United States
              Environmental Protection
              Agency
             Office of Air Quality
             Planning and Standards
             Research Triangle Park NC 27711
EPA-450/3-87-008
April 1987
              Air
s>EPA
Zinc/Zinc Oxide
Preliminary Source
Assessment

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                                   EPA-450/3-87-008
    Zinc/Zinc Oxide
        Preliminary
 Source Assessment
  Emission Standards and Engineering Division
U.S. ENVIRONMENTAL PROTECTION AGENCY
       Office of Air and Radiation
  Office of Air Quality Planning and Standards
     Research Triangle Park NC 27711
           April 1987

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This report has been reviewed by the Emission Standards and Engineering Division of the Office of Air Quality
Planning and Standards, EPA, and approved for publication. Mention of trade names or commercial products is not
intended to constitute endorsement or recommendation for use. Copies of this report are available through the
Library Services Office (MD-35), U S Environmental Protection Agency, Research Triangle Park NC 27711, or, for
a fee, from the National Technical Information Services, 5285 Port Royal Road, Springfield VA 22161

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                             TABLE OF CONTENTS

                                                                      Page

    INTRODUCTION	     1

1.  THE PRIMARY ZINC/ZINC OXIDE INDUSTRY	     1-1

    1.1  BACKGROUND INFORMATION	     1-1
         1.1.1  Electrolytic Zinc Production	     1-1
                1.1.1.1  Roasting	     1-1
                1.1.1.2  Leaching and Purification	     1-3
                1.1.1.3  Electrodeposition	     1-3
                1.1.1.4  Melting and Casting	     1-3
         1.1.2  Electrothermic Zinc Production	     1-4
                1.1.2.1  Roasting and Sintering	     1-4
                1.1.2.2  Electrothermic Furnace Operations	     1-4
                1.1.2.3  Zinc Casting	     1-6
                1.1.2.4  Zinc Refining	     1-6
         1.1.3  The American Zinc Oxide Process	     1-7
    1.2  EMISSIONS	     1-7
    1.3  REFERENCES FOR CHAPTER 1	     1-13

2.  THE SECONDARY ZINC INDUSTRY	    2-1

    2.1  BACKGROUND INFORMATION	    2-1
         2.1.1  Scrap Preparation	    2-1
         2.1.2  Distillation and Remelting	    2-4
    2.2  EMISSIONS	    2-5
    2.3  REFERENCES FOR CHAPTER 2	    2-9

3.  SECONDARY BRASS AND BRONZE PLANTS	    3-1

    3.1  BACKGROUND INFORMATION	    3-1
         3.1.1  Raw Materials Preparation	    3-1
         3.1.2  Melting	    3-4
    3.2  EMISSIONS	    3-5
         3.2.1  Emissions From Materials Preparation	    3-5
         3.2.2  Emissions From Smelting	    3-6
                3.2.2.1  Charging	    3-7
                3.2.2.2  Melting	J	    3-7
                3.2.2.3  Refining	    3-8
                3.2.2.4  Alloying	    3-8
                3.2.2.5  Pouring	    3-8
    3.3  REFERENCES FOR CHAPTER 3	    3-8
                                  in

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                                                                      Page

4.  THE IRON AND STEEL INDUSTRY	     4_1

    4.1  BACKGROUND INFORMATION
         4.1.1  General Process Description	     4-1
                4.1.1.1  Blast Furnace	     4_1
                4.1.1.2  Steel Furnaces	     4_2
                4.1.1.3  Galvanizing	        4_2
    4.2  EMISSIONS	     4.2
         4.2.1  Blast Furnaces	     4_3
         4.2.2  Steel Furnaces	     4.3
         4.2.3  Galvanizing	     4_4

5.  MISCELLANEOUS ZINC EMISSION SOURCES	     5-1

    5.1  BACKGROUND INFORMATION	     5_1
         5.1.1  Zinc-Base Alloys	     5-1
         5.1.2  Zinc Electroplating	     5-2
         5.1.3  Rolled Zinc	     5_2
         5.1.4  Other Miscellaneous Sources	       5-3
    5.2  EMISSIONS	     5.3
         5.2.1  Zinc-Base Alloys	'.     5.3
         5.2.2  Zinc Electroplating	      5_3
         5.2.3  Rolled Zinc	     5_4
         5.2.4  Other Miscellaneous Sources	     5-4
    5.3  REFERENCES FOR CHAPTER 5	     5-4

6.  MISCELLANEOUS ZINC OXIDE EMISSION-SOURCES	     6-1

    6.1  BACKGROUND INFORMATION	     6-1
         6.1.1  Rubber Production	     6-1
         6.1.2  Photocopying	     6-1
         6.1.3  Zinc Paints	     6-3
         6.1.4  Other Miscellaneous Sources	     6-3
    6.2  EMISSIONS	     6-4
         6.2.1  Rubber Production	     6-4
         6.2.2  Photocopying	     6-4
         6.2.3  Zinc Paints	     6-4
         6.2.4  Other Miscellaneous Sources	^	     6-4
    6.3  REFERENCES FOR CHAPTER 6	     6-5

    APPENDIX	    A-l

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                              LIST OF TABLES
Table                                                                Page

 1-1      Primary Zinc Plant Locations and Capacities	    1-9

 1-2      Zinc Emission Sources at Electrolytic Zinc Smelters	    1-10

 1-3      Zinc Emission Sources at the Electrothermic
            Zinc Smelter	    1-11

 1-4      American Process Zinc Oxide Sources at
            New Jersey Zinc	    1-12

 2-1      Secondary Slab Zinc Plant Capacity in the
            U.S., by Company	    2-2

 2-2      Secondary Zinc Oxide Producers	    2-2

 2-3      Emission Points and Effluents of Secondary
            Zinc-Sweat Processes	    2-6

 2-4      Emission Points and Effluents of Secondary
            Zinc-Distillation Processes	    2-7

 3-1      Brass and Bronze Alloys, Chemical Specifications,
            and Product Characteristics	    3-2

 3-2      Producers of Brass and Bronze, February 1983	    3-3

 4-1      U.S. Iron and Steel Plants	    4-10

 4-2      Chemical Analysis of the Fumes Collected by a
            Baghouse and an ESP From Zinc Galvanizing Kettles	    4-19

 6-1      Distribution of Zinc Oxide Shipments,
            by Industry, 1984	    6-2

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                             LIST OF FIGURES

                                                                    Page

         Process flow diagram for a typical electrolytic
           zinc smelter	    1_2

1-2      Process flow diagram for the electrothermic zinc
           smelter, St. Joe Resources Company,
           Monaca, Pennsylvania	    1-5

1-3      Process flow diagram for the American zinc oxide
           process, The New Jersey Zinc Company,
           Palmerton, Pennsylvania	    1-6

2-1      Flow diagram for secondary zinc processing	    2-3

4-1      General flow diagram for the iron and steel industry...    4-5

4-2      Model blast furnace plant for an integrated
           steel mill	    4_6

4-3      Model basic oxygen furnace shop for an
           1 ntegrated steel mill	    4-7

4-4      Model electric arc furnace shop for an
           integrated steel mill	    4-8

4-5      Model open hearth furnace shop for an
           integrated steel mill	    4-9

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                               INTRODUCTION

     The purpose of this project was to identify the major sources of zinc
and/or zinc oxide emissions.  This was accomplished through a literature
search, through contacts with State air pollution agencies, and from
information gathered as part of the cadmium Phase I project
(ESED 80/42).  Additional information was retrieved from the National Air
Toxics Information Clearinghouse (NATICH) database in the form of permit
information and from the National Environmental Data System (NEDS)
database.  The information from NATICH was limited to permit data from the
States of Texas, Minnesota, Illinois, and New York.  The majority of the
information came from New York.  A significant amount of permit
information was obtained from New York by retrieving and prioritizing the
permit-numbers available in NATICH.  Eighty permits were identified and
requested that represented 50 of the 70 industries where zinc or zinc
oxide are manufactured, used, or emitted.  The other 20 industries were
eliminated from consideration because the permit information showed either
trace emissions or emissions of less than or equal to 0.001 pounds of
zinc/zinc oxide per hour.
     This report contains six chapters.  The first four chapters present
four industries for which a large amount of information was readily
available.  These industries, primary zinc, secondary zinc, brass and
bronze, and iron and steel, were studied separately because the literature
showed them to be potentially large sources of zinc emissions.   The other
two chapters contain information on miscellaneous uses of zinc  and zinc
oxide.
     For the iron and steel chapter, four model plants were presented
because they had been developed during an earlier study of cadmium
emissions.  Insufficient information was readily available to develop
model plants for other industry categories.

                                     1

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     For the primary zinc/zinc oxide chapter, inputs for the Human
Exposure Model  (HEM) were available for specific emission sources at each
plant from the  cadmuim Phase I project.  In addition, zinc/zinc oxide
specific information including HEM data was available from the States of
New York, Kentucky, and Illinois.  The HEM input data are presented in the
Appendix to this report.

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                 1.  THE PRIMARY ZINC/ZINC OXIDE INDUSTRY

1.1  BACKGROUND INFORMATION
     There are currently four primary zinc smelters in operation in the
U.S.  Of these, one is an electrothermic smelter while the other three are
electrolytic smelters.  All four plants process zinc sulfide ore
concentrates that may range from 50 to 63 percent zinc.   The electro-
thermic smelter, due to the nature of the production process, also
processes zinc secondary materials such as zinc skimmings, drosses, scrap
metal, and oxidics.  There is one primary zinc oxide smelter in
operation.  The following sections briefly discuss the three production
processes.
1.1.1  Electrolytic Zinc Production
     A process flow diagram for a typicfal electrolytic zinc smelter is
shown in Figure 1-1.
     1.1.1.1  Roasting.  The first step in the production of zinc metal
from ore concentrates at both electrolytic and electrothermic zinc
smelters is the roasting operation.  Zinc roasting consists of heating the
ore concentrates to 650° to 1000°C (1200° to 1800°F) in an oxidizing
environment.  The roast is carried out below the melting temperature of
the charge and has three primary functions:  (1) elimination of sulfur as
S02, (2) conversion of zinc sulfide to impure zinc oxide, and (3) removal
of volatile impurities from the ore concentrate.  The degree of sulfur
elimination accomplished in a zinc roaster varies from about 93 to
97 percent.2
     The fluid bed roaster is the newest roasting system for zinc sulfide
concentrates and is currently the only type in use.  The offgas stream
from a fluid bed zinc roaster typically has an S02 concentration of 10 to
13 percent, and up to 85 percent of the roaster product (calcine) is

                                    1-1

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ZINC ORE
CONCENTRATE
       AIR
                        SULFUR1C AGIO
       ZINC M6TAL «^-
                                              ZINC OUST
                                              ZINC OUST
     ELECTROLYTIC
     CELL HOUSE
                                        COLO
                                        PURIFICATION
                                        REACTOR
                                        PURIFICATION
                                        REACTOR
HOT PURIFICA-
TION REACTOR
                                                                 ZINC OUST
                                                                                       RON CAKE
                                                                                  COPPER CAKE
                                                                                CADMIUM CAKE
                                                                               C08ALT CAKE
         Figure 1-1.
Typical process  flow diagram  for an  electrolytic
              zinc smelter?
                                             1-2

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carried out with the offgas. ' Waste heat boilers, cyclones, and
electrostatic precipitators are used in series to capture the entrained
portion of the calcine.  The cleaned gas is then ducted to a sulfuric  acid
plant.  At electrolytic zinc plants, the collected materials are normally
combined with the remaining portion of the calcine and stored prior to
                          2
leaching and purification.
     1.1.1.2  Leaching and Purification.  The roaster calcine is first
leached in a dilute sulfuric acid solution to dissolve the impure zinc
oxide.  Manganese dioxide (Mn02) is generally added to the leach tank to
cause the precipitation of an iron cake that contains iron and significant
amounts of arsenic, antimony, and silicic acid.  The leachate is then sent
to a series of cold and hot purification tanks where cadmium, copper, and
cobalt are removed from solution.  The precipitation reactions that occur
are induced by the addition of zinc dust, which reduces Cd"1"2, Cu4"2, and
Co"1"  to their respective metallic forms.   All three electrolytic smelters
recover the precipitated cadmium and sell it as cadmium metal or cadmium
oxide.
     1.1.1.3  Electrodeposition.  The purified zinc sulfate solution from
the purification system is passed to the cell room where an electric
potential applied to the solution causes zinc metal to form on the surface
of aluminum cathodes.  Hydrogen gas is also evolved causing the formation
of sulfuric acid, which is recycled to the leach tank.   The zinc metal
sheets are subsequently stripped from the cathodes and stored prior to
melting and casting.
     1.1.1.4  Melting and Casting.  The zinc metal sheets are charged to
an electric induction furnace and melted down.  Ammonium chloride
typically is added to the zinc sheets as a flux.  The molten zinc is then
pumped to a holding furnace where pneumatic jets direct the molten zinc
into molds.  Any impurities that form on the top of the freshly poured
zinc are skimmed off.  Water is sprayed on top of the molds to aid in
cooling.  At some plants, the area in which this cooling takes place is
enclosed.  The zinc slabs are subsequently removed from the molds,
stacked, and stored for sale.
                                    1-3

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 1.1.2  Electrothermic Zinc Production**
     The process flow diagram for the electrothermic zinc smelter  is  shown
 in Figure  1-2.
     1.1.2.1  Roasting and Sintering.  The zinc sulfide ore concentrates
 are dried  in a rotary dryer prior to roasting.  Emissions from the dryer
 are controlled by a venturi scrubber.  The dried ore concentrates are then
 roasted in a fluid bed roaster.  Emissions from the roaster are controlled
 in series  by a cyclone, waste heat boiler, electrostatic precipitator, and
 a wet scrubber.  The cleaned gas is then ducted to a double-adsorption
 sulfuric acid plant.
     Roaster calcine, sand, coke breeze, electrothermic furnace residue,
 blue powder from the electrothermic furnaces, scrubbers, and return sinter
 fines are mixed together and pelletized.  The pelletized material is then
 roasted in downdraft sinter machines at an operating temperature from
 1200° to 1300°C (2200° to 2400°F).  The sinter machine product is
 subsequently crushed and screened.  Sinter fines from screening are
 recycled to the sinter machines.  Emissions from the sinter machines and
 from the crushing and sizing operation are controlled by separate
 baghouses.
     1.1.2.2  Electrothermic Furnace Operations.  The advantage of the
electrothermic process over the electrolytic process is that a significant
portion of the feed may be comprised of secondary material.   Sinter,  coke,
and secondary materials are heated and mixed in a rotary preheater and
then charged to an electrothermic furnace.  Emissions from the electro-
thermic furnace preheaters are controlled by a baghouse.  Electricity is
passed through eight pairs of graphite electrodes located at the  top  and
bottom of the furnace to generate the heat required for smelting.   Furnace
vapors, including zinc vapor, are drawn through a water-cooled condenser
and bubbled through a molten zinc bath.   The gases vented from the
condenser are scrubbed with water from high-velocity impingers.   The  clean
gas, which contains about 80 percent carbon monoxide,  is recovered and
used as fuel.  Any uncondensed zinc  is recovered by settling the  water
slurry in ponds.   This zinc,  which is called blue powder,  is recycled to
the roaster.   Furnace residue is discharged on a rotary table  at  the  base
                                    1-4

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                                         EXHAUST TO
                                         ATMOSPHERE
CO USED
AS FUEL
              REACTOR OFEGAS  TO
              ACID PLANT CIRCUIT
     ZINC ORE
     CONCENTRATE
i,   AIR
                                 SINTER MACHINE
                                 OFFGAS
                  FLUID BED
                  ROASTER
                             CALCINE
  ELECTROTHERMIC
  SMELTING
  FURNACES (4>
                                                                                                                                 ZINC
                                                                                                                            ZINC OXIDE
                                                                                    SLAG TO RESIDUE
                                                                                    TREATMENT
             Figure 1-2.   Process flow diagram for the electrothermic  zinc smelter,  St.  Joe  Resources Company,
                                                         Monaca, Pennsylvania.

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of the furnace.  It is then treated to recover coke and unsmelted zinc and
to segregate slag and ferrosilicon by-products.
     1.1.2.3  Zinc Casting.  Molten zinc from the electrothermic furnace
condenser is passed to a holding furnace.  The zinc may then be cast into
25-kilogram (kg) (55 Ib) slabs, 227-kg (500-lb) blocks, or 1,090-kg
(2,400-lb) jumbo blocks.  The casting process is fully automated.  Molten
zinc from the holding furnace is tapped into molds which travel on a
conveyor.  Dross that forms on the surface of the molten zinc after
tapping is skimmed off and stored for later use as furnace feed
material.  As the conveyor proceeds, water is poured on top of the molten
zinc to aid in cooling the slabs.  The slabs then pass into a hooding and
ventilation system where more water is sprayed onto the slabs; the steam
produced is drawn off to the atmosphere.  The cooled slabs of zinc are
then mechanically removed from the molds, stacked, and stored for
shipment.
     1.1.2.4  Zinc Refining.  Further refining of the zinc metal is
accomplished using two refining columns known as the cadmium column and
the lead column.  Molten zinc from the electrothermic furnace is
transferred to the cadmium column in large ladles.  The molten zinc is fed
at a constant rate to the column and flows inside carbide trays.  The
column is operated at a temperature high enough to drive off metals,
including cadmium, with a lower boiling point than zinc.  Vapor from the
column is condensed in a condenser.  The resulting cadmium/zinc alloy
contains approximately 3 percent cadmium by weight.  This alloy is
recycled to the electrothermic furnaces.
     The partially purified zinc collected at the bottom of the cadmium
column is processed through another column known as the lead column.
Here, the zinc is further purified by driving off zinc vapor and leaving
behind higher boiling metals such as lead and iron.  The zinc vapor is
either condensed to produce high purity zinc metal slabs or oxidized to
produce high purity zinc oxide.  The zinc oxide powder is captured in
product collection baghouses.  Offgases from the refining columns are
vented to two other baghouses.
                                    1-6

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1.1.3  The American Zinc Oxide Process
     In the American zinc oxide manufacturing process, zinc ore
concentrates are used as the zinc feed material.  Another process used to
manufacture zinc oxide, known as the French process, uses high purity zinc
metal as a feed material and, is, therefore, a secondary zinc process.
Secondary zinc processes are described in Chapter 2 of this report.
     The process flow diagram for the American zinc oxide process at The
New Jersey Zinc Company in Palmerton, Pennsylvania, is shown in
Figure 1-3.  The current design capacity of the American process at this
plant is 15,000 megagrams per year (16,500 tons per year).   This plant
processes a low-sulfur zinc ore known as Sterling crude ore that has a
cadmium content of about 0.004 percent by weight.   Ore and coal are fed
to the Waelz kilns where metals are volatilized and oxidized.  The Waelz
oxide product is cooled and collected in a bagroom.  The oxide is then
sintered in a downdraft sinter machine to reduce impurities, such as lead
and chloride.  The last step in the process is the final oxidation and
purification.  The sinter is mixed with coal and fed to a moving grate
furnace.  The oxide is volatilized, reduced to metallic zinc, and then
oxidized again.  The purified zinc oxide is then collected in a
baghouse.
1.2  EMISSIONS
     Table 1-1 lists the primary zinc plant locations and production
capacities.
     Tables 1-2 and 1-3 list the zinc emission sources for electrolytic
and electrothermic plants, respectively.  For the most part, zinc
emissions to the atmosphere are controlled.  The exceptions are zinc ore
concentrate storage and handling and zinc metal tapping and casting.  Each
of the four plants has a building for storage of zinc ore concentrates.
However, the outdoor storage of this material is a potential fugitive
source of zinc sulfide emissions at three plants.  Zinc tapping and
casting is uncontrolled at each of the four plants although ventilation to
the atmosphere is in place at three of the plants.
     Table 1-4 lists the zinc oxide emission sources for the American
process at The New Jersey Zinc Company.   Zinc oxide emissions to the
atmosphere are controlled by baghouses at each source.

