United States !
              Environmental Protection
              Agency :   !
Enforcjement And
Compliance Assurance
(2221A)
EPA310-R-95-005
September 1995
               Profile Of Tihe
               Iron And Steel Industry
                             m
   EPA'

                                               \.
                                            t (
NOTEBOOK^
              EPA Office Of .Compliance Sector Notebook Projdct

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                 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
                                WASHINGTON, D.C. 20460
                                                                         THE ADMINISTRATOR
Message from the Administrator

Over the past 25 years, our nation has made tremendous progress in protecting public health and
our environment while promoting economic prosperity. Businesses as large as iron and steel
plants and businesses as small as the dry cleaner on the corner have worked with EPA to find
ways to operate cleaner, cheaper, and smarter.  As a result, we no longer have rivers catching on
fire. Our skies are clearer. American environmental technology and expertise are in demand
throughout the world.

The Clinton Administration recognizes that to continue this progress, we must move beyond the
pollutant-by-pollutant approaches of the past to comprehensive, facility-wide approaches for the
future. Industry by industry and community by community, we must build a new generation of
environmental protection.                   !

Within the past two years, the Environmental Protection Agency undertook its Sector Notebook
Project to compile, for a number of key industries, information about environmental problems and
solutions, case studies and tips about complying with regulations. We called on industry leaders,
state regulators, and EPA staff with many years of experience in these industries and with their
unique environmental issues. Together with notebooks for 17 other industries, the notebook you
hold in your hand is the result.                                                :

These notebooks will help business managers to better understand their regulatory requirements,
learn more about how others in their industry have undertaken regulatory compliance and the
innovative methods some have found to prevent pollution in the first instance. These notebooks
will give useful information to state regulatory agencies moving toward industry-based programs.
Across EPA we will use this manual to better integrate our programs  and improve our compliance
 assistance efforts.

 I encourage you to use this notebook to evaluate and improve the way that together we achieve
 our important environmental protection goals. I am confident that these notebooks will help us to
 move forward in ensuring that — in industry after industry, community after community —
 environmental protection and economic prosperity go hand in hand.
                                                Carol M. Browni
           Recycled/Recyclable • Printed with Vegetable Based Inks on Recycled Paper (20% Postconsumer)

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Sector Notebook Project
                    Iron and Steel Industry
                                                                 EPA/310-R-95-005
                  EPA Office of Compliance

                Profile of the Iron
 Sector Notebook Project

and Steel Industry
                                  September 1995
                                Office of Compliance
                    Office of Enforcement i nd Compliance Assurance
                         U.S. Environmental Protection Agency
                             401 M St., SW (MC 2221-A)
                               Washington, DC 20460
                             For sale by the U.S. Government Printing Office
                     Superintendent of Documents, Mail Stop: SSOP, Washington, DC 20402-9328
                                  ISBN 0-1J5-048272-0
September 1995
                                  SIC 331

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Sector Notebook Project
Iron and Steel Industry
This report is one in a series of volumes published by the U.S. Environmental Protection Agency
(EPA) to provide information of general interest regarding environmental issues associated with
specific industrial sectors. The documents were developed under contract by Abt Associates
(Cambridge, MA), and Booz-Allen & Hamilton, Inc. (McLean, VA). This publication may be
purchased from the Superintendent of Documents, U.S. Government Printing Office. A listing
of available Sector Notebooks and document numbers are included on the following page.
All telephone orders should be directed to:

      Superintendent of Documents
      U.S. Government Printing Office
      Washington, DC 20402
      (202)512-1800
      FAX (202) 512-2250
      8:00 a.m. to 4:30 p.m., ET, M-F
Using the form provided at the end of this document, all mail orders should be directed to:

       U.S. Government Printing Office
       P.O. Box 371954
       Pittsburgh, PA 15250-7954                    .'.'•'..
Complimentary volumes are available to certain groups or subscribers, such as public and
academic libraries, Federal, State, local, and foreign governments, and the media. For further
information, and for answers to questions pertaining to these documents, please refer to the
contact names and numbers provided within this volume.
Electronic versions of all Sector Notebooks are available on the EPA Enviro$en$e Bulletin
Board and via the Internet on the Enviro$en$e World Wide Web. Downloading procedures are
described in Appendix A of this document.
Cover photograph courtesy of American Iron and Steel Institute.
September 1995
               SIC 331

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Sector Notebook. Project
                                                      Iron and Steel Industry
                        Contacts for Available Sector Notebooks
 The Sector Notebooks were developed by the EPA Office of Compliance. Particular questions
 regarding the Sector Notebook Project in general can be directed to the EPA Work Assignment
 Managers:
       Michael Barrette
       US EPA Office of Compliance
       401 M St., SW (2223-A)
       Washington, DC 20460
       (202) 564-7019
                                     .Gregory Waldrip
                                     US EPA Office of Compliance
                                     401 M St., SW (2223-A)
                                     Washington, DC 20460      j
                                     (202)564-7024
 Questions and comments regarding the individual documents can be directed to the appropriate
 specialists listed below.
 Document Number   Industry
 EPA/310.
 EPA/310
 EPA/310.
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
 EPA/310-
-R-95-001.
-R-95-002.
-R-95-003.
-R-95-004.
-R-95-005.
-R-95-006.
-R-95-007.
-R-95-008.
•R-95-009.
•R-95-010.
•R-95-011.
•R-95-012.
•R-95-013.
•R-95-014.
•R-95-015.
•R-95-016,
•R-95-017.
R-95-018.
 Dry Cleaning Industry         •  . ,
 Electronics and Computejr Industry
 Wood Furniture and Fixtures mdustry
 Inorganic Chemical Industry
 Iron and Steel Industry  |
 Lumber and Wood Products Industry
 Fabricated Metal Products Industry
 Metal Mining Industry
 Motor Vehicle Assembly Industry
 Nonferrous Metals Industry
 Non-Fuel, Non-Metal Mining Ind.
 Organic Chemical hidustjy
 Petroleum Refining Industry
 Printing Industry       j
 Pulp and Paper Industry
 Rubber and Plastic Industry
 Stone, Clay, Glass and Concrete hid.
Transportation Equip. Cleaning Ind.
Contact

Joyce Chandler
Steve Hoover
Bob Marshall
Walter DeRieux
Maria Malave
SethHemuiway  .
Greg Waldrip
Keith Brown
Suzanne Childress
Jane Engert
Keith Brown
Walter DeRieux
Tom Ripp
Ginger Gotliffe
Maria Eisemann
Maria Malave
Scott Throwe
Virginia Lathrop
                                                                 Phone
 564-7073
 564-7007
 564-7021
 564-7067
 564-7027
 564-7017
 564-7024
 564-7124
; 564-70 18
 564-5021
 564-7124
 564-7067
 564-7003
 564-7072
 564-7016
 564-7027
 564-7013
 564-7057

September 1995
                                                                    SIC 331

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Sector ."Notebook. Proj cct
Iron and Steel Industry
              Industry Sector Notebook Contents: Iron and Steel Industry
 Exhibits Index	 |		{{{
                •  • -           •       ...  j     •           '-.••••
 List of Acronyms		 v

 I. INTRODUCTION TO THE SECTOR NOTEBOOK PROJECT	 1
    A: Summary of the Sector Notebook Project!	 f	 1
    B. Additional Information ............. j	           2
                                      .  i          ,                  .   .
 II. INTRODUCTION TO THE IRON AND STEEL INDUSTRY	-	 3
    A. Introduction, Background, and Scope of ijhe Notebook		 3
    B. Characterization of the Iron and Steel Industry	 3
       1. Industry Size and Geographic Distribution		 3
      2. Product Characterization	j	'..... 8
      3. Economic Trends	 .j	 9
                •                        I  •      • .       .,   '  •            • '
 III. INDUSTRIAL PROCESS DESCRIPTION J.	. . ;. .	.	 .	.. .... . .  13
    A. Industrial Processes in the Iron and Steel Industry	  13
       1. Steelmaking Using the Basic Oxygen rurnace		  16
      2. Steelmaking Using the Electric Arc Furnace (EAF)	.		.....'  21
      3. Forming and Finishing Operations . j	 .  21
    B. Raw Material Inputs and Pollution Outpujts ..... ^	  23
    C. Management of Chemicals in the Production Process	  25

 IV. CHEMICAL RELEASE AND TRANSFER PROFILE	 .,	  27
    A. EPA Toxic Release Inventory for the Irbr. and Steel Industry	......;...  29
    B. Summary of Selected Chemicals Released	......_	 ,37
    C. Other Data Sources	 j		...;.....	/.	'41
    D. Comparison of Toxic Release Inventory Between Selected Industries	  44

 V. POLLUTION PREVENTION OPPORTUNITIES  .			  47

 VI. SUMMARY OF APPLICABLE FEDERAL! STATUTES AND REGULATIONS ...:..  53
    A. General Description of Major Statutes . .1. ..	'.....	 . . ...  53
    B.' Industry Specific Regulatory Requirements 		,	  63
    C. Pending and Proposed Regulatory Requirements	:	.		..  68
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Sector Notebook Project
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VII. COMPLIANCE AND ENFORCEMENT HISTORY	..	  75
   A. Iron and Steel Industry Compliance History	  79
   B. Comparison of Enforcement Activity Between Selected Industries	  81
   C. Review of Major Legal Action		  86
       1. Review of Major Cases	  86
       2. Supplementary Environmental Projects (SEPs)	  86

Vffl. COMPLIANCE ACTIVITIES AND INITIATIVES	  89
   A. Sector-related Environmental Programs and Activities 	  89
   B. EPA Voluntary Programs	  90
   B. EPA Voluntary Programs  	'.			  94
   C. Trade Association/Industry Sponsored Activity	  95
       1. Industry Research Programs	  95
       2. Summary of Trade Associations 	.......;	  97

DC CONTACTS/ACKNOWLEDGMENTS/RESOURCE MATERIALS ............... 101

Endnotes	 105

APPENDIX A: Instructions for Downloading Notebooks	A-l
September 1995
11
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Sector Notebook Project
                                                        Iron and Steel Industry
                                     Exhibits Index
 Exhibit 1: Geographic Distribution of SIC 331 Establishments: Steel Works, Blast Furnaces,
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit

 Exhibit

 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit
 Exhibit

 Exhibit;
   and Rolling and Finishing Mills  . . . . . ......... .......... ...-..'.- ............ 7
2: Top U.S. Iron and Steel Producers .........'.. •'. ............. ', .   . . .'. ....... 8
3: Iron and Steel Manufacturing Process Overview ." ..... ....... ........... . . .   15
4: Iron and Steel Manufacturing Cokemaking and Ironmaking  ........  ...........   19
5 : Iron and Steel Manufacturing Steelmaking .............. ..... .......... .1 .   21
6: Source Reduction and Recycling Activity for Iron and Steel Industry
   (SIC 331) as Reported within TRI  .[. ...... ...... . , . ____ ........ ____ . ....   26
7: Releases for Iron and Steel Facilities! (SIC 33 1) in TRI, by Number of Facilities
   Reporting . . ...... . ------ .... ...(.. ....... . . .... ...... ____ ... . ____ . . /.   32
8: Transfers for Iron and Steel Facilities in TRI, by Number of Facilities Reporting . .   34
9: Top 10 TRI Releasing Iron and Steel] Facilities  ... ..... ,. . ...... ..... ..... . .   36
10: Top 10 TRI Releasing Facilities Reporting SIC 331 Operations ..... ...... ...   37
1 1 : Pollutant Releases (short tons/year); .............. ...... .......... ......   43
12: Summary of 1993 TRI Data: Releases and Transfers by Industry  ...... .......   45
13: Toxics Release Inventory Data for Selected Industries .......... ....... .....   46
14: Five- Year Enforcement and Compliance Summary for Iron and Steel   . . . . . ....   80
15: Five- Year Enforcement and Compliance Summary for Selected Industries  . . ...   82
16: One- Year Inspection and Enforcemnt Summary for Selected Industries  .......   83
17: Five- Year Inspection and Enforcement Summary by Statute, Selected Industries .
18: One- Year Inspection and Enforcement Summary by Statute, Selected Industries
1 9 : F Y- 1 993 - 1 994 Supplemental Environmental Proj ects Overview:
   Iron and Steel Manufacture
20: SIC 331 Facilities Participating in the EPA's 33/50 Program		  91
      84
      85

      86
September 1995
                                  in
SIC 331

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Sector Notebook Project
                   Iron and Steel Industry
                                 List of Acronyms

AFS-       AIRS Facility Subsystem (CAA database)
AIRS -      Aerometric Information Retrieval System (CAA database)
BIFs -       Boilers and Industrial Furnaces (RCRA)
BOD-      Biochemical Oxygen Demand
CAA-      Clean Air Act
CAAA-     Clean Air Act Amendments of 1990
CERCLA -  Comprehensive Environmental Response, Compensation and Liability Act
CERCLIS-  CERCLA Information System
CFCs-      Chlorofiuorocarbons    ,
CO-        Carbon Monoxide
COD-      Chemical Oxygen Demand
CSI-       Common Sense Initiative
CWA-      Clean Water Act                           ,
D&B -      Dun and Bradstreet Marketing Index
ELP-       Environmental Leadership Program
EPA-       United States Environmental Protection Agency
EPCRA-   Emergency Planning and Community Right-to-Know Act
FIFRA-     Federal Insecticide, Fungicide, and Rodenticide Act               :
FINDS-     Facility Indexing System
HAPs-     "Hazardous Air Pollutants (CAA)
HSDB -     Hazardous Substances Data Bank
IDEA-     Integrated Data for Enforcement Analysis
LDR-      Land Disposal Restrictions (RCRA)
LEPCs-     Local Emergency Planning Committees
MACT-    Maximum Achievable Control Technology (CAA)
MCLGs -   Maximum Contaminant Level Goals
MCLs -     Maximum Contaminant Levels
MEK-      Methyl Ethyl Ketone
MSDSs-   Material Safety Data Sheets
NAAQS  -   National Ambient Air Quality Standards (CAA)
NAFTA -   North American Free Trade Agreement
NCDB-     National Compliance Database (for TSCA, FIFRA, EPCRA)
NCP -      National Oil and Hazardous Substances Pollution Contingency Plan
NEIC-     National Enforcement Investigation Center
NESHAP-  National Emission Standards for Hazardous Air Pollutants
NO2-       Nitrogen Dioxide                                           •
NOV-      Notice of Violation
NOX -      Nitrogen Oxide
NPDES -   National Pollution Discharge Elimination System (CWA)
NPL-      National Priorities List
NRC -      National Response Center        "
 September 1995
IV
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Sector Notebook Project
                                                 Iron and Steel Industry
NSPS-
OAR-
OECA-
OPA-
OPPTS-
OSHA-
OSW -
OSWER-
OW-
P2-
PCS-
POTW -
RCRA-
RCRIS-
SARA-
SDWA -
SEPs-
SERCs-
SIC-
SO2 -
SOX-
TOC-
TRI-
TRIS -
TCRIS-
TSCA -
TSS -
UIC-
UST-
VOCs-
New Source Performance Standards (CAA)
Office of Air and Radiation
Office of Enforcement and Comp
iance Assurance
Oil Pollution Act
Office of Prevention, Pesticides, sjnd Toxic Substances
Occupational Safety and Health Administration
Office of Solid Waste
Office of Solid Waste and Emergency Response
Office of Water
Pollution Prevention
Permit Compliance System (CWA Database)
Publicly Owned Treatments Works
Resource Conservation and Recovery Act
RCRA Information System     |
Superfund Amendments and Reaikthorization Act
Safe Drinking Water Act       j
Supplementary Environmental Projects
State Emergency Response Commissions
Standard Industrial Classification!
Sulfur Dioxide
Sulfur Oxides
Total Organic Carbon
Toxic Release Inventory
Toxic Release Inventory System
Toxic Chemical Release Inventory System
Toxic Substances Control Act
, Total Suspended Solids
Underground Injection Control (SDWA)
Underground Storage Tanks (RCRA)
Volatile Organic Compounds
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Sector Notebook P.yojject
Iron and SteeJ Industry
I. INTRODUCTION TO THE SECTOR NOTEBOOK PROJECT

LA. Summary of the Sector Notebook Project j

                    Environmental policies based upon comprehensive analysis of air, water and
                    land pollution are an inevitable and logical supplement to traditional single-
                    media approaches to environmental protection.  Environmental regulatory
                    agencies are beginning to embrace comprehensive, multi-statute solutions to
                    facility permitting,  enforcement and  compliance  assurance, education/
                    outreach, research, and regulatory development issues. The central concepts
                    driving  the  new policy direction are  that pollutant  releases to  each
                    environmental medium (ajir, water and land) affect each other, and that
                    environmental strategies ijnust actively identify and address these  inter-
                    relationships by designing policies for the "whole" facility.  One way to
                     achieve a whole facility focus is to design environmental policies for similar
                     industrial facilities. By doing so, environmental concerns that are common
                    to  the  manufacturing  of similar products  can  be  addressed  in  a
                     comprehensive manner.  Recognition of the need to develop the industrial
           ;          "sector-based" approach within the EPA Office of Compliance led  to the
           '          creation of this document.

                     The Sector Notebook. Project was  initiated by the Office of Compliance
                     within the Office of Enforcement and Compliance Assurance (OECA) to
                     provide its staff and managers with  summary information for eighteen
                     specific industrial sectors!.   As other EPA offices, states, the  regulated
                     community, environmental groups, and the public became interested  in this
                     project, the scope of the original project was expanded. The ability to design
                     comprehensive,  common  sense environmental protection  measures for
                     specific industries is dependent on knowledge of several inter-related topics.
                   .  For the purposes of this project, the key elements chosen for inclusion are:
                     general  industry information (economic  and geographic); a description of
                     industrial processes; pollution outputs; pollution prevention opportunities;
                     Federal statutory and regulatory framework; compliance history;  and a
                     description of partnerships that have been formed between regulatory
                     agencies, the regulated cormnunity and the public.

                     For any given industry, each topic listed above could alone be the subject of
                     a lengthy volume. However,  in order to produce a manageable document,
                     this project focuses on providing summary information for each topic. This
                     format provides the reader with a synopsis of each issue, and references
                     where more in-depth information is available. Text within each profile was
                     researched from a variety of sources, and  was usually condensed from more
                     detailed sources pertaining to specific topics.  This approach allows for a
                     wide  coverage of activities that can be further explored based upon the
                     citations and references listed at the end of this profile.  As a check on the
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 Sector Notebook Project
Iron and Steel Industry
                     information included,  each notebook went through an external  review
                     process.  The Office of Compliance appreciates the efforts of all those that
                     participated in this process and enabled us to develop more complete,
                     accurate  and up-to-date summaries.  Many of those who reviewed this
                     notebook are  listed as contacts in Section IX and may be sources  of
                     additional information. The individuals and groups on  this list  do not
                     necessarily concur with all statements within this notebook.

 I.B. Additional Information

 Providing Comments

                     OECA's  Office of Compliance plans to periodically review and update the
                     notebooks and will make  these updates available both  in hard copy and
                     electronically.  If you have any comments on the existing notebook, or if you
                     would like to provide additional information, please send a hard copy and
                     computer disk to the EPA Office of Compliance, Sector Notebook Project,
                     401 M St., SW (2223-A), Washington, DC 20460.  Comments can also be
                     uploaded to the Enviro$en$e Bulletin Board or the Environ$ense  World
                     Wide Web for general access to all users of the system. Follow instructions
                     in Appendix A for accessing these data systems. Once you have logged in,
                     procedures for uploading text are available from the on-line Enviro$en$e
                     Help System.

 Adapting Notebooks to Particular Needs

                     The scope of the existing notebooks reflect an approximation of the relative
                     national occurrence of facility types that occur within each sector.  In many
                     instances, industries within specific geographic regions or states may have
                     unique characteristics that are not fully captured in these profiles.  For this
                     reason, the Office of Compliance encourages state and local environmental
                     agencies and other groups to supplement or re-package the information
                     included in this notebook to include more specific industrial and regulatory
                     information that may be  available.  Additionally, interested states may want
                     to  supplement the  "Summary  of  Applicable  Federal  Statutes  and
                     Regulations" section with  state and local requirements.  Compliance or
                     technical  assistance providers  may also  want to develop the "Pollution
                     Prevention" section in more detail. Please contact the appropriate specialist
                     listed on the opening page of this notebook if your office is interested in
                     assisting  us  in the  further development of the information or  policies
                     addressed within this volume. If you are interested in assisting  in the
                     development of new notebooks for sectors not covered in the  original
                     eighteen, please contact  the Office of Compliance at 202-564-2395.
September 1995
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Sector Notebook Project
                                             Iron and. Steel Industry
II. INTRODUCTION TO THE IRON AND STEEL INDUSTRY
                     This section provides background information on the size,  geographic
                     distribution, employment, production, sales, and economic condition of the
                     iron and steel industry. The type of facilities described within the document
                     are also described in terms of their Standard Industrial Classification (SIC)
                     codes.  Additionally, this section contains a list of the largest companies in
                     terms of sales.

II.A. Introduction, Background, and Scope of the Notebook
                     The iron and steel industry
                     the  Standard Industrial
                        is categorized by the Bureau of the Census under
                        Classification  (SIC) code  33, primary  metal
industries.  The industry 13 further classified by the three-digit codes 331,
Steel Works, Blast Furnaces, and Rolling and Finishing Mills, and 332 Iron
and Steel Foundries.  Since steel works, blast furnaces, and rolling  and
finishing  mills  account  for the  majority of  environmental releases,
employees, and value of s|hipments, this profile concentrates on the three-
digit SIC 331.  The environmental releases associated with foundries are
similar to the steel casting!and finishing processes included under SIC 331,
                     therefore SIC 332, will not
                     the profile focus specifica
                        be addressed in this notebook.  Some sections of
                        ly on industries in the four-digit SIC 3312, since
                     virtually all establishments producing primary products (iron and steel) under
                     SIC 3312, also produce secondary products that fall under some of the other
                     iron and steel SIC codes under SIC 331.           ,
 II.B. Characterization of the Iron and Steel Industry

       II.B.l. Industry Size and Geographic Distribution
                     There are approximately
                         1,118  manufacturing facilities under SIC  331
                     according to 1992 Census of Manufactures data.1  The payroll totaled $9.3
                     billion for a workforce of 241,000 employees, and value of shipments totaled
                     $58 billion.  Net shipments of steel mill products for all grades including
                     carbon, alloy, and stainless totaled 92.7 million net tons in 19932 and 95.1
                     million net tons in 1994J3   In terms of environmental issues, value of
                     shipments, and number of employees, SIC  3312 (Blast Furnaces and Steel
                     Mills), is the most significant  four-digit code under SIC 331.  The 1992
                     Census data reported 247 establishments under SIC 3312, with an estimated
                     172,000 employees, a payroll of $7 billion, and a value of shipments totaling
                     $42 billion.  For the same year, the American  Iron and Steel Institute
                     estimated 114 companies operated 217 iron and steel facilities; this estimate
                     included any facility with one or more iron  or steelmaking operation.4
                     The 1987 Census of Manufactured further categorizes SIC 3312 by the type
 September 1995
                        I
. SIC 331

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Sector Notebook Project
Iron and Steel Industry
                     of steel mill: integrated or non-integrated.  A fully  integrated facility
                     produces steel from  raw materials of coal, iron ore,  and scrap.   Non-
                     integrated plants do not have all of the equipment to produce steel from coal,
                     iron ore, and scrap on-site, instead they purchase some of their raw materials
                     in a processed form.               '
       SIC Diversity
                     The Bureau of the Census categorizes the three- and four-digit SIC codes
                     related to iron and steel as follows:

                     SIC 331 - Steel works, blast furnaces, coke ovens, rolling and finishing mills
                            3312 - Steel works, blast furnaces, and rolling mills
                            3313 - Electrometailurgical products, except steel
                            3315 - Steel wiredrawing and steel nails and spikes
                            3316 - Cold-rolled steel sheet, strip, and bars
                            3317 - Steel pipe and tubes

                     The remainder of the industries! classified under  SIC code 33 cover the
                     ferrous and non-ferrous foundriejs, and smelting, refining,  and shaping of
                     nonferrous metals which are not covered in this profile.
       Two Steel Industries
                     In the past fifteen years, the U.S. steel industry has lost over 61 percent of its
                     employees and 58 percent of its facilities.  Slow growth in demand for steel,
                     markets lost to other materials, increased imports, and older, less efficient
                     production facilities are largely to blame for the industry's decline.  While the
                     integrated steel industry was contracting,  a group of companies, called
                     minimills, more than doubled their capacity in the same period and they
                     continue to expand into new markets.  Minimills use electric arc furnaces
                     (EAFs) to melt scrap and other materials  to make steel products,  instead of
                     using coke, iron ore, and scrap as the integrated producers do.  In addition to
                     fundamentally different production technologies, other differences between
                     the integrated steel mills and minimill are also significant: minimills have
                     narrow product lines, they often have small, non-unionized work forces that
                     may receive higher pay per hour than a comparable unionized work force, but
                     without union benefits. Additionally, minimills typically produce much less
                     product per facility (less than  1 million tons of steel per year).  Lower scrap
                     prices in the 1960s and 1970s created opportunities for the minimill segment
                     of the market to grow rapidly. Initially, the EAF technology could only be
                     used in the production of low quality  long products,  such  as concrete
                     reinforcing bar, but over the years minimill products have improved in
                     quality and have  overcome  technological  limitations to diversify their
                     product lines. Recently, minimills have entered new markets, such as flat-
September 1995
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Sector Notebook Project
                      Iron and Steel Industry
                     rolled products, however!, more than half of the market for quality steel
                     products still remains beyond miriimill capability.  The EAF producers do
                     face the problems of fluctuating scrap prices which are more volatile than the
                     prices of raw materials used by integrated producers.
       Geographic Distribution
                     The highest geographic concentration of mills is in the Great Lakes region,
                     where most integrated plants are based (Exhibit 1).  According to the 1987
                     Census of 'Manufactures,|46 percent of steel mills are located in six Great
                     Lakes states: New York, P'ennsylvania, Ohio, Indiana, Illinois, and Michigan,
                     with a heavy concentration of steel  manufacturing in the Chicago area.
                     Approximately 80 percentiof the U.S. steelmaking capacity is in these states.
                     The South is the next largest steel-producing region, although there are only
                     two integrated steel plants  Steel production in the western U.S. is limited to
                     one integrated plant and several minirnills. historically, the mill sites were
                     selected for their proximity to water (tremendous amounts are used  for
                     cooling and processing, and for transportation) and the sources of their raw
                     materials, iron ore and coal. Traditional steelmaking regions included the
                     Monongahela River valley near Pittsburgh and along the Mahoning River
                     near Youngstown,  Ohio, f  The geographic concentration of the industry
                     continues tp change as minimills are built anywhere electricity and scrap are
                     available at a reasonable cost and there is a local market for a single product. •
       Size Distribution
                     Large, fully-integrated ste el mills have suffered considerably in the last 15
                     years, largely due to loss qf market share to other materials, competition, and
                     the  high cost of pension liabilities.   In comparing the 1992 Census of
                     Manufacture data with the data from 1977, these changes are clear. While
                     the number of establishments under SIC  3312 fell by 58 percent from 504
                     facilities in 1977 to 247 in 1992, the absolute number of integrated mills has
                     always been small, and the reduction is largely due to a drop in the number
                     of small establishments.  A more relevant statistic is the reduction in
                     employees during the same time period. The work force for these facilities
                     was dramatically reduced as plants closed or were reorganized by bankruptcy
                     courts.  Those that remained open automated,and streamlined operations
                   .  resulting in a 61 percent reduction in the number of production employees
                     over the same 15 year period. Approximately 172,000 were still employed
                     in SIC 3312 establishments in 1992.

