	Net concentration is less than 0.010 tag/1
0 :	Zero value (included in averages)
NOTE:	Negative values (-) are counted as zero in calculating averages.

-------
TABLE V-3
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
HOT FORMING-SECTION	, .
NET CONCENTRATION OF POLLUTANTS IN RAW WASTEWATERS
H
to
00
Reference Code:
024 OA
0176
0684D
0432J
0424
0284A&B
0256
0176
01126
0291C
0196A
0384A
0640A
0432A
08560

Plant Code :
R
0
Q
M
C
H
K
0
A-2
D-2
E-2
F-2*
G-2
H-2
1-2

Sample Points :
(4-1)
(10-11)
(8-10)
(6-9)
(8-5)
(13-14)
(10-7)
(1-2)
(4-3)
(4+5M6+7)
(3+2M4+6)
(2-3)
l-(2+4)
(3-1)
(2-6)
Average
Flow (gal/ton):
7960
12,860
1780
670
5260
4210
1470
4970
600
5750
6700
1910
14,020
6950
5010
5341
Suspended Solids
25
78.8
30
53.6
36.8
44
63
_
86.3
30.6
55.3
12.7
22.2
33
124
46.3
Oil & Grease
3.3
-
1 .2
9.7
1.0
7.8
3.5
3.4
13.9
13.9
6.4
-
0.5
13.8
1.4
6.3
pH (Units)
7.1
7.5
7.5
6.5
5.1
6.2
7.2
8.4
7.6
8.0
8.3
7.7
7.7
6.6
7.6
5.1 to
Chromium
0.0
0.01
-
0.06
0.0
0.0
0.0
-
NA
NA
NA
NA
NA
NA
NA
0.0088
Copper
0.0
0.0
0.01
0.0
0.0
0.0
0.4
-
NA
NA
NA
NA
NA
NA
NA
0.0063
Nickel
0.05
-
0.0
0.10
0.11
0.0
-
0.0
NA
NA
NA
NA
NA
NA
NA
0.032
Zinc
0.0
0.0
0.04
-
0.011
0.0
-
0.0
NA
NA
NA
NA
NA
NA
NA
0.0064
(1) All values are in tng/1 unless otherwise noted.
: Calculation yielded negative result
* :	Includes scarfing flow
0 : Included in average
NA :	Not analyzed
+ : Cannot be evaluated
NOTES: a. Negative values counted as zero in average calculations.
b. Because of the difficulty in sampling the raw wastes directly from the operations,
the sampling results shown above are all based on the mills' discharge from the primary scale pits.

-------
TABLE V-4
SUMfAKT Or ANALYTICAL DATA OF SAMPLED PLANTS
TOXIC POLLUTANT STUDY
HOT FORMING-SECTION
NET CONCENTRATION OT FOLLUTAHTS IN HAM WASTEWATBtS
to
vO
Kef.rence Coiti
0176
0660H
0860H
OA 32 A
0684H
0684H
0684H
068411
0684B
0176


Plant Cod. i
081-142
081 St.
083 tod
087-14"
088-10"/ll"
088-34"
088-36"8illet
088-32"
088-14"
081-#4Not

Overall..
8¦¦pi. Pointt I
(C-D)
(G-l-4)
(K-B-B-A)
(D-B)

It-Q)


(r-A)(2)
Average Average
Flow (gal/ton)t
3570
4690
6930
6340
3400
580
3050
930
4800
8229
41S2
4867
Suapanded Solid*
0
26
199
23
34
20
18
27
Unable
84
47.8
46.9
Oil t Creaae
4
37
a
1
10
-
-
7
to
251
35.3
16.6
(Unit.)
7.9 '
6.9
7.4
7.3
7.5
7.7
7.9
7.8
Determine
7.2
6.9-7.9
5.1-8.4
Cadaiua
0.0
0.0
0.0
~
0.01
0.0
-
0.0

0.0
*
*
Copper
0.07
o.os
0.07
0.024
0.01
0.06
0.2
0.06

0.11
0.07
0.040
Nickel
0.16
0.0
0.07
~
0.01
0.08
O.OS
0.03

0.8
0.15
0.094
Zinc
-
0.0
0.02
0.15
0.2
0.02
0.0
0.0

0.04
0.05
0.029
Methyles. Chloride
-
-
-
0.0
0.19
0.006
0.19
0.013

-
0.044
0.044
Naphthalan.
0.0
-
0.0
0.0
0.01
0.010
0.002
0.0
-
-
*
*
2,4 Dinitrophenol
-
-
0.0
0.0
0.019
0.013
0.0
O.OOS

0.0
*
*
Bia(2-Ethy lti.xy 1) phth. l.t.
0.015
-
-
0.02
1.28
-
-
0.37

0.15
0.19
0.19
Butyl Beoiyl 111 tha late
0.014
-
-
-
0.0
-
-


0.0
*
*
Diaethyl Fhthalate
0.0
-
-
-
0.011
0.0
0.005
O.OOS

0.0
*
*
Pyrene
o.oos
-
o.oos
-
-
0.0
-
-

0.0
*
*
<1> Atl valve* «r« ia ag/1 unlet* otherwise noted.
(2)	Some conpany supplied analytical data vat used for net concentration calculation.
(3)	Average of all values on Table* V-3 mad V-4.
*	i Average ia leaa than 0.010 ag/1
~	t Cannot be evaluated
t Calculation yielded negative results
NOTES Because of the difficulty in sampling the raw wastes directly fron the operations, the
senpling results shown above are all bssed on the nills* diachrge fro* their priaary scale pit.

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TABLE V-5
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
HOT FORMING - HOT STRIP & SHEET
NET CONCENTRATION OF POLLUTANTS IN RAW WASTEWATERS
Reference Code	0248B
Plant Code	D
Sample Points	(6-1)
Flow (gal/ton)	3314
Suspended	Solids 31
Oil & Grease	16.4
pll	6.3
Chromium	NA
Copper	0.00
£ Mercury	NA
° Nickel	0.13
Zinc	0.00
0020B	0860H	0060
E	1-2	L-2
(7-10)	(l+3+4)-6	(1-2)
4518	7848	4525
23	6.6	11
13.6	0.6	4.2
5.9-6.1	7.3-8.3	7.6-8.1
NA	NA	NA
0.00	NA	NA
NA	0.00	0.00
0.00	NA	NA
0.00	NA	NA
0384A	0396D
M-2	N-2
(2+3)-5	(6-7)	Average
8436	7273	5986
11	15	16.3
1.7	0.0	6.1
8.4	7.3-7.5	5.9-8.4
NA	NA	NA
NA	NA	0.00
0.00	0.00	0.00
NA	NA	0.00
NA	NA	0.00
(1): All values are in mg/1 unless otherwise noted.
NA : Not Analyzed

-------
TABLE V-6
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
TOXIC POLLUTANT SURVEY
HOT FORMING: FLAT-HOT STRIP AND SHEET
NET CONCENTRATIONS OF POLLUTANTS IN RAW WASTEWATERS
Reference Code	Oil 2D
Plant Code 086(80" Hill)
Sample Points	(B-A)
Flow (gal/ton)	5,719
Suspended Solids	41
Oil and Grease	6
pH (Units)	8.0-8.1
Beryllium	NA
Cadmium	0
Chromium	+
Copper
Lead	+
Nickel.	+
Silver	+
Zinc	+
Phenolic Compounds	0.002
Chloroform
Methylene Chloride	+
2,4-Dini.trophenol	0.028
Bi8-(2-ethyl hexyl) phthalate	0.279
Butyl benzyl phthalate	0.024
Di-n-butyl phthalate	0.001
0432A	Overall(2)
087 (44" Mill)	Average	Average
(C-B)
UNK	5,719	5,948
18	30	19.7
3	4	5.6
7.4-7.6	7.4-8.1	5.9-8.4
~	+	+
~	+	+
~	~	+
0.011	0.005	0.002
+	~	+
~	~	0.06
*	+	+
+	+	0.00
0.046	0.024	0.024
0.018	0.009	0.009
+	+	+
0	0.014	0.014
0	0.140	0.140
0	0.012	0.012
0.023	0.012	0.012
(1)	All values are expressed in mg/1 unless otherwise noted.
(2)	Average of all values on Tables V-5 and V-6,
NA: Not Analysed
+ : Cannot be evaluated
- : Calculations yielded a negative value

-------
TABLE V-7
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
HOT FORMING - PLATE	( .
NET CONCENTRATION OF POLLUTANTS IN RAW WASTEWATERS
Reference Code
0856H
0176
0868B

Plant Code
F
0
K-2

Sample Points
(7-9)
(10-11)
(1-2)
Average
Flow (gal/ton)
4293
12,800
3,692
6,928
Suspended Solids
85
79
56
73.3
Oil & Grease
50.9
0.00
4.6
18.5
pH (units)
6.3-6.7
7.4-7.5
6.9-7.1
6.3-7.5
Chromium
0.01
NA
NA
0.01
Copper
NA
0.00
NA
0.00
Mercury
NA
NA
0.00
0.00
Nickel
0.48
0.00
NA
0.24
Zinc
0.02
0.00
NA
0.01
(1) : All values are in mg/1 unless otherwise noted.
NA : Not Analyzed
NOTE: Because of the difficulty in sampling the raw wastes directly from the operations,
the sampling results shown above are all based on the mills' discharge from the primary scale pit.

-------
TABLE V-8
SUMMARY OF ANALYTICAL DATA OP SAMPLED PLANTS
TOXIC POLLUTANT SURVEY
HOT FORMING; FLAT-PLATE	...
NET CONCENTRATIONS OF POLLUTANTS IN RAW WASTEWATERS1
Reference Code
0496
0496
0496
0496
0496
0860H
01120


Plant Code
082-112"/120M
082-112'7120"
082-140"
082-140"
082-140*7206"
083-30"
086-160"

Overall.
Sanple Pointa
(I>-A)
(C-A)
(H-A)
(G-A)
(J-A)
I-(B+A)
(H-A)
Average
Average
Flow (gal/ton)
869
2,653
118
144
206
9,821
3,221
2,433
3,782
Suspended Solids
22
31
65
109
25
12
30
42
51.4
Oil and Grease
8
6
34
60
4
10
13
19
18.9
pH (Units)
7.2
7.5
7.7-8.9
7.8
7.4
7.2-7.3
8.0-8.2
7.2-8.9
6.3-8.9
Chroaiua
~
0.09
0.04
0.04
0.01
-
+
0.03
0.027
Copper
0.18
0.15
0.11
0.18
0.20
0.06
0.02
0.13
0.11
Lead
~
+
0.21
0.42
+
~
+
0.09
0.09
Nickel
0.10
0.27
0.32
0.93
0.12
0.01
0.04
0.26
0.26
Silver
~
4-
+
~
<4-
~
+
+
+
Zinc
0.05
0.04
0.03
0.05
0.05
0.04
0.01
0.04
0.033
Benxene
0.017
0.009
-
-
-
-
0
0.004
0.004
2,4-Diaethylphenol
0.014
0
0
0
0
0.005
0
0.003
0.003
Methylene Chloride
-
NA
0.002
0.116
0.014
-
+
0.022
0.022
4-Nitropheno1
0
0.017
0
0
0
-
0.007
0.003
0.003
Pentachlorophenol
0.012
0
0.005
0
0
-
0
0.002
0.002
Bis-(2-ethyl hexyl) phthalate
0.599
0.604
0.149
0.254
0.006
-
0.816
0.347
0.347
Di-n-butyl phthalate
-
0.032
-
-
-
0
0
0.005
0.005
Diethyl phthalate
0
0
0
0
0
0.023
0
0.003
0.003
(1)	All values are in ag/l unless otherwise noted.
(2)	Average of all values in Tables V-7 and V-8.
-: Calculations yielded a negative value
+: Cannot be evaluated
NA: Not Analysed

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TABLE V-9
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
ORIGINAL GUIDELINES SURVEY
HOT WORKING PIPE AND TUBE	, )
NET CONCENTRATIONS OF POLLUTANTS IN RAW WASTEWATERS
Reference Code
0196A
0240B
0916A
0728
0256G
Average
Plant Code
E-2
GG-2
11-2
J J-2
KK-2

Sample Points
(1-6)
(1-4)
(1-5)
2-(l+3)
(1-3)

Flow (gal/ton)
12,800
1,700
2,760
2,290
520
4,010
Suspended Solids
27
40
224
102
61
91
Oil and Grease
13.4
7.3
2.2
6.7
-
5.9
pH (Units)
8.2-8.7
7.0-7.8
7.0
6.8-6.9
6.8-7.1
6.8-8.7
Beryllium
NA
NA
NA
NA
NA
NA
Cadmium
NA
NA
NA
NA
NA
NA
Chromium
NA
NA
NA
NA
NA
NA
Copper
NA
NA
NA
NA
NA
NA
Lead
NA
NA
NA
NA
NA
NA
Nickel
NA
NA
NA
NA
NA
NA
Silver
NA
NA
NA
NA
NA
NA
Zinc
NA
NA
NA
NA
NA
NA
Phenolic Compounds
NA
NA
NA
NA
NA
NA
(1) All values are expressed in mg/1 unless otherwise noted
Calculations yielded a negative value
NA: Not Analyzed

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TABLE V-10
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
TOXIC POLLUTANT SURVEY
HOT WORKING PIPE AND TUBE	...
NET CONCENTRATIONS OF POLLUTANTS IN RAW WASTEWATERS
U)
Ln
Reference Code
Plant Code
Sample Points
Flow (gal/ton)
Suspended Solids
Oil and Grease
pH (Units)
Beryllium
Cadmium
Chromium
Copper
Lead
Nickel
Silver
Zinc
Phenolic Compounds
0432A
087
(E-B)
8,080
27
2
7.1-7.4
0.010
+
+
0.029
0.27
+
+
0.13
0.0020
0684H
088
(I+J+K+L)-Q
7,010
31
1.9
7.2-7.8
NA
*
+
0.060
0.012
0.069
0.0
0.037
0.078
Average
7,540
29
2
7.1-7.8
0.010
+
+
0.044
0.14
0.069
0.0
0.084
0.040
Overall
Average
(2)
5,020
73
4.8
6.8-8.7
0.010
+
+
0.044
0.14
0.069
0.0
0.084
0.040
(1)	All values are expressed in mg/1 unless otherwise noted
(2)	Average of all values in Tables V-9 and V-10
+ : Cannot be evaluated
NA: Not Analyzed

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TABLE V-ll
SUMMARY OF NET RAW WASTE CONCENTRATIONS^
	HOT FORMING SUBCATEGORY
Parameter
Primary
Section
Hot Strip & Sheet
Plate
Pipe & Tube
Total Suspended Solids
77.0
46.9
19.7
51.4
73
Oil & Grease
37.4
16.6
5.6
18.9
4.8
pH (Units)
2.6-8.9
5.1-8.4
5.9-8.4
6.3-8.9
6.8-8.7
Chromium
0.04
0.0088
*
0.027
+
Copper
0.22
0.040
*
0.11
0.044
Lead
0.28
*
*
0.09
0.014
Nickel
0.23
0.094
0.06
0.26
0.069
Zinc
0.032
0.029
*
0.033
0.084
Phenolic Compounds
*
*
0.024
*
0.040
Methylene Chloride
0.020
0.044
*
0.022
*
2,4-Dinitrophenol
*
*
0.014
¦k
*
Bis-(2-ethyl hexyl) phthalate
0.071
0.019
0.140
0.347
*
Butyl benzyl phthalate
*
*
0.012
*
*
Di-n-butyl phthalate
*
*
0.012
*
*
Te t rachloroe thylene
0.063
*
*
*
*
(1) All values are in mg/1 unless otherwise noted
*: Average value is less than 0.010 mg/1
+: Cannot be evaluated

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HOT FORMING SUBCATEGORY
SECTION VI
WASTEWATER POLLUTANTS
Introduction
This section describes the selection, rationale for selection, and the
process sources of those pollutants characteristic of hot forming
operations. As a first step in the selection procedure, the Agency
developed a list of pollutants considered to be most representative or
characteristic of hot forming processes. This initial list of
pollutants was confirmed and augmented with data collected from
extensive field sampling programs which included analysis for toxic
pollutants. A review of the analytical data from all of the field
sampling programs formed the basis for the final selection of
pollutants for hot forming operations. On the basis of the expected
and observed similarities among hot forming operations, a common list
of selected pollutants was then developed for the four hot forming
subdivisions.
Conventional Pollutants
Suspended solids, oil and grease, and pH were the three pollutants
limited by the BPT limitations promulgated in 1976. Suspended solids
was chosen as a limited pollutant based upon the large quantities of
scale generated in all of the hot forming processes. As noted in
Section V, these scale particles enter the process wastewaters as a
result of the application of water on the steel product and roll
stands. Suspended solids also indicate the degree of process
wastewaters contamination and can be used as a measure of treatment
performance. Various other pollutants, including the toxic metals,
are often entrained within the suspended particulate matter thus,
suspended solids removal results in the removal of other pollutant
levels.
The Agency selected oil and grease since many lubricants are used in
hot forming processes. Oils and greases are present in hot forming
wastewaters as a result of oil conditioning, oil spills, line breaks,
excessive application of lubricants, and equipment washdown.
Finally, pH, a measure of the acidity or alkalinity of a wastewater,
was chosen due to the environmentally detrimental effects which can
result from extremes in pH. In addition, extremes in pH can cause
problems, such as corrosion and scaling, to process and wastewater
treatment equipment and facilities. The pH of hot forming process
wastewaters typically falls within the range of 6.0 to 9.0 without
control.
137

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Toxic Pollutants
This study also considered the discharge of toxic pollutants.
Initially, all pollutants classified as "known to be present" were
included. This classification was made on the basis of industry
responses to the DCPs, and analyses performed during the screening
phase of this project. Table VI-1 lists toxic pollutants selected on
the basis of the above considerations.
Upon completion of the analyses of the hot forming wastewaters for the
various pollutants, the Agency determined those pollutants which were
found at 0.010 mg/1 or greater in the raw wastewaters. The final
toxic pollutant list was developed by including pollutants detected in
hot forming wastewaters at average concentrations of 0.010 mg/1 or
greater. This list, which includes the original BPT limited
pollutants, is presented in Table VI-2. These pollutants are
considered to be most representative and indicative of hot forming
operations and are addressed accordingly throughout this report.
The toxic metal pollutants present as a result the raw materials used
in the steelmaking and alloying processes, enter the hot forming
process wastewaters when the product scale contaminates the process
wastewaters. The five toxic metal pollutants (refer to Table V—11)
included in the list are used to generally characterize all hot
forming wastewaters. These toxic metals are found above treatability
levels in the process wastewaters of all hot forming subdivisions.
Control of these five predominant toxic metals will also indicate
control of the other toxic metals, which could be present in
wastewater from a particular plant. Toxic metals were found in
wastewaters from both carbon and specialty mills.
The list of selected pollutants does not include any toxic organic
pollutants. Although several toxic organic pollutants were detected
at levels greater than 0.010 mg/1 in some of the hot forming
subdivisions, various factors mitigated against the selection of these
pollutants. In the case of methylene chloride and the phthalates,
these pollutants are considered to be artifacts (i.e., resulting from
laboratory procedures) and are not contributed by hot forming
operations. The remaining toxic organic pollutants (e.g., phenol,
2,4-dinitrophenol) were not included in the final list because of
their presence at levels which indicate that, aside from recycle,
specific treatment for organic pollutant removal is generally not
feasible. The Agency believes that those pollutants do not tend to
concentrate in recycle systems. Although the concentrations of those
pollutants in recycle system blowdowns will be approximately the same
as the discharge from once-through systems, the mass loadings of those
pollutants will be reduced proportionately to the degree of recycle.
Accordingly, with the high degree of recycle incorporated in the BCt)
BAT, NSPS, PSES, and PSNS alternative treatment technologies, the
Agency believes that compliance with the proposed limitations for
toxic metal pollutants will indicate a comparable reduction in the
discharge of those toxic organic pollutants present in hot forming
wastewaters.
138

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TABLE VI-1
PRIORITY POLLUTANTS KNOWN TO BE PRESENT
HOT FORMING SUBCATEGORY
Priority Pollutant
Numeric Designation	Pollutant Parameter
65	Phenol
66	Bis(2-ethylhexyl)Phthalate
85	Tetrachloroethylene
118	Cadmium
119	Chromium
120	Copper
121	Cyanide
122	Lead
123	Mercury
124	Nickel
125	Selenium
126	Silver
127	Thallium
128	Zinc
139

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TABLE VI-2
SELECTED POLLUTANTS
HOT FORMING SUBCATEGORY
Suspended Solids
Oil and Grease
PH
119	Chromium
120	Copper
122 Lead
124 Nickel
128 Zinc
140

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HOT FORMING SUBCATEGORY
SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
Introduction
A review of the control and treatment technologies currently in use or
available for use in the hot forming subcategory provided the basis
for the development of the BPT, BAT, BCT, NSPS, PSES, and PSNS
alternative treatment systems. This review involved summarizing
questionnaire and plant visit data to identify those treatment
components and systems in use at hot forming operations.
Capabilities, either demonstrated or based on treatment of similar
wastewaters, were used in evaluating those advanced treatment
technologies for toxic metal pollutant removal. The above
considerations were then used to determine which treatment components
and systems were most appropriate for the various levels of treatment.
This section presents a summary of the treatment practices currently
in use or available for use in the treatment of hot forming process
wastewaters.
This section also presents raw wastewater and treated effluent data
for the plants sampled, as well as the methods used to determine
wastewater loads and actual raw wastewater quality. As noted
previously, raw wastewater samples could only be obtained following
primary scale pits at most plants. The analytical data, from the
toxic pollutant surveys along with long-term effluent monitoring data
from the industry, were used to establish treatment system
capabilities. Also included in this section are descriptions of the
treatment systems at each of the sampled plants.
Summary of Treatment Practices Currently Employed
As noted previously, wastewaters generated in the various hot forming
processes are similar in character, and as a result, the treatment
technologies in use at these operations are basically the same. A
survey of the treatment components in use indicates that the following
basic treatment units are prevalent: primary sedimentation, surface
oil removal, secondary settling or filtration, and recycle. Over
ninety-six percent of all hot forming operations have primary scale
pits to collect and recover the heavier suspended particulate matter
and to allow the tramp oils to float to the surface. These pits are
cleaned either frequently or continuously in order to prevent excess
solids accumulation. Slotted tube, rope, or belt-type oil skimmers
are the principal devices in use for surface oil removal. The
efficiency of scale pits is dependent upon design. In many mills a
portion of the scale pit discharge is recycled to the process for
flume flushing. The scale pit discharges which are not recycled,
typically undergo physical/chemical treatment prior to discharge or
recycle to the process.
141

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Referring to Tables III-2 through III-7, the Hot Forming General
Summary Tables, the following treatment technologies have been noted
to be in use at many hot forming operations:
A.	Scale Pit or similar type settling basin
Intended to provide primary sedimentation of the raw process
wastewaters and oil separation.
B.	Surface Skimming
The various tramp oils inherent in mill operations are removed
from the surface of the wastewater (generally during primary
settling).
C.	Clarifiers or Thickeners
These components provide additional suspended solids removal.
Settling lagoons and secondary scale pits are also capable of,
providing the same degree of treatment as clarifiers or
thickeners.
D.	Vacuum Filters
These filters are used to dewater the sludges removed from
various sedimentation operations, principally clarifiers and
thickeners.
E.	Filters
These components can provide a much higher degree of suspended
solids removal than attainable with sedimentation facilities.
F.	Recycle
A portion of the effluent from one . or more of the treatment
system components is recycled to the process.
Hot forming wastewaters are often treated in central treatment
facilities in which wastewaters from several hot forming mills (or, in
many instances, from other subcategories) are combined for treatment.
With this type of facility, advantage can be taken of the economies of
scale and the ease of centralized process control.
Control and Treatment
Technologies for BAT, BCT, NSPS, PSES, and PSNS
In order to achieve the high wastewater recycle rates for hot forming
operations, an evaporative cooling tower is normally used to reduce
the temperature of the recycled water. It should be noted that
cooling towers are used at many hot forming operations as major
components in high recycle rate systems. Heat load reduction is
necessary to ensure sufficient roll cooling capacity and to minimize
fog formation in the mill. Some mills practice a high degree of
recycle without cooling towers.
142

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Because of the presence of toxic organic and toxic metal pollutants in
hot forming process wastewaters, the Agency considered advanced levels
of treatment in the BAT, NSPS, PSES, and PSNS alternative treatment
systems beyond recycle. Each of the technologies considered are
reviewed below.
Sulfide Precipitation
The addition of sulfide compounds has been shown to result in a
greater degree of toxic metals removal than can be achieved with
typical flocculation and sedimentation procedures. Some of the toxic
metals which can be effectively precipitated with sulfide are zinc,
copper, nickel, lead and silver. The increased removal efficiencies
can be attributed to the comparative solubilities of metal sulfide
with metal hydroxides. In general, the metal sulfides are less
soluble than the respective metal hydroxides. It must be noted,
however, that an excess of sulfide may result in objectionable odor
problems. A decrease in wastewater pH will aggravate this problem,
and if process control problems result in an acidic pH, operating
personnel can be affected. One method of controlling excess sulfide
addition involves the use of a ferrous sulfide slurry addition.
Ferrous sulfide will not readily dissociate in the waste stream with
the result that the free sulfide level is kept well below
objectionable limits. However, the affinities of the other metals in
the waste stream for sulfide are greater than that of iron, with the
result that other metal sulfide precipitates are formed preferentially
to iron sulfide. Once the sulfide requirements of the other metal
precipitates are satisfied, the remaining sulfide remains in the
ferrous sulfide form and the excess iron from the ferrous sulfide is
precipitated as a hydroxide. With the use of filtration following
sulfide addition, significant toxic metal reductions can thus be
achieved.
Evaporation
Vapor compression distillation, in which a wastewater with a high
dissolved solids level (the treatment system blowdown) is concentrated
to a slurry consistency, was considered as an alternate means of
attaining zero discharge in the hot forming subcategory. The
resulting slurry would be dried by various means while the distillate
quality effluent would be recycled to the process. However, this
technology did not receive further consideration because of excessive
energy requirements and high cost. Zero discharge is being achieved
at many hot forming operations without this technology.
Summary of Analytical Data
Raw wastewater and effluent data for the hot forming operations which
were visited are presented by subdivision in Tables VI1-2 through
VII—11. Table VII-1 provides a legend for the various control and
treatment technology abbreviations used on the above tables and in
other tables throughout this report. The concentration values
presented represent, except where footnoted, averages of measured
values. In some cases these data were obtained from central treatment
systems.
143

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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 Agency determined the percentage contribution of an
individual operation to the total treatment system influent load and
subsequently applied this contribution 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.
As a supplement to the sampled plant analytical data, long-term
effluent analytical data from D-DCPs are presented on Table VII-12,
These data are presented as a means of demonstrating treatment
capabilities and consistency over an extended period.
As mentioned previously nearly all raw wastewater samples were
obtained from primary scale pit effluents. Therefore, other methods
were needed to determine raw process wastewater characteristics. Data
provided by the D-DCP respondents served as the basis for establishing
the levels of raw wastewater suspended solids and oil and grease.
Since suspended solids in hot forming wastewaters are almost entirely
due to scale generation in the hot forming process, a determination of
the quantities of scale generated provides a reasonable estimate of
suspended solids levels present in process wastewaters. As a result
of similar scale generation rates and wastewater characteristics, the
Agency averaged mill scale generation data from all D-DCP respondents
to derive a single scale generation rate for application to all hot
forming operations. These data are presented in Table VII-13. The
average product loss of approximately 2.1% represents a scale
generation rate and resulting suspended solids loading of 42 lbs of
solids per ton of production. This solids loading was then applied to
the various treatment model sizes and raw wastewater flow rates to
determine raw wastewater suspended solids levels for each treatment
system. It must be noted that the above rate applies only to mills
without machine scarfer operations. A review of available information
indicates that primary mills with scarfing operations generate about
twice as much suspended solids than those systems without scarfing.
Raw wastewater oil and grease levels were also established on the
basis of data provided in the D-DCP responses. Virtually all of the
oils and greases present in hot forming wastewaters are present as a
result of leakages or spills of oils (i.e., lubricants) which are
immiscible in water. Based on the data received from the D-DCP
respondents, the Agency determined an average oil and grease
generation rate of 0.23 gallons/ton (Table VII-13). This volume is
equivalent to a mass generation rate of 1.6 lbs/ton. This rate was
applied to each treatment system as discussed above for suspended
solids. Oil generation rates much greater than this value are
considered to be the result of inadequate maintenance and operational
control.
144

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Plant Visits
Brief descriptions of the visited plants are presented below.
Treatment system flow schematics are provided at the end of this
section.
Plant C - Figure VII-1 (Section)
The wastewaters from the specialty bar mills at Plant C empty into a
cooling reservoir which receives wastewaters from other processes as
well. A portion of the reservoir overflow is discharged to a
receiving stream, while the remaining overflow is recycled to the
process.
Plant D - Figure VI1-2 (Primary)
Universal mill (specialty) wastewaters discharge to a scale pit
equipped with oil removal facili'ties. The scale pit effluent of this
once-through system is discharged to a receiving stream.
Plant D - Figure VII-3 (Flat)
This plant provides once-through treatment for specialty hot strip
mill wastewater. Wastewater is pumped to primary scale pits and then
discharged to a receiving stream after mixing with wastewater from the
universal mill mentioned above.
Plant E - Figures VII-4 and VII-5 (Primary and Flat)
Specialty steel hot strip, blooming and universal mills are treated in
a central treatment system. After first passing through primary scale
pits, the wastewaters then discharge to a main collection sump which
discharges to two clarifiers. The clarifier overflow is pumped
through deep bed filters and then discharged to a receiving stream.
The filter backwash is returned to the clarifiers.
Plant F - Figure VII-6 (Flat)
Plant F has a once-through process wastewater system for a specialty
plate mill. Wastewaters flow through a primary scale pit and then are
discharged to a receiving stream. Reheat furnace noncontact cooling
water also flows through the primary scale pit.
Plant H - Figure VII-7 (Primary)
Plant H practices once-through treatment of its specialty steel
blooming mill wastewaters. Scarfer wastewater, reheat furnace cooling
water, and blooming mill wastewater all empty into the same scale pit
and discharge to a receiving stream.
Plant H - Figure VII-8 (Section)
Merchant mill wastewaters are pumped to a scale pit and discharged to
a receiving stream by this specialty mill. No recycle is employed at
this mill.
145

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Plant K - Figure VII-9 (Primary)
The treatment facility for this specialty blooming mill incoporates a
recycle system with a blowdown to a receiving stream. Treatment
includes a primary scale pit with oil removal facilities.
Plant K - Figure VII-10 (Section)
This specialty bar mill's process effluent discharges to a scale pit
from where it is discharged to a receiving stream. No recycle is
employed at this mill.
Plant M - Figure VII-11 (Primary)
This specialty steel plant's wastewater treatment system serves
primary and section rolling mills (blooming mill, billet mill, and bar
mill).
The primary mill wastewaters, including hot scarfer wastewater, are
discharged to a primary scale pit. The scale pit effluent is recycled
to the mills and hot scarfer with a blowdown going to a sump pit which
receives section mill wastewaters. Overflow from this sump pit is
discharged to a spray pond and to a POTW. Water is recycled from the
spray ponds to the mills after addition of cooling water makeup.
Plant M - Figure VII-12 (Section)
The wastewater treatment system for this specialty plant serves
several mills including a billet bar mill, a blooming mill and a bar
mill. Bar mill wastewater is pumped to a sump pit along with other
mill wastewaters. A portion of the sump pit effluent is discharged
while the remainder is pumped to a spray pond and is subsequently
recycled.
Plant 0 - Figure VII-13 (Section)
This specialty mill's wastewaters are discharged to a clarifier for
sedimentation. A blowdown is discharged from the clarifier to a
central wastewater treatment facility. The remainder of the clarifier
overflow is recycled.
Plant 0 - Figure VII-14 (Section and Flat)
The wastewater treatment system for these specialty mills is a
combined system serving both rod and strip mills. Wastewaters are
discharged to a scale pit, then recycled to these mills. A blowdown
is discharged to a central wastewater treatment facility.
Plant Q - Figure VI1-15 (Primary)
This specialty blooming mill employs a once-through system which uses
a scale pit and oil skimming equipment to treat process wastewaters.
Other plant process wastewaters discharge to the scale pit as well.
The scale pit overflow is discharged to a receiving stream.
146

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Plant Q - Figure VII-16 (Section)
The wastewaters from the specialty bar mills at Plant	Q are delivered
to a scale pit equipped with oil removal facilities.	As no recycle is
employed, all process wastewaters are discharged from	the scale pit to
a receiving stream.
Plant R - Figure VII-17 (Primary)
This specialty plant's treatment system serves several mills including
primary and section rolling mills (blooming mill and bar mills).
Blooming mill wastewaters are discharged to a common primary scale
pit. The scale pit effluent is discharged to a settling lagoon for
final polishing. This system is once-through.
Plant R - Figure VII-18 (Section)
Wastewaters from the two specialty bar mills at this plant are
discharged to two separate scale pits which in turn discharge to a
common scale pit. Wastewaters from this scale pit are pumped to a
settling lagoon, then discharged to a receiving stream. No recycle is
employed.
Plant A-2 - Figure VII-19 (Primary and Section)
The wastewater treatment system for this plant serves a combination of
hot forming mills (billet and rail mills). The wastewaters from each
of the mills pass through primary scale pits and are then discharged
into a secondary clarification device called a settling cone. The
settling cone is elevated to allow for gravity flow to the deep bed
filters. A portion of the settling cone overflow is recycled to the
hot forming mills with the balance going to the deep bed filters.
Filter effluent is discharged to a lake. Filter backwash is
discharged back into the primary scale pits.
Plant B-2 - Figure VI1-20 (Primary)
This treatment is identical to that of Plant A-2 except that no
recycle is employed.
This treatment facility is a combination system serving both blooming
and structural mills, although the structural mill was not operating
at the time of sampling. Wastewater passes through primary scale pits
and then is discharged to a settling cone. The settling cone is
elevated to allow for gravity flow to the deep bed filters. The
settling cone effluent is discharged to the deep bed filters and the
filter effluent is then discharged to a lake. Filter backwash is
discharged back into the primary scale pits.
Plant C-2 - Figure VII-21 (Primary)
147

-------
Wastewaters from this blooming mill are discharged to a primary scale
pit. The scale pit overflow is then pumped to a pressure (media) deep
bed filter which discharges to a receiving stream. Filter backwash is
discharged to clarifiers for final sedimentation. Clarifier overflow
is also discharged. No recycle is employed.
Plant D-2 - Figure VII-22 (Primary and Section)
The wastewater treatment system for Plant D-2 serves several hot
forming mills including a blooming mill, two merchant bar mills, and a
bar mill. The wastewaters from each of the mills pass through primary
scale pits and then discharge to the thickener. The bar mill
wastewater, though, is recycled to the process prior to the thickener.
Also, one of the merchant bar mills' wastewater bypasses the thickener
and combines with the thickener overflow. The thickener underflow is
discharged to a blast furnace thickener. The rolling mill's thickener
overflow is discharged to a central scale pit equipped with oil
collection facilities. The wastewaters are then discharged to deep
bed filters. The blast furnace thickener overflow is processed
through a cyanide destruction system and then filtered in the same
deep bed filtering system. The filter effluent is then pumped to a
main plant recycle pumping station where river makeup is added and the
wastewaters are then recycled to the hot forming mills. The remaining
filter effluent is reused for noncontact blast furnace cooling and
then discharged.
Plant E-2 - Figure VII-23 (Section and Pipe and Tube)
Rod mill, bar mill, and seamless tube mill wastewaters are treated by
this combination system. Wastewaters discharge to a primary settling
basin from which they are pumped to a clarifier. Clarifier overflow
is then filtered by six high rate sand filters. Filter backwash and
clarifier underflow are taken to settling pits and a lagoon which
empties into the main reservoir. The filter effluent is recycled to
only the rod and bar mills after first passing through a cooling
tower. Makeup to the system is provided by a main reservoir which
also accepts any blowdown from the system. The reservoir overflow is
discharged to a receiving stream.
Plant F-2 - Figure VI1-24 (Section)
Section mill wastewaters first pass through a series of primary and
secondary scale pits which are equipped with oil removal facilities.
Scale pit effluent is pumped to clarifiers for quiescent settling.
Oil skimming is also practiced at the clarifiers. The clarifier
overflow is recycled to the process after first passing through a
two-cell cooling tower. Clarifier underflow is dewatered using vacuum
filters and the filtrate is returned to the clarifiers. The cold well
of the cooling tower provides the point of treatment system blowdown.
Plant G-2 - Figure VII-25 (Section)
Wastewaters from the 10" and 12" bar mills first pass through scale
pits. Scale pit effluents are pumped to two settling basins equipped
with waste ejectors and oil skimmers. Overflow from the settling
148

-------
basins is pumped to three wastewater strainers. Strainer backwash
water is conveyed to a dirty water sump which follows the scale pits.
Strainer effluent is recycled to the process after first passing
through a cooling tower. Makeup water from the river is added to the
inlet sump. There is no discharge from this system.
Plant H-2 - Figure VII-26 (Section)
Rod mill wastewaters are discharged to a scale pit. The effluent from
the scale pit is pumped to five cyclones which discharge to a
receiving stream. This system is once-through with no recycle.
Plant 1-2 - Figure VII-27 (Section)
The wastewater treatment system for this plant is a combination system
treating both section mill and pickling wastewaters. Rod mill
wastewater is first sent to a scale pit. The scale pit effluent is
then discharged to a terminal settling lagoon which receives pickling
wastewater as well. All process effluent is discharged to a receiving
stream.
Plant J-2 - Figure VII-28 (Flat)
The wastewater treatment system for Plant J-2 serves two carbon steel
hot strip and sheet mills, one, an 84" hot strip mill and the other,
an 80" hot strip mill.
The wastewaters from the 84" hot strip mill reheat furnaces, roughing
mill stands, and motor room flume flush are discharged to a roughing
scale pit system with both primary and secondary scale pits. The
overflows from these scale pits are discharged to a receiving stream.
Oily wastewaters from the 84" mill motor room are discharged to a
terminal treatment system which removes the oil and pumps the water to
the receiving stream. The 84" mill finishing stands and a portion of
the runout tables wastewaters are pumped to the 84" finishing scale
pit. Also, the overflows from the 80" finishing and roughing scale
pits are routed to this same scale pit. The balance of the 84" hot
strip runout table and coilers wastewater is discharged to a three
compartment scale pit. Part of this scale pit's effluent is taken to
the 84" mill finishing-scale pit, while the remaining portion is
discharged to a receiving stream. Finally, the overflow from the 84"
finishing scale pit is pumped to gravity media filters and then
discharged to a receiving stream. Filter backwash water is treated in
a clarifier and returned to the 84" mill finishing scale pit.
Clarifier underflow is dewatered by vacuum filters.
Plant K-2 - Figure VII-29 (Flat)
The wastewater treatment system for this operation serves a carbon
steel 160" plate mill. Wastewaters from the 160" plate mill pass
through primary scale pits and are discharged into two secondary scale
pits. The primary scale pits are baffled and have oil removal and
collection facilities. The sludge from the secondary scale pits is
discharged to a thickener and the thickener overflow is returned to
the secondary scale pits. The effluent from these scale pits is
149

-------
pumped through high rate media filters and then recycled to the plate
mill after first passing through a cooling tower. The treatment
system blowdown is discharged to a receiving stream.
Plant L-2 - Figure VII-30 (Primary and Flat)
Primary and flat product rolling mill wastewaters are treated by this
combination system. Treatment initially consists of primary scale
pits equipped with oil collection facilities. The scale pit overflow
is discharged to a mixing tank where lime and ferric sulfate are
added. From the mix tank, wastewaters enter flocculator tanks which
in turn discharge to flocculating clarifiers. The clarifier overflow
is recycled to the mills after passing through a cooling tower where
makeup water is added. Some of the recycle flow is blown down and
some is also used as makeup water to fume scrubbers at the pickling
facilities. Clarifier underflow is dewatered by vacuum filters with
the filtrate being returned to the flocculator tanks.
Plant M-2 - Figure VII-31 (Flat)
The treatment system for this operation treats wastewaters from an 80"
carbon steel combination hot strip and sheet mill. Wastewaters from
the primary roughing mill stands and the secondary roughing mill
stands are pumped to primary scale pits and then to a mixing tank for
lime and ferric sulfate addition. Settling of the wastewater is
accomplished in clarifiers where skimmed oils are collected and routed
to an oil separator tank. The clarifier effluent is discharged to a
receiving stream and the sludge is dewatered by vacuum filters.
Plant N-2 - Figure VII-32 (Flat)
The primary scale pit receives wastewaters from the roughing and
finishing mill stands of this hot strip mill and then discharges the
wastewaters to pressure media filters. Strip cooling and coiler
wastewater is also discharged to a primary scale pit but is then
recycled after first passing through a cooling tower. A blowdown from
the cooling tower is delivered to the filters. Filtered water is
recycled to the mill roughing and finishing stands. A clarifier
receives the filter backwash. The clarifier overflow is returned to
the filter inlet while the clarifier underflow is dewatered by vacuum
filters. A blowdown is discharged to a POTW.
Plant GG-2 - Figure VI1-33 (Pipe and Tube)
This plant is a seamless pipe mill producing specialty steel seamless
pipe from reheated billets. This pipe mill practices 100% recycle and
utilizes primary sedimentation (scale pits), oil separation (API
separators) and sedimentation in a lagoon. Wastewaters are recycled
to the pipe mill from the lagoon.
Plant I1-2 - Figure VI1-34 (Pipe and Tube)
This plant is a butt welded pipe mill producing carbon steel pipe from
skelp. The butt welded pipe mill mixes noncontact and contact coolina
waters and discharges its wastewaters on a once-through basis to a
150

-------
double compartment scale pit which is equipped with oil skimming
facilities. The scale pit effluent is then pumped to radial, media
type pressure filters. The filtered water is discharged to a final
settling lagoon. The filter backwash is discharged to a clarification
tank where neutralization is provided along with polymer addition.
The clarification tank then discharges back into the scale pits. The
filtered effluent is discharged to a receiving stream.
Plant JJ-2 - Figure VII-35 (Pipe and Tube)
This plant is a butt welded pipe mill producing carbon steel pipe from
skelp. The pipe mill mixes pickling rinse wastewaters with primary
scale pit effluent and discharges the mixed wastewaters to a settling
lagoon. The lagoon overflow is pumped to a storage tank which
recycles all of the wastewaters to the butt welded pipe mill. Service
makeup water and lime are added to the recycled water. Solids from
the scale pit and lagoon are landfilled.
Plant KK-2 - Figure VII-36 (Pipe and Tube)
This plant is a butt welded pipe mill producing carbon and low alloy
pipe from skelp. This pipe mill provides once-through treatment with
primary and secondary scale pits. The primary scale pit has oil
skimming facilities and is also equipped for the addition of polymer.
TYie secondary scale pit discharges to a receiving stream.
PI aftt 081 - Figure VI1-37 and VII-38 (Primary and Section)
The wastewater treatment system for this plant provides treatment for
a combination of hot forming mill (primary and section rolling mills),
combination acid pickling, kolene and hydride descaling, wire pickling
and coating, and continuous alkaline cleaning wastewaters.
The wastewaters from the primary and section rolling mills are
discharged to a "Lamella" separator after passing through primary
scale pits. The overflow from the separator is recycled to the
primary and section rolling mills. The blowdown from the separator is
discharged to a central wastewater treatment system which also treats
the wastewaters described above. Makeup water is added to the
"Lamella" separator and section mills as required. It should be noted
that the effluent analytical data presented in this section's tables
represent only the discharge from the "Lamella" separator. These data
thus depict hot forming wastewater treatment only.
Plant 082 - Figure VI1-39 (Primary and Flat)
The wastewater treatment system for this plant serves a combination of
carbon and specialty steel primary (slab) mills and flat (plate)
mills. The mills are designated as 112V120", 140", and 140"/206"
combined. Samples were collected to differentiate between carbon and
specialty steel production on the same mills. A 112" primary mill can
either roll ingots or slabs to heavy plate which, in turn, is the feed
stock to a 120" plate mill which provides a further reduction in plate
size. A 140" primary mill can also roll either ingots or slabs into
heavy plate which, in turn, is the feed stock for a 206" plate mill.
151

-------
Wastewaters from the 112" mill and the 120" plate mill pass through
primary scale pits and are discharged into a common secondary scale
pit. Likewise, wastewaters from the 140" and the 206" plate mills
flow to primary scale pits and subsequently to a combined secondary
scale pit. Overflows from the secondary scale pits are discharged to
three parallel settling basins. The effluent from the settling basins
is then delivered to a set of gravity filters. The filtered effluent
is discharged to a receiving stream. Filter backwash is delivered to
a backwash settling basin which discharges to the three parallel
settling basins.
Plant 083 - Figure VII-40 (Primary, Section, and Flat)
The wastewater treatment system for Plant 083 is a central facility
which serves several hot forming mills and steelmaking facilities
(i.e., BOF, electric arc furnace). The hot forming mills include
primary, section, and plate rolling mills, (blooming mill, structural
mill, plate mill, and rod mill). The blooming mill wastewaters are
discharged to a main pump station after passing through primary scale
pits equipped with oil removal facilities. The rod mill has its own
treatment system and discharges only a blowdown to the central
treatment system. Other mill wastewaters discharge to the main pump
station. The combined wastewaters undergo treatment in flocculating
clarifiers and are then recycled through a cooling tower to the
various mills.
A portion of the clarifier effluent is blowndown to a POTW. The
clarifier underflow is pumped to a thickener which, in turn,
discharges to a sludge decant tank. After decanting, sludge is hauled
away by private contractor. Overflow from the decant tank is returned
to the thickener.
Plant 086 - Figure VII-41 (Flat)
The wastewater treatment system for these mills (an 80" hot strip mill
and a 160" plate mill) is a central treatment facility serving
steelmaking operations and two hot forming mills.
Wastewaters from the 80" hot strip mill primary and secondary roughing
stands pass through a primary scale pit. The effluent from the
primary scale pit is recycled to the roughing mill flumes. The
roughing mill scale pit also has an overflow to the finishing scale
pit. The two scale pits are separated by a concrete wall and are
equipped with oil baffles and collectors. The overflow from the
finishing scale pit is discharged to the central treatment clarifiers.
The 160" plate mill wastewaters pass through a primary scale pit,
which also discharges to the clarifiers. Some of the scale pit
effluent is recycled to the plate mill stands for flume flushing. The
160" plate mill also has in-line plate heat treatment facilities in
which reheated plates pass through a quenching station. Some of the
quench pit overflow is delivered to the central treatment facility via
two sump pump stations on either end of the quench pits.
152

