SUPPLEMENT TO THE SITE INSPECTION FORM
Manufacture of Organic Chemicals and
Plastics and Synthetic Fibers
COMPANY NAME _____________________________________________________________
1.
THE ORGANIC CHEMICALS MANUFACTURING INDUSTRY HAS BEEN DIVIDED INTO
DIFFERENT SUBCATEGORIES BASED ON TYPE OF PRODUCT MADE BY THE
INDUSTRY AND THE TYPE OF WASTEWATER PRODUCED.
THESE
SUBCATEGORIES ARE LISTED BELOW. PLEASE CHECK THE SUBCATEGORY OR
SUBCATEGORIES APPLICABLE TO THE COMPANY.
[ ]
Manufacturer of plastics and synthetic fibers only.
[ ]
Manufacturer of organic chemicals which discharges wastewaters from the
oxidation generic process.
[ ]
Manufacturer of both organic chemicals and plastics and synthetic fibers
which discharges wastewaters from the oxidation generic process.
[ ]
Manufacturer of organic chemicals which discharges wastewaters from any of
the "Type I" generic processes listed below.
[ ]
Manufacturer of both organic chemicals and plastics and synthethic fibers
which discharges wastewaters from any of the "Type I" generic processes
listed below.
"Type I" Generic Processes
a.
b.
c.
d.
Peroxidation
Acid Cleavage
Condensation
Isomerization
e. Esterification
f. Hydroacetylation
g. Hydration
h. Alkoxylation
i. Hydrolysis
j. Carbonylation
k. Hydrogenation
l. Neutralization
[ ]
Manufacturer of organic chemicals only but not classified under one of the
previous subcategories.
[ ]
Manufacturer of organic chemicals as well as plastics and synthetic fibers but
not classified under one of the previous subcategories.
[ ]
None of the above.
synthetic fibers.
Do not manufacture organic chemicals, Plastics, or
If "None of the above" has been checked, the company is not subject to Pretreatment
Standards for the Organic Chemicals category and there is no need to complete the remainder
of this supplement.
M:\T&F\IWP\Organic Chemicals, Plastics
and Synthetic Fibers_5-01
K-15-1
2.
3.
PLEASE CHECK APPROPRIATE BOX BELOW.
[ ]
Construction of the facility began before March 21, 1983. (Existing Source)
[ ]
Construction of the facility was begun after March 21, 1983. (New Source)
SIGNATURE
Signature
Title
Date
M:\T&F\IWP\Organic Chemicals, Plastics
and Synthetic Fibers_5-01
K-15-2
SUPPLEMENT TO THE SITE INSPECTION FORM
INORGANIC CHEMICALS MANUFACTURING
COMPANY NAME _____________________________________________________________
1.
THE INORGANIC CHEMICALS MANUFACTURING INDUSTRY HAS BEEN DIVIDED
INTO DIFFERENT SUBCATEGORIES BASED ON THE TYPE OF CHEMICAL MADE BY
THE INDUSTRY. THESE SUBCATEGORIES ARE LISTED BELOW. PLEASE CHECK
THE APPROPRIATE BOX OR BOXES IF THE COMPANY MANUFACTURES OR
PRODUCES ANY OF THESE SUBSTANCES.
