APTD-1508
NATIONAL INVENTORY
OF SOURCES
AND EMISSIONS:
BERYLLIUM - 1968
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Water Programs
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
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APTD-1508
NATIONAL INVENTORY
OF
SOURCES AND EMISSIONS:
BERYLLIUM - 1968
by
W. E. Davis § Associates
9726 Sagamore Road
Leawood, Kansas
Contract No. CPA-70-128
EPA Project Officer: C. V. Spangler
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Water Programs
Office of Air Quality Planning and Standards
Research Triangle Park, N.C. 27711
September 1971
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The APTD (Air Pollution Technical Data) series of reports is issued by
the Office of Air Quality Planning and Standards, Office of Air and
Water Programs, Environmental Protection Agency, to report technical
data of interest to a limited number of readers. Copies of APTD reports
are available free of charge to Federal employees, current contractors
and grantees, and non-profit organizations - as supplies permit - from
the Air Pollution Technical Information Center, Environmental Protection
Agency, Research Triangle Park, North Carolina 27711 or may be obtained,
for a nominal cost, from 'the National Technical Information Service,
5285 Port Royal Road, Springfield, Virginia 22151.
This report was furnished to the Environmental Protection Agency
in fulfillment of Contract No. CPA-70-128. The contents of this report
are reproduced herein as received from the contractor. The opinions,
findings, and conclusions expressed are those of the author and not
necessarily those of the Environmental Protection Agency. The report
contains some information such as estimates of emission factors and
emission inventories which by no means are representative of a high
degree of accuracy. References to this report should acknowledge the
fact that these values are estimates only.
Publication No. APTD-1508
11
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PREFACE
This report was prepared by W. E. Davis & Associates pursu-
ant to Contract No. CPA 70-128 with the Environmental Protec-
tion Agency, Office of Air Programs.
The inventory of atmospheric emissions has been prepared to
provide reliable information regarding the nature, magnitude,
and extent of the emissions of beryllium in the United States for
the year 1968.
Background information concerning the basic characteristics of
the beryllium industry has been assembled and included. Pro-
cess descriptions are given, but they are brief, and are limited
to the areas that are closely related to existing or potential at-
mospheric losses of the pollutant.
Due to the limitation of time and funds allotted for .the study,
the plan was to personally contact the two primary producers
and about fifteen percent of the companies in each major emis-
sion source group to obtain the required information. It was
known that published data concerning emissions of the pollutant
were virtually nonexistent, and cbntacts with industry ascer-
tained that atmospheric emissions were not a matter of record.
ill
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The bervl.lium emissions and emission factors that are pre-
sented are based chiefly on the summation of information ob-
i
tained during field trips to inspect the air pollu'.ior, ce.c'roi
equipment, used at various locations and observe processing
operations :
Beryllium emissions and emission factors are considered to
be reasonably accurate
IV
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ACKNOWLEDGEMENTS
This was an industry oriented study and the authors express
their appreciation to companies and individuals in the beryl-
lium industry for their contributions.
We wish to express our gratitude for the assistance of the
Office of Air Programs, and to many branches of the Federal
and State Governments.
Our express thanks to Mr. C. V. Spangler., Project Officer,
Office of Air Programs, for his helpful guidance.
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CONTENTS
SUMMARY 1
Emissions by Source 2
Emissions by States 3
Emission Factors 4
Table ' 5
MINERAL SOURCES OF BERYLLIUM 6
MATERIAL FLOW THROUGH THE ECONOMY ... 9
Chart 11
USES AND EMISSIONS OF BERYLLIUM
Mining 12
Processing of Beryllium Metal, Alloys,
and Compounds 15
End Product Uses of Beryllium Metal,
Alloys, and Compounds 26
OTHER SOURCES OF BERYLLIUM EMISSIONS
Coal 34
Oil 37
Incineration. 39
Miscellaneous Emissions 41
APPENDIX A
Companies Dealing in Beryllium and
Beryllium Alloys A-l
VI l
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TABLES
Table I Emission Factors 5
Table II Air Pollution Control Equipment,
Brush Beryllium Company,
Elmore, Ohio 22
Table III Air Pollution Control Equipment,
Kawecki Berylco Industries, Inc. ,
Hazelton, Pennsylvania 24
Table IV Industrial Data - Air Pollution
Control 29
Table V Average Minor Element Contents
of Coal from Various Regions of
the United States 36
Table VI Shipments of Residual Fuel Oil in
the United States - 1968 38
Vlll
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SUMMARY
The production and use of beryllium in the United States
has been traced and charted for the year 1968. The con-
sumption was 351 short tons, while production from domes-
tic mines was only 7 short tons. About 98 percent of the
beryllium processed was from imported beryl ore, part of
which was imported during the year and part during prior
years. About 35 percent (125 tons) of the beryllium was
used to produce beryllium metal, about 50 percent (175 tons)
to produce beryllium alloys, about 5 percent (16 tons) to pro-
duce ceramics, and the remaining 10 percent (35 tons) was
lost during processing.
Emissions to the atmosphere during 1968 totaled 164 tons.
Emissions due to the combustion of coal and fuel oil were
147 tons and 8 tons, respectively. Emissions resulting from
the production of cast iron were 4 tons.
Emission estimates for coal combustion are considered to
be reasonably accurate. They are based on the average
beryllium content of many coal samples.