                                    1-7

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                                                                   SINTER MACHINE
                                                                   BAGHOUSE OFFGAS
                                                  FUME KILN
                                                                                        BAGHOUSE
                                                                                        OFFGAS
                                                                FUME
                                                                KILN
                                                                BAGHOUSE
                                  FUME
                                                                                                                       TO FUME
                                                                                                                       TREATMENT
                              WAELZ KILN PRODUCT
                              BAGHOUSE OFFGAS
                                  SINTER
                                  MACHINE
                                  BAGHOUSE
                                                                                   OUST
                                                                                                  FUME KILN
              WAELZ KILN FUGITIVE
              BAGHOUSE OFFGAS
i
co
WAELZ
KILN
PRODUCT
BAGHOUSE
                                               WAELZ OXIDE
                        FUGIIWS
                        BACHOUSf
                 WAELZ
                 FUGITIVE
                 DUST
           ORE
                                                                           SINTER MACHINE
                                                                           OFFGAS
                                                                   SINTER MACHINE
                         CALCINE
     NAELZ KILN
     OFFGAS
                             WAELZ KILN
WAELZ SINTER
                                                                                                FURNACE PRODUCT
                                                                                                BAGHOUSE OFFGAS
                              HORIZONTAL  GRATE
                              FURNACE
                                                                                       FURNACE
                                                                                       OFFGAS
                        FURNACE
                        PRODUCT
                        BAGHOUSE
PKOOUCT ZINC
OXIDE
                           WAELZ RESIDUE
                                                                 FURNACE RESIDUE
                               Figure  1-3.   Process  flow diagram for  the American Zinc Oxide Process,
                                           New  Jersey Zinc Company,  Palmerton,  Pennsylvania. 10

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         TABLE 1-1.  PRIMARY ZINC PLANT LOCATIONS AND CAPACITIES7

                                                              Capacity,
Plant name                      Location                   Mg/yr (tons/yr)


AMAX Zinc Company, Inc.         East St. Louis, 111.      72,000 (80,000)

Jersey Miniere Zinc             Clarksville, Tenn.        82,000 (90,000)

St. Joe Resources/National      Bartlesville, Okla.       51,000 (56,000)
  Z1nc Division

St. Joe Resourcesa              Monaca, Pa.             90,000b (100,000)b


aSt. Joe, Monaca, is the only electrothermic zinc smelter.  The others are
 electrolytic smelters.
bAs zinc equivalent (includes slab zinc, zinc dust, and zinc oxide).
                                    1-9

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      TABLE 1-2.   ZINC EMISSION SOURCES AT ELECTROLYTIC ZINC SMELTERS
Emission source
           Emission control
Ore storage and handling
Roasters
Zinc melting
Zinc tapping/casting

Haul roads
Baghouses, buildings, or none
Acid plant and associated gas cleaning
  equipment
Baghouse
None; ventilation to the atmosphere in
  place at three plants
Road sweepers and water sprays
                                   1-10

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   TABLE 1-3.  ZINC EMISSION SOURCES AT THE ELECTROTHERMIC ZINC SMELTER
Emission source
           Emission control
Ore storage and handling

Ore dryer
Roaster

Sinter machines.
Sinter sizing/crushing
Electrothermic furnace
  preheaters
Electrothermic furnaces

Zinc holding furnace
Zinc tapping/casting
Zinc metal powder process
Refining columns
Zinc oxide process
Haul roads
Storage building and dust suppressant on open
  storage piles
Scrubber
Acid plant and associated gas cleaning
  equipment
Baghouse
Baghouse
Baghouse
Condenser and scrubber in a closed loop
  system
Baghouse
None; ventilation to atmosphere
Closed loop system; no emissions
Baghouses
Baghouses
Road sweeper with water sprays
                                   1-11

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    TABLE 1-4.  AMERICAN PROCESS ZINC OXIDE SOURCES AT NEW JERSEY ZINC
Emission source
Emission control
Ore storage and handling
Waelz kiln fugitives
Waelz kiln process
Sinter machine
Fume kiln
Horizontal grate furnace
None
Baghouse
Baghouse
Baghouse
Baghouse
Baghouse
                                   1-12

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1.3  REFERENCES FOR CHAPTER 1

 1.  Section 114 questionnaire responses from AMAX Zinc, Jersey Miniere
     Zinc, St.  Joe Resources (National Zinc Division), and St. Joe
     Resources, Monaca.   April through June, 1986.

 2.  Radian Corp.  Background Information Document for Cadmium Emission
     Sources.   EPA No.  68-02-3818,  Assignment No. 23.   May 1985.   p. 43.

 3.  Reference  2, p. 44.

 4.  Turner, M. B., MRI,  Trip Report to St. Joe Resources, Monoca,
     Pennsylvania.  August 6, 1986.

 5.  Section 114 questionnaire response from The New Jersey Zinc  Company,
     Palmerton, Pennsylvania.  May  16, 1986.

 6.  Reference  2, p. 61-63.

 7.  Reference  2, p. 40.

 8.  Reference  2, p. 42.

 9.  Reference  2, p. 45.

10.  Reference  2, p. 62.
                                   1-13

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                      2.   THE  SECONDARY  ZINC INDUSTRY

2.1  BACKGROUND INFORMATION
     The secondary zinc industry is defined here as those facilities that
refine scrap zinc materials into other zinc products such as slab zinc,
zinc dust, zinc oxide, and zinc-based alloys.  The distinction between
primary and secondary zinc is  based on the source of the zinc feed
material; primary zinc is derived from zinc-bearing ores while secondary
zinc is produced from zinc scrap materials.  The manner in which zinc
scrap materials are processed  is dependent entirely on their type and
quality.  Low grade scrap typically requires some form of refining before
production of end-products while high grade scrap may require relatively
little pretreatment.  The following sections describe the various
processes associated with the  secondary zinc industry including scrap
preparation, distillation and  remelting.  Table 2-1 lists the secondary
slab zinc producers, locations,  and total  production capacity (individual
capacities were not available.)   Table 2-2 lists the secondary zinc oxide
producers, locations, and capacities.
2.1.1  Scrap Preparation
     The zinc scrap feed material may be grouped into four broad
categories:  galvanizers'  scrap  (mainly drosses, skimmings, ashes), new
die-cast scrap (reject castings), mixed die-cast scrap (auto shredders'
scrap, auto parts, appliance parts),  and general zinc scrap (clippings,
engravers plates).  Figure 2-1 shows  a typical  process flow diagram.
     Typically, the new die-cast scrap and general  zinc scrap require
little or no preparation prior to processing.  These materials may be
melted down and blended to achieve the proper market specifications.
     Galvanizers1  scrap (primarily drosses, skimmings, sal  skimmings, and
ashes) are largely shipped from  galvanizing operations in drums or solid

                                   2-1

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  TABLE 2-1.   SECONDARY SLAB ZINC PLANT CAPACITY IN THE U.S., BY COMPANY'
Company/Plant location
                                                             Capacity,
                                                            metric tons
    1983
1984
Arco Alloys Corp., Detroit, Mich.
W. J. Bullock, Inc., Fairfield, Ala.
T. L. Diamond and Company, Inc., Spelter, W. Va.
Gulf Reduction Corp., Houston, Tex.
Hugo Neu-Proler Company, Terminal Island, Calif.
Huron Valley Steel Corp., Belleville, Mich.
Interamerican Zinc Company, Adrian, Mich.
The New Jersey Zinc Company, Inc., Palmerton, Pa.
Pacific Smelting Company, Torrance, Calif.
Pacific Smelting Company, Memphis, Tenn.
Prolerized Schiabo Neu Company, Jersey City, N.J.
•'95,000  '    95,000
                TABLE  2-2.   SECONDARY  ZINC  OXIDE  PRODUCERS'
Plant name/location
        Capacity,
       metric tons
American Chemet Corp.                                             8,000
ASARCO, Inc., Hillsboro, 111.                                    13,000
T. L. Diamond and Company, Inc., Hillsboro, 111.                 20,000
St. Joe Resources Company, Monaca, Pa.                           45,000
Huron Valley Steel Corp., Trenton, Mich.                         16,000
Inland Zinc, Spokane, Wash.                                       2,000
Midwest Zinc Corp., Chicago, 111.                                10,000
The New Jersey Zinc Company, Palmerton, Pa.                      41,000
Pacific Smelting Company, Millington, Tenn.; Torrance, Calif.    20,000
Philipp Brothers Chemis., Inc., The Prince Mfg. Company,          5,000
  subsidiary, Bowmanstown, Pa.
Superior Zinc Corp., Bristol, Pa.                                 3,000
                                    2-2

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                       MIXED DIE-CAST SCRAP
                        AUTO DIE-CAST SCRAP
   SCRAP

PREPARATION
                                      NEW DIE-CAST SCRAP
                                      GENERAL ZINC SCRAP
ro
i
CJ
               ZINC DROSSES
               AND SKIMMINGS
                                        AIR

                                   CLASSIFICATION
                                                                                                                    ZINC DUST
                                                               CAST ZINC ALLOY


                                                               SI AB ZINC
                                                                                                                    ZINC OXIDE
                                      Figure 2-1.   Flow  diagram for secondary  zinc  processing.

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blocks to the scrap-consuming plant.  In many plants, they are charged to
the distillation furnace either directly or after first being melted  in a
separate operation.  Some plants dry mill and air classify the zinc
skimmings to separate the metallic zinc from zinc oxide.  In other plants,
skimmings are crushed and then treated in the following manner.  The
crushed skimmings are washed with water to separate nonmetals as a slurry
and allow zinc-containing metal particles to settle out; the slurry is
then treated with Na2C03 to convert chlorides (mainly ZnCl2) to NaCl,
forming insoluble Zn(OH)2.  Most of the NaCl is separated from the
insoluble residues by filtration and settling; the residue is dried and
calcined in a kiln to convert Zn(OH)2 to ZnO by driving off H20 and
vaporizing any remaining ZnCl2.  The calcined product is mostly ZnO and is
suitable for smelting.  The kiln fume is collected and recycled.
     Mixed die-cast scrap contains a large amount of ferrous and
nonferrous material.  It is a low grade zinc scrap material  and requires
pretreatment in a sweating process to produce a higher purity zinc product
suitable for further processing in a distillation operation.  Sweating
involves melting the zinc scrap to separate both unmeltable attachments
and nonmetallic residues.  Agitation and the addition of a fluxing agent
help promote metal separation.  The unmeltable attachments settle to the
bottom of the furnace and are removed, and the nonmetallic residues are
skimmed from the molten surface.  The resulting zinc metal may then be
cast into blocks for further processing; fed directly to a distillation
furnace; or it may be sampled, analyzed, and alloyed with other metals to
obtain the desired specification.  Several types of furnaces are available
for sweating operations including reverberatory furnaces, rotary furnaces,
and kettle furnaces.
2.1.2  Distillation and Remelting2
     New die-cast scrap, general scrap,  and purified zinc from sweating
furnaces are processed further either by pot melting or by distillation.
     Pot melting involves remelting and  heating the scrap material  to
enhance separation of impurities that are skimmed from the metal
surface.  The purified zinc metal may then be cast into zinc slabs  or
alloyed and cast into zinc alloy ingots.
                                   2-4

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     Distillation involves boiling the zinc scrap material and either
condensing the vapor rapidly to produce powdered zinc, condensing the
vapor more slowly to produce liquid zinc,  or contacting the vapor with an
air stream to produce zinc oxide.  The zinc oxide stream is captured in a
product collection baghouse.
2.2  EMISSIONS
     Tables 2-3 and 2-4 list the zinc emission sources and effluents for
both secondary sweating processes and secondary distillation processes.
Typically, these systems are controlled by baghouses.   Some plants augment
baghouse control on sweating processes with afterburners to control  any
organic emissions resulting from the processing of scrap contaminated with
oil, paint, etc.3
                                   2-5

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                        TABLE 2-3.   EMISSION  POINTS AND EFFLUENTS OF SECONDARY ZINC-SWEAT  PROCESSES6
       Process  (defined
       by  type  of
       furnace  used)
Emitting process
equipment unit
Emission point of
process equipment  unit
    Constituents of  effluents  from emission points
       Kettle  furnace
       Reverberatory furnace
ro
en
       Rotary  furnace
       flue
Melt kettle
Combustion chamber,
containing melting
hearth.  (May also
be referred to as
"sweating chamber".)
Rotating, cyIindricaI
melt unit.  (May also
be referred to as
"sweating chamber" or
"combustion chamber.")
Top of melt kettle (or
surface of  metallurgical
process bath,  formed from
charge).
Furnace flue (exhausting
combustion chamber).
                       Openings for charging and
                       fluxing; and removal of
                       unmet tables and skimmings.
Furnace flue (high end of
melting cylinder).
A.  Emissions from process  charge.
    I.  Products of combustion  or  thermal  decomposi-
        tion of  organic materials  in charge.
    2.  Emissions derived  from  metals,  fluxes,  and
        residues in metallurgical  process  bath,
        including metal  oxides  resulting from
        presence of air contacting metal.

A.  1.-2.   Emissions from  process  charge (same  items
    as Iisted above.)
B.  Air induced  or infiltrated  into  furnace, then
    into flue (would be in  excess  of air consumed  in
    combust ion).
C.  Products of  combustion  of  fuel (usually natural
    gas).

A.  1.-2.;  B.; and C.   Same items  as  listed above
    for furnace  flue.   These effluents  are formed
    from (1) gases escaping from the furnace;
    (2) emissions from the  molten  metal and
    skimmings being withdrawn  from furnace with
    unmeI tables; and (3) ambient air.

A.  I.-2.;  B.; and C.   Same as  listed above for
    reverberatory furnace,  except  emissions
    derived from flux  are not normally  contained
    in rotary furnace  effluent.

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                   TABLE 2-4.  EMISSION SOURCES AND  EFFLUENTS OF  SECONDARY ZINC-DISTILLATION PROCESSES7
      Process (defined
      by type of
      furnace used)
Emitting process
equipment unit
Emission point of
process equipment  unit
    Constituents of  effluents  from emission  points
      Retort furnace
      system
D i st iI I at i on  retor t
                              Condenser
ro
i
                              Condenser
      Muffle furnace
      system
Melt unit
(reverberatory
furnace)
Opening of distillation
unit.  (Emissions occur
during removal  of distil-
lation residues.  This
opening may be  refered to
as "charging holes."
It is used for  applying
charge to retort and
removing residues.)

Pressure relief valve.
(Used to retain positive
pressure and exclude air
from condenser.)
"Speise" hole.   (Used
instead of pressure relief
for same purpose.   Zn vapor
escaping from condenser
through speise hole is
oxidized in air, producing
ZnO particulates.)

Flue of melt-unit  combus-
tion chamber.
A.  Emissions from distillation  residues.
    1.  ZnO (makes up most  of  emitted  particulates).
    2.  Oxides of  other  metals (mainly  AI-0,) -
        smalI amounts.
B.  Ambient air.
A.  Emissions from vapors  distilled  from  retort
    charge.   Partly oxidized  by  residual  air  in
    retort and condenser system.
    1.   ZnO parti cut ate.
    2.   Metallic zinc dust (particuI ate).
    3.   Chloride particuIates,  derived  from  flux.
        (Very small amounts may  occur when dross  is
        charged to retort.)
B.  N_  from residual  air in retort  and  condenser.

A.  Emissions from vapors  distilled  from  retort
    charge and oxidized.
    I.   ZnO particulate, nearly  pure.   (The
        charge to retort is of  molten metal  which
        would not produce  chloride  emissions)
B.  N~  from residual  air in retort  and  condenser.
C.  Ambient air.

A.  Emissions from melt-unit  charge.
    1.   Products of combustion  or  thermal  decomposi-
        tion of organic  materials  in charge.
    2.   Emissions derived  from  metals and  residues
        (usually no flux)  in  metal IurgicaI-process
        bath, including  metal oxides resulting  from
        presence of air.
B.  Air induced or infiltrated  into  melt  unit,  then
    into flue.  (Would be  in  excess  of  air consumed
    in  combustion.)
C.  Products of combustion of  fuel  (usually  natural
    gas),  burned in melt unit and vaporizing  unit.
                                                                                                                           (cont i nued)

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                                                        TABLE  2-4.    (continued)
       Process  (defined
       by  type  of
       furnace  used)
                 Emitting  process
                 equipment unit
Emission point of
process equipment unit
Constituents of effluents from emission points
       Muffle
       system
furnace
(continued)
                              Vaporizing unit
                              (muffle furnace)
Openings in melt unit for
charging scrap material
and removing unmet tables
skimmings.
                                        Tap hole of  vaporizing unit.   A.
                                        (Emissions occur during
                                        removal  of disti11 at ion       B.
                                        residue.)
1.; 2.; and C.  Same items as listed above for
furnace flue.  These effluents are formed from
(1) gases escaping from the melt unit;  and
(2) emissions from the molten metal  and
skimmings being withdrawn from melt  unit with
unmeltables; and (3) ambient air.

Emissions from distillation residues.
I.  ZnO particulate, nearly pure.
Ambient air.
ro
i
co

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2.3  REFERENCES FOR CHAPTER 2

1.  McElroy, A. D. et al.  Source Category Survey:  Secondary Zinc
    Smelting and Refining Industry.  U. S. Environmental Protection
    Agency.  EPA-450/3-80-012, May 1980.  pp. 28-29.

2.  Reference 1.  pp. 32, 34, 36.

3.  Reference 1.  p. 49.

4.  Jolly, James H.  Zinc Chapter in Minerals Yearbook.  U.S. Department
    of the Interior, Bureau of Mines, Washington, D.C.  1984.  p. 16.

