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
-------
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
-------
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
-------
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.
-------
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
-------
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
-------
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.
-------
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)
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
4-1
1/1
a;
cu
c
o
O
i.
03
•r—
-o
o
a;
01
4-5
-------
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
-------
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.
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
------- |