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Source Category
EMISSIONS BY SOURCE
1968
Source Group
Emissions - Pounds
Emissions
%
Mining
Processing of Beryllium Metal-
Alloy s, and Compounds
10, 500
3.2
End Product Uses of Beryllium
Metal.. Alloys, and Compounds:
Beryllium Fabrication
Beryllium Alloys
Beryllia Ceramics
13
26
16
55
Other Sources of Beryllium
Emissions:
TOTAL
Coal
Oil
Miscellaneous
294,000
16, 000
8,000
3.18,000
328,556
or
164 tons
96.8
100. 0
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EMISSIONS BY STATES
1 968
Beryllium Emissions
State Short Tons
Pennsylvania and Ohio 41
Illinois 12
Indiana 12
Michigan 11
New York 7
Alabama and Mississippi 7
West Virginia 7
Kentucky 5
North Carolina 5
Tennessee 5
Wisconsin 4
Delaware and Maryland 4
Virginia ' 4
Georgia and Florida 4
All Other States 24
Undistributed 12
TOTAL 164
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EMISSION FACTORS
The emission factors given herein are believed to be the
best currently available. They were determined through a
combination of methods consisting of: (1) direct observation
of emission data and other related plant processing and engi-
neering data where available; (2) estimations based on infor-
mation obtained from literature, plant operators, and others
knowledgeable in the field; (3) calculations based on. experi-
ence and personal knowledge of metallurgical processing
operations; a.nd (4) specific analytical results (in the case
of coal and fuel oil).
The basic data used to calculate the emission factors are
contained in the files of the Contractor and the Office of Air
Programs of the Environmental Protection Agency. Rea.ders
of this document are encouraged to submit data to the EPA
in confirmation of these factors or additional data which can
be used to further refine the factors in subsequent publica-
tions.
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TABLE I
EMISSION FACTORS
Mining 0. 2 Ib/ton of beryllium produced
Processing of Beryllium
Metal, Alloys, and
Compounds 30 Ib/ton of beryllium processed
End Product Uses of
Beryllium Metal, Alloys,
and Compounds
Beryllium fabrication 10 lb/100 tons of beryllium processed
Beryllium alloys 15 lb/100 tons of beryllium processed
Beryllia ceramics 1 Ib/ton of beryllium processed
Other Sources of
Beryllium Emissions
Coal 0. 58 lb/1, 000 tons of coal burned
Oil 0. 03 lb/1, 000 bbls of oil burned
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MINERAL SOURCES OF BERYLLIUM
Beryllium (Be), a grayish metal, is the only light:-weigh*
metal with, a high, melting point. Its specific gravity (1. 85)
is only slightly greater than magnesium, but its melting
point (1, 283 C) is nearly twice as high. It also has a. very
high stren.gth-to-weight ratio, great stiffness, and valuable
nuclear properties.
The earth's crust is estimated to contain 10 ppm beryllium _/
compared with 0. 1 ppm silver and 16 ppm lead. Beryllium
is widely distributed geographically but is found in concen-
t.ra.ted form in relatively few minerals. Beryl, bertrandite,
phena.cite, chrysoberyl, and barylite are some of the best
known of the thirty or more beryllium minerals, but the
principal commercial source prior to 1968 has been beryl.
Usually beryl is found associated with, other minerals in het-
erogeneous granite pegmatites where the beryl occurs in en-
riched zones; however, pegmatites are seldom mined for
beryl alone. More often the mineral is recovered as a. co-
product or by-product while recovering feldspar, mica,
1- Clark, F. W. and Washington, H. S. U. S. Geological
Survey Professional Pa.pers 127: 1924.
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cassiterite, columbite, quartz, tantalite, kaolinite, hema-
tite, and lithium minerals. Many deposits contain less than
one hundred tons of cobbed beryl.
Beryllium also occurs in nonpegmatite deposits. Bertran-
dite has been found associated with fluorite, montmorillon-
ite, opal, and chalcedony at Spor Mountain, Utah; commer-
cial mining in this district began during 1969. Similar de-
posits have been found elsewhere in Utah. In Nevada, phen-
acite and bertrandite occur with, scheelite, flourite, pyrite,
and other minerals in limestone. In Colorado, beryl and ber-
trandite occur with fluorite in mica-quartz crystalline rock.
In. Labrador, ba.rylite occurs in small veins with quartz and
albite; in Mexico, bertrandite is found in fluorite which also
contains other minerals.
Beryl, when pure, is a beryllium aluminum silicate,, con-
taining about 14 percent BeO, 19 percent Al-O,, and 67 per-
cent SiO.,. The precious forms of beryl, emerald, and aqua-
marine approach the pure form in composition; however, the
commercial grades generally contain 11 to 13 percent BeO,
17 to 19 percent A12
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During recent years the major world sources of ores that
contain beryllium have been India, Brazil, Uganda, Mozam-
bique, Argentina, and the U. S. S. R. Even though the United
States has not been a ma.jor producer in the past:, small quan-
tities of beryl ore have been mined in Colorado, South Dakota,
New Mexico, and West Virginia..
Other domestic sources of beryllium have been, investigated
and reported by the Bureau of Mines, the U. S. Geological
Survey, and others. These reports indicate some beryllium
is found in coal and oil, as well as in pegmatite ores mined
extensively in North Carolina., principally for the production
of feldspar, quartz, mica, and spodumene.
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MATERIAL FLOW THROUGH THE ECONOMY
The sources and uses of beryllium in the United States dur-
ing 1968 are shown in Figure I. About 44 percent of the beryl
ore that was processed was imported, 34 percent was from
Government stocks, 20 percent was from industry stocks,
and only 2 percent was from domestic mines.
Beryl Ore Imports - In 1968 the imports of beryl ore totaled
3, 822 short tons (Be content. - 153 short tons). About 42 per-
cent was imported from Brazil, 14 percent from Argentina,
10 percent from Uganda, 9 percent from the Republic of South
Africa, and 5 percent or less from each of ten other coun-
tries V.
Beryl Ore Stocks - At the beginning of the year industry
stocks of beryl ore were 8, 177 short: tons /, but by the end
of the year the total was only 6, 390 short tons /, a decrease
of 1., 787 short tons (71 short tons Be content). During the
same period Government stocks of beryl also decreased 3, 000
short tons (120 short tons Be content) /.
1- Minerals Yearbook: Bureau of Mines; 1968.
2- Minerals Yearbook; Burea.u of Mines; 1967.
3- Private communication with, industrial sources.
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BeryIlium Uses - A large proportion of the beryllium is
ultimately used in space and national defense applications.
.Information regarding many of these uses is classified and
the details are not revealed in this report. Other uses of
beryllium are discussed in detail in the following section.
