National Inventory Of Sources And Emissions Nickel 1968


ONAL INVENTORY
      OF SOURCES
  AND EMISSIONS:
     NICKEL - 1968
^MENTAL PROTECTION AGENCY
f Air and Water Programs
Quality Planning and Standards
ngle Park, North Carolina 27711

-------

-------
                                          APTD-69



  NATIONAL  INVENTORY


                 OF


SOURCES  AND EMISSIONS:


         NICKEL -  1968



                  by

          W. E.  Davis § Associates
            9726 Sagamore Road
             Leawood,  Kansas
         Contract No. CPA-22-69-131
      EPA Project Officer:  C. V. Spangler
               Prepared for


        ENVIRONMENTAL PROTECTION AGENCY

        Office of Air and Water Programs

   Office of Air Quality Planning and Standards


              February 1970

-------
The APTD (Air Pollution Technical Data) series of reports is issued by
the Office of Air Quality Planning and Standards, Office of Air and
Water Programs, Environmental Protection Agency, to report technical
data of interest to a limited number of readers.  Copies of APTD reports
are available free of charge to Federal employees, current contractors
and grantees, and non-profit organizations - as supplies permit - from
the Air Pollution Technical Information Center, Environmental Protection
Agency, Research Triangle Park, North Carolina 27711 or may be obtained,
for a nominal cost, from the National Technical Information Service,
5285 Port Royal Road, Springfield, Virginia 22151.
This report was furnished to the Environmental Protection Agency
in fulfillment of Contract No. CPA-22-69-131.  The contents of this report
are reproduced herein as received from the contractor.  The opinions,
findings and conclusions expressed are those of the author and not
necessarily those of the Environmental Protection Agency.  The report
contains some information such as estimates of emission factors and
emission inventories which by no means are representative of a high
degree of accuracy.  References to this report should acknowledge the
fact that these values are estimates only.
                       Publication No. APTD-69
                                   11

-------
                 ACKNOWLEDGEMENTS
This was an industry oriented study and the authors express




their appreciation to the many companies and individuals in




the nickel industry for their contributions.






We wish to express our gratitude for the assistance of the




various societies and associations, and to many branches




of the Federal and State Governments.






Our express thanks to  Mr. C. V. Spangler, Project Officer,




National Air Pollution Control Administration, for his helpful




guidance.
                              v

-------

-------
                        PREFACE









This report was prepared by W. E. Davis  & Associates pursuant to




Contract No. CPA 22-69-131 with the U.  S. Public Health Service,




U.S. Department of Health, Education, and Welfare, National Air




Pollution Control Administration.






The inventory of atmospheric emissions has been prepared to




provide reliable  information regarding the  nature, magnitude, and




extent of the emissions of nickel in the United States for the year




1968.






Background information concerning the basic characteristics of




the nickel industry has been assembled and included. Process




descriptions are given, but  they are  brief, and are limited to the




areas that are closely related to existing  or potential atmospheric




losses of the pollutant.






Due to the limitation of time and funds allotted for the study,  the




plan was to  personally contact about twenty percent of the companies




in each major emissions source group to obtain the  required infor-




mation. It was known that published data concerning emissions  of




the pollutant was virtually non-existent,  and contacts with industry




ascertained that atmospheric emissions were not a matter of record.
                              111

-------
The nickel emissions and emissions factors presented are based




on information obtained from the only production company in the




United States, and from reprocessing companies that handled




about sixty percent of the nickel consumed in 1968.  The




companies visited were responsive and provided estimates of




their emissions. Nickel emissions and emissions factors are




considered to be reasonably accurate.

-------
                         CONTENTS
SUMMARY	     1

SOURCES OF NICKEL	     2

MATERIAL FLOW

       Material Flow Chart	     4
       Mining and Processing	     5
       Nickel Imports and Exports	     6
       Nickel Stocks	     6
       Reprocessing	     7
              Stainless Steel  	     7
              Alloy Steel	     8
              Nickel Alloys	     9
              Electroplating	    11
              Copper Base Alloys	    12
              Catalysts	    13
              Coinage	    13
              Batteries	    13

EMISSIONS

       Nickel Emissions	    15
       Nickel Emissions  By Source	    17
       Nickel Emissions  By States	    18
       Nickel Emissions Factors	    19
       Mining And Metallurgical Processing	    20
       Reprocessing	    22
              Stainless & Heat Resisting Steels ....    23
              Alloy Steel	    23
              Nickel Alloys	    26
              Cast Iron	    26
              Copper Base Alloys	    26
              Electrical  Resistance Alloys	    26
              Electroplating	    27
              Batteries	    28
              Catalysts	    28
              Nickel Plated Scrap	    29
                           VI1

-------
              CONTENTS
Consumptive Uses	   31
       Oil	   31
       Gasoline	   33
       Coal	   33
                  Vlll

-------
                          -1-
                       SUMMARY









The flow of nickel in the United States has been traced and charted




for the year 1968. Consumption for the year was reported to be




159,306 tons and domestic production to be 29,215 tons including




the production from both primary and secondary sources.  Imports,




mostly from Canada, totaled 147,950 short tons.







Emissions to the atmosphere during the year were  6,475 short




tons. About  83 percent of the  emissions were due to the  burning




of heavy fuel oil and coal.