                     The 1987 Census of Manufactures breaks the SIC code 3312 down into four
                     sub-industries: Fully-integtated (consists of coke ovens, blast furnaces, steel
                     furnaces, and rolling and finishing mills), partially integrated with blast
                     furnace (consists of blast
furnaces, steel furnaces, and rolling and finishing
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                     mills), partially integrated without blast furnaces (consists of steel furnaces
                     and either rolling and finishing mills or a forging department; includes mini
                     mills), and non-integrated (all others, including  stand-alone rolling and
                     finishing mills, and stand-alone coke plants). This division highlights some
                     important characteristics about the size of facilities in this industry. Only 8
                     percent (20 plants) of the establishments under SIC 3312 in 1987 were folly
                     integrated mills.  However, 46 percent of the industry's employees worked
                     in these 20 plants.
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                  Iron and Steel Inciusfay
       Exhibit 1: Geographic Distribution of
                  Blast Furnaces, and Rolling
SIC 331 Establishments: Steel Works,
and Finishing Mills
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 Top Steel Producers
                      Market Share Reporter, published by Gale Research Inc., annually compiles
                      reported market share data on companies, products, and services. The 1995
                      edition ranks top U.S. steel producers by 1993 sales in millions of dollars, as
                      shown in Exhibit 2.
Exhibit 2: Top U.S. Iron and Steel Producers
Rank
1
2
3
4
5
6
7
8
Company
US Steel Group - Pittsburgh, PA
Bethlehem Steel Corp. - Bethlehem, PA
LTV Corp. - Dallas, TX . • -
National^ Steel Corp. - Pittsburgh, PA
Inland Steel Industries, Inc. - Chicago, IL
Armco Inc. - Parsippany, NJ
Weirton Steel Corp. - Weirton, WV
Wheeling-Pittsburgh Steel - Pittsburgh, PA
1993 Sales
(millions of dollars)
5,422
4,219
3,868
2,418
2,175
1,595
1,201
1,047
Source: Market Share Reporter, 1995,
       H.B.2. Product Characterization
                     The iron and steel industry produces iron and steel mill products, such as
                     bars, strips, and sheets, as well as formed products such as steel nails, spikes,
                     wire,  rods,  pipes, and non-steel  electrometallurgical products such  as
                     ferroalloys. Under SIC 3312, Blast Furnaces and Steel  Mills, products also
                     include coke, and products derived from, chemical recoveiy in the coking
                     process such as coal tar and distillates.

                     Historically, the automotive and construction sectors  have been the two
                     largest steel consuming industries.  Consequently, fluctuations in sales and
                     choice of materials in these industries have a significant impact on the iron
                     and steel industry.  Over the last two  decades,  the structure of the
                     steelmaking industry has changed  dramatically  due to new technologies,
                     foreign competition, and loss of market share to other materials.  Many of the
                     large, fully-integrated facilities have closed, and those that are still operating,
                     have reduced their workforce, increased automation, and invested in new
                     technologies to remain competitive.
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       II.B.3. Economic Trends
       Domestic Market
                     After years of collapsing iriarkets, bankruptcies, mill closings and layoffs, the
                     steel industry experienced a turnaround in 1993.  Shipments were at their
                     highest level since 1981.6 For the first time since 1989, steelmakers were
                     able to boost their prices. This increase in demand is due in part to the weak
                     dollar, which makes importing foreign steel more expensive than it used to
                     be.  The relatively high level of shipments was also attributable to a strong
                     demand from the steel industry's two largest customers - the automotive and
                     construction sectors.7  Recently, prices  for steel sold to the automotive -
                     industry have been  set in long-term contracts.  The prices set  in the
                     automotive contracts tend to influence the steel prices of other contract
                     negotiations, such as thosejwith appliance manufacturers. Overall, more than
                     half of all steel sold in the U.S. is, covered by long-term contracts; the rest is
                     sold on the spot market.
       International Trade
                     Problems in international
steel trade intensified in the last 5 years due in
                     large part to a worldwide weakening in demand.  With the exception of
                     China, where rapid economic growth has led to a steady increase in steel
                     demand, the  export market has been weak.   The "voluntary restraint
                     arrangements" that limitedj imports in the 1980s expired in 1992. Since then,
                     the U.S. steel industry has discouraged imports by filing complaints that
                     products are being dumped - sold at less than the cost of production.  Similar
                     cases have also been filed against U.S. exporters.  To address the problems
                     of unfairly traded steell  most  major steel-producing countries  have
                     participated in multilateral steel agreement (MSA) negotiations under the
                     General Agreement on Tariffs,and Trade (GATT).8
                     Steel imports for 1992 tote led 15.2 million metric tons. From 1989 to 1993,
                     the quantity of steel imported was fairly consistent, from 15.7 million metric
                     tons in 1989 to 15.3 million metric tons estimated for 1993. The exception
                     is a slight dip to 14.3 million metric tons in 1991. The forecast for 1994, at
                     16.3 million metric tons, is a more significant increase than has been seen in
                     the last five years. The export market has seen slightly more variability over
                     the same time period, withj a high of 5.7 million metric tons exported in 1991,
                     and 3.8 million metric tons in exports forecast for 1994.9
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       Labor
                     According to 1992 Census of Manufactures, there were an estimated 172,000
                     people employed in SIC 3312 industries, with a payroll of $7 billion. This
                     was a 61 percent decrease from 1977 levels of 442,000 employees, and a
                   ,  42% reduction from 1982 levels of 295,000 employees.  This dramatic
                     reduction hi workforce was primarily due to reductions at the large integrated
                     facilities.  For example, the U.S. Steel plant in Gary, Indiana, employed
                     30,000 people during the plant's peak employment in 1953. In 1992, there
                     were about 8,000 employees working at the 4,000-acre facility.

                     This reduction in workforce, coupled with investments in new equipment,
                     automation, and management restructuring has resulted in the increased
                     productivity that was essential for integrated mills to remain competitive in
                     the face of the severe competitive pressures both from EAF producers in the
                     U.S. and from abroad. With these changes, the U.S. industry has become one
                     of the lowest-cost producers  in the  developed world.   Productivity in
                     steelmaking is often measured in man-hours per ton of finished steel.  For
                     every ton produced, American steelmakers spend 5.3 man-hours, compared
                     with 5.6 for the Japanese and Canadian industries, and 5.7 for the British,
                     French, and Germans.  The increase in  productivity is also reflected in
                     changes  in the value added by manufacture, as reported by the  Census.
                     During the ten year period where employment in the industry dropped by
                     42% (1982 - 1992), the value added by manufacture increased by 39% from
                     $11.8 million in 1982 to $16.5 million in 1992.

                     Problems from such a sizable workforce reduction persist. The industry says
                     one big  cost is "legacy costs"  - obligations to pay pensions and health
                     benefits  to  the tens of thousands  of retirees  and their spouses.   Some
                     integrated companies have five retired workers for every active employee.
                     For many of the large, integrated facilities, these pensions are underfinanced.
                     Of the 50 most underfinanced pension plans, five are in the steel industry.
                     This puts the newer minimills, who do not have such legacy costs, at a clear
                     competitive advantage.

                     hi addition to pension payments, major U.S. steel producers are now paying
                     out an average $5.30 per hour worked, 17 percent of total hourly employment
                     costs, for health care.  The industry argues that these high costs place it at a
                     disadvantage with its major foreign competitors, some of whom pay no direct
                     health care expenses.
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       Long-term Prospects
                     Production of steel products in 1993 totaled 89.0 million net tons which
                     represents an 89.1 percent! capacity utilization. Shipments for 1994 rose to
                    .95.1 million net tons and it is forecasted that demand will stay high, with
                     industry capacity utilization increasing through 1995.16  After years of losing
                     market share to other materials, steel appears to be regaining a competitive
                     position.  In the automotive market, some parts that were recently made of
                     plastic, such as fenders, roofs, and hoods, are being returned to steel.  The
                     decades-long downtrend in steel content in automobiles appears to  have
                     slowed and recently has actually reversed.  According to Ford Motor
                     Company, the average vehicle built in 1993 contained 1,726 pounds of steel,
                     up from  1,710 pounds in 1992, marking the second consecutive yearly
                     increase.  A further increase is anticipated in 1994 due to new and expanding
                     applications of steel. In
                     sector, the residential construction sector is a potentially rich market for steel
                     producers.  Steel framing
                     high strength alternative 13 wood framing.  A galvanized steel frame for a
                     2,000 square foot house would weigh approximately one-fourth the weight
                     of a lumber structure.
ddition to increased orders from the automotive
for houses is being promoted as a light-weight,
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                                              [ •
 III. INDUSTRIAL PROCESS DESCRIPTION
                      This section describes the major industrial processes within the iron and steel
                      industry, including the materials and equipment used, and the processes
                      employed.  The section is designed for those interested in gaining a general
                      understanding of the  industry,  and for those  interested in the inter-
                      relationship between the industrial process and the topics described in
                      subsequent sections of this profile - pollutant outputs, pollution prevention
                      opportunities, and Federal (regulations.   This section does not attempt to
                      replicate published engineering information that is available for this industry.
                      Refer to Section IX for a list of reference documents that are available.
                        ..       i   '.    -        •          ,     •'''•'.....
                      This section specifically contains a description of commonly used production
                      processes, associated raw materials, the byproducts produced or released, and
                      fhe'materials either recycled or transferred off-site.  This discussion, coupled
                      with schematic drawings of the identified  processes, provide a concise
                      description of where wasteb may be produced in the process. This  section
                     also describes the potential
                     waste products.
   fate (via air,'water, and soil pathways) of these
 III.A. Industrial Processes in the Iron and Steel Industry
                                    •          I       •
                     In view of the high cost of most new equipment and the relatively long lead
                     time necessary to bring new equipment online in the steel industry, changes
                     in production methods and products in the steel industry are typically made
                     gradually. Installation of major pieces of new steelmaking equipment may
                     cost millions of dollars and require additional retrofitting of other equipment.
                     Even new process technologies that fundamentally improve productivity,
                     such as the continuous casting process (described below), are adopted only
                     over long periods of time.  "'              ~
                     steel  industry, the ability
                     equipment is limited.

                     Environmental legislation is
                     more efficient steelmaking ^
                     substitute materials are  forcing steelmakers' to invest in cost-saving and
                     quality enhancing technologies.  In the long term, the steel industry will
                     likely  continue  to  move! towards more  simplified  and  continuous
                     manufacturing technologies) that reduce the capital  costs for new mill
                     construction and allow smaljler mills to operate efficiently. The companies
                     that excel will be.those that have the resources and foresight to invest in such
                     technologies.
   Given the recent financial performance of the
   ;o  raise the capital needed  to purchase  such


   challenging the industry to develop cleaner and
   processes at the same time  competition from
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                    Steel is an alloy of iron usually containing less than one percent carbon. The
                    process of steel production occurs in several sequential steps (Exhibit 3).
                    The two types of steelmaking technology in use today are the basic oxygen
                    furnace (EOF) and the electric arc furnace  (EAF).  Although these two
                    technologies use different input materials, the output for both furnace types
                    is molten steel which is subsequently formed into steel mill products. The
                    EOF input materials are molten iron, scraprand  oxygen.  In the EAF,
                    electricity and scrap are the input materials used. BOFs are typically used
                    for high tonnage production of carbon steels, while EAFs are used to produce
                    carbon steels and low tonnage alloy  and specialty steels. The processes
                    leading up to  steelmaking  in a EOF are very different than  the steps
                    proceeding steelmaking in an EAF; the steps after each of these processes
                    producing molten steel are the same.

                    When making steel using a EOF, cokemaking and ironmaking precede
                    steelmaking; these steps are not needed for steelmaking with an EAF. Coke,
                    which is the fuel and carbon source, is  produced by heating costl in the
                    absence of oxygen at high temperatures in  coke ovens.  Pig iron is then
                    produced by heating the coke, iron ore, and limestone in a blast furnace. In
                    the EOF, molten iron from the blast furnace is combined with flux and scrap
                     steel where high-purity oxygen is injected. This process, with cokemaking,
                     ironmaking, steelmaking, and subsequent forming and finishing operations
                     is referred to as fully integrated production.  Alternatively, in an  EAF, the
                     input material is primarily scrap steel, which is melted and refined by passing
                     an electric current from the electrodes through the scrap.  The molten steel
                     from either process is formed into ingots or slabs that are rolled into finished
                     products.  Rolling operations may require reheating, rolling, cleaning, and
                     coating the steel.  A description of both steelmaking processes follows:
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       III.A.l. Steelmaking Using the Basic Oxygen Furnace

                    The process of making steel in a Basic Oxygen Furnace (BOF) is preceded
                    by cokemaking and ironmaking operations. In cokemaking, coke is produced
                    from coal.  In ironmaking, molten iron is produced from iron ore arid coke.
                    Each of these processes and the subsequent steelmaking process in the BOF
                    are described below.

                    Cokemaking
                    Coal processing in the iron, and steel industry typically involves producing
                    coke, coke gas and by-product chemicals from compounds released from the
                    coal during the cokemaking process (Exhibit 4). Coke is carbon-rich and is
                    used as a carbon source and fuel to heat and melt iron ore in ironmaking.
                    The cokemaking process starts with bituminous pulverized coal charge which
                    is fed into the coke oven through ports in the top of the oven. After charging,
                    the oven ports are sealed and the coal is heated at high temperatures (1600
                    to 2300°F), in the absence of oxygen. Coke manufacturing is done in a batch
                    mode where each cycle lasts for  14 to 36 hours.  A coke oven battery
                    comprises a series of 10 to 100 individual ovens, side-by-side, with a heating
                    flue between each oven pair. Volatile compounds are driven from the coal,
                    collected from each oven, and processed for recovery of combustible gases
                    and other coal byproducts.11 The solid carbon remaining in the  oven is the
                    coke.  The necessary heat for distillation is supplied by external combustion
                    of fuels (e.g., recovered coke oven gas, blast furnace gas) through flues
                    located between ovens.12  At the end of the heating cycle, the coke is pushed
                    from the oven into a rail quench car.  The quench car takes it to  the quench
                    tower, where the hot coke is cooled with a water  spray.  The coke is then
                     screened and sent to the blast furnace or to storage.

                     In the by-products recovery process, volatile components' of the coke oven
                     gas stream are recovered including the coke oven gas itself (which is used as
                     a fuel for the coke oven), naphthalene, ammonium compounds, crude light
                     oils, sulfur compounds, and coke breeze (coke  fines).  During the coke
                     quenching, handling, and screening operation, coke breeze is produced.
                     Typically, the coke breeze is reused in other manufacturing processes on-site
                     (e.g., sintering) or sold off-site as a by-product.13

                     The cokemaking process is  seen by  industry experts as one of the steel
                     industry's areas of greatest environmental concern, with air emissions and
                     quench water as major  problems.   In efforts to  reduce  the emissions
                     associated with cokemaking, U.S. steelmakers are turning to technologies
                     such as pulverized coal injection, which substitutes coal for coke in the blast
                     furnace. Use of pulverized coal injection can replace about 25 to 40 percent
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                      of coke in the blast furndce, reducing the amount of coke required and the
                      associated emissions. Stejel producers also inject other fuels, such as natural
                      gas, oil, and tar/pitch to Replace a portion of the coke.

                      Quench water from cokeiiiaking is also an area of significant environmental
                      concern. In Europe, some plants have implemented technology to shift from
                      water quenching to dry quenching which eliminates suspected carcinogenic
                      particulates and VOCs. However, major construction changes are required
                      for such a solution and considering the high capital costs of coke batteries,
                      combined with the depressed state of the steel industry and increased
                      regulations for cokemaking,  it  is unlikely that  new facilities will be
                      constructed. Instead, industry experts expect to see an increase in the amount
                      of coke imported.

                      Ironmaking
                      In the blast furnace, moltejn iron is produced (Exhibit 4).  Iron ore, coke, and
                      limestone are fed into the top of the blast furnace. Heated air is forced into
                      the bottom of the furnace through a bustle pipe and tuyeres (orifices) located
                      around the circumference; of the furnace.  The carbori monoxide from the
                      burning of the coke reduces iron ore to iron.  The acid part of the ores reacts
                      with the limestone to create a slag which is drawn periodically from the
                      furnace.  This slag contaibs  unwanted impurities in the ore, such as sulfur
                      from the fuels. When the furnace is tapped, iron is removed through one set
                      of runners and molten slag  via another. The molten iron is tapped  into
                      refractory-lined cars for transport to the steelmaking furnaces.  Residuals -
                      from .the process are mainly sulfur dioxide or hydrogen sulfide,  which are
                      driven off from the hot slag. The slag is the largest by-product generated
                      from the ironmaking process and is reused extensively in the construction
                      industry.14  Blast furnace flue gas is cleaned and used to generate steam to
                     preheat the air coming intjo the furnace, or it may be used to supply heat to
                     other plant processes. The cleaning of the gas may generate air pollution
                     control dust in removing coarse particulates (which may be reused in the
                     sintering plant or landfilled), and water treatment plant sludge in removing
                     fine particulates by venturi scrubbers.

                     Sintering is the process that agglomerates fines (including iron ore fines,
                     pollution control dusts,  cbke breeze, water treatment plant sludge, coke
                     breeze, and flux) into a porous mass for charging to the blast  furnace.15
                     Through sintering operations, a mill can  recycle iron-rich material, such as
                     mill scale and processed slag.  Not all mills have sintering capabilities. The
                     input materials are mixed together, placed on a slow-moving  grate and
                     ignited. Windboxes under jthe grate draw air through the materials  to deepen
                     the combustion throughout the traveling length of the grate.  The coke breeze
                     provides the carbon source for sustaining the controlled combustion. In the
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                     process, the fine materials are fused into the sinter agglomerates, which can
                     be reintroduced into the blast furnace along with ore. Air pollution control
                     equipment removes the particulate matter generated during the thermal fusing
                     process. For wet scrubbers, water treatment plant sludge are generally land
                     disposed waste. If electrostatic precipitators or baghouses are used as the air
                     pollution control equipment, the dry particulates captured  are typically
                     recycled as sinter feedstock, or are landfilled as solid waste.

                     Steelmaking Using the Basic Oxygen Furnace
                     Molten iron from the blast furnace, flux, alloy .materials, and scrap are placed
                     in the  basic oxygen furnace, melted and refined by injecting high-purity
                     oxygen.  A chemical reaction occurs, where the oxygen reacts with carbon
                     and silicon generating the heat necessary to melt the scrap and oxidize
                     impurities. This is a batch process with a cycle time of about 45 minutes.
                     Slag is produced from impurities removed by the combination of the fluxes
                     with the injected oxygen.  Various alloys are added to produce different
                     grades of steel. The molten steel is typically cast into slabs, beams or billets.

                     The waste products from the basic oxygen Steelmaking process include slag,
                     carbon monoxide, and oxides of iron emitted as dust. Also, when the hot iron
                     is poured into ladles or the furnace, iron oxide fumes are released and some
                     of the carbon in the iron is precipitated as graphite (kish). The BOF slag can
                     be processed to recover the high metallic portions for use in sintering or blast
                     furnaces, but its applications as a saleable construction materials are more
                     limited than the blast furnace slag.

                     Basic  oxygen furnaces are equipped with air pollution control systems for
                     containing, cooling, and cleaning the volumes of hot gases and sub-micron
                     fumes that are released during the process. Water is used to quench or cool
                     the gases and fumes to temperatures at which they can be effectively treated
                     by the gas cleaning  equipment.  The resulting waste streams from  the
                     pollution control  processes include air pollution control dust and water
                     treatment plant sludge. About 1,000 gallons of water per ton of steel (gpt)
                     are used for a wet scrubber. The principal pollutants removed from the off-
                     gas are total suspended solids and metals (primarily zinc, and some lead).16
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               (9


               £
               2 a
             m


             iuiui
             UJ UJ UJ

               (A CO

               Q
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         III.-A.2. Steelmaking Using the Electri
                         : Arc Furnace (EAF)

 In the steelmaking process that uses  an electric arc furnace  (EAF), the
 primary raw material is jjcrap metal, which is melted and refined using
 electric energy.   During  melting,  oxidation of phosphorus,  silicon,
 manganese; carbon and other materials occurs and a slag containing some of
 these oxidation products fcfahs on top of the molten metal.17 Oxygen is used
 to decarburize the molten steel and to  provide thermal energy.  This is a
 batch process with a cycle time of about two to three hours.  Since scrap
 metal is used instead of molten iron, there are no cokemaking or ironmaking
                      operations associated with
                         steel production that uses an EAF.
                      The process produces metal dusts, slag, and gaseous products. Particulate
                      matter and  gases evolve together during the steelmaking process and are
                      conveyed into a gas cleaning system. These emissions are cleaned using a
                     .wet or dry system.  The particulate matter that is removed as emissions in the
                      dry system  is referred to as EAF dust, or EAF sludge if it is from a wet
                      system' and  it is a listed hazardous waste (RCRAK061).  The composition
                      of EAF  dust can  vary greatly depending  on the scrap  composition and
                      furnace additives. The primary component is iron or iron oxides, and it may
                      also contain flux (lime and/or fluorspar), zinc, chromium and nickel oxides
                      (when stainless  steel is being produced) and other metals associated with the
                      scrap. The two primary hazardous constituents of EAF emission control dusf
                      are lead and cadmium.18  Generally, 20 pounds of dust per ton of steel is
                     expected, but as much as 40 pounds of dust per ton of steel may be generated
                     depending on production practices. 19  Oils are burned off "charges" of oil-
                     bearing scrap in the furnace. Minor amounts of nitrogen oxides and ozone '-
                     are generated during the melting process. The furnace is extensively cooled
                     by water; however, this water is recycled through cooling towers.
        III. A.3. Forming and Finishing Operations
Whether the molten steel is
into a product, it must be solidified
                                              produced using a EOF or an EAF, to convert it
                                                    " into a shape suitable and finished,
                     Forming
                     The traditional forming method, called ingot teeming, has been to pour the
                     metal into  ingot molds, allowing the steel to cool and  solidify.   The
                     alternative method of forming steel, called continuous casting accounted for
                     more 86% of raw steel produced in  the U.S. in  199220, compared with
                     approximately 30 percent in 1982.  The continuous casting process bypasses
                     several steps of the  conventional ingot  teeming process by casting steel
                     directly into semifinished shapes. Molten steel is poured into a reservoir
                     from which it is released intb the molds of the casting machine.  The metal
                    ;is cooled as it descends through the molds, and before emerging, a hardened
                     outer shell is formed.  As the semifinished shapes proceed on the runout
                    table, the center also solidifies, allowing the cast shape to be cut intb lengths.
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                     Process contact water cools the continuously cast steel and is collected in
                     settling basins along with oil, grease, and mill scale generated in the casting
                     process  The scale settles out and is removed and recycled for sintering
                     operations, if the mill has. a Sinter Plant. Waste treatment plant sludge is also
                     generated.21

                     The steel is further processed to produce slabs, strips, bars, or plates through
                     various forming operations. The most common hot forming operation is hot
                     rolling, where heated steel is passed between two rolls revolving in opposite
                     directions. Modern hot rolling units may have as many as 13 stands, each
                     producing an incremental reduction in thickness.  The final  shape and
                     characteristics of a hot formed piece depend on the  rolling temperature, the
                     roll profile, and the cooling process after rolling. Wastes generated from hot
                     rolling include waste treatment plant sludge and scale.

                     In subsequent cold forming,  the cross-sectional area of unheated steel is
                     progressively reduced in thickness as the steel passes through a series  of
                     rolling stands.  Generally, wires, tubes, sheet and strip  steel products are
                     produced  by cold rolling  operations.  Cold forming  is used to  obtain
                     improved mechanical properties, better machinability, special size accuracy,
                     and  the production  of thinner gages than  hot rolling  can accomplish
                      economically.22  During cold rolling, the steel becomes hard and brittle. To
                      make the steel more ductile, it is heated in an annealing furnace.

                      Process contact water is used as a coolant for rolling mills to keep the surface
                      of the steel clean between roller passes.   Cold rolling operations also
                      produce a waste treatment plant sludge, primarily  due to the lubricants
                      applied during rolling.  Grindings from resurfacing of the worn rolls and
                      disposal of  used rolls  can  be  a significant  contributor to  the  plant's
                      wastestream.

                      Finishing
                      One of the most important aspects of a finished product is the surface quality.
                      To prevent corrosion,  a protective  coating may  be applied to the steel
                      product.  Prior to coating, the surface of the steel must be cleaned so  the
                      coating will  adhere to the steel. Mill scale, rust, oxides, oil, grease, and soil
                      are chemically removed from the surface of steel using  solvent cleaners,
                      pressurized water or air blasting, cleaning with abrasives, alkaline agents or
                      acid pickling. In the pickling process, the steel surface is chemically cleaned
                      of scale, rust, and other materials. Inorganic acids such as hydrochloric or
                      sulfuiic acid are most commonly used  for pickling. Stainless steels  are
                      pickled with hydrochloric, nitric, and hydrofluoric acids.  Spent pickle liquor
                      may be a listed hazardous waste (RCRA K062), if it contains considerable
                      residual acidity and high concentrations of dissolved iron salts. Pickling
                      prior to coating may use a mildly acidic bath which is not  considered K062.
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                     Steel generally passes fijom the pickling bath through a series of rinses.
                     Alkaline cleaners may also be used to remove mineral oils and animal fats
                     and oils from the steel surface prior to cold rolling.  Common alkaline
                     cleaning agents include: caustic soda, soda ash, alkaline silicates, phosphates.

                     Steel products are often given a coating to inhibit oxidation and extend the
                     life of the product.  Coaied products can also be painted to further inhibit
                     corrosion. Common coating processes include: galvanizing (zinc coating),
                     tin coating, chromium coating, aluminizing, and terne coating (lead and tin).
                     Metallic coating application processes include hot dipping, metal spraying,
                     metal  cladding  (to  produce bi-metal  products),  and electroplating.
                     Galvanizing is a  common coating process where a thin layer of zinc is
                     deposited on the steel surface.
 III.B. Raw Material Inputs and Pollution Outputs
                     Numerous outputs are prjoduced as a result of the manufacturing of coke,
                     iron, and steel, the forming of metals into basic shapes, and the cleaning and
                     scaling of metal surfaces.  These outputs, categorized by process (RCRA
                     waste code provided whe
       Cokemaking

              Inputs:
•e applicable),, include:
                     1 Coal, heat, quench water
              Outputs:
                     • Process residues from coke by-product recovery (RCRA K143, K148)
                     • Coke oven gas by-products such as coal tar, light oil, ammonia liquor, and
                  ,   the remainder of the gas stream is used as fuel.  Coal tar is typically refined
                     to produce commercial and industrial products including pitch, creosote oil,
                     refined tar, naphthalene, and bitumen.
                     • Charging emissions (fine' particles of Coke generated during oven pushing,
                     conveyor transport, loading and unloading of coke that are captured by
                     pollution control equipment.  Approximately one pound per ton of coke
                     produced are captured anc[ generally land disposed).
                     • Ammonia, phenol, cyanide and hydrogen sulfide
                     • Oil (K143 and K144)          '
                     • Lime sludge, generated from the ammonia still (K060)
                     • Decanter tank tar sludge (K087)               <
                     • Benzene releases in coke by-product recovery operations
                     • Naphthalene residues, generated in the final cooling tower
                     • Tar residues (K035, K141, K142,  and K147)
                     • Sulfur compounds, emitted from the stacks of the coke ovens
                     • Wastewater from cleaning and cooling (contains zinc, ammonia still lime
              ,       (K060), or decanter tank tar (K087), tar distillation residues (K03 5))
                     • Coke oven gas condensate from piping and distribution  system; may be a
                     RCRA characteristic waste for benzene.
September 1995
                                    SIC 331

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Sector Notebook Project
                      Iron and Steel Industry
       Ironmaking

              Inputs:
                     • Iron ore  (primarily in the form of taconite pellets), coke, sinter, coal,
                     limestone, heated air
              Outputs:
                     •  Slag,  which is either sold as a by-product, primarily  for use  in the
                     construction industry, or landfilled
                     • Residual sulfur dioxide or hydrogen sulfide
                     • Particulates captured in the gas, including the air pollution control (APC)
                     dust or waste treatment plant (WTP) sludge
                     • Iron is the predominant metal found in the process wastewater
                     • Blast furnace gas (CO)
       Steelmaking

              Inputs:
                     • In the steelmaking process that uses a basic oxygen furnace (EOF), inputs
                     include molten iron, metal scrap, and high-purity oxygen
                     • In the steelmaking process that uses an electric arc furnace (EAF), the
                     primary inputs are scrap metal, electric energy and graphite electrodes.
                     • For both processes, fluxes and alloys are added, and may include: fluorspar,
                     dolomite, and alloying agents such as aluminum, manganese, and others.