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BERYLLIUM
MATERIAL FLOW THROUGH THE ECONOMY - 1968
(Short Tons - Be Content)
Sources
Beryl Ore Domestic Production
153
Beryl Ore Imports
120
Government Stocks
71
Industry Stocks
.351
Uses
125
Be Metal
175
Be Alloys
16
Ceramics
35
Processing Loss
Consumer
Figure I
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USES AND EMISSIONS OF BERYLLIUM
MINING
In the United States hand- sorted beryl ore was produced in
Colora.do, New Mexicos and South Dakota during 1968, but
domestic production for the year was only 160 short tons /
containing about: 4 percent beryllium (Be content - 7 short
tons).
Prior to 1969 beryllium ore mined in the United States was
from open pits or shallow underground workings and most of
the ore was concentrated by hand.-sorting. The mining was
usually done on a small scale by crude opencut methods. It
commenced on an outcrop where the minerals of value could
be seen and cuts were made or pits were sunk by drilling
and blasting the rock. The cycle of drilling, blasting, cob-
bing, and hauling waste to dumps was repeated until the op-
eration could no longer be worked economically.
Output from the mines remained at a low level in the United
States for several years even though domestic consumption
1- Minerals Yearbook; Bureau of Mines: 1968.
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increa.sed substantially. However, construction of new large-
scale facilities was commenced during 1968 by Brush Beryl-
lium Company at Spor Mountain in Utah. At the open-pit mine
site removal of overburden wa.s sta rted about the middle of
the year. Forty-seven miles from the mine, at a location
near Delta, Utah, construction of the mill was in progress
and completion was scheduled for midyear 1969. Even though
there were no emissions from operations in Utah during 1968,
this will be a significant factor to be taken into account in
future years.
Emissions from Mining - While this study was in progress,
several mining compa.nies were contacted concerning their
operations and their emissions to the atmosphere. They
stated that records of beryllium emissions were not main-
tained.
Beryllium emissions to the atmosphere from sources of min-
ing are estimated at 0.2 pound per ton. of beryllium handled.
This gives a figure of 1.4 pounds of beryllium emitted to the
atmosphere during 1968. This estimate is made by The Con-
tractor on the basis of better known emissions from similar
mining operations that have been studied in more depth for
oiKer'trace metal emission reports.
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Beryllium is also found associated with minerals other than
beryl and bertrandite. Tn copper mining and smelting it is
often present in the ore in trace amounts, but there is no by-
product beryllium recovery. Another similar example is
mining of spodumene at Kings Mountain in North. Carolina.
Mining at that location is principally for the recovery of lith-
ium even though the ore uniformly contains about 0. 05 per-
cent BeO according to United States and North Carolina geo-
logical surveys.
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PROCESSING OF
BERYLLIUM, METAL, ALLOYS, AND COMPOUNDS
The production of beryllium products in .1968 was principally
from imported ores processed by the Brush Beryllium Com-
pa,ny, Elmore, Ohio, and Kawecki Berylco Industries, Inc. ,
Hazelton, Pennsylvania. Although these companies use dif-
ferent processing methods, the basic product made from
beryl ore is beryllium hydroxide. This material is further
processed to produce beryllium metal, beryllium oxide, and
master alloys. During 1968 the beryllium processed into
products was 351 short tons (Be content) '/.
Beryllium Hydroxide - In the Copaux-Ka.wecki fluoride pro-
cess used by Ka.wecki Berylco Industries, the beryl ore is
finely powdered by dry grinding to minus 200 mesh, then
mixed with, soda ash and sodium f.l.uo silicate prior to sinter-
ing at 1,400 F. After sintering., the product is crushed,
ground, leached with water, and the in solubles are filtered
off to waste. The filtrate is treated with caustic soda to pre-
cipita.te beryllium hydroxide.
The Sawyer-Kjej.Igren sulfa.te extraction process, as used
I- Private communication with, industrial sources.
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by the Brush Beryllium Company, is a process in which the
beryl ore is first crushed and melted at about 3, 200 F. The
beryl is then quenched in cold water and the crystalline struc-
ture is destroyed. Next, the beryl glass is heated to about
1, 700 F in a gas-fired rotary kiln, then ground in a ball mill
to increase its activity prior to the addition of sulfuric acid.
Sulfatlon is followed by water leaching and the resulting silica
sludge is discarded. The soluble beryllium and aluminum
sulfates are extracted with the water and the bulk of the alum-
inum present is sepa.rated as ammonium alum by adding am-
monium hydroxide. The solution is cooled to cause crystal-
lization and the alum is removed by centrifuging. Next,
chela ting agents are added to the filtrate and a sodium hy-
droxide solution is introduced to produce sodium beryllate.
Hydrolysis follows a.nd the precipitate, beryllium hydroxide,
is separated by .centrifuging.
Beryllium Oxide - In one method of producing beryllium
oxide, the beryllium hydroxide is first redissolved in water,
sulfuric acid, and a.mmonium sulfide. Then, the solution is
passed through the steps of filtration, evaporation, and cry-
stallization, centrifuging follows to obtain beryllium sulfate.
The final steps a.re blending and calcination at about 1, 900 F.
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Beryllium-Copper Alloys - The first step in the production
of beryllium-copper alloys is to prepare a master alloy.
Beryllium hydroxide is calcined at about 800 F to form be-
ryllium oxide. Then weighed quantities of carbon powder,
copper, and beryllium oxide are mixed and melted in an elec-
tric arc furnace. The product, beryllium-copper master
alloy, is cast into ingots containing about 4 percent beryllium.
In the final step, the master alloy and copper are melted to-
gether in an induction furnace to form beryllium-copper al-
loy containing about 2 percent beryllium.
Beryllium Metal - Both of the primary producers of beryl-
lium in the United States :re]y on the same basic principals
for the production of beryllium fluoride, but there are cer-
tain differences in the process details. The Brush Beryl-
lium Company uses the Schwenzfeie.r - Pomelee purification
process / and is able to use a rather impure input mater-
ial. The hydroxide product of the su.lfate extraction process
and. various scrap recycle products are used a.s the input to
the beryllium fluoride process. These feed materials are
.! White, D. W. and Burke, J. E. ; The Metal Beryllium;
American Society for Metals; Cleveland, Ohio: 1959.