5.  SRI International 1985 Directory of Chemical  Producers,  p.  966.

6.  Reference 1.  p. 31.

7.  Reference 1.  p. 38.

8.  Reference 1.  p. 27.
                                   2-9

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                   3.   SECONDARY  BRASS  AND  BRONZE  PLANTS

3.1  BACKGROUND INFORMATION
     Classically,  when copper is  alloyed with zinc the product is termed
brass, and when copper is alloyed with  tin the product is termed bronze.
Normally the zinc  content of brass ranges from 5 to 37 percent, while the
zinc content of bronze is generally not more than 5 percent.  Other copper
alloys are identified by the alloying metals such as aluminum bronze and
silicon bronze. Table 3-1 lists  the 12 categories of brass and bronze
that have been designated by the  Brass  and Bronze Ingot Institute.  The
table also shows subcategories of the alloys along with the chemical
specifications and characteristics of each.
     Secondary brass and bronze companies are usually small, individually
owned firms consisting of one plant. A few are subsidiary operations of
large mining companies or of conglomerates.  As of 1983,  37 secondary
brass and bronze plants in 13 States were in'operation; these plants are
listed in Table 3-2.l
     The brass and bronze manufacturing industry basically consists of
three operations:   raw materials  collection and preparation, metal melting
and ingot production, and metal product fabrication.
     The following sections discuss raw materials preparation and melting
as they relate to  zinc emissions  in the brass and bronze  ingot production
process.
3.1.1  Raw Materials Preparation
     The raw materials used in the secondary brass and bronze ingot
industry consist mainly of brass  and bronze scrap, with virgin metals used
only to adjust the composition of the product.  Some scrap may require
cleaning before furnace charging  to remove contaminants such as oil,
grease, paint, insulation, and chemicals.
                                   3-1

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TABLE 3-1.  BRASS AND BRONZE  ALLOYS,  CHEMICAL SPECIFICATIONS, AND PRODUCT CHARACTERISTICS"
Alloy
No.
1A
IB
2A
2B
2C
3A
3B
3C
30
3E
4A
4B
5A
SB
6A
6B
6C
7A
BA
8B
8C
9A
9B
9C
90
10A
10B
11A
11B
12A
12b
Classification
Tin bronze
Tin bronze
Leaded tin bronze
Leaded tin bronze
Leaded tin bronze
High- lead tin bronze
High- lead tin bronze
High- lead tin bronze
High- lead tin bronze
High- lead tin bronze
Leaded red brass
Leaded red brass
Leaded sen -red brass
Leaded seni-red brass
Leaded yellow brass
Leaded yellow brass
Leaded yellow brass
Manganese bronze
Hi-strength nanganese bronze
Hi-strength nanganese bronze
Hi-strength nanganese bronze
Alum nun bronze
A lull inure bronze
Alumnun bronze
Alum nun bronze
Leaded nickel brass
Leaded nickel brass
Leaded nickel bronze
Leaded nickel bronze
Si 1 icon bronze
Sil icon brass
Cu. *
88.0
88.0
88.0
87.0
87.0
80.0
83.0
85.0
78.0
71.0
85.0
83.0
81.0
76.0
72.0
67.0
61.0
59.0
57.5
64.0
64.0
88.0
89.0
85.0
' 81.0
57.0
60.0
64.0
66.5
88.0
82.0
Sn, X
10.0
8.0
6.0
8.0
10.0
10.0
7.0
5.0
7.0
5.0
5.0
4.0
3.0
2.5
1.0
1.0
1.0
1.0







2.0
3.0
4.0
5.0


Pb, X


1.5
1.0
1.0
10.0
7.0
9.0
15.0
24.0
5.0
6.0
7.0
6.5
3.0
3.0
1.0
1.0







9.0
5.0
4.0
1.5


In. I fe. X Al. X Hi. X Si, X Hn. X Characteristics
2.0 Corrosion resistant; good for casting.
4.0
4.0
4.0
2.0
Malleable; readily machined.
3.0
1.0


5-0 Inexpensive, corrosion res istant , good for casting and
'•0 machining (useful for water systems).
9.0
15.0
24.0 Moderately strong; easily machines and polishes
29.0
37.0
37-° 1-0 0.6 0.5 High tensile strength; toirosion resistant to sea
39.0 1.0 1.0 1.5 water.
24.0 3.0 '5.0 3.5
24.0 3.0 5.0 3.5
3.0 9.0 High tensile strength and hardness; resistant to
1-0 10. 0 fatigue and high temperature.
4.0 11.0 2.0 0.5
4.0 11.0 4.0 3.0
20-° 12.0 Excellent mechanical piopeilies; tarnish and
'6.0 16.0 corrosion resistant.
8. 0 20. 0
2. 0 25. 0

14.0 4.0

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        TABLE 3-2.  PRODUCERS OF BRASS AND  BRONZE,  FEBRUARY  1983
                                                                 1 9
Company
Location
American Brass, Inc.
ASARCO, Inc.
The G.A. Avril Company
Bay State Refining Company, Inc.
Belmont Smelting & Refining Works, Inc.

Bohn Aluminum and Brass
Bridgeport Brass
Brush Wellman, Inc.
W. J. Bullock, Inc.
Harry Butter & Company, Inc.

Cabot Berylco Ind. Inc.
Cerro Metals
Cerro Metals
Chase Brass and Copper
Chase Brass and Copper

Chicago Extruding Metals
Colonial Metals Company
Federal Metal Company
N. Kamenske & Company, Inc.
Kearny Smelting & Refining Corp.

H. Kramer & Company
H. Kramer & Company
R. Lavin & Sons, Inc.
Liberman S Gittlen Metal Company
Milward Alloy, Inc.

Mishawaka Brass Manufacturing, Inc.
National Metals, Inc.
New England Smelting Works, Inc.
North American Smelting Company
North Chicago Refining & Smelting, Inc.

River Smelting & Refining Company
Roessing Bronze Company
S-G Metals, Ind., Inc.
I. Schumann & Company
Sipi Metals Corp.
Specialloy, Inc.
Headland, Ala.
San Francisco, Calif.
Cincinnati, Ohio
Chicopee, Mass.
Brooklyn, N.Y.

Adrian, Mich.
Indianapolis, Ind.
Cleveland, Ohio
Fairfield, Ala.
Dorchester, Mass.

Reading, Pa.
Newark, Calif.
Bellefonte, Pa.
Montpelier, Ohio
Solon, Ohio

Chicago, 111.
Columbia, Pa.
Bedford, Ohio
Nashua, N.H.
Kearny, N.J.

El Segundo, Calif.
Chicago, 111.
Chicago, 111.
Grand Rapids, Mich.
Lockport, N.Y.

Mishawak, Ind.
Leeds, Ala.
West Springfield, Mass.
Wilmington, Del.
Anniston, Ala.

Cleveland, Ohio
Mars, Pa.
Kansas City, Kans..
Bedford, Ohio
Chicago, 111.
Chicago, 111.
                                    3-3

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     Material preparation processes may be mechanical, hydrometallurgical,
or pyrometallurgical.  The first two processes are not considered in this
description since they are not sources of particulate emissions.
Mechanical processing is not a source of particulate emissions because the
scrap is typically in large pieces with any smaller pieces being coated in
oil or grease.  Hydrometallurgical processing takes place in a water
medium.
     Pretreatment by pyrometallurgical "methods" may include any of the
following:  sweating, burning, drying, blasting furnaces, and cupola.
These methods all involve the use of heat in varying amounts for
preliminary processing of brass and bronze scrap.  A brief description of
each method is given below.
     Sweating furnaces may be used to remove valuable low-melting point
metals, such as lead, solder, and babbit metal.  This is done by heating
the scrap in a furnace, which causes the low-melting components to be
separated from the desirable metals.  Carefully controlled burning usually
is performed for removal of insulation, wrappings, and other specialized
materials from wire or cable scrap.  Drying furnaces are used to vaporize
substances such as cutting fluids from machine shop scrap.
     The terms "blast furnace" and "cupola" are often used inter-
changeably.  However, the cupola is used to melt down metals or reduce
metal oxides, while the blast furnace is used for reduction of metal
oxides or smelting virgin ores.  Both furnaces also are used to recover
metal from skimmings and slags.  In both blast and cupola furnaces,  coke
is used as both fuel and reducing agent.  The resulting product (black
copper or cupola melt) is impure and must be refined to produce brass and
bronze ingots.  The blast furnace and cupola operate on a continuous feed
basis with charge material, coke, and fluxes introduced at the top.
Finished metal is drawn from the bottom, generally on an intermittent
basis.  Slag is usually tapped on a continuous basis through a separate
spout at a level immediately above the metal  pouring height.
3.1.2  Melting5
     Brass and bronze are usually heated in large natural-,  gas-, or oil-
fired reverberatory furnaces or electric arc or induction furnaces.
Indirect-fired furnaces are sometimes used for specific foundry
applications.

                                    3-4

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     Any furnace in which the burner flames and/or hot gases come  in
direct contact with the charged material is considered to be a
reverberatory furnace.  Reverberatory furnaces may also be the rotating,
rocking, or tilting type.  All reverberatory furnaces operate in the batch
mode.  The charge material and fluxes may be introduced before firing or
may be added periodically throughout the heat.  The fuel burned is either
oil or natural gas.  Stationary furnaces usually are larger (100-  to
200-Mg [110- to 220-ton] capacity) than the other types of reverberatory
furnaces, which have capacities ranging from 1 to 45 Mg (1 to 50 tons).
     Electric furnaces are mainly used for special purpose alloys.  Major
advantages of the electric furnace over fuel-fired furnaces are better
furnace atmosphere control and high-temperature operation.  Temperatures
as high as 3300°C (6000°F) are possible for special processes.  In all
cases, charging and pouring are generally done through the top of  the
furnace.
     Indirect-fired furnaces (crucible or pot furnaces) usually are
significantly smaller than reverberatory furnaces and are similar  in
function to .electric furnaces.  Indirect-fired furnaces are used either in
small foundries or for special purpose alloys in small batches.  Crucibles
may be the tilting, pit, or stationary type and include the small, low-
temperature pot furnaces.  Charge materials are introduced through the top
of the furnace along with inert fluxes.  Finished alloys are removed from
the furnaces through the top, either by tilting and pouring or by the use
of ladles.  Generally, crucible furnaces are used to heat metals up to
1300°C (2400°F).  Pot furnaces are used only for temperatures up to about
760°C (1400°F).
3.2  EMISSIONS
     Baghouses are considered to be the best demonstrated technology for
the control of particulate emissions in the secondary brass and bronze
industry.6
3.2.1  Emissions From Materials Preparation
     Pyrometallurgical processing (sweating, wire burning, drying,  and
using blast or cupola furnaces) releases the greatest amount of
particulate matter of any of the secondary brass and bronze production
                                    3-5

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procedures.  It has been estimated that approximately 72 percent of
secondary brass and bronze emissions are from pyrometallurgical
processes.
     Sweating processes are carried out at fairly low temperatures and, as
a result, have low metal fume losses associated with them.7  Wire burning
is the largest single source of particulate matter in the secondary brass
and bronze industry with an uncontrolled particulate emission factor of
6.88 kilograms per megagram of scrap processed (13.75 pounds per ton).8
Many companies are eliminating the use of these processes by being more
selective in the scrap they accept.
     A rotary dryer is often used to vaporize excess cutting fluids from
machine'shop chips or borings.  The potential process fugitive particulate
matter emission factor for rotary dryers is the same as that for wire
burning; however, the nature of the combustion process determines the
degree to which these emissions are oxidized.9
     Preparation of materials in blast furnaces and cupolas results in
emissions that are similar to emissions from the smelting/melting
furnaces.  However, since blast furnaces and cupolas are generally used to
concentrate low-grade scrap, slag, and skimmings, emissions from these
sources have a higher percentage of nonmetallic particles than do
emissions from smelting/melting furnaces.  Reports of uncontrolled
emissions from three blast furnaces of unspecified size range from 16 to
100 kg/h (36 to 220 lb/h).10
3.2.2  Emissions From Smelting
     Air pollutants emitted from secondary brass and bronze smelting
furnaces consist of products of combustion, dusts, and metallic fumes.
The particulate matter comprising the dust and fume load varies according
to the fuel, alloy composition, type of furnace, melting temperature, with
the presence of impurities in the scrap feed, and other operating
factors.  In addition to fly ash, carbon, and mechanically produced dust,
furnace emissions generally contain fumes resulting from oxidation and
condensation of the more volatile elements, including zinc, lead, and
others.  Most of the particulate emissions are metal  oxides, predominately
zinc oxides (45 to 77 percent zinc by weight) and lead oxides (1 to
13 percent lead by weight).  Zinc fumes are 0.03 to 0.5 ym in
diameter.

                                    3-6

-------
     Uncontrolled reverberatory furnaces can emit as much as 80  Ibs of
particulate matter per ton of ingot produced.  The level of emissions from
blast furnaces (cupolas) is approximately equal to that from reverbatory
furnaces; the level of emissions from electric furnaces is typically far
lower.  The composition of emissions from blast furnaces is similar to
that from reverberatory furnaces.  Emissions from electric furnaces are
also expected to be similar because the process and raw materials are
identical.
     Direct-fired furnaces of the reverberatory and rotary type produce
larger quantities of metallic fumes, such as zinc and lead oxjde, than do
                                                            ^J,
the indirect-fired furnaces, which are usually small  in size'. /This is due
to the introduction of the hot burner flames and gases directly on the
charge, resulting in vaporization of large quantities of the lower boiling
point metals.
     The potential for particulate emissions, both primary (through the
stack) and secondary (fugitive), varies with the stage of the production
cycle which may be divided into five parts:  charging, melting, refining,
alloying, and pouring.  In general, the ratio of metallic fumes to other
particulate substances in the emissions will increase as the production
cycle proceeds."'This is due to the constant elimination of impurities in
the charge which account for the bulk of the nonmetallic particulates.13
     3.2.2.1  Charging.  Charging emissions are dependent on the condition
of the scrap, location of the charging doors, percentage of volatile alloy
constituents, and upon whether the entire charge is made at the beginning
of the heat or at intervals during the melt.  Even if scrap has been
pretreated to remove contaminants, particulate and unburned hydrocarbon
emissions can still occur during charging.  Overhead  charging  doors, used
in stationary reverberatory furnaces (which are being replaced  by rotary
reverberatory furnaces) permit losses of hot gases, fly ash,  and fume into
the plant when charges are loaded at intervals during the heat.  End and
side charging doors in rotary-type furnaces significantly reduce the
escape of furnace gases during charging.11*
     3.2.2.2  Melting.  The furnace is closed for the meltdown  process.
Increased zinc oxide emissions can result from improper combustion,
overheating of the charge, and heating the charge too fast.   The use of
nonuniform scrap can also increase emissions.11*

                                    3-7

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     3.2.2.3  Refining.  Refining, a chemical process of purification, is
that cycle of smelting in which impurities and other constituents of the
charge, present in excess of specifications, are reduced or removed.
Refining methods vary depending on the type of furnace, composition of the
scrap, and the desired alloy, but the basic approach is the same for
all.  The chemicals used in refining, commonly termed fluxes, may be
gaseous, liquid, or solid.  Compressed air is the most extensively used
flux.  Zinc is partially oxidized during this process.15
     3.2.2.4  Alloying.  Alloy modifications are made during the heating
process by the addition of virgin metals or scrap.  This can cause an
increase in fume emissions.  The formation of fumes increases as the
percentage of volatile constituents increases.  Due to its very low
boiling point, zinc is the most serious problem, with the rate of zinc
loss being approximately proportional to the zinc percentage in the
 11   16
alloy.
     3.2.2.5  Pouring.  Physical methods of pouring the molten alloy into
molds vary; however, in all cases, metal oxide fumes are emitted when the
hot molten metal is poured through the air.  For a given percentage of
zinc, an increase in temperature of 56°C (100°F) increases the rate of
loss of zinc about three times.  Other dust may be produced, depending
upon the type of linings or coverings associated with the mold as it is
filled with molten metal.
3.3  REFERENCES FOR CHAPTER 3
 1.  Review of New Source Performance Standards for Secondary Brass and
     Bronze Plants.  EPA-450/3-84-009.  May 1984.  p. 2-2.
 2.  Reference 1, p. 2-8.
 3.  Reference 1, pp.  2-8 - 2-11.
 4.  A Review of Standards of Performance for New Stationary Sources--
     Secondary Brass and Bronze Plants.   EPA-450/3-79-011.   June 1979.
     pp. 4-20 - 4-21.
 5.  Reference 1, pp.  2-11 - 2-14.
 6.  Reference 1, p. 4-5.
 7.  Reference 4, p. 4-32.
                                   3-8

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 8.'  U.  S.  Environmental  Protection Agency.  Compilation of Air Pollutant
     Emission Factors, Supplement No. 9.  Third Edition (including
     supplements 1-7).  Office of Air and Waste Management.  Research
     Triangle Park, N.C.   AP-42.  July 1979.  p. 7.9-7.

 9.   Reference 1,  pp.  4-1 - 4-2.

10.   Reference 4,  p. 4-33.

11.   Reference 4,  p. 4-2.

12.   Technical Report  No. 11—Secondary Brass and Bronze Ingot Production
     Plants,   p. 45.

13.   Reference 4,  p. 4-36.

14.   Reference 1,  p. 4-3.

15.   Reference 1,  pp.  4-3 - 4-4.

16.   Reference 1,  p. 4-4.

17.   Reference 1,  p. 2-3.

18.   Reference 1,  pp.  2-5 - 2-6.
                                    3-9

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                      4.   THE IRON AND STEEL INDUSTRY

4.1  BACKGROUND INFORMATION
     The iron and steel industry is defined as all producers of coke,
iron, steel, specialty steel, and cast iron.  Iron and steel producing
plants are located in 39 States.  Most of the plants, however, are located
in the areas east of the Mississippi River and north of the Ohio River.1
Table 4-1 lists the iron and steel producers in the U.S.  This list was
compiled from the 1985 Directory of Iron and Steel Plants.
     Steel mills are important sources of zinc emissions because zinc in
the iron ore is volatilized in the blast furnace and zinc in the scrap
iron is volatilized in the open-hearth, basic oxygen, and electric arc
furnaces.   Zinc is also emitted during iron and steel galvanizing.  The
following sections briefly describe the iron and steel production process
and the sources of zinc emissions in this process.
4.1.1  General Process Description
     Coke is used in steel mills and iron foundries to provide the heat
necessary to produce molten iron.  Coke is either hauled to the steel mill
or made in a coke facility at the steel mill.  Coke, limestone, and iron
ore are combined in the blast furnace.  The blast furnace produces molten
iron.  Molten iron is removed from the blast furnace _and transferred to
the steel-making furnaces.  Scrap metal is commonly mixed with the molten
iron in the steel furnaces.  The whole mix is then made into steel by
heat-refining the metal and adding alloying materials and fluxes.  The
molten steel is cast into various shapes, then sent through a finishing
process.   Figure 4-1 illustrates the process flows for an integrated
steel mill representing the iron and steel industry.
     4.1.1.1  Blast Furnace.  Iron is produced in the blast furnace from a
charge of iron ore, coke, and limestone.   The iron ore descends down the
                                    4-1

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furnace and is reduced and melted by the countercurrent flow of hot gases
produced by the partial combustion of coke.  Hot metal is removed from the
bottom of the blast furnace and transferred to steel-making operations.3
     4.1.1.2  Steel Furnaces.  There are three types of steel-making
furnaces in use today.  These are the open hearth furnace (OHF), the basic
oxygen furnace (BOF), and the electric arc furnace (EAF).  Most of the
nation's steel is made in BOF's and EAF's.  The OHF takes the longest time
(between 8 and 12 hours) to produce a batch of finished steel.  The BOF
uses about 70 percent hot metal and 30 percent scrap and requires a cycle
of less than an hour to produce a batch of finished steel.  In the BOF, a
water-cooled lance is used to supply pure oxygen to a mixture of hot
metal, steel scrap, and flux materials.  The oxygen reacts exothermically
with the carbon in the metal, producing the heat required for melting.  In
the EAF, carbon electrodes supply the heat necessary for melting the
metal.  Flux is added after the metal is molten.  Molten metal is tapped
from the steel furnace and poured into ingot molds.  The EAF can melt up
to 100 percent scrap metal.
     4.1.1.3  Galvanizing.  Galvanizing is a process by which iron and
steel are protected against corrosion.  The hot dip process is the most
important galvanizing method used for coating clean iron and steel
surfaces with a thin layer of zinc.  Zinc readily combines with iron to
form an alloy coating consisting of several layers, each increasing in
zinc content from the steel to the surface.  The basic steps in the
galvanizing process are:  (a) preparation of the metal surface by
degreasing, rinsing, pickling, and rerinsing; (b) prefluxing by immersion
of the metal in a tank of preflux; (c) galvanizing by immersion in a tank
of molten zinc for 3 to 20 seconds at a temperature of 450°C (840°F);  and
(d) finishing by shaking or centrifuging, water quenching, deburring,  and
inspecting.   For continuous operations, the average galvanizing kettle
capacity 1s about 18 megagrams (Mg) (20 tons) of zinc per Mg (ton) of
material galvanized per hour.
4.2  EMISSIONS
     Model  facilities were developed to estimate the hourly and annual
zinc emissions expected from individual  sources and to provide information
                                    4-2

-------
that is useful for future dispersion analyses.  These model  facilities are
a blast furnace shop, a BOF shop, an EAF shop, and an OHF shop at an
integrated steel mill.  Figures 4-2 through 4-5 present the  model facility
parameters.   These model facilities were developed by GCA Corporation
during a 1981 study of cadmium emissions from iron and steel plants.  Zinc
emission factors developed during other studies were used to calculate
zinc emissions from tf
4.2.1  Blast Furnaces
zinc emissions from the GCA model facilities. '
     Various types of control equipment are presently used to control
particulate emissions from blast furnaces.  Dry cyclones, wet scrubbers,
and electrostatic precipitators (ESP's) are common.  Essentially all of
the zinc is volatilized into the blast furnace gas.  The estimated zinc
content of the particulate is 0.5 percent.2
     Blast furnace gas is almost universally treated to produce a high
purity, low heating value fuel.  The only time even a trace amount of zinc
would be emitted would be from process upsets such as blast furnace slips
that actuate the relief valve, which discharges uncontrolled particulates
to the atmosphere.  These upsets are infrequent; consequently, there are
only trace zinc emissions from blast furnaces.
4.2.2  Steel Furnaces
     The small size of the particulate matter emitted from OHF's
necessitates the use of high-efficiency collection equipment such as
venturi scrubbers and ESP's.  Baghouses also have been installed for
particulate emission control but they require that the gases be
precooled.  The average emission factor (controlled) for all OHF's is
10.2 Ib of particulate per ton of steel produced, with an average zinc
content of 12.5 percent.2
     Venturi scrubbers and ESP's are commonly used to control particulate
emissions from BOF's.  The emissions are usually routed through either an
open or closed hood.  The controlled emission factor for BOF's is 14 Ib of
particulate per ton of steel produced with an average zinc content of
2.24 percent.
     Fabric filters are the most commonly used devices for cleaning EAF
gases, although venturi scrubbers and ESP's are also used.  The use of a
baghouse on an EAF necessitates precooling of gases to protect the bags.
                                    4-3

-------
The average controlled emission factor for EAF's is 2.5 Ib participate
matter per ton of steel produced, with a zinc content of 29.6 percent.
4.2.3  Galvanizing
     During hot dip galvanizing operations, most of the atmospheric
pollutants are discharged when fresh flux is added or when the flux cover
is disturbed as an article is immersed in the zinc bath.  Ammonium
chloride is the principle pollutant; however, there are significant
quantities of zinc, zinc oxide, and zinc chloride in the fumes as shown in
Table 4-2.  Based on these emission data, zinc emissions to the atmosphere
are estimated to be 0.0018 Mg/Mg of zinc processed (4 lb/ton).2
                                    4-4

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                                                            4-1

                                                            1/1
                                                            a;
                                                            cu
                                                            c
                                                            o
                                                            O
                                                            i.

