Prepublication issue for F.PA libraries
SW-145c.3 and titate Solid Waeta Management Ayancivtt
ASSESSMENT OF INDUSTRIAL HAZARDOUS WASTE PRACTICES
IN THE METAL SMELTING AND REFINING INDUSTRY
Volume III
Ferrous Smelting and Refining
This final report (SW-245c.3) describes work performed
for the Federal solid waste management programs
under contract no, 68-01-2604
cmd ie reproduced as received from the contractor
The report is in four volumes: (I) Executive Summary, (II) Primary
and Secondary Nonferrous Smelting and Refining, (III) Ferrous Smelting
and Refining, and (IV) Appendices
Copies will be available from the
National Technical Information Service
U.S. Department of Commerce
Springfield, Virginia 22161
U.S. ENVIRONMENTAL PROTECTION AGENCY
1977 U.S. Environmental Protection Agency
Region 5, Library (PL- 12J)
77 West Jackson Boulevard, 12th Floor
Chicago, IL 60604-3590
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This report has been reviewed by the U.S. Environmental Protection
Agency and approved for publication. Its publication does not signify
that the contents necessarily reflect the views and policies of the U.S.
Environmental Protection Agency, nor does mention of commercial products
constitute endorsement or recommendation for use by the U.S. Government,
An environmental protection publication (SW-145c,3) in the solid waste
management series.
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ABSTRACT
Investigations of on-land disposal of process and pollution
control residuals from the United States metal smelting and refining
industry were conducted. This volume presents the results of studies of
the U.S. ferrous smelting and refining industry including iron and steel
(SIC 3312), iron and steel foundries (SIC 332), ferroalloys (SIC 3313),
and primary metal products not elsewhere classified (SIC 3399). Volume
II of this report includes the results of investigations of hazardous
waste generation and treatment and disposal in the primary and secondary
nonferrous smelting and refining industry. Volume I summarizes major
findings in both ferrous and nonferrous categories. Characteristics of
each industry sector, including plant locations, production capacities,
and smelting and refining processes, have been identified and described.
Land-disposed or stored residuals, including slags, dusts, and
sludges, have been identified and characterized by physical and chemical
properties. State, regional and national estimates have been made of
the total quantities of land-disposed or stored residuals and potentially
hazardous constituents thereof.
Current methods employed by the ferrous metals industry for
the disposal or storage of process and pollution control residuals on
land are described. Principal methods include lagocn storage of sludges,
and open dumping of slags, sludges and dusts. Methods of residual
treatment and disposal considered suitable for adequate health and
environmental protection have been provided. Finally, the costs incurred
by typical plants in each smelting and refining category for current and
environmentally sound residual disposal or storage on land have been
estimated.
ill
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ACKNOWUilXlMRNTS
The EPA Project Officers responsible for overall direction of
this program were Messrs. Allen Pearce, and Timothy Fields, Jr., Office
of Solid Waste, Hazardous Waste Management Division. Technical program
performance was vested with Calspan Corporation, Buffalo, New York. The
Calspan Project Engineer was Mr. Richard P. Leonard. Dr. Robert Ziegler,
Calspan Consultant, assumed technical program responsibility in the Iron
and Steel, Ferroalloy, and Iron and Steel Foundry sectors. Mr. Hans
Re if of Calspan provided cost analyses of waste treatment and disposal
technology. Mrs. Sharron Pek and Mr. Michael Wilkinson of Calspan
assisted in plant visits and waste sampling and analysis.
Assistance in industry characterization and review of draft
reports was provided by the following associations:
American Iron and Steel Institute
Ferroalloy Association
American Foundrymen's Society
Appreciation is extended to the American Iron and Steel
Institute which recommended and enabled the extensive composite sampling
nnd analyses program to he carried out in the iron and steel sector. Tn
addition appreciation is extended to the many companies who allowed
plant visits and interviews, and supplied samples for chemical analyses.
1v
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TABLE OF CONTENTS
Section Page
ABSTRACT i 11
ACKNOWLEDGMENTS i v
LIST OF FIGURES VI
LIST OF TABLES vi i
I. CONCLUSIONS 1
II. INTRODUCTION 3
III. FERROUS METAL SMELTING AND REFINING 5
1. Iron and Steel (SIC 3312) 6
2. Iron and Steel Foundries (SIC 332) 70
3. Ferroalloys (SIC 3313) 97
4. Primary Metal Products Not Elsewhere Classified
(SIC 3399) 145
LIST OF REFERENCES 149
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LIST OF FIGURES
Figure NoA
I Mow Diagram );or Iron and Steel Making 11
2 Foundry Operations 74
3 Ferromanganese and Silicomanganese Production 101
4 Process and Solid Waste Flow Diagram For Ferronickel
Production 103
V1
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LIST OF TABLES
Table No.
1 Major United States Steel Ingot Producers, 1972 7
2 State Distribution of United States Iron and Steel
Production Capacity, 1974 8
3 EPA Regional Distribution of U.S. Iron and Steel
Capacity, 1974 9
4 Production Data For Typical Integrated Steel Plant 15
5 Waste Generation Factors For Iron and Steel Plants 21
6 Yearly Generation of Residuals By Typical Iron and
Steel Plant 23
7 Estimated State, Regional and National Land Disposed
Wastes From Iron and Steel Production 27
8 Summary Table, Level I, II and III Treatment and
Disposal Technology, Iron and Steel 46
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LIST OF TABLES (Cont.)
Table No. Page
17 Waste Generation Factors, Ferroalloy Production 108
18 Yearly Generation of Residuals by Typical Ferroalloy
Plants 109
19 Estimated State, Regional and National Solid Waste
for the Ferroalloy Industry 110
20 Summary Table, Level I, II and III Treatment and
Disposal Technologies - Ferroalloys 116
21 Cost of Level I Treatment and Disposal Technology -
Ferromanganese and Silicomanganesc 127
22 Cost of Level I Treatment and Disposal Technology -
Ferrochrome 130
23 Cost of Level I Treatment and Disposal Technology -
Ferronickel 134
24 Cost of Level III Treatment and Disposal Technology -
Ferromanganese and Silicomanganese 137
25 Cost of Level III Treatment and Disposal Technology
Ferrochrome 138
26 Cost of Level III Treatment and Disposal Technology
Ferronickel 139
27 Summary Costs, Ferromanganese and Silicomunganese 141
28 Summary Costs, Ferrochrome 142
29 Summary Costs Ferronickel 143
30 Geographic Distribution of Miscellaneous Primary Metal
Product Manufacturing Firms, 1972 (SIC 3399) 146
31 Production of Metal Powders 147
32 Disposition of Residuals From Metal Powder Production .. 148
vm
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SECTION I
CONCLUSIONS
The ferrous smelting and refining industry disposes or stores
large quantities of process and pollution control residuals on land.
These residuals are predominantly inorganic slags, sludges, and dusts
containing oxides and other compounds of iron, silicates, and trace
metals. The only highly organic sludge encountered is decanter tar
sludge from iron and steel industry byproduct coke plants. In addition
to slags, sludges and dusts, the iron and steel foundries dispose of
significant quantities of waste sand on land. Significant quantities of
acid waste pickle liquor and waste oil are produced at iron and steel
plants and usually handled by contract disposal services for reclamation
or disposal.
The principal potentially hazardous constituents found in
ferrous smelting and refining residuals are heavy metals including
chrome, copper, zinc, lead, and nickel, and fluorides. Coke plant
wastes contain phenols, cyanides, ammonia, oils and greases. Phenol and
cyanide appear to a much lesser extent in blast furnace dust and wet
scrubber sludges as well. Foundry sands may contain phenol as a result
of the use of phenolic binders which are not degraded by process heat.
Some mill scales from steel plant rolling mills contain significant
amounts of oils and grease.
The predominant practice used j.n the ferroalloy and iron and
steel industries for the disposal of non-recyclable slag and dust resi-
duals is open dumping. Because the iron and steel industry generally
dewaters sludges before disposal, sludges are more often open dumped
rather than contained in lagoons. The foundry industry produces relatively
small quantities of sludge and generally mixes them with waste sands and
dusts before land disposal. The ferroalloy industry is more likely to
employ lagoons for containment of sludges.
The iron and steel industry generally reclaims iron from slags
before land disposal or sale as road ballast or aggregate. A much
higher percentage of blast furnace slag is sold because of lower density
and greater chemical stability than basic oxygen or electric furnace
slag. Approximately 80% of mill scales generated in steel mills is
recycled to recover iron value. Blast furnace dust is normally recycled
to sinter or blast furnaces while basic oxygen furnace dust is occasionally
recycled to sinter. The high zinc content of electric furnace dust and
many basic oxygen furnace (EOF) dusts generally makes it impractical to
recycle these dusts. The industry is attempting to develop technology
for accepting greater quantities of dusts and sludges as sinter or blast
furnace inputs. In a similar manner the ferroalloy industry which
generally cannot accept dusts as furnace inputs because of trace metal
contamination is exploring technology for greater recycling of dusts.
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The foundry industry directly recycles significant quantities of
moiii sund and reclaims significant quantities nf core sand for recycle.
The presence of potentially hazardous constituents in slags,
Siudges, sands, and dusts has been shown including heavy metal and fluorides.
Solubility tests described in Appendix B of this report indicates that
some of these hazardous constituents may be leached from some wastes.
In general, slags were found to solubilize to a lesser extent than sludges
..,- uusts. Process wastes have been categorized us potentially hazardous
or not hazardous based on the results of the solubility tests and con-
sideration pf physical (i.e. particle size) and chemical properties.
Practices to protect ground and surface waters in the event of
demonstrated significant leaching of potentially hazardous constituents
include the use of lined lagoons for storage or permanent disposal of
sludges. Leachable sludges which are dredged or pumped from lagoons or
settling pits and dumped on land can often be chemically "fixed" so that
leaching of heavy metals is prevented according to fixing chemical manu-
facturers. Alternatively, sealing of soil in disposal areas with bentonite
or other sealants should prevent leachate percolation.
For those slags, dusts, sludges, and or other land-disposed
or stored solid residues shown to, or suspected to solubilize toxic con-
stituents significantly, then soil sealing of disposal or storage areas
would be needed. Collection of runoff from disposal dumps containing slags,
sludges or dusts with leachable heavy metals or other potentially hazardous
constituents may he needed. Collected runoff would require treatment
before discharge or retention and evaporation in lagoons.
Costs lor present and environmentally .nleijuaU1 potentially
hazardous wa , 1 c treatment and disposal are given tor each smelting and
refining category.
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SECTION II
INTRODUCTION
This report is the result of study commissioned by the U.S.
Environmental Protection Agency to assess "Industrial Hazardous Waste
Practices in the Smelting and Refining Industry. Concurrently, the
DSl.l'A is pursuing similar studies of other industry categories. This
program is intended to provide the USEPA with as detailed and pertinent
information on the generation, management, treatment, disposal, and
costs related to wastes considered to be "potentially hazardous."
Such information will be used by the USEPA in developing guidelines or
standards for the management of hazardous wastes.
Throughout this report whenever the terms "hazardous wastes" or
"potentially hazardous wastes" are used, it should be kept in mind that
no final judgements are intended as to such classification. It is
recognized and understood that additional information will be required
as to the actual fate of such materials in a given "disposal" or "manage-
ment" environment before a final definition of "hazardous waste" evolves
and is used. As an example, for certain of the waste streams identified
in this report, the USEPA is currently supporting other studies designed
to investigate leaching characteristics in various soil and moisture con-
di tions.
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SECTION III
FERROUS METAL SMELTING AND REFINING
This section presents the results of investigations and analyses
of on-land disposal or storage of process and pollution control residuals
from the United States ferrous smelting and refining industry including
iron and steel,, iron and steel foundries, ferroalloys and ferrous metals
not elsewhere classified such as metal powders. Characteristics of each
industry sector including plant locations, production capacities and
smelting and refining processes have been identified and described.
Land disposed or stored residuals including slags, dusts, sands
and sludges have been identified and characterized physically and chemically.
State, regional and national estimates have been made of the total quantities
of land disposed or stored residuals and potentially hazardous constituents
thereof for 1974, 1977, and 1983.
Current methods employed by the ferrous metals industry for the
disposal or storage of process and pollution control residuals on land
are described. Principal methods include lagoon storage of sludges and
open dumping of slags, sludges, dusts and sands. Methods of residual treat-
ment and disposal considered suitabls for adequate health and environmental
protection have been provided. Finally, the costs incurred by typical
plants in each primary smelting and refining industry for current and
environmentally sound residual disposal or storage on land have been esti-
mated.
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1.0 IRON AND STEEL
I.i. INDUSTRY CHARACTERIZATION
The United States steel industry is very large. The industry
ranks third in the nation, behind the automotive and petroleum industries,
in the value of its total shipments and, with approximately 487,000
employees, is second only to the automotive industry in the number of
people on the direct payroll. Over the decade since 1962, steel industry
?;.ies have increased 60%, from sales of $14.0 to over $22.0 billion
(.Ref. 1). Steel mills may range from comparatively small plants to
completely integrated steel complexes. Even the smallest of plants will
generally represent a fair sized industrial complex. Because of the
wide product range, the operations will vary with each facility.
Approximately ninety-two per cent of the 1972 total United
States annual steel ingot production was produced by fifteen major steel
corporations. This total also represents 22.5% of the world total of
556,875,000 metric tons (625,000,000 tons). Table 1 presents the pro-
duction breakdown by corporation. Tables 2 and 3 list the number of
si eel plants by state, EPA regional, and national total iron and steel
capacity. The capacity by each of the three major steel producing modes
(i.e. basic oxygen furnace, open hearth furnace, and electric furnace)
nre also given in these tables.
Three basic steps are involved in the production of steel.
First, coal is converted to coke. Second, coke is then combined with
iron ore and limestone and fired in a blast furnace to produce iron.
Third, the iron is purified into steel in either an open hearth or basic
oxygen, or furnaces. Electric furnaces remelt and refine predominantly
scrap iron and steel. Further refinements include degassing by subjecting
the steel to a high vacuum. Molten steel is usually cast into ingot
molds but the use of a process called continous casting is increasing
steadily. These processes are discussed in more detail in Section 1.2.
Coke plants are operated as parts of integrated steel mills to
supply the coke necessary for the production of iron in blast furnaces.
Nearly all coke plants today are byproduct plants, i.e., products such
as coke oven gas, coal tar, crude and refined light oils, ammonium
sulfato, anhydrous ammonia, ammonia liquor, and naphthalene, are produced
in mill it ion to coko. A very smull portion of coke is also produced in
the beehive coke process. A byproduct coke plain consists essentially
of the ovens in which bituminous coal is heated, out of contact with
air, to drive off the volatile components. The residue remaining in the
ovens is coke; the volatile components are recovered and processed in
the byproduct plant to produce tar, light oils, and other materials of
potential value, including coke oven gas.
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Table I
MAJOR UNITED STATES STEE.L INGOT PRODUCERS, 1$?2
Metric Tons/Year Tons/Year
United States Steel 31,750,000 35,000,000
Bethlehem Steel 19,960,000 22,000,000
Republic Steel 9,980,000 11,000,000
National Steel 9,520,000 10,500,000
\rmco Steel 7,710,000 8,500,000
Jones & Laughlin Steel 7,280,000 8,000,000
Inland Steel 6,800,000 7,500,000
Youngstown Sheet 5 Tube 5,440,000 6,000,000
Whrrl iii)'. Pittsburgh 3,540,000 3,900,000
Kiiisor 2,720,000 3,000,000
McLouth 1,819,000 2,000,000
Colorado Fuel fi Iron 1,360,000 1,500,000
Sharon 1,360,000 1,500,000
Interlake 907,000 1,000,000
Alan Wood 907,000 1,000,000
Source: Development Document For Proposed Effluent Limitations Guidelines
For the Steel Making Segment of the Iron and Steel Manufacturing
Point Source Category, U.S. Environmental Protection Agency,
February, 1974.
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TABLE 2
ESTIMATED STATE DISTRIBUTION OF UNITED STATES IRON AND STEEL PLANTS
AND PRODUCTION CAPACITY, 1974 (METRIC TONS)
;t,'.te
>\1 abawa
Ari?.ona
Ark insas
Cr' 1 } fornia
Colorado
Connecticut
Delaware
Florida
Gf-irgia
i.'-i /'.',; i
risiuis
Indiana
Kentucky
Maryland
Michigan
Minnesota
Mi ssi ssippi
Missouri
New Jersey
New York
North Carolina
Ohio
Oklahoma
Oregon
Pennsylvania
South Carolina
Tennessee
Texas
Utah
Virginia
West Virginia
Washington
Totals
No. of
Plants
5
1
1
10
1
1
1
2
1
1
16
8
4
3
5
1
1
1
2
7
2
20
1
2
42
1
->
9
1
1
2
3
158
list i mated Iron
Capacity (Blast
Furnace)
5,208,500
0
0
2,194,300
938,800
0
0
0
0
0
6,906,700
15,977,300
1,039,700
5,558,500
7,815,600
0
0
0
0
4,807,600
0
17,181,100
0
0
21,179,600
0
0
634,100
1,779,500
0
3,106,302
0
94,327,600
Estimated Steel Capacity
Basic Oxygerf Open Hearth
Furnace
2,656,700
0
0
1,600,400
1,066,900
0
0
0
0
0
7,261,500
15,239,100
1,717,900
2,528,700
8,830,800
0
0
0
0
5,469,200
0
11,213,800
0
0
15,224,000
0
0
0
0
0
4,062,200
0
76,871,200
Furnace
1,024,000
0
0
1,904,700
0
0
0
0
0
0
841,800
5,790,500
0
2,729,800
0
0
0
0
0
0
0
8,881,300
0
»
11,932,400
0
0
1,160,600
2,483,300
0
0
0
36,748,400
Electric
Furnace
601,800
82,500
57,800
674,400
165,000
234,400
524,700
257,600
302,000
20,600
4,427,000
1,013,200
790,400
343,700
1,382,400
209,900
72,800
961,900
453,000
503,900
213,200
4,642,700
244,800
301,300
4,500,500
346,400
122,000
2,832,200
0
71,100
106,600
536,600
26,996,400
fist inu-u od
Total Steel
Capacit»
4,282,5u;!
82,500
57,800
4, 179, SOU
1,231,900
234,401'
524,700
257,600
502,000
20,600
12,530,300
22,042,800
2,508,300
5,602,200
10,213^200
209,900
72,800
961,900
453,000
5,973,100
213,200
24,737,800
244,800
301,300
31,656,900
346,400
122,000
3,992,800
2,483,300
71,100
4,168,800
536,600
140,616,000
Source; Iron and Steal Works Directory
of the United States and Canada, Iron and
Steel Institute, 1974.
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TABLE 3
EPA REGIONAL DISTRIBUTION OF U.S. IRON AND STEEL PLANTS
AND PRODUCTION CAPACITY, 1974 (METRIC TONS)
SPA No. of Estimated Iron Estimated Steel Capacity Estimated
Region Plants Capacity (Blast Basic Oxygen Open Hearth Electric Total Steel
Furnace) Furnace (EOF) Furnace Capacity
I
II
ill
IV
V
VI
VII
VIII
IX
X
1
10
48
18
50
11
1
2
12
5
0
4,807,600
29,844,400
6,248,200
47,880,700
634,100
0
2,718,300
2,194,300
0
0
5,469,200
21,814,900
4,374,700
42,545,200
0
0
1,066,900
1,600,400
0
0
0
14,662,200
1,024,000
15,513,500
1,160,600
0
2,483,300
1,904,700
0
234,400
1,481,500
5,021,900
2,706,200
11,675,100
3,134,800
961,900
165,100
777,600
837,900
234,400
6,950,700
41,499,000
8,104,900
69,733,800
4,295,400
961,900
3,715,300
4,282,700
837, 90t
158 94,327,600 76,871,300 36,748,300 26,996,400 140,616,000
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] 2 WASTE CHARACTERIZATION
This section contains descriptions of production technology at
iron and steel plants and the resultant byproducts or wastes which are
«, ithrr recycled, handled by contract disposers, or disposed of on site.
Estimates are given for the quantities of wastes and potentially hazardous
constituents thereof which are disposed of on land, either in lagoons or
dumps.
1.2.1 Process Descriptions
Integrated steel mills perform all the operations required to
convert the principal raw materials of iron ore, limestone, and coal
into finished steel products. The principal operations consist of raw
material processing, iron making, steel making, primary rolling or
roughing, and hot and cold finishing. Additional operations might
include forging, annealing, tempering, tin plating and galvanizing. The
interrelationships between the operations carried out in a typical large
integrated steel plant are shown in the flow diagram of Figure 1.
Smaller plants might lack the facilities for some of the operations
;hown, such as sintering, continuous casting, tin plating and galvanizing.
The major operations are described in the following paragraphs.
Sintering. The sintering operation takes natural fine iron
ores and metallic fines derived from residues of other steel plant faci-
lities (e.g., flue dust from the blast furnace and scale from hot rolling
mills) and fuses them into pieces large enough to be charged into the
blast furnaces. In a typical sintering machine the fine material is
mixed with coke breeze or powdered coal and spread on a moving bed. The
mixture is ignited as it passes under an intense flame. The reaction is
sustained by the combustion of the coke or coal as air is drawn downward
through the bed. At combustion temperatures, the particles fuse together
into n caked layer which is usually quenched with air and broken into
pieces of the desired size. Particulates collected by one or more of a
variety of emission control systems are generally recycled back into the
sintering process. Therefore, no significant amounts of wastes are
generated at sintering plants.
Coke .uid Byprodui 1 Product ion. I'okr MTVI'S both .is a t'uol
and as a reducing agent in the making of iron. To produce the required
coke, bituminous coal is heated to drive off Uiu volalile components.
Two methods of producing metallurgical coke are in use today, the byproduct
method and the beehive process, although the beehive process accounts
for less than two percent of all metallurgical coke produced.
In the beehive process, the volatile components are burned
through the addition of control Jud amounts of .11 r into the- coking chambers.
The heat generated by burning of the combustible volatilcs provides
energy for maintaining the distillation process.
10
-------
mi'»..., cc I«I«H'I
SLUDGE TO DUMP
10.1 kg
NUMERICAL VALUES ARE
KILOGRAMS OF WASTE PER
METRIC TON OF STEEL PRODUCT
Figure 1 FLOW DIAGRAM FOR STEEL MAKING
11
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In the byproduct process, no air is admittea , o the coking
chambers, the heat for distillation being provided by the combustior, - *
rue, gas in contact with the walls of the coke ovens. The volatile^
dri/en off during distillation are piped from the coke ovens and processed
fer recovery of useful byproducts. After coking is completed (16 to 24
r'n.-rs), the hot coke is pushed from the ovens into a waiting car which
transfers it to a quenching tower where it is cooled by water sprays.
Iron and Steel Making. In iron and steel making, fluxes are
I'.ilc'ed which combine with impurities to form slag Fluxes include lime-
stone, lime, dolomite, und fluorspar. Linn.- is often made onsite at the
steel plant by the calcination of 1imestono. The dusts meliorated in tho
required crushing, screening, and handling of tho matorinls are generally
collected and recycled.
i Blast Furnace. Almost all of the b;
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All three furnaces use limestone and/or fluorspar fluxes to facilitate
the removal of impurities as slag.
For control of emissions from basic oxygen furnaces, the use
of high energy wet scrubbers appears to be predominant. Of the ton
steel plants visited during this program, seven plants had EOF furnaces;
and of these plants, six were controlled by wet scrubbers. One plant
used a dry electrostatic precipitator preceded by a wet spray system for
gas cooling.
Five of the plants visited had electric furnaces. Three of
these plants used dry baghouses for dust collection. The other two used
a wet scrubber followed by a clarifier and vacuum filter for handling
the scrubber water.
Four of the plants had open hearth furnaces and, in all cases,
emission control was handled by dry electrostatic precipitators.
Thus, wastes from steel making consist of slag for all furnace
types, and dusts and/or sludges, depending on the type of furnace and
the associated emission control system. For BOF furnaces, sludges
appear to be the most common form of pollution control waste, while for
electric furnaces and open hearths dry dust appears to be most common.
In addition to the above wastes, particulates called "kish" are released
to the air during the pouring of the molten pig iron. In BOF shops,
thi^ material is commonly collected in baghouses.
Ingot Molding and Rolling. Molten steel is tapped from the
steel making furnaces into teeming ladles and then transferred to a
teeming area or to a continous casting area. In the teeming area, the
molten steel is poured into ingot molds. Upon solidification, the
ingots are placed in soaking pits to bring them to the desired uniform
temperature. They are then rolled into billets, blooms, or slabs which
are blocks having different shapes and weights. Wastes consist of slag
that accumulated at the bottoms of the soaking pits, scale generated in
the rolling operations and sludges from treatment of scale pit water.
Continous Casting. In continous casting, the molten steel in the
teeming ladles is cast directly into billets, blooms, or slabs, thereby
eliminating the need for ingot molds, soaking pits and primary rolling
described in the next paragraph. As the castings leave the molds, they
are sprayed with cooling water. As a result of coming in direct contact
with the steel, this water contains fine scale that is removed as sludge
during treatment of the water. Coarser scale accumulates in settling nits.
Rolling. The billets, blooms, and slabs formed in the roughing
mill or in the continous caster are sent to the hot rolling mills where
they are converted into a wide variety of finished or semi-finished products,
including bars, rods, tubes, rails, structured shapes, sheets, and plates.
These hot rolling operations produce scale which is collected in pits.
Sometimes surface defects in billets, blooms and slabs are removed prior
13
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tu r>/:ijr.|> !-v automatic or hand scarfing, an operation h; which exygei !er
,itc .-.'.-.* ' '';.%cted at the surface. Grinding and chipping are also u-,e'ht of steel produced will vary.
14
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TABU; 4 - PRODUCTION DATA FOR TYPICAL INTEGRATED STEEL PLANT
Hue a 1j ty
Coke Ovens
Blast Furnaces
Basic Oxygen Furnaces
1! lee trie Furnaces
Soaking Pits
Primary Mi 11s
Cuntinuous Caster
lloi Rol linj; Mills
Cold Hoi 1 i UK Mi I I".
Tin Plat inn Mi I 1
Ca 1 vaiii -ing Mill
Product
Coke
Iron
Steel
Steel
Steel Ingots
Billets, Blooms, Slabs
Billets, Blooms, Slabs
Sheet Steel, Bars, Rods
Structural Shapes, etc.
Sheet Steel
Tin Plated Sheets
Zinc Coated Sheets
Annual Amounts (Metric tons)
1,120,000
1,600,000
2,000,000
500,000
1,560,000
1,350,000
790,000
1,800,000
700,000
100,000
125,000
15
-------
I.::. : DL sc > Ljpjtioji of Waste Streams
'I'h'r-- section describes the typos (if wastes associated with
«.-:.(!', ct t>*,' ste<--l making processes previous I v described. Generation
factors for each type of wastes are given as well as an assessment of
their potential environmental hazard.
-""i"' iJiid Byproduct Plants. Wastes generated rcom coke and byproduct
cuke plants include waste ammonia liquor, ammonia still lime sludge and
decant or tank tar. The relative amounts of t.'.ese wastes will vary
considerably from plant to plant depending on the specific design of the
byproduct recovery plant.
W.'istc Ammoiua_ Li quor. Ammonia is recovered from coke gas by
one of two methods. In some plants ammonia is recovered in the form of
ammonium sulfate by passing the coke gas through dilute sulfuric acid.
'liii:-, produces a waste ammonia liquor generated at a rate of 190 kg/MT of
coke- produced or 125 kg/MT of steel produced based on the use of 0.66 MT
of c.oke for 1 ton of steel. Waste ammonia liquor contains significant
con.c entrations of phenol and cyanide and is therefore considered potentially
hazardous.
Ammonia Still Lime Sludge. At other plants ammonia is removed
initially from the coke oven gas by spray cooling and scrubbing and sold
as a concentrated ammonia liquor. Concentration of the liquor is achieved
in a ammonia still which produces a waste lime sludge formed as a result
of adding milk of lime to decompose ammonium salts. Ammonia still lime
sludge along with decanter tank tar to be described is generated at a
rate of 0.28 kg/MT of finished steel product (dry weight). This sludge
will contain significant concentrations of cyanide, phenol, and oils and
greases. In solubility tests described in Appendix B ammonia still lime
sludge was found to leach significant concentrations of phenol and
cyanide (198 ppm Cn, 20 ppm phenol). It is therefore considered potentially
hazardous.
Decanter Tank Tar. The spray cooling of coke oven gases also
condenses tars which are sent to a decanter tank where lighter recoverable
oil fractions are decanted off. The heavier tar goal-rated at a rate of
.'.3 kf,/MT steel along with ammoni.i still lime ;.lndi;c is ^ent to open
dumps. In solubility tests described in Appendix B de-cantur tank tar
was found to leach significant concentrations of phenol (500 ppm) and
oil and grease (198 ppm) and is therefore considered potentially hazardous.
Wastes generated from iron and steel making include slags,
sludges and dusts. The quantities and nature M" these residuals are
described in the following paragraphs as well as an assessment of their
hazardousness or non-hazardousness.
Blast Furnace. Residuals from blast furnace processing of iron ore to
produce molten iron metal include slag, dus;s from dry air emissions
controls or sludge from wet air emissions controls.
16
-------
Slu£. Blast furnace slag is generated at a rate of 348 kg/MT
of iron outjnit from the blast furnace or 250 kg/MT of finished stool.
It is normally granulated by quenching the molten slap, with water. This
produces sand size to large chunks of a hard vesicular slug containing
predominantly silica, lime, iron, sulfur and traces of minor metals
including chromium, manganese, lead, copper and zinc. In solubility
tests described in Appendix B blast furnace slag did not leach toxic
constituents in significant concentrations and is therefore not con-
sidered potentially hazardous.
Oust. Dust from dry emissions controls on blast furnaces
including baghouses and electrostatic precipitators is predominantly
iron oxide, silica and lime but contains significant concentrations of
chromium, copper, manganese, nickel, lead and zinc. Concentrations of
these metals is significantly higher in dusts than in slag. It is
generated at a rate of 16.2 kg/MT of blast furnace iron output or 11.7
kg/MT of steel product. In solubility tests described in Appendix B
blast furnace dust did not leach toxic heavy metals significantly and is
therefore not considered potentially hazardous at this time.
S ludge. Sludge from wet emissions controls on blast furnaces
including wet electrostatic precipitators, venturi scrubbers, and spray
towers is also predominantly iron oxide, silica and lime and contains
significant concentrations of the trace metals chromium, copper, manganese,
nickel, lead and zinc. Concentrations of these metals is significantly
higher in sludges than in slags. It is generated at a rate of 24.4 kg
per metric ton of blast furnace iron output or 17.6 kg/MT of steel (dry
weights] . In solubility tests described in Appendix B blast furnace
sludge was not found to leach toxic constituents in significant concentrations
and is therefore not considered a potentially hazardous waste.
Basic Oxygen Furnace (BOF) . Residuals from BOF processing of iron,
scrap and alloying metals to produce steel while reducing carbon sulfur,
phosphorus and other impurities, include slag, dusts and sludges.
A dense slag containing large amounts of silica, iron and
lime, minor amounts of sulfur and phosphorus and significant concentrations
of the trace metals chromium, copper, manganese, nickel, lead and zinc is
generated at a rate of 145 kg/MT of steel output. In solubility tests des-
cribed in Appendix B blast furnace slag was not found to leach significant
concentrations of toxic constituents and is therefore not considered poten-
tially hazardous.
I)i£st. Fine dust from dry air emissions controls is mainly iron
oxide, silica oxide and lime but also contains significant concentrations
of trace metals including chrome, copper, manganese, nickel, lead and zinc.
Dust is generated at a rate of 16 kg/NTT of steel product. Data indicates
zinc and lead are more concentrated in dusts and sludges whereas chrome
tends to stay with slag. In solubility tests described in Appendix B
BOF sludge did not leach appreciable concentrations of toxic constituents.