[
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[
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[
] Aluminum Chloride
] Aluminum Fluoride
] Aluminum Sulfate
] Ammonium Chloride
] Ammonium Hydroxide
] Barium Carbonate
] Borax
] Boric Acid
] Bromine
] Cadmium Chloride
] Cadmium Nitrate
] Cadmium Pigments
] Cadmium Salts
] Cadmium Sulfate
] Calcium Carbide
] Calcium Carbonate
] Calcium Chloride
] Calcium Hydroxide
] Calcium Oxide
] Carbon Dioxide
] Carbon Monoxide
] Chlorine
] Chrome Pigments
] Chromic Acid
] Cobalt Salts
] Copper Carbonate
] Copper Chloride
] Copper Iodine
] Copper Nitrate
] opper Sulfate
] Cuprous Oxide
] Ferric Chloride
] Ferrous Sulfate
] Fluorine
] Hydrochloric Acid
] Hydrofluoric Acid
] Hydrogen
] Sodium Sulfite
M:\T&F\IWP\Inorganic Chemicals Mfg_5-01
[
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[
K-5-1
] Hydrogen Cyanide
] Hydrogen Peroxide
] Iodine
] Lead Monoxide
] Lithium Carbonate
] Manganese Sulfate
] Nickel Carbonate
] Nickel Chloride
] Nickel Fluoborate
] Nickel Nitrate
] Nickel Sulfate
] Nitric Acid
] Nitric Acid (Strong)
] Nitrogen (Liquid)
] Oxygen (Liquid)
] Potassium Chloride
] Potassium Dichromate
] Potassium Hydroxide
] Potassium Iodide
] Potassium Metal
] Potassium Permanganate
] Potassium Sulfate
] Silver Nitrate
] Sodium Bicarbonate
] Sodium Bisulfite
] Sodium Carbonate
] Sodium Chlorate
] Sodium Chloride
] Sodium Dichromate
] Sodium Fluoride
] Sodium Hydrosulfide
] Sodium Hydrosulfite
] Sodium Hydroxide
] Sodium Metal
] Sodium Silicate
] Sodium Silicofluoride
] Sodium Sulfate
[
[
[
[
[
[
[
[
[
] Sodium Thiosulfate
] Stannic Oxide
] Sulfur Dioxide
] Sulfuric Acid
] Titanium Dioxide
] Zinc Chloride
] Zinc Oxide
] Zinc Sulfate
] None of the above
If "None of the above" has been checked, the company is not subject to Pretreatment
Standards for the Inorganic Chemicals Category and there is no need to complete the
remainder of this supplement.
2.
3.
4.
PLEASE CHECK APPROPRIATE BOX BELOW.
[ ]
Construction of the facility began before July 24, 1980. (Existing Source
Phase I)
[ ]
Construction of the facility was begun after July 24, 1980. (New Source Phase
I)
PLEASE CHECK APPROPRIATE BOX BELOW.
[ ]
Construction of the facility began before October 25, 1983. (Existing Source
Phase II)
[ ]
Construction of the facility began after October 25, 1983. (New Source Phase
II)
SIGNATURE
Signature
Title
Date
M:\T&F\IWP\Inorganic Chemicals Mfg_5-01
K-5-2
INORGANIC CHEMICALS MANUFACTURING
STATUS OF PRETREATMENT REGULATIONS
CHEMICAL PRODUCT
PRETREATMENT1
STANDARDS FOR
APPLICABLE
SUBPART
Aluminum Chloride
Aluminum Fluoride
Aluminum Sulfate
Ammonium Chloride
Ammonium Hydroxide
Barium Carbonate
Borax
Boric Acid
Bromine
Cadmium Chloride
Cadmium Nitrate
Cadmium Pigments
Cadmium Salts
Cadmium Sulfate
Calcium Carbide
Calcium Carbonate
Calcium Chloride
Calcium Hydroxide
Calcium Oxide
Carbon Dioxide
