DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES AND STANDARDS
for the
NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
VOLUME IV
Primary Zinc
Primary Lead
Secondary Lead
Primary Antimony
William K. Reilly
Administrator
Rebecca Hanmer, Acting
Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
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ORGANIZATION OF THIS DOCUMENT
This development document for the nonferrous metals manufacturing
category consists of a general development document which
considers the general and overall aspects of the regulation and
31 subcategory specific supplements. These parts are organized
into 10 volumes as listed below.
The information in the general document and in the supplements is
organized by sections with the same type of information reported
in the same section of each part. Hence to find information on
any specific aspect of the category one would need only look in
the same section of the general document and the specific
supplements of interest.
The ten volumes contain contain the following subjects:
Volume I General Development Document
Volume II Bauxite Refining
Primary Aluminum Smelting
Secondary Aluminum Smelting
Primary Copper Smelting
Primary Electrolytic Copper Refining
Secondary Copper Refining
Metallurgical Acid Plants
Primary Zinc
Primary Lead
Secondary Lead
Primary Antimony
Primary Precious Metals and Mercury
Secondary Precious Metals
Secondary Silver
Secondary Mercury
Primary Tungsten
Secondary Tungsten and Cobalt
Primary Molybdenum and Rhenium
Secondary Molybdenum and Vanadium
Primary Beryllium
Primary Nickel and Cobalt
Secondary Nickel
Secondary Tin
Volume VIII Primary Columbium and Tantalum
Secondary Tantalum
Secondary Uranium
Volume IX Primary and Secondary Titanium
Primary Zirconium and Hafnium
Volume X Primary and Secondary Germanium and Gallium
Primary Rare Earth Metals
Secondary Indium
Volume III
Volume IV
Volume V
Volume VI
Volume VII
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TABLE OF CONTENTS
Supplement Page
Primary Zinc 1449
Primary Lead 1657
Secondary Lead 1825
Primary Antimony 2045
For detailed contents see detailed contents list in
individual supplement.
111
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NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY-
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Primary Zinc Subcategory
Lee M. Thomas
Administrator
Rebecca Hanmer, Acting
Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Acting Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
December 1988
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
1449
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PRIMARY ZINC SUBCATEGORY
TABLE OF*CONTENTS I
Section
I SUMMARY 1461
II CONCLUSIONS 1463
III
-------
Section
PRIMARY ZINC SUBCATEGORY
TABLE OF CONTENTS (Continued)
VI
VII
VIII
SELECTION OF POLLUTANT PARAMETERS 1583
Conventional and Nonconventional Pollutant 1584
Parameters
Conventional and Nonconventional Pollutant 1584
Parameters Selected
Toxic Pollutants 1584
Toxic Pollutants Never Detected 1584
Toxic Pollutants Never Found Above Their 1584
Analytical Quantification Limit
Toxic Pollutants Present Below Concentrations 1584
Achievable by Treatment
Toxic Pollutants Detected in a Small Number of 1585
Sources
Toxic Pollutants Selected for Further 1587
Consideration for Establishing Limitations and
Standards
CONTROL AND TREATMENT TECHNOLOGIES 1597
Technical Basis of BPT 1597
Current Control and Treatment Practices 1597
Zinc Reduction Furnace Wet Air Pollution Control 1598
Preleach Wastewater 1598
Leaching Wet Air Pollution Control 1598
Electrolyte Bleed Wastewater 1598
Cathode and Anode Washing Wastewater 1598
Casting Wet Air Pollution Control 1599
Casting Contact Cooling 1599
Cadmium Plant Wastewater 1599
Control and Treatment Options 1599
Option A 1600
Option B 1600
Option C 1600
Treatment Technologies Rejected at Proposal 1600
Option D 1600
Option F 1601
COSTS, ENERGY AND NONWATER QUALITY ASPECTS 1603
Treatment Options Considered . 1603
Option A 1603
Option B 1603
Option C 1603
Cost Methodology • 1603
Nonwater Quality Aspects 1604
Energy Requirements 1605
Solid Waste 1605
Air Pollution 1606
1452
-------
PRIMARY ZINC SUBCATEGORY
Section
IX
X
XI
TABLE OF CONTENTS (Continued)
Page
BEST PRACTICABLE TECHNOLOGY CURRENTLY AVAILABLE 1609
BEST AVAILABLE TECHNOLOGY ECONOMICALLY 1611
ACHIEVABLE ,
Technical Approach to BAT 1611
Option A 1612
Option B 1612
Recycle of Water Used in Wet Air Pollution 1612
Control
Recycle of Casting Contact Cooling Through 1613
Cooling Towers
Option C 1613
Industry Cost and Pollutant Removal Estimates 1614
Pollutant Removal Estimates 1614
Compliance Costs 1614
BAT Option Selection - Proposal 1615
BAT Option Selection - Promulgation 1615
Wastewater Discharge Rates 1616
Zinc Reduction Furnace Wet Air Pollution Control 1617
Wastewater
Preleach Wastewater 1617
Leaching Wet Air Pollution Control Wastewater 1617
Electrolyte Bleed Wastewater 1618
Cathode and Anode Washing Wastewater 1618
Casting Wet Air Pollution Control 1619
Casting Contact Cooling 1619
Cadmium Plant Production 1619
Regulated Pollutant Parameters 1620
Effluent Limitations 1621
NEW SOURCE PERFORMANCE STANDARDS ' 1633
Technical Approach to BDT 1633
Option A 1633
Option B 1633
Option C 1633
BDT Option Selection 1633
Regulated Pollutant Parameters 1634
New Source Performance Standards 1634
..,-_«£
1453
-------
PRIMARY ZINC SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
XII PRETREATMENT STANDARDS 1641
Technical Approach to Pretreatment 1641
Pretreatment Standards for Existing and New 1642
Sources
Option A 1642
Option B 1642
Option C 1642
Industry Cost and Pollutant Removal Estimates 1642
— PSES Option Selection 1643
PSNS Option Selection 1643
Regulated Pollutant Parameters 1643
~ Pretreatment Standards 1643
XIII BEST CONVENTIONAL POLLUTANT CONTROL 1655
TECHNOLOGY
1454
-------
PRIMARY ZINC SUBCATEGORY
LIST OF TABLES
Table No. Page
III-l INITIAL OPERATING YEAR (RANGE) SUMMARY OF I486
PLANTS IN THE PRIMARY ZINC SUBCATEGORY
BY DISCHARGE TYPE
III-2 PRODUCTION RANGE FOR THE PRIMARY ZINC 1487
SUBCATEGORY
III-3 SUMMARY OF PRIMARY ZINC PROCESSES AND 1488
ASSOCIATED WASTE STREAMS
V-l WATER USE AND DISCHARGE RATES FOR ZINC 1506
REDUCTION FURNACE WET AIR POLLUTION CONTROL
V-2 WATER USE AND DISCHARGE RATES FOR LEACHING WET 1506
AIR POLLUTION CONTROL
V-3 WATER USE AND DISCHARGE RATES FOR CATHODE AND 1507
ANODE WASHING WASTEWATER
V-4 WATER USE AND DISCHARGE RATES FOR CASTING WET 1507
AIR POLLUTION CONTROL
V-5 WATER USE AND DISCHARGE RATES FOR CASTING 1508
CONTACT COOLING
V-6 WATER USE AND DISCHARGE RATES FOR CADMIUM 1508
PLANT WASTEWATER
V-7 ELECTROLYTE BLEED RAW WASTEWATER SAMPLING DATA 1509
V-8 CATHODE BRUSH WATER AND ANODE CLEANING WATER 1513
RAW WASTEWATER SAMPLING DATA
V-9 PRIMARY ZINC SAMPLING DATA COMBINED RAW 1526
WASTEWATER
V-10 PRIMARY ZINC SAMPLING DATA MISCELLANEOUS RAW 1528
WASTEWATER
V-ll MISCELLANEOUS WASTEWATER SAMPLING DATA 1531
V-12 MISCELLANEOUS WASTEWATER SAMPLING DATA 1542
(Additional Streams)
1455
-------
PRIMARY ZINC SOBCATEGORY
LIST OF TABLES (Continued)
Table No. Page
V-13 PRIMARY ZINC SAMPLING DATA, TREATMENT PLANT 1552
SAMPLES, PLANT' A .
V-14 PRIMARY ZINC SAMPLING DATA, TREATMENT PLANT 1554
SAMPLES, PLANT B
V-15 PRIMARY ZINC SAMPLING DATA, TREATMENT PLANT 1556
SAMPLES, PLANT C
V-16 PRIMARY ZINC SAMPLING DATA, TREATMENT PLANT 1558
SAMPLES, PLANT D
V-17 PRIMARY ZINC SAMPLING DATA, TREATMENT PLANT 1559
SAMPLES, PLANT E
V-18 PRIMARY ZINC SAMPLING DATA, TREATMENT PLANT 1564
SAMPLES, PLANT G
VI-1 FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS . 1590
PRIMARY ZINC RAW WASTEWATER
VI-2 TOXIC POLLUTANTS NEVER DETECTED 1594
VI-3 TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR 1596
ANALYTICAL QUANTIFICATION LIMIT
VIII-1 COST OF COMPLIANCE FOR THE PRIMARY ZINC 1507
SUBCATEGORY, DIRECT DISCHARGERS
VIII-2 COST OF COMPLIANCE FOR THE PRIMARY ZINC 1507
SUBCATEGORY, INDIRECT DISCHARGERS
X-l CURRENT RECYCLE PRACTICES WITHIN THE PRIMARY 1622
ZINC SUBCATEGORY
X-2 POLLUTANT REMOVAL ESTIMATES FOR PRIMARY ZINC, 1623
DIRECT DISCHARGERS
X-3 BAT WASTEWATER RATES FOR THE PRIMARY ZINC 1624
SUBCATEGORY
X-4 BAT EFFLUENT LIMITATIONS FOR THE PRIMARY ZINC 1625
SUBCATEGORY
XI-1 NSPS WASTEWATER DISCHARGE RATES FOR THE 1635
PRIMARY ZINC SUBCATEGORY
1456
-------
PRIMARY ZINC SUBCATEGORY
LIST OF TABLES (Continued)
Table No. Page
XI-2 NSPS FOR THE PRIMARY ZINC SUBCATEGORY 1636
XII-1 POLLUTANT REMOVAL ESTIMATES FOR PRIMARY ZINC 1645
INDIRECT DISCHARGERS
XI1-2 PSES AND PSNS WASTEWATER DISCHARGE RATES FOR 1646
THE PRIMARY ZINC SUBCATEGORY
XII-3 PSES FOR THE PRIMARY ZINC SUBCATEGORY 1647
XII-4 PSNS FOR THE PRIMARY ZINC SUBCATEGORY 1651
1457
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PRIMARY ZINC SUBCATEGORY
LIST OF FIGURES
Figure No. Page
III-l ELECTROLYTIC ZINC PRODUCTION PROCESSES 1489
III-2 GENERALIZED FLOWSHEET OF PYROLYTIC ZINC PLANTS 1490
III-3 PYROMETALLURGICAL CADMIUM PRODUCTION PROCESS 1491
III-4 HYDROMETALLURGICAL CADMIUM PRODUCTION PROCESS 1492
III-5 GEOGRAPHICAL LOCATIONS OF PRIMARY ZINC PLANTS 1493
V-l SAMPLING SITES AT PRIMARY ZINC PLANT A 1576
V-2 SAMPLING SITES AT PRIMARY ZINC PLANT B 1577
V-3 SAMPLING SITES AT PRIMARY ZINC PLANT C 1578
V-4 SAMPLING SITES AT PRIMARY ZINC PLANT D 1579
V-5 SAMPLING SITES AT PRIMARY ZINC PLANT E 1580
V-6 SAMPLING SITES AT PRIMARY ZINC PLANT F 1581
V-7 SAMPLING SITES AT PRIMARY ZINC PLANT G 1582
X-l BAT TREATMENT SCHEME, OPTION A 1629
PRIMARY ZINC SUBCATEGORY
X-2 BAT TREATMENT SCHEME, OPTION B 1630
PRIMARY ZINC SUBCATEGORY
X-3 BAT TREATMENT SCHEME, OPTION C 1631
PRIMARY ZINC SUBCATEGORY
1459
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PRIMARY ZINC SUBCATEGORY SECT - I
SECTION I
SUMMARY
On February 27, 1975, EPA promulgated technology-based effluent
limitations and performance standards for the primary zinc
subcategory of the Nonferrous Metals Manufacturing Point Source
Category. On March 8, 1984, EPA promulgated amendments to the
effluent limitations and standards for this subcategory pursuant
to the provisions of the Clean Water Act as amended. This
supplement provides a compilation and analysis of the background
material used to develop these effluent limitations and
standards. This subcategory regulation includes BPT, BAT, NSPS,
PSES and PSNS.
The primary zinc subcategory is comprised of nine plants. Of the
nine plants, three discharge directly to rivers, lakes, or
streams; one discharges to a publicly owned treatment works
(POTW); and five achieve zero discharge of process wastewater.
EPA first studied the primary zinc subcategory to determine
whether differences in raw materials, final products,
manufacturing processes, equipment, age and size of plants, water
usage, required the development of separate effluent limitations
and standards for different segments of the subcategory. This
involved a detailed analysis of wastewater discharge and treated
effluent characteristics, including (1) the sources and volume of
water used, the processes employed, and the sources of pollutants
and wastewaters in the plant; and (2) the constituents of
wasfcewaters, including toxic pollutants.
Several distinct control and treatment technologies (both in-
plant and end-of-pipe) applicable to the primary zinc subcategory
were identified. The Agency analyzed both historical and newly
generated data on the performance of these technologies,
including their nonwater quality environmental impacts (such as
air quality impacts and solid waste generation) and energy
requirements. EPA also studied various flow reduction techniques
reported in the data collection portfolios (dcp) and plant
visits.
Engineering costs were prepared for each of the control and
treatment options considered for the subcategory. These costs
were then used by the Agency to estimate the impact of
implementing the various options in the industry. For each
control and treatment option that the Agency found to be most
effective and technically feasible in controlling the discharge
of pollutants, the number of potential closures, number of
employees affected, and impact on price were estimated. These
results are reported in a separate document entitled Economic
Impact Analysis of Effluent Limitations and S_t,\ndard_s f_or the
Npnferrous S~elt_ing and Refining I_ndus_t r_y.
-------
PRIMARY ZINC SUBCATEGORY SECT - I
Based on consideration of the above factors, EPA identified
various control and treatment technologies which formed the basis
for BPT and selected control and treatment appropriate for each
set of standards and limitations. The mass limitations and
standards for BPT, BAT, NSPS, PSES, and PSNS are presented in
Section II. .
For BAT, the Agency has built upon the BPT basis by adding in-
process control technologies which include recycle of process
water from air pollution control and metal contact cooling waste
streams. Filtration is added as an effluent polishing step to
the end-of-pipe treatment scheme. Sulfide precipitation and
sedimentation technology is included after lime precipitation and
sedimentation to achieve the performance by application of lime,
settle, and filtration technology. To meet the BAT effluent
limitations based on this technology, the primary zinc
subcategory is estimated to incur a capital cost of $0.457
million (1982 dollars) and an annual cost of $0.236 million (1982
dollars).
The best demonstrated technology (BDT), which is the technical
basis of NSPS, is equivalent to BAT. In selecting BDT, EPA
recognizes that new plants have the opportunity to implement the
best and most efficient manufacturing processes and treatment
technology. As such, the technology basis of BAT has been
determined as the best demonstrated technology.
EPA did not propose pretreatment standards for existing sources
(PSES) for the primary zinc subcategory. Since that time, the
Agency has learned that one primary zinc plant previously thought
to be a zero discharger is actually an indirect discharger.
There fore, the Agency is promulgating PSES for the primary zinc
sub- category based on the BAT model technology and flow
allowances. The technology basis is in-process flow reduction,
lime precipitation and sedimentation, sulfide precipitation and
sedimentation, and multimedia filtration.
The technology basis for pretreatment standards for new sources
(PSNS) is the best demonstrated technology, and the PSNS are
identical to NSPS for all building blocks.
1462
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PRIMARY ZINC SUBCATEGORY SECT - II
SECTION II
CONCLUSIONS
EPA has divided the primary zinc subcategory into eight
subdivisions or building blocks for the purpose of effluent
limitations and standards. These building blocks are:
(a) Zinc reduction furnace wet air pollution control,
(b) Preleach of zinc concentrates,
(c) Leaching wet air pollution control,
(d) Electrolyte bleed,
(e) Cathode and anode wash wastewater,
(f) Casting wet air pollution control,
(g) Casting contact cooling, and
(h) Cadmium plant wastewater.
EPA promulgated BPT and BAT effluent limitations for the primary
zinc subcategory on February 27, 1975 as Subpart H of 40 CFR Part
421. At this time, EPA is not promulgating any modifications to
BPT effluent limitations. The effluent limitations and standards
apply to discharges resulting from the production of primary zinc
by either electrolytic of pyrolytic means. BPT was promulgated
based on the performance achievable by the application of
chemical precipitation and sedimentation (lime and settle)
technology.
The following BPT effluent limitations were promulgated:
Effluent Limitations
Average of Daily Values
Effluent Maximum for for 30 Consecutive
Characteristic Any One Day Days Shall Not Exceed
Metric Units (kg/kkg of product)
English Units (lb/1,000 Ib of product)
TSS
As
Cd
Se
Zn
pH
0.42
1.6 x 10-3
0.008
0.08
0.08
Within the
0.21
8 x 10-4
0.004
0.04
0.04
range of 6.0 to 9.0
1463
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PRIMARY ZINC SUBCATEGORY SECT - II
EPA is modifying the BAT effluent limitations to take into
account the pollutant concentrations achievable by the
application of lime precipitation and sedimentation, sulfide
precipitation and sedimentation, multimedia filtration
technology, and in-process flow reduction control methods. The
following BAT effluent limitations are promulgated for existing
sources:
(a) Zinc Reduction Furnace Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Cadmium
Copper
Lead
Zinc
0.334
2.135
0.467
1.702
0.134
1.018
0.217
0.701
(b) Preleach of Zinc Concentrates BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Cadmium 0.180 0.072
Copper 1.153 0.550
Lead 0.252 0.117
Zinc 0.919 0.378
1464
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PRIMARY ZINC SUBCATEGORY SECT - II
(c) Leaching Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property . Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ibs/million Ibs of zinc processed through
leaching
Cadmium 0 0
Copper 0 0
Lead 0 0
Zinc 0 0
(d) Electrolyte Bleed Wastewater BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Cadmium 0.086 0.035
Copper 0.553 0.264
Lead 0.121 0.056
Zinc 0.441 0.182
1465
-------
PRIMARY ZINC SUBCATEGORY SECT - II
(e) Cathode and Anode Wash Wastewater BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Cadmium
Copper
Lead
Zinc
0.150
0.961
0.210
0.766
0.060
0.458
0.098
0.315
(f) Casting Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Cadmium 0.051 0.021
Copper 0.329 0.157
Lead 0.072 0.033
Zinc 0.262 0.108
1466
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PRIMARY ZINC SUBCATEGORY SECT - II
(g) Casting Contact Cooling BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Cadmium
Copper
Lead
Zinc
0.036
0.232
0.051
0.185
0.014
0.110
0.024
0.076
(h) Cadmium Plant Wastewater BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Cadmium
Copper
Lead
Zinc
1.234
7.899
1.728
6.295
0.494
3.765
0.802
2.592
NSPS are promulgated based on the performance achievable by the
application of lime precipitation, sedimentation, sulfide
precipitation, sedimentation, and multimedia filtration
technology and in-process flow reduction control methods. The
following effluent standards are promulgated for new sources:
1467
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PRIMARY ZINC SUBCATEGORY SECT - II
(a) Zinc Reduction Furnace Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property . Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Cadmium 0.334 0.134
Copper 2.135 1.018
Lead 0.467 0.217
Zinc 1.702 0.701
TSS 25.020 20.020
pH Within the range of 7.0 to 10.0
at all times
(b) Preleach of Zinc Concentrates NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Cadmium 0.180 0.072
Copper 1.153 0.550
Lead 0.252 0.117
Zinc 0.919 0.378
TSS 13.520 10.810
pH Within the range of 7.0 to 10.0
at all times
1468
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PRIMARY ZINC SUBCATEGORY SECT - II
(c) Leaching Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property . Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ibs/million Ibs of zinc processed through
leaching
Cadmium 0 0
Copper 0 0
Lead 0 0
Zinc 0 0
TSS 0 0
pH Within the range of 7.0 to 10.0
at all times
(d) Electrolyte Bleed Wastewater NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Cadmium 0.086 0.035
Copper 0.553 0.264
Lead 0.121 0.056
Zinc 0.441 0.182
TSS 6.480 5.184
pH Within the range of 7.0 to 10.0
at all times
1469
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PRIMARY ZINC SUBCATEGORY SECT - II
(e) Cathode and Anode Wash Wastewater NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Cadmium 0.150 0.060
Copper 0.961 0.458
Lead 0.210 0.098
Zinc 0.766 0.315
TSS 11.270 9.012
pH Within the range of 7.0 to 10.0
at all times
(f) Casting Wet Air Pollution Control NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Cadmium 0.051 0.021
Copper 0.329 0.157
Lead 0.072 0.033
Zinc 0.262 0.108
TSS 3.855 3.084
pH Within the range of 7.0 to 10.0
at all times
1470
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PRIMARY ZINC SUBCATEGORY
SECT -II
(g) Casting Contact Cooling NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Cadmium
Copper
Lead
Zinc
TSS
pH
0.036 0.014
0.232 0.110
0.051 0.024
0.185 0.076
2.715 2.172
Within the range of 7.0 to 10.0
at all times
(h) Cadmium Plant Wastewater NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Cadmium
Copper
Lead
Zinc
TSS
pH
1.234 0.494
7.899 3.765
1.728 0.802
6.295 2.592
92.570 74.050
Within the range of 7.0 to 10.0
at all times
PSES are promulgated based on the performance achievable by the
application of lime precipitation and sedimentation, sulfide
precipitation and sedimentation, multimedia filtration
technology, and in-process flow reduction control methods. The
following pretreatment standards are promulgated for new sources:
1471
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PRIMARY ZINC SUBCATEGORY SECT - II
(a) Zinc Reduction Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Cadmium 0.334 0.134
Zinc 1.702 0.701
(b) Preleach of Zinc Concentrates PSES
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Cadmium 0.180 0.072
Zinc 0.919 0.378
(c) Leaching Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ib/m'illion Ibs of zinc processed through leaching
Cadmium 0.000 0.000
Zinc 0.000 0.000
1472
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PRIMARY ZINC SUBCATEGORY SECT - II
(d) Electrolyte Bleed Wastewater PSES
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ib/million Ibs of cathode zinc produced
Cadmium 0.086 0.035
Zinc 0.441 0.182
(e) Cathode and Anode Wash Wastewater PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ib/million Ibs of cathode zinc produced
Cadmium 0.150 0.060
Zinc 0.766 0.315
(f) Casting Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ib/million Ibs of zinc cast
Cadmium 0.051 0.021
Zinc 0.262 0.108
1473
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PRIMARY ZINC SUBCATEGORY SECT - II
(g) Casting Contact Cooling PSES
Pollutant or Maximum for Maximum for
Pollutant Property . Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Cadmium 0.036 0.014
Zinc 0.185 0.076
(h) Cadmium Plant Wastewater PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Cadmium 1.234 0.494
Zinc 6.295 2.592
PSNS are promulgated based on the performance achievable by the
application of lime precipitation and sedimentation, sulfide
precipitation and sedimentation, multimedia filtration
technology, and in-process flow reduction control methods. The
following pretreatment standards are promulgated for new sources:
(a) Zinc Reduction Furnace Wet Air Pollution Control PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Cadmium 0.334 0.134
Zinc 1.702 0.701
1474
-------
PRIMARY ZINC SUBCATEGORY SECT - II
(b) Preleach of Zinc Concentrates PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Cadmium 0.180 0.072
Zinc 0.919 0.378
(c) Leaching Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ibs/million Ibs of zinc processed through
leaching
Cadmium 0 0
Zinc 0 0
(d) Electrolyte Bleed Wastewater PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ib/million Ibs of cathode zinc produced
Cadmium 0.086 0.035
Zinc 0.441 0.182
1475
-------
PRIMARY ZINC SUBCATEGORY SECT - II
(e) Cathode and Anode Wash Wastewater PSNS
Pollutant orMaximum forMaximum for
Pollutant Property ' . Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Cadmium 0.150 0.060
Zinc 0.766 0.315
(f) Casting Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Cadmium 0.051 0.021
Zinc 0.262 0.108
(g) Casting Contact Cooling NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Cadmium 0.036 0.014
Zinc 0.185 0.076
1476
-------
PRIMARY ZINC SUBCATEGORY SECT - II
(h) Cadmium Plant Wastewater PSNS
Pollutant or Maximum for Maximum for
Pollutant Property • Any One Day Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Cadmium 1.234 0.494
Zinc 6.295 2.592
1477
-------
Page Intentionally Blank
-------
PRIMARY ZINC SUBCATEGORY SECT - III
SECTION III
INDUSTRY PROFILE
This section of the primary zinc supplement describes the raw
materials and processes used in producing primary zinc and
presents a profile of the primary zinc plants identified in this
study.
DESCRIPTION OF PRIMARY ZINC PRODUCTION
There are two zinc -production processes; pyrolytic and
electrolytic. The pyrolytic process involves the roasting of
zinc concentrates followed by preparation of the roasting calcine
for reduction in either electrothermic or vertical retort
furnaces. The electrolytic process also involves roasting
followed by leaching and electrolytic precipitation. At the
present time, four plants use the electrolytic process and one
uses the pyrolytic process. Three other plants produce zinc
oxide pyrolytically. One of the three plants purifies zinc oxide
intermediates -produced at another facility. The ninth plant
currently operating in the subcategory produces only cadmium from
baghouse dust collected at other facilities.
There are a number of by-products associated with the production
of zinc. Cadmium and sulfuric acid are the two major by-
products. Currently, six zinc plants have sulfuric acid plants
and cadmium plants on site. (For further discussion of acid
plants, refer to the Metallurgical Acid Plants Subcategory
Supplement).
RAW MATERIALS
The principal raw material used to produce zinc is zinc ore
concentrate. More than two-thirds of the zinc concentrate
produced in the United States is recovered as a co-product from
lead and copper ores; slightly less than one-third originates
from zinc ores.
ELECTROLYTIC ZINC PRODUCTION
Figure III-l (page 1489) presents a general flow diagram of the
electrolytic zinc production process. The primary steps involved
in this process are:
1. Roasting,
2. Leaching,
3. Purification,
4. Electrolytic precipitation, and
5. Cathode melting and casting.
Prior to roasting, magnesium may be removed from high-magnesia
concentrates by preleaching with weak sulfuric acid. This is
1479
-------
PRIMARY ZINC SUBCATEGORY SECT - III
done to prevent the build-up of magnesium in the electrolyte.
Currently, two of the four electrolytic plants leach prior to
roasting. One of the two reports a wastewater stream resulting
from the leaching process. The second plant currently is not
operating the process. The build-up of magnesium in the
electrolyte also can be alleviated by bleeding spent electrolyte
from the electrolytic precipitation process. One plant practices
this method of magnesium removal. The spent electrolyte is sent
to treatment. From the available data, it appears that the
fourth electrolytic plant does not operate a distinct step for
removing magnesium.
Roasting the zinc concentrates prior to leaching converts the
zinc sulfide present in the concentrates to zinc oxide and sulfur
dioxide. The chemical reaction for this process is:
ZnS + 3O2 = ZnO + SO2 (1)
Zinc oxide is more amenable to leaching than zinc sulfide. The
zinc concentrates are roasted in multiple hearth, flash, and
fluid bed roasters. All four of the plants that produce zinc
electrolytically use fluid bed roasters. The exhaust gases from
the roasters are conditioned by dust collection equipment prior
to entering an acid plant where the sulfur dioxide is converted
to sulfuric acid. Wastewater produced by the conditioning of
roaster off-gases is considered part of the acid plant.
The zinc oxide calcines from the roaster may be finely ground in
a ball mill and charged to the leaching process. Spent
electrolyte containing sulfuric acid and residual zinc sulfate,
and make up sulfuric acid are added to the process as the
solvent. The spent electrolyte is recycled from the electrolytic
precipitation cells which follow. The acid dissolves the ZnO
present in the calcines. The chemical reaction for this process
is:
ZnO + H2SO14s = ZnSO4 + H2O (2)
Through careful control of pH, the various impurities present in
the calcines such as iron, silica, arsenic, and antimony are
converted to insoluble hydroxides and oxides. These insoluble
impurities become part of the underflow and can be processed
further to recover residual zinc. Following residual zinc
recovery, the final residue containing lead and precious metals
is usually sent to a lead smelter.
Cadmium and a portion of the copper present in the calcine are
dissolved along with zinc and leave the leaching process as part
of the overflow. Because an acid is used as the solvent, air
pollution control may be necessary to control air emissions from
the leaching process. Three plants report the use of wet
scrubbers to control the air emissions. The scrubber liquor
produced by these scrubbers is a source of wastewater.
After leaching, the overflow is filtered to remove suspended
1480
-------
PRIMARY ZINC SUBCATEGORY SECT - III
%.
solids and then purified. The purpose of the purification
process is to remove copper and cadmium from solution. Lesser
impurities such as cobalt, germanium, arsenic, and antimony must
also be removed. Purification must be extremely efficient
because even minute quantities of impurity metals adversely
affect the electrolytic precipitation process. Purification is
accomplished by adding zinc dust, which precipitates the copper,
cadmium, and lesser impurities by replacement. By adding zinc
dust in multiple stages, it is possible to make rough
separations, such as a high-copper precipitate and a high cadmium
precipitate, while precipitating impurities. The cadmium
precipitate is sent to a cadmium plant. Copper precipitate may
be releached with spent electrolyte to remove zinc, and then be
sent to a copper refinery.
The purified zinc sulfate solution from the leaching process is
now ready for electrolytic precipitation. The electrolytic
precipitation process is carried out in a tankhouse containing 50
to 250 tanks. Each tank contains a number of alternate anodes
and cathodes. The zinc containing electrolyte flows slowly from
tank to tank. Zinc is deposited from solution onto the cathodes
until the deposit attains the required thickness. The cathodes
are then removed for zinc stripping. Wastewater is generated by
washing the cathode zinc prior to casting. The spent electrolyte
is sent to the leaching process where it is used as the solvent.
One plant bleeds some of the spent electrolyte to treatment as a
means of controlling magnesium build-up in the circuit.
The cathode sheets are melted in an electric furnace prior to
casting. Fumes and dust from this process are usually collected
in a baghouse, however one plant uses a scrubber to collect these
emissions. The scrubber liquor produced is another source of
wastewater.
After melting, the molten zinc is cast into ingots, sows, slabs,
or other shapes. The contact cooling water used in casting is a
source of wastewater.
PYROLYTIC ZINC PRODUCTION
Figure III-2 (page 1490) presents a general flow diagram of the
pyrolytic zinc production process. The primary steps involved in
this process are:
1. Roasting,
2. Sintering,
3. Reduction, and
4. Refining.
Three plants process zinc concentrates pyrolytically. Two of the
plants use rotary concentrate dryers ahead of the roasters for
moisture content adjustment of the concentrate. Venturi
scrubbers are used to clean the gaseous emissions from these
dryers. The liquor produced by these scrubbers is a potential
source of wastewater.
1481
-------
PRIMARY ZINC SUBCATEGORY SECT - III
After drying, the zinc concentrates are fed to the roasting
plant. Zinc concentrates currently used consist of zinc sulfide
(ZnS) or franklinite (ZnFe204). Two plants roast zinc sulfide
and the third plant roasts franklinite. In the two plants
processing zinc sulfide, roasting converts the ZnS present in the
concentrates to ZnO and S02« More than 90 percent of the sulfur
is removed in the roasters, however, it is not necessary to
remove all the sulfur since the sintering process which follows
will consume the remaining sulfur. Roasting also volatizes the
cadmium and lead impurities present in the concentrates. The
gaseous emissions from roasting pass through dust collection
equipment before entering an acid plant where S02 is converted to
sulfuric acid. Both pyrolytic plants processing zinc sulfide use
dry collection equipment to condition the roaster off-gases. The
pyrolytic plant that roasts franklinite does not currently
operate its acid plant because franklinite does not contain
sulfur. Roasting converts the franklinite to zinc oxide.
The roasting may be accomplished in flash, multiple hearth, or
fluid bed roasters. One plant uses a fluid bed roaster, one
plant uses flash roasters, and the third plant uses all three.
Because of the high temperatures associated with the off-gases,
waste heat boilers may be used to conserve energy. Two of the
three pyrolytic plants with roasters produce zinc oxide as their
final product. A fourth pyrolytic plant processes the calcine
from another pyrolytic plant to produce high-purity zinc oxide.
Calcine from the roasters along with baghouse or electrostatic
precipitator dusts, various residues, zinc oxide materials, and
return portions for resintering make up the feed for sintering.
This feed is mixed with coke and a small portion of silica sand.
The silica is added for structural strength, and is pelletized to
assure a uniform, permeable bed for sintering. Sintering is a
heating process that agglomerates the small feed particles into a
granular form without melting. One plant currently practices
sintering. Sintering removes the remaining sulfur from the
calcine along with as much as 90 percent of the cadmium and 70
percent of the lead. Sulfur is oxidized to S02, while cadmium
and lead are volatilized. The one plant with sintering uses air
pollution control on its sintering machines. This plant uses
three electrostatic precipitators and one fabric filter bag
collector in parallel. The electrostatic precipitators are
preceded by spray chambers. The spray chamber water is recycled
with a bleed stream used at the sinter plant in the pelletizing
process. After pelletizing, some of this water is discharged.
The product from the sintering plant is now ready for reduction.
The reduction process is accomplished in either electrothermic or
vertical retort furnaces. The one plant with a sintering
operation uses electrothermic furnaces. In the electrothermic
furnaces, preheated coke and sinter, along with miscellaneous
zinc bearing products are fed to the furnace. Vertical retort
furnaces could also be used. The vertical retort furnaces
require the sinter to be ground, mixed with pulverized coal,
1482
-------
PRIMARY ZINC SUBCATEGORY SECT - III
clay, moisture, a binder, and then briquetted. In both furnaces
the zinc oxide is reduced by carbon to metallic zinc and carbon
monoxide. The chemical reactions for this process are:
ZnO + CO = Zn( vapor) + CC>2 (3)
+ CC-2 + C = 2CO (4)
ZnO + C = Zn + CO (5)
The zinc vaporizes and is collected in a condensing device. A
wet scrubber in combination with a baghouse is used to rid the
carbon monoxide stream of entrained solids. The plant with this
scrubber practices extensive recycle of the scrubber liquor. Blue
powder, a mixture of metallic zinc and zinc oxide, is
periodically collected as a scrubbing or baghouse residue. This
material is recycled.
The condensed zinc metal may be purified by liquation or
redistillation. In liquation, the metal is allowed to cool to
just above the melting point of zinc. At this temperature, any
lead and iron.present in amounts exceeding their solubility in
zinc separate by precipitation and can be removed mechanically.
Redistillation involves the use of dual fractionating columns to
separate the zinc from cadmium, iron, and lead impurities. Zinc
and cadmium are vaporized in the first column while the iron and
lead remain liquid. The zinc and cadmium vapors are condensed
and then fed to the second fractionating column, where zinc
remains as a liquid while the cadmium vaporizes. Cadmium vapors
are condensed to produce a cadmium-zinc alloy containing
approximately 15 percent cadmium. The high-grade zinc metal
removed from the bottom of the second column is used for special
applications which require high purity metal, such as die casting
alloys.
After liquation or redistillation, the zinc is cast into various
shapes such as ingots or sows. Wastewater associated with
casting contact cooling is produced by one of the pyrolytic
plants.
CADMIUM PRODUCTION
Figures III-3 and III-4 (pages 1491 and 1492) present the general
flow diagrams for two different cadmium production processes.
Figure III-3 shows a pyrometallurgical process while Figure III-4
presents a hydrometallurgical process. In 'both processes,
various residues from zinc refining operations, and cadmium
precipitated by zinc dust in purifying zinc solutions are
important cadmium sources. Cadmium-bearing dusts and residues may
be allowed to oxidize in air or roasted to further oxidize
cadmium prior to leaching. Infrequently, one plant washes the
feed material with water to remove chloride before roasting. The
cadmium-bearing material is leached by either a sulfuric acid
solution or a solution made up of spent electrolyte and sulfuric
-------
PRIMARY ZINC SUBCATEGORY SECT - III
acid. Cadmium is then precipitated from solution by galvanic
displacement with zinc dust. After the precipitation step,
cadmium is extracted either pyrometallurgically or
hydrometallurgically. In the pyrometallurgical process, the
cadmium sponge is washed to remove water-soluble impurities and
compacted by briquetting. As a final purification step, the
briquettes may be melted using sodium hydroxide as a flux to
remove impurities such as iron, tin, lead, copper, and antimony.
The cadmium is then cast into various shapes.
In the hydrometallurgical process, the cadmium sponge is leached
with sulfuric acid and spent electrolyte from the cadmium
electrolysis cells which follow. Following filtration, the
cadmium sulfate solution is processed electrolytically. Cadmium
deposits on the cathode and is stripped when the desired
thickness is acquired. Following stripping, the cadmium is cast
into various shapes. Contact cooling water is sometimes used in
casting. The cast cadmium may be cleaned with caustic or
solvents and rinsed. Rinse water is usually discharged to waste
treatment. There are a number of wastewater sources in the
cadmium recovery process. The major sources are associated with
the following:
1. Cadmium feed wash water,
2. Leaching tank discharge,
3. Cadmium sponge wash water,
4. Cathode wash water,
5. Casting contact cooling water, and
6. Cadmium metal cleaning water.
PROCESS WASTEWATER SOURCES
The principal sources of wastewater in the primary zinc
subcategory are:
1. Wet air pollution control on reduction furnaces,
2. Preleach wastewater,
3. Wet air pollution control on leaching process,
4. Electrolyte bleed wastewater,
5. Cathode and anode washing,
6. Casting contact cooling water,
7. Casting wet air pollution control, and
8. Cadmium plant wastewater.
OTHER WASTEWATER SOURCES
There are other wastewater streams associated with the
manufacture of primary zinc. These wastewater streams may
include; water from residue washings, storm water runoff, water
from pelletizing process, water from briquetting process, air
pollution control on concentrate dryers, zinc purification
process, and maintenance and clean up water. These wastewater
streams are not considered as a part of this rule making. EPA
believes that the flows and pollutant loadings associated with
these waste streams are insignificant relative to the waste
1484
-------
PRIMARY ZINC SUBCATEGORY SECT - III
streams selected and are best handled by the appropriate permit
authority on a case-by-case basis under authority of Section 402
of the CWA.
In the dcp, two plants report using Venturi scrubbers to control
air emissions from the drying of zinc concentrates prior to
roasting. Plant 282 reports it operates this scrubber
approximately 30 days per year and the scrubber is a net user of
water. Plant 283 reports reusing scrubber liquor common to both
the ore dryer scrubber and roaster scrubbing system. In this
way, the ore dryer scrubber at this plant does not use source
water as makeup to the system. Since both existing concentrate
drying scrubbers are net users of water, a building block was not
provided for this process. In addition, EPA received no
comments concerning concentrate drying wet air pollution control.
This waste stream will not be discussed in the remainder of this
document.
AGE, PRODUCTION, AND PROCESS PROFILE
A distribution of primary zinc plants in the United States is
shown in Figure III-5 (page 1493). Primary zinc or zinc oxide is
produced electrolytically by four plants and pyrolytically by
four plants; cadmium is a by-product at six plants.
Table III-1 (page 1486) indicates that the average plant age is
about 50 years. Table III-2 (page 1487) shows that the average
size plant has a production less than 100,000 tons per year.
Table III-3 (page 1488) provides a summary of the plants having
the various primary zinc processes. The number of plants
generating wastewater from the processes is also shown.
1485
-------
Table III-1
INITIAL OPERATING YEAR (RANGE) SUMMARY OF PLANTS
IN THE PRIMARY ZINC SUBCATEGORY BY DISCHARGE TYPE
Plant Age Range (Years)
00
CTl
Type of Plant
Discharge
Direct
Indirect
Zero
Total
1983-
1959
0-25
1
0
0
1
1958-
1949
25-35
0
0
2
2.
1948-
1939
35-45
1
0
0
1
1938-
1929
45-55
1
0
0
1
1928-
1919
55-65
0
1
1
2
1918-
1904
65-80
0
0
0
0
1903-
1879
80-105
0
0
1
1
Before
1879
105+
0
0
0
0
Insuf f .
Data
0
0
1
1
Total
3
1
_5
9
fd
H
>
»
IS1
H
55
o
M
G
M
O
W
O
fd
en
W
o
H
H
-------
PRIMARY ZINC SUBCATEGORY SECT - III
TABLE III-2
PRODUCTION RANGES FOR THE PRIMARY ZINC SUBCATEGORY
Production Range Number of Plants
(tons/yr)
Less than 100000 5
100001 - 200000 3
Total plants surveyed 8
NOTE: Production data for one plant was not availabale
1487
-------
PRIMARY ZINC SUBCATEGORY SECT - III
TABLE II1-3
SUMMARY OF PRIMARY ZINC PROCESSES AND ASSOCIATED WASTE STREAMS
Number of Plants Number of Plants
Process • With Process Generating Wastewater
Preleaching 2 1
Roasting 9 (a) 0
Sulfuric Acid Production 6 6
Sintering 1 1
Zinc Reduction 1
-Air Pollution Control 1 1
Leaching 5 1
-Air Polllution Control 4 3
Purification 4 1
Electrolysis - 4
-Electrolyte Bleed 1 1
-Anode and Cathode wash 3 3
Casting 5
-Casting Contact Cooling 4 3
-Air Pollution Control 3 0
Cadmium Plant 6 4
NOTE: Through reuse or evaporation practices, a plant may
generate a wastewater from a particular process but not discharge
it.
(a) One plant only purifies zinc oxide.
1488
-------
PRIMARY ZINC SUBCATEGORY SECT - III
Zinc Concentrace
Preleach
Wastewater
to Treatment
Underflov
Solids to
Copper or
Lead Refinery
Solids to
Cadmium Plant
Zinc Oxide
Water
Caseous Emissions to
Acid Plant
Calcine Dust
Zinc Solution from Cadmium
Plant
Spent
Cell
Acid
Electrolyte Bleed
~^o Treatment
_^Anode and Cathode
Wash Water to
Treatment
Cooling Tower Slowdown
Otner Shapes
Blocks
FIGURE III-l
ELECTROLYTIC ZINC PRODUCTION PROCESS
1489
-------
PRIMARY ZINC SUBCATEGORY
SECT - III
ZINC CONCENTRATES
Storage, drying, blending
Secondary or
oxidic materials
i
Gaseous Emissions
to Acid Plant
Fumes, dusts,
residues
t
T
Calcine
Moisture
Preparation
Oxides
li
Coke
Sand
Pelletizing
Return
sinter
Recycle dust
Dust
Collection
t
Metallics
Coke
T
Briquetting
Cadmium plant
_____ Coal, clay
Electrothertnic
reduction
Vertical retort
reduction
Blue powder
\
and binder
Stack
• 1 Carbon monoxide
~! Products of reduction
1
SLAB ZINC -^
, --_'_••" - —"•
Lower grades
Liauation
"W
Oxidation
ZINC OXIDE
1 —
American
process
SLAB ZINC
special
high grade
ZINC OXIDE
t
Plant use
Residue treatment
Refining
(redistillation)
Slag
discard
French process
Ferros ilicon
/
zinc
concentrate
recycled
Reclaimed coke
'recvcled
Lead-silver cone.
to lead plant
FIGURE III-2
GENERALIZED FLOWSHEET OF PYROLYTIC ZINC PLANTS
1490
-------
PRIMARY ZINC SUBCATEGORY SECT - III
Cadmium Rich Solids
Water & H,S04
Solids to
Zinc Leaching
Zinc Rich Solution
to Zinc Leaching or
Waste Treatment
Wash Water to Waste
Treatment
Casting Contact
Cooling Water co
Waste Treatment
Rinse Water to
Waste Treatment
, CuSO,, SrSO,
4 4
Zinc Dust
•Water
NaOH
Water
•Water
Cadmium Shapes
FIGURE III-3
PYEOh£TALLUB.GICAL CADMIUM PRODUCTION PROCESS
1491
-------
PRIMARY ZINC SUBCATEGORY SECT - III
Solids eo
Zinc Leaching
Zinc Rich Solution
co Zinc Leaching or
Waste Treatment
Casting Contact Cool-
ing Water to Waste
Treatment
Rinse Water to
Waste Treatment
Cadmium Rich Solids
I
Water and H.SO,
2 4
Zn, CuSO , SrSO
4 4
inc Dust
Water and
Spent Electrolyte
Water
Cadmium Shapes
FIGURE III-4
HYDROMETALLURGICAL CADMIUM PRODUCTION PROCESS
1492
-------
OJ
IIAWM
I-Indirect Process Wastewater Discharge Plants
D-Direct Process Wastewater Discharge Plants
Z-Zero Process Wastewater Discharge Plants
FIGURE III-5
GEOGRAPHIC LOCATIONS OF PRIMARY ZINC PLANTS
N
H
iz:
o
en
c
03
O
M
Q
I
C/l
M
n
-------
Page Intentionally Blank
-------
PRIMARY ZINC SUBCATEGORY SECT - IV
SECTION IV
SUBCATEGORIZATION
This section summarizes the factors considered during the
designation of the primary zinc subcategory and its related
subdivisions. Primary zinc was considered as a single
subcategory during the previous 1975 rulemaking. The rulemaking
established BPT and BAT effluent limitations for the primary zinc
subcategory. The purpose of this rulemaking is to promulgate
modifications to the BAT effluent limitations, and to establish
NSPS, PSES, and PSNS.
FACTORS CONSIDERED IN SUBDIVIDING THE PRIMARY ZINC SUBCATEGORY
The factors listed for general subcategorization were each
evaluated when considering subdivision of the primary zinc
subcategory. In the discussion that follows, the factors will be
described as they pertain to this particular subcategory.
The rationale for considering segmentation of the primary zinc
subcategory is based primarily on the production process used.
Within this subcategory, a number of different operations are
performed, which may or may not have a water use or discharge,
and which may require the establishment of separate effluent
limitations and standards. While primary zinc is still
considered a single subcategory, a more thorough examination of
the production processes, has illustrated the need for
limitations and standards based on a specific set of wastewater
streams. Limitations and standards will be based on specific flow
allowances for the following building blocks:
1. Zinc reduction furnace wet air pollution control,
2. Preleach wastewater,
3. Leaching wet air pollution control,
4. Electrolyte bleed wastewater,
5. Cathode and anode washing wastewater,
6. Casting wet air pollution control,
7. Casting contact cooling, and
8. Cadmium plant wastewater.
*
OTHER FACTORS
A number of other factors considered in this evaluation were
shown to be inappropriate bases for further segmentation. These
are discussed briefly below.
TYPE OF PLANT
As discussed in Section III, there are two types of production
processes used in the primary zinc subcategory: electrolytic and
pyrolytic. Initially, it was thought that the primary zinc
subcategory should be divided into two segments, electrolytic and
pyrolytic. This segmentation is too general. It is the
1495
-------
PRIMARY ZINC SUBCATEGORY SECT - IV
individual operations such as electrolysis and zinc reduction
which produce wastewater. The wastewaters from these operations
have distinctly different characteristics. Pyrolytic and
electrolytic zinc production share common operations such as
roasting, casting, and cadmium production. Thus, pyrolytic and
electrolytic zinc production are not totally different.
Individual operations such as leaching, casting, and zinc
reduction are distinctly different. Accordingly, the building
blocks used to segment the subcategory are determined by
individual operations which produce significant amounts of
wastewater, not by plant type.
PLANT SIZE
It is difficult to categorize zinc plants on the basis of size.
The individual processes involved in zinc production often
produce different amounts of zinc-bearing material. Therefore, it
is more appropriate to categorize zinc plants on the basis of
process production e.g., leaching production. The production
normalizing parameter for the primary zinc subcategory is process
production. Thus, process size is an important parameter in
determining the production normalized flow (PNF), which is the
flow divided by production, values of the eight zinc building
blocks.
PRODUCTION NORMALIZING PARAMETERS
The effluent limitations and standards developed in this document
establish mass limitations on the discharge of specific pollutant
parameters. To allow these regulations to be applied to plants
with various production capacities, the mass of pollutant
discharged must be related to a unit of production. This factor
is known as the production normalizing parameter (PNP).
In general, for each production process which has wastewater
associated with it, the actual mass of zinc product will be used
as the PNP. The PNP's for the eight subdivisions are as follows:
Building Block PNP
1. Zinc reduction furnace kkg of zinc reduced
Wet air pollution control
2. Preleach wastewater kkg of concentrate
leached
3. Leaching wet air pollution kkg of zinc
control processed through
leaching
4. Electrolyte bleed wastewater kkg of cathode zinc
produced
5. Cathode and anode kkg of cathode zinc
washing wastewater produced
1496
-------
PRIMARY ZINC SUBCATEGORY SECT - IV
6. Casting wet air pollution kkg of zinc cast
control
7. Casting contact cooling kkg of zinc cast
8. Cadmium plant wastewater kkg of cadmium
produced
1497
-------
Page Intentionally Blank
-------
PRIMARY ZINC SUBCATEGORY SECT - V
SECTION V
WATER USE AND WASTEWATER CHARACTERISTICS
This section describes the characteristics of wastewater
associated with the primary zinc subcategory. Data used to
quantify wastewater flow and pollutant concentrations are
presented, summarized, and discussed. The contribution of
specific production processes to the overall wastewater discharge
from primary zinc plants is identified whenever possible.
Two principal data sources were used in the development of
effluent limitations and standards for this subcategory: data
collection portfolios and field sampling results. Data
collection portfolios contain information regarding wastewater
flows and production levels. Data gathered through comments on
the proposed mass limitations and Section 308 requests are also
principal data sources.
In order to quantify the pollutant discharge from primary zinc
plants, a field sampling program was conducted. Wastewater
samples were collected in two phases: screening and
verification. The first phase, screen sampling, was to identify
which toxic pollutants were present in the wastewaters from
production of the various metals. Screening samples were
analyzed for 125 of the 126 toxic pollutants and other pollutants
deemed appropriate. (Because the analytical standard for TCDD was
judged to be too hazardous to be made generally available,
samples were never analyzed for this pollutant. There is no
reason to expect that TCDD would be present in primary zinc
wastewater). A total of 10 plants were selected for screen
sampling in the nonferrous metals manufacturing category. A
complete list of the pollutants considered and a summary of the
techniques used in sampling and laboratory analyses are included
in Section V of the General Development Document. In general,
the samples were analyzed for three classes of pollutants: toxic
organic pollutants, toxic metal pollutants, and criteria
pollutants (which includes both conventional and nonconventional
pollutants). A verification sampling effort was conducted at one
primary zinc plant between proposal and promulgation. EPA
believed additional process and wastewater data were needed to
better characterize the subcategory.
As described in Section IV of this supplement, the primary zinc
subcategory has been further segmented into eight subdivisions or
building blocks, so that the regulation contains mass discharge
limitations and standards for eight unit processes discharging
process wastewater. Differences in the wastewater
characteristics associated with these building blocks are to be
expected. For this reason, wastewater streams corresponding to
each segment are addressed separately in the discussions that
1499
-------
PRIMARY ZINC SUBCATEGORY SECT - V
follow.
WASTEWATER SOURCES, DISCHARGE RATES, AND CHARACTERISTICS
The wastewater data presented in this section were evaluated in
light of production process information compiled during this
study. As a result, it was possible to identify the principal
wastewater sources in the primary zinc subcategory. These
include:
1. Zinc reduction furnace wet air pollution control,
2. Preleach wastewater,
3. Leaching wet air pollution control,
4. Electrolyte bleed wastewater,
5. Cathode and anode washing wastewater,
6. Casting wet air pollution control,
7. Casting contact cooling, and
8. Cadmium plant wastewater.
Data supplied by dcp responses were evaluated, and two flow-to-
production ratios were calculated for each stream. The two
ratios, water use and wastewater discharge flow, are
differentiated by the flow value used in calculation. Water use
is defined as the volume of water or other fluid (e.g.,
emulsions, lubricants) required for a given process per mass of
zinc product and is therefore based on the sum of recycle and
make-up flows to a given process. Wastewater flow discharged
after pretreatment or recycle (if these are present) is used in
calculating the production normalized flow — the volume of
wastewater discharged from a given process to further treatment,
disposal, or discharge per mass of zinc produced. Differences
between the water use and wastewater flows associated with a
given stream result from recycle, evaporation, and carryover on
the product. The production values used in calculation
correspond to the production normalizing parameter, PNP, assigned
to each stream, as outlined in Section IV. The production
normalized flows were compiled and statistically analyzed by
stream type. Where appropriate, an attempt was made to identify
factors that could account for variations in water use. This
information is summarized in this section. A similar analysis of
factors affecting the wastewater values is presented in Sections
X, XI and XII where representative BAT, BDT, and pretreatment
discharge flows are selected for use in calculating the effluent
limitations and standards. As an example, zinc reduction furnace
scrubbing wastewater flow is related to reduction furnace
production. As such, the discharge rate is expressed in liters
of scrubber wastewater produced per metric ton of zinc reduced.
Since the data collection portfolios have been collected, the
Agency has learned that two primary zinc facilities have shut
down. Flow and production data (when available) for these plants
are presented in this section and in the remainder of this
supplement. Analytical data gathered at these plants are also
presented. Although the plants are closed, these data are an
integral part of the BAT effluent limitations because these
1500
-------
PRIMARY ZINC SUBCATEGORY SECT - V
plants were representative processes and provide useful measures
of the relationship between production and discharge. Therefore,
it is appropriate to present this information.
In order to quantify the concentrations of pollutants present in
wastewater from primary zinc plants, wastewater samples were
collected at six of the zinc plants before proposal. After
proposal, a seventh plant was sampled. Diagrams indicating the
sampling sites and contributing production processes are shown in
Figures V-l through V-7 (pages 1576 - 1582).
The raw wastewater sampling data for the primary zinc subcategory
are presented in Tables V-7 through V-9 (pages 1509 - 1526).
Miscellaneous waste-water sampling data are presented in Tables
V-10 through V-12 (pages 1528 - 1542). Treated wastewater
sampling data are shown in Tables V-13 through V-18 (pages 1552 -
1564). The stream codes displayed in Tables V-7 through V-18 may
be used to identify the location of each of the samples on the
process flow diagrams in Figures V-l through V-7. Where no data
is listed for a specific day of sampling, the wastewater samples
for the stream were not collected. If the analysis did not detect
a pollutant in a wastestream, the pollutant was omitted from the
table.
The data tables include some samples measured at concentrations
considered not quantifiable. The base-neutral extractable, acid
extractable, and volatile organics are generally considered not
quantifiable at concentrations equal to or less than 0.010 mg/1.
Below this concentration organic analytical results are not
quantitatively accurate; however, the analyses are useful to
indicate the presence of a particular pollutant. The pesticide
fraction is considered not quantifiable at concentrations equal
to or less than 0.005 mg/1. Nonquantifiable results are
designated in the tables with an asterisk (double asterisk for
pesticides).
These detection limits shown on the data tables are not the same
in all cases as the published detection limits for these
pollutants by the same analytical methods. The detection limits
used were reported with the analytical data and hence are the
appropriate limits to apply to the data. Detection limit
variation can occur as a result of a number of labor'atory-
specific, equipment-specific, and daily operator-specific
factors. These factors can include day-to-day differences in
machine calibration, variation in stock solutions, and variation
in operators.
The statistical analysis of data includes some samples measured
at concentrations considered not quantifiable. Data reported as
an asterisk are considered as detected but below quantifiable
concentrations, and a value of zero is used for averaging. Toxic
organic, nonconventional and conventional pollutant data reported
with a "less than" sign are considered as detected, but not
further quantifiable. A value of zero is also used for
averaging. If a pollutant is reported as not detected, it is
1501
-------
PRIMARY ZINC SUBCATEGORY SECT - V
excluded in calculating the average. Finally, toxic metal values
reported as less than a certain value were considered as not
detected and a value of zero is used in the calculation of the
average. For example, three samples reported as ND, *, and 0.021
mg/1 have an average 'value of 0.010 mg/1. The averages
calculated are presented with the sampling data; these values
were not used in the selection of pollutant parameters.
The method by which each sample was collected is indicated by
number, as follows.
1 one-time grab
2 24-hour manual composite
3 24-hour automatic composite
4 48-hour manual composite
5 48-hour automatic composite
6 72-hour manual composite
7 72-hour automatic composite
8 8-hour manual composite
In the data collection portfolios, plants were asked to indicate
whether or not any of the toxic pollutants were believed to be
present in their wastewater. Responses for the toxic metals
chosen as pollutant parameters are summarized below for those
plants responding to that portion of the questionnaire.
Known Believed Believed Known
Pollutant Present Present Absent Absent
Arsenic 42 00
Cadmium 6 00 0
Chromium 21 21
Copper 40 11
Lead 50 01
Nickel 21 21
Selenium 41 10
Silver 22 20
Zinc 6 00 0
ZINC REDUCTION FURNACE WET AIR POLLUTION CONTROL
In pyrolytic zinc plants, zinc oxide is reduced to metallic zinc
in vertical retort or electrothermic furnaces. Zinc vapor and
carbon monoxide enter a water cooled condenser through a vapor
ring. Most of the zinc is condensed while the carbon monoxide
and uncondensed zinc pass into air pollution control equipment.
One pyrolytic plant uses a scrubber to treat the carbon monoxide
and uncondensed zinc. The carbon monoxide may be recovered for
use as a fuel and the zinc may be recovered at the plant's
wastewater treatment system. Zinc reduction furnace wet air
pollution control water use and discharge rates are in liters per
metric ton of zinc reduced as shown in Table V-l (page 1506).
1502
-------
PRIMARY ZINC SUBCATEGORY SECT - V
Table V-17 (page 1559) summarizes the field sampling data for the
toxic and selected conventional and nonconventional pollutants
detected. The Agency did not collect any raw wastewater samples
from the reduction furnace scrubbers at either of the two
pyrolytic zinc plants 'with wet scrubbers on zinc reduction
furnaces. However, treatment plant samples were collected. As
shown by Table V-17, zinc reduction furnace scrubbing wastewater
may contain treatable concentrations of zinc, cadmium, and other
toxic metals.
The treatment plant samples contained wastewater from the
reduction furnaces, contact cooling, and leaching. No samples of
the individual streams were taken because these streams were
inaccessible. Therefore, it is necessary to assume that each
stream exhibits similar characteristics.
PRELEACH WASTEWATER
Preleaching of zinc concentrates to control magnesium in the
electrolytic circuit is practiced currently at one electrolytic
zinc plant. Another plant with a preleach circuit is currently
not in operation. The plant operating this process discharges
901 1/kkg (216 gal/ton) of concentrate leached. Wastewater
samples for this waste stream were not collected by the Agency.
However, data for seven parameters taken over a two-week period
were submitted by the plant with this wastewater. These data are
included in the administrative record supporting this regulation.
Preleach wastewater contains treatable concentrations of arsenic,
cadmium, lead, zinc, and total suspended solids. This stream is
also strongly acidic (pH of approximately 2.5).
LEACHING WET AIR POLLUTION CONTROL
Three electrolytic plants report the use of contact scrubbers to
reduce leaching air emissions. The water use and discharge rates
reported for leaching wet air pollution control, in liters per
metric ton of zinc processed through leaching, are shown in Table
V-2 (page 1506). Two of the three plants report no discharge
from leaching wet air pollution control. The Agency did not
collect any raw wastewater or treatment plant samples from
leaching scrubbers. Waste streams from leaching scrubbers should
contain various toxic metals based on the raw materials and
process used.
ELECTROLYTE BLEED WASTEWATER
One electrolytic plant bleeds a portion of the spent electrolyte
after electrolysis to control magnesium. This plant discharges
432 1/kkg (104 gal/ton) of cathode zinc produced. Wastewater
sampling data for this stream is presented in Table V-7 (page
1509). This wastewater is characterized by treatable
concentrations of chromium, zinc, and total suspended solids.
Electrolyte bleed is strongly acidic with a pH of approximately
1.0.
1503
-------
PRIMARY ZINC SUBCATEGORY SECT - V
CATHODE AND ANODE WASHING WASTEWATER
Three plants in this subcategory currently produce a waste stream
associated with the washing.of cathodes and anodes. The water
use and discharge rates from these plants are presented in liters
per metric ton of cathode zinc produced in Table V-3 (page 1507).
Wastewater sampling data for cathode and anode wash water are
presented in Table V-8 (page 1513). This wastewater contains
treatable concentrations of chromium, copper, lead, zinc, total
suspended solids, and oil and grease. The waste stream is also
acidic with a pH of approximately 2.5.
CASTING WET AIR POLLUTION CONTROL
In the electrolytic production of zinc, the stripped cathode zinc
must be melted prior to casting. Three plants report the use of
air pollution control equipment to clean the off-gases from the
casting furnace. One plant which is now shut down used a wet
scrubber. All three plants use dry air pollution control
equipment. .The water use and discharge rate for the scrubber was
2,580 liters per metric ton of zinc cast, as shown in Table V-4
(page 1507).
Raw wastewater samples were collected from a waste stream which
contained wastewater from the casting furnace scrubber. The
waste stream is characterized by the presence of treatable
concentrations of toxic metals and suspended solids. The raw
wastewater data are shown in Table V-9 (page 1526).
CASTING CONTACT COOLING
Contact cooling water may be used for casting. The cooling water
may be recycled but a bleed stream (blowdown) may be required to
dissipate the build-up of dissolved solids. The water use and
discharge rates for casting contact cooling, in liters per metric
ton of zinc cast, are shown in Table V-5 (page 1508). One plant
evaporates all of its cooling water in an evaporation pond.
Another plant uses noncontact cooling water and contact water
sprays. The contact water completely evaporates on contact with
the zinc metal. Other plants report partial evaporation when the
water contacts the cast zinc. None of the plants report
recycling of contact cooling water. Tables V-14 (page 1554) and
V-17 (page 1559) present data on the composition of waste streams
which contain contact cooling wastewater. These streams may
contain treatable concentrations of several toxic metals.
CADMIUM PLANT WASTEWATER
Six zinc plants currently have the technology in place to recover
cadmium as a by-product. Wastewater from cadmium plants may
originate from various sources such as rinsing cadmium balls,
casting contact cooling, cadmium sponge washing, or discharging
leaching tank water. Four plants report waste streams generated
by their cadmium recovery process. The water use and discharge
1504
-------
PRIMARY ZINC SUBCATEGORY SECT - V
rates for the cadmium plants, in liters per metric ton of cadmium
produced, are shown in Table V-6. Treatment plant samples were
taken from a stream which contained cadmium plant wastewater.
This stream contained treatable concentrations of cadmium, lead,
selenium, and zinc. Data from the samples are shown in Table V-
17 (page 1559).
1505
-------
PRIMARY ZINC SUBCATEGORY SECT - V
TABLE V-l
WATER USE AND DISCHARGE RATES FOR ZINC REDUCTION FURNACE
WET AIR POLLUTION CONTROL
(1/kkg of Zinc Reduced)
Plant Percent Production Normalized Production Normalized
Code Recycle Water Use FLow Discharge Flow
282* 100 NR 0
283 87.7 16340 2002
TABLE V-2
WATER USE AND DISCHARGE RATES FOR LEACHING
WET AIR POLLUTION CONTROL
(1/kkg of Zinc Processes Through Leaching)
Plant Percent Production Normalized Production Normalized
Code Recycle Water Use FLow Discharge Flow
279 NR NR NR
281 100 667 0**
283 100 8607 0
NR - data not reported in dcp.
* - Plant currently produces only zinc oxide. Zinc reduction
furnace not operating
** - 100 percent evaporation
1506
-------
PRIMARY ZINC SUBCATEGORY
SECT - V
TABLE V-3
WATER USE AND DISCHARGE RATES FOR CATHODE AND ANODE
WASHING WASTEWATER
(1/kkg of Cathode Zinc Produced)
Production Normalized
Discharge Flow
NR
NR
19850
751
Plant
Code
278
280*
281
9060
Percent
Recycle
NR
NR
NR
0
Production Normalized
Water Use FLow
NR
NR
NR
751
TABLE V-4
WATER USE AND DISCHARGE RATES FOR CASTING
WET AIR POLLUTION CONTROL
(1/kkg of Zinc Cast)
Plant Percent Production Normalized
Code Recycle Water Use FLow
280* 0 2570
Production Normalized
Discharge Flow
2570
NR - not reported in dcp
* - plant closed
1507
-------
PRIMARY ZINC SUBCATEGORY
SECT - V
TABLE V-5
WATER USE AND DISCHARGE RATES FOR
CASTING CONTACT COOLING
(1/kkg of Zinc Cast)
Plant Percent
Code Recycle
279
280 (a)
281
283
9030
0
0
0
0
0
Production Normalized
Water Use FLow
NR
4366
1050
50
NR
Production Normalized
Discharge Flow
NR
4366
0 (b)
2.1 (c)
0 (d)
Notes:
(a) - Plant Closed
(b) - 100 percent evaporation in evaporation pond
(b) - 96 percent evaporation while cooling
(d) - Spray water 100 percent evaporated on contact with metal
NR - Not reported in dcp
TABLE V-6
WATER USE AND DISCHARGE RATES FOR CADMIUM PLANT WASTEWATER
(1/kkg of Cadmium Produced)
Plant Percent Production Normalized
Code Recycle Water Use FLow
279 NR NR
281 100 NR
282 (a) NR NR
283 NR NR
1166 0 NR
Notes:
(a) - Plant closed
(b) - Infrequent discharge
NR - Data not reported in dcp
Production Normalized
Discharge Flow
NR
450360 (b)
6171
17517
1508
-------
Table V-7 .
ELECTROLYTE BLEED RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant
Toxic Pollutants (a)
1. acenaphthene
4. benzene
11. 1,1,1-trichloroethane
18. bis(2-chloroethyl)ether
21. 2,4,6-trichlorophenol
22. p-chloro-m-cresol
23. chloroform
38. ethylhenzene
39. fluoranthene
A3. bls(2-chloroethoxy )methane
47. bromofonn (tribromomethane)
57 2-nltrophenol
58, 4-nltrophenol
62. N-nltrosodlphenylamlne
65. phenol
66. bis(2-ethylhexyl)phthalate
68. di-n-butyl phthalate
69. dl-n-octyl phthalate
70. dlethyl phthalate
76. rhrysene
80. fluorene
81. phenanthrene
84. pyrene
8"). tetrachloroethylene
86. toluene
87. trichloroethylene
95. alpha-endosulfan
Stream
Code
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
Sample
Type*
3
1
1
3
3
3
1
1
3
3
1
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
3
Source
ND
ND
*
ND
ND
0.040
0.013
0.049
ND
ND
*
*
ND
ND
ND
0.040
*
ND
ND
ND
ND
ND
ND
ND
ND
*
ND
Day 1
*
0.018
*
*
*
ND
*
ND
*
0.020
*
*
*
*
*
0.243
*
0.012
ND
*
*
*
*
ND
ND
ND
*
Day 2
ND
ND
*
*
ND
ND
*
0.044
ND
0.013
*
ND
ND
ND
ND
*
*
ND
*
ND
ND
ND
ND
ND
ND
*
ND
Day 3
ND
ND
*
ND
ND
ND
*
ND
ND
*
*
ND
ND
ND
ND
0.020
0.028
ND
ND
ND
ND
ND
ND
*
*
ND
ND
Average
*
0.018
*
*
*
*
0.044
*
0.011
*
*
*
*
*
0.088
0.009
0.012
*
*
*
*
*
*
*
*
*
H
S
K
N
M
O
O
M
CD
M
O
-------
Table V-7 (Continued)
ELECTROLYTE BLEED RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant
Toxic Pollutants (a) (Continued)
101.
102.
103.
104.
105.
M 114.
£ 115.
o 117.
118.
119.
120.
121.
122.
123.
124.
125.
126
127
128.
aeptachlor epoxide
alpha-BHC
1 eta- BUG
gamma -BHC
delta-BHC
antimony
arsenic
beryl Hum
cadmium
chromium (total)
copper
cyanide (total)
lead
mercury
nickel
selenium
silver
thallium
zinc
Nuuconventlonal Pollutants
acldl y
a 1 ka 11 ni r.y
c"i luml ix'im
ammonia nitrogen
Stream
Code
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
Sample
Type* Source Day 1
3
3
3
3
3
3
3
3
3
3
3
1
3
3
3
3
3
3
3
3
3
3
3
*
ND
*
ND
ND
<0.01
<0.01
<0.005
<0.02
<0.02
<0.05
<0.02
<0.05
<0.001
<0.05
<0.05
<0.01
<0.01
0.06
<1
73
<0.10
<1
ND
ND
ND
ND
*
0.03
<0.01
<0.1
<0.4
<0.4
<1.0
<0.02
<10.0
<0.001
<1.0
(b) (c)
0.01
(c)
20,700.0
252,000
<1
10.0
10
Day 2 Day 3
ND
ND
*
*
ND
<0.10 (b)
<0.01
<0.1
<0.4
0.8
<1.0
<0.02
<10.0
<0.001
<1.0
(c)
0.01
<0.02 (b)
24,000.0 22
254,000 257
<1
12.0
24
*
*
*
ND
ND
<0.10
<0.01
<0.1
<0.4
1.2
<1.0
0.02
<1.0
<0.001
<1.0
(c)
<0.01
(c)
,300.0
,000
<1
12.0
5.5
Average
*
*
*
*
*
(b) 0.01
<0.01
<0.1
<0.4
0.7
<1.0
0.01
<7.0
<0.001
<1.0
0.01
22,333.0
254,000
<1
11.3
13
N
H
55
O
W
3
n
w
Q
M
w
o
-------
Table V-7 (Continued)
ELECTROLYTE BLEED RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant
Nonconventional Pollutants (Continued)
barium
boron
calcium
chemical oxygen demand (COD)
ch]orlde
cobalt
fluoride
Iron
magnesium
manganese
molybdenum
phenollcs
phosphate
sodium
sulfate
tin
titanium
total dissolved solids (TDS)
total organic carbon (TOC)
total solids (TS)
vanad! :i:n
y" I r 1 vim
Stream
Code
d)
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
322
Sample
Type*
3
3
3
3
3
3
3
3
3
3
3
1
3
3
3
3
3
3
3
3
3
3
Source
<0.05
<0.10
37.2
<1
5
<0.05
0.1
0.30
5.50 12
<0.05 1
<0.05
<0.005
0.26
4.10
36 277
0.50
<0.05
189 <364
3
200 <305
<0.05
<0.05
Day 1
<1.0
2.0
364.0
8
38
<1.0
1.5
<1.0
,100.0 11
,860.0 1
<1 .0
<0.005
<0.01
386.0
,000 276
<10.0
<1 .0
,000 307
39
,000(d)<368
<1 .0
<1.0
Day 2
<1.0
2.0
338.0
<1
98
<1.0
1.3
<1.0
,900.0
,780.0
<1 .0
0.01
<0.01
386.0
,000
<10.0
<1 .0
,000
18
Day 3 Average
<1.0
2.0
374.0
11
84
<1.0
1.5
2.0
11,600.0 11
1,800.0 1
<1.0
<0.005
<0.03
390.0
112,000 222
<10.0
<1 .0
<370,000(d) 102
15
,000(d)<334,000(d)<336
-------
Ln
I—1
NJ
Table V-7 (Continued)
ELECTROLYTE BLEED RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
I'oMutant
Conventiona1 Pol hitants
oil and grease
total suspended solids (TSS)
I'll (standard units)
Stream Sample
Code Type* Source Day 1 Day 2 Day 3 Average
322
322
322
1
3
3
3 4 <1 3 2.3
1 1,470 1,600 1,324 1,464
6 0.7 1.0 1.0
H
3
N
H
3
O
to
C
W
O
*Samp'e '"ype - Note: These numbers also apply to subsequent sampling data tables.
1 - one-time grab
2 - 24-hour manual composite
3 - 24-hour automatic composite
4 - 48-hour manual composite
5 - 48-hour automatic composite
6 - 72-hour manual composite
~* 72-hour automatic composite
8 - 8-hour manual composite
(a) All toxic pollutant fractions were analyzed
(b) Detection limit raised due to interference
(c) Interference
(d) Sulfurlc acid interference
to
M
O
H3
-------
fable V-8
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant (a)
Toxic Pollutants
1. acenaphthene
4. benzene
11. 1,1,1-trichloroethane
22. p-chloro-m-cresol
23. chloroform.
34. 2,4-dimethylphenol
36. 2,6-dtnitrotoluene
Stream
Code
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type*
8
8
2
1
1
1
1
1
1
8
8
2
1
1
1
8
8
2
8
8
2
Source Day 1
1
*
ND
0.019
ND
* *
*
* *
0.040 ND
0.040
0.040 ND
0.013 0.011
0.013
0.013 *
*
ND
*
ND
Day 2
ND
ND
ND
ND
ND
ND
*
*
0.017
ND
ND
0.014
ND
*
*
ND
*
ND
ND
ND
ND
Day 3
ND
ND
ND
ND
*
*
ND
0.042
*
*
*
ND
ND
ND
Average
*
'
0.019
*
*
0.005
0.035
0.011
*
*
*
*
*
g
H
3
3
H
3
O
to
§
O
^
M
0
o
H<
to
M
O
1-3
1
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Pollutant (a)
Toxic Pollutants (Continued)
38. ethyl benzene
44. methylene chloride
47. bromoform (trtbromomethane)
48. diehlorobromomethane
56. nitrobenzene
57. 2-nltrophenol
Concentrations (mg/lt except as noted)
Stream
Code
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type*
1
1
1
I
I
1
I
1
1
1
1
1
8
8
2
8
8
2
Source Day I
0.049 ND
0.049
0.049 ND
0.013 0.032
0.013
0.013 0.018
*
ND
ND
*
*
*
* ND
*
* ND
Day 2
0.051
ND
0.051
0.016
0.015
0.017
*
*
*
ND
ND
ND
ND
ND
ND
ND
ND
ND
Day 3
ND
ND
*
0.015
*
*
ND
ND
ND
ND
*
ND
Average
0.051
0.051
0.024
0.007
0.016
*
*
*
*
*
*
*
T)
H
3
«!
IS)
H
55
O
W
c
td
o
[3
w
o
o
si
W
M
o
n
I
<
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Po i ! u t an ( a )
Toxic Pollutants (Continued)
62. KJ-nl trob-odlphenylamlne
65. pt-enol
66. his(2 ethylhexyl)phthalate
68. din butyl phthalate
70. dlethyl phthalate
76. chrysene
Stream
Code
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type* Source
8
8
2
8
8
2
8 0.040
8 0.040
2 0.040
8 *
8 *
2 *
8 ND
8 ND
2 ND
8
8
2
Day 1
ND
*
*
*
*
*
0.015
*
*
*
*
ND
Day 2
*
ND
ND
ND
ND
ND
*
*
0.012
*
*
*
ND
ND
ND
ND
ND
ND
Day 3
ND
ND
ND
ND
0.031
0.010
*
*
ND
ND
ND
ND
Average
*
*
*
*
*
0.015
0.007
0.007
*
*
*
*
*
,
H
>
K
H
2;
o
to
c;
0
H
K
8
K
V
t
C.
H.
1
'
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Pol.lutant_ (a)
Toxic Pollutants (Continued)
80. fluorene
81. phenanthrene
84. pyrene
85. tetrachloroethylene
86. toluene
87. trichloroethylene
Concentrations (mg/1, except as noted)
Stream
Code
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type* Source
8
8
2
8
8
2
8
8
2
1 ND
1 ND
1 ND
1
1
1
1 *
1 *
1 *
Day 1
*
*
ND
ND
ND
*
ND
ND
ND
ND
ND
ND
Day 2
ND
ND
ND
*
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
*
*
*
Day 3 Average
ND
ND *
*
ND
ND
ND
ND *
* *
ND
0.019 0.019
0.016 0.016
*
ND *
ND *
H
»
H
O
C/l
a
o
M
o
w
M
o
i-3
1
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pol hit ant (a)
Toxic Pollutants (Continued)
99. endrin aldehyde
100. heptachlor
101. heptachlor epoxlde
102. ... Ipha-BHC
103. bfta-BHC
104. g,imma--BHC
Stream
Code
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type*
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
Source ,
ND
ND
ND
**
**
**
ND
ND
ND
**
**
**
Day 1
ND
ND
ND
**
ND
ND
**
ND
**
**
ND
ND
Day 2
ND
ND
**
ND
ND
ND
ND
ND
ND
**
**
**
ND
ND
**
ND
**
ND
Day 3 Average
ND
ND **
ND
ND **
** **
ND
**
** **
** **
**
** **
ND **
ND **
ND
M
3
K
M
O
C/J
d
w
0
H
M
0
O
K
W
M
O
1-3
1
<
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
!'<.•! luUml (a)
• >xlc Pollutants (Continued)
I -).
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Ul
Pollutant (a)
Toxic Pollutants (Continued)
• '0. copper
12V . cyanide (total)
122 lead
123. mercury
124. nickel
125. selenium
Stream
Code
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type*
8
8
2
1
1
1
8
8
2
8
8
2
8
8
2
8
8
2
Source
<0.05
<0.05
<0.05
<0.02
<0.02
<0.02
<0.05
<0.05
<0.05
<0.001
<0.001
<0.001
<0.05
<0.05
<0.05
<0.05 (c)
<0.05 (c)
<0.05 (c)
Day 1
1.85
0.15
No data
<0.02
94.4
<0.05
0.001
<0.001
<0.05
0.2
<0.01
<0.05 (c)
Day 2
2.10
1.55
0.15
<0.02
<0.02
<0.02
16.4
40.4
<0.05
<0.001
<0.001
<0.001
<0.05
<0.05
0.25
<0.01
<0.01
<0.05 (c)
Day 3
1.55
0.10
<0.02
<0.02
24.6
0.05
<0.001
<0.001
<0.05
0.15
(b)
<0.05
Average
1.97
1.55
0.13
<0.02
<0.02
<0.02
55.4
32.5
0.016
0.0005
<0.001
<0.001
<0.05
<0.05
0.2
<0.01
<0.01
(c)<0.05(c)
PRIMARY ZINC
C/3
C
tfl
o
M
o
0
M
o
H
<
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Stream
Pol !nt ant (a) Code
Toxic Pollutants (Continued)
126. silver 331
332
323
'-' 127. thallium 331
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant (a)
Nonconventlonal
ammonia nitrogen
barium
boron
c ". 1 c 1 urn
chtmical oxygen
chloride
Stream
Code
Pollutants (Continued)
331
332
323
331
332
323
331
332
323
331
332
323
demand (COD) 331
332
323
331
332
323
Sample
Type*
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
Source ' Day 1
a
<0.05 0.15
<0.05
<0.05 0.15
<0.10 <0.10
<0.10
<0.10 <0.10
37.2 247.0
37.2
37.2 56.3
<1
<1
<1 4
5
5
5 5
Day 2
1.5
<0.05
0.10
0.15
<0.10
<0.10
<0.10
255.0
207.0
54.7
13
15
21
5
8
3
Day 3
3
0.10
0.10
<0.10
<0.10
189.0
50.0
25
6
9
5
Average
2.25
0.075
0.10
0.13
<0.10
<0.10
<0.10
251
198
53.6
13
20
10
5
8
4
RIMARY ZINC SUBC2
M
0
C/1
M
O
1
<
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (rng/1, except as noted)
Ul
Pollutant (a)
N nconventlonal Pollutants
cobalt
fluoride
Iron
raagnesl urn
manganese
molybdenum
Stream
Code
(Continued)
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type*
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
Source
<0.0.5
<0.05
<0.05
0.1
0.1
0.1
0.30
0.30
0.30
5.50
5.50
5.50
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 1
<0.05
<0.05
0.2
1.45
7.45
68.7.
166.0
116.0
59.1
<0.05
<0.05
Day 2
<0.05
<0.05
<0.05
0.2
0.2
<0.1
5.0
4.25
9.40
75.3
51.7
151.0
16.6
49.3
65.1
<0.05
<0.05
<0.05
Day 3
<0.05
<0.05
0.2
0.1
4.10
8.95
65.5
112.0
44.6
54.3
<0.05
<0.05
Average
<0.05
<0.05
<0.05
0.2
0.2
0.1
3.2
4.10
8.60
72.0
58.6
143.0
66.3
46.9
59.5
<0.05
<0.05
<0.05
H
N
H
O
W
§
O
Jjj
w
1
K
W
0
^
1
<
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Pol Uitant (a)
.^onconventional Pollutants (Continued)
• henol 1 cs
phut, plu; te
sodium
fate
tin
I 1tanlum
Concentrations (mg/
Stream
Code
d)
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type*
1
1
1
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
Source
<0.005
<0.005
<0.005
0.26
0.26
0.26
4.10
4.10
4.10
36
36
36
0.50
0.50
0.50
<0.05
<0.05
<0.05
Day 1
<0.005
No Data
<0.01
6.1
9.6
3,500
<0.05
<0.5
<0.05
0.1
1, except
Day 2
0.015
<0.005
0.005
<0.01
0.12
0.15
6.7
6.6
9.4
3,110
2,540
3,580
<0.5
<0.5
<0.5
<0.05
<0.05
0.1
as noted)
Day 3
<0.005
<0.005
<0.01
<0.01
7.5
7.6
2,180
2,850
<0.5
<0.5
<0.05
0.1
Average
0.015
<0.005
0.001
<0.01
0.06
0.005
6.4
7
8.8
3,110
2,360
3,310
0.28
<0.5
<0.5
<0.05
<0.05
0.1
tM
2!
0
c
w
0
M
O
O
tt
0
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as no ted)
to
rollutant (a)
Nonconventlonal Pollutants (Continued)
lotrfl dissolved solids (IDS)
tot.il organic carbon (TOG)
total solids (TS)
vanadi urn
yttrium
Stream
Code
d)
331
332
323
331
332
323
331
332
323
331
332
323
331
332
323
Sample
Type*
8
8
2
8
8
2
8
8
2
8
8
2
8
8
2
Source
189
189
189
3
3
3
200
200
200
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 1
6,560
10
6,790
<0.05
<0.05
<0.05
<0.05
Day 2
5,260
4,080
6,000
7
5
6
4,970
3,830
5,820
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 3
2,300
4,630
6
6
3,680
4,610
<0.05
<0.05
<0.05
<0.05
Average
5,260
3,190
5,730
7
5.5
7
4,970
3,760
5,740
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
ID
M
>
Csl
M
525
O
to
G
td
o
1-3
M
0
o
en
M
o
1-3
i
<
-------
Table V-8 (Continued)
CATHODE BRUSH WATER AND ANODE CLEANING WATER
RAW WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Ln
Pollutant ( t)
Conventional Pollutants
oil and grease
total suspended solids (TSS)
pH (standard units)
Stream
Code
331
332
323
331
332
323
331
332
323
Sample
Type*
1
1
1
8
8
2
8
8
2
Source
3
3
3
1
1
1
6
6
6
Day 1 Day 2
,
29 3,530
33
19 12
No Data 166
220
18 17
1-2 Unable
Unable
2.7 2.5
Day 3
1
10
4
122
9
to Determine
to Determine
2.5
Average
,779
21
12
166
171
15
1-2
H
3
*)
N
M
"Z
0
w
<=!
w
o
H
M
O
*
w
w
o
H
* - <^ 0.010 mg/1
** - £ 0.005 mg/1
(a) Mi toxic pollutant fractions were analyzed
(b) Interference
(c) Detection limit raised due to Interference.
-------
Table V-9
PRIMARY ZINC SAMPLING DVTA COMBINED RAW WASTHWATER
Concentrations (mg/lt except as noted)
Pol lutant
Stream
Code
Sample
Typet Source (a) Day 1
Day 2 Day 3 Average
Toxic Pollutants
44.
114.
115.
lib.
S117'
^118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
methyl pne chloride
antimony
arsenic
asbestos (MFL)
beryllium
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
thallium
zinc
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
2
2
2
1
2
2
2
2
2
2
2
2
2
2
2
2
0
<0
0
<0
6
0
1
<0
24
0
0
0
0
-------
Table V-9 (Continued)
PRIMARY ZINC SAMPLING DATA COMBINED RAW UASTEWATER
Concentrations (mg/1, except as noted)
Ln
to
Pollutant
Nonconventionals
chemical oxygen demand
(COD)
total organic carbon
(TCXJ)
phenols (total; by
4-AAP method)
Conventional
total suspended solids
(TSS)
pH (standard units)
Stream
Code
4
4
4
4
4
Sample
Typet Source(a)
2
2
2
2
1
Day 1
220
2
<0.002
88
2.15
Day 2 Day 3 Average
200 210
2 2
<0.002 <0.002
130 109
2.15
hd
»
K
tsi
H
^
n
en
c
to
o
>
H
M
§
3
K
cn
M
o
1^
1
**
(a) Source water was not analyzed.