Estimates of  emissions for mining, metallurgical processing,  and




reprocessing operations are based on data obtained by personal




contact with  processing and reprocessing companies, and are con-




sidered to be reasonably accurate.  Further effort  is recommended




to confirm the accuracy of the  emissions from the  burning of




residual fuel oil and coal.

-------
                          -2-
                 SOURCES OF NICKEL









Nickel is a light gray, tough, ductile and partially magnetic metal




that belongs to the  iron-cobalt family.  It melts at 1452 C and has




an atomic weight of 58.69.  Next to chromium, it is considered the




most important steel alloying metal.







Nickel is widely distributed over the face of the  earth, but there




are relatively  few workable deposits.  It occurs in the earth's crust




at about 0.016 percent, and in the world's reserves the concentration




in the ore ranges from 0.4 to 5.0 percent.







Nickel deposits fall into three  general classifications - nickel -




copper sulfides, nickel silicates, and nickel laterites.  About half




of the world's production  at present is from large Canadian deposits




of the sulfides of nickel,  copper and iron;  chiefly pentalandite,




chalcopyrite,  and pyrrhotite.  These ores also contain varying




quantities of cobalt,  gold, silver,  selenium, tellurium, and plati-




num group metals.







The largest known deposits of nickel silicate ores are in New




Caledonia, but there  are commercially significant deposits in South




America, Indonesia and the United  States.  Ore in the United States




contains about 1.2  percent nickel.

-------
                          -3-
There is only one operating nickel mine in the United States which




is located near Riddle, Oregon.

-------
o
hJ
u. J
W

<*
HH O
oo
vO
I

O
PJ
W
H
o
H
'O

STAINLESS
STEEL
ALLOY

OO /
U u
S 'S
o *-
Q

{

ELECTRO-

ro
•^
m
N

O
z
ETAL REFINI:
*7 ^. 1 *7
S

W
M
H
O

PLATING

H
D
••

P4
W
CO
0
t

t
(
(
\

*
vO
o

in
»— t

Vt STOCKS
147950
O
p

O
tf
I— 1
H
O

M
M
•O
0

•—t
00
to o
0 m
PH
HH

1
1
1
1
i 1 4 i
!
CO ^ I
«£ 3£ * i
* 0 gO W |
M J H J £ 1
*3 X3 g
& <; w •< u I
0 M I
u w
i
I
\O CO ^O
cr> oo o 1
Tj* CO 00
1
1
1
1

1
1
OJ
U i
W '
VO I
5 i
i
i
>« s
j 5 2 '
>-i
-------
-5-
MINING AND PROCESSING

Nickel produced in the United States during 1968 was about 18 per-

cent of the nickel consumed and half of the production was from

secondary sources derived from reprocessing nickel-base, copper-

base, and aluminum-base scrap.

Domestic primary production was from domestic nickel ore and as

a by-product of other metal refining. All domestic ore was mined

at one location near Riddle, Oregon.

NICKEL PRODUCTION IN UNITED STATES I/

1968

Nickel Produced Short Tons

Domestic Ore 13,124

By Product 2,030

Secondary 14,061

1- Bureau of Mines Minerals Yearbook - 1968
-------
-6-
NICKEL IMPORTS AND EXPORTS

During 1968 nickel imports totaled 165,986 tons gross weight

(147,950 short tons - nickel content) , consisting chiefly of un-

wrought metal, slurry, ferronickel, oxide, and oxide sinter.

About 90 percent of the unwrought metal was imported from

Canada, and 9 percent from Norway. The imported slurry was

about 91 percent from Canada and 9 percent from the Republic of

South Africa. Ferronickel was 83 percent from New Caledonia.

Oxide and oxide sinter was 99.9 percent from Canada. _/

Exports of nickel and nickel alloy products during 1968 were

33,681 short tons, including 16,762 tons waste and scrap,

2
6,498 tons unwrought metal and 3,340 tons in catalysts. __/

The balance of the exports were plates, sheets, strip, bars,

rods, shapes, anodes, wire, powder, foil, tubes, etc.

NICKEL STOCKS

Industry stocks at the beginning of 1968 were 31,007 short tons,

and at the end of the year the total was 26,534 short tons. Dur-

ing the same period Government nickel stocks decreased 3,144

short tons due to deliveries made on contracts that existed prior

1-2- Bureau of Mines Minerals Yearbook - 1968
-------
-7-
to 1968. _/ During 1968, 7,617 short tons of nickel from stocks

went to reprocessing.
REPROCESSING
The apparent consumption of nickel in the United States during 1968

2
has been reported at 159,306 short tons. _/
STAINLESS STEEL

For many years the largest use of nickel in the United States has

been in stainless steel; about 28 percent of the total use during

1968 was for this purpose. Stainless steel is used in many industries

because of its corrosion resistance, attractive appearance, and it

does not require periodic repainting. The commercial and industrial

applications for stainless steel are numerous; including, components

for automobiles, aircraft, textile equipment, food processing equip-

ment, chemical industry equipment, general industrial equipment,

pulp and paper equipment, metal working equipment, electrical

machinery, appliances, and other equally important items.