The low solubility of BOF sludge indicates that dust will also not leach
17
-------
r icai'.tiv, Por this reason BOF dust is not considered potentially
dous at this time.
Sludgj.;. Sludge from wet control of air emissions from BOF's
is a]so predominantly iron oxides, silica oxide and lime with small but
significant concentrations of the trace metals r.hrome, copper, manganese,
iK'kel, lead and zinc. It is generated at a rate of 17.3 kg/MT of steel
,,-roJuct (dry weight). In solubility tests described in Appendix B BOF
sludge did not leach significant concentrations of toxic constituents
and is therefore not considered potentially hazardous at this time.
Open Hearth Furnaces. Residuals generated from open hearth furnaces
include slag, dusts and sludges.
Slaji- A dense, hard slag is generated at a rate of 243 kg/NTT
of sti'ol product.. It is mainly iron oxides, silica oxide and lime, with
minor amounts of sulfur and phosphorus compounds. Trace metals present
in significant concentrations include chromium, copper, manganese,
nickel, lead and zinc. In solubility tests described in Appendix B
toxic constituents did not leach to a significant extent. Open hearth
slag Is therefore not considered hazardous at this time.
Dust. Dust from dry emissions control is generated at a rate
of 13.7 kg/MT of steel product. It is predominantly iron oxides, silica
oxides and lime but contains significant concentrations of chrome,
copper, manganese, nickel, lead and zinc. As with BOF furnaces data
indicates that lead zinc, and to a lesser extent copper concentrate to a
greater extent in dusts whereas chrome stays with the slag. Solubility
tests described in Appendix B showed no appreciable leaching of toxic
constituents. For this reason open hearth dust is not considered potentially
hazardous at this time.
Sludge. None of the plants visited or surveyed during this
study used wet emissions controls on open hearth furnaces. Thus no
generation factors could be developed or chemical analyses made. The
sludge would be similar in composition to dust and would not be expected
to leach significantly so as to be considered hazardous.
I-ledric Furnaces. Residuals from electric furnaces include slag, dust
and sludge.
Slag. A dense hard slag is generated at a rate of 120 kg/NfT
of steel. It is composed principally of iron, silica and calcium compounds
with minor amounts of sulfur and phosphorus compounds. Trace metals
include chromium, copper, manganese, nickel, lead, and zinc. In solubility
tests described in Appendix B toxic constituents did not leach significantly.
Electric furnace slag is therefore considered non-hazardous at the
present time.
18
-------
Dust from dry emissions controls is generated at a
rate of 1J.K kg/Ml' of steel. It is principally iron and silica oxides
;nid lime witli significant concentrations of the trace metals chromium,
copper, manganese, nickel, lead, and zinc. Zinc, lead and copper are
much more concentrated in dusts and sludges than in slag. In solubility
tests described in Appendix B lead was found to leach at appreciable
concentrations (150 ppm). Electric furnace dust is therefore considered
potentially hazardous.
Sjudge. Sludge from wet emissions controls is generated at a
rate of 8.7 kg/MT of steel product. It is comprised principally of iron
and silica oxides and lime and contains significant concentrations of
the trace metals chromium, copper, manganese, nickel, lead and zinc. In
solubility tests described in Appendix B electric furnace sludge leached
chromium (94 ppm) and lead (2.0 ppm) in significant concentrations.
Floctric furnace sludge is therefore considered potentially hazardous at
this time.
Soaking Pits. Soaking pit slag of gravel to boulder size is generated
at a rate of 35.2 kg/MT of steel. It is composed principally of iron
and contains significant concentrations of trace metals including
chromium, copper, manganese, nickel, lead and zinc. In solubility tests
described in Appendix B this slag did not leach significant concentrations
of toxic metals. It is therefore considered non-hazardous at this time.
Mill Sludges. Mill sludges are produced from a number of steel plant
facilities as a result of water pollution control operations,, Generation
factors for various mill sludges are as follows:
Primary Mills (production of ingots, slabs, billets 1.87 kg/MT steel
Continuous Casting Mill - 0.104 kg/MT steel
Hot Rolling Mill - 1.74 kg/MT steel
Cold Rolling Mill - O.lb kg/MT steel
Tin Plating Mill - 5.32 kg/MT steel
Galvanizing Mill 10.8 kg/MT steel
Samples of two of the above types of sludges were obtained and
chemically analyzed including hot rolling mill sludge and tin plating
mill sludge. Both of these sludges contained significant concentrations
of trace metals including chromium, copper, manganese, nickel, lead,
zinc and oil and grease.
Solubility tests were not conducted on mill sludges. They are
believed to be susceptible to leaching of oil and grease and quite
possibly some toxic metals because of the presence of these constituents
and fine size of sludge particulates.
19
-------
Mi]_.' bj._j_Lf.-s Mill scales containing over 50% iron are generated froti*
the L\,[ Lowing mi 1 Is :
Primary Mills 44.9 kg/MT steel
Continuous Casting Mills 8.7 kg/MT steel
Mot Rolling Mills 18.3 kg/Ml1 steel
Cold Rolling Mills 0.052 kg/Ml steej
Mill scales contain over 50% iron a& well as small but significant
concentrations of trace metals including chromium, copper, manganese,
nickel, lead and zinc. Mill scales can also contain as much as 0.4% oil
and grease. Oil and grease can be leached from mill scale and pose a
threat of ground water contamination. For this reason mill scales are
considered potentially hazardous at this time.
l'k-klo_ I,iq_uors. Acid pickle liquors (HOI, H~SO.) are used in cold
rolling mills and galvanising mills to clean iron and steel metal surfaces.
Spent uc ul is generated at a rate of 22.8 kg/MT steel from cold rolling
mills and S.17 kg/MT steel from galvanizing mills. Waste pickle liquor
lontains about 4-bl, acidity and large concentrations of dissolved and
.uibponded iron. Chromium, copper, nickel, lead and zinc are also present
in minor concentration (less than 20 ppm). The high acidity (pH less
th;'n 1.0) of waste pickle liquor and resultant solubilization of toxic
metal constituents are reasons why waste pickle liquor is considered
potentially hazardous.
1.2.3 Waste Quantities
During the conduct of this study, intensive sampling and
chemical analyses .of steel plant residuals were carried out. Ten steel
plants located in the North Central and Great Lakes region of the United
States provided personnel to obtain daily samples of steel plant production
and pollution control residuals, including slags, sludges, dusts, scales,
and pickle liquor. These samples were shipped to the Calspan Laboratory
at Buffalo, New York, where the daily samples were composited into
weekly samples and then chemically analyzed. Steel plant residuals were
therefore well characterized as to average chemical content and variability
in composition. Results of chemical analyses from the ten steel plants
are given in Appendix A.
Table 5 gives generation factors for the various residuals
from iron and steel production as well as concentration factors for
potentially hazardous constituents. These factors were computed by
averaging aii available data collected from the 10 iron and steel plants
visited on generation rates and chemical analyses data from collected
residuals samples of slacs, sludges, dusts and other wastes.
Using the residuals generation factors given in Table 5 the
yearly amount of residuals generated from a typical integrated steel
plant producing 2,500,000 MT of molten steel as described in Table 4
were estimated. Quantities of potentially hazardous constituents were
also calculated for the typical integrated plant. These estimates are
given in Table 6. 20
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24
-------
Using state-by-state production capacities as previously given
and waste generation and hazardous constituent factors per unit of
product as previously given in Table 5 estimates were made of the state,
regional, and national land-disposed wastes and hazardous constituents
from iron and steel production. These estimates are given in Tables 7a
to 71 for 1974, 1977 and 1983. E-xtrapolations of waste quantities to
1977 and 1983 were based on an annual growth rate of the steel industry
(and accompanying residuals generation) of 2.1% from 1974-1977 and 2.5%
from 1974 to 1977. This compares with annual growth of 2.5% predicted
by the industry over the same period (Reference 9).
Tables 7a to 7e contain estimates of the total quantity of
slags from all sources (blast furnace, BOF, open hearth, electric furnaces,
soafcjng pit) which are or which will be generated in the iron and steel
industry in 1974, 1977, and 1983. Although practices may vary widely
from plant to plant it is estimated that approximately 90% of generated
slag is processed for recovery of contained iron and steel and then sold
for use as road fill building aggregate and other purposes. It may be
stored for many months before use. The remainder is open dumped.
Tables 7d through 7f gives estimates of sludges generated from
all sources in the iron and steel industry for the years 1974, 1977, and
1983. Approximately 55 percent of the total sludge generation originates
from wet scrubbers of the blast furnace and is considered non-hazardous.
Approximately 70% of blast furnace sludge is recycled to the sinter strand
for recovery of iron.
Approximately 20% of the sludge estimated in Tables 7a to 7c
originates from wet emissions controls on BOF furnaces, 10% of which is
recycled to sinter strands. In total some 75% of estimated sludge
generated is from blast furnaces plus BOF furnaces and is not considered
potentially hazardous.
The remaining 25% of the sludge estimates given in Tables 7d
through 7f consists of sludges from electric furnaces, galvanizing mills,
primary and secondary rolling mills, lime pit sludges, and tin mill
sludges. These sludges are considered potentially hazardous.
Tables 7g through 7i contain estimates of the total quantities
of dust generated by the iron and steel industry for 1974, 1977 and 1983
through dry emissions controls on blast furnaces. Approximately 57% of
the state, regional and national estimates consists of blast furnace
dust. Approximately 90% of blast furnace dust is recycled to the sinter
for iron reclamation with the remainder being placed on land dumps.
Blast furnace dust is not considered potentially hazardous.
Approximately 12% of the dust generated in the iron and steel
industry is from electric furnaces and is considered potentially hazard-
ous. Electric furnace dust is not presently recycled. The remaining 31%
of the dust quantity estimates given in Tables 7g through 7i consist
predominantly of BOF dust with a small percentage of open hearth dust.
BOF dust and open hearth dust are not considered potentially hazardous.
2.S
-------
Tables 7j through 71 contain estimates of quantities of scalt
.-atod i" tin' iron aod steel industry from hot rolling mill, cold
rolling mills, primary mills, and continuous casting mills. It is esti-
mated tli.it MO'i of mill sealos uro recycled for roclumat ton of iron
co i, int. The presence of high contents of oil and grease prevents
complete recycle, and for the same reason causes mill scales to be a
danger to the environment, and be considered potentially hazardous.
Tables 7m through 7o contain estimates of the quantities of
spe.it pickle liquor (dilute solutions of sulfuric or hydrochloric acid
containing iron oxide and iron metal particles and traces of other
metals) generated in the iron and steel industry. They are normally
disposed of by contract disposal services but may be regenerated for
reuse. Pickling liquors are considered potentially hazardous.
Generation of slags, sludges, and dusts follows production
patterns. The largest producers of total iron and steel residuals and
potentially hazardous wastes from the iron and steel industry are the
states of Pennsylvania, Ohio, and Indiana followed by Illinois, Michigan
and New York in that order. Alabama, West Virginia, California, and
Utah aiso generate significant quantities of total and hazardous wastes.
1.3 TREATMENT DISPOSAL TECHNOLOGY
1.3.1. Current Treatment and Disposal Practices
This section will describe the prevalent methods used by the
iron and steel industry for the treatment and disposal of all waste
types be they considered hazardous or non-hazardous. Sections 1.3,2
through 1.3.4 will present more detailed discussions of the technologies
used to treat and/or dispose of those waste streams which are considered
to be potentially hazardous. Waste types are discussed with reference
to the plant facilities from which they originate.
Coke Plant. Land disposed wastes from the coke plant of an integrated
steel facility includes waste ammonia liquor, anunonia still lime sludge
and decanter tank tar. All of these wastes are considered potentially
hazardous because of the presence of phenols, and cyanides which are
susceptible to leaching. The ususal treatment of waste ammonia liquor
is input to biological waste-water treatment plants. This is environ-
mentally acceptable since the toxic constituents (phenol, cyanide) will
be detoxified in the bjologicul treatment. Sonietimcs this waste is dis-
posed of in deep wells.
Ammonia still lime '.ludge and decanter tank tar are normally
disposed of by open dumping which is not environmentally acceptable
because of the suspei ti li i1ity ID leaching of phenol, cyanide and oils.
Blast Furnace. Residuals from blast furnaces include slag, dust from
dry emissions control, or sludge from wet emissions controls. Slag is
usually processed for recovery of iron metal before sale as road fill,
26
-------
Table 7a
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL INDUSTRY
TOTAL SLAG, 1974 (METRIC TONS)
STATfc
A1ABAMA
ARIZONA
ARKANSAS
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
HAWAII
ILL INOIX
INDIANA
Kl NTUCKY
MARYLAND
MICHIGAN
MINNESOTA
MISSISSIPPI
MISSOURI
Nl w Jf nSI V
Nrw YelMK
N < AtllM INA
OHIO
UKIAHOMA
OHtUON
HINMSVll-AMIA
S CAROLINA
TENNESSEE
TEXAS
UTAH
VIRGINIA
WASHINGTON
W VIRGINIA
EPA REGION
1
u
m
or
y
m
EH
an
IX
z
NA1IONAL rUTAtl
TOTAt
GENERATED
?.1
823(6
219625
2 70697
12131
4206
568 12
26468
1.46/89
I2J23
10.446 10
141 M
17796
1301020
20024
70.66
2,362.61
1.4(3 99
41.97
31690
90453
13641
1.73266
16.689 53
3.156 M
25 188 16
2,537.60
56(12
1.60967
1 926 91
49496
64 71 J 76
Cu
110.96
159
056
W.91
2516
4.43
744
244
570
0.20
2t>060
44(90
4444
14229
206 79
199
009
1916
042
12241
2112
bM32
2 J2
669
700 38
in
1 16
83.27
6746
1.34
1013
6732
443
12M1
(1(77
170*9
1.46250
(6.14
1816
9260
»188
16 U
}.(*(]
CONSTITUENT!
F
8J0948
20.21
14 14
3,6(1.06
1J66U
5737
12644
6306
739]
608
10,159 10
22*6800
1.M440
6.463 46
10.431 90
61.31
1781
23647
110(9
6.3M (1
n2 19
2 1 JJb 00
59*9
7376
29.99000
MM
29 .a«
1.747.63
2.4(687
1740
13136
4,401.99
67.37
6.467.60
40.091.30
7.6(666
66.535.38
1421 72
23547
3.743 75
3.10631
90611
!!>.» 4«
Mn
36.521.46
516-06
360.52
36,496.00
§,63732
1.4(422
3,231 34
1^6351
136692
125.76
66.75(10
178.1(000
16.64720
62.469 10
71.63730
1.27383
441 66
(.009(6
2799M
42 1 II 40
\njat
211) 1U UU
1.4(6X1
1.H246
270,446 00
2.102(0
740.90
30,(06«
2(.0>1.»
444.01
3.36233
26,36] 20
1.4(422
44.921.13
366.43366
61.1B7.96
649,9«0^3
32/445.27
6.009.65
36.71S62
J7. 137 31
6.2M78
I.IJ09J27
Nl
46.24
OJ7
037
3916
10.26
2.44
4.43
1.67
3.14
0.13
111.69
112.12
19/9
5676
(6 17
1.36
047
1001
3.M
4900
1 M
73(17
11M
1.13
2M43
2.24
0.7*
UM
Z6J3
0.74
5M
26.12
244
5242
I4W.46
7473
(18J1
44.33
1001
39.1*
4016
(71
i.tntt
i*
172.51
2.49
0-23
14C.06
41.17
(M
IM
1.01
894
0.01
401.41
711,97
71J4
2J744
341M
OJ2
0.2»
2644
7.M
200(6
DM
9366
096
(M
1,141.38
1.36
0.41
1J4J6
11X06
2.10
15«
MJ3
(44
20145
M7U6
2S7J7
2J49.M
136.76
2846
15423
160.62
MM
4.7W.H
Zn
47.69
0*1
OJU
4646
»2S
273
539
2A9
3i2
0.20
111J7
IM.»
1(11
6601
nx»
2.03
070
1172
4.»
4340
206
2/0 IK
217
361
33(42
3.36
1 18
MM
MM
04]
(21
24.59
2.73
4(23
43744
(0.06
(MM
53.61
1122
4(31
4766
77
I.JM.47
90* Of ILAO II PROM ((CO FOH fllCOVEHY OP ME IAILICI ANO THIN (OLD FOH UM Al NOAO I III, ITC
HEMAINDiK II LAND DIIPOWO. AMD/OH KMD Al 'LUX 61ACI6 'ROM HI AIT FURNACES. OPEN HIARTH
FUHNACFS. BASIC OXVUFN FURNACES, EltCTHIC ruRNACI S AND SOAKING PITY NOT CONIIDINID
HA/AHOOU5ON THE BASH Of CALSPANfOLtyiNtir V rlSTS UfSCHIftffJ IN AfPINOIX B
SOURCE CALSfAN CORPORATION
27
-------
Table 7b
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL INDUSTRY
TOTAL SLAG, 1977 (METRIC TONS)
1
ilAlt
ALABAMA
ARIZONA
ARKANSAS
CALIFORNIA
COLORADO
CONNECTICUT
DE'-AvVAPE
H-ORICiA
GEORGIA
HAWAII
ILLINOIS
INDIANA
KENTu/CKV
MARYLAND
MICHIGAN
MINM SOT A
MIMIII.MPPI
MISIHItJMI
Ntw ji iiar v
Nt W /Ot00
10.627.300
929000
J 304.500
4 781,900
/it /M
« <"i(t
IMlHfJf)
Ml 7 Ml
Ittti 1100
It 120
1 1 /« 1 .000
31,160
49.120
14.875,600
NA
44.060
15330
1.016,100
1,386.900
11,690
87,470
1.8 75,900
38,200
2,967,730
20,223.620
3.833 Uf,
31 90(1 400
1 0/4 fUO
166.800
l.Dfi/ JIJO
1 IV 1 146
136690
64 1W 860
TOTAL
POTiNTIALLY
HA2AHOOUI
1
KHAL
HA2AHDOUS
CONITiruENTS
OIIPOHAL*
METHOD
SOLO AS
ROAD BASE
OR
BUILDING
10GHEGATE
on
OPEN
DUMPED
I
tUNSTITtftNTS
C*
1.60681
51 70
3638
1.977 11
14537
14672
32497
19783
1B907
1264
4,94106
7.68664
87299
2,640 03
2.869 39
12859
4468
60221
290 6«
1.66696
11062
11,07287
16003
16863
13,79081
NA
21226
7479
2 6O444
1,57288
4449
33691
966 10
14672
1.83661
17.659 10
3.34796
26.669 4>
266986
bUJ 21
1 918 2b
2.041 45
524 M
67.466 03
Cu
11/62
1 67
066
9631
2366
4 W
7H'j
26B
606
021
266 6J
47361
47 11
16082
22112
2 II
0 71
Itt /s
AIM
12U n
2 14
68758
246
603
74241
NA
348
123
9827
71 50
142
1074
7136
4 69
13666
97390
18095
166026
91 11
19 76
M n.
97 19
1677
3 1M03
f
5.691 66
2142
14 99
3,795 91
1,312 29
6081
l-lh 14
06.H4
/B j;
fi 16
10 76H 66
23.911 69
200806
6.64069
11.05781
M 4(1
Mn
38.71250
647 01
37155
38,68687
9.1665C
1,65207
4,426 21
1.667 J?
2.000 14
132 7H
94.08147
188,87080
17 64603
5,&66 t>6
769)654
1 35026
lit Htl Jliil 15
749 6«
II7M
6.736 01
6612
24.736 10
6366
7816
31.71972
NA
6989
3167
1,862 46
2,63606
1844
13923
4,66610
6081
6866 56
43,461 OS
604068
70.62; 71
1.931 03
74ti6o
1 ***NI 37
3.822 69
21741
139.12494
6 17(144
2 U67 11
44.66U 21
1.371 W
222.71976
1,67553
1,99640
286,674.90
NA
2,22882
785 35
32.444 90
29.766 18
470.66
3.S63 47
30 592 27
1,66207
47,61639
376 759 69
64,86» 93
'*82.&f>7 H6
34 391 38
h 1/044
JM y/1 74
19.366 «6
5,64887
1.19M643
Ni
48.01
0.92
040
41.61
10.67
2.66
469
1 77
333
0 14
11(29
193.25
2094
6228
9026
1 44
0541
10 61
406
S1H3
146
J6207
168
333
31633
HA
238
084
4491'
30 66
078
592
2768
268
5598
411 76
7923
66£93
47 00
1061
4! 6J
4257
924
1,36643
Pfc
18266
264
074
1H.93
43.64
7.16
932
107
48
008
42570
L_ Z"
5045
102
0.59
49 J7
9.10
290
693
264
171
OJI
12018
75469 20786
7616
241 51
36206
067
030
1019
8.06
212.61
089
94711
1.02
«4«
1.208,86
NA
1 44
061
142.66
119,84
2.23
1684
102 84
735
22096
1.66656
27271
1,490 «
14392
30 18
16348
159 W
2630
6.060. 75
2031
7209
8148
2,6
ll 76
1189
6.12
4601
216
28692
251
373
355.15
NA
355
1-26
5172
41.41
038
061
2607
2.90
51 13
46412
64.86
6*861
6682
nee
61 21
6040
4.36
1/4 7640
DISPOSAL PRACTICE FOR 1977 IS I XPfCTFO 1O BE £SSENTtAl t V THl SAMt AS CURfUNT PflAcriCf
(SI I 19Jl 11 AH 1ABLD IN< t HUM Si ALS I MOM HI AM I UMNAt I S Ol'l N HEARTH PIMNACFS HAJIO
oxvutN fUHNAcil, ei KIRK; f UHNACIS ANOSOAKIWQ PITS ILAUCONKOPHFPNON HA/ANDOU*.
ON MJtii "' CAI HP AN *r
-------
Table 7c
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL INDUSTRY
TOTAL SLAG, 1983 (METRIC TONS)
I I
STATE TOIALt
GFNEHATEO
ALABAMA 3.279.800
AHI/ONA
ARKANSAS
CALIFORNIA
COL 1>M ADO
CONNECTICUT
DELAWARE
HOHIOA
tifOHGiA
HAWAII
ILLINOIS
INDIANA
KENTUCKY
MAflVLAND
MICHIGAN
MINNESOTA
MISSISSIPPI
MISSOURI
NtW JE HSEY
NIW VOMK
N i.AHUHNA
OHIO
OKI AHOMA
OHMiON
I't NNftYl VANIA
HHUMI IM ANN
'. I AIIOI INA
16 700
a, BOO
1 DM,700
68/./00
44 100
H8. 3 00
30.000
V.100
3,000
'.-, Bbb.100
12215.600
96 1.900
3,8? 7, 300
S.&4I.BOO
11.000
10 700
ItiVlHM)
; «.3oo
3 Jbb BOO
JJ>00
13b/0,300
36,200
&/,. 1 UKJ
li rvM ' V r ' in iilttl
1 1 HAS
UTAH
] VIHdlttlA
1 yd 7, 300
1 609300
U.400
'WASHINGTON ! tOI 500
fcf A Ht lilUN
I
U
m
IV
TT
TZI
yn
vra
DC
X
NATIONAL TOTALS
44300
3 432. tOO
23,486.900
4.444.100
37,120.800
1,247,000
182,000
j 2 n ooo
2 073.400
166,600
74 460.100
TOTAL
POTENTIALLY
HAZARDOUS
0
I
TOTAL
HAZARDOUS
CONSTITUENTS
0
1
i
DISPOSAL-
METHOD
SOLO AS
HOAD BASE
OR
HUH DING
AGURFGAIt
OR
OPFNl
---
(
nunt
CONSTITUENTS
ci
1.93297
1*99
41 06
2.79420
40076
17026
377 00
18314
21940
1497
9.73681
(.)» 13
101300
2.947 »
3.3»b7
14(21
H 73
W7D
17hM
1 ROlt 49
1(1 bl
12,842 70
17409
218S8
lt.002 Ml
2493(1
»e 70
2.90610
1,826 14
6162
38978
17028
2.131%
20.411 22
3.884 90
M.98142
3 121 26
8M7I
2.228M
2.MIM
eaett
8668230
Cu
13648
1M
067
11019
W»
644
It
300
701
OJ4
30623
M>M
M86
17601
26641
746
I) Ml
2; J4
r w
V'O Wl
1 4'(
6fll 81
28fl
; tio
BB147
1 04
1 1J
1(V 4.1
8297
1 6!i
1246
644
16846
moot
20998
1.79887
10698
2234
1 1 1 90
112 77
ID 40
3.877 Z4
F
6.80446
an
1138
4.40469
1,Mi»6
70 67
16798
77M
9094
621
12.496 M
27. M» M
2.3M11
7.»37 78
12,831 24
till
J191
28961
[J(l »
; 11 IB 03
M20
28.70206
71 75
m 72
JHHUKO/
1IH 11
li. ;.
2 140 6?
3.06886
?1 40
161 t>6
7067
7.9(6 02
50.41967
9.310 24
11,83876
2.240 71
2(983
4 604 81
4,436 ft
am
161x137 44
Mn
44921.06
83474
431 14
44,890 20
10U390
1,80096
3.974 H
1X1312
2.320 (1
16407
109.17000
219.16140
20.476 08
S4.624 69
(8,113.68
1.M681
b4323
IMI 12
J,4'
-------
Table 7d
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM THE IRON AND STEEL INDUSTRY
TOTAL SLUDGE, 1974 (METRIC TONS) DRY WEIGHTS
ALABAMA
ARIZONA
ARKANSAS
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
GEORGIA
HAWAII
ILLINOIS
INDIANA
KENTUCKY
MARYLAND
MIChlQAN
MINNESOTA
MISSISSIPPI
'
N6W YORK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S CAROLINA
TENNESSEE
TEXAS
UTAH
VIRGINIA
WA'.HINMf>N
W JWMNIA
H-A lirtllON
1
U
SI
a
V
SI
mn
n
x
NATIONAL TOTALS
GENERATED
188,300
102
141
97.740
43.940
1,880
1.600
1.400
875
321 300
735.900
60.640
109.060
349,100
514
487
'
217,000
452
719,200
600
1 100
901 300
204
870
500
336bO
61,360
700
1 HI, 1
1I./ IIMI
/ nU4
/IK, DUO
1 2M670
203.600
2 126 014
34.391
3950
106.300
96130
3.063
4 124.612
POTENTIALLY
HAZARDOUS
48440
765
163
24410
104*0
470
400
211
160
219
80.330
184.000
16160
J7.270
87.280
129
122
90S
398
54,260
113
179800
150
276
725,300
510
243
125
8 410
16.340
fif.O
41*1
111 I1U
Wl
>A 040
»2M6
6 KM
U1.Uf
496
988
2SJ20
24527
TOTAL
HAZARDOUS
CONSTITUENTS
14M43
2W
190
9629
3(366
668
18 13
768
1096
1 17
302206
644498
51274
2.148 59
3.27500
440
239
34 89
IS 68
206
636
7 .208 70
804
1093
9.000 13
003
10J7
401
a-,4'j
73138
}:«
1.*9
1406
**'**
4JJM46
1210
14415 10
1640
2141
18.11140
Oil
19.*6
8.19
'6208
1 610 so
514
PHENOL
X*
NA
NA
Mil
40
NA
NA
NA
NA
60.73
117.36
7.64
4043
5740
NA
16 Jl
NA
12619
NA
NA
16C46.
NA
NA
NA
466
1307
NA
i»m s.i
J B.1 1 It
1768
4 OWI /2
2844J.7*
44U»
41J19S42
78238
*.n
IJOVIte
196073
60*5
043102
77 «/
NA
K Jl
219J1
4*49
16147
44*
NA
t».»7
1912
NA
6*244
APCROXIMATELV 66 PERCENT Of THE TOTAL (LUDOE II FROM THE HET KRUUCfll ON THE BLAIT FUDNACEI
PROBABLY MORE THAN 70 PERCENT OF THIS It RECYCLED VIA SINTERING OR OTHER AO.O.LOMERATING PROCESSES
ABOUT 20 PERCENT OF THE SLUOQE IS PROM BASIC OXYGEN FURNACC4. ^ 10 PERCf NT Of WHICH IS
CURRENTLY RECYCLED BLAST FURNACE SLUDGE AND BOF SLUDGE ARE NOT CONSIDERED HAZARDOUS
THE REMAINING SLUD6E 126% OF TOTAL GENERATED) 15 LAND DISPOKD AND CONSIDERED HAZARDOUS
THIS CONSISTS OF SLUDGES FROM ELECTRIC FURNACES GALVANIZING MILLS PRIMARY AND SECONDARY
MILLS, DECANTER SLUDGE. LIME PIT SLUDGE AND TIN MILL SLUDGE
NOTE NA DENOTES THAT DATA WERE NOT AVAILABLE
SOUHCfc CALSPAN CORPORATION
30
-------
Table 7e
ESTIMATED STATE. REGIONAL, AND NATIONAL SOLID WASTE
FROM THE IRON AND STEEL INDUSTRY
TOTAL SLUDGE, 1977 (METRIC TONS) DRY WEIGHTS
{ STATE
i
I ALABAMA
ARIZONA
AkKANSA*
(At tlOHHIA
COtORAOO
CONNECTICUT
DELAWARE
f-LORIDA
GEORGIA
HAWAII
ILLINOIS
INDIANA
KENTUCKY
, MARYLAND
1WU.HIQAN
MINNESOTA
MISSIUIPPI
MISSOURI
NEW JERSEY
NEW YOHK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PINNSVl VANIA
HUQIil 151 ANtt
b CAHCH INA
1 N"JI -iM 1
M kA'.
l . . AH
VIHQINIA
WASHINGTON
W VIRGINIA
FPA REGION
!
11
III
cr
V
TO.
YD
vm
rx
X
NATIONAL TOTALS
E TOTAL
ENEflATEC
210700
3)0
mo
103 A 10
46 A 70
1,990
1.700
900
1.490
93
MO £40
760.000
64.260
231.600
370.000
546
61}
4.190
1.WO
230000
MO
762.300
U6
1.170
KB 400
716
1 030
'JV
W 070
«j 040
7 '6
2,080
166.700
7 ?0«
22-1.680
1.346.676
279.426
2.263.405
36.466
4.190
111 610
1IM.023
3.260
4.371422
J TOTAL
K>TENTIALLV
HAZARDOUS
52.660
0
18
76.000
11.MO
496
426
226
373
23
86.140
196.000
16070
64,400
92600
136
128
1.060
420
67 600
170
190.660
169
293
238860
fi4
76H
1 tj
8970
in ?flo
69
520
41.680
562
67,820
3Mj424
W,«67
563 J64
9,117
VtffiO
27.900
26,003
613
1.092.992
TOTAL
HA2ARDOUS
CONSTITUENTS
2.04302
1 17
70
1.00408
41777
970
19 71
8 14
1161
1 24
3.20337
7,25667
54361
2.27761
347160
730
263
M96
1667
2 176 73
474
7.64123
877
11 68
9.64013
004
11 no
4 ;'.
4on 'j/
;?'. 77
2 73
2063
1.44188
924
2.14336
13 281 46
2.67*80
21 67907
41934
3696
1.19254
1,06047
3221
42.3*446
DISPOSAL'
METHOD
OPEN
DUMP
OR
CONSTITUENTS
Ct
36 18
027
2608
11 76
077
15*
0 70
098
007
9309
22391
41 03
9769
020
113
1.3'
6933
0M
177 36
OM
098
231 66
Cu
179«
017
008
1484
469
060
092
015
063
004
4106
12822
76 W
3819
0 10
200
080
7292
029
106.27
016
063
13767
Necn'atBLE
OM
034
12 30
726
023
1 76
6080
077
6070
3X21
69 J]
69264
13 15
313
1904
2642
273
1.11147
048
0 IB
10 19
964
016
1 12
1420
060
2372
18909
2792
31406
1062
200
14.23
1706
176
1094
Mn
91200
178
) 14
4*8 «
24117
10.64
2118
9.20
13 a
099
1464.11
3.77636
96646
2.014 W
269
4284
1848
1779M
'»
3.691.72
906
1347
4.57042
002
12.64
4.51
21275
22631
116
2190
64660
10.56
1.247 U
6.41622
1 17941
11.25826
22194
4784
466JJ
604 BB
17.12
21.1H.6J
Ml
1468
011
0.06
10.79
347
Oil
067
0 19
041
0.01
1268
68.31
1717
1J79
006
l»
060
1963
01>
6836
020
041
6664
077
0 10
678
r> 73
0 10
072
1564
033
2003
11996
22.16
201 74
661
110
960
1043
1 13
Ml 21
n>
11762
077
062
201 U
8648
208
464
2-23
246
023
64666
1,416 60
37026
70914
066
643
400
436 10
1.8&
1 36743
264
1.766 10
In
2.11966
1 11
078
U72 J»
41446
114
7.06
144
4.06
Oil
U01.ll
7,96390
53269
2.672 14
144742.
