United States
Environmental Protection
Agency
Office of Pollution EPA 745-K-94-003
Prevention and Toxics May 1994
7408
&EPA
EPA's 33/50 Program
Company Profile
Acme Metals Incorporated
Printed on Recycled Paper
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THE 33/50 PROGRAM
This Company Profile is part of a series of reports being developed by EPA to highlight the accomplishments
of companies participating in the 33/50 Program. The 33/50 Program is an EPA voluntary pollution reduction
initiative that promotes reductions in direct environmental releases and offsite transfers of 17 high-priority toxic
chemicals. The program derives its name from its overall goals — an interim goal of a 33% reduction by 1992 and
an ultimate goal of a 50% reduction by 1995. The program uses 1988 Toxics Release Inventory (TRI) reporting
as a baseline. In February, 1991, EPA began contacting the parent companies of TRI facilities that reported using
33/50 Program chemicals since 1988 to request their participation in the 33/50 Program. As of April, 1994, a total
of 1,216 companies had elected to participate in
the Program, pledging to reduce emissions of the
17 target chemicals by more than 355 million
pounds by 1995. Companies are encouraged to
set their own reduction targets, which may vary
from the Program's national 33% and 50%
reduction goals. Company commitments and
reduction pledges continue to be received by EPA
on a daily basis.
The 1992 TRI data revealed that releases
and transfers of 33/50 Program chemicals de-
clined by 40% between 1988 and 1992, surpass-
ing the Program's 1992 interim reduction goal by
more than 100 million pounds. This accomplish-
ment, together with evidence from analysis of
facilities' projected releases and transfers of the
17 priority chemicals, reported to TRI under the
Pollution Prevention Act, offers strong encourage-
ment that the 33/50 Program's ultimate goal of a
50% reduction by 1995 will be achieved.
17 PRIORITY CHEMICALS TARGETED
BY THE 33/50 PROGRAM
BENZENE
CADMIUM & COMPOUNDS
CARBON TETRACHLORIDE
CHLOROFORM
CHROMIUM & COMPOUNDS
CYANIDES
DICHLOROMETHANE*
LEAD & COMPOUNDS
MERCURY & COMPOUNDS
METHYL ETHYL KETONE
METHYL ISOBUTYL KETONE
NICKEL & COMPOUNDS
TETRACHLOROETHYLENE
TOLUENE
1,1,1-TRICHLOROETHANE
TRICHLOROETHYLENE
XYLENES
Also referred to as methylene chloride
EPA is committed to recognizing companies
for their participation in the 33/50 Program and
for the emissions reductions they achieve. The
Program issues periodic Progress Reports, in
which participating companies are listed and highlighted. In addition, Company Profiles, such as this one, are being
prepared to provide more detailed information about companies that have written to EPA describing significant
emissions reduction initiatives. Information presented in these profiles is drawn primarily from the company's
written 33/50 Program communications and the annual TRI reports submitted by their facilities (including Pollution
Prevention Act data reported to TRI in Section 8 of Form R). All company communications to EPA regarding
the 33/50 Program are available to the public upon request.
EPA does not endorse the performance, worker safety, or environmental acceptability of any of the technical
options discussed in this Profile. Mention of any product or procedure in this document is for informational
purposes only, and does not constitute a recommendation of any such product or procedure, either express or
implied, by EPA.
For information on the 33/50 Program, contact the TSCA Hotline at (202) 554-1404 or contact 33/50
Program staff directly by phone at (202) 260-6907 or by mail at Mail Code 7408, Office of Pollution
Prevention and Toxics, U.S. EPA, 401 M Street, SW, Washington, D.C. 20460.
33/50 Program Company Profile: Acme Metals Incorporated
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Acme Metals Incorporated
Acme Metals Incorporated reduced its releases
and transfers of 33/50 Program chemicals by more
than 833,000 pounds from 1988 to 1992, a reduc-
tion of 89%. These reductions far surpass Acme's
33/50 Program goal of a 70% reduction by 1995.
I. CORPORATE BACKGROUND
Acme Metals Incorporated, based in Riverdale,
Illinois, is the parent company of an integrated
steelmaker and three steel fabricating subsidiaries.
Although interrelated, each subsidiary is
responsible for its own environmental programs.
Two of these subsidiaries, Acme Steel Company
and Acme Packaging Corporation, currently
participate in the 33/50 Program.