-------
Table V-10
PRIMARY ZINC SAMPLING DATA MISCELLANEOUS RAW WASTEWATER
Concentrations (rog/1, except as noted)
oo
Pollutant
Toxic l'oUutant3( a)
4. bunzene
6. carbon tetr^chloride
10. 1,2-H
-------
I--'
u>
NJ
Table V-10 (Continued)
PRIMARY ZINC SAMPLING DATA MISCELLANEOUS RAW WASTEWATER
Concentrations (mg/1, except as noted)
Pol h i ant.
Toxic Pollutants (a)
121. cyanide
\22. Lead
126. nickel
125. selenium
128. zinc
Nonconventionals
chemical oxygen demand (COD)
phenols (total; by 4-AAP method)
total organic carbon (TOC)
Conventional^
oi 1 and grease
total suspended solids (TSS)
pH (standard units)
Stream
Code
7
7
7
7
7
7
7
7
7
7
7
7
Sample
Type
3
3
3
3
3
3
3
2
3
1
3
1
Source (b) Day 1
0.692
0.003
3.0
6.0
<0.002
100.0
76.0
0.002
10.0
13.0
23.0
2.0
Day 2
0.009
0.003
3.0
4.0
0.2
100.0
56.0
0.01
9.0
13.0
12.0
2.3
Day 3
0.503
0.004
3.0
3.0
0.1
100.0
46.0
0.001
9.0
16.0
9.0
2.1
Average
0.401
0.003
3.0
4.3
0.10
100.0
59.3
0.004
9.3
14.0
14.7
M
K
tsi
M
25
O
C
W
O
W
O
O
^
W
O
-------
I—
1.71
Table V-10 (Continued)
PRIMARY ZINC SAMPLING IttTA MISCELIANEOUS RAW WSTEWATER
.0
-------
Table V-ll
MISCELLANKOUS WASTEWATER SAMPLING DATA
Pollutant (a )
Toxic Pollutants
1 . aceimplithene
. carbon te11aoh1 or 1de
' 1 . 1,1 ,1-r.r lohl oroetliane
2'. . p-chloro-m-r reso 1
23. ch lo roform
TR. et h\'1
Stream
Code
333
328
333
328
333
334
328
333
334
328
333
334
328
333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
*
*
*
0.040
0.040
0.040
0.013
0.013
0.013
0.049
0.049
0.049
Day I Day 2
*
ND
ND
3.010
*
*
*
ND
0.014
0.015
*
*
0.016
ND
0.057
ND
Day 3 Average
*
3.010
*
*
*
0.014
0.015
*
*
0.016
0.057
50
M
s
K
tsi
M
n
w
n
M
o
0
50
K
M
n
1
^
39. fluoranthene
334
0.002
0.002
-------
Table V-L1 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pol Jutant (a)
Toxic Pollutants (Continued)
4 A . methylene chloride
l\ 1, btmpoform (t r ibromomethane)
48. dIrhlorobromcmethane
1. chlorodibromomethane
6 •. bts(2-ethylhexyl)phthai ate
68. di-n-butyl phthalate
70. dlethyl phthalate
Stream
Code
333
33A
328
333
33A
328
333
33A
328
333
33A
328
333
33A
328
333
33A
328
333
33A
328
Sample
Type*
1
1
1
1
L
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
*
*
*
O.OAO
O.OAO
O.OAO
*
*
*
ND
ND
ND
Day I Day 2
*
0.01A
0.013
ND
ND
*
ND
ND
*
ND
ND
*
*
ND
*
*
0.01A
0.012
*
*
*
Day 3 Average
*
0.01A
O.OL3
*
*
*
*
*
*
0.01A
0.012
*
*
*
H
N
HH
2S
O
C/J
c
GO
O
M
8
Kj
^N
C/J
M
O
1
<
-------
TableV-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Pn I In? ;int ( a )
Toxlr PoJIntants (Continued)
84. pyrene
R r>. tetrachloroethy 1 ene
<1-- t r 1 chloroet liylene
94. 4,4'-ODD
)r>. a Ipha-endosulf an
100. heptachlor
101. lieptachlor epoxlde
Concentrations (rog/1, except aa noted)
Stream
Code
333
328
333
328
333
334
328
333
334
328
333
328
333
328
333
334
328
333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
1
ND
ND
ND
*
*
*
ND
ND
ND
*
*
*
Day I Day 2 Day 3 Average
* *
ND
* *
ND
ND
* *
ND
ND
* *
* *
ND
** **
ND
** **
ND
** **
** **
ND
ND
** **
PRIMARY ZINC SI
*— i
M
n
M
o
en
M
n
^
-------
Table V-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (ing/1, except as noted)
£pj Ititant ( a )
Toxic Pollutants (Continued)
102. alpha-BHC
103. beta-BHC
104. gamma-BUG
delta-BHC
114. antimony
115. arsenic
17. beryl Hum
Stream
Code
333
334
328
333
334
328
333
328
333
328
333
334
328
333
334
328
333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
ND
ND
ND
*
*
*
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.005
Day 1 Day 2
**
**
** •
ND
ND
ND
**
**
ND
ND
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.005
Day 3 Average
**
**
**
**
**
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.005
PRIMARY ZINC SUBC,
i-3
W
O
O
K
w
w
n
^
<
-------
Table V-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (tng/1, except as noted)
Pollutant (a)
Toxic Pollutants (Continued)
Stream Sample
Code Type* Source Day 1 Day 2 Day 3
118. cadmlurn
119. chromium (total)
Ln
120.
copper
121. cyanide (total)
122. lead
123. mercury
124. nickel
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
<0.02
<0.02
<0.02
<0.02
<0.02
<0.02
<0.05
<0.05
<0.05
<0.02
<0.02
<0.02
<0.05
<0.05
<0.05
<0.001
<0.001
<0.001
<0.05
<0.05
<0.05
<0.02
0.18
0.3
<0.02
0.04
0.06
<0.05
0.45
0.3
<0.02
<0.02
<0.02
<0.05
0.95
0.25
<0.001
0.028
0.27
<0.05
<0.05
<0.05
Average
<0.02
0.18
0.3
<0.02
0.04
0.06
<0.05
0.45
0.3
<0.02
<0.02
<0.02
<0.05
0.95
0.25
<0.001
0.028
0.27
<0.05
<0.05
<0.05
M
53
n
en
d
ca
n
M
en
o
M
n
-------
cr\
Table V-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (rng/1, except as noted)
Pollutant (a)
Toxic Pollutants (Continued)
125. selenium
126. stiver
12V. thallium
128. zinc
Nonconventional Pollutants
acidity
alkalinity
Stream
Code
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source Day 1 Day 2
<0.05(b) <0.01
<0.05(b) <0.01
<0.05(b) <0.01
<0.01 <0.01
<0.01 <0.01
<0.01 <0.01
<0.01 <0.01
<0.01 <0.01
<0.01 <0.01
0.06 1.46
0.06 48.5
0.06 45.9
<1 <1
<1 184
<1 139
73 3
73 <1
73 <1
Day 3 Average
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
1.46
48.5
45.9
-------
Table V-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
tn
Pollutant (a)
Nonconventional Pollutants (Continued)
a lumi num
ammonia nitrogen
barium
boron
calcium
chemical oxygen demand (COD)
Concentrations (mg/1, except aa noted)
Stream
Code
d)
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
<0.10
<0.10
<0.10
-------
Table V-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
U)
00
Pollutant (a)
Nonconventional Pollutants (Continued)
chloride
cobalt
fluoride
iron
magnesium
r .nganese
Concentrations (mg/1, except aa noted)
Stream
Code
d)
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
5
5
5
<0.05
<0.05
<0.05
0.1
0.1
0.1
0.30
0.30
0.30
5.50
5.50
5.50
<0.05
<0.05
<0.05
Day 1 Day 2
2
27
<0.05
<0.05
<0.05
<0.1
<0.1
<0.1
0.450
3 .95
1.10
0.20
9.70
8.50
<0.05
2.0
0.70
Day 3 Average
2
27
<0.05
<0.05
<0.05
<0.1
<0.1
<0.1
0.450
3.95
1.10
0.20
9.70
8.50
<0.05
2.0
0.70
N
H
n
w
s
n
w
a
8
en
w
o
-------
Table V-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (rng/1, except as noted)
Pollutant (a)
Stream
Code
Nonconventlonal Pollutants (Continued)
molybdenum
phenol 1 i'
phosphate
sodium
sulfate
tlr,
Sample
Type*
Source
Day 1
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
333
334
328
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
<0.05
<0.05
<0.05
<0.005
<0.005
<0.005
0.26
0.26
0.26
4.10
4.10
4.10
36
36
36
0.50
0.50
0.50
<0.05
<0.05
<0.05
<0.005
0.01
0.01
<0.01
<0.01
3.05
0.20
1.20
7.2
3
229
188
<0.05
<0.05
0.15
Day 2
Day 3 Average
<0.05
<0.05
<0.05
<0 .005
0.01
0.01
<0.01
<0.01
L>l
H
25
n
in
c!
W
n
H)
M
Q
o
»
3.05
0.20
1.20
7.2
3
229
188
<0.05
<0.05
0.15
in
W
n
-------
Table V-ll (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Stream
Pollutant (a) Code
Nonconventlonal Pollutants (Continued)
titanium 333
334
328
total dissolved solids (TDS) 333
K 334
£ 328
total organic carbon (TOC) 333
334
328
total solids (TS) 333
334
328
vanadium 333
334
328
yttrium 333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
<0.05
<0.05
<0.05
189
189
189
3
3
3
200
200
200
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 1 Day 2
<0.05
<0.05
<0.05
33
328
394
4
5
11
33
431
436
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 3 Average
<0.05
<0.05
<0.05
33
328
394
4
5
11
33
431
436
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
*
H
*
H
2
O
w
§
o
HI
M
Q
O
s
w
o
1-3
1
<
-------
Table V-ll Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant (a)
Conventional Pollutants
o f 1 and grease
tot il suspended solids (TSS)
pi! (standard units)
Stream
Code
333
334
328
333
334
328
333
334
328
Sample
Type*
1
1
1
1
1
1
1
1
1
Source Day 1 Day 2 Day 3 Average
35 5
3 <1 <1
3 <1 <1
1 <1 <1
18 8
14 4
6 7.5
6 3-4
6 4
*
50
H
Kj
N
H
0
M
C
dd
0
1-3
W
8
£3
en
w
o
1
<
* - <_ 0.010 mg/1
** - _< 0.005 mg/1
(a) All toxic pollutant fractions were analyzed
(b) Detection limit raised due to Interference
-------
Table V-12
MISCELLANEOUS WASTEWATER SAMPLING DATA
Ln
Ji.
ro
Pollutant (a)
Toxic Pollutants
1. acenaphthene
1 . 1,1,1-trlchloroethane
18. bls(2-chloroethyl)ether
22. p-chloro-m-cresol
23. chloroform
. ethylbenzene
Concentrations (mg/1, except as noted)
Stream
Code
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
*
*
*
0.040
0.040
0.040
0.013
0.013
0.013
0.049
0.049
0.049
Day 1
ND
* '
*
*
ND
*
ND
ND
*
*
ND
ND
*
*
Day 2 Day 3 Average
ND
*
* *
*
*
ND
*
ND
* *
*
*
ND
* *
*
*
*
H
3
N
H
2!
n
c;
w
n
>
1-3
M
Q
0
»
M
n
i
<
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
*>.
U)
Pollutant (a)
Toxic Pollutants (Continued)
'»7. broraoform (trlbromomethane)
.1. chlorodlbromomethane
66. bls(2-ethylhexyl)phthalate
68. dl-n-butyl phthalate
70. dlethyl phthalate
73. benzo(a)pyrene
76. chrysene
Concentrations (mg/1, except as noted)
Stream
Code
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
*
*
*
0.040
0.040
0.040
*
*
*
ND
ND
ND
Day 1 Day 2
*
ND
*
*
ND
ND
ND
*
*
*
0.014
*
ND
ND
*
*
ND
ND
*
*
*
Day 3 Average
*
*
*
*
*
*
0.014
*
*
*
*
*
*
IT)
\J
H
K
N
H
•z
0
en
C
tfl
o
H
a
o
K!
en
M
0
1
,
V
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Pollutant (a)
Toxic Pollutants (Continued)
84. pyrene
85. tetrachloroethylene
87. trichloroethylene
101. heptachlor epoxlde
102. alpha-BHC
103. beta-BHC
104. gamma-BHC
Concentrations (mg/1, except as noted)
Stream
Code
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
ND
ND
ND
*
*
*
*
*
*
ND
ND
ND
*
*
*
Day 1 Day 2 Day 3 Average
* *
* *
* *
ND
ND
ND
* *
ND
* *
ND
ND
ND
ND
* *
ND
ND
* *
ND
ND
* *
ND
*
H
N
H
O
w
c:
w
o
5
M
O
£*
w
M
0
""3
1
<
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Ln
*>.
Ln
Pollutant (a)
Toxic Pollutants (Continued)
105. delta-BHC
114. antimony
115. arsenic
117. beryllium
118. cadmlura
Ii9. chromium (total)
120. copper
Concentrations (rag/1, except as noted)
Stream
Code
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
<0.02
<0.02
<0.05
<0.05
<0.05
Day 1
*
ND
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
<0.05
<0.05
Day 2 Day 3 Average
ND
*
<0.01 <0.01
<0.01
<0.01
<0.01 <0.01
<0.01
<0.01
<0.005 <0.005
<0.005
<0.005
<0.02 <0.02
<0.02
<0.02
<0.02 <0.02
<0.02
<0.02
<0.05 <0.05
<0.05
<0.05
H
H
O
to
§
o
i-3
M
Q
O
K
M
M
O
(-3
I
<
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pol'utant (a)
Toxic Pollutants (Continued)
121. cyanide (total)
122. lead
123. mercury
124. nickel
125. selenium
126. silver
127. thallium
Stream
Code
32A
329
330
32A
329
330
32A
329
330
32A
329
330
32A
329
330
32A
329
330
32A
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
-------
MISCELLANEOUS WASTEWATER SAMPLING DATA
LT!
J^
-J
Pollutant (a)
Toxic Pollutants (Continued)
128. zinc
Nonco.ivent lonal Pollutants
acidity
alkalinity
alumlnum
ammonia nitrogen
barium
boron
Concentrations (tng/1, except as noted)
Stream
Code
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
i
i
i
i
i
i
i
i
i
i
i
Source
0.06
0.06
0.06
<1
<1
<1
73
73
73
<0.10
<0.10
<0.10
<1
<1
<1
<0.05
<0.05
<0.05
<0.10
<0.10
<0.10
Day 1 Day 2
0.08
1.84
0.380
<1
<1
<1
74
73
74
<0.10
<0.10
<0.10
<1
<1
<1
<0.05
<0.05
<0.05
<0.10
<0.10
<0.10
Day 3 Average
0.08
1.84
0.380
<1
<1
<1
74
73
74
<0.10
<0.10
<0.10
<1
<1
<1
<0.05
<0.05
<0.05
<0.10
<0.10
<0.10
o
w
c
M
o
a
o
VI
M
n
I
<
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Stream
Pollutant (a) Code
Nonconventlonal Pollutants (Continued)
calcium • 324
329
330
chemical oxygen demand (COD) 324
M 329
E 330
oo
chloride 324
329
330
cob;:lt 324
329
330
fluoride 324
329
330
Iron 324
329
330
magnesium 324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
37.2
37.2
37.2
<1
<1
<1
5
5
5
<0.05
<0.05
<0.05
0.1
0.1
0.1
0.30
0.30
0.30
5.50
5.50
5.50
Day 1 Day 2
37.3
36.2
37.8
2
7
6
4
4
4
<0.05
<0.05
<0.05
0.1
0.1
0.1
<0.05
0.35
<0.05
5.50
5.80
5.60
Day 3 Average
37.3
36.2
37.8
2
7
6
4
4
4
<0.05
<0.05
<0.05
0.1
0.1
0.1
<0.05
0.35
<0.05
5.50
5.80
5.60
%
H
K
H
O
tn
c
w
0
>
%
w
S
OT
W
O
1-3
1
<
\
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant (a)
Nonconventlonal
inangaiu =s>
molybde"iit!i
phenollcs
pho; >hate
socilun;
sulfate
tin
Stream
Code
Pollutants (Continued)
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.005
<0.005
<0.005
0.26
0.26
0.26
4.10
4.10
4.10
36
36
36
0.50
0.50
0.50
Day 1 Day 2
<0.05
0.05
<0.05
<0.05
<0.05
<0.05
0.022
<0.005
0.010
0.18
0.24
0.12
3.70
3.9
3.90
37
43
40
<0.05
<0.05
<0.05
Day 3 Average
<0.05
0.05
<0.05 ,
<0.05
<0.05
<0.05
0.022
<0.005
0.010
0.18
0.24
0.12
3.70
3.9
3.90
37
43
40
<0.05
<0.05
<0.05
3
H
1
IN]
M
2
*-\
0
W
G
O
HI
M
§
K
W
W
o
1-3
1
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (ing/1, except as noted)
Pollutant (a)
Stream
Code
Sample
Type*
Source
Day 1 Day 2
Day 3 Average
Nonconventional Pollutants (Continued)
t Itanium
total dissolved solids (TDS)
total organic carbon (TOC)
total solids (TS)
vanadium
yttrium
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
324
329
330
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
<0.05
<0.05
<0.05
189
189
189
3
3
3
200
200
200
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
194
182
191
:
5
16
5
169
199
187
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
194
182
191
5
16
5
169
199
187
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
3
H
s
/*J
N
H
25
O
M
§
O
^
w
o
o
K
M
W
0
1
-------
Table V-12 (Continued)
MISCELLANEOUS WASTEWATER SAMPLING DATA
Concentrations (mg/1, except as noted)
Pollutant (a)
Conventional Pollutants
oil and grease
total suspended solids (TSS)
pH (standard units)
Stream
Code
324
329
330
324
329
330
324
329
330
Sample
Type*
1
1
1
1
1
1
1
1
1
hj
to
i i
Source Day 1 Day 2 Day 3 Average 3
3 <1
3 <2
3 7
1 <1
1 <1
1 <1
6 7.5
6 8.3
6 8.0
§
IS!
H
<1 25
<2 n
7C/3
r-t
§
n
<1 M
<1 °
V1 O
to
K
w
w
n
* - _< 0.010 mg/1
** - _< 0.005 mg/1
(a) All toxic pollutant fractions were analyzed,
(b) Detection limit raised due to Interference.
-------
Table V-13
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT A
Concentrations (mg/1, except as noted)
Pollutant:
Toxic Pollutants
23. chloroform
66. bis(2-ethylhexyl) phthalate
106. PCB-1242 (a)
107. PCB-1254 (a)
108. PCB-1221 (a)
Ln
Ln
NJ
109.
110.
111.
112.
118.
120.
122.
123.
128.
PCB-1232
PCB-1248
PCB-1260
PCB-1016
cadmium
copper
lead
mercury
zinc
(b)
(b)
(b)
(b)
Nonconvent ionaIs
ammonia
chemical oxygen demand (COD)
phenols (total; by 4-AAP method)
total organic carbon (TOC)
Stream
Code
37
37
37
37
37
37
37
37
37
37
37
37
37
Sample
Type
2
3
3
3
3
3
3
3
3
2
2
2
2
Source Day 1
* ND
* *
** **
** **
0.02 <0.002
0.007 0.03
0.05 0.1
<0.0001 0.0032
0.9 0.8
0.8
23.0
1.0
0.004
Day 2
*
0.176
**
**
0.003
<0.006
<0.02
0.003
0.9
19.0
22.0
5.0
<0.001
Day 3
0.029
*
0.018
0.0084
0.2
0.02
<0.02
0.0028
10.0
12.0
28.0
3.0
<0.001
Average
0.015
0.0587
0.006
0.0028
0.07
0.017
0.03
0.003
3.9
10.60
24.3
3.0
0.0013
N
H
55
O
O
I
M
O
1-3
I
<
-------
Pollutant
Con vent I ona Is
Table V-13 (Continued)
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT A
Concentrations (rog/1, except as noted)
Stream Sample
Code Type Source Day 1 Day 2 Day 3 Average
oil and grease
total suspended solids (TSS)
pll (standard units)
37
37
37
2
2
2
4.0
4.0
37.0
11.3
6.0
33.0
10.6
2.0
82.0
11.0
4.0
50.7
H
25
O
cn
c
Cd
o
M
CD
I
cn
M
o
i
<
(a),(b) Reported together.
**l,ess than 0.005 mg/1.
-------
Table V-14
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT B
Concentrations (mR/1, except as noted)
Pol jtant
Toxi. Pollutants
2 3. ~h loro form
44. methylene chloride
49. trichlorofluoromethane
66. bis(2-ethylhexyl) phthalate
114. antimony
115. arsenic
117. beryllium
118. cadmium
119. chromium
Stream
Code
210
211
210
211
210
211
210
211
210
211
210
211
210
211
210
211
210
211
Sample
Type Source
5 *
5
5 *
5
5 *
5
5 *
5
5 <0.8
5
5 <0.01
5
5 <0.01
5
5 <0.005
5
5 <0.01
5
Day 1 Day 2
0.055
ND
2.61
*
0.101
ND
0.107
*
<0.8
<1 .52
<0.01
0.836
<0.01
<0.02
0.022
8.08
0.14
2.186
Day 3 Average
0.055
2.61
*
0.101
0.107
*
<0.8
<1 .52
<0.01
0.836
<0.01
<0.02
0.022
8.08
0.14
2.186
N
o
w
§
o
w
o
8
M
w
o
-------
Ln
Table V-14 (Continued)
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT B
Concentrations (mg/ltexcept as noted)
Pollutant
Stream
Code
Sample
Type
Source
Day 1 Day 2
Day 3 Average
Toxic Pollutants
1
1
1
1
1
1
1
20.
22,
23.
24.
25.
26.
28.
copper
lead
mercury
lickel
selenium
s i 1 ver
zinc
210
211
210
211
210
211
210
211
210
211
210
211
210
211
5
5
5
5
5
5
5
5
5
5
5
5
5
5
0
<0
<0
<0
<0
<0
0
.019
.05
.002
.005
.001
.0063
.38
0
6
<0
8
<0
0
-------
Table V-15
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT C
Concentrations (mg/1, except as noted)
en
i_n
(Ti
Pollutant
Toxic Pollutants
10. 1 ,2-dichloroethane
23. chloroform
29. 1 ,1-dichloroethylene
47. bromoform
6 . bls(2-ethylhexyl) phthalate
6*: di-n-butyl phthalate
85, tetrachloroethylene
87. trlchloroethylene
114. antimony
115. , rsenlc
118. c admium
119. Cftromlum
120. copper
121. cyanide
122. lead
124. nickel
125. selenium
128. zinc
Stream
Code
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
Sample
Type Source(a)
2
2
2
2
3
3
2
2
3
3
3
3
3
3
3
3
3
3
Day 1
0.012
0.385
0.015
0.053
0.041
*
0.03
0.061
0.1
<0.03
0.129
0.291
0.009
0.007
0.16
<0.05
0.6
0.308
Day 2
0.072
0.087
ND
ND
0.018
*
ND
<0.031
<0.002
0.005
0.143
0.306
0.019
0.003
0.188
<0.05
0.05
5.0
Day 3
ND
0.054
ND
ND
0.022
0.013
*
<0.036
0.1
0.002
0.071
0.463
0.113
0.05
0.115
<0.05
0.15
0.834
Average
0.042
0.18
0.015
0.053
0.027
0.004
0.02
0.02
0.07
0.002
0.11
0.353
0.05
0.02
0.15
<0.05
0.3
2.0
H
3
N
H
25
o
en
C
w
o
5
w
O
O
cn
w
o
i-3
-------
TableV-15 (Continued)
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT C
Concentrations (mg/1, except as noted)
Pollut iiU
Nonconventionals
chemical oxygen demand (COD)
phenols (total; by 4-AAP method)
total organic carbon (TOC)
Convent ionaIs
oil and grease
total suspended solids (TSS)
pH (standard units)
Stream
Code
8
8
8
8
8
8
Sample
Type Source(a)
2
2
2
2
2
1
Day 1
18.0
0.008
9.0
11.0
9.0
8.2
Day 2
17.0
0.008
8.0
1.0
1.0
8.4
Day 3
15.0
0.011
8.0
18.0
9.0
8.6
Average
16.7
0.009
8.3
10.0
9.3
M
»
tXl
M
O
SUBCA
M
1
K
w
M
O
(-3
(a) Source water was not analyzed.
-------
Table V-16
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT D
Concentrations (nig/1, except as noted)
en
t_n
CO
Pollutant
Toxic Pollutants
118. cadmium
119. chromium
120. copper
122. lead
123. mercury
125. selenium
128. zinc
Nonconventionals
ammonia
chemical oxygen demand (COO)
phenols (total; by 4-AAP method)
total organic carbon (TOG)
Convent tonals_
oil ind grease
total suspended solids (TSS)
Stream
Code
214
214
214
214
214
214
214
214
214
214
214
214
214
Sample
Type Source(a) Day 1
2
2
2
2
2
2
2
2
2
2 <0.017
2
2
2
Day 2 Day 3
0.02
• 0.48
1.01
0.2
0.0006
0.25
0.65
0.4
4.0
3.0
3.0
1.0
Average
0.02
0.48
1.01
0.2
0.0006
0.25
0.65
0.4
4.
<0.017
3.0
3.0
1.0
N
H
2
n
c
w
n
5
w
I
w
n
(-3
I
<
(a) So.irce water was not analyzed.
-------
Table V-17
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT E
Pollutant
Toxic Pollutants
'\. benzene
9. hexachlorobenzene
LT, 10. 1 ..'-dxchloroethane
23, chloroform
29. 1,1-dichloroethylene
39. fluoranthene
44. methylene chloride
54. isophorone
66. bis(2-ethylhexyl) phthalate
Concentrations (mg/1, except as noted)
Stream
Code
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
Sample
Type Sourcet
2
2
3
3
2
2
2
2
2
2
3
3
2
2
3
3
3
3
Day 1
<0.029
*
ND
0.047
*
0.019
0.378
0.329
0.011
0.015
ND
0.221
0.133
0.018
ND
ND
*
Day 2
*
0.02
ND
ND
ND
ND
0.098
0.0955
ND
ND
ND
ND
ND
ND
ND
ND
0.023
0.012
Day 3
<0.014
*
0.1
ND
0.073
0.046
0.077
0.088
ND
ND
ND
ND
ND
ND
ND
ND
*
0.013
Average
<0.018
0.007
0.1
0.047
0.037
0.033
0.18
0.17
0.011
0.015
0.221
0.133
0.018
0.01
0.008
PRIMARY
H
55
n
in
n
M
O
en
n
i
<
-------
Ln
CT\
o
Table V-17 (Continued)
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT E
Concentrations (rng/1, except as noted)
Pollutant
Toxic Pollutants
67. butyl benzyl pbthalate
. dl-n-butyl phthalate
. diethyl phthalate
71. dimethyl phthalate
76. chrysene
7 7. acenaph thylene
80. fluorene
84. pyrene
87. trichloroethylene
Stream
Code
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
Sample
Type
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2
Sourcet Day 1
0.03
ND
0.03
*
0.018
ND
0.022
ND
0.011
ND
0.018
*
0.014
*
0.014
*
<0.182
<0.049
Day 2
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
*
ND
Day 3
ND
ND
ND
0.015
*
ND
ND
ND
*
ND
ND
ND
ND
ND
0.015
ND
<0.074
ND
Average
0.03
0.03
0.0075
0.009
0.022
0.0055
0.018
*
0.014
*
0.015
*
<0.089
<0.049
3
H
3
S
K
IS]
H
0
en
c:
Q)
0
M
»
*
en
M
o
1-3
i
<
-------
tn
CTl
Pollutant
Toxic Pollutants
106. PCB-1242
107. PCB-1254
108. PCB-1221
109. PCB-1232
110. PCB-1248
111. PCB-1260
112. PCB-1016
113. toxaphene
1 14. antimony
115. arsenic
117. beryllium
118. cadmium
119. chromium
(a)
(a)
(a)
(b)
(b)
(b)
(b)
Table V-17 (Continued)
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT E
Concentrations (mg/1, except as noted)
Stream
Code
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
Sample
Type Sourcet
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Day 1
**
<0.02
**
<0.015
**
<0.007
<0.002
0.004
0.003
<0.002
<0.002
<0.002
0.41
0.595
<0.024
<0.024
Day 2
ND
<0.02
ND
<0.015
ND
<0.007
<0.002
<0.002
<0.002
0.003
<0.002
<0.002
0.24
0.666
<0.024
<0.024
Day 3
ND
<0.02
ND
<0.015
ND
<0.007
<0.002
<0.002
0.003
0.002
<0.002
<0.003
0.391
0.638
<0.024
<0.024
Average
**
<0.02
**
<0.015
**
<0.007
<0.0023
0.001
0.002
0.002
<0.002
<0.002
0.35
0.633
<0.024
<0.024
M
N
M
55
O
M
O
1-3
M
O
O
M
M
O
-------
Table V-17 (r ntlnued)
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT E
Concentrations (mg/1, except as noted)
Pollutant
Toxic Pollutants
120. copper
121. cyanide
122. lead
£ 123. mercury
K)
124. nickel
125. selenium
1/8. zinc
N onconven t ionals
cheml ~1 oxygen demand (COD)
phenols (total; by 4-AAP method)
total organic carbon (TOC)
Stream
Code
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
5
6
Sample
Type Sourcet
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2
2 0.010
2
2
2
Day 1
0.011
0.032
0.518
0.007
<0.06
<0.06
0.0011
0.0005
<0.05
<0.05
0.03
0.025
9.0
7.0
18.0
14.0
0.018
0.011
8.0
9.0
Day 2
0.023
0.013
0.13
0.008
0.1790
<0.06
0.0035
0.0004
<0.05
<0.05
0.0018
0.025
8.0
8.0
24.0
23.0
0.021
0.01
6.0
7.0
Day 3
0.076
0.009
0.477
0.009
0.599
<0.06
0.004
0.0005
<0.05
<0.05
0.25
0.03
9.0
8.0
19.0
14.0
0.036
0.005
8.0
9.0
Average
0.037
0.02
0.38
0.008
0.26
<0.06
0.0029
0.0005
<0.05
<0.05
0.094
0.027
8.7
7.7
20.3
17.0
0.025
0.009
7.3
8.3
fd
8
N
M
55
O
M
CO
O
M
Q
O
M
n
-------
TableV-17 (Continued)
PRIMARY ZINC SAMPLING DATA TREATMENT PLANT SAMPLES PLANT E
Concentrations (rog/1, except as noted)
I'ol Int.ant
Ci >i-v/f>nt. i.onals
oil and gr'-ase
)tal suspended solids (TSS)
(standard iini rsl
' ' ' •
Stream
Code
5
6
5
6
5
6
Sample
Type
2
2
2
2
1
1
Sourcet Day 1
6.0
3.0
12.0
<1 .0
7.35
7.4
Day 2
1.0
12.0
8.0
1.0
7.95
7.6
Day 3 Average
24.0 10.3
7.0 7.3
20.0 13.3
<1.0 0.33
7.4
7.65
50
H
H
O
CO
<=!
W
O
(-3
M
O
O
50
CO
M
O
(-3
tSource water analyzed for asbestos and phenols only. Asbestos was not detected.
-------
Table V-18
PRIMARY ZINC TREATMENT PLANT SAMPLES - PI.ANT G
' JL'lLl'llL (
-------
I-'
in
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PLANT SAMPLES - PLANT G
Concentrations (rog/1, except as noted)
Stream
nllutant (a) Code
•••(.: Pollutants (Continued)
'4. 2 ,4-dimethyl phenol 325
326
'•' , 2,6-dinitrotoluene 325
326
''• othylbonzene 325
326
327
' luoranthene 325
326
44 . px-thylene chloride 325
326
327
47. hromofonn (tribromomethane) 325
326
327
48. di chlorobromomethane 325
326
327
56. nitrobenzene 325
326
Sample
Type*
2
3
2
3
1
1
1
2
3
1
1
1
1
1
1
1
1
1
2
3
Source
0.049
0.049
0.049
ND
ND
ND
ND
*
*
*
ND
ND
ND
Day 1
ND
ND
ND
*
ND
ND
*
ND
0.018
0.021
ND
*
ND
*
ND
*
Day 2
ND
*
ND
ND
ND
ND
*
*
*
*
*
*
ND
ND
ND
ND
Day 3
ND
ND
ND
ND
0.055
0.043
0.049
ND
ND
0.012
0.013
0.016
*
*
*
ND
ND
ND
ND
ND
Average
*
*
0
0
0
*
*
0
0
0
*
*
*
*
*
.055
.043
.049
.01
.011
.016
K;
tsi
M
Z
o
in
Cfl
o
M
C5
O
in
M
o
H3
-------
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PLANT SAMPLES - PLANT G
Concentrations (mg/1, except as noted)
Pollutant (a)
Toxic Pollutants (Continued)
")/. 2-nitrophenol
i 2. N-nitrosodiphenylamine
6). phenol
66. bis(2-ethylhexyl)phthalate
68. di-n-butyl phthalate
69. di-n-octyl phthalate
70. diethyl phthalate
Stream
Code
325
326
325
326
325
326
325
326
327
325
326
327
325
326
325
326
327
Sample
Type*
2
3
2
3
2
3
2
3
2
2
3
2
2
3
2
3
2
Source
ND
ND
ND
ND
ND
ND
0.040
0.040
0.040
*
*
*
ND
ND
ND
Day 1
ND
ND
ND
0.014
*
ND
*
*
*
*
ND
*
*
ND
Day 2
ND
ND
*
*
ND
*
*
ND
*
*
ND
ND
*
ND
Day 3
ND
*
ND
ND
ND
ND
ND
*
*
0.014
0.012
0.016
ND
ND
ND
*
*
Average
*
*
0
*
*
*
*
*
0
0
0
*
*
*
*
.007
.0046
.004
.016
N
H
55
n
n
5
M
W
M
n
-------
cr>
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PLANT SAMPLES - PLANT G
Pollutant (a)
Toxic Pollutants (Continued)
76. chrysene
80. fluorene
81. phenanthrene
84. pyrene
85. tetrachloroethylene
86. toluene
87. trichloroethylene
Concentrations (mg/1. except as noted)
Stream
Code
325
326
327
325
326
325
326
325
326
327
325
326
327
325
326
325
326
327
Sample
Type*
2
3
2
2
3
2
3
2
3
2
1
1
1
1
1
1
1
1
Source
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
*
*
*
Day 1
*
ND
ND
*
*
*
*
ND
ND
0.034
ND
0.019
*
*
Day 2
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
if
*
Day 3
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
*
*
ND
*
ND
ND
*
Average
*
if
*
*
*
0.017
*
0.009
*
*
*
J0
N
H
5S
O
cn
c
ca
o
M
cn
M
-------
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PLANT SAMPLES - PLANT G
Ul
&.
00
Pollutant (a)
Toxic Pollutants (Continued)
101. heptachlor epoxide
102. alpha-BIIC
HO. beta-BMC
HVi. gamma-RHC
1t>5. delta-BHC
114. antimony
115. arsenic
Concentrations (mg/1, except as noted)
Stream
Code
327
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
Sample
Type*
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
Source
*
ND
ND
ND
*
*
*
ND
ND
ND
ND
ND
ND
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
Day 1
ND
**
ND
ND
ND
ND
ND
ND
0.01
<0.01
0.02
<0.01
Day 2
**
**
**
**
**
ND
**
ND
<0.01
<0.01
0.02
<0.1
Day 3
*
**
**
**
ND
ND
**
ND
ND
**
**
**
ND
<0.01
<0.01
<0.01
<0.02(b)
<0.01
<0.01
Average
*
**
**
**
**
**
**
**
**
**
**
0.003
<0.01
<0.01
0.013
<0.04
<0.01
pa
*
N
H
2J
n
to
§
n
t-3
M
o
pa
M
n
t-3
I
**
-------
Table V-t8 (Continued)
PRIMARY ZINC TREATMENT PIANT SAMPLES - PLANT G
Concentrations (wig/1, except as noted)
tn
en
VD
Pollutant (a)
T'qxic PoLIutants (Continued)
H7, beryllium
12,'
cadiiijum
119. chromium (total)
20, copper
I'M. cyanide (total)
lead
23. mercury
Stream
Code
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
Sample
Type*
2
3
2
2
3
2
2
3
2
2
3
2
1
1
1
2
3
2
2
3
2
Source
<0.005
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
<0.02
<0.02
<0.05
<0.05
<0.05
<0.02
<0.02
<0.02
<0.05
<0.05
<0.05
<0.001
<0.001
<0.001
Day 1
<0.005
<0.005
9.12
0.08
0.06
<0.02
5.4
<0.05
0.03
<0.02
0.4
<0.05
0.064
<0.001
Day 2
<0.005
<0.005
10.0
0.08
0.06
0.02
5.95
<0.05
0.02
<0.02
0.45
<0.05
0.068
<0.001
Day 3
<0.005
<0.005
<0.005
9.38
0.08
0.08
0.06
<0.02
<0.02
5.55
<0.05
<0.05
<0.02
<0.02
<0.02
0.55
<0.05
<0.05
0.082
<0.001
<0.001
Average
<0.005
<0.005
<0.005
9.5
0.08
0.08
0.06
0.006
<0.02
5.6
<0.05
<0.05
0.02
<0.02
<0.02
0.5
<0.05
<0.05
0.071
<0.001
<0.001
hd
H
3
H
O
c
w
o
Hi
w
Q
O
K
C/l
w
o
<
-------
h-'
Ln
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PLANT SAMPLES - PLANT G
Concentrations (mg/1, except as noted)
Po1
lutant (a)
Stream
Code
Sample
Type*
Source
Day 1
Day 2
Day 3
na
H
rs
Average >
Toxic Pollutants (Continued)
K'4
121)
126
127
128
nickel
selenium
silver
thallium
zinc
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
<0.05
<0.05
<0.05
<0.05(b)
<0.05(b)
<0.05(b)
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
0.06 1,
0.06
0.06
0.05
<0.05
<0.05(b)
<0.01
<0.01
<0.01
<0.01
<0.01
680 1
0.460
<0
<0
<0
<0
<0
<0
<0
<0
,810
0
.05
.05
.05(b)
.01
.01
.01
.01
.01
1
.880
<0.05
<0.05
<0.05
<0.05(b)
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
,760 1
0.960
0.980
0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
,750
0
0
.02
.05
.05
.05
.01
.01
.01
.01
.01
.01
.01
.01
.766
.980
K
N
H
55
0
cn
W
0
HI
M
0
O
K
cn
M
0
1-3
i
<
Nonconventional Pollutants
acidity
325
326
327
2
3
2
<1 7,
<1
<1
270 6
<1
,980
2
7
,190 7
<1
5
,146
0
5
.7
-------
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PLANT SAMPLES - PLANT G
Concentrations (mg/1, except as noted)
Stream
Pollutant (a) Code
Nonconventional Pollutants (Continued)
alkalinity 325
326
327
' liimlniB:. 325
326
327
ammonia ni trogen 325
326
327
barium 325
326
327
boron 325
326
327
calcium 325
326
327
chemical oxygen demand (COD) 325
326
327
Sample
Type*
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
Source
73
73
73
<0.10
<0.10
<0.10
<1
<1
<1
<0.05
<0.05
<0.05
<0.10
<0.10
<0.10
37.2
37.2
37.2
-------
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PLANT SAMPLES - PLANT G
LH
Pollutant (a)
Nonconventional Pollutants (Continued)
chloride
cobalt
fluoride
iron
magnes ium
manganese
Concentrations (mg/1, except as noted)
Stream
Code
id)
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
Sample
Type*
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
Source
5
5
5
<0.05
<0.05
<0.05
0.1
0.1
0.1
0.30
0.30
0.30
5.50
5.50
5.50
<0.05
<0.05
<0.05
Day 1
214
104
0.05
<0.05
15
6.3
41.8
<0.05
763.0
476.0
128.0
2.95
Day 2
112
103
0.10
<0.05
19
11
46.3
<0.05
809.0
464.0
129.0
3.70
Day 3
119
105
96
0.05
<0.05
<0.05
19
11
11
43.8
<0.05
<0.05
819.0
517.0
487.0
136.0
4.65
7.5
Average
148
104
96
0.06
<0.05
<0.05
17
9.4
11
43.9
<0.05
<0.05
797
485
487.0
131
3.7
7.5
H
2
n
c;
M
n
n
i
<
-------
Table V-18 (Continued)
PRIMARY ZINC TREATMENT P1ANT SAMPLES - PIANT G
Concentrations (ing/1, except as noted)
Pollutant t-0
Nonconyent.i or s; j! Pollutants (Con11 nued)
molyhclenum
phenolics
phosphate
soc, urn
sulfate
tin
Stream
Code
id)
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
Sample
Type*
2
3
2
1
1
1
2
3
2
2
3
2
2
3
2
2
3
2
Source
<0.05
<0.05
<0.05
<0.005
<0.005
<0.005
0.26
0.26
0.26
4.10
4.10
4.10
36 11
36 3
36
0.50
0.50
0.50
Day 1
<0.05
<0.05
<0.005
<0.005
<0.01
<0.01
147.0
143.0
,300 11
,990 3
<0.5
<0.5
Day 2
<0.05
<0.05
<0.005
<0.005
<0.01
<0.01
146.0
131.0
,000
,470
<0.5
<0.5
Day 3
<0.05
<0.05
<0.05
<0.005
0.006
<0.005
<0.01
<0.01
<0.01
158.0
144.0
147.0
5,670
3,510
3,420
<0.5
<0.5
<0.5
Average
<0.05
<0.05 ,
<0.05
<0.005
0.002
<0.005
<0.01
<0.01
<0.01
150
139
147.0
9,320
3,660
3,420
<0.5
<0.5
<0.5
tsi
M
z
n
W
a
w
n
M
Q
o
to
M
n
-------
Ln
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PIANT SAMPLES - PLANT G
Pollutant (a)
Nonconventional Pollutants (Continued)
t itanium
total dissolved solids (TDS)
total organic carbon (TOC)
total solids (TS)
vanadium
yttrium
Concentrations (mg/1, except as noted)
Stream
Code
>d)
/
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
325
326
327
Sample
Type*
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
2
3
2
Source
<0.05
<0.05
<0.05
189 16
189 6
189
3
3
3
200 7
200 6
. 200
<0.05
. <0.05
<0.05
<0.05
<0.05
<0.05
Day 1
0.6.
<0.05
,500
,120
6
9
,010
,250
<0.05
<0.05
<0.05
<0.05
Day 2
0.65
<0.05
16,400
6,130
5
3
17,500
6,210
<0.05
<0.05
<0.05
<0.05
Day 3
0.60
<0.05
<0.05
17,200
6,370
6,170
4
3
1
16,800
6,420
6,100
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Average
0.6
<0.05
<0.05
16,700
6,210
6,170
5
5
1
13,770
6,300
6,100
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
H
3
K
N
H
2!
O
C
w
£
bd
Q
0
*
W
bd
n
1-3
i
<
-------
LM
^J
Ul
Table V-18 (Continued)
PRIMARY ZINC TREATMENT PI ANT SAMPLES - PLANT G
Pollutant (a)
Conventional Pollutants
o'I and grease
)l -u.spended solids (TSS)
pll (::t-.andard units)
Concentrations (ing/1, except as noted)
Stream
Code
325
326
327
325
326
327
325
326
327
Sample
Type*
1
1
1
2
3
2
2
3
2
Source
3
3
3
1
1
1
6
6
6
Day 1
6
<2
27
14
2.2
9.9
Day 2
<1
33
16
1.5
9.3
Day 3
<1
<1
32
14
16
1.5
8.8
8.4
Average
2
1.3
<1
30
14
16
tsi
H
n
C
w
n
5
M
O
* - < 0.010 mg/1
** - <. 0.005 mg/1
(a. All toxic pollutant fractions were analyzed
Detection limit raised due to interference
-------
PRIMARY ZINC SUBCATEGORY SECT - V
VOA Blank
Contact
Cooling From
Rolling Mill
Oil Skimmers
(Four)
Waelz Kiln
Residue
Quenching
Kiln
Quench Pit
0.48 MOD ^^V | 037
Discharge
Discharge
24 MGD
Discharge
»•
036
Figure V-l
SAMPLING SITES AT PRIMARY ZINC PLANT A
1576
-------
PRIMARY ZINC SUBCATEGORY SECT - V
Tap
Water
—s-
Lab anc!
Pilot Plan:
Acrivines
: Acic
:Scruooer «s:
0.766 MGD
Figure V-2
SAMPLING SIT:£S AT PRIMARY ZI^'C PLANT B
1577
-------
PRIMARY ZINC SUBCATEGORY
SECT - V
Underflow to
Vacuum Filter
Then to Landfill
Discharge
Figure V-3
SAMPLING SITES AT PRIMARY ZINC PLANT C
-------
PRIMARY ZINC SUBCATEGORY SECT - V
Discharge
*•
Figure V-4
SAMPLING SITES AT PRIMARY ZINC PLANT D
1579
-------
PRIMARY ZINC SUBCATEGORY
SECT - V
Return to Scrubber
•*
Discharge
Discharge
Well
Water •
Figure V-5
SITE;' A: PRIMARY ZINC PLANT E
1580
-------
PRIMARY ZINC SUBCATEGORY SECT - V
Chemical
Precipitation
and
Discharge
SAMPLING
F .-.-are V-6
: AT PRIMARY ZINC PLANT F
1581
-------
PRIMARY ZINC SUBCATEGORY SECT - V
Figure V-7
SAMPLING SITES AT PRIMA.T?V "INC PLANT G
1582
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
SECTION VI
SELECTION OF POLLUTANT PARAMETERS
This section examines chemical analysis data presented in section
V from primary zinc plants and discusses the selection or
exclusion of pollutants for potential limitation. The basis for
the regulation of toxic and other pollutants is discussed in
Section VI of Vol. 1. Additionally, each pollutant selected for
potential limitation is discussed there. That discussion provides
information about where the pollutant originates (i.e., whether
it is a naturally occurring substance, processed metal, or a
manufactured compound); general physical properties and the form
of the pollutant; toxic effects of the pollutant in humans and
other animals; and behavior of the pollutant in POTW at the
concentrations expected in industrial discharges.
The discussion that follows describes the analysis that was
performed to select or exclude pollutants for consideration for
limitations and standards. Pollutants are considered for
limitations and standards if they are present in concentrations
treatable by the technologies considered in this analysis. The
treatable concentrations used for the toxic metals were the long-
term performance values achievable by lime precipitation,
sedimentation, and filtration. The treatable concentrations used
for the toxic organics were the long-term performance values
achievable by carbon adsorption.
As discussed in Section V, EPA collected additional wastewater
sampling data after proposal in an attempt to further
characterize the primary zinc subcategory. As a result of the
new data, the Agency revised its pollutant frequency of
occurrence analysis. However, the same pollutants selected for
further consideration for limitation at proposal have been
selected for consideration at promulgation as discussed below.
After proposal, the Agency also re-evaluated the treatment
performance of activated carbon adsorption to control toxic
organic pollutants. The treatment performance for the acid
extractable, base-neutral extractable, and volatile organic
pollutants has been set equal to the analytical quantification
limit of 0.010 mg/1. The analytical quantification limit for
pesticides and total phenols (by 4-AAP method) is 0.005 mg/1,
which is below the 0.010 mg/1 accepted for the other toxic
organics. However, to be consistent, the treatment performance
of 0.010 mg/1 is used for pesticides and total phenols. The
0.010 mg/1 concentration is achievable, assuming enough carbon is
used in the column and a suitable contact time is allowed. The
frequency of occurrence for 36 of the toxic pollutants has been
redetermined based on the revised treatment performance value.
However, the revised frequency counts did not change the
pollutants selected for consideration for limitation at proposal.
1583
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
CONVENTIONAL AND NONCQNVENTIONAL POLLUTANT PARAMETERS
This study considered samples from the primary zinc subcategory
for three conventional pollutant parameters (oil and grease,
total suspended solids, and pH) and three nonconventional
pollutant parameters (chemical oxygen demand, total organic
carbon, and total phenols).
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED
The following conventional pollutant parameters were selected for
limitation in this subcategory:
Total suspended solids (TSS)
pH
TSS concentrations ranged from 9 to 1,600 mg/1. Current
treatment technology can reduce the TSS concentration to 2.6
mg/1. Treatable concentrations of TSS were found in all ten
samples analyzed. Also, most of the specific methods used to
remove toxic metal do so by chemical precipitation, and the
resulting toxic metal-containing precipitants should not be
discharged. Therefore, total suspended solids are selected for
limitation in this subcategory.
A pH range of 0.7 to 2.7 was observed in the ten raw wastewater
samples. Many deleterious effects are caused by acidic pH
values, or by rapid change in pH. Effective removal of toxic
metals by chemical precipitation requires careful control of pH.
Therefore, pH is selected for limitation in this subcategory.
TOXIC POLLUTANTS
The frequency of occurrence of the toxic pollutants in the raw
wastewater samples taken is presented in Table VI-1 (page 1590).
These data provide the basis for the categorization of specific
pollutants, as discussed below. Table VI-1 'is based on the raw
wastewater data from streams 4, 322, 323, and 332 (see Section
V). These streams include the data the Agency collected at an
electrolytic zinc plant after proposal. Treatment plant sampling
data were not used in the frequency count.
TOXIC POLLUTANTS NEVER DETECTED
The toxic pollutants listed in Table VI-2 (page 1594) were not
detected in any wastewater samples from this subcategory;
therefore, they are not selected for consideration in
establishing limitations:
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION LIMIT
The toxic pollutants listed in Table VI-3 (page 1596) were never
found above their analytical quantification concentration in any
1584
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
wastewater samples from this subcategory; therefore, they are not
selected for consideration in establishing limitations.
TOXIC POLLUTANTS PRESENT BELOW CONCENTRATIONS ACHIEVABLE BY
TREATMENT
The pollutants listed below are not selected for consideration in
establishing limitations because they were not found in any
wastewater samples from this subcategory above concentrations
considered achievable by existing or available treatment
technologies. These pollutants are discussed individually
following the list.
123. mercury
125. selenium
Mercury was detected above its analytical quantification limit in
two of ten raw wastewater samples. The two reported
concentrations are 0.01 mg/1 and 0.008 mg/1. These
concentrations are below the 0.036 mg/1 concentration considered
attainable by identified treatment technology. Therefore,
mercury is not selected for limitation.
Selenium was detected above its analytical quantification limit
in one of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of selenium in the sample was
0.02 mg/1. This value is below'the 0.20 mg/1 concentration
considered attainable by identified treatment technology.
Therefore, selenium is not selected for limitation.
TOXIC POLLUTANTS DETECTED IN A SMALL NUMBER OF SOURCES
Toxic pollutants detectable in the effluent from only a small
number of sources within the subcategory and uniquely related to
only those sources are not appropriate for limitation in a
national regulation. The following pollutants were not selected
for limitation on this basis.
4. benzene
11. 1,1,1-trichloroethane
22. parachlorometa-cresol
38. ethylbenzene
44. methylene chloride
66. bis(2-ethylhexyl) phthalate
68. di-n-butyl phthalate
69. di-n-octyl phthalate
86. toluene
Although these pollutants were not selected for consideration in
establishing nationwide limitations, it may be appropriate, on a
case-by-case basis, for the local permit writer to specify
effluent limitations.
Benzene was found above its treatable concentration (0.010 mg/1)
in one of ten samples with a concentration of 0.018 mg/1.
1585
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
Analysis of two other samples from the same raw wastewater stream
did not detect benzene. Also, no other streams at that same
plant contained this pollutant. In the dcp, all responding
plants indicated that this pollutant was known to be absent or
believed to be absent. For these reasons, benzene is not
selected for limitation.
1,1,1- Trichloroethane was detected above its treatable
concentration (0.01 mg/1) in one of ten samples with a
concentration of 0.017 mg/1. Since 1,1,1-trichloroethane was
found in only one waste stream and since in the dcp all
responding plants indicated that this pollutant was known to be
absent or believed to be absent, it is not selected for
limitation.
Parachlorometa-cresol was detected above its treatable
concentration (0.010 mg/1) in two of ten samples with the
concentrations of 0.014 and 0.042 mg/1 from the same raw
wastewater stream. Analysis of a third sample from the same raw
wastewater stream reported no parachlorometa-cresol. In the dcp,
all responding plants indicated that this pollutant was known to
be absent or believed to be absent. Therefore, it is not
selected for limitation.
Ethylbenzene was found above its treatable concentration (0.01
mg/1) in two of ten samples with concentrations of 0.051 mg/1 and
0.044 mg/1. Analysis of four other samples from the same raw
wastewater streams detected no ethylbenzene. For these reasons,
and since in the dcp all responding plants indicated that this
pollutant was known to be absent or believed to be absent, it is
not selected for limitation.
Methylene chloride was detected above its treatable concentration
(0.010 mg/1) in five of ten samples with concentrations of
ranging from 0.015 to 0.4 mg/1. This pollutant is not
attributable to specific materials or processes associated with
the primary zinc subcategory, however, it is a common solvent
used in analytical laboratories. For these reasons, methylene
chloride is not selected for limitation.
Bis(2-ethylhexyl) phthalate was found above both its analytical
quantification limit and its treatable concentration (0.010 mg/1)
in four of 10 samples, with a maximum concentration of 0.243
mg/1. The presence of this pollutant is not attributable to
materials or processes associated with the primary zinc
subcategory. It is commonly used as a plasticizer in laboratory
and field sampling equipment. EPA suspects sample contamination
as the source of this pollutant. Also, in the dcp all responding
plants indicated that this pollutant was known to be absent or
believed to be absent. Therefore, bis(2-ethylhexyl) phthalate is
not selected for limitation.
One of ten samples analyzed for di-n-butyl phthalate was found to
contain a concentration above its analytical quantification
limit. This sample was above the 0.010 mg/1 concentration
1586
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
considered achievable with treatment. The presence of . this
pollutant is not attributable to materials or processes
associated with the secondary lead subcategory. It is commonly
used as a plasticizer in laboratory and field sampling equipment.
EPA suspects sample contamination as the source of this
pollutant. Also, in the dcp all responding plants indicated that
this pollutant was known to be absent or believed to be absent.
It is thus not selected for limitation.
Di-n-octyl phthalate was found above its analytical
quantification limit (0.010 mg/1) in one of ten samples. The
presence of this pollutant is not attributable to materials or
processes associated with the primary zinc subcategory. It is
commonly used as a plasticizer in laboratory and field sampling
equipment. EPA suspects sample contamination as the source of
this pollutant. Also, in the dcp all responding plants indicated
that this pollutant was known to be absent or believed to be
absent. Therefore, di-n-octyl phthalate is not selected for
limitation.
Toluene was detected in three of ten samples. All three
detections occurred in three separate raw wastewater streams from
the same plant. Additional samples from these streams did not
contain toluene. Two of the measured concentrations were above
the treatable concentration (0.010 mg/1), with values of 0.016
mg/1 and 0.019 mg/1. In the dcp, all responding plants indicated
that this pollutant was known to be absent or believed to be
absent. For these reasons, and since toluene was detected only at
one plant, it is not selected for limitation.
TOXIC POLLUTANTS SELECTED FOR FURTHER CONSIDERATION FOR
ESTABLISHING LIMITATIONS AND STANDARDS
The pollutants listed below are selected for consideration for
establishing limitations and standards for this subcategory. The
toxic pollutants selected are discussed individually following
the list.
115. arsenic
116. asbestos
118. cadmium
119. chromium
120. copper
122. lead
124. nickel
126. silver
128. zinc
Arsenic was detected above its analytical quantification limit in
two of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of arsenic was 0.4 mg/1 in both
raw wastewater samples. This concentration is above the 0.34
mg/1 concentration considered attainable by identified treatment
technology. Therefore, arsenic is selected for further
consideration for limitation.
1587
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
Asbestos was detected in the only raw wastewater sample taken
from the primary zinc subcategory with a concentration of 68
million fibers per liter (MFL). This value is above the 10 MFL
considered attainable by identified treatment technology. There
fore, asbestos is selected for consideration for limitation.
Cadmium was detected above its analytical quantification limit in
two of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of cadmium in the samples was 6.8
mg/1 and 8.3 mg/1. These values are above the 0.049 mg/1
concentration considered attainable by identified treatment
technology. Therefore, cadmium is selected for further
consideration for limitation.
Chromium was detected above its analytical quantification limit
in nine of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of chromium in the samples ranged
from 0.04 mg/1 to 1.2 mg/1. Seven of the nine values are above
the 0.07 mg/1 concentration considered attainable by identified
treatment technology. Therefore, chromium is selected for
further consideration for limitation.
Copper was detected above its analytical quantification limit in
seven of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of copper in the samples ranged
from 0.10 mg/1 to 1.9 mg/1. Four of the seven values are above
the 0.039 mg/1 concentration considered attainable by identified
treatment technology. Therefore, copper is selected for further
consideration for limitation.
Lead was detected above its analytical quantification limit in
five of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of lead in the samples ranged
from 0.05 mg/1 to 40.4 mg/1. Four of the five values are above
the 0.08 mg/1 concentration considered attainable by identified
treatment technology. Therefore, lead is selected for further
consideration for limitation.
Nickel was detected above its analytical quantification limit in
five of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of nickel in the raw wastewater
samples ranged from 0.08 mg/1 to 0.25 mg/1. Two of the five
samples are above the 0.22 mg/1 concentration considered
attainable by identified treatment technology. Nickel is an
extremely toxic pollutant and its discharge should be carefully
monitored. Therefore, nickel is selected for further
consideration for limitation.
Silver was detected above its analytical quantification limit in
five of ten raw wastewater samples taken from the primary zinc
subcategory. The concentration of silver in the samples ranged
from 0.01 mg/1 to 0.18 mg/1. Two of the five values are above
0.07 mg/1 concentration considered attainable by identified
treatment technology. Therefore, silver is selected for further
1588
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
consideration for limitation.
Zinc was detected above its analytical quantification limit in
all ten of the raw wastewater samples taken from the primary zinc
subcategory. The concentration of zinc in the samples ranged
from 259 mg/1 to 24,000 mg/1. These values are well above the
0.23 mg/1 concentration considered attainable by identified
treatment technology. Therefore, zinc is selected for further
consideration for limitation.
1589
-------
Table VI-1
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY ZINC
RAW WASTEWATER
O
I'ol Infant
I . arcu;!) Jit hcne
I. .u-iylnnltrl lc
'
uMizliline
fc . carlx>ii t *!t rarh lor Ido
/ ttilorolwn/ciie
It
4 1
II)
1 1.
12. 1
1 ).
14.
I1).
If..
17.
IB.
. 2 .4- 1 1 ti:h loi otteim'no
loxacliliiriitienzme
,2 i s(chloroinethyl) ether
jls(2 rliloro"lhyl) ether
19. 2-chlorwihyl vinyl ether
20. 2 -ch loronaphthalene
21 . 2.4,6-t rlchlorophenol
22. parachlororoeta cresol
2). chloroform
24. 2-ch lorophenot
25.
26.
27.
28.
2'J.
JO.
51.
32.
)).
,2-dlchlorobenzone
, i-dlchlorobenzene
,4 dlchlorobenzene
, V -dlchlorobunzldlne
, 1 -dichltjr'oethy lei>e
. 2 - 1 r;ui3 -d 1 ch loroethy lene
,4 di(1iTon)()hti)ol
, 2 -cl I cli loropropane
,3-dlrhlnrupropyleiie
34.
2.4-dlnltrotoluene
2,6-d1nlt rotoInene
1 ,2 dtplteny Ihydraziw?
Analyt leal
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY ZINC
RAW WASTEWATER
(.n
W
H'
Pol Kit ant.
IH. ethyl benzene
19. fhioranthene
-M). 't-chlorophenyl phenyl ether
'"' 'i lunnophonyl phmyl rl her
rW. !»(n(2 -chloroi3<»pi <)i»yI) ethtT
'•]. bts(2-chloroellioxy) methane
Vi. melhylene chlorl'). methyl chlorlile
'i(>. iwthyl hromlile
tt • . hrmnoform
'iH illchlorobromomethane
V). t r I chlorof IIMX <*m't \\nrv
50. illchlorudir liuroinethaiie
51. chlorodlhr'>. naphthalene
56. nit.robenzaie
*) /. i nl t tophctml
58. 'i-nltrophenol
59. 2.4-clinItrophenol
6ls(2-ethylhexyl) phthalate
67. biityl Ix-nzyl phthalate
68. mcent rat Ion
Ins/ 1) (a)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
Treatable
Concentra-
tion (mR/l)(
0.010
0.010
0.010
0.010
0.010
o.oto
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
Number of
Streams
b) Analyzed
It
It
It
It
It
It
4
It
It
It
It
It
It
It
It
1^
It
It
It
It
It
It
It
It
It
It
It
It
It
It
It
It
It
It
it
It
It
Number of
Samples
Analyzed
10
10
10
10
10
10
10
10
to
10
to
to
10
to
to
10
10
10
10
10
10
10
10
10
10
10
10
10
to
10
10
10
10
to
10
to
to
ND
8
9
10
10
10
10
3
10
10
3
9
10
10
10
10
10
to
to
9
8
9
to
10
10
8
10
10
8
2
10
2
9
8
to
10
10
10
Detected Detected
Detected Below Below Treat- Above Treat-
Quant If Icat Ion able Concen- able Concen-
Concentration t ration t rat ion
2
\
1 1 5
7
1
1
2
1
2
2
it it
1 \
1
2
ISI
H
"Z
o
en
c
ro
o
S
w
en
M
o
I
<
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY ZINC
RAW WASTEWATER
Ul
U3
tsj
75.
76.
1 1 .
/8.
79.
80.
81.
82.
83.
84.
8").
86.
87.
88.
89.
•HI.
91 .
92.
93.
'tt)0
alplia-endctsulfan
betH-er*lo9ul f an
emiosul fan sulfate
erxlrln
eivlrln alrKiyC1!-I2'.8
K:B-I260
(Til- 1 016
(tl)
(cJ)
(cJ)
(e)
(e)
(e)
(e)
Analytical
(>wnt If (cation
CixK'entratlon
(n«/l)(a)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
O.OU5
0.005
Treatable
Concentra-
tion (n«/l)(b)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
Number of
Streams
Analyzed
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
3
4
3
3
3
Number of
Samples
Analyzed
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
8
8
10
8
8
8
Itetected Detected
Detected Below Below Treat- Alxwe Treat
Quantification able Concen- able Concen-
ND Concentration t rat Ion tratlon
10
V
10
10
10
8
t
10
10
8
8
7
7
10
10
10
10
10
10
10
9
10
10
10
9
9
8
5
5
8
5
10
8
8
10
8
8
8
1
2
1
2
2
1 I
3
1
1
1
2
5
5
'i
5
N
H
2!
o
en
c!
W
o
M
O
O
Cfi
M
O
-------
Table .VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY ZINC
RAW WASTEWATER
VD
UJ
Pollutant.
1 i '3. tnxaphene
1 1 4. aril 1 m inv
1 15. aittmlc
1 16. asbestos
117. beryllium
1 IB. ca<
o.oto
0.47
0.34
10 MFL
0.20
0.49
0.07
0.39
0.047
0.08
0.036
0.22
0.20
0.07
0.34
0.23
Not Analyzed
Ninter of
Streams
Analyzed
4
4
4
1
4
4
4
4
4
4
4
4
3
4
4
4
Nuifcer of
Samples
Analyzed
10
10
10
1
to
10
10
10
10
10
10
10
6
10
8
10
Detected Below
Quantification
ND Concentration
10
9 1
5
10
8
1
3
9 1
5
8
5
5
1 4
8
Detected
Below Treat-
able Concen-
tration
3
2
3
1
2
3
1
3
Detected
Above Treat-
able Concen-
tration
2
1
2
7
4
4
2
2
10
(a) Analytical quantification concentration was reported with the data (see Section V).
b) Treatable concentrations are based on performance of line precipitation, sedimentation, and filtration for toxic metal pollutants and activated
en i lion adsorption for toxic organic pollutants.
i--).(d).(e) Reported together for two samples.
50
H
3
55
O
in
c,
w
O
M
O
O
M
O
I
<
(M Analytical quantification concentration for EPA Method 335.2. Total Cyanide Methods for Chemical Analysis ot Water and Wastes. EPA-6OO/4- 79-020,
March 1979.
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
TABLE VI-2
TOXIC POLLUTANTS NEVER DETECTED
2. acrolein
3. acrylonitrile
5. benzidine
6. carbon tetrachloride (tetrachloromethane)
7. chlorobenzene
8. 1,2,4-trichlorobenzene
9. hexachlorobenzene
10. 1,2-dichloroethane
12. hexachloroethane
13. 1,1-dichloroethane
14. 1,1,2-trichloroethane
15. 1,1,2,2-tetrachloroethane
16. chloroethane
17. DELETED
19. 2-chloroethyl vinyl ether
20. 2-chloronaphthalene
24. 2-chlorophenol
25. 1,2-dichlorobenzene
26. 1,3-dichlorobenzene
27. 1,4-dichlorobenzene
28. 3,3'-dichlorobenzidine
29. 1,1-dichloroethylene
30. 1,2-trans-dichloroethylene
31. 2,4-dichlorophenol
32. 1,2-dichloropropane
33. 1,3-dichloropropylene
35. 2,4-dinitrotoluene
36. 2,6-dinitrotoluene
37. 1,2-diphenylhydrazine
40. 4-chlorophenyl phenyl ether
41. 4-bromophenyl phenyl ether
42. bis(2-chloroisopropyl) ether
43. bis(2-chloroethoxy) methane
45. methyl chloride
46. methyl bromide
49. DELETED
50. DELETED
51. chlorodibromomethane
52. hexachlorobutadiene
53. hexachlorocyclopentadiene
54. isophorone
55. naphthalene
59. 2,4-dinitrophenol
60. 4,6-dinitro-o-cresol
61. N-nitrosodimethylamine
63. N-nitrosodi-n-propylamine
64. pentachlorophenol
67. butyl benzyl phthalate
71. dimethyl phthalate
72. benzo(a)anthracene
73. benzo(a)pyrene
1594
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
74. 3,4-benzofluoranthene
75. benzo(k)fluoranthene
77. acenaphthylene
78. anthracene (a)
79. benzo(ghiJperylene
82. dibenzo(a,h)anthracene
83. indeno (1,2,3-cd)pyrene
88. vinyl chloride
89. aldrin
90. dieldrin
91. chlordane
92. 4,4'-DDT
93. 4,4'-DDE
94. 4,4'-ODD
96. beta-endosulfan
97. endosulfan sulfate
98. endrin
106. PCB-1242 (b)
107. PCB-1254 (b)
108. PCB-1221 (b)
109. PCB-1232 (c)
110. PCB-1248 (c)
111. PCB-1260 (c)
112. PCB-1016 (c)
113. toxaphene
117. beryllium
127. thallium
129. 2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD)
(a) Reported with phenanthrene for two samples.
(b),(c) Reported together for two samples.
1595
-------
PRIMARY ZINC SUBCATEGORY SECT - VI
TABLE VI-3
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION LIMIT
1. acenaphthene
18. bis(chloromethyl)ether
21. 2,4,6-trichlorophenol
23. chloroform
34. 2,4-dimethyl phenol
39. fluoranthene
47. bromoform
48. dichlorobromomethane
56. nitrobenzene
57. 2-nitrophenol
58. 4-nitrophenol
62. N-nitrosodiphenylamine
65. phenol
70. diethyl phthalate
76. chrysene
80. fluorene
81. phenanthrene (a)
84. pyrene
85. tetrachloroethylene
87. trichloroethylene
95. alpha-endosulfan
99. endrin aldehyde
100. heptachlor
101. heptachlor epoxide
102. alpha-BHC
103. beta-BHC
104. gamma-BHC
105. delta-BHC
114. antimony
121. cyanide (total)
(a) Reported with anthracene as a combined value for two samples,
1596
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PRIMARY ZINC SUBCATEGORY SECT - VII
SECTION VII
CONTROL AND TREATMENT TECHNOLOGIES
The preceding sections of this supplement discussed the waste
water sources, flows and characteristics of the wastewaters from
primary zinc plants. This section summarizes the description of
these wastewaters and indicates the treatment technologies which
are currently practiced in the primary zinc subcategory.
TECHNICAL BASIS OF BPT
EPA promulgated BPT effluent limitations guidelines for the
primary zinc subcategory on February 27, 1975. The BPT effluent
limitations limited the discharge of arsenic, cadmium, selenium,
zinc, and TSS and required the control of pH. The best
practicable control technology currently available is the reuse
or recycle of specific wastewater to minimize discharge and
treatment of the remaining wastewater by lime precipitation and
sedimentation. Specific water reuse and recycle measures included
are recycle of casting contact cooling water, and the
minimization of acid plant blowdown through water reuse and
recycle. Acid plant blowdown is included in the BPT effluent
limitations for both the primary zinc and metallurgical acid
plants subcategories. However, this double counting of
limitations is eliminated in the promulgated BAT effluent
limitations for this rulemaking.
CURRENT CONTROL AND TREATMENT PRACTICES
This section presents a summary of the control and treatment
technologies that are currently being applied to each of the
wastewater sources in this subcategory. As discussed in Section
V, wastewater associated with the primary zinc subcategory is
characterized by the presence of the toxic metal pollutants and
suspended solids. The raw (untreated) wastewater data for
specific sources as well as combined waste streams is presented
in Section V. Generally, these pollutants are present in each of
the waste streams at treatable concentrations, so these waste
streams are commonly combined for treatment to reduce the
concentrations of these pollutants. Construction of one
wastewater treatment system for combined treatment allows plants
to take advantage of economies of scale and, in some instances,
to combine streams of differing alkalinity to reduce treatment
chemical requirements. Six plants in this subcategory currently
have combined wastewater treatment systems, three have lime
precipitation and sedimentation, and two have lime precipitation,
sedimentation and filtration. One plant practices lime
precipitation and sedimentation and sulfide precipitation and
filtration. One of the two plants operating lime and settle also
utilizes sulfide precipitation periodically. As such, three
options have been selected for consideration for BAT, BDT, and
pretreatment in this subcategory, based on combined treatment of
1597
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PRIMARY ZINC SUBCATEGORY SECT -VII
s
these compatible waste streams.
ZINC REDUCTION FURNACE WET AIR POLLUTION CONTROL
In the pyrolytic production of zinc, zinc oxide is reduced to
metallic zinc in vertical retort or electrothermic furnaces. The
off-gases from this process may be treated by wet air pollution
control equipment to remove particulate matter, uncondensed zinc,
and carbon monoxide. One of the pyrolytic zinc plants currently
uses wet scrubbers on its electrothermic furnaces. The
wastewater from the wet scrubbers is treated by chemical
precipitation (with NaOH) and sedimentation. Following
treatment, approximately 88 percent of the scrubbing liquor is
recycled.
PRELEACH WASTEWATER
Two plants preleach zinc concentrates to control magnesium in the
electrolytic circuit. At one plant, the wastewater is equalized
with other process wastewater, then treated with lime
precipitation and sedimentation before discharge. The second
plant currently is not operating this process. However, when
operating, the preleach wastewater is treated with other plant
wastewater in a lime precipitation and sedimentation treatment
system.
LEACHING WET AIR POLLUTION CONTROL
Contact scrubbers are used at two of the electrolytic plants to
control leaching air emissions. One of the pyrolytic plants also
uses leaching scrubbers in its cadmium recovery process. One of
the plants (the pyrolytic plant) completely recycles its
scrubbing liquor. One of the electrolytic plants completely
evaporates the scrubber liquor in an evaporation pond. The third
plant did not report its discharge rate, however, it did report
that recycling is used to reduce the discharge from the leaching
scrubbers. Wastewater from this plant is treated by chemical
precipitation (with lime) and sedimentation. A polymer
flocculant is added to aid in the settling of solids.
ELECTROLYTE BLEED WASTEWATER
One plant bleeds a portion of the spent electrolyte after
electrolysis to control magnesium. This wastewater is
neutralized with limestone, then mixed with other plant process
water before entering central treatment. Central treatment
consists of lime precipitation and sedimentation.
CATHODE AND ANODE WASHING WASTEWATER
Several plants report that wastewater is produced from
electrolytic zinc refining operations. At three plants this
wastewater is associated with the washing of cathodes and anodes.
The two plants which wash cathodes and anodes use chemical
precipitation and sedimentation to treat their waste streams.
1598
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PRIMARY ZINC SUBCATEGORY SECT - VII
The third plant reuses the wash water in roaster scrubbers . after
settling in a holding pond. Lime is the usual precipitating
agent used. Polymer is also sometimes used as a flocculant.
CASTING WET AIR POLLUTION CONTROL
Particulates produced from the melting of cathode zinc prior to
casting are removed by air pollution control devices. Three of
the electrolytic plants use baghouses to remove melting furnace
emissions. Another electrolytic plant that is now shut down used
wet scrubbers. The scrubbing liquor was discharged for treatment
by chemical precipitation and sedimentation.
CASTING CONTACT COOLING
Four of the nine plants in this subcategory report wastewater
associated with casting contact cooling. Two plants achieve zero
discharge through evaporation of the contact cooling wastewater.
Other plants limit the discharge of contact cooling wastewater
through partial evaporation and recycle. Partial evaporation
results when the cooling water vaporizes after contacting the
cast zinc. At two plants in this subcategory, contact cooling
wastewater is combined with wastewater from other processes and
treated by chemical precipitation (a polymer flocculant is used
by one of the plants to aid in the settling of solids) and
sedimentation. One of these plants also uses a polishing filter.
CADMIUM PLANT WASTEWATER
Wastewater from cadmium plants may originate from various sources
such as cadmium sponge washing, leaching tank discharge, or
rinsing cadmium balls. Four plants report wastewater associated
with their cadmium plants. One plant recycles its cadmium plant
wastewater. Two plants use chemical precipitation and
sedimentation (filtration is also used at one plant) to treat
their wastewater. The fourth plant practices precipitation with
caustic, filtration, and sulfide precipitation and filtration,
followed by lime neutralization before discharge to an
evaporation impoundment.
CONTROL AND TREATMENT OPTIONS
The Agency considered three control and treatment technology
options that are applicable to the primary zinc subcategory.
These options, discussed below, were selected, after examination
of the raw wastewater data, which showed the presence of toxic
metal pollutants and TSS.
Examination of the raw wastewater data does not show any toxic
organic pollutants at or above treatable concentrations. Also,
organic pollutants are not characteristic of the raw materials
and processing agents used in this subcategory. Therefore/
Option E, which includes activated carbon adsorption, was not
considered as an appropriate treatment technology.
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PRIMARY ZINC SUBCATEGORY SECT - VII
OPTION A
Option A for the primary zinc subcategory is equivalent to the
BPT control and treatment technologies. The BPT end-of-pipe
treatment scheme consists of chemical precipitation and
sedimentation. Chemical precipitation and sedimentation consists
of lime addition to precipitate metals followed by gravity
sedimentation for the removal of suspended solids, including the
metal precipitates.
OPTION B
Option B for the primary zinc subcategory consists of the
chemical precipitation and sedimentation considered in Option A,
plus in-plant reduction of process wastewater flow. Water
recycle and reuse are the control mechanisms for flow reduction.
OPTION C
Option C for the primary zinc subcategory includes sulfide
precipitation and sedimentation followed by multimedia filtration
technology added at the end of the Option B treatment scheme,
which consists of chemical precipitation, sedimentation, and in-
process flow reduction. Extensive treatment performance data
submitted to the Agency by two properly designed plants in the
subcategory demonstrate that the proposed BAT mass limitations
are not achievable. The principal reason for not being able to
attain the filtration performance data is the inability to
achieve the combined metals data lime and settle values.
However, the Agency believes the addition of sulfide
precipitation, in conjunction with multimedia filtration, will
achieve the treatment performance values as proposed (see Section
X - Option Selection). Multimedia filtration is used to remove
suspended solids, including precipitates of metals, beyond the
concentrations attainable by gravity sedimentation. The filter
suggested is the gravity, mixed-media type, although other forms
of filters such as rapid sand filters or pressure filters also
perform satisfactorily.
TREATMENT TECHNOLOGIES REJECTED AT PROPOSAL
Two additional treatment technologies were considered prior to
proposing effluent limitations for this subcategory as discussed
below. Activated alumina and reverse osmosis were rejected
because they were not demonstrated in the nonferrous metals
manufacturing category nor were they readily transferable from
other categories. These options are discussed below.
OPTION D
Option D for the primary zinc subcategory consisted of the
chemical precipitation, sedimentation, in-process flow reduction,
and multimedia filtration technologies considered in Option C
with the addition of activated alumina technology at the end of
the Option C treatment scheme. Option D was considered as the
1600
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PRIMARY ZINC SUBCATEGORY SECT - VII
technology basis because it could, in theory, reduce arsenic
concentrations in wastewaters generated from primary zinc
smelters.
OPTION F
Option F for the primary zinc subcategory consisted of reverse
osmosis and evaporation technology added to the treatment scheme
of Option C, which consisted of chemical precipitation,
sedimentation, in-process flow reduction, and multimedia
filtration. Option F was provided for complete recycle of the
treated water by controlling the concentration of dissolved
solids. Multiple effect evaporation was included to dewater the
brines rejected from reverse osmosis.
1601
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PRIMARY ZINC SUBCATEGORY SECT - VIII
SECTION VIII
COSTS, ENERGY AND NONWATER QUALITY ASPECTS
This section presents the costs associated with the control and
treatment technologies identified in Section VII for wastewaters
from primary zinc plants. The energy consumption of each
technology is presented, and the effect of each technology on
non-water quality aspects of the environment, such as air
pollution, are discussed.
TREATMENT OPTIONS CONSIDERED
Three treatment options have been considered since proposal for
the primary zinc subcategory. These options are summarized below
and are schematically presented in Figures X-l through X-3 (pages
1629 - 1631).
OPTION A
Option A consists of chemical precipitation and sedimentation
(lime and settle) technology applied to combined wastewater
streams. Option A represents no additional cost since this
technology is in place at all plants in the primary zinc
subcategory.
OPTION B
Option B consists of in-process flow reduction measures added to
the chemical precipitation and sedimentation (lime and settle)
technology of Option A. Specifically, flow reduction measures
include the recycle of zinc reduction furnace scrubber water,
casting scrubber water, leaching scrubber water, and the recycle
of casting contact cooling water. Flow reduction for wet air
pollution control liquor is based on holding tanks, while contact
cooling water flow is reduced through the use of cooling towers.
OPTION C
Option C consists of the in-process flow reduction measures of
Option B, and chemical precipitation and sedimentation, sulfide
precipitation and sedimentation, and multimedia filtration end-
of-pipe treatment technology.
COST METHODOLOGY
A detailed discussion of the methodology used to develop the
compliance costs is presented in Section VIII of the General
Development Document. Plant-by-plant compliance costs have been
estimated for the nonferrous metals manufacturing category and
are presented in the administrative record supporting this
regulation. A comparison of the costs developed for proposal and
1603
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PRIMARY ZINC SUBCATEGORY SECT - VIII
the revised costs for the regulation are presented in Tables
VIII-1 and VIII-2 (page 1507) for the direct and indirect
dischargers.
Each of the major assumptions used to develop compliance costs is
presented in Section VIII of Vol. I. However, each subcategory
contains a unique set of waste streams requiring certain
subcategory-specific assumptions to develop compliance costs.
Seven major assumptions are discussed briefly below.
(1) Capital and annual costs for plants discharging
wastewater in both the primary zinc and metallurgical
acid plants subcategories were attributed to each
subcategory on a flow-weighted basis.
(2) Because the compliance costs need only represent
incremental costs which primary zinc plants may be
expected to incur in complying with this regulation,
annual costs for in-place treatment used to comply
with the promulgated BPT regulation for this
subcategory were not included in a plant's total cost
of compliance for this regulation.
(3) Zero discharge of the leaching scrubber water is
accomplished by 100 percent recycle through a holding
tank.
(4) Sludge generated by the sulfide precipitation and
settle process was considered hazardous waste for
disposal purposes.
(5) Recycle of zinc reduction furnace scrubber liquor
and casting scrubber liquor is based on recycle
through holding tanks. Annual costs associated
with maintenance and sludge disposal are included in
the estimated compliance costs. If a plant currently
recycles scrubber liquor, capital costs of the
recycle equipment (piping, pumps, and holding tanks)
were not included in the compliance costs. (6)
Recycle of casting contact cooling water is
accomplished with cooling towers. Annual costs
associated with maintenance and chemical treatment
to prevent biological growth, corrosion, and scale
formation are included in the estimated compliance
costs. If a plant currently recycles casting contact
cooling water, capital costs of the recycle
equipment (piping, pumps, and cooling tower) were
not included in the compliance costs.
NONWATER QUALITY ASPECTS
Nonwater quality impacts specific to the primary zinc
subcategory, including energy requirements, solid waste and air
pollution, are discussed below.
1604
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PRIMARY ZINC SUBCATEGORY SECT - VIII
ENERGY REQUIREMENTS
The methodology used for determining the energy requirements for
the various treatment options is discussed in Section VIII of the
General Development Document. No additional energy is required
for Option A as a result of this regulation since BPT is in
place. Energy requirements for Options B and C are 0.02 MW-hr/yr
and 0.08 MW-hr/yr, respectively. These values include the energy
requirements of lime precipitation and sedimentation technology
for plants without this technology in place. Option C represents
less than one percent of a typical plant's electrical energy
usage. It is therefore concluded that the energy requirements of
the treatment options considered will have no significant impact
on total plant energy consumption.
SOLID WASTE
Sludges associated with the primary zinc subcategory will
necessarily contain additional quantities (and concentrations) of
toxic metal pollutants. Wastes generated by primary smelters and
refiners are currently exempt from regulation by Act of Congress
(Resource Conservation and Recovery Act (RCRA)), Section 3001(b).
Consequently, sludges generated from treating primary industries'
wastewater are not presently subject to regulation as hazardous
wastes.
Sludges generated by lime precipitation, sedimentation, and
filtration are not likely to exhibit a characteristic of
hazardous waste. By the addition of excess lime during
treatment, similar sludges, specifically toxic metal bearing
sludges, generated by other industries such as the iron and steel
industry passed the Extraction Procedure (EP) toxicity test. See
40 CFR 261.24. The Agency believes that the wastewater sludges
will similarly not be EP toxic if the recommended technology is
applied.
However, the technology basis for the primary zinc subcategory
also includes sulfide precipitation for the control of zinc,
cadmium, and other toxic metals. The Agency believes sludge
generated through sulfide precipitation (followed by
sedimentation) will be classified as hazardous under RCRA. .The
costs of hazardous waste disposal for sulfide sludges were
considered in the economic analysis for this subcategory (even
though the waste is now exempt), and they were determined to be
economically achievable.
The Agency estimates implementation of lime and settle, in
conjunction with sulfide precipitation and settle technology,
will generate approximately 235 tons per year of wastewater
treatment sludge. Sulfide precipitation will generate
approximately 35 tons per year of this total. Multimedia
filtration technology will not generate any significant amount of
sludge over that resulting from lime precipitation and sulfide
precipitation.
1605
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PRIMARY ZINC SUBCATEGORY SECT - VIII
Although it is the Agency's view that solid wastes generated as a
result of lime precipitation are not expected to be hazardous,
generators of these wastes must test the waste to determine if
the wastes meet any of the characteristics of hazardous waste
(see 40 CFR 262.11).
If these wastes should be identified or are listed as hazardous,
they will come within the scope of RCRA's "cradle to grave"
hazardous waste management program, requiring regulation from the
point of generation to point of final disposition. EPA's
generator standards would require generators of hazardous
nonferrous metals manufacturing wastes to meet containerization,
labeling, recordkeeping, and reporting requirements; if plants
dispose of hazardous wastes off-site, they would have to prepare
a manifest which would track the movement of the wastes from the
generator's premises to a permitted off-site treatment, storage,
or disposal facility. See 40 CFR 262.20 45 FR 33142 (May 19,
1980), as amended at 45 FR 86973 (December 31, 1980). The
transporter regulations require transporters of hazardous wastes
to comply with the manifest system to assure that the wastes are
delivered to a permitted facility. See 40 CFR 263.20 45 FR 33151
(May 19, 1980), as amended at 45 FR 86973 (December 31, 1980).
Finally, RCRA regulations establish standards for hazardous waste
treatment, storage, and disposal facilities allowed to receive
such wastes. See 40 CFR Part 464 46 FR 2802 (January 12, 1981),
47 FR 32274 (July 26, 1982).
Even if these wastes are not identified as hazardous, they still
must be disposed of in compliance with the Subtitle D open
dumping standards, implementing 4004 of RCRA. See 44 FR 53438
(September 13, 1979). The Agency has calculated as part of the
costs for wastewater treatment the cost of hauling and disposing
of these wastes. For more details, see Section VII of the
General Development Document.
