xvEPA
United States
Environmental Protection
Agency
Office of Pollution
Prevention and Toxics
7408
EPA 745-K-a5-003
May 1995
EPA's 33/5O Program
Company Profile
Inland Steel
a subsidiary of
Inland Steel Industries, Inc.
Printed on Recycled Paper
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EPA's 33/50 PROGRAM
COMPANY PROFILES
BY THE 33/50 PROGRAM
CADMIUM & COMPOUNDS
. - CHLOROFORM,, ' s' '
CHROMIUM & COMPOUNDS
'" "', CYAMSDBS >
- - DICHLGJ&OMETHAtSiB* -
, LEAD & COMPOUNDS
NICKEL ^COMPOUNDS'
atdlROE'
TOLISENE
This Company Profile is part of a series of reports
being developed by EPA to highlight the accom- ,
plishments of companies participating in the 33/50
Program. The 33/50 Program is an EPA voluntary.
pollution reduction initiative thai promotes reduc^
tions in direct environmental releases and offsite
transfers of 17 high-priority toxic chemicals. The
program derives its name from its overall goals
an interim goal of a 33% reduction by 1992 and
an ultimate goal of a 50% reduction by 1995. The
program uses 1988 Toxics Release Inventory (TRI)
reporting as a baseline. In February, 1991, EPA
began contacting the parent companies of TRI
facilities that reported using 33/50 Program
chemicals sin'ce 1988. to request their participation
in the 33/50 Program.' As of November, 1995,
nearly 1,300 companies had elected to participate
in the Program, pledging to reduce emissions of
the 17 target chemicals fey more than 380 million
pounds by 1995. Companies set their own reduc-
tion targets, which may vary from the Program's
national 33% and 50% reduction goals.
Industry exceeded the 33/50 Program's interim 33%
reduction goal by more than 100 million pounds in
1992. National emissions of Program chemicals
were reduced by an additional 100 million pounds
in 1993, bringing total reductions since 1988 to
v more than 685 million pounds (46%). Facilities' TRI projections suggest that the Program's ultimate 50%
reduction goal will be observed to have been achieved or exceeded in the 1994 TRI data, a full year ahead
of schedule. The 1,300 .companies enrolled in the 33/50 Program have accounted for most of the Progra-
m 's pollution reductions. Representing just 15% of eligible companies and owning only a third ofthefacil-
. ities reporting Program chemicals to TRI, participants are responsible for 78% of the reductions since
1988 and 98% Of the 100 million pounds reduced in 1993. .."..'
EPA is committed to recognizing companies for their participation in the 33/50 Program and for the
emissions reductions they achieve. The Program issues periodic Progress Reports, in which participate
ing companies are listed and highlighted. In addition, Company Profiles, such as this.one, are being
prepared to provide more detailed information about how companies have achieved their emissions
reductions. Information presented in these profiles is drawn from a number of sources, including the
company's written communications to the 33/50 Program, extensive interviews with company representa-
tives, the annual TRI reports submitted by the company's facilities (including Pollution Prevention Act
data reported to TRI in Section 8 of Form R), and, in many cases, site visits to one or more of the com-
pany's facilities. Mention of trade names, products, or services in this-document does not convey, and
should not be interpreted to convey, official EPA approval, endorsement, or recommendation.
Copies of other 33/50 Program Company Profiles, as well as Reductions Highlights documents
summarizing all of these Profiles, may be obtained by contacting the Program as specified in the box
.. below. In addition, all written company communications to EPA regarding the 33/50 Program are avail-
able to the public upon request.
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&K m tlte 33/S&Tr&$f£tm,'J<;ffWact the. TSCA HaiKtie 4t $202) 554-1404 "^r^otitmt 33/5Q
' -Program sfffjfdireellx by^ ph&ite ia (2P2) M^9Q7 or by matt at Mail Code 74$$,
' '
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL
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SUMMARY
/nland Steel Company reduced .annual
releases and transfers of 33/50 Program
chemicals from 5,174,500 pounds in 1988
to 733,786 pounds in 1993. This translates to a
reduction of approximately 86 percent. The com-
pany accomplished all of these reductions at its
' Indiana Harbor Works (IHW) steelmaking facili-
ty. In light of its success, in reducing releases and
transfers, Inland Decently amended its 33/50
, -. /
Program reduction goal to 90 percent in place,of
» its original 50 percent reduction goal. ,
This case study provides an overview of
Inland Steel's experiences related to the 33/50
Program. It highlights the reductions achieved by '
COMPANY BACKGROUND
two projects undertaken at the IHW the
replacement of tetrachloroethylene cleaning with
aqueous processes, and the recycling of blastfur-
nace and steelmaking dust and sludges. In addi-
tion ' to these projects, Inland achieved large
reductions in releases and transfers of ^ 33/50
Program chemicals as a result .of several addi-
tional actions the elimination of on-site land-
filling of slag and the closure of the facility's cok-
ing operations. Slag, which had previously been
used to fill in the portion of Lake Michigan on
which the IHW is sited, .is now sold to a company
that uses it in the manufacture of products such as
concrete. Coke is now purchased from an outside
supplier. ,
Inland Steel Company, one of the business units owned by Inland Steel
Industries, Inc., is the fifth largest integrated steel producer in the United
States. Its products accounted for approximately five percent of U.S. steel
production in 1993. As an integrated producer, Inland mines ore and produces
iron as well as most of the raw steel used in its manufacturing operations. The
company employed approximately 12,000 individuals in 1993.