The construction industry is the largest single market for stainless

at present, and it appears likely that this market will continue to

expand rapidly.
1-2- Bureau of Mines Minerals Yearbook - 1968
-------
-8-
In the United States the use of nickel in stainless steel during

1968 was 44, 858 short tons._/
ALLOY STEEL

Nickel is used in steel to help make it tough. It is used in auto-

mobiles, trucks, heavy construction equipment, agriculture equip-

ment, mining equipment, etc. - principally in gears and engine

parts. The steel for these applications generally contains 0.40

to 4.25 percent nickel, and as speeds increase or the size of

equipment becomes larger, the nickel content will likely be in-

creased. In aircraft, aerospace, and hydrospace applications,

the alloy steel contains up to 18 percent nickel. In submarine

hulls there is a considerable usage of HY-80 armor plate steel

(2.75 Ni).

Electric generating equipment is another important application

from the standpoint of tonnage. Steels containing 2 to 4 percent

nickel are used currently, but the trend is toward larger turbines

and generators which will require richer nickel-bearing steels.

In the United States during 1968, the consumption of nickel in

alloy steel, other than stainless steel, was 22,692 short tons or

about 14 percent of the nickel used during the year.
1- Bureau of Mines Minerals Yearbook - 1968
-------
-9-
NICKEL ALLOYS

For many years, the second largest use of nickel in the United States

has been in nickel alloys; including, sand and investment castings,

monel alloy, nickel-silvers, electrical alloys, and electrical resis-

tance alloys.

Castings containing nickel are the heat resistant castings used chiefly

in the petroleum, chemical and automotive industries; the corrosion

resistant castings used in the petroleum and chemical industries; the

alloy steel castings for agriculture, mining and construction equip-

ment; gray iron castings used in the automotive industry; ductile iron

castings for agricultural and metal working equipment; cast brasses

and bronzes for marine and process industry equipment.

Monel alloys contain more than 50 percent nickel, and one of the

largest fields of application for these alloys is chemical processing

equipment handling fluorides. Other applications are for equipment

used in steam power plants, and in the salt and potash industries.

The nickel content in the family of copper-nickel-zinc alloys (known

as the nickel-silvers) likely averages about 15 percent. Applications

for these alloys include thousands of small items; such as zipper

fasteners, cigarette lighters, silver-plated flatware, contact springs,

electron tube pins, etc.
-------
-10-
Electrical alloys are used in electron tubes and cathode ray tubes

as glass-to-metal sealing alloys.

Electrical resistance alloys are used for resistance heating appli-

cations, thermostats, thermocouples, and thermopiles.

During the past ten years 23 percent of the nickel used in the United

States was in nickel alloys, and in 1968 the consumption for that

prupose was 42,085 short tons or about 26 percent. _/
1- Bureau of Mines Minerals Yearbook - 1968
-------
-11-
ELE CIRCULATING

In this report on nickel the term electroplating is used to cover all

types of plating operations; including, electroplating, chemical

plating, electroforming, nickel cladding, sprayed coatings, and

vapor deposited coatings.

Nickel plating is used extensively in the United States for plating

automobile parts and consumer products; such as, appliances,

furniture, utensils, etc. About 50 percent of the nickel consumed

in plating is for automotive use, and 25 percent for consumer pro-

ducts. It is used principally for decorative applications; however,

corrosion protection, wear, and impact resistance are important

considerations that are also taken into account by those specifying

materials and finishes.

During the past ten years, 14 percent of the nickel used in the

United States was for plating. In 1968 the consumption for that

purpose was 25,433 short tons or about 16 percent of the nickel

used that year. _/
1- Bureau of Mines Minerals Yearbook - 1968
-------
-12-
COPPER-BASE ALLOYS

Alloys containing less nickel than copper are referred to as cup-

ronickels. The high copper types containing 90 percent copper/10

percent nickel and 70 percent copper/30 percent nickel are widely

used for components of condensers, heat exchangers, and other

heat transfer equipment in power plants, and applications where

the media are water and steam. These alloys are resistant to

general corrosion; have good anti-fouling characteristics; retain

useful strength at temperatures up to about 700 F; are easily formed

and welded; and are reasonable in cost.

Another type of cupronickel alloy containing about 45 percent nickel

also has an established reputation. The principal applications are

thermocouples, thermopiles, and resistors. For these uses the

alloy is usually produced in the form of wire, flattened wire, and

ribbon.

In the United States, nickel used for copper-base alloys during 1968

was 4,963 short tons. _/
1- Bureau of Mines Minerals Yearbook - 1968
-------
-13-
OTHER

Catalysts

Nickel catalysts are used in essential industries producing hydro-

genated vegetable oils, hydrogen, ammonia, petrochemicals, syn-

thetic fibers, plastisols, and also in general hydrotreating processes

in the refining industry.

Coinage

The use of nickel in coinage in the United States jumped dramatically

in 1965 when cupronickel cladded coins were introduced for dimes

and quarters. During 1968, the use for this purpose was about 1000

short tons.