AIR POLLUTION
There is no reason to believe that any substantial air pollution
problems will result from the implementation of flow reduction,
chemical precipitation and sedimentation, and filtration. These
technologies generally transfer pollutants to solid waste and do
not involve air stripping or any other physical process likely to
transfer pollutants to air. Minor amounts of sulfur may be
emitted during sulfide precipitation, and water vapor containing
some particulate matter will be released in the drift from
cooling tower systems which are used for recycling casting
contact cooling water. However, the Agency does not consider
this impact to be significant.
1606
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PRIMARY ZINC SUBCATEGORY SECT - VIII
TABLE VIII-1
COST OF COMPLIANCE FOR THE PRIMARY ZINC SUBCATEGORY
DIRECT DISCHARGERS
Proposal Promulgation
Option Capital Cost Annual Cost Capital Cost Annual Cost
A 00 0 0
B 310000 64000 94000 55000
C 3498000 2215000 457000 236000
TABLE VIII-2
COST OF COMPLIANCE FOR THE PRIMARY ZINC SUBCATEGORY
INDIRECT DISCHARGERS
Proposal Promulgation
Option
A
B
C
Capital Cost
*
*
*
Annual Cost
*
*
*
Capital Cost
0
2900
112000
Annual C
0
4600
58000
NOTE: All values in March, 1982 Dollars
* EPA did not promulgate pretreatment standards for existing
sources in the primary zinc subcategory.
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PRIMARY ZINC SUBCATEGORY SECT - IX
SECTION IX
BEST PRACTICABLE TECHNOLOGY CURRENTLY AVAILABLE
EPA promulgated BPT effluent limitations for the primary zinc
subcategory on February 27, 1975 as Subpart H of 40 CFR Part 421.
At this time, EPA is not proposing any modifications to these
existing BPT effluent limitations. The BPT effluent limitations
apply to discharges resulting from the production of primary zinc
by either electrolytic or pyrolytic means, as well as discharge
resulting from the by-product recovery of sulfuric acid in
primary zinc acid plants.
Discharges from primary zinc acid plants are also regulated at
BPT in the metallurgical acid plants subcategory. This
modification of the metallurgical acid plants subcategory to
include primary zinc acid plants, without deletion of the BPT
acid plant allowance provided in the primary zinc subcategory,
creates the potential for double counting of the BPT acid plant
allowance at primary zinc plants. However, EPA believes that
existing permits at these plants will be modified to reflect the
BAT requirements where there is no such double counting.
Therefore, this apparent inconsistency should not have any actual
effect on existing permits. Pollutants regulated by these
limitations are arsenic, cadmium, selenium, zinc, TSS, and pH.
The effluent limitations established by BPT standards are based
on chemical precipitation and sedimentation and are as follows:
Effluent Limitations
Average of Daily Values
Effluent Maximum for for 30 Consecutive
Characteristic Any One Day Days Shall Not Exceed
Metric Units (kg/kkg of product)
English Units (lb/1,000 Ib of product)
TSS 0.42 0.21
As 0.0016 0.0008
Cd 0.008 0.004
Se 0.08 0.04
Zn 0.08 0.04
pH Within the range of 6.0 to 9.0
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PRIMARY ZINC SUBCATEGORY SECT - X
SECTION X
BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
The effluent limitations are based on the best control and
treatment technology used by a specific point source within the
industrial category or subcategory, or by another industry where
it is readily transferable. Emphasis is placed on additional
treatment techniques applied at the end of the treatment systems
currently employed for BPT, as well as reduction of the amount of
water used and discharged, process control, and treatment
technology optimization.
The factors considered in assessing best available technology
economically achievable (BAT) include the age of equipment and
facilities involved, the process used, process changes, nonwater
quality environmental impacts (including energy requirements),
and the costs of application of such technology (Section 304(b)
(2)(B) of the Clean Water Act). BAT represents the best
available technology economically achievable at plants of various
ages, sizes, processes, or other characteristics. Where the
.Agency has found the existing performance to be uniformly
inadequate, BAT may be transferred from a different subcategory
or category. BAT may include feasible process changes or
internal controls, even when not in common industry practice.
The required assessment of BAT considers costs, but does not
require a balancing of costs against effluent reduction benefits
(see Weyerhaeuser v. Costle, 590 F.2d 1011 (D.C. Cir. 1978)).
However, in assessing the proposed BAT, the Agency has given
substantial weight to the economic achievability of the
technology.
On February 27, 1975, EPA promulgated technology-based effluent
BAT limitations for the primary zinc subcategory. The main
purpose of these effluent guidelines was to limit quantities of
total suspended solids, arsenic, cadmium, selenium, zinc, and the
range of pH found in primary zinc discharges. EPA is amending
the promulgated BAT effluent limitations for the primary zinc
subcategory pursuant to the provisions of Sections 301, 304, 306,
and 307 of the Clean Water Act and its amendments.
TECHNICAL APPROACH TO BAT
The Agency reviewed a wide range of technology options and
evaluated the available possibilities to ensure that the most
effective and beneficial technologies'were used as the basis of
BAT. To accomplish this, the Agency elected to examine three
technology options which could be applied to the primary zinc
subcategory as BAT options.
The three options examined for BAT are discussed below. The
1611
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PRIMARY ZINC SUBCATEGORY SECT - X
first option considered is the same as the BPT treatment and
control technology.
In summary, the treatment technologies considered for the primary
zinc subcategory are:
Option A (Figure X-l, page 1629) is based on:
o Chemical precipitation (lime) arid sedimentation
Option B (Figure X-2, page 1630) is based on:
o Chemical precipitation (lime) and sedimentation
o In-process flow reduction of scrubber liquor and
casting contact cooling water
Option C (Figure X-3, page 1631) is based on:
o Chemical precipitation (lime) and sedimentation
o In-process flow reduction of scrubber liquor and
casting contact cooling water
o Sulfide precipitation and sedimentation
o Multimedia filtration
OPTION A
Option A for the primary zinc subcategory is equivalent to the
BPT control and treatment technologies. The BPT end-of-pipe
treatment scheme consists of chemical precipitation and
sedimentation. Chemical precipitation and sedimentation consists
of lime addition to precipitate metals followed by gravity
sedimentation for the removal of suspended solids including metal
precipitates (see Figure X-l, page 1629).
OPTION B
Option B for the primary zinc subcategory consists of the
chemical precipitation and sedimentation technologies of Option A
plus in-plant reduction of process wastewater flow (see Figure X-
2, page 1630). Flow reduction measures, including in-process
changes, result in the elimination of some wastewater streams and
the concentration of pollutants in other effluents. As explained
in Section VII of Vol. I, treatment of a more concentrated
effluent allows achievement of a greater net pollutant removal
and introduces the possible economic benefits . associated with
treating a lower volume of wastewater. Methods used in Option B
to reduce process wastewater generation or discharge rates
include the following:
Recycle of Water Used iri Wet Air Pollution Control
Recycle or reuse of water used in wet air pollution control is
being considered for BAT. There are three wastewater sources
associated with wet air pollution control which are regulated
under these effluent limitations:
1612
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PRIMARY ZINC SUBCATEGORY SECT - X
1. Zinc reduction furnace wet air pollution control,
2. Leaching wet air pollution control, and
3. Casting.
Table X-l (page 1622) presents the number of plants reporting
wastewater use with these sources, the number of plants
practicing recycle or reuse of scrubber liquor, and the range of
recycle values being used. The water picks up particulates and
fumes from the air, and a blowdown or periodic cleaning may be
necessary to prevent the build-up of dissolved and suspended
solids.
Recycle of_ Casting Contact Cooling Through Cooling Towers
Recycle of casting contact cooling water is being considered for
BAT. The function of casting contact cooling water is to quickly
remove heat from the cast zinc. Therefore, the principal
requirement of the water is that it be cool.
There is sufficient industry experience with casting contact
cooling wastewater within the nonferrous metals manufacturing
category to assure the success of this technology using cooling
towers or heat exchangers to cool the water prior to recycle
(refer to Section VII of Vol. I). A blowdown or periodic
cleaning may be needed to prevent a build-up of dissolved and
suspended solids, which causes surface imperfections on the cast
metal. (EPA has determined that a blowdown of 10 percent of the
water applied in a process is adequate.)
OPTION C
Option C for the primary zinc subcategory consists of the in-
process flow reduction, chemical precipitation, and sedimentation
technologies of Option B plus sulfide precipitation,
sedimentation, and multimedia filtration technology added at the
end of the Option B treatment scheme (see Figure X-3, page 1631).
Sulfide precipitation and sedimentation is added to reduce
cadmium, zinc, and other toxic metal concentrations below
concentrations achievable with lime and settle. Multimedia
filtration is used to remove suspended solids, including
precipitates of metals, beyond the concentration attainable by
gravity sedimentation. The filter suggested is of the gravity,
mixed media type, although other forms of filters, such as rapid
sand filters or pressure filters, would perform satisfactorily.
1613
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PRIMARY ZINC SUBCATEGORY SECT - X
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
As one means of evaluating each technology option, EPA developed
estimates of the pollutant removal estimates and the compliance
costs associated with each option. The methodologies are
described below.
POLLUTANT REMOVAL ESTIMATES
A complete description of the methodology used to calculate the
estimated pollutant removals achieved by the application of the
various treatment options is presented in Section X of Vol. I.
The pollutant removal estimates have been revised from proposal
based on comments and new data. However, the methodology for
calculating pollutant removals was not changed. The data used
for estimating pollutant removals are the same as those used .to
revise the compliance costs.
Sampling data collected during the field sampling program were
used to characterize the major waste streams considered for
regulation. At each sampled facility, the sampling data were
production normalized for each unit operation (i.e., mass of
pollutant generated per mass of product manufactured). This
value, referred to as the raw waste, was used to estimate the
mass of toxic pollutants generated within the primary zinc
subcategory. By multiplying the total subcategory production for
a unit operation by the corresponding raw waste value, the mass
of pollutant generated for that unit operation was estimated.
The volume of wastewater discharged after the application of each
treatment option was estimated for each operation at each plant
by comparing the actual discharge to the regulatory flow. The
smaller of the two values was selected and summed with the other
plant flows. The mass of pollutant discharged was then estimated
by multiplying the achievable concentration values attainable by
the option (mg/1) by the estimated volume of process wastewater
discharged by the subcategory. The mass of pollutant removed is
simply the difference between the estimated mass of pollutant
generated within the subcategory and the mass of pollutant
discharged after application of the treatment option. The total
of both these calculations represents estimated mass loadings for
the subcategory. The pollutant removal estimates for the direct
dischargers in the primary zinc subcategory are presented in
Table X-2 (page 1623).
COMPLIANCE COSTS
Compliance costs presented at proposal were estimated using cost
curves, which related the total costs associated with.
installation and operation of wastewacer treatment technologies
to plant process wastewater discharge. EPA applied these curves
on a per plant basis, a plant's costs — both capital, and
operating and maintenance -- being determined by what treatment
it has in place and by its individual process wastewater
discharge (from dcp). The final step was to annualize the capital
1614
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PRIMARY ZINC SUBCATEGORY SECT - X
costsf and to sum the annualized capital cost, and the operating
and maintenance costs, yielding the cost of compliance for the
subcategory. Since proposal, the cost estimation.methodology has
been changed as discussed in Section VIII of this document and in
Section VIII of the General Development Document. A design model
and plant specific information were used to size a wastewater
treatment system for each discharging facility. After completion
of the design, capital and annual costs were estimated for each
unit of the wastewater treatment system. Capital costs were
developed from vendor quotes and annual costs were developed from
literature. The revised compliance costs are presented in Table
VIII-1 (page 1607).
BAT OPTION SELECTION - PROPOSAL
At proposal, EPA selected Option C without sulfide precipitation
as the basis for BAT in this subcategory. The BAT treatment
scheme proposed consisted of in-process wastewater flow
reduction, chemical precipitation, sedimentation, and multimedia
filtration. Wastewater flow reduction was based on increased
recycle of scrubber water and casting contact cooling water. EPA
proposed filtration as part of the BAT technology because this
technology is demonstrated in the subcategory (two of five direct
discharging plants presently have filters) and results in
additional removal of toxic pollutants. In addition, filtration
adds reliability to the treatment system by making it less
susceptible to operator error and to sudden changes in raw
wastewater flows and concentrations.
Other treatment technologies considered in Options D and F
included activated alumina and reverse osmosis. Although these
technologies are theoretically applicable to wastewaters
generated in the primary zinc subcategory, they were rejected
because they are not demonstrated in the. nonferrous metals
manufacturing category, nor are they clearly transferable.
BAT OPTION SELECTION - PROMULGATION
For promulgation, the Agency amended the proposed BAT technology
basis for the primary zinc subcategory to include sulfide
precipitation. The complete technology basis promulgated for BAT
thus consists of in-process flow reduction through recycle and
end-of-pipe lime and settle, sulfide precipitation (followed by
sedimentation), and multimedia filtration technology. Extensive
self-monitoring data were submitted through comments for the
primary zinc subcategory. The data were analyzed statistically
for comparison with the combined metals data base. In addition,
design and operating parameters for the treatment systems from
which the data were collected was solicited through Section 308
authority. The Agercy has determined that data from one of the
three plants shou d not be used to establish treatment
effectiveness because of inadequate equalization of process
wastewater prior to treatment. The treatment systems at the
other two primary zinc plants submitting data appear to .be
properly designed. These plants appear to have problems
1615
-------
PRIMARY ZINC SUBCATEGORY SECT - X
complying with the proposed zinc limitations due to extremely
high influent zinc concentrations or to ammonia interferences not
previously considered. However, the Agency believes the addition
of sulfide precipitation, in conjunction with multimedia
filtration, will achieve the treatment performance values as
proposed based on the lower solubility of metal sulfides (i.e.,
lower than metal hydroxides) as well as performance data for this
technology on inorganic chemical wastewaters. (Sulfide
precipitation technology is discussed .fully in Section VII of
Vol. I.) Sulfide precipitation is currently demonstrated in the
nonferrous metals manufacturing category at a cadmium plant in
the primary zinc subcategory, at a primary molybdenum plant with
a metallurgical acid plant, and at two secondary silver plants.
Sulfide precipitation, in conjunction with lime, is also used
occasionally at one primary electrolytic zinc facility.
EPA used data and information submitted through comments and
solicited through Section 308 requests, as well as information
obtained in an engineering site visit to a primary zinc plant, to
revise the flow allowances for this subcategory. In the proposed
mass limitations, a flow allowance was provided for leaching of
zinc concentrates. The Agency has withdrawn this allowance and
promulgated flow allowances for preleach and electrolyte bleed in
its place. The Agency believes these revised flow allowances
more accurately reflect operating practices at electrolytic zinc
plants. The Agency has also revised the flow allowance for anode
and cathode wash water based on an engineering site visit. These
revisions are discussed in detail below.
Application of the proposed BAT effluent mass limitations will
result in the removal of an estimated 1.16 million kg/yr of toxic
pollutants above the estimated raw discharge rate. The final BAT
effluent mass limitations will remove 1,260 kg/yr of toxic metals
over the intermediate BAT option considered, which lacks
filtration. Both options are economically achievable. The
Agency believes that incremental removal (including additional
removals of cadmium, one of the more toxic metals) justifies
selection of filtration as part of BAT model technology. In
addition, filtration is demonstrated at one primary zinc
facility. The estimated capital investment cost of the
promulgated BAT is $457,000 (March, 1982 dollars) and the
estimated annualized cost is $236,000 (March, 1982 dollars).
WASTEWATER DISCHARGE RATES
Important operations in the electrolytic production of zinc are
leaching, electrolysis, and casting. Reducing and casting are
important operations in the pyrolytic production of zinc. All of
these operations along with cadmium recovery are potential
sources of wastewater and ai'e evaluated to establish effluent
limitations for the primary zinc subcategory.
Specific wastewater streams associated with the primary zinc
subcategory are discharges from air pollution emission control
devices for the zinc reduction furnace, casting melting furnace,
1616
-------
PRIMARY ZINC SUBCATEGORY SECT - X
and leaching, and those from casting contact cooling, cathode and
anode washing, preleaching, electrolyte bleed, and cadmium
production. Table X-3 (page 1624) lists the production
normalized wastewater discharge allowances allocated at BAT for
these wastewater streams. The values represent the best existing
practices of the subcategory, as determined from the analysis of
dcp. The basis for the BAT discharge allowance is discussed
below for each waste stream. Individual discharge rates from the
plants surveyed are presented in Section V of this supplement for
each wastewater stream.
ZINC REDUCTION FURNACE WET AIR POLLUTION CONTROL WASTEWATER
The BAT wastewater discharge allowance proposed for zinc
reduction furnace wet air pollution control was 1,668 1/kkg (400
gal/ ton) of zinc reduced. This allowance was provided only for
the users of wet air pollution control devices. Two pyrolytic
plants used wet scrubbers to control reduction furnace emissions.
Both plants practiced extensive recycle of their scrubbing
wastewater. One plant practiced complete recycle while the other
plant recycles 88 percent of the scrubbing liquor. Wastewater
discharge rates are presented in Section V (Table V-l, page
1506). The proposed BAT discharge allowance was based on 90
percent recycle or reuse of the water used in the single
discharging plant. Information on water use was not available at
the plant which practices complete recycle.
The BAT wastewater discharge allowance used at promulgation is
1,668 1/kkg (400 gal/ton) of zinc reduced. This is equivalent to
the BAT allowance used at proposal. The Agency received no new
data or comments demonstrating that this allowance should be
revised.
PRELEACH WASTEWATER
The BAT wastewater discharge allowance used at promulgation is
901 1/kkg (216 gal/ton) of concentrate leached. This allowance
is based on the average of 14 discharge flow and production data
points provided by the plant with this stream. The second plant
with a preleach circuit is currently not operating this process
and flow data were not available. This waste stream, along with
electrolyte bleed, replaces the leaching waste stream which * was
proposed. The purpose of the leaching waste stream was to provide
a means of removing magnesium from the electrolytic circuit.
However, with the new data, more accurate flow allowances can be
provided.
LEACHING WET AIR POLLUTION CONTROL WASTEWATER
At proposal, no BAT wastewater discharge allowance was provided
for leaching wet air pollution control devices. Two of the five
electrolytic plants used scrubbers to control leaching air
emissions. One plant completely recycled its scrubbing water.
Information on water discharge was not available for the other
plant, however this plant reported that some recycle is used.
1617
-------
PRIMARY ZINC SUBCATEGORY SECT - X
One of the pyrolytic plants reported that leaching wet air
pollution control was used in its cadmium recovery process.
Total recycle of the scrubbing liquor was practiced by this
plant. Water use and discharge rates are presented for this
stream in Table V-2 (page 1506). Since two out of three plants
practiced total recycle of leaching wet air pollution control
wastewater, the BAT allowance for leaching wet air pollution was
zero discharge of wastewater pollutants.
For promulgation, no BAT wastewater pollutant discharge allowance
is provided for leaching wet air pollution control. The Agency
received no new data demonstrating that this allowance should be
revised.
ELECTROLYTE BLEED WASTEWATER
The promulgated BAT wastewater discharge allowance for
electrolyte bleed is 432 1/kkg (104 gal/ton) of cathode zinc
produced. This rate is based on the discharge flow of the one
plant with this waste stream. This stream, along with preleach,
replaces the leaching waste stream which was proposed. The
purpose of the leaching waste stream was to provide a means of
removing magnesium from the electrolytic circuit. However, with
the new data, more accurate flow allowances can be provided.
CATHODE AND ANODE WASHING WASTEWATER
The BAT wastewater discharge allowance proposed for cathode and
anode washing wastewater was 19,850 1/kkg (4,760 gal/ton) of
cathode zinc produced. Three plants discharge wastewater from
cathode and anode washing. The BAT discharge allowance was based
on the discharge from one of these plants. There was no
information available on water use and discharge rates from the
other plants to use in establishing the allowance.
The promulgated BAT wastewater discharge rate is 751 1/kkg (180
gal/ton) of cathode zinc produced. After proposal, the Agency
collected flow and production data for this stream during a
wastewater sampling effort. The discharge from this plant
(#9060) is 751 1/kkg, which is the regulatory flow. The proposed
regulatory flow was based on plant 281. Plant 281 reported an
annual production for this process that is 128 times less than
the capacity. It is apparent that the plant did not operate
continuously over the period that the production data were
collected. However, the annual wastewater flow was calculated
from the plant daily discharge rate from the process based on 365
operating days per year because actual process operating hours
were not reported in the dcp. The Agency does not believe the
production normalized flow calculated for plant 281 is
representative of a normal operating electrolytic process.
Furthermore, plant 281 reported washing cathodes only, while
plant 9060 washes both anodes and cathodes. For these reasons,
EPA has modified the regulatory flow allowance based on the flow
and production data collected during the sampling site visit at
1618
-------
PRIMARY ZINC SUBCATEGORY SECT - X
plant 9060.
CASTING WET AIR POLLUTION CONTROL
The BAT discharge allowance proposed for casting wet air
pollution control is 257 1/kkg (61.8 gal/ton) of zinc cast. This
rate was allocated only for the users of wet air pollution
control devices. The majority of electrolytic zinc plants used
dry air pollution control devices at their casting plant. One
plant used wet scrubbers to control melting furnace emissions.
This plant did not recycle any of the scrubbing liquor. The
proposed BAT discharge allowance was based on 90 percent recycle
or reuse of the water used at the single discharging plant (refer
to Section VII of the General Development Document). Since
plants in this subcategory recycled other scrubber waters (such
as zinc reduction furnace scrubber water or leaching scrubber
water) at rates exceeding 90 percent, the Agency believed the
single plant discharging casting wet air pollution control could
achieve 90 percent recycle.
The promulgated BAT wastewater discharge rate for casting wet air
pollution control is 257 1/kkg (61.8 gal/ton) of zinc cast. This
is equivalent to the proposed BAT allowance. The Agency received
no new data or comments demonstrating that this allowance should
be revised.
CASTING CONTACT COOLING
The BAT wastewater allowance proposed for casting contact cooling
was 181 1/kkg (43.4 gal/ton) of zinc cast. Four plants reported
wastewater from contact cooling. Three of these plants did not
recycle casting contact cooling water. The other plant
evaporates all of its casting contact cooling water in a pond.
The distribution of wastewater rates for casting contact cooling
is presented in Table V~5 (page 1508). The proposed BAT
discharge allowance was based on 90 percent recycle of the water
used at three plants (based on 90 percent recycle of average
water use). Information on water use and discharge was not
available at the other plant.
The promulgated BAT wastewater discharge rate for casting contact
cooling is 181 1/kkg (43.4 gal/ton) of zinc cast. This is
equivalent to the proposed BAT allowance. The Agency received no
new data or comments demonstrating that this allowance should be
revised.
CADMIUM PLANT PRODUCTION
The BAT discharge allowance proposed for cadmium plant wastewater
was 6,171 1/kkg (1,480 gal/ton) of cadmium produced. Four plants
reported wastewater associated with cadmium production. One
plant completely recycled cadmium plant wastewater. Recycle
rates were not available from the other plants. The proposed BAT
discharge allowance was based on the discharge rate at one of the
plants. Information on water discharge rates was not reported by
1619
-------
PRIMARY ZINC SDBCATEGORY SECT - X
the other plants. Water use and discharge rates are presented in
Table V-6 (page 1508).
The promulgated BAT is based on a wastewater discharge allowance
of 6,171 1/kkg (1,480 gal/ton) of cadmium produced. This is
equivalent to the flow allowance basis for proposal of BAT.
After proposal the Agency received flow and production data for
this process from one plant previously not in the data base.
However, the Agency did not receive comments demonstrating that
this allowance should be revised.
REGULATED POLLUTANT PARAMETERS
In implementing 33 U.S.C. (1314(b)(2)(A and B)(1976)), the Agency
placed particular emphasis on the toxic pollutants. The raw
wastewater concentrations from individual operations and the
subcategory as a whole were examined to select certain pollutants
and pollutant parameters for consideration for limitation. This
examination and evaluation, presented in Section VI, concluded
that nine toxic pollutants are present in primary zinc
wastewaters at concentrations that can be effectively reduced by
identified treatment technologies.
However, the cost associated with analysis for toxic metal
pollutants has prompted EPA to develop an alternative method for
regulating and monitoring toxic pollutant discharges from the
nonferrous metals manufacturing category. Rather than developing
specific effluent mass limitations and standards for each of the
toxic metals found in treatable concentrations in the raw
wastewaters from a given subcategory, the Agency is proposing
effluent mass limitations only for those pollutants generated in
the greatest quantities as shown by the pollutant reduction
benefit analysis. The pollutants selected for specific
limitation are listed below:
118. cadmium
120. copper
122. lead
128. zinc
By establishing limitations and standards for certain toxic metal
pollutants, discharqers will attain the same degree of control
over toxic metal po.lutants as they would have been required to
achieve had all the toxic metal pollutants been directly limited.
This approach is technically justified since the treatment
effectiveness concentrations used for lime precipitation and
sedimentation technology are based on optimized treatment for
concomitant multiple metals removal. Thus, even though metals
have somewhat different theoretical solubilities, they will be
removed at very nearly the same rate in a lime precipitation and
sedimentation treatment system operated for multiple metals
removal. Filtration as part of the technology basis is likewise
justified because this technology removes metals non-
preferentially.
1620
-------
PRIMARY ZINC SUBCATEGORY SECT - X
The following toxic pollutants are excluded from limitation on
the basis that they are effectively controlled by the limitations
developed for cadmium, copper, lead, and zinc:
115. arsenic
116. asbestos
119. chromium
124. nickel
126. silver
EFFLUENT LIMITATIONS
The treatment effectiveness concentrations achievable by
application of the BAT treatment technology are discussed in
Section VII of this supplement. The treatment effectiveness
concentrations (both one day maximum and monthly average values)
are multiplied by the BAT normalized discharged flows summarized
in Table X-3 (page 1624) to calculate the mass of pollutants
allowed to be discharged per mass of product. The results of
these calculations in milligrams of pollutant per kilogram of
product represent the BAT effluent limitations and are presented
in Table X-4 (page 1625) for each individual wastewater stream.
The regulatory tables which follow, (Tables X-4, XI-3 and XI-4)
contain the limitations established for each regulated
pollutant (indicated by *). The limitations which would have been
established if the other pollutants found at treatable
concentrations were regulated are also shown in these tables.
This additional information may be used by the permit writer when
establishing a permit regulating the. discharge of wastewaters
from this subcategory and other sources and which may contain
pollutants present but not specifically regulated under this
subcategory.
1621
-------
PRIMARY ZINC SUBCATEGORY SECT - X
TABLE X-l
CURRENT RECYCLE PRACTICES WITHIN THE
PRIMARY ZINC SUBCATEGORY
Number of Number of Range of
Plants with Plants with Recycle
Wastewater Recycle Values (%)
Zinc Reduction Furnace 2 2 88 - 100
Leaching 3 3 NR - 100
Casting 1 0 -
NR - not reported in dcp
1622
-------
Table X-2
POLLUTANT REMOVAL ESTIMATES FOR PRIMARY ZINC DIRECT DISCHARGERS
CTi
M
POLLUTANT
Arsenic
Cadmium
Chromium
Lead
Nickel
Selenium
Copper
Zinc
TOTAL TOXIC METALS
Aluminum
Ammonia
Fluoride
I ron
TOTAL NONCONVENTIONALS
TSS
.TOTAL CONVENTIONALS
TOTAL POLLUTANTS
FLOW (1/yr)
TOTAL
RAW WASTE
(kg/yr)
6,081.6
205.336.6
2.880.0
147.559.3
4.216.4
274.7
48.849.6
744.719.4
1 .159.917.7
2.369.5
421.5
47.3
242.8
3.081 .0
47,518.2
47.518.2
1.210.516.9
OPTION B
DISCHARGED
(kg/yr)
270.5
169.7
44.6
63.6
392.5
159.1
307.6
689.5
2.097.2
1 .188.1
421 .5
47.3
217.5
1,874.4
6,364.8
6.364.8
10.336.4
530,400,000
OPTION B
REMOVED
(kg/yr)
637.7
205.166.8
2,835.4
147.495.7
3,823.9
115.5
48,542.0
744.029.9
1 .152.647.0
1 .181 .4
0.0
0.0
25.3
1.206.7
41.153.4
41,153.4
1.195,007.1
OPTION C
DISCHARGED
(kg/yr)
180.3
26.0
37.1
42.4
116.7
106.1
206.9
122.0
837.5
790.3
421 .5
47.3
148.5
1 ,407.6
1.379.0
1.379.0
3.624.1
530,400,000
OPTION C
REMOVED
(kg/yr)
5.901.3
205.310.6
2.842.9
147.516.9
4,099.7
168.6
48.642.8
744.597.4
1 .159,080.2
1 .579.2
0.0
0.0
94.3
1 .673.4
46.139.2
46.139.2
1.206,892.8
H
S
N
M
O
CJ
td
o
•M
^TEGOR
K;
w
o
(-3
I
X!
NOTE: TOTAL TOXIC METALS - Arsenic * Cadmium + Chromium + Lead + Nickel + Selenium + Copper * Zinc
TOTAL NONCONVENTIONALS - Aluminum + Ammonia + Fluoride + Iron
TOTAL CONVENTIONALS - TSS
TOTAL POLLUTANTS - Total Toxic Metals + Total Nonconventlonals + Total Conventiona13
OPTION B - Lime Precipitation, Sedimentation, and In-process Flow Reduction
OPTION C - Option B, plus Sulflde Precipitation and Sedimentation, and Multimedia Filtration
-------
Table X-3
BAT WASTEWATER DISCHARGE RATES FOR THE PRIMARY ZINC SUBCATEGORY
BAT Normalized
Discharge Rate
Wastewater Stream
Zinc Reduction Furnace Wet
Air Pollution Control
Preleach Wastewater
Leaching Wet Air Pollution
Control
Electrolyte Bleed Wastewater
Cathode and Anode Wash
Wastewater
Casting Wet Air Pollution
Control
Casting Contact Cooling
Cadmium Plant Wastewater
1/kkg
1,668
901
0
432
751
gal/ton
400
216
0
104
180
257
181
6,171
61.8
43.4
1,480
Production Normalizing
Parameter
Zinc reduced
Concentrate leached
Zinc processed through
leaching
Cathode zinc produced
Cathode zinc produced
Zinc cast
Zinc cast
Cadmium produced
H
K;
N
H
55
n
w
3
n
I
a
8
w
M
n
-------
ZINC SUBCATEGORY SECT - X
TABLE X-4
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY ZINC SUBCATEGORY
(a) Zinc Reduction Furnace Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Arsenic
*Cadmium
Chromium
*Copper
*Lead
Nickel
Silver
*Zinc
2.319
0.334
0.617
2.135
0.467
0.917
0.484
1.702
1.034
0.134
0.250
1.018
0.217
0.617
0.200
0.701
*Regulated Pollutant
(b) Preleach of_ Zinc Concentrates BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Arsenic 1.252 0.559
*Cadmium 0.180 0.072
Chromium 0.333 0.135
*Copper 1.153 0.550
*Lead 0.252 0.117
Nickel 0.496 0.333 '
Silver 0.261 0.108
*Zinc 0.919 0.378
*Regulated Pollutant
1625
-------
PRIMARY ZINC SUBCATEGORY SECT - X
TABLE X-4 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY ZINC SUBCATEGORY
(c) Leaching Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ibs/million Ibs of zinc processed through
leaching
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
*Regulated Pollutant
(d) Electrolyte Bleed Wastewater BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.600
0.086
0.160
0.553
0.121
0.238
0.125
0.441
0.268
0.035
0.065
0.264
0.056
0.160
0.052
0.182
*Regulated Pollutant
1626
-------
PRIMARY ZINC SUECATEGORY SECT - X
TABLE X-4 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY ZINC SUBCATEGORY
(e) Cathode and Anode Wash Wastewater BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic 1.044 0.466
*Cadmium 0.150 0.060
Chromium 0.278 0.113
*Copper 0.961 0.458
*Lead 0.210 0.098
Nickel 0.413 0.278
Silver 0.218 0.090
*Zinc 0.766 0.315
*Regulated Pollutant
(f) Casting Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic
*Cadmium
Chromium
*Copper
*Lead
Nickel
Silver
*Zinc
0.357
0.051
0.095
0.329
0.072
0.141
0.075
0.262
0.159
0.021
0.039
0.157
0.033
0.095
0.031
0.108
*Regulated Pollutant
1627
-------
PRIMARY ZINC SUBCATEGORY SECT - X
TABLE X-4 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY ZINC SUBCATEGORY
(g) Casting Contact Cooling BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.252
0.036
0.067
0.232
0.051
0.100
0.052
0.185
0.112
0.014
0.027
0.110
0.024
0.067
0.022
0.076
*Regulated Pollutant
(h) Cadmium Plant Wastewater BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Arsenic 8.578 3.826
*Cadmium 1.234 0.494
Chromium 2.283 0.926
*Copper 7.899 3.765
*Lead 1.728 0.802
Nickel 3.394 2.283
Silver 1.790 0.741
*Zinc 6.295 2.592
*Regulated Pollutant
1628
-------
. :•'• Hediictlon Furnace Scrutiher I.Iquor
CTi
p
l.otr hi ng Sc i "'liter l.lqunr
' .'»( h >du and Amide Washing Uastewater
s^**! I n£ Scrubber M-iuur ^
"••>!'» fug Coiitiict Cooling Water
• : f'»?um Plant Wastt-water ^
!'*«'>«>lyte Bleed Uastewater
Q
I / v
Equal 1-
ID s
t7^ 7 V m,r.nr8c °
»» ' » - ^ en
Chemical ' C
Precipitation Sedimentation ^
M
Sludee ^
Sludge Recycle !S
h 1 I /'/' I Disposal
Vacuuii Filtrate V \I^ J 1 \
^- -S * 1 M
<~>
^
Sludge Dewa taring Ji|'i!tr>$i%.tl^!l 1
Figure X-l
BAT TREATMENT SCHEME OPTION A
PRIMARY ZINC SUBCATEGORY
-------
('.aKtliip, C.onliicl Cooling Water
Recycle
Pri-lf.irh Uiist ewater
('atliode ,-inil Anode Washing Waatevater
Cadmium PI.-int Wnstewater
Klcctrolyte Bleeil Waslevater
Chemical Addition
Reduction KuriiHce Scrubber l.lquor
Cast Ing Si-rubber l.lcjuor
c. Scrubber l.lquor
Holding
Tank
Recycle
Sludge Removal
Total Recycle
Holding
Tank
Sludge Removal
Figure X-2
BAT TREATMENT SCHEME OPTION B
PRIMARY ZINC SUBCATEGORY
-------
lnK '-intact ConllnR Water
Recycle
Prelparli Uantruater
('ittliode anj An«ule Washing WaBtewater
Cadmium Plant ''asteuater
Electrolyte Bli'fd Waatewater
lnc Reduction Frrnace Scruhher Liquor
('astlng ScruMtnr Liquor
I.caching Kcruhlier Liquor
Sludge to
Disposal
Sludge Removal
Figure X-3
BAT TREATMENT SCHEME OPTION C
PRIMARY ZINC SUBCATEGORY
-------
Page Intentionally Blank
-------
PRIMARY ZINC SUBCATEGORY SECT - XI
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
The basis for new source performance standards (NSPS) under
Section 306 of the Act is the best available demonstrated
technology (BDT). New plants have the opportunity to design the
best and most efficient production processes and wastewater
treatment technologies, without facing the added costs and
restrictions encountered in retrofitting an existing plant.
This section describes the technologies for treatment of
wastewater from new sources, and presents mass discharge
standards for regulated pollutants for NSPS based on the selected
treatment technology.
TECHNICAL APPROACH TO BDT
All of the treatment technology options applicable to a new
source were previously considered for the BAT options. For this
reason, five options were considered for BDT, all identical to
the BAT options discussed in Section X. The treatment
technologies used for the five BDT options are:
OPTION A
o Chemical precipitation (lime) and sedimentation
OPTION B
o Chemical precipitation (lime) and sedimentation
o In-process flow reduction of scrubber liquor and
casting contact cooling water
OPTION C
o Chemical precipitation (lime) and sedimentation
o In-process flow reduction of scrubber liquor and
casting contact cooling water
o Sulfide precipitation and sedimentation
o Multimedia filtration
Partial or complete reuse and recycle of wastewater is an
essential part of each option. Reuse and recycle can precede or
follow end-of-pipe treatment. A more detailed discussion of
these treatment options is presented in Section X.
BDT OPTION SELECTION
EPA is promulgating best available demonstrated technology for
the primary zinc subcategory equal to BAT technology, which
consists of in-process wastewater flow reduction, chemical
precipitation and sedimentation, sulfide precipitation and
1633
-------
PRIMARY ZINC SUBCATEGORY SECT - XI
sedimentation, and multimedia filtration (Option C). Review of
the subcategory indicates that no new demonstrated technologies
exist that improve on BAT technology. Reverse osmosis is not
demonstrated in this subcategory and is not clearly transferable
to nonferrous metals manufacturing wastewater. The Agency also
does not believe that new plants could achieve any additional
flow reduction beyond that promulgated for BAT.
Dry scrubbing is not demonstrated for controlling emissions from
zinc reduction furnaces, leaching and product casting. The
nature of these emissions (acidic fumes, hot particulate matter)
technically precludes the use of dry scrubbers. Therefore, we
are including an allowance from this source at NSPS equivalent to
that proposed for BAT. EPA does not believe that new plants
could achieve any additional flow reduction beyond that proposed
for BAT.
REGULATED POLLUTANT PARAMETERS
The Agency has no reason to believe that the pollutants that will
be found in treatable concentrations in processes within new
sources will be any different than with existing sources.
Accordingly, pollutants and pollutant parameters selected for
limitation under NSPS, in accordance with the rationale of
Sections VI and X, are identical to those selected for BAT. The
conventional pollutant parameters TSS and pH are also selected
for limitation.
NEW SOURCE PERFORMANCE STANDARDS
The NSPS discharge flows are the same as the BAT discharge flows
for all processes. These discharge flows are listed in Table XI-
1 (page 1635). The mass of pollutant allowed to be discharged
per mass of product is calculated by multiplying the achievable
treatment concentration (mg/1) by the normalized wastewater
discharge flow (1/kkg). New source performance standards, as
determined from the above procedure, are shown in Table XI-2
(page 1636) for each waste stream. Since both the discharge
flows and achievable treatment concentrations for new sources and
BAT are identical, the NSPS are identical to the BAT mass
limitations.
1634
-------
Table XI-1
NSPS WASTEWATER DISCHARGE RATES FOR THE PRIMARY ZINC SUBCATEGORY
NSPS Normalized
Discharge Rate
Wastewater Stream
Zinc Reduction Furnace Wet
Air Pollution Control
Preleach Wastewater
Leeching Wet Air Pollution
Control
Electrolyte Bleed Wastewater
Cathode and Anode Wash
Wastewater
Casting Wet Air Pollution
Control
Casting Contact Cooling
Cadmium Plant Wastewater
1/kkg
1,668
901
0
432
751
gal/ton
400
216
0
104
180
257
181
6,171
61 .8
43.4
1,480
Production Normalizing
Parameter
Zinc reduced
Concentrate leached
Zinc processed through
leaching
Cathode zinc produced
Cathode zinc produced
Zinc cast
Zinc cast
Cadmium produced
23
n
n
1-3
w
1
w
o
1-3
X
-------
PRIMARY ZINC SUBCATEGORY SECT - XI
TABLE XI-2
NSPS FOR THE PRIMARY ZINC SUBCATEGORY
(a) Zinc Reduction Furnace Wet Air Pollution Control NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Arsenic 2.319 1.034
*Cadmium 0.334 0.134
Chromium 0.617 0.250
*Copper 2.135 1.018
*Lead 0.467 0.217
Nickel 0.917 0.617
Silver 0.484 0.200
*Zinc 1.702 0.701
*TSS 25.020 20.020
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
(b) Preleach of Zinc Concentrates NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Arsenic 1.252 0.559
*Cadmium 0.180 0.072
Chromium 0.333 0.135
*Copper 1.153 0.550
*Lead 0.252 0.117
Nickel 0.496 0.333
Silver 0.261 0.108
*Zinc 0.919 0.378
*TSS 13.520 10.810
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1636
-------
PRIMARY ZINC SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR-THE PRIMARY ZINC SUBCATEGORY
(c) Leaching Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ibs/million Ibs of zinc processed through
leaching
Arsenic 0.000 0.000
*Cadmium 0.000 0.000
Chromium 0.000 0.000
*Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver - 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
(d) Electrolyte Bleed Wastewater NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic 0.600 0.268
*Cadmium 0.086 0.035
Chromium 0.160 0.065
*Copper 0.553 0.264
*Lead 0.121 0.056
Nickel 0.238 0.160
Silver 0.125 0.052
*Zinc 0.441 0.182
*TSS 6.480 5.184
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1637
-------
PRIMARY ZINC SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY ZINC SUBCATEGORY
(e) Cathode and Anode Wash Wastewater NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic 1.044 0.466
*Cadmium 0.150 0.060
Chromium 0.278 0.113
*Copper ' 6.961 0.458
*Lead 0.210 0.098
Nickel 0.413 0.278
Silver 0.218 0.090
*Zinc 0.766 0.315
*TSS 11.270 9.012
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
(f) Casting Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic 0.357 0.159
*Cadmium 0.051 0.021
Chromium 0.095 0.039
*Copper 0.329 0.157
*Lead 0.072 0.033
Nickel 0.141 0.095
Silver 0.075 0.031
*Zinc " ' 0.262 0.108
*TSS 3.855 3.084
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1638
-------
PRIMARY ZINC SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY ZINC SUBCATEGORY
(g) Casting Contact Cooling NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic 0.252 0.112
*Cadmium 0.036 0.014
Chromium 0.067 0.027
*Copper . . 0.232 0.110
*Lead 0.051 0.024
Nickel 0.100 0.067
Silver 0.052 0.022
*Zinc 0.185 0.076
*TSS 2.715 2.172
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
(h) Cadmium Plant Wastewater NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Arsenic 8.578 3.826
*Cadmium 1.234 0.494
Chromium 2.283 0.926
*Copper 7.899 3.765
*Lead 1.728 0.802
Nickel 3.394 2.283
Silver 1.790 0.741
*Zinc 6.295 2.592
*TSS 92.570 74.050
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1639
-------
Page Intentionally Blank
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
SECTION XII
PRETREATMENT STANDARDS
Section 307(b) of the Act requires EPA to promulgate pretreatment
standards for existing sources (PSES), which must be achieved
within three years of promulgation. PSES are designed to prevent
the discharge of pollutants which pass through, interfere with,
or are otherwise incompatible with the operation of publicly
owned treatment works (POTW). The Clean Water Act of 1977
requires pretreatment for pollutants, such as toxic metals, that
limit POTW sludge management alternatives. Section 307(c) of the
Act requires EPA to promulgate pretreatment standards for new
sources (PSNS) at the same time that it promulgates NSPS. New
indirect discharge facilities, like new direct discharge
facilities, have the opportunity to incorporate the best
available demonstrated technologies, including process changes,
in-plant controls, and end-of-pipe treatment technologies, and to
use plant site selection to ensure adequate treatment system
installation. Pretreatment standards are to be technology-based,
analogous to the best available technology for removal of toxic
pollutants.
This section describes the control and treatment technologies for
pretreatment of process wastewaters from existing sources and new
sources in the primary zinc sUbcategory. Pretreatment standards
for regulated pollutants are presented based on the selected
control and treatment technology.
TECHNICAL APPROACH TO PRETREATMENT
Before proposing pretreatment standards, the Agency examines
whether the pollutants discharged by the industry pass through
the POTW or interfere with the POTW operation or its chosen
sludge disposal practices. In determining whether pollutants
pass through a well-operated POTW, achieving secondary treatment,
the Agency compares the percentage of a pollutant removed by POTW
with the percentage removed by direct dischargers applying the
best available technology economically achievable. A pollutant
is deemed to pass through the POTW when the average percentage
removed nationwide by well-operated POTW meeting secondary
treatment requirements, is less than the percentage removed by
direct dischargers complying with BAT effluent limitations
guidelines for that pollutant. (See generally, 46 Fed. Reg. at
9415-16 (January 28, 1981).)
This definition of pass through satisfies two competing
objectives set by Congress: (1) that standards for indirect
dischargers be equivalent to standards for direct dischargers,
while at the same time, (2) that the treatment capability and
performance of the POTW be recognized and taken into account in
regulating the discharge of pollutants from indirect dischargers.
1641
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
The Agency compares percentage removal rather than the mass or
concentration of pollutants discharged because the latter would
not take into account the mass of pollutants discharged to the
POTW from non-industrial sources nor the dilution of the
pollutants in the POTW effluent to lower concentrations due to
the addition of large amounts of non-industrial wastewater.
PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES
Options for pretreatment of wastewaters are based on increasing
the effectiveness of end-of-pipe treatment technologies. All in-
plant changes and applicable end-of-pipe treatment processes have
been discussed previously in Sections X and XI. The options for
PSNS, therefore, are the same as the BAT options discussed in
Section X.
A description of each option is presented in Section X, while a
more detailed discussion, including pollutants controlled by each
treatment process and expected effluent quality for each option,
is presented in Section VII of Vol. I.
The treatment technology options for the PSES and PSNS options
are:
OPTION A
o Chemical precipitation (lime) and sedimentation
OPTION B
o Chemical precipitation (lime) and sedimentation
o In-process flow reduction of scrubber liquor and
casting contact cooling water
OPTION C
o Chemical precipitation (lime) and sedimentation
o In-process flow reduction of scrubber liquor and
casting contact cooling water
o Sulfide precipitation and sedimentation
o Multimedia filtration
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
The industry cost and pollutant removal estimates of each
treatment option were used to determine the most cost-effective
option. The methodology applied in calculating pollutant removal
estimates and plant compliance costs is discussed in Section X.
Table XII-1 (page 1645) shows the estimated pollutant removals
for indirect dischargers. Compliance costs are presented in
Table VIII-2 (page 1646).
1642
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
PSES OPTION SELECTION
EPA did not propose pretreatment standards for the primary zinc
subcategory. Since that time, the Agency has learned that one
primary zinc plant previously thought to be a zero discharger is
actually an indirect discharger. Therefore, the Agency is
promulgating PSES for the primary zinc subcategory based on the
BAT model technology and flow allowances.
Implementation of the proposed PSES limitations would remove an
estimated 685,000 kg/yr of toxic pollutants over estimated raw
discharge. The final PSES effluent mass limitations will remove
210 kg/yr of toxic metals over the intermediate PSES option
considered, which lacks filtration. Both options are
economically achievable. The Agency believes the incremental
removal justifies selection of filtration as part of PSES model
technology. Filtration as an end-of-pipe treatment technology is
currently demonstrated by one plant in the subcategory. Capital
cost for achieving proposed PSES is $122,000 (March, 1982
dollars) and annual cost of $58,300 (March, 1982 dollars).
PSNS OPTION SELECTION
The technology basis for promulgated PSNS is identical to NSPS
and BAT (Option C). The treatment scheme consists of in-process
wastewater flow reduction, chemical precipitation and
sedimentation, sulfide precipitation and sedimentation, and
multimedia filtration. EPA knows of no demonstrated technology
that provides more efficient pollutant removal than NSPS and BAT
technology.
REGULATED POLLUTANT PARAMETERS
Pollutants and pollutant parameters selected for limitation under
PSNS, in accordance with the rationale of Sections VI and X, are
identical to those selected for BAT except for copper and lead.
PSES and PSNS prevent the pass-through of cadmium and zinc, which
are the regulated pollutants. The Agency has determined that
copper and lead will not pass through a well-operated POTW and
therefore they are not controlled.
PRETREATMENT STANDARDS
The PSES and PSNS regulatory discharge flows are identical to the
BAT regulatory discharge flows for all processes. These flows
are listed in Table XII-2 (page 1646). The mass of pollutant
allowed to be discharged per mass of product is calculated by
multiplying the achievable treatment concentration (mg/1) by the
regulatory wastewater discharge flow. (1/kkg). Pretreatment
standards for existing and new sources, as determined from the
above procedure, are shown in Tables XII-3 (page 1647) and XII-4
(page 1651) for each waste stream.
1643
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
Mass-based standards are proposed for the primary zinc
subcategory to ensure that the standards are achieved by means of
pollutant removal rather than by dilution. They are particularly
important since the standards are based upon flow reduction.
Pollutant limitations associated with flow reduction cannot be
measured any other way but as a reduction of mass discharged.
1644
-------
Table XII-1
POLLUTANT REMOVAL ESTIMATES FOR PRIMARY ZINC INDIRECT DISCHARGERS
nj
en
POLLUTANT
Arsenic
Cadmium
Chromium
Lead
Nickel
Copper
Zinc
TOTAL TOXIC MF.TALS
TOTAL
A luml num
Ammonia
Fluoride
Iron
NONCONVENTIONALS
TSS
TOTAL CONVENTIONALS
TOTAL POLLUTANTS
FLOW (1/yr)
TOTAL
RAW WASTE
(kg/yr)
2.143.0
3.574.1
4.5
22.343.7
1 .9
2.01 7.6
645.827.5
645,957.3
2.186.7
86.4
10.3
239.4
2.522.8
351 .160.2
351 .160.3
1 ,038.640.3
OPTION B
DISCHARGED
(kg/yr)
60.5
38.0
4.5
14.2
1.9
68.8
154.3
342.3
265.9
86.4
10.3
48.7
41 1 .2
1 .424.4
1.424.4
2.177,9
118.700.000
OPTION B
REMOVED
(kg/yr)
637.7
3,536.1
0.0
22,329.4
0.0
1 ,948.8
654,718.2
683,170.2
1.920.9
0.0
0.0
190.7
2, III .6
349.735.8
349.735.8
1 .035.017.6
OPTION C
DISCHARGED
(kg/yr)
40.4
5.8
4.5
9.5
1.9
46.3
27.3
135.7
176.9
86.4
10.3
33.2
306.7
308.6
308.6
751 .0
1 18,700,000
OPTION C
REMOVED
(kg/yr)
2,102.7
3.568.3
0.0
22.334.2
0.0
1 .971.3
654,845.2
684.821 .6
2.009.9
0.0
0.0
206.2
2.216.0
350.851 .6
350.851.6
1 .037,889.3
A*
M
*)
K
O
CO
c:
w
0
(-3
M
Q
O
frj
K
CO
M
O
(-3
i
NOTE: TOTAL TOXIC METALS - Arsenic + Cadmium + Chromium + Lead «• Nickel + Copper + Zinc
TOTAL NONCONVENTIONALS - Aluminum * Ammonia + Fluoride * Iron
TOTAL CONVENTIONALS - TSS
TOTAL POLLUTANTS - Total Toxic Metals + Total Nonconventtonals + Total ConventtonaIs
OPTION B - Lime Precipitation, Sedimentation, and In-process Flow Reduction
OPTION C - Option B, plus Sulflde Precipitation and Sedimentation, and Multimedia Filtration
-------
Table XII-2
PSES AND PSNS WASTEWATER DISCHARGE RATES FOR THE PRIMARY ZINC SUBCATEGORY
PSES and PSNS
Normalized
Discharge Rate
Wastewater Stream
Zinc Reduction Furnace Wet
Air Pollution Control
Preleach Wastewater
Leaching Wet Air Pollution
Control
Electrolyte Bleed Wastewater
Oathode and Anode Wash
Wastewater
Casting Wet Air Pollution
Control
Casting Contact Cooling
Cadmium Plant Wastewater
1/kkg
1 ,668
901
0
432
751
gal/ton
400
216
0
104
180
257
181
6,171
61.8
43.4
1 ,480
Production Normalizing
Parameter
Zinc reduced
Concentrate leached
Zinc processed through
leaching
Cathode zinc produced
Cathode zinc produced
Zinc cast
Zinc cast
Cadmium produced
N
H
2!
O
a
w
n
•5
M
O
O
W
n
1-3
H
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE XII-3
PSES FOR THE PRIMARY ZINC SUBCATEGORY
(a) Zinc Reduction Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
2.319
0.334
0.617
2.135
0.467
0.917
0.484
1.702
1.034
0.134
0.250
1.018
0.217
0.617
0.200
0.701
*Regulated Pollutant
(b) Preleach of Zinc Concentrates PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Arsenic 1.252 0.559
*Cadmium 0.180 0.072
Chromium 0.333 0.135
*Copper 1.153 0.550
*Lead 0.252 0.117
Nickel 0.496 0.333
Silver 0.261 0.108
*Zinc 0.919 0.378
*Regulated Pollutant
1647
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE XII-3 (Continued)
PSES FOR THE PRIMARY ZINC SUBCATEGORY
(c) Leaching Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ibs/million Ibs of zinc processed through
leaching
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
*Regulated Pollutant
(d) Electrolyte Bleed Wastewater PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.600
0.086
0.160
0.553
0.121
0.238
0.125
0.441
0.268
0.035
0.065
0.264
0.056
0.160
0.052
0.182
*Regulated Pollutant
1648
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE XII-3 (Continued)
PSES FOR THE PRIMARY ZINC SUBCATEGORY
(e) Cathode and Anode Wash Wastewater PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic
*Cadmium
Chromium
*Copper
*Lead
Nickel
Silver
*Zinc
1.044
0.150
0.278
0.961
0.210
0.413
0.218
0.766
0.466
0.060
0.113
0.458
0.098
0.278
0.090
0.315
*Regulated Pollutant
(f) Casting Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.357
0.051
0.095
0.329
0.072
0.141
0.075
0.262
0.159
0.021
0.039
0.157
0.033
0.095
0.031
0.108
*Regulated Pollutant
1649
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE XI1-3 (Continued)
PSES FOR THE PRIMARY ZINC SUBCATEGORY
(g) Casting Contact Cooling PSES
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.252
0.036
0.067
0.232
0.051
0.100
0.052
0.185
0.112
0.014
0.027
0.110
0.024
0.067
0.022
0.076
*Regulated Pollutant
(h) Cadmium Plant Wastewater PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Arsenic 8.578 3.826
*Cadmium 1.234 0.494
Chromium 2.283 0.926
*Copper 7.899 3.765
*Lead 1.728 0.802
Nickel 3.394 2.283
Silver 1.790 0.741
*Zinc 6.295 2.592
*Regulated Pollutant
1650
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE XI1-4
PSNS FOR THE PRIMARY ZINC SUBCATEGORY
(a) Zinc Reduction Furnace Wet Air Pollution Control PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc reduced
English Units - Ibs/million Ibs of zinc reduced
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
2.319
0.334
0.617
2.135
0.467
0.917
0.484
1.702
1.034
0.134
0.250
1.018
0.217
0.617
0.200
0.701
*Regulated Pollutant
(b) Preleach of Zinc Concentrates PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of concentrate leached
English Units - Ibs/million Ibs of concentrate leached
Arsenic 1.252 0.559
*Cadmium 0.180 0.072
Chromium 0.333 0.135
*Copper 1.153 0.550
*Lead 0.252 0.117
Nickel 0.496 0.333
Silver 0.261 0.108
*Zinc 0.919 0.378
*Regulated Pollutant
1651
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE Xll-4 (Continued)
PSNS FOR THE PRIMARY ZINC SUBCATEGORY
(c) Leaching Wet Air Pollution Control PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc processed through leaching
English Units - Ibs/million Ibs of zinc processed through
leaching
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
*Regulated Pollutant
(d) Electrolyte Bleed Wastewater PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.600
0.086
0.160
0.553
0.121
0.238
0.125
0.441
0.268
0.035
0.065
0.264
0.056
0.160
0.052
0.182
*Regulated Pollutant
1652
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSNS FOR THE PRIMARY ZINC SUBCATEGORY
(e) Cathode and Anode Wash Wastewater PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cathode zinc produced
English Units - Ibs/million Ibs of cathode zinc produced
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
1.044
0.150
0.278
0.961
0.210
0.413
0.218
0.766
0.466
0.060
0.113
0.458
0.098
0.278
0.090
0.315
*Regulated Pollutant
(f) Casting Wet Air Pollution Control PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic
*Cadmium
Chromium
* Copper
*Lead
Nickel
Silver
*Zinc
0.357
0.051
0.095
0.329
0.072
0.141
0.075
0.262
0.159
0.021
0.039
0.157 .
0.033
0.095
0.031
0.108
*Regulated Pollutant
1653
-------
PRIMARY ZINC SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSNS FOR THE PRIMARY ZINC SUBCATEGORY
(g) Casting Contact Cooling PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of zinc cast
English Units - Ibs/million Ibs of zinc cast
Arsenic
*Cadmium
Chromium
*Copper
*Lead
Nickel
Silver
*Zinc
0.252
0.036
0.067
0.232
0.051
0.100
0.052
0.185
0.112
0.014
0.027
0.110
0.024
0.067
0.022
0.076
*Regulated Pollutant
(h) Cadmium Plant Wastewater PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of cadmium produced
English Units - Ibs/million Ibs of cadmium produced
Arsenic 8.578 3.826
*Cadmium 1.234 . 0.494
Chromium 2.283 0.926
*Copper 7.899 3.765
*Lead 1.728 0.802
Nickel 3.394 2.283
Silver 1.790 0.741
*Zinc 6.295 2.592
*Regulated Pollutant
1654
-------
PRIMARY ZINC SUBCATEGORY SECT - XIII
SECTION XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
EPA is not promulgating best conventional pollutant control
technology (BCT) for the primary zinc subcategory at this time.
1655
-------
-------
NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Primary Lead Subcategory
William K. Reilly
Administrator
Rebecca Hanmer
Acting Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office cf Water Regulations and Standards
.Industrial Technology Division
Washington, D. C. 20460
1657
-------
Page Intentionally Blank
-------
PRIMARY LEAD SUBCATEGORY
TABLE OF CONTENTS
Section Page
I SUMMARY 1667
II CONCLUSIONS 1671
III SUBCATEGORY PROFILE 1679
Description of Primary Lead Production 1697
Raw Materials 1697
Sintering 1697
Blast Furnace Reduction 1698
Dressing 1699
Softening and Refining 1700
Casting 1701
Process Wastewater Sources 1701
Other Wastewater Sources 1701
Age, Production and Process Profile 1701
IV SUBCATEGORIZATION 1707
Factors Considered in Subdividing the Primary 1707
Lead Subcategory 1707
Other Factors 1708
Production Normalizing Parameters 1709
V WATER USE AND WASTEWATER CHARACTERISTICS 1711
Wastewater Sources, Discharge Rates, and 1711
Characteristics
Sinter Plant Materials Handling Wet Air 1714
Pollution Control
Blast Furnace Slag Granulation 1715
Blast Furnace Wet Air Pollution Control 1715
Dross Reverberatory Furnace Granulation 1715
Wastewater
Dross Reverberatory Furnace Wet Air Pollution 1715
Control
Zinc Fuming Furnace Wet Air Pollution Control 1716
Hard Lead Refining Wet Air Pollution Control 1716
and Slag Granulation
Facility Washdown 1716
Employee Handwash 1717
Employee Respirator Wash 1717
Laundry of Uniforms 1717
1659
-------
PRIMARY LEAD SUBCATEGORY
Section
VI
VII
VIII
TABLE OF CONTENTS (Continued)
SELECTION OF POLLUTANTS
Conventional and Nonconventional Pollutant
Parameters
Conventional and Nonconventional Pollutant
Parameters Selected
Toxic Pollutants
Toxic Pollutants Never Detected
Toxic Pollutants Never Found Above Their
Analytical Quantification Concentration
Toxic Pollutants Present Below Concentrations
Achievable by Treatment
Toxic Pollutants Detected in a Small Number of
Sources
Toxic Pollutants Selected for Consideration in
Establishing Limitations
CONTROL AND TREATMENT TECHNOLOGIES
Prior Regulations
Current Control and Treatment Practices
Sinter Plant Materials Handling Wet Air
Pollution Control
Blast Furnace Wet Air Pollution Control
Blast Furnace Slag Granulation
Dross Reverberatory Slag Granulation Wastewater
Dross Reverberatory Furnace Wet Air
Pollution Control
Zinc Fuming Furnace Wet Air Pollution Control
Hard Lead Refining Wet Air Pollution
Control and Slag Granulation
Facility Washdown
Wastewater from Industrial Hygiene Compliance
Control and Treatment Options
Option A
Option B
Option C
Treatment Options Rejected
Option F
COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
Treatment Options Costed for Existing Sources
Option A
Option B
Option C
Cost Methodology
Nonwater Quality Aspects
Energy Requirements
Solid Waste
Air Pollution
1732
1732
1733
1733
1734
1735
1743
1743
1744
1744
1745
1745
1745
1746
1746
1746
1746
1746
1747
1747
1747
1747
1748
1748
1749
1749
1749
1749
1750
1750
1751
1751
1752
1753
1660
-------
PRIMARY LEAD SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section . Page
IX BEST PRACTICABLE TECHNOLOGY CURRENTLY AVAILABLE 1755
Technical Approach to BPT 1756
Industry Cost and Pollutant Removal Estimates 1758
BPT Option Selection 1758
Wastewater Discharge Rates 1759
Sinter Plant Materials Handling Wet Air 1760
Pollution Control
Blast Furnace Wet Air Pollution Control 1760
Blast Furnace Slag Granulation 1760
Dross Reverberatory Slag Granulation Wastewater 1760
Dross Reverberatory Furnace Wet Air 1761
Pollution Control
Zinc Fuming Furnace Wet Air Pollution Control 1761
Hard Lead Refining Wet Air Pollution Control 1761
Hard Lead Refining Slag Granulation 1761
Facility Washdown 1762
Employee Handwash 1762
Respirator Wash 1761
Laundering of Uniforms 1762
Regulated Pollutant Parameters 1762
Stormwater and Precipitation Allowances 1763
Effluent Limitations 1763
X BEST AVAILABLE TECHNOLOGY ECONOMICALLY 1771
ACHIEVABLE
Technical Approach to BAT 1773
Option A 1774
Option B 1774
Recycle of Water Used in Wet Air Pollution 1775
Control
Recycle or Reuse of Dross Reverberatory Furnace 1775
Granulation Wastewater
Option C 1775
Industry Cost and Pollutant Removal Estimates 1776
Pollutant Removal Estimates 1776
Compliance Costs 1776
BAT Option Selection 1777
Wastewater Discharge Rates 1778
Blast Furnace Slag Granulation 1778
Zinc Fuming Furnace Wet Air Pollution Control 1779
Dross Reverberatory Furnace Wet Air 1779
Pollution Control
Dross Reverberatory Slag Granulation Wastewater 1779
Hard Lead Refining Wet Air Pollution Control 1780
Regulated Pollutant Parameters 1780
Stormwater and Precipitation Allowances 1781
Effluent Limitations 1781
1661
-------
PRIMARY LEAD SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
XI NEW SOURCE PERFORMANCE STANDARDS
Technical Approach to BDT 1793
BDT Option Selection 1793
Regulated Pollutant Parameters 1794
New Source Performance Standards 1794
XII PRETREATMENT STANDARDS 1803
Technical Approach to Pretreatment 1803
Pretreatment Standards for Existing Sources and 1804
New Sources
Industry Cost and Pollutant Removal Estimates 1804
Pretreatment Standards for Existing Sources 1805
Pretreatment Standards for New-Sources 1805
Regulated Pollutant Parameters 1805
Pretreatment Standards 1806
XIII BEST CONVENTIONAL TECHNOLOGY 1823
1662
-------
PRIMARY LEAD SUBCATEGORY
LIST OF TABLES
Number Page
III-l INITIAL OPERATING YEAR SUMMARY OF PLANTS IN 1703
THE PRIMARY LEAD SUBCATEGORY BY DISCHARGE TYPE
III-2 PRODUCTION RANGES FOR THE PRIMARY LEAD 1703
SUBCATEGORY
III-3 SUMMARY OF PRIMARY LEAD SUBCATEGORY PROCESSES 1704
AND ASSOCIATED WASTE STREAMS
V-l WATER USE AND DISCHARGE RATES FOR SINTER 1718
PLANT MATERIALS HANDLING WET AIR POLLUTION
CONTROL
V-2 WATER USE AND DISCHARGE RATES FOR BLAST 1718
FURNACE SLAG GRANULATION
V-3 WATER USE AND DISCHARGE RATES FOR DROSS 1719
REVERBERATORY FURNACE GRANULATION WASTEWATER
V-4 WATER USE AND DISCHARGE RATES FOR DROSS 1719
REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
V-5 WATER USE AND DISCHARGE RATES FOR ZINC FUMING 1720
FURNACE WET AIR POLLUTION CONTROL
V-6 WATER USE AND DISCHARGE RATES FOR HARD LEAD 1720
REFINING WET AIR POLLUTION CONTROL
V-7 WATER USE AND DISCHARGE RATES FOR HARD LEAD 1721
REFINING SLAG GRANULATION
V-8 PRIMARY LEAD SAMPLING DATA RAW SMELTING 1722
WASTEWATER
V-9 PRIMARY LEAD SAMPLING DATA MISCELLANEOUS 1724
WASTEWATER
•
V-10 PRIMARY LEAD SAMPLING DATA PARTIAL TREATMENT 1726
SAMPLES PLANT A
VI-1 FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS 1736
PRIMARY LEAD RAW WASTEWATER
VI-1 TOXIC POLLUTANTS NEVER DETECTED 1740
1663
-------
PRIMARY LEAD SUBCATEGORY
LIST OF TABLES (Continued)
Number Page
VIII-1 COST OF COMPLIANCE FOR THE PRIMARY LEAD 1754
SUBCATEGORY DIRECT DISCHARGERS
VII1-2 COST OF COMPLIANCE FOR THE PRIMARY LEAD 1754
SUBCATEGORY INDIRECT DISCHARGERS
IX-1 BPT WASTEWATER DISCHARGE RATES FOR THE 1765
PRIMARY LEAD SUBCATEGORY
IX-2 BPT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD 1766
SUBCATEGORY
X-l POLLUTANT REMOVAL ESTIMATES FOR PRIMARY LEAD 1782
DIRECT DISCHARGERS
X-2 BAT WASTEWATER DISCHARGE RATES FOR THE PRIMARY 1783
LEAD SUBCATEGORY
X-3 BAT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD 1784
SUBCATEGORY
XI-1 NSPS WASTEWATER DISCHARGE RATES.FOR THE PRIMARY 1796
LEAD SUBCATEGORY
XI-2 NSPS FOR THE PRIMARY LEAD SUBCATEGORY 1797
XII-1 POLLUTANT REMOVAL ESTIMATES FOR PRIMARY LEAD 1807
INDIRECT DISCHARGERS
XII-2 PSES WASTEWATER DISCHARGE RATES FOR THE PRIMARY 1808
LEAD SUBCATEGORY
XI1-3 PSNS WASTEWATER DISCHARGE RATES FOR THE PRIMARY 1809
LEAD SUBCATEGORY
XI1-4 PSES FOR THE PRIMARY LEAD SUBCATEGORY 1810
XII-5 PSNS FOR-THE PRIMARY LEAD SUBCATEGORY 1816
1664
-------
PRIMARY LEAD SUBCATEGORY
LIST OF FIGURES
Number - Page
III-l PRIMARY LEAD MANUFACTURING PROCESS 1705
III-2 GEOGRAPHIC LOCATIONS OF PRIMARY LEAD 1706
SUBCATEGORY PLANTS
V-l SAMPLING SITES AT PRIMARY LEAD PLANT A 1728
V-2 SAMPLING SITES AT PRIMARY LEAD PLANT B 1729
V-3 SAMPLING SITES AT PRIMARY LEAD PLANT C 1730
IX-1 BPT TREATMENT SCHEME FOR PRIMARY LEAD 1771
SUBCATEGORY
X-l BAT TREATMENT SCHEME OPTION A 1788
X-2 BAT TREATMENT SCHEME OPTION B 1789
X-3 BAT -TREATMENT SCHEME OPTION C 1790
1665
-------
PRIMARY LEAD SUBCATEGORY
THIS PAGE INTENTIONALLY LEFT BLANK
1666
-------
LEAD SUBCATEGORY SECT - I
SECTION I
SUMMARY
On February 27, 1975, EPA promulgated technology-based effluent
limitations for the primary lead subcategory of the Nonferrous
Metals Manufacturing Point Source Category. Best practicable
control technology currently available (BPT) and best available
technology economically achievable (BAT) effluent limitations
were established. Under these limitations, discharge of process
wastewater pollutants into navigable waters was prohibited for
plants located in historical areas of net evaporation with the
following exceptions. Discharge without limitation was allowed
for a volume of process wastewater equivalent to the volume of
stormwater in excess of that attributable to a 10-year, 24-hour
rainfall falling on the wastewater cooling impoundment.
Discharge, subject to concentration-based limitations, was
allowed for a volume equal to the net monthly precipitation on
the wastewater cooling pond.
The best practicable control technology currently available was
also established for plants located in historical areas of net
precipitation. These limitations allowed a constant discharge of
process wastewater and limited the quantities of total suspended
solids, cadmium, lead, zinc, and the range of pH found in primary
lead effluents.
EPA promulgated amendments to BPT and BAT, and establish BDT and
pretreatment standards for this subcategory pursuant to the Clean
Water Act amendments of 1977. This supplement provides a
compilation and analysis of the background material used to
develop these effluent limitations and standards.
The primary lead subcategory is comprised of six plants. Of the
six plants, four discharge directly to a river, lake, or stream;
two discharge to publicly owned treatment works (POTW); and none
achieve zero discharge of process wastewater.
EPA first studied the primary lead subcategory to determine
whether differences in raw materials, final products,
manufacturing processes, equipment, age and size of plants, and
water usage, required the development of separate effluent
limitations and standards for different segments of the
subcategory. This involved a detailed analysis of wastewater
discharge and treated effluent characteristics, including (1) the
sources and volume of water used, the processes used, and the
sources of pollutants and wastewaters in the plant; and (2) the
constituents of wastewaters, including toxic pollutants.
Several distinct control and treatment technologies (both in-
plant and end-of-pipe) applicable to the primary lead subcategory
were identified. The Agency analyzed both historical and newly
generated data on the performance of these technologies,
1667
-------
PRIMARY LEAD SUBCATEGORY SECT - I
including their nonwater quality environmental impacts (such as
air quality impacts, and solid waste generation) and energy
requirements. EPA also studied various flow reduction techniques
reported in the data collection portfolios (dcp) and plant
visits.
Engineering costs were prepared for each of the control and
treatment options considered for the subcategory. These costs
were then used by the Agency to estimate the impact of
implementing the various options on the subcategory. For each
control and treatment option that the Agency found to be most
effective and technically feasible in controlling the discharge
of pollutants, the number of potential closures, number of
employees affected, and impact on price were estimated. These
results are reported in a separate document entitled Economic
Impact Analysis of_ Effluent Limitations Guidelines and Standards
for the Nonferrous Smelting and Refining Industry.
Based on consideration of the above factors, EPA identified
various control and treatment technologies which formed the basis
for BPT and selected control and treatment appropriate for each
set of standards and limitations. The mass limitations and
standards for BPT, BAT, NSPS, PSES, and PSNS are presented in
Section II.
After examining the various treatment technologies, the Agency
has identified BPT to represent the average of the best existing
technology. Metals removal based on lime precipitation and
sedimentation technology is the basis for the BPT limitations. To
meet the BPT effluent limitations based on this technology, the
primary lead subcategory is expected to incur an estimated
capital cost of $0.260 million (1982 dollars) and an estimated
annual cost of $0.116 million (1982 dollars).
For BAT, the Agency has built upon the BPT basis by adding in-
process control technologies which include recycle of process
water from air pollution control, dross reverberatory
granulation, and facility washdown waste streams. Multimedia
filtration followed by sulfide precipitation is added as an
effluent polishing step to the end-of-pipe treatment scheme.
Sulfide precipitation and sedimentation technology is added after
lime precipitation 'and sedimentation to achieve the performance
of lime, settle, and filter technology. To meet the BAT effluent
limitations based on this technology, the primary lead
subcategory is expected to incur an estimated capital cost of
$0.215 million (1982 dollars) and an estimated annual cost of
$0.118 million (1982 dollars).
The best demonstrated technology (BDT), which is the technical
basis of NSPS, has been determined as zero discharge of process
wastewater pollutants except for wastewater generated from those
industrial hygiene streams provided an allowance at BAT. In
selecting BDT, EPA recognizes that new plants have the
opportunity to implement the best and most efficient
manufacturing processes and treatment technology. As such, new
1668
-------
PRIMARY LEAD SUBCATEGORY SECT - I
plants entering the primary lead subcategory will have the
opportunity to install dry slag conditioning devices, or reuse
and recycle process wastewater if a wet granulating system is
installed.
The Agency is promulgating pretreatment standards for existing
sources based on the same technology as BAT. The technology
basis is in-process flow reduction, lime precipitation,
sedimentation, sulfide precipitation, sedimentation, and
multimedia filtration. To meet the PSES, the primary lead
subcategory will incur an estimated capital cost of $0.038
million (1982 dollars) and an estimated annual cost of $0.007
million (1982 dollars). The technology basis for pretreatment
standards for new sources (PSNS) is equivalent to the technology
used for NSPS. The PSNS do not allow a discharge of process
wastewater pollutants except for wastewater generated from
industrial hygiene streams.
1669
-------
PRIMARY LEAD SUBCATEGORY SECT - I
THIS PAGE INTENTIONALLY LEFT BLANK
1670
-------
PRIMARY LEAD SUBCATEGORY SECT - II
SECTION II
CONCLUSIONS
EPA has divided the primary lead subcategory into 12 subdivisions
or building blocks for the purpose of effluent limitations and
standards. These building blocks are:
(a) Sinter plant materials handling wet air pollution
control,
(b) Blast furnace wet air pollution control,
(c) Blast furnace slag granulation,
(d) Dross reverberatory slag granulation,
(e) Dross reverberatory furnace wet air pollution control,
(f) Zinc fuming furnace wet air pollution control,
(g) Hard lead refining slag granulation,
(h) Hard lead refining wet air pollution control,
(i) Facility washdown,
(j) Employee handwash,
(k) Respirator wash, and
(1) Laundering of uniforms.
A modified BPT is promulgated based on the performance
achievable by the application of chemical precipitation, and
sedimentation (lime and settle) technology. The following
BPT effluent limitations are promulgated:
(a) Sinter Plant Materials Handling Wet Air Pollution
Control BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Lead 594.000 270.000
Zinc 525.000 219.600
TSS 14,760.000 7,020.000
pH Within the range of 7.0 to 10.0
at all times
1671
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(b) Blast Furnace Wet Air Pollution Control BPT
Pollutant or•Maximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
(c) Blast Furnace Slag Granulation BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Lead 6,155.000 2,798.000
Zinc 5,446.000 2,276.000
TSS 153,000.000 72,740.000
pH Within the range of 7.0 to 10.0
at all times
1672
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(d) Dross Reverberatory Slag Granulation BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Lead 9,499.000 4,318.000
Zinc 8,405.000 3,512.000
TSS 236,000.000 112,300.000
pH Within the range of 7.0 to 10.0
at all times
(e) Dross Reverberatory Furnace Wet Air Pollution Control BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Lead 15,920.000 7,235.000
Zinc 14,080.000 5,884.000
TSS 395,500.000 188,100.000
pH Within the range of 7.0 to 10.0
at all times
1673
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(f) Zinc Fuming Furnace Wet Air Pollution Control BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 702.900 319.500
Zinc 622.000 259.900
TSS 17,470.000 8,307.000
pH Within the range of 7.0 to 10.0
at all times
(g) Hard Lead Refining Slag Granulation BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
1674
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(h) Hard Lead Refining Wet Air Pollution Control BPT
Pollutant or • Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 32,730.000 14,880.000
Zinc 28,960.000 12,100.000
TSS 813,300.000 386,800.000
pH Within the range of 7.0 to 10.0
at all times
(i) Facility Washdown BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
1675
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(j) Employee Handwash BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 5.445 2.475
Zinc 4.818 2.013
TSS 135.300 64.350
pH Within the range of 7.0 to 10.0
at all times
(k) Respirator Wash BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 8.745 3.975
Zinc 7.738 3.233
TSS 217.300 103.400
pH Within the range of 7.0 to 10.0
at all times
1676
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(1) Laundering of Uniforms BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 25.580 11.630
Zinc 22.630 9.455
TSS 635.500 302.300
pH Within the range of 7.0 to 10.0
at all times
A modified BAT is promulgated based on the performance achievable
by the application of lime precipitation, sedimentation, sulfide
precipitation, sedimentation, and multimedia filtration
technology, and in-process flow reduction control methods. The
following BAT effluent limitations are promulgated for existing
sources:
(a) Sinter Plant Materials Handling Wet Air Pollution
Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Lead 100.800 46.800
Zinc 367.200 151.200
1677
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PRIMARY LEAD SUBCATEGORY SECT - II
(b) Blast Furnace Wet Air Pollution Control BAT
Pollutant or . Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(c) Blast Furnace Slag Granulation BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(d) Dross Reverberatory Furnace Slag Granulation BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte/ or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Lead 1,612.000 748.400
Zinc 5,872.000 2,418.000
1678
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PRIMARY LEAD SUBCATEGORY SECT - II
(e) Dross Reverberatory Furnace Wet Air Pollution Control BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Lead 0.000 0.000
Zinc 0.000 0.000
(f) Zinc Fuming Furnace Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(g) Hard Lead Refining Slag Granulation BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
1679
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(h) Hard Lead Refining Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property • Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
(i) Facility Washdown BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.000 0.000
Zinc 0.000 0.000
(j) Employee Handwash BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units '- Ibs/billion Ibs of lead bullion produced
Lead 0.924 0.429
Zinc 3.366 1.386
1680
-------
PRIMARY LEAD SUBCATEGORY SECT -II
(k) Respirator Wash BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 1.484 0.689
Zinc 5.406 2.226
(1) Laundering of Uniforms BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 4.340 2.015
Zinc 15.810 6.510
NSPS are promulgated based on the performance achievable by
the application of lime precipitation, sedimentation, sulfide
precipitation, sedimentation, and multimedia filtration
technology, and in-process flow reduction control methods. The
following effluent standards are promulgated for new sources:
1681
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(a) Sinter Plant Materials Handling Wet Air Pollution
Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
(b) Blast Furnace Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
1682
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(c) Blast Furnace Slag Granulation NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
(d) Dross Reverberatory Slag Granulation NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
1683
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(e) Dross Reverberatory Furnace Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
(f) Zinc Fuming Furnace Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
1684
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(g) Hard Lead Refining Slag Granulation NSPS
Pollutant or . Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
(h) Hard Lead Refining Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
1685
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(i) Facility Washdown NSPS
Pollutant or . Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.000 0.000
Zinc 0.000 0.000
TSS 0.000 0.000
pH Within the range of 7.0 to 10.0
at all times
(j) Employee Handwash NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.924 0.429
Zinc 3.366 1.386
TSS 49.500 39.600
pH Within the range of 7.0 to 10.0
at all times
1686
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(k) Respirator Wash NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 1.484 0.689
Zinc 5.406 2.226
TSS 79.500 63.600
pH Within the range of 7.0 to 10.0
at all times
(1) Laundering of Uniforms NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 4.340 2.015
Zinc 15.810 6.510
TSS 232.500 186.000
pH Within the range of 7.0 to 10.0
at all times
1687
-------
PRIMARY LEAD SUBCATEGORY SECT - II
PSES are promulgated based on the performance achievable by
the application of lime precipitation, sedimentation, sulfide
precipitation, sedimentation, and multimedia filtration
technology, and in-process flow reduction control methods. The
following pretreatment• standards are promulgated for existing
sources:
(a) Sinter Plant Materials Handling Wet Air Pollution
Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Lead 100.800 46.800
Zinc 367.200 151.200
(b) Blast Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
1688
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(c) Blast Furnace Slag Granulation PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(d) Dross Reverberatory Slag Granulation PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Lead 1,612.000 748.400
Zinc 5,872.000 2,418.000
(e) Dross Reverberatory Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Lead 0.000 0.000
Zinc 0.000 0.000
1689
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(f) Zinc Fuming Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(g) Hard Lead Refining Slag Granulation PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
(h) Hard Lead Refining Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
1690
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(i) Facility Washdown PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.000 ' 0.000
Zinc 0.000 0.000
(j) Employee Handwash PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.924 0.429
Zinc 3.366 1.386
(k) Respirator Wash PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 1.484 0.689
Zinc 5.406 2.226
1691
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(1) Laundering of Uniforms PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead
Zinc
4.340
15.810
2.015
6.510
PSNS are promulgated based on the performance achievable by
the application of lime precipitation, sedimentation, sulfide
precipitation, sedimentation, and multimedia filtration
technology, and in-process flow reduction control methods. The
following pretreatment standards are promulgated for new sources:
(a) Sinter Plant Materials Handling Wet Air Pollution
Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Lead 0.000 0.000
Zinc 0.000 0.000
1692
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(b) Blast Furnace Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(c) Blast Furnace Slag Granulation PSNS
Pollutant or - Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(d) Dross Reverberatory Slag Granulation PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Lead .0.000 0.000
Zinc 0.000 0.000
1693
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(e) Dross Reverberatory Furnace Wet Air Pollution Control PSNS
Pollutant or . Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Lead 0.000 0.000
Zinc 0.000 0.000
(f) Zinc Fuming Furnace Wet Air Pollution Control . PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Lead 0.000 0.000
Zinc 0.000 0.000
(g) Hard Lead Refining Slag Granulation PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
1694
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(h) Hard Lead Refining Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property . Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Lead 0.000 0.000
Zinc 0.000 0.000
(i) Facility Washdown PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.000 0.000
Zinc 0.000 0.000
(j) Employee Handwash PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead 0.924 0.429
Zinc 3.366 1.386
1695
-------
PRIMARY LEAD SUBCATEGORY SECT - II
(k) Respirator Wash PSNS
Pollutant or
Pollutant Property
Maximum for Maximum for
Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead
Zinc
1.484
5.406
0.689
2.226
(1) Laundering of Uniforms PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Lead
Zinc
4.340
15.810
2.015
6.510
1696
-------
PRIMARY LEAD SUBCATEGORY SECT - III
SECTION III
SUBCATEGORY PROFILE
This section of the Primary Lead Supplement describes the raw
materials and processes used in smelting and refining primary
lead and presents a profile of the primary lead plants identified
in this study. For a discussion of the purpose, authority, and
methodology for this study and a general description of the
nonferrous metals manufacturing category, refer to Section III of
Vol. I.
DESCRIPTION OF PRIMARY LEAD PRODUCTION
Primary lead production can be divided into five distinct steps
sintering, blast furnace reduction, dressing, softening and
refining, and casting. With only a few exceptions, the
pyrometallurgical processes used in the U.S. primary lead
industry have changed little in the last 75 years. The primary
lead production process is presented schematically in Figure III-
1 (page 1705) and described below.
RAW MATERIALS
Galena (PbS), cerusite (PbC03), and anglesite (PbS04) are
the principal mineral ores used in the production of primary
lead. Most of these ores originate in southeastern Missouri, but
Idaho and Utah also produce significant amounts. Missouri ore
concentrates have a lead content exceeding 70 percent and few
.impurities; the combined zinc and copper content of these ores is
less than 3 percent. Fewer refining steps are required for
Missouri ores because of their high grade. Other domestic lead
smelters process different domestic and imported ores. The ore
concentrates used by these smelters vary, but generally contain
less lead and more impurities than concentrates from Missouri.
SINTERING
The initial step in the production of primary lead is a smelting
operation which consists of blending the ore concentrates with
recycle products and fluxes. The blend is moistened, pelletized
using ball drums, and fed to a traveling grate furnace or
sintering machine.
The objectives of the sintering operation are not only to remove
sulfur as S02 and 863 and to eliminate, by volatilization, much
of the cadmium present in the ore concentrate, but, equally
important, to produce "sinter" of suitable size distribution and
strength for subsequent treatment in the blast furnace.
In the most common type of sintering operation, a layer of
pellets is placed on a grate and ignited by overhead downdraft
burners. Another layer of pellets is then laid upon the first
1697
-------
PRIMARY LEAD SUBCATEGORY SECT - III
layer, and the traveling grate enters the updraft windbox section
of the sintering machine. The applied updraft causes the bed of
sinter to burn from the bottom up. In another sintering method,
the air flows from above (downdraft system) and the burners are
placed below the charge. Whichever system is used, the charge is
sintered in the front half of the sintering machine, called the
strong gas strand, while the rear half, the weak gas strand, is
used to cool the sintered charge. Sulfur oxides, arsenic,
antimony, and cadmium are volatized during this process. The
highly concentrated SOX stream emitted during the initial part of
the sintering operation is usually sent to a sulfuric acid plant.
Particulates entrained in the off-gases are removed from gas by a
flue or baghouse or both. The collected particulate is then
mixed with water in a pugmill and then recycled to the sintering
machine.
In the next step, the sinter is passed through a sinter breaker
at the end of the sintering machine, broken, and sized. Oversize
particles are fed to the blast furnace, while undersize particles
are crushed and water cooled before returning to the sinter feed
operation. Sinter breaking produces significant amounts of dust
that are collected and recycled to the sinter feed.
Two plants report using wet scrubbers to control fugitive lead
emissions from transfer points, conveyers, and crushing
operations associated with sintering. A separate subcategory,
metallurgical acid plants, has been created to account for the
control of by-product recovery from the acidic SOX gas stream
which sintering generates.
