EPA-600/2-77-023X February 1977 Environmental Protection Technology Series Research Trt3rtafe:P3rJ<. North ------- RESEARCH REPORTING SERIES Research reports of the Office of Research and Development, U.S. Environmental Protection Agency, have been grouped into five series. These five broad categories were established to facilitate further development and application of environmental technology. Elimination of traditional grouping was consciously planned to foster technology transfer and a maximum interface in related fields. The five series are: 1. Environmental Health Effects Research 2. Environmental Protection Technology 3. Ecological Research 4. Environmental Monitoring 5. Socioeconomic Environmental Studies This report has been assigned to the ENVIRONMENTAL PROTECTION TECHNOLOGY series. This series describes research performed to develop and demonstrate instrumentation, equipment, and methodology to repair or prevent environmentaf degradation from point and non-point sources of pollution. This work provides the new or improved technology required for the control and treatment of pollution sources to meet environmental quality standards. EPA REVIEW NOTICE This report has been re viewed by the U.S. Environmental Protection Agency, and approved for publication. Approval does not signify that the contents necessarily reflect the' views and policy of the Agency, nor does mention of trade names or commercial products constitute endorsement or recommendation for use. This document is available to the public through the National Technical Informa- tion Service, Springfield, Virginia 22161. ------- EPA-600/2-77-023x February 1977 INDUSTRIAL PROCESS PROFILES FOR ENVIRONMENTAL USE: CHAPTER 24. THE IRON AND STEEL INDUSTRY by V.S. Katari andR.W. Gerstle (PEDCo.) Terry Parsons, Editor Radian Corporation P. O. Box 9948 Austin, Texas 78766 Contract No. 68-02-1319, Task 34 ROAPNo. 21AFH-025 Program Element No. 1AB015 EPA Project Officer: I.A. Jefcoat Industrial Environmental Research Laboratory Office of Energy, Minerals, and Industry Research Triangle Park, NC 27711 Prepared for U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Research and Development Washington, DC 20460 ------- TABLE OF CONTENTS Page INDUSTRY DESCRIPTION 1 Raw Materi al s 5 Products 7 Companies 8 Environmental Impact 8 Bibliography , 11 INDUSTRY ANALYSIS 13 Ore Preparation 14 Process No. 1 Mining 16 Process No. 2 Preliminary Ore Preparation 20 Process No. 3 Ore Concentration 22 Process No. 4 Sintering 28 Process No. 5 Pelletizing 32 Process No. 6 Nodulizing 35 Process No. 7 Briquetting 37 Coke Production 38 Process No. 8 Coal Mining and Transportation 40 Process No. 9 Coal Preparation 43 Process No. 10 Charging of Coke Ovens 46 Process No. 11 Coking 49 Process No- 12 Pushing and Quenching 53 Process No. 13 Coke Handling 57 Coke By-Products Recovery 58 Process No. 14 Primary Cool ing/Reheating 60 Process No. 15 Tar Decanting 62 Process No. 16 Phenol Recovery 64 Process No. 17 Ammonia Still 66 Process No. 18 Ammonia Absorption 71 ------- TABLE OF CONTENTS (Continued) Page Process No. 19 Crystallization and Filter Drying 73 Process No. 20 Light Oil Recovery 74 Process No. 21 Fractionation and Refining of Light Oil 76 Pig Iron Production 78 Process No. 22 Blast Furnace 80 Steel Production 89 Process No. 23 Electric Furnace 91 Process No. 24 Open-Hearth Furnace 98 Process No. 25 Basic Oxygen Furnace 104 Process No. 26 Vacuum Degassing 109 Process No. 27 Continuous Casting or Ingot Castings Ill Process No. 28 Polling and Shaping 112 Process No. 29 Acid Treatment (Pickling) 116 Process No. 30 Finishing 118 APPENDIX A - Raw Materials 121 APPENDIX B - Industry Products 127 APPENDIX C - Companies 139 APPENDIX D - Energy and Utility Requirements 179 APPENDIX E - Emission Data 183 APPENDIX F - Types and Numbers of Steel Furnaces 195 REFERENCES FOR APPENDICES 199 IV ------- LIST OF FIGURES Fi gure Page 1 IRON ORE PRODUCTION 15 2 COKE PRODUCTION 39 3 COKE BY-PRODUCTS RECOVERY 59 4 PIG IRON PRODUCTION 79 5 STEEL PRODUCTION 90 ------- LIST OF TABLES TABLE Page 1 COMPANIES ENGAGED IN IRON AND STEEL OPERATIONS, 1970 2 2 NUMBER OF COKE PLANTS ENGAGED IN RECOVERING BY- PRODUCTS IN 1974 4 3 IRON ORE ANALYSIS 6 4 ANALYSIS OF TACONITE ORES 6 5 SUMMARY OF SEVEN LARGEST STEEL COMPANIES 9 6 CONSTITUENTS OF IRON MINE LIQUID DISCHARGES 18 7 CHEMICAL CHARACTERISTICS OF SETTLING-POND DISCHARGE AT ONE MINE 19 8 REAGENTS USED FOR FLOTATION OF IRON ORES 23 9 TYPICAL ANALYSIS OF TAILINGS 25 10 TYPICAL PARTICLE SIZE ANALYSIS OF TACONITE TAILINGS 26 11 CONSTITUENTS OF THE STRAND BURDEN FOR A TYPICAL SUPERFLUXED SINTER 29 12 PARTICLE SIZE ANALYSIS OF PARTICULATE EMISSIONS FROM A SINTERING MACHINE 29 13 ENERGY CONSUMPTION FOR PROCESSES AT A 2 MILLION TPY MAGNETIC TACONITE PLANT 33 14 PARTICLE SIZE DISTRIBUTION 33 15 HOURLY INPUT AND OUTPUT RATES FROM NODULIZING KILN AT EXTACA 35 16 TYPICAL NODULIZING PROCESS OPERATING TEMPERATURES 36 17 NODULIZING ENERGY REQUIREMENTS, PER KILOGRAM OF NODULES 35 18 CHEMICAL ANALYSES OF WATER AT DIFFERENT MINE SITES 42 ------- LIST OF TABLES (Continued) TABLE Page 19 ANALYSIS OF A TYPICAL COKE OVEN CHARGE, DRY BASIS 43 20 TIME-WEIGHTEN AVERAGE CONCENTRATIONS OF GASES INSIDE THE LARRY CAR 47 21 TYPICAL YIELDS FROM ONE TON OF COKING COAL 50 22 EMISSION FACTORS FOR COKING AND COKE OVEN PUSHING 52 23 PARTICLE SIZE DISTRIBUTION FOR COKE OVEN EMISSION SAMPLE DURING TYPICAL PUSH AT MAJOR NORTHWEST INDIANA STEEL CO. 54 24 SCREEN ANALYSIS OF QUENCH-TOWER PARTICULATES 55 25 AVERAGE ANALYSIS OF QUENCH WATER SAMPLES 55 26 ANALYSES OF WEAK AMMONIA LIQUOR FROM THREE PLANTS 67 27 ANALYSES OF WASTE LIQUOR FROM AMMONIA STILLS 69 28 EXAMPLE OF BLAST FURNACE MATERIAL BALANCE 81 29 UTILITIES REQUIREMENTS OF A SELF-CONTAINED BLAST- FURNACE PLANT WITH TWO FURNACES, PRODUCING A TOTAL OF 3810 NET TONS OF HOT METAL PER DAY 83 30 CHEMICAL COMPOSITION OF DRY, BLAST-FURNACE FLUE DUST 84 31 SIZE ANALYSIS OF FLUE DUST FROM U.S. BLAST FURNACES 85 32 ANALYSIS OF FURNACE GAS .. 85 33 POLLUTANTS IN WASTEWATER FROM BLAST FURNACE 87 34 PRODUCTION DATA FOR A PARTICULAR ELECTRIC FURNACE SHOP 93 35 OPERATING DATA FOR A PARTICULAR ELECTRIC FURNACE SHOP .... 93 36 CHEMICAL COMPOSITION OF ELECTRIC FURNACE DUSTS 94 Vll ------- LIST OF TABLES (Continued) TABLE Page 37 CHANGES IN COMPOSITION OF ELECTRIC FURNACE DUST DURING A SINGLE HEAT ........ ............. ..... ...... .. 