EXAMPLE #2 CITED IN PUBLIC COMMENT: 

EPA REGION IX WASTE MANAGEMENT DIVISION, RCRA E NFORCEMENT OFFICE, RCRA 

COMPLIANCE E VALUATION INSPECTION R EPORT FOR .BHP COPPER SAN MANUEL FACILITY 

(APRIL 8, 2002) 

{UNOFFICIAL COPY) 
UNITEO STATES ENVI"ONMINTAL PROTECTION AG!NCY 

AIGIC* 'X 

71 HIWChome ltnlt 

atn Pr'IIIICIICCI, CA 1410! 

.,. 

CERTrFtF.n MAll. N0.70001A700009l1729g75 

RETURN RECEIPT REQUESTED 

4Dnl a. 2002 

Jeff J. Parker 

Manaa•r. EnvirQnmontml Afl"oirs 

BHP Capper 

P.O. BoxM . 

San M:mucl, AZ 8S63l 

J n reply. refer to WST .. J 

W11ming Letter nnd Ccctjfis;gtjon orVio!atjon Correction forBijf CAPPel 

Ue:.tr Mr. Parker: 

Frorn Aug\lst 7-ll, 2000. a hUZJlrdow waste investigation was conducted by reprcsenta~ 

tives of the United Sl(ltfl Envlronmentnl Protection A¥'itlOY (U.S. BPI\') ot BHP Copper (herein 

refcm!d to as "BHP" or "the f».cillty'r) !Cleated in San Manue~ AZ, U.S. EPA Identification 

Number AZD t>Ol UCS .597. A samplins event was subsequently conducted on Septemba· ·21. 

'2000. During the course or th i! investiption, information was gathered in ac:cord~~nee with 

Section 3007 of the Resource Consl!mllion and Recovery Act (RCRA), as amcnded.[42 U.S.C. 

"Q27J. 

A cupy uf lht: inv~st gution report is c:nclosc:d for your lnfornuttion and response. Th~ 

report describe~ condition~ ut the facility nl the time of the inv~1igation. and 1dentit1es areas of 

non~ompllan~:e with RCRA regulacil)ns ~&nd potential violations of the Arizona authorized 

program 'Undor RCR.A Sub\ithl C. Any omi~Sit)ns In the repon shall not be construt4 us a 

dctc:rminntion of compliance with all applicable ~gulations. 

BHP's prompt responl5e, dated Ausust 24, 2000, 'adequately addreswu the co~tingency 

plan ar.d training plan potl!ntiul viulutions noted in the report. In addition. s\nce BHP ceased 

operations in 1999. it Is no lonJ&~r tn:atina 4 land di~sal ~tricted waste (i.e. 11cid plant 

bluwdown) by dilution, d potential violation also noted in lhe report. · 

w~ apolozize for the del11y in issuing this report. Scvenil ofthe rcaulatory iSsues 

addressed In the! report wen: inl1u~ced by recent rc:gulacory chaniCI 01nd court dec&sions. :w1 

were similar tn issues affecting ojher industry fncllitics. W.: took additional time to en1urc the 

\:onsistcncy ur nur conclusions given these c;bnnges and similarities. While thia effort cuntrib· 

utod to th~: dcl:1y in i'suing tht report, we believe thnt it :~l o contribuled to the qunlity of our 

unulysi:~. We welcome: a11y IJpdared information yo11 wish ta submit. 
LS9£ S~S: OZ5 8 Alddns dHB 

By copy ot' rhi:t lc:tt\Or, U.S. EPA i' provlduiKlhe SL\'&lc: uf Ari:tUna wllh nodc.e of the 

referenced vinlatlun of Subtitle C of RCRA. U.S. EPA is also providJna the State with notice 

that it intends to rakt nu further enforcement attlon for the violation noted. The State of Arizona 

may notify U.S. EPA of its intent to assume or declh1e rc.'\('IOn~ibility ro take fmth.er su~tJon to 

address the referenced federal violstian. 

U.S. I.H'A routinely provides copies ofirtv~tiption reports to State 1&1C:R\Oic11, and upon 

request, to me public. Such rel.ellSeS a~ bandlcd ICCOl'ding to the Freedom or rnrormation Act 

regulatfons ( 40 CFR Pllrt 2 ). (f you believe this r@Ort contains privileged or coofidl:ndal 

information. you may make 11 claim within fifteen (1 S) calendnr days from the date of this letter. 

Ll.S. EPA will construe your l\ilu~ t~ furnish ll timoly claim 11~ u wniver of the confldenthdity 

claim. 

BHP should continue to take the neces&axy steps to maintain and ensure compJi~t with 

nll ppli abt~ F~ml, S~t~ and local envitOI\!t\ental requirements. lf you ha\'e que3tions related 

to tt~ehnical aspects of lh~t inve:>tigation raport or thi5 lcngr, ph:a.'1e (Onract K~oN Morimoto at 

(415) 972-33~ or Barry Cofer.nt (415) 972-3303. 

Enc: 

cc·. laura M:llonc. ADEQ (w/o t nc.) 

Sincerely, 

Fram:es Schultz, Manaacr 

RCRA enforct!ment Office 
UNITED STATIIINV1"0NMINTAL PROT!CTION AOEHCY 

RIQION IX 

Purpoet: 

Pac:illty: 

Pa~u ity Address: 

Facility Mailing Address: 

EPA JD Nwnbcr. 

Dates of 11w~L 9"tiun : 

EPA R.cpn:s-:ntnLiv~: 

FaciUty Repre!lentatives: 

711Hadorne..._ 

SUI PnMieeo, CA t4101 

WASTE MANAOEM!NT OCVTSlON 

RCRA ENFORCEMSNT Of:F1CE 

RCRA Compliance Evaluation 

Inspection 

BHP Copper 

200 South RedJnpm .Road 

SM.U MmueJ, AZ 85631 

P.O. BoxM 

Snn Mnnuel, AZ ~5631 

AZD 00 J 886 ~97 

August 7 ·11, 2000 

S~tembcr 21 , 2000 

· Kaor~ Murimuto 

EnvironmenUll Engineer 

(4lS) 972.3306 

DtrryCofer 

Environmental Protc:c.:tion Specialist 

(4J ~) 972-3303 

Fnn~cs Sohultz 

Manager, RCRA Enforcement Office: 

(41$) 972·3297 

Jeff J. Pnr1cer 

Manaacr. Environmc:ntA\ Affairs 

(~20) 3~5·3~81 . 

Ja.mes Glasston 

Envfranm•ntnf CoardJna<or 

(520) 38j 35~2 

Norm GrtNnwalrl 

GteenWRid Associntes 

(G02) 577·5621 

LS9i S8i: OZS S 
Rcpon PRpartd By; 

DateofR~: 

2 

BuwnDay 

Bryan Cave LLP 

(602) 364-7403 

Kaoru Morimoto 

Marth 6, 2002 

LS9£ 58£ OZS & 
84CK.CROUNDt 

BHF Copper (h~rein ret'erred to as ''BHP,. or .. the facility,.), locucd in San M111uel, 

Arizona. conducted min11rlll prcel!ssing o~tianc (smeltin1 and reflniaa or eopp1r) until 

June 1999. A dlasrnm of th-: tneility ia provided as At1achmcm N2. 

Tbit facility hu b-=1m in can: and maintenan~ since June 1999 cx.acpt for ~e operations 

conuu\:ll:\l au tht: SX/EW. The !RU:ller wu shut down on May l, 1999. Per!onnelat BHl' was 

~duced tom 3.500 to 190. 

[n the mo.st r.:cc:nt nodfic01tic:m Fof11'lt •~bmittad June 6. 1996, BHP lndicutcd thc:y wgrc • 

large quantity generator orhazardous waste. 

iNVESTIGATION: 

Fram Au(l\llt 7, 2000- August 11,2000,11 RCRJ\ Complinnce Evnluotlon In~cnion 

(CEt) was conducted hy insp~ctors from the United States Environmmtal Protection Agency 

(U.S. EPA). The purpose or the tMpectlon was [0 dctennine the compJlance of HHP with 

hazardous wute regulations in 40 Code ofF~l Resulatinns (CFR) Subtitle C Ulld th~ 

~guhnion!4 adopted by the: AritoM authot•ized program undt:r RCRA Subtitle C in Arizona Anmi"i~ITMi"e Code (AAC)~ Tit1• 18, Chapter 8, A.niele 2. 

A CEI uf BHP wus prtv\ously conducted by the Ari<mna Despanment Qf !nvtronmental 

Quality (ADEQ) on Nov~mber 2, l 994. 

Gcamllnfnunotipn · 

The pr~t:l!i inl'brmation provided ~low supplementll4 ttle pruccsa iofonnatlon provi~u 

in the facilitfs July 14. 2000 ru~nlle to EPA's 3007(11) infonnation request (Anachmcnt #3). 

The additionlll information detail!!d below inQiudcs clarifications and additional process 

in formation obtained durin~ and '"'~eq\M:nt to tho lnt.,-ction. 

DZL:~cd upon inli:Jnnation ~lllln::tc:u uurhl¥ lhc irufpc~o;liun, the BHF CopperS~ Manuel 

Operarions Production Flow Chart (fnund In AOKluucnt tJ) was modified to ~fleet cum:nt 

operations. The rcviSt!d prllCtss flow sheet crented by BPA i111 enclosed as Attacbmgt tM. 