BLAST FURNACE REDUCTION
The blast furnace is the primary reduction unit of a lead
smelter. By a combination of heat and reducing gases, it
separates the constituents into two phases: molten metal and
slag. The metals that are easily reduced, such as lead, copper,
silver, gold, bismuth, antimony, and arsenic, become part of the
metal phase; metals that are not easily reduced become part of
the slag phase along with the nonmetallic elements. Blast
furnaces are usually rectangular, water cooled, and charged from
the top while air, sometimes enriched with oxygen, is introduced
into the bottom by tuyeres. The charge consists of sinter, flux,
and coke, and usually includes recycled slag and dust from other
operations.
Two or three molten layers form in the blast furnace. The top
layer of the melt is slag containing iron, calcium, and magnesium
silicates; small quantities of arsenic and antimony; and variable
amounts of lead (1.5 to 4 percent). Slags with economically
recoverable zinc may be processed on-site by slag fuming for zinc
recovery. In this process, the slag is heated with coal to high
temperatures that oxidize zinc into particles which are then
collected with dust-collecting equipment. Wet air pollution
control methods may also be applied to these zinc fuming
furnaces. Slag after zinc fuming, or slag which is discarded
1698
-------
PRIMARY LEAD SUBCATEGORY SECT - III
without fuming, is usually granulated by impacting a stream of
the molten slag with a high-pressure water jet. The granulated
slag may be dewatered and either recycled as part of the charge
materials to the sinter process or, depending on slag composition
and plant facilities, totally discarded.
A middle layer, matte, may be formed in some cases. Matte is
composed of copper and iron sulfides, along with precious metals.
If significant quantities of arsenic are present in the charge,
speiss is also formed. Matte and speiss are usually sent to
copper smelters for further treatment.
The bottom layer, lead bullion, is retained and further refined.
Lead bullion normally contains quantities of copper, arsenic,
antimony, or bismuth. These impurities must be removed by
further processing to produce an acceptable lead product. The
lead bullion also may contain precious metals in quantities that
are economically recoverable.
BROSSING
Dressing is the initial step in refining the molten lead bullion
from the blast furnaces. The bullion is transferred to open-
topped, gas heated dressing kettles. Agitation and oxidation is
provided by submerged air lances or mechanical means. The molten
lead is cooled to a temperature at which oxides of lead and the
common impurities in lead, particularly copper, solidify but the
lead remains liquid. Since lead has such a high specific
gravity, the separated impurities float to the top of the metal
bath and form a solid scum, or "dross," which is subsequently
skimmed off. The liquid lead may be transferred to a second
kettle, where a second cycle can be performed. Sulfur is
sometimes added to the melt to enhance the removal of copper as
black copper sulfide powder which also rises to the top of the
kettle. By dressing, the copper content of the lead is reduced
from as high as several tenths of a percent to as low as 0.005
percent.
The skimmed dross, which typically contains about 90 percent lead
oxide, 2 percent copper, and 2 percent antimony, as well as gold,
silver, arsenic, bismuth, indium, zinc, tellurium, nick*el,
selenium, and sulfur is charged to a by-product reverberatory
furnace (i.e., dross reverb) to recover lead bullion and other
marketable products. Sodium carbonate and coke breeze are also
charged to the furnace as fluxes to facilitate matte and speiss
formation. Matte and speiss separate into two layers beneath the
top slag and are removed and sold to a copper smelter. Liquid
lead is tapped from the bottom of the furnace and returned to the
dross kettles. Slag is returned to the lead blast furnace. Wet
air pollution control scrubbers may be used to control emissions
from the dross reverberatory furnace. Additionally, wastewater
may be generated by the granulation of slag, matte, and speiss.
1699
-------
PRIMARY LEAD SUBCATEGORY SECT - III
SOFTENING AND REFINING
After dressing, the bullion is subjected to a "softening" step.
This refining operation is performed to remove antimony by
oxidation and produces a product of lower hardness and strength.
In contrast, lead alloyed with antimony is commonly referred to
as "hard lead" or antimonial lead.
Softening may be done in a reverberatory-type furnace or by an
oxidative slagging procedure using a sodium hydroxide and sodium
nitrate mixture as an oxidant. In the reverberatory furnace
operation, air is introduced through pipes or lances into the
melt to oxidize impurities and form a slag which is then skimmed
from the melt. This oxidation-skimming step is repeated to
remove a second slag. The two slags are treated for recovery of
antimony, antimonial lead, and sodium arsenate. Sodium arsenate
is usually discarded. Tin slag generated in this process is sent
to a tin recovery operation.
There are two oxidative slagging techniques for antimony removal
from lead bullion: the kettle process and the Harris process. In
both processes, a sodium hydroxide and sodium nitrate mixture is
added to the molten metal, and impurities are then removed by
skimming. The slag is discarded in the kettle process, but
sodium hydroxide is recovered hydrometallurgically from the slag
in the Harris process. Other metals, such as arsenic, antimony,
and tin, may also be recovered.
Arsenical and anhimonial skims may be sent to a furnace and then
to a refining kettle to produce antimonial lead. Coke, silica,
and sodium carbonate are sometimes added to the furnace, as
fluxes, and lead oxide may be added to the refining kettle. Wet
air pollution control methods or granulation of furnace slag with
water may also be practiced.
Final refining of softened lead bullion is undertaken to remove
gold, silver, and bismuth. Gold and silver are removed by the
Parke's process in which zinc is added to the molten bullion to
form insoluble zinc-gold and zinc-silver compounds. These
compounds are subsequently skimmed, and residual zinc is removed
from the bullion by vacuum dezincing. Vacuum dezincing is
performed in a separate cell which vaporizes and removes zinc
from the melt under a vacuum.
The Betterton process is used to remove bismuth from lead.
Calcium and magnesium are simultaneously added to molten lead to
precipitate CaMg2Bi2 crystals which float to the surface and are
skimmed. Antimony or organic agents are sometimes added to
facilitate removal. Residual calcium and magnesium are removed
by adding caustic soda to the bullion in a final refining kettle.
A slag containing calcium, magnesium, and other trace impurities
is removed from the refined bullion and recycled to the blast
furnace.
1700
-------
PRIMARY LEAD SUBCATEGORY SECT - III
CASTING
Refined lead, which now assays greater than 99.9 percent purity,
is sent to a casting operation where it is cast into ingots or
pigs. None of the plants in the primary lead subcategory
reported using contact cooling water.
PROCESS WASTEWATER SOURCES
Although a variety of processes are involved in primary lead
production, the significant wastewater sources that will be
associated with the primary lead subcategory can be subdivided as
follows:
1. Sinter plant materials handling wet air pollution
control,
2. Blast furnace wet air pollution control,
3. Blast furnace slag granulation,
4. Zinc fuming furnace wet air pollution control,
5. Dross reverberatory furnace wet air pollution control,
6. Dross reverberatory furnace granulation wastewater,
7. Hard lead refining wet air pollution control, and
8. Hard lead refining slag granulation.
Although not related to any one specific operation, contaminated
wastewater is generated due to industrial hygiene requirements.
Wastewater associated with employee hand washing, laundering of
uniforms, respirator wash, and facility washdown are all
contaminated with lead.
OTHER WASTEWATER SOURCES
There are other waste streams associated with the primary lead
subcategory. These waste streams include stormwater runoff,
maintenance and cleanup water, and miscellaneous granulation
water. These waste streams are not considered as a part of this
rulemaking. EPA believes that the flows and pollutant loadings
associated with these waste streams are too insignificant to
warrant a discharge allowance and are best handled by the
appropriate permit authority on a case-by-case basis under
authority of Section 402 of the Clean Water Act.
AGE, PRODUCTION, AND PROCESS PROFILE
Figure III-2 (page 1706) shows the locations of the six primary
lead plants operating in the United States. All six are located
west of the Mississippi River with the greatest concentration
near the rich lead ore deposits in Missouri.
1701
-------
PRIMARY LEAD SUBCATEGORY SECT - III
Table III-l (page 1703) illustrates the relative age and
discharge status of the primary lead plants throughout the United
States. Four plants were built prior to or during World War I,
and the other two have . been built in the last 15 years.
Smelting, which includes sintering, blast furnace reduction, and
dressing, is performed by five of the six plants. Two of these
plants also soften, refine, and cast the lead. One plant
performs only the last three refining steps.
From Table III-2 (page 1703) it can be seen that of the six
facilities which produce primary lead, production is between
100,000 and 250,000 tons/yr. Mean production is about 150,000
tons/yr.
Table III-3 (page 1704) provides a summary of the number of
plants generating wastewater for the waste streams associated
with the various processes and the number of plants with the
process.
1702
-------
PRIMARY LEAD SUBCATEGORY
SECT - III
TABLE III-l
INITIAL OPERATING YEAR SUMMARY OF PLANTS IN THE
PRIMARY LEAD SUBCATEGORY BY DISCHARGE TYPE
Initial Operating Year
(Plant Age in Years)
Type of
Plant
Direct
Indirect
Zero
Total
1983-
1967
(0-15)
2
0
£
2
1966-
1947
(15-35)
0
0
£
0
1946-
1927
(35-55)
0
0
£
0
1926-
1907
(55-75)
1
0
£
1
1906-
1883
(75-100)
1
2
£
3
Total
4
2
£
6
TABLE III-2
PRODUCTION RANGES FOR THE PRIMARY LEAD SUBCATEGORY
Production Ranges for 1976
(Tons/Year)a
50000 - 100000
100001 - 200000
200001 - 250000
Total
Number of Plants
1
2
3
6
(a) - Based on production from blast furnace,
1703
-------
Table III-3
SUMMARY OF PRIMARY LEAD SUBCATEGORY PROCESSES AND ASSOCIATED WASTE STREAMS
Waste Stream
Sinter Plant Materials Handling
o Air Pollution Control
Blast Furnace
o Slag Granulation
o Air Pollution Control
Zinc Fuming Furnace
o Air Pollution Control
Dross Reverberatory Furnace
o Slag Granulation
•> Air Pollution Control
Hard Lead Refining
o Slag Granulation
o Air Pollution Control
Number of Plants
With Process
5
2
5
3
5
2
2
4
2
4
k
Ob
Number of Plants
Generating Wastewater3
3
0
o
o
5
tr"
W
c!
W
n
S
w
o
o
w
n
a Through reuse or evaporation practices, a plant may "generate" a wastewater from
a particular process but not discharge it.
b At proposal one plant generated wastewater from this process. The plant has
since closed.
H
H
-------
PRIMARY LEAD SUBCATEGORY SECT - III
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fun-
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Figure III-l
PRIMARY LEAD MANUFACTURING PPOCESS
1705
-------
I - Indirect process wastewater discharge plants
D - Direct process wastewater discharge plants
Z - Zero discharge of process wastewater plants
H
K
W
in
s
o
w
a
w
M
Figure III-2
GEOGRAPHIC LOCATIONS OF PRIMARY LEAD SUBCATEGORY PLANTS
-------
PRIMARY LEAD SUBCATEGORY SECT - IV
SECTION IV
SUBCATEGORIZATION
This section summarizes the factors considered during the
designation of the primary lead subcategory and its related
subdivisions. The production of lead is distinguished from that
of other nonferrous metals because the type of metal product
accounts for differences in production processes, raw materials,
and many other characteristics that are unique to the production
of specific nonferrous metals. Lead is produced from both
primary and secondary materials. Since the extraction processes
and waste generation are dissimilar, lead production is divided
into primary and secondary lead subcategories on the basis of raw
materials.
FACTORS CONSIDERED IN SUBDIVIDING THE PRIMARY LEAD SUBCATEGORY
Because different production processes generate dissimilar
wastewaters and the combination of production processes utilized
varies from plant to plant within the subcategory, effluent
limitations and standards are developed for each specific
wastewater source or building block. The limitations and
standards will be based on specific flow allowances for the
following building blocks.
1. Sinter plant materials handling wet air pollution
control,
2. Blast furnace wet air pollution control,
3. Blast furnace slag granulation,
4. Dross reverberatory furnace granulation wastewater,
5. Dross reverberatory furnace wet air pollution control,
6. Zinc fuming furnace wet air pollution control,
7. Hard lead refining slag granulation,
8. Hard lead refining wet air pollution control,
9. Facility washdown,
10. Employee hand wash,
11. Respirator wash, and
12. Laundering of uniforms.
These subdivisions follow directly from differences between the
processing steps of primary lead production. Blast furnace
reduction, dressing, and refining each have various steps which
may generate wastewaters.
Sinter plant materials handling wet air pollution control is a
result of wet scrubbers used in the ventilating system to control
fugitive emissions emitted during the transportation of
concentrate prior to sintering. A separate subdivision has been
created for this waste stream because its operation is
independent of the blast furnace area.
1707
-------
PRIMARY LEAD SUBCATEGORY SECT - IV
Blast furnace reduction of sinter into lead bullion establishes a
need for the next three subdivisions — blast furnace slag
granulation, blast furnace wet air pollution control, and zinc
fuming furnace wet air pollution control. Slag from the blast
furnace, or from a zinc fuming furnace, is granulated by
impacting a stream of molten slag with a high pressure water jet.
The water from this process may be recycled or discharged. Wet
air pollution control devices may be used to control particulate
and volatile emissions from the blast furnace and from a high
temperature furnace used to oxidize and "fume" recoverable zinc
from a blast furnace slag. Three separate subdivisions are
necessary because some plants do not use all these processes.
The fifth and sixth subdivisions result from differences in the
dressing practices at plants. Reverberatory furnaces, which are
used to separate impurities from the skimmed dross from the
dressing kettles, may require wet air pollution control devices.
Additionally, if the copper rich matte and speiss are recovered
for resale, water may be used to granulate the matte and speiss
layers in much the same way as slag from blast furnace reduction
is granulated. Creation of these two subdivisions is necessary
to account for the presence or absence of these wastewater
sources.
The rationale for creation of subdivisions seven and eight is
based on a potential wastewater source in the softening and
refining step. Wet air pollution control methods may be used to
reduce particulate emissions from "hard lead" furnaces, while
slag from the "hard lead" furnaces may be granulated with water.
Subdivision is necessary to account for the actual presence or
absence of each source.
Subdivisions for the final four waste streams have been created
to account for wastewater generated due to industrial hygiene
requirements. A subdivision is created for each source because
respirators and uniforms may be cleaned off-site or dry vacuuming
methods may be used instead of washdown waters. Separate
allowances for each source will provide the permit or control
authority with the flexibility to provide only those allowances
that are appropriate for operations conducted on-site.
OTHER FACTORS
The other factors considered in this evaluation either support
the establishment of the 12 subdivisions or were shown to be
inappropriate bases for subdivision. Air 'pollution control
methods, treatment costs, and total energy requirements are
functions of the selected subcategorization factors — metal
product, raw materials, and production processes. As discussed
in Section IV of Vol. I, certain other factors, such as plant
age, plant size, and the number of employees, were also evaluated
and determined to be inappropriate for use as bases for
subdivision of nonferrous metal subcategory.
1708
-------
PRIMARY LEAD SUBCATEGORY
SECT - IV
PRODUCTION NORMALIZING PARAMETERS
As discussed previously, the effluent limitations and standards
developed in this document establish mass limitations on the
discharge of specific pollutant parameters. To allow these
regulations to be applied to plants with various production
capacities, the mass of pollutant discharged must be related to a
unit of production. This factor is known as the production
normalizing parameter (PNP). The Agency received no comments on
the proposed effluent limitations questioning the selection of
production normalizing parameters. Therefore, the Agency is not
changing the PNP for any waste stream. The PNP's for the 12
subdivisions or building blocks are as follows:
Building Block
1. Sinter plant materials handling
wet air pollution control
2. Blast furnace wet air pollu-
tion control
3. Blast furnace slag granulation
Dross reverberatory furnace
granulation wastewater
Dross reverberatory furnace
wet air pollution control
6. Zinc fuming furnace wet air
pollution control
7. Hard lead refining slag gran-
ulation
8. Hard lead refining wet air
pollution control
9. Facility washdown
10. Employee hand wash
11. Respirator wash
12. Laundering of uniforms
PNP
kkg of sinter production
kkg of blast furnace lead
bullion produced
kkg of blast furnace lead
bullion produced
kkg of slag, matte, or
speiss granulated
kkg of dross
reverberatory
furnace production
kkg of blast furnace lead
bullion produced
kkg of hard lead produced
kkg of hard lead produced
kkg of lead bullion
produced
kkg of lead bullion
produced
kkg of lead bullion
produced
kkg of lead bullion
produced
1709
-------
PRIMARY LEAD SUBCATEGORY SECT - IV
THIS PAGE INTENTIONALLY LEFT BLANK
1710
-------
PRIMARY LEAD SUBCATEGORY SECT - V
SECTION V
WASTE USE AND WASTEWATER CHARACTERISTICS
This section describes the characteristics of wastewater
associated with the primary lead subcategory. Data used to
quantify wastewater flow and pollutant concentrations are
presented, summarized, and discussed. The contribution of
specific production processes to the overall wastewater discharge
from primary lead plants is identified whenever possible.
Two principal data sources were used in the development of
effluent limitations and standards for this subcategory: data
collection portfolios and field sampling results. Data
collection portfolios contain information regarding wastewater
flows and production levels. Data gathered through comments on
the proposed mass limitations and specific data requests to
evaluate these comments are also principal data sources.
In order to quantify the pollutant discharge from primary lead
plants, a field sampling program was conducted. A complete list
of the pollutants considered and a summary of the techniques used
in sampling and laboratory analyses are included in Section V of
the General Development Document. Wastewater samples were
collected in two phases: screening and verification. The first
phase, screen sampling, was to identify which toxic pollutants
were present in the wastewaters from production of the various
metals. Screening samples were analyzed for 125 of the 126 toxic
pollutants and other pollutants deemed appropriate. (Because the
analytical standard for TCDD was judged to be too hazardous to be
made generally available, samples were never analyzed for this
pollutant. There is no reason to expect that TCDD would be
present in primary lead wastewater.) A total of 10 plants were
selected for screen sampling in the nonferrous metals
manufacturing category. In general, the samples were analyzed
for three classes of pollutants: toxic organic pollutants, toxic
metal pollutants, and criteria pollutants (which includes both
conventional and nonconventional pollutants).
As described in Section IV of this supplement, the primary lead
subcategory has been segmented into 12 building blocks, so that
the promulgated regulation contains mass discharge limitations
and standards for 12 process wastewaters. Differences in the
wastewater characteristics associated with these building blocks
are to be expected. For this reason, wastewater streams
corresponding to each segment are addressed separately in the
discussions that follow.
WASTEWATER SOURCES, DISCHARGE RATES, AND CHARACTERISTICS
The wastewater data presented in this section were evaluated in
light of production process information compiled during this
study. As a result, it was possible to identify the principal
1711
-------
PRIMARY LEAD SUBCATEGORY SECT - V
wastewater sources in the primary lead subcategory. These
include:
1. Sinter plant materials handling wet air pollution
control,
2. Blast furnace wet air pollution control,
3. Blast furnace slag granulation,
4. Dross reverberatory furnace granulation wastewater,
5. Dross reverberatory furnace wet air pollution control,
6. Zinc fuming furnace wet air pollution control,
7. Hard lead refining slag granulation,
8. Hard lead refining wet air pollution control,
9. Facility washdown,
10. Employee hand wash,
11. Respirator wash, and
12. Laundering of uniforms.
Data supplied by data collection portfolio responses were
evaluated, and two flow-to-production ratios were calculated for
each stream. The two ratios, water use and wastewater discharge
flow, are differentiated by the flow value used in calculation.
Water use is defined as the volume of water required for a given
process per mass of lead product and is therefore based on the
sum of recycle and make-up flows to a given process. Wastewater
flow is used in calculating the production normalized flow — the
volume of wastewater discharged from a given process to further
treatment, disposal, or discharge per mass of lead produced.
Differences between the water use and wastewater flows associated
with a given stream result from recycle, evaporation, and
carry-over on the product. The production values in calculation
correspond to the production normalizing parameter, PNP, assigned
to each stream, as outlined in Section IV. The production
normalized flows were compiled by stream type. Where
appropriate, an attempt was made to identify factors that could
account for variations in water use. This information is
summarized in this section. A similar analysis of factors
affecting the wastewater values is presented in Sections X, XI,
and XII, where representative BAT, BDT, and pretreatment
discharge flows are selected for use in calculating the effluent
limitations and standards. As an example, blast furnace slag
granulation wastewater flow is related to blast furnace lead
bullion production. As such, the discharge rate is expressed in
liters of blast furnace slag granulation wastewater per metric
ton of blast furnace lead bullion production (gallons of blast
furnace slag granulation wastewater per ton of blast furnace lead
bullion production).
Since the data collection portfolios have been collected, the
Agency has learned that one primary lead facility has shut down.
Flow and production data from this plant are still presented in
this section and in the remainder of the document. Analytical
data gathered at this plant are also presented. Although the
plant is closed, flow and production data from the plant are an
integral part of the flow components for BPT and BAT effluent
mass limitations. Therefore, it is necessary to present this
1712
-------
PRIMARY LEAD SUBCATEGORY SECT - V
information so that BPT and BAT limitations are documented. EPA
believes that the data from this plant provide useful measures of
the relationship between production and discharge. In light of
this conclusion, (and indications that the plant closure may not
be permanent), the Agency is using these data in its
consideration of BPT and BAT performance.
In order to quantify the concentrations of pollutants present in
wastewater from primary lead plants, wastewater samples were
collected at three of the seven plants. Diagrams indicating the
sampling sites and contributing production processes are shown in
Figures V-l through V-3 (pages 1728 - 173C).
The sampling data for the primary lead subcategory are presented
in Tables V-8 through V-10 (pages 1722 - 1726). The stream codes
displayed in Tables V-8 through V-10 may be used to identify the
location of each of the samples on process flow diagrams in
Figures V-l through V-3. Where no data are listed for a specific
day of sampling, the wastewater samples for the stream were not
collected. If the analysis did not detect a pollutant in a waste
stream, the pollutant was omitted from the table.
The data tables-include some samples measured at concentrations
considered not quantifiable. The base-neutral extractable, acid
extractable, and volatile organics are generally considered not
quantifiable at concentrations equal to or less than 0.010 mg/1.
Below this concentration, organic analytical results are not
quantitatively accurate; however, the analyses are useful to
indicate the presence of a particular pollutant. The pesticide
fraction is considered not quantifiable at concentrations equal
to or less than 0.05 mg/1. Nonquantifiable results are
designated in the tables with an asterisk (double asterisk for
pesticides).
These detection limits shown on the data tables are not the same
in all cases as the published detection limits for these
pollutants by the same analytical methods. The detection limits
used were reported with the analytical data and hence are the
appropriate limits to apply to the data. Detection limit
variation can occur as a result of a number of laboratory-
specific, equipment-specific, and daily operator-specific
factors. These factors can included day-to-day differences in
machine calibration, variation in stock solutions, and variation
in operators.
The statistical analysis of data includes some samples measured
at concentrations considered not quantifiable. Data reported as
an asterisk are considered as detected but below quantifiable
concentrations, and a value of zero is used for averaging. Toxic
organic, nonconventional, and conventional data reported with a
"less than" sign are considered as detected, but not further
quantifiable. A value of zero is also used for averaging. If a
pollutant is reported as not detected, it is excluded in
calculating the average. Finally, toxic metal values reported as
less than a certain value were considered as not detected and a
1713
-------
PRIMARY LEAD SUBCATEGORY SECT - V
value of zero is used in the calculation of the average. For
example, three samples reported as ND, *, and 0.021 mg/1 have an
average value of 0.010 mg/1. The averages calculated are
presented with the sampling data; these values were not used in
the selection of pollutant parameters.
The method by which each sample was collected is indicated by
number as follows:
1 one-time grab
2 24-hour manual composite
3 24-hour automatic composite
4 48-hour manual composite
5 48-hour automatic composite
6 72-hour manual composite
7 72-hour automatic composite
In the data collection portfolios, plants were asked to indicate
whether or not any of the toxic pollutants were present in their
effluent. Six of the plants indicated that toxic organic
pollutants were believed to be absent from their effluent. One
plant indicated that a few of the toxic organic pollutants are
believed to be present in its effluent. A majority of the plants
stated that some of the toxic metals were known to be present in
their effluent. The responses for the toxic metals are
summarized below:
Known Believed Believed Known
Pollutant Present Present Absent Absent
Antimony 4 1 20
Arsenic 5110
Beryllium 0061
Cadmium 7000
Chromium 1 2 4 0
Coppe r 6 1 0 0
Lead 7000
Mercury 2122
Nickel 3310
Selenium 2221
Silver 4210
Thallium 1 2 40
Zinc 7 0 0 0
SINTER PLANT MATERIALS HANDLING WET AIR POLLUTION CONTROL
Fugitive lead emissions in the sintering area are controlled with
scrubbers at two plants. Ventilation systems utilizing Venturi
scrubbers are used to capture lead and other dusts emitted at the
transfer points, conveyers, and crushing operations. Both plants
using scrubbers currently recycle scrubber liquor as shown in
Table V-l (page 1718). Although the Agency did not sample this
waste stream, it is expected to contain lead, cadmium, copper,
zinc, and suspended solids based on the raw materials used and
1714
-------
PRIMARY LEAD SUBCATEGORY SECT - V
the pollutants detected in blast furnace slag granulation
wastewater.
BLAST FURNACE SLAG GRANULATION
Slag after zinc fuming, and blast furnace slag which is recycled
or discarded without fuming, may be granulated by impacting the
molten slag with a high-pressure water jet. Four plants report
this waste stream. Three of these plants granulate discarded
blast furnace slag, and one plant granulates zinc fuming furnace
slag. The water use and discharge rates for blast furnace slag
granulation are shown in Table V-2 (page 1718).
Blast furnace slag granulation sampling data are presented in
Table V-10 (page 1726). This waste stream is characterized by
the presence of treatable concentrations of cadmium, copper,
lead, zinc and suspended solids.
BLAST FURNACE WET AIR POLLUTION CONTROL
There are six plants in this subcategory that smelt lead in blast
furnaces. All six plants use baghouses to control blast furnace
off-gases and particulates. None of the plants report any
wastewater associated with blast furnace wet air pollution
control.
DROSS REVERBERATORY FURNACE GRANULATION WASTEWATER
Sometimes slag, speiss, or matte produced in the dross
reverberatory furnaces are granulated in water. Three plants
report a dross reverberatory furnace granulation waste stream.
The water use and discharge rates for this stream are shown in
Table V-3 (page 1719).
As shown by Figure V-2, slag and matte granulation wastewater was
a constituent of a sampled stream. The sampling data for this
stream are presented in Table V-9 (page 1724). The sampled
stream was characterized by treatable concentrations of lead and
zinc. Speiss granulation wastewater may also contain these
pollutants along with treatable concentrations of suspended
solids, antimony, and arsenic.
DROSS REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
Five plants report the use of dross reverberatory furnaces. Four
of these plants use baghouses to control fumes from the furnace,
while one plant uses a wet scrubber. The water use and discharge
rates for the plant that uses the scrubber are presented in Table
V-4 (page 1719).
Dross reverberatory furnace scrubber water was also part of the
lead smelter discharge stream shown in Figure V-3. As discussed
previously, this stream is characterized by treatable
concentrations of antimony, cadmium, lead, zinc, and suspended
solids.
1715
-------
PRIMARY LEAD SUBCATEGORY SECT - V
ZINC FUMING FURNACE WET AIR POLLUTION CONTROL
Three plants report the use of fuming furnaces to recover zinc
from blast furnace slag. The slag is heated with coal to high
temperatures that oxidize zinc into particles which are then
collected with air pollution control equipment. One plant uses a
wet scrubber to collect the zinc particles while the other plants
use baghouses. The water use and discharge rates for the plant
that uses wet air pollution control are presented in Table V-5
(page 1720).
As shown by Figure V-3, a lead smelter discharge stream was
sampled. This stream contained zinc fuming furnace scrubber
water and other wastewaters. The sampling data for the discharge
stream are presented in Table V-8 (page 1722). Treatable
concentrations of antimony, cadmium, lead, zinc, and suspended
solids characterize this stream.
HARD LEAD REFINING WET AIR POLLUTION CONTROL AND SLAG GRANULATION
Two plants use hard lead refining to produce antimonial lead.
One of these plants generates wastewater from both refining
furnace slag granulation and refining furnace wet air pollution
control. The other plant reports that no wastewater is
associated with its hard lead refining process. The respective
water use and discharge rates for hard lead refining wet air
pollution control and hard lead refining slag granulation are
shown in Tables V-6 and V-7 (pages 1720 and 1721).
Hard lead refining wet air pollution control and slag granulation
wastewaters were also constituents of the lead smelter discharge
stream shown in Figure V-3. As discussed previously, this stream
is characterized by treatable concentrations of antimony,
cadmium, lead, zinc, and suspended solids.
FACILITY WASHDOWN
Work areas in primary lead facilities are often washed down to
minimize employee exposure to fugitive lead. As might be
expected, water used for facility washdown is quite variable due
to physical differences in plant size. Information obtained from
the dcp and from Section 308 requests indicates that facility
washdown is often combined with other waters and is inseparable.
However, information from three plants indicates that
approximately 12 1/kkg (3 gal/ton) to 175 1/kkg (42 gal/ton) of
lead produced is used for facility washdown. This wastewater is
expected to contain treatable concentrations of toxic metals and
suspended solids.
1716
-------
PRIMARY LEAD SUBCATEGORY SECT - V
EMPLOYEE HAND WASH
Primary lead plant employees must wash their hands before breaks
and end-of-shift to reduce occupational lead exposures. The
Agency obtained water use and sampling data for this waste stream
to discern whether a flow -allowance as needed. The method for
determining the regulatory flow allowance is presented in Section
IX. Flow and sampling data were collected by the Agency at two
integrated secondary lead smelters and battery manufacturing
plants. The Agency has determined that each employee uses
approximately 4.53 liters (1.2 gallons) of wash water per day.
(There is no reason to believe that this would differ for primary
lead plant employees.) It is reasonable to assume that this
wastewater will contain treatable concentrations of lead, zinc,
and TSS because occupational exposures are similar. Wastewater
samples from secondary lead plants indicate that this wastewater
is basic (pH of 8.0) and contains treatable concentrations of
copper, lead, zinc, total suspended solids, and oil and grease.
Wastewater sampling data are presented in the secondary lead
supplement.
EMPLOYEE RESPIRATOR WASH
Respirators worn at primary lead smelters to reduce occupational
lead exposures must be cleaned daily. The Agency collected water
use and wastewater sampling data for this stream at two
integrated secondary lead-battery manufacturing plants. The
Agency has determined that approximately 7.34 liters (1.94
gallons) of wash water is used per employee per day to clean
respirators, a rate unlikely to vary if primary lead respirators
are washed. Calculation of the production normalized discharge
allowance for this waste stream is discussed in Section IX.
Wastewater sampling data, presented in the secondary lead
supplemental development document, indicate the presence of
copper, lead, zinc, and total suspended solids in this water.
The pH is neutral (7.0).
LAUNDERING OF UNIFORMS
Employee uniforms must be laundered daily to meet industrial
hygiene requirements. The Agency measured flows and sampled this
wastewater since industry data were not available. Data were
collected at two secondary lead and battery manufacturing
facilities. The Agency has determined that approximately 21.6
liters (5.7 gallons) of water per employee per day is used for
laundering of uniforms. (This rate is applicable to primary lead
employee uniforms as well). The regulatory flow allowance for
this stream is discussed in Section IX. Wastewater sampling data
for this waste stream are presented -in the secondary lead
supplemental development document. These data show treatable
concentrations of lead, zinc, and total suspended solids. The pH
is slightly acidic (6.0).
1717
-------
PRIMARY LEAD SUBCATEGORY
SECT - V
TABLE V-l
WATER USE AND DISCHARGE RATES FOR SINTER PLANT
MATERIALS HANDLING WET AIR POLLUTION CONTROL
(1/kkg of sinter production)
Plant
Code
288
290
Production Production
Percent Recycle Normalized Normalized
or Reuse* Water Use Flow Discharge Flow
92
87
2538
3976
203
517
TABLE V-2
WATER USE AND DISCHARGE RATES FOR BLAST
FURNACE SLAG GRANULATION
(1/kkg of blast furnace lead bullion produced)
Plant Percent Recycle
Code or Reuse*
280 100**
286 100
288 100
290 71
Production
Normalized
Water Use Flow
13060
20150
4135
13060
Production
Normalized
Discharge Flow
0
0
0
3730
* Reuse in processes associated with this subcategory.
** 55 percent of the water used in blast furnace slag granulation
at this plant is entrained in the slag and transported to a slag
pile. All reusable - not entrained in slag - is recycled tp slag
granulation.
1718
-------
PRIMARY LEAD SUBCATEGORY
SECT - V
TABLE V-3
WATER USE AND DISCHARGE RATES FOR DROSS
REVERBERATORY FURNACE GRANULATION WASTEWATER
(1/kkg of slag, speiss or matte granulated)
Plant Percent Recycle
Code or_ Reuse*
280 0
290 0
4502 100**
Production
Normalized
Water Use Flow
NR
8379
3134
Production
Normalized
Discharge Flow
NR
8379
3134
* Reuse in process associated with this subcategory
** 100 percent reuse in other planta processes
NR - Not reported in dcp
TABLE V-4
WATER USE AND DISCHARGE RATES FOR DROSS
REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
(1/kkg of dross reverberatory furnace production)
Plant
ode
280
Production
Percent Recycle Normalized
or Reuse Water Use Flow
0
9646
Production
Normalized
Discharge Flow
9646
1719
-------
PRIMARY LEAD SUBCATEGORY SECT - V
TABLE V-5
WATER USE AND DISCHARGE RATES FOR ZINC
FUMING FURNACE WET AIR POLLUTION CONTROL
(1/kkg of blast furnace lead bullion produced)
Production Production
Plant Percent Recycle Normalized Normalized
Code o_£ Reuse* Water Use Flow Discharge Flow
280 0 426 426
* Reuse in processes associated with the primary lead subcategory
TABLE V-6
WATER USE AND DISCHARGE RATES FOR HARD
LEAD REFINING WET AIR POLLUTION CONTROL
(1/kkg of hard lead produced)
Production Production
Plant Percent Recycle Normalized Normalized
Code or Reuse* Water Use Flow Discharge Flow
280 0 19836 19836
1720
-------
PRIMARY LEAD SUBCATEGORY SECT - V
TABLE V-7
WATER USE AND DISCHARGE RATES FOR HARD
LEAD REFINING SLAG GRANULATION
(1/kkg of hard lead produced)
Production Production
Plant Percent Recycle Normalized Normalized
Code or Reuse* Water Use Flow Discharge Flow
280 NR 251297 251297
1" 21
-------
NJ
NJ
Pollutant (a)
Stream
Code
Toxic
114.
115.
116.
117.
1 18.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
Pollutants
ant imony
arsenic
asbestos
beryllium
cadmium
chromium
copper
cyanide
lead
mercury
n ickel
selenium
s ilver
thallium
zinc
Nonconventionals
chemical oxygen
demand (COD)
phenols (total; by
by 4-AAP method)
total organic
carbon (TOG)
205
205
205
Table V-8
PRIMARY LEAD SAMPLING DATA
RAW SMELTING WASTEWATER
Sample
Typet
Concentrations (mg/1, except as noted)
Source
205
205
205
205
205
205
205
205
205
205
205
205
205
205
205
2
2
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Day 1
1.0
6
0.086
5
Day 2
/o
Day 3 Average H
6.0
4
0.059
8.8
0.006
1.0
5.3
3.3
0.050
2.0
-------
Table V-8 (Continued)
PRIMARY LEAD SAMPLING DATA
RAW SMELTING WASTEWATER
Concentrations (mg/1, except as noted)
M
U)
Pollutant (a)
Conventionals
total suspended
solids (TSS)
pH (standard uni
(a) Two samples
found above
Stream Sample
Code Typet Source Day 1 Day 2 Day 3 Average
205 2 25 12 40 26
ts) 205 1 10.7 9.45 6.2
were analyzed for each of the toxic organic pollutants; no organlcs were
their analytical quantification limit.
H
§
w
>
\J
to
C
w
o
w
g
»
to
w
1
<
tSample type. Note:
These numbers also apply to subsequent samplng data tables In this
section.
1 - one time grab
2 - 24-hour manual composite
3 - 24-hour automatic composite
4 - 48-hour manual composite
5 - 48-hour automatic composite
6 - 72-hour manual composite
7 --72-hour automatic composite
-------
Table V-9
PRIMARY LEAD SAMPLING DATA
MISCELLANEOUS WASTEWATER
Concentrations (mg/1, except as noted)
^j
ro
Pollutant (a)
Stream
Code
Sample
Type
Source
Day 1 Day 2
Day 3 Average
Toxic Pollutants
1 14.
115.
1 18.
119.
120.
122.
123.
124.
m.
antimony
arsenic
cadmium
chromium
copper
lead
mercury
nickel
selenium
201
202
201
202
201
202
201
202
201
202
201 .
202
201
202
201
202
201
202
1
1
1
1
1 -
1
1
1
1
1
1
1
1
1
1
1
1
1
<0.01
<0.01
<0.005
<0.005
<0.001
<0.001
<0.005
<0.005
0.026
0.026
0.014
0.014
<0.0002
<0'.0002
<0.02
<0.02
<0.005
<0.005
<0.01
<0.01
0.018
<0.005
0.044
0.04
0.011
0.005
0.082
0.033
1.6
0.8
<0.0002
<0.0002
0.04
0.05
<0.005
<0.005
<0.01
<0.01
0.018
<0.005
0.044
0.04
0.01 1
0.005
0.082
0.033
1.6
0.8
<0.0002
<0.0002
0.04
0.05
<0.005
<0.005
'O
M
3
tr"
W
M
§
n
w
o
o
w
w
n
i
<
-------
Table V-9 (Continued)
PRIMARY LEAD SAMPLING DATA
MISCELLANEOUS WASTEWATER
fo
ui
Pollutant (a)
126. s ilver
127. thallium
128. zinc
Noncon vent ionals
ammonia
chemical oxygen
demand (COD)
phenols (total; by
4-AAP method)
Convent ionals
total suspended
solids (TSS)
pH (standard units)
Stream
Code
201
202
201
202
201
202
201
202
201
202
201
202
201
202
201
202
Sample
Type
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
<0.001
<0.001
<0.005
<0.005
0.047
0.047
0.4
0.4
30
30
0.008
0.008
45
45
7.3
7.3
Day 1
<0.001
<0.001
<0.005
<0.005
1.19
1.09
0.4
0.5
11
18
0.016
0.009
10
22
8.4
8.1
Concentrations (tng/1, except as noted)
Day 2 Day 3 Average
<0.001
<0.001
<0.005
<0.005
19
09
0.4
0.5
11.0
18.0
0.016
0.009
10.0
22.0
f
w
w
§
o
CD
O
W
W
O
1-3
(a) No toxic organic pollutants were analyzed for in samples from Streams 201 and 202.
-------
Table V-10
PRIMARY LEAD SAMPLING DATA
PARTIAL TREATMENT SAMPLES
PLANT A
Pollutant (a)
Stream
Code
Sample
Type
Concentrations (mg/1, except as noted)
Source Day 1 Day 2 Day 3 Average
Toxic Pollutants
115.
116.
118.
119.
120.
122.
123.
124.
126.
128.
129.
arsenic
asbestos
cadmium
chromium
copper
lead
mercury
nickel
selenium
thallium
zinc
1
1
1
1
1
1
1
1
1
1
1
97
97
97
97
97
97
97
97
97
97
97
3
1
3
3
3
3
3
3
3
3
3
0
0
<0
0
0
<0
0
<0
<0
0
.011
.001
.005
.093
.25
.0002
.04
.005
.005
.25
0
1
0
0
1
38
<0
0
0
<0
54
.13
.8 MFL
.292
.015
.7
.0002
.2
.005
.005
.2
0
1
0
0
1
38
<0
0
0
<0
54
.13
;8 MFL
.292
.015
.7
.0
.0002
.2
.005
.005
.2
PRIMARY LEAD
W
C
O
1
1
w
o
1
<
-------
Table V-10 (Continued)
PRIMARY LEAD SAMPLING DATA
PARTIAL TREATMENT SAMPLES
PLANT A
Concentrations (mg/1, except as noted)
Pollutant (a)
Nonconventionals
ammonia
chemical oxygen
demand (COD)
Convent ionals
total suspended
solids (TSS)
pH (standard units)
Stream
Code
197
197
197
197
Sample
Type Source Day 1
3 1 .3
3 64
3 336
1 6.8
H
s»
Day 2 Day 3 Average >
M
1.3 .6
64.0 §
n
1-3
M
a
0
336.0 K!
w
M
n
i
<
(a) No toxic organic pollutants were analyzed for in samples from Stream 197.
-------
Figure V-l
SAMPLING SITES AT PRIMARY LEAD PLANT A
H
3
KJ
00
IT1
M
Cd
O
5
M
Blast Furnncc
nrnniil.il Ion
Wastcwater
Sell 1 Ing
Channels
Settling
Pit
DlBclmrp.e
S to 9 MT,n
tfl
O
I
<
-------
VD
Source
Creek Water
____j
XX
200
<8>
— ^.
Slag
tfatte
Granulation
Blast Furnace
Cooling
Water
Acid
Plant Slowdown
Undefined
_
Process
Wastes
0.432
MGD
r**s\^
'~~V^y
s>^
Settling and
Cooling
Towers
Hot
Water Pond
Settling Pond
0.20 MGD
/V^ fc
V/V '
1 202 1
0.432 MGD
iS-x»
J201 j
__ hd
r ^xTx\ 5-0
' ^-^ ^
0.864 MGD §
tr"
W
O
W
C
W
O
H3
td
§
3
w
o
Excess H
Construction i
Water .
^^
"""^'Discharge
Figure V-2
SAMPLING SITES AT PRIMARY LEAD PLANT B
-------
PRIMARY LEAD SUBCATEGORY
SECT - V
Discharge
Figure V-3
SAMPLING SITES AT PRIMARY LEAD PLANT C
1730
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
SECTION VI
SELECTION OF POLLUTANTS
This section examines chemical analysis data presented in section
V from primary lead plants and discusses the selection or
exclusion of pollutants for potential limitation. The basis for
the regulation of toxic and other pollutants is presented in
Section VI of the General Development Document. Additionally,
each pollutant selected for potential limitation is discussed
there. That discussion provides information about the nature of
the pollutant (i.e., whether it is a naturally occurring
substance, processed metal, or a manufactured compound); general
physical properties and the form of the pollutant; toxic effects
of the pollutant in humans and other animals; and behavior of the
pollutant in POTW at the concentrations expected in industrial
discharges.
The discussion that follows describes the analysis that was
performed to select or exclude pollutants for further
consideration for limitations and standards. The data from five
wastewater samples collected at three lead plants are considered
in this analysis. Three samples are .raw wastewater samples
collected on three separate days at one of the plants. Two of
the samples are from partially treated wastewater collected at
the remaining two plants. The partial treatment samples were
collected from wastewater which passed through settling channels
and a settling pit at one plant, and a hot water pond at the
other plant. Pollutants are selected for further consideration
if they are present in concentrations treatable by the
technologies considered in this analysis. In Sections IX through
XII, a final selection of the pollutants to be limited will be
made, based on relative factors.
After proposal, the Agency re-evaluated the treatment performance
of activated carbon adsorption to control toxic organic
pollutants. The treatment performance for the acid extractabj.e,
base-neutral extractable, and volatile organic pollutants has
been set equal to the analytical quantification limit of 0.010
mg/1. The analytical quantification limit for pesticides and
total phenols (by 4-AAP method) is 0.005 mg/1, which is below the
0.010 mg/1 accepted for the other toxic organics. However, to be
consistent, the treatment performance of 0.010' mg/1 is used for
pesticides and total phenols. The 0.010 mg/1 concentration is
achievable, assuming enough carbon is used in the column and a
suitable contact time is allowed. The frequency of occurrence
for 36 of the toxic pollutants has been redetermined based on the
revised treatment performance value. However, the revised
analysis has not changed the pollutants which were selected for
further consideration for limitation at proposal. No toxic
organic pollutants were detected above their analytical
quantification limit, as discussed below.
1731
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS
This study examined samples from primary lead plants for three
conventional pollutant parameters (oil and grease, total
suspended solids, and pH) and four nonconventional pollutant
parameters (ammonia, chemical oxygen demand, total organic
carbon, and total phenols).
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED
The conventional and nonconventional pollutants or pollutant
parameters selected for limitation in this subcategory are:
total suspended solids (TSS)
pH
Total suspended solids (TSS) concentrations in the five samples
ranged from 12 mg/1 to 336 mg/1. All of the observed
concentrations are above the 2.6 mg/1 concentration considered
achievable by identified treatment technology. Furthermore, most
of the technologies used to remove toxic metals do so by
converting these metals to precipitates. A limitation on total
suspended solids ensures that sedimentation to remove
precipitated toxic metals is effectively operating. For these
reasons, total suspended solids is a pollutant parameter
considered for limitation in this subcategory.
The pH values observed ranged from 6.2 to 10.7. Effective
removal of toxic metals by precipitation requires careful control
of pH. Therefore, pH is considered for limitation in this
subcategory.
TOXIC POLLUTANTS
The frequency of occurrence of the toxic pollutants in the
wastewater samples considered in this analysis is presented in
Table VI-1 (page 1736). These data provide the basis for the
categorization of specific pollutants, as discussed below. Table
VI-1 is based on the raw wastewater sampling data from stream
205. Streams 197 and 202 were sampled after settling and were
also used in the frequency count. In addition, streams 197 and
202 were not analyzed for toxic organic pollutants.
TOXIC POLLUTANTS NEVER DETECTED
The toxic pollutants listed in Table VI-2 (page 1740) were not
detected in any wastewater samples from this subcategory;
therefore, they are not selected for consideration in
establishing effluent limitations and standards.
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION CONCENTRATION
The toxic pollutants listed below were never found above their
1732
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
analytical quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
consideration in establishing effluent limitations and standards.
4. benzene
6. carbon tetrachloride
23. chloroform
44. methylene chloride
TOXIC POLLUTANTS PRESENT BELOW CONCENTRATIONS ACHIEVABLE BY
TREATMENT
The pollutants listed below are not selected for consideration in
establishing limitations and standards because they were not
found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies. These pollutants are discussed
individually following the list.
115. arsenic
117. beryllium
119. chromium
123. mercury
124. nickel
125. selenium
126. silver
Arsenic was detected above its analytical quantification limit in
four of the five samples. The observed concentrations ranged
from 0.05 mg/1 to 0.016 mg/1. All of these values are below the
0.34 mg/1 concentration considered achievable by identified
treatment technology. Therefore, arsenic is not considered for
limitation.
Beryllium was detected at its analytical quantification limit
(0.01 mg/1) in one of the five samples considered in this
analysis. The single reported value is below the 0.2 mg/1
concentration considered achievable by identified treatment
technology. Therefore, beryllium is not selected for limitation.
Chromium was detected at or above its analytical quantification
limit in four of the five samples. The observed concentrations
ranged from 0.005 mg/1 to 0.05 mg/1. All of these values are
below the 0.07 mg/1 concentration considered achievable by
identified treatment technology. Therefore, chromium is not
considered for limitation.
Mercury was detected above its analytical quantification limit in
three of the five samples. The observed concentrations ranged
from 0.005 mg/1 to 0.0095 mg/1. All of these values are below
the 0.036 mg/1 concentration considered achievable by identified
treatment technology. Therefore, mercury is not considered for
limitation.
Nickel was detected above its analytical quantification limit in
1733
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
three of the five samples. The observed concentrations ranged
from 0.05 mg/1 to 0.2 mg/1. All of these values are below the
0.22 mg/1 concentration considered achievable by identified
treatment technology. Therefore, nickel is not considered for
limitation.
Selenium was detected above its analytical quantification limit
in two of the five samples considered in this analysis. The two
reported concentrations are 0.02 mg/1, and 0.015 mg/1. Both of
these values are below the 0.20 mg/1 concentration considered
achievable by identified treatment technology. For this reason,
selenium is not considered for limitation.
Silver was detected at its analytical quantification limit (0.02
mg/1) in one of the five samples. The single reported value is
below the 0.07 mg/1 concentration considered achievable by
identified treatment technology. Therefore, silver is not
selected for limitation.
TOXIC POLLUTANTS DETECTED IN A SMALL NUMBER OF SOURCES
Toxic pollutants detectable in the effluent from only a small
number of sources within the subcategory and uniquely related to
only these sources are not appropriate for limitation in a
national regulation. The following pollutants were not selected
for limitation on this basis:
114. antimony
120. copper
Antimony was detected above its analytical quantification limit
in only one of the five samples considered in the analysis. The
reported value (0.8 mg/1) is above the 0.47 mg/1 concentration
considered achievable by identified treatment technology.
Antimony was not detected in the other four samples, including
two from the same plant which yielded the 0.8 mg/1 value. Since
antimony was not detected at two plants, and only detected in one
of three samples at one plant, it is not selected for limitation.
Copper was detected above its analytical quantification limit in
all five samples. However, copper was present in concentrations
greater than the 0.39 mg/1 concentration considered achievable by
identified treatment technology in only one of these samples.
Because it was found at a treatable concentration in only one of
five samples, copper is not selected for limitation.
1734
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
TOXIC POLLUTANTS SELECTED FOR CONSIDERATION IN ESTABLISHING
LIMITATIONS
The toxic pollutants listed below are selected for further
consideration in establishing limitations and standards for this
subcategory. The toxic pollutants selected are each discussed
following the list.
116. asbestos
118. cadmium
122. lead
128. zinc
Asbestos was detected in one of two samples analyzed with values
of 1.8 and 11 million fibers per liter (MFL). One of these
values is above the 10 MFL attainable by identified treatment
technology. Therefore, asbestos is selected for further
consideration for limitation.
Cadmium was detected above its analytical quantification limit in
all five of the samples considered in this analysis. The
observed concentrations ranged from 0.04 mg/1 to 2.5 mg/1. Four
of the five samples contain concentrations of cadmium that are
above the 0.049 mg/1 concentration considered achievable by
identified treatment technology. Therefore, cadmium is selected
for further consideration for limitation.
Lead was detected above its analytical quantification limit in
all five samples. The observed concentrations ranged from 0.8
mg/1 to 38 mg/1. All of these values are well above the 0.08
mg/1 concentration considered achievable by identified treatment
technology. Therefore, lead is selected for further
consideration for limitation.
Zinc was detected above its analytical quantification limit in
all five samples. The observed concentrations ranged from 1.0
mg/1 to 54.2 mg/1. All of these values are above the 0.23 mg/1
concentration considered achievable by identified treatment
technology. Therefore, zinc is selected for further
consideration for limitation.
1735
-------
Table VI-1
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY LEAD
RAW WASTEWATER
Pollutant
1. acenaphthene
2. acroleln
3. acrylonltrlle
A. benzene
5. benzldlne
6. carbon tetrachlori.de
7. chlorobenzene
8. 1,2,4-trlchlorobenzene
9. hexachlorobenzene
10. 1,2-dlchloroethane
11.1,1,1 -trlchloroethane
12. hexachloroethane
13. 1 ,1-dlchloroethane
14. 1,1,2-trlchloroethane
15. 1.1,2,2-tetrachloroethane
16. chloroethane
17. bls(chloromethyl) ether
18. bls(2-chloroethyl) ether
19. 2-chloroethyl vinyl ether
20. 2-chloronaphthalene
21. 2,4.6-trlchlorophenol
22. parachlorometa cresol
23. chloroform
24. 2-chlorophenol
25. ,2-dLchlorobenzene
26. ,3-d Ichlorobenzene
27. ,4-dlchlorobenzene
28. 3.3'-dlchlorobenzldlne
29. ,1-dlchloroethylene
30. ,2-trans-dlchloroethylene
31. 2,4-dlchTorophenol
32. ,2-dlchloropropane
33. ,3-dlchloropropylene
3/i. 2,4-dlinethylphenol
35. 2.4-dlnltrotoluene
Vt. 2,6-dlnltrotoluene
37. I,2-dLphenyIhydrazlne
Analytical
Quantification
Concentration
(n«/l)(a)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
Treatable
Concentre- Number of Number of
tlon Streams Samples
(ny/l)(b) Analyzed Analyzed
0.010 1 2
0.010 1 2
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
ND
2
2
2
2
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Detected Below
Quantification
Concentration
Detected
Below Treat-
able Concen-
tration
Detected
Above Treat-
able Concen-
tration
M
W
O
H
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY LEAD
RAW WASTEWATER
Pollutant
38. ethylbenzene
39. fluoranthene
40. 4-chlorophenyl phenyl ether
41. 4-bromophenyl phenyl ether
42. bls(2-chlorolsopropyl) ether
43. bls(2-chloroethoxy) methane
44. methylene chloride
45. methyl chloride
46. methyl bromide
47. bromoform
48. dlchlorobromomethane
49. trlchlorofluoromethane
50. dlchlorodlflnoromethane
51. chlorodlbranomethane
52. hexachlorobutaillene
53. hexachlorocyclopentadlene
54. Isc/phorone
55. naphthalene
56. nitrobenzene
57. ''-nltrophenol
58. 4-nltrophenol
59. 2.4-dlnltrophenol
60. 4.6-dlnltro-o-cresol
61. N-nltrosodlmethylamlne
62. N-nltrosodlphenylamlrre
63. N-nltrosodl-n-propylamlne
64. pentachlorophenol
65. phenol
66. bls(2-ethylhexyl) phthalate
67. butyl benzyl phthalate
68. dl-n-butyl phthalate
69. dl-n-octyl phthalate
70. dlethyl phthalate
71. dimethyl phthalate
72. benzo(a)anthracene
73. benzo(a)pyrene
74. 3,4-benzofliioranthene
Analytical
Quantification
Concentration
(ing/ 1) (a)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
Treatable
Concentre- Number of Number of
tlon Streams Samples
(mft/l)(b) Analyzed Analyzed
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Detected Below
Quantification
ND Concentration
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Detected Detected
Below Treat- Above Treat-j^
able Concen- able Coocen-^
t rat Ion tration 3
§
K
F
M
n
1 w
s
Cd
o
1-3
M
i">
UJ
o
K
O
1
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY LEAD
RAW WASTEWATER
Pollutant
OJ
oo
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
benzo(k)f luoranthene
chrysene
acenaphthy 1 ene
anthracene (c)
benzo (ghl)perylaie
fluorene
phenanthrene (c)
dibenzo(a h)anthracene
lndeno(1 ,/,3-cd)pyraie
pyrene
tetrachloroethylene
toluene
tr Ichloroethy lone
vinyl chloride
aldrln
die I fir In
chlordane
4. 4 '-DDT
4, 4 '-DDE
4, 4 '-01)0
a Ipha-endosu I fan
beta-endosulfan
endnsulfan sulfate
en«- In
endrln aldehyde
heptachlor
'•eptachlor epoxlde
alpha- BUG
beta-Ill 1C
granna-BIIC
delta-BIIC
PCB-1242 (d)
PCB-1254 (d)
PCB-1221 (d)
PCB-1232 (e)
PCB-1248 (e)
PCB-1260 (e)
PCB-1016 (e)
Analytical
Quantification
Concentration
(mR/Wa)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
Treatable
Goncentra- Number of Number, of
tlon Streams Samples
QiK/l)(b) Analyzed Analyzed
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
ND
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Detected Below
Quant ICleat Ion
Concentration
Detected
Below Treat-
able Concen-
tration
Detected
Above Treat-
able Concen-
tration
fd
F
M
01
3
O
M
Q
O
Cfl
M
O
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
PRIMARY LEAD
RAW WASTEWATER
u>
>£>
Pollutant
113. toxaphene
114. antimony
115. arsenic
116. asbestos
'17. beryllium
1)8. cadmium
119. chromium
120. copper
121. cyanide
122. lead
123. mercury
124. nickel
125. selenium
126. silver
127. thallium
128. zinc
129. 2,3.7,8-tetrachlorodlbenzo-
p-dloxln (TCDD)
Analytical
Quantification
Concent rat Ion
(mg/l)(a)
0.005
0.100
0.010
10 MFL
0.010
0.002
0.005
0.009
0.02(f)
0.020
0.0001
0.005
0.01
0.02
0.100
0.050
Treatable
Concentra-
tion
(mg/l)(b)
0.01
0.47
0.34
10 MFL
0.20
0.049
0.07
0.39
0.047
0.08
0.036
0.22
0.20
0.07
0.34
0.23
Number of
Streams
Analyzed
1
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3
Number of
Samples
Analyzed
2
5
5
2
5
5
5
5
5
5
5
5
5
5
4
5
Detected Below
Quantification
ND Concentration
2
4
1
1
4
1
5
2
2
2 1
4
4
Detected
Below Treat-
able Concen-
tration
4
1
1
4
4
3
3
2
1
Detected
Above Treat-
able Concen-
tration
1
1
4
1
5
5
Not Analyzed
C/l
M
n
(a) Analytical quantification concentration was reported with data (see Section V).
(b) Treatable concentrations are based on performance of lime precipitation, sedimentation, and filtration for toxic metal pollutants and activated
carbon adsorption for toxic organic pollutants.
(c). (d), (e) Reported together.
(f) Analytical quantification concentration for EPA Method 335.2, Toxic Cyanide Methods for Chemical Analysis
of Water and Wastes. EPA-600/4-79-020, March 1979.
I
<
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
TABLE VI-2
TOXIC POLLUTANTS NEVER DETECTED
1. acenapthene
2. acrolein
3. acrylonitrile
5. benzidine
7. chlorobenzene
8. 1,2,4-trichlorobenzene
9. hexachlorobenzene
10. 1,2-dichloroethane
11. 1,1,1-trichloroethane
12. hexachloroethane
13. 1,1-dichloroethane
14. 1,1,2-trichloroethane
15. 1,1,2,2-tetrachloroethane
16. chloroethane
17. DELETED
18. bis(2-chloroethyl) ether
19. 2-chloroethyl vinyl ether
20. 2-chloronaphthalene
21. 2,4,6-trichlorophenol
22. parachlorometa cresol
24. 2-chlorophenol
25. 1,2-dichlorobenzene
26. 1,3-dichlorobenzene
27. 1,4-dichlorobenzene
28. 3,3'-dichlorobenzidine
29. 1,1-dichloroethylene
30. 1,2-trans-dichloroethylene
31. 2,4-dichlorophenol
32. 1,2-dichloropropane
33. 1,3-dichloropropylene
34. 2,4-dimethylphenol
35. 2,4-dinitrotoluene
36. 2,6-dinitrotoluene
37. 1,2-diphenylhydrazine
38. ethylbenzene
39. fluoranthene
40. 4-chlorophenyl phenyl ether
41. 4-bromophenyl phenyl ether
42. bis(2-chloroisopropyl) ether
43. bis(2-chloroethoxy) methane
45. methyl chloride
46. methyl bromide
47. bromoform
48. dichlorobromomethane
49. DELETED
50. DELETED
1740
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
51. chlorodibromomethane
52. hexachlorobutadiene
53. hexachlorocyclopentadiene
54. isophorone
55. naphthalene
56. nitrobenzene
57. 2-nitrophenol
58. 4-nitrophenol
59. 2,4-dinitrophenol
60. 4,6-dinitro-o-cresol
61. N-nitrosodimethylamine
62. N-nitrosodiphenylamine
63. N-nitrosodi-n-propylamine
64. pentachlorophenol
65. phenol
66. bis(2-ethylhexyl) phthalate
67. butyl benzyl phthalate
68. di-n-butyl phthalate
69. di-n-octyl phthalate
70. diethyl phthalate
71. dimethyl phthalate
72. benzo(a)anthracene
73. benzo(a)pyrene
74. 3,4-benzofluoranthene
75. benzo(k)fluoranthene
76. chrysene
77. acenaphthylene
78. anthracene (a)
79. benzo(ghiJperylene
80. fluorene
81. phenanthrene (a)
82. dibenzo(a,h)anthracene
83. indeno (1,2,3-cd)pyrene
84. pyrene
85. tetrachloroethylene
86. toluene
87. trichloroethylene
88. vinyl chloride
89. aldrin
90. dieldrin
91. chlordane
92. 4,4'-DDT
93. 4,4'-DDE
94. 4,4'-ODD
1741
-------
PRIMARY LEAD SUBCATEGORY SECT - VI
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
95. alpha-endosulfan
96. beta-endosulfan
97. endosulfan sulfate
98. endrin
99. endrin aldehyde
100. heptachlor
101. heptachlor epoxide
102. alpha-BHC
103. beta-BHC
104. gamma-BHC
105. delta-BHC
106. PCB-1242 (b)
107. PBC-1254 (b)
108. PCB-1221 (b)
109. PCB-1232 (c)
110. PCB-1248 (c)
111. PCB-1260 (c)
112. PCB-1016 (c)
113. toxaphene
121. cyanide
127. thallium
129. 2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD)
(a), (b), (c) Reported together, as a combined value
1742
-------
PRIMARY LEAD SUBCATEGORY SECT - VII
SECTION VII
CONTROL AND TREATMENT TECHNOLOGIES
The preceding sections of this supplement discussed the
wastewater sources, flows, and characteristics of the wastewaters
from primary lead plants. This section summarizes the
description of these wastewaters and indicates the treatment
technologies which are currently practiced by the primary lead
subcategory.
PRIOR REGULATIONS
EPA promulgated BPT effluent limitations for the primary lead
subcategory on February 27, 1975 under Subpart G of 40 CFR Part
421. These effluent limitations are based on control technologies
dependent on geographical location. For primary lead smelters
located in areas of net evaporation, zero discharge of all
process wastewater pollutants is required. It was determined
that the best practicable control technology currently available
for facilities in net evaporation areas is recycle and reuse of
wastewater after, as needed, neutralization and settling, and
disposal through solar evaporation. The Agency recognized that
facilities located in geographic areas of historical net
evaporation may experience periods of net precipitation which
would inhibit their ability to meet zero discharge of process
wastewater pollutants. As such, catastrophic and net monthly
precipitation stormwater allowances were promulgated. Plants
located in areas of net evaporation under the promulgated BPT are
allowed to discharge, during any calendar month, a volume of
process water equal to the difference between the precipitation
for that month that falls within the wastewater impoundment and
the evaporation from the surface of the impoundment for that
month. Discharges resulting from net monthly precipitation were
subject to concentration-based limitations achievable with lime
precipitation and sedimentation technology.
•
The BPT effluent limitations also contained a catastrophic storm
water allowance for plants located in areas of net evaporation.
This stormwater exemption states that a volume of process
wastewater in excess of the 10-year, 24-hour storm event falling
on a wastewater impoundment may be discharged. This discharge
was not subject to effluent limitations.
For those facilities located in geographic areas of net
precipitation, the best practicable control technology currently
available was determined to be chemical precipitation and
sedimentation. Effluent limitations developed from this
technology are mass-based limitations and allow a continuous
discharge of process wastewater including discharges from
associated acid plants. Pollutant parameters regulated under BPT
were cadmium, lead, zi :\c, pH, and TSS.
1743
-------
PRIMARY LEAD SUBCATEGORY SECT - VII
BAT effluent limitations previously promulgated for the primary
lead subcategory were essentially identical to BPT. However, BAT
required impoundments to be sized for the 25-year, 24-hour storm
event instead of the 10-year event that was used for BPT.
CURRENT CONTROL AND TREATMENT PRACTICES
This section presents a summary of the control and treatment
technologies that are currently applied to each of the sources
generating wastewater in this subcategory. As discussed in
Section V, wastewater associated with the primary lead
subcategory is characterized by the presence of the toxic metal
pollutants and suspended solids. This analysis is supported by
raw (untreated) wastewater data presented for specific
sources as well as combined waste streams in Section V.
Generally, these pollutants are present in each of the waste
streams at treatable concentrations, so these waste streams are
commonly combined for treatment to reduce the concentrations of
these pollutants. Construction of one wastewater treatment
system for combined treatment allows plants to take advantage of
economies of scale and, in some instances, to combine streams of
differing alkalinity to reduce treatment chemical requirements.
Two plants in this subcategory currently have combined wastewater
treatment systems, one has lime precipitation and sedimentation,
and one has lime precipitation, sedimentation, and filtration.
As such, three options have been selected for consideration for
BPT, BAT, BDT, and pretreatment in this subcategory, based on
combined treatment of these compatible waste streams. As
mentioned in Section V, the Agency has learned that one primary
lead facility has closed since the dcp information was collected.
Wastewater treatment data from this plant are included in the
following discussion.
SINTER PLANT MATERIALS HANDLING WET AIR POLLUTION CONTROL
Two plants use wet scrubbers to control fugitive lead and other
dusts emitted at the transfer points, conveyers, and crushing
operations in the sintering area. Both plants practice extensive
recycle of this wastewater (87 and 92 percent). One of the
plants uses a thickener and settling basins to recover lead
solids from this wastewater. The solids are returned to the
sintering process. Water is recycled to the scrubber from the
settling basins. Some of the wastewater is discharged to central
treatment consisting of lime and polymer addition and settling,
followed by additional settling in a pond. ' The other plant
settles this wastewater in a thickener before recycle. Overflow
from the thickener is sent to a settling pond which provides
makeur water to the blast and dross reverbeiatory slag
granulation operations.
-------
PRIMARY LEAD SUBCATEGORY SECT - VII
BLAST FURNACE WET AIR POLLUTION CONTROL
As discussed in Section V, no primary lead plants report any
wastewater associated with blast furnace wet air pollution
control. All plants with blast furnaces use baghouses to control
particulates in the off-gases.
BLAST FURNACE SLAG GRANULATION
This wastewater is generated when blast furnace slag or zinc
fuming furnace slag is granulated by water. Four of the seven
primary lead plants reported this waste stream. All four plants
practice extensive or total recycle or reuse of blast furnace
slag granulation wastewater (three plants practice total recycle
or reuse).
The blast furnace slag granulation wastewater is treated by most
of the plants prior to recycle or reuse. The treatment schemes
include the following:
(1) No treatment, total recycle of reusable water (some
water entrained in the slag goes to a slag pile),
(2) Lime precipitation, total reuse,
(3) Cooling towers, settling ponds, total recycle or reuse;
and
(4) Neutralization with caustic, sedimentation in lagoons,
cooling towers, partial recycle, and end-of-pipe
treatment consisting of lime precipitation,
flocculation, sedimentation, and filtration.
As mentioned in Section V, slag granulation wastewater contains
suspended solids and metals.
DROSS REVERBERATORY SLAG GRANULATION WASTEWATER
Slag, speiss, and matte produced in the dross reverberatory
furnaces are granulated with water at three plants. Wastewater
from this process contains suspended solids and dissolved toxic
metal pollutants present at treatable concentrations. All three
plants report treating the granulation wastewater prior to reuse
or discharge. Treatment schemes include the following:
(1) Sedimentation, reuse;
(2) Settling, lime precipitation, flocculation, sedimenta-
tion, reuse in ore mining operations or discharge; and
(3) Neutralization with caustic, sedimentation, cooling
towers, and partial recycle followed by end-of-pipe
treatment consisting of lime precipitation,
flocculation, sedimentation, and filtration.
1745
-------
PRIMARY LEAD SUBCATEGORY SECT - VII
DROSS REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
One plant uses a once-through wet scrubber to control dross
reverberatory furnace fumes. The scrubbing wastewater is
combined with other process wastewater and treated. The
treatment scheme includes initial settling in ponds, lime
precipitation, flocculation, and thickening. As discussed in
Section V, the combined wastewater stream contains suspended
solids and metals.
ZINC FUMING FURNACE WET AIR POLLUTION CONTROL
Three plants use fuming furnaces to recover zinc from blast
furnace slag. One of these plants uses a once-through scrubber
to clean the emissions from the zinc fuming furnace. The
scrubbing wastewater is combined with other process wastewater
and treated using settling ponds and thickening. As mentioned in
Section V, the combined wastewater stream contains suspended
solids and metals.
HARD LEAD REFINING WET AIR POLLUTION CONTROL AND SLAG GRANULATION
Antimonial lead is produced at two plants with only one of these
plants generating wastewater from hard lead refining. At this
plant, refining furnace scrubber wastewater, and refining furnace
slag granulation wastewater are combined with other process
wastewater and treated prior to reuse in ore mining operations or
discharge. The treatment scheme includes settling, lime
precipitation, flocculation, and sedimentation. The combined
wastewater contains suspended solids and metals.
FACILITY WASHDOWN
Four plants report use of plant washdown water to minimize
employee exposure to fugitive lead. This wastewater is expected
to contain treatable concentrations of lead and other toxic
metals, as well as suspended solids. The following treatment
practices are currently in use:
1. Lime addition, clarification, and multimedia filtration
- one plant,
2. Lime and polymer addition, followed by sedimentation -
one plant,
3. Sedimentation in lagoons, followed by reuse - one plant,
and
4. Evaporation and reuse - one plant.
WASTEWATER FROM INDUSTRIAL HYGIENE COMPLIANCE
Primary lead smelters are required to reduce occupational lead
exposures by laundering employee uniforms, washing employee
1746
-------
PRIMARY LEAD SUBCATEGORY SECT - VII
respirators, and ensuring that employees use hand wash
facilities. Through wastewater sampling efforts after proposal
at two secondary lead-battery manufacturing facilities, the
Agency has determined that these wastewaters are contaminated and
warrant treatment. (There is no reason to believe that
industrial hygiene wastewater from primary lead plants should
vary from that at secondary lead plants.) The following
treatment schemes are used to treat the lead and suspended solids
contained in this wastewater.
1. Lime addition, clarification, and multimedia filtration
- one plant,
2. Lime and polymer addition followed by sedimentation -
one plant,
3. Treatment along with sanitary wastes - one plant, and
4. No treatment - discharge to POTW - three plants.
CONTROL AND TREATMENT OPTIONS
Based on an examination of the wastewater sampling data, three
control and treatment technologies that effectively control the
pollutants found in primary lead smelting wastewaters were
selected for evaluation. The options selected for evaluation are
discussed below.
OPTION A
Option A for the primary lead subcategory is chemical
precipitation and sedimentation followed by partial recycle of
treated effluent for facility washdown. Chemical precipitation
and sedimentation consists of lime addition to precipitate metals
followed by gravity sedimentation for the removal of suspended
solids, including the metal precipitates.
OPTION B
Option B for the primary lead subcategory consists of chemical
precipitation and sedimentation (lime and settle) technology
considered in Option A plus in-plant reduction of process
wastewater flow. Water recycle and reuse are the principal
control mechanisms for flow reduction.
OPTION C
Option C for the primary lead subcategory consists of in-process
flow reduction, chemical precipitation, and sedimentation
technology of Option B plus sulfide precipitation, sedimentation,
and multimedia filtration technology. Sulfide precipitation is
used to further reduce the concentration of dissolved metals and
multimedia filtration is used to remove suspended solids,
including precipitates of metals, beyond the concentration
1747'
-------
PRIMARY LEAD SUBCATEGORY SECT - VII
attainable by gravity sedimentation. The filter suggested is the
gravity, mixed-media type, although other forms of filters such
as rapid sand filters or pressure filters would perform
satisfactorily.
TREATMENT OPTIONS REJECTED
Prior to proposing mass limitations for the primary lead
subcategory, reverse osmosis was evaluated as a treatment
technology. Reverse osmosis was rejected, however, because it is
not demonstrated in the nonferrous metals manufacturing category,
nor is it clearly transferable. The reverse osmosis treatment
scheme considered is discussed below.
OPTION F
Option F for the primary lead subcategory consisted of reverse
osmosis and evaporation technology added to the in-process flow
reduction, chemical precipitation, sedimentation, and multimedia
filtration technology considered in Option C. Option F was
provided for complete recycle of the treated water by controlling
the concentration of dissolved solids. Multiple effect
evaporation was used to dewater the brines rejected from reverse
osmosis.
1748
-------
PRIMARY LEAD SUBCATEGORY SECT - VIII
SECTION VIII
COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
This section presents the costs associated with the control and
treatment technologies identified in Section VII for wastewaters
from primary lead plants. The energy consumption and nonwater
quality aspects of each technology, such as air pollution, are
discussed below.
Compliance costs were developed for the six operating primary
lead plants. Costs are estimates of capital and annual costs
necessary to add and operate treatment not currently in place and
necessary for each plant to meet the applicable limitation or
standard.
The seventh plant is currently closed with no known immediate
plans of reopening. Therefore, compliance costs were not
developed for-this plant.
TREATMENT OPTIONS COSTED FOR EXISTING SOURCES
Three treatment options were considered for the primary lead
subcategory. These options are summarized below and
schematically presented in Figures X-l through X-3 (pages 1788 -
1790), Section X.
OPTION A
Option A consists of chemical precipitation and sedimentation
(lime and settle) technology applied to combined wastewater
streams followed by partial recycle of treated effluent for
facility washdown. Lime and settle technology is currently in
place at two plants.
OPTION B
For Option B, in-process flow reduction measures, consisting of
the recycle or reuse of granulation wastewater, are added to the
chemical precipitation and sedimentation (lime and settle) end-
of-pipe technology of Option A. There is only one plant that
discharges blast furnace slag granulation wastewater and dross
reverberatory furnace granulation wastewater. At this plant,
these wastewaters are partially recycled through a preliminary
treatment system consisting of cooling towers, neutralization
with caustic, and sedimentation lagoons. This plant has the
hardware in place to achieve the additional flow reduction that
is required for these wastewaters at BAT. Costs associated with
Option B for this plant are due to the segregation of the blast
furnace slag granulation wastewater from dross reverberatory
granulation wastewater. Two plants operate sinter plant
materials handling wet scrubbers and practice extensive recycle
1749
-------
PRIMARY LEAD SUBCATEGORY SECT - VIII
and should therefore experience no costs due to flow reduction
for this stream.
OPTION C
Option C adds to the Option B treatment scheme by adding sulfide
precipitation and sedimentation followed by multimedia
filtration. Thus, the Option C end-of-pipe treatment scheme
consists of lime and settle, sulfide and settle, and multimedia
filtration. One plant currently has end-of-pipe filtration in
place.
Cost Methodology
A detailed discussion of the methodology used to develop the
compliance costs is presented in Section VIII of the General
Development Document. Plant-by-plant compliance costs have been
estimated for the nonferrous metals manufacturing category and
are presented in "the administrative -record supporting this
regulation. A comparison of the costs developed for proposal and
the revised costs for the final regulation are presented in
Tables VIII-1 (page 1754) and VIII-2 (page 1754) for the direct
and indirect dischargers, respectively.
Each of the major assumptions used to develop compliance costs is
presented in Section VIII of the General Development Document.
However, each subcategory contains a unique set of waste streams
requiring certain subcategory-specific assumptions to develop
compliance costs. Seven major assumptions are discussed briefly
below.
(1) Costs for sulfide precipitation and settle treatment
are estimated for those primary lead plants which
reported a discharge of acid plant blowdown. However,
the costs associated with sulfide precipitation are
attributed to the metallurgical acid plant subcategory
because the lead smelter contributes only a small por-
tion of the total discharge.
(2) Regulatory flow allowances were developed for three
waste streams attributable to industrial hygiene
requirements: hand wash, respirator wash water, and
laundering of uniforms. These discharges are routed to
lime and settle treatment along with other process
waste streams unless the data indicated that a plant
does not discharge process wastewater'. In the latter
case, it is assumed the plant can combine industrial
hygiene waste streams with process wastewaters and
still achieve zero discharge. This assumption is based
on the fact that industrial hygiene wastewaters are a
small percentage of the overall plant water use.
Regulatory flows of industrial hygiene and other waste
streams were used for cost estimation if a plant's
actual discharge flow was unknown.
1750
-------
PRIMARY LEAD SUBCATEGORY SECT - VIII
(3) Recycle of treated water for use as plant washdown
water is accomplished via a 1,000 gallon tank., recycle
piping, and a pump.
(4) Because the compliance costs only represent incremental
costs that primary lead plants may be expected to incur
in complying with this regulation, operation and main-
tenance costs for in-place treatment used to comply
with the 1975 promulgated BPT regulation for this
subcategory are not included in a plant's total cost of
compliance for this regulation. However, a flow-
weighted fraction of the annual cost was retained to
represent treatment of the industrial hygiene and
washdown flows, which are not covered by the
promulgated BPT regulation.
(5) Capital and annual costs for plants discharging waste-
water in both the primary lead and metallurgical acid
subcategories are attributed to each subcategory on a
flow-weighted basis. The entire cost for washdown
recycle is attributed to the primary lead subcategory.
(6) No cost is included for direct dischargers to comply
with elimination of net precipitation allowances.
(7) Recycle of air pollution control scrubber liquor is
based on recycle through holding tanks. Annual costs
associated with maintenance and sludge disposal are
included in the estimated compliance costs. If a plant
currently recycles scrubber liquor, capital costs of
the recycle equipment (piping, pumps, and holding
tanks) were not included in the compliance costs.
Nonwater Quality Aspects
Nonwater quality impacts specific to the primary lead
subcategory, including energy requirements, solid waste and air
pollution, are discussed below.
ENERGY REQUIREMENTS
Energy requirements for the three options considered are
estimated at 0.13 MW-hr/yr, 0.066 MW-hr/yr, and 1.1 MW-hr/yr for
Options A, B, and C respectively. Option B energy requirements
decrease over those for Option A because less water is being
treated, thus saving energy costs for lime and settle treatment.
Option C at a typical primary lead facility represents roughly
one percent of the total plant's electrical usage. It is
therefore concluded that the energy requirements of the treatment
options considered will have no significant impact on total plant
energy consumption.
1751
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PRIMARY LEAD SUBCATEGORY SECT - VIII
SOLID WASTE
Sludges associated with the primary lead subcategory will
necessarily contain additional quantities (and concentrations) of
toxic metal pollutants. Wastes generated by primary smelters and
refiners are currently exempt from regulation by Act of Congress
(Resource Conservation and Recovery Act (RCRA), Section 3001(b)),
as interpreted by the Agency. Consequently, sludges generated
from treating primary industries' wastewater are not presently
subject to regulation as hazardous wastes.
The Agency contends that lime sludges generated in the primary
lead subcategory will not be classified as a hazardous waste if a
small excess of lime is added during treatment. The
metallurgical acid plant subcategory, however, has added sulfide
precipitation to the technology basis for BAT. The Agency
believes sludge generated through sulfide precipitation (followed
by sedimentation) will be classified as hazardous under RCRA
because sulfide precipitation leaves metals in a form amenable to
leaching. Two primary lead plants operating acid plants are
affected by this added technology. The Agency estimates that the
plants will generate 56 tons per year of sulfide sludge and
require disposal as a hazardous waste. This added cost for
disposal was considered in developing compliance costs and in the
Economic Analysis (even though the waste is now exempt).
Multimedia filtration technology will not result in any
significant amount of sludge over that generated from lime
precipitation and sulfide precipitation.
Although it is the Agency's view that lime sludges generated as a
result of these guidelines are not expected to be hazardous,
generators of these wastes must test the waste to determine if
the wastes meet any of the characteristics of hazardous waste
(see 40 CFR 262.11) .
If these wastes should be identified or are listed as hazardous,
they will come within the scope of RCRA'.s "cradle to grave"
hazardous waste management program, requiring regulation from the
point of generation to point of final disposition. EPA's
generator standards would require generators of hazardous
nonferrous metals.manufacturing wastes to meet containerization,
labeling, recordkeeping, and reporting requirements; if plants
dispose of hazardous wastes off-site, they would have to prepare
a manifest which would track the movement of the wastes from the
generator's premises to a permitted off-site treatment storage,
or disposal facility. See 40 CFR 262.20 45 FR 33142 (May 19,
1980), as amended at 45 FR 86973 (December 31, 1980). The
transporter regulations require transporters of hazardous wastes
to comply with the manifest system to assure that the wastes are
delivered to a permitted facility. See 40 CFR 263.20 45 FR 33151
(May 19, 1980), as amended at 45 FR 86973 (December 31, 1980).
Finally, RCRA regulations establish standards for hazardous waste
treatment, storage, and disposal facilities allowed to receive
such wastes. See 40 CFR Part 464 46 FR 2802 (January 12, 1981),
47 FR 32274 (July 26, 1982).
1752
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PRIMARY LEAD SUBCATEGORY SECT - VIII
Even if these wastes are not identified as hazardous, they still
must be disposed of in compliance with the Subtitle D open
dumping standards, implementing 4004 of RCRA. See 44 FR 53438
(September 13, 1979). The Agency has calculated as part of the
costs for wastewater treatment the cost of hauling and disposing
of these wastes. Section VIII of Vol. I presents the costs
associated with contract hauling.
AIR POLLUTION
There is no reason to believe that any substantial air pollution
problems will result from implementation of chemical
precipitation, sedimentation, and multimedia filtration. These
technologies transfer pollutants to solid waste and do not
involve air stripping or any other physical process likely to
transfer pollutants to air. Minor amounts of sulfur may be
emitted during sulfide precipitation, and water vapor containing
some particulate matter will be released in the drift from the
cooling tower systems which are used as the basis for flow
reduction in the primary lead subcategory. However, the Agency
does not consider this impact to be significant.
-------
PRIMARY LEAD SUBCATEGORY SECT - VIII
TABLE VIII-1
COST OF COMPLIANCE FOR THE PRIMARY LEAD SUBCATEGORY
DIRECT DISCHARGERS
(March, 1982 Dollars)
Proposal Cost Promulgation Cost
Option
A
B
C
Capital Cost
0
0
0
Annnual Cost
0
0
0
Capital Cost
242000
192000
196000
Annual Cost
112000
81600
114000
TABLE VII1-2
COST OF COMPLIANCE FOR THE PRIMARY LEAD SUBCATEGORY
INDIRECT DISCHARGERS
(March, 1982 Dollars)
Proposal Cost Promulgation Cost
Option Capital Cost Annnual Cost Capital Cost Annual Cost
A - -
B - -
C - -
56900
56900
56900
10600
10600 .
10600
NOTE: No known indirect dischargers at time of proposal
1754
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PRIMARY LEAD SUBCATEGORY SECT - IX
SECTION IX
BEST PRACTICABLE TECHNOLOGY CURRENTLY AVAILABLE
EPA promulgated BPT effluent limitations for the primary lead
subcategory on February 27, 1975 as Subpart G of 40 CFR Part 421.
These effluent limitations are based on control technologies
dependent on geographical location. For primary lead smelters
located in areas of net evaporation, zero discharge of all
process wastewater pollutants is required. It was determined
that the best practicable control technology currently available
for facilities in net evaporation areas is recycle and reuse of
wastewater after, as needed, neutralization and settling, and
disposal through solar evaporation. The Agency recognized that
facilities located in geographic areas of historical net
evaporation may experience periods of net precipitation which
would inhibit their ability to meet zero discharge of process
wastewater pollutants. As such, catastrophic and net monthly
precipitation stormwater allowances were promulgated. Plants
located in areas of net evaporation under the promulgated BPT are
allowed to discharge, during any calendar month, a volume of
process water equal to the difference between the precipitation
for that month that falls within the wastewater impoundment and
the evaporation from the surface of the impoundment for that
month. Discharges resulting from net monthly precipitation are
subject to concentration-based limitations achievable with lime
precipitation and sedimentation technology.
The BPT effluent limitations also contain a catastrophic storm
water allowance for plants located in areas of net evaporation.
This stormwater exemption states that a volume of process
wastewater in excess of the 10-year, 24-hour storm event falling
on a wastewater impoundment may be discharged. This discharge is
not subject to effluent limitations.
For those facilities located in geographic areas of* net
precipitation, the best practicable control technology currently
available was determined as chemical precipitation and
sedimentation. Effluent limitations developed from this
technology are mass-based limitations and allow a continuous
discharge of process wastewater including discharges from
associated acid plants. Pollutant parameters regulated under BAT
are cadmium, lead, zinc, pH, and TSS.
However, new information became available to the Agency that
supported the need for discharge of wastewater from blast furnace
slag granulation, an operation previously considered and included
in the promulgated zero discharge regulation. Information
obtained in 1975 indicated that slag granulation is a net water
consuming operation and, therefore, it did not justify a
discharge allowance. Data supplied to the Agency since 1975 show
1755
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PRIMARY LEAD SUBCATEGORY SECT - IX
that one plant uses an ore with a lead content that makes it
feasible to recycle blast furnace slag into the sintering machine
to recover the remaining lead content. After studying this
further, it was found that there may be an accumulation of
dissolved salts in recycled slag granulation wastewater.
Accumulation of dissolved salts, particularly sodium salts, in
the recycle water and ultimately in the recycled slag is
detrimental to the sintering process chemistry. For this reason,
the promulgated BPT is modified for this subcategory to allow a
discharge to prevent the accumulation of solids in slag
granulation water circuits. (Refer to the discussions of
Wastewater Discharge Rates below and in Section X.)
Additionally, the Agency is modifying its approach to stormwater.
The technology basis of the promulgated BPT is not wastewater
impoundments or cooling ponds, but rather cooling towers and
clarifiers. Hardware of this nature is not as susceptible to
fluctuations due to rainfall. Therefore, there is no need for a
monthly or catastrophic rainfall allowance.