0*6
128*
610
2 17066
246
6,61337
404
1046663
IVEQLIGIBIE
101
1 09
71 60
11325
062
470
31095
206
43910
246147
466.74
4.161 60
7411
843
196 73
20246
714
(.012.711
463
1 b'..
47t>40
1 Ob*> 65
095
7 19
1,446 14
3 14
2.12*64
1448292
2.6O.M
23.12066
48049
1289
1.48060
177417
1123
4*MM2«4
0
044
NA
NA
1JO
041
NA
NA
NA
NA
NA
377
6.73
047
104
4J7
NA
NA
NA
263
NA
938
NA
1167
NA
NA
f
M219
OJO
071
12048
61 JO
04*
141
0.86
1 11
041
44612
967.01
410
2H41
607.98
077
144
147
31229
0.78
8*142
1 11
174804
NA
177
NA 1 046
0 36
097
NA
NA
1 70
NA
>2.*1
>16.11
>341
>26 15
)0.36
NA
146
1120
NA
>II.U
3167
5833
076
1 97
21643
086
31196
1407.97
13312
240297
32.7*
354
11953
12046
341
5.H847
OIL
&
GREASE
446446
«.33
410
2.068.11
».*>
11.61
18.76
154*
2117
114
6.42972
14.343*0
1,017.34
441079
471 71
817
7140
1141
47*814
1242
15,704 00
1738
2112
19.196 10
0 12
2041
867
80781
1.60008
545
41 17
2.7*1 31
1873
4.10171
2*4*440
646741
41.486 K
82979
7340
241700
24*7.78
479
44*044
PHENOL
4046
NA
NA
174*
731
NA
NA
NA
NA
NA
63.77
1247*
10*
417*
045
NA
NA
NA
NA
1741
NA
1117*
NA
NA
1*4.80
NA
NA
NA
4 94
1385
IVA
NA
1418
NA
> 1741
>212J*
>4844
) 372 77
)4.94
NA
21 16
>170*
NA
>7»J8
DIIPOSAL METHODI WILL PROBABLY FOLLOW PRGSf NT PRACTICES (SEE H74 TABLE) WITH QRCATCfl TENOCNCY
TOWARD RECYCLE
NOTE NA DENOTES THAT DATA WERE NOT AVAILABLE
SOUflCe CALJTAW CORPORATtON
31
-------
Table 7f
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM THE IRON AND STEEL INDUSTRY
TOTAL SLUDGE, 1983 (METRIC TONS) DRY WEIGHTS
STMS
ALABAMA
,RUONA
ARKANSAS
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
HAWAII
II 1 1*018
INDIANA
XtNTUCKV
MANY) AND
MH.hHIAN
'^NNCIOTA
J M B4IMIM-I
M'3»
26? 000
666
884,000
/3s
1,366
1.108,800
251
1 193
814
41,390
75460
320
2,410
193,460
2,661
268,960
1,661490
334 1HJ
2,«14,H12
42 3QJ
4»2
u %«i
3*08^
^ *>
50* 5^
2644 ;>
Ml 6(1
(t m
41000
^34 H.
861
9,20/23
1 91
662 £>
1 ^36 S«
1 11
H 34
1.879.0*
36b
2 467 72
!7,««B?
S.DB4 U
2S,«lt»2
1496
1 ,' . 7 W
1,47851
130]
53,450:11
Cn
330
NA
NA
148
059
NA
NA
NA
NA
436
10 12
066
367
4IK
NA
NA
NA
30ft
NA
10.88
NA
NA
1342
NA
NA
NA
040
1 13
NA
NA
197
NA
^308
M801
>3W
>»W
>o«a
NA
1 72
»3S
NA
;W77
r
291.03
0.36
OJS
13»J1
71 01
1.00
2.24
1 tO
129
O.M
61731
1.M060
M91
261 16
68842
090
0.14
1M
nam
O.ttt
1.DMM
106
Ii»
1JJOM
NA
148
062
xn
67 «
OJO
;?»
«I.9C
> 1 00
3*431
1.XI.M
3WM
I.WJB1
W06
4 11
1J« /O
14(176
3.U
e.iMJo
Oil.
*
ORIA1E
1.1HM
7J*
4.7«
IJW.1I
ff71 IS
J1i»
44*7
17 M
nm
in
7460 90
16,643 M
1.160.W
S.6MM
1.0U16
17 1»
6«
n<4
M.M
4.IU.N
14 W
IMtttJO
20 17
2«i2
Z2J77.W
0.14
24.17
JOM
37 J7
1^56 70
6^3
4777
3j»g;
2173
4.M16!
31,17261
I.44B.32
60.4M.M
Ml 10
M64
j^a/»b
2JM41
7469
WV432.20
mCNOi.
47 J»
NA
NA
16J2
841
NA
NA
NA
NA
NA
62.40
144.34
3<
SOB
>O6t
NA
NA
NA
NA
4341
NA
1K.2I
NA
NA
19144
NA
NA
NA
673
1606
NA
NA
2»M
NA
>4343
>!6fJU
>H44
.403 »7
> 173
NA
24.se
M6J2
NA
662,17
'METHODS OF HANDLING SLUDGE WILL PROBABLY FOLLOW CURRENT PRACTICE, BUT WITH INCREASED EMPHAttS ON RECYCLING
NOTE NA DENOTES THAT DATA WEflE NOT AVAlLABLfc
SOURCE CALSPAN CORPORATION
32
-------
Table 7g
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL INDUSTRY
TOTAL DUST, 1974 (METRIC TONS)
t
1
STATE
Al ABAMA
Afll/UMA
AMMANKAI
CALIFORNIA
COIOHAOO
] CONNECTICUT
DELAWARE
FLORIDA
j GEORGIA
! HAWAII
ILLINOIS
INDIANA
KENTUCKY
MARYLAND
MICHIGAN
MINNESOTA
1 MISSISSIPPI
MISSOURI
NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKI AHOMA
on 1 oil*
1-rNNIVI VANIA
imllKI l&i AND
} ( Altlll INA
ItNNtSStt
It *AS
UTAH
VIRGINIA
AASH1NGTON
A VIRGINIA
EPA REGION
j
U
ffl
or
X
B
yu
uni
IX
X
NATIONAL TOTALS
TOTAL
GENERATED
117 700
MM
MO
13*00
21.200
2.100
1,060
2.960
1.600
2M
213.350
11400
36.MO
137.000
193JM
2.400
160
IT, 100
SJOO
116.100
2460
4M.900
;,«QO
J.4M
M.800
4 fXW
1 4IM)
V. UUU
54750
KM
6.200
74.660
2.700
120.300
826.600
166,160
1.316,260
66,460
It 100
77,960
73.600
9,660
2.663.760
TOTAL
POTENTIALLY
HAZARDOUS
14 160
114
II
6.6M
2 710
324
726
364
420
30
26,600
60710
4.300
1«.440
21, 160
266
102
1.1M
624
13.110
JW
61,670
I3«
414
7J.1JO
4HO
166
66UO
6,670
66
744
a wo
324
14.434
9.072
20,176
167,946
7.014
1.330
9J60
1*14
1.166
319.642
TOTAL
HAZARDOUS
CONSTITUENTS
461
16
13
640
71
66
122
60
70
6
1.410
1 740
230
676
«0«
46
17
224
106
294
SO
30BO
t,t
10
JfltO
HI
26
804
446
17
126
147
66
399
4,634
967
6J67
14
224
51 9
W4
196
16.371
DISPOtAf
METHOD
OPIN
OUMP
OH
RtCYCLl
'
COHmrUENTS
Ci
n 16
i>i
093
1614
l.»l
372
631
409
4«0
013
6M
10147
17 17
M47
49J7
119
116
18 Jt
720
2493
319
17200
166
4 79
701 04
660
1 94
6282
1739
1 13
662
13.67
172
J213
266.64
6620
424*4
6761
16.26
21.12
2>79
1311
92475
Cu
M46
IJ6
IJ«
41 M
6JI
6.M
11 n
676
«7«
046
12761
11161
2120
6124
U.76
466
1.19
21J1
1011
24.76
4 77
24766
A47
674
29107
176
273
7901
3206
1.H
1200
1161
6-24
3466
M712
6704
M6.26
4 77
2181
3836
606
1174
\X»M
t"
>6,22
>I9
110
3M4
4.17
41
14.64
7 14
637
0.67
130.60
OM
21M
3497
JO
681
202
2«66
1266
13 M
Sit
21142
6 76
6 36
23661
900
136
6924
2316
117
1487
2 to
6,49
2661
290.36
464
46809
717
2616
27.72
M30
2122
1.010.66
Mn
t.MO.1*
40 6J
2616
Ml 41
181.64
111.04
26764
126-44
141 M
1013
1.667 J9
4,066.71
64677
IJtOJ*
J^ll.W
101 J>2
3672
472 M
12214
1.21473
104 M
6.N6.78
120 19
147 M
640714
17006
6992
1. 53884
17133
MM
16337
766 U
11604
1,60707
9,117.27
2.J6207
U.071.M
1J17.11
47211
Ml 87
89113
41121
31,491 J4
Nl
1166
013
014
nn
204
O.M
14*
0.73
O.M
0.01
21 46
46.70
433
1671
1197
O.M
0.21
271
1-28
48
060
1661
068
o.«
11 M
096
016
1242
910
0.20
162
6J6
0.66
1076
106 Jl
T».71
16636
13J7
271
I1»
1164
237
HB.OO
n>
417 J]
7101
Mil
4M.41
MJH
66.M
146.40
71J>
64^7
(71
1 .670-41
1JU.7I
2J6J7
MJ2
7*7.tt
HM
20.10
M840
121.39
H»32
MM
212144
6112
64.07
3.4)747
666
3406
914 S3
31074
1943
14972
212.31
6J9
616.71
4J78JJ
1.090.3S
7. 11079
1 ,011*6
26840
406 Jl
626.27
133.79
16J2»J3
Z»
IJH.06
141
6167
1.0J»M
210.0
26811
inM
21402
312.M
22.76
1.0M.70
6J«»
912*4
ijmin
I.TMjDt
23140
10 Jl
1.010*7
499.43
OMJ2
2K.05
16,960 «J
2MM
ujio
I9.M2JO
311 96
134.M
4.497 OB
2,944.35
7116
M1.M
220.07
261 M
1.I96J6
M.07U3
4J2I-41
32J7671
4*1071
1.060.67
3.164J6
1. 163.79
923.79
76J63J1
d|*«
.77
0
O.M
M
0
0
0
0
0
1.02
2J7
0.11
OJJ
1.16
0
0
0
0
071
0
164
0
0
114
0
0
009
0.21
0
0
041
0
071
442
OJ2
7.0»
00»
0
0.4
0.32
0
1396
MtNOl"
Oil
0
0
OJ»
0.02
0
0
0
0
0
0.17
0.38
OJ»
Oil
018
0
0
0
0
012
a
041
0
0
041
0
0
002
004
0
0
0.07
0
012
071
0.14
1.16
0.02
0
0.0«
0.06
0
2J6
APPROXIMATELY 67% OF TOTAL GENERATED IS BLAST FURNACE DUST Of WHICH ~ 90* IS RECYCLED
APfflOXIMAmv IK OF OUST GENERATED II FROM ELECTRIC FURNACE AND LAND DISPOSED
ELECTRIC FURNACE DUIT IICON1IDEREDPOTENTIALLY HAZARDOU1 REMAINING 11% OF DUST IS
I ROM OPtN HEAR TH AND HOF FURNACEI IT II OPEN DUMPED 6UT NOT CONSIDERED HAZARDOUS
VALUES FOR CN. F. AND PHENOL ARE TOM CONSIDERED Al MINIMUM SINCE DATA WIRE NOT
AVAILABLE FOR THESE CONSTITUENTS FOR ALL TYPES OF OUST INCLUDED IN THE SUMMATIONS
OUNCE CALVAN CORPORA riON
33
-------
Table 7h
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL INDUSTRY
TOTAL DUST, 1977 (METRIC TONS)
| STATE
ALABAMA
ARIZONA
ARKANSAS
1 CALIFORNIA
J OH Oft ADO
CO*«CT{CUT
DELAWARE
FLORIDA
GEORGIA
HAWAII
ILLINOIS
INDIANA
KENTUCKY
MAR V LAND
MICHIGAN
MINNESOTA
MISSISSIPPI
MISSOURI
NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S CAROLINA
TENNESSEE
TEXAS
1 UTAH
VIRGINIA
' WASHINGTON
' W VIRGINIA
EPA REGION
I
n
fll
nr
V
VI
VD
iflij
a
x
NATIONAL TOTALS
TOTAL
GENERATED
124,300
1OOO
700
7(700
24.600
2460
400
3,150
3.70O
250
221.200
443.600
37.960
146.700
204800
2.560
000
II /BO
6,660
122.000
2.100
518.200
3.000
3.700
MS 300
4,260
1,500
58.300
SB 000
860
6.550
79JSO
2 850
127 5«iO
11 76, 100
ITS IRQ
1 3M .DO
U.OOO
\\.na
2,600
77.MO
10 21ft
2.823,660
TOTAL
KJTENTIALLV
HAZARDOUS
14,»20
120
84
tXO
2.9*0
342
7M
37B
444
30
27.140
53,220
4660
17.420
24,680
Mi
108
1.410
666
14640
312
62.160
380
444
77,200
510
ISO
7000
6.9bO
102
786
9520
34?
16 loti
!()> HIM
71 402
107 420
7444
1.410
.10
9,360
1 710
336,830
TOTAL
HAZARDOUS
CONSTITUENT!
47«
20
14
572
77
M
130
64
75
5
1500
1.840
244
710
644
52
IB
237
112
311
S3
3.240
60
74
3.690
86
30
916
473
DISPOSAL*
METHOD
OKN
DUMr
OR
RECVCLE
18
132
156
5B
471
i HI i
1 IMI!
/ //(I
MO
237
MO
597
?0fi
16,?98
CONSTITUENTS
Cr
2*44
1 38
097
M93
n
1M
4 34
601
036
10449
10768
1120
36U
6233
3M
133
1620
763
2643
366
18246
4 12
607
213 10
5«3
2 06
65 9«
IB 43
1 20
904
1438
395
34 06
274 04
70 111
400 31
6109
1120
14 71
31 87
14 11
HO 21
Cu
3884
1M
1 37
46,11
670
666
6 11
7 18
049
13629
MOM
2247
5432
6592
497
172
2280
10 74
2623
tot
2*241
580
714
30653
>21
289
F"
27 7t
242
170
39 «
4»b
688
758
!.«7
061
13833
M.98
2321
3707
4080
618
214
28-25
13,30
1480
«26
224 11
7 19
885
25006
Un
1^36.91
42 9B
30U
89303
30068
121 M
13403
167 14
1074
3,887 33
4,28951
6J6 68
133653
J 502 86
109.20
37,86
(0049
236.68
1J4141
110(2
6.248 M
12740
158 77
Hi
12 as
OJS
0 17
1192
316
070
077
n>
462J7
2442
17JJI
S2«-27
100.27
9 JJ
1M19
7619
0.91 i 89 33
0.61
2(09
4950
469
17 76
17 99
063
022
2.89
1 36
1006
084
6955
074
610
1.77069
1.78427
3U 15
58277
34 W
62.07
21.62
284,61
1 33,96
412JH
63.06
3.09S73
7242
091 | 89.12
721579 8645
10 U ISO 2S 104
3 !>b
B2 f)9 94 64
34 00 24 '-4
1 88 209
12 72 i 16 76
1240 313
... _!_
555
3897
310 17
92 25
SW It
9018
22*0
40 70
47 7>d6 61-
J ^4 11 111 H' 4 W '4
.' M'. '(' .'!' !'" 1 1PK T*
1 / u.tu ^ i
1 F8M ll.<
IW, .
14 IW
HW 4U 1 89
701 B«
94672
tt.bOO 74
13 68
U78
2 ^7
Jbt >!
/.5bH 04
1.080 10
284 M
429 87
IM 79
74/82
1656702
Zm
1JK2JM
MS
«7*l
3J2'J7
J2JJ»
1TSJK
613JO
301.0*
3U.*7
2411
6432 J2
SJ71 10
M7.2>
3J>14J1
1JXM1
246 i»
86«
1,124 JO
62«,40
740.7J
249,15
16,907 K
2M.11
«2.!3
20,672 J3
40447
142 Be
4.7ee.ao
3121,00
83.06
627.09
233.28
27390
1 270 16
7551867
4 685 99
» 411 .It
6 1MM
1,124,20
3X3JH
U41M
979.22
714744*
Ck
OJ2
0
0
0.34
O.li
0
0
0
0
0
1.09
Ul
0.16
OJ7
123
0
0
0
0
0.71
C
2.70
0
0
3,32
0
0
010
031
0
0
0/49
0
0 76
4 68
098
7«
0.10
0
043,
OJ4
0
144
mcnoi.
0-13
«
0
00*
0.01
0
0
0
0
0
0.1*
0.41
am
a 14
0.20
0
0
0
0
0.12
0
044
0
0
0-64
0
0
0.02
0.04
0
0
0.0*
0
0 12
or*
0.1*
123
0,02
0
0.0*
OJ*
0
241
"DISPOSAL PRACTICE FOR 1977 IS EXPECTED TO ESSENTIAILY Bt THE SAME AS THE CURRENT PRACTICE BUI VtiTH k Tut NO
TQWAHO (NCMAIEO UtE Of SINTERING OR AGGLOMERATING TO ALLOW RECYCLE
"VALUES FOR CN, F AND PHENOl AHF TO flf CONE I Of fit £' AS MINIMUM SffJCE DATA WERE NOT AVAH ABLE t'OR 1 MI ";[
CONSTITUENTS FOR ALL TYPES OF DUST INClUDf U IN \Ht bLMMMAFiONS
fOURCf CALtfAN CORPORATION
34
-------
Table 7i
ESTIMATED STATE. REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL INDUSTRY
TOTAL DUST, 1983 (METRIC TONS)
I1
STAH
At A0AMA
AHI/ONA
AMKANSA*.
CAtlf UHMA
LOLOHADO
CONNEC ricur
DELAWARE
FLOHIDA
GEOHGIA
HAWAII
ILLINOIS
INDIANA
KENTUCKY
; MAHVJANO
' MICHH.AN
1 MINNfSOIA
MUmtlPPI
MIIKHIHI
N»W It Mtl V
NIW VOI1K
N ( AMD! INA
IWIO
OKLAHOMA
OREGON
PENNSYLVANIA
S CAROLINA
rfNNF-SSF. Jr
Tl XAS
IIIAH
VIIU.INIA
WASHINGTON
W VIRGINIA
EPA REGION
I
n
m
IV
V
VI
VII
yin
ix
X
NATIONAL TOTALS
TOTAL
GENERATED
144200
l.l&O
BOU
Rfl.OOO
7B 600
1 JOT
74«jO
36bl>
4.300
300
262.400
514.700
44 OOO
! 68,500
m 100
I IIV)
i «»o
1 1 5f>0
A 4110
141, Mill
1000
601 300
3460
4260
746 6OO
4,900
1.780
67 660
n; v.o
1 WO
/.600
92 100
3.300
147,900
1 016,660
you Hbo
I ntu unit
; i IMKI
I I n'.il
96 9M)
90460
1 l.H&O
3.2 78,460
TOTAL
POTENTIALLY
HAZARDOUS
17.300
1J«
it
10,680
3.430
»
s»4
438
516
M
31 .490
61.760
5280
20.220
2fl b20
ir>4
176
1 MO
/Oi
IB HMO
Inn
7? 160
414
610
89680
588
210
a 120
H OHO
I/O
9i;
now
39*
17,741
121,864
24 H1H
l»4 2N4
it nil)
1 Mil
II 610
10 ah4
1 !!
393146
TOTAL
HAZARDOUS
CONSTITUENTS
554
24
I/
664
90
67
150
74
87
6
1 740
2.140
283
«34
747
60
21
2I«
130
»!
61
3,760
70
ao
4610
99
35
1 060
M9
70
1'.4
181
67
491
!,,«96
1 JH
44;
1 t4/
nn
blU
694
J40
18,910
DISPOSAL*
METHOD
OPfN
DUMP
OR
RECVCLt
CONSTITUENTS
Ci
3463
161
1 13
3481
729
468
1026
603
690
040
12126
124 JO
21 12
4230
6073
4 10
14J
11 NO
N M
30 17
4 17
211«7
4 n
sag
24728
677
23>
6497
21 39
1 39
1041
16W
468
3952
3160
8143
W7M
tout
in HO
28 6a
Mtl
l<37
.13743
Cu
44*4
227
169
62 57
7,78
645
1443
70S
31
0.67
16699
163.11
28.07
ttW
4M
»77
100
M4B
1241
X44
»I6
KM 49
173
I2»
36801
>6J
136
KM
N43
1W
1476
1438
6.46
42 M
461(0
10706
1M76
104 »
M4-.
47J1
B«41
23 06
l.JMIb
hbi
t.t»l«
4tM
3417
1.0M.26
14876
14149
31678
16652
18234
1246
4,51077
4,977 45
79653
1 ,55098
2.90426
12871
4383
MO 76
17941
161011
128 71
7J61I1
14713
l«l«t
8,373 03
20816
7370
1.893 77
46636
4290
333 98
93066
141 49
1,88370
11.21424
3 139 OK
It 7710
1 4i/r. 4/
.nil 'ti
14 11
10M66
6O&B6
41.19423
Ni
141]
0»
020,
1383
281
082
183
090
toe
0.07
3267
87.44
533
20 »!
2087
0 73
026
33ft
1M
1184
074
10.70
0.86
106
100.31
1.21
043
1628
1208
028
117
7 19
082
1324
130 10
2424
182 J1
in It
> II,
14 67
14 19
292
412.16
n>
82882
2833
19.12
61087
11« 36
043
18007
88 at
10366
708
2.08487
2.082.03
364 54
6*7*4
98877
7203
»»7
U014
16141
47817
7317
3,693 37
84.03
10141
4,22121
118 M
41 M
1.14947
182. 11
24 N
18416
28108
8043
83433
638163
1 341 trt
./roar
i .". i n
III) 14
49666
648116
nit*
19.223 97
Zn
2.417 01
HIM
78.12
3.736 00
26829
31782
71165
349.34
40968
27 M
7.464.60
10.293.82
1.12242
4X2 H
2.18694
2*462
6.86
I304.M
614.10
86*66
2*911
19,818.24
333.06
406.fi
23.9*7.71
4*941
1*6.M
6431.41
3.62161
96J7
727 M
270.99
317.82
1.473J6
29 808 98
6,371 49
3*.*» 12
bU4l It
1 IO4 Ml
3^7» H
3.177 M
1.13627
92.664 69
CN"
0.66
-0
-0
040
0.17
-0
-0
~0
~0
-0
1J«
2J1
0.19
1.01
141
~0
.0
-0
-0
0.6*
-0
113
~0
-0
346
0
~0
0.12
0.32
~0
0
0.67
~0
OJ6
644
1 14
71
0 \J
II
049
040
~0
716
f"
SIM
2J1
1.67
44.62
563
799
17.8*
878
10.29
070
16091
100.93
26.93
4301
47 11
716
1.46
1178
18.44
17.17
726
260.06
614
10.27
2*01*
11J1
41*
10982
28.46
142
18.21
1.63
796
3261
18711
10308
67676
UU IJ
j.' ;u
34 11
4833
2865
I.J4I.J4
PHINOL,"
0.18
-0
~0
0.06
0.03
»o
-0
~0
- 0
~0
OM
047
0.03
016
073
* 0
vO
~0
'VO
0.14
-0
0.61
~0
-0
082
-0
~0
002
0.08
~0
~0
009
~0
0.14
0.17
0 18
141
1)1)2
0
008
008
~0
276
DISPOSAL PRACTICE f OR 1983 II EXPECTED TO ES8ENTIALLV BE THE SAME At THE CURRENT PRACTICE. BUT WITH A TREND
TOWARD INCREASED USE OF SINTERING OR AGGLOMERATING TO ALLOW RECYCLE.
VALUES FOR CN, F AND PHENOL AHE 10 BE CONSIDERED AS MINIMUM SINCE DATA WERE NOT AVAILABLE FOH THESE
CONSTITUENTS FOR ALL TYPES OF DUST INCLUDED IN THE SUMMATION*.
SOURCE CALSPAN CORPORATION
35
-------
Table 7j
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM THE IRON AND STEEL INDUSTRY
TOTAL SCALE, 1974 (METRIC TONS)
STAT*
ALABAMA
ARIZONA
ARKANSAS
j CALIFORNIA
' COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
HAWAII
ILLINOIS
INDIANA
KENTUCKY
MARYLAND
MICHIGAN
MINNESOTA
MISSISSIPPI
MISSOURI
NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
S CAHOl INA
UNNLSUE
TEXAS
UTAH
VIRGINIA
WASHINGTON
W VIHQtNlA
t?A HEGION
1
II
ra
nr
V
in
vn
Tj^n
a
X.
NATIONAL TOTALS
TOTAL
GtNIHATED
1M.400
3.780
1.3*0
185.0*0
46600
10.700
18.300
1.340
13.800
710
562.2W
938,000
1 09,500
256.800
468300
& 000
1.730
44.100
15, BOO
273.900
2.760
1.150.200
5,830
13.800
1.416.600
f 440
2 010
183 OOO
113,000
3 JbO
74.600
206 100
10 700
299.700
1,801.180
337X180
3.123,700
190,210
44,100
170,400
189380
38,400
6.295,830
TOTAL
POTENTIALLY
HAZARDOUS
39.260
7M
276
37,020
11,300
2.140
3.660
666
2.760
144
112.440
187,600
21.900
61.380
93.680
1,000
346
8.820
3,160
54,780
662
230.040
1,170
2.760
213.120
1 -19(1
582
36 800
22 780
l>bO
4 920
11 7?n
1 IdO
67.940
360,230
67,678
824,740
38.046
6.820
34.080
37.920
7.6(0
1.269.174
TOTAL
HAZARDOUS
CONSTITUENTS
9919
191
88
S441
2862
54.3
1006
31 1
699
67
2.866 1
4.842 9
Ml 1
1.2873
2.3661
319
11 1
2227
869
14834
268
6.032 8
37 2
6tf fi
72061
4'j 1
1)16
9244
!>!!, 1
16 !.
124 2
984 0
1>4 3
1,4703
9,603.5
1.7546
16.1278
970.4
2227
8803
9899
194 0
32,217 «
DISPOSAL
METHOD
RE<
OPEI
YCLE
OK
IOUMP
C- '
96.34
109
031
5267
1820
308
487
069
397
0.15
16069
264.46
3106
7369
134 34
1 14
039
1265
422
7858
067
324.83
133
3M
404 18
1 71
0 86
52 51
3267
093
7 08
,aa«
308
6260
542 56
9539
88536
6416
1265
4887
5391
11.02
1.7W.77
Cu
7146
161
042
7327
2286
426
671
091
653
020
223 49
36735
4318
102.62
18708
153
063
1762
581
10942
076
451 32
1 78
5b2
56241
.' 3i.
UB9
73 12
4649
t 3(1
9 II)
81 «',
4 ?y
11523
75499
12703
1,2X77
76.32
1762
6805
7498
1636
3,48916
CONSTITUENTS
Mn
03747
1806
491
87486
26960
61 31
7970
1087
6809
228
2.66640
4.382 72
51651
1,226 14
2.23640
1783
6.18
21049
6898
1,30746
874
5.386 b3
2080
6693
6,71697
2687
10 37
873 ?4
M3 54
Hi
8449
1 63
071
8025
24 30
463
840
1.82
596
0.39
24291
41038
4783
11061
20147
268
090
1897
7.27
11784
151
n>
1672
0.32
0.19
1413
4.81
0.92
1.8J
0.51
1.11
011
4841
8396
983
21.87
39,87
066
024
379
1.63
23 J2
0.43
602 34 102 43
301 j 0 80
594 1 18
61274
i *:
1 bO
IS 73
J899
1 10
it; s > in 5H
'ins no a» 07
.
bl 31
1.37644
9,017 16
1,58180
14,69088
899.96
210.49
813 14
89620
16334
2971921
483
12611
82212
14763
1.35P68
8246
1897
7329
8227
ia.62
2,732.68
122.57
1 K
040
15*18
969
D28
209
1778
092
24.96
16438
3011
276.42
19.67
3.7S
1450
1666
3.27
660.43
2n
8.07
012
-------
Table 7k
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM THE IRON AND STEEL INDUSTRY
TOTAL SCALE, 1977 (METRIC TONS)
STATf
ALABAMA
AMI/UNA
AHHANiA',
< A I 1 1 U M N I A
(.01 IHIAIM)
< ONNI 1 1 IMM
Of 1 AWAHt
1 1 OHIUA
Gf (IHt',1 A
HAWAII
ILLINOIS
INDIANA
KENTUCKY
MARYLAND
MICHIGAN
MINNESOTA
MISSISSIPPI
MISSOURI
NEW JFRSEY
NEA YORK
N CAROLINA
OHIO
OK LAHOMA
OREGON
PFNNtYI VANIA
HHUhl t*t AND
1 i AUDI INA
UNNrHfli t
It MAfe
(11 AM
VIHUINIA
WASHINGTON
W VIRGINIA
EPA REGION
I
n
ra
D7
r
TZT
TOT
'i7l'II
IX
3.
NATIONAL TOTALS
IOIAL.
708,200
4.010
MM
IUA J(tU
MI.UOII
1 l.4t«J
1U.4LMI
J.b40
14./00
'60
b9b.900
994,300
116 TOO
272300
TOTAL
HAZARDOUS
41 640
107
MJ
>ani\
11 Will
t 2HU
i HHU
708
I 940
152
119 1HO
196 860
23220
54460
496.400 99 280
5300
1 640
46 700
16.800
290.300
2.930
U19.200
8.180
14600
1 '.01.800
Nl (1
;>wi
HWII
184 (KM)
IJLUOO
3,404)
26.000
21H.60O
11,400
307.100
2.016,300
368.290
3311.100
201.640
46.700
180.600
200.970
40.600
6,673.740
1 060
368
9 340
3360
b80<>0
586
253.840
1.240
2.920
)00 370
t r.HO
r, 111
in into
24,140
BOO
6200
43 720
2,280
61,420
403.070
71668
«62.220
40J32
9J40
36120
40.194
8 120
1.334.7W
TO1AL
CONSTITUENTS
1.061 4
20 1
(1 1
1 000 /
IIIJ 1
t,/ 0
IDA ;
31 n
/4 1
7 1
3.0264
b 133 1)
594 7
1.376 1
2.5070
33 8
11 7
236 1
92 1
1 4664
273
6394 8
396
739
7«1/ 1
4; II
lu /
y/un
Ikw ft
17 4
131 7
1.043 1
578
1.&586
10.179 7
1.8697
17,0X6
i.one
236 1
9119
1.028 1
2056
34.161 3
DISPOSAL-
METHOD
RtCVCl E
OH
Off N DUMP
CONSTITUENTS
C<
6B72
1 IE
033
bbH
17 17
327
il 17
0 74
421
016
17022
28031
329!