Carbon Monoxide
Chlorine
- Mercury Cell
- Diaphragm Cell
Chrome Pigments
Chromic Acid
Cobalt Salts
Copper Carbonate
Copper Chloride
Copper Iodine
Copper Nitrate
Copper Sulfate
Cuprous Oxide
Ferric Chloride
Ferrous Sulfate
Fluorine
Hydrochloric Acid
Hydrofluoric Acid
Hydrogen
Hydrogen Cyanide
Hydrogen Peroxide
Iodine
Lead Monoxide
Lithium Carbonate
Manganese Sulfate
Nickel Carbonate
Nickel Chloride
Nickel Fluoborate
Nickel Nitrate
Nickel Sulfate
M:\T&F\IWP\Inorganic Chemicals Mfg_5-01
PRETREATMENT1
STANDARDS FOR
EXISTING SOURCES
(PSES)
NEW SOURCES
(PSNS)
A
W
B
X
Y
Z
AA
AB
AC
BL
BL
BL
BL
BL
C
AD
D
AE
E
AF
AG
P1
E
P1
E
E
E
R
E
R
P2
P2
P2
P2
P2
R
E
R
R
R
E
E
N
E
P1
E
E
E
R
E
R
P2
P2
P2
P2
P2
P1
E
P1
E
P1
E
E
F
F
AH
AI
BM
AJ
AJ
AJ
AJ
AJ
AK
AL
AM
AN
G
H
AO
AP
I
AQ
AR
AS
AT
AU
AU
AU
AU
AU
E
P1
P1
R
P2
P2
P2
P2
P2
P2
E
P
E
R
E
E
R
E
E
R
P
E
E
P2
P2
P2
P2
P2
P1
P1
P1
R
P2
P2
P2
P2
P2
P2
E
N
E
R
E
P1
R
P1
E
R
E
E
E
P2
P2
P2
P2
P2
K-5-3
CHEMICAL PRODUCT
PRETREATMENT1
STANDARDS FOR
APPLICABLE
SUBPART
Nitric Acid
Nitric Acid (Strong)
Nitrogen (Liquid)
Oxygen (Liquid)
Potassium Chloride
Potassium Dichromate
Potassium Hydroxide
- Mercury Cell
- Diaphragm Cell
Potassium Iodide
Potassium Metal
Potassium Permanganate
Potassium Sulfate
Silver Nitrate
Sodium Bicarbonate
Sodium Bisulfite
Sodium Carbonate
Sodium Chlorate
Sodium Chloride
Sodium Dichromate
Sodium Fluoride
Sodium Hydrosulfide
Sodium Hydrosulfite
Sodium Hydroxide
- Mercury Cell
- Diaphragm Cell
Sodium Metal
Sodium Silicate
Sodium Silicofluoride
Sodium Sulfate
Sodium Sulfite
Sodium Thiosulfate
Stannic Oxide
Sulfur Dioxide
Sulfuric Acid
Titanium Dioxide
Zinc Chloride
Zinc Oxide
Zinc Sulfate
PRETREATMENT1
STANDARDS FOR
EXISTING SOURCES
(PSES)
NEW SOURCES
(PSNS)
J
AV
AW
Awl
AX
L
E
E
E
E
R
P1
E
E
E
E
R
P1
F
F
AY
K
AZ
M
BA
N
BB
O
BN
P
Q
BC
BD
BE
E
P1
E
R
E
R
P
R
E
E
R
R
E
P
E
E
P1
P1
E
P1
E
P1
N
P1
P
E
R
P1
P1
E
E
E
F
F
R
S
BF
Q
T
BG
BH
BIB
U
V
BO
BJ
BK
E
P1
E
E
R
E
R
E
R
E
E
E
P2
E
R
P1
P1
E
E
R
P1
P2
E
R
E
E
P1
P2
E
R
1
Key: P1 = Promulgated under Phase I (Federal Register for June 29, 1982)
P2 = Promulgated under Phase II (Federal Register for August 22, 1984)
R = Reserved
N = Not Addressed
E = Excluded under provisions of the NRDC Settlement Agreement
(Paragraph 8)
M:\T&F\IWP\Inorganic Chemicals Mfg_5-01
K-5-4
3.
PLEASE CHECK THE ONE BOX MOST APPROPRIATE TO YOUR FACILITY FOR EACH
OF THE THREE SETS OF CHOICES LISTED BELOW.
Check one:
Check one:
Check one:
4.
[ ]
Integrated Facility (Combines regulated electroplating and metal finishing
waste streams with significant amounts over 10% - of process waste
streams not covered by the electroplating or metal finishing regulations)
[ ]
Nonintegrated Facility (Significant wastewater discharges only from
operations covered by the electroplating or metal finishing regulations)
[ ]
Construction of the facility began before January 28, 1981.
