iron and steel effluent guidelines development document - …development document for final effluent...

Development Document for FinalEffluent Limitations Guidelines andStandards for the Iron and SteelManufacturing Point Source Category

April 2002

U.S. Environmental Protection AgencyOffice of Water (4303T)

1200 Pennsylvania Avenue, NWWashington, DC 20460

EPA-821-R-02-004

Development Document for FinalEffluent Limitations Guidelines andStandards for the Iron and SteelManufacturing Point Source Category

EPA 821-R-02-004

Christine Todd WhitmanAdministrator

G. Tracy Mehan, IIIAssistant Administrator, Office of Water

Geoffrey H. GrubbsDirector, Office of Science and Technology

Sheila E. FraceDirector, Engineering and Analysis Division

Donald F. AndersonActing Chief, Chemical Engineering Branch

William Anderson and George JettProject Managers

Yu-Ting GuilaranProject Engineer

Jade Lee-FreemanStatistician

April 2002

U.S. Environmental Protection Agency, Office of WaterWashington, DC 20460

ACKNOWLEDGMENT AND DISCLAIMER

This report has been reviewed and approved for publication by the Engineeringand Analysis Division, Office of Science and Technology. The Agency would like toacknowledge the contributions of the Engineering and Analysis Division staff toward thedevelopment of this technical document.

This report was prepared with the technical support of Eastern Research Group,Inc. and statistical support of Science Applications International Corporation (SAIC), under thedirection and review of the Office of Science and Technology. Neither the United StatesGovernment nor any of its employees, contractors, subcontractors, or their employees make anywarrant, expressed or implied, or assume any legal liability or responsibility for any third party’suse of or the results of such use of any information, apparatus, product, or process discussed inthis report, or represents that its use by such party would not infringe on privately owned rights.

The primary contact regarding questions or comments on this document is:

George JettU.S. EPA Engineering and Analysis Division (4303T)1200 Pennsylvania Avenue NWWashington, DC 20460

(202) 566-1070 (telephone)(202) 566-1053 (fax)[email protected]

Table of Contents

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TABLE OF CONTENTS

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1 APPLICABILITY AND SUMMARY OF FINAL REGULATION . . . . . . . . . 1-11.1 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 Applicability Interface With Other Regulations . . . . . . . . . . . . . . . . . . 1-2

1.2.1 Electroplating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.2.2 Metal Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.2.3 Coil Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.2.4 Ferroalloy Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.2.5 Metal Molding and Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.3 Summary of Proposed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41.4 Summary of Final Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61.5 Protection of Confidential Business Information . . . . . . . . . . . . . . . . . 1-91.6 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

2 BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1 Legal Authority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 Legislative Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1.2 Section 304(m) Requirements and Litigation . . . . . . . . . . . . . . 2-3

2.2 History of Iron and Steel Category Rulemaking Activities . . . . . . . . . . 2-42.2.1 Prior Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.2.2 Current Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.2.3 Preliminary Study of the Iron and Steel Category . . . . . . . . . . . 2-72.2.4 Proposed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.2.5 Notice of Data Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102.2.6 Extension to Public Comment Period . . . . . . . . . . . . . . . . . . . 2-102.2.7 Public Outreach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3 DATA COLLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1 Base Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 Surveys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.3 Site Visits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73.4 Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93.5 Other Data Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113.6 Public Participation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.7 Summary of Post-Proposal Data Collected . . . . . . . . . . . . . . . . . . . . . 3-143.8 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

4 ANALYTICAL METHODS AND BASELINE VALUES . . . . . . . . . . . . . . . . 4-14.1 Explanation and Importance of Baseline Values . . . . . . . . . . . . . . . . . . 4-14.2 Reporting Conventions Associated with Analytical Results . . . . . . . . . 4-24.3 Nominal Quantitation Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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4.4 Comparisons to Baseline Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34.4.1 Individual Data Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44.4.2 Assessment of Treatability of Influent . . . . . . . . . . . . . . . . . . . . 4-4

4.5 Analytical Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54.5.1 Methods 1613B, 1625, 1664 (2,3,7,8-TCDF, Benzo(a)pyrene,

Naphthalene, Phenol, HEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54.5.2 Method 1620 and 200.7 (Metals) . . . . . . . . . . . . . . . . . . . . . . . . 4-64.5.3 Method 160.2, 209C, and 2540D (Total Suspended Solids) . . . 4-64.5.4 Method 218.4 (Hexavalent Chromium) . . . . . . . . . . . . . . . . . . . 4-74.5.5 Method 239.2 (Lead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74.5.6 Method 245.1 (Mercury) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84.5.7 Method 3120B (Chromium and Hexavalent Chromium) . . . . . 4-84.5.8 Method 3130B (Lead, Zinc) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84.5.9 Method 335.2 (Total Cyanide) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94.5.10 Method 340.2 (Fluoride) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94.5.11 Methods 350.2, 417/350.2, and 4500-NH (Ammonia as3

Nitrogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104.5.12 Methods 353.1, 353.2, and 353.3 (Nitrate/Nitrite) . . . . . . . . . 4-104.5.13 Methods 4500-CN M and D4374-98 (Thiocyanate) . . . . . . . . 4-104.5.14 Methods 625 and 610 (Naphthalene) . . . . . . . . . . . . . . . . . . . . 4-114.5.15 Method 8270 (Benzo(a)pyrene) . . . . . . . . . . . . . . . . . . . . . . . . 4-114.5.16 Methods 420.1 and 420.2 (Phenols (4AAP)) . . . . . . . . . . . . . . 4-12

4.6 Requirements for Laboratory Analysis for Compliance Monitoring . . 4-134.7 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

5 DESCRIPTION OF THE INDUSTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.1 Types of Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.2 Manufacturing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.1 Cokemaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45.2.2 Sintering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.2.3 Briquetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.2.4 Blast Furnace Ironmaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85.2.5 Direct-Reduced Ironmaking . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95.2.6 Steelmaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105.2.7 Vacuum Degassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125.2.8 Ladle Metallurgy and Secondary Steelmaking . . . . . . . . . . . . 5-125.2.9 Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135.2.10 Hot Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145.2.11 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20


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6 SUBCATEGORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1 Subcategorization Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.2 Proposed Subcategorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.3 Final Subcategorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3.1 Proposed Subpart A: Cokemaking . . . . . . . . . . . . . . . . . . . . . . . 6-56.3.2 Proposed Subpart B: Ironmaking . . . . . . . . . . . . . . . . . . . . . . . . 6-76.3.3 Proposed Subpart C: Integrated Steelmaking . . . . . . . . . . . . . . 6-86.3.4 Proposed Subpart D: Integrated and Stand-Alone Hot

Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106.3.5 Proposed Subpart E: Non-Integrated Steelmaking and Hot

Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106.3.6 Proposed Subpart F: Steel Finishing . . . . . . . . . . . . . . . . . . . . 6-116.3.7 Proposed Subpart G: Other Operations . . . . . . . . . . . . . . . . . . 6-12

7 WASTEWATER CHARACTERIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.1 Water Use and Wastewater Generation and Discharge . . . . . . . . . . . . . 7-1

7.1.1 Cokemaking Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27.1.2 Sintering and Ironmaking Operations . . . . . . . . . . . . . . . . . . . . 7-67.1.3 Integrated Steelmaking Operations . . . . . . . . . . . . . . . . . . . . . . 7-77.1.4 Integrated and Stand-Alone Hot Forming Operations . . . . . . . 7-107.1.5 Non-Integrated Steelmaking and Hot Forming Operations . . . 7-117.1.6 Steel Finishing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137.1.7 Other Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7.2 Identification of Pollutants of Concern (POCs) . . . . . . . . . . . . . . . . . . 7-187.2.1 Cokemaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-207.2.2 Ironmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-217.2.3 Integrated Steelmaking Subcategory . . . . . . . . . . . . . . . . . . . . 7-227.2.4 Integrated and Stand-Alone Hot Forming Subcategory . . . . . 7-237.2.5 Non-Integrated Steelmaking and Hot Forming Subcategory . 7-237.2.6 Steel Finishing Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . 7-267.2.7 Other Operations Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7.3 Untreated Process Wastewater Characterization Data for Pollutants ofConcern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

