PART 438—METAL PRODUCTS AND MACHINERY POINT SOURCE CATEGORY Authority: 33 U.S.C. 1311, 1314, 1316, 1317, 1318, 1342 and 1361. Source: 68 FR 25735, May 13, 2003, unless otherwise noted. § 438.1 General applicability. (a) As defined more specifically in subpart A, except as provided in paragraphs (b) through (e) of this section, this part applies to process wastewater discharges from oily operations (as defined at § 438.2(f) and appendix B of this part) to surface waters from existing or new industrial facilities (including facilities owned and operated by Federal, State, or local governments) engaged in manufacturing, rebuilding, or maintenance of metal parts, products, or machines for use in the Metal Product & Machinery (MP&M) industrial sectors listed in this section. The MP&M industrial sectors consist of the following: Aerospace; Aircraft; Bus and Truck; Electronic Equipment; Hardware; Household Equipment; Instruments; Miscellaneous Metal Products; Mobile Industrial Equipment; Motor Vehicle; Office Machine; Ordnance; Precious Metals and Jewelry; Railroad; Ships and Boats; or Stationary Industrial Equipment. (b) The regulations in this part do not apply to process wastewaters from metal-bearing operations (as defined at § 438.2(d) and appendix C of this part) or process wastewaters which are subject to the limitations and standards of other effluent limitations guidelines (e.g., Metal Finishing (40 CFR part 433) or Iron and Steel Manufacturing (40 CFR part 420)). The regulations in this part also do not apply to process wastewaters from oily operations (as defined at § 438.2(f) and appendix B of this part) commingled with process wastewaters already covered by other effluent limitations guidelines or with process wastewaters from metal-bearing operations. This provision must be examined for each point source discharge at a given facility. (c) Wastewater discharges resulting from the washing of cars, aircraft or other vehicles, when performed only for aesthetic or cosmetic purposes, are not subject to this part. Direct discharges resulting from the washing of cars, aircraft or other vehicles, when performed as a preparatory step prior to one or more successive manufacturing, rebuilding, or maintenance operations, are subject to this part. (d) Wastewater discharges from railroad line maintenance facilities (as defined at § 438.2(h)) are not subject to this part. Wastewater discharges from railroad overhaul or heavy maintenance facilities (as defined at § 438.2(i)) may be covered by subpart A of this part, the Metal Finishing Point Source Category (40 CFR part 433), or by other effluent limitations guidelines, as applicable. (e) The following wastewater discharges are not subject to this part: (1) Non-process wastewater as defined at § 438.2(e). (2) Wastewater discharges introduced into a Publicly Owned Treatment Works (POTW) or a Federally owned and operated Treatment Works Treating Domestic Sewage (TWTDS), as defined at 40 CFR 122.2. (3) Process wastewater generated by maintenance and repair activities at gasoline service stations, passenger car rental facilities, or utility trailer and recreational vehicle rental facilities. (4) Wastewater discharges generated from gravure cylinder preparation or metallic platemaking conducted within or for printing and publishing facilities. (5) Wastewater discharges in or on dry docks and similar structures, such as graving docks, building ways, marine railways, lift barges at shipbuilding facilities (or shipyards), and ships that are afloat. (6) Wastewater generated by facilities primarily performing drum reconditioning and cleaning to prepare metal drums for resale, reuse, or disposal. § 438.2 General definitions. As used in this part: (a) The general definitions and abbreviations at 40 CFR part 401 shall apply. (b) The regulated parameters are listed with approved methods of analysis in Table 1B at 40 CFR 136.3, and are defined as follows: (1) O&G (as HEM) (2) TSS (c) Corrosion preventive coating (d) Metal-bearing operations (e) Non-process wastewater (f) Oily operations (g) Process wastewater (h) Railroad line maintenance facilities (i) Railroad overhaul or heavy maintenance facilities Subpart A—Oily Wastes § 438.10 Applicability. (a) This subpart applies to