'\\ »\ \^p?"|St!E-:S;v»/sJl *,&*:-:. -' ;^«^'3r^tates--' " . '£ . Office :. Environmental Protection Compliance Assurance .(2222A) Septemb ^ Agency " Washington, *jf«--^»!«"-^a vvEPA a «_. *T- j-\ * The Micronytrii Industry: Byproduct confaihing at least 30% postconsumer recovered fiber. ------- ------- The Micronutrient Fertilizer Industry: From Industrial Byproduct to Beneficial Use Office of Compliance Office.of Enforcement and Compliance Assurance U.S. Environmental Protection Agency Washington, D.C. 20004 September 2001 ------- 'Disclaimer The U.S. Environmental Protection Agency (EPA) has reviewed this document and approves it for publication. This document does not constitute rulemaking by the EPA and may not be relied on to create a substantive or procedural right or benefit enforceable at law or in equity, by any person. The EPA may take actions at variance with this document and its internal procedures. Disclaimer ------- Table of Contents Page 1.0 Purpose of Report - 1-1 2.0 Overview of the Micronutrient Fertilizer Industry , . . . . 2-1 2.1 Classes of Micronutrients 2-1 2.2 Industrial Byproducts Used in Micronutrients . 2-1 2.3 General Micronutrient Fertilizer Production Overview . 2-3 3.0 Industrial Sources of Zinc-Bearing Byproducts 3-1 3.1 Steel Manufacturing: Electric Arc Furnace Dust (K061) 3-2 3.2 Brass Smelters and Foundries: Brass Fume Dust (D006, D008) 3-4 3.3 Tire Incineration for Energy Recovery: Tire Ash (D006, D008) 3-6 3.4 Galvanizing Operations: Zinc Dross and Skimmings and Spent Acids 3-6 4.0 Processing/Recovery of Zinc Micronutrients 4-1 4.1 Zinc Sulfate . 4-1 4.2 Zinc Oxysulfate . . . . 4-2 4.3 Ammoniated Zinc Sulfate ........ 4-3 4.4 Zinc Chloride .-"... 4-3 4.5 Zinc Oxide : . . 4-4 5.0 Product Formulation 5-1 5.1 Liquid Formulating 5-1 5.2 Dry Formulating 5-2 6.0 Land Application of Zinc Micronutrients 6-1 6.1 Application Methods 6-1 6.2 Application Concentrations and Exposures 6-3 7-0 Overview of Existing Regulations 7-1' 7.1 Resource Conservation and Recovery Act (RCRA) 7-1 7.2 Hazard Communication Standard 7-7 7.3 State Regulations 7-7 7.4 International Regulations.' 7-9 8.0 References. . 8-1 'V*: " Table of Contents i* ------- List of Tables Page 2-1 Industrial Byproduct Sources for the Top Micronutrients in Use in the U.S. ........ 2-2 3-1 Industrial Byproducts Most Commonly Used in Zinc Micronutrient Fertilizers 3-1 3-2 Comparative Chemical Composition of Dust from EAPs 3-3 4-1 Sample Results for Zinc Sulfate Monohydrate Micronutrient Products 4-2 4-2 Sample Results for Zinc Oxysulfate Micronutrient Products 4-4 6-1 Sources of Zinc Used for Land Application 6-3 6-2 Information For Applying Zinc Micronutrient Fertilizers Using Band and Broadcast Procedures 6-4 7-1 Washington Standard for Annual Metal Additions to Soil "... 7-8 7-2 State of Texas Limitations for Commercial Fertilizers ' 7-9 7-3 Canadian Maximum Acceptable Cumulative Metal Additions to Soil and Maximum Acceptable Metal Concentration in Products 7-10 List of Tables ------- List of Figures Page 2-1 Overview of Micronutrient Production 2-3 3-1 Electric Arc Furnace Steel Manufacturing 3-2 3-2 Brass Smelting Process : . 3-4 3-3 Brass Foundry Processing .3-5 3-4 Hot-Dip Zinc Galvanizing Process ' 3-7 4-1 Zinc Sulfate Manufacturing . . . 4-1 4-2 Zinc Oxysulfate Manufacturing 4-3 5-1 Typical Liquid-Based Formulating Line 5-1 5-2 Typical Granular Formulating Line 5-2 5-3 Typical Dry Spray-Coated Formulating Line 5-2 6-1 Broadcast Spreading 6-1 6-2 Band Application 6-2 6-3 Injection .' 6-2 6-4 Fertigation 6-2 - I List of Figures ff~ t ------- Acknowledgment The U.S. EPA would like to thank Dr. Charles W. Perry for his technical assistance during the prepa- ration of this compliance assistance manual. Dr. Perry was employed in the Office of Compliance under the Senior Environmental Employee Program during the development of this manual when he held the nationwide distinction of having the longest career as a chemical engineer. Dr. Perry began his chemical engineering career in 1937. Acknowledgment ------- Purpose of Report Micronutrients Important to Higher Plant Life Martens, Westermann, 1991 Borori; Copper; Iron; Manganese; Molybdenum; and Zinc. Micronutrients help cultivate healthy crops and are a necessary part of the human diet. Deficiencies impact plant growth by hindering photosynthesis, respiration, and other basic internal chemical processes that allow the plant to grow. Six micronutrients are regarded as important to higher plant life: boron, copper, iron, manganese, molybdenum, and zinc1. These micronutrients are typically added to fertiliz- ers as oxides, sulfates (and their hydrates), sodium salts,' and chelates (combined chemically with resins). As important as they are, micronutrients are only needed in small quantities. As a result, when micronutrients are applied to deficient cropland, they are generally used in trace or small amounts and applied as ,an additive to the primary crop fertilizers of nitrogen, phosphorous, and potassium2. Some industrial wastes contain elements which can be used, or converted for use, in-micro'nutrient fertilizers. The United States encourages the recycling of industrial waste in a safe manner for use in micronutrient fertilizers. However, some wastes may contain hazardous constituents that provide no nutritive value to the plant. The use of these wastes in micronutrient fertilizers introduces these con- stituents into the greater ecosystem. These constituents could be hazardous to handle by applicators, contribute to contaminated runoff from land application sites, or be taken up in plants. This report is intended for use by the public, industry, users of micronutrient products, regulatory agency representatives, and federal and state auditors, all of whom share a common interest in the development and use of micronutrient fertilizers made from industrial byproducts. The information in this report provides a common technical framework to facilitate discussion between these groups. Specifically, the report contains a summary of existing information about micronutrient fertilizers manufactured from industrial byproducts, descriptions of the industrial processes involved in their development and use, information on the contaminants that may be present, and methods to land apply micronutrient fertilizers. The process information presented focuses primarily on zinc micronu- trient fertilizers, since they account for the majority of fertilizers made from industrial byproducts. An overview of the current federal and state regulations applicable to this industry, as well as existing international regulations, is included at the end of this report. However, due to the changing nature of regulations applicable to this industry, this report is not intended to serve as a guide to compliance with regulatory programs. Purpose of Report ------- Organization of Report Chapter 2 presents an overview of the micronutrient fertilizer industry; Chapters discusses the industrial processes that result in zinc-bearing byproducts; Chapter 4 discusses the processes used in the micronutrient industry to create the products that are sold to fertilizer blenders; Chapter 5 discusses methods of formulating fertilizer products; Chapter 6 presents a discussion of land application methods used with zinc micronutrients; presents an overview of regulations that impact the micronutrient fertilizer industry; and Chapter 7 Chapters contains a list of references. Purpose of Report ------- Overview of the Micrnniitrient Fertilizer Industry The main micronutrients used in U.S. agriculture today are zinc, iron, manganese, and copper3. Micronutrients are typically used in small amounts and are often mixed with other fertilizers (i.e.,. nitrogen, phosphorus, and potassium). In 1996, U.S. agriculture used 23 million tons of nitrogen fertilizers, 7 million tons of phosphorus fertilizers, and 6 million tons of potassium fertilizers4. Micronutrient fertilizers account for only 1% to 1.5% of the total. This chapter presents an overview of the micronutrient fertilizer industry, including the classes of micronutrients, the industrial byprod- ucts used, and an overview of the production process. . 2.1 Classes pf Micronutrients Micronutrients vary in physical and chemical state, cost, and availability to the plant. There are three classes of micronutrients: Inorganic sources; Synthetic chelates; and Natural organic complexes. At one time, fritted glass products were also considered a class of micronutrients, but they are not in use to the extent they once were. . Inorganic sources include oxides, carbonates, and metallic salts and are usually the least costly sources of micronutrients. Oxides, such as manganese oxide and zinc oxide, are in common use, but are insol- uble in water and therefore less effective in crop use. Sulfates are water-soluble and dissolve quickly after application, making them especially useful. Common sulfates include copper sulfate, iron sul- fate, manganese sulfate, and zinc sulfate. Oxysulfates are oxides that have been partially acidulated, or made acidic, with sulfuric acid. The water solubility of these Oxysulfates is related to the degree of' acidulation2. Synthetic chelates are manufactured by combining a chelating agent with a metal cation. The most common chelating agent is EDTA (ethylenediaminetetraacetic acid). Other chelating agents, such HEDTA (N-hydroxyethyl-ethylenediaminetriacetic acid) and EDDHA (ethylenediamine as di (o-hydroxyphenylacetic acid)), are more expensive and used primarily with high-value crops. Chelated micronutrients are most often in liquid form and mixed with liquid fertilizers, although dry chelates are sometimes mixed with solid fertilizers2. Natural organic complexes are created by reacting metallic salts with organic byproducts. Most often, digest liquors from the wood pulp industry (both sulfite and kraft pulp processes) may be reacted to form a metal sulfate or metal oxide. Zinc, iron, copper, and manganese have all been used in natural organic complexes2. , 2.2 Industrial Byproducts Used in MicrunutriEnts Most micronutrients produced in die United States for use in agriculture originate from