[ ]
Construction of the facility was begun after January 28, 1981.
[ ]
The facility discharges a total of 10,000 gallons or more per operating day of
process wastewater.
[ ]
The facility discharges less than 10,000 gallons per operating day of
process wastewater.
IF THE FACILITY DOES PRINTED CIRCUIT BOARD MANUFACTURING, INDICATE THE
MAXIMUM AND AVERAGE SQUARE FOOTAGE OF CIRCUIT BOARD WHICH IS
IMMERSED IN AQUEOUS PROCESS WATER EACH MONTH.
Average = _______________ft2/month based on _______ operating days
Maximum = _______________ft2/month based on _______ operating days
5.
ARE ANY ORGANIC SOLVENTS, DEGREASERS, PAINTS, OR OIL ADDITIVES USED
OR STORED AT THE FACILITY? Check one: [ ] Yes [ ] No
If yes, please list all organic solvents, degreasers, or oil additives regularly used or stored
at the facility:
M:\T&F\IWP\Electroplating and Metal
Finishing Industries_5-01
K-4-1
OVERVIEW OF THE METAL PRODUCTS INDUSTRY
Federal Pretreatment regulations divide the metal products industry into six categorical
industries. Three major criteria are used to divide the industry. These criteria are:
1.
Principal Function of the Industry
Does The industry refine (purify) raw ore or scrap materials or does the
industry change the shape of an already refined metal to produce a final
product?
2.
Manufacturing processes used to reshape the metal.
3.
Type of metal used.
A schematic diagram showing the classification system is shown on the attached page.
M:\T&F\IWP\Overview of the Metal
Products Industries_5-01
K-7-1
Metal Industry
principal function
Produces a high purity
metal from raw ore or
recycled materials
Uses an already refined
metal and reshapes it to
a final product
type of metal produced
type of manufacturing
processes used
iron and steel
Iron and Steel
Manufacturing
(40 CFR 403 &
420)
nonferrous
metals
metal is
remelted
and cast
(foundries)
Nonferrous
Metal Molding
Metals
and Casting
Manufacturing
Industry
(40 CFR 421)
(40 CFR 464)
metal is
reformed
by rolling,
extrusion,
forging or
drawing
type of
metal used
in production
Aluminum
Aluminum
Forming
(40 CFR 467)
Copper
Copper
Forming
(40 CFR 468)
Applicable categorical standards are shown in bold type.
M:\T&F\IWP\Overview of the Metal
Products Industries_5-01
K-7-2
powdered
metals are used
or produced
Nonferrous
Metals
Forming
(40 CFR 471)
metal is cut,
ground,
drilled only
Machine Shop
no categorical
standards apply
Nonferrous
Nonferrous
Metals
Forming
(40 CFR 471)
SUPPLEMENT TO THE SITE INSPECTION FORM
NONFERROUS METALS MANUFACTURING
COMPANY NAME _____________________________________________________________
The nonferrous metals manufacturing category includes plants producing metals from ore
concentrates (primary metals) and plants recovering metals from scrap materials such as
aluminum cans, lead batteries, etc. (secondary metals).
Recovery of silver from
photoprocessing solutions, sludges, and films is also included.
Smelting, refining, extraction, and the initial casting are the principal industrial processes
practiced by this industry. The objective of this processing is to increase the purity of the metal
being recovered. Later processes such as recasting, forming, or alloying are more concerned
with reshaping the metal, and are covered by the Aluminum Forming, Nonferrous Metal
Forming, and Metal Molding and Casting Pretreatment Standards.
1.
PLEASE CHECK THE TYPE OF RAW MATERIAL USED AT THE FACILITY.
[
[
[
[
2.
Ore concentrates
Scrap materials (recycled metallic wastes such as aluminum cans, batteries, etc.)