Inland operates a 2,400 acre (approximately 3.5 square miles) steelmak-
ing facility known as the, Indiana Harbor Works (IHW) in East Chicago, Indiana.
With an annual production capacity of 5.8 million tons of raw steel, this facility
is one of the largest steelmaking facilities in the U.S. The IHW was originally
built in 1897 on the shore oJ^Lake Michigan and began steelmaking operations in
1903. Sinc.e that time, the facility has expanded significantly and now sits on a
man-made peninsula extending into Lake Michigan. An aerial view of the faeili-
Inland Steel
a subsidiary of
inland Stool Industries, Inc.
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL COMPANY
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I ' "'.""i"!
Exhibit1
.......... I!!, ............. , ..... : ..... : ...... ;; ............................... ; ..... ...... AerfalView of Inland
...... "' .............
"''? ................................ ;! .................................. i ............ .............. ........... ; ........ " .......... « .......... fWorks Facility
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No. 7
Blast Furnace
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Electric
Repair Shop
No. 4
Basic Oxygen
Furnace Shop
Briquetting
Facility
No. 5 and 6
Basic Furnaces
iiiliii i.iiiw
No. 2
Basic Oxygen
Furnace Shop
Mam
Roll Shop
!!(^
Plant 1
Galvanizing
No. 6
3Roll Shop
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ty is shown in Exhibit 1. The facility contains a wide variety of operations,
including' blast furnaces, basic oxygen furnaces, electric arc furnaces, cold-roll
shops, hot-roll shops, and a number of repair shops. The facility also had :eolkirig
operations, which were closed in 1993.
-- . .' '--:-- -.;..,-,, ,.,-.».,,,.,.,,--,»,, . f .. . . . - .: .-_.__.-,. -
Inland Steel's; final products are manufactured by two divisions' Inland
Steel Bar Company and Inland Steel Flat Products Company. Inland Steel Bar
Company manufactures and sells steel bars, which account for approximately 10
percent of Inland Steel Company's shipments each year. The Bar Company's
products are used in a wide variety of applications, including transportation (axles
and steering columns), cold finishing, forging, mining, heavy equipment manu-
facturing, and in Steel service centers.
Inland Steel Flat Products Company manufactures and sells sheet steel
and steel-plate, which account for approximately 90 percent of Inland Steel
Company's annual shipments. Products include hot-rolled, cold-rolled, and coat-
ed steel sheet primarily utilized by the automotive, appliance, office furniture,
electrical motors, and steel service center industries. In addition, the Flat
Products Company produces steel plate for the agriculture, rail, construction, and
steel service center industries.
In 1993, Inland Steel shipped approximately 4.8 million tons of steel and
had net sales of nearly $2.2 billion.
ENVIRONMENTAL STRATEGY ,
In addition to its participation in the 3,3/50 Program, Inland Steel has a num-
ber of other initiatives to help protect the environment. The company sup-
ports domestic and international efforts to conserve energy and natural
resources while pursuing economic development. It endorses the International
Chamber of Commerce's "Business Charter for Sustainable Development
Principles for Environmental Management" and has adapted these Principles to
Inland as shown in Exhibit 2, The company is also a Charter Member of
WasteWi$e, a U.S. EPA voluntary program to promote solid waste reduction and
recycling. ,
The Environmental Health and Safety Department of Inland Steel is
responsible for working with operating personnel,to carry out the mandates of its
environmental program. Ongoing efforts include the implementation of formal
waste minimization programs at each operating facility (e.g., Blast Furnace
Shops, Basic Oxygen Furnace Shop's, Cold Mill) and an ongoing environmental
audit program to ensure compliance with applicable regulations.