industrial metal-bearing byproducts. Zinc micronutrients are of particular interest because they are the most common fertilizer additive made from recycled hazardous waste5. The use of industrial byproduct material as a micronutrient source raises the question of potential contamination. Untreated byprod- ucts may contain lead, cadmium, or other heavy metals and dioxins. Because of their availability as Overview of the Micronutrient Fertilizer Industry ------- industrial Byproducts, zinc and iron are the two micronutrients most likely to be incorporated in fer- tilizers from materials designated as a hazardous waste under the Resource Conservation and Recovery Act(RCRA)6. . , Table 2-1 lists examples of industrial byproduct sources for the most common micronutrients in the U.S. The table separates the byproducts by micronutrient, focusing on the micronutrients of primary concern. Where known or suspected, potential contaminants for each source are listed. Gaps in the table are areas where data are lacking or have not yet been identified Table 2-1 Industrial Byproduct Sources for theTop Micronutrients in Use in the U.S. Micro- Byproduct or Byproduct Source Micronutrient Product(s) ! Potential ! niitrient : Contaminant(s) | Zinc Iron Manganese Copper Electric arc furnace dust (K061) Brass foundry dust Brass mill slag Tire ash Galvanizing waste Mill scale Pickle liquor Mining waste (tailings) Demetallized photographic fluid Hydroquinone production byproduct Manganese carbonate baghouse dust Copper industry wastes Zinc sulfate, zinc oxide, ammoniated zinc sulfate, zinc chloride, zinc oxide Zinc sulfate, zinc oxysulfate, ammoniated zinc sulfate, zinc chloride, zinc oxide Zinc sulfate, zinc oxysulfate, ammoniated zinc sulfate, zinc chloride, zinc oxide Zinc sulfate, zinc oxysulfate, ammoniated zinc sulfate, zinc chloride, zinc oxide Zinc sulfate, iron sulfate, ammoniated zinc sulfate, zinc chloride, zinc oxide Ferrous sulfate monohydrate Blended multi-nutrient Manganese sulfate (animal feed) Manganese sulfate (animal feed) Copper sulfates, copper oxides Lead, cadmium, dioxins Lead, cadmium Heavy metals Cadmium Heavy metals Heavy metals Heavy metals Heavy metals Heavy metals Heavy metals Heavy metals Heavy metals Overview of the Micronutrient Fertilizer Industry ------- Z.3 General MicrnnutriEtit Fertilizer Prnductinn Overview Figure 2-1 presents a simple overview of the major steps in micronutrient production using industri- al byproducts. Industrial processes that generate zinc-bearing byproducts are discussed in Chapter 3. Industrial byproducts are sent to a micronutrient manufacturer for processing. The form and quality of the byproduct and the specific micronutrient being produced determines the process used to create the micronutrient. For example, some industrial byproducts must be filtered before being processed into a micronutrient fertilizer.7 The processing and recovery of zinc micronutrients are discussed in more detail in Chapter 4. Micronutrients are then packaged as a liquid or solid and sold to a fertiliz- er production facility or an end user where they are typically blended with primary nutrients (N, P, or K) into fertilizer. Fertilizer formulation is discussed in Chapter 5. .._... '_. There are various methods by which fertilizers, including micronutrients, can be applied to-cropland. The selection of the method depends on a variety of factors such as crop type, soil type, timing of application (i.e., at which stage "of the crop growth cycle), and fertilizer type. Fertilizer can be applied in three basic forms: pellets (the most common); powder; and liquid. The m'ain methods of applica- tion are broadcast spreading, band application, injection, and fertigation (i.e., application of fertilizer through an irrigation system). Methods of land application are discussed in more detail in Chapter 6. Figure 2-1. Overview of Micronutrient Production N,P,K Fertilizer Brass Mill Slag Galvanizing Skimmings RE3E5 *;..- v ..^. ^-' Spent Acids Tire Ash Brass EAFDusI Fume Dust (K061) Land Application Sources :,_;, Overview of the Micronutrient Fertilizer Industry ------- Overview of the Micronutrient Fertilizer Industry ------- Industrial Sources d Zinc-Bearing Byproducts A Imost any zinc-bearing industrial byproduct could be used to manufacture micronutrients. /\ However, .the Resource Conservation and Recovery Act (RCRA) places certain restrictions on JL JLdie use of hazardous waste-derived fertilizers (discussed in Chapter 7). In 1999, the tons of zinc micronutrient fertilizers produced from nonhazardous materials was roughly equivalent to the tons of zinc micronutrient fertilizers produced from hazardous waste8. Table 3-1 lists the most common industrial byproducts used in the production of zinc micronutrients, including the estimated amount generated and used in fertilizer production in 1997 (or the most current year data was available), the typical RCRA status of that material (i.e., whether hazardous or nonhazardous), and the zinc content. Table 3-1 Industrial Byproducts Most Commonly Used in Zinc Micronutrient Fertilizers Annual Arinual Amount Used in Typical Zinc Content Wlatenai Generation (tons) Pert lizer Production (tons) RCRA Status (%) ! i . EAF dust (K061) Brass fume dust (D006, D008) Tire ash (D006, D008) Zinc fines from galvanizing 925,000 32,200 7,500 Unknown 10,000 842 3,120 10,836 Hazardous (Pb, Cr, Cd) Hazardous . (Pb, Cd) Hazardous (Pb, Cd) Nonhazardous 15-25 40-60 27-35 60-75 Currently, the following industrial processes are identified as sources of zinc for the micronutrient industry: steel manufacturing, galvanizing, brass manufacturing (foundries and mills), and tire incineration. This list may change over time due to changes in industrial processes and the changing regulatory environment for zinc micronutrients. This chapter provides a brief description of each manufacturing process that creates zinc byproduct materials for use in the micronutrient industry. Process flow diagrams are included at the end of the section. Industries Generating Zinc-Bearing Byproducts Steel Manufacturing; Galvanizing; Brass Foundries; Brass Mills; and Tire Incineration. Industrial Sources of Zinc-Bearing Byproducts ------- 3.1 Steel Manufacturing: Electric Arc Furnace Dust (KDBt) The electric arc furnace (EAF) is uniquely suited for the production of high quality steels. The furnace is a cylindrical vessel with a dish-shaped refractory hearth and three electrodes that lower from the dome-shaped, removable roof. Tar-bonded magnesite bricks form the lining of the furnace. The walls typically contain water-cooled panels that are covered to minimize heat loss. The electrodes may also be equipped with water- cooling systems. The cycle in EAF steelmaking consists of scrap charging, melting, refining, de-slagging, and tapping. In addition to scrap steel, the charge may include pig iron and alloying materials. As the steel scrap is melted, additional buckets of scrap may be added to the furnace. The EAF generates heat by passing an electric current between electrodes through the charge in the furnace. Lime-rich slag removes the steel impurities (e.g., silicon, sulfur, and phosphorus) from the molten steel. Oxygen may be added to the furnace to speed up the steelmaking process. At the end of a heat, the furnace tips forward and the molten steel is poured off. Most EAFs are operated with dry air cleaning systems which capture released particulates as dust, although a small number of wet and semi-wet systems also exist which capture particulates as sludge. Figure 3-1 presents a simple schematic of the EAF steelmaking process. Figure 3-1. Electric Arc Furnace Steel Manufacturing Air Outlet Baghouse Scrap Furnace EAF Oust (K061) Operation of an EAF generates K061, a listed RCRA hazardous waste defined as "emission control dust/sludge from the primary production of steel in electric furnaces." Approximately 90% of partic- ulate emissions from an EAF are generated during the melting and refining steps and the remaining 10% are generated during charging and tapping9. Generally a mill generates between 20 and 40 pounds of EAF dust per ton of steel produced9. Industrial Sources of Zinc-Bearing Byproducts ------- K061 generation includes entrainment of particles of calcium oxide (CaO), rust, and dirt that are in the scrap metal and pulled out of the EAF in the off-gas system. In addition, certain metals volatilize as the scrap metal heats up (iron, zinc, lead, cadmium, and ckrorhium). These metals .tend to form oxides following volatilization and are present as such in the EAP dust. EAF dust can vary greatly in composition depending on the composition of the scrap and additives used. When lower grades of steel are used (mainly in carbon steel production), the dust generated can contain, concentrations as high as 44% for zinc oxide and 4% for lead' oxide9. Dust from stainless steel production can contain high levels of chromium and nickel oxides (12% and 3%, respectively), as well as lower levels of cad- mium (around 0.1%)9. Table 3-2 presents concentrations of metals in EAF dust for stainless and car- bon steel production. Table 3-2 Comparative Chemical Composition of Dust from EAFs I * ' . . . Stainless Steel Dust Carbon Steel Dust unemicai (% bi wejght) (% by wejght) Iron Zinc Cadmium Lead Chromium Calcium Oxide 31.7 1.0 0,16 1.1 10.2 3.1 28.5 19.0 <0.1 2.1 0.39 10.7 (a) (a) Calcium oxide and magnesium oxide combined. Source: AISI, 2000. Over the past few years, dioxin and furan generation in the incineration processes used in steel man- ufacturing has become an area of study since the components of the off-gas stream in an EAF may result in the formation of dioxins. The Foundation of Metallurgical Research showed that the biggest contributors to dioxins in scrap steel melting were polyvinyl chloride (PVC) coated scrap and oily scrap10. It was also found that the baghouse outlet emission concentrations of dioxins ranged from 20% to 60% of the inlet stream concentration. These data indicate that dioxins are captured in the baghouse and this conclusion is supported by research that indicates that 20% to 30% of dioxins are bound to particulates". There are 17 forms of dioxins considered to be toxic. The most toxic dioxin is 2,3,7,8-tetra- chlorodibenzo-p-dioxin (TCDD). Other similar dioxins have been assigned toxicity equivalency fac- tors (TEFs) relative to 2,3,7,8-TCDD, which is assigned a TEF of 1. The total dioxin equivalency (TEQ) is determined by summing the toxicity weighted values of all dioxins. Raw EAF dust (K061) was found to have a TEQ concentration of 815 ng/kg and granular zinc fertilizer from K06l was found to have concentrations of 342 and 322 ng/kg4. The TEQ values for K061 and granular zinc fer- tilizer do not exceed the RCRA nonwastewater standard for all TCDDs of 1,000 ng/kg12. In recent years, most micronutrient companies have stopped using K061 and moved to other sources of zinc. One U.S. company still uses K061 to create zinc oxysulfate in a process located on site at a steel manufacturing plant. Since the facility is located at the byproduct source, there is no transporta- tion or storage of the K06113. Industrial Sources of Zinc-Bearing Byproducts f "." -".