-------
The central treatment clarifier overflow is discharged to two
twenty-five million gallon terminal lagoons which in turn discharge to
a receiving stream. During the time of sampling, the plant was in the
process of installing a recycle pump system for the purpose of
returning the terminal lagoon effluent to the mill complex.
Plant 087 - Figure VII-42 (Section, Flat, and Pipe and Tube)
This plant employs a central treatment system which serves a merchant
mill, butt weld pipe mill, blooming mill, hot scarfer, and a hot strip
mill. Wastewaters from the various sources first pass through their
individual scale pits, which are equipped with baffles and oil removal
equipment, and are then pumped to clarifiers. Coagulant aids are
added at the clarifier inlet to assist in settling. The clarifier
overflow is discharged to a receiving stream and the underflow is
dewatered by vacuum filters. At the time of sampling all of the
clarifier overflow was discharged to a receiving stream, although
provisions have been made for a future recycle system.
Plant 088 - Figure VI1-43 and VI1-44 (Primary, Section, and Pipe and
Tube)
The wastewater treatment system for Plant 088 serves a combination of
hot forming mills and steelmaking facilities (i.e., vacuum degassing,
electric arc furnace). The hot forming mills include primary,
section, and seamless pipe and tube operations (blooming mills, three
bar mills, and a rod mill).
The wastewaters from the 32" and 34" bar, blooming, billet, and pipe
and tube mills are pumped to a collection sump after passing through
primary scale pits equipped with oil collection facilities. The
wastewaters are then pumped to deep bed pressure filters. The filter
effluent is discharged to a pump station from where all of the
wastewaters are recycled to the mills. The steelmaking, vacuum
degassing, and other wastewaters are directed to the same pump station
for reuse throughout the plant. Filter backwash is conveyed to
clarifiers after passing through backwash storage and rapid mix tanks.
Other rod mill, bar mill, and seamless tube finishing mill wastewaters
are also pumped to the filter backwash clarifiers. The clarifier
overflow is conveyed to the recycle pump station for return to the
processes. The clarifier underflow is delivered to a thickener for
further settling. The thickener underflow is dewatered by vacuum
filtration while the thickener effluent is returned to the clarifiers.
Makeup river water is added at the recycle pump house.
Wastewaters from the 10" rod and 11" bar mills are discharged to a
common scale pit and then to a drag link conveyor. A large portion of
the drag link conveyor effluent is recycled to the process after first
passing through a retention basin. The rest of the drag link conveyor
effluent is pumped to the filter backwash rapid mix tank and
clarifiers. The clarifier overflow is recycled to the various mills.
Clarifier underflow is conveyed to a thickener and is further
dewatered by a vacuum filter. The two systems noted above blow down a
small amount of wastewater (0.5%) to the 14" bar mill water system
described below.
153

-------
Separately, wastewaters from the 14" bar mill are first treated by two
sets of scale pits (refer to Figure VII-44). One set receives
wastewaters from the hot saws, shears, stands, pull rods, and bar
rotators and then recycles these wastewaters to the process. The
second set of scale pits accepts bar mill stands effluent and skip
cooling water. A partial recycle is taken from the scale pits back to
the process. The remainder of the scale pit effluent is pumped to a
mix tank which then discharges to a clarifier. A large portion of the
clarifier effluent is recycled to this bar mill. The remaining
clarifier effluent is discharged to a POTW system. The clarifier
underflow is discharged to a sludge pond.
154

-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
Symbols
Operating Modes
1.	OT
2.	Rt,s,n
Once-Through
Recycle, where t '
s '
n «
t:
type waste
stream recycled
X recycled
U
T
Untreated
Treated
4.
p
Process Wastewater
X
of
raw waste
flow
F
Flume Only
X
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.
X
of
FH flow

3. REt,n
BDn
Reuse, where t ¦ type
n ¦ X of raw waste flow
t: U ¦ before treatment
T * after treatment
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
155

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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 %
of makeup
t: DW ¦ Dirty Water
CW ¦ Clean Water
D.
23.
EME
Evaporation, Multiple Effect
24.
ES
Evaporation on Slag
25.
EVC
Evaporation, Vapor Compression
Treatment
Technology
30.
SC
Segregated Collection
31.
E
Equalization/Blending
32.
Scr
Screening
33.
OB
Oil Collecting Baffle
34.
SS
Surface Skimming (oil, etc.)
35.
PSP
Primary Scale Pit
36.
SSP
Secondary Scale Pit
37.
EB
Emulsion Breaking
38.
A
Acidification
39.
AO
Air Oxidation
40.
GF
Gas Flotation
41.
M
Mixing
42.
Nt
Neutralization, where t ¦ type
t: L " Lime
C ¦ Caustic
A » Acid
W ¦ Wastes
0 ¦ Other, footnote
156

-------
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 s 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)
157

-------
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 a 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
158

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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
% 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
159

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TABLE VI1-2
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES SURVEY
	HOT FORMING-PRIMARY	
RAW WASTEWATERS















Reference Code
0I12B-01,02(1*
01I2B-03(1)
0684H
(1)
0946A*1 *

0060(1)
0248B(1*
0020B
Plant Code

A~?2)

B-2

C-2


D-2

h~h)

°(3)
E
Sampling Point(s)

4W'

3

1


1 + 2



8V '
6
Flow (gal/ton)

890

510

780


700

610

535
2740

mg/1
#/1000#
Wft/1
#/1000#
ng/1
#/1000#
ng/1
#/1000#
me/1 #/1000#
ng/1
#/1000#
mg/1 #/1000#
Suspended Solids
103
0.38
61
0.13
26

0.085
49

0.14
16
0.041
161
0.36
109 1.24
Oi1 & Grease
17.3
0.064
151
0.32
6.8

0.029
19

0.055
12
0.031
59
0.13
28 0.32
pll (Units)

7.6
8.0-
ft
00
7.
00
i
&
1
7
00
1
00
2
7
6-8.1
1.
6-6.5
7.0-7.5
Chromium
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
NA
* *
Copper
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
NA
* *
I,cad
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
NA
0.03 0.00034
Nickel
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA*
NA
NA
0.19 0.0022
Zinc
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
NA
0.04 0.00046
EFFLUENTS















Reference Code
0112B-01,02
0112B-03

0684H

0946A

0060

0248B
0020B
Plant Code

A-2

B-2

C-2


IV-




D

Sampling Point(s)

2(2)

2

2


6
2)

2

9
5
Flow (gal/ton)

520

510

780


460

10.3

535
2740
C&TT
PSP,
>S ,Se t. Cone
PSP,SS,Set.Cone
PSP
CL.FDS.OT
PSP
.CL.FDP,
PSP
.FLL.FLP.CL
PSP.SS.OT
PSP,CL,FDPt0T

FDP.RTP42
FDP.OT



RTP35
CT, RTP98




"g/1
1/1000#
reg/1
#/1000#
wg/1
#/1000#
"g/1
#/1000#
mg/1 #/1000#
or/1 #/1000#
rag/1 */1000#
Suspended Solids
1.6
0.0035
2.3
0.0049
5

0.016
23

0.044
4.9
0.00021
104
0.23
13 0.15
Flow (gal/ton)
1.7
0.0037
2.2
0.0047
6.7

0.022
8.3

O.0J6
7.9
0.00034
52
0.12
2.0 0.023
pH (Units)
7.
6-8.0
7.7
-7.8
7.
6-7.
7
8
.1-8
2
8
6-8.7
2.
5-6.4
5.8-6.6
Chromium
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
NA
~ *
Copper
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
NA
* *
l.e.-,d
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
NA
0.03 0.00034
Nickel
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
HA
* *
Zi nc
NA
NA
NA
NA
NA

NA
NA

NA
NA
NA
NA
m
0.03 0.00023
(1)	Data includes flow from scarfing operations.
(2)	Sample includes wastewaters from hot forming operations other than primary.
(3)	Sample of inlet to primary scale pit.
NA: Not Analyzed
* : Concentration is <0.010 rag/1

-------
TABLE Vil-2
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES SURVEY
HOT FORMING-PRIMARY
PAGE 2		 	
RAW WASTEWATERS
Reference Code
Plant Code
Stapling Point(s)
0248A(1)
H
7+8v
2480
b(3)
0256K
K
11
5600
(3)
0432J
M
4350
0684D
3420
0240A
R
6
4780
(3)
<*>
Average
2280

"*/!
#/1000#
me/1 #/1000#
mg/1 #/1000#
mg/1
#/1000#
mg/1
#/1000#
mg/1
#/1000#
Suspended Solids
158
1.63
ANALYTICAL
NO SEPARATE
48
0.68
81
1.61
81
0.63
Oil & Grease
5.5
0.057


12.8
0.18
2.9
0.058
32
0.12
pH (Units)
5.8-6
.2
DATA
SAMPLE OF
7.0-7
.6
7.4-7
.6
1.6-8.
,3
Chromium
*
*
HOT
PRIMARY
0.54
0.0077
*
*
0.14
0.0020
Copper
0.02
0.00021


*
*
0.01
0.00020
0.01
0.00017
Lead
0.03
0.00031
AVAILABLE
WASTEWATERS
0.03
0.00043
0.03
0.00060
0.03
0.00042
Nickel
*
*


0.17
0.0024
0.07
0.0014
0.11
0.0015
Zinc
0.03
0.00031


0.08
0.0011
0.02
0.00040
0.04
0.00057
EFFLUENTS

Reference Code ;
Plant Coda :
Sampling Point(s):
Flow (gal/ton) :
C&TT :
0248A
H
9
2480
PSPt0T

0256K
K
12
800
PSP,SS,RUP86
0432J
"(2)
68
PSP,SSP,RUP90
RTP8.5
0684D
j(2)
3420
PSP,SS,0T
0240A
1(2)
4780
PSP,SL,0T

mil

#/1000#
re/1 #/1000#
re/1 #/1000#
mg/1
#/1000#
me/1 #/1000#
Suspended Solids
137

1.41
ANALYTICAL
35 0.0099
29
0.41
45 0.90
Oil & Grease
2.3

0.024

27 0.0077
4.0
0.057
5.3 0.036
pH (Units)
6
2-6.3
DATA
5.8-6.3
7
2-7.6
7.4-7.5
Chromium
*

*
NOT
0.24 0.00007
*
*
* *
Copper
*

*

0.04 0.00001
0.02
0.00028
0.01 0.00020
I-ead
0.03

0.00031
AVAILABLE
NA NA
0.03
0.00043
0.03 0.00060
Nickel
*

*

0.15 0.00004
0.63
0.0090
0.05 0.0010
Zinc
0.01

0.00010

0.02 Neg.
0.07
0.0010
0.02 0.00040
(1)	Data includes flow from scarfing operations.
(2)	Staple includes wastewaters from hot forming operations other than primary.
(3)	Sample of inlet to primary scale pit.
(4)	In calculating averages, all * data is included as 0.01 mg/1 concentration, and the load equivalent to 0.01 mg/1
is calculated for inclusion in the load averages.
NA $ Not Analyzed
* : Concentration is <0.010 mg/1
Neg.: Negligible. Load is <0.00001 #/l000#

-------
TABLE VII-3
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
TOXIC POLLUTANT SURVEY
	HOT FORMING-PRIMARY	
RAW WASTEWATERS
Reference Code
Plant Code
Sampling Point(s)
Flow (gal/ton)
Suspended Solids
Oil & Crease
pH (Units)
Chromium
Copper
Lead
Nickol
Zinc
0496(1>
082-140"
mg/1	#/1000#
83	0.059
75	0.053
7.7-7.8
0.05	0.00004
0.19	0.00013
0.40	0.00028
0.57	0.00040
0.08	0.01006
0496(1)
082-140"/206"
"l602
mg/1	f/1000#
54	0.10
16	0.031
2.6-8.9
0.05	0.00010
0.30	0.00058
0.07	0.00013
0.22	0.00042
0.10	0.00019
0860H
083
E
320	
mg/1 »/1000»
244	0.33
35	0.047
7.0-7.1
0.12
0.00016
0.53
0.00071
0.07
0.00009
0.09
0.00012
0.10
0.00013
0684H 1'
088
B+C
1700	
ng/1 */1000*
24	0.17
6.5	0.046
7.9
0.04	0.00028
0.21	0.0015
0.30	0.0021
0.12	0.00085
0.05	0.00035
0176
081
B
760	
ng/1 »/1000*
29 0.092
165 0.52
7.9-8.1
0.13
0.00041
0.97
0.0031
0.81
0.0026
0.55
0.0017
0.14
0.00044
Average
680	
mg/1 #/10000#
87	0.15
60 0.14
2.6-8.9
0.08
0.00020
0.44
0.0012
0.33
0.0010
0.31
0.00070
0.09
0.00023
Overall^^
Average
1810
¦°g/l
#/1000#
83
0.47
41
0.13
oo
1
.9
0.10
0.0010
0.24
0.00074
0.20
0.00076
0.22
0.0011
0.07
0.00038
EFFLUENTS
to
Reference Code
0496

0496
0860H
0684H
0176
Plant Code
082-140"
082
-140"/206"
083

088

081
Sampling Point(s)
O.+P

46P3

B

(B+C/M)P
E
Flow (gal/ton)
170


12

5

51
C&TT
PSP.SSP,
Set.Basin,FDMG
PSP.SSP
Set.Basin,FDMG
PSP,CL,i
CT, RTP96
PSP,FDP
,RTP99.7
PSP,TP,RTP93

mg/1 #/1000#
mg/1

t/1000*
ng/1
#/1000#
ng/1
#/1000#
ng/1 #/1000#
Suspended Solids
1 0.00071
1

0.0019
9
0.00045
2
0.000038
18 0.0038
Oil & Crease
12 0.0085
9

0.017
10
0.00050
4
0.00018
10 0.0021
pH (Units)
7.4-7.5

J.h

7.1-7
.6
7.6-7,
.8
7.8-8.1
Chromium
0.03 0.00002
0.04

0.00008
0.13
Neg.
0.03
Neg.
0.08 0.00002
Copper
0.04 0.00003
0.04

0.00008
0.04
Neg.
0.02
Neg.
0.76 0.00016
Lead
0.05 0.00004
0.05

0.00010
0.05
Neg.
0.05
Neg.
0.32 0.00007
Nickel
0.05 0.00004
0.02

0.00004
0.02
Neg.
0.02
Neg.
0.48 0.00010
Zinc
0.03 0.00002
0.02

0.00004
0.07
Neg.
0.02
Neg.
0.10 0.00002
(1)	Data includes flow from scarfing operations.
(2)	Average of all values from Tables VII-2 and VII-3.
Neg,: Negligible. Load is less than 0.00001 #/1000#.

-------
TABLE VII-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
	HOT FORMING-SECTION	
RAM WASTEWATERS













Reference Code:
0424
(01-03)
0248A & B
0256K
0432J
0176-04
0176 (01-03)
0684D
(02 & 03)
240A (01 & 02)
Plant Code ;

C
H

K

M
0 (Rod Hill)
0( Rolling

Q
R










Mills)



Smple Point :

8
13

10

6

10
1

8
4
Flow (gal/ton):

S260
4210

1470

670
12
,860
4970

1780
7950

lb./
lbs/

lbs/

lbs/

lbs/
lbs/

lbs/
lbs/

=6/1
1000 lbs
¦e/l 1000 lbs
¦sZi
1000 lbs
sZi
1000 lbs
•Sil
1000 lbs
tm/l 1000 lbs
¦g/1
1000 lbs
¦k/1 1000 lbs
Suspended Solids
3.3
0.86
54 0.95
93
0.57
54
0.15
113
6.060
15 0.31
43
0.32
32 1.061
Oil & Grease
1.9
0.42
9.2 0.16
4.7
0.029
9.9
0.020
0.2
0.011
4.9 0.10
1.5
0.011
3.8 0.13
pH (Units)
3.2
-7.0
6.0-6.3
7.2
-7.5
6.
3-6.5
7.4
-7.5
8.3-8.5
7.
4-7.6
6.7-6.8
Chroniua
*
*
* *
*
*
0.07
0.00020
*
*
* *
0.03
0.00022
* *
Copper
*
*
* *
0.05
0.00030
0.04
O.OOOU
0.01
0.00054
0.08 0.0017
0.03
0.00022
* *
Lead
0.03
0.00066
0.03 0.00053
0.03
0.00018
NA
NA
0.03
0.0016
0.03 0.00062
0.03
0.00022
0.03 0.00099
Nickel
0.14
0.0031
* *
0.82
0.00050
0.11
0.00031
0.29
0.16
0.43 0.0089
*
*
0.06 0.0020
Zinc
0.02
0.00044
0.02 0.00035
0.02
0.00012
0.012 0.000034
0.02
0.0011
0.03 0.00062
0.06
0.00045
0.02 0.00066
TREATED EFFLUENT













Reference Code:
0424
(01-03)(l)
0248A 6 B
0256K
0432J
0176-04(2)
0176 (01-03)(2)
0684D(02 t 03)(1) 240A (01 & 02)
Plant Code :

C
H

K

M

0
0

Q
R
Saaple Point :
(8*(fr»6»7))l
13

10

6

11
3
(8/4)(5)
8
Flow (gal/ton):

5260
4210

1470

140

320
270

1780
7950
C4TT :
PSP,SB(UNK),SS
PSP.OT
PSP.OT
PSP
SS.KTP80,
SL,PSP,RTP97,
SSP,SS,TP
psp,or,cirr(45)
PSP,SSP,SL(UNK)

RET84. BD16




BD20

BD3
CT.RTP94.BD6


OT


lbs/
lbs/

lbs/

lbs/

lbs/
lbs/

lbs/
lbs/

¦g/1
1000 lbs
M/l 1000 lb«
¦g/1
1000 lbs
n/l
1000 lbs
n/l
1000 lbs
¦g/1 1000 lbs
¦8/1
1000 lbs
¦g/1 1000 lbs
Suspended Solids
28
0.66
54 0.95
93
0.57
54
0.032
35
0.047
57 0.065
29
0.20
45 1.59
Oil A Grease
5.4
0.058
9.2 0.16
4.7
0.02 9
9.9
0.0058
0.7
0.00094
12.3 0.014
4.0
0.010
5.3 0.18
pH (Units)
5.0
-7.7
6.0-6.3
7.2
-7.5
6
3-6.5
7
6-8.1
8.2-8.5
7.2
-7.6
7.4-7.5
Chromium
0.04
0.0
* *
*
*
0.07
0.000041
0.003 Neg.
* *
*
*
* *
Copper
0.03
0.0
* *
0.05
0.00030
0.04
0.000023
0.01
0.000013
0.04 0.000045
0.02
0.00040
0.01 0.00033
Lead
0.03
0.0
0.03 0.00053
0.03
0.00018
NA
HA
0.03
0.000040
0.03 0.000034
0.03
0.00050
0.03 0.00099
Nickel
0.12
0.0057
* *
0.82
0.00050
0.11
0.000064
0.32
0.00043
0.44 0.00050
0.63
0.0
0.04 0.0013
Zinc
0.03
0.00015
0.02 0.00035
0.02
0.00012
0.012 Neg.
0.02
0.000027
0.02 0.000023
0.07
0.00094
0.02 0.00066

-------
TABLE VIl-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
HOT FORMING-SECTION
PACE 2				__ _ 	
RAW WASTEWATERS
Reference Code :
Plant Code	:
Sample Point(s):
Flow (gal/ton) :
Suspended Solids
Oil & Grease
pH ( Un i t s )
0112 B
A-2
4
600
0291C
D-2
(4*5i3)
6420
lbs/
1000 lbs
103 0.26
17.3 0.044
7.6
tag/ 1
41 1.10
18.5 0.49
8.0-8.1
0196a (09 &
E-2
10)
(2+36>
4690
lbs/
1Q00 lbs
56/1
lbs/
1Q0Q lbs
60 1.13
15.1 0.28
8.2-8.3
0384A-06
F-2
2
1910
mg/1
41 0.33
5.9 0.047
7.7
Chromium
NA
NA
NA
NA
NA
NA
NA
NA
Copper
NA
NA
NA
NA
NA
NA
NA
NA
Lead
NA
NA
NA
NA
NA
NA
NA
NA
Nickel
NA
NA
NA
NA
NA
NA
NA
NA
Zinc
NA
NA
NA
NA
NA
NA
NA
NA
0640A (01 & 02)
G-2
1
14,020
lbs/
1000 lbs
mg/1
lbs/
1000 lbs
68
3.'
2.7
o.:
7
.4-8.(
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0432A-04
H-2
3
6950
mg/1
96 2.78
18.6 0.54
6.6-6.8
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
08560
1-2
1
5010
lbs/
1000 lbs
wg/1
185 3.86
122 2.54
7.6-7.7
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Average
5657
lbs/
1000 lbs
lbs/
ma/1 1000 lbs
69 1.52
15.7 0.33
3.2-8.5
0.030 0.00036
0.03 0.00069
0.23 0.022
0.025 0.00047
CTi
TREATED EFFLUENT
Reference Code:
Plant Code :
Sample Point :
Flow (gal/ton):
C&TT	:
0112B
A-2
2
360
PSP.CL.FDS
RTP40, BD60
0291C
D-2
6
4490
PSP.T.SS.FD,
RTP30, RET70
0196A (09 & 10)
E-2
5
1640
PSP.CL.FDS rCT,
SL.RTP65.BD35
0384A-06
F-2
3
140
PSP.SSP.SS.CL.
FLL.FLP.NW.VF,
CT.RTP98.BD2
02)
0640A(01 &
G-2
2
0
PSP.SS.SL.FD.
CT.RTP100
(4)
0432A-04
H-2
2
6590
PSP.CY.OT
08560
1-2
5
5010
PSP.SL.OT
58/i
lbs/
1000 lbs
mt/i
lbs/
1000 lbs
"g/'
lbs/
1000 lbs
Suspended Solids
1.7
0.0043
23.3
0.44
10.0
0.1
Oil & Grease
1.7
0.0043
8.3
0.16
9.8
0.1
pH (Units)
7.
6-8.0
7.
9-8.2
8.
3
Chromium
NA
NA
NA
NA
NA
NA
Copper
NA
NA
NA
NA
NA
NA
Lead
NA
NA
NA
NA
NA
NA
Nickel
NA
NA
NA
NA
NA
NA
Zinc
NA
NA
NA
NA
NA
NA
ag/1
29
8.3
lbs/
1000 lbs
0.017
0.0048
7.8-8.5
mg/1
lbs/
1000 lbs
ag/1
lbs/
1000 lbs
47 Complete 71 1.95
2.3 Recycle 17.8 0.49
Operation
7.4-8.1	6.8-7.0
lbs/
Mg/1 1000 lbs
39
14.0
0.81
0.29
6.7
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
(1)	The lbs/1000 lbs value for this operation cannot be derived directly from the concentrations and flow rate shown.
See the Section VII text for further explanation.
(2)	The effluent sample results shown are for an intermediate sample point. The discharge from the noted treatment
components receives additional treatment in a central treatment system.
(3)	Flow rate (gallons/ton) is based on 2 turns/day operation.
(4)	The analysis for the treated effluent saaple for this operation is on the wastewater that is recycled back to the process.
NA : Not Analysed
HD : Hoc Detected
Weg.j Value for lbs/1000 lbs calculation is less than 0.00001
*: Value is less than 0.010 mg/1
Por the definition of C&TT Codes see Table VII-1

-------
TABLE VI1-5
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
TOXIC POLLUTANT STUDY
	HOT FORMING-SECTION	
RAW WASTEWATERS
Reference Code
Plant Code
Saaple Point(#)
Flow (gal/ton)
0176-(01-03)
08l-#l Mills
C
3S70		
-fiZi
lbs/
1000 lbs
0860H-02
083-34" Hill
C
4720
-SZl
0860H-03
083-Rod Mill
K
6930
lbs/
1000 lbs
SZl
lbs/
1000 lbs
0432A-02
087-14" Mill
D
6340
SZl
lbs/
1000 lbs
0684H-(06&07)
088-10*711" Mill
T
3400
ill
0684H-02
088-34" Mill
F
580
lbs/
1000 lbs
iZl
lbs/
1000 lbs
0684H-01
088-36" Mill
IHF
4710
ill
lbs/
1000 lbs
Suspended Solids
Oil & Grease
pD (Units)
14	0.21
12 0.18
7.8-8.1
35
47
0.69
0.93
6.9
259 7.48
38 1.10 *
7.3-7.5
62
4
1.64
0.11
7.1-7.4
52	0.74
33 0.47
7.3-7.5
20
2
0.048
0.0048
.6-7.8
22 0.43
2.6 0.052
7.6-8.0
Chroaiua
Copper
Lead
Nickel
Zinc
0.035
0.60
0.22
0.50
0.040
0.00052
0.0089
0.0033
0.0074
0.00060
0.11
0.090
0.050
0.020
0.080
0.022
0.018
0.00098
0.00039
0.0016
0.045
0.14
0.050
0.020
0.080
0.0013
0.0040
0.0014
0.00058
0.0023
0.24
0.050
0.79
0.50
0.26
0.0063
0.0013
0.021
0.013
0.0069
0.030
0.070
0.050
0.090
0.77
0.00043
0.00099
0.00071
0.0013
0.011
0.030
0.14
0.050
0.055
0.045
0.000073
0.00034
0.00012
0.00013
0.00011
0.030	0.00060
0.14	0.0028
0.050	0.00098
0.045	0.00095
0.030	0.00058

-------
TABLE VI1-5
SWMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
TOXIC POLLUTANT STUDY
HOT FORMING-SECTION
PACE 2	
RAM WASTEMATOLS
Reference Code
Plant code
Saaple Point(s)
Flow (gal/ton)
0684H-03
088-32" Mill
C
930
0684H-05
88-14" Hill
U+Y
4800
0176-04
081-No.4 Hill
r
8230
Average
	4420
Overall Average
	5160
(4)
lb»/
lb./
Iba/
lb*/
lba/


1000 lba
¦bZ!
1000 lba
l/l
1000 lba
5&ZI
1000 lb*
¦t/i
1000 lba
Suspended Solid*
31
0.12'
80
1.61
84
2.88
65.9
1.58
67.8
1.54
Oil 4 Grease
12
0.047
68
1.38
253
8.68
47.2
1.30
28.3
0.72
pH (Units)
7.7-7
.9
7.0-7.5
7.1-
7.3
Co
f
0B
.1
3.2-8.5
Chromium
0.030
0.00012
0.030
0.00061
0.090
0.0031
0.067
0.0035
*
*
Copper
0.080
0.00031
0.075
0.0015
0.13
0.0045
0.15
0.0043
0.076
0.0020
Lead
0.050
0.00019
0.066
0.0013
0.050
0.0017
0.14
0.0041
0.073
0.0020
Nickel
0.055
0.00021
0.18
0.0037
0.83
0.028
0.23
0.0057
0.23
0.010
Zinc
0.055
0.00021
1.23
0.025
0.085
0.0029
0.27
0.0051
0.13
0.0024
cn
TREATED EFFLUEHT
Reference Code
Plant Code
Saaple Point(a)
Flow (gal/ton)
C&TT
0684H-03
088-32" Hill
(C/H)(r>
2.8
PSP,FD(UIK),CL,T,
068*8-05
088-14** Hill
AC
10
PSP,CT,CL,RUP44
BTP55.7.800.3
0176-04
081-Ho.4 Mill
6
MO
SL,BTP96,ID4


lba/

lbs/

lb*/

9BZi
1000 lba
-ftli
1000 lba
sUi
1000 lbs
Suspended Solida
2
0.000025
87
0.0036
23
0.033
Oil t Greaae
4
0.00018
15
0.00063
8
0.011
pH (Units)
7.6-

7.5

7.7-7
.9

7.8





ChroaliMi
0.030
Ne*.
0.12
Neg.
0.070
0.000099
Copper
0.020
Nag.
0.27
0.000011
0.075
0.00011
Lead
0.050
Nag.
0.095
Neg.
0.050
0.000091
Nickel
0.020
Neg.
0.47
0.000020
0.49
0.00069
Zinc
0.020
Nag.
2.2
0.000092
0.045
0.000064
(1)	The lba/1000 lba value for tbia operation cannot be derived directly froa the concentrations and flow rate ahown.
See the Section VII text for further explanation.
(2)	The effluent iMple result* shown ere for an intermediate sample point. Hie discharge from the noted treatment
components receives sdditionsl treatment in • central system.
(3)	Flsat 083 (Rod Hill) eventually achieves a dischsrge flow rate of 3.) gal/ton by recycling sdditionsl wsstewster
from s large centrsl treatment system. The effluent sample results shown sre for an intermediate sample point*
(4)	Average of all values on Tables V1I-4 and VII-5.
NAs NoC Analysed
HDi MoC Detected
Neg.: Value for lbs/1000 lbs cslculations is less thsn 0.00001
For the definition of C4TT codes see Table VII-1

-------
TABLE VII-6
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
HOT FORMING-FLAT: HOT STRIP AND SHEET
RAW WASTEWATERS











Reference Code:
02A8B
0020B
0176
0860B
0060

0384A
0396D

Plant Codes

D
E
0

J-2
L-2

M-2
N-2

Sa^>le Point(s):

#6
#7
#10
#l+#3*#4
#1

#2+#3
#6
Average
Flow (gal/ton):

3310
4520
12,800

7850
4520

8440
7270
6960

lbs/
lbs/
lbs/

lbs/
lbs/

lbs/
lbs/
lbs/

-&ZI
1000 lba
ae/1 1000 lbs
ae/1 1000 lbs
ssZl
1000 lbs
¦K/l 1000 lbs
sZi
1000 lbs
sac/1 1000 lbs
Wt/1 1000 lb;
Suspended Solids
57
0.79
42 0.79
113 6.03
16.6
0.54
16 0.30
25
0.88
54 1.64
46 1.57
Oil ft Grease
19.2
0.27
15.3 0.29
0.2 0.011
6.8
0.22
12.1 0.23
6.4
0.22
31 0.94
13 0.31
pH (Units)
6
.3
5.9-6.1
7.4-7.5
7.3-8.3
7.6-8.1
8.
.4
7.3-7.5
5.9-8.4
Chromium
*
*
* *
* *
NA
NA
NA NA
NA
NA
NA NA
* *
Copper
*
*
* *
0.01 0.00053
NA
NA
NA NA
NA
NA
NA NA
* *
Lead
NA
NA
0.03 0.00057
0.03 0.0016
NA
NA
NA NA
NA
NA
NA NA
0.03 0.0011
Nickel
0.13
0.0018
* *
0.29 0.015
NA
NA
NA NA
NA
NA
NA NA
0.14 0.060
Zinc
0.02
0.00028
0.07 0.0013
0.02 0.0011
NA
NA
NA NA
NA
NA
NA NA
0.04 0.00089
TREATED EFFLUENT
Reference Code:
Plant Code:
Saaple Point(s):
Flow (gal/ton):
C4TT:
0248B
D
#6
3310
PSP,OT
»g/i
0020B
E
#7
(l
(1)
)#5
#6»#7
4520
PSP,CL,FDBS,0T
lbs/
1000 lba

lbs/
1000 lb»
0176
0
#11
320
PSP.RUP-97.5,
BD-2.5
0860B
J-2
#2+#3+#4
7850
PSP,SSP,FLP,
Filter,CL,VF,OT
111
lbs/
1000 lbs
0060
L-2
#2
76
PSP.FLL.FLOl,
CL,VF,CT,
KTP-98.3.BD-1.7
e/i
lbs/
1000 lbs
g/l
lbs /
1000 lbs
0384A
M-2
#4
8440
PSP.CL,
VF,OT
03960
N-2
#7
PSP,CT,VF,CL,
F(UNK)S(UNK),
KTP-100
lbs/
g/1 1000 lbs
ill
lbs/
1000 lbs
Suspended Solids
57
0.79
13
0.18
35
0.047
8.1
0.26
5
0.0016
16
0.56
39
0
Oil & Grease
19.2
0.27
2.0
0.030
0.7
0.00093
5.7
0.19
7.9
0.0025
6.9
0.24
61
0
pH (Units)
6.
,3
5.8-
-6.6
7.6-
-8.1
7,
, 7-8.3
8.
6-8.7
8,
.4-8.5
7.
4-7
Chromium
*
*
*
*
0.003
0.000004
NA
NA
NA
NA
NA
NA
NA
0
Copper
*
*
*
*
0.09
0.00012
MA
NA
NA
NA
NA
NA
NA
0
Lead
NA
NA
*
*
0.03
0.000040
NA
NA
NA
NA
NA
NA
NA
0
Nickel
0.13
0.0018
*
*
0.32
0.00043
NA
NA
NA
NA
NA
NA
NA
0
Zinc
0.02
0.00028
0.03
0.00065
0.02
0.000027
NA
NA
NA
NA
NA
NA
NA
0
(1) The lhs/1000 lbs values for this operation cannot be derived directly from the concentration and flow rate values.
See the Section VII text for further explanation.
* : Concentration is less than 0.01 ag/l*
FLOl: Flocculation with ferric sulfate
NOTE: For definition of remaining C&TT codes, see Table VII-1.

-------
TABLE VIi-7
SUMMARY OF ANALYTICAL DATA FKOM SAMPLED PLANTS
TOXIC POLLUTANT STUDY
HOT FORMING FLAT: HOT STRIP & SHEET
RAVi WASTEWATERS
Reference Code:
Plant Code:
Sample Point(s):
Flow, (gal/ton):
Suspended Solids
Oil & Grease
pH (Units)
rag/1
46
10
0112D-02
086
R
5790
lbs/1000 lbs
1.11
0.24
04 32 A
087
C	Average
4800	5300
mg/1	lbs/1000 lbs mg/1	lbs/1000 lbs mg/1
Overall Average^^
6590
lbs/1000 lbs
8.0-8.1
57	1.14
6	0.12
7.4-7.6
52	1.13
8	0.16
7.4-8.1
47	1.47
12	0.28
5.9-8.4
Chromium
Copper
Lead
Nickel
Zinc
0.03
0.025
0.05
0.02
0.025
0.00072
0.00060
0.0012
0.00048
0.00060
0.170
0.045
0.200
0.0034
0.00090
0.0040
0.100
0.035
0.05
0.02
0.112
0.0024
0.00075
0.0012
0.00048
0.0023
0.06
0.15
0.067
0.0011
0.0058
0.0015
CJ>
00
TREATED EFFLUENT
Reference Code:
Plant Code:
Sample Poiut(s):
Flow, (gal/ton):
C6TT:
(2)
0112D-02
086
(F+C+I+E)D
5790
PSP,SS,CL,FLP,NL,NW,
CR,SL(UNK),0T
rog/1 lbs/1000 lbs
0432A
087
	c_
C+D+E
(2)
)F
4800
FLP,FLM,CL,SS,SCR,VF,
mg/1
lbs/1000 lbs
Suspended Solids
4
0.061
38
Oil & Crease
2
0.020
4
pH (Units)
7.6-7.
.9
7.4
Chromium
0.03
0.00018
0.174
Copper
0.02
0.00014
0.031
Lead
0.05
0.00019
+
Nickel
0.02
0.00044
~
Zinc
0.04
0.00028
0.206
0.73
0.088
0.0030
0.00057
0.0037
(1)	Applied and discharge flows do not include the flow from the scale pit to flume flushing. This
recycle loop was inaccessible for flow measurements during the time of sampling.
(2)	The lbs/1000 lbs values for this operation cannot be derived directly from the concen-
tration and flow rate values. See the Section VII text for further explanation.
(3)	Average of all values in Tables VII-6 and VII-7.
+ : Cannot be evaluated
NOTE: For definition of remaining C&TT codes, see Table VII-l.

-------
TABLE VII-8
RAW WASTEWATERS
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
	HOT FORMINC-FLAT: PLATE	
Reference Code:
Plant Code:
Sample Point(s):
Flow (gal/ton):
nig/1
0856H
F
#7-09
4290
lbs/1000 lbs
mg/l
0868B
K-2
#1
3690
Average
3990
lbs/1000 lbs
mg/l
lbs/1000 lbs
Suspended Solids
Oil & Grease
pH (Units)
Chromium
Copper
Lead
Nickel
Zinc
269	4.81
128	2.29
6.3-6.5
0.01
~
0.03
1.2
0.07
0.00018
*
0.00036
0.021
0.0012
61	0.94
10.9	0.17
6.9-7.2
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
165	2.88
69.4	1.23
6.3-7.2
0.01
*
0.03
1.2
0.07
0.00018
*
0.00036
0.021
0.0012
TREATED EFFLUENT
Reference Code:
Plant Code:
Sample Point(s):
Flow (gal/ton):
C&TT:
Suspended Solids
Oil & Grease
pH (Units)
mg/l
0856H
F
M
4290
PSP,OT
lbs/1000 lbs
104	1.86
79	1.41
6.6-6.7
0868B
K-2
#2
100
PSP,SSP,T,Filter,CT,
RTP97.3,BP2.7
mg/l
5.3
6.3
lbg/1000 lbs
0.0022
0.0026
7.0-7.3
Chromium
Copper
Lead
Nickel
Zinc
0.08
0.05
0.0014
0.00089
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
* : Concentration is less than 0.01 mg/l.
NOTE: Explanation of C&TT abbreviations is presented in Table VII-1.
169

-------
TABLE VII-9
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
TOXIC POLLUTANT STUDY
	HOT FORMING-FLATS PLATE	
RAW WASTEWATERS
Reference Code:
Plant Code:
(1)
0496-01
.082(140**
Carbon)
Sanpie Point(s):	H-A
Flow, (gal/ton):	120
0496-01(l'
082(140"
Specialty)
C-A
870
0496-02
082(140"/
206")
J-2-A
210
(1)
0496-03&04(l)
082(112"/120"
Carbon)
D-A
870
0496-03&04(1)
082(112"/120"
Specialty)
C-A
2650
0860H-01
083
I
9790
0112D-01
086
H
3240
Average
2540
Overall
Average
(2)
2860
ill
lbs/
1000 lbs
1/1
lbs/
1000 lbs
lbs/
8/1 1000 lbs
l/l
lbs/
1000 lbs
lbs/
B/l 1000 lbs
lbs/	lbs/	lbs/
t/1 1000 !<>» wt/1 1000 lbs ng/1 1000 lbs
sZi
lbs/
1000 lbs
Suspended Solids 67 0.43 111 0.61 SO 0.52 24 0.15 33 0.58 21 0.86 35 0.47 49 0.52 75 1.04
Oil & Crease 46 0.35 72 0.41 16 0.38 20 0.13 18 0.32 20 0.82 18 0.24 30 0.38 39 0.57
pH (Units)	7.7-8.9	7.8	7.7	7.2	7.5	7.2-7.3	8.0-8.2	7.2-8.9	6.3-8.9
Chroaiua
0.06
0.0011
0.07
0.0019
0.04
0.0015
0.03
0.00019
0.03
0.00053
0.12
0.0049
0.03 0.00041
0.05 0.0015
0.04
0.0013
Copper
0.16
0.0022
0.22
0.0028
0.33
0.0025
0.22
0.0014
0.21
0.0037
0.10
0.0041
0.06 0.00081
0.19 0.0025
0.19
0.0025
Lead
0.26
0.0010
0.47
0.0015
0.05
0.00050
0.06
0.00038
0.06
0.0011
0.05
0.0020
0.05 0.00068
0.U 0.0010
0.13
0.00092
Nickel
0.37
0.00080
0.98
0.0020
0.16
0.0014
0.15
0.00096
0.15
0.0026
0.03
0.0012
0.06 0.00081
0.2. 0.0014
0.39
0.0039
Zinc
0.08
0.00031
0.09
0.0026
0.10
0.0020
0.09
0.00057
0.09
0.0016
0.11
0.0045
0.03 0.00041
O.Oii 0.0018
0.08
0.0017
^1
O
TREATED EFFLUENT
Reference Codes
Plant Code:
Saaple Point(s): ^
(1)
0496-01
082(140"
Carbon)
H
H+D+J-l
HP-A) (
0496-01(1)
082(140"
Specialty)
C
C+C+J-l
¦)(0-A) (
0496-02
082(140"/
206")
J-2
(1)
J-2*II*D
(1)
)(P-A) (
0496-03404
082(112"/120
Carbon)
D
D+HO-I
)(P-A) (
0496-03404(1)
082(112"/120"
Specialty)
C
C+C+J-l
0860H-01
083
(1)
)(0-A)
(5,B
01120-01
086
(1)
F+C+I+E
)D
Flow, (gal/ton):
CiTTi
120
PSP,SSP,DR,
FDHC.OT
s*/I
870
PSP,SSP,DR
FDHR.OT
lbs/
1000 lbs
til
lbs/
1000 lbs
210
PSP,SSP,DR,
FIMC,0T
lbs/
e/l 1000 lbs
870
PSP,SSP,Dft,
FDMC.OT
SZI
lb*/
1000 lbs
2650
PSP,SSP,DR
FDMC.OT
lbs/
H/l 1000 lbs
360	3240
PSP,CL,CT, PSP,CL,FLP
RTP96.3.B03.7 SL(UNK),OT
g/1
lbs/
1000 lbs
lbs/
g/1 1000 lbs
Suspended Solids 1 0.00088 1 0.0085 1 0.0021 1 0.0064 1 0.018
Oil 6 Grease 10 0.0088 13 0.076 10 0.018 10 0.064 13 0.23
pN (Units)	7.4	7.5	7.4	7.4	7.5
9	0.00011 4 0.026
10	0.0014 2 0.021
7.1-7.6	7.6-7.9
Chroniua
1
0.00011
0.03
0.00023
1
0.0021
1
0.0064
0.03
0.00053
0.13 Neg.
0.03 0.000096
Copper
0.04
0.000089
0.05
0.00034
0.04
0.00010
0.04
0.00026
0.05
0.00088
0.04 Neg.
0.02 0.00018
Lead
0.04
0.000089
0.05
0.00034
0.04
0.00010
0.04
0.00026
0.05
0.00088
0.05 Neg.
0.05 0.00021
Nickel
0.04
0.000089
0.04
0.00027
0.04
0.00010
0.04
0.00026
0.04
0.00071
0.02 Neg.
0.02 0.00073
Zinc
0.03
0.000038
0.02
0.00018
0.03
0.000006
0.03
0.00019
0.02
0.00035
0.07 Neg.
0.04 0.00019
(1)	The lbs/1000 lbs values for this operation cannot be derived directly froa the concentration* and flow rates shorn. See the
Section VII text for further explanation.
(2)	Average of all values in Tables VI1-4 and VII-9.
Hon: Por definition of C&TT code*, see Table VII-1.

-------
TABLE VII-10
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
	HOT WORKING PIPE AND TUBE	
RAW WASTEWATERS
Re ference Code
Plant Code
Saaple Point(»)
Flow (gal/ton)
0196A
E-2
1
12,800
0240B
GG-2
1
1,700
0916A
II-2
1-5
2,760
(1)
0728
JJ-2
2
2,290
0256G
KK-2
1
520
g/1 lbs/1000 lbs w&l 1 lbs/1000 lb»
i/l lb»/1000 lbs ag/1 lbs/1000 lbs ag/1 lbs/1000 lbs
Average
4,010
e/1 lbs/1000 lbs
Suspended Solids
39
2.08
44
0.31
202
2.97
123
1.18
117
0.25
105
1.36
Oil and Grease
20
1.07
8.3
0.059
4.3
0.066
11.4
0.11
6.7
0.014
10.1
0.26
pH (Units)
8
.2
7
.0-7.8
7.
0
6.
.8-6.9
r*
1
00
yO
.1
6.8-8
.2
Chroaiua
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Copper
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Lead
NA
NA
NA
NA
NA
NA
KA
NA
NA
NA
NA
NA
Nickel
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Zinc
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
TREATED EFFLUENTS
Reference Code :

0196A
0240B
0916A
Plant Code :

E-2
GG-2
II-2
Saaple Point(s):

(1/1+2+3)5
-
(1-5/1)4
Flow (gal/ton) :

4,570
-
2,760
C&TT:
CNT2-32.9,PSP,SS,
PSP,0il Separator,
PSP,SS,FD(UW)P

SSP,
SS,SL(U(K),CL,
SL(UNK)
SL(UNK)

FDSP
,CT,RTP-M.3



ag/1
lbs/1000 lbs
¦r/1 lbs/1000 lbs
as/1 lbs/1000
Suspended Solids
10
0.14

34 0.50
Oil and Crease
9.8
0.22

2.0 0.026
pH (Units)

8.3
Cosq>lete
7.7
Chroaiua
NA
NA
Recycle
NA NA
Copper
NA
NA

NA NA
Lead
NA
NA
Operation
NA NA
Nickel
NA
NA

NA NA
Zinc
NA
NA

NA NA
0728
JJ-2
PSP,SL(UNK),RTP
and RET-100
0256G
KK-2
2
520
PSP,SS,SSP
g/1 lbs/1000 lbs ag/1 lbs/1000 lbs
Complete •
Recycle
and Reuse
Operat ion
116
0.25
7
0.015
6.8-7
.4
NA
NA
NA
NA
HA
NA
NA
NA
NA
NA
(1) The lbs/1000 lbs values for this operation cannot be derived directly froa the concentrations and flow rates shown.
See the Section VII text for further explanation.
NA : Not Analyzed
NOTE: For definition of C&TT codes, see Table VII-l.