Batteries

The nickel-cadmium battery has come into use in the United States

since World War II, and has been used for diesel locomotives, buses

and other heavy machinery, as well as for rechargeable flashlights,

electric shavers, etc. It is also used for numerous military and space

applications. The advantages include - long life, simple maintenance,

maximum current delivery with minimum voltage drop, quick charging,

and the ability to operate effectively over a wide temperature range,

but its price is considerably higher than for a comparable lead-acid

battery.
-------
-14-
In 1968, nickel used in batteries is estimated to be 600 short tons

based on information received from manufacturers.
-------
-15-

EMISSIONS

NICKEL EMISSIONS

Several statements in this report indicate that the companies visited

during this study were responsive and provided estimates of nickel

emissions even though there were no emissions records available.

In one instance the estimate was based on test data but in all other

cases the determination of nickel emissions was the result of materi-

al balance studies.

Some information was obtained regarding the chemical nature of

emissions. At one processing location the emissions were referred

to as fine ore and at another they were described as nickel oxide.

All of the reprocessing companies indicated their nickel emissions

were in the oxide form.

Information was obtained concerning the chemical nature of emissions

due to the use of nickel in gasoline. Industry reports that extensive

studies have shown the combustion of the hydrocarbon soluble nickel

compounds used as additives in gasoline results in the formation of

inert inorganic nickel salts; such as the oxides and sulfates. No

further reactions of these salts after emission were detected. The

only company known to use nickel in gasoline has stated they will

phase out the use of nickel in their products by early 1970.

No data was available regarding the chemical nature of emissions
-------
-16-
resuiting from the burning of residual oil.

Even though industry furnished no data regarding the particle size

of nickel emissions, there is information available stating that when

burning residual oil, eighty five percent of the particulates are less

than one micron. _/ It is also reported that the particle size of metal
2
fume is 0.1 to 1 micron. _/ Based on this information it is assumed

that particle size of nickel oxide emissions is 0.1 to 1 microns.
1 - Allen, G. L.; F. H. Viets; and L. C. McCabe - 1952
Control of Metallurgical and Mineral Dusts and Fumes
in Los Angeles County, California. Bureau of Mines
Information Circular 7627.

2 - Danielson, John A.; Editor: Air Pollution Engineering
Manual; U.S. Dept. of Health, Education, and Welfare;
Public Health Service: 1967.
-------
-17-
NICKEL EMISSIONS BY SOURCE - 1968
SOURCE CATEGORY
SOURCE GROUP
SHORT TONS
MINING AND
METALLURGICAL PROCESSING

REPROCESSING

CONSUMPTIVE USES

Mining & Smelting

Stainless Steel
Alloy Steel
Nickel Alloys
Cast Iron
Copper Base Alloys
Electrical Alloys
Other

Oil
Gasoline
Coal
TOTAL

248

442
147
53
79
6
5
102

4970
25
100

248

834

5095

6177
Nickel emissions during processing and use are based on particulate control
indicated as follows:

Mining and Smelting - Wet scrubbers, bag filters, and electrostatic precipitators,

Stainless Steel - Fifty percent of plants controlled with bag filters.

Alloy Steel - Fifty percent of plants controlled with bag filters.

Nickel Alloys - All plants controlled with bag filters.

Cast Iron - Uncontrolled.

Copper Base Alloys - All plants controlled with bag filters.

Electrical Alloys - All plants controlled with bag filters.

Oil Burning - Uncontrolled.

Gasoline - Uncontrolled.

Coal Burning - Seventy five percent particulate control.
-------
-18-
NICKEL EMISSIONS BY STATES
(Short Tons)
1968
State
New York
Pennsylvania
Massachusetts
New Jersey
California
Florida
Connecticut
Illinois
Ohio
Indiana
Maryland
Virginia
All Other States
Undistributed
Reprocessing
46
275
0
0
0
0
18
29
86
33
29
0
80

Consumptive Uses
1005
370
573
539
444
332
242
214
54
101
84
105
1032

Total
1051
645
573
539
444
332
260
243
140
134
113
105
1112
486
TOTAL
6177
-------
-19-
NICKEL EMISSIONS FACTORS
MINING AND PROCESSING C

REPROCESSING

Stainless Steel C

Alloy Steel C

Nickel Alloys C

Cast Iron NC

Copper Base Alloys C

Electrical Alloys C

Production of Iron and Steel C

CONSUMPTIVE USES

Burning Residual Oil NC

Burning Coal C
17 Ib/ton of nickel processed
10 Ib/ton of nickel charged

10 Ib/ton of nickel charged

2 Ib/ton of nickel charged

20 Ib/ton of nickel charged

2 Ib/ton of nickel charged

0.0015 Ib/ton of iron & steel
0.017 Ib/bbl of oil

0.0026 Ib/ton of coal
C - Controlled

NC - Not Controlled
-------
-20-
MINING

and

METALLURGICAL PROCESSING

The entire domestic production of nickel ore is from a single open-

pit mine located in Douglas County, Oregon. The ore containing

about 1.4 percent nickel is dug from the mountain, largely without

blasting, and trammed down about two thousand feet to the smelter.

It is then melted in electric furnaces, and poured into reaction ladles

where reduction is accomplished by adding crushed ferrosilicon to

the molten ferronickel.

The ore is dug from 40 foot minimum width benches, spaced at 20

foot vertical intervals, and moved to screens where it is classified

before it is sent to the tramway surge pile. Efforts to blend the ore

into a uniform feed to the melting furnaces begin at the mine and

continue throughout all the subsequent operations.