, Inland Steel holds a patent on an innovative pollution control technology
to reduce sulfur dioxide emissions from coal-fired electricity generation. This
technology involves limestone injection and is installed at the IHW's coal-fired
In 1993, Inland Steel
shipped approximately
4.8 million tons of steel
and had net sales of
nearly $2.2 billion.
Inland Steel holds a
patent on an innovative
pollution control tech-
nology to reduce sulfur
dioxide emissions from
coal-fired electricity
generation.
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL COMPANY
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i±: Inland Sfeel's Adaptation
, ; ', ', ', of the International
thaniber Of Commerce's
' 4.: Principles for
,; *; £n ytronmental
Management
pe/j,enfn
* ! f" '"; " ? 1992 and by 50 per-
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~~
;!T
as a baseline.
1. Integrate responsible environmen-
tal policies, programs, and prac-
tices into each business unit as
an essential element of manage-
ment;
2. Plan, install, maintain, and operate
facilities to be in compliance with
applicable environmental laws
and regulations;
3. Minimize generation of wastes and
promote recycling, recovery and
reuse of residual materials to the
maximum extent practicable, and
dispose of any remaining wastes
in an environmentally responsible
manner;
4. Encourage research and develop-
ment related to environmental
control technologies and more
efficient utilization of natural
resources, materials, and energy;
5. Participate in the development of
technologically sound and cost-
effective environmental laws and
regulations;
6. Communicate with share holders,
the Board of Directors, employ-
ees, customers, suppliers, com-
munity officials, and the public on
environmental issues and
progress towards meeting objec-
tives; and
7. Educate, train, and motivate
employees to conduct them-
selves in an environmentally
responsible and safe manner.
No. 4 A.C. Power Station. This technology is currently being marketed to other
companies by an outside firm. ,
OVERVIEW OF 33/50 AND TRI CHEMICAL
RELEASES AND TRANSFERS
s
ince 1988, Inland Steel has reported releases and transfers of 11 of the 17
33/50 Program chemicals. The following is a list of these chemicals and
their source of releases at Inland Steel:
Chromium, lead, and nickel compounds are present in blast furnace
and basic oxygen furnace slag, waste dust, and sludges that have his-
torically been landfilled on-site (slag) or transferred off-site (dust and
sludge).
enzenie, cyanide compounds, toluene, and xylene were generated as ."". |
byproducts in the manufacturing of coke used in the steelmaking
prdcess, and were released primarily as air emissions. ,
Dichloromethane and methyl ethyl ketone (MEK) were used as sol-
vents for hand-cleaning of parts, and were released as air emissions.
Tetrachloroethylene was used to clean a variety of parts in vapor
degreasing equipment, and was released entirely as air, emissions.-
1,1,1-Trichloroethane was tested as a replacement for tetrachloroeth-
ylene in cleaning applications in 1990, and was released entirely as air
emissions. ,
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According to data
provided by the company,
releases and transfers of
eight of these 11 chemi-
cals were still reported in
1993; those not reported
are dichloromethane,
methyl ethyl ketone
(replaced with alternative
solvents such as mineral
spirits), and 1,1,1-
trichloroethane (tested in
1990 but not implement-
ed as an alternative for
tetrachloroethylene).
In the 33/50
Program's base year of
198&, Inland Steel report-
ed a total of 61,364,500
pounds of releases and
transfers of TRI chemi-
cals. Of this total, 5,174,500 pounds were of 33/50 Program chemicals. Exhibit
3 presents the company's TRI data for 1988 and 1993. Exhibit 4 shows the break-
down of 33/50 chemicals used at Inland during 1988. These data are presented in
greater detail in Appendix A. The largest percentage of total 33/50 chemical
releases and transfers were from chromium releases to land, accounting for
approximately 31 percent, and benzene emissions to air, accounting for approxi-
mately 24 percent.
As shown in Exhibit 5, Inland Steel's 1988 releases and transfers of 33/50
Program chemicals were split between releases to land (50 percent of total) and
to air (42 percent of total), with transfers off-site and releases to surface water
accounting for the remainder. The releases to land resulted primarily from
Inland's use of its slag as fill for the expansion of the IHW facility. Until recent-
33/50 Chemicals (locos ibs.) 1988
Benzene 1 ,246
Chromium Compounds 1,627
Cyanide Compounds 27
Dichloromethane 12
Lead Compounds 943
Methyl Ethyl Ketone 12
Nickel Compounds 432
Tetrachloroethylene 41 7
Toluene 251
1,1,1-Trichioroethane* NR
Xylene : 206
33/50 Subtotal** 5,175
Other TRI Chemicals 56.190
TOTAL 61,365
Exhibits
" Releases and Transfers of
80 TRI Chemicals by Inland
269 Steel Company (in Thou- ,
7 sands of Pounds)
NR
176
NR
15
181
4 / .