                                                            03
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                                                           01
4-5

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               MODEL BLAST FURNACE SHOP
                 •3 BLAST FURNACES
                 •8 CASTS PER DAY EACH
                 •NO CASTHOUSE EMISSION CONTROL
                 •TOTAL PARTICULATE EMISSIONS:  90 kg/h (195  Ib/h)
                 •TOTAL ZINC EMISSIONS:  0.45 kg/h (0.98 lb/h)
                 •PRIMARY OFF-GASES RECYCLED:  CLEANED BY  A DUST COLLECTOR AND TWO  SCRUBBERS
             IRON  ORE
             COKE
             LIMESTONE
             SINTER
i
01
4 2
<1> (4)
9 d)

RF


4 ?
(9) (J}
T 
24
(52)
CASTHOUSE
1

ci AC. i ?*ift6
(1.3x10



flF


(52)
(i)
CASTHOUSE

^ \

tons/yr)

/

4 2
(i> (4)
9 ^





nr


24
(5.2)
©
CASTIIOUSC



^
PARTICULATE
 IN kg/h  (Ib/h):

       0  BF  TOP EMISSIONS
       (?

       (3
                         BF COMBUSTION [MISSIONS
                         CASTING EMISSIONS
                                                    IRON PRODUCTION:  2.4x10* Mg/yr
                                                                     (2.6x10* tons/yr)
   SlEfL-MAKING
>  OPtRATlONS
                             Figure  4-2.   Model blast  furnace plant  for  an  integrated steel mill.

-------
    MODEL BOF-SHOP

       •PRODUCTION:  2.27x10* Mg/yr (2.5x10*  tons/yr)
       •TOP BLOWN-OPEN HOOD DESIGN
       •EVACUATION OF ONLY ONE FURNACE AT A TIME
       •DURATION OF ONE HEAT:
         45 m1n WITH 0 BLOW OF 20 mln
       •22 heats/d
       •TOTAL PARTICULATE EMISSIONS:  126 kg/h
                                    (276 Ib/h)
       •TOTAL ZINC EMISSIONS:  2.8 kg/h
                             (6.2 Ib/h)
         i ,
 22  kg part/h
(48  Ib part/h)
                               538"C
                              (1000-F)
   ESP  STACK
  65  kg part/h
(143  Ib part/h)
                                                        •-,   STACK GAS
                                                         ^-*  38-149"C (100-300"F)
kg
Ib
t
| CHARGE
part/h
part/h)
t
& TAP
•
HOT METAL
TRANSFER

NO
272
(300
C
. 1 BOF
Mg/heat
ton/heat)
1650"C
3000 °F)

x'
* 	 70
<; 	 F
* 	 Al
    MISCELLANEOUS
      FUGITIVES
     7 kg part/h
    (15 Ib part/h)
   30 PERCENT SCRAP

70 PERCENT MOLTEN 10

  FLUXEST COOLANTS
  ALLOYING ADDITIONS
V
ON 	 >
*x

538"C
~ (iOOO"F)
\
NO. 2 BOF
272 Mg/heat
(300 ton/heat)
-16500C
(-3000-F)

22 kg part/h
(48 Ib part/h)
t
CHAIXir & TAP 1

8 kg part/h
(18 Ib part/h)
t
Til Ml NO

          Figure 4-3.  Model  basic oxygen  furnace  shop for an  integrated  steel  mill.J

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                MODEL EAF SHOP
                  •PRODUCTION:  694,000 Mg steel/yr  (765,000 tons/yr)
                  •EMISSION  COLLECTION SYSTEM:   CANOPY HOOD..OVER FURNACES
                  •ONE HEAT  LAST 4 h
                  •FIVE HEATS/d/FURNACE
                  •TOTAL PARTICULATE EMISSIONS:   47  kg/h (104 Ib/h)
                  •TOTAL ZINC  EMISSIONS:,  13.9  kg/h  (30.8 Ib/h)
                                                                                BAGHOUSE STACK
                                                                                 21 kg/h part
                                                                                (46 Ib/h part)
i
c»
                INLET MATERIALS:

                   SCRAP
                   FLUXES
                   OXYGFN         (
                    (OCCASIONALLY)'
                           8 kg part/h
                          (18 Ib part/h)
  8  kg part/h
(18  Ib part/h)
   EAF NO. 1
  127 Mg/heat
(140 tons/heat)
                       2 kg  part/h
                      (4 Ib  part/h)
   EAF  NO. 2
  12/ Mg/heat
(140 tons/heat)
                                       8 kg pdrt/h
                                     (18 Ib part/h)
   EAF  NO.  3
 127 Mg/heat
(140 tons/heat)
                                                                               \)  CHARGE, TAP,  SLAG  IMISSIONS

                                                                               f)  MISfFHANCOUS FUGITIVE IMISSIONS
                           Figure  4-4.   Model  electric arc furnace shop  in an  integrated  steel  mill.

-------
 MODEL OPEN HEARTH FURNACE SHOP
   •PRODUCTION:  625.950 rog/yr (690.000 tons/yr)
   •TAP TO TAP TIME:  9 h
   •TOTAL PARTICULATE EMISSIONS:  31.3 kg/h  (69  Ib/h)
   •TOTAL ZINC EMISSIONS: 3.9 kg/h (8.6 lb/h)
INPUT MATERIAL:
  SCRAP  (50 PERCENT)
  HOT METAL (50 PERCENT)
  FLUXES
  ALLOYING ADDITIONS
                                4.5 kg part/h  4.5 kg  part/h  4.5 kg part/h  4.5 kg part/h  4.5 kg part/h
                                (10 Ib part/h) (10 Ib  part/h) 10 Ib part/h) (10 Ib part/h) (10 Ib part/h)
                                         ROOF
                                       MONITOR
                                136 Mg/heat
                              (150 tons/heat)


5.4, kg part/h
(12 Ib part/h)
i_
704"C
"""(1300'T)
OH NO. 1



OH NO. 2


2 kg part/h
(4 Ib part/h)
_l

OH NO. 3



1.4 kg pdrt/h
(3 Ib part/h)
OH NO. 4
V


OH NO. 5
                                                                                      IIMT
          Figure  4-5.   Model open hearth furnace shop in  an  integrated steel  mill.

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                       TABLE 4-1.   U.S.  IRON  AND  STEEL  PLANTS
Company/location
Integrated Steel  Producers

U.S. Steel Corp., Fairfield,  Ala.
Inter lake, Inc.,  Lodi,  Calif.
Cyclops Corp., Los Angeles,  Calif.
Interlake, Inc.,  Pittsburg,  Calif.
U.S. Steel Corp., Pittsburg,  Calif.

Armco, Inc., Torrance,  Calif.
CF4I Steel Corp., Pueblo,  Colo.
LTV Steel  Company, East Hartford, Conn.
Cyclops Corp., Hamden,  Conn.
LTV Steel  Company, Willimatic, Conn.

Armco, Inc. (Specialty  Steels Division),  Wildwood, Fla.
LTV Steel  Company, Cedar Springs, Ga.
Interlake, Inc.,  Burr Ridge,  III.
Inland Steel  Company, Chicago,  III.
Interlake, Inc.,  Chicago,  III.

LTV Steel  Company, Chicago,  III.
U.S. Steel Corp., Chicago, III.
National  Steel Corp., Granite City,  III.
LTV Steel  Company, Hennepin,  III.
Interlake, Inc.,  Oak  Brook,  III.

Interlake, Inc.,  Oak  Forest,  III.
Interlake, Inc.,  Pontiac,  III.
Bethlehem Steel Corp.,  Chesterton,  Ind.
Inland Steel  Company, East Chicago,  Ind.
LTV Steel  Company, East Chicago,  Ind.

LTV Steel  Company, Gary, Ind.
U.S. Steel Corp.  Gary,  Ind.
LTV Steel  Company, Hammond,  Ind.
National  Steel Corp., Portage,  Ind.
LTV Steel  Company, Whiting,  Ind.

Armco, Inc.,  Ashland, Ky.
Interlake, Inc.,  ShepardsviIle, Ky.
Armco, Inc.,  Baltimore, Md.
Bethlehem Steel Corp.,  Sparrows Point, Md.
Rouge Steel Company,  Dearborn, Mich.

Sharon Steel  Corp., Dearborn, Mich.
Cyclops Corp., Detroit, Mich.
LTV Steel  Company, Detroit, Mich.
National  Steel Corp., Ecorse, Mich.
LTV Steel  Company, Ferndale,  Mich.

McLouth Steel  Products  Corp., Gibralter,  Mich.
McLouth Steel  Products  Corp., Trenton, Mich.
Cyclops Corp., Minneapolis, Minn.
Armco, Inc.,  Kansas City,  Mo.
LTV Steel  Company, Atco, N.J.
                                                                                 (continued)
                                           4-10

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                                TABLE 4-1.   (continued)
Company/location
Integrated Steel  Producers  (continued)

Cyclops Corp.,  Elmwood  Park,  N.J.
Inter lake, Inc.,  Riverton,  N.J.
Inter lake, Inc.,  Rockleigh, N.J.
Sharon Steel  Corp.,  Union,  N.J.
LTV Steel  Company,  Brooklyn,  N.Y.

Cyclops Corp.,  Glen  Cove, N.Y.
Bethlehem Steel  Corp.,  Lackawanna,  N.Y.
CFAI  Steel Corp., New York, N.Y.
Cyclops Corp.,  Cambridge, Ohio
LTV Steel  Company,  Campbell,  Ohio

LTV Steel  Company,  Canton,  Ohio
LTV Steel  Company,  Cleveland, Ohio
Cyclops Corp.,  Coshocton, Ohio
Cyclops Corp.,  Dover, Ohio
LTV Steel  Company,  Elyria,  Ohio

U.S.  Steel Company,  Lorain, Ohio
LTV Steel  Company,  Louisville, Ohio
Cyclops Corp.,  Mansfield, Ohio
Wheeling-Pittsburgh  Steel Corp., Martins ferry,  Ohio
LTV Steel  Company,  MassiI Ion, Ohio

Armco, Inc.,  Middletown, Ohio
Wheeling-Pittsburgh  Steel Corp., SteubenviIle, Ohio
LTV Steel  Company,  Warren,  Ohio
Sharon Steel  Company, Warren, Ohio
Wheeling-Pittsburgh  Steel Corp., Yorkville,  Ohio
LTV Steel  Company,  Youngstown, Ohio

Armco, Inc.,  Zanesville, Ohio
Gilmore Steel Corp., Portland, Oreg.
LTV Steel  Company,  Aliquippa, Pa.
Wheeling-Pittsburgh  Steel Corp., Allenport,  Pa.
Armco, Inc.,  Ambridge,  Pa.

LTV Steel  Company,  Beaver Falls, Pa.
Bethlehem Steel  Corp.,  Bethlehem, Pa.
Cyclops Corp.,  Bridgeville, Pa.
Armco, Inc.,  Butler, Pa.
U.S.  Steel Corp., Fairless  Hills, Pa.

Sharon Steel  Corp.,  Parrel I,  Pa.
Sharon Steel  Corp.,  Greenville, Pa.
Cyclops Corp.,  Heidelberg,  Pa.
U.S.  Steel Corp., Homestead,  Pa.
Bethlehem Steel  Corp.,  Johnstown, Pa.

Bethlehem Steel  Corp.,  Lebanon, Pa.
LTV Steel  Company,  Midland, Pa.
Wheeling-Pittsburgh  Steel Corp., Monessen, Pa.
Cyclops Corp.,  Pittsburgh,  Pa.
LTV Steel  Company,  Pittsburgh, Pa.
                                                                                  (continued)
                                            4-11

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                                 TABLE 4-1.   (continued)
 Company/location
 Integrated  Steel Producers  (continued)

 National  Steel Corp., Pittsburgh, Pa.
 U.S.  Steel  Corp., Pittsburgh, Pa.
 Wheeling-Pittsburgh Steel Corp., Pittsburgh, Pa.
 Cyclops Corp., Sharon, Pa.
 Sharon Steel Corp., Sharon, Pa.

 Bethlehem Steel Corp., Steel ton, Pa.
 Sharon Steel Corp., Templeton, Pa.
 Cyclops Corp., Titusville, Pa.
 Bethlehem Steel Corp., wi11iamsport, Pa.
 Interlake,  Inc., Fountain Inn, S.C.

 Interlake,  Inc., Sumter, S.C.
 LTV Steel- Company, Counce, Tenn.
 Interlake,  Inc., Gal latin, Tenn.
 U.S.  Steel  Corp., Baytown, Tex.
 Lone  Star Steel Company, Dallas, Tex.

 Cyclops Corp., Houston, Tex.
 Lone  Star Steel Company, Lone Star, Tex.
 U.S.  Steel  Corp., Provo, Utah
 Bethlehem Steel Corp., Seattle, Wash.
 Wheeling-Pittsburgh Steel Corp., Beech Bottom, W. Va.

 Wheeling-Pittsburgh Steel Corp., Benwood, W. Va.
 Weirton Steel Corp., Weirton, W. Va.
 Wheeling-Pittsburgh Steel Corp., Wheeling, W. Va.
 Interlake,  Inc., Racine, Wis.

 Specialty Producers

 National  Standard Company, Columbia, Ala.
 Quanex Corp., Fort Smith, Ark.
 Carpenter Tech. Corp., El Cajon, Calif.
 California Steel  Ind., Inc., Fontana, Calif.
 Earle M.  Jorgensen Company,  Los Angeles, Calif.

 Pacific Tube Company,  Los Angeles,  Calif.
 Washington Steel  Corp.,  Los  Angeles, Calif.
 Pinole Point Steel  Company,  Richmond, Calif.
 The Atlantic Wire Company, Branford, Conn.
 Carpenter Tech. Corp., Bridgeport,  Conn.

Baines Group, Inc.,  Bristol, Conn.
Associated Spring,  Bristol,  Conn.
Wallace Baines Steel,  Bristol, Conn.
Wallace Baines Steel,  New Britain,  Conn.
Wyckoff Steel, Putnam, Conn.

Allegheny Ludlum Steel Corp.,  Wallingford, Conn.
Phoenix Steel Corp., Claymont, Delaware
 Laclede Steel Company, Alton,  III.
Bliss & Laughlin  Steel Company,  Batavia, III.
Copperweld Corp.,  Chicago, III.
                                                                                 (conti nued)
                                           4-12

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                                TABLE  4-1.   (continued)
Company/location
Specialty Producers (continued)

A. Finkl 4 Sons, Chicago, III.
KEYCON  Industries, Inc.,
Wyckoff Steel, Chicago, III.
Welded Tube Company of America, Chicago, III.
Columbia Tool Steel Company, Chicago Heights, III.

Keystone Steel 4 Wire Company, Chicago Heights,  III.
Pittsburgh Tube Company, Fairbury, III.
Thompson Steel Company, Inc., Franklin Park, III.
Bliss 4 Laughlin Steel Company, Harvey, III.
Continental Steel  Corp., Joilet. III.

AXIA, Inc., Oak Brook, III.
Keystone Steel 4 Wire Company, Peoria, III.
Spencer Clark Metal Industries, Inc., South  Holland,  III.
Plymouth Tube Company, Winfield, III.
KEYCON  Industries, Inc., CrawfordsviIle, III.

Slater Steels Corp.,  Fort Wayne, Ind.
Stanadyne, Western Steel  Division, Gary, Ind.
La Salle Steel Company, Griffith,  Ind.
Copperwe Id Corp.,  Hamlet, Ind.
La Salle Steel Company, Hammond, Ind.

Quanex Corp., Hammond, Ind.
Quanex Corp., Huntington, Ind.
Cabot Corp. Wrought Products Division, Kokomo,  Ind.
Continental Steel  Corp., Kokomo, Ind.
Indiana Steel 4 Wire  Company, Muncie, Ind.

Ingersol Steel, Division of Avesta, Inc.,  New Castle,  Ind.
National-Standard  Company, Corbin, Ky.
Crucible Inc., Operating Corp., El izabethtown, Ky.
Green River Steel  Corp., Owensboro, Ky.
Copperwe Id Corp.,  Baltimore, Md.

Eastern Stainless  Steel Company, Baltimore,  Md.
Eastmet Corp., CockeysviIle, Md.
Cumberland Steel Company, Cumberland, Md.
Thompson Steel Company, Inc., Sparrows Point, Md.
Thompson Steel Company, Inc., Canton, Mass.

Teledyne Rodney Metals, New Bedford,  Mass.
Johnson Steel 4 Wire  Company, Inc., Worcester, Mass.
G. F. Wright Steel  4  Wire Company, Worcester, Mass.
Quanex Corp., Ann  Arbor,  Mich.
Greer Steel Company,  Detroit, Mich.

Wnittar Steel Strip,  Detroit, Mich.
Michigan Dynamics,  Inc.,  Garden City,  Mich.
Quanex Corp., MacSteel Division, Jackson, Mich.
Quanex Bar Group,  Jackson, Mich.
National-Standard  Company, Niles,  Mich.
                                                                                  (continued)
                                            4-13

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                                TABLE 4-1.   (continued)
Company/location
Specialty Producers (continued)

Wyckoff Steel, Plymouth. Mich.
Quanex Corp., S. Lyon, Mich.
Delta Wire Corp., Clarksdale, Miss.
Laclede Steel Company, St. Louis,  Mo.
Missouri  Rolling Mill  Corp.,  St.  Louis,  Mo.