- ". - f ;*,M;- -- ?~'^: 4 ------- Currently, the primary user of K061 in the United States is Horsehead Industries. Horsehead uses high temperature separation techniques to obtain zinc and lead products for sale back to the metals indus- try". Zinc Nationale in Monterrey, Mexico receives some zinc oxide from Horsehead14. Zinc Nationale produces zinc oxide and zinc sulfate compounds from K061 for use as animal feed and fertilizer. It is suspected that some of these micronutrients are sold in the United States7. 3.2 Brass Smelters and Foundries: Brass Fume Dust (DDDB, DDDB) Both foundries and smelters melt metals and form them for use. Smelters take metal-bearing materi- als and process them into ingots. Foundries process ingots into shapes that can be used commercially. Smelters and foundries exist for every industrial metal. Brass is an alloy composed of copper and zinc. Red brass contains 6 percent of zinc while yellow brass contains up to 41 percent15. Brass smelters and foundries are of interest because the zinc content of their byproducts is sufficient for use in micronu- trients. Smelters'. Brass smelting involves collecting and melting raw materials for forming into ingots. A general diagram of the process is depicted in Figure 3-2. Copper- and zinc- bearing raw or recycled materials, such as copper wire and radiators, are collected and melted. Chemicals and other elements are added to the molten metal to create a desired mixture. The mixture is poured into forms and allowed to cool. After removal from the forms, the product is cleaned and excess metal is removed to be recycled. Metal shav- ings can either be recycled back into the process or sold to a byproduct industry. The final product is a metal ingot with specific, known properties16. Figure 3-2. Brass Foundry Processing D006/D008 Furnace Mold Cooling Brass Ingots industrial Sources of Zinc-Bearing Byproducts ------- Foundries. Brass foundry processes typically involve melting brass ingots and brass scrap in an induction furnace, which consists of hollow vertical cylinder lined with heat-resistant refractory material arid ringed with electric coils17. Heat induced by the electric coils melts metal inside the furnace. The molten metal is then cast in molds, which are most frequently made of a moist sand media ("green sand"), although other molding methods, including investment casting and permanent molding are also used for brass. Molds are prepared by compressing sand in a box or "flask" around a wood or plastic pattern (shaped like the exterior of the desired product); once the sand is mechanically compacted in shape, die pattern is removed. The top and bottom halves, or "cope" and "drag"of the mold, are formed separately and a core (shaped like the interior space of the product) is set into the mold when the two halves are joined, forming a cavity. Molten brass is transferred (tapped) from the furnace and poured into the mold cavity through a prepared channel in the mold, "called a sprue18-19. The molds are then transferred from the dedicated pouring area and cooled, allowing the metal to solidify. When cool, the castings are separated from the mold and core sand by shak- ing, knocking or tumbling in a process known as "shake out"18. Sprues and other excess metal and sand are removed from die casting with hammers and saws and are returned to the furnace as scrap. Finally, the product surface is cleaned and finished using grind- ingi shot blasting, and machining methods. A general diagram of the process is depict- ed in Figure 3-3. ' . Figure 3-3. Brass Foundry Processing 1 Finishing * Inspecting Cleaning Both brass smelters and brass foundries have similar byproduct sources that could be used by the micronutrient industry. During the melting and pouring process, particles coming off the molten metal are collected using air cleaning systems, similar to the systems used with electric arc furnaces to capture released particulates as dust or sludge16. Brass fume dust is usually characteristically hazardous for both lead and cadmium and is designated as D006 and D008. Lead levels in brass fume dust can be as high as six percent20. Currently, brass fume dust is primarily used in animal feed production or for zinc reclamation8. Shavings or chips from cleaning or-post-process forming are also valuable sources of zinc. Industrial Sources of Zinc-Bearing Byproducts ------- 3.3 Tire Incineration for Energy Recovery: Tire Ash (DQDB, DD08) Tire-to-energy facilities use the heat generated from the incineration of tires as a source of energy. About 5% of the weight of the tires incinerated remains as ash. The ash is collected from particulate matter captured in a baghouse similar to brass and steel fume collection. The baghouse dust, which contains zinc, has been used as a micronutrient source in the past8. Tire ash is characteristically hazardous for both lead and cadmium and designated as D006 and D0088. Tire ash, as a raw material, has a total dioxin equivalency unit concentration (toxicity weight- ed average of dioxin congeners) of 1.62 ng/kg; granular zinc fertilizer made with tire ash has a con- centration of 5.60 ng/kg4. Dioxins are discussed in more detail in Section 3.1. The dioxin levels in tire ash are well below the RCRA nonwastewater standard for all TGDDs of 1,000 ng/kg12. It is not believed that micronutrient manufacturers use tire ash as an input to their process at this time7. 3.4 Galvanizing Operations: Zinc Dross and Skimmings and Spent Acids Galvanizing is the process of applying a zinc coating to iron or steel for protection from corrosion. The zinc coating is applied using a hot-dip galvanizing or electrogalvanizing process. Spent acids as well as zinc-bearing skimmings from either galvanizing process can be processed and used as raw materials in the micronutrient industry2. Zinc skimmings are considered a non-hazardous waste and are not sub- ject to RCRA controls20. Lead levels in non-hazardous galvanizing waste are typically between one and two percent21. Hot-dip galvanizing is a five-step process that includes cleaning, annealing, coating with zinc, chemi- cal treating, and working. Four different processes can be used in the cleaning step, all resulting in the removal of surface oils and impurities: 1. Flame oxidation of the steel; 2. Electrolytic cleaning, scrubbing, hot-water rinsing, and hot-air drying of the steel; 3. Acid pickling, alkaline cleaning, and fluxing of the steel; and 4. Cleaning and annealing in one step using a reducing-flame furnace. Annealing is the process by which the steel (or iron) is heated to prepare the surface for reaction with molten zinc. Annealing usually takes place during the cleaning process but can be conducted after- wards. After cleaning and annealing, the metal is dipped in molten zinc for one to ten seconds. The galvanized metal is cooled before being treated with chromium compounds to resist staining. Finally, the product is cold worked to ensure a more consistent surface21. Figure 3-4 presents a simple diagram for the hot-dip galvanizing process. Figure 3-4. Hot-Dip Zinc Galvanizing Process Cleaning Rinsing Annealing Rinsing Zinc bath (Coating) Chemical Treating Cooling and inspection Industrial Sources of Zinc-Bearing Byproducts ------- The zinc micronutrient industry is primarily interested in waste products from the coating step. During the galvanizing process an oxide film can develop on the surface of the molten zinc; this film must be removed to prevent interference with the reaction of the zinc with the metal to be galvanized. It is common for the zinc bath to contain a small amount of lead, iron, and aluminum. Excess iron can settle to the bottom of the bath as dross (FeZn13) or it may react with excess aluminum to form an iron-zinc-aluminum alloy which floats to the surface as skimmings before being removed21. Zinc-bearing materials recovered from the bath that can not be recycled into the process are sold to zinc recycling facilities who process the materials for sale back to galvanizers, to brass foundries, or to the micronutrient industry. Electrogalvanizing involves preparation steps similar to hot-dip galvanizing. The methods differ in the application of the zinc to the galvanized metal. Electrogalvanizing does not require the use of furnaces, molten zinc, or a cooling tower. The electrogalvanizing process uses an electrical current which passes through the zinc solution from an anode to the galvanized metal. The process allows the zinc to bond to the iron or steel. Zinc can be applied from anodes that are constructed of a soluble zinc material or the zinc can be applied from a process solution21. Any spent solution that contains zinc still in solu- tion is a viable byproduct for the micronutrient industry. Before use, the galvanizing byproduct material is processed by the zinc reclaiming industry to create two products: zinc fines and zinc metal ingots. Zinc fines are sold to the micronutrient industry while zinc metal ingots are sold back to the galvanizing industry or to brass foundries7. Industrial Sources of Zinc-Bearing Byproducts ------- Industrial Sources of Zinc-Bearing Byproducts ------- of Zinc MicrnnutriEnts Types of Zinc Micronutrients Zincsulfate; Zincoxysulfate; Ammoniated zinc sulfate; Zinc chloride; and Zinc oxide. The compounds most commonly used to deliver zinc to the soil are zinc sulfate and zinc oxysulfate. Zinc sulfate is normally used in the form zinc sul- fate monohydrate. The physical properties of sulfates make them well suited for fertilizer use because they are water soluble and dissolve easily into the soil2. Additional compounds that can be used to deliver zinc are ammoni- ated zinc sulfate, zinc chloride, and zinc oxide. Ammoniated zinc sulfate is used when blending with liquid phosphorus fertilizers. Zinc chloride and zinc oxide are not used as frequently but maintain a small portion of the market7. The processes used to develop each compound are similar, and are described below. EPA has estimated that there were approximately 16 facilities producing zinc micronutrient fertilizers in 1998. Only two of the zinc micronutrient fertilizer producers were known to use hazardous feed- stocks; the remainder use nonhazardous sources. Two additional facilities are believed to use hazardous byproducts to produce zinc micronutrients for use in animal feedstocks8. 