Inventory and costing of best available pollution control technologies for the iron and steel sector in Ontario

508 Pages·1992·12.5 MB·English

by  Hatch Associates

P^e^ SSLL'^'^Z.
STOPPING
WATER POLLUTION
AT SOURCE
ITS
MISA
Municipal/IndustrialStrategyforAboiement
INVENTORY AND COSTING OF BEST AVAILABLE
POLLUTION CONTROL TECHNOLOGIES FOR THE
IRON AND STEEL SECTOR IN ONTARIO
Ontario
•«•KlBWii«*>

ISBN 0-7778-3498-7
INVENTORY AND COSTING OF BEST AVAILABLE
POLLUTION CONTROL TECHNOLOGIES FOR THE
IRON AND STEEL SECTOR IN ONTARIO
Report Prepared By:
Hatch Associates Ltd.
2800 Speakman Drive
Mississauga, Ontario
Report Prepared For:
Program Development Branch
Ministry of Environment and Energy
FEBRUARY
1992
Cette publication technique
n'est disponible qu'en anglais.
Copyright: Queen's Printer for Ontario, 1992
This publication may be reproduced for non-commercial purposes
with appropriate attribution.
PIES 3322E02
PRINTEDON
BECYCLfDPAPER
Proprietary and registered trade names are used in this rejx)rt where appropriate to improve the clarity of
explanations or to define sources ofinformation. Thisshould not be construed as approval or
recommendation for use in Ontario, either on the part ofthe report's authors or the Ministry of
Environment and Energy. The Ministry recognises that the registered trade names remain the projjerty of
their registered owners.
Foreword
The Ontario Ministry of Environment and Energy retained Hatch
Associates to develop a database of technical design, operating,
performance and cost for the available pollution control
technologies, in-plant controls and best management practices of
each process subcategory of the Iron and Steel Sector.
This report includes assessment of five Best Available Technology
(BAT) models:
1. Best in Ontario
2. Best in U.S.A.
3. Best at selected world locations North America,
(
Germany, Japan and South Korea)
4. Technology train that produces non-lethal effluent
5. Technology train that achieves virtual elimination of
persistent toxic pollutants
The capital cost and operating & maintenance cost to apply each
BAT model to Ontario plants were developed.
During the preparation of this report, some data essential for
the development of effluent limits (i.e. process flows, cooling
water flows and performance levels) were not available. These
data were collected during the development of effluent limits.

TABLE OF CONTENTS
EXECUTIVE SUMMARY
i
INTRODUCTION
1.0 1
1.1 The MISA Initiative ... 1
1.2 Purpose of the Study 3
The Approach Taken 4
1.3
1.4 Costing Methodology .' 8
2.0 ONTARIO STEEL INDUSTRY SECTOR PROFILE 11
2.1 Introduction 11
2.2 Integrated Mills 14
2.2.1 The Algoma Steel Corporation, Limited (Algoma) 14
2.2.2 Dofasco Inc. (Dofasco) 17
2.2.3 SteIco Inc., Hilton Works (Steico Hilton) 22
2.2.4 Steico Inc., Lake Erie Works (Steico LEW) 26
2.3 Non-Integrated Mills, Mini Mills and Specialty Mills 30
2.3.1 Atlas Specialty Steels (Atlas) 30
2.3.2 Lake Ontario Steel Corporation (Lasco) 33
2.3.3 Ivaco Rolling Mills (Ivaco) 35
.
3.0 AVAILABLE DATA AND INFORMATION SOURCES 38
3.1 Introduction 38
3.2 Ontario Mill Initial Reports . . 38
3.3 EPA Development Documents and Regulations 39
3.3.1 Introduction 39
3.3.2 Process Categories 41
3.3.3 Costing and Economic Analysis 44
3.4 MISA Effluent Data 46
3.5 Environment Canada Treatment Facilities Performance Evaluation
Studies '. 47
3.6 Technical Literature Review 47
3.7 Ontario Industry Questionnaire and Responses 48
3.8 Mill Visits 49
3.8.1 Ontario Mills 49
3.8.2 United States Mills 49
3.8.3 Overseas Mills 51
1
3.9 Toxicity Data 52
i
3.9.1 Definition of Toxicity for Use in BAT #4 52
3.9.2 Ontario Toxicity Protocols 53
3.9.3 Toxicity Data References 53
4.0 SELECTION OF KEY CONTAMINANT PARAMETERS
FOR ASSESSMENT OF BAT OPTIONS 54
4.1 Review of MISA Data 54
4.2 Methodology of Parameter Selection For BAT Evaluation 54
. .
4.3 Incongruous Parameters for Further Evaluation 57
4.4 Parameters Selected for BAT Evaluation 61
4.5 Characteristics of Selected Parameters 68
4.5.1 Total Suspended Solids (TSS) 68
4.5.2 Oil and Grease 69
4.5.3 Ammonia (NH3) and Ammonium (NH^*) 70
4.5.4 Total cyanide 71
4.5.5 Phenolic Compounds (4AAP) 72
4.5.6 Benzene 73
.74
4.5.7 Benzo(a)pyrene
4.5.8 Naphthalene 74
4.5.9 Lead 75
4.5.10 Zinc 76
4.5.1 Chromium 77
4.5.12 Cadmium 78
4.5.13 Nickel 79
4.5.14 pH 80
. .
4.5.15 Toxicity 81
4.6 Toxicity of Selected Contaminant Parameters 81
5.0 MODEL BAT TECHNOLOGIES AND EFFLUENT CHARACTERISTICS 83
5.1 Methodology for Selection of BAT Technology 83
5.1.1 Introduction . • 83
5.1.2 Model BAT #1 Best in Ontario - Integrated Mills 88
5.1.3 BAT #2 Best in the USA 100
5.1.4 BAT #3 Best at Selected World Locations 107
5.1.5 BAT #4 Non-Lethal 110
5.1.6 BAT #5 Virtual Elimination of Persistent Toxics 110
5.1.7 Non-Integrated Mills -. 110
5.1.8 Model BAT Costing . 113