process wastewater directly discharged from facilities specified at § 438.1. (b) This subpart applies to process wastewater discharges from oily operations (as defined at § 438.2(f) and appendix B of this part). (c) This subpart does not apply to process wastewater discharges from metal-bearing operations (as defined at § 438.2(d) and appendix C of this part). § 438.12 Effluent limitations attainable by the application of the best practicable control technology currently available (BPT). Except as provided at 40 CFR 125.30 through 125.32, any existing point source subject to this subpart must achieve the following effluent limitations representing the application of BPT. Discharges must remain within the pH range 6 to 9 and must not exceed the following: Effluent Limitations [BPT] Regulated parameter Maximum daily 1 1. TSS 62 2. O&G (as HEM) 46 1 § 438.13 Effluent limitations attainable by application of the best control technology for conventional pollutants (BCT). Except as provided at 40 CFR 125.30 through 125.32, any existing point source subject to this subpart must achieve the following effluent limitation representing the application of BCT: Limitations for TSS, O&G (as HEM) and pH are the same as the corresponding limitation specified at § 438.12. § 438.15 New source performance standards (NSPS). New point sources subject to this subpart must achieve the new source performance standards (NSPS) for TSS, O&G (as HEM), and pH, which are the same as the corresponding limitation specified at § 438.12. The performance standards apply with respect to each new point source that commences discharge after June 12, 2003. Subpart B [Reserved] Appendix A to Part 438—Typical Products in Metal Products and Machinery Sectors AEROSPACE AIRCRAFT BUS & TRUCK ELECTRONIC EQUIPMENT HARDWARE HOUSEHOLD EQUIPMENT INSTRUMENTS MOBILE INDUSTRIAL EQUIPMENT MOTOR VEHICLE INSTRUMENTS OFFICE MACHINE ORDNANCE PRECIOUS METALS & JEWELRY RAILROAD SHIPS & BOATS STATIONARY INDUSTRIAL EQUIPMENT MISCELLANEOUS METAL PRODUCTS Appendix B to Part 438—Oily Operations Definitions Note: The definitions in this appendix shall not be used to differentiate between the six “core” metal finishing operations ( i.e., Abrasive Blasting Adhesive Bonding Alkaline Cleaning for Oil Removal (1) Alkaline cleaning is performed to remove foreign contaminants from parts. This operation usually is done prior to finishing (e.g., electroplating). (2) Emulsion cleaning is an alkaline cleaning operation that uses either complex chemical enzymes or common organic solvents (e.g., kerosene, mineral oil, glycols, and benzene) dispersed in water with the aid of an emulsifying agent. The pH of the solvent usually is between 7 and 9, and, depending on the solvent used, cleaning is performed at temperatures from room temperature to 82 °C (180 °F). This operation often is used as a replacement for vapor degreasing. Alkaline Treatment Without Cyanide Aqueous Degreasing Assembly/Disassembly Burnishing Calibration Corrosion Preventive Coating Electrical Discharge Machining Floor Cleaning (in Process Area) Grinding i.e., Heat Treating Impact Deformation Iron Phosphate Conversion Coating i.e., Machining Painting-Spray or Brush (Including Water Curtains) i.e., Polishing Pressure Deformation Solvent Degreasing Steam Cleaning Testing (e.g., hydrostatic, dye penetrant, ultrasonic, magnetic flux) Thermal Cutting Tumbling/Barrel Finishing/Mass Finishing/Vibratory Finishing Washing (Finished Products) Welding Wet Air Pollution Control for Organic Constituents Appendix C to Part 438—Metal-Bearing Operations Definitions Note: The definitions in this appendix shall not be used to differentiate between the six “core” metal finishing operations ( i.e., Abrasive Jet Machining Acid Pickling Neutralization Acid Treatment With Chromium Acid Treatment Without Chromium Alcohol Cleaning Alkaline Cleaning Neutralization Alkaline Treatment With Cyanide Anodizing With Chromium Anodizing Without Chromium Carbon Black Deposition Catalyst Acid Pre-Dip Chemical Conversion Coating without Chromium (1) In phosphate conversion, coatings are applied for one or more of the following reasons: to provide a base for paints and other organic coatings; to condition surfaces for cold forming operations by