8 POLLUTION PREVENTION AND WASTEWATER TREATMENTTECHNOLOGIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18.1 Wastewater Minimization and Pollution Prevention Technologies . . . 8-2

8.1.1 High-Rate Recycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28.1.2 Countercurrent Cascade Rinsing . . . . . . . . . . . . . . . . . . . . . . . . 8-38.1.3 Acid Reuse, Recycle, and Recovery Systems . . . . . . . . . . . . . . 8-4


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8.1.4 Extension of Process Solution Life . . . . . . . . . . . . . . . . . . . . . . 8-68.1.5 Evaporation with Condensate Recovery . . . . . . . . . . . . . . . . . . 8-7

8.2 Process Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78.2.1 Effluent-Free Pickling Process with Fluid Bed Hydrochloric

Acid Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78.2.2 Nitric-Acid-Free Pickling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88.2.3 Effluent-Free Exhaust Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.3 Treatment Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88.3.1 Physical/Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98.3.2 Biological Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-288.3.3 Sludge Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

8.4 Best Management Practices (BMPs) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-358.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

9 TECHNOLOGY OPTIONS CONSIDERED AS THE BASIS OF THEREGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19.1 Cokemaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.1.1 By-Product Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . . 9-29.1.2 Non-Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9.2 Ironmaking and Sintering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-79.3 Integrated Steelmaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-119.4 Integrated and Stand-Alone Hot Forming . . . . . . . . . . . . . . . . . . . . . . 9-149.5 Non-Integrated Steelmaking and Hot Forming . . . . . . . . . . . . . . . . . . 9-169.6 Steel Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-209.7 Other Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

9.7.1 Briquetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-249.7.2 Direct-Reduced Ironmaking (DRI) . . . . . . . . . . . . . . . . . . . . . 9-249.7.3 Forging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

10 INCREMENTAL INVESTMENT AND OPERATING AND MAINTENANCECOSTS FOR THE REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.1 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.1.1 Investment Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-310.1.2 Operating and Maintenance Costs . . . . . . . . . . . . . . . . . . . . . . 10-710.1.3 One-Time Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

10.2 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1310.2.1 Cokemaking Subcategory - By-Product Recovery and

Non-Recovery Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1310.2.2 Ironmaking and Sintering Subcategories . . . . . . . . . . . . . . . . 10-1610.2.3 Integrated Steelmaking Subcategory . . . . . . . . . . . . . . . . . . . 10-1910.2.4 Integrated and Stand-Alone Hot Forming Subcategory . . . . 10-21


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10.2.5 Non-Integrated Steelmaking and Hot Forming Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

10.2.6 Steel Finishing Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . 10-2410.2.7 Other Operations Subcategory . . . . . . . . . . . . . . . . . . . . . . . . 10-27

10.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

11 POLLUTANT LOADINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-111.1 Sources and Use of Available Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-211.2 Methodology Used to Estimate Baseline Pollutant Loadings . . . . . . . 11-3

11.2.1 Determination of Site-Specific Average Baseline PollutantConcentrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.2.2 Determination of Subcategory-Specific Average BaselinePollutant Concentrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.2.3 Cotreatment of Wastewater . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-611.2.4 POCs Included in the Pollutant Loadings Analysis . . . . . . . . . 11-711.2.5 Sites and Data Used in the Pollutant Loadings Analysis . . . . . 11-711.2.6 Baseline Pollutant Loadings Calculation . . . . . . . . . . . . . . . . . 11-8

11.3 Methodology Used to Estimate Treated Pollutant Loadings . . . . . . . 11-1011.3.1 Treated Pollutant Loadings Calculation . . . . . . . . . . . . . . . . 11-10

11.4 Pollutant Removals Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1111.5 How the Costing Analysis Coordinates with the Method Used to

Calculate Treated Pollutant Loadings and Pollutant Removals . . . . . 11-1211.6 Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13

11.6.1 Baseline Pollutant Loadings Calculation . . . . . . . . . . . . . . . 11-1311.6.2 Treated Pollutant Loadings Calculation . . . . . . . . . . . . . . . . 11-1511.6.3 Pollutant Removals Calculation . . . . . . . . . . . . . . . . . . . . . . 11-16

11.7 Pollutant Loadings and Removals for the Cokemaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1811.7.1 Methodology Used to Estimate Baseline Pollutant

Loadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1911.7.2 Methodology Used to Estimate Treated Pollutant Loadings

and Pollutant Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2111.8 Pollutant Loadings and Removals for the Ironmaking Subcategory . 11-22

11.8.1 Methodology Used to Estimate Baseline Pollutant Loadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22

11.8.2 Methodology Used to Estimate Treated Pollutant Loadingsand Pollutant Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25

11.9 Pollutant Loadings and Removals for the Sintering Subcategory . . . 11-2511.9.1 Methodology Used to Estimate Baseline Pollutant

Loadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26


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11.9.2 Methodology Used to Estimate Treated Pollutant Loadingsand Pollutant Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27

11.10 Pollutant Loadings and Removals for the Integrated SteelmakingSubcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2811.10.1 Methodology Used to Estimate Baseline Pollutant

Loadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2911.10.2 Methodology Used to Estimate Treated Pollutant

Loadings and Pollutant Removals . . . . . . . . . . . . . . 11-3011.11 Pollutant Loadings and Removals for the Integrated and Stand-Alone

Hot Forming Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3111.11.1 Methodology Used to Estimate Baseline Pollutant


Loadings and Pollutant Removals . . . . . . . . . . . . . . . 11-3311.12 Pollutant Loadings and Removals for the Non-Integrated Steelmaking

and Hot Forming Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3411.12.1 Methodology Used to Estimate Baseline Pollutant


Loadings and Pollutant Removals . . . . . . . . . . . . . . . 11-3611.13 Pollutant Loadings and Removals for the Steel Finishing

Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3711.13.1 Methodology Used to Estimate Baseline Pollutant


Loadings and Pollutant Removals . . . . . . . . . . . . . . 11-4011.13.3 Alternative Methodology to Estimate

Pollutant Loadings and Removals for the SteelFinishing Subcategory . . . . . . . . . . . . . . . . . . . . . . . . 11-41

11.14 Pollutant Loadings and Removals for the Other OperationsSubcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4111.14.1 Methodology Used to Estimate Baseline Pollutant


Loadings and Pollutant Removals . . . . . . . . . . . . . . . 11-4311.15 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43

12 REGULATED POLLUTANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-112.1 Regulated Pollutant Selection Methodology for Direct Dischargers . 12-1

12.1.1 Cokemaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-312.1.2 Sintering Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6


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12.1.3 Other Operations Subcategory . . . . . . . . . . . . . . . . . . . . . . . . 12-612.2 Regulated Pollutant Selection Methodology for Indirect

Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-712.2.1 Methodology for Determining BAT Percent Removals . . . . . 12-812.2.2 Methodology for Determining POTW Percent Removals . . . . 12-912.2.3 Results of POTW Pass-Through Analysis . . . . . . . . . . . . . . . 12-10

13 PRODUCTION-NORMALIZED FLOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-113.1 Overview of Data Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-113.2 Overview of PNF Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-213.3 Subpart A: Cokemaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

13.3.1 By-Product Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . 13-313.3.2 Non-Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8

13.4 Subpart B: Ironmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . 13-813.4.1 Sintering With Wet Air Pollution Controls . . . . . . . . . . . . . . . 13-813.4.2 Sintering With Dry Air Pollution Controls . . . . . . . . . . . . . . 13-1013.4.3 Blast Furnace Ironmaking . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

13.5 Subpart C: Integrated Steelmaking Subcategory . . . . . . . . . . . . . . . . 13-1313.5.1 Basic Oxygen Furnace (BOF) Steelmaking . . . . . . . . . . . . . . 13-1413.5.2 Ladle Metallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1813.5.3 Vacuum Degassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1813.5.4 Continuous Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20