-------
IABLE VII-11
tOKMtXT OF AHALTTICAL DATA ROM SAMPLED PLAHTS
TOnC POLLUTANT SURVEY
¦OT WOBXXHG PIPE AHD TUBE	
EAW WASTEWATERS
Kaf aranc* Cod*
Plant Cod*
Saapl* Point(•)
Plow (gal/ton)
0432A
087
I
a ,oao
0684H
088
I+J+K+L
7,010
Awn
mvm
twt
Ovarall
Ann
nnti
(4)

a/i
66
lba/1000 lba
¦t/1
lba/1000 lba
S/1
lba/1000 lb*
¦t/1
lba/1000
9uap*nd*d Solid*
2.22
33
1.01
30
1.62
89
1.43
Oil and Greaae
5
0.17
7.9
0.23
6.5
0.20
9.1
0.23
pH (Onita)
7.1-7
.4
7.2-7.8
7.1-1
r.s
6.
8-6.2
Chraiui
0.24
0.0081
0.03
0.00092
0.14
0.0045
0.14
0.0043
Copper
0.063
0.0022
0.08
0.0023
0.07
0.0022
0.07
0.0022
Lead
0.80
0.027
0.06
O.OOIS
0.43
0.014
0.43
0.014
¦iekel
0.30
0.017
0.09
0.0026
0.30
0.0098
0.30
0.0098
line
0.23
0.00(4
0.06
0.0017
0.16
0.0030
0.16
0.0030
TIEATED imOEHTS
Eafarane* Cod*
Plant Cod*
laapl* Point (¦)
Flow (gal/ton)
C4TT
0432A
087
(«/I+C+D)F
8,080
arr2-n.6tPL?,PLH,
cl, si.sat, vf
0684H(3>
088
(I+J*K*L/M)P
21
FLL,FLP,CT,CL,T,
ITF99.7

¦t/1
lb*/1000 lba
sil
lb*/1000
Suapended Solid*
sa
1.42
2
0.00021
Oil and Greaaa
4
0.13
4
0.000S7
pB (Unite)
7.4-7
.6
7.
6-7.8
Chroaiia
0.043
0.0032
0.03
*•«.
Copper
0.031
0.014
0.02
a*(.
Lead
~
~
0.03
¦eg.
nickel
+
*
0.02
i*i.
Zinc
0.21
0.011
0.02

(1)	lb* ag/1 vsluaa axpraa»*d for thia operation nfrant tb* eoncantrationa which would b* pr*a*nt in tb* coabinad
mtwauti.
(2)	Th* lba/1000 lba valuai for thia operation eannot b* derived directly fro* tha concentration* and flew rat**
abown. Saa th* Saetioa Til test for further explanation.
(3)	9m a(/l vain** praaanc*d for thia operation rapraaaat th* filtara' affluent quality.
(4)	Average of all value* in Table* VII-10 and VII-11.
~ < Cannot b* evaluated
MOTEi For definition of CtIT eodaa **a Table VII-1.
172

-------
TABLE VII-12
SUMMARY OF LONG-TERM DATA
HOT FORMING SUBCATEGORY
Total Suspended Solids (mg/1)	 	Oil and Grease (mg/1)
Plant
No. of


Standard
No. of


Standard
Principle Treatment
Code
Observations
Average
Maximum
Deviation
Observations
Average
Maximum
Deviation
Component
0112B
87
10.6
24.4
3.9
87
1.1
3.8
0.6
Filtration
0112C-011
580
8.9
44.0
7.0
690
6.7
47.1
6.5
Filtration
0112C-122
496
13.3
63.4
12.4
684
2.0
20.3
2.2
Filtration
0112C-334
415
2.3
23.5
3.0
727
1.3
12.2
1.4
Filtration
0112C-617
399
4.8
33.8
5.5
647
1.3
7.9
1.3
Filtration
0684H
40
6.0
21.0
5.5
27
3.4
20.0
4.0
Filtration
0684 F
78
22.2
60.0
13.7
79
9.6
27.0
4.3
Filtration, Lagoon
0320
151
15.8
39.0
7.4
35
0.1
0.3
0.06
Lagoons
0584A
101
25.4
55.0
9.1
98
5.9
20.6
4.3
Settling Basin
0584B
98
24.6
50.0
8.6
58
8.4
29.0
4.2
Lagoons
0856N
101
32.1
114.0
21.6
103
7.0
20.3
2.7
Settling Basin
MOTE: Additional details on long-term data analysis are provided in Volume I.

-------
TABLE VII-13
D-DCP SCALE AND OILS GENERATION DATA
HOT FORMING SUBCATEGORY	
Subcategory
Primary
Section
Flat
Pipe b Tube
AVERAGE
Plant Code
0868A
0320
0864A
0432 J
0920A
0460A
0440A
0112B
0068B
0136B
0088A
0136B
067 2 B
0672B
0684 H
0860H
0612
0060
0176
0432C
0448A
0448A
06B48
0684 F
0684 V
0920N
0240B
0652A
0728
Pounds of Scale
Per Ton
of Production
50-75
47
47
23
42
36
41
HA
60
40
30
NA
50
50
26
20
36
20
NA
23
46
NA
Suspended Solid*
12
(1)
JM
32
40
50
82
41.1
(1)
(1)
Z of
Production
2.5-3.75
2.35
2.35
1.15
2.1
1.8
2.05
NA
3.0
2.0
1.5
NA
2.5
2.5
1.3
1.0
1.8
1.0
NA
1.15
2.3
NA
0.6
0.84
0.05
1.6
2.0
2.6
4.1
(1)
(1)
(1)
2.05Z
Say: 2.IX
(1)
Oils and Greaaes
Gallons of oils
Per Ton
of Production
0.14
NA
0.126
°*15 (2)
0.0025^'
0.010v,£;
Negligible
NA
NA
NA
NA
J(2)
NA
0.45
Unknown
NA
NA
0.01'
0.22
• (2)
NA
Unknown
NA
NA
0.05
0.01
NA
0.23
(2)
(2)
(2)
Summary:
Suspended Solid*
Hills without scarfers: 2.IX, 42 lba/ton
Kills with scarfers : 4.2X, 84 lbs/ton
Oils and Greaaes
Based on oils with densities 85Z that of water
0.23 gal/ton, 1.6 lb/ton
(1)	The data from those mills reporting a solids generation rate less than II (leas than
20 lb/ton) were not included in the average as these values were considered to be
atypically low.
(2)	The oil generation valuea less than 0.1 gal/ton were not included in the average as
these values were considered to be atypically low.
NA: Not Available.
174

-------
-J
U1
PROCESS*	HOT FORMING (BAR MILL)
PLANT'	C
PRODUCTION: 26.3 mttric ton* ilitl/day
(29 tout ct*«l/day)

ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Vn. 3/6/79


FIGURE 3ZIt-r



SURFACE.
WATER
OVERFLOW
TO RIVER
6.7 IA*C
(106
COOLING
RESERVOIR
I2S l/Mc
(1993 apm)
126.4 IA«c
(2004 apm)
26.2 Ifec
(~16 tP«)
RECYCLED
TO OTHER
PROCESSES
OTHER
PROCESSES

-------
2231 l/kkg
(533 gal/Ion)
PROCESS(
WATER
T^T
-j
CTi
UNIVERSAL MILL
PROCESS^ Hot Forming - Univer*ol Mill
PLANT1 D
PRODUCTION!
2231 l/kkg
(533 gal/Ion)
SCALE PIT
i—
DISCHARGE
TO RIVER
SURFACE
OIL
A
SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING-PRIMARY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/2/79
FIGURE W-9

-------
13,819 lAkfl
(3314 gal/ton)
HOT
STRIP
MILL
PROCESS
WATER
PROCESS;
HOT FORMING (HOT STRIP)
PLANT;	D
PRODUCTION:
UNIVERSAL
MILL
DISCHARGE
TO RIVER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM	
Dwn.3/23/79
FIGURE MI-3

-------
PROCESS1 Hot Forming - Blooming & Universal Mill*
PLANT)E
BLOOMING AND
UNIVERSAL
MILLS
PRODUCTION! 2144.1 metric Ions «teel/day
(2364 loot steel/day)
SCALE
283.9 I/MC (45O0 gpm)
HOT STRIP
MILL
605.6 |/MC
(9600 gpm)
CLARIFIER
CLARIFIER
COLLECTION SUMP
UNTREATEO
RIVER WATER
*2 DEEP BED FILTER
I DEEP BEO FILTER
-689.5 l/tec
(14,100 gpm)
A SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
ttOT FORMING- PRIMARY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn. 3/2/79
FIGURE 3ZE-4

-------
•J
U3
PROCESS-
HOT FORMING-HOT STRIP MILL
PLANT-*
PRODUCTION: 1851.1 METRIC TONS STEEL/DAY
(2041 TONS STEEL/DAY)
BACKWASH
BLOOMING ft
UNIVERSAL «
MILLS
CLARIFIER
til
III
CLARIFIER
605.fi l/s9C
(9600 gpm)
889.5 l/sec
(14,100 gpm)
BACKWASH
iii
ENVIRONMENTAL PROTECTION AGENCY
^SAMPLING POINTS
STEEL INDUSTRY STUDY
HOT FORMING (FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
FIGURE 3ZEL-5
SCALE
PIT
COLLECTION SUMP
HOT STRIP
MILL
DEEP
BED
FILTER
~2
DEEP
BED
FILTER

-------
PROCESS:
PLANTS
HOT FORMING - PLATE MILL
PRODUCTION: 478.9 METRIC TONS STEEL/DAY
(528 TONS STEEL/OAY)
00
O
SERVICE WATER,
COOLING
WATER
446.9 IA*c
(7084 OP*)
297.9 l/MC
SCALE PIT
REHEAT FURNACES
PLATE MILL
_297.9 l/MC
(4722 gpm)
/\SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/22/75
FIGURE 3ZH-6

-------
00
PROCESS! Hoi Formiag - BI«o«iM Mill
PLANT: H
PRODUCTION:
FURNACE COOLING WATER
-7581 l/kkfl
(1818 gal/tOA)
SCARFER
SCALE PIT
BLOOMIN6 MILL
A SAMPLING POINTS
ENVIRONTAL PROTECTION AGENCY
STEEL INDUSTRY STUOY
HOT FORMING-PRIMARY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dm. 3/2/79
FIGURE 211-7

-------
PROCESS: HOT FORMING - MERCHANT MILL
PLANT: H
PROOUCTION:
MERCHANT MILL
SCALE PIT
SERVICE WATER
/\SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
	WATER FLOW DIAGRAM
Qml V6/7S


FIGURE 331-8




-------
PROCESS:
HOT FORMING (BLOOMING MILL)
PRODUCTION 1633 mtrie
«80
RECYCLED
PLANT
WATER
—A
	*0*
DISCHARGE
TO RIVER
63 I/mc
(lOOcpm)
44.2 I/mc
(700 flpaO
SURFACE
OIL
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (PRIMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
FIGURE mr-9
SCALE
PIT

-------
CD
ife.
PROCESS! HOT FORMING(BAR MILLS)
PLANTi
PRODUCTION 45.4 metric loot iteaMday
(50 Ions tleel/day)
MINOR
RECYCLE
DISCHARGE
TO RIVER
RECYCLED
PLANT
WATER
-3.2 IA«c
(51 gpml
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
SCALE
PIT
BAR
MILLS

-------
1.3 l/*ac
oo
171
MUNICIPAL
WATER
.17.7 l/iu
(280 gpm)
MUNICIPAL
WATER
R ECYCLE
165.3 l/««c (2620 gpm)
SCALE
PIT
HOT
SCARFER
BLOOMING
MILL
PROCESS:
HOT FORMING (BLOOMING MILL)
PLANT: M
PRODUCTION; 895.2 metric tons steel/day
(987 ton» steel/day)
RECYCLED
TO PROCESS
iai l/MC
(160 gpm)
18.9 I/sm
(300 gpm)
BILLET AND
BAR MILLS
126.2
(2000 gpm)
134.4 l/s«c
(2130 gpm)
37.2 l/sac
(590 gpm)
15.8 l/sac
(250 gpm)
TO
SANITARY
SUMP
PIT
SPRAY
POND
TO
SANITARY
SEWER
COOLING
WATER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (PRIMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
3wn. 3/2/79
FIGURE IHEII

-------
H*
CD
HOT FORMING (BILLET MILL)
PLANT:
PRODUCTION: 740.1 metric lon« fteel/day
(816 tons steal/day)
5.05 l/ttc
PURCHASED <80
WATER
18.9 l/(«c
(300 gpm)
RECYCLED
TO OTHER
PROCESS
126 I/sec
(2000 gpm)
DISCHARGE
114.5 l/i«c
(230 gpm)
37.2 l/sec
(590 gpm)
BLOOMING MILL
119.9 l/sec
(1900 gpm)
BAR MILL
NON CONTACT 	
COOLING WATER
15.75 lAec (250 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
/\SAMPLING POINTS
FIGURE 3ZE-I2
HOT SAW
PUMP PIT
PUMP PIT
SPRAY POND
BILLET MILL

-------
PROCESS)	HOT FORMING - SECTION
PLANT:	0
PRODUCTION; 152.6 m«trlc tons cle«l/day
(I6B Ion* steel/day)
CODING, WATER
2.0 lAec
(32 gpm)
34.6 IA«c
(54 B gpai)
ROLLING MILLS
HEAT TREAT a
HAMMERS
CLARIFIER
TO
COMBINED
WATER
TREATMENT
PLANT —
34.6 Msac (54B gpm)
RECYCLED
/\sAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
	WATER FLOW DIAGRAM
Dwn. 3/7/79


figure :ari3




-------
PROCESS:
HOT FORMING-SECTION a FLAT
PLANT:	O
PRODUCTION: 203.2 METRIC TONS STEEL/DAY
(224 TONS STEEL/DAY)
3.2 I/mc (SO gpm)
oo
03
SERVICE WATER
126.2 I/mc
(2000 gpm)
3.2 lAac
(SO gpm)
COMBINED
WATER
TREATMENT
PLANT
123.0 l/iac (1950 gpm)
RECYCLED
SCALE PIT
ROO AND STRIP
MILLS
RECYCLED
A
SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION 8 FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.3/26/7S
FIGURE 3ZH-I4

-------
OTHER
PROCESSES
2I4.S l/sac
(3400 gpm)
BLOOMING
Ml LL
WELL
WATER
OTHER
PROCESSES
PROCESS'
HOT FORMING (BLOOMING MILLS)
PLANT:	Q
PRODUCTION: 381.8 metric ton* »lo#l/day
(421 tons «Uel/day)
SURFACE
OIL
SCALE
-7^V-
277.6 l/sec
(4400 gpm)
DISCHARGE
TO RIVER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (PRIMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dva3/2/7S
FIGURE 2Drl5

-------
124.1 Mmc
(1967 gpm)
BAR
MILLS
WELL
WATER
PROCESS:
HOT FORMING (BAR MILLS)
PLANT:
PRODUCTION
1443.0 metric Ions * teal/day
(1591 ton* steel/day)
OTHER
PROCESSES

IS3.5 l/MC
(2433 gpm)
•A—~
277.6 l/tec
(4400 gpn^
SURFACE
OIL
DISCHARGE
TO RIVER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/7/79
FIGURE Z5fflzl6

-------
PROCESS:	HOT FORMING - BLOOMING MILL
PLANT:	R
PRODUCTION: 10923 metric Ions sl«al/day
(1205 loos steal/day)
BAR
MILLS
OTHER
PROCESS
WASTE WATER
2000 gpm
252.4 l/sac
(4000 gpm)
yiv

BLOOMING

MILL
4000 gpm
SCALE
PIT
6000 gpm
SETTLING
LAGOON
15,700 gpm
A
/\ SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (PRIMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/2/79
FIGURE "3ZEL-I7

-------
U3
IO
PROCESS:
PLANTi
HOT FORMING-BAR MILLS
PRODUCTIONS 328 metric Ion*, steal/day
(362 toni steel/day)
MISC. PROCESS
WATER
BLOOMING
MILL
252.3 I/tec
(4000 gpm)
RIVER
WATER
-&r
BAR MILL
63.1 l/sec
(1000 gpm)

63.1 IA«c
BAR MILL
(1000 gpm)
I
126.2 |/tec
(2000 gpm)
SETTLING
LAGOON
SCALE PIT
SCALE P T
990.4 l/sec
(15.700 gpm)
SCALE PIT
PLANT
OUTFALL
/\SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/8/79
FIGURE 3ZH-I8

-------
scale pits
(PRI MARY
CLARIFICATION)
MILL CQMPUSy
C BLOOMING . &ILL&T
AMD RAIL M I LLfa )
-RAW UNTREATED PROCESS EFFLUENT
^UWSECteBSSPHlpR.MARV-T 'ftg>*/fe6C(gMOaP^ FLUMM **JHS
1141/StCl 38	'	L 4q l/S£CftfeS GPM) AVf6. aCABEINfi FLOW
UBl/SgcfggGOfiPM) SECTION
PARTIALLY CLAQlFlfcO
RECYCLE: IA£> -IfeO l/£EC.
PROCE=S°3 : MOT ROOMING - PRIMARY
4 SECTION
PLANT "• A - *2-
PBODUCTlONi *. 4351 MErTBlC TONS
t|a slTT^k 8^ir&&l/
dav) Primary ;
A3£>l METBlC TON*b
OF 5T&&L- / DAY ,
(54S& TONS OF STEEL/
	CAY) SECTION
-t^r
t
PLANT TNTAHE
WAT&g.
NPLU&NT
/L-AK.& WAT&B^
TYPICAL F-OP ALL S&VfcN
AMD g>AKlta
QOWNFLOW BATE. Cb.19f/StC./SQM
(loapM/p-r .Tp
( 232Q - 23&Q GPM)


56TTLINQ
teSCON DaBY CLABIFICA.TI
E.IS7.45Q UTEBS .VOLUME
(5TOOOOaAL&)
DEEP
bfO
PILTtR
DEEP
BED
FILTER
BED
FILTER
BED
FlUER
BftO
FILTER
BACH WASH WATER
TO SCALE: PIT
&LUD6& TO
SCALfe PIT
gSk-ffiiSB
-treatment plant
EFPLU&NT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY" STUDY'
WOT FORMING
WASTEWATER TREATMENT SVSTIrM
WATER FLOW DlA&RAM

|8&/. I frM-Td
R&UK& 311-19

-------
>£>
SCALfc. PITS>
(PBt MAO.V
CLAglPICATtOKp
MILL. COMPLEX
BLOOM I NS AMD STRUCTURAL
MtLL"=>
fsTPt)CTURAL MOT QPE.RATI N& PUP-
INC. SAMPL1KIS peaiopt)
-RAW PPOCESS WASTE.WATEO.S
FBOM PRIMARY OPERATIONS
nz i/sec. (%730 gpm)
ppoc&as
PLANT
HOT FORMlMe -
p>RI MAQV
B - 1
POODUCTIOK1-- G9Q7 M6TCIC TONS
r
*	A Q «
OF- ST&ElL. / PAY"
iTGfeO TONS OP
STfc&L /DAV)
INF-LL1&-NT" CLAII.& WAT£tt)
PLANT INTAK.& WAT Eg.
t
StsTTLI M6 CONfc-
y(S6COMO&OY CLAQlF-ICATlOMl
„ tt.OQg.gfcS LITERS,VOLUME:,
(&Z3.0QO )
a.& M&T&B.'a PI A. (I2. FT.)
4..4Z M&T&C5 MI&U(l4.Spr)
MEDIA t SUPPOBTINS
GQAVfrL AND SAND
DOWN FLOW RAT& ; (5.79 g/~
&EC-/sq m-(lO<3PvVFT*-)
, >7 2.1/atC
( 275O GPMj
Sr
TT?£AT MErNT PUAKiT
e^F-L-UBtJT
&ACU.WA&U VMAT&C- TO
SCALE. PIT
A - SAMPLING poikits
ENVIRONMENTAL. PROTECTION A&ENCY
STEEL IMDUSTBY STUDY
MOT PORLtING
WASTEWATER TBEATMENT SYSTEM
WAT&C. PLOW DIAGRAM
CW6 6 20-74
BEVt tUTL
[REUt 1-7Q-M
FIGURE: 31-20

-------
M
VO
en
PROCESS : HOT FORMING-PRlMARV
plant ; c-a
PRODUCTIONS 3£Sfe METRIC tons of steeU
"TOMS OF ST£EL/PA>A
PUMP*

145.1 J/sec.
(2300 £|PM\
RIV/ER
WKTER
~At
¦*• EFFLUENT
145.1 4/sec
(2300 $PM^
DEER BED
FILTER BACKVYAs>W
TO CLARtRER*
ClNTERfcAttTENT FU>*A
A
SAMPLING POINT
ENVIRONMENTAL PROTECTION A$EWC\
STEEL INDUSTRY STUDY
HOT FORMIKJCj
WASTEWATER TREATMENT SYSTENX
WATER FLOW DIAGRAM
4-Z-14
RM2-H-7 fa
FIGURE 3H-2I

-------
MOB
mcrchaut bar
Mlkk
Tj
SCALE PIT -»|
aosA/feHc. A
^4aoo EO
FILTERS
IOTS^/SEC.
(17,080 QPM)
	Ss
2S"24 je/SEC.
(40,000 GPM^
RIVER IWTAKE
ENVIPOMMEUTAL PROTECTION A
-------
A A	FMM
RESERVOIR
PRODOCTI OM: METRIC TOWS (541 TONS)/
dm pipe t Toe>e.
44-jS/SEC..
(tas &pm)
3&0-6/SEC.
(ssssgpm)
BOD MILL.
V^Sr-
3S4--4/6EC..
^arsoaPM^
ll*BA>R MtLL-
"Z^r
PROCESS: HOT FORMIUG-SECTION.PIPE ^Tuae.
PLAUT-.E-2-	1
PRODUCTION! HOT FORMING SECTION TOTAL.
•929 MET WC TOMS/DAY
(iur TOMS/O^V)
'3eSULTRIC TONS f\OiOTOM5)/
DAY ROD
1004 METRIC TON 1,107 TONS.)/
0AYBAR(l SHIFTS/DAY)
MILL.
(SCAO «MjOI>eiUTIH6
57-C/SECT) MILL
(»OOCPMJDOWM
SEAMLESS
TUfcE
¦A
lJjs
PRIMARY
SETTLING
BASIN
93l^/SEC.(l4,'TaoSPMl WITH BAR MILL OPERATING
*
307^/sec^
(4%go gpm)

KecrCLE WkTtft
V^L,
COOLIM&
HI6H RATE. SAMO FILTERS (G>)
EACH S.&&M (It) DtAXS.03^
O&.s') LONG,
FILTER. RANGE.MO |/SEC//»n>z
(iVaoPM/ft1)
•A-
LARIFK
»0.6M
(WOFl)
SURCB.
^6 65 P. VOIR
-513,000 LITERS
(Sr ia&,000 GALLONS)

HAIN
ag.&etwe>i»
"5*1,640,000 LITERS
{* 4-Ofc ,SOO GALLONS'*
LAGOON
170k000 LITERS
(4.4.900 (MJ.OMS)
SETTLING
ax
3134/SEC.
£\(S7-VS GPM)
ON ERF LOW TO
RECEIVING STREAM
SETTLING
PIT
FILTER.
BACKWASH
CLAvRIPtEP. UNDE-R-FLOW
l 6AMPLE. POINTS
ENVIROHMEKITAL PROTECTION AfiENCY-
STE.EL. INOUSTRY STUDY
HOT FORMING
WASTEWATER TRE.AT MEKlT SYSTEM
WATER FLOW DIAAN*
0WG.3lC.T1
ftJLy. llAli
FIGURE 3ZH-23

-------
PROCESS: HOT FORMING- SECTION
PLANT •• F-2
froi
CONTACT WASTEWATER
FROM MILL 
PRIMARY
SCALE
PIT

-&r
SECONDA.RY
SCALE
PIT
SECONDARY
SCALc
Ell
PRODUCTION5 2048 METRIC TONS OF
STEeL/DAY
(2257TONS OF STEEL/DAY)
OIL
RECEIVER
MOM-CONTACT
COOLING WATER
FROM MILL
4731 "504.6 41 SEC.
(isoo-aooc
TOSCAVENGER
CONTACT AND
NON-CONTACT WATER
TO MILL

POLV- ELECTRO LYTEp >
SPLITTER
BOX
PICKLE LIQUORp
LIME-
HOT
WELL
1
BILLET
REHEAT
FURNACE
COOLING
TOWER
((TWO -CELL'))
CoiQ>JgLL
hArj
1
CLARIFIER
t
/ V
UNDERFLOW
POLY- ELECTROLYTE^
PICKLE LIQUOR^

OIL
RECEIVER
MAKE-UP
WATER
COLD WELL SLOWDOWN
APR Z°b OF RECIRCULATION
13.91/ 5EC. (220 G PM)
1
CLARIFIER
VACUUM FILTRATE
sz
VACUUM
FILTER
/ \_
SLUDGE CAKE
-VACUUM FILTRATE
1?
UNDERFLOW
• VACUUM
FILTER
SLUDGE CAKE
. TO
SCAVENGER
A" SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT- FORMING SECTION
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
OW& 4-B14-
Rtvt HUH1
fan7 tun.
FIGURE 301-24

-------
NON-CONTACT COOL I N (a WATEB.
24C.lVfifcC- j39QO GPM)
MOT FORM I Nfi -SECTION
G - 2.
P8DOUCTION « 654. METttlC. TONS
OIL SUMP
PLOW
TOTAL
30lieol
(8QOOGAL)
326 O-31ft S.1/SEC.
Mll_LOOQ GPM)
10 MILL
PRIUAQY
lx' MILL
PQIMhRV
SC&Lt PITSffl
5CM-E PITS®
J
/
V&ETICAL. WASTfc-
IQIM=
3tfc.Q-37a.5fi/gfcC
(570Q-&OOOCPH)
PI LTfcft.
SIS41V3EC
FILTER
315.4 6./&&C.
(fdOO GPM)
wet solids
toTCXsooni
315.4 I/SEC
(£000 GPM)
(.5000 6PM)
BACItWASH W&TER.
A\ ^	316.0 -37aAtelC
/
(MOO -<,000 CPM)
QOQLINQ
TOWER
3&ZJ2/3£G.
* li573S&PM)
PUMPS (3)
Slb.4 l/S&C
(&OOQ &PM)
ENVIRONMENTAL. PROTECTION AGENCY
3TBBL INDUSTRY STUDY
BAR M I L.I—^3
WASTeWATEtt TRE-ATME-NT SYSTEM
WATER FLO# CHAtS/tAM
INLET SUMP
S&gVIC Br WATER
FQOM fclVErE.
A- &WPLIN& POI NTS
R.APPEJE. VALN/&
ISTllMteK?!
FIGURE m-25

-------
SERVICE
WATER
A
ROD
MILL

.
[	>
k
242.4 -l/SEC
f3850 <=»PKA)

SOLIDS RETURN
-A
12.7 J/SEC
200 C,PM
process: hot forming,-sectiokj
plawt : H-a
PRODUCTION: 724 METRIC TONS OP STEEiVDAN
lT9a TCWS. OF STEEL/DAN^

2 BO. 2. J/SEC
(3fcyo <*pkO>
^ TO SEWER
A KID RIVER
CYCLONES
C5-*
A
SAMPLE POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
4-2-74
fey 2-W-7fc
FIGURE 1ZII-26

-------
PQOCfcSS>
MILL SERVICE
MOT FQRMlKia— SECTION
FHCeUNQ MgSO^-HCI
HOT COATING GALVANIZING
PLANT t 1-2
PRODUCTION :
A ~ 5-&ajg/S£C
^ (MOOGPM)
'4-PiCULE LIN a
3 3~>l/S£C
(Co 3 CbPAf)
MILL.
A
-awl/sec.
(5547 6PM)
SCALE
PIT
PICKLE
TANK*
"-f
'sj
SPBtV
PIN^fc
RINSE-
*&PICULfc LINfc
^&4_£/_SBC
{150, 6PM)
PUUB MOOD
LMO &COUBBIM6)
: taa^» MeTaic ton^
(lS36ToN^/DAV gob
634 M&TQtC TONS
Cei9 tons)/ oav
HtSP4 F=>ICU.t-l Nfi«
Q>5 METQ.IC. TONS
(7Z TONS)/ PAY MCI
PICKLING i GALVANIZING
WATfcP SPRAVS
Q.71/SEC.. (11 6PM)
HCI_

RUNNING

HOT

MOT
PlCltLE

RlhlSEr

STANDING

DIP
TAMI1



RINSE:

<5ALV.
337//56C
' (5fr47 <5^)
SF»E*tT ACID
TO CONTCACTSO
Olt>POSAL.
(V9 (?PM)
^ O 7 i/SEC
(IIGPM)
_y% » 3SQ^/Sec. ^S5S<2» gpm)
TO RECEIVING STREAM
TERMINAL- SETTLINS LA&OON
A£>, *200,000 e
fl*2L ,300,000 GAL)
A-
SAMPLING. ROI K1T&
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINED WIRE, ROD, PICKLING a
WIRE GALVANIZING LINES
WASTEWATER TREATMENT SYSTEM
	 WATER FLOW OIAGRAM
OWS-fr-M-Mf
RE*.I 1-lO-Ki
(ft V I lifc-16
FI&UQ6.mi-27

-------
fo
o
to
EM6B6EMCV WATER. SUPPLY
MOIJ-COIJTAC.T
COOLIMIa WATER.
PROCESS: HOT FORMING- FLAT- HOT STRIP £
SHEET
SERVICE-
WATER
mm
ELEVATE
H STORAGE
TAMK
plamt: it.
PRODUCTION
Bo"MILL 4-4-£3 METRIC TOMS
(4,3 SO TONS)/OKV
&4*MILL 3iSI METRIC TOWS
(lO, ZOO TOU S)/ DAY
TOTAL I3JI4 METRIC TONS
(I5»l Z a To W S V D A V
STATION
34'MILL
FlMISHIMfe
SECTIOU
64- MILL
84* MILL
S4-MILL
ROUGH IMG
S4MILL
MOTOR ROOM
64-' milu
f*E.HEM
FURNA.C&S
RUNOUT
TABLE.
COIL-EP.S
FINISH I MH
Bkl£s
FILTRATION
LPL^KIT

FIGURE. W-28
TO LAUD PJLL

-------
feCAL&
OIL
PRIMARY
SCALE: P3IT
PPOC&SS J HOT POBMI N<5 - P-LAT
P^t-A T&
PLANT s e-2.
POOOUCTIQN » 25ft& METRIC TONS
OF- STEfcL. / DAY
CSSSOTOMS OF STfc&U/OWt)
EVAPORATION
*
puMP»ihjLIMG RPI NTS>
ST66L INDUSTRY STUDY
MOT ROLLINS MILL
WASTE- WAT&C. TQE-ATMENT SYSTEM
WAT&e PLOW DIAGRAM
KV.I	I
FI&URE 301-29

-------
PROCESS: HOT FORMING-PRIMARY
HOT FORMING-FLAT-HOT STRIP ft. SHEE1
PLANT: L-2
PRODUCTION: 9854 METRIC TONS
(10,864 TONS/DAY) PRIMARY
10,506 METRIC TONS
(11,583 TONS/DAY) FLAT
K
SLAB MILL
aSCARFER
197 I/mc(3I20 gpm)
FLUME a SPRAY
95 lAec (15(0gpm)
SCARFING
3
PRIMARY ROUGHING
STANDS (3)
SCALE PIT
W5K1MMER
HS a STRIP
SECONDARY ROUGHING
STANDS (3)
FINISHING
STANDS
RUNOUT TABLE AND COILERS
HOT STRIP MILL
SCALE PIT
UMSKIMMER
F3
SCALE PIT

SCALE PIT

PUMP

PUMP
WSKIMMER

W/5K1MMER

PIT

PIT
j 4457 1AM
I (70,630 gpm)
A <~L|ME
4165 1/mc
(66,000 gpm)
FAST MIX
TANKS(3)
FERRIC
SULFATE
FVjOOCULAIOR
TANKS (3)

CLARIFIERS (3)
41m (135') Dl A.
RISE RATE*0S6 lAec
(Oj8 gpm/ft
OCCULATOR
TANKS(3)
CLARIFIERS (3)
41m (135*) DIA.
RISE RATE « 056 Ihtcfof
(OS gpm/f|2
"reated RIVER WATER
AS MAKE-UP
AVG.F10W»79 I/mc
0250 gpm)
WELL WELL
COOLING
TOWERS
SLUDGE DISPOSAL
VACUUM
FILTERS(4)

MAKE-UP TO FUME SCRUBBER
SYSTEM AT PICKLER 8 NON-
CONTACT COOLING WATER
ELSEWHERE 48 Msec
(760 gpm)
ft
'TO RECEIVING STREAM
26.5 lAec (420 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
»m.3/26/7S
FIGURE 3ZE-30

-------
PROCESS*. HOT FORMIC-FLAT-HOT STRIP i
SHEET
plant; m-2.
PRODUCTION Will METRIC TOWS OF STEEL)
DAS
(IIOOO TOMS OF STeeL/DAY*)
SCALE BREAKERS
{ROU^HIKM^S
TABLE ROLLS,
SCALE BREAKERS{
ROO^HlKKa STANDS
*3,4 15
SERVICE WATER
FEED
COIIERS
RUNOUT TABLES
1^- FINISHING
RUNOUT TABLES
f FINISHING STANDS
*$4 <>
STANDS
"1,2.3 <4
\

\


MON- CONTACT
COOLIKIQ
. rrifa J/scc x
£Z7,200

-------
PROCESS: hot FORMING-FLAT-HOT STRIP
4 SHEET
PLANT ! KJ-2.
PRODUCTION :|79& METRIC TONS OF STE£L/OAY
(I960 TONS OF STEEL/DM)
MILL SERVICE
WATER FOR MAK.E.-UP
3o"HOT STRIP MIL-l.
ROUGH IM 
-------
KJ
O
^1
PROCESS s PIPE < TUBES
PLANT: GQ-Z
PRODUCTION: 211 METRIC TONS OF STEEL/DAY
(Z 33 TONS OF STEEL/ DAY
CITY WATER
STORM WATER
CREEK WATER
NON-CONTACT
COOLING water
TO
OIL —
RECOVERY
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
PIPE < TUBE MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
A- SAMPLING POINTS
IpMS.S-C-1* IHtV7
seamless tube mill
ELECTRO WELD MILLS
SURFACE EVAPORATION ONLY
WEST POND
EAST POND
FIRE WATER i MAKE UP WATER POND

-------
hj
o
00
¦RIVER IMTAK.B
PROCESS : PIPES I TUBE.S
PLAMT i II-a
PP.OOUC.TIOM ; 5C7 METRIC TOMS/DAY
TONS/OAV)
10a jt/SEC.
(17iO GPM)
COM TACT
COOUHS
OF- fikial
PROOUCT
COM TACT
COOLING
OF ROLLS
t 6HEMIS
NOU-CONTACT
COOLIKICb
USES
zs.i £/sec..
(400C.PM)
37.3 ^/SB C
('COO GPM)
37.3 4/SEC
CC.OOGPM)
ioi^/sec 60.00 aPM)
OIL SKIMMER
FILTER.
5UPPLY
TANK
TWO COMPARTMENT
SCALS PIT
PUMPS
OIL SKIMMER
5LUPqe. DISPOSAL
&OXES
n
RADIAL FLOW
BACKWASH
CLARIFICATION
FILTER,
RADIAL
FLOW
BLTE-P.
TANK
O
STAMP BY
FILTER

-------
LIME
SERVICE
A-*\
tAW*E UP
o.bji/sec
(»t.OG,PKV^
PROCfbi: PlPE$T0E>£=>-V\O"T Vv/ORKED
PlANT i \T
"t^°4
7~7
77T
P\c*ue.~\ mva.(bmch)
o.aii/^EC
(\t.O GPt-^
-A—
HzOVKPOR
SPENT ACID
*--fO CONTRACT
0\t>PO*3M_
293 VSEC.
(46S G,PIA^
To LM40 F"\U\_
26.0. 4/ t>EC
(.^VbSGPlA)
~VO VAND^NLL
A
"SMAPUVili POINT5
ENVlROmAENTM- PRO"tECT\ON AGENCY
•=>TEE\_ INDUSTRY STUDY
PIPE A-NDTUBE t*\\LL
W^STEWtaER TREKTVAEHT 'SYSTEIA
Vv/ACTER FLOW OlKGtRfvtA
CW6. 6-&Q5
Ztvl Mo-It
BW2 2.25TA
FIGURE fflH-35

-------
SERVICE WATER
PtPE MILL
, flT.35l/SEC.
(ZTSGPM)
POLYELECTROLYTE
OIL SKIMMER
OIL RECOV/ERV
PRIMARY SCALE PIT
9.1m X 3.1m X4-Om
(30* XI2*XI3)
132,500 LITERS
(35,000 <*AL/)
PROCESS: PIPES* TUBES-HOT WORKED
PLANT' KK-2
PRODUCTION« 465 METRIC TONS OF ST£EL/o*Y
(512.5 TONS OF STEEL/DAY)
J7.0l|SEC. ^ TO RECEIVmQ STREAM
(ZTOGPM)
SECONDARY SCALE PIT
tO.3mXT.2mX 1.2 m
(33.83* X Z35'X 4-')
90,000 LITERS
(Z3,BOO GAL.)
A' SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUOY
PIPE AND TUBE MILL
WASTEWATER TREATMENT SYSTEM
WATE.R FLOW DIAGRAM
CMS 6 C -1S
Rl«.

FIGURE 3fl£36
RMI 2 20-16



-------
If m I V, HOT FORMING, PICKLING,SCALE REMOVAL, WIRE
COATING, Al KA1 INE CUANING
PLANT 081, 122, 132,142,152
PRODUCT ION-'M" 65 METRIC TONS/TURN(72 TONS/TURN)
N(*l a*2 MILLS)- 43 METRIC TONS/TORN
(46 TONS/TURN)
N<*4 MILL) -64 METRIC T0NS/TURN(70 TONS/TURN)
W-*2BL0CK 85 METRIC TONS/TURNOO TONS/TURN)
BENCH CLEANING 76 METRIC TONS/TURN(84 TONS/TURN)
MAKE-UP
021 l/SEC.
(3.3 6PM)
5.6 l/SEC.( 90
I.I l/SEC.06.8 GPM)
0.38 l/SEC.(6.1 GPM 1
0.76 l/SEC.(12 GPM)
0.88 I/SEC.Q4 GPM)
0.30 I/SEC.M.8 GPM)
0.95 I/SEC.05 GPM)
1.3 l/SEC.(20 GPM)
9	(X20 l/SEC.(3.C GPM)
10	0.44 l/SEC.(7.0 GPM)
6.6 I/SEC.0O6 GPM)
DISC
INSPECTION
HOT M LL
7.2 l/SEC. \
(114 GPM) V
27.7 l/SEC.
(439 GPM)
3.1 l/SEC.
(4 9 GPM)
0.66 l/SEC.
(10.5 GPM)
LAMELLA
SEPARATOR
22.3 t/sec.-^
(354 GPtt) Y
3.1 l/SEC
(49 GPM)
l/SEC
5 GPM) \
75.7 l/SEC.
(I2O0 GPM)
2	0.22 l/SEC.(3.5 GPM)
3	2.5 I/SEC.M0 GPM)
SEDIMENTATION
20.5 l/SEC.
(325 GPM)
*16*2
HOT MILL
UNIT
5.7 l/SEC.
(91 GPM)
1.8 l/SEC.
(28.2 GPM)
FURNACE COOLING WATER
LIFT
STATION
OVERFLOW
LAGOON
KOLENE/HYDROCHLORIC RINSE
OTHER PROCESS
WASTEWATERS
SECONDARY RINSE
HOSE
RINSE
HEX CHROMIUM
TREATMENT
SCRUBBER
276 l/SEC
1438 GPM)
SCRUBBER
CENTRAL
TREATMENT
PLANT
ROOF
SCRUBBER
SAMPLE
POINTS
NORTH SCRUBBER
48.5 l/SEC
(769 GPM)
Cu-NaOH RINSE
48.7 l/SEC
1772 GPM)
DISCHARGE
Cu/CN
TREATMENT
Cu-PLATE
RINSE
ENVIRONMENTAL
PROTECTION
0.6 l/SEC
(9 GPM)*
AGENCY
15.5 l/SEC. (245 GPM)
LEAD COATING
RINSE
STEEL INDUSTRY STUDY
HOT FORMING, PICKLING, SCALE REMOVAL,
WIRE COATING, ALKALINE CLEANING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
HIGH SPEED
DEGREASER
SODIUM
HYDRIDE
QUENCH
HOSE
RINSE
WATER
FUME
SCRUBBER
DWN.II/21/78
FIGURE 3ZII~37
•COMPANY SUPPLIED (DCP RESPONSE) FLOW RATE

-------
to
H
to
PROCESS: HOT FORMING. PICKLING.SCALE REMGMM-,
WIRE COATING, ALKAUNE CLEANING
PLANT: 081,122.132.142.152
PRODUCTION: SAME AS FIGURE SH-37.
SLUDGE TO
DISPOSAL
FLOCCULANT
AID
ClafHUf Wof>
Overflow
TREATED WATER
FROM Cu/CN
Hg SO^
ADDITION
h2so4
ADDITION
TO EMERGENCY
OVERFLOW LAGOON
NoOH
ADDITION
NoOH
ADDITION
OUTFALL
Sludge
COMPRESSED
AIR
COAGULANT/
FLOCCULATION AID
SLUDGE TO
DISPOSAL
SAMPLE POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING .PICKING. SCALE REMOVAL
WIRE COATING,ALKALINE CLEANING
CENTRAL TREATMENT PLANT
WATER FLOW DIAGRAM
FIGURE 331-38
SURGE
TANK
SLUDGE
CONCENTRATOR
MECHANICAL
CENTRIFUGE
CLARIFIER
"/OIL SKIMMING
NEUTRALIZATION
FLOCCULATION
NEUTRALIZATION
EQUALIZATION

-------
NJ
H
W
PROCESS
HOT FORMING- PRIMARY a FLAT
RECYCLE FOR
l?OLL COOLING AND
OTHER NON-CONTACT
COOLINQ
PLANTS
OB2
M - 1265 METRIC TONS/DAY
PRODUCTION: 1593 TONS/OAY
OIL TO
DISPOSAL
PRODUCT
112 MILL
120 MILL
0 - 1516 METRIC TONS/DAY
1670 TONS/DAY
STREAM
a
.solids to
TOISPOSiAL
PRIMARY
PRIMARY
BACKWASH
SETTLING
BASIN
FILTER
NO
66.Z AfSEC
(1050 QPM)
FILTER
NO4?
66.2 J/SZC
(lO^oqPM
SETTLING BASIN
132.5 tfSEC
(2WO QPM)
COMBINED
SECONDARY
SCALE PIT
152-5 f/SEC
(2IOO QPM)
FILTER
^pNCiS"
SETTLING BASIN
FILTER
^NO-^
BACKWASH
PUMP
SETTLING BASIN
206 MILL
MO MILL
PRODUCT
132.5 j/S&C
RAW
MKTER
94 Jtfst
Ufo a«n)
PRIMARY
SCALE
PIT
RECYCLE
TO MOM-
CONTACT
COOLINQ
SAMPLING POINT
_56.e S/SEC
ENVIRONMENTAL PROTECTION AGENCY
too 
-------
to
h->
HOT FORMING - PRIMARY(M). SECTION(N),
FLAT-PLATi (O)
Subcategory (m)
$1* BLOOMING
MILL SCALE Pit
**17 Ajsec
poo gpm)
-&r*t
SUBCATEGORY (N)
34* STRUCTURAL
MILL SCALE PIT
SUBCATEGORY (01
30* PLATE MILL
SCALE PIT
27924/mc
flAtA
V)
nSni'
"¦ftaTSi
(5115
MjJ
fe43v5T
13.33 A/scc
SUBCATEGORY (N)
ROD MILL
J
4!
WASTE TREATMENT
SYSTEM
I
-A-
&LOWDOWM
- REcvtif
7 7 i/i«
022 gpm)
3 '
NORTH
MILLS
AND
WEST
MILLS
CENTRAL PUMP
RECYCLE
STATION
PROCESS'-
PLANT:
OSS
AH*M 1*<-
.W'<»2«E*L
LAK
J'WATER
PRODUCTIONS
H-S3" BLOOMINO MILL 993 METRIC T0NS/TURN(ip3O TONS/TURN)
H-M" STRUCTURAL MIU. 409 METRIC T0NSmiRN(45O TONS/TURN)
N	ROD MILL 369 METRIC TONS/TURN(627 TONS/TURN)
0-30* PLATE MILL 227 METRIC TONS/TURN(2SO TONS/TURN)
\
COOLING
TOWER
SOUTH MILLS
2142 J/we
(46.630 gptri
114.3 Jtfsec
(1012 gpm)
BLONOOMftl
TO POTW
PUMP - i STATION
HOT
WELL
1
N« I
CLARlFIER
1
N9 2
CLARlFIER
N« 3
CLARlFIER
V jVIV
DECAMT
TANK
THICKENER
SOUTH
LIFT STATION
PUMP HOUSE
NORTH
LI FT STATION
PUMP HOUSE
5057 j/se-C
448,442 gpm)
DISTRIBUTION
BOX
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT F0RMIN6
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DWNS/28/7 £
FIGURE3ZH-40
A SAMPLING POINT

-------
~RECYCLE TO
ROUGHING MILLS
PROCESS: HOT
PLANT-' 086
PRODUCTION:
80" HOT STRIP MILL-3084 METRIC TONS/TURN
(3400 TONS/TURNS)
160" FLAT MILL-1089 METRIC TONS/TURN
(1200 TONS/TURN)
FORMING
FLAT (0)
FINISHING
ROUGHING
SCALE
PI T
SCALE
£11
SOUTH
NORTH
TERMINAL
FROM 80
HOT STRIP MILL
ROUGHING MILL FLUME
25 M GAL
25MGAL
LAGOONS
FROM 80
HOT STRIP MILL
FINISHING MILL FLUME
FUTURE
RECYCLE SYSTE
4
MICHIGAN
in u
II HOUR
DETENTION TIME
ACROSS CLARIFIERS a LAGOONS
(7)FL0CCULAT0R
CLARIFIERS 10.4 M GALLONS
30641/SEC
148,562 GPM)
41731/SEC
(66.123 GPM)
CHEMICAL FEED a DISTRIBUTION
SLAB MILL
110" PLATE MILL
BLAST FURNACE
SINTER PLANT
BOF PLANT
CONTINUOUS CASTER
POWER STATION
7 7 91/SE C
(12,341 GPM)
/gV—
Mn
fromTheet
a TIN UILL
MH
^-50fll/SEC(B053 GPM)
RECYCL
TO
*2
PUMP
station
e
PUMP
STATION
SCALPING
TANKS
FLUME -FLUSHING
3394J/SEC
153,780 GPM)
2IOi/SEC(3448GPM)
QUENCHING ^Quench return
STATION
I2X/SEC
(17 70 GPU)
SUMP PUMPS
LAKE
WATER INTAKE
TO ALL
MILLS
OVERFLOW
QUEN
160 PLATE
MILL SCALE
MAKE-UP
A SAMPLING POINT
M.H.
ENVIRONMENTAL PROTECTION AGENCY
FROM 160
PLATE MILL
SUMP PUMPS
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
QUENCH RETURN
OWN S/1S/7B
FIGURE 3ZTHI

-------
to
H
ON
A
WATER ZflT
MERCHANT
MILL
PRIMARY
SCALE PIT
PUtAP
STATION
CHLORINATOR
7&—1
44 HOT
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PROCESS ¦- HOT FORMINC} SECTION AND FIAT.
HOT STRIP% P/PEAND TUBE WELDED
PLANT: 087
PRODUCTION	p Mn . -481 METRIC TONS/tUR»$
N - 14 3AR MILL ^3Q TONijruRN^)
O -HOT STRIP MILL 163* METRIC TONS/TUFfiS
(l800 TOVS/TURtJs)
P-WELDED TUBS MILLI12. METRIC TO*/£/TU«Afc
	_	 (tfo tons/turns)
/ 7 SO J?/SEC
CZ7t700 6PM)
BUTT
WELD
PIPE
MILL
BLOOMING
MILL HOT
SCARFED
PRIMARY
SCALE PIT
PRIMARY
SCALE PIT
&
442 J?/SEC	L___f H0*-f/SEC
(7ooo qPM) T l(i7, soo qpM)
'DISTRIBUTION
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COA&ULANT
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COAGULANT
AIDS
&
DISCHARGE
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A
Sampling pomt
ENVIRONMENTAL
PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SECTION4FLAT; HOT STRIP.
AND PlPEtTUQE WELDED
WASTEWATER TREATMENT SYSTEM
WATER FLOW D/AG/tAM
OHHi 7-1511