Film, sludges, and solutions from photographic processes
Other. Please explain
PLEASE CHECK THE FINAL PRODUCT PRODUCED AT THE FACILITY.
[
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[
[
[
[
[
[
[
[
[
[
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[
[
3.
]
]
]
]
] Aluminum
] Antimony
] Beryllium
] Boron
] Cesium
] Cobalt
] Columbium
] Copper
] Gallium
] Germanium
] Gold
] Hafnium
] Indium
] Iridium
] Lanthanum
] Lead
] Lutetium
] Mercury
] Mischmetal
] Molybdenum
] Other
[
[
[
[
[
[
[
[
[
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[
[
[
[
[
[
[
[
[
[
] Nickel
] Osmium
] Palladium
] Platinum
] Rhenium
] Rhodium
] Rubidium
] Ruthenium
] Scandium
] Silver
] Sulfuric Acid
] Tantalum
] Tin
] Titanium
] Tungsten
] Uranium
] Vanadium
] Yttrium
] Zinc
] Zircon
PLEASE CHECK THE APPROPRIATE BOX BELOW.
[ ]
Construction of the facility began before March 8, 1984. (Existing Source Phase I)
M:\T&F\IWP\Nonferrous Metals Mfg_5-01
K-8-1
[ ]
4.
5.
Construction of the facility was begun after March 8, 1984. (New Source Phase I)
PLEASE CHECK THE APPROPRIATE BOX BELOW.
[ ]
Construction of the facility began before June 27, 1984. (Existing Source Phase
II)
[ ]
Construction of the facility was begun after June 27, 1984. (New Source Phase II)
SIGNATURE
Signature
Title
Date
M:\T&F\IWP\Nonferrous Metals Mfg_5-01
K-8-2
SUPPLEMENT TO THE SITE INSPECTION FORM
ALUMINUM FORMING
COMPANY NAME _____________________________________________________________
Aluminum forming is a set of manufacturing operations in which aluminum and aluminum alloys
are made into semifinished products by hot or cold working such as rolling, extrusion, forging,
and drawing. Also included under these regulations are a number of ancillary operations such
as casting, heat treatment, and surface treatment. Common operations and terminology used
by the aluminum forming industry are defined on the attached page.
The aluminum forming industry has been divided into six different subcategories based on the
types of major manufacturing operation(s) done at the facility. Subcategories have been further
divided based on the specific types of manufacturing operations used and type of wastewaters
produced.
1.
PLEASE CHECK ANY OF THE FOLLOWING MANUFACTURING OPERATIONS THAT
ARE USED AT THE FACILITY.
[
[
[
[
[
[
[
2.
PLEASE CHECK ANY OF THE FOLLOWING MANUFACTURING OPERATIONS OR
SOURCES OF WASTEWATER THAT EXIST AT THIS FACILITY.
[
[
[
[
[
[
[
[
[
[
[
[
[
3.
] Rolling with Neat Oils
] Rolling with Emulsions
] Extrusion
] Forging
] Drawing with Neat Oils
] Drawing with Emulsions or Soaps
] None of the above
] Annealing Furnace Scrubber
] Continuous Sheet Casting Lubricant
] Continuous Rod Casting Spent Lubricant
] Continuous Rod Casting Contact Cooling Water
] Direct Chill Casting Cooling Water
] Extrusion Press Leakage
] Press Heat Treatment Contact Cooling Water
] Forging Scrubber Liquid
] Solution Heat Treatment Contact Cooling Water
] Cleaning or Etching Bath
] Cleaning or Etching Rinse
] Cleaning or Etching Scrubber
] None of the above
PLEASE CHECK APPROPRIATE BOX BELOW.
[ ]
Construction of the facility began before October 24, 1983. (Existing Source)
[ ]
Construction of the facility was begun after October 24, 1983. (New Source)
M:\T&F\IWP\Aluminum Forming_5-01
K-9-1
4.