4.1 Zinc Sulfate Figure 4-1 presents a simple process flow diagram for zinc sulfate manufacturing. Zinc sulfate is cre- ated by digesting a zinc source in sulfuric acid and water. The amount of sulfuric acid used in the process is determined stoichiometrically to react with all of the zinc contained in the byproduct. Since zinc sulfate is water soluble, the liquid may be filtered to remove wastes and impurities (lead and cad- mium are of greatest concern). Filtered metals are sent to a smelter for reprocessing or stabilized and sent to a landfill. The resulting zinc sulfate slurry is either packaged for sale as a liquid fertilizer or sent to a drier where it is crystallized. Some of the dry zinc sulfate is sold in the crystallized form, but most is granulated and sized for sale. Oversized materials are sent through a hammer mill and reintroduced to the granulator with any undersized materials7. The filtration process results in a consistent product, regardless of the specific raw materials used8. Table 4-1 presents some limited results of contaminants present in samples of zinc sulfate micronutrient products made from industrial byproducts. Table 4-1 Sample Results for Zinc Sulfate Monohydrate Micronutrient Products Fertilizer Range of Zinc in CadrUum Lead Comments Type Fertilizer (%) (mg/kg); (mg/kg) Zinc Sulfate [Zinc Sulfate Monohydrate 35.5 - 36 31.4-37.7 <2.7 - 28 4 - 28.8 25-69 3 - 84.2 Based on average values for four different products. Based on composite samples of five different products over four years. ^T 111 \ |1 m\ ,.:*WI Source: Big River Zinc, Tetra Micronutrients. Processing/Recovery of Zinc Micronutrients ------- Figure 4-1. Zinc Sulfate Manufacturing Tractor 4.2 Zinc DxysulfatE Zinc oxysulfate is created by combining a zinc-bearing byproduct with sulfuric acid. This process involves putting byproduct dust in a rotating drum or tube type granulator and spraying it with a sul- furic acid and water mix. As discussed in Chapter 2, the byproduct may have to be ground into a usable form before entering the process. The raw material, water, and sulfuric acid mixture is granu- lated and dried to remove excess water. Granulated zinc oxysulfate is sent through a series of sizing screens to divide the mixture into marketable sizes. Sometimes this process is reversed and the granu- lated zinc oxysulfate is sized before being dried. Oversized materials are sent through a hammer mill and reintroduced to the granulator with any undersized materials. After packaging, the sized zinc oxy- sulfate is sold to fertilizer manufacturers. For effective crop use, typically 35% to 50% of the zinc is in water-soluble form2. Figure 4-2 presents a simple process flow diagram for zinc oxysulfate manufac- turing. Traditionally, zinc fertilizer manufactured from K061 has been produced in oxysulfate form. Since there is no filtration step in the manufacture of zinc oxysulfate, any deleterious materials in the raw materials that are not filtered out during byproduct processing are in the final product23. There has recently been a movement away from the manufacturing of zinc oxysulfate using industrial byprod- ucts20. Table 4-2 presents some limited results of contaminants present in samples of zinc oxysulfate micronutrient products made from industrial byproducts. Processing/Recovery of Zinc Mieronutrients ------- Figure4-2. Zinc Oxysulfate Manufacturing Farmers Table 4-2 Sample Results for Zinc Sulfate Monohydrate Micronutrient Products Source Range of Zinc in Cadmiurr) Lead Comments Fertilizer (%) (mg/kg)| (mg/kg) i Characteristic Hazardous Waste (non-K061) K061 Non Hazardous Raw Materials 17.7-20 '18-19 20-36 ND-39 <270 - 297 <20-<150 800-1,300 14,280-15,000 <50-<1,000 Based on the average of product monthly composite analyses for 1997 and other sample data. Based on the average of product monthly composite analyses for 1997 and other sample data. Based on information provided on typical analysis results for three products. Source: Tetra Micronutrients, Bay Zinc. 4.3 Ammnniated Zinc Sulfate Chemical properties prevent zinc sulfate from being soluble in phosphate-based liquid fertilizer. Mixing ammonia with zinc sulfate creates a product, ammoniated zinc sulfate, which is soluble in phosphate-based liquid fertilizer7. Ammoniated zinc sulfate is created by adding ammonia after the creation of liquid zinc sulfate. Manufacturing'companies either create the zinc sulfate themselves or buy it before it goes to the fertilizer blender7. The final product is sold to a fertilizer blender. 4.4 Zinc Chloride Zinc chloride is created using the same process as zinc sulfate except hydrochloric acid is used in place of sulfuric acid. However, the lead contaminants that may be present from industrial byproduct sources are dissolved by hydrochloric acid during this process. Because the lead is now dissolved, it is no longer possible to remove this contaminant through filtration. Therefore, if starting with the same source of zinc byproduct, zinc chloride has higher concentrations of lead than zinc sulfate. In addi- tion, while sulfides are considered beneficial to crops, chlorides may sometimes harm them7. Processing/Recovery of Zinc Micronutrients ------- 4.5 Zinc Oxide Zinc oxide is not typically made from industrial sources. One method of producing zinc oxide is by roasting sphalerite (ZnS), a naturally occurring zinc compound. The zinc oxide is sold as a fine pow- der or in granular form. Since it is insoluble, it is not immediately available to crops when applied in a granular form2. Zinc oxide is not extensively used as a fertilizer7. Processing/Recovery of Zinc Micronutrients ------- Product Formulation 1 "V ecommended application rates for mioronutrients are typically much lower than for N-P-K fer- 1^^ tilizers. Because of this, micronutrients may be combined with N-P-K fertilizers to reduce costs JL ^and improve application. Micronutrients are incorporated, bulk blended, or coated onto gran- ular fertilizers, or mixed with liquid fertilizers, to create final formulated fertilizer products. 5.1 Liquid Formulating Liquid formulations typically contain mixtures of one or more raw materials, inert ingredients, and a base solvent (such as water), and may also contain emulsifiers or surfactants. Solid materials, such as powders or granules, may also be used as part of a liquid formulation by dissolving or emulsifying the dry materials to form a liquid or suspension. The formulated product may be in a concentrated form requiring dilution before application, or may be ready to apply. Micronutrients may be applied in a liquid form alone or mixed with fluid N-P-K fertilizers. For exam- ple, zinc micronutrients are often mixed in starter fertilizers. However, the solubility of the micronu- trient impacts the degree to which it may be mixed in a fluid fertilizer. Where solubility limits the amount of micronutrient that can be added to a fluid fertilizer, a suspension fertilizer may also be used. Typically, powdered sources of micronutrients are incorporated to the fluid fertilizer just prior to application in the field. Because complete solution of the micronutrient is not required, higher con- centrations of micronutrients (such as zinc oxide) can be incorporated. An example of a liquid-based formulating line is shown in Figure 5-1. Typical liquid formu- lating lines consist of storage tanks or con- tainers to hold active and inert raw materials, and a mixing tank for formulating the final product. A storage tank may also be used on the formulating line to hold the formulated product, prior to a packaging step. Facilities may receive their raw materials in bulk and store them in bulk storage tanks, or they may receive the raw materials in smaller quantities, such as 55-gallon drums, 50-pound bags, or 250-gallon minibulk containers or "totes." These raw materials are either piped to the formulation vessel from bulk storage tanks, or added directly to the vessel from drums, bags, or minibulks (smaller, refillable containers). Typically, water or the base solvent is added to the formulation vessel in bulk quantities. Figure 5-1. Typical Liquid-Based Formulating Line Drums Formulated Product Storage Formulation Vessel Minibulk The formulating line may also include piping and pumps for moving the raw material from the stor- age tanks to the mixing tank, and for moving formulated product to the packaging line. Other items that may be part of the line are pre-mixing tanks, stirrers, heaters, bottle washers, and air pollution control equipment. Some lines may also contain refrigeration units for formulation and storage units, scales, and other equipment. v 4 Product Formulation ------- 5.2 Dry Formulating Dry formulations may be in different forms, such as powders, dusts, or granules. They are formulated in various ways, including mixing powdered or granular actives with dry carriers, spraying or mixing a liquid ingredient onto a dry carrier, soaking or using pressure and heat to