              Outputs:
                     • Basic Oxygen Furnace emission control dust and sludge, a metals-bearing
                     waste.
                     • Electric Arc Furnace emission control dust and sludge (K061); generally,
                     20 pounds of dust per ton of steel is expected, but as much as 40 pounds of
                     dust per ton of steel may be generated depending on the scrap that is used.
                     • Metal dusts (consisting of iron particulate, zinc, and other metals associated
                     with the scrap and flux (lime and/or fluorspar)) not associated with the EAF.
                     • Slag.
                     • Carbon monoxide.
                     • Nitrogen  oxides and ozone, which   are  generated during the melting
                     process.                    .                     ;
 Forming, Cleaning, and Descaling
               Inputs:
                      •Carbon steel is pickled with hydrochloric or sulfuric acid; stainless steels
                      are pickled with hydrochloric, nitric, and hydrofluoric acids.
                      • Various organic chemicals are used in the pickling process.
                      • Alkaline cleaners may also be  used to remove mineral oils and animal fats
                      and oils from the.steel surface.  Common alkaline cleaning agents include:
                      caustic soda, soda ash, alkaline silicates, phosphates.
 September 1995
24
                                                                                   SIC 331

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 Sector Notebook Project
                       Iron and Steel Industry
              Outputs:
                     1 Wastewater sludge from
 rolling, cooling, descaling, and rinsing operations
                     which may contain cadmium (D006), chromium (D007), lead (D008)
                     • Oils and greases from hot and cold rolling
                     • Spent pickle liquor (K0^2)
                     • Spent pickle liquor rinse water sludge from cleaning operations
                     • Wastewater from the rinse baths. Rinse water from coating processes may
                     contain zinc, lead, cadmium, or chromium.
                     • Grindings from roll reftyiishing may be RCRA characteristic waste from
                     chromium (D007)
                     • Zinc dross
III.C. Management of Chemicals in the Production Process
                     The Pollution Prevention Act of 1990 (PPA) requires facilities to report
                     information about the management of TRI chemicals in waste and efforts
                     made to eliminate or reduce those quantities. These data have been collected
                     annually in Section 8 of Hie TRI reporting Form R beginning with the 1991
                     reporting year. The data summarized below cover the years 1992-1995 and
                     is meant to provide a basics understanding of the quantities of waste handled
                     by the industry, the methods typically used to manage this waste, and recent
                     trends in these methods. TRI waste management data can be used to assess
                     trends in source reduction within individual industries and facilities, and for
                     specific TRI chemicals.  This information could  then be used as a tool in
                     identifying opportunities
                     activities.
  for pollution prevention compliance assistance
                     From the yearly data presented below it is apparent that the portion of TRI
                     wastes reported as recycled on-site has increased and the portions treated or
                     managed through energy recovery on-site have decreased between 1992 and
                     1995 (projected).  While the quantities reported for 1992 and 1993 are
                     estimates of quantities already managed, the quantities reported for 1994 and
                     1995 are projections only.  The PPA requires these projections to encourage
                     facilities to consider future waste generation and source reduction of those
                     quantities as well as movement up the waste management hierarchy. Future-
                     year estimates are not commitments that facilities reporting under TRI are
                     required to meet.                   ,   •                   ,            ,

                     Exhibit 6 shows that the i-on and steel industry managed about 1.3 billion
                     pounds of production-related waste (total quantity of TRI chemicals in the
                     waste from routine production operations) in 1993 (column B).  Column C
                     reveals that of this produjction-related waste, over half (52%)  was either
                     transferred off-site or released to the environment, and most of this quantity
                     was recycled off-site (typically in a metals recovery process).  Column C is
                     calculated by  dividing th^ total TRI transfers and  releases by the total
                     quantity of production-related waste.  In other words, about 48% of the
                     industry's TRI wastes were managed on-site through recycling, energy
September 1995
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Sector Notebook Project
                      Iron and Steel Industry
                    recovery, or treatment as shown in columns E, F and G, respectively.  The
                    majority of waste that is released or transferred off-site can be divided into
                    portions that are recycled off-site, recovered for energy off-site, or treated
                    off-site as shown in columns H, I and J, respectively. The remaining portion
                    of the production related wastes (15% for 1993), shown in column D, is
                    either released to the environment through direct discharges to air, land,
                    water, and underground injection, or it is disposed off-site.
Exhibit 6: Source Reduction and Recycling Activity for Iron and Steel Industry
(SIC 331) as Reported within TRI
A
Year
1992
1993
1994
1995
B
Quantity of
Production-
Related
Waste
(106 Ibs.)1
1,301
1,340
1,341
1,357
C
% Released
and
Transferred1"
40%
52%
—

D
% Released
and
Disposed0
Off-site
10%
15%
15%
15%
Qn-Site
E
%
Recycled
32%
24%
23%
22%
F
%
Energy
Recovery
2%
1%
1%
1%
G
%
Treated
16%
17% .
18%
18%
Off-Site
H
%
Recycled
34%
35%
37%
38%
I
%
Energy
Recovery
1%
1%
1%
1%
J
%
Treated
5%
6%
6%
6%
* Does not include any accidental, non-production related wastes.
k Total TRI transfers and releases as reported in Section 5 and 6 of Form R as a percentage of production related
wastes; this value may not equal the sum of the percentages released and transferred due to reporting errors in
Section 8.
e Percentage of production related waste released to the environment and transferred off-site for disposal.
September 1995
26
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Sector 'N otebooVt Proj cct
                      Iron and Steel Industry
IV. CHEMICAL RELEASE AND TRANSFER PROFILE

                    This section is designed to! provide background information on the pollutant
                    releases that are reported py this industry.  The best source of comparative
                    ^pollutant release information is the Toxic Release Inventory System (TRI).
                    Pursuant to the Emergency Planning and Community Right-to-Know Act,
                    TRI includes self-reported facility release and transfer data for over 600 toxic
                    chemicals. Facilities within SIC Codes 20-39 (manufacturing industries) that
                    have more than 10 employees, and that are above  weight-based reporting
                  >' thresholds are required to report TRI on-site releases and off-site transfers.
                    The information presentejl within the sector notebooks is derived from the
                    most recently available (1993) TRI reporting year (which then included 3.16
                    chemicals), and focuses primarily on the on-site releases reported by  each
                    sector.  Because TRI requires consistent reporting regardless of sector, it is
                    an excellent tool for drawing comparisons across industries.
                     Although this sector no
 tebook  does not present historical information
                     regarding TRI chemical releases, please note that in general, toxic chemical
                     releases reported in TRI have been declining.  In fact, according to the 1993
                    Toxic Release Inventory Data Book, reported releases dropped by 42.7%
                     between 1988 and 1993. Although on-site releases have decreased, the total
                     amount of reported toxic waste has not declined because the amount of toxic
                     chemicals transferred off-site has increased. Transfers have increased from
                     3.7 billion pounds hi 1991 to-4.7 billion pounds hi 1993. Better management
                     practices have led to increases  in off-site transfers of toxic chemicals for
                     recycling. More detailed information can be obtained from EPA's annual
                     Toxics Release  Inventory Public Data Release book (which is available
                     through the EPGRA Hotline at 1-800-535-0202), or directly from the Toxic
                     Release Inventory System database (for user support call 202-260-1531).

                     Wherever possible, the sector notebooks present TRI data as the  primary
                     indicator of chemical  release within each industrial category.  TRI data
                     provide the type, amount and media receptor of each chemical released or
                     transferred.   When other sources of pollutant release data have been
                     obtained, these data have been included to augment the TRI information.
TRI Data Limitations
                     The reader should keep in
 mind the following limitations regarding TRI data.
                     Within some sectors,'the majority  of facilities  are not subject-to TRI
                     reporting because they are not considered manufacturing industries,  or
                     because they are below TRI reporting thresholds. Examples are the mining,
                     dry cleaning, printing, and transportation equipment cleaning sectors. For
                     these sectors, release information from other sources has been included.
September 1995
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Sector Notebook Project
                       Iron and Steel Industry
                   ,  The reader should also be aware that TRI "pounds released" data presented
                     within the notebooks is not equivalent to a "risk" ranking for each industry.
                     Weighting each pound of release equally does not factor in the relative
                     toxicity of each chemical that is released.  The Agency is in the process of
                     developing an approach to assign toxicological weightings to each chemical
                     released so that one can differentiate between pollutants with  significant
                     differences  in toxicity.  As a preliminary indicator of the environmental
                     impact of the industry's most commonly released chemicals, the notebook
                     briefly summarizes the toxicological properties of the top five chemicals (by
                     weight) reported by each industry.

Definitions Associated With Section IV Data Tables

       General Definitions

                     SIC Code ~ is the Standard Industrial  Classification (SIC) is a statistical
                     classification standard used for all  establishment-based Federal economic
                     statistics. The SIC codes facilitate comparisons between facility and industry
                     data.                             ,

                     TRI Facilities -- are manufacturing facilities that have 10 or more full-time
                     employees  and are above established chemical  throughput  thresholds.
                     Manufacturing facilities  are defined as facilities in Standard Industrial
                     Classification primary codes 20-39.  Facilities must submit estimates for all
                     chemicals that are on the EPA's defined list  and are above throughput
                     thresholds.

       Data Table Column Heading Definitions

                     The following definitions are based upon standard definitions developed by
                     EPA's Toxic Release Inventory Program. "The categories below represent the
                     possible pollutant destinations that can be reported.

                     RELEASES ~  are an  on-site discharge of a  toxic  chemical to the
                     environment. This includes emissions  to the air, discharges to bodies of
                     water, releases at the  facility to  land, as  well  as contained disposal into
                     underground injection wells.

                     Releases to Air (Point and Fugitive  Air Emissions) -- Include all air
                     emissions from industry activity. Point emission occur through confined air
                     streams as found in stacks, ducts, or pipes. Fugitive emissions include losses
                     from equipment leaks, or evaporative losses from impoundments, spills, or
                     leaks.

                     Releases to Water (Surface Water Discharges) -- encompass any releases
                     going directly to streams, rivers, lakes, oceans, or other bodies of water. Any
                     estimates for storm water runoff and non-point losses must also be included.
September 1995
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 Sector TSotetoook Project
                                               Iron and Steel Industry
                     Releases to Land — includes disposal of toxic chemicals in waste to on-site
                     landfills, land treated or incorporation into soil, surface impoundments,
                     spills, leaks, or waste -pilejs.  These activities must occur within the facility's
                     boundaries for inclusion in this category.
                     Underground Injection |~ is a contained release of a fluid into a subsurface
                     well for the purpose of w'aste disposal.
                     TRANSFERS -- is a transfer of toxic chemicals in wastes to a facility that
                     is geographically or physically separate from the facility reporting under
                     TRI.  The quantities reported represent a movement of the chemical away
                     from the reporting facility.  Except for off-site transfers for disposal, these
                     quantities do not necessarily represent entry of the chemical into  the
                     environment.

                     Transfers to POTWs -- *re wastewaters transferred through pipes or sewers
                     to a publicly owned treatments works (POTW).  Treatment and chemical
                     .removal  depend on the
                     Chemicals not treated or
                        chemical's nature  and treatment  methods used.
                        destroyed by the POTW are generally released to
                     surface waters or landfilled within the sludge.

                     Transfers to Recycling j- are sent off-site for the purposes of regenerating
                     or recovering still valuable materials.  Once these chemicals have been
                                             returned to  the originating  facility  or sold
 recycled, they
"commercially.
may be
                     Transfers to Energy Rec overy — are wastes combusted off-site in industrial
                     furnaces for energy recovery. Treatment of a chemical by incineration is not
                     considered to be energy recovery.

                     Transfers  to  Treatment —  are wastes  moved  off-site for  either
                     neutralization, incineration, biological destruction, or physical separation.
                     In some cases, the chemicals are not destroyed but prepared for further waste
                     management.                                •    ,

                  1   Transfers to Disposal - are wastes taken to another facility for disposal
                     generally as a release to land or as an injection underground.

IV.A. EPA Toxic Release Inventory for,the Iron and Steel Industry
                        r
                     This section summarizes TpRI data of facilities involved in the production of
                     iron and steel products who report their operations under SIC 331. These
                     include blast furnaces and steel mills, steel wire manufacture, and cpld rolled
                     steel products but also.include a small number of nonferrous operations (such
                     as facilities manufacturing nonferrous electrometalurgical products under
                     SIC 3313).  The Census of Manufactures reports  1,118  iron and  steel
                    establishments under SIC
                        331.  Although 381 iron and steel facilities filed
September 1995
                       29
                                             'SIC 331-

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Sector Notebook Project
                      Iron and Steel Industry
                     TRI reports in 1993 (under SIC 3312, 3313, 3315, 3316, 3317), the 155
                     facilities (41 percent) classified under SIC 3312 (blast furnaces and steel
                     mills) are responsible for over. 75 percent of reported releases and transfers.
                     TRI information is likely to provide a fairly different profile for the facilities
                     not reporting under 3312 (non-steel producing facilities).

                     According to TRI data, the iron and steel industry released and transferred
                     a total of approximately 695 million pounds of pollutants during calendar
                    .year 1993. These releases and transfers are dominated by large volumes of
                     metal-bearing wastes.   The majority of these wastes (70 percent or 488
                     million pounds) are transferred off-site for recycling, typically for recovery
                     of the metal content. Transfers of TRI chemicals account for 86 percent of
                     the iron and steel industry's total TRI-reportable chemicals (609  million
                     pounds) while releases make up 14 percent (85 million pounds).  Metal-
                     bearing wastes account for approximately 80 percent of  the  industry's
                     transfers and over fifty percent of the releases.

                     Releases from the industry continue to decrease, while transfers increased
                     from 1992 to 1993. The increase in transfers is likely due to increased off-
                     site shipments for recovery of metals from wastes. This shift may also have
                     contributed to the decrease in releases. Another factor influencing an overall
                     downward trend since 1988  in  releases and transfers is the  steel  mill
                     production decrease during the 1988 to 1993 period. In addition, pollution
                     control equipment and a shift to new technologies,  such as continuous
                     casting, are responsible for  significant changes in the amount and type of
                     pollutants released during steelmaking.  Finally, the  industry's efforts in
                     pollution preventing also play a role in driving pollutant release reductions.

                     Evidence of the diversity of processes at facilities reporting to TRI is found
                     in the fact  that  the most frequently reported chemical (sulfuric  acid) is
                     reported by only 41  percent of the  facilities; the sixth most frequently
                     reported chemical  was used by just one-fourth of TRI facilities.   The
                     variability in facilities' pollutant profile may be attributable to a number of
                     factors.  Fewer than 30 of the facilities in the TRI database for SIC 331 are
                     fully  integrated  plants making coke, iron, and steel products.  The non-
                     integrated facilities do not perform one or more of the production steps and,
                     therefore, may have considerably different emissions profiles. Furthermore,
                     steel making operations with electric arc furnaces have significantly different
                     pollutant profiles than those making steel with basic oxygen furnaces.

                     Releases

                     The iron and steel industry releases just 14 percent of its TRI total poundage.
                     Of these releases, over half go to on-site land disposal, and  one quairjter of
                     releases are fugitive or point source air emissions  (Exhibit 7). Manganese,
                     zinc,  chromium, and lead account for over 90 percent of the on-site land
                     disposal.  The industry's air releases are associated with volatilization, fume
 September 1995
30
SIC 331

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Sector Notebook. Project
                       Iron and Steel Industry
                     or 'aerosol formation  inj  the  high temperature furnaces and" byproduct
                     processing. Ammonia, lighter weight organics, such as methanol, acids and
                     metal contaminants found in the iron ore are the principal types of chemicals
                     released to the air. In addition to air releases of chemicals reported in TRI,
                     the iron and steel industry is a significant source of particulates, carbon
                     monoxide, nitrogen oxides and  sulfur compounds due to  combustion.
                     Ammonia  releases account for the largest part of the  fugitive releases
                     (approximately 42 percent) and 1,1,1-trichloroethane, hydrochloric acid, zinc
                     compounds, and trichloroethylene each contribute another 4 - 5 percent.
                     Underground injection (principally of hydrochloric acid) makes up about 14
                     percent of the releases re; jorted by the industry.

                     Transfers

                     Eighty percent of transfers reported by SIC 331 industries are sent off-site for
                     recycling. Zinc, manganese, chromium, copper, nickel, and lead are the six
                     metals transferred by the
greatest number of facilities (Exhibit 8).
                     Acids used during steel finishing, such as hydrochloric, sulfuric, nitric, and
                     phosphoric acids, account for another 17 percent of transfers.  These acids
                     are most often sent off-site for recycling or for treatment. Hydrochloric acids
                     are also managed by  on-site underground injection.  The next class  of
                     chemicals of significant Atolume in TRI are solvents and lightweight carbon
                     byproducts, including:  1,1,1 -trichloroethane,  trichloroethylene,  phenol,
                     xylene, methanol, and toluene.  These solvents are primarily released  as
                     fugitive air emissions, but also from point sources. A small percentage of
                     these solvents are transferred off-site for recycling.

                     Chemicals sent off-site for disposal (primarily zinc, sulfuric acid, manganese,
                     and ammonium sulfate)  account for another 10 percent of transfers. Only
                     approximately 7 percent of chemicals transferred off-site go to treatment.
                     These  chemicals are primarily hydrochloric acid,  sulfuric acid, and nitric
                     acid.  Only about one percent of transfers by weight are POTW discharges
                     (mainly sulfuric acid). Another one percent of transfers are sent for energy
                     recovery (with hydrochloric acid as the most significant contributor).
 September 1995  .
31
SIC 331

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  Sector Notebook Project
                      Iron and Steel Industry



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September 1995
32
SIC 331

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Sector Notebook Project





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-------
 Sector Notebook Project
                      Iron and Steel Industry





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-------
Sector Notebook Project
Iron and Steel Industry





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-------
Sector Notebook Project
                        Iron and Steel Industry
                     The TRI database contains a detailed compilation of self-reported, facility-
                     specific chemical releases. The top reporting facilities for this sector based
                     on pounds released are listed below. Facilities that have reported only the
                     SIC codes covered under this notebook appear on the first list.  The second
                     list contains additional facilities that have reported the SIC code covered
                     within this report, and one or more SIC codes that are not within the scope
                     of this notebook.  Therefore, the second, list includes facilities that conduct
                     multiple operations - some that  are under the scope of this notebook, and
                     some that are not.  Currently, the facility-level data do not allow pollutant
                     releases to be broken apart by industrial process.
Exhibit 9: Top 10 TRI Releasing Iron and Steel Facilities"
Rank
1
2
3
4
5
6
7
8
9
10
Facility
Elkem Metals Co* - Marietta, OH
Northwestern Steel & Wire Co. - Sterling, IL
Granite City Steel - Granite City, IL
Midwest Steel Div. Midwest Steel Div. - Portage, IN
AK Steel Corp. Middletown Works - Middletowri, OH
Bethlehem Steel Corp. Burns Harbor Div. - Burns
Harbor, IN
Wheeling-Pittsburgh Steel Corp Mingo Junction Plant -
Mingo, Junction, OH
USS Gary Works - Gary, IN
LTV Steel Co. Inc. Cleveland Works - Cleveland, OH
Gulf States Steel Inc. - Gadsden, AL
Total TRI
Releases in
Pounds
18,604,572
14,274,570
5,156,148
4,735,000
4,189,050
3,899,470
3,089,795
2,403,348
1,985,131
1,959,707
Source: U.S. EPA Toxic Release Inventory Database, 1993.
* This is an Electrometallurgical Products facility (SIC 3313), not a steel mill.
* Being included on this list does not mean that the release is associated with non-compliance with environmental
laws.
September 1995
36
SIC 331

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Sector Notebook Project
                       Iron and Steel Industry
Exhibit 10: Top 10 TRI Releasing JFacilities Reporting SIC 331 Operations"
Rank
. \ 1
.2 '
3
4
5
6
, ,? ;
8
9
10
SIC Codes
Reported
in TRI
3313 .
3312,3315
3312,3274
3313,2819
3312
3316
3312 •
3312
3312
3312
Facility
.
[• - - •
Elkem Metals Co[ - Marietta, OH ,
Northwestern Steel & Wire Co. - Sterling, IL
Inland Steel Co. - East Chicago, IN
Kerr-McGee Che
Hamilton, MS*
Granite City Steel •
nical Corp. Electrolytic Plant -
Granite City, IL
• • • ' 1' ' • ' • • '
Midwest Steel Div.| Midwest Steel Div. - Portage, IN
AK Steel Corp. Mi|idletown Works - Middletown, OH .
Bethlehem Steel C<
IN
Wheeling-Pittsburg
Mingo Junction, O
irp. Burns Harbor Div. - Burns Harbor,
h Steel Corp Mingo Junction Plant -
I
USS Gary Works -JGary, IN
Total TRI
Releases in
Pounds
18,604,572
14,274,570
10,618,719
5,446,555
5,156,148
4,735,000
4,189,050
3,899,470
3,089,795
2,403,348
. . | •_--•;
Source: U.S. EPA Toxic Release Inventory Database, 1993. .
* • J •
This is an Electrometallurgical Products facility (SIC 3J313), not a steel mill.
IV.B. Summary of Selected Chemicals Released
                     The following is a synopsis of current scientific toxicity and fate information
                     for the top chemicals (by weight) that facilities within this sector self-
                     reported as released to the |environment based upon 19,93 TRI data.  Because
                     this section is based upon self-reported release data, it does not attempt to
                     provide information on .management practices employed by  the sector to
                     reduce the  release of these  chemicals.  Information regarding pollutant
                     release reduction over time may be available from EPA's TRI and 33/50
                     programs, or directly from the industrial trade associations that are listed in
                     Section IX of this document. Since these descriptions are cursory, please
                     consult the sources referenced below for a more detailed description of both
                     the chemicals described in- this section, and the chemicals that appear on the
                     full list of TRI chemicals appearing in Section IV. A.
b Being included on this list does not mean that the release
laws.
 is associated with non-compliance with environmental
September 1995
J7
SIC 331

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Sector Notebook Project
                       Iron and Steel Industry
                     The brief descriptions provided below were taken from the 1993 Toxics
                     Release Inventory Public Data Release (EPA, 1994), and the Hazardous
                     Substances Data Bank (HSDB), accessed via TOXNET.  TOXNET is a
                     computer system run by the National Library of Medicine.  It includes a
                     number of toxicological databases managed by EPA, the National Cancer
                     Institute,  and the National Institute for Occupational  Safety and Health.6
                     HSDB  contains chemical-specific  information on manufacturing and use,
                     chemical  and physical  properties,  safety and  handling,  toxicity and
                     biomedical  effects, pharmacology, environmental  fate  and exposure
                     potential, exposure standards and regulations,  monitoring  and analysis
                     methods,  and additional references.  The information contained below is
                     based upon exposure assumptions that have been conducted using standard
                     scientific  procedures. The effects listed below must be taken in context of
                     these exposure assumptions that are more  fully  explained within the full
                     chemical profiles hi HSDB. For more information on TOXNET, contact the
                     TOXNET help line at 1-800-231-3766.

                     Ammonia (CAS: 7664-41-7)

                     Sources,  hi cokemaking, ammonia is produced by the decomposition of the
                     nitrogen-containing compounds which takes place during the secondary
                     thermal reaction (at temperatures greater  than  700°C  (1296°F)),   The
                     ammonia formed during coking exists in both the water and gas that form
                     part of the  volatile products.   The recovery  of this ammonia can be
                     accomplished  by  several  different  processes Where  the  by-product
                     ammonium sulfate is formed by the reaction between the ammonia and
                     sulfuric acid.23

                     Toxicity.  Anhydrous ammonia is irritating to the skin, eyes, nose, throat, and
                     upper respiratory system.

                     Ecologically, ammonia is a source of nitrogen (an essential element for
                     aquatic plant growth), and may therefore contribute to  eutrophication of
                     standing or  slow-moving surface  water, •particularly  in nitrogen-limited
                     waters  such as the Chesapeake Bay. In addition, aqueous ammonia is
                     moderately toxic to aquatic organisms.

                     Carcinogenicity.   There is currently  no  evidence to  suggest that this
                     chemical is carcinogenic.
c Databases included in TOXNET are: CCRIS (Chemical Carcinogenesis Research Information System), DART
(Developmental and Reproductive Toxicity Database), DBIR (Directory of Biotechnology Information Resources),
EMICBACK (Environmental Mutagen Information Center Backfile), GENE-TOX (Genetic Toxicology), HSDB
(Hazardous Substances Data Bank), IRIS (Integrated Risk Information System), RTECS (Registry of Toxic Effects
of Chemical Substances), and TRI (Toxic Chemical Release Inventory).
September 1995
38
SIC 331

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Sector Notebook Project
                        Iron and Steel Industry
                                  '  •-     "";  I- •  •  '"*"•                             .
                     Environmental  Fate.   Ammonia  combines  with sulfate  ions in the
                     atmosphere and  is washep out by rainfall, resulting in rapid return of
                     ammonia to the soil and surface waters.
                     Ammonia is a central compound in the environmental cycling of nitrogen.
                     Ammonia in lakes, rivers, and streams is converted to nitrate.

                     Physical Properties.  Ammonia is a corrosive and severely  irritating gas
                     with a pungent odor.
                     Hydrochloric Acid (CAS:
                     Sources. During hot rollin
                     of,the steel.  This "scale1
                     which commonly uses
                     Toxicity. Hydrochloric ac
   7647-01-1)
   y, a hard black iron oxide is formed on the surface
    is  removed chemically in the pickling process
hydrochloric acid.24
   d is primarily a concern in its aerosol form. Acid
                     aerosols have been implicated in causing and exacerbating a variety of
                     respiratory ailments. Dermal exposure and ingestion of highly concentrated
                     hydrochloric acid can result in corrosivity..  .

                     Ecologically,,accidental releases of solution forms of hydrochloric acid may
                     adversely affect aquatic life by including a transient lowering of the pH (i.e.,
                     increasing the acidity) of surface waters.
                     Carcinogenicity.  There
                     chemical is carcinogenic.
    is currently no  evidence to suggest that this
                     Environmental Fate. Releases of hydrochloric acid to surface waters and
                     soils will be neutralized to an extent due to the buffering capacities of both
                     systems.  The extent of these reactions will depend on the characteristics of
                     the specific environment.

                     Physical Properties.  Concentrated hydrochloric acid is highly corrosive.

                     Manganese and Manganese Compounds (CAS: 7430-96-5; 20-12-2)

                     Sources. Manganese is found in the iron charge and is used as an addition
                     agent added to alloy steel to obtain desired properties in the final product.
                     In carbon steel, manganese is used to combine with sulfur to improve the
                     ductility of the steel. An alloy steel with manganese is used for applications
                     involving relatively small sections which are  subject to severe service
                     conditions, or in larger sections where the weight saving derived from the
                     higher strength of the alloy steels is needed.25

                     Toxicity.  There is currently no evidence that human exposure to manganese
                     at levels commonly observed hi ambient atmosphere results hi adverse health
                     effects.   However, recent EPA  review of  the  fuel  additive MMT
 September 1995
                                         SIC 331

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 Sector Notebook Project
                       Iron and Steel Industry
                     (methylcyclopentadienyl manganese tricarbonyl) concluded that use of MMT
                     in gasoline could lead to ambient exposures to manganese at a level sufficient
                     to cause adverse neurological effects in humans.

                     Chronic manganese poisoning  bears some similarity to  chronic  lead
                     poisoning. Occurring via inhalation of manganese dust or fumes, it primarily
                     involves the central nervous system.  Early symptoms include  languor,
                     speech disturbances, sleepiness, and cramping and weakness in legs. A stolid
                     mask-like appearance  of face, emotional disturbances  such as  absolute
                     detachment broken by uncontrollable laughter, euphoria, and a spastic gait
                     with a tendency to fall while walking are seen in more advanced cases.
                     Chronic manganese poisoning is reversible if treated early and exposure
                     stopped. Populations at greatest risk of manganese toxicity are  the very
                     young and those with iron deficiencies.

                     Ecologically, although manganese is an essential nutrient for both plants and
                     animals, in excessive concentrations manganese inhibits plant growth.

                     Carcinogenicity.  There  is  currently no evidence to  suggest that  this
                     chemical is carcinogenic.

                     Environmental Fate.  Manganese is an essential nutrient for plants and
                     animals. As such, manganese accumulates in the top layers of soil or surface
                     water sediments and cycles between the soil and living organisms. It occurs
                     mainly  as a solid under environmental  conditions, though  may also be
                     transported in the atmosphere as a vapor or dust.

                     1.1.1-Trichloroethane TCAS: 71-55-6^

                     Sources. Used for surface cleaning of steel prior to coating.

                     Toxicity.  Repeated contact of 1,1,1-trichloroethane (TCE) with skin may
                     cause serious skin cracking and infection.  Vapors cause a slight smarting of
                     the eyes or respiratory system if present in high concentrations.