During 1968, the domestic production of nickel ore was 1,217,906

dry short tons which contained 17,294 tons of nickel. Production

at the smelter was 25,835 tons of ferronickel, containing 13,124

tons of nickel. _/

Secondary Nickel Alloy Smelters are also an important factor in the
1- Bureau of Mines Minerals Yearbook - 1968
-------
-21-
industry. They utilize scrap and prepare a nickel base alloy specifi-

cation metal with residual elements held to stipulated limits. This

product is sold principally to alloy steel mills for use as a nickel

alloying addition to their production heats.

The secondary smelters also produce a nickel alloy or shot product

produced to exact specification for foundry use.

During 1968, the nickel emissions to the atmosphere from sources

of mining and metallurgical processing are estimated at 248 short

tons, based on an emissions factor of 17 pounds per ton of nickel

produced.
-------
-22-
REPROCESSING

The principal use of nickel is as an alloying element. When alloyed

with other metals, nickel imparts strength, toughness, hardness,

and ductility together with resistance to oxidation and corrosion. It

is used extensively in the production of ferroalloys, and the largest

single application is in the manufacture of stainless steels.

In the melting and alloying of stainless and heat resisting steels,

other steel alloys, nickel alloys, copper-base alloys, electrical

resistance alloys, and cast iron, nickel is lost to the atmosphere

in the form of nickel oxide or as a complex oxide combined with

other alloying elements; therefore, from the standpoint of atmos-

pheric emissions, it is important to determine the total amount of

nickel that is melted during alloying.

In the manufacture of alloy steels a considerable amount of alloy

steel scrap is used in the melt along with primary materials.

Published data does not show amount of nickel contained in this

scrap. Information is available showing the amount of stainless

and heat resisting steels produced, and the percentage of nickel

contained therein.
-------
-23-
STAINLESS & HEAT RESISTING STEELS

The production of stainless and heat resisting steels is reported

annually by the American Iron and Steel Institute according to type

number, and for 1968 the reported data is summarized as follows:
Type Number
200 Series
300 Series
400
& Series
500
Production Nickel Content
(short tons) {percent) (short tonsl
38,290 4.50 1,725
932,138 9.30 86,500
459,508 negligible
Total 88,225
During 1968 nickel emissions to the atmosphere resulting from the

production of stainless and heat resisting steels are estimated at

442 short tons based on an emissions factor of 10 pounds per ton

of nickel charged to the melt. The emissions factor used is the

average of the factors estimated by the manufacturers contacted

during the study.

ALLOY STEEL

In order to estimate the amount of nickel in the alloy steel pro-

duced during 1968, published data for 1967 has been used. Alloy

steel production during 1967 (other than stainless) is reported by
-------
-24-
the American Iron and Steel Institute according to category as

follows:

CATEGORY SHORT TONS

Nickel 34,452

Nickel-Chromium 90,997

Nickel-Moly 383,132

Ni-Chrome-Mo ly-Van 159,330

Ni-Chrome-Moly 1,420,588

Other Alloy not containing nickel
or silicon 9,251,177
Total 11,339,676

Primary nickel consumed in alloy steel in 1967 was 23,661 short

tons; _/ an average nickel content of 1.13 percent. Scrap con-

sumed in alloy steel in 1967 was 3,005,000 short tons. _/ Since

nickel alloy steels are about 18.5 percent of all alloy steel, then

alloy scrap should average about 18.5 percent nickel alloy. On

this basis 558,000 short tons of nickel alloy scrap (1.13 percent

nickel content) would contain 6300 short tons of nickel. Assuming

the same use during 1968, the 6300 short tons of nickel in scrap

added to the 22,692 short tons of primary nickel used in 1968

would result in a total of 28,992 short tons of nickel in the alloy
1-2- Bureau of Mines Minerals Yearbook - 1967.
-------
-25-
steel melt during 1968.

Nickel emissions to the atmosphere resulting from the production

of alloy steels are estimated for 1968 on the basis of an emissions

factor of 10 pounds per ton of nickel charged to the melt. Total

emissions for alloy steels are estimated at 147 short tons.
-------
-26-
NICKEL ALLOYS - CAST IRON

COPPER BASE ALLOYS - ELECTRICAL ALLOYS

Accurate information concerning the total tonnage of scrap used in

nickel alloys, cast iron, copper-base alloys and electrical re-

sistance alloys is not available; therefore it is assumed that 25

percent scrap is added to the melt.

Emissions factors and emissions for 1968 are listed as follows:
Emissions Factor Emissions
Ibs/ton of nickel (short tons)
charged
Nickel Alloys 2 53

Cast Iron 20 79

Copper-Base Alloys 2 6

Electrical Resistance Alloys 2 5
-------
-27-
ELECTROPLATING

The process of electroplating with nickel consists of setting up

the article to be coated as the cathode in an electrolytic bath.

The electrolyte is a solution of the metal to be deposited and

the anode is metallic nickel. When an electric current is pass-

ed through the electrolyte, ions from the electrolyte are deposited

at the cathode, and an equivalent amount of nickel is disolved at

the anode.