force ingredients into a solid matrix, and drying or hardening an ingredient solution into a solid form. These dry products may be designed for application in solid form or to be dissolved or emulsified in water or solvent prior to application. Micronutrients may be applied in a granular form alone or blended with N-P-K fertilizers. More often, a fertilizer dealer purchases fertilizer products in bulk and blends them together in specific proportions according to the needs of the end user or farmer. Blending typically occurs just prior to field applica- tion to minimize the chance for chemical reactions to occur. Dry formulating lines typically have tanks or containers to hold the active ingredients and inert raw materials, and may include mixing tanks, ribbon blenders, extruding equipment, vacuum or other type of drying equipment, tanks or bins for storage of the formulated product, pelletizers, presses, milling equipment, sieves, and sifters. Figures 5-2 and 5-3 are examples of granular and dry spray-coated pro- duction lines. The coating procedure for micronutrient fertilizers is usually simple, using rotary drum or ribbon mix- ers. Typically, a finely ground micronutrient is combined with a granular fertilizer. A liquid binding agent is then sprayed onto the granules during mixing. Binding agents include water, waxes, oils, or a fertilizer solution. Anti-caking agents may also be used. Due to the increased costs associated with this formulation, coating is used primarily to add micronutrients to specialty fertilizers. Figure 5-2. Typical Granular Formulating Line Figure 5-3. Typical Dry Spray-Coated Formulating Line Bags Ribbon Mixer Formulated Product Storage Heated Air Spray Dryer Air Liquid Ingredient Hold Tank Solids Cyclone Dust Final Product Bin Product Formulation ------- Raw materials for dry fertilizer products may be liquid or solid. Liquid raw materials may be stored in rail tank cars, tank trucks, minibulks, drums, or bottles. Dry raw materials may be stored in silos, rail cars, tank trucks, minibulks, supersacks, metal drurns, fiber dflimsj bags, or boxes. Liquid raw mate- rials may be pumped, poured, or sprayed into formulation vessels, while dry raw materials are fre- quently transferred to formulation equipment by screw conveyors (consisting of a helix mounted on a shaft and turning in a trough), through elevators, or by pouring. Dry formulating lines may also include piping and pumps for moving raw materials from storage tanks to the formulation equipment, and for moving formulated product to the packaging equipment. Other items that may be included in the dry product line are pre-mixing tanks, tanks for storing for- mulated product prior to packaging, stirrers, heaters, refrigeration units on formulation and storage equipment, scales, and air pollution control equipment (e.g., cyclones, filters, or baghouses). Dry products may be packaged into rail tank cars, tank trucks, totes, and minibulks, but are typically pack- aged into bags, boxes, or drums. - .f \ Product Formulation ------- Product Formulation ------- Land Application nf Zinc Micrnnutrients s oil applications are the most commonly used and effective methods for correcting zinc deficiencies2. This chapter briefly discusses the application of zinc micronutrient fertilizers to cropland. The sources and classes of zinc micronutrient fertilizers were discussed in Chapter 2. B.I Application Methods Micronutrients may be applied alone or may be mixed in with a nitrogen, phosphorus, or potassium (NPK) fertilizer. Micronutrients are typically applied in combination with a NPK fertilizer, which results in a more uniform fertilizer distribution. It also helps to reduce application costs since all the required fertilizer is applied at once. One drawback is possible reactions between the various chemi- cals in the fertilizer2. , There is no conclusive data on which type of zinc fertilizer is most effective. Most fertilizer distribu- tors perceive no difference between the two major types of zinc micronutrient fertilizers: zinc oxysul- fate and zinc sulfate monohydrate. Zinc sulfate monohydrate may be more readily available to plants since it is more soluble. However, it is possible that chemical reactions in the soil can convert zinc oxy- sulfate into a more usable form. Zinc is applied to cropland based on the concentration needed. The average zinc application rate is 5 pounds per acre.8 Fertilizers can be applied in many forms, such as pellets (the most common), powders, or liquids. The selection of the application method depends on a variety of factors including fertilizer class, crop type, soil type, and timing of application (i.e., at which stage of the crop growth cycle the fertilizer is to be applied). The basic application methods include surface application (e.g., broadcast or band applica- tion), subsurface application (or injection), irrigation, and foliar application which are described in greater detail below. Broadcast Spreading. Broadcast spreading is a method by which the fertilizer is evenly spread across the soil surface. It is most often used to apply dry fertilizers and is performed prior to planting. Incorporation of the fertilizer through plowing or harrowing can help prevent runoff and help make the nutrients more available for uptake at the root zone. The preferred form of fertilizer for broadcast spreading is pellets since they are easier to handle than powder. Powder can stick together, preventing free flow in the hopper of the spreading equipment25. Figure 6-1 depicts a broadcast spreader. Figure 6-1. Broadcast Spreading Fertilizer Hopper Broadcast Spreader - ^%&>m ='%* I Ss-i-t '« :f. I ' g: . -^---r^^ j§ij * ' -~fr: Land Application of Zinc Micronutrients ------- Band Application. Band application (banding) is a method of applying fertilizer to the soil surface in narrow bands along the side of a row of plants. A fertilizer that can be broadcast spread can also be band applied. Banding is generally performed dur- ing cultivation but may occur during the growing season (side dressing). Lower application rates, compared with broadcast application, may be used due to the lower amount of soil-zinc contact2. Figure 6-2 depicts band application. Injection. Injection is used to apply dry or liquid fertilizers below the soil surface and close to the root zone. Blades or furrow openers are used to cre- ate channels into which the fertilizer is dropped. Injection of fertilizers helps prevent loss of nutri- ents due to wind and rain erosion. Injectors, how- ever, require more power than other methods of application and they do not perform well in stony soil. Fertilizer injection is often performed at the time of seeding to get the crop off to a fast-start25. Figure 6-3 shows an example of injection of liquid fertilizer. Fertigation. Fertigation is the liquid application of a water-soluble fertilizer with irrigation water. The concentrated fertilizer is metered into the irrigation supply line. Fertigation can be used with both trickle and overhead irrigation systems. Fertigation can save time, fuel, and equipment compared with other application methods, and it reduces the amount of compaction from equipment traveling over the soil25. Fertilizers are best applied using fer- tigation for crops that use drip irrigation systems. Figure 6-4 shows an example of a fertigation sys- tem. Foliar Application. Foliar application is the appli- cation of a fertilizer directly to the crop foliage and is generally used as an emergency measure to cor- rect a zinc deficiency that occurs during the grow- ing season. Foliar application is accomplished by spraying the fertilizer onto the leaves of the plant. Foliar application is usually less effective than broadcast and band application for correcting zinc deficiencies and care must be taken not to damage the leaves of the plant2. Figure' 6-2. Band Application Fertilizer hopper Drop tube Fertilizer applicator Figure 6-3. Injection Figure 6-4. Fertigation Fertilizer injector Liquid fertilizer stock tank Land Application of Zinc Micronutrients ------- 6.2 Application Concentrations and Exposure O.L Application uonceniraiiDns anu exposure Table 6-1 presents common sources of zinc micronutrients use,d in land applicai with the approximate concentration of zinc in each source. Table 6-2'presents gen^c^ ^^^ band and broadcast application procedures for correcting zinc deficiencies in various crops. U CXpUSUrE inc micronutrients use,d in land application activities, along inc in each source. Table 6-2'presents general information on Table 6-1 Sources of Zinc Used for Land Application Source Formula Concentration of Zinc (g/kg) Inorganic Compounds Zinc ammonia complex Zinc carbonate Zinc chloride Zinc frits Zinc nitrate Zinc oxide Zinc oxysulfate Zinc sulfate monohydrate Zinc sulfate heptahydrate Basic zinc sulfate Organic Compounds Zinc chelate Zinc chelate Zinc chelate Zinc lignosulfonate Zinc polyflavonoid Zn-NHg ZnC03 ZnCI2 Fritted glass Zn(l\l03)2-6H20 ZnO ZnO + ZnS04 ZnS04-H20- ZnS04-7H20 ZnS04-4Zn(OH)2 l\la2ZnEDTA l\la2ZnHEDTA IMaZnNTA - .... 100 520-560 480-500 100-300 , 220 500-800 400-550 360 230 550 140 90 90 50-80 50-100 Source: Mortvedt Land Application of Zinc Micronutrients ------- Table 6-2 Information For Applying Zinc Micronutrient Fertilizers Using Band and Broadcast Procedures i : Crop Zinc Source Zinc Application Application : Comment ! Rate (kg/ha) Method ' I Red Mexican bean, sweet corn Rice Corn Corn Corn Corn, "snapbean, vegetables Corn, snapbean, vegetables Flax Corn, bean, grain, sorghum, sweet corn Corn, bean, grain, sorghum, sweet corn Corn, sorghum Corn, bean, flax, potato, sorghum, soybean Na2ZnEDTA ZnS04, ZnO ZnS04 ZnS04, ZnO Zn chelate ZnS04, ZnO Zn chelate ZnS04 ZnEDTA ZnS04 ZriEDTA ZnS04 ZnS04 ZnS04 Na2ZnEDTA ZnS04 ZnS04 0.9-1.8 9.0 34.0 6.6 11.0 2.2 - 3.3 3.3 0.6-1.1 4.5 - 9.0 1.1 -2.2 2.2 - 4.5 0.6-1.1 11.0 11.0-17.0 5.6-11.0 1.1 -2.2 <1.1 11.0 5.5 5.6-11.0 1.0-5.5 Broadcast Broadcast Broadcast Band Broadcast Broadcast Band Band Broadcast Broadcast Band Band Broadcast Broadcast Broadcast Band Band Broadcast Broadcast Broadcast Band Apply with macronutrient fertilizer and plow in. Surface apply before flooding. Reapply every 4 to 5 years. Use finely divided ZnO. Band with starter fertilizer; use finely divided ZnO. Apply with l\l, P, and K fertilizer. Band with l\l, P, and K fertilizer. Incorporate by plowing. DTPA extractable Zn, <0.5 mg/kg DTPA extractable Zn, . 