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dissolved in ammonium bifluoride in a step which includes
the addition of calcium carbonate. The resulting solution
enters a thickener under conditions where precipitation of
all heavy-metal impurities occurs, except manganese and
chromium. Lead dioxide is then added to the solution to con-
vert the manganese content to insoluble manganese dioxide
and the chromium content to insoluble lead chromate. A fil-
tration step follows, then a. sulfide treatment and a second
filtration step. At this point; the solution enters a. vacuum
crystallizer, then passes through a centrifuge and a dryer
on its wa.y to a decomposition furnace. In the furnace, a.m-
monium fluoride is driven off into a scrubber whi.le beryllium
fluoride flows from the bottom and is solidified.
In the next step, magnesium and the beryllium fluoride are
charged to a reduction furnace in solid form. An excess of
beryllium fluoride is -used in relation t:o the amount of mag-
nesium / in. order to produce a slag of magnesium fluoride
and beryllium fluoride with a melting point substa.niia.lly be-
low the melting point of beryllium. The beryllium fluoride
ex.cess is essential to permit separation of the beryllium
1- U. S. Patent No. 2, 384, 291 r Aug. 7, 1945;, B. R. F.
Kjellgren to the Brush. Beryllium Company.
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metal reaction product from the slag by water leaching.
Solid beryllium is recovered after the reaction is completed
by raising the temperature above the melting point of beryl-
lium to approximately 2, 300 F. At this temperature the
slag is very liquid and the molten beryllium floats on top.
The mass is then poured into a receiving pot where it solid-
ifies. Next, this product is crushed a.nd then water-leached
in a ba.J.l mill. During leaching the excess beryllium fluoride
is quickly dissolved; the metallic beryllium is released in
the form of pebbles that generally contain about 3 percent
trapped slag and unrea.cted magnesium. To remove these
impurities, the pebbles are vacuum -melted a.nd cast into in-
gots. During this operation magnesium is eliminated from
the melt in the vapor form. Excess beryllium fluoride is
also vaporized. Nonvolatil.es separate from the melt as a
dross and are removed from the crucible after the purified
metal has been, poured into the ingot mold,
Emissions from the Processing of _B ery.11.ium
and Compounds - During the past 25 yea.rs it has been rec-
ognized that excessive beryllium concentrations in the atmos-
phere are a serious hazard to health. As a result many con-
trols have been installed at industrial plants where beryllium
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is processed.
During this study meetings were held with Brush Beryllium
Company at Elmore, Ohio, and Kawecki Berylco Industries
at Reading, Pennsylvania. Both companies furnished de-
tailed information regarding the use of air pollution control
equipment as shown in. Tables II and III.__-They also provided
information concerning beryllium concentrations in the at-
mosphere surrounding plant sites, but could not provide
stack emission data.
During the months of May, June, and July, 1971, by agree-
ment with the Brush Beryllium Company and Kawecki Berylco
Industries, field crews of the Environmental Protection Agen-
cy conducted preliminary field source sampling tests at the
metallurgical processing facilities of the two beryllium com-
panies. These tests covered major stacks but did not cover
all sources of atmospheric emissions. Ba.sed on the known
results of these preliminary tests the EPA estimates that
total emissions during 1968 from all metallurgical process-
ing facilities of both companies were no less than 30 pounds
per day, average for the year, or 10,500 pounds for a year
of 350 operating days /.
1- Private communication from the Environmental Protec-
tion Agency, Office of Air Progra.ms; July 14, 1971.
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Further refinement to determine actual emissions from
these plants awaits the results of a more complete testing
program, now planned as of the date of release of this re-
port.
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TABLE II
AIR POLLUTION CONTROL EQUIPMENT
BRUSH BERYLLIUM COMPANY - ELMORE, OHIO
Production
Area
Process Description
Control Equipment
Beryllium
Hydroxide
Ore storage, crushing
and melting
Quenching, heat treating
and grinding
Sulfation and dissolving
Leaching, crystallization
and beryllation
Wet cyclone and
baghouse
Cyclone and baghouse
Packed tower - water
scrubbing
Ventilation
Beryllium Mixing, thickening, filter-
Pebbles ing and sulfi.de treating
Crystallizing and
c en.tr ifuging
Decomposition furnace
Reduction furnace
Crushing
Packed tower ~ water
scrubbing
Baghouse
Packed tower- two
scrubbers in series
Ven.turi scrubber and
packed tower
Packed tower
Beryllium
Metal
Pebble melting and casting Packed tower
Baghouse
Billet cleaning and
inspection
Chipping, sizing, screen-
ing and blending
Die loading, hot pressing,
rough and finish machining
Cyclone and baghouse
Cyclone and baghouse
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Beryllium Dissolving, filtering,
Oxide evaporation and crystal-
lization
Blending and calcining
Ventilation
Packed tower-
caustic scrubbing
Master
Alloy
Calcining
Mixing
Arc furnace
Ba.gh.ouse
Baghouse
Cyclone and baghouse
Beryllium
Copper
Melting
Casting
Baghouse
Baghouse
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TABLE III
AIR POLLUTION CONTROL EQUIPMENT
KAWECKI BERYLCO INDUSTRIES. INC.