From the standpoint of emissions to the atmosphere, most of the

electroplating processes are of little interest because the emissions

are of negligible volume. Generally, air pollution control equip-

ment is not required for any of the processes except for chrome

plating.

The people in the plating industry that were contacted during this

study reported that their emissions to the atmosphere are negligible.
-------
-28-
OTHER

Batteries

In the process of producing nickel-cadmium batteries of the sintered-

plate type, more nickel is used than cadmium. The grids of both

positive and negative plates consist of sintered carbonyl nickel powder

and the active material of the positive plate, when charged, is nickel

oxide.

Each plate of the core assembly has as its foundation a screen of

nickel-wire mesh which is converted into a sheet as nickel powder

is deposited in its meshes by a sintering process. It is the active

material electrochemically deposited within the pores of the sheets

that distinguishes between positive and negative plates.

Battery manufacturers contacted during this study report nickel emis-

sions to the atmosphere at an average of 8 pounds per ton of nickel

processed.

Nickel emissions to the atmosphere during 1968 are estimated at

2.4 tons.

Catalysts

Manufacturers of catalysts contacted during this study stated that

their atmospheric emissions of nickel are negligible.
-------
-29-
Nickel Plated Scrap

Steel production during the past ten years has varied from about

93 million tons in 1959 to 131 million tons in 1968; an average of

115 million tons per year. During the same period, nickel used

in plating has varied from about 16 thousand tons in 1959 to

25 thousand tons in 1968; an average of 20 thousand tons per

year. (Table I)

Based on the assumption that 75 percent of the nickel plating was

on iron and steel, the ratio of nickel to steel in scrap steel is

about 0.26 pounds of nickel per ton of steel.

The 38.5 million tons of steel scrap purchased by the steel industry

in 19681/ is estimated to contain 5000 tons of nickel.

Nickel emissions to the atmosphere during the making of steel

(other than alloy steel) are estimated at 100 tons or 0.0015 pounds

of nickel per ton of steel produced.
1 - Metal Statistics 1969; American Metal Market Company,
New York, New York.
-------
-30-
TABLE
NICKEL USED IN PLATING - STEEL PRODUCTION
(Short tons - Thousands)
YEAR NICKEL USED STEEL
IN PLATING PRODUCTION
1959
1960
1961
1962
1963
1964
1965
1966
1967
1968

16
17
17
19
20
21
21
16
28
25
200
93,446
99,282
98,014
98,328
109,261
127,076
131,462
134,070
126,920
131,098
1,148,957
Metal Statistics - 1969; The American Metal Market Co.;
New York, New York
-------
-31-
CONSUMPTIVE USES

Alloys that contain nickel are used in many instances because they

are corrosion resistant. This is the principal reason that they are

used extensively in the pulp and paper, petroleum, and chemical

industries. In order to increase the useful life of the equipment

and reduce maintenance costs, they are used for piping and equip-

ment that is in contact with corrosive liquids. Nickel losses do

occur during use, but mostly they are of such a nature that they

would not result in emissions to the atmosphere.

There are other instances where nickel alloys are used because

they are heat resistant. One such application is in jet engines,

and in this case, the losses that occur undoubtably become atmos-

pheric emissions; however, these losses are considered negligible.

Oil

Many crude oils contain trace amounts of a number of metals, _/

including nickel, which is present in higher concentrations than

many other metals. The concentrations of nickel can range from

nearly zero to over 100 ppm (Tables II & III). The higher concen-

trations of nickel often are detected in asphaltic crude oils.
1 - Ball, J. S., W. J Wenger, C. A. Horr, and A. T. Myers.
Metal Content of Twenty-Four Petroleums; J. Chem. & Eng.
Data; v. 5; No. 4; Oct. 1960.
-------
-32-
Even though nickel is found in most crude oil, it is generally agreed

that there is no nickel in motor fuel unless it is intentionally used

as an additive. Refineries report that during the refining process,

the nickel in the crude remains with the heavy ends; in road oil,

asphalt and heavy fuels.

In the United States the demand for petroleum products, during 1968,

was 4,901,789,000 bbls.; including - residual fuel oil at 668,239,000

bbls., asphalt at 141,151,000 bbls., road oil at 7,080,000 bbls.

(Table IV) Using the nickel content of the crude as 10 ppm average,

the crude contained approximately 7,350 tons of nickel. After refining,

about 95 percent of the nickel remained in the residual fuel oil, the

asphalt, and the road oil. The residual fuel oil then contained 5,710

tons of nickel.

The residual fuel oil used in the United States during 1968, exclusive

of use in vessels, was 581.9 million bbls. This oil, containing about

4,970 tons of nickel, was used by industrials, electric-utility compa-

nies, railroads, oil companies, the military, as well as for heating.

(Table V)
Based on negligible paniculate control_/, emissions to the atmos-

phere during 1968 are estimated at 4,970 tons of nickel.
1 - Control Techniques for Particulate Air Pollutants; NAPCA Pub.
No. AP - 51; U.S. Dept. of Health, Education and Welfare.
-------
-33-
Gasoline

It has been suggested that the use of nickel in gasoline may explain

the presence of nickel in the soil at sites near dense traffic. _/

During this study, all the major oil companies were contacted regard-

ing their use of nickel, and all but one have reported no nickel was

used during 1968.