0.5 to 1 .0 mg/kg DTPA extractable Zn1 <0.5 mg/kg; band with starter fertilizer DTPA extractable Zn, <0.40 mg/kg DTPA extractable Zn, 0.41 to 0.81 mg/kg Reapply every 2 to 4 years. Source: Mortvedt EPA performed a risk assessment to estimate the potential risks to human health and the environment from contaminants in NPK fertilizers, micronutrient fertilizers, and soil amendments26. Zinc micronu- trient fertilizers were evaluated as part of the study. The study evaluated the exposure risk to farmers and their children through the following exposure routes23: Direct ingestion; Ingestion of soil amended widi fertilizers; Inhalation of particles and vapors during fertilizer application and tilling; Land Application of Zinc Micronutrients ------- Ingestion of plant and animal products produced on soil amended with fertilizers; and, Ingestion of fish from streams located adjacent to fertilizer-amended fields. The study concluded hazardous constituents in fertilizers generally do not pose a health or environ- mental risk. The study did find there was a risk from dioxins and arsenic which may be found in some micronutrient fertilizers. However, usually the risk could be attributed to a single fertilizer sample that had an unusually high contaminant concentration. For zinc micronutrient fertilizers, only 1 sample in 12 showed a risk for indirect exposure to dioxin.26 For more information, including estimates of the addition of metals to soil from zinc micronutrients, this study can be accessed through EPA's web site, at www.epa.gov/epaoswer/hazwaste/recyde/fertiliz/risk/index.htm. Land Application of Zinc Micronutrients - - ------- Land Application of Zinc Micron'utrients ------- Overview of Existing Regulations This chapter provides a brief overview of existing regulations that affect the micronutrient fertilizer industry. The chapter contains background material on certain federal and state reg- ulations that would be applicable to facilities generating industrial byproducts containing zinc, as well as micronutrient processing facilities. The chapter also provides a brief look at international regulations. 7.1 Resource Conservation and Recovery Act (RCRA) The Solid Waste Disposal Act (SWDA), as amended by the Resource Conservation and Recovery Act (RCRA) of 1976, addresses solid and hazardous waste management activities. The Act is commonly referred to as RCRA. The Hazardous and Solid Waste Amendments (HSWA) of 1984 strengthened RCRA's waste management provisions and added Subtitle I, which governs underground storage tanks (USTs), Regulations promulgated pursuant to Subtitle C of RCRA (40 CFR Parts 260-299) establish a "cra- dle-to-grave" system governing hazardous waste from the point of generation to disposal. RCRA haz- ardous wastes include the specific materials listed in the regulations (discarded commercial chemical products, designated with the code "P" or "U"; hazardous waste from specific industries/sources, des- ignated with the code "K"; or hazardous wastes from non-specific sources, designated with the code "F") or materials which exhibit a hazardous waste characteristic (ignitability, corrosivity, reactivity, or toxicity and designated with the code "D"). Most RCRA requirements, are not industry specific, but apply to any company that generates, transports, treats, stores, or disposes of hazardous waste. Entities that generate hazardous waste are subject to waste accumulation, manifesting, and record- keeping standards. A hazardous waste facility may accumulate hazardous waste for up to 90 days (or 180 days depending on the amount generated per month) without a permit or interim status. Generators may also treat hazardous waste in accumulation tanks or containers (in accordance with the requirements of 40 CFR Section 262.34) without a permit or interim status. Facilities that treat, store, or dispose of hazardous waste are generally required to obtain a RCRA per- mit. Subtitle C permits for treatment, storage, or disposal facilities contain general facility standards such as contingency plans, emergency procedures, recordkeeping and reporting requirements, finan- cial assurance mechanisms, and unit-specific standards. RCRA also contains provisions (40 CFR Part 264 Subparts I and S) for conducting corrective actions which govern the cleanup of releases of haz- ardous waste or constituents from solid waste management units at RCRA treatment, storage, or dis- posal facilities. Although RCRA is a federal statute, many states implement the RCRA program. Currently, EPA has delegated its authority to implement various provisions of RCRA; to 47 of the 50 states and two United States territories. Delegation has not been given to Alaska, Hawaii, or Iowa. - rr-r v ;' ''--- ti S: feil Overview of Existing Regulations ------- EPA controls the use of hazardous materials in micronutrients through the RCRA program. .RCRA Subpart C regulates hazardous waste management from the point of generation to ultimate disposal. Regulation of zinc micronutrient byproducts falls under Subpart C. The primary topics of Subpart C that are applicable to zinc byproduct generators and processors are: * Hazardous Waste Identification and Listing Identifies characteristics of hazardous wastes and provides lists of wastes. Generators of Hazardous Wastes Divides hazardous waste generators into categories based on-quantities generated which determines the level of RCRA compliance required. Transporters of Hazardous Wastes Establishes standards for recordkeeping, labeling,-and transporting hazardous wastes. Treatment, Storage, and Disposal Establishes standards for treatment, storage, and disposal of hazardous wastes listed or identified in Subpart C. The land disposal restrictions (LDR) set standards for wastes disposed directly on the land or in the ground. The following sections discuss general RCRA regulations that are applicable to zinc byproduct gener- ators and fertilizer processors. Overview of Existing Regulations ------- Waste Determinations The definition of hazardous waste is specified in 40 CFR 261.3. This section describes what constitutes a hazardous waste. Exclusions and exemptions from the hazardous waste definition are outlined in 40 CFR 261.4 through 261.6. The primary haz- ardous wastes used in the zinc micronutrient industry are K061, D006, and D008. The type of zinc micronutrient waste present at a site depends on how the waste is generated and what hazardous constituents are present. Waste generators, such as steel mills and brass foundries, generate sources of zinc micronutrients that fall. under the definition of hazardous waste. These wastes are therefore regulated by RCRA. The accu- mulation and transport of these wastes to the micronutrient processor must follow RCRA regu- lations. Any storage taking place at the processor's facility prior to introducing the waste into the fertilizer production processmust also comply with RCRA regulations. Once the waste is con- verted to a fertilizer, the waste-derived fertilizer would not be regulated under RCRA provided it meets the applicable land disposal restriction treat- ment standards. Hazardous Wastes Used in Zinc Micronutrient Industry K061 -Emission control dust/sludge from the primary production of steel in electric furnaces. D006 - Any waste having a concentration of cadmium greater than 1.0 mg/L. Brass fume dust and tire ash can fall into this category. D008 - Any waste having a concentration of lead greater than 5.0 mg/L. Brass fume" dust and tire ash can fall into this category. Summary of RCRA Requirements for the Determination of Hazardous Waste Waste Generator (e.g., steel mill, brass foundry, etc.) . Sources of hazardous zinc micronutrient waste (e.g., electric arc furnace dust) must be identified. « The facility must accurately identify ' -its waste. Micronutrient Processor (e.g., fertilizer producer) Sources of hazardous wastes used in the production of micronutrients (e.g., K061, D006, D008) must be identified. The facility must be permitted or licensed to receive the hazardous waste. Any production processes using the hazardous waste that generates hazardous waste must be identified. Overview of Existing Regulations ------- Hazardous Waste Generator Activities The specific RCRA requirements for generators of hazardous waste depend on the amount of waste generated on site. Generators fall into one of three categories: 1. Conditionally Exempt Small Quantity Generators (CESQG) Generators of less than Ikg/month of acute hazardous waste or less than 100 kg/month of other hazardous waste. 2. Small Quantity Generators (SQG) - Generators of greater than TOO but less than 1,000 kg/month of nonacute hazardous waste. 3. Large Quantity Generator (LQG) - Generators of greater than Ikg/month of acute haz- ardous waste or greater than or equal to 1,000 kg/month of other hazardous waste. The generator's classification determines the level of RCRA compliance required. LQGs are subject to the most stringent standards, while CESQGs are exempt from most requirements. Large and small quantity gen- erators may only accumulate hazardous wastes on site for a limited amount of time. CESQGs are limited to storing 1,000 kg of wastes at any one time. Storing amounts greater than 1,000 kg would reclassify them as a SQG. Waste accumulation units must comply with certain standards. Generators must complete a hazardous waste manifest to accompany all shipments of hazardous waste off site for treatment or disposal. Generator recordkeeping and reporting requirements are outlined in Subpart D of Part 262 of the RCRA regulations (40 CFR 262.40 through 262.44). Large and small quantity generator facilities must retain signed copies of manifests for 3 years from the date the waste was accepted by the initial transporter. Generators must also keep records of any test results, waste analyses, or other required determinations for at least 3 years from the date the waste was sent for processing. In addition, LQGs must submit a biennial report that includes the following: Summary of RCRA Requirements for Hazardous Waste Generators The facility must determine the quantity of hazardous waste- generated on a monthly basis. Waste streams must be properly identified. The facility must have an EPA Identification number. The facility must comply with all waste accumulation requirements (40 CFR 262.34). The facility must follow all waste manifest requirements for off-site waste shipments (40 CFR 262.420-423). "The facility must retain copies of all manifests, exception reports, biennial reports (if required), records of test results, waste analyses, and other required determinations for at least 3 years. 