FIGURE 3ZH-42




-------
HOT FORMING-PRIMARY(M), SECTION(N),
PIPE a TUBE(P)
PLANT: 088
PRODUCTION
i) i/SEr
(210 GPU!
M(44 BLOOMtNQ MILL)-1725 METRIC TOtC/TURN
11900 TONS/TURN)
NC56" BILLET MILLM72 METRIC TONS/TURN(520 TONS/TURN)
N04"BAR MILL)-690 METRIC TONS/TURN(760 TONS/TURN*
79.03 VSlC
14GO GPMt-
"62 l/SFT
mi?) f>pv
PLUG Ml
SCALE
hHQU^^lEfrH'16
NC^BgiR MILL)-517 METRIC TONS/TORN (570 T0N3/TURN)
BAR Mlt_U-»S4 METRIC T0N3/TURN1720 TONS/TURN)
-163 METRIC TON:
H60 TONS/TURN
5CARFER
PlSEAMLESS PIPE 8 TUBE MILL)-I63 METRIC TONS/TURNS)
I
frMIII CIFAMIWr.l
SCALE PH
PICKLING OPERATIONS
WGMtl
209 l/SEC
PH AOJUSlMENt
5CALE Pll
' C33K) QPM)
5 l/SEC 13420 CPU!
162 l/SEC
[2876
8PM)
10 ROO
<< BLOOMING MILL
Mil IANK
M 49 l/SEC
_[M6 GP«t
Hi
T? »9 "SE
(1144 OPM)
REHEAT FURNACES
f/SEC
12* 30 GPW)
scale
PIT
ap6
T 				_fclIl!tN
FINISHING MILL
CI ARlFIER
CI ARlFIER
Mill
EFFLUENT
11 6AR mill
520 Gf i/StC
(SOB? GPM)
34BAR MRI
l/^C
<923 GPM)
209.49 «/S£C
133*9 GPMI
M? 95 I/5CC
0790 orwi
PUHP
MOUSE
tt BILLET MltL
THICKENER
FIL TRAIF
RAPID
Mil TANK
Mill EFFLUENT
OPERATING
EFFLUENT
MILL SCAlf P.?
A
yemcT miu
r\ ii i/SEC
11127 CPM> V
SOLlOS
U BAR MII.1
PUMP STATION
OTHER Mill EFFltCNT NtfERS
(VACUUM OCGASSING.ETC)
1764 t/SEC
(27,969 OPwr *
PUMP
hM
283 l/SEC
(4490 WH)

MAKE
TO 14"BAR MILL
RETENTION
B A SIN
RWfeR
MAKE UP-^
<7 ^ 1/SEC
5*2 GHM)
MAI COLLECTION SUMP
/\ SAMPLING POINF
5* i/r-Ec
1849 GPMI
F1TER
p]/MP	I	°EC*llE
I 711 27 CC
?M29 GPM)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
RIVER WATER
MAKE-UP
ENfft8M/78
FIGURE 3ZE-43

-------
REHEAT
FURNACE SKID
COOUNQ WATER
PROCESS:
PLANT-
PRODUCTION:
SECTION MILL (N)
14" BAR MILL
088
381 METRIC TONS STEEL/TURN
420 TONS STEEL/TURN
SCALE PIT RECYCLE COOLING
BAR MILL
ELFFLUENT
SOUTH
HOT SAWS
SHEARS
STANDS
PULL RODS
BAR ROTATORS
RECYCLE TO
BAR MILL
"za.2. Jf/SBC.
Qpfifk-
(703QPM)
44 ^sec
RECYCLE
REHEAT
FURNACES
NON-
2NIAC1
COOUNQ
TOWER
COOLIMQ
TOWER
COLD
WELL
coourf
WATER
T
CITY WATER
MAKE-UP
NORTH
BLOWDOWN
(126 GPM)
0 t/tec
(2.366 QPM)
141 t/sec
CLARIFIER
LARIFIER
(874 ^PM)
55 Vsec
WELL
om.9/20m
MAKE-UP WATER
FROM RIVER WATER
PUMP HOUSE * I A
"^7/ Jt/5£C ^
{!1S qPAA,
BAR MILL
STANDS
EFFLUENT £ SKIP
COOLINQ WAT^R
SCALE PIT COOUNQ
WATER POND
u
ui
I
cr
z
8
o
RECYCLE TO
BAR MILL
76 %jsec
RECYCLE
TO HOT SAWS
(\20 qpM)
7.6 JP/sec
BLOWDOWN TO SEWER
ENVIRONMENTAL PROTECTION AGENCY
CLARIFIER
UNDERFLOW
POND
STEEL INDUSTRY STUDY
SECTION MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM	
FIGURE SH-44

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HOT FORMING SUBCATEGORY
SECTION VIII
COST, ENERGY, AND NONWATER QUALITY IMPACTS
Introduction
This section presents the incremental costs incurred in applying the
different levels of pollution control technology to the hot forming
subcategory. The analysis addresses energy requirements, nonwater
quality impacts, and the techniques, magnitude, and costs associated
with the application of the proposed BPT, BAT, BCT, NSPS, PSES, and
PSNS limitations and standards. In addition, air pollution, solid
waste disposal, the BCT cost comparison, and the consumptive use of
water are addressed.
Actual Costs Incurred By the Plants Sampled for this Study
The water pollution control costs supplied by the industry for the hot
forming operations sampled during this study and those for operations
responding to the D-DCPs are presented in Tables VIII-1 through
VIII-5. These costs were adjusted to July 1, 1978 dollars from the
actual cost (current year) data supplied by the industry. In most
cases the D-DCP cost data are more detailed than the costs supplied
for the sampled plants, and are considered to be more representative
of treatment costs. Also, where central treatment systems were
present, the industry often supplied total costs data for the entire
treatment system. The Agency analyzed these costs and apportioned
them to determine costs attributable to hot forming wastewaters.
Because of the extensive use of central treatment for hot forming
wastewaters, the Agency could not directly verify its model-based cost
estimates for each hot forming subdivision with cost data reported by
the industry for central treatment systems. However, the Agency did
compare its model-based treatment costs with industry costs for
several central treatment systems by summing the model-based 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 hot forming wastewaters in particular. In
fact, as shown by the data presented in Volume I, the Agency's cost
estimates for separate treatment for all finishing operation
wastewaters are likely to be significantly higher than industry costs
for central treatment.
Control and Treatment Technology (C&TT)
Recommended for Use in the Hot Forming Subcategory
The treatment system components considered for BPT and BAT are
presented in Tables VII1-6 and VII1-7. The C&TT steps are identical
for primary, section and flat operations and are described in Table
219

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VII1-6. The model BPT treatment system for hot working pipe and tube
operations are slightly different than those for the other hot forming
operations and are described separately. The proposed limitations do
not require the use of the model treatment systems; any treatment
system which achieves the proposed limitations is acceptable.
The following items are described in Tables VIII-6 and VIII-7:
1.	The individual treatment components
2.	Status and reliability
3.	Problems and limitations
4.	Implementation time
5.	Land requirements
6.	Environmental impact other than water
7.	Solid waste generation and primary constituents
Cost, Energy, and Nonwater Qualitv Impacts
General Introduction
The installation of the BPT, BCT, BAT, NSPS, PSES, and PSNS
alternative treatment systems will involve additional expenditures of
money and energy. The Agency estimated costs and energy requirements
based upon alternative treatment systems developed in Sections IX
through XIII of this report. These data are presented in tables
appearing in this section.
Development of Costs for the Hot Forming Subcategory
A treatment model concept and the application of co-mingling factors
were used to develop the hot forming cost estimates. These two
factors are described below.
Hot Forming Treatment Model Concept
To develop the compliance costs for the alternate treatment systems,
actual treatment practices within the hot forming subcategory were
analyzed to determine the types of treatment facilities currently in
use. First, the Agency found that over 90% of the hot forming
operations treat their wastewaters in central treatment systems.
Although there are 485 separate hot forming operations in this
country, there are about 250 joint treatment facilities. EPA model
treatment systems were initially costed on the basis of joint
treatment for mills in the same hot forming subdivision. For example,
if there are five section mills at one plant site, it was assumed that
the combined waste stream from these mills will be treated in one
system. Therefore only one treatment system was costed based upon the
combined tonnage of the five mills. In this way the affect of joint
treatment of like wastewaters (same subdivision) was accounted for in
the cost estimates. The Agency believes that this approach is
justified since almost all hot forming plants treat the hot forming
wastewaters from the same types of mills in a joint treatment system.
Likewise, if different hot forming wastewaters are combined in one
system (i.e., primary and section wastewaters) still greater cost
reductions can be achieved. The cost reductions achieved with this
220

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type of treatment system are accounted for by the application of
co-mingling factors. These factors are explained below.
Besides identifying plants which jointly treat wastewaters, it was
found that the types of treatment systems installed fall into three
basic categories. These categories have been developed into treatment
model configurations and are shown in Figure VIII-1. Plants that did
not fall into one of the three categories were assigned to the third
category. As shown, the three models will feed into the BCT/BAT-1
system at different flows and concentrations. However, the BCT/BAT-1
effluents have the same wastewater quality and flow regardless of
model type.
Model 1 has treatment components identical to the treatment system
proposed in the 1976 regulation for hot forming operations. However,
the revised data base has demonstrated different applied flows from
the 1976 data base. Out of the 250 joint treatment systems in
existence, about 3% were of the Model 1 configuration as of January 1,
1978.
The Model 2 treatment system is the same as Model 1 with the exception
that the primary scale pit recycle is not included in Model 2.
Approximately 12.5% of the hot forming joint treatment systems were of
the Model 2 configuration as of January 1, 1978. Because of the
higher flows for Model 2 plants, the cooling tower and recycle
components of BCT/BAT-1 are more costly.
For the purpose of costing, all remaining treatment plants have been
classified as Model 3 systems. The treatment systems installed at
Model 3 plants range from only primary scale pits to extensive central
treatment systems. Large and unnecessary capital and annual
expenditures would be incurred by the industry if the Model 3 plants
were required to install the BPT model treatment system components
prior to installing the BCT/BAT treatment technology. It is more
efficient to install the BAT treatment system directly without
incurring the additional costs for the intermediate BPT model
treatment systems. By developing the model concept and recognizing
this trend, a more accurate representation of the cost of compliance
for the hot forming subcategory has been determined, and a more
realistic cost impact on the steel industry can be assessed.
Derivation of Co-Minalinq Factors
It has been well documented that central treatment systems are the
least costly way to treat wastewaters with similar pollutant
characteristics. However, treatment costs have previously been
developed strictly from the model plant approach with little
consideration of the cost savings achieved with central treatment
systems. For hot forming, the Agency completed an inventory which
detailed existing joint treatment systems and the types of hot forming
wastewaters which are combined. Because all hot forming wastewaters
have similar wastewater characteristics and treatability, their
combination in joint treatment systems is warranted and practiced
throughout the industry.
221

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The Agency calculated the cost reductions achieved with these joint
systems on a percentage basis. First, the Agency developed a cost
estimate assuming that all plants employed separate treatment. Next,
it completed the cost estimate based upon actual treatment practices.
For example, if wastewaters from a primary mill and a section mill are
combined, the combined treatment system was costed. This type of cost
development was done plant by plant and subdivision by subdivision.
The costs for the subdivision calculated on the basis of central
treatment systems were then divided by the costs for the subdivision
developed on the basis of separate treatment to calculate the
co-mingling factor for that subdivision. These factors, shown in
Tables VIII-9A and 9B, account for the cost reductions achieved with
the central treatment systems and were used to more accurately develop
the BPT, BAT, and BCT cost estimates presented herein.
Estimated Costs for the Installation of Pollution Control Technologies
A. Costs Required to Achieve the Proposed BPT Limitations
The Agency has estimated that the industry will need to spend
about 200 million dollars (capital cost) to bring present water
pollution control facilities into compliance with the proposed
BPT limitations. The BPT model cost data for the hot forming
subcategory are presented in Tables VIII-10 through VIII-19.
This 200 million dollars is out of a total estimated capital cost
for compliance with the proposed BPT limitations of 650 million
dollars. This estimate assumes that 1976 BPT technology will be
installed at hot forming operations prior to the BCT/BAT systems,
and that the hot forming operations have flow rates as originally
developed for the 1976 BPT limitations.
However, the Agency has determined that neither of these
assumptions are valid. For example, the new data base has shown
that many of the average applied and discharge flow rates are
different from those developed from the limited data available in
1975. Additionally, as noted earlier, it is more expensive to
install the 1976 BPT model treatment system prior to installing
BCT/BAT systems (i.e., installing from Models 1, 2 and 3 to 1976
BPT, then installing BCT/BAT) than to directly install the
BCT/BAT treatment systems.
Estimates have been made of the expenditures needed to bring the
facilities from current treatment levels to a level from which
they can then install the BAT treatment technology; 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 type of components that the plants
will install in the future.
Using the rationale explained above, a plant by plant inventory
was conducted for each hot forming subdivision to determine the
222

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number of plants in each model configuration. Model sizes were
then developed for each subdivision based upon average plant
sizes of plant sites in each model. Then, using the updated flow
rates (see Section X), unit costs for each treatment component
were developed. Total cost requirements were then calculated by
multiplying the unit costs by the number of components required.
The capital and annual cost summaries for the hot forming
subcategory are presented in Tables VIII-9A and VIII-9B.
As can be seen in these tables, about $135 million dollars and
$13.4 million of additional capital and annual costs,
respectively, will be required. These costs are a realistic
estimate of hot forming BPT cost requirements taking into account
the cost reductions achieved by the use of central treatment
systems at hot forming operations.
B.	Costs Required to Achieve the Proposed BAT Limitations
The Agency considered two BAT alternative treatment systems for
the hot forming operations. BAT Alternative 1 consists of a
cooling tower and recycle system for Models 1 and 2 and a cooling
tower, recycle system and filter system for Model 3 plants. BAT
Alternative 2 includes the components of Alternative 1 and also a
sulfide addition system. These alternatives are described in
more detail in Section X. The additional capital and operating
costs for the hot forming operations are presented in Tables
VI11-20 through VI11-45. These costs were developed by
subdivision and by model type (1, 2, or 3). Summaries of these
costs by subcategory are shown in Tables VI11-46 and VI11-47.
Total costs for the two BAT Alternatives are presented below.
Costs (Millions of Dollars)
Capital	Total
In-place Required Annual
BAT-1	100.8	434.7	110.8
BAT-2	100.8	453.5	114.8
C.	Costs Required to Achieve the Proposed BCT Limitations
The Agency developed a BCT model treatment system for the hot
forming subcategory. The BCT system, component-wise, is
identical to the BAT Alternative No. 1. However, the proposed
BCT limitations are for only the conventional pollutants. Refer
to Section XI for additional information on BCT. Costs for BCT
are presented in Table VIII-48 and are fully included in the BAT
costs.
D.	Costs Required to Achieve NSPS
The Agency considered two NSPS alternative treatment systems for
the hot forming operations. New facilities constructed after
proposal of these standards will be required to achieve NSPS.
The NSPS systems are similar to the BAT alternative treatment
systems previously discussed. Model costs have been developed
223

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for the two NSPS alternative treatment systems. These costs are
shown in Tables VII1-49 through VII1-59 for the hot forming
operations.
E. Costs Required to Achieve Pretreatment Standards
Pretreatment standards apply to those plants discharging to POTW
systems. The Agency considered one pretreatment model treatment
system for all hot forming operations. This system reduces the
discharge flow from the plants considerably and reduces the
discharge of toxic metal pollutants to low levels. The
pretreatment treatment system is identical to the BPT/BAT Model 1
Alternative No. 1 system discussed earlier.
The model cost data for the pretreatment treatment model are the
same as the costs for the NSPS No. 1 system. For this reason,
additional model costs have not been listed for the pretreatment
system. To determine these costs the appropriate NSPS model cost
data should be consulted as pointed out in Table VIII-60.
Industry-wide PSES costs are included in those for BPT and BAT.
Energy Impacts Due to the
Installation of the Requisite Technology
Moderate imounts of energy will be required to operate the various
levels oi treatment for the hot forming operations. The only
significant expenditures will occur at the BAT level due to the energy
usage required for recycle systems. The BPT model treatment system
components require very little energy partially because of energy
credits resulting from reduced intake pumping costs. Energy
requirements at NSPS, PSES, and PSNS will be about the same as the
total corresponding BAT alternative treatment system.
A.	BPT
The Agency estimated the energy expenditures for the BPT
treatment systems. These estimates are based upon the assumption
that all hot forming operations will install treatment systems as
described by the treatment models and at the flow rates
determined from the updated data base. It is estimated that the
BPT model treatment system components for all hot forming
operations in the United States will consume approximately 54.1
million kilowatts of electricity per year. This represents about
0.10% of the 57 billion kilowatts used by the steel industry in
1 978.
B.	BAT
Additional power consuming equipment will be necessary to upgrade
the industry from the BPT treatment system to the two BAT
alternative treatment systems. The energy requirements for the
two BAT alternatives are presented in Table VIII-61. Assuming
all the hot forming operations install Alternative No. 1
technology, the total energy used will be 795.8 million kw, or
1.4% of the electrical energy used by the steel industry in 1978.
224

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If BAT Alternative No. 2 is installed, a small additional amount
of energy will be consumed. The total energy requirements for
Alternative No. 2 are estimated at 800.1 million kilowatts per
year. The Agency considers these energy requirements to be
reasonable in light of the substantial environmental benefits
achieved, the total energy requirements of the industry, and,
energy requirements for zero discharge systems. Moreover, the
effluent reduction benefits associated with compliance with this
proposed regulation justify these requirements.
C. NSPS, PSES, and PSNS
The NSPS, PSES, and PSNS treatment systems are comprised of the
BPT model treatment system and BAT alternative treatment system
components. Therefore, the energy requirements per model plant
will be equivalent to the summation of the BPT and BAT energy
requirements. The Agency did not calculate the energy impacts
for NSPS and PSNS since the number of new source hot forming
operations was not projected as part of this study. The energy
impacts of PSES are included in those listed above for BPT and
BAT.
Nonwater Quality Impacts
In general, there are minimal nonwater quality impacts associated with
the proposed treatment technologies. The Agency analyzed three
impacts; air pollution; solid waste disposal; and water consumption.
The Agency found that no significant nonwater quality impacts will
result from the installation of the hot forming subcategory treatment
systems under consideration.
A.	Air Pollution
The use of cooling towers in the BAT Alternative No. 1 system
will result in the generation of water vapor plumes; however,
these plumes should not contain significant levels of
particulates or volatile organics. No other air impacts are
expected to occur as a result of the installation of the cooling
towers. Therefore, no significant air pollution impacts from
this alternative are expected.
BAT Alternative No. 2 (also NSPS Alternative No. 2), contains a
sulfide addition system. The use of this component could result
in the release of sulfide fumes to the atmosphere in the event of
a plant upset when H2S is used. However, the use of FeS is
recommended to avoid this problem. The Agency believes that H*S
emissions would be minimal since hot forming wastes are not
acidic. No other air pollution impacts will result from the
installation of any of the treatment components considered.
B.	Solid Waste Disposal
Sedimentation of the hot forming wastewater, which are high in
suspended solids, results in the generation of significant
quantities of sludges. The Agency has estimated the amount of
225

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solid waste generated in the BPT and BAT treatment systems and
has listed these levels in Tables VIII-62 and VIII-63. A summary
of these solid wastes generation levels are listed below for BPT
and BAT.
As shown above, a significant amount of sludge is generated at
the BPT level of treatment. However, most of this solid waste,
which consists of both solids and oils, is collected in the
primary scale pit. The solids are removed either by clam shell
or by drag link conveyor. Oils are usually collected by skimmers
or oil troughs. The oils are collected and disposed of off-site
if they cannot by reused or reclaimed for other uses. The scale,
because of its high iron content, is collected and often reused
as feed to sinter plants.
Because most solid and oil collection occurs at the BPT level of
treatment, sludge generation at the BAT level of treatment is
small, being on the order of 1-2% of the sludge generation at the
BPT level. Therefore, there is very little impact with respect
to sludge generation as a result of the implementation of either
BAT system.
As noted previously, NSPS, PSES, and PSNS systems are made up of
BPT and BAT treatment system components. Therefore, the sludge
generation at NSPS, PSES, and PSNS will be equivalent to the
sludge generation rates of the BPT and BAT systems. However, as
explained above, most of the sludge produced at the BPT level of
treatment can be reclaimed and reused. This, in combination with
the small sludge generation rates in the BAT treatment system
components, results in negligible impacts at NSPS, PSES, and
PSNS.
C. Water Consumption
In the hot forming subcategory, cooling towers are components of
the BAT, BCT, NSPS, PSES, and PSNS alternative treatment systems.
Those towers will evaporate some water. Cooling towers are being
considered as treatment components in order to allow higher
degrees of recycle. The Agency analyzed the degree of water
consumption and its impact. However, it found that the degree of
water consumption that results from the use of the alternative
treatment systems is not severe. The analysis detailed the type
of cooling devices in use at hot forming operations, the
evaporation rates for the cooling devices in use, and quantified
the amount of water that would be consumed in order to meet BAT
limitations. It was determined that of the 3900 MGD of process
water applied to the hot forming operations, less than 19.4 MGD
Treatment Level
Solid Waste Generation
Hot Forming Subcategory
	(Tons/Year)	
BPT
BAT-1
BAT-2
6,014,000
94,829
98,B29
226

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or 0.5% of this water will be consumed due to evaporation from
BAT treatment components. This amount of water consumption is
insignificant, even to plants in "arid" or "semi-arid" regions.
This analysis is discussed in Section III of Volume I of the
Development Document. The Agency finds that the amount of water
consumed in complying with this proposed regulation is justified
in both a nation-wide and water scarce region basis when compared
to the effluent reduction benefits achieved. The high recycle
rates also serve to minimize necessary surface and subsurface
water withdrawals and run-of-the-river type cooling which can
cause nearly as much consumptive loss as evaporative cooling
facilities. Plants in arid and semi-arid regions have had high
rate recycle systems in operation for many years.
Summary of Impacts
The Agency concludes that the pollution control benefits described
below for the hot forming subcategory justify the adverse impacts
associated with energy consumption, air pollution, solid waste
disposal, or water consumption.
Effluent Loadings (Tons/Year)
Raw Waste Proposed BPT BAT
Proposed
BAT and BCT
Flow, MGD
TSS
Oil and Grease
Toxic Metals
4, 188
6,017,455
272,440
34,620
2,225
43,860
24,140
1,670*
168
2,724
908
90
* BAT Feed Value
227

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TABLE VIII-1
EFFLUENT TREATMENT COSTS
HOT FORMING: PRIMARY
(All Costs Are Expressed in July, 1978 Dollars)
Plant Code	A-2
Reference No.	0112B
Mill
Initial Investment	$951,800
Cost
Annual Costs
Cost of Capital	$ 40,000
Depreciation	95,180
Operation and Maintenance	86,600
Energy, Power, Chenicals, etc. NA
Credit (Sale of Scale)
Other
TOTAL	$221,180
$/Ton	$0,203
B-2
0112B
C-2
0684H
$1,913,300 $4,083,300
(1)
(2)
80,400
191,330
125,400
NA
(1)
(2)
172,100
408,340
142,900
D-2
0946A
$1,307,900
(1)
(2)
55,000
130,790
43,200
088
0684H
$2,550,800
0112B
45 x 90
Slabbing
$2,577,800
(1)
(2)
$ 109,700^ $ 195,910
255,080
128,200
45,800
(2)
143,210
2,640
65,700
14,550
0460A
Billet
$122,100
(3)
(3)
$ 2,430
17,440
3,590
36,900
34,000
(3)
(3)
$ 397,130 $ 723,340 $ 228,990 $ 538,780 $ 442,010 $ 26,360
$0,286	$0,483	$0,447	$0,400	$0,251	$0,094

-------
TABLE VIII-1
EFFLUENT TREATMENT COSTS
HOT FORMING: PRIMARY
PAGE 2	
Plant Code	E X 081
Reference No	0B68A 0020B 0256 0176	0440A
Mill	W" Blooming - Slab
Initial Investment	$207,700 $1,307,300 $65,300 $29,800	$2,138,600
Cost
Annual Costs	. . . . , -	. .	, .
Cost of Capital	$ 8,930;" $ 56,200}" $ 2,810),' $ 1,280),'	$ 64,160^?
Depreciation	20,770w' 130,73011 6,530^'	2,980l/J	142,570^'
Operation and Maintenance	15,900 2,290 12,100	83,600
Energy, Power, Chemicals, etc.	' 13,100 1,740 1,100	110,000
Credit (Sale of Scale)
Other	3,600
TOTAL	$ 57,000 $ 202,830^ $13,370 $17,470	$ 403,930
$/Ton	$0,151 $0,285 $0,204 $0.22	$9.85
(1)	Cost of capital is based on the formula, Initial Investment x 0.043.
(2)	Depreciation is based on the formula, Initial Investment x 0.10.
(3)	Company supplied data.
NOTE: For those plants employing central treatment facilities, costs are apportioned on the basis of flow.

-------
TABLE VIII-2
EFFLUENT TREATMENT COSTS
HOT FORMING-SECTION
(All costs are expressed in July, 1978 dollars)
Plant Code	A-2	D-2	E-2 F-2	G-2 H-2	1-2 C	H
Reference No.	0112B	0946A	0196A 0384A	0640A 0432A	08560 0424	0248A+B
Mill	____	_____
Initial Investment	2,004,900	1,676,300	2,695,060 4,375,210	1,036,170 471,040	6,935,190 33,790	NA
Cost($)
Annual Costs($)	..	. j.	, j.	.. ..	. .
Cost of Capital .	86,210),'	72,080	115,890}'' 188,130);'	44,560)'' 20,250)'	298,210" MSO)*'
Depreciation	200,4901'	167,6301	; 269,510VZJ 437,5201	' 103,620^' 47,100^'	693,520U; 3,380U;
to Operation and	181,760	55,290	43,960 163,090	23,130 16,640	108,870 490
O Maintenance
Energy, Power,	NA	83,200	60,630 112,980	6,990	840 1,340
Chemicals, etc.
Other	250	5,570	65,750
T0TAL($)	468,460	378,200	490,140 907,290	171,310 90,980	1,167,190 6,660
$/ton	0.308	0.674	0.977 2.56	1.109 0.244	2.75 0.630
(1)	Cost of capital is based on the formula: Initial Investment x 0.043.
(2)	Depreciation is based on the formula: Initial Investment x 0.10.
(3)	Company Basis Data.
(4)	Costs of central treatment cannot be apportioned; therefore, these are total system costs.
NOTE: For those operations employing central treatment facilities, costs are apportioned on the basis of flow.

-------
TABLE VIII-2
EFFLUENT TREATMENT COSTS
HOT FORMING—SECTION
FACE 2	
Plant Code
Reference No.
Mill
K
0256
O
0176
R
0240A
M
0432 J
Q
0684D
081
0176(01-03)
Nos. 1+2
083
0860H
087
0432A-02
14"
Merchant
088
0684H( 06-07)
lO'VH"
to
ijj
M
Initial Investment
Coat($)
Annual Costa($)
Cost of Capital
Depreciation
Operation and
Maintenance
Energy, Power
Chemicals, etc.
Other
292,570
12,580
29,260
10,240
(1)
(2)
110
383,900
16,510
38,390
13,440
(2)
140
NA
NA
226,580
9,740
22,660
12,790
(1)
(2)
28,500
1,200
2,850
11,600
1,100
(1)
(2)
Cost
Data Was
Not
Supplied
3,042,700
130,800
304,270
67,200
12,400
469,800
(1)
(2)
20,200
47,000
23,600
8,400
(1)
(2)
T0TAL($)
$/ton
52,190
2.86
68,480
1.15
45,190
0.078
16,750
0.278
514,670
0.887
99,200
0.126
(1)	Cost of capital is based on the formula: Initial Investment x 0.043.
(2)	Depreciation is based on the formula: Initial Investment z 0.10.
(3)	Company Basis Data.
(4)	Costs of central treatment cannot be apportioned; therefore, these are total system costs.
NOTE: For those operations employing central treatment facilities, costs are apportioned on the basis of flow.

-------
TABLE VIII-2
EFFLUENT TREATMENT COSTS
HOT FORMING-SECTION
PAGE 3
NJ
00
to
Plant Code
Reference No.
Mill
Initial Investment
Cost($)
Annual Costs($)
Cost of Capital
Deprec iat ion
Operation and
Maintenance
Energy, Power
Chemicals, etc.
Other
T0TAL($)
$/ton
088
0684H-03
32"
100,900
4,300
10,100
5,100
1,800
21,300
0.0341
088
0684H-01
36"
469,800
(1)
(2)
20,200
47,000
23,600
8,400
99,200
0.174
(1)
(2)
081
0176-04
No. 4 Spec.
1,880
80
190
760
(1)
(2)
70
1,100
0.014
088
0684H-02
34" Spec.
79,100
3,400
7,910
4,000
1,400
16,710
0.020
(1)
(2)
0060F-05(5)
Wide Flange
2,736,900
(1)
(2)
117,700
273,700
146,230
49,120
40,140
626,890
3.19(6)
0068B(4)
12" Bar
237,770
35,670
13,210
50,880
(3)
(3)
3,230
102,990
1.080
008SD(5)
Bar Mill
491,400
21 L30^^
' (2)
49,140
29,090
8,760
800
108,920
0.42(&)
0136B
10" Bar
Costs
Are Not
Applicable
Discharge
to
POTW
(1)	Cost of capital is based on the formula: Initial Investment x 0.043.
(2)	Depreciation is based on the formula: Initial Investment x 0.10.
(3)	Company Basis Data.
(4)	Cos18 of central treatment cannot be apportioned; therefore, these are total system costs.
(5)	Cost apportionment is based on company estimate of percentage.
(6)	Total Annual Cost J Total 1977 Production.
NOTE: For those operations employing central treatment facilities, costs are apportioned on the basis of flow.

-------
TABLE VIII-2
EFFLUENT TREATMENT COSTS
HOT FORMING-SECTION
PAGE 4	
to
u>
u>
Plane Code
Reference No.
Mill
Initial Investment
Cos t ( $ )
Annual Costs($)
Cost of Capital
Deprec iation
Operation and
Maintenance
Energy, Power,
Cheaicals, etc.
Other
TOTAL($)
5/ton
0136B
14" Bar
Operation
Discontinued 11/77
0612(01-04)(5)
24" Wide Flange
5,760,000
247,680(*>
576,000
181,760
266,240
1,271,680
1.01
0672B
I-Bean, Rail
No Co81
Data Available
0684H-05
14" Bar
5,014,790
215,540<*>
501,480
106,750
81,800
28,950
934,520
1.99
0860H-03
Rod
3,331,650
143,260^
333,170
167,000
643,430
1.82
(1)	Cost of capital is based on the formula: Initial Investment x 0.043.
(2)	Depreciation is based on the formula: Initial Investment x 0.10.
(3)	Company Basis Data.
(4)	Costa of central treatment cannot be apportioned; therefore, these are total system costs.
(5)	Cost apportionment is based on company estimate of percentage.
(6)	Total Annual Cost S Total 1977 Production.
NOTE: For those operations employing central treatment facilities, costs are apportioned on the basis of flow.

-------
TABLE *111-3
EFPunr TREAxmrr costs
¦07 FOMK-IUT
HOT ST* If AMP SBEET
(All cost* are expretsed in July, 1978 dollar*)
Plant Code
Reference Mo.
Initial Investment
Cost
E
0020B
1,901,300
n-2
0384A
10,604,000
1-2
0060B
2,007,800
086
0112D
80"
30,734,300
087
0432A
44"
8,153,600
0060
80"
0432C
80"
23,133,760 7,050,800
0684V
South
Jobbing
459,530
0920*
80"
4,381,000
to
u>
Annual Costs($)
Cost of Capital
Depreciation
Operation and
Maintenance
Energy, Power,
Cheaicals, etc.
Other
TOTAL(S)
$/Ton
81,800
190,130
66,500
27,900
366,330
0.492
(1)
(2)
441,20ofl>
1,050,400
344,400
196,400
2,062,400
0.606
84,300"}
200,780'' '
252,900
537,980
0.928
1,322,000
3,074,530
809,700
316,800
5,523,030
1.496
(1)
(2)
350,600.J?
815,360
166,000
30,700
1,362,660
0.705
1,943,240
1,156,690
787,350
606,940
25,360
4,519,580
1.935
(3)
(3)
303,180
705,080
246,780
(1)
(2)
(4f
1,255,040
0.469
19,760
45,950
16,080
81,790
10.622
(4)"
188,380
438,100
153,340
(1)
(2)
(4)
779,820
0.321
(1)	Cost of capital is based on the foraula, Initial Investaent x 0.043.
(2)	Depreciation is based on the foraula, Initial Investaent x 0.10.
(3)	Coapany Basis Data.
(4)	Costs are based on the foraula, Initial Investaent x 0.035.
NOTE: For those operations eaploying central treataent facilities, costs are apportioned on the basis of flow.

-------
TABLE VIII-4
EFFLUENT TREATMENT COSTS
HOT FORMING-FLAT
PLATE
(All cost are expressed in July, 1978 dollars)
to
0J
l/l
Plant Code
Reference No.
Mill
Initial Investment
Cost
Annual Costs
Cost of Capital
Depreciation
Operation and
Maintenance
Energy, Power,
Chemicals, etc.
Other
TOTAL($)
$/Ton
J-2
0860B
14,478,500
621,100
1,447,850
269,100
(1)
(2)
105,200
98,500
2,541,750
0.812
K-2
0860B
4,482,900
(1)
(2)
188,300
488,290
555,400
1,231,990
1-19
086
0112D
160"
7,560,300
325,100j'j
756,030
415,900
162,700
24,100
1,593,830
1.213
0684B
56"
2,219,100
95,420<*>
221,910
UNK
114,700
45,180
447,210
0.313
0684F
84"
32,799,500
(3)
1,311,980^'
1,639,980
587,950
542,360
60,660
3,872,930
2.055
(1)	Cost of capital is based on the formula, Initial Investment x 0.043.
(2)	Depreciation is based on the formula, Initial Investment x 0.10.
(3)	Company Basis Data.
NOTE: For those operations employing central treatment facilities, costs are apportioned on the basis of flow.

-------
TABLE VIII-5
EFFLUENT TREATMENT COSTS
HOT WORKED PIPE AMD TUBE
(All coats are expressed in July, 1978 dollars)
KJ
OJ
cn
Plant Code
Ke ference No.
Hill
Initial Investaent
Cost(S)
Annual Costs($)
Coat of Capital
Depreciation
Operation and
Maintenance
Energy, Power,
Cheaiicals, etc.
Other
0196A
E-2
0916A
II-2
0728
JJ-2
0256G
KK-2
TOTAL ( $ )
$ /Ton
879,400
36,900
87,940
14,300
19,800
158,940
0.930
(1)
(2)
393,300
16,500
39,330
2,760
5,900
64,490
0.379
(1)
(2)
57,900
2,400
5,790
9,200
10,400
27,790
0.398
(1)
(2)
9,800
415
980
9,400
1,000
11,795
0.093
(1)
(2)
0432A
087
1,285,600
55,280
128,560
28,400
5,250
217,490
1.087
(1)
(2)
0684H
088
1,201,400
51,700
120,100
36,900
21,500
230,200
0.166
(1)
(2)
0240B
Hot Mill
824,400
82,44o">
41,220
14,350
1,970
12,990
152,970
*
0652A
Tube
285,300
12,270
28,530
10,000
1,000
51,800
1.079
(1)
(2)
0728
CW
192,500
8,280<1>
19,250
30,780
NA
58,310
1.500
(1)	Cost of Capital is based on the fornula, Initial Investaent x 0.043.
(2)	Depreciation ia based on the formula, Initial Investment x 0.10.
(3)	Company Basis Data.
* : Confidential Inforaation.
NOTE: For those operations employing central treatment facilities,
costs are apportioned on the bases of flov.

-------
TABLE VIII-6
CONTROL AMD TREATMENT TECHNOLOGIES
HOT FORMING - PRIMARY. SECTION, AMD FLAT
Treatment and/or
Control Methoda Employed*
A. Primary Scale Pit - Thia
atep providea the initial stage
for removal of heavy aill acale
and the heavier auapended aolida.
(o
u>
Statu* and
Reliability
Widely used in the hot forming
aubcategory aa an integral
part of their operationa.
B. Surface Skiaing - Remove a
oila and greaae* from the aurfaee
of the wastewater.
C. Recycle - Recyclea a portion
of the priaary acale pit effluent
back to the hot forming operation
(principally for flume flushing).
Problems
and Limitations
Accumulated acale must
be removed by clam
•hell or other devicea
on a regular basis.
Implemen-
tation
Time
6-9
months
Land
Requires
Refer to
Table VIII-8
Very widely uaed in the hot
forming aubcategory aa well
as in other steel plant vaate-
water treatment operationa.
Thia type of recycle operation
ia widely uaed throughout the
hot forming subcategory.
Hydraulic overload or 3 months
aurfaee turbulence
will result in poor oil
removal performance.
The potential exist* 12-15
for scaling and plug- months
ging due to the in-
creaaed diasolved aolida
concentrationa aaaociated
with recycle operationa.
Refer to
Table VIII-8
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
Although mill
scale removed
from the acale
pit ia usually
returned to other
ateel plant opera-
tions, any remain-
ing scale and
aolida must re-
ceive proper
diapoaal.
The skimmed oils
and greases must
receive proper
disposal.
Solid Waste
Generation and
Prisury
Constituents
The solid waste
generation rates
are presented in
Table VIII-62.
The scale consists
basically of metal-
lic oxides removed
from the surface
of the hot formed
product.
None
Refer to Table
VIII-62 for the
skinned oil genera-
tion rates as-
sociated with the
varioua hot forming
operations.
None

-------
TABLE VIII-6
CONTROL AND TREATMENT TECHNOLOGIES
HOT FORMING - PRIMARY, SECTION, AND FLAT
PAGE 2
Treatment and/or
Control Methods Employed*
D. Roughing Clarifier - Provides
the capability for additional
suspended solids removal.
nj
to
oo
Status and
Reliability
Widely used in the hot forming
subcategory and throughout
the steel industry in various
wastewater treatment opera-
tions .
Problems
and Limitations
Implemen-
tation
Time
Hydraulic surges must 15-18
be controlled. In	months
addition, routine or
continuous solids re-
moval must be provided
in order to prevent
excessive solids accumu-
lation which in turn
could damage the clari-
fier rake drive mechanism.
Land
Requirements
Refer to
Table VIII-8
Env i ronmenta1
Impact Other
Than Water
The sludges re-
moved from the
clarifier and de-
livered to the
vacuum filter
must ultimately
receive proper
disposal.
Solid Waste
Generation and
Primary
Constituents
Refer to Table
VIII-62 for the
generation rates
of solids, con-
sisting primarily
of metal oxides,
for each hot
forming operation.
E. Vacuum Filter - Used to dewater Very widely used both in the
the sludges removed in Step D.	hot forming subcategory and
in many other steel industry
wastewater treatment opera-
tions .
Routine maintenance of 15-18
vacuum pumps and filter months
mechanism is necessary.
F>ilter media must be
replaced periodically.
Refer to
Table VIII-8
The dewatered
solids (filter
cake) must re-
ceive proper
disposal.
The quantities of
filter cake gen-
erated at this step
are included in
Table VIII-62. The
solids in the filter
cake are similar in
nature to those
removed at the scale
pit and are the same
as those removed
from the roughing
clarifier.

-------
TABLE VIII-6
CONTROL AND TREATMENT TECHNOLOGIES
HOT FORMING - PRIMARY, SECTION, AND FLAT
PACE 3	
(O
CJ
vo
Treatment and/or
Control Methods Eaployed*
F. Deep Bed Pressure Filter -
These filters provide additional
suspended solids removal capa-
bility. The backwash is returned
to the roughing clarifier.
Status and
Reliability
Probleas
and Limitations
Daed at a number of hot forming Hydraulic overloads
operations as well as in a wide must be controlled,
variety of other steel industry Poor solids removal
wastewater treatment applica-
tions.
G. Cooling Tower - Used to reduce
the heat load o£ the wastewater
recycle system.
Widely used in the hot forming
subcategory as well as in
numerous other steel industry
water/wastewater recycle
processes.
Implemen-
tation	Land
Time Requirement!
15-18
months
Refer to
Table VIII-8
in Step D will impede
efficient filter
operation.'
The potential exists
for scaling and plug-
ging due to the in-
creased dissolved
solids concentrations
associated with cooling
and recycle operations.
In addition, biological
fouling within the
cooling tower sust be
controlled.
18-20
months
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
The backwash
solids must re-
ceive proper
disposal.
Solid Waste
Generation and
Primary
Constituents
The backwash solids
are eventually re-
moved from the
treatment system by
the vacuum filter
(Step E). Refer to
Table VIII-62 for
the quantities of
solids resK>ved.
The backwash solids
are similar in
nature to the other
solids removed by
this treatment
system.
Any sludge which Virtually nil.
may accumulate in
the cooling tower
will require proper
disposal. Care oust
be exercised in the
selection and use of
chemicals used to
control fouling.

-------
TABLE VIII-6
CONTROL AND TREATMENT TECHNOLOGIES
HOT FORMING - PRIMARY, SECTION, AND FLAT
PAGE 4
NJ
lb-
CD
Treatment and/or
Control Methods Employed*
H. Recycle - Increase the recycle
rate to reduce the discharge
flows to the BAT/BCT levels.
I. Filtration - These filters
provide additional suspended
solids removal capability.
The backwash is returned
to the roughing clarifier.
Status and
Reliability
This type of recycle operation
is widely used throughout the
hot forming subcategory.
Problems
and Limitations
The potential exists
for scaling and plug-
ging due to the in-
creased dissolved
solids concentrations
associated with recycle
operations.
Implemen-
tation	Land
Time Requirements
12-15
months
Used at a number of hot forming Hydraulic overloads
operations as well as in a wide must be controlled,
variety of other steel industry Poor solids removal
wastewater treatment applies- in Step D will impede
tions.	efficient filter
operation.
15-18
months
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
None
Refer to
Table VIII-8
The backwash
solids must re-
ceive proper
disposal.
Solid Waste
Generation and
Primary
Constituents
None
The backwash solids
are eventually re-
moved from the
treatment system by
the vacuum filter
(Step E). Refer to
Table VIII-62 for
the quantities of
solids removed.
The backwash solids
are similar in
nature to the other
solids removed by
this treatment
system.

-------
TABU VIII-6
CONTROL AND TREATMENT TECHNOLOGIES
HOT FORMING - PRIMARY, SECTION, AND FLAT
PAGE 5 	 	
to
¦{*
Treatment and/or
Control Methods Employed*
J. Sulfide Precipitation - Addi-
tion of iron sulfide to form metal-
lic sulfide precipitates which
are subsequently removed via
filtration.
Status and
Reliability
Used in various industrial
wastewater treatment opera-
tions for the purpose of
toxic metals removal.
Problems
and Limitations
Implemen-
tation	Land
Time Requirements
Care must be exercised 6 months
in the handling of the
feed solution. Careful
treatment process con-
trol is required to pre-
vent odor problems.
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
The resultant
metallic sulfide
precipitates re-
quire proper
disposal. Sulfide
odors can result
if the treat-
ment process is
not adequately
control led.
Solid Waste
Generation and
Primary
Constituents
The metallic
sulfide pre-
cipitates gen-
erated in this
step are re-
moved by the
deep bed pressure
filter and sub-
sequently through
the vacuum filter.
The amounts of
solids generated
in this step are
minimal and have
already been in-
cluded in the
filtration steps
(refer to Table
VIII-63).
K. Filtration -These filters
provide additional suspended
solids removal capability.
The backwash is returned
to the roughing clarifier.
Used at a number of hot forming Hydraulic overloads
operations as well as in a wide must be controlled,
variety of other steel industry Poor solids removal
wastewater treatment applica- in Step D will impede
tions.	efficient filter
operation.
15-18
months
Refer to
Table VIII-8
The backwash
solids must re-
ceive proper
disposal.
The backwash solids
are eventually re-
moved from the
treatment system by
the vacuum filter
(Step E). Refer to
Table VIII-63 for
the quantities of
solids removed.
The backwash solids
are similar in
nature to the other
solids removed by
this treatment
system.

-------
TABLE VIII-7
CONTROL AMD TREATMENT TECHNOLOGIES
HOT WORKING PIPE AND TUBE
Treatment and/or
Control Methods Employed*
A. Primary Scale Pit - This step
provides the initial stage for
removal of heavy mill scale and
the heavier suspended solids.
to
>(*
K1
B. Surface Skimming - Removes
oils and greases from the surface
of the wastewater.
Status and
Reliability
Widely used in the hot
forming subcategory as an
integral part of their opera-
tions.
Very widely used in the hot
forming subcategory as well
as in other steel plant waste-
water treatment operations.
Problems
and Limitations
Accumulated scale must
be removed by clam
shell or other devices
on a regular basis.
Implemen-
tation	Land
Time Requirements
6-9
months
Refer to
Table VIII-8
Hydraulic overload
or surface turbulence
will result in poor oil
removal rates.
3 months
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
Although mill
scale removed from
the scale pit is
usually returned
to other steel
plant operations,
sny remaining
scale and solids
must receive pro-
per disposal.
The skimmed oils
and greases must
receive proper
disposal.
Solid Haste
Generation and
Primary
Constituents
The solid waste
generation rates
are presented
in Table VIII-62.
The scale consists
basically of metal-
lic oxides removed
from the surface
of the hot formed
product.
Refer to Table
VIII-62 for the
skimmed oil gen-
eration rates as-
sociated with the
hot working pipe
and tube operations.
C. Roughing Clarifier - Provides
the capability for additional
suspended solids remova1.
Widely used in the hot forming
subcategory and throughout
the ateel industry in various
wastewater treatment opera-
tiona.
Hydraulic surges must 15-18
be controlled. In addi- months
tion, routine or con-
tinuous solids removal
must be provided in
order to prevent exces-
sive solids accumulation
which in turn could
damage the clarifier
rake drive mechanism.
Refer to
Table VIII-8
The sludge re-
moved from the
clarifier and
delivered to the
vacuum filter
must ultimately
receive proper
disposal.
Refer to Table
VIII-62 for the
generation rates
of solids, con-
sisting prisiarily
of metal oxides,
for each hot
forming operation.

-------
TABU VII1-7
CONTROL AND TREATMENT TECHNOLOGIES
HOT WORKING PIPE AND TUBE
PAGE 2		
Treatment and/or
Control Methods Employed*
D. Vacuum Filter - Used to de-
water the sludges removed in
Step C.
to
¦c*
CJ
Status and
Reliability
Very widely used both in the
hot forming subcategory and
in many other steel industry
wastewater treatment opera-
tions.
E. Recycle - Recycles a portion
of the roughing clarifier effluent
back to"the pipe and tube opera-
tion.
This type of recycle operation
is widely used throughout the
hot forming subcategory.
Solid Waste

Implemen-

Environmental
Generation and
Problems
tation
Land
Impact Other
Primary
and Limitations
Time
Requirements
Than Hater
Constituents
Routine maintenance
15-18
Refer to
The dewatered
The quantities
of vacuum pumps and
months
Table VIII-8
solids (filter
of filter cake
filter siechanism is


cake) must re-
generated at
necessary. Filter


ceive proper
this step are
media must be re-


disposal.
presented in
placed periodically.