Quanex Corp., Verdie,  N.Y.
National  Standard Company, Clifton,  N.J.
Wheat I and Tube Company, Col Iingswood,  N.J.
Quanex Corp., South Plainfield,  N.J.
Carpenter Tech. Corp., Union, N.J.

Gibraltar Steel Corp., Buffalo,  N.Y.
Ramco/Fitzsimons Steel Company,  Inc.,  Buffalo,  N.Y.
Seneca Steel  Corp., Buffalo,  N.Y.
CAX, Inc., Carle Place, N.Y.
Al Tech Specialty Steel Corp.,  Dunkirk,  N.Y.

Electralloy Corp., New York,  N.Y.
CopperweId Corp., Oswego, N.Y.
Rome Strip Steel Company, Inc.,  Rome,  N.Y.
Crucible Inc., Operating Corp.,  Syracuse,  N.Y.
Al Tech Specialty Steel Corp.,  Watervllet, N.Y.

Babcock i Wilcox Company, Alliance,  Ohio
Latrobe Steel Company, Bowling  Green,  Ohio
The Timken Company, Canton, Ohio
Mid America Steel Corp., Cleveland,  Ohio
The Timken Company, Columbus, Ohio

Grier Steel Company, Dover-f Ohio
Stanadyne, Western Steel Division, Elyria, Ohio
Seneca Wire and Manufacturing Company, Fostoria,  Ohio
McDonald Steel Corp.,  McDonald,  Ohio
Bliss & laughlin Steel Company,  Medina,  Ohio

The Champion Steel Company, Orwell,  Ohio
Copperweld Corp., Shelby, Ohio
Quanex Corp., Shelby,  Ohio
Cuyahoga Steel & Wire,  Inc.,  Solon,  Ohio
Baron Drawn Steel Corp., Toledo,  Ohio

Copperweld Corp., Warren, Ohio
Thomas Steel  Strip Corp., Warren,  Ohio
Latrobe Steel Company, Wauseon,  Ohio
The Timken Company, Wooster,  Ohio
Allegheny Ludlum Steel Corp., Claremore, Ok I a.

National-Standard Company, Still water, Okla.
Babcock 4 Wilcox Company, Beaver Falls,  Pa.
Moltrup Steel Products Company,  Beaver Falls, Pa.
Allegheny Ludlum Steel Corp., Brackenridge, Pa.
Standard Steel, Burnham, Pa.
                                                                                 (continued)
                                            4-14

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                                TABLE  4-1.   (continued)
Company/1ocat i on
Specialty Producers (continued)

Teledyne Columbia-SummerviI Ie, Carnegie, Pa.
Lukens, Inc., Steel  Division, Coatesville, Pa.
Lukens Conshohocken,  Conshohocken,  Pa.
Mclnnes Steel Company, Corry, Pa.
Pittsburgh Tube Company, Darlington, Pa.

Washington Steel  Corp., Darlington, Pa.
Fitch Works—Hot Metal Plant, Houston, Pa.
Fitch Works—Hot Strip Mill,  Houston, Pa.
Jersey Shore Steel  Company,  Jersey  Shore, Pa.
Latrobe Steel Company, Latrobe,  Pa.

Standard Steel, Latrobe, Pa.
Teledyne Vasco, Latrobe, Pa.
Braeburn Alloy Steel  Division, Lower BurrelI, Pa.
CCX, Inc., Lower BurrelI, Pa.
National Rolling Mills, Inc., Ma I vein, Pa.

Pittsburgh Tube Company, Monaca, Pa..
Superior Drawn Steel  Company, Monaca, Pa.
Teledyne Pittsburgh Tool  Steel,  Monaca, Pa.
Teledyne Vasco, Monaca, Pa.
National-Standard Company, Mount Joy, Pa.

Allegheny Ludlum Steel Corp., Natrona Heights, Pa.
Blair Strip Steel  Company, New Castle, Pa.
Elliott Brothers Steel Company,  New Castle,  Pa.
Edgewater Corp.,  Oakmont, Pa.
Electralloy Corp.,  Oil City,  Pa.

Phoenix Steel Corp.,  PhoenixviIle,  Pa.
Allegheny Ludlum Steel Corp., Pittsburgh, Pa.
Copperweld, Corp.,  Pittsburgh, Pa.
Alumoweld Products  Division,  Pittsburgh, Pa.
Cyclops Corp., Pittsburgh, Pa.

Wyckoff Steel, Pittsburgh, Pa.
Carpenter Tech. Corp., Reading,  Pa.
Teledyne Columbia-SummeriI I,  Scottdale, Pa.
Sharon Tube Company,  Sharon,  Pa.
Jersey Shore Steel  Company, South Avis, Pa.

La Salle Steel Company, Spring City, Pa.
Quanex Corp., Spring  City, Pa.
Jessop Steel  Company,  Washington, Pa.
Washington Steel  Corp., Washington, Pa.
Allegheny Ludlum Steel Corp., W. Leechburg,  Pa.

Wheat I and Tube Company, Wheat I and.  Pa.
Newman-Crosby Steel,  Inc., Pawtucket, R.I.
Carpenter Tech. Corp., Orangeburg,  S.C.
Copperweld Corp.,  FayetteviIle,  Tenn.
Chromium Mining and Smelting  Corp., Memphis,  Tenn.
                                                                                  (continued)
                                            4-15

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                                TABLE  4-1.   (continued)
Company/location
Specialty Producers (continued)

Quanex Corp., Bel Ivilie, Tex.
Babcock & Wilcox Company, Bryan,  Tex.
KEYCON Industries,  Inc., Dallas,  Tex.
Keystone Consolidated Industries, Inc.,  Dallas,  Tex.
Cameron Iron Works, Inc., Houston,  Tex.

Hurricane Industries, Inc., Houston,  Tex.
Quanex Corp., Houston, Tex.
Hurricane Industries, Inc., LaGrange,  Tex.
Texas General Steel Company, Inc.,  Lubbock,  Tex.
Ingersol  Rand Specialty Steel  Division,  Pampa, Tex.

Quanex Corp., Rosenburg, Tex.
Hurricane'Industries, Inc., Sealy,  Tex.
KEYCON Indsutries,  Inc., Sherman, Tex.
Earle M.  Jorgensen  Company, Seattle,  Wash.
Pittsburgh Tube Company, Jane  Lew,  W.  Va.
Crucible, Inc., Operating Corp.,  E. Troy, Wis.

Mini Plants

Birmingham Bolt Company, Birminham, Ala.
SMI Steel, Inc., Birmingham, Ala.
Marathon  Steel  Company, Phoenix,  Ariz.
Marathon  Steel  Company, Tempe, Ariz.
Razorback Steel Corp., Newport, Ark.

Soule Steel  Company,  Carson, Calif.
Judson Steel  Corp., Emeryville, Calif.
TAMCO, Etiwanda, Calif.
Marathon  Steel  Company, Santa  Fe  Springs, Calif.
Soule Steel  Company,  Walnut Creek,  Calif.

Connecticut Steel Corp., Wallingford,  Calif.
Florida Steel Corp.  Baldwin,  FI a.
Florida Steel
Florida Steel
Florida Steel
              Corp.
              Corp.
              Corp.
Florida Steel  Corp.
Florida Steel  Corp.
Florida Steel  Corp.
Ft. Lauderdale, Fla.
Ft. Meyers, Fla.
Indiantown, Fla.
                     Jacksonvi Me,  Fla.
                     Orlando,  Fla.
                     Tampa,  Fla.
Florida Transportation Division,  Tampa,  Fla.
Tampa Reinforcing Steel  Plant,  Tampa,  Fla.
Tampa Steel  Mill, Tampa, Fla.
Atlantic Steel  Company, Atlanta,  Ga.
Atlanta Steel  Company, Cartersvi I le,  Ga
Florida Steel  Corp., Duluth, Ga.
Hawaiian Western Steel, Ltd, SubWestern  Canada  Steel Division, Ewa, Hawaii
                                                                                 (continued)
                                            4-16

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                                TABLE  4-1.   (continued)
Company/location
Mini Plants (continued)

Birmingham Bolt Company, Bourbonnais,  III.
Wire Sales Company, Chicago, III.
B. W. Steel,  Inc.,  Chicago Heights,  III.
Calumet Steel  Company, Chicago Heights,  III.
Thomas Steel  Corp., Lemont, III.

Northwestern  Steel  4 Wire Company, Sterling,  III.
North Star Steel  Company, Wilton,  Iowa
Kentucky Electric Steel  Company,  Ashland,  Ky.
Ohio River Steel  Corp.,  Calvert City,  Ky.
Newport Steel  Corp., Newport,  Ky.

Bayou Steel Corp.,  LaPlace, La.
Florida Steel  Corp., SIidel I,  La.
North Star Steel  Company, Monroe,  Mich.
North Star Steel  Company, Duluth,  Minn.
North Star Steel  Company, Minneapolis, Minn.

North Star Steel  Company, St.  Paul,. Minn.
Mississippi Steel,  Division of Magna Corp.,  Jackson,  Miss.
Raritan River  Steel Company, Perth Amboy,  N.J.
N.J. Steel Corp., Sayreville,  N.J.
Roblin Steel  Company, N. Tonawanda,  N.Y.

Roblin Steel  Company, Dunkirk, N.Y.
Robin Steel Company, North Tonawanda,  N.Y.
Florida Steel  Corp., Charlotte, N.C.
Nucor Corp.,  Charlotte,  N.C.
Florida Steel  Corp., Raleigh,  N.C.

N.B. Steel Mill,  Inc., Cincinnati, Ohio
Marion Steel  Company, Marion,  Ohio
Oklahoma Steel  Mill, Inc., Oklahoma  City, Ok I a.
Sheffield Steel  Corp., Sand Springs, Okla.
Cascade Steel  RolI ing Mi I Is, Inc., McMinnville,  Oreg.

Ameri-Steel Company, Carnegie, Pa.
Franklin Steel,  Franklin, Pa.
Milton Manufacturing Company,  Milton,  Pa.
Ameri-Steel,  Uniontown,  Pa.
Florida Steel  Corp., Aiken, S.C.

Georgetown Steel  Corp.,  Andrews, S.C.
Owen Electric  Steel Company of S.C., Columbia, S.C.
Georgetown Steel  Corp.,  Georgetown,  S.C.
Georgetown Steel  Corp.,  Gal latin,  Tenn.
Florida Steel  Corp., Jackson,  Tenn.

Knoxville Iron  Company,  Inc.,  Knoxville, Tenn.
Knoxville Iron  Company,  Inc.,  Rockwood, Tenn.
North Star Steel  Company,  Beaumont,  Tex.
Border Steel Mills, Inc.,  El Paso, Tex.
Texas Steel Company, Ft. Worth, Tex.
                                                                                 (continued)
                                           4-17

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                                TABLE 4-1.   (continued)
Company/location
Mini  Plants (continued)

Marathon Steel  Company,  Houston,  Tex.
Marathon LeTourneau  Company,  longview,  Tex.
Chaparral  Steel  Company,  Midlothian, Tex.
Structural  Metals,  Inc.,  Seguin,  Tex.
Marathon Steel  Company,  Salt  Lake City, Utah

Intercoastal  Steel Corp., Chesapeake, Va.
Roanoke Electric Steel Corp.,  Roanoke,  Va.
Northwest  Steel  Rolling  Mills,  Inc., Seattle, Wash.
Charter Rolling, Division of  Charter Manufacturing,  Inc., Saukville, Wis.

*Net  ingots.
^Cold melt electric  furnace steel.
TTons bars and  tubes.
 Tons pipe and  tubing.
jlons galvanized pipe  and tubing.
fTons billets.
=Tons merchant  and special bar  quality  rolled products.
                                           4-18

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  TABLE 4-2.  CHEMICAL ANALYSIS OF THE  FUMES  COLLECTED
BY A BAGHOUSE AND AN ESP FROM ZINC GALVANIZING KETTLES5





Component
NH^Cl
ZnO
ZnCl2
Zn
NH3
Oil
H20
C
Not identified

Fumes
collected in
a baghouse
(job shop kettle),
weight percent
68.0
15.8
3.6
4.9
1.0
1.4
2.5
2.8
— _
Fumes
collected in
an ESP
(chain link
galvanizing) ,
weight percent
23.5
6.5
15.2
—
3.0
41.4
1.2
—
9.2
                         4-19

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4.4  REFERENCES FOR CHAPTER 4

1.  Directory, Iron and Steel Plants, 1985.  Published by Association of
    Iron and Steel  Engineers.  Pittsburgh, Pennsylvania.  616 p.

2.  National Inventory of Sources and Emissions:  Barium, Boron, Copper,
    Selenium and Zinc.  Section V, Zinc.  U. S. Environmental Protection
    Agency, NTIS Document No. PB 210 680.  May 1972.  pp. 32-37, 66-69.

3.  Survey of Cadmium Emission Sources.   GCA Corporation,
    EPA 450/3-81-013.  September 1981.  pp. 105-132.

4.  Cuscino, T. A.   Particulate Emission Factors Applicable to the Iron
    and Steel Industry.  Midwest Research Institute.  U. S. Environmental
    Protection Agency, Research Triangle Park, North Carolina.
    EPA 450/4-79-028.  September 1979.

5.  Air Pollution Engineering Manual.  Public Health Service Publication
    No. 999-AP40.  p. 405.   1967.  (In Reference 2,  p. 36).

6.  Characterization, Recovery, and Recycling of Electric Arc Furnace
    Dusts.  Lehigh  University.  Bethlehem, Pennsylvania.  Prepared for
    U.S. Department of Commerce.  February 1982.  7  pp.
                                   4-20

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                  5.   MISCELLANEOUS ZINC EMISSION SOURCES

5.1  BACKGROUND INFORMATION
     The following sections discuss miscellaneous sources of zinc
emissions.  Where available, emission factors and nationwide emission
estimates are provided.
5.1.1  Zinc-Base Alloys
     According to 1985 production data, zinc-base alloys consumed
25 percent or 177,500 megagrams (Mg) [195,700 tons] of total zinc.1
     Aluminum is the major alloying constituent and is used in quantities
ranging from 3.5 to 4.3 percent.  A zinc-aluminum alloy exhibits increased
strength and slows the attack of the alloy on iron and steel parts.2
                                                                    •
Alternatively, zinc may be added to copper in concentrations of 5 to
40 percent to form the alloy series known as the brasses.  Zinc increases
both tensile strength and hardness of the copper alloy.  Zinc, in
concentrations of up to 5 percent, may be added to tin-bronze alloys to
tighten the structure and act as a deoxidizer.3
     Virgin metals are preferred for the manufacture of the alloys for die
casting.  The procedure itself is usually accomplished in a pot or
reverberatory furnace.  The alloy is cast into bars that fill  the melting
pots at the die-casting machine.1*  The alloy is then melted in pots that
range in size from 910 to 3,640 kilograms (Kg) [2,000 to S.OOO^pounds
(lb)].  The temperature of the metal in the pots is typically 150° to
200°C (300° to 400°F) and should not exceed 430°C (800°F).   The molten
metal flows from the pots into an adjacent cylinder.  A plunger is forced
down into the cylinder, and the overflow liquid is displaced into a
stainless steel  die,  which is filled at temperatures up to  510°C
(950°F).  The operator then opens the die and removes the casting."*
                                   5-1

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     An alternative casting method, thin wall die casting, was  developed
 in the late 1970's in response to a demand  in the automotive market  for
 lighter materials.  This method reduces the thickness of  the casting wall
 and results in a 30 to 50 percent reduction in casting weight.5
     At most plants, the scrap generated during die-casting operations is
 remelted, cleaned, and reused.
 5.1.2  Zinc Electroplating
     Zinc plating is a commonly used electroplated finish for the
 corrosion protection of iron and steel.  Zinc offers "sacrificial"
 protection of ferrous metals because it is anodic to the  substrate;  the
 latter is protected so long as some zinc remains in the immediate area.
 Zinc may be plated on continuous sheet and wire, conduit, and all types of
 hardware such as tools, nuts, bolts, and screws.7'8
     A cyanide bath is use for general plating.   However, zinc chloride,
 sulfate, and fluoborate baths are used in strip and wire plating because
 they are capable of higher plating speeds.  These and other alternative
 baths may be used to meet EPA regulations to reduce or eliminate cyanide
 in the effluent. '8
 5.1.3  Rolled Zinc
     Production of rolled zinc accounted for 6,percent of 1985 zinc
            g
 consumption.   Rolled zinc is used in photoengraving, lithography, dry
 cells, weather stripping, and many building applications.  It can take the
 form of sheet, strip, plate, rod, and wire and is composed of high-grade
 zinc to which alloying metals such as copper,  magnesium,  manganese,
 chromium, and titanium are added in controlled amounts.   A zinc content of
99.8 percent or more gives good drawing characteristics  and the alloy
 additions provide a material with a wide range of tempers and strengths.10
     The zinc and its alloying elements are usually melted in a
reverberatory furnace although induction furnaces may be  used when careful
product control  is necessary.   The furnace temperature for melting is
 about 450° to 510°C (850° to 950°F).   After melting,  the  zinc is cast into
molds for rolling slabs which  are heated to 150°  to 260°C (300°  to 500°F)
depending on the final  product.   The rate  of reduction during rolling is
determined by the analysis of  the metal, the type of  equipment,  and the
desired finish.10
                                    5-2

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5.1.4  Other Miscellaneous Sources
     In 1985, other miscellaneous sources of zinc consumption accounted
for 6 percent or 9,440 Mg (8,560 tons)  of total zinc.    This estimate
includes consumption in paints,  which are discussed in Chapter 6,
Miscellaneous Zinc Oxide Sources.  Miscellaneous sources addressed below
are lead desilvering, zinc batteries, and light metal alloys.
     In the desilvering of lead, the lead bullion gives up its silver
content to zinc.  In general,  the two processes used include the
"stirring-in" of zinc, cooling,  skimming silver-zinc crusts, and
distillation of crusts.
     Zinc is used as the anode of various "wet" batteries such as the
Lalande cell, Eveready air cell, National Carbon air cell, and silver-zinc
batteries.    Nickel-zinc batteries are currently being investigated for
potential commercial use in rechargable, electric vehicles.
     Zinc is a secondary or minor ingredient in many light metal alloys,
including both the cast and wrought alloys of aluminum and magnesium.  It
is also frequently alloyed with  tin in aluminum solders, Britannia metal,
pewter, and "Queen's metal."  In silver solders, the zinc content ranges
from about 5 to 40 percent.1
5.2  EMISSIONS
5.2.1  Zinc-Base Alloys
     According to available information, the scrap reclamation operation
is the major source of zinc emissions to the atmosphere.    Induced draft
ventilation systems are used,  but there is no dust or fume collection
equipment.  Information obtained from die-casting companies indicated that
average emissions equal 10 Ib  per ton of zinc processed in 1969 although
the range of emissions was from  much less than 10 to-up to 60 Ib^per
ton.    However, it is not known if the same emission factors would apply
to thin wall technology (more  or less scrap could be generated).  It is
also possible that plants are  better controlled today than they were in
1969.
5.2.2  Zinc Electroplating
     Emissions to the atmosphere due to electrolytic deposition of zinc
are considered negligible.    The EPA Air Pollution Engineering Manual
                                   5-3