'The EPA identification number, name, and address of the generator; 1 The EPA identification number, name, and address for each off-site treatment, storage, and disposal facility to which waste was shipped during the year; 1 The EPA identification number and name of each transporter used; Overview of Existing Regulations ------- "A description, EPA hazardous waste number, DOT hazard class, and quantity of each hazardous waste shipped off-site for shipments to a treatment, storage, or disposal facility; . 3 '.- "A description of efforts to reduce the volume and toxicity of the wastes generated; and "A signed certification stating the information is true, accurate,'and complete. Treatment, Storage, and Disposal Activities Processors of zinc micronutrient-containing hazardous waste must comply with certain RCRA regulations. If the facility receives a zinc micronutrient-containing waste from an off-site generator and stores the waste for any amount of time prior to using it in the fertil- izer production process, it must have a RCRA hazardous waste storage permit. If the received waste is inserted directly into the fertilizer production process (i.e., no storage takes place) then a hazardous waste storage permit is not needed. While the fertilizer production process itself is not regulated By RCRA, any handling or storage of the waste prior to entering the fertilizer production process must comply with the hazardous waste management and storage require- ments. The waste-derived fertilizer product is not considered a hazardous waste, but residues from its production might be. Like generators, processors must keep signed copies of all waste manifests for any haz- ardous waste received or generated for at least 3 years from the date of delivery. They must also maintain an operating record, which includes descriptions of waste quanti- ties, dates received, and storage methods. The closes. Processing facilities that store hazardous the following: Summary of RCRA Requirements for Treatment, Storage, and Disposal Facilities The facility must be permitted or licensed to receive the zinc micronutrient-containing hazardous waste. Waste storage requirements must be met. The facility must properly identify and manage any hazardous wastes residues from the processing of the zinc micronutrient-containing waste during the fertilizer production process. The facility must retain copies of all manifests, exception reports, and biennial reports for at least 3 years. The facility must maintain an operating record.- operating record must be maintained until the facility waste must also submit a biennial report that includes 1 The EPA identification number, name, and address of the facility; 'The EPA identification number, name, and address for each generator that shipped haz- ardous waste to the facility during the year; "A description of the quantity of each hazardous waste received; 'A description of method of storage; and 'A signed certification. Overview of Existing Regulations ------- Land Disposal Restrictions The land disposal restriction (LDR) program was developed to protect groundwater. The land disposal restrictions prohibit hazardous waste from being placed on the land until the waste is treated to reduce the mobility or toxic- ity of its hazardous constituents. Once a haz- ardous waste is generated, it becomes subject to LDR. EPA has developed LDR standards for almost all hazardous Wastes that are land disposed. The standards are expressed as concentrations in leachate when tested according to the Toxicity Characteristic Leaching. Procedure (TCLP) and are generally technology-based standards. TCLP was originally designed by EPA to simu- late contaminants leaching from wastes in municipal solid waste landfills4. LDR requires sites to maintain notification and certification paperwork to ensure the wastes are properly managed. Zinc micronutrient fertilizers produced from, or containing, hazardous wastes are subject to regulations for hazardous waste-derived prod- ucts. These fertilizers can be manufactured from several different types of zinc-bearing haz- ardous wastes, such as dusts collected in emis- sion control devices from electric arc furnaces and brass foundries and ash from the combus- tion of tires. These fertilizers can be made from waste materials not classified as hazardous wastes, as well as from raw materials such as refined zinc ores24. For zinc micronutrient fer- tilizers, the micronutrient processor converts the hazardous waste into a -usable fertilizer. The resulting ferdlizer is not considered a hazardous waste as long as the LDR treatment standards are met. There are, however, exceptions to LDR. For example, wastes are exempt if generated by CESQGs. In addition, fertilizers produced from K061 waste are exempt from the LDR treatment standards at this time. Summary of RCRA Requirements Under the Land Disposal Restrictions Program Waste Generator The generating facility must send a one-time notice to each facility that receives its waste. The generating facility must maintain and follow a waste analysis plan if it is treating its waste prior to shipment! The generator must maintain copies of all notices, certifications, waste analysis data, and other related, documentation for at least 3 years. Micronutrient Processor The processing facility must maintain and follow a waste analysis plan containing a detailed chemical and physical analysis or any hazardous waste treated on site. The processing facility must submit a certification to the appropriate official(s). Proposed Changes to Federal .Requirements Federal requirements for RCRA, including the land disposal restrictions program, are currently undergoing review and possible revision by EPA. For example, proposed changes would establish technology-based limits for the maximum amount of arsenic, cadmium, chromium, lead, mercury, and nickel allowed in zinc micronutrient fertilizer and would establish a limit on the amount of dioxins. Up-to-date information on these changes can be found at: http://www.epa.gov/epaoswer/hazwaste recycle/fertiliz/index.htm. Overview of Existing Regulations ------- 7.2 Hazard Communication Standard The Occupational Safety and Health Administration (OSHA) also regulates the use of hazardous waste-derived fertilizer products. The OSHA Haz'ara Corfiniunication .Standard (29 CFR Part 1910.1200) applies to chemical manufacturers and importers of "hazardous chemicals," including agricultural operations. The'standard includes measures for warning workers about chemical hazards through labels, material safety data sheets (MSDSs), other warning mechanisms and employee train- ing. The standard does not apply to family members working on farms, only employees. According to the standard, chemicals in concentrations of 1% or more (0.1% for carcinogens) must be listed on the MSDSs for products used in the workplace. Manufacturers and importers must pro- vide MSDSs for their products. Part 1910.1200 (b) (1) requires manufacturers or importers to assess the hazards of chemicals which they produce or import. All employers must provide a hazard com- munication program, labels and other forms of warning, MSDSs, and information and training to educate employees about hazardous chemicals to which they are exposed4. Part 1910.1200 (d) (1) states: "If a mixture has not been tested as a whole to determine whether the mixture is a health hazard, the mixture shall be assumed to present the same health hazards as do the components which comprise one percent (by weight or volume) or greater of the mixture, except that the mixture shall be assumed to present a carcinogenic hazard if it contains a component in concen- trations of 0.1 percent or greater which is considered to be a carcinogen under paragraph (d) (4) of this section"4. Chemicals subject to labeling requirements under specific acts such as the Federal Insecticide, Fungicide and Rodenticide Act (FIFRA), the Toxic Substance Control Act (TSCA), and the Federal Food, Drug, and Cosmetic Act (FFDCA), and consumer products regulated under the Consumer Product Safety Act (CPSA) and the Federal Hazardous Substances Act (FHSA) are not required to fol- low the MSDS requirement. Additionally, this section of the OSHA regulations does not apply to any waste defined as hazardous under the Solid Waste Disposal Act (SWDA), as amended by the Resource Conservation and Recovery Act (RCRA) and any hazardous substance defined by the Comprehensive Environmental Response, Compensation and Liability Act (CERCLA) when the product is the focus of remedial or removal action being conducted in accordance with EPA Regulations. 