NR
1 . -. ' -
734 ,
., 10.155 .
10,889
NR Not Reported
* 20,000 Ibs. of 1,1,1 -Trichlomethane were reported '
as "Air Emissions" in 1990. .
** Columns may not sum to totals due to rounding.
Lead Compounds (18.23%)
Nickel Compounds (8.36%)
Tetrachloroethylene (8.06%)
Other* (4.98%)
Benzene (24.08%)
.Chromium Compounds (31.44%)
Toluene (4.85%)
'Other: Xylene, Cyanide Compunds, Dichloromethane, and MEK
In August 1993, Inland
Steel recognized that it
had achieved its origi-
nal goal of a 50 percent
reduction several years
ahead of schedule.
Exhibit 4
Percentage Breakdown of
33/50 Chemical Releases
and Transfers for 1988 (by
Chemical)
33/50 PROGRAM COMPANY PROFILE: INLAND, STEEL COMPANY
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Exhibit 5
j'lHn
Percentage Breakdown
l | of 33/50 Chemical
Releases and Transfers
i i for 1988 (by Media)
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Releases to Surface Water (.47%)
Releases to Land (50.16%)
Transfers Off-Site for Treatment (7.36%)
Disposal/Other
'Air Emissions (42.01%)
Iy, Inland Steel used blast furnace slag to fill in the Indiana Jshoals, the portion of
Lake Michigan on which the company's man-made peninsula is located. During
this period, the metals in the slag were reported to the TRI as .releases to land.
Inland now sells the slag to a company that uses it in a variety of processes, such
|s the manufacture of concrete. Benzene, toluene, and xylene, which are byprod-
ucts of the coke manufacturing process, accounted for a large portion of the air
emissions in 1988. Inland closed its coke manufacturing facilities at the IHW in
1993 and began purchasing coke from an outside supplier.
33/5O PROGRAM GOALS AND REDUCTION
PROJECTS
When Inland Steel joined the 33/50 Program in March, 1991, the com-
pany set a goal of reducing releases and transfers of 33/50 Program
chemicals 33 percent by 1992 and 50 percent by 1995, using 1988 as
a baseline. These percentages translate to a reduction of 1,707,585 pounds by
19^2 and2387,250"pounds by'"19'95'from 1988"levels' oF5J74,5bO pounds. At
the time, the company indicated that while it expected to meet or exceed this goal,
reductions for certain chemicals might be less than 50 percent by 1995 because of
limitations i'h" available technologies.
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In August 1993, Inland Steel recognized that it had achieved its original
goal of a 50 percent reduction several years ahead of schedule. In order to further
its participation in the 33/50 Program, the company revised and augmented its
achiev^ j goal to a 90 percent reduction in releases and transfers of 33/50 Program, chemi-
Program , cals by 1995. This translates into a pledged reduction of 4,657,050 pounds.
goal was reducing tie
use of tetrachloroeth-
ylene in solvent clean-
ing applications.
The overall implementation of the 33/50 Program at Inland Steel's IHW
steelmaking facility is the responsibility of the 30-member Environmental,
Healthj and Safety staff. Several employees in this office, working with operat-
ing personnel, are tasked with identifying areas in which releases and transfers of
33/50 Program chemicals can be reduced and eliminated, as well as with evaluat-
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The next sections describe two of the projects, that reduced releases and
transfers of four 33/50 Program chemicals: replacing tetrachloroethylene clean-
ing with aqueous cleaning, and recycling blast furnace and steelmaking dust and
sludges: : ; -
Project #1:
Cleaning
Replace Tetrachloroethylene Cleaning with Aqueous
' One of the initial projects identified by Inland Steel that would assist the
.company in achieving its 33/50 Program goal was reducing the use of tetra-
chloroethylene in solvent cleaning applications. After investigating tetra-
chloroethylene usage at the facility, Inland staff found that the largest quantities
were used in four pieces of vapor degreasing equipment two in the Electric
Repair Shop and one in each of two roll shops. The degreasers in the Electric
Repair Shop were used to clean electric motors and other electrical equipment,
while the degreasers in the roll shops were used to degrease roll bearings used in
the steel rolling lines. Inland agreed to replace the degreasers in the Electric
Repair Shop as part of a Consent Decree with Region V of the EPA. As part of
the agreement, the company was allowed to apply part of the cost of equipment
installation towards a fine levied against the company for late submission of its
1987 TRI report. The replacement of the degreasers in the roll shops was volun-
tary and has been attributed by the company to participation in the 33/50 Program.