Colluatrate Stonsc: 

lDcpmjni mat;xtal: 

Past: Concentrac~ . scrubber duns, ps cleaning system dusts (stored on a eoncmc pad). 

Pr~ent: Concentrate (6,000 tons), stored adjacwnt to the n•w Concentrate Storaae 

Buildln¥ (~ee phote&nlPl11 #L·2). Subsequenc to the lna~tion, this mlltfi&l 

was sold to :1 German conrpany. · 

l.S9i: 58~ OZS 8 ,J.lddnS dH8 
Parr. FJuh furnace feed. 

Present: No activity. 

Additional Ersrcess informatjgn: (Supplements information on pages 6· 7 of AIJiehmcnt #J1. 

• In the future, c:oncentrnte and converter dusts will be stored in lhc new Cnncentl'llte 

Storage building. This bu\lding was ttes;ancd to store 40,000 tons of~onceutrate. 

• When BHP was operatini, tbc smelter UMd aJl11rox1mately 4,000 tons of concentrate per 

day. 

• Analytical rcsultto of concentrate from 1n EPA sampling event are provlded in 

Attaebment ~S (s;amplc lD BHP0-4). Sample ID BHPOS was for a duplicate sample. 

Sample ID BHP06 was for a blind spik~. Sample ID BHP07 wu for a field blank. 

• EPA analYtical results of the berm alongside th~ concentrate storaJe area are provided in 

A!ti'&hrosmt#S (sample IO BHP08). 

Issue t# 1: Analyticlll results show that "re\'ertJ .. from eoppcr Jmelting operations can be 

chamcteliRticlllly hazardous for lead and cadmium. and can contain 50% copper. 

rf the rc-vc=rt mAt-erial hat~ ITlliCb hisn•r com:emmtions at eoppr:r and toxic m•tal.1 

thnn we ore, l11 re-introduction of the revert m~terial into the smelter process 

lr:gilirne~U:'? 

The copper ore typically contains approximately 0.3% m 0.6% copper. BliP's July 14, 

l01)0 aubminnl sta[cd that th~ir copper conccntralc nuruc: from the: on: ils approximately 30'/b 

copper, and dcds not exceed any of the toxicity charac:tcrislics (ace Attachcunt II]). After 

smelting, the copper anodes contain approximately 99.9% eupper. 

During the smelting procc:ss, the: smelter opcr.uol"!' generntc a variety of copper-bearing 

m.oceriols they call .. revert~ ... for tbe purposes of tt.ais discushiuu, we: we diviwng r=vertlJ into 

two broad cate1oric:s: 

• "La.r~t~" reverts: Fairly l~rge , dense and aolid plec:ll of n,etal or J'rimarily matalJLc 

material (in(lluding slag, t1Hltte, and blister copper) 1cncrated from the coolina of molten metal 

that baa csc:apcd or been rr;movtd f.rom th• srneltin.g or convenins process. This e•tcgocy ot 

revens indudc me rat that bu cooled on the inside of ladl11s (skulls), drips and spills !rom the 

hillldltng of molten metal, and hish-.copper cona:nr material lbat has ·been skimmed from the 

turface of cC)nvertors. · · · 

LS9£ SB£ OZS 8 AlddnS dH8 
. • "Pin~" rcvert11: Cuoled c:oppcr from !lmDiltr !plAshes ~n\1 dript, alona wiCh copper beachlj 

sands, mud, sweepings, water !Sump solids, ~t . 1enuoced during or subsequent to the smelting 

proc:ns. These reverts are finer in partlC'Ie size than the oUen louse and solid pite• of metallic 

c:aPJ)er diJcua.wi above. 

B•c:aU3o dlo initialc:onc•ntrotion ot c:oppor ia the: on: Is ~o low, matuials m.t \:oWcJ be 

c:ons idered "waste. like" in ocher industries (aolids ftom the bottom of sumps. etc.) -contain 

copper values s~veral orders of magnitude higher lban tbe ore. aHP cons1den the 

re .. introducrion of reverts ns a means of recoverin 1 copper that would otherwise c9cape ftom the 

arMlter processes. 

The 1ame grinding, flotation, and smeiUng processes that conccntrute cbe copper presenr 

in the ore al v ~uu~,;c:r11ru1e th~ arsenlc, lead. mm:ury, and ocher Toxicity Chonctertstic metals 

prcaent in the ore. Th~~ toxic metals are concentrated into the reverts along witb the copper. 

Reverts are u.tmatly ll!U:l)lrd for copp~r content but not for toxic mttab, because the smelter does 

not con1ider reverb; a waste. 

The large reverts, S~)metlmes catlcd "cobble''. are usually generated i.n or adjacent to the 

converter aialc. They typically contain over .50% eopper. Afbtr any needed CtUshina and si.zing, 

the majority of the la1]1! reverts are ~ither fed directly into the fuma~e or ure used in the 

C'lOrtVI!Iters a1 "coiJ-dtlpe". "fh,: unsoiny cll~lions in tha QOnVeM12r.l are l))t(llbC:tmiC, &nd the I.:Oid 

mero.l pie«m arc used .. , ·'dope" to contrOl the .temperature inside tbe converters. 

These large revem are requirod for I he ongoing opemtion of the coovertert, ~nd are 

stored. bought. or sold hy 11tnehers depending on n•ed. The /11~ rev~rts are often atonsd on the 

iround1 end we~ not heing f1 P. t1t11 tively aecnmulawu at the tlme of the im•p•c:tlona. 

In contrA.!%, rbc:fol~ reverts an: rc:u:haJ cithtr by bltmdlng them uno the smelter t'tedstock 

or at the solids recovery plant d-=ptrnding on their copper cot\tent. The ji'fe revens are collected 

from (!rain und process sumps, vehicle wasllmcks, rainwater run-off sumps. converter dust 

boJtes. convvrter ai~l• ni . m.elt r lll'ell w~, ete. 

Thcj111t rcvcl1S huvc: 11 uunkt:t valur:, 1rc usually stored on [h~ &round. and were not 

being specul~tively accumulated durin& our inspcttions. Tbcflne r~vesrts sampled durina ~he 

investieation cantnined npproxlmntely .40% copper and excccduc.l th~t Toxlclcy Characteristics for 

lead and eadmium. BHP oon,.ider Jitt~t even~ c:nnt:.iniftS n I ittle as 3% <:opper st.ailablc for 

bleodina into the concentrate. 

1 40 CFR § 26 I .4(n)( 1'7) require., ce:uin bl&ndli.n8 Gnd orAa.c: prud icc:a fat min•ral procelt!lins 

secondatY materid!s. 110 CFR * 261 .2Cel(Jl, u codlfi•d. ref•ntnc:ed thtt~ requirement." rn ... miner~~J 

processina secoridary rnatcri:Us UJiU ace reclaimed. The "Bantry" decision (Association ofBatkry Rec:yclen~, fnc. cor I " · United StaNt &n~tironmenral Protcotion As.:n~y, (D.C. Cir. N'o. 9$-l368), dl:cldcd 

April 2 t, 2000) ~vouide the rc:fen:ncc cu 40 CFR § 261.4(aX 17) for ~haractaist c-only mJterials (sUet\ 1$ 

Die f'lne re't'W'to) that cu·• "ot :~ulld wutcJ whc:n reclaimed. 

' 

lS9~ SS£ OZS 8 . A.1ddnS dHB 
Aoab'ais god lnt;rnwtatign; 

We have determined thai rhe la.,.,t reveru aro t)-[)ically &llc:d by returning them directly 

into the onaoing .!fmeltinK pmeess. EssenriaJiy, rh~y Are pfeees of copper beias Uzsed as copper. 

Molten mttal spilled onto smelter floors u not nsoJid waste if it is picked up u pnctJcaland 

placed bade into the sm•lting proce.:SS {6.3 Fit 28S8J). We bav~ t.lc:h:nninc:d that tb_o /a'ie revens 

oreobble, if not speculatively accumulated, are not solid wastes when uaed in lhha mao.ner. 

The status of the fine reverts apt'C3fS to require a more detailed analysis.. Material a are 

not solid wastes when they are legitimately recycled by being .. used or reused" as an ingredient 

in an industri3l procttu to make 4 product, pro'lidcd the materials arc not bd.ra~ .. reclaJmed'' (ctO 

CFR § 261 .2(e)( I }(i)). Materials arc .. used or rcusttd" if they rue ·• ... employed cu ctn 

lnlfl'edlenr ... ln an lndu.vtr/al process ro make a prQduct ... "except where ..... distinct components 

of the IJtat~rial art r~covered aR sq,arate end products (as wJr~m ml!tnl~ (lr• ,.cov.l'ed from 

mltaf.containl'ng Sl!C.Oildary matoria/1) ... "(40 CPR§ 26 t .l(c)(~)(i), ctnph4ais adc!cd), 40 CFR § 

261 . l(c){4) deflne11 .. realaimtd" as: "A m4terlal Lr ''•·t:daimerl"lfit 1'3· prvc:~uer.l zo rtcoller a 

usahlt produc.•t, or if it 11 l'i!generaled. E..-camp/19 arr. ftfCO\ltl1'}1 ~1 buul va/u1s ji'OIH ~,.':'1 

butrtrfes ... " ThLtS, because the copper amelter .recovers copper from the reverts as a separate 

~nd product, and a\ so because this recovery C01l!titutH ~lamation. th! rev~m do nat qualify foT 

the "used or reused'' !olid waste cxclu.t;ion in 40 CFR 0 261.2(e}( l)(i). 