95 38 PARTICLE SIZE DISTRIBUTION OF EMISSIONS FROM A PARTICULAR ELECTRIC-ARC FURNACE ....................... 95 39 HEAT BALANCE OF A MODERN OP EN- HEARTH FURNACE kcal/ton OF STEEL ....... _______ ..... . .......... .......... 99 40 PARTICIPATE EMISSION' - UNCONTROLLED ... .............. .... TOO 41 PARTICLE SIZE DISTRIBUTION OF EMISSIONS FROM QPEI-BEARTH FURNACES ....... ....... ........ ............. 101 42 CHEMICAL COMPOSITION OF OPEN-HEARTH PARTICIPATE EMISSIONS, OXYGEN LANCING .... ......................... 102 43 CHEMICAL COMPOSITION OF BASIC OXYGEN FURNACE STEEL- MAKING DUST rROM THREE U.S. PLANTS, WEIGHT PERCENT .... T06 44 PARTICLE SIZE DISTRIBUTION OF RED DUST FROM BASIC OXYGEN FURNACES ....................................... 107 45 CALCULATED GAS COMPOSITION FOR 91-TON BOF BLOWN AT 6000 LITERS/SEC. 02 RATE FOR 20 MINUTES ............... 1Q7 46 DUST AND METAL ANALYSES FOR VACUUM-TREATED STEELS ....... HO 47 POWER CONSUMTPION IN ROLLING OR SHAPING MILLS ........... 113 48 QUANTITIES OF SOLID AND WATER WASTE FROM TYPICAL ROLLING MILL ........... . .............................. 114 A-l IRON ORE MINED IN THE UNITED STATES ............ , ........ 1 22 A-2 CONSUMPTION OF MATERIALS OTHER THAN IRON ORE IN IRON AND STEEL INDUSTRY - 1973 ....... . ................ 123 A-3 ORIGIN OF COAL RECIEVED BY COKE-OVEN PLANTS IN THE UNITED STATES IN 1974 BY PRODUCING STATE AND VOLATILE CONTENT . ............................................. 124 A-4 ANALYSIS OF LIMESTONE FROM COLUMBUS, OHIO B-l AVERAGE GRADE OF SINTER PRODUCED IN 1968 NORTHEASTERN IRON ORES (DRY BASIS) k .................. ............. 1 28 viil ------- LIST OF TABLES (Continued) TABLE Page B-2 TYPICAL TACONITE CONCENTRATE PRODUCT ANALYSIS 12g B-3 COMPOSITIONS OF PELLETS PRODUCED IN 1968 (DRY BASIS) 130 B-4 CHEMICAL ANALYSIS OF NODULIZED PRODUCT, AVERAGE 131 B-5 SUMMARY OF THE COKE INDUSTRY IN THE UNITED STATES IN 1974 132 B-6 TYPICAL SIZES OF COKE 133 B-7 TYPICAL PROPERTIES OF COKE 134 B-8 YIELDS AND ANALYSES OF PRODUCTS OF CARBONIZATION PROCESS 135 B-9 COMPOSITION OF HIGH-TEMPERATURE COKE-OVEN TAR 136 B-10 ANALYSIS OF CRUDE AMMONIA LIQUOR 1 37 C-l IRON AND STEEL PRODUCING FACILITIES 140 C-2 DIRECT REDUCTION PLANTS IN OPERATION AND ON ORDER AS OF DECEMBER 1974 163 C-3 U.S. IRON ORE PRODUCERS, SALIENT DATA 164 C-4 MINE AND PLANT EXPANSIONS - IRON AND STEEL INDUSTRY IN USA - 1975 169 C-5 MAJOR CAPTIVE STEEL COAL MINES 170 C-6 COKE-OVEN PLANTS IN THE UNTIED STATES ON DECEMBER 31,1973. 172 C-7 SUMMARY OF COKE-OVEN OPERATIONS IN THE UNITED STATES IN 1974 BY STATES 178 D-l ENERGY CONSUMPTION IN THE STEEL INDUSTRY - 1972 180 D-2 WATER REQUIREMENTS OF THE IRON AND STEEL INDUSTRY - 1964.. 181 E-l QUANTITIES OF POLLUTANTS DISCHARGED FROM IRON AND STEEL INDUSTRY BEFORE TREATMENT IN 1971 184 E-2 SUMMARY OF WASTE STREAMS (NON-RADIOACTIVE) RELEASED FROM IRON AND INDUSTRY 185 IX ------- LIST OF TABLES (Continued) TABLE E-3 METAL ANALYSIS OF EMISSION TESTS (CONDUCTED IN 1973) ON VARIOUS PROCESSES AT A MAJOR NORTHWEST STEEL PLANT ..186 E-4 ANALYSIS OF WASTEWATER DISCHARGE FROM IRON ORE MINING AND CONCENTRATION OPERATIONS AT ONE MILL 187 E-5 SOURCES OF MILL WASTEWATER AT RESERVE MINING 187 E-6 POTENTIALLY HAZARDOUS EMISSIONS FROM COKE PLANTS 188 E-7 CHEMICALS POTENTIALLY PRESENT IN EMISSIONS FROM COKE QUENCHING AND DIRECT COOLING OPERATION 191 F-l ELECTRIC DIRECT-ARC STEELMAKING FURNACES IN THE UNITED STATES, AS OF JANUARY 1, 1970 196 F-2 BASIC OPEN-HEARTH FURNACES IN THE UNITED STATES 197 F-3 BASIC OXYGEN I-ROCESS STEELMAKING FURNACES IN THE UNITED STATES, CLASSIFIED INTO CAPACITY RANGES 198 ------- IRON AND STEEL INDUSTRY INDUSTRY DESCRIPTION The Iron and Stae= Industry encompasses a variety of processes for transformation of iron ore into fabricated iro~ and steel products. In addition to the manufacture of steel products, rest large steel mi Vis operate by-product co:Ct? plants producing metallurgical coke and coke by- products. The industry is divided into five segments: 1) ore prepara- tion, 2) coke production, 3) coke by-products' recovery, 4) pig iron pro- duction, 5) steel manufacturing. The processes involved in ore preparation are iron ore beneflcia- tion including minings upgrading and concentration operations; and agglom- eration or preparation of the ore for charging into £ blast furnace. In the coking seoi-ient, mined metallurgical coal is prepared for charging into coke ovens, coked (nondestructive distillation) and quenched. Coke-oven gas, a by-product from coking, is treated for by- product recovery and also used as a fuel. Crude tar, ammonia, light oil, phenol and other by-products of coking are further processed, depending on plant design and on markets for specific products. Pig iron production involves production of pig iron from iron ore, coke and limestone in a blast furnace. The steel manufacturing segment primarily involves production of steel from pig iron and scrap in electric, open-hearth or basic oxygen furnaces and finishing operations in which raw steel is shaped, rolled drawn, coated or otherwise treated to produce sheets, strips, plates, pipe, wire or other forms of steel products. Many steel plants generally do not incorporate all combinations and variations of the operations described in this document. The indus- try encompasses a variety of plants ranging from small to very large and ------- from older marginally operating facilities built early in the century to ' * -> ''-' ^ : ' ' *« A more efficient modern facilities built or upgraded in recent years. Table T shows the numbers of companies involved in various phasesi of the inte- grated iron and steel industry. Table T. COMPANIES ENGAGED IN IRON AND STEEL OPERATIONS, 1970 Operation Operate steel facilities Pig iron (for sale and for in-plant use) Coke Raw steel Carbon quality steel Alloy steel Stainless steel Steel bars Wire products Plates Pipe and tubing Cold rolled sheets Tool steel Number of companies 200 30 48 95 78 54 28 50 50 26 60 25 15 In 1973, the iron and steel industry employed 672,695 workers, of whom 511,220 were hourly wage employees and the remaining were salaried.2 In 1974, iron ore mining and preparation units employed 19,804 people of which 2,460 were in underground mines, 8,202 in surface mines and 9,142 in preparation.mills.* * Information provided by L.P. Larson, Health and Safety Analysis Center. Mining and Safety Administration. United "States Department of ; Interior, Washington, D.C. July 22, 1974." ------- Total U.S. iron ore requirements in 1973 for blast furnace feed and other minor uses were 139.24 million tons.