7.3 State Regulations Most states regulate fertilizer composition for plant nutrients under state fertilizer regulatory pro- grams. State laws generally require product registration and/or licensing and testing to assure that label claims are valid. Most regulations also include statements about product adulteration and a prohibi- tion against including any product that is harmful to plants, animals, humans, or the environment. Only two states, Washington and Texas, have regulations that establish specific limits on heavy metal contaminants and testing and labeling requirements. Washington. In 1998, the State of Washington passed legislation requiring fertilizer manufacturers to disclose the content of arsenic, cadmium, cobalt, mercury, molybdenum, lead, nickel, selenium, and zinc in fertilizer products. Washington's Safe Fertilizer Act mandates certain requirements regard- ing contaminant testing, registration and labeling, and contaminant standards. Washington estab- lished standards for the maximum acceptable annual application of metals to soil. The standards were derived from Canadian standards which specify long-term cumulative metals additions to soils. Because the Canadian standards cover forty-five years, the annual standards developed for Washington were developed by dividing the Canadian standards by forty-five. The Washington standards are list- ed in Table 7-1. Overview of Existing Regulations ------- Table 7-1 Washington Standard for Annual Metal Additions to Soil Maximum Acceptable Annual Application (Ibs/acre/year) Arsenic Cadmium Cobalt Mercury Molybdenum Nickel Lead Selenium Zinc 0.297 0.079 0.594 0.019 0.079 0.713 ' 1.981 0.055 7.329 Source: Washington State Department of Agriculture Cobalt, molybdenum, and zinc are considered plant nutrients and can be applied at rates greater than those shown in Table 7-1 if they are guaranteed on the label. If any of those three metals are not meant for use by the plants to which the product is applied, then those metals must meet the state standards28. In addition to meeting the standards listed in Table 7-1, plant nutrients other than nitrogen, phos- phorus, and potassium must be guaranteed on the label. Guarantees ensure that the nutrient has been registered with the state and must include the nutrient source28. If a fertilizer or any part of a fertilizer is derived from solid or hazardous wastes, the fertilizer is defined as being waste-derived and must be identified as such. For more information on the State of Washington's program, go to http:llwww.ecy.wa.govlprogramslhwtr/fertilizer/index.htm. . Texas. The State of Texas has regulations analogous to those of Washington. However, Texas based their limits on EPA's standards for sewage sludge (40-CFR Part 503). Texas commercial fertilizers must meet allowable concentration limits for trace elements or annual loading rates for trace elements, shown in Table 7-2. For more information on the State of Texas' program, go to httf./lotscweb. tamii. edu/. Overview of Existing Regulations ------- Table 7-2 State of Texas Limitations for Commercial Fertilizers 1 I ! Pollutant Maximum Allowable Concentration of Trace Cumulative Element Elements in Commercial Fertilizers ( ppm) Loading Rate (Ibs/acre/year) i Arsenic Cadmium Copper Lead Mercury Molybdenum Nickel Selenium Zinc 41 39 1500* 300 17 18* - 420 100* 2800* 0.37 0.35 13..4* 2.68 0.15 0.16* 3.75 0.89*- 25.0* *These elements may be required at higher concentrations for plant growth. Fertilizers containing concentrations of these elements at levels higher than the maximum must be guaranteed. Source: Texas §65, Tables 1 and 2. , " , Other States. Pennsylvania requires testing and approval from the Department of Environmental Protection before selling fertilizers made from industrial waste products4. 7.4 International Regulations International fertilizer regulations differ from United States laws in content and enforcement. Canada limits concentrations of heavy metals in fertilizer products, while Japan limits the heavy metal and organic chemical content in incinerator ash from industrial and municipal waste treatment incinera- tors. The European Union has fertilizer regulations that all member nations are required to follow. Canadian Fertilizer Act. The Canadian Fertilizers Act R.S., c. F-9, s.l (1993) and Fertilizers Regulations contain metal limits used by the Canadian Food Inspection Agency. The limits apply to all fertilizers and soil supplements sold in Canada. Developed in 1978 and revised in 1980, the limits were intended for the land application of biosolids4. Table 7-3 shows the limits for the metals in fer- tilizer and soils following the application of fertilizers. The limits are designed to be cumulative limits over a 45-year period. The standards were designed to be conservative since significant concentrations are already present in the soil in some areas29. . Overview of Existing Regulations ------- Table 7-3 Canadian Maximum. Acceptable Cumulative Metal Additions to Soil and Maximum Acceptable Metal Concentration in Products Cumulative Metal Addition to Soil, 45-year period (kg/ha) Arsenic Cadmium Cobalt Mercury Molybdenum Nickel Lead Selenium Zinc 15 4 30 1 4 - 36 100 2.8 370 Source: EPA.1999 All micronutrient fertilizers, fertilizer/pesticide mixes, and most supplements must be registered through the Canadian Food Inspection Agency (CFIA). A product can become registered after the manufacturer has submitted metal analyses and the levels are shown to be below the Canadian limits. Non-registered fertilizers are randomly selected for metal analyses. Products exceeding metal limits can be detained and seized4. Canadian regulations also control the labeling of micronutrient fertilizers. They require the identifica- tion and description .of the product and its constituents, the industrial process from which the prod- uct is derived, the benefits of the product, rates and methods of application, and documented analy- ses for heavy metals, dioxins, and furans4. For more information on Canada's program, go to http:llinspection.gc. calenglishlplaveglferenglferenge. html. European Union Requkements. The European Union directive on fertilizers concerns fertilizer con- tent and package markings. In a simplified form it is similar to the U.S. EPA rules. While not provid- ing guidance on limits of contaminants in the environment, the directive includes the following state- ment: "Member States shall take the necessary measures to ensure that waste is recovered or disposed of without endangering human health and without using processes or methods which could harm the environment." Overview of Existing Regulation's ------- References 1. Martens, D.C. and D.T. Westermann. "Fertilizer Applications for Correcting Micronutrient Deficiencies." In: SSSA Book Series: 4, Micronutrients in Agriculture, J.J. Mortvedt, F.R. Cox, L.M. Shuman, and R.M. "Welch, eds. Soil Science Society of America, Inc. Madison, WI, 1991. pp. 703-723. 2. Mortvedt, J.J. "Micronutrient Fertilizer Technology." In: SSSA Book Series: 4, Micronutrients in Agriculture, J.J. Mortvedt, F.R. Cox, L.M. Shuman, and R.M. Welch, eds. Soil Science Society of America, Inc. Madison, WI, 1991. pp. 523-548. 3. Telephone conversations with Paul B. Queneau, P.B. Queneau & Associates Inc., 4 and 23 October 2000. 4. U.S. EPA. "Background Report on Fertilizer Use, Contaminants and Regulations." 747-R-98- 003, January 1999. 5. U.S. EPA. Inside EPA. Vol. 21, No. 49, 8 December 2000. : 6. Telephone conversation with Paul A. Borst, U.S. EPA, 4 October 2000. 7. Telephone conversations with Dick Camp, Bay Zinc Corporation, 25 October and 1 November 2000. ~ ' 8. U.S. EPA. "Economic Analysis for Regulatory Modifications to the Definition of Solid Waste for Zinc-Containing Hazardous Waste-Derived Fertilizers, Notice of Proposed Rulemaking: Final Report"-November 2000k 9. American Iron and Steel Institute (AISI). Steel Industry Technology Roadmap. http-.llwww.steel.org/mt/roadmap/roadmap.htm. Accessed December 2000. 10. Lindblad, B. and E. Burstrom. A Scandinavian View On Coated Scrap and the Environment. Lulea, Sweden: MEFOS. 11. Acharya, P., S.G. DeCico, and R.G. Novak. "Factors that Can Influence and Control the Emissions of Dioxins and Furans From Hazardous Waste Incinerators." Journal of Air Waste ManagementAssoc. 41:12 (1991): 1605-1615. 12. U.S. EPA. "Universal Treatment Standards." 40 CFR §268.48. 13. Telephone conversation with Carl Schauble, Frit Industries, 24 October 2000. 14. Petition of Horsehead Resource Development Company, Inc., for an adjusted standard under 35 111. Adm. Code 720.131© before Illinois Pollution Control Board, 28 October 1999. 15- Michels, H.T. "Understanding Copper-based Alloy," Engineered Casting Solutions. American Foundry Society. Summer edition, 2000. pp. 54-57. 16. Telephone conversation with Steve Robinson, American Foundries Society, 8 December 2000. References ------- 17. Telephone conversation with a representative of Foundry Products Supplier C, 28 November 2000. 18. U.S. EPA, et al. Development Document for the Effluent Limitations Guidelines and Standards for the Foundries (Metal Molding and Casting) Point Source Category. EPA440-l-80-070a. Washington, DC, April 1980. 19. Schleg, E and D. Kanicke. "Guide to Casting and Molding Processes." Engineered Casting Solutions. American Foundry Society. Summer edition, 2000. pp. 18-27. 20. U.S. EPA. "Requirements for Zinc Fertilizers Made From Recycled Hazardous Secondary Materials; Proposed Rule." 40 CFR § 261, 266, and 268. 28 November 2000. 21. Lankford, W.T. Jr., N.L. Samways, R.F. Craven, H.E. McGannon, eds. The Making, Shaping and Treating of Steel, 10th Edition. Herbick & Held, Pittsburgh, PA, 1985- 22. "Land Application of Hazardous Waste Derived Micronutrient Fertilizers," Bay Zinc Company and Tetra Technologies, Inc., 19 November 1999. 23. Queneau, Paul B. "Fertilizer and Feed." Recycling Metals from Industrial Wastes Workshop. Colorado School of Mines, Golden, CO, June 1999. 24. "EPA Rule Making RE: Secondary Zinc Oxides Used in the Production of Fertilizer Ingredients," Big River Zinc Corporation Position Paper. 25. Northeast Regional Agricultural Engineering Services (NRAES). Fertilizer and Manure Application Equipment, NRAES-57. 1994. 26. U.S. EPA. Estimating Risk from Contaminants Contained in Agricultural Fertilizers: Draft Report. Washington, DC, 1999. http://www.epa.gov/epaoswer/hazwaste/recycle/fertiliz/risk/index.htm. 27. U.S. EPA. "Hazardous Waste Recycling; Land Disposal Restrictions; Final Rule." Fed. Reg. 63: 168. 31 August 1998. 28. Washington State Department of Agriculture. Rules Relating to Fertilizers, Minerals, and Limes. 1 May 1999. ' 29. Canadian Food Inspection Agency (CFIA). Guidelines to the Fertilizers Act and Regulations, Plant Health and Production Division Plant Products Directorate Canadian Food Inspection Agency, http://www.cfia-acia.agr.ca/english/plaveg/fereng/guide.html. Accessed 6 October 2000. References ------- |