The fine reverts are not listed hazardoUi wastes and are not speculatively accumulated by 

DriP. Therefore, whc:lhtr rhey are considered "b)'·product3" as defined in 40 CFR § 261.l(c)(J), 

"sludp(s)" u defined in 40 CFR § 260.10, or mineral processing 11Secondelry materials" (s;~t! 40 

CFR § 26 I .4(aX J 7)), the fine reverts an: not solid wastes when legitimately rcclaimell by the 

smelting J'l't)Cess (40 CFR § 261.2(e)(l)). 

TI1~ 4LR:~tiun now becomes: Are the fine revc:rt& legitimately rccla.imed by the smelting 

proce!s? The smeltjng process clearly recovers the copper value Jn the revert.t;. Orte critl!rion in 

datettnining the legitimacy of reclamation is whether there are "toxics alons for tht ride" . .: 

EPA bas stated: "Situati(tn ~ mo.rt/1/c~~v to he tle~m11J sham rocyclbt)J would, 1h11.s, b~ theMe 

fnvol\'lng low amounts of ff.>crJwrab/e material plus /Itt preJenct of non·contribuiln.g lrazQI'dou.s 

ccnutllwc:nt~ in th~ wa.TtE (parlicuJarly lru.urcluus consrttJAents not orheN.•n·e P"ruent 111 tlte 

lformlll Jeed1toc/c of tiJe proctsJ). " (63 FR 28587} · 

As noted, the .fine reverts contain significant Amounts of copper. Cadmium :tnd lad, 

which the fin~ rev~rts contain in <:oncc:ntrationl that exceed the Toxicity CharllCtcristic, are 

non-contributing hCllntdow cM:ttitucnta {!te Attachment H,5l. Huw~vc:r , cadmium and lead are 

J'resent in rhe nom1al feedstock of the ~mcess, and the same smelting processes thot concentrate 

copper into the reverts also conecn[rDtt! the heavy metals.' Although the: cadmium and lead arc 

2 See 53 FR .522 (I/818M), 52 FR 170lJ (5/6/,.7). And 50 FR lil8 ( 114185) for ~xamplu of 

recyclins Jeaitlmacy criteriL 

) L'lllikc some of the secondafl' material II re}Jortcdly uti Jized in the smclrin& of other me~al& 

(Cillhodl nl)' rubllt halnJC.NShed Bt lend smelters, C:tC.), thCjlllc RYCN llfC 8C:Il1111141t:\l uurin1 thl <:Opper 

6 
.. a(nng t(,. tM nd•", th•flm• NV9tU arv ~{ftl ntrodUC~ illtO the SmCitinwrecla~ltlOD proceU 

primarily ro reclllim their hlsh copper c:ontent, not a:. a sham mean! of dispo•ins of cadmium and 

lead. Thull, th~ Jlnc n!Verts are bcinS legitimately reclaimed in the smelter. 

flaSh furnace: 

Pa:tt; ttumacc reecs: sUic:~ flux~ "bl~nd pile'' material (items reh:aacd durin& 

mnnagement which have b~en clean.d up). 

Present: No activity. 

Qy•ao.ina matsdal; 

Present: No activity. 

AddjtiQPAl Process infonnation; (Suf'plementt infotmation on I'"P::t 7·12 of An&Cbmeot ttJ >. 

None. 

·Jncomina matcrlal: 

Pnst: Oxygen: matte from flngh furnace (ma~ nvtn}'. convcrt~r 3pillagc; attoclc: MIMi; 

silica flwc; cold dope bbles, ~~~~' etc.) reverts; sp4:ntlrcject anode!: foul 

cothodu: speias. 

Pn:scm: No activity. 

ameltlna process and d1e toxic net~ls found l.n rbojt~rr rcvcru appear to have primarily oriaiaated from 

the. ore. Since c'd~rum is already rratent in tlw ametw C'e.d, 1he ~ycll111 of the rewuvel; srnllll 

quanritiu llf re ert.~~ into the feed is unlilccly to .. si&niRcandy afftet .. (see 40 CPR § 266.112} the BcvUIexempt etlfl~r am•ltin.a ul•s· 

7 

LS9£ S8i OZS 8 ~1dd0S d~S 
Out&aiua N'•ti•l: 

Past: Slas; 501 gas; converter brick; bUsrer copper: white metnl. 

Present: No activit)'. 

Additional Process informotjan: (SupPletnenta ln(onnation on pap J 2- 17 of Atw:lmtppt fQ). 

• Determinations we"' made for uac of the slJica bead and quart7. ror.fc ttu\t we~ ba"d on 

the pcrc:entaac: of ail ita content 1n the material. Jfit wa.~ under SOOA silica content. the 

mareriAI wu not used as null:. 

• The c:on~crtt:r bricks were replaced e\fet'y 3~4 C)'tles (approximately five months at 2 

eye: leal day). 

• The fAcility is !!quipped with four oaftvcrtcn (sec photosraphs tf. 3-<5). 

• Analytial resultS of dust ~md otller material from the converter aisle ire provided in 

Attachment#~ (sample JD BHPO 1 and BHP02 respectively). 

Canmer Roaulatory hsucs: 

f51NC: fll 1: OHP U$ca.l spent slltea lmprean11C<1 with vanadium penlo lli d~ t13 a aubsti&ute Cor 

mined silica. ls this practicD lo<imatc? 

VanQdlum pcntof'tide (V10,) is U3eU ti • catlll)'lt Jn che acid J11ant's convertins'towcr to 

conven SOJ sas into so) yus. The VWtadium pcntoxidc ~ mp~)Ulaled into silica ~ads 

supported by a bed of quartt rock, After a period of time the physical size of tbe silic:a beads 

becomes $ffii\H enough to inhihit lhe flow of gcu through the c:ltalyst bed. Th~ undersized be ad s 

and pteet! of beads (''fines'') are physic:al)y !creenl!d out of the cottalyst btd. The coarse 

material• are reused in the convcrtius tower. Approximately 30~0 tons of used catalyst fines 

and quam rock are produced 1very 18-24 manttu. The used catalyst fines are lYJ'iC:ally stored ln 

tarse wn"tn fiber c:ontainers c:a.llc:d supc~~~~ • 1nd were not being ~pecutativcly accumulated 

at the time of iDSpection. 

RHP did not have ,;pont cat3ly5t fines on·.titc or available fof sa1uplinij ut die tlmt of our 

inspections. BHP stated 1h.at they had never tetted the catalyst fines for the RCRA to~ticity 

chuactcristic:s, asnd noted ~uch tesLCJ are not requtred 1br rnatcrinls that nre not soJid.wastes. BHP 

alao determined tlult 1bc clltalyst finn arc as effective 1 fluxing aacnt as the cru.,ht'.d siliu from 

mines that ~ normally used In the smtltet feed, and that the catalyst fines are directly used~ an 

inaredlenr (sHieR) in the smelrer fc~d; tbua, the underai.ud silica bca<b wen: never a ~Wlid waste. 

The ftn~ contsin &J)prc"imately ?016 Vl.lltdlum pentoxide, about the ~n'lc prrcentase aa the new 

iltlprosmtcd bcaJs. V~madlum penroxlde is a commen:ial chemical product li.tted in 40 CPR § 

261.31 a.• acute h:l7.ardou!\ ..Wstc: numb.:~' 'P 120 itAod wbGn dii\Oiuded or Intended to he 

8 
di&carded. 

lHiP r~portod Uu: l,;nJshcd, sllica4eontaintns quartz rock is routinely used In tbe smeJtar 

feed u a .. flux" to " ... co1Jfbllft with iHJ" DJtd alum;nttfrom tllft con entrat~J ormott11 t~ttd nJtWv• 

tr cu .slag.·· {see definition of flyx, pag~ 2. AttachwmtJ3). BHP uses the vonadiwn pentoxide 

imtJtelll\lted silion tlnes a." a Auhititutao tbr silica sand mined from qwartz. The lllincd silica sand 

does nor appe11r lCJ bC' chor.Jcterisric ror to)[ic metals ot eontnin detectable l4tvei.J ot vanadium ~tooUcM. 

Itaugh calculations indieatc: that rhe vanadhml poncoxlde in the ~ilica is about 00.00025% 

of the total feedatoclc UJed h~ lh~ smc1tu e~b year. 11\t boilingl)Oint of varntdium il much 

higber1ban the working tempcrarure of the cc)pper ~meUina fumace, which indi~ate.s the 

vanadium in the spcnl ~atalyst fines will not vaporize and cnrcr rh~ furnace exhaust stack. 

ln.stea.d, tl\e vanadium pentoxide witJ likely ckomically n:dut!! m the fumRce ro a vanadium 

meutl, and would be removed (:alon25 with iron and alumina} In 'he Bc:vill4exempt slas. 

Petroleum reftneries al&o use vanadium catnlysrs to conven SO~ pe into sol au. The 

--r~ r v&Mdium ccnatysts uaod for hy\lrun:nning and bydrotrealins ia pctrolcUDl rOttning 

operations arc K I 11 and K t 72 listed h~ardous \tfastes, Concern about the toxicity of \lea.diwn 

pcnto~fdc was on\: ~ll.'!on the wastes were listed.+ Tbe 14 inert support media" for K.111 and 

K 172 ere axempted from tho definition of hn7.4lrdcw wast• { 40 CFR § 261 .3(' )(2)(1i)(E.)). 