78 11
14240
1 21
042
1341
447
83.2»
061
34431
1.41
410
42R44
1 It!
0 70
MM
M<3
OM
744
6242
327
8776
67611
101 13
9M4«
6740
11.41
51M
6714
11M
.89717
Cu
8316
160
046
77 U
2J»2
4i,h
7 12
097
588
021
23889
38939
4B78
10877
19831
162
056
1867
616
11599
OJO
47840
1.0
S86
SM 16
144
(IU4
II hi
Hit
t 38
1042
8667
4.66
122.15
80030
140.61
l.»4«
nt»
1667
7214
7»,47
1627
2,63862
Mn
99372
1916
610
27%
»l>76
54311
8448
1120
7006
142
2.820 56
4.64566
54644
1.1M71
2.369 &2
Ni
89.S6
1 73
on
HbOS
2676
490
891
193
6 31
042
267.49
436.00
50.49
117 14
J13 5«
1890 274
6 55 i 0 95
22312
73 12
1,38591
927
5708.66
2206
6989
7 1 19 19
»4(
to uu
Ml lit
876 16
1648
11446
2.037 6Z
5439
1 ,459 03
9.658 18
1.676 70
16.672 32
6341
22312
861 93
9W92
194 35
31.502 35
2011
7 71
12491
1 60
53248
319
630
R4q r.o
i im
1 t>M
447
51*3
1 49
1122
9442
490
13262
871 46
16848
1,44177
8741
2011
7799
8721
17 b2
2,89667
n>
1773
(134
020
17 10
(10
097
199
OM
1.25
0 12
6140
8898
1021
23.18
42.26
073
0.25
398
1 72
24.72
046
10857
0*6
12S
12902
1 [HI
II 4.'
\e«
IOM
029
2.21
1886
0.97
28.44
17423
3191
191 W
1747
3.98
1539
17.M
347
5(345
Zn
6.44
0.12
0.04
904
in
03(1
0.58
010
0.46
0.02
1839
30.49
3.67
842
1535
015
DOS
1 44
OM
898
006
17.41
0.17
0,46
4630
0 JJ
UIW
01)
373
Oil
0.81
674
0.3S
949
92.16
11.00
10171
J1
144
>.6<
18
1-2*
206.44
OIL
GREASE
4.00«,68
7719
»»7
JJM.I?
1,16111
21936
42606
14949
282.41
12.24
11.567 W
K.797.U
2 .284 17
6^40.38
9^6378
14379
49.86
89952
3(7 00
6,5»8.12
12372
24,7*4 14
187 7S
281 75
29.21699
Ml 0«
»J«J
i,IUti
1.111 97
66 45
5017*
3.909.46
219.16
5^66.12
38367 JO
7,191.20
M27.ll
1*41 14
89962
347608
3>4410
763^1
131.01353
TMI AMOUNT (U S( At I HI CVfl U> IS t XHFt 11 0 T<) INCREASE OVtH PRESENT AMOUNTS
MUIH< t ('AI Sf AN ( OMKOHATION
37
-------
Table 71
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM THE IRON AND STEEL INDUSTRY
TOTAL SCALE, 1983 (METRIC TONS)
STATE
ALABAMA
ARIZONA
AHKANSAS
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
HAWAII
ILLINOIS
INDIANA
K* NIUCK V
MAHVl ANI>
Mir HIOAN
MINNESOTA
MISSISSIPPI
MISSOURI
NtW JfHStV
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
ORIQON
PfMHtVI VANIA
fH'itjt 1*1 AM«
ft CAHOl IhA
UHSfbill
UXA4
UTAH
VIRGINIA
WASHINGTON
W VIRGINIA
EPA REGION
I
II
m
D?
V
VI
m
vni
tt
X
NATIONAL TOTALS
TOTAL
GENERATED
241,100
4.660
two
227.600
68.600
13,200
22.600
4.110
17.000
800
691.600
I.IM.SIIU
iM.Hio
J16.HOO
5/6.000
6,160
2.130
64,200
18,600
336.100
3.400
1,414,700
7.176
1/000
1. 747,4 00
NHi
a, 100
JbdO
226,100
140,000
4,000
30,300
253.600
13.200
366.400
2J38.400
416.680
3,842,160
233,966
54,200
209,600
233.140
47.300
7.743.936
TOTAL
POTENTIALLY
HAZARDOUS
41 .320
130
nt
46,620
13.900
2,640
4.600
822
3,400
178
138300
jxi.iaa
/n 041)
HI 1*0
1 1S, 200
1,230
426
10.840
J.8OO
67.380
680
282.940
1.43!,
3.400
MI.4IIII
1,1.12
716
41,020
28.000
800
6.060
50,720
2,640
71.280
467.880
83.138
768,430
46.793
10.840
41,900
46,628
9,460
1.S40, 78/
TOTAL
HAZARDOUS
CONSTITUENTS
1,2201
236
108
1.161 2
360.8
MS
1Z38
383
860
83
1,611 7
(l.BMa
nuo i
i r.Vi /
2.909 1
393
136
2739
1069
1,7016
31 7
7,4204
468
1KB
1 «»2 .1
bbb
22 »
1.U/0
/0/3
202
1628
1,2103
668
1,806,5
11.8123
2,1S61
19.8373
1.193.6
2739
1.0561
1,193.0
238.6
39,6402
DISPOSAL-
METHOD
HiC
0
DUN
«U
fl
DUMP
CONST TUtNTS
C, 1 Cu
69.30
1.34
039
64 79
19.92
379
S99
086
489
0 18
197 b2
3>ti27
U21
9064
16524
1 40
049
1666
619
96.66
071
39963
1 03
487
497 16
2 ID
081
M'.O
40 17
1 1b
8b8
7243
379
101 84
66736
11736
1,08896
6661
1666
6009
6631
1366
2,201 43
98 GO
1.86
062
90.12
2776
528
826
1 13
U80
024
2/4,61)
461 IK
0.1 U
120 Jl
230 11
1 88
Ot>6
21 «/
7 It.
13469
093
566 12
2 1"
8/n
Ml II
I «J
10U
8994
M>96
160
Mn
1,1!>30S
2222
604
1,076 OB
331 61
6311
9603
1300
81 29
2.80
'I /8 3 30
r. luo /tt
nvi oy
1 I.OII Ih
/ /4<> !.a
2193
/to
2bB91
K4 84
1.608 18
10.76
6 624 211
2!» f>y
fl! Ill
«,2«lll/
U l»,
12 /ll
1 U/4 10
MW'.',
Mt U
1209 1 14442
100 80
528
141 74
9280S
16306
1,b13£3
62 S5
21.67
8370
9222
IB 88
3,061 «7
U0392
63 11
1,69.1.02
11,091 10
1,94^62
18,069 78
1.106.33
25891
1,00016
1.101 10
22662
M.S64«b
N. | Pb
10393
200
087
98 70
2989
663
1033
224
733
048
298 /U
h)1 /U
nil nil
1 tfi I*/
74 / Ml
3 18
1 10
23.33
894
14494
1 85
617 BW
1 M
; ii
/hj fl-1
1 Ml
im.
«!*> 80
en 26
1 U
13 02
109.66
669
16398
1.011 20
181 SB
1,67241
101.44
2333
90 14
101 18
2033
3.J61 18
. , - J
20.57
0.40
0.23
19(84
5.91
1.13
2.31
0,63
1.46
014
MM
10120
MM
?A 90
49 04
084
029
4.82
200
2868
062
12B98
098
145
1M> 76
124
049
19 I/
1192
034
258
21 87
1 13
3068
20218
3704
338 76
20.38
4.62
17.83
20.36
4.03
677.02
L
Zn
7.47
014
0.06
7.01
216
0.41
067
0.11
0.53
0.02
21.31
JtJ.W
4 >4
9/V
17.11
0.17
006
1 68
0.58
10.42
ooe
4341
020
0.63
KI.73
-
DM
0.10
6.96
433
0.12
0*4
7.82
0.41
11.00
72.11
12.76
118.10
7.21
1.68
641
7.17
147
231.31
OIL
&
GREASE
4.64950
MJ7
46.91
4,449.6*
1,338.89
2S4JS2
493.23
173.47
227.72
3741
13.42311
tt fit 20
2,H»0.tO
6.0*0.7*
11,08699
16686
57.86
1XM3.7B
428 W
6.414.33
14366
28.735.76
1IM.ee
32694
11.M2.M
23329
97.0*
4.33264
2.6*6.62
77.11
562.23
4 ,536^8
2S4i2
6,910.19
46,069.15
8J32J3
76J63.90
4>73J1
1XM3.78
4,03241
4^7».64
909.17
1B2.106J7
THE AMOUNT OF SCALE RECYCLED IS EXPECTED TO INCREASE OVER PRESENT AMOUNTS
SOURCE CALSPAN CORPORATION
38
-------
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road haliast or building aggregate. It may be >.r<>i:.-! urs tin- ground fz\
many months or years before use for these purposes, i;i;io dust contain'-
significant eo centration of iron and is normally sent to sinter strand
to ',r agglomerated prior to reprocessing for iron recovery. Sludge from
wet emissions control is also sent to the sinter facility for agglomera-
ti.,. ..riM- to reprocessing for iron recovery.
All of the blast furnace residuals (i.e. slag, dust, sludge) are
considered non- hazardous. Fluorides may leach to the extent of a few parts
oer million from these materials which is noi considered sufficient to pose
an environmental threat.
-_li!jL£l1^f£2.> Residuals from basic oxygen furnaces include slag,
dusts t*rom dry emissions controls, sludges from wet emissions controls and
kish from metal pouring. Basic oxygen furnace slag is usually open dumped
after recovery of metal lies. This practice is adequate since basic oxygen
furnace slag is not considered potentially hazardous at the present
time.
Dusts and sludges from emissions controls are usually open dumped
as is kish. This practice is adequate since none of these wastes are con-
sidered potentially hazardous at the present time.
Open Hearth Furnaces. Slag from open hearth furnaces is usually open
dumped after processing for recovery of metal lies. Open hearth dusts from
emissions controls are open dumped and are often wetted down before dis-
posal to prevent blowing. At some steel plants open hearth dusts and BOF
dusts are recycled to the sinter. Disposal practices are adequate since
these wastes are considered non-hazardous at the present time.
Electric Furnaces. Residuals from electric furnaces include slag, dusts
from dry emissions controls and sludge from wet emissions control. Slag
is usually open dumped after recovery of metallic^. .-' small amount of
slag (approximately 101,) is used as road fill or railroad track ballast.
These methods are adequate since electric furnace slug is not considered
potentially hazardous.
Dusts from dry emissions control and sludge from wet emissions
control can leach potentially hazardous heavy metals as previously dis-
cussed. Open dumping of these wastes as currently practiced is environ-
mentally inadequate.
Soaking Pits. Slag is the only waste generated at the soaking pits.
It is generally broken into chunks and hauled to open dumps. This practice
is adequate since this waste is not considered potentially hazardous.
Mill Sludges. This category of residuals includes sludges from various
mill operations at an integrated steel plant including primary mills
which produce ingots, slabs and other primary steel shapes, continuous
casting mills, hot rolling mills, cold rolling mills, galvanizing mills,
and tin plating mills. Sludges from these nulls are produced as a result
of water pollution control operations including oil and grease removal,
flocculation and settling of particulates, and pi I adjustment.
42
-------
All of the above sludges are considered potentially hazardous
because of possible leaching of hazardous constituents including chro-
mium, copper, nickel, lead, zinc and oil and grease.
Currently the most prevalent management, of the above sludges
is open dumping except for tin plating sludges which arc put in unlined
lagoons. These practices are inadequate because of the danger of toxic
heavy metal leaching through permeable soils to groundwater.
Mill Scales. Mill scales containing over 50% iron are generated in
primary and hot rolling mills, continuous casting mills, and cold rolling
mills. Scales from primary and hot rolling mills and continous casting
mills are recycled to the sinter or blast furnace for iron recovery.
This practice is environmentally sound since land disposal is precluded.
Scale from cold rolling mills is often highly contaminated
with oil which discourages recycle to the sinter because of hydrocarbon
emissions in the sinter. Normal disposal is by open dumping. This
practice is not environmentally adequate because of the possible movement
of oil and grease through permeable soils to groundwaters or surface
waters.
1'Lckle Liquors. Currently the prevalent practice employed by steel
plants for handling of waste pickle liquor is the service of outside
contract disposal services who generally neutralize the acid before
disposal in unlined lagoons. Disposal in unlined lagoons is inadequate
if heavy metals leach from the sludge formed from neutralization and
percolate through permeable soils to groundwater.
1.3.2 Present Treatment and Disposal Technology (Level I)
Coke Plant. Wastes from coking operations and associated byproduct
production which are considered potentially hazardous include waste
ammonia liquor, ammonia still lime sludge and decanter tank tar. Treatment
of ammonia liquor in a biological treatment plant is adequate since des-
truction of potentially hazardous constituents (i.e. phenol, cyanide) is
achieved. Inputs of these wastes to the biological treatment plant must
be sufficiently dilute so as to not interfere with normal biological
activity. Deep well disposal of waste ammonia liquor is adequate only
when done according to EPA guidelines as stated in EPA Administrator's
Decision Statement No. 5 dated February 6, 1973 (Reference 10).
Ammonia still lime sludge and decanter tank tar are presently
open dumped. This practice is environmentally inadequate because of the
danger of toxics including phenol, ammonia, or cyanide leaching and
percolating to ground or surface water.
Electric Furnaces. Residuals from electric furnaces which are con-
sidered potentially hazardous include emission control dusts and sludges.
Present disposal of dusts and sludges is open dumping. This practice is
environmentally inadequate because of the danger of heavy metal leaching
through permeable soils to groundwater or surface water.
43
-------
Potentially hazardous sludges are generated from wate,
_
pollution control operations in primary mills, continuous casting mills,
hot roir:iig mills, cold rolling mills, galvanizing mills and tin plating
mil's. Present treatment and disposal is open dumping which is environ-
T.e-r'Tilly inadequate because of the threat of heavy metal and oil or grease
Mill S^JJjjJ^- Potentially hazardous mill sculoi nro generated in primary
,iixl hot rolling mills, continuous casting mills and cold rolling mills.
The .scale from all of these operations excepting cold rolling mills is
normally recycled to the sinter for iron recovery and is environmentally
adequate. Highly oil contaminated scale from cold rolling mills is
presently open dumped. This practice is not environmentally adequate.
Pickle Liquor. Present treatment and disposal technology generally
consists of disposal by contract disposal companies who neutralize the
acid pickle liquor and leave the neutralization sludge in unlined lagoons.
Some steel plants dispose of pickle liquor by deep weJl disposal. The
use of unlined lagoons is not environmentally adequate because of the
danger of toxic heavy metal leaching through permeable soils to groundwater
or surface waters. Deep well disposal is adequate when done in accordance
with HPA guidelines.
1.3.3 Best Technology Currently Employed (Level II)
Coke Plant. Level II technology for treatment and disposal of waste
ammonia liquor, ammonia still lime sludge and decanter tank tar is the
same as Level I and is inadequate except for deep well disposal of
pickle liquors which is adequate.
Electric Furnaces. Level II technology for treatment and disposal of
potentially hazardous electric furnace dusts and sludges is the same as
Level I (i.e. open dumping) and is inadequate.
Mill Sludges. At approximately 5% of the steel plants sludges from
primary and hot rolling mills are recycled through the sinter for iron
recovery. This precludes land disposal and is therefore environmentally
adequate.
Colt! rolling mill and galvanizing mill shuh'rs .m> open dumped
which is inadequate for environmental protection.
At some plants tin plating mill water treatment sludge is
reprocessed for tin recovery. This is environmentally adequate.
Mill Scales. Level II treatment and disposal tcchnolog) for mill
scales from primary mills , continuous casting mills, hot rolling mills,
and cold rolling mills is the same as Level I.
44
-------
Pickle Liquors. At a few steel plants spent pickling liquor is processed
for reclamation of sulfuric acid or hydrochloric acid and reuse in the
pickling operations. The iron oxide or iron sulfate residues can be
recycled for recovery of iron. This practice is environmentally adequate.
Deep well disposal of pickle liquors according to EPA guidelines is
adequate.
1. .3.4 Technology to Provide Adequate Health and Environmental
Protection (Level III)
Coke Plant.. Biological treatment of waste ammonia liquor from the
byproduct coke plant will detoxify toxic constituents including phenol,
cyanide, and ammonia if present in low concentrations. Solvent recovery
and ammonia stripping will normally precede biological treatment of
ammonia liquor. Deep well disposal of pickle liquors in accordance with
L;PA guidelines is adequate for environmental protection.
Sealing of permeable soils at dump sites to prevent leaching
of phenol, cyanide, or ammonia from lime sludge or decanter tank tar, or
collection and treatment of leachate constitutes Level III treatment and
disposal technology.
1:1ectric Furnaces. Sealing of permeable soils at dump sites for disposal
of sludge or dust, from control of emissions from electric furnaces or
collection and treatment of leachate will be necessary for adequate
environmental protection.
Mill Sludges. If primary or hot rolling mill sludges are not recycled
to the sinter, chemical fixation would be required prior to open dumping.
Chemical fixation of cold rolling and galvanizing sludges would be
required before open dumping.
Metal reclamation from tin plating sludge would qualify as
Level III technology. If this sludge is lagoon disposed, the use of
lined lagoons would be needed for adequate environmental protection.
Mill Scales. If mill scales are recycled to the sinter adequate environ-
mental protection is assured. If mill scales are open dumped the use of
bentonite or other soil sealants would be required to prevent percolation
of toxic heavy metals or oil and grease,or collection and treatment of
leachate would be necessary.
Pickle Liquor. Processing of spent pickle liquor to reclaim hydrochloric
or sulfuric acid and metallic value (i.e. iron),or deep well disposal
according to EPA guidelines is Level III technology.
Tables 8a through 8f summarize features of Levels I, II and
III treatment and disposal technologies for potentially hazardous wastes
from the iron and steel smelting and refining industry.
45
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i.-i COST ?t:,AifSIS
In the last section various treatment and disposal technologies
currently employed or considered for adequate health and environmental
protection were described. Tjie costs of implementing this technology for
n typical integrated iron and steel mill complex are estimated in this
sect;on. Costs of land disposal from individual operations such as steel
fur ;r^fs and rolling mills are also given. The exemplary plant has an
annual capacity of 2,500,000 MT of steel and is assumed to operated 350
days per year. Facilities at the plant include the operations given in
Table 4 and generate the wastes listed previously in Table 5. All disposal
dtts are situated on semi-industrial land.
Dust
Dust results from blast furnace, basic oxygen furnace and
electric furnace operations. Dust from the blast furnaces is recycled
to the sinter plant. No disposal cost is incurred. The dust-from the
basic oxygen furnace operations amounts to only 288 MT (222 m )/year.
It is not considered hazardous.
Electric Furnace Dust. Dust from the electric furnaces considered poten-
tially hazardous (7,500 MT or 4165 m /yr) is hauled to an on-site dump.
This requires 1 hr/day of front loader and truck time plus 40 hrs/yr of
nulldozer time at the dump. The dust is piled to a height of 5 m. The
dump area is sized to hold 20 years of waste and extends over 1.7 ha.
Electric Furnace Dust
Capital Cost
Dust Dump
Survey $ 1,065
Land 6,725
Equipment
Truck (12.5%) 3,125
Front Loader (12.5%) 2,500
Bulldozer (2%) 320
Total $13,735
Annual Cost
Land $ 675
Construction Amortization 125
Equipment Amortization 945
Equipment Repair and Maintenance 295
Operating Personnel 8,045
Energy
Fuel 995
Electricity 100
Taxes 170
Insurance 155
Total $11,485
58
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Sludge wastes are generated by all operations except by the
electric furnaces (where a dry control system is assumed) and the soaking
pits.
3
Coke Oven Sludge. Ammonia still lime sludge (6,160 NfT or 5,135 m /yr) is
produced at the coke ovens. The sludge is disposed at a dump. One hr/day
of frontloader and truck time are needed for loading and transporting the
sludge and 50 hrs/yr of bulldozer time at the dump site. The sludge is
piled to a height of 5 m. The dump occupies 2.1 hectares and accommodates
20 years of waste sludge.
Coke Oven Sludge (ammonia still lime sludge)
Capital Cost
Sludge Dump
Survey $ 1,315
Land 8,305
Equipment
Truck (12.5%) 3,125
Front Loader (12.5%) 2,500
Bulldozer (2.5%) 400
Total $15,645
Annual Cost
Land $ 830
Construction Amortization 155
Equipment Amortization 960
Equipment Repair 5 Maintenance 300
Operating Personnel 8,170
Energy
Fuel 1,005
Electricity 100
Taxes 210
Insurance 155
Total $11,885
Primary and Other Hot Rolling Mill Sludge. The primary and other hot
rolling mills produce 5739 MT of sludge per year. The scale wastes
generated by these operations are recycled to sinter on the blast furnace.
However, about 2 percent of the scale, containing oil contaminants, is
skimmed off and disposed with the sludge.
The total yearly waste disposed is about 7,750 MT or 4840 m .
Loading and hauling require 1 hr/day of front loader and truck time, and
50 hrs/yr of bulldozer time is assigned at the dumpe site. The dump
occupies 1.9 ha.
59
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Primary and Other Hot Rolling Mill Sludge
Capital Cost
Sludge Dump
Survey $ 1,190
Land 7,515
Equipment
Truck (12.5%) 3,125
Front Loader (12.5%) 2,500
Bulldozer (2.5%) 400
Total $14,730
Annual Cost
Land $ "50
Construction Amortization 140
hquipment Amortization 9bO
Lquipment Repair § Maintenance 300
Operating Personnel 8,170
Energy
Fuel 1,005
Electricity 100
Taxes 190
Insurance 145
Total $11,760
Cold Rolling Mill Sludge. The cold rolling mills produce only 111 MT of
sludge annually. For the purpose of costing, the disposal cost of this
sludge is combined with that generated by the galvanizing mill.
Tin Plating Mill Sludge. The sludge from the tin plating mill is disposed
in a lagoon. The wet sludge (50°6 solids) produced annually amounts to
1064 MT. The lagoon is sized to hold 20 years of waste. The lagoon character-
istics are:
Volume 21,300 nf Circumference 390 m.
Bottom Width 55 m Dike volume 5,900 m^
Top width 67 m Dike surface 5,540 m
Bottom length 110 m Total width 81 m
Top length 122 m Total length 136 m
Total depth 3 m Required area 1.1 ha
Depth of Excavation .9 m
60
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'in Plating Mill Sludge
Capital Cost
Site Preparation
Survey $ 690
Test Drilling 980
Sample Testing 500
Report Preparation 1,500
Construction
Hxcavation and Forming 7,845
Compacting 10,910
Fine Grade Finishing 2,490
Soil Poisoning 485
Transverse Drain Fields 1,500
I, a ml __
Total $31,250
Annual Cost
Land $ 435
Construction Amortization 2,695
Construction Maintenance § Repair 695
Taxes 110
Insurance 315
Total $ 4,250
Galvanizing Mill Sludge. The sludge produced by the galvanizing mill is
combined with that from the cold rolling mill. Also included is the small
amount of scale waste (36 MT/yr) from the cold rolling mill. The total waste
disposed is 1500 MT/yr. Loading, hauling and diposing on land requires
about .25 hrs/day of front loader and truck time and a .4 ha sludge dump.
Galvanizing and Cold Rolling Mill Sludge
Capital Cost
Sludge Dump
Survey $ 250
Land 1,580
Equipment
Truck (5%J 1,250
Front Loader (5%) 1,000
Total $ 4.080
61
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Annual Cost
Land $ 160
Construction Amortization 30
Equipment Amortization 360
Equipment Repair § Maintenance 115
Operating Personnel 1,890
Bnergy
Fuel 240
Electricity 25
Taxes 40
Insurance 40
Total $ 2 , 900
Scale
Scale is produced by primary and hot rolling mills and the cold
rolling mills. Practically all of the scale of the former is recycled to
sinter or blast furnaces. No disposal costs are incurred. Scale from the
cold rolling mill is land disposed together with the sludge from that opera
tion. No separate costs are incurred.
Waste pickle liquor results from cold rolling and galvanizing mill
operations. The liquor is treated and disposed of by an outside contractor
at a cost of $10.55/m ($.04/gal).
No capital costs are incurred. The annual cost is $149,010.
Waste Ammonia Liquor
Waste ammonia liquor is normally not land disposed. It is normally
detoxified in a biological treatment plant as a minor flow. Occasionally it
is disposed of in deep wells. The associated costs of deep well disposal
were not ascertained since no land disposal is considered as Levels I, II and
III treatment and disposal technology.
1.4.2 Cost of Best Technology Currently Employed (Level II}.
Dust
Dust disposal and associated costs are the same for Level II as
Level 1.
Sludge
Sludge from the Mast furnaces, basic oxygen furnaces and primary
and hot rolling mills can be recycled to sinter depending on its composition.
62
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Tin plating mill sludge in some plants has a sufficiently high
metal content so that it can be sold to an outside contractor for metal
reclamation. We were unable to obtain information on prices paid by
reclaimers for the sludge. This treatment method would eliminate the need
for the lagoon specified for Level I and its associated costs. Level II
treatment for the other sludges is the same as for Level I.
Waste PickJe Liquor
Acid regeneration is the Level II treatment for waste pickle
liquor. Reference 2 indicates a cost of $13/nf of waste treated. This
cost is included as an annual cost. It includes the amortization of capital
treatment plant investment. Acid regeneration results in an annual cost
of $183,610 which is about a $35,000 increase over the Level I treatment cost.
Incremental changes resulting from the implementation of Level II
technology are shown below.
Capital Cost Annual Cost
Slag
Dust
Sludge ($31,250) ($4,250)
Waste Pickle Liquor - 34,600
Total ($31,250) $30,350
( ) = savings engendered by sale of tin plating mill sludge and
resultant elimination of sludge lagoon.
1.4.5 Cost of Technology to Provide Adequate Health and Environmental
Protection (Level III)
Dust
The soil is sealed at the dump used for storing the dust from
the electric furnaces. Collection ditches, pump and piping are provided
at the dump site.
Electric Furnace Dust
Capital Cost
Soil Sealing $34,000
Collection ditches 1,970
Pump 9,100
Piping 2,210
Total $47,280
63
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Annual Cost
Construction Amortization $ 4,175
Equipment Amortization 1,800
Construction Repair & Maintenance 1,080
Equipment Repair § Maintenance 565
Energy
Fuel
Electricity 95
Insurance 475
Total $ 8,190
The soil is sealed at the coke oven sludge dump; collection
ditches, pump and piping are installed.
Coke Oven Sludge
Capital Cost
Soil Sealing $ 42,000'
Collection Ditches 2,195
Pump 9,300
Piping -.-JJL
Total $ 55,705
Annual Cost
Construction Amortization $ 5,130
Equipment Amortization 1,835
Construction Repair $ Maintenance 1,325
Equipment Repair § Maintenance 575
Energy
Fuel
Electricity 110
Insurance 560
Total $ 9,535
The sludges from the primary and other hot rolling mills as
well as those from the galvanizing and cold rolling mills are chemically
fixed prior to land disposal.
Primary and Other Hot Ho I ling Mill Sludge
- -. .»-.._./-. --~ . -. -..-.. .. .- -.*-.-M. ....... -- . ..... I. ,M. ,
Capital Cost Not Applicable
Annual (.'usI
Chemical Fixation $63,930
Total $63.930
64
-------
Galvanizing and Cold Rolling Mill Sludge
Capital Cost Not Applicable
Annual Cost
Chemical Fixation $13,175
Total $13,175
Level III for tin plating mill sludge disposal consists either
of the sale of the sludge to a metal reclaimer or installing a lagoon liner
where the sludge is disposed on land. The former entails no cost to the
plant. Costs for the latter are shown below.
Tin Mill Sludge
Capital Cost
Lagoon Liner $38,235
Total $38,235
Annual Cost
Construction Amortization $ 4,440
Construction Repair $ Maintenance 1,145
Insurance 380
Tot;il $
Level III treatment of waste pickle liquor consists either of
acid regeneration or neutralizing the waste by lime treatment, allow for
settling of the sludge in a lined lagoon followed by chemical fixation and
land disposal of the sludge. Acid regeneration involves no additional costs
beyond those listed under Level II treatment. Costs for the other alternative
is shown in Table 9.
The total annual waste liquor.amounts to 15,100 MT. This results
in the formation of 6,285 MT or 4,910 m .of sludge. The selected lagoon size
Is 10,000 m and it assumed that 4,910 m of sludge are dredged annually.
The removed sludge is chemically fixed and hauled to a dump site.
A J3(> I/min slurry pump is used for dredging. The pump is operated
3f»0 lirs/yr and 400 hours of labor are assigned to its operation. Loading
and hauling of the sludge to the dump site requires 2t>5 hrs/yr of front
loader and truck time and 50 hrs/yr of bulldozer time at the sludge dump.
65
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TABLE 9 .COST OF LEVEL III TREATMENT AND DISPOSAL TECHNOLOGY
INTEGRATED STEEL MILL - PICKLE LIQUOR SLUDGE
Capital Cost
Lagoon
Site Preparation
Survey $ 375
Test Drilling 490
Sample Testing 250
Report Preparation 1,200
Construction
Excavation and Forming 4,535
Compacting 6,310
Fine Grade Finishing 1,705
Soil Poisoning 345
Transverse Drain Field 855
Lagoon Liner 20,025
Land 2,375
Sludge Dump
Survey 625
Land 3,955
Equipment
Slurry Pump 13,730
Flexible Pipe (100 m) 440
Front Loader (15%) 3,000
Truck (15%) 3,750
Bulldozer (2.5%) 400
Total $ 64,565
66
-------
TABLE 9 (Continued)
Annual Cost
Land 635
Construction Amortization 4,270
Equipment Amortization 3,405
Construction Repair and 1,015
Maintenance
Equipment Repair and 1,065
Maintenance
Operating Personnel 10,110
Energy
Fuel 775
Electricity 90
Chemical Fixation 64,810
Taxes 160
Insurance 645
Total $ 86.980
Less Acid Regeneration (183,610)
Total ($96,930)
C ) = savings
67
-------
Tlic lagoon characteristics are:
Volume 10,000 m Circumference 277 w
Bottom width 36 m Dike volume 3,410 m
Top width 48 m Dike surface 3,790 m
Bottom length 72 m Total width 62 m
Top length 84 m Total length 98 m
Total depth 3 m Required area 16 ha
Depth of excavation 1.15 m
The dump is sized to hold 20 years of waste piled to a height of
10 m. It occupies 1.0 ha. The lime treatment facility used to neutralize
the waste pickle liquor is considered part of the water treatment system
and its cost is not included.
Summary costs for Level I, II and III waste treatments for an
integrated steel plant are given in Table 10. Annual costs for Levels I
and II disposal of potentially hazardous wastes are estimated as $7,570,000
which represents less than 0.1% of the estimated 1973 sales value.
Annual costs for Level III technology (i.e. adequate for environmental
protection) are estimated as $12,930,000 or 0.15% of estimated 1973 sales
value.
68
-------
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1.0 IRON AND STHEL TOUNDRUiS
.M INDUSTRY CHARACTERIZATION
Die three major groupings of ferrous castings are gray and
auci.i.'t, iron castings, malleable iron castings, and steel castings. While ^
specific procedures might vary from foundry to foundry, the overall opera-
tions for producting castings of all three types are essentially the same
tnd include metal melting and pouring, casting shakeout and cleaning and
ti'iishing.
There are about 2000 foundries in the U.S. producing ferrous
castings. There is great variability in plant si'.e with monthly capacities ^
ranging from 20 net tons to over 10,000 net tons.* It is important to note
that only about 60 percent of all castings produced in the United States
are covered under SIC 332 (Iron and Steel Foundries). The remaining 40
percent are produced under other SIC categories, such as SIC 3714 (Motor
Vehicles), SIC 3541 (Machine Tools), etc.