HAZELTON. PENNSYLVANIA
Production
Area
Beryllium
Hydroxide
Process Description
Ore handling and grinding
Sintering
Crushing and grinding
Leaching and filtering
Control Equipment;'
Cyclone a.nd baghouse
Venturi scrubber
Cyclone and baghouse
Hydraulic scrubber
and venturi scrubber
Beryllium
Beads
Mixing, purifying and
filtering
Evaporation
Drying
Decomposition furnace
Reduction furr.ace
Crushing and mi.iling
Hydraulic scrubber
and dem.ist.er
Hydraulic scrubber
Ve.nturi scrubber and
demi ster
VenTuri scrubber and
demister
Venturi scrubber,
cvcJone and baghov.se
Scrubber and demist:er
Be ry Ilium
Metal
Melting and casting
Billet cleaning
Chipping
Grinding
Cyclone and baghouse
Scrubber and demister
Cyclone and baghouse
Cyclone and baghouse
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Mf i Screening> blending Baghouse
Metal (cont.) and loading
Vacuum hot pressing
Machining
Baghouse
Cyclone and baghouse
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Beryllium Dissolving, filtering,
Oxide evaporation and crystal-
lization
Blending and calcining
Ventilation
Packed tower-
caustic scrubbing
Master
Alloy
Calcining
Mixing
Arc furnace
Baghouse
Baghouse
Cyclone and baghouse
Beryllium
Copper
Melting
Casting
Baghouse
Baghouse
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END PRODUCT USES OF
BERYLLIUM METAL, ALLOYS. AND COMPOUNDS
The use of beryllium has grown from 180 short tons in 1964
to 351 short tons in 1968. Much of this rapid growth has
been due to the increased use of beryllium metal, in high-
speed aircraft, missies, a.nd space exploration.
Beryllium Metal - Beryllium metal has the unusual physi-
cal properties of high stiffness., high heat capacity, and low
density. It is used in. nuclear rea.ctors as a moderator and
reflector material, as well as in gyroscopes, accele.rome-
ters, internal guidance systems parts for high-speed flight
and marine navigation, rocket propellent fuel, airplane
brakes, and heat shield.s for space capsules. Newly report-
ed uses include rotor bl.a.des and other pa.rts for gas turbine
engines, sola.r cell, mounting boards for satellites, mirrors,
and other optical pa.rts. During .1968 the beryllium metal
produced was .1.25 short tons _/.
Beryllium-Copper Alloy - Beryllium-copper has high elec-
trical and thermal conductivity coupled with strength, a.nd re-
sistance to fatigue at elevated temperatures. There are
1- Private communication with. Brush Beryllium Company.
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many uses for beryllium-copper including springs, bellows,
diaphragms, electrical contacts, aircraft engine parts,
plastic molds, marine propellers, gears, bearings and
bea.ring retainer rings, precision castings, and rollers.
New applications include housings to protect undersea tele-
phone systems, automobile starter springs, bucket wheels
used in instruments which measure the velocity of water,
and antennas for space vehicles and satellites.
In the United States during 1968 the beryllium used in beryl-
lium-copper alloys totaled 175 short tons /.
Ceramics - Beryllium in the form of beryllium oxide has
ceramic applications. It is useful for certain ceramics be-
cause of a high melting point, high thermal conductivity,
high specific hea.t, and a high electrical insulation resist-
ance over a wide tempera.ture range. Beryllia ceramics
are used in high-voltage electrical porcelains, suspension
insulators, spark plugs, and microwave windows.
There were 16 tons of contained beryllium used in beryllia
ceramics during 1968 _/.
1- Private communication with Brush Beryllium Company.
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-28-
End Product Emissions of Beryllium Metal, Alloys, and
Compounds - The companies manufacturing end products of
beryllium that were contacted during this study, without ex-
ception, advised that they do not maintain records of stack
samples. Most of them sample in-plant air at regular inter-
vals, but very few sample out-plant air.
Special ventilation systems are incorporated in these facili-
ties; however, the type of system and the air pollution con-
trol equipment that is used varies considerably. In general,
the small fabricators are not as strict with their environ-
mental monitoring as the metallurgical processing compa-
nies or the larger reprocessors. Table IV shows the type
of ventilation and equipment used by typical beryllium metal
fabricators.
Beryllium Fabrication - Beryllium metal is generally pur-
- ________.___ _ ^
chased as rod, bar, or billet for use in making aircraft,
computer, and spacecraft parts. The usual fabrication, op-
erations include turning, milling, drilling, reaming, grind-
ing, honing, sawing, and abrasive cutting. Chemical and
electrochemical procedures are also employed. Losses
may occur in dust form during these operations.
-------
-29-
TABLE IV
INDUSTRIAL DATA - AIR POLLUTION CONTROL
Code No. Ventilation
System
3. 101 Flexible
ducts
3. 102 Local
3. 103 Lo-cal
Flexible
ducts
3. 104 Central
Flexible
ducts
Local
3.105 Local
Flexible
ducts
3. 106 Central
Flexible
ducts
3. 10? Central
Flexible
ducts
3. 108 Central
Flexible
ducts
Control
Equipment
Cyclone
Baghouse
Absolute
filter
None
Absolute
filter
Cyclone
Baghouse
Absolute
filter
Chemical
Scrubber
Cyclone
filter
Absolute
filters
Absolute
filter
Baghouse
Waste
Type
Solid
Solid
Liquid
Solid
Liquid
Solid
Liquid
Solid
Liquid
Solid
Liquid
Solid
Liquid
Solid
Liquid
Waste
Packaging
Plastic
bags
Plastic
bags
Plastic
bags
Plastic
bags
Metal
drums
Plastic
bags
Metal
drums
Plastic
drums
Plastic
drums
Plastic
drums
Waste
. Disposal
Local
contract
Local
Sewer
Commercial
Sewer
Burial
Local
Sludge
separator
Sewer
City
dump
Return to
supplier
"
Local or
Return to
supplier
Return to
supplier
-------
-30-
At one large plant all beryllium machining except debarring
is accomplished by wet process methods. The debarring
operation, is enclosed in a. hood that is maintained \mder neg-
ative pressure, and the exhaust air is passed through, abso-
lute filters before it is returned to the room.
At another location where machining is done under dry condi-
tions, the drilling, sawing, and cutting operations are served
by close-capture, high-velocity exhaust hoses held within one
base diameter of the point of operation. Ventilated enclosures
are used for wet and. dry sanding, vapor honing, and wet abra-
sive cutoff wheels. Lateral slot exhaust is used for acid etch-
ing, chem-milling, electrical discharge machines, and coun-
ter sinking.