providing a base for drawing compounds and lubricants; to impart corrosion resistance to the metal surface; or to provide a suitable base for corrosion-resistant oils or waxes. Phosphate conversion coatings are formed by immersing a metal part in a dilute solution of phosphoric acid, phosphate salts, and other reagents. (2) Metal coloring by chemical conversion coating produces a large group of decorative finishes. Metal coloring includes the formation of oxide conversion coatings. In this operation, the metal surface is converted into an oxide or similar metallic compound, giving the part the desired color. The most common colored finishes are used on copper, steel, zinc, and cadmium. (3) Passivation forms a protective coating on metals, particularly stainless steel, by immersing the part in an acid solution. Stainless steel is passivated to dissolve embedded iron particles and to form a thin oxide film on the surface of the metal. Wastewater generated during chemical conversion coating includes spent solutions and rinses ( i.e., Chemical Milling (or Chemical Machining) Chromate Conversion Coating (or Chromating) i.e., Chromium Drag-out Destruction Cyanide Drag-out Destruction Cyaniding Rinse Electrochemical Machining Electroless Catalyst Solution Electroless Plating i.e., Electrolytic Cleaning (1) Electrolytic alkaline cleaning produces a cleaner surface than do nonelectrolytic methods of alkaline cleaning. This operation uses strong agitation, gas evolution in the solution, and oxidation-reduction reactions that occur during electrolysis. In addition, dirt particles become electrically charged and are repelled from the part surface. (2) Electrolytic acid cleaning sometimes is used as a final cleaning before electroplating. Sulfuric acid is most frequently used as the electrolyte. As with electrolytic alkaline cleaning, the mechanical scrubbing effect from the evolution of gas enhances the effectiveness of the process. Wastewater generated during electrolytic cleaning includes spent process solutions and rinses. Electrolytic cleaning solutions become contaminated during use due to the dissolution of the base metal and the introduction of pollutants. The solutions typically are batch discharged for treatment or disposal after they weaken. Rinsing following electrolytic cleaning removes residual cleaner to prevent contamination of subsequent process baths. Electroplating with Chromium i.e., Electroplating with Cyanide i.e., Electroplating without Chromium or Cyanide i.e., Electropolishing Galvanizing/Hot Dip Coating Hot Dip Coating Kerfing Laminating Mechanical and Vapor Plating Metallic Fiber Cloth Manufacturing Metal Spraying (Including Water Curtain) Painting-Immersion (Including Electrophoretic, “E-coat”) (1) Autophoretic Painting involves applying an organic paint film by electrophoresis when a part is immersed in a suitable aqueous bath. (2) Electrophoretic Painting is coating a part by making it either anodic or cathodic in a bath that is generally an aqueous emulsion of the organic coating material. (3) Other Immersion Painting includes all other types of immersion painting such as dip painting. Water is used in immersion paint operations as a carrier for paint particles and to rinse the part. Aqueous painting solutions and rinses typically are treated through an ultrafiltration system. The concentrate is returned to the painting solution, and the permeate is reused as rinse water. Sites typically discharge a bleed stream to treatment. The painting solution and rinses are batch discharged periodically to treatment. Photo Imaging Photo Image Developing Photoresist Application Photoresist Strip Phosphor Deposition Physical Vapor Deposition Plasma Arc Machining Plastic Wire Extrusion Salt Bath Descaling Shot Tower—Lead Shot Manufacturing Soldering Solder Flux Cleaning Solder Fusing Solder Masking Sputtering Stripping (Paint) Stripping (Metallic Coating) Thermal Infusion Ultrasonic Machining Vacuum Impregnation Vacuum Plating Water Shedder Wet Air Pollution Control (1) Wet Air Pollution Control for Acid Alkaline Baths; (2) Wet Air Pollution Control for Cyanide Baths; (3) Wet Air Pollution Control for Chromium-Bearing Baths; and (4) Wet Air Pollution Control for Fumes and Dusts. Wire Galvanizing Flux