TECHNICAL APPROACH TO BPT
The Agency studied the nonferrous metals manufacturing category
to identify the processes used, the wastewaters generated, and
the treatment processes installed. Information was collected
from the category using data collection portfolios, and specific
plants were sampled and the wastewaters analyzed. Some of the
factors which must be considered in establishing effluent
limitations based on BPT have already been discussed. The age of
equipment and facilities, processes used, and raw materials were
taken into account in subcategorization and subdivision and are
discussed fully in Section IV. Nonwater quality impacts and
energy requirements are considered in Section VIII.
As explained in Section IV, the primary lead subcategory has been
subdivided into 12 potential wastewater sources or segments.
Since the water use, discharge rates, and pollutant
characteristics of each of these wastewaters is potentially
unique, effluent limitations will be developed for each of the 12
building blocks.
For each segment, a specific approach was followed for the
development of BPT mass limitations. To account for production
and flow variability from plant to plant, a unit of production or
production normalizing parameter (PNP) was determined for each
waste stream which could then be related to the flow from the
process to determine a production normalized flow. Selection of
the PNP for each process element is discussed in Section IV.
Each process within the subcategory was then analyzed to
determine (1) whether or not operations included generated
wastewater, (2) specific flow rates generated, and (3) the
specific production normalized flows for each process. This
analysis is discussed in detail in Section V. Nonprocess
wastewater such as rainfall runoff and noncontact cooling water
is not considered in this analysis.
1756
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PRIMARY LEAD SUBCATEGORY SECT - IX
Normalized flows were analyzed to determine which flow was to be
used as part of the basis for BPT mass limitations. The selected
flow (sometimes referred to as a BPT regulatory flow or BPT
discharge rate) reflects the water use controls which are common
practices within the industry. The BPT normalized flow is based
on the average of all applicable data. Plants with normalized
flows above the average may have to implement some method of flow
reduction to achieve the BPT limitations. It is not believed
that these modifications would incur any costs for the plants.
For the development of effluent limitations, mass loadings were
calculated for each wastewater source. This calculation was made
on a stream-by-stream basis, primarily because plants in this
category may perform one or more of the operations in various
combinations. The mass loadings (milligrams of pollutant per
metric ton of production unit - mg/kkg) were calculated by
multiplying the BPT normalized flow (1/kkg) by the concentration
achievable using the BPT treatment system (mg/1) for each
pollutant parameter to be regulated under BPT.
The mass loadings which are allowed under BPT for each plant will
be the sum of the individual mass loadings for the various
wastewater sources which are found at particular plants.
Accordingly, all the wastewater generated within a plant may be
combined for treatment in a single or common treatment system,
but the effluent limitations for these combined wastewaters are
based on the various wastewater sources which actually contribute
to the combined flow. This method accounts for the variety of
combinations of wastewater sources and production processes which
may be found at primary lead plants.
The Agency usually establishes wastewater limitations in terms of
mass rather than concentration. This approach prevents the use
of dilution as a treatment method (except for controlling pH).
The production normalized wastewater flow (1/kkg) is a link
between the production operations and the effluent limitations.
The pollutant discharge attributable to each operation can be
calculated from the normalized flow and effluent concentration
achievable by the treatment technology and summed to derive an
appropriate limitation for each subcategory.
BPT effluent limitations are based on the average of the
discharge flow rates for each source; consequently, the treatment
technologies which are currently used by the lowest dischargers
will be the treatment technologies most likely required to meet
BPT effluent limitations. Section VII discusses the various
treatment technologies which are currently in place for each
wastewater source. In most cases, the current treatment
technologies consist of chemical precipitation and sedimentation
(lime and settle technology) and a combination of reuse and
recycle to reduce flow.
The overall effectiveness of end-of-pipe treatment for the
removal of wastewater pollutants is improved by the application
1757
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PRIMARY LEAD SUBCATEGORY SECT - IX
of water flow controls within the process to limit the volume of
wastewater requiring treatment. The controls or in-process
technologies recommended under BPT include only those measures
which are commonly practiced within the subcategory and which
reduce flows to meet the production normalized flow for each
operation.
In making technical assessments of data., reviewing manufacturing
processes, and assessing wastewater treatment technology options,
both indirect and direct dischargers have been considered as a
single group. An examination of plants and processes did not
indicate any process differences based on the type of discharge,
whether it be direct or indirect.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
In balancing costs in relation to pollutant removal estimates,
EPA considers the volume and nature of existing discharges, the
volume and nature of discharges expected after application of
BPT, the general environmental effects of the pollutants, and the
cost and economic impacts of the required pollution control
level. The Act does not require or permit consideration of water
quality problems attributable to particular point sources or
industries, or water quality improvements in particular water
quality bodies. Accordingly, water quality considerations were
not the basis for selecting the proposed BPT. See Weyerhaeuser
Company v. Costle, 590 F.2d 1011 (D.C. Cir. 1978).
The methodology for calculating pollutant removal estimates and
plant compliance costs is discussed in Section X. Table X-l
shows the pollutant removal estimates for each treatment option
considered for promulgation for the direct dischargers in the
primary lead subcategory. Compliance costs for direct
dischargers are presented in Table VIII-1 (page 1754).
BPT OPTION SELECTION
EPA proposed mass limitations for the primary lead subcategory to
allow a discharge to prevent dissolved solids from accumulating
in slag granulation circuits. The technology basis for the
promulgated BPT limitations is lime precipitation and
sedimentation (Option A). This technology is demonstrated at two
plants in the subcategory. (One of the two plants also has end-
of-pipe filtration technology.) The promulgated BPT is identical
to the technology basis proposed for BPT.
The Agency has also considered additional waste streams
identified in comments to the proposed regulation. Data
solicited by the Agency after proposal were used to determine a
BPT flow allowance for sinter plant materials handling wet air
pollution control. This wastewater source is due to compliance
with OSHA standards which limit fugitive lead emissions. An
additional four building blocks were added for the wastewater
sources generated due to industrial hygiene requirements. Based
on information and data gathered at two integrated secondary lead
1758
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PRIMARY LEAD SUBCATEGORY SECT - IX
and battery manufacturing plants (which have lead concentrations
similar to what one would realistically expect to find in the
analogous primary lead wastewaters), the Agency has determined
that floor washing, employee hand wash, respirator wash, and
employee uniform laundering generate wastewaters sufficiently
contaminated with lead to warrant treatment. As discussed below,
the Agency is not providing a discharge allowance for one of
these wastewater sources (floor washing) because this operation
can use recycled treatment plant effluent.
Commenters argued that the treatment performance values used
(CMDB) for the lead subcategory are inappropriate for primary
lead plants, and submitted long-term treatment performance data
from two primary lead plants operating BPT equivalent (i.e., lime
and settle) treatment systems. The performance data submitted to
the Agency demonstrated that primary lead wastewaters have
different characteristics than those wastewaters comprising the
Agency's treatment performance data base. The Agency conducted a
statistical analysis on the performance data and studied the
design and operating characteristics of the treatment systems
from which the commenters1 data were obtained. The Agency has
determined that the performance data from one of the plants are
representative of a well-operated treatment system and has used
treatment effectiveness concentrations obtained from the data to
calculate the primary lead BPT mass limitations. Treatment
performance from the other plant was not used due to the lack of
equalization before lime and settle treatment.
The Agency is eliminating the allowances for net precipitation
catastrophic storms as was done in primary electrolytic copper
refining when it was revised in 1980. As explained previously,
EPA does not believe this allowance is necessary because of the
relatively small surface area impoundments that would be used to
comply with these limitations. The Agency does not believe any
costs will result from this change. Plants using impoundments
for other purposes, such as storm water collection, may need to
receive net precipitation allowances from permit authorities on a
case-by-case basis.
Implementation of the promulgated BPT limitations will r,emove
from raw wastewater an estimated 3,900 kg/yr of toxic metals and
261,000 kg/yr of TSS. The promulgated BPT will result in an
estimated capital cost of $0.260 million (March, 1982 dollars)
and an estimated annual cost of $0.116 million (March, 1982
dollars). The best practicable technology selected for the
primary lead subcategory is presented in Figure IX-1 (page 1771).
WASTEWATER DISCHARGE RATES
A BPT discharge rate is calculated for each subdivision based on
the average of the flows of the existing plants, as determined
from analysis of dcp. The discharge rate is used with the
achievable treatment concentration to determine BPT effluent
limitations. Since the discharge rate may be different for each
wastewater source, 12 wastewater sources are discussed below and
1759
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PRIMARY LEAD SUBCATEGORY SECT - IX
summarized in Table IX-1 (page 1765). The discharge rates are
normalized on a production basis by relating the amount of
wastewater generated to the mass of the intermediate product
which is produced by the process associated with the waste stream
in question. These production normalizing parameters, or PNP's,
are also listed in Table IX-1.
SINTER PLANT MATERIALS HANDLING WET AIR POLLUTION CONTROL
The BPT wastewater discharge allowance for sinter plant materials
handling wet air pollution control is 360 1/kkg (86.3 gal/ton) of
sinter production. An allowance for this waste stream was not
provided at proposal. Comments to the proposed regulation
identified this wastewater source as necessary for compliance
with OSHA standards which limit fugitive lead emissions. Data
solicited by the Agency after proposal show that two plants
operate sinter plant materials handling scrubbers. Both plants
practice extensive recycle of the scrubber liquor (87 and 92
percent). The BPT discharge allowance is based on the average
scrubber discharge from the two plants. Water use and discharge
rates are presented in Table V-l (page 1718).
BLAST FURNACE WET AIR POLLUTION CONTROL
Currently there are no facilities in the primary lead subcategory
controlling emissions from a blast furnace with a wet scrubber.
Therefore, a discharge allowance is not allocated for this
potential source of wastewater.
BLAST FURNACE SLAG GRANULATION
The BPT wastewater discharge allowance for blast furnace slag
granulation is 3,730 1/kkg (895 gal/ton) of blast furnace lead
bullion produced. Four plants reported a blast furnace slag
granulation waste stream. Two plants achieve zero discharge of
this waste stream through total reuse. One plant achieves zero
discharge of this waste stream through total recycle of water
that is not entrained in the slag (water entrained in the slag is
transferred to a slag pile). One plant discharges blast furnace
slag granulation wastewater. This plant recycles 71 percent of
this waste stream. The BPT discharge rate is based on the
discharge rate of the single discharging plant. Water use and
wastewater discharge rates for blast furnace slag granulation are
presented in Section V (Table V-2 page 1718).
DROSS REVERBERATORY SLAG GRANULATION WASTEWATER'
The proposed BPT wastewater discharge rate for dross
reverberatory furnace granulation wastewater was 3,134 1/kkg (750
gal/ton) of slag, matte, or speiss granulated. Three plants
report a dross reverberatory furnace granulation waste stream.
The proposed BPT discharge was based on the discharge rate from
one of these plants. One plant's discharge rate was reported as
22,887 1/kkg (5,490 gal/ton). This plant's discharge rate was
considered too high to use in determining the BPT discharge rate
1760
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PRIMARY LEAD SUBCATEGORY SECT - IX
for dross reverberatory furnace granulation wastewater. A third
plant with a dross reverberatory furnace granulation waste stream
did not report sufficient dcp information to determine the
wastewater discharged from this process.
Plant 290 resubmitted a dcp after the mass limitations were
proposed for the primary lead subcategory. Data contained in the
new dcp indicate that the discharge from dross reverberatory
furnace granulation has been lowered from 22,893 1/kkg to 8,379
1/kkg. EPA omitted the Plant 290 discharge from the calculations
for the proposed regulation because it found the water use to be
excessive. However, the revised flow does not appear to be
excessively high so the Agency has averaged it with the flow for
Plant 4502 used at proposal. The revised flow allowance for this
operation is 5,757 1/kkg (1,381 gal/ton) of slag, speiss, or
matte granulated.
DROSS REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
The BPT wastewater discharge rate for dross reverberatory furnace
wet air pollution control is 9,646 1/kkg (2,313 gal/ton) of dross
reverberatory " furnace production. The BPT discharge rate is
based on the discharge rate of the single plant which practices
wet air pollution control on its dross reverberatory furnace.
This plant does not recycle this wastewater.
ZINC FUMING FURNACE WET AIR POLLUTION CONTROL
The BPT wastewater discharge for zinc fuming furnace wet air
pollution control is 426 1/kkg (102 gal/ton) of blast furnace
lead bullion produced. This rate is allocated only for plants
practicing wet air pollution control for zinc fuming furnaces.
The BPT discharge allowance is based on the discharge rate of the
single plant that practices wet scrubbing on this process. This
plant does not recycle this wastewater.
HARD LEAD REFINING WET AIR POLLUTION CONTROL
The BPT wastewater discharge rate for hard lead refining wet air
pollution control is 19,836 1/kkg (4,747 gal/ton) of hard lead
produced. This rate is allocated only to plants that practice
hard lead refining wet air pollution control. The BPT discharge
rate is based on the discharge rate of the single plant reporting
this waste stream. This plant does not recycle this wastewater.
HARD LEAD REFINING SLAG GRANULATION
No BPT discharge allowance is provided for hard lead refining
slag granulation. Only one plant reports this waste stream. This
plant granulates slag from a hard lead refining furnace prior to
transferring the slag to a slag pile. EPA believes that this
plant can recycle 100 percent of the granulation wastewater since
this slag is not returned to the smelter for further processing.
Alternatively, it could reuse this wastewater in other plant
processes. The Agency received no comments questioning the
1761
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PRIMARY LEAD SUBCATEGORY SECT - IX
requirement of 100 percent recycle or reuse for hard lead
refining slag granulation.
FACILITY WASHDOWN
No BPT discharge allowance for facility washdown is provided.
Because floor washing does not require potable water, the Agency
believes lime and settle treatment effluent can be used to hose
down work areas in a lead smelter to control fugitive lead and
dust. Compliance costs developed for the subcategory included 6
1/kkg (of lead produced) of facility washdown water in the total
plant flow when the clarifier was sized.
EMPLOYEE HAND WASH
Data gathered at an integrated secondary lead-battery
manufacturing plant demonstrated that wastewaters generated due
to industrial hygiene requirements mandated by OSHA may be
sufficiently contaminated with lead to require treatment. Field
measurements performed by an EPA representative indicate 1.5
liters (0.4 gallons) of water is used per employee to wash
his/her hands. Data taken from the primary lead dcp indicate
that approximately 3.6 employees-year are used per pound of lead
produced. Assuming each employee washes their hands three times
per day, the production normalized water usage for hand wash is
approximately 3.3 1/kkg (0.79 gal/ton) of lead produced. This
value is selected as the BPT discharge rate.
RESPIRATOR WASH
The Agency estimates approximately 7.34 liters (1.94 gallons) of
wastewater is generated to clean a respirator based on actual
field measurements. Assuming each employee wears a respirator,
it is cleaned each day, and using the 3.6 employees-year/lb of
lead factor, the BPT discharge rate is 5.3 1/kkg (1.27 gal/ton)
of lead produced.
LAUNDERING OF UNIFORMS
Field samples obtained at two integrated secondary lead smelters
and battery manufacturing plants indicate that 21.4 liters (5.66
gallons) of wastewater is generated per uniform washed. If
employee uniforms are washed once per day, and a factor of 3.6
employees-year/lb of lead is used, the production normalized BPT
discharge rate is 16 1/kkg (3.7 gal/ton) of lead produced.
REGULATED POLLUTANT PARAMETERS
Four pollutant parameters were selected for BPT effluent
limitations for the primary lead subcategory. These pollutants
and pollutant parameters are present in primary lead wastewaters
at concentrations that can be effectively reduced by identified
treatment technologies. The following pollutants or pollutant
parameters will be limited under BPT:
1762
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PRIMARY LEAD SUBCATEGORY SECT - IX
122. lead
124. zinc
TSS
pH
STORM WATER AND PRECIPITATION ALLOWANCES
The promulgated 1975 BPT effluent limitations include net
precipitation and catastrophic storm allowances for facilities
located in historical geographic areas of net evaporation.
Facilities are allowed a discharge of process wastewater which is
equivalent to the volume of precipitation that falls within the
wastewater impoundment in excess of that attributable to the 10-
year, 24-hour rainfall event, when such event occurs. In
addition, facilities are allowed to discharge a volume of process
wastewater on a monthly basis that is equal to the net difference
between the rainfall falling on the impoundment and the mean
evaporation from the pond water surface. This monthly discharge
is subject to concentration-based standards, whereas the
catastrophic storm is not subject to any effluent limitations.
As discussed in greater detail in Section IX of the General
Development Document, the Agency is modifying its approach to
storm water. The Agency is promulgating BPT effluent limitations
based on lime precipitation and sedimentation, not on large
cooling water impoundments. The Agency believes the technology
basis of BPT does not require a monthly rainfall and catastrophic
storm water allowance.
EFFLUENT LIMITATIONS
The data base used to establish treatment concentrations for the
limitations in the promulgated 1975 BPT were based solely on acid
plant data. EPA has since gathered a combined metals data base
which EPA believed is a superior measure of the performance of
lime precipitation and sedimentation on nonferrous metals
wastewaters. Treatable concentrations for lime precipitation and
sedimentation, as determined from the combined metals data base,
are discussed in Section VII of this supplement.
*
As discussed in the BPT Option Selection, two plants in the
primary lead subcategory submitted long term treatment
performance data for lime and settle, and lime, settle, and
filter after mass limitations were proposed for this subcategory.
The Agency analyzed the data statistically for comparison with
the combined metals data base. In addition, design and operating
parameters for the treatment systems from the two plants were
collected through Section 308 authority. The Agency has
determined that data from one of the two plants should not be
used to establish treatment performance because of design
deficiencies. However, the other plant appears to be properly
designed and is not meeting the proposed performance for cadmium
and lead. Examination of the influent to the treatment system
shows a great deal of of lime and settle treatment at this plant
and has not identified any plant in this subcategory meeting the
1763
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PRIMARY LEAD SUBCATEGORY SECT - IX
combined metals data base limits with lime and settle treatment.
Therefore, treatment performance derived from the submitted data
are used in calculating the promulgated BPT effluent limitations.
The treatable concentrations (both one-day maximum and monthly
average values) are multiplied by the BPT normalized discharge
flows summarized in Table IX-1 to calculate the mass of
pollutants allowed to be discharged per mass of product. The
results of these calculations in milligrams of pollutant per
metric ton of product represent the BPT effluent limitations and
are presented in Table IX-2 (page 1766) for each individual waste
stream.
1764
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PRIMARY LEAD SUBCATEGORY
SECT - IX
Table IX-1
BPT WASTEWATER DISCHARGE RATES FOR THE
PRIMARY LEAD SUBCATEGORY
Wastewater Stream
Sinter Plant Materials
Handling Wet Air
Pollution Control
Blast Furnace Wet Air
Pollution Control
Blast Furnace Slag
Granulation
Dross Reverberatory
Slag Granulation
Wastewater
Dross Reverberatory
Furnace Wet Air
Pollution Control
Zinc Fuming Wet Air
Pollution Control
Hard Lead Refining
Slag Granulation
Hard Lead Refining
Wet Air Pollution
Control
Facility Washdown
Employee Hand Wash
Respirator Wash
Laundering of
Uniforms
BPT Normalized
Discharge Rate
1/kkg gal/ton
360
0
3,730
Production
Normalizing
Parameter
Sinter production
86
0
895 Blast furnace lead
bullion produced
5,757 1,381 Slag, speiss, or
matte granulated
9,646 2,313 Dross reverberatory
furnace production
426 102 Blast furnace lead
bullion produced
19,836 4,747 Hard lead produced
0 0
3.3 0.8 Lead bullion produced
5.3 1.3 Lead bullion produced
16 3.'7 Lead bullion produced
-------
PRIMARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2
BPT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(a) Sinter Plant Materials Handling Wet Air Pollution
Control BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Cadmium 122,400 54,000
*Lead - 594.000 270.000
*Zinc 525.000 219.600
*TSS 14,760.000 7,020.000
*pH Within the range of 7.0 to 10.0
at all times
(b) Blast Furnace Wet Air Pollution Control BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1766
-------
PRIMARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(c) Blast Furnace Slag -Granulation BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Cadmium 1,268.000 559.500
*Lead 6,155.000 2,798.000
*Zinc 5,446.000 2,276.000
*TSS 153,000.000 72,740.000
*pH Within the range of 7.0 to 10.0
at all times
(d) Dross Reverberatory Slag Granulation BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Cadmium 1,957.000 863.000
*Lead 9,499.000 4,318.00*0
*Zinc 8,405.000 3,512.000
*TSS 236,000.000 112,300.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1767 '
-------
PRIMARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(e) Dross Reverberatory Furnace Wet Air Pollution Control BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Cadmium 3,280.000 1,447.000
*Lead 15,920.000 7,235.000
*Zinc 14,080.000 5,884.000
*TSS 395,500.000 188,100.000
*pH Within the range of 7.0 to 10.0
at all times
(f) Zinc Fuming Furnace Wet Air Pollution Control BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 144.800 63.900
*Lead 702.900 319.500
*Zinc 622.000 259.900
*TSS 17,470.000 8,307.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1768
-------
PRIMARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(g) Hard Lead Refining Slag Granulation BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium
*Lead
*Zinc
*TSS
*pH
0
0
0
0
Within the
.000
.000
.000
.000
range
at all
of 7.0
times
0.
0.
0.
0.
to
000
000
000
000
10.
0
(h) Hard Lead Refining Wet Air Pollution Control BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 6,744.000 2,975.000
*Lead 32,730.000 14,880.000
*Zinc 28,960.000 12,100.000
*TSS 813,300.000 386,800.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1769
-------
PRIMARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(i) Facility Washdown BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc . 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
(j) Employee Handwash BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 1.222 0.495
Lead 5.445 2.475
Zinc 4.818 2.013
TSS 135.300 64.350
pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1770
-------
-J
-J
Blast Furnarp Slag Granulation Wastewater
Zinc Fuming Furnace Scrubber Liquor
Hard Lead Refining Scrubber Liquor
Employee Handwash Waatewater
Employee Respirator Wash Uaatewater
1. n under Ing of Uiil forma Uaatewater
Facility Waalidnwn Waatewater
SliU-r Plant Materials Handling Scrubber Liquor
V
a.
Holding
Tank
1
1
Sludge Re»c
tecycle
>v«l
9,
i
Equal t-
^O^K
Sludge Recycle
Vncmm Filtrate
:a ~
Holding
tat Ion Tnnk
to*' '
Sludge
^(t)/07 1"'-
^^~~'^' \
Sludge Dewaterlng |ll|ji|Mi||»
PRIMARY LE;
a.
QL A
u
(T
Z
•j.
^D SUBCATEGORY SEC:
i
H
X
Figure IX-1
BPT TREATMENT SCHEME
PRIMARY LEAD SUBCATEGORY
-------
PRIMARY LEAD SUBCATEGORY SECT - IX
THIS PAGE INTENTIONALLY LEFT BLANK
1772
-------
PRIMARY LEAD SUBCATEGORY SECT - X
SECTION X
BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
The effluent limitations are based on the best control and
treatment technology used by a specific point source within the
industrial category or subcategory, or by another industry where
it is readily transferable. Emphasis is placed on additional
treatment techniques applied at the end of the treatment systems
currently used, as well as reduction of the amount of water used
and discharged, process control, and treatment technology
optimization.
The factors considered in assessing best available technology
economically achievable (BAT) include the age of equipment and
facilities involved, the process used, process changes, nonwater
quality environmental impacts (including energy requirements),
and the costs of application of such technology (Section 304(b)
(2)(B) of the Clean Water Act). At a minimum, BAT represents the
best available technology economically achievable at plants of
various ages, sizes, processes, or other characteristics. Where
the Agency has found the existing performance to be uniformly
inadequate, BAT may be transferred from a different subcategory
or category. BAT may include feasible process changes or
internal controls, even when not in common industry practice.
The required assessment of BAT considers costs, but does not
require a balancing of costs against effluent reduction benefits
(see Weyerhauser v. Costle, 590 F.2d 1011 (D.C. Cir. 1978))-
However, in assessing the promulgated BAT, the Agency has given
substantial weight to the economic achievability of the
technology.
TECHNICAL APPROACH TO BAT
In pursuing this second round of effluent limitations, the Agency
reviewed a wide range of technology options and evaluated the
available possibilities to ensure that the most effective and
beneficial technologies were used as the basis of BAT. To
accomplish this, the Agency elected to examine four technology
options prior to proposing mass limitations which could be
applied to the primary lead subcategory as treatment options for
the basis of BAT effluent limitations. Three'of the technology
options were re-evaluated for the final rule. Based on comments
regarding inapplicability of the combined metals data base
treatment performance levels, the Agency also evaluated (and
developed compliance costs) alternative technology that could be
used to achieve these levels.
For the development of BAT effluent limitations, mass loadings
were calculated for each wastewater source or subdivision in the
subcategory using the same technical approach as in Section IX
1773
-------
PRIMARY LEAD SUBCATEGORY SECT - X
for BPT limitations development. The differences in the mass
loadings for BPT and BAT are due to increased treatment
effectiveness achievable with the more sophisticated BAT
treatment technology and reductions in the effluent flows
allocated to various waste streams.
In summary, the treatment technologies considered for the primary
lead subcategory are:
Option A (Figure X-l, page 1788) is based on:
o Chemical precipitation (lime) and sedimentation
o Recycle of treated effluent for facility washdown
Option B (Figure X-2, page 1789) is based on:
o Chemical precipitation (lime) and sedimentation
o Flow reduction
o Recycle of treated effluent for facility washdown
Option C (Figure X-3, page 1790) is based on:
o Chemical precipitation (lime) and sedimentation
o Flow reduction
o Recycle of treated effluent for facility washdown
o Sulfide precipitation and sedimentation
o Multimedia filtration
The three technology options examined for BAT are discussed in
greater detail below. The first option considered is the same as
considered for BPT and presented in the previous section. The
last three options each represent substantial progress toward the
prevention of polluting the environment above and beyond the
progress achievable by BPT.
OPTION A
Option A for the primary lead subcategory is equivalent to the
control and treatment technologies selected as the basis for BPT
in Section IX. The BPT end-of-pipe treatment scheme includes
chemical precipitation and sedimentation (see Figure X-l, page
1788). Additionally treated effluent is partially recycled for
use as facility washdown water. The discharge allowances for
Option A are equal to the discharge allowances allocated to each
stream at BPT.
OPTION B
Option B for the primary lead subcategory achieves lower
pollutant discharge by building upon the Option A end-of-pipe
treatment technology. Option B consists of lime precipitation,
sedimentation, and in-process flow reduction (see Figure X-2,
page 1789). Flow reduction measures, including in-process
changes, result in the elimination of some wastewater streams and
the concentration of pollutants in other effluents. Treatment of
1774
-------
PRIMARY LEAD SUBCATEGORY SECT - X
a more concentrated effluent allows achievement of a greater net
pollutant removal and introduces the possible economic benefits
associated with treating a lower volume of wastewater.
Methods used in Option B to reduce process wastewater generation
or discharge rates through flow reduction are discussed below.
Recycle of Water Used iri Wet Air Pollution Control
There are three wastewater sources associated with wet air
pollution control which are regulated under these effluent
limitations:
1. Sinter plant materials handling wet air pollution
control,
2. Zinc fuming furnace wet air pollution control,
3. Dross reverberatory furnace wet air pollution control,
and
4. Hard lead refining wet air pollution control.
Two plants reported using sinter plant materials handling wet air
pollution control. Both plants practice approximately 90 percent
recycle.
Only one plant in this subcategory reported the latter three
waste streams. This plant does not recycle its scrubber liquor;
however, a portion of the scrubber liquor is reused in ore mining
and milling operations following treatment.
Recycle or_ Reuse of Dross Reverberatory Furnace Granulation
Wastewater
Three plants in this subcategory reported this waste stream.
Recycle or reuse practices of dross reverberatory furnace
granulation wastewater were not available from two of the plants.
The third plant routes its dross reverberatory furnace
granulation wastewater to a blast furnace slag granulation
treatment system for treatment followed by recycle or discharge.
OPTION C
Option C for the primary lead subcategory consists of all control
and treatment requirements of Option B (lime precipitation,
sedimentation, and in-process flow reduction) plus sulfide
precipitation, sedimentation, and multimedia filtration
technology added at the end of the Option B treatment scheme (see
Figure X-3, page 1790). Sulfide precipitation will remove toxic
metals to levels otherwise achievable by lime and settle
treatment. Multimedia filtration is used to remove suspended
solids, including precipitates of toxic metals, beyond the
concentration attainable by gravity sedimentation. The filter
suggested is of the gravity, mixed media type, although other
1775
-------
PRIMARY LEAD SUBCATEGORY SECT - X
filters, such as rapid sand filters or pressure filters, would
perform satisfactorily.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
As a means of evaluating each technology option, EPA developed
estimates of the pollutant removals and the compliance costs
associated with each option. The methodologies are described
below.
POLLUTANT REMOVAL ESTIMATES
A complete description of the methodology used to calculate the
estimated pollutant removal, achieved by the application of the
various treatment options is presented in Section X of the
General Development Document. The pollutant removal estimates
have been revised from proposal based on comments and new data.
However, the methodology for calculating pollutant removals was
not changed. The data used for estimating removals are the same
as those used to revise compliance costs.
Sampling data collected during the field sampling program were
used to characterize the major waste streams considered for
regulation. At each sampled facility, the sampling data were
production normalized for each unit operation (i.e., mass of
pollutant generated per mass of product manufactured). This
value, referred to as the raw waste, was used to estimate the
mass of toxic pollutants generated within the primary lead
subcategory. By multiplying the total subcategory production for
a unit operation by the corresponding raw waste value, the mass
of pollutant generated for that unit operation was estimated.
The volume of wastewater discharged after the application of each
treatment option was estimated for each operation at each plant
by comparing the actual discharge to the regulatory flow. The
smaller of the two values was selected and summed with the other
plant flows. The mass of pollutant discharged was then estimated
by multiplying the achievable concentration values attainable by
the option (mg/1) by the estimated volume of process wastewater
discharged by the subcategory. The mass of pollutant removed is
the difference between the estimated mass of pollutant generated
within the subcategory and the mass of pollutant .discharged after
application of the treatment option. The pollutant removal
estimates for the direct dischargers in the primary lead
subcategory are presented in Table X-l (page 1788).
COMPLIANCE COSTS
Compliance costs presented at proposal were estimated using cost
curves, which related the total costs associated with
installation and operation of wastewater treatment technologies
to plant process wastewater discharge. EPA applied these curves
on a per plant basis, a plant's costs — both capital, and
operating and maintenance — being determined by what treatment
it has in place and by its individual process wastewater
1776
-------
PRIMARY LEAD SUBCATEGORY SECT - X
discharge (from dcp). The final step was to annualize the capital
costs, and to sum the annualized capital costs, and the operating
and maintenance costs, yielding the cost of compliance for the
subcategory.
Since proposal, the cost estimation methodology has been changed
as discussed in Section VIII of this document. A design model
and plant specific information were used to size a wastewater
treatment system for each discharging facility. After completion
of the design, capital and annual costs were estimated for each
unit of the wastewater treatment system. Capital costs were
developed from vendor quotes and annual costs were developed from
literature. The revised compliance costs are presented in Table
VIII-1 (page 1754).
BAT OPTION SELECTION
Lime precipitation, sedimentation, in-process flow reduction, and
filtration were selected as the basis for the proposed BAT in
this subcategory. Wastewater generated from slag granulation was
the only waste stream allocated a flow allowance.
Data submitted through comments, as discussed in Section IX,
demonstrated that primary lead plants operating acid plants
cannot achieve lime and settle treatment performance of the
combined metals data base. If a plant cannot achieve lime and
settle performance, it probably could not achieve the incremental
removal over lime and settle performance proposed for filtration.
However, the Agency believes the addition of sulfide
precipitation and sedimentation in conjunction with polishing
multimedia filtration will achieve the treatment performance
values proposed. The Agency bases this conclusion on the
demonstrated performance of this technology and the fact that
metal sulfides have a much lower solubility than metal
hydroxides. The costs associated with sulfide precipitation are
attributed to the metallurgical acid plant subcategory because
the primary lead smelter contributes only a small portion of the
flow. For those plants only generating wastewater to meet
industrial hygiene requirements, the technology basis does not
include sulfide precipitation since these waste streams are not
so contaminated and variable as to require the additional
treatment.
In the final rule, the Agency has moved the proposed flow
allowance for the granulating system from blast furnace slag
granulation to dross furnace speiss granulation. The Agency made
this change so that the plant achieving zero discharge of blast
furnace slag granulation would not receive an allowance they do
not need, and yet still provide an allowance for the plant that
has demonstrated the need for a granulating allowance. The
methodology and the basis for revisions of flow allowances
discussed for BPT are also applicable for BAT.
EPA estimates that the promulgated BAT limitations will remove
4,700 kg/yr of the toxic metals generated in the subcategory. The
1777
-------
PRIMARY LEAD SUBCATEGORY SECT - X
final BAT effluent mass limitations will remove 160 kg/yr of
toxic metals over the intermediate BAT option considered, which
lacks filtration. Both options are economically achievable. The
Agency believes that the incremental removal justifies selection
of sulfide precipitation and multimedia filtration as part of BAT
model technology. Filtration as an end-of-pipe treatment
technology is demonstrated by one facility in the primary lead
subcategory. Sulfide precipitation is demonstrated by two plants
in the nonferrous metals manufacturing phase I category and at
three plants in the phase II portion of this point source
category. Estimated capital cost for achieving the promulgated
BAT is $0.215 million (March, 1982 dollars) and the estimated
annual cost is $0.118 million.
WASTEWATER DISCHARGE RATES
A BAT discharge rate was calculated for each subdivision based
upon the flows of the existing plants, as determined from
analysis of dcp and data collected through comments and Section
308 requests. The discharge rate is used with the treatment
performance concentrations to determine BAT effluent limitations.
Since the discharge rate may be different for each wastewater
source, separate production normalized discharge rates for each
of the 12 wastewater sources were determined and are summarized
in Table X-2 (page 1783). The discharge rates are normalized on
a production basis by relating the amount of wastewater generated
to the mass of the intermediate product which is produced by the
process associated with the waste stream in question. These
production normalizing parameters (PNP) are also listed in Table
X-2.
The promulgated BAT discharge allowances for five waste streams
are identical to those promulgated for BPT. BPT, as promulgated,
for materials handling wet air pollution control is based on 90
percent recycle. The Agency does not believe any further
reduction in flow is justified for BAT based on demonstrated
recycle rates. Flow allowances for hand wash, respirator wash,
laundering of uniforms, and facility washdown are equal to BPT.
A discussion of the other wastewater sources in the primary lead
subcategory is presented below.
BLAST FURNACE SLAG GRANULATION
The BAT wastewater discharge allowance proposed for primary lead
was developed for discharges resulting only from blast furnace
slag granulation. There are four plants that-report generating
this waste stream with three of the plants recycling or reusing
100 percent of this wastewater. The production normalized
discharge for the one discharging facility is 3,730 1/kkg (895
gal/ton) of lead bullion produced. This plant also reported
recycling 71 percent of this waste stream. Although the Agency
proposed a discharge allowance for this unit operation, we think
the allowance more properly belongs to the dross reverberatory
furnace building block. A discharge from this process was
thought necessary so that blast furnace slag can be recycled to
1778
-------
PRIMARY LEAD SUBCATEGORY SECT - X
the sintering machine.
The one discharging plant currently commingles dross
reverberatory slag granulation and blast furnace slag granulation
wastewater together prior to reuse. Sodium carbonate is used as
a fluxing agent in dressing furnace so that when when dross slag
is granulated, sodium dissolves in the granulating water and
subsequently contaminates the blast furnace slag. It is reported
that sodium contaminated slag is detrimental to the sintering
process. The plant contends it needs a 150 gpm bleed from the
system to prevent sodium contamination. In response to this
requirement, a blast furnace slag granulation flow allowance
based on the production normalized discharge at this plant was
included in the proposed regulation. However, since proposal the
Agency has reconsidered this allowance and provided a discharge
for dross reverberatory slag granulation based on segregation of
the two types of slag granulation water. By changing the flow
allowance, the plant described above will still have a slag
granulation bleed to reduce sodium, and those plants currently
achieving zero discharge of blast furnace slag granulation would
not receive an unneeded discharge allowance.
ZINC FUMING FURNACE WET AIR POLLUTION CONTROL
No BAT discharge allowance is provided for zinc fuming furnace
wet air pollution control. Of the three plants that have air
pollution control on zinc fuming furnaces, two of the plants use
dry air pollution control. The BAT discharge rate is based on
dry scrubbing or, alternatively, 100 percent reuse or recycle of
air pollution scrubber liquor in .other plant processes.
Possibilities for reuse of this waste stream include blast
furnace slag granulation and acid plant scrubber liquor.
DROSS REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
No BAT discharge allowance is provided for dross reverberatory
furnace wet air pollution control. Only one plant reported a
waste stream associated with dross reverberatory furnace wet air
pollution control. The BAT discharge rate is based on dry
scrubbing or, alternatively, 100 percent reuse of air pollution
scrubber liquor in other plant processes. Possibilities' for
reuse of this waste stream include blast furnace slag granulation
and acid plant scrubber liquor.
DROSS REVERBERATORY SLAG GRANULATION WASTEWATER
A BAT discharge allowance is provided for this waste stream as
described in the changes to the proposed blast furnace slag
granulation discharge rate. The BAT discharge rate for dross
reverberatory furnace slag granulation is equal to BPT, or 5,757
1/kkg (1,381 gal/ton) of slag, speiss, or matte granulated. The
Agency believes this discharge rate represents the maximum flow
reduction attainable for this process.
1779
-------
PRIMARY LEAD SUBCATEGORY SECT - X
HARD LEAD REFINING WET AIR POLLUTION CONTROL
No BAT discharge allowance is provided for hard lead refining wet
air pollution control. There were two plants that reported
refining hard lead. One of these plants uses a wet scrubber to
control emissions during this process, while the other plant
reported no air pollution control. The BAT discharge rate is
based on dry scrubbing or, alternatively, 100 percent reuse or
recycle of air pollution scrubber liquor. Possibilities for
reuse of waste stream include blast furnace slag granulation and
acid plant scrubber liquor.
REGULATED POLLUTANT PARAMETERS
In implementing the terms of the Consent Agreement in NRDC v.
Train, Op. Cit., and 33 U.S.C. (1314(b)(2)(A and B)) (1976), the
Agency placed particular emphasis on the toxic pollutants. The
raw wastewater concentrations from individual operations and the
subcategory as a whole were examined to select certain pollutants
and pollutant parameters for consideration for limitation. This
examination and evaluation, presented in Section VI, concluded
that six pollutants and pollutant parameters are present in
primary lead wastewaters at concentrations that can be
effectively reduced by identified treatment technologies. (Refer
to Section VI).
However, the cost associated with analysis for toxic metal
pollutants has prompted EPA to develop an alternative method for
regulating and monitoring toxic pollutant discharges from the
nonferrous metals manufacturing category. Rather than developing
specific effluent mass limitations and standards for each of the
toxic metals found in treatable concentrations in the raw waste
waters from a given subcategory, the Agency is proposing effluent
mass limitations only for those pollutants generated in the
greatest quantities as shown by the pollutant reduction benefit
analysis. The pollutants selected for specific limitation are
listed below:
122. lead
128. zinc
By establishing limitations and standards for certain toxic metal
pollutants, dischargers will attain the same degree of control
over toxic metal pollutants as they would have been required to
achieve had all the toxic metal pollutants been directly limited.
This approach is justified technically since the treatable
concentrations used for lime precipitation and sedimentation
technology are based on optimized treatment for concomitant
multiple metals removal. Thus, even though metals have somewhat
different theoretical solubilities, they will be removed at very
nearly the same rate in a chemical precipitation and
sedimentation treatment system operated for multiple metals
removal. Filtration as part of the technology basis is likewise
justified because this technology removes metals non-
1780
-------
PRIMARY LEAD SUBCATEGORY SECT - X
preferentially.
The following toxic pollutants are excluded from limitation on
the basis that they are effectively controlled by the limitations
developed for lead and zinc:
116. asbestos
118. cadmium
STORMWATER AND PRECIPITATION ALLOWANCES
The promulgated 1975 BAT effluent limitations include net
precipitation and catastrophic storm allowances for facilities
located in historical geographic areas of net evaporation.
Facilities are allowed a discharge of process wastewater which is
equivalent to the volume of precipitation that falls within the
wastewater impoundment in excess of that attributable to the 25-
year, 24-hour rainfall event, when such event occurs. In
addition, facilities are allowed to discnarge a volume of process
wastewater on a monthly basis that is equal to the net difference
between the rainfall falling on the impoundment and the mean
evaporation from the pond water surface. This monthly discharge
is subject to concentration-based standards, whereas the
catastrophic storm is not subject to any effluent limitations.
The Agency is modifying its approach to stormwater. The Agency
is promulgating BAT effluent limitations based on chemical
precipitation and sedimentation, not on large cooling water
impoundments. The Agency believes the technology basis of BAT
does not require a monthly rainfall and catastrophic stormwater
allowance.
EFFLUENT LIMITATIONS
The effluent concentrations achievable by the application of the
BAT treatment technology are discussed in Section VII of this
supplement. The treatable concentrations (both one-day maximum
and monthly average values) are multiplied by the BAT normalized
discharge flows summarized in Table X-2 to calculate the mass of
pollutants allowed to be discharged per mass of product. The
results of these calculations in milligrams of pollutant per
metric ton of product represent the BAT effluent limitations and
are presented in Table X-3 (page 1784) for each individual waste
stream.
ITS:
-------
Table X-i
POLLUTANT REMOVAL ESTIMATES FOR PRIMARY LEAD DIRECT DISCHARGERS
TOTAL OPTION A
RAW WASTE DISCHARGED
POLLUTANT (kg/yr)
Arsenic 0.3
Cadmium 0.6
Lead 2.075.9
Zinc 2.686.9
TOTAL TOXIC METALS 4.763.6
TSS 273,850.4
, T"''M POLLUTANTS 278,614.0
Co FLOW (1/yr)
(kg/yr)
0.3
0.6
487.6
349.8
838.3
12,720.0
13,558.3
1 .060,000,000
NOTE: TOTAL TOXIC METALS - Arsenic + Cadmium + Lead +
OPTION A
OPTION B
REMOVED DISCHARGED
(kg/yr)
0.0
0.0
1,588.3
2.337.1
3,925.4
261.130.4
265.055.7
335.
Zinc
(kg/yr)
0.3
0.6
154.1
110.6
265.5
4.020.0
4.285.5
000,000
OPTION B
REMOVED
(kg/yr)
0.0
0.0
1.921.8
2,576.4
4.498.1
269,830.4
274.328.5
335
OPTION C
DISCHARGED
(kg/yr)
0.3
0.6
26.8
77.1
104.7
871 .0
975.7
.000.000
OPTION C
REMOVED
(kg/yr)
0.0
0.0
2.049.1
2,609.9
4.658.9
272,979.4
277,638.3
W
H
Kj
tr1
W
§
in
a
n
M
Q
o
$
IOTAL POLLUTANTS = Total Toxic Metals + TSS
O'TION A = Lime Preclpltat
OCTION B - Option A. plus
OPTION C = Option B, plus
Ion and Sedimentation
In-process Flow Reduction
SulClde Precipitation and Sedimentation,
and Multimedia Filtration
w
M
0
1
X
-------
PRIMARY LEAD SUBCATEGORY
SECT - X
Table X-2
BAT WASTEWATER DISCHARGE RATES FOR THE
PRIMARY LEAD SUBCATEGORY
Wastewater Stream
Sinter Plant Materials
Handling Wet Air
Pollution Control
Blast Furnace Wet Air
Pollution Control
Blast Furnace Slag
Granulation
Dross Reverberatory
Slag Granulation
Wastewater
Dross Reverberatory
Furnace Wet Air
Pollution Control
Zinc Fuming Wet Air
Pollution Control
Hard Lead Refining
Slag Granulation
Hard Lead Refining
Wet Air Pollution
Control
Facility Washdown
: mployee Hand Wash
Kespirator Wash
Laundering of
Uniforms
BAT Normalized
Discharge Rate
1/kkg gal/ton
360
0
0
3.3
5.3
16
86
5,
0
0
757
0
0
1 ,381
0
0
0
0
0
0
Production
Normalizing
Parameter
Sinter plant
production
Slag, speiss, or
matte granulated
0
0.79 Lead bullion produced
1.3 Lead bullion produced
3.7 Lead bullion produced
1783
-------
PRIMARY LEAD SUBCATEGORY SECT - X
TABLE X-3
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(a) Sinter Plant Materials Handling Wet Air Pollution
Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Cadmium 72.000 28.800
*Lead 100.800 46.800
*Zinc 367.200 151.200
(b) Blast Furnace Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
1784
-------
PRIMARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(c) Blast Furnace Slag Granulation BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium
*Lead
*Zinc
0.000
0.000
0.000
0.000
0.000
0.000
(d) Dross Reverberatory Furnace Slag Granulation BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Cadmium 1,151.000 460.600
*Lead 1,612.000 748.400
*Zinc 5,872.000 2,418.000
* Regulated Pollutant
1785
-------
PRIMARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(e) Dross Reverberatory Furnace Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc . 0.000 0.000
(f) Zinc Fuming Furnace Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
1786
-------
PRIMARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(g) Hard Lead Refining Slag Granulation BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium
Lead
Zinc
0.000
0.000
0.000
0.000
0.000
0.000
(h) Hard Lead Refining Wet Air Pollution Control BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
1787
-------
PRIMARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(i) Facility Washdown •BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
(j) Employee Handwash BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.660 0.264
*Lead 0.924 0.429
*Zinc 3.366 1.386
* Regulated Pollutant
1788
-------
PRIMARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE PRIMARY LEAD SUBCATEGORY
(k) Respirator Wash BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 1.060 0.424
*Lead 1.48.4 0.689
*Zinc 5.406 2.226
(1) Laundering of Uniforms BAT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 3.200 1.280
*Lead 4.340 2.015
*Zinc 15.810 6.510
1789
-------
--J
VD
O
HjiiHt Furnace Sing Granulation Waatewater
Druss Ke«erl.ct jlory Furnace Cranulatlon Uastewater
7. lite Fuming Furnace Scrubber Liquor
DTOSS Reverberntory Furnace Scrubber Liquor
Hard l.i;ad Kef Icilng Scruliber l.lquor
Kmplo^ee llanilwash Waatewater
Eiiijiloyee Reapl rator Wash Wastewater
Laundering of UnlfDrniB Uaatewater
F.irlllty Wastulown Wastewater
Sinter l'l;lut Hnli-tlala llantlilng Scrubber Liquor^
Holding
Tank
Recycle
Sludge Removal
Complete Recycle of Facility
,h
-------
Dross Reverberatory Furnace Granulation Wastewatcr
Employee llandwash Uaatewater
Employee Respirator Uasli U.istewater
Laundering of Uniforms Uastewater
Facility Mashdown Uastewater
\7
Sinter Plant Materials Handling Scrubber **
Liquor Holding
* Tank
i
1
Sludge Rei
Blast Furnace Slag Granulation
U.ncrpu.trnr Reryrl* -
*
^7 1
7. Inc Fuming Furnace Scrubber ~ 1
1, 1 quor ^ Ho 1 d 1 ng
Tank
Dross Reverberatory Furnace Scrub- -
uer I. iquor
Hard Lead Ref In Ing Scrubber
Liquor
Uaulidown Uater
Clu-mlcal Addition
/ V7 i t"^ rr r? T-7 Hd
S-" a pre"P;::::0n L^'itat;°"j ' "?::;"• * |
f
Sludge M
Sludge Recycle (3)
/" \ (1 w
/ \ f^\^ • c;
~^ \ T* rr^ Disno^-ii w
Vacuun Filtrate \ \ | / / IFIS.IWN.II Q
^^ *• H
Recycle W
Sludge Dewaterlng Q
BttflttflBBMB: ^
•oval
M
O
1
Sludge
Figure X-2
BAT TREATMENT SCHEME OPTION B
PRIMARY LEAD SUBCATEGORY
-------
Backwaalt
(•l>loyee llandwasti Uautewater
Facility Uaali
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
The basis for new source performance standards (NSPS) under
Section 306 of the Act is the best available demonstrated
technology. New plants have the opportunity to design and use
the best and most efficient nonferrous metals manufacturing
processes and wastewater treatment technologies, without facing
the added costs and restrictions encountered in retrofitting an
existing plant. Therefore, Congress directed EPA to consider the
best demonstrated process changes, in-plant controls, and end-of-
pipe treatment technologies which reduce pollution to the maximum
extent feasible.
This section describes the control technology for treatment of
wastewater from new sources, and presents mass discharge
limitations of regulated pollutants for NSPS in the primary lead
subcategory, based on the described control technology.
TECHNICAL APPROACH TO BDT
All of the treatment technology options applicable to a new
source were previously considered for the BAT options. For
this reason, three options were considered for BDT, all identical
to BAT Options A, B, and C, which are discussed in Section X.
Briefly, the treatment technologies used for the three options
are as follows:
OPTION A
o Chemical precipitation and sedimentation
o Partial recycle of treated effluent for facility washdown
OPTION B
o Chemical precipitation and sedimentation
o Partial recycle of treated effluent for facility washdown
o In-process flow reduction
OPTION C
o Chemical precipitation and sedimentation
o Partial recycle of treated effluent for facility washdown
o In-process flow reduction
o Sulfide precipitation and sedimentation
o Multimedia filtration
BDT OPTION SELECTION
The proposed best available demonstrated technology eliminated
the discharge of all process wastewater pollutants from primary
1793
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
lead production. Zero discharge of process wastewater pollutants
was based on the complete recycle and reuse of slag granulation
wastewater or through slag dumping.
EPA is promulgating NSPS. that prohibit the discharge of all
process wastewater from primary lead smelting except for those
industrial hygiene streams provided an allowance at BAT and for
which an allowance remains necessary. The addition of hand wash,
respirator wash, and laundering of uniforms wastewater has made
this change from proposal necessary. Sinter plant materials
handling wet air pollution control has not been provided an
allowance based on the use of dry scrubbers. Conversations with
industry representatives indicate that dry systems, such as
baghouses, can be used just as effectively as wet scrubbers.
However, BAT does not require dry scrubbing because of the
extensive retrofits required to replace wet scrubbers with dry
systems. EPA believes NSPS do not present any barrier to entry
for new plants, since no retrofit costs.are associated with dry
scrubbing. Zero discharge from all other streams can be achieved
by the demonstrated complete recycle and reuse of slag
granulation wastewater or through slag dumping. The Agency
believes new plants can be designed to eliminate discharge from
the dross reverberatory furnace slag granulation process at no
significant additional cost by 100 percent recycle and reuse of
this waste stream. Only two of six primary lead plants currently
operating produce dross reverberatory. slag granulation
wastewater. One of these practices 100 percent reuse in other
plant processes.
Comments were received asking that NSPS for the primary lead
subcategory be held in reserve because new sources would be built
using hydrometallurgical processes instead of the conventional
pyrometallurgical processes. The Agency believes that the
effluent reductions achievable by pyrometallurgical sources
represent Best Demonstrated Technology. New hydrometallurgical
processes should therefore have to meet limitations associated
with this technology. In fact, there are no existing
hydrometallurgical plants and it is not at all clear if there
will be any new sources using this process. If such a
(hypothetical) facility could demonstrate that it could not
achieve better effluent reductions than pyrometallurgical
sources, the Agency will consider amending NSPS. However, no
such demonstration has been made.
REGULATED POLLUTANT PARAMETERS
The Agency has no reason to believe that the pollutants that will
be found in treatable concentrations in processes within new
sources will be any different than with existing sources.
Accordingly, pollutants and pollutant parameters selected for
limitation in Section X are also selected for limitation in NSPS.
NEW SOURCE PERFORMANCE SJ_ANDARDS
The NSPS discharge flows for hand wash, respirator wash, and
1794
-------
PRIMARY LEAD SUBCATEGORY
SECT - XI
laundering of uniforms are the same as the BAT discharge rates
listed in Section X. The NSPS discharge flows are presented in
Table XI-1 (page 1796). The mass of pollutant allowed to be
discharged per mass of product is calculated by multiplying the
appropriate achievable treatment concentration by the production
normalized wastewater discharge flows (1/kkg). The treatment
concentrations are discussed in Section VII of this supplement.
The results of these calculations are the production-based new
source performance standards, and are presented in Table Xl-2
(page 1797).
1795
-------
PRIMARY LEAD SUBCATEGORY
SECT - XI
Table XI-1
NSPS WASTEWATER DISCHARGE RATES FOR THE
PRIMARY LEAD SUBCATEGORY
Wastewater Stream
Sinter Plant Materials
Handling Wet Air
Pollution Control
Blast Furnace Wet Air
Pollution Control
Blast Furnace Slag
Granulation
Dross Reverberatory
Slag Granulation
Wastewater
Dross Reverberatory
Furnace Wet Air
Pollution Control
.line Fuming Wet Air
Pollution Control
Hard Lead Refining
Slag Granulation
Hard Lead Refining
Wet Air Pollution
Control
Facility Washdown
imployee Hand Wash
Respirator Wash
Laundering of
Uniforms
NSPS Normalized
Discharge Rate
1/kkg gal/ton
0 0
0
0
0
0
0
3.3
5.3
16
0
0
0
(5
0
0
0
0
0
0
0.79
1.3
3.7
Production
Normalizing
Parameter
Lead bullion produced
Lead bullion produced
Lead bullion produced
1796
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2
NSPS FOR THE PRIMARY LEAD SUBCATEGORY
(a) Sinter Plant Materials Handling Wet Air Pollution
Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Cadmium
*Lead
*Zinc
*TSS
*pH
(b) Blast Furnace Wet Air
0.000
0.000
0.000
0.000
Within the range of 7.0
at all times
Pollution Control NSPS
0.000
0.000
0.000
0.000
to 10.0
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1797
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY LEAD SUBCATEGORY
(c) Blast Furnace Slag Granulation NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace
lead bullion produced
Cadmium . . 0.000 0.000
*Lead " ' 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
(d) Dross Reverberatory Slag Granulation NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY LEAD SUBCATEGORY :
(e) Dross Reverberatory Furnace Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Cadmium
*Lead
*Zinc
*TSS
*pH
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
Within the range of 7.0 to
at all times
10.0
(f) Zinc Fuming Furnace Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 0.000 0.00.0
*Lead 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1799
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY LEAD SUBCATEGORY
(g) Hard Lead Refining 'Slag Granulation NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
(h) Hard Lead Refining Wet Air Pollution Control NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1800
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY LEAD SUBCATEGORY
(i) Facility Washdown NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.0 to 10.0
at all times
(j) Employee Handwash NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.660 0.264
Lead 0.924 0.429
Zinc 3.366 1.386
TSS 49.500 39.600
pH Within the range of 7.0 to 10.0
at all times
* Regulaced Pollutant
1801
-------
PRIMARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY LEAD SUBCATEGORY
(k) Respirator Wash NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 1.060 0.424
*Lead . 1.484 0.689
*Zinc " 5.406 2.226
*TSS 79.500 63.600
*pH Within the range of 7.0 to 10.0
at all times
(1) Laundering of Uniforms NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 3.200 1.280
*Lead 4.340 2.015
*Zinc 15.810 6.510
*TSS 232.500 186.000
*pH Within the range of 7.0 to 10.0
at all times
* Regulated Pollutant
1802
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
SECTION XII
PRETREATMENT STANDARDS
Section 307(b) of the Act requires EPA to promulgate pretreatment
standards for existing sources (PSES)/ which must be achieved
within three years of promulgation. PSES are designed to prevent
the discharge of pollutants which pass through, interfere with,
or are otherwise incompatible with the operation of publicly
owned treatment works (POTW). The Clean Water Act of 1977
requires pretreatment for pollutants, such as heavy metals, that
limit POTW sludge management alternatives. Section 307(c) of the
Act requires EPA to promulgate pretreatment standards for new
sources (PSNS) at the same time that it promulgates NSPS. New
indirect discharge facilities, like new direct discharge
facilities, have the opportunity to incorporate the best
available demonstrated technologies, including process changes,
in-plant controls, and end-of-pipe treatment technologies, and to
use plant site selection to ensure adequate treatment system
installation. Pretreatment standards are to be technology-based
and analogous to the best available technology for removal of
toxic pollutants.
TECHNICAL APPROACH TO PRETREATMENT
Before proposing pretreatment standards, the Agency examines
whether the pollutants discharged by the subcategory pass through
the POTW or interfere with the POTW operation or its chosen
sludge disposal practices. In determining whether pollutants
pass through a well-operated POTW achieving secondary treatment,
the Agency compares the percentage of a pollutant removed by POTW
with the percentage removed by direct dischargers applying the
best available technology economically achievable. A pollutant
is deemed to pass through the POTW when the average percentage
removed nationwide by well-operated POTW meeting secondary
treatment requirements, is less than the percentage removed by
direct dischargers complying with BAT effluent limitations
guidelines for that pollutant. (See generally, 46 Federal
Register at 9415-16 (January 28, 1981).)
This definition of pass through satisfies two competing
objectives set by Congress: (1) that standards for indirect
dischargers be equivalent to standards for direct dischargers,
while at the same time, (2) the treatment capability and
performance of the POTW be recognized and taken into account in
regulating the discharge of pollutants from indirect dischargers.
The Agency compares percentage removal rather than the mass or
concentration of pollutants discharged because the latter would
not take into account the mass of pollutants discharged to the
POTW from non-industrial sources nor the dilution of the
pollutants in the POTW effluent to lower concentrations due to
the addition of large amounts of non-industrial wastewater.
1803
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES
Options for pretreatment of wastewaters are based on increasing
the effectiveness of end-of-pipe treatment technologies. All
in-plant changes and applicable end-of-pipe treatment processes
have been discussed previously in Sections X and XI. The options
for PSES and PSNS, therefore, are the same as the BAT options
discussed in Section X.
While a more detailed discussion, including pollutants controlled
by each treatment process and achievable treatment concentrations
are presented in Section VII of Vol. I.
The treatment technology options, presented more fully in Section
X, for PSES and PSNS are:
Option A
o Chemical precipitation and sedimentation
c Partial recycle of treated effluent for facility washdown
Option B
o Chemical precipitation and sedimentation
o Partial recycle of treated effluent for facility washdown
o In-process flow reduction
Option C
o Chemical precipitation and sedimentation
o Partial recycle of treated effluent for facility washdown
o In-process flow reduction
o Sulfide precipitation and sedimentation
o Multimedia filtration
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
The methodology applied in calculating pollutant removal
estimates and plant compliance costs is discussed in Section X.
This methodology for calculating the pollutant removals has been
changed slightly for primary lead indirect dischargers. Table
XII-1 (page 1807) shows the estimated pollutant removal estimates
for indirect dischargers. The primary lead indirect dischargers
only discharge hand wash, respirator wash, and laundry
wastewater. As explained in Section X, these wastewaters are not
as contaminated as the other primary lead wastewaters and acid
plant blowdown. The Agency believes it is less expensive to
segregate this wastewater and incorporate it into the plant's
process water balance, which is already zero discharge.
Therefore, in estimating pollutant removals, no process flow is
sent through treatment since the wastewater is not discharged.
Consequently, the polluta it removal estimates show no discharge
of pollutants for indirect dischargers for all three options.
Compliance costs are presented in Table VIII-2 (page 1754).
1804
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
PRETREATMENT STANDARDS FOR EXISTING SOURCES
EPA did not propose pretreatment standards for existing sources
for the primary lead subcategory since there were no existing
indirect dischargers. However, the addition of hand wash,
respirator wash, and laundering of uniforms makes two plants
previously considered zero dischargers indirect dischargers. The
technology basis for the promulgated PSES is identical to BAT
(Option C). Although Option C includes sulfide precipitation,
the Agency does not expect the indirect dischargers will need
this technology since they only discharge hand wash, respirator
wash, and laundry wastewater. As explained for BAT, these
wastewaters are not as contaminated as other primary lead waters
and acid plant blowdown. In fact, the Agency believes it is less
expensive for these plants to segregate this wastewater and
incorporate it into the plant's process water balance, which is
already zero discharge. These flows are a small percentage (less
than five percent) of the process waters, and therefore, their
addition will have a negligible effect on the water balance.
Therefore, compliance costs are based on segregation and reuse
(or evaporation) rather than on treatment. Wastewater discharge
allowances are shown in Table XII-2 (page 1808).
Implementation of the promulgated PSES limitations will remove an
estimated 117 kg/yr of toxic pollutants over estimated raw
discharge. Capital cost for achieving PSES is $0.038 million
(March, 1982 dollars) and annual cost is $0.007 million. These
costs represent the cost of segregating these waste streams.
PRETREATMENT STANDARDS FOR NEW SOURCES
As with NSPS, EPA is promulgating PSNS that prohibit the
discharge of certain process wastewater pollutants from primary
lead production. Discharge allowances are provided only for hand
wash, respirator wash, and laundering of uniforms wastewater. A
zero discharge requirement of granulating process wastewater
pollutants is achievable through complete recycle and reuse of
slag granulation wastewater or through slag dumping. Zero
discharge for sinter plant materials handing air pollution
control is based on dry scrubbing. Thus PSNS prevent the pass
through of lead and zinc, the toxic pollutants selected for
specific limitation under BAT effluent limitations. New sources
are not allocated catastrophic rain storm allowances since
recycle and reuse of process wastewater is based on cooling
towers and clarifiers (if needed), not cooling impoundments.
Wastewater discharge allowances for PSNS are p'resented in Table
XII-3 (page 1809).
REGULATED POLLUTANT PARAMETERS
Pollutants selected for limitation, in accordance with the
rationale of Sections VI and X, are identical to those selected
for limitation for BAT. It is necessary to promulgate PSES and
PSNS to prevent the pass-through of lead and zinc, which are the
limited pollutants.
1805
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
PRETREATMENT STANDARDS
Pretreatment standards are based on the treatable concentrations
from the selected treatment technology, (Option C), and the
discharge rates determined in Section X for BAT. A mass of
pollutant per mass of product (mg/kkg) allocation is given for
each subdivision within the subcategory. This pollutant
allocation is based on the product of the treatable concentration
from the proposed treatment (mg/1) and the production normalized
wastewater discharge rate (1/kkg). The achievable treatment
concentrations for BAT are identical to those for PSES and PSNS.
These concentrations are discussed in Section VII of this
supplement. PSES and PSNS are presented in Tables XII-4 and XII-
5, respectively (pages 1810 and 1816).
1806
-------
Table XII-1
POLLUTANT REMOVAL ESTIMATES FOR PRIMARY LEAD INDIRECT DISCHARGERS
POLLUTANT
Arsenic
Cadmium
Lead
Zinc
TOTAL TOXIC MKTALS
TSS
TOTAL POLLUTANTS
h-> KLOW (l/yr)
00
O
^ NOTK: TOTAL TOXIC
TOTAL
RAW WASTE
(kg/yr)
0.1
0.0
111 .0
5.4
116.4
1.380.8
t ,497.2
OPTION A OPTION A
DISCHARGED REMOVED
(kg/yr) (kg/yr)
0.0 0.1
0.0 0.0
0.0 111.0
0.0 5.4
0.0 116.5
0.0 1.380.8
0.0 1.497.3
0
OPTION B
DISCHARGED
(kg/yr)
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0
OPTION B OPTION C OPTION C
REMOVED DISCHARGED REMOVED
(kg/yr) (kg/yr) (kg/yr)
0.1 0.0 0.1
0.0 0.0 0.0
111.0 0.0 111.0
5.4 0.0 5.4
116.5 0.0 116.5
1.380.8 0.0 1.380.8
1.497.3 0.0 1.49.7.3
0
METALS - Arsenic + Cadmium + Lead + Zinc
TOTAL POLLUTANTS - Total Toxic Metals +• TSS
OPTION A =
OPTION B =
OPTION C =
Lime Preclpltat
Option A, plus
Opt Ion B, plus
Ion and Sedimentation •
In-process Flow Reduction
Sulflde Precipitation and
Sedimentation.
and Multimedia Filtration
H
3
>
K
IT"
W
O
in
c:
w
n
jf
hj
W
O
KJ
tn
w
n
t-3
-------
PRIMARY LEAD SUBCATEGORY
SECT - XII
Table XII-2
PSES WASTEWATER DISCHARGE RATES FOR THE
PRIMARY LEAD SUBCATEGORY
Wastewater Stream
Sinter Plant Materials
Handling Wet Air
Pollution Control
Blast Furnace Wet Air
Pollution Control
Blast Furnace Slag
Granulation
Dross Reverberatory
Slag Granulation
Wastewater
Dross Reverberatory
Furnace Wet Air
Pollution Control
Zinc Fuming Wet Air
Pollution Control
Hard Lead Refining
Slag Granulation
Hard Lead Refining
Wet Air Pollution
Control
Facility Washdown
Employee Hand Wash
Respirator Wash
Laundering of
Uniforms
PSES Normalized
Discharge Rate
1/kkg gal/ton
360
0
0
3.3
5.3
16
86
5,
0
0
757
0
0
1,381
0
0
0
0
0
0
0
Production
Normalizing
Parameter
Sinter plant
production
Slag, speiss, or
matte granulated
0
0.79 Lead bullion produced
1.3 Lead bullion produced
3.7 Lead bullion produced.
1808
-------
PRIMARY LEAD SUBCATEGORY
SECT - XII
Table XII-3
PSNS WASTEWATER .DISCHARGE RATES FOR THE
PRIMARY LEAD SUBCATEGORY
Wastewater Stream
Sinter Plant Materials
Handling Wet Air
Pollution Control
Blast Furnace Wet Air
Pollution Control
Blast Furnace Slag
Granulation
Dross Reverberatory
Slag Granulation
Wastewater
Dross Reverberatory
Furnace Wet Air
Pollution Control
Zinc Fuming Wet Air
Pollution Control
Hard Lead Refining
Slag Granulation
Hard Lead Refining
Wet Air Pollution
Control
Facility Washdown
Employee Hand Wash
-ator Wash
PSNS Normalized
Discharge Rate
1/kkg gal/ton
0 0
Production
Normalizing
Parameter
Laundering of
Uniforms
0
0
0
0
0
0
0
0
3.3
5.3
16
0
0
0
0
0
0
0
0.79 Lead bullion produced
1.3 Lead bullion produced
3.7 Lead bullion produced
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(a) Sinter Plant Materials Handling Wet Air Pollution
Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Cadmium - .72.000 28.800
*Lead 100.800 46.800
*Zinc 367.200 151.200
(b) Blast Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(c) Blast Furnace Slag Granulation PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium
*Lead
*Zinc
0.000
0.000
0.000
0.000
0.000
0.000
(d) Dross Reverberatory Slag Granulation PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units - Ibs/billion Ibs of slag, matte, or speiss
granulated
Cadmium 1,515.000 460.600
*Lead 1,612.000 748.400
*Zinc 5,872.000 2,418.000
* Regulated Pollutant
1811
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(e) Dross Reverberatory' Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
(f) Zinc Fuming Furnace Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
1812
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(g) Hard Lead Refining Slag Granulation PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
(h) Hard Lead Refining Wet Air Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
* Regulated Pollutant
1813
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(i) Facility Washdown PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
(j) Employee Handwash PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.660 0.264
Lead 0.924 0.429
Zinc 3.366 1.386
* Regulated Pollutant
1814
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(k) Respirator Wash PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 1.060 0.424
Lead 1.484 0.689
Zinc 5.406 2.226
(1) Laundering of Uniforms PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 3.200 1.280
*Lead 4.340 2.015
*Zinc 15.810 6.510
* Regulated Pollutant
1815
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XI1-5
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(a) Sinter Plant Materials .Handling Wet Air Pollution
Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of sinter production
English Units - Ibs/billion Ibs of sinter production
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
(b) Blast Furnace Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
1816
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XI1-5 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(c) Blast Furnace Slag Granulation PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium
*Lead
*Zinc
0.000
0.000
0.000
0.000
0.000
0.000
(d) Dross Reverberatory Slag Granulation PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of slag, matte, or speiss granulated
English Units ~ Ibs/billion Ibs of slag, matte, or speiss
granulated
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
1817
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(e) Dross Reverberatory Furnace Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of dross reverberatory furnace production
English Units - Ibs/billion Ibs of dross reverberatory furnace
production
Cadmium . 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
(f) Zinc Fuming Furnace Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of blast furnace lead bullion produced
English Units - Ibs/billion Ibs of blast furnace lead bullion
produced
Cadmium 0.000 0.00
*Lead 0.000 0.000
*Zinc 0.000 0.000
* Regulated Pollutant
1818
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(g) Hard Lead Refining Slag Granulation PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
(h) Hard Lead Refining Wet Air Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of hard lead produced
English Units - Ibs/billion Ibs of hard lead produced
Cadmium 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
* Regulated Pollutant
1319
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
. TABLE XII-5 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(i) Facility Washdown 'PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.000 0.000
*Lead 0.000 0.000
*Zinc 0.000 0.000
( j ) Emp_loy_ee Handwash PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 0.660 0.264
*T,ead 0.924 0.429
*Zinc 3.366 1.386
* Regulated Pollutant
1820
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSES FOR THE PRIMARY LEAD SUBCATEGORY
(k) Respirator Wash PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 1.0.60 0.424
*Lead 1.484 0.689
*Zinc 5.406 2.226
(1) Laundering of Uniforms PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
, Metric Units - mg/kkg of lead bullion produced
English Units - Ibs/billion Ibs of lead bullion produced
Cadmium 3.200 1.280
*Lead 4.340 2.015
*Zinc 15.810 6.510
* Regulated Pollutant
1821
-------
PRIMARY LEAD SUBCATEGORY SECT - XII
THIS PAGE INTENTIONALLY LEFT BLANK
1822
-------
PRIMARY LEAD SUBCATEGORY SECT - XIII
SECTION XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
EPA is not promulgating best conventional pollutant control
technology (BCT) for the primary lead subcategory at this time.
.823
-------
PRIMARY LEAD SUBCATEGORY SECT - XIII
THIS PAGE INTENTIONALLY LEFT BLANK
1824
-------
NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Secondary Lead Subcategory
William K. Reilly
Administrator
Rebecca Hanmer
Acting Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
1825
-------
Page Intentionally Blank
-------
SECONDARY LEAD SUBCATEGORY
TABLE OF CONTENTS
Section
I SUMMARY 1837
II CONCLUSIONS 1841
III SUBCATEGORY PROFILE . 1861
Description of Secondary Lead Production 1861
Raw Materials 1861
Scrap Pretreatment 1861
Battery Breaking by Shear or Saw 1861
Hammer-Mill Battery-Breaking 1862
Battery Case Classifiers 1862
Low-Energy Shredders 1862
Whole Battery Charging 1862
Lead Paste Desulfurization 1862
Smelting Operations 1863
Refining and Casting 1864
Process Wastewater Sources 1865
Other Wastewater Sources 1865
Age, Production and Process Profile 1865
IV SUBCATEGORIZATION 1873
Factors Considered in Subdividing the Secondary 1873
Lead Subcategory
Other Factors 1873
Production Normalizing Parameters 1874
V WATER USE AND WASTEWATER CHARACTERISTICS 1875
Wastewater Sources, Discharge Rates, and 1876
Characteristics
Battery Cracking 1879
Blast, Reverberatory, or Rotary Furnace Wet Air .1879
Pollution Control
Kettle Wet Air Pollution Control 1880
Lead Paste Desulfurization 1880
Casting Contact Cooling Water 1880
Truck Wash . 1880
Facility Washdown 1881
Battery Case Classification 1881
Employee Handwash 1881
Employee Respirator Wash 1881
Laundering of Uniforms 1882
1827
-------
SECONDARY LEAD SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
VI SELECTION OF POLLUTANTS
Conventional and Nonconventional Pollutant
Parameters
Conventional and Nonconventional Pollutant
Parameters Selected
Toxic Pollutants 1944
Toxic Pollutants Never Detected 1945
Toxic Pollutants Never Found Above Their 1945
Analytical Quantification Concentration
Toxic Pollutants Present Below Concentrations 1945
Achievable by Treatment
Toxic Pollutants Detected in a Small Number 1945
of Sources
Toxic Pollutants Selected for Consideration in 1945
Establishing Limitations
VII CONTROL AND TREATMENT TECHNOLOGIES 1967
Current Control and Treatment Practices 1959
Battery Cracking 1959
Blast, Reverberatory, and Rotary Furnace Wet 1960
Air Pollution Control
Kettle Wet Air Pollution Control 1960
Lead Paste Desulfurization 1960
Casting Contact Cooling Water 1960
Truck Wash 1960
Facility Washdown 1960
Battery Case Classification 1962
Wastewater from Industrial Hygiene Compliance 1962
Control and Treatment Options 1963
Option A 1963
Option B . 1964
Option C 1964
Control and Treatment Options Rejected 1964
Option D 1964
Option F 1964
VIII COSTS, ENERGY, AND NONWATER QUALITY ASPECTS 1967
Treatment Options Costed for Existing Sources 1967
Option A 1967
Option B 1967
Option C 1967
Cost Methodology 1968
Nonwater Quality Aspects 1969
Energy Requirements 1970
Solid Waste 1970
Air Pollution 1971
1828
-------
Section
SECONDARY LEAD SUBCATEGORY
TABLE OF CONTENTS (Continued)
IX BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY 1975
AVAILABLE
Technical Approach to BPT 1975
Industry Cost and Pollutant Removal Estimates 1977
BPT Options Selection 1978
Wastewater Discharge Rates 1978
Battery Cracking 1979
Blast, Reverberatory, or Rotary Furnace Wet Air 1980
Pollution Control
Kettle Wet Air Pollution Control 1981
Lead Paste Desulfurization 1981
Casting Contact Cooling Water 1982
Truck Wash 1982
Facility Washdown 1982
Battery Case Classification 1983
Employee Handwash 1983
Employee Respirator Wash 1983
Laundering of Uniforms 1983
Regulated Pollutant Parameters 1983
Effluent Limitations 1984
X BEST AVAILABLE TECHNOLOGY ECONOMICALLY 1993
ACHIEVABLE
Technical Approach to BAT 1993
Option A 1994
Option B 1994
Recycle of Casting Water Through Cooling Towers 1995
Option C 1995
Industry Cost and Pollutant Removal Estimates 1995
Pollutant Removal Estimates 1995
Compliance Costs 1996
BAT Option Selection - Proposal 1996
BAT Option Selection - Promulgation 1997
Wastewater Discharge Rates 1998
Casting Contact Cooling Water 1998
Regulated Pollutant Parameters 1999
Effluent Limitations 2000
XI NEW SOURCE PERFORMANCE STANDARDS 2013
Technical Approach to BDT 2013
BDT Option Selection 2014
Regulated Pollutant Parameters 2014
New Source Performance Standards 2015
1829
-------
SECONDARY LEAD SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
XII PRETREATMENT STANDARDS
Technical Approach to Pretreatment 2023
Pretreatment Standards for Existing Sources 2024
and New Sources
Industry Cost and Pollutant Removal Estimates 2024
PSES Option Selection 2025
PSNS Option Selection 2025
Regulated Pollutant Parameters 2025
Pretreatment Standards 2026
XIII BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY 2043
1830
-------
SECONDARY LEAD SUBCATEGORY
LIST OF TABLES
Number Paqe
III-l INITIAL OPERATING YEAR SUMMARY OF PLANTS IN 1867
THE SECONDARY LEAD SUBCATEGORY BY DISCHARGE TYPE
III-2 PRODUCTION RANGES FOR THE SECONDARY LEAD 1868
SUBCATEGORY
III-3 SUMMARY OF SECONDARY LEAD SUBCATEGORY PROCESSES 1869
AND ASSOCIATED WASTE STREAMS
V-l WATER USE AND DISCHARGE RATES FOR BATTERY 1883
CRACKING OPERATIONS
V-2 SECONDARY LEAD SAMPLING DATA BATTERY CRACKING 1884
RAW WASTEWATER
V-3 WATER USE AND DISCHARGE RATES FOR BLAST 1889
REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
V-4 SECONDARY LEAD SAMPLING DATA BLAST AND 1890
REVERBERATORY FURNACE SCRUBBER LIQUOR RAW
WASTEWATER
V-5 WATER USE AND DISCHARGE RATES FOR KETTLE WET 1894
AIR POLLUTION CONTROL
V-6 SECONDARY LEAD SAMPLING DATA KETTLE SCRUBBER 1895
LIQUOR RAW WASTEWATER
V-7 WATER USE AND DISCHARGE RATES FOR CASTING 1896
CONTACT COOLING
V-8 WATER USE AND DISCHARGE RATES FOR TRUCK WASH 1896
1831
-------
SECONDARY LEAD SUBCATEGORY
LIST OF TABLES (Continued)
Number Paqe
V-9 SECONDARY LEAD SAMPLING DATA TRUCK WASH RAW 1897
WASTEWATER
V-10 WATER USE AND DISCHARGE RATES FOR FACILITY 1900
WASHDOWN
V-ll WATER USE AND DISCHARGE RATES FOR BATTERY CASE 1900
CLASSIFICATION
V-12 SECONDARY LEAD SAMPLING DATA HAND WASH RAW 1901
WASTEWATER
V-13 SECONDARY LEAD SAMPLING DATA RESPIRATOR WASH 1904
RAW WASTEWATER
V-14 SECONDARY LEAD WASTEWATER SAMPLING DATA 1907
LAUNDRY RAW WASTEWATER
V-15 SECONDARY LEAD WASTEWATER SAMPLING DATA 1910
MISCELLANEOUS RAW WASTEWATER
V-16 SECONDARY LEAD WASTEWATER SAMPLING DATA 1913
TREATMENT PLANT SAMPLES - PLANT A .
V-17 SECONDARY LEAD WASTEWATER SAMPLING DATA 1917
TREATMENT PLANT SAMPLES - PLANT B
V-18 SECONDARY LEAD WASTEWATER SAMPLING DATA 1918
TREATMENT PLANT SAMPLES - PLANT C
1832
-------
SECONDARY LEAD SUBCATEGORY
LIST OF TABLES (Continued)
Number Page
V-19 SECONDARY LEAD WASTEWATER SAMPLING DATA 1920
TREATMENT PLANT SAMPLES - PLANT D
V-20 SECONDARY LEAD WASTEWATER SAMPLING DATA 1922
TREATMENT PLANT SAMPLES - PLANT E
V-21 SECONDARY LEAD WASTEWATER SAMPLING DATA 1924
TREATMENT PLANT SAMPLES - PLANT G
V-22 SECONDARY LEAD WASTEWATER SAMPLING DATA 1932
TREATMENT PLANT SAMPLES - PLANT H
VI-1 FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS 1951
SECONDARY LEAD RAW WASTEWATER
VI-2 TOXIC POLLUTANTS NEVER DETECTED 1955
VI-3 TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR 1957
ANALYTICAL QUANTIFICATION CONCENTRATION
VIII-1 COST OF COMPLIANCE FOR THE SECONDARY LEAD 1973
SUBCATEGORY, DIRECT DISCHARGERS
VII1-2 COST OF COMPLIANCE FOR THE SECONDARY LEAD 1973
SUBCATEGORY, INDIRECT DISCHARGERS
IX-1 BPT WASTEWATER DISCHARGE RATES FOR THE 1985
SECONDARY LEAD SUBCATEGORY
IX-2 BPT EFFLUENT LIMITATIONS FOR THE SECONDARY 1986
LEAD SUBCATEGORY
1833
-------
SECONDARY LEAD SUBCATEGORY
LIST OF TABLES (Continued)
Number Paqe
X-l POLLUTANT REMOVAL ESTIMATES FOR SECONDARY LEAD 2001
DIRECT DISCHARGERS
X-2 BAT WASTEWATER DISCHARGE RATES FOR THE 2002
SECONDARY LEAD SUBCATEGORY
X-3 BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD 2003
SUBCATEGORY
XI-1 NSPS KAST^WATER DISCHARGE RATES FOR THE 2016
;-:" ' RV-LEAD SUBCATEGORY '• .
XI-2 n-'.PS FOR THE SECONDARY LEAD SUBCATEGORY 2017
XII-1 POLLUTANT REMOVAL ESTIMATES FOR SECONDARY LEAD 2027
INDIRECT DISCHARGERS
XII-2 PSES WASTEWATER DISCHARGE RATES FOR THE 2028
SECONDARY LI..D SUBCATEGORY
XII-3 PSNS WASTEWATER DISCHARGE RATES FOR THE 2029
SECONDARY LEAD SUBCATEGORY
XII-4 PSES FOR THE SECONDARY LEAD SUBCATEGORY 2030
XI1-5 PSNS FOR THE SECONDARY LEAD SUBCATEGORY 2036
1834
-------
SECONDARY LEAD SUBCATEGORY
LIST OF FIGURES
Number
III-l SECONDARY LEAD SMELTING PROCESS
II1-2 GEOGRAPHIC LOCATIONS OF SECONDARY LEAD
SUBCATEGORY PLANTS
V-l SAMPLING SITES AT SECONDARY LEAD PLANT A
V-2 SAMPLING SITES AT SECONDARY LEAD PLANT B
V-3 SAMPLING SITES AT SECONDARY LEAD PLANT C
V-4 SAMPLING SITES AT SECONDARY LEAD PLANT D
V-5 SAMPLING SITES AT SECONDARY LEAD PLANT E
V-6 SAMPLING SITES AT SECONDARY LEAD PLANT F
V-7 SAMPLING SITES AT SECONDARY LEAD PLANT G
V-8 SAMPLING SITES AT SECONDARY LEAD PLANT H
IX-1 BPT TREATMENT SCHEME FOR THE SECONDARY
LEAD SUBCATEGORY
X-l BAT TREATMENT SCHEME FOR OPTION A
X-2 BAT TREATMENT SCHEME FOR OPTION B
X-3 BAT TREATMENT SCHEME FOR OPTION C
Paqe
1870
1871
1935
1936
1937
1938
1939
1940
1941
1942
1992
2009
2010
2011
1835
-------
Page Intentionally Blank
-------
SECONDARY LEAD SUBCATEGORY SECT - I
SECTION I
SUMMARY
This supplement provides a compilation and analysis of the
background material used to develop these secondary lead
subcategory effluent limitations and standards. The secondary
lead subcategory is comprised of 49 plants. Of the 49 plants,
eight discharge directly to rivers, lakes, or streams; 26
discharge to publicly owned treatment works (POTW); and 15 do not
discharge process wastewater.
EPA first studied the secondary lead subcategory to determine
whether differences in . raw materials, final products,
manufacturing processes, equipment, age and size of plants, and
water usage, required the development of separate effluent
limitations and standards for different segments of the
subcategory. This involved a detailed analysis of wastewater
discharge and treated effluent characteristics, including (1) the
processes used (2) the sources and volume of water used, (3) the
sources of pollutants and wastewaters in the plant; and (4) the
constituents (including toxic pollutants) and volume of
wastewaters.
Several distinct control and treatment technologies (both in-
plant and end-of-pipe) applicable to the secondary lead
subcategory were identified. The Agency analyzed both historical
and newly generated data on the performance of these
technologies, including their nonwater quality environmental
impacts and air quality, solid waste generation, and energy
requirements. EPA also studied various flow reduction techniques
reported in the data collection portfolios (dcp) and plant
visits.
Engineering costs were prepared for each of the control and
treatment options considered for the subcategory. These costs
were then used by the Agency to estimate the impact of
implemenlincj the various options on the subcategory. For each
control anc treatment option that the Agency found to be* most
effective and technically feasible in controlling the discharge
of pollutants, the number of potential closures, number of
employees affected, and impact on price were estimated. These
results are reported in a separate document entitled Economic
Impact Analysis of Effluent Standards and Limitations for the
Nonferrous Smelting and Refining Industry.
Based on consideration of the above factors, EPA identified
various control and treatment technologies which formed the basis
for BPT and selected control and treatment appropriate for each
set of standards and limitations. The mass limitations and
standards as promulgated for BPT, BAT, NSPS, PSF'S, and PSNS are
presented in Section II.
1837
-------
SECONDARY LEAD SUBCATEGORY SECT - I
After examining the various treatment technologies, the Agency
has identified BPT to represent the average of the best existing
technology. Metals removal based on lime precipitation and
sedimentation is the basis for the BPT limitations. Wastewater
discharge rates used in developing BPT effluent limitations
represent the average of the subcategory discharge and usage for
process wastewater. To meet the BPT effluent limitations based
on this technology, the secondary lead subcategory is estimated
to incur a capital cost of $1.63 million (1982 dollars) and an
annual cost of $1.12 million (1982 dollars).
For BAT, the Agency has built upon the BPT basis of lime
precipitation and sedimentation for metals removed by adding in-
process control technologies which include recycle of process
water from air pollution control and metal contact cooling waste
streams. Filtration is added as an effluent polishing step to
the end-of-pipe treatment scheme. To meet the BAT effluent
limitations, the secondary lead subcategory will incur an
estimated capital cost of $1.86 million (1982 dollars) and an
annual cost of $1.24 million (1982 dollars).
The best demonstrated technology, BDT, which is the technical
basis of NSPS, is equivalent to BAT with additional flow
reduction based on dry air pollution control of kettle refining,
or alternately, complete recycle of kettle scrubber liquor. In
selecting BDT, EPA recognizes that new plants have the
opportunity to implement the best and most efficient
manufacturing processes and treatment technology.