Table VIII-62.




The solids in




the filter cake




are similar in




nature to those




removed at the




scale pit and




are the same as




those removed




from the roughing




clarifier.
The potential exists
12-15
Refer to
None
None
for scaling and plug- months Table VIII-8
ging due to the in-
creased dissolved
solids concentrations
associated with recycle
operations, however,
numerous pipe and tube
operations*have operated
these recycle systems
without any problems.

-------
TABLE VIII-7
CONTROL AND TREATMENT TECHNOLOGIES
HOT WORKING PIPE AND TUBE
PAGE 3
to
Treatment and/or
Control Methods Employed*
F. Deep Bed Pressure Filter -
These filters provide additional
suspended solids removal capa-
bility. The backwash is returned
to the roughing clarifier.
Status and
Reliability
Problems
and Limitations
Impleoen-
tat ion	Land
Time Requirements
Used at a number of hot forming Hydraulic overloads
operations as well as in a	must be controlled,
wide variety of other steel Poor solids removal
industry wastewater treatment in Step C will impede
applications.	efficient filter opera-
tion.
15-18
months
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
The backwash
solids must
receive proper
disposal.
Solid Waste
Generation and
Primary
Constituents
The backwash
solids are
eventually re-
moved from the
treatment system
by the vacuum
filter (Step D).
Refer to Table
VI1I-62 for the
quantities of
solids removed.
The backwash
solids are
similar in nature
to the other
solids removed by
this treatment
system.
The following step is presented in association with the isolated treatment system model developed for BPT in the original study. All of the
previous steps (A through F) are incorporated in the integrated BPT treatment system model developed during the original study. Steps A, B, and
E are used in conjunction with this step for the isolated treatment aodel.

-------
TABLE VIII-7
OONTBOL AND TREATMENT TECHNOLOGIES
HOT WORKING PIPE AND TUBE
PACE 4
Treatment: aod/or
Control Methods Employed*
6. Settling Lagoon - This compo-
nent provides suspended solids
reaoval capability in addition to
that provided in the scale pit.
to
UI
Status and
Reliability
Problems
and Limitations
Widely used in the hot forming Land requirements are
subcatgory as well as in a	greater than those
variety of other steel industry of other treatment
wastewater treatment and/or
recycle operations.
components (roughing
clarifiers, etc.)
capable of similar
performance.
Implemen-
tation	Land
Time Requirements
9-12
months
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
Land usage
Solid Waste
Generation and
Primary
Constituents
The solids,
which consist
primarily of
metal oxides,
are removed
periodically by
clam shell.
The solid waste
generation rates
for this step
are presented
in Table VIII-62.
H. Cooling Tower - Dsed to reduce Widely used in the hot forming
the heat load of wastewater recycle subcategory as well as in
system.	numerous other steel industry
water/waatewater recycle
processes.
The potential exists
for scaling and plug-
ging due to the in-
creased dissolved
solids concentrations
associated with cooling
and recycle operations.
In addition, biological
fouling within the
cooling tower auat be
controlled.
18-20
months
Refer to
Table VIII-8
Any sludge which
¦ay accumulate in
the cooling tower
will require pro-
per disposal. Care
Hist be exercised
in the selection
and use of chemi-
cals used to con-
trol fouling.
Virtually nil.

-------
TABLE VIII-7
CONTROL AND TREATMENT TECHNOLOGIES
HOT WORKING PIPE AND TUBE
PAGE 5
to
CTi
Treatment and/or
Control Methods Employed*
I. Recycle - Increase the recycle
rate to reduce the discharge
flows to the BAT/BCT levels.
Status and
Reliability
This type of recycle operation
ia widely used throughout the
hot forming subcategories.
Problems
and Limitations
While the potential
exists for scaling
and plugging due to
the increased dissolved
solids concentrations
associated with recycle
operations, none were
reported by the pipe
and tube operations
utilizing high recycle
systems.
Implemen-
tation	Land
Time Requirements
12-15
months
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
None
Solid Waste
Generation and
Primary
Conatituents
None
J. Filtration - These filters
provide additional suspended
solids removal capability.
The backwash is returned
to the roughing clarifier.
filter (Step D).
Refer to Table
VIII-62 for the
quantities of
solids removed.
The backwash
solids are
similar in nature
to the other
solids removed by
this trestment
system.
Used at a number of hot forming Hydraulic overloads
operations as well as in a
wide variety of other steel
industry wastewater treatment
applications.
must be controlled.
Poor solids removal
in Step C will impede
efficient filter opera-
tion.
15-18
months
Refer to
Table VIII-8
The backwash
solids must
receive proper
disposal.
The backwash
solids are
eventually re-
moved from the
treatment system
bv the vacuum

-------
TABLE VIII-7
CONTROL AND TKEATJCKT TECHNOLOGIES
HOT WORKING PIPE AMD TUBE
PACE 6 		
ro
Treatment and/or
Control Methods Employed*
Status and
Reliability
Problems
and Limitations
Implemen-
tation
Time
Land
Requirements
K. Sulfide Precipitation - Addi- Used in various industrial	Care aust be exercised 6 bodtha
tion of iron sulfide to form aetal- wastewater treatment operations in the handling of the
lie sulfide precipitates which	for the purpose of toxic aetals feed solution. Careful
are subsequently removed via	removal.	treatment process control
filtration.	is required to prevent
odor problems.
Refer
Table
to
VIII-8
Environmental
Impact Other
Than Water
The resultant
metallic sulfide
precipitates re-
quire proper
disposal. Sulfide
odors can result
if the treatment
process is not
adequately con-
trolled.
Solid Haste
Cenerstion and
Primary
Constituents
The metallic
precipitates
generated in
this step are
removed by the
deep bed pres-
sure filter and
subsequently
through the
vacuum filter.
The amounts of
solids generated
in this step
are minimal and
have already been
included in both
filtration steps
(refer to
Table VIH-63).

-------
TABLE VIII-7
CONTROL AND TREATMENT TECHNOLOGIES
HOT WORKING PIPE AND TUBE
PAGE 7
to
00
Treatment and/or
Control Methods Employed*
L. Filtration - These filters
provide additional suspended
solids removal capability.
The backwash is returned
to the roughing clarifier.
Status and
Reliability
Problems
and Limitations
Used at a number of hot forming Hydraulic overloads
Implemen-
tation
Time
15-18
operations as well as in a
wide variety of other steel
industry wastewater treatment
applications.
must be controlled.
Poor solids removal
in Step C will impede
efficient filter opera-
tion.
months
Land
Requirements
Refer to
Table VIII-8
Environmental
Impact Other
Than Water
The backwash
solids must
receive proper
disposal.
Solid Waste
Generation and
Primary
Constituents
The backwash
solids are
eventually re-
moved from the
treatment system
by the vacuum
filter (Step D).
Refer to Table
VIII-63 for the
quantities of
solids removed.
The backwash
solids are
similar in nature
to the other
solids removed by
this treatment
system.
*: Listed in order of increasing effectiveness.

-------
TABLE VIII-8A
LAND REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
BPT Treatment Models
C&TT Steps
ABC	D	E	F
Subdivision	(PSP)	(SS)	(RUP)	(CL)	(VF)	(Filter)
PRIMARY
a. Carbon
w/o scarfers
30'
X
50'
(1)
20' x
30'
40' x
40'
20'
x
20'
50'
x 50'
w/scarfers
30'
X
40*
(1)
20' x
30'
35' x
35'
15'
X
15'
45'
x 45'
b. Specialty
25'
X
40'
(1)
25' x
25'
30' x
30'
15'
X
15'
30'
x 30'
SECTION
a. Carbon
40'
X
65'
(1)
20'
X
30'
45'
X
45'
20'
X
20'
65' x 65'
b. Specialty
30'
X
50'
(1)
20'
X
301
35'
X
35»
15'
X
15'
45' x 45'
FLAT














a. Hot Strip and Sheet
60'
X
110*
(1)
15'
X
50'
80'
X
80'
30'
X
30'
100' x 100'
b. Carbon Plate
40'
X
70*
(1)
20'
X
30'
60'
X
60'
20'
X
20'
85' x 85'
c. Specialty Plate
35'
X
65'
(1)
25'
X
25'
55'
X
55'
20'
X
20'
75' x 75'
(1) No additional land required
NOTE: For definitions of C&TT codes refer to Table VII-1.

-------
TABLE VIII-8B
LAND REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
BPT Treatment Models
Subdivision
PIPE AND TUBE
A
(PSP)
B
(SS)
C&TT Steps
C
(CL)
D
(VF)
E
(RTP)
(Filter)
G
.(SL-1)
a.
b.
Integrated
Isolated
25' x 35'
25' x 35'
(1)
(1)
35' x 35*
(2)
15' x 15'
(2)
15' x 35'
25' x 25'
25' x 25'
(2)
(2)
200' x 400'
(1)	No additional land required
(2)	This component is not included in this particular model.
NOTE: For definitions of C&TT codes refer to Table VII-1.

-------
TABLE VIII-8C
LAND REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
BAT and BCT Treatment Models
C&TT Steps
PRIMARY
BAT Alternative No. 1/BCT
G
(CT)
H
(RTP)
(Filter)
BAT Alternative No. 2
(1)
J
(PS)
K
(Filter)
a. Carbon w/o scarfing
Model No. 2
45'
X
45'
35'
X
35'

(2)

(3)
30'
x 35
Model No. 3
40'
X
40'
30'
X
30'
30'
x 40'
14*
x 14'

(2)
Carbon w/scarfing












Model No. 1
30'
X
30'
25'
X
25'

(2)

(3)
30*
x 35
Model No. 2
55'
X
55'
35'
X
35'

(2)

(3)
31*
x 45
Model No. 3
40'
X
40*
35'
X
35'
45'
x 45'
15'
x 15*

(2)
Specialty w/o scarfing












Model No. 2
40'
X
40*
32'
X
32'

(2)

(3)
20'
x 35
Model No. 3
20'
X
20'
20'
X
20'
15'
o
CM
X
10'
x 10'

(2)
Specialty w/scarfing











(2)
Model No. 3
25'
X
25'
25'
X
25'
20'
x 20*
10'
x 10'

SECTION
a. Carbon
Model No.
1
25'
X
25'
25'
X
25'
(2)

(3)
20' x 25'
Model No.
2
60'
X
60'
40*
X
40'
(2)

(3)
30' x 55'
Model No.
3
40'
X
40'
30'
X
30'
30' x 40*
14'
x 14'
(2)
Specialty











Model No.
1
25'
X
25'
25'
X
25'
(2)

(3)
20' x 25'
Model No.
2
35'
X
35'
30'
X
30'
(2)

(3)
30' x 30'
Model No.
3
25'
X
25'
25'
X
25'
20' x 20'
10'
x 10'
(2)
FLAT
a. Hot Strip and Sheet
Model No. 1
65'
X
195'
40'
X
60'
(2)

(3)
50'
x 100
Model No. 2
65'
X
125'
40'
X
60'
(2)

(3)
50'
x 65'
Model No. 3
55'
X
105'
40'
X
50'
50' x 60'
17'
x 17'

(2)
Carbon Plate











Model No. 2
50'
X
100'
40'
X
40'
(2)

(3)
45'
x 50'
Model No. 3
40'
X
40'
30'
X
30'
30' x 30'
10'
x 15'

(2)
Specialty Plate











Model No. 2
35'
X
35'
30'
X
30*
(2)

(3)
30'
1 x 30'
Model No. 3
10'
X
10'
15'
X
15'
10' x 15'
8'
x 8'

(2)
(1)	These land requirements are in addition to those of Alternative No. 1. Each Model's
Alternative No. 2 incorporates all of the components of Alternative No. 1.
(2)	Not required.
(3)	Included in Step F's requirements.
251

-------
TABLE VIII-8D
LAND REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
BAT and BCT Treatment Models
C&TT Steps
BAT Alternative No. 1/BCT
H
(CT)
I
(RTP)
J
(Filter)
BAT Alternative No. 2^^
K
(PS)
L
(Filter)
PI?E AND TUBE
a. Carbon
Model No.
1
25'
X
25'
25' x
25*

(2)

(3)
20' x 25'
Model No.
2
25'
X
25'
25* x
25'

(2)

(3)
20' x 20'
Model No.
3
25'
X
25'
25' x
25'
20'
1 x 25'
10'
1 x 15'
(2)
Specialty











Model No.
2
40'
X
40'
30' x
30'

(2)

(3)
20' x 35'
Model No.
3
15'
X
15'
20' x
20'
15'
' x 20'
8'
1 x 10'
(2)
(!) These land requirements are in addition to those of Alternative No. 1. Each Model's
Alternative No. 2 incorporates all of the components of Alternative No. 1.
(0 Not Required.
(0 Included in Step F's requirements.
252

-------
TABLE VIII-9A
BAT FEED CAPITAL COST REQUIREMENTS
	HOT FORMING	
CONTROL AND TREATMENT TECHNOLOGY STEPS


Total

Total

Total

Total

Total

No.
Cost ,
No.
COSt .
No.
Co 31
No.
Cost
No.
Cost
Subcategory
Reg.
($xl
-------
TABLE VIII-9B
BAT FEED ANNUAL COST REQUIREMENTS
	HOT FORMING	
CONTROL AND TREATMENT TECHNOLOGY STEPS
Total
Adjusted


Total

Total

Total

Total

Total
Annual
Co-
Annual.
Cost*\

No.
Cost
No.
Cost
No.
Cost
No.
Cost
No.
Cost
Cost
Minglint.
Factor
Subcategory
Req.
($xl0 6)
Req.
C$x10 )
Rei-
($xl0 6)
Req.
($xl0"

($xi0 6)
($xl0 )
($xl0 )
PRIMARY













a. Carbon













w/o scarfers
4
-6.4
3
0.002
17
2.5
5
0.4
24
1.0
-2.5
.62
-1.6
w/scarfers
1
-2.9
6
-0.004
15
2.7
6
l.t
24
1.1
2.0
1.2
b. Specialty













w/o scarfers
1
-0.2
3
0.009
5
0.5
1
0.06
9
0.2
0.6
.76
0.5
w/scarfers
1
-0.5
0
0
2
0.2
0
0
1
0.02
-0.3
-0.2
to
in
a.	Carbon	0	0
b.	Specialty	0	0
FLAT
a.	Hot Strip & Sheet	2	-0.9
b.	Plate (Carbon)	0	0
c.	Plate (Specialty)	0	0
PIPE AND TUBE
11
6
-0.02
0.01
0.06
-0.2
0.002
23
5
16
5
3
3.2
0.4
4.4
0.6
0.08
1.3
0.3
43
10
1.5
0.2
6.0
0.9
.83
.83
5.0
0.7
6
3.7
34
0.1
7.4
.88
6.5
1
0.1
11
0.3
0.8
.70
0.6
2
0.03
5
0.1
0.2
.96
0.2
a.	Carbon
b.	Specialty
-1.5
0
0.02
0
10
2
0.9
0.1
0.7
0.06
20
6
0.6
0.06
0.7
0.2
.55
.62
0.4
0.1
TOTALS:
16.0
13.4
(1)	Calculated factors which account for cost reductions achieved by the use of central treatment systems.
(2)	These annual costs have been adjusted by applying co-mingling factors which reduce overall costs by taking into account cost reductions
achieved by the use of central treatment systems in the hot forming operations.
KEY TO C&TT STEPS
A: Primary Scale Pit (PSP)	D:
B: Surface Skimming	E:
C: Recycle from PSP
Clarifier or Settling Cone
Vacuum Filter

-------
TABLE VIII-10
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory:
Hot Forming
Primary
Carbon
Without Scarfers
Model Size-TPD
Oper. Days/Year
Turns/Days
6400
260
C&TT Steps
A
B
C

D
E

F

Total
_3
Investment $ X 10 __
219.6
31.5
556.
0
568.5
193.
2
1436

3004.8
Annual Cost $ X 10










Capital
9.4
1.4
23.
9
24.5
8.
3
61.
> 8
129.3
Depreciation
22.0
3.1
55.
6
56.9
19.
3
143,
.6
300.5
Operation & Maintenance
7.7
1.1
19.
5
19.9
6.
8
50.
,3
105.3
Sludge Disposal , ^
Energy and Power
215.2
14.7

/ON
-
4.
3


234.2
-
0.3
25.
6
1.3
2.
9
25.
,6
30.1
Chemical Costs
-
-


-




-
TOTAL
254.3
20.6
99.
0
102.6
41.
6
281.
,3
799.4
Credit for Sludge Recovery
1864.0
-



16.
6


1880.6
Credit for Oil Recovery
—
21.0


-




21.0
TOTAL
-1609.7
-0.4
99.
0
102.6
25.
0
281.
,3
-1102.2
(3)
Effluent Quality
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
Raw Waste
Level
1092
7560
145
6-9
BPT
Effluent
Level
692
13
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Oil Skimming
C: Recycle
D: Clarifier
E: Vacuum Filter
Fs Filtration
255

-------
TABLE VIII-11
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Primary
Carbon
With Scarfers
Model Size-TPD
Oper. Days/Year
Turns/Days
6620
260
C&TT Steps
_3
Investment $ X 10 __
Annual Cost $ X 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy and Power
Chemical Costs
TOTAL
Credit for Sludge Recovery
Credit for Oil Recovery
TOTAL
(3)
Effluent Quality
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
9.1
21.1
7.4
136.7
1184.5
222.4
528.1
508.4
170.0
9.6
22.7
21.9
7.3
22.2
52.8
51.0
17.0
0.8
18.5
17.8
5.9
9.5
0.4
22.0(2)
0.7
3.3
2.1
42.5
94.0
91.4
35.6
_
—
-
12.8
13.5
—
-
-
29.0
94.0
91.4
22.8
Raw Waste
Level
1334
4270
160
6-9
1587
68.2
158.7
55.6
28.3
310.8
310.8
Total
3226.8
138.8
322.8
106.0
149.5
31.5
748.6
1197.3
13.5
-462.2
BPT
Effluent
Level
845
13
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit D:
B: Oil Skimming	E:
C: Recycle	F:
Clarifier
Vacuum Filter
Filtration
256

-------
TABLE VIII-12
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming Model Size-TPD :	1440
: Primary Oper. Days/Year:	260
: Specialty	Turns/Days : 	3
C&TT Steps
Investment $ X 10
-3
,-3
Annual Cost $ X 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy and Power
Chemical Costs
(1)
TOTAL
Credit for Sludge Recovery
Credit for Oil Recovery
TOTAL
(3)
Effluent Quality
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
126.2
5.4
12.6
4.4
51.9
16.5
0.7
1.7
0.6
2.9
0.3
4.1
-375.6 2.1
Raw Waste
Level
1912
2640
100
6-9
353.9
8.6
74.3 6.2 63.0
449.9
63.0
291.3
15.2	12.5
35.4	29.0
12.4	10.2
(2)
0.4
52.1
52.1
94.8
4.1
9.5
3.3
1.2
1.6
19.7
4.5
15.2
981.8
45.7
98.2
34.4
18.6
196.9
196.9
Total
1864.5
83.6
186.4
65.3
56.0
20.9
412.2
454.4
4.1
-46.3
BPT
Effluent
Level
1220
13
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit D: Clarifier
B: Oil Skimming	E: Vacuum Filter
C: Recycle	F: Filtration
257

-------
TABLE VIII-13
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Section
Carbon
Model Size-TPD : 2920
Oper. Days/Year: 260
Turns/Days	: 	3
C&TT Steps
A
B
C
D
E
F
Total
_3
Investment $ X 10
328
412
777
792
200
1165
3674
Annual Cost $ X 10







Capital
14.1
17.7
33.4
34.1
8.6
50.1
158.0
Depreciation
32.8
41.2
77.7
79.2
20.0
116.5
367.4
Operation & Maintenance
11.5
1.4
27.2
27.7
7.0
40.8
115.6
Sludge Disposal .
Energy and Power
75.4
22.4
34.9(2)
-
1.8
-
99.6
-
0.6
1.2
2.6
20.8
25.2
Chemical Costs
-
-
-
-
-
-

TOTAL
133.8
83.3
138.3
142.2
40.0
228.2
765.8
Credit for Sludge Recovery
653.0
—
-
-
8.2
—
661.2
Credit for Oil Recovery
-
32.1
-
—
—
—
32.1
TOTAL
-519.2
51.2
138.3
142.2
31.8
228.2
72.5
BPT
Effluent Quality^
Raw Waste





Effluent
Level





Level
Flow, gal/ton
6029





2626
Suspended Solids
840





22
Oil & Grease
32





10
pH, Units
6-9





6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Oil Skimming
C: Recycle
D: Clarifier
E: Vacuum Filter
F: Filtration
258

-------
TABLE VIII-14
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Section
Specialty
C&TT Steps
_3
Investment $ X 10 __
Annual Cost $ X 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal , .
Energy and Power
Chemical Costs
TOTAL
Credit for Sludge Recovery
Credit for Oil Recovery
TOTAL
257
11.0
25.7
9.1
55.0
100.8
476.0
-375.2
33.7
1.4
3.4
1.2
10.3
0.5
14.6
Model
Size-TPD
: 1475


Oper.
Days/Year
260


Turns/Days
3


C
D
E
F
Total
722
594
114
1757
3477.7
31.0
25.5
4.8
75.6
149.3
72.2
59.4
11.4
175.7
347.8
25.2
20.8
3.9
61.5
121.7
17.5(2)
_
0.8
—
66.1
0.9
1.4
31.3
34.1
128.4
106.6
22.3
344.1
719.0
_
—
3.8
—
479.8
-
-
-
-
14.6
128.4
106.6
18.5
344.1
224.6
Effluent Quality
(3)
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
Raw Waste
Level
6029
840
32
6-9
BPT
Effluent
Level
2626
22
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Oil Skimming
C: Recycle
D: Clarifier
E: Vacuum Filter
F: Filtration
259

-------
TABLE VIII-15
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Flat
Hot Strip & Sheet
Model Size-TPD
Oper. Days/Year
Turns/Days
6165
260
C&TT Steps
Investment $ X 10
Annual Cost $ X 10
-3
-3
712
108
1863
4132
429
1643
Chemical Costs
TOTAL
Credit for Sludge Recovery
Credit for Oil Recovery
TOTAL
Effluent Quality
(3)
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
216.5
777.0
19.9
95.8
-560.5 -75.9
Raw Waste
Level
8015
630
24
6-9
331.3 740.2 95.8
56.9
331.3 740.2 38.9
319.3
Total
8887
Capital
30.6
4.6
80.1
178.0
18.4
70.6
382.3
Depreciation
71.2
10.8
186.0
413.0
42.9
164.3
888.2
Operation & Maintenance
25.0
3.8
65.2
145.0
15.0
57.5
311.5
Sludge Disposal , .
Energy and Power
89.7
-
138.4(2)
-
12.6
-
102.3
-
0.7
4.2
6.9
26.9
38.7
319.3 1723.0
833.9
95.8
793.3
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit D:
B: Oil Skimming	E:
C: Recycle	F:
Clarifier
Vacuum Filter
Filtration
260

-------
TABLE VIII-16
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory:	Hot Forming
:	Flat
:	Plate
:	Carbon
Model Size-TPD :
Oper. Days/Year:
Turns/Days :
3485
260
3
C&TT Steps
Investment $ X 10
-3
-3
Annual Cost $ X 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal , .v
Energy and Power
Chemical Costs
TOTAL
Credit for Sludge Recovery
Credit for Oil Recovery
TOTAL
Effluent Quality*3*
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
481
5500
920
35
6-9
38.3 1086
127.1
359.0
-231.9
Raw Waste
Level
18.3
1138
304
2378
193.7
15.7
2.6 193.7
203.5 52.2 462.2
16.1
203.5 36.1 462.2
Total
5425.3
20.7
1.7
46.7
48.9
13.1
102.2
233.3
48.1
3.8 1
' 109.0
113.0
30.4
237.8
542.1
16.8
1.3
38.0
39.8
1.1
83.2
180.2
41.5
11.0
44.2(2)
-
3.6
-
56.1
-
0.5
1.8
4.0
39.0
45.3
1057.0
375.1
15.7
666.2
BPT
Effluent
Level
4000
10
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Oil Skimming
C: Recycle
D: Clarifier
E: Vacuum Filter
F: Filtration
261

-------
TABLE VIII-17
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Flat
Plate
Specialty
Model Size-TPD : 1065
Oper. Days/Year: 260
Turns/Days : 	3
C&TT Steps
.-3
Investment $ X 10 __
Annual Cost $ X 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy and Power
Chemical Costs
TOTAL
Credit for Sludge Recovery
Credit for Oil Recovery
TOTAL
Effluent Quality
(3)
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
509
125
110.7
174.0
-63.3
Raw Waste
Level
12,879
390
15
6-9
25.8
3.4
22.4
1427
859
519
2906
206.6
206.6
156.2 95.7
3.4
156.2 92.3 564.8
Total
6345
21.9
5.4
14.6
36.9
22.3
124.9
226.0
50.9
12.5
142.0
85.9
51.9
290.6
633.8
17.8
4.4
50.0
30.1
18.2
101.7
222.2
20..1
2.4
10.9(2)
-
0.8
-
23.3
-
1.1
3.3
2.5
47.6
54.5
564.8 1159.8
177.4
3.4
979.0
BPT
Effluent
Level
9366
10
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Oil Skimming
C: Recycle
D: Clarifier
E: Vacuum Filter
F: Filtration
262

-------
TABLE VIII-18
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Pipe & Tube
Carbon
Model Size-TPD
Oper. Days/Year
Turns/Days
965
260
3
C&TT Steps
Total
Investment $ X 10 -
168
19.2
390

561

149
261

1548.2
Annual Cost $ X 10










Capital
7.2
0.8
16,
.8
24.
,1
6.4
11.
.2
66.5
Depreciation
16.8
1.9
39,
.0
56.
1
14.9
26.
,1
154.8
Operation & Maintenance
5.9
0.6
13
.6
19.
6
5.2
9.
.2
54.1
Sludge Disposal
Energy and Power
43.2
-




1.6


44.8
-
0.2
9,
.4
0.
9
2.1
3.
,0
6.2
Chemical Costs
-
-
-

-

-


-
TOTAL
73.1
3.5
69.
.4
100.
1
30.2
49.
,5
326.4
Credit for Sludge Recovery
373.9
—
—

—

7.4


381.3
Credit for Oil Recovery
7.1
—
-

-

-


7.1
TOTAL
-307.9
3.5
69.
.4
100.
7
22.8
49.
,5
-62.0










BPT
(3)
Effluent Quality
Raw Waste








Effluent
Level








Level
Flow, gal/ton
Suspended Solids
Oil & Grease
pH , Units
4209
1200
15
6-9
1002
34
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Oil Skimming
C: Recycle
D: Clarifier
E: Vacuum Filter
F: Filtration
263

-------
TABLE VIII-19
BPT MODEL COST DATA: BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Pipe & Tube
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Days
460
260
3
-3
.(1)
C&TT Steps
Investment $ X 10
Annual Cost $ X 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy and Power*
Chemical Costs
TOTAL
Credit for Sludge Recovery
Credit for Oil Recovery
TOTAL
(3)
Effluent Quality
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
113
4.8
11.3
3.9
17.6
37.6
152.0
-114.4
Raw Waste
Level
4209
1200
15
6-9
19
0.8
1.9
0.6
0.3
306
13.1
30.6
10.7
4.7
(2)
3.6 54.4
2.9
0.7 54.4
359
15.4
35.9
12.6
0.6
75.3
3.2
7.5
2.6
0.7
0.9
64.5 14.9
3.0
64.5 11.9
396.5
17.1
39.7
13.9
4.5
75.2
75.2
Total
1268.8
54.4
126.9
44.3
18.3
6.3
250.2
155.0
2.9
92.3
BPT
Effluent
Level
1002
34
10
6-9
(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 mg/1 unless otherwise noted.
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Oil Skimming
C: Recycle
D: Clarifier
E: Vacuum Filter
F: Filtration
264

-------
TABLE VIII-20
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory
Hot Forming
Primary
Without Scarfing
Carbon
Model Size-TPD : 4400
Oper. Days/Year: 260
Turns/Day	: 	3
Alternative

1


2 - Alt.
1 Plus:






Total
C&TT Step
G
H
Total
J
K
Incl. G&H
_3
Investment $ x 10 _
1773
893
2666
34
241
2941
Annual Cost $ x 10






Capital
Depreciation
76.2
177.3
38.4
89.3
114.6
266.6
1.5
3.4
10.4
24.1
126.5
294.1
Operation & Maintenance
62.1
31.3
93.4
1.2
8.4
103.0
Sludge Disposal
Energy and Power
69.8
46.5(2)
69.8
0.1
1.3
71.2
Chemical Costs
-
-
-
1.8
-
1.8
TOTAL
385.4
159.0(2)
544.4
8.0
44.2
596.6
(3)
Effluent Quality
BAT
Feed
Level

Flow, gal/ton
2300

Susp• Solids
15

Oil & Grease
5

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
BAT No. 1
Effluent
Level
BAT No. 2
Effluent
Level
90
15
5
6-9
90
15
5
6-9
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	J: Precipitation using sulfide
H: Recycle to process at 96Z	K: Filtration
265

-------
TABLE VIII-21
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT F
-------
TABLE VIII-22
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 1 TYPE
Subcategory
Hot Forming
Primary
With Scarfing
Carbon
Model Size-TPD
Oper. Days/Year
Turns/Day
2200
260
Alternative
C&TT Step
Investment $ x 10
-3
-3
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy and Powerv
Chemical Costs
TOTAL
.(1)
(3)
Effluent Quality
BAT
Feed
Level

Flow, gal/ton
1700

Suspended Solids
15

Oil & Grease
5

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1

1


2 - Alt.
1 Plus:





Total
G
H
Total
J
K
Incl. G&H
807
573
1380
34
241
1655
34.7
24.6
59.3
1.5
10.4
71.2
80.7
57.3
138.0
3.4
24.1
165.5
28.3
20.0
48.3
1.2
8.4
57.9
32.0
/—N
CM
w
l r-»
32.0
0.1
1.3
33.4
-
-
-
1.8
-
1.8
175.7
101.9(2)
277.6
8.0
44.2
329.8


BAT No. 1


BAT No. 2


Effluent


Effluent
Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G - Cooling Tower
H - Recycle to process increased to 96%
J - Precipitation using sulfide
K - Filtration
267

-------
TABLE VIII-23
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory:
Hot Forming
Primary
With Scarfing
Carbon
Model Size-TPD
Oper. Days/Year
Turns/Day
4400
260
Alternative
C&TT Step
Investment $xl0
2 - Alt. 1 Plus:
Total
-3
-3
Annual Cost $xl0
Capital
Depreciation
Operation & Maintenance
Sludge Disposal ,. »
Energy and Power
Chemical Costs
TOTAL
Effluent Quality^
BAT
Feed
Level

Flow, gal/ton
3400

Suspended Solids
15

Oil & Grease
5

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
G
H
Total
J
K
Incl. G&H
2265
1121
3386
41
293
3720
97.4
48.2
145.6
1.8
12.6
160.0
226.5
112.1
338.6
4.1
29.3
372.0
79.3
39.2
118.5
1.4
10.3
130.2
110.5
69.8(2)
110.5
0.2
1.9
112.6
-
-
-
2.8
-
2.8
513.7
199.5(2)
713.2
10.3
54.1
777.6


BAT No. 1


BAT No. 2


Effluent


Effluent


Level


Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle to process at 96%
J: Precipitation using sulfide
K: Filtration
268

-------
TABLE VIII-24
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory
Hot Forming
Primary
With Scarfing
Carbon
Model Size-TPD
Oper. Days/Year
Turns/day
6700
260
Alternative
C&TT Step
,-3
,-3
Investment $ x 10
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal ,
Energy and Power
Chemical Costs
TOTAL
Effluent Quality
(3)
Flow, gal/ton
Suspended Solids
Oil & Grease
pH, Units
119	Chromium
120	Copper
122	Lead
124	Nickel
128	Zinc
BAT
Feed
Level
1700
30
10
6-9
0.1
0.1
0.1
0.2
0.1
2 - Alt. 1 Plus:
Total
G
H
I
Total
J
Incl. G-I
1881
1058
426
3365
47
3412
80.9
45.5
18.3
144.7
2.0
146.7
188.1
105.8
42.6
336.5
4.7
341.2
65.8
37.0
14.9
117.7
1.6
119.3
81.4
58.2(2)
2.4
83.8
0.2
84.0
-
-
-
-
4.2
4.2
416.2
188.3(2)
78.2
682.7
12.7
695.4



BAT No. 1

BAT No. 2



Effluent

Effluent



Level

Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
6: Cooling Tower
H: Recycle to process increased to 96Z
It Filtration
Jt Precipitation using sulfide
269

-------
TABLE VIII-25
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory
Hot Forming
Primary
Without Scarfing
Specialty
Model Size-TPD : 3000
Oper. Days/Year: 260
Turns/day	: J
Alternative
C&TT Step
.-3
,-3
Investment $ x 10
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal ,
Energy and Power
Chemical Costs
TOTAL
2 - Alt. 1 Plus:
Tot al
G
H
Total
J
K
Incl.
1384
771
2155
33
178
2366
59.5
33.2
92.7
1.4
7.7
101.8
138.4
77.1
215.5
3.3
17.8
236.6
48.4
27.0
75.4
1.1
6.2
82.7
52.3
29.1(2)
52.3
0.1
1.0
53.4
-
-
-
1.2
-
1.2
298.6
137.3(2)
435.9
7.1
32.7
475.7

BAT
BAT No. 1
(
Feed
Effluent
Effluent Quality
Level
Level
Flow, gal/ton
2300
90
Suspended Solids
15
15
Oil & Grease
5
5
pH, Units
6-9
6-9
119 Chromium
0.1
0.1
120 Copper
0.1
0.1
122 Lead
0.1
0.1
124 Nickel
0.1
0.1
128 Zinc
0.1
0.1
BAT No. 2
Effluent
Level
90
15
5
6-9
•
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle to process at 96X
J: Precipitation using sulfide
K: Filtration
270

-------
TABLE VII1-26
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory
Hot Forming
Primary
Without Scarfing
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
1350
260
Alternative
2 - Alt. 1 Plus:
Total
C&TT Step

G
H
I
Total
J
Incl. G-
-3
Investment $ x 10

47 ?
320
118
910
27
937
Annual Cost $ x 10







Capital

20.3
13.8
5.1
39.2
1.2
40.4
Depreciation

47.2
32.0
11.8
91.0
2.7
93.7
Operation & Maintenance
16.5
11.2
4.1
31.8
1.0
32.8
Sludge Disposal ....
Energy and Power

-
(1}
-
-
-
-

14.5
7.0
0.4
14.9
0.1
15.0
Chemical Costs

"*
-
-
-
0.5
0.5
TOTAL

98.5
57.0(2)
21.4
176.9
5.5
182.4

BAT



BAT No. 1

BAT No. :
(3)
Effluent Quality
Feed



Effluent

Effluent
Level



Level

Level
Flow, gal/ton
1150



90

90
Suspended Solids
30



15

15
Oil & Grease
10



5

5
pH, Units
6-9



6-9

6-9
119 Chromium
0.1



0.1

0.1
120 Copper
0.1



0.1

0.1
122 Lead
0.1



0.1

0.1
124 Nickel
0.2



0.1

0.1
129 Zinc
0.1



0.1

0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied £or existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle to process increased to 96X
I: Filtration
J: Precipitation using sulfide
271

-------
TABLE VIII-27
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory
Hot Forming
Primary
With Scarfing
Specialty
Model Size-TPD
Oper. Days/Year
Turn8/Day
1350
260
Alternative		1		2 - Alt. 1 Plus:
Total
C&TT Step	G H I Total	J	Incl. G-I
Investment $ x 10"^	605 402 143 1150	29	1179
Annual Cost$ x 10
Capital	26.0 17.3 6.2 49.5	1.2	50.7
Depreciation	60.5 40.2 14.3 115.0	2.9	117.9
Operation & Maintenance	21.2 14.1 5.0 40.3	1.0	41.3
Sludge Disposal , .	- -	-
Energy and PowerU;	23.3 11.6^ ' 0.7 24.0	0.1	24.1
Chemical Costs	- - - -	0.9	Q.9
TOTAL	131.0 71.6(2) 26.2 228.8	6.1	234.9
Effluent Quality^"^
BAT
Feed
Level

Flow, gal/ton
1700

Suspended Solids
30

Oil & Grease
10

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.2
128
Zinc
0.1
BAT No. 1
Effluent
Level
BAT No. 2
Effluent
Level
140
15
5
6-9
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	I: Filtration
H: Recycle to process increased to 96%	J: Precipitation using sulfide
272

-------
TABLE VIII-28
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 1 TYPE
Subcategory
Hot Forming
Section
Carbon
Model Size-TPD
Oper. Days/Year
Turns/Day
970
260
Alternative
C&TT Step
_3
Investment $ x 10 _
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal ,
Energy and Power
Chemical Costs
TOTAL

1

2
- Alt.
1 Plus:





Total
G
H
Total
J
K
Incl. G&H
614
404
1018
29
135
1182
26.4
17.4
43.8
1.2
5.8
50.8
61.4
40.4
101.8
2.9
13.5
118.2
21.5
14.1
35.6
1.0
4.7
41.3
23.3

23.3
0.1
0.7
24.1
-
-
-
0.9
-
0.9
132.6
71.9(2)
204.5
6.1
24.7
235.3
(3)
Effluent Quality
BAT
Feed
Level

Flow, gal/ton
2550

Suspended Solids
15

Oil & Grease
5

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
BAT No. 1
Effluent
Level
200
15
5
6-9
0.1
0.1
0.1
0.1
0.1
BAT No. 2
Effluent
Level
200
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	J: Precipitation using sulfide
H: Recycle to process increased to 96%	K: Filtration
273

-------
TABLE VIII-29
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory: Hot Forming Model Size-TPD :	3340
: Section Oper. Days/Year:	260
: Carbon	Turns/Day	: 	3
Alternative
C&TT Step
_3
Investment $ x 10 ,
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal ,
Energy and Power
Chemical Costs
TOTAL

1

2
- Alt.
1 Plus:
G
H
Total
J
K
Total
Incl. G&H
2507
1316
3823
42
340
4205
107.8
250.7
87.8
56.6
131.6
46.1
164.4
382.3
133.9
1.8
4.2
1.5
14.6
34.0
11.9
180.8
420.5
147.3
110.5
69.8<2)
110.5
0.2
3.0
1.9
112.6
3.0
556.8
234.3(2)
791.1
10.7
62.4
864.2

BAT
BAT No. 1
BAT No. 2

Feed
Effluent
Effluent
Effluent Quality
Level
Level
Level
Flow, gal/ton
5100
200
200
Suspended Solids
15
15
15
Oil & Grease
5
5
5
pH, Units
6-9
6-9
6-9
119 Chromium
0.1
0.1
0.1
120 Copper
0.1
0.1
0.1
122 Lead
0.1
0.1
0.1
124 Nickel
0.1
0.1
0.1
128 Zinc
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	J: Precipitation using sulfide
H: Recycle to process at 96Z	Kt Filtration
274

-------
TABLE VIII-30
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory
Hot Forming
Section
Carbon
Model Size-TPD
Oper. Days/Year
Turns/Day
Alternative
C&TT Step
Investment $ x 10
2 - Alt. 1 Plu8:
Total
-3
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal ,
Energy and Power
Chemical Costs
total
Effluent Ouality^^
BAT
Feed
Level
Flow, gal/ton
2550
Suspended Solids
30
Oil & Grease
10
pH, Units
6-9
119 Chromium
0.1
120 Copper
0.1
122 Lead
0.1
124 Nickel
0.2
128 Zinc
0.1
G
H
I
Total
J
Incl. G-I
1440
777
314
2531
41
2572
61.9
33.4
13.5
108.8
1.8
¦ 110.6
144.0
77.7
31.4
253.1
4.1
257.2
50.4
27.2
11.0
88.6
1.4
90.0
58.2
34.9(2)
1.9
60.1
0.2
60.3
-
-
-
-
2.6
2.6
314.5
138.3(2)
57.8
510.6
10.1
520.7



BAT No. 1

BAT No. 2



Effluent

Effluent



Level

Level



200

200



15

15



5

5



6-9

6-9



0.1

0.1



0.1

0.1



0.1

0.1



0.1

0.1



0.1

0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	I: Filtration
H: Recycle to process increased to 96%	J: Precipitation using sulfide
275

-------
TABLE VIII-31
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 1 TYPE
Subcategory: Hot Forming Model Size-TPD : 1600
: Section Oper. Days/Year: 260
: Specialty	Turns/Day	: 	3
Alternative
C&TT Step

1

2
- Alt.
1 Plus:
6
H
Total
J
K
Total
Incl. G&H
_3
Investment $ x 10 -
614
404
1018
29
135
1182
Annual Cost $ x 10






Capital
26.4
17.4
43.8
1.2
5.8
50.8
Depreciation
61.4
40.4
101.8
2.9
13.5
118.2
Operation & Maintenance
21.5
14.1
35.6
1.0
4.7
41.3
Sludge Disposal , >
Energy and Power
-
( 91
-
-
-
-
23.3
11.6
23.3
0.1
0.7
24.1
Chemical Costs
-
-
-
0.9
-
0.9
TOTAL
132.6
71.9(2)
204.5
6.1
24.7
235.3
(3)
Effluent Quality
BAT
Feed
Level

Flow, gal/ton
1600

Suspended Solids
15

Oil & Grease
5

pH, Units
6-9
118
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
BAT No. 1
Effluent
Level
130
15
5
6-9
0.1
0.1
0.1
0.1
0.1
BAT No. 2
Effluent
Level
130
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	J: Precipitation using sulfide
H: Recycle to process increased to 96Z	K: Filtration
276

-------
TABLE VIII-32
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory
Hot Forming
Section
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
1800
260
Alternative
C&TT Step


1

2
- Alt.
1 Plus:
G
H
Total
J
K
Total
Incl. G&H
_3
Investment $ x 10 ,

1029
672
1701
32
205
1938
Annual Cost $ x 10







Capital

44.3
28.9
73.2
1.4
8.8
83.4
Depreciation

102.9
67.2
170.1
3.2
20.5
193.8
Operation & Maintenance
36.0
23.5
59.5
1.1
7.2
67.8
Sludge Disposal ,
Energy and Power

-
a\
-
-
-
-

40.7
23.3
40.7
0.1
0.7
41.5
Chemical Costs

-
-
-
1.0
-
1.0
TOTAL

223.9
119.6<2)
343.5
6.8
37.2
387.5

BAT


BAT No. 1


BAT No. 2
(3)
Effluent Quality
Feed


Effluent


Effluent
Level


Level


Level
Flow, gal/ton
3200


130


130
Suspended Solids
15


15


15
Oil & Grease
5


5


5
pH, Units
6-9


6-9


6-9
119 Chromium
0.1


0.1


0.1
120 Copper
0.1


0.1


0.1
122 Lead
0.1


0.1


0.1
124 Nickel
0.1


0.1


0.1
128 Zinc
0.1


0.1


0.1
(1) Costs are all power unless
otherwise
noted.