The production data and waste data presented in this report
represents only those operations covered under SIC 332 which are within
the primary metal smelting and refining industry.
The 1973-74 directory of members of the Gray and Ductile Iron
Founders Society, Inc. lists 186 foundries. The monthly average production 9
of these foundries was calculated to be about 1125 MT of finished castings
giving an average annual production of 13,500 MT. Using data from "The
Metal Casting Industry Census Guide" (1972 Edition, published by Penton
Publishing Co., Cleveland, Ohio), the average annual production for all
gray and ductile iron foundries (an estimated 1300 to 1500 foundries) was
calculated to be about 9,250 MT. Thus, a reasonable capacity figure for ^
a typical gray and ductile iron foundry plant would be about 11,000 net
tons per year.
Steel foundries average about 5,440 MT of capacity per year and
malleable iron foundries average about 12,700 MT per year. ^ i
Table 11 gives state by state, regional, and national shipments *
of the various type of ferrous castings for 1973. These figures are ;
believed to reflect 1973 capacity. Iron and Steel foundries , <
are concentrated in states heavy in manufacture of iron and steel and \
automobiles and heavy industrial equipment which are principal consumers I
of foundry castings. i
2.2 WASTH CHARACTERIZATION j!
This section contains descriptions of production technology at
ferrous foundries and the resultant byproducts or wastes which are either |
recycled directly, reprocessed, or disposed of on land or in lagoons. j
* amount of metal smelted for finished castings exceeds net output of T
castings products. i
70 i
-------
TABLE 11
STATE, REGIONAL, AND NATIONAL SHIPMENTS OF IRON AND STEEL CASTINGS, 1973*
(METRIC TONS)
State
Alabama
Arizona
California
Colorado
Connecticut
Delaware
Florida
Georgia
Illinois
Indiana
Iowa
Kansas
Kentucky
Lousiana
Maryland
Massachusetts
Michigan
Minnesota
Missouri
Nebraska
New Jersey
New York
North Carolina
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
raj
roi
r § Ductile
i Castings
1,543,121
0
412,769
98,883
35,380
0
9,072
10,886
1,364,406
2,
2,
1,
970,688
368,317
10,886
291,206
9,072
72,575
59,870
597,270
170,551
63,503
10,886
347,452
822,820
107,048
255,260
34,473
9,979
954,980
28,120
Malleable
rron Castings
17,237
0
0
0
8,165
0
0
0
118,841
35,380
9,072
0
0
0
0
1,814
395,533
10,886
0
0
0
16,329
0
128,820
0
0
111,584
3,629
Steel
Casting
87,090
58,060
60,781
5,443
0
6,350
10,886
6,350
236,775
72,575
23,587
59,874
0
12,701
6,350
0
60,781
20,865
49,895
13,608
6,350
72,575
0
318,422
10,886
32,659
221,353
0
Total Iron
Steel Cast
1,647,448
58,060
473,550
104,326
43,545
6,350
19,958
17,236
1,720,022
1,078,643
400,976
70,760
291,206
21,773
78,925
61,684
3,053,584
202,302
113,398
24,494
353,802
911,724
107,048
2,702,502
45,359
42,638
2,287,917
31,749
71
-------
TABLE
STATf-, REGIONAL, AND NATIONAL SHIPMENTS OF IRON AND STEEL CASTINGS, 197:-- (METRIC TONS)
St'Jie
South Carolina
South Dakota
I tmnessee
Texas
Utah
Vermont
Virginia
Washington
West Virginia
Wisconsin
EPA Region
I
1 1
111
IV
V
VI
VII
VIII
IX
X
Gray $ Ductile
Iron Castings
25,401
0
378 , 296
495,323
196,859
9,980
162,386
9,072
74,389
453,592
133,350
1,170,272
2,264,330
2,365,030
7,811,767
538,868
453,592
295,742
412,769
19,051
Malleable
Iron Castings
0
0
0
29,030
Q
907
0
0
1,814
46,266
14,515
16,329
113,398
17,237
735,726
29,030
9,072
0
0
0
Steel
Castings
0
2,722
37,195
42,638
3, 072
0
5,443
26,308
9,979
130,635
0
78,925
249,475
141,521
840,053
66,225
146,964
17,237
118,841
58,967
Total Iron $
Steel Castin;
25,401
2,722
387,368
566,991
205,93;
10,887
167,829
35,380
86,182
630,493
147,865
1,265,526
2,627,203
2,523,788
9,387,546
634,123
609,628
312,979
531,610
78,018
U.S. Total
15,464,771
935,307 1,718,208
18,118,286
Believed to Reflect U.S. Production Capacity in 1973
72
-------
f'stimates are given for the quantities of wastes and potentially hazardous
constituents thereof which are disposed of on land either in lagoons,
landfills or open dumps.
2,2.1 Pcocess PCScrij>ti ons
While specific procedures might vary from foundry to foundry,
i he iwrall operations Tor producing iron castings, malleable iron
<.;.ting;., arid stvol castings arc essentially the same and include: sand
preparation, mold and core making, metal melting and pouring, casting
shakeout, and cleaning and finishing. The interrelationship between
major operations in a typical foundry is shown in Figure 2. Also shown
are the major sources of solid wastes. Although not all foundries
practice sand reclamation, its use has become sufficiently widespread in
the industry to require its inclusion in Figure 2.
Clay bonded molding sands are prepared by mixing silica sand,
organic additives, bentonite clay and water together. Some foundries
use olivine, zircon, chromite, biasill or other aggregates instead of
silica sand. Carbonaceous material in the amount of 2 to 10 percent is
also added to the molding sand as may be required to impart special
properties. Materials in this category include finely ground bituminous
coal, ground corn flower, fuel oil, and finely ground cellulose material.
The molds are made by packing the molding sand around previously
made patterns to form the required shapes. For castings having hollows
or recesses, cores are required to complete the mold. Since the cores
must be removed after the castings have solidified, the core sands have
special properties that facilitate their removal. The desired properties
are achieved through the use of special binders, the most common of
which are: (1) combinations of vegetable, fish and petroleum oils; (2)
phenol formaldehyde resin, (3) sodium silicate; (4) phenolic isocyanate;
(5) alkyd isocyanate; and (6) mixtures of urea and furfural alcohols.
The first item is generally baked to promote hardening, and items 2 and
6 are generally heat-cured. The difference is that baking is done at
the rate of approximately one hour per inch of thickness while curing is
done in a matter of 30 to 60 seconds at approximately the same temperature.
In the case of sodium silicate binders, hardening is achieved by forcing
CO gas through the sand. For the isocyanate binders setting occurs at
room temperature through the use of special catalysts. For the urea-
furfural alcohol binders, setting is possible at room temperature or
higher depending on the type of catalyst used. With the successful use
of the newer core binders that do not require high temperatures for
setting, it appears that fewer and fewer foundries will continue the
practice of core baking.
In addition to special binders, certain other materials are
frequently used in preparing core sands. These include: iron oxide,
ground corn flour; water soluble compounds of wood sugar; coke pitch;
and ground hardwood cellulose. Those materials facilitate removal ol"
cores.
73
-------
ro ah Sand
Binders
Fresh Sand
Binders
(Reclaimed
JGand
?and
Reclam-
ation
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Figure 2 - Foundry Operations
74
-------
Once the cores are formed and cured, they are integrated with the
final molds which are then transferred to the metal pouring area. Molten
metal of the desired composition is prepared in one of several different
types of commonly used furnaces. Charge materials for the cupola furnace
usually consist of a flux material, coke, and metallics. Electric arc or
induction furnaces do not require coke. Typical fluxes include limestone
(CaCO,), fluorspar (mostly CaF,), and soda ash (Na C)_). The metallic
charge consists mainly of external scrap and some internally generated
scrap. For producing gray and ductile iron castings, cupolas and electric
induction furnaces are the most widely used, with cupolas accounting for
an estimated 60 to 65 percent of total production. Reverberatory furnaces
account for one percent or less of gray and ductile iron castings. Most
malleable iron castings are produced in cupolas and electric induction
furnaces, although a number of air furnaces are still in operation. Electric
arc furnaces account for almost all of the steel castings produced with
electric induction furnaces accounting for probably less than 5 percent.
The molten metal is tapped from the furnaces into ladles and
poured into the waiting molds. After the castings have solidified they
are separated from the molds in the shakeout area. The separated castings
arc then cooled prior to cleaning and finishing. Cleaning and finishing
operations include shot blasting, chipping and grinding.
Following casting shakeout, the mold and core sands are screened.
Larger remnants of undisintegrated cores (core butts) and larger chunks of
molding sand are transferred to a disposal area. Most of the molding sand,
along with the degraded core sand, proceed directly back to molding sand
preparation without going through sand reclamation (i.e., this sand is
recycled, rather than being reclaimed). In some foundries a portion of
this return sand is bypassed through a reclamation system and then returned
i.o either Lhu core or molding sand mixing operation. In the case of no-bake
sands, most of the sand from the shakeout may be returned through the sand
reclamation unit before recoating. Excess sand is sent to landfill.
2.2.2 Description of Waste Streams
The major types of solid wastes generated at iron and steel
foundries were indicated in Figure 2. The general types of waste generated
are essentially independent of the type of metal being cast and the type
of furnace in use. On the other hand, metal type and furnace type can
affect the quantities of waste produced. The numbers in parentheses in
Figure 2 indicate the amounts of waste in each category expressed as kilo-
grams of waste per ton of metal melted. The numbers correspond to an
average plant producing iron in a cupola. The values are given on the
basis of a ton of metal me1 tod rather than on the basis of a ton of finished
castings, because yield factors (weight of finished casting/weight of metal
melted) vary depending <>;i the- foundry and tho type of metal cast. For
iron (gray, ductile and malleable) the yield factor is generally in the
r.ui^f of ().() to 0.7, while for .steel values of 0.5 are common. For the
purpose of computing total waste quantities for an average iron foundry,
75
-------
a yield factor of 0.65 would be reasonable. Thus, a typical iron founo.--/
woul.i molt about 11,000/0.65 - 16,900 tons of metal per year (15,300
iT.etiic tons/year).
.Hi!1" ^'L''J As stated previously and shown in Figure 2 there are two
types of waste sand. One type is the clay bonded molding sand used in
interior parts of the mold. Combined product!-*" of the two types of
wute sand is 330 kg/MT of cast product. AJthough these sands have
>KxTerent organic additives as described on ,-^e ?2 the organic fractions
are burned and charred during the pouring of molten metal leaving principally
sand coated with carbon residues and traces of metal compounds including
copper, lead, chromium and zinc. Solubility tests on spent foundry sand
us described in Appendix B did not show significant leaching of heavy
metals or phi-no 1. For this reason foundry sands are not considered
potentially hazardous at this time.
Core Butts. After the metal pouring process most of the sand is devoid
of binder and has little aggregation. Quite often portions of the core
sand retain its binder. It is removed as large chunks known as core
butts and brought to dumping areas. Core butts are generated at a rate
oi" 48.1 kg/MT of casted metal. Although solubility testing on core
butts was not conducted it is not expected to leach to a greater extent
than spent sand. Core butts are therefore not considered potentially
hazardous at this time.
Dust. Dust is generated at a rate of 31.7 kg/MT of foundry product
from the sand reclamation process and from baghouuses on metal milling
furnaces. Dust will principally be silica oxides and iron oxides with
traces of heavy metals including lead, cadmium, copper chromium, nickel,
and zinc. Solubility tests on foundry dust as described in Appendix B
did not show significant leaching of potentially hazardous metals. For
this reason foundry dust is not considered potentially hazardous at this
time.
Sludges. Wet scrubbers used to scrub emissions from metal pouring
operations produces a wastewater which in turn produces a sludge at a
rate of 18.2 kg/MT cast metal product. This sludge will contain iron
for the most part along with traces of cadmium, copper, chromium, nickel,
lead and zinc. Solubility tests were not conducted on sludges. They
would be expected to be of similar composition and nature as furnace
dusts however which were studied in solubility tests as described in
Appendix B. Since the dusts did not leach significant concentrations of
toxic constituents sludge was assumed to be of a similar solubility and
therefore is considered as not potentially hazardous at this time.
Slag. Slag from iron and scrap steel furnace smelting is produced at a
rate of 56.3 kg/MT of finished iron and steel casting. The gravel size
to sand size pieces of slag contains iron, lime and soda ash principally,
with small traces of heavy metals including cadmium, copper, chromium,
nickel, lead and zinc. Solubility tests as described in Appendix B did
not show significant leaching of potentially toxic constituents. For
this reason furnace slag from iron and steel foundries is not considered
hazardous at this time.
-------
I Jonrswei'piii^r.. Cleanup of floor;, in core making r\,oms results in
liuuly floor sweepings ;it a rate of 11.8 kg/MT of product. This is
assumed similar to other waste sands and therefore non-hazardous at this
time. Solubility tests were not conducted on floor sweepings.
Refract or ios. Broken and weathered brick refractories from metal
melting furnaces are generated at a rate of 10 kg/MT of finished castings.
These bricks are predominantly highly insoluble fired clay ceramic and
are not considered potentially hazardous.
Appendix A gives analyses of iron and steel foundry wastes
including sands, dust and slag.
2.2.3 Waste Quantities
Table 12 gives generation factors for the various residuals
from iron and steel foundry production as well as concentration factors
for potentially hazardous constituents. The waste' residual factors
given in Table 12 are estimated average values for all foundries in each
of the three major foundry categories. In developing the waste factors,
consideration was given to the different types of furnaces used in each
metal category and to tho different typos of furnace omission control
systems, For example, gray and ductile iron is made in cupola furnaces
and electric induction furnaces in the ratio of about 3 to 2. Control
for cupola furnace emissions is devided about equally between wet and
dry systems, while electric induction furnaces generally require no
emission control.
In generating the overall waste factors, the computation of
sludges, and dusts and slag accounted for the percentage of castings
within a given category made from a specific type of furnace with a
specific type of control by weighing the waste factors for specific
combinations according to the frequency of their occurrence.
Table 13 presents the amounts of wastes and the amounts of
specific potentially hazardous constituents generated annually for an
average plant in each of the three major foundry categories. The amounts
shown were calculated using the waste factors given in Table 12 and
taking the following average annual production figures for finished
castings for each type of foundry: (a) gray and ductile iron foundries -
10,000 metric tons, (b) malleable iron foundries - 12,700 metric tons;
and (c) steel foundries - 5,400 metric tons.
The quantity of waste generated by ferroalloy plants on a state-
by-stiite basis arc given in Table 14 for 1974, 1977, and 1983. The quantities
of sludges and dusts arc based directly on information derived from a solid
waste survey sponsored by the Ferroalloy Association in which the quantities
of wastes from furnace emission control were tabulated for each state for each
type of ferroalloy. The sludges result from the collection of furnace
emissions using wet scrubbing systems. The dusts represent the furnace
77
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tO CN CN to 1
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A
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rH
rHJ
«4H w
0 X C
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4-> -H S^tJ
<-> IO U C rH O
(0 *|H *O ^M *rH (/)
V M O 4J
'M S S, "^ *a °
S tlO S C r< *J
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LO tO Q tO Oi
-------
Table 14a
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SLAG, 1974 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
UIUUON
I'LNNbYLVANlA
HHOIH iM ANI1
S CAHOI INA
S DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W VIRGINIA
WISCONSIN
EPA REGION
I
n
m
or
V
m
sn
dn
IX
X,
NATIONAL TOTALI
TOTAL
DISPOSED
122.400
1.800
37.800
7,800
3,040
MO
2.110
1.630
134,500
81,000
29.800
8.860
20.680
2.360
6.010
4,370
218.200
16.600
11.240
2,600
25,500
69.300
7,600
211.400
3.1120
!> I1U
i n.vou
J 1 10
I.HUO
370
31.880
42,800
15.200
770
12,270
4.200
6,750
52.800
10,410
94.800
201,790
188.100
715,600
49,080
62,6*0
23.170
46,300
*.JIU
1.300.2(0
TOTAL
POTENTIALLY
HAZARDOUS-
(
1
TOTAL
HAZARDOUS
CONSTITUENTS
1
DISPOSAL
METHOD
LANDFILL
OP.
OPEN DUMP
1
CONSTITUENTS
Cd
0122
0001
0038
0008
0003
0.001
0002
3.002
o ni
0.081
a on
0008
0020
0002
0006
0004
0218
0016
0.011
0.003
0.026
0070
0008
0211
0004
0006
0170
0002
0002
- 0
0032
0043
001S
0001
0012
0004
0.007
0.053
0.010
0.098
0202
0.188
0.716
0049
0062
0021
(1046
ODD*
1.3*0
Cu
3 16
041
1.10
0.2
007
0.04
0.09
006
40*
2.16
0.78
0.44
048
0 10
016
010
532
044
045
0 11
061
1 88
0 18
613
0 13
II .",
4 9 )
II IV
0 04
0 0?
OSS
1 16
039
0.02
0.30
020
U JO
1 73
024
2.49
6.83
4.89
19.87
1 39
1 /8
0 61
1 til
0,4!>
38110
Cc
580
1 17
230
037
OU'
013
024
0.16
8.67
409
14«
1.24
0.76
0.28
032
0.16
9.16
090
1 17
030
1 03
365
0.28
12.66
031
0 t.!l
' tl/
Mn
217.7
407
840
137
45
44
8.S
55
316 1
1522
64.5
43 1
29.2
98
11 7
6.2
3473
329
413
106
393
1352
10 7
463 7
11 1
239
je.i /
,MM i;
u,i' J !,
n at, i y
1 / ' (.4 0
2 ?T
0.70
003
053
Oi>5
040
395
039
4.68
1126
904
39.42
282
4 17
1 1J
1 4 '
1 U
7/00
(12.8
261
1 1
20 1
193
14 /
1422
150
174.6
414.6
338 1
1,454.4
1037
140 b
41 7
124 /
4J2
2.K94
Nl
122
008
0.38
0.08
003
0.01
0.02
0.02
1.37
041
0.2*
0.09
0.20
0.02
0.06
0.04
2.18
0.16
0.11
0.03
0.26
0.70
0.08
211
0.04
006
1 7C
H13
002
~0
032
043
0.19
0.01
0.12
0.04
0.07
0.63
0.10
O.M
2.02
1.84
716
0.4*
0.6J
on
046
00«
13*0
Pta
0.92
0.13
0.33
0.06
0.02
0.01
0.03
0.02
1.20
0.63
0.23
0.13
0.14
0.03
0.06
0.03
154
0.13
0.14
003
018
0.66
0.06
141
0.04
008
1 46
00!
0 01
~0
026
034
0.11
0.01
0.0*
0.06
006
0.62
0.07
0.73
146
143
543
0.41
0.63
0.17
048
0 14
11.40
Zn
2.12
0.33
an
0.13
005
0.04
0.07
0.06
240
1.4<
043
0.36
0.30
0.06
0.11
0,06
349
OJI
0.3»
00*
0.40
1J9
0.11
4.30
0.10
020
342
003
003
0.02
OS1
079
0.26
0.01
0.20
0.16
014
1.28
0.16
1.6*
341
3-29
13.72
0.17
1.32
041
1.11
O.M
2040
FOUNDRY SLAQ NOT CONSIDERED HAZARDOUS
ON BAII8 OF CALSPAN SOLUBILITY TESTS
DESCRIBED IN APPENDIX B
SOURCE CALSPAN CORPORATION
80
-------
Table 14b
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SLAG, 1977 (METRIC TONS)
r~~~ ' *"*
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
IE i AWARE
| luininA
! UtONliM
| ItllNOIS
INDIANA
IOWA
KANSAS
! KENTUCKY
', LOUISIANA
MARYLAND
| MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
, NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
OHCOON
PENNSYLVANIA
HHODI ISl AND
S CAROLINA
,' $. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W.VIRGINIA
WISCONSIN
EPA REGION
1
n
m
JS
V
m
TZH
VIH
K
X
NATIONAL TOTAL
TOTAL
DISPOSED
135.374
8.627
41,476
8,627
3,362
961
1.334
IJ03
160.9M
69.586
33.069
9.788
22,872
2,610
6.847
4.833
241.329
17.254
72.431
2,876
28.203
76.646
B.406
233.808
4.336
&.B62
104.646
2.466
1,991
408
36.259
47,337
16.811
862
13.571
4,646
7.466
68,397
11,613
104,849
223.180
208.039
791,343
54,282
58.166
1 26.847
60.102
10,297
1.537.616
TOTAL
POTENTIALLY
HAZARDOUS'
1
)
TOTAL
HAZARDOUS
CONSTITUENTS
1
)
DISPOSAL
METHOD
LANDFILL
OR
OPEN DUM
1
CONSTITUENTS
Cd
0.136
0.009
0.042
0.009
0003
0.001
0.002
0002
0162
0.000
0032
0.010
0022
0.002
0.007
0004
0241
0.018
0.012
0.003
0.029
0.077
0.009
0233
0004
0.006
0.195
0002
0.002
~0
0.036
0.048
0.017
0.001
0.013
0.004
0.008
0.089
0.011
0.106
0.223
0.208
0.792
0.084
0.068
0.025
0.051
0.010
1.S4
Cu
3.49
0.46
1.2
0.2
0.08
0.04
0.10
0.07
4.62
239
0.86
0.49
0.53
011
0.18
Oil
5.88
0.49
050
0.12
067
2.08
020
6.78
0.14
028
R45
006
0.04
0.02
0.97
1.28
0.43
0.02
0.33
0.22
0.22
1,91
0.26
2.76
6.23
6.41
21.98
1.S4
197
067
1 67
050
43.0
Cr
641
1.29
2.S4
0.41
013
0.14
0.26
OH
(.69
4.62
181
1.37
0.84
0.31
0.35
0.18
10.12
100
1.29
0.33
1.14
4.04
0.31
1400
0.34
078
10 »2
0.08
008
0.06
1.91
2.47
0.77
003
0.59
0.61
0.44
4.37
0.43
6.18
1244
10.00
4380
3 12
461
1 24
334
1.37
85.8
Mn
240.3
45.0
92.9
15.2
5.0
4.9
94
1.1
349.6
168.3
603
47.7
32.3
10.8
12.9
6.8
384.1
MA
457
11.7
435
149.5
118
512.8
12.3
26.4
4022
3.5
2.8
21
708
91.6
28.9
1.2
22.2
21.3
16.2
167.3
1C.6
193.0
468.5
373.9
1.6086
1147
165.3
46 1
137.9
47,8
3.162.6
Nl
1.36
o.oe
0/42
0.09
003
0.01
0.02
0.02
1.62
0.90
0.32
010
0.22
0.02
0.07
0.04
2.41
0.18
012
0.03
0.29
0.77
009
233
0.04
0.06
19S
002
002
"0
0.35
048
0.16
0.01
0.13
0.04
0.08
O.S9
0.11
1.06
223
2.08
7.92
0.54
O.S8
0.25
0.51
0 10
16.4
Pb
1.02
0.14
0.36
0.07
002
0.01
0.03
0.02
1.3)
0.70
0.28
0.14
0.15
0.03
0.06
0.03
1.70
0.14
015
0.03
0.20
061
006
2.00
0.04
0.09
1.60
001
0.01
~0
0.29
0.38
0.12
0.01
0.10
0.07
0.07
0.64
0.08
0.81
1.84
1.8*
646
0.45
0.59
0 19
O.S1
0.15
12.6
Zn
2.34
03«
0.88
014
0.06
0.04
0.08
0.06
3.11
1.61
0.69
0,39
0.33
0.09
0.12
0.07
3.86
0.34
0.39
0.10
0.44
1.43
0.12
4.76
0.11
072
3.78
0.03
0.03
0.02
0.67
0.87
079
0.01
0.22
0.18
0.15
1.39
0.16
1.87
4.32
3.S4
16.17
1.07
1.46
0.45
1.23
040
29.8
TOUNOH Y SLAO NOT CONSIDERED HAZARDOUS ON
HAIIt Ot CALSPAN SOLUBILITY TFSTS DESCRIBED
IN APPFNOIX N
HOIIHCt CAIWAN CORPORATION
81
-------
Table 14c
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SLAG, 1983 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
coNNicricur
DELAWARi
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NFWJEHSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
ORCOON
PENNSYLVANIA
RHODE ISLAND
S. CAROLINA
S. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W.VIRGINIA
WISCONSIN
EPA REGION
I
n
ffl
nr
V
m
VD
nn
IX
*
NAIIIINAI 1OIAI
TOTAL
DISPOSED
166400
10,800
61.100
10,600
4,140
1,170
2,880
2,220
186,100
110,400
40,800
12,100
28,1(0
3720
8,190
5,960
297,400
21,300
16,320
3,540
34,100
94.600
10,400
288,100
6,340
0,970
239,800
1,040
2/160
504
43.450
58,300
20,700
1,060
18,700
6,730
9.200
72.000
14,190
129.300
276.060
266,390
876,300
66,860
71.760
31. INM
(171X1
t»./0fl
1 nyft IMM
TOTAL
POTENTIALLY
HAZARDOUS*
1
TOTAL
HAZARDOUS
CONSTITUENTS
(
)
DISPOSAL
METHOD
LANDFILL
OR
OPEN DUMP
!
CONSTITUENTS
Cd
0.166
0011
0.062
o.oti
0.004
0.001
0.003
0.003
0.187
0.110
0.040
0.012
0.027
0.003
0.008
0.006
0.297
0.022
0.016
0.004
0.035
0.0(6
0.011
0.288
0.006
0.007
0.240
0.003
0.003
-vO
0.044
0.059
0.020
0.001
0.016
0.006
0.010
0.072
0.014
0.131
0.275
0.256
0876
0.067
0.071
0.031
0083
O.OO
in
r Cu
4.31
0.66
1.60
O.JO
0.10
0.0(1
0.12
0.08
5.57
2.94
1.06
0.60
0.66
0.14
0.22
0.14
7.26
0.60
0.61
0.15
0.83
266
0.24
8.36
0.18
0.34
6.72
0.07
0.06
0.03
1.20
1.68
053
0.03
0.41
0.27
0.27
2.36
0.33
3.39
7.67
8.66
27.08
1.88
2.43
083
in*
0 (11
r, in
Cr
7JO
1.69
3.13
0.60
0.16
0.18
0.33
0.22
11.82
5.67
1.99
1.69
1.04
0.38
0.44
0.22
12.47
123
1 59
041
140
4.97
0.38
17.28
0.42
0.94
13.48
0.11
0.10
0.07
2.36
3.04
096
0.04
0.72
0.75
0.64
6.38
0.63
5.38
15.33
12.32
63.73
3.84
5.88
i m
4 Jt
1 OH
Kit, II
Mn
296.7
66,6
114.6
187
61
6.0
11.6
7.5
4304
2074
74.3
68.7
394
13/4
16.9
8.4
473.4
44.8
58.3
144
63.A
184.3
14.0
632.0
16.1
32.8
496.7
44
3.4
2.6
67.2
112.8
36.8
1.6
27.4
26.3
20.0
193.8
204
2374
566.1
4604
1,982.3
141.3
2034
(ill 6
1700
r.np
i no; 4
Ni
1.66
0.11
0.62
0.11
0.04
0.01
0.03
0.03
147
1.10
040
0.12
0.27
0.03
o.ue
0.06
247
0.22
0.15
0.04
036
0.99
0.11
2.86
0.06
0.07
2.40
0.03
0.03
~0
044
049
0.20
0.01
0.16
0.06
0.10
0.72
0.14
1.31
2.78
238
9.76
0.67
0.71
031
001
0 U
inm
Pb
1.26
0.18
0.46
0.08
0,03
0.01
0.04
0.03
1.64
046
0.31
0.18
0.19
0.04
0.07
0.04
2.10
0.18
0.19
0.04
0.24
0.76
0.07
2.47
0.06
0.11
1.98
0.01
0.01
~0
OJ6
0.46
0.15
O.O1
0.12
0.06
0.06
0.71
0.10
1.00
2.26
146
7.96
046
0.72
0.23
o.«
1) 111
it. r.
Zn
249
04S
1.04
0.1»
0.07
0.06
0.10
0.07
346
149
0.7Z
046
041
0.11
0.16
0.08
4.76
042
048
0.12
0.64
1.7S
0.15
6.86
0.14
0.27
4.66
0.04
0.04
0.03
043
1.08
0.36
0.01
0.27
0.22
0.19
1.72
0.20
2.30
5.33
448
1S.70
0.32
140
0.66
1.61
0.41)
m >
f OIINDRY *l AC NOT CONSinFHFD HA7Afir>OlH ON
IIASIS Oh CA1 SCAN SOLUBILITY It SI', III SUtllll II
IN APPENDIX B
SOURCE. CALSPAN CORPORATION
82
-------
Table 14d
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SLUDGE, 1974 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
JLOHAUO
, tMNtClU'.ltl
' I AWAHf
< t KWIOA
, ilOHUIA
li-ilNOIS
INDIANA
IOWA
>w NSAS
KENTUCKY
i-OUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
v-SSOURI
VF8RASKA
NtW JERSEY
NEW YOHK
N l.AHOl INA
OHIO
OKLAHOMA
OHEOON
PENNSYLVANIA
HHODf ISLAND
6 CAROLINA
S DAKOTA
ItNNtSStt
HXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W VIRGINIA
WISCONSIN
II'A M1UION
1
D
m
is
V
m
ra
ran
IX
X
NATIONAL TOTALS
TOTAL
DISPOSED
61.260
2,350
17.760
3.900
l,«00
200
BOO
860
04,460
40,160
14,900
2,800
10,800
860
2,960
2.300
113,260
7.S>50
4.360
860
13.100
33.800
3,880
101.100
1,700
1.700
86,400
1.200
960
100
16.600
21,100
7,860
400
6,200
1,400
3.200
23.800
0,1100
47,000
IM.OOO
03,900
360.300
23.660 :
23,000
11.860
20.100
3.100
878,200
TOTAL
POTENTIALLY
HAZARDOUS*
'
9
IOTAL
HAZARDOUS
CONSTITUENTS
I
DISPOSAL
METHOD
OPEN DUMP
AND
LANDFILL
i 1
CONSTITUENTS
Cd
0.12
0.01
0.04
0.01
0
0
0
0
013
0.08
0.03
0.01
0.02
0
0.01
0
0.22
0.02
001
~* 0
0.03
0.07
0.01
0.20
~0
~0
0.17
~0
~0
-0
0.03
0.04
0.02
vO
0.01
0
0.01
0.06
-0
010
020
0.18
0.70
0.04
006
0.03
0.06
~0
1.40
Cu
8.94
0.3S
2.58
O.B7
0.74
0.04
0.11
0.10
8.44
5.87
218
0.42
1.57
0.13
0.43
0.33
16.52
1.11
0.64
0.14
1.91
4.97
0.68
14.78
0.26
0.26
12.48
0.17
0.14
0.02
2.Z7
1.09
1.12
O.M
091
0.21
0.47
348
0.80
6.9*
I4.J4
13.71
61.22
347
3.38
1.71
2.94
046
9880
Cr
2.92
0.12
0.86
0.18
0.08
0.01
0.04
0,03
3.08
1.92
0.71
0.14
O.S1
0.04
0.14
O.tl
6.40
0.36
0.21
0.06
0.62
1.82
070
4.84
0.08
008
4.09
0.06
0.04
0.01
0.74
1.01
O.M
0.02
0.30
0.07
0.16
1.14
0.27
214
4.88
4.48
16.76
1.13
1.11
0.66
0.97
0.16
32.40
Mn
48.98
0.8S
13.64
311
1.31
0.10
0.44
0.43
46.61
91.76
11.87
1.24
8.90
0.47
2.32
1.88
91 33
5.83
2.70
0.54
10.72
26.71
3.27
7738
122
0.80
88.23
0.96
0.78
0.04
12.13
16.60
816
0.33
6.06
0.68
2.48
17.13
4.46
37.43
78.18
74.B3
272.02
18.29
18.36
9.31
1442
1.48
524.90
Ni
0.30
NA
008
0.02
0.01
NA
~0
~0
0.29
0.20
0.07
~ 0
0.06
~0
0.01
0.01
0.57
004
0.01
vO
0.07
0.16
002
0.48
0.01
~0
040
0.01
0.01
NA
0.07
0.10
0.04
~0
0.03
~0
001
0.10
0.01
0.23
046
046
1-86
an
0.09
0.06
0.09
~0
3.16
i*
8.18
0.30
2.36
0.52
0.22
0.03
0.10
0.09
8.89
6.36
1.99
0.37
1.44
0.11
0.39
0.31
15.14
1.01
0.58
0.13
1.76
4.64
0.63
13.48
0.23
0.22
1140
0.16
0.13
0.01
2.07
2.82
1.0]
0.06
0.83
0.18
0.43
3.16
0.74
6.M
13.09
12.65
46,74
3.16
1.07
1.55
2.88
0.40
90.2
2n
25.28
0.69
7.07 1
1.60'
0.87
0.06
0.26
0.23
26.47
1644
6.13
0.77
4.56
0.27
1.20
0.98
47.03
3.04
1.50
0.31
5.50
13.86
1.68
4038
0.66
0.49
34.46
0.49
0.40
0.03
6.30
8.61
3.17
0.17
2.80
0.41
1.29
8.09
2.29
19.16
39.60
3870
141.46
9.63
8.71
4.80
7.98
0.90
273.00
FOUNDRY SLUDGE NOT CONSIDERED HAZARDOUS
ON BASIS OF CALSPAN SOLUBILITY TESTS
DESCRIBED IN APPENDIX B.
