7/25/2014
CALCULATING PRODUCTION BASED
LIMITS
EPA REGION VI 30TH ANNUAL PRETREATMENT
WORKSHOP
AUGUST 6, 2014
Allen Gilliam
ADEQ State Pretreatment Coordinator
[email protected]
JUST SOME EXAMPLES OF PRODUCTION BASED
CATEGORICAL STANDARDS THAT HAVE TO BE
CONVERTED TO EITHER MASS- OR CONCENTRATIONBASED PERMIT LIMITS
• Kg/kkg (pounds per 1,000 lb) of product
• mg/kg (pounds per million pounds) of dross washed
• mg/off-kg (lb/million off-lbs) of aluminum rolled with
neat oils
• mg/off-kg (lb/million off-lbs) of extruded
• mg/off-kg (lb/million off-lbs) of aluminum cast
• kg/1,000 kkg (pounds per million pounds) of metal
poured
• kg/62.3 million Sm3 (pounds per billion SCF) of air
scrubbed
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40 CFR 465, Coil Coating Subpart B –
Galvanized Basis Material Subcategory
Pollutant or
pollutant
property
Chromium
Copper
Cyanide
Zinc
Pollutant or
pollutant
property
Chromium
Copper
Cyanide
Zinc
PSNS
Maximum for any 1
Maximum for monthly
day
average
mg/m2 (pounds per 1 million ft2) of area processed
0.13 (0.027)
0.052 (0.011)
0.44 (0.090)
0.21 (0.043)
0.07 (0.015)
0.028 (0.006)
0.35 (0.072)
0.15 (0.030)
PSNS
Maximum for any 1
Maximum for monthly
day
average
(pounds per 1 million ft2) of area processed
(0.027)
(0.011)
(0.090)
(0.043)
(0.015)
(0.006)
(0.072)
(0.030)
Need to know AREA PROCESSED in million
ft2 and VOLUME of process water
(Daily Max calcs)
IU says 10 million ft2 was processed over a 22 day period in
the last 6 months = 0.4545 Mil.ft2/day using 783 gal/day
(0.000783 MGD) during that same 6 month period.
1) Convert to lbs/day. Cr for example:
Max daily Categorical limit = 0.027 lbs/1 Mil.ft2
(0.4545 Mil.ft2/day) X (0.027 lbs/1 Mil.ft2) = 0.0123 lbs/day
2) Convert to mg/l = (lbs/day) =
.0123_____
(8.34)(MGD) (8.34)(.000783)
= 1.88 mg/l daily max limit for Cr
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SAME EXERCISE FOR MONTHLY AVG LIMIT
Given: 0.4545 Mil.ft2/day & 0.000783 MGD
1) Convert to lbs/day for Cr Max monthly average
Max for monthly average = 0.011 lbs/1 Mil.ft2
(0.4545 Mil.ft2/day) X (0.011 lbs/1 Mil.ft2) = 0.005 lbs/day
2) Convert to mg/l =
.005 _
(8.34)(.000738)
= 0.81 mg/l monthly avg limit for Cr
“BUILDING BLOCK” APPROACH USING CFR 464 – METAL
MOLDING AND CASTING’S SUBPART A – ALUMINUM
CASTING SUBCATEGORY
Who was asking about a Category’s subparts’
(subcategories’) subprocesses?
(a) Casting Cleaning Operations
PSES
Pollutant or pollutant
property
Copper (T)
Lead (T)
Zinc (T)
Maximum for any
Maximum for monthly average
1 day
kg/1,000 kkg (pounds per million pounds) of metal
poured
0.0771
0.0421
0.0791
0.039
0.114
0.0431
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AND MORE SUBPROCESSES FOR THIS ONE
SUBPART (SUBCATEGORY)
•
•
•
•
(b) Casting Quench Operations
(c) Die Casting Operations
(d) Dust Collection Scrubber Operations
(e) Grinding Scrubber Operations. No discharge of
process wastewater pollutants to a POTW
• (f) Investment Casting
• (g) Melting Furnace Scrubber Operations
• (h) Mold Cooling Operations
City and IU rep agreed only these 3 subprocesses
were present & discharging regulated W.W.