                     Exposure to high concentrations of TCE causes reversible mild liver  and
                     kidney dysfunction, central nervous system depression, gait disturbances,
                     stupor, coma, respiratory depression,  and even death.  Exposure to lower
                     concentrations of TCE leads to light-headedness, throat irritation, headache,
                     disequilibrium, impaired coordination, drowsiness, convulsions and mild
                     changes in perception.

                     Carcinogenicity.  There is currently no evidence  to suggest that this
                     chemical is carcinogenic.

                     Environmental Fate. Releases of TCE to surface water or land will almost
                     entirely volatilize.  Releases to air may be transported long distances and
                     may partially return to earth in rain, hi the lower atmosphere, TCE degrades
September 1995
40
SIC 331

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Sector Notebook Project
                      Iron and Steel Industry
                     very slowly by photooxidation and slowly diffuses to the upper atmosphere
                     where photodegradation is rapid.              •

                     Any  TCE that  does not evaporate from  soils leaches to  groundwater.
                     Degradation in soils and water is slow.  TCE does not hydrolyze in water, nor
                     does  it significantly biocdncentrate in aquatic organisms.

                     Zinc  and Zinc Compounds (CAS: 7440-66-6: 20-19-9^)
                     Sources. To protect steel ifrom rusting, it is coated with a material that will
                     protect it from moisture and air. hi the galvanizing process, steel is coated
                     with zinc.26

                     Toxicity. Zinc is a nutriti mal trace element; toxicity from ingestion is low.
                     Severe exposure to zinc might give  rise to gastritis with vomiting due to
                     swallowing of zinc dusts. Short-term exposure to very high levels of zinc is
                     linked to  lethargy,  dizziness,  nausea, fever,  diarrhea,  and  reversible
                     pancreatic and neurological damage.   Long-term zinc poisoning causes
                     irritability, muscular stiffness and pain, loss of appetite, and nausea.

                     Zinc chloride fumes  cause injury to mucous membranes and to the skin.
                     Ingestion of soluble zinc salts may cause nausea, vomiting, and purging.
                     Carcinogenicity.  Ther^  is currently no evidence to suggest that  this
                     chemical is carcinogenic.          >

                     Environmental Fate. Significant zinc contamination of soil is only seen in
                     the vicinity of industrial pinnt sources. Zinc, is a relatively stable soft metal,
                     though burns in air.  Zinc
IV.C. Other Data Sources
 bioconcentrates in aquatic organisms.
                     The toxic chemical release data obtained from TRI captures the vast majority
                     of facilities in the iron arid steel industry. It also allows for a comparison
                     across years and industry sectors. Reported chemicals are limited however
                     to the 316 reported chemicals.  Most of the hydrocarbon emissions from iron
                     and steel facilities are not captured by TRI.27 The EPA Office of Air Quality
                     Planning and  Standards has compiled air pollutant emission factors for
                     determining the total  air  emissions of priority pollutants  (e.g.,  total
                     hydrocarbons, SOx, NOx, CO, particulates, etc.) from many iron and steel
                     manufacturing sources.28

                     The Aerometric Information Retrieval System (AIRS) contains a wide range
                     of information related to. stationary sources  of air pollution, including the
                     emissions of a number of air pollutants which may be of concern within a
                     particular industry.  With the exception of volatile  organic compounds
                     (VOCs), there is little overlap with the TRI chemicals reported above.
                     Exhibit 11  summarizes  annual releases  (from the industries for which a
September 1995,  ,
41
SIC 331

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Sector Notebook Project
                       Iron and Steel Industry
                     Sector Notebook Profile was prepared) of carbon monoxide (CQ), nitrogen
                     dioxide  (NO2),  participate matter of 10  microns or less (PM10), total
                     participates (PT),  sulfur dioxide (SO2), and volatile organic compounds
                     (VOCs). With 1.5 million short tons/year of carbon monoxide, the iron and
                     steel industry emissions are estimated as more than twice as much as the next
                     largest releasing industry, pulp and paper. Of the eighteen industries listed,
                     the iron and steel industry also ranks as one of the top five releasers for NO2,
                     PM10, PT, and SO2.  Carbon monoxide releases occur during ironmaking (in
                     the  burning of coke, CO produced reduces iron oxide ore), and during
                     steelmaking (in either the basic oxygen furnace or the electric arc furnace).
                     Nitrogen dioxide is generated during steelmaking.  Particulate matter may be
                     emitted  from the cokemaking  (particularly in  quenching operations),
                     ironmaking, basic oxygen furnace (as oxides of iron that are emitted as sub-
                     micron dust), or from the electric arc furnace (as metal dust containing iron
                     participate, zinc, and other materials associated with the scrap).  Sulfur
                     dioxide can be released in ironmaking or sintering.
September 1995
42
SIC 331

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Sector Notebook Project
Iron and Steel Industry
Exhibit 11: Pollutant Releases (short tons/year)
Industry Sector
U.S. Total
Metal Mining
Nonmetal Mining
Lumber and Wood
Production , . ,
Furniture and Fixtures
Pulp and Paper
Printing ,
Inorganic Chemicals
Organic Chemicals
Petroleum Refining
Rubber and Misc. Plastics
Stone, Clay and Concrete
Iron and Steel
Nonferrous Metals
Fabricated Metals
Computer and Office
Equipment •
Electronics and Other
Electrical Equipment and
Components
Motor Vehicles, Bodies,
Parts and Accessories
Dry Cleaning
CO
97,208,000
5,391
4,525
123,756
2,069
624,291
8,463
166,147
, 146,947
419,311
2,090
58,043
1,518,642
448,758
3,851
24
367
35,303
101

NO,.
23,402,000




28,583
28,804
42,658
2,981
3,94,448


•;
4,915
03,575
36,826
380,641

11,914
3,38,482







138,985
55,658
-16,424
0
1,129
23,725
179
. PMIO
45,489,000
39,359
59,305
-', 14,135
- 2,165
35,579
399
1 4,107
26,493
18,787
2,407
74,623
42,368
20,074
1,185
. 0
f
207
2,406
3
PT
7,836,000
140,052
167,948
63,761
3,178
113,571
1,031
39,062
44,860
36,877
- 5,355
171,853
83,017
22,490
-3,136
0
293
12,853
28
SO2
21,888,000
84,222
24,129
9,419
1,606
541,002
1,728
182,189
132,459
648,155
29,364
339,216
238,268
373,007
4,019
0
453
25,462
152
voc
23,312,000
1,283
1,736
41,423
59,426
96,875
101,537
52,091
201,888
369,058
140J41
30,262
82,292
27,375
102,186
0
4,854
101,275
7,310
. - - • - 1 '•• . •
Source: U.S. EPA Office of Air and Radiation, AIRS Database, May 1995.
September 1995
              SIC 331

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Sector Notebook Project
                      Iron and Steel Industry
IV.D. Comparison of Toxic Release Inventory Between Selected Industries

                     The following information is presented as a comparison of pollutant release
                     and transfer data across industrial categories. It is provided to give a general
                     sense as to the relative scale of releases and transfers  within each sector
                     profiled under this project. Please note that the following figure and table do
                     not contain  releases and transfers for industrial categories that are  not
                     included  in  this project, and thus cannot be used to draw conclusions
                     regarding the total release and transfer amounts that are reported to TRI.
                     Similar information is available within the annual TRI Public Data Release
                     Book.                 ;

                     Exhibit 12 is a graphical representation of a summary of the 1993 TRI data
                     for the iron and steel industry  and the  other sectors profiled in separate
                     notebooks.  The bar graph presents the total TRI releases and total transfers
                     on the left axis and the  triangular points show the average releases per
                     facility on the right axis.  Industry sectors are presented  in me order of
                     increasing total TRI releases.  The graph is based  on the data shown in
                     Exhibit 13 and is meant to  facilitate comparisons between the relative
                     amounts  of releases, transfers,  and releases per facility both within  and
                     between these sectors. The reader should note, however, that differences in
                     the proportion of facilities captured by TRI exist between industry sectors.
                     This can be a factor of poor  SIC matching and relative differences in the
                     number of facilities reporting to TRI from the various sectors. In the case of
                     the iron and steel industry, the 1993 TRI  data presented here covers  381
                     facilities. These facilities listed  SIG 331  (Steel Works, Blast Furnaces, and
                     Rolling and Finishing Mills) as  a primary SIC code.
September 1995
44
SIC 331

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Sector Notebook. Project
                                                           Iron and Steel industry
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                                      45
SIC 331

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Sector Notebook Project
                    Iron and Steel Industry







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September 1995
46
SIC 331

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       Notebook. Project
                       Iron and Steel Industry
V. POLLUTION PREVENTION OPPORTUNITIES
                     The best way to reduce pollution is to prevent it in the first place. Some
                     companies have creatively Implemented pollution prevention tephniques that
                     improve efficiency and incjrease profits while at the same time minimizing
                     environmental impacts. This can be done in many ways such as reducing
                     material inputs, re-engineering processes to reuse by-products, improving
                     management practices, and bmploying substitution of toxic chemicals. Some
                     smaller facilities are able to actually get below regulatory thresholds just by
                     reducing pollutant releases through aggressive pollution prevention policies.

                     In order to encourage these approaches, this section provides both general
                     and company-specific descriptions of some pollution prevention advances
                     that have been implemented within the iron and steel industry. While the list
                     is not exhaustive, it does provide core information that can be used as the
                     starting point  for facilitiejs interested in beginning their own pollution
                     prevention projects.  This section provides summary information from
                     activities that may be, or  are being implemented by this sector.   When
                     possible, information is provided that gives  the context  in  which  the
                     technique can be  effectively used.  Please note that the activities described
                     in this section do not necessarily apply to all facilities that fall  within this
                     sector.   Facility-specific conditions must be carefully  considered when
                     pollution prevention options are evaluated, and the full impacts of the change
                    must examine how each op
  ion affects air, land and water pollutant releases.
                     Most of the pollution preve: ition activities in the iron and steel industry have
                     concentrated on reducing cokemaking emissions, Electric Arc Furnace (EAF)
                     dust, and spent acids used |in finishing operations. Due to the complexity,
                     size, and age of the equipment used in steel manufacturing, projects that have
                     the highest pollution prevention potential often require significant capital
                     investments. This section describes pollution prevention opportunities for
                     each of the three focus areas (cokemaking, EAF dust, and finishing acids),
                     and then lists some general pollution prevention opportunities that have been
                     identified by the iron and s :eel industry.

                     Cokemaking
                     The cokemaking process  is seen by industry experts as one of the steel
                     industry's areas  of greatest environmental concern, with  coke oven air
                     emissions and quenching waste water as the major problems. In response to
                     expanding regulatory constraints, including the Clean Air Act National
                     Emission Standards for coke pvens completed hi 1993, U.S. steelmakers are
                     turning to new technologiejs to decrease the sources of pollution from, and
                     their reliance on, coke.  Pollution prevention in cokemaking has focused on
                     two areas: reducing  coke oven emissions  and  developing cokeless
                     ironmaking techniques. Although these processes have not yet been widely
                     demonstrated on a commercial scale, they may provide significant benefits
                     for the integrated segment o|f the  industry in the form  of substantially lower
                     air emissions and wastewater discharges than current operations.
September 1995
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Sector Notebook Project
                      Iron and Steel Industry
                    Eliminating Coke with Cokeless Technologies

                    Cokeless technologies substitute coal for  coke in the  blast furnace,
                    eliminating the need for cokemaking.  Such technologies have enormous
                    potential to reduce pollution generated during the steelmaking process. The
                    capital investment required  is  also significant.   Some of the cokeless
                    technologies in use or under development include:

                    • The Japanese Direct Iron Ore Smelting (DIOS) process.  This process .
                    produces molten iron directly with coal and sinter feed ore. A 500 ton per
                    day pilot plant was started up in October, 1993 and the designed production
                    rates were attained as a short term average.  During 1995, the data generated
                    will be used to determine economic feasibility on a commercial.scale.

                    • HIsmelt process.  A plant  using the HIsmelt process for molten iron
                    production, developed by HIsmelt Corporation of Australia, was started up
                    in  late 1993.   The process, using  ore fines  and coal,  has achieved a
                    production  rate of 8  tons per hour  using  ore  directly  in the smelter.
                    Developers anticipate reaching the production goal of 14 tons per hour.
                    During 1995, the  data  generated will be used  to determine economic
                    feasibility on commercial scale. If commercial feasibility is realized, Midrex
                    is expected to become the U.S. engineering licensee of the HIsmelt process.

                    • Cor ex process. The Corex or Cipcor process has integral coal desul&rizing,
                    is amenable, to a variety of coal types, and generates electrical power in
                    excess of that required by an iron and steel mill which can be sold to local
                    power grids. A Corex plant is in operation in South Africa, and other plants
                    are expected to be operational in the next two years in South Korea and
                    India.                          ,

                    Reducing Coke Oven Emissions

                     Several technologies are available or are under development to reduce the
                    emissions from coke ovens.   Typically, these technologies reduce  the
                    quantity of coke needed by changing the method by which coke is added to
                    the blast furnace or by substituting a portion of the coke with other fuels.
                    The  reduction in the amount of coke produced proportionally reduces the
                     coking emissions.  Some of the most prevalent or promising coke reduction
                    technologies include:

                     • Pulverized coal injection. This technology substitutes pulverized coal for
                     a portion of the coke in the blast furnace.  Use of pulverized coal injection
                     can replace about 25 to 40 percent of coke  in the blast furnace, substantially
                     reducing emissions associated with cokemaking operations. This reduction
                    ' ultimately depends on the fuel injection rate applied to the blast furnaces
                     which will, in turn be dictated by the aging of existing coking facilities, fuel
                     costs,  oxygen availability, capital  requirements  for fuel injection, and
                     available hot blast temperature.
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Sector Notebook Project
                     Iron and Steel Industry
                     • Non-recovery coke battery. As opposed to the by-product recovery coke
                     plant, the non-recovery coke battery is designed to allow combustion of the
                     gasses from the coking process, thus consuming the by-products that are
                     typically recovered.   The  process  results  in lower air emissions and
                     substantial reductions in c oking process wastewater discharges.

                     • The Davy Still Autoproc ess.  In this pre-combustion cleaning process for
                     coke ovens, coke oven battery process water is utilized to strip ammonia arid
                     hydrogen sulfide from coke oven emissions.
                     •Alternative fuels. Steel producers can also inject other fuels, such as natural
                     gas, oil, and tar/pitch, instead of coke into the blast furnace, but these fuels
                    . can only replace coke in 1 mited amounts.

                     Recycling of Coke By-products

                     Improvements in the in-pjrocess recycling of tar decanter sludge, a RCRA
                     listed hazardous waste (KJ087) are common practice.. Sludge can either be
                     injected into the ovens to
c6ntribute to coke yield, or converted into a fuel
                    that is suitable for the blast furnace.

                    Reducing Wastewater Volume

                    In addition to air emissions, quench water from cokemaking is also an area
                    of  significant environmental concern.  In  Europe,, some plants have
                    implemented technology to shift from water quenching to dry quenching in
                    order to reduce energy costs.  However, major construction changes are
                    required for such a solution and considering the high capital costs of coke
                    batteries, the depressed state of the steel industry, and increased regulations
                    for cokemaking, it is unlikjely that this pollution prevention opportunity will
                    be widely adopted in the U.S.          ~          -

                    Electric Arc Furnace Di st
                    Dust generation in the, EAF, and its disposal, have also been recognized as
                    a serious  problem, but one with potential for pollution prevention through
                    material recovery. EAF dust is a RCRA listed waste (K0.61) because of its
                    high concentrations of lead and cadmium.  With 550,000 tons of EAF dust
                    generated annually in the U.S., there is great potential to reduce the volume
                    of this hazardous waste. I  Steel companies typically payxa disposal fee of
                    $150 to $200 per ton of dust.  With an average zinc concentration of 19
                    percent, much of the EAF dust is shipped off-site for zinc reclamation. Most
                    of the EAF dust recovery <|>ptions are only economically viable for dust with
                    a zinc content of at least 15 - 20 percent. Facilities producing specialty steels
                    such as stainless steel witi a lower zinc content,.still have opportunities to
                    recover chromium and nickel from the EAF dust.
September 1995
                                     SIC 331

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Sector Notebook Project
                       Iron and Steel Industry
                     In-process recycling of EAF dust involves pelletizing and then reusing the
                     pellets in the furnace, however, recycling of EAF dust on-site has not proven
                     to be technically or economically competitive for all mills.  Improvements
                     in technologies have made off-site recovery a cost effective alternative to
                     thermal treatment or secure landfill disposal.

                     Pickling Acids
                     In  finishingj pickling acids  are recognized as an area where  pollution
                     prevention efforts  can  have  a significant  impact  in  reducing  the
                     environmental impact of the steel mill.  The pickling process removes scale
                     and cleans the surface of raw steel by dipping it into a tank of hydrochloric
                     or sulfuric acid. If not recovered, the spent acid may be transported to deep
                     injection wells for disposal, but as those wells continue to close, alternative
                     disposal costs are rising.

                     Large-scale steel manufacturers commonly recover hydrochloric acid in their
                     finishing operations, however the techniques used are not suitable for small-
                     to medium-sized steel plants.28 Currently, a recovery technique for smaller
                     steel manufacturers and galvanizing plants is in pilot scale testing.  The
                     system under development removes iron chloride (a saleable product) from
                     the hydrochloric acid, reconcentrates the acid for reuse, and recondenses the
                     water to be reused as a rinse water in the pickling process. Because the only
                     by-product of the  hydrochloric acid recovery process is a non-hazardous,
                     marketable metal chloride, this technology generates  no hazardous wastes.
                     The manufacturer projects industry-wide hydrochloric acid waste  reduction
                     of 42,000 tons/year by 2010.  This  technology is less expensive than
                     transporting and disposing waste acid, plus it eliminates the associated long-
                     term liability. The total savings for a small- to medium-sized galvanizer is
                     projected to be $260,000 each year.

                     The pilot scale testing project is funded in part by a grant from the U.S.
                     Department of Energy under the NICE3 program (see section VIII.B. for
                     program information) and the EPA. (Contact: Bill Ives, DOE, 303-275-4755)

                     To reduce spent pickling liquor (K062) and simultaneously reduce fluoride
                     in the plant effluent, one facility modified their existing treatment process to
                     recover the fluoride ion from rinse water and spent pickling acid raw water
                     waste streams.  The fluoride is recovered as calcium fluoride (fluorspar), an
                     input product for steelmaking. The melt shop in the same plant had been
                     purchasing 930 tons of fluorspar annually for use as a furnace flux material
                     in the EAF at a cost of $100 per ton.  Although the  process is still under
                     development, the recovered calcium fluoride is expected to be a better grade
                     than the purchased fluorspar, which would reduce the amount of flux used by
                     approximately 10 percent. Not only would the generation rate of sludge from
                     spent pickling liquor treatment be reduced (resulting in a savings in off-site
                     sludge  disposal costs), but  a savings in chemical  purchases would  be
                     realized.
September 1995
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Sector Notebook Project
                       Iron and Steel Industry
                     Other areas with pollution prevention opportunities
                     Other areas in iron and steel manufacturing where opportunities may exist for
                     pollution  prevention  are listed  .below,  in three  categories:  process
                     modifications, materials substitution, and recycling.
                    Process Modification
                     Redesigning or modifying process equipment can reduce pollution output,
                     maintenance costs, and eriergy consumption, for example:
                    . • Replacing single-pass wastewater systems with closed-loop systems to
                     minimize chemical use in wastewater treatment and to reduce water use.
                     • Continuous casting, now used for about 90% of crude steel cast in the U.S.,
                     offers great improvements  in process efficiency when compared to the
                     traditional ingot teeming method.  This increased efficiency also results in a
                     considerable savings in energy and some reduction in the volume of mill
                     wastewater.

                     Materials Substitution

                     • Use scrap steel with low lead and cadmium content as a raw material, if
                     possible.                           .                           ,      .
                     • Eliminate the generation  of reactive desulfurization slag generated in
                     foundry work by replacing calcium carbide with a less hazardous material.
                     Recycling
                     Scrap and other materials are recycled extensively in the iron and steel
                     industry to reduce the raw materials required and the associated pollutants.
                     Some of these recycling activities include:
                     • Recycle or reuse oils arid greases.
                     • Recover acids by removing dissolved iron salts from spent acids.
                     • Use thermal decomposition for acid recovery from spent pickle liquor.
                     • Use a bipolar membrane/electrodialytic process to separate acid from metal
                     by-products in spent NO3JHF pickle liquor.
                     • Recover sulfuric acid using low temperature separation of acid and metal
                     crystals.
September 1995
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SIC 331

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Sector Notebook. Project
                     Iron and Steel Industry
 VI. SUMMARY OF APPLICABLE FEDERAL STATUTES AND REGULATIONS

                     This section discusses the Federal regulations that may apply to this sector.
                     The purpose of this sectiorij is to highlight and briefly describe the applicable
                     Federal requirements, and to provide citations for more detailed information.
  -                   The three following sections are included:

                     •      Section VIA. contains a general overview of major statutes
  •  '                 •      Section VLB. contains a list of regulations specific to this industry
                     •      Section VI.C. contains a list of pending and proposed regulations
                     The  descriptions  within
                     information.  Depending
 Section  VI  are  intended  solely  for  general
upon the nature or scope of the activities at a
                     particular facility, these summaries may or may not necessarily describe all
                     applicable environmental requirements.  Moreover, they do not constitute
                     formal interpretations or clarifications of the statutes and regulations.  For
                     further information, readers should consult the Code of Federal Regulations
                     and other state or local regulatory agencies.  EPA Hotline contacts are also
                     provided for each major statute.
VI.A. General Description of Major Statutes

       Resource Conservation and Recovery Act
                   ,  The Resource Conservation And Recovery Act (RCRA) of 1976 which
                     amended the Solid Waste Disposal Act, addresses solid (Subtitle D) and
                     hazardous (Subtitle C) waste management activities.  The Hazardous and
                     Solid Waste Amendments (HSWA) of 1984 strengthened RCRA's waste
                     management provisions ar.d added Subtitle I, which governs underground
                     storage tanks (USTs).

                     Regulations promulgated pursuant to Subtitle C of RCRA (40 CFR Parts
                   1  260-299) establish a "cradle-to-grave" system governing hazardous' waste
                     from the point of generation to disposal. RCRA hazardous wastes include
                     the  specific materials listed in  the  regulations (commercial  chemical
                     products, designated with the code. "P" or "U"; hazardous wastes from
                     specific  industries/sources!, designated 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").

                     Regulated entities that generate  hazardous  waste are subject  to waste
                     accumulation, manifesting, and record keeping standards.   Facilities  that
                     treat, store, or dispose of hazardous waste must obtain a permit, either from
                     EPA or from a State agency which EPA has authorized to implement the
                     permitting program.  Subtitle C permits contain general facility standards
                     such as  contingency plans, emergency procedures, record keeping  and
                     reporting requirements, fir ancial assurance mechanisms, and unit-specific
September 1995
                                    SIC 331

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Sector Notebook Project
                      Iron and Steel Industry
                    standards. RCRA also contains provisions (40 CFR Part 264 Subpart S and
                    §264.10) for conducting corrective actions which govern the cleanup of
                    releases of hazardous waste or constituents from solid waste management
                    units at RCRA-regulated 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 46 of the 50 States.

                    Most RCRA requirements are not industry specific but apply to any company
                    that transports, treats, stores, or disposes of hazardous waste.  Here are some
                    important RCRA regulatory requirements:

                           Identification of Solid and Hazardous Wastes (40  CFR Part 261)
                           lays out the procedure every generator should follow to  determine
                           whether the material created is considered a hazardous waste, solid
                           waste, or is exempted from regulation.

                           Standards for Generators of Hazardous Waste (40 CFR Part 262)
                           establishes  the responsibilities  of  hazardous waste generators
                           including obtaining an ID number, preparing a manifest, ensuring
                           proper packaging  and  labeling, meeting  standards for waste
                           accumulation units, and record keeping and reporting requirements.
                           Generators can accumulate hazardous waste for up to 90 days (or 180
                           days depending on the amount of waste generated) without obtaining
                           a permit.

                    •      Land Disposal Restrictions (LDRs) are regulations prohibiting the
                           disposal of hazardous waste on land without prior treatment. Under
                           the LDRs (40 CFR 268), materials must meet land disposal restriction
                           (LDR) treatment standards prior to placement in  a  RCRA land
                           disposal  unit (landfill, land treatment  unit, waste pile,  or surface
                           impoundment).  Wastes  subject to the LDRs include solvents,
                           electroplating wastes, heavy metals, and acids.  Generators of waste
                           subject to  the LDRs  must provide  notification of  such  to the
                           designated TSD facility to ensure proper treatment prior to disposal.

                           Used Oil Management  Standards (40  CFR Part 279)  impose
                           management requirements affecting  the storage,  transportation,
                           burning, processing, and re-refining of the used oil.  For parlies that
                           merely generate used oil, regulations establish storage standards. For
                           a party considered a used  oil marketer (one who generates and sells
                           off-specification used oil  directly to a used oil burner),  additional
                           tracking and paperwork requirements must be satisfied.

                    •      Tanks and Containers used to store hazardous waste with a high
                           volatile organic concentration must meet emission standards under
                           RCRA.  Regulations (40  CFR Part 264-265, Subpart CC) require
September 1995
54
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Sector INotcbook ^Project
                      Iron and Steel Industry
                          generators to test he waste to determine the concentration of the
                          waste, to satisfy tank and container  emissions standards, and to
                          inspect and monitor regulated units. These regulations apply to all
                          facilities who store jsuch waste, including generators operating under
                          the 90-day accumulation rule.                •

                          Underground Storage  Tanks (USTs) containing petroleum and
                          hazardous substance are regulated  under Subtitle I of  RCRA.
                          Subtitle I regulations (40 CFR Part 280) contain tank design and
                          release detection requirements, as well as financial responsibility and
                          corrective action standards for USTs.  The UST program also
                          establishes increasingly  stringent  standards,  including  upgrade
                          requirements for existing tanks, that must be met by 1998.
                           Boilers and Industrial Furnaces (BIFs) that use  or burn  fuel
                           containing hazardous waste must comply with design and operating
                           standards.  BIF regulations (40 CFR Part 266, Subpart H) address
                           unit design, provide performance standards, require emissions
                           monitoring, and restrict the type of waste that may be burned.
                                           i
                    EPA's  RCRA/Superfund/yST Hotline,  at (800)  424-9346, responds to
                    questions and distributes guidance regarding all RCRA regulations.  The
                    RCRA Hotline operates weekdays from 8:30 a.m. to 7:30 p.m., ET, excluding
                    Federal holidays.
       Comprehensive Environmental Response^
  Compensation, And Liability Act
                    The Comprehensive Environmental Response, Compensation, and Liability
                    Act (CERCLA), a 1980 lay commonly known as Superfund, authorizes EPA
                    to respond to releases, or threatened releases, of hazardous substances that
                    may endanger public health, welfare, or the environment.  CERCLA also
                    enables EPA to force parties responsible for environmental contamination to
                    clean it up or to reimburse the Superfund for response costs incurred by EPA.
                    The Superfund Amendments and Reauthorization Act (SARA) of 1986
                    revised various sections of CERCLA, extended the taxing authority for the
                    Superfund, and created a free-standing law, SARA Title III, also known as
                    the Emergency Planning a id Community Right-to-Know Act (EPCRA).

                    The CERCLA hazardous substance release reporting regulations (40 CFR
                    Part 302) direct the person in charge of a facility to report to the National
                    Response Center (NRC) any environmental release of a hazardous substance
                    which exceeds a reportable quantity. Reportable quantities are defined and
                    listed in 40 CFR §302.4. A release report may trigger a response by EPA, or
                    by one or more Federal or
 State emergency response authorities.
                    EPA implements hazardous substance responses according to procedures
                    outlined  iri the  National  Oil and Hazardous Substances  Pollution
                    Contingency Plan (NCP) (40 CFR Part 300). The NCP includes provisions
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                    for permanent cleanups, known as remedial actions, and other cleanups
                    referred to as "removals." EPA generally takes remedial actions only at sites
                    on the National Priorities List (NPL), which currently includes approximately
                    1300 sites.   Both EPA and states can act at other sites; however, EPA
                    provides responsible parties the opportunity to conduct removal and remedial
                    actions and encourages community involvement throughout the Superfund
                    response process.