SOURCE CALSPAN CORPORATION
83
-------
Table 14e
ESTIMATED STATE, REGIONAL. AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SLUDGE, 1977 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
NEW YORK
N. CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S.CAROLINA
S. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W. VIRGINIA
WISCONSIN
EPA REGION
I
n
m
nc
T
SI
m
T7TTT
IX
X
NATIONAL TOTAL
TOTAL
DISPOSED
7.740
2,600
19,630
4,316
1,770
280
885
720
71,280
44,410
16,480
3,100
11.945
«40
3,266
2,545
126,280
8460
4.810
1,060
14,490
37,500
4,370
111,820
1380
1.880
94,460
1,330
1,060
110
17.140
23.340
8,460
440
6,860
1360
3.640
26,326
6.086
6*366
1M.3M
103,860
387,446
2«,160
26440
12,886
22730
3,430
7S4378
TOTAL
POTENTIALLY
HAZARDOUS-
1
1
TOTAL
HAZARDOUS
CONSTITUENTS
\
i
DISPOSAL
METHOD
OPEN DUMP
AND
LANDFILL
1
CONSTITUENTS
ca
0.13
0.01
004
0.01
-0
^a
-0
-0
0.14
o.oa
0.03
001
0.02
~0
0.01
~c
0.24
0.02
0.01
"0
0.03
0.08
0.01
0.22
~0
~0
0.19
-0
~0
~0
0.03
0.04
0.02
~0
0.01
~0
0.01
0.08
~0
0.11
0.22
0,20
0.77
0.04
0.06
0.03
0.06
~0
1.6
Co
9.8*
0.39
2.86
063
0.27
004
0.12
0.11
10.44
6.40
2.41
0.46
1.74
014
0.48
0.36
18.27
1.23
0.71
0.16
2.11
5.50
0.64
16.36
0.28
0.28
13*1
0.19
0.16
0.02
2.S1
3.42
1.24
0.07
1.01
0.23
0.62
386
038
7.61
ISM
16.16
58.65
3.84
3.74
1.89
3.26
031
109.4
Ct
3.23
013
O.W
U21
0.09
0.01
0.04
0.03
3.42
212
0.79
0.16
O.S6
004
0.16
0.12
5.97
0.40
0.23
0.06
0.69
1.79
0.22
5.36
o.oa
0.08
432
0.07
0.04
0.01
0.82
1 12
0.40
0.02
0.33
O.OB
0.17
1.26
0.30
248
6.19
4.*«
18.53
1.2S
1.23
0.62
1.07
0.17
363
Mn
64.17
0.87
14.98
3.44
1.4ft
0.11
0.49
0.48
63.76
3513
1313
1.37
9.84
0.52
2.67
2.08
101.01
6.46
2.99
o.ao
1136
29.64
3.62
8636
1.3E
038
73-26
1.06
036
0.04
1342
18.36
631
0.36
5.59
0.75
2.74
1896
436
4140
84.28
8237
300 85
20.23
18.08
10.30
1636
1.64
5M3
H\
0.33
NA
0.0*
0.02
0.01
NA
~0
~0
032
072
0.08
~0
0.07
~0
p.01
0.01
0.63
0.04
031
~0
0.08
ait
0.02
031
0.01
~0
044
031
0.01
NA
0.08
0.11
0.04
-0
0.03
-~.fl
0.01
0.11
0.03
0.26
030
031
184
0.12
0.09
0.07
0.09
~0
33
Pk
9.08
0.33
2.41
0.6*
0.24
0.03
0.11
0.10
930
6.93
230
0.41
139
0.12
0.43
0.34
16.74
1.12
0.64
0.14
134
S.02
039
1431
0.25
0.24
12.61
0.18
0.14
0.01
2.29
3.12
1.13
0.06
032
0.20
048
349
032
3*
1447
133*
61.69
349
340
1.71
234
044
893
Zn
273*
0.88
7.82
1.77
0.74
0.07
03*
036
28.17
18.18
6.78
035
6.04
0.30
1.33
1.06
62.02
3J6
1.86
0.34
8.08
15.32
136
44.86
0.72
034
38.10
034
044
0.03
637
932
331
0.19
23>
046
143
10.06
233
2140
4330
4230
156.44
1034
9.03
5.31
847
1.00
3013
FOUNDRY SLUDOE NOT CONSIDERED HAZARDOUS
ON BASiS OF CALSPAN SOLUBILITY TESTS
DESCRIBED !N APPENDIX B.
SOURCE: CALSPAN CORPORATION
84
-------
Table 14f
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SLUDGE, 1983 (METRIC TONS)
STATE ' TOTAL TOTAL TOTAL DISPOSAL
I ' DISPOSED POTENTIALLY HAZARDOUS METHOD
1 HAZARDOUS* 1 CONSTITUENTS
j ALABAMA
ARIZONA
CALIFORNIA
83.410 0
3.200 i
24,190
COLORADO b,320
CONNfCflCUT 2.180 I
DHAWAHl 340
IIOH1DA j 1,0*0
UIOHCilA 8(0
lltlNOIS H/.atiU
i INDIANA M.770
IOWA 20.J10 '
KANSAS 3,820
KENTUCKY 14.720
LOUISIANA i 1.160
MARYLAND 4,020
i
MASSACHUSETTS 3,135
MICHIGAN 164.300 (
MINN! SO I A 10.7110 ,
MISSOURI !>.R30 i
NEBRASKA ' 1.70b
NEWJEHSiY 1 7.880
NEW YORK 46.210
N. CAROLINA 6.380
OHIO 137,800
OKLAHOMA
7.310
0111 (ION 2. Mil
HtNNDVI VANIA 110.400
HllOllt 111 AMI | B40
| S CAROLINA
1.296
S DAKOTA 140
TfNNfSSff 21,130
TEXAS 28.7*0
UTAH 10.430
VERMONT 646
VIRGINIA 8,460 i
] WASHINGTON
W. VIRGINIA
WISCONSIN
~\
EPA REGION
1
U
m
m
I V
vr
en
VIII
TJt
X
NAIIONAL IOIAI
1,910 i
4,360
32,440
7.600
64,070
133.570
127.985
477,460
32,240
31,366
16.8*0
27,3(0
4,230
31. 8W)
1
0
I
!
|
|
\
OPEN DUMP
AND
LANDFILL
]
1
t
1
1
! 1
CONSTITUENTS
a
0.16
0.01
0.06
0.01
Cu
1219
0.48
3.S3
0.78
Cr
3.98
0.16
1.16
Mr
66.76
1.20
J8.46
0.26 4 24
-0 0.33 ! 0.11
~ 0 0.06
- 0 0.16
0.01
Nl
041
NA
0.11
0.03
Pb
11.16
0.41
3.22
0.71
1 79 0.01 0.30
0.14 j NA
0.06 0.60 -0
0.04
0.14
- 0 014 i 0.04 06* -0 I 0,12
0.18 12.87
0.11 j 1.00
4.21 66.26 | 0.40 11.71
2.62 4329 0.27
7J1
0.04 ' 2.97 0.97 1618 | 0.1Q 2.71
0.01
0.03
0.67
2.14
-0 0.18
0.01
-0
0.30
0.03
001
0
004
010
001
0.27
0
0.69
0.46
0.19 , 1.6* "0
0.70 12.13 0.08
0.06
0.19
0.60
1.96
0.64 ~0 0.16
3.16
0.01 0.63
0.16 2.66 0.01
Zn
3446
0.80
.84
2.18
,
0.91
0.08
0.34
0.31 i
3«.n
22.41
»M
1.06
6.22
0.37
1.64
0.42 1.31
22.62 7.36 12448 078 1 20.64 64.10
1.61 04* 7*6 0.06 1.38
OJ7 0.29 ! 3.68
0,19 007 ; 0.74
0.01
- 0
0.7*
018
4.14
2.04
042
2.60 085 1461 i 010 2.39 760
677 1 221 , 3641 072 6.19 1888
0.79 0 27 4 46 0 03 0 72 2 29
2016 6 HO 10644
034
0 0.34
0.11 ISO
0.11 i 10*
0/J !i/02 vkl 9ujt
0 tW i 0 ItH 1 .1 1
- 0 019
-0 003
0.06 1.06
001
003 | 18,37 : 6604
0.01 0.31 0.8*
~o
Otitt
001
0.01
0.10
10. M
0 2_>
0.1*
006 NA 1 001
0.67
4«,W
067
0.66
004
004 ' 309 101 1 1853 0.10 282 ! 859
0.06 421 138 22.63 0.14 3.84
0.03
1.63
0 009
0.01
-0
0.01
0.07
.-0
014
0.27
0.25
0.95
0.06
0.07
004
0.07
- 0
1 »
1.24
o.ze
0.64
4.76
1.M
0.49 8.40
0.03 0.46
0.41
0.10
0.20
1.56
0.37
6.88
0.93
3.38
23.36
6.11
9.38 3.06 , 61.02
1955
18.69
MJt
4.73
4.61
2.33
4.01
0.63
13(8
6.38
6.11
22.83
1.64
1.61
078
1.32
0.70
44 1
10343
102.13
370.78
24.93
22.29
12.60
19.66
2.0]
7164
0.06 1.3*
~0 0.07
0.04
0
0.01
0.14
0.04
0-31
0.61
0.63
2.26
0.16
0.11
0.01
0.11
-0
43
1.13
0.26
0.6*
4.31
1.01
8.67
17.83
17.11
63.71
4.31
4.18
2.11
3.63
0.66
122*
11.74
4.32
033 |
3.64
0.66
1.W
12.3*
3.12
26.37
6347
62.76
M2JO
12.99
1147
9M
10.44
1.23
372.1
HlDNUHY nlUUUt NOI (.ONBIOtHI I) HA/AHUOU1
ON BASIS OF CALSPAN SOLUBILITY TE6TS
DESCRIBED IN APPENDIX B
SOURCE CALSPAN CORPORATION
85
-------
Table 14g
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL DUST, 1974 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
OEQRQIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
i MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
N6W YORK
N. CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S. CAROLINA
S DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W VIRGINIA
WISCONSIN
f PA HI UION
1
11
Itt
TS
V
m
Vtt
VTTT
DC
I
NATIONAL TOTAL
TOTAL
DISPOSED
111,400
11.9*0
41,100
9.4(0
3,260
1.300
2.900
2,100
It* .BOO
W.460
Il.tOO
13.100
211.1,0
3.300
6.700
4.550
234.600
17.760
16.000
3.000
27.000
77.100
7.900
242.300
4400
7*00
196.700
2,350
1,900
660
36.660
47,850
16,450
BOO
13.150
8,100
7.700
04.000
10.WU1
104.11X1
UltitlO
206,400
Boe.aoo
56,780
64,560
25,450
55.250
13,600
1,609.400
TO
POTEN
HAZA
1
TAL
TIALLY
1DOU1
0
TOTAL
HAZARDOUS
CONSTITUENTS'
1
1
DISPOSAL
METHOD
OPEN
DUMP AND
LANDFILL
i
CONSTITUENT!
Dl
O.tl
001
OOB
0.01
-0
-0
~0
| -0
1
01>
008
003
002
002
001
OJ)1
-0
0.22
002
0.02
0.01
003
o.oe
0.01
0.26
0.01
0.01
021
-0
-0
~0
004
oos
002
-0
001
001
001
007
0
0 11
024
020
O.B3
0.07
O.OB
0.03
0.07
0.02
17
Cu
11.54
2 71
KM
0.68
0.26
0.33
OM
0.311
2006
960
l.M
28«
t n
066
074
037
2101
20B
272
070
241
8,48
0.66
2934
072
1.89
22.88
0.19
0 15
0.13
403
6.17
162
0.07
1.24
1 28
013
9 13
0»D
10 M
J8I2
21.06
91 12
854
9,67
260
80S
287
1795
Cr
90]
1 2*
3.22
067
020
014
023
020
1197
618
2.24
1 36
1 33
032
047
0.28
1601
129
IK
0.16
1 72
542
049
17.87
0.40
076
14.29
0 15
012
006
2.64
333
1 10
006
0.09
062
Mn
174.50
3J60
da 01
1102
3*6
3.67
702
<54
26486
111 »»
43.66
3661
2J 17
807
945
490
27276
2649
1193
874
3111
108.73
8.1,2
37376
904
19.69
29235
252
202
168
61 62
6635
2091
086
(607
1595
067 j 1183
6 16
O.M
7 14
lbt>4
13 M
67.47
406
534
173
450
1.31
111,8
116.10
II 71
14004
J3S37
171 m
1166.16
83.46
12184
1361
101 61
3664
22978
N!
4.46
1.00
1SJ
0.2*
0.06
0.11
020
013
6.8*
316
1 U
106
0.66
0.24
0-JS
0.12
6.74
070
0.9V
026
0.77
2.84
0.20
1000
0.2S
0.68
7.73
0.06
0.06
0.06
136
1 73
0.63
0.02
0.40
0.47
032
320
on
1.61
111
6.96
30.89
222
340
0.96
' 283
106
607
n>
11.84
122
417
0.76
024
0-24
0.47
O.X
17.14
«M
3M
236
168
0.54
0.64
0.14
18.66
1.79
226
0.58
2.14
736
0.68
25.18
0.80
1JO
19,71
0.17
0.14
0,10
3.48
4.49
1.42
0.06
1.08
1.06
0.80
7.72
0.11
9.49
1250
11.40
79.74
561
9.14
2.27
679
2.36
168.1
Zn
18.61
1M
1.40
124
0.4*
0.21
046
032
23.64
11.12
4.80
207
3 1)
0.61
098
086
33.60
2.61
2.11
068
3.92
11.34
1.16
36.70
0.72
1.17
29.20
0.34
027
0.09
6.26
6.97
2. 40
012
1 91
0.88
1.14
1.66
tM
1*.M
3344
30.0*
111.03
8.20
9.74
3.73
8.29
2.01
230.4
IRON AND STEEL FOUNDRY DUSTS NOT CONSIDERED HAZARDOUS BASED
ON SOLUBILITY TESTS BY CALSPAN AND DESCRIBED IN APPENDIX B
SOURCE. CALSPAN CORPORATION
86
-------
Table) 14h
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL DUST, 1977 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
M NHK'KY
ItnilMANA
MARYLAND
MASSACHUSf 1 TS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEWJFRSFV
NEW VORK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S CAROLINA
S. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W VIRGINIA
WISCONSIN
fPA liriMDN
1
n
IH
IB
y
XI
jtn
\7TTT
IX
X
NATIONAL TOTAL
TOTAL
DISPOSED
14 7. BOO
11,200
47.900
8,360
3.800
1,460
3.200
2.300
175,600
98.960
36.JOO
M.f.fto
1 1 m,o
J.OWI
7.40U
6.000
259.360
18.660
16.600
4.000
29,900
86.300
8.7&0
268,000
6,300
8.300
219.800
2.600
2,100
600
39,400
52.700
18700
900
14,550
6.760
8,600
'o.goo
U ICKI
11I> t
ni.tao
127,200
992.300
61.660
71,400
28.150
61,100
15.000
1,736,760
TOTAL
POTENTIALLY
HAZARDOUS
1
0
TOTAL
HAZARDOUS
CONSTITUENTS'
1
0
DISPOSAL
METHOD
LANDFILL
OR
OPEN DUMP
1
CONSTITUENTS
CD
0.14
0.02
0.06
0.01
~o
~0
~0
~0
0 19
010
0.03
002
0.02
0.01
001
-0
024
0.02
0.02
0.01
003
0.09
0.01
0.28
001
0.01
0.23
-~0
~0
^.0
0.04
006
002
-0
0.01
0.01
0.01
001
.0
0.11
0.17
0.11
0«
0.08
0.0*
0.03
0.01
002
1J
Cu
14.M
3.00
591
0.94
0.29
0.03
062
0.40
2219
10.50
376
ate
1*6
072
082
041
2324
230
3.00
0.77
267
9.38
072
32.46
0.80
1.75
2631
071
017
0.14
4.48
672
178
0.08
1.37
1.42
1.03
10.10
091
120*
29 Ml
M.2*
tOO. 7*
7J»
10.70
238
8.90
3.17
186.6
Cr
9.99
1,42
3.M
0.63
0.22
0.16
031
0.22
13.24
6.84
2.41
1.10
147
038
OB2
0.31
16.60
1.43
1.S4
039
1.90
5.99
0.54
19.78
0.44
0.84
15.80
0.17
013
0.07
2.81
3.68
122
0.06
0.10
0.69
0.63
6.70
0 7t
7.80
17.21
IMJ
»M
4.48
6.81
1.81
4.88
1.83
123.7
Mi
1*3.00
W.tf
75.22
12.19
3.82
4.06
776
602
281 88
134.92
48.29
3927
2566
893
1045
S.42
301.67
28.30
37.S3
8.67
3463
12026
9.42
413.38
10.00
21.78
323.34
2,78
223
1 75
67.08
73.38
23.13
0.86
17.77
17.84
13.08
127.52
126*
1*488
388.70
300.07
1288.67
92.31
134.78
37.07
112.38
39.42
26413
Nl
4.83
Ml
2.02
0.31
0.08
0.12
0.22
014
7.C2
360
1.24
1 16
061
0.27
028
013
7.45
0.77
1.08
0.28
0.86
3.14
0.22
11.0*
OJ8
0.64
8*6
0.07
0.0*
0.06
1*0
1*1
0.69
0.02
0.44
0.52
0.3C
3.64
0.31
3.8*
6,74
7.88
3J.84
tM
376
0.86
3.13
118
871
Pb
13.10
2.46
8.06
0.83
0.27
0.27
0.52
0.33
18.86
9.14
3J7
2.60
1.76
060
071
0.38
20.83
1.98
2.49
0.64
2.37
8.13
064
27.86
0.66
144
' 21.82
0.19
0.1S
Oil
3*5
4,87
1.67
0.07
1.21
1.17
OJ8
8.64
0.80
10.80
24 J*
JO, 38
67.08
673
9.00
2il
7^1
2.61
171J
Zn
21.80
2.08
7.0*
1.37
0.81
0.23
0.60
0.36
26.04
14.61
631
229
3.44
058
1.08
0.73
37.06
2.89
ISA
0.82
4.34
12.64
1.27
38.48
0.80
1.28
32.30
0.36
030
010
5.82
7.71
2.86
0.13
2.11
0.86
1-»
10.67
1.7»
16.8*
36.8*
UJI
130.64
tjn
10.77
4.12
9.17
2J4
2MJ
IRON AND STEEL FOUNDRY DUSTS NOT CONSIDERED HAZARDOUS BASED
ON SOLUBILITY TESTS BY CALSPAN AND DESCRIBED IN APPENDIX B
SOURCE. CALSPAN CORPORATION
87
-------
ESTIMATED STAT E, REGIONAL. AND NA IIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL DUST, 1983 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNI Mil II!
[>! 1 AWAMI
1 mltlOA
(IKMIIIIA
111 INOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S CAROLINA
S DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W VIRGINIA
WISCONSIN
EPA REGION
I
n
m
JS
a
m
an
Tnn
n
z
NATIONAL TOTAL
TOTAL
DISPOSED
181,800
16.300
69,000
11.600
441X1
I.80O
i.iKKi
/ HftO
210,1.00
121,900
44.700
17.900
29.400
4.600
9,100
6.200
319,600
24,200
20,460
4,900
36,800
105. 100
10.800
330.260
6.660
10.200
270.800
3.200
2.600
760
48.600
64.960
22.400
1.090
17,900
8,300
10,600
87,260
14,900
141.900
310,160
279,960
1,099,960
76.000
88.000
34,700
76,300
18.660
2.139.100
TOTAL
POTENTIALLY
HAZARDOUS'
1
3
TOTAL
HAZARDOUS
CONSTITUENTS"
1
0
DISPOSAL
METHOD
LftNDHLL
OR
OPEN DUMP
1
Cd
018
003
007
001
- 0
. 0
- 0
0
021
0 17
0 04
003
0 03
001
001
~0
030
003
003
001
004
Oil
001
035
001
001
029
~0
~0
~0
004
007
0.03
~0
0.01
001
001
0 10
~tt
0 15
033
0.27
1 13
0 10
0 11
004
0 10
003
23
Cu
18 46
309
728
1 16
036
11 tt4
0 /6
0 J1I>
11 14
17 UG
462
390
241
009
101
050
2864
284
3 71
095
328
11 56
089
3999
098
2 17
31 19
026
020
018
549
7 05
221
0 10
169
1 74
127
1244
1 21
1484
3519
2870
12420
891
1318
3B4
1097
3.91
244.7
CO
Cr
1231
1.74
439
078
NSllTUtNTS
Mil
23784
4680
9270
1602
027 4/0
0 111
U Ul
nil
18 J?
84?
305
1 8b
1 01
044
0.64
038
2016
1 78
1 89
048
234
739
067
2436
055
104
19.48
0,20
016
008
346
454
150
007
0 12
086
0 7ft
702
0.93
9.73
2121
1907
7833
562
728
2J6
613
1.88
624
b 00
ot,l
0 19
14737
1662'
6961
4840
31 Sfl
11 00
1288
668
371 71
36 11
4626
1191
4268
14820
11 61
50943
1232
2684
39847
343
275
216
7036
9044
2860
1 17
21 90
21 74
1812
157 16
1598
19088
46437
36990
1688 10
11376
16607
4b67
13850
4868
3131 8
Nl
6. 06
1 36
2.49
038
0 11
0 16
027
0 18
939
4 31
1 53
143
075
033
034
016
9 19
095
134
0.34
10S
3.87
027
1363
0.34
0.79
1064
0.08
007
007
1 85
236
072
003
055
064
044
436
0.38
4.92
12.01
9.47
41.83
3.03
483
1.17
3.86
1.43
82.7
(b
16 14
3.03
623
1 02
033
03.1
084
041
2336
11 26
403
320
217
0 74
087
048
2642
244
307
079
292
1002
0.79
34.32
0.82
1.77
26.89
0.23
0.19
014
474
612
1 94
008
1 49
1 44
109
10.62
1 10
12.93
30.67
25.08
10732
767
1109
3.09
9.26
3.22
211.4
Zn
2862
268
872
1.69
063
029
001
044
3209
1788
654
282
424
0 70
1 34
090
4566
356
315
0,76
534
15,15
157
4866
098
1.59
39.80
046
037
012
7 17
9.50
327
0 16
260
1 17
165
1303
2.16
2049
45.58
4102
160-88
11.18
13.27
608
1130
2.76
313.7
IRON AND STEEL FOUNDRY DUSTS NOT CONSIDERED HAZARDOUS BASED
ON SOLUBILITY TESTS BY CALSPAN AND DESCRIBED IN APPENDIX B
SOURCE CAISPAN CORPORATION
88
-------
Table 14j
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDARIES
TOTAL SAND, 1974 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
NEW YORK
N. CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S CAROLINA
S. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W. VIRGINIA
WISCONSIN
EPA REGION
I
n
m
iff
ir
m
TOT
VHf
IX
X
NATIONAL TOTAL
TOTAL
DISPOSED
1.131.900
50.200
332.000
71.600
29.700
5500
15.500
12.900
1,211,400
744,500
276,000
59,200
197.100
17.100
54,600
41,800
2.086.900
141.100
86.100
19,100
240,700
631.200
72,600
1,892,000
32.700
35.000
1.592,700
21,600
17,200
2.400
288.200
392,400
141.100
7.400
114.600
28,900
60,300
462,300
100,500
871.900
1327,700
1,736,300
6.628,200
442,200
440,400
215.100
382,200
63,900
12,807.400
TOTAL
POTENTIALLY
HAZARDOUS*
0
TOTAL
HAZARDOUS
CONSTITUENTS
0
I
DISPOSAL
METHOD
ALL OPEN
DUMP
OR
LANDFILL
'
CONSTITUENTS
Cu
938
0.42
275
059
025
005
013
0.11
1004
6.17
223
0.49
1.63
0.14
045
0.35
17.29
1.17
071
016
199
5.23
060
1568
0.27
0.29
13.20
0.18
014
0-02
239
3.25
1 17
0.06
096
0.24
050
375
084
7.22
16.16
14.38
S4.10
3.66
359
1.78
3.17
0.53
104.40
Cr
S39
0.24
1.58
034
0.14
003
007
006
577
354
1 31
028
0.94
O.OEI
026
0.20
993
067
0.41
0.09
1.15
300
035
900
016
0 17
7.58
0 10
008
0.01
1.J7
1.87
067
0.04
055
0.14
0.29
2.15
048
4.15
8.71
B.26
31.06
2.11
2.08
1.02
142
0.31
60.00
Mn
5990
2.66
17.57
3.79
157
0.29
0.82
0.68
64.10
3940
1461
3.13
10.43
0.91
2.89
2.21
110.40
747
4.66
1.01
12.74
3340
3.84
10010
1.73
185
8428
1.14
091
0 12
li>2b
20.77
7.47
039
6.07
1.63
3.19
23.94
6.31
46.14
86.72
91.83
35441
23.31
23.31
11.38
20.23
3.38
667.10
Ni
31.75
1.41
9.31
2.01
0.83
015
0.44
0.36
33.98
20.88
7.74
1.66
653
0.48
1.53
1.17
58.54
396
2.42
0.54
6.76
1770
2.03
53.07
0.92
0.98
44.68
061
0.48
0.07
8.08
1001
396
0.21
3.22
0.81
1.69
12.69
2.82
24.45
51.27
48.68
183.12
11.41
12.36
6.04
10.72
1.79
352.70
Pb
60.63
2.69
17.78
3.84
1.59
0.29
0.63
0.69
64.89
39.88
1479
3.17
10.56
0.92
2.93
2.24
111.80
7.56
4.81
1.03
12.89
33.81
3.88
10130
1.75
1 38
85.32
1.16
0.92
0.13
15.44
21.02
7.S6
0.40
6.14
1.56
3.23
24.23
5.39
46.70
87.91
92.95
349.66
23.69
23.60
11.53
20.47
3.43
675.30
Zn
6.73
0.30
1.97
0.43
0.18
0.03
0.09
0.08
7.20
442
1.64
0.36
1.17
0.10
0.32
0.26
12.40
0.84
0.61
0.11
1.43
3.75
0.43
1124
0.1*
0.21
947
013
0.10
001
1.71
2.33
0.84
0.04
0.68
0.17
0.36
2.69
0.60
E.18
10.86
10.31
38.79
2.62
2.61
1.28
237
0.38
74.90
PHENOL
1.21
0.05
0.35
0.08
003
0.01
0.02
0.01
1.30
0.80
0.30
0.06
0.21
0.02
0.06
0.04
2.24
0.16
0.08
0.02
0.26
0.67
008
2.02
0.04
0.04
1.70
0.02
002
0
0.31
042
DIE
0.01
0.12
0.03
0.06
048
0.10
0.93
1.96
1.86
6.99
0.48
047
0.23
0.40
0.07
13.50
FOUNDRY SANOS NOT CONSIDERED HAZARDOUS
ON BASIS OF CALSPAN SOLUBILITY TESTS
DESCRIBED IN APPENDIX a
SOURCE: CALSPAN CORPORATION
89
-------
Table 14k
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SAND, 1977 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
TOTAL
DISPOSED
1,251,800
55,520
367,200
7>,200
TOTAL
POTENTIALLY
HAZARDOUS*
0
32,800
DELAWARE ', 6,100
' HORIOA ! 17.100
GEORGIA 14,300
ILLINOIS
INDIANA
1,339400
823.400
IOWA i 306.300
KANSAS 66,500
KENTUCKY 211.000
LOUISIANA
MARYLAND
19,000
60.400
MASSACHUSETTS 46,200
MICHIGAN
MINNESOTA
MISSOURI
NtBRASKA
NtW JtMSCY
2.308.100
166,100
95,200
21.100
266.200 j
NEW YORK 698.100
N CAROLINA 80.200
OHIO 2,092.600
OKLAHOMA 36,200
OREGON 38.700
PENNSYLVANIA 1,761.500 i
RHODE ISLAND 23,900
' S CANO1INA 10.000
'. OAKIITA ' /(Ml
TtNNLSSLL ' J1U.700 |
IFXAS ' 414.000
, UIAM l'it,,0(X)
VIRMONI 8.200
VIRGINIA ' 126.800 i
WASHINGTON 32.000 :
W VIRGINIA 66,700
WISCONSIN
500,200
1 - . .-,--- T -
> EPA REGION
I 111,100
n
m
Iff
y
H
vn
^STJ.
IX
X
NATIONAL TOTAL
964,300
2,021,500
1,919,100
7.220,100
469,200
467,100
237,900
422.720
70.700
13.943.720
'
TOTAL
HAZARDOUS
CONSTITUENTS
0
|
1
!
'
DISPOSAL
METHOD
LANDFILL
OR
OPEN DUMP
i
!
1
1
i
i
'
CONSTITUENTS
Cu
1037
0.22
304
066
0.28
i 0.06
014
012
1110
6.82
247
0.54
140
O.tt
0.60
0.39
1912
1.29
0.79
016
2.20
5.78
066
17.34
0.30
1 0.32
14,80
020
016
; 002
264
J59
1 29
0.07
1.05
027
! 055
415
083
7,99
16.76
1590
69 S3
406
397
197
3.61
058
[,,.,n
c.
5.96
017
1.76
038
0 15
003
0.06
007
6J8
392
146
0.11
1.04
O.OB
029
022
10.96
074
0.46
0.10
127
332
0.39
9.95
018
0 19
838
0 11
009
I) 01
1 !)2
2.07
IJ /4
0 O4
060
0 IS
0.32
238
ot>3
459
963
9 14
3436
233
2.31
1.13
201
034
"I
Mn
66.26
294
19.43
4.19
' 174
032
0.91
07S
7089
43 5»
1616
3.46
11.64
101
3.20
2.44
122 10
8.26
504
1.12
1409
36.94
425
110.81
191
205
8321
1 26
1 01
U IJ
Ib 87
2297
H /"I.
U Jl
671
169
3.53
2648
5B7
5103
10640
10156
36202
26.19
25 76
12.59
22.37
374
Ni
3S.12
! "*
10.30
2.22
092
0.17
049
040
37.68
23.09
8.66
144
6.12
0.63
1.88
129
6474
4.38
268
0.60
747
1958
2.45
6870
102
1.08
4942
0.67
063
« OH
8 yt.