(b) Casting Quench
Pollutant or pollutant property
Copper (T)
Lead (T)
Zinc (T)
TTO
Oil and Grease (for alternate monitoring)
Maximum for any 1 day
Maximum for monthly average
kg/1,000 kkg (pounds per million pounds) of metal poured
0.0093
0.0051
0.0096
0.0047
0.0138
0.0052
0.029
0.0095
0.363
0.121
(c) Die Casting
Pollutant or pollutant property
Copper (T)
Lead (T)
Zinc (T)
Total Phenols
TTO
Oil and Grease (for alternate monitoring)
Maximum for any 1 day
Maximum for monthly average
kg/1,000 kkg (pounds per million pounds) of metal poured
0.0066
0.0036
0.0068
0.0034
0.0098
0.0037
0.0074
0.0026
0.0308
0.01
0.259
0.0864
(h) Mold Cooling Operations
Pollutant or pollutant property
Copper (T)
Lead (T)
Zinc (T)
TTO
Oil and Grease (for alternate monitoring)
Maximum for any 1 day
Maximum for monthly average
kg/1,000 kkg (pounds per million pounds) of metal poured
0.297
0.162
0.305
0.151
0.44
0.166
0.935
0.304
11.6
3.86
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DAILY MAX EXAMPLE CALCs FOR Cu
• (b) Casting Quench
Pollutant of Pollutant
Property
Max for any 1 day
Max for Monthly Avg
pounds per million pounds of metal poured
Copper (T)
0.0093
0.0051
• (c) Die Casting
Pollutant of Pollutant
Property
Max for any 1 day
Max for Monthly Avg
pounds per million pounds of metal poured
Copper (T)
0.0066
0.0036
• (h) Mold Cooling
Pollutant of Pollutant
Property
Max for any 1 day
Max for Monthly Avg
pounds per million pounds of metal poured
Copper(T)
0.297
0.162
“Givens”
• January to December ‘13 production & flow avgs:
– (b) Casting Quench: 0.0897 Mlbs/day poured
@ 0.005772 MGD
– (c) Die Casting: 0.0897 Mlbs/day poured @
0.000083 MGD
– (h) Mold Cooling: 0.0897 Mlbs/day poured @
0.002391 MGD
TOTAL flow from this facility = 0.00825 MGD
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CASTING QUENCH CALCs
For daily max:
Convert to lbs/day = (production in million lbs of
metal poured/day) X (standard in pounds per
million pounds of metal poured) =
Please download the presentation with answers after the workshop
Die Casting Calcs
For daily max:
Convert to lbs/day = (production in million lbs of
metal poured/day) X (standard in pounds per
million pounds of metal poured) =
Please download the presentation with answers after the workshop
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Mold Cooling Calcs
For Daily Max:
Convert to lbs/day = (production in million lbs of
metal poured/day) X (standard in pounds per
million pounds of metal poured) =
Please download the presentation with answers after the workshop
To the Dreaded Combined Wastestream
Formula in CFR 403.6(e)(1)(ii)
Where: MT=the alternative mass limit for a pollutant in the combined
wastestream
FT =The average daily flow (at least a 30-day average) through the combined
treatment facility (includes Fi, FD and unregulated streams)
Mi =the categorical Pretreatment Standard mass limit for a pollutant in the
regulated stream I
Fi =the daily flow (at least a 30-day average) of stream i to the extent that it is
regulated for such pollutant
FD = Flow of Dilution Streams (boiler blowdown, non-contact cooling
streams, stormwater, etc [IN THIS CASE FD = 0 gpd THEREFORE THE 2ND
PORTION OF THE ABOVE FORMULA IS 1]
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LET’S ADD ‘EM UP!
• Casting Quench = 0.000834 lbs/day Cu
• Die Casting = 0.00059 lbs/day Cu
• Mold Cooling = 0.027 lbs/day Cu
TOTAL = 0.0284 lbs/day Cu daily max from this
facility
Convert to mg/l using TOTAL IU flow of .00825 MGD:
Please download the presentation with answers after the workshop.
Now, it’s a simple matter of converting ALL the other
production based limits to concentration based
(b) Casting Quench
Pollutant or pollutant property
Copper (T)
Lead (T)
Zinc (T)
TTO
Oil and Grease (for alternate monitoring)
Maximum for any 1 day
Maximum for monthly average
kg/1,000 kkg (pounds per million pounds) of metal poured
0.0093
0.0051
0.0096
0.0047
0.0138
0.0052
0.029
0.0095
0.363
0.121
(c) Die Casting
Pollutant or pollutant property
Copper (T)
Lead (T)
Zinc (T)
Total Phenols
TTO
Oil and Grease (for alternate monitoring)
Maximum for any 1 day
Maximum for monthly average
kg/1,000 kkg (pounds per million pounds) of metal poured
0.0066
0.0036
0.0068
0.0034
0.0098
0.0037
0.0074
0.0026
0.0308
0.01
0.259
0.0864
(h) Mold Cooling Operations
Pollutant or pollutant property
Copper (T)
Lead (T)
Zinc (T)
TTO
Oil and Grease (for alternate monitoring)
Maximum for any 1 day
Maximum for monthly average
kg/1,000 kkg (pounds per million pounds) of metal poured
0.297
0.162
0.305
0.151
0.44
0.166
0.935
0.304
11.6
3.86
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7/25/2014
HINT:
BUILD A SPREADSHEET FOR THESE
TIME CONSUMING CALCS!!!!!
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