-------
(AP-40) notes that, with the exception of chromium plating processes, most
of the electrolytic plating and cleaning processes are of little  interest
from a standpoint of air pollution because the emissions are  inoffensive
and of negligible volume because of low gassing rates.18
5.2.3  Rolled Zinc
     According to currently available information, zinc emissions from
rolled zinc are negligible.19
5.2.4  Other Miscellaneous Sources
     Estimates of zinc emissions to the atmosphere from miscellaneous uses
of zinc were developed in a previous study almost entirely without
assistance from industrial sources.  Only two manufacturers provided
emission estimates.  More than 30 others stated that their emissions were
negligible; however, some defined negligible emissions as less than
1 percent loss of raw material.  It is apparent that there are some losses
to the atmosphere during the desilverizing of lead and alloying as well as
in operations using smaller quantities of zinc.  During 1969, zinc
emissions to the atmosphere due to processing and manufacturing operations
were estimated at 100 tons, or approximately 0.001 percent of the zinc
consumed for such miscellaneous purposes.20
5.3  REFERENCES FOR CHAPTER 5
 1.  Mineral Industry Surveys.  U.S.  Department of the Interior.  July 29,
     1986.  p. 4.
 2.  Davis, W. E.  (W. E. Davis & Associates) National Inventory of
     Sources and Emissions:  Barium,  Boron, Copper,  Selenium and Zinc.
     Prepared for U. S. Environmental  Protection Agency.   Research
     Triangle Park, North Carolina.  May 1972.   p. 28.
 3.  Kirk-Othmer.  Encyclopedia of Chemical Technology.  Third Edition.
     New York, John Wiley and Sons.  p.  7:82.
 4.  Reference 2.  p.  29.
 5.  Broadhead, James L.   Zinc in the 1980's.  In:  Lead-Zinc-Tin '80.
     Cigan, J. M., Mackey, T.  S., and O'Keefe,  T.  J.,  eds.   New York,
     American Institute of Mining, Metallurgical,  and  Petroleum Engineers,
     Inc.   1979.  p. 23.
 6.  Reference 2.  p.  30.
 7.  Reference 2.  p.  40.
                                   5-4

-------
 8.  Reference 3.  p. 8:855.
 9.  Reference 1.
10.  Reference 2.  pp. 53-54.
11.  Reference 1.
12.  Reference 2.  p. 58.
13.  Reference 2.  p. 58.
14.  Yao, N. P. and Miller, J. F. T.  Nickel/Zinc Battery:  A Promising
     Candidate for Electric Vehicle Propulsion.  In:  Lead-Zinc-Tin '80.
     Cigan, J. M., Mackey, T. S., and O'Keefe, T. J., eds.  New York,
     American Institute of Mining, Metallurgical, and Petroleum Engineers,
     Inc. 1979.  p. 871.
15.  Reference 2.  p. 59.
16.  Reference 2.  pp. 30-31.
17.  Reference 2.  p. 40.
18.  Danielson, J. A.  Air Pollution Engineering Manual.  Second Edition.
     U. S. Environmental Protection Agency, Research Triangle Park, North
     Carolina.  Publication No.  AP-40.  May 1973.  p. 830.
19.  Reference 2.  p. 56.
20.  Reference 2.  p. 59.
                                   5-5

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               6.   MISCELLANEOUS ZINC OXIDE EMISSION SOURCES

6.1  BACKGROUND INFORMATION
     The following sections discuss miscellaneous sources of zinc oxide
emissions.  Emissions from production of zinc oxide are discussed in
Chapter 2.  Table 1 presents distribution of zinc oxide shipments, by
industry, in 1984.l
6.1.1  Rubber Production
     The largest use of zinc oxide at the present time is in rubber
products.  Vulcanizing accelerators such as aldehyde-amines, guianidines,
and thiuram sulfides are used to decrease the time and temperature
required for vulcanization, and zinc oxide is one of a series of
                                                            •
accelerator activators used to supplement the accelerators.  Zinc oxide
also helps to modify finished product characteristics such as resistance
to ultraviolet (UV) light and increased elasticity.2'3
     During the manufacturing process, the additives to be compounded into
the rubber must be homogeneously dispersed throughout the blend.  Rubber
mills and Banbury mixers are the principal types of equipment used for
,, .          3
this purpose.
6.1.2  Photocopying
     The second largest use of zinc oxide is in photocopying owing to the
photoconductive and electrostatic properties of zinc oxide.   Conventional
printing paper is coated with zinc oxide powder that is dye-sensitized by
adsorption to extend its photosensitivity across the visible region.   The
copy is made by placing the material  to be reproduced between a light
source and the charged paper.  Where the light passes through to the-zinc
oxide paper, the electrostatic charge is dissipated.  The image is
developed by applying a pigmented resin powder that adheres  only to the
areas where the electrostatic charge has not been removed.   The image is
                           4- 5
fixed to the paper by heat. '

                                   6-1

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       TABLE 6-1.   DISTRIBUTION OF ZINC .OXIDE SHIPMENTS,
                      BY  INDUSTRY,  1984'
Industry
   Mg
                                               Shipments
  (Tons)
Agriculture
Ceramics
Chemicals
Paints
Photocopying
Rubber
Other
TOTAL
2,380
7,472
23,611
8,117
9,246
79,390
16,702
(2,624)
(8,237)
(26,027)
(9,014)
(10,192)
(87,513)
(18,411)
146,918
(162,018)
                             6-2

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6.1.3  Zinc Paints
     Zinc oxide is an additive in paints for exterior wood surfaces.   It
aids in mixing and grinding, improves drying and hardening of the paint
film, reduces paint discoloration, improves mildew resistance and self-
cleaning, and reduces chalking.  Emulsion-type latex paints for use on
cement and masonry surfaces also require the use of zinc oxide for the
same purpose as oil-base paints, with the added benefit of helping to
reduce container corrosion.
     Zinc paints are particularly important in applications where it is
necessary to protect steel from oxidation.  In 1978, this market segment
accounted for approximately 11 percent of the total zinc consumed in zinc
coatings.  With lead being virtually eliminated as a paint pigment, zinc
paints are expected to achieve an annual growth rate of 5 percent per year
through the 1980's.7
     At the paint factory, the zinc oxide is received in paper sacks and
emptied into vats containing a liquid.  There is a small amount of dust
generated as the sacks are emptied, but most plants are equipped with
                    Q
ventilation systems.
6.1.4  Other Miscellaneous Sources
     According to one study, the other miscellaneous uses of zinc oxide
accounted for approximately 23 percent of total consumption in 1969.9  In
ceramics and glass (including glazes, enamels,  and frits) it is an
essential ingredient.  In glass it reduces the  melting time,  lowers
viscosity, and raises chemical  and mechanical  resistance.  Up to
15 percent zinc oxide may be used for heat-resisting glass, technical
glass,  optical glass, selenium ruby glass,  and  yellow nickel  glass.   For
special  purposes,  the zinc oxide content may go up to 50 percent.9
     In glazes it  contributes to fusibility, increases resistance to
thermal  and mechanical  shock, improves luster,  and enhances opacity.   In
porcelain enamels  for sheet iron and  vitreous enamels for cast iron it
contributes to electrical  resistivity.  These enamels are used extensively
on refrigerators,  ranges,  washers,  sinks,  and toilet fixtures.9
     Zinc oxide,  because it is  an opaque material  that blocks  and scatters
light,  is used as  a mechanical  sunscreen barrier.10   Zinc oxide  is also
used in combination with eugenol  to  form impression  and  surgical  pastes
                                   6-3

-------
used in dental work.    Another use of zinc oxide is as an  industrial
anticaking agent to control storage properties and retain the  freeflow
characteristics of crystalline masses.    Finally, zinc oxide  is used as  a
stabilizer against UV radiation in plastics and feed additives, floor
coverings, soaps, and other products.l3'll*
6.2  EMISSIONS
6.2.1  Rubber Production
     Some zinc oxide emissions, in the form of finely ground particulates
(less than 15 micrometers), occur while charging the mills or mixers or at
the blending stage.  Mills and mixers typically are controlled with
baghouses that are capable of operating with 98 to 99.5 percent
efficiency.    The more significant source of emissions occurs during wear
of vehicle tires.  According to one study, the usual  dosage of zinc oxide
is in the range of 60 to 100 pounds (Ib) per ton of rubber, and the
average quantity per vehicle tire has been reported to be about 0.5 Ib.
Assuming a 20 percent wear-rate, an average tire life of 20,000 miles, and
1.05x10   miles traveled per year, the zinc emissions from tire wear
during the year of the study (1969) total  8,400 tons.16
6.2.2  Photocopying
     Emissions from zinc oxide coated paper result primarily from the
burning of discarded copies.    Zinc oxide is applied to printing paper in
a paint form.  Therefore, the manufacture  of zinc oxide coated paper is
unlikely to be a major source of zinc oxide emissions.
6.2.3  Zinc Paints
     Zinc oxide emissions occur when the zinc oxide dust is emptied into
the mixing vats.  In addition, some dust may remain in the empty bags that
are either burned or discarded with the trash.  According to one study,  no
emission records were available at paint factories,  but the authors
estimated that atmospheric emissions of zinc oxide do not exceed 1  Ib per
ton of zinc oxide processed.
6.2.4  Other Miscellaneous Sources
     The principal sources of zinc emissions during  the making of glass,
glazes, and enamels are the initial dry mixing operation and the melting
furnaces.  Emission sources for the other  miscellaneous uses are not
                                   6-4

-------
known, but it is thought that overall emissions are low considering the

fact that these sources account for less than 0.3 percent of total zinc
    1 9
use.

6.3  REFERENCES FOR CHAPTER 6

 1.  Jolly, J. H. Zinc.  In:  Minerals Handbook, 1984.  p. 981.

 2.  Danielson, J. A.  Air Pollution Engineering Manual.  Second
     Edition.  U. S. Environmental Protection Agency.   Research Triangle
     Park, North Carolina.  Publication No. AP-40.   May 1973.
     pp. 375-377.

 3.  Davis, W. E. (W. E. Davis and Associates) National Inventory of
     Sources and Emissions:  Barium, Boron, Copper, Selenium, and Zinc.
     Prepared for U. S. Environmental Protection Agency.  Research
     Triangle Park, North Carolina.  May 1972.  pp. 46-47.

 4.  Reference 3.  p. 48.

 5.  Kirk-Othmer.  Enclyclopedia of Chemical Technology.  Third Edition.
     New York, John Wiley and Sons.  p. 8:813.

 6.  Reference 3.  p. 49.

 7.  Kirk T. F., -Ling, F. W., McClure, W. R., and Weyand, T. E.  Zinc-
     Based Coatings:  Process, Products and Markets.  In:  Lead-Zinc-Tin
     '80.  Cigan, J. M., Mackey, T. S., and O'Keefe, T. J., eds.  New
     York, American Institute of Mining, Metallurgical, and Petroleum
     Engineers, Inc.  1979.  pp. 853-854.

 8.  Reference 3, p. 49.

 9.  Reference 3.  p. 51.

10.  Reference 5.  p. 7:152.

11.  Reference 5.  p. 7:498.

12.  Reference 5.  p. 7:283.

13.  Radtke, S. F. and Parthasarathi, M. N.  R&O Programs to Meet New
     Challenges for Lead and Zinc.  In:  Lead-Zinc-Tin '80.  Cigan, J. M.,
     Mackey, T. S., and O'Keefe, T. J., eds.  New York, American Institute
     of Mining, Metallurgical, and Petroleum Engineers, Inc.  1979.
     p. 834.

14.  Reference 3.  p. 52.

15.  Reference 2.
                                    6-5

-------
16.'  Reference 3.
17.  Reference 3.  p. 48.
18.  Reference 3.  pp. 49-50.
19.  Reference 3.  pp. 51-52.
                                   6-6

-------
                                 APPENDIX

     This appendix contains two sets of HEM information.  The first set
contains HEM data for sources in the primary zinc/zinc oxide industry
taken from the cadmium Phase I project.  Zinc and zinc oxide emissions for
these sources were calculated using emission factors developed from test
data and Section 114 responses obtained during the cadmium project.
     The second set contains HEM data as obtained from permits from the
States of New York, Kentucky, and Illinois.  The majority of the data are
from New York, and the following assumptions or changes were made to these
data:
     1.  Three plants (General Electric, 01 in Corp., and F. R.
Manufacturing, Inc.) reported stack temperatures of 8°F.  This seemed to
be an error, and temperatures of 70°F (01 in) and 120°F (GE and F. R.
Manufacturing) were substituted as being more representative of the
processes involved.
     2.  One company (Flomatic) reported a stack height of 6 feet.
However, closer inspection of the permit revealed that 25 feet was more
likely correct.  (The company had reported a 6-feet-high stack that was
25 feet higher than the closest building.  It was assumed that the correct
interpretation is a 25-foot stack that is 6 feet higher than the closest
bu i1d i ng.)
     3.  Some companies reported the dimensions of a square stack (26x26
for example).  In this case, the area of the cross section was calculated
and the equivalent diameter of a circular stack was calculated and used as
the HEM input value.
     4.  Companies reporting <1 Ib/yr of emissions were deleted as were
lightweight aggregate producers and one municipal incinerator.  The
processes in the latter cases were assumed to be atypical zinc/zinc oxide
                                   A-l

-------
emission sources.  Inspection of the permit for lightweight aggregate
producers revealed the use of a waste solvent as fuel that contained
traces of zinc.  The municipal incinerator was eliminated because it did
not fit any of the source categories under study.
     The following assumptions/decisions were made regarding permit
information from other States:
     1.  For the State of Illinois, only one source was included (zinc
oxide emissions from paint manufacturing at Sherwin Williams)  because all
other data were either for TSP or were incomplete.  A printout of the data
received from Illinois is attached.
     2.  Latitudes and longitudes were computed from the UTM coordinates
reported in the permits using a BASIC computer program obtained from
MDAD/PAB.
     3.  The emission source at Bluegrass Plating  (Kentucky) was assumed
to be an area source of 0.001 km2.  The permit listed an area of zero.
                                   A-2

-------
     HtM input parameters  tor  primary
         zinc/zinc  oxide smelters.
PLONT
NOME
OMOX ZINC CO.
ftMOX ZINC CO.
ftMOX ZINC CO.
JERSEY MINIERE ZINC
JERSEY MINIERE ZINC
JERSEY MINIERE ZINC
JERSEY MINIERE ZINC
NOTIONftL
NOTIONfiL
NOTIONOL
ST. JOE
ST. JOE
SI . JOE
ST. JOE
ST. JOE
ST. JOE
ST. JOE
ST. JOE
ST. JOE
ST. JOE
NJ ZINC
NJ ZINC
NJ ZINC
NJ ZINC
NJ ZINC
Z INC
ZINC
ZINC
RESOURCES
RESOURCES
RESOURCES
RESOURCES
RESOURCES
RESOURCES
RESOURCES
RESOURCES
RESOURCES
RESOURCES
EOST PLONT
EftST PLONT
EOST PLONT
EOST PLONT
EOST PLONT
POLLUTONT
Z inc
Z inc
Z me
Z i nc ox ide
Zinc
Zinc
Z i nc
Zinc
Z inc
Z i nc
Z i nc
Z inc
Zinc
Zinc oxide
Zinc oxide
Zinc oxide
Zinc
Zinc oxide
Z i nc
2 i nc
Zinc oxide
Zinc oxide
Z i nc ox ide
Zinc oxide
Zinc oxide
LOTirUDE LONGITUDE
383611 9O1O13
383611 9O1013
383611 9O1O13
363 1OO 87243O
3631OO B7£43O
363 1OO B7£43O
363 1 OO
364436
364436
364436
404014
4O4O14
4O4O14
4O4O14
4O4O14
4O4O14
4O4O14
4O4014
4O4O14
404O14
4O4B4O
4O4B4O
4O4B4O
4O4B4O
4O484O
87243O
955932
955932
955932
8O2O 1 1
BO2O 1 1
8O20 1 1
8O2O 1 1
8O£O 1 1
8O2O1 1
B02O 1 1
8O£01 1
BO2O 1 1
802O 1 1
75352O
75352O
75352O
753520
75352
STOTE TYPE
IL H
IL F
IL H
TN H
TN H
TN H
TN
OK
OK
OK
PO
PO
PO
PO
Pft
PO
PO
PO
PO
Pft
PO
PO
PO
PO
Pft
F
H
F
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
STOCK
NUMBtR
£
3
4
£
3
4
5
^
3
5
3
4
5
6
7
8
9
1O
12
13
2
3
4
5
6
HEIGHT
M
22. 86
O. OO
10. 36
3O. 48
15. 85
15.24
O. OO
O. OO
14. O2
13. 1 1
19. 2O
O. OO
18. 29
121. 9£
36.88
6O. 96
£2. 86
14. 33
£2.86
IB. £9
9. 1O
24. 4O
15. £O
13. 1 1
£2. 9O
OREO
SO. M
1O. 45
O. OO
5.52
7. 41
14. 49
13.93
O. OO
O. OO
5. 13
7. 19
9.75
O. OO
16. 72
658. 84
78.69
£O4. 39
£7. 87
19. 65
£4. 39
16. 72
10.92
122. OO
£3. 16
18. O4
52.67
DIftM. VELOCITY TEMP.
M M/S K
O. 457 29. 565 383
O. OOO O. OOO £94
0.530 16.1 £94
0. 405 9. 886 294
O. 914 11.203 327
O. 914 9. 17O 294
O. OOO
O. OOO
0. 366
O. 549
O. 5O8
O. OOO
O.914
5. 4O4
2. 134
3. 353
1. £19
1. 372
1 . O6 7
0. 914
1 . £OO
5. OOO
1. 5£4
1. 376
£. 30O
O. OOO
O. OOO
£O. £13
£ 1 . 960
9. 389
O. OOO
3. 597
5. OO1
17.028
1£. £95
13. 346
17. 569
1 7. 424
1 1 . 068
17. 4OO
7. 300
1O. 868
14. 924
7. 3OO
£94
£94
3£2
3££
339
£94
341
353
335
303
4 OB
408
£94
466
41 1
307
497
355
EMISSIONS,
Kb/ YR
56O. 89O
56O8. 86O
19059. S7O
1O£6. 8BO
67O. £90
174U. 33O
67O£.
3362
1655.
396.
476.
4764.
1OB.
1 4814.
35359.
63O42.
2013.
25900.
.-J013.
1O8.
168.
£7918.
£737.
1 06 1 .
£-6388.
9OO
7OO
OOO
£7O
450
5 1 *"i
860
34O
OOO
OOO
95O
OO<_>
950
860
9 BO
49O
£5O
48O
£2o
                                                                ZN MELT  FURN  BH
                                                                ZN TOP/COST
                                                                FUbS
                                                                ZN DUST  PROCESS
                                                                BH
                                                                COLCINE  BH
                                                                ZN MELT  FURN
                                                                ZN METOL POWDER
                                                                BH
                                                                ZINC  TOP/COST
                                                                ZN TOP/COST
                                                                ZN METftL POWDER
                                                                BH
                                                                ZN MELTING
                                                                FUKNOCE
                                                                ZN HOLDING
                                                                FURNOCE
                                                                ZN TOP/COST
                                                                ZN METftL POWDER
                                                                BH
                                                                SINTER MOCHINES
                                                                BH
                                                                SINTER
                                                                SIZE/CRUSH BH
                                                                ZN FURN  PREHEflT
                                                                BH
                                                                REFINING COL  BH
                                                                t* 1
                                                                ZNU  FURN BH:i
                                                                Rt I- 1NING CUL  BH

                                                                NUISONCE ZN
                                                                DUST  BH
                                                                WLOl.Z KII N FUGS
                                                                BH
                                                                WEOLZ KILN PROD
                                                                BH
                                                                SIN1FR BH
                                                                FUME  KILN BH
                                                                MOVING GRO1E
                                                                FURNOCE
                                                                BOGHOUSE
A-3