Anoly&is anQ lntct;rttQtiOpl: 

A MSDS providfd b}' one .smelter liata vAnadium pmm.Ude orthorhombic crystall, at 

over 82%, as the only inarcdlent. Annlytit-al ~ul l provide<! by anoth<;r smelter repurted their 

'PtDt catalyst fines llfe cbmcteri~tic t'or ilraenic (0004), cadmium (0006), lead (0008), and "~leaium {00 t 0). A llhourb BtU' hu lllairucd that the used fine' were ne'r'er a •olid wutc, for 

purposes or regulatory discussion, we wiU corutder that 'lanlldium pentoxide is the ~le Relive 

ingA'C\Umt and rhat rbe y.SCU tlnes ure 'baraGteriatic: for metals. 

Althouah the van4dlum pcntoJtlde Is the ~ole active ingredient in the catalyst,' it is not 

"a~n " after ust;'l,• ll11d berefQ~ dues not rnc:ct the P 120 h'ilurdous wuste li5ting. A3 detailed 

4 The " ..• .sclf· h""'ting pyrOf!boric propenin and porcnual n:au:llvity ..... of die su /fi ~ fn the 

rt'flnny wutes wen: 11lso a concem (60 FR 5778J.8.S and 6~ FR (1168). This is not a ~oncem ac c:opper "'~ for.t. whtnc U\t rop ori~ na.:ti\ln u ( &he suttur fn lbe ore II Ul td to hc;~t the 1\m\acc. 

~ The silica bca~s llpPt81' to act as a •upport media to in.:rwc the Jurface uea exposing the 

c:atalyU imp~gnarcd in the beads to th~ SO! su treGm~. not u an active fn&rtcUcnt in rhe eonwttioll of 

so, ¥•s cu S03 ps. · 

• 40 t;FR § 261 .1 {c)( 1 ): "A 'J~m mUICU'Itl/' fs any lffat~l"'a{ 1h11t hclJ h~, •u•d and a3 tJ ,..tu/1 tJ/ 

c:onUJmintlliurr att rro IOifl"' Jt!!I'W rhc- purfXJ.te/n' wltldt If~' pi'OtltJ~ wltlcout ptu ~lftJl ... " 

1\CC'Ording to facility ~ubmiuala, when ~moved from the con erttD~ tow~r. lhe nnes·conwn 

llPProllimately thO! 11:\me t&r (1'~) of van\\dlum ~n oJtilte as the new imprecnau:\S boada. We 

9 
abo\'C. the c~tt:tly t~t is u••d in the m~nufac:turins oraulturic nc:id. "Therefore:. 1b.~: u11ed c.:llhtl~5t is 4 

manu&cturina proets3 waste. Because tbe used catalyst is ' manufacturing process waste, It 

dottf "ot ft'\OCt the; vam1uium pento)tld~ lilting in ~0 CFR § 261 .33.' The used ~calyst is also not 

a listed process wo.ste (the K 171 and K1?2 li1tin9s apply only to rhc: cab&l~r ~ genenated at 

petroleum re.tlneric~). 

Vanadium pentoxlde, however, is no' £ound ill the normal smelting f"mac:c focdatcx;k, 

11nd thut any dctc~blblc amount or vanadium pentolide in tbe resulting ~mcltina furnace stag 

could "significantly affect" the sJaa (and irs Bevill....,xempt st1ttu). As n(lled, the vaoadiunt 

pwnto~l(Se in the catalyst will be ch~mically reduced to a vanadium metal in the ameftet ftunace 

or convenors. 40 CFR § 2M.112{")(l) etdea: "Tile JWUte·d•rll16:1 rtJidu~ tnll.)t nat contain 

appendu V//1, pa,t 161 con.tlitueniJ (toxtc C0113tltutrnls) thut could fl!dSontJbly "- attrr'butaole to 

lhtl 1tatQ1't/t}W.f W(I.Stc ... .. While VIUlacUum pentoxlde il an appendix vm toxic constituent, 

vmadium metals are not. Thus, the vanadium pentoxidt! in the U3cci c4tAlyst wilt nnr 

"alsnJticanny affect .. the smeltl!r ila.g. 

Materials are not solid waste when recycled by being Cl:used as ingredient• in an 

induatrio.l f'")O•II!'I to m~ u prot1Lu:t ut· as i:rr.crlve subatitutes for commercial produc~ (40 CPR 

§ 261.2(a)( 1 )), Although Jhe vanadtum in .the used ~talyat is not recycled by BHP.

1 they stated 

that rhe catalyst fin~ are ns effcctiv~ a flwtina agent as the Cnl!bed silica from mines that is 

ncmnally used in the smt!lter f.-l\d. Oistinc:t compw:~enrs of the u1cd catalyst af~ nul n:covered a.s 

separate end product& (i.e . it ia not rc~:laimcd . See 40 CFR § 26\ .l(c:){S)(i)). 

The question now becomes: Ale the used catalysr fines lc::~itimardy recycled ny rhe 

smctnna proccss'l One criterion in determininB the lesitimacy ofr~ycllns is whether there a~ 

"toxies alonA for the rlde". The ~hara~teri11tic molals in th~ wed c:o.tal)'st finos nrc "toxlc.s alon.s 

t'or the ride'' when the Wled catalyst flne6 are fCU.Ied for its silica value. As previouaJy noted in 

the rov~rts iatue, ~ilU4tions likoly to be dc:emc:d sbam recy~ling would involve low amouuts of 

· recoverable material plus the pre~encc ofnon-contributins ha:urdous (;Qnstitucnt& in lh• woure. 

believe U\la indicates the vanadium penloxide-imprti""'ert hP..-ds 11reo contldereJ unfit for uac: bcco1uu the 

size of the atlica bcad~t fat~ below :speciflc•tiona, not bee~use the vanndium ptntoxido f& consumed. 

contamin&led: or no lon11•' hcmieA II y ctT.cdve a11 a oe.t.lil)'lt. 

1 l'h" ~ommcnt ln 40 CPP. § 261.33 tt4b::t thtl " ... 71rt pit/au 'colflltlt'I'L'Jnl ~hllntiCIJI 

/)""DlDucr' ... doe$ Mt f'e/~r to a marer£t1/, Jtu:lt cu a manufocrurlng pror&, M•a.ttr, tJwt cotJiailfs "ny a[ tJ., 

.tubdt~llr:at ll~trt!d in prmtgraph.1 (t:J ur (/) (lncludl"l Pill)~ Wlfln: a mtJttujaclllri'IJl proceu WG:f/tt is 

dhmtH/to ~ rt lttGDrciJJII.S WClJI~ btc'QILtr it COIIfdWD suJutan~ li~led i ll pt~mgNp/t (t!) or(/), IUCit waste 

wiU lw IJ¥Ril i1t rfllt•r § 20/.J I or .f JtH .J2 or W(ll 1¥ iderJtljle4 as IJ haZilrd(JU3 wrme by tAw 

cltaJOacltrlJttc.r .111t forth In Subpart Co/ this pG/'1. " 

' 11\e Sltbmtnal from BHP did not list vanzdlum pentOJtide u 1t J~ireblc: cnmrnnent In the ore or 

the mtncd .slllcL.- Nor hllve \lte found any informaliol\ thlt vanadium penloJCide is a deeinhlo or IUC't\ll 

n~t~d cnt In the copper tmeltinll (amaco feed.atock, Vanadium nr vanadium col"'\pDUDcb ua not prochu:tS 

aepant!Cily produced nr sold by the smelter. Tbus, the vanadium penroJtlde ill nor reeycled by the .smelting 

proeGtl. · 

10 

LS9£ sa£ ozs & 
" .• ./Hl11k&t/tv>ly lttJ:ttlrot# .~ ~ ~lf rl•' u~nu flO I Otherw/10 pi"CHIII (If tiJ~ fiOI"IfiGI for:d.rtrJck ofllafl 

pi"'~I ... " (63 FR 28587). The catalyst nm:a have larac: ltnOWllS or n!Coverablo matl:riAl 

(ailica). 

A d~tailed review of the proceues ind c~ that tho ~ralyst fines deri\'e all dfita toxic 

m•ral.a from the ore. W • cil..t 11ot tlnd any ocher 1ourc:oa or matorials that would ac-oCJunt fur the 

hazardous cluu·a(:teri~tt c! of the "amlyst fines. 

A copper smelting fUrnaC\: Is a BlF if It proceue1 haz4tdo1J$ wucc ( 40 Cflt t 

260. JOO(aJ). "'Toxi~ along for the ridt" are evahwted at B!Fs by dcu:rmining if the to.xi~:s 

··significantly aft'ect" tbe fumace rctSiciuft (40 CFR § :z~cu ll(~)(l) and (b)(\)). Oi~A the 

extremely low proportion of aatcdyst fines in the total smelter feedstock, and the fact that the 

toxic m.~lii in BH'P' • used ~nt4ly:sc 11rc nortllllHy found in the: amelter f~ Qnd copper 

concentrate, the use of the ~haracteri&tic:al1y hazardour c-.nalyst finca would be unlluty tn 

.. atgnutanuy atTect" the residue (the Bevill ~empt s.rneltins slag}.' 

Tb~. the used catalyst ~ being lqirimatoly used or reused as an nar~ie.nt :~ilic~) in the 

sme lter (ccd, a nil ;., nol q ~a lid W~~o:Slc ( ~ CPR§ 26 I .2(e)( l )). 