SIGNATURE
Signature
Title
Date
M:\T&F\IWP\Aluminum Forming_5-01
K-9-2
OPERATIONS AND TERMINOLOGY USED BY
THE ALUMINUM FORMING INDUSTRY
Contact cooling water is any wastewater which contacts the aluminum workpiece or the raw
materials used in forming aluminum.
Continuous casting is the production of sheet, rod, or other long shapes by solidifying the metal
while it is being poured through an open-ended mold using little or no contact cooling water.
Direct chill casting is the pouring of molten aluminum into a water-cooled mold. Contact cooling
water is sprayed onto the aluminum as it is dropped into the mold, and the aluminum ingot falls
into a water bath at the end of the casting process.
Drawing is the process of pulling metal through a die or succession of dies to reduce the
metal's diameter or alter its shape. Emulsions, soaps, and neat oils are used as lubricants
during the drawing process.
Emulsions are stable dispersions of two immiscible liquids. In aluminum forming, this is usually
an oil and water mixture.
Cleaning or etching is a chemical solution bath and a rinse or series of rinses designed to
produce a desired surface finish on the workpiece.
Extrusion is the application of pressure to a billet of aluminum, forcing the aluminum to flow
through a die orifice.
Forging is a process of forming aluminum in which the aluminum is forced into shape by use of
compressive forces such as hammering or squeezing. The forging process usually uses hot
aluminum, and is a dry operation. Dies or rolls are used to exert pressure. When dies are
used, the forged aluminum takes the shape of the die.
Heat treatment is the application of heat of specified temperature and duration to change the
physical properties of the metal.
Neat oil is a pure oil with no or few impurities added. In aluminum forming its use is mostly as a
lubricant.
Rolling is the reduction in thickness or diameter of a workpiece by passing it between lubricated
steel rollers. Emulsions or neat oils are used as lubricants for the rolling process.
Scrubbers are air pollution control devices used to remove particulates and fumes from air by
entraining the pollutants in a water spray.
M:\T&F\IWP\Aluminum Forming_5-01
K-9-3
SUPPLEMENT TO THE SITE INSPECTION FORM
COPPER FORMING
COMPANY NAME _____________________________________________________________
The copper forming category includes those plants that form copper or copper alloys. Five
basic processes are used: hot rolling, cold rolling, extrusion, drawing, and forging. Casting of
copper and copper alloys is not covered by this regulation (see 40 CFR 451); nor is the
manufacturing of copper powders or use of copper powders (see 40 CFR 471).
1.
PLEASE CHECK ANY OF THE FOLLOWING PROCESSES THAT ARE PERFORMED AT
THIS FACILITY.
[
[
[
[
[
[
] Hot rolling
] Cold rolling
] Drawing
] Extrusion
] Forging
] None of the above
If you checked "None of the above," the facility is not covered by EPA regulations for the
copper forming category and you should skip to Part 4 of this form.
2.
PLEASE CHECK ANY OF THE FOLLOWING MANUFACTURING OPERATIONS OR
SOURCES OF WASTEWATER THAT EXIST AT THIS FACILITY.
[
[
[
[
[
[
[
[
[
[
[
[
[
[
[
[
[
3.
] Alkaline Cleaning Bath
] Alkaline Cleaning Rinse
] Annealing with Oil
] Annealing with Water
] Cold Rolling Spent Lubricant
] Drawing Spent Lubricant
] Extrusion Heat Treatment
] Hot Rolling Spent Lubricant
] Hydrotesting
] Pickling Bath
] Pickling Fume Scrubber
] Pickling Rinse
] Sawing
] Solution Heat Treatment
] Surface Coating
] Surface Milling
] Tumbling or Burnishing
PLEASE CHECK APPROPRIATE BOX BELOW.
[ ] Construction of the facility began before August 15, 1983. (Existing Source)
M:\T&F\IWP\Copper Forming_5-01
K-10-1
[ ] Construction of the facility was begun after August 15, 1983. (New Source)
4.