After identifying degreasing as the major use of tetrachlbroethylene at the
facility, Inland staff and operating personnel set out to identify an alternative
cleaning method. Inland's primary objective in the search for an alternative clean-
ing method was to eliminate the use of all solvents, if possible. As the search was
initiated, the team observed that motors were being successfully cleaned using an
aqueous detergent system at Inland's Mobile Equipment Repair Shop located at
another part of the facility. Consequently, the team decided to implement such a
system at the Electric Repair Shop and the two roll shops.
Because aqueous cleaning cannot be carried out using standard vapor
degreasing equipment, the project implementation team next identified the equip-
ment that would be necessary for the new process. In addition to considering the
equipment used in the Mobile Equipment Repair Shop, the team gathered infor-
mation on cleaning equipment from a number of industry trade journals.
However, most of the equipment identified turned out to be parts washers, which
were not well suited for a heavy industrial application. After further dialogue with
the operators in the Mobile Equipment Repair Shop about their aqueous cleaning
process, the team concluded that the same process most likely would be adequate
for replacing the tetrachloroethylene vapor degreasers in the electric repair shop
and the roll shops. ','..
The equipment selected to replace each of the vapor degreasers in the
Electric Repair Shop is manufactured by MART Incorporated. One of the pieces
Inland's primary objec-
tive in the search for
an alternative cleaning
method was to elimi-
nate the use of all sol-
vents, if possible.
The generation of haz-
ardous waste has-been
completely eliminated
with the switch to the
aqueous cleaning sys-
tem.
33/50 PROGRAM COMPANY PROFILE: INLANB STEEL COMPANY
-------
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Exhibit 6
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Pictured Here Was "
Installed in December of
1993 to Replace the
Tetrachhroethytene
Vapor Degreaser
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t systems, the cost of
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and the cost of the
i , i1.
aqueous cleaner used
In all four machines is
less than $500 per
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purchased is shown in Exhibit 6. Similar equipment manufactured by Proceceo
was purchased for the roll shops. Each unit is a large steel-plate box with a front-
hinged door. The inside of the equipment is lined with fine-tipped water-jet spray
nozzles. In the first step of the cleaning process, the parts are blasted with hot
water to remove grease and dirt.' The dirty water from this process flows to a
reservoir in the bottom of the unit where some of the solids settle out and the
grease and oil are skimmed off. The second portion of the cleaning process is a
rinse stage where the parts are, sprayed with clean water. This step serves a dual
purpose of rinsing the parts and replacing water that may have escaped as steam
from the unit. After the rinse stage, the parts are removed from the machine and
dried in a separate drying oven.
' :; .." ' . '. .., .'.'.: :'""" M, , - > , .!
There is no waste-
water discharge asso-
ciated with this clean-
ing process. Water is
lost through steam
generation and must
be replaced with fresh
water as described
above. The grease
and oil that are
skimmed from the
cleaning water are.
sent to an on-site oil
reclamation facility
and are blended into
fuel oil. Solids built up on the bottom of the cleaning unit are removed quarterly
and are disposed of as a non-hazardous RCRA Subtitle D waste. The wastes from
the vapor degreasers had been RCRA listed hazardous wastes (F002).
. ' - "' '' ;, . !: --I ii . .-;.,
The cleaning solution used in Inland Steel's new process is hot water with
an added detergent/cleaner. The cleaner used is a non-caustic alkaline cleaner
called Roundhouse and is manufactured by Calgon Corporation.
The environmental, health, and safety impacts of the new aqueous clean-
ing system are all less than those associated with the previous tetrachloroethylene
vapor degreasing system. For both systems, the major environmental impact is
disposal of the cleaning solution. In the past, the spent tetrachloroethylene
required handling and disposal as a hazardous waste. With the aqueous cleaning
system, the water is continuously recycled back into the cleaning process, while
the waste grease and oil are blended into fuel oil and the solids are disposed of
quarterly as a non-hazardous waste. Therefore, the generation of hazardous waste
has been completely eliminated with the switch to the new process.
II* 'I''' ,,> ' ,," "'' '..""MiliV .,/ 'li '" ,' ;,; '" 'h ", ' '','" ; ,*' / i , '! \ ' " ' ''' . ,!', ',: ,'Vf II ' i ,' > | ', V !'^ ' " ' ' ' IS iiil jlil- '! ' ', " , in , ill "I, 'V I'1 '! ,"i\ ,' ..... '''ill . I',!'"'1; , '^l!
"
'adverse' health effects,''' which' "resulted 'from" worker /exjposure' to
tetrachloroethylene vapors, were reduced with the switch to aqueous cleaning.