AAQIIC V11111 and Anode ClltlJJI Wheel 

lncomina matorial: 

Put; Blister copper from eonverten: purtbutd. copper ' <:riP! natural p.s; •tEam. 

Prc&ent: No activity. 

Qytppiga maurial: 

Paar: Anode c,)pper; l.llled anode furnace brick; anode slaa (to the converters): revert1 

from minor Jplaslu:s and SJ)ills; rejer.t anodes (to the eonv•rters). 

Present! No activity. 

Additional Pswg~ tnr nn~tlon : lSupplements inrormation on pa1cs 20-22 uf AmcbmenJ !J}. 

• See pbotograJ)h #7 of an anode cA~t tina wbccl. 

Anodt Ywsl and Angdc Casting Whcc:l Bcplasory lquca: 

Nooc. 

' Bccnu.c rhe <emcher it not p~~onina a ha7.fttdou• waste, tl\• BIF NiUIQtiotU arc not &pp\ il~llblw. 

The ttlndardll• t 40 CFl\ § 2()6.1 I 2(:1)(2) and {b)( l) lltC tllll usefUl. howcYCr, in dc1enninlnll tbc lf!'ICt or 

tbc toltic mcbll! on tht Bevilt-eut"'P' al-a. . 

11 

L~9£ S8i OZS Jl. 
cu ca., ... Syptsm tnd Jbc SgJQlrlc OShl P\lat; 

lu'i.Y9'ina ipmrlal: 

Past Flash furnace and converter off.pscs. 

Prt5ent: No activity. 

Ouxaolni material: 

uf ~ Llloos acrpar~tor solids; acid pl.of\t blnwdown; 51.1ll'u1 ic 1cid; silica beads; quartz 

rock. 

Pra1ent: No 11cti vity. 

Additional Process informC\tigJ:l: (Suppl•mcn~ infonnotian on pasco~ 17-20 of .6tuu:b.m;nt !3). 

- Tbc lut time t)UAL llCiu plant brick WIS senarated WU in 1996. 

• See photographs # 8-9 or sump(" J2A ") where weak :acid plant blowdown was 

neutrali2ed. 

011 Cloqnin& Sntcm and Sulfiuiw Acid Plant Rcmrtasorv Isaug: 

ISJllC ttl: 

Detallt: 

See discussion on use of used sili<:ll flne, a.s flux in "Converter" regulatory 

di:u:u"11i011 section. 

BliP "neutralized" lhcir weak acid planr btowdown hy mbdna it in: ll sump (called 

"J2A") with Bovill-exempt mill taillass. Waa thi:S pructic~: legitimate? 

Thia capper on~ contain~ sulfate,, U"oth~:rwic :sulrur reactions provide the h.eat used in 

the furnaces .and converters, and sulfur-laden sues from tbe smelter are collected by air 

pollution control devlees and used to produce aulfuric acid. BflP used "om~ or the sulfuric acid 

they produced in thEir beap le~b solut{ons. but ~1gnifir.ant qu11ntitie' of sulfuric acid were 3old 

as product. BHP rtpOrt~:d that th~ acid they produced was often of such hiab quillity, and b~d 

.11\IC!h a bish ntarbc va(u., <lS o commodity, that they :~old the sulfuric acid produaed in their acid 

plants lltld purchased a Jcs.'ler quality sulfuric add from the open market tor usc on the heap 

lew: h. 

Tile particulate material that c:ollect:l in the: gas clcqntng sy~tl!m are ':blown down." 8HP 

stated thtl the blnwnown hAll a pH of appra"imatoly 0.3 1nd was gcnc:nalC:d ar a rate of ~00-

1,000 pi Ions per minute (see Attacbmsnt !3). R.c:t'med ro as "weak acid .. , "blowdown'\ and "wco.k a~id blowdown", it is a :slrong comuive with a pH of approximately 0.3 · 1.0. (Sulfuric 

a~:id from the gAS scrubbing rower is ~n!IIM by tb• ahf!Ofl)tion of water vapor from rhe S01 

12 

LS91: 58£ 02S A 
"as. while the sulfuric: 11Cid ~nlcl :IS a produ~:t il .l(l'llf81h•ll•d by the ahsurption of SOJ au.) 

"Acid plc.urt blcn,-dmwr slrtrr; JiucJ~ rtsulr111gj'fotn IU tluckrn/Hg o} b/owdoWPI Jliiii')J 

from prima') ' 'f1PP" productt'cm " wns formerly listed u hanrdous waste number K064. On 

October 2u. 1999 (64 FR 56470) t;PA removed the lilting forX.064, aftt=r previously explaining 

that these wutes ean be effectiv.,ly n:gulaled if' th"y eMlbit D huatdous characteristic {GJ Fit 

28600).

10 BHP did not thicken their acid plant blowdown. and thus would n.ot ha.ve gencntcd-. 

1(064 lietad t.AurdoU3 wa:stc ~vt:n if lhc K004ll!ting wu still in effeet. EPA letters to Magma 

Copper Company dated July 6 ilnd Jul~ 12, 1989 reiterated th.is f~ct. Tbu$, BHP's acid plant 

blowdown is :1 characreristi~. but not Hstcd, haardoUJ waare. 

BHP's acid plant blowdown wua ix~ with liquids and slurcy from rhe tuiliass 

tbiL.'k.ncr. Thia mixina CX'currc:d in ll lai'JC sump tiM i5 cunmucted o( concrete, is partially 

below grade, and reponcdl:t hil.~ an intnct coner.!te floor. The resulting mix cure: oftaiJlngs 111d 

Bcic,l plant blowdown W3S disciW'ged into the tailings impoundmcnt.l. 

BHP is not cunc:ndy opcrllling, and no 11cid plant blowdown, tailings •lurry, or mixed 

t~ilia~ "YctO avQi)gb\c ror 3amp\ins durin& UIC inspecdon. lnfonnlltion trom ~HP indic:ates rhe 

blowdown ha\ilcss than 1% ~ollds and wu eha111cteristic for corroaivity (pH of0.3), arxenic, 

cndmlum, le:~d, anl.i selenium (0004, 0006, 0008, and 001 0) (sea AttaQ\ment ~l). Previous 

information obtained by £PA trom when the facility was opefO.ting noted the t!Uli.Das conuiu.l.! 

approximately 5001:. 3olid:s and 50"/u Jfqulm, bad 3 pH ofaJ)proJtimately 8.0 to 8.5 betore mjxing. 

~tnd thAt the re•ulring blowdowl'llteilinss mixtul'c b!W " pH of 6., tu 7 .0. BHP's submittal (:sec 

Attawbmcm !}) stated that th.: mbted tailinaa did not exhibit any hiU':nrdous chara~;teristJcs, and EPA ~ analyttc:ll results show the soHd (dried) taflings from the cnilinaP pond were not RCRA 

chanctmstic: for toxic metals (see AttMbmcnt tS). 

Th~ facility notud that lh!!y Ml oonsid~1ing rcpU.cin¥ th~ hti\in!J.!I neutralization system 

with a lim~ treatmcofsystem, which would generate an ex~:mpr t!:alc:iunt sulfate wastewater 

trc11uncnt ~l\.I\J¥e (olO Cfl\ § 261.4(b)(/)(it)(H)). 

Analyst• •~ad lntupntatJanr 

BHP 'chsimtd thl! "weak acid" was " ... unifU~ly a.1soclatr:d with the prOCf!Uiltl o[oreJ 

and minllrals becuu.re it d~ri~s its ~. Jtal't1cttt:rz~liafra"' ''" IPMn/s nnd xu/falflt in ilia tm~. 

concDurar•. and maltt!. " (Quoted from facility submittal.) 

10 40 CFR § letl.4(h)(7)(ii) lists conain solid wuces from the pnxessins ufcires and minerals 

(i.e. "minerql proc:CS$ n~ Wl'lt4!S'•) Uunure not huardouM waares. Although teciduM fforn rhc treabncnt uf 

acid p\tf\1 blowdo'hn (calc:ium auJrat~ ~u:llcwllfcr treatment plllllt sludge rrom primary copplrf ptoc:euins) 

arc incJuded ln the li :~t (40 c.r-R § :'61.4(hJ(7)(1i)(li)), ocid plonl blowdown i' n\ll. 
~'PA di~u.tlkd ''uni'\"cly ufiocialld" in the LOR. Phase IV final nslc} 1 and backyround 

docwnen~ inc:orpoTI[cd Into the LOR Phue tv docket indkate EPA ha5 determined tbat acid 

plonta ace HuL uniquely associated 10 smeltlng. £PA reitentttd this point in the LOR Phase IV 

final rule. ltatina that the acid ptont blowdown al copper •meltcl'1 is subject to the RCR.A 

hazardcus waste rcgulo.tions lf it exhibita 1 haz.ardous c:hamcteristic: (63 FR 28600). BHP's acid 

plant blowdown i~ c:harnctl!!,.;•tically hantdoUI. 

Prior co mhdng. chc tal/ins~ an~ bcnenctatton wastes that Jar! excluded from regulation 111 

a solid waste (atld thus as t luzardous waste) under subtitla C ofRCRA (40 CFR § ll51.4(b)(7)). 