(2)	Total does not include power cost as a credit is supplied £or existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle to process at 96%
J: Precipitation using sulfide
K: Filtration
277

-------
TABLE VIII-33
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory
Hot Forming
Section
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
1400
260
Alternative
2 - Alt. 1 Plus:
Total ~
C&TT Step
G

H
I
Total
J
Incl.
_3
Investment $ x 10 .
603

400
143
1146
27
1173
Annual Cost $ x 10







Capital
25.
.9
17.2
6.2
49.3
1.2
50.5
Depreciation
60.
,3
40.0
14.3
114.6
2.7
117.3
Operation & Maintenance
21.
1
14.0
5.0
40.1
1.0
41.1
Sludge Disposal , *
Energy and Power
-


-
-
-
-
23.
.3
11.6
0.7
24.0
0.1
24.1
Chemical Costs
-

-
-
-
0.8
0.8
TOTAL
130,
.6
71.2(2)
26.2
228.0
5.8
233.8

BAT
BAT No. 1
/o \
Feed
Effluent
Effluent Quality
Level
Level
Flow, gal/ton
1600
130
Suspended Solids
30
15
Oil & Grease
10
5
pH, Units
6-9
6-9
119 Chromium
0.1
0.1
120 Copper
0.1
0.1
122 Lead
0.1
0.1
124 Nickel
0.2
0.1
128 Zinc
0.1
0.1
BAT No. 2
Effluent
Level
130
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle to process increased to 96Z
I: Filtration
J: Precipitation using sulfide
278

-------
TABLE VIII-34
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 1 TYPE
Subcategory: Hot Forming Model Size-TPD : 13200
: Flat-Hot Strip & Sheet Oper. Days/Year: 260
: Carbon-Specialty	Turns/Day	: 	3
Alternative 	1	 2 - Alt.	1 Plus:
Total
C&TT Step	G H Total	J K	Incl. G&H
Investment $ x 10"^-	5156 2339 7495	83 910	8488
Annual Cost $ x 10
Capital	221.6 100.6 322.2	3.5 39.1	364.8
Depreciation	515.6 233.9 749.5	8.3 91.0	848.8
Operation & Maintenance	180.5 81.8 262.3	2.9 31.8	297.0
Sludge Disposal m	- ~ m
Energy and Powerv '	349.0 279.2^ ' 349.0	0.7 11.9	361.6
Chemical Costs	- -	 -	18.3 -	18.3
TOTAL	1266.7 416.3(2) 1683.0	33.7 173.8	1890.5

BAT
BAT No. 1

Feed
Effluent
Effluent Quality
Level
Level
Flow, gal/ton
4480
260
Suspended Solids
15
15
Oil & Grease
5
5
pH, Units
6-9
6-9
119 Chromium
0.1
0.1
120 Copper
0.1
0.1
122 Lead
0.1
0.1
124 Nickel
0.1
0.1
128 Zinc
0.1
0.1
BAT No. 2
Effluent
Level
260
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	J: Precipitation using sulfide
H: Recycle to process increased to 96%	K: Filtration
279

-------
TABLE VIII-35
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory
Hot Forming
Flat-Hot Strip & Sheet
Carbon-Specialty
Model Size-TPD : 5900
Oper. Days/Year: 260
Turns/Day	: 	3
Alternative
C&TT Step
Investment $ x 10
-3
-3
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal , .
Energy and Power
Chemical Costs
TOTAL

1

2
- Alt.
G
H
Total
J
K
3804
1950
5754
57
561
163.6
83.8
247.4
2.5
24.1
380.4
195.0
575.4
5.7
56.1
133.1
68.2
201.3
2.0
19.6
244.3
174.5(2)
244.3
0.2
3.7
-
-
-
6.9
-
921.4
347.0(2)
1268.4
17.3
103.5
Total
Incl. G&H
6372
274.0
637.2
222.9
248.2
6.9
1389.2

BAT
BAT No. 1
~ Q \
Feed
Effluent
Effluent Quality
Level
Level
Flow, gal/ton
6400
260
Suspended Solids
15
15
Oil & Grease
5
5
pH, Units
6-9
6-9
119 Chromium
0.1
0.1
120 Copper
0.1
0.1
122 Lead
0.1
0.1
124 Nickel
0.1
0.1
128 Zinc
0.1
0.1
BAT No. 2
Effluent
Level
260
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle to process at 96%
J: Precipitation using sulfide
K: Filtration
280

-------
TABLE VIII-36
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory: Hot Forming Model Size-TPD : 5800
: Flat-Hot Strip & Sheet Oper. Days/Year: 260
: Carbon-Specialty	Turns/Day	: 	3
Alternative

1


2 - Alt.
1 Plus:






Total
C&TT Step
G
H
I
Total
J
Incl. G-I
-3
Investment $ x 10 „
3076
1617
566
5259
57
5316
Annual Cost $ x 10






Capital
132.3
69.5
24.3
226.1
2.5
228.6
Depreciation
307.6
161.7
56.6
525.9
5.7
531.6
Operation & Maintenance
107.7
56.6
19.8
184.1
2.0
186.1
Sludge Disposal , .
Energy and Power
180.3
116.3(2)
3.7
184.0
0.2
184.2
Chemical Costs
-
-
-
-
6.8
6.8
TOTAL
727.9
287.8(2)
104.4
1120.1
17.2
1137.3
Effluent Quality^^
BAT
Feed
Level

Flow, gal/ton
4480

Suspended Solids
30

Oil & Grease
10

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.2
128
Zinc
0.1
BAT No. 1
Effluent
Level
BAT No. 2
Effluent
Level
260
15
5
6-9
260
15
5
6-9
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	I: Filtration
H: Recycle to process increased to 96%	J: Precipitation using sulfide
281

-------
TABLE VIII-37
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory: Hot Forming Model Size-TPD : 6900
: Flat Plate Oper. Days/Year: 260
: Carbon	Turns/Day	: 	3
Alternative
C&TT Step
-3
Investment $ x 10 «
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal . .
Energy and Power
Chemical Costs
TOTAL
1
G
H
Total
2897
1584
4481
124.6
289.7
101.4
68.1
158.4
55.4
192.7
448.1
156.8
168.7
104.7(2)
168.7
684.4
281.9(2)
966.3
2 - Alt. 1 Plus:	
Total
J	K	Incl. G&H
47 417 4945
2.0
17.9
212.6
4.7
41.7
494.5
1.6
14.6
173.0
0.1
2.4
171.2
4.3
	
4.3
12.7
76.6
1055.6
Effluent Quality^^
BAT
Feed
Level

Flow, gal/ton
3400

Suspended Solids
15

Oil & Grease
5

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
BAT No. 1
Effluent
Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
BAT No. 2
Effluent
Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	J: Precipitation using sulfide
H: Recycle to process at 96Z	K: Filtration
282

-------
TABLE VIII-38
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory: Hot Forming Model Size-TPD : 2800
: Flat Plate Oper. Days/Year: 260
: Carbon	Turns/Day	: 	3
Alternative	1			2 - Alt. 1 Plus:
Total
C&TT Step
G
H
I
Total
J
Incl.
_3
Investment $ x 10 „
1316
744
250
2310
34
2344
Annual Cost $ x 10






Capital
56.6
32.0
10.8
99.4
1.5
100.9
Depreciation
131.6
74.4
25.0
231.0
3.4
234.4
Operation & Maintenance
46.1
26.0
8.8
80.9
1.2
82.1
Sludge Disposal^
Energy & Power
52.3
29.1(2)
1.3
53.6
0.1
53.7
Chemical Costs
-
-
-
-
1.8
1.8
TOTAL
286.6
132.4(2)
45.9
464.9
8.0
472.9

BAT
BAT No. 1

Feed
Effluent
Effluent Quality
Level
Level
Flow, gal/ton
2380
140
Suspended Solids
30
15
Oil & Grease
10
5
pH, Units
6-9
6-9
119 Chromium
0.1
0.1
120 Copper
0.1
0.1
122 Lead
0.1
0.1
124 Nickel
0.2
0.1
128 Zinc
0.1
0.1
BAT No. 2
Effluent
Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
G: Cooling Tower	I: Filtration
H: Recycle to process increased to 96%	J: Precipitation using sulfide
283

-------
TABLE VIII-39
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory
Hot Forming
Flat Plate
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
3600
260
Alternative
C&TT Step
2 - Alt. 1 Plus:
Total
„-3
.-3
Investment $ x 10
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal , .
Energy and Power
Chemical Costs
TOTAL
Effluent Quality^^
BAT
Feed
Level

Flow, gal/ton
1500

Suspended Solids
15

Oil & Grease
5

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
G
H
Total
J
K
Incl. G&H
994
665
1659
31
193
1883
42.8
28.6
71.4
1.4
8.3
81.1
99.4
66.4
165.9
3.1
19.3
188.3
34.8
23.3
58.1
1.1
6.8
66.0
40.7
23.3<2)
40.7
0.1
0.7
41.5
-
-
-
1.0
-
1.0
217.7
118.4(2)
336.1
6.7
35.1
377.9


BAT No. 1


BAT No. 2


Effluent


Effluent


Level


Level


60


60


15


15


5


5


6-9


6-9


0.1


0.1


0.1


0.1


0.1


0.1


0.1


0.1


0.1


0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as	a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise	noted.
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle to process at 96Z
J: Precipitation using sulfide
K: Filtration
284

-------
TABLE VII1-40
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory: Hot Forming	Model Size-TPD
: Flat Plate	Oper. Days/Year
: Specialty	Turns/Day
220
260
3
Total
Alternative		1_	2 - Alt. 1 Plus:
C&TT Step	G	H
Investment $ x 10 \	140	121-
Annual Cost $ x 10
Capital	6.0	5.2
Depreciation	14.0	12.1
Operation & Maintenance	4.9	4.2
Sludge Disposal	-	-
Energy and Power	3.8	1.2
Chemical Costs
TOTAL	28.7 21.5<2)
I
Total
J
Incl. G-I
57
318
21
339
2.4
13.6
0.9
14.5
5.7
31.8
2.1
33.9
2.0
11.1
0.7
11.8
0.1
3.9
0.1
4.0
-
-
0.1
0.1
10.2
60.4
3.9
64.3
(3)
Effluent Quality
BAT
Feed
Level

Flow, gal/ton
1050

Suspended Solids
30

Oil & Grease
10

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.2
128
Zinc
0.1
BAT No. 1
Effluent
Level
BAT No. 2
Effluent
Level
60
15
5
6-9
60
15
5
6-9
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
6: Cooling Tower	I: Filtration
H: Recycle to process increased to 96%	J: Precipitation using sulfide
285

-------
TABLE VII1-41
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 1 TYPE
Subcategory
Hot Forming
Pipe & Tube
Carbon
Model Size-TPD
Oper. Days/Year
Turns/Day
822
260
3
Alternative
C&TT Step

1

2
- Alt.
1 Plus:

H
I
Total
K
L
Total
Incl. H6.I
-3
Investment $ x 10
605
135
740
28
135
903

Annual Cost $ x 10







Capital
26.0
5.8
31.8
1.2
5.8
38.8

Depreciation
60.5
13.5
74.0
2.8
13.5
90.3

Operation & Maintenance
21.2
4.7
25.9
1.0
4.7
31.6

Sludge Disposal , *
Energy and Power
-
(2)
-
-
-
-

23.3
11.6
23.3
0.1
0.7
24.1

Chemical Costs
-
0
0
0.8
-
0.8

TOTAL
131.0
CM
O
155.0
5.9
24.7
185.6


BAT
BAT No. 1
BAT No. 2
/ON
Feed
Effluent
Effluent
Effluent Quality
Level
Level
Level
Flow, gal/ton
2760
220
220
Suspended Solids
15
15
15
Oil & Grease
5
5
5
pH, Units
6-9
6-9
6-9
119 Chromium
0.1
0.1
0.1
120 Copper
0.1
0.1
0.1
122 Lead
0.1
0.1
0.1
124 Nickel
0.1
0.1
0.1
128 Zinc
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
H: Cooling Tower	K: Precipitation using sulfide
I: Recycle to process increased to 96%	L: Filtration
286

-------
TABLE VI11-42
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM! MODEL 2 TYPE
Subcategory: Hot Forming	Model Size-TPD
: Pipe & Tube	Oper. Days/Year
: Carbon	Turns/Day
547
260
3
Alternative
C&TT Step
_3
Investment $ x 10
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal ...
Energy and Power
Chemical Costs
TOTAL
1
H
I
Total
689
478
1167
29.6
20.6
50.2
68.9
47.8
116.7
24.1
16.7
40.8
26.2
14.5(2)
26.2
148.8
s
CM
H
m
00
233.9
2 - Alt. 1 Plus:
Total
K L	Incl. H&I
27
117
1311
1.2
5.0
56.4
2.7
11.7
131.1
1.0
4.1
45.9
0.1
0.4
26.7
0.5
-
0.5
5.5 21.2 260.6

BAT
BAT No. 1
BAT No. 2
/A\
Feed
Effluent
Effluent
Effluent Quality
Level
Level
Level
Flow, gal/ton
5520
220
220
Suspended Solids
15
15
15
Oil & Grease
5
5
5
pH, Units
6-9
6-9
6-9
119 Chromium
0.1
0.1
0.1
120 Copper
0.1
0.1
0.1
122 Lead
0.1
0.1
0.1
124 Nickel
0.1
0.1
0.1
128 Zinc
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT 8TEPS
H: Cooling Tower	K: Precipitation using sulfide
I: Recycle to process at 96Z	Lt Filtration
287

-------
TABLE VIII-43
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory:
Hot Forming
Pipe & Tube
Carbon
Model Size-TPD : 1036
Oper. Days/Year: 260
Turns/Day	: 	3
Alternative
C&TT Step
TOTAL
Effluent Quality^
BAT
Feed
Level

Flow, gal/ton
2760

Suspended Solids
30

Oil & Grease
10

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.2
128
Zinc
0.1
H
146.2
Investment $ x 10 _
674
472
Annual Cost $ x 10


Capital
29.0
20.3
Depreciation
67.4
47.2
Operation & Maintenance
23.6
16.5
Sludge Disposal , .
Energy and Power
-

26.2
11.6
Chemical Costs
-
-
(2)
84.0
(2)
2 - Alt. 1 Plus:
Total
J
Total
K
Incl. H-J
181
1327
32
1359
7.8
57.1
1.4
58.5
18.1
132.7
3.2
135.9
6.3
46.4
1.1
47.5
0.7
26.9
0.1
27.0
-
-
1.0
1.0
32.9
263.1
6.8
269.9

BAT No. 1

BAT No. 2

Effluent

Effluent

Level

Level

220

220

15

15

5

5

6-9

6-9

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
H: Cooling Tower
I: Recycle to process increased to 96%
J: Filtration
K: Precipitation using sulfide
288

-------
TABLE VIII-44
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 2 TYPE
Subcategory:
Hot Forming
Pipe & Tube
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
1195
260
Alternative
C&TT Step

1

2
- Alt.
1 Plus:
H
I
Total
K
L
Total
Incl. H&I
_3
Investment $ x 10 ,
1316
744
2060
33
178
2271
Annual Cost $ x 10






Capital
56.6
32.0
88.6
1.4
7.7
97.7
Depreciation
131.6
74.4
206.0
3.3
17.8
227.1
Operation & Maintenance
46.1
26.0
72.1
1.1
6.2
79.4
Sludge Disposal . *
Energy and Power
-
~ (n\
-
-
-

52.3
29.1
52.3
0.1
1.0
53.4
Chemical Costs
-
-
-
1.2
-
1.2
TOTAL
286.6
132.4(2)
419.0
7.1
32.7
458.8

BAT
BAT No. 1

Feed
Effluent
Effluent Quality
Level
Level
Flow, gal/ton
5520
220
Suspended Solids
15
15
Oil & Grease
5
5
pH, Units
6-9
6-9
119 Chromium
0.1
0.1
120 Copper
0.1
0.1
122 Lead
0.1
0.1
124 Nickel
0.1
0.1
128 Zinc
0.1
0.1
BAT No. 2
Effluent
Level
220
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
H: Cooling Tower	K: Precipitation using sulfide
I: Recycle to process at 96Z	L: Filtration
289

-------
TABLE VIII-45
BAT MODEL COST DATA-BASIS 7/1/78 DOLLARS
BAT FEED SYSTEM: MODEL 3 TYPE
Subcategory:
Hot Forming
Pipe & Tube
Specialty
Model Size-TPD : 338
Oper, Day8/Year: 260
Turns/Day	: 3
Alternative
C&TT Step
Investment $ x 10
2 - Alt. 1 Plus:
Total
-3
.-3
Annual Cost $ x 10
Capital
Depreciation
Operation & Maintenance
Sludge Disposal . .
Energy and Power
Chemical Costs
TOTAL
Effluent Quality^
BAT
Feed
Level

Flow, gal/ton
2760

Suspended Solids
30

Oil & Grease
10

pH, Units
6-9
119
Chromium
0.1
120
Copper
0.1
122
Lead
0.1
124
Nickel
0.1
128
Zinc
0.1
298
12.8
29.8
10.4
9.3
62.3
246
10.6
24.6
8.6
4.7
(2)
43.8
(2)
J
Total
K
Incl. H-J
106
650
25
675
4.6
28.0
1.1
29.1
10.6
65.0
2.5
67.5
3.7
22.7
0.9
23.6
0.3
9.6
0.1
9.7
-
-
0.3
0.3
19.2
125.3
4.9
130.2

BAT No. 1

BAT No. 2

Effluent

Effluent

Level

Level

220

220

15

15

5

5

6-9

6-9

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for existing
process water requirements.
(3)	All values are mg/1 unless otherwise noted.
KEY TO C&TT STEPS
H: Cooling Tower
1: Recycle to process increased to 96%
J: Filtration
K: Precipitation using sulfide
290

-------
TABLE VIII-46
BAT ALTERNATIVE NO. 1 COST SUMMARY
HOT FORMING SUBCATEGORY
Subdivision
Flow Rates (gal/ton)
BAT Feed Discharge
BAT Costs
($ x 10 fe)
Capital
Adjusted BAg ^<^ts
Annual Capital Annual
PRIMARY
a. Carbon
w/o scarfers
2,300
90
71.0
14.3
44.0
8.9
w/ scarfers
3,400
140
102.4
20.8
63.5
12.9
b. Specialty






w/o scarfers
2,300
90
14.9
2.9
11.3
2.2
w/scarfers
3,400
140
3.5
0.7
2.7
0.5
SECTION






a. Carbon
5,100
200
179.5
36.5
149.0
30.3
b. Specialty
3,200
130
21.1
4.7
17.5
3.9
FLAT






a. Hot Strip & Sheet
6,400
260
227.8
48.9
200.5
43.0
b. Plate (Carbon)
3,400
140
32.1
6.6
22.5
4.6
c. Plate (Specialty)
1,500
60
2.6
0.5
2.5
0.5
PIPE & TUBE






a. Carbon
5,520
220
30.8
6.5
19.0
3.4
b. Specialty
5,520
220
5.3
1.0
3.3
0.6



692.2
154.4
535.5
110.8
(1) These costs have been adjusted by applying co-mingling factors which reduce the
overall costs by taking into account cost reductions achieved by the use of central
treatment systems. For more information on these factors, see footnotes (1) and (2)
in Table VIII-9A.
291

-------
TABLE VII1-47
BAT ALTERNATIVE NO. 2 COST SUMMARY
HOT FORMING SUBCATEGORY
Subdivision
PRIMARY
a.	Carbon
w/o scarfers
w/scarfers
b.	Specialty
w/o scarfers
w/scarfers
SECTION
a.	Carbon
b.	Specialty
FLAT
Flow Rate
(gal/ton)
90
140
90
140
200
130
BAT Costt
($ x IP"'
)
Capital
72.5
104.7
15.5
3.6
186.5
24.6
Annual
14.7
21.4
3.0
0.7
37.9
4.9
Adjusted BAT Costs
($ x lO'V17
Capital	Annual
45.0
64.9
11.8
2.7
154.8
20.4
9.1
13.3
2.3
0.5
31.5
4.1
a.	Hot Strip & Sheet
b.	Plate (Carbon)
c.	Plate (Specialty)
PIPE & TUBE
a.	Carbon
b.	Specialty
260
140
60
220
220
234.9
33.4
2.9
32.0
5.6
716.2
50.5
6.9
0.6
6.4
1.1
148.1
206.7
23.4
2.8
17.6
3.5
554.3
44.4
4.8
0.6
3.5
0.7
114.8
(1) These costs have been adjusted by applying co-mingling factors which reduce the
overall costs by taking into account cost reductions achieved by the use of central
treatment systems. For information on these factors, see footnotes (1) and (2) in
Table VIII-9A.
292

-------
TABU ¥III-48
but comnrioiiAL roixinAKT contkol tscmolocy (BCT) a malts is
hot forming subcategory
OLD BPT
BCT FSK06 (WW DATA IASI)
"ssr
BCT
Iadaatry BCT Coata
Capital Annual
Nodal
Sixa
(TPD)
Applied
Plow
(CPT)
Diacfcarga
Plow
(CPT)
Coac.
(ail/1)
tti 6iff

Modal
Sisa
(TPD)
Nwbar
of
Plaata
Applied
Plow
(CPT)
Applied
Plow
(CPT)
Coac.
(-B/1)
TSS OfcC
Diacharge
(OPT)1"
Coat f .
(»/lb)t2'
Coat,
•alO"4
(3)
Coat
8*io"*
(3)
PtIMUY















a. Carboa











-V



w/o acarfara 4000
1092
692
13
10
i
-
0
-
-
-
-









2
4400
1
2300
2300
15
5
90 \

71.0
14.3





3
6700
27
2300
1150
30
10
90 )



w/acarfara 4000
1334
•45
13
10
1
2200
1
34O0
1700
15
5
140 I








2
4400
2
3400
3400
15
5
140 I

102.4
20. S





3
6700
20
3400
1700
30
10
140 \















\
0.54


k. Specialty











/



w/o acarfara 2364
1912
1220
13
10
1
-
0
-
-
-
-
- (








2
3000
1
2300
2300
15
5
90 /

14.9
2.9





3
1350
14
2300
1150
30
10
90



w/eearfera 2364
1912
1220
13
10
1

0
_
_
-
-
- \








2
-
0
-
-
-
-
\

3.5
0.7





3
1350
3
3400
1700
30
10
140 J



acrioa















a. Carboa 1300
6029
2626
22
10
1
970
2
5100
2530
15
5
200








2
3340
12
5100
5100
15
5
200 /

179.5
36.5





3
2900
52
5100
2550
30
10
200 1



b. 8p.ci.lt, 360
6029
2626
22
10
1
1600
1
3200
1600
15
5
130 (
0.46







2
1800
3
3200
3200
15
5
130 \

23.3
4.7





3
1400
15
3200
1600
30
10
130 _J



HAT
a. Hot Strip 4
Sbaat
mm;
8015 4180
19
10
1
13,200
2
6400
4480
15
5
260

2041



2
5900
5
6400
6400
IS
5
260





3
5800
35
6400
4480
30
10
260
b. Plata












(Car boa)
2000
5500 4000
10
10
1
-
0
-
-
-
-






2
6900
2
3400
3400
15
5
140





3
2800
10
3400
2380
30
10
140
c. Plata












(Specialty)
578
12,879 9366
10
10
1
-
0
-
-
-
-






2
3600
1
1500
1500
15
5
60





3
220
3
1500
1050
30
10
60
0.63	227. a 48.9
0.94	32.1 6.6
0.98	2.6	0.5

-------
TABLE VIII-48
ROT FORMING SUBCATEGORY
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY (BCT) ANALYSIS
PAGE 2
BCT FEEDS (NEW DATA BASE)
Model
Size
(TPD)
OLD BPT
Applied
Flow
(GPT)
Discharge
Flow
(GPT)
Cone.
(mg/1)
TSS 06G
ModH)
No.
Model
Size
(TPD)
Ninber
of
Plants
Applied
Flow
(GPT)
BCT
Applied
Flow
(GPT)
BCT
Cone.
(mg/1)
TSS O&G
Discharge
F1°!fl>
(GPT)
Cost
($/lb)
(2)
Industry BCT Costs
Capi tal Annual
Cost,
$xlO
(3)	(3)
Cost,
$x 10
PIPE & TUBE
(7)

a. Carbon
400
4209
1002
34
10
1
822
1
5520
2760
15
5
220 )







2
547
3
5520
5520
15
5
220
30.8 6.1






3
1036
20
5520
2760
30
10
270 I
0.89
b. Specialty
400
4209
1002
34
10
1
-
0
-
-
-

f







2
1195
1
5520
5520
15
5
220 \
5.3 1.0






3
338
5
5520
2760
30
10
220 _J

(1)	All aodels at: TSS at 15 mg/1; O&G at 5 mg/1
(2)	Proposed BPT to Proposed BCT (A Adjusted Annual $ CP Load)
(3)	Total dollars to BCT
(4)	Model 1: PSP,RUP,CL,VF,F
Model 2; PSP,CL,VF,F
Model 3: PSP, RUP, CL, VF
(5)	This model size was for Carbon HS & S plants
(6)	This model size was for Specialty HS & S plants
(7)	Originally, the Pipe & Tube subcategory was split into
isolated and integrated facilities

-------
TABLE VllI-49
USPS MODEL COST DATA-BASIS 7/1/78 DOLLAltS
Subcategory: Hoc Foraing	Model Siie-TPD :	6620
Priaary	Oper. Days/Year l	260
s Without Scarfers	Turns/Day	; 	3
I Carbon
ro
>£>
ui
-3
Alternative
CiTT Step
Investment Coat $ i,10
Annual Coat $ x 10
Capital
Depreciation
Operation t Maintenance
Sludge Disposal .
Energy i Power
Cheaical Costa
Oil Diapoaal
TOTAL
Less Credit
NET TOTAL
A
>
C
0°'
e<3)
F
C
H
332
15
832
801
268
1430
771
312
14.3
1.5
- 35.8
34.5
11.5
61.4
33.2
13.4
31.2
3.5
•3.2
80.1
26.8
141.0
77.1
31.2
11.6
1.2
29.1
28.0
9.4
50.0
27.0
10.9
215.4

_
_
5.2
_

_

0.6
34.6(2>
1.2
3.4
57.8
34.6<2)
1.9
-
14.9
-
_
_
_
_
_
"*S<4>
1866.6
21.7
21.3°'
I48.l<2>
143.8
" 1(4)
20.2
312.2
I37.3t2)
57.4
2 - Alt. No. I Plus i
-1592.1
0.4
16.1
Total
4781
205.6
478.1
167.)
220.6
64.9
14.9
1151.4
1908.1
-756.7

Raw
NSPS No.1
(6)
Waste
Effluent
Effluent Quality
Level
Level
Flow, gal/ton
2300
90
Suspended Solids
2190
15
Oil t Crease
84
5
pH, Unita
6-9
6-9
119 Chroaiua
2.9
0.1
120 Copper
2.9
0.1
122 Lead
1.5
0.1
124 Nickel
1.4
0.1
128 Zinc
3.2
0.25
I
41
1.8
4.1
1.4
0.2
2.7
10.2
Total
4822
207.4
482.2
168.7
220.6
65.1
14.9
1158.9
1)08.1
-749.2
NSPS No.2
Effluent
Level
90
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costa are all power unless otherwise noted.
(2)	Total does not include power coat aa a credit ia supplied for process water requirements.
(3)	Treatment c&apoaents are used in tudea.
(4)	Credit for recovery of solids to sinter plsnt.
(5)	Credit for recovery of oil.
(6)	All valuea are in ag/l unleas otherwise noted.
KEY TO C6TT STEPS
A: Priaary Scale Pit	D; Roughing Clsrifier	G: Recycle
B: Surface Skiaaing	E: Vacuus Filter	U: Filtration
C: Recycle	F: Cooling Tower	1: Precipitation with sulfide

-------
TABLE VI11-50
NSFS MODEL COST DATA-BASIS 7/1/78 DOLLARS
Subcategory
Hoc Forming
Pr inary
With Scarfers
Carbon
Model Size-TPD ;
Oper. Days/Year;
Turns/Day	:
6410
260
3
ho
VO
ON
Alternative*
C&TT Step
-3
Investment Coat $ x.10
Annual Cost § x 10
Capital
Deprec iation
Operation 4 Maintenance
Sludge Disposal..
Energy I Power
Chemical Coat*
Oil Disposal
TOTAL
Less Credit
I
2 - Alt. Mo. 1 Plus:
NET TOTAL
Effluent Quality^^
Flow, gal/ton
Suspended Solids
Oil k Grease
ptt. Units
119	Chromium
120	Copper
122	Lead
124	Nickel
128	Zinc
A
389
a
56
C
984
eiil
1007
(3)
E	
342
r
1832
C
1030
H
415
Total
6055
46
450.2
-3299.9
-2849.7
(4)
Raw
Uaate
Level
2300
2970
56
6-9
1.9
3.9
2.1
1.8
4.4
26.0
36.5
37.1
-0.6
(5)
175.2
(2)
181.5
73.5
29.4
44.1
(4)
405.4
183.4(2) 76.1
26.0
1581.9
-3233.4
-1651.5
NSPS Ho.1
Effluent
Level
140
15
5
6-9
0.1
0.1
0.2
0.1
0.25
4.1
12.5
Total
6101
16.7
2.4
42.3
43.3
14. 7
78.8
44.3
17.8
260.4
2.0
262.4
38.9
5.6
98.4
100. 7
34.2
183.2
103.0
41.5
605.5
4.6
610.1
13.6
1.9
34.5
35.2
12.0
64.1
36.1
14.5
211.9
1.6
213.5
381.0
-
45.3(2)
-
7.5
-
56.7(2>
-
388.5
-
388.5
-
0.6
2.3
5.1
79.3
2.3
89.6
0.2
89.8
4.1
26.0
1594.4
-3233.4
-1639.0
NSPS Ho.2
Effluent
Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for process water requirements.
(3)	Treatment components are uaed in tandea.
(4)	Credit for recovery of solids to sinter plant.
(5)	Credit for recovery of oil.
(6)	All values are in ng/1 unless otherwise noted.
KEY TO CATT STEPS
As Primary Scale Pit	D: Roughing Clarifier	C: Recycle
B; Surface Skianing	E: Vacuus Filter	H; Filtration
C: Recycle	ft Cooling Tower	I: Precipitation with sulfide

-------
TABLE VlIl-51
NSPS MODEL COST DATA-BASIS 7/1/78 POLLABS
Subcategory
Hot Forming
Priaary
Without Scarfers
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
Alternative
CtTT Step
Investment Coat $ x^lO 3
Annual Coat $ i 10
Capital
Depreciation
Operation 4 Maintenance
Sludge Diapoaal..
Energy 4 Power
Cheaical Coata
Oil Diapoaal
TOTAL
Leu Credit
NET TOTAL
2 - Alt. No. 1 Plus:

B
C
1^1
E^O
¥
C
H
0
22
407
333
134
495
335
124
6.5
0.9
17.5
14.3
5.8
21.3
14.4
5.3
15.0
2.2
40.7
33.3
13.4
49.5
33.5
12.4
5.3
0.8
14.2
11.7
4.7
17.3
11.7
4.3
36.8
0.4
7.3<2)
0.6
1.1
2.3
15.2
7:3(2>
0.4
63.6
318.6
2.1
(4)
-255.0
6.4
3.0
3.4
(5)
72.4
(2)
59.9
27.3
4.3
23.0
(4)
103.3
59.6(2> 22.4
Total
2000
86.0
200.0
70.0
37.9
18.9
2.1
414.9
325.9
89.0
(2)
5.6
1
Total
28
2028
1.2
87.2
2.8
202.a
1.0
71.0
-
37. f
0.1
19.0
0.5
0.5
2.1
420.5
325.9
94.6
to

Raw
NSPS No.1
NSPS No.2
/< \
Waate
Effluent
Effluent
Effluent Quality
Level
Level
Leve 1
Flow, gal/ton
2300
90
90
Suapended Solida
2190
15
15
Oil 6 Crease
84
5
5
pit, Unit a
6-9
6-9
6-9
119 ChrOaiua
2.9
0.1
0.1
120 Copper
2.9
0.1
0.1
122 Lead
1.5
0.2
0.1
124 Nickel
4.9
0.1
0.1
128 Zinc
1.6
0.25
0.1
(l> Coata are all power unleaa otherwise noted.
(2)	Total doea not include power coat aa a credit ia supplied for process water requireaents.
(3)	Treatment coaponents are used in tsndea.
(4)	Credit for recovery of solids to ainter plant.
(5)	Credit for recovery of oil.
(6)	All values are in aig/1 unless otherwise noted.
KEY TO C4TT STEPS
A: Priaary Scale Pit
Is Surface Skiaaing
C: Recycle
D: Roughing Clarifier
E: Vacuua Filter
F: Cooling Tower
Recycle
Filtration
Precipitation with sulfide

-------
TABLE VIII-52
NSPS MODEL COST DATA-BASIS 7/1/7B DOLLARS
Subcategory
ling
Hoc Fora
Priaary
With Scarfera
Specialty
Model Size-TPD
Oper. Days/Year
Turna/Day
to
KD
CO
Alternative
CtTT Step
2 - Alt. No. I Plus:

Invest sent Coat 9 S3'"
Annual Cut $ x 10
Capital
Depreciation
Operation I Maintenance
Sludge Diapoaalj.
Energy 4 Power
/ Cbeaical Colt*
Oil Diapoaal
TOTAL
Leaa Credit
Hfc'T TOTAL
Effluent Ouality(6>
•aw
Uaatc
Level

Flow, gal/too
3400

Suspended Solid*
2970

Oil 6 Crease
56

Hi. itaU*
6-9
IIS
Ckrtaiaa
3.9
120
Copper
3.9
122
Lead
2.1
124
Niche 1
6.4
128
Zinc
2.2
A
171
7.3
17.1
6.0
70.2
100.6
607.9
-507.3
B
22
1.0
2.2
0.8
0.3
3.9
(4)
8.2
5.5
2.7
(5)
C
0»>
e(3)
47B
394
128
20.6
47.a
16.7
U.6 <"
16.9
39.4
13.8
0.6
5.S
12.8
4.5
1.6
2.2
85.1
(2)
70.7
26.6
6.1
20.5
(4)
f
605
26.0
60.5
21.1
23.3
131.0
C
402
H
143
17.3 6.2
40.2 14.3
14.1 5.0
11.6
(2)
0.7
71.6<2) 26.2
Total
I
Total
2343
29
2372
100.7
1.2
101.9
234.3
2.9
217.2
82.0
1.0
83.0
71.8
-
71.8
27.1
0.1
27.2
-
0.9
0.9
3.9

3.9
519.8
6.1
525.9
619.5

619.5
-99.7
HSFS No.l
Effluent
Level
140
15
5
6-9
0.1
0.1
0.2
0.1
0.25
-93.6
NSPS No.2
Effluent
Level
140
15
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Coat* are all power unlets otherwise noted.
(2)	Total doca not include power coat aa a credit ia aupplied for proceaa water requireaenta.
(3)	Treatment coapooeata are uaed in taadea.
(4)	Credit for recovery of aolida to ainter plant.
(5)	Credit for recovery of oil.
(6)	All value* are ia ag/1 unlesa otberwiae noted.
KEY TO C6TT STEPS
A: Priaary Scale Pit	0: Roughinf Clarifier	C: Recycle
¦i Surface Skianing	E: Vacuus Filter	B: Filtration
C: Recycle	Fj Coaling Tower	I: Precipitation witb aulfide

-------
TABLE VI11-53
MS PS MODEL COST DATA-BASIS 7/1/78 DOLI.AgS
Subcategory: Hot Foraing Model Size-TPD : 2920
i Seccioo Oper. Days/Years 260
; Carbon	Turna/Day	: 	J
-3
Alternative
CtTt Step
lnveataent Coat $ 1.10
Annual Coat $ a 10
Capital
Depreciation
Operation i Maintenance
Sludge Disposal .
Energy t Power
Cheaical Coat*
Oil Diapoaal
TOTAL
Leia Credit
NET TOTAL
1
2 - Alt. Mo. I Pluai
A
329
14.1
32.9
II. 5
75.7
134.2
655.7
-521.5
B
41
1.8
4.1
1.4
0.6
22.6
(4)
30.5
32.2
-1.7
C
780
33.5
78.0
27.3
35.0
(2)
(5)
138.8
(2)
796
34.2
79.6
27.8
1.2
142.8
£C3)
201
8.6
20.1
7.0
1.8
2.6
40.1
8.2
(4)
r
1446
62.2
144.6
50.6
C
780
33.5
78.0
27.3
58.4 35.0
(2)
H
315
13.6
31.5
11.0
1.9
315.8 138.8
(2)
58.0
Total
4688
201.6
468.8
164.1
77.5
64.7
22.6
999.3
696.1
303.2
1
41
1.8
4.1
1.4
0.2
2.6
10.1
Total
4729
203.4
472.9
165.5
77.5
64.9
2.6
22.6
1009.4
696.1
313.3
to
ID
ID

¦aw
NSPS No.1
NSPS No.2

Waate
Effluent
Effluent
Effluent Quality
Level
Level
Level
Flow, gal/ton
5100
200
200
Suspended Solids
990
15
15
Oil 6 Creaae
38
5
5
pH, Unita
6-9
6-9
6-9
119 Chroaiua
1.3
0.1
0.1
120 Copper
1.3
0.1
0.1
122 Lead
0.68
0.2
0.1
124 Nickel
0.61
0.1
0.1
128 Zinc
1.5
0.25
0.1
<1) Coata are all power unleaa otherwise noted.
(2)	Total doea not include power coat aa a credit ia supplied for process water requirements.
(3)	Treataent coaponenta are uaed in tandea.
(4)	Credit for recovery of aolida to ainter plant.
(5)	Credit for recovery of oil.
(6)	All valuea are in ag/1 unleaa otherwiae noted.
KEY TO C6TT STEPS
A: Priaary Scale Pit	D: toughing Clarifier	C: Recycle
Bs Surface Skiaaing	E: Vacuua Filter	Ht Filtration
Ci Recycle	F: Cooling Tower	It Precipitation with sulfide

-------
TABLE VUI-54
USPS HO DEL COST DATA-1ASIS 7/1/76 P0LLA8S
Subcategory) Hoc Foraing
I Section
I Specialty
Model Sixe-TPD : 1470
Oper. Day*/Year: 160
Turns/Day	i 	1
Alternative
an step
Intitatat Coat t x. 10
Annual Coat t « 10
-J
Cbeaical Costa
Oil Diapoaal
TOTAL
Leaa Credit
NET TOTAL
A
176
1
23
C
492
«o>
405
¦<1>
78
F
621
C
412
H
147
Total
2354
60.7
324.6
-255.9
(4)
7.0
11. 5
10.0
1.5
(i)
•7.6
(2)
72.7
IS.4
2.5
12.9
(4)
134. S
73.3(1> 26.9
7.0
490.8
337.1
153.7
2 - Alt. Mo. 1 flun
1 Total
28	2182
Capital
7.5
1.0
21.2
17.4
3.3
26.7
17.7
6.3
101.2
1.2
102.4
Depreciation
17.6
2.3
49.2
40.5
7.8
62.1
41.2
14.7
235.4
2.8
238.2
Operation 6 Maintenance
6.1
0.8
17.2
14.2
2.7
21.7
14.4
5.2
82.4
1.0
83.4
Sludge Diapoaal..
37.5
-
12.0(2)
-
0.6
-
ll.9<2)
-
38.1
-
38.1
Energy 6 Power
-
0.4
0.6
1.0
24.0
0.7
26.7
0.1
26.8
0.8
5.9
0.8
7.0
496.7
317.1
159.6
USPS No. 1
USPS Mo.2
OJ
o
o
if!
Waate
Effluent
Effluent
Cffluant Oualitv
Level
Level
L«vel
Flow, gal/ton
3200
130
130
Suspended Solida
1580
15
15
Oil 6 Creaa.
60
5
5
pi, Units
6-9
6-9
6-9
119 Chroaiws
2.1
0.1
0.1
120 Copper
2.1
0.1
0.1
122 Lead
1.1
0.2
0.1
124 Nickel
1.5
0.1
0.1
128 Zinc
1.2
0.25
0.1
(1)	Coats are *11 power unlets otherwise noted.
(2)	Total does not include power cost as a credit is supplied for process water requirements.
(3)	Treatment components arc used in tandem.
(4)	Credit for recovery of solids to sinter plant.
(5)	Credit for recovery of oil.
(6)	All valuea era in ag/1 unleaa otherwise noted.
KEY TO CfcTT STEPS
~: Primary Scale Pit	0: Roughing Clacifiar	Ct Recycle
It Surface Skimming	Ei Vacuum Filter	Hi Filtration
Ct Recycle	ft Cooling Tover	It Precipitation with sulfide

-------
TABLE VII1-55
USPS MQUEL COST DATA-tASIS 7/1/78 DOLLAMS
Subcategory: Hoc Foraing	Model Si»-TfO :
: Flat	Oper. Deys/Yeer:
t Hot Strip 6 Sheet	Turns/Day s
I Carbon-Specialty
u>
O
-3
Alternative
CtTT Sto»
Inveetaeat Coat $ t.10
Annual Coat $ i 10
Capital
Deprecietion
Operation fc Maintenance
Sludge Biapoaal..
Energy i Power
Cbeaicel Coata
Oil Disposal
TOTAL
Leaa Credit
NET TOTAL
Effluent Quelit*^^
taw
lleate
Level

Flow, gal/ton
6400

Suspended Solids
790

Oil i Creaae
30

p>, llnita
6-9
119
Chroaiua
1.0
120
Copper
1.0
122
Lead
0.54
124
Nickel
1.1
12*
Zinc
0.07
n<3>
«.(!)
Total
2 - Alt. Ho. I Plum*
I Total
621
94
1623
3600
374
3189
1676
587
11,764
59
11,823
26.7
62.1
21.7
70.2
4.1
9.4
3.3
0.6
sa.s
69.S
162.3
56.8
120.6(2)
154. 8
360.0
126.0
3.6
16.1
37.4
13.1
11.0
6.0
137.1
318.9
111.6
186.9
72.1
167.6
58.7
120.6
25.2
58.7
20.5
3.8
505.9
1176.4
411.7
89.2
321.5
58.5
2.5
5.9
2.1
0.2
7.1
508.3
1179.3
413.8
89.2
321.7
7.1
58.5
US. 7
677.0
"•'(5)
SJ.S15'
288.9*2)
644.4
«3-4(4)
49.5
754.5
298.4(2)
108.2
2563.2
810.0
*
17.8
2577.9
810.0
-488.3
-7.6


34.1



1753.2
HSFS Ho.1
Effluent
Level

1767.9
HSFS Ho.2
Effluent
Level
260
13
5
6-9
0.1
0.1
0.2
0.1
0.2S
260
13
5
6-9
0.1
0.1
0.1
0.1
0.1
(1)	Coata are ell power unleaa otherwise noted.
(2)	Total doaa not include power coat ea e credit ia aupplied (or proceaa weter requireaents.
(3)	Treatment conponsnts are uaed in tendea.
(A) Credit for recovery of solids to ainter plant.
(5) Credit for recovery of oil.
16) All values are ia mg/l unleaa otherviae noted.
KET TO CtTT STEPS
Ai Friatry Scale Fit	Ds Roughing Clerifier	Cs Recycle
k: Surface Skinning	El Vacuus filter	II: Filtration
Cs gecycle	F> Cooling Tower	I: Precipitation witb sulfide

-------
TABLE VII1-56
NSPS HQDEL COST DATA-BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Flat
Plate
Carbon
Model Size-TPD ;
Oper. Days/Year;
Turns/Day	;
Alternative
C&TT Step


Total
TOTAL
Less Credit
MET TOTAL
95.3
269.4
-174.1
(4)
13-7
11.a
1.9
(5)
144.9
(2)
153.2
46.3
12.1
34.2
(4)
829.3 327.9
(2)
119.0
1729.6
293.3
1436.3
1 - Alt. Mo. 1 Plus:
Total
Investment Cost $ x.10
361
29
814
853
228
3305
1842
645
8277
65
8342
Annual Cost $ x 10











Capital
15.5
1.2
35.0
36.7
9.8
150.7
79.2
27.7
355.9
2.8
358.7
Depreciation
36.1
2.9
81.4
85.3
22.8
350.5
184.2
64.5
827.7
6.5
834.2
Operatiou & Maintenance
12.6
1.0
28.5
29.9
8.0
122.7
64.5
22.6
289.7
2.3
292.0
Sludge Disposal .
Energy 6 Power
31.1
-

-
2.7
-
132.5(2>
-
33.8
-
33.8
-
0.4
1.1
3.0
205.4
4.2
214.3
0.2
214.5
Chemical Costs
-
-
-
-
-
-
-
-
-
7.7
7.7
Oil Disposal
-
8.2
-
-
-
-
-
-
8.2
-
8.2
19.5
1749.1
293.3
1455.8
La
O
NJ
Effluent Quality
(6)
Raw
Waste
Level
Flow, gal/ton 3400
Suspended Solids 1480
Oil 6 Crease 56
pH, Units	6-9
119	Chromium
120	Copper
122	Lead
124	Nickel
128	Zinc
1.9
1.9
1.0
0.92
2.2
NSPS No.1
Effluent
Leve 1
140
15
5
6-9
0.1
0.1
0.2
0.1
0.25
NSPS No.2
Effluent
Level
140
15
5
6-9
0.1
0.1
0. 1
0.1
0.1
(1)	Costs are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for process water requirements.
(3)	Treatment components are used in tandem.
(4)	Credit for recovery of solids to sinter plant.
(5)	Credit for recovery of oil.
(6)	All values are in -8/» unless otherwise noted.
KEY TO C6TT STEPS
A; Primary Scale Pit	D: Soughing Clarifier	G: Recycle
B: Surface Skimming	E; Vacuum Filter	H; Filtration
C; Recycle	F: Cooling Tower	I: Precipitation with sulfide

-------
TABLE VIII-57
USPS MODEL COST DATA-BASIS 7/1/18 DOLLAKS
Subcategory!	Hot Foraiog	Model Sixe-TPD s
:	Flat	Oper. Dayt/Year:
2	Place	Turna/Day	s
s	Specialty
Alternative
Alt. Mo. 1 Pluai
CtTT Ste»
A
B
C

eO>
F
C
H
Totel
1
Total
Inveataeat Coat t ;.10 '
117
17
11B
240
105
387
264
97
1547
23
1590
Annual Coat f s 10











Capital
5.0
0.7
13.7
11.2
4.5
16.4
11.4
4.1
67.4
1.0
68.4
Depreciation
11.7
1.7
31.8
24.0
10.5
38.7
26.6
9.7
1S6.7
2.3
159.0
Operation 4 Maintenance
4.1
0.4
11.1
9.1
3.7
13.5
9.0
3.4
54.8
0.8
33.6
Sludge Diepoaal,.
Energy i Power
28.7
0.3
s>>
0.5
0.9
1.8
11.9
5:.«>
0.3
29.6
14.8
0.1
29.6
14.9
Cheaical Coata
-
-
-
-
-
-
-
-
-
0.3
0.3
Oil Oiapoaal
-
1.7

-
-
-
-
-
1.7
-
1.7
TOTAL
4».S .
248.9
S0(S)
2.4
56.6<2)
44.a
2l4(4)
3.4
80.7
47.0<2>
17.5
32S.O
4.S
329.3
Leas Credit





254.7

254.7
MET TOTAL
-199.4
2.4


18.0



70.3

74.8
USPS Mo.1
USPS No.2
W
O
u>

Haste
Effluent
Effluent
Effluent Quality
Level
Level
Level
Flow, gal/ton
IS00
60
60
Suspended Solida
3360
IS
15
Oil 6 Creaae
130
5
5
pi. Unite
6-9
6-9
6-9
119 Cbroaiua
4.4
0.1
0.1
120 Copper
4.4
0.1
0.1
122 Lead
2.3
0.2
0.1
124 Nickel
7.4
0.1
0.1
128 Zinc
2.5
0.25
0.1
(1) Coata ar* ail power ualeaa otberwiaa noted.
(2} Total doaa not include power coat aa a credit ia aupplied for proceaa water requirementa.
(3)	Treataent coaponenta are used in taodea.
(4)	Credit for recovery of aolida to ainter plant.
(5)	Credit for recovery of oil.
(6)	All valuea are ia ag/1 ualeaa otherwiae aoted.
Ot TO CtTT STEPS
As Priaary Scale Pit	D: Boughing Clarifier	Ci Becycle
Bi Surface Skiaaing	Es Vacuua Filter	¦> Filtration
Ci Becycle	Ft Cooling Tower	It Precipitation with aulfide

-------
TABLE VIII-58
WSPS HODEL COST DATA-BASIS 7/1/78 DOLLAKS
Subcategory
Hoc Forming
Pipe i Tube
Carbon
Model Size-TPD : 970
Oper. Days/Years 260
Turns/Day	; 	3
Alternative
C6TT Step
Investment Coat $ >^10 '
Annual Coat $ it 10
Capital
Depreciation
Operation fc Maintenance
Sludge Diapoaal .
Energy & Power
Chemical Costa
Oil Diapoaal
TOTAL
Leaa Credit
NET TOTAL
1
2 - Alt. Ho. 1 Pluti
A
200
8.6
20.0
7.0
51.2
86.8
443.7
-356.9
B
23
1.0
2.3
0.8
0.3
5.9
(4)
10.3
8.5
1.8
C
463
19.9
46.3
16.2
11.2
(2)
(5)
82.4
(2)
1.1
119.5
E^
177
7.6
17.7
6.2
1.9
2.5
35.9
8.8
27.1
F
C
H
648
454
174
27.8
19.5
7.5
64.8
45.4
17.4
22.7
15.9
6.1
25.2
11.2(2)
0.
(4)
140.5
80.8(2) 31.7
Total
2804
120.6
280.4
98.1
53.1
29.8
5.9
587.9
461.0
126.9
I
31
1.3
3.1
1.1
0.1
1.0
6.6
Total
2835
121.9
283.5
99.2
53.1
29.9
1.0
5.9
594.5
461.0
133.5
U>
o

Raw
NSPS No.1
NSPS No.2

Uaate
Effluent
Effluent
Effluent Ouality^^
Leve 1
Level
Leve 1
Flow, gal/ton
5520
220
220
Suspended Solids
210
15
15
Oil & Grease
35
5
5
pH, Units
6-9
6-9
6-9
119 Chromium
1.2
0.1
0.1
120 Copper
1.2
0.1
0.1
122 Lead
0.63
0.2
0.1
124 Nickel
0.57
0.1
0.1
126 Zinc
1.3
0.25
0.1
(1)	Coses are all power unless otherwise noted.
(2)	Total does not include power cost as a credit is supplied for process water requirements.
(3)	Treatment components ire used in tandem,
(A)	Credit for recovery of solids to sinter plant.
(5)	Credit for recovery of oil.
(6)	All values are in mg/l unless otherwise noted.
KEY TO CATT STEPS
A: Primary Scale Pit	0
Hi Surface Skimming	£
C; Recycle	F
Roughing Clarifier
Vacuum Filter
Cooling Tower
C: Recycle
H: Filtration
I: Precipitation with sulfide

-------
TABLE VI11-39
NSPS MODEL COST DATA-BASIS 7/1/78 DOLLARS
Subcategory
Hot Forming
Pipe 4 Tube
Specialty
Model Size-TPD
Oper. Days/Year
Turns/Day
480
260
3
Alternative
CATT Step
Investment Coat $ i^IO *
Annual Coat $ i 10
Capital
Depreciation
Operation 6 Maintenance
Sludge Diapoaal .
Energy & Power
Chemical Coata
Oil Disposal
TOTAL
Leas Credit
NET TOTAL
Alt. No. 1 Plus
A
139
6.0
13.9
4.9
21.7
46.5
187.6
-141.1
(4)
B
23
1.0
2.3
0.8
0.4
2.5
7.0
3.6
3.4
(5)
C
377
16.2
37.7
13.2
5.7
(2)
67.1
(2)
0.7
79.6
3.7
(4)
E(1)
93
4.0
9.3
3.3
0.8
1.1
IS.5
14.8
f
368
IS.8
36.8
12.9
11.5
77.0
G
304
13.1
30.4
10.6
5.8
(2)
H
131
5.6
13.1
4.6
0.4
54.1<2) 23.7
Total
1878
80.8
187.8
65.7
22.5
14.1
2.5
373.4
194.9
178.5
31
1.3
3.1
1.1
0.1
0.4
6.0
Total
1909
82.1
190.9
66.8
22.5
14.2
0.4
2.5
379.4
194.9
184.5
U>
O
U1
Effluent Quality
(6)
Raw
Waste
Level
Plow, gal/ton 5520
Suspended Solida 910
Oil & Crease 35
pH, Units	6-9
NSPS No.1
Effluent
Level
220
15
5
6-9
NSPS No.2
Effluent
Level
220
15
5
6-9
119	Chromium
120	Copper
122	Lead
124	Nickel
128	Zinc
1.2
1.2
0.63
2.0
0.67
0.1
0.1
0.2
0.1
0.25
0.1
0.1
0.1
0.1
0.1
(1)	Costs are all power unlesa otherwise noted.
(2)	Total does not include power coat as a credit is supplied for process water requirements.
(3)	Treatment components are used in tandem.
(4)	Credit for recovery of solids to sinter plant.
(5)	Credit for recovery of oil.
(6)	All values are in ng/1 unless otherwise noted.
KEY TO C6TT STEPS
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
0: Roughing Clarifier	C: Recycle
E: Vacuum filter	U: Filtration
F; Cooling Tower	I; Precipitation with sulfide

-------
TABLE VIII-60
PRETREATMENT MODEL COST DATA
The pretreatment system proposed for hot forming
operations is identical to the NSPS Alternative No. 1
treatment system. Therefore, the pretreatment model
costs for each hot forming operation are the same as
those developed for NSPS Alternative No. 1. For the
appropriate pretreatment costs, refer to Tables VIII-49
through VIII-59.
306

-------
TABLE VIII-61
ENERGY REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
BAT and BCT Treatment Models
BAT Alternative No. 1/BCT	BAT Alternative No. 2^^
(2) Annual(2) Total(3) Total(3)	(2) Annual(2) Total(3) Total(3)
Subdivision	kw/hr	Cost	kw/hr Annual Cost kw/hr	Cost	kw/hr Annual Cost
PRIMARY
a. Carbon w/o Scarfing
Model No. 2
447
$69,800
447
$69,800
456
$71,200
456
$71,200
Model No. 3
385
$60,100
11,935
$1,862,000
386
$60,300
11,969
$1,867,000
Carbon w/Scarfing





$33,400


Model No. 1
205
$32,000
205
$32,000
214
214
$33,400
Model No. 2
708
$110,500
1416
$221,000
721
$112,600
1442
$225,000
Model No. 3
538
$83,800
15,064
$2,350,000
539
$84,000
15,095
$2,355,000
Specialty w/o Scarfing







Model No. 2
336
$52,300
336
$52,300
343
$53,400
343
$53,400
Model No. 3
95.6
$14,900
1338
$209,000
96.4
$15,000
1350
$211,000
Specialty w/Scarfing








Model No. 3
154
$24,000
460
$71,800
154
$24,100
463
$72,200
SECTION
a. Carbon
Model No.
1
149
$23,300
298
$46,500
154
$24,100
308
$48,000
Model No.
2
708
$110,500
8496
$1,325,000
721
$112,600
8653
$1,350,000
Model No.
3
385
$60,100
20,020
$3,123,000
386
$60,300
20,077
$3,132,000
Specialty









Model No.
1
149
$23,300
149
$23,300
154
$24,100
154
$24,100
Model No.
2
261
$40,700
783
$122,000
266
$41,500
799
$125,000
Model No.
3
154
$24,000
2302
$359,000
154
$24,100
2314
$361,000

-------
TABLE VIII-61
ENERGY REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
PAGE 2
BAT and BCT Treatment Models
	BAT Alternative No. 1/BCT	BAT Alternative No. 2^^	
(2> Annual(2) Total(3) Total(3)	(2) Annual(2) Total(3) Total(3)
Subdivision	kw/hr	Cost	kw/hr Annual Cost kw/hr	Cost	kw/hr Annual Cost
FLAT
Hot Strip and Sheet








Model No. 1
2237
$349,000
4474
$698,000
2318
$361,600
4635
$723,000
Model No. 2
1566
$244,300
7830
$1,221,000
1592
$248,200
7958
$1,241,000
Model No. 3
1180
$184,000
41,300
$6,443,000
1182
$184,200
41,352
$6,451,000
Carbon Plate








Model No. 2
1081
$168,700
2162
$337,000
1097
$171,200
2195
$342,000
Model No. 3
344
$53,600
3440
$537,000
345
$53,700
3448
$538,000
Specialty Plate








Model No. 2
261
$40,700
261
$40,700
261
$40,700
261
$40,700
Model No. 3
24.8
$3900
74.2
$11,600
25.1
$4000
75.4
$11,800
PIPE AND TUBE
a. Carbon
Model No.
1
149
$23,300
149
$23,300
154
$24,100
154
$24,100
Model No.
2
168
$26,200
504
$78,600
171
$26,700
514
$80,200
Model No.
3
172
$26,900
3450
$538,000
173
$27,000
3465
$541,000
Specialty









Model No.
2
336
$52,300
336
$52,300
343
$53,400
343
$53,400
Model No.
3
62
$9600
310
$48,400
62.8
$9700
314
$49,000
(1)	Includes the energy requirements from Alternative No. 1, which is incorporated with Alternative No. 2.
(2)	These data are based upon the treatment model.
(3)	Treatment model energy requirements expanded to encompass the requirements for the industry.