Tetrachlorbethylene has been classified by the U.S!"EPA as a "possible/probable"
"( '
"iti , ,
-------
carcinogen. Although the vapor degreasers were covered by hoods, solvent
vapors were released into the work area when the equipment was opened for load-
ing and unloading. While concentrations of tetrachlordethylene did not exceed
the Permissible Exposure Limit (PEL) of 100 ppm, the vapors posed some risk to
the workers and created an unpleasant odor in the shop. One of the constituents
of the Calgon aqueous cleaner used at Inland Steel is dipropylene glycol methyl
ether, which also has a PEL of 100 ppm. However, this constituent makes up less
than five percent of the total cleaner formulation. In addition, the, aqueous
.degreasing equipment vents to the outdoors rather than into the work area. As a
result, the concentrations of dipropylene glycol methyl ether to which workers are
exposed are lower than the concentrations of tetrachloroethylene. Based on these
factors, Inland Steel's workers presumably face fewer health and safety risks with
the use of the aqueous cleaner than they did with the tetrachloroethylene
degreasers.
The aqueous cleaning equipment was installed in the Electric Repair Shop
in December, 1993, and in the roll shops in October, 1994. Implementing the new
aqueous cleaning systems required significant capital expenditures on the part of
Inland management. The purchase and installation of the four aqueous cleaning
systems cost approximately $200,000. According to the company, the daily oper-
ating costs (electricity and gas) for the aqueous cleaning systems are approxi-
mately the same as those for the tetrachloroethylene vapor degreasers. However,
there are significant cost savings in the purchase of cleaning materials and the dis-
posal of waste. Inland Steel paid approximately $0.23/pound for tetrachloroeth-
ylene and approximately $0.19/pound for its disposal. The company estimates
that the annual costs for the purchase and disposal of the solvent totalled about
$40,000. With the
new aqueous sys-
tems, the cost of
water is negligible,
-and the cost of the
aqueous cleaner
used in all four
machines is less
than $500 per year.
The only waste dis-
posal cost associat-
ed with the aqueous
cleaning process is
for the disposal of
solids removed from the bottom of the machines. This disposal cost is approxi-
mately $2,000 per year for all four machines. Thus, Inland Steel has replaced pur-
chases and disposal costs of $40,000 per year associated with tetrachloroethylene
with costs of approximately $2,500 per year for aqueous cleaning (see Exhibit 7).
Overall, the replacement of tetrachloroethylene vapor degreasers with
aqueous systems in parts cleaning applications eliminated the use of tetra-
chloroethylene at the IHW facility as of October, 1994.
THE SAVINGS
I Old Method
Tetrachloroethlene
Vapor Degreaser
New Method
Operating Costs
$40,000,a year
Aqueous System $ 2,500 a year
TOTAL SAVINGS $37,500 a year
The company indicated
that implementation of
the aqueous cleaning
system eliminated the
use of tetrachloroethyl-
ene as of October,
1994.
Exhibit 7
, The Yearly Savings to
Inland Steel Via Cost
' Reductions in the Pur-
chase of Cleaning Materi-
als and Their Disposal
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL COMPANY
-------
II I
'"'I i ! I
;;;, ; ii
, jjJL !' ,H| ; , , ;|;inlil; iin;:n
|lj;jliiiH iijiiiiijjjllijjjjjjiijiiij!ijiiiii!iirji!jjjijijjjjjjijiiijii«!r IIP 111; jiij nf'i'i iiiij J!!;ni
ent dsed in line'
' -|:: ~ - ' : ' Bnquetling Process
«
1J
lI'I'iililhllllll.lllilliillLn'illlllllllllillllllllliJIllllll,,'!!,,!!. Illli
111! liPIIIE IIIIRIniHIIP'mil'PB!!!"' lUlfll1"!,! MMK ilillilH 1411'! IlilH'll Mill1!1::'iJIIIBIIIIIIIJIJIIIIjjjIBI!! 'Ulldlj
liiiitllHliliiK'il'HINill!! Illllilllihi ill1"!1'
iliiJIJijIlillllliliiFliilllilliiiillilii'l i'PIILiilill'lIliliriliitl1!:, ' lljjll1 'I'llfllliB'! iliillP'l lilll'l ,!|!l I1!!
-------
BH Dust, Scale,
Lime, Molasses
(135 tons/day)
Product to
BOF's & BF's
(600 Tons/Day)
Air Emissions
to Atmosphere
after the dewatering of the sludge
significant environmental, health,
ting operation.
ity. The process begins by dewatering the
sludge from the blast and basic oxygen fur-
naces. The dewatering is performed by
Baker Hughes, which currently processes
approximately 465 tons of sludge per day.