* Of this amount, 92.24 million tons* were produced domestically and 47 million tons* were im- ported. Canada supplied approximately 22.68 million tons,* Venezuela more than 11.79 million tons,* Brazil 2.9 million, Liberia 2.45 million, Peru 1.35 million, Austria 453.6 thousand, Sweden 305 thousand and Chile 272.15 thousand tons,* Consumption of Iron ors increased to 147 million tons* in 1974, and blast furnace pig iron output was 97.44 million tons.* In the same year, steel production totalled 132 million tons.* Production in open-hearth -"urnaces was 36.1 million tons,* in basic oxygen furnaces 82.91 million tons,* and in electric furnaces 28.86 million tons.*3 There were 48 coke plants at integrated iron and steel facilities in 1974. Total coke production in that year was 55.87 million tons,* of which 51.2 4 million tons* were used in blast furnaces. Table 2 shows the number of coke plants recovering various by-products. Major portions of iron ore come from the Lake Superior region. Other areas of iron ore production are California, Utah, Wyoming, Texas, Missouri, Alabama, Pennsylvania, and New York. Combined output of these 3 areas makes the U.S. the world's third largest producer of iron ore. Most of the major steel companies own or control domestic mines that supply at least part of their ore needs. These companies also have invested substantially in iron mines in Canada» Venezuela, Chile, Brazil, Liberia, and Australia. The major companies producing iron ore in Canada are owned or controlled principally by U.S. interests. It is estimated that captive mines furnish about 85, percent of the ore used by the domestic iron and steel industry. Trends in iron ore mining are significant. Taconite pellets are replacing iron ores, huge open-pit mines are replacing underground mines and mining is changing from a seasonal to a year-round basis. Changes in steel manufacturing operations are equally significant. Oxygen furnaces, and to a lesser degree electric furnaces, are rapidly replacing open * Metric tons (1000 kg or 2205 pounds) are used throughout this report. ------- Table 2. NUMBER OF COKE PLANTS ENGAGED IN RECOVERING BY-PRODUCTS IN 1974. By-product recovered Ammonium sulfate Ammonia liquor (NH, content) Diammonium phosphate Crude coal tar Creosote oil,, straight distillate Crude chemical oil (tar acid oil) Sodium phenol ate (carbolate) Phenol Cresol s Cresylic acid Pitch Crude light oil Benezene, all grades Toluene, alT grades Xylene, all grades Solvent naphtha, all grad.es Intermediate light oil; Naphthalene Pi co lines Sulfur Number of plants Furnace9 41 2 1 48 5 3 15 2 1 1 6 45. 18 1,3 13 10 10 15 1 1 Merchant0 2 4 14 - 4 1 - - - - 6 1 1 1 1 1 - - - Total 43- 6 1 62 5 7 16 2 1 1 6 51 19 14 14- 11 11 15 1 1 Owned by iron and steel companies and produce blast furnace coke for their own use. Associated with chemical companies or gas utilities, or operate to produce coke and coal chemical materials for sale to steel companies or foundries ------- hearths; continuous casting eliminates some of the conventional steel mill operations such as ingots, soaking pits, and slabbing, blooming, or billet mills. In addition, mills are producing all grades of steel with fewer men. In the U.S., r :sc steel plants are located in areas of fairly dense population. More t'-^r, 200 companies that make iron and primary steel mill products operate In 37 states. About 65 to 70 percent of the Na'ron's steel industry is situated ir, vie great industrial complex surrounding the lower Great Lakes ports in Illinois, Indiana, Michigan, Ohio, and western P^rr.&ylvam'a. Larg-; "rstegrated steel mills are also operated in norther. N^w York, eastern Pennsylvania, eastern Mary- land, and the Birmirgnai'n district of Au-bama; relatively small integrated steel mills are operated in southern Illinois, Texas, Colorado, Utah, and California. In 1980, the U.S. ,:;ust produce 175 million tons* of raw steel if ecor;ofiiic growth is to be maintained. Consumption of iron ore will Increase substantially ;o provide for rO million tons* more of blast furnace output as well c.s the amounts needed (possibly as much as 5 million tons*} for d-'ract reduction. 3y the year 2000, the demand for iron ore in the l.i. is projected t,:- rise to 215 million tons* and )tc ,8 domestic production of ore to 127 millici tons.* The projected total coke consumption in 19SO is estimated t& oe about 70 million tons.* Raw Materials Iron ore, the ma4:; raw material of th.-s industry, is a mixture having varying Cjuantitn-s of mineral impurities. Contaminants that can be present in iron ore include phosphorous, sulfur, titanium, vanadium, zinc, copper, chromium, nickel, arsenic, lead, tin, and cobalt. Tables 910 3 and 4 give typical analyses of different iron ores. Details of the major types of ores, and their characteristics and data on the con- sumption of other raw materials used are given in Tables A-l and A-2, Appendix A. At coke producing plants, low-sulfur coal is the main raw * Metric tons (1000 kg) 5 ------- Table 3. IRON ORE ANALYSIS Kind of ore Range Mesabi Menominee Labrador Name Hanna Weirton (Michigan) Composition, percent Fe 53.29 to 54.96 51.5 to 54.90 48.58 to 55.51 Si02 8.04 to 10.01 3.02 to 4.23 3.84 to 6.84 A1203 0.43 to 0.57 2.17 to 2.61 0.73 to 1.08 CaO 0.15 0.65 0.02 to 0.15 MgO 0.10 0.90 0.02 to 0.05 P 0.041 to 0.047 0.464 to 0.542 0.054 to 0.117 Mn 0.39 to 0.60 0.17 to 0.33 0.56 to 4.50 Table 4. ANALYSIS OF TACONITE ORES Component Total Iron Magnetic Iron Silicon Dioxide Manganese Aluminum Oxide Calcium Oxide Magnesium Oxide Phosphorus Sulfur Titanium Dioxide Avg. percent by weight 32.0 24.5 45.2 0.3 0,8 2.3 3.0 0.05 0.02 Trace ------- material. Details of coke production for use in coke ovens is given in Table A-3. In addition to the ore materials, iron production requires fluxes such as silica, limestone or dolmite. Various ferroalloys (as alloying agents) and all types of metal scrap are used in steelmaking. The pro- cesses require large amounts of fuel, mainly coke and oxygen. Statistics on energy and water consumption in the steel industry are given in Tables D-l and 0-2. Appendix D. A number of metallic elements and compounds may be added to molten iron or steel to effect specific properties in the end products or to coat finished products. Additives are