-------
TABLE VIII-62
SOLID WASTE GENERATION SUMMARY
HOT FORMING SUBCATEGORY
BPT Treatment Models
CI)
Subdivision
Pound s / Ton	Pounds /Day
Tons/Year
(4)
PRIMARY
a.	Carbon
w/o scarfers
w/scarfers
b.	Specialty
SECTION
a.	Carbon
b.	Specialty
FLAT
a.	Hot Strip and Sheet
b.	Carbon Plate
c.	Specialty Plate
PIPE AND TUBE
43.4
85.5
43.4
43.1
43.1
42.7
43.1
41.9
286,000
393,000
62,500
126,000
64,600
265,000
151,000
46,000
1,190,000
1,580,000
146,000
1,080,000
160,000
1,450,000
236,000
24,000
a. Integrated or
Isolated
43.3
38,000
148,000
(1)	Includes solids and oils and greases.
(2)	Pounds of solid waste per ton of production based on the treatment model.
(3)	Pounds of solid waste per day based on the treatment model.
(4)	Model solid waste generation data expanded to encompass solid waste
generation for the mills within the particular subdivision.
309

-------
TABLE VIII-63
SOLID WASTE GENERATION summary(1)
HOT FORMING SUBCATEGORY
BAT and BCT Treatment Models
Subdivision
BAT Alternative No. 1/BCT
BAT Alternative No. 2
(2)
Pound 8/ Ton	Pounds/Day^^
Tons/Year^^ Pounds/Ton	Pounds/Day	Tons/Year^ ^
PRIMARY
a.
b.
Carbon w/o Scarfers
Model No. 2	0.37
Model No. 3	0.37
Carbon w/Scarfers
Model No. 1	0.26
Model No. 2	0.54
Model No. 3	0.54
Specialty w/o Scarfers
Model No. 2	0.37
Model No. 3	0.37
Specialty w/Scarfers
Model No. 3	0.54
1630
2480
570
2380
2540
1110
500
730
210
10,000
74
620
9200
140
910
280
0.37
0.37
0.26
0.54
0.54
0.37
0.37
0.54
1630
2480
570
2380
2540
1110
500
730
210
10,000
74
620
9200
140
910
280
SECTION
a.
b.
Carbon
Model No.
Model No.
Model No.
Specialty
Model No.
Model No.'
Model No.
0.39
0.82
0.82
0.24
0.51
0.51
380
2740
2380
380
920
710
100
4300
16,000
50
360
1400
0.39
0.82
0.82
0.24
0.51
0.51
380
2740
2380
380
920
710
100
4300
16,000
50
360
1400

-------
TABLE VIII-63
SOLID WASTE GENERATION SUMMARY
HOT FORMING SUBCATEGORY
PAGE 2
BAT and BCT Treatment Models
Subdivision
BAT Alternative No. 1/BCT
BAT Alternative No. 2
(2)
Pounds/Ton^ 3 ^ Pounds/Day	Tons/Year ^ Pounds/Ton^ Pounds/Day^^ Tons/Year ^
FLAT
a.	Hot Strip and Sheet
Model Ho. 1
Model Ho. 2
Model No. 3
b.	Carbon Plate
Model Ho. 2
Model Ho. 3
c.	Specialty Plate
Model No. 2
Model No. 3
0.70
1.02
1.45
0.54
0.77
0.24
0.34
9240
6020
8410
3730
2160
860
75
2400
3900
38,000
970
2800
110
29
0.70
1.02
1.45
0.54
0.77
0.24
0.34
9240
6020
8410
3730
2160
860
75
2400
3900
38,000
970
2800
110
29
£ PIPE AND TUBE
Carbon
Model No.
Model No.
Model No.
Specialty
Model No.
Model No.
0.42
0.88
0.88
0.88
0.88
350
480
910
1050
300
46
190
2400
140
200
0.42
0.88
0.88
0.88
0.88
350
480
910
1050
300
46
190
2400
140
200
(1)	Includes solids and oils and greases.
(2)	Includes the solid wastes generated from Alternative No. 1, which is incorporated in Alternative No. 2.
(3)	Pounds of solid waste per ton of production based on the treatment model.
(4)	Pounds of solid waste per day based on the treatment model.
(5)	Model solid waste generation data expanded to encompass solid waste generation for the mills within
the subdivision.

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FIGURE VI11-1
BAT FEED TREATMENT MODEL SUMMARY
HOT FORMING SUBCATEGORY
MODEL I	BAT	BCT/
FEED	BAT NO. I
LEVEL
LEVEL
RECYCLE
RECYCLE
TO DISCHARGE
FLOW ¦ X GPT*
Flow (0.3 to 0.5MX GPT)j
Susp. solids 15 mg/l
Oil 8 urease 5 mg/l 1
OIL
VACUUM
FILTER
Flow (0.96XX GPT)
Susp. solids 15 mg/l
Oil 8 grease 5 mg/l
RECYCLE
TO DISCHARGE
Flow X GPT
Susp. solids 15 mg/l
Oil a grease 5 mg/l
FLOW* X
OIL
VACUUM
FILTER
MODEL 3
Flow(0.3 to 0.5)( X GPT)|
. Susp. solids 30 mg/l ,
"•"n Oil a grease 10 mg/l
RECYCLE
RECYCLE
^TO DISCHARGE
•FLOW«X GPT*
•VACUUM FILTER
(FOR CLARIFIER)
OIL
PSP
PSP
PSP
FILTER
COOLING
TOWER
COOLING
TOWER
CLARIFIER
OR
LAGOON
FILTERS
FILTERS
ROUGHING
CLARIFER
COOLING
TOWER
ROUGHING
CLARIFIER
* X SPT 0ESI6NATES THE APPLIED FLOW FOR ANY ONE TYPE OF HF OPERATION
( I ) RECYCLE LOCATION FOR HOT WORKING PIPE 8 TUBE OPERATIONS
(2) NOT ALL MOOEL 3 PLANTS HAVE ALL OF THE TREATMENT COMPONENTS SHOWN INSTALLED

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HOT FORMING SUBCATEGORY
SECTION IX
EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF THE BEST PRACTICABLE CONTROL
TECHNOLOGY CURRENTLY AVAILABLE
The Agency is proposing Best Practical Control Technology Currently
Available (BPT) limitations which are the same as those originally
promulgated in March, 1976. The subcategories and segments
established for the original guidelines are as follows:
Hot Forming - Primary
Carbon Steel Mills Without Scarfers
Carbon Steel Mills With Scarfers
Specialty Steel Mills
Hot Forming - Section
Carbon and Specialty Steel Mills
Hot Forming - Flat
Hot Strip and Sheet Mill
Plate (Carbon Steel) Mills
Plate (Specialty Steel) Mills
Pipe and Tube
Integrated Mills
Isolated Mills
The March, 1976 development document* described the methods used to
develop the originally promulgated limitations. The intent of this
section is to demonstrate that these limitations are achievable. A
review of the treatment processes and limitations associated with the
hot forming subcategory follows.
Identification of BPT
The original BPT model treatment systems for primary, section and flat
operations included primary scale pits equipped with oil skimming
facilities, partial recycle, roughing clarifiers, vacuum filters, and
filters. In these models, recycle followed sedimentation of the
process wastewaters in primary scale pits with the high blowdown from
the partial recycle loop undergoing additional treatment. The BPT
model treatment system for integrated hot working pipe and tube
operations is similar to the system described above, however; recycle
*EPA-440/1-76/084-b, Development Document for Interim Final Effluent
Limitation Guidelines and Proposed New Source Performance Standards
for the Forming, Finishing and Specialty Steel Segment of the Iron and
Steel Manufacturing Point Source Category.
313

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in this system follows sedimentation in a roughing clarifier instead
of after the scale pit. Filtration was provided for the recycle
blowdown. The model treatment system for isolated pipe and tube
operations incorporated a primary scale pit equipped with oil skimming
facilities, settling basin, and recycle. Partial recycle followed
sedimentation in the settling basin, with the blowdown of the recycle
loop receiving no further treatment. Makeup water is required to
compensate for system losses in each of the cases presented above.
Figures IX-1 through 3 depict the treatment systems discussed above.
Table IX-1 presents a summary of the characteristics of the various
hot forming process wastewaters. Sampled plant monitoring data were
used to determine the raw wastewater pH values; however, the raw
wastewater suspended solids and oil and grease concentrations were
determined from information supplied in the D-DCPs (refer to Section
VII). Sampled plant monitoring data could not be used for this
purpose because, in almost all instances, samples could only be
collected following primary scale pits. The proposed BPT effluent
limitations, which represent 30-day average limitations, are presented
in Table IX-2. The maximum daily effluent limitations are three times
the average limitations. The costs associated with the installation
of the BPT model treatment systems are presented in Table VIII-9A and
9B.
Rationale for BPT
Treatment System
As noted in Section VII, each of the components of the BPT model
treatment systems is in use at many hot forming operations. Thus, the
use of each treatment system component is substantiated.
Justification of Proposed BPT Effluent Limitations
Tables IX-3 through IX-9 present sampled plant effluent data which
demonstrate that the proposed BPT effluent limitations for each hot
forming subcategory and process are achievable.
In reviewing the above tables, it should be noted that the proposed
effluent limitations are achieved at many plants which employ modest
recycle rates (thus being similar to the BPT model treatment system)
and by plants which employ no recycle at all. In addition, the
proposed limitations are achieved at plants with discharge flows
significantly greater than those presented in the various BPT model
treatment systems. The data presented highlight the ability of
various plants to attain the desired treatment performance by means
other than those specifically incorporated in the BPT model treatment
systems. Generally, those sampled plants which do not achieve the
proposed effluent limitations have systems in which only preliminary
sedimentation is provided. Treatment (and, in some instances,
additional recycle) would enable those plants to achieve the proposed
BPT effluent limitations. A few plants employing filtration which
were sampled did not achieve the proposed effluent limitations;
however, these operations have little or no recycle. Therefore,
treatment equipment modifications or the use of additional wastewater
314

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recycle would enable those operations to achieve the proposed BPT
effluent limitations.
315

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TABLE IX" I
BPT MODEL TREATMENT SYSTEM RAW WASTEWATER CHARACTERISTICS
HOT FORMING SUBCATEGORY
OPERATIONS
SUSPENDED*0
SOLIDS
(mg/L)
OIL AND(,)
GREASE
(mg/L)
pH
(UNITS)
HOT
FORMING
(PRIMARY)
(1) Carbon Steel Operations
without Scarfing
4,270
160
6-9
(2) Carbon Steel Operations
with Scarfing
7,560
145
6-9
(3) Specialty Steel Operations
2,640
100
6-9




HOT FORMING
(SECTION)
(1) Carbon and Specialty
Steel Operations
040
32
6-9
HOT
FORMING
(FLAT)
(1) Hot Strip and Sheet
Operations
630
24
6-9
(2) Carbon Steel Plate
Operations
920
35
6-9
(3) Specialty Steel Plate
Operations
3 90
1 5
6-9
HOT FORMING
(PIPE AND TUBE)
(1) Carbon and Specialty
Steel Operations
1,200
46
6-9
(I) THE LEVELS PRESENTED ON THIS TABLE REPRESENT WASTE LOADS APPLIED TO THOSE
PROCESS FLOWS DEVELOPED IN THE ORIGINAL BPT DOCUMENT.

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TABLE IX - 2
BPT EFFLUENT LIMITATIONS GUIDELINES
HOT FORMING SUBCATEGORY
OPERATION
UNITS
FLOW
(gal/ton)
TOTAL ...
SUSPENDED SOLIDS
0!L a(|)
GREASE
HOT
FORMING
(PRIMARY)
(1) Carbon Steal Plants
• /I000*
—
0.0371
0.0288
w/o Scarfing
MG/L
692
13
10
(2) w/Scarfing
•/I000*
—
0.0082
0.0064
Add to (1)
MG/L
153
13
10
(3) Specialty Steel
»/IOOO»
—
0.0654
0.0508
Plants
MG/L
1220
13
10
HOT
FORMING
(SECTION)
(I) Carbon And
•/IOOO*
—
0.2420
0.1095
Specialty Plants
MG/L
2626
22
10
HOT
FORMING
(FLAT)
(1) Hot Strip
WIOOO*
—
0.3308
0.1743
And Sheet Plants
MG/L
4180
19
10
(2) Carbon
#/IOOO*
—
0.1668
0.1668
Steel Plate
MG/L
4000
10
10
(3) Specialty
•/IOOO*
—.
0.3760
0.3760
Steel Plate
MG/L
9366
10
10
HOT
FORMING
(PIPE 8TUBE)
(1) Carbon And
#/IOOO*
—
0.1418
0.0418
Specialty Plants
MG/L
1002
34
10
(I) ALL VALUES REPRESENT 30"DAY AVERAGE LIMITATIONS
NOTE: pH IS ALSO LIMITED AT BPT AND IS LIMITED TO 60 To 9.0 STANDARD UNITS FOR ALL HOT FORMING
OPERATION.

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TABLE IX-3
Or iginally
Promulgated
BPT
Plant Visits
(2)
A-2 Oil2B
(2)
B-2 0112B
C-2^3^ 0684H(2^
(2)
D-2 0946A
(2)
L-2 0060
082	0496
140,,(2)
083	0860H^
088(3) 0684H(2)
EFFLUENT LOAD (lbs/1000 lbs) JUSTIFICATION
	HOT FORMING-PRIMARY (CARBON)
Discharge
Flow (gal/ton)
692
845
(1)
(2)
Suspended
Solids
0.0371
0.0453
(1)
(2)
Oil and
Grease
0.0288
0.0352
(1)
(2)

6-9
C&TT Components
PSP,SS,RUP,CL,VF,FDMP
520
510
780
460
10
0.0035
0.0049
0.016
0.044
0.00021
0.0037
0.0047
0.022
0.016
0.00034
7.6-8.0
7.7-7.8
7.6-7.7
8.1-8.2
8.6-8.7
PSP,SS,SSP,FDP,RTP-42
PSP,SS,SSP,FDP
PSP,CL,FDS
PSP,CL,FDP,RTP-35
PSP,FLL,FLP,CL,CT,RTP-98+
170
12
5
0.00071
0.00045
0.00038
0.0085
0.00050
0.00018
7.4-7.5
7.1-7.6
7.6-7.8
PSP,SSP,DR,FDMG
PSP,CL,CT,RTP-96
PSP,CL,FDS,RTP-99.7
(1)	Operations without scarfers.
(2)	Operations with scarfers - total including (1).
(3)	This plant was sampled twice. As C-2 the flow was once-through and as 088, recycle was then in use.

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TABLE IX-4
EFFLUENT LOAD (lbs/1000 lbs) JUSTIFICATION
HOT FORMING-PRIMARY (SPECIALTY)	
Originally
Promulgated
BPT
Plant Visits
E	0020B
M	0432J
081	0176
082	0496
140H
Ul
S	140M/206"
Discharge
Flow (gal/ton)
1200
2740
68
51
(1)
170
460
Suspended
Solids
0.0654
0.15
0.0099
0.0038
0.00071
0.0019
Oil and
Grease
0.0508
0.023
0.0077
0.0021
0.0085
0.017
_eL
6-9
5.8-6.6
5.8-6.3
7.8-8.1
7.4-7.5
7.4
C&TT Components
PSP,SS,RUP,CL,VF,FDMP
PSP,CLfFDP
PSP,SSP,RUP-90,RTP-8.5
PSP,TP,RTP-94
PSP,SSP,DR,FDMG
PSP,SSP,DR,FDHG
(1) This data represents the discharge from preliminary treatment prior to discharge to central treatment.

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TABLE IX-5
EFFLUENT LOAD (lbs/1000 lbs; JUSTIFICATION
	HOT FORMING-SECTION


Discharge
Flow (gal/ton)
Suspended
Solids
Oil and
Grease
PH
C&TT Components
Originally
Promulgated
BPT
2626
0.2420
0.1095
6-9
PSP,SS,RUP,CL,VF,FDMP
Plant
Visits





M
0432J
140
0.032
0.0058
6.3-6.5
PSP,SS,RTP-80
0
0176-04(1)
320
0.047
0.00094
7.6-8.1
PSP,RTP-97
Q
0684D-02 & 03
1780
0.20
0.010
7.2-7.6
PSP,CNT(45)
A-2
0112B
360
0.0043
0.0043
7.6-8.0
PSP,CL,FDS,RTP-40
E-2
0196A
1640
0.075
0.059
8.3
PSP,CL,FDS,CT,SL(UNK),RTP-65
F-2
0384A-06
140
0.017
0.0048
7.8-8.5
PSP,SSP,SS,CL,FLL,FLP,NW,
VF,CT,RTP-98
G-2
0640A-01 & 02
0
0
0
-
PSP,SS,SL(UNK),FD,CT,RTP-100
081
0176-01 to
03(d
250
0.014
0.0024
7.8-8.1
SSP,SS,TP,CT,RTP-93
083
0860H-02(1)
180
0.00082
0.015
7.1-7.6
PSP,CL,CT,T,CNT,RTP-96.3
083
0860H-03(2)
90
0.023
0.011
7.4
PSP,CL,RTP-99
088
0684H-06 & 07
10
0.00081
0.00068
*
PSP,SSP,SB,CL,T,VF,FLP,RTP-99.

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TABLE IX-5
EFFLUENT LOAD (lbs/1000 lbs) JUSTIFICATION
HOT FORMING-SECTION
PAGE 2 	
Originally
Promulgated
BPT
Plant Visits
088
088
088
088
081
0684H-02
0684H-01
0684H-03
0684H-05
0176-04(1)
Discharge
Flow (gal/ton)
2626
1.7
14
2.8
10
340
Suspended
Solids
0.2420
0.000012
0.000090
0.000025
0.0036
0.033
Oil and
Grease
0.1095
0.000033
0.00016
0.00018
0.00063
0.011
_e2_
6-9
7.6-7.8
7.6-7.8
7.6-7.8
7.5
7.7-7.9
C&TT Components
PSP,SS,RUP,CL,VF,FDMP
PSP,FD(UNK),CL,T,VF,RTP-99.7
PSP,FD(UNK),CL,T,VF,RTP-99.7
PSP,FD(UNK),CL,T,VF,RTP-99.7
PSP,CT,CL,RUP-44,RTP-53
SL,RTP-96
(1)	This data represents the discharge from preliminary treatment prior to discharge to central treatment.
(2)	This plant eventually achieves a discharge flow rate of 3.5 gal/ton by recycling from a large central
treatment system.
*: Level not justified.

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TABLE IX-6
EFFLUENT LOAD (lbs/1000 lb.) JUSTIFICATION
HOT FORMING-FLAT (HOT STRIP AND SHEET)


Discharge
Flow (sal/ton)
Suspended
Solids
Oil and
Grease
PH
C&TT Components
Originally
Promulgated
BPT
4180
0.3308
0.1743
6-9
PSP,SS,RUP,CL,VF,FDHP
Plant
Visits





E
0020B
4520
0.18
0.030
5.8-6.6
PSP,CL,FDS
0
0176
320
0.047
0.00093
7.6-8.1
PSP,RUP-97.5
J-2
0860B
7850
0.26
0.19
7.7-8.3
PSP,SSP,FLP,Filter,CL,VF
L-2
0060
76
0.0016
0.0025
8.6-8.7
PSP,FLL,FLM,CL,VF,CT,RTP-98.3
N-2
0396D
0
0
0
-
PSP,CT,VF,CL,F(UNK)S(UNK),RTP-100
086
0112D-02
5790
0.061
0.020
7.6-7.9
PSP,SS,CL,FLP,NL,NW,CR,SL(UNK)

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TABLE IX-7
EFFLUENT LOAD (lbs/1000 lbs) JUSTIFICATION
HOT FORMING-FLAT (CARBON STEEL PLATE)
Originally
Promulgated
BPT
Plant Visits
K-2
082
083
086
0868B
0496
112,,/120"
0860H
0112D
Discharge
Flow (gal/ton)
4000
100
870
360
3240
Suspended
Solids
0.1668
0.0022
0.0064
0.00011
0.026
Oil and
Grease
0.1668
0.0026
0.064
0.0014
0.021
_rL
6-9
7.0-7.3
7.4
7.1-7.6
7.6-7.9
C&TT Components
PSP,SS,RUP,CL,VF,FDMP
PSP,SSP,T,Fi1ter,CT,RTP-97.3
PSP,SSP,DR,FDMG
PSP,CL,CT,RTP-96.3
PSP,CL,FLP,SL(UNK)

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TABLE IX-8
EFFLUENT LOAD (lbs/1000 lbs) JUSTIFICATION
HOT FORMING-FLAT (SPECIALTY STEEL PLATE)
Originally
Promulgated
BPT
Discharge
Flow (gal/ton)
9366
Suspended
Solids
0.3760
Oi1 and
Grease
0.3760
j>H_
6-9
C&TT Components
PSP,SS,RUP,CL,VF,FDMP
Plant Visits
082 0496
112"/120"
2650
0.018
0.23
7.5
PSP,SSP,DR,FDMG
w
KJ

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TABLE IX-9
EFFLUENT LOAD (lbs/1000 lbs) JUSTIFICATION
HOT WORKING PIPE AND TUBE
Originally
Promulgated
BPT
Plant Visits
E-2 0196A
GG-2	0240B
I1-2	0916A
JJ-2	0728
088	0684H
Discharge
Flow (gal/ton)
1002
4570
0
2760
0
2.8
Suspended
Solids
0.1418
0.14
0
0.50
0
0.00021
Oil and
Grease
0.0418
0.22
0
0.026
0
0.00087
_eh_
6-9
8.3
7.7
C&TT Components
7.6-7.8
PSP, SS, CL, VF,RTP,FDMP or
PSP, SS,SL,RTP
PSP,SS,SSP,SS,SL(UNK),CL,
FDSP,CT,RTP-64.3
PSP, Oil Separator, SL(UNK)
PSP,SS,FD(UNK)P,SL(UNK)
PSP,SL(UNK),RTP and RET-100
FDSP,VF,FLL,FLP,CT,CL,T,RTP-99.7

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RECYCLE
HOT FORMING
OPERATION
OIL
SKIMMER
SCALE
-TREATMENT SYSTEM INFLUENT
(REFER TO TABLE ]£-|)
FILTER
CLARIFIER
TREATMENT SYSTEM EFFLUENT-
(REFER TO TABLE K-2)

VACUUM
FILTER

J m


SOLIDS TO DISPOSAL
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING - PRIMARY,
SECTION AND FLAT
	BPT MODEL
Dwn-l/E2vGO
FIGURE 3Xr

-------
u>
10
RECYCLE
SKI MMER
HOT WORKING
PIPE AND TUBE
OPERATION
CLARIFIER





ER/^




FILTER
-TREATMENT SYSTEM INFLUENT
(REFER TO TABLE K'l)
TREATMENT SYSTEM EFFLUENT-
(REFER TO TABLE JX"2)

VACUUM

FILTER

¦SOLIDS TO DISPOSAL
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
PIPE AND TUBE - INTEGRATED
BPT MODEL
FIGURE HX-2

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RECYCLE
OIL
SKIMMER
HOT WORKING
PIPE a TUBE
OPERATION
LAGOON
SCALE PIT
TREATMENT SYSTEM INFLUENT
(R«f«r to TobU EC-I)
TREATMENT SYSTEM EFFLUENT
(R«f*r to Table IX-2)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
PIPE AND TUBE-ISOLATED
BPT MODEL
Own. 1/18/80
FIGURE 3X1-3

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HOT FORMING 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 achieved by July 1, 1984. Best available
technology is determined by identifying the best economically
achievable control and treatment technology employed within the
subcategory. Also, where a technology is readily transferable from
one industry to another, such technology may be identified as BAT".
The BAT treatment technologies developed herein reflect the wastewater
quality and treatment systems currently in widespread use in the hot
forming subcategory.
This section identifies two BAT alternative treatment systems and the
resulting effluent levels. In addition, the rationale for selecting
the treatment technologies, discharge flow rates and effluent
concentrations are presented. In addition, the BAT model treatment
system which is selected to serve as the basis for the proposed BAT
effluent limitations is described.
Prior to the development of the BAT alternative treatment systems, the
Agency reviewed the DCP and D-DCP responses for the hot forming
subcategory to determine the treatment practices in use. As a result
of this review, the Agency developed three basic treatment systems, to
which the BAT alternative treatment systems could be "added on."
Following are descriptions of these models:
Model No. 1 - Primary sedimentation is provided in a scale pit
equipped with oil skimming facilities. Additional solids removal is
accomplished in a clarifier or thickener. The solids removed in the
clarifier/thickener are dewatered by vacuum filtration. Fifty percent
of the scale pit effluent is recycled in the primary and section mill
models, and thirty percent of the scale pit effluent is recycled in
the flat mill models. Fifty percent of the clarifier/thickener
effluent is recycled in the pipe and tube mill model. The blowdown
from the clarifier is further treated in a filtration system.
Model No. 2 - This model follows the same basic treatment as	Model No.
1; however, no recycle is provided and the entire flow in	each hot
forming subcategory is filtered prior to discharge.
Model No. 3 - This model is similar in each subcategory to	the first
model, with the exception that the process wastewaters	are not
filtered prior to discharge.
329

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In each of the models, the secondary sedimentation step can involve
clarifiers, thickeners, lagoons, and secondary scale pits. Additional
details on the treatment model concept were presented in Section VIII.
Identification of BAT
Based upon the information developed in Sections III through VIII the
Agency developed the following treatment technologies to attain BAT
(formulated as add-ons to the models described above) for the hot
forming subcategory.
BAT Alternative No.
In Models Nos. 1 and 2 the filter effluents are pumped over
evaporative cooling towers. In each case, a sufficient portion of the
cooling tower effluent is recycled so that an overall treatment system
recycle rate of ninety-six percent can be attained.
In Model No. 3, the clarifier/thickener effluent is pumped to an
evaporative cooling tower. A sufficient portion of the cooling tower
effluent is recycled in each case so that an overall recycle rate of
ninety-six percent can be attained. In this model the cooling tower
blowdown is filtered as this model does not include filtration
technology in the recycle system loop. As noted in Section VII, the
cooling tower is incorporated as a means of reducing recycle system
heat loads. The reduction in discharge volume greatly reduces the
discharge of toxic and conventional pollutants.
BAT Alternative No. 2
In this alternative the cooling tower blowdowns of Model Nos. 1 and 2
receive additional treatment aimed at further reducing toxic metals.
The additional treatment consists of sulfide precipitation followed by
filtration. As filtration is already included in the third model of
the first BAT alternative, only sulfide precipitation is included in
Model No. 3. For this model, the sulfide slurry is added prior to
filtration but downstream of the recycle station provided in the first
BAT alternative. Figures X-l and X-2 illustrate the various model and
BAT Alternative combinations for the hot forming subcategory. Aside
from sulfide precipitation, the treatment technologies shown are
widely used throughout the hot forming subcategory.
The effluent limitations associated with the alternative treatment
systems are presented in Tables X-l and X-2. Section VI presented the
rationale for the limitation of five toxic metals. However, the
Agency has determined that limitations for three of these - chromium,
lead, and zinc - will effectively control the five toxic metals
present at treatable levels. As noted in Section VI, other toxic
metal pollutants may be found in the wastewaters from a particular
mill; however, control of the three toxic metals limited at BAT will
also provide adequate control fonother toxic metal pollutants which
may be present at low levels. As noted in Section VI, the high degree
of recycle incorporated at the BAT level will also result in removal
of those organics detected at low levels in hot forming wastes.
330

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Rationale for Selection of the BAT Alternatives
The following discussion presents the rationale for selecting the BAT
model treatment systems, selecting model flow rates, and determining
the concentration levels of the pollutants selected for limitation.
Treatment Scheme
After reviewing the various treatment systems in use in the hot
forming subcategory (as described in the DCP and D-DCP responses), the
Agency developed three basic models upon which the various BAT
alternative treatment systems could be applied.
The rates of primary scale pit recycle included in the basic models
were developed from data presented in DCPs and D-DCPs responses. This
initial recycle is generally provided for flume flushing. This
recycle is not included in Model 2. The reported primary scale pit
effluent recycle rates for the hot forming subdivisions are summarized
in Table X-3. The basic model recycle rates of fifty percent for
primary, section, and pipe and tube operations and thirty percent for
flat operations are well demonstrated. A key factor iff the use of a
preliminary recycle is the reduction in the volume of wastewater
requiring subsequent treatment, which reduces costs for the subsequent
treatment components.
In order to reduce discharge flows, and thus reduce discharged
pollutant loads, the Agency considered additional recycle for the BAT
alternatives. The overall recycle rate (combining the basic model and
BAT recycles) for hot forming operations was established by reviewing
recycle rates in each subdivision and then averaging those recycle
rates considered to be the best in each case. Those recycle rates
greater than ninety percent are considered to be representative of
good treatment. Table X-4 presents a summary (from highest to lowest)
of the recycle rates observed in the hot forming subcategory. The
average of the best recycle rates for each hot forming subdivision
follow.
Subdivision	Recycle Rate
Primary	97%
Section	97%
Flat	96%
Pipe and Tube	97%
Based upon these data, the Agency believes that a ninety-six percent
recycle rate is achievable across all hot forming subdivisions. The
Agency believes that a common recycle rate for all hot forming
operations is applicable because many plants have central treatment
for wastewaters from two or more hot forming subdivisions.
In order to facilitate the attainment of the recycle rate described
above, cooling towers are included as part of each alternative
treatment system. Evaporative cooling towers are incorporated in the
BAT alternative treatment systems to reduce the increased heat loads
that can result with extensive recycle systems. As noted in Section
331

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VII, many hot forming operations employ cooling towers as integral
components of recycle systems.
Filtration is included in Model 3 for the first and second BAT
alternative treatment systems to bring this model's treatment
capabilities up to the levels of the other two basic models. The use
of filtration technology was previously substantiated in Sections VII
and IX.
Sulfide precipitation in association with filtration is incorporated
in BAT Alternative No. 2 for the purpose of reducing the levels of the
various toxic metals to 0.10 mg/1 or less. Although not employed in
this subcategory, this treatment technology has been demonstrated for
treatment of wastewaters from other metal finishing processes.
Filtration for the recycle system blowdown is added in conjunction
with sulfide precipitation in Models Nos. 1 and 2. If sulfide
precipitation were to be incorporated prior to filtration in the basic
models, the cfst of toxic metals removal would be substantially
greater than the proposed BAT treatment scheme due to the much higher
flow undergoing treatment in the basic model as opposed to the BAT
discharge flow. Since BAT Alternative No. 1 for Model No. 3
incorporates filtration of only the system blowdown, sulfide
precipitation from BAT Alternative No. 2 need only be incorporated
prior to filtration in this model.
Applied Flows
The Agency determined average applied flows for each hot forming
subdivision for the purposes of sizing and costing treatment systems,
and establishing effluent limitations. Production weighted flow
averages were determined for each hot forming process (Tables X-5
through X-*12). All available flow data were used to derive the
average flow rates. It should be noted that a separate flow allowance
of 1050 GPT was provided for machine scarfing operations at primary
mills. Additionally, a 50 GPT flow was added for wet scrubbers used
on scarfing units.
Discharge Flows
The discharge flows incorporated in the treatment systems for BAT
Alternatives Nos. 1 and 2 are based upon the recycle of ninety-six
percent of the applied flow. Depending upon model type, different
degrees of recycle will occur at BAT. The BAT feed applied flows,
treated recycle rates, and resultant discharge flows for the hot
forming subdivisions, by model type, are summarized in Table X-13. it
can be seen in this table that plants of the Model 2 configuration
must recycle 96% of the flow to the BAT components to achieve the
model discharge flow. However, plants of the Model 1 and 3
configurations do not have to recycle the entire 96% at BAT because
the plants in these models have recycle steps at BPT. The industry
reported achieving high recycle rates without any problems due to
plugging or scaling.
332

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Wastewater Quality
The average effluent concentrations levels incorporated in each BAT
alternative treatment system (the maximum values are enclosed in
parentheses) are as follows.
As noted above, the Agency is proposing BAT limitations for three
toxic metals: chromium, lead, and zinc. These three have been chosen
because of their ability to serve as indicators for the other toxic
metals present in hot forming wastewaters. The development of these
concentration values is presented in Volume I.
Effluent Limitations for BAT Alternatives
The effluent limitations for the BAT alternative treatment systems
were calculated by multiplying the effluent flows of the alternative
treatment system by the effluent concentration of each pollutant and
an appropriate conversion factor. Tables X-l and X-2 present the
proposed effluent limitations for each process within each BAT
alternative treatment system.
Selection of a BAT Alternative
The Agency selected BAT Alternative No. 1 as the BAT model treatment
system upon which the proposed BAT effluent limitations are based.
The Agency decided that, at this time, Alternative No. 1 is the most
appropriate BAT alternative system because of the significant removal
of toxic metals.
The proposed BAT effluent limitations are presented in Table X-l.
BAT Alt. No. 1
BAT Alt. No. 2
Chromium, mg/1
Lead, mg/1
Zinc, mg/1
0.10(0.30)
0.10(0.30)
0.10(0.30)
0.10(0.30)
0.10(0.30)
0.10(0.30)
333

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TABLE X ~ I
BAT ALTERNATIVE NO.I EFLUENT LIMITATIONS*
HOT FORMING SUBCATEGORY


CONCENTRATION
BASIS
BAT NO. 1 EFFLUENT LIMITATIONS (lbs/1000 lbs)


ALL HOT
FORMING
OPERATIONS
PRIMARY MILLS
SECTION MILLS
FLAT MILLS
PIPE-a TUBE
MILLS
WITHOUT
SCARFERS
WITH
SCARFERS
CARBON
SPECIALTY
HOT STRIP
8 SHEET
CARBON
PLATE
SPECIALTY
PLATE
CARBON a
SPECIALTY
DISCHARGE
FLOW (gal/ton)


90
140
ZOO
130
260
140
60
220
CHROMIUM
AVE.
O.IO
0.0000375
0.0000584
0.0000834
00000542
Q000IO8
0.0000584
0.0000250
0.0000917
MAX.
0.30
0.000113
0.000175
0.000250
0.000163
0.000325
0.000175
0.0000751
0.000275
LEAD
AVE.
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX.
0.30
0.000113
0.000175
0.000250
0.000163
0.000325
0.000175
0.0000751
0.000275
ZINC
AVE.
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX.
0.30
0.000113
0.000175
0.000250
0.000163
0.000325
0.000175
0.000075!
0.000275
U)
U)
XALTERNATIVE I HAS BEEN SELECTEO AS THE BAT SYSTEM

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TABLE X-2
BAT ALTERNATIVE NOt 2 EFFLUENT LIMITATIONS
HOT FORMING SUBCATEGORY

CONCENTRATION
BASIS
BAT N*2 EFFLUENT LIMITATIONS (Ibs/IOOOlbs)
ALL HOT
FORMING
OPERATIONS
PRIMARY MILLS
SECTION MILLS
FLAT MILLS
PIPE ATU8E
MILLS
WITHOUT
SCARFERS
WITH
SCARFERS
CARBON
SPECIALTY
HOT STRIP
& SHEET
CARBON
PLATE
SPECIALTY
PLATE
CARBON &
SPECIALTY
OISCHARGE
FLOWtgol/too)


90
140
200
130
260
140
60
220
CHROMIUM
AVE
O.IO
0.0000375
00000584
Q0000834
0.0000542
0.000108
a0000584
00000250
0.0000917
MAX
0.30
0000113
Q000I75
0.000250
Q000I63
01000325
0.000175
010000751
Q000275
LEAD
AVE
0.10
a0000375
0.0000584
0.0000834
0XXX)0542
0.000108
0.0000584
0.0000250
0.0000917
MAX
0.3Q
Q000II3
01000175
0.000250
0.000163
0.000325
0.000175
0.0000751
Q000275
ZINC
AVE
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
00000250
Q00009I7
MAX
0.30
OjOOOII3
O.OOOI75
Q000250
0.000163
0.000325
0.000175
00000751
0.000275

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TABLE X-3
ANALYSIS OF RECYCLE RATES
FROM PRIMARY SCALE PITS
HOT FORMING SUBCATEGORY
Subdivision	Plant Code	Recycle Percentage
0946A
9.0*
0684G
14.7*
0856F
25.0
0432C
44.9
0856N
47.0
0868A-03
48.8
0060-01
50.0
0112A-01
53.0
0948A
63.5
0920B
68.0
0640
70.8
0112A-03
75.0*
0864A-01
75.0*
0724A
79.2*
0864A-02
85.7*
0060G-01
86.0*
0320-02
96.2*
0940
100.0*
Average of Unstarred Values = 53.3%
0060G-01
6.3*
0684G-01
8.8*
0060H-01
32.0
0384A-06
33.0
0684H-05
42.0
0684H-04
44.4
0856F-03
50.0
0856F-02
50.0
0060F-04
56.5
0856F-02
66.7
00601-02
75.0
0864A
78.9
0476A-03
97.2*
0864B
97.3*
0460B
99.0*
0068B
100.0*
0256N-01
100.0*
0256N-02
100.0*
0256N-03
100.0*
0316A
100.0*
Average of Unstarred Values ¦ 53.7%
336

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TABLE X-3
ANALYSIS OF RECYCLE RATES
FROM PRIMARY SCALE PITS
HOT FORMING SUBCATEGORY
PAGE 2
Subdivision
Plant Code
Recycle Percentage
C. Flat
0060
0860B-01
0432C
0684F-02
0856F
0384A-02
0320-02
0920C
0920N
0856F-02
0112A-03
0112A-04
4.0*
11.1
11.5
18.9
22.9
27.6
32.3
33.7
40.8
66.7
71.4*
89.6*
Average of Unstarred Values = 29.5%
D. Pipe & Tube
0856F(01 & 02)
0476A
0548
0856C
Average of Unstarred Values = 77.0%
(1) Average includes some confidential values
*: To determine a typical untreated process water recycle rate, both high and
low values were omitted so that a more realistic median value could be
approached.
337

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TABLE X-4
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
Subdivision
A. Primary
Plant

Recycle Rates

Code
RUP
RTP
Total
0940
100.0
0
100.0
00601
0
100.0
100.0
0440A
0
100.0
100.0
0684H
0
99.7
99.7
0088D
99.0
0
99.0
0248B
0
98.8
98.8
0060D
0
98.4
98.4
0612 (01 & 02)
0
98.0
98.0
043 2J
90.0
7.5
97.5
0860A (01-03)
0
96.5
96.5
0320-02
96.2
0
96.2
0248C
0
93.3
93.3
0176
0
93.0
93.0
0864C
0
92.7
92.7
0432C
44.9
47.4
92.3
0248A
0
90.3
90.3
0060
50.0
39.6
89.6
0476A
0
88.3
88.3
0920N
0
88.2
88.2
0496
87.5
0
87.5
0920A
0
86.2
86.2
0060G
86.0
0
86.0
0684A-02
85.7
0
85.7
0424
0
80.0
80.0
0672B
80.0
0
80.0
0724A
79.2
0
79.2
0864A-01
75.0
0
75.0
0112A-03
75.0
0
75.0
0640
70.8
0
70.8
0920B
68.0
0
68.0
0948A
63.5
0
63.5
0112A-01
53.0
0
53.0
0396E
0
53.0
53.0
0868A-03
48.8
2.6
51.4
0188B
0
49.5
49.5
06841
0
47.0
47.0
0856N
47.0
0
47.0
046OA
0
37.3
37.3
0946A
9.0
26.0
35.0
0112B-03
0
34.5
34.5
0856F
25.0
0
25.0
0684G
14.7
0
14.7
0868A-02
0
2.4
2.4
338
Average of All Values ¦ 74.4%
Average of Values >902 - 96.6%