ErA previoUS()' dcrennined this copp~r smelter placed exempt ad linKS and non-exempt acid 

pJ&Df b}OWdOWn into the Startle WA11te 0\ID.mc.Dr unjt, Ia 

The r03u\tingtailiniP/bl,lwlluwu mi~t\lre is not characteristically hazardo\15. Thus, an 

exempt waste {tailin&$) was mi~ed with a noa.ex.empt charac;;tGritEicaUy hazardoua wa."ta 

(blowdown}, and the ~ulting mix4td acid plant blowdo~thfc:kenc:d tailings mixture did not 

exhibit any of the hazard,u.c; WAlde characteriadc:R. According to the "Bevill ml"turc rule" lu 40 

CFR 0 261.3(a}(2}(i) 13 because: . 

\) Tlle rallinga were exempt bet'ore mixina-. and, 

2) The blawdown was a chat~cteristic·only haunkn&! waati; and. 

3) The resultin~ ta.ilinirt'lblowdown mixhu-e WRS not cb:uac:teri8tic• then, 

4} The tllHinss/l,lowdown mixture: l'!cains fh~ solid waste (and tltus hllZ8tdoua waste) 

~c:luaion. 

11 

" •• • a"y HXJste.frQttt a11cill:rry operatiolf.'l art lfOI •uniquel)l ru:s«iatft/'' bt.·caUJ~ Ihry art ll(}t 

propt.'rlJ ll!r'Nt!t/ cl.l· fH!Ing ~from" mil1tlfg or fffmf?'nl proceJI'i.1tg. f~t •va~lllrlf wost.m from XOII•Q1fCI/lQT)' 

ope'tltlons. o11e must con.rlder tltt exrerrt to wJtlch tit• \44(}81~ tJ'/flrtalc.r ot lr:riws.f;vnt J»"f!CtSia thdr 

ren1f! to rl'mOVf nrineral value., frrJm the grou11d, cont:entrate or otherwilfl enlrcmce their r:ltaracterl.rlfc~ 

Of'l"f!move i~npuritles. and tAt! utc:rrJ to 14lllttJh the mi'"flll ncovllr)l prouss lntpn1'tt iu are~ttf~l 

chllftlcterutics to th~ wo.ste. " (6l r: .It 11UO I) 

12 MINERAL PROCESSING JI'ACILITtES PLACING MIXTUR&:S OF EXEMPT AND 

NON-EXiMP't' WAST£S IN ON·SIT~ W,t\STI MANACEMF.NT UN(TS: Tcchnleal Dac:JcaroLnhJ 

Document Supl")rtins tbo Supplement~! Proposed Rule Appl)'ins Phase IV L1tnd DIAposal Restri~dona to 

Newly ldentiri~ Mi11erel Proc:c:JIIins W:~scos. Offi~e o(Snlid Waste, U.S. f.PA , Occcrnb~ 1995. 

I) 4() CPR ~ 26l .J(d)(2}(i): '' ·- arr.)• mixfllr.: uf a Wfl¥l~ from tlu? t!.'(trnctwtt. bttfrjlr: rt~ion. and 

procr:.uing oforu dlfd ntin("rtt/J c!'lclud~ undtr ,. 261.4tbJ{7) alfti any otll•,. n,/id w'tlst~ ~ltlhlttnr a 

cJ.ardt:lertstlc of flaza,.Juu.v tt.'tl.Yre Ulldtl' Sllb{Xlrt C IJ a lfa:ardola wastt nnly if II txAibit.r u 

dram~rerislit: ll.at would ffot httYC bHn rxJrihiJ«l b}llh ~luJH wu1~ aJorre If .JUCII tniX&re hfJii lfO{ 

ucc~trrld. or If (t conrlnus to tXhibil any rif tht ~htrl"t~Ct•ristlcl ~lllbittd by tire lfOII•&'fchuied wtUtU prior 

to m~llll"e. Further, for thrt purpou.f t>/ GpplyllfR tit~ To;rict'l)• Clraracrcrtrtlc to .orurh mirll,~s. rlt• lf!li.ttU,.II 

iJ (JJ~o a hrDtudous WQJitl/ /J t!rcceds tlte maxflfllllft conctlllralion for at~y c()fltQIH/IIant ll1trd in Table I 

IQ f 261 .. U that would Mlltovtl b"" a'tcf!ft/ni by til~ cxrlfl1ittd IAIIIJt• tJI""' if lhu ,.wu,., /tad lfOt 

occurnd or if IJ cottfilfu~J to e.TCt•d tlr~ mtJJCifrRim concenmuton for any ~ontanrinatrl e.TCtJtdttd b)lth• 

nonUflfiJJI WHJ.III .PI'ior /() Jttixturt'!. " 

14 

l.S9i SS£ 02S Ji 
~noted, th~ mi"ina reducea tbe pH of tbo tailinaa. Th.: resultl of a prcvioUJ lnlp~ectiuu 

. of this copper smelter conducted by Region 9's Water Division indicae• that th• reduction iu the 

pH orthc llliJinJ~:~ iJ noc deslrablt~ 14• Because the acid value ofthc acid plunr blo~dawn il used ~olely to <kcreasc the pH of tbe milinJiCS, and tb.U decrease docs not serve 11 hcnetlcial ptJrpOie, 

the acid componl!n~ ~r the aciJ plant blowdown ~are noc legitimately recycled by the mixine 

proceu. 

Abo..., nuL~ lhc mtxed tailltlp are dtlc:harpd directly to the tail in as poada. The 

£ailinplblowdown mixrure is not reeycled to recover any mineral value~ prior fO diJeharae. TbU-9. the acid plant btowdown contaiN acid and mineral valuea, but the b(owdown is not 

lesiti1111tely ret!yded t6 rcc;ovcr th~ vaiuca and the RCRA ~ycling c=Aclusiun.s do not apply. 

The question now bc:cumes: Is the mixing of the blowdown and rhe tailinss ~nowa~le tnlatmcnc 

under wo R.Cl\A R:gulatJons'! · 

Beeause the rc=Multing toiliny11blowclown mixtu~ ia not cluu·acrc:rislic. the mixin1 of the 

cbaracteris1icatJy .. hA7-llrrl""' blowdown (with tbe taJUnp) apparently n~utrDJizg the conosivity 

characteristic of the blowdawn and reducea the concenuatlons of toxic metal~ in 1\e roaultin1 

mixtu.rc ~o they ~rc Ucluw characreristicaUy-hazardoua levcll. 't'llua tho mixins of the blowdown 

with the tailings could be ~onsidcred 11b'eatment" as defined in 40 CFR § 2tS 1.1 0 and 270_2, 

tl~cause the mixing of the chanu.:teristically-hazardous blowdown serves " ... to rtlfdtr such wmw Mlt~ltnztfJI'tln&J!I. nr lou huzardou.r ... ,.u 

F~-.iJitlc:s ~unOuctlna cl~mcntary nc:urralizarlon of a hazardous waste in tanb or 

containers are generally not required to obtain a RCRA permit or interim srarus fnrthe treatment 

Ut1it (40 CFR § 270.1(c)(2)(v)}. However, an "el~entacy ncutnlllz.arion W1it" is defined as: '' ... a 

dey/ct which: f) l.t: tt ~f fi"· lf~ttt,.allJ ng wcut•t tltQI Gl'lJ h'"ardoiU Off(V b.cuau. tll~)l uhlbil th~ 

CDI'rostvtcy churacreristic ... '' (40 CPR§ 260.10). BecaUiethe acid blowdown is alto 

cluln&~tcristico tor toxie llh:tal:s, the: clc:mcrnary ncutr~Uzation pennlt exclua\on docl not apply. 

·Hazardou.i waste generators may treat their wute in tanks and containers without a 

permit oa lon~t as th•w comply with rhe eent.rutor requifl!ments: ror ac:cumularion ill bank! or 

container~ in 40 CFR § '262.34 und the treatment takes place within the QJiowoble time ,Ptriod:i 

for &Pn•rGtor atoru5c ($ 1 fR l 0 I Ci8). 1110 \:OU\innc unit in which the: smelter mixes tb~ laiJings 

aad blowdo~n appears to meet the definitions ofbotb "~l.lmp" and .. rank" in 40 CPR§ 260.1 o. 

We have been unable, how~ver, t.n identify any chemic:ll ~~ctions (fix:ltion, floc~lation, 

p~ipitation , etc.) that occur to any significant degRD between the toxic metals in_ the acid plant 

u. Sultld~ in the m•nc: oyerburdm and wGJte rock react wilh water to torm •ulfuric .chi runotT. 

The taillnp (oriainal pH or "·0 · 8.5) t.'ttn be used to http ncutraliu thi, " ac:id rock''. 

u 4() CFR. 4 260.1 0: 'T,iuln~tUfllftflll~ .uty me1hod. twciWi'Jilt!. J'r{lt'#!fl, lJtCIJ~tiiHg 

lflutf'f.lizalfolf, d'llglfr!d to clrullgft tltt. plrysicttl, r.hemlcal. ol' blologtcr~l characltl' or compQI/tiQn of any 

hcuardow W/Uil sn a¥ 1o ltdull'nli'!.l' -'''<'h '141()Sll', o, 60 IJI/o '•to~,. CIU.'I'fD' 01'1Halrrlal1 ,...1awc:a f,-um 

tit~ W(Uit-. or so tU '" ''"'d~,. .v11C'Ir wa.rr~ tltm·htlZI.Irdous, or las ha:af'(/ous,· rafrr to trtVUport, ste~e. OT 

dl'fiCl." of; 01 dtH41ffniJI~ for ,.~c;-g\ CI')', Qtn~nablefar stOI'CJit:• or ~u,nl in WJiume." 

