No. 210 Wednesday, October 30, 1985 Rules and Regulations ... · 10/30/1985 · No. 210 /...

45212 Federal Register / Vol. 50, No. 210 / Wednesday, October 30, 1985 I Rules and RegulationsENVIRONMENTAL PROTECTIONAGENCY

40 CFR Part 464

[FRL-2898-7]

Metal Molding and Casting IndustryPoint Source Category EffluentLimitations Guidelines, PretreatmentStandards and New SourcePerformance Standards

AGENCY: Environmental ProtectionAgency (EPA).ACTION: Final regulation.

SUMMARY: This regulation establisheseffluent limitations guidelines andstandards that limit the discharge ofpollutants into navigable waters andpublicly owned treatment (POTWs) byexisting and new sources engaged inmetal molding and casting operations.The Clean Water Act and a consentdecree require EPA to issue thisregulation.

EPA is promulgating effluentlimitations guidelines attainable by theapplication of the "best practicablecontrol technology currently available"(BPT) and the "best availabletechnology economically achievable"(BAT), pretreatment standardsapplicable to existing and newdischarges to POTWs (PSES and PSNS,respectively), and new sourceperformance standards (NSPS)attainable by the application of the"best available demonstratedtechnology."DATES: In accordance with 40 CFR Part23 (50 FR 7268, February 21, 1985), thisregulation shall be considered issued forpurposes of judical review at 1:00 p.m.Eastern time on November 13, 1985.These regulations shall become effectiveDecember 13, 1985.

The compliance date for pretreatmentstandards for existing sources PSES isOctober 31, 1988. The compliance datefor new source performance standards(NSPSJ and pretreatment standards fornew sources (PSNS) is the date the newsource begins operation.

Under section 509(b)(1) of the CleanWater Act, judicial review of thisregulation can be made only by filing apetition for review in the United StatesCourt of Appeals within 90 days afterthe regulation is considered issued forpurposes of judicial review. Undersection 509(b)(2) of the Clean Water Act,the requirements in this regulation maynot be challenged later in civil orcriminal proceedings brought by EPA toenforce these requirements.ADDRESSES: The basis for this regulationis detailed in four major documents. See

Section XV-Availability of TechnicalInformation for information on thosedocuments. Copies of the technical andeconomic documents may be obtainedfrom the National Technical InformationService, Springfield, Virginia 22161(Phone: (703) 487-4600). For additionaltechnical information, contact Mr.Donald F. Anderson, IndustrialTechnology Division (WH-552), U.S.Environmental Protection Agency, 401 MStreet, SW., Washington, DC 20460(Phone (202) 382-7189). For additionaleconomic information, contact Ms. DenaCaldwell, Office of Analysis andEvaluation (WH-586), U.S.Environmental Protection Agency, 401 MStreet, SW., Washington, DC 20460(Phone (202) 382-5397).

On January 3, 1986, the completepublic record for this rulemaking,including the Agency's responses tocomments received during rulemaking,will be available for review in EPA'sPublic Information Reference Unit,Room 2404 (Rear) (EPA Library), 401 MStreet, SW., Washington, DC. The EPApublic information regulation (40 CFRPart 2) provides that a reasonable feemay be charged for copying.

FOR FURTHER INFORMATION CONTACT:Mr. Donald F. Anderson at (202) 382-7189.SUPPLEMENTARY INFORMATION:

Overview

This preamble describes the legalauthority, background, the technical andeconomic bases, and other aspects ofthe final regulation. The abbreviations,acronyms, and other terms used in theSupplementary Information sections aredefined in Appendix A to this notice.

Organization of This Notice

I. Legal AuthorityII. Scope of This RulemakingIII. BackgroundIV. Methodology and Data Gathering EffortsV. Summary of Changes to Proposed

RegulationsVI. Control and Treatment Options and

Technology Basis for thd FinalRegulation

VII. Pollutants Excluded From RegulationVIII. Economic ConsiderationsIX. Non-Water Quality Aspects of Pollution

ControlX. Best Management Practices (BMPs)XI. Upset and Bypass ProvisionsXII. Variances and ModificationsXIII. Relationship to NPDES PermitsXIV. Public Participation and Response to

Major CommentsXV. Availability of Technical InformationXVI. Office of Management and Budget

(OMB) ReviewXVII. List of Subjects

Appendices:

A-Abbreviations, Acronyms And OtherTerms Used In This Notice

B-Pollutant Parameters RegulatedC-Toxic Pollutants Not Detected or Not

Detected At or Above the NominalAnalytical Limits of Quantitation in AnySubcategories of the Metal Molding andCasting Point Source Category

D-Aluminum Subcategory-Toxic PollutantsNot Detected or Not Detected At orAbove the Nominal Analytical Limits ofQuantitation; Toxic Pollutants Present inAmounts Too Small to be ReducedEffectively by Technologies Known tothe Administrator;- and Toxic PollutantsDetected in the Effluent From Only aSmall Number of Sources

E--Copper Subcategory-Toxic PollutantsNot Detected or Not Detected At orAbove the Nominal Analytical Limits ofQuantitation; Toxic Poillutants Present inAmounts Too Small to be ReducedEffectively by Technologies Known tothe Administrator; Toxic PollutantsDetected in the Effluent From Only aSmall Number of Sources; and ToxicPollutants for Which Equal or MoreStringent Protection Is Provided byExisting Effluent Limitations andStandards

F-Ferrous Subcategory-Toxic PollutantsNot Detected or Not Detected At orAbove the Nominal Analytical Limits ofQuantitation; Toxic Pollutants Present inAmounts Too Small to be ReducedEffectively by Technologies Known tothe Administrator; Toxic PollutantsDetected in the Effluent From Only aSmall Number of Sources; and ToxicPollutants for Which Equal or MoreStringent Protection Is Provided byExisting Effluent Limitations andStandards

G-Zinc Subcategory-Toxic Pollutants NotDetected or Not Detected At or Abovethe Nominal Analytical Limits ofQuantitation; Toxic Pollutants Present inAmounts Too Small to be ReducedEffectively by Technologies Known tothe Administrator, and Toxic PollutantsDetected in the Effluent From Only aSmall Number of Sources

H-Subcategories and Process Segments NotRegulated Because They Do NotGenerate Process Wastewaters

I-Other Subcategories And ProcessSegments Not Regulated by the MetalMolding and Casting Regulations

J-Metal Molding and Casting Flow Ratesand Recycle Rates

K-Metal Molding and Casting TreatmentEffectiveness Concentrations Lime andSettle

L-Metal Molding and Casting TreatmentEffectiveness Concentrations for Limeand Settle, Filtration

M-Total Toxic Organic (TTO)Concentrations for PSES AND PSNSMass Limitations

I. Legal Authority

This regulation is promulgated underthe authority of sections 301, 304, 306,307, 308, and 501 of the Clean Water Act

45212 Federal Register / Vol. 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulations

No. 210 / Wednesday, October 30, 1985 / Rules and Regulations 45213

(the Federal Water Pollution Control ActAmendments of 1972, 33 U.S.C. 1251 etseq., as amended by the Clean WaterAct of 1977, Pub. L. 95-217), also referredto as "the Act". It is also promulgated inresponse to the Settlement Agreement inNatural Resources Defense Council, Inc.v. Train, 8 ERC 2120 (D.D.C. 1976),modified, 12 ERC 1833 (D.D.C. 1979),modified by Orders dated October 26,1982, August 2, 1983, January 6, 1984,July 5, 1984, and January. 7, 1985.

It. Scope of This Rulemaking

This final regulation, which wasproposed on November 15, 1982 (47 FR5151.2), establishes effluent limitationsguidelines and standards for existingand new metal molding and castingfacilities. The metal molding and castingcategory includes those plants thatremelt and cast metal. These plants forma cast intermediate or final product bypouring or forcing the molten metal intoa mold.

For the purpose of this final rule, themetal molding and casting category isdivided into four'subcategories and 28process segments. The pollutantsregulated for each of the subcategorysegments under the BPT, BAT, NSPS,PSES, and PSNS regulations areidentified in Appendix B.

EPA is promulgating BPT effluentlimitations guidelines for foursubcategories of the metal molding andcasting category. BCT effluentlimitations guidelines are reserved untilthe promulgation of the final BCTmethodology. EPA is promulgating NSPSequal to BAT effluent limitations foreach subcategory segment beingregulated. BAT limitations morestringent than BPT limitations are beingpromulgated for the copper and zinccasting subcategories and for the ferroussubcategory except for (a) plants wheresteel is the primary metal cast or (b)plants pouring less than 3,557 tons ofmetal per year where malleable iron isthe primary metal cast. BAT limitationsequal to BPT limitations are beingpromulgated for the aluminum castingsubcategory and for direct dischargersin the ferrous subcategory where steel isthe primary metal cast and for directdischargers pouring less than 3,557 tonsof metal per year where malleable ironis the primary metal cast. PSES andPSNS are being promulgated equal toBAT for all subcategories except in theferrous subcategory for indirectdischargers pouring less than 1,784 tonsof metal per year where gray iron is theprimary metal cast. In this case, PSESand PSNS are equal to BPT. Indirectdischargers in the metal molding andcasting category also must comply with40 CFR Part 403-General Pretreatment

Regulations, in addition to PSES andPSNS.

II1. Background

A. The Clean Water Act

The Federal Water Pollution ControlAct Amendments of 1972 established acomprehensive program to "restore andmaintain the chemical, physical, andbiological integrity of the Nation'swaters." (Section 101(a).) To implementthe Act, EPA was required to issueeffluent limitations guidelines;pretreatment standards, and new sourceperformance standards for industrialdischargers.

In addition to these regulations fordesignated industrial categories, EPAwas required to promulgate effluentlimitations and standards applicable toall dischargers of toxic pollutants. TheAct included a timetable for issuingthese standards. However, EPA wasunable to meet many of the deadlinesand, as a result, in 1976, it was sued byseveral environmental groups. In settlingthis lawsuit, EPA and the plaintiffsexecuted a "Settlement Agreement" thatwas approved by the Court. Thisagreement required EPA to develop aprogram and adhere to a schedule forcontrolling 65 "priority" toxic pollutantsand classes of pollutants. In carrying outthis program, EPA must promulgate BATeffluent limitations guidelines,pretreatment standards, and new sourceperformance standards for 21 majorindustries. See Natural ResourcesDefense Council, Inc. v. Train, 8 ERC2120 (D.D.C. 1976), modified, 12 ERC1833 (D.D.C. 1979); modified by Ordersdated October 26, 1982, August 2, 1983,January 6, 1984, July 5, 1984, and January7, 1985.

Many of the basic elements of theSettlement Agreement wereincorporated into the Clean Water Actof 1977. Like the Agreement, the Actstressed control of toxic pollutants,including the 65 "priority" toxicpollutants and classes of pollutants. Inaddition to strengthening the toxiccontrol program, Section 304(e) of theAct authorizes the Administrator toprescribe "best management practices"(BMPs) to prevent the release of toxicand hazardous pollutants from plant siterunoff, spillage or leaks, sludge or wastedisposal, and drainage from rawmaterial storage associated with, orancillary to, the manufacturing ortreatment process.

Under the Act, the EPA is to establishseveral different kinds of effluentlimitations guidelines and standards.These are discussed in detail in thepreamble to the proposed regulation andin the proposed technical Development

Document. They are summarized brieflybelow:

1. Best Practicable Control TechnologyCurrently Available (BPT)

BPT effluent limitations guidelines aregenerally based on the average of thebest existing performance by plants ofvarious sizes, ages, and unit processeswithin the category or subcategory forcontrol of familiar (i.e., classical)pollutants.

In establishing BPT effluentlimitations guidelines, EPA considersthe total cost in relation to the effluentreduction benefits, the age of equipmentand facilities involved, the processesemployed, process changes required,engineering aspects of the controltechnologies, and non-water qualityenvironmental impacts (including energyrequirements). The Agency balances thecategory-wide or subcategory-wide costof applying the technology against theeffluent reduction benefits.

2. Best Available TechnologyEconomically Achievable (BAT)

BAT effluent limitations guidelines, ingeneral, represent the best existingperformance in the category or .subcategory. The Act establishes BATas the principal national means ofcontrolling the direct discharge of toxicand nonconventional pollutants tonavigable waters.

In establishing BAT, the Agencyconsiders the age of the equipment andfacilities involved, the processesemployed, the engineering aspects of thecontrol technologies, process changes,the cost of achieving such effluentreduction, and non-water qualityenvironmental impacts.

3. Best Conventional Pollutant ControlTechnology (BCT)

The 1977 Amendments to the CleanWater Act added section 301(b)(2)(E),establishing "best conventionalpollutant control technology" (BCT) forthe discharge of conventional pollutantsfrom existing industrial point sources.Section 304(a)(4) designated thefollowing as conventional pollutants:BOD, TSS, fecal coliform, pH, and anyadditional pollutants defined by theAdministrator as conventional. TheAdministrator designated oil and greasea conventional pollutant on July 30, 1979(44 FR 44501).

BCT is not an additional limitation butreplaces BAT for the control ofconventional pollutants. In addition toother factors specified in section304(b)(4)(B), the Act requires that theBCT effluent limitations guidelines beassessed in light of a two part "cost-

Federal Register / Vol. 50,

45214 Federal Register I Vol. 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulationsreasonableness" test. American PaperInstitute v. EPA, 660 F.2d 954 (4th Cir.1981). The first test compares the costfor private industry to reduce itsdischarge of conventional pollutantswith the costs to publicly ownedtreatment works for similar levels ofreduction in their discharge of thesepollutants. The second test examines thecost-effectiveness of additionalindustrial treatment beyond BPT. EPAmust find that limitations are"reasonable" under both tests beforeestablishing them as BCT. In no casemay BCT be less stringent than BPT.

EPA has not yet promulgated amethodology for establishing BCTeffluent limitations guidelines.Therefore, in today's rulemaking, EPA isnot establishing BCT effluent limitationsguidelines for the metal molding andcasting category. When the final BCTmethodology is promulgated, EPA willuse this methodology to determinewhether BCT effluent limitationsguidelines should be established for thefour subcategories of the metal moldingand casting category.

4. New Source Performance Standards(NSPS)

NSPS are based on the performance ofthe best available demonstratedtechnology (BDT). New plants have theopportunity to install the best and mostefficient production processes andwastewater treatment technologies.5. Pretreatment Standards for ExistingSources (PSES)

PSES are designed to prevent thedischarge of pollutants that passthrough, interfere with, or are otherwiseincompatible with the operation ofpublicly owned treatment works(POTWs). They must be achieved withinthree years of promulgation. The CleanWater Act of 1977 requires pretreatmentstandards for toxic pollutants that passthrough POTWs in amounts that wouldviolate direct discharger effluentlimitations guidelines or interfere witheither the POTW's treatment process orchosen sludge disposal method. Thelegislative history of the 1977 Actindicates that pretreatment standardsare to be technology-based, analogousto the BAT effluent limitationsguidelines for removal of toxicpollutants. EPA generally determinesthat there is pass through of toxicpollutants if the nation-wide averagepercentage of toxic pollutants removedby a well-operated POTW achievingsecondary treatment is less than thepercent removed by the BAT modeltreatment system. The GeneralPretreatment Regulations, which serveas the framework for categorical

pretreatment standards, are found at 40CFR Part 403.

6. Pretreatment Standards for NewSources (PSNS)

Like PSES, PSNS are designed toprevent the discharge of pollutants thatpass through, interfere with, or areotherwise incompatible with theoperation of a POTW. PSNS are to beissued at the same time as NSPS. Newindirect dischargers, like new directdischargers, have the opportunity toincorporate in their plant the bestavailable demonstrated technologies.The Agency considers the same factorsin promulgating PSNS as it considers inpromulgating NSPS.

B. Overview of the Industry. Metal molding and casting plants are

included within the United StatesDepartment of Commerce, Bureau of theCensus Standard IndustrialClassification (SIC) Major Group 33-Primary Metal Industries. Those parts ofthis Major Group 33 covered by thisregulation are the Subgroup SIC Nos.3321, 3322, 3324, 3325, 3361, 3362, and3369. The types of metal associated withthese SIC codes and considered forregulation under this category are: grayiron, ductile iron, malleable iron, steel,aluminum, copper, magnesium, and zincand their respective alloys. The castingof these metals represents over 98percent of the total of all metals cast inthe country. The Agency also consideredfor regulation the casting of nickel, tin,and titanium but has determined that noprocess wastewater pollutants resultfrom the casting of these metals.

The Agency's data from a 1977 surveyof the industry indicate that over 3,600commercial casting plants are located inthe United States employingapproximately 300,000 workers andproducing over 19 million tons per yearof cast products. Plants in this industryinclude both "job shops" (plants thatsold 50 percent or more of theirproduction to customers outside thecorporate entity) and "captive plants"(plants that sold 50 percent or more oftheir products internally or were usedwithin the corporate efitity). They varygreatly in metal cast, production,wastewater source and volume, size,age, and number of employees.

Annual castings production hasranged between 15 and 20 million tonsduring most of the last 20 years. Ferrouscastings have accounted for about 90percent of the total tons producedannually since 1956.

The number of smaller ferrousfoundries has dropped dramatically inthe past 20 years, while the number oflarge and medium size ferrous foundries

has moderately increased. Among thenonferrous metals, aluminum castinghas been increasing whereas the trendsfor the other metals are mixed. There isa trend toward a decreasing percentageof zinc casting shipments compared withtotal metal molding and castingshipments and compared to aluminumcasting shipments.

Metal casting is done in several ways,and the selection and use of a particularmanufacturing process, e.g., type of moldmedium, is often governed by the type ofmetal cast and by the intricacy andtolerances required of the cast product.However, the variety of manufacturingprocesses can be typified by essentiallysix standard process steps: (1) Metal isremelted in a furnace, (2) molds areprepared, (3) the molten metal is pouredor injected into a mold, (4) the moldmedium is separated from the casting,(5) the casting is cooled, and (6) thecasting is further processed beforeshipment.

Of the 3853 commercial metal moldingand casting plants projected to operatein the United States in 1986, only 1059will generate process wastewater.Among the 1059 plants, 259 will have nodischarge of process wastwater, 301 willdischarge directly to surface waters, and499 will discharge indirectly to POTWs.

Water is used throughout thesevarious process steps at plants withprocess wastewater discharges. Processwater becomes contaminated eitherthrough its use in air pollution controldevices associated with the variousmanufacturing processes or throughdirect contact of the water with somepart of the process or casting. Thepollutant characteristics of the resultingwastewaters may vary depending on thetype of metal cast, the manufacturingprocess employed, and the type of airpollution control device associated withthe manufacturing process. About 80percent of the wastewater associatedwith metal molding and castingoperations is generated by air pollutioncontrol devices. This wastewater doesnot contact directly the products cast.

The most significant pollutants andpollutant properties present in metalmolding and casting industrywastewaters are suspended solids, oiland grease, copper, lead, zinc, nickel,iron, aluminum, nonconventionalphenols, pentachlorophenol,parachlorometa cresol, chrysene,benzo(a)pyrene, benzo(a)anthracene,benzo-(b)fluoranthene,benzo(k)fluoranthene, pyrene,dichloromethane, trichloromethane,bis(2-ethyl hexyl) phthalate, and pH.


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C. Applicability

For the purpose of this final rule, theseregulations are applicable towastewater discharges from metalmolding and casting plants includedwithin the United States Department ofCommerce, Bureau of the CensusStandard Industrial Classification (SIC)Major Group 33-Primary MetalIndustries. Those parts of major group33 covered by this regulation aresubgroup SIC Nos. 3321, 3322, 3324, 3325,3361, 3362, and 3369. Twenty-eightprocess segments in four subcategoriesare specifically covered by theseregulations.

The casting of copper ingots, pigs, orother cast shapes is covered under theseregulations. The casting of ingots, pigs,or other cast shapes related to primarynonferrous metal smelting (exceptcopper smelting) are not included in thiscategory; these operations are coveredunder regulations for the nonferrousmetals. manufacturing category (see 40CFR Part 421). Whenever the casting ofaluminum or zinc is performed as anintegral part of aluminum or zincforming and is located on:site of analuminum or zinc forming plant, then thealuminum casting operation is coveredby the aluminum forming regulations(see 40 CFR Part 467) and the zinccasting operations are covered under thenonferrous forming regulations (see 40CFR Part 471). The casting of ferrousingots, pigs, or other cast shapes isprimarily a dry operation involving noprocess wastewater and, consequently,no regulations have been developedcovering this operation.

In general, these regulations do notcover processing operations followingthe cooling of castings (see-previoussection "Overview of the Industry").These processing operations, if notcovered under 40 CFR Part 467 or 471,are covered by effluent limitations andstandards applicable to electroplatingand metal finishing. See 46 FR 9462[January 28, 1981, Part 413] and 47 FR38462 [August 31,1982, Parts 413 and433]. The exceptions include grindingscrubber operations in the aluminum,ferrous, and copper castingsubcategories.

IV. Methodology and Data GatheringEfforts

The Agency has gathered backgroundinformation and supporting data for thisregulation'since 1974. A substantialportion of the data gathering andanalysis efforts occurred before theregulation was proposed. Additionaldata were obtained after proposal andanalyses were performed using thesedata. These additional data and the

analysis results were made available forpublic comment.

The initial methodology and datagathering efforts used in developing theproposed metal molding and castingregulation were summarized in thepreamble to the proposed regulation (47FR 51512; November 15, 1982) and weredescribed in detail in the ProposedDevelopment Document for Effluent

'Limitations Guidelines and Standardsfor the Metal Molding and Casting(Foundries) Point Source Category (U.S.EPA, November, 1982).

In summary, before proposal, EPAstudied the metal molding and castingcategory to determine whetherdifferences in the raw materials, finalproducts, manufacturing processes,equipment, age and size of plants, wateruse, wastewater characteristics, or otherfactors required the development ofseparate effluent limitations guidelinesand standards for different segments (orsubcategories) of the category. Thisstudy included the identification of rawwaste characteristics, sources andvolumes of water used, processesemployed, and sources of wastewater.Sampling and analysis of specificwastewaters enabled EPA to determinethe presence and concentration ofpollutants in wastewater discharges.

EPA also identified wastewatercontrol and treatment technologies forthe metal molding and casting category.The Agency analyzed data on theperformance, operational constraints,and reliability of these technologies. Inaddition, EPA considered the impacts ofthese technologies on air quality, solidwaste generation, water scarcity, andenergy requirements.

The Agency estimated the costs ofeach control and treatment technologyconsidered using cost equations basedon standard engineering analyses. EPAderived control technology costs formodel plants representative of the metalmolding and casting plants in theAgency's data base. The Agency thenevaluated the potential economicimpacts of these costs on the category.

The Agency also developed afinancial profile for model plantsrepresentative of the plants in EPA'sdata base using production data fromData Collection Portfolios (DCPs) andfinancial data from publicly availabledata. Using financial information and'compliance cost estimates, the impactsof the proposed regulations on plantswith a discharge were determined.Those impacts were extrapolated to theestimated total number of plants in themetal molding and casting category thatdischarge wastewaters directly orindirectly to navigable waters.

Following publication of the proposed* regulations on November 15, 1982 (see

47 FR 51512), the Agency receivednumerous comments. A number ofsignificant issues were raised by thecommenters; these included thefeasibility of complete recycle, thevalidity of the data base supportingcomplete recycle, the treatmenteffectiveness data base, the magnitudeof the discharges from die castingoperations, the accuracy of EPA'sestimates of compliance costs, and theprojected economic impacts of theproposed regulations. Commentsrelating to these issues prompted theAgency to verify its technical data baseand to reconsider many aspects of theproposed regulations.

After a review of the data base, theAgency corrected, as appropriate, theerrors noted in the comments relating topreviously-reported data. As part'ofthese efforts, the Agency made anumber of comment verificationrequests to plants that submittedcomments on the proposed regulationsor were cited specifically in commentssubmitted by others. These commentverification activities are discussed inthe Agency's first notice of availabilityand request for comments published inthe Federal Register on March 20, 1984at 49 FR 10280. Also discussed in the.March 20, 1984 notice, are the results ofthe Agency's analyses of thesupplemented data base and anyappropriate modifications to orconfirmations of the underlying facets ofthe proposed regulations. The Agencyalso solicited comments and informationconcerning a number'of other aspects ofthe rulemaking.

On February 15, 1985, the Agencypublished, at 50 FR 6572, another noticeof availability and request for commentsconcerning additional data that weregathered and analyses that werecompleted after March 20, 1984. In theFebruary 15 notice, the Agencysummarized the major issues raised incomments on its March 20, 1984 noticeand requested additional specificinformation.

The Agency has reviewed allinformation received since its November15, 1982 proposal and the publication ofthe two notices of availability justdescribed. EPA used the new data andinformation to analyze and respond topublic comments. To the extent that newinformation confirmed arguments madeby commenters, EPA revised itsregulatory options and performedadditional analyses to evaluate therevised options. These additional-analyses and the regulatory optionsconsidered by EPA as the bases for the


final regulations are discussed in moredetail in the following sections of thepreamble.V. Summary of Changes to ProposedRegulations

In reviewing comments on theproposed regulations and on the March1984 and February 1985 notices, theAgency conducted extensive analyses ofexisting data and new data andinformation submitted by thecommenters. As a result, the Agency hasmade several changes to the proposedregulations. These are summarizedbelow. Where changes have been madeas a direct result of comments, this isnoted in the following discussions.

A. Industry Coverage

At proposal, the Agency identified 19process segments in six metal moldingand casting subcategories for which itproposed regulations. The subcategorieswere aluminum, copper, ferrous, lead,magnesium, and zinc casting. TheAgency is promulgating final regulationsfor four of these subcategories(aluminum, copper; ferrous, and zinccasting). The lead casting subcategoryoperations were transferred to thebattery manufacturing category as notedin the Agency's first post-proposalnotice of availability (see 49 FR 10280).No regulations are being promulgatedfor the magnesium casting subcategoryfor the reasons explained in the riextsection of this preamble. In thisrulemaking, the Agency is promulgatingfinal regulations covering 28 processsegments of the metal molding andcasting category. The Agency identifiedadditional processes not covered in theproposed regulations which are found atmany metal molding and casting plants.Some process segments were combined(e.g., die lube and die casting, now diecasting), and some combined processsegments (casting quench and moldcooling) were separated into individualprocess segments. These 28 processsegments are as follows:

Subpart A-Aluminum CastingSubcategory

" Casting cleaning" Casting quench" Die casting" Dust collection scrubber" Grinding scrubber* Investment casting" Melting furnace scrubber" Mold cooling

Subpart B-Aluminum CastingSubcategory

" Casting quench" Direct chill casting" Dust collection scrubber

* Grinding scrubber" Investment casting" Melting furnace scrubber* Mold cooling

Subpart C-Ferrous CastingSubcategory

" Casting cleaning* Casting quench" Dust collection scrubber" Grinding scrubber" Investment casting* Melting furnace scrubber" Mold cooling• Slag quench" Wet sand reclamation

Subpart D-Zinc Casting Subcategory" Casting quench" Die casting* Melting furnace scrubber* Mold coolingThese changes were described in the

March 1984 notice, and no adversecomments were received.

B. Applied Flow Basis of theRegulations

During the Agency's post-proposaldata gathering, review, and analysisefforts, additional applied flow datawere acquired and incorporated into thedata base. Median productionnormalized applied flow rates werelisted in Appendix F of the March 20,1984 Federal Register notice at 49 FR10309-10310, for-each of 31 processsegments then considered for regulation.Only those applied flow rates applicableto certain of the melting furnace,scrubber and dust collection scrubberprocess segments were questioned incomments on the March 20, 1984 notice.These comments focused on theproduction normalizing factors (tons ofmetal poured versus air flow throughwet scrubbers) used to develop mass-based limitations for scrubbers. (See theProduction Normalizing Parametersdiscussion later in this section.)

Not all responses to EPA commentverification requests had been receivedby March 20, 1984. Additional data,including applied flow data, werereceived after publication of the March1984 notice; additional analyses wereperformed after these new data werereceived. A listing of revised medianproduction normalized applied flowswas included in Appendix A of theFebruary 15, 1985 Federal Registernotice of availability at 50 FR 6579.

The Agency received comments onthe February 15, 1985 notice whichquestioned the decreases in someapplied flow rates from those publishedin the March 20, 1984 notice. Theprocess segments specifically noted ashaving applied flows that decreased

were as follows: aluminum die casting,aluminum mold cooling, copper directchill casting, and zinc die casting. Othercomments questioned applied flow ratesfor certain other process segments andstated they should be increased. Theseinclude the ferrous melting furnacescrubber, the ferrous dust collection,and the zinc melting furnace scrubberprocess segments. Applied flow data forspecific plants with wet scrubbers alsowere questioned. Finally, a fewcommenters stated that cupola meltingfurnaces that have been installedrecently have been designed withrecuperative energy recovery; theyasserted that the air flow normalizedapplied flow for these new cupolas ismuch higher than the applied flowallowed by EPA for the ferrous meltingfurnace scrubber process segment (seeAppendix A, February 15, 1985 notice at50 FR 6579). It was further asserted thatadditional flow allowances werenecessary for multiple venturis,quenchers, after coolers, fan washes,and other ancillary water used in ascrubber system described by onecommenter.

The Agency has reviewed plant dataused in developing productionnormalized applied flow rates for theprocess segments, including all of thosecited by the commenters. The Agencyalso has reviewed the processdefinitions utilized for these segments to.ensure that the data were used properly.As a result of this review, a number ofchanges have been made to applied flowrates, including clarification of processdefinitions for die casting and ferrousmelting furnace scrubber operations.Appendix J lists the productionnormalized applied flow rates to beutilized for developing mass-basedlimitations and standards for all 28process segments to be included in thepromulgated regulations. The mostsignificant changes were clarification ofthe definition of die casting to excludedata for process waters at some plantsthat incorporated mold cooling and/orcasting quench process wastewater withdie casting process wastewater.Similarly, mold cooling data werereviewed for the aluminum and zincsubcategories, where they often arecombined with die casting data. Moldcooling data for the copper and ferroussubcategories also were reviewed.

The Agency reviewed the data for thecupola melting furnaces installed inrecent years at plants in the ferrouscasting subcategory and found thatthese data did not support thecommenters' assertions that theseprocesses required higher flow rates. Infact, the newer designs with below-the-


charge gas take-off for scrubbers hadalmost the identical air flow normalizedapplied flow rates as for the olderdesigns. The Agency found that aftersegregation of the data from plants withmultiple scrubbers, the applied flow ratefor ferrous melting furnace scrubbersdecreased. The Agency did find,however, that where more than onescrubbing device, such as both a fixedand variable venturi or a fixed venturiand a quencher, is used in series toscrub a given gas stream, water use wasfound to be significantly greater. Thus,effluent limitations and standards forferrous casting plants having multiplescrubbing devices in series to scrub agiven air stream will be based upon thesummation of the median applied flowfor each of the scrubbing devices. Amore detailed discussion of how appliedflows were developed is presented inthe technical Development Document.Each of the applied flows whichchanged from the values included in theFebruary 15, 1985 notice is discussedbelow.

The process definition for die castingwas clarified to exclude wastewatersother than die casting wastewaters, suchas mold cooling and casting quenchwastewaters. Detailed review of theplant files revealed that some of theapplied flow data that had beenattributed to die casting wastewaterscontained noncontact water; these datawere excluded. In addition, a substantialnumber of die casting plants submittedflow data after the close of the commentperiod for the March 20, 1984 notice. A.significant porion of the plants with diecasting. operations include casting ofboth aluminum and zinc in the sameplant. Therefore, the revised appliedflow data bases for aluminum and zinchave been combined, and the resultingmedian applied flow of 41.4 gallons perton has been applied to the aluminum(previously 106 gallons per ton) and zinc(previously 109 gallons per ton) die-casting process'segments. The separateeffluent limitations and standards thatare established for the mold cooling,casting quench, and other processsegments will apply for these processeswhen they are employed at aluminumand zinc die casting plants.

The Agency reviewed the appliedflow data for all of the mold coolingprocess segments. Detailed review ofplant files revealed that some of theapplied flow data in the copper and zincsubcategories included noncontactcooling water. In the aluminumsubcategory, a number of data pointsthat had been used in the die castingprocess segment were removed andadded to mold cooling as the result of

the clarification in the die castingprocess definition. This was true also forzinc mold cooling where some data fromdie casting was added. In addition, somedata for noncontact cooling waterleakage was added to the aluminummold cooling data base. Datarepresenting commingled noncontactcooling water were removed from thedata base and revised median flow ratesdeveloped. The applied flow rate foraluminum mold cooling changed from506 gallons per ton to 1,850 gallons perton. The applied flow rate for coppermold cooling changed from 5,530 gallonsper ton to 2,450 gallons per ton. Theapplied flow rate for zinc mold coolingchanged from 4,000 gallons per ton to1,890 gallons per ton.

* The Agency also reviewed appliedflow data for investment casting.Limited data were available for copperand ferrous investment casting. Wateruse for these processes typically is highon a production normalized basis.However, the amount of metal pouredand the total flow of processwastewater typically is small. Theproduction processes are similar and,therefore, water use should be similar,and so the Agency combined allavailable applied flow data'anddeveloped a new median applied flowrate, 17,600 gallons per ton, to be usedfor all three investment casting processsegments. The aluminum investmentcasting applied flow rate was 20,800gallons per ton; the copper investmentcasting applied flow rate was 764gallons per ton; and the ferrousinvestment casting-applied flow ratewas 300 gallonsper ton.

The applied flow rate for copperdirect chill casting was 4,018 gallons perton in the March 20, 1984 notice. •Additional data were received and the

* applied flow rate included in theFebruary 15, 1985 notice was 3,130gallons per ton. One plant submittedrevised data to correct data in therecord. Other plant flow data werefound to be in error. After correcting alldata errors, the Agency recalculated themedian applied flow rate for thisprocess segment. The revised-medianapplied flow rate used to develop thefinal regulations is 5,780 gallons per ton.

The preceding discussions noted thatenergy efficient cupola melting furnacesinstalled recently at ferrous plants didnot require higher air flow normalizedapplied flow rates. These cupolasexhibited flow rates virtually the sameas for older cupola designs. However,the Agency segregated data for plantswith more than one scrubber in series ina given air stream, so that only plantswith single scrubbers remained. The

water to air ratio decreased somewhatfrom 13.6 gallons per 1000 standardcubic feet to 10.5 gallons per 1000standard cubic feet. Ferrous plants withmore than one scrubbing device inseries in a given air stream will havelimitations and standards based uponan applied flow rate of 10.7 gallons per1000 standard cubic feet for each of thescrubbing devices.

The applied flow data for zinc meltingfurnace scrubbers also was reviewed.We found that the median applied flow(water to air) ratio was very low whencompared.to the water to air flow ratiosfor the other melting furnace scrubberprocess segments even though thisprocess is very similar as employed inall three regulated nonferroussubcategories. Because the meltingfurnace scrubber process is similar forall nonferrous subcategories, water toair ratio data for all nonferrous meltingfurnace scrubbers were combined toestablish the basis for the zincsubcategory. The median of thatcombined data base was 6.07 gallonsper 1000 standard cubic feet and is beingused for the zinc melting furnacescrubber process segment.

In response to comments, the Agencyreviewed other applied flow data aswell. For example, one commenter

'asserted that 3.0 gallons per 1000standard cubic feet was too stringent fordust collection scrubbers, and that theupper end of the typical range of waterto air ratios (3-5 gallons per 1000standard cubic feet) asserted to be usedin scrubber design should be adoptedfor all scrubbers. Another commenterasserted that a mumber of the water toair ratios for individual plants in thedata base could not be verified or wereotherwise considered questionable.Upon review, the Agency has found thatthese water to air flow data appear tobe valid, and the resulting median waterto air ratios are correct and achievablebased on available data. Therefore, noother changes in applied flow data werewarranted.

C. Complete Recycle/No Discharge

In the proposed regulation, nodischarge of pollutants based oncomplete recycle of process wastewaterwas proposed for 14 of 19 processsegments-of the metal molding andcasting category.

Subsequent to the proposal, theAgency found that there were numerousreporting errors by plants in its completerecycle/no discharge data base.Responses to additional inquiries sent to

,all plants in the complete recycle/nodischarge data base revealed that anappreciable number of plants were

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45218 Federal Register / Vol. 50, No. 210 f Wednesday, October 30, 1985 / Rules and Regulations

discharging wastewaters on anintermittent basis (once per week toonce every five years). Some plantswere disposing of wastewaters on. landand thus not discharging wastewaters towaters of the United States or POTWs;however, these plants were notdemonstrating complete recylce. Insummary, the portion of the industry forwhich complete recycle is demonstratedis much smaller than the Agency-believed at proposal. Therefore, theAgency reevaluated' completelyachievable recycle rates, primarilythrough evaluation of recycle ratesdemonstrated within the industry. TheAgency also developed a model ofrecycle systems to better understand thewater chemistry of these systems, toassist in identifying achievable ranges ofrecycle rates, and to supplement thedata base for the processes for whichrecycle experience within the industrywas limited. With the assistance of therecycle model, the Agency determinedthe sensitivity of recycle rates to make-up water quality and sludge moisture.content, the effectiveness of chemicaladdition. to control scaling andcorrosion, and the sensitivity ofattainable, recycle rates to recycle fromcentral treatment facilities.

After consideration of demonstratedrecycle rates by plants in the industryand after appropriate adjustments basedon recycle model analysis, the Agency ispromulgating effluent limitationsguidelines and standards developedwith discharge flow allowances basedon high rate recycle for 25 of the 28regulated process segments of the metalmolding and. casting category. Nodischarge.of pollutants based oncomplete recycle of process wastewateris being required in the final BPT, BAT;NSPS, PSES, and PSNS regulations forthe grinding scrubber process segmentsin the aluminum, copper, and zincsubcategories.

A summary of recycle rates used- todetermine mass-based blowdown flowallowances is presented in Appendix J.It should be noted that the recycle ratespresented in Appendix J of thispreamble are the same as presented inAppendix A of the February 15, 1985notice. For a detailed explanation ofhow these recycle rates weredetermined, see the February 1985notice and the technical DevelopmentDocument. It also must be noted that therecycle rates per se are not beingregulated by EPA. The recycle rates arebeing used- to develop productionnormalized flows which, in turn, areused with treatment effectivenessconcentrations and variability factors todevelop mass-based limitations.

Discussions, of treatment effectiveness.and, variability, mass-based effluentlimitations and standards, anddevelopment of permit limitations arepresented in the following sections ofthis preamble and in the technicalDevelopment Document.

D. Regulated PollutantsThe Agency proposed regulations

controlling the discharge of pH, TSS, oiland grease, lead, zinc, phenols (4AAP),acenaphthene, 2,4,6-trichlorophenol,parachlorometacresol, chloroform,phenol, butyl benzyl phthalate,chrysene, and tetrachloroethylene asappropriate for those process segmentsfor which discharge of pollutants wereallowed. In the proposed technicalDevelopment Document, the Agencypresented alternative effluentlimitations and standards based on 90percent recycle and 50 percent recycle.These alternate limitations andstandards would also have controlledthe discharge of copper. The March 20,1984 and February 15, 1985 noticesindicated EPA was consideringregulating pH, TSS, oil and grease, totalphenols. (4AAP), total.toxic organics.,(TTO), copper, lead, and zinc.

The final regulations control thedischarge of TSS, oil and grease, pH,copper, lead, zinc, total phenols (4AAP).and TTO for a number of processsegments of the metal molding andcasting category. Where TTO isregulated, an alternate monitoringparameter Coil and grease) may besubstituted, as explained late in thepreamble.

Selection of pollutants being regulatedis based on the presence of thesepollutants in treatable concentrations.Recalculation of raw wastewatercharacteristics from the data presentedin the March 20, 1984 and February 15,1985 notices has resulted in somewhatdifferent raw wastewaterconcentrations and loads. Taking intoaccount raw waste variability, theAgency anticipates that copper, lead,and zinc will be found in treatableconcentrations across all processsegments. EPA has reached thisconclusion, in part, because, wherecopper, lead, or zinc data wereunavailable, treatable levels of the toxicmetal pollutant were present in thedischarges from other regulatedprocesses employed within thesubcategory. Therefore, the Agency isregulating copper, lead, and zinc for allprocess segments. After re-evaluatingthe raw waste load data, the Agencyfound phenols (4AAP) above treatableconcentrations in raw wastewaters for -ten process segments and toxic organic.pollutants: in treatable concentrations in

raw wastewaters for 22 process -segment's. ,

A summary of the development oftreatment effectiveness concentrationsfor all regulated pollutants is presentedin the "Treatment Effectiveness DataBase" discussion later in this section ofthe preamble. A listing of pollutantsregulated for each subcategory ispresented in Appendix B of thispreamble. The specialized definitionssections of the regulation (§§. 464.11,464.21, 464.31, and 464.41) present'a listof toxic organic pollutants which arecontrolled by means of the TTO (totaltoxic organ ics]) parameter in eachprocess segment.

E. Production Normalzing Parameters

Production normalizing parametersare used to correlate wastewatervolume '(flow rate) and pollutant loadsto production or production relatedactivities. The Agency received--comments on -the March 20, 1984 noticewhich asserted that the productionnormalizing parameter for wet scrubbersshould be air flow through- the scrubbersrather than tons of metal poured andtons of sand handled, which were usedfor developing the mass-basedlimitations discussed in the preamble ofthe proposed rule (alternative -limitations for options based on 90percent and 50 percent recycle) and theMarch 20, 1984 notice. The Agencyreviewed the statistical correlationanalysis supporting the use of tons ofmetal' and tons of sand handled as thenormalizing parameters and found that acomputer programming error had beenmade rendering the results invalid.

The correlation analysis was rerun forwet scrubbers comparing water use totons of metal poured, tons of sand used,.and air flow. The results confirmed thecommenters' assertions that air flowthrough scrubbers is the mostappropriate normalizing parameter for.the scrubber-based process segments.:On the basis of this finding, water useratios (gallons pei minute per 1000standard cubic feet per minute--gpm perscfm) were calculated separately for allscrubber-based process segments ineach separate metal subcategory. Thesedata were presented in summary form inAppendix A of the February 15, 1985notice at 50 FR 6579, and in the record.The median water use ratios for wetscrubbers served as the basis for .developing the compliance costs formodel plants and, as the production.normalizing parameter for developingmass-based effluent limitations and.standards. As discussed in a precedingsection of this preamble, two of thesewater to air ratios, for the ferrous and..

Federal Register / Vol. 50, No. 210'/ Wednesday, October 30, 1985 / Rules and Regulations 45219.

zinc melting furnace scrubber processsegments, were changed in response tocomments on'the February 15, 1985notice. See Appendix J of this preamble.'Also, see the technical DevelopmentDocument.

The production normalized appliedand blowdown flow rates shown inAppendix J of this preamble areexpressed as a function of scrubber airflow (gpm per 1000 scfm, or gallons per1000 scf). Also, the Agency determinedthat the most appropriate normalizingparameter for the ferrous wet sandreclamation process segment was thetons of sand reclaimed.

In summary, the Agency hasdetermined that the most appropriateproduction normalizing parameters are:(a) Air flow through scrubbers for themelting furnace scrubber and dustcollection scrubber process segments(grinding scrubbers are not includedbecause no discharge allowance isprovided), (b) tons of metal poured forthe casting cleaning, casting quench, diecasting, investment casting, moldcooling, and slag quench processsegments, and (c) tons of sand reclaimedfor the wet sand reclamation processsegment of the ferrous castingsubcategory.

F. Control and Treatment TechnologiesConsidered

1. Treatment Technology Components

The treatment technology componentsused in the systems which served as thebasis for the proposed regulationsincluded both in-plant and end-of-pipecomponents. The components were asfollows:

a. In-Plant Controls: In-plant controlswere based primarily upon processwastewater recycle. The results ofapplication of recycle (recycle rates)and the limitations and operationalrequirements' (e.g., scaling and corrosioncontrol) has been discussed in detail inthe proposal, the March 20, 1984 noticeat 49 FR 10265-10295, and the February15, 1985 notice at 40 FR 6573-6574, 6579(Appendix A). Appendix J of this

*preamble presents a summarytabulation of achievable recycle ratesused in the development of the finaleffluent limitations and standards.These recycle rates generally havedecreased from 100 percent recycle asproposed for most process segments,and thus.allow for treated wastewaterdischarges. Complete recycle with nodischarge allowance has been retainedfor the three grinding scrubber processsegrments. The recycle rates presented inAppendix J have not changed from thosepresented in the February 15, 1985notice.

b. End-of-Pipe TreatmentComponents: The end-of-pipe treatmentcomponents considered at proposalincluded chemical precipitation andsedimentation, generally referred to aslime and settle. Additional componentswere as follows: chemical emulsionbreaking, oil skimming, filtration, andcarbon adsorption. These technologieswere summarized at 47 FR 51516-51517,discussed in detail in Section VII of theproposed technical DevelopmentDocument. In the March 20, 1984 notice,-at 49 FR 10297, the Agency indicatedconsideration of and describedadditional components including simplesettling, chemical oxidation bypotassium permanganate, and biologicaloxidation. In the February 15, 1985,notice, at 49 FR 6575, the Agencyindicated that it was also consideringincluding in the lime and settletreatment train enhanced metalsremoval prior to filtration. Thetechnologies considered were theaddition of chemicals to effect metalsulfide and metal carbonateprecipitation, and more extensiveapplication among process segments ofchemical oxidation to minimize thepotential for metals complexing byorganic compounds. No Qthercomponents were considered indeveloping the final regulations.