-------
 UPDflTF
          POLLUTANT
                      SOURCE
                      CATEGORY
PLANT SIC
  NO. CODE
                                                          PLANT NOME
 State  Permit Data
HEM  Input  Parameters
         ZINC

 LATITUDE  LONGITUDE URBAN CITV
                                             STATE  TYPE
 O9/2E./86 Zinc        Brass/Bronze
 09/£6/B6 Zinc        Brass/Bronze
 O9/26/B6 Zinc        Brass/Bronze
 O9/£G/fl6 Zinc        Pi gment s/Pa ir.t s
 O'3/£&/8& Zinc        Galvanizing
 O9/26/86 Zinc:        Zinc Plating
 O9/E-&/B& Zinc        7 i nc Plating
 O9/£fc/86 Zinc        Zinc Plating
 O9/26/8& Zinc        Zinc Plating
 O9/£6/8& Zinc        Pi gnient s/Pa i nt s
 O9/26/66 Zinc        Surface Coating
 O9/£&/86 Zinc        Surface Coating
 O9/2&/86 Zinc        Brass/Bronze
 O9/26/86 Zinc        Brass/Bronze
 O9/26/B& Zinc        Brass/Bronze
 O9/2&/86 Zinc        Brass/Bronze
 09/£&/a& Zinc        Secondary Zinc
 09/26/Bfc Zinc        Zinc Die Casting
 O9/£6/B6 Zinc        Brass/Bronze
 09/£6/86 Zinc        Brass/Bronze
 O9/2&/8& Zinc        Galvanizing
 n9/£&/86 Zinc        Semiconductors
 09/2&/8& Zinc        Zinc Plating
 O9/£6/B6 Zinc        Secondary Zinc
 O9/2&/B6 Zinc        Secondary Zinc
 O9/2&/8& Zinc        Secondary Zinc
 O9/£&/86 Zinc        Secondary Zinc
 O9/2&/B& Zinc        Secondary Zinc
 O9/2&/86 Zinc        Brass/Bronze
 09/£&/86 Zinc        Brass/Bronze
 O9/£6/8& Zinc        Zinc Die Casting
 O9/2&/86 Zinc        Brass/Bronze
 O9/2&/8& Zinc        Brass/Bronze
 O9/2&/8& Zinc        Zinc Die Casting
 09/26/86 Zinc        Zinc Die Casting
O9/2&/6& Zinc        Zinc Die Casting
O9/E&/86 Zinc        Surface Coating
O9/2&/86 Zinc        Surface Coating
09/£6/66 Zinc        Brass/Bronze
O9/2&/86 Zinc        Brass/Bronze
 O9/£&/8& Zinc        Surface Coating
O9/2&/8& Zinc        Zinc Die Casting
03/£6/B6 Zinc        Hardware
O9/£6/B6 Zinc        Construct,  'machinery
09/26/86 2inc        Plating,  polishing
O9/2&/8& Zinc        Metal  coating
09/26/86 Zinc        Metal  coating
O9/2&/86 Zinc        Motor  vehicle parts
O9/£6/86 Zinc        Motor  vehicle parts
£ 3361
£ 3361
£ 3361
3 2851
4 331£
5 3714
5 3714
5 3714
5 3714
6 £818
7 3999
8 3964
9 3360
9 3360
9 33GO
9 3360
1O 3369
1 1 34£3
1£ 3362
12 3362
13 3322
14 3662
15 3452
16 33OO
16 33OO
16 33OO
16 33OO
16 3300
17 3494
17 3494
18 3315
19 3325
£1 33£1
£2 3644
24 3369
£5 3544
£6 3471
£7 3953
28 3362
£8 336£
£9 3823
3O 3369
31 3429
32 3531
33 3471
34 3479
34 3479
35 3714
35 3714
FR Manufacturing, Inc
FR Manufacturing, Inc
FR Manufacturing, Inc
Pratt ft Lambert, Inc
BSC Galvanizing
Delco Products Div.
Delco Products Div.
Delco Products Div.
Delco Products Div.
Ol in Corp.
East Pattern/Model
Bout hco— Lion Div.
Columbian Bronze
Columbian Bronze
Columbian Bronze
Columbian Bronze
Gim Metal Products
Great Neck Saw Mfgs
Cal dwell S Ward
Cal dwell ft ward
Frazer and Jones Co.
General Electric Co.
Star E« pans lor, Ind.
Eastern Alloys Inc.
Eastern Alloys Inc.
Eastern Alloys Inc.
Eastern Alloys Inc.
Eastern Alloys Inc.
Flornatic Corp.
Flornat ic" Corp.
Arner. Tack/Hardware
General Electric Co.
Goulds Pumps Inc
Crown Die Casting
Die Cast A Forge Co
Elms ford Die Casting
Etnbee Plating
Berry Metals Ltd.
Thomas Paulson 4 Sons
Thomas Paulson ftSons
O. Z. Gedney Co.
Allen Stevens Corp.
Faultless Caster Co.
FMC Const r. Equipint.
Centr. Ky Processing
Blue Grass Plating
Blue Grass Plating
Signet Systems Inc.
Signet Systems Inc.
4£3£40
4£3£4O
42324O
4£5546
4£4756
430947
430947
43O947
430947
43O9O4
43O5O1
425716
4O3952
4O3952
4O3952
403952
4O4442
4O4439
43O3O5
430305
43033B
43O618
4 1 £4 1O
4 1 3O£9
4130£9
413O29
4 1 3O29
4 1 3029
425528
4255£8
4 1 O635
4£48£4
4£5448
4O5329
4O5337
4 1 O4 1 7
404837
4043£4
4O4O43
4O4043
4O4O53
404519
365048
38OO5O
38O104
374415
374415
374638
374638
79O953
79O953
79O953
785357
785035
774OO4
774OM4
774OO4
774OO4
774OO2
773531
773427
733510
733510
733510
733510
733708
?33742
76O852
760852
761345
761131
74O5O1
741215
741215
741215
741215
741215
732O36
732O36
74O358
735742
764838
734942
734725
734826
735420
735724
7359£6
7359£6
735926
735358
87£7£7
842557
842653
871715
871715
8451 1O
8451 1O
O
O
o
o
o
o
o
o
0
o
o
o
o
o
o
o
o
tl
o
o
o
o
o
o
o
o
C)
o
o
o
0
o
o
0
o
o
o
o
o
o
o
o
o
0
o
o
o
0
G
                                                               Si 1ver Creek
                                                               Si 1ver Creek
                                                               Silver Creek
                                                               Buffalo
                                                               Lackawanr.a
                                                               Rochester-
                                                               Rochester'
                                                               Rochester
                                                               Rochester-
                                                               Rochester
                                                               Rochest er
                                                               Honeoye Falls
                                                               Freeport
                                                               Freeport
                                                               Freeport
                                                               Freeport
                                                               Carle Place
                                                               Mineo1 a
                                                               Syracuse
                                                               Syracuse
                                                               Solvay
                                                               Salin a
                                                               Mount ainvi lie
                                                               Maybrook
                                                               Maybrook
                                                               Maybrook
                                                               Maybrook
                                                               Maybrook
                                                               N.  Hoosick
                                                               N.  Hoosick
                                                               Monsey
                                                               Schenect ady
                                                               Seneca  Falls
                                                               Mt. Vernon
                                                               New Roche 1 le
                                                               E Irnsf ord
                                                               Bronx
                                                               Brook 1yn
                                                               Brook 1yn
                                                               Brook 1yn
                                                               Brook 1yn
                                                               Queens
                                                               Hopkinsvi11e
                                                               Lexington
                                                               Lex i rig ton
                                                               Ri chtnond
                                                               R i chrnorid
                                                               Harrodsburq
                                                               Harrodsburq
NY
NY
NY
NY
NY
NY
NV
NY
NY
NY
NV
NY
NY
NY
NV
NY
NY
NY
NY
NY
NV
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NV
NY
NY
NY
KY
KY
KY
KY
KY
KY
KY
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
r
F"
H
H
                                                                   A-4

-------
PLONT STOCK
NU. NO.

2
2
£
3
4
5
5
5
5
&
7
a
9
9
9
9
1C
1 1
12
IS
13
14
15
ie
IE
16
ie.
16,
1 7
17
18
19
£1
22
£•4
£5
£6
£7
£fl
2a
£3
3D
31
32
33
34
34
35
35

1
£
^
1
1
1
£
2
4
1
1
1
1
2
3
4
1
1
1
o
1
1
1
1
1
2
2
^
1
£
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
•^
STOCK
HEIGHT,
M
6. 10
6. 1O
3. O5
15. £4
40. 54
10. 36
10. 36
10. 36
1O. 36
7. 32
4. 88
9. 45
7.6£
9. 14
6. 71
5. 18
8. £3
5. 49
9. 14
9. 14
6. 1O
15. 85
7. 9£
15. 54
15.54
15. 54
15. 54
15. 54
7. fc£
7.6£
7.6£
1£. 19
1O. O6
7. 3£
6. 4O
5. 49
1O. O6
10. 67
6. 71
1£. 19
6. 10
5. 49
8. OO
1O. OO
3. OO
O. OO
O. OO
9. OO
£. OO
POBE 2
ZINC
OREO, VFNT STOCK VELOCITY, TEMP., EMISSIONS EMISSIONS,
M£ TYPE DIOMC1ER, M/S K MOXIMUM, K6/YR

6. £0
6.£0
1.24
2. 3£
54. 57
3. 42
3. 42
3. 42
3. 42
£.97
3.49
7.O3
£. 90
13. 93
4. 95
2. 90
£. 93
£. O9
4. 18
4. 18
9. 30
6. 85
1 1. £6
1 1. 84
1 1. 84
1 1. 84
1 1. 84
1 1. 84
5.81
5. 81
4. 65
£. 47
5. 88
1O. 91
2. £8
5. O£
15. OO
9. 15
3. 46
12. 51
2. 79
6. 69
4. OO
2. OO
0. 90
10OO. OO
1OOO. OO
1. 80
C). 4O

O
O
O
O
0
O
0
O
O
0
O
O
O
O
0
O
0
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
q
O
0
0
0
O
O
O
O
O
O
O
O
O
O
O
O
M
1 . 0 1 6
1 . 0 1 6
O. 4O6
O. 1 52
1.346
0. 330
0. 330
0. 33O
O. 33O
0. 4O6
0.716
O. 744
0.381
1.5£4
O. 737
O. 559
O. 356
O. 3B1
O. 457
O. 457
1.524
O. 432
1.422
O. 76£
O. 762
0. 76£
O. 762
O. 762
0. 76£
O. 76£
0. 61 O
O. £O3
0. 584
1. 491
0. 356
0.914
1. 491
0. 858
0.516
1 . O26
0.457
1.219
0. 5OO
O. 2OO
O. 3OO
O. OOO
O. OOO
O. 2uO
O. 2OO

15. 85O
1 5. 85O
£4. 7 SO
17. 343
13. £59
8.534
7. 315
9. 144
8. 534
O. B2O
5. 861
1 O. 82O
£7. O36
2. 774
38. 557
19. 9O3
6. 401
21. 336
O. OOO
0. OOO
4. 877
1 1. 156
1£. 19£
10. O58
10. O5B
1O. O58
10.058
10. O58
£4. 079
£4.O79
1O. 973
3. 840
1 1. 582
4. 907
10. 363
O. 457
2.896
2. 316
25. 286
0. 671
6. 325
7. 681
9. OOO
15. OOO
1 . OOO
O. OOO
O. OOO
4. OOO
4. OOO

32£
322
322
294
644
£97
297
297
297
294
.294
£95
£94
294
£94
£94
394
294
477
477
294
294
297
339
339
339
339
339
344
293
294
322
305
294
316
477
£94
294
477
366
£94
3OO
316
£98
31 1
299
£99
£99
£99
KB/YR
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
0. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
0. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO

707. 616
707. 616
489. 888
9O. 720
83. 1OO
1.814
1. 814
1. 814
1. 814
69.673
2. 322
93. 895
127. OO8
154. ££4
54. 43£
54. 43£
81. 648
1451. 5£O
6O9. 638
609. 638
261. 274
52. 255
5. 216
108. 864
399. 168
1O8. 864
399. 168
199. 584
81 1O. 368
8110. 368
69.673
3. £66
33. 612
1 1. 975
0. 798
1 . O£ 1
48. 535
15. 876
76. 658
££. £26
9. 979
162. 915
5O. 84 8
3. 632
227. OOO
76. 272
88. O76
8. 172
8. 172
PROCESS
DESCRIPTION

Crucible Furnace
Crucible Furnace
Pol ish inq
M i K i n y
Flux Dry inq Oven
Plating Bath
Plating Bath
Plating Bath
Plat ing Bath
Sol ids Dry i nq
Metal Spray
Bake Oven
Melting Pot
Po 1 i sh i ng
Pol ish ing
Pol ish ing
Scrap Rerneltinq
Pol ish ing
Crucible Furnace
Crucible Furnace
Gal van i zer
Manufacture SC
Plat ing Tank
Ball Mill
Chip Melting
Bal 1 Mill
Chip Melt inq
Rotary Kiln
Crucible Furnace
Elec/ I riduct Furn
Cast ing
Crucible Furnace
E lee/ Induct Furn
Cast ing
Cast i ng
Melt/Cast
Pol ish ing
Sand i ng
Melting Pot
Melt inq Pot
Spray Booth
Melt/Cast
Melting furnace
Brazing operation
Zinc pi at inq tank
Rack z i nc plate
Barrel zinc plate
Solder repair"
Solder repair
TYPE OF
CONfHOL

UNC
UNC
UNC
SC
UNC
UNC
UNC
UNC
UNC
UNC
UNC
UNC
BH
CYC
CYC
CYC
UNC
CYC
UNC
UNC
UNC
LINC
WS
BH
BH/OB
BH
BH/OB
BH/OB
UNC
UNC
UNC
UNC
BH
UNC
UNC
UNC
CYC
CYC
CYL
UNC
F 1L TEf<
UNC
UNC
UNC:
UNC
UNC
UNC
UNC
UNL
A-5

-------
UPDATE

09 / £6/86
09/£6/86
U9/S6/86
09/26/86
09/26/86
O9/ 26/86
O9/26/86
O9/ 26/86
09/26/flG
O9/26/86
09/26/B6
O9/ 26/86
0')/26/86
09 /.-'&/ 86
119/^6/86
i'i9/26/86
09/26/86
O9/ 26/86
POLLUTANT

Z i nc
Z me
Z i nc
Z i nc
Zinc
Z me
Z i nc
Z i nc
Zinc
Z i nc
Z me
Z i nc
Z i ric
Z i nc
Z i nc
Zinc
Z i nc
Z i nc

ox ide
ox ide
ox ide
o x i d e
ox ide
ox ide
ox ide
ox ide
ox ide
ox ide
oxide
oxide
o x i d e
ox ide
oxide
ox ide
ox ide
oxide
SOURCE
CATEGORY
Business Machines
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Surface Coating
Gl ass/Cerarnics
G 1 ass/Cerarni cs
Glass /Ceramics
Detergents, etc.
Detergents, etc.
Detergents, etc.
Detergents, etc.
Detergents, etc.
Surface Coating
Pa int s/pi gment s
PLANT
NO.
1
2
3
4
6
6
6
6
7
7
7
9
9
9
9
9
1O
11
SIC
CODE
3573
3555
£522
3484
3569
3569
3569
3569
3297
3297
3297
2842
£842
2842
£842
2842
3823
2851
PLANT  NOME
                       State  Permit Data
                      HEM Input  Parameters
                           ZINC  OXIDE
                       LATITUDE  LONGITUDE URBAN CITY
Proctor  ft
Proctor  ft
Proctor  ft
Proctor  ft
O. Z. Gedney Co.
Sherwin  Williams
                                                                   STATE  TYPE
IBM Corp.
Lurniru te
Afro—Lecon,Mat sonInd
Remington Arms Co.
Metco  Inc.'-
Metco  Inc.
Metco  Inc.
Metco  Inc.
Tarn Ceramics
Tarn Ceramics
Tarn Ceramics
Proctor  ft  Gamble
           Gamble
           Gamble
           Gamble
           Gamble
                  Co.
420621
421 12O
42O544
43OO47
4O4550
40455O
4O455O
404550
43O852
43OB52
430852
4O3822
403822
4O3822
4O3822
403822
4O4O5.3
4 1 4 1 O5
760241
784452
791351
750 1 59
733308
7333O8
733308
733308
7902 1 8
7902 1 8
7902 1 8
741 1O2
741 102
741 1O2
741 1O2
741 1O2
735926
873628
O
0
O
O
0
O
O
0
o
o
0
o
o
o
o
o
o
o
End i cot t
Sa 1 arnanca
Jarnest own
I 1 i on
West bury
West bury
West bury
West bury
Niaqra Fa lls
Ni agra Fa 1 1 s
Niagra Falls
Staten Island
Staten Island
Staten Island
Staten Island
Staten Island
Brook lyn
Ch icapo
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
NY
IL
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
         A-6

-------
                    POGE  £

                  ZINC OXIDE
PLONT STOCK
NO. Nil.