1$ 

J.S9£ 58~ OlS A 
b(owdO'IIII\ and lhe lQitings in the: mixin~ t&U\k, ln addition, the cower amdtet' did DOl .. poll ~11 

11ianilicaru ga1c.rntion of sJudgea or skimmfnss fn the tank, whioh would be expected if the tank 

was perform.lna these treatment acti'Vitie!. Thus, the toxic mc:tals in the acid plant blowdown are 

app~nt\y "lruted" simp!)' by dilutinJ rclativel)' :o~mall vnlumro.s of acid .Plant blowdown w;th 

very llllJe volumes of tailins3. 

EPA Ietten to the smelter's fonner Plf2tlt company d:atcd Ju.ly 6 und July 12, 1989, noted 

that lhc acltJ pJam blowdnwn gJlSJ;d rhe Extraotion Proeecturc (EP) toldcltY rtsr, As noted. th1 

acid plant bJowdown .fa.ikd the To"ic;iry Char~teriati~ Leacblnllt Procedure '(TCLP) for ~UUnic, 

cadmium, lead. and ~elenium (0004, [)()()6, 0008, and DO 10). Thus, the ecid plant blowdOW!\ 

may he eon.~~:iderarll\ 4'nowly idendti~d" h~ou.s wute QlJ defined in 40 CFR. § .268.3<C{a)." 

Dilution is scncr.1lty prohibited as il sub5titution for treatment in .40 CFR § 268.3 for wutcs rbat a~ subject ro rtJc: hmll t.lll'lpmtal rcsrrlclions and rhat wi\\ be disposed. 

11 The tailinp'blowdown 

rni)CM does not meet the LOR. treatment standards. ,. Thus. tl\e mixina of the ~id plant 

16 40 CFR. f 268J4{a): "~(Jtctlve A.~Jgult 24. !098, tltt~fD/IowilfB WtJ~tc.1 ti~ proiUbllwd [I'OIPI 

/ami Jupft:lal: tM wa.rtt~ .spt!tiflt!tl ''' 40 CF/ll'an Ul as EPA HartUYfowr Wa.rtt IIW11ben D004-DOI ( 

'"'u fll'l 11ewly ldCJitlfttd (i.e. wa.tlt.f, .~ nil, tJr tfebrlr id1rr1i{tfii as hCllardOrl$ b)J the T~tc {aic:] 

Ch4rtJctQrl3tic Llfaclrmg /~rocedure bur 11ot the Extraction Pfoctdurd), 41td tWt.rre, Joll. o; dtbrtt from 

Mi1t~'Ql proc~.uing ~pel'atlfJiflf 1ltat u /Jcnt{fi.J as !la:ardrJusiJy ll1t .tpecfjlcnt/ons 111 40 CFR Pan 16/." 

17 ~captions incl~dc some: forms ofwurewater tttatmenr when:: the wajtelll.re hautdoua only 

becauu they elth.ibir :a chwracteri~tic , and dtlutioD fl requirtd to meet cenain requirement. o(tbe Clean 

Water Act(~~ 40 CFR I 2111'-l(h) ""d 40 CFR § 268.1 (e)(4)(i·hr)). O.Qta provided by the amcJtc:r 

indicates the aoid pl4nt blowdown mny moct rbe definition o("waste .. -aters" in 40 CFR I ·268.l(f). 

Wlll~h'.$ that il~ hnAIOous only beet\ Wit th~ nhiblt a eharac:teristic may be dilulcLI ill Lfc:atment ays~ 

reaulatcd under Ute dean Water Act (CWA) or cw A~uiv~ltn t $)'11l0r!U " ... wt/t:.ro1 Q metltod Dtilu than 

DEACT lla$ btWI 6p«tji.:rl itt t/0 CFR § 2~4. ,0 as tit~ /1'f!acm•"t .rlnlttJarr/. " ( 4U ~k-'K 9 268.3(D)). 

loxlclty characteristic: metJI WIUits". !nlch a11 the acid pJant b\owdow11, muse meet 11\lmcrical treatment 

a tan dania, ncn just detetlvation t 40 (;JOlt § 161J .34 ), 

1

' Allhollgh tho c~ ili ngslblowdown mixture doe1 not exbibit any of the hazantous wu!! 

eharaeteristi~. BHP bo.s '""demonstrated thD.t the miuure mu:. th~ LOR treattnC11t•'-ndards in 40 C~R 

t 268.40 and the underlying hnznrdou,; eunstituenrs trntmmt :St&ndards in 40 CJ:'R § 268.48, 40 CFR t 

268 • .3(b) and ~0 CPR § ::l.tilt.1(c:)(4)(i.iv) wtte modif'\td afttr the L4nd Oispolal f'roiJfllft'l Fl.-i~llily A\:' 

of 1996 (promulpted April tc, 1996). Tho "point of compliance .. ' with the LOA.s f'or watttwatcra treated 

in CWA or CWA-equlvalont troGtmcnt plant.• and aurface impouatllrueniJo wM~~ olarlficd, ~ tba 

f«JUittmcrn to detennino if del:haraderizcd wutewaters met rh~ trntment :~tlndarda tbr underlying 

hautdoU.'\ conlltituc:,rs In 40 CFR § 268.48 w~&~~ nmoved (6J FR l.5S99). 

The mucJlfled 40 CPR. 4 ll'iH. I (c)t4)(i·iv) alto~ the land dlaponl of certain dcchara,cerlzcd 

WGitcs rhot were treated In CWA or CWA-cqui\'alcnt lrcatmenl unlu even lflhey do not meef the LOR 

trcmntat standards. pro.,ided the w:u.taa no lon1cr cl'lhibit a piQhlblted charocteriatic at the point of land 

disposal. However. 40 CFR i 26R.ltc)(4)(i·ivl baa rhc 5ame O!ACT proYision 11."4(1 r.FR. f 268.J(b), 

and aa n~d the blowdown is required to meet tht numerical LDR trauncnt •tand&rds. Thua. the 

exclusion in 40 CFR. § 268. l(c)(4)(i·iv) rlrw.!l nc-r Rpply, and it appears the t.Jilintslblawdowwa mix~nt 

must Jtlett the LOR trartmcnt stindatd$ tbr huardoua was ttl prior to land dillpoM.I. 

t6 

..... ' .... ~ ... -
blowdown and the: minot tnllln~:~ ~ftc:r Aul\llt 24, l998 (when the acid p1uul bluwdown bcame 

subject to the land di~tposal restrictions} to May l. 1999 (when BHpta sme\tina OJ*raUOl\ 

~:eased) wu prohiblled as lmp!rmJsaibJ.t dilution. 

Past: Anodes: sulfuric ~id. 

Present: No activity. 

Qutaoina matJriaJ: 

Past: C11thod~; copper scnap (trlmminp, !pent •nod~, n:jc~t \:•thlKJq); refinery 

slirneli; refinery slima leach solution: refinery bleed solution. 

Present: NQ aclivity. 

Additional P~ess informytioa: (Supplements Information on pages 22·24 ot AtJas:bmput H.l>· 

• The ~lime~ .. ,"t: s~nl to U1c autoclave (epprox. 3,000 lbs in 4 hours) and then to a rllter 

press. The resulting filter cake ia oYen-dried (to le,:s than 1% moi!Cture) arid tent to the 

vibrating cru~her. '11u! coll~eted material is shipped otr·sito to various facilitie3 for 

nrecinu~ metl\la ral'!c)v c~ <aold}. 

• Sec phQtogtopll # 10 uJ' a sample ER cell. 

How~ver, 40 CPR ~ 2~8.40(e) &totes that choractcriJtic wutes (DOO l ·0043) mu.st meet dtd 

treatmcnc Jtnnciards for undc:rl)lio~ hA·z ~u·do,., t'OnSCicu•nrt only if they Clre " ... not mu"~ ,,. ca 

WtJJtl'Wtlter rl'ratlfl~nt f,l~/Mf thttt i..'> rcgulattrd lllfdtf tit~ Cftcur Wotctl' A('J (CWAJ. (or) rltm il CW.Aeq&~lvall'ltl .. ·•. Tbw. it would capplr.lr th• tanlnplblowdown mi'tture (if nut BcviU·elCimpl) W011ld have to 

meet the tru.hn~nt standnr~:. for cttaracterisric metals, but not the und4!tiying h:l~ardoue ccmsUwentl, prior 

to lnncl ciispo•oL 

As p~vlc.HISIY di!ICU:t!led, lhe tailin,gYblowdown mixture i1 e)l.cluded ftom I he defloitlon of solid 

waart! (lnd lh.u1 hv-'lnious wure) under the .. Bevill mhrrure rule" in 40 CfR § 2f\ I .J(•)(l)(i). Althoueh 

it lf C\tlrly nor EPA·~ inL«:nrion to allow wastes rh4t are impcnni:s1lbly diluted to be land dilpo:led without 

meetiDil the n~anJou.o; W:\Stt: tJ'I!,Ument cWid.Ard11. for tha re:ucon~ cti~~eutted &bo\le it appl&l'l tha& oace 

O.Cnarac:rcrilcd by the milling th«: tscid plant bluwdown i!1 not a solid w.11C1 'Und-er the ·•Bevill mhthn 

rule'' and mall bt: lut1d ditDused wim"ur mf:lftlng thl! la11d Oiltpol:al Slftlttictions. 