The Agency selected the same technology for PSES as for BAT. To
meet the pretreatment standards for existing sources, the
secondary lead subcategory will incur an estimated capital cost
of $4.26 million (1982 dollars) and an annual cost of $2.51
million (1978 dollars).
For pretreatment standards for new sources (PSNS), the Agency
selected end-of-pipe treatment and in-process flow reduction
control techniques equivalent to BDT. As such, the PSNS are
identical to the NSPS for all waste streams.
1838
-------
SECONDARY LEAD SUBCATEGORY SECT - II
SECTION II
CONCLUSIONS
EPA has divided the secondary lead subcategory into eleven
subdivisions or building blocks for the purpose of effluent
limitations and standards. These building blocks are:
(a) Battery cracking;
(b) Blast, reverberatory, or rotary furnace wet air
pollution control;
(c) Kettle wet air pollution control;
(d) Lead paste desulfurization;
(e) Casting contact cooling;
(f) Truck wash;
(g) Facility washdown;
(h) Battery case classification;
(i) Employee hand wash;
(j) Employee respirator wash; and
(k) Laundering of uniforms.
BPT is promulgated based on the performance achievable by
the application of chemical precipitation and sedimentation
(lime and settle) technology. The following BPT effluent
limitations are promulgated:
(a) Battery Cracking BPT Effluent Limitations
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
1.932 0.862
1.407 0.579
0.283 0.135
0.983 0.411
0.000 0.000
27.600 13.130
Within the range of 7.0 to 10.0
at all times
1839
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control BPT Effluent Limitations
Pollutant or_ Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
7.491 3.341
5.455 2.245
1.096 0.522
3.811 1.592
0.000 0.000
107.000 50.900
Within the range of 7.0 to 10.0
•. at all times
;c) Kettle v-?ct Air Pollution Control BPT
Pollutant or Pollutant P:opercy
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.129 0.058
0.094 0.039
0.019 0.009
0.066 0.027
0.000 0.000
1.845 0.878
Within the range of 7.0 to 10.0
at all times
1840
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(d) Lead Paste Desulfurization BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead processed through desulfurization
English Units - Ibs/million Ibs of lead processed through
desulfurization
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Within the range of 7.0 to 10.0
at all times
(e) Casting Contact Cooling BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.634
0.462
0.093
0.323
0.000
9.061
Within the range of 7.0 to 10.0
at all times
0.283
0.190
0.044
0.135
0.000
4.310
184:
-------
SECONDARY LEAD SUBCATEGORY
SECT - II
(f) Truck Wash BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.060 0.027
0.044 0.018
0.009 0.004
0.031 0.013
0.000 0.000
0.861 0.410
Within the range of 7.0 to 10.0
at all times
(g) Facility Washdown BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
Within the range of 7.0 to 10.0
at all times
1842
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(h) Battery Case Classification BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
Within the range of 7.0 to 10.0
at all times
(i) Employee Handwash BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
0.077
0.056
0.011
0.039
0.000
1.107
0.035
0.023
0.005
0.016
0.000
0.527
Within the range of 7.0 to 10.0
at all times
1843
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(j) Employee Respirator Wash BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Cnits - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.126 0.056
0.092 0.038
0.018 0.009
0.064 0.027
0.000 0.000
1.804 0.858
Within the range of 7.0 to 10.0
at all times
(k)
Jrii forms BPT
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - m^.-ro :•£ lead produced from smelting
English Units - Ibs/n^i Ili::n Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.367 0.164
0.268 0.110
0.054 0.026
0.187 0.078
0.000 0.000
5.248 2.496
Within the range of 7.0 to 10.0
at all times
BAT is promulgated based on the performance achievable by
the application of chemical precipitation, sedimentation,
and multimedia filtration (lime, settle, and filter)
technology and in-process flow reduction control methods.
The following BAT effluent limitations are promulgated for
existing sources:
1844
-------
SECONDARY LEAD SUBCATEGORY SECT - II
\
(a) Battery Cracking BAT
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony 1.299 0.579
Arsenic 0.936 0.384
Lead 0.189 0.087
Zinc 0.687 0.283
Ammonia (as N) 0.000 0.000
(b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control BAT
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 5.038 2.245
Arsenic 3.628 1.448
Lead 0.731 0.339
Zinc 2.662 1.096
Ammonia (as N) 0.000 0.000
(c) Kettle Wet Air Pollution Control BAT
Maximum for Maximum for
Pollutant or_ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
Antimony 0.087 0.039
Arsenic 0.063 0.026
Lead 0.136 0.006
Zinc 0.046 0.019
Ammonia (as N) 0.000 0.000
1845
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(d) Lead Paste Desulfurization BAT
Maximum for Maximum for
Pollutant or_ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead processed through desulfurization
English Units - Ibs/million Ibs of lead processed through
desulfurization
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(e) Casting Contact Cooling BAT
Maximum for Maximum for
Pollutant p_r Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
Antimony 0.042 0.019
Arsenic 0.031 0.013
Lead 0.006 0.003
Zinc 0.022 0.009
Ammonia (as N) 0.000 0.000
(f) Truck Wash BAT
Maximum for Maximum for
Pollutant o_r Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.041 0.018
Arsenic 0.029 0.012
Lead 0.006 0.003
Zinc 0.021 0.009
Ammonia (as N) 0.000 0.000
1846
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(g) Facility Washdown BAT
Maximum for Maximum for
Pollutant or_ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(h) Battery Case Classification BAT
Maximum for Maximum for
Pollutant p_r_ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(i) Employee Handwash BAT
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.052 0.023
Arsenic 0.038 0.015
Lead 0.008 0.004
Zinc 0.028 . 0.011
Ammonia (as N) 0.000 0.000
1847
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(j) Employee Respirator Wash BAT
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.085 0.038
Arsenic 0.061 0.025
Lead 0.012 0.006
Zinc 0.045 0.018
Ammonia (as N) 0.000 0.000
( k ) Laundering c f r:,- -' forms EAT
Me> imum for Maximum for
Poliutar, I ,'j: Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.247 0.110
Arsenic 0.178 ' 0.073
Lead 0.036 0.017
Zinc 0.131 0.054
Ammonia (as N) 0.000 0.000
4. NSPS are promulgated based on the performance achievable by
the application of chemical precipitation, sedimentation,
and multimedia filtration (lime, settle, and filter)
technology, in-process flow reduction control methods, and
the elimination of pollutant discharged from kettle air
pollution control through the use of dry scrubbing methods.
The following effluent standards are promulgated for new
sources:
1848
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(a) Battery Cracking NSPS
Pollutant o_r_ Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
1.299 0.579
0.936 0.384
0.189 0.087
0.687 0.283
0.000 0.000
10.100 8.076
Within the range of 7.0 to 10.0
at all times
(b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control NSPS
Pollutant o_r Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
5.038 2.245
3.268 1.448
0.731 0.339
2.662 1.096
0.000 0.000
39.150 31.320
Within the range of 7.0 to 10.0
at all times
(c) Kettle Wet Ai_r Pollution Control NSPS
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
Within the range of 7.0 to 10.0
at all times
1849
-------
SECONDARY LEAD SUBCATEGORY
SECT - II
(d) Lead Paste Desulfurization NSPS
Pollutant or_ Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead processed through desulfurization
English Units - Ibs/million Ibs of lead processed through
desulfurization
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
Within the range of 7.0 to 10.0
at all times
(e) Casting Contact Cooling NSPS
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.042
0.031
0.006
0.022
0.000
0.330
Within the range of 7.0 to 10.0
at all times
0.019
0.013
0.003
0.009
0.000
0.264
(f) Truck Wash NSPS
Pollutant p_r Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.041 0.018
0.029 0.012
0.006 0.003
0.021 0.009
0.000 0.000
0.315 0.252
Within the range of 7.0 to 10.0
at all times
1850
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(g) Facility Washdown NSPS
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
Within the range of 7.0 to 10.0
at all times
(h) Battery Case Classification NSPS
Pollutant o_£ "Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
Within the range of 7.0 to 10.0
at all times
(i) Employee Handwash NSPS
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N) .
Total Suspended Solids
pH
0.052 0.023
0.038 0.015
0.008 0.004
. 0.028 0.011
0.000 0.000
0.405 0.324
Within the range of 7.0 to 10.0
at all times
1851
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(j) Employee Respirator Wash NSPS
Pollutant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.085 0.038
0.061 0.025
0.012 0.006
0.045 0.018
0.000 0.000
0.660 0.528
Within the range of 7.0 to 10.0
at all times
(10 !-••
.;.;:" Uniforms NSPS
^ ] ur.ant or Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mq, <.g of lead produced from smelting
English Units - Ibs/mill1oa Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
0.247 0.110
0.178 0.073
0.036 0.017
0.131 0.054
0.000 0.000
1.920 1.536
Within the range of 7.0 to 10.0
at all times
PSES is promulgated based on the performance achievable by the
application of chemical precipitation, sedimentation, and
filtration (lime, settle, and filter) technology and in-process
flow reduction control methods. The following pretreatment
standards are promulgated.
1852
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(a) Battery Cracking PSES
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony 1.299 0.579
Arsenic 0.936 0.384
Lead 0.189 0.087
Zinc 0.687 0.283
Ammonia (as N) 0.000 0.000
(b) Blast, Reverberatory, p_r Rotary Furnace Wet Air
Pollution Control PSES
Maximum for Maximum for
Pollutant o£ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 5.038 2.245
Arsenic 3.268 1.448
Lead 0.731 0.339
Zinc 2.662 1.096
Ammonia (as N) 0.000 0.000
(c) Kettle Wet Air Pollution Control PSES
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
•
Antimony 0.087 0.039
Arsenic 0.063 0.026
Lead 0.013 0.006
Zinc 0.046 0.019
Ammonia (as N) 0.000 0.000
1853
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(d) Lead Paste Desulfurization PSES
Maximum for Maximum for
Pollutant or_ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead processed through desulfurization
English Units - Ibs/million Ibs of lead processed through
desulfurization
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(e) Casting Contact Cooling PSES
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
Antimony 0.042 0.019
Arsenic 0.031 0.013
Lead 0.006 0.003
Zinc 0.022 0.009
Ammonia (as N) 0.000 0.000
(f) Truck Wash PSES
Maximum for Maximum for
F-SilH^JLnJL °JL Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.041 0.018
Arsenic 0.029 0.012
Lead 0.006 0.003
Zinc 0.021 0.009
Ammonia (as N) 0.000 0.000
1854
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(g) Facility Washdown PSES
Maximum for Maximum for
Pollutant p_£ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(h) Battery Case Classification PSES
Maximum for Maximum for
Pollutant pjr Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(i) Employee Handwash PSES
Maximum for Maximum for
Pollutant or Pollutant Property^ Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.052 0.023
Arsenic 0.038 0.015
Lead 0.008 0.004
Zinc 0.028 0.011
Ammonia (as N) 0.000 0.000
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(j) Employee Respirator Wash PSES
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.085 0.038
Arsenic 0.061 0.025
Lead 0.012 0.006
Zinc 0.045 0.018
Ammonia (as N) 0.000 0.000
(k) Laundering of Uniforms PSES
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.247 0.110
Arsenic 0.178 0.073
Lead 0.036 0.017
Zinc 0.131 0.054
Ammonia (as N) 0.000 0.000
PSNS are promulgated based on the performance achievable by the
application of chemical precipitation, sedimentation, and
multimedia filtration (lime, settle, and filter) technology and
in-process flow reduction control methods. The following
pretreatment standards are promulgated:
(a) Battery Cracking_ PSNS
Maximum for Maximum for
Pollutant or Pollutarvt Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony 1.299 0.579
Arsenic 0.936 0.384
Lead 0.189 0.087
Zinc 0.687 0.283
Ammonia (as N) 0.000 0.000
1856
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control PSNS
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 5.038 2.245
Arsenic 3.268 1.448
Lead 0.731 0.339
Zinc 2.662 1.096
Ammonia (as N) 0.000 0.000
(c) Kettle Wet Air Pollution Control PSNS
Maximum for Maximum for
Pollutant p_r Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(d) Lead Paste Desulfurization PSNS
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead processed through desulfurization
English Units - Ibs/million Ibs of lead processed through
desulfurization
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
1857
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SECONDARY LEAD SUBCATEGORY SECT - II
(e) Casting Contact Cooling PSNS
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
Antimony 0.042 0.019
Arsenic 0.031 0.013
Lead 0.006 0.003
Zinc 0.022 0.009
Ammonia (as N) 0.000 0.000
(f) Truck Wash PSNS
Maximum for Maximum for
Pollutant or Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.041 0.018
Arsenic 0.029 0.012
Lead 0.006 0.003
Zinc 0.021 0.009
Ammonia (as N) 0.000 0.000
(g) Facility Washdown PSNS
Maximum for Maximum for
Pollutant o£ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
1858
-------
SECONDARY LEAD SUBCATEGORY SECT - II
(h) Battery Case Classification PSNS
Maximum for Maximum for
Pollutant o_r Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
Antimony 0.000 0.000
Arsenic 0.000 0.000
Lead 0.000 0.000
Zinc 0.000 0.000
Ammonia (as N) 0.000 0.000
(i) Employee Handwash PSNS
Maximum for Maximum for
Pollutant o_r_ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.052 0.023
Arsenic 0.038 0.015
Lead 0.008 0.004
Zinc 0.028 0.011
Ammonia (as N) 0.000 0.000
(j) Employee Respirator Wash PSNS
Maximum for Maximum for
Pollutant 0£ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.085 0.038
Arsenic 0.061 0.025
Lead 0.012 0.006
Zinc 0.045 0.018
Ammonia (as N) 0.000 0.000
1859
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SECONDARY LEAD SUBCATEGORY SECT - II
(k) Laundering of Uniforms PSNS
Maximum for Maximum for
Pollutant or_ Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
Antimony 0.247 0.110
Arsenic 0.178 0.073
Lead 0.036 0.017
Zinc 0.131 0.054
Ammonia (as N) 0.000 0.000
1860
-------
SECONDARY LEAD SUBCATEGORY SECT - III
SECTION III
SUBCATEGORY PROFILE
This section of the secondary lead supplement describes the raw
materials and processes used in converting lead-bearing scrap to
metallic lead and lead-based alloys and presents a profile of the
secondary lead plants identified in this study.
DESCRIPTION OF SECONDARY LEAD PRODUCTION
There are three major processes involved in secondary lead
production scrap pretreatment, smelting, and refining and
casting. Figure III-l (page 1870) is a block flow diagram
depicting the various process steps involved in secondary lead
manufacture. The following discussion summarizes the raw
materials and the processes used with emphasis on th§ steps where
water may be used. Not all secondary lead plants perform all of
the process steps described.
RAW MATERIALS
The principal raw material for secondary lead production is
storage battery plates and other scrap reclaimed from discarded
batteries. Minor amounts of solder, babbitt, cable coverings,
type metal, soft lead, and antimonial lead, as well as drosses
and residues generated as a result of operations within the
secondary lead plant, are also utilized.
SCRAP PRETREATMENT
The scrap pretreatment process may involve crushing or cutting
discarded batteries, crushing of drosses and oversize scrap, and
sweating of lead scrap containing other metals. The general
crushing operations reduce the pieces of scrap to a suitable size
using machinery such as jaw crushers. Sweating involves charging
scrap to a furnace where the lead value is separated by selective
melting. The molten lead is collected and cast and the residue is
removed from the furnace. Reverberatory furnaces are used for
this operation. Particulate emissions can be controlled with a
baghouse, a scrubber, or both. Preparing discarded batteries for
smelting is called battery cracking or breaking and there are a
number of different approaches used in battery breaking. The
different methods are described below.
Breaking by Shear or Saw
Many smelters dismantle batteries in a hand operation in which
employees (1) separate plastic and rubber batteries, (2) cut the
top of the battery off, and (3) empty the contents of the battery
onto a pile. Typically, front-end loaders then move the battery
parts to storage and disposal.
1861
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SECONDARY LEAD SUBCATEGORY SECT - III
Hammer Mill Battery Breaking
In order to speed up the process/ remove employees from exposure
and utilize plastic battery cases for fuel or resale, some plants
use hammer mills to break batteries. Unfortunately, this
approach continues to require hand separation of plastic and
rubber cased batteries and manual handling of rubber cased
batteries.
Battery Case Classifiers
A number of flotation type battery classifiers are currently used
in today's smelters. The technique uses a combination of shears,
saws, and hammer mills to reduce battery scrap to small pieces.
Battery cases and tops are conveyed directly from the battery
breaker to a hammer mill for crushing. The crushed cases and
tops are then separated through specific gravity differences in a
counter flow flotation system using water. The classifier
produces output streams of hard lead (grids and posts), oxide and
sulfate sludge, plastic, and rubber. The advantages of this
system are (1) positive control of furnace feed enables use of
more sophisticated furnaces, e.g., rotary, and (2) separate
recycling of plastic case material. Wash water, water for
flotation, and a small quantity of battery electrolyte are the
sources of wastewater from the battery classifier.
Low-Energy Shredders
At least five secondary smelters have (or have had) low energy
shredders installed for breaking batteries. This system uses a
low rpm, low energy shredding device to slowly shred batteries
into chargeable or separable pieces.
Whole Battery Charging
This technique, developed at the Bergsoe smelter in Denmark,
purposely utilizes as little battery breaking as possible (only
about 20 percent of the battery mass needs to be broken). The
acid is drained from the battery before charging. The unbroken
batteries are mixed with other charge materials on concrete beds
using a rubber-tired front end loader. After the charge is
prepared, it is loaded into the furnace with a front end loader.
The battery cracking operation may be performed either on- or
off-site. Spent electrolyte, along with saw or shredder cooling
water and wash water, constitutes a major source of wastewater at
plants where battery cracking is performed.
Lead Paste Desu_l_fur_i_z_at_i_p_n
One plant currently operates a patented process to convert lead
sulfate to lead oxide. Lead sulfate, in the form of paste or
mud, is a product of battery breaking and classification. In this
process, lead sulfate is leached with aqueous ammonium carbonate
to produce lead carbonate and aqueous ammonium sulfate. The
1862
-------
SECONDARY LEAD SUBCATEGORY SECT - III
insoluble lead carbonate is then filtered from the ammonium
sulfate solution and-calcined to produce lead oxide. Lead oxide
is refined to pure or metallic lead (see discussion below).
Carbon dioxide evolved during calcination is recovered and
reacted with aqueous ammonia to make additional ammonium
carbonate solution for the leach step. The filtrate, an ammonium
sulfate solution, is sent to a crystallizer or a spray drier to
recover solid ammonium sulfate which can be sold as a by-product.
Ammonia, carbon dioxide, and water are recovered by absorption
and used as makeup for the ammonium carbonate leach solution.
It is reported that since the ammonia and water are recycled
within the process, there is no wastewater discharged from lead
paste desulfurization. The principal advantage of this process
is the reduction of noxious sulfur oxide (SOX) emissions during
smelting, while producing a useful by-product, ammonium sulfate.
Removal of sulfur from the lead thus eliminates the need for flue
gas desulfurization units in the smelting process.
SMELTING OPERATIONS
The smelting operation takes place in either a reverberatory or a
blast furnace. In the reverberatory furnace, heat is radiated
.from the burner flame and the furnace roof and walls onto the
melt. It is usually one of the least expensive furnaces to
operate because the flame and hot combustion products come in
direct contact with the melt.
Reverberatory smelting partially purifies and compacts lead scrap
and paste. The charge to the furnace can be untreated scrap
(where the sweating and smelting operations are combined),
treated scrap, or a mixture of both. The process steps for this
operation are: (1) charging the scrap to the furnace, (2)
melting the scrap, (3) allowing the slag to rise to the surface
of the metal, (4) tapping the slag as feed for the blast furnace,
and (5) tapping the molten lead. The product lead can then be
sent either to the refining and casting operation, cast into
semisoft or hard lead (antimonial) ingots, or converted to
various forms of lead oxide using kettle (Barton pot) or
reverberatory oxidation methods.
The secondary lead blast furnace is a refractory-lined steel
cylinder with air ports known as tuyeres located at the bottom,
through which air is supplied by a blower. Coke, used as fuel,
is placed in the shaft in alternating layers along with scrap,
slag, and limestone (a flux). One of the most important control
variables is the addition rate of combustion air through the
tuyeres. Preheating the combustion air may increase the
efficiency of the furnace.
The product of the blast furnace is semisoft or hard lead
produced from pretreated scrap, reverberatory slag, and recycled
blast furnace slag (rerun slag). A typical charge for the blast
furnace is composed of 4.5 percent rerun slag, 4.5 percent scrap
cast iron, 3.0 percent limestone, 5.5 percent coke, which serves
1863
-------
SECONDARY LEAD SUBCATEGORY SECT - III
both as a fuel and as a reducing agent, and 82.5 percent lead
oxides, drosses, scrap, and reverberatory slags obtained from
other smelting and refining operations.
Emissions from reverberatory and blast furnaces are usually
controlled with baghouses, although wet scrubbers may be used.
Most secondary lead plants which practice wet scrubbing of
furnace emissions utilize some degree of recycle of the scrubbing
liquor.
REFINING AND CASTING
Softening, alloying, and refining processes take place in kettle
furnaces which are larger versions of pot furnaces. Kettles may
be cylindrical or rectangular in shape and are normally used to
melt metals with melting points below 760°C. They are usually
poured by tilting, dipping, or pumping. These large pot or
kettle furnaces may have many small burners along all sides.
They are usually natural gas or oil fired.
The product of the kettle softening and refining process is soft,
high purity lead. The process steps involved are (a) charging
the preheated kettle furnace with an intermediate semisoft or
hard lead obtained from the smelting operation, (b) melting the
charge, (c) fluxing and agitating the molten charge, (d) skimming
the slag, and (e) pouring and casting the,soft lead into ingots.
Fluxes which may be used include sodium hydroxide, sodium
nitrate, aluminum, aluminum chloride, sawdust, sulfur, and air.
Sodium hydroxide, sodium nitrate, or air may be used to reduce
the antimony content. Aluminum reacts preferentially with
antimony, copper, and nickel to form drosses, as does sulfur with
copper. Adding sawdust to the molten metal forms carbon which
produces elemental lead by the reduction of lead oxide. This
process is known as dry dressing.
The operating temperatures of refining kettles range between 371
to 482°C. Emissions are normally vented through a baghouse,
although wet scrubbing also may be used. Solid wastes,
consisting of drosses and skimmings along with baghouse dust, are
generally recycled to the blast furnace.
The alloying and refining process utilizes the same type furnace
as the kettle softening and refining operation and involves
treatment and adjustment of the composition of the lead to
produce the desired alloy. Antimony, arsenic, copper, silver,
and tin are commonly used for lead alloys.
Cooling of lead or lead alloy castings is usually done with
indirect (noncontact) cooling water in closed loop recirculating
systems. Contact cooling may also produce a small volume
discharge stream.
1864
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SECONDARY LEAD SUBCATEGORY SECT - III
PROCESS WASTEWATER SOURCES
In summary, the principal generators of wastewater in secondary
lead production are:
1. Battery cracking,
2. Furnace wet air pollution control,
3. Kettle wet air pollution control,
4. Lead paste desulfurization,
5. Casting contact cooling water,
. 6. Truck wash,
7. Facility washdown,
8. Battery case classification,
9. Employee hand wash,
10. Employee respirator wash, and
11. Laundering of uniforms.
OTHER WASTEWATER SOURCES
There are other wastewater streams associated with the production
of secondary lead smelters such as stormwater runoff and
groundwater seepage. These waste streams are not considered as
part of this rulemaking. EPA believes that the flows and
pollutant loadings associated with these wastewaters are best
handled by the appropriate permit authority on a case-by-case
basis under the authority.of Section 402(a) of the Clean Water
Act.
AGE, PRODUCTION, AND PROCESS PROFILE
After the 1983 proposal, EPA became aware of 12 secondary lead
plants which were previously not included in the subcategory data
base. Additionally, 16 plants closed or have ceased secondary
lead production since the initial 1977 dcp survey was conducted.
Figure III-2 (page 1871) shows the location of the 49 secondary
lead plants currently operating in the United States. These
plants are predominantly located in or near major urban centers
where most of the raw materials are readily available. Of the 49
secondary plants shown, 16 plants (33 percent) are located west
of the Mississippi River. The remaining 33 plants are located in
two bands east of the Mississippi, around the Great Lakes and in
the South.
An additional 19 plants remelt or alloy secondary lead. These
plants are not considered as part of the secondary lead
subcategory. All 19 of these plants achieve zero discharge of
waste water.
As seen fron> Figure III-2 (page 1871), plants discharging to POTW
(indirect dischargers) and zero discharge plants (zero
dischargers) are found in all areas, while plants discharging
directly to receiving waters are found in the East and South.
186'
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SECONDARY LEAD SUBCATEGORY SECT - III
Table III-l (page 1867) shows that the median age of secondary
lead plants is within a span of 25 to 44 years. Table III-2
(page 1868) shows that, for the 48 plants providing lead
production data, only nine produce over 20,000 kkg per year.
Most secondary lead plants are relatively small operations;
roughly two-thirds produce under 15,000 kkg per year.
Table III-3 (page 1869) provides a summary of the number of
plants in the secondary lead industry which utilize the various
process operations discussed previously, and the number of plants
which generate wastewater associated with each process. All
plants practicing battery cracking generate wastewater. For the
other processes, most plants avoid producing wastewater by
utilizing dry air pollution control methods (e.g., baghouses)
where an pollution controls are implemented.
186G
-------
Table III-1
INITIAL OPERATING YEAR (RANGE) SUMMARY OF PLANTS
IN THE SECONDARY LEAD SUBCATEGORY BY DISCHARGE TYPE
Plant Age Range (Years)
T983 T9T3 T968 T958 1948 1938 T928 T9T8
Type of to to to to to to to to Before
Plant 1974 1969 1959 1949 1939 1929 1919 1904 1904 Insuff. g
Discharge 0-10 10-15 15-25 25-35 35-45 45-55 55-65 65-80 80+ Data Total o
o
o
Direct 031120010 0 8§
f
Ii Hrect 232212220 10 26 g
(-»
oo to
^ Ze' •"» 122^1110 0_i 11 o
w
Total 38565533011 49 o
w
o
1-3
-------
SECONDARY LEAD SUBCATEGORY SECT - III
TABLE III-2
PRODUCTION RANGES FOR THE SECONDARY LEAD SUBCATEGORY
Production Ranges
(kkg/yr) Number of_ Plants
0 - 2500 7
2501 - 5000 6
5001 - 10000 9
10001 - 15000 11
15001 - 20000 6
20001 - 30000 6
30001 - + 3
Not Reported 1
Total Number Plants 49
1868
-------
SECONDARY LEAD SUBCATEGORY SECT - III
TABLE III-3
SUMMARY OF SECONDARY LEAD SUBCATEGORY PROCESSES
AND ASSOCIATED WASTE STREAMS
Number of Plants Number of Plants
Process With Process Generating Wastewater*
Battery Cracking 35 35
-Battery Case Classification 8 8
-Led Paste Desulfurization 1 1
-Lead Dross Preparation .4 0
Smelting 48
-Air Pollution Control 48 7
Lead Oxide Production 11 1
Refining and Alloying 42
-Air Pollution Control 28 . 10
Casting 26 9
* Through reuse or evaporation practices, a plant may generate a
wastewater from a process but not discharge it.
• 1869
-------
SECONDARY LEAD SUBCATEGORY SECT - III
LEAD RESIDUES
H,0
WASTE BATTERIES
-t- ELECTROLYTE
TO TREATMENT
I — ^ CASTINGS TO DISPOSAL
H,0
EMISSIONS
BES
RECYCLE
r
'ILT
T.E
r
i
SOFT LE
BARTON
OXIDATION
1
ANTTMONIAL.LEAD
ALLOYING AGENTS
(e.g., As, Cm)
REFINED LEAD
LEAD OXIDE
ANTIMOSIAL LEAD
LEAD ALLOY
Figure III-1
SECONDARY LEAD SMELTING PROCESS
1870
-------
D-Direct Process Wastewater Discharge Plants
I-Indirect Wastewater Discharge Plants
Z-Zero Wastewater- Discharge Plants
w
o
o
25
I
f
w
ft)
o
M
o
8
M
o
1-3
Figure III-2
GEOGRAPHIC LOCATIONS OF SECONDARY LEAD PLANTS
-------
Page Intentionally Blank
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SECONDARY LEAD SUBCATEGORY SECT - IV
SECTION IV
SUBCATEGORIZATION
This section summarizes the factors considered during the
designation of the secondary lead subcategory and its related
subdivisions. EPA promulgated BPT and BAT effluent limitations,
and NSPS, PSES, and PSNS for the secondary lead subcategory in
March 1984.
FACTORS CONSIDERED IN SUBDIVIDING THE SECONDARY LEAD SUBCATEGORY
The factors listed for general subcategorization were each
evaluated when considering subdivision of the secondary lead
subcategory. In the discussion that follows, the factors will be
described as they pertain to this particular subcategory.
The rationale for considering segmentation of the secondary lead
subcategory is based primarily on the production process used.
Within this - subcategory, a number of different operations are
performed, which may or may not have a water use or
discharge, and which may require the establishment of separate
effluent limitations and standards. While secondary lead
production is still considered a single subcategory, a more
thorough examination of the production processes, water use and
discharge practices, and pollutant generation rates has
illustrated the need for limitations and standards based on a
specific set of waste streams. Limitations and standards will be
based on specific flow allowances for the following building
blocks:
1. Battery cracking,
2. Furnace wet air pollution control,
3. Kettle wet air pollution control,
4. Lead paste desulfurization,
5. Casting contact cooling water,
6. Truck wash,
7. Facility washdown,
8. Battery case classification,
9. Employee hand wash,
10. Employee respirator wash, and
11. Laundering of uniforms.
OTHER FACTORS
The other factors considered in this evaluation were shown to be
inappropriate as a bases for further segmentation of the
secondary lead subcategory. Air pollution control methods,
treatment costs, nonwater quality aspects, and total energy
requirements were each shown to be functions of the selected
subcategorization factors -- metal product, raw materials, and
production processes. As such, they support the method of
subcategorization which has been applied. As discussed in
1873
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SECONDARY LEAD SUBCATEGORY
SECT - IV
Section IV of Vol. I, such other factors as plant age, plant
size, and the number of employees were also evaluated and
determined to be inappropriate for use as bases for
subcategorization of nonferrous metal plants.
PRODUCTION NORMALIZING PARAMETERS
The effluent limitations and standards developed in this document
establish mass limitations on the discharge of specific pollutant
parameters. To allow these regulations to be applied to plants
with various production capacities, the mass of pollutant
discharged must be related to a unit of production. This factor
is known as the production normalizing parameter (PNP). In
general, the amount of lead produced by the respective
manufacturing process is used as the PNP. This is based on the
premise that the amount of water generated is proportional to
the amount of product made. Variations in the association
between the amount of water generated and the amount of product
made are not felt to be significant enough to prevent the
establishment of effluent limitations and standards. The PNP's
for the secondary lead building blocks are as follows:
Building Block
1. Battery cracking
2. Furnace wet air pollution
control
3. Kettle wet air pollution
control
4. Lead paste desulfurization
PNP
kkg of lead scrap produced
kkg of lead produced from
smelting
kkg of lead produced from
refining
kkg of lead processed through
desulfurization
5. Casting contact cooling water kkg of lead cast
6. Truck wash
7. Facility washdown
8. Battery case classification
9. Employee hand wash
10. Employee respirator wash
11. Laundering of uniforms
kkg of lead produced from
smelting
kkg of lead produced from
smelting
kkg of lead scrap produced
kkg of lead produced from
smelting
kkg of lead produced from
smelting
kkg of lead produced from
smelting
1874
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SECONDARY LEAD SUBCATEGORY SECT - V
SECTION V
WATER USE AND WASTEWATER CHARACTERISTICS
This section describes the characteristics of wastewater
associated with the secondary lead subcategory. Data used to
quantify wastewater flow and pollutant concentrations are
presented, summarized, and discussed. The contribution of
specific production processes to the overall wastewater discharge
from secondary lead plants is identified whenever possible.
Two principal data sources were used: data collection portfolios
(dcp) and field sampling results. Data collection portfolios
contain information regarding wastewater flows and production
levels.
In order to quantify the pollutant discharge from secondary lead
plants, a field sampling program was conducted. A complete list
of the pollutants considered and a summary of the techniques used
in sampling and laboratory analyses are included in Section V of
Vol. I. Wastewater samples were collected in two phases:
screening and verification. The first phase, screen sampling,
was to identify which toxic pollutants were present in the
wastewaters from production.of the various metals. Screening
samples were analyzed for 125 of the 126 toxic pollutants and
other pollutants deemed appropriate. Because the analytical
standard for TCDD was judged to be too hazardous to be made
generally available, samples were never analyzed for this
pollutant. There is no reason to expect that TCDD would be
present in nonferrous metals manufacturing wastewater. A total
of 10 plants were selected for screen sampling in the nonferrous
metals manufacturing category, one of them being a secondary lead
facility. Verification sampling was conducted at seven secondary
lead plants. In general, the samples were analyzed for three
classes of pollutants: toxic organic pollutants, toxic metal
pollutants, and criteria pollutants (which includes both
conventional and nonconventional pollutants).
•
Two additional verification sampling efforts were conducted
between the February 1983 proposal and the March 1984
promulgation. Both plants are integrated battery manufacturing
and secondary lead smelting facilities. EPA believed
additional process and wastewater data were needed to completely
characterize the secondary lead subcategory.
As described in Section IV of this supplement, the secondary lead
subcategory has been further segmented into 11 building blocks,
so that the regulation contains mass discharge limitations and
standards for 11 process waste waters. Differences in the
wastewater characteristics associated with these building blocks
are to be expected. For this reason, wastewater streams
corresponding to each segment are addressed separately in the
discussions that follow.
1875
-------
SECONDARY LEAD SUBCATEGORY SECT - V
WASTEWATER SOURCES, DISCHARGE RATES, AND CHARACTERISTICS
The wastewater data presented in this section were evaluated in
light of production process information compiled during this
analysis. From this information, it was possible to identify the
principal wastewater sources in the secondary lead subcategory.
These wastewater sources include:
1. Battery cracking,
2. Furnace wet air pollution control,
3. Kettle wet air pollution control,
4. Lead paste desulfurization,
5. Casting contact cooling water,
6. Truck wash,
7. Facility washdown,
8. Battery case classification,
9. Employee hand wash,
10. Employee respirator wash, and
11. Laundering of uniforms.
Waste streams number 4 and 6 through 11 were added after the
February 1983 proposal as a result of comments and new data
received by the Agency. Through specific data requests, new dcp,
and telephone contacts, the Agency determined that these building
blocks should be included within the secondary lead subcategory.
Wastewater from two secondary lead facilities was sampled after
proposal to verify that these streams were sufficiently
contaminated to warrant treatment. All of this new information
was available for public comment in the Notice of Availability of
Information published on November 4, 1983 (49 FR 50906).
Data supplied by dcp responses were evaluated and two flow-to-
production ratios were calculated for each stream. These two
ratios, normalized water use and normalized wastewater discharge
flow rate, differ by the water flow rates used in their
calculation. Water use is defined as the volume of water or
other fluid (e.g., battery electrolyte) required for or generated
in a given process per mass of lead produced by the process and
is therefore based on the sum of recycle and makeup flows to a
given process. The production normalized discharge flow rate is
defined as the volume of wastewater actually discharged from a
given process for further treatment, disposal, or discharge per
mass of lead produced. Differences between the water use and
discharge flows associated with a given stream may result from
combinations of recycle, evaporation, and carryover on the
product. The production values used in calculating these ratios
correspond to the production normalizing parameter (PNP) assigned
to each stream, as discussed in Section IV of this supplement.
The production normalized flows were compiled by stream type. An
attempt was made to identify factors that could account for
variations in the water use from plant to plant. This
information is summarized in this section. A similar analysis
of factors affecting the normalized wastewater flow rates is
presented in Sections IX, X, XI, and XII where representative
1876
-------
SECONDARY LEAD SUBCATEGORY SECT - V
BPT, BAT, BDT, and pretreatment discharge flows are selected for
use in calculating effluent limitations.
After proposal, EPA became aware of 12 secondary lead plants
which were previously not included in the subcategory.
Wastewater flew rates and production data were solicited from
these plants through dcp, special requests, and telephone
contacts. Additionally, 16 plants either closed or ceased
production of secondary lead. Some data from plants already in
the Agency's data base were updated or revised because of
comments received concerning the proposed regulations. The new
data were used to revise and evaluate production normalized flow
rates where appropriate (see Section IX). Data from the closed
plants are included in this section and throughout the remainder
of this document. The Agency believes that flow and production
data from these plants provide useful measures of the
relationship between production and discharge. In light of this
conclusion (and indications that some of the plant closures may
not be permanent), the Agency is using these data in its
consideration of BPT and BAT performance.
In order to quantify the concentrations of pollutants present in
wastewaters from secondary lead plants, wastewater samples were
collected at seven plants before proposal. Data from one of the
seven plants (Plant G) were not used in determining the proposed
regulation but are included for promulgation. After proposal,
two additional integrated secondary lead and battery
manufacturing facilities were sampled. Analytical data
pertaining to battery manufacturing is not presented in this
document; it can be found in the Battery Manufacturing
Development Document. Block diagrams indicating the locations of
sampling points and the production processes involved for each of
these nine plants are given in Figures V-l through V-9 (pages
1934 - 1941).
Raw wastewater sampling data for the secondary lead industry are
presented in Tables V-2 (page 1884), V-4 (page 1890), V-6 (page
1895), V-9 (page 1897), V-12 (page 1901), V-13 (page 1904), V-14
(page 1907), and V-15 (page 1910). Treated wastewater sampling
data are shown in Tables V-16 through V-22 (pages 1913 - 1932).
The stream codes displayed in the tables may be used to identify
the location of each of the samples on the process flow diagrams
in Figures V-l through V-9 (pages 1934 - 1941). Where no data
are listed for a specific day of sampling, the wastewater samples
for the stream were not collected. If the analysis did not
detect a pollutant in a waste stream, the pollutant was omitted
from the table.
The data tables include some samples measured at concentrations
considered not quantifiable. The base neutral extractables, acid
extractables, and volatile organics are considered not
quantifiable at concentrations equal to or less than 0.010 mg/1.
Below this concentration, organic analytical results are not
quantitatively accurate; however, the analyses are useful to
indicate tte presence of a particular pollutant. The pesticide
1877
-------
SECONDARY LEAD SUBCATEGORY SECT - V
fraction is not considered quantifiable below concentrations of
0.005 mg/1. Nonquantifiable results are designated in the tables
with an asterisk (double asterisk for pesticides).
These detection limits shown, on the data tables are not the same
in all cases as the published detection limits for these
pollutants by the same analytical methods. The detection limits
used were reported with the analytical data and hence are the
appropriate limits to apply to the data. Detection limit
variation can occur as a result of a number of laboratory-
specific, equipment-specific, and daily operator-specific
factors. These factors can include day-to-day differences in
machine calibration, variation in stock solutions, and variation
in operators.
The statistical analysis of data includes some samples measured
at concentrations considered not quantifiable. Data reported as
an asterisk are considered as detected but below quantifiable
concentrations, and'a value of zero is used for averaging. Toxic
organic, nonconventional, and conventional data reported with a
"less c.ha;-;'•' sign are considered as detected, but not further
quantifiable. A value of zero is also used for averaging. If a
pollutant is reported as not detected, it is excluded in
calculating the average. Finally, toxic metal values reported as
less than a certain value were considered as not detected, and a
value of zero was used in the calculation of the average. For
example, three samples reported as ND, *, and 0.021 mg/1 have an
average value of 0.010 mg/1. In selecting pollutants and
pollutant parameters for specific regulation, individual samples
were used rather than average values.
The method by which each sample was collected and composited is
indicated on the data tables by a code number, as follows:
1 one-time grab
2 24-hour manual composite
3 24-hour automatic composite
4 48-hour manual composite
5 48-hour automatic composite
6 72-hour manual composite
7 72-hour automatic composite
8 8-hour manual composite
In the data collection portfolios, the secondary lead plants
which discharge were asked to specify the presence or absence of
the toxic pollutants in their effluent. Of the 49 secondary lead
smelters, 23 responded to this portion of the questionnaire. All
plants responding to the organic compounds portion reported that
all toxic organic pollutants were known to be absent or believed
to be absent from their wastewater.
1878
-------
SECONDARY LEAD SUBCATEGORY SECT - V
The responses for the toxic metals are summarized below.
Known Believed Believed Known
Pollutant Present Present Absent Absent
Antimony 13 6 4
Arsenic 97 7 -
Cadmium 77 63
Chromium 3 5 11 4
Copper 12 2 8 1
Lead 18 4 -
Mercury 24 13 4
Nickel 64 11 2
Silver 23 18 -
Thallium 16 17 3
Zinc 10 7 6 -
BATTERY CRACKING
Plants utilizing lead-acid batteries as a source of process raw
materials produce a wastewater stream associated with the battery
cracking operation. Battery cracking involves the breaking of
battery cases by any of a number of methods described in Section
III. Wastewater may be generated in the form of electrolyte
drained from the battery cases, by the use of saw or breaker
cooling water, and by area wash water. All 35 plants currently
having battery cracking operations generate wastewater. Table V-
1 (page 1883) summarizes the normalized discharge flows for these
plants in terms of liters per metric ton of lead scrap produced
(recovered) from battery cracking operations. The Agency knows
of no reason to differentiate discharge flows based on the method
used to break batteries. The discharge flows include the
operations that generate the most wastewater, i.e., battery
electrolyte, saw or breaker contact cooling water, and area wash
water. Table V-2 (page 1884) summarizes the field sampling data
for the toxic, conventional, and nonconventional pollutants
detected. This waste stream contains quantifiable concentrations
of toxic organics. The metals antimony, arsenic, cadmium, copper,
and zinc are generally present in concentrations fcom 1
to 47 mg/1. Lead concentrations range from approximately 5 to
1,300 mg/1. Treatable concentrations of total suspended solids,
and oil and grease, and low pH (less than 2) also characterize
the raw wastewater from this building block.
BLAST, REVERBERATORY, OR ROTARY FURNACE WET AIR' POLLUTION CONTROL
Blast, rotary, and reverberatory furnaces used in the smelting
operation in secondary lead plants generally require some type of
air pollution control to limit emissions, especially of
particulates and sulfur oxide compounds. Out of 48 plants having
smelting operations, seven use lime or sodium wet air pollution
control devices; 41 use dry air pollution control. Table V-3
(page 1889) summarizes the water use and discharge rates for
these plants. Sampling and analytical data obtained on furnace
' 1879
-------
SECONDARY LEAD SUBCATEGORY SECT - V
scrubbing liquor are shown in Table V-4 (page 1890). Treatable
concentrations of toxic metals, oil and grease, and total
suspended solids characterize this wastewater stream.
KETTLE WET AIR POLLUTION' CONTROL
Kettles used in refining and alloying operations in secondary
lead plants may also produce air pollutants, especially
particulate matter, which may require control. Ten of the 42
plants reporting the use of refining and alloying kettles use
wet air pollution control. Table V-5 (1894) shows the production
normalized water use and discharge rates for these plants. Data
obtained on the kettle scrubber liquor at one of these plants
(presented in Table V-6 page 1895) contained measurable
concentrations of ammonia and treatable concentrations of total
suspended solids, arsenic, and lead (50 to 380 mg/1) with
measurable concentrations of other metals.
LEAD PASTE DESULFURIZATION
One plant operates a process to convert lead sulfate paste into
lead oxide using ammonium carbonate. All "wastewater" streams
generated in the process are recycled. Ammonium sulfate solids
are sold as by-products. The plant with this operation does not
discharge wastewater from the process. No sampling of this water
was conducted but it is expected to contain lead and total
suspended solids.
CASTING CONTACT COOLING WATER
Contact cooling water may be used in the casting operation. The
cooling water is frequently recycled and may be totally
evaporated, but a small stream may be blown down to limit the
buildup of dissolved solids, which may cause surface
imperfections on the cast metal. Nine plants of the 46 reporting
the use of a casting operation use direct contact cooling. The
normalized water use and discharge data .for these plants are
summarized in Table V-7 (page 1896). The Agency used wastewater
sampling data for casting contact cooling from a nonferrous
metals forming lead ingot casting operation to evaluate if this
contains treatable concentrations of pollutants. The Agency
believes that lead ingot casting contact cooling water from
nonferrous forming is similar in characteristic to casting
contact cooling water from secondary lead smelters because of
the similarity of the operations. The casting contact cooling
water from nonferrous forming contains treatable concentrations
of lead and total suspended solids. This stream has a pH of
approximately 7.8.
TRUCK WASH
Some plants wash trucks and pallets that are used to haul scrap
batteries. Wastewater use and discharge rates for this waste
stream are presented in Table V-8 (page 1896). Wastewater
1880
-------
SECONDARY LEAD SUBCATEGORY SECT - V
V
sampling data for truck wash were collected after proposal from
two secondary lea'd facilities (see Table ,V-9 1897). This
wastewater contains treatable concentrations of arsenic, cadmium,
chromium, lead, nickel, zinc, oil and grease, and total suspended
solids. The wastewater 'is also acidic (pH of 3).
FACILITY WASHDOWN
Nine plants report using water to wash floors and equipment as a
control of fugitive lead emissions. Table V-10 (1900) presents
the water use and discharge rates practiced at the nine plants.
Wastewater samples from secondary lead plants were not taken but
analogous wastewater from a battery manufacturing plant contains
treatable concentrations of toxic metals and total suspended
solids. The battery manufacturing data are included in the
administrative record supporting this regulation.
BATTERY CASE CLASSIFICATION
Eight plants operate battery case classification processes. Lead
and battery cases are separated using water as a flotation
medium. All eight plants generate wastewater. Water use and
wastewater discharge rates are presented in Table V-ll (1900).
Waste water samples for this waste stream were not collected by
the Agency. However, data for five parameters were submitted by
a secondary lead plant operating this process. These data,
included in the administrative record, show treatable
concentrations of arsenic, antimony, lead, and zinc. This
wastewater is also very acidic (pH of approximately 2.9).
Although not analyzed, total suspended solids are also expected
to be present at a treatable concentration.
EMPLOYEE HAND WASH
Secondary lead plant employees must wash their hands before
breaks and end-of-shift to reduce occupational lead exposures.
The Agency obtained water use and sampling data for this waste
stream to discern whether a flow allowance was needed. Very
little flow data were available for this stream. The method for
determining the regulatory flow allowance is presented in Section
IX - Wastewater Discharge Rates. Flow and sampling data were
collected by the Agency at two integrated secondary lead smelter
and battery manufacturing plants. The Agency has determined that
each employee uses approximately 4.53 liters (1.2 gallons) of
wash water per day. Wastewater samples indicate that this
wastewater is basic (pH of 8.0) and contains treatable
concentrations of copper, lead, zinc, total suspended solids, and
oil and grease. Wastewater sampling data are presented in Table
V-12 (page 1901) .
EMPLOYEE RESPIRATOR WASH
Respirators worn at secondary lead smelters to reduce
occupational lead exposures must be cleaned daily. The Agency
collected w, ter use and wastewater sampling data for this stream
1881
-------
SECONDARY LEAD SUBCATEGORY SECT - V
at two integrated secondary lead battery manufacturing plants.
The Agency has determined that approximately 7.34 liters (1.94
gallons) of wash water are used per employee per day to clean
respirators. This flow includes germicide used to disinfect the
respirators. Calculation of the production normalized discharge
allowance for this waste stream is discussed in Section IX.
Wastewater sampling data, shown in Table V-13 (page 1904),
indicate the presence of copper, lead, zinc, and total suspended
solids in this water. The pH is neutral (7.0).
LAUNDERING OF UNIFORMS
Employee uniforms must be laundered daily to meet industrial
hygiene requirements. The Agency measured flows and sampled this
wastewater since industry data were not available. Data were
collected at two secondary lead-battery manufacturing facilities.
The Agency has determined that approximately 21.6 liters (5.7
gallons) of water par employee per day are used for laundering of
uniforms. T;.-; regulatory flow allowance for this stream is
discussed in Section IX. Wastewater sampling data for this waste
stream an presented in Table V-14 (page 1907). These data show
treataj±e concentrations of lead, zinc, and total suspended
solica. The pH is slightly acidic (6.0).
1882
-------
SECONDARY LEAD SUBCATEGORY
SECT - V
TABLE V-l
WATER USE AND DISCHARGE RATES FOR BATTERY CRACKING OPERATIONS
(1/kkg of lead scrap produced)
Plant Percent
Code Recycle
222
223
224
225
227
234
236
239
244
246*
248
249
250
254
263
264
265
266
271
272
273
391
392
428
652
655
4210*
4211
6601
6602
6603
6604
6605
6606
6611
9001
9002*
26001
26003*
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Production Normalized
Water Use and Discharge Rate
139
775
834
763
384
437
142
154
306
315
1618
442
1984
796
1046
1647
1084
4669
81
5086
286
922
369
244
429
905
671
377
467
484
617
NR
292
671
NR
1063
638
705
600
NOTE: Water use and discharge rate are the same for all plants in
data base.
* - Plant closed.
NR - Data not reported in dcp
1883
-------
Table V-2
SECONDARY LEAD SAMPLING DATA
BATTERY CRACKING
RAW WASTEWATER
CO
oo
Po] 'j_
Ly 1 |JLJL^ii lutanta
23. chloroform
'i7. biomoform
66. bis(2-ethylhexyl)
phthalate
68. dl-n-butyl phthalate
69. dl-n-octyl phthalate
71. dimethyl phthalate
76. chrysene
77. acenaphthylene
ConcentratIons
(iBR/1, Except as Noted)
CoJe
73
106
208
73
106
208
73
106
152
208
73
106
152
208
73
106
208 .
73
106
208
73
106
208
73
106
208
Typet Source
2
2
1
2 ND
2
1
7 0.575
7
3
2
7 *
7
3
2
7 *
7
2
7 ND
7
2
7 ND
7
2
7 *
7
2
Day 1 Day 2
ND 0.014
* *
ND
ND ND
ND ND
ND
0.575
0.585
* 0.2
ND
*
0.028
ND *
ND
*
0.026
ND
ND
0.013
ND
ND
0.545
ND
ND
0.035
ND
Day 3 Average
0.026 0.02
ND *
0.049 0.049
0.575
0.585
* 0.067
*
0.028
ND *
*
0.026
0.013
0.545
0.035
M
W
O
O
2;
D
>
^
1^
W
D
M
C,
W
0
&
H3
W
O
O
»
**
M
0
H)
I
-------
Table V-2 (Continued)
SECONDARY LEAD SAMPLING DATA
BATTERY CRACKING
RAW WASTEWATER
ConcentratIons
00
00
Ln
Ho l_hi ^an t s__ ( a )
pyrene
114. antimony
115. arsenic
117. hery I I I vim
118.
119. ohromi um
Stream
Code
73
106
208
73
106
152
208
412
73
106
152
412
73
106
152
412
73
106
152
208
412
73
106
152
208
412
Sample
Typet
7
7
2
7
7
3
2
8
7
7
3
8
7
7
3
8
7
7
3
2
8
7
7
3
2
8
Source
*
<0.1
<0.01
<0.01
<0.01
<0.001
<0.005
0.03
<0.02
<0.005
<0.02
(•PR/ 1
Day 1
NO
0.013
ND
95
77
16
18.41
24
8.5
9.1
1.2
0.43
0.002
0.003
0.006
<0.05
1
3
2.1
3
5.2
0.4
1
0.15
0.43
0.4
, Except as Noted)
Dajr 2
12
12
3
0.78
0.007
<0.05
2.2
1.8
0.23
0.2
Day 3
49
47
8
1.8
0.03
0.002
<0.05
0.09
4.8
15.4
0.06
0.27
1
Average
0.013
1
95
77
26
18.41
27
8.5
9.1
4. 1
1.0
0.016
0.003
0.005
<0.05
0.545
3
3
3
7.4
0.23
|
0.22
0.43
0.5
CO
W
O
§
0
3
KI
IT"
W
O
co
ffl
O
w
O
!*j
Kj
CO
w
O
(-3
1
<
-------
Table V-2 (Continued)
SECONDARY LEAD SAMPLING DATA
BATTERY CRACKING
KAW \JASTKWATKR
Ions
oo
oo
en
I'ol Lnl.il>! •! fa)
copper
L I . cyanide
122. lead
I 2'). mercury
12/4. nickel
126. silver
127. thallium
128. zinc
Stream
Code
73
106
152
208
412
73
106
208
73
106
152
208
412
73
106
152
208
73
106
152
208
412
73
106
152
73
106
152
73
106
152
208
412
Sample
Typet
7
7
3
2
8
3
7
2
7
7
3
2
8
7
7
3
2
7
7
3
2
8
7
7
3
7
7
3
7
7
3
2
8
("'£/ '
Source Day ?
0.01 4
6
3.5
1.8
0.15 24
0.004
:i o
<«.01
0.05 SO
40
11
92.2
<0.05 605
0.0001 0.0014
0.0101
0.0004
<0.62
<0.005 1
2
0.65
0.94
<0.05 2
<0.02 0.32
0.16
0. 34
<0.l 0.8
1
-------
Table V-2 (Continued)
SECONDARY LEAD SAMPLING DATA
BATTERY CRACKING
RAW WASTEWATER
00
Pollutants (a)
Noncon vent I ona I
n linni ruim
ammo n la
bar 1 urn
boron
ca Ic luin
chemical oxygen demand
(COD)
coba 1 t
I ron
m.ignes lum
manganese
mo lybdnnum
phenols (total; by 4-AAP
method)
sod lum
t i n
t I Ian i urn
Stream
Code
412
152
412
412
412
412
73
106
412
412
412
412
412
73
106
208
412
412
*
412
Sample
Typet
8
2
8
8
8
8
7
7
8
8
8
8
8
2
2
2
8
8
8
Source
<0. 1
0.05
<0. 1
51.5
<0.05
<0.05
22.3
<0.05
<0.05
7.1
<0.05
<0.05
(n.R/1
Day 1
20
0.
<0.
6
93
384
174
<0.
Ill
29
0.
<0.
0.
0.
<0.
142
<0.
1.
<
02
5
5
5
5
001
022
004
5
5
l.oncentrat ion
8
, Except as Noted)
Day 2
9
7.9
15
<0.5
2
39
<0.5
58
15
<0.05
<0.05
0.003
0.016
58
<0.05
<0.05
Pay 3
38
7.5
<0.02
<0.5
9
166
<0.5
173
60
11
<0.5
0.017
0.009
375
<0.5
<0.5
A
22
5.
7.
<0.
6
99
384
174
<0.
114
34
4
<0.
0.
0.
<0.
190
<0.
0.
verage
1
5
5
5
35
007
01567
004
35
5
W
0
§
o
fd
K
tT«
W
o
M
c
Cd
n
H3
M
8
fd
W
n
H3
i
<
1
-------
Table V-2 (Continued)
SECONDARY LEAD SAMPLING DATA
BATTERY CRACKING
RAW WASTEWATER
oo
oo
oo
Concentrations
Stream
Code
73
106
412
412
73
106
412
73
106
152
208
412
73
106
152
208
412
Sample
Typet
7
7
8
8
|
I
1
7
7
3
5
8
1
1
1
1
8
Source Da)
330
69
<0.05 <0.5
<0.05 <0.5
65
8
5.4 2.2
10.050
1.447
270
0.2
<1 2.000
2
1.9
0.6
7.0 3
(niR/1. Except as
r 1 Day 2
<0.05
<0.05
56
7
> 50. 000
300
75
2
1.1
1.7
1
Noted^
Day 3
<0.5
<0.5
56
6
6,100
400
20.200
2
0.6
1.0
1
Average
330
69
0.35
0.35
59.0
7.0
19.000
10,050
1.447
323
0.2
7.400
W
W
O
o
§
O
3
tr1
W
G
W
n
!>
M
o
V
KJ
to
W
o
1-3
I
<
Nonconventlonals (Continued)
total organic carbon
(TOO
vanadium
y 11 rIum
Con ventlonals
oil and grease
total suspended solids
(TSS)
pll (standard units)
(a) No samples were analyzed for the acid extractpbles of toxic organic pollutants. Six samples
pesticide fraction; no pesticide was reported present above Its analytical quantification lln
fractions were analyzed for stream 412.
fS.=im[)U' type: Note: These numbers also apply to subsequent sampling data tables In this section.
were analyzed
lit. No toxic
for the
organic
1 One-time grab
2 24-hour manual composite
3 24-hour automatic composite
'i 48-hour manual composite
* - Less.than or equal to 0.01 mg/l.
** - Less than or equal to 0.005 mg/l.
5 48-hour automatic composite
6 72-hour manual composite
7 72-hour automatic composite
8 8-hour manual composite
-------
SECONDARY LEAD SUBCATEGORY SECT - V
TABLE V-3
*
WATER USE AND DISCHARGE RATES FOR
FURNACE WET AIR POLLUTION CONTROL
(1/kkg of lead produced from smelting)
Plant Percent Production Normalized
Code Recycle Water Use and Discharge Rate
266
26001
272
265
265
234
222
6602
6611
(a) 0
100
83.7
(b) 83.3
93.3
100
97.8
95
99.8
3252
151050
40411
11433
26521
942
NR
154752
NR
3252
0
6587
1909
1776
0
NR
7831
NR
(a) Since the 1977 dcp survey, this scrubber has been shut down.
(b) Plant 265 controls air emissions on two furnaces with
separate scrubbers
NR - Not reported in dcp.
1889
-------
Table V-4
SECONDARY LEAD SAMPLING DATA
FURNACE WET AIR POLLUTION CONTROL
RAW WASTEWATEk
Pol Ini ant s(,i)
Tox 1 c Pol lutants
4. hi'nz ene
II. 1,1,1 -I rlchloroethane
2 1 . 2 , 4 , 6- l r Ich lor ophenol
23. chloroform
l_i 31. 2 ,4 -dlchlorophenol
00
^° )9. Fluorant hene
O
44. methyl ene chloride
' / . .'-nil rophenol
h ') . phenol
M>. l>l.s(2-ethylhexyl)
phthalat e
f>/. hntyl benzyl phthalate
68. dl -n -butyl ph'tlialate
72. l>enzo(a)anthracene
/6. chrysene
78. anthracene (a)
Hit. Flnoi eno
Ml. phonant hrene (a)
84. pyrt'iie
S t ream
Code
401
401
401
401
401
401
401
401
401
401
401
401
401
401
401
..() 1
401
401
Sample
Type
1
1
3
1
3
3
1
3
3
3
3
3
3
3
3
3
3
3
Source
*
*
ND
*
ND
*
*
ND
*
0.009
ND
*
*
*
*
*
*
*
•IJ * • I 1 ' ^ t_ 1 1 L L d L. I.UI|t)
("ip/>, , Except as Noted)
Day_ 1 Day 2 Day 3 Average
* * * *
* ND ND *
* * * *
* * * *
* * * *
ND * ND *
* * * *
* ND ND *
0.003 0.006 0.004 0.004
0.006 0.002 * 0.002
ND * * *
* * * *
ND * * *
* * * *
* * NO *
* * * *
* * ND *
ND * ND *
CO
w
o
o
2!
O
i
tr1
M
O
CO
W
O
^
M
O
O
50
K
CO
M
0
,
<
-------
CO
Table V-4 (Continued)
SECONDARY LEAD SAMPLING DATA
FURNACE WET AIR POLLUTION CONTROL
RAW WASTEWATER
Concent rat Ions
Toxic
86.
89.
96.
97.
102.
105.
114.
115.
11 7.
118.
119.
120.
121.
122.
123.
124.
125.
1 26..
127.
128.
Pollutants(a)
Pollutants (Continued)
toluene
aldrln
beta-endosiilfan
endosulfan sulfate
alpha-BIIC
delta-BHC
ant Imony
arsenic
bery 1 1 lum
cadmium
chromium (total)
copper
cyanide (total)
lead
mercury
nickel
selenium
s 1 1 ver
thai I I urn
zinc
Stream
Code
401
401
401
401
401
401
401
401
401
401
401
401
401
401
176
401
401
401
401
401
401
Sample
Type
1
3
3
3
3
3
3
3
3
3
3
3
1
3
3
3
3
3
3
3
Source
*
ND
ND
**
ND
ND
5.700
0.067
<0.001
0.003
0.005
0.05
0.0074
0.008
<0.0002
<0.001
8.8
0.02
<0.001
0.04
<•*/!
Day 1
ND
**
0.003
ND
**
ND
0.560
1.400
0.004
0.35
0.28
0.40
<0.001
1.7
23
<0.0002
4.9
10
0.38
2.6
0.32
, Except as Noted)
Day 2
*
ND
ND
**
ND
ND
0.390
7.3
<0.001
0.02
0.010
0.05
0.003
0.006
0.097
0.45
7.9
<0.001
0.037
0.03
Day 3
*
ND
ND
**
ND
**
14.000
4.900
0.012
0.36
0.25
0.26
0.0015
1.4
0.096
4.6
15
0.30
3.2
0.32
Average
*
**
0.003
**
**
**
4.98
4.5
0.005
0.24
0.18
0.23
0.0015
1 .0
23
0.064
3.3
10
0.22
1.9
0.22
SECONDS
*
tr1
M
O
to
W
O
W
8
^
to
M
O
i-i
1
-------
Table V-4 (Continued)
SECONDARY LEAD SAMPLING DATA
FURNACE WET AIR POLLUTION CONTROL
RAW WASTEWATER
Concentrations
I'ol Ititant s(a)
Nonconvent 1 ona 1 Pollutants
Alkalinity
A 1 inn! mini
Aniinon i a
Rnr ium
I-*
°£ Boron
NJ
C^a lei urn
Chemical Oxygen Demand (COD)
Chloride
Cobalt.
Kl-.orMe
I run
Mamies ium
Han)'
M
0
O
50
CO
M
n
i
<
-------
oo
Table V-4 (Continued)
SECONDARY LEAD SAMPLING DATA
FURNACE WET AIR POLLUTION CONTROL
RAW WASTEWATER
Pollytan i.a(a)
Convent ional Pollutants
r 1 and Grease
Stream Sample
Code Type
401
Total Suspended Solids (TSS) 401
176
pll (standard units)
401
Source
ConcentratIons
(mfe/1. Except as Noted)
Day I Day ~2 Day 3
1
3
1
7.3
22
12
650
28,000
6.9
7.3
12
940
7.4
AvcraRe
45
1 .000
23
860
28,000
6.8
W
M
O
o
23
O
M
>
a
tn
c
w
o
M
Q
O
(a) Stream 176 was analyzed only for lead and TSS.
* - Less than or equal to 0.01 mg/l
** - Less than or equal to 0.005 rag/I
NA - not analyzed
en
M
n
I
<
-------
SECONDARY LEAD SUBCATEGORY SECT - V
TABLE V-5
WATER USE AND DISCHARGE RATES FOR
KETTLE WET AIR POLLUTION CONTROL
(1/kkg of lead produced from kettle furnaces)
Plant Percent Production Normalized
Code Recycle Water Use Discharge Rate
0 (a)
0 (a)
0 (a)
1818
74
0 (b)
0 (a)
45 (c)
0 (a)
NR
(a) - Infrequent batch discharge; frequency and flow not reported
(b) - 100 percent of the wastewater is recycled to decasing
washing
(c) - Based on batch discharge once per week
(d) - Use same scrubber system on smelting furnace
NR - Not reported in dcp
26001
655
391
273
264
250
,>25
224
223
6611 (d)
100
100
100
91.7
96
-
100
100
100
99,8
151050
3071
361
21900
1845
1718
11373
5724
7089
NR
1894
-------
Table V-6
SECONDARY LEAD SAMPLING DATA
KETTLE SCRUBBER LIQUOR
RAW WASTEWATER
Concentrations
Toxic
115.
117.
118.
119.
M 120.
00
^0 | 'i 2 .
01
123.
124.
126.
128.
Pollutants (a)
Pol lutants
arsenic
beryl 1 I urn
cadmium
chromium
copper
lead
mercury
nickel
s 1 Iver
zinc
Stream
Code
151
151
151
151
151
151
151
151
151
151
Sample
Type
3
3
3
3
3
3
3
3
3
3
Source
40
0
1
0
0
75
0
0
0
0
(mg/l.
Day 1
.001
.2
.003
.59
.0003
.37
.003
.17
Except as
Day 2
60
0.008
0.43
0.002
1.1
95
0.0025
0.32
0.002
0.17
Noted)
50
0
0
0
0
29
0
0
0
0
Day 3
.001
.41
.001
.73
.0027
.54
.002
.15
50
0
0
0
0
66
0
0
0
0
Average
.003
.68
.002
.807
.3
.0018
.41
.0023
.16
N on con vent Ion a I
ammonia
151
1
22
25
29
25
.33
W
M
O
23
O
la
K;
M
o
to
§
o
H
M
8
2S
w
w
n
?
Conventional "^
total
suspended solids
151
3
240
550
340
376
.7
(TSS)
pll (standard units)
151
1
8
.1
8.0
7
.8
(a) No samples were analyzed for either the acid extractable or volatile fractions of the toxic organic pollutants.
Three samples were analyzed for the pesticide fraction; none was detected above Its analytical quanti-
fication limit.
-------
SECONDARY LEAD SUBCATEGORY
SECT - V
TABLE V-7
WATER USE AND DISCHARGE RATES FOR
CASTING CONTACT COOLING
(1/kkg of lead cast)
Plant Percent
Code Recycle
4211
26001
427
422
248
244
234
224
247
252
100 (a)
100
0
0
0
0
0 (a)
0
NR
NR
171
504
120
963
5
184
22
33
(b)
(b)
Production Normalized
Water Use Discharge Rate
0
0
120
963
5
184
22
33
(b)
(b)
(a) 100 percent recycle or evaporation
(b) Reported in dcp as "insignificant"
(c) Plant closed
NR Not reported in dcp
TABLE V-8
WATER USE AND DISCHARGE RATES FOR
TRUCK WASH
(1/kkg of lead produced from smelting)
Plant Percent
Code Recycle
227
234
0
0
Production Normalized
Water Use Discharge Rate
12.6
29.7
12.6
29.7
1896
-------
Table V-9 (Continued)
SECONDARY LEAD SAMPLING DATA
TRUCK WASH
RAW WASTEWATER
Concentrations
~J
Pol lutants(a)
NonconVent lonal Pollutants
Hoi on
Ca 1 cinm
Cobalt
I ron
Mapnes him
Manganese
Mo lybdemim
Sodi urn
T I n
T i t .aninm
Vanadium
Yl.tr lum
Stream Sample
Code Type
(Continued)
417 1
455 1
417 1
455 1
417 1
455 1
417 1
455 1
417 1
455 1
41? 1
455 1
417 1
455 1
417 1
455 1
417 1
455 1
417 1
455 1
417 1
455 1
417 1
455 1
(mg/L, Except as Noted)
Source Day 1
<0.1
51.5
93.2
<0.05
<0.05
<0.05
<0.05
22.3
27.2
<0.05
<0.05
<0.05
<0.05
7.1
14.9
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 2 Day 3
0.1
0.8
104
1 ,200
<0.05
0.05
53.8
1 .050
34.4
42.6
1.15
7.2
<0.05
<0.05
37.6
107
<0.05
<0.5
0.1
0.05
<0.05
0.1
<0.05
<0.05
Average
0.1
0.8
1 ,200.
<0.05
0.05
53.8
1 ,050
34.4
42.6
1.15
7.2
<0.05
<0.05
37.6
107
<0.05
<0.5
0.1
0.05
<0.05
0.1
<0.05
<0.05
SECONDAR
K
W
0
to
c!
W
O
•bi
kTEGORY
W
O
H3
1
<
-------
Table V-9
SECONDARY LEAD SAMPLING DATA
TRUCK WASH
RAW WASTEWATER
Stream Sample
Concent rat Ions
Except as Noted)
oo
VO
00
Pol lutants (..i)
Toxic Pollutants
114. ant linony
115. arson 1 c
117. hery 1 1 lum
I 1 8 . cadmium
119. chromium (total)
1 20. copper
122. lead
124. nickel
128. zinc
Nonconvent lona I Pollutants
A lumt niun
Ammonia
Ha r i urn
Code Type Source Day I
4 1 7
455
417
455
417
455
417
455
417
455
417
455
417
455
417
455
417
455
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
0.15
0.15
<0.05
<0.05
<0.05
<0.05
<0.02
<0.02
417 1 <0.1
455 1 0.1
417 1 NA
455 1 NA
417 1 0.05
455 1 <0.05
Day 2 Day 3
0.810
0.31
0.060
0.05
<0.005
<0.005
0.24
0.04
0.14
0.18
0.8
1.2
63.4
20.9
0.15
0.25
6.12
1.58
160
37.8
NA
NA
0.35
0.05
Average
0.810
0.31
0.060
0.05
<0.005
<0.005
0.24
0.04
0.14
0.18
0.8
1.2
63.4
20.9
0.15
0.25
6.12
1.58
160
37.8
0.35
0.05
Cfi
M
O
O
z
O
ja
K
f
M
B
en
c!
IS
O
M
O
3
cn
M
0
1-3
i
<
-------
00
Table V-9 (Continued)
SECONDARY LEAD SAMPLING DATA
TRUCK WASH
RAW WASTEWATER
Pollutants(a)
Conventional Pollutants
Oil and Grease
Total Suspended Solids (TSS)
pll (standard units)
Stream Sample
Code Type
417 1
455 1
4)7 1
455 1
41 7 1
455 1
Concent rat Ions
(rag/ I, Except as Noted)
Source Day 1
5.4
<'
<1
9.0
7.0
7.0
Day 2 Day 3 Average
26 26
7 7
1 ,080 1 .080
2.500 2.500
3.0
3.0
to
w
o
o
55
O
J<
tr<
W
O
to
W
O
w
w
o
t-3
I
<
(a) The toxic organic fractions were not analyzed for these streams.
NA - Not analyzed
-------
SECONDARY LEAD SUBCATEGORY
SECT - V
TABLE V-10
WATER USE AND DISCHARGE RATES FOR
FACILITY WASHDOWN
(1/kkg of lead produced from smelting)
Plant Percent Production Normalized
Code Recycle Water Use Discharge Rate
224
239
249
271
655
6603
6604
6605
6608
* - Practices
NR - Data not
0
NR*
0
NR*
86*
0
0
0
NR
recycle
reported
550
817
1535
2540
646
237
NR
876
NR
and reuse after treatment
in dcp
550
817
1535
2540
646
237
NR
876
NR
TABLE V-ll
WATER USE AND DISCHARGE RATES FOR
BATTERY CASE CLASSIFICATION
(1/kkg of lead scrap produced)
Plant Percent
Code Recycle
Production Normalized
Water Use Discharge Rate (a)
1268
796
5546
409
15400
2624
1314
2915
(a) Includes some batch discharge normalized to continuous basis
* - Practices recycle and reuse after treatment
NR Data not reported in dcp
223
224
227
239
271
6601
6603
6605
NR *
0
0
NR
NR *
88.2*
0
0
1268
796
5546
409
15400
2624
1314
2915
1900
-------
Table V-12
SECONDARY LEAD SAMPLING DATA
HAND WASH
RAW WASTEWATER
Stream Sample
Concent rat Ions
(mg/1. Except as Noted)
Pollutants (a)
Toxic Pollutants
114. ant Imony
115. arsenic
117. beryllium
118. cadmium
119. chromium (total)
1 20. copper
122. lead
124. nickel
128. zinc
Nonconvent ional Pollutants
A 1 uml num
Ammon la
Rd r 1 urn
Code Ti
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
fpe Source Day 1
'
M
O
O
^
to
M
n
i
<
-------
Table V-12 (Continued)
SECONDARY LEAD SAMPLING DATA
HAND WASH
RAW WASTEWATER
St ream Sample
Concentrations
(niR/1, Except aa Noted)
i'o I . utcinls (a)
Nonconvent iona I Pollutants
Ho ron
Cal r him
Cobalt
1 ron
Mapnes lum
Manganese
Mo 1 yhdennm
Sodi um
Tin
T 1 tanl um
Vanadium
Y t I rium
Code
(Continued)
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
416
451
Type
1
1
1
1
1
|
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
- Source Day 1
<0 . 1
<0.l
51.5
93.2
<0.05
<0.05
<0.05
<0.05
22.3
27.2
<0.05
<0.05
<0.05
<0.05
7.1
14.9
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 2 Day 3
29.9
12.5
27.2
104
<0.05
<0.05
0.65
1 .45
11.2
29.2
<0.05
<0.05
<0.05
<0.05
123
293
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Average
29.9
12.5
27.2
104
<0.05
<0.05
0.65
1 .45
11 .2
29.2
<0.05
<0.05
<0.05
<0.05
123
293
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
M
O
§
O
U5*
K!
IT*
M
0
[/)
c
w
O
M
Q
O
K
W
M
O
1
<;
-------
Table V-12 (Continued)
SECONDARY LEAD SAMPLING DATA
HAND WASH
RAN VJASTKUATEK
Concent rat Ions
Convent tonal Pol lutants,
1)1 1 and (Jrease
Total Suspended Solids (TSS) 416
pll (standard units)
Code
416
451
416
451
416
451
Type
1
1
1
1
1
1
Source Day 1
5.4
<'
<,
9.0
7.0
7.0
Day 2 Day 3 Average
330 330
-------
Table V-13
SECONDARY LEAD SAMPLING DATA
RESPIRATOR WASH
RAW WASTEWATER
Concent rat ions
I'oilutantsOO
Toxtc Pollutants
I I4. nnt imony
H5. ;' r s e n I c
117. beryllium
118. • a din I urn
1.19. chromium (total)
120. . copper
122. lead
124. nickel
Stream Sa
Code T
nple (mg/1. Except as Noted) m
ftte Source Day 1
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
<0.02
<0.02
0.15
0.15
0.15
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.02
<0.02
<().() 2
Day 2
<0.01
0.06
<0.01
0.03
<0.005
<0.005
<0.02
0.04
<0.02
<0.02
0.3
0.4
0.3
5.15
<0.05
<0.05
0.3
1.04
Day 3 Average
• -
<0.01
-------
Table V-13 (Continued)
SECONDARY LEAD SAMPLING DATA
RESPIRATOR WASH
RAW WASTEWATER
NoncgnventlonaI Pollutant^
A1 tun 1 nu in
Ammonia
Bar I vim
Boron
Oa 1 c him
Cobalt
I ron
Map,nes lum
Sr. ream
Code
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
Source
0.1
0.1
NA
NA
NA
0.05
<0.5
<0.5
51.5
93.2
93.2
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Concentrations
(niR/l. Except as Noted)
Day. 1 Day 2Day 3
Average
22
27
27.2
<0.05
<0.05
<0.05
<0.05
<0.05
85.5
91 .3
<0.05
<0.05
<0.05
0.35
25.3
25.3
<0.05
<0.05
NA
NA
NA
<0.05
39.5
<0.05
0.35
15.2
<0.05
<0.05
<0.05
<0.05
39.5
85.5
91 .3
<0.05
<0.05
<0.05
0.35
<0.05
0.35
15
25.
25,
W
O
§
O
K
W
en
c:
w
o
W
0
cn
w
o
I
<
<0.05
<0.05
<0.05
-------
Table V-13 (Continued)
SECONDARY LEAD SAMPLING DATA
RESPIRATOR WASH
RAW WASTEWATER
Concentrations
O
Pollutants (_a_)
Nonconvont lonal Pol
Mo lybdenum
Sod 1 urn
Tin
Tl tan! urn
Vanadl urn
Yttrium
Stream Sample
Code Type Source
lutants (Continued)
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
415
453
454
<0.05
<0.05
<0.05
7.1
14.9
14.9
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
(mg/l, Except as Noted)
Day 1 Day 2
<0'.05
<0.05
25.6
18.3
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Day 3 Average
<0.05 <0.05
<0.05
<0.05
40.9 40.9
25.6
18.3
<0.05 <0.05
<0.05
<0.05
<0.05 <0.05
<0.05
<0.05
<0.05 <0.05
<0.05
<0.05
<0.05 <0.05
<0.05
<0.05
to
0
55
O
S
KJ
W
>
0
t/i
c
w
n
H3
w
O
O
K
to
M
n
l-q
' J
1
Conventional Pollutants
Oil and (Jrease
Total Suspended Sol
pll (standard unl t s)
415 5.4
453 <1
454 <1
Ids (TSS) 415 <1
453 9.0
454 9.0
415 7.0
453 7.0
454 7.0
6.2
NA
7.0
21
7.0
7.0
5 5
6.2
14 14
7.0
21
7.0
(a) The roxic orjvmUr fractions were not analyzed for these streams
NA - not analyzed
-------
Table V-14
SECONDARY LEAD WASTEWATER SAMPLING DATA
LAUNDRY
RAW WASTEWATER
Scream Sample
Concentrations
(mg/I. Except as Noted)
Pol lot anus (a)
Toxic Pollutants
1 1 't . ant Imony
II. arsenl c
117. bery 1 1 lum
118. cadmium
VD
o
--J 119. chromium (total)
1 20 . copper
122. lead
124. n 1 eke 1
128. zinc
Nonconvent lonal Pollutants
A luml nnm
Aimn'on 1 a
Code JTj
414
452
414
452
414
452
4)4
452
414
452
414
452
414
452
414
452
414
452
414
452
414*
452
rpe Source Day 1
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
0.15
0.15
<0.05
<0.05
<0.05
<0.05
<0.02
<0.02
1 <0.1
1 0.1
1 NA
1 NA
Day 2 Day 3
0.06
0.15
<0.01
0.02
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
0.25
0.2
11.5
14.9
<0.05
<0.05
0.1
1 .06
0.2
0.3
/ NA
NA
Average
0.06
0.15
<0.01
0.02
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
0.25
0.2
1 1 .5
14.9
<0.05
<0.05
0.1
1 .00
0.2
0.3
to
M
0
n
2
0
w
K
IT1
M
B
to
C
O
*%1
8
to
M
O
1-3
1
<
•
-------
Table V-14 (^ontinueu;
SECONDARY LEAD WASTEWATER SAMPLING DATA
LAUNDRY
RAW WASTEWATER
Concent rat Ions
Stream
PollutantsOO Code
Nonconvent lonal Pollutants (Continued)
Barium 414
452
Boron 414
452
(,'alclum 414
452
h-> Cobalt 414
& 452
o
oo
I ron 414
452
M. >>nes lum 4 1 4
452
Manganese 414
452
Molybdenum 414
452
Sodi urn 4 1 4
452
Tin 414
452
Titanium 414
452
Vanadium 414
452
Yll r him 414
452
Sample
Type
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Source
0.05
<0.05
<0.1
<0 . 1
51.5
93.2
<0.05
<0.05
<0.05
<0.05
22.3
27.2
<0.05
<0.05
<0.05
<0.05
7.1
14.9
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<().() 5
(mg/l, Except as Noted)
Day 1 Day 2 Day 3
0.05
0.1
0.2
37.8
94.1
<0.05
<0.05
0.55
1.35
14.8
25.5
<0.05
<0.05
<0.05
<0.05
78.9
26.9
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
Average
0.05
0.1
0.2
37.8
94.1
<0.05
<0.05
0.55
1.35
14.8
25.5
<0.05
<0.05
<0.05
<0.05
78.9
26.9
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
W
W
0
O
§
O
jti
Kj
tr1
W
O
S
O
•^
l_q
M
a
o
3
W
W
O
1-3
1
<
-------
Table V-14 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
LAUNDRY
RAW WASTEWATER
PoUutant3(a)
Convent tona1 Foilutants
Oil anil (>'rease
Stream Sample
Code Type
414
452
Total SuK|>em1<>d Solids (TSS) 414
452
pll (standard units)
414
452
Source
5.4
9.0
7.0
7.0
Concentrations
(oiR/1. Except as Noted)
Day I
Day 2
Day 3
Average
90
160
110
6.0
6.0
8.4
90
160
110
M
O
O
55
tr1
M
§
o
M
Q
O
M
O
I
<
(a) The toxic organic fractions were not analyzed for these streams
NA - not analyzed
-------
Table V-15
SECONDARY LEAD WASTEWATER SAMPLING DATA
MISCELLANEOUS
RAW WASTEWATER
ConcentraLIons
I'ol lutants(a)
Toxir Pollutants
23. chloroform
jy . 1 luuranthene
44. methylene chloride
56. nitrobenzene
l — *
[5 66. bls(2-ethylhexyl)
o phthalate
67. butyl benzyl phthalate
68. (li-n-butyl phthalate
69. itl-n-octyl phthalate
76. chrysenp (b)
/•!. anthracene (c)
81. phenantttrene (c)
84 pyrene
87. | r Ichloroethy 1 ene
1 1 'i . iinl 1 inony
Stream
Code
20
75
75
20
20
108
20
75
108
75
20
108
75
20
75
108
20
108
75
20
20
75
76
77
108
411
413
Sample
Type
1
2
6
1
7
2
7
6
2
6
7
2
6
7
6
2
7
2
6
1
7
6
1
1
2
8
8
(rng/1, Except as Noted)
Source Day 1 Day 2 Da^ 3
0.024 0.012 0.018
0.049 0.018 0.079
* 0.027
0.06 ND ND
ND
0.016
0.027
0.575 0.865
0'.031
* 0.089
0.031
0.014
* 0.019
<0.04
ND 0.139
ND
<0.04
*
* 0.038
ND * <0.27
16
<0.1 45
<0.1 0.6
<0.1 11
83
<0.01 21 13 12
<0.01 45 120 110
Average
0.018
0.047
0.027
0.06
0.016
0.027
0.865
0.031
0.089
0.031
0.014
0.019
<0.04
0.139
<0.04
*
0.038
*
16
45
0.6
It
83
15
91
M
M
n
o
K;
f
w
o
en
c!
w
o
1-3
W
§
K;
w
w
n
H3
i
<
-•
-------
Table V-15 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
MISCELLANEOUS
RAW WASTEWATER
ConcentratIons
Pollutant3(a)
Toxic t'ol lutants (Continued)
115. nrsen 1 c
117. beryI 1 lum
118.
r;n.
cadmium
1 19. chromium (total)
copper
I L \ . cyanide
12?. lead
1. . inercury
Stream
Code
20
75
76
n
108
611
613
41 1
613
611
613
611
613
20
75
108
611
'.13
20
73
108
20
73
108
175
411
613
20
73
108
Sample
Type
7
6
1
1
2
8
8
8
8
8
8
8
8
7
6
2
8
8
7
6
2
7
6
2
1
8
8
7
6
2
(rog/1, Except as NotedJ
Source
<0.01
<0.01
<0.01
<0.01
<0.01
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
0.01
0.15
0.15
0.05
<0.03
<0.05
0.0001
Day 1
3
6.4
0.01
1 .2
16
4.9
14
<0.05
<0.005
21.6
38.1
0.2
0.66
3
3
10
6.5
41 .6
<0.001
0.007
0.006
7
80
7
9.9
15.5
13.9
0.006
0.0007
0.0126
Day _2
2.8
36
<0.05
<0.05
6
103
<0.2
1.6
3.5
36.5
<0.001
0.006
16.0
14.5
Day 3
1 .7
14
<0.05
<0.005
2.6
33.8
<0.2
0.96
<0.006
1.5
23.9
0.004
0.013
<0 .02
21.0
10.6
<0.0001
Average
3
6.6
0.01
1 .2
16
3.1
20
<0.05
<0.02
10
58.3
0.06
1.07
3
3
10
3.8
36
0.002
0.0087
0.006
7
60
7
9
16.8
13.0
0.006
0.0004
0.0126
cn
n
O
53
O
2
K
f
M
O
Tf\
\J 1
0
H
M
0
g
"*
cn
M
n
i
-------
Table V-15 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
MISCELLANEOUS
RAW WASTEWATER
Concentrat iona
Pol lulants(a)
Toxic Pollutants (Continued)
1 :"i. nickel
1 2 f> . s 1 1 ve r
\21. thai Hum
128. zinc
Nonconvent Iona I Pol lutants
a 1 umi nuin
amtnonl a
hat i inn
boron
c.ilcium
St ream
Code
20
75
108
411
413
20
75
76
77
108
20
75
76
77
108
20
75
108
41 1
413
41 1
413
20
413
411
413
411
411
411
413
Sample
Type
7
6
2
8
8
7
6
1
1
2
7
6
1
1
2
7
6
• 2
8
8
8
8
1
8
8
8
8
8
8
8
Source
<0.005
<0.05
<0.05
<0.02
<0.02
<0.02
<0.1
<0.1
<0. 1
0.1
<0.02
<0.02
<0.1
<0.1
NA
0.05
0.05
<0.1
<0.1
51 .5
51 .5
(n>g;
Day 1
1
<0.9
2
5
17.3
<0.25
0.04
<0.02
<0.02
0.07
<0.05
0.3
<0.1
<0 . 1
0.'5
3
4
20
38.4
97.9
24
52.3
4.86
NA
<0.5
<0.5
2
5.7
754
52.8
'1, Except as
Day 2
2.5
48
14.6
120
17
94
25.08
7
<0.5
<0.5
2
12
471
437
Noted)
Day 3
<0.0()5
1 .5
24.6
0.6
5.8
67.2
15
66.4
6.42
<0.02
<0.5
<0.5
<1
9.5
639
635
Average
1
<0.45
2
3
29.9
<0.25
0.04
<0.02
<0.02
0.07
<0.05
0.3
<0. 1
<0 . 1
0.*5
3
2.3
20
19.6
95.0
18
70.9
12.12
3.5
<0.5
<0.5
1.3
9.0
621
374
to
W
o
g
O
w
K
f
w
o
to
cj
W
O
H
W
O
O
s
*s
to
w
o
"~3
1
<
-------
TableV-15 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
MISCELLANEOUS
RAW WASTEWATER
Concentrations
Stream Sample
Pollutants(a)
Nonconvent lonal Pollutants
chemical oxygen demand
(COD)
cohal t
I ron
M
I—1 magnesium
OJ
manganese
mol y bdenum
phenols (total; by A-AAP
method)
sodium
tin
1 1 1 a n I urn
ti>i.,-il organic carbon
(TOG)
Code
(Cont Inued)
20
75
108
All
4 1 3
All
413
AM
A13
All
A13
AM
A13
20
75
108
AH
A13
All
413
AH
413
20
75
108
Type
7
2
2
8
8
8
8
8
8
8
8
8
8
1
2
2
8
8
8
8
8
8
7
2
2
Source
<0.05
<0.05
<0.05
<0.05
22.3
22.3
<0.05
<0.05
<0.05
<0.05
7.1
7.1
<0.05
<0.05
<0.05
<0.05
(mg/1. Except as
Day 1
65
152
IAA
<0.5
O.A
173
75A
A. 390
258
2.5
1.35
<0.5
<0.05
0.007
0.006
0.01
661
1 ,170
<5
<0.5
2.5
5.7
A
AA
70
Day 2
<0.5
1
129
1 ,170
7.0AO
233
2
2
<0.5
<0.5
0.012
0.018
559
1 ,A20
<5
<5
2
3.5
,
Noted)
Day 3
<0.5
0.6
67.5
982
7,390
23A
2
1.A5
<0.5
<0.05
0.006
0.01
538
823
<5
<0.5
0.5
5.25
Average
65
152
IAA
<0.5
0.6
123
968
6,270
2A1
2.1
1.6
<0.5
<0.2
0.0083
0.011
0.01
586
1,1 AO
<5
<2
1.6
A. 8
A
A A
70
Cfl
n
o
1
K
f1
M
O
W
§
n
(_3
w
g
K
W
W
Q
1
<
-------
Table V-15 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
MISCELLANEOUS
RAW WASTEWATER
Stream Sample
Concent rat ions
(roR/1. Except as Noted)
I'ol lulant s (a)
Nunconvent tonal I'ol lutants
~ ""
v aii.-id t urn
y ( 1 i I inn
Convent 1 on a 1 Pol 1 ntants
o 1 1 and j> rease
lot nl suspended solids
( TSS)
j>ll (s 1 iindard unl t s)
Code
(Cont Inued)
41 1
413
41 1
41 3
20
7 5
108
413
20
75
108
175
41 1
413
20
75
108
411
413
Type
8
8
8
8
1
2
1
1
1
7
2
2
1
8
8
1
1
1
8
8
Source
<0.05
<0.05
<0.05
<0.05
5.4
5.4
<1
<1
7.0
7.0
Day 1
<0.5
0.1
<0.5
<0.05
76
23
7
14
3.3
428
1 .122
836
-------
Table V-16
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATMENT PLANT SAMPLES - PLANT A
Stream Sample
Concentrations
(niR/1. Except as Noted)
Toxic
23.