                    EPA'sRCRA/Superfund/USTHotline, at (800) 424-9346, answers questions
                    and references guidance pertaining to the Superfund program.  The CERCLA
                    Hotline operates weekdays from  8:30 a.m. to 7:30 p.m., ET, excluding
                    Federal holidays.

       Emergency Planning And Community Right-To-Kno\v Act

                    The Superfund Amendments and Reauthorization Act (SARA) ,of 1986
                    created  the  Emergency  Planning and Community  Right-to-Know Act
                    (EPCRA, also known as SARA Title III), a statute designed to improve
                    community access to information about chemical hazards and to facilitate the
                    development of chemical emergency response plans by State and local
                    governments.  EPCRA required  the establishment  of  State emergency
                    response commissions  (SERCs),  responsible for coordinating  certain
                    emergency response activities and for appointing local emergency planning
                    committees (LEPCs).

                    EPCRA arid the EPCRA regulations (40 CFR Parts 350-372) establish four
                    types of reporting obligations for facilities which store or manage specified
                    chemicals:

                    •      EPCRA §302 requires facilities to notify the SERC and LEPC of the
                           presence of any "extremely hazardous substance"  (the list of such
                           substances is in 40 CFR Part 355, Appendices A and B) if it has such
                           substance in excess of the  substance's threshold planning quantity,
                           and directs the  facility to appoint an emergency response coordinator.

                           EPCRA §304 requires the facility to notify the SERC and the LEPC
                           in the event of a release  exceeding the reportable  quantity  of a
                           CERCLA hazardous substance or an EPCRA extremely hazardous
                           substance.

                    •      EPCRA §311 and §312 require a facility at which a hazardous
                           chemical, as defined by the Occupational Safety and Health Act, is
                       .   present in an amount exceeding a specified threshold to submit to the
                           SERC, LEPC and local fire department material safety data sheets
                           (MSDSs) or lists of MSDS's and hazardous chemical inventory forms
                           (also known as Tier I and II forms). This information helps the local
                           government respond in the event of a spill or release of the chemical.
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                     •       EPCRA §313 requires manufacturing facilities included in SIC codes
                            20 through 39, which have ten or more employees, and which
                            manufacture, process, or use specified chemicals in amounts greater
                            than threshold quantities, to submit an annual toxic chemical release
                            report.  This reportj commonly known as the Form R, covers releases
                            and  transfers  of( toxic  chemicals  to  various  facilities  and
                            environmental media, and allows EPA to compile the national Toxic
                            Release Inventory (TRI) database.

                     All information submitted pursuant to EPCRA regulations is  publicly
                     accessible, unless protected by a trade secret claim.

                     EPA's EPCRA Hotline, at (800) 535-0202, answers questions and distributes
                     guidance regarding the emergency planning and community right-to-know
                     regulations.  The EPCRA tiotline operates weekdays from 8:30 afm. to 7:30
                     p.m., ET, excluding Federal holidays.                  .
       Clean Water Act
                     The primary objective of the Federal Water Pollution Control Act, commonly
                     referred to as the Clean Water Act (CWA), is to restore and maintain the
                     chemical, physical, and biological integrity of the nation's surface waters.
                     Pollutants regulated under the CWA include "priority" pollutants, including
                     various toxic pollutants; "conventional" pollutants, such  as biochemical
                     oxygen demand (BOD), to al suspended solids (TSS), fecal coliform, oil and
                     grease, and pH; and "ndn-conventional" pollutants, including any pollutant
                     not identified as either conventional; or priority.   ,

                     The  CWA regulates both direct and  indirect discharges.   The National
                     Pollutant Discharge Elimination System (NPDES) program (CWA §402)
                     controls direct discharges into navigable waters. Direct discharges or "point
                     source" discharges are from sources such as pipes and sewers.  NPDES
                     permits, issued by either EPA or an authorized State  (EPA has authorized
                     approximately forty  States to  administer the NPDES  program),  contain
                     industry-specific, technology-based and/or water quality-based limits, and
                     establish pollutant monitoring  requirements.  A facility that intends  to
                     discharge into the nation's waters must obtain a permit prior to initiating  its
                     discharge.  A permit applicant must provide quantitative analytical data
                     identifying the types of pollutants present in the facility's effluent.  The
                     permit will then set forth tijie conditions and effluent limitations under which
                     a facility may make a discharge.

                     A NPDES permit may also include discharge limits based on Federal or State
                     water quality criteria or standards, that were designed to protect designated
                     uses of surface waters, such as supporting aquatic life or recreation. These
                     standards, unlike the technological standards, generally do  not take into
                     account  technological feasibility or costs.   Water  quality criteria and
                     standards vary from  State to State, and site  to site, depending on the use
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                     classification of the receiving body of water.  Most States follow EPA
                     guidelines which propose aquatic life and human health criteria for many of
                     the 126 priority pollutants.

                     Storm Water Discharges

                     In 1987 the CWA was amended to require EPA to establish a program to
                     address storm water discharges. In response, EPA promulgated the 1MPDES
                     storm water permit application regulations.  Storm water discharge associated
                     with industrial activity means the discharge from any conveyance which is
                     used for collecting and conveying storm water and which is directly related
                     to manufacturing, processing, or raw material storage areas at an industrial
                     plant (40 CFR 122.26(b)(14)). These regulations require that facilities with
                     the following storm water discharges apply for an NPDES permit:  (1) a
                     discharge associated with industrial activity; (2) a discharge from a large or
                     medium municipal storm sewer system; or (3) a discharge which EPA or the
                     State determines to contribute to a violation of a water quality standard or is
                     a significant contributor of pollutants to waters of the United States.,

                     The term "storm water discharge associated with industrial activity" means
                     a storm water discharge from one of 11  categories  of industrial activity
                     defined at 40 CFR 122.26. Six of the categories are defined by SIC codes
                     while  the other five are identified through  narrative descriptions of the
                     regulated industrial activity. If the primary SIC code of the facility is one of
                     those identified in the regulations,  the facility is subject to the  storrn water
                     permit application requirements.  If any activity at a facility is covered by
                     one of the five narrative categories,  storm water discharges from those areas
                     where the  activities occur are subject to storm water  discharge permit
                     application requirements.

                     Those facilities/activities that are subject to storm water discharge permit
                     application requirements are identified below.  To determine whether  a
                     particular facility falls within one of these categories, consult the regulation.

                     Category i:  Facilities subject to storm water effluent guidelines, new source
                     performance standards, or toxic pollutant effluent standards.

                     Category ii:  Facilities classified as SIC 24-lumber and wood  products
                     (except wood kitchen cabinets); SIC 26-paper and allied products (except
                     paperboard containers and products); SIC 28-chemicals and allied products
                     (except drugs and paints); SIC 291-petroleum refining; and SIC 31 l--leather
                     tanning and finishing.

                     Category iii:  Facilities classified as SIC 10-metal mining; SIC 12-coal
                     mining; SIC  13-oil and gas  extraction; and SIC 14-nonmetallic mineral
                     mining.

                     Category iv: Hazardous waste treatment, storage, or disposal facilities.
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                     Category v:  Landfills, land application sites, and open dumps that receive
                     or have received industria
wastes.
                     Category vi:  Facilities classified as SIC 5015-usedmotor vehicle parts; and
                     SIC 5093-automotive scrap and waste material recycling facilities.

                     Category vii: Steam electric power generating facilities.

                     Category viii: Facilities c assified as SIC 40-railroad transportation; SIC 41-
                     local passenger transportation; SIC 42-trucking and warehousing (except
                     public warehousing and storage); SIC 43-U.S. Postal Service; SIC 44-water
                     transportation; SIC 45-transportation by air; and SIC 5171-petroleum bulk
                     ,storage stations and terminals.

                     Category ix: Sewage treatment works. .        ,

                     Category x:   Construction activities except operations that result in the
                     disturbance of less than five acres of total land area.
                                            i           ;     "•'•''''.'
                     Category xi:  Facilities classified as SIC 20-food and kindred products; SIC
                     21-tobacco products; SIC 22-textile mill products; SIC 23-apparel related
                     products; SIC 2434-wood kitchen cabinets manufacturing; SIC 25-furniture
                     and fixtures; SIC 265-paperboard containers and boxes;  SIC 267-converted
                     paper and paperboard prpducts; SIC  27-pfinting, publishing, and  allied
                     industries; SIC 283-drugs;jSIC 285-paints, varnishes, lacquer, enamels, and
                     allied products;  SIC 30-rubber and plastics; SIC 3 Weather and leather
                     products (except leather arid tanning and finishing); SIC 323-glass products;
                     SIC 34-fabricated metal products (except fabricated structural metal); SIC
                     35-industrial and commercial machinery and computer equipment; SIC 36-
                     electronic and other electrical  equipment and components; SIC 37-
                     transportation equipment (except ship and boat building and repairing); SIC
                     38-measuring, analyzing, arid controlling instruments;"SIC 39-miscellaneous
                     manufacturing industries]  and SIC 4221-4225-public warehousing and
                     storage.
                     Pretreatment Program
                     Another type of discharge
that is regulated by the CWA is" one that goes to
                     a publicly-owned treatment works (POTWs). The national pretreatment
                     program (CWA §307(b)i controls the indirect discharge of pollutants to
                     POTWs by "industrial users." Facilities regulated under §307(b) must meet
                     certain pretreatment standjards. The goal of the pretreatment program is to
                     protect municipal wastewater treatment plants from damage that may occur
                     when hazardous, toxic, OB other wastes are discharged into a sewer system
                     and to protect the quality of sludge generated by these plants. Discharges to
                     a PQTW are regulated primarily by the POTW itself, rather than the State or
                     EPA. . .; •''.   '         ,| •'   •.  . •"   •        '.'
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                    EPA has developed technology-based standards for industrial users of
                    POTWs. Different standards apply to existing and new sources within each
                    category. "Categorical" pretreatment standards applicable to an industry on
                    a nationwide basis are developed by EPA.  In addition, another kind of
                    pretreatment standard, "local limits," are developed by the POTW in order
                    to assist the POTW in achieving the effluent limitations in its NPDES permit.

                    Regardless of whether a State is authorized to implement either the NPDES
                    or the pretreatment program, if it develops its own program, it may enforce
                    requirements more stringent than Federal standards.

                    Spill Prevention, Control and Countermeasure Plans

                    The 1990 Oil Pollution Act requires that facilities posing a  substantial threat
                    of harm to the environment prepare and implement more rigorous Spill
                    Prevention Control and Countermeasure (SPCC) Plan required under the
                    CWA (40 CFR §112.7). As iron and steel manufacturing is an energy
                    intensive industry, an important requirement affecting iron and steel facilities
                    is oil response plans for above ground storage. There are also criminal and
                    civil penalties for deliberate or negligent spills of oil.  Regulations covering
                    response to oil discharges and contingency plans (40 CFR Part 300), and
                    Facility Response Plans to  oil discharges (40 CFR Part 112) and for PCB
                    transformers and PCB-containing items are being revised and finalized in
                    1995.29 .

                    EPA's Office of Water, at (202) 260-5700, will direct callers with questions
                    about the CWA to the  appropriate EPA office.   EPA also maintains a
                    bibliographic  database of Office of Water publications which can  be
                    ' accessed through the Ground Water and Drinking Water resource center, at
                    (202)260-7786.
                                                        i       •
       Safe Drinking Water Act

                    The  Safe Drinking Water Act  (SDWA) mandates that EPA establish
                    regulations to protect human health from contaminants in drinking water.
                    The law authorizes EPA to develop national drinking water standards and to
                    create a joint  Federal-State system to  ensure  compliance with  these
                    standards. The SDWA also directs EPA to protect underground sources of
                    drinking water through the control of underground injection of liquid wastes.

                    EPA has developed primary and secondary drinking water standards under
                    its  SDWA authority.   EPA and authorized States  enforce the  primary
                    drinking water standards,  which are, contaminant-specific  concentration
                    limits that apply to certain public drinking water supplies. Primary drinking
                    water standards consist  of maximum contaminant level  goals (MCLGs),
                    which are non-enforceable health-based goals, and maximum contaminant
                    levels (MCLs), which are  enforceable limits set as close to MCLGs as
                    possible, considering cost and feasibility of attainment.
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                    The SDWA Underground- Injection Control (UIC) program (40 CFR Parts
                    144-148)  is a permit program which protects underground sources of
                    drinking water by regulating five classes of injection wells.  UIC permits
                    include design,.operating, inspection, and monitoring requirements.  Wells,
                    used to inject hazardous wastes must also comply with RCRA corrective
                    action standards in order (to be granted a RCRA permit, and must meet
                    applicable RCRA  land disposal restrictions standards.  The UIC permit
                  :• program is primarily State-tenforced, since EPA has authorized all but a few
                    States to administer the program.
                    The SDWA also provides
                    may contaminate the sole
br a Federally-implemented Sole Source Aquifer
                    program, which prohibits Federal funds from being expended on projects that
or principal source of drinking water for a given
                    area, and for a State-implemented Wellhead Protection program, designed to
                    protect drinking water wells and drinking water recharge areas.
                    EPA's Safe Drinking Water Hotline, at (800) 426-4791, answers questions
                    and distributes guidance] pertaining to SDWA  standards.  The Hotline
                    operates from 9:00 a.m. th *ough 5:30 p.m., ET, excluding Federal holidays.
       Toxic Substances Control Act
                    The Toxic Substances Control Act (TSCA) granted EPA authority to create
                    a regulatory framework to collect data on chemicals in order to evaluate,
                    assess, mitigate, and control risks which may be posed by their manufacture,
                    processing, and use. TSCA provides a variety of control methods to prevent
                    chemicals from posing unreasonable risk.

                    TSCA standards may apply at any point during a chemical's life cycle.
                    -Under TSCA §5, EPA has
established an inventory of chemical substances.
                     If a chemical is not already on the inventory, and has not been excluded by
                    .TSCA, a premanufacture notice (PMN) must be submitted to EPA prior to
                     manufacture or import.  The PMN must identify the chemical and provide
                     available information on health and environmental effects. If available data
                     are not sufficient to evaluate  the chemicals effects, EPA  can impose
                     restrictions  pending the development of information on its health and
                     environmental  effects.  EPA  can also. restrict significant  new  uses of
                     chemicals based upon factors such as the projected volume and use of the
                     chemical.

                     Under TSCA §6, EPA can ban the manufacture or distribution in commerce,
                     limit the use, require labeling, or place other restrictions on chemicals that
                     pose unreasonable risks.
 Among the chemicals EPA regulates under §6
                     authority are asbestos, chlorofiuorocarbons (CFCs), and polychlorinated
                     biphenyls (PCBs).         '

                     EPA's, TSCA Assistance Information Service, at (202) 554-1404, answers
                     questions and distributes guidance pertaining to Toxic Substances Control
                                            I
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                                   Act standards. The Service operates from 8:30 a.m. through 4:30 p.m., ET,
                                   excluding Federal holidays.
                      Clean Air Act
                                   The Clean Air Act (CAA) and its amendments, including the Clean Air Act
                                   Amendments (CAAA) of 1990, are designed to "protect and enhance the
                                   nation's air resources so as to promote the public health and welfare and the
                                   productive capacity of the population."  The CAA consists of six sections,
                                   known as Titles, which direct EPA to establish national standards for.
                                   ambient air quality and for EPA and the States to implement, maintain, and
                                   enforce these standards through a variety of mechanisms. Under the CAAA,
                                   many facilities will be required to obtain permits for the first time. State and
                                   local governments oversee, manage, and enforce many of the requirements
                                   of the CAAA. CAA regulations appear at 40 CFR Parts 50-99.

                                   Pursuant to Title I of the CAA, EPA has established national ambient air
                                   quality standards (NAAQSs) to limit levels of "criteria pollutants," including
                                   carbon monoxide,  lead, nitrogen dioxide,  particulate matter, ozone, and
                                   sulfur dioxide.  Geographic areas that meet NAAQSs for a given pollutant
                                   are classified as attainment areas;  those that do not meet NAAQSs are
                                   classified as non-attainment areas. Under §110 of the CAA, each State must
                                   develop a State Implementation Plan (SIP) to identify sources of air pollution
                                   and to determine what reductions are required to meet Federal air quality
                                   standards.

                                   Title I also authorizes EPA to establish New Source Performance Standards
                                   (NSPSs), which are nationally uniform emission standards for new stationary
                                   sources falling within particular industrial categories. NSPSs  are based on
                                   the pollution control technology available to that category of industrial
                                   source but  allow the  affected  industries the flexibility  to  devise a
                                   cost-effective means of reducing emissions.

                                   Under Title I, EPA establishes and enforces National Emission Standards for
                                   Hazardous Air Pollutants (NESHAPs), nationally uniform standards oriented
                                   towards controlling particular hazardous air pollutants (HAPs). Title III of
                                   the  CAAA further directed EPA to develop a list of sources that emit any of
                                   189 HAPs, and to develop regulations for these categories of sources.  To
                                   date EPA has  listed  174 categories and  developed a  schedule for  the
                                   establishment of emission  standards.   The emission standards will be
                                   developed for both new and existing sources based on "maximum achievable
                                   control technology" (MACT)."  The MACT is defined as the control
                                   technology achieving the maximum degree of reduction in the emissibn of
                                   the  HAPs, taking into account cost and other factors.

                                   Title II of the CAA pertains to mobile sources, such as cars, trucks, buses,
                                   and planes.  Reformulated gasoline, automobile pollution control devices,
                                   and vapor recovery nozzles on gas pumps are a few of the mechanisms EPA
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                     uses to regulate mobile air emission sources.

                     Title IV  establishes  a  sijilfur dioxide nitrous  oxide emissions program
                  '•   designed to reduce the formation of acid rain. Reduction of sulfur dioxide
                     releases will be obtained by granting to certain sources limited emissions
                   '  allowances, which, beginning in 1995, will be set below previous levels of
                     sulfur dioxide releases.
                     Title V of the CAAA o
                     of the operating permit is
                     requirements that apply to
 1990 created a permit program for all "major
                     sources" (and certain other sources) regulated under the CAA. One purpose
to include in a single document all air emissions
a given facility. States are developing the permit
                     programs in accordance vrith guidance and regulations from EPA. Once a
                     State program is approved by EPA, permits will be issued and monitored by
                     that State.
                     Title VI is intended to
                     manufacture  of ozone-d
                     distribution.  Production
Drotect stratospheric ozone by phasing out the
epleting  chemicals and  restrict their use and
 of Class I substances,  including 15 kinds  of
                     U1SU1UUUU11.  JTIUUUV^LIVJI UJ. V^iaao i OLIUOICUIV^O,  lll^l uviiiig,  JL~-  JLVJ.XJ.VIO \ji
                     chlorofluorocarbons (CFGs), will be phased out entirely by the year 2,000,
                     while certain hydrochlor jfluorocarbons (HCFCs) will be phased out by
                     2030.                  ,                                      , -

                     EPA's Control  Technology Center, at  (919) 541-0800, provides general
                     assistance .and  information on CAA standards.  The Stratospheric Ozone
                     Information Hotline, at (800) 296-1996, provides general information about
                     regulations promulgated! under Title VI of the CAA, and EPA's EPCEA
                     Hotline, at (800) 535-0202, answers questions about accidental release
                  .   prevention under CAA §112(r).  In addition, the Technology Transfer
                     Network Bulletin Board System (modem access (919) 541-5742)) includes
                     recent CAA rules, EPA guidance documents, and updates of EPA activities.
 VLB. Industry Specific Regulatory Requiren
 cuts
                     The steel industry has ir Vested substantial resources in compliance with
                     environmental regulations.  Expenditures for environmental air control
                     totaled $279 million in 19J91, while water and solid waste control combined
                     totaled $66 million. This translates to 15 percent of total capital expenditures
                     for the industry in 1991. The high percentage of total environmental capital
                     expenditures for air control (81 percent) is primarily due to keeping coke
                     ovens operating in compliance with the Clean Air Act. Although coke ovens
                     are considered by many industry experts to be the biggest environmental
                     problem of the iron and steel industry, environmental regulations affect the
                     industry throughout all stages of the manufacturing and forming processes.
                     An overview of how federal environmental regulations affect this industry
                     follows.
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 Clean Air Act (CAA)
                     The CAA, with its 1990 amendments (CAAA), regulates the pollutants that
                     steel mills can add to the air. Title I of the Act addresses,requirements for
                     the attainment and maintenance  of the  National Ambient Air Quality
                     Standards (NAAQS) (40 CFR, §50).  EPA has set NAAQS for six criteria
                     pollutants, which states must plan to meet through state implementation
                     plans (SIPs). NAAQS for nitrogen  dioxide,  lead, and particulate matter
                     frequently affect the iron and steel industry.

                     One of the most significant impacts of the CAAA on the iron and steel
                     industry  is tied  to  the  standards developed for toxic air emissions or
                     Hazardous Air Pollutants (HAPs). For the steel industry, these standards,
                     National Emission Standards for Hazardous Air Pollutants (NESHAPs), have
                     a significant effect on the industry's  coke ovens. In late 1991, the coking
                     industry  entered  into  a formal regulatory  negotiation with EPA  and
                     representatives of environmental groups, state and local air pollution control
                     agencies, and the steelworkers union to develop a mutually acceptable rule
                     to implement the terms of the Act's coke oven provisions.  After a year of
                     discussions, an agreement on a negotiated rule was signed. In exchange for
                     a standard that is structured to give operators certainty and flexibility in the
                     manner they  demonstrate  compliance,  the industry  agreed to daily
                     monitoring, to install flare systems to control  upset events, and to develop
                     work practice plans to  minimize emissions. National Emissions Standards
                     currently in effect that  pertain to the iron and steel industry include:

                            Coke Oven Batteries (40 CFR §63 Subpart L). As of April 1, 1992,
                            there were 30 plants with  87 by-product coke oven batteries that
                            would be affected by this regulation.

                     •       Benzene Emissions from Coke By-product Recovery Plants (40 CFR
                            §61  Subpart L). Regulates benzene  sources in coke by-product
                            recovery  operations  by requiring that specified  equipment  be
                            enclosed and the emissions be  ducted to an enclosed point in the by-
                            product recovery process where they  are recovered or destroyed.
                            Monitoring requirements are also stated.

                            Halogenated  Solvent Cleaning (40  CFR §63 Subpart T). Emission
                            standards for the source categories listed  in  §112(d), including
                            solvents used  in the iron  and steel  industry  such as  1,1,1-
                            trichloroethane, trichloroethylene, and  methylene chloride.

                            Chromium - Industrial Process Cooling Towers (40 CFR §63 Subpart
                            Q). This standard will eliminate chromium emissions from industrial
                            process cooling towers.  Industrial process  cooling towers using
                            chromate-based water treatment programs have been identified as.
                            potentially significant sources of chromium air emissions; chromium
                            compounds being among the substances listed as HAPs in §112(e).
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                    The CAA also impacts the( minimill segment of the industry.  The Electric
                    Arc Furnace was identified as a possible source of hazardous air pollutants
                    subject to a MACT determination, however, EPA data indicates that the
                    impact is much less than originally anticipated and mere are currently no
                    plans for establishing a MACT standard.                      \        •

                    The 1990 CAAA New So'urce  Review (NSR) requirements apply to new
                    facilities, expansions of existing facilities, or process modifications. New
                    sources of the "criteria" pollutants regulated by the NAAQS in excess of
                    levels defined by EPA as "major".are subject to NSR requirements (40 CFR
                    Section 52.21(b)(l)(i)(a)-(ft>)).  NSRs are typically conducted by the state
                    agency under standards set by EPA and adopted by the state as part of its
                    state implementation plan (SIP). There are two types of NSRs: Prevention
                    of Significant Deterioration (PSD) reviews for  facilities in areas that are
                    meeting the NAAQS, and] Nonattainment (NA) reviews for areas that are
                    violating the NAAQS. Permits are required to construct or operate the new
                    source for PSD and NA areas.
                                           ]•
                                          auire
For NA areas, permits require the new source to meet the lowest achievable
emission rate (LAER) standards and the operator of the new source must
procure reductions in emissions of the same pollutants from other sources in
                    the NA area in equal or greater amounts to the new source. These "emission
                    offsets" may be banked and traded through state agencies.
                    For  PSD areas, permits
                        require the best available control  technology
                    (BACT), and the  operator or owner of the  new source must conduct
                    continuous on-site air quality monitoring for one year prior to the new source
                    addition to determine the effects that the new emissions may have on air
                    quality. This one year waiting period before construction can be disruptive
                    to some mills' expansion plans. In several cases, mills looking to construct
                    or expand have attempted| to be reclassified as a "synthetic minor," where
                    they ask the state to put tighter restrictions on their quantity of emissions
                    allowed on their air permit. With these reduced emissions, they become a
                    minor instead of a major source, thereby becoming exempt from the lengthy
                    and expensive PSD revie\

                    EPA sets the minimum standards for LAER and BACT for iron and steel mill
                    NSRs in its new source performance standards (NSPS), 40 CFR 60:
                           Standards of Performance for Steel Plants: Electric Arc Furnaces
                           (40 CFR §60,  Sub part AA). Regulates the opacity and particulate
                                            discharged from EAFs constructed after October
       matter m any gases
       21, 1974  and on
                                            'or  before August 17, 1983. Also  requires a
                           continuous monitoring system for the measurement of the opacity of
                           emissions discharged-from control equipment.

                           Standards of Performance for Steel Plants:  Electric Arc Furnaces and
                           Argon-Oxygen D^carburization Vessels (AODs)  (40 CFR §60,
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                           Subpart AAa). Regulates the opacity and particulate matter in any
                           gases discharged from EAFs and AODs (used to blow argon and
                           oxygen or nitrogen into molten steel for further refining) constructed
                           after August 7,1983. Also requires a continuous monitoring system
                           for the measurement of the opacity of emissions discharged  from
                           EAF and AOD air pollution control equipment.

                           Standards of Performance for Primary Emissions from Basic Oxygen
                           Process Furnaces (BOPF) (40. CFR §60, Subpart N). Regulates the
                           discharge of gases for particulate matter and  opacity.  These
                           standards apply to BOPFs for which construction is commenced after
                           June  11,  1973. '  Primary emissions refer to particulate matter
                           emissions from the BOPF generated during the steel production cycle
                           and captured by the BOPF primary control system.

                           Standards of Performance for  Secondary Emissions  from. Basic
                           Oxygen Process Steelmaking Facilities  (40 CFR §60, Subpeirt Na).
                           Regulates the discharge of gases for particulate matter  and opacity
                           for BOPFs for which construction is commenced after  January 20,
                           1983. Secondary emissions means particulate matter emissions that
                           are not captured by the BOPF primary control system.
Clean Water Act (CWA)
                    The steel industry is a major water user and 40 CFR 420 established Effluent
                    Limitations Guidelines and Standards for the Iron and Steel Manufacturing
                    Point Source Category. These are implemented through the NPDES permit
                    program and through state and local pretreatment programs.   Part 420
                    contains production-based effluent limitations guidelines and  standards,
                    therefore steel mills with higher levels of production will receive higher
                    permit discharge allowances.  The regulation contains 12 subparts for 12
                    distinct manufacturing processes:
                           A. Cokemaking
                           B. Sintering
                           C. Ironmaking
                           D. Steelmaking
                           E. Vacuum Degassing
                           F. Continuous Casting
           G. Hot Forming
           H. Salt Bath Descaling
           I. Acid Pickling
           J. Cold Forming
           K. Alkaline Cleaning
           L. Hot Coating
                    The pollutants regulated by 40 CFR 420 are divided into three categories:

                    1. Conventional Pollutants: Total Suspended Solids, Oil and Grease, pH
                    2. Nonconvention Pollutants: Ammonia-N, Phenols
                    3. Priority or Toxic. Pollutants: Total cyanide, total chromium, hexavalent
                    chromium,  total lead, total nickel, total zinc, benzene, benzo(a)pyrene,
                    naphthalene, tertrachloroethylene.
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                    Wastewater is often recycled "in-plant" and at the "end-of-pipe" to reduce the
                    volume of discharge.  Process wastewater is usually filtered, and/or clarified
                    on-site before being directly or indirectly discharged.  Oil and greases are
                    removed from the process wastewater by several methods which include oil
                    skimming, filtration, and ^ir flotation.  These oils can then  be used as
                    lubricants and preservative! coatings. The remaining sludge contains waste
                    metals and organic chemicals.  Iron in the sludges can be recovered and
                    reclaimed through sintering and pelletizing operations.  Many steel mills
                    discharge industrial waste v rater through sewers to publicly owned treatment
                    works.

                    The Storm Water Rule (40 CFR 122.26(b)(14) subparts (i, ii)) requires the
                    capture and treatment of storm water at primary metal industry facilities
                    including iron and steel manufacturing.  Management of storm water will
                    reduce discharges with respect to conventional pollutants (suspended solids
                    and biological oxygen demand (BOD)), as well as other pollutants, such as
                   •- certain metals and oil and grease.
 Resource Conservation and Recovery Act (RCRA
                     Several  RCRA-listed wastes  are produced during  coke, iron, 'and
                     steelmaking, forming, and tleaning/descaling operations-. These wastes are
                     identified below by process,        '         .
              Coke Manufacturing
                           Tar residues (K035, K087, K1.41, K142, and K147)  .
                           Oil (K143 and K144)
                           Naphthalene residues (K145)     .                .  '   '   <
                           Lime sludge (K06Q)
                           Wastewater sump residues  containing benzene and polynuclear
                           aromatic hydrocarbons (K144)
                           Coke oven gas cone .ensate from transfer and distribution lines
              Iron and Steel Manufacturing
                            EAF emission control dust and sludge (K061). Annually,
                            550,000 short tonsjbf K061 are produced; 90 percent of this
                            waste (500,000 short tons) is managed for metal recovery.
                                    29
              Finishing
                            Wastewater sludg; from cooling, descaling,  and rinsing
                            (D006, D007, D00.8, D009, D010, and D011)
                            Spent pickle liquor! (K062). An exemption for this waste is detailed
                            in 40 CFR 261.3(c)(2)(ii)(A).  904,945 short tons of K062 are"
                            generated annually in the U.S. and 52 percent of this waste is
                            managed for recovery of iron, chromium, and nickel.30
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 Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA)

                     The  metals and  metal compounds  used in steelniaking, as  well  as
                     steelmaking process chemicals, are often found in steel mills' air emissions,
                     water discharges, or waste shipments for off-site disposal include chromium,
                     manganese, nickel copper, zinc, lead, sulfuric acid, and hydrochloric acid.
                     Metals are frequently found at CERCLA's problem sites. When Congress
                     ordered EPA and the Public Health Service's Agency for Toxic Substances
                     and Disease Registry (ATSDR)  to list  the  hazardous  substances most
                     commonly found at problem sites and that pose the greatest threat to human
                     health, lead, nickel, and aluminum  all made the list.31 Several sites of former
                     steel mills are on the National  Priorities List.   Compliance  with  the
                     requirements of RCRA lessens the chances that CERCLA compliance will
                     be an issue in the future.

 Vl.C. Pending and Proposed Regulatory Requirements

                     The iron and steel industry has been  identified in the Source Reduction
                  '   Review Project (SRRP) as an industry for which a more integrated (across
                     environmental media) approach to rulemaking is warranted. Efforts such as
                     the Office of Water's review of the need for revised effluent guidelines for
                     the industry (described below) and the technology-based standards for coke
                     oven emissions under the Clean Air Act Amendments will be coordinated
                     among several media offices.
Clean Air Act
                     Even with the flexibility the industry gained through the formal negotiations
                     to develop the rule to implement the coke oven provisions of the CAA, coke-
                     producing steel companies face difficult decisions of how best to utilize
                     scarce capital to meet the CAAA standards.  Additionally, coke oven
                     operators still face unknown technology-based standards in 2010 and risk-
                     based standards in 2020.

                     The Act's air toxic provisions will also ultimately have other major impacts.
                     Included on the list of chemicals under the air toxics program are compounds
                     of chromium, nickel, manganese, cadmium and other heavy metals. Because
                     many of these metals are routinely found hi iron ore, scrap, and alloying
                     materials that are processed  in iron and steel plants, most  steelmaking
                     processes will  be affected in some  way.   EPA's priority list of source
                     categories calls for the development of regulations for most of these sources
                     by 2000, but until EPA identifies the technology corresponding to MACT for
                     these sources and promulgates regulations, it is difficult to determine the
                     additional impacts and costs to the industry for this program.

                     Tightening the national ambient air quality standard for particulate matter
                     (PM-10) may also affect the iron and steel industry. Under the CAAA, EPA
                     will be reviewing the basis for the existing ambient air PM-10  standard.  A
                     lower standard may cause more areas of the country to be classified as non-
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                                         "  - I   .,   ' -if-        ,
                    attainment areas and would trigger requirements for states to impose much
                    more stringent emission control standards for sources of particulate matter,
                    including iron and steel so irces.

                    Hydrochloric acid and chlorine are among the pollutants listed as hazardous
                    air pollutants in  §112 of
 the CAAA.  Steel pickling processes that use
                    hydrochloric acid have been identified by the EPA as potentially significant
                    sources of hydrochloric acid and chlorine air emissions and, as such, a source
                     category for which nationa
                    the final rule promulgatior
  emission standards are likely.  EPA is expected
                    to make a determination on the steel pickling process sometime in 1995, with
 L scheduled for 11/96. Many facilities either are
                     already in compliance, or they have the required control equipment, but need
                     to upgrade it or perform niaintenance procedure to come into compliance.
                     (Contact: James Maysilles, EPA Office of Air Quality Planning  and
                     Standards, 919-541-3265)]

                     Title III of the CAAA, requires EPA to develop national emission standards
                     for hazardous air pollutarits (NESHAP) from specific stationary sources
                     including iron  and steel mills (contact: Phil  Murine, EPA Office of Air
                     Quality Planning and Standards, 919-541-5289) and iron and steel foundries
                     (contact:  James Maysilles, EPA Office  of Air Quality Planning  and
                     Standards, 919-541-3265).  Both of these types of facilities have been
                     identified by the EPA as potentially significant sources of air emissions of
                     substances that are among the pollutants listed as hazardous air pollutants in
                     §112 of the CAAA- As such, these industries may be source categories for
                     which national emission standards may be warranted.  In integrated iron and
                     steel mills, air emission of HAPs may include compounds of chromium, lead,
                     manganese,  and polycyclic organic matter, in quantities  sufficient to
                     designate these facilities ajs major sources. Emission standards were to be
                     developed for Electric Arc Furnaces also. However, EPA data does not show
                     that EAFs emit sufficient hjazardous pollutants to include them on the list of
                     major sources of these pollutants. Therefore,  a proposed regulatory action
                     is scheduled to remove this category from the list of sources where new
                     regulations will be promulgated.

                     Other, more  general, proposed regulatory actions under the CAA have an
                     effect on some facilities within the iron and steel industry. These include:

                     • Risk Management Program for Chemical Accidental Release Prevention
                     (40 CFR 68).  Requires facilities where a regulated substance is present
                     (defined by the list, with threshold quantities, promulgated under §112(r)(3))
                     to prepare and implement
 a risk management plan and provide emergency
                     response. The final rule will be promulgated by 3729'796.

                      New Source Review Reform (40 CFR 51, 52). This action will amend the
                     new source review regula
                     The final rule will be promulgated 1/96.
 ions to reduce the level of program complexity.
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                     • Revised New Source Performance Standard for NOx (40 CFR 60, Subpart
                     Db). Revisions  apply to NOx  emissions from  fossil fuel-fired  steam
                     generating units, including industrial boilers and must reflect improvements
                     in NOx reduction methods. The final rule will be promulgated by 12/31/96.

                     • Title V Federal Air Operating Permit Rules (40 CFR 70 and 71). Sets
                     requirements for  state permitting programs for  major stationary  air
                     pollutants.  Also establishes a federal permitting  program for use  where
                     states fail to establish or implement an adequate program. The final rule will
                     be promulgated by 11/95.

                     • Title V State Air Operating Permit Rules (40 CFR 70). Revisions of the
                     state operating permit rules promulgated in 1992. This regulation is intended
                     to restructure the process for issuing and revising permits, to give state
                     agencies more flexibility.  States will be allowed to issue a single permit
                     covering both.New Source Review and Title V permitting requirements.
Clean Water Act (CWA)
                     Since approximately  80 percent of the  nation's integrated steelmaking
                     capacity is located in the Great Lakes states, the current efforts to develop
                     uniform water  quality standards under the Great Lakes  Water Quality
                     Initiative may have a significant impact on the industry. According to the
                     American Iron and Steel Institute  (AISI), the industry is concerned with the
                     establishment of uniform water quality  guidance for  all waters.   AISI
                     believes that states should "be given the responsibility of designating uses and
                     associated water quality  standards  for  all  water bodies within  their
                     jurisdictions.  These designations, AISI believes, should take into account the
                     feasibility of the attainment of swimmable  and fishable waters where
                     naturally occurring pollutants prevent its attainment, where pollution sources
                     prevent attainment and correction of these sources would cause more
                     environmental  harm than good, or where attainment would  result  in
                     unreasonable social and economic impacts.  AISI concludes that requiring
                     discharges of non-contact cooling water to be cleaner than when drawn from
                     the stream or lake, while at the same time disregarding the water quality
                     impacts of non-point  sources such  as urban or agricultural runoff, will
                     impose huge costs, restrict growth, or  force zero discharge on  direct
                     dischargers.  By March 23, 1997, the Great lakes states (Illinois, Indiana,
                     Michigan, Minnesota,  New York, Pennsylvania, Ohio, and Wisconsin), as
                     well as tribes in the area, must adopt rules and procedures consistent .with the
                     Water Quality Guidance for the  Great Lakes System (40 CFR  132; also
                     amends 122,  123, and  131). The Guidance places particular emphasis on
                     decreasing bioaccumulative toxics and also provides a process for addressing
                     both point and non-point source pollution.

                     The EPA is currently revisiting the CWA Effluent Guidelines and Standards
                     for Iron and Steel Manufacturing Point Source Category. A two-year study
                     is scheduled  to be completed in late 1995 which reviews the existing
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                     regulations to determine What changes have been made in the industry since
                     the  1982 regulations werje promulgated.  One focus of the project is to
                     investigate the  types  of
                     implemented.  The study
                     Defense Council (NRDC)'
                     of Water, 202-260-7151).
 pollution prevention measures  that have been
 was initiated as a result of a Natural Resources
 consent decree. (Contact: George Jett, EPA Office
                     .The Office of Water is also initiating a 3-year data collection and analysis
                     effort (which began in 1994) to quantify the adverse impacts from cooling
                     water intake  structures arid the efficacy  of certain control mechanisms^
                     Regulatory options will be developed and a regulation proposed based on the
                     study results. This regulation may have a relatively significant impact on the
                     iron and steel industry.
Resource Conservation and Recovery Act (RCRti)
                     Under RCRA, emission control dust and sludge from electric arc furnaces
                     (EAF) are a listed hazardous waste (K061) and are subject to land disposal
                     restrictions.  This pollution" control dust/sludge is composed  of various
                     metals: primarily iron with lesser concentrations of zinc, lead, cadmium, and
                     sometimes nickel and chromium.  The metajs primarily recovered are iron
                     or nickel alloys or zinc. Two or the primary hazardous constituents, lead and
                     cadmium, are not initially recovered, although they are usually shipped off-
                     site for further  recovery.  Annually,  550,000 short tons of K061 are
                     produced; 90 percent of this waste (500,000 short tons) is managed for metal
                     recovery.32  EPA's treatment standards  were  originally based on high
                     temperature metals recovery, but were recently revised to generic treatment
                     levels.  As a result, a generator may select one of a variety of options,
                     including  stabilization, as  alternatives  to  recycling.   Other recovery
                     alternatives include: use as a fertilizer ingredient, use an ingredient in glass
                     grit for abrasive blast, roofing shingles, glass ceramic or ceramic glaze, use
                     as an ingredient in the p:
                     production of special agg
 •oduction of cement, use as an ingredient in the
 •egates.
33
                     Such recovery practices reduce the quantity of hazardous waste disposed of,
                     however, the industry is concerned with the limitations that are placed on the
                     disposal or uses of non-hazardous residuals from the high temperature metals
                     recovery processes that might serve to discourage or inhibit metal recovery
                     practices.   According to several steel  industry trade associations (SMA,
                     SSINA, AISI), RCRA has discouraged metal recovery from hazardous
                     wastes generated in steel production. For example, the derived-from rule has
                     discouraged investment in on-site or regional recycling operations because
                     of the additional cost of residual management. The trade associations also
                     state that the lack of adequate metal recovery capacity in the U.S. requires
                     their members to spend ata average of $650,000 annually in transportation
                     costs to ship K061 off-site, and a total  of $1.4 million annually to recycle
                   .--  K061.34 Other RCRA impediments stated by the trade associations include
                     the 90-day  storage limit  for generators, and corrective action/financial
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                     assurance.

                     As part of a 1992 settlement agreement, EPA has agreed to propose (by June
                     30, 1995) and promulgate (by June 30, 1996) regulations for land disposal
                     restrictions on mineral processing wastes. These regulations will set land
                     disposal restrictions and standards for those mineral processing wastes that
                     are found to be hazardous under RCRA Subtitle G. Currently, all extraction
                     and beneficiation wastes,  as well as 20 mineral processing wastes, are
                     exempt from federal hazardous waste regulations.

                     Under a proposed regulation,  "Hazardous Waste Management System:
                     Amendment to Generic Exclusion for Encapsulated Uses (K061, K062,
                     F006),"  (40 CFR 261), the slags created from the treatment of pollution
                     control dusts resulting from scrap metal recycling (i.e., electric arc furnace
                     dust), will be reclassified as nonhazardous and be allowed for road-related
                     uses if the toxic metals in the wastes have been reduced to safe levels by
                     treatment. The,final rule will be promulgated by 6/13/96.

                    .Also under RCRA Subtitle C (40 CFR 261),  the  "Hazardous Waste
                     Identification Rule" will be proposed in 1995 to allow listed wastes which
                     are low risk to be removed from the hazardous waste regulatory scheme.
                     This rule is intended to better align the burden of RCRA regulation with the
                     risks being controlled.

 Comprehensive Environmental Response,  Compensation, and Liability Act (CERCLA)

                     Steel companies involved in Superfund sites would be affected by changes
                     under impending CERCLA reauthorization! Questions of liability, funding
                     mechanisms, selection of remedial actions, and application of risk concepts
                     are all of concern to the steel industry.

Safe Drinking Water Act (SDWA)                       .

                     The 1986 SDWA amendments required EPA to complete a study of Class V
                     underground injection wells.  These are all wells not included in Classes I
                     through IV; they vary from simple septic systems and shallow cesspools to
                     deep, technically sophisticated wells  with a wide range of environmental
                     impacts. As a follow up to the study, EPA developed  a strategy to assess
                     whether additional controls of these wells would be appropriate. A proposed
                     regulation on Class V wells is being developed as part of this strategy and
                     could potentially affect some iron and steel facilities. Final rule promulgation
                     is scheduled for 11/96.
Global Climate Change
                    Legislative initiatives .that address global climate change will also affect the
                    iron and steel industry. Steel is a highly energy intensive industry, where 15
                    to 20 percent of the manufacturing cost of steel is for energy. Most of that
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                    energy is derived from coal, principally in the form of coke. Consequently,
                    a carbon tax could have ajmajor impact on the steel industry. While such a
                    tax is designed to reduce carbon dioxide emissions and to curb energy
                    consumption, industry  analysts expect such a tax would also results in
                    177,000 to 362,000 job (losses across the country, according to Wilbur
                    Steger, president of COl^SAD Research Corp., as  reported in the March
                    1993 issue of Iron Age.
                    Increasing the corporate
                    been identified as a means
                    carbon dioxide emissions.
                    to downsizing automobi
                    demand-for certain steel products.
verage fuel economy (CAFE) of automobiles has
of encouraging energy conservation and reducing;
 An increase in fuel economy standards may lead
es,  which will affect steel markets  by reducing
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VII. COMPLIANCE AND ENFORCEMENT HISTORY
       Background
                     To date, EPA has focused much of its attention on measuring compliance
                     with specific environmental statutes.  This approach allows the Agency to
                     track compliance with the Clean Air Act, the Resource Conservation and
                     Recovery Act, the Clean! Water Act, and other environmental statutes.
                     Within the last several years, the Agency has begun to supplement single- .
                     media compliance indicators with facility-specific, multimedia indicators of
                     compliance. In doing so, EPA is hi a better position to track compliance with
                     all statutes at the facility level, and within specific industrial sectors.

                     A major step  in building the capacity to compile multimedia data, for
                     industrial sectors was the cjreation of EPA's Integrated Data for Enforcement
                     Analysis (IDEA) system.  IDEA has the capacity to "read into" the Agency's
                     single-media databases, extract compliance records, and match the records
                     to individual facilities.  Tfhe IDEA system can match Air, Water, Waste,
                     Toxics/Pesticides/EPCRAj TRI, and Enforcement Docket records for a given
                     facility, and generate a list !of historical permit, inspection, and enforcement
                     activity. IDEA also has the capability to analyze data by geographic area
                     and corporate holder. As
                     data improves, EPA will
  the capacity to generate multimedia compliance
  make available more in-depth compliance and
                     enforcement information. Additionally, sector-specific measures of success
                     for compliance assistance lefforts are under development.
                                            i                .  '     f '
       Compliance and Enforcement Profile Description

                     Using inspection, violation and enforcement data from the IDEA system, this
                     section provides inform;
 ition regarding the historical compliance and
                     enforcement activity of this sector. In order to mirror the facility universe
                     reported in the Toxic Chemical Profile, the data reported within this section
                     consists of records only frojm the TRI reporting universe.  With this decision,
                     the selection criteria are consistent across sectors with certain exceptions.
                     For the sectors that do not normally report to the TRI program, data have
                     been provided from EPA's Facility Indexing System (FINDS) which tracks
                     facilities in all media databases.  Please note, in this section, EPA does not
                     attempt to define the actual number of facilities that fall within each sector.
                     Instead, the section portrays the records of a subset of facilities within the
                     sector that are well defined within EPA databases.
                    As a check on the relative size of the full sector universe, most notebooks
                    contain an estimated number of facilities within the sector according to the
                    Bureau of Census  (See  Section II).  With sectors dominated by small
                    businesses, such as metal finishers and printers, the reporting universe within
                    the EPA databases may be small in comparison to Census data. However,
                    the group selected  for inclusion in this  data analysis section should be
                    consistent with this  sector's general make-up.
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                    Following this introduction is a list defining each data column presented
                    within this section.  These values represent a retrospective summary of
                    inspections and enforcement actions, and solely reflect EPA, State, and local
                    compliance assurance activities that have been entered into EPA databases.
                    To identify any changes in trends, the EPA ran two data queries, one for the
                    past five calendar years (August 10, 1990 to August 9, 1995) and the other
                    for  the most recent twelve-month period (August 10, 1994 to August 9,
                    1995).  The five-year analysis gives an average level of activity for that
                    period for comparison to the more recent activity.

                    Because most inspections focus on single-media requirements, the data
                    queries  presented in this section are taken from  single media databases.
                    These databases do not provide data on whether inspections are state/local
                    or EPA-led.  However, the table breaking down the universe of violations
                    does give the reader a crude measurement of the EPA's and states' efforts
                    within each  media program.  The presented data illustrate the variations
                    across regions for  certain sectors."1 This variation may be  attributable to
                    state/local .data  entry variations, specific  geographic  concentrations,
                    proximity to  population centers, sensitive ecosystems, highly toxic chemicals
                    used in production, or historical noncompliance. Hence, the exhibited data
                    do not rank regional performance or necessarily reflect which regions may
                    have the most compliance problems.

Compliance and Enforcement Data Definitions

       General Definitions

                    Facility Indexing System (FINDS) -- this system assigns a common facility
                    number to EPA  single-media permit records. The  FINDS identification
                    number allows  EPA t6 compile and review  all permit, compliance,
                    enforcement and pollutant release data for any given regulated facility.

                    Integrated Data for Enforcement Analysis (IDEA) -- is a data integration
                    system that  can retrieve information from the major EPA program office
                    databases. IDEA uses the FINDS identification number to "glue together"
                    separate data records from EPA's databases.  This is done to create a "master
                    list" of data records  for any given facility.  Some of the data systems
                    accessible through IDEA are: AIRS (Air Facility Indexing and Retrieval
                    System, Office of Air and Radiation), PCS (Permit Compliance System,
                    Office of Water), RCRIS (Resource Conservation and Recovery Information
                    System, Office of Solid Waste), NCDB (National Compliance Data Base,
                    Office  of Prevention,  Pesticides,  and  Toxic  Substances),  CERCLIS
                    (Comprehensive  Environmental   and Liability  Information  System,
* EPA Regions include the following states: I (CT, MA, ME, RI, NH, VT); II (NJ, NY, PR, VI); III (DC, DE, MD,
PA, VA, WV); IV (AL, FL, GA, KY, MS, NC, SC, TN); V (IL, IN, MI, MN, OH, WI); VI (AR, LA, NM, OK, TX);
VII (IA, KS, MO, NE); VIII (CO, MT, ND, SD, UT, WY); IX (AZ; CA, HI, NV, Pacific Trust Territories); X (AK,
ID,OR,WA).
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                     Superfund), and TRIS  ('
'oxic Release Inventory System).  IDEA  also
                     contains information from outside sources such as Dun and Bradstreet and
                     the Occupational Safety and Health Administration (OSHA). Most date
                     queries displayed in notebook sections IV and VII were conducted using
                     IDEA.

       Data Table Column Heading Definitions

                  1   Facilities in Search— are based on the universe of TRI reporters within the
                     listed SIC  code range.  For industries not covered under TRI reporting
                     requirements, the notebook uses the FINDS universe for executing data
                     queries.  The SIC code range selected for each search is defined by each
                     notebook's selected SIC code coverage described in Section II.

                     Facilities Inspected — indicates the level of EPA  and state agency
                     inspections for the facilities in this data search.  These values show what
                     percentage of the facility universe is inspected in a 12 or 60 month period.
                    Number  of Inspections
                    conducted in this sector.
                    entered into a single media
-- measures the total  number of inspections
An inspection event is counted each time it is
database.
                    Average Time Between Inspections -- provides an average length of time,
                    expressed hi months, between compliance inspections at a facility within the
                    defined universe.        '
                    Facilities with One or More Enforcement Actions -- expresses the number
                    of .facilities that were the subject of at least one enforcement action within
                    the defined time period. This category is broken down further into federal
                    and state actions.  Data are obtained for administrative,  civil/judicial, and
                    criminal enforcement actions.  Administrative actions include Notices of
                    Violation (NOVs). A facility with multiple enforcement actions is only
                    counted once in this column (facility with 3 enforcement actions counts as
                                            '  "   '        '                 '
                    Total Enforcement Actions -- describes the total number of enforcement
                    actions identified for an iridustrial sector across all environmental statutes.
                    A facility with multiple enforcement actions is counted multiple times (a
                    facility with 3 enforcement actions counts as 3).
                    State Lead Actions -- shows what percentage of the total enforcement
                    actions are taken by state and local environmental agencies. Varying levels
                    of use by states of EPA data systems may limit the volume- of actions
                    accorded  state enforcement  activity.   Some states extensively  report
                    enforcement activities into EPA data systems, while other states may use
                    their own data systems.
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                    Federal Lead Actions — shows what percentage of the total enforcement
                    actions are taken by the United States Environmental Protection Agency.
                    This value includes referrals from state agencies. Many of these actions
                    result from coordinated or joint state/federal efforts.

                    Enforcement to Inspection Rate ~ expresses how  often enforcement
                    actions result from inspections. This value is a ratio of enforcement actions
                    to inspections, and is presented for comparative purposes only. This measure
                    is a rough indicator of the relationship between inspections and enforcement.
                    This measure simply indicates historically how many enforcement actions
                    can  be attributed to inspection activity.   Reported inspections  and
                    enforcement actions under the Clean Water Act (CWA), the Clean Air Act
                    (CAA) and the Resource Conservation and Recovery Act (RCRA)  are
                    included in this ratio.  Inspections and actions  from  the TSCA/FIFRA/
                    EPCRA database are not factored into this ratio because most of the actions
                    taken under these programs are not the result of facility inspections. This
                    ratio does  not account for enforcement actions arising from non-inspection
                    compliance monitoring'activities (e.g., self-reported water discharges) that
                    can result  in enforcement action within the CAA, CWA, and RCRA.

                    Facilities  with One or More Violations  Identified  — indicates  the
                    percentage of inspected facilities having a violation identified in one of the
                    following  data categories:  In Violation or .Significant Violation Status
                    (CAA); Reportable Noncompliance,  Current  Year Noncompliance,
                    Significant Noncompliance (CWA);  Noncompliance and Significant
                    Noncompliance (FIFRA, TSCA, and EPCRA); Unresolved Violation and
                    Unresolved High Priority Violation (RCRA). The values presented for this
                    column reflect the extent of noncompliance within the measured time frame,
                    but do not distinguish between the  severity of the noncompliance. .Violation
                    status may be  a precursor to an enforcement action, but does not necessarily
                    indicate that an enforcement action will occur.

                    Media Breakdown of Enforcement  Actions  and Inspections -- four
                    columns identify the proportion of total inspections and enforcement actions
                    within EPA Air, Water, Waste, and TSCA/FIFRA/EPCRA databases. Each
                    column is a percentage  of either the  "Total Inspections," or the "Total
                    Actions" column.                -
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 VILA. Iron and Steel Industry Compliance History
                     Exhibit 14 provides an overview of the reported compliance and enforcement
                     data for the iron and steel industry over the past five years (August 1990 to
                     August 1995).  These da a are  also broken out by EPA Region thereby
                     permitting geographical co: nparisons. A few points evident from the data are
                     listed below.
                                             ' '. "     ^   .        '•'".''•'
                     •     Eighty-five percem of iron and steel facility inspections occurred in
                           Regions III, IV, and V, where the most facilities are located.
                            Within the three regions where iron and steel mills are concentrated,
                            the proportion of state-lead enforcement actions  was significantly
                            greater than federal action for Regions IE and IV (87% state-lead and
                            91% state-lead, respectively).  In Region V, the region with the
                            greatest number of iron and steel facilities, enforcement actions were
                            fairly evenly split between state-lead and federal-lead..

                            Of the 275 facilities inspected over the five-year period examined,
                            115 had one  or more enforcement  actions (42%), however, the
                            aggregate Enforcement to Inspection Rate across  all Regions was
                            0.14 (499 enforcement actions/3,555 inspections).
September 1995
79
SIC 331

-------
Sector Notebook Project
                    Iron and Steel Industry







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September 1995
80
SIC 331

-------
Sector Notebook Project
                      Iron and Steel Industry
VII.B. Comparison of Enforcement Activity Between Selected Industries
                    Exhibits 15 and 16 allow
                    to be compared to the
                    identification of trends
                    industry by comparing
the compliance history of the iron and steel sector
other industries covered by the  industry sector
                    notebooks.   Comparisons  between  Exhibits  15 and, 16  permit the
 n compliance and  enforcement records  of the
 ita covering the last five years to that of the past
                    year.' Some points evident from the data are listed below.

                    •      Of those sectors Ijisted, facilities in iron and steel sector have been
                           one of the most frequently inspected industries over the past five
                           years  with an average of 6 months between inspections.   Only
                           petroleum refining and pulp and paper facilities were inspected, on
                           average, more frequently.

                    •      Over the past yean the enforcement to inspection rate for the iron and
                           steel industry has decreased from 0.14 for 1990 through 1995 to 0.09
                           for August 1994 through August 1995.'

                    Exhibits 17 and  18 provide a more in-depth comparison between iron and
                    steel industry and  other  sectors by breaking out the compliance and
                    enforcement data by em ironmental statute. As in the previous Exhibits
                    (Exhibits 15 and 16), the data cover the last five years (Exhibit 17) and the
                    last one year (Exhibit 18)  to facilitate the identification of recent trends. A
                    few  points evident from the data are listed below.

                    •      The percentage of inspections carried out under each environmental
                           statute has changed little between the average of the past five years
                           and that of the past year.  Inspections are roughly divided equally
                           among, CAA, CWA, and RCRA,  although the past year has shown
                           a slight increase :n the percentage of CAA inspections and a slight
                           decrease in the percentage of RCRA inspections.

                    •      While approximaely one-third of inspections are carried out under
                           each statute  (CAA, CWA, and RCRA),  the  majority  of the
                           enforcement actions are taken under RCRA.
September 1995
                                     SIC 331

-------
Sector Notebook Project
Irom and Steel Industry









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September 1995
                                  84
                                                        SIC 331

-------
Sector Notebook. Project
Iron and Steel Industry

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-------
Sector Notebook Project
                      Iron and Steel Industry
VII.C. Review of Major Legal Action

       Major Cases/Supplemental Environmental Projects
                    This section provides summary information about major cases that have
                    affected this  sector, and  a list of Supplemental Environmental Projects
                    (SEPs).  SEPs are compliance agreements that reduce a facility's non-
                    compliance penalty in return for an environmental project that exceeds the
                    value of the  reduction.  Often, these projects fund pollution prevention
                    activities that can significantly reduce the future pollutant loadings of a
                    facility.

       VII.C.1. Review of Major Cases

                    The Office  of Regulatory  Enforcement does not  regularly compile
                    information related to major cases and pending litigation within an industry
                    sector. The staff are willing to pass along such information to  Agency staff
                    as requests are made.  (Contact: Pete Rosenberg 202-260-8869)  In addition,
                    summaries of completed enforcement actions are published each fiscal year
                    in the Enforcement Accomplishments  Report;  the  summaries  are  not
                    organized by industry sector.  (Contact: Robert Banks 202-260-8296).

       VII.C.2. Supplementary Environmental Projects (SEPs)

                    Supplemental environmental projects (SEPs) are enforcement options that
                    require the non-compliant facility to complete specific projects.  Regional
                    summaries  of SEPs undertaken in the 1993 and 1994 federal fiscal years
                    were reviewed. Three projects were undertaken that involved iron and steel
                    facilities, as shown in Exhibit  19.

                    In the iron and steel  sector, SEPs  resulted from violations  of EPCRA,
                    CERCLA, and RCRA.  Due  to  differences in regional descriptions, the
                    specifics of the original violations are not known. The cost for the projects
                    ranged from $53,000 to $900,000 corresponding to initial penalties ranging
                    from $110,000 to $746,438.            .  .
September 1995
86
SJC331

-------
Sector Notebook Project
Iron and Steel Industry
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September 1995
               SIC 331

-------

-------
Sector Notebook Project
                                            Iron and Steel Industry
VIII. COMPLIANCE ACTIVITIES AND INITIATIVES
                    This section highlights the activities undertaken by this industry sector and
                    public  agencies  to voluntarily  improve  the  sector's  environmental
                    performance.  These activities include those independently initiated by
                    industrial trade associations. In this section, the notebook also contains a
                    listing and description of national and regional trade associations.

VIII.A. Sector-related Environmental Programs and Activities

Common Sense Initiative

                    The EPA's Common Sens; Initiative (CSI)was announced in November of
                    1993 to encourage  pollution prevention in a few pilot industrial sectors
                    including:  iron  and  ste'el, electronics, metal  plating and finishing,
                    automobiles, printing, and oil refining. The .program shifts regulatory focus
                    from concentrating  on individual toxic chemicals and media, to industry-
                    wide approaches to environmental problems.  A subcommittee will be
                    formed for each  industry and a strategic plan will be drawn up to identify
                    opportunities to  coordinate  rulemaking, to streamline record-keeping and
                    permitting requirements, and to identify innovative approaches in pollution
                    prevention and environmental technology. For the iron and steel industry,
                    a subcommittee has been formed and four workgroups have been established.
                    The .workgroups include representatives  from industry, EPA (federal and
                    regional),  state  environmental agencies, public  interest  groups, trade
                    associations, and research! institutions. The iron and steel CSI workgroups
                    include: Innovative Technology,  Permits  Process, Compliance,  and
                    Brownfields.  Projects proposed by each of the workgroups are subject to
                    approval by the subcommittee. Project approval is expected in May, 1995.
                    Common Sense Initiative contacts at EPA are:
                                           t
                    Designated Federal Official (EPA Office of Water):
                                        MaheshPpdar, 202-260-53 87

                    Subcommittee Co-Chair (EPA Office of Water):
                                      .  Bo 3 Perciasepe, 202-260-5700

                    Subcommittee Co-Chair (0EPA Region V):
                        .                Dave Ullrich, 312-886-3000
                     OECA contact (Compliance Workgroup):
                                        - Maria Malave, 202-564-7027
                                       lits Pr
OECA contact (Permits Pjrocess Workgroup):
                    Mike Calhoun, 202-564-6031
 September 1995
                      89
SIC 331

-------
 Sector Notebook Project
                       Iron and Steel Imdustry
 VIII.B. EPA Voluntary Programs
 33/50 Program
                     The "33/50 Program" is EPA's voluntary program to reduce toxic chemical
                     releases and transfers of seventeen chemicals from manufacturing facilities.
                     Participating companies pledge to reduce their toxic chemical releases and
                     transfers by 33% as of 1992 and by 50% as of 1995 from the 1988 baseline
                     year.  Certificates  of Appreciation have been given out to participants
                     meeting their 1992 goals.  The list of chemicals includes seventeen high-use
                     chemicals reported in the Toxics Release Inventory. Exhibit 20 lists those
                     companies participating in the 33/50 program that reported the SIC code 331
                     to TRI.  Many  of the companies  shown listed multiple SIC codes and,
                     therefore, are likely to carry out operations in addition to the iron and steel
                     industry.  The SIC codes reported by each company are listed in no particular
                     order.  In addition, the number  of facilities within each company that are
                     participating hi the 33/50 program and that report SIC 331 to TRI is shown.
                     Finally, each company's total 1993 releases and transfers of 33/50 chemicals
                     and the percent reduction in these chemicals since 1988 are presented.

                     Thirteen of the seventeen target chemicals are used in the iron and steel
                     industry.  Of all TRI chemicals released by the iron and steel industry,
                     chromium and chromium compounds, a 33/50 target chemical, were released
                     most frequently  (from 347 facilities), and were the third greatest volume.
                     Other target chemicals that were in  the top ten TRI releases by volume and
                     by number of facilities reporting that chemical released were nickel and
                     nickel compounds, lead and lead compounds, and l,l,lrtrichloroethane.
                     Approximately twelve percent  of  eligible iron  and steel companies are
                     currently participating in the program. Exhibit 20 shows that 49 companies
                     comprised of 115 facilities reporting SIC 331  are participating in the 33/50
                     program.  (Contact: Mike Burns 202-260-6394 or 33/50 Program 202-260-
                     6907).
September 1995
90
SIC 331

-------
Sector Notebook Project
                     Iron and 'Steel Industry
Exhibit 20: SIC 331 Facilities Participating in the EPA's 33/50 Program* '
Parent Company
Acme Metals Inc. ,
Allegheny Ludlum Corporation
American Cast Iron Pipe Co.
Ameron Inc Delaware
Amsted Industries Incorporated
Arrnco Inc. . ...
Armco Steel Company L.P,
Avesta Sheffield Holding Co.
Bayou Steel Corporation
Bethlehem Steel Corporation
Cargill Detroit Corporation
Carpenter Technology Corp.
CF&L Steel Corp.
Commercial Metals Company
Contran Corporation
Cooper Industries Inc.
CSC Industries Inc. , .
Emerson Electric Co.
First Mississippi Corporation
Ford Motor Company
Geneva Steel
Inland Steel Industries Inc.
J & L Specialty Steel Inc.
Kanthal Furnace Prods:
Katy Industries Inc.
Kerr-Mcgee Corporation
LTV Steel Co. Inc.
Lukens Inc.
Naco Inc.
National Steel Corporation
Olin Corporation
Oregon Steel Mills Inc.
Plymouth Tube Company
Renco Group Inc.
Republic Engineered Steels
Roanoke Electric Steel Corp,
City, State
Riverdale, IL
Pittsburgh, PA
Birmingham, AL
Pasadena, CA
Chicago;. IL
Pittsburgh, PA
Middletown, OH
New Castle, IN
La Place, LA
Bethlehem, PA
Clawson, MI
Reading, PA
Pueblo, CO
Dallas, TX
Dallas, TX
Houston, TX
Warren, OH
Saint Louis, MO
Jackson; MS'
Dearborn, MI
Orem, UT
Chicago, IL
Pittsburgh, PA
Bethel, CT
Englewood, CO
Oklahoma City, OK
Cleveland, OH
Coatesville, PA
Lisle, IL
Mishawaka, IN
.Stamford, CT
Portland, OR
Warrenville, IL
New York, NY
Massillon, OH
Roanoke, VA
f
SIC, Codes
Reported
331,2, 3499,3479
331
2
33^2, 33 17, 3325
327,2,3317,3443
33
5,3496,3471
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33J2
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346,9,3315
33
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33J2, 3317, 3325
33 J2, 3274
33
33
33
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6, 3351, 3353
28J9, 3313
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33 J2, 3295
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1 : '• '
1
- , .- 1
1.
1 '
1
1
1 .
2 ' .
1
1
1
7 .
4
1
2
1
1
1
2
4
1
1993 Releases
and Transfers
(Ibs)
. 157,232
1,031,164
315,184
184,882
1,834,493
; 1,849,709
.>'> 159,944
; • 27,025
1,892
792,550
717,558
57,155
308,892
36,457
735,655
1,048,465
8,808
2,140,497
200,977
15,368,032
12,448
733,7.86
669,309
21,581
82,256
374,098
612,924
312,442
71,800
682^86
574,673
14,533
76,694
204,629
193;662
476
% Reduction
1988 to 1993
38
*
25 '
**
66
4
*
99
98
50
31
86
50
47
50 .
75
50
, 50
***
15
***
48
100
41
52
35
60
14
***
50
70
12
*
1 7
3
***

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Exhibit 20: SIC 331 Facilities Participating in the EPA's 33/50 Program
Parent Company
SKW Alloys Inc.
Slater Steels Corporation
Svwa Inc.
Talley Industries Inc.
Texas Industries Inc.
Thomas Steel Strip Corp.
Timken Co.
Toledo Coke Corporation
USS Posco Industries
USX Corporation
Walter Industries Inc.
Weirton Steel Corporation
Wheeling-Pittsburgh Corp.
City, State
Niagara Falls, NY
Fort Wayne, IN
Huntington, WV
Phoenix, AZ
Dallas, TX
Warren, OH
Canton, OH
Toledo, OH
Pittsburg, CA
Pittsburgh, PA
Tampa, FL
Weirton, WV
Wheeling, WV
SIC Codes
Reported
3313
3312
3312
3312
3312
3471,3316
3312
3312
33}2
33J2
3312
3312
3312
Total
Number of
Participating
Facilities
1
1
1
1
1
1
5
1
1
6
1
1
6
115
1993 Releases
and Transfers
(Ibs)
7,777
22,205
43,405
3,804
20,964
6,839
278,695
18
182,431
1,510,772
859,751
183,497
560,055
% Reduction
1988 to 1993
*
50
27
***
*
50
30
90
56
25
***
**
66

*•« not quantifiable against 1988 data. ,
** = use reduction goal only.
*** = no numerical goal.
Source: U.S. EPA, Toxics Release Inventory, 1993.
Environmental Leadership Program
                    The Environmental Leadership Program (ELP) is a national initiative piloted
                    by EPA  and state  agencies in which facilities have volunteered  to
                    demonstrate  innovative approaches  to  environmental  management and
                    compliance.  EPA has selected 12 pilot projects at industrial facilities and
                    federal installations  which will demonstrate the principles of the  ELP
                    program.  These principles include: environmental management systems,
                    multimedia compliance assurance, third-party verification of compliance,
                    public measures of accountability, community involvement, and mentor
                    programs.  In return for participating, pilot participants receive public
                    recognition and are given a period of time  to correct any  violations
                    discovered during these experimental projects. In the iron and steel industry,
                    one company (California Steel of Fontana, California) submitted a proposal.
                    (Contact: Tai-ming Chang, ELP Director, 202-564-5081 or Robert Fentress,
                    202-564-7023.)
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Project XL
                    Project XL was initiated
 in March 1995 as a part of President Clinton's
                    Reinventing Environmental Regulation initiative.  The'projects seek to
                    achieve cost effective environmental benefits by allowing participants to
                    replace or modify existing ^regulatory requirements on the condition that they
                    produce greater envrronmental benefits.  EPA and program participants will
                    negotiate and sign a Final Project Agreement, detailing specific objectives
                    that the-regulated entity shall satisfy.  In exchange, EPA will allow the
                    participant a certain degree of regulatory flexibility and may seek changes
                    in underlying regulations or statutes. Participants are encouraged to seek
                    stakeholder support from local governments, businesses, and environmental
                    groups.  EPA hopes to,implement fifty pilot projects  in four categories,
                    including facilities, sectors,, communities, and government agencies regulated
                    by EPA.  Applications will be accepted on a rolling basis and'projects will
                    move to  implementation within six months of their selection. For additional
                    information regarding XL projects, including application procedures and
                    criteria, see the May 23,1995 Federal Register Notice, or contact Jon Kessler
                    at EPA's Office of Policy Analysis (202) 260-4034.
Green Lights Program
                     EPA's Green Lights pro jram was initiated in 1991 and has the goal of
                     preventing pollution by enjcouraging U.S. institutions to use energy-efficient
                     lighting technologies.  The program has over 1,500 participants which
                   ,  include major corporations; small and medium sized businesses; federal,
                     state and local governments; non-profit groups; schools; universities; and
                     health care facilities^ Each participant is required to survey their facilities
                     and upgrade lighting wherever it is profitable.  EPA provides technical
                     assistance to the participants through a decision support software package,
                     workshops and manuals, and a financing registry. EPA's Office of Air and
                     Radiation is responsible for operating the Green Lights Program.  (Contact:
                     Susan Bullard at 202-233-9065 or the Green Light/Energy Star Hotline at
                     202-775-6650)
 WasteWi$e Program
                     The WasteWi$e Progranji was started in 1994 by EPA's Office of Solid
                     Waste and Emergency Response.   The program is aimed at  reducing
                     municipal  solid wastes  by  promoting waste  minimization, recycling
                     collection and the manufacturing andxpurchase of recycled products.  As of
                     1994, the program had about 300 companies as members, including a number
                     of major corporations. Members agree to identify and implement actions to
                     reduce their solid wastes and must provide EPA with their waste reduction
                     goals along with yearly progress reports., EPA in turn provides technical
                     assistance to member companies and allows the use of the WasteWi$e logo
                     for promotional purposes.  (Contact: Lynda Wynn,  202-260-0700 or the
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                     WasteWi$e Hotline at 1-800-372-9473)

 Climate Wise Recognition Program
NICE3
                     The Climate Change Action Plan was initiated in response to the U.S.
                     commitment to reduce greenhouse gas emissions in accordance with the
                     Climate Change Convention of the 1990 Earth Summit.  As part of the
                     Climate Change Action Plan, .the Climate Wise Recognition Program is a
                     partnership initiative run jointly by EPA and the Department of Energy. The
                     program is designed to reduce  greenhouse gas emissions by encouraging
                     reductions across all sectors of the economy, encouraging participation in the
                     full range of Climate Change  Action Plan initiatives,  and fostering
                     innovation. Participants in the program are required to identify and commit
                     to actions that reduce greenhouse gas emissions. The program, in turn, gives
                     organizations early recognition  for their reduction commitments; provides
                     technical assistance through consulting services, workshops, and guides; and
                     provides access to the program's centralized information system. At EPA,
                     the program is operated by the Air and Energy Policy Division within the
                     Office of Policy Planning and Evaluation.  (Contact: Pamela Herman, 202-
                     260-440?)
                     The U.S. Department of Energy and EPA's Office of Pollution Prevention
                     are jointly administering a grant program called The National Industrial
                     Competitiveness through Energy, Environment, and Economics (NICE3). By
                     providing grants of up to 50 percent of the total project cost, the program
                     encourages industry to reduce industrial waste at its source and become more
                     energy-efficient and cost-competitive through waste minimization efforts.
                     Grants are used by industry to design, test, demonstrate, and assess the
                     feasibility of new processes and/or equipment with the potential to reduce
                     pollution and increase energy efficiency.  The program is open  to all
                     industries; however, priority is given to proposals from participants in the
                     pulp and paper, chemicals, primary metals, and petroleum and coal products
                     sectors. The program has worked with the iron and steel industry to evaluate
                     the feasibility of an on-site hydrochloric acid recovery system for galvanizers
                     and  small- to medium-sized steel manufacturers. (Contact: Bill Ives at
                     DOE's Golden Field Office, 303-275-4755)
VII.B. EPA Voluntary Programs

Strategies for Pulp & Paper and Steel Industries
                    The U.S. Department of Energy is examining the relationships between
                    productivity, energy efficiency and environmental compliance in the pulp &
                    paper and steel industries. Productivity and energy efficiency investments
                    often complement each other, but can conflict with end-of-pipe emission
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                    control projects designed 1
                    project, the DOE seeks :
                      o reduce regulated pollutants. By sponsoring this
                         better understand such conflicts and use this
                    information to help identify ways,DOE and other federal agencies can help
                    industry meet mutual goal 3 in these important areas. The project consists of
                    two phases: 1) industry field consultations will be conducted to discuss and
                    clarify the issues; and 2)
                    between  productivity,
                       quantitative analysis will evaluate the interplay
                       ;nergy  efficiency,  and  pollution   abatement
                    investments. (Contact: Jeff Dowd at 202-586-7258)

VIII.C. Trade Association/Industry Sponsored Activity

       VHI.C..1.  Industry Research Program s

                    Without technological cianges, the  requirements of the Clean Air Act
                    affecting coke ovens ma> force the shutdown of many facilities.  To avoid
                    possible facility closings] the industry is actively investigating alternatives
                    to the conventional cokejoven/blast furnace method of making iron. One
                    promising technology, the direct steelmaking project which was jointly
                    funded by the Americai Iron and  Steel Institute (AISI)  and the U.S.
                    Department of Energy (DOE), concluded  on March 31,  1994.   This
                   • technology reduces, mells, and refines iron in a'single reactor. An opt-in,
                    DOE cost-sharing program for the smelting of steel plant waste oxides began
                    on April  1, 1994.  Based on the success of recent trials, and the further
                    knowledge that was gained from this follow-on program, the technology is
                    now well understood and  fully developed.  A feasibility study  for a
                    demonstration plan is beiijtg developed. Under a related project, the AISI and
                    member companies are working with the U.S. Bureau of Mines on a jointly
                    funded research proj ect to improve the dewatering of a variety of steel plant
                    sludges.   Currently,  thej  sludges  contain too much moisture  to permit
                    .economic recycling to re
                     4130).
                       ;over metal values. (Contact: Dave Rice 801-584-
                     Another  cokeless ironmaking technology,  called the Cipcor  or Corex
                     process, eliminates the nejecl for a coke plant, has integral coal desulfurizing,
                     is amenable to a variety of coal types, and produces a gas that can be used to
                     fire a cogeneration plant. [This project will begin in 1995; capital outlays are
                     expected to reach $800 niillion.  Under the DOE Clean Coal Technology
                     Demonstration Program, the Corex construction project may receive a $150
                                            information on the DOE project, contact J. Lee
million grant.  For more
Bailey (216) 447-3235.

Instead of eliminating coke production, two research projects run by
Bethlehem Steel are focused on reducing coke process emissions.  The
Sparrows Point facility on Chesapeake Bay was the proposed site for one
project.  At this facility!, the Davy Still Autoprocess for pre-combustion
cleaning of coke ovens was to be demonstrated.  This process utilizes coke
oven battery process water to strip ammonia and hydrogen sulfide from coke
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                      oven emissions. The facility was constructed but is not in operation due to
                      a suspension of coke-making operations by Bethlehem Steel at that facility.
                      Discussions are  ongoing over re-establishment  of coke production at
                      Sparrows Point. The other Bethlehem Steel project is a demonstration plant
                      of the British Steel blast furnace granulated coal injection process.  In this
                      process, granulated coal is used instead of oil and natural gas in the blast
                      furnace.  Unlike  natural gas,  granulated  coal does not  cause furnace
                      temperature reductions when it is introduced and thus  improves process
                      efficiency.  Pollutant outputs are reduced as coal sulphur is removed by flux
                      and bound in the slag. The process replaces natural gas usage and reduces
                      40 percent of the  coke requirement.  The project facility, located in Burns
                      Harbor, Indiana, is expected to be complete in January of 1995.  The EPA
                     project manager for the Bethlehem Steel projects is Jeff Summers (301) 903-
                     4412.

                     Another project focussing on reduced emissions  from cokemaking is a
                     process under development by Calderon Energy. A small scale oven was
                     constructed and operated in Alliance, Ohio and a full scale oven is under
                     consideration for funding by the Department of Energy (DOE). For further
                     DOE information, contact John Augustine (412) 892-4524.
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       VIII.C.2. Summary of Trade Associations

             American Iron and Steel Institute
             1101 17th Street, NW
             Washington, DC 20036-4700
             Phone: (202) 452-7100
             Fax: (202) 463-6573
       Members: 50 companies
       Staff: 44
       Budget:
       Contact: Bruce Steiner,.
       VP-Environment and Energy
              The American Iron and Steel Institute (AISI), founded in 1908, mainly represents
              integrated iron and steel manufacturers.  Based on tonnage of production, AISI
              represents the companies responsible for 70 percent of U.S. steel manufacture.  As
              the  major trade group for the industry, AISI has a diverse agenda.  The AISI
              conducts market development by working with major customer groups  (e.g.,
              automotive, machinery) to maintain and promote steel as the material of choice. The
              AISI is also involved in legislative and regulatory activities; AISI members rely on
              the organization to keep them abreast of legislative and regulatory developments.
              The AISI conducts  research on manufacturing technology, basic materials,
              environmental  quality control,  energy,  and fuel  consumption.   The AISI also
              compiles industry (including  non-members) statistics through surveys.   AISI
              publications are the American /ro/jz and Steel Institute-Annual Statistical Report, as
              well'as technical manuals and pamphlets oh steel. The AISI holds several meetings
              and other workshops and seminars for member company representatives.
              Specialty Steel Industry North America        Members: 21 companies
              3050 K Street, NW
              Suite 400
              Washington, DC 20007
              Phone:202-342-8630
              Fax:202-338-5534

              The Specialty Steel Industry of North America (SSINA) is a  national trade
              organization comprised  of 21  producers of specialty steel products, including
              stainless, electric, tool, magnetic, and other alloys.  SSINA represents over 90
              percent of the North American specialty steel industry.  The primary purpose of
              SSINA is to promote and encourage a better understanding between members of the
              North  American specialty steel I industry and federal and state officials,  and to
              provide and encourage governmental action in support of the continued growth of
              a strong North American specialty steel industry. SSINA is comprised of a number
              of task forces and committees which pursue issues of interest to the North American
              specialty steel industry, including domestic and international trade, environmental,
              critical materials  matters,  manufacturing  and  standards issues,  and other
              government-related matters. The SSINA committees meet quarterly, normally
              alternating between Washington,
 D.C. and Pittsburgh.
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               Steel Manufacturers Association (SMA)
               1730 Rhode Island Avenue, NW
               Suite 907
               Washington, DC 20036-3101
               Phone: 202-296-1515
               Fax: 202-296-2506
                   email: steelnet@aol.com
                   World Wide Web home page:
                   http ://www. steelnet.org
                   Members: 55
               The SMA is the primary trade association of electric arc furnace steelmakers.  Last
               year, EAF steelmakers recycled 38.2 million metric tons of iron and steel scrap.
               Purchased scrap accounts for almost 100% of the feedstocks used in an EAF to make
               new  steel. ' Other  SMA  companies  are  reconstituted  integrated (ore-based)
               steelmakers, with management practices similar to those of the EAF companies. The
               SMA Environment Committee meets frequently to address issues affecting the  steel
               industry and works with the EPA and other government agencies to implement
               effective environmental programs.  The SMA  also  has  technical and human
               resources committees which meet to exchange information and develop public
               policy positions, as well as ad-hpc task forces to handle specific matters such as
               radioactive scrap detection, development of emission monitoring protocols, and the
               EPA's Common Sense Initiative. With 44 U.S., 8 Canadian, and 3 Mexican member
               companies geographically dispersed across the continent, the SMA is the largest
               steel trade association in North America in. terms of membership, hi 1994, the SMA
               membership accounted for approximately 40% of all steel shipments in the U.S., and
               as a growing segment of the industry, the-SMA share of total U.S. steel production
               is expected to account for 50% within one decade.
              International Iron and Steel Institute
              Institut International du Fer et de 1'Acier
              120, rue Colonel Bourg, B-l 140
              Brussels, Belgium 32 2 726 50 95
               Members: 165
               Staff: 20
               Budget:
               Contact: Ian Christmas, Deputy
               Secretary General
              The International Iron and Steel Institute (IISI) is comprised of steel-producing
              companies, affiliated federations, and technical societies in 48 countries.  The IISI
              seeks to contribute to the steel industry worldwide. Major functions are: to provide
              a forum for free and open discussions of the industry's problems and opportunities;
              to undertake research in scientific, technological, economic, financial, governmental,
              sociological, legal, environmental, and other aspects of the industry; to collect,
              evaluate, and disseminate statistics and information concerning matters affecting the
              steel industry; to establish and maintain liaisons with other organizations related to
              steel; to promote the use of steel. Some IISI committees include Economic Studies,
              Environmental Affairs,  and Industrial Relations.  The IISI publishes the  monthly
              Iron and Crude  Steel Production (in English) and the annuals Steel Statistical
              Yearbook (in English) and  World Steel in Figures (in English). IISI also publishes
              conference proceedings and  reports  on  the  following issues:  environment,
              economics, raw materials, technology, market promotion, and public relations. The
              IISI holds an annual world conference.
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             Association of Iron and Steel Engineers
             3 Gateway Center, Suite 2350
             Pittsburgh, PA 15222
             Phone:(412)281-6323
             Fax: (412) 281-4657
          Members: 10,000
          Staff: 19
          Budget: $2,500,000
             The Association of Iron and Steel Engineers (AISE) consists of engineers, operators,
             and suppliers in the steel industry. Founded in 1907, this association works to
             improve the technical phases of the production and processing of iron and steel .via
             technical  reports  and  industry                              ~
             Engineering, Steel Producing, and
  awards.    Divisions  include Environmental
 Continuous Casting  AI$E publications include
             a monthly, Iron and Steel Engineer and a Directory of Iron and Steel Plants.
             Conferences are semi-annual.

             Additional Related Associations
             ASM International
             9639 Kinsman Rd.
             Materials Park, OH 44073-0002
             Phone:(216)338-5151
              Society for Mining, Metallurgy, and Exploration, Inc. (SME, Inc.)
              P.O. Box 625002
              Littleton, CO 80162-5002
              Phone: (303) 973-9550
              The Mining Metals and Materials
              420 Commonwealth Drive
              Warrendale, PA 15086 .
              (412)776-9000
 Society (TMS)
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                                          I/RES
IX. CONTACTS/ACKNOWLEDGMENTS/RESOURCE MATERIALS
     •   ....          '     -        V      I •   .  •  • .                •-...-
For further information on selected topics within the iron and steel industry a list of contacts and
publications are provided below.

Contacts6
,
Name
Maria Malave
Steve Sisk
James Maysilles
Bernard Caton
Gobind Jagtiani
JeffDowd
Bruce Steiner
Javier Garcia
Ed Wojciechowski
Gerald Houck
- '•
Organization
EPA/OECA (Office of Enf<
and Compliance Assurance
NEIC (National Enforceme
Investigations Center),
EPA/OAR (Office of Air ai
Radiation)
EPA/OW (Office of Water
DOE (Department of Energ
_,
AISI (American Iron and S
Institute)
EPA/Region IV
EPA/Region V
U.S. Bureau of Mines
• .•

rcement
it
.d

y> .
:eel
«


1 .
U.S. Bureau of Mines: Center for
Health and Safety . |
Telephone >
202-564-7027
303-236-3636
ext. 540
919-541-3265
202-260-7849
202-586-1826
202-586-7258
202-452-7100
404-347-3555
312-886-6785
202-501-9439
412-892-6602
Subject
JRegulatory requirements
and compliance
assistance
Regulatory requirements
and industrial processes
Regulatory requirements
(air)
Regulatory requirements
(water)
Energy efficiency and
environmental
compliance
Environment and energy
Inspections, regulatory
requirements (RCRA)
Inspections, regulatory
requirements (air) ,
Industrial processes
Health and safety issues
 e Many of the contacts listed above have provided valuabl
 this document. EPA appreciates this support and acknowl
 all' statements made within this notebook.
                                            Ip information and comments during the development of
                                             edges that the individuals listed do not necessarily endorse
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 General Profile
 U.S. Department of Commerce, U.S. Industrial Outlook 1994.

 U.S. Department of Commerce, 1987 Census of Manufactures Industry Series: Blast Furnaces, Steel
 Works, and Rolling and Finishing Mills, 1990:                                ;

 U.S. Department of Commerce, 1992 Census of Manufactures Preliminary Report Industry Series:
 Blast Furnaces, Steel Works, and Rolling and Finishing Mills, MC92-I-33A(P), May 1994.

 American Iron and Steel Institute, Annual Statistical Report, Washington, D.C., 1993.

 Barnett,  Donald F. and Robert W. Crandall,  Up From the Ashes, The Brookings Institution,
 Washington D.C., 1986.
 Process Descriptions and Chemical Use Profiles
 American Iron and Steel Institute, Report on Steel Industry Waste Generation, Disposal Practices,
 and Potential Environmental Impact, Washington, D.C., February, 1992.

 Lankford, William T., et. al., The Making, Shaping, and Treating of Steel, Tenth Edition, United
 States Steel Corporation, Pittsburgh, PA, 1985. (Available from the Association of Iron and Steel
 Engineers, Pittsburgh, PA).

 Organization for Economic Co-operation and Development, The Role of Technology in Iron and
 Steel Developments, 1989.

 Russell, Clifford S. and William J. Vaughan, Steel Production: Processes, Products, and Residuals,
 John Hopkins University Press, Baltimore, 1976.

 Regulatory Profile
Sustainable Environmental Law, Environmental Law Institute, West Publishing Co., St. Paul Minn
1993.

U.S. EPA, Office of Solid Waste, Hazardous Waste Generation: 2. Iron and Steel Manufacturing,
February, 1994.

U.S. EPA, Office of Pollution Prevention and Toxics, Toxics Release Inventory, Public Data
Release, 1992, April, 1994. (EPA 745-R-94-001).

U.S. EPA, Solid Waste and Emergency Response,  Report to  Congress on Metal Recovery,
Environmental Regulation & Hazardous Waste, February 1994. (EPA 530-R-93-018).
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U.S. EPA, Office of Solid Waste, Report to Confess on Special Wastes from Mineral Processing,
February 1990.

U.S: EPA, Office of Air and Radiation, Office of Air Quality Planning and Standards, Compilation
of Air Pollutant Emission Factors, Volume I: Stationary Point and Area Sources, Metallurgical
Industry, Research Triangle Park, NC, U.S. Government Printing  Office,  Washington/ D.C.,
September 1985.               ,               •           ;            ,    ,     '

U.S. EPA, Development Document for Effluent Limitations Guidelines and Standards for the Iron
and Steel Manufacturing Point Source Category^ Washington, B.C., May 1982 (EPA 4407
1-82-024).
 Pollution Prevention
 Grieshaber, K. W., C. T. Philipp, and G.F:-Bennett,' "Process for Recycling Spent Potliner and
 -Electric Arc Furnace Dust into Commercial Products using Oxygen Enrichment," Priorities in
 Pollution Prevention. Annual Gulf Coast Environmental Conference Proceedings, pp. 84-95, March,
 1994.                                     j         "V

 Freeman, Harry, Pollution Prevention Research at EPA's Risk Reduction Engineering Laboratory:
 Cleaner Production Processes and Cleaner Products for a Cleaner Environment, Priorities in
 Pollution Prevention. Annual Gulf Coast Envircininental Conference Proceedings, pp. 1-9, March,
 1994.                                     I

 U.S. EPAj Office of Research and Development,\IndustriatPollution Prevention Opportunities for
 the 1990s, EPA/600/8-91/052, August, 1991.                                   .
 Drabkin, Marvin and Edwin Rissmann, Wash
Minimization Opportunities at an Electric Arc
 Furnace Steel Plant Producing Specialty Steels, Environmental Progress, vol.8, no.2, pp. 88-97,
 May, 1989.                                       _.            :

 U.S. EPA, Region HI, Pollution Prevention Progr un, Pollution Prevention Opportunities in the Steel
 Industry, October 1990.

 Center for Hazardous Materials Research, Polhtion Prevention: Strategies for the Steel Industry,
 CHMR Fact Sheet, University of Pittsburgh.

 Rimer, A.E. and L.A. Reinders, A Practical Guide to Pollution Prevention Planning for the Iron and
 Steel Industries, Blasland, Bouck & Lee, Chapel Hill, N.C., 1992.

 Air & Waste Management Association, Hazardous Waste Minimization Industrial Overviews, 1989'.
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                       Iron and Steel Industry
 Trade Journals
 New Steel (formerly Iron Age)
 Iron and Steelmaker
 Iron and Steel Engineer
 Metal Bulletin, (212) 213-6202
 World Steel Dynamics, (212) 713-2498
 Iron Age Manufacturing Management, (215) 741-4000
 Steel: Semiannual Monitoring Report, (202) 205-2000
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                                         J,
                                       Endnotes

1. Variation in facility counts occur across data sources due to many factors including, reporting
and definitional differences. This notebook does not attempt to reconcile these differences, but
rather reports the data as they are maintained by each source. Only preliminary data is available
from the 1992 Census of Manufactures.  The final version which includes all data will not be
available until mid-1995. Census of Manufactures, U.S. Department of Commerce, Bureau of
the Census, Preliminary Report Industry Series, MC92-I-33A(P) (Industries 3312,3313, 3315,
3316, and 3317), 1994.
2. Annual Statistical Report, American Iron and
                                            Steel Institute, Washington, D.C., 1993.
3. Net Shipments of Steel Mill Products, table,. American Iron and Steel Institute, Washington,
D.C., 1994.

4. Report on Steel Industry Waste Generation, Disposal Practices, and Potential Environmental
Impact, American Iron and Steel Institute, Washington, D.C., February, 1992.          ,

5. Census of Manufactures, U.S: Department ofj Commerce, Bureau of the Census, Industry
Series, MC87-I-33A (Industries 3312, 3313, 33 5, 3316, and 331?X 1987.

6. U.S. Industrial Outlook, U.S. Department of Commerce. Washington, D.C., 1994, p. 13-1.

7.1bid,p.l3-l.

8.,Ibid, 13-3.

9. Ibid, p. 13-5.

10. Annual Statistical Report, American Iron and Steel Institute, Washington D.C., 1993. p.73.
 11 .Compilation of A ir Pollutant Emission Factors, Volume I: Stationary Point and Area
 Sources, Metallurgical Industry, U.S. Environmental Protection Agency, Office of Air and
 Radiation, Office of Air Quality Planning and Standards, Research Triangle Park, NC, U.S.
 Government Printing Office, Washington, D.C., September 1985.

                                            Disposal Practices, and Potential Environmental
                                            lington, D.C., 1992, p.8.
 12. Report on Steel Industry Waste Generation,
 Impact, American Iron and Steel Institute, Wa&
 13. The Making, Shaping, and Treating of Steel, Tenth Edition, McGannon, Harold E., ed.,
 United States Steel Corporation, Pittsburgh, PA, 1971.
 14. Report on Steel Industry Waste Generation,
 Impact, American Iron and Steel Institute, Was'
                                            Disposal Practices, and Potential Environmental
                                           tiington, D.C., 1992, p.14.
 15. The Making, Shaping, and Treating of Steel, Tenth Edition, McGannon, Harold E., ed.,
 United States Steel Corporation, Pittsburgh, PA, 1971, p.189.
 September 1995
                                            05
SIC 331

-------
 Sector Notebook Project
                        Iron and Steel Industry
  16. Development Document for Effluent Limitations Guidelines and Standards for the Iron and
 Steel Manufacturing Point Source Category, U.S. EPA, Washington, D.C., May 1982 (EPA
 440/1-82-024).

 17. Report on Steel Industry Waste Generation, Disposal Practices, and Potential Environmental
 Impact, American Iron and Steel Institute, Washington, D.C., 1992, p. 17.

 l&.Reportto Congress, on Metal Recovery, Environmental Regulation and Hazardous Waste,
 U.S. EPA, Office of Solid Waste and Emergency Response, 1994, p. 3 (EPA 530-R-93-018).

 19.Comment from Bruce Steiner, American Iron and Steel Institute, Washington, D.C., May 5,


 20.U.S. Steel Industry at a Glance, American Iron and Steel Institute, Washington, D.C., 1992.

 21. Report on Steel Industry Waste Generation, Disposal Practices, and Potential Environmental
 Impact, American Iron and Steel Institute, Washington, D.C., 1992, p.21.

 22. The Making, Shaping, and Treating of Steel, Tenth Edition, McGannon, Harold E., ed.,
 United States Steel Corporation, Pittsburgh, PA, 1971, p.565.

 23. Ibid, p. 121.

 24. Ibid.

 25. Ibid.

 26. Ibid.

 27. Amoco - U.S. EPA Pollution Prevention Project, Yorktown, Virginia, Project Summary
 January 1992.

 28. Compilation of Air Pollutant Emission Factors,  Volume I: Stationary Point and Area
 Sources, Chapter 9, Petroleum Industry. U.S. EPA, Office of Air and Radiation, Office of Air
 Quality Planning and Standards, Research Triangle Park, North Carolina, U.S. Government
 Printing Office, Washington, D.C., September 1985.

 27. Report to Congress on Metal Recovery, Environmental Regulation and Hazardous Waste.
 U.S. EPA, Office of Solid Waste and Emergency Response, 1994, p.20 (EPA 530-R-93-018).

 28. Hydrochloric Acid Recovery System for Galvanizers and Steel Manufacture, U.S.
 Department of Energy, NICE3 (National Industrial Competitiveness through Energy,
 Environment, Economics), DOE/CHI0093-233, October 1993.

 29.Sustainable Environmental Law, Environmental Law Institute, West Publishing Co., St. Paul,
 Minn., 1993.
September 1995
106
.  SIC 331

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Sector Notebook Project
                      Iron and Steel Industry
29.Report to Congress on Metal Recovery, Environmental Regulation and Hazardous Waste.
U.S. EPA, Office of Solid Waste and Emergenc^ Response, 1994, p.20 (EPA 530-R-93-018)

30. Ibid.

31. Sustainable Environmental Law, Environmental Law Institute, West Publishing Co., St. Paul,
MN, 1993, p.1238.
32.Report to Congress on Metal Recovery, Envii
 'onmental Regulation and Hazardous Waste.
»J ,f-i*Ji\K>L/\JI I tr\J ' \w^t//*jC/ &OO \JIIf .ir.f.C'H^f *• i\^f\s\J Ft*/ Vj •*—•' * V lil\\JI *•/*lr**'l l,li\r*tf -itw-^t k«(-k*l-»>i_'/ * fc*f »•*»»• J. *-*~+±Ji*+i \si,is wtj r r isuji-^ •
U.S. EPA, Office of Solid Waste and Emergeric} Response, 1994, p.20 (EPA 530-R-93-018).

33. Ibid, p. 23.

34. Ibid, p. 44.
 September 1995
107
SIC 331

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     APPENDIX A - INSTRUCTIONS  FOR DOWNLOADING NOTEBOOKS
                  Electronic Access to the Sector Notebooks via
                the Enviro$en$e World Wide Web (E$WWW) and
                 the Enviro$en$e Bulletin Board System (E$BBS)
      The Sector Notebooks are available throu; jh two electronic systems, the Enyiro$en$e
Bulletin Board System (via modem connection), and the Enviro$en$e World Wide Web (via
Internet). The Enviro$en$e Communications Network is a free, public, interagency^supported
system operated by EPA's Office of Enforcementjand Compliance Assurance and the Office of
Research and Development. The-Network allows regulators, the regulated community, technical
experts, and the general public to share information regarding:  pollution prevention and innovative
technology; environmental enforcement and compliance assistance; laws, executive orders,
regulations and policies; points of contact for services and equipment; and other related topics. The
Network welcomes receipt of environmental messages, information and data from any public or
private person or organization. This document first provides summary information on E$WWW
access, then provides information on downloading protocols from within the E$BBS.
A.
B.
ACCESS THROUGH ENVIRO$EN$E WORLD WIDE  WEB

      To access the Sector Notebooks through the Enviro$en$e World Wide Web, set
your World Wide Web Browser to the following address:    '   .
                  - r   .         ••  •  •  •  -      •  '•-•••    '':
WWW/INTERNET  ADDRESS:  http://wastenot.inel.gov/envirosense/

HOTLINE NUMBER FOR E$WWW ONLY: 208-526-6956

EPAE$WWWMANAGER:  Myles Morse, 202-260-3161

      From the Enviro$en$e home page] click on "Compliance and Enforcement" to
obtain instructions on how .to access the Sector Notebooks and how to provide comments.
Names, e-mail addresses, and telephone numbers will also be provided should you require
assistance. The same documents listed bdlow under the E$BBS instructions are available
ontheE$WWW.
ACCESS THROUGH THE
Instructions for Connecting, Regis
ENVIRO$EN$E BULLETIN BOARD  SYSTEM
        ering and  Downloading  Notebooks
      E$BBS MODEM CONNECTION NUMBER:

      HOTLINE FOR E$BBS ONLY: 703-908-2007
                                                703-908-2092
      MANAGER: BBS Platform: Louis Paley, 202-260-4640
                                        Jc
      The following instructions are condensed from longer documents that provide
information on the full features of the Envjiro$en$e Bulletin Board.  Further documentation
is available on-line in the.files that are listed at the end of this Appendix.

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STEP  1.     ESTABLISHING  MODEM  SETTINGS

             Connecting to the ENVIRO$EN$E BBS is done using a modem and
      communications software. The modem can be either an internal or external model
      connected directly to your computer or part of a modem pool that is accessible through your
      Local Area Network (LAN) system. The communications software (e.g.. CrossTalk,
      ProComm, QModem, Microphone, etc.) is what allows you to access and control your
      modem. Your software needs to be set to the values noted below (many of these settings
      are the standard defaults used):

      •      Telephone number - 703-908-2092 (Tip:  Be sure you have entered
             the appropriate dialing prefix; e.g., 9 for an outside line, 1 for long
             distance...)

      •      Baud rate -  up to 14,400 EPS is supported (always select the highest
             speed which YOUR modem will support).

             Terminal Emulation -  BBS, ANSI,  VT-100, VT-102 etc.  (Tips:
             Do not use TTY. After you log in, if you see screen characters appear on
             the lines where you need to enter information, chances are that you need to
             properly set your terminal emulation. The emulation can normally be reset
             before or during communication with Enviro$en$e).

      •      Data  Bits -  8  (Eight).

             Stop Bits -  1 (One).

      •      Parity -  None.
             Transfer Protocols  - ZModem, YModem, XModem, HS/Link,
             BiModem, ASCII (text files only). If your communications software
             must select me same proiocoi inai cu in your communications som
             and the BBS support so that they can "talk the same language" when
             sending and receiving files.      '
      •      Error  correction/data compression  protocols  - v.32, v.42, and
             other older, hardware-dependent ones are supported.

             Refer to your communications software manual on how to set and save the
      communication parameters noted above (these will generally be the default). Also check to
      make sure you know where the communications software will send the files you
      download. Due to document sizes it is best not to download Sector Notebooks to floppy
      disks.               .                                                        ',
                                        A-2

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STEP 2.
CONNECTING  AND  REGISTERING
             Connect to E$BBS via a modem,
             above settings by dialing:
                             ising communications software set to the
                                  (703)  908-2092.

             NOTE: EPA Employees can access E$ directly via LAN from the Agency Lan
            - Services Menu or Icon and then follow the instructions below. The end of this
             document lists additional resources for accessing E$BBS through the LAN.
             Once you are in the BBS, hit the'.
             the default values for the screen.
                                 iR/RETURN key twice (2) to accept -
             on successive pages, type your first name and hit
             ENTER/RETURN; type your last name and hit.ENTER/RETURN;
             and,type your password (if you have  NOT registered yet,
             make one up, and remember it for subsequent logons to
             E$) and hit ENTER/RETURN; and
             Register (first time only) and imm
             for 120 minutes per day;
                              sdiately receive access to the BBS
                    Type responses to the Registration questions, and hit
                    ENTER/RETURN to begin using ENVIRO$EN$E. (Tip: the last   '
                    registration question is Country?      )

                    You may need to hit ENTER/RETURN several times to move past System
                    News and Alert messages     ,                     ,
STEP 3.
DOWNLOADING SECTOR
NOTEBOOKS
             The files that appear on the follow ing table can be downloaded from E$. Most files
      .cannot be viewed on-screen within the ESjBBS. As indicated on the following table, each
       document appears in several formats - WordPerfect 5.1 (PC), WordPerfect 6.1 (PC),
       Microsoft Word 5. la (Mac) or WordPerfect 2.0 (Mac).  Please note that the quality of
       formatting and graphics is highest in the file version in which the notebook was originally
       created. The high quality versions are underlined on the following list of filenames.

       Information on Macintosh/Microsoft Word Files
       Available Macintosh files are not compressed. The files are easily identified by th<3 seventh
       and eighth position in the filename - which is "MA." The extension They can be directly
       downloaded and read using Microsoft WJ)rd 5.la, or within other word processing
       software that supports conversion of Microsoft Word 5. la documents. Conversion to
       other programs may alter formatting and graphics quality.

       Information on PC/WordPerfect Files

       The WordPerfect files are all compressed ("zipped" files ending with the .ZIP extension)
       files that need to be decompressed ("unzipped") after they are downloaded. The notebooks
       that are available in WP 5.1 and WP 6.0 are zipped together (this is why the filenames on
       the following table are the same). When |these files are downloaded and "unzipped," you
       will have a version with the extension ".WP5" and one with ".WP6".
                                         A

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                Available Notebooks, Filenames  and File Formats
Profile of  the	Industry         PC WP 5.1

Dry Cleaning                       DRYCLNSN.Z-IP
Electronics and Computer          ELECMPSN.ZIP
Wood Furniture and Fixtures       WDFURNSN.ZIP
Inorganic Chemical                INRGCHSN.ZIP
Iron and Steel                    IRONSTSN.ZIP
Lumber and  Wood Products,          LMBRWDSN.ZIP
Fabricated  Metal Products         FABMETSN.ZIP
Metal Mining                       METMINSN.ZIP
Motor Vehicle  Assembly            MOTVEHSN.ZIP
Nonferrous  Metals                 NFMETLSN.ZIP
Non-Fuel, Non-Metal Mining        NOMTMISN.ZIP
Organic Chemical                  ORGCHMSN.ZIP
Petroleum Refining                PETREFSN.ZIP
Printing                           PRINTGSN.ZIP
Pulp and Paper           .    ••    PULPPASN.ZIP
Rubber and  Plastic                RUBPLASN.ZIP
Stone, Clay, Glass and Concrete   STCLGLSN.ZIP
Transportation Equipment Cleaning TRNSEQSN.ZIP
 PC WP 6.1
   Macintosh
Word 5.1a/WP2.0
DRYCLNSN.ZIP
INRGCHSN.ZIP
IRONSTSN.ZIP
  DRYCLNMA,
  ELECMPMA,
         WP2
         WD5
                WDFURNMA.WD5
   INRGCHMA
   IRONSTMA
   LMBRWDMA
         .WP2
         .WP2
         .WD5
ORGCHMSN.ZIP
PETREFSN.ZIP
PRINTGSN.ZIP
PULPPASN.ZIP
                FABMETMA.WD5
                METMINMA.WD5
                MOTVEHMA.WD5
                NFMETLMA. WD5
                NOMTMIMA.WD5
           ,WP2
           .WP2
           ,WP2
           .WP2
           .WD5
ORGCHMMA
PETREFMA
PRINTGMA
PULPPAMA
RUBPLAMA
                STCLGLMA.WD5
TRNSEOSN.ZIP    TRNSEQMAiWP2
Note: Underlined files contain the highest quality  format/graphics


STEP 3 CONTINUED - PROCEDURES FOR DOWNLOADING

      •     From the E$ Main Menu, select "D" to Download then hit ENTER/RETURN.

      •     Type in the Sector Notebook filename from above that you would like to select for
            downloading and hit ENTER/RETURN.

      •     The system will ask you to select a file transfer protocol. Select the file transfer
            protocol that matches what you have selected within your PC communications
            software (ZModem is recommended) and hit ENTER/RETURN. (Tip: ZModem
            users may also be allowed to enter more than one filename to download more than
            one document at a time. Simply continue to enter a new filename each time a new
            filename prompt appears on the screen. This option is disabled for other users.)

      •     At this point, you may                              .

                   begin downloading by hitting ENTER/RETURN.  This should begin the
                   download if you are using the ZModem transfer protocol. If you don't see
                   information on the screen showing the progress of the download, follow the
                   next step.

      •     If the download does not begin after following the last step, you need to tell your
            communications software to start receiving the file.  To do this, look for a
            "RECEIVE" icon or command on your communications software menu and activate
            it This tells your software to begin the download.
                                      A-4

-------
            When the download is complete^, a message will appear on the screen to confirm
            transmission.

            The downloaded file will appear in the folder or directory that you defined in your
            communications software.

            Repeat the above procedure to download other notebooks.

            Macintosh users can logoff using the [G]oodbye command from the main menu

            THE FOLLOWING  STEP MUST BE TAKEN BY ALL  USERS THAT
            HAVE DOWNLOADED ZIPPED FILES (files with a ".ZIP" filename
            extension) FROM E$.  MACINTOSH USERS CAN SKIP  THIS
            STEP.
                   In order to read the zipped file(s) you have downloaded, you
                   must download  the  decompression software  required to
                   "unzip" your files. To I download the decompression software, follow
                  . the same download instructions given above. Type in the filename
                   "PKZ204G.EXE"  and hit ENTER/RETURN. You only need to download
                   this file to your hard drive once.

            Logoff using the [G]oodbye command from the main menu.

            To end the phone connection, the user should use the "hang up" or "terminate call"
            option provided with your communications software.
STEP 4     DECOMPRESSING  ".ZIP'E
            Macintosh files do not need
 ' DOWNLOADED FILES (PC Only
 to be decompressed)
            After you have downloaded a co mpressed (".ZIP") file to your PC, you must
      decompress it to its original format and s|ize by using the "PKUnzip" file which you
      downloaded at the beginning of Step 3. jThe file which you downloaded;
      "PKZ204G.EXE", contains PKZip.EXE and PKUnzip.EXE files.  PKUNZIP will
      decompress the file, returning it to its original size and format as if it had never been
      compressed or transmitted over the BBSL To use the PK commands (pkunzip.exe &
      pkzip.exe), you must be at the DOS prompt (third-party software interfaces exist for
      Windows).  For details on how to use either command, simply type the command at the
      DOS prompt (without any parameters, i.e., just type "PKUNZIP") and hit
      ENTER/RETURN.. Since parameters are required for the PKs to work they will
      automatically go into help mode and give you a brief explanation of how they work. If a
      user needs more direction, there is full documentation included in the PKZ204G.EXE in
      the "Hints" file.
      To decompress any file, use PKUNZIP.
iXE by taking the following steps:
            Go to the DOS C: prompt and type PKUNZIP.EXE; then,

            Type "PKUNZIP [Filename]" (eg., the filename and the path of the
            compressed file you wish to decompress).
            NOTE: after the paired files are
            extension ".WP5" and one with the extension ".WP6.
                                       A-5
unzipped, two files will exist, one with the

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            C.    COMMENTING OR PROVIDING ADDITIONAL INFORMATION ON THE
                   SECTOR NOTEBOOKS  VIA E$BBS

                         Comments on the Sector Notebooks, or supplemental documents of interest can be
                   uploaded to the Enviro$en$e BBS. Follow upload instructions that appear on the screen,
                   or look at the instructions for compressing and uploading documents.  The instructional
                   documents are listed below under Section D of this Appendix. All documents that you
                   upload will be publicly accessible, and should contain a short abstract (less than 50 words)
                   that describes the document.  It is recommended that this abstract contain the words "Sector
                   Notebook Comments," the title of the Notebook that the comments are directed toward,
                   and the words "SIC «Insert applicable 2-digit SIC code»".

                         NOTE: To help the system operator know what you've uploaded and where it
                         should be put within the BBS, it is helpful to send a message to the system
                         operator.  Before logging out of E$, you will be given the option to comment to the
                         system operator (Sysop). Please indicate what files you have sent, and that tide
                         comments or supplemental documents should be placed in Directory 51 - "Sector
                         Compliance Information and Notebooks." Messages can also be.sent to the Sysop
                         from the main menu using the Message option.


            D.    ADDITIONAL  RESOURCE DOCUMENTS AVAILABLE ON E$BBS

                         The following files can be viewed from the "Bulletins" section of E$BBS main
                   menu. To receive these documents electronically, the files can be downloaded (and
                   viewed") from Directory #160 (utilities). If you would like to download these files, follow
                   the same procedures that are outlined (Section C). The directions for direct dial modem
                   users are different than the directions for EPA LAN users. How you have accessed the
                   E$BBS determines which of the paired files below that you should follow.
                   Entered E$
                   via Modem

                   CONREGWP.TXT


                   FINDVIEW.TXT


                   CONVCOMP.TXT


                   DNLDTXWP.TXT


                   DNLDZPWP.TXT


                   UPLOADWP.TXT


                   SNHOWTO.TXT
Entered E$
  EPA LMT


CNREGLAN.TXT


FNDVWLAN.TXT


CVCMPLAN.TXT


DNLTXLAN.TXT


DNZPLAN.TXT


UPLDLAN.TXT


SNHOWLAN.TXT
Description of  File

How to  Connect and Register on the E$BBS
via Modem
Finding and Viewing Files  from E$BBS via
Modem
Converting,  Compressing  &  Uncompressing
Fil.es. via Modem
Flagging and Downloading "Uncompressed"
Files from E$BBS
Flagging and Downloading "Compressed"'
Files from E$BBS
Directions for Uploading Files via Modem
to :the  E$BBS
Contains this document "Appendix A -
Downloading Instructions"
                                                    A-6
_
                                                             •it U.S. GOVERNMENT PRINTING OFFICE: 1995-399-230E

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              To  order other EPA Sector  Notebooks
                                use the form  below
          United States Government
          INFORMATION
Order Processing Code:
*3212
                                                              Charge your order.
                                                                      It's easy!

                                                                Fax your orders (202) 512-2250
                                                              Phone your orders (202) 512-1800
Qty.
Stock Number
 ..'.  Title'. .
Price
Each
Total
Price
          055-000-00512-5
                   Dry Cleaning Industry, 104 pages
                                      6.50
          055-000-00513-3
                   Electronics and Computer Industry, 160 pages
                                     *11.00
          055-000-00518-4
                   fabricated Metal Products Industry, 164 pages
                                     *11.00
          055-000-00515-0
                   Inorganic Chemical Industry, 136; pages
                                      9.00
          055-000-00516-8
                   Iron and Steel Industry, 128
                                      8.00
          055-000-00517-6
                   Lumber and Wood Products Industry, 136 pages
                                      9.00
          055-000-00519-2
                   Metal Mining Industry, 148 pages
                                     * 10.00
          055-000-00520-6
                   Motor Vehicle Assembly Industry] 156 pages
                                     * 1.1.00
          055-000-00521-4
                   Nonferrous Metals Industry, 140fcages
                                     * 9.00
          055-000-00522-2
                   Non-Fuel, Non-Metal Mining Industry, 108 pages
                                     * 6.50
          055-000-00523-1
                   Organic Chemical Industry, 152 pages
                                     $11.00
          055-000-00524-9
                   Petroleum Refining Industry, 160| pages
          055-000-00525-7
                   Printing Industry, 124 pages
                                      7.50
          055-000-00526-5
                   Pulp and Paper Industry, 156 pages
                                     *11.00
          055-000-00527-3
                   Rubber and Plastic Industry, 152 pages
                             Stone, Clay, Glass and Concrete (ndustry, 124 pages
                                     $11.00
055-000-00528-1
                                      7.50
          055-000-00529-0
                   Transportation Equipment Cleaning Industry. 84 pages
                                      5.50
          055-000-00514-1
                   Wood Furniture and Fixtures Industry, 132 pages
                                                                                          8.00
The total cost of my order is $_
                            Price includes
Company or personal name
                       (Please type or print)
Additional address/attention line
Street address
City, State, Zip code
Daytime phone including area code
Purchase order number (optional)
       ' Important: Please include this cpmp:
                                                                              Total for Publications
regular'shipping and handling and is subject to change.
    Check method of payment:
    Q Check payable to Superintendent of Documents
    Q GPO Deposit Account                       ~~
    Q VISA   a MasterCard
                                                      I (expiration date)   Thank you for your order!
                                             Authorizing signature                              9/95

                                             Mail to: Superintendent of Documents
                                                    P.O. Box 371954, Pittsburgh, PA 15250-7954

                                         ieted prefer form-with your remittance.

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