Coal

A study has been made regarding emissions from coal fired power

plants and emissions of nickel paniculate have been recorded.

Nickel concentrations found in fly ash samples, taken after fly ash
o
collection, ranged from 0.58 to 3.0 grains per scf x 10" . _/

Based on 300,000,000 tons of coal consumed by power plants in
o
1968, 75 percent particulate control _/, nickel concentration of

0.58 grains per scf x 10~4, and 160 scf per pound of coal, the nickel

emissions were 100 tons.
1 - Lagerwerff, J. V. and A. W. Specht; Contamination of Roadside
Soil and Vegetation with Cadmium, Nickel, Lead and Zinc: U.S.
Soils Laboratory, Beltsville, Md.

2 - Cuffe, Stanley T. & Gerstle, Richard W.; Emissions from Coal
Fired Power Plants; A Comprehensive Summary; Public Health
Service Publication No. 999-AP-35.

3 - Control Techniques for Particulate Air Pollutants; NAPCA Pub.
No. AP-51; U.S. Dept. of Health, Education, and Welfare.
-------
-34-
TABLE II

NICKEL CONTENT OF DOMESTIC CRUDE OILS

CRUDE NICKEL CONTENT - ppm

West Texas Sour 4.3

West Texas Intermediate 1.4

Texas-Oklahoma Panhandle 3.0

East Texas 1.7

Louisiana Ostrica 2.1

West Kansas 6. 3

Wyoming Sweet 2. 7

Wyoming Sour 6.1

California L. A. Basin 64.0

California S.J.V. Blend 53.0

Alaska North Slope 11.3
-------
-35-
TABLE III
NICKEL CONTENT OF IMPORTED CRUDE OILS
CRUDE NICKEL CONTENT - ppm
Cabinda 11.6
Gamba 1.0
Hassi Messaoud 0.3
Serir 4. 0
El Alamein 4.8
El Morgan 28.0
Kirkuk 11.0
Basrah Zubair 3.1
Souedie 22.2
Agha Jari 10.1
Gach Saran 29.5
Arabian Export 3. 2
Kuwait Export 6.0
Safaniya Khafji 11.0
Murban 0.8
Zakum 0.3
Minas 2.3
Seria 0.5
Orito 12.9
Tigre 10.0
Tia Juana 28. 0
Britamoil 7.7
Inter Provincial PL Mix 1. 8
Saskatchewan 28.9
-------
-36-
TABLE IV

SUPPLY AND DEMAND OF ALL OILS IN THE UNITED STATES

Supply Thousands of Barrels

Domestic Production 3,879,353

Imports 1.042.746
Total New Supply -- 4,922,099

Domestic Demand

Gasoline 1,956,000

Jet Fuel 349,378

Ethane 55,152

Liquefied Gases 330,589

Kerosine 102,934

Distillate Fuel Oil 874,539

Residual Fuel Oil 668 , 239

Petrochemical Feedstocks 92,936

Special Napthas 27,007

Lubricants 48,467

Wax 4,360

Coke 76,319

Asphalt 141,151

Road Oil 7,080

Still Gas 149,796

Miscellaneous Products 17, 842
Total Demand 4,901,789

Mineral Industry Surveys; U.S. Department of Interior; Bureau of Mines;
Crude petroleum, petroleum products and Natural gas liquids - 1968
-------
-37-
TABLE V

SHIPMENTS OF RESIDUAL FUEL OIL IN THE UNITED STATES - 1968
USE

Heating

Industrial

Electric Utilities

Military & Other

STATE

New York

Massachusetts

New Jersey

California

Pennsylvania

Florida

Connecticut

Illinois

Virginia

Indiana

Washington

OTHER STATES
Pacific-Mountain

North Central

Southern

Northeast
MILLION BARRELS

174.3

175.0

185.0

47.6
581.9

116.4

67.8

62.6

51.8

42.4

38.6

28.1

24.1

12.0

11.4

10.0

25.5

23.6

48.3

19.3

581.9
Mineral Industry Surveys; Shipments of Fuel Oil & Kerosine in 1968;
U.S. Dept. of Interior, U.S. Bureau of Mines, Sept. 17, 1969.
U. S. GOVERNMENT PRINTING OFFICE: 1973 746771/4183
-------
-------
BIBLIOGRAPHIC DATA
SHEET
1. Report No.
APTD-69
3. Recipient's Accession No.
PB 192-251
4. Title and Subtitle
National Inventory of Sources and Emissions: Nickel - 1968
5. Report Date
6.
7. Author(s)
. E. Davis
8- Performing Organization Kept.
No.
9. Performing Organization Name and Address
W. E. Davis § Associates
9726 Sagamore Road
Leawood, Kansas
10. Project/Task/Work Unit No.
11. Contract/Grant No.