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TABLE X-4
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
PAGE 2
Plant
Subdivision	Code
B. Section	00601-01
00601-02
0256N
0316A
0316B
046OA (01 & 02)
0672B (01 & 02)
0684H (01-03)
0684H-05
0060K-01
0060F-05
0136B-02
0860F-03
0088D
046OB
0468B
0136B-01
0188C
0612 (01-04)
0188B
0384A-06
0864B
0476A-03
0640A (01 & 02)
0612-05
0176 (01-04)
0060H-01
0860H (01 & 02)
0946A-03
0136C
0684H-04
0864C (01 & 02)
0864A
0804B-01
0860F (01 & 02)
0672A (01 & 02)
0112-07
0476A-02
0868A (03-05)
0112A-01
0946A (01 & 02)
0856F-01
0468F
0920B-01
0684E (01 & 02)
Recycle Rates
RUP
RTP
Total
75.0
25.0
100.0
0
100.0
100.0
100.0
0
100.0
100.0
0
100.0
0
100.0
100.0
0
100.0
100.0
0
100.0
100.0
0
99.7
99.7
42.0
57.7
99.7
0
99.6
99.6
56.5
43.0
99.5
0
99.5
99.5
0
99.5
99.5
0
99.2
99.2
99.0
0
99.0
0
98.9
98.9
0
98.8
98.8
0
98.1
98.1
0
98.0
98.0
0
98.0
98.0
33.0
64.6
97.6
97.3
0
97.3
97.2
0
97.2
0
97.0
97.0
0
96.8
96.8
0
96.4
96.4
32.0
64.0
96.0
0
96.0
96.0
0
95.8
95.8
0
95.1
95.1
0
94.9
94.9
0
92.7
92.7
78.9
12.3
91.3
0
90.7
90.7
0
90.0
90.0
0
89.6
89.6
0
89.0
89.0
0
88.8
88.8
0
86.4
86.4
0
83.3
83.3
0
82.0
82.0
66.7
0
66.7
0
66.6
66.6
0
59.4
59.4
0
53.3
53.3
339

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TABLE X-4
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
PAGE 3		

Plant

Recycle Rates

Subdivision
Code
RUP
RTP
Total
B. Section
0856F (02 & 03)
50.0
0
50.0
(Cont.)
0856F-04
44.4
0
44.4

0316
0
37.0
37.0

0476A-01
0
33.8
33.8

0424-01
0
17.0
17.0

0424 (02 & 03)
0
9.0
9.0

0060G-01
6.3
0
6.3

Average of All Values
= 84.6%

Average
of Values >90%
= 97.5%
0248B
0
98.8
98.8
0060
4.0
94.0
98.0
0684F-02
18.9
78.7
97.6
0860H-02
0
97.2
97.2
0860H-01
0
96.3
96.3
0868B
0
96.3
96.3
0176
0
92.8
92.8
0112-04
89.6
0
89.6
0868A-03
0
88.5
88.5
0868A-02
13.6
77.9
88.5
0868A-01
0
88.5
88.5
0684B
0
84.5
84.5
0432C
11.5
69.8
81.3
0112A-03
71.4
0
71.4
0856F-02
66.7
0
66.7
0476A
0
59.8
59.8
06841-02
0
53.0
53.0
06841-01
0
47.0
47.0
0920N
40.8
0
40.8
0920C
33.7
0
33.7
0320-02
32.3
0
32.3
0856F-01
22.9
0
22.9
0860B-01
11.1
0
11.1
Average of All Values ** 71.2%
Average of Values >90% = 96.7%
D. Pipe & Tube 0060R (01 & 02) 0	100.0	100.0
0856C	99.4 0	99.4
0684A 0	97.0	97.0
0728 0	96.8	96.8
0396E 0	91.0	91.0
0240B-05 0	87.5	87.5
340

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TABLE X-4
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
PAGE 4
Subdivision
D. Pipe & Tube
(Cont.)
Plant
Code

Recycle Rates

RUP
RTP
Total
0796B
0
82.4
82.4
0548
80.0
0
80.0
0476A
78.7
0
78.7
0548A-01
0
77.6
77.6
0196A
0
64.3
64.3
0088C-01
0
61.4
61.4
0548A-02
0
50.0
50.0
0856F (01 & 02)
50.0
0
50.0
0796A-02
0
41.6
41.6
0492A-05
0
18.9
18.9

Average of All Values
- 73.5%

Average of Values >90%
- 96.8%
KEY TO CODES
RUP: Recycle process water from primary scale pit.
RTP: Recycle treated process water.
341

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TABLE X-5
BAT APPLIED FLOW DETERMINATION
HOT FORMING-PRIMARY: CARBON & SPECIALTY
Basic Flow, Excluding Machine Scarfing
Plant
Applied
Production
Total
Reference
Flow
Capacity
Applied Flow
Code
(Gal/Ton)
(Tons/Day)
(MGD)
0020B
1594
4065
6.48
0060
1012
8537
8.64
0060D
254
2268
0.58
0060G
3891
2868
11.16
00601
3782
495
1.87
0176
1011
285
0.29
0188A
5585
825
4.61
0188B
3656
804
2.94
0248C
2186
415
0.91
0320-02
805
9600
7.73
0384A-01
7483
3864
28.91
0396E
4465
1419
6.34
0424
800
450
0.36
0430C-01
288
90
0.026
0430C-02
1655
114
0.19
0440A
27,163
387
10.51
0476A
3273
1699
5.56
0492A
1551
3714
5.76
0528A
1090
5550
6.05
0612-01
3913
3312
12.96
0612-02
4926
2631
12.96
0640
4332
1878
8.14
0652A
1087
795
0.86
0672B
6517
453
2.95
0684A
742
4851
3.60
0684B
734
4905
3.60
0684E
857
2520
2.16
0684F-01
3698
1752
6.48
0684H
954
5565
5.31
0856H-01
2725
1872
5.10
0856H-02
2787
1830
5.10
0856T-01
1281
4059
5.20
0860B-04
3587
2529
9.07
0860H-01
6747
2988
20.16
0860H-02
1866
8490
15.84
0860H-03
5859
3441
20.16
0864A-01
1272
6795
8.64
0864A-02
2124
2373
5.04
0864C
1280
450
0.58
0868A-01
1236
3000
3.71
342

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TABLE X-5
BAT APPLIED FLOW DETERMINATION
HOT FORMING-PRIMARY: CARBON & SPECIALTY
PAGE 2	 	
Plant
Applied
Production
Total
Reference
Flow
Capacity
Applied Flow
Code
(Gal/Ton)
(Tons/Day)
(MGD)
0868A-02
614
2340
1.44
0868A-03
1886
4692
8.85
0920A
3100
5361
16.62
0920B
2382
5325
12.68
0940
1067
135
0.14
0946A
1296
3066
3.97
0948A
1105
3909
4.32
0948B
1095
3930
7.49
0948C-01
710
4461
3.17
0948C-02
3308
7923
26.21
Production Weighted
2 Total Applied Flow (MGD)** _
369,246,000 GPD
Applied Flow Average*
£ Production Capacity (TPD)**
162,242 TPD


m
2276 Gal/Ton


Use:
2300 Gal/Ton
* : Based on available data. Those operations with unknown flows or with flows
which included scarfing or noncontact cooling water are not included.
**: These totals include flow and production data for plants requesting
confidential treatment of their individual data.
343

-------
TABLE X-6
BAT APPLIED FLOW DETERMINATION
HOT FORMING-PRIMARY: CARBON & SPECIALTY
MACHINE SCARFING OPERATIONS
Plant
Applied
Production
Total
Reference
Flow
Capacity
Applied
Code
(Gal/Ton)
(Tons/Day)
(MGD)
0060
1012
8537
8.64
006 0G
1004
2868
2.88
0320-02
1370
9600
13.15
0528A
1038
5550
5.76
0684F-01
2466
1752
4.32
0684H
857
5.". 65
4.77
0920A
365
5361
1.96
0946A
254
3066
0.78
0948H
2376
3909
9.29
0948C-02
600
7923
4.75
Production Weighted
Applied Flow Average*
E Total Applied Flow (MGD)
E Production Capacity (TPD)
56,300,000 Gal/Day
54,131 Ton/Day
Use:
1040 Gal/Ton
1050 Gal/Ton**
* : Based on available data. Those operations with unspecified or nonsegregated
scarfer flow data are not included in this computation.
**: An additional applied flow of 50 gal/ton is provided to account for blowdowns
from scarfer fume scrubbers. Total applied flow from scarfing operations is
1100 gal/ton.
344

-------
TABLE X-7
BAT APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
Plant
Reference
Code	
0060F-05
0060H-01
0060K-01
0068B
0112A-01
0136B-01
0136B-02
0136C
0188B
0188C
0288A-05
0288A-06
0288A-07
0288A-08
0316
0316A
0316B
0384A-02
0384A-03
0384A-04
0384A-05
0384A-06
0432A-02
0460A-01
0460A-02
046 OB
0468B
0468F
0476A-01
0476A-02
0476A-03
0584F
0612-01
0612-02
0612-03
Applied
Flow
(gal/ton)
11,576
3,025
8,045
20,386
4,627
8,372
22,942
11,859
7,258
7,480
1,995
7,014
316
1,328
9,044
7,543
10,383
3,055
3,797
3,860
8,029
3,376
6,340
4,816
7,744
32,686
7,811
29,465
16,719
9,018
10,075
14,900
4,204
9,870
12,527
Production
Capacity
(tons/day)
1,224
1,071
537
353
3,735
522
354
411
804
462
21
4
334
37
446
420
423
3,420
1,479
933
816
1,758
1,167
897
702
441
1,294
312
190
502
800
807
3,162
1,386
1,092
Total Applied
Flow
(MGD)	
14.17
3.24
4.32
7.20
17.28
4.37
8.12
4.87
5.84
3.46
0.042
0.028
0.11
0.049
4.03
3.17
4.39
10.45
5.62
3.60
6.55
5.94
7.39
4.32
5.44
14.41
10.10
9.19
3.18
4.53
8.06
12.02
13.29
13.68
13.68
345

-------
TABLE X~7
BAT APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
PAGE 2		
Plant
Applied
Production
Total Applied
Reference
Flow
Capacity
Flow
Code
(gal/ton)
(tons/day)
(MGD)
0612-04
4,204
948
3.99
0612-05
5,462
1,239
6.77
0640
3,352
903
3.03
0640A-01
11,449
203
2.32
0640A-02
13,775
507
6.98
0652A-01
7,111
243
1.73
0652A-02
6,261
345
2.16
0672A-01
5,418
817
4.43
0672A-02
10,967
328
3.60
0684A-01
1,705
2,112
3.60
0684A-02
10,052
573
5.76
0684F-01
3,767
1,338
5.04
0684F-02
8,282
765
6.34
0684F-03
8,190
756
6.19
0684G-01
2,240
900
2.02
0684G-02
4,774
1,131
5.40
0684G-03
5,026
573
2.88
0684G-04
9,722
237
2.30
0684H-01
4,710
2,898
13.65
0684H-03
930
2,898
2.70
0684H-04
3,792
1,314
4.98
0684H-05
4,800
1,707
8.19
0684H-06
3,933
996
3.92
0684H-07
9,067
432
3.92
0804B-01
138
150
0.021
0804B-02
131
342
0.045
0856F-01
1,258
6,867
8.64
0856F-02
952
6,867
6.54
0856F-04
12,238
1,057
12.94
0856F-05
8,101
2,133
17.28
0856H-01
1,515
1,683
2.55
0856H-02
1,906
1,338
2.55
0856K-01
61
123
0.0075
0856K-02
198
255
0.050
0856K-03
1,770
732
1.30

-------
TABLE X-7
BAT APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
PAGE 3
Plant	Applied	Production	Total Applied
Reference	Flow	Capacity	Flow
Code		(gal/ton)	(tons/day)	(MGD)	
0856N-01	3,226	3,348	10.80
0856N-02	6,272	1,722	10.80
0856P	5,656	1,233	6.97
0856T-01	535	1,029	0.55
0856U-01	14,894	204	3.04
0856U-02	6,699	690	4.62
0856U-03	5,638	378	2.13
0856U-04	12,288	225	2.76
0856U-05	8,125	693	5.63
0860B-01	3,309	2,132	7.05
0860B-02	5,909	536	3.17
0860B-03	6,522	486	3.17
0860B-04	2,663	1,135	3.02
0860B-05	9,399	429	4.03
0860B-08	11,993	492	5.90
0860B-09	7,590	474	3.60
0860B-10	12,751	892	11.37
0860B-11	6,880	1,464	10.07
0860F-01	7,934	726	5.76
0860F-02	4,936	1,167	5.76
0860H-01	7,796	2,616	20.39
0860H-02	4,690	1,380	6.47
0860H-03	6,930	2,058	14.26
0864A	10,729	2,040	21.89
0864B	9,054	1,161	10.51
0864C-01	3,840	450	1.73
0864C-02	10,000	360	3.60
0868A-01	1,020	1,902	1.94
0868A-02	709	2,307	1.64
0868A-03	1,647	1,386	2.28
0868A-04	3,909	249	0.97
0868A-05	963	537	0.52
0920B-01	1,037	1,806	1.87
0920B-02	1,674	516	0.86
347

-------
TABLE X-7
BAT APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
PAGE 4		
Plant
Reference
Code	
0946A-01
0946A-03
0948B
0948F-03
Applied
Flow
(gal/ton)
7,589
7,798
2,625
3,750
Production
Capacity
(tons/day)
759
831
768
29
Total Applied
Flow
(MGD)	
5.76
6.48
2.02
0.11
Production Weighted _ I Total Applied Flow**	_ 661,980,000 gal/day
Applied Flow Average* £ Production Capacity**	130,892 tons/day
¦	5058 gal/ton
Use: 5100 gal/ton
* : Based on available data. Those operations with unknown or not available
data are not included in the data base.
**: This total includes flow and production data for confidential operations.
348

-------
TABLE X-8
BAT APPLIED FLOW DETERMINATION
HOT FORMING SECTION-SPECIALTY MILLS
Plant
Applied
Production
Total Applied
Reference
Flow
Capacity
Flow
Code
(gal/ton)
(tons/day)
(MGD)
00601-01
10,636
176
1.87
00601-02
13,040
138
1.80
0088A
561
531
0.30
0088D
9,836
885
8.70
0112-07
33,391
138
4.61
0176-01
6,190
30
0.19
0176-02
34,285
11
0.38
0176-03
4,911
78
0.38
0176-04
8,228
210
1.73
0288A-01
4,114
7
0.029
0288A-02
2,527
14
0.035
0288A-03
2,359
22
0.052
0288A-04
3,136
11
0.034
0384A-01
3,055
2,418
7.39
0384A-07
3,276
879
2.88
0424-01
7,283
44
0.32
0424-02
11,707
25
0.29
0424-03
10,537
25
0.26
0440A
3,200
45
0.14
0672B-01
4,880
270
1.32
0672B-02
5,922
462
2.74
0684D-01
1,493
1,929
2.88
0684D-02
1,689
1,626
2.75
0684E-01
3,087
1,185
3.66
0684E-02
8,571
504
4.32
0684H-02
580
2,280
1.32
0776H-01
2,347
37
0.087
0946A-02
8,742
906
7.92
Production Weighted m £ Total Applied Flow** m 64,910,000 gal/day m 3157 gal/ton
Applied Flow Average* £ Production Capacity 20,563 tons/day use 3200 gal/ton
* : Based on available data. Those operations with unknown or not available data are
not included in the data base.
**: This total includes £low and production data for confidential operations.
349

-------
TABLE X-9
BAT APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT: HOT STRIP AND SHEET
Plant
Reference
Code	
0020B
0060
0060D
0112A(03)
0112A(04)
0112D
0176
0248B
0320(02)
0384A(02)
0384A(03)
0384A(04)
0396D(01)
0396D(02)
0424(02)
0432C
0476A
0492A
0528A
0584B
0584C
0584F
0684B
0684F(02)
06841(01)
0684V(02)
0776H(02)
0856D
0856F(01)
0856F(02)
0856P
0856U(01)
Applied
Flow
(gal/ton)
5,421
8,297
7,143
4,911
5,619
5,719
9,630
7,680
9,951
10,193
17,511
8,573
24,935
7,033
716
4,429
6,282
3,471
4,686
5,370
3,680
4,014
4,503
9,347
5.802
8.803
6,400
4,450
5,497
2,840
5,125
11,277
Production
Capacity
(tons/day)
2,550
10,032
2,520
6,978
7,893
12,744
240
1,500
8,232
12,291
3,666
5,400
231
1,638
20.1
10,404
828
3,152
5,549
14,022
9,375
8,322
6,396
8,223
3,429
20.7
18
8,445
9,168
3,042
253
558
Total Applied
Flow
(MGD)
13.82
83.24
18.00
34.27
44.35
72.88
2.31
11.52
81.92
125.28
64.20
46.29
5.76
11.52
0.01
46.08
5.20
10.94
26.00
75.30
34.50
33.40
28.80
76.86
19.90
0.18
0.12
37.58
50.40
8.64
1.30
6.29
350

-------
TABLE X-9
BAT APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT: HOT STRIP AND SHEET
PAGE 2
Plant
Applied
Production
Total Applied
Reference
Flow
Capacity
Flow
Code
(gal/ton)
(tons/day)
(MGD)
0856U(02)
22,944
150
3.44
0856U(03)
6,400
639
4.09
0856U(04)
4,847
915
4.44
0856U(05)
11,809
2,907
34.33
0860BC01)
8,448
12,204
103.10
0860B(02)
5,594
5,895
32.98
0864A
4,666
6,018
28.08
0868A(02)
21,356
177
3.78
0868A(03)
2,905
4,854
14.10
0920C
7,767
3,300
25.63
0920N
3,198
7,992
26.56
0948A
6,076
7,584
46.08
0948C
6,602
8,724
57.60
Production Weighted _ TOTAL APPLIED FLOW**	
Applied Flow Average* " TOTAL PRODUCTION CAPACITY**
„ 1,460,070,000 gal/day , 639Q gal/t
228,498.8 tons/day	0J™ gai/ton
Say 6,400 gal/ton
* : Based on available data. Those operations with unknown or not available
data are not included in the data base.
**: These totals do not include the data from the one plant claiming
confidentiality.
351

-------
TABLE X-10
BAT APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT: PLATE (CARBON)
Plant
Applied
Production
Total Applied
Reference
Flow
Capacity
Flow
Code
(gal/ton)
(tons/day)
(MGD)
0060F(01)
3,976
2,115
8.41
0112A(01)
2,455
1,056
2.59
0112A(02)
2,778
2,592
7.20
0112D(01)
3,221
3,360
10.82
0384A(01)
7,867
972
7.65
0496(140")
118
1,830
0.22
0496(140"/206")
206
6,300
1.30
0496(112"/1201)
869
1,740
1.51
06841(02)
7,558
1,629
12.31
0856H(01)
117
984
0.12
085611(02)
5,473
3,939
21.56
0856H(03)
3,652
2,916
10.65
0860B(03)
2,550
3,162
8.06
0860H(C1)
9,821
648
6.36
0860HO2)
5,489
2,886
15.84
0868A(01)
3,922
1,800
7.06
0868B
4,992
3,894
19.44
Production Weighted
TOTAL
APPLIED FLOW

Applied Flow Average* TOTAL PRODUCTION CAPACITY
. 141,100,000 fial/day ,3374 gal/t
-------
TABLE X-ll
BAT APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT: PLATE (SPECIALTY)
Plant Applied	Production	Total Applied
Reference Flow	Capacity	Flow
Code	 (gal/ton)	(tons/day)	(MGD)
0424(01)	800	450	0.36
0496(140")	144	1,830	0.26
0496(112M/120")	2,653	1,740	4.62
0684V(01)	8,803	119.4	1.05
0776H(01)	960	60	0.06
Production Weighted x TOTAL APPLIED FLOW*	
Applied Flow Average * TOTAL PRODUCTION CAPACITY*
" tl%VtowLy " 1512
Say - 1500 gal/ton
*: These totals do not include the data £rom the one plant claiming confidentiality.
353

-------
TABLE X-12
BAT APPLIED FLOW JUSTIFICATION
HOT WORKING PIPE AND TUBE
Plant
Applied
Production
Total Applied
Reference
Flow
Capacity
Flow
Code
(gal/ton)
(tons/day)
(MGD)
0088A-03
2,712
171
0.46
0088C-01
3,552
283.8
1.01
0088C-02
6,436
268.5
1.73
0196A
12,794
822
10.52
0240B-05
1,858
213
0.40
0256G
515
564
0.29
0396E
450
480
0.22
0432A-01
8,084
699
5.65
0476A
4,672
381.6
1.78
0492A-05
10,154
156
1.58
0548
4,573
196.8
0.90
0548A-01
8,000
126
1.01
0548A-02
6,857
42
0.29
0652A
3,672
363
1.33
0684A-02
4,311
1,002
4.32
0684H
7,013
540
3.79
0728
2,560
240
0.61
0856C
16,000
36
0.58
0856F-01
7,111
663
11.52
0856F-02
957
0856N-01
3,418
1,011
3.46
0856N-02
3,648
1,500
5.47
0856N-03
3,083
981
3.02
0856N-04
3,730
888
3.31
0916A-01
2,765
600
1.66
0920C-01
4,706
229.5
1.08
0920C-02
5,788
373.2
2.16
0948A-01
6,207
615
8.64
0948A-02
777
0948A-03
3,077
468
1.44
0948C-01
21,405
444
9.50
0948C-02
6,611
501
3.31
Production Weighted = TOTAL APPLIED FLOW**	
Applied Flow Average* = TOTAL PRODUCTION CAPACITY**
= 99,290,000 gal/day =	Ral/ton
17,985 tons/day	8"/">n
Say 5,520 gal/ton
* : Based on available data. Those operations with unknown or not available data are
not included in the data base.
**: These totals include the confidential data.
354

-------
TABLE X-13
BAT FLOW & RECYCLE SUMMARY
HOT FORMING SUBCATEGORY
Subdivision
PRIMARY
a.	Carbon & Specialty
w/o scarfers
b.	Carbon & Specialty
w/scarfers
Model
1
2
3
1
2
3
BAT Feed
Applied
Flow
(gal/ton)
1150
2300
1150
1700
3400
1700
Recycle
Rate (2)
92
96
92
92
96
92
BAT
Discharge
Flow
(gal/ton)
90
90
90
140
140
140
SECTION
a. Carbon
b. Specialty
1
2
3
1
2
3
2550
5100
2550
1600
3200
1600
92
96
92
92
96
92
200
200
200
130
130
130
FLAT
a.	Hot Strip & Sheet
b.	Carbon Plate
c.	Specialty Plate
1
2
3
1
2
3
1
2
3
4480
6400
4480
2380
3400
2380
1050
1500
1050
94
96
94
90
96
90
94
96
94
260
260
260
140
140
140
60
60
60
PIPE & TUBE
a. Carbon & Specialty
1
2
3
2760
5520
2760
92
96
92
220
220
220
355

-------
MODEL I
BAT
FEED

—H»—1
RECYCLE
RECYCLE'
_ _L
I	
-L	mi FILTERS
^TO DISCHARGE
VACUUM
FILTER
OIL
RECYCLE
MODEL 2
^ ROUGHING
. CLARIFIER
	PSP (—
	M FILTERS h
^TO DISCHARGE
OIL
VACUUM
FILTER
MODEL 3
	
-------
MODEL I
RECYCLE ¦
		(l>-
I	L~|
H PSP I	
l__tj
i
OIL
1
BAT
FEED
LEVEL
!~1ROUGHING-1	\_
,_CLARJFIER j~
H FILTERS |-
I	I
*
VACUUM
FILTER
MODEL 2
PSP |	
	rJ
i
OIL
I ROUGHING j_
LCLAmFIERj
~
VACUUM
FILTER
FILTERS I	
MODEL 3
RECYCLE^- -j
		1.
	(I)—|
M PSP •	
I	r J
I
~
OIL
CLARIFIER
laSoon	|
RECYCLE*
COOLING
TOWER
RECYCLE•
COOLING
TOWER
RECYCLE*
COOLING
TOWER
(I) ALTERNATE RECYCLE POSITION FOR HOT WORKING PIPE AND TUBE OPERATIONS
NOTES: FOR ADDITIONAL DETAILS AND RATIONALE FOR THE BAT TREATMENT MODEL CONCEPT SEE
THE SECTION VIII AND X TEXT
-SULFIDE
iWi
FILTERS
r
SULFIDE
7\
FILTERS
-SULFIDE

Ya
FILTERS
	BPT COMPONENTS
	BAT COMPONENTS
TO
DISCHARGE
TO
DISCHARGE
-»• TO
DISCHARGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SUBCATEGORY
BAT MODEL-ALTERNATIVE 2
Dwn. 2/W/80
FIGURE X-2

-------
HOT FORMING 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 methodology for this
cost test. (See 43 Fed. Reg. 37570, August 23, 1978).
Explanation of the BCT Cost Test
The criteria for the BCT Cost Test are contained in Section
304(b)(4)(B) of the Clean Water Act, which requires a consideration of
the "cost reasonableness" of effluent limitations for conventional
pollutants. The BCT cost comparison is between the cost and aevel of
reduction of the BCT pollutants at a publicly-owned treatment works
and the cost and level of reduction of such pollutants in the
appropriate iron and steel subcategory (i.e., hot forming).
For the hot forming subcategory, the BCT cost test includes the cost
of achieving the proposed BCT limitations from the proposed BPT
limitations, and the conventional pollutant load removal from BPT to
BCT. The Agency calculated the BCT cost test two ways. It calculated
the test based upon both the proposed BPT effluent limitations and the
"BAT FEED" effluent quality discussed in Section VIII. Although not
required to calculate the BCT test based on "BAT FEED", the Agency did
so to see if the results might change; they did not. In all cases,
the BCT test was passed.
Development of BCT
The BCT model treatment system is the same as BAT Alternative No. 1
and includes a cooling tower and recycle system for Models 1 and 2,
and a cooling tower, recycle system and filter for Model 3.
359

-------
The BCT test results were detailed previously in Table VIII-48. As
shown in that table, the BCT cost test values range from $0.46/lb to
$0.94/lb. Systems designed to reduce the proposed BPT discharge to
the proposed BCT limitations were developed and then costed so that
the cost test could be completed as accurately as possible. The POTW
removal cost is $1.34/lb (July 1978 dollars). Therefore, the BCT
systems as developed, pass the BCT cost tests and were used to develop
the proposed BCT effluent limitations.
Development of Proposed BCT Limitations
Because BCT limitations apply to conventional pollutants, the Agency
considered limitations solely for suspended solids, oil and grease,
and pH. The proposed BCT effluent limitations for the hot forming
subcategory are presented in Table XI-1. The BCT model treatment
system is completely compatible with BAT Alternative No. 1 illustrated
in Figure X-l.
Reference is made to Appendix A of Volume I for a detailed review of
the derivation of the performance standards for TSS and oil and
grease. The proposed limitations for pH (6-9) are the same as those
proposed for BPT.
BCT Cost Summary
The Agency developed the costs for the BCT model treatment system.
These costs are the same as those for BAT Alternative No. 1, and are
summarized in Table VIII-48. As shown, the capital and annual costs
for all hot forming operations considering facilities in place as of
January 1, 1978 are $434.7 million and $110.8 million, respectively.
360

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TABLE XI" I
BCT EFFLUENT LIMITATIONS
HOT FORMING SUBCATEGORY
OPERATION
UNITS
FLOW
(GAL/TON)
TOTAL SUSPENDED SOLIDS
OIL a GREASE
AVE
MAX
AVE
MAX
PRIMARY
MILLS
WITHOUT SCARFERS
tt/IOOO**
	
0.00563
0.0150
	
0.00375
MG/L
90
15
40
—
10
WITH SCARFERS
tt/IOOO#
—
0.00878
O0234
—
0.0136
MG/L
140
1 5
40
—
10
SECTION
MILLS
CARBON
=tt/IOOO#
—
0.0125
0.0334
—
0.00834
MG/L
200
15
40
—
10
SPECIALTY
tt/IOOO#
—
0.00813
00217
—
0.00542
MG/L
130
15
40
—
10
FLAT
MILLS
HOT STRIP a SHEET
*t/IOOO#
—
0.0163
0.0434
—
0.0108
MG/L
260
15
40
—
10
CARBON PLATE
*1/1000*
—
0.00878
0.0234
—
0.00584
MG/L
140
15
40
—
10
SPECIALTY PLATE
St/IOOO4*
	
0.00375
0.0100
—
0.00250
MG/L
60
15
40
—
10
pipe a
TUBE MILLS
CARBON a
SPECIALTY
#/IOOO#
—
0.0138
0.0367
—
0.00917
MG/L
220
15
40
—
10
NOTE: pH IS ALSO REGULATED AT BCT AND IS LIMITED TO 6.0 to 9.0 UNITS.

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HOT FORMING 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 proposal of
new source performance standards (NSPS). NSPS standards are to
consider the degree of effluent reduction achievable through
application of best available demonstrated control technology (BADCT),
processes, operating methods, or other alternatives, including, where
practicable, a standard permitting no discharge of pollutants. Zero
discharge, may be a feasible NSPS treatment alternative for the hot
forming subcategory and the Agency is soliciting comments on this
issue.
Identification of NSPS
NSPS Alternative ]_
The first NSPS alternative treatment system includes the BPT model
treatment system and the BAT Alternative 1 components discussed in
Section IX and X. This system includes sedimentation of the raw
wastewater in primary scale pits equipped with oil removal facilities.
Both oil and scale removed by this step are reclaimed. A portion of
the scale pit effluent is recycled to the process for flume flushing
or other uses. In the pipe and tube subcategory this initial recycle
occurs after the secondary settling, which directly follows the
primary scale pit. After the roughing clarifier, the wastewater is
cooled, and recycled to an overall recycle rate of 96%. A four
percent blowdown from the cooling tower effluent is filtered and
discharged.
NSPS Alternative 2
The NSPS Alternative 2 system is similar to the system described
above, except that sulfide precipitation ' is employed prior to the
filtration step. This system is similar to the BPT model treatment
system and BAT Alternative 2 system discussed in Sections IX and X.
The NSPS treatment systems described above are depicted in Figures
XII-1 and XI1-2. The corresponding effluent standards for these
systems are presented in Tables XII-1 and XI1-2. Cost data for the
treatment systems is detailed in Tables VIII-49 through VIII-59.
Rationale for Selection of NSPS
The NSPS alternative treatment systems developed for the hot forming
subcategory are similar to the BAT alternative treatment systems
363

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described in Sections IX and X. Therefore, the rationale presented in
these sections are applicable to NSPS and are not be repeated here.
Treatment Scheme
The NSPS alternative treatment systems include primary scale pits,
roughing clarifiers, oil skimming, deep bed pressure filters, cooling
towers, recycle and sulfide precipitation. With the exception of
sulfide precipitation, all of these technologies are well demonstrated
in the hot forming subcategory. As discussed in Section X, sulfide
precipitation has been successfully applied to other metals
manufacturing process wastewaters and is suitable for steel industry
wastewaters as well. The recommended treatment technologies are
reliable and demonstrated methods of treatment and are appropriate for
NSPS.
The resulting effluent quality for the NSPS alternatives is presented
in Tables XII-1 and XI1-2. As discussed in Section X, the selected
pollutants and the respective effluent concentration values are based
upon the capabilities of the various water treatment technologies.
Flows
The applied and discharge flow rates that are used with the NSPS
Alternatives for the hot forming subcategory were developed in Section
X. The discharge flow within each hot forming subdivision is
applicable to both NSPS alternative treatment systems. These flows
are demonstrated by plants in the respective subcategories and
represent an overall system blowdown rate of 4%. The recycle rate of
96% is also well demonstrated in each of the hot forming subdivisions.
Selection of a NSPS Alternative
The Agency selected NSPS Alternative No. 1 as the NSPS model treatment
system upon which the proposed NSPS effluent standards are based.
This alternative was selected for the same reasons noted in the
discussion in Section X regarding the selection of a BAT model
treatment system. The proposed NSPS effluent standards are presented
in Table XII-1.
364

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TABLE XH-1
NSPS ALTERNATIVE Na I EFFLUENT STANDARDS *
HOT FORMING SUBCATEGORY


CONCENTRATION
BASIS
NSPS NO. 1 EFFLUENT STANDARDS (lbs/I000 lbs)


ALL HOT
FORMING
OPERATIONS
PRIMARY MILLS
SECTION MILLS
FLAT MILLS
PIPE a TUBE
MILLS
WITHOUT
SCARFERS
WITH
SCARFERS
CARBON
SPECIALTY
HOT STRIP
a SHEET
CARBON
PLATE
SPECIALTY
PLATE
CARBON a
SPECIALTY
DISCHARGE
FLOW (gal/ton)


90
140
200
130
260
140
60
220
TOTAL
SUSPENDED SOLIDS
AVE.
IS
0.00563
0.00878
0.0125
0.00813
0.0163
0.00878
0.00375
0.0138
MAX.
40
0-0150
0.0234
0.0334
00217
0.0434
0.0234
0.0100
0.0367
oil a
GREASE
AVE.
—
STANDARDS WILL BE ON A MAXIMUM BASIS ONLY
MAX.
10
0.00375
0.00584
0.00834
0.00542
0.0108 <
0.00584
0.00250
0.00917
CHROMIUM
AVE.
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX.
0.30
0.000113
O.OOOI75
0.000250
0.000163
0.000325
0.000175
0.0000751
0.000275
LEAD
AVE.
0.10
Q0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX.
0.30
0.000113
0.000175
0.000250
0.000163
0.000325
0.000175
0.0000751
0.000275
ZINC
AVE.
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX.
0.30
0.000113
0.000175
0.000250
0.000163
0.000325
0.000175
0.0000751
0.000275
NOTE: pH it also regulated at NSPS and it limited to 6.0-9.0
standard units for all hot forming operations.
* Alternative I has bee* selected as the N8PS system

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TABLE Xn-2
NSPS ALTERNATIVE N0.2 EFFLUENT STANDARDS
HOT FORMING SUBCATEGORY
-
CONCENTRATION
BASIS
NSPS N0.2 EFFLUENT STANDARDS (lbs/1,000 lbs)
ALL HOT
FORMING
OPERATIONS
PRIMARY MILLS
SECTION MILLS
FLAT MILLS
PIPE a TUBE
MILLS
WITHOUT
SCARFERS
WITH
SCARFERS
CARBON
SPECIALTY
HOT STRIP
8 SHEET
CARBON
PLATE
SPECIALTY
PLATE
CARBON a
SPECIALTY
DISCHARGE
FLOWlgal/ton)


90
140
200
130
260
140
60
220
TOTAL
SUSPENDED SOLIDS
AVE
15
0.00563
0.00878
0.0125
0.00813
0.0163
0.00878
0.00375
0.0138
MAX
40
0.0150
0.0234
0.0334
0.0217
0.0434
0.0234
0.0100
0.0367
OIL S GREASE
AVE
-
STANDARDS WILL BE ON A MAXIMUM
MAX
10
0.00375
0.00584
0.00834
0.00542
0.0108
0.00584
0.00250
0.00917
CHROMIUM
AVE
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX
0.30
0.000113
0.000175
0.000250
0.000163
0.000325
0.000175
0.0000751
0.000275
LEAD
AVE
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX
0.30
0.000113
0.000175
0 000250
0.000163
0.000325
0.000175
0.C00075I
0.000275
ZINC
AVE
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX
0.30
0.000113
0000175
0.000250
0.000163
0.000.325
0.000175
0.0000751
0.000275
NOTE'pH is also regulated at NSPS ond is limited to 6.0-9.0
standard units for all hot forming operations.

-------
RECYCLE BACK
TO PROCESSOR
BACKWASH
-(I) |
PROCESS
5
SOLIDS TO
DISPOSAL
FILTER
/ V
COOLING
TOWER
FILTER
<54
SUSR SOLIDS
OIL a GREASE
PH
CHROMIUM
COPPER
LEAD
NICKEL
ZINC
FLOW* SEE TABLE XII-
SOLIDS TO
DISPOSAL

15 mg7T\
5 mg/l I
6-9 /
O.I mg/l\
0.1 mg/l V
0.1 mg/l (
0.1 mg/l I
0.1 mg/l\
TO
DISCHARGE
(1)	ALTERNATE RECYCLE LOCATION FOR PIPE ft TUBE OPERATIONS
(2)	RECYCLE PERCENTA8E
TO* FOR PRIMARY, SECTION, AND PIPE « TUBE OPERATIONS
30% FOR FLAT OPERATIONS
(5) SYSTEM RECYCLE RATE IS INCREASEO TO ACHIEVE AN OVERALL RECYCLE
RATE OF »«%
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SUBCATEGORY
NSPS MODEL-ALTERNATIVE
fen.2/15/80
FIGURE 3H-I

-------
RECYCLE BACK _
TO PROCESS(3)*
RECYCLE
PROCESS
(BACKWASH)
COOLING
TOWER
.c.
SULFIDE
-H IWH filteh
SOLIDS TO
DISPOSAL
SOLIDS TO«
DISPOSAL
VACUUM

FILTER


SUSR SOLIDS
OIL a GREASE
pH
CHROMIUM
COPPER
LEAD
NICKEL
ZINC
IS mg/l
5 mg/li
6-9
O.I mg/l\
0.1 mg/l
0.1 mg/l I
Oil mg/ll
0.1 mg/ll
FLOW* SEE TABLE XI 1*2
TO
"DISCHARGE
(1)	ALTERNATE RECYCLE LOCATION FOR PIPE ft TUBE OPERATIONS
(2)	RECYCLE PERCENTAGE
SO% FOR PRIMARY, SECTION, AND PIPE a TUBE OPERATIONS
:30V. FOR FLAT OPERATIONS
(3)	SY9TEM RECYCLE RATE IS INCREASED TO ACHIEVE AN OVERALL RECYCLE
RATE OF 99%
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SUBCATEGORY
NSPS MODEL-ALTERNATIVE 2
Dwa 2/15/80
FIGURE JHL-2

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HOT FORMING SUBCATEGORY
SECTION XIII
PRETREATMENT STANDARDS FOR DISCHARGES TO
PUBLICLY OWNED TREATMENT WORKS
Introduction
This section discusses the alternative control and treatment systems
available for hot forming operations which discharge wastewaters to
publicly owned treatment works (POTWs). Separate consideration has
been given to the treatment of hot forming process wastewaters from
new sources (PSNS) and from existing sources (PSES). The main factors
considered in the development of pretreatment systems were to insure
that hot forming wastewaters received sufficient treatment to avoid
overloading POTW systems and that toxic pollutants that interfere
with, pass through, or are otherwise incompatible with POTW operations
are controlled. The general pretreatment and categorical pretreatment
standards applying to hot forming 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), revisions of categorical standards, and POTW
pretreatment programs.
In establishing pretreatment standards for hot forming operations, the
Agency gave primary consideration to the objectives and requirements
of the General Pretreatment Regulations. In addition, the Agency
considered factors specifically applicable to hot forming operations
which 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.
Although wastewaters from about twenty operating hot forming
operations are discharged to POTWs, POTWs are usually not designed to
treat the toxic pollutants present in hot forming wastewaters.
Instead, POTWs are designed to treat biochemical oxygen demand (BOD),
suspended solids (TSS), fecal coliform bacteria, and pH. Whatever
removal obtained by POTWs for toxic pollutants is incidental to the
POTWs main function of treating conventional pollutants. POTWs have
historically accepted large amounts of many pollutants well above
369

-------
their capacity to treat them adequately. As the issue of municipal
sludge use has become more important, pretreatment standards must
address toxic pollutant removal, rather than transfer of these
pollutants to POTWs where many pollutants concentrate in the sludges.
Due to the high process flows and the presence of toxic pollutants in
wastewaters from hot forming operations, extensive 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. The pretreatment wastewater
treatment technologies are the same as the BAT treatment levels. The
Agency is not proposing pretreatment standards for suspended solids
and oil and grease because these pollutants, in the amounts present in
the recycled effluents from hot forming operations are compatible with
POTW operations. Hot forming wastewaters are compatible with POTW
operations and can be effectively treated at POTWs. However, due to
the high flow and lack of high organic content in the hot forming
wastewaters, these wastes are generally not discharged to POTW
operations. Toxic pollutants are reviewed below.
Identification of Pretreatment
The pretreatment systems developed for both New Sources and Existing
Sources are identical to the New Source Performance Standard
Alternative No. 1 treatment system (refer to Section XII), thus
eliminating the need for separate New Source and Existing Source
Pretreatment Standards (PSNS and PSES).
The principal goal of the treatment model developed for pretreatment
is the control and removal of the toxic metal pollutants. Primary
scale pits equipped with oil removal facilities provide for the
initial removal of suspended solids, and oil and grease. A portion of
the scale pit effluent in all but pipe and tube operations is recycled
to the process for the purpose of flume flushing. For primary and
section operations, fifty percent of the scale pit effluent is
recycled, while thirty-percent of the scale pit effluent is recycled
in flat operations. The remaining scale pit effluent is then
delivered to roughing clarifiers for the purpose of providing
additional suspended solids removal by sedimentation. Fifty percent
of the clarifier effluent is recycled in the case of pipe and tube
operations. The roughing clarifier underflow is dewatered by vacuum
filtration, while the roughing clarifier overflow is delivered to a
cooling tower and, recycled. Four percent of the cooling tower
effluent is blown down. The cooling tower blowdown is filtered prior
to discharge to the POTW to reduce toxic metals. The filter backwash
is returned to the roughing clarifier inlet. As noted previously, the
toxic metals which are present in hot forming wastewaters exist
primarily in the suspended particulate matter. Therefore, suspended
solids control will achieve removal of toxic metals.
Figure XIII-1 illustrates the pretreatment system described above.
The proposed pretreatment effluent standards for the various hot
forming operations are presented in Table XIII-1. As mentioned
previously, the pretreatment system is identical to the NSPS
Alternative No. 1 model and, as a result, reference can be made to the
370

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NSPS model cost data (Tables VII1-49 through VII1-59) for pretreatment
cost information.
Rationale for the Selection of Pretreatment Technologies
The recycle rates incorporated in the pretreatment system have been
previously justified in Section X. Extensive recycle is needed in hot
forming pretreatment systems in order to minimize the hydraulic impact
of hot forming operation wastewater discharges to a.POTW. Hot forming
operations employing little or no recycle can generate volumes of
wastewater large enough to, in many instances, either approach or
exceed the limits of the POTW to accept any additional flow.
Excessive flows of hot forming wastewaters to a POTW are restricted
not only by physical limitations (i.e., hydraulics) but also by
process limitations (the "washing out" of the biological treatment
media caused by excessive flows). The model discharge flows which
were developed by application of supportable recycle rates (Section X)
to the applied flows are identical to the BAT and NSPS model discharge
flows and are presented in Table XIII—1.
As noted previously, the toxic metals present in hot forming
wastewaters exist primarily in the product scale which in turn is
represented by the suspended solids. As a result, toxic metals can be
initially controlled by removing suspended solids. Recycle and
filtration are therefore included in the pretreatment scheme as a
means of reducing toxic metals levels and subsequently loads.
Pretreatment standards must limit the discharge of toxic metals
because high concentrations of the metals can affect the POTW in the
following ways: (1) inhibition of the POTW treatment process; (2)
pass through POTW treatment; and, (3) contamination of POTW sludges.
Reference is made to Section V of Volume I for additional information
on those metals and POTW operations.
Various studies2 have demonstrated that, in particular, two of the
toxic metals (lead and zinc) found in hot forming wastewaters inhibit
the biological treatment process when found at levels typical of hot
forming wastewaters. The filters included in the treatment scheme
insure that the adverse impacts of metals in the discharges to POTWs
will be minimized.
Other studies* involving the electroplating industry (with toxic
metals present and at similar levels) indicated that from fifty
percent to ninety percent of the toxic metals entering a POTW
treatment system will pass through the treatment system. The
possibility therefore exists that POTWs could discharge
environmentally detrimental levels of toxic metals when accepting
2EPA-430/9-76-017a, Construction Grants Program Information; Federal
Guidelines, State and Local Pretreatment Programs.
'Refer to Federal 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.
371

-------
various industrial wastewaters. Since domestic wastewaters typically
do not contain objectionable amounts of toxic metals, it is necessary
for industrial wastewater contributors to control the levels of toxic
metals in their discharges to POTWs. In the case of hot forming
operations, this would be accomplished through recycle and filtration.
The toxic metals which do not pass through a POTW and are not
destroyed by the biological treatment and thus concentrate in the POTW
sludges. Generally, land application is the least expensive and most
advantageous method of POTW sludge disposal. A primary advantage
derived from the land application of POTW sludges is the ability of
these sludges to provide essential soil nutrients. Excessive amounts
of toxic metals in the sludges would, however, inhibit plant growth
thus making these sludges unacceptable for use as a fertilizer. Also,
these toxic metals could enter either the plant and animal food chain
or ground waters, and eventually water supplies. For the above
reasons, the control of toxic metals discharges from hot forming
operations to POTWs is necessary.
372

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TARI F TTTT-1
PRETREATMENT EFFLUENT STANDANDS
HOT FORMING SUBCATEGORY


CONCENTRATION
BASIS
PRETREATMENT STANDARDS (lbs/1000 lbs)


ALL HOT
FORMING
OPERATIONS
PRIMARY MILLS
SECTION MILLS
FLAT MILLS
PIPE 8 TUBE
MILLS
WITHOUT
SCARFERS
WITH
SCARFERS
CARBON
SPECIALTY
HOT STRIP
& SHEET
CARBON
PLATE
SPECIALTY
PLATE
CARBON a
SPECIALTY
DISCHARGE
FLOW (gal/ton)


90
140
200
130
260
140
60
220
CHROMIUM
AVE.
O.IO
0.0000375
00000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
0.0000917
MAX.
0.30
0.000113
0.000175
0.000250
0.000163
0.000325
0.000175
0.0000751
0.000275
LEAD
AVE.
0.10
0.0000375
0.0000584
0.0000834
Oi0000542
0000108
0.0000584
Q0000250
0.0000917
MAX.
0.30
0.000H3
0.000175
0.000250
OOOOI63
0.000325
0.000175
0.0000751
0.000275
ZINC
AVE.
0.10
0.0000375
0.0000584
0.0000834
0.0000542
0.000108
0.0000584
0.0000250
00000917
MAX.
0.30
0.000113
0.000175
O000250
0.000163
Q000325
0.000175
0.0000751
0.000275

-------
.(2)
RECYCLE
OIL
PROCESS
SOLIDS TO
DISPOSAL
VACUUM
FILTER
SOLIDS TO
DISPOSAL
(1)	ALTERNATE RECYCLE LOCATION FOR PIPE B TUBE OPERATIONS
(2)	RECYCLE PERCENTAGE
=30% FOR PRIMARY, SECTION, ANO PIPE B TUBE
:30* FOR FLAT OPERATIONS
(3)	mrr^^^cvc^E^ate^s increaseo to achieve an overall
RECYCLE BACK
TO PR0CESS(3)
(BACKWASH)
•—(I) |
/\_
COOLING
TOWER
FILTER
66
* TO
DISCHARGE

CHROMIUM
0.1 mg/l
COPPER
0.1 mg/l
LEAD
Ql mg/l
NICKEL
0.1 mg/l
ZINC
0.1 mg/l
pH
6-9
FLOW-SEE
TABLE Xlll-I
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SUBCATEGORY
PRETREATMENT MODEL
DW12/I9/80
FIGURE XIH-I

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