11 07
4 48
U 23
356
0.90
1.87
1404
3 12
2704
66.70
53.64
20283
1242
13.67
648
11.86
Pb
6708
298
19.66
4.26
1 76
Zn
7.44
0.33
2.1*
0.48
0.20
0.32 0.03
0.92 0 10
0 76 0.09
71.77 7.96
44 11
1636
351
11.68
1,02
3.24
4.89
141
0,3»
1.29
0.11
0.36
248 021
12365 1371
PHENOL
1.34
046
OJ»
0.09
0.03
0.01
0.02
0.01
1.44
04*
0.33
0.07
0.23
0.02
007
004
2.48
8.38 ' 0.93 i 0.17
510 066 010
1 14 0.12 ! 002
14 26 1 58 0 29
3739 415 0.74
4.29 048 0.08
11204 1243 2.23 :
1 94 0.21 0.04
208 0.23 | 0.04
9438 10.47 ' 189
1 28 0 14 0.02
102 Oil 002
0 14 0 01 0
1 / OH 1 M9 0 J4
2326 i 258 I 046
8 Jb 0 »J 017
044 004 ' 001
679 j 075 0.13
1 71
3.67
27 JO
0.19
0.40
2.98
596 066
6166
108.29
102.80
386.72
26.20
21.10
12.76
22.64
1 98 3 79
- ---, ---,
7378 3901
746.9
S73
12.01
11.40
4240
240
241
142
241
042
82.8
0.03
0.07 j
0.63
0 11
103
2.16
2.06
7.73
0.63
0.62
025
0.44
O.OS
14.9
FOUNDRY IANOS NOT CONSIDERED HA/AROOUS
ON BASIS OF CALIPAN SOLUBILITY TESTS
DESCRIBED IN APPENDIX 8
SOURCE CALSPAN CORPORATION
90
-------
Table 141
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
TOTAL SAND, 1983 {METRIC TONS)
STATE 1 TOTAL
DISPOSED
ALABAMA 1,542,800
ARIZONA 1 68,400
CALIFORNIA 462.600
COLORADO 07.6OO
CONNtCIICIir 40.600
DllAWARt /.bOO
FLORIDA 21,100
GEORGIA 17.600
ILLINOIS 1,651.100
INDIANA 1.014.800
IOAA 376,200
KANSAS 80.700
KtMUCKY ^bU.600
LOUISIANA 23,300
MAHVLANO 74.400
MASSACHUSETTS ',/ 000
MICHIGAN 2,844.400
MINNESOTA 192.300
MISSOURI 117,400
NEBRASKA 26.000
NEW JERSEY 328 100
NEW YORK 860.300
N CAROLINA 98.800
OHIO 2.578.800
OKLAHOMA 44,600
OREGON 47,700
PENNSYLVANIA 2,170,800
RHODE ISLAND 29.400
S CAROLINA 23.400
S DAKOTA 3.270
TENNESSEE 392.800
TEXAS 634,800
UTAH 192.300
VERMONT 10100
VIRGINIA 156.200
WASHINGTON 39,400
W VIRGINIA 82.200
WISCONSIN 616, bOO
EPA REGION
I 137,000
II 1.188.400
111 2.491,100
IV 'I 09fi lil>ll
V 8.89 / !H)0
W 602.700
VII BOO. .100
nil ' 293 i ;o '
IX 1 620.900 '
X | 87.100 j
NAIKINM JOIAl ' ll),91b,U/E>
i .- -j
TOTAL
POTENTIALLY
HAZARDOUS *
TOTAL
HAZARDOUS
CONSTITUENTS
DISPOSAL
METHOD "~ ~~
Cu
0 ! 0 .MNDFILL 1278
1 no
\
1
i
'
1
.. _J
Off N OUMP ; ° 5*
1
; 375
I 080
| 034
i 007
I 018
: 015
1368
841
' 3.04
067
; 222
019
061
1 048
, 2357
159
, 0.98
022
; 271
j 7.13
1 0.82
' Z137
i 037
0.40
| 1799
0.25
019
0.03
326
443
1 59
0.08
, 1 M
033
0.68
I6" J
1 14
984
20.65
19.60
7374
4.99
4.89
241
4.32
0.72
142.3
CONSTITUENTS
C»
7.35
033
2.16
1 o.4e
0.19
014
0.10
0.08
7.86
4.83
179
038
128
0.11
OK
027
13.63
091
0.66
012
157
4 10
0.48
12.27
0.22
0.23
1033
0.14
Oil
0.01
187
256
091
005
076
0 19
0.40
Mil
61.64
3.63
23.96
6.17
1 14
0.40
1-fe
093
87.37
53,70
19.91
427
14.22
1.24
394
301
16048
10.18
622
1.38
17.36
4552
6.23
138.44
2.36
2.52
114.87
1.56
1.24
0.16
20.79
28.31
10.18
053
827
209
4.35
2.93 32.63
f j.
0.66
568
1187
11 26
4233
288
286
1 39
2.48
042
818
J
7.24
6289
13183
12516
47079
3191
31.77
1551
27.57
4.61
9093 ,
J
Nl
43.28
1.92
12.69
274
113
0.20
0.60
0.49
4631
2846
10.55
226
7.64
065
2 OS
159
7979
540
330
074
920
24.13
277
7233
175
134
60.90
0.83
0.65
0.10
11 03
13.64
540
029
439
1 10
2.30
17.30
3.84
33 39
6988
6635
24959
1565
16.85
823
14.6,
2.44
4807
Pta
82.64
3.67
24.23
5.23
2.17
0.40
1 13
0.94
a».45
63.14
20.16
432
14.3*
,25
3.99
305
,62,38
,0.30
6.28
,.40
1757
46.08
6.29
138.07
239
2.56
116.29
1.58
1.25
0.18
2104
28.66
10.30
0.55
8.31
2.11
4.40
33.03
7.35
63.65
13345
12669
476 59
2329
J2 17
1572
27.90 j
4.68 J
9204
2,.
8.17
0.41
2.68
0.5S
0.26
0.04
0.12
0.11
9.81
6.02
2.24
0.48
1 59
0.14
PHENOL
1.88
0.07
0.48
0.11
0.04
0.01
0.03
0.01
1.77
109
0.41
0.08
079
0.03
0.44 0.08
0.34 | 0.06
16.90 3.05
1 14 0.20
0.70 0.12
0 IS 0.03
1.95 ! 0.36
6.11 0.91
0.69 0.11
16.32 2.7S
0.26
0.05
0.29 0.05
12.91
0.18
2.32
0.03
0.14 0.03
0.01 0
2.33 ; 0.42
3.17 ; 067
1.14 070
0.06 , 0.01
093 1 016
073 ; 0.04
0.49
0.08
3.67 0.65
0.82
0.14
706 127
14 80 ' 2 66
14.05 2 54
62 87 9 53
3.67
3.66
174
3.08
0.52
102 1
065
0.64
0.31
0.56
0.10
184
1 OUNUHY SANi>J> NOJ LONUD1 MUJ HA^AMUUU^
ON BASIS OF CALSPAN SOLUBILITY TESTS
DESCRIBED IN APPENDIX B
SOURCE CALSPAN CORPORATION
91
-------
Table 14m
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
REFRACTORIES, 1974 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S. CAROLINA
S. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W. VIRGINIA
WISCONSIN
EPA REGION
I
n
m
nr
V
VI
TMT
Sffl
IX
X
NATIONAL TOTAL
TOTAL
DISPOSED
29,320
3.410
9.980
1.860
670
370
780
540
36.910
19,870
7.240
3.690
A.620
890
1,600
960
49.960
'.040
3,920
9/0
6.700
17.280
1,6*0
6G.6M
1.170
2,070
46,060
490
390
IN
8,060
10.MO
3.690
170
2.840
1,690
1,770
16,430
2.290
23,040
61, 630
46,280
161.880
1././00
16,820
b.600
1.1.190
3.780
385,270
TOTAL
POTENTIALLY
HAZARDOUS
1
i
DISPOSAL
METHOD
ALL
DISPOSED
OF IN
OPEN DUMP
OR
LANDFILLS
1
SOURCE: CALSPAN CORPORATION
92
-------
Table 14n
ESTIMATED STATE, REGIONAL. AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
REFRACTORIES. 1977 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
NEW YORK
N CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S. CAROLINA
g. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W VIRGINIA
WISCONSIN
EPA REGION
I
n
in
IK
V
TO.
m
PlkT
a.
X
NATIONAL TOTAL
TOTAL
DISPOSED
33,428
3.771
11,038
2,046
741
409
863
597
40.822
21.976
8,0(17
4,081
4,999
984
1,069
1,002
56 .245
4,468
4.338
1,073
6,371
19,112
1,836
1.582
1.294
2,M»
49,826
542
431
177
8.903
11,766
3.971
188
3,141
1,869
1,958
17,066
2,533
25,482
58,992
50,06*
201,159
14,046
17.497
6.194
14,809
4,159
392,929
TOTAL
POTENTIALLY
HAZARDOUS
0
!
(
\
DISPOSAL
METHOD
ALL
DISPOSED
Of IN
OPEN DUMP
OR
LANDFILL
\
SOURCE CA1 SCAN CORPORATION
93
-------
Table 14o
ESTIMATED STATE, REGIONAL, AND NATIONAL SOLID WASTE
FROM IRON AND STEEL FOUNDRIES
REFRACTORIES, 1983 (METRIC TONS)
STATE
ALABAMA
ARIZONA
CALIFORNIA
COLORADO
CONNECTICUT
DELAWARE
FLORIDA
GEORGIA
ILLINOIS
INDIANA
IOWA
KANSAS
KENTUCKY
LOUISIANA
MARYLAND
MASSACHUSETTS
MICHIGAN
MINNESOTA
MISSOURI
NEBRASKA
NEW JERSEY
NEW YORK
N. CAROLINA
OHIO
OKLAHOMA
OREGON
PENNSYLVANIA
RHODE ISLAND
S. CAROLINA
S. DAKOTA
TENNESSEE
TEXAS
UTAH
VERMONT
VIRGINIA
WASHINGTON
W VIRGINIA
WISCONSIN
EPA REGION
1
n
01
nr
V
m
yn
cm
IS
X
NATIONAL TOTAL
TOTAL
DISPOSED
39,963
4,M«
13,60]
2.622
913
604
1,063
736
50,308
27.083
9,868
8,029
6.161
1.213
2.045
1,308
68,082
5,506
5,143
1,322
7.861
23,663
2.263
75,892
'.,895
2321
61.403
666
632
218
10.972
14,502
4493
232
3,871
2,303
2.413
21,031
3,121
31.403
70.236
61, 6W
247,902
17.310
21,663
/,633
18,261
5.126
484.233
TOTAL
POTENTIALLY
HAZARDOUS
C
1
i
DISPOSAL
METHOD
ALL
DISPOSED
OF IN
OPEN DUMP
OR
LANDFILL
1
SOURCE: CALSPAN CORPORATION
94
-------
emissions collected by dry control systems. The amounts of individual
constituents were calculated by multiplying the total waste figures by
the concentration values derived from laboratory analyses of waste
samples collected at several plants.
An alternative approach for comniling sludge and dusts values
for each state might be to multiply tuc, waste generation factors given
in Table 12 by the production figures on a state-by-state basis. This
approach was not used since state production figures were not directly
available for each type of ferroalloy and the numbers of plants using
each type (wet/dry) of control system was not known.
The waste slag quantities were calculated by multiplying the
slag generation factors obtained from plant visits (see Table 12) by the
state production figures for each type of ferroalloy as estimated from
the sludge and dust values obtained from in the ferroalloy survey and
from furnace- emission data contained in Reference 7. The sums of the
sludge and dust values were divided by the furnace emission factors for
each ferroalloy category for each state to obtain production estimates.
The state production estimates for each ferroalloy were then summed and
compared with published national figures. The individual state figures
were then adjusted as appropriate so that the national figures agreed.
The slag constituent values for each state were obtained by multiplying
the total slag values for each alloy type by the concentration values
determined through the analyses of collected slag samples, and summing
over all alloys.
2.3 TREATMENT AND DISPOSAL TECHNOLOGY
2-3-1 Current Treatment and Disposal Practices
Slag. Slag which originates from the metal smelting furnaces is open
dumped. This practice is considered environmentally adequate at this
time in the absence of significant leaching of toxic constituents as
ascertained in solubility tests as described in Appendix B.
Waste Sand. Waste sand from cores and molds may either be reclaimed
for making new molds or disposed of in open dumps. Open dumping is
considered environmentally acceptable at this time in the absence of
significant leaching of toxic constituents as ascertained in solubility
tests described in Appendix B.
Coro Butts. Ciorv butts containing non-degraded sands ami binders are
also open dumped. Although solubility tests were not conducted on core
butts they are not considered potentially hazardous at this time.
Solubility testing on core butts is needed to confirm non-leachability.
95
-------
Sludges. Sludges originating from wet scrubbing of furnace emissions
is generally mixed with dry sands, dusts or other dry wastes and open
dumped along with these wastes. This practice is considered environ-
mentally adequate at this time in the absence of significant leaching of
toxic constituents as ascertained in solubility tests described in
Appendix B.
Dusts. Dusts originating from sand reclaiming or control of emissions
from furnaces are open dumped. This practice is considerad environmentally
acceptable at this time in the absence of significant leaching of toxic
constituents as ascertained in solubility tests described in Appendix B.
Refractories. The broken, or eroded brick refractories from furnaces
are open dumped and are considered non-hazardous. Open dumping is
considered environmentally acceptable.
Floor Sweepings. Sweepings from the core making room are principally
sand and are not considered potentially hazardous at this time. Solu-
bility tests were not conducted on sweepings but are needed to confirm
designation as non-hazardous.
Since all of the wastes from iron and steel foundries are
considered non-hazardous at this time Levels I, II and III technology
need not be addressed at this time.
2.4 COST ANALYSIS
Because none of the iron and steel foundry wastes have been
considered potentially hazardous based on available evidence at this
time there are no costs attributable to hazardous waste disposal.
96
-------
3.0 PRIMARY SMELTING AND REFINING OF FERROALLOYS (SIC 3313)
3.1 INDUSTRY CHARACTERIZATION
Ferroalloy is the generic term for alloys consisting of iron
and one or more other metals. Ferroalloys are used in steel production
as alloying elements and deoxidants.
The major types of ferroalloys produced are ferromanganese,
silicon manganese, ferrosilicon, ferrochrome and silvery iron. The 1972
production of the ferroalloys and percent of total ferroalloy production
for that year are as follows: (Reference 6)
Ferromanganese 726,416 MT 32%
Silicomanganese 139,014 6%
Ferrosilicon 767,505 33%
Ferrochrome 319,611 14%
Silvery Iron 147,940 61,
Other 206,294 9%
Total U.S. ferroalloy production in 1971 and 1972 was 2,114,733
and 2,292,153 MT respectively. Production of the above alloys comprises
over 90% of the industry. Ferroalloys produced in minor quantities
(approximately 9% of total) are ferronickel, ferrophosphorus, ferrotitanium,
ferrocolumbian, ferrotungsten and ferromolybdenum.
U.S. producers of ferroalloys are listed in Table 15. Table
16 gives ferroalloy plants by process by state, EPA region and nationally.
There is insufficient information available to estimate state by state
and regional production capacities. Total value of U.S. ferroalloy
shipments in 1973 was $720,542,000 (Ref. 8).
3.2 WASTE CHARACTERIZATION
This section contains descriptions of production technology at
ferroalloy plants and the resultant byproducts or wastes which are
either recycled directly or disposed of on land. Estimates are given
for the quantities of wastes and potentially hazardous constituents
thereof which are disposed of on land either in lagoons or open dumps.
3.2.1 Process Descriptions
Because of the common coproduction of ferromanganese and
silicoman^anese within the same plants and close similarities in pro-
duction technology these ferroalloys will be treated together. Production
of ferrosilicon, ferrochrome, and ferronickel will be dealth with separately.
Ferromanganese and Silicomanganese. The assumed plant has a
daily capacity of 236 metric tons (260 short tons) of ferromanganese and
74 metric tons (82 short tons) of Silicomanganese. Ferromanganese is
produced in two furnaces. The Silicomanganese is produced in a single
97
-------
>**$^W(
TABLF. 15. PRODUCF.RS OP FERROALLOYS IN THM UNITED STATKS IN 1972
Producer
Plant location
Produrt '
Tyiw of furaeoe
Agrico Chemical Cd .
Alreo Atloya ft Carbide
A l»b»roa Metallurgical Corp
Chromium Mining A Smelting Co. .
Diamond Shamrock Corp
FMC Corp . .....
Foote Mineral Co . .
Hanna Nickel Smelting Co .. ...
Kaweckl Chemical Co
Molybdenum Corp. of America
y p
Reading Alloya
ShieldaTloy Corp . .
Plerc*. Pla
Calwt City, Ky
Charleston. S.C
Niagara r'alli N.Y
Selma, Ala
Woodstock', Tenn
Langaloth, Pa
Klngwood, W. Va
i'ocatello, Idaho
Cambridge* Ohio
Graham, w. Va
Keokuk, Iowa
Vaacoram, Ohio..
Wenatchee, Waah .
Buffalo, N.Y
Riddle, Oreg
Beverly, Ohio
Eaeton, Pa
Nlchnla, Fla
Washington, Pa
Columbia, Tenn 1
Niagara Fall*. N.Y
Palmerton. Pa
Brilliant, Ohio .
Phllo.Ohio
Powhatan, Ohio
Robeeonla, Pa
Newfleld, N.J
KeP
FeCr, FeCrSI,
FeMn, FeSi.
SIMn.
Fed
F«Mn
FeMn, SIMn, F«Cr,
FeSi. FeCrSl.
FeMo
FeP
FeB FeCb FeTI
FeV, FeCr,
FeCrSI FeSi
other.1
FeNi
FeP
FeCr FeCrSt FeSi
SIMn.
FeCb
FeP
FeMo, FeW, FeCb,
FeB.
FeP
FeTI, Oliver '
Spin
FeCr. FeSi, Fefl,
other.'
FeCb, FeV
FeV FeTi FeB
FeCb, NICb,
CrMo, other.'
Electric
Do
Do.
Blast
Electm-.
Electric.
Do
Blast
Do
Do
Alumlnothermic.
Electric
Eloctric and
alumloothermlo.
Electric.
Do.
Do.
Alumlnothennfc.
Do
Siauffer Chemical Co.
TeaneeeM Alloy. Corp
TennewM Valley Authority
Tenn-Tex Alloy (>homtcal Corp. of
Hotuton.
l.'aioo Carbid« Corp
I * M LSUU up' UI^B. t; I*.
(Mt. Pleaaant, Tenn.
(Silver Bow, Mont...
/Bridgeport, Ala
< Klmball, Tenn
FeP Electric.
mfiiuifc. ...
Mu«cleSho.l«, Ala..
Hotuton, Te«
FeSI
FeP
FeMn, SiMn
t;.S. Stml Curp .
Woodward Iron Co.
Alloy, W. Va
AahUbula, Ohio
Marietta, Ohio
Nlaiara Falli. N.Y.
Portland, Oret
Sheffield, Ala. .
Clalrton, Pa
McKenport, Pa....
Woodward, Ala
Roekwood, Tenn...
FeB. FeCr. KeCrSI,
FoCb, FeSi,
FeMn. Fnfi,
F»W, F»V.
SIMn, other.'
Do.
Do.
Do.
Do.
F«MD Illaet.
F«SI, FeMn. SIMn.. Klertric.
OrMo, Chromium molybdenum; FeMn, (erromnnKaneie: Spin, niJie .
KwSi. ferroitilicon: FfP, ferrophovphorun; Fef'r, ferrochromium; FeMn f'-rriSmolvb'lcnum: KeMi, ff-rronlckel,
SiMn. ailicomanganvee;
Mi, ff-rronlckel,
fturuculumbium;
. , o , e n '
Ft-Ti, (errotitjinium; FeW, lerrotungnt«ni FeV, ferrovanadium; FeH, furroburun.
NICb, nickel rolumbium; Si, silicon metal.
1 1ncludes Alaifer, Simanal, Ktrconium alloye, ferroailicon boron, aluminum .ilicon alloys, ar^d miacellaaeoua
l.rroalloya.
Source: Minerals Yearbook, Volume I, U.S. Dept. of Interior, 1972
98
-------
TA£L£ :fc
STATE, REGIONAL, AND NATIONAL DISTRIBUTION
OF FERROALLOY PLANTS BY PROCESS
Plant Distribution
State
Alabama
Florida
Idaho
Iowa
Kentucky
Montana
New Jersey
New York
Ohio
Oregon
Pennsylvania
South Carolina
Tennessee
Texas
Washington
West Virginia
No. of
Plants
6
3
2
1
1
1
1
4
8
2
8*
1
6
1
2
3
B£
0
0
0
0
0
0
0
1
0
0
3
0
0
0
0
0
By Process
A
0
0
0
0
0
0
1
0
0
0
4
0
0
0
0
0
E_
6
3
2
1
1
1
0
3
8
2
2
1
6
1
2
3
1
2
3
4
5
6
7
8
9
10
Nation
Plant Distribution
No. of
Plants
0
5
11*
17
8
1
1
1
0
6
E*
0
0
3
0
0
0
0
0
0
0
By Process
A
0 '
1
4
0
0
0
0
0
0
0
E_
0
3
5
17
8
1
1
1
0
6
50
42
BF = Blast Furnace
A = Aluminothermic
E - Electric Furnace
One plant employs both aluminothermic and electric furnace processes
-------
furnace. Annual production is given as 81,100 metric tons (89,400 short
tons] of ferromanganese and 25,400 metric tons (28,000 short tons) of
silicomanganese on the hasis of an 11.3 month operating year for each of
the three furnaces.
Raw materials for the production of standard ferromanganese (80%
Mn and 6.5% C, with the balance mostly iron) consist of manganese ore, coke,
mill scale and melted ferromanganese. The input materials are sized,
mixed together and introduced into the furnaces directly over the molten
bath. An overall flow sheet is shown in Figure 3. The furnaces are of
the open submerged-arc type having three vertical Soderberg-type electrodes
arranged in a triangle. The ends of the electrodes protrude 5 to 6 feet
below the molten bath material. A paste, consisting of coke and pitch,
is fed into the electrode shells from the top. As the paste descends,
it is baked into a solid mass by the heat of the furnace.
The molten ferromanganese collects at the bottom of the furnace
and is tapped into ladles for transfer to a cooling area. Slag is decanted
from the top of the ladles, and the product is poured into a cooling bed
in layers, a process called layer casting. The solidified product is broken
into pieces and sized for sale. The ferromanganese slag is rich in manganese
and most of it is used as charge material for silicomanganese production.
The silicomanganese is also made in an open submerged-arc furnace
whose general operation is similar to that of the ferromanganese furnaces.
The process flow diagram is shown in Figure 3. Input materials for silico-
manganese production consist of coal, coke, manganese ore, ferromanganese
slag, quartz, mill scale, dolomite, and remelt. The molten silicomanganese
is tapped from the furnace into ladles, and the slag is decanted off. The
product is cast into layers prior to final sizing. The slag cannot be
recycled within the plant so most of it is sold to contractors for use as
road fill. Some is sent to an on-s i to. disposaj .'irea.
The air emissions for all three furnaces are controlled by wet
scrubber systems. The emissions scrubwater from the ferromanganese furnaces
with solids amounting to 150.6 kg/MT of product is lime treated and-clarified.
Ferrosilicon. There are three major types of ferrosilicon
produced in the United States: 75% FeSi, 50% FeSi, and 16-22% FeSi, where
the percentages indicate the amount of silicon in the product. The 16-22%
FeSi type is commonly called silvery pig iron and accounts for about 20
percent of the total ferrosilicon production.
Most of the ferrosilicon produced in the United States is made in
electric submerged-arc furnaces. An average furnace size might be about
15 megawatts with a daily capacity of 37 MT (41 tons) to 65 MT (72 tons),
depending on whether the furnace produces 75% FeSi or 50% FeSi. The energy
required for 75% FeSi production is about 75% greater than that required for
50% FeSi production. Specifically, the production of 75% FeSi requires
only 5.5 mw-hr per MT. Input materials for ferrosilicon production consist
of quartzite, scrap steel, coal, and coke.
100
-------
MANGANESE ORE
COKE
MILL SCALE
REMELTS
EMISSIONS
167.4 kg
FERROMANGANESE
FURNACES
(2)
F«Mn
MANGANESE ORE
COAL
CLXE
QUARTZ
MILL SCALE
DOLOMITE
REMELTS
1 (METAL PRODUCT)
* V
1000kg
SLAG
EMISSIONS
109 kg
1000kg
SOLD FOR ROAD BASE
NOTE: OUTPUTS EXPRESSED IN
KILOGRAMS/MT OF PRODUCT.
/ DREDGED \
( MATERIAL )
\OPEN DUMP/
Figure 3 FERROMANGANESE AND SILICOMANGANESE PRODUCTION
101
-------
I er-rochrome Product urn. Ferroehrome is made in two grades, high
carbon (HCj and low carbon (LC). Most of the ferrochrome produced in the
United States is of the high carbon type, Input mate-rials consist of chromium
ore, quartzitc, limestone, coal and coke. The electrical energy required
to produce (HC) ferrochrome averages about 4.6 megawatt-hours per metric ton
of product. Furnace emissions average 168 kg of particulates per metric
ton of product (335 Ib/ton) for either high or low carbon ferrochrome. An
average ferrochrome furnace might be rated at 20 megawatts. Thus, the
average furnace would produce about 104 metric tons (115 short tons) of
ferrochrome per day.
Fc-rronickel. There is only one ferronickel producing plant in
the United States located at Riddle, Oregon. Nickel ore is mined at the
top of a mountain and transported to the plant by tram cars.
The plant operates around-the-clock producing approximately 23,600
metric tons (26,000 short tons) of ferronickel (50% Fe, 50% Ni) annually.
Reduction of the nickel ore is accomplished by mixing the melted nickel ore
with ferrosilicon (48% silicon). The required ferrosilicon is produced in
the same plant at the rate of about 20,620 metric tons (22,730 short tons)
per year.
The sequence of operations for producing ferronickel consists of
ore mining and preparation, melting, reduction, and refining. A flow
diagram is presented in Figure 4. The mined ore is first dried and then
screened into three fractions. The coarser, low grade rock is diverted to
a reject ore pile for possible use in the future if an economical process
for nickel extraction can be developed. The ore fraction in the 5/16" to
3/4" range is crushed and temporarily stored. The-5/16" fraction is
further screened to remove the fines which are stored separately. The
coar.scr retained ore fractions arc calcined and the fines are roasted.
The coarse and fine fractions arc- then transferred to hot ore bin.s from
which they are gravity fed to the furnaces. Ore melting i^ curried out in
four JO,000 KVA electric furiures. The molten nickel ore i - rapped into
ladles and vigorously mixed with ferrosilicon which acts as the reducing
agent. Mixing is accomplished by transferring the molten mixture back and
forth between two ladles. During the reduction process, a fraction of the
ferronickel is removed from the ladle at regular intervals and introduced
into two small electric furnaces for refining. Other input materials for
the refining operations are limestone, dolomite, fluorspar, iron ore, and
coarse concentrates from the skull plant.
The skull plant processes slag from the refining furnaces, metal
spills and residues from the ladles (called skulls) to produce concentrates
of high metal content that are recycled to the refining furnaces and to the
ferrosilicon furnace. A hammer mill pulverizes the input materials and
the coarser metal-rich fraction is removed magnetically. The finer tailings
are slurried with water and piped to a tailings pilo.
102
-------
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103
-------
l;errosiI icon is produced in a 15,000 KVA electric furnace with
input maUn-iuls consisting of quarrz, iron turnings, coke, wood chips, and
.kul I plant concentrates. All t'orrosilicon produced is cast, crushed and
used for reduction of tho nickel ore.
The molten slag generated during the reduction of the nickel ore
is granulated by high pressure water sprays and transferred to the slag
pile by conveyor belt. The fines derived from granulation of the slag are
carried in the water stream to settling ponds (or lagoons).
3.2.2 Description of Waste Streams
l-erromanganese and Silicomanganese
Slags. A dense vesicular slag is generated from ferromanganese
production at a rate of 600 kg/NTT ferromanganese product. Approximately
360 kg/MT of the 600 kg/MT generated is used as an input to the silica-
manganese furnace. The remaining 240 kg/NTT is stored on the ground for
possible future use in Silicomanganese production.
In the production of Silicomanganese a glassy textured slag is
generated at a rate of 1100 kg/MT of Silicomanganese product. Of this
amount approximately 785 kg/MT product is sold for road base with 315 kg/MT
product disposed of in open dumps.
Major constituents of ferromanganese and Silicomanganese slag
are manganese, manganese oxide, silica, alumina, calcium oxide and magnesium
oxide. Trace metals in these slags include chromium, copper, lead and zinc.
In solubility tests described in Appendix B there was no leaching
of toxic heavy metals at greater than 0.2 ppm from either ferromanganese or
iiiiv.oi.:aiiganese slag. For this reason in addition to the dense nature of
the - la;; ,,ferromanganese and Silicomanganese slags are not considered hazardous
at this time.
Dusts and Sludges. Depending on whether wet or dry emissions
controls are used on furnaces, dusts or sludges are produced. Figure 3
illustrates emissions control residuals using wet scrubbers. Emissions
from the ferromanganese furnaces are generated at a rate of 167.4 kg/MT
of product. Ninety percent of these emissions or ISO.6 kg/MT product are
captured in wet scrubbing systems. The scrubber water is lime treated and
clarified. Underflow sludge from the clarifier is generated at a dry
weight rate of 164.8 kg/MT product and settled in a lagoon.
Emissions from the silico-manganese furnace are generated at a
rate of 109 kg/MT Silicomanganese product. Ninety percent of the emissions
are captured in wet scrubbers as shown in Figure 3 and sent to a settling
basin at a rate of 98.5 kg/MT product. Solids are collected in the settling
basin, dredged several times per week and trucked to an on-site open dump
at a rate of 7-1 kg/MT product.
104
-------
Overflow from the settling basin carries 23 kg of dry solids /MT
product to the lagoon. Solids from the lagoon are periodically dredged and
open ilumpud -it w rate of 1K7.H kg/MT of product.
In solubility tests described in Appendix B, dusts and sludges
from silicomanganese emissions control leached lead at approximately 1.3 ppm.
Ferromanganese dusts leached 110 ppm zinc and 560 ppm lead. For these reasons,
along with the fine particulate nature of these wastes, sludges and dust,
residuals from ferromanganese and silicomanganese production are considered
potentially hazardous at this time.
Ferrosilicon
Dust. The production of ferrosilicon generates no slag. Therefore,
control of furnace emissions produces the only significant solid waste. While
dry-and-wet emissions control systems are utilized, dry type systems are more
prevalent. Furnace emissions average about 450 kg/NTT (900 Ib/ton) for
75"s FeSi and 225 kg/MT (450 Ib/ton) for 50% FeSi. Thus, for furnaces controlled
by bughouse collection systems the average quantity of collected dry dust will
vary between 405 kg/MT product and 202.5 kg/MT product depending on the type
of FeSi being made. An overall hooding and capture efficiency of 90 percent
is assumed. The collected dusts are trucked to a land disposal area for
open dumping.
In solubility tests described in Appendix B there was no leaching
of toxic heavy metals greater than 0.3 ppm from ferrosilicon baghouse dust.
Sludge would be expected to behave similarly. For this reason dusts and
sludges from ferrosilicon production are not considered potentially hazardous
at this time.
Ferrochrome
Slag. In ferrochrome production the slag-to-product ratio is
estimated to vary from 1.5 to 2.0. Therefore the slag generation factor is
approximately 1750 kg/MT of ferrochrome product. The slag occurs in dense 4
to 6 inch diameter clumps and has a vesicular surface. The slag is either
open dumped or processed to produce two or more fractions and sold for use
in road building.
In solubility tests described in Appendix B, there was insignificant
leaching of toxic constituents from ferrochrome slag. This slag is therefore
not considered potentially hazardous at this time.