CPA 22-69-131
12. Sponsoring Organization Name and Address
Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, N.C. 27711
13. Type of Report & Period
Covered Final
1968
14.
15. Supplementary Notes
16. Abstracts
The inventory of atmospheric emissions has been prepared to provide reliable informatior
regarding the nature, magnitude, and extent of the emissions of nickel in the United
States for the year 1968. Background information concerning the basic characteristics
of the nickel industry has been assembled and included. Process descriptions are given,
but they are brief, and are limited to the areas that are closely related to existing
or potential atmospheric losses of the pollutnat. The nickel emissions and emissions
factors presented are based on information obtained from the only production company in
the United States, and from reprocessing companies that handled about sixty percent of
the nickel consumed in 1968. The companies visited were responsive and provided esti-
mates of their emissions. Nickel emissions and emissions factors are considered to be
reasonably accurate.
17. Key Words and Document Analysis. 17a. Descriptors

Inventory
Atmospheric emissions
Emissions
Nickel
Nickel industry
Pollutant
Nickel emissions
Nickel emission factors
17b. Identifiers/Open-Ended Terms
17c. COSATI Field/Group
13B
18. Availability Statement

Unlimited
FORM NTIS-35 (REV. 3-72)
19. Security Class (This
Report)
UNCLASSIFIED
20. Security Class (This
Page
UNCLASSIFIED
21. No. of •Pages

44
22.rf
USCOMM-DC 140S2-P72
-------
INSTRUCTIONS FOR COMPLETING FORM NTIS-35 (10-70) (Bibliographic Data Sheet based on COSATI
Guidelines to Format Standards for Scientific and Technical Reports Prepared by or for the Federal Government,
PB-180 600).

1. Report Number. Each individually bound report shall carry a unique alphanumeric designation selected by the performing
organization or provided by the sponsoring organization. Use uppercase letters and Arabic numerals only. Examples
FASEB-NS-87 and FAA-RD-68-09.

2. Leave blank.

3. Recipient's Accession Number. Reserved for use by each report recipient.

4- Title ond Subtitle. Title should indicate clearly and briefly the subject coverage of the report, and be displayed promi-
nently. Set subtitle, if used, in smaller type or otherwise subordinate it to main title. When a report is prepared in more
than one volume, repeat the primary title, add volume number and include subtitle for the specific volume.

5- Report Date. Each report shall carry a date indicating at least month and year. Indicate the basis on which it was selected
(e.g., date of issue, date of approval, date of preparation.

6. Performing Organization Code. Leave blank.

7. Authors). Give name(s) in conventional order (e.g., John R. Doe, or J.Robert Doe). List author's affiliation if it differs
from the performing organization.

8. Performing Organization Report Number. Insert if performing organization wishes to assign this number.

9. Performing Organization Name and Address. Give name, street, city, state, and zip code. List no more than two levels of
an organizational hierarchy. Display the name of the organization exactly as it should appear in Government indexes such
as USGRDR-I.

10. Project/Task/Work Unit Number. Use the project, task and work unit numbers under which the report was prepared.

11. Contract/Grant Number. Insert contract or grant number under which report was prepared.

12. Sponsoring Agency Name and Address. Include zip code.

13- Type of Report and Period Covered. Indicate interim, final, etc., and, if applicable, dates covered.

14* Sponsoring Agency Code. Leave blank.

15. Supplementary Notes. Enter information not included elsewhere but useful, such as: Prepared in cooperation with . . .
Translation of ... Presented at conference of ... To be published in ... Supersedes . . . Supplements .

16. Abstract. Include a brief (200 words or less) factual summary of the most significant information contained in the report.
If the report contains a significant bibliography or literature survey, mention it here.

17. Key Words and Document Analysis, (a). Descriptors. Select from the Thesaurus of Engineering and Scientific Terms the
proper authorized terms that identify the major concept of the research and are sufficiently specific and precise to be used
as index entries for cataloging.
(b). Identifiers and Open-Ended Terms. Use identifiers for project names, code names, equipment designators, etc. Use
open-ended terms written in descriptor form for those subjects for which no descriptor exists.
(c). COSATI Field/Group. Field and Group assignments are to be taken from the 1965 COSATI Subject Category List.
Since the majority of documents are multidisciplinary in nature, the primary Field/Group assignment(s) will be the specific
discipline, area of human endeavor, or type of physical object. The application(s) will be cross-referenced with secondary
Field/Group assignments that will follow the primary posting(s).

18. Distribution Statement. Denote releasability to the public or limitation fot reasons other than security for example "Re-
lease unlimited". Cite any availability to the public, with address and price.

19 & 20. Security Classification. Do not submit classified reports to the National Technical

21. Number of Pages. Insert the total number of pages, including this one and unnumbered pages, but excluding distribution
list, if any.

22. Price. Insert the price set by the National Technical Information Service or the Government Printing Off ice, if known.

FORM NT1S-35 (REV. 3-721 USCOMM-DC I4852-P7
-------
-------
o

4
- r
ui o
Q
cc
Ul
0
4
Z
O

U
UJ
0
cc
a.
_j
K
UJ
t
c
CO
£

tf>
§
a
u

I
a
«

§
••
n
(A
C
i
•o
?
e
u
p:
fj
u

Z
I

o
!
CD
K
(0
tn
UJ
Z
c/)
3
GO

_1
<
U
u_
o
0
CL
LU

>-
K
Z
D
rf
o
CL.
Q_
O
_J

• g-
C. . U) m
„
>- ra — a.
'en a) £
c c
CO O)
_
2.0 «—
-~

-------