1 1
a i
3 1
4 1
6 1
t 1
& 1
t, 1
7 1
7 1
7 1
9 1
9 1
3 1
9 1
9 1
1C 1
1 1 1
STOCK
HEIGHT,
M
9. 75'
5. 49
19. 81
9. 14
4. £7
4. £7
4. £7
4. £7
7. 6£
7. 6£
7. 6£
£0. 73
£O. 73
£0. 73
SO. 72
£0. 73
6. 1O
£4. 1C
OREO, VENT STOCK VELOCITY, TEMP., EMISSIONS
M£ TYPE DIOMtTER, M/S K MflXIMUM,

5.67
1.67
1£. OS
5.58
£. 6O
£. 6O
£. 60
£. 60
8. 13
8. 13
a. 13
1£. 65
1£. 65
1£. 65
12.6,5
1£. 65
£.79
14. 70

O
O
O
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
M
0. 5B£
O. 305
O. 61 0
O. 61 0
O. 6 1 0
0.610
O. 610
O. 610
1 . 067
1.O67
1 . 06 7
0.610
0. 61O
O. 61O
O. 61O
O. 61O
O. 457
O. 61O

£.819
19. 4O4
15. O39
1£. 19£
15. 85O
15. 85O
15. 85O
15. 850
9. 1 14
9. 1 14
9. 1 14
3. 719
3. 719
3. 719
3. 719
3. 719
6. 3£5
38. 100

£94
311
£94
£97
£94
£94
£94
£94
489
489
489
£94
£94
£94
£94
£94
£94
£94
KG/YR
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O. 000
O. OOO
0. 000
o.ooo
O. OOO
0. OOO
                       3IONS,  PROCESS
                       KG/YR DESCRIPTION
                       4. 99O Furne Hood
                      71.£15 Metal Spray
                      91.6£7 Paint Spray
                       1.361 Metal Spray

                       3.6£9 Wire/powder  Spr.
                       3.6£9 Wire/powder  Spr.
                       3.6£9 Wire/powder  Spr.
                      1O.686 Wire/powder  Spr.
                     £88.49O Rotary Calciner

                     15£.41O Rotary Calciner

                     44O.899 Rotary Calciner

                       9.5£6 Fat  Blend  Tank
                       3. 5£6 Fat  Blend  rank
                       9.5£6 Fat  Blend  Tank
                       9.5£6 Fat  Blend  Tank
                      37.643 Fat  Blend  Tank

                       8.165 Spray Booth
                      16.£4O Paint
                              m1 Hers,dispersers
TYPE  OF
CONTROL
ONC
FILTER
FILTER
Louver
col lector
UNC
UNC
UNC
FILTER
Sett 1 int)
chamber
Sett 1inq
chamber
Sett1inq
chamber
UNC
UNC
UNC
UNC
Spray
t ower
FILTER
UHBHUUSES
A-7

-------
                                                                Summary of  State of Illinois
                                                              Permit Data  for Zinc/Zinc Oxide
                                                                   Producers  and Emitters
Source Category
Iron/Steel
Iron/Steel
Iron/Steel
Iron/Steel
Iron/Steel
Iron/Steel
Iron/Steel
Iron/Steel
Iron/Steel
Iron/Steel
Gal vanizing
Galvanizing
Gal vanizing
Gal v aril zing
Ga1 vanizinq
Galvanizing
Ga1vanizing
Galvanizing
Secondary  Zinc
Secondary  Zinc
Brass/Bronze
Brass/Bronze
Brass/Bronze
Brass/Bronze
Secondary  2inc
Secondary  Zinc
Secondary  Zinc
Secondary  Zinc
Secondary  Zinc
Secondary  Zinc
                      Process
                                       Pollutant   Plant  Name
Line Cleaner
Galvanizing Pot
Galvanizing Pot
Galvanizing Line
£ vessels
Charge and Tap
Metal Reladling
Metal Charging
CalCarb. Desulf
Inject ion
Zinc Bath
Muffle Annealing
Nail Galvanizing
Inqot Teeming
Cont. Caster
Rrc Furnace
Nail Galvanizing
Nail Galvanizing
Elee/Induct  Furn
Elec/lnduct  Furn
Reverb.  Furnaces
Brass Cupola
Crucible Furnace
Rotary Furnaces
Fr. Muffle  Furn.
Fr. Muffle  Furn.
Fr. Z.O. Packer
Storage/Hand1ing
Bo 11lnq  Mill
W.S. Crusher
                                                                                                                   Emissions,


Zinc
Zinc
Z l nc
Z inc
Z inc
Zinc
Z inc
Zinc
Z inc
Zinc
Zinc
Zinc
Z inc
Zinc
Z inc
Z inc
Zinc
Zinc
Z inc
2 me
Zinc
2 inc
Zinc
Z inc
Z inc
Z inc
Z inc
Zinc
Z inc
Zinc


Granite City Steel
Granite City Steel
Granite City Steel
Granite City Steel
Granite City Steel
Granite City Steel
Granite City Steel
Granite City Steel
Granite City Steel
Granite City Steel
Keystone Steel/Mire
Keystone Steel /Wi re
Keystone Steel /Wire
Keystone Steel /Wi re
Keystone Steel /Wi re
Keystone Steel /Wi re
Keystone Steel /Wire
Keystone Steel/Mire
R. Lav in and Son
R. Lavin and Son
N. Chicago Refiners
N. Chicago Refiners
N. Chicago Refiners
N. Chicago Refiners
Oxide Asarco, Inc.
Oxide Asarco, inc.
Oxide Asarco, Inc.
Oxide Asarco, Inc.
Oxide Asarco, Inc.
Oxide Asarco, Inc.
Height
Ft.
56. 00
8O. OO
ao. oo
BO. OO
16O. OO
ISO. OO
6O. 00
67. OO
6O. OO
6O. OO
6O. OO
50. OO
1O. OO
1 00. OO
BO. OO
7O. OO
4O. OO
4O. OO
42. OO
7O. OO
28. OO
48. OO
43. 00
5O. OO
25. OO
1O. OO
15.00
£5. OO
5. OO
8. 00
Diameter
Ft.
2. 5OO
O. OOO
o. ooo
£. 5OO
18. OOO
O. OOO
9. 3OO
£. aoo
4. 6OO
4. 6OO
O. OOO
O. OOO
O. OOO
O. OOO
O. OOO
17. OOO
2. 500
2. 5Oo
6. OOO
3. OOO
6. 40O
1 1 . 5OO
1 . 8OO
O. 000
O. OOO
4. goo
O. 5OO
1. 10O
1 . 1 OO
O. OOO
ri OWRATF
MLI-M
1 7O3O. OOO
O. OOO
O. OOO
17672. OOO
8OOOOO. OOO
O. OOO
3OuuOO. OOO
3OOOO. OOO
3OOOOO. OOO
3OOOOO. OOO
O. OOO
O. OOO
O. OOO
O. OOO
O, OOO
2OOOOO. OOO
1 OOOO. ("M.M.I
1OOOO. OOO
23O71. U'.'O
175SO. OOO
i^t.lO I.M.I. OOU
435OO. OOO
1858. OOO
O. OOo
376flii. OOO
4553O. OOo
122O. OOo
1EOO. OOO
12OO. OOO
O. OOO
Temp
F
80
0
O
80
550
O
425
14O
350
350
O
O
o
o
o
25O
4OO
4OO
5OO
1 OO
145
23O
83O
O
150
ISfl
70
7O
70
•o
IBP

16O3O. 8OO
157&8.000
19272. OOO
438O. OOO
324996. OOO
19344. OOO
4993. 2OO
350. 400
42O4. 8OO
438. OOO
sea. ooo
1 176. OOO
37632. OOO
48O2O. OOO
8232. OOO
2193OO. OOO
924O. OOO
9£4O. OOO
798. OOO
789. 6OO
5 1 B6 1 . 6OO
1 1664O. OOO
4 1 . 6OO
53913. 6OO
23652. fiOfi
23652. OOO
35O. 4OO
525. 600
525. 6OO
£4O. OOO
                                                            A-8

-------
HEM INPUT PARAMETERS FOR ZINC/ZINC OXIDE  PRELIMINARY  SOURCE ASSESSMENT
SPECIALITY STEEL PLANTS

PLANT
NAME
Al 1 egheny
Ludlum













Al Tech



Armco



Armco












HEIGHT
STATE LAT. LONG. POLLUTANT

PA 403500 794300 ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
NY 424238 734326 ZnO
Zn
ZnO
Zn
MD 391815 763408 ZnO
Zn
ZnO
Zn
PA 405100 795300 ZnO
Zn
'ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn


30
30
30
30
30
30
30
30
30
30
30
30
15
15
Ib
16
19
19
H
24
17
17
46
46
46
46
46
46
23
23
44
44
(M)

.48
.48
.48
.48
.48
.48
.48
.48
.48
.48
.48
.48
.2
.2
.76
.76
.8
.8
.68
.68
.06
.06






.7
.7


VERTICAL
AREA
(SQ. M.)

929
929
929
929
557
557
465
465
1486
1486
1115
1115
2787
2787
536.5
536.5
2657
2657
451.5
451.5
2123
2123
84.2
84.2
84.2
84.2
84.2
84.2
550
550
5898
5898


DIAMETER AREA
(M) (SQM)

65
65
65
65
39
39
32
32
148
148
148
148
5574
5574
117
117
4460
4460
39
39
57
57
1.8
1.8
1.8
1.8
1.8
1.8
395
395
332
332

.03
.03
.03
.03


.5
.5
.64
.64
.64
.64






.01
.01
.96
.96






.2
.2



VELOCITY
(M/S)

0.61
0.61
0.61
0.61
0.7
0.7
0.4
0.4
2.37
2.37
2.17
2.17
0.5
0.5
2.41
2.41
0.5
3.53
3.53
3.53
0.5
0.5
20.8
20.8
20.8
20.8
20.8
20.8
0.88
0.88
0.5
0.5

TEMP.
(°K)

333
333
333
333
333
333
333
333
333
333
333
333
305
305
316
316
305
305
311
311
305
305
333
333
333
333
333
333
319
319
305
305

EMISSIONS
(Kg/yr)

10.9
4.3
10.9
4.3
10.9
4.3
10.9
4.3
2480
984
2.2
0.86
13300
5300
1690
671
6620
2630
570
226
13900
5500
70
28
70
28
70
28
1080
429
38400
15300

SOURCE
DESCR.

EAF-DEC

EAF-DEC

EAF-DEC

EAF-DEC

2 EAF's;
AOD
2 EAF's

Fug.- EAF,
AOD
2 EAF's;
2 AOD
Fug.- EAF,
AOD
AOD; EAF

Fug. EAF,
AOD
EAF, DEC

EAF, DEC

EAF, DEC

3 EAF, AOD

Fug.- EAF,
AOD

CONTROL
DEVICE

BH

BH

BH

BH

BH

BH

Closed
Roof

BH
Closed
Roof
BH

Roof
Monitor
Venturi
Scrubber
Venturi
Scrubber
Venturi
Scrubber
2 BH's

Roof
Monitor
                         A-9

-------
HEM INPUT PARAMETERS FOR ZINC/ZINC OXIDE PRELIMINARY SOURCE ASSESSMENT
                SPECIALITY  STEEL  PLANTS (continued)
                  VERTICAL
PLANT HEIGHT
NAME STATE LAT. LONG. POLLUTANT (M)
Cabot IN 402830 860944
Carpenter CN 411000 731000
Tech-
nology
Carpenter PA 402147 755555
Tech-
nology
Crucible NY 400300 761000
Eastern MD 391744 763051
Stain-
less
Empire OH 404700 823100
Detroit
Steel
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
6.24
6.24
12.95
12.95
19.8
19.8
28
28
30.5
30.5
24.4
24.4
23.7
23.7
24.4
24.4
15.2
15.2
38.8
38.8
22.86
22.86
25.9
25.9
22.86
22.86
22.86
22.86
28
28
28
28
AREA DIAMETER AREA VELOCITY
(SQ. M.) (M) (SQM) (M/S)
47.6
47.6
237
237
2415
2415
932
932
5574
5574
795
795
775
775
4460
4460
232
232
649
649
2787
2787
632
632
15.8
15.8
2090
2090
735
735
3419
3419
0.93
0.93
6.96
6.96
1742
1742
142
142
2787
2787
54.67
54.67
119.3
119.3
5574
5574
8.36
8.36
40.87
40.87
92.9
92.9
29.7
29.7
2.28
2.28
1394
1394
138.5
138.5
9232
9232
7.9
7.9
4.67
4.67
0.5
0.5
2.2
2.2
0.5
0.5
3.35
3.35
2.67
2.67
0.5
0.5
6.2
6.2
3.87
3.87
0.5
0.5
3.65
3.65
26.5
26.5
0.5
0.5
1.71
1.71
0.5
0.5
TEMP.
394
394
355
355
305
305
311
311
305
305
303
303
303
303
305
305
408
408
311
311
305
305
316
316
311
311
305
305
339
339
305
305
EMISSIONS
(Kg/yr)
40
16
0.87
0.35
510
210
740
294
3260
1300
37
15
207
82
2230
884
72
29
420
167
1970
783
1650
655
21
8.4
18800
7460
71
28
7830
3110
SOURCE CONTROL
DESCR. DEVICE
2 AOD
2 EAF
Fug.- AOD,
EAF
2 EAF,
AOD
Fug.- EAF,
AOD
EAF, AOD
3 EAF's,
AOD
Fug.- EAF's,
AOD
2 EAF's,
DEC
1 AOD
Fug.- EAF's,
AOD
AOD
EAF
Fug.- EAF,
AOD
2 EAF's,
AOD - DEC
Fug.- EAF,
AOD
BH
BH
Roof
fans
BH
Closed
Roof
BH
BH
Closed
Roof
BH
BH
Roof
Monitor
BH
BH
Closed
Roof
BH
Roof
Monitor
                        A--50

-------
HEM INPUT PARAMETERS FOR ZINC/ZINC  OXIDE  PRELIMINARY  SOURCE  ASSESSMENT
                SPECIALITY  STEEL  PLANTS  (continued)
                 VERTICAL
PLANT

HEIGHT
NAME STATE LAT. LONG. POLLUTANT (M)
Jessop PA 401038 801602
Steel




Earle WA 471200 1220200
M.
Jorgensen

Slater IN 410412 851017
Steel






Wash- PA 401500 801200
1 ngton
Steel

Cytemp PA 402100 800700
Spe-
ciality
Steel
LTV OH 404812 812010
Steel






ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
2nO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
12.8
12.8
11.3
11.3
19.8
19.8
15.2
15.2
19.8
19.8
8.8
8.8
8.2
8.2
12.2
12.2
25.9
25.9
19.2
19.2
19.8
19.8
21.3
21.3
27.4
27.4
33.5
33.5
29.6
29.6
26.2
26.2
43.3
43.3
AREA DIAMETER AREA VELOCITY
(SQ. M.)
215
215
120 .
120
2657
2657
290
290
2415
2415
13.37
13.37
16.23
16.23
40.87
40.87
4738
4738
632
632
2415 -
2415
650
650
3344
3344
3065
3065
2451
2451
3515
3515
5804
5804
(M) (SQM)
12
12
6
6
5946
5946
6
6
2323
2323
1.52
1.52
1.98
1.98
3.35
3.35
1394
1394
110
110
2323
2323
56
56
4460
4460
446
446
202
202
637
637
163
163
.5
.5
.27
.27


.b
.5










.4
.4


.7
.7








.5
.5
(M/S)
9.81
9.81
4.2
4.2
0.5
0.5
38.1
38.1
0.5
0.5
13
13
15.4
15.4
10.7
10.7
0.5
0.5
1.32
1.32
0.5
0.5
5.07
5.07
0.5
0.5
2.09
2.09
2.7
2.7
0.5
0.5
0.5
0.5
TEMP.
(°K)
316
316
339
339
305
305
294
294
305
305
394
394
308
308
322
322
305
305
316
316
305
305
322
322
305
305
314
314
303
303
305
305
305
305
EMISSIONS
(Kg/yr)
7.3
2.9
420
166
2280
907
163
65
178
71.3
608
242
19.6
7.8
10.7
4.3
1410
559
1010
400
10700
4230
549
218
1150
458
6.38
2.53
1140
452
44
17.3
28400
11300
SOURCE
DESCR.
3 EAF

AOD

Fug.-
AOD
2 EAF
AOD
Fug.-
AOD
AOD

EAF,

EAF

Fug.-
AOD
2 EAF
AOD
Fug.-
AOD
's



EAF,

's,

EAF,



AOD



EAF,

's,

2 EAF's

3 EAF's,
AOD
Fug.-
AOD
4 EAF
DEC
3 EAF
AOD
Fug.-

Fug.-
AOD

EAF,

's -
Systems
's,

EAF

EAF,

CONTROL
DEVICE
BH

BH

Closed
Roof
BH

Closed
Roof
BH

BH

BH

Closed
Roof

BH
, Closed
Roof
BH

Closed
Roof
BH

BH

Roof
Monitor
Roof
Monitor
                        A-

-------
HEM INPUT PARAMETERS  FOR  ZINC/ZINC OXIDE PRELIMINARY SOURCE ASSESSMENT
                SPECIALITY  STEEL  PLANTS (continued!

                   VERTICAL
PLANT

HEIGHT
NAME STATE LAT. LONG. POLLUTANT (M)
Electrolloy PA 794700 412550





Standard PA 773356 403924
Steel


ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
24.4
24.4
12.2
12.2
24.9
24.9
26.5
26.5
25
25
AREA DIAMETER AREA VELOCITY
(SQ. M.)
42.2
42.2
2000
2000
4517
4517
675
675
2390
2390
(M) (SQM)
1.1
1.1
10
10
1360
1360
72.8
72.8
750
750
(M/S)
18.1
18.1
10
10
2
2
2.3
2.3
0.5
0.5
TEMP.
(°K)
325
325
311
311
311
311
395
395
305
305
EMISSIONS SOURCE
(Kg/yr)
964
383
52
21
1090
435
254
101
2180
864
DESCR.
EAF,

EAF,

EAF,

EAF,

EAF,

AOD

AOD

AOD

AOD

AOD

CONTROL
DEVICE
Scrubber

BH

Closed
Roof
BH

Roof
Monitor
                       A-12

-------
        HEM Input Parameters for Zinc/Zinc Oxide Preliminary Source Assessment
BOF Furnace

A.  Plant 7 - Primary Stack
            - Secondary Stack

B.  Plant 8 - Primary Stack
            - Secondary Stack

Electric Arc Furnace

A.  Furnace A - Carbon Steel
    (25 T/Heat)
              - Roof Monitor
B.  Furnace B - Carbon Steel
    (100 T/Heat)
              - Roof Monitor
C.  Furnace C - Carbon Steel
    (300 T/Heat)
              - Roof Monitor
D.  Furnace D - Carbon Steel
    (150 T/Heat)
              - Roof Monitor
Pollutant
ZnO
ZnO
ZnO
ZnO
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
ZnO
Zn
Annual
Emissions
(Kg/yr)
3080
19000
14080
15200
576
288
979
490
2490
1250
4270
2140
3690
1850
15600
7800
4600
2300
11500
5750
Vent
Height
(m)
114
114
144
144
22
22
27
27
22
22
33
33
30
30
38
38
30
30
36
36
.3
.3
.8
.8
.9
.9
.4
.4
.9
.9
.5
.5
.5
.5
.1
.1
.5
.5
.6
.6
Vent
Di ameter
(m)


15.
15.
45.
45.
15.
15.
68.
68.
22.
22.
107
107
22.
22.
76.
76.
2,
4,
6,
4,
2
2
7
7
2
2
6
6
9
9


9
9
2
2
.4
.9
.0
.4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X


3.
3.
3.
3.
3.
3.
3.
3.
3.
3.
3.
3.
3.
3.
3.
3.
Discharge
Velocity
(m/sec)


1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
18
18
18
18
0
0
3
3
3
3
3
3
3
3
4
4
4
4
3
3
.3
.3
.3
.3
.98
.98
.38
.38
.91
.91
.74
.74
.15
.15
.00
.00
.06
.06
.90
.90
Discharge
Temp. (°K)
350
338
477
338
394
394
320
320
394
394
320
320
394
394
320
320
394
394
320
320
                                           A-13

-------
                                    TECHNICAL REPORT DATA
                            (Please read Instructions on the reverse before completing)
  REPORT NO.
    EPA 450/3-87-008
                                                            3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
    Zinc/Zinc Oxide
    Preliminary  Source Assessment
                                                            5. REPORT DATE
                 April  1987
              6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
                                                            8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS
    Office of Air  Quality Planning  and  Standards
    U.S. Environmental  Protection Agency
    Research Triangle  Park,  NC  27711
              10. PROGRAM ELEMENT NO.
              11. CONTRACT/GRANT NO

                68-02-3891
12. SPONSORING AGENCY NAME AND ADDRESS
    DAA for Air Quality Planning and  Standards
    Office of Air and  Radiation
    U.S. Environmental  Protection Agency
    Research Triangle  Park, NC  27711
                                                             13. TYPE OF REPORT AND PERIOD COVERED
              14. SPONSORING AGENCY CODE
                EPA/200/04
15. SUPPLEMENTARY NOTES
16. ABSTRACT                                          ~~	~~	~~~	

    A preliminary source assessment of  industries with zinc  and/or zinc oxide  emissions
    is presented.   Brief descriptions of  these industries  and  associated air pollution
    control equipment  are presented.  Zinc/zinc oxide emission  data were primarily
    obtained from the  National Air Toxics Information Clearinghouse.  The Appendix
    presents zinc/zinc oxide emission data  that were used  inthe Human Exposure Model.
    This Model is used by EPA's Pollutant Assessment Branch  to  evaluate health risks
    from various pollutants.
17.
                                KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
                                               b.lDENTIFIERS/OPEN ENDED TERMS
                                                                          c.  COSATl Field/Group
   Air Pollution
   Pollution Control
   Preliminary Source Assessment
   Hazardous Air Pollutants
   Zinc/Zinc, oxide emissions
 Air Pollution  Control
    13B
18. DISTRIBUTION STATEMENT
    Unlimited
19. SECURITY CLASS (This Report)
   Unclassified
21. NO. OF PAGES

    79
                                               20. SECURITY CLASS (Tins page)

                                               	Unclassified
                                                                          22. PRICE
EPA Form 2220-1 (R«v. 4-77)    PREVIOUS EDITION is OBSOLETE

-------