Available data show that both wet and dry emissions controls
systems are used in ferrochrome production. If the furnace emissions are
controlled by a dry system 151 kg of dust per MT of ferrochrome product will
be collected on the assumption that the overall hooding and collection
efficiency is 90%. The collected dust is usually trucked to an on-site
dump for final disposal.
105
-------
In solubility tests described in Appendix B it was found that
dusts from ferrochrome production leached over 100 ppm chrome and around
1 ppm lead. For this reason dust from ferrochrome emissions control is
considered potentially hazardous at this time.
For a wet collection system operating at an overall
capture efficiency of 90*, the same weight of particulates would be contained
in the scrubber water as were captured by the dry system. The scrubber water
would be piped to a settling basin to allow the particulates to settle. An
estimated 97% or 146.5 kg/MT product of the solids would be retained in the
settling basin. Accumulated bottom sediments in the settling basin would be
pumped out or clammed out periodically and dumped on adjacent land areas.
As discussed previously ferrochrome dust released chrome and lead
In solubility tests. Sludge would be expected to behave similarly and is
therefore considered potentially hazardous at this time.
Ferronickel
Slag. Granulated slag from the reduction operation is generated
at a rate of 31 MT/MT production, a very high ratio of waste to product.
Accumulation of this sla& since the plant began operation in H)54 has produced
a huge slag pile covering many acres and extending up to a height of 100 feet
or greater. A very small fraction of the slag is purchased by a local con-
tractor for road base.
So.Uds are carried from the slag granulation operation into a large
lagoon (approximately 12 acres) at a rate of 697 kg/MT ferronickel product
(see Figure 4 ) . Sludge amounting to 576 kg/MT product is dredged once a year
from the lagoon and open dumped on land adjacent to the lagoon. Overflow
from the settling lagoon is diverted to a second lagoon which is not dredged.
In solubility tests described in Appendix B zinc leached from slag
at 2.0 ppm and lead at 1.0 ppm. The fines from this slag (i.e. sludge) how-
ever, did not leach toxic heavy metal constituents beyond 0.3 ppm in the
solubility tests. For this reason slag and slag fines (sludge) are not con-
sidered hazardous at this time.
Skul 1 V t ant Tai ] ing s . Tailings from the skull plant as shown in
Figure 4 are generated at the high rate of 5.3 MT/MT product. The tailings
are piped to the tailings pile at the rate of 360 MT (400 short tons) per day.
Water runoff from the tailings pile is diverted to the lagoon which receives
slag granulation water. Since the skull plant began operation the skull
plant tailings pile has grown to an impressive area and height but is dwarfed
by the mountainous slag pile.
In solubility tests described in Appendix B, skull plant tailings
leached copper and zinc at approximately 50 ppm. For this reason skull plant
tailings are considered potentially hazardous at this time.
106
-------
busts. Dusts collected during ore preparation including drying,
crushing, calcining and roasting are fed to the furnaces so no significant
solid waste accumulates from control of emissions from these operations.
Dusts from the electric turnace are captured in baghouses and
recycled to the furnaces with the exception of dust collected from the
ferrosilicon furnace. The ferrosili.on dusts are collected at the rate
of 84 kg/MT product, wetted to preven; blowing, and disposed of in the
slag pile.
In solubility tests described in Appendix B ferrosilicon furnace
dust did not leach any toxic heavy metals greater than 0.3 ppm and is
therefore considered non- hazardous.
3.2.3 Waste Quantities
A number of ferroalloy plants were visited and samples of waste
residuals obtained for subsequent chemical analyses. These analyses are
given in Appendix A. From these analyses and data provided by individual
plants on quantities of wastes, waste generation and constituent concentra-
tion factors were developed. These factors are given in Table 17. Using the
generation and concentration factors in Table 17 the yearly generation of
waste residuals from typical plants have been estimated. These estimates
are given in Table 18 for typical plants producing the various ferroalloys
(FeMn, SiMn, FeSi, FeCr, FeNi). Based on plant capacities, data supplied
by individual plants, and chemical analyses of collected samples, estimates
of the total quantities of land disposed wastes and potentially hazardous
constituents thereof have been made on state by state, EPA regional, and
national levels. This data is tabulated in Table 19 for 1974, 1977 and
1983. Estimates for growth, in ferroalloy capacity by 1983 is approximately
4%. Inherent error in estimated waste quantities does not warrant meaningful
increased 1977 and 1983 projections at this growth rate.
Oregon with only two ferroalloy plants generates the greatest
amount of slag and sludge than other states with ferroalloy industries. This
is a result of the ferronickel plant which generates very large quantities of
waste per unit of product. Ohio which has 8 ferroalloy plants generates the
second largest quantity of slag and sludge and the greatest quantity of dusts.
3.3 TREATMENT AND DISPOSAL TECHNOLOGY
3.3.1 Current Treatment and Disposal Practices
Ferromanganese and Silicomanganese
Slag. Slag from the ferromanganese furnace which is not used
as charge material in Silicomanganese production (approximately 40% of total
slag) is stored on land for possible future use. Approximately 30% of
residual slag from Silicomanganese furnaces which is not able to be sold as
road fill is open dumped. Open dumping or salo as roadfill are environmentally
.HlcquaJc sinro forromariKanose and silicomangaru'se slags are not considered
potentially hazardous at this Lime.
107
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Sludges and Dusts. At the present time lime treated scrub-
water from ferromanganese furnace emissions control and wet scrubber
sludge from silicomanganese emissions control is settled in lagoons or
settling basins. Settled sediments are periodically dredged and dumped
on land. Dusts are either directly dumped on land or wetted before
dumping to prevent blowing. The present methods of disposing of sludges
or dusts are considered inadequate because of the danger of leaching of
lead and zinc.
Ferrosilicon
Dusts and Sludges. Collected dust from ferrosilicon furnaces
is usually trucked to on-site open dump areas. Dust is wetted down to
prevent blowing from the truck while being transported. If wet emissions
control is used a sludge is generated ^hich is open dumped. Open dumping
of dust or sludge is environmentally acceptable since they are not con-
sidered hazardous at this time.
Ferrochrome
Slag. Electric furnace slag is open dumped or sold for use
in road building. These practices are environmentally adequate since
solubility tests indicated that ferrochrome furnace slag is non-hazardous
at this time.
Dusts and Sludge. Either dusts or scrubber water is generated
from emissions control on ferrochrome electric furnaces depending on the
method of air pollution control practiced. Dusts are open dumped while
scrubber waters are put in unlined lagoons with periodic dredging of
settled sediments. Dredged sediments are open dumped. Current practices
of dust and sludge disposal are considered inadequate because of the
possibility of chrome and lead leaching.
Ferronickel
Slag. Granulated slags from reduction furnaces are presently
open dumped. This practice is adequate since ferronickel slag is not
considered hazardous at this time.
Skull Plant Tailings. Skull plant tailings are currently open
dumped. This practice is not considered adequate because of evidence of
zinc and copper leaching at approximately 50 ppm in solubility tests.
Sludges. Sludges result from settling of slag granulation
water and skull plant tailing water in an unlined lagoon. The sludges
are dredged from the lagoon and open dumped. The sludge from slag granu-
lation is not considered potentially hazardous while that from skull plant
tailings is considered potentially hazardous. Since they accumulate in the
same lagoon, the entire sludge volume must be considered hazardous at this
time and the use of an unlined lagoon as not acceptable.
113
-------
Dust . The only land disposed dust from ferronickel production is
the emission control dust from the associated ferrosilicon furnace. This
dust is open dumped on land, an environmentally acceptable practice since
ferrosilicon dust is not considered potentially hazardous at this time.
Levels of treatment and disposal technology for those ferroalloy
wastes which are considered potentially hazardous are discussed in the
following sections.
3.3.J Present Treatment and Disposal Technology (Level I)
Ferroinanganese and Silicomanganese
Sludges and Dust. Lime treated scrubwater from ferromanganese
furnace emissions controls and wet scrubber sludge from silicomanganese
emissions control is settled in lagoons or settling basins. Settled
sediments are dredged and open dumped. Dusts are either open dumped directly
or wetted before open dumping. These practices are inadequate because of
the possibility of heavy metal leaching and subsequent percolation through
permeable soils to groundwater.
Ferrochrome
niis^_s jind S 1 udjj es . Dusts are open dumped and scrubber waters are
settled in un lined lagoons with periodic dredging of settled sediments.
Dredged sediments are open dumped. These practices are inadequate because
of the possibility of heavy metal leaching and subsequent percolation
through permeable soils to groundwater.
F e rrp i}_[£__
SKul. j^ I'Jant Tailings. Skull plant tailings are presently open
dumped. This is not adequate since solubility tests indicate leaching of
zinc and copper which could percolate through permeable soils to groundwater.
Sludges. Sludges from skull plant tailings water accumulates
in a lagoon along with sludge from slag granulation water. Sludge is
periodically dredged and open dumped. The lagoon is unlined. The use of
an unlined lagoon and open dumping of dredged sludge are considered in-
adequate because of the danger of heavy metal leaching through permeable
soils to groundwater.
3.3.3 Best Technology Currently Employed (Level II)
Ferromanganese and Silicomanganese
5 liiiLt0!. JiU'LJJii-lLS.1 Level II technology is the same as Level I
(i.e. open dumping oi' dust and dredged slud^o).
114
-------
Ferrochrpme
Dusts and Sludges. Love] IT technology is the same as Level
(i.e. open dumping of dust and dredged sludge).
Ferronickel
Skull Plant Tailings. Level II technology is the same as
Level I (i.e. open dumping).
Sludges. Level II technology is the same as Level I (i.e. lagoon
settling and open dumping of dredged sludge).
3.3.4 Technology To Provide Adequate Health And Environmental
Protection (Level III)
Ferromanganese and Silicomanganese
Sludges and Dust. The use of lined lagoons would be required for
settling of sludges. Dredged sludges would need chemical fixation before
dumping on land to prevent heavy metal leaching. Ground upon which dusts are
disposed would require soil sealing to prevent percolation of potentially
hazardous constituents.
Ferronickel
Skull Plant Tailings. The ground area for disposal of skull
plant tailings would require sealing with bentonite or other sealant to
prevent percolation of leachate. Runoff water would be collected and
diverted to the lagoon.
Sludges. The lagoon receiving sludge from the skull plant
tailings pile and slag granulation would require a lining. Dredged lagoon
sediments would be dried and disposed of in sealed soil areas.
Tables 20a through 20e summarize features of Levels I, II and III
treatment and disposal technology for those wastes from the ferroalloy
industry which are considered potentially hazardous at this time.
3.4 COST ANALYSIS
In the last section, various treatment and disposal technologies
currently employed or considered for adequate health and environment pro-
tection were described. The costs for implementing this technology for
typical plants is considered in this section. Costs are given separately
for plants producing ferromanganese and silicomanganese, ferrosilicon,
ferrochrome, and ferronickel.
115
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125
-------
3.4.1 Cost of Present Treatment and Disposal Technology (Level T)
Ferromanganese and Silicomanganese. The typical plant produces
81,000 MT of ferromanganese and 25,400 MT of Silicomanganese operating
about 345 days/year.
Effluents from both operations go to a lagoon. It has a
volume of 10,700 m and allows for 4 days of residence. Its design
characteristics are:
Volume 10,700 m3
Bottom width 38 m
Top width 50 m
Bottom length 75 m
Top length 87 m
Total depth 3 m
Depth of excavation 1.15 m
Circumference 286 m.
Dike volume 3,546 nu
Dike surface 3,921 m
Total width 63 m
Total length 101 m
Required area .65 ha
The daily inflow into the lagoon contains 40.6 MT of solids which
form about 29 m of sludge. This requires that the lagoon is dredged about
1.9 times/yr assuming that it is dredged when half filled with sludge.
This requires about 380 hours of dragline time based on a capacity of 27 m /yr
of frontloader and truck time. The lagoon is located on semi-industrial
land.
Scrubber water from the Silicomanganese furnace flows through a
concrete-lined settling pit before entering the lagoon. The pit is sized
to allow a settling time of 30 minutes. About ^K.7 Nfl of .solids are
removed weekly from the pit and trucked to the on-site dump. This operation
is estimated to require 80 hours of truck and backhoe time/yr.
Capital and annual costs of Level 1 treatment and disposal
technology are given in Table 21.
Ferrochrome. The selected plant produces 62,790 MT of ferro-
chrome/year operating 345 days. Two types of wastes are generated. One
is furnace slag (non-hazardous) which is open dumped or sold for use in
road building. The other consists of wastes collected by air emission
control systems considered hazardous. Both dry and wet systems are
employed for handling the latter waste, and costs are developed for both
systems.
126
-------
TABLE 21
COST OF LHVEL I TRE VTMENT AND DISPOSAL TECHNOLOGY
R'RKOALLOYS - FT.RROMANGANESE AND SILICOMANGANESE
Capital Cost
Lagoon
Site Preparation
Survey $ 375
Test Drilling 490
Sample Testing 250
Report Preparation 1,200
Construction
Excavation § Forming 4,715
Compacting 6,560
Fine Grading 1,765
Soil Poisoning 355
Transverse Drain Fields 580
Land 2,570
Sump 3,870
Equipment
Truck (1.1) 8,250
Front Loader (1.1) 6,600
Dragline (20%) 14,000
Bulldozer (30%) 2,305
Dump
Survey 1,350
Land 8,545
TOTAL $63,780
127
-------
TABLE 21 (Cent.)
Annual Cost
Land
Amortization
Construction 2,495
Equipment 4,955
Operating Personnel 20,110
Repair and Maintenance
Construction 535
Equipment 1,560
Energy
Fuel 2,310
Electricity 230
Taxes 280
Insurance
(Slag Sale) 640
TOTAL $34,225
128
-------
The dry system results in tha collection of 15.7 M7 >f dust/day
with a density of 500 Kg/m . The dust is transported to an op-site dump,
which requires 2 hrs/day of frontloader and truck time.
In the wet system, the scrubber water is piped to a lagoon.
The lagoon, like all other waste disposal facilities is assumed located
on semi-industrial land. Inflow into the lagoon is at a rate of 80 I/sec.
The lagoon size allows for 4 days detention. Its characteristics are:
Volume 27,550 m3
Bottom width 63 m
Top width 75 m
Bottom length 126 m
Top length 138 m
Total depth 3 m
Depth of excavation .85 m
Circumference 438 m_
Dike volume 6,872 m
Dike surface 6,282 m
Total width 90 m
Total length 153 m
Required area 1,4 ha
, About 15.2 WT of solids settle in the lagoon daily which form
12.7 m of sludge. Dredging is required only once every three years.
On the average, 4,150 m of sludge are dredged annually which represents
220 hours of frontloader and truck time.
The sludge dump is designed to accommodate lagoon sludge
dredged over a 20-year period.
Capital and annual costs of Level I treatment and disposal
technology are given in Table 22. .
Ferrosilicon. Since there are no hazardous wastes believed
associated with ferrosilicon production at this time, there are no costs
associated with hazardous waste treatment and disposal.
Ferronickel. The model plant produces 23,600 NTT of ferronickel
operating 365 days/year. Ferrosilicon required for the reduction of
nickel is produced in the same plant at a rate of about 20,620 MT/yr.
The only wastes associated with ferronickel production which is believed
hazardous is skull plant tailings and associated sludge.
Tailings from the skull plant are piped to a tailings pile.
Solids accumulate at a rate of about 360 NTT/day. The water from the
tailings slurry drains into a lagoon which also receives water and
solids from slag granulation. The tailings have an estimated density of
1,300 kg/m . Thus, about 275 m of solids form daily and 100,375 m
annually. The accumulation over a 20-year period amounts to about
2,000,000 m . This will require a 7 ha area given that the tailings are
built-up to a height of 30 m.
129
-------
TABU! 22
COST OF LEVEL 1 TREATMENT AND DISPOSAL TECHNOLOGY
FERROALLOYS - FERROCHROME PLANT - DRY COLLECTION SYSTEM
Equipment
Truck (35%)
Front Loader (35%)
Bulldozer (5%)
Dump
Survey
Land
Capital Cost
Dust
$ 8,750
7,000
1,000
1 , 3
TOTAL
$26,870
Annual Cost
Land
Amorti zation
Const ruction
Operating Personnel
Repair and Maintenance
Const ruction
Equipment
Energy
Fuel
Electricity
Taxes
Insurance
TOTAL
130
Dust
$ 875
It.D
/ .<>'>'.
8-k)
2,000
200
220
270
-------
TA'iU 2L (L'ont.J
FURROCHROME PLANT - WKT COLLECTION SYSTEM
Capital Cost
Lagoon
Site Preparation
Survey $ 875
Test Drilling 980
Sample Testing 500
Report Preparation 1,500
Construction
lixcavation (i Forming 9,140
Compacting i2,715
I nit- Crading 2,825
Soi J Poisoni ny. 545
Transverse Drain Melds 2,070
Land 5,535
Equipment
Truck (KttJ 2,500
l;ront Loader (10"«) 2,000
Hulldozer (II) 200
Drag Line (10"o) 7,000
Dump
Survey 505
Land 3,250
TOTAL $52,120
131
-------
TABLE 22 (Cont.)
Annual Cost
Sludge
Land $ 875
Amortization
Construction 3,670
Equipment 1,860
Operating Personnel 7,145
Repair and Maintenance
Construction 820
Equipment 585
Energy
Fuel 820
Electricity 80
Taxes 220
Insurance 520
TOTAL $16,595
132
-------
Solids carried into the settling lagoons accumulate at an estimated
rate of 13,600 MT/yr. The sludge formed has a wet density of 1,260 Kg/m'
and a dry density of 1,390 Kg/m . Most of the solids settle in the first of
two lagoons (Lagoon A). The overflow from Lagoon A goes to the second lagoon
^Lagoon B). The characteristics ot i.he lagoons are:
- la£y5 ^ Lagoon B
Volume ,<0,Q(.'0 ni3 95,000 m3
Bottom width 1T9 m 152 m
Top width 147 m 160 m
Bottom length 278 m 304 m
Top length ::6 m 312 m
Circumference 879 m 955 m
Depth 2 >n 2m
Depth of excavation .25 m, .25 m
Dike volume 9,990 m^ 10,863 m
Dike surface 9,893 m 10,758 m
Total width 160 m 173 m
Total length 299 m 325 m
Required area 4.8 ha 5.6 ha
Lagoon A is dredged once per year at which time about 10,800 m
of sludge is removed. This requires about 400 hours of dragline time. The
sludge is then deposited on adjacent land. The transport is estimated to
require 520 hours of frontloader and truck time annually.
3 3
In a dry state, sludge removed amounts to 9,785 m /yr or 195,700 m
in 20 years. This will require a 2 ha area if the built-up is to 10 m.
All dust except those from the ferrosilicon furnace are recycled.
The latter are not considered hazardous and therefore have no hazardous
waste disposal costs attributed to their disposal.
Altogether, about 680,000 m of solids are deposited on land
each year. This is estimated to require 6,800 hrs of bulldozer time yearly
for spreading, shaping and compacting. Capital and annual costs of Level I
treatment and disposal technology are given in Table 23.
3.4.2 Cost of Best Technology Currently Employed (Level II)
Ferromanganese and Silicomanganese. Technology and costs for
Level II are the same as those for Level I.
Ferrochrome. Technology and costs for Level II are the same as
those for Level I.
Ferronickel. Technology and costs for Level II are the same as
those for Level I.
133
-------
TABLE 23
COST OF LEVEL I TREATMENT AND DISPOSAL TECHNOLOGY
FERROALLOYS - FERRONICKEL PLANT
Capital Cost
Lagoon A
Site Preparation
Survey
Test Drilling
Sample Testing
Report Preparatio n
Construction
Excavation § Forming
Compacting
Fine Grading
Soil Poisoning
Transverse Drain Fields
Land
Lagoon B
Site Preparation
Survey
Test Drilling
Sample Testing
Report Preparation
Construction
Excavation § Forming
Compacting
Fine Grading
Soil Poisoning
Transverse Drain Fields
Land
Tailing's Dump
Survey
Land
Sludge Dump
Survey
Land
Equipment
Truck (35%)
iTont Loader (35o)
Bulldozer (55'i)
Belt (,'onvcyor
Dragline (201)
$ 3,000
900
250
1,500
13,285
18,480
4,450
1,090
6,625
8,400
3,500
900
250
1 ,SOO
14,450
20,095
4,840
1,185
7,960
9,800
i,250
3,500
6,565
.> , J30
545
14,000
Tailings
4,375
12,250
7,615
TOTAL
$153,390 $24,240
134
-------
TABLF 23 (Cont.)
Annual Cost
Sludge Tailings
Land $ 2,170 $ 1,225
Amortization
Construction 12,220 510
Equipment 4,190 1,210
Operating Personnel 16,920 11,565
Repair and Maintenance
Construction 2,775
Equipment 1,320 380
Energy
Fuel 1,945
Electricity 195
Taxes 545
Insurance 1,535
TOTAL $43,815
135
-------
34^ Cost of Technolug/ to Provide Adequate Health and Bnvironmental
Protection (Level III)
Ferromanganese and Silicomanganese. The lagoon is lined and the
accumulated sludge is removed hy pumping instead of dredging. The sludge
is chemically fixed prior to being deposited at the slag dump. The slurry
pump is operated about 720 hrs/yr, and 1,000 labor hours are assigned for its
operation. The use of the slurry pump eliminates the use of the dragline.
Capital and annual costs are given in Table 24.
Forrochrome. The lagoon is lined, and the sludge or slurried
dust is removed by pumping instead of dredging. The sludge is chemically
fixed prior to being deposited at the dump. The dump surface is sealed and
colli-rtion ditches installed, together with a pump and piping. The slurry
pump is operated about 300 hrs/yr and 450 hrs are assigned for its operation.
The use of the slurry pump eliminates use of the dragline. Capital and annual
costs arc given in Table 25.
l-'orronickcl. Both lagoons are lined and the accumulated sludge
is removed from Lagoon A by pumping instead of dredging. The slurry pump
used for this purpose is operated about 765 hrs/yr and 1,000 labor hours
are assigned for its operation. The use of the slurry pump eliminates the
need for the dragline.
The pumped sludge is deposited on a sealed .25 hectare area
adjacent to Lagoon A for drying. The runoff is collected in ditches and
then flows by gravity into Lagoon B. The dried sludge is then hauled to
dump where the ground has been sealed.
The tailings from the skull plant are deposited on sealed ground
and collection ditches are constructed at the dump site. The capital and
annual costs of Level III treatment and disposal technology are given in
Table 2(>.
Tables 27 Through 29 summarize the capital and annual costs for
Levels I, 11 ;md III treatment and disposal technologies for hazardous
land disposed waste from the U.S. ferroalloys industry. Costs arc given per
metric ton of dry and wet wastes (i.e. sludges) and per metric ton of
product. Cumulative total industry costs for each ferroalloy sector to
meet Levels I, II and 111 treatment and disposal technology are also given.
Costs for each type of waste and total costs for each ferroalloy sector are
also expressed as percentages of product selling prices.
Estimated 1973 annualized industry costs for Levels I and II
treatment and disposal technology of potentially hazardous wastes from
ferromanganese and silicomanganese production are $250,000 or 0.2% of
estimated national sales value. The industry cost of Level III treatment
and disposal technology (adequate for environmental protection) is estimated
as $1,310,000 or 0.8% of estimated national sales value.
136
-------
UOS'I OF LLv'EL il] TREATMENT AND DISPOSAL TECHNOi..,,,Y
FERROALLOYS - FLKROMANGANES AND SILICOMANGANESF. PLANT
(,;i|U t ;i I Co'tt
Construction
Lagoon Liner
Equipment
Slurry Pump
Piping, Flexible
(Dragline)
$21,440
13,730
440
(14,000)
$21,610
Annual (lost
Land
Amortization
Construction
Equipment (1)
Operating Personnel (1)
Repair and Maintenance
Construction
Equipment (1)
Energy
Fuel (11
I i 1 e i-1 r i c i t y
Taxes
Insurance (1)
Chem. Fixation
TOTAL
$ 2,485
25
4,835
645
10
(435)
15
215
134,180
$141,975
(1) Costs shown are net costs, i.e. costs of new equipment less
dragline associated costs which are no longer incurred.
137
-------
TABLE 25
COST OF LEVEL III TREATMENT AND DISPOSAL TECHNOLOGY
FERROALLOYS - FERROCHROME PLANT
Capital Cost
Sludge
Construction
Lagoon Liner $47,630
Equipment
Slurry Pump 13,730
Pipe, Flexible 440
(Dragline) (7,000)
TOTAL $54,800
Annual Cost
Land
Amortization
Construction $ 5,525
liquipment (1) 1,140
Operating Personnel (1) 2,370
Repair and Maintenance
Construction 1,430
Equipment (1) 360
Energy
Fuel (1) (175)
Electricity 10
Taxes
Insurances (1) 550
Chem. Fixation 54,780
TOTAL $65,990
(1) Costs shown are net costs, i.e. costs of new equipment less
dragline associated costs which are no longer incurred.
138
-------
TABLE 26
COST OF Ll'VKL III TREATMENT AND DISPOSAL TECHNOLOGY
FL'RUOALLGYS - FLRRONICKliL PLANT
Capital Cost
Construction
Lagoon (A) Liner
Lagoon (B) Liner
Hquipment
Slurry Pump
Piping, Flexible
Sludge Drying Area
Land Sealing
Collection Ditches
Pipe Rigid
Dumps
Survey
Land
Land Sealing
Collection Ditches
Pump ;md Piping
Sludge
$180.080
212,655
13,730
440
5,000
760
1,730
40,000
2,145
11.140
Tailings
140,000
4,010
18,210
TOTAL
-------
TABLE 26 (Cont.)
Annual Cost
Sludge Tailings
Land - I
Amortization
Construction $51,115 $16,705
Equipment 2,075 2,895
r
Operating Personnel 4,590 - f
Repair and Maintenance
Construction 13,220 4,320
Equipment 650 910
Energy g
Fuel (455) - *
Electricity ' 95 325
Taxes
Insurance 4,535 1,620
TOTAL $75,825 $26,775
140
-------
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Assuming that wet systems are used for emissions control for
ferrochrome production the industry annualized costs for Levels I and II
treatment and disposal technology are estimated as $110,000 or 0.07% of
estimated national sales. The industry annual cost of Level III technology
using wet emissions controls is estimated as $560,000 or 0.36% of 1973 4
national sales.
The estimated annual cost for Level I and II treatment and
disposal technology for potentially hazardous waste from the one United
States ferronickel plant is $60,000 or 0.18% of estimated 1973 sales
value. Estimated annual costs for Level III treatment and disposal tech- -
nology are $160,000 or 0.48% of estimated national sales.
144
-------
4.0 PRIMARY METAL PRODUCES NOT ELSEWHERE CLASSIFIED (?JC 3399)
This SIC category includes a number of miscellaneous metal
products and associated manufacturing processes including production of
ferrous and non-ferrous metal powders, metal paste, and ferrous and non-
ferrous nails, brads, wire and stapi ;S. Table 30 shows the geographic
distribution of industries in this .-v '3+cfory as of 1972,
Brads, nails, tacks, -;pin *,:>.? i.iiilsr items are manufactured
from metal by machining, extrn: Ion .-ir: oc^er similar processes. Solid
wastes will consist principally of .= i: .innings, clippings and other
metal remnants. These wastes are r_,.,vcrxl for scrap and therefore do
not constitute a solid or hazardous , ~
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TABLE 30
GEOGRAPHIC DISTRIBUTION OF MISCELLANEOUS PRIMARY METAL PRODUCT MANUFACTURING
FIRMS, 1972 (SIC 3399)
Geographic Area
Total No. of
Establishments
U.S. Total 161
N.li. Region 56
New England Div. 8
Connecticut 3
Middle Atlantic Div. 48
New York 9
New Jersey 14
Pennsylvania 25
N. Central Region 55
Ohio 14
Illinois 10
S. Region 28
S. Atlantic Div. 6
E.S. Central Div. 14
Tennessee 6
W.S. Central Div. 8
to. Re;; ion .'.'
Mountain Div. r>
Pacific Div. 17
No. with 20+
Employees
101
35
7
3
28
5
8
15
34
9
5
18
3
9
4
6
14
4
10
Value of Ind
Shipments
$341M
153
25
9
128
9
63
57
91
19
10
64
8
37
17
20
?3
9
24
Source: Census of Manufacturing 1972
146
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TABLE 31 PREDICTION OF METAL POWDERS
K»«
m*t*rUI
Metal
Bute
Solid
Molten
Vapor
Solid
Has
,>
Ma. ';i«in^
Be&a; mar L, .; ; ; >%.
Screening t>r-, < :,
8un p mil!.
Iliimptaic nii; ,; ' i ;s':;
l'Micc-
trulytic nit'talt)
firinding liristlc nieeaU
lll:iiii! I'lln by hoi Ul ',
Atoiui/atiun )iy ,i\f
Mant or HICHIM
(irarmUlion l.y Hlir-
ruiK
ConilciiKatiun at nor-
mal or low preasuri'
Rfduction by hydro-
KI'II or other gases
at U'liiix'rKturt'H bv-
ki* iiu'lliiix (xiiiit
Cliciuu nl |>rcri|>!tntK>ii
Kli'clrodcin wit KIII aH a
powder
("urhonyl proifsa
.-nn.-lpis lovotved
Tearing
H»ivon\ working
FraoturinK of clita-
VURI; planoH
Intercrystaliine
Spraying
(1 ruining
(Condensation
Hoduction
1'recipitalion
lCK'ct.ro)>sin
'I'hennal ilerom-
posilinn
Product
Mg
Cu and Al alloys
An, Ou, and alloys
Al, Cu, and alloys
Al, Cu, and alloy*
Ko
«'u
I'V
Hi, Sb. «tc.
Fe
Ni-Fo alloys
Al
Pb
I'll alloys
AJ
l'l> alloys
Zn, Mg
W.Mo
Ni, Co
Ft!
Fe, Cu
Pt, I'd
Bn
(Ju, Fe, etc.
Fe
Ni, N'i Fe alloys
Source: Treatise on Powder
Metallurgy, Vol. I,
Interscience Publishers,
NY, 1949
147
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-------
LIST OF REFERENCES
Development Dcc;,di£ st For Proposed Effluent Limitations Guide-
lines and New Source Performance Standards For the Steel
Making Segment '' ~'.* : an and Steel Manufacturing Point Source
Category, EPA 4-ir/i 7:,/'j24, U. S. Environmental Protection
Agency, Fobruary t -4.
Sulfuric Acid and Ferrous Sulfate Recovery From Waste Pickle
Liquor, Joseph K. Sr'ler et. al., EPA-660/2-73-032,
January 1974.
A Study of Foundry Waste Material, Carmen Santa Maria, M.S.
Thesis, University of Wisconsin, 1974.
Compilation of Air Pollutant Emission Factors, 2nd Edition,
AP-42, U. S. Environmental Pr.ot«ction Agency, 1973.
Washington Alert, Published by American Foundrymen's Society,
July 1975.
6. Minerals Yearbook 1972, Vol. I, Metals, Minerals and Fuels.
Prepared by Staff of the Bureau of Mines, U. S. Government
Printing Office, Washington, D. C. 1974.
7. Engineering And Cost Study of The Ferroalloy Industry, EPA-
450/2-74-008, March 1974.
8. Minerals Yearbook 1973, Vol. I, Metals, Minerals and Fuels.
Prepared by Staff of the Bureau of Mines, U.S. Government
Printing Office, Washington, D.C. 1975.
9. Steel Industry Economics and Federal Income Tax Policy,
American Iron and Steel Institute, June 1975.
10. EPA Policy On Subsurface Emplacement of Fluids By Well
Injection, Administrator's Decision No. 5, February 6,
1973.
y01538
SW-145c.3
149
U.S. Environmental Protection Agency
fiegion 5, Library (PL-12J)
77 West Jackson Boulevard, 12th Floor
Chicago, IL 60604-3590
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