United472B States Environmental473B Protection 474BAgency Preliminary270B Review of the Metal Finishing Category April 2018 THIS PAGE INTENTIONALLY LEFT BLANK. U.S. Environmental Protection Agency Office of Water (4303T) 1200 Pennsylvani a Avenue, NW Washington, DC 20460 EPA 821-R-18-003 www.epa.gov/eg/metal-finishing-effluent-guidelines THIS PAGE INTENTIONALLY LEFT BLANK Table of Contents TABLE OF CONTENTS Page 1. INTRODUCTION ................................................................................................................ 1-1 2. SUMMARY OF 2015 STATUS REPORT .............................................................................. 2-1 2.1 Existing Metal Finishing ELGs ............................................................................. 2-1 2.2 2015 Status Report Summary of Findings ............................................................. 2-3 3. RECENT STUDY ACTIVITIES ............................................................................................ 3-1 3.1 Site Visits to Metal Finishing Facilities ................................................................. 3-1 3.2 Discharge Monitoring Report (DMR) and Toxics Release Inventory (TRI) Data Analysis ....................................................................................................... 3-1 3.3 Pollution Prevention (P2) Review ......................................................................... 3-5 3.4 Metal Products and Machinery (MP&M) Rulemaking ......................................... 3-6 3.5 Technical Conferences ........................................................................................... 3-7 3.6 Stakeholder Outreach ............................................................................................. 3-8 3.6.1 Pretreatment Coordinators .................................................................... 3-9 3.6.2 Industry and Trade Organizations ......................................................... 3-9 3.6.3 Other Stakeholders ................................................................................ 3-9 3.7 Other Regulation Review ....................................................................................... 3-9 4. RECENT STUDY FINDINGS ............................................................................................... 4-1 4.1 Site Visits to Metal Finishing Facilities ................................................................. 4-1 4.2 DMR/TRI Data Analysis ....................................................................................... 4-4 4.2.1 Industries under the Metal Finishing Category Contributing Top Pollutant Discharges in 2014 ................................................................ 4-4 4.2.2 Pollutant Analyses ................................................................................ 4-6 4.2.3 Unregulated Pollutant Analysis ............................................................ 4-7 4.2.4 Regulated Pollutant Analysis ................................................................ 4-8 4.2.5 Summary of Results and Conclusions .................................................. 4-9 4.3 Pollution Prevention (P2) Review ....................................................................... 4-10 4.3.1 Process Technology Controls and Alternatives .................................. 4-10 4.3.2 Alternative Process Chemistries ......................................................... 4-11 4.3.3 Wastewater Recycling, Materials Recovery, and Treatment Alternatives ......................................................................................... 4-11 4.3.4 P2 Initiatives and Resources for the Metal Finishing Industry ........... 4-12 4.4 Metal Products and Machinery (MP&M) Rulemaking ....................................... 4-16 4.4.1 Subcategories Containing Metal Finishers ......................................... 4-16 4.4.2 Pollutants of Concern .......................................................................... 4-18 iii Table of Contents TABLE OF CONTENTS (Continued) Page 4.4.3 P2 Practices and Wastewater Treatment Technologies Identified Between the Metal Finishing and MP&M Rulemakings .................... 4-19 4.4.4 Technology Bases and Proposed ELGs .............................................. 4-20 4.4.5 Key MP&M Findings for the Metal Finishing Industry ..................... 4-26 4.5 Technical Conferences ......................................................................................... 4-26 4.5.1 NASF SUR/FIN® Conference ........................................................... 4-27 4.5.2 NACWA Conferences ........................................................................ 4-28 4.6 Stakeholder Outreach ........................................................................................... 4-28 4.6.1 Local Control Authorities and EPA Regional Pretreatment Coordinators........................................................................................ 4-28 4.6.2 Industry and Trade Organizations ....................................................... 4-29 4.6.3 Other Stakeholders .............................................................................. 4-30 4.7 Other Regulations and Initiatives Affecting the Metal Finishing Industry.......... 4-30 4.7.1 Federal Regulations ............................................................................ 4-30 4.7.2 Other Environmental Directives ......................................................... 4-32 4.7.3 Customer Specifications and Certifications ........................................ 4-34 5. PRELIMINARY REVIEW CONCLUSIONS ........................................................................... 5-1 6. QUALITY ASSURANCE ..................................................................................................... 6-1 6.1 Project Objectives .................................................................................................. 6-1 6.2 Data Sources .......................................................................................................... 6-1 6.3 Data Quality Objectives and Criteria ..................................................................... 6-1 6.4 Data Quality Evaluation ......................................................................................... 6-3 6.4.1 Site Visits to Metal Finishing Facilities ................................................ 6-4 6.4.2 Government Databases with Discharge Data (DMR and TRI) ............ 6-4 6.4.3 Conference Proceedings, Peer-Reviewed Journal Articles, Other Academic Literature ............................................................................. 6-4 6.4.4 Existing Government Publications and Supporting Information .......... 6-5 6.4.5 Information Obtained from Industry, Vendors, and Trade Associations .......................................................................................... 6-5 7. REFERENCES .................................................................................................................... 7-1 Appendix A: SIC and NAICS Codes for the Metal Finishing Industry Appendix B: Pollution Prevention (P2) Practices Identified in EPA’s P2 Review iv List of Tables LIST OF TABLES Page Table 2-1. Unit Operations Regulated by ELGs for the Metal Finishing Category .................... 2-1 Table 2-2. Regulated Pollutants and ELG Limits for the Metal Finishing Category .................. 2-2 Table 3-1. Summary of Analyses of the DMR and TRI Data Presented in this Report .............. 3-4 Table 3-2. Keywords Used for Identifying Metal Finishing TRI P2 Practices ........................... 3-5 Table 3-3. Keywords Used for Literature Search of Metal Finishing P2 Practices ..................... 3-6 Table 4-1. List of Metal Finishing Site Visits.............................................................................. 4-1 Table 4-2. Top Metal Finishing Dischargers by SIC and NAICS Codes Identified from 2014 DMR and TRI Data ........................................................................................... 4-5 Table 4-3. Top Pollutants by TWPE Based on Reported DMR Data, 2010 – 2014 .................... 4-6 Table 4-4. Top Pollutants by TWPE Based on Reported TRI Data, 2010 – 2014 ...................... 4-7 Table 4-5. Summary of DMR and TRI Concentration Data for Unregulated Pollutants Compared to Baseline Values .................................................................................... 4-8 Table 4-6. Summary of DMR and TRI Concentration Data for Regulated Pollutants Compared to Metal Finishing ELGs and Relevant LTAs .......................................... 4-9 Table 4-7. Major Regional P2 Technical Assistance Websites ................................................. 4-14 Table 4-8. Pollutants Considered for the Proposed MP&M Regulation for Metal-Bearing Subcategories ........................................................................................................... 4-18 Table 4-9. Practices and Technologies Identified in the 2001 MP&M TDD and Not Discussed in the 1983 Metal Finishing TDD ........................................................... 4-20 Table 4-10. Proposed MP&M BPT/BAT Limits and Promulgated Metal Finishing BPT and BAT Limits ....................................................................................................... 4-22 Table 4-11. Proposed P2 Alternatives for Metal Finishing Job Shop Subcategory................... 4-23 Table 6-1. Data Quality Criteria Summary .................................................................................