2. Control Technology Options

These control technology components-were incorporated into control andtreatment technology options whichserve as the primary basis for theproposed~regulations and optionsconsidered in the subsequent twonotices. In the March 20, 1984 notice,each of the eleven generic processes.was determined to require the sametechnology components for eachtechnology option in all subcategories.The treatment technology options werediscussed for each of the eleven genericprocess segments in the March 20, 1984notice at 49 FR 10297-10299. TheAgency further simplified theidentification of these options in theFebruary 15, 1985 notice, at 50 FR 6575,and 6579--6580 (Appendix B). The basic,structure and treatment functions ofthese options has not been changed.since proposal with only minormodifications as described in the twonotices. These options, which areidentical to those described in theFebruary 15, 1985 notice (see 50 FR6575), are discussed throughout thebalance of this preamble and, for ease ofreference, they are repeated here.

a. Option 1: Recycle, Simple Settle-This Option is comprised of high raterecycle achieved by settling (and free oilskimming), recycle to the process

(including pH adjustmerit for someprocesses for scaling and corrosioncontrol, and cooling towers for someprocesses to remove heat), followed bysimple settling of the blowdown stream.This Option was developed as a less,.costly treatment option in the event thata substantial number of closures mightoccur, especially among small plants,due to the cost of recycle, lime andsettle (Option 2). However, uponrecalculation of raw wasteloads andfurther review of wastewatertreatability, the Agency has concludedthat Option I is not applicable to metalmolding and casting wastewaters. TheAgency's economic impact analysisshowed that, for direct dischargers,there would be only one plant closure atOption 2 that Would not also occur atOption 1. Moreover, simple settling doesnot provide removal of heavy metals,emulsified oils, and phenols from thesewastewaters. Therefore, the Agency hasnot considered blowdown treatment bysimple settling to be the best practicablecontrol technology for any portion ofthis industry.

b. Option 2: Recycle, Lime and Settle:This Option augments Option I by theaddition of chemicals (e.g., lime andpolymer) to effect hydroxideprecipitation of metals and coagulationof solids prior to settling. Option 2 foraluminum, copper, and ferrous dustcollection process segments, thealuminum, copper, ferrous, and zincmelting furnace subber processsegments, and-the ferrous wet sandreclamation process segment include*chemical (potassium permanganate)oxidation of the blowdown stream totreat phenolic and other organiccompounds. This Option includessequential emulsion breaking, oilskimming, and chemical (potassiumpermianganate) oxidation of the entirestream prior to lime and polymeraddition and settling followed byrecycle to the process for aluminum andzinc die casting.-The Agency has concluded that

Option 2 is the minimum BPT technologywhich can be installed to remove heavy,metals, emulsified oil and grease, andphenolic and organic compounds inmetal molding and.casting:wastewaters.-Generically, lime and settle treatment,Including emulsion breaking, is bothavailable and has been widely appliedin this industry. Both short-term EPA,data and long-term industry DischargeMonitoring Report (DMR) data areavailable to characterize the . -effectiveness of this technology.

Final limitations' and standards fortotal phenols are based on levelsachieved at plants employing high rate


recycle plus lime and settle treatment.These plants do not use chemicaloxidation technology. For this reason,EPA believes, that many plants in thisindustry will be able to achieve the totalphenols. limitations and standardswithout applying chemical oxidation. In.those cases where total phenolslimitations and standards cannot be metusing recycle and. lime and settletreatment alone, compliance can beattained through the use of chemicaloxidation (potassium permanganateaddition). Thus, the Agency hasincluded potassium permanganateaddition as part of the model technologyfor those 10 process segments containingtreatable levels of totar phenols.Additionally, data from an industrystudy and an EPA study confirm that theeffluent limitations- and standards arereadily achievable with the additional'removal effected by chemical oxidationat those plants that cannot achieve thelimitations and standards through theapplication.of recycle, and lime andsettle treatment alone.

c. Option 3: Recycle, Lime and Settle,Filtration: This Option. adds filtration ofthe treated effluent from technologiesemployed for Option 2 for all processsegments to remove residuals of toxicheavy metals and suspended solids.Filtration, technology is considered byEPA to'be among the best availabletechnologies (BPT) for further treatmentof lime and settle (BPT) effluents. Thistechnology is availabla and has beenapplied at full scale in, at least, threeplants in. this industry.

The Agency has not adopted residual:metals removal' either by second stagesulfide precipitation or by second stagecarbonate precipitation. We havedetermined, that the concentrations ofmetals residuals that remain after theapplication of lime and, settle treatmenttechnology are well within the range of'concentrations observed for other,related industries. These levels are notsufficiently high to justify the addedexpense, of two-stage chemical. additionand clarification. For this industry; theAgency believes that filtration would beeffective and less costly than theapplication of second' clarification, step.

d. Option 4: Recycle, Lime and Settle,,Filtration, Activated CarbonAdsorption: This Option adds removalof residuals of toxic organic' compoundsby granular activated' carbon columns.This Option was considered forapplication in further treating Option 3'effluents in the event that treatableconcentrations of organics would bepresent after-the application of theOption 3 model technology. This is atechnology that is commonly evaluated

as a means of removing residual organiccompounds. The technology has limitedapplication in the metal molding, andcasting industry (it has been applied attwo metal molding and casting plants)and is an available technology.

Upon completing our review oftreatment system performance in themetal molding, and casting industry, wefound that those plants that employedeffective oil and grease removal'technologies effectively removed toxicorganic pollutants. For this reason, EPArejected Option 4 as the technologybasis for nationally-applicable effluentlimitations guidelines and standards.Treatment effectiveness information foractivated carbon technology, based ontheoretical treatability concentrations,are presented in the technicalDevelopment Document supporting thefinal regulations.

e. Option 5: Complete Recycle/NoDischarge: This Option is, applicableonly to the three grinding scrubberprocess segments where completerecycle/no discharge has beendemonstrated and is achievable, and,therefore is considered to' be the bestpracticable technology (BPT). This,option is comprised of simple settling(e.g., drag tank) and complete recycle ofall wastewater back to the process(including pH adjustment for scaling andcorrosion control).

3. Treatment Systems Considered forGeneric Processes

The technologies described belowwere considered as the bases for theregulations for'each of the eleven. generic metal molding'and, casting.processes. The technologies areessentially the same technologiesdescribed in the March- 1984 andFebruary 1985 notices, as describedbelow. Where the process was includedin. the proposed regulation, the model:treatment system proposed at that timeis also discussed. The design and cost ofinstalling and operating the modeltreatment systems for each genericprocess will vary across metalsubcategori'es due to differences inapplied process water flow-rates,recycle and blowdown wastewater flowrates requiring treatment, and thepollutant concentrations in theblowdown (i.e., O&M costs for chemical.addition to destroy phenols, precipitate,metals, and, maintain high rates ofrecycle if necessary). These variationsalso will result in different rates of massdischarge; thus supporting thesubcategorization scheme based onmetal type.

As noted in the proposed technicalDevelopment Document, the treatmentsystems considered by EPA are similar

or identical to treatment systems now inplace in the industry. The onlyexceptions to this are chemicaloxidation by potassium permangariatewhich has received limited applicationin this industry, but has been shown ona bench-scale basis to be very effectivein removing readily-oxidizable organics,and granular activated carbon whichhas been used at only two plants in thisindustry.

In the March 20, 1984 notice ofavailability, at 49 FR 10296-10299, theAgency indicated that it wasconsidering less than complete recyclefor 27 of the 31 process segments thenbeing considered for regulation. Limeand settle blowdown treatment wasbeing considered for these 27 processsegments. Aluminum and zinc diecasting included emulsion breaking andlime and settle inside the recycle loop.The Agency also indicated, it wasconsidering further treatment. byfiltration for residual metals removaland activated carbon for residualorganics removal. For aluminum andzinc die casting, filtration was notconsidered necessary inside the recycleloop.

Chemical (potassium permanganate)oxidation was an additional' technologycomponent incorporated in lime andsettle (Option 2) in the February 15,,1985:notice of availability, at 50 FR 6575. TheAgency also indicated it wasconsidering once-through (with norecycle) treatment of wastewater bysimple settling and lime and settle,where economic impacts were identifiedat Option I and where thesetechnologies were less costly thanOption 1. Treatment traih schematicdiagrams are presented in the record foreach of these generic process segments.

a. Casting Cleaning:'This process wasnot included in the proposed regulation.Based on data gathered since the time ofproposal, as discussed' in the March 1984notice, the Agency has determined thatcasting cleaning is' a foundry processsuitable for regulation in the ferrous andaluminum subcategories.

Casting, cleaning wastewaters containelevated levels of solids, oil and grease,and toxic metal pollutants. Thetreatment components considered asmodel technologies for the castingcleaning process included processwastewater settling followed by recycle,chemical addition to maintain recycle,and treatment of the blbwdown streamthrough-lime and polymer addition andsettling in a clarifying device equippedwith oil skimming, (Option 2). Filtration(Option 3)' was also considered.

b. Castihg' Quench: The castingquench process is included for all four


metal groups. The wastewater from thisprocess was found to vary somewhatfrom metal group to metal group, but, inall metal groups, high levels ofsuspended solids, oils and greases, andtoxic metals were detected.

The model treatment system includedin the proposed regulation consisted ofsedimentation followed by completerecycle over cooling towers. Indeveloping the final regulations, theAgency considered sedimentation in adrag tank with oil skimming, followedby recycle with chemical addition tomaintain recycle (with recycle over acooling tower at larger plants), andblowdown treatment through theapplication of lime and settle treatmentincluding polymer addition (Option 2).Filtration (Option 3) and activatedcarbon (Option 4) also were considered.

c. Die Casting: As describedpreviously, the die casting processdescription has been revised to includewastewater contributions from wastedie lubricants. Casting quench and mold,cooling wastewaters are not included aspart of this process. Most wastewaterconstituents originate in leaks from thedie casting machine hydraulic systems,and die lubricant solutions. Thecombined wastewater from the diecasting process, though it can be ofsmall volume at numerous plants, ishighly contaminated. High levels oftoxic metals and toxic organic pollutantswere detected at all six die castingplants sampled by EPA. The wastewateralso is contaminated with high levels ofsuspended solids, phenols, andemulsified and free oils and greases.

At proposal, a range of technologieswas considered for die castingoperations. The model treatment systemfor zinc die casting includedsedimentation, oil skimming, andcomplete recycle. The -proposedaluminum die casting model includedphysical-chemical treatment byemulsion breaking, hydroxideprecipitation, sedimentation, andfiltration, followed by recycle.

In developing the final regulations, theAgency considered a modified lime andsettle technology which consists ofemulsion breaking, oil skimming,chemical oxidation with potassiumpermanganate, lime and polymerprecipitation and sedimentation in aclarifier, followed by recycle withchemical addition to maintain recycle(Option 2). This system treats the entirewastewater volume prior to recycle.Blowdown treatment by filtration(Option 3) and carbon adsorption(Option 4) also were considered.

Biological treatment technology is aviable alternative but was notconsidered as the basis for the final

regulations. This alternative wouldconsist of equalization tanks, followedby an activated sludge biologicaltreatment system consisting of aeration,chemical feed systems, sedimentation,sludge return lines, followed byfiltration.

d. Direct Chill Casting: As discussedin the March 1984 notice, this process isbeing regulated by the Agency under themetal molding and casting categorywithin the copper casting subcategoryonly. This process was not separatelyidentified as a distinct casting process inthe proposed regulation. The principalpollutants of concern in direct chillcasting wastewaters are toxic metals,suspended solids, and oil and grease.

The treatment components consideredby the Agency to control the levels ofthese pollutants include sedimentation(drag tank) followed by recycle over acooling tower and chemical addition tomaintain recycle, and treatment of theblowdown flow by oil skimming, limeand polymer precipitation, andsedimentation in a clarifier (Option 2].Also, filtration (Option 3] wasconsidered.

e. Dust Collection: The Agency isregulating the dust collection process inall metal groups except zinc. Thewastewater from the dust collectionprocess can contain high levels of toxicmetals, suspended solids, and oil andgrease. Also, at several plants, highlevels of phenols (4AAP) and severalorganic toxic pollutants were detected.

The model treatment system includedin the proposed regulation for dustcollection consisted of sedimentation(drag tank) with oil skimming followedby complete recycle. The treatmentsystem considered in developing thefinal regulations includes sedimentation.(e.g., drag tank) followed by recyclewith chemical addition to maintainrecycle, with blowdown flow beingtreated by oil skimming, chemicaloxidation with potassiumpermanganate, lime and polymerprecipitation and sedimentation in aclarifier (Option 2). Filtration (Option 3)and carbon adsorption (Option 4) alsowere considered. This blowdowntreatment would control the high levelsof toxic metal pollutants and the toxicorganic pollutants and phenoliccompounds found in dust collectionwastewaters.

f. Grinding Scrubber: The Agency isregulating the grinding scrubber processin the aluminuTn, copper, and ferroussubcategories. Grinding scrubberwastewaters contain elevated levels ofsuspended solids, oil and grease, andseveral toxic metals.

The model treatment system includedin the proposed regulation for the

grinding scrubber process consisted ofsedimentation followed by completerecycle with no discharge includingchemical addition to maintain recycle.This is the same technology identified inthe March 1984 and February 1985notices and considered in developingthe final regulations.

g. Investment Casting: As discussed inthe March 1984 notice, the Agency isregulating the investment castingprocess for the aluminum, copper, andferrous subcategories. At proposal,investment casting was included only inthe aluminum subcategory. Thewastewater for this process segmentcontains high levels of suspended solidsand moderate amounts of oil and grease,and toxic metals.

The model treatment system includedin the proposed regulation consisted oflime addition followed by sedimentationin a clarifier with no recycle. The modelsystem now includes a drag tank

'followed by recycle based on the resultsof the recycle model analysis. Chemicaladdition is included to maintain recycle.The blowdown from the recycle systemis treated by lime and settle (Option.2).Also, filtration (Option 3), to removemetals residuals, and activated carbon(Option 4), to remove residual organics,were considered.

h. Melting Furnace Scrubber: TheAgency is regulating the melting furnacescrubber process in all metal groups.The wastewaters from this processcontain treatable levels of toxic metals,suspended solids, and oils and greases.Also, treatable levels of phenols (4AAP)and organic toxic pollutants weredetected.

The model treatment system includedin the proposed regulption for themelting furnace scrubber process variedslightly depending upon the major metalgroup, but generally consisted ofsedimentation followed by recycle(aluminum and zinc) or complete recycle(ferrous), with provisions for oilskimming, chemical addition, andsedimentation in a clarifier. Solidsremoved from the system would bedewatered by vacuum filters. In the zincsubcategory, potassium permanganateaddition also was included to reduce thehigh levels of phenols (4AAP) found inzinc melting furnace scrubberwastewater.

The treatment system considered as amodel for the final regulation for thisprocess consists of sedimentation (dragtanks) followed by high rate recyclewith chemical addition to maintainrecycle. Blowdown treatment consists ofoil skimming, chemical oxidation bypotassium permianganate, lime andpolymer addition and sedimentation in a


45222 Federal Register I Vol. 50, No. 210 I Wednesday, October 30, 1985 / Rules and Regulationsclarifier (Option 2) to control solids andmetals. Filtration (Option 3) and carbonadsorption (Option 4) also wereconsidered.

i. Mold Cooling: The Agency isregulating the mold cooling process forall metal groups. The wastewater fromthis process contains treatable levels ofsuspended solids, oil and grease, andtoxic metals. Additionally, thetemperature of the process wastewateris elevated, and numerous plants usecooling towers to maintain acceptabletemperature levels when high raterecycle is practiced.

The model treatment system includedin the proposed regulation consisted ofsedimentation followed by completerecycle over a cooling tower. Thetreatment system considered as a modelfor developing the final regulationsconsisted of a drag tank followed byrecycle with chemical addition tomaintain recycle (with recycle over acooling tower for larger plants), andblowdown treatment by oil skimming,lime addition and sedimentation in aclarifier (Option 2). Filtration (Option 3)also was considered.

j. Slag Quench: The Agency isregulating the slag quench process in theferrous subcategory, the only metalgroup where slag is water quenched.The wastewater from this processcontains treatable levels of suspendedsolids and toxic metals.

The model treatment system includedin the proposed regulation consisted ofsedimentation in a drag tank followedby complete recycle. The Agencyconsidered as the basis for finalregulations a system including a dragtank followed by recycle with chemicaladdition to maintain recycle, withblowdown treatment to include lime andpolymer precipitation and sedimentationin a clarifier (Option 2). Filtration(Option 3) also was considered forremoval of residual metals andactivated carbon (Option 4) wasconsidered for removal of residualorganics.

k. Wet Sand Reclamation: TheAgency is regulating the wet sandreclamation process (formerly the "sandwashing" process) in the ferrous castingsubcategory. The primary pollutants ofconcern in this process are suspendedsolids, phenols (4AAP), toxic organics,and toxic metals, primarily copper, lead,and zinc.

The model treatment system utilizedfor the proposed regulation consisted ofsettling in drag tanks, chemical additionfor phenol destruction and metalsprecipitation, sedimentation in aclarifier, and complete recycle.

The Agency considered as the basisfor the final regulations a model

treatment system for the wet sandreclamation process consisting of thefollowing: primary sedimentation withoil skimming followed by recycle withchemical addition to maintain recycle,with blowdown treatment consisting ofchemical addition (for metalsprecipitation and phenol destruction)and sedimentation in a clarifier (Option2). Filtration (Option 3) and carbonadsorption (Option 4) also wereconsidered.

G. Treatment Effectiveness Data Base

1. Lime arid Settle (Option 2)

At proposal and in the March 1984and February 1985 notices, the Agencydescribed several methods ofdeveloping treatment effectivenessvalues reflective of the application ofhigh rate recycle and lime and settletreatment including oil remoyal byemulsion breaking and/or skimming andphenol removal by the addition ofpotassium permanganate.

a. Metals: The Combined Metals DataBase (CMDB) is a data base, from well-operated lime and settle treatmentsystems employed by plants in variousindustries, that was used to establishlime and settle treatment effectivenessfor several industrial point sourcecategories. At proposal, the Agencyused ie CMDB as the basis forestablishing proposed treatmenteffectiveness concentrations for limeand settle treatment of wastewaters forthose process segments in whichcomplete recycle with no discharge wasnot proposed. Numerous commenterscriticized the Agency for using a database from industrial sources asserted tobe unrelated to the metal molding andcasting industry. These commentersstated that limitations should be basedon data from treatment systems appliedin the metal molding and castingindustry. The Agency's methodology fordeveloping limitations from the'CMDBalso was criticized.

In response to comments on theproposal, the Agency acquiredDischarge Monitoring Report (DMR)data on the performance of treatmentsystems at metal molding and castingfacilities. The Agency also assembleddata acquired under its supervision bysampling at plants in the industry. TheMarch 20, 1984 notice at 49 FR 10292-10295, presented the statisticalmethodology used to analyze these EPAand DMR data and the results of theanalyses. In brief, the Agency found that(a) raw wastewaters in this industrywere similar statistically to those in theCMDB industries, and (b) treatedeffluent concentrations also weresimilar to treated effluent

concentrations based on the CMDB,with the exception of lead and zincconcentrations based on DMR data.Lead and zinc final effluentconcentrations were higher than theCMDB final effluent concentrations.

Subsequent-to the March 1984 notice,the Agency obtained additional DMRdata. The February 15, 1985 notice, at 50FR 6575-6576, presented the results ofthe analyses of the expanded DMR database and the EPA data base. TheAgency developed three approaches toanalyze treatment effectiveness data.The first method used short-term EPAdata together with long-term DMR datafor plants where short-term EPA datawere available and confirmed the DMRdata. The second method used onlyshort-term EPA data. The third methodused short-term EPA plus DMR data forall plants whether or not EPA data wereavailable for.confirmation of the DMRdata. Long-term DMR data wereconsidered confirmed in cases whereEPA short-term sampling data wereavailable for the same plant and,preferably, the same period of timecovered by the DMR data, and wherethe short-term data were consistent withthe long-term DMR data. The EPA andDMR data also were segregated for allthree approaches into one group offerrous plants and another group ofnonferrous plants. The results of theseanalyses were tabulated in AppendicesD, E, and F of the February 15, 1985notice, at 50 FR 6580. The Agencyindicated its preference for basingtreatment effectiveness concentrationson EPA data plus confirmed DMR data(Appendix D), if the Agency decided notto use the CMDB.

Limitations based on the results ofthis analysis for the first two groups ofdata (EPA plus confirmed DMR,Appendix D; and EPA data only,Appendix E) generally were similar toeffluent concentrations derived from theCMDB. The notable exception wascopper for which the concentrationswere substantially lower than CMDBcopper concentrations for ferrous plantsfor both data groups, and higher thanCMDB for nonferrous plants based onEPA data only. Analysis of the thirdgroup of data (EPA plus all DMR data)showed relatively high treatmenteffectivenss concentrations for lead andzinc. The Agency indicated it wouldendeavor to expand the Appendix Ddata base by obtaining confirmation ofadditional DMR data. The February 1985notice also explained that finallimitations and standards might bebased upon.additional controltechnologies to reduce the levels of leadand zinc.

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The Agency sent letters requestingadditional supporting data anddocumentation to four plants with limeand settle treatment included in thethird data group described above. EPArequested that each plant submit datafrom short-term (three days) samplingand analysis of its treatment systeminfluent (raw) and effluent. EPAreceived short-term sampling data fromthree of the four plants. One of the fourplants did not sample its wastewatersbecause the data requested werealready available without sampling.Based upon these data anddocumentation, the Agency determinedthat DMR data for three of the fourplants could be considered confirmedand used in the development of finaleffluent limitations and standards. Datafor one of the plants could not be useddue to the presence of excessivequantities of noncontact cooling watercommingled with process wastewatersin the plant's treatment system. Theexpanded data base, including the datafrom these three plants, was used inestablish lime and settle treatmenteffectiveness concentrations for the finalregulations.

After detailed review of all data anddocumentation, other changes weremade-in both the EPA and the DMR databases for lime and settle treatment. Datawere deleted for plants: (1) Wherepollutants of concern were present invery low concentrations and/or whereno recycle (once through) was practicedand (2) where excessive quantities ofnoncontact cooling water were present.The reasons for the changes in the database are presented in the record at§ 22.58 and in the technicalDevelopment Document.

At proposal and in the subsequenttwo notices of availability, the Agency'spH requirement was a range of 7.5 to10.0. In its review and evaluation oftreatment effectiveness data, EPAobserved no appreciable differences inthe metals concentrations in treatedeffluents at pH 7.5 as compared to pH7.0. Below pH 7.0, however, increasedconcentrations of metals were observed,thus confirming theoretical relationshipsbetween 'metals solubilities and pH.Accordingly, the final lime and settletreatment effectiveness data baseincludes data from plants where the pHranged from 7.0 to 10.0. Consistent withthis, the pH range used in the finalregulations is 7.0 to 10.0.

The Agency analyzed the revised database (EPA plus confirmed DMR) usingthe methodology described in the recordfor the February 15, 1985 notice, anddetailed in the record at § 22.48, and asfurther described in the record at

§ 22.58. After careful review of allavailable raw waste and treated effluentdata, the Agency has determined thatraw waste treatability characteristics,as well as treated effluentconcentrations and characteristics, donot vary significantly from subcategoryto subcategory within the metal moldingand casting category. Therefore, withthe exceptions noted below, the Agencydeveloped treated effluentconcentrations for lime and settletreatment systems for all subcategoriesbased on the combined set of all EPAand confirmed DMR data.

The long-term mean treated effluentconcentration for copper, based on thecombined EPA and confirmed DMR database, is 0.065 mg/l. This concentration isconsistently achieved by lime and settletreatment systems treating ferrouswastewaters. -For this reason, EPA isestablishing the long-term mean copperconcentration for ferrous plants at 0.065mg/l. In contrast, the one copper castingplant in the EPA and confirmed DMRdata set had a long-term mean treatedeffluent copper concentration of 0.17mg/. Thus, the limited data available onthe performance of well-designed andwell-operated lime and settle treatmentsystems treating wastewaters generatedby nonferrous plants indicate thatnonferrous plants may not be able toachieve consistently long-term meanconcentrations of .065mg/l. For thisreason, the long-term mean copper .concentration for nonferrous plants isbeing set at 0.17 mg/l..

The long-term mean treated effluentconcentration for zinc based on thecombined effluent concentration dataset is 0.27 mg/l. This concentration isconsistently achieved by lime and settletreatment systems at the nonferrousplants. For this reason, EPA isestablishing the long-term mean zincconcentration for nonferrous plants at0.27 mg/l. The long-term mean treatedeffluent zine concentration based onferrous plant data only is 0.40 mg/l.Based on these data, the long-term meanof 0.27 mg/l may not be consistentlyachieved by ferrous subcategory plants.Thus, to ensure that ferrous plantsemploying lime and settle treatmentwould consistently achieve thetreatment effectiveness concentrationsfor zinc, EPA established the long-termmean for zinc at 0.40 mg/l.

Appendix K of this preamble is atabular summary of the long-term,average, maximum monthly average,and maximum one-day treatmenteffectiveness concentrations for limeand settle treatment.

b. TSS, Oil and Grease, Phenols: TheAgency determined treatment

effectiveness concentrations for TSS, oiland grease, and total phenols using thesame EPA and confirmed DMR database described above. These parametersmeasure specific bulk properties of awastewater matrix. However, based onavailable data, EPA has determined thatthe treatability of these parameters isnot expected to vary significantly Withinthe subcategories of the metal moldingand casting category.

The long-term average treated effluentconcentration of TSS for both ferrousand nonferrous plants is 9 mg/l. Thelong-term average concentration forferrous plants is 10 mg/l. Based on theavailable data from two nonferrousplants with well-operated lime andsettle treatment, the long-term averageconcentration for nonferrous plants is 5mg/l. Three of the six ferrous plants inthe data base have long-term averageTSS concentrations of 10 mg/, and twoothers have long-term averages of 13mg/l and 20 mg/l. On the basis of theseobservations, EPA has determined thata long-term average concentration of 10mg/l for TSS is more appropriate andconsistently achievable by lime andsettle technology for both the ferrousand nonferrous subcategories.

The long-term average treated effluentconcentration of oil and grease atferrous and nonferrous plants in theEPA and confirmed DMR data base is 5mg/l. Five of the nine plants for whichEPA and DMR oil andgrease data areavailable and were used in developinglimitations achieve the maximum one-day limitations. This includes analuminum and zinc die casting plantwhich has high concentrations *ofemulsified oil and grease in its rawwastewaters.

The long-term average total phenolstreated effluent concentration forferrous and: nonferrous plants is 0.20mg/I based on incidental removalthough lime and settle systems. Three ofthe five plants for which EPA and DMRphenols data were available and used indeveloping limitations achieve the long-term average and maximum dayconcentrations for total phenols.Available data indicate that manyplants in this industry will be able toachieve the total phenols limitations andstandards without applying-chemicaloxidation. In those cases where the totalphenols limitations and standardscannot be met using recycle and limeand settle treatment alone, bench-scalestudies conducted on metal molding.andcasting wastewaters show thatcompliance can be attained through theuse of chemical oxidation.

c. Total Toxic Organics: The Agencyis regulating TTO for 22 process


45224 Federal R~gister I Vol. 50, No.- 210 1- Wednesday, October 30, 1985 / Rul~s and Regulationssegments. Total toxic organics (TTO) inraw wastewaters is defined separatelyfor each process segment and includesthose toxic organic pollutants that werefound in treatable concentrations in theprocess segment. The Agency analyzeddata for toxic organic compounds in allprocess segments. As described in theMarch 10, 1984 notice of availability, at49 FR 10295, and 10310-10312, AppendixG, the Agency found different groups oforganic pollutants at-differentconcentrations in raw wastewaters ineach process segment, with the greatestnumber of pollutants and highestconcentrations found in the die casting.melting furnace scrubber, and dustcollection process segments.

The TTO treatment effectiveness database consists of data from four plants;an aluminum and zinc die casting plantwith a central treatment systemincluding emulsion breaking, oilskimming, and lime and settle treatmentoperated on a batch basis; a ferrousplant with high rate recycle and acentral'lime and settle treatment systemwith oil skimming; an aluminum diecasting plant with recycle and centraltreatment including oil skimming andalum and settle; and a ferrous plant-withtreatmqnt including oil skimming andsimple settle followed by recycle. Toxicpollutant sampling data for the twoplants that did not have lime and settlewere used in this analysis because theyemployed oil and grease removal andexhibited effective removal of toxicorganic pollutants.

The treated effluent concentrationsachieved by these four plants wereaveraged for the individual toxic organicpollutants which were found at theseplants. Treatability concentrations fororganic pollutants that were notdetected in raw wastewaters wereestimated by dividing all pollutants forwhich data were available into groupsof pollutants with similar octanol/waterpartition coefficients. Organic pollutantsfor which sampling data were notavailable were assigned to one of thegroups depending on their partitioncoefficient and were assumed to have atreatability concentration equal to themean effluent concentration of allpollutants in the group. For somepollutants, neither sampling data norliterature values for partitioncoefficients were available. In suchcases, estimates were calculated using aparallel method based on thecompound's solubility in water. Theresulting range of treated effluentconcentrations for the individual toxicorganic pollutants was from 0.010 mg/lto 0.078 mg/1. It is noteworthy that thisrange of average effluent concentrations

was achieved by the die casting plantswhich had high raw wasteconcentrations of toxic organicpollutants. This demonstrates theachievability of the TTO limitations bymetal molding and casting plants withhigh raw waste loads.

The TTO concentrations were derivedby starting with the list of toxic organicpollutants in each process segmentwhich were present above treatableconcentrations. The treated effluentconcentrations for each of the toxicorganic pollutants were summed foreach process segment to determine thelong-term average total effluent (TTO)concentration for all of these organicpollutants. The variability.factorsdetermined statistically and used tocalculate the maximum month andmaximum one-day limitations for oil andgrease also were applied to the long-term average, TTO concentrations foreach process segment to calculate themaximum month and maximum one-dayTTO limitations. The specializeddefinitions sections of the regulationpresent a list-of toxic organic pollutantswhich are controlled by means of theTTO parameter in each process segmentwhere TTO is regulated..Appendix Mincludes .a tabulation of the TTOconcentrations for each of the 22process segments.

2. Lime and Settle Plus Filtration (Option3)

a. Metals: Concentrations of lead andzinc in the treated effluent from a limeand settle plus filtration treatmentsystem are based on the long-term meanlime and settle treatment effectivenessconcentrations developed from analysisof the data base (EPA plus confirmedDMR) In the metal molding and castingindustry, reduced by one-third. EPAIndicated, in the February 15, 1985notice, at 40 FR 6576, and detailed inSection VII of the proposed technicalDevelopment Document, thatconsideration was being given to a 33percent reduction in toxic metals basedon the performance of filters in treatingwastewaters from other metalsindustries (nonferrous metals smelting,and refining and procelain enameling).

Filtration technology has beeninstalled at 32 plants and, therefore, isdemonstrated in the metal molding andcasting industry. EPA has DMR data forthree of these plants. However, the DMRdata for these plants are not appropriatefor use in developing lime and settleplus filtration treatment effectivenessconcentrations. One filtration system isoperated in conjunction with a. biological treatment system; filteredeffluent from the biological system isrecycled back to the process operations.

A second filtration system is employedto treat the blowdown from a recyclesystem employing simple settling only.The third treats the effluent from a limeand settle system treating wastewaterdischarged from a ferrous foundry on aonce-through basis. None of thesesystems is identical to the modeltechnology that describes technologyOption 3-recycle, lime and settle, plusfiltration. Therefore, the treatmenteffectiveness data were transferred fromthe other metals categories.

As discussed in the February 15. 1985notice, results of an EPA pilot plantstudy at a ferrous plant (Tyler PipeIndustries, Inc., Tyler, TX) showed thatfiltration reduced the concentrations oflead and zinc by about 67 percent belowthat achieved by a lime and settletreatment system. These pilot datasupport the attainability of the metalsremoval characteristics of filtration asapplied in other metals industries.

The metals and TSS concentrationsfrom the lime and settle treatmentsystem operated as part of the pilot unitwere higher than those that generallycharacterize the -effluent concentrationsfrom lime and settle systems employedin the-metal molding and castingindustry. Therefore, it is quite likely thatthe pilot filters removed metals to agreater degree than if lowerconcentrations of metals and TSS, suchas those expected to result from the useof well-operated lime and settle systemsin the metal molding and castingcategory, had been treated in the pilotfiltration unit. For this reason, ratherthan assuming that 67 percent removalof lead and zinc will occur after theapplication of filtration technology, theAgency has assumed that 33 percentremoval of lead and zinc will occur, ashas been documented in other, similarindustries. The Agency has concludedthat metal molding and castingwastewaters are equally amenable tofiltration of lime and settle effluentbecause of the similarity of thesewastewaters with lime and settlewastewater from porcelain enamelingand nonferrous metals manufacturing.The Agency received no commentsasserting that a one-third reduction wasnot achievable.

Further reduction of the long-termtreated effluent copper concentrationsbelow the lime and settle treatmenteffectiveness concentrations of 0.065mg/l (ferrous subcategory) and 0.17 mg/l(nonferrous subcategories) using filtershas not been demonstrated by dataavailable-from other industries.Therefore, the long-term treated effluentcopper concentrations for ferrous andnonferrous wastewater treated by lime,

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settle, and filtration is being maintainedequal to the lime and settle treatmenteffectiveness concentrations.

b. TSS, Oil and Grease, Phenols: Thelong-term average treated effluentconcentration for TSS is 2.6 mg/i. Thisconcentration is based on data fromseveral metals industry plants presentecin Section VII of the proposedDevelopment Document. Greaterremoval of TSS than metals is achievedbecause the concentration of TSSinfluent to the filters is substantiallyhigher (10 mg/l) than the metals, andthus a greater proportion of solidsremain to be removed. Also, only asmall portion of the influent suspended

.solids are metals, the remainder beingnondescript inert solids.

Some incidental removal of oil andgrease and total phenols may beachieved in a filtration system.However, significant reductions intreated effluent concentrations below 5mg/I oil and grease and 0.20 mg/I phenoare not expected. Therefore, no furtherreductions in oil and grease and totalphenols beyond those achieved by limeand settle are being assumed forfiltration.

c. Total Toxic Organics: As noted inthe discussion of lime and settle, themechanism for removal of toxic organiccompounds is the removal of oil andgrease. As noted above, the Agencydoes not expect further removal of oiland grease by filtration. Therefore, nofurther removal of toxic organicpollutants fs expected through filtration.

Appendix L of this preamble is atabular summary-of the long-termaverage, maximum month, andmaximum day treated effluentconcentrations for each regulatedparameter.

H. Compliance Costs

Comments on the proposedregulations asserted that compliancecosts were significantly underestimated.In the March 20, 1984 notice, at 49 FR10296, the Agency indicated that itsmodel plant costing methodology_.hadbeen reviewed and revised to reflectchanges in equipment and installationcosts, updated'from 1978 to first quarter1983, and changes in raw wastewater.characteristics. After updates andrevisions, the Agency found that costshad not changed substantially. In fact,the Agency also compared model plantcosts with actual plant costs submittedto EPA. In the aggregate, EPA modelplant costs were approximately 25percent higher than the plant costs,although EPA estimates for individualplants were both higher and lower thanindustry data due to site specific factors

On this basis, the Agency concludedthat its costs were not underestimated.

Similar comments on the March 20,1984 notice prompted the Agency toreview the costs again. We found thatthe costing methodology, which wasderived from larger continuous flowapplications such as the iron and steelindustry, resulted in a substantialoverestimation of costs for the very lowflow rates typical of many of the modelplants which represent the metalmolding and casting industry. Forexample, a number of componentswhich comprise the options for thisindustry required sizes (e.g., in gallonsper minute) far below the minimum sizewhich could be costed accurately byextrapolating costs from largecontinuous flow applications. TheAgency also eliminated unnecessaryredundancy in many individualcomponents that were included inblowdown treatment systems. Also, the*Agency revised both the designs,components, and sizes of componentequipment utilized in these systems toadapt more realistically the generalmethodology to the low flowapplications in this industry. These lowflow systems have been designed to beoperated on a batch basis. Similarly, theprocess wastewater recycle systems,also very low flow systems in manycases, were recosted to be morerealistic, but remained as continuousflow systems in design to be consistentwith production processes.

The Agency also evaluated the costsavings that may accrue to plants whichhave more than one process wastewaterstream and treat these combinedwastewater streams in a central facility.On the average, these cost savings(reductions) were found to beapproximately 29 percent of the capitalcost and 36 percent of the annual costscompared to the cost of constructing andoperating separate treatment systemsfor each of the contributing processwastewater streams. These average costreductions were applied to the costs ofseparate treatment systems in theeconomic impact analysis of modelplants with typical processcombinations.

The Agency's review of costing alsoincluded an indepth revision of the costsestimated for control technology alreadyin place. Individual components of thevarious options, such as settling tanks,clarifiers, and pumping systems,reported to be in place by individualplants, were accounted for by way ofspecific component utilization factors.These utilization factors weredetermined for 6ach of the componentswhich comprise a given optionseparately for both direct and indirect

dischargers, and for each employeegroup, process segment, and type ofmetal-poured. In this manner, a moreaccurate accounting of in-placetechnology was completed by type, size,and discharge mode of plants in the database.

The comments received on theFebruary 15, 1985 notice focused morenarrowly on certain aspects of the costs,such as the cost of monitoring forregulated pollutant parameters,operation and maintenance laborrequirements, and segregation ofnoncontact waters from processwastewaters. One commenter, inreviewing the compliance costs for smallplants, commented that the Agency'smodel plant investment costs werecorrect.

The Agency reviewed its costingmethodology again to respond to thesecomments and has made a few minor.changes. Operation and maintenancelabor requirements and hourly wages forthe small model plants were asserted tobe underestimated. Upon review, theAgency determined that thecommenter's assertion was partiallycorrect, As a result, EPA increased theamount of time provided for operationallabor for a few of the very small modelplants. However hourly wages allowedfor treatment system operators were notfound to be underestimated as assertedand were not changed. In the course ofthis review, the Agency found that no.cost allowance was provided formaintenance materials. An annual costallowance of 2 percent of investmentcost was added for maintenancematerials.

A commenter asserted that unitanalytical costs for a number ofpollutants included in compliance-monitoring costs were too low. Uponreview, the Agency found that the unitcost estimate for analyzing wastewatersfor certain parameters were moreappropriate for charges experienced bylarge volume customers of analyticallaboratories. Cost estimates wereobtained for low volume analyticalservices actually charged to industrialclients by two other analyticallaboratories operated by EPAcontractors. These charges for-theregulated pollutant parameters were

.added to those used previously, andnew average analytical charges for eachparameter were calculated andincorporated into the costs forcompliance monitoring.

The Agency also has reviewed thecomment that many plants would haveto incur costs to segregate noncontactwaters from process wastewaters inorder to comply with mass-based

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effluent limitations anid standards. TheAgency reviewed specific circumstancesat twenty randomly selected plants todetermine whether these plantscommingle noncontact water withprocess wastewater and, if so, toestimate the cost of segregating thesewastewaters. The Agency found that 30percent of the plants reviewed wouldincur costs for retrofitting to segregatenoncontact waters from processwastewaters. These costs were found tobe necessary for plants in themagnesium subcategory becausenoncontact waters were not commingledwith process wastewaters. Costestimates were developed for repipingnoncontact waters separate fromprocess wastewaters and rerouting themaround process wastewater treatmentsystems. The average costs for theseplants were added as percentages to thetotal required investment cost for eachtechnology option for all model plants.However, because only 30 percent of theplants were found to need to segregatenoncontact cooling waters, only 30percent of these costs were added to thetotal cost of compliance for eachsubcategory, except magnesium whereno additional costs were added.Similarly, only a portion of any.economic impacts were considered to beattributable to the incremental costs for,stream segregation. Projected impactshave been adjusted to account for thefact that 30 percent of the plants mayincur the costs of stream segregation.Additional details on these changes arepresented in the technical and economicDevelopment Documents and in therecord for this rulemaking.

As discussed in the EconomicAnalsis section of this preamble, modelplant production data based on datasubmitted by plants in the industry inData Collection Portfolios (DCPs) havebeen adjusted to reflect the reduceddemand for castings. The model plantrevenue projections used in theeconomic analysis have been similarlyreduced. Compliance costs for modelplants also have been adjusted in orderto be consistent with the adjusted modelplant production data. These costs werereduced by the ratio of the twoproduction values taken to a powerfactor determined for each option andplant size. The power factor of that ratiowas determined by plotting the totalcost of each option for representativemodel plants in all sizes and for eachprocess segment and metal subcategory.The result of this analysis was a groupof power factors specific to each optionmodel plant size, process segment, andsubcategory. These power factors reflectchanges in the relationship of cost to

model plant treatment system designand capacity.

I. Intermittent Discharge

Limitations and standards presentedat proposal and in the two notices ofavailability assumed that dischargesfrom metal molding and casting plantswould always be on a continuous basis.Information submitted in comments andconfirmed by EPA indicate thattreatment is -commonly done on a batchbasis with discharge on an intermittentbasis.

To allow this practice to continuewhere plants find batch treatment to bean effective control technique, the finalregulations contqin provisions thatwould allow metal molding and castingplants to discharge on an intermittentbasis provided that they comply withannual average limitations or standardsthat are equivalent to the effluentlimitations and standards applicable tocontinuous discharging plants. Plantsare eligible for the annual averagelimitations and standards wherewastewaters are stored for periods inexcess of 24 hours to be treated on abatch basis. NPDES permits establishedfor these "noncontinuous" dischargingplants must contain concentration-basedmaximum day.and maximum formonthly average limitations orstandards that are equivalent to themass-based limitations or standardsestablished for continuous discharging

"plants.Municipal authorities may also elect

to allow noncontinuous discharge toPOTWs. They may do so by establishingconcentration-based pretreatmentstandards equivalent to the mass-basedstandards provided in § § 464.15, 464.16,464.25, 464.26, 464.35, 464.36, 464.45, and464.46 of the regulations. Equivalentconcentration standards may beestablished by multiplying the massstandards included in the regulations byan appropriate measurement of averageproduction, raw material usage, or airflow (kkg of metal poured, kkg of sandreclaimed, or standard cubic meters ofair scrubbed) and dividing by anappropriate measure of averagedischarge flow of the POTW, taking intoaccount the proper conversion factors toensure that the units (mg/I) are correct.

. Economic Analysis

The economic analysis performedduring the development of the finalregulations for the metal molding andcasting category differs in four respectsfrom the analysis performed during thedevelopment of the proposedregulations. First, EPA is basing metalmolding and casting sales estimates onproduction data reported in the DCPs

instead of the Census sales data used atproposal. Both the sales and costestimates used in the analysis, whichreflect economic conditions reported bythe industry in 1978, were adjusted toaccount for the downturn experiencedby the Industry in 1981-1982, from whichthe industry has only partiallyrecovered. The Agency has adoptedDCP-based sales estimates as the basisfor the economic analysis for thefollowing reasons: (1) The source andaccuracy of the DCP production data isknown to EPA, whereas the accuracyand reporting methods used for theCensus production data are not ascertain, and (2) EPA bases its estimatesof the costs of the various technologyoptions considered for the finalregulations on DCP production data;therefore, the revenue and costinformation now have a common source.In summary, the use of the DCP data asthe basis for sales makes the impactanalysis consistent with the costingmethodology and all other technicalanalysis.

Second, EPA adjusted its salesestimates derived from the DCPproduction data by the percent declinesin shipments experienced in each of thesubcategories between 1978 and 1982(1983 for ferrous subcategory plantscasting primarily steel). EPA made thisadjustment in order to assure that theeconomic analysis was representative oflong-run industry production, sales, andfinancial performance. The adjustedrevenue estimates used in the analysisare more consistent with the revenue,estimates reported in other sources,notably Census. Although 1983 and 1984data indicate that the industry inrecovering from the 1982 levels, therecovery is uneven across subcategories;1984 shipments ranged from 46 percent(malleable iron segment of the ferroussubcategory) to 87 percent (ductile ironsegment of the ferrous subcategory) of1978 shipments.

Third, at proposal. EPA assumed thateconomic conditions at promulgationwould be similar to economic conditionsin 1984, and based its analysis on thefinancial capabilities of the metalmolding and casting industry on data forthat year. For the final economicanalysis, EPA has used financial datafrom the entire period between 1975 and1984 to develop the financial basis formeasuring compliance impacts. EPAbelieves that this information depicts amore accurate representation of thelong-term economic viability of themetal molding and casting industry thanis shown by data for a single year.

Fourth, EPA has developed the finaleconomic impact analysis using the

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FINSTAT data base as the source offinancial data for the industry. FINSTATdata are derived from the same Dun &Bradstreet data used at proposal;however, the FINSTAT data are morereliablesince the data base hasundergone rigorous verification; weconsider these data to be more accuratethan the unedited Dun & Bradstreetdata. For example, interim balance sheetstatements have been removed from theFINSTAT data base because interimstatements are thought to be less 'reliable than annual balance sheetstatements. A complete discussion ofthe FINSTAT data base is included inthe economic impact analysis supportingthis regulation.

VI. Control and Treatment Options andTechnology Basis for the FinalRegulation

A. Technology.Basis for the FinalRegulation

A brief summary of the technologybasis for the final regulation ispresented below. A more detaileddiscussion is presented in the final.technical Development Document.

1. BPT

EPA is promulgating BPT mass-basedeffluent limitations for all metalsubcategories except magnesium. Theselimitations are based on recycle ofprocess wastewater and treatment ofrecycle system blowdown by oilskimming and lime precipitation andsettling ("lime and settle"). Treatmentfor some process segments also includesoil emulsion breaking to removeemulsified lubricant oils and chemicaladdition (potassium permanganate) tooxidize phenolic and other organiccompounds.