13.6 Subpart D: Integrated and Stand-Alone Hot Forming Subcategory . 13-2213.7 Subpart E: Non-Integrated Steelmaking and Hot Forming

Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2313.7.1 Electric Arc Furnace (EAF) Steelmaking . . . . . . . . . . . . . . . 13-2413.7.2 Ladle Metallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2413.7.3 Vacuum Degassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2413.7.4 Continuous Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2613.7.5 Hot Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2813.7.6 Combined Thin Slab Casting and Hot Forming . . . . . . . . . . 13-31

13.8 Subpart F: Steel Finishing Subcategory . . . . . . . . . . . . . . . . . . . . . . 13-3313.8.1 Acid Pickling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3313.8.2 Cold Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3613.8.3 Alkaline Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3713.8.4 Continuous Annealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3813.8.5 Hot Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3913.8.6 Electroplating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-40

13.9 Subpart G: Other Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4113.9.1 Direct-Reduced Ironmaking (DRI) Segment . . . . . . . . . . . . . 13-4113.9.2 Forging Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-41


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13.9.3 Briquetting Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4113.10 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-42

14 LIMITATIONS AND STANDARDS: DATA SELECTION ANDCALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-114.1 Overview of Data Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-114.2 Episode Selection for Each Subcategory and Option . . . . . . . . . . . . . 14-3

14.2.1 Cokemaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-414.2.2 Sintering Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-714.2.3 Other Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8

14.3 Data Exclusions and Substitutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-914.4 Data Aggregation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9

14.4.1 Aggregation of Field Duplicates . . . . . . . . . . . . . . . . . . . . . . 14-1014.4.2 Aggregation of Grab Samples . . . . . . . . . . . . . . . . . . . . . . . . 14-1114.4.3 Aggregation of Data Across Outfalls (“Flow-Weighting”) . . 14-11

14.5 Data Editing Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1214.6 Overview of Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13

14.6.1 Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1314.6.2 Selection of Percentiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1314.6.3 Compliance with Limitations . . . . . . . . . . . . . . . . . . . . . . . . . 14-14

14.7 Summary of the Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1614.8 Estimation of Concentration-Based Limitations . . . . . . . . . . . . . . . . 14-17

14.8.1 Calculation of Option Long-Term Averages . . . . . . . . . . . . . 14-1814.8.2 Calculation of Option Variability Factors . . . . . . . . . . . . . . . 14-1914.8.3 Transfers of Option Variability Factors . . . . . . . . . . . . . . . . . 14-1914.8.4 Summary of Steps Used to Derive Concentration-Based

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2014.9 Conversion to Production-Normalized Limitations . . . . . . . . . . . . . . 14-21

14.9.1 Conversion from Concentration-Based Limitations . . . . . . . 14-2214.9.2 Significant Digits for Production-Normalized Limitations . . 14-22

14.10 Naphthalene PSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2314.10.1 Daily Maximum Standard . . . . . . . . . . . . . . . . . . . . . 14-2314.10.2 Monthly Average Standard . . . . . . . . . . . . . . . . . . . . 14-24

15 NON-WATER QUALITY ENVIRONMENTAL IMPACTS . . . . . . . . . . . . . 15-115.1 Energy Requirement Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

15.1.1 Cokemaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-115.1.2 Ironmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-215.1.3 Sintering Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-315.1.4 Integrated Steelmaking Subcategory . . . . . . . . . . . . . . . . . . . . 15-315.1.5 Integrated and Stand-Alone Hot Forming Subcategory . . . . . 15-4


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15.1.6 Non-Integrated Steelmaking and Hot Forming Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

15.1.7 Steel Finishing Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . 15-415.1.8 Other Operations Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . 15-515.1.9 Energy Requirements Summary . . . . . . . . . . . . . . . . . . . . . . . 15-5

15.2 Air Emission Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-515.3 Solid Waste Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

15.3.1 Cokemaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-815.3.2 Ironmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-815.3.3 Sintering Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-915.3.4 Integrated Steelmaking Subcategory . . . . . . . . . . . . . . . . . . . . 15-915.3.5 Integrated and Stand-Alone Hot Forming Subcategory . . . . . 15-915.3.6 Non-Integrated Steelmaking and Hot Forming

Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1015.3.7 Steel Finishing Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . 15-1015.3.8 Other Operations Subcategory . . . . . . . . . . . . . . . . . . . . . . . . 15-1115.3.9 Solid Waste Impacts Summary . . . . . . . . . . . . . . . . . . . . . . . 15-11

15.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11

16 IMPLEMENTATION OF PART 420 THROUGH THE NPDESAND PRETREATMENT PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-116.1 Applicability of the Revised Part 420 . . . . . . . . . . . . . . . . . . . . . . . . . 16-216.2 Changes in Subcategorization Structure and Applicability . . . . . . . . . 16-416.3 Subcategory-Specific Process Wastewater Sources . . . . . . . . . . . . . . 16-516.4 Calculating NPDES Permit and Pretreatment Effluent Limitations . . 16-6

16.4.1 Production Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-616.4.2 Calculating NPDES Permit and Pretreatment Limitations . . . 16-8

16.5 Application of Best Professional Judgement . . . . . . . . . . . . . . . . . . 16-1216.6 Water Bubble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1416.7 Ammonia Waiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1616.8 Compliance Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-16

16.8.1 Sample Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1716.8.2 Monitoring Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1716.8.3 Compliance Monitoring Locations . . . . . . . . . . . . . . . . . . . . 16-18

16.9 NPDES Permit and Pretreatment Variances and Exclusions . . . . . . . 16-1916.9.1 Economic Variances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1916.9.2 Variances Based on Localized Environmental Factors . . . . . 16-2016.9.3 Central Treatment Provision . . . . . . . . . . . . . . . . . . . . . . . . . 16-20

16.10 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21

17 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

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LIST OF TABLES

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3-1 Iron And Steel Industry Survey Strata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-2 Number of Sites Visited in Each State and in Canada . . . . . . . . . . . . . . . . . . . 3-20

3-3 Number of Sites Visited for Each Type of Site . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-4 Number of Sites Visited With Each Type of Manufacturing Process . . . . . . . 3-22

3-5 Manufacturing Processes Sampled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-6 Treatment Systems Sampled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-7 Analytical Methods Used During Sampling Program . . . . . . . . . . . . . . . . . . . 3-28

3-8 Analytes Included Within Analyte Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

4-1 Analytical Methods and Baseline Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

5-1 1997 National Estimate of Types of Iron and SteelSites in the United States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-2 1997 National Estimate of Sites Producing or Processing Carbon, Alloy, orStainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-3 1997 National Estimate of Direct, Indirect, and Zero or AlternativeDischarging Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-4 1997 National Estimate of Actual Production and Rated Capacity byManufacturing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

6-1 Subcategory Comparison of the 1982 and Proposed Regulations . . . . . . . . . . 6-14

6-2 Final Subcategorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

7-1 1997 National Estimate of Annual Discharge from Manufacturing Operationsby Discharge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7-2 Pollutants Not Detected in Untreated Wastewater Samples . . . . . . . . . . . . . . 7-31

7-3 Pollutants Not Identified as Pollutants of Concern, Cokemaking Subcategory -By-Product Recovery Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

LIST OF TABLES (Continued)

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7-4 Pollutants of Concern, Cokemaking Subcategory - By-Product RecoverySegment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-5 Pollutants Not Identified as Pollutants of Concern, IronmakingSubcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

7-6 Pollutants of Concern, Ironmaking Subcategory - Sintering Segment . . . . . . 7-46

7-7 Pollutants of Concern, Ironmaking Subcategory - Blast Furnace Segment . . 7-49

7-8 Pollutants Not Identified as Pollutants of Concern, Integrated SteelmakingSubcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

7-9 Pollutants of Concern, Integrated Steelmaking Subcategory . . . . . . . . . . . . . 7-58

7-10 Pollutants Not Identified as Pollutants of Concern, Integrated and Stand-AloneHot Forming Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

7-11 Pollutants of Concern, Integrated and Stand-Alone Hot FormingSubcategory - Carbon and Alloy Steel Segment . . . . . . . . . . . . . . . . . . . . . . . 7-64

7-12 Pollutants of Concern, Integrated and Stand-Alone Hot FormingSubcategory - Stainless Steel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

7-13 Pollutants Not Identified as Pollutants of Concern, Non-integrated Steelmakingand Hot Forming Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

7-14 Pollutants of Concern, Non-Integrated Steelmaking and Hot FormingSubcategory - Carbon and Alloy Steel Segment . . . . . . . . . . . . . . . . . . . . . . . 7-73

7-15 Pollutants of Concern, Non-Integrated Steelmaking and Hot FormingSubcategory - Stainless Steel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

7-16 Pollutants Not Identified as Pollutants of Concern, Steel FinishingSubcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75

7-17 Pollutants of Concern, Steel Finishing Subcategory - Carbon and AlloySteel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79

7-18 Pollutants of Concern, Steel Finishing Subcategory - Stainless SteelSegment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81


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7-19 Pollutants Not Identified as Pollutants of Concern, Other OperationsSubcategory - Direct-Reduced Ironmaking Segment . . . . . . . . . . . . . . . . . . . 7-83

7-20 Pollutants of Concern, Other Operations Subcategory - Direct-ReducedIronmaking Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90

7-21 Untreated Process Wastewater Characteristics for Pollutants of Concern,Cokemaking Subcategory - By-Product Recovery Segment . . . . . . . . . . . . . . 7-91

7-22 Untreated Process Wastewater Characteristics for Pollutants of Concern,Ironmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94

7-23 Untreated Process Wastewater Characteristics for Pollutants of Concern,Integrated Steelmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98

7-24 Untreated Process Wastewater Characteristics for Pollutants of Concern,Integrated and Stand-Alone Hot Forming Subcategory . . . . . . . . . . . . . . . . 7-100

7-25 Untreated Process Wastewater Characteristics for Pollutants of Concern,Non-Integrated Steelmaking and Hot Forming Subcategory . . . . . . . . . . . . 7-102

7-26 Untreated Process Wastewater Characteristics for Pollutants of Concern,Steel Finishing Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104

7-27 Untreated Process Wastewater Characteristics for Pollutants of Concern,Other Operations Subcategory - Direct-Reduced Ironmaking Segment . . . . 7-108

8-1 Wastewater Minimization, Pollution Prevention, and Process ModificationTechnologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

8-2 Wastewater Treatment and Sludge Handling Technologies . . . . . . . . . . . . . . 8-41

9-1 Wastewater Treatment Technologies Reported by Industry SurveyRespondents for By-Product Recovery Cokemaking Sites . . . . . . . . . . . . . . . 9-27

9-2 High-Rate Recycle and Blowdown Treatment Technologies Reported by IndustrySurvey Respondents for Blast Furnace Ironmaking and Sintering Sites . . . . . 9-28

9-3 High-Rate Recycle and Blowdown Treatment Technologies Reported byIndustry Survey Respondents for Integrated Steelmaking Sites . . . . . . . . . . . 9-29


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9-4 High-Rate Recycle and Blowdown Treatment Technologies Reportedby Industry Survey Respondents for Integrated and Stand-Alone HotForming Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

9-5 High-Rate Recycle and Blowdown Treatment Technologies Reported byIndustry Survey Respondents for Non-Integrated Steelmaking and HotForming Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31

9-6 In-Process and End-of-Pipe Wastewater Treatment Technologies Reportedby Industry Survey Respondents for Steel Finishing Sites . . . . . . . . . . . . . . . 9-32

9-7 High-Rate Recycle Equipment and Blowdown Wastewater TreatmentTechnologies Reported by Industry Survey Respondents forDirect-Reduced Ironmaking (DRI) and Forging Sites . . . . . . . . . . . . . . . . . . . 9-33

10-1 Assumptions Used to Develop Cost Estimates in Tables 10-2 through 10-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30

10-2 Design Specifications for Cokemaking Granular Activated Carbon ModelTreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31

10-3 Estimated Investment Costs for Cokemaking Granular Activated CarbonModel Treatment Systems (100,000 - 2,700,000 gpd) . . . . . . . . . . . . . . . . . 10-32

10-4 Design Specifications for Cokemaking Breakpoint Chlorination ModelTreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37

10-5 Estimated Investment Costs for Cokemaking Breakpoint Chlorination ModelTreatment Systems (100,000 - 2,700,000 gpd) . . . . . . . . . . . . . . . . . . . . . . . 10-38

10-6 Design Specifications for Metals Precipitation Model Treatment Systems forBlast Furnace and Sintering Wastewater . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46

10-7 Estimated Investment Costs for Metals Precipitation Model TreatmentSystems for Blast Furnace and Sintering Wastewater (150,000 - 2,000,000 gpd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47

10-8 Design Specifications for Breakpoint Chlorination Model Treatment Systemsfor Blast Furnace and Sintering Wastewater . . . . . . . . . . . . . . . . . . . . . . . . . 10-53


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10-9 Estimated Investment Costs for Breakpoint Chlorination Model TreatmentSystems for Blast Furnace and Sintering Wastewater (150,000 - 2,000,000 gpd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54

10-10 Design Specifications for Metals Precipitation Model Treatment Systemsfor Basic Oxygen Furnace, Vacuum Degassing, and Continuous CastingWastewater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61

10-11 Estimated Investment Costs for Metals Precipitation Model Treatment Systemsfor Basic Oxygen Furnace, Vacuum Degassing, and Continuous CastingWastewater (150,000 - 2,000,000 gpd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62

10-12 Design Specifications for Multimedia Filtration Model TreatmentSystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69

10-13 Estimated Investment Costs for Multimedia Filtration Model TreatmentSystems (150,000 - 20,000,000 gallons per day) . . . . . . . . . . . . . . . . . . . . . . 10-70

10-14 Cost Factors to Determine Investment Costs . . . . . . . . . . . . . . . . . . . . . . . . . 10-78

10-15 Iron and Steel Investment Cost Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79

10-16 Iron and Steel Operating and Maintenance (O&M) Cost Equations . . . . . . . 10-83

10-17 Summary of Incremental Costs for the Cokemaking Subcategory(in millions of 1997 dollars) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96

10-18 Summary of Incremental Costs for the Ironmaking and SinteringSubcategories (in millions of 1997 dollars) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96

10-19 Summary of Incremental Costs for the Integrated SteelmakingSubcategory (in millions of 1997 dollars) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96

10-20 Summary of Incremental Costs for the Integrated and Stand-Alone HotForming Subcategory (in millions of 1997 dollars) . . . . . . . . . . . . . . . . . . . . 10-97

10-21 Summary of Incremental Costs for the Non-Integrated Steelmakingand Hot Forming Subcategory (in millions of 1997 dollars) . . . . . . . . . . . . . 10-97

10-22 Summary of Incremental Costs for the Steel Finishing Subcategory(in millions of 1997 dollars) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98


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10-23 Summary of Incremental Costs for the Other Operations Subcategory(in millions of 1997 dollars) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98

11-1 Pollutants of Concern Not Detected in Effluent at Any Site . . . . . . . . . . . . . 11-45

11-2 Pollutants of Concern That Failed the Influent Editing Criteria . . . . . . . . . . 11-49 11-3 POTW Percent Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51

11-4 Subcategory-Specific Average Baseline Pollutant Concentrationsfor the Cokemaking Subcategory - By-Product Recovery Cokemaking Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-54

11-5 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the By-Product Recovery Cokemaking Segment, Direct Dischargers . . . 11-56

11-6 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the By-Product Recovery Cokemaking Segment, Indirect Dischargers . 11-58

11-7 Subcategory-Specific Average Baseline Pollutant Concentrations for theIronmaking Subcategory, Blast Furnace Wastewater Only . . . . . . . . . . . . . . 11-60

11-8 Subcategory-Specific Average Baseline Pollutant Concentrations forthe Ironmaking Subcategory, Commingled Blast Furnace and SinteringWastewater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62

11-9 Arithmetic Means of BAT Performance Data for the IronmakingSubcategory, Blast Furnace Wastewater Only . . . . . . . . . . . . . . . . . . . . . . . 11-64

11-10 Arithmetic Means of BAT Performance Data for the IronmakingSubcategory, Commingled Blast Furnace and Sintering Wastewater . . . . . . 11-66

11-11 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Ironmaking Subcategory, Direct Dischargers . . . . . . . . . . . . . . . . . . 11-69

11-12 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Ironmaking Subcategory, Indirect Dischargers . . . . . . . . . . . . . . . . . 11-71

11-13 Subcategory-Specific Average Baseline Pollutant Concentrations for the SinteringSubcategory, Commingled Blast Furnace and Sintering Wastewater . . . . . . 11-73


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11-14 Minimum Levels Used as Treated Effluent Concentrations for theSintering Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-75

11-15 Summary of Baseline and Treated Pollutant Loadings and PollutantRemovals for the Sintering Subcategory, Direct Dischargers . . . . . . . . . . . . 11-76

11-16 Subcategory-Specific Average Baseline Pollutant Concentrations for theIntegrated Steelmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-78

11-17 Arithmetic Means of BAT Performance Data for the IntegratedSteelmaking Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-79

11-18 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Integrated Steelmaking Subcategory, Direct Dischargers . . . . . . . . . 11-80

11-19 Subcategory-Specific Average Baseline Pollutant Concentrations for theIntegrated and Stand-Alone Hot Forming Subcategory - Carbon and AlloySteel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-81

11-20 Subcategory-Specific Average Baseline Pollutant Concentrationsfor the Integrated and Stand-Alone Hot Forming Subcategory - StainlessSteel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-82

11-21 Arithmetic Means of BAT Performance Data for the Integrated and Stand-Alone Hot Forming Subcategory - Carbon and Alloy Steel Segment . . . . . . 11-83

11-22 Arithmetic Means of BAT Performance Data for the Integrated and Stand-Alone Hot Forming Subcategory - Stainless Steel Segment . . . . . . . . . . . . . 11-84

11-23 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Integrated and Stand-Alone Hot Forming Subcategory - Carbon andAlloy Steel Segment, Direct Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-85

11-24 Summary of Baseline and Treated Pollutant Loadings and Removals for the Integrated and Stand-Alone Hot Forming Subcategory - Carbon and AlloySteel Segment, Indirect Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-86

11-25 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Integrated and Stand-Alone Hot Forming Subcategory - Stainless SteelSegment, Indirect Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-87


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11-26 Subcategory-Specific Average Baseline Pollutant Concentrations for theNon-Integrated Steelmaking and Hot Forming Subcategory - Carbon andAlloy Steel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-88

11-27 Subcategory-Specific Average Baseline Pollutant Concentrations for theNon-Integrated Steelmaking and Hot Forming Subcategory - Stainless SteelSegment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-89

11-28 LTAs for the Non-Integrated Steelmaking and Hot Forming Subcategory - Carbon and Alloy Steel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-91

11-29 Arithmetic Means of BAT Performance Data for the Non-IntegratedSteelmaking and Hot Forming Subcategory - Stainless Steel Segment . . . . 11-92

11-30 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Non-Integrated Steelmaking and Hot Forming Subcategory - Carbonand Alloy Steel Segment, Direct Dischargers . . . . . . . . . . . . . . . . . . . . . . . . 11-93

11-31 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Non-Integrated Steelmaking and Hot Forming Subcategory - StainlessSteel Segment, Direct Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-94

11-32 Summary of Baseline and Treated Pollutant Loadings for the Non-IntegratedSteelmaking and Hot Forming Subcategory - Carbon and Alloy SteelSegment, Indirect Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-96

11-33 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removals forthe Non-Integrated Steelmaking and Hot Forming Subcategory - Stainless SteelSegment, Indirect Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-97

11-34 Subcategory-Specific Average Baseline Pollutant Concentrations for theSteel Finishing Subcategory - Carbon and Alloy Steel Segment . . . . . . . . . 11-98

11-35 Subcategory-Specific Average Baseline Pollutant Concentrations for theSteel Finishing Subcategory - Stainless Steel Segment . . . . . . . . . . . . . . . . 11-100

11-36 Arithmetic Means of BAT Performance Data for the Steel FinishingSubcategory - Carbon and Alloy Steel Segment . . . . . . . . . . . . . . . . . . . . . 11-102

11-37 Arithmetic Means of BAT Performance Data for the Steel FinishingSubcategory - Stainless Steel Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-104


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11-38 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Steel Finishing Subcategory - Carbon and Alloy Steel Segment, Direct Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-106

11-39 Summary of Baseline and Treated Pollutant Loadings and PollutantRemovals for the Steel Finishing Subcategory - Stainless Steel Segment, Direct Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-108

11-40 Summary of Baseline and Treated Pollutant Loadings and Pollutant Removalsfor the Steel Finishing Subcategory - Carbon and Alloy Steel Segment, Indirect Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-110

11-41 Summary of Baseline and Treated Pollutant Loadings and PollutantRemovals for the Steel Finishing Subcategory - Stainless Steel Segment, Indirect Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-112

11-42 Subcategory-Specific Average Baseline Pollutant Concentrations for theOther Operations Subcategory - Forging Segment . . . . . . . . . . . . . . . . . . . 11-114

11-43 Arithmetic Means of BAT Performance Data for the Other OperationsSubcategory - DRI Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-115

11-44 Arithmetic Means of BAT Performance Data for the Other OperationsSubcategory - Forging Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-116

11-45 Summary of Baseline and Treated Pollutant Loadings and PollutantRemovals for the Other Operations Subcategory - DRI Segment, DirectDischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-117

11-46 Summary of Baseline and Treated Pollutant Loadings PollutantRemovals for the Other Operations Subcategory - Forging Segment,Direct Dischargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-118

12-1 Pollutants Considered for Regulation for Direct Dischargers CokemakingSubcategory - By-Product Recovery Segment . . . . . . . . . . . . . . . . . . . . . . . 12-15

12-2 Henry’s Law Constants for Organic Pollutants of Concern CokemakingSubcategory - By-Product Recovery Segment . . . . . . . . . . . . . . . . . . . . . . . 12-19

13-1 Model PNF by Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-43


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14-1 Aggregation of Field Duplicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25

14-2 Aggregation of Grab Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26

14-3 Aggregation of Data Across Streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27

14-4 Cases where Option Variability Factors Could Not be Calculated . . . . . . . . 14-28

15-1 Summary of Current and Incremental Energy Requirements and SludgeGeneration by Subcategory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12

15-2 Incremental Energy Requirements by Subcategory and Option . . . . . . . . . . 15-13

15-3 Incremental Sludge Generation by Subcategory and Option . . . . . . . . . . . . . 15-14

16-1 40 CFR Part 420 - Subcategorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22

16-2 40 CFR Part 420 - Process and Non-Process Wastewaters . . . . . . . . . . . . . . 16-25

16-3 Example 1: Application of 40 CFR Part 420 - Direct Discharge BlastFurnaces and Sinter Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-27

16-4 Example 2: Application of 40 CFR Part 420 - Indirect DischargeCoke Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-28

16-5 List of Approved Test Methods for Pollutants Regulated Under the Final Rulefor the Iron and Steel Point Source Category . . . . . . . . . . . . . . . . . . . . . . . . 16-29

List of Figures

xx

LIST OF FIGURES

Page

5-1 Iron and Steelmaking Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-2 Forming and Finishing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-3 Integrated Steel Manufacturing Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-4 Cokemaking Sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-5 By-Product Recovery Cokemaking Process Diagram . . . . . . . . . . . . . . . . . . . 5-29

8-1 Illustration of a Fluidized Bed Acid Regeneration Process . . . . . . . . . . . . . . . 8-47

8-2 Typical Free and Fixed Ammonia Distillation Column . . . . . . . . . . . . . . . . . 8-48

8-3 Typical Cooling Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

8-4 Typical Oil/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

8-5 Typical Dissolved Air Flotation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51

8-6 Typical Hexavalent Chromium Reduction System . . . . . . . . . . . . . . . . . . . . . 8-52

8-7 Process Flow Diagram of a Typical Chemical Precipitation System forMetals Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

8-8 Minimum Solubilities of Various Metals Hydroxides . . . . . . . . . . . . . . . . . . . 8-54

8-9 Typical Ion Exchange System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

8-10 Typical Clarification System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

8-11 Typical Multimedia Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57

8-12 Process Flow Diagram of a Typical Biological Treatment System . . . . . . . . . 8-58

8-13 Typical Sequencing Batch Reactor Operation for One Cycle . . . . . . . . . . . . . 8-59

8-14 Process Flow Diagram of Typical Biological Denitrification Systems . . . . . . 8-60

8-15 Typical Gravity Thickener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61

LIST OF FIGURES (Continued)

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8-16 Typical Vacuum Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62

8-17 Typical Plate-and Frame Filter Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63

9-1 BAT-1 for By-Product Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . . . . 9-34

9-2 BAT-3 for By-Product Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . . . . 9-35

9-3 PSES-1 for By-Product Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . . . 9-36

9-4 PSES-3 for By-Product Recovery Cokemaking . . . . . . . . . . . . . . . . . . . . . . . 9-37

9-5 BAT-1 for Ironmaking (Blast Furnace and Sintering Operations) . . . . . . . . . 9-38

9-6 PSES-1 for Ironmaking (Blast Furnace and Sintering Operations) . . . . . . . . . 9-39

9-7 BAT-1 and PSES-1 for Integrated Steelmaking (All Segments) . . . . . . . . . . 9-40

9-8 BAT-1 and PSES-1 for Integrated and Stand-Alone Hot Forming (All Segments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41

9-9 BAT-1 and PSES-1 for Non-Integrated Steelmaking and Hot Forming (AllSegments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42

9-10 BAT-1 and PSES-1 for Carbon and Alloy Steel Finishing . . . . . . . . . . . . . . . 9-43

9-11 BAT-1 and PSES-1 for Stainless Steel Finishing . . . . . . . . . . . . . . . . . . . . . . 9-44

9-12 BPT-1 for Direct Reduced Ironmaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45

9-13 BPT-1 for Forging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46

10-1 Activated Carbon System for By-Products Recovery Cokemaking Wastewater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99

10-2 Breakpoint Chlorination for By-Product Recovery CokemakingWastewater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100

10-3 Blowdown Metals Precipitation for Ironmaking Wastewater . . . . . . . . . . . 10-101

10-4 Breakpoint Chlorination for Ironmaking Wastewater . . . . . . . . . . . . . . . . . 10-102

LIST OF FIGURES (Continued)

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10-5 Blowdown Metals Precipitation for Steelmaking Wastewater . . . . . . . . . . 10-103

10-6 Filtration of Wastewater from All Subcategories . . . . . . . . . . . . . . . . . . . . 10-104

Section 1 - Applicability and Summary of Final Regulation

1-1

SECTION 1

APPLICABILITY AND SUMMARY OF FINAL REGULATION

This section presents a brief overview of the Iron and Steel Category, discussesthe applicability of the effluent limitations guidelines and standards for the category, and presentsthe applicability interface between the final rule and other regulations for the metals industry.This section also briefly summarizes the final rule and describes the Agency’s efforts to protectconfidential business information.

1.1 Applicability

The Iron and Steel Category comprises sites that produce raw materials used inironmaking and steelmaking or produce finished or semifinished steel products. Operationsinclude cokemaking, sintering, ironmaking, steelmaking, ladle metallurgy, vacuum degassing,continuous and ingot casting, hot forming, salt bath and electrolytic descaling, acid pickling, coldforming, alkaline cleaning, hot coating, direct-reduced ironmaking, briquetting, and forging.

Manufacturing operations that may be subject to the promulgated Iron and Steelrule are generally reported under one or more of the following North American IndustryClassification System (NAICS) codes (Reference 1-1):

� 324199, Other Petroleum and Coal Products Manufacturing;

� 331111, Iron and Steel Mills;

� 331210, Iron and Steel Pipe and Tube Manufacturing from PurchasedSteel;

� 331221, Rolled Steel Shape Manufacturing; and

� 332812, Metal coating, engraving (except jewelry and silverware), andallied services to manufacturers.

Specifically, the promulgated Iron and Steel effluent limitations guidelines andstandards apply to wastewater discharges resulting from the following manufacturing operations:

� By-product recovery and other cokemaking operations manufacturingmetallurgical coke (both furnace and foundry coke);

� Sintering, briquetting, and other beneficiation or agglomeration operationsconducted by heating iron-bearing materials (e.g., iron ore, mill scale, blastfurnace flue dust, blast furnace wastewater treatment sludge), limestone,coke fines, and other materials in a traveling grate combustion system toproduce a beneficiate or agglomerate for charging to a blast furnace;


1-2

� Ironmaking operations in which iron ore and other iron-bearing materialsare reduced to molten iron in a blast furnace;

� Direct-reduced ironmaking in which iron pellets are produced through areaction of iron ore with hot reducing gases;

� Basic oxygen furnace (BOF) steelmaking, ladle metallurgy, vacuumdegassing, and continuous casting operations at integrated steel mills. Therule also applies to BOF steelmaking conducted at any location;

� Electric arc furnace (EAF) steelmaking, ladle metallurgy, vacuumdegassing and continuous casting operations conducted at non-integratedsteel mills. The final rule also applies to EAF steelmaking conducted atany location;

� Hot forming operations conducted at integrated steel mills, non-integratedsteel mills, and stand-alone hot forming mills;

� Steel forging operations performed at iron and steel mills; and

� Carbon, alloy, and stainless steel finishing operations, including salt bathand electrolytic sodium sulfate descaling, acid pickling, cold forming,alkaline cleaning, hot coating and continuous annealing at integrated, non-integrated, and stand-alone facilities.

1.2 Applicability Interface With Other Regulations

Several existing regulations currently establish effluent limitations guidelines andstandards for the metals industry. Regulations covering nonferrous materials, includingaluminum forming (40 CFR Part 467), copper forming (40 CFR Part 468), nonferrous metalsmanufacturing (40 CFR Part 421), and nonferrous metals forming (40 CFR Part 471) do notinterface with the effluent limitations guidelines and standards promulgated for the Iron and SteelCategory. Regulations that cover ferrous materials, however, do interface with the final rule forthe Iron and Steel Category.

For facilities with process operations in more than one category, NationalPollutant Discharge Elimination System (NPDES) permit writers must use a building-blockapproach to develop technology-based effluent limitations. Similarly, pretreatment controlauthorities must use the combined wastestream formula (Reference 1-2) to develop pretreatmentrequirements for facilities with process operations in more than one category. Permit writers andcontrol authorities should refer to the applicability statements of the regulations for furtherclarification.


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1.2.1 Electroplating

Facilities that are covered by the Electroplating Category and discharge to apublicly owned treatment works (POTW) are regulated under 40 CFR Part 413. This categorycomprises indirect discharging job shop electroplating and independent printed circuit boardmanufacturers that were in operation prior to July 15, 1983. The electroplating rule specificallyexcludes continuous strip electroplating operations conducted at indirect discharging iron andsteel facilities; therefore, the electroplating rule does not overlap with the final Iron and Steelrule.

1.2.2 Metal Finishing

Wastewater discharges from facilities within the Metal Finishing Category areregulated under 40 CFR Part 433. This category comprises facilities that perform any of thefollowing six metal finishing operations on any basis material: electroplating, electroless plating,anodizing, coating (chromating, phosphating, and coloring), chemical etching and milling, andprinted circuit board manufacturing. The Metal Finishing rule establishes effluent limitationsguidelines and standards for 40 surface treatment operations at facilities within this category.

1.2.3 Coil Coating

Wastewater discharges from facilities within the Coil Coating Category areregulated under 40 CFR Part 465. Coil coating facilities typically clean, conversion coat, andapply organic polymeric materials (such as paint) to continuous strips of metal coil (typicallysteel, galvanized metal, or aluminum). The Coil Coating Category comprises facilities thatperform at least two of these three operations. The Iron and Steel rule is not intended to regulatemild acid or mild alkaline cleaning operations conducted at coil coating facilities, nor is itintended to regulate conversion coating or the application of organic polymeric material to steel;therefore, the promulgated Iron and Steel rule does not overlap with the Coil Coating rule.

1.2.4 Ferroalloy Manufacturing

Wastewater discharges from facilities Within the Ferroalloy ManufacturingCategory are regulated under 40 CFR Part 424. This category comprises facilities that smeltferroalloys in electric furnaces or other devices with wet air pollution control, recover andprocess furnace slag, produce calcium carbide in covered electric furnaces with and without wetair pollution control and manufacture electrolytic manganese products and electrolytic chromiumproducts. A ferroalloy is an iron-bearing product, not within the range of those products calledsteel, which contains a considerable amount of one or more alloying elements, such asmanganese, silicon, phosphorus, vanadium, and chromium. The Iron and Steel Category does notcover any ferroalloy manufacturing operations.


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1.2.5 Metal Molding and Casting

Wastewater discharges from facilities within the Metal Molding and CastingCategory are regulated under 40 CFR Part 464. This category comprises facilities that remelt,mold, and cast aluminum, copper, zinc, and ferrous metals and alloys into intermediate orfinished products. The Iron and Steel rule does not overlap with the Metal Molding and Castingrule.

1.3 Summary of Proposed Regulation

On October 31, 2000, the EPA Administrator signed proposed revisions totechnology-based effluent limitations guidelines and standards for wastewater discharges fromnew and existing iron and steel facilities. The proposed rule was published in the FederalRegister on December 27, 2000 (65 FR 81964). EPA proposed to alter the applicability andscope of the existing rule by adding electroplating operations and by including direct ironreduction, briquetting, and forging operations. In addition, EPA proposed excluding from theiron and steel guideline in Part 420 some wire, cold forming, and hot dip coating operations. In aproposed rule for the Metal Products and Machinery (MP&M) industrial category published onJanuary 3, 2001 (66 FR 424), EPA proposed to address these operations under Part 438.

The Agency proposed to revise the subcategorization scheme to create sevensubcategories of iron and steel facilities based on co-treatment of compatible waste streams. Thiswould have replaced the present structure of 12 subcategories. The proposed subcategorizationapproach would have reflected the way treatment systems are run in the iron and steel industry. EPA proposed the following seven subcategories:

Subpart Subcategory Segment

Subpart A Cokemaking Subcategory By-productNon-recovery

Subpart B Ironmaking Subcategory Blast FurnaceSintering

Subpart C Steelmaking Subcategory

Subpart D Integrated and Stand-Alone Hot FormingMills Subcategory

Carbon and AlloyStainless

Subpart E Non-Integrated Steelmaking and HotForming Operations Subcategory

Carbon and AlloyStainless

Subpart F Steel Finishing Subcategory Carbon and AlloyStainless

Subpart G Other Operations Subcategory Direct-Reduced IronmakingForgingBriquetting


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For most of the subcategories, except for cokemaking, finishing, and the newlyadded subcategory for other operations, the Agency proposed limits based on improvedperformance and operation of the same technologies that were the basis for the limits andstandards promulgated in 1982 and amended in 1984. Consequently, the proposed limitationswere more stringent than the limitations promulgated in 1982. For the cokemaking subcategory,EPA proposed BAT limits based on a technology option that was essentially the same as the1982 technology basis but included an additional treatment step -- alkaline chlorination. Forfinishing, EPA proposed limits based on the 1982 technology basis with the addition ofcounter-current rinsing and acid purification.

For many of the proposed subcategories, wastewater flow reduction steps, inconcert with better performance of the blowdown treatment systems, provided the primary basisfor the proposal limits and standards. The proposed rule included the following features:

� EPA proposed two different BAT approaches for the carbon and alloysegment of the integrated and stand-alone hot forming subcategory. Theoptions differed in the amount of time that facilities in the segment wouldhave to achieve BAT limitations. Under one option, a facility would besubject to BAT limitations as soon as these limitations are placed in theNPDES permit. Under the other option, a facility could obtain additionaltime to achieve BAT limitations.

� The Agency proposed zero discharge as NSPS for the non-integratedsteelmaking and hot forming subcategory.

� EPA considered defining a reasonable measure of actual production forcalculating NPDES and pretreatment permit production rates.

� EPA proposed regulating, among others, mercury and selenium based ontoxicity and presence in cokemaking wastewater.

� EPA proposed regulating 2,3,7,8-tetrachlorodibenzofuran (2,3,7,8-TCDF)in sinter plant wastewater and requiring compliance monitoring either afterthe primary treatment of sinter plant wastewater or after sinter plant andblast furnace wastewater discharges are cotreated, but before sinter plantwastewater is combined with any other process or non-process discharges.

� EPA considered developing a limit, based on acid purification technologyor product substitution, for nitrate/nitrite (in the form of nitrate-nitrite-N)for stainless steel finishing operations with nitric acid and combinationacid pickling.

� EPA considered waiving the pretreatment standards for ammonia asnitrogen for blast furnace wastewater indirectly discharged to POTWs thathave the capability to conduct nitrification.


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� EPA proposed revising the units of pollutant limitations from kilograms ofallowable pollutant discharge per thousand kilograms of production(kg/kkg), also expressed as pounds of allowable pollutant discharge perthousand pounds of production (lbs/1,000 lbs), to pounds of allowablepollutant discharge per ton of production (lbs/ton).

� EPA proposed making the following revisions to the 1982 “Water Bubble”provision, but leaving the remainder unchanged:

— Allow trades for cold rolling operations,

— Allow trades for cokemaking operations, but only when morestringent limits result,

— Prohibit trades for sintering operations when less stringent limitsresult, and

— Prohibit trades for oil and grease.

� While the 1982 regulation often prompts permit writers and controlauthorities to apply pH limitations at internal discharge monitoringlocations, prior to additional treatment or mixing with other wastewaterdischarges, the proposed rule allows permit writers and control authoritiesto establish pH effluent limitations at final outfalls such that redundant andunnecessary pH neutralization can be avoided.

The presentation in the remainder of this Technical Development Document willbe organized around the proposed subcategorization scheme. The proposed subcategorizationscheme was the basis on which EPA evaluated the technology options described and on whichEPA made its final determinations regarding the content of the promulgated rule.

1.4 Summary of Final Regulation

EPA has decided to revise effluent limitations guidelines and standards only forcurrent Subpart A (cokemaking), Subpart B (sintering), Subpart C (ironmaking), and Subpart D(steelmaking), and to promulgate new effluent limitations guidelines and standards for newSubpart M (other operations).

As a result of EPA’s technical and economic review, EPA is promulgating revisedBAT limitations, NSPS and pretreatment standards for the cokemaking by-product recoverysegment based on technologies that are different than those proposed. Specifically, EPA ispromulgating effluent limits based primarily on ammonia still and biological treatment withnitrification for direct dischargers and pretreatment standards based primarily on ammonia stilltreatment for indirect dischargers.


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For the cokemaking subcategory, today’s rule combines the “iron and steel” and“merchant” segments into a newly-created “by-product recovery” cokemaking segment for mostregulatory purposes, although EPA is retaining the “iron and steel” and “merchant” segments forpurposes of reflecting the existing BPT limitations. EPA concluded that this was appropriatebecause the production processes, wastewater characteristics, and wastewater flow rates from allby-product recovery cokemaking operations, including merchant facilities, are similar.

EPA is also eliminating the segment in BAT for by-product coke plants withphysical chemical treatment systems. EPA has determined that technology basis for BATlimitations promulgated in today’s rule are technically and economically achievable for all directdischarging by-product coke plants.

EPA is not establishing limitations and standards for selenium, mercury, orthiocyanate, nor is it establishing pretreatment standards for phenol in cokemaking subcategory.EPA is establishing limitations for phenols (4AAP) in the cokemaking subcategory.

For the sintering subcategory, EPA is revising the current regulation to addlimitations and standards for one additional pollutant, 2,3,7,8-TCDF, while keeping the rest ofthe limits unchanged. The technology basis for new TCDF limitations and standards for thesintering subcategory remains unchanged from the proposal and is the same as the technologybasis for the 1982 regulations with the addition of mixed-media filtration. EPA is alsoestablishing limitations of no discharge of process wastewater pollutants for new and existingdirect dischargers and new and existing indirect dischargers for sintering operations with dry airpollution control systems.

EPA is codifying language providing that the ammonia as nitrogen pretreatmentstandards do not apply to cokemaking, ironmaking, and sintering facilities discharging toPOTWs with nitrification capability.

For the steelmaking subcategory, EPA is revising BPT, BCT, BAT, and PSESlimitations for the semi-wet basic oxygen furnace (BOF) operations to allow discharge of processwastewater, when merited by safety considerations. EPA is allowing discharge of processwastewater because certain safety concerns currently prevent some sites from balancing the waterapplied for BOF gas conditioning with evaporative losses to achieve zero discharge. Also in thesteelmaking subcategory, for the semi-wet EAF operations, EPA is establishing limitations of nodischarge of process wastewater pollutants for new direct dischargers and existing and newindirect dischargers, making these limitations equivalent to the previously promulgated BPT,BCT, and BAT limitations applicable to semi-wet electric arc furnace (EAF) operations. EPAidentified none of the safety or production concerns discussed for semi-wet BOF operations.

EPA is establishing, as proposed, the limitations and standards for the OtherOperations subcategory.


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Due to the small number of subcategories affected by today’s rule, the Agency hasdecided to retain the 1982 subcategory structure with the addition of an “other operations”subcategory. As a result, the final rule covers the following 13 subcategories:

Subcategory Description

Subcategory A Cokemaking (includes by-product and non-recovery operations)

Subcategory B Sintering (includes wet and dry air pollution control operations)

Subcategory C Ironmaking

Subcategory D Steelmaking (includes basic oxygen furnace and electric arcfurnace operations)

Subcategory E Vacuum degassing

Subcategory F Continuous casting

Subcategory G Hot forming

Subcategory H Salt bath descaling

Subcategory I Acid pickling

Subcategory J Cold forming

Subcategory K Alkaline cleaning

Subcategory L Hot coating

Subcategory M Other operations (includes forging, direct-reduced ironmaking,and briquetting operations)

EPA is eliminating segments for the following obsolete operations: beehivecokemaking, ferromanganese blast furnaces, and open hearth furnaces.

EPA is promulgating the following revisions to the “Water Bubble” provision:

� Allow trades for cold rolling operations;

� Allow trades for cokemaking operations, but only when more stringentlimits result;

� Allow trades for Subpart M operations;

� Prohibit trades for 2,3,7,8-TCDF;

� Eliminate the net reduction provision;


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� Prohibit trades for oil and grease; and

� Allow trades for new as well as existing sources.

1.5 Protection of Confidential Business Information

EPA recognizes that certain data in the rulemaking record have been claimed asconfidential business information (CBI). The Agency has withheld CBI from the public record inthe Water Docket. In addition, the Agency has withhold from disclosure some data not claimedas CBI because the release of these data could indirectly reveal CBI. Furthermore, EPA hasaggregated certain data in the public record, masked facility identities, or used other strategies toprevent the disclosure of CBI. The Agency’s approach to CBI protection ensures that the data inthe public record both explain the basis for the final rule and provide the opportunity for publiccomment, without compromising data confidentiality.

1.6 References

1-1 North American Industry Classification System, U.S. Office of Management andBudget. Washington, DC, 1997.

1-2 U.S. Environmental Protection Agency. Guidance Manual for the Use ofProduction-Based Pretreatment Standards and the Combined WastestreamFormula. Washington, DC, September 1985.

Section 2 - Background

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SECTION 2

BACKGROUND

This section provides background information on the development of revisedeffluent limitations guidelines and standards for the Iron and Steel Category. Sections 2.1 and2.2 discuss the legal authority and legislative background for the rule. Section 2.3 presentsreferences for the Iron and Steel Category rulemaking activities.

2.1 Legal Authority

EPA is revising effluent limitations guidelines and standards for the Iron and SteelCategory under the authority of Sections 301, 304, 306, 307, 308, 402, and 501 of the CleanWater Act, 33 U.S.C. 1311, 1314, 1316, 1317, 1318, 1342, and 1361.

2.1.1 Legislative Background

Congress adopted the Clean Water Act (CWA) to “restore and maintain thechemical, physical, and biological integrity of the Nation’s waters” (Section 101(a), 33 U.S.C.1251(a)). To achieve this goal, the CWA prohibits the discharge of pollutants into navigablewaters except in compliance with the statute. The CWA confronts the problem of waterpollution on a number of different fronts. Its primary reliance, however, is on establishingrestrictions on the types and amounts of pollutants discharged from various industrial,commercial, and public sources of wastewater.

Congress recognized that regulating only those sources that discharge effluentdirectly into the nation’s waters would not be sufficient to achieve the goals of the CWA. Consequently, the CWA requires EPA to promulgate nationally applicable pretreatmentstandards that restrict pollutant discharges for those facilities that discharge wastewater indirectlythrough sewers flowing to publicly owned treatment works (POTWs) (Section 307(b) and (c), 33U.S.C. 1317(b) and (c)). National pretreatment standards are established for wastewaterpollutants that may pass through or interfere with POTW operations. Generally, pretreatmentstandards are designed to ensure that wastewater from direct and indirect industrial dischargersare subject to similar levels of treatment. In addition, POTWs are required to implement localtreatment limits applicable to their industrial indirect dischargers to satisfy any localrequirements (40 CFR 403.5).

Direct dischargers must comply with effluent limitations in National PollutantDischarge Elimination System (NPDES) permits; indirect dischargers must comply withpretreatment standards. These limitations and standards are established by regulation forcategories of industrial dischargers and are based on the degree of control that can be achievedusing various levels of pollution control technology.

Section 2 - Background

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Best Practicable Control Technology Currently Available (BPT) --Section 304(b)(1) of the CWA

In establishing the effluent limitations guidelines and standards for the Iron andSteel Category, EPA generally defines BPT effluent limitations for conventional, non-conventional, and priority pollutants. In specifying BPT, EPA looks at a number of factors. EPAfirst considers the cost of achieving effluent reductions in relation to the effluent reductionbenefits. The Agency also considers the age of equipment and facilities, the processes employedand any required process changes, engineering aspects of the control technologies, non-waterquality environmental impacts (including energy requirements), and other factors the Agencydeems appropriate (CWA 304(b)(1)(B)). Traditionally, EPA establishes BPT effluent limitationsbased on the average of the best performances of facilities within the industry of various ages,sizes, processes, or other common characteristics. Where, however, existing performance isuniformly inadequate, EPA may require higher levels of control than currently in place in anindustrial category if the Agency determines that the technology can be practically applied.

Best Conventional Pollutant Control Technology (BCT) -- Section 304(b)(4)of the CWA

The 1977 amendments to the CWA

iron and steel effluent guidelines development document - …development document for final effluent...

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