66.
67.
64.
1 14.
in.
117.
1 IH.
II').
120.
121 .
122.
12 •' .
124.
26.
127.
12B.
Pol lutants
Pol lutants
chl orof orm
bls(2-ethylhexyl)
ph thai ate
butyl benzyl phthalate
dl-n-octyl phthalate
ant Imony
arsenl c
beryl 1 Inm
cadinl um
chromium
copper
cyanide
lead
mercury
nickel
si 1 ver
thai 1 I urn
zinc-
Code
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
Type
2
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
Source
0.575
*
*
<0.1
<0.01
<0.001
0.03
<0.005
0.01
0.05
0.0001
<0.005
<0.02
<0.1
0.1
Day 1
0.017
0.021
ND
Nl)
20
2.9
<0.01
0.4
0.2
1
<0.001
6
0.0004
0.6
<0.02
0.2
3
Day 2 Day 3
0.015 0.037
ND
ND
-------
Table V-16 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATMENT PLANT SAMPLES - PLANT A
Stream Sample
C
Concent rat Ions
(me/I, Except as Noted)
VD
h-1
CT\
chemical oxygen demand
(COD)
chl or Ide
phenols (tor a 1 ; by
AAAP method)
total organic carbon
(IOC)
Conventlona1
o t 1 anil Rrease
I oral suspended solids
(TSS)
pll (standard units)
lode Type Source Day 1 Day 2 Day 3 Average
7/4 2
74 2
7A 2
7/4 2
74 2
74 2
74 1
W
O
O
32 32 g
309 309 K;
0.008 0.01 0.007 0.008 ^
O
19 19 M
C
W
O
3 NO 28 15.5 W
0
351 351 §
234
W
O
(-3
I
<
-------
Table V-17
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATMENT PLANT SAMPLES - PLANT B
Concentrations
Pollutants
Toxic Pollutants
114. antimony
118. cadmium
119. chromium
120. copper
122. lead
123. mercury
124. nickel
12H. zinc
Nonconvent lonal
phenols (total: hy
4-AAP method)
Conventional
total suspended solids
(TSS)
pll (standard units)
Stream
Code
206
207
206
207
206
207
206
207
206
207
206
207
206
207
206
207
206
207
206
207
206
207
Sample
Type Source
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
5
5
5
5
5
5
(ng/1. Except as Noted)
Day 1 Day 2 Day 3
1.22
1.13
0.03
0.11
0.09
0.09
0.04
0.16
0.27
11.7
<0.0002
0.00066
0.15
O.U
0.06
0.58
<0.004
<0.004
0.01
0.05
8.3
1.4
Average
1.22
1.13
0.03
0.11
0.09
0.09
0.04
0.16
0.27
11.7
<0.0002
0.00066
0.15
0.14
0.06
0.58
<0.004
<0.004
0.01
0.05
C/J
M
0
o
la
K;
IT"
M
§
C/J
w
o
M
Q
O
»
C/J
M
0
••3
I
-------
Table V-18
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATMENT PLANT SAMPLES - PLANT C
00
Pol jut ants
Toxtc Pollutants
21. clilorof orra
Ml. 1 ,2-trans-dlchloro-
ethylene
66. bls(2-ethylhexyl)
phtlialat e
8/. tr Ichloroethy1ene
I I 4. ant Imony
118. cadmium
119. chromium
120. copper
121. cyan I He
\'n. lead
12'). mercury
124. nickel
127. thallium
128. zinc
Nonconvent tona I
chemical oxygen
(U'lii.md (U(li))
total organic carbon
(TOO
phenol s (r.ot.a I ; by
4-AAP me I hod)
Stream Sample
ConcentratIons
(rag/1. Except as Noted)
Code
107
107
107
107
107
109
107
107
107
107
107
107
107
107
107
107
107
107
Type Source
2
2
2
2
2
1
2
2
2
2
2
2
2
2
2
2
2
2
Day 1
0.028
0.026
0.0199
<0. 02800
<0.1000
0.7
0.02
0.07
0.02
0.001
0.2
<0.1
0.02
<0.1
0.1
55
21
0.006
Day 2
0.03
' 0.013
0.022
*
1.1
<0.002
0.04
0.03
<0.001
0.2
<0.l
<0.005
0.1
0.1
63
48
0.004
Day 3 Average
0.03
0.0195
0.0.205
*
0.5
0.7
0.02
0.055
0.025
0.001
0.2
<0.l
0.0 1
0.1
0.1
59
34.5
0.005
CO
M
O
O
2;
O
§
IT1
M
>
O
CO
CJ
to
o
ft
1-3
M
O
O
*)
CO
M
O
i-3
I
<
-------
Table V-18 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATMENT PLANT SAMPLES - PLANT C
Pollutants
Conventional
<> i I and grease
l.utal suspended solids
(TSS)
pi (standard units)
Stream Sample
Code Type
107
107
107
ConcentratIons
(mR/1. Except as Noted)
Source
Day I
Day 2
Day 3
Average
4
51
8.8
5
84
4.5
67.5
8.8
t/1
M
O
§
O
§
f
M
g
cn
o
w
o
i
<
-------
Page Intentionally Blank
-------
Table V-19 (Continued)
SECONDARY LEAD VMSTEVJATER SAMPLING DATA
TRKATMKNT PLANT SAMPLES - PLANT D
I'll I I in ant H
Convent I on,i I
o i I anil f',1 case
total suspended sol l
-------
Table V-20
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATMENT PLANT SAMPLES - PLANT E
to
i'ol lutants
T»xlc I'ol lutarits
66. l>is(2-erhylhexyl)
phi lial ate
68. ili-n-buiyl
pht halate
/6. ohrysene
/H. anthracene (a)
81. plu'nanthrene (a)
114. a lit I ninny
M 5. arsen I c
17. h e r y11i urn
118. cadmium
1 1 '(. oh roinl inn
I 20. copper
Stream Sample
.-CoiifL- Type
Concent rat Ions
OR/1. Except as Noted)
~
153
1 54
155
156
153
154
155
156
155
156
155
156
153
154
156
153
155
156
153
154
155
156
153
154
155
156
153
154
155
156
153
154
155
2
1
1
2
2
1
1
2
1
2
1
2
2
1
2
2
1
2
2
1
1
2
1
1
1
2
2
1
1
2
2
1
1
1 Sf>
Source Day 1
*
0.02
ND
ND
ND
*
ND
*
ND
0.2
0.3
9
0.03
200
18
0.03
0.001
<0.001
0.002
0.048
0.04
0.29
1.8
0.02
0.003
0.002
0.2
0.07
0.07
0.2
4.5
Day 2
*
0.02
*
ND
ND
ND
ND
ND
ND
*
ND
0.3
1.3
1..5
0.16
160
18
<0.001
0.004
<0.001
0.002
0.046
0.08
0.039
2.4
0.035
0.006
0.001
0.19
0.08
0.17
0.07
Day 3
*
0.1
ND
ND
ND
ND
*
ND
1.4
0.5
88
4
0.001
0.001
0.001
0.12
0.028
'•7
0.006
0.001
0.21
0.25
0.06
3.6
Average
*
0.0067
0.067
0.033
*
ND
*
*
0.25
1
3.7
0.095
149.3
1 3.3
<0.03
0.002
0.0003
0.017
0.047
0.08
0.119
2.0
0.28
0.005
0.001 3
0.2
0.075
0.163
0.11
4.3
M
O
§
d
*
M
cn
c;
w
o
M
O
cn
M
n
-------
UD
NJ
CO
Pol lutants
122. lead
12). mercury
124. nickel
126. silver
127. thallium
128. zinc
Nonconvent tonal .
ammonia
Conventlonal
total suspended solids
(TSS)
pll (standard units)
Table V-20 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATMENT PLANT SAMPLES - PLANT E
Concent rat Ions
Stream Sample (roR/l, Except as Noted)
Code Type ~ ~ ~ ~"
153
154
155
156
153
154
155
156
153
154
155
156
153
154
155
156
155
156
153
154
155
156
153
154
155
156
153
154
155
156
153
154
155
156
3
1
I
2
2
1
1
2
2
I
I
2
2
I
I
2
I
2
2
I
I
2
Source Day 1
1 .7
0.19
40
II
0.0003
0.0004
0.0014
0.0009
0.16
0.13
0.11
0.92
0.001
0.008
0.002
0.004
-------
Table V-21
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
Concent rat 1ons
f "1 lut ants (a)
K)
.to.
4. benzene
carbon t et rach 1 or l
-------
Table V-21 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
ConcentratIons
VD
Stream Sample (mg/1, Except as Noted)
Pollutants(a)
Code Tj
me Source Day 1
Day 2
Day 3
Average
Toxic Pollutants (Continued)
39.
44.
47.
48.
49.
•)•>.
57.
65.
f lucranthene
methylene chloride
bromof orm
(t r Ibromomethane)
dlchlorobromomethane
trtchlorof luoromethane
naphthalene
2-nl trophenol
phenol
402 3 * *
403 3 * •
404 3 *
405 3 ND
402
403
404
405
402
403
404
405
402
404
402
403
404
405
* *
*
*
*
ND ND
ND
ND
ND
ND ND
ND
ND ND
*
ND
*
402 3 ND ND
404 3 ND
402 3 ND *
404 3 *
405 3 ND *
402 3 * *
403 3 *
404 3 *
405 3 *
*
*
*
*
*
*
*
*
*
*
*
ND
ND
ND
ND
*
NU
NA
*
ND
ND
NU
NA
*
*
*
*
ND
*
*
*
*
*
*
*
*
*
*
*
*
*
ND
*
ND
NU
ND
NU
*
*
*
*
*
*
*
* ,
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
W
|
^
f
O
C
Cfl
0
tf
w
Q
2
»
to
w
0
1-3
I
<
-------
Table V-21 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
Concentrations
VD
ro
CTv
Toxic
66.
67.
68.
69.
70.
72.
76.
78.
Pollntant3(a)
Pollutants (Continued)
bls(2-ethylhexy 1)
phthal ate
butyl benzyl plithalate
dl-n-butyl plithalate
dl-n-octyl phthalate
dlethyl phthelate
benzo(a)anthracene
chrysene
anthracene (b)
Stream
Code
402
403
404
405
402
403
404
405
402
403
404
405
402
404
402
404
402
403
404
405
402
403
404
405
402
403
404
405
Sample
Type
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
(«R/l
Source Day 1
0.009 0.160
*
*
*
ND *
*
*
*
* *
*
*
*
ND 0.010
ND
ND ND
ND
* ND
*
*
*
* *
*
*
*
, Except as Noted)
Day 2
0.160
*
*
*
0.010
*
*
*
*
*
NA
*
0.010
*
*
*'
'*
ND
*
*
*
*
*
*
*
*
*
*
Day 3
0.099
*
*
*
*
*
*
*
*
*
*
*
*
*
*
ND
*
*
*
*
*
*
*
*
*
*
*
*
Average
0.140
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
cn
M
O
M
>
s
*
(_,
M
O
cn
C
Cd
o
^
M
O
o
8
K
W
M
1
<
-------
Table V-21 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
ConcentratIons
Stream
Pollutants(a)
Toxic Pollutants (Continued)
80. Clunrene
8). plienantlirene (b)
84. pyrene
i — *
VD
M
-J
85. tetrachloroethy lene
8f>. toluene
87. tr ichloroethy lene
89. al.lrln
91. 4. 4' -DDK
9">. a Ipha-endosn If an
97. cnclosu If an snlface
%
Code
402
403
404
405
402
403
404
405
402
403
404
403
404
402
403
404
405
402
403
404
403
404
403
402
402
403
404
405
Sample
Type Source-
3 *
3
3
3
3 *
3
3
3
3 *
3
3
*
*
*
3
3
3
3 ND
3 **
3
3
3
(niR/l
Day 1
*
*
NA
*
*
*
*
*
*
*
*
ND
NU
*
*
*
*
ND
ND
*
NU
*
ND
ND
ND
ND
**
**
, Except as Noted)
Day 2
*
*
*
*
*
it
*
*
*
*
*
ND
ND
*
*
*
*
NU
ND
*
*
ND
**
**
**
** /
**
**
Day 3
it
*
*
*
*
*
*
*
*
ND
*
*
*
*
*
*
*
*
*
*
ND
ND
ND
NU
ND
**
**
**
Average
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
**
**
**
**
**
**
tn
w
o
o
Q
!>
K
tr1
W
0
\*s
U)
o
i~3
w
o
K
tn
W
o
h3
1
<
'
-------
Table V-21 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
VD
NJ
00
Pollutants(a)
Toxic Pollutants (Continued)
103. beta-BIIC
104. p,;imma-BHC
105. delta-NIC
114. ant imony
115. arsenlc
117. beryllium
118. cadmium
119. chromium (total)
I ?.(}. copper
Stream
Code
402
403
405
403
405
402
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
Concentrations
(iBR/1. Except as Noted)
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Source
ND
Average
ND
5.700
0.067
<0.001
0.003
0.005
0.05
ND
**
**
ND
**
ND
**
ND
ND
**
**
<0.001
5.300
0.990
9.800b
6.000
2.000
0.650b
0.022
0.002
<0.001
<0.001
<0.001b
8.1
4.5
2.9
2.4b
0.96
0.060
0.082
0.006b
3.2
2.4
1.8
1.5
9.400
7.200
6.700
2.900
<0.005C
<0.005C
0.47
1 .400
<0.001
<0.001
<0.001
<0.001
3.2
2.4
2.8
2.4
0.70
0.009
0.039
0.012
3.0
1.6
1.7
1.4
ND
ND
ND
ND
ND
ND
7.400
9.8d
7.100
4.1
1.000
3.7
0.860
1.4
<0.001
<0.001
<0.001
<0.001
3.4.
2.7b
2.2
2.2
0.57
0.004b
0.017
0.012
-
2.0b
2.0b
1.6
**
**
**
**
**
5.6
7.4
4.9
5.6
2.333
1.9
0.66
0.940
0.001
<0.001
<0.001
<0.001
4.9
3.2
2.6
2.3
0.74
0.024
0.046
0.01
2.8
2.0
1.8
1.5
to
M
O
i
M
§
en
c
td
O
M
Q
to
M
O
I
<
-------
Table V-21 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
Poilutants(a)
Toxic Pollutants (Continued)
121 . cyanide (total)
122. lead
123. mercury
124. nickel
125. selenium
126. si Iver
127. thallium
Stream
Code
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
Source
0.0074
0.008
<0.0002
<0.001
8.8
0.02
<0.001
3
Concentrations
(mR/I. Except as Noted)
Day 1Day 2Day 3
0.0094
0.0074
0.0035
0.0045b
11
16
12
0.83
0.0014
0.027
0.030
<0.0002
4.2
3.1
'•7w
1.7b
9.5
11
12
lib
0.02
0.02
0.02
<0.001b
0.38
0.23
0.051
0.22
0.023
<0.001b
<0.001
0.0015
92
8.4
5.9
0.40
0.0016
0.017
0.015b
0.0037
2.5
1.6
1.9
1.8
9.7
11
12
9.9
0.02
<0.001
<0.001
<0.001
0.35
0.22
0.20
0.20
0.011
0.0035
0.0015
<0.001
52 K
5.1b
13
0.55
0.0017
0.0047
0.015b
0.0069
1.8
2.1b
1.5
1.6
K
14b
13
12
0.03
0.02b
<0.001
<0.001
0.40
0.38
0.25
0.25
Average
0.014
0.0036
0.0016
0.002
51
9.8
43
0.59
0.0015
0.016
0.020
0.004
2.8
2.2
1.7
1.7
10
12
12
10
0.02
0.01
0.006
<0.001
0.37
0.27
0.16
0.22
W
O
O
W
6
c
w
O
w
Q
w
O
1-3
I
<
-------
Table V-21 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
Pollutants (a)
Toxic Pollutants (Continued)
1>8 . z 1 nc
Stream
Code
402
403
405
Source
0.04
ConcentratIons
Except as Noted)
2.0
0.80
0.81
0.38
1.5
0.68
0.74
0.42
• K
0.92b
0.73
0.60
Average
1.6
0.8
0.76
0.46
to
W
O
Nonconvent tonal Pollutants
Alkal Inlty
CO
O
Ammonia
Calcium
Chemical Oxygen Demand (COD)
Magnes lum
Phenol 1
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
402
403
404
405
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
1
1
160
2.1
23
<1
11
<0.001
0
180
260
50Qb
11.000
7.200b
7,200
7.200
6.1
27
3V
36b
440
400b
320
. 130
42
19
21K
22b
<0.001
<0.001
<0.001
<0.001
80b
280
240
15.000
6,800
5.700
6,500
63
32
3.9
7.2
300
120
160
130
37
22
25
20
0.170
-------
OJ
Table V-21 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT G
Concent rat Iona
Pol lutants(a)
Nonconvent lonal Pol
Sul f al e
Stream
Code
lutants (Continued)
402
403
404
405
Conventional Pollutants
O 1 1 and (.'rease
Total Suspended Sol
pll
402
403
404
405
ids (TSS) 402
403
404
405
402
403
404
405
Sample
Type Source
3 55
3
3
3
1 7.3
1
1
1
3 22
3
3
3
1 6.9
1
1
1
(n.g/1.
Day 1
860
780
800
870
53
7.3
5.4
7.6
1 .400
250
340
110
7.1
7.3
7.7
7.7
Except as Noted)
Day 2
940
780
810
860
54
17
21
13
830
150
170
140
6.7
6.3
7.6
7.7
Day 3
670
720
810
840
63
20
20
6
800
240
240
280
7.0
6.4
7.2
7.5
Average
820
760
810
860
56
14
15
8.8
1,010
210
250
180
Cfl
M
n
§
o
j>
K
f
M
§
Cfl
tfl
n
i T
H
M
O
O
K
w
M
n
(a) Three samples for each stream were analyzed for all toxic organic pollutants.
(h) Average of duplicate analysis
(c) Chemical matrix Interference
NA - not analyzed
-------
Table V-22
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT H
l'ollutants(a)
Pollutants
I I lt. ant l-nnny
Stream Sample
Code Type
420
Source
<0.01
<0.01
<0.01
ConcentratIons
(mg/I, Except as Noted)
2.1
1.3
1.4
3.6
1.6
1.5
7
1.7
2.4
Average
4.2
I .5
1.7
t/l
M
O
§
O
U)
M
II"). ars enl c
117. beryllium
I 18 . cadmium
19. chromium (total)
418
419
420
418
419
420
418
419
4 '20
418
419
420
<0.01
<0.01
<0.01
<0.005
<0.005
<0.005
<0.02
<0.02
<0.02
<0.02
<0.02
<0.02
0.42
(-3
M
O
O
I 20. copper
122. lead
418
419
420
418
419
420
0.15
0.15
0.15
<0.05
<0.05
<0.05
0.5
0.05
0.05
25
0.1
0.1
1
<0.5
<0.5
21.0
0.07
0.260
2.5
<0.5
<0.5
41.0
0.19
0.15
1.3
0.02
0.02
29
0.12
0.17
M
O
1-3
nickel
418
419
420
<0.05
<0.05
<0.05
0.5
<0.05
<0.05
0
<0
<0
<0
0.8
<0.4
<0.4
zinc
418
419
420
<0.02
<0.02
<0.02
3.2
<0.02
<0.02
2.6
<0.2
<0.2
10.8
<0.2
<0.2
5.5
<0.14
<0.14
-------
Table V-22 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER SAMPLES - PLANT H
ConccntratIons
I'ol
VD
U)
A Inml innn
H,i i i 1 1 HI
Moron
C ;> ! r I um
Cobalt
1 ron
aKiies i urn
MaitKanese
Mo I ylxlenum
Stream
Code
lutants
j!»
420
418
419
420
418
419
420
418
41 9
420
418
419
420
418
419
420
418
419
420
418
419
420
418
419
420
Sample
Type
2
3
3
2
3
3
2
3
3
2
3
3
2
3
3
2
3
3
2
3
3
2
3
3
2
3
3
(niR/1, Except as Noted)
Source
<0
<0
0
0
0
<0
<0
<0
51
51
51
<0
<0
<0
<0
<0
<0
22
22
22
<0
<0
<0
;J
•'
.05
.05
.05
j
. 1
•'
.5
.5
.5
.05
.05
.05
.05
.05
.05
.3
.3
.3
.05
.05
.05
<0.05
<0
<0
.05
.05
4
0
<0
<0
0
0
<,
0
0
256
644
725
<0
<0
<0
21
0
0
1 ,290
849
867
1
0
0
<0
<0
<0
Day 1
.2
•'
.5
.05
.05
.1
.1
.5
.05
.05
.1
.1
.150
.15
.5
.05
.05
4
<'
<0
<0
<0
<,
-------
Table V-22 (Continued)
SECONDARY LEAD WASTEWATER SAMPLING DATA
TREATED WASTEWATER' SAMPLES - PLANT H
Concentrations
''"LlllLa"ts (a)
N °J1<: 9 "_¥ t!' Li "_" al Polhit ajnt js (Continued)
Sodl urn
Tin
Ti ! anlum
Vanad him
Yttrium
Conventional Pollutants
() i 1 and Crease
Tolal Suspended Solids (TSS) 418
pll (standard units)
Stream
Code
ont Inued)
418
419
420
418
419
420
418
419
420
418
419
420
418
419
420
418
419
420
418
419
420
418
419
420
S a mp 1 e
Type
2
3
3
2
3
3
2
3
3
2
3
3
2
3
3
1
1
1
2
3
3
2
3
3
Source
7
7
7
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
5
5
5
<1
<|
<1
7
7
7
.1
.1
.1
.05
.05
.05
.05
.05
.05
.05
.05
.05
.05
.05
.05
.4
.4
.4
.0
.0
.0
192
142
140
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
<0
2
9
<)
22
140
37
3
9
9
(n.R/1,
Day 1
.5
.5
.05
.5
.05
.05
.5
.05
.05
.5
.05
.05
.4
.0
.5
Except
Day
124
132
123
<0.5.
<0.5
<0.5
<0. 5
<0.5
<0.5
<0.5
<0.5
<0.5
<0.5
<0.5
<0.5
9.4
<|
<)
95
46
56
1
9.0
9.5
as Noted)
2^ Day 3
171
150
150
<0
<0
<0
<0
<0
-------
SECONDARY LEAD SUBCATEGORY SECT - V
072
! 0 71 70A 3LANX
SOTOCS
VAIE3.
S7EJTT
HATTEXY
ELSCTaOLTTE
CASTING
COIITACT
cact.i?rc
UATE2.
CASTTUG
NON-CONTACT
COOLING
WAITS.
PLANT
WASHDOWS
SAW ci SliADt.
CCCLI'IG
[073 j
0.0021 MCO
^
073
»
0.004 MCD
r
SITTLIXG
&
5TLT2ATION
f
MaOH
i nrT^^nM
M13I5C
SETTLING
pssssrsz
rrr."«»""* nv
«-/! (^\
0741 (X) O.OC
076
Hose Discharge
Laad Piglec Mold
Floor Drain for
Sectary Cracking
DISCHARGE
Figure V-1
SAMPLING SITES AT SECONDARY LEAD PLANT A
1935
-------
SECONDARY LEAD SUBCATEGORY
SECT - V
WASHDCKK
NONCONTAC7
COOLING
WAIS3.
5000 G?D
139
SOTJSCZ
5000 G?D
DISCHARGE
Figure V-4
SAMPLING SITES AT SECONDARY LEAD . 'LANT D
1936
-------
SLUDGE TO I.ANDFILL
TAP
WATER
KETTLE
SCRUBBERS
RUNOFF &
WASIIDOWN
CONCRETE
SETTLING PIT
PI Tf I KG
f.
SETTLING
TANK
BATTERY
CRACKING
t,
POND
PLASTIC
BATTERY
CASE CHIPS
TO LANDFILL
FUTURE
DISCHARGE
(SFCOKD
LAGOON
KOT YET
FULL)
SLUDGE
TO
LANDFILL
M
O
i
I
c;
w
o
M
O
O
o
t-3
I
<
Figure V-5
SAMPLING SITES AT SECONDARY LEAD PLANT E
-------
SECONDARY LEAD SUBCATEGORY
SECT - V
176
FURNACE
SCRUBBER
BATTERY
STORAGE
RUNOFF
RUNOFF &
WASHDOWN
DRYING
FURNACE
SCRUBBER
NONCONTACT
COOLING
WATER
LIME
NEUTRALIZATION
TANK
0.036 MGD
175
SOLIDS TO
LANDFILL
t
TAP WATER
SCRUBBER
RESERVOIR
COOLING
TOWER
TAP WATER
1
u
Figure V-6
SAMPLING SITES AT SECONDARY LEAD PLANT F
1938
-------
SECONDARY LEAD SUBCATEGORY SECT - V
Discharee
Figure V-7
SAMPLING SITES AT SECONDARY LEAD PLANT G
1939
-------
SOURCE
WATER
SECONDARY LEAD SUBCATEGORY
© ^ »
SECT - V
410
FILTER
PRESS
FILTRATE
LANDFILL
LEACHATE
SCRUBBER
SLUDGE
SPILLAGE
INDUSTRIAL
BATTERY
BREAKING
TRUCK
WASH
TRUCK
WASH
BATTERY
ELECTROLYTE
FROM
<^WT? mnEB
INDUSTRIAL
BATTERY
BREAKING
SHREDDED
BATTERY
ELECTROLYTE
& RUNOFF
LAUNDRY
WATER
RESPIRATOR
WASH
HANDWASH
STORMWATER
RUNOFF
JMISC. BATTERY
MANUFACTURING
WASTEWATER
419
0.314 MGD
DISCHARGE
Figure V-8
SAMPLING SITES AT SECONDARY LEAD PLANT H
1940
-------
SECONDARY LEAD SUBCATEGORY SECT - V
450
SOURCE
WATER
^*+^
»• DISCHARGF
TO SANITARY
SEVER
DISCHARGE
0.000099 MGD
SAMPLING
Figure V-9
AT SECONDARY LEAD PLANT I
1941
-------
Page Intentionally Blank
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
SECTION VI
SELECTION OF POLLUTANTS
This section examines chemical analysis data presented in Section
V from secondary lead plants, and discusses the selection or
exclusion of pollutants for potential limitation. Each pollutant
selected for potential limitation is discussed in of Vol. I.
That discussion provides information about where the pollutant
originates (i.e., whether it is a naturally occurring substance,
process metal, or a manufactured compound); general physical
properties and the form of the pollutant; toxic effects of the
pollutant in humans and other animals; and behavior of the
pollutant in POTW at the concentrations expected in industrial
discharges.
The discussion that follows describes the analysis that was
performed to select or exclude pollutants for further
consideration for limitations and standards. Pollutants are
further considered for limitation if they are present in
concentrations treatable by the technologies considered in this
analysis. The concentrations used for the toxic metals were the
long-term performance values achievable by lime precipitation,
sedimentation, and filtration. The concentrations used for the
toxic organics were the long-term performance values achievable
by carbon adsorption.
As discussed in Section V, EPA collected additional wastewater
sampling data after the February 1983 proposal in an attempt to
further characterize wastewater in the secondary lead
subcategory. As a result of the new data, the Agency revised its
pollutant frequency of occurrence analysis was revised.
After proposal, the Agency re-evaluated the treatment performance
of activated carbon adsorption to control toxic organic
pollutants. The treatment performance for the acid extractable,
base-neutral extractable, and volatile organic pollutants has
been set equal to the analytical quantification limit of 0.010
mg/1. The analytical quantification limit for pesticides and
total phenols (by 4-AAP method) is 0.005 mg/1, which is below the
0.010 mg/1 accepted for the other toxic organics. However, to be
consistent, the treatment performance of 0.010 mg/1 is used for
pesticides and total phenols. The 0.010 mg/1 concentration is
achievable, assuming enough carbon is used in 'the column and a
suitable contact time is allowed. The frequency of occurrence
for 36 of the toxic pollutants has been redetermined based on the
revised treatment performance value. However, no toxic organic
pollutants have been selected for further consideration for
limitation in this subcategory.
1943
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
This study examined samples from the secondary lead subcategory
for three conventional pollutant parameters (oil and grease,
total suspended solids, and pH) and four nonconventional
pollutant parameters (ammonia, chemical oxygen demand, total
organic carbon, and total phenols).
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED
The following conventional and nonconventional pollutant
parameters were selected for limitation in this subcategory:
ammonia
total suspended solids (TSS)
pH
Ammonia was detected in all 11 samples analyzed. Quantifiable
concentrations ranged from 0.2 to 29 ing/1. Although none of
these concentrations are above the 32 mg/1 considered achievable
with ammonia steam stripping, ammonia is selected for limitation.
Only one kettle scrubber waste stream was sampled, and ammonia is
known to be present in this stream with concentrations of 22, 25,
and 29 mg/1. Ammonia is used in many wastewater treatment plants
in the subcategory as a neutralizing agent. EPA believes that
use of ammonia for wastewater treatment causes ammonia carried in
recycled sludges to volatilize in the kettle. For this reason,
ammonia is selected for limitation.
Total suspended solids ranged from 7 to 28,000 mg/1 in 36
samples. All but three of the observed concentrations are above
that considered achievable by treatment. Further, most of the
methods used to remove toxic metals do so by converting these
metals to precipitates. Meeting a limitation on total suspended
solids also helps ensure that removal of these precipitated toxic
metals has been effective. For these reasons, total suspended
solids is considered for limitation in this subcategory.
The pH of a wastewater measures its relative acidity or
alkalinity. In this study, the pH values observed ranged from
0.6 to 8.1. Many harmful effects may be caused by extreme pH
values or by rapid changes in pH. Therefore, pH is considered
for limitation in this subcategory.
TOXIC POLLUTANTS
The frequency of occurrence of the toxic pollutants in the waste
water samples taken is presented in Table VI-1 (page 1951).
These data provide the basis for the selection or exclusion of
specific pollutants, as discussed below. Table VI-1 is based on
the raw wastewater data from streams 73, 75, 208, 106, 108, 151,
152, 176, 401, 411, 412, 413, 414, 415, 416, 417, 451, 452, 453,
454, and 455 (see Section V). Treatment plant sampling data were
not used in the frequency count.
1944
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
TOXIC POLLUTANTS NEVER DETECTED
The toxic pollutants listed in Table VI-2 (page 1955) were not
detected in any wastewater samples from this subcategory. They
are not selected for consideration in establishing limitations.
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION LIMIT
Toxic pollutants which are not detectable include those
pollutants whose concentrations fall below EPA's nominal
detection limit. The toxic pollutants listed in Table VI-3
(page 1957) were never found above their analytical
quantification concentration in any wastewater samples from this
subcategory; therefore, they are not selected for consideration
in establishing limitations.
TOXIC POLLUTANTS PRESENT BELOW CONCENTRATIONS ACHIEVABLE BY
TREATMENT
The pollutants listed below are not selected for consideration in
establishing limitations because they were not found in any
wastewater samples from this subcategory above concentrations
considered achievable by existing or identified treatment
technologies. These pollutants are discussed individually
following the list.
47. bromoform
65. phenol
117. beryllium
Bromoform was detected in only one of 13 samples, and that one
was below the concentration to which identified treatment can
reduce its concentration (0.010 mg/1). Bromoform is thus not
selected for consideration for limitation.
Phenol was found above its analytical quantification limit in
three of four samples analyzed, but the highest concentration
reported was 0.006 mg/1, and identified treatment can reduce its
concentration only to 0.010 mg/1. Phenol is thus not selected
for further consideration in establishing limitations.
Beryllium exceeded its analytical quantification limit in only
two of 34 samples, with concentrations of 0.03 and 0.012 mg/1.
These are below the concentration to which available treatment
can reduce beryllium concentrations (0.20 mg/1), so beryllium is
not selected for consideration for limitation.
TOXIC POLLUTANTS DETECTED IN A SMALL NUMBER OF SOURCES
Toxic pollutants detectable in the effluent from only a small
number of sources within the subcategory and uniquely related to
only those sources are not appropriate for limitation in a
1945
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
national regulation. The following pollutants were not selected
for limitation on this basis.
23. chloroform
39. fluoranthene
56. nitrobenzene
66. bis(2-ethylhexyl) phthalate
67. butyl benzyl phthalate
68. di-n-butyl phthalate
69. di-n-octyl phthalate
71. dimethyl phthalate
76. chrysene
77. acenaphthylene
84. pyrene
121. cyanide
123. mercury
125. selenium
Although these pollutants were not selected for consideration in
establishing nationwide limitations/ it may be appropriate/ on a
case-by-case basis, for the local permit writer to specify
effluent limitations.
Chloroform, a common laboratory solvent, was detected in 10 of 13
samples, ranging from below the analytical quantification limit
to 0.079 mg/1. Five of the 10 sample concentrations of
chloroform detected were above the treatable concentration (0.010
mg/1). All five treatable samples were taken from the same
plant. The presence of this pollutant is not attributable to
materials or processes associated with the secondary lead
subcategory. EPA suspects sample contamination as the source of
this pollutant. In the dcp, all responding plants indicated that
this pollutant was known to be absent or believed to be absent.
For these reasons, chloroform is not selected for consideration
for limitation.
Fluoranthene was detected above its treatable concentration in
one of 11 samples analyzed, with a concentration of 0.027 mg/1.
The concentration to which treatment is effective is 0.01 mg/1.
Since fluoranthene was found in only one waste stream, and since
all responding plants indicated in their dcp that this pollutant
was known to be .absent or believed to be absent, it is not
selected for further consideration for limitation.
Nitrobenzene occurred above its treatable concentration (0.010
mg/1) in only one of the 11 samples, where i't measured 0.016
mg/1. Two other samples of this waste stream at two different
plants were reported as not detected. This site-specific result
is not sufficient to characterize the whole subcategory,
therefore, nitrobenzene is not selected for further consideration
for limitation.
Bis(2-ethylhexyl) phthalate was found above both its analytical
quantification limit and its treatable concentration (0.01 mg/1)
in five of 11 samples, with a maximum concentration of 0.585
1946
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
mg/1. The presence of this pollutant is not attributable to
materials or processes associated with the secondary lead
subcategory. It is commonly used as a plasticizer in laboratory
and field sampling equipment. EPA suspects sample contamination
as the source of this pollutant. Also, in the dcp all responding
plants indicated that this pollutant was known to be absent or
believed to be absent. Therefore, bis(2-ethylhexyl) phthalate is
not selected for further consideration for limitation.
One of 11 samples analyzed for butyl benzyl phthalate was found
to contain a concentration above its analytical quantification
limit. This value was above the 0.010 mg/1 concentration
considered achievable with treatment. The presence of this
pollutant is not attributable to materials or processes
associated with the secondary lead subcategory. It is commonly
used as a plasticizer in laboratory and field sampling equipment.
EPA suspects sample contamination as the source of this
pollutant. Also, in the dcp all responding plants indicated that
this pollutant was known to be absent or believed to be absent.
It is thus not selected for further consideration for limitation.
Two of 11 samples analyzed for di-n-butyl phthalate were found to
contain concentrations above its analytical quantification limit,
one of these above the 0.010 mg/1 concentration considered
achievable with treatment. The presence of this pollutant is not
attributable to materials or processes associated with the
secondary lead subcategory. It is commonly used as a
plasticizer in laboratory and field sampling equipment. EPA
suspects sample contamination as the source of this pollutant.
Also, in the dcp all responding plants indicated that this
pollutant was known to be absent or believed to be absent. It is
thus not selected for further consideration for limitation.
Di-n-octyl phthalate was found above its analytical
quantification limit (0.01 mg/1) in two of 11 samples. The
presence of this pollutant is not attributable to materials or
processes associated with the secondary lead subcategory. It is
commonly used as a plasticizer in laboratory and field sampling
equipment. EPA suspects sample contamination as the source of
this pollutant. Also, in the dcp all responding plants
indicated that this pollutant was known to be absent or believed
to be absent. Therefore, di-n-octyl phthalate is not selected for
further consideration for limitation.
Dimethyl phthalate was found in only one of 11 samples analyzed.
The concentration detected was above the concentration considered
achievable with treatment (0.010 mg/1). The presence of this
pollutant is not attributable to materials or processes
associated with the secondary lead subcategory. It is commonly
used as a plasticizer in laboratory and field sampling equipment.
EPA suspects sample contamination as the source of this
pollutant. Also, in the dcp all responding plants indicated that
this pollutant was known to be absent or believed to be absent.
For these reasons, dimethyl phthalate is not selected for further
consideration for limitation.
1947
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
Chrysene was reported present above its analytical quantification
limit in two of 11 samples. The two reported concentrations of
chrysene were 0.139 and 0.545 mg/1, which are above the 0.010
mg/1 concentration considered attainable with treatment. The
process waste stream that produced the 0.545 mg/1 value, also
produced five not detected values at two other facilities.
Chrysene is not considered characteristic of the subcategory
because it was found in only two samples from two different
process waste streams. Therefore, chrysene is not selected for
further consideration for limitation.
Acenaphthylene occurred above its treatable concentration (0.010
mg/1) in only one of 11 samples, where it measured 0.035 mg/1.
Two other samples of this waste stream at two different plants
were reported as not detected. This site-specific result is not
sufficient to characterize the whole subcategory, so
acenaphthylene is not selected for further consideration for
limitation. ' •
Pyrene exceeded its analytical quantification limit (0.010 mg/1)
in only two of 11 samples. The two reported concentrations of
pyrene were 0.013 mg/1 and 0.038 mg/1. These two values are from
two different process waste streams. This site-specific result
is not sufficient to characterize the whole subcategory. Also,
in the dcp all responding plants indicated that this pollutant
was known to be absent or believed to be absent. Therefore,
pyrene is not selected for further consideration for limitation.
Cyanide was found at a treatable concentration in three of 14
samples, all at the same plant. All three concentrations (3.0,
4.0, and 6.0 mg/1) that were reported above the 0.047 mg/1
concentration considered attainable are from the same plant.
Because of the site-specificity of this result, cyanide not
selected for consideration for limitation.
Mercury was found at treatable concentrations in two of 16
samples. Both treatable samples, with concentrations of 0.097
and 0.096 mg/1, were taken at the same plant. Because of the
site-specificity of this result, mercury is not selected for
further consideration for limitation.
Selenium was detected in three of 14 samples, with three
detections occurring at the same plant. All three samples
exceeded the 0.2 mg/1 treatable concentration, with
concentrations of 7.9, 10, and 15 mg/1. Because of the site-
specificity of this result, selenium is not selected for further
consideration for limitation.
1948
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
TOXIC POLLUTANTS SELECTED FOR FURTHER CONSIDERATION FOR
LIMITATIONS
The toxic pollutants listed below were selected for establishing
limitations and standards for this subcategory. The toxic
pollutants selected are each discussed following the list.
114. antimony
115. arsenic
118. cadmium
119. chromium
120. copper
122. lead
124. nickel
126. silver
127. thallium
128. zinc
Twenty of 34 samples analyzed for antimony exhibited
concentrations over the treatable concentration (0.47 mg/1).
Most of these were above 10 mg/1, with a maximum of 120 mg/1.
Antimony is thus selected for further consideration for
limitation.
Arsenic was found above its treatable concentration (0.34 mg/1)
in 22 of 33 samples analyzed. Treatable concentrations ranged
from 0.43 to 34 mg/1. Arsenic is thus selected for further
consideration for limitation.
Twenty-four of 36 samples analyzed for cadmium were found to have
concentrations in excess of the treatable concentration (0.049
mg/1). Treatable concentrations ranged from 0.24 to 103 mg/1.
Therefore, cadmium is selected for further consideration for
limitation.
Chromium was found to exceed its treatable concentration (0.07
mg/1) in 21 of 36 samples, with a maximum of 1.6 mg/1.
Therefore, chromium is selected for further consideration for
limitation.
Copper was found above its treatable concentration (0.39 mg/1) in
29 of 36 samples analyzed, with a maximum of 41.6 mg/1.
Therefore, copper is selected for further consideration for
limitation.
Lead was detected above its treatable concentration (0.08 mg/1)
in 34 of 37 samples analyzed. Treatable concentrations ranged
from 0.3 to 1,300 mg/1, with the majority above 10 mg/1. Lead is
thus selected for further consideration for limitation.
Twenty-two of 37 samples analyzed for nickel exh bited
concentrations exceeding its treatable concentration (0.22 ig/1).
Treatable concentrations ranged from 0.25 to 48 mg/1. Therefore,
nickel is selected for further consideration for limitation.
1949
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
Silver was found above its treatable concentration (0.07 mg/1) in
five of 14 samples, ranging from 0.16 to 0.34 mg/1. The
treatable concentrations were found in four different waste
streams.
Therefore, silver is selected for further consideration for
limitation.
Thallium was detected above its treatable concentration (0.34
mg/1) in five of 14 samples, ranging from 0.5 to 3.2 mg/1. The
treatable concentrations were found in four different waste
streams. Therefore, thallium is selected for further
consideration for limitation.
Zinc was found above its treatable concentration (0.23 mg/1) in
30 of 36 samples analyzed. Most of these were above 1.0 mg/1,
with a high of 48 mg/1. Zinc is thus selected for further
consideration for limitation.
1950
-------
Table VI-1
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
SECONDARY LEAD
RAW WASTEWATER
VD
U1
Pollutant
I acenaphthene
2. acroleln
3. ucrylonltrile
4. benzene
5. benzidlne
6. carbon tetrachlorlde
7. chlorobenzeiie
8. 1,2,4-trlchlorobenzene
9. hexachlorobenzene
10. 1,2-dichloroelhane
II. 1,1,1-irlchloroethajie
12. hexachloroethane
13. 1.1-dtchloroethane
14. I.1,2-trichlorouthane
13. 1,1,2.2-tetrachloroelhane
16. chloroethane
17. bls(chloroineLhyl) ether
18. bls(2-chloroethyl) ether
19. 2-chloroethyl v/inyl ether
20. 2-chloronaphthalcne
21. 2.4,6-trtchlorophfnol
22. parachlorumeta cresol
23. chloroform
24. 2-chlorophenol
25. I,2-dtchlorobenzene
26. I,3-dtchlorobenzene
27. 1,4-illclilorobenzeite
28. 3.3'-dichlorobenzidine
29. l.l-ilichloroethylene
30. I,2-trans-dtchloroethylene
31. 2.4-rllchlorophenol
32. I,2-dlchloropropane
i'J. 1,3-dlchloropropylene
34. 2.4-diroethylphenol
35. 2,4-dinltrotoluene
36. 2,6-dlnltroioluene
37. 1,2-cilphenylhydrazine
Analytical
(>iantiflcatlon
Concentration
(n«/l) (a)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
Treatable
Concentration
(HK/D (b)
0.010
0.0 10
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
o.oio
0.010
o.oio
0.010
O.OIO
0.010
O.OIO
0.010
O.OIO
O.OIO
O.OIO
O.OIO
O.OIO
Nuifcer of
Stream
Analyzed
7
5
5
5
7
5
5
7
7
5
5
7
5
5
5
5
5
7
5
7
2
2
5
2
7
7
7
7
5
5
2
5
i
2
7
7
7
Number of
Sables
Analyzed
II
0
O
13
II
13
13
II
It
13
13
II
13
13
13
13
13
II
13
11
A
A
13
A
II
II
II
II
O
O
4
O
13
4
II
II
11
Detected Bo low
Quantification
NO Concentration
II
13
13
10 3
II
13
13
II
II
13
12 1
II
13
13
1)
13
13
II
13
II
1 3
A
3 5
A
II
II
II
II
13
13
1 3
13
13
4
II
II
II
Detected Detected
Below Treat- Above Treat-
able Conceit-. able Concen-
tration t rat Ion
5
cn
M
O
§
I
f
M
t/J
c!
W
O
M
n
I
M
O
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
SECONDARY LEAD
RAW WASTEWATER
10
Ln
NJ
Pollutant
38. ethylbenzene
39. fluoranthene
40. 4-chlorophenyl phenyl ether
41. 4-bromophenyl pnenyl ether
42. bl8(2-chlorol80propyl) ether
43. bla(2-chloroethoxy) methane
44. methylene chloride
45. methyl chloride
46. methyl bromide
47. bromoform
48. dlchlorobromomethane
i9. trlchlorofluoromethane
30. dlchlorodlfluoromethane
'I. chlorodlbromomethane
'/'. hexachlorobutadlene
5 . hexachlorocyclopentadlene
5'. Isophorone
5'. naphthalene
56 nitrobenzene
57. 2-nltrophenol
58. 4-nltrophenol
59. 2.4-dlnltrophenol
60. 4.6-dlnltro-o-cresol
61. N-nltrosodlmethylaralne
62. N-riltrosodlphenylamlne
63. N-nltrosodl-n-propylamlne
64. pentachlorophenol
65. phenol
66. bls(2-ethylhexyl) phthalate
67. butyl benzyl phthalate
68. dl-n-butyl phthalate
69. dl-n-oclyl phthalate
70. dlethyl phthalate
71. dimethyl phthalate
72. benzo(a)anthracene
73. benzo(a)pyrene
74. 3,4-benzofluoranthene
75. benzo(k)fUioranthene
7f>. chrysene
Analytical
Quantification
Concentration
(i*/ 1) (a)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
o.oto
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
o.oto
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
Treatable
Concentration
(•K/D (b)
0.010
0.010
0.010
o.oto
0.010
0.010
o.oto
0.010
0.010
0.010
o.oto
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
o.oto
0.010
0.010
0.010
0.010
0.010
o.oto
0.010
0.010
0.010
0.010
0.010
Number of
Streams
Analyzed
5
7
7
7
7
5
5
5
5
5
5
5
5
5
7
7
7
7
7
2
2
2
2
7
7
7
2
2
7
7
7
7
7
7
7
7
7
7
7
Number of
Samples
Analyzed
13
II
II
II
II
13
13
13
13
13
13
13
13
13
II
II
II
II
11
4
4
4
4
II
II
II
4
4
II
II
11
II
II
II
II
II
II
II
II
NO
13
9
10
II
II
13
10
13
13
12
13
13
13
13
II
II
II
II
10
3
4
4
4
II
II
II
4
1
1
8
4
8
It
10
9
II
II
II
6
Delected
Detected Below Below Treat-
Quantification able Concen-
Coocentrat Ion trallon
1
1
3
1
1
3
5
2
S 1
1
2
J
Detected
Above Treat-
able Concen-
tration
1
1
5
1
I
2
1
2
w
o
o
w
§
1
o
w
w
o
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
SECONDARY LEAD
RAW WASTEWATER
<£>
77.
78.
79.
HI).
81.
82.
81.
8'..
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
101.
104.
105.
106.
107.
108.
109.
110.
111.
112.
111.
114.
115.
Pollutant
acLiiaphthylene
anthracene (c)
benzoC^h Operylene
fluorene
phenanthrene (c)
il i benzo(a. h)anthracene
lmlmo( 1.2, l-cd)pyrene
py rene
letrachloroethylene
toluene
trlchloroethylene
vinyl chloride
aldrln
dlehlrln
chlordaue
4.4'-DDT
4,4'-OIJE
4.4'-DI)0
alplia-erxlosulfan
beta-emlosulfan
eivlosulfan 3111 tale
eiidrin
endrln aldehyde
heptuchlor
heptachlor epoxlde
alpha-BHC
beta-BIIC
Kainna-BIIC
delta-BIIC
PCB-1242 (d)
PCB-1254
PCB-I22I
PCB-1212
PCB-1248
PCB-1260
HCB-1016
toxajihene
antImony
arsenic
(d)
(d)
(e)
(e)
(e)
(e)
Analytical
Quantification
Concentration
(TO/I) (a)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.100
, 0.10
Treatable
Concentration
0*/l) (b)
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.010
0.001
0.010
0.010
0.010
0.010
0.470
0.340
Number of
Streams
Analyzed
7
7
/
/
/
7
7
7
5
5
5
5
6
6
6
6
6
6
6
6 .
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
20
19
Number of
Samples
Analyzed
11
11
II
II
11
II
II
II
11
11
13
11
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
Vt
33
Detected Below
Quantification
NO Concentration
10
8
II
8
8
II
II
8
11
II
11
13
10
9
8
9
9
10
II
9
9
10
10
8
9
9
a
8
II
8
8
8
a
8
8
8
II
6
4
1
1
1
1
2
1
2
3
2
2
1
2
2
1
1
1
2
2
1
1
3
1
3
1
1
1
3
3
Detected Detected
Below Treat- Above Treat-
able Concen- able Concen-
tration trait on
1
2
5 20
7 22
M
n
o
Ir1
w
n
M
Q
O
M
O
I
<
-------
Table VI-1 (Continued)
FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
SECONDARY LEAD
RAW WASTEWATER
Ho U main
1 16. asbestos
117. beryl linn
118. cailmlum
119. chroinlun
120. copper
121 . cyanide
122. lead
123. mercury
124. nickel
125. selenlin
126. silver
127. lhalllun
128. zinc
(f)
129. 2,3.7,8-lelrachlorodlbenzo-
p-dloxln
(TCDD)
Analytical
(jnanllf Icallon Treatable
Concenlral lun
("K/D (a)
10 MKL
0.010
0.002
0.005
0.009
.02
0.020
0.0001
O.OOi
0.01
0.02
0.100
0.050
Not
Concentration
(BK/1) (b)
10 MFt
0.200
0.049
0.070
0.390
0.047
0.080
0.036
0.220
0.200
0.070
0.340
0.230
Analyzed
Nmtmr of
Streams
Analyzed
2
20
20
20
20
6
21
8
20
8
8
8
20
Number of
Samples
Analyzed
3
34
36
36
36
14
37
16
36
14
14
14
36
ND
3
20
8
8
1
1
2
2
11
11
1
1
1
Detected Below
Quant Ideal lun
Concentration
12
3
7
1
1
4
1
1
Delected
Below Treat-
able Concen-
tration
2
4
4
6
3
11
3
4
1
4
Uulecled
Alxve Treai-
able Concen-
tration
24
21
29
3
34 '
2
22
3
5
5
30
CO
M
O
O
2
D
f
W
CO
c;
w
o
(a) Analyllcal quanl Ideal [on concentration was reported with the data (see Section V).
t >) Treatable concent rat Ions are based on performance of line precipitation, sedimentation, and filtration for toxic metal pollutants and activated
carbon adsorption for toxic organic pollutants.
(<). (d), (e) Reported together.
(t! Analytical quantification concentration for HA Method 335.2 Total Cyanide Methods for Chemical Analysis of Water and Wastes, IPA-6UO/4-79-020,
March 1979.
CO
W
O
1-3
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
TABLE VI-2
TOXIC POLLUTANTS NEVER DETECTED
1. acenaphthene
2. acrolein
3. acrylonitrile
5. benzidene
6. carbon tetrachloride (tetrachloromethane)
7. chlorobenzene
8. 1,2,4-trichlorobenzene
9. hexachlorobenzene
10. 1,2-dichloroethane
12. hexachlorethane
13. 1,1-dichloroethane
14. 1,1,2-trichloroethane
15. 1,1,2,2-tetrachloroethane
16. chloroethane
17. DELETED
18. bis(2-chloroethyl)ether
19. 2-chloroethyl vinyl ether (mixed)
20. 2-chloronaphthalene
22. parachlorometa cresol
24. 2-chlorophenol
25. 1,2-dichlorobenzene
26. 1,3-dichlorobenzene
27. 1,4-dichlorobenzene
28. 3,3'-dichlorobenzidine
29. 1,1-dichloroethylene
30. 1,2-trans-dichloroethylene
32. 1,2-dichloropropane
33. 1,2-dichloropropylene (1,3-dichloropropene)
34. 2,4-dimethylphenol
35. 2,4-dinitrotoluene
36. 2,6-dinitrotoluene
37. If2-diphenylhydrazine
38. ethylbenzene
41. 4-bromophenyl phenyl ether
42. bis(2-chloroisopropyl)ether
43. bis(2-chloroethoxy)methane
45. methyl chloride (chloromethane)
46. methyl bromide (bromomethane)
48. dichlorobromomethane
49. DELETED
50. DELETED
51. chlorodibromomethane
52. hexachlorobutadiene
53. hexachlorocyclopentadiene
54. isophorone
55. naphthalene
1955
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
58. 4-nitrophenol
59. 2,4-dinitrophenol
60. 4,6-dinitro-o-cresol
61. N-nitrosodimethylamine
62. N-nitrosodiphenylamine
63. N-nitrosodi-n-propylamine
64. pentachlorophenol
70. diethyl phthalate
73. benzo(a)pyrene
74. 3,4-benzofluoranthene
75. benzo(k)fluoranthene
79. benzo(ghi)perylene
82. dibenzo(a,h)anthracene
83. indeno(l,2,3-cd)pyrene
85. tetrachloroethylene
87. trichloroethylene
88. vinyl chloride
95. alpha-endosulfan
105. delta-BHC
113. toxaphene
116. asbestos
129. 2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD)
1956
-------
SECONDARY LEAD SUBCATEGORY SECT - VI
TABLE VI-3
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION LIMIT
4. benzene
11. 1,1,1-trichloroethane
21. 2,4,6-trichlorophenol
31. 2,4-dichlorophenol
40. 4-chlorophenyl phenyl ether
44. methylene chloride
57. 2-nitrophenol
72. benzo(a)anthracene (1,2-benzanthracene)
78. anthracene (a)
80. fluorene
81. phenanthrene (a)
86. toluene
89. aldrin
90. dieldrin
91. chlordane
92. 4,4'-DDT
93. 4,4'-DDE
94. 4,4'-ODD
96. beta-endosulfan
97. endosulfan sulfate
98. endrin
99. endrin aldehyde
100. heptachlor
101. heptachlor epoxide
102. a-BHC-Alpha
103. b-BHC-Beta
104. r-BHC (lindane)-Gamma
106. PCB-1242 (Arochlor 1242) (b)
107. PCB-1254 (Arochlor 1254) (b)
108. PCB-1221 (Arochlor 1221) (b)
109. PCB-1232 (Arochlor 1232) (c)
110. PCB-1248 (Arochlor 1248) (c)
111. PCB-1260 (Arochlor 1260) (c)
112. PCB-1016 (Arochlor 1016) (c)
(a), (b), (c) Reported together, as a combined value
1957 '
-------
Page Intentionally Blank
-------
SECONDARY LEAD SUBCATEGORY SECT - VII
SECTION VII
CONTROL AND TREATMENT TECHNOLOGIES
The preceding sections of this supplement discussed the
wastewater sources, flows, and characteristics of the wastewaters
from secondary lead plants. This section summarizes the
description of these wastewaters and indicates the level of
treatment which is currently practiced by the secondary lead
subcategory for each waste stream.
CURRENT CONTROL AND TREATMENT PRACTICES
This section presents a summary of the control and treatment
technologies that are currently applied to each of the sources
generating wastewater in this subcategory. As discussed in
Section V, wastewater associated with the secondary lead
subcategory is characterized by the presence of the toxic metal
pollutants and suspended solids. This analysis is supported by
the raw (untreated) wastewater data presented for specific
sources as well as combined waste streams in Section V.
Generally, these pollutants are present in each of the waste
streams at concentrations above treatability, so these waste
streams are commonly combined for treatment to reduce the
concentrations of these pollutants. Construction of one
wastewater treatment system for combined treatment allows plants
to take advantage of economies of scale and, in some instances,
to combine streams of differing alkalinity to reduce treatment
chemical requirements. Twenty-four plants in this subcategory
currently have lime precipitation and sedimentation or caustic
precipitation and sedimentation treatment, and seven have lime
precipitation, sedimentation and filtration. As such, three
options have been selected for consideration for BPT, BAT, BDT,
and pretreatment in this subcategory, based on combined treatment
of these compatible waste streams.
BATTERY CRACKING
Wastewater from the battery cracking operation may result from
the following sources:
1. Waste battery electrolyte,
2. Saw or breaker cooling water, and
3. Area washdown.
The combined wastewater from these sources has the
characteristics of the battery electrolyte; pollutant
concentrations are strongly dependent on the amount of dilution
from the other water sources. In general, this wastewater is
characterized by treatable concentrations of suspended and
dissolved solids, toxic metals, and arsenic. Of the 35 plants
with battery cracking surveyed, four do not currently have any
1959
-------
SECONDARY LEAD SUBCATEGORY SECT - VII
control on this wastewater stream; they either discharge it or
use contract disposal. The majority neutralize the spent acid
using various neutralizing agents. Ammonia, lime, and caustic
are the most common chemicals used to raise the wastewater pH.
Thirty-one plants provide for settling of solids after
neutralization with sedimentation equipment (e.g., clarifiers).
Seven plants filter the treated wastewater; in two of these
plants the filtration step occurs after sedimentation, and in the
others filtration is used alone to remove suspended solids.
Several plants add polymer to enhance the settling of this
wastewater. One plant combines battery cracking wastewater with
stormwater runoff, noncontact cooling water, water softener
backflush and sanitary wastes after preliminary treatment,
consisting of neutralization with ammonia and sedimentation.
Approximately 20 percent of the combined wastewater is evaporated
in a cooling tower and recycled to the plant process. Cooling
tower blowdown is treated by ion exchange and then discharged.
This allows the plant to effectively recycle or evaporate 90
percent of its wastewater. Treated water is recycled in four of
the plants; others send it to ponds, or discharge it either
directly or to a POTW.
BLAST, REVERBERATORY, AND ROTARY FURNACE WET AIR POLLUTION
CONTROL
Air emissions from the blast, rotary, and reverberatory furnaces
contain particulate matter and sulfur oxides (SOX) which must be
removed to meet air emissions standards. Either dry or wet
methods may be used for particulate control; of the 48 plants
surveyed which have blast, rotary, or reverberatory furnaces, 41
utilize baghouses or dry scrubbers, while seven plants have wet
lime or sodium scrubbers to control sulfur oxide emissions. One
of the seven plants operates two scrubbers on two different
smelting furnaces. Furnace scrubbing solution contains treatable
concentrations of suspended solids and lead. All of the seven
plants with wet scrubbers recycle a portion of the scrubber
water; the average recycle ratio is 94 percent. Two plants
indicate they recycle 100 percent of the scrubber water. All
seven plants use an alkaline scrubbing solution to neutralize
the sulfur oxide fumes. The neutralizing agents used are lime
(two plants), ammonia (one plant), and soda ash (one plant).
Three plants also settle or filter the scrubber liquor before
recycle. Treated wastewater is discharged to a POTW in the plants
not practicing total recycle.
KETTLE WET AIR POLLUTION CONTROL
Kettles used in the refining and alloying operation may produce a
gaseous stream which may require control, primarily to reduce
particulate emissions. Of the plants surveyed, 14 do not control
kettle emissions, 18 use dry controls (baghouses), and the
remaining 10 use wet scrubbers. Kettle scrubber effluent
contains lead, arsenic, other alloying metals, and suspended
solids at treatable concentrations. Nine of the 10 plants with
wet scrubbers recycle the scrubber water; the average recycle
1960
-------
SECONDARY LEAD SUBCATEGORY SECT - VII
ratio is over 98 percent, with six plants reporting 100 percent
recycle. However, . in conversations with the Secondary Lead
Smelters Association, the Agency has learned that these six 100
percent recycling plants discharge their scrubber liquor on a
batch basis. Although these discharges were not quantified at
five of the six plants, some are as infrequent as one time per
month. These plants did not report the treatment practiced (if
any) on the batch discharge. The remaining plant utilizes the
scrubber wastewater in the battery cracking operation. Of the
two plants not using 100 percent recycle, one treats the blowdown
using sodium carbonate, sedimentation and filtration, while the
other does not treat the blowdown. Both plants discharge the
blowdown to a POTW.
LEAD PASTE DESULFURIZATION
As discussed in Section V, one plant operates a process to
convert lead sulfate paste into lead oxide using ammonium
carbonate. This process is designed for zero discharge of
wastewater, with all product streams being recycled or recovered
for sale. No wastewater treatment is needed.
CASTING CONTACT"COOLING WATER
Water may be used in the casting operation to accelerate the
cooling of the cast metal. Of the plants surveyed, only nine use
direct contact cooling. One plant uses total recycle of the
cooling water, two rely on total or partial evaporation to
eliminate the wastewater, and one of these also practices
recycle. The remaining plants discharge wastewater with no
treatment.
TRUCK WASH
Most of the 35 plants which crack batteries wash the trucks used
to haul the raw material. Only four plants report treating the
waste wash water. One plant evaporates the wastewater
completely. Another plant treats the wastewater in its central
treatment system consisting of lime, polymer addition, and
sedimentation. A third plant neutralizes the wastewater with
soda ash and settles in a concrete pit; the pit effluent is
reused for truck washing. Solids are recycled to the smelting
furnace. The fourth plant neutralizes the wastewater with
caustic and settles in a clarifier.
FACILITY WASHDOWN
Of the nine plants reporting the use of water for equipment and
floor wash to control fugitive lead emissions, eight treat the
water before reuse or discharge. The following treatment schemes
are currently practiced:
1. Neutralization with ammonia, polyelectrolyte addition,
sedimentation and reuse;
1961
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SECONDARY LEAD SUBCATEGORY SECT - VII
2. Wash water is mixed with treated sanitary waste and
discharged to a septic lagoon;
3. Neutralization with soda ash, sedimentation, and reuse;
4. Neutralization with caustic, sedimentation with a
clarifier and reuse;
5. Neutralization with caustic, sedimentation, followed by
lime and settle treatment;
6. Sedimentation, pH adjustment (chemical not specified),
sedimentation, filtration, and discharge to a
percolation pond;
7. Cooling tower followed by ion-exchange before discharge;
and
8. Sedimentation, pH adjustment (chemical not specified),
and final sedimentation followed by reuse.
BATTERY CASE CLASSIFICATION
Eight plants use water for a flotation medium during
classification of scrap battery materials. All eight plants
treat this wastewater before recycle or discharge. The following
treatment schemes are currently in place:
1. Neutralization with ammonia and sedimentation - one
plant,
2. Lime neutralization and sedimentation - two plants,
3. Neutralization with soda ash and sedimentation followed
by reuse - one plant,
4. Neutralization with caustic and sedimentation - one
plant,
5. Sedimentation, pH adjustment (chemical unspecified), and
final sedimentation followed by reuse - one plant;
6. Sedimentation, pH adjustment (chemical unspecified),
sedimentation, filtration and discharge to a percolation
pond. Reuse of water from pond - one plant; and
7. Neutralization with ammonia, polyelectrolyte addition,
and clarification followed by reuse.
WASTEWATER FROM INDUSTRIAL HYGIENE COMPLIANCE
Most secondary lead smelters are required to reduce occupational
lead exposures by laundering employee uniforms, washing employee
respirators and ensuring that employees use hand wash facilities.
Through wastewater sampling efforts after proposal, the Agency
1962
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SECONDARY LEAD SUBCATEGORY SECT - VII
determined that these wastewaters are contaminated and warrant
treatment. All plants did not report these wastewater streams
present. The Agency assumed that all plants operating smelting
furnaces would be required to comply with applicable industrial
hygiene regulations. Most plants reporting these wastewater
streams do not treat the discharge, but segregate this wastewater
from other process wastewater and discharge it to POTW. One
plant reports settling laundry water before discharge to a POTW.
Another plant neutralizes laundry water with ammonia, along with
other process water. Neutralization is followed by
sedimentation.
CONTROL AND TREATMENT OPTIONS CONSIDERED
As the sampling and analytical data in Section V indicate, the
wastewaters from the secondary lead subcategory contain various
types of contaminants. The primary constituents of concern are
dissolved metals, suspended solids, dissolved solids, and pH
extremes or fluctuations. The Agency examined three control and
treatment technology options since proposal that are applicable
to the wastewaters from the secondary lead subcategory.
OPTION A
Option A for the secondary lead subcategory requires treatment
technologies to reduce pollutant mass. The Option A treatment
scheme consists of lime and settle treatment (chemical
precipitation and sedimentation) applied to the combined streams
of battery cracking wastewater, furnace air pollution scrubbing
wastewater, casting contact cooling water, kettle air pollution
scrubbing wastewater, truck wash, facility washdown, battery case
classification wastewater, and industrial hygiene wastewater.
Treatment is followed by the complete recycle of facility
washdown and battery case classification wastewater. Preliminary
treatment with oil skimming is also required for waste streams
containing treatable concentrations of oil and grease. Chemical
precipitation is used to remove metals by the addition of lime,
followed by gravity sedimentation. Suspended solids is also
removed in the process. At proposal, this option also required
dry control methods to control air emissions from kettle refining
or alternately, 100 percent recycle of kettle scrubber liqilor.
However, data gathered through Section 308 requests indicate that
a periodic blowdown is needed, and so a discharge allowance now
is provided. Although a specific mass limitation is not provided
for oil and grease, oil skimming is needed for battery cracking,
furnace wet air pollution control, truck wash, laundry, handwash,
and respirator wash wastewater to ensure proper metals removal.
Oil and grease interferes with the chemical addition and mixing
required for chemical precipitation treatment.
1963
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SECONDARY LEAD SUBCATEGORY SECT - VII
OPTION B
Option B for the secondary lead subcategory requires control and
treatment to reduce the discharge of wastewater volume and
pollutant mass. Option B includes preliminary treatment with oil
skimming (where required)/ chemical precipitation and
sedimentation, total recycle of treated facility washdown and
battery case classification wastewater, plus wastewater flow
reduction to reduce the volume of wastewater discharged. Water
recycle and reuse are the principal control mechanisms for flow
reduction.
OPTION C
Option C for the secondary lead subcategory consists of Option B,
(in-process flow reduction, oil skimming (where required), lime
precipitation, sedimentation, and total recycle of treated
facility washdown and battery case classification wastewater)
with the addition of multimedia filtration at the end of Option
B treatment. Multimedia filtration is used to remove suspended
solids, including precipitated metals, below the concentration
attainable by gravity sedimentation. The filter suggested is of
the gravity, mixed-media type, although other forms of filters
such as rapid sand filters or pressure filters would perform
satisfactorily. The addition of filters also provides for
consistent removal during periods when there are rapid increases
in flows or loadings of pollutants to the treatment system.
CONTROL AND TREATMENT OPTIONS REJECTED
Two additional treatment technologies were considered prior to
proposing effluent limitations for this subcategory as discussed
below. Activated alumina and reverse osmosis were rejected
because they were not demonstrated in the nonferrous metals
manufacturing category nor were they readily transferable from
other categories.
None of the toxic organic pollutants were selected for further
consideration in establishing limitations for the secondary lead
subcategory. Therefore, Option E, which includes activated
carbon adsorption for organic removal, was not applicable to this
subcategory.
OPTION D
Option D for the secondary lead subcategory consists of Option C,
(in-process flow reduction, lime precipitation, sedimentation,
multimedia filtration) with the addition of activated alumina
technology at the end of Option C treatment. The activated
alumina process is used to remove dissolved arsenic which remains
after lime precipitation.
1964
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SECONDARY LEAD SUBCATEGORY SECT - VII
OPTION F
Option F for the secondary lead subcategory consists of Option C,
(in-process flow reduction, lime precipitation, sedimentation,
multimedia filtration) with the addition of reverse osmosis and
multiple-effect evaporation technology at the end of Option C
treatment. Option F is used for complete recycle of the treated
water by controlling the concentration of dissolved solids.
Multiple-effect evaporation is used to dewater brines rejected
from reverse osmosis.
1965
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SECONDARY LEAD SUBCATEGORY SECT - VIII
SECTION VIII
COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
This section describes the method used to develop the costs
associated with the control and treatment technologies discussed
in Section VII for wastewaters from secondary lead plants. The
energy requirements of the considered options as well as solid
waste and air pollution aspects are also discussed in this
section.
TREATMENT OPTIONS COSTED FOR EXISTING SOURCES
As discussed in Section VII, three control and treatment options
are considered for treating wastewater from the secondary lead
subcategory. Cost estimates have been developed for each of
these control and treatment options. The control and treatment
options are presented schematically in Figures X-l through X-3
(pages 2009 - 2011), and summarized below.
OPTION A
Option A for the secondary lead subcategory consists of
preliminary treatment with oil skimming (where required), lime
precipitation and sedimentation end-of-pipe technology. Total
recycle of facility washdown and battery case classification
wastewater is also required for Option A.
OPTION B
Option B for the secondary lead subcategory requires control and
treatment technologies to reduce the discharge of wastewater
volume and pollutant mass. The recycle of casting contact
cooling water through cooling towers and the recycle of wet air
pollution control water through holding tanks are the control
mechanisms for flow reduction. The Option B end-of-pipe
treatment technology consists of preliminary treatment with oil
skimming (where required), plus lime precipitation and
sedimentation with total recycle of facility washdown and battery
case classification wastewater.
OPTION C
Option C for the secondary lead subcategory consists of all the
control and treatment technologies of Option B (in-process flow
reduction through cooling towers and holding tanks; lime
precipitation and sedimentation and total recycle of facility
washdown, and battery case classification wastewater end-of-
pipe treatment, and preliminary treatment with oil skimming
(where required)) with the addition of multimedia filtration to
the end-of-pipe treatment scheme.
1967
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SECONDARY LEAD SUBCATEGORY SECT - VIII
COST METHODOLOGY
A detailed discussion of the methodology used to develop the
compliance costs is presented in Section VIII of the General
Development Document. Plant-by-plant compliance costs have been
estimated for the nonferrous metals manufacturing category and
are presented in the administrative record supporting this
regulation. A comparison of the proposal and the revised costs
for the final regulation are presented in Tables VIII-1 and VIII-
2 (page!973) for the direct and indirect dischargers,
respectively.
Each of the major assumptions used to develop compliance costs
are presented in Section VIII of Vol. 1. Each subcategory
contains a unique set of waste streams requiring certain
subcategory-specific assumptions to develop compliance costs.
Seven major assumptions are discussed briefly below.
(1) For plants having existing treatment of insufficient
capacity, the required capital costs are based on
providing the incremental capacity needed and annual
costs are based on operation of a single system at the
expanded capacity.
(2) Information available to the Agency is not detailed
enough to determine if all industrial hygiene waste
streams, truck wash, and floor wash, are present at
each plant. Therefore, where EPA had no information
on these wastewater sources, the Agency assumed all of
these are present at the regulatory flow rate.
Although a discharge allowance for floor wash is not
necessary, EPA included extra treatment capacity to
accommodate this need. Acceptable floor wash water may
be obtained from recycling treated wastewater.
Therefore, costs are included for a holding tank after
chemical precipitation and settling to recycle water
for floor wash use under all options.
(3) Lime addition is used in most cases throughout the
secondary lead subcategory in estimating costs for
chemical precipitation. However, if a plant currently
uses ammonia, soda ash, or caustic as the chemical
precipitant, the costs are based on caustic addition.
(4) Annual costs for contract hauling are not included when
sludge from existing treatment is recycled either to a
smelter or back to a process. If a plant has a lagoon
for sedimentation and sludge storage, the investment
costs for sedimentation and vacuum filtration are not
included since these technologies would probably not be
installed to comply with the effluent limitations.
However, operation and maintenance costs for these
technologies (and contract hauling) were included as an
estimate of the cost likely to be incurred by the plant
to ultimately dispose of the sludge. All sludges
1968
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SECONDARY LEAD SUBCATEGORY SECT - VIII
produced through wastewater treatment are considered to
be nonhazardous in estimating costs. However, the
EPA cost for solid waste disposal is equivalent to
hazardous waste disposal. In addition, the Agency
performed a sensitivity analysis in which sludge
disposal costs were doubled without an increase in
plant closures.
(5) Compliance costs for three plants that are integrated
with battery manufacturing operations are estimated
only for multimedia filtration of the amount of waste
water associated with secondary lead operations. Costs
were developed for a treatment configuration assuming
filtration of an amount of wastewater equal to the
secondary lead subcategory flow, following centralized
lime and settle treatment of combined flows. At two
plants the secondary lead flow consists only of
wastewater from industrial hygiene practices. The
third plant produces battery cracking, furnace
scrubber, and kettle scrubber wastewater but
at rates lower than the BPT regulatory
discharge flows (see Section IX). The Agency adopted
this method of costing because the plants are battery
manufacturing plants, and the wastewater from the
manufacturing operations is very large in comparison to
the secondary lead wastewater flow. Therefore, all
other compliance costs are attributed to the battery
manufacturing regulation.
(6) The costs of holding tanks to achieve recycle of
furnace scrubber liquor and kettle scrubber liquor were
not included in compliance costs since the holding
tanks are an integral part of the air pollution control
system and are not the basis of wastewater treatment.
All 17 plants operating furnace or kettle scrubbers
practice recycle exceeding 83 percent.
(7) Recycle of casting contact cooling water is based on
recycle through cooling towers. Annual costs associated
with maintenance and chemicals to prevent biological
growth, corrosion, and scale formation are included
in the estimated compliance costs. If a plant
currently recycles casting contact cooling water,
capital costs of the recycled equipment (piping, pumps,
and cooling towers) were not included in the
compliance costs.
NONWATER QUALITY ASPECTS
Nonwater quality impacts specific to the secondary lead
subcategory including energy requirements, solid waste and air
pollution are discussed below.
1969
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SECONDARY LEAD SUBCATEGORY SECT - VIII
ENERGY REQUIREMENTS
The methodology used for determining the energy requirements for
the various options is discussed in Section VIII of Vol. 1.
Energy requirements for the three options considered are
estimated at 5.17 MW-hr/yr, 5.23 MW-hr/yr, and 5.42 MW-hr/yr for
Options A, B, and C respectively. Option C represents roughly
two percent of a typical plant's electrical usage. It is
therefore concluded that the energy requirements of the treatment
options considered will have no significant impact on total plant
energy consumption. Option C would increase energy
requirements over Option A by approximately 4.8 percent.
SOLID WASTE
Sludges associated with the secondary lead subcategory will
necessarily contain additional quantities (and concentrations) of
toxic metal pollutants.
Wastes generated by secondary metal industries can be regulated
as hazardous. However, the Agency examined the solid wastes that
would be generated at secondary lead plants by the suggested
treatment technologies and believes they are not hazardous wastes
under the Agency's regulations implementing Section 3001 of the
Resource Conservation and Recovery Act. None of these wastes are
listed specifically as hazardous, nor are they likely to exhibit
a characteristic of hazardous waste. This judgment is made based
on the recommended technology of lime precipitation,
sedimentation and filtration. By the addition of excess lime (5-
10 percent) during treatment, similar sludges, specifically toxic
metal bearing sludges, generated by other industries such as the
iron and steel industry passed the Extraction Procedure (EP)
toxicity test. See 40 CFR 261.24. The Agency believes that the
wastewater sludges will similarly not be EP toxic if the
recommended technology is applied.
The Agency received several comments from the secondary lead
subcategory claiming sludges generated through the use of lime as
a wastewater treatment chemical were hazardous due to lead. To
properly evaluate these comments, the Agency requested specific
data and information from the commenters. From the material
received, it appears lime sludges at two secondary lead and
battery manufacturing plants sometimes exhibit toxicity due to
lead (six of the 19 samples exhibited EP toxicity in the data
submitted). The Agency contends these sludges would not have
been classified as hazardous under RCRA if a small amount (5-10
percent) of excess lime had been used during wastewater
treatment. (The Agency's trip reports for these facilities
indicate that the facilities do not use excess lime to treat
wastewater). A third plant (operated by one of the two
companies), which tests its lime sludges on a batch-by-batch
basis, indicated that it disposed of its wastewater treatment
sludges as a hazardous material less than two percent of the time
(over a two year period), indicating that operation of the
treatment system affects sludge quality.
1970
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SECONDARY LEAD SUBCATEGORY SECT - VIII
It is also the Agency's understanding, based on comments, that
one of the facilities disposing of lime sludges as a hazardous
waste has entered into an agreement with a local landfill at
preferential rates. The Agency contends that if this plant did
not have a local disposal site to dispose of its lime sludge as
hazardous, it could operate its treatment system using excess
lime, which would make the sludges nonhazardous.
The Agency has recalculated the compliance costs for the
secondary lead subcategory on a plant-by-plant basis. In the
cost model, a contract hauling fee of $90 per ton (as
nonhazardous waste) was used in estimating annual costs. The
Agency solicited data on sludge disposal costs and only received
information from one corporation. Data submitted by the
commenter show the contract hauling costs when sludges are
disposed of as hazardous wastes ranging from $90 to $110 per ton.
This would indicate that the Agency's sludge disposal costs are
conservative when lime sludges are disposed of as nonhazardous
wastes. In addition, the Agency doubled the contract hauling
costs for secondary lead sludge from $90 per ton to $180 per ton
and found no economic impacts for this subcategory.
The Agency also received comments stating it had not accounted
for additional costs of sludge disposal in states where hazardous
waste disposal is more stringent than the federal requirements.
The Agency is not aware of any state regulations more stringent
than the federal EP toxicity test, except for the state of
California. However, California only requires additional
paperwork for wastes that fail their procedure but pass the
federal EP toxicity test, and does not impose additional disposal
costs or requirements.
Although it is the Agency's view that solid wastes generated as a
result of these guidelines are not expected to be hazardous,
generators of these wastes must test the waste to determine if
the wastes meet any of the characteristics of hazardous waste
(see 40 CFR 262.11).
If these wastes should be identified or are listed as hazardous,
they will come within the scope of RCRA's "cradle to grave"
hazardous waste management program, requiring regulation from the
point of generation to point of final disposition. EPA's
generator standards would require generators of hazardous
nonferrous metals manufacturing wastes to meet containerization,
labeling, recordkeeping, and reporting requirements; if plants
dispose of hazardous wastes off-site, they would have to prepare
a manifest which would track the movement of the wastes from the
generator's premises to a permitted off-site treatment, storage,
or disposal facility. See 40 CFR 262.20 45 FR 33142 (May 19,
1980), as amended at 45 FR 86973 (December 31, 1980). The
transporter regulations require transporters of hazardous
wastes to comply with the manifest system to assure that the
wastes are delivered to a permitted facility. See 40 CFR 263.20
45 FR 33151 (May 19, 1980), as amended at 45 FR 86973 (December
1971
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SECONDARY LEAD SUBCATEGORY SECT - VIII
31, 1980). Finally, RCRA Regulations establish standards for
hazardous waste treatment, storage, and disposal facilities
allowed to receive such wastes. See 40 CFR Part 464 46 FR 2802
(January 12, 1981), 47 FR 32274 (July 26, 1982).
Even if these wastes are not identified as hazardous, they still
must be disposed of in compliance with the Subtitle D open
dumping standards, implementing 4004 of RCRA. See 44 FR 53438
(September 13, 1979). The Agency has calculated as part of the
costs for wastewater treatment the cost of hauling and disposing
of these wastes. EPA estimates that implementation of lime,
settle, and filter technology will produce approximately 5,100
tons of sludge per year at 20 percent solids. Multimedia
filtration technology will not result in any significant amount
of sludge over that generated by lime precipitation.
AIR POLLUTION
There is no reason to believe that any substantial air pollution
problems will result from implementation of chemical
precipitation, sedimentation, and multimedia filtration. These
technologies transfer pollutants to solid waste and do not
involve air stripping or any other physical process likely to
transfer pollutants to air. Water vapor containing some
particulate matter will be released in the drift from cooling
tower systems; however, the Agency does not consider this impact
to be significant.
1972
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SECONDARY LEAD SUBCATEGORY
SECT - VIII
TABLE VIII-1
COST OF COMPLIANCE FOR THE SECONDARY LEAD SUBCATEGORY
DIRECT DISCHARGERS
(March, 1982 Dollars)
Proposal Costs
Promulgation Costs
Option
A
B
C
Capital
639000
639000
2880000
Annual
310000
310000
1850000
Capital
1630000
1630000
1860000
Annual
1120000
1120000
1240000
TABLE VII1-2
COST OF COMPLIANCE FOR THE SECONDARY LEAD SUBCATEGORY
INDIRECT DISCHARGERS
(March, 1982 Dollars)
Proposal Costs
Promulgation Costs
Option
A
B
C
Capital
1660000
2020000
4130000
Annual
758000
760000
2640000
Capital
3690000
3720000
4260000
Annual
2240000
2240000
2510000
1973
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SECONDARY LEAD SUBCATEGORY SECT - IX
SECTION IX
BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
This section defines the effluent characteristics attainable
through the application of best practicable control technology
currently available (BPT), Section 301(b)(a)(A). BPT reflects
the existing performance by plants of various sizes, ages, and
manufacturing processes within the secondary lead subcategory, as
well as the established performance of the recommended BPT
systems. Particular consideration is given to the treatment
already in place at plants within the data base.
The factors considered in identifying BPT include the total cost
of applying the technology in relation to the effluent reduction
benefits from such application, the age of equipment and
facilities involved, the manufacturing processes used, nonwater
quality environmental impacts (including energy requirements),
and other factors the Administrator considers appropriate. In
general, the BPT level represents the average of the existing
performances of plants of various ages, sizes, processes, or
other common characteristics. Where existing performance is
uniformly inadequate, BPT may be transferred from a different
subcategory or category. Limitations based on transfer of
technology are supported by a rationale concluding that the
technology is, indeed, transfer able, and a reasonable prediction
that it will be capable of achieving the prescribed effluent
limits (see Tanner's Council of America v. Train, 540 F.2d 1188
(4th Cir. 1176). BPT focuses on end-of-pipe treatment rather than
process changes or internal controls, except where such practices
are common subcategory practice.
TECHNICAL APPROACH TO BPT
The Agency studied the nonferrous metals manufacturing category
to identify the processes used, the wastewaters generated, and
the treatment processes installed. Information was collected
from industry using data collection portfolios, and specific
plants were sampled and the wastewaters analyzed. Additional
data used in the final rule were obtained through comments, new
dcp, and specific data requests. Some of the factors which must
be considered in establishing effluent limitations based on BPT
have already been discussed. The age of equipment and
facilities, processes used, and raw materials were taken into
account in subcategorization and subdivision and are discussed
fully in Section IV. Nonwater quality impacts and energy
requirements are considered in Section VIII.
As explained in Section IV, the secondary lead subcategory has
been segmented into 11 building blocks each of which is a
potential wastewater sources. Since the water use, discharge
rates, and pollutant characteristics of each of these wastewaters
1975
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SECONDARY LEAD SUBCATEGORY SECT - IX
is potentially unique, effluent limitations will be developed for
each of the 11 building blocks.
For each of the segments, a specific approach was followed for
the development of BPT mass limitations. To account for
production and flow variability from plant to plant, a unit of
production or production normalizing parameter (PNP) was
determined for each waste stream which could then be related to
the flow from the process to determine a production normalized
flow. Selection of the PNP for each process element is discussed
in Section IV. Each process within the subcategory was then
analyzed to determine (1) whether or not operations included
generated wastewater, (2) specific flow rates generated, and (3)
the specific production normalized flows for each process. This
analysis is discussed in detail in Section V. Nonprocess
wastewater such as rainfall runoff and noncontact cooling water
is not considered in the analysis.
Normalized flows were analyzed to determine which flow was to be
used as part of the basis for BPT mass limitations. The selected
flow (sometimes referred to as a BPT regulatory flow or BPT
discharge rate) reflects the water use controls which are common
practices within the subcategory. The BPT normalized flow is
based on the average of all applicable data. Plants with
normalized flows above the average may have to implement some
method of flow reduction to achieve the BPT limitations. In most
cases, this will involve improving housekeeping practices,
better maintenance to limit water leakage, or reducing excess
flow by turning down a flow valve. It is not believed that these
modifications would incur any costs for the plants.
For the development of effluent limitations, mass limitations
were calculated for each wastewater source or subdivision. This
calculation was made on a stream-by-stream basis, primarily
because plants in this category may perform one or more of the
operations in various combinations. The mass limitations
(milligrams of pollutant per kilogram of production unit
mg/kg) were calculated by multiplying the BPT normalized flow
(1/kkg) by the concentration achievable using the BPT treatment
system (mg/1) for each pollutant parameter to be limited under
BPT.
The mass limitations which are allowed under BPT for each plant
will be the sum of the individual mass loadings for the various
wastewater sources which are found at particular plants.
Accordingly, all the wastewater generated within a plant may be
combined for treatment in a single or common treatment system,
but the effluent limitations for these combined wastewaters are
based on the various wastewater sources which actually contribute
to the combined flow. This method accounts for the variety of
combinations of wastewater sources and production processes which
may be found at secondary lead plants.
The Agency usually establishes wastewater limitations in terms of
mass rather than concentration. This approach prevents the use
1976
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SECONDARY LEAD SUBCATEGORY SECT - IX
of dilution as a treatment method (except for controlling pH).
The production normalized wastewater flow (1/kkg) is a link
between the production operations and the effluent limitations.
The pollutant discharge attributable to each operation can be
calculated from the normalized flow and effluent concentration
achievable by the treatment technology and summed to derive an
appropriate limitation for each subcategory.
BPT effluent limitations are based on the average of the
wastewater discharge flows for each building block combined with
the commonly used treatment methods in the subcategory. Section
VII discusses the various treatment technologies which are
currently in place for each wastewater source. In most cases, the
current treatment levels consist of chemical precipitation and
sedimentation (lime and settle technology) and a combination of
reuse and recycle to reduce flow.
The overall effectiveness of end-of-pipe treatment for the
removal of wastewater pollutants is improved by the application
of water flow controls within the process to limit the volume of
wastewater requiring treatment. The controls or in-process
technologies recommended under BPT include only those measures
which are commonly practiced within the subcategory and which
reduce flows to meet the production normalized flow for each
operation.
In making technical assessments of data, reviewing manufacturing
processes, and assessing wastewater treatment technology options,
both indirect and direct dischargers have been considered as a
single group. An examination of plants and processes did not
indicate any process differences based on the type of discharge,
whether it be direct or indirect.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
In balancing costs in relation to pollutant removal estimates,
EPA considers the volume and nature of existing discharges, the
volume and nature of discharges expected after application of
BPT, the general environmental effects of the pollutants, and the
cost and economic impacts of the required pollution control
level. The Act does not require or permit consideration of water
quality problems attributable to particular point sources or
industries, or water quality improvements in particular water
quality bodies. Accordingly, water quality considerations were
not the basis for selecting BPT. See Weyerhaeuser Company v.
Costle, 590 F.2d 1011 (D.C. Cir. 1978).
The methodology for calculating pollutant removal estimates and
plant compliance costs is discussed in.Section X. Table X-2
(page 2002) shows the estimated pollutant removals for each
treatment option for direct dischargers. Compliance costs for
direct dischargers are presented in Table VIII-1 (page 1973).
1977
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SECONDARY LEAD SUBCATEGORY SECT - IX
BPT OPTION SELECTION
The BPT treatment scheme (Figure IX-1 page 1992) consists of
complete recycle of facility washdown and battery case
classification wastewater following chemical precipitation and
sedimentation (lime and settle) end-of-pipe technology. Although
a specific mass limitation is not provided for oil and grease,
oil skimming is included in EPA cost estimates for battery
cracking, furnace wet air pollution control, truck wash, laundry,
hand wash, and respirator wash wastewater to ensure proper metals
removal. Oil and grease interferes with the chemical addition
and mixing required for chemical precipitation treatment. The
BPT treatment is equivalent to Option A described in Section VII.
The promulgated technology is equivalent to the proposed
technology with the addition of oil skimming and the omission of
complete recycle of kettle scrubbing wastewater. The promulgated
BPT will result in the removal of approximately 25,354 kg/yr of
toxic metal pollutants and 2,852,000 kg/yr of conventional
pollutants from the estimated raw discharge. The estimated
capital cost of BPT is $1,630,000 (March, 1982 dollars) and the
estimated annual cost is $1,120,000 (March, 1982 dollars).
In the proposed limitations, ammonia was given a discharge
allowance of zero to prevent the discharge of kettle scrubber
liquor. Data gathered through special requests have shown those
plants previously thought to be recycling kettle scrubber liquor
100 percent do actually have a periodic discharge. EPA is
promulgating a discharge allowance of zero for ammonia for
secondary lead plants. Ammonia in secondary lead wastewaters is
the result of its use as a wastewater treatment chemical.
Effluent data from a secondary lead plant were found to have
ammonia in its treated effluent at an average concentration of
6,500 mg/1. It is the Agency's understanding that ammonia is
used because it reduces the amount of sludge generated and
produces a sludge more amenable for reuse as a raw material than
lime sludges. However, the use of caustic as a wastewater
treatment chemical is also widely demonstrated in the secondary
lead subcategory. Caustic is as applicable as ammonia for
reducing sludge generation and producing sludges that can be
recycled. In developing plant-by-plant costs, the Agency
provided costs for substituting neutralization with caustic for
neutralization with lime or ammonia. This will eliminate the
discharge of ammonia and still produce a sludge acceptable for
recycling. However, if a plant chooses to continue using ammonia
as a treatment chemical, it will have to maintain zero discharge
of ammonia.
WASTEWATER DISCHARGE RATES
A BPT discharge rate is calculated for each subdivision based on
the average of the flows of the existing plants, as determined
from analysis of the dcp. The discharge rate is used with the
achievable treatment concentrations to determine BPT effluent
limitations. Since the discharge rate may be different for each
wastewater source, separate production normalized discharge rates
1978
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
for each of the 11 wastewater sources are discussed below and
summarized in Table IX-1 (page 1985). The discharge rates
generally are normalized on a production basis by relating the
amount of wastewater generated to the mass of the intermediate
product which is produced by the process associated with the
waste stream in question. These production normalizing
parameters, or PNP's, are also listed in Table IX-1.
In light of the comments received on the flow allowances
used in the 1983 proposal, the Agency reviewed existing flow and
production information from data collection portfolios and
solicited additional information through specific data requests.
The Agency also performed engineering site visits at two
integrated secondary lead and battery manufacturing plants.
These additional data have been used by the Agency to develop
flow allowances for five waste streams not considered at
proposal. Three of these wastewater streams — hand wash,
respirator wash, and laundries — result from occupational
hygiene needs. Flow allowances have also been developed for
truck washing. The Agency also considered whether to provide
allowances for three other streams, facility washdown, lead paste
desulfurization, and battery case classification, but determined
that no allowance required because treated effluent can be used
as makeup water or because complete recycle and reuse is
practiced. Flow allowances for each of the 11 wastewater streams
identified in the secondary lead subcategory are discussed below.
BATTERY CRACKING
The BPT wastewater discharge rate used at proposal for battery
cracking was 940 1/kkg (225 gal/ton) of lead produced. All 32 of
the plants with this process discharged this wastewater at rates
ranging from 80.5 to 5,086 1/kkg (19.3 to 1,220 gal/ton). None
of the plants practiced recycle of this wastewater, therefore the
BPT rate was the average discharge rate of 32 plants.
The BPT wastewater discharge rate for battery cracking is 673
1/kkg (161 gal/ton) of lead scrap produced. This rate is based
on the average of the discharge flows from 30 plants with this
process. Water use and discharge rates are presented in Table V-
1. The promulgated BPT allowance is different from the proposed
BPT allowance because two plants included in the calculation of
the allowance at proposal were deleted from the average at
promulgation. Plants 266 and 272 were excluded from the average
because of excessive water use compared to the other 30 plants.
The Agency believes there is no technical justification for such
high water usage. Data from five plants which submitted new dcps
subsequent to proposal further support the promulgated BPT
allowance. Inclusion of the new data in the calculation of the
regulatory flow allowance could have resulted in a difference of
less than four percent from the promulgated allowance (673
1/kkg). The Agency received no comments requesting
differentiation in flow allowances based on battery breaking
methods.
1979
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
Since the new data support the promulgated flow allowance, the
new data were not included in the regulatory flow calculation.
Twenty of the 35 plants with this wastewater stream meet the BPT
discharge rate.
BLAST, REVERBERATORY, OR ROTARY FURNACE WET AIR POLLUTION CONTROL
The BPT regulatory wastewater discharge rate for blast and
reverberatory furnace wet air pollution control was 3,380 1/kkg
(811 gal/ton) of lead produced. This rate was allocated only for
those plants having wet air pollution control for smelting
operations. Of the 47 plants with this process, seven used wet
air scrubbing devices. One of the seven plants did not report
sufficient production data to calculate a discharge rate but
reported a recycle rate of 97.8 percent. One plant discharged
with no recycle. Two plants practiced partial recycle, ranging
from 83.3 to 93.3 percent. (One plant operates two separate
scrubbers on different smelting furnaces.) Two of the seven
plants achieved zero discharge by 100 percent recycle. Extensive
recycling is possible for this wastewater stream, but a zero
discharge may not be technically feasible unless a recycle
system controls dissolved solids build-up, the wastewater is
evaporated, or there is a production operation that can accept
the quality of treated wastewater. Some of these zero discharge
possibilities are site-specific and, therefore, are not
applicable to the secondary lead subcategory as a whole. The
discharge rates from the four discharging scrubbers ranged from
1,776 to 6,587 1/kkg (426 to 1,580 gal/ton). The average of
these four discharges was the basis for the BPT rate. Wastewater
rates for blast and reverberatory furnace wet air pollution
control are presented in Table V-3 of the proposed secondary lead
supplemental development document.
The BPT regulatory wastewater discharge rate for furnace wet air
pollution control is 2,610 1/kkg (626 gal/ton) of lead produced
from smelting. This rate is based on 90 percent recycle of the
average water use for three scrubbers at Plants 265 and 272.
(One plant operates separate scrubbers on two smelting furnaces).
The actual recycle rates of the three scrubbers range from 83.3
to 93.3 percent. Recycle exceeding 83 percent is demonstrated
for all eight furnace scrubbers currently operated in the
subcategory. Water use and discharge rates are presented in
Table V-3 (page 1889). The final BPT regulatory discharge
allowance differs from the proposed BPT discharge allowance. As
discussed above, the proposed allowance was based on the average
wastewater discharge from four scrubbers at three plants. One of
these plants did not practice recycle and has since shut down its
scrubber. This plant (#266) was not included in the calculation
of the promulgated discharge allowance because no recycle was
practiced at this plant and the allowance is based on widely
demonstrated recycle. Data from new dcps received subsequent to
proposal were also excluded from calculation of the discharge
allowance. One plant reports recycling 99.8 percent of its
scrubber water but does not provide sufficient information to
1980
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
calculate production normalized water use. A second plant
(#6602), which practices 95 percent recycle, was excluded from
the calculation of the discharge allowance because of excessive
water use. The water use at this plant is almost four times that
of the highest water user included in the calculation. The
Agency believes there is no technical justification for such high
water use. All seven plants operating furnace scrubbers use
alkaline scrubber solutions to neutralize the sulfur oxides (SOX)
removed from the furnace off-gases. Neutralizing agents used are
lime, caustic, soda ash, and ammonia. The Agency received no
comments requesting differentiation in flow allowances based on
type of scrubber solution. Three of the five plants reporting
sufficient information to calculate discharge rates meet the
promulgated BPT discharge rate.
KETTLE WET AIR POLLUTION CONTROL
No BPT regulatory wastewater discharge allowance was provided for
kettle scrubbing wastewater at proposal. Twenty-eight plants
reported controlling kettle air emissions; 19 used dry
controls (baghouses), and nine used scrubbers. Six plants
reported practicing complete recycle of the scrubber liquor and
one plant used the liquor in the battery cracking and decasing
operation. The remaining two plants practiced recycle of 91.7
and 96 percent. Since complete recycle of kettle scrubber
wastewater was so widely demonstrated in this subcategory, the
Agency believed that zero discharge of wastewater pollutants was
feasible for all secondary lead kettle wet air pollution control.
The BPT regulatory wastewater discharge allowance is 45 1/kkg (11
gal/ton) of lead produced from refining. Data gathered through
specific data requests after proposal have shown those plants
previously thought to practice 100 percent recycle of kettle
scrubber liquor actually have a periodic discharge. As shown in
Table V-5 (page 1894), only three plants reported sufficient
information to calculate production normalized discharge rates.
The BPT regulatory discharge rate is based on the discharge from
Plant 224, which practices 99.2 percent recycle if the periodic
discharge is normalized on a continuous basis. Plants 264 and
273 were excluded because of excessively high discharge rates
compared to Plant 224. The discharge rate for Plants 264 and 273
are approximately two times and 40 times higher, respectively,
than the discharge rate for Plant 224. The Agency can find no
technical reason for such variation in discharge practices at
these plants.
LEAD PASTE DESULFURIZATION
No BPT wastewater discharge allowance is provided for lead paste
desulfurization. Only one plant currently operates this process
and no wastewater is discharged.
1981
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
CASTING CONTACT COOLING WATER
The BPT wastewater discharge rate used at proposal for casting
contact cooling water was 221 1/kkg (53.1 gal/ton) of lead cast.
At proposal, 11 of the 66 secondary lead plants with casting
operations, generated wastewater from the process. Three plants
practiced total recycle and two plants reported discharging
"insignificant" amounts of wastewater. Six plants were once-
through dischargers, with flow rates ranging from 5 to 963 1/kkg
(1 to 231 gal/ton). Wastewater rates for casting contact cooling
are presented in Table V-7 (page 1896). The BPT discharge rate
was based on the average of the six discharging plants.
The BPT regulatory discharge allowance for casting contact
cooling is 221 1/kkg (53.1 gal/ton) of lead cast. This is
equivalent to the proposed flow allowance. The Agency received
no new flow data for casting contact cooling and thus sees no
reason to change the proposed allowance.
TRUCK WASH
The BPT regulatory wastewater discharge rate for truck wash is 21
1/kkg (5 gal/ton) of lead produced from smelting. This allowance
includes wastewater discharge from washing pallets on which scrap
batteries are transported. Although many plants which crack
batteries generate wastewater from truck and pallet washing, the
Agency measured flow data from only two plants. However, there
is no reason to think that truck and pallet washing varies
appreciably from plant to plant. Truck wash flows were
calculated by measuring the water flow rate from hoses used for
washing and the time required to wash a truck. The pallet
washing flow was calculated by multiplying the average number of
pallets per truck by the average flow rate from the hoses used to
wash the trucks and an assumed time needed to wash one pallet.
The number of pallets contained in a truck was calculated from
average truck dimensions and was determined to be 20. The
washing of one pallet was assumed to take 10 seconds. The pallet
flow was calculated as 125 liters (33 gallons) per truck. Truck
wash at two facilities was measured at 151 liters (40 gallons)
and 125 liters (33 gallons) per truck. The production normalized
flow rates for combined truck and pallet wash are presented in
Table V-8 (page 1896). The BPT regulatory flow rate is the
average production normalized discharge at the two plants with
the addition of pallet washing.
FACILITY WASHDOWN
No BPT wastewater discharge allowance is provided for facility
washdown. The Agency believes this wastewater can be treated and
reused as wash water. Recycle or reuse of this wastewater after
treatment is currently demonstrated in four of the nine plants
reporting this wastewater. Compliance costs include the larger
size treatment equipment needed to accommodate this wastewater
stream.
1982
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
BATTERY CASE CLASSIFICATION
No BPT wastewater discharge allowance is provided for battery
case classification wastewater. The Agency believes this
wastewater can be treated and reused in this process based on
demonstrated practices. Four of the eight plants with this
wastewater stream currently reuse battery case classification
wastewater after treatment. Compliance costs include the larger
size treatment equipment needed to accommodate this waste stream.
EMPLOYEE HAND WASH
The BPT regulatory wastewater discharge allowance for employee
hand wash is 27 1/kkg (6.5 gal/ton) of lead produced from
smelting. This allowance is needed for plants to meet industrial
hygiene requirements. Since flow data were not available for all
but two plants in the subcategory, the discharge allowance was
determined in the following manner. Available production data
and number of employees at each plant (taken from the dcp) were
used to calculate a factor of 0.0217 employees per year per ton
of smelting production. From sampling efforts at two integrated
secondary lead battery manufacturing plants, it was determined
that the average employee uses 1,132.5 liters (300 gallons) per
year of water for hand wash (based on three washes per day, 250
days per year). This results in the production normalized flow
of 27 1/kkg (6.5 gal/ton).
EMPLOYEE RESPIRATOR WASH
The BPT wastewater discharge allowance for employee respirator
wash is 44 1/kkg (10.5 gal/ton) of lead produced from smelting.
This allowance is needed for plants to meet industrial hygiene
requirements. This allowance was determined with the same method
used for employee hand wash. The production factor of 0.0217
employees per year per ton of production was multiplied by the
average water use per employee at two plants (1,836 liters or 485
gallons per year).
LAUNDERING OF UNIFORMS
•
The BPT regulatory wastewater discharge allowance for laundering
of uniforms is 128 1/kkg (30.7 gal/ton) of lead produced from
smelting. This allowance is needed for plants to meet industrial
hygiene requirements. The methodology used to determine this
rate is the same as employee handwash. From the sampling effort,
it was found that the average water use per employee is 5,356
liters (1,415 gallon) per year. The production factor is 0.0217
employees per year per ton of production. This results in the
allowance of 129 1/kkg (30.7 gal/ton). This allowance is only
intended for those plants that launder uniforms on-site.
REGULATED POLLUTANT PARAMETERS
The raw wastewater concentrations from individual operations and
the subcategory as a whole were examined to select certain
1983
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
pollutants and pollutant parameters for consideration for
limitation. This examination and evaluation was presented in
Section VI. A total of seven pollutants or pollutant parameters
are selected for limitation under BPT and are listed below:
114. antimony
115. arsenic
122. lead
128. zinc
ammonia
total suspended solids (TSS)
pH
EFFLUENT LIMITATIONS
The treatable concentrations achievable by the proposed BPT
treatment scheme are explained in Section VII of Vol. 1 and
summarized there in Table VII-21 (page 248). The treatable
concentrations (both one day maximum and monthly average values)
are multiplied by the BPT normalized discharge flows summarized
in Table IX-1 to calculate the mass of pollutants allowed to be
discharged per mass of product. The results of these
calculations in milligrams of pollutant per kilogram of product
represent the BPT effluent limitations and are presented in Table
IX-2 (page 1986) for each individual waste stream.
1984
-------
Table IX-T
BPT WASTEWATER DISCHARGE RATES FOR THE SECONDARY LEAD SUBCATEGORY
00
Ln
Wastewater Stream
Battery Cracking
Furnace Wet Air Pollution
Control
Kettle Wet Air
Pollution Control
Lead Paste
Desulfur iza t ion
Cast ing.Contact
Cooling Water
Truck Wash
Facility Washdown
Battery Case
Classificat ion
Employee Hand Wash
Employee Respirator Wash
Laundering of Uniforms
BPT Normalized
Discharge Rate
1/kkg gal/ton
673 161
2,610
45
0
626
11
0
221
21
0
0
27
44
128
53
5
0
0
6.
10.
30.
5
5
7
Production Normalizing Parameter
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from kettle
furnaces
kkg of lead processed through
desulfurizat ion
kkg of lead cast
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead produced from smelting
M
O
O
M
c;
CO
O
M
M
O
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2
BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(a) Battery Cracking BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced"
English Units - Ibs/million Ibs of lead scrap produced
*Antimony 1.932 0.861
*Arsenic 1.407 0.579
Cadmium 0.229 0.101
Chromium 0.296 0.121
Copper 1.279 0.673
*Lead 0.283 0.135
Nickel - 1.292 0.855
Silver 0.276 0.114
Thallium 1.380 0.612
*Zinc 0.983 0.411
*Ammonia (as N) 0.000 0.000
*TSS 27.590 13.120
*pH Within the range of 7.5 to 10.0
at all times
(b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 7.491 3.341
*Arsenic 5.455 2.245
Cadmium 0.887 0.392
Chromium 1.148 0.470
Copper 4.959 2.610
*Lead 1.096 0.522
Nickel 5.011 3.315
Silver 1.070 0.444
Thallium 5.351 2.375
*Zinc 3.811 1.592
*Ammonia (as N) 0.000 0.000
*TSS 107.000 50.900
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1986
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(c) Kettle Wet Air Pollution Control BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
*Antimony 0.129 0.058
*Arsenic 0.094 0.039
Cadmium 0.015 0.007
Chromium 0.020 0.008
Copper 0.086 0.045
*Lead 0.016 0.009
Nickel 0.086 0.057
Silver 0.018 0.008
Thallium 0.092 0.041
*Zinc 0.066 0.027
*Ammonia (as N) 0.000 0.000
*TSS 1.845 0.878
*pH Within the range of 7.5 to 10.0
at all times
(d) Lead Paste Desulfurization BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced through desulfurization
English Units - Ibs/million Ibs of lead produced through
desulfurization
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.5 to 10.0
at all times
^Regulated Pollutant
1987
-------
SECONDARY LEAD SUBCATEGORY
SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(e) Casting Contact Cooling. BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units -
English Units -
*Antimony
*Arsenic
Cadmium
Chromium
Coppe r
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*TSS
*pH
(f) Truck Wash BPT
mg/kg of lead cast
Ibs/million Ibs of lead cast
0.634
0.462
0.075
0.097
0.420
0.093
0.424
0.091
0.453
0.323
0.000
9.061
Within the range of 7.5
at all times
0.283
0.190
0.033
0.040
0.221
0.044
0.281
0.038
0.201
0.135
0.000
4.310
to 10.0
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*TSS
*pH
0.060 0.027
0.044 0.018
0.007 0.003
0.009 0.004
0.040 0.021
0.009 0.004
0.040 0.027
0.009 0.004
0.043 0.019
0.031 0.013
0.000 0.000
0.861 0.410
Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1988
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(g) Facility Washdown BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc - 0.000 0.000
*Ammonia (as N) 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.5 to 10.0
at all times
(h) Battery Case Classification BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*TSS 0.000 0.000
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1989
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(i) Employee Handwash BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
Englisn Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.077 0.035
*Arsenic 0.056 0.023
Cadmium 0.009 0.004
Chromium 0.012 0.005
Copper 0.051 0.027
*Lead 0.011 0.005
Nickel - 0.052 0.034
Silver 0.011 0.005
Thallium 0.055 0.025
*Zinc 0.039 0.016
*Ammonia (as N) 0.000 0.000
*TSS 1.107 0.527
*pH Within the range of 7.5 to 10.0
at all times
(i) Employee Respirator Wash BPT
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.126 0.056
*Arsenic 0.092 0.038
Cadmium 0.015 0.007
Chromium 0.019 0.008
Copper 0.084 0.044
*Lead 0.018 0.009
Nickel 0.084 0.056
Silver 0.018 0.007
Thallium 0.090 0.040
*Zinc 0.064 0.027
*Ammonia (as N) 0.000 O.OOC
*TSS 1.804 0.858
*pH Within the range of 7.5 to 10.0
at all times
*Regulated Pollutant
1990
-------
SECONDARY LEAD SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(j) Laundering Uniforms BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*TSS
*pH
0.367
0.268
0.044
0.056
0.243
0.054
0.246
0.052
0.262
0.187
0.000
5.248
Within the range of
at all times
0.164
0.110
0.019
0.023
0.128
0.026
0.163
0.022
0.116
0.078
0.000
2.496
7.5 to 10.0
*Regulated Pollutant
1991
-------
U.iHtpwnlpr
Kmplovfc M.. -wnsh W.iatewnt er
drrliip, of Uniforms Wastewnter
h H*!* A. ^
Oil
V
^>» A
SMmitng
"T
Removal of
OE1 and
Grease
cry Case Class! f l«:nt Ion Uastewater
It- Scrubber Liquor
Reuse*
llty Wnshdown Waatewater
V
Molding
Tank
/
Kqu*
rail"
cn
w
n
O
O
Chemical AcMU*oP
-1^, I
Covplete Recycle of Facility Vashdovn
and Battery Case Classification Uatcr
f ^ I! f
f , ^
Chemlcnl | i )
Pr •< ipltnt Inn j \ Sedl>«ntatlon •
-_.j
4.J
Inldln
Tank
Sludge
tr"
W
>
Dlaclinrt O
n
>
W
Vacuun Filtrate
Sludge to
Disposal
Sludge Dewaterlng
O
V
I
M
•Fin Illty Wnili.lnun Wn-tpuntpr Is rciinpd as Battory Case Cl UBS I f Irntlon makeup water. Any exceas Facility Unnhdnun Wasteuater la sent to trpatmpnt.
Figure IX-1
BPT TREATMENT SCHEME
-------
SECONDARY LEAD SUBCATEGORY SECT - X
SECTION X
BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
These effluent limitations are based on the best control and
treatment technology used by a specific point source within the
industrial category or subcategory, or by another category where
it is transferable. Emphasis is placed on additional treatment
techniques applied at the end of the treatment systems currently
used, as well as reduction of the amount of water used and
discharged, process control, and treatment technology
optimization.
The factors considered in assessing best available technology
economically achievable (BAT) include the age of equipment and
facilities involved, the process used, process changes, nonwater
quality environmental impacts (including energy requirements),
and the costs of application of such technology (Section 304(b)
(2)(B) of the Clean Water Act). BAT represents the best
available technology economically achievable at plants of various
ages, sizes, processes, or other characteristics. Where the
Agency has found the existing performance to be uniformly
inadequate, BAT may be transferred from a different subcategory
or category. BAT may include process changes or internal
controls, even when not in common subcategory practice.
The statutory assessment of BAT considers costs, but does not
require a balancing of costs against effluent reduction benefits
(see Weyerhaeuser v. Costle, 590 F.2d 1011 (D.C. Cir. 1978))-
However, in assessing BAT, the Agency has given substantial
weight to the economic achievability of the technology.
TECHNICAL APPROACH TO BAT
The Agency reviewed and evaluated a wide range of technology
options to ensure that the most effective and beneficial
technologies were used as the basis of BAT. The Agency examined
three technology options which could be applied to the secondary
lead subcategory as alternatives for the basis of BAT effluent
limitations.
In summary, the treatment technologies considered for BAT are
presented below:
Option A is based on:
o Preliminary treatment with oil skimming (where required),
o Chemical precipitation and sedimentation, and
o Complete recycle of facility washdown and battery case
classification wastewater after treatment.
1993
-------
SECONDARY LEAD SUBCATEGORY SECT - X
Option B is based on:
o In-process flow reduction of casting contact cooling
water,
o Preliminary treatment with oil skimming (where required),
o Chemical precipitation and sedimentation, and
o Complete recycle of facility washdown and battery
classification wastewater after treatment.
Option C is based on:
o In-process flow reduction of casting contact cooling
water,
o Preliminary treatment with oil skimming (where required),
o Chemical precipitation and sedimentation,
o Complete recycle of facility washdown and battery case
classification wastewater after treatment, and
o Multimedia filtration.
The three options examined for BAT are discussed in greater
detail below. The first option considered (Option A) is the same
as the BPT treatment technology which was presented in the
previous section.
OPTION A
Option A for the secondary lead subcategory is equivalent to the
control and treatment technologies which were analyzed for BPT in
Section IX. The BPT end-of-pipe treatment scheme consists of
preliminary treatment with oil skimming (where required),
chemical precipitation, and sedimentation (lime and settle) end-
of-pipe technology (see Figure X-l page 2009). Although a
specific mass limitation is not provided for oil and grease at
BAT, oil skimming is needed to remove oil and grease from battery
cracking, furnace wet air pollution control, truck wash, laundry,
hand wash, and respirator wash wastewater to ensure proper metals
removal. Oil and grease interferes with chemical addition and
mixing required for chemical precipitation treatment. The
discharge rates for Option A are equal to the discharge rates
allocated to each stream as a BPT discharge flow.
OPTION B
Option B for the secondary lead subcategory achieves lower
pollutant discharge by building upon the Option A end-of-pipe
treatment technology. In-process flow reduction measures are
added to the Option A treatment consisting of oil skimming,
chemical precipitation and sedimentation (see Figure X-2 page
2010). These flow reduction measures result in concentration of
pollutants in other effluents. As previously explained,
treatment of a more concentrated effluent allows achievement of a
greater net pollutant removal and introduces possible economic
benefits associated with treating a lower volume of wastewater.
1994
-------
SECONDARY LEAD SUBCATEGORY SECT - X
The following method is used in Option B to reduce process waste
water generation and discharge rates:
Recycle of_ Casting Contact Cooling Water Through Cooling Towers
The function of casting contact cooling water is to quickly
remove heat from the newly formed lead ingots. Therefore, the
principal requirements of the water are that it be cool and not
contain dissolved solids at a concentration that would cause
water marks or other surface imperfections. There is sufficient
experience within the category with the cooling and recycling of
casting contact cooling wastewater to assure the success of this
technology using cooling towers or heat exchangers. Recycle is
currently practiced at two of the eight plants in the secondary
lead subcategory reporting data for casting contact cooling. A
blowdown or periodic cleaning is likely to be needed to prevent a
build-up of dissolved and suspended solids. EPA has determined
that a blowdown of 10 percent of the water applied in a process
is adequate.
OPTION C
Option C for the secondary lead subcategory consists of the
Option B treatment in-process flow reduction, oil skimming (where
required), chemical precipitation, sedimentation, and complete
recycle of treated facility washdown and battery case
classification wastewater plus multimedia filtration technology
added at the end of Option B treatment (see Figure X-3 page
2011). Multimedia filtration is used to remove suspended solids,
including precipitates of toxic metals, beyond the concentration
attainable by gravity sedimentation. The filter suggested is of
the gravity, mixed media type, although other filters, such as
rapid sand filters or pressure filters, would perform
satisfactorily.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
As a means of evaluating each technology option, EPA developed
estimates of the pollutant removal estimates and the compliance
costs associated with each option. The methodologies are
described below.
POLLUTANT REMOVAL ESTIMATES
A complete description of the methodology used to calculate the
estimated pollutant removal achieved by the application of the
various treatment options is presented in Section X of Vol. I.
The pollutant removal estimates have been revised from proposal
based on comments and new data. However, the methodology for
calculating pollutant removals was not changed. The data used
for estimating pollutant removals are the same as those used to
revise the compliance costs.
Sampling data collected during the field sampling program were
used to characterize the major wastewater streams considered for
1995
-------
SECONDARY LEAD SUBCATEGORY SECT - X
regulation. At each sampled facility, the sampling data were
production normalized for each building block (i.e., mass of
pollutant generated per mass of product manufactured). This
valuef referred to as the raw waste-, was used to estimate the
mass of toxic pollutants generated within the secondary lead
subcategory. By multiplying the total subcategory production for
a unit operation by the corre-.o^nding raw waste value, the mass
of pollutant generated for that unit operation was estimated.
The volume of wastewater discharged after the application of each
treatment option was estimated for each operation at each plant
by comparing the actual discharge to the regulatory flow. The
smaller of the two values was selected and summed with the other
plant flows. The mass of pollutant discharged was then estimated
by multiplying the achievable r^nrentration values attainable by
the option (rac.O/ ';.:y tit fKrin.ated volume of process wastewater
discharged by tr;; ."i-'.f^rrv The mass of pollutant removed is
simply the r i ?: •<-, ,ce becwe~r_ Lr.e estimated mass of pollutant
generator1 i-;*: i the subcategorv and the mass of pollutant
discharge a i t - r application of the i 'eatment option.
The \ •' '...-,_": removal e?'.:iirates for direct discharges in the
secondary lead subcategory are presented in Table X-l (page
2001).
COMPLIANCE COSTS
Compliance certs eo at propers! were estimated using cost
curves, which related the total costs associated with
installation and operation of wastewater treatment technologies
to plant process wastewater discharge. EPA applied these curves
on a per plant basis, a plant's costs -- both capital, and
operating ana maintenance -- being determined by what treatment
it has in place and by its individual process wastewater
discharge (from dcp). The final step was to annualize the capital
costs, and to sum the annua]i7ed capital costs, and the operating
and maintenance costs, yielding the total annual cost of
compliance for the subcategory.
Since proposal, the cosu esti.^cion methodology has been changed
as discussed in Section VIII of this supplement. A design model
and plant specif 1: 1 nl, , 3: iC-r, were used to size a wastewater
treatment system for each discharging facility. After completion
of the design, capital and annual costs were estimated for each
unit of the wastewater treatment system. Capital costs rely on
vendor quotes, while annual costs were developed from the
literature. The revised compliance costs for direct dischargers
are presented in Tabl^ T7!VT-1 (page 1973).
BAT OPTION SELECT 1C N) - PROPOSAL
At proposal, EPA selected both Option B and Option C as the basis
for alternative BAT effluent limitations for the secondary lead
subcategory due to current adverse structural economic changes
that were not reflected in the Agency's economic analysis. These
1996
-------
SECONDARY LEAD SUBCATEGORY SECT - X
alternative limitations were based on lime precipitation,
sedimentation, and in-process control technologies to reduce the
volume of process wastewater discharged for Option B and the
addition of multimedia filtration for Option C.
Activated alumina (Option D) was considered; however, this
technology was rejected because it was not demonstrated in this
subcategory nor was it clearly transferable to nonferrous
wastewater. Reverse osmosis (Option F) was considered for the
purpose of achieving zero discharge of process wastewater;
however, the Agency ultimately rejected this technology because
it was determined that its performance for this specific purpose
was not adequately demonstrated in this subcategory nor was it
clearly transferable from another subcategory or category.
BAT OPTION SELECTION - PROMULGATION
After proposal the Agency obtained data through special requests,
dcp submittals, and telephone contacts. Additionally, two
secondary lead facilities were sampled to further characterize
wastewater. The new data were used to recalculate compliance
costs and pollutant removal estimates and evaluate regulatory
flow allowance's where appropriate.
EPA is promulgating BAT effluent mass limitations based on the
promulgated BPT treatment with additional reduction in pollutant
discharge achieved through in-process flow reduction over BPT
levels and the use of multimedia filtration as an effluent
polishing step. The BAT treatment consists of preliminary
treatment with oil skimming (where required), in-process flow
reduction, lime precipitation, sedimentation, and multimedia
filtration. Wastewater flow reduction over BPT levels is based
on recycle of casting contact cooling water through cooling
towers. The promulgated BAT flow allowances are identical to the
promulgated BPT flow allowances except for casting contact
cooling. The end-of-pipe treatment technology basis for BAT
limitations being promulgated is the same as that for the
proposed Alternative B limitations. The Agency has revised the
compliance costs and economic analysis. Results of this analysis
indicate filtration as an end-of-pipe polishing step is
economically achievable.
Implementation of the promulgated BAT would remove 25,700 kg of
toxic metals annually. The promulgated BAT effluent mass
limitations will result in the removal of 350 kg/yr of toxic
pollutants above the estimated BPT discharge. The selected
option is economically achievable. The Agency believes this
incremental removal justifies selection of filtration as part of
BAT model technology. In addition, filtration is demonstrated at
seven secondary.lead plants. The estimated capital investment
cost of BAT is $1.86 million (March, 1982 dollars) and the
estimated annual cost is $1.24 million (March, 1982 dollars).
As discussed in the BPT Option Selection, EPA is promulgating
zero discharge of ammonia for secondary lead plants. Ammonia in
1997
-------
SECONDARY LEAD SUBCATEGORY SECT - X
secondary lead wastewaters is the result of its use as a
wastewater treatment chemical.
It is the Agency's understanding that ammonia is used because it
reduces the amount of sludge generated and produces a sludge more
amenable for reuse as a raw material than lime sludges. However,
the use of caustic as a wastewater treatment chemical is also
widely demonstrated in the secondary lead subcategory. Caustic
is as applicable as ammonia for reducing sludge generation and
producing sludges that can be recycled. In developing plant-by-
plant costs, the Agency evaluated costs for substituting
neutralization with caustic for neutralization with lime or
ammonia. This will eliminate the discharge of ammonia and still
produce a sludge acceptable for recycling. However, if a plant
chooses to continue using ammonia as a treatment chemical, it
will have to maintain zero discharge of ammonia.
WASTEWATER DISCHARGE RATES
A BAT discharge rate was calculated for each subdivision based
upon the flows of the existing plants, as determined from
analysis of the data collection portfolios. The discharge rate
is used with the achievable treatment concentration to determine
BAT effluent limitations. Since the discharge rate may be
different for each wastewater source, separate production
normalized discharge rates for each of the 11 wastewater sources
were determined and are summarized in Table X-2 (page 2002). The
discharge rates are normalized on a production basis by relating
the amount of wastewater generated to the mass of the
intermediate product which is produced by the process associated
with the waste stream in question. These production normalizing
parameters (PNP) are also listed in Table X-2.
The BAT wastewater discharge rate equals the BPT wastewater
discharge rate for all waste streams except casting contact
cooling water. This stream is discussed below.
The Agency proposed zero discharge of wastewater pollutants from
kettle scrubbers and flow reduction over BPT levels for furnace
scrubbers. As discussed in Section IX, data gathered through
specific data requests have shown those plants thought to
practice 100 percent recycle of kettle scrubber liquor actually
have a periodic discharge. A wastewater discharge allowance is
provided for kettle scrubbers at BPT. However, the proposed
BPT discharge allowance has been changed for promulgation and is
now based on 90 percent recycle. Further flow reduction is not
demonstrated in the subcategory. The allowance is based on 90
percent recycle of scrubber liquor and is equal to the BPT
discharge allowance.
CASTING CONTACT COOLING WATER
The BAT wastewater regulatory discharge allowance is 22 1/kkg
(.5.3 gal/ton), based on 90 percent recycle of the BPT discharge
allowance. Ten of the 46 plants currently reporting casting
1998
-------
SECONDARY LEAD SUBCATEGORY SECT - X
operations use contact cooling water. Two plants achieve zero
discharge through 100 percent recycle or evaporation. Six plants
are once-through dischargers with flow rates ranging from 5 to
963 1/kkg (1 to 231 gal/ton). Four of the eight plants reporting
flow data meet the BAT discharge allowance.
REGULATED POLLUTANT PARAMETERS
In implementing the terms of the Consent Agreement in NRDC v.
Train, Op. Cit., and 33 U.S.C. 1314(b)(2)(A and B) (1976), the
Agency placed particular emphasis on the toxic pollutants. The
raw wastewater concentrations from individual operations and the
subcategory as a whole were examined to select certain pollutants
and pollutant parameters for consideration for limitation. This
examination and evaluation, presented in Section VI, concluded
that 13 pollutants or pollutant parameters are present in
secondary lead wastewaters at concentrations that can be
effectively reduced by identified treatment technologies.
The high cost associated with analysis for toxic metal pollutants
has prompted EPA to develop an alternative method for regulating
and monitoring toxic pollutant discharges from the nonferrous
metals manufacturing category. Rather than developing specific
effluent mass limitations and standards for each of the toxic
metals found in treatable concentrations in the raw wastewater
from a given subcategory, the Agency is promulgating effluent
mass limitations only for those pollutants generated in the
greatest quantities as shown by the pollutant removal analysis.
The pollutants selected for specific limitation are listed below:
114. antimony
115. arsenic
122. lead
128. zinc
ammonia (as N)
By establishing limitations and standards for certain toxic metal
pollutants, dischargers will attain the same degree of control
over toxic metal pollutants as they would have been required to
achieve had all the toxic metal pollutants been directly limited.
»
This approach is justified technically since the treatment
effectiveness concentrations used for lime precipitation and
sedimentation technology are based on optimized treatment for
concomitant multiple metals removal. Thus, even though metals
have somewhat different theoretical solubilities, they will be
removed at very nearly the same rate in a lime precipitation and
sedimentation treatment system operated for multiple metals
removal. Filtration as part of the technology basis is likewise
justified because this technology removes metals non-
preferential ly.
The toxic metal pollutants selected for specific limitation in
the secondary lead subcategory to control the discharges of toxic
metal pollutants are antimony, arsenic, lead, and zinc. The
1999
-------
SECONDARY LEAD SUBCATEGORY
SECT - X
following toxic pollutants are excluded from limitation on the
basis that they are effectively controlled by the limitations
developed for the selected toxic metals:
118. cadmium
119. chromium (Total)
120. copper
124. nickel
126. silver
127. thallium
Effluent mass limitations are promulgated to eliminate the
discharge of ammonia. Ammonia is used by some plants in the
secondary lead subcategory as a wastewater treatment chemical.
Monitoring and analysis for ammonia is not necessary if ammonia
is not used. Plants must demonstrate to the permit and control
authority that ammonia is not used in the plant as a process or
wastewater treatment chemical.
EFFLUENT LIMITATIONS
The concentrations, achievable by application of the BAT
technology (Option C) are summarized in Table VII-21 (page
248) of Vol. 1. These treatment effectiveness concentrations
(both one day maximum and monthly average) are multiplied by the
BAT normalized discharge flows summarized in Table X-2 to
calculate the mass of pollutants allowed to be discharged per
mass of product. The results of these calculations in milligrams
of pollutant per kilogram of product represent the BAT effluent
limitations for the secondary lead subcategory. The BAT effluent
limitations are presented in Table X-3 (page 2003) for each waste
stream.
2000
-------
Table X-1
POLLUTANT REMOVAL ESTIMATES FOR SECONDARY LEAD DIRECT DISCHARGERS
POLLUTANT
Arseni c
An t Imony
C;idn) i um
Chromium
Lead
Nickel
Si Iver
Thallium
Copper
7. 1 nc
TOTAL TOXIC METALS
Q A lumlnnm
O Ammonia
M Iron
TOTAL NONCONVENTIONALS
TSS 2
Oil Si Grease
TOTAL CONVENT IONAI.S 2
TOTAL POLLUTANTS 2
FLOW r'/yr) 235
TOTAL
RAW UASTE
(kR/yr)
1 .784.5
3.572.7
169.9
333.8
18.693.5
578.1
40.2
262.0
330.5
468.4
26,233.6
8.753.7
494.9
9,759.5
19.008.2
.853.536.0
4,082.0
,857,618.0
,902,859.8
,080,000
OPTION A
DISCHARGED
(kR/yr)
119.9
164.6
18.6
19.7
28.2
174.0
23.5
117.5
136.3
77.6
879.9
526.6
0.0
96.4
623.0
2.821.0
2.350.8
5.171.8
6.674.6
OPTION A
REMOVED
(kR/yr)
1 .664.6
3.408.1
151.3
314.0
18.665.3
404.1
16.7
144.5
194.2
390.8
25.353.7
8.227.2
494.9
9,663.2
18,385.2
2.850.715.1
1.731.2
2.852.446.3
2.896.185.2
235.080,000
OPTION B
DISCHARGED
(kR/yr)
119.9
, 164.6
18.6
19.7
28.2
174.0
23.5
117.5
136.3
77.6
879.9
526.6
0.0
96.4
623.0
2,821.0 2
2.350.8
5.171.8 2
6.674.6 2
235
OPTION B
REMOVED
(kR/yr)
1 .664.6
3.408.1
151 .3
314.0
18.665.3
404.1
16.7
144.5
194.2
390.8
25.353.7
8.227.2
494.9
9.663.2
18.385.2
.850,715.1
1 .731.2
.852,446.3
.896.185.2
.080.000
OPTION C
DISCHARGED
(kR/yr)
79.9
110.5
11.5
16.5
18.8
51.7
16.5
79.9
91.7
54.1
531 .0
350.3
0.0
65.8
416.1
611.2
2.350.8
2,962.0
3,909.1
OPTION C
REMOVED
(kR/yr)
1 ,704.6
3,462.2
158.4
317.3
18,674.7
526.3
,23.7
182.1
238.9
414.3
25.702.6
8.403.5
494.9
9.693.7
18.592.1
2,852,924.8
1.731 .2
2,854,656.0
2,898,950.7
W
M
O
O
M
K
tr1
M
B
w
c:
0
(-3
W
O
O
»
W
M
0
1-3
*
NOT' TOTAL TOXIC METALS = Arsenic 4 Antimony + Cadmium + Chromium + Lead 4- Nickel + Sliver + Thallium + Copper 4- Zinc
TOTAL NONCONVENTIONALS = Aluminum 4 Ammonia 4 Iron
Ol'TlOH A = Lime Precipitation, Sedimentation, and Oil SklmmlnR
0 IT ION H = Option A, plus In-process Flow Reduction
OPTION C « Option B, plus Multimedia Filtration
-------
Table X-2
BAT WASTEWATER DISCHARGE RATES FOR THE SECONDARY LEAD SUBCATEGORY
O
O
Wastewater Stream
Battery Cracking
Furnace Wet Air Pollution
Control
Kettle Wet Air
Pollution Control
Lead Paste
Desulfurlzation
Casting Contact
Cooling Water
Truck Wash
Facility Washdown
Battery Case
Class ification
Employee Hand Wash
Employee Respirator Wash
Laundering of Uniforms
BAT Normalized
Discharge Rate
1/kkg gal/ton
673 161
2,610
0
626
11
0
22
21
0
0
27
44
128
5.
5
0
0
6.
10.
30.
3
5
5
7
Production Normalizing Parameter
kkg of lead scrap produced
to
w
O
§
a
kkg of lead produced from smelting F
w
kkg of lead produced from kettle
furnaces
kkg of lead processed through
desulfurization
kkg of lead cast
W
w
o
W
O
8
kkg of lead produced from smelting pj
o
kkg of lead produced from smelting
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead produced from smelting
-------
SECONDARY LEAD SUBCATEGORY SECT - X
TABLE X-3
BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(a) Battery Cracking BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
* Antimony
*Arsenic
Cadmium
Chromium
Coppe r
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
1.299
0.935
0.135
0.249
0.861
0.188
1.370
0.195
0.942
0.686
0.000
0.579
0.384
0.054
0.101
0.411
0.087
0.249
0.081
0.411
0.283
0.000
(b) Blast, Reverberatory, or Rotary. Furnace Wet Air
Pollution Control BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Coppe r
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*Regulated Pollutant
5.037
3.628
0.522
0.966
3.341
0.731
1.436
0.757
3.654
2.662
0.000
2.245
1.488
0.209 '
0.392
1.592
0.339
0.966
0.313
1.592
1.096
0.000
200'3
-------
SECONDARY LEAD SUBCATEGORY
SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(c) Kettle Wet Air Pollution Control BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
* Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Thali : ?~
*Zinc
* Ammonia
0.087
0.063
0.009
0.017
0.058
0.013
J.025
J.013
0.063
0.046
0.000
0.039
0.026
0.004
0.007
0.027
0.006
0.017
0.005
0.027
0.019
0.000
(d) Lead Paste Desuli:urization BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced through desulfurization
English Units - Ibs/million Ibs of lead produced through
desulfurization
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*Regulated Pollutant
0.000 •
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
2004
-------
SECONDARY LEAD SUBCATEGORY
SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(e) Casting Contact Cooling BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units
English Units
mg/kg of lead cast
Ibs/million Ibs of lead cast
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
0.042
0.031
0.004
0.008
0.028
0.006
0.012
0.006
0.031
0.022
0.000
0.019
0.013
0.002
0.003
0.013
0.003
0.008
0.003
0.013
0.009
0.000
(f) Truck Wash BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from
smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*Regulated Pollutant
0.041
0.029
0.004
0.008
0.027
0.006
0.012
0.006
0.029
0.021
0.000
0.018
0.012
0.002
0.003
0.013
0.003
0.008
0.003
0.013
0.009
0.000
2005
-------
SECONDARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(g) Facility Washdown BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
(h) Battery Case Classification BAT
Pollutant or . Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*Regulated Pollutant
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
2006
-------
SECONDARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(i) Employee Handwash BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.052 0.023
*Arsenic 0.038 0.015
Cadmium 0.005 0.002
Chromium 0.010 0.004
Copper 0.035 0.016
*Lead 0.008 0.004
Nickel 0.015 0.010
Silver 0.008 0.003
Thallium 0.038 0.016
*Zinc 0.028 0.011
*Ammonia (as N) 0.000 0.000
*Regulated Pollutant
2007
-------
SECONDARY LEAD SUBCATEGORY SECT - X
TABLE X-3 (Continued)
BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(i) Employee Respirator Wash BAT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.085 0.038
*Arsenic 0.061 0.025
Cadmium 0.009 0.004
Chromium 0.016 0.007
Copper 0.056 0.027
*Lead 0.012 0.006
Nickel 0.024 0.016
Silver 0.013 0.005
Thallium 0.062 0.027
*Zinc 0.045 0.018
*Ammonia (as N) 0.000 0.000
(j) Laundering Uniforms BAT
Pollutant orMaximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
* Ammonia (as N)
0.247
0.178'
0.026
0.047
0.164
0.036
0.070
0.037
0.179
0.131
0.000
0.110
0.073
0.010
0.019
0.078
0.017
0.047
0.015
0.078
0.054
0.000
*Regulated Pollutant
2008
-------
NJ
O
O
VD
H.i'li'iy Cl.liVln(! Uilslruillcr
Km|t|oyrp .(wash W.-iBt pwnt er
Kmploycf Rrnplrhtnr W.isli
t.mtntlnrlnR of Uniforms W/
Tru< k U;IR|I Wnstpwntcr
n.-u-f Scrnhtipr Liquor
C.i-il liir Cmil.-irl (-iiiiHiii! Wiitrr
(!ase Classification Wnstewater
KeJ^t le Scruhher l.lqnor
Reuse*
Km ''Ity Washdown Wastewater
Oil
Skinning
Removal of
Oil anil
Crease
Molding
Tank
Chemical Addition
Complete Recycle of Facility Washdovn
and lattery Case Classification Water
Equali-
zation
Chealcal
PrectpltatIon
V
Sed.tvtntAt Ion
w
Holding
Tank
niaclia
SludKe Recycle
Sludge
Vacuuni Filtrate
Sludge Deuaterlng
W
O
i
O
tr1
w
>
O
c
w
o
w
o
o
w
o
(-3
•Facility Wnsli.lown UantewatPr Is reuspd as Battery Case Classl f Icat Ion makeup water. Any exceaa Facility Unslidoun Wastewater Is sent to treatment.
Figure X-1
BAT TREATMENT SCHEME FOR OPTION A
SECONDARY LEAD SUBCATEGORY
-------
M
O
H • ! n y Ciark* - W.i.-il i-w.U *•!
Hit|t liiyrt? ll.tmlw.ibli WiiHl ew*il or
* y _/-^'.v;
t-jupliiyee Heap 1 ml or Wash W.iatewdler ^ . A,A^>^
, Oil ^
l.tiindt;! INK of Uniforms Wasteualer ^ • Sk InuiihiK
frin k u.i ill Wasli-ualer ... .
Kninacu Struhher l.li|uor ^ J
Removal of
Oil and
f.reaae
-.'Iriltery Case Claaal f leal Ion Waateuater
Kettle Scrubber l.luuor
keuse*
^
r.iclllly llaalidoun llaateuater Holding — — - k>
Tank
\ Tiiwer j
Conplete Recycle ol Facility Waalidnwn
and Battery Case Clauulf Icat lun Water
Che* lea I Addition
9, IP,
t/-.'«fc ^ = '•'"i
Equall- Chemical llol.lliiR
zatlon Precipitation Sedimentation Tan)-
Tank /
Sludge
Sludge Recycle
f ^ r^(
\\ rr^ «'t»poa»i
Vacuum Filtrate \ \ 1 // 1
^^/ *
SludKe Deuaterlnn
L^sd'isi'iijsi-iili'.
p
w
w
n
tfl
n
'facility Waslidnun Uauteuater la reused a« Battery Case Cluuaslfteat Ion makeup water. Any excess Facility Wushdoun Wasteuater Is sent to treatment.
Figure K-2
BAT TREATMENT SCHEME FOR OPTION B
SECONDARY LEAD SUBCATEGORY
-------
U.-inti'w.-tt t*r
X/— * — 'iv
Employer Rosplratiir Wnsh Uastewnter //>. ^T.A. 3C ,•? A
* Oil
Truck Wash Waslewater
1
Knrua. .' Srrulihor l.lquin A
Kemoval of
Oil and
Create
•^Rnltery Cane Classification Uastewater
*
ro
0
I-1 Reuse-1
~~
Fnclllty Un^lidown Wastewater Holding ~ *
Tank
*\ Cool Ing / *
\ Tower J
Recycle ^
Backwash
Conplete Recycle of Facility
Uaslidown and Battery Case
Classification Water
Chen lea I Addition
0 Jo ,-J
/"^ T7 * /^ T7
-*• / = -n» ' = » = » ^ » ""'"'
SECONDARY
f
n-dln OlB.li.-irw M
F.<<(,all- Che«lc.l FIHr;iil..n " j>
'"J0" Prerloltatlon SedliMntat Ion Holding O
Sludge
Sludge Recycle
/"" "V _f ^ Sludge :..
L. I /-p L,O 1 Ol8po8al
Vacuum Filtrate \^ 1 / / I
^ I1
Sludge Dewaterlng 1
Blltli!tyL')(l'>ir"
BCATEGORY SECT - X
C
01
e
3
Jt
U
a
n
Figure X-3
BAT TREATMENT SCHEME FOR OPTION C
SECONDARY LEAD SUBCATEGORY
-------
Page Intentionally Blank
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
The basis for new source performance standards (NSPS) under
Section 306 of the Act is the best available demonstrated
technology (BDT). New plants have the opportunity to design the
best and most efficient production processes and wastewater
treatment technologies, without facing the added costs and
restrictions encountered in retrofitting an existing plant.
Therefore, Congress directed EPA to consider the best
demonstrated process changes, in-plant controls, and end-of-pipe
treatment technologies which reduce pollution to the maximum
extent feasible.
This section describes the control technology for treatment of
wastewater from new sources and presents mass discharge
limitations of regulatory pollutants for NSPS in the secondary
lead subcategory, based on the described control technology.
TECHNICAL APPROACH TO BDT
All of the treatment technology options applicable to a new
source were previously considered for the BAT options. For this
reason, three options were considered for BDT, which are all
identical, with one exception, to the BAT options discussed in
Section X. The kettle wet air pollution control discharge
allowance is eliminated under BDT through use of dry air
pollution control. Dry scrubbing is widely demonstrated for
controlling emissions from kettle refining. Of the 28 plants
with kettle air pollution control, 19 use dry scrubbing. The
Agency also considered proposing dry scrubbing for controlling
emissions from blast and reverberatory furnaces, but the nature
of these emissions precludes the use of dry scrubbing. Exhaust
gases from blast and reverberatory furnaces contain sulfur
dioxide fumes, which require wet air pollution scrubbing.
The treatment technologies used for the three BDT options are:
OPTION A
o Preliminary treatment with oil skimming (where required),
o Chemical precipitation and sedimentation,
o Dry air pollution control of kettle refining, or alter-
nately, complete recycle of kettle scrubber liquor, and
o Complete recycle of facility washdown and battery case
classification wastewater after treatment.
OPTION B
o In-process flow reduction of casting contact cooling
water,
o Preliminary treatment with oil skimming (where required),
2013
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
o Chemical precipitation and sedimentation,
o Dry air pollution control of kettle refining, or alter-
nately, complete recycle of kettle scrubber liquor, and
o Complete recycle of facility washdown and battery
classification wastewater after treatment.
OPTION C
o In-process flow reduction of casting contact cooling
water,
o Preliminary treatment with oil skimming (where required),
o Chemical precipitation and sedimentation,
o Dry air pollution control of kettle refining, or alter-
nately, complete recycle of kettle scrubber liquor,
o Complete recycle of facility washdown and battery case
classification wastewater after treatment, and
o Multimedia filtration.
Partial or complete reuse and recycle of wastewater is an
essential part of each option. Reuse and recycle can precede or
follow end-of-pipe treatment. A more detailed discussion of
these treatment options is presented in Section X.
BDT OPTION SELECTION
EPA is promulgating NSPS for the secondary lead subcategory equal
to the technology basis of BAT and is requiring additional flow
reduction over BPT levels by using dry scrubbing to control
emissions from kettle refining. Existing wet scrubbers are used
to control emissions and prevent baghouse fires caused by
sparking when sawdust and phosphorus are applied to the surface
of the metal while in the kettle. Dry scrubbers can be used for
this purpose if spark arresters and settling chambers are
installed to trap sparks. According to the Secondary Lead
Smelters Association, this is a demonstrated and viable
technology option. Dry scrubbing is not required at BAT because
of the extensive retrofit costs of switching from wet to dry
scrubbing.
The Agency recognizes that new sources have the opportunity to
implement more advanced levels of treatment without incurring the
costs of retrofit equipment, the costs of partial or complete
shutdown necessary for installation of the new equipment, and the
costs of startup and stabilization of the treatment system that
existing plants would have. Specifically, the design of new
plants can be based on recycle of contact cooling waters, recycle
of air pollution control scrubber liquor, and use of dry air
pollution equipment.
REGULATED POLLUTANT PARAMETERS
The Agency has no reason to believe that the pollutants that will
be found in treatable concentrations in processes within new
sources will be any different than with existing sources.
Accordingly, pollutants and pollutant parameters selected for
2014
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
limitation under NSPS, in accordance with the rationale of
Sections VI and X, are identical to those selected for BAT. The
conventional pollutant parameters TSS and pH are also selected
for limitation.
NEW SOURCE PERFORMANCE STANDARDS
The NSPS discharge flows for each wastewater source are the same
as the discharge rates for BAT except for kettle wet air
pollution control and are presented in Table XI-1 (page 2016).
The mass of pollutant allowed to be discharged per mass of
product is calculated by multiplying the appropriate treatment
effectiveness concentration by the production normalized
wastewater discharge flows (1/kkg). These concentrations are
listed in Table VII-21 (page 248) of Vol. I. New source
performance standards are presented in Table Xl-2 (page 2017).
2015
-------
Table XI-1
NSPS WASTEWATER DISCHARGE RATES FOR THE SECONDARY LEAD SUBCATEGORY
ISJ
O
CTi
Wastewater Stream
Battery Cracking
Furnace Wet Air Pollution
Control
Kettle Wet Air
Pollution Control
Lead Paste
Desulfurizat ion
Casting Contact
Cooling Water
Truck Wash
Facility Washdown
Battery Case
Classification
Employee Hand Wash
Employee Respirator Wash
Laundering of Uniforms
NSPS Normalized
Discharge Rate
1/kkg gal/ton
673 161
2,610
0
0
626
0
0
22
21
0
0
27
44
128
5.
5
0
0
6.
10.
30.
3
5
5
7
Production Normalizing Parameter
kkg of lead scrap produced
en
M
n
§
I
K;
kkg of lead produced from smelting ^
en
kkg of lead produced from kettle d
furnaces £d
kkg of lead processed through M
desulfurization §
en
kkg of lead cast
kkg of lead produced from smelting w
K"
kkg of lead produced from smelting t
><
h-
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead produced from smelting
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2
NSPS FOR THE SECONDARY LEAD SUBCATEGORY
(a) Battery Cracking NSPS .
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
* Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
*TSS
*pH
1.299
0.935
0.135
0.249
0.861
0.188
1.370
0.195
0.942
0.686
0.000
10.100
Within the range 7.5 to
at all times
0.579
0.384
0.054
0.101 .
0.411
0.087
0.249
0.081
0.411
0.283
0.000
8.076
10.0
(b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 5.037 2.245
*Arsenic 3.628 1.488
Cadmium 0.522 0.209
Chromium 0.966 0.392
Copper 3.341 1.592 '
*Lead 0.731 0.339
Nickel 1.436 0.966
Silver 0.757 0.313
Thallium 3.654 1.592
*Zinc 2.662 1.096
*Ammonia (as N) 0.000 0.000
*TSS 39.150 31.320
*pH Within the range 7.5 to 10.0
at all times
*Regulated Pollutant
2017
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE SECONDARY LEAD SUBCATEGORY
(c) Kettle Wet Air Pollution Control NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*TSS 0.000 0.000
*pH Within the range 7.5 to 10.0
at all times
(d) Lead Paste Desulfurization NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced through desulfurization
English Units - Ibs/million Ibs of lead produced through
desulfurization
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 ' 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*TSS 0.000 0.000
*pH Within the range 7.5 to 10.0
at all times
*Requlated Pollutant
2018
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE SECONDARY LEAD SUBCATEGORY
(e) Casting Contact Cooling NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
*Antimony 0.042 0.019
*Arsenic 0.031 0.013
Cadmium 0.004 0.002
Chromium 0.008 0.003
Copper 0.028 0.013
*Lead 0.006 0.003
Nickel 0.012 0.008
Silver 0.006 0.003
Thallium 0.031 0.013
*Zinc 0.022 0.009
*Ammonia (as.N) 0.000 0.000
*TSS 0.330 0.264
*pH Within the range 7.5 to 10.0
at all times
(f) Truck Wash NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.041 0.018
*Arsenic 0.029 0.012
Cadmium 0.004 0.002
Chromium 0.008 0.003
Copper 0.027 0.013
*Lead 0.006 0.003
Nickel 0.012 0.008
Silver 0.006 0.003
Thallium 0.029 0.013
*Zinc 0.021 0.009
*Ammonia (as N) 0.000 0.000
*TSS 0.315 0.252
*pH Within the range 7.5 to 10.0
at all times
*Reqjlated Pollutant
1019
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE SECONDARY LEAD SUBCATEGORY
(g) Facility Washdown NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel ' 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*TSS 0.000 0.000
*pH Within the range 7.5 to 10.0
at all times
(h) Battery Case Classification NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*TSS 0.000 0.000
*pH Within the range 7.5 to 10.0
at all times
*Regulated Pollutant~
2020
-------
SECONDARY LEAD SCJBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE SECONDARY LEAD SUBCATEGORY
(i) Employee Handwash NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.052 0.023
*Arsenic 0.038 0.015
Cadmium 0.005 0.002
Chromium 0.010 0.004
Copper 0.035 0.016
*Lead 0.008 0.004
Nickel 0.015 0.010
Silver 0.008 0.003
Thallium 0.038 0.016
*Zinc 0.028 0.011
*Ammonia (as N) 0.000 0.000
*TSS 0.405 0.324
*pH Within the range 7.5 to 10.0
at all times
(i) Employee Respirator Wash NSPS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.085 0.038
*Arsenic 0.061 0.025
Cadmium 0.009 0.004
Chromium 0.016 0.007
Copper 0.056 0.027'
*Lead 0.012 0.006
Nickel 0.024 0.016
Silver 0.013 0.005
Thallium 0.062 0.027
*Zinc 0.045 0.018
*Ammonia (as N) 0.000 0.000
*TSS 0.660 0.528
*pH Within the range 7.5 to 10.0
at all times
^Regulated Pollutant
2021
-------
SECONDARY LEAD SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE SECONDARY LEAD SUBCATEGORY
(j) Laundering Uniforms NSPS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
"Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.247 0.110
*Arsenic 0.178 0.073
Cadmium 0.026 0.010
Chromium 0.047 0.019
Copper 0.164 0.078
*Lead 0.036 0.017
Nickel 0.070 0.047
Silver 0.037 0.015
Thallium 0.179 0.078
*Zinc 0.131 0.054
*Ammonia (as N) 0.000 0.000
*TSS 1.920 1.536
*pH Within the range 7.5 to 10.0
at all times
* Regulated Pollutant
2022
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
SECTION XII
PRETREATMENT STANDARDS
PSES are designed to prevent the discharge of pollutants which
pass through, interfere with, or are otherwise incompatible with
the operation of publicly owned treatment works (POTW). The
Clean Water Act of 1977 requires pretreatment for pollutants,
such as toxic metals, that limit POTW sludge management
alternatives. Section 307(c) of the Act requires EPA to
promulgate pretreatment standards for new sources (PSNS) at the
same time that it promulgates NSPS. New indirect discharge
facilities, like new direct discharge facilities, have the
opportunity to incorporate the best available demonstrated
technologies, including process changes, in-plant controls, and
end-of-pipe treatment technologies, and to use plant site
selection to ensure adequate treatment system installation.
Pretreatment standards are to be technology based, analogous to
the best available technology for removal of toxic pollutants.
This section" describes the control and treatment technologies for
pretreatment of process wastewaters from existing sources and new
sources in the secondary lead subcategory. Pretreatment
standards for regulated pollutants are presented based on the
selected control and treatment technologies.
TECHNICAL APPROACH TO PRETREATMENT
Before promulgating pretreatment standards, the Agency examines
whether the pollutants discharged by the industry pass through
the POTW or interfere with the POTW operation or its chosen
sludge disposal practices. In determining whether pollutants
pass through a well-operated POTW achieving secondary treatment,
the Agency compares the percentage of a pollutant removed by POTW
with the percentage removed by direct dischargers applying the
best available technology economically achievable. A pollutant
is deemed to pass through the POTW when the average percentage
removed nationwide by well-operated POTW meeting secondary
treatment requirements, is less than the percentage removed by
direct dischargers complying with BAT effluent limitations
for that pollutant.
This definition of pass through satisfies two competing
objectives set by Congress: (1) that standards for indirect
dischargers be equivalent to standards for direct dischargers,
while at the same time, (2) that the treatment capability and
performance of the POTW be recognized and taken into account in
regulating the discharge of pollutants from indirect dischargers.
The Agency compares percentage removal rather than the mass or
concentration of pollutants discharged because the latter would
not take into account the mass of pollutants discharged to the
POTW from non-industrial sources nor the dilution of the
pollutants in the POTW effluent to lower concentrations due to
2023
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
the addition of large amounts of non-industrial wastewater.
PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES
The treatment technology options for PSES and PSNS are the same
as the BAT Options discussed in Section X. For promulgation PSNS
requires that the kettle furnace air scrubbing waste stream be
eliminated through the use of dry air pollution control. A more
detailed discussion, including pollutants controlled by each
treatment process and achievable treatment concentration for each
option, is presented in Section VII of Vol. 1.
Treatment technologies considered for PSES:
OPTION A
o Chemical precipitation and sedimentation,
o Complete recycle of facility -washdown and battery case
classification wastewater after treatment.
OPTION B
o In-process flow reduction of casting contact cooling
water,
o Chemical precipitation and sedimentation,
o Complete recycle of facility washdown and battery case
classification wastewater after treatment.
OPTION C
o In-process flow reduction of casting contact cooling
water,
o Chemical precipitation and sedimentation,
o Complete recycle of facility washdown and battery case
classification wastewater after treatment, and
o Multimedia filtration.
COST AND POLLUTANT REMOVAL ESTIMATES
The cost and pollutant removal estimates of each treatment
option were used to determine the most cost-effective option.
The methodology applied in calculating pollutant removal
estimates and plant compliance costs is discussed in Section X.
Table XII-1 (page 2027) shows the estimated pollutant removals
for indirect dischargers. Compliance costs are presented in
Table VIII-2 (page 1973).
2024
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
PSES OPTION SELECTION
EPA has selected Option C as the basis for PSES for the secondary
lead subcategory. This technology is equivalent to the
promulgated BAT. The Option C treatment consists of in-process
flow reduction, chemical precipitation, sedimentation, and
multimedia filtration. This selection follows the rationale used
in the selection of BAT. This option prevents pass-through and
equals promulgated BAT.
Implementation of the promulgated PSES limitations would remove
annually an estimated 15,531 kg of toxic pollutants over
estimated current discharge. Removals based on estimated raw
discharge are approximately 46,500 kg of toxic pollutants. The
final PSES effluent mass limitations will remove 620 kg/yr of
toxic metals over the intermediate PSES option considered, which
lacks filtration. Both options are economically achievable. The
Agency believes the incremental removal justifies selection of
filtration as part of PSES model technology. Filtration is
currently demonstrated by five indirect discharging secondary
lead plants. The estimated capital cost for achieving promulgated
PSES is $4.26 million (March, 1982 dollars), and the estimated
annual cost is $2.51 million.
PSNS OPTION SELECTION
The technology basis for promulgated PSNS is identical to NSPS.
The PSNS treatment consists of in-process flow reduction,
chemical precipitation, sedimentation, and multimedia filtration.
The Agency recognizes that new sources have the opportunity to
implement more advanced levels of treatment without incurring the
costs of retrofitting and the costs of partial or complete
shutdown necessary for installation of the new equipment that
existing plants should have.
Promulgated PSNS prevents pass through and equals promulgated
NSPS. The PSNS flow allowances are based on minimization of
process wastewater wherever possible through use of cooling
towers to recycling casting contact cooling water. Complete
recycle of treated facility washdown and battery case
classification wastewater is also included. Dry scrubbing is
required for kettle air pollution control for the reasons
provided in NSPS.
BJ?Gl!LAT_ED POLLUTANT PARAMETERS
Pollutants and pollutant parameters selected for limitation in
accordance with the rationale of Sections VI and X, are identical
to those selected for limitation for BAT. EPA is promulgating
PSES and PSNS for ammonia, antimony, arsenic, lead, and zinc to
prevent pass-through. The conventional pollutants are not
limited under PSES and PSNS because they are effectively
controlled by POTW.
2025
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
PRETREATMENT STANDARDS
The PSES and PSNS discharge flows are identical to the BAT
discharge flows for all processes except PSNS for kettle air
pollution control. These discharge flows are listed in Tables
XII-2 and XII-3 (pages 2027 and 2028). The mass of pollutant
allowed to be discharged per mass of product is calculated by
multiplying the achievable treatment concentration (mg/1) by the
normalized wastewater discharge flow (1/kkg). The achievable
treatment concentrations are presented in Table VII-21 of Vol. I
(page 248). Pretreatment standards for existing and new sources,
as determined from the above procedure, are shown in Tables XII-4
and XII-5 (pages 2030 and 2036) for each waste stream.
2026
-------
Table XII-1
POLLUTANT REMOVAL ESTIMATES FOR SECONDARY LEAD INDIRECT DISCHARGERS
POLLUTANT
Arsenl c
Ant Imony
Cadml urn
Chromium
Lead
Nickel
SI Iver
Tha I 1 lum
Copper
7, Inc.
TOTAL TOXIC MKTALS
KJ
O A luml ntim
^J Ammonia
1 roil
TOTAL NONCONVKNTIONALS
TSS
Oil & Grease
TOTAL CONVENT 1ONALS
TOTAL POLLUTANTS
KLOW (l/yr)
NOTK • TOTAL TOXIC MKTAI
TOTAL
RAW WASTE
(kg/yr)
3.867.6
6.907.1
338.4
537.9
33.495.4
523.7
44.0
190.2
666.0
916.8
47.487.0
19,652.6
1 ,527.2
21,902.6
43,082.4
1 ,278,058.9
3,693.4
1 .281 .752.2
1 .372.321.7
441 ,600,000
I.S " Arspnir +• AnM
OPTION A
DISCHARGED
(kg/yr)
225.2
309 . 1
34.9
37.1
53.0
326.8
44.0
190.2
256.1
145.7
1 .622.1
989.2
0.0
181.1
1.170.2
5.299.2 1
3,693.4
8.992.6 1
11,784.9 1
36
Imrtnv 4- Carlmi 11
OPTION A
REMOVED
(kg/yr)
3.642.4
6.598.0
303.5
500.8
33,442.4
196.9
0.0
0.0
409.8
771.1
45,864.9
18,663.4
1 .527.2
21 .721.5
41 .912.2
.272.759.7
0.0
,272.759.7
,360,536.8
,900.000
m -1- Chromium
OPTION B
DISCHARGED
(kg/yr)
222.8
305.8
34.5
36.7
52.4
323.3
43.7
190.2
253.4
144.2
1,607.0
978.7
0.0
179.1
1.157.8
5,242.8 1
3,693.4
8,936.2 1
11 ,701.0 1
36
+ Lead + Mirk
OPTION B
REMOVED
(kg/yr)
3.644.8
6,601 .3
303.9
501.2
33,442.9
200.4
0.3
0.0
412.6
772.6
45.880.0
18,674.0
1 .527.2
21,723.4
41,924.6
,272.816.1
0.0
,272,816.1
,360,620.7
,900.000
pi + SI 1 ver +
OPTION C
DISCHARGED
(kg/yr)
148.5
205.3
21,4
30.6
35.0
96.1
30.6
148.5
170.4
100.5
987.0
651.0
0.0
122.3
773.3
1,135.9
3.693.4
4,829.3
6.589.6
Thall turn -1- f
OPTION C
REMOVED
(kg/yr)
3,719.1
6.701.8
317.0
507.3
33.460.4
427.6
13.4
41.6
495.6
816.3
46.500.1
19.001 .6
1 .527.2
21 ,780.2
42.309.1
1,276.922.9
0.0
1 .276,922.9
1 ,365,732.1
^onnpr 4- 71nr
to
M
O
O
jjj
K
!_,
M
§
to
G
Cfl
O
i-3
M
Q
O
K
to
M
0
1
X
H
H
TOTAL NONCONVKNTIONALS = Aluminum + Ammonia + Iron
TOTAL CONVENTIONALS = TSS + Oil & Grease
OPTION A - Lime Precipitation and Sedimentation
OPTION R = Option A, plus In-process Flow Reduction
OPTION C = Option B, plus Multimedia Filtration
-------
o
tvj
00
Table XII-2
PSES WASTEWATER DISCHARGE RATES FOR THE SECONDARY LEAD SUBCATEGORY
Wd:i t. t.wii L . uf Stream
Cracking
]r,,rn ,,- o i,jpf-
Control
Pollution
Kettle Wet Air
!.'o 1 . n Control
Lead Paste
Oesulfurizat ion
Casting Contact
Cooling Water
Truck Wash
Ficility Washdown
Battery Case
Classification
Kmployee Hand Wash
Employee Respirator Wash
Laundering of Uniforms
PSES Normalized
Discharge Rate
I/kkg gal/ton
673 161
2,610 626
45 11
0
0
22
21
0
0
27
44
128
5.3
5
0
0
6.5
10.5
30.7
Production Normalizing Parameter
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from kettle
furnaces
kkg of lead processed through
desulfurization
kkg of lead cast
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead produced from smelting
w
o
§
I
IT"
W
§
o
w
CD
O
w
o
-------
Table XII-3
PSNS WASTEWATER DISCHARGE RATES FOR THE SECONDARY LEAD SUBCATEGORY
NJ
O
K)
VD
Wastewater Stream
Battery Cracking
Furnace Wet Air Pollution
Control
Kettle Wet Air
Pollution Control
Lead Paste
Oesulfurization
Casting Contact
Cooling Water
Truck Wash
Facility Washdown
Battery Case
Classification
Employee Hand Wash
Employee Respirator Wash
Laundering of Uniforms
PSNS Normalized
Discharge Rate
I/kkg gal/ton
673 161
2,610
0
0
626
0
0
22
21
0
0
27
44
128
5.3
5
0
0
6.5
10.5
30.7
Production Normalizing Parameter
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from kettle
furnaces
kkg of lead processed through
desulfurlzatlon
kkg of lead cast
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead scrap produced
kkg of lead produced from smelting
kkg of lead produced from smelting
kkg of lead produced from smelting
en
M
o
§
M
6
cn
W
o
w
Cl
8
K
cn
W
o
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4
PSES FOR THE SECONDARY LEAD SUBCATEGORY
(a) Battery Cracking P'SES.
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
1.299
0.935
0.135
0.249
0.861
0.188
1.370
0.195
0.942
0.686
0.000
0.579
0.384
0.054
0.101
0.411
0.087
0.249
0.081
0.411
0.283
0.000
[b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 5.037. 2.245
^Arsenic 3.628 1.488
Cadmium 0.522 0.209
Chromium 0.966 0.392
Copper 3.341 1.592
*Lead 0.731 0.339
Nickel 1.436 0.966
Silver 0.757 0.313
Thallium 3.654 1.592
*Zinc 2.662 1.096
*AmmQnia (as N) 0.000 0.000
*Regulated Pollutant
2030
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE SECONDARY LEAD SUBCATEGORY
(c) Kettle Wet Air Pollution Control PSES
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
* Ammonia (as- N)
0.087
0.063
0.009
0.017
0.058
0.013
0.025
0.013
0.063
0.046
0.000
0.039
0.026
0.004
0.007
0.027
0.006
0.017
0.005
0.027
0.019
0.000
(d) Lead Paste Desulfurization PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced through desulfurization
English Units - Ibs/million Ibs of lead produced through
desulfurization
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*Reg uTa t ecT'Po 1 '
2031
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE SECONDARY LEAD SUBCATEGORY
(e) Casting Contact Cooling PSES
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
~"Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
* Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
* Ammonia (as N)
0.042
0.031
0.004
0.008
0.028
0.006
0.012
0.006
0.031
0.022
0.000
0.019
0.013
0.002
0.003
0.013
0.003
0.008
0.003
0.013
0.009
0.000
(f) Truck Wash PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Anlimony 0.041 0.018
*Arsenic 0.029 0.012
Cadmium 0.004 0.002
Chromium 0.008 0.003
Copper 0.027 0.013
*Lead 0.006 0.003
Nickel 0.012 . 0.008
Silver 0.006 0.003
Thallium 0.029 0.013
*Zinc 0.021 0.009
*Ammonia (as N) 0.000 0.000
*Requlated Pollutant
2032
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE SECONDARY LEAD SUBCATEGORY -
(g) Facility Washdown PSES
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver ' 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
(h) Battery Case Classification PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Airunonia (as N) 0.000 0.000
*Regulated Pollutant
2033
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
. TABLE XI1-4 (Continued)
PSES FOR THE SECONDARY LEAD SUBCATEGORY
(i) Employee Handwash PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
0.052
0.038
0.005
0.010
0.035
0.008
0.015
0.008
0.038
0.028
0.000
0.023
0.015
0.002
0.004
0.016
0.004
0.010
0.003
0.016
0.011
0.000
(i) Employee Respirator Wash PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
0.085
0.061
0.009
0.016
0.056
0.012
0.024
0.013
0.062
0.045
0.000
0.038
0.025
0.004
0.007
0.027
0.006
0.016
0.005
0.027
0.018
0.000
*Regulated Pollutant
2034
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-4 (Continued)
PSES FOR THE SECONDARY LEAD SUBCATEGORY
(j) Laundering Uniforms PSES
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.247 0.110
*Arsenic 0.178 0.073
Cadmium 0.026 0.010
Chromium 0.047 0.019
Copper 0.164 0.078
*Lead 0.036 0.017
Nickel 0.070 0.047
Silver 0.037 0.015
Thallium 0.179 0.078
*Zinc 0.131 0.054
*Ammonia (as-N) 0.000 0.000
* Regulated Pollutant
2035
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5
PSNS FOR THE SECONDARY LEAD SUBCATEGORY
(a) Battery Cracking PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zj.nc
*Ammonia (as N)
1.299
0.935
0.135
0.249
0.861
0 . 188
1.370
0.195
0.942
0.686
0.000
0.579
0.384
0.054
0.101
0.411
0.087
0.249
0.081
0.411
0.283
0.000
(b) Blast, Reverberatory, or Rotary Furnace Wet Air
Pollution Control PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
5.037
3.628
0.522
0.966
3.341
0.731
1.436
0.757
3.654
2.662
0.000
2.245
1.488
0.209
0.392
1.592
0.339
0.966
0.313
1.592
1.096
0.000
*Regulated Pollutant
2036
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSNS FOR THE SECONDARY LEAD SUBCATEGORY
(c) Kettle Wet Air Pollution Control PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from refining
English Units - Ibs/million Ibs of lead produced from refining
*Antimony
*Arsenic
Cadmium
Chromium
Coppe r
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
(d) Lead Paste Desulfurization PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced through
desulfurization
English Units - Ibs/million Ibs of lead produced through
desulfurization
*Antimony 0.000 0.000
*Arsenic 0.000 0.000 *
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 . 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*Regulated Pollutant
2037
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSNS FOR THE SECONDARY LEAD SUBCATEGORY
(e) Casting Contact Cooling. PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead cast
English Units - Ibs/million Ibs of lead cast
*Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
0.042
0.031
0.004
0.008
0.028
0.006
0.012
0.006
0.031
0.022
0.000
0.019
0.013
0.002
0.003
0.013
0.003
0.008
0.003
0.013
0.009
0.000
TABLE XII-5 (Continued)
PSNS EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
(f) Truck Wash PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.041 0.018
*Arsenic 0.029 0.012
Cadmium 0.004 0.002
Chromium 0.008 0.003
Copper 0.027 0.013
*Lead 0.006 0.003
Nickel 0.012 0.008
Silver 0.006 0.003
Thallium 0.029 0.013
*Zinc 0.021 0.009
*Ammonia (as N) 0.000 0.000
*Regulated Pollutant
2038
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSNS FOR THE SECONDARY LEAD SUBCATEGORY
(g) Facility Washdown PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average -
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc - 0.000 0.000
*Ammonia (as N) 0.000 0.000
(h) Battery Case Classification PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead scrap produced
English Units - Ibs/million Ibs of lead scrap produced
*Antimony 0.000 0.000
*Arsenic 0.000 0.000
Cadmium 0.000 0.000
Chromium 0.000 0.000
Copper 0.000 0.000
*Lead 0.000 0.000
Nickel 0.000 0.000
Silver 0.000 0.000
Thallium 0.000 0.000
*Zinc 0.000 0.000
*Ammonia (as N) 0.000 0.000
*Regulated Pollutant
2039
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSNS FOR THE SECONDARY LEAD SUBCATEGORY
(i) Employee Handwash PSNS.
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
* Antimony
*Arsenic
Cadmium
Chromium
Copper
*Lead
Nickel
Silver
Thallium
*Zinc
*Ammonia (as N)
0.052
0.038
0.005
0.010
0.035
0.008
0.015
0.008
0.038
0.028
0.000
0.023
0.015
0.002
0.004
0.016
0.004
0.010
0.003
0.016
0.011
0.000
(i) Employee Respirator Wash PSNS
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from
smelting
*Antimony 0.085 0.038
*Arsenic 0.061 0.025
Cadmium 0.009 0.004
Chromium 0.016 0.007
Copper 0.056 0.027
*Lead 0.012 0.006
Nickel 0.024 0.016
Silver 0.-013 0.005
Thallium 0.062 0.027
*Zinc 0.045 0.018
*Ammonia (as N) 0.000 0.000
*Regulated Pollutant
2040
-------
SECONDARY LEAD SUBCATEGORY SECT - XII
TABLE XII-5 (Continued)
PSNS FOR THE SECONDARY LEAD SUBCATEGORY
(j) Laundering Uniforms PSNS
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
Metric Units - mg/kg of lead produced from smelting
English Units - Ibs/million Ibs of lead produced from smelting
*Antimony 0.247 0.110
*Arsenic 0.178 0.073
Cadmium 0.026 0.010
Chromium 0.047 0.019
Copper 0.164 0.078
*Lead 0.036 0.017
Nickel 0.070 0.047
Silver 0.037 0.015
Thallium 0.179 0.078
*Zinc 0.131 .0.054
*Ammonia (as N) 0.000 0.000
*Regulated Pollutant
2041
-------
Page Intentionally Blank
-------
SECONDARY LEAD SUBCATEGORY SECT - XIII
SECTION XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
EPA is not promulgating best conventional pollutant control
technology (BCT) for the secondary lead subcategory at this time.
2043
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NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Primary Antimony Subcategory
William K. Reilly
Administrator
Rebecca Hanmer
Acting Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
Mav 1989
U.S. Environmental Protection Agency
Office, of Water
Office of Water Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
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PRIMARY ANTIMONY SUBCATEGORY
TABLE OF CONTENTS
Section " Page
I SUMMARY 2053
II CONCLUSIONS 2055
III SUBCATEGORY PROFILE 2061
Description of Primary Antimony Production 2061
Raw Materials 2062
Pyrometallurgical Processes 2062
Leaching 2062
Aut |