used to remove gases, decrease inclusions, counteract harmful effects of sulfur, or change the char- acteristics of the metal. The more common additives are aluminum, chromium, cobalt, columbium, copper, lead, magnesium, manganese, molyb- denum, nickel, carbon, phosphorus, boron, silicon,tin, titanium, tungsten, and vanadium. Products The iron and steel industry produces coke; various chemicals recovered from the by-product coking process; pig iron; and various grades of basic steel in such shapes as ingots, blooms, billets, plates, structurals, bars, wire, coils, sheet, tubing, tinplate, galvanized, and other. Pig iron is the product of the blast furnace formed by smelting iron ore with a carbonaceous reducing agent, usually coke. About 90 per- cent of the pig iron produced in the United States is consumed in making steel; the remainder is used for iron castings. Steel is a refined iron-base alloy containing up to 1.7 percent carbon. Some principal types of steels are: 1) carbon, 2) manganese, 3) nickel, 4) nickel-chromium, 5) molybdenum, 6) chromium-molybdenum, 7) nickel-chromium-molybdenum, 8) nickel-molybdenum, 9) chromium, 10) chromium vanadium, 11) tungsten chromium, 12) silicon manganese, 13) low alloy high tensile, 14) stainless, 15) boron intensified, 16) leaded. Hundreds of different grades of steel are manufactured. ------- Small amounts ot gold, silver, sulfur, copper, cobalt, and phos- phate minerals are recovered occasionally as by-products and coproducts during iron mining operations at a few domestic deposits. Manganese is often a coproduct. Blast furnace slags are used principally in the construction and maintenance of roads, buildings, railroads, and airports; in manufacture of mineral wool; and to some extent in agriculture. Steel slags either alone or in blends with blast furnace slags, are used similarly. The integrated iron and steel industries produce coke and recover by-products such as ammonia, tars, light oils, phenols, and benzene. Companies In 1974 there were more than 86 integrated iron and steel companies in the U.S. and more than 200 operating entities. The seven largest com- panies are listed in Table 5. Table C-l lists all companies in the U.S. that produce iron and steel. These companies operated 164 blast furnaces and four direct reduction ore plants (Table C-2). The 45 ore producing companies as listed in Table C-3 are closely associated with the steel companies. The largest mining areas are in Minnesota, with three companies, U.S. Steel's Minntac Plant, Republic and Armco's Reserve Mining Co., and Erie Mining Co. (controlled by 5 com- panies), producing approximately 40 percent of the ore. Table C-4 lists the recent iron mine and plant expansions in the United States. A list of the captive steel coal mines in the United States supplying basically coal for coking purposes is given in Table C-5. Most coke plants were also operated by steel companies at 63 loca- tions. Operations 1n Ohio and Pennsylvania account for 25, of these plants, as shown in Tables C-6 and C-7, Appendix C. Environmental Impact Wastes from the various operations in steelmaking vary widely in characteristics and in volume. The main environmental concerns at iron and steel plants pertain to air and water. An estimated 14.4 million tons* of atmospheric particulate and 11.3 tons* of water-borne suspended * Metric tons (1000 kg) 8 ------- Table 5. SUMMARY OF SEVEN LARGEST STEEL COMPANIES Company and headquarters United States Steel Corp. Pittsburgh, Pa. Bethlehem Steel Corp. Bethlehem, Pa. Republic Corp. Cleveland, Ohio National Steel Corp. Pittsburgh, Pa. Armco Steel Corp. Middletown, Ohio Jones & Laugh! in Steel Corp., Pittsburgh, Pa. Inland Steel Co. Chicago, 111. Totals Number of steel mills 15 8 9 3 8 3 1 47 Tons of steel produced in 1971a 27,200,000 17,400,000 8,700,000 8,600,000 7,900,000 6,600,000 6,400,000 82,800,000 % of U.S. steel production 1971 22.5 14.4 7.2 7.1 6.5 5.4 5.3 68.4 Metric tons (1000 kg). ------- 12 solids were discharged from steel mills in 1971. In addition to parti culates, fluorides, carbon monoxide, hydrocarbons, and sulfur oxides are emitted to a lesser extent by the various steelmaking pro- cesses. The uncontrolled emissions of selected pollutants discharged from the iron and steel industry in 1971 and the amounts discharged from the industry by region are given in Tables E-l and E-2, Appendix E. Coal mining for coke production, and iron ore mining and beneficia- tion produce large quantities of tailings and potential water pollution problems. These problems can vary from acid mine drainage to asbestos- like fibers in ore tailings. The principal air pollution problems resulting from coke production are sulfur dioxide from combustion of the coal in the coke ovens, partic- ulate and gaseous emissions from ovens during charging and pushing, leak- age from doors and lids; and emissions from quenching of the coke with waste water. Carcinogenic hydrocarbons in coke oven smoke have been reported. Principal water pollution problems in coke plant operation are in the wastes from ammonia stills and light oil decanters, which average about 185 liters per ton of coal carbonized and contain phenol, ammonia, cyanides, chlorides, and sulfur compounds. The coal tar storage area is also a major source of hazardous emissions in a coke plant. Many control measures are practiced to curb emissions from coke plants. Since the coke breeze from the various operations is either used within the plant or sold, coke production does not constitute a solid waste problem. The iron and steel industry, one of the largest users of water in America, requires 110,000 to 150,000 liters of water to produce a ton* of steel. These immense volumes of water accumulate many tons of contami- nants including metallic particles, dirt, oil, and grease. The use of water for cooling causes significant thermal pollution problems. Typical coke plants produce about 13 liters of wastewater per ton of . . 