Production normalized applied flowrates, recycle rates, and blowdown flowrates have been discussed previously inthis. preamble and a summary tabulationof these rates is presented in AppendixJ. The applied flow rates used tocalculate the blowdown flow rates andthe mass-based limitations are generallythe median production normalized flowsfor each process segment. For moredetail, see the technical DevelopmentDocument. Treatment effectivenessconcentrations for lime and settle alsowere discussed previously in thispreamble and a summary tabulation ofthese concentrations is presented inAppendix K.

The pollutants selected for limitationat BPT are pI, suspended solids (TSS),oil and grease, copper, lead, zinc, andtotal phenols 14AAP). Totalphenols arelimited for ten process segments. Theseare the same pollutants EPA selected for

regulation in the proposal and the twonotices of availability.

The Agency projects that there areabout 300 direct dischargers in the metalmolding and -casting industry which willbe affected by this regulation. The totalrequired investment cost [beyondequipment in place) for these plants (in1985 dollars] is $39.7 million and thetotal annualized costs would be $17.4million. The economic impact analysisindicates that three small gray ironplants in the ferrous subcategorypotentially may close, with a loss of 81jobs.

One of two direct dischargers in themagnesium subcategory is projected toclose. For this reason, the Agency isexcluding magnesium plants fromnational BPT regulations. Permittingauthorities will develop permitconditions for these plants on a case-by-case basis.

Total removal of toxic pollutants fromraw wastewaters would be about2,950,000 kg/yr (6,480,000 lbs/yr). Inaddition, compliance with BPT willresult in the removal of about 113million kg/yr (249 million lbs/yr) of total(conventional, nonconventional, and.toxic) pollutants from raw wastewaters.The Agency has determined that theeffluent reduction benefits associatedwith compliance with BPT limitationsjustify the costs for all regulatedsubcategories. A presentation of thebasis for the BPT effluent limitations foreach process segment follows below.

a. Aluminum Subcategory:'(1) CastingCleaning Process Segment. .The BPTeffluent limitations are derived from aproduction normalized applied flow of480 gallons per ton of metal poured. Therecycle rate established for this processsegment is 95 percent. Therefore, theblowdown discharge flow of 24 gallonsper ton of metal poured serves as theflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment -effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Therestilting mass effluent limitations arepresented in Section 464.12(a) of theregulations.

(2) Casting Quench Process Segment.The BPT effluent limitations are derivedfrom a production normalized appliedflow of 145 gallons per ton of metalpoured. The recycle rate established forthis process segment is 98 percent.Therefore, the blowdown discharge flow

of 2.9gallons per ton of metal pouredserves as the flow basis for the masseffluent limitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in Section 464.12(b) of theregulations.

(3) Die Casting Process Segment. TheBPT effluent limitations are derivedfrom a production normalized -appliedflow of 41.4 gallons per ton of metalpoured. The recycle rate established forthis process segment is 95 percentTherefore, the blowdown discharge flowof 2.07 gallons per ton of metal pouredserves as the flow basis for the masseffluent limitations. The model controltechnology is treatment of the entireprocess wastewater flow in a lime andsettle system which includes chemicaloxidation by potassium permanganate,emulsion breaking, oil skimming, limeand polymer addition, and settlingfollowed by recycle. Chemical addition.is also included to maintain recycle. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.12(c) of theregulations.

(4) Dust Collection Scrubber ProcessSegment The BPT effluent limitationsare derived from a productionnormalized applied flow of 1.78 gallons'per 1000 standard cubic feet of scrubberair flow. The recycle rate established forthis process segment is 98 percent.Therefore, the blowdown discharge flowof 0.036 gallons per 1000 standard cubicfeet of scrubber air flow serves as theflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes chemical oxidation bypotassium permanganate, oil skimming,lime and polymer addition, and settling.The treatment effectivenessconcentrations for lime and settle arepresented in Appendix K of thispreamble. The resulting mass effluentlimitations are presented in § 464.12(d)of the regulations.

(5) Grinding Scrubber ProcessSegment. The BPT effluent limitations


are based upon no discharge of processwastewater pollutants. The modelcontrol technology basis for thisrequirement is process wastewatersettling in a drag tank followed bycomplete recycle, with chemicaladdition to maintain recycle. The BPTeffluent limitation is presented in§ 464.12(e) of the regulations.

(6) Investment Casting ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 17,600gallons per ton of metal poured. Therecycle rate established for this processsegment is 85 percent. Therefore, theblowdown discharge flow of 2,640gallons per ton of metal poured servesas the flow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle. Theblowdown from the recycle system istreated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.12(f) of theregulations.

(7) Melting Furnace Scrubber ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 11.7 gallonsper 1000 standard cubic feet of scrubberair flow. The recycle rate established forthis process segment is 96 percent.Therefore, the blowdown discharge flowof 0.468 gallons per 1000 standard cubicfeet of scrubber air flow serves as theflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes chemical oxidation bypotassium permanganate, oil skimming,lime and polymer addition, and setting.The treatment effectivenessconcentrations for lime and settle arepresented in Appendix K of thispreamble. The resulting mass effluentlimitations are presented in § 464.12(g)of the regulations.

(8) Mold Cooling Process Segment.The BPT effluent limitations are derivedfrom a production normalized appliedflow of 1,850 gallons per ton of metalpoured. The recycle rate established forthis process segment is 95 percent.Therefore, the blowdown discharge flowof 92.5 gallons per ton of metal pouredserves as the flow basis for the masseffluent limitations. The model control

technology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich include oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.12(h) of theregulations.

b. Copper Subcategory: (1) CastingQuench Process Segment. The BPTeffluent limitations are derived from aproduction normalized applied flow of478 gallons per ton of metal poured. Therecycle rate established for this processsegment is 98 percent. Therefore, theblowdown discharge flow of 9.56 gallonsper ton of metal poured serves as theflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.22(a) of theregulations.

(2) Direct Chill Casting ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 5,780 gallonsper ton of metal poured. The recycle rateestablished for this process segment is95 percent. Therefore, the blowdowndischarge flow of 289 gallons per ton ofmetal poured serves as the flow basisfor the mass effluent limitations. Themodel control technology is settling(drag tank) followed by recycle, withchemical addition to maintain recycle,recycle over cooling towers, andblowdown treatment in a lime and settlesystem which includes oil skimming,lime and polymer addition, and settling.The treatment effectivenessconcentrations for lime and settle arepresented in Appendix K of thispreamble. The resulting mass effluentlimitations are presented in § 464.22(b)of the regulations.

(3) Dust Collection Scrubber ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 4.29 gallonsper 1000 standard cubic feet of scrubberair flow. The recycle rate established forthis process segment is 98 percent.Therefore, the blowdown discharge flow

of 0.086 gallons/i000 standard cubic feetof scrubber air flow serves as the flowbasis for the mass effluent limitations.The model control technology is processwater settling in a drag tank followed byrecycle, with chemical addition tomaintain recycle. The blowdown fromthe recycle system is treated in a limeand settle system which includeschemical oxidation by potassiumpermanganate, oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.22(c) of theregulations.

(4) Grinding Scrubber ProcessSegment. The BPT effluent limitationsare based upon no discharge of processwastewater pollutants. The modelcontrol technology basis for thisrequirement is process wastewatersettling in a drag tank followed bycomplete recycle, with chemicaladdition to maintain recycle. The BPTeffluent limitation is presented in§464.22(d) of the regulations.

(5) Investment Casting ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 17,600gallons per ton of metal poured. Therecycle rate established for this processsegment is 85 percent. Therefore, theblowdown discharge flow of 2,640gallons per ton of metal poured servesas the flow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrations,for lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.22(e) of theregulations.

(6) Melting Furnace Scrubber ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 7.04 gallonsper 1000 standard cubic feet of scrubberair flow. The recycle rate established forthis process segment is 96 percent.Therefore, the blowdown discharge flowof 0.282 gallons per 1000 standard cubicfeet of scrubber air flow serves as theflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.

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The blowdown from the recycle systemis treated in a lime and settle systemWhich includes chemical oxidation bypotassium permanganate, oil skimming,lime and polymer addition, and settlirg.The treatment effectivenessconcentrations for lime and settle arepresented in Applendix K of thispreamble. The resulting mass effluentlimitations are presented in § 464.22(fo ofthe regulations.

(7) Mold Cooling Process Segment.The BPT effluent limitations are derivedfrom a production normalized appliedflow of 2,450 gallons per ton of metalpoured. The recycle rate established forthis process segment is 95 percent.Therefore, the blowdown discharge flowof 122 gallons per ton of metal pouredserves as the flow basis for the masseffluent limitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.22(g) of the'regulations.

c.Ferrous Subcategory: (1) CostingCleaning Process Segment. The BPTeffluent limitations are derived from aproduction normalized applied flow of213 gallons per ton of metal poured. Therecycle rate established for this processsegment is 95 percent. Therefore, theblowdown discharge flow of 10. gallonsper ton of metal poured serves as theflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag'tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated'in a lime and settle systemwhich includes oil skimming, lime andand polymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.32(a) of theregulations.

(2) Casting Quench Process Segment.The BPT effluent limitations are derivedfrom a production normalized appliedflow of 571 gallons per ton of metalpoured. The recycle rate established forthis process segment is 98 percent.Therefore, the blowdown discharge flowof 11.4 gallons per ton of.metal pouredserves as the flow basis for the masseffluent limitations. The model*control

technology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.32(b) of theregulations.

(3) Dust Collection Scrubber ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 3.0 gallonsper 1000 standard cubic feet of scrubberair flow. The recycle rate established forthis process segment is 97 percent.Therefore, the blowdown discharge flowof 0.09 gallons per 1000 standard cubicfeet of scrubber air flow serves as theflow basis for the mass-effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime' and settle systemwhich includes chemical oxidation bypotassium permanganate, oil skimming,lime and polymer addition, and settling.The treatment effectivenessconcentrations for lime and settle arepresented in Appendix K of thispreamble. The resulting mass effluentlimitations are presented in § 464.32(c)of the regulations.

(4) Grinding Scrubber ProcessSegment.. The BPT effluent limitationsare based upon no discharge of processwastewater pollutants.'The modelcontrol technology basis for thisrequirement is process wastewatersettling in a drag tank followed bycomplete recycle, with chemicaladdition to maintain recycle. The BPTeffluent limitation is presented in§ 464.32(d) of the regulations.

(5) Investment Casting ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 17,600gallons per ton of metal poured. Therecycle rate established for this processsegment is 85 percent. Therefore, theblowdown discharge flow of 2,640gallons per ton of metal poured servesas the flow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime and,polymer addition, and settling. The

treatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.32(e) of theregulations.

(6) Melting Furnace Scrubber ProcessSegment. The BPT effluent limitationsare-derived from a 'productionnormalized applied flow of 10.5 gallonsper 1000 standard cubic feet of scrubberair flow. The recycle rate established forthis process segment is 96 percent.Therefore, the blowdown discharge flowof 0.42 gallons per 1000 standard cubicfeet of scrubber air flow serves as theflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes chemical oxidation bypotassium permanganate, oil skimming,lime and polymer.addition, and settling.The treatment effectivenessconcentrations for lime and settle arepresented in Appendix K of thispreamble. The resulting mass effluentlimitations are presented in § 464.32(f) ofthe regulations.

(7) Mold Cooling Process Segment.The BPT effluent limitations are derived'from a production normalized appliedflow of 707 gallons per ton of metalpoured. The recycle rate established forthis process segment is 95 percent.Therefore, the blowdown discharge flowof 35.4 gallons per ton of metal pouredserves as the flow basis for the masseffluent limitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations are'presented in § 464.32(g) of theregulations.

(8),Slag Quench Process Segment. TheBPT effluent limitations are derivedfrom a production normalized appliedflow of 727 gallons per ton of metalpoured. The recycle rate established forthis process segment is 94 percent.Therefore, the blowdown discharge flowof 43.6 gallons per ton of metal pouredserves as the flow basis for the masseffluent limitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.

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4520 Fdeal egite I Vl 0 o 1 ensaOtbr3,18 ue n euain

The b!owdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.32(h) of theregulations.1 (9) Wet Sand Reclamation ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 895 gallonsper ton of sand reclaimed. The recyclerate established for this process segmentis 80 percent. Therefore, the blowdowndischarge flow of 179 gallons per ton ofsand reclaimed serves as the flow basisfor the mass effluent limitations. Themodel control technology is processwater settling in a clarifier followed byrecycle, with chemical addition tomaintain recycle. The blowdown fromthe recycle system is treated in a limeand settle system which includeschemical oxidation by potassiumpermanganate, oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.32(i) of theregulations.

d. Zinc Subcategory: (1) CostingQuench Process Segment. The BPTeffluent limitations are derived from aproduction normalized applied flow of533 gallons per ton of metal poured. Therecycle rate established for this processsegment is 98 percent. Therefore, theblowdown discharge flow of 10.7 gallonsper ton of metal poured serves astheflow basis for the mass effluentlimitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.42(a) of.theregulations.

(2) Die Casting Process Segment. TheBPT effluent limitations are derivedfrom a production normalized appliedflow of 41.4 gallons per ton of metalpoured. The recycle rate established forthis process segment is 95 percent.Therefore, the blowdown discharge flowof 2.07 gallons per ton of metal pouredserves as the flow basis for the mass

effluent limitations. The model controltechnology is treatment of the entireprocess wastewater flow in a lime andsettle system which includes chemicaloxidation by potassium permanganate,emulsion breaking, oil skimming, limeand polymer addition, and settlingfollowed by recycle, with chemicaladdition to maintain recycle. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.42(b) of theregulations.

(3) Melting Furnace Scrubber ProcessSegment. The BPT effluent limitationsare derived from a productionnormalized applied flow of 6.07 gallonsper 1000 standard cubic feet of scrubberair flow. The recycle rate established forthis process segment is 96 percent.Therefore, the blowdown discharge flowof 0.243 gallons per 1000 standard cubicfeet of blowdown scrubber air flowserves as the flow basis for the masseffluent limitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes chemical oxidation bypotassium permanganate, oil skimming,lime and polymer addition, and settling.The treatment effectivenessconcentrations for lime and settle arepresented in Appendix K of thispreamble. The resulting mass effluentlimitations are presented in § 464.42(c)of the regulations.

(4) Mold Cooling Process Segment.The BPT effluent limitations are derivedfrom a production normalized appliedflow of 1,890 gallons per ton of metalpoured. The recycle rate established for,this process segment is 95-percent.Therefore, the blowdown discharge flowof 94.5 gallons per ton of metal pouredserves as the flow basis for the masseffluent limitations. The model controltechnology is process water settling in adrag tank followed by recycle, withchemical addition to maintain recycle.The blowdown from the recycle systemis treated in a lime and settle systemwhich includes oil skimming, lime andpolymer addition, and settling. Thetreatment effectiveness concentrationsfor lime and settle are presented inAppendix K of this preamble. Theresulting mass effluent limitations arepresented in § 464.42(d) of theregulations.2. BAT

EPA is promulgating BAT mass-basedeffluent limitations for all metalsubcategories except magnesium. For

the magnesium subcategory, the Agencyhas determined that compliance withBAT effluent limitations based on thetreatment technologies identified in thisrulemaking would not be economicallyachievable (see also the section entitledCosts, Effluent Reduction Benefits, andEconomic Impacts).

The Agency considered thetechnologies included in Options 2, 3,and 4 (see Section V of this preamble) aspossible BAT model technologies. Theflow rates for BAT are the same as thoseselected for BPT for all processsegments and are presented inAppendix J. As discussed previously,EPA established the flow basis of BPTeffluent limitations guidelines on thelowest flow rate it could justify withexisting data in order to ensure thattreatment systems would be optimizedand that the BPT and BAT technologyoptions would be totally compatible.Thus, the flow basis of BPT alsorepresents the best available flow ratesfor the metal molding and casting pointsource category.

BAT effluent limitations for thecopper and zinc subcategories and forthe major portions of the ferroussubcategory (all plants except those thatcast steel and small plants that castmalleable iron), are based on recycle,lime and settle, plus filtration. Asdiscussed previous, filtration technologyis demonstrated in the metal moldingand casting industry. The treatmenteffectiveness concentrations for recycle,lime and settle, plus filtration arepresented in Appendix L. Compliancewith the effluent limitations based onfiltration is economically achievable andresults in significant reductions in thedischarge of toxic metal pollutants.

BAT effluent limitations for thesmallest plants in the ferroussubcategory which cast primarilymalleable iron and pour less than 3,557tons 6f metal per year are based onrecycle, lime and settle. The Agency'seconomic impact analysis determinedthat the cost of complying with effluentlimitations based on filtrationpotentially may cause closure of one ofthree malleable iron plants in this sizegroup. Therefore, EPA determined thatthe addition of filtration would not beeconomically achievable for thissubcategory segment. Accordingly, theAgency is not basing BAT effluentlimitations on recycle, lime and settle,and filtration for the smallest malleableiron plants.

The BAT effluent limitations arebased on the. same control andtreatment technologies (recycle, limeand settle) as BPT for all plants in thealuminum subcategory and for those

4i230 Federal Register / Vol. 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulations


plants in the ferrous subcategory thatcast primarily steel. The treatmenteffectiveness concentrations for recycle,lime and settle are presented inAppendix K.

For the aluminum subcategory, EPAestimates that filtration would removean additional 0.003 kg per plant per day(0.007) lb per plant per day) of toxicmetals. Aluminum subcategorywastewater discharges are comprisedprimarily of zinc, nickel, and copper.This contrasts with the zinc subcategorywhere a substantial portion of the totaltoxic metals discharged is lead, which ishighly toxic, and the copper subcategorywhere treatable levels of cadmium, anextremely toxic metal, remain after theapplication of lime and settle treatment.The incremental costs of the.effluentreductiofis that filtration would achieveare $0.31 million in investment costs and$0.26 million in total annualized costs.The Agency has concluded that, in lightof all these factors, filtration should notbe the technology basis for BAT effluentlimitations for the aluminumsubcategory.

For the steel segment of the ferroussubcategory, EPA estimates thatfiltration would remove an additional0.036 kg per plant per day (0.08 lb perplant per day) of toxic metals. Theseremovals would consist mainly of zincand nickel. The incremental costs ofthese incremental effluent reductionswould be $0.48 million in i'vestmentcosts and $0.29 million in totalannualized costs. The Agency hasconcluded that, in light of all thesefactors, filtration should not be thetechnology basis for BAT effluentlimitations for plants in the ferroussubcategory that cast primarily steel.

The pollutants selected for regulationat BAT are copper, lead, zinc, and totalphenols. Total phenols (4AAP) areregulated at the BPT level in those 10process segments where treatable levelsof phenolic compounds are found in theraw waste discharge. These pollutantsare among the same pollutants selectedfor regulation at BAT in the proposaland the two notices of availability. TotalToxic Organics (TTO) are not regulatedat BAT because compliance with theBPT effluent limitations for total phenolsand oil and grease provides effectiveremoval of toxic organic compounds. Noappreciable incremental removals ofTTO or total phenols are expected dueto the application of filtration.

Implementation of the BAT effluentlimitations will represent reasonablefurther progress in reducing thedischarge of pollutants and will removean additional 3,230 kg/yr (7,100 lb/yr) oftoxic metals beyond BPT, at a totalincremental investment cost (beyond

equipment in-place) of $3.9 million andan incremental total annual cost of $2.3million (1985 dollars).

3. NSPSEPA is promulgating NSPS for all

regulated subcategories based on thesame technology as for BAT for thereasons explained in the BAT section.The blowdown discharge flowallowances for NSPS are the same as forBAT and are summarized in Appendix Jof this preamble. Treatmenteffectiveness concentrations are presentin Appendix K and Appendix L.

New sources in the magnesiumsubcategory are not regulated by NSPSbecause the costs of compliance withstandards based on the treatmenttechnologies identified in thisrulemaking, which would have resultedin closure for one of two existingsources, are likely to serve as barriers toentry into magnesium casting. Theregulations do not present entry barriersfor the remaining subcategories.

The pollutants regulated by NSPS arethe pollutants regulated by BPT andBAT effluent limitations: pH, TSS, oiland grease, total phenol (4AAP) for tenprocess segments, copper, lead, andzinc. Toxic organic pollutants are notregulated because compliance-with theoil and grease limitation will provideeffective removal.

4. PSES

Pursuant to section 307 of the CleanWater Act, EPA must establishpretreatment standards for pollutantswhich pass through or interfere withPOTWs. The Agency has compared theremovals of toxic metal and toxicorganic pollutants which occur inPOTWs with the removals of these toxicpollutants by direct dischargers in themetal molding and casting industryapplying the best available technologyeconomically achievable. A well-operated POTW with secondarytreatment will remove about 58 percentof the copper, 48 percent of the lead, 65percent of the zinc, 89 percent of thetotal phenols (4AAP), and 80 percent ofthe Total Toxic Organics (TTO). Theaverage removal of these pollutants atBAT for each of the regulatedsubcategories was greater than thePOTW removals. Accordingly, theAgency has concluded that thesepollutants pass through POTWs andthus must be regulated by PSES.

EPA is promulgating PSES based onthe application of technology equivalentto BAT. With the following exceptions,PSES are based on the application ofhigh rate recycle with lime and settletreatment plus filtration. As for BAT,EPA has based PSES on recycle, lime

and settle for all plants with indirectdischarge in the aluminum subcategory,the ferrous subcategory where steel isthe primary metal cast, and for therelatively small plants in the ferroussubcategory which cast primarily

.malleable iron. As for BAT, EPA is notestablishing PSES for plants in themagnesium subcategory because theeconomic impact analysis indicates thatthe regulation is not economicallyachievable for the magnesiumsubcategory. Plants in the magnesiumsubcategory are subject to the GeneralPretreatment Regulations (40 CFR Part403]. Finally, the Agency's economicimpact analysis indicates that for smallplants in the ferrous subcategory whichcast primarily gray iron and pour lessthan 1,784 tons of metal per year, thecost of complying with pretreatmentstandards based on recycle, lime andsettle, and filtration is not economicallyachievable. Therefore, PSES for thesesmall gray iron plants is based onrecycle, lime and settle.

PSES are mass-based with the sameproduction normalized discharge flow(blowdown) allowances as establishedfor BAT and BPT. Flow reduction byprocess wastewater recycle technologyis applicable to and demonstrated byboth direct and indirect dischargers. Toassure that indirect dischargers achievethe effluent reduction benefits of theregulation, EPA has elected to establishmass-based PSES. See the discussion ofapplied flow rates, recycle rates, andblowdown flow rates in a previoussection of this preamble. Appendix J ofthis preamble presents a tabularsummary of all applied flow rates,recycle rates, and blowdown flow ratesfor each process segment. Treatmenteffectiveness also is discussed in apreceding section of this preamble, andsummarized in Appendix K (recycle,lime and settle) and Appendix L(recycle, lime and settle, and filtration).

As discussed in the March 20, 1984notice of availability, at 49 FR 10295, thefinal regulations include standards forTotal Toxic Organics (TTO). TTOinclude all toxic organic compoundsfound at treatable concentrations in rawwastewaters from these processsegments. At that time, the Agencyindicated that TTO would be controlledfor 14 process segments including themelting furnace scrubber processes inthe aluminum, copper, ferrous, and zincsubcategories; the casting quenchprocesses in the aluminum, ferrous, andzinc subcategories; the die castingprocesses in the aluminum and zincsubcategories; the dust collection

* scrubber processes in the aluminum,copper, and ferrous subcategories; and



the slag quench and wet sand plants in this industry with indirectreclamation processes in the ferrous discharge have installed and aresubcategory. After reviewing all operating properly the technologyavailable data and recalculating the raw necessary for complying with PSES.waste loads characteristic of each Many plants in this and other industriesproduction process, the Agency has will be procuring engineering servicesdetermined that treatable levels of TTO and installing treatment -equipmentoccur in an additional eight process utilized as model technologies for thesesegments. Accordingly, EPA is regulations. This may result in delays inestablishing PSES controlling TTO engineering design, equipment orderingdischarges from the 22 process segments and delivery, installation, start-up, andwhere TTO are found above. treatable operating these systems. For theselevels in the raw waste discharges. reasons, the Agency has decided toSections 464.11, 464.21, 464.31, and establish the PSES compliance date for464.41 of the regulation present lists of all facilities at three years from the datethose toxic organics included in'the TTO of promulgation.pretreatment standards foreach process " 5. PSNSsegment. The basis for the TTO treatedeffluent concentrations for these 22 As discussed for PSES, EPA hasprocess segments was presented in a determined that toxic metal and organicpreceding section of this preamble. The pollutants will pass through POTWstreatment effectiveness concentrations without adequate pretreatment and,used in developing the mass-based therefore, pretreatment standards forpretreatment standards are presented in new source indirect dischargers (PSNS)Appendix M. are required. PSNS for all subcategories

The analysis of wastewaters for toxic are the same as PSES.organics is costly and requires New sources in the magnesiumsophisticated equipment. Therefore, the subcategory are not regulated by PSNSAgency has included in the final because the costs of compliance withregulations an alternate monitoring standards based on the technologiesparameter for TTO. Data indicate that considered in this rulemaking, whichthe toxic organics are more soluble in oil would have resulted in closure for oneand grease than in water, and that of two existing sources, are likely toremoval of oil and grease will remove serve as barriers to entry intosubstantially the toxic organics. The magnesium casting. New source indirectTTO standard is based on the discharging plants in the magnesiumapplication of oil and grease removal subcategory are subject to the Generaltechnology. If oil and grease is Pretreatment Regulations (40 CFR Partcontrolled at the regulated level, 403). The Agency has concluded thatcompliance with the TTO pretreatment PSNS will not serve as barriers to entrystandard is ensured. of new plants into the remaining

The pollutants selected for regulation subcategories of the metal molding andare copper, lead, and zinc for all process casting industry.segments, total phenol (4AAP) for ten The pollutants regulated by PSNS areprocess segments, and TTO for 22 total phenol (4AAP) for ten processprocess segments. Removal allowances segments, TTO for 22 process segments,pursuant to 40 CFR 403.7(a) may be copper, lead, and zinc. Oil and grease isgranted for TTO, but not for oil and an alternate monitoring parameter forgrease. TTO. Removal allowances pursuant to

In 1986, EPA projects that there will 40 CFR 403.7(a) may be granted for TTO,be about 500 plants with indirect but not for oil and grease.discharge. Implementation of PSES will V Pollutants Excluded Fromremove a total of 2,860,000 kg/yr Regultn(6,299,000 lbs/yr) of toxic metal and Regulationtoxic organic pollutants, at a total The Settl6ment Agreement in NRDCrequired investment cost (beyond v. Train, supra contains provisionsequipment in place) of $46.7 million, and authorizing the exclusion froma total annualized cost of $21.5 million regulation in certain instances of toxic(1985 dollars). The PSES requirements pollutants and industry subcategories.are projected to result in three plant These provisions have been rewritten inclosures-two in the gray iron segment a Revised Settlement Agreement thatof the ferrous subcategory and one in was approved by the District Court forthe ductile iron segment of the ferrous the District of Columbia on March 9,subcategory. The Agency has concluded 1979. See NRDC v. Castle, 12 ERC 1833that. the PSES are economically (D.D.C. 1979).achievable for the metal molding and The Agency has deleted the followingcasting point source category. three pollutants from the toxic pollutant

The Agency has considered the time list: (49) trichlorofluoromethane and (50)for compliance with PSES. Few of the dichlorofluoromethane (46 FR 79692;

January 8, 1981) and (17)bis(chloromethyl)ether (46 FR 10723;February 4, 1981).

Paragraph 8(a)(i) of the SettlementAgreement allows the Administrator toexclude from regulation pollutantswhere equal or more stringent protectionis already provided by effluentlimitations guidelines, new sourceperformance standards, or pretreatmentstandards promulgated pursuant tosections 301, 304, 306, 307(a), 307(b), or307(c) of the Act. Paragraph 8(a)(iii) ofthe Settlement Agreement allows theAdministrator to exclude fromregulation toxic pollutants notdetectable by section 304(h) analyticalmethods or other state-of-the-artmethods. Paragraph 8(a)(iii) also allowsthe Administrator to exclude fromregulation toxic pollutants detectable inthe effluent from only a small number ofsources within the subcategory becausethey are uniquely related to thosesources. Paragraph 8 (a)(iii) allows theAdministrator to exclude fromregulation toxic pollutants present inamounts too small to be effectivelyreduced by technologies known to theAdministrator.

Forty of the priority pollutants arebeing excluded from regulation acrossall subcategories because they were notdetected at or above the nominal limitsof quantification by state-of-the-artanalytical methods at any of the plantssampled by the Agency. Appendix Ccontains a list of these toxic pollutants.

The presence and absence of theremaining priority pollutants in metalmolding and casting wastewaters variesby subcategory. Therefore, furtherpollutant exclusions are presented foreach subcategory in Appendices Dthrough G. Each appendix includes asubtitle which presents the reason forexclusion of the list of priority pollutantsthat follows.

VIII. Economic Considerations

A. Introduction

The Agency's economic impactassessment of this regulation ispresented in the report entitledEconomic Impact Analysis of EffluentLimitations Guidelines and Standardsfor the Metal Molding and CastingIndustry (U.S. EPA, Washington, DC,September 1985). This report details theinvestment and annualized costs ofcompliance with this regulation for themetal molding and casting industry. Thecompliance costs are based onengineering estimates of capital andoperating and maintenance costs for theeffluent control systems describedearlier in this preamble and in detail in


Section VIII of the technicalDevelopment Document. The economicimpact analysis assesses the impact ofthese effluent control costs on the metal'molding and casting industry in terms ofprice changes, production. cost. changes,plant closures, employment effects, andbalance of trade effects. The economic.impact analysis reflects revisions in-estimates of treatment costs that haveoccurred since proposal as discussed inSection VIII of the technicalDevelopment Document.

In addition, EPA has conducted an:analysis of the incremental removal costper pound equivalent for each of the.technology options. A pound equivalentis calculated by multiplying .the numberof pounds of a toxic pollutantdischarged by a weighting factor for thatpollutant. The weighting factor is equalto the water quality criterion for astandard pollutant (copper),.divided by-the water quality criterion for thepollutant being evaluated..The use of"pound equivalent" gives relativelymore weight to removal of more toxic-pollutants. Thus, for a givenexpenditure, the cost per poundequivaleht removed would be lowerwhen a. highly toxic pollutant- is removedthan if a less toxic pollutant-is removed..This analysis is. included in: therecord- ofthis rulemaking.

B. Costs and Economic Impacts

The Agency projects that 3,853foundries will be in operation in 1986.An estimated 2,794 of these willbe dryfoundries using no process waters intheir manufacturingoperations and 259,foundries.will discharge no effluent tosurface waters. The Agency estimatesthat 796 foundries will incur costs due to;this regulation. We project that ' 299 ofthese facilities will discharge theirwastewater directly into navigablewaters, and 497 will. discharge into'publicly owned treatment works(POTWs).

Total capital costs for the dischargingplants as a result of this-regulation areestimated to be $90.4 million, while totalannualized costs, including depreciation-and interest, are estimated to be $41.2'million. These costs are expressed in1985 dollhrs.

Three gray iron facilities are-expectedto close as a result of the BPT level ofcontrol with an accompanyingemployment loss of 81 jobs. Twoadditional gray iron facilities areexpected to close due to the PSES level-of control resultingin an employmentloss of 54 jobs. The- only other closureprojected is in the ductile-iron segmentof the ferrous casting-subcategory andwill result from implementation-of thePSESlimitations. The job loss

associated with this one closure isprojected to be 27 employees.

Magnesium foundries are exemptedfrom this regulation because the Agencydetermined that- the effluent limitationsand standards that would result from,the application of the technology optionsconsidered as the basis for thisregulation are not economicallyachievable for existing plants in thesubcategory and the options ofcoripliance with. such costs would -present a barrier to entry to-new plhnts.Two of the four affected'magnesiumfoundries were projected to close underthe BPT/BAT limitations and'PSES Allof the magnesium foundries that would'have been covered by. the reulation aresmall businesses employing 50"or fewer -

persons.No further significant impacts are

projected as a result of the regulation.Increases in the cost of productiongenerally average less than one percent,although small gray ironand: ductile ironfoundries may experience cost increases-as high as 4.0. and 2.5 percent,respectively. Foundries are not. assumed'to be able to pass on these- costincreases in the form- of higher pricesdue to competition from, the 3053 .foundries not incurring costs due to theregulation (the dry-foundries and- zerodischarges). No incremental tradeimpacts are expected to occur from thisregulation.

For purposes of the, economic-analysis, the Agency created-eightseparate economic subcategories basedon metal types: four ferroussubcategories-gray iron, ductile iron,malleable iron steel; and fournonferrous- subcategories-alminum,zinc, copper,. and-magnesium. Use ofthese subcategories (which- correspond

-to SIC codes) recognizes that mostfoundries: derive their-sales fromcastings of one-or primaril from onemetal- type and that the products derived'from these metals have differentproperties, applications;. and values.Therefore, this. subcategorization'enabled the Agency-to develop an'economic-analysis- sensitive todifferent'financial profiles based. on-product type.

Each metal subcategory-was furtherdivided into employment, siz e groups.The employment size groups were fewer-than- 0 , 10-4o 49i 50 to 99, 100-to 249; and250 or moret Employment size groupings'were used as a'proxy- for productionlevels because data necessaryfor theanalysis-were reported ihthis.mannerby industry-in-the major trade-journal'.Mbdbl- plant' financial' profiles;representing-affected; foundries in eacheconomic-employment subcategory werethen developed to-estimate-the incomethat could be generated, by foundries.

and used (in part) to pay for pollution-control equipment. These-incomeestimates were used to' determinewhether the costs of complianbe with-the regulationwould cause significanteconomic-impacts.

The financial profiles developedrepresented the balance sheets andincome statements for a "typical"foundryin each-employment sizesegment and metal type.-These profileswere-developed exclusively from jobshop financial-data, which-represent themost complete picture of job shop or"standalone" operations.available. Forthe purpose ofthe analysis, captiveoperations (ie., those selling 50-percentor more of their output. to a parentcompany) were assumed, to have thesame fihanciar characteristics as jobshop -operations. This- approach mayoverstate impacts because-it assumesthat captives are. treated! the same asjobbers-by-their parent companies,thereby ignoring-potential benefits-ofownership by a larger corporation suchas-an assured product market, access to.professional.management techniques,and easier access- to. credit: markets.Compliance- cost estimates-were basedon the costs ofadditional' treatmentrequired to meet the effluent limitationsand standards. If compliance costsexceeded the plant's ability to generatecapital and ihcome at a specific level, aclosure was predicted. Determination ofa plant's.ability to pay for the-treatmentcosts-was based-on-three closures tests:Debt to total. assets; return on total'assets and cash flow to- total debt.Failure oftwo-of these three testssignaled a closure. Total plant closureswere, then extrapola ted: from the. model'plant results tothe estimatedpopulatibnof foundries in 1986.

The-Agency revised' some of its earliereconomic methodology as detailbd inthis preamble under the,"Changes SinceProposal" section. Briefly,; these changesentailed using multi-year data for-theanalysis, using, the FINSTAT data basefor development of the financial profiles;using-sales revenues which werederivedfrom- data collectibn portfolio,(DCP) informatibn, and adjusting theDCP-based-produetion to-account for-economic trends in the industry. Otherchanges since proposal, are discussed inthe March:1984 Notice of Availability.-

Following are summaries of the costsand'impacts under the promulgatedlimitations and-standards.

BPT: BPT regulations are beihg,promulgated for direct dincliargers in, alleconomic subcategories except- formagnesium By 1986i the Agency,projects that 297 direct, dischargers willhave to install, and operate additional

i .... F .i 'I', "

. 2 / W Re . " ions4524 erlra Rgi'se ,/ Vl0,0N. ,1 /WdeaY,' October 3, 1 ,5 Rules and Regulations

equipment to comply with.the BPTlimitations. Investment costs for BPT are$39.7 million; total annual costs ire $17.4million, including interest anddepreciation (1985 dollars). As a resultof compliance with this regulation, threegray iron facilities out of 91 directdischarging gray iron plants areexpected to close, resulting in anemployment loss of 81 jobs. Increases inthe cost of production at the affectedplants will generally be less than onepercent. No balance of trade effects areexpected.

BAT: BAT regulations are also beingpromulgated for all the economicsubcategories except for magnesium.

-However, incremental costs to complywith BAT will arise in the gray iron,ductile iron, malleable iron, zinc, andcopper subcategories. BAT limitationsfor steel, zinc and aluminum foundriesare based on the BPT technology;therefore, no incremental compliancecosts will result. The incremental.investment costs due to BAT total $3.9million while annualized costs total $2.3million (1985 dollars). The incrementalincrease in the cost of productionassociated with the BAT technology isless than one percent in all affectedeconomic subcategories. BAT formalleable iron in foundries withproduction levels associated with theless than 99 employment size (i.e., 3,557tons/year of metal poured) is also equalto BPT. One of the three foundries in thisemployment size grouping was projectedto close; thus, regulations based on lime,settle, and filtration were considered tobe not economically achievable for thissubgroup. Therefore, a less stringentcontrol level is being promulgated forlower production levels in the malleableiron subcategory segment. Malleableiron foundries with greater productionlevels must comply with the morestringent limitations based on the BATtechnology of recycle, lime, settle, andfiltration.

PSES: Categorical pretreatmentstandards are being promulgated forindirect dischargers in all economicsubcategories except magnesium. By1986, the Agency proJects that there willbe, 497 indirect dischargers -that willhave to install and operate additionalequipment to comply with the PSESlimitations. The Agency estimates thatcapital costs to comply with PSES are$46.7 million and annualized costs are$21.5 million (1985 dollars). Two plantclosures in the gray iron subcategorysegment are projected. Theaccompanying employment loss isexpected to be 54 jobs. The modeltechnology for PSES is the same asthose for BAT except for small gray iron

foundries. Six foundries representingapproximately fifteen percent of grayiron indirect discharging foundries in theless than 50 employment size groupingwould be expected to close if the modeltechnologies for PSES were recycle,lime, settle, and filtration. Thus, EPAdetermined that standards based onlime, settle, and filter were noteconomically achievable for this groupof plants. Therefore, the technology andcosts for plants which pour less than1,784 tons of metal per year reflect theless stringent level of recycle, lime, andsettle. Closure estimates were reducedfrom six to two gray iron foundries atthis less stringent level of control. Oneadditional plant closure is projected inthe ductile iron segment of the ferroussubcategory, resulting in an employmentloss of 27 jobs. Production cost increasesaverage less than one percent overallunder PSES.

NSPS/PSNS: The new sourcestandards (NSPS and PSNS) are basedon the same level of technology as BATand PSES, respectively. Therefore, thereare no incremental costs and there areno barriers to entry attributable to thenew source standards.

C. Regulatory Flexibility Analysis

Public Law 96-354 requires that EPAprepare a Regulatory FlexibilityAnaylsis for regulations that have asignificant impact on a substantialnumber of small entities. A smallbusiness analysis is included in theeconomic impact analysis for thisregulation.

If all foundries had to comply withlimitations and standards based onrecycle, lime, settle, and filtration,closures would total 13 and theemployment loss would total 387 jobs.These closure estimates represent lessthan two percent of dischargingfoundries and less than 0.5 percent of allfoundries. These impacts occur in thesmaller employment size groupings ofless than 100 employees. Partly inrecognition of this disproportionateeffect on smaller foundries, the Agencyis promulgating less stringent effluentlimitations guidelines and standards tomitigate these effects. (In the instance ofthe magnesium subcategory, the entiresubcategory is being exempted fromthese nationally-applicable regulations.)The effluent limitations guidelines andstandards being promulgated today areprojected to result in only six closuresand an employment loss of 162 jobs. TheAgency believes that these fewremaining plant closures do not result ina significant effect on a substantialnumber of small businesses, and Ihereby certify to this effect for thepurpose of 50 U.S.C. 605(b). While this

conclusion obviates-the need for aformal Regulatory Flexibility Anaylsia, asmall business analysis has beenincluded in the economic impactanalysis report and supports theconclusion that the regulation iseconomically achievable for smallplants.

D. SBA Loans

The Agency is continuing toencourage small plants to use SmallBusiness Administration (SBA)financing as needed for the purchase ofpollution control equipment. The threebasic programs are: (1) The PollutionControl Bond Program (tax exempt), (2)the section 503 Program, and (3) theRegular Business Loan Program.Eligibility for SBA programs varies byindustry. Generally, a company must beindependently owned; not dominant inits field; the employee size ranges from250 to 1,500 employees (dependent uponindustry); and annual sales revenueranges from $275,000 to $22 million(varies by industry). The estimatedeconomic impacts for this category donot include consideration of financingavailable through these programs.

For further information and specificson the Pollution Control Bond Program,contact: U.S. Small BusinessAdministration, Office of PollutionControl Financing, 4040 North FairfaxDrive, Suite 500, Arlington, Virginia22203, (703) 235-2920.

The section 503 Program, as amendedin July 1980, allows long-term loans tosmall and medium sized businesses.These loans are made by SBA approvedlocal development companies. Thesecompanies are authorized to issueGovernment-backed debentures that arebought by the Federal Financing Bank,an arm of the U.S. Treasury.

Through SBA's Regular Business LoanProgram, loans are made available bycommercial banks are guaranteed by theSBA. This program has interest ratesequivalent to market rates.

For additional information on theRegular Business Loan and section 503Programs, contact your local SBAOffice. The coordinator at EPAheadquarters is Ms. Frances A. Dessellewho may be reached at (202) 382-5373.

E. Executive Order 12291Executive Order 12291 requires EPA

and other agencies to perform regulatoryimpact analyses of major regulations.Major rules are those that impose a coston the economy of $100 million a year ormore or have certain other economicimpacts. This regulation is not a majorrule because its annualized cost of $41.2million is less than $100 million and it

Federal Register / Vol. 50;. No. 210 /' Wednesday, October 30,. 1985 / Rules and Regulations 45235

meets none of the other'criteria:specified in Section .paragraph- (b);ofthe Executive Order The economic.impact analysis prepared for thisrulemaking meets the requirements fornon-major rules.

IX. Non-Water Quality Aspects ofPollution Control

The elimination or reduction of oneform of pollution may cause otherenvironmental problems. Therefore,sections 304(b) and 306 of the-Actrequire EPA to consider the nQn-waterquality environmental impact (includingenergy, requirements) of certainregulations. In compliance with these.provisions, EPA has considered theeffect of this regulation on air pollution.solid waste generation, water scarcity.,,and energy consumption..This rule was,circulated to and reviewed by EPApersonnel responsible for non-waterquality environmental programs. Whileit is difficult to balance pollutionproblems against each other and againstenergy utilization, EPA is promulgatingaregulation, that it believes best servesoften competing national goals.

The following are the non-waterquality environmental impacts(including energy requirements)associated with this final regulation:

A. Air PollutionImposition of the BPT, BAT, NSPS,

PSES, and PSNS will not create anysubstantial air pollution problems.Minor very localized air pollutionemissions currently exist irt the ferrouscasting subcategory where wastewatersare used to quench the hot slaggenerated in the melting process. Also,water vapor containing some, particulatematter is released from the cooling,tower systems used in the castingquench and mold cooling processsegments. However, none of theseconditions'currently are consideredsignificant and'no significant futureimpacts are expected as the result ofthese regulations.

B. Solid WasteEPA estimates that the BPT

requirements will generate an additional522,000 kkg (575,000 tons) per year ofsolid wastes (at 25 percent solids) overthat which is currently being generatedby the.metal molding andcasting .category. This includes 1,730 kkg (1,900tons) of oily wastes, EPA estimates thatBAT requirements will increase these-wastes by about 240 kkg (265 tons):peryear beyond BPT levels. In addition;

-PSES will increase these wastes byapproximately 442,000 kkg (486,000 tons)per year beyond current levels. New'metal molding and casting plants'

subject tb PSNSor NSPS'also willgenerate treatment system sludges.

The Agency-examined the solidwastes that would be.generated bymetal, molding and casting processesusing the model treatment technologies,and has concluded that they are nothazardous. under section, 3001 of theResource, Conservation and RecoveryAct (RCRA), This judgment is based ona review of the results of the ExtractionProcedure (EP). toxicity tests that, wereconducted on metal molding-and castingsolid wastes. Nbne of thepollutants forwhich the extracts in, the.EP, test areanalyzed were, found. in metal molding.and casting sludges above the allowableconcentration (i.e., the concentrationthat makes the waste hazardous).. Metalmolding and casting wastes also. are notlisted currently as hazardous under 40:CFR 261.11 (45 FR 33121, May'19, 1980;as amended by 45 FR. 76624, November19, 1980). Moreover, the 1984amendments to RCRA provided specificexemptions to: the double linerrequirement for this industry forhazardous.wastes as long as these do.not contain certain constituents whichwould render the-Wastes hazardous'forreasons other than the EP.toxicitycharacteris tic. Included in-the,exemption are waste molding sands(production waste) and wastes frommelting furnace emission controls. Theseare. among.the highest volume wastesgenerated at metal molding and- castingplants. For the above reasons, EPA hasnot developed estimates of the costs todispose of hazardous solid wastes. EPAhas included costs for nonhazardous.waste dihposal' of $21.00/tonfor sludgesand $28.60/ton for oily wastes generatedin treating metal molding and castingwastewaters.

Although, it is the Agency's view thatsolid wastes generated as a result ofthese regulations are not expected to beclassified as hazardous under theregulations implementing Subtitle C ofRCRA, individual generators of thesewastes must test the waste to determineif they meet any of the characteristics ofhazardous wastes. See 40 CFR 262.11 (45FR 12732-12733, February 26, 1980); Asmore information becomes available, it'is possible that certain sludges could.belisted'as. hazardous pursuant to 40 CFR261.11.

Should any metal. molding and'castingwastes.be identified'as hazardous, theywill come within the scope of' RCRA's"cradle to grave" hazardous wastemanagement program, requiringregulation from the point of generationto the point of final disposition. EPA'sgenerator standards'require generators'of hazardous wastes to meetcontainerization,, labeling,

recordkeeping, and'reporting,requirements.. if metal molders or

'casters dispose of hazardous wastes"offsite,. they would' have to. prepare amanifest that tracks the:movementofthe wastes.from the.generator'spremises. to. an appropriate- off-sitetreatment, 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 transporterregulations require transporters ofhazardous wastes. to comply with the,manifest system to ensure that thewastes are-delivered to a, permittedfacility. See 40 CFR 263.20 (45 FR 33142,May 19, 1980; as amended at 45 FR86973, December 31, 1980): FinallyRCRA regulations establish standardsfor hazardous waste treatment, storage,and! disposal, facilities allowed toreceive such wastes. See 40 CFR Parts.264 and 265.(46 FR 2802, January 12,1981; 47'FR 32274, July 26, 1982).

Even though'metal molding and'casting wastes are notidentified as'hazardous, they still must be disposedIofin a manner that will not violate theopen dumping.prohibition of section '4005 of RCRA. The Agency has' ' -calculated,. as part-of the costs foiwastewater treatment, the cost formodel plants of hauling and disposing ofthese wastes (using the unit-costs noted'above) in accordance with this'requirement. For more details, seeSection IX of the technical DevelopmentDocument..

C. Consumptive Water'Loss

EPA estimates that the evaporativewater losses from the recycle systemsthat we project. will be used to comply'with the. final regulations will be lessthan about 0.1 percent of the waterlosses that now occur from the airpollution.control scrubbers usedextensively throughout this industry.Therefore, compliance with this finalregulation: is.not expected to result in. a-significant consumptive water loss..TheAgency' concludes that the benefitsderived' from. compliance with the finalregulations j*ustify the minimal waterloss-associated with 'the application ofrecycle technology;

D. Energy Requiiements

EPA estimates that, compliancewith:the BPT requirements of theseregulations by direct dischargers 'will:result in a total electrical, energy-consumption of 18.8 x, 10c kilowatt-hoursper year. over current energy usage forwastewater treatment. EPA estimatesthat compliance with the.BAT -requirements of. these regulatidns by,direct dischargers will result In a total

45236 Federal Register I Vol. 50, No. 210 I Wednesday, October 30, 1985 I Rules and Regulations

electrical energy consumption of 4.2 x106 kilowatt-hours per year in additionto the energy usage to comply with BPT.Compliance with the PSES requirementsof these regulations by indirectdischargers will result in a totalelectrical energy consumption of 17.3 x106 kilowatt-hours per year over currentenergy usage for wastewater treatment.Industry compliance with the BPT, BAT,and PSES limitations will result in anenergy increase of 0.13 percent over thts31.3 x 106 kilowatt-hours used in 1978 forproduction purposes.

The energy requirements for NSPSand PSNS are estimated to be similar toenergy requirements for BAT. Moreaccurate estimates are difficult to make-because projections for new plantconstruction are variable. It is estimatedthat new plants will design, whereverpossible, production techniques and airpollution control devices that eitherrequire less water than current practicesor require no water such as dry airpollution control devices.

X. Best Management Practices (BMPs)

Section 304(e) of the Clean Water Actauthorizes the Administrator toprescribe "best management practices"(BMP). EPA is not promulgating BMPsspecific to the metal molding andcasting category.

XI. Upset and Bypass Provisions

A recurring issue of concern has beenwhether industry guidelines shouldinclude provisions authorizingnoncompliance with effluent limitationsguidelines during periods of "upset" or"bypass." An upset, sometimes calledan "excursion," is an unintentionalnoncompliance occurring for reasonsbeyond the reasonable control of thepermittee. Industry argues that an upsetprovision in EPA's effluent limitationsguidelines is necessary because suchupsets inevitably occur even in properlyoperated control equipment. Becausetechnology-based effluent limitationsguidelines require only what technologycan achieve, they claim that liability for.such situations is improper. Whenconfronted with this issue, courts havebeen divided on the question of whetheran explicit upset or excursion exemptionis necessary or whether upset orexcursion incidents may be handledthrough EPA's exercise of enforcementdiscretion. Compare, Marathon Oil Co.v. EPA, 564 F.2d 1253 (9th Cir. 1977) withWeyerhaeuser Co. v. Costib, 590 F.2d1011 (D.C. Cir. 1978] and Corn RefinersAssociation, Inc. v. Costle, 594 F.2d 1223(8th Cir. 1979.) See also, AmericanPetroleum Institute v. EPA, 540 F.2d 1023(I0th Cir. 1976); CPC International, Inc.v. Train, 540 F.2d 1320 (8th Cir. 1976);

FMC Corp. v. Train 539 F.2d 973 (4th Cir.1976).

While an upset is an unintentionalepisode during which effluentlimitations guidelines are exceeded, abypass is an act of intentionalnoncompliance during which wastetreatment facilities are circumvented inemergency situations. Bypass provisionshave, in the past, been included inNPDES permits.

EPA has determined that both upsetand by-pass provisions should beincluded in NPDES permits and haspromulgated NPDES regulations thatinclude such permit provisions (40 CFR122.41; 45 FR 14146, April 1, 1983). Theupset provision establishes an upset asan affirmative defense to prosecution forviolation of technology-based effluentlimitations guidelines. The bypassprovision authorizes bypassing toprevent loss of life, personal injury orsevere property damage. Becausepermittees in the metal molding andcasting category are entitled to upsetand bypass provisions in NPDESpermits, this final regulation does notaddress these issues.

XII. Variances and Modifications

Upon the promulgation of the finalregulation, the numerical effluentlimitations guidelines for theappropriate subcategory must beapplied in all federal and state NPDESpermits thereafter issued to metalmolding and casting direct dischargers.In addition, upon promulgation, thepretreatment standards are directlyapplicable to indirect dischargers.

For the BPT effluent limitationsguidelines, the only exception to thebinding limitations is EPA's"fundamentally different factors"variance. See, E. I duPont de Nemoursand Co. v. Train, 430 U.S. 112 (1977);Weyerhaeuser Co. v. Castle, supra. Thisvariance recognizes factors concerning aparticular discharger that arefundamentally different from the factorsconsidered in this rulemaking. However,the economic ability of the individualoperator to meet the compliance cost forBPT effluent limitations guidelines is nota consideration for granting a variance.See, National Crushed StoneAssociation v. EPA, 449 U.S. 64 (1980).This variance clause was originally setforth in EPA's 1973-1976 industryregulations but is now cross-referencedTin the metal molding and casting andother specific industry regulations. Seethe NPDES regulations at 40 CFR Part125 Subparts A & D for the text andexplanation of the "fundamentallydifferent factors" variance.

The BAT limitations in this regulationalso are subject to EPA's

"fundamentally different factors"variance. In addition, BAT limitationsfor nonconventional pollutants aresubject to modification under sections301(c) and 301(g) of the Act. Thesestatutory modifications do not apply totoxic or conventional pollutants.According to section 301(j)(1)(B),"applications for these modificationsmust be filed within 270 days afterpromulgation of final effluent limitationsguidelines. See 40 CFR 122.21(1)(2).

The economic modification section ofthe Act (Section 301(c)) gives theAdministrator authority to modify BATrequirements for nonconventionalpollutants for dischargers who file apermit application after July 1, 1978,upon showing that such modifiedrequirements will: (1) Represent themaximum use of technology within theeconomic capability of the owner oroperator, and (2) result in reasonablefurther progress toward the eliminationof the discharge of pollutants. Theenvironmental modification (Section301(g)) allows the Administrator, withthe concurrence of the State, to modifyBAT limitations for nonconventionalpollutants from any point source upon ashowing by the owner or operator ofsuch point source satisfactory to theAdministrator that:

(a) Such modified requirements willresult at a minimum in compliance withBPT limitations or any more stringentlimitations necessary to meet waterquality standards;

(b) Such modified requirements willnot result in any additionalrequirements on any other point ornonpoint source; and

(c) Such modification will not interferewith the attainment or maintenance ofthat water quality which shall assureprotection of public water supplies, andthe protection and propagation of abalanced. population of shellfish, fish,and wildlife, and allow recreationalactivities, in and on the water, and suchmodification Will not result in thedischarge of pollutants in quantitieswhich may reasonably be anticipated topose an unacceptable risk to humanhealth or the environment because ofbioaccumulation, persistence in theenvironment, acute toxicity, chronictoxicity (including carcinogenicity,mutagenicity, or teratigenicity), orsynergistic propensities.

Section 301(j)(1)(B) of the Act requiresthat applications for modificationsunder section 301(c) or (g) be filedwithin 270 days after the promulgationof an applicable effluent limitationsguideline regulation. Initial applicationsmust be filed with the RegionalAdministrator and, in States with

No. 210 / Wednesday, October 30, 1985 / Rules and Regulations45236 Federal Register / Vol. 50,


approved NPDES programs, a copy mustbe sent to the Director of the Stateprogram. Initial applications to complywith section 301(j) must include thename of the permittee, the permit andoutfall number, the applicable effluentlimitations guideline regulation, andwhether the permittee is applying for a301(c) or 301(g) modification or both.

Indirect dischargers subject to PSESand PSNS are eligible for credits forpollutants removed by a POTW. See 40CFR 403.7.

New sources subject to NSPS andPSNS are not eligible for any otherstatutory or regulatory modifications.See E.. duPont de Nemours & Co. v.Train, supra.

Indirect dischargers subject to PSESare eligible for the "fundamentallydifferent factors" variance. See 40 CFR403.13. On September 20, 1983, theUnited States Court of Appeals for theThird Circuit held that "FDF variancesfor toxic pollutants are forbidden by theAct," and remanded § 403.13 to EPA.NAMFet al. v. EPA, 719 F.2d 624 (3rdCir. 1983). In response to this decision,EPA amended § 403.13(b)(2) to suspendthe availability of FDF variances fortoxic pollutants covered by categoricalpretreatment standards. See 49 FR 5131(February 10, 1984). In addition, EPAsought review of this portion of theThird Circuit's decision. On February 27,1985, the Supreme Court reversed theThird Circuit Court of Appeals and heldthat FDF variances for toxic pollutantsare not prohibited by the Clean WaterAct. Chemical Manufacturers Assoc. v.Natural Resources Defense Council, 105.S. Ct. 1102 (1985). Accordingly, indirectdischargers covered by categoricalpretreatment standards for existingsources may be eligible for an FDFvariance. Any interested person shouldrefer to 40 CFR 403.13 for the proceduresand deadline for applying for thisvariance.

XIII. Relationship to NPDES Permits

The BPT and BAT effluent limitationsguildelines and NSPS in this regulationwill be applied to individual metalmolding and casting processes throughNPDES permits issued by EPA orapproved state agencies under section402 of the Act. The preceding sections ofthis preamble discussed the bindingeffect of this regulation on NPDESpermits, excepf to the extent thatvariances and modifications areexpressly authorized. This sectiondescribes several other aspects of theinteraction of this regulation and NPDESpermits.

One matter that has been subject todifferent judicial views is the scope ofNPDES permit proceedings in the

absence of effluent limitationsguidelines and standards. Undercurrently applicable EPA regulations,states and EPA Regions issuing NPDESpermits before promulgation of thisregulation did so on a case-by-casebasis. This regulation provides atechnical and legal base for any newpermit proceedings.

Another noteworthy topic is the effectof this regulation on the powers ofNPDES permit issuing authorities. Theregulation does not restrict the power ofany permit-issuing authority to act in amanner that is consistent with the lawor these or any other EPA regulations,guidelines, or policy. For example, thefact that this regulation does not controla particular pollutant does not precludethe permit issuer from limiting suchpollutant on a case-by-case basis whennecessary to carry out the purposes ofthe Act. In addition, to the extent thatstate water quality standards or otherprovisions of state or Federal lawrequire limitation of pollutants notcovered by this regulation (or requiremore stringent effluent limitations oncovered pollutants), the permit-issuingauthority must apply such effluentlimitations.

One additional topic that warrantsdiscussion is the operation of EPA'sNPDES enforcement program, manyaspects of which have been consideredin developing this regulation. TheAgency wishes to emphasize that,although the Clean Water Act is a strictliability statute, the initiation ofenforcement proceedings by EPA isdiscretionary (Sierra Club v. Train, 557"F.2d 485 (5th Cir. 1977)). EPA hasexercised and intends to exercise thatdiscretion in a manner that recognizesand promotes good faith complianceefforts.

XIV. Public Participation and Responseto Major Comments

Individual metal molding and castingcompanies, trade associations,andgovernment agencies have participatedin the development of these regulations.Following the publication of theproposed rule on November 15, 1982, inthe Federal Register, the technicalDevelopment Document, the economicimpact analysis, and supporting recordmaterials were made available forreview by industry, governmentalagencies, and the public sector. Thecomment period, originally scheduled toclose on January 14, 1983, was extentedto February 14, 1983. On January 10,1983, a public hearing was held inWashington, DC on the proposedpretreatment standards. On January 12,1983, a permit writers workshop washeld in Chicago, IL. On November 12-13,

1983, a permit writers workshop washeld in Buffalo, NY. EPA announced in.the Federal Register on March 20, 1984(49 FR 10280), the availability for publicreview of additional information andanalysis, with the comment periodclosing on May 4, 1984. On November13-14, 1984, a permit writers workshopwas held in Buffalo, NY. EPAannounced in the Federal Register onFebruary 15, 1985 (50 FR 6572) theavailability of further information and.analyses. The comment period,originally scheduled to close on March18, 1985, was extende d to April 8, 1985.The Agency held permit writerworkshops in Springfield, IL onFebruary 19-20, 1985, and inIndianapolis, IN on April 16-17, 1985.

Since proposal, the Agency hasreceived over 1500 individual commentsfrom 94 different commenters on theproposal and the two notices ofavailability. The Agency also receivedmore than 100 inquiries from theMembers of Congress.

All comments received have beenconsidered carefully and appropriatechanges in the regulations have beenmade where data and informationsupported those changes. Those majorissues raised by the comments that werenot discussed previously in thepreamble (see Summary of Changes toProposed Regulations) are addressed inthis section of the preamble. Allcomments received and detailedresponses to these comments areincluded in three documents entitledResponses to Public Comments,Proposed Metal Molding and CastingEffluent Limitations and Standards;Responses to Public Comments, March20, 1984 Notice of Availability, MetalMolding and Casting Industry; andResponses to Public Comments.February 15, 1985 Notice of Availability,Metal Molding and Casting Industry.These documents will be placed in thepublic record for this regulation.

The following is a discussion of theAgency's responses to the majorcomments.

A. Feasibility of and Data BaseSupporting Complete Recycle

Comment: The most prevalentcomment received by the Agency on theproposed regulation was that theproposed requirement for completerecycle with no allowance forwastewater discharge was not feasibletechnically. It was asserted that recyclesystems must have discharge("blowdown") to remove dissolvedpollutants which would build up andotherwise cause. scaling and corrosion.Commenters asserted that sophisticated,

453Ieea eitrIVl 50 o 1 ededaOtbr 0 95/Rls1n euain

costly, and undemonstratedtechnologies (e.g., reverse osmosis) werenecessary to achieve complete recycle.

It also was asserted that numerousindividual plants indicated by EPA todemonstrate complete recycle with nodischarge were misrepresented in thedata base. These conmenters assertedthat most of the plants in EPA's database have recycle systems which do notdemonstrate complete recycle becausethey discharge periodically to allowequipment repair and maintenance,regular removal of "wet" sludges,"discharges" to groundwater, dischargesthat are removed for off-site disposal bycontract haulers, and discharges toadjacent industrial treatment facilities.

Response: EPA requested all plantswith processes identified as havingcomplete recycle with -no discharge toverify the -status of recycle anddischarge. Responses to the Agency'srequests revealed that a large portion.ofthose plants previously considered tohave complete recycle of wastewateractually had discharges on anintermittent basis, such as for repair andperiodic maintenance. These dischargesranged from once per week to once 'infive years. Another group of plants alsohad discharges from recycle systems,but these discharges were not to surfacewaters orPOTWs. Some plants hadtheir discharges contract hauled off-site,,and other plants reported or weresuspected to have lossers of wastewaterby seepage from storage ponds togroundwater. The Agency removed fromthe complete recycle/no discharge database all such plants which reporteddischarges and thus were not validdemonstrations of complete recycle. Thenumber of plants which were confirmedto be complete recycle/no discharge issubstantially smaller than at proposal;they are concentrated in the followingprocess segments: melting furnacescrubbers, dust collection scrubbers,grinding scrubbers, and slag quench.

As explained previously.in Section Vof this preamble, the Agency alsoperformed a model analysis of recyclesystem water chemistry. The modelanalysis of 19 process segments forwhich sufficient data were availableshowed that achievable recycle ratesdid not vary appreciably with differingmake-up .intake) water, and that highrate recycle or complete xecycle wasachievable even with the poorest -qualitymake-up water. However, threeprocesses in the ferrous subcategory(dust collection, melting furnacescrubber, and .slag quench) were shownto be somewhat sensitive to poor qualitymake-up water. Recycle rates for thesethree process segments were decreased

by the marginal differences (1-2 percent)in recycle rates between predictedrecycle rates based on average andworst make-up water quality.

Some commenters asserted that totaldissolved solids (TDS) build-up inrecycle loops and cause scaling andcorrosion. However, the Agency foundthat many plants successfully operatehigh rate recycle systems with very highTDS concentrations (greater than 40,000mg/I).

Several comnmenters asserted thatcomplete recycle of scrubber waterwould impact adversely the ability ofplants to comply With air emissionsstandards. Responses by plants toAgency inquiries did not reveal (withthe exception of one plant's assertions]that scrubber water recycle was a factorwhere violations of air standardsoccurred.

Recycle model sensitivity analysisshowed that by increasing moisture andpollutant "blowdown" 'by way ofsludges, recycle rates can be increasedto a limited extent. Thus, some plants inthe EPA data base may have achievedcomplete recycle by a water chemistrybalance achieved in part by removing aportion of the problem constituents withthe moisture in the sludge..

Recycle model analysis showed thatrecycle sidestream treatment would benecessary to retain the higher recyclerates (for the three ferrous processsegments) not adjusted for make-upwater qtiality. The investment andoperating cost of sidestream treatmenttechnology identified, chemicalcoagulation and sedimentation for silicaand sulfate removal, was found to bevery high for a small increase (96 to 98percent) in recycle rates. Therefore, thefinal regulations do not utilize the higherrecycle rates for these processes and arenot based on sidestream treatment.

The Agency has updated and verifiedits data base and has selected recyclerates primarily based on the highestpracticable recycle rates demonstratedin the industry. These recycle rates,presented in Appendix J of thispreamble, have been selected withconsideration of the influence of make-up water quality and related waterchemistry (i.e., scaling, corrosion),recycle from central treatment, sludgemoisture content, and other factors.Complete recycle with no discharge hasbeen demonstrated in the industry andselected by the Agency for .the ,threeregulated grinding scrubber processsegments. High rate recycle withallowance for blowdown discharge hasbeen selected by the Agency for the 25other process segments included in thefinal regulations. These recycle rates are

the same as published in Appendix A ofthe February 15, 1985 notice, at 50 FR6579. See the technical DevelopmentDocument for a discussion of how theserecycle rates were derived.

B. Central Treatment

Comment: A number of commentersasserted that the Agency had notconsidered central treatment ofcombined process wastewater streamsand whether central treatment wouldaffect a plant's ability to achieve highrate or complete recycle. Specifically,comments on the March 20, 1984 noticeof availability stated that the Agency'srecycle model did not include asensitivity analysis of differences inachievable recycle rates, asserted to besignificant, between plants with singleprocesses and plants with centraltreatment of multiple processes.

Response: The Agency utilized therecycle model to analyze the influenceon achievable recycle rates of combinedtreatment of two or more processwastewaters in a central treatmentfacility. In all cases analyzed, thecombined recycle rate was found toincrease with central treatment, notdecrease as asserted in comments. Thethree individual ferrous processsegments which did indicate marginalsensitivity to make-up water alsoshowed decreases in recycle rates incentral treatment application. However,the increases in discharge (blowdown)rates to account for make-up waterquality were found to be adequate toallow facilities with central treatment toachieve the separate stream recyclerates. The recycle model also showedthat plants, especially larger plants,which recycle back to the processessafter their central treatment facilities,experience increased pollutantremovals, thereby allowing achievementof sufficiently higher recycle rates, notlower as asserted in comments, suchthat the individual process recycle rateswould be achieved or surpassed. Thus,recycle after central treatment of theentire wastewater volume was shown tobe beneficial but not necessary inachieving recycle rates, even thoughsuch an approach can be more costly toimplement. Further, older large plantscould elect to upgrade these existingcentral treatment facilities rather thancompletely replace them -with smallerblowdown central treatment systems.

EPA.has carefully considered centraltreatment of combined processwastewaterstreams. A substantialportion of the data base used toestablish the treatment effectivenessconcentrations that form the basis of thefinal regulations are from metal mnolding


Federal Register / Vol. 50, No. 210] Wednesday, October 30, 1985 J Rules and Regulations 45239

and casting plants employing centraltreatment systems treating multipleprocess streams. Additionally, EPA hasestablished effluent limitations andstandards for copper, lead, and zinc foreach of the regulated process setmentsfor which a discharge is allowed. Thisensures that plants employing centraltreatment systems are given anallowance for metals present in all ofthe wastestreams discharged to thecentral treatment facilities.

C. Lime and Settle TreatmentEffectiveness Data Base

Comment: A number of comments onthe proposed regulations stated that theAgency had not used an appropriatedata base for establishing effluentlimitations for those process segmentswhere discharges were allowed. It wasasserted that the Agency's use of theCombined Metals Data Base (CMDB-the data base from well operated 'limeand settle treatment systems, used inother industries, that was used toestablish lime and settle treatmenteffectiveness for the metal molding andcasting industry) was not appropriatebecause these data represent treatmentof wastewaters from industries whosewastewaters are not comparable to themetal molding and casting industry.

Comments on the Agency's analysisof ferrous foundry treatmenteffectiveness data, included in theFebruary 15, 1985 notice (50 FR 6580,Appendix F), asserted that lime andsettle treated effluent concentrations forlead and zinc, developed from EPAsampling data and all available industrydischarge monitoring report (DMR) data,were not excessively high and did notwarrant application of further treatmenttechnologies being considered by EPA.Commenters asserted that the Agencyhas promulgated effluent limitations andstandards for lead and zinc in othercategories (i.e., inorganic chemicals,metal finishing) based on treatedeffluent concentrations that are higherthan those being considered (AppendixF) for this category. These commentersurged that all DMR data available to theAgency be used in the treatmenteffectiveness analysis, and questionedthe Agency's judgment that some of theDMR data required further confirmation.

Commenters questioned the Agency'sstatistical methodology that gave -equalweight to plant level estimatesregardless of the amount of dataavailable from the plant. Thesecommenters asserted that the short-termEPA data could not be used for analysisof variability, and that the industry DMRdata should be weighted statisticallybased on the number of data points. Italso was asserted that there were

discrepancies in application of the dataediting rules to the DMR data.

Response: Subsequent to proposal, theAgency acquired a substantial amountof DMR data from the metal moldingand casting industry. Some of the long-term DMR data as well as the short-termsampling data acquired under EPAsupervision were analyzed preliminarilyand the results published in the March20, 1984 notice, at 49 FR 10292-10294,and 10308-10310, Appendix F. Thebalance of the available DMR data wereanalyzed and the resulting limitationswere presented for review and commenfin the February 15, 1985 notice ofavailability, at 50 FR 6575, and 6580,Appendices D, E, and F. The results ofthese analyses indicated that limitationsfor lead and zinc, based on short-termEPA data and long-term confirmed DMRdata, were higher than lead and zinclimitations based on the CMDB. TheAgency indicated it still was consideringusing the CMDB, but efforts would bemade to confirm all DMR data, andadditional control technologies wouldbe considered to reduce theconcentrations of lead and zinc.

The Agency obtained additionalsupporting data and documentationfrom four plants for which DMR datawere available but not confirmed. Threeof these four plants sampled andanalyzed the influent to and the effluentfrom their wastewater treatmentsystems. The fourth plant already hadsampling data for both influent andeffluent that were usable in theAgency's analysis. Based on thesesubmissions, the Agency determinedthat the DMR data for three of the fourplants could be considered confirmed

* and have been incorporated in the EPAplus confirmed DMR data base used todevelop the final effluent limitations andstandards. Data for one of the plantscould not be used due to the presence ofexcessive quantities of noncontactcooling water commingled with processwastewaters in the plant's treatmentsystem.

The. Agency analyzed the edited EPAplus confirmed DMR data base, anddeveloped final treatment effectivenessconcentrations for lime and settletreatment. These concentrations arepresented in Appendix K of thspreamble. Comparison of theseconcentrations with the concentrationsbased on the CMDB reveals that somedifferences exist; lead limitations arehigher, zinc limitations areapproximately the same, and copperlimitations are lower. Effluentlimitations for TSS and oil and greaseare approximately the same. Furthercomparisons of short-term EPA data

with long-term DMR data reveals that inmany cases DMR data were lower inconcentration than short-term EPA datafor the same plants. Recent short-termself-sampling by three plants inresponse to specific Agency requestsfurther confirms the ranges ofconcentrations represented 'by the DMRdata. Where differences do occur ineffluent limitations based on CMDB andmetal molding and casting data, theAgency has concluded that thesedifferences may be attributable tovariations in the chemistry of thewastewater matrices and concomitantdifferences in the solubility of thesepollutants, especially metals, in treatedeffluents. Also, the suspended solidswhich contain the metals may includevery fine particulates which do notcoagulate or settle readily. The Agencyhas concluded that the treatmenteffectiveness concentrations for limeand settle treatment based on -metalmolding and casting industry data arethe best data for developing the mass-based effluent limitations and standardscontained in the final regulations.

The Agency has retained the use ofshort-term EPA sampling data togetherwith long-term confirmed DMR data indeveloping the effluent limitations andstandards. In cases where both short-term EPA data and DMR data wereavailable from a plant, they werecombined to determine statistically thelong-term mean and variabilities intreatment effectiveness for the plant.These plant specific summary statisticsare further combined, as describedbriefly in a preceding section of thispreamble, in detail in the technicalDevelopment Document, and elsewherein the rulemaking record, to determinethe maximum monthly and maximumone-day effluent limitations andstandards for the metal molding andcasting category. This methodology doesnot rely solely on short-term EPA datato describe variability. In only a fewcases are the final plant level estimatesfor a pollutant based only on short-termEPA data and these are combined withdata from other plants that includeextensive DMR data sets for use in thecalculation of treatment effectivenesslevels. The data have been combined ina statistically-appropriate manner. TheAgency's objective was to representproperly the information -from plantswith appropriate treatment in the finallimitations. This objective has beenachieved. Further statistical weighting ofthe DMR data is neither necessary norappropriate in this case.

Some minor errors in the descriptionof the application of the data editingrules were found in the record

45240 Federal Register / Vol. 50, No. 210 / Wednesday, October 30, 1985 I Rules and Regulationssupporting the February 15, 1985 notice.The editing criteria were properlyapplied. Only the description of whichcriteria were applied to certain datapoints was incorrect in a few cases.These errors have been corrected. TheAgency has included in the record aseparate and complete listing of all datawhich have been used in developing thefinal treatment effectivenessconcentrations for lime and settletechnology.

D. Control of Toxic Organic Pollutants

Comment: Several commenters statedthat toxic organic pollutants should beregulated as an aggregate, rather thanby~setting limitations for individualtrace pollutants which would requireunnecessarily expensive monitoring.Additionally, commenters suggestedthat requiring the application ofactivated carbon technology wasunnecessary because existing systemsemployed in the industry, oil skimmingand lime and settle treatment, arecapable of removing significant levels oftoxic organic pollutants.

Response: As explained previously,EPA found that plants in the metalmolding and casting industry thatemployed effective oil and greaseremoval technologies effectivelyremoved toxic organic pollutants. Forthis reason, the final regulations are notbased on the application of activatedcarbon technology. Additionally,because the model BPT treatment option(recycle and lime and settle treatmentwith associated oil and grease removalequipment) is capable of effectivelyremoving toxic organic pollutants frommetal molding and casting wastewaters,EPA is not establishing BAT effluentlimitations guidelines or standards ofperformance for new sources for toxicorganic pollutants. EPA believes thatcompliance with the limitations andstandards controlling oil and grease willeffectively control toxic organics.

EPA has determined that toxic organicpollutants are likely to pass throughPOTWs. For that reason, EPA isestablishing pretreatment standardscontrolling toxic organic pollutants. Toreduce monitoring costs, EPA (a) iscontrolling Toxic Organics ('rTO) ratherthan each individual toxic organicpollutant detected in metal molding andcasting wastewaters, (b) has definedTTO differently for each processsegment where TTO is regulated on thebasis that different organic pollutantswere found above treatable levels in thedischarges from the various processsegments, and (c) has established oiland grease as an alternative monitoringparameter for TTO to minimizemonitoring costs. If oil and grease is

controlled at the identified level,compliance with the TTO pretreatmentstandard will be assumed.

E. Applied Flow DataComment: One commenter requested

an additional flow allowance for wetsluicing of dry baghouse scrubber dust.Another commenter noted thatnumerous miscellaneous process watersources present at plants in the metalmolding and casting industry had notbeen identified by EPA in the proposalor subsequent notices.

Response: The Agency reviewedavailable data for process water sourcesnot previously identified in the proposalor the March 1984 and February 1985notices. The miscellaneous processesare not widely employed in the metalmolding and casting industry. Therefore,insufficient information is available tocharacterize these miscellaneouswastestreams. Thus, in the finalregulations, EPA is not establishingeffluent limitations guidelines andstandards for processes other than thosediscussed in the February 1985 notice.The need for flow allowances for thesemiscellaneous processes must beestablished and justified on a case-by-case basis during the permitting process.Permit writers will use their bestprofessional judgment in establishingtechnology-based effluent limitationsand standards for those miscellaneousstreams, such as sluice water used toconvey dry baghouse scrubber dust,which are not covered by thisregulation.

F. Environmental Assessment/SmallPlant Exclusion

Comment: In comments on theFebruary 15, 1985 notice, the SmallBusiness Administration (SBA) assertedthat there were numerous errors in theenvironmental assessment madeavailable in the record supporting theFebruary 15, 1985 notice. Most of theSBS's detailed comments focused on thedata used to represent current dischargelevels. SBA stated that, after theseerrors were corrected, a revisedenvironmental assesssment wouldconfirm their assertion that regulation ofsmall plants (less than 100 employees)would yield no environmentalimprovement. SBA and othercommenters requested that EPA exempt,or adopt less stringent regulatorystandards for, ferrous foundriesemploying less than 100 employees andthat EPA exempt from nationalregulation all nonferrous foundries. Thecommenters asserted that EPA wasauthorized to implement theserecommendations by the SettlementAgreement in NRDC v. Castle, and that

the recommended approach isconsistent with other Agency decisionsto exclude from national regulationsdischarges of toxic pollutants inamounts below one kilogram per plantper day.

Response: In response to comments,

tlhe Agency reevaluated all of the dataused in the environmental assessment,including data used to characterize rawwastewaters, current discharges, anddischarges for each of the technologyoptions. The Agency did not find datainput or computer errors as asserted incomments. However, upon detailedreview, the Agency did find that certainof the short-term EPA sampling dataused to characterize raw wastewatershad not been used properly. The Agencyfound that raw waste mass loads forplants which were sampled wereutilized incorrectly in calculating theraw waste loads for the various processsegments. Even in cases where a plantwhich was sampled had an applied flowdifferent from the applied flowdetermined by the Agency to berepresentative of the process segment,the plant's actual measured raw wasteconcentration was still used with theprocess segment applied flow rate tocalculate the mass loading for theprocess segment. This resulted in theuse of erroneous mass loading tocharacterize raw wastewaters for theprocess segment. The Agencyrecalculated all raw waste data basedon the masses of pollutants found atsampled plants, rather than the-concentrations, so that the rawwasteloads for each process segmentwould be characterized properly. Thefinal regulations and EPA's assessmentof current pollutant discharge levels arebased on the corrected information.

The NRDC consent decree requiresthat the Agency promulgate nationally-applicable effluent limitations guidelinesand standards for 21 major industries,including the metal molding and castingcategory. Under Paragraph 8 of theconsent decree, the Agency may exemptcertain pollutants or industrialsubcategories from national regulationsprovided that EPA makes certainfindings. In the past, EPA has notexempted portions of a subcategoryfrom nationally-applicable BATregulations under the conditionsspecified in Paragraph 8 of the consentdecree. Decisions have been made on asubcategory-wide basis. In certain ofthese cases, the average raw wastedischarges of toxic pollutants from all'plants in the subcategory approachedone kilogram (2.2 pounds) per plant perday. Over the next two years, EPA willbe reviewing several of these decisions

No. 210 / Wednesday, October 30, 1985 / Rul'es and Regulations45240 Federal Register / Vol. 50,


to re-evaluate their appropriateness.Included will be reviews of theParagraph 8 decisions for the causticand/o water wash subcategories of thepaint and ink categories and theindustrial laundries subcategory of theauto and other laundries category.

In the case of the metal molding andcasting industry, substantial quantitiesof toxic pollutants are expected-to .bedischarged from plants in everyregulated subcategory-raw wastedischarge levels range from 6.5 to over220 pounds per plant per day dependingon the subcategory considered. Toxicpollutant discharges from small metalmolding and casting plants (less than 50employees) are also expected to besubstantial-raw waste discharge levelsrange from 166 pounds per year perplant (aluminum casting subcategory) toover 27,000 pounds per year per plant(ferrous subcategory). For all thereasons discussed elsewhere in thispreamble, we have decided to establishnationally-applicable effluentlimitations guidelines and standards toregulate these discharges.

The commenter also appears tomisunderstand the significance of adecision not to establish nationalregulations for a subcategory. Such adecision would not exempt directdischargers in that subcategory frombeing required to obtain an NPDESpermit in order to dischargewastewaters. The Clean Water Actrequires that EPA issue NPDES permitsto direct dischargers that contain, at aminimum, technology-based effluentlimitations that reflect the bestpracticable control technology currentlyavailable, the best available technologyeconomically achievable, and the bestconventional pollutant controltechnology, regardless of the size of thedischarging plant. If these technology-based levels of control have not beenestablished by national regulations, theymust be determined on a case-by-casebasis. In the event that theserequirements do not adequa'tely protectreceiving waters, the permit authoritywould issue more stringent limitationsbased on state water qualityconsiderations.- The Agency has found that treatablelevels of toxic pollutants (both metals,and organics) and other pollutants -(suspended solids, oil and grease, and

'total phenols] are present in wastewaterdischarges from all subcategories of themetal molding and casting industry.Thus, limitation based on theapplication of some level of treatmenttechnology must be specified, whethercase-by-case permits axe issued or ifnationally-applicable limitations and

standards were applied uniformlythroughout the country. Taking this intoaccount and also noting that theindustry is comprised of about 796 directand indirect discharging plants, 247 ofwhich are projected to be small plants(plants that employ less than 50employees], the Agency has determinedthat it is the best use of EPA, State, andlocal resources to establish nationally-.applicable standards for the metalmolding and casting industry rather thanto make separate, case-by-casedeterminations of appropriatelimitations and standards. Thus, withthe exception of the magnesiumsubcategory, where we have determinedthat nationally-applicable effluentlimitations and standards are noteconomically achievable, EPA isestablishing regulations applicable to alldischarging metal modeling and castingplants, including small plants.

G. Economic Analysis

Comment: Commenters asserted thatthe economic impact of effluent-limitations and standards beingconsidered has been understatedbecause (a) sales revenues wereoverestimated, especially for'smallplants, (b) financial ratios projected for1986 overestimate the financial strengthof the industry in light of the major.downturn in the industry since 1978, (c)economic impact criteria now rely solelyon plant closure as the basis forconsidering less costly regulatoryoptions, (d) the influence of foreigncompetition on the demand for domesticcastings was not considered, are (e]compliance costs have beenunderestimated, particularly for smallplants.

The Small Business Administrationrecommended that EPA use theFINSTAT data base in place of the Dunand Bradstreet data base as the sourceof financial profiles for this industry.SBA also commented that its analysis ofEPA's cost data showed a-larger numberof plant closures than that estimated bythe Agency. SBA also commented thatEPA had not conducted sufficientsensitivity analyses of the impacts onfoundries.

*EPA also received comments that, inview of the likelihood of severe-economic impact on small plants, EPAmust prepare a Regulatory FlexibilityAnalysis. The Small BusinessAdministration stated that EPA should -

consider less stringent regulatory ,options for small plants or exemptionsfor small plants from all categoricalregulations. ''.

'Response: In response .to comments,the Agency has made the following•' .changes in the methodology and data

base used for the economic impactanalysis.

With regard to plant sales estimates,including those of small plants, theAgency is basing sales on productiondata reported in the DCPs and thenextrapolated to the industry accordingto metal type and foundry size. Theproduction data were adjusted.downward to account for the economicconditions experienced by the industryin more recent years. The magnitude ofthe-production reductions ranged from30 percent to 65 percent depending uponthe particular metal type. The respectivepercentage declines were applied to allfoundries in a subcategory regardless ofsize. Costs Were adjusted downwardusing cost curves that account for thefixed nature of certain operating andmaintenance costs; the cost adjustmentsare therefore proportionally less thanthe reductions in production and salesrevenue. These adjustments make EPA'sproduction estimates more consistentwith values reported by other sources,notably Bureau of the Census.

The Agency is confident that theseproduction and)cost'data are the bestavailable since they represent datareported directly by the industry(including Many small foundries). Thesedata iave been adjusted to account formore recent economic conditions,therefore more accurately reflecting theabili.ty of the industry to comply withthis regulation.

With regard to the financial ratiovalues used to estimate the industry'shealth (and in response to SBA'srecommendation concerning financialdata), the Agency is using the FINSTATdata base presented by SBA to projectthe financial strength of the industry.The FINSTAT data base includesfinancial records from the period 1975 to1984. These data are now used in theeconomic impact analysis as the basisfor financial profiles. In estimating thequartile ratios needed-for the economicanalysis,. EPA rejected observations that"either (1) did not satisfy SBA'sconsistency criteria or (2) failed thethreshold tests used in the economicimpact analysis. EPA believes thatinclusion of firms whose ratios do notmeet the threshold tests would beinconsistent with the use of the tests.The Agency is confident that this multi-year data base represents the best'available information on foundryfinancial performance and thatincorporation of the FINSTAT data inthe economic impact analysis has • 'provided more reliable results for thisparticularindustry....'The financial test cut-off values used-in the economic analysis are based on a

No. 210 / Wednesday, October 30, 1985 / Rules and Regulations

thorough. review of financial literatureverified by data for recent closures in.the industry. Review of the FINSTATand Dun & Bradstreet date bases showthat many-metal molding and castingplants with weaker values remain inbusiness for extended periods.Therefore, use of more stringent values(as suggested by SBA).is inconsistentwith available data.

With regard to the financial impactsused to consider alternative regulatoryoptions, plant closure is the primaryindicator that triggers consideration ofless stringent options. However, theAgency considered several otherfinancial impact measures indetermining the appropiiate options.The impacts of compliance costs as they-relate to sales and production costswere two major impact measuresconsidered by the Agency. The manyother financial impact measuresexamined and considered by the Agencyare reported in the economic impactanalysis. EPA especially examined theclosures and financial measures results.for small foundries...

With regard to the effect of impacts offoreign castings on the competitiveability of domestic manufacturers, theAgency has included suchconsiderations in the economic analysis.Although imports are increasing, thevalue of foreign castings is less thanthree percent of the total U.S. market.The major sources of competition for thefoundries affected by this regulation arethe domestic foundries which do notdischarge wastewaters and thus incurno compliance costs as a result of theregulation.

With regard to comments made by theSmall Business Administration, EPA hasmade the following changes in itsanalysis. First, the Agency has adoptedSBA's FINSTAT data base as the basisfor determining the financial status ofthe industry. Second, EPA hasconsidered SBA's comments on thevalues used in the economic analysis for.closure- criteria. Based on all informationand data available (including thatprovided by SBA), EPA has retained thecut-off values for the three financialtests used to determine closures. Third,EPA has increased compliance costswhere appropriate. These revisions,which deal with operating laborrequirements and other changes, leaveEPA's analysis largely in agreementwith SBA insofar as costs'areconcerned. Given the changes madewith regard to its sales and costestimates, an additional sensitivityanalysis is not warranted.

The Agency has selected regulatoryoptions that are appropriate in view of-the statutory requirements and in view

of the costs and effluent reductionsachieved. In view of these costs andpollutants removals, EPAhas selectedthe same option selected for BPT to. bethe basis for BAT effluent limitations forplants in the aluminum subcategory andthe steel segment of the ferroussubcategory. In addition, the smallestplants in the ferrous subcategory thatcast primarily malleable iron (less than3,557 tons of metal poured per year)have BAT equal to BPT, and small grayiron plants (less than 1,784 tons of metalpoured per year) have PSES equal toBPT (Option 2). Also, the Agency hasexempted magnesium plants from theseregulations because of the projectedsevere economic impacti projected forthis subcategory. All of the exemptmagnesium foundries are small plants.

In view of the few remaining closuresprojected from smaall foundries, theAgency has determined the preparationof a Regulatory Flexibility Analysis isnot appropriate or necessary. TheAgency has, however, included a smallbusiness analysis within the overalleconomic impact analysis.

H. Control TechnologiesComment: A few commenters asserted

that the entire train of model controltechnologies being considered by theAgency has not been demonstrated atany plants within the industry,particularly as they would be applied atplants with multiple processes andcentral treatment facilities. Chemicaloxidation by potassium permanganate,and carbonate and sulfide precipitationof metals also were cited specifically astechnologies that commenters assertedhave not been demonstrated in theindustry. The transfers of thesetechnologies were asserted to beunsupported, and their use wasconsidered expensive, and technicallyproblematic. Moreover, the commentersindicated that the Agency's treatedeffluent concentrations for total phenols(4AAP) published in the February 15,1985 notice (50 FR 6580, Appendices D-F) were the result of dilution andincidental removal, not chemicaloxidation.

Response: The model BPT controltechnology train generally consists ofhigh rate recycle followed by blowdowntreatment with lime and settle. High raterecycle is widely demonstrated byplants in this industry, and has been-discussed at length in the March 20, 1984notice, at 49 FR 6573-6574, summarizedin a preceding section of this preamble,and discussed in detail in the technicalDevelopment Document. A significantnumber of these plants incorporatecentral treatment. The treatmenteffectiveness data base for lime and

settle treatment is from metal moldingand casting-plants, almost all of whichhave high, rate recycle, and centraltreatment of combined processwastewaters. Therefore, the key controland treatment technologies (recycle, andlime aid settle treatment) which serveas the basis for BPT effluent limitationshave been. widely demonstrated.

Chemical oxidation by potassiumpermanganate has received very limitedapplication in this industry. Thecommenters are correct that the effluentlimitations.for total phenol are notbased on treatment systems withpotassium. permanganate oxidation. TheAgency attempted to obtain data on thistechnology but no usable data wereavailable. The total phenol limitations,are based on incidental removal throughlime and settle treatment systems. Itshould be noted that information anddata in the literature on a pilot chemicaloxidation treatment system and a recentEPA pilot treatability study reveal. that,.the potasium permanganate technology,is available and applicable to metalmolding and casting wastewaters, and.the effluent limitations for total phenol.(4AAP) are achievable readily. The costof potassium permanganate oxidationhas been included in the lime and settletreatment system for those ten processsegments where treatable quantities ofphenols are present. This technology isnot any more difficult to implement thanthe other technologies incorporated inthe basis for the regulations. Moreover,the cost of potassium permanganate isnot excessive and effluent limitationsbased on the entire recycle, lime andsettle model treatment system werefound to be economically achievable.

Filtration technology is widely used inindustrial wastewater treatment, and ithas been applied in the metal moldingand casting industry. Those fewapplications in the metal molding andcasting industry for which a limitedamount of filtration performance dataare available have not been used indeveloping.BAT limitations becausethey are for plants which either haveother than lime and settle treatmentpreceding. filtration (e.g., biologicaltreatment, simple settle) or treat verylow strength wastewaters. As described

'in a preceding section of this preamble,data from a pilot filtration study onmetal molding and casting wastewaterswas not used to establish limitationsbased on filtration because ofsignificantly higher lime and settleeffluent concentrations influent to thatpilot filter. Therefore, as indicated in theFebruary 15, 1985 notice at 50 FR 6576,,the Agency is adopting treatmenteffectiveness data for filtration applied

45242 : Federal Register / Vol. 50,


in other industries (porcelain enamelingand nonferrous smelting and refining),as described in the proposal.

Residual toxic metals removal bycarbonate and sulfide precipitationtechnologies are applicable alternativesto metal molding and casting industrywastewaters. However, the dataavailable are limited, .with noapplication of sulfide precipitation inthis industry. Therefore, the Agency isrelying on filtration for removal of,residual toxic metals.

The commenters are correct that thereare no plants known to the Agencywhich have all of the model treatmentsystem components in place in the*

sequence selected, and long-term dataavailable to describe their performance.However, the data which are available.indicate that plants in both the ferrousand nonferrous industry segments areachieving the BPT effluent treatmenteffectiveness concentrations based onlime and settle. Therefore, the Agencyhas concluded that all of thetechnologies are applicable .and havebeen implemented on at least a limitedbasis in this industry, and that theeffluent limitations and standards areachievable and available to the metalmolding and casting industry.

I Dry Scrubbers

Comment: In response, to the Agency'.request for inforiiatin on the viabilityof substituting dry scrubbers for wetscrubbers, one commenter presented thEresults of a study which indicated that atotally dry metal molding and castingplant is not necessarily optimal and ma 3not be feasible in all cases. The reasoncited in support of this conclusion Wasthat the choice between wet and dryscrubbing equipment was affected bysite specific factors, such as moisturecontent of the air stream, dust loadingand particle size distribution, andscrubber total life cycle and cost.Another commenter stated that thepresence of combustible materials mayprevent the use of dry scrubbers.Finally, it was asserted in commentsthat the Agency had not considered thecost of replacing a wet scrubber with adry scrubber, and the potential forchanges in air emissions that may effectcompliance with air pollution permits.

Response: The Agency has concludedthat while replacing wet scrubbers withdry scrubbers may be a feasiblealternative to wastewater treatment inmany cases, site specific factors cited b:commenters will prevent some plants,including new sources, from convertingto dry scrubbers. Therefore, conversionto dry scrubbers has not been includedas the basis for effluent limitations andstandards applicable to this industry.

. Guidance to Permit Authorities

Comment: A few commenters statedthat the Agency must provide guidanceto permitting and pretreatmentauthorities to ensure proper use of theeffluent limitations and standards forplants with single processes, and forintegrated plants with more than oneprocess where central treatment isemployed. These commenters alsoasserted that without additionalclarification and guidance, plants maybe subjected to permit conditions whichspecify flow rates, recycle andblowdown rates, technologies, or otherconditions. Such specific permitconditions would eliminate theflexibility plants should have incomplying with these effluent limitationand standards.

Response: The Agency has included adetailed presentation in the technicalDevelopment Document which providesguidance to permitting and pretreatmentauthorities in the use of theseregulations. This guidance clearly statesthat the Agency is not regulating flowrates, recycle rates, and blowdownrates, nor is it specifying controltechnologies. Example permit limitatioEare developed for hypothetical plants toillustrate the intended use of theregulations.

K Inadequate Notice and Opportunityfor Comment

e Comment: Comments on the February15, 1985 notice asserted that EPA hasnot identified specific technologies,costs, effluent reduction benefits andassociated.effluent limitations andstandards based upon best practicabletechnology, best available technology,standards of performance for newsources, and pretreatment standards fornew and existing sources. These

* commenters believe that in the absenceof specific limitations and standards,and indications in the record ofconsideration of other statutory criteria,EPA has not given adequate notice andopportunity for comment. Also, it was

asserted that the length of time allowedfor comment was not adequate, and thatthe record was incomplete andcontained discrepancies.

Response: The Agency has provideddetailed notice and extensiveopportunity for comment on how newinformation and data were likely toaffect final regulations After the

y regulations were proposed, the Agencyworked cooperatively with industrytrade associations and individualcompanies to identify in detail andobtain the information and datanecessary to correct and update the datbase used to establish the final

regulations. More than 250 plants werecontacted, including seven plantsampling visits and 38 plant engineeringvisits,, to gather new information. TheAgency. published in the FederalRegister for March 20, 1984, at 49 FR10280, an extensive notice of availabilitywhich discussed in detail thesupplementary information and dategathered after proposal, and thepreliminary technical and economicanalysis of that information. The noticecovered important issues raised in priorcomments and all aspects of the basisfor final regulations including datagathering, subcategorization, data baseverification, analysis of recycle,treatment effectiveness data base,method for calculation of mass-basedeffluent limitations, control technologiesand costs, economic impact analysis,regulatory flexibility, and furthersolicitation of comments..The Agencyalso presented tabulations of importantinformation and data, including atabulation of mass-based effluentlimitations for the primary technologyoption (recycle, lime and settle) underconsideration (at 49 FR 10308-10310,Appendix F). The Agency provided a 45day comment period, and sent acomplete copy of the entiresupplementary record to each of twotrade associations (AmericanFoundrymen's Society, American DieCasting Institute) to assist in thoroughand timely review and presentation ofcomments.

The Agency published in the FederalRegister for February 15, 1985, at 50 FR6572, a second notice of availabilitywhich discussed'in detail the results offurther analyses of information receivedafter the March 20, 1984 notice. Thenotice discussed important issues raisedin comments on the March 20, 1984notice, and all technical, economic, andenvironmental analyses that would bearupon development of final regulations.The Agency provided a complete copy,of the entire supplementary record toeach of the two trade associations. A 30-day comment period was providedoriginally, and extended to 51 days afterdifficulties were encountered inreproducting and shipping the twocopies of the record.

The Agency chose not to select amongoptions for these two notices in order tocontribute to a more balancedpresentation of comments on all issuesand areas of analysis. Nonetheless, it isthe Agency's judgment that these twonotices presented very clear indications

a of the Agency's intentions in proceedingtoward final regulations.

Federal- Register /. Vol. ,50;,

45244' Federal Register / Vol. 50, No. 210 'I Wednesday, October 30. 1985 I Rules and ReaulationsXV. Availability of TechnicalInformation

The major documents on which thisregulation is based are (1) DevelopmentDocument for Effluent LimitationsGuidelines, New Source PerformanceStandards, and Pretreatment Standartsfor the Metal Molding and Casting PointSource Category (USEPA, Washington,D.C., October 1985), (2) EconomicImpact Analysis of Effluent LimitationsGuidelines and'Standards for the MetalMolding and Casting Industry (USEPA,Washington, D.C., October 1985), (3)Response to Public Comments, ProposedMetal Molding and'Casting EffluentLimitations Guidelines and Standards(USEPA. Washington. D.C., October1985), and (4) Sampling.and AnalysisProcedures for Screening of IndustrialEffluents for Priority Pollutants (USEPA,Cincinnati, Ohio, April 1977).

On- December 14, 1985, copies of thetechnical Development Document andthe economic analysis will be availablefor public review in EPA's PublicInformation Reference Unit, Room 2404(Rear) (EPA Library), 401 M Street, SW.,Washington, DC on January 3, 1986, thecomplete Record, including the Agency'sresponses to comments on the proposedregulation, will be available for reviewat the Public Information ReferenceUnit. The EPA information regulation (40CFR Part 2) allows theAgency to chargea reasonable fee for copying.

Copies of the technical DevelopmentDocument and the economic analysis,may also be obtained from the NationalTechnical Information Service (NTIS ,Springfield, Virginia 2216T (703/487-6000). A notice will be- published in theFederal- Register announcing theavailability of these documents fromNTIS). (This should occur within 60 daysof publication of this regulation.)

XVL Office of Management and, Budget(OMB) Review

This regulation was submitted to theOffice of Management and Budget(OMB) for review as required byExecutive Order 12291. Writtencomments made by OMB are in therecord for this final rulemaking.iVII. List of Subjects

Iron and steel foundries, Nonferrousfoundries, Waste treatment and'disposal Waterpollution control.

Dated: October 8, 1985.Lee M. Thomas,Administrator.

Appendix A-Abbreviations, Acronyms,.and Other Terms Used in This Notice

Act-The Clean Water Act;.

Agency-The U.S. EnvironmentalProtection Agency.

BAT-The best available technologyeconomically achievable under section304(b)(2),of the Act..

BCT-The best conventional pollutantcontrol technology, under section304(b)(4) of the Act.

BMP-Best management practicesunder section 304(e) of the Act.

BPT-The best practicable controltechnology currently available undersection 304(b)(1) of the Act.

Clean. Water Act-The Federal WaterPollution Control Act Amendments of1972 (33 U.S.C; 1251 et seq.), as amendedby the Clean Water Act of 1977 (Pub. L.95-217;

Direct Discharger-A plant that

discharges of may discharge pollutantsinto waters of the United States.

Indirect Discharger-A plant thatintroduces.or may introduce pollutantsinto a publicly owned treatment works.

NPDES Permit-A National PollutantDischarge Elimination System permitissued under section 402 of the Act.

NSPS-New source performancestandards under section 306 of the Act.

POTW--Publicly. owned treatmentworks.

PSES-Pretreatment standards forexisting sources of indirect dischargesunder section 307(b) of the Act.

PSNS-Pretreatment standards fornew sources of indirect dischargesunder section 307 (b) and (c) of the Act.

RCRA-Resource: Conservation andRecovery. Act (Pub. L. 94"589),of 1976, asamended.

Appendix B-Pollutant Parameters Regulated

S Characteristic pollutants Toxic pollutantsPH TSS O&0 Phenol Tr Copper Lead Zinc

Aluminum:Castingctearing,...................... 'X X X 'X" XCasting quench. .................. X X, X X. 'X X xDie Castng ....................................... X X X X X X X- XDust collection scraber ............. X X X X X* 'X X X-Grinding scrubber._............_.. (2) (1) (3) (1) 43), .(1) 1() (1)

Investment casting ............. X X X X X X .XMelting furnace scrubter .................... 'X X X X X x X. XMold cooling ......................................... X X X X 'X X X

CopperCasting quench .......... _......... X x x ix x X xDOW chill casting ............................... X X X X A*X XDust collection scru bbe r ............. ... X X X X. :X X ,Grinding scrbber .~......... 3 (3) (3) (30 Vk) V() ()' 49Investment caf ............................ X K X X. IT X -.Melting fu asctier........ X X X ;X I KX XMold cooing-. ............... X K X x ;X TX X

Ferrous:Castng IX c n....................... x x .X x XCasting quench . ................ ' X X X X X XOust collection scrubber ................ .X X X ! X X XGrinding scrubbier . ...............(3) (3) (3) (V9. (a) (319 (3) *(1)Investment cs. . X X X X rX X KXMelting furnace scrubber__........ .X X X -X. ;X. X: X. XMold cooling .............. . . .... IX X X XStag quench . _............X X X :X X XWet sand recliaton ................ X *X KX X- X X x

Zinc:Casting quench .............................. X X X X X X ,ADie ... .. .... X X X X 'X X. 'KX ,Melting furnac scrubber ................ .X X K K X IX XMold cooling ... .... X X *X !X X X. X:Total Phenots--Phenol as measured by the 4 aftmnatipyne method-4AAP.7'TTO-Totl Toxi, Orlcs.measured as the s of at toxic organic. compounds found in treatable concentrations. See

the Genraldeloufona setionl te ataced egua1 n (§ 464.02): for -the definitiont of 770 and the 'Spaciallizeddefinition " sections of the attached regulation (@464.1 . 484.21, 464.31. and 464.41) for lists of the specific toxic- organicsIncluded in TTO for each subcatagor segment. Limitations for TTO are established only for PSES and.PSNS.3No discharge of pollutants.

Appendix C-Toxic Pollutants Not 25. 1,2-dichlorobenzeneDetected or Not Detected At or Above 26. l,3-dichlorobenzene-the Nominal Analytical Limits of 27.1,4-dichlorobenzene,Quantification in Any Subcategories of 28. 3,3-dichlorobenzidinethe Metal Molding and Casting Point 29. 1,1-dichloroethyleneSource Category 32. 1,2-dichloropropane

2. acrolein 33. 1,2-dichloropropylene (1,2-3. acrylonitrile dichloropropene)8. 1,2,4-trichlorobenzene 37..1,2- diphenylhydrazine9. hexachlorobenzene 40. 4-chlorophenyl phenyl ether12. hexachloroethane 41. 4-bromophenyl phenyl ether16. chloroethane 42. bis(2-chloroisopropyl) ether17. bis(chloro methyl) ether (deleted) 46. methyl bromide (bromomethane)19. 2-chloroethyl vinyl ether (mixed) 47. bromoform (tribromomethane)

No. 210,/Wednesday, October 30, 1985 / Rules and Regulations45244 'Federal Register / Vol. 50,

Federal Register / Vol. 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulations

49. trichlorofluoromethane (deleted)50. dichlorodifluoromethane (deleted)51. chlorodibromomethane52. hexachlorobutadiene53. hexachlorocyclopentadiene61. N-nitrosodimethylamine79. benzo(ghi) perylene (1,12-

benzoperylene)82. dibenzo(a,h)anthracene (1,2,5,6-

dibenzanthracene)83. indeno (1,2,3-cd)pyrene(2,3,o-'

phenylenepyrene)88. vinyl chloride (chloroethylene)89. aldrin90. dieldrin91. chlordane92. 4,4'-DDT93. 4,4'-DDE94.4,4'-DDD (p,p' TDE)95. a-endosulfan.(Alpha)96. b-endosulfan (Beta)97. endosulfan sulfate98. endrin100. heptachlor101. heptachlor epoxide102. alpha-Bl-IC103. beta-BHC104. gamma-BHC105. delta-BHC113. toxaphene116. asbestos129. 2,3,7,8-tetrachlorodibenzo-p-dioxin

(TCDD)

Appendix D-Aluminum Subcategory

Toxic Pollutants Not Detected or NotDetected At or Above the NominalAnalytical Limits of Quantification

14. 1,1,2-trichloroethane20. 2-chloronaphthalene30. 1,2-trans-dichloroethylene35. 2,4-dinitrotoluene36. 2,6-dinitrotoluene43. bis(2-choroethoxy) methane45. methyl chloride (chloromethane)54. isophprone56. nitrobenzene69. di-n-octyl phthalate74. 3,4-benzofluoranthene75. benzo(k)fluoranthene (11,12-

benzofluoranthene)99. endrin aldehyde114. antimony117. beryllium"118. cadmium125. selenium126. silver127. thallium

Toxic Pollutants Present in AmountsToo Small to be Reduced Effectively byTechnologies Known to theAdministrator

106. PCB-1242 (Arochlor 1242)107. PCB-1254 (Arochlor 1254)108. PCB-1221 (Arochlor 1221)109. PCB--1232 (Arochlor 1232)110. PCB-1248 (Arochlor 1248)

111. PCB-1260 (Arochlor 1260)112. PCB-1016 (Arochlor 1016)115. arsenic119. chromium121. cyanide (total)123. mercury124. nickel

Toxics Pollutants Detected in theEffluent From Only a Small Number ofSources

5. benzidine6. carbon tetrachloride10. 1,2-dichloroethane13. 1,1-dichloroethane15. 1,1,2,2-tetrachloroethane18. bis(2-chloroethyl) ether24. 2-chlorophenol31. 2,4-dichlorophenol38. ethylbenzene48. dichlorobromomethane57. 2-pitrophenol58. 4-nitrophenol59. 2,4-dinitrophenol60. 4,6-dinitro-o-cresol62. N-nitrosodiphenylamine63. N-nitrosodi-n-propylamine64. pentachlorophenol71. dimethyl phthalate77. acenaphthylene

Appendix E-Copper Subcategory


4. benzene5. benzidine7. chlorobenzene10. 1,2-dichloroethane13. 1,1-dichloroethane15. 1,1,2,2-tetrachloroethane18. bis(2-chloroethyl) ether20. 2-chloronaphthalene24. 2-chlorophenol30. 1,2-trans-dichloroethylene31. 2,4-dichlorophenol35. 2,4-dinitrotoluene38. ethylbenzene39. fluoranthene43. bis{2-choroethoxy) methane44. methylene chloride

(dichloromethane)48. dichlorobromomethane54. isophorone56. nitrobenzene59. 2,4-dinitrophenol60. 4,6-dinitor-or-cresol62. N-nitrosodiphenylamine63. N-nitrosodi-n-propylamine80. fluorene86. toluene99. endrin aldehyde106. PCB-1242 (Arochlor 1242)107. PCB-1254 (Arochlor 1254)108. PCB-1221 (Arochlor 1221)109. PCB-1232 (Arochlor 1232)110. PCB-1248 (Arochlor 1248)111. PCB-1260 (Arochlor 1260)

112. PCB-1016 (Arochlor 1016)114. antimony117 beryllium125. selenium127. thallium

Toxic Pollutants Present in AmountsToo Small to be Reduced Effectively byTechnologies Known to theA dministrator

115. arsenic121. cyanide (total)123. mercury126. silver

Toxic Pollutants Detected in theEffluent From Only a Small Number ofSources

6. carbon tetrachloride11. 1,1,1-trichloroethane14. 1,1,2-trichloroethane21.2,4,6-trichlorophenol"36. 2,6-dinitrotoluene45. methyl chloride57. 2-nitrophenol69. di-n-octyl phthalate73. benzo(a)pyrene85. tetrachloroethylene87. trichloroethylene118. cadmium119. chromium124. nickel

Appendix F-Ferrous Subcategory -


5. benzidine6. carbon tetrachloride7. chlorobenzene10. 1,2-dichloroethane13. 1,1-dichloroethane14. 1,1,2-trichloroethane15. 1,1,2,2-tetrachloroethane18. bis(2-chloroethyl) ether21. 2,4,6-trichlorophenol38. ethylbenzene45. methyl chloride (chloromethane)48. dichlorobromomethane63. N-nitrosodi-n-propylamine73. benzo(a)pyrene (3,4-benzopyrene)

Toxic Pollutants Present in AmountsToo Small To Be Reduced Effectively byTechnologies Known to theAdministrator

20. 2-chloronaphthalene115. arsenic117. beryllium121. cyanide (total)123. mercury126. silver127. thallium


4. benzene

45245


11. 1,1,1-trichloroethane22. para-chloro-meta-cresol24. 2-chlorophenol30. 1,2-trans-dichloroethylene35. 2,4-dinitrotoluene.36. 2,6-dinitrotoluene43. bis(2-chloroethoxy) methane54. isophorone56. nitrosbenzene57. 2-nitrophenol58. 4-nitrophenol59. 2,4-dinitrophenol60. 4,6-dinitro-o-cresol62. N-nitrosodiphenylamine69. di-n-octyl phthalate74. 3,4-benzofluoranthene75. benzo(k)fluoranthene85. tetrachloroethylene86. toluene87. trichloroethylene99. endrin aldehyde106. PCB-1242 (Arochlor 1242)107. PCB-1254 (Arochlor 1254)108. PCB-1221 (Arochlor 1221)109. PCB-1232 (Arochlor 1232)110. PCB-1248 (Arochlor 1248)111. PCB-1260 (Arochlor 1260)112. PCB-1016 (Arochlor 1016)

Toxic Pollutants for Which Equal orMore Stringent Protection Is Providedby Existing Effluent Limitations andStandards114. antimony118. cadmium119. chromium124. nickel125. selenium

Appendix G-Zinc Subcategory

Toxic Pollutants Not Detected or NotDetected at or Above the NominalAnalytical Limit of Quantification

5. benzidine7. chlorobenzene10. 1,2-dichloroethane13. 1,1-dichloroethane14. 1,1,2-trichloroethane15. 1,1,2,2-tetrachloroethane18. bis(2-chloroethyl) ether20. 2-chloronaphthalene35. 2,4-dinitrotoluene36. 2,6-dinitrotoluene43. bis(2-chloroethoxy) methane45. methyl chloride (chloromethane)48. dichlorobromomethane.54. isophorone56. nitrobenzene57. 2-nitrophenol60. 4,6Cdinitro-o-cresol62. N-nitrosodiphenylamine63. N-nitrosodi-n-propyla mine64. pentachlorophenol71. dimethyl phthalate73. benzo(a)pyrene (3,4-benzopyrene)74. 3,4-benzofluoranthene75. benzo(k)flouranthene (11,12-

benzofluoranthene)

77. acenapthylene80. flourene99. endrin aldehyde114. antimony115. arsenic117. beryllium118. cadmium119. chromium125. selenium126. silver127. thallium

Toxic Pollutants Present in AmountsToo Small To Be Reduced Effectively byTechnologies Known to theAdministrator

106. PCB-1242' (Arochlor 1242)107. PCB-1254 (Arochlor 1254)108. PCB-1221' (Arochlor 1221)109. PCB-1232 (Arochlor 1232)110. PCB-1248 (Arochlor 1?48)111. PCB-1260 (Arochlor 1260)112. PCB-1016 (Arochlor 1016)121. cyanide (total)123. mercury124. nickel


4. benzene6. carbon tetrachloride11. 1,1,1-trichloroethane23. chloroform30. 1,2-trans-dichloroethylene

38. ethylbenzene58. 4-nitrophenol59. 2,4-dinitrophenol67. butyl benzyl phthalate69. di-n-octyl phthalate72. benzo(a)anthracene76. chrysene'78. anthracene81. phenanthrene84. pyrene

Appendix H

Subcategories and Process SegmentsNot Regulated Because They Do Not.Generate Process Wastewater

Nickel CastingTin CastingTitanium Casting

Appendix I

Other Subcategories and ProcessSegments Not Regulated by the MetalMolding and Casting Regulations

Magnesium Casting-Compliance withregulations is not economicallyachievable for existing sources andwould pose a barrier to entry for newsources

Lead Casting-Now covered under thebattery manufacturing point sourcecategory

Appendix J-Metal Molding and Casting Flow Rates and Recycle Rates

Subcategory process segment Applied flow cy lowdown

rate flow rate

Aluminium:Casting cleaping ................................................................................................................. 480/240 95 24.0/12Casting quench .................................................................................................................... 145/72.5 98 2.90/1.45Die casting ........................................................................................................................... 41.4/20.7 95 2.07/1.04Dust collection scrubber .................................................................................................... 31.78 98 30.036Grinding scrubber ................................................. 20.063 100 0Investment casting .......................................................................................................... 17.600/8,800 85 2.640/1.320Melting furnace scrubber ........................................................................................... 11.7 96 30.468Mold cooling ........................................................................................................................ 1,850/925 95 92.5/46.3

Copper.Casting quench .................................................................................................................. 478/239 98 9.56/4.78Direct chill casting ............................................................................. .............................. 5,780/2,890 95 289/145Dust collection scrubber .................................................................................................... '4.29 98 20.086Grinding scrubber ............................................................................................................... 20.111 100 0Investment casting ............................................................................................................. 17,600/8,800 85 2.640/1.320Melting furnace scrubber .................................................................................................. '7.04 96 10.282Mold cooling ........................................................................................................................ 2,450/1.225 95 122/61.3

Ferrous:Casting cleaning ........................................................................................................ 213/107 95 10.7/5.332Casting quench ................................................................................................................... 571/286 98 11.4/5.71Dust collection scrubber .................................................................................................... '3.0 97 0.090Grinding scrubber ............................................................................................................... 33/17 100 0Investment casting ............................................................................................................. 17,600/8,800 85 2,640/1,320Melting furnace scrubber ................................................................................................... 110.5 96 '0.420Mold cooling ....................................................................................................................... 707/354 95 35.4/17.7Slag quench ...................................................................................................................... 727/364 94 43.6/21.8Wet sand reclamation ........................................................................................................ 3895/448 80 3179/89.5

Zinc:Casting quench ............... : ................................................................................................. 533/267 98 10.7/5.34Die casting ..................................................................................................... 41.4/20.7 95 2.07/1.04Melting furnace scrubber ............................................................................. '6.07 96 '0.243Mold cooling .................................................. . . . ............................................ 1,890/945 95 94.5/47.3

IApplied and blowdown flow rates are In gallons per ton/gsllons per 1,000 lbs of metal poured except as otherwIse noteo.2 Applied and blowdown flow rates in gallons per 1.000 SCF.' Applied and blowdown flow rates are in gallons per ton/gallons per 1,000 lbs of sand reclaimed.


APPENDIX K.-METAL MOLDING AND CASTINGTREATMENT EFFECTIVENESS CONCENTRA-TIONS LIME AND SETTLE

Maxi- Maxi- Long-mum mum termday' month I aver-age'i

Ferrous subcategory:Copper ....................................... 29 0.16 0.065Lead .......................................... 0.79 0.39 0.22Zinc .................... 1.47 0.56 0.40Total phenols ............................. 0.86 0.30 0.20Oil and grease ........................... 30 10 5TSS .......................... 38 15 10

Nonferrous subcategories:Copper ....................................... 0.77 0.42 0.17Lead ........................................... 0.79 0.39 0.22Zinc .................... 1.14 0.43 0.27Total phenols ........... ; ............... 0.86 0.30 0.20Oil and grease .......................... 30 10 5TSS ....................... 38 15 10

I Concentration units are milligrams per litor (mg/I).

APPENDIX L-METAL MOLDING AND CASTINGTREATMENT EFFECTIVENESS CONCENTRA-TIONS LIME AND SETTLE, FILTRATION

Maxi- Maxi- Long-'MUM mum term"mum mum

Iaver-day month ager-

Ferrous subcategory.Copper .................. : ............ 0.29 0.16 0.065Lead ........... . ............................ 0.53 .0.26 0.15Zinc ........... i ........ ......... 0.98 0.37 0.26Total phenols ........................... 0.86 0.30 0.20Oil and grease ........................... 30 10 5.TSS ............ . 15 12 2.6

Nonferrous subcategories:Copper ..................................... 0.77 0.42 0.17Lead .............................................. 0.53 0.26 0.15Zinc ............ .. 0.76 0.29 0.18Total phenols .............................. 0.86 0.30 0.20Oil and grease .......................... 30' 10 5TSS ............................................. 15 12 2.6

'Concentration units are milligrams per liter (mg/I).

APPENDIX M.-TOTAL TOXIC ORGANIC (T7O)CONCENTRATIONS FOR PSES AND PSNSMASS LIMITATIONS

Maxi- Maxi- Long-Subcategory process segment mum mum term

day month aver-age'

Aluminum:Casting quench ........................... 2.42 0.788 0394Die casting ................................... 3.56 1.16 0.580Dust collection scrubber ............ 2.04 0.666 0.333Investment casting .......... 1.64 0.536 0.268Melting furnace scrubber ........... 2.04 0.666 0.333Mold cooling ................................. 2.42 0.788 0.394

CopperCasting quench .................. 0.84 0.274 0.137Dust collection scrubber ............. 2.30 0.752 0.376Investment casting ...................... 2.30 0.752 0.376Melting furnace scrubber ........... 2.30 0.752 0.376Mold cooling ........................ 0.84. 0.274 0.1.37

Ferrous:Casting quench ............ 0.539 0.176 0.088Dust collection scrubber ........... 2.71 0.884 0.442Investment casting ..................... 1.20 0.390 0.195Melting furnace scrubber.. 2.38 0.778 0.389Mold cooling ........................... 0.539 0.176 0.088Slag quench ................................. 0.141 0.046 0.023Wet sand reclamation ................. 1.58 0.516 0.258

Zinc:Casting quench ........... : ................ 2.08 0.68 0.340Die casting ................................... .2.27 0.74 0.370Melting furnace scrubber ............ 1.95 0.636 0.318Mold cooling ........... 2.08 0.68 0.340

'Concentration units are milligrams per liter (mg/).

Accordingly, Title 40, Chapter I, of theCode of Federal Regulations is amended

by adding new Part 464 to read as setforth below:

PART 464-METAL MOLDING AND

CASTING POINT SOURCE CATEGORY

General Provisions

Sec.464.01 Applicability.464.02 General definitions.464.03 Monitoring and reporting

requirements.464.04 Compliance date for PSES.

Subpart A-Aluminum CastIng Subcategory464.10 Applicability; description of the

aluminum casting subcategory.464.11 Specialized definitions.464.12 Effluent limitations guidelines

representing the degree of effluentreduction attainable by the application ofthe best practicable control technologycurrently available.

484.13 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best available technologyeconomically achievable..

464.14 New source performance standards.464.15 Pretreatment standards for existing

I sources.464.16 Pretreatment standards for new

sources.464.17 Effluent limitations guidelines

representing the degree of effluentreduction attainable by the application ofthe best conventional pollutant controltechnology [Reserved].'

Subpart B-Copper Casting Subcategory464.20 Applicability; description of the

copper casting subcategory.464.21 Specialized definitions.484.22 Effluent limitations guidelines


464.23 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best available technologyeconomically achievable.


sources.464.26 Pretreatment standards for new


representing the degree of effluentreduction'attainable by the application ofthe best conventional pollutant controltechnology [Reserved].

Subpart C-Ferrous Casting Subcategory464.30. Applicability description of the

ferrous casting subcategory.464.31 Specialized definitions.464.32 Effluent limitations guidelines

representing the degree of effliientreduction attainable by the application ofthe best practicable control technologycurrently available.

464.33 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the attainable bythe application of the best availabletechnology economically achievable.




representing the degree of effluentreduction attainable by the application ofthe best conventional pollutant controltechnology [Reserved].

Subpart D-Zinc Casting Subcategory464.40 .Applicability; description of the ziric

.casting subcategory.464.41 Specialized definitions.464.42 Effluent limitations guidelines


464.43 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best available technologyeconomically achievable.



sources.

464.47 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application of'the best conventional pollutant controliechnology [Reserved].

Aithority: Secs. 301, 304 (b), (c), (e); and(g), 306 (bl and (c). 307,308, and 501 of theClean Water Act (Federal Water PollutionControl Act Amendments of 1972.'asamended by the Clean Water Act of 1977)(the "Act"); 33 U.SC. 1311. 1314 (b), (c), (e)and (g), 1316 (b)and (c), 1317 (b), and (c).1318, and 1361; 86 Stat. 816, Pub.L. 92-500; 91Stat. 1567, Pub. L.,95-217.

General Provisions

§ 464.01 Applicability.

* (a) This part applies to metal moldingand casting facilities that discharge ormay discharge pollutants to waters ofthe United States or that introducepollutants into a publicly ownedtreatment works.

§ 464.02 General definitions.

In addition to the-definitions set forthin 40 CFR Part 401, the followingdefinitions apply to this part:

"(a) Aluminum Casting; The remeltingof aluminum or an aluminum- alloy toform a cast intermediate or final productby pouring or forcing the molten metalinto a mold" except for ingots, pigs, orother cast shapes related to nonferrous(primary -and secondary) metalsmanufacturing (40 CFR Part 421) and -aluminum foruiing (40 CFR Part 467).


45248 Federal Register / Vol. 50, No. 210 /. Wednesday, October 30, 1985 /. Rules and Regulations

Processing operations following thecooling of castings not covered underaluminum forming, except for grindingscrubber operations which are coveredhere, are covered under theelectroplating and metal finishing pointsource categories (40 CFR Parts 413 und433).

(b) Copper Costing. The remelting ofcopper or a copper alloy to form a castintermediate or final product by pouringor forcing the molten metal into a mold,except for ingots, pigs, or other castshapes related to nonferrous (primaryand secondary) metals manufacturing(40 CFR Part 421). Also excluded arecasting of beryllium alloys in whichberyllium is present at 0.1 or greaterpercent by weight and precious metalsalloys in which the precious metal is,present at 30 or greater percent byweight. Except for grinding scrubberoperations which are covered here,processing operations:following the,cooling of castings are covered underthe electroplating and metal finishingpoint source categories (40 CFR Parts413 and 433].* (c) Ferrous Casting. The remelting offerrous metals to form a castintermediate or finished product bypouring the molten metal into a mold.Except for grinding scrubber operationswhich are covered here, processingoperations following the cooling ofcastings are covered under theelectroplating and metal finishing pointsource categories (40 CFR Parts 413 and433). '

(d) Zinc Casting. The remelting of zincor zinc alloy to form a cast intermediateor final product by pouring or forcing themolten metal into a mold, except foringots, pigs, or other cast shapes relatedto nonferrous (primary) metalsmanufacturing (40 CFR Part 421) andnonferrous metals forming (40 CFR Part471). Processing operations.following thecooling of castings not covered undernonferrous metals forming are coveredunder the electroplating and metalfinishing point source categories (40 CFRParts 413 and 433).

(e) POTW shall mean "publiclyowned treatment works."

(f) A non-continuous discharger is aplant which does not dischargepollutants during specific periods of timefor reasons other than treatment plantupset, such periods being at least 24hours in duration. A typical example ofa non-continuous discharger is a plantwhere wastewaters are routinely storedfor periods in excess of 24 hours to betreated on a batch basis. For non-continuous discharging directdischarging plants, NPDES permitauthorities shall apply the mass-basedannual average effluent limitations or

standards and the concentration-basedmaximum day and maximum formonthly average effluent limitations orstandards established in the regulations.POTWs may elect to establishconcentration-based standards for non-continuous discharges to POTWs. Theymay do so by establishingconcentration-based pretreatmentstandards equivalent to the mass-basedstandards provided in § § 464.15, 464.16,464.25, 464.26, 464.35, 44.36, 464.45, and464.46 of the regulations. Equivalentconcentration standards may .beestablished by following the proceduresoutlined in Section 464.03(b).

(g) Total Phenols shall mean totalphenolic compounds as measured by theproceduie listed in 40 CFR Part 136Idistillation followed by colorimetric-4AAP).

(h) Sm 3 shall mean standard cubicmeters.

(i) SCF shall means standard cubicfeet.

(j) Total Toxic Organics (TTO) shallmean the sum of the mass of each of thetoxic organic compounds which arefound at a concentration greater .than0.010 mg/l. The specialized definitionsfor each subpart contain a discrete listof toxic organic compounds comprisingTTO for each process segmefit in whichTTO is regulated.

§ 464.03 Monitoring and reportingrequirements.

(a) As an alternative to monitoring forTTO (total toxic organics), an indirectdischarging plant may elect to monitorfor Oil and Grease instead. Compliancewith the Oil and Grease standard shall'be considered equivalent to complyingwith the TTO standard. Alternate Oiland Grease standards are provided assubstitutes for the TTO standardsprovided in § § 464.15, 464.16, 464.25,464.26, 464.35, 464.36, 464.45, and 464.46.

(b) POTWs may establishconcentration standards rather thanmass standards, but must ensure thatthe concentration standards are exactlyequivalent to the mass-based standardsprovided in § § 464.15, 464.16, 464.25,464.26, 464.35, 464.36, 464.45, and 464.46.Equivalent concentration standards maybe determined by multiplying the mass-based standards included in'theregulations by an appropriatemeasurement of average production,raw material usage, or air scrubber flow(kkg of metal poured, kkg of sandreclaimed, or standard cubic meters ofair scrubbed) and dividing by anappropriate measure of averagedischarge flow to the POTW, taking'intoaccount the proper conversion factors toensure that the units (mg/I) are correct.

'(c) The "'monthly average" regulatoryvalues shall be the basis for the monthlyaverage effluent limitations guidelinesand standards in direct dischargepermits and for pretreatment standards.Compliance with the monthly averageeffluent limitations guidelines andstandards is required regardless of thenumber of samples analyzed andaveraged.

§ 464.04 'Compliance date for PSES.The compliance date of PSES is

October 31, 1988.

Subpart A-Aluminum CastingSubcategory

§ 464.10 ApplcabUlty description of thealuminum casting subcategory.

'The provisions of this subpart areapplicable to discharges to waters of theUnited States and to the introduction ofpollutants into publicly owned treatmentworks resulting from aluminum castingoperations as defined in § 464.02(a).

§ 464.11 Specialized definitions. "For the purpose of this subpart:(a) Total Toxic Organics (T). TTO

Is a regulated parameter under PSES(§ 464.15) and PSNS (§ 464.16) for thealuminum subcategory and is comprisedof a discrete list of toxic organicpollutants for each process segmentwhere it is regulated, as follows:

(1) Casting Quench (§ 464.15(b) and§ 464.16(b)):4. benzene21. 214,6-trichlorophenol22. Para-chloro meta-cresol23. chloroform (trichloromethane)34. 2,4-dimethylphenol39. fluoranthene44. 'methylene chloride

(dichloromethane)65. phenol66: bis(2-ethylhexyl)phthalate67. butyl benzyl phthalate84. pyrene85. tetrachloroethylene87. trichloroethylene

(2) Die Casting (§ 464.15(c) and§ 464.16(c)):1. acenaphthene4. benzene7. chlorobenzene11. 1,1,1-trichloroethane21. 2,4,6-trichlorophenol22. para-chloro meta-cresol23. chloroform (trichloromethane)34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

(dichloromethane)55. naphthalene65. phenol66. bis(2-ethylhexyl)phthalate

Federal Register / Vol. 50, No. 210 / Wednesday, October 30, 1985./ Rules and Regulations 45249

67. butyl benzyl phthalate68. di-n-butyl phthalate70..diethyl phthalate72. benzo (a)anthracene (1,2-

benzanthracene)73. benzo (a)pyrene (3,4-benzopyrene)76. chrysene78. anthracene80. fluorene81. phenanthrene84. pyrene85. tetrachloroethylene86. toluene

(3) Dust Collection Scrubber(§ 464.15(d) and- § 464.16(d)):1. acenaphthene21. 2,4,6-trichlorophenol23. chloroform (trichloromethane)34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

(dichloromethane)65. phenol66. bis (2-ethylhexyl) phthalate68. di-n-butyl phthalate70. diethyl phthalate73. benzo (a)pyrene (3,4-benzopyrene)84. pyrene

(4) Investment Casting (§ 464.15(f) and§ 464.16(f)]:11. 1,1,1-trichloroethane23. chloroform (trichloromethane)44. methylene chloride

(dichloromethane)66. bis (2-ethylhexyl) phthalate84. pyrene85. tetrachloroethylene87. trichloroethylene

(5) Melting Furnace Scrubber(§ 464.15(g) and § 464.16(g)):1. acenaphthene21. 2,4,6-trichlorophenol23. chloroform (trichloromethane)34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

(dichloromethane)65. phenol66. bis (2-ethyihexyl) phthalate68. di-n-butyl phthalate70. diethyl phthalate73. benzo (a)pyrene (3,4-benzopyrene)84. pyrene

(6) Mold Cooling (§ 464.15(h) and§ 464.16(h)):-4. benzene21. 2,4,6-trichlorophenol22. para-chloro meta-cresol23. chloroform (trichloiomethane)34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride65. phenol66. bis(2-ethylhexyl) phthalate67. butyl benzyl phthalate84. pyrene85. tetrachloroethylene

87. trichloroethylene

§ 464.12 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best practicable control technologycurrently available.

Except as provided in 40 CFR 125.30-125.32, any existing point source subjectto this subpart must achieve thefollowing effluent limitationsrepresenting the degree of effluentreduction attainable by the applicationof the best practicable controltechnology currently -available, exceptthat non-continuous dischargers shallnot be subject to the maximum day andmaximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sm3 or lb/billionSCF of air scrubbed) effluent limitationsfor copper, lead, zinc, total phenols, oiland grease, and TSS. For non-continuous dischargers, annual averagemass limitations and maximum day andmaximum for monthly averageconcentration (mg/I) limitations shallapply. Concentration limitation andannual average mass limitation shallonly apply to non-continuousdischargers.

(a) Casting Cleaning Operations.

BPT EFFLUENT LIMITATIONS

MxmmfrMaximum forPollutant or pollutant property Ixi any fo day Maxm fo

average

kg/1,000 kkg (pounds permillion pounds) of metalpoured

Copper T) ............... 0.0771 0.0421Lead (T) .......... 0.0791 0.039Zinc T) ......................................... 0.114 0.0431Oil & grease ............................ 3.0 1.0TSS ......... . ... 3.80 1.50pH ............................... (') C()

Within the range of 7.0 to 10.00 at all times.

Maximum Maximum Annualfr forfor any 1 monthly aver-

day average ages

(mg/I)' (mg/I)'copper () ........................... 0.77 0.042 0.017Lead T) ........................... 0.79 0.39 0.022Zinc (). 1.14 0.43 0.027Oil & grease ...................... 30 10 • " 0.501TSS ........ .... 38 15 1.0pH .................... (.) . () ()

s kg/1,000 kkg (pounds per million pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(12/x) where x Is the actual normalized process wastewaterflow (in gallons per 1,000 pounds of metal poured) for aspecific :ant .

' Within the range of 7.0 to 10.0 at all times.

(b) Costing Quench Operations.


Pollutant or pollutant Maximum for Maximum f6rmonthly

property average


Copper (M) .................................... 0.0093 0.0051Lead () 0.0096 0.0047Zinc (1) ....................................... 0.0138 0.0052Oil & grease ................. 0.363 0.121TSS ............................................... 0.46 0.182pH ........ .................. ................ ( ) (')


Maimum Maximum AnnualforxIu for av rmonthly agesaverage

(mg/I) (mg/02

Copper T) ..................... 0.77 0.42 0.0021Lead () ............................... 0.79 0.39 0.0027Zinc T) ................................ 1.14 0.43 '0.0033Oil & grease ........................ 30 10 0TSS .................. 38 15 0.121pH ............................... (3) 1') (3)

kg/1,000 kkg (pounds per million pounds) of metalpoured.

2These concentrations must be multiplied by the ratio of(1.45/x) where x Is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant

'Within the range of 7.0 to 10.0 at all times.

(c) Die Casting Operations.


pMaximm for

Pollutant or pollutant prperty Maximum for MaiurMaxnmu I d montyaydy average

.kg/i,000 kkg (pounds permillion pounds) of metalpoured

Copper (M) .............. 0.0066 0.0036Lead M ...................................... 0.0068 0.0034Zinc T) ............ .. 0.0098 0.0037Total Phenols .......... .................... 0.0074 0.0026Oil & Grease ................................. 0.259 0.0864TSS ............... ....................... 0.33 0.13pH ............. () ()

With the range of 7.0 to 10.0 at all times.

Maximum' Maximum Annualfor any 1 for aver-

day monthly agesaverage

(mg/I) (2) (mg/I) (2)Copper () ........................... 0.77 0.42 0,0015Lead () ..... .... 0.79' 0.39 0.0019Zinc () ................................ 1.14 0.43 0.0023Total Phenols .................. 0.86 0.3 0,0017Oil & Grease: ..................... 30 10 0.0432TSS .................. 38 15 0.0864pH ......................................... ' (3) (3) (3)

ikg/l,000 kkg (pounds per million pounds) of metalpoured.

' These concentrations must be multiplied by the ratio of(1.04/a) where x is the actual normalized processwastewater flow (in gallons per 1.000 pounds of metalpoured) for a specific plant.* 3 Within the range of 7.0 to 10.0 at all times,

(d) Dust Collection ScrubberOperations.


BPT EFFLUENT LIMTrATIONS

Maximum for Maximum forPollutant or pollutant property any 1 day monthly

average

kg/62.3 million Sm'(pounds per billion SCF)of air scrubbed

Copper (T) ............. 0.231 0.126,Lead (T) ............................. . 0.237 0.117Zinc CT) -......... ....... 0.343 0.129TotalPhenols...... .............. ... 0.258 0.09Oil & Grease ....... . ' 9.01 3.0TSS .............................................. 11.4 4.51pH .................... . . .. .. .. ( )( )


Maxi.Maximum mum Annualfor any 1 for aver-

day monthly age'average

(mg/0 mg/I) 2

Copper (T) .............................. 0.77 0.42 0.0511Lead ) ................................. 0.79 0.39 0.00661Zinc (T) .......................... . 1.14 '0.43 0.0811Total Phenols ........................ 0.86 0.3 '0.0601Oil & Grease .......................... 30 10 1.5TSS ................... 38 15 :3.0pi ......... ....... .. ............ .....- (1) (3) (V)

kg/62.3 milion SM' (pounds per billion SCF) of airscrubbed.

2 These concentrations must be multiplied by the ratio of(0.036/x) where x is the actual normalized process waste-water flow (in gallons per 1,000 SCF of air scrubbed) for aspecific plant


(e) Grinding Scrubber Operations. Nodischarge of process wastewaterpollutants to navigable waters.

(f) Investment Casting.

BPT EFFLUENT LtMITATIONS

for Maximum forPollutant or pollutant property Manu 'for monthlyay 1 day average


Copper T) . .................. .8.48 4.63Lead (T) ......................................... 8.7 4.3Zinc ( ... . . . .. ...... 12.6 4.74Oil and grease ............................ 330 110TSS .......................... . 419 165Pl .... ... ..................... (') .. (')

Within the range ,of 7.0 to 10.0 at all times.

Maximum foamum Annualfor any I moly -

day average age

oopper(T....Le ( .r) ... ...............Zinc T) ................................:i1 and ,grease ....................TSS ....................................PH .........................................

(mg/I)=0.770.791.14

3038(3)

(mg/I)'0.420.390.431015

V)

I kg/1,000 kkg (pounds per million pounds) of metalpoured.

' These concentrations must be multiplied by the ratio of(1.320/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.


(g) Melting Furnace ScrubberOperations.


or Maximum for Ma forPollutant or~polutant Property , any I day average

kg/62.3 million Sm.(pounds per billion SOP)of air scrubbed

Copper CT) ....... ............................ 3.01 1.64Lead ) ............................... 3.09 1.52Zinc (T) ......................................... 4.45 1.68Total phenols ......... .. 3.36 1.17Oil and grease.............. 117 39.1TSS . ................... 146 58.6pH -... ... - ..... ') (-


Maximum Maximum Annualfor any afo ver-monthly ager

day average age

(mgl) ' (mog/) aCopper M .......... 0.47 0.42 0.664Lead (1) ...................... 0.79 0.39 0.859ZincC )

(T)................ 1.14 0.43 1.05Total phenoss.... 0.88 0.3 0.781Oil and grease. 30 10 19.5TSS .................. 38 15 39.1

= 3 million Sm' (pounds per billion SCF) of air

' These concentrations must be multiplied by the ratio of(0.468/x) where x ;is the acutal normalized proeaswastewater flow (in galions per 1%000 SCF of air scrubbed)for a specific plant.

0 Within the frange of 7.0 to 10.0 at all times.

(h) Mold Cooling Operations.

BPT EFFLUENT LiMITATIONS

Pollutant or pollutant property Mximu f Maximum fordayI otyayI average

,kg/1,000 kkg (pounds -permillion pounds) of metalpoured

Copper fn ................ . 0.297 0.162Lead (T) ................. 0.305 0.151Zinc (1) ......................... .. .. 0.44 0.166'Oil and grease ........................... 11.6 3.86TSS .............................................. 14.7 5.79pH .............................. .. ............... ()


Maximum Maximum Annuallor any 1 for aver-

dy monthly agIday average age'

(mg/I) I (mg/) ICopper (T) ........................... 0.77 0.42 0.0656Load " .. . ...... 0.79 0.39 0.0849Zinc (TM ...................... 1.14 - 0.43 0.104Oil and grease ........ 30 10 1.93TSS .................................. 38 15 3.96P ........- .. ................. (1) (3)

.1 kg/1,000 kkg (pounds per million pounds) of metal2These concentrations must be multiplied by the ratio ,of(46.3/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds -of metalpoured) for a specific plant.

3 Within the range of 7.0 to 10.0 at all times.

§ 464.13 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best available technology economicallyachievable.

Except as provided in 40 CFR 125.30-125.32, any existing point source subjectto this subpart must achieve thefollowing effluent limitations

representing the degree of effluentreduction attainable by the applicationof the best available technologyeconomically achievable, except thatnon-continuous dischargers shall not besubject to the maximum day andmaximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sms or lb/billionSOF of air scrubbed) effluent limitationsfor copper, lead, zinc, and total phenols.For non-continuous dischargers, annualaverage mass limitations and maximumday and maximum for monthly averageconcentration (mg/I) limitations shalapply. Concentration limitations andannual average mass limitations shaUlonly apply to non-continuousdischargers.


BPT EFFLUENT UMITATIONS

S aimumfor :Maimum farPollutant or pollutant property ! 1 day monithly

kg/.000 kkg Wounds Ipermillion -pounds) of metalpoured

Copper () .................. . 0.771 0.0421Lead T) ................ ....... 0.0791 ,039Zinc (1) ....................................... 0.114 0.0431

M aximum IMaximum.for any 1 or

day _verage g

(mg/i)' ,(mg/i) 'copper MT) ........... ............ 0.77 0.42 0.017Lead T) ............................. 0.79 6.39 0.022Zinc T) ........... 1.14 0.43 0.027

'kg/1,000 kkg (pounds per million punds) of -metalpoured.uThese concentrations must be multiplied by the ratio of(12/x) where x is the actualnormalized process .wastowaterlow (in glons per 1,000 pounds of metal poured) for I

specific PCaq.

(b) Casting Quench Operations.

BAT EFFLUENT LIMITATIONS

Pollutant or pollutant property M month lo oraverage

kg/1.00 'kkg (pounds e.mflIon pounds) of metalpoured

Copper (. 0.0099 0.0051Lead ) ........................... . 0.0096 0,0047Zinc (T) ......................................... . 0 . 38 V.0052

Mxmm Maximum'aimum M mforfor aI for aver-

da mont ageaverage

(Mg/) 5 (mg/) ,Copper M .......................... 0.77 0.42 0.0021Lead ) ............................... 0.79 0.39 0.0027Zinc ) ............................... 1.14 0.43 ,0.0033

I kg/1,000 kkg (pounds per million pounds) of metalpoured.

2These concentrations must be multiplied by the ratio 'of(1.45/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metapoured) for a specific plant.


(c) Die Casting Operations.


Maximum for Maximum torPollutant or pollutant property any I day averagey

kg/1.000 kkg (pounds permillion pounds) of metalpoured

Copper = ...................... 006 0.0036Lead (1) ....................................... 0.0068 0.0034Zinc (T). 0.0098 0.0037Total Phenols .................... 0.0074 0.0026

Maximum Maximum Annualforiany for aver.

fday monthlyaverage age

(mg/)' (mg/i) ICopper (T) ...................... 0.77 0.42 0.0015Lead ( . 0.79 0.39. 0.0019Zinc .() ... .............. 1.14 0.43 0.0023Total Phenols ........... 0.6 0.3 0.0017

I kg/1.000 kkg (pounds per million pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(1.04/x) where x is the actual normalizedwastewatr flow (in gallons Per 1,000 pounds 01Fmepoured) for a specific plant



I Maximum frMaximum to,

Pollutant or po lluk ant property oathl y u for

Imonhly


Copper (T) ........................... . .. .231 0.126Lead (")........... 0.3 n 0.17

zin m ............-I 0.343 0 .129Total Phenols .................... 0.258 0.09

Maximum Maximum Annualfor arty 1 monthly aver-

daY average age

(moll) I (rag/0 a

Copper () ..... ...........-. 0.77 0.42 0.0511Lead (T) .............. 0.79 0.39 0.0661Zinc) .. . 1.14 0.43 0.0811Total Pheno1s............ 0.86 0.3 0.0601

W11g/62.3 mllilon Sm' (lb per billion SCF) of air scrubbed.'These concentrations must be multiplied by the ratio of

(0.036/x) where x is the actual normalized processwastewater flow (in gallons per 1.000 SCF of air scrubbed)for a specific plant.


(f) Investment Casting.


Pollutant or pollutant property M for n

ay1day monthly[ a y 1 ay I ave ra ge

k9/1,000 kkg (pounds permillion pounds) of metalpure6

Copper .... ....... e4 I 4.6Lead V'" ..............J 87 4.3zjnc M ..................... 1....t 2.6 4.74

Maximum Maximum Annualfor any I for

day monthy agedy average la

(mo/I) I (mg/i) 1Copper (T) .......................... 0.77 0.42 1.87Load () ............................... 0.79 0.39 242Zinc (T) ............................... 1.14 0.43

• 2.97

'kg/1,000 kg OUnds per million pounds of metal poured.' These concetrations must be muffiplied by the ratio of

(1.320/x) where a is the actual noralized processwastewater flow (in gallons per 1.000 pounds of metalpoured) for a specific plant.



Pollutant or pollutant property Maximum for montlyaverage

k9162.3 million Sm(pounds per billion SCF)of air scrubbed

Copper (T) ................................... 3.01 1.64Lead (T) . ......................... .. " 3.09 1.52Zinc T ....................................... 4.45 ' 1.68Total phenols. .......................... 3.36 1.17

Maximum Maximum AnnualforanIm forfor any 1 monthly aver-

ageagday arerage e

(mg/0 I (mg/) ICopper (T) ........................... 0.77 0.42 0.664Lead (T) .................. 0.79 0.39 0.859Zinc T) ......... .. 1.14 0.43 1.05Total phenols. 0.86 0.3 0.781

kS62.3 million Sml (pounds per billion SCF) of airR These concentrations must be multiplied, by the ratio of

(0.468/x) where a is the actual normalized processwastewater flow (in gallons per 1.000 SCF of air scrubbed)for a specific plant



Maximum for IM ximum for

Pollutant or Pollutant property I mum I oa


Copper (1) ................................. 0.2971 0.162Lead M ") .. ..................... .. " 0.305 0.151Zinc ( ..) ....... ............. 0.44 0.166

Maximum Maximum Annualf r a y 1 fo r A n n u alfanyl monthly ageI

day average

(mg/)' (mg/) 2Copper IT) ......... - .......... 0.77 0.42 0.0656Lead (T) ... ..... 0.79 0.39 0.0849Zinc () ............................. 1.14 0.43 0.104

kg/1.000 kkg (pounds per million pounds) of metalpoured.'These concentrations must be multiplied by the ratio of(46.3/x) where a is the . actual normalized r sswastewater flow (in galons per 1,000 pounds of metalpoured) for a specific plant.

§ 464.14 New source performancestandards.

Any new source subject to thissubpart must achieve the following newsource performance standards (NSPS),except that non-continuous dischargers

shall not be subject to the maximum dayand maximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sm s or lb/billionSCF of air scrubbed) effluent standardsfor copper, lead, zinc, total phenols, oiland grease, and TSS. For non-continuous dischargers, annual averagemass standards and maximum day andmaximum for monthly averageconcentration (mg/) standards shallapply. Concentration standards andannual average mass standards shallonly apply to non-continuousdischargers.


NSPS

M " axim Maximum forPollutant or Pollutant prpert y oaverage

kg/1,000 kkg (pounds per,million pounds) of metalpoured

Copper m ......... .... 0.*0771 0.0421Lead 0.0............................. 0.0791 0.039Zinc (T) ............ 0.114 0.0431Oil and grease ................... .... 3.0 1.0TH .. .............. 38 1.


Maximum Maximum Annual

for any for aver-day monthy .aeaverage ago

(mg/ll (mg/) 2Copper (T) ........... 0.77 0.42 0.017Lead (T) ................... 0.79 0.39 0.022Zinc (T) ............................. 1.14 0.43. 0.027Oil and grease . 30 10 0.501TSS .............. ... .. 38 15 1.0PH.. ................... . . (a ) V)

I kg/1.000 kkg (pounds per million pounds) of metalpoured.

2These concentrations must be multiplied by the ratio of(12/x) where x is the, actual normalized process wastewatarflow (in gallons per 1.000 pounds, of metal poured) -for aspecilic plant.

a Within the range of 7.0 to 10.0 at all times.

(b). Casting Quench Operations.

NSPS

"Maximum forPollutant or pollutant property I Madimum for I Max er


Copper .) ................... 0.0093 0.0051Lead (T) ............ ................ o.oo 0.0047Zinc (T) ........... 0...3.......... 0.0138 0,0052Oil and grease ............................ . 0.363 0.121TS ..................... .................... 0.46 0.182


Maximu Maximum Annu.for any I alfday monthly , aver.

day [average age

Copper T) .......... ............Lead;() ......... .... . ...Zinc ( .......................Oil and grease ................TSS ..................

(m/I).'0.770.791.14

3038

(mg/i '0.420.390.43

1015

0.00210.00270.00330.06050.121


Maximum Maximur Annu-for any 1 for almonthly aver-

day average age'

Maximum for Annualfor any I monthly aver-

day average age

p (m g l) x (m /I) .. - (m g / ) 3 (m g / ) 'PH . ... ........... V) ............ (3) P H ......................................... 1 = () ( ) v

• I kg/1,000 kkg (pounds per million pounds) of metalpoured.2

These concentrations must be multiplied by the ratio of(1.45/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant


(c) Pie Costing Operations.

NSPS

Maximum forPollutant or pollutant property on fo monthlyMmmdir average_

kg/1,000 kkg (pounds permillion pounds of metalpoured

Copper (1). ................. 0.0066 0.0036Lead (T) ................. 0.0068 0.0034Zinc (T) .................... 0.0098 0.0037Total Phenols ............................. 0.0074 0.0026Oil and grease ............................. 0.259 0.0864-TSS and .................... 0.33 0.13pH ................................................. (3) (3)


MaximumMaximum for Annualfor any monthly aver-day average

(mg/I) 2 (mg/I) -Copper ) ........................... 0.77 0.42 0.0016Lead () ................. 0.79 0.39 0.0019Zinc () ................................ 1.14 0.43 0.0023Total phenols .................. 0.86 0.3 0.0017Oil and grease ................... 30 10 0.0432TSS and....... ........ 38 15 0.0864pH .................... (3 (3). (M I M

kg/l,000 kkg (pounds per million pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(.04/x) whore x is the actual normalized processwastewaler flow (in gallons per 1,000 pounds of metalpoured)



NSPS

maximum for IMaximum forPollutant of pollutant property any 1 day monthly

average

kg/62.3 million Sm 3(pounds per billion SCF)of air scrubbed

Cooper (r) ..................................... 0.231 0.126Lead (T) ......................................... 0.237 0.117Zinc () .......................................... 0.343 0.129Total phenols .................. " 0.258 0.09Oil and grease .............................. 9.01 3.0TSS ................................................ 11.4 4.51pH ................................................ . () (1)


Maximum maximum Annual

frayI forfor any 1 monthly aver-day average age

Cooper (") ..........................Lead (T) ..............................Zinc (T) ...............................Total phenols .....................Oil and grease ...................TSS ....................................

(mg/) '0.770.791.140.56

3038"

(mg/I) 20.420.390.430.3

1015

sc~u= .3 million Sm' (pounds per billion SCF) of air

OThese concentrations must be multiplied by the ratio of(0.036/x) where x Is the actual normalized processwastewater flow (In gallons per 1,000 SCF of air scrubbed)for a specific plant.



(f) Investment Costing

NSPS

Maximum for Maximum forMaiu monthlyPollutant or pollutant property any 1 day monthly

nyIdy average


Copper M .................................... 0.48 4.63Lead (1) ........................................ 8.7 4.3Zinc T) ......................................... 12.6 4.74Oil and grease .................... 300 110TSS .............................................. 419 165pH ................................................. . (3) (1)


Maximum Maximum Annualfor any 1 for aver-

day monthly age3

average

(Mg/) 2 (mg/)'Copper (T) ............ 0.77 0.42 1.87Lead (T) ..... 0.79 0.39 2.42Zinc () .............................. 1.14 0.43 2.97Oil and grease .................... 30 10 55.1TSS ..................................... 38 15 110pH ....................................... (a) (1) (3)

P kg/1,000 kkg (pounds per million pounds) of metalpoured m' These oncentrations must be multiplied by the ratio of

(1,320/a) where is the actual normalized processwstewaer flow (in gallons per 1,000 pounds of metalpoured) for a apecific plant.


(g) Melting Furnace ScrubberOperations

NSPS

MxmmfrMaximum forPollutant or pollutant property ay 1 d mon

PZ ny l a y

Iaverage

kg/62.3 million Sm(pounds per billion SCF)of air scrubbed

Copper M ..................................... 3.01 1.64Lead () ......................................... 3.09 1.52Zinc T) .......................................... 4.45 1.68Total phenols ............................... 3.36 1.17Oil and grease ..... .... 117 39.1TSS ............... . 148 68.6pH ....................................... .. ...... [ ( 1 (,)

Within the range.of 7.0 to 10.0 at all times.

1maximum Maximum TAnnualfor any 1 for aver.

day monthly age3

________ __ I average 1

Copper (T) ..........................Lead ( ) ............................Zinc (T) ...............................Total phenols .....................

(mg/I) '0.770.791.140.86

(rg/] '0.420.390.430.3

Maximum Maximum Annualfor any I for ly aver-


(ag/l) I (rag/1) 2Oil and grease ........... 30 10 19.5

TSS ....... ........ 38 15 39.1pH ... ... . .... 1 () () (3)

'g102.3 million SmO (pounds per billion SCF) of airscrubbed.2 These concentrations must be multiplied by the ratio of

(0.468/x) where x is the actual normalized process water.water flow (in gallowns per 1,000 SCF of-air scrubbed) for aspecific plant

I Within the range of 7.0 to 10.0 at all times.

(h) Mold Cooling Operations

NSPS

Pollutant or pollutant property Maximum t, Maximum forany 1 day monthly

kg/l,000 kkg (pounds permillion pounds) of metalpoured

Copper (T) ................................... 0.297 0.162Lead M .................................... 0.305 0.151Zinc T) ......... ... 0.44 0.166Oil and grease ............................ 11.6 3.86TSS .................. 14.7 5.79pH ............................. ...... ... ........ . (1) (1)


Maximum Maximumfor for Annual

day monthly average. average

(mg/I). (mg/I),copper (T)......................... 0.77 0.42 0.06 6Lead (T) ............... 0.79 0.39 0.0849Zinc M ........................... 1.14 0.43 0.104Oil and grease ................. 30 10 1.93TSS ................................... 38 15 3.86PH .......................... 0 () (6)

3 kg/1,000 kkg (pounds per million pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(46.3/x) where x Is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant


§ 464.15 Pretreatment standards forexisting sources.

Except as provided in 40 CFR 403.7and 403.13, any existing source subjectto this subpart which introducespollutants into a publicly ownedtreatment works must comply. with 40CFR Part 403 and achieve the followingpretreatment standards for existingsources..


PSES

Maximum for Maximum forPollutant or pollutant Prope a 1 monthyaverage


Copper () ................................ 0.0771 0.0421Lead (1) ........... 0................7.9......... 0.071 0.039ZincM ............ 0.114 0.0431

(b) Casting Quench Operation.

im

Federal Register /. Vol. 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulations 45253

PSES PSES

Maxim~um forIM a x im um for 'Maximum for M for

Pollutant or pollutant prop any day mnthly Pollutant or pollutant property any a averagy

I anyI day averageI an1yIavrg


Copper T).........................0............ 'o.0093 0.0051Lead IT).... ..................... 0.0096 0.0047Zinc (T).. ................... 0.0138 0.00521TO ................. .............................. 0.029 0.0095Oil and grease (for alternate

monitoring) .............................. 0.363 0.121

(c) Die Costing Operations.

PSES

kg/62.3 million Sm3

(pounds per billion SCF)of air scrubbed

Copper T) ..................................... 3.01 1.64Lead (") ........................................ 3.09 1.52Zinc ) .......................................... 4.45 1.68Total phenols .......................... . 3.36 1.17TTO ...................... . 7.97 2.8

-Oil and grease (for alternatemonitoring) ................................ 117 39.1


PSES

Maximum " or1 Maximumfor Maxmumfor

monthy Polutant or pollutantmo1olutant r pollutant ropery any 1 day average mpropery Maximu monthly"" - .1 "-- average


copperm .................... 0.0066 0.003Lead CT)..................... 0.0068 0.0034Zinc (T) ................................ 0.0098 0.0037Total phenoll................. : 0.0074 0.0026ITO . ....... 0.0308 0.01Oil and grease (for alternate

monitonng ................. 0.259 0.0864

(d) Dust Collection Scrubber

Operations.

PSES

Miximu for Maximum forPollutant or pollutant property Manyiu day imonthly

any y average

kg/62.3 million Sm3

(pounds per billion SCF)or air scrubbed

Copper CT................ .... 0.231 0,126Lead T) ............ ' 0.237 0.0117Zinc ) ....................................... 0.343 0.129Total phenols ............. ................. 0.258 0.09TTO ........................................... 0.613 0.2Oil and grease (for alternate

monitoring ............................... 9.01 3.00

(e) Grinding Scrubber Operations. Nodischarge of process wastewaterpollutants to a POTW.

(f) Investment Casting

PSES" am" . Maximum for

Pollutant or pollutant propert-.axy day for Molray1 ay average


Copper .................................. 8.48 4.63Lead M ........................................ 8.7 4.3Zinc T). .............. .................. 12.6 4.74TTO ........... 18.1 5.91Oil and grease (for alternate

monitoring.: ............................ 330 110



Copper CT) .......... ............... 0.297 0.162Lead MT)..............! ........... 0.305 0.151Zinc ). 0.44 0.166TTO ..... ................................. 0.935 o.304Oil and grease (for alternate

monitoring) .......... .......... 11.6 3.'86

§ 464.16 Pretreatment standards for newsources.

Except as provided in 40 CFR 403.7,any new source subject to this subpartwhich introduces pollutants intopublicly owned treatment works mustcomply with 40 CFR Part 403 andachieve the following pretreatmentstandards for new sources.(a) Costing Cleaning Operations.

PSNS

Maximum for Maximum forPollutant or poltutant property any 1 day monthly

average


Copper (1). .. 0.0771 0.0421Lead T) ............ .... 0.0791 .0.039Zinc (T) .......................................... 0.114 0.0431

(b) Casting Quench Operations.

PSNS

Maximum for Maximum for-Pollutant or-pollutant property any I day monthly

PZ'P;F~nday average

kg/1,000 kkg (pounds permillion pounds) of metal

* poured

Copper MT) ...... .......................... 0.0093 0.0051Lead (T) ...................... . 0.0096 0.0047Zinc T) ....... .......... ; ................... 0.0138 0.00521TO ................. . ... .9 0.0095Oil and grease (for alternate

monitoring) . ............. 0.363 0.121

PSNS

IMaximum forPollutant or pollutant property Mnu 1for mony

FI - - y average


Copper ............................ . 0.006 0.0038Lead () ............. _: .......... 0.00.... 0.0068 0.0034Zinc (T) ...................... 0.0098 0.0037Total Phenols .................... .. 0.0074 0.0026TO ....................................... ... 0.0308 0.01

Oil and grease (for alternatemonitoring) ......... ....... ........ 0.259 0.0864

(d) Dust Collection Scrubber

Operations.

PSNS

Mimm fo Maximum forPollutant or pollutant property mo day mthly

kg/62-3 million Sm3


copper 0.. 0.231 0. 126Lead () .......... ........ . .....- 0.237 0.117Zinc T) ............................. 0.343 0.129Total Phenols...-... 0258 0.09"rO . ....... ... 0.613 0.2Oil and, grease (for alternate

monitoring) ....... t 9.011 3.0

(e) Grinding Scrubber Operations. Nodischarge of process wastewaterpollutants to a POTW.

(f Investment Casting.

PSNSMaxmum forMaiufo

Pollutant or pollutant property nay aianylday veag


Copper (T) .............................. 8.48 4.63Lead T) ...... ...... 8.7 4.3Zinc (T) ............. . 12.6 4.74ITO ......... ..... 18.1 5. .91Oil and grease (for alternate

monitoring) ................................ :330 110

(g) Melting Furnace Scrubber

Operations.

PSNS

Maximum for IMaximum forPollutant or pollutant property any I day monthly

average

kg/62.3 million Sma(pounds per billion SCF)of sir scrubbed

Copper (T) .......... ........................ 3.01 1.64Lead M ..................................... 3.09 1.52Zinc ) ........................................ 4.45 1.68Total Phenols .......................... 3.38 1.17TTO .......................... ................... 7.97 2.8Oil and grease (for alternate

monitoring) ........... 117 39.1

(h) Mold Cooling Operations.(c) Die. Cas'ting Opera tions.

No. 210 / Wednesday, October 30, 1985 / Rules and Regulations

PSNS

i oMaxi mum forPollutant or pollutant property Mim f mforly

average


Copper M ...................................... 0.297 0.162Lead (T) . ...... 0.305 0.151Zinc (T) .......................... 044 0.166"T O ............................................... 0.935 0.304Oil and grease (for alternate

monitoring) .............................. 11.6 3.86

§ 464.17 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best conventional pollutant controltechnology. [Reserved].

Subpart B-Copper CastingSubcategory

§ 464.20 Applicability; description of the.copper casting subcategory.

The provisions of this subpart areapplicable to discharges to waters of theUnited States and to the introduction ofpollutants into publicly owned treatmentworks resulting from copper castingoperations as defined in § 464.02(b).

§ 464.21 Specialized definitions.For the purpose of this subpart:(a) Total Toxic Organics (TO). 'TO.

is a regulated parameter under PSES(R 464.25) and PSNS (§ 464.26) for theCopper subcategory and is comprised ofa discrete list of toxic organic pollutantsfor each process segment where it isregulated, as follows:

(1) Casting Quench (§ 464.25(a) and'§ 464.26(a)):23. chloroform (trichloromethane)64. pentachlorophenol66. bis(2-ethylhexyl)phthalate71. dimethyl phthalate

(2) Dust Collection Scrubbers(§ 464.25(c) and 464.26(c)):1. acenaphthene22.-para-chloro meta-cresolt23. chloroform (trichloromethane)34. 2,4-dimethylphenol55. naphthalene58. 4-nitrophenol64. pentachlorophenol65. phenol66. bis(2-ethylhexyl)phthalate67. butyl benzyl phthalate .68. di-n-butyl phthalate70. diethyl phthalate71. dimethyl phthalate72. benzo(a)anthracene (1,2,. -.

benzanthracene) -74. 3,4-benzofluoranthene75. benzo(k) fluoranthene.76. chrysend *77. acenaphthylene.78. anthracene81. phenanthrene

84. pyrene(3) Investment Casting (§ 464.25(e)

and § 464.26(e)):1. acenaphthene22. para-chloro meta-cresol23. chloroform (trichloromethane)34. 2,4-dimethylphenol55. naphthalene58. 4-nitrophenol64. pentachlorophenol65. phenol66. bis (2-ethylhexyl)phthalate67. butyl benzyl phthalate68. di-n-butyl phthalate70. diethyl phthalate71. dimethyl phthalate72. benzo(a)anthracene (1,2-

benzanthracene)74. 3,4-benzofluoranthene75. benzo(k) fluoranthene76. chrysene77. acenaphthylene78. anthracene

81. Phenanthrene84. pyrene

(4) Melting Furnace Scrubber(§ 464.25(f) and § 464.26(f)):1. acenaphthene22. para-chloro meta-cresol23. chloroform (trichloromethane)34. 2,4-dimethylphenol55. naphthalene58. 4-nitrophenol64. pentachlorophenol65. phenol66. bis (2-ethylhexyl) phthalate67. butyl benzyl phthalate68. di-n-butyl phthalate70. diethyl phthalate71. dimethyl phthalate72. benzo(a)anthracene (1,2-

benzanthracene)74. 3,4-benzoflouranthene75. benzo(k) flouranthene76. chrysene77. acenaphthylene78. anthracene81. phenanthrene84. pyrene

(5) Mold Cooling (§ 464.25(g) and§ 464.26(g)):23. chloroform (trichloromethane)64. pentachlorophenol66. bis(2-ethylhexyl)phthalate71. dimethyl phthalate

§ 464.22 Effluent limitations guidelinesrepresenting the degree of effluent,reduction attainable by the application of..the best practicable control technology.currently available.

Except as provided in 40 CFR.125.30-125.32, any existing point source subjectto this subpart must achieve thefollowing effluent limiiationsrepresenting the degree of effluentreduction attainable by the applicationof the best practicable controltechnology currently available, except

that non-cohtinuous dischargers shallnot be subject to the maximum day andmaximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sm 3 or lb/billionSCF of air scrubbed) effluent limitationsfor copper, lead, zinc, total phenols, oiland grease, and TSS. For non-continuous dischargers, annual averagemass limitations and maximum day andmaximum for monthly averageconcentration (mg/I) limitations shallapply. Concentration limitations andannual average mass limitations shallonly apply to non-continuous.dischargers.

(a) Casting Quench Operations.



average


Copper ................................... 0.0307 0.0168Lead (T) ............. . 0.0315 0.0156Zinc M ................. ..................... 0.0455 0.0171Oil and grease ............................. 1.2 0.399TSS .. .............................. 1.52 0.598.pH ................................................. (') (,)


Maximum Maximum Annualfo for Anafor any I monthly aver-,day .average age

(mq/l"= (mg/I)Copper () ........................ 0.77 0.42 0.0068Lead (1) ........................... 0.79 0.39 0.0088Zinc () .................... 1.14 0.43 0.0108Oil and grease .................. 30 10 0.199TSS .......... :...................... 38 15 0.399PH ............................. :..... p ) p

kg/1000 kkg, (pounds per million pounds) of metalpouredThese concentrations must be multiplied by the ratio of

(4.8/x) where x is the actual normalized process wastewaterflow otn gallons per 1,000 pounds of metal poured) for aSpeifi Plant .. . .


(b) Direct Chill Casting Operations.


Pollutant or pollutan Maximum for Maximum forproperty any 1 day hly

average


Copper M ............ ; ........................ 0.928 0.506Lead M .t : .......... .. 0.952 0.47Zinc T) ............... ._, 1.37 0.518Oil and grease .................. ........... 36.2 12.1TSS.: ............ 45.8 18.1pH ......... ............ ................... (1) (')


maximum maximum Annualfor any I for aver-monthlyday average

Copper (r):................Lead (T)..... .......Zinc T) ....................... ....

(mg/I)3

•0.77

0.791.14

.(mg/)=0.420.390.43

0.2050.2650.326

45254 Federal Register / Vol. 50,


Maximum Maximum Annualfor afor r

monthly. aver-.. _ _ _ y. average egeo_

(mg/I)' 2 (rg/I)'Oil and grease .................... 30. • 10 6.03.T S .............................. . 38 15 12.1pH:..:...... ......... .......... ......... (6) (3) (1)

,'ikg/1000 k 9g (pounds per million pounds) of metal

'These concentrations must be multiplied by the ratio of(145/x) where x is the actual normalized process wastewaterflow (in gallons per 1.000 pounds of. metal poured) for aspeifi pane

SWithin the range of 7.0 to 10.0 at all times.

(a) Dust Collection Scrubber

Operations


Maximum for Maximum forPollutant or pollutant property amonthlyp any I day Iaverage

k9/62.3 million Sm3


Cpp ............................. 0.553 0.301Lead (T) ........................................ 0.567 0.28Zinc .........................................(I 0.818 0.306Total phenols ............................... 0.617 0.215Oil and grease .................... 21.5 7.18TSS ............................................ 27.3 10.8ph ..... ..................................... .. (') (')

I Within the range of 7.0 to 10.0 at all times.

Maximum Maximum Annualfor any I or aver-day monthly age I

(mg/I)' (mg/I)'Copper (T) .......................... 0.77 0.42 .0.122Lead () ......................... 0.79 0.39 0.15QZinc (T) ................ 1.14 0.43 0.194Total phenols ..................... 0.86 0.3 0.144Oil and grease .................. 30 10 3.59TSS .................................. 38 15 7.18pH . ... . . .. (3) (3) (3)

k/162.3 million Sm3

(pounds per billion SCF) of air

'These concentrations muat be multiplied by the ratio of(0.086/x) where x is the actual normalized processwastawater flow (in gallons per 1,000 SCF of air scrubbed)for a specific plant.

3Within the range of 7.0 to 10.0 at all times.

(d) Grinding Scrubber Operations. Nodischarge of process wastewaterpollutants to navigable waters.

(e) Investment Casting.


Maximum f-r1

Maximum for

Pollutant or pollutant property any 1 dy4 monthlyaverage

k/1,000 kkg (pounds permillon pounds) of metalpoured

Copper ()..................................... 8.48 4.63Lead (1) ............ . 8.7 4.3Zinc () .......................................... 12.6 4.74Oil and grease ........................... 330 110TTS ............................................... 419 165Ph ................................................. . (') (')


Maximum Maximum Annual.. for Anafor any I aver-

day monthly ageaverage

(mg/I) 2 (mg/I) iCopper ( ) .......................... 0.77 0:42 1.87Lead (T) .......................... 0.79, 0.39 , 2.42Zinc (1) ................................ 1.14 0.43 2.97Oil and grease .................... 30 10 55.1TSS .................. 38 15 110pH . ............. () (3) (3)

lkg/I.,000 kkg (pounds per million pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(1.320/x) where x Is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant


(f) Melting Furnace ScrubberOperations.


Pollutant or pollutant p Maximum for Maximum foranrty I r1 day avmr


Copper () .................................... 1.81 0988Lead ) ......................................... 1.88 0.918Zinc .......................................... I 2.68 1.01Total phenols ................................ 2.02 0.706Oil and grease .............................. 70.6 23.5TSS . ...... 89.4 35.3pH .................................................. . (


Maximum Maximum Annualforary for a

day monthly aver-average

age'

(mg/I) ' (mg/I) 'Copper () ........................... 0.77 0.42 0.4Lead (1) . ... .. 0.79 0.39 0.518Zinc () ................................ 1.14 0.43 0.635Total phenols ............ 0.68 0.3 0.467Oil and grease ................... 30 10 11.7TSS . .............................. 38 15 23.5pH ................... (3) (3) (3)

'1I62.3 million Sm' (pound per billion SCF) of air

'These concentrations must be multiplied by the ratio of(0.282/x) where x is the actual normalized processwastewater flow (in gallons per 1.000 SCF of air scrubbed)for a specific plant.


(g) Mold Cooling Operations.



average

kg/1,000 kkg (pounds mil.-- lion pounds) of metal

poured

Copper M ..................................... 0.392 . 0.214Lead T) ......................................... 0.402 0.199Zinc T ............................. 0.58 0.219Oil and grease .................. :........ '15.3 5.09TSS .................... 19.3 7.63pH .. ............. .. ............................... ()

'Within the ?ange of 7.0 to 10.0 at all times.

Maximum Maximumfor any 1 for Annual

day monthly average'y Iaverage

Copper ( ) .........................Lead T .............................

(mg/) (mng/I)'0.77 0.42 0.08650.79 0.39 0.112

Maximumfor any 1

day

Maximumfor

monthlyaverage

Annualaverage

(mg/I) ' (mg/I)Zinc (I) .............................. 1.14 0.43 0.137Oil and. grease. ......... I 30 10 2.54TSS .......... * . . . . 38 15 5.09PH ................ ..... .......... (1 ) M)

'k/1000 kkg pounds per million pounds of metal poured.'These concentrations must be multiplied by the ratio of

(61/x) where x is the actual normalized process wastewaterflow (in gallons per 1,000 pounds of metal poured) for aspecific plant.'


§ 464.23 Effluent limitations guidelinesrepresenting the degree of effluent

reduction attainable by the application of..the best available technology economicallyachievable.

Except as provided in 40 CFR 125.30-125.32, any existing point source subjectto this subpart must achieve thefollowing effluent limitationsrepresenting the degree of effluentreduction attainable by the applicationof the best available technologyeconomically achievable, except thatnon-continuous dischargers shall not besuject to the maximum day andmaximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sm3 or lb/billionSCF of air scrubbed) effluent limitationsfor copper, lead, zinc, and total phenols.For non-continuous discharges, annualaverage mass limitations and maximumday and maximum for monthly averageconcentration (mg/I) limitations shallapply. Concentration limitations andannual average mass limitations shallonly apply to non-continuousdischargers.



Maximum MaximumPollutant or pollutant property for any 1 for monthly

aa verage

kg/1,000 kkg (pounds permillion pounds) of-metalpoured

Copper (T) ....................................... 0,0307 .0168Lead T) ..................(T..................... 0.0211 .0104Zinc ()............................................ 0.0303 .0116

Mxmm MaximumMaximum faor ~ Annual

for any 1 o Anaday monthly average'

average

(mg/I) 2 (mg/) a

Copper (T) ...................... 0.77 0.42 0.0068Lead (T)........................... 0.53 0.26 0.006inc M .......................... 0.76 0.29 0.0072

' kg/1.000 kk9 (pounds per million pounds) of metalpoured.eThese concentrations must be multiplied by the ratio of

(4.8/x) where x is the actual normalized process waste-waterow (in gallons per 1.000 pounds of metal poured) for a

specific plant


45256 Federal Register / Vol. 50, No. 210 ,/ Wednesday, October 30, 1985 / Rules and Regulations

BAT.EFFLUENT LIMITATIONS

!* Maximum Maximum forPollutant or pollutant.property for any I monthly

day I average


Copper T) ..... ........ 0.928 0.506Lead (' .......................................... 0.639 .0.314Zinc (T) .................... ................ 0.916 0.35

Maximum Maximumfor Annualay monthly average'

J ~ average

4mg/A)' !(rag/I),2

C pper () ................ . ! (0.77 0.42 0.205Lead (T) ............................. 0.53 0.26 '0.181Zinc (T) ............................. 0.76 0.29. 0.217

ig/1,000 kkg (pounds per million pounds) of metalpoured.

I These concentrations-must:be multiplied by the ratio of(145/x) where x is the actual normalized ,process waste-water flow (in gallons per 1,000.pounds of meal,poured)'fora specific plant

(c) Dust Collection ScrubberOperations.

'BAT EFFLUENT LIMITATIONS

Maxium fr Maaum orPollutant or pollutant propety ax 1 dafor monthlan ' y " .average

kg/62.3 million Sm'(pounds per billion 'SCF)of air scrubbed

Copper (T) ......... . 0.553 0.301Lead (T) ........... ........... 0.38 0.187Zinc (T) ......... ........... 0.545 0.208Total phenols ............................... ' 0.617 0.215

Maximum Maximum Annualfor any I for aver-

day monthly averaverage ag

,(mg/I) ' (mg/I) 2Copper (T) ........................... 0.77 0.42 0.122Lead (7) ............... ' 0:53 0.26 0.108Zinc (T) ........................... 0.76 0.29 0.129Total phenols ............. 0.86 0.3 0.144

kg/62.3 million Sm' (pounds per billion SCF) of airscrubbed

' Thesaeconfentrations must be multiplied by the ratio of(0.086/x) where x 4s the actual normalized processwastewater flow (in gallons.per 1.000 SCF of air scrubbed)for a specific plant.

(d) Grinding Scrubber Operations. Nodischarge of process -wastewaterpollutants to navigable waters.



i Maximum for I Mil oMaxmu Maximum for

Pollutant or pollutant property I any 1 day trontlyaverage

kg/1000 kkg (pounds .permillion *pounds) of metalpoured

Copper (T) ............... I 8.48 4.63Lead (T) .............. 5.84 2.86Zinc ( ) .......................................... 8.37 3.19

Maximum Maximumforany I for

ray monthlyaverage

Annualaver-age

(rg/I) (mg/I)'Copper (T) ........................... 0.77 0.42 1.87Lead (T) .............................. 0.53 0.26 1.65Zinc (T) ................................ 0.76 0.29 4.98

kg/1000 kkg (pounds per million pounds) of metalpoured.

' These concentrations must be multiplied by the ratio of(1,320/) where x Is 'the actual normalized procasawastewater flow (In gallons per 1,000 -pounds o.tpoured) for a specific plant.

'(f) Melting .Furnace. ScrubberOperations.

BAT EFFUENTU'IMITATIONS

M omum for Maximum forPollutant or pllutaniproperty any 1 day monthly

average

kg/62.3 ;million Sm5i

(pounds per billion SCF)Of air scrubbed

Copper () ............................... 1.81 0.988Lead (T) ................. 1.25 0.612Zinc (T) .... ..................... 1.79 0.673Total phenols ............................... 2.02 .0.706

Maximum Maximum Annualfor'any 4 for Aveu-

day monthly Aver-_________average

(mgTI)' (mg/I)'Copper IT) ................ a .......... 0.77 0.42 0.4Lead (T) ............................ 0.53 0.26 0.353Zinc .()................ 0.76 0.29 0.424Total phenols .......... 0.8 0.3 0.471

I kg/62.3 million Sm' (pounds per billion SCR) or airscrubbed.

' These concentrations must be multiplied by the ratio.of(0.282/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 SCF of air scrubbed)for a specific plant



maximum for IMaximum forPollutant or pollutant property ! a y monthlyIanylday average


Copper (') ..................................... 0.392 0.214Lead () ........................................ .0.27 0.132Zinc () ............................ 0.387 0.148

Maximum Maximum-for any for Annual

fay monthly averagedaay " 'average

kg/1,000 kkg poundsper million pounds of,metal poured

(mg/i)' "g/I0.77 0.42 0.065

Lead () ................... 0.53 026 0.0763Zinc (T) .......................... 0.76 0.29 0.0916

lkg/1,000 kkg (pounds per million pounds) of metalpoured.

2 These concentrations must be multiplied by the ratio of(61/x) where x is the actual normalized process wastewaterflow (in'gallons 'per 1,000 !pounds of .metal .poure6) for aspecific~plant.


.Any.new.source-subject to .thissubpart must radhieve the following new'source performance standards (NSPS),except that mon-continuous dischargersshall -not be -subject to 'the maximum dayand maximum for monthly average mass{hg/1,0oo kkg or lb/million lb of-metalpoured; kg/62.3 million Sm9 or lb/bilfionSCF of air scrubbed) 'effluent -standardsfor copper, lead, zinc, total phenols, oiland grease, and TSS. for non-continuous dischargers, annualaveragemass standards and maximum day and'maximum .for monthly averageconcentration (mg/l) standards -shallapply. Concentration standards :andannual 'average mass standards shallonly apply to non-continuousdischargers.


NSPS .

for M I . "maximu m for

Pollutant or Pollutant property Maximum fr Im --d.lany 1 day ' monthy.verage

k1l,000 kkg (pounds per'mIllon pounds) of metalpoured

Copper ( ............. 0.0307 0.0168"Lead (T) ................... ........ .. 0.0211 0.0104Zinc (T) ................... 0.0303 0.0116Oil and grease ............................. '1.2 0.399TSS ............................................... 0.598 0.479pH ........................................ ... () (')


Maximum Maximum Annual

for any 1 aver-

average , age,

(mg/I)' (mg/I)'Copper (T) ........................... 0.77 0.42 0.068Lead. ) .............................. 0.53 0.26 0.006Zinc () ............................... 0.76 0.29 0.0072Oil and grease ........... 30 10 0.199'TSS ..................................... i5 12 0.104PH ............................ ............ ( ) (1) (3)

kg/1,000 kkg (pounds per million pounds of metalpoured.

'These concentratiorls 'must be multiplied by the ratio f(4.8/x) where x is the actual normalized process wastewaterflow On gallons per 1,000,pounds of metal *poured) for ,aspecific plant.

3 Within the range of 7.0 to 10.0.at all times.

"(b) Direct Chill Casting Operations.

NSPS

Maximum for Maximum forPoilutant or pollutant property any 1 day monthly

average

kg/1,000 kkg (pounds per"million 'pounds) of metal,poured

Copper () .................................... . g.928 0.506Lead ( ) ......................................... '0.639 '0.314Zinc ) ......................................... .0.916 035Oil and grease ....................... '36.2 '12.1TSS ................................................ 18.1 14.5pH ................................................. (1) (')



Maximum Maximum Annualfor any I for avrfay monthly age-dayh' average

(mg/I)2= (mg/I)2

Copper -.......................... 0.77 0.42 0.205Lead (T) ............................ 0.53 0.26 0.181Zinc () .................... 0.76 0.29 0.217Oil and grease .................. 30 10 6.03TSS ........... . 15 12 3.13

' 1,000 kkg (pounds per million pounds of metalpoured.

2 These concentrations must be multiplied by the ratio of(145/x) where x is the actual normalized process wastewaterflow (in gallons per 1.000 pounds o1 metal poured for aspecific plant.



NSPS

Maximum Maximum Annualfor

for any 1 monthly aver.day average age I

(mg/I) a mg/I) ICopper (1) .......................... 0.77 0.42 1.87Lead (1) ............................. 0.53 0.26 1.65Zinc (") .......................... 0.76 0.29 1.98Oil and grease...........30 10 55.1TSS .................. . 15 12 28.6PH................... .. . . () (-) (2)

S kgl1.000 kkqi (pounda per million pounds of metal

2 These concentrations must be multiplied by the ratio of(1.320/k) where x is the actual normalized processwastewater How (in gallons per 1,000 pounds of metalpoured) for a specific plant.



NSPS

,.. Maximum for Maximum for .--mfoPluatopoltnprpry Maximum 1 eagi antl oltn r oltn rpr y I-da avergP la op l om onthly Pollutant or pollutant propey ny 1 f

I a 1ay average m

kg/62.3 million Sm 3(pounds per billion SCF)of air scrubbed

Copper (T) ..... 0.553 0.301Lead ( .) . .............. 0.38 0.167Zinc (T) ............... .."-.. . 0.545 0208Total phenols ........ 0.617 0.215Oil and grease ............................. 21.5 7.18TSS ........... ... .. 10.8 8.61pH .... . . . ...... .. t (1) (1)


Maximum Maximum Annualfor any .1 monthly avei-

day monthly age_____ average

(mg/I) 2 (mg/I)Copper (T) .......................... • 0.77 0.42 0.122Lead D.......... 0.53 0.26 0.108Zinc (T) .. .................... 0.76 0.29 0.129Total phenols ..................... 0.86 0.3 0.144Oil and grease--..-.. 30 10 3.59

S15 12 1.87.... ........ ................ (1) (3) V)-

t kc /23 million Sm ' (pounds per billion SCF) of airscru .bbed.

2 These concentrations must be multiplied by fe ratio of(0.086/x) where x is the actual normalized processwastewater flow (In gallons per 1.000 SCF of air scrubbed)for a specific plant.

Within the range of 7.0 to 10.0 at all times


(el Investment Casting.

NSPSximum for Maximum for

Pollutant or pollutant property [ day monthayI average

kg/l,000 kkg (pounds permillions pounds) of metal

poured

Copper (1)....... 8.48 4.63Lead ........................... 5.84 2.86Zinc (T) ........................................ 8.37 3.19Oil and grease ........................ 33 110TSS ............ .... 165 132,PH ................... (1) (1)



Copper (T) ................................... 1.81 0.988Lead ( ...................... ................... 1.25 0.612Zinc T) ......................................... 1.79 0.673Total phenols 2.02 0.706Oil and grease ............................ 70.6 23.5TSS ............................................... 35.3 28.2pH ........................................ . .... C() J I

'Within the range-of 7.0 to 10.0 at all times.

Maximum Annual

for any for aver.day- monthlyaverage age

(mg/I)2

(mg/I)2

Copper () .............. 0.77 0.42 0.4Lead ) ............................... 0.53 0.26 0353Zinc T) ............................... 0.76 0.29 0.424Total phenols ...................... 0.86 0.3 0.471Oil and grease .................... 30 10 11.8

TSS. . 15 12 6.12TSS .................... ..... *............ 1 2 6 1PH .......................... .) ( ) (3)

'ltg/62.3 million Sm' pounds per billion SCF) of airscrubbed.

'These concentrations must be multiplied by the ratio of(0.282/x) where a is the actual normalized process waste-water flow (in gallons per 1.000 SCF of air scrubbed) for aspecific plant.



NSPS

Maximum fo Maxium for,Pollutant or pollutant property Man 1 day monthly

I average

kg/1,000 kkg pounds permillion pounds of metalpoured

Copper M") .................................. 0.392 0.214Lead MT) ................................... 0.27 0.132Zinc M ...... 0.387 0.148

/ Oil and grease .............................. 15,3 5.09TSS ........ ......... ... 7.63 6,11p H .. . ........................................... t al ti

I Within the range lof 7.0 to 10.0 at alli imee.

Maximum Maximum AnnualfranImu forfor any 1 monthly a"veday average age

(mg/914 (mg/I)2

Copper () ...... 0.77 0.42 0.0865Lead (T) ................... 0.53 0.26 0.0763Zinc T) ................ 0.76 0.29 0.0916Oil and grease 30 10 2.54TSS . ........... .. 15 1 2 11.32pH ....................... () () (1)

£ kg/I.000 kkg (pounds per million pound) of metalpoured.

I These concentrations must be multiplied by the ratio of(61/x) where i is the actual normalized process waste-waterspcofin gallons per 1,000 pounds of metal poured) for a



Except as provided in 40 CFR 403.7and 403.13, any existing source subjectto this subpart which introducespollutants into a publicly ownedtreatment works must comply with 40CFR Part 403 and achieve the followingpretreatment standards for existingsources.

(a) Costing Quench Operations.

PSES

Maximum for Maximum forPollutant or pollutant p e ay I d monthly

average

kg/lO'00 kkg (pounds permillion pounds) of metalpoured

Copper T) .................................. .. 0.0307 0.0168Lead (T) .......... . . ..... 0.0211 0.0104Zinc () . . ........ 0.0303 0.0116TTO . ... . ..... 0.0335 0.0109Oil and grease (for altemate -"

monitoring) ............................. . 1 .2 0.399

(b) Direct Chill Casting Operations

PSES

n Maximum for Maximum forPollutant or POllUtant propetty I any I day monthly

.average


Copper ) ...... ......... 0.928 0.506Lead MT). . 0.639 0.314Zinc ") ................................... 0.916 0.35

(c) Dust Collection Scrubber

Operations.

PSES

IMaximum for aimumfo

Pollutant or pollutant property ianym1 day amunmh1

average

kg/62.3 million Sm2


Copper M ..................................... 0.552 1 0.301Lead .................. 0.38 0.187Zinc M.) . .............. 0.545 0.206Total phenols .................. 0.617 0.2151rO ............................ 1.65 0.54


PSES-Continued,

Maximum forMaximum forPollutant or pollutant property Manyu dar monthlyany I day average

ol and grease (for alternatemontoring) .............................. 21.5 7.18

(d) Grinding Scrubber Operations. Nodischarge of process wastewaterpollutants to a POTW.


PSES

Plt Maximum f Maximum forPollutant or pollutant property any 1 day I average

kgll,000 kkg (pounds permillion pounds) of metalpoured

Copper ..................................... 8.48 4.63Lead (). ................ 5.84 2.86Zinc T) ........ . ... 8.37 3.19TTO ...... .. . .. I 25.4 8.29Oil and grease for alternate

monitoring) ...... .................. 330 110


PSES

.Maximum for irufoPollutant or pollutant property mo nhxl

any sy average


Copper (T) ............... 6............. 1 0.988Lead M') ..................................... 1.25 0.612Zinc M ......................................... 1.79 0.673Total phenols .................. . ... 2.02 0.706TO ......................................... 5.41 1.77,Oil and grease (for alternate

monitoring) ................. 70.6 23.5

(g) Mold Cooling Operations.PSES

Mvaximum or Maximum forPollutant or pollutant property any 1 d ay monthlySany1 y average

kgJ! ,000 kkg (pounds permltion pounds) of metalpoured

Copper ) ................................... 0.392 0.214Lead (T) ............ .. ........ 0.27 0.132Zinc m...:........... ................ .. 0.387 0.148TTO .............................................. 0.428 0.14Oil and grease (for alternate

monitoring) .......... ................... 16.3 6.09


Except as provided in 40 CFR 403.7,any new source subject to this subpartwhich introduces pollutants Intopublicly owned treatment works mustcomply w ith 40 CFR Part 403 andachieve the following pretreatmentstandards for new sources.'


PSNS

Maximum for Maximum forany.lday monthlyPollutan or pollutan popert I 1 vrg

I verage

kg/1,000 kkg (pounds permillion pounds) of metalpoured .

CopperM ..................................... 0.0307 0.0168Lead () ....................................... 0.0211 0.0104Zinc M') ........................................ 0.0303 0.0116T O ................................................ 0.0335 0.0109Oil and grease (for alternate

monitoring) .................. ......... 1.2 0.399


PSNS

. Maximum forrmonthlyPollutant or pollutant property Maximum for imo

any y average

kg/i,000 kkg (pounds permillion pounds) of metalpoured

copper M .................................... 0.928 0.606Lead (T)........ ... 0.639 0.314Zinc (1)...................... 0.916 0.36

(c) Dust Collection Scrubber

Operations.

PSNSMaximum for Maximum for

Pollutant or pollutant property any f monthlyany 1 day average

kg/62.3 M|illon Sm3(pounds per billion SCF)of air scrubbed

Copper M .................................... '0.552 0.301Lead (M) ...................................... 0.38 0.187Zinc ............. .......... 0.545 0.208Total Phenols ............................. 0.617 0.216TTO.: ............. 1.65 0.54Oil and Grease (for alternate

monitoring ............................. R1.5, 7.18

(d) Grinding Scrubber Operations. Nodischarge of process wastewater.pollutants to a POTW.


PSNS

Pollutant or pollutant property Maximum for Maximum

P n p I a 1 dy average

kg/l.00 kkq (pounds per

million.pounds) of metal

poured

Copper T) 8.48 4.63Lead T) ...................... 5.84. 2.86Zinc M) ............................................ 8.37 3.19T7o ........................ : ....................... 25.4 8.29Oil and Grease (for alternate

monitoring ........... ... 330 110


PSNS

Pollutant or pollutant property Maximum for Maximum forany 1 day motlI' any dsy Iaverage


Copper (T) ................................ ' 1.81 0.988Lead T)....................... ............... 1.25 0.612Zinc (M" ................... .................... 1.79 0.673Total Phenols ........... 2.02 0.706T 'O ................................................ 5.41 1.77Oil and Grease (for alternate

monitoring ... ............. .. 70.6 23.5


PSNS

Maximum for Maximum foran h monthlyPollutant or pollutant property, any 1 day monthly

Iaverage


Copper IT) ..................................... 0.302 0.214Lead (T) ...................................... 0.27 0.132Zinc MT) ......................................... 0.387 0.148TTO ...................................... 0.428 0.14Oil and Grease (for alternate

monitoring . ......................... 15.3 , 5.09


Subpart C-Ferrous CastingSubcategory

§ 464.30 Applicability; description of theferrous casting subcategory.

The provisions of this subpart areapplicable to discharges to waters of theUnited States and to. the introduction ofpollutants into publicly owned treatmentworks resulting from ferrous castingoperations as defined in § 464.02(c).

§ 464.31 Specialized definitions.

For the purpose of this subpart:(a) Total Toxic Organics (770). TTO

is a regulated parameter under PSES(§ 464.35) and PSNS (§ 464.36) for theferrous subcategory and is comprised ofa discrete list of toxic organic pollutantsfor each process segment where it is-regulated, as follows:

(1) Casting Quench (§ 464.35(b) and§ 464.36(b)):23. chloroform (trichioromethane)

34. 2,4-dimethylphenol(2) DustCollection Scrubber

(§ 464.35(c) and § 464.36(b)):

1. acenaphthene23. Chloroform (trichloromethane)31. 2,4-dichlorophenol34. 2,4-dimethylphenol39. fluoranthene


44. methylene chloride(dichloromethane)

55. naphthalene64. pentachlorophenol65. phenol66. bis(2-ethylhexyl)phthalate67. butyl benzyl phthalate68. di-n-butyl phthalate70. diethyl phthalate71. dimethyl phthalate72. benzo (a)anthracene (1,2-

benzanthracene)76. chrysene77. acenaphthylene78. anthracene80. fluorene81. phenanthrene84. pyrene* (3) Investment Casting (§ 464.35(e)and § 464.36(e)):23.-chloroform (trichloromethane)44. methylene chloride* (dichloromethane)66. his (2-ethylhexyl) phthalate77. acenaphthylene-84. pyrene

(4) Melting Fuzrnace Scrubber(§ 464.35(f) and § 464.36(fl):23. chloroform (trichloromethane)31. 2,4-dichlorophenol34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

(dichloromethane)55. naphthalene65. phenol66. bis (2-ethylhexyl) phthalate67. butyl benzyl phthalate68. di-n-butyl phthalate72. benzo (a)anthracene (1.2-

benzanthracene)76. chrysene77. acenaphthylene78. anthracene80. fluorene81. phenanthrene84. pyrene

(5) Mold Cooling (§ 464.35(g) and§ 464.36(g)):23. chloroform (trichloromethane)34. 2,4-dimethylphenol

(6) Slag Quench (§ 464.35(h) and§ 464.36(h)):34. 2,4-dimethylphenol71. dimethyl phthalate

(7) Wet Sand Reclamation (§ 464.35(i)and § 464.36(i)):1. acenaphthene34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

(dichloromethane)55. naphthalene65. phenol66. bis (2-ethylhexyl) phthalate68. di-n-butyl phthalate70. diethyl phthalate71. dimethyl phthalate

72. benzo(a)anthracene rl.2-benzanthracene)

77. acenaphthylene:84. pyrene

(b) Cast Iron. An iron containingcarbon-in excess of the solubility in theaustentite that exists in the alloy at theeutectic temperature. Cast iron also isdefined here to include any iron-carbon.alloys containing 1.2 percent or morecarbon by weight.

(c) Ductile Iron. A cast iron that hasbeen treated while molten with a masteralloy containing an element such asmagnesium or cerium to induce theformation of free graphite as nodules orspherules, which imparts a measurabledegree of ductility to the cast metal.

..(d) Gray Iron. A cast iron that gives a.gray fracture due to the presence offlake graphite.

(e) Malleable lron. A cast iron made -by a prolonged anneal of white cast ironin which decarburization orgraphitization, or both, take place toeliminate some or all of the cementite.Graphite is present in the form of tempercarbon.

(f) Steel. An iron-base alloycontaining carbon, manganese, andoften other alloying elements. Steel isdefined here to include only those iron-carbon alloys containing less than 1.2percent carbon by weight.

(g) The "primary metal cast" shallmean the metal that is poured in thegreatest quantity at an individual plant.

(h) Multiple Ferrous Melting FurnaceScrubber Configuration. A multipleferrous melting furnace scrubberconfiguration is a configuration wheretwo or more discrete wet scrubbingdevices are employed in series in asingle melting furnace exhaust gasstream. The ferrous melting furnacescAibber mass allowance shall be givento each discrete wet scrubbing devicethat has an associated wastewaterdischarge in a multiple ferrous meltingfurnace scrubber configuration. Themass allowance for each discrete wetscrubber shall be identical and based onthe air flow of the exhaust gas streamthat passes through the multiplescrubber configuration.

(i) Discrete Wet Scrubbing Device. Adiscrete wet scrubbing device is adistinct, stand-alone device thatremoves particulates and fumes from acontaminated gas stream by bringing thegas stream into contact with a scrubberliquor, usually water, and from whichthere is a wastewater discharge.Examples of discrete wet scrubbingdevices are: Spray towers andchambers, venturi scrubbers (fixed andvariable), wet caps, packed bedscrubbers, quenchers, and orificescrubbers. Semi-wet scrubbing devices

where water is added and totallyevaporates prior to dry air pollutioncontrol are not considered to be discretewet scrubbing devices. Ancillaryscrubber operations such as fan washesand backwashes are not considered to'be discrete wet scrubber devices. Theseancillary operations are covered by themass limitations of the associatedscrubber. Aftercoolers are notconsidered to be discrete wet scrubbingdevices, and water discharges fromaftercooling are not regulated as aprocess wastewater in this category.§ 464.32 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best practicable control technologycurrently available.

Except as provided in 40 CFR 125.30-125.32, any existingpoint source subjectto this subpart must achieve thefollowing effluent limitationsrepresenting the degree'of effluentreduction attainable by-the applicationof the best practicable controltechnology currently available, exceptthat non-continuous dischargers shallnot be subject to the maximum day andmaximum for monthly average mass(kg/1,000kkg or lb/million lb of metalpoured; kg/1,000 kkg or lb/million lb ofsand reclaimed; kg/62.3 million Sm3 orlb/billion SCF of air scrubbed) effluentlimitations for copper, lead, zinc, totalphenols, oil and grease, and TSS. Fornon-continuous dischargers, annualaverage mass limitations and maximumday and maximum for monthly averageconcentration (mg/I) limitations shallapply. Concentration limitations Andannual average mass limitations shallonly apply to non-continuousdischargers.

(a) Casting Cleaning OperationsBPT EFFLUENT LIMITATIONS

Maoi ximu or mfor

P ollntxr pollutant property Man I a lug,

kg/1,000 kkg (pounds perrnilkn pounds) of metalpoured

Copper ) .................. 0.0129 0.0071Lead . ....................... 0.0353 0.074Zinc (T) .. ............ . 0.0656 0.025Oil and grease.e.. . 1.34 0.446TSs.. ... .. .. 1.7 0.67. -... . _ . (' I


Maximum Manimum Annuafor any I mont aver

day aontale age'average

(mgI) 2 (mgft ICopper 0;.............. . 0.29 0.16 0.0029Lead (T) ........... .... 0.79 0.39 0.0098Zinc (1) 1.47 0.56 00179O and grease-_ 30 10 0.223TSS 38 15 0.448


Ikg/.1,00 kkg (pounds per million pounds) of metal,poured.

2 These concentrations must be multiplied by the ratio of(5.35/x) where x is the actual normalized processwastewater flow (in gallons per 1.000 pounds of metalpoured) for a specific plant.


(b) Casting Quench Operations


Masm fo Maximum forPollutant or pollutant property an 1 dyor monthly

average


Copper T ................... 0.0138 0.0076Lead () .................... 0.0376 0.0185:Zinc (1) ............ 0.0699 0.0266Of and grease ............................. 1.43 0.476TSS ..................................... ....... 1.81 0.713pH .................................................. (1) (1)


Maximum Maximum Annualfor any I for aver

day monthly ager-___ay____average

(mg/I) 2 (mg/I) a

Copper () ........................... 0.29" 0.16 0.0031Lead (T) ........................... 0.79 0.39 0.0105Zinc (T) ................................ 1.47 0.56 0.019Oil and grease .................... 30 10 0.238TSS ...................................... 38 15 0.476PH...... ............. (3) (a) ()


=.These concentrations must be multiplied by the ratio of(5.7/x) where x is the actual normalized process wastwstarlow (in gallons per 1.000 pounds of metal poured) for a

specific plant.3.Withn the range of 7.0 to 10.0 at all times.



aimu fo Maxlmum for

Pollutant or pollutant property Maximu fo M mnhaverage

kg/62.3 million Sm a


Copper ) ................ .0.216. 0.12Lead (1) .................. ............... 0.593 0.293Zinc T) ...................... 1.1 0.421Total phenols ............................... 0.656 0.225Oil and grease ................ 22.5 7.51TSS ....................... 28.5 11.3PH .................................................. .(') ( )


Maximum Maximum Ahnualfor any I for averray monthly ageday average

(mg/I) (mg/I) I (mg/)Copper ) ........................... 0.29 0.16 0.0488Lead () .............................. - 0.79 0.39- 0.165Zinc (T)..: ..... ......... 1.47. 0.56 0.3Total phenols ...................... . 0.86 0.3 0.15Oil and grease ........... 30 10 3.76TSS .................. : ............. 38 . 15 7.51pH ................... (3) (3). (9)

k /6I.3 million Sm3 (pounds per' billion SCF) of air

2 These concentrations must be multiplied by the ratio of(0.039/x) where x is the actual -normalized processwastewater flow (in gallons per 1,000 SCF of air scrubbed)for a specific plant. , "

3 Within. the, range of 7,0. to 10.0 at all times.

(d) Grinding Scrubber Operations.. Nodischarge of process wastewaterpollutants to navigable waters.



MxmmfrMaximum forPollutant or pollutant propery n dy moi ,

average

kg/t,000 kkg (pounds permillion pounds) of metalpoured

Copper IT) ..................................... 3:19 I.76Lead (T) ......................................... 8.7 4.3Zinc (T) .......................................... 16.2 6.17Oil and grease .............................. 330 110TSS ........................... 419 165pH .................................................. (') (')


Maximum MaximumI-ay for Annual

any monthly aver-d ay average I

Copper T) ...........................Lead ) ...............................Zinc ( ) ................................Oil and grease ....................TSS ......................................pH .........................................

(mg/1) 10.290.791.47

3038(1)

(mg/I) a0.160.390.56

1015(3)

0.7162.424.41

55.1110(2)

Ikg/1,000 kkg (pounds per million pounds) of metalpoured.

RThese concentrations must be multiplied by the ratio of(1.320/x) where x Is the actual normalizedprocesswastewater flow (in gallons per 1,000 pounds otmetalpoured) for a specific plant.




Maximum for imumforPollutant or pollutant property Many f Maverx ge

Ie ny l s y

l"average

kg/62.3 million Sma(pounds per billion SCF)of air scrubbed

copper M . 1.02 0.561Lead M .r)...................... 2.77 1.37Zinc (T .................... 5:15 1.96Total phenols ................................ 3.01 1.05Oil and grease ............... 105 35TSS ................................................ 133 52.6pH . ........................ (,) (')


Maximum Maximum Annualfor any 1 for a

day monthly ae'average age

(mg/I) 2 (mg/) 2copper ) ........................... 0.29 0.16 0.228Lead M ........................ 0.79 0.39 0.771Zinc (T) ................................ 1.47 0.56 1.4Total phenols ...................... 0.86 0.3 0.701Oil and grease .................... 30 10 17.5TSS ....................................... 38 is 35PH .................. ) (3) (3)

.k1/62.3 million Sm3

(pounds per billion SCF) or airscrubbed.

2 These concentrations must be multiplied by the ratio of(0.42/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 SCF of air scrubbed)for a specific plant.


(g) Mold Cooling Operations.,


Maximum for Maximum forPollutant or pollutant property M 1 day mnthly

ayId average


CoppOr (T) ..................................... 0.04213 0.0236Lead IT) ...................................... . 0.117 0.0576Zinc (T) .......................................... 0.217 0.0827Oil and grease ....................... 4.43 1.48TSS ....... .............. .................... 5.61 2.22pH ................................................. .. (') 4')


Maximum Maximum Annualforanyl. formonthly age

d average

(mg/I) 2 (mg/I) ICoppor CT) ........................... 0.29 0.16 0.0098Lead (T) .............................. 0.79 0.39 0.0325Zinc (r) ............................. 1.47 0.56 0.0591Oil and grease.. 30 10 0.738TSS .................. 38 15 1.48PH .................. (5) (S) (2)

'kg/1,000 kkg (pounds per million pounds) of metalpoured

2These concentrations must be multiplied by the ratio of(17.7/x) where x is the actual normalizedprocesswastewater flow (in gallons per 1j000 pounds o metalpoured) for a specific plant.3


(h) S!ag Quench Operations.


Mxumxorimu o

Pollutant or pollutant property Maximum for Maximumforany I day monthly

average

kg/1,000 .kkg (pounds permillion pounds) of metalpoured

Cooper ..................................... 0.0527 0.0291Lead (T) ................... ; 0.144 0.0709Zinc (T) .......................................... 0.267 0.102Oil and grease .............................. 5.46 1.82TSS ...................... 6.91 2.73PH : ................................. (') (1)

'Within the range 7.0 to 10.0 at all times.

Maximum Maximum Annualfor any I for aver.

day - monthly age.average

(mg/I) (mg/I) 2Copper CT) ......................... 0.29 0.16 0.0118Lead ) .............................. 0.79 0.39 0.04Zinc MT) ............................. 1.47 0.56 0.0728Oil and grease .................... 1 30 10 0.909TSS .................................... 38 15 1.82PH ................................... .. (2) (s) (s)

'kg/1.000 kkg (pounds per million pounds) of metalpoured.

= These concentrations -must be multiplied by the ratio of(21.8/x) where x is the actual normalized process waster-water flow (in gallons per 1,000 pounds of metal poured) fora specific plant.

Within the range of 7.0 to 10.0 at all times. -

(i) Wet Sand Reclamation Operations.


Maiu fo Maximum forPollutant or pollutant property any 1 monthly

average

kg/1,000 kkg (pounds permillion pounds) of sandreclaimed

Cooper ..............................C)...... 0.217 0.12


BPT EFFLUENT LIMITATIONS-Continued

-Maximum fo Maximum forPollutant or pollutant property a 1 imonthlyny 1 day average

Lead (T).................... 0.59 0,291Zinc (T) . 0...... . 0,418Total phenols ................................ 0.642 0,224Oil and grease... ... 22.4 747TSS ...... ................. 28.4 11.2pH ........................ (( )


Maximum Maximum Annualfray1 forfor any 1 monthly aver-day aeae age

average

(mg/I) I (mg/t)Cooper )............. I ........... 0.29 0.16 0.0485Lead (T), .... ........... 0.79 0.39 0.164Zinc (T).i .............................. 1,4 0.56 0.299Total pint s ...................... 0.86 0.3 0.149Oil and grease ...... ..... 30 10 3.73TSS ....................................... 38 15 7.47p . ........"..... ..... ................... (3) (1) v )

'.i=.OO kkg (pounds per miflion pounds) of sand re-

2 These concentrations must be multiplied by the ratio of(89.5/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of sandreclaimed) for a specific plant.

3Within the range of 7.0 to 10.0 at alt times.

§ 464.33 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best available technology economicallyachievable.

Except as provided in 40 CFR 125.30-125.32, any existing point source subjectto this subpart must achieve thefollowing effluent limitationsrepresenting the degree of effluentreduction attainable by the applicationof the best available technologyeconomically achievable, except thatnon-continuous dischargers shall not besubject to the maximum day andmaximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/1,000 kkg or lb/million lb ofsand reclaimed; kg/62.3 million Sm" orlb/billion SCF of air scrubbed) effluentlimitations for copper, lead, zinc, andtotal phenols. For non-continuousdischargers, annual average masslimitations and maximum day andmaximum for monthly averageconcentration (mg/I) limitations shallapply. Concentration limitations andannual average mass limitations shallonly apply to non-continuousdischargers.

(a) Casting Cleaning Operations.(1) Applicable to plants that are

casting primarily ductile or gray ironand to plants that are casting primarilymalleable iron where greater than 3,557tons of metal are poured per year.


n or pMaximum for Maximum forPoll utt monthlypollutant property any 1day. average


Copper ().... ............................. 0.0129 o 0071Lead (T) ......................................... 0.0237 0.0116Zinc () .......................................... 0.0437 0.0165

Maximum Maximum Annualf- ay forfor any I monthly aver-

day average age

(mg/)' (mg/I)'Copper (T) .......................... 0.29 0.16 0.0029Lead T) ......................... 0.53 0.28 0.0067Zinc () ............................ 0.98 0.37 0.0116

'kg/1,000 kkg (pounds per million pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(5.35/x) where x ,is the actual normalized processwastewater flow (in gallons per 1.000 pounds of metalpoured) for a specific plant

(2) Applicable to plants that arecasting primarily steel to plants that arecasting primarily malleable iron whereequal to or less than 3,557 tons of metalare poured per year.


m f Maximum forPollutant or pollutant property MaxmUmny day monthly

ayIdy average


Copper T) ................................... 0.0129 0.0071Lead (T).......... 0.0353 0.0174Zinc (1) .......................................... 0.0656 0.025

Maximum Maximum AnnualMaxmu I foror monthly ae

average

(mg/I)' (mg/I )Copper () ............................ 0.29 0.16 0.0029Lead CT).................. 0.79 0.39 0.0098Zinc T) ......... & ..................... 1.47 0.56 0.0179


'These concentrations must be multiplied by the ratio of(5.35/x) where x is the actual normalized processwastewater flow (In gallons per 1,000 pounds of metalpoured) for a specific plant

(b) Casting Quench Operations.(1) Applicable to plants that are



Maiu fo Maximum forPollutant or pollutant property I any 1day J monthlya

average

kg/100 kkg (pounds permillion pounds) of metalpoured

Copper T .......... ................... 0038 0.0076Lead IT) ........................................ 0.0252 0.0124Zinc ......................................... 0.0466 0.0176

Maximum Maximum AnnualS for aver-for any I monthly age'day . average

(mgiI)2 (mg/I)'Copper T) ........................... 0.29 0.16 0.0031Lead M1) .............. * * . 0. . :53 0.26 0.0071Zinc T) ................................ 0.98 0.37 0.0124

k kg/1,000 kkg (pounds per million, pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of5.7/x) where x is.the actual normalized process wastewaterspec(in galons per 1,000 pounds of metal poured) for aspecific plant"

(2) Applicable to plants that arecasting primarily steel and to plants thatare casting primarily malleable ironwhere equal to or less than 3,557 tons of.metal are poured per year.


MxmmfrIMaxiuhm f'orPollutant or pollutant property M Imum for amonthlyany 1 day average


Copper (T) .............. 0.0138 0.0076Lead M .................. 0.0376 0.0185Zinc M ............... ....... 0.0699 0.0266


day monthty age,average

(mg/1)' (mg/I)'Copper (T) ... ............... 0.29 0.16 0.0031Lead (T) .............................. 0.79 0.39 0.0105Zinc () ................ ............... 1.47 0.56 0.019

kg/l000 kkg (pounds per' million pounds) of metalpoured.

' These concentrations must be multiplied by the ratio" of(5.7/x) where x is the actual normalized process wastewaterow (in gallons per 1,000 pounds of, metal poured) for a

specific plant.


(1) Applicable to plants that arecasting primarily ductile or gray ironand to plants that are casting primarilymalleable iron where greater than 3,557tons of metal are poured per year.


-- .M~um fr J nth-yPollutant or pollutant property Maximum r M aximum for

"d " average


Copper () ............ 0.218 0.12Lead (T) ............................ 0.398 0.195Zinc (T) .................. ............... 0.736 0.278Total phenols ........................ 0.646 0.225



(mg/I)' (mg/I)'Copper (T) .......................... 0.29 0.16 0.0488Lead T) ............................... 0.53 0.26 0.113Zinc .) . .............. . 0.98 0.37 0.195Total phenols ...................... 0,86 0.3 . 0.15

---- 4

45262 Federal Register / Vol. 50, No. 210/ Wednesday, October 30, 1985 / Rules and Regulations

sc kt...S million Sm' '(pounds per billion 7SCF) of air

These concentrations must be multiplied by the ratio of(0.09/a) where x is the actual normalized processwastewater flow (In gallons per 1,000 SCF of air scrubbed)for a specific plant

(2) Applicable to plants that arecasting primarily steel and to plants thatare .casting ,primarily malleable ironwhere equal lo or less than 3,557 tons ofmetal are poured peryear.


O -- Maximum forI Max mforPollutant or.pollutant property : oday . n'ey

a-., Ia average

kg/623 million Sm'(pounds per bIllion SCF)of ar scrubbed

Copper (T) .................................... t .2 0.12Lead (T) ......................................... . 3 .0.293Zinc (T) ............. . .1 0.421Total phenols .............................. 0.65 . 0.225

Maximum Maximum Annualforfor any I monthly aver-

day monthly age 'average

(mg/I)' (mg/I)'Copper ) ........................... 0.29 0.16 0.0488Lead (T) .............................. 0.79 0.39 0.165Zinc (T) .............. .1.47 0.56 0.3Total phenols ..................... 0.86 0.3 0.15

sc .3r o

million -Sm (pounds per billion SCF) of air

' These concentrations must be multiplied by the ratio of(0.09/x) where a is the actual normalized processwastewater flow (in gallons per 1,000 SCF of air scrubbed)for a specific plant


(e) Investment Casting.(1) Applicable to plants that are



.aan m o Maximum for

Pollutant or pollutant property many1t day monthlry

ayIdyIaverage


Copper T) . .............. 3.19 1.76Lead M ....... .... 5 5.84 2.86Zinc MIT)............................. 10.8 4.07

Maximum Maximum Annualfor," I forfor any 1 monthly aver-day average age'

(mg/f)' (mg/I)'copper T .......................... 0.29 0.16 0.716Lead M .............................. 0.53 0.26 1.65Zinc (T) ................... 0.98 0.37 2.86

;kg/1,000 kkg (pounds per million pounds) of metalpourd.

'These concentrations must be multiplied by the ratio of(1,320/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.

(2) Applicable to plants that arecasting primarily steel and to plants that

are casting primarily malleable ironwhere equal to or less than 3,557 tons ofmetal are poured per year.


Maiu frMaximum forPollutant or pollutant property any 1 montlmy

I average


Copper T) ...... .. 3.19 1.76Lead IT) .......... .. .............. 8.7 4.3Zinc .T) ........... ............... 16.2 8.17

Maximum Maximum Annualfor any I ot aver-

day . ohlt age'average

(mg/1)' .(mg/I)'Copper () ........ .. ....... .0.29 0.16 0.716Lead (T) ................... 0.79 0.39 2.42Zinc 1) ................ 1.47 0.56 4.41

,kg/1,000 kkg (pounds per million pounds) of metalpoureck' These concentrations must be multiplied by the ratio of(1,320/x) where x Is the actual normalizedpcwastewater flow (in gallons .per 1.000 pounds of metalpoured) for a s(Ieclfic plant.


(1) Applicable to plants that arecasting primarily ductile ,or gray ironand -to plants that are casting primarilymalleable iron where greater than 3,557tons of metal are poured per year.


M f Maximum forPollutant or pollutant property any 1 day average

kg/62.3 million Sm3(pounds per billion SCF)of air scrubbed

Copper (T) ..................................... 1.02 0.561Lead M ......................................... 1.86 0.911Zinc (T) ............. 3.44 1.3Total Phenols ............................... 3.01 1.05

Maximum Maximum Annualfor any 1 for

day monthly aver-day average age'

(mg/l) 2 (mg/I) 2

Copper (T) ........................ 0.29 0.16 0.228Lead T) .............................. 0.53 -0.26 0.526Zinc (T) . . . .. 0.98 0.37 0.911Total Phenols .................... 0.86 0.3 0.701

Ikg/62.3 million Sm' (pounds per billion SCF) of airscrubbed

2 These concentrations must be multiplied by the ratio of(0.42/x) where x is the actual normalized processwastewater flow (in gallons-per 1,000 SCF of air scrubbed)for a specific plant.

(2) Applicable to plants that arecasting primarily steel and to plants thatare casting primarily malleable ironwhere equal to or less than 3,557 tons ofmetal are poured per year.


Pollutant or pollutant property Maximum for Maximum forany 1 day monthl r

average

kg/62.3 million Sms

.(pounds per billion SCF)of air scrubbed

copper ) ................... .............. .02 0.561Lead .......... ....... 2.77 1.37

Total Phenols ............ 3.01 1.05

Maximum Maximum Annualforay 1 for aver-monthly age,day average eo

'(mgI)' (mg7IICopper (T) ......................... 0.29 0.16 0.228Lead,.I) .............................. 0.79 0.39 0.771Zinc (.)................. 1.47 0.56 1.4Total Phenols .................... 0.86 0.3 0.701

s kC6 2.3 million Sm' (pounds per billion SCF) of air2 These concentrations must be multiplied by the ratio of

(0.42/x) where x Is the actual normalized processwastewater flow (In gallons per 1,000 SCF of air scrubbed)for a specific plant

(g) Mold Cooling Operations.(1) Applicable to plants that are



Maximum forI Maximum forPollutant or pollutant property any 1 day average


Copper T).................................... 0.0428 0.0236Lead ) ..................................... 0.0783 0.0384Zinc M ..................... 0.145 -0.0546

Maximum Maximum Annuaforfor any 1 monthly aver-day average age'

(mgsI) (mg/1) 2

Copper T) .............. 0,29 0.26 0.0222Lead ( 1) ............................... 0.53 0.26 0.022Zinc (T) ................................ 0.98 0.37 0.0384


'These concentrations must be multiplied by the ratio of(17.7/x) where x is the actual normalized process waste-water flow (in gallons per 1,000 pounds of metal poured) fora specific plant.


Federal Register / Vol, 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulations 45263

BAT EFFLUENT LIMITATIONS-Continued

maximum for I Maximum for Maimu for Maximum forPollutant or pollutant property any 1 monthly Poilutant or pollutant property a average

eveany a day monthly


Copper (T).... . ..... 0 .,0428 0.0236Lead (1) .................. 0.117 0.0576Zinc () .......................................... 0.217 0.0827

Maximum Maximum Annualforfor any 1 monthly ever-day average age,

(mg/I) 2 (mg/I) •Copper (T) ........................... 0.29 0.18 0.0096Lead (T) ............................... 0.79 0.39 0.0325Zinc () ................................ 1.47 0.56 0.0591


2 These concentrations must be multiplied by the ratio of(17.7/x) where x is the actual normalized process waste-water flow (in gallons per 1,000 pounds of metal poured) fora specific plant.

(h) Slag Quench Operations.(1) Applicable to plants that are



Maximum MaximumMimm forPollutant or pollutant property for any 1 monthly

day average

kg/1,000 kkg (poundsper million pounds)of metal poured

Copper (T) ............................... ... 0 .052 I 0.0291Lead m .............. 0.6.............................. 0 . 0.0473Zinc (T).................. .. 0.178 o0 6 3

Maximtum Maximum Annual(orinyur I for Annuafor any monthly aver;

day average r.e

(mg/i) 2 (mg/I) 2

Copper T) ........................... 0.29 0.16 0.0118Lead T) ............................... 0.53 0.26 0.0273Zinc (T) ................................ 0.98 0.37 0.0473

SKg/1.000 kkg (pounds per million pounds) of metalpoured.

2 These concentrations must be multiplied by the ratio of(21.8/x) where x is the actual normalized processwastewater flow (in gallons per 1.000 pounds of metalpoured) for a specific plant



Maximum for Maximum forPollutant or pollutant poperty any 1 day monthly

average

kg/1,000 kkg (pounds permillion pounds) 01 metalpoured

Copper (T) .................................. 0.0527 0.0291Lead M1) ..................................... 0.144 0.0709

Zinc (T) ........................................ 0.267 0.102

Maximum Maximum Annualfor ae

day monthly agerday average a

(mg/I) a (mg/I) Icopper ) ............ 0.29 0.16 0.0118Lead () ............................... 0.79 0.39 0.04Zinc (T) ............................. 1.47 0.56 0.0728


2 These concentrations must be multiplied by the ratio of(21.8/x) where x is the actual normalized processwastewater flow (in gallons per 1.000 pounds of metalpoured) for a specific plant.

(i) Wet Sand Reclamation Operations.(1) Applicable to plants that are

casting primarily ductible or gray ironand to plants that are casting malleableiron where greater than 3,557 tons ofmetal are poured per year.


. Maximum forPollutant or pollutant property or mo

poIany1day average

kg/1,000 kkg (pounds permillion pounds) of sandreclaimed

Copper )................................ 0.217 0.12Lead T) ...................... 0.396 0.194Zinc ( ) .......................................... 0.732 0.276Total Phenols .............................. 0.642 0.224

Maximum Maximum Annualfor any I for aver-1a monthly age'I

y average

(mg/) a (mg/I) 2copper T) ............. 0.29 0.16 0.85Lead (T) ............... 0.53 0.26 0.112Zinc T) .............. . 0.98 0.37 0.194Total Phenols............ 0.86 0.3 0.149

kg/1000 kkg (pounds per million pounds) of sand re-claimed.

'These concentrations must be multiplied by the ratio of(89.5/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of sandreclaimed) for a specific plant



Maximum forPollutant or polutant property Maximum for monthlyany 1 day average

kg/1.000 kkg (pounds permillion pounds) of sendreclaimed

copper () .............. 0.217 0.12Lead T) ...... .. ............. 0.59 0.291Zinc (T) ......... 1.1.. 0.418Total Phenols ........................ 0.642 0.224

Maximumfor any 1

day

Maximumfor

monthlyaverage

Annualever-age'

(mg/) - (mg/I) 2Copper ) ........................ 0.29 0.16 0.0485Lead () ............................ 0.79 0.39 0.164ic ....... ............. 1.47 0.56 0.299

Total Phenols ...................... 0.86 0.3 0.149

' kg/1000 kkg (pounds per million pounds) of sand re-claimed.

2 These concentrations must be multiplied by the ratio of(89.5/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of sandreclaimed) for a specific plant.

§ 464.34 New source performance

standards.

Any new source subject to thissubpart must achieve the following newsource performance standards (NSPS),except that non-continuous dischargersshall not be subject to the maximum dayand maximum for monthly average mass(kg/1,00o kkg or lb/million lb of metalpoured; kg/1,000 kkg or lb/million lb ofsand reclaimed; kg/r62.3 million Sm 3 orlb/billion SCF of air scrubbed) effluentstandards for copper, lead, zinc, totalphenols, oil and grease, and TSS. Fornon-continuous dischargers, annualaverage mass standards and maximumday and maximum for monthly averageconcentration (mg/1) standards shallapply. Concentration standards andannual average mass standards shallonly apply to non-continuousdischargers.



NSPS

Maximum for Maximum forPollutant Or pollutant property any 1 day monthly

average


Copper M ..................................... 0.0129 0.0071Lead M ..) .................... 0.0237 0.0116Zinc (1) ............... 0.0437 0.0165Oil and grease .......... . 1.34 0.446TSS ........... ... 0.67 0.536pH ................................................. (') (')


Maximum Maximum 'Annualforfor any 1 monthl ver-

day a e age Iaverage

(mg/I) a (mg/I) 2Copper (T) ........................ 0.29 0.16 0.0029Lead M ............................ 0.53 0.26 0.0067Zinc (1) .......................... 0.98 0.37 0.0116Oil and grease ........ 30 10 0.223TTS ................................... 15 12 0.116pH ...... .... . ...... (1) (2) 1(2)

kg/l00 kkg (pounds per million pounds) of metalpoured.

2 These concentrations must be multiplied by the ratio of(5.35/x) where x is the actual normalized process



wastawater flow (in gallons per 1,000 pounds of metalpoured) foi a specific plant. -



NSPS

Maximum for Maximum forPollutant or pollutant property a 1 daY monthyay yIaverage


Copper (T) .................. 0.0129 0.0071Lead (T) .................... 0.0353 0.0174Zinc (T) ......................................... 0.0656 0.0025Oil and grease ................ - 1.34 0.446TSS ................................................ 1.7 0.67pH ....................... (') (')

W'thin the range of 7.0 to 10.0 at all times.

Maximum Maximum Annualfo ryI for v-for any 1 monthly aver-

day average age'

(mg/I) 2 (mg/I) -Copper () ........................... 0.29 0.16 0.0029Lead (T) .............................. 0.79 0.39 0.0098Zinc (T) .......... 1.47 0.56 0.0179Oil and grease...........30 10 0.223ITS .................. 38 15 0.446PH .................... (.) (3) (3)

,kgl.000 kkg (pounds per million pounds) of metalpoured.2 These concentrations must be multiplied by the ratio of

(5.35/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.




NSPS

P Maximum for Maximum fPollutant or pollutant property any 1 day monthly

Iaverage


Copper (T) .................................... 0.0138 0.0076Lead (T) ........................................ 0.0252 0.0124Zinc (T) ......................................... 0.0466 0.0176Oil and grease ............................. 1.43 0.476TSS ............................................... 0.713 0.571p.H .................................................. (') (')

IWithin the range of 7.0 to 10.0 at all times.

Maximum Maximum Annualfor any 1 fortoedany 1 monthlyday average age

(mg/I)' img/i)'Copper (T) ........................... 0.29 0.16 0.0031Lead (T) .............. 0.53 0.26 0.0071Zinc (1) ................................ 0.98 0.37 0.0124Oil and grease .................... 30 10 0.238TSS .................. 15 12 0.124PH ...................................... . (') (') )

Kg/1000 kkg (pounds per million pounds) of metalpoured.


3 These concentrations must be multiplied by the ratio of(5.7/x) where x is the actual normalized process wastewaterflow (in gallons per 1.000 pounds of metal poured) for aspecific plant


NSPS

Pollutant or pollutant property Maximum for' Maximum forany 1 day m nthty


Copper (T) ..................................... 0.0138 0.0076Lead (T) ......................................... 0.0376 0.0185Zinc T) .......................................... 0.0699 0.0266Oil and grease ................ 1.43 0.476TSS ....................... 1.81 0.713pH .................................................. (i) (i)



day monthly age Iaverage

(mg/I)' (mg/)'Copper () ........................... 0.29 0.16 0.0031Lead ) ............................... 0.79 0.39 0.0105Zinc () ..................... 1.47 0.56 0.019Oil and grease .................... 30 10 0.238TSS .................. 38 15 0.476PH ................... (') (') (')

,Kg/1000 kkg (pounds per million pounds) of metalpoured,

' These concentrations must be multiplied by the ratio of(5.7/x) where x is the actual normalized process wastewaterflow (in gallons per 1.000 pounds of metal poured) for aspecific plant.



(1) Applicable to plants that arecasting primarily ductible or gray ironand to plants that are casting primarilymalleable iron where greater than 3,557tons of metal are poured per year.

NSPS

Pollutant or pollutant property Maximjumfor Maximum forany 1 day eag

kg/62.3 million Sms


copper ) .................................... 0 .218 0.12Lead () ........................................ 1 0.398 0.195Zinc T ......................................... 0.736 0.278Total Phenols ................. 0.646 0.225Oil and grease ............................. 22.5 7.51TSS ............................................... 11.3 9.01pH ................................................. () (')



day monthly age'Iday______average

Copper (1) ..........................Lead (1) ..............................Zinc (T ...............................Total phenols .....................Oil and grease ...................TSS .....................................

(mg/I)'0.290.530.980.86

3015

(mg/I)'0.160.260.370.3

1012

0.04880.1130:1950.153.761.95



(mg/I)' (mg/I) 'PH . ..... (3) (3) (3)

*kg62.3 millions Sm' (pound per billion SCF) of airscrubbd.

Within the range of 7.0 to 10.0 at all times.'These concentrations must be multiplied by the ratio of

(0.09/x) where x is the actual normalized processwastewatar flow (in gallons per 1.000 SCF of air scrubbed)for a specific plant


NSPS

Maximu fo Maximum forPollutant or pollutant property a for M a monthlyfo

n y average

kg/62.3 million Sm3


Copper (T) .................................... 0.218 0.12Lead (T) ........................................ 0.593 0.293Zinc T) ......................................... 1.1 0.421Total phenols ............................... 0.656 0.225Oil and grease ............................. 22.5 7.51TSS ............................................... 28.5 11.3pH .................................................. ( ) (1)


Maximum Maximum Annualfor ay for aver-

ray 1 monthly ageIday average

(mg/I), (mg/I)'Copper (1) .......................... 0.29 0.16 0.0488Lead (1) ............................... 0.79 0.39 0.165Zinc (T) ....................... 1.47 0.56 0.3Total phenols ............ 0.86 0.3 0.15Oil and grease ...... ..... 30 10 3.76TSS ................................ 38 15 7.51PH ................... (3) (s) (s)

k/62.3 millions Sm3

(pound per billion SCF) of air

'Within the range of 7.0 to 10.0 at all times.'These conc,,trations must be multiplied by the ratio of

(0.09/) where is the actual normalized process wastewaterflow (in gallons per 1.000 SCF of air scrubbed) for a specificplant.


(3) Investment Casting.(1) Applicable to plants that are

casting primarily ductile or gray ironand toplants that are casting primarilymalleable iron where greater than 3,557tons of metal are poured per year.

NSPSMaximum forI Maximum for

me monthlyPollutant or pollutant property any 1 day average


Copper (T) .................................... 3.19 1.76Lead (T) ..................... : 5.84 2.86Zinc (T) ......................................... 10.8 4.07Oil and grease .............................. 330 110


NSPS-Contnued

Pollutant or Pollutant p Maximum for Maximum for

any I day monthlyaverage

TSS ............................... 165 132pH .................. ') ()

'Within the range of 7.0 to 10.0 at a.times.

Maximum Maximum Annualfor Anafor any 1 monthly aver-

day monthly age I________________ ______ average

(mg/0 a (mg/I) 2Copper () ........................... 0.29 0.16 0.716Lead MT) ........................... . 0.53 0.26 1.65Zinc (T) ............................ 0.98 0.37 2.86Oil and grease 30 10 55.1TSS .................. 15 12 28.6

...... . ...... . ......... (3) 11) (3)


' These concentrations must be multiplied by the ratio of(1,320/x) where x is the actual normalized processwastawater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.

Wrthhln the range of 7.0 to 10.0 at al times.


NSPS

Maximum for Maximum forPollutant or pollutant prolty any monthly

average


Copper T) . .... ......... 3.19 1.76Lead " ......................................... 8.7 4.3Zinc (1) .......................................... 16.2 6.17Oil and grease .............................. 330 110TSS .......... 419 165pH ................................................. (1) "

( )

Within the range of 7.0 to 10.0 at all lanes.

Maximum Maximum Annualfor any i for ever


(mg/1) ' (mg/)'Copper ....................... 0.29 0.16 0.716Lead () ............................. 0.79. 0.39 2.42Zinc T) ................................ 1.47 0.56 4.41Oil and grease .................... 30 10 55.1TSS .................. 38 15 110PH ................................. ....... (3) 1 (3) 1 (3)

Ikg/1,000 kkg (pounds per million pounds) of metalpoured.

' These concentrations must be multiplied by the ratio of(1 .320/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.

' Within the range of 7.0 to 10.0 st all times,

(0 Melting Furnace ScrubberOperations.

(1) Applicable to plants that arecasting primarily ductile or gray ironand to plants that are casting primarilymalleable iron where greater than 3,557tons of metal are poured per year.

NSPS

Maximum for Maximum for

Pollutant or pollutant property any 1 dy monthlyaverage

kg/62.3 million Sm(pounds per billion SOF)of air scrubbed

Copper (T) ................................. 1.02 0.661Lead () ........................................ 1.86 0.911Zinc ) ....................................... 3.44 1.30Total phenols ................................ 3.01 1.05Oil and grease ....................... 105 35TSS . .... 52.6 42.1pH.......... ...................... (1) (1)


Maximum Maximumm for Annual

for any I monthly averageday average .

(mg/l) 2 (mg/)'Copper (T) . . ......... 0.29 0.16 0.228Lead () ............................. 0.53 0.26 0.526Zinc (r) .............................. 0.98 0.37 0.911Total phenols ............ 0.86 0.3 0.701Oil and grease ......... 30 10 17.5TSS ..................................... 15 12 9.11pH ............................ ...... ... (3) ()) (')

sc=/23million Sm a (pounds per billion SCF) of air

'These concentrations must be multiplied by the ratio of(0.42/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 SCF of air.scrubbed)for a specific plant.

'Withn the range of 7.0 to 10.0 at all times.


NSPS

. Maximum forPollutant or pollutant property aximmfor mot hl or

any I c average


Copper (T) ..................................... 1.02 0.561Lead MT) ....................................... 2.77 1.37Zinc T) ......................................... 5.15 1.96Total phenola .................... .. 3.01 1.05Oil and grease .............................. . 105 35TSS ............................................. 133 52.6pH ............................................... . (') (,)


Maximum Maximumor any 1 for Annual

day monthly averageaverage

(mg/)' (mg/)'Copper (T) ......................... 0.29 0.16 0.228Lead (T) .............................. 0.79 0.39 0.771Zinc (T) ........................... 1.47 0.56 1.4Total phenols ...................... 0.38 0.3 0.701Oil and grease ................... 30 10 17.5TSS ......... .. 38 15 35PH ....................................... ( ) (3) 1 ( )

k/62.3 million Sm' (pounds per billion SCF) of airsrubbed

'These concentrations must be multipied by the ratio of(0.42/x) where a is the actual normalized process

-wastewater flow (in gallons per 1,000 SCF of air scrubbed)for a specific plant.


(g) Mold Cooling Operations.•(1) Applicable to plants that are

casting primarily ductile or gray irohand to plants that are casting primarily

malleable iron where greater that 3,557tons of metal are poured per year.

NSPS

Maim for IMam forPollutant or pollutant property Manymdumay monthlyany day average


Copper (T) ..................................... 0.0428 0.0236Lead (T) .......................................... 0.0783 0.0384Zinc T) .......................................... 0.0145 0.0546Oil and grease .............................. 4.43 1.48

-ss . ... 2.22 1.77pH ... .... .......... ....................... (') (1)

Within the range of 7.01to 10.0 at all times.



(mg/I)' (mg/) 'Copper M ......................... 0.29 0.16 0.0096Lead T) ......... 0.53 0.26 0.0222Zinc () ............... . 0.98 0.37 0.0384Oil and grease ................... 30 10 0.738TSS .................................... 15 12 0.384pH ................... (3) () (3)

kg/1.000 kkg (pounds per million pounds) of metal-poured.

•These concentrations'must be multiplied by the ratio of(1,320/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of melalpoured) for a specific plant.

Within the range o! 7.0 to 10.0 at all times.

(2) Applicable to plants that arecasting primarily steel and to plants thatare casting primarily malleable ironwhere equal to less that 3,557 tons ofmetal are poured per year.

NSPS

P Maximum for Maximum forPollutant or pollutant property any 1 day month

average


Copper ) .................................. (T)0.0428 0.0236Lead (T) ....................................... 0.117 0.0576Zinc M) ....................................... 0.217, 0.0827Oil and, grease .......................... 4.43 1.48TSS .............................................. 5.61 2.22pH ...... ...... . . . ... (.) 0

Within the range, of 7.0 to 16.0 at all times.

Maximum Mfxiur Annualfor any 1 monthly

day average age

(mg/i)' (mg/)'Copper M ................ 0.29 0.16 0.0096Lead M) ............................. 0.79 0.39 0.0325Zinc MT) ............... 1.47 0.56 0.0591Oil and grease ............ . 30 10 0.738TSS ............................. . 38 15 1.48pH ................... . . (3) (3) (3)

'kg/1,000 11kg (pounds per milioin pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(1.320/a) where x Is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.

SWithin the range of 7.0 to 10.0 at all times.


casting primarily ductile or gray ironand to plants that are casting primarily

45266 Federal Register / Vol. 50, No. 210 /,Wednesday, October 30, 1985 / Rules .and Regulations

malleable iron where greater than 3,557tons of metal are poured per year.

NSPS

malleable iron where greater than 3,557tons of metal are poured per year.

NSPSMaximum for Maximum for

Pollutant or pollutant property monthly Maximum for Maximum forany 1 d average Pollutant or pollutant property any 1 day monthlyaverage

kg/1.000 kkg (pounds permillion pounds)'of metalpoured

Copper (T) 0.0527 0.0291Lead (1) .................... 0.0964 0.0473Zinc () ................... 0.178 0.0673Oil and grease ............................. 5.46 1.82TSS ....................... 2.73 •2.18pH ............... (1) ()



day monthly ager-average

(mg/l)' (mg/)'Copper T) ........................... 0.29 0.16 0.0118Lead ) ................ 0.53 0.26 0. 0273Zinc (T) .............. 0.98 0.37 0.0473Of and grease.................. 30 10 0.909TSS .................. 15 12 '0.473pH ................... (') () (3)


' These concentrations must be multiplied by the ratio of(21.8/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.


kg/1,000 kkg (pounds permillion pounds)' of ,sandreclaimed

Copper (1) ................. 0.217 0.12Lead (T) ....................................... 0.396 0.194Zinc (T) ................ 0.732 0.276Total phenols . .......... . 0.642 0.224Oil and grease ............................ 22.4 7.47TsS ............................................... 11.2 8.96pH ....... ..... {


Maximum Maximum Annualfor Anafor any 1 o aver-

day monthly avraverage age

(mg/I)' (mg/I) .Copper (T) ........................... 0.29 0.16 0.0485Lead (T) .............................. 0.53 0.26 0.11 2Zinc T) ................................ 0.98 0.37 0.194Total phenols ...................... 0.86 0.3 0.149Oil and grease .................... 30 10 3.71TSS .................. 15 12 194pH .......................... .............. (3) (3) (3)

kg/1,000 kkg (pounds per million pounds) of sand re-claimed.

' These concentrations must be multiplied by the ratio of(89.5/x) where x is the actual normalized processwstewater flow (in alons or 1.000 posunds nf s~and

(2) Applicable to plants that are reclaimed) for a specifi plant.casting primarily steel and to plants that Within the range of 7.0 to 10.0 at all times

are casting primarily malleable iron (2) Applicable to plants that arewhere equal to or less than 3,557 tons of casting primarily steel and to plants thatmetal are poured per year. are casting primarily malleable iron

NSPS where equal to or less than 3,557 tons ofmetal are poured per year.

Maiu o Maximum forPollutant or pollutant property Maximuda for m o

average


Copper (T) ..................................... 0.0527 0.0291Lead T) .......... .. 0.144 0.0709Zinc T) ....................................... 0.267 0.102Oil and grease ............................. 5.46 - . 1.82T ............................................... 6.91 2.73PH ................................................ .. (1) ( I


Maximum Maximum

for any 1 for Annualday monthly average

average

(mg/I)' (mg/i)'Copper (T) .......................... 0.29 .0.16 0.0118Lead ) ................ 0.79 0.39 0.04Zinc ) ......................... 1.47 0.56 0,0728Oil and grease ................... 30 10 0.909TSS .................. 38 15 1.82pH .................. (S) (') ()

kg1000 kkg pounds per million pounds) of metal poured.These concentrations must be multiplied by the ratio of

(21.8/x) where x Is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.


(i) Wet Sand Reclamation Operations.(1) Applicable to plants that are

casting primarily ductile or gray iron.and to plants that are casting primarily

NSPSPollutant or pollutant property Maximum for Maximumfor

ony I day mnthlyaverage

kg/l,0oo kkg (pounds. permillion pounds) of sandreclaimed

Copper (T) .................................... 0.217 0.12Lead (T) ........... ............. 0.59 0.291Zinc (T) .......................................... 1.1 0.418Total phenols............................... 0.642 0.224Oil and grease .............................. 22.4 7.47TSS ................................................ 28.4 11.2pH ................................................. ( ) (I)

Within the range of 7.0 to at all times.



(mgI)' (mg/I)'Copper () .................. 0.29 0.16 0.0485Lead (T) ............................... 0.79 0.39 0.164Zinc () .................... 1.47 0.56 0.299Total phenols : ............. 0.88 0.3 . 0.149Oil and grease .................... 30 10 3.73TSS ................................... 38 15 7.47pH ......................................... () 0 1 (3)

'kg/1,000 kkg (pounds per million pounds) of sand re=claimed.

' These concentrations must be multiplied by the ratio of(89.5/x) where x Is the actual normalized. process.wastewater flow (in gallons per 1,000 pounds 'of sandreclaimed) for a specific plant.



Except as provided in 40 CFR 403.7and 403.13, any existing source subjectto this subpart which introducespollutants into a publicly ownedtreatment works must comply with 40CFR Part 403 and achieve the followingpretreatment standards for existingsources.


casting primarily ductile iron, to plantsthat are casting primarily malleable ironwhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

PSES

Pollutant or pollutant property Manmum for da mtlyoany I da y

average

kgll,000 kkg (pounds permillion pounds) of metalpoured

Copper M ..................................... 0.0129 0.0071Lead T) .................. 0...................... 0.0237 . 0.0116Zinc CT):..... .......... 0. 0.0437 0,0165

(2) Applicable to plants that arecasting primarily, steel, to plants that arecasting primarily malleable iron whereequal to or less than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron whereequal to or less than 1,784 tons of metalare poured per year.

PSES

' IMaximumfo Maximum forPollutant or pollutant property Many 1 day I mor nthl

PZOTY any 1day Iaverage.


Copper (T)..... ............................ 0.0129 0.0071Lead (T) ......................................... 0.0353 0.0174Zinc m ............................... 0.. 06 56 1 0.025


casting primarily ductile iron, to plantsthat are casting primarily malleable ironwhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal'arepoured per year.

Federal Register / Vol. 50, No. 210 / Wednesday, October 30, 1985 1 Rules and Regulations 45267

PSES PSES

• J Maximum forproperty Maximum for M axim Maximum for m

Pollutant or pollutant any 1 day navera Pollutant or pollutant property f1 day monthlyge average


Coppe M ...................... 0.......... 00138 0.0076Lead (T) ......... .. I 0.0252 0.0124Zinc T) ........... . . .. 0.0466 0.0176' O ....................................... 0.0257 0.00838

Oil and grease (for alternatemonitoring).................... 1.43 0.476

(2) Applicable to plants'that arecasting primarily steel, to plants that arecasting primarily malleable iron whereequal to or less than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron whereequal to or less than 1,784 tons of metalare poured per year.

PSES

Maiu frMaximum forPolutant or pollutant property any f monthly

I average

kg/1.000 kkg (pounds per•million pounds) of metalpoured

CoperM ........................... 0.0138 0.0076Lead M ......................................... 0.0376 0.0185Zinc () .......................................... 0.0699 0.0266TO ................. . .. 0.0257 0.00838

Oil and grease (for alternatemonitoring) ............................... 1.43 0.476


(1) Applicable to plants that arecasting primarily ductile iron, to plantsthat are casting primarily malleable ironwhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

" PSES

Maximum for Maximum forPollutant or pollutant propery Iany 1 day monthly

average

kg/62.3 million Sm3


CopperM ..................................... 0.218 0.12'Lead (T) ..................... 0.398 0.195:Zinc )...... . 0.736 0.278Total Ph6nols ............................... 0.646 0.225

o. .... ..... ......... 2.04 0.664oi and Grease (for alternate

monitoring) ............................ 22.5 7.51

(2) Applicable to plants that arecasting primarily steel, to plants that arecasting primarily malleable iron whereequalto or less than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron whereequal to or less than 1,784 tons of metalare poured per year.

kg/62.3 million Sm3(pounds per billion SCF)of air scrubbed

Copper (T) ............................... 0.218 0.12Lead (T) ....................................... 0.593 0.293Zinc (T) ......................................... 1.1 0.421Total Phenols ............................... 0.656 0.225To ............................................... 2.04 0.664Oil and Grease (for alternate

monitoring) ............................... 22.5 7.51



casting primarily ductile ijon, to plantsthat are casting primarily malleable ironwhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

PSES

MaxmumforMaximum forPollutant or pollutantl property any

a yor amonthly

aqMNy a average


Copper ( T.................... 3.19 1.76Lead ().... ................................... . 5.84 2.86Zinc T) .......................... * .............. . 10.8 4.07TTO . ...... 13.2 4.3Oil and Grease (for altemal

monitoring) ................................ 330 110

(2) Applicable to plants that arecastinlg nrimartlvl Rtelf itl. nlnts that aret

are poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

PSES

Maximum for Maximum forPollutnt or pelant propt any 1 day monty

average

kg/62.3 million Sms(pounds per billion SCF)of air scrubbed

Copper (T) .......................... 1.02 0.561Lead T) ........................................ 1.86 0.911zinc.(T) ..................................... 3.44 1.30Total phenols ................................ 3:01 1.05TO .............................................. . 8.34 2.73

Oil and grease (for alternatemonitoring) ............................. 105 35

(2) Applicable to plants that arecasting primarily steel, to plants that arecasting primarily malleable iron whereequal to or less than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron whereequal to or less than 1,784 tons of metalare poured per year.

PSES

Maximum for Maximum forPollutant or pollutant property ydaym f monthlyan y 1 I average


Copper (T) .................................... 1.02 0.561Lead (1) ....................................... 2.77 1.37Zinc (T) ........................................ 5.15 1.96Total phenols ............ .......... 3.01 1.05TTO ..... .... ... 8.34 2.73Oil and grease (for alternate

monitoring) ............ ... 105 35

casting primarily malleable iron where (g) Mold Cooling Operations.equal to or less than 3,557 tons of metal (1) Applicable to plants that areare poured per year, and to plants that casting primarily ductile iron, to plantsare casting primarily gray iron .where that are casting primarily malleable ironequal to or less than 1,784 tons of metal where greater than 3,557 tons of metalare poured per year.. are poured per year, and to plants that

are casting primarily gray iron wherePSES greater than 1,784 tons of metal are

Maximum for poured per year.Pollutant or pollutant propery Maximum for monthrl

Iany 1 dy Iaverage PSES

kg/1,000 kkg (pounds permillion pounds) of metal

4 poured

Copper ................. ...... 3.19 1.76Lead (T) .................................... . 8.7 4.3Zinc (T) ........................................ . 16.2 6.17170 ............................. ................ 13.2 4.3Oil and Grease (for alternate

monitorng) ................ 330 110

Mamu frMaximum forPollutant or pollutant property any 1 day monthly

average

kg/1,000 kkg (pounds perbillion pounds) of metalpoured

Copper M ....................... . 0.0428 0.0236Lead T) ......................................... 0.0783 0.0384Zinc (T) ................... . .. 0.145 0.05461IO ............................................... . 0.0797 0.026

(f) Melting Furnace Scrubber Oil and grease (for alternateOperations. monitoring) ............. 4.43 1.48

(1) Applicable to plants that are

casting primarily ductile iron, to plants (2) Applicable to plants that arethat are casting primarily malleable iron casting primarily steel, to plants that arewhere greater than 3,557 tons of metal casting primarily malleable ironwhere


greater than 3,557 tons of metal arepoured per year, and to plants that arecasting primarily gray iron where equalto or less than 1,784 tons of metal arepoured per year.

PSES

where greater than 3,557 tons of metalare poured per year, and to plants thatare casting gray iron where greater than1,784 tons of metal are poured per year.

PSES

Maximum for .Mmum for Pollutant or pollutant property Maximum for Maximum forPollutant or pollutant property n 1 monly

average

a

kg/1,000 kkg (pounds perbillion pounds) of metalpoured

Copper (T) ......... . .. 0.0428 0.0236Lead (T) ......................................... 0.117 .0.0576Zinc T) ..................... 0.217 0.0827TTO ............................................... 0.0797 0.028Oil and grease (for alternate

monitoring) ................................ 4.43 1.48


casting primarily ductile iron, tO plantsthat are casting primarily malleable ironwhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

PSESJMaximum for JMaximum fr

Pollutant or pollutant property Many f d monthlym% averg

SanylIy r arge


Copper (T) .................................. 0.0527 0.0291Lead T) ......................................... 0.0964 0.0473Zinc ) .......................................... 0.178 0.0673TTO .......... . .. 0.0257 0.00838Oil and grease (for alternate

monitoring) ............................... 5.46 1.82.


PSESMaximum for Maximum for

Pollutant or pollutant proparty any 1 day maverage


Copper 1) ..................................... 0 0.0527 0.0291Lead (T) ......................................... 0.144 0.0709Zinc (1) ......................................... 0267 0.1021ro ................................................ 0.0257 "0.00838Oil and grease (for alternate

monitoring) ............................... 5.46 1.82

(i) West Sand ReclamationOperations.

(1) Applicable to plants that arecasting primarily ductile iron, to plantsthat are casting primarily malleable iron

kg/1,000 kkg (pounds permillion pounds) of sendreclaimed

Copper T) ................................... 0.217 0.12Lead (T) ....................................... 0.396 0.194Zinc ) ......................................... 0.732 0.276Total Phenols .............................. 0.642 0.224T0 .................. 1.18 0.388Oil and grease (for alternate -

monitoring) ............................... 22.4 7.47


PSESMaximum for Maximum for

Pollutant or pollutant property any 1 day mnthly

ay1dy average

kg/1,000 kkg .(pounds permillion pounds) of sandreclaimed

Copper T) ..................................... 0.217 0.12Lead (") ........................................ 0.59 0.291Zinc T) ......................................... 1.1 0.418Total Phenols ............................... 0.642 0.224TTO ............................................... 1.18 0.386Oil and grease (for alternate

monitoring) ........... . . .... 22.4 7.47


Except as provided in 40 CFR 403.7,any new source subfect to this subpartwhich introduces pollutants intopublicly'owned treatment works mustcomply with 40 CFR Part 403 andachieve the following pretreatmentstandards for new sources.



. PSNSMaiu fi'Maximum for

Pollutant or pollutant property axi monyany1da


Copper M ..................... 0.0129 0.0071.Lead .T)..................... 0.0237 0.0116.Zinc (T) ....................................... 0.0437 0.0165

(2) Applicable to plants that arecasting primarily steel, to plants that arecasting.primarily malleable iron whereequal to or less than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron whereequal to or less than 1,784 tons of metalare poured per year.

PSNS

Pollutant or pollutant Property Maximum for Maximum for'P omonthlyanyl. day 1average


copper M ........................... 0......... 00129 0.0071Lead (T) .... ........... : 0.0353 0.0174Zinc (T). .. . ....................... 0.0656 0.025



PSNSSMaximum fo .Maximum for,

Pollutant or pollutant property Many f ma thlya average

kg/1,000 kkg (pounds permitlion pounds) of metalpoured

Copper (T) ................................... 0.0138 0.0076Lead M ..................................... 0.0252 0.0124Zinc T) ......................................... 0.0466 0.0176TO ....................... 0.0257 0.00838Oit and Grease (for attenate

monitoring) ................................ 143 0.476

(2) Applicable to plants that arecasting primarily steel, to plants that arecasting primarily malleable iron whereequal to or less than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron whereequal to or less than 1.784 tons of metalare poured per year.

Federal Register / Vol. 50, No. 210 -/ Wednesday, October 30, 1985 / Rules and Regulations 45269

PSNS are poured per year, and to plants thatare casting primarily gray iron where

Maximum for Maximumo r greater than 1,784 tons of metal arePollutant or pollutant property any 1 day monthly

average poured per year.


Copper M ................. 0.0138 0.0076Lead (T) ......................................... 0.0376 0.0185Zinc (T) .................. 0.0699 0.0266TTO ......... .......................... : ..... .0257 0.0 3

.......... 0.05 0.00838Oil and Grease (for alternate

monitoring) ................................ 1.43 0.476


(1) Applicable to plants that arecasting primarily ductile iron, to plantsthat are casting primarily malleable ironwhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

PSNS

Maximum for Maximum for

Pollutant or pollutant property any i dayor, monthly

nydyIaverage

kg/62.3 million Sma


Copper ' ..................................... 0.218. 0.12Lead (T) ......................................... 0.398 0.195Zinc (T) ..................... 0.736 0.278Total Phenols ............................. 0.646 0.225TTO *-......... ...... .. 2.04 0.664Oil and Grease (for alternate

monitoring) ................................ 22.5 7.51


PSNS

Maximum for Maximum forPollutant or putant property any I day monthlyaverage

kg/62.3 million Sm,(pounds per billion SCF)

of axi scrubbed

Copper (T) .................................... 0.218 0.12Lead (T) ....................................... 0.593 0.293Zinc ( ) .......................................... 1.1 0.421Total Phenols .............................. . 0.656 0.225ro .................... .2.04 0.664

Oil and Grease (for alternatemonitoring) ................ . .22.5 7.51



dasting primarily ductile iron, to plantsthat are casting primarily malleable ironwhere greater than 3,557 tons of metal

PSNS

Maximum for Maximum forPollutant or pollutant property any I day monthly

average


Copper (T) ................................... 3.19 1.76Lead (T) ......................................... 5.84 2.86Zinc ) ................................ . 10.8 4.07TTO .............................................. . 13.2 4.3Oil and Grease (for alternate

monitoring) ................................ 330 110


PSNS

Maximum for Maximum forPollutant or pollutant property M day monthlyaverage


Copper M ..................................... 3.19 1.76Lead (T) ......................................... 8.7 4.3Zinc T) ...... ..... 16.2 6.17TTO ........ ............... 13.2 4.3Oil and Grease (for alternate

monitoring) ....... ......... 330 110


(1) Applicable to plants that arecasting primarily ductile iron, to plantsthat'are casting primarily malleable ironwhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

PSNS

are poured per year, and to plants thatare casting primarily gray i0on whereequal to or less than 1,784 tons of metalare poured per year.

PSNS

Pollu r Maximumr Maximum forPollutant or pollutant property any 1 da monthly

ay1dy average

kg/62.3 million Sm3


Copper( ..................................... O1.02 0.561.Lead (T) ......................................... 2.77 1.37Zinc (T) 5.15 1.96Total Phenols ................. 3.01 1.051o ........................ 8.34 2.73Oil and Grease (for alternate

monitoring) : ...................... 105 '35

(g) Mold Cooling Operations.(1) Applicable to plants that are


PSNS


Iaverage


Copper ) ........ .............. 0.0428 0.0236Lead (T) . .... 0.0783 0.0384Zinc ) .............. . ........... 0.145 0.0546

-TO . ... .... 0.0797 0.026Oil and Grease (for alternate

monitoring) .............................. 4.43 1.48


PSNSMaximum for M Maximum for

Pollutant'or petlant propery' Many 1 dayo monthly_ Mamufo Maimfraverage Pollutant or pollutant property Maximum for a monthly

. 1. .t aydyIaverage

kg/1,000 kkg (pounds perimillion pounds) of metalpoured

Copper M ............. 0.0428 0.0236Lead (T) ..... .. ............. 0.117 0.0576Zinc (T) ....... .... . ... 0.217 0.0827"TO ......................................... 0.0797 0.026Oil and Grease (for alternate -

monitoring) ............................... 4.43 1.48


casting primarily ductile iron, to plantsthat are casting primarily malleablb iron

kg/62.3 million Sm'(pounds per billion SC)of air scrubbed

Copper (T) ..................................... 1.02 0.561Lead (T) ......................................... 1.86 0.911Zinc MT) .................................... 3.44 1.3Total Phenols.. ............... 3.01 1.05TTO ............ ............ 8.34 2.73Oil and Grease (for alternate

monitoring) ................ 105 35

(2) Applicable to plants that arecasting primarily steel, to plants that arecasting primarily malleable iron whereequal to or less than 3,557 tons of metal

45270 Federal Register I Vol. 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulationswhere greater than 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron wheregreater than 1,784 tons of metal arepoured per year.

. PSNS

M.iu frMaximum forPollutant or pollutant property Many 1 day aver

an y average_


Copper M .................... 0.0527 0.0291Lead (T) ...................................... 0.0964 0.0473Zinc T) .......................................... 0.178 0.0673TTO ............................. 0.0257 0.00838Oil and grease (for alternate

monitoring) ................. 5.46 1.82

(2) Applicable to plants that arecasting primarily steel, to plants that arecasting primarily malleable iron whereequal to or less thai 3,557 tons of metalare poured per year, and to plants thatare casting primarily gray iron whereequal to or less than 1,784 tons of metalare poured per year.

PSNSMaximum for Maximum for

Pollutant or pollutant property any 1 day rmonthly

I I average

kg/1,000 kkgmillion pourpoured

Copper (r) ................................... 0.0527Lead (T)0...... .Zinc T) . .... 0.267Tro ........... ............ 0.0257Oil and grease (for alternate

monitoring) ................................ 5.48

(i) Wet Sand Reclamation Op

(1) Applicable to plants that acasting primarily ductile iron, tcthat are casting primarily mallewhere greater than 3,557 tons ofare poured per year, and to planare casting primarily gray irongreater than 1,784 tons of metalpoured per year.

PSNS

Maximum forPollutant or pollutant property any 1 day

kg/1,000 kkgmillion. poureclaimed

Copper ") .................................... 0.217Lead ).................................... 0.396Zinc T) ......................................... 0.732Total phenols ............................... 0.642TO .......... ................. 1.18

Oil and grease (for alternatemonitoring) ............................. 2Z4

(2) Applicable to plants thatcasting primarily steel, to plantcasting primarily malleable irotequal to or less than 3,557 tons

(pounds pernda) of metal

are poured per year, and to plants thatare casting primarily gray iron whereequal to or less than1,784 tons of metalare poured per year.

PSNS

Maxiu fr aximum forPollutant or pollutant property any 1 day averagnthly

kgll.000 kkf (pounds permillion pounds) of sandreclaimed

Copper M ....................................... 0.217 0.12Lead ) ......................................... 0.59 0.291Zinc T) .......................................... 1.10 0.418Total phenols ................ 0.642 0.224TTO ............................................... 1.18 0.386Oil and grease (for alternate

monitoring) ............................... 22.4 7.47


Subpart D-Zinc Casting Subcategory

§ 464.40 Applicability; description of thezinc casting subcategory.

The provisions of this subpart areapplicable to discharges to waters of theUnited States and to the introduction ofpollutants into publicly owned treatmentworks resulting from zinc castingoperations as defined in § 464.02(d).

0.0291 § 464.41 Specialized definitions.0.07090.102 For the purpose of this subpart:0.00838 (a) Total Toxic Organics (TTO). TTO1.8 is a regulated parameter under PSES

(§ 484.45) and PSNS (§ 44.46) for thezinc subcategory and is comprised of a

erOtions. discrete list of toxic organic pollutantsire for each process segment where it isplants regulated, as follows:

able ironametal (1) Casting Quench (§ 464.45(a) andfts that § 464.46(b)):

wvhere 21. 2,4.6-trichlorophenolare 22. para-chloro meta-cresol

31. 2,4-dichlorophenol34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

Maximum for (dichloromethane)monthlyaverage 65. phenol

66. bis(2-ethylhexyl) phthalate(pounds W 68. di-n-butyl phthalate

nds) of sand 70. diethyl phthalate

85. tetrachloroethylene"0.120.194 (2) Die Casting (§ 465.45(b) and0.276 § 464.46(b)):0.2240.386 1. acenaphthene

21. 2,4,6-trichlorophenol.4 22. para-chloro meta-cresol

24. 2-chlorophenolare 34. 2,4-dimethylphenols that are 44. methylene chloriden where (dichloromethane)of metal 55. naphthalene

65. phenol66. bis (2-ethylhexyl) phthalate68. di-n-butyl phthalate70. diethyl phthalate85. tetrachloroethylene86. toluene87. trichloroethylene

(3) Melting Furnace Scrubber(§ 464.45(c) and § 464.46(c)):31. 2,4-dichlorophenol34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

(dichloromethane)55. naphthalene65. phenol66. bis(2-ethylhexyl) phthalate68. di-n-butyl phthalate85. tetrachloroethylene,86. toluene87. trichloroethylene

(4) Mold Cooling (§ 464.45(d) and§ 464.46(d)):21. 2,4,6-trichlorophenol22. para-chloro meta-cresol31. 2,4-dichlorophenol34. 2,4-dimethylphenol39. fluoranthene44. methylene chloride

(dichloromethane)65. phenol66. bis(2-ethylhexyl) phthalate68. di-n-butyl phthalate70. diethyl phthalate85. tetrachloroethylene

§ 464.42 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best practicable control technologycurrently available.

Except as provided in 40 CFR 125.30-125.32, any existing point source subjectto this subpart must achieve thefollowing effluent limitationsrepresenting the degree of effluentreduction attainable by the applicationof the best practicable controltechnology currently available, exceptthat non-continuous dischargers shallnot be subject to the maximum day andmaximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sm3 or lb/billionSCF of air scrubbed) effluent limitationsfor copper, lead, zinc, total phenols, oiland grease, and TSS. For non-continuous dischargers, annual averagemass limitations and maximum day andmaximum for monthly averageconcentration (mg/i) limitations shallapply. Concentration limitations andannual average mass limitations shallonly apply to noncontinuousdischargers.


1 o. 210 / Wednesday, October 30, 1985 / Rules and Regulations452-70 Federal Register / Vol. 50,



Sproperty Maximum o Maximum for Maximum fr m forPollutant Or pollutant n y a y monthly Pollutant Pollutant property a y onth

any ay average I any I average


Copper M ..................................... 0.0344 0.0187Lead (M") .................... 0.0353 0.0174Zinc (1) .......................................... 0.0509 0.0192Oil and grease .............................. 1.34 0.446TSS ......... .............. 1.7 0.67pH ....................... C() 7...(()


Maximum aximum Annualor any 1 rfor

monthly aver-day average age -

(mg/1)1 (mg/1)'Copper T) ........................... 0.77 0.42 0.0076Lead -). ........... 0.79 0.39 0.0098Zinc M T .)................. 1.14 0.43 0.0121Oil and grease .................. 30 10 0.223TSS . ..... 38 15 0.446PH .................. ..... ............... (3) (3) (3)

'kg/1000 kkg (pound per million pounds) of metal poured.These concentrations must be multiplied by the ratio of

(5.35/x) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.


(b) Die Casting Operations.


Maximum for Maximum forPollutant or pollutant properly any 1 day I eragmonthly


Copper m.... ........ 0.0066 0.0036Lead () ...................................... 0.0068 0.0034Zinc (T) .......................................... 0.0098 0.0037Total phenols ................................ 0.0074 0.0026Oil and grease .............................. 0.259 0.0864TTS* .............................................. 0.328 0.13pH ............................................... .. C ') C')


Maximum Maximum Annualfor any 1 or aver-

average age

(mg/I)2 (mg/I)'Copper T) ........................ 0.77 0.42 0.0015Lead (T) ............................. 0.79 0.39 0.0019Zinc (r) ............................. 1.14 0.43 0.0023Total phenols .................... 0.86 0.3 0.0017Oil and grease .................. 30 10 0.0432TSS .................................. 38 15 0.0864pH .. ............ ....................... Vs, () (s)

'kg/1000 kkg (pound per milton pounds) of metal poured.' These concentrations must be multiplied by the ratio of

(1.04/x) where x is the actual. normalized processwastewater flow (in gallons per 1,000 pounds of metal"poured) for a specific planL

' Within the range:of 7.0 to 10.0 at all times.

(c) Melting Furnace Scrubber.Operations.

kg/62.3 millions Sm'(pounds per billion SCF)of air scrubbed

Copper T) ................. .. 1.56 0.852Lead (T) ......................................... 1.6 0.791Zinc ) .......................................... 2.31 0.872Total Phenols ................. 1.74 0.608Oi and grease ............ :.. 60.8 20.3TSS .............................. 77.1 30.4pH .................................................. (') (')


Maximum Maximum Annualfray1 for aeror any 1 monthly aver-day average age'

(mg/I) ' (mg/I) ICopper ) ........................... 0.77 0.42 0.345Lead (T) ............................... 0.79 0.39 0.446Zinc MT) ............................... 1.44 0.43 0.548Total Phenols ...................... 0.86 0.3 0.406Oil and grease .................... 30 10 10.1TSS ...................................... 38 15 20.3PH ......................................... (1) (3) (V )

I kg/62.3 million Sm' (pounds per billion SCF) of airscrubbed.

'These concentrations must be multiplied by the ratio of(0.243/x) where x is the actual normalized processwastewater flow (In gallons per 1,000 SCF of air scrubbedfor a specific plant.


(d) Mold Cooling Operations.


P Maximu f Maximum forPollutantorPollutantproperty any 1 day monthly

average

kg/1,000 kkg (pounds permillion SCF) of metalpoured

Copper ) ..................................... 0.304 0.166Lead () ......................................... 0.311 0.154Zinc () ................................... 0.449 0.17Oil and grease ............................. 11.8 3.94TSS .... .15 5.91pH .. .... .................... :*,* *** *.......... - (1)


Maximum Maximum Annualforfor any 1 monthly aver

day mt age 'average

(mg/I) ' (mg/I) 'Copper ) ........................... 0.77 0.42 0.067Lead M ............................... 0.79 0.39 0.0867Zinc ) .......... 1.44 0.43 0.106Oil and grease .................... 30 10 1.97TSS . ............ 38 15 3.94pH ...............,.... (3) (3) (1)

"kg/1,000 kkg (pounds per million pounds) of metalpoured.

' These concentrations must be multiplied by the ratio of(47.3/x) where x is -the actual! normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.


g 464.43 Effluent limitations guidelinesrepresenting the degree of effluentreduction attainable by the application ofthe best available technology economicallyachievable.

Except as provided in 40 CFR 125.30-125.32, any existing point source subjectto: this subpart must achieve thefollowing effluent limitations

BPT EFFLUENT LIMITATIONS representing the degree of effluentreduction attainable by the applicationof the best available technologyeconomically achievable, except thatnon-continuous dischargers shall not besubject to the maximum day andmaximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sm 3 or lb/billionSCF of air scrubbed) effluent limitationsfor copper, lead, zinc, and total phenols.For non-continuous dischargers, annualaverage mass limitations and maximum.day and maximum for monthly averageconcentration (mg/1) limitations shallapply. Concentration limitations andannual average mass limitations shallonly apply to non-continuousdischargers.



Maximum for

Pollutant or pollutant property Maximyum lot ai orlyayIdy monthlay1d-Iaverage

kg/l1.000 kkg (pounds permillion pounds) of metalpoured

Copper ) ............ 0.0344 0.0167Lead () .................... 0.0237 0.0116Zinc ) ....................................... 0.0339 0.0129

Maximum Maximum Annualmm forfor any 1 monthly aver-

day 'average age I

(mg/) (mg/I) 'Cooper ) .............. 0.77 0.42 0.0076Lead, M ............................. 0.53 0.26 0,0067Zinc (1) . ...... .. 0.76 0.29 0.008.

' kg/1,000 kkg (pounds per million pounds) of metal:poured' These concentrations must be multiplied by' the ratio o1(5.35/x) where x is the actua normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.



.Maximum foruloPollutant or pollutant property Man 1 day r o

any 1da average


Copper MT) .............. . 0.006 0.0036Lead T) ......................................... 0.0046 0.0022Zinc ) ....................................... 0.0066 0.0025Total phenols; .............................. . 0.0074 0.0026

Maximum Maximum, Annualfor any 1 for aver.

day monthly: age'average ag

(mg/I) ' (mg/I) aCopper (T,),. ......................... 0.77 0.42 0.0015Lead T) . ................. 0.53 0.26 0.0013Zinc )1............ 076 0.29 0.0016Total phenols .. 0.86 0.3 0.0017

'kg/1,000 kkg (pounds per million pounds) of metalpoured..

'These concentrations must be multiplied by the ratio of(1.04/x) where, x is the- actual normalized, process


wastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant

(c) Melting Furnace ScrubberOperations.


]Maximum for aimum f ,• Maximm forPollutant or pollutant property ] many 1 day Maverage


Copper (T) .................................... 1.56 0.852Lead () ......................................... 1.07 0.527Zinc (1) ..................................... 1.54 0.580Total phenolse ............................. 1.74 0.608


day monthly. age'.average

(mg/I) I (mg/I) 0Copper IT) ........................... 0.77 0.42 0.345Lead (T) ................ 0.53 0.26 0.304Zinc (T) ........................... 0.76 0.29 0.365Total phenols ............ 0.86 0.3 0.406

'kg/62.3 million Sm 3 (pounds per billion SCF) of airsrubbd

' These concentrations must be multiplied by the ratio of(0.243/) where x is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.



maximum for monthly averageconcentration (mg/) standards shallapply. Concentration standards andannual average mass standards shallonly apply to non-continuousdischargers.

(a) Casting Quench Qperations

NSPS

Maximum for I Maiu forPollutant or pollutant property any 1 day monthlyaverage


Copper (T) ..................................... 0.0344 0.0187Lead (T) ......................................... 0.0237 0.0166Zinc ( .......................................... 0.0339 0.0129Oil and grease .............................. 1.34 0.446TSS ............................................... 0.67 0.536pH ................................................. ( ) (1)


Maximum Maximum

u a for Annualfor any monthly average'

day average

(mg/I)' (mg/I)'Copper (T) ..................... 0.77 0.42 0.0076Lead () ........................... 0.53 0.26 0.0067Zinc ) ............................ 0.76 0.29 0.008Oil and grease ................ 30 10 0.2237SS ................................ 15 12 0.116pH ...................... . ............. ()

Maximum fo polMaximum p kg/1,000 kkg (pounds per million pounds) of metalPollutant or pollutant property l I fmony poured.

y average 'These concentrations must be multiplied by the ratio of(5.35/a) where x Is the actual normalized processwastewater flow (in gallons per 1,000 pounds of metal

kg/1,000 kkg (pounds per poured) for a specific plant.million pounds) of metal 3 Within the range of 7.0 to 10.0 at all times.poured

Copper IT) 0.304 0.166Lead M .............. ..... "0.209 0.103.n¢ (1)... ........ ..................... 03 . 0 f1Zinc CT)..... ... 0.3 0.114

Maximum Maximumfor any 1 for Annual

day monthly average'average

(mg/I)' (mg/I)'Copper () ............... 0.77 0.042 0.067Lead (7) . ..... 0.53 0.26 0.0591Zinc (T) ............................. 0.76 0.29 0.071


'• 'These concentrations must be multiplied by the ratio of(47.3/x) where x Is the actual normalized rocesswastewater flow (in gallons per 1,000 pounds of metalpoured) for a specific plant.


Any new source subject to thissubpart must achieve the following newsource performance standards (NSPS),except that non-continuous dischargersshall not be subject to the maximum dayand maximum for monthly average mass(kg/1,000 kkg or lb/million lb of metalpoured; kg/62.3 million Sm3 or lb/billionSCF of air scrubbed) effluent standardsfor copper, lead, zinc, total phenols, oiland grease, and TSS. For non-continuous dischargers, annual averagemass standards and maximum day and


NSPS

Maiu•o Maximum forPollutant or pollutant property Many 1 day I mo

ay1dyIaverage


Copper M .) 0.0066 0.0036Lead () .................................. 0.0046 0.0022Zinc (T) .......................................... 0.0066 0.0025Total phenols ................................ 0.0074 0.0026Oil and grease .......... . 0.259 0.0864TSS ............................................. 0.13 0.104pH ............... () (1)


Maximum Maximumfor n I for Annual

monthly averageaverage

(mg/)' (mg/I)'Copper T) ........... 0.77 0.42 "0.0015Lead .) ............ 0.53 0.26 0.0013Zinc IT) ........ 0.76 0.29 0.0016Total phenols .................. 0.86 0.3 0.0017Oil and grease ........... ... 30 10 0.0432TSS ........................... 15 12 0.0225pH: .......... ................. ......... () (3). (3)

lkg/1,000 kkg (pounds per million pounds) of metalpoured.

'These concentrations must be multiplied by the ratio of(1.04/x) where x is the actual normalized processwastewater flow (in gafons per 1,000 pounds of metatpoured) for a specific pant


(cl Melting Furnace ScrubberOperations.

NSPSMaximum for Maximum for

Pollutant or pollutant property any 1day montlyayIdy average

kg/62.3 million Sm,(pounds per billion SCF)of air scrubbed

Copper (T) .................... 1.56 0.852Lead MT ........................ 1.07 0.527Zinc M( ................ .--.. I 1.54 0.588Total phenols ................................ 1.74 0.608Oil and grease ................ 60.8 20.3TSS ............................................... 30.4 24.3pH .................................................. ( ) (')

-Within the range of 7.0 to 10.0 at all times.

Maximum MaximumMxi a I for Annual

day monthly average'average

(mg/I)' (mg/I)'Copper IT) ...................... 0.77 0.42 0.345Lead (T)............... 0.53 0.26 0.304Zinc T) ............ .............. 0.76 0.29 0.365Total phenols ................. 0.86 0.3 0.406Oil and grease ............... 30 10 10.1TSS ................................. 15 12 5.27pH ................................... (3) () 1 ()

lkg/62.3 million Sm ' (pounds per billion SCF) of airscrubbed.

'These concentrations must be multiplied by the ratio of(0.243/a) where x is the actual normalized processwastawater flow (in gallons per 1,000 SCF of air scrubbed)for a specific plant.

Within ithe range of 7.0 to 10.0 at all times.


NSPS

Maximum for Maximum forPollutant or pollutant property any 1 day averagnthly


Copper (T).................................... . 0.304 0.166Lead M ........................................ 0.209 0.103Zinc ( ) .......................................... 0.3 0.114Oil and grease .............................. 11.8 3.94TSS ......... ............... 5.91 4.73pH ................................................. (1) (1)


Maximumn MaximumMraI for Annualr any 1 monthly average'day average

(mg/)' (mg/) 'Copper () ....................... 0.77 0.42 0.067Lead T) .............. 0.53 0.26 0.0591Zinc T) .. ............ 0.76 0.29 0.71Oil and grease ................ 30 10 1.97TSS ................................ 15 12 1.03pH.. ................. (3) 1 () (')


'These concentrations must be multiplied by the ratio of(47.3/a) where x is the actual normalized processwastewater flow (in gallons per 1.000 pounds of metalpoured) for a specific plant



Except as provided in 40 CFR 403.7and 403.13, any existing source subjectto this subpart which introduces

Federal Register*/ Vol. 50, No. 210 / Wednesday, October 30, 1985 / Rules and Regulations 45273

pollutants into a publicly ownedtreatment works must comply with 40CFR Part 403 and achieve the followingpretreatment standards for existingsources.

(a) Costing Quench Operations.

PSES

Maximum fo Maximum forPollutant or pollutant property any 1 day monthly

average


Copper (1").. ............... 0.0344 0.0187Lead (T) .................... 0.0237 0.0116Zinc (T) ........................ 0.0339 0.0129ITO ................................ 0.093 0,0304Oil and grease (for alternate

monitoring) ................................ 1.34 0.446

(b) Die Costing Operations.

PSES

Maximum for Maximum

Pollutant or pollutant property Max 1 d for vmonthlyayIdy average

kg/1.000 kkg (pounds permillion pounds of metalpoured)

Copper (T) .................................... 0.0066 0.0036Lead (T) ......................... 0. .... ." 0.0046 0.0022Zinc (1) ........................................... 0.0066 0.0025Total phenols ................................ 0.0074 0.0026

TO ................................................ 0.0196 0.0064Oil and -grease for alternate

monitoring) ................................ 0.259 0.0864

(c) Melting Furnace Scrubber

Operations.

PSES

Maximum for Maximum forPollutantorpollutant proprty. any day monthly

average

kg/62.3 million -Sm3


Copper Mt)................... 1.0 0.852Lead () .................... 1.07 0.527Zinc (T) ......................................... 1.54 0.588Total phenols .............................. 1.74 0.608TTO ................................................ 3 95 1.29Oil and grease for alternate

monitoring) ................. 0.8 20.3


PSES

. Maximum forPollutant or pollutant property Maximum Maonthl

any 1 day average


Copper (T) ..................................... 0.304 0.166Lead (T) ......................................... 0.209 0.103Zinc (T) .......................................... 0.3 0.114170 .............................................. 0.821 0.268

Oil and grease for alternatemonitoring) ................................ 11.8 3.94


Except as provided in 40 CFR 403.7,any new source subject to this subpartwhich introduces pollutants intopublicly owned treatment works mustcomply with 40 CFR Part 403 andachieve the following pretreatmentstandards for new sources.


PSNS

Maxi Maximum forPollutant or pollutant property any 1 dar month yaverage


Copper (T) ................................ 0.0344 0.0187Lead (T) ......................................... 0.0237 .0116Zinc (T) .......................................... 0.0339 0.0129ITO ................................................ 0.093 0.0304Oil and grease (for alternate

monitoring) ................................ 1.34 0.446


PSNS

PSNS-Continued

Pollutant or pollutant property Maximum for airmmnthlyS" M a for Montmum

any Idy average

Total phenols ................. 0.0074 0.0026.ro . . .... . ......... 0.0196 0.0064

Oil and grease (for alternatemonitoring) ................................. 0.259 0.0864

(c) Melting Furnace Scrubber

Operations.

PSNS

Maximum for Maximum forPollutant or pollutant propert any. 1 day monthly

average

kg/62.3 million Sma(pounds per billion SCF)of air scrubbed

Copper M ..................................... 1.56 0.852Lead T) ......................................... - 1.07 .0.527Zinc () ..................... 1.54 0.588Total phenols ................................ 1.74 0.608TTO ...... .. . .. 3.95 1.29Oil and grease (for alternate

monitoring) ................................ 60.8 20.3


PSNS

Maximum for Maximum forPolutant or pollutant property any 1 day monthly

average


Copper () ..................................... 0.304 0.166Lead () ......................................... 0.209 0.103Zinc (T) .......................................... 0.3 0.114TTO ................................................ 0.821 0.268Oil and grease (for altemate

monitoring) .. . .. 11.8 3.94

§ 464.47 Effluent limitations guidelinesPollutant or pollutant property Maximum representing the degree of effluenty for monthlyany average reduction attainable by the application of

the best conventional pollutant controlkg/1,000 kkg (pounds per technology [Reserved].

million pounds) of metalpoured [FR Doc. 85-25252 Filed 10-29-85; 8:45 am]

Copper .............................. '00066 0.0036Lead (F) .................. 00046 0.0022Zinc T) ........................................... 0.0066 0.0025

BILLING CODE 6560-50-M

No. 210 Wednesday, October 30, 1985 Rules and Regulations ... · 10/30/1985 · No. 210 /...

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Transcript of No. 210 Wednesday, October 30, 1985 Rules and Regulations ... · 10/30/1985 · No. 210 /...