17 

,.., ,1 enr , ,,,... 
BeiQ,llatqry ltiUQ! 

None. 

ADDmONAL AREAS INSPECTED: 

Soh:ent uaction <SXWitttxowinnina fEW) Faciluy: 

• The facility r;mresentatle,·cs inrormed th~ in!!f'CCtoTl'i rhe~ t tne only 01ctive porti01\ of the 

facility is the SXIEW facility. 

• The slime:1 from the EW proc:ess are rich in 1C6d and are shipp!d off·s.ite ta Doo Run. 

• The insJ:)cctors noted a 20 ubic yard bin lot cbe lad anode: flab. The facility 

representatives stated that it takes 6-12 months to fill the bin. A bill of ladin& from a 

previous ~hipment i• en"loaod u Attqqgmepr tl6. 

• On.: aniltiun pound.~ of topper 15 manufactured from thit process annu11Uy. 

• No potential violations were noted. 

~Qdh End Bunk;r ausl East Ylrd cRcyuyJ: 

• Most of the revert inventory was kept at the East Vard (~ photngr&J"'hR #11-12). All of 

tbe material ar the East Yard wu •old to 11 Oc:rman company. Subsequent to the 

inArtectinn. thiJ nt2~CJ rial "~W•s &oltd.-d onto I'WJcans 4ftd ahippod o~itc;. 

• AnelyticaJ c:Juh~ or UIC EU!d Yard benn ~om lln !PA ggmpUn~& e~ enE are provided in 

AU&chment tf5 tsomple TO BHP09). 

• The facilitYs i oa1 Wol: tn nnn ume wb.ate,~r reverta were generaU!d during ll ~hif\. 

Otherwise, it Wlls 3torcd at the North Encl Bunker (see photographs ##13-17). 

• No potential violations were noted. 

Main Elc:ctrical Shop Satellite Ag:umulptjon NJ;g <5M): 

• Universal wutc bulbs, .!pCnt aerosol C8J~, 111ll u~cu uil are yenl!ratcd hc:re. 

• No poa:nUal violations were noted 

• U~\1 ull, !lpcnr o~sol cans. and universal waste bulb! are s•neroted here. 

18 

l59i: SBi OZS i\ 
• No PQtcnti.al Yiulilrion.~: were nnted. 

• ~o W&lStc was •1oted here at the time of· the inspec1ion. No pocen~\ violaliona were 

noted. · 

iO-P,Y Stomu Aryg: 

• tt~ardous wastes stored in this area included ackb, polaona, all<l IOBUSUOI. 

• The inspet'tors also not~d n lO-cubic yard wasta bin for D006, 0008. &. DO 10 hazardoua 

was to. 

• The f11c:flicy representative stated that used lead acid batteries arc managed u \miversal 

wute. 

Uniyg Wute Qocumcntadoa: 

The in~ectors reviewed che docuntmtation for fluontllcent USht bul~ and lead a'id 

batter in. 

A sample rccyc.Un~ ccrtitkate far the: lead acid batteri"s is enclo~d as Att11gbnu:o.t @7. 

No poNrttial violatioaa were noted, 

W;ckJy Hl2jmjoos W!I.Ste Storaa, lnSJX!CtimJt: 

The inspectort rr:vio\Wd randorn ins~c:tian:s (January 7, 2000 UuuUM}a Aujus1 4, lOQO) 

for the for 90-day stor.1ge area nnd the SAAli (see sample. Atla£hrm:;gt 1#8). 

No potenti;~l violntillJU were noted. 

MSDS# for n:., ~ru. whirc mc:t~J. lUmllc:~ bottoms! and copper cold dope were obtained 

and reviewed. 

No ootential viobtion" wer• nated. 

l9 

l. 59£ 581 ozs A 
AQ&lytjgtl Rf1NCUi: 

~ ina~ tors reviewed analytical reports for various matcrialt, includlna: Flash 

furnace imulatinat brick, acid plant tdulige.. t•flkhauac iloor c:hips, :u:id plant blowdow~ w~te 

brfclc binder, gas t!OOlina tower packing, and contaminated soU. 

A June 7, 2000 report !jummarizin& a sampling event to tvaluat! BHP's used amcltcr 

brick was aJao revu:wed (ace Aoactuncnt #9), 

No potential violations were noted. 

T . . [IJOJQ8! 

The facility representaliVeli lltaled that tf\e trainina pl:tn was Q\lrt'eOtl)' btlllg ~vUed. The 

inspectors noted that lhe existing pJan did not cont11in position d~criptions, and initial and 

re&esher training requin:mcntl infocmation. n1c inspcctun; IJid note that the trll(binB l'e(Ords for 

Mr. James Glasston and Mr. Jeff Parker were current. 

Tht inSJ)ectors re'-i~d \he J"nc: 2000 contingency phm. 1hc inspectors noted lbru: 

• tbe contlnacncy pion did not contain home tehspbonl! number• for the em~gcncy 

coordin1tors, 

• the industrial hygiene contact wa' no lonser working a' the filcillty. 

• the~ was no e\'acuntion plan for the 9()..day ~nor:Jge 11~ urlll . 

• there \\'ere no descriptions oftbe capabilities of the emergency eqwprnent. 

The in~peec.totS ~"!viewed the 19~9 F~ility Annuul Report: dcucd fcbrua.ry 29, 2000. 

The inspeetor.t ruviewed manifc:~t.s from October 1999 to pre.icnt. 

No PQtc:nri<tl violarions were noted 

hv.ia~.a Conwlidatcd Procc:s.a De<+trlption Rgyiaiqaq: 

Sub111cqu.ent tu the inspection, '" chcic "'UJJU~t 2 ... 2000 ~sponse, SliP provided a reVI.!Ied 

Consolidated Process Description (sec hlr,sbmtQt tHQ). 

No potential violations were noted. 

20 

LS9i: Si£ 02S & 
POTI.NTIAL VtOLA -r:tONS: 

A.A.C. RJ 8-8-268 

40 CFR § 26&.l 

No genenuor. transporter. handler. or owner or operator of a treatment, 

storage, or disposal facility 5hall in any way dilute a restricted waste or the 

rwiduol from ll'Citment of 1 restricted waste as a sub!titutc: for adcqualt 

treatlncnt to uchleve complioncc with subpart 0 of this put. to circumvent 

the eft'cctive dare of a pfOhtbition in subpart C of thia part. to otb.lr.Nasc 

avoid a l'rohibition in l\lbpart C of this part. or to cln:umvant a land 

di~po l prohibition Imposed by RCRA section 3004. 

BHP'!i add pbnl blowdown is characteristic for corrosivity, 'lt'lenic. cadmium, lead, ud 

!SCitnlum (0002, 0004, 0006, 0008, and DOlO). All noted in Uti.s report, • ... tho mixina 

of the acid plant blowdawn and the mint tailings atlor August 24. 1998, when tbc acid 

plant blowdown bec:.mo subject to the land disposal ~stric:tions, l:J pNIUbitcd as· 

impcnniuibJe dilution''. Due 10 tht pnsenc:e ofUtt oharactcrbtic metals, the a~tivity 

conducted in 12A could not be c:tnssific:d as elementary neutratization jn an elementary 

ncun-alization unit (defined In 40 CFR 260.10). Therefore. from Auauat 24, 1998 to May 

1, 1999. when BHP ceased its smtltingaetivitics. BHP W&3 in violation nf.ThJa 

requirement. 

Tbe inspectors nott!tJ that thi! acti-..ity wu not being conducted at the time of the 

ilt»pt:ICtiun, 

A.A.C. Rl R-26~ 

40 CFR ~ 265.52(d)·(t) 

The ~on lin seney pl:~n muet li'1 the bom11 numbel'8 of e~.ll por3an3 

qualified tc u't u emerg~ttc:y_ coordinator. must include a brief 

uutJine of the ~:apobflltles of rht! ~merven y equtpment at the 

fneility, and must inc:lude an cvncuMtion pldn for facility personnel 

wh~r~ there is a possibility that evucuation couJd be necessary. 

At the time of ~ in:spcttion, the cont\ngcncy plan did nQt contain these required ~ompon.cnta. 

The fllcility!s re11pun e. dnted Ausust 24, 2000, adequately addressed theae I slues. 

A.A.C. Rl 26S The lruining plan must ~uuuain u written job description for e:~cb positi<m 

40 CFR § 265 .16(d) und the amount of introductory and eon.tinuina tr-aining thllt will be giv.:n 

to each person filling n position. 

At the time orth~ in~ction, the tnin.ins plan did not contain these required 

eomponcntll, 

The tbciHty's nt"pun e. dated Augu5t 24, 2000, ade u~lcly :tcJdresud these ·iaauu. 

:u 

lS9£ ~B~ 025 Ji 
Attacb~ne~~ta: 

l. Photo~ 11-17 

2. F'~ili'J dlqraam 

3. P'acmty·a July 14, 2000 response to EPA 3007(a) information request 

4. BHP Copper San Manuel Operations Production Flow Chan 

S. September 21, 2000 sampHn1 event analytical results 

fi. Sam file Jead ~ulfAte hilt nt )Jldins 

7. Samplo lead <l~ d ~ttcry m;~ling \iGttiflcatc 

8. Sample weekly inspection form 

9. June 7, 2000 used 5meltcr brick evaluation report 

10. Revised CoMolidated Process Dcacripdon 

22 

l S9i sa1 ozs a . AlddnS dHB