15 coal processed. According to recent tests on process stream and stack sampling conducted at a major northwest Indiana steel company, the steel industry Metric ton (1000 kg) 10 ------- is among the leading contributors to the cadmium burden in the environ- ment. The other metal!ics released include lead and zinc. Potential mechanisms for the release of cadmium, lead, and zinc-bearing dust in steelmaking are associated with six major processes: agglomeration plant, blast furnace, open-hearth furnace, basic oxygen furnace (BOF), and elec- tric furnace. Release of these metals is mainly attributed to No. 2 scrap steel (containing galvanized and plated metal) melted in the open hearth, BOF, and electric furnaces; and existence of these metals in trace quanti- ties in the iron ore, limestone and coal used in these processes. Table E-3, Appendix E gives the average cadmium, lead and zinc contents of the emissions from different processes of iron and steel industry. Bibliography 1. Raw Material for the Industry. In: Charting Steel's Progress During 1970, American Iron and Steel Institute, July 1971. p. 3841. 2. American Iron and Steel Institute. Annual Statistical Report. 1973. 3. Hogan, S.J., Iron and Steel-U.S. Output off Slightly in 1974 from Record Highs of '73. Engineering and Mining Journal, 176:207-213, March 1975. 4. Coke and Coal Chemicals in 1974 (Preliminary release of information pending publication of the Bureau of Mines Mineral Yearbook), Mineral Industry Surveys, U.S. Department of Inter- ior, Bureau of Mines. Washington, D.C. November 11, 1975. 5. Coke Producers in the United States in 1974. U.S. Department of Interior, Bureau of Mines, Washington, D.C. November 6, 1975. 6. Reno, H.T., and F.E. Brantley. Iron In: Mineral Facts and Problems, Bureau of Mines, Washington, D.C., U.S. Government Printing Office, 1970. Page 301. 7. The Editors of EMJ. North American Iron Ore: Launching of Rescue Mission for a Steel Short Economy. Engineering and Mining Journal. 83-85, November 1974. 8. Perch, M., and R.E. Muder. Coal Carbonization and Recovery of Coal Chemicals. In: Riegel's Handbook of Industrial Chemistry. Seventh Edition, New York, Van Nostrand Reinhold Company, 1974. p. 193-206. 11 ------- 9, Labee, C.J. Steel Making at Weirton. Iron and Steel Engineer- W1-W60, October 1969. 10, Lee, 0. Taconite Beneficiation Comes of Age at Reserve's Babbitt Plant. Mining Engineering. 484-488, May 1954. 11. Cannon, J.S., et al. Environmental Steel. Pollution in the Iron and Steel Industry. The Council on Economic Priorities, 1973. 12. Ralph Stone and Company, Inc. The Effects of Air and Water Pollution Controls on Solid Waste Generation, 1971-1985. Executive Summary. Environmental Protection Agency, Cincinnati, Ohio, EPA-67Q/2-74-095. December 1974. 13. Bramer. H.C, Pollution Control in the Steel Industry. Environmental Science and Technology. 1004=1008, October 1971. 14. Cook, W.R,, and L,V. Rankin, Polymers Solve Waste Water Problems. I^on and Steel Engineer, 51:43-46. 15. Industrial Waste Profiles No. 1 * Blast Furnace and Steel Mills. Volume III. The Cost of Clean Water. Federal Water Pollution Control Administration, FWPCA Contract Number 14-12-98, September 28, 1967. 16 Yost, K.J., et al. Purdue University. The Environmental Flow of Cadmium and Trace Metals, Volume 1. National Sceince Foundation, Project Number PB-229478, June 30, 1973. 12 ------- INDUSTRY ANALYSIS The environmental Impact of all aspects of the iron and steel indus- try has received wide attention and has been the subject of many industry and governmental studies. Emission data, though variable, is available,* Information for this study was largely obtained from literature. Description of five industry segments are presented: ore prepara- tion, coke production, by-product recovery, pig iron production, and steelmaking. Each segment begins with a basic raw material and ends with a finished product. Products from one segment frequently become the raw material for another segment. * A special scientific group has been formed consisting of representa- tives of the American Iron and Steel Institute and U.S. EPA to clar- ify the emission data controversy. 13 ------- ORE PREPARATION Figure 1 illustrates the processes in ore preparation including agglomeration. The processes in the order of their discussion are: Ore Concentration 1. Mining 2. Preliminary ore preparation 3. Ore concentration Agglomeration 4. Sintering 5. Pelletizing 6. Moduli zing 7. Briquetting 14 ------- 1A 9 GASEOUS EMISSIONS -A LIQUID WASTE ^ SOLID WASTE FLOCCULATING AGENTS (WATER IRON ORE MINING "tl, ORE PREPARATION X ORE CONCENTRATION ^ 9 MISC. RETUI FLUX W CONCEN- \ TDflTCn 1 ORE / <^S ORE FINI COKE f COAL AIR ?N« F m i F INI :R INI ;s :s »p' i ^, ;s IN f N S IN 40 HOC :s FU )IT :L IVI :s CTUTCDIWC 4 PELLETIZIN6 5 NODULIZING 6 BRIQUETTINQ 7 9 9 9 Figure 1. Iron ore production. Note: Material handling and storage which is not shown on the flow sheet is required throughout pig iron production and has fugitive emissions, liquid waste and solid waste. ------- ORE PREPARATION PROCESS NO.J. Mining 1. Function r- Ore is mined by open-pit and underground methods, depend- ing upon the shape, depth, and attitude of the ore body being mined. Open-pit mining is used whenever possible since underground mining requires a larger investment per ton of capacity. Open-pit mining in colder cli- mates may be shut-down during severe winters, whereas underground mining can be maintained, if so desired, the year around. Ores are extracted by several methods utilizing the basic mining techniques of drilling and blasting, and heavy machinery to convey the loose ore into transfer systems. The mining of taconite poses some special problems because of its extreme hardness. Ore is transported from mines to mills by rail cars, trucks, truck-trialers, belt conveyors, ore boat carriers or com- binations of these car/'iers. In underground mining, ore is transported to the surface by rail trams, trackless shuttle cars, scrapers, or conveyor belts. 2. Input Materials - The formations of ore contained in hematite and magnetite consist largely of iron oxides, carbonates, and silicates. These ores contain approximately 25 to 30 percent iron. Iron content of taconite is much lower. In 1971, 2.45 tons* of crude ore was mined p per ton of usable product. Drilling and dynamite blasting are utilized. 3. Operating Parameters - Mining is done at ambient conditions. 4. Utilities - The basic utility needs are electricity, water and fuels for mobile equipment and drilling. 5. Waste streams - The mining wastes consist of vast quantities of overburden, rock, and low-grade ore which ore removed in the beneficiation mills and concentration of the mined ore. In the Mesabi Range area of Minnesota alone, mining waste dumps cover some 55 million square meters. Iron mines are responsible for little air pollution other than fugitive dust emissions. Transportation of ores also entails significant emissions of fugitive dust. It is estimated that as much as 2 percent of the ore * Metric tons (1000 kg) 16 ------- can be lost in transport in open cars unles dust-suppressing chemicals are added. In open-pit mining, water causes many problems; whenever possible, water is collected in sumps, pumped from the open-pit mine, and sometimes used as make-up water. Mine water may contain significant quantities of dissolved solids. The quantities and composition of water discharged vary from operation to operation. Table 6 gives the constIT 4 tuents of iron-mine discharges before and after treatment. Table 7 gives chemical characteristics of settling-pond discharge at one open-pit mine that accumulates water. Mine water contains varying concentrations of ammonia, nitrite and nitrate, if nitrogen-based blasting agents are used. 6. EPA Source Classification Code - None exists, 7. References - 1. Kirk-Othmer. Iron. In: Encyclopedia of Chemical Technology, Volume 12, New York, John Wiley and Sons, Inc., 1968. p. 1-21. 2. Klinger, F.L., and H.J. Polta. Iron ore. In: Minerals Year Book, Volume I, Bureau of Mines. Washington, D.C., U.S. Government Printing Office, 1973. 3. Berkowitz, J.B., et al. Industrial Solid Waste Classification Systems. Environmental Protection Agency, Cincinnati, Ohio Publication Number 670/2-75-024. January 1975. 4. Claspan Corporation. Development Document for Effluent Limitations Guidelines and Standards of Performance for Ore Mining and Dressing Industry. Point Source Category (Draft). Environmental Protection Agency. Contract No. 68-01-2682. April 1975. 17 ------- Table 6. CONSTITUENTS OF IRON MINE LIQUID DISCHARGES Parameter Total suspended solids Total dissolved solids Chemical oxygen demand PH Oil and grease Aluminum Calcium Chromium Copper Iron Lead Magnesium Mercury Nickel Sod i urn Manganese Zinc Chloride Cyanide Concentration, mq/£ Before treatment Min 1.000 140.0 0.200 5,00a 1.800 0.003 0.003 0.001 0.001 0.060 0.001 0 020 0.002 0.003 0.023 0.001 0.001 1.000 0.010 Max 5000.0 1880.0 36.0 8.40a 9.000 0.350 256.0 0.010 1.000 178.0 0.100 118.0 2.00 0.100 15.0 18.0 8.0 120.0 0.02 Avg 371.51 436.18 6.470 7.45a 4.511 0.066 85.39 0.007 0.167 13.3 0.018 39.35 1.001 0.024 7.511 2.462 1.869 27.143 0.013 No. of samples 19 17 10 18 9 7 3 9 12 14 9 3 2 6 2 14 9 14 4 After treatment Min 1.000 100.0 0.026 6.800a 0.400 0.007 0.002 0.010 0.005 0.008 0.008 0.008 0.010 0.001 0.010 0.900 0.005 Max 30.0 1090.0 42.0 8.500a 20.400 0.350 0.158 0.010 0.370 2.100 0.100 0.029 0.075 6.900 0.340 180.00 0.020 Avg 10.693 390.10 12.116 7.652a 4.313 0.131 0.045 0.010 0.120 0.446 0.023 0.017 0.023 1.720 0.185 33.225 0.011 No. of sampl e 27 20 20 21 16 9 4 6 10 11 8 3 5 11 5 20 4 a Value in pH units Note: Significant figures as reported in reference. ------- Table 7. CHEMICAL CHARACTERISTICS OF SETTLING-POND DISCHARGE AT ONE MINE Parameter pH TSSb TDSC CODd Oil and grease Total Iron Dissolved Ire Manganese Sulfate Average mine-discharge concentration, mq/1 7.9a 6 243 4.5 <5 - n <0.1 <0.1 - Average settling-pond discharge concentration, mq/1 8.0a 8.5 291 15 <5 - <0.1 <0.1 - a Value in pH units. Total suspended solids c Total dissolved solids Chemical Oxygen demand 19 ------- ORE PREPARATION PROCESS NO. 2 Preliminary Ore Preparation 1. Function -reorder to Increase the iron content, some of the mined ores are first screened, washed and crushed, then blended, The undersized material from the scalping screens having high moisture content are dried before shipment or, in some cases, sintered at the mine. Crushing frees most of the siliceous material from ore, screening removes coarse iron- poor rock, and blending produces a uniform product from iron ores of dif- ferent characteristics and compositions by methods known as stacking and reclaiming. The blended material is transported by a belt conveyor to a screening station and then shipped, if at the mine or at the plant, for usage at the mine or at the plant. At some plants treating magnetic taconite ore from the Mesabi Range, the mine run ore containing a small amount of fines and a heavy proportion of large blocks is brought in and dumped from high-capacity trucks directly into the top of a crusher installed at the mine site. The crushed material is conveyed to a surge pile, from which it is hauled by rail to concentrat- 2 ing plants. 2. Input Materials - Mined ore. 3- Operating Parameters - Ambient. 4. Utilities - Electricity, water and fuel. Grinding of hard taconite requires about 8 kWh of power per gross ton* of primary feed (See Process 5). 5- Waste Streams - Dust emissions from crushing and blending operations amount to about 1 kilogram per ton of ore and have essentially the same com- 3 position as the ore being treated. Dust emissions contain ferrous or fer- ric oxide, some silica, and limestone. Other fugitive dust emissions come from transportation (conveyors, etc.) transfer points, storage, reclaim and screening. In crushing of taconite ores, 15 to 20 percent of the primary crusher feed is eliminated and dumped. 6. EPA Source Classification Code - None exists. 20 ------- 7, References 1, Iron Ores, In; The Making, Shaping and Treating of Steel, Ninth. Edition, McGannon, H,E. (ed,). Pittsburgh, Pennsylvania, United States Steel Co., 1971. p. 210-218, 2. Merrit, P.C, Mesabi Enters a New Era. Mining Engineering, p, 93-10.8, October 1965. 3. Billings, C.E. Technological Source of Air Pollution, Chapter 14, In: Industrial Pollution, Sax, N.I. (ed.). New York, Van Nostrand Reinhold Company, 1974. p, 350-480. 21 ------- ORE PREPARATION PROCESS NQ.^3 Ore Concentration 1. Function - The quality of iron ores is further improved by concen- tration by one of five methods: washing, jigging, heavy-media separation, magnetic separation (physical operations), and flotation (chemical pro- cess). Washing separates the iron-bearing minerals from gangue materials by techniques based on differences in specific gravity. Jigging involves the stratification of ore particles and gangue by subjecting the crude ore to alternating upward and downward pulsations of water. The gangue overflows the jig, while ore particles are removed as an underflow pro- duct. The methods selected are based on physical and chemical properties of crude ore. In heavy-media methods, separation is achieved by sus- pending ore materials in a liquid having an intermediate specific grav- ity, in which the heavier iron mineral will sink and the lighter gangue will float to the surface. Magnetic separation is mainly used witti taco- nite ores to separate magnetic valuables from nonmegnetic materials. Flotation techniques are effective in the separation of fine particles of iron minerals and gangue preduced by grinding iron ore.! Various 2 frothing and modifier agents are used to aid in the separation. At present only three iron ore flotation plants exist in the United States. o Flotation methods include: Anionic flotation of specular hematites Upgrading of natural magnetite concentrates by cationic flotation Upgrading of artificial magnetite concentrates by cationic flotation Cationic flotation of crude magnetites Anionic flotation of silica from natural hematites Cationic flotation of silica from nonmagnetic iron formation. The concentrate is conveyed on belt conveyors to storage facilities. 2. Input Materials - At Republic Mine, located on the Marquette Iron Range, the beneficiation plants process roughly 20,000 tons* of low-grade hematite per day to produce about 10,000 tons* per day of concentrated ore, containing 60 to 65 percent iron. Table 8 gives typical reagents and their quantities used for flotation of iron ore.2 * Metric tons (1000 kg). 22 ------- Table 8. REAGENTS USED FOR FLOTATION OF IRON ORES Type of flotation agent 1. Anionic flotation of iron oxides(from crude ore) Petroleum sulfonate Low rosin, tall oil fatty acid Sulfuric acid No. 2 fuel oil Sodium silicate 2« Catiom'c flotation of hematite (from crude ore) Rosin amine acetate Sulfuric acid Sodium fluoride Plant also includes phosphate flotation and pyrite flotation steps. Phosphate flotation employs sodium hydroxide, tall oil fatty acid, fuel oil and sodium silicate. Pyrite flotation employs xanthate collector 3. Catiom'c flotation of silicaffrom crude ore) Amine Gum or starch (tapioca flour) Methyli sobutyl carbi nol 4. Cationic flotation of silica (from magentite concentrate) Amine Methylisobutyl carbinol Quantity, kg/ton* of iron ore processed 0.5 0.25 1.25 0.15 0.5 0.2 0.15 0.15 ' 0.15 0.5 As required 5.0 grams/ ton As required * Metric ton (1000 kg). 23 ------- 3. Operating Parameters - These concentration processes are usually carried out at ambient conditions. 4. Utilities - Producing 1 ton* of concentrate from 4 tons* of crude ore can require from 2000 to 20,000 liters of water, depending on the process. Upon leaving the process this water can serve to transport the waste 3 materials to the tailings' basins. Data on energy consumption in mining and concentration processes are fragmentary and not well-defined (See Process 5). 5. Waste Streams - A total of 55 million tons* of tailings is produced from more than 100 million tons* of crude taconite mined annually. TJie daily release of tailings from some mines is: 57,400 tons* at Reserve Mining, 61,400 tons* at Erie Mining, and 11,500 tons* at Eveleth Taconite Co. (see Table C-3). The composition of the-tail ings varies with ore seam and the beneficiation processes. Detailed composition and particle size of tailings froir, Reserve Mining's plant at Silver Bay, Minnesota are 4 given in Table 9 and Table 10, respectively. Tailings contain both 4 coarse and fine particles. The tailings can cause some fugitive dust emissions. Drying of ore fines before beneficiation also creates air pollution problems. Other fugitive dust emissions come from conveyors, transfer points, storage, reclaim and screening. Slurry containing gangue materials and frothing agents from flotation operations which could present serious pollution problems, is usually sent to waste water ponds. 5 According to one report, iron ore mining and concentration adds little to the process water other than hardness. In some plants, where a heavy medium of finely divided ferrosilicon is involved, a slight solubility of iron in plant water may result. Generally, however, clarified water from the iron mining industry can be discharged into public waters. The tailings wastewater from low-grade ore concentration contains about 70,000 to 500,000 milligrams per liter of suspended solids (98 percent of which settles rapidly). Large volumes of solids are deposited, roughly equivalent to three-fourths of the volume of ore mined. Table E-4 gives the analysis of wastewater discharge from iron ore beneficiation Metric ton (1000 kg). 24 ------- Table 9. TYPICAL ANALYSIS OF TAILINGS Composition Iron Silicon Aluminum Calcium Magnesium Manganese Titanium Phosphorus Sodium Potassium Sulfur Lead Zinc Nickel Copper Molybdenum Vanadium Cobalt Chromium Cadmium Carbon Hydrogen Oxygen Percent 14.93 33.03 0.35 1.67 2.55 0.37 0.030 0.026 0.20 0.08 0.03 0.005 0.004 0.002 0.004 <0.001 <0.001 0.002 0.004 0.0003 0.11 0.10 46.40 25 ------- Table TO. TYPICAL PARTICLE SIZE ANALYSIS OF TACQNITE TAILINGS* Size, microns 6,730 4,760 3,360 2,380 1 ,680 1,190 841 595 420 "17 210 149 105 74 53 45 30 20 10 5 Percent 9,6.7 90.4 81.6 72,8 66.3 61.6 57.5 55.5 53.6 51.9 49.6 45.9 41.7 38.0 34.7 32.5 24.7 18.4 9.3 5.3 a From the plant referred to in Table 10. ------- involving milling, flotation, and agglomeration at one mill. Asbestos like fibers found in the drinking water supply in Duluth, Minnesota, are believed to be due to the wastewater from taconite ore mining and concentration processes. Table E-5 shows the sources of mill waste- water from concentrating low-grade ore at Reserve mine.3 In a typical practice the tailings are sent to the pond where coarse tailings are removed and treated in a hydroseparator and a thickener. Overflow from the thickener may be pumped back to the concentrating plant. Two generally practiced tailings' disposal methods are: 1) ponding with eventual reclamation of the tailings pond, and 2) direct disposal into Lake Superior (used solely by Reserve Mining). 6. EPA Source Classification Code - None exists. 7. References - 1. Iron Ores. In: The Making, Shaping and Treating of Steel. Ninth Edition. McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 178 - 239. 2. Calspan Corporation. Development Document for Effluent Limitations Guidelines and Standards of Performance for Ore Mining and Dressing Industry, Point Source Category (Draft). Environmental Protection Agency. Contract No. 68-01-2682. April 1975. 3. Baillod, C.R., G.R. Alger, and H.S. Santeford, Jr. Waste Water Resulting from the Beneficiation of Low-Grade Iron Ore. Michigan Technological University. (Proceedings of 25th Industrial Waste Conference. Purdue University. Lafayette, Indiana, May 1970.) p. 54-59. 4. Phillips, N.P., and R.M. Wells. Solid Waste Disposal Final Report. Environmental Protection Agency, Washington, D.C. Publication Number 650/2-74-033. May 1974. p. 101-115. 5. Lewis, C.J. Metal Mining. In: Industrial Waste Water Control, Chemical Technology, A Series of Monographs, Volume 2, Gurnham, C.F. (ed.). New York, Academic Press, 1965. ?7 ------- ORE PREPARATION PROCESS NO. 4 Sintering 1. Function - The fine Iron particles whether in natural or in con- centrated ores are agglomerated to a size suitable for blast furnace charging. Sintering and pelletizing are by far the most common agglo- meration methods. The sintering process converts materials such as fine ore concentrates, blast furnace flue dust, mill scale, turnings, coke fines, limestone fines, and miscellaneous fines into an agglomerated product that is suitable for blast furnace feed material. Some water may be added in preparing the agglomerate mix. The mixture is deposited on a traveling grate that conveys a bed of ore fines, or other finely divided iron-bearing materials, mixed with finely divided coke breeze and fluxes. Combustion air is drawn in, and the mixture is ignited by natural gas of fuel oil. It burns and forms a fused mass, which is fed to a cooler, crushed and screened.1 The sinter production rate, which depends on the chemical and physical characteristics of the raw materials as well as control exercised in the sinter process, ranges from 0.002 to 0.0043 ton* per square centimeter (2.00 to 4.00 net tons per square foot) 2 of grate area per 24 hours. Table B-l, Appendix B presents average com- position of sinter produced in 1968. 2. Input Materials - Table 11 lists the constituents of the strand 3 burden required to produce 1 ton* of sinter. 3. Operating Parameters - Combustion is maintained at a temperature of about 1300 to IBOO^.1 4. Utilities - Electricity, water and fuel (gas or oil). 5. Waste Streams - The sintering process is a source of significant atmospheric emissions. Particulate emissions are estimated to be about 4 11 kilograms per ton* of sinter. Table 12 presents particle size data 5 of particulate emissions. Total vented gases released during sintering amount to approximately 1.56 to 2.08 liters per second per kg/hour (1.5 to 2.0 scfm per Ib/hour) of sinter. The gases generally leave the machine at a temperature of *Metric tons (1000 kg) 28 ------- Table 11. CONSTITUENTS OF THE STRAND BURDEN FOR A TYPICAL SUPERFLUXED SINTER Raw materials Amount per 1000 kg of sinter product Ore and reclaim Return fines Coke Flux Water Sinter (hearth layer) Air required 1,000 kg 500 kg 50 kg 250 kg 120 kg 250 kg 3100 m3 Table 12. PARTICLE SIZE ANALYSIS OF PARTICULATE EMISSIONS FROM A SINTERING MACHINE Screen size, microns 5 10 20 30 44 Weight retained, percent 25.1 47.6 14.6 5.8 5.0 Cumulative weight, percent 25.1 72.7 87.3 93.1 98.1 29 ------- 200°C or lower. Thec.e gases are emitted from the windbox collection ducts and the bed of the grate.. Emissions from the product cooler range from 0.21 to 1.26 liter per second per kg/hour (0.2 to 0.25 scfm per Ib/hour) of sinter processed. Therefore, the total stack gas flow from sinter plants can be expected to range from 1.77 to 2.39 liters per second per kg/haur (1.7 to 2.3 scfm per Ib/hour} of sinter production. The average particulate loading is 1.14 grams per cubic meter (0.50 grain/scf) of gas. Moisture content of gases ranges from 4.5 to 10 percent, depending on the quantity of water added during preparation of o sinter mix. The process emits not only sulfur oxides (about 30 to 40 percent of the sulfur in the charge is liberated), but also other volatile constituents. The sulfur content of gases could be as high as 2000 ppm. Hydrocarbon fumes may be evolved if oily scrap is used in 2 preparation of sinter mix. In addition to s.nter machines and sinter screens, all conveyor transfer points, loading points, chutes, and bins handling sinter are potential sources of fugitive dust. Many industries control the dust from these points by using a chemical wetting agent mixed with water. Electrostatic precipitators, baghouses and scrubbers are used to control emissions from sintering. A dry cyclone reduces the emissions to 1.0 kilogram per ton* of sinter; an electrostatic precipitator in series with a dry cyclone reduces emissions to 0.5 kilogram per ton* of sinter.* 6. EPA Source Classification Code - Sintering general - 3-03-008-03. 7. References - 1. Kirk-Othmer. Iron. In: Encyclopedia of Chemical Technology, Volume 12, New York, John Wiley and Sons, Inc., 1968. p. 1-21. 2. Genton, R.G. Steel Mill Sinter Plant. (Presented at the 65th annual meeting of the Air Pollution Control Association, June 18-22, 1972.) p. 8. 3. PEDCo-Environmental Specialists, Inc., New Source Performance Standards Support Document for the Sintering Industry - Summary Report. Environmental Protection Agency. Contract Number 68-02-1321. Cincinnati, August 1974. * Metric ton (1000 kg) 30 ------- 4. Iron and Steel Mills. In: Compilation of Air Pollutant Emission Factors. Environmental Protection Agency, Research Triangle Park, N.C., Contract Number CPA-22-69-119. April 1973. 5. Varga, J. Jr., and H. W. Lownie. Final Technological Report on A System Analysis Study of the Integrated Iron and Steel Industry. Battelle Memorial Institute, Columbus, Ohio. May 1969. 6. Exhaust Gases from Combustion and Industrial Processes. Engineering Science, Incorporated. Publication Number PB- 204861. Distributed by National Technical Service. October 2, 1971. 7. Frame, C. P., and R. J. Elson. The Effects of Mechanical Equipment on Controlling Air Pollution at No. 3 Sinter Plant, Indiana Harbor Works, Inland Steel Company. Journal of Air Pollution Control Association, p. 600-603. December 1963. 8. Billings, C. E. Technological Sources of Air Pollution. Chapter 14. In: Industrial Pollution, Sax, N.I. (ed.). New York, Van Nostrand Reinhold Company, 1974. p. 350-408. 31 ------- ORE PREPARATION PROCESS NO. 5 Pelletizing 1. Function - Palletizing is used primarily for agglomerating fine magnetic concentrations of taconite ores. The ore is ground, sized and mixed with water and binder, then rolled into small balls. A small amount of fine coal fuel may be added to the pellet mix. