United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park, NC 27711
Research and Development
EPA/600/S2-90/044 Jan. 1991
x>EPA Project Summary
Emission Factors for Iron
Foundries: Criteria and Toxic
Pollutants
Gerhard Gschwandtner and Susan Fairchild
This report lists criteria and toxic
pollutant emission factors for
sources commonly found in iron
foundries. Emission factors are
identified for process source and
process fugitive emissions. The
emission factors, representing
uncontrolled emissions, may be used
to estimate emissions when site-
specific information and data are not
available.
This Project Summary was
developed by EPA's Air and Energy
Engineering Research Laboratory,
Research Triangle Park, NC, to
announce key findings of the research
project that is fully documented in a
separate report of the same title (see
Project Report ordering information at
back).
Introduction
Iron foundries have been identified in
certain areas of the U.S. to be potentially
significant sources of air pollution. The
Control Technology Center of the U.S.
Environmental Protection Agency, in
response to a request for air toxic
emission factors by the Hamilton County
Air Pollution Control Bureau of
Chattanooga, Tennessee, commissioned
this report. The report is a compilation of
current emission factor information that
may be used by state and local agencies
in estimating emissions from iron
foundries This report is a follow-on to a
previous report {EPA/600/2-90/024; NTIS
PB-90 242 314) on emission factors for
iron and steel manufacturing facilities.
The objective of this study was to
provide a comprehensive set of emission
factors for sources of both criteria and
toxic air pollutants in gray and ductile iron
foundries. Emission factors are identified
for process sources, process fugitive and
open source fugitive emissions. The
emission factors are not specific to any
one facility.
For several years, attention has
focused mostly on emissions of criteria
pollutants. These pollutants include
particulate matter, sulfur dioxide (SO2),
carbon dioxide (CO2), nitrogen oxide
(NOX), volatile organfc compounds
(VOCs), and lead (Pb) . More recently,
attention has focused on toxic air
pollutants. These pollutants include many
different organic and inorganic
compounds. This report summarizes the
information available for both criteria and
toxic pollutants. It is a guide for
estimating the emissions when emission
measurements are not available.
This study involved a literature search
of the libraries of the U.S. EPA and the
American Foundrymen's Society. Articles
were reviewed for information that could
be used to develop emission factors for
processes associated with iron foundries.
The emission factors are presented in
terms of an average value or range of
values together with a rating of quality or
reliability.
The emission factors developed for the
National Acid Precipitation Assessment
Program (NAPAP) emission inventory
normally represent uncontrolled
emissions. For PM10 emission factors,
consult Compilation of Air Pollutant
Emission Factors, AP-42, Supplement B,
Volume I, Fourth Edition (NTIS PB-89
128 631), since the particulate emission
factors developed as part of the NAPAP
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effort were for total suspended
participates (TSP), not PMi0.
Table 1, showing criteria air pollutant
emission factors, is an example of the
data presented in the project report.
Those emission factors derived from AP-
42 represent a range of emissions,
samples, and foundries under which
testing was conducted. Those emission
factors derived from NAPAP
were developed from states files,
published reports from both industrial and
government sources, AP-42, engineering
estimates, and communication with
industry representatives. Where NAPAP
used AP-42 data, the AP-42 data range
was averaged to present a single value.
Figure 1 shows all the major air
pollutant emission sources one might find
in iron foundries. In any given foundry,
one would not expect to find more than
one type of melting furnace although
there may be some exceptions. Only
foundries producing ductile iron would
have magnesium inoculation facilities.
The major emission sources are the
melting, pouring, shakeout, and cooling
operations.
Table 1. Criteria Emissions from Iron Foundry Operations, mg/Mg Metal Melted
Operation
Emission Cupola
PM10 62x106
6.2 x 106
voc
9 x 104
NOX
5 x 104
CO 7.25 x 107
7.25 x 107
SO2 1.8 x103
Electric Arc Greensand
Furnace Inoculation Pouring Shakeout
5.8 x 106 1.03 x 106 1.12 x 106
5.7 x 106 1.6x106 2.5x106 1.12x106
3 x 1 04
1.5 x 105
9 x 104 2.5 x 103 7 x 104 6 x 105
2 x 1 04
3 x 1 05
9.0 x 104 5 x 103
5 x 104
1.9 x 105
9.5 x 106
1.25 x 105 1.0 x 104
Source
AP-42
NAPAP
AP-42
NAPAP
AP-42
NAPAP
AP-42
NAPAP
AP-42
NAPAP
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Metallics
>;fcw-."' Gas and
r Particulate
: Emissions
^ , r/:{;, :• Gas and
Cupola :(mParticulate
^
"'uc' -fQ\. —-Ox
A \S>.^AV.i:is-s^
Binder
^^ Hot
<\^r^] ^-^"^ Mefa/
Induction ^^^
Molding
Figure 1 Emission points in a typical iron foundry
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Gerhard Gschwandtner and Susan Fairchild are with E. H. Pechan and
Associates, Inc., Durham, NC 27707.
Robert C. McCrillis is the EPA Project Officer (see below).
The complete report, entitled "Emission Factors for Iron Foundries: Criteria and
Toxic Pollutants" (Order No. PB 90-266 7431 AS; Cost: $17.00, subject to
change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
BULK RATE
POSTAGE & FEES PAID
EPA
PERMIT No. G-35
Official Business
Penalty for Private Use $300
EPA/600/S2-90/044
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