SIGNATURE
Signature
Title
Date
M:\T&F\IWP\Copper Forming_5-01
K-10-2
SUPPLEMENT TO THE SITE INSPECTION FORM
METAL MOLDING AND CASTING INDUSTRY (FOUNDRIES)
COMPANY NAME _____________________________________________________________
The metal molding and casting (foundry) category includes those plants that remelt and cast
metal. These plants form a cast intermediate or final product by pouring or forcing the molten
metal into a mold. Six process steps typify the metal molding and casting category: (1) metal
is remelted in a furnace, (2) molds are prepared, (3) the molten metal is poured or injected into
a mold, (4) the mold medium is separated from the casting, (5) the casting is cooled, and (6)
the casting is further processed before shipping.
The metal molding and casting (foundry) category has been divided into different subcategories
based on the type of metal cast. Discharge standards have been established for individual
manufacturing processes within each subcategory.
1.
PLEASE CHECK THE TYPE OF METAL CAST AT THIS FACILITY.
[
[
[
[
[
[
[
2.
PLEASE CHECK ANY OF THE FOLLOWING MANUFACTURING OR AIR POLLUTION
CONTROL PROCESSES THAT ARE USED AT THIS FACILITY.
[
[
[
[
[
[
[
[
[
[
[
[
[
3.
] Aluminum
] Copper
] Iron and Steel
] Lead
] Magnesium
] Zinc
] None of the above
] casting quench
] continuous strip casting
] die casting
] die lube
] dust collection scrubber
] grid casting scrubber
] grinding scrubber
] investment casting
] melting furnace scrubber
] mold cooling
] sand washing
] slag quench
] None of the above
PLEASE CHECK THE APPROPRIATE BOX BELOW.
[ ] Construction of this facility began before November 15, 1982. (Existing Source)
[ ] Construction of this facility was begun after November 15, 1982. (New Source)
M:\T&F\IWP\Metal Molding & Casting Ind_5-01
K-11-1
4.
SIGNATURE
Signature
Title
Date
M:\T&F\IWP\Metal Molding & Casting Ind_5-01
K-11-2
OPERATIONS IN THE NONFERROUS METALS FORMING, IRON AND STEEL/
COPPER/ALUMINUM METAL POWDER PRODUCTION, AND POWDER
METALLURGY INDUSTRIES
Rolling reshapes cast ingots by exerting pressure as the metal passes between rollers,
reducing the thickness and cross-sectional area of the metal. Example: square ingots are
rolled to produce rods, bars, or wire.
Extrusion is the application of force to a metal bar causing the metal to flow through a die
orifice. The resulting product is an elongated shape or tube of uniform cross-sectional area.
Forging uses compressive forces to deform (usually hot) metal into desired shapes, with or
without the use of dies.
Drawing is the pulling of metal through a die or series of dies to reduce its diameter, alter the
cross-sectional shape, or increase its hardness. Rods, wire, and reduced diameter tubing are
produced by drawing.
Surface Treatment Operations
Treatment to Remove Oxidized Material (Rust) - acid etching, pickling, hot molten salt
baths. Usually the formed metal is dipped into a surface treatment bath and then rinsed by
dipping in an overflowing bath or by spraying with clean water.
Treatment to Clean Metal Surfaces - Alkaline cleaning solutions, usually detergents, are
applied by immersion or spraying. Solvent cleaners such as trichloroethylene, l,1,1trichloroethane, and perchloroethylene can also be used. Another cleaning method is
vapor degreasing which uses the hot vapors of chlorinated solvents to remove oils,
greases, and waxes.
Mechanical Surface Treatments - machining, grinding, polishing, tumbling and barrel
finishing.
Cladding is the process of bonding two or more metals together to form a multi-layered,
composite metal. Bonding may be done by rolling, melting of a solder type metal sandwiched
between two other metals (brazing), or by using a carefully controlled explosion (explosion
bonding).
Metal Powder Production is done by atomization or mechanical grinding. In the atomization
process, a stream of water or gas impinges upon a molten metal stream, breaking it into
droplets which solidify as powder particles.
Powder metallurgy is the formation of metal powders into parts. This is done by a "press and
sinter" operation consisting of blending metal powders, compacting the mixture in a die, and
then heating or sintering the compacted powder in a controlled atmosphere to bond the
particles into the desired shape.
M:\T&F\IWP\Nonferrous Mtls Forming/Iron
& Steel/Copper/Alum Mtl Powder Prod/
& Powder Metallurgy Industries_5-01
K-12-1
SUPPLEMENT TO THE SITE INSPECTION FORM
NONFERROUS METALS FORMING
IRON AND STEEL/COPPER/ALUMINUM METAL POWDER PRODUCTION
POWDER METALLURGY FACILITIES
COMPANY NAME _____________________________________________________________
The nonferrous metals forming category includes those establishments engaged in the forming
of nonferrous metals and their alloys. The nonferrous metals covered by this category are
listed in question #1 below. Forming of iron, steel, copper, or aluminum are not included in this
category.
Forming is the deformation of a metal into specific shapes by hot or cold working. The major
forming operations include rolling, extruding, forging, and drawing. Minor forming operations
include cladding, metal powder production, and powder metallurgy. There are also a number of
associated operations that are performed as part of the forming process. These include casting
for subsequent reforming, heat treatment, surface treatment, alkaline cleaning, solvent
degreasing, sawing, grinding, tumbling, burnishing, and product testing. The less familiar of
these operations are described on the attached page.
Because of the wide variety of metals contained in this category, a wide variety of fabricated
products are produced by the industries subject to these regulations. These products include
hullets, solder, insulated cable, pipe, metal sheets, metal plates, metal strips, foil, rods, bars,
tubing, wire, I-beams, clad metals, metal powders, control rods for nuclear reactors, battery
cases, and filaments for light bulbs.
1.
PLEASE CHECK THE TYPE OF METAL(S) USED AT THIS FACILITY.
[
[
[
[
[
[
[
[
[
[
[
[
[
] Beryllium
] Bismuth
] Cobalt
] Columbium
] Copper (powdered)
] Gold
] Hafnium
] Iron (powdered)
] Lead
] Magnesium
] Molybdenum
] Nickel
] Palladium
M:\T&F\IWP\Nonferrous Mtls Forming/Iron
& Steel/Copper/Alum Mtl Powder Prod/
& Powder Metallurgy Industries_5-01
[
[
[
[
[
[
[
[
[
[
[
[
K-12-2
] Platinum
] Rhenium
] Silver
] Steel (powdered)
] Tantalum
] Tin
] Titanium
] Tungsten
] Uranium
] Vanadium
] Zinc
] Zirconium
-2-
2.
PLEASE CHECK ANY OF THE FOLLOWING MANUFACTURING PROCESSES THAT
ARE USED AT THIS FACILITY.
[
[
[
[
[
[
[
[
] alkaline treatment
] burnishing
] casting
] cladding
] drawing
] extruding
] forging
] heat treatment of metals
[
[
[
[
[
[
[
] metal powder metallurgy
] metal powder production
] rolling (hot or cold)
] solvent degreasing
] surface treatment of metals
] tube reducing
] tumbling
3.
BRIEFLY EXPLAIN ANY ITEM(S) CHECKED IN QUESTION #2.
4.
PLEASE CHECK APPROPRIATE BOX BELOW.
[ ] Construction of the facility began before March 5, 1984. (Existing Source)
[ ] Construction of the facility was begun after March 5, 1984. (New Source)
5.
SIGNATURE
Signature
Title
Date
M:\T&F\IWP\Nonferrous Mtls Forming/Iron
& Steel/Copper/Alum Mtl Powder Prod/
& Powder Metallurgy Industries_5-01
K-12-3