The material is then trucked to the briquet-
ting facility. At the briquetting facility, the
sludge is blended with other high-iron con-
tent materials and dried. Various materials,
including a binder (e.g., molasses), are then
added and mixed in rotary drum mixers
known as "pug mills." At this point, the
material is cold-formed into a briquette.
Finally, the briquettes pass through a vibra-;
tor screen that separates out the pieces that
.are too small to be reintroduced into the fur-
naces. National Recovery is responsible for
performing all of the processing functions
The company has indicated that there are no
or safety impacts associated with the briquet-
At the present time, the briquetting operation is capable of generating
600 tons of recycled material per'day (219,000 tons per year) that can b'e fed into
the facility's blast and basic oxygen furnaces. Inland estimates that the annual
amount of sludges used in the briquetting-operation contains approximately
7,277,000 pounds of metals. This total includes approximately 216,000 pounds
of 33/50 Program chemicals 22,000 pounds of chromium compounds,
186,000 pounds of lead compounds, and 8,000 pounds of nickel compounds.
The remainder of the metals are primarily manganese, copper, and zinc.
- . ' ' \ '- ' . ' ,
Because the briquetting operation is still in the pilot stage at Inland Steel,
it does not currently result in cost savings. At present, the company estimates
that the briquetting operation costs between $40 and $50 per ton of sludge
Exhibit 9
Inland Steel's Briquetting
Process
According to the com-
pany, participation in
the 33/50 Program,
coupled with high land-
fill and waste-handling
costs, resulted in
Inland's staff searching
for a way to reduce
releases
and transfers of
chromium, lead and
nickel compounds.
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL COMPANY
-------
I! i : !- ii, | ; 'i r I, >. '' ' .-'- ' : ! -' - < t< "H i ' * »""' '#" ; '~ HI !'
T; < : r1"" : ~ ; ; ;" ~ :,":"': :"; ;T' '"; ; ,;> r: v', ' ; IT" ''' ff""," r; "1 : ;
,,i nmiiiii iilLuiNigLiiil' nAli 'n ili,!li:i>, naiiiiiiiil'iin'liiiiiiiPii n,,!1: 'hili i', "im jir. !,;,i injiin Illiillll Ilillinfculii
proclssed, wfiile me cost of landKIfing" tne sluBges woofa'"!}'^" approximately' $35
'11! 'irn- ::;:
I
feral In aHHition,"i3ie'cotnpaiay' is experiencing some prbBIems in maintaining
the consistency of output from the briquettmgprocess. The fairly significant vari-
ability in the rate of production of briquettes during the pilot testing stage has
posed some problems for operators of the basic oxygen furnace that accepts the
briquettes. However, the company expects both the cost and consistency prob-
lems to correct themselves as the process is improved and the volume of sludge
briquetted is increased.
33/50 PROGRESS AND TRI DATA SUMMARY
I
Inland Steel has successfully worked toward achieving its 33/50. Program
goals. As mentioned previously the company realized that it could reduce
releases and transfers that were below its initial goal of a 50 percent reduction
Several years ahead of schedule. As a result, the company officially amended its
goal to a 90 percent reduction by 1995. According to 1993 TRI data, Inland Steel
has almost met its revised goal as of the end of 1993 (see Exhibit 10).
Inland Steel reported 733,786 pounds of releases and transfers of 33/50
Program chemicals in 1993, compared with 5,174,500 pounds in 1988. This rep-
H L mnJj i ! j
!i ! ; ii i ii:i::i iii i:,:'
;;,! ' ; ; i i ;,: ,
TRI
Releases
and
Transfers
(in 1000s)
70,000
Non-33/50 Chemicals
33/50 Chemicals
Iff
S
-n
'-
ffi
tftt
n
'
;
_,
1
1988 1989 1990 1991 1992 19
10,000 T-
9,000 --
Transfers
(in 1000s)
TRI
Releases 8,000
and 7,000
6,000
5,000
4,000
3,000
2,000
1,000
0
33/50
GOAL
Revised
33/50
GOAL
1988 1989 1990 1991 1992 1993
11 Illllllllllll III 11 III1111 IIIIIIIII 111 111 III 11 II IIII11
ill II ' ' ' " "I ('11 I T'l11
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL COMPANY
II
Illliil' 1
'1
III 1 I 1 1 1 1 1 1
III ]l
Illllll ii «| 111 |l 1 I i i 1 i , ii ill ii ill) ii lluli llii ill i - ii
I
1 1
-------
Cyanide Cornpunds, Tolune & Xylene (1.68%) y |Nickel Compounds (2.02%)
Benzene (10.95%)
Chromium Compounds (36.63%)
Tetrachloroethylene (24.64%)
Lead Compounds (24.08%)
resents art overall reduction of approximately 86 percent. (Exhibits 11 and 12
offer further information on Inland's transfers and releases for 1993.) This reduc-
tion included a complete elimination of releases and transfers of dichloromethane
and methyl ethyl ketone.