At three small plants where operations were studied, beryl-
lium machining was not separated from other parts of the
shop area. At one facility in plant air samples a.re collect-
ed frequently, but the other two have no regular sampling
schedule.
An. emission factor of 10 pounds be.ryllium per 100 tons of
beryllium metal processed is based on estimates obtained
from fabricators. In 1968 the beryllium emissions to the
-------
3.1
atmosphere due to fabricating beryllium metal were 13
pounds.
Field source sampling by the EPA is planned for certain
facilities, which will refine the emission factors given above.
Beryllium Alloys Beryll.ium-copper is the principal alloy
and most plants using this material do not: remelt or make
basic changes in the alloy. The processing generally in-
volves stamping or drawing into finished shapes.
An emission fa,cto.r of 15 pounds bervlliom per 100 tons of
beryllium processed is estimated a.s the average for beryl-
lium alloys. The total emissions to the atmosphere during
1968 were 26 pounds.
^e_ry].lia Cera.rni£S Beryllia is one of the best refractory
materials known and it can be fabricated by normal ceramic
i B rf[ - < -> >.
processes. The principal emission haza rd arises in the
original fabrication of the ceramics, where beryllium ox.ide
dust or fume may be inhaled. Machining of pa ris also gives
rise to dust, but in storage or final handling of finished arti-
cles there is little danger of emissions except from dusting
due to attrition, or breaka.ge.
-------
One ceramic operation is briefly described as a process
commencing with, beryl and other materials batched inro a
large floor cistern containing water. After milling, wet
screening, and adjustments, the glaze is applied to the un
r.7 !'>--. i-i-M- -c- '. if o -<.'-',: !',*? - "i -'.-
fired porcelain. When fired, the glaze is permanently fused
to the ceramic article. A typical glaze contains about; 2 per-
cent beryl.
The ventilation systems inspected during this study included
glove boxes, hoods, central ventilation ducts, and absolute
filters. Some reprocessing companies contacted claimed
no loss of beryllium to the atmosphere, while others indi-
cated their loss did not exceed. 2 percent.
An emission factor of one pound per ton of beryllium pro-
cessed is estima.ted as the average emission rate for beryl-
Ha ceramics. The total emissions to the atmosphere during
.1.968 were 16 pounds. This emission estima.te was made by
The Contractor on. the ba.sis of information supplied by the
manufacturers.
Rocket Propellants - Beryllium has been used in solid
rocket fuels, but due to its high, toxicity its use for that pur-
pose has been virtually discontinued. Even though most of
-------
the test work was done prior to 1968, a brief description of
fuel, manufacturing is included.
The beryllium is usually received in powder form in poly-
ethylene containers packed in steel drums. It is added to
other materials in a dough mixer, va.cuum cast, cured, and
machined into final shapes. Emissions occur during handl-
ing the dry powder and during the machining.
During 1967 strict standards were set by the Public Health
Service followed by a Department of Defense order limiting
testing by Government agencies and their subcontractors.
With these restrictions, .it is doubtful there will be any future
emissions.
Spa£ecraft Reactors - Analytical studies have been con-
ducted to determine re-entry ablation of beryllium in SNAP-
10A reactor reflectors, a.nd the toxic ha.zard produced at
ground level by the resultant residue. It ha,s been concluded
- -' :(-.-! .-or' f-" ~ <~" ". 'f c ''" '
that varying degrees of ablation will occur, but that no ground
level toxic hazard will exist: even with a. reflector completely
ablated at the lowest possible ablation altitude. /.
- Field, A. L. Jr., "Ar.a.lyfcica] Studies of Beryllium Abla-
tion and Dispersion During Re-Entry": J. Spacecraft;
1; No. -.1, Jan. 1964.
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34..
OTHER SOURCES OF BERYLLIUM EMISSIONS
COAL
A study has been made regarding emissions from coal fired
power plants and the emissions of beryllium have been re-
corded. Six power boilers were tested, each a different
type., and each value reported was the average of at least
two tests. Two of the boilers were fired with Illinois coal;
two burned Pennsylvania, coal; one used some coal from
Ohio and some from West Virginia: one burned part Ken-
tucky and part West Virginia, coal. Beryllium concentra-
tions in the fly ash samples taken before fly ash. collection
A
ranged from 0. 20 to 0. 94 grains per scf x 10' . The aver-
A
a.ge was 0.45 grains per scf x: 10" . In the samples taken
after fly ash collection, the beryllium concentration ranged
4
from .0. 02 to. 0. 24 grains per scf x 10 and the a.verage
-4 1
was 0.11 grains per scf x 10 /. Calculations have
been made based on 508, 990, 000 tons of coal consumed in
the United States during .1968 /, 90 percent: application
1- Cuffe, Stanley T. and Ger sile, Richard W. ; "Emissions
from Coal Fired Power Plants"; Public Health Service
Publication No. 999-AP-35: 1967.
2- Minerals Yearbook: Bureau of Mines; 1968.
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-35-
of control, 160 scf of flue gas per pound of coal, and the
average beryllium concentrations in fly ash stated above.
According to this method the beryllium emissions for 1968
due to the combustion of coal were 167 tons.
508, 990, OOP x 160 x 2,OOP
7,000 x 2,000
[(0. 11 x 10-4x 0.9) +(0.45 x lO'4 x 0. 1)J = 167
Many samples of coal have been analyzed and the beryllium
content has been reported as shown in Table V. Calculations
have also been made based on a concentration of 1. 9 ppm be-
ryllium in coal, 90 percent application of control, 85 percent
efficiency of control, and fly ash at 65 percent of total ash.
The beryllium emissions calculated by this method total 147
tons.
508, 990, 000 x 1. 9 x 10"6 x 0. 65 j_l - (0. 85 x 0. 90)] = 147
In this report the figure of 147 tons is used as the beryllium
emissions to the atmosphere during 1968 due to the combus-
tion of coal.