Acme Steel Company, an integrated producer
of steel products, operates coke and ironmaking
facilities in Chicago, IL and a steelmaking plant in
Riverdale, IL. Acme Packaging Corporation, a
manufacturer of steel strapping tools, operates
facilities located in Riverdale, IL, Leeds, AL, New
Britain, CT, and Pittsburg, CA. These two subsid-
iaries are responsible for virtually all releases and
transfers of 33/50 chemicals and are the focus of
this profile.
Table 1, at the end of this profile, presents
the company's data on releases and transfers of
TRI chemicals from these two subsidiaries. The
facilities currently report releases and transfers of
six 33/50 Program chemicals: benzene, chromium
compounds, cyanide compounds, lead compounds,
toluene, and xylene. The company reported total
releases and transfers of 934,825 pounds of 33/50
Program chemicals to the TRI in 1988.
Acme Metals Incorporated reduced an-
nual releases and transfers of 33/50
Program chemicals by more than
833,000 pounds by 1992 from 1988
levels.
Table II provides Acme's data on releases and
transfers of TRI chemicals for selected facilities.
Acme's Chicago Coke plant accounts for all of the
releases and transfers of benzene, toluene, cyanide,
and xylene, while its two Riverdale operations
Releases and Transfers of TRI Chemicals
Reported by Acme Metals Incorporated1
(1000 Ibs)
1988 1992
33/50 Chemicals
Benzene 189 17
Chromium compounds 14 4
Cyanide compounds 279 3
Lead compounds 406 73
Nickel compounds 6 NR
Toluene 33 3
Xylene (mixed isomers) 7 1
33/50 Subtotal2 935 102
Other TRI chemicals 3,464 864
Total2 4,399 966
NR = Not reported to TRI, use below reporting
threshold.
1 Includes only facilities participating in the 33/50
Program.
2 Columns do not sum to totals due to rounding.
account for most of the releases and transfers of
lead.
Benzene, toluene, cyanide, and xylene are
generated during the production of coke. Coke
production involves the use of heat to drive off
these constituent chemicals, among others, from
coal. The raw gases from the coking operations
(including benzene, toluene, xylene, and cyanide)
pass through recovery systems that cool the gases
and recover the constituent byproducts. These
recovery systems include gas absorbers, decanters,
scrubbers, and cooling systems. The byproducts
are recovered and sold, and the clean gas is reused
as fuel in the coke and iron production processes.
Lead is used in the production of steel strap-
ping both as a surface preparation agent and as an
electrical contact medium in the processes that
produce steel strapping. There are also trace
amounts of lead in the non-hazardous sludges
generated from pollution control activities in the
steelmaking areas.
33/50 Program Company Profile: Acme Metals Incorporated
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II. 33/50 PROGRAM GOALS AND
POLLUTION REDUCTION ACTIVITIES
Acme Metals Incorporated pledged to reduce
releases and transfers of 33/50 Program chemicals
by 70% by 1995, using its 1988 TRI reports as the
baseline. As part of this pledge, the company
projected a reduction of 470,000 pounds of ben-
zene, toluene, xylene, and cyanide from projects at
its Chicago Coke plant.
Acme achieved an 89% reduction in
releases and transfers of 33/50 Program
chemicals from 1988 to 1992, surpass-
ing its pledged reduction of 70% by
1995.
In 1986, before TRI reporting was required,
Acme installed a scrubber in the light oil con-
denser vent at the Chicago Coke plant to capture
benzene and toluene. This resulted in annual
reductions of air releases of benzene and toluene
of 68,000 pounds and 3,000 pounds respectively.
cooling system resulted in reductions of releas-
es of approximately 143,000 pounds of ben-
zene, 276,000 pounds of cyanide, 28,000
pounds of toluene, and 6,000 pounds of xylene,
as well as 1,450,000 pounds of ammonia, and
10,000 pounds of naphthalene.
• Install emission collector headers. Acme
installed emission collector headers to remove
volatile chemicals, such as benzene, toluene,
and xylene, from the headspaces of process
units and storage tanks. This process uses
steam moving under negative pressure to
sweep the volatile chemicals into the byprod-
uct recovery system. Emission collector head-
ers were installed at the light oil storage tank,
the wash oil decanter, and the wash oil circu-
lation tank and resulted in a 14,000 pound
reduction in releases of benzene, as well as
smaller reductions of toluene and xylene.
In addition, at Acme Packaging's Riverdale
facility, spent lead dross from the steel strapping
production process is now sent to an off-site
recycler. The increased recycling of lead resulted
in a reduction of approximately 333,000 pounds of
releases and transfers of lead.
Sources of Reductions in
Releases and Transfers
Cooling
Tower
54%
Gas Collector
Headers
2%
Lead
Recovery
40%
Since 1988, Acme has implemented several
programs aimed at further reducing releases and
transfers of 33/50 Program chemicals. Acme has
completed the following projects at its Chicago
Coke plant:
• Replace cooling system. Acme replaced its
contact gas cooling system with a non-contact,
wet surface air cooler in the coke byproducts
recovery process. The replacement of the
Acme reduced releases and transfers of
non-33/50 TRI chemicals by nearly
2,600,000 pounds (75%) between 1988
and 1992.
Although not part of the company's 33/50
efforts, Acme significantly reduced releases and
transfers of non-33/50 chemicals between 1988 and
1992 through the following activities:
• Upgrade pickling exhaust scrubber. The steel
pickling operation uses hydrochloric acid to
remove oxides from the surface of steel strip.
The scrubber upgrade project resulted in a
reduction of approximately 338,000 pounds of
hydrochloric acid emissions at the Riverdale
Steel facility.
• Install a wastewater treatment plant. By
installing a wastewater treatment plant to treat
the blowdown from the water recycle system at
its Chicago Furnace Plant, the company re-
33/50 Program Company Profile: Acme Metals Incorporated
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duced releases and transfers of manganese by
2,000 pounds and zinc by 1,400 pounds.
• Reduce VOC and chromium content of steel
strapping coating. Volatile organic compound
(VOC) emissions from steel strapping produc-
tion processes were significantly reduced
through reductions in the VOC content of the
coatings used. Also, chromium releases were
eliminated from this application by switching
to non-chromium-containing paints.
III. PROGRESS TOWARDS 33/50
REDUCTION GOALS
Acme's releases and transfers of 33/50 Program
chemicals were reduced 89% between 1988 and
1992, from 934,825 pounds to 101,759 pounds at
its facilities participating in the 33/50 Program.
The majority of these reductions were due to the
replacement of the contact cooling system at
Acme's Chicago Coke Plant (54% of the reduc-
tions), and the recycling of lead from Acme's
Riverdale strapping facility (40% of the reduc-
tions).
In addition to reducing releases and transfers
of 33/50 chemicals, Acme has achieved a 75%
reduction in releases and transfers of non-33/50
chemicals.
IV. SUMMARY OF ACME'S
EXPERIENCE
Acme Metals Incorporated has had great
success in meeting its 33/50 Program goals. The
company pledged to reduce its releases and trans-
fers of 33/50 Program chemicals by 70% by 1995
(compared to 1988 levels), and has surpassed this
goal by achieving a reduction of 89% by 1992.
Acme's Progress
Towards Meeting 33/50 Goals
.g
4500
4000
3500
, 3000
w
n
± 1000
2500
2000
1500
ONorv33/SO
Chemicals
• 33/50 Chemicals!
33/60
Goal
1968 1969 1990 1981 1992
33/50 Goal: 70% reductions In releases and
transfers of 33/50 chemicals by 1996
Acme has realized its largest reductions in
releases and transfers of 33/50 Program chemicals
by implementing a number of projects that focus
on benzene, toluene, cyanide, xylene, and lead. In
addition to its outstanding reductions for 33/50
Program chemicals, Acme has also reduced releas-
es and transfers of non-33/50 TRI chemicals.
These reductions, which have so far amounted to
nearly 2,600,000 pounds, demonstrate Acme's com-
mitment to environmental protection.
33/50 Program Company Profile: Acme Metals Incorporated
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Table I
Acme Metals Incorporated (1)
Releases and Transfers of TRI Chemicals, 1988-1992
Chemical
Benzene
Chromium compounds
Cyanide compounds
Lead compounds
Nickel compounds
Toluene
Xylene (mixed isomers)
Year
1988
1989
1990
1991
1992
1988
1989
1990
1991
1992
1988
1989
1990
1991
1992
1988
1989
1990
1991
1992
1988
1989
1990
1991
1988
1989
1990
1991
1992
1988
1989
1990
1991
1992
Surface
Total Air Water
Emissions Discharges
(pounds) (pounds)
175,926
177,444
171,613
118,300
14,900
750
110
182
113
500
277,229
277,722
277,199
140,420
570
5,026
8,362
4,898
5,022
5,880
750
33
42
15
31,606
32,154
32,329
23,300
3,350
7,404
7,438
8,010
5,890
1,390
0
0
0
5
5
0
0
0
0
0
288
51
85
250
250
3,100
3,650
0
0
250
0
0
0
0
0
0
0
5
5
0
0
0
5
5
Transfers Percent
Off-site Change
Transfers for Treatment/ Total Releases 1988-1992
to POTW Disposal/Other and Transfers Total Releases
(pounds) (pounds) (pounds) (2) and Transfers
13,047
13,047
1,862
1,600
1,800
250
164
143
180
133
1,804
2,564
2,768
2,800
2,400
1 ,039
528
283
167
286
250
436
381
146
998
998
119
99
120
92
92
68
58
26
0
0
0
0
0
12,900
7,070
8,621
3,860
3,748
0
0
0
0
0
397,216
185,171
126,164
77,920
66,141
5,150
2,249
3,934
1,180
0
0
0
0
0
0
0
0
0
0
188,973
190,491
173,475
119,905
16,705
13,900
7,344
8,946
4,153
4,381
279,321
280,337
280,052
143,470
3,220
406,381
197,711
131,345
83,109
72,557
6,150
2,718
4,357
1,341
32,604
33,152
32,448
23,404
3,475
7,496
7,530 '
8,078
5,953
1,421
x
-91%
-68%
-99%
-82%
-100%
-89%
-81%
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Table I
Acme Metals Incorporated (1)
Releases and Transfers of TRI Chemicals, 1988-1992
Chemical
33/50 ProEram Chemicals
Non 33/50 Program Chemicals
All TRI Chemicals
Percent Change, 1988-1992
33/50 Program Chemicals
Non 33/50 Program chemicals
All TRI Chemicals
Year
1988
1989
1990
1991
1992
1988
1989
1990
1991
1992
1988
1989
1990
1991
1992
Surface
Total Air Water
Emissions Discharges
(pounds) (pounds)
498,691
503,263
494,273
293,060
26,590
1,891,256
1,893,126
1,647,138
1 ,057,425
175,500
2,389,947
2,396,389
2,141,411
1 ,350,485
202,090
-95%
-91%
-92%
3,388
3,701
85
265
515
14,200
30,856
14,279
15,759
8,546
17,588
34,557
14,364
16,024
9,061
-85%
40%
-48%
Transfers Percent
Off-site Change
Transfers for Treatment/ Total Releases 1988-1992
to POTW Disposal/Other and Transfers Total Releases
(pounds) (pounds) (pounds) (2) and Transfers
17,480
17,829
5,624
5,050
4,765
130,772
157,518
243,958
256,295
162,387
148,252
175,347
249,582
261,345
167,152
-73%
24%
13%
415,266
194,490
138,719
82,960
69,889
1,427,583
759,389
381,092
508,200
517,884
1,842,849
953,879
519,811
591,160
587,773
-83%
-64%
-68%
934,825
719,283
638,701
381,335
101,759 -89%
3,463,811
2,840,889
2,286,462
1,837,679
864,317 -75%
4,398,636
3,560,172
2,925,163
2,219,014
966,076 -78%
-89%
-75%
-78%
(1) Includes only facilities participating in the 33/50 Program.
(2) Total Releases and Transfers for 1991 and 1992 do not include on- or off-site recycling or energy recovery.
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Table II
Acme Metals Incorporated (Selected Facilities)
Releases and Transfers of TRI Chemicals, 1988-1992
Chemical Year
Chicago Coke - Torrence Ave., Chicago, IL
Benzene 1988
1989
1990
1991
1992
Cyanide compounds 1988
1989
1990
1991
1992
Toluene 1988
1989
1990
1991
1992
Xylene (mixed isomers) 1988
1989
1990
1991
1992
33/50 Program Chemicals 1988
1989
1990
1991
1992
Total Air
Emissions
(pounds)
175,926
177,444
171,613
118,300
14,900
277,229
277,722
277,199
140,420
570
31,606
32,154
32,329
23,300
3,350
7,404
7,438
8,010
5,890
1,390
492,165
494,758
489,151
287,910
20,210
Surface
Water
Discharges
(pounds)
0
0
0
5
5
288
51
85
250
250
0
0
0
5
5
0
0
0
5
5
288
51
85
265
265
Transfers
Off-site
Transfers for Treatment/ Total Releases
to POTW Disposal/Other and Transfers
(pounds) (pounds) (pounds) (1)
13,047
13,047
1,862
1,600
1,800
1,804
2,564
2,768
2,800
2,400
998
998
119
99
120
92
92
68
58
26
15,941
16,701
4,817
4,557
4,346
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
188,973
190,491
173,475
1 19,905
16,705
279,321
280,337
280,052
143,470
3,220
32,604
33,152
32,448
23,404
3,475
7,496
7,530
8,078
5,953
1,421
508,394
511,510
494,053
292,732
24,821
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Table II
Acme Metals Incorporated (Selected Facilities)
Releases and Transfers of TRI Chemicals, 1988-1992
Chemical Year
Non 33/50 Program Chemicals 1988
1989
1990
1991
1992
All TRI Chemicals 1988
1989
1990
1991
1992
Riverdale (Steel & Packaging) - Perry Ave. , Chicago,
Chromium compounds 1988
1989
1990
1991
1992
Lead compounds 1988
1989
1990
1991
1992
Nickel compounds 1988
1989
1990
1991
Total Air
Emissions
(pounds)
1,503,368
1,521,147
1,614,376
1,035,435
145,928
1,995,533
2,015,905
2,103,527
1,323,345
166,138
IL(2)
500
82
137
77
500
4,195
2,705
1,153
1,307
1,755
500
9
22
15
Surface
Water
Discharges
(pounds)
0
127
3,674
1,020
770
288
178
3,759
1,285
1,035
0
0
0
0
0
3,100
3,650
0
0
0
0
0
0
0
, Transfers
Off-site
Transfers for Treatment/ Total Releases
to POTW Disposal/Other and Transfers
(pounds) (pounds) (pounds) (1)
123,810
147,380
238,521
251,700
158,915
139,751
164,081
243,338
256,257
163,261
250
89
72
109
133
750
523
282
152
266
250
286
239
146
0
0
0
0
0
0
0
0
0
0
12,900
7,070
8,621
3,860
3,748
326,900
24,751
16,164
32,520
32,541
5,150
2,249
3,934
1,180
1,627,178
1,668,654
1,856,571
1,288,155
305,613
2,135,572
2,180,164
2,350,624
1,580,887
330,434
13,650
7,241
8,830
4,046
4,381
334,945
31,629
17,599
33,979
34,562
5,900
2,544
4,195
1,341
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Table II
Acme Metals Incorporated (Selected Facilities)
Releases and Transfers of TR1 Chemicals, 1988-1992
Chemical Year
33/50 Program Chemicals 1988
1989
1990
1991
1992
Non 33/50 Program Chemicals 1988
1989
1990
1991
1992
All TRI Chemicals 1988
1989
1990
1991
1992
Total Air
Emissions
(pounds)
5,195
2,796
1,312
1,399
2,255
387,388
371,546
31,046
20,800
28,316
392,583
374,342
32,358
22,199
30,571
Surface
Water
Discharges
(pounds)
3,100
3,650
0
0\
0.'
14,200
30,729
10,605
14,469
7,526
17,300
34,379
10,605
14,469
7,526
Transfers
toPOTW
(pounds)
1,250
898
593
407
399
4,228
6,234
4,727
4,055
3,042
5,478
7,132
5,320
4,462
3,441
Transfers
Off-site
for Treatment/
Disposal/Other
(pounds)
344,950
34,070
28,719
37,560
36,289
1 ,427,583
759,389
381,092
508,200
517,884
1 ,772,533
793,459
409,811
545,760
554,173
Total Releases
and Transfers
(pounds) (1)
354,495
41,414
30,624
39,366
38,943
1,833,399
1,167,898
427,470
547,524
556,768
2,187,894
1,209,312
458,094
586,890
595,711
(1) Total Releases and Transfers for 1991 and 1992 do not include on- or off-site recycling or energy recovery.
(2) In 1992, the Riverdale Packaging facility began reporting to TRI as a separate facility from the Riverdale
Steel facility. The two facilities are reported as one on this table.
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