The other contributors to Inland's reductions include the following:
Chromium compounds
Lead compounds
Nickel compounds
Tetrachloroethylene
1,358,078 pounds (83%)
767,039 pounds (81%)
417,624 pounds (97%)
236,078 pounds (57%)
Transfers Off-Site for Treatment/
Releases to Surface Water (1.72%)
Disposal/Other (8.97%)
Releases to Land (52.54%)
Air Emissions (36.77%)
Exhibit 11
Percentage Breakdown of
33/50 Chemical Releases
and Transfers in 1993 (by
Chemical) '
The company expects
the implementation of
the briquetting process
to reduce releases and
transfers of 33/50
Program chemicals by
approximately 216,000
pounds per year.
Exhibit 12
Percentage Breakdown of
33/50 Chemical Releases
and Transfers in 1993 (by
Media)
As noted previously, the majority of these reductions were achieved by
two activities not discussed in this case study: the elimination of on-site landfill-
ing of slag and the closure of the facility's coking operations. Slag, which had
previously been used to fill in the portion of Lake Michigan on which the IHW is
sited, is now sold to a company that uses it in the manufacture of products like
concrete. Coke is now purchased from an outside supplier.
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL COMPANY
-------
Illi 1 1 III lllllil II II 111 1 1 111
1111 1 I1' i I1
II '1 " 1111 " 1 ,1-1111 1 k
"ill 1 \\< '1 " ' " '
1 III 1 11 III 1 1 1 1 " III 1 < III.
I1 " I 1"
, 1 ., 1
ll'l 1 , 1 ,
II 1 1 1 11 1 1 1 ' ' " " 1
11,1 1 II 1 1 II
1 1 * | »,l ( L 1 | HIM , 1
II' 1 ' 1 I|IH|
" ' ' .. \ ' *
\ | 1 1 '
u
l
, , 1,
11
The two activities discussed in this case study the replacement of tetra-
chloroethylene cleaning with aqueous processes, and the recycling of blast fur-
nace and steelmaking dust and sludges were both implemented recently and
their irnpacts" on releases arid transfers of 33/50 Program chemicals will therefore
not be observed,until j[994'TRl' data are^pqmp'iled"."' Trie cbmpariy indicated that
implementation of the aqueous cleaning system eliminated the use of tetra-
chloroethylene as of October, 1994. The company expects the implementation of
the briquetting process to reduce releases and transfers of 33/50 Program chemi-
cals by approximately 216,000 pounds per year.
Although it was not a part of the 33/56 Program goal, Inland Steel has also
significantly reduced releases and transfers of non-33/50"' tRl chemicals during
the period 1988 to 1993. According to me company's1993 TRl data, total non-
33/50 TRl releases and transfers were 10,155,227 pounds in 1993, a reduction of
46,034,773 pounds (82 percent) from 1988. the majority of these reductions can
be attributed to reductions in manganese compounds (36,069,829 pounds - an 83
percent reduction), hydrochloric acid (5,865,242 pounds - a 99 percent reduction),
and zinc compounds (3,013,874 pounds - a 60 percent reduction).
lllilIllllillllllllllilllKllliill i
Kill 1 1 jfiMt 111 lill1llllll|i|lllil Ilillllllll |lll| lllIllliillilll|ll|lllll|ill|llll|i|ll|lllMllll i Hill ll I II I II 1 1 I'll I III II II Ml 1 ill 111 H |i ' ill 111 III
CONTACT FOR FURTHER INFORMATION
1 l
Ilillliilll lillllH
For additional information on any of the infor-
mation provided in this case study, please con-
tact the following individual:
Mr. Tom Barnett
Staff Engineer
Environmental, Health, and Safety
Inland Steel Company
3210 Watling Street 8-130
East Chicago, IN 46312
Tel: (219)399-6296
Fax: (219)399-6039
II Ilillllllll 111 Ilillllllll I I Ilillllllll IIII II Illll ill Ilillllllll Ilillllllll IIIIIIIIM 11111 111 1 III n ll 111
I
I Ilillllllll III 11 (111 111 111 III II1 Illl^ III (111 ill 111! Ill i ill Ilillllllll I I Ilillllllll I 111 Ilillllllll 11111 II IP 11 III 111 111 1111 III 111 II IK II11 III
33/50 PROGRAM COMPANY PROFILE: INLAND STEEL COMPANY
i
iiii! lllil n
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