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-36-
TABLE V
AVERAGE MINOR ELEMENT CONTENTS OF COAL
FROM VARIOUS REGIONS OF THE UNITED STATES /
P . Ash Content Be Content
of Coal - % of Coal - pptn
Northern Great Plains 13.42 1.5
Eastern Interior 6. 16 2. 5
Appalachian 6.11 2.5
Western and Southwestern NR* 1. 1
Average Beryllium Content in Coal 1.9
*Not Reported
NOTE - It is anticipated that, with reference to the largest
source of emissions for 1968, from coal (294, 000 pounds),
the ONRL in a joint program with TVA will conduct a coal
fired boiler plant test aimed at a complete materials bal-
ance for all trace metals. For oil fired boiler plants, the
second largest suspected source, EPA has obtained resid-
ual fuel samples which await analysis as of the date of the
release of this report.
1- The above table based on U. S. Geological Survey
Bulletins 1117-Cand 1117-D.
-------
-37
OIL
Data regarding the beryllium content of crude and residual
oils used in the United States is virtualJy nonexistent. Only
,s i - ±
one large electric utility"compariy was able to fu'r'ni's'n* data.
showing the beryllium content of residual oil. That company
reported the beryllium content of the oil used during 1968
as less than 0. 1 ppm.
The residual oil used in the United States during 1968, ex-
clusive of use in vessels, was 581.9 million barrels. The
oil, containing beryllium at an estimated 0. 08 ppm, was
used by industrials, electric utility compa.nies, railroads,
oil companies, and the military, as well as fox heating
(Table VI).
RESIDUAL OIL DATA - 1968
Residual Oil Burned (bbls) 581, 900,000
Pounds per Barrel 340
Beryllium Content of Oil (ppm) 0. 08
During 1968 beryllium emissions to the atmosphere due to
the combustion of residual oil totaled 8 tons.
-------
-38-
TABLE VI
SHIPMENTS OF RESIDUAL FUEL OIL
IN THE UNITED STATES - 1968
Use Million Barrels
Heating ,^, .,... ,t «_. , . . , 174.3
Industrial 175. 0
Electric Utilities 185.0
Military and Other 47. 6
581.9
State
New York 116.4
Massachusetts 67.8
New Jersey . 62. 6
California 51. 8
Pennsylvania 42.4
Florida 38.6
Connecticut 28. 1
Illinois 24. 1
Virginia 12.0
Indiana 11.4
Washington 10.0
Other States
Pacific-Mountain 25. 5
North Central 23.6
Southern 48.3
Northeast lir_3
581.9
"Shipments of Fuel Oil & Kerosine in 1968"; Mineral Indus-
try Surveys; U. S. Dept. of the Interior; U. S. Bureau of
Mines; Sept. 17, 1969.
-------
-39-
INCINERATION
Those references that list the major emission sources of
beryllium include the production of beryllium hydroxide,
beryllium metal, and beryllium oxide, as well as the'com-
bustion as coal. Few sources mention emissions that may
occur in connection with scrap and waste disposal.
The possibility of significant emissions from municipal in-
cinerators or sewage disposal plants is considered remote.
The ores are not widely distributed and only a small quanti-
ty of metal, alloys, and compounds are incorporated into
consumer products.
Solid Waste Material from Beryllium Fabrication - Infor-
mation was obtained during this study regarding the handling
of waste and scrap materials that result from the machining
of beryllium metal. All fabricators contacted reported that
3 ifoj .<.
scrap is collected, packaged, and labeled for return to the
supplier or sale through a dealer. The usual practice is to
package the material in polyethylene bags inside steel drums.
Waste material in solid form that is contaminated with beryl-
lium and is not suitable for sale is usually collected, packaged,
-------
-40-
and labeled in the control area before it is turned over to an
approved contractor for disposal. In a few instances the
fabricator returns the waste to the producer for disposal.
Contaminated liquid waste, such as the coolant from machin-
ing operations, is sometimes discarded to the sanitary sew-
er; in some instances it is disposed of through an approved
contractor.
During 1968 the beryllium emissions to the atmosphere due
to the disposal of waste from machining operations were
negligible.
-------
-41-
MISCELJLANEOUS EMISSIONS
During this study spectrographic analyses of dust samples
from foundries have been examined and they show the dust
contains beryllium, arsenic, manganese, vana.dium, cad-
mium, nickel, barium, copper, zinc, and 19 other elements.
This information confirms that foundries and possibly steel
mills are sources of beryllium emissions to the atmosphere.
In spite of recent advancements in the technology of melting
with electric arc and induction furnaces, the cupola is still
the most popular method for producing cast iron. The rate
of particulate emissions from gray iron cupolas has been re-
ported as 4 to 26 pounds per ton of process weight not includ-
ing emissions from handling, storage, cha.rging, or other
non-melting operations.
Based on this information obtained from industry, the par-
ticulate emission factor is estimated at 22 pounds per ton
of process weight including melting and non-melting opera-
tions. The beryllium content of the particulate is 0. 003 per-
cent _/ and the degree of emission, control approximately
25 percent.
1- Private communication with industrial source.
-------
-42-
During 1968 the pig iron and scrap used by iron foundries
totaled 16,788,000 short tons _/. Beryllium emissions to
the atmosphere due to the production of cast iron were esti-
mated by the Contractor to be 4 tons.
i ' - i ' f I'/-? f ..')-", 1 7 r -.
1- Minerals Yearbook; Bureau of Mines; 1968.
-------
A-l
APPENDIX A
COMPANIES DEALING IN
BERYLLIUM AND BERYLLIUM ALLOYS
CALIFORNIA
Electronic Space Products, Inc.
Lockheed Missiles and Space Co.
North American Rockwell Corp.
Solar Aircraft Company
Whittaker Corporation
LOCATION
.Los
Sunnyvale
El Segundo
San Diego
Los Angeles
COLORADO
Beryl Ores Company
Coors Porcelain Company
Dow Chemical Company
U. S. Beryllium Corporation
Arvada
Golden
Rocky Flats
Pueblo
FLORIDA
American Beryllium Company, Inc.
Sarasota
ILLINOIS
D & S Wire, Incorporated Chicago
Goldsmith Chemical and Metal Corp. Evanston
Tri-Cast Corporation Chicago
IOWA
Alloy Metal Products, Incorporated
Davenport
MARYLAND
Max Zuckerman & Sons
Owings Mills
MASSACHUSETTS
Leach and Garner Company
Whittaker Corporation
Attic bo ro
West. Concord
-------
A-2
MICHIGAN
Champion Spark Plug Company
Speedring Corporation
Detroit
Warren
MISSO'URI
McDonnell-Douglas Corporation
St. Louis
NEW JERSEY
Allied Chemical Corporation
J. T. Baker Chemical Company
Be Cu Manufacturing Company., Inc.
Braun H. Tool and Instrument Co. , Inc.
Consolidated Ceramics and
Metalizing Corporation
Englehard Industries, Incorporated
Little Falls Alloys, Incorporated
Machined-Shapes, Incorporated
Mini-Tool Technical Industries, Inc.
National,Beryllia Corporation
Var-Lac,-Oid Chemical Company
Morristown
Phillips burg
Scotch Plains
Hawthorne
Flemington
Newark
Pater son
East Rutherford
Ridgefield
Haskell
Elizabeth
NEW YORK
Alloys Unlimited, Incorporated
American Precision Industries, Inc.
American "Silver Company, Inc.
Astrometal Company
Atomergic Chemetals Company
Barden-Leemath
Belmont Smelting & Refining Works
Beryllium Manufacturing Corp.
Beryllium Metals & Chemicals Corp.
City Chemical Corporation
T. E. Conklin Brass & Copper Co.
General Aerospace Materials Corp.
General Astrometals Corp.
International Selling Corporation
Keystone Corporation
Melville
East Aurora
Flushing
Yonkers
Carle Place
Woodbury, L. I.
Brooklyn
Valley Stream, L. I.
New York
New York
New York
Plainview, L. I.
Yonkers
New York
Buffalo
-------
A-3
JLapp Insulator Company
Loral Corporation
MKB Manufacturing Corporation
A. D. Mackay, Inc.
Metallurg, Inc.
Pancoast International Corporation
Philipp Brothers
Saturn Industries, Inc.
Semi Alloys, Inc.
C. Tennant Sons & Company
United Mineral and Chemical Corp.
Le Roy
Scarsdale
Deer Park, L. I.
New York
New York
New York
New Yo;rk;.; ]x
New York
Mount Vernon
New York
New York
OHIO
Brush Beryllium Company
Clifton Products, Incorporated
Ferriot Brothers, Incorporated
Cleveland
Plainesville
Akron
PENNSYLVANIA
Aluminum Company of America
Beryllium Corporation
Bram Metallurgical Chemical Co.
Foote Mineral Company
Kawecki-Berylco Industries, Inc.
Mercer Alloys Corporation
Metals Engineering Company
Nuclear Materials & Equipment Co.
Pen'n Nuclear
Pittsburgh
Reading
Philadelphia
Exton
Reading
Greenville
Reading
Apollo
Perm
TENNESSEE
American Lava Corporation
Union Carbide
Chattanooga
Oak Ridge
WASHINGTON
Boeing Company
Seattle
-------
A-4
WEST VIRGINIA
Pennsylvania Glass Sand Corp. Hancock
WISCONSIN
l ' *
Ladish Corporation Milwaukee
Thomas Register, Dec. 1968 Ed. , and other sources.
-------
BIBLIOGRAPHIC DATA
SHEET
1. Report No.
APTD-1508
3. Recipient's Accession No.
4. Title and Subtitle
National Inventory of Sources and Emissions: Beryllium - 1968
5. Report Date
September 1971
6.
7. Author(s)
8. Performing Organization Rept.
No.
9. Performing Organization Name and Address
W. E. Davis & Associates
9726 Sagamore Road
Leawood, Kansas
10. Project/Task/Work Unit No.
11. Contract/Gram No.
CPA 70-128
12. Sponsoring Organization Name and Address
ENVIRONMENTAL PROTECTION AGENCY
Office of Air Programs
Durham, North Carolina
13.-Type-of-Re-poit.& Period
Covered
14.
15. Supplementary Notes
16. Abstracts
The inventory of atmospheric emissions has been prepared to provide reliable information
regarding the nature, magnitude, and extent of the emissions of beryllium in the United
States for the year 1968. Background information concerning the basic characteristics 01
the beryllium industry has been assembled and included. Brief process descriptions are
given. The beryllium emissions and emission factors presented are based chiefly on the
summation of information obtained during field trips to inspect the air pollution con-
trol equipment used at various locations and observe processing operations. The produc-
tion and use of beryllium in the United States has been traced and charted for the year
1968. The consumption was 351 short tons, while production from domestic mines was only
7 short tons. About 98% of the beryllium processed was from imported beryl ore, 35% of
which was used to produce beryllium metal, about 50% to produce beryllium alloys, about
5% to produce ceramics, and about 10% was lost during processing. Emissions to the
atmosphere during 1968 totaled 164 tons.
17* Key Words and Document Analysis. 17o. Descriptors
Air pollution
Emission
Inventories
Sources
Beryllium
Industries
Minerals
Utilization
Air pollution control equipment
17b. Identifiers/Open-Ended Terms
Year 1968
United States
17c. COSATI Field/Group ] 33
18. Availability Statement
Unlimited
FORM NTIS-35 (REV/a-73)
19. Security Class (This
Report)
UNCLASS1F1F.D
20. Security Class (This
Page
UNCLASSIFIED
21. No. of Pages
53
22. Price
USCOMM-DC 14SS2-P72
-------
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Guidelines to Format Standards for Scientific and Technical Reports Prepared by or for the Federal Government,
PB-180 600).
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2. Leave blank.
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nently. Set subtitle, if used, in smaller type or otherwise subordinate it to main title. When a report is prepared in more
than one volume, repeat the primary title, add volume number and include subtitle for the specific volume.
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6- Performing Organization Coda. Leave blank.
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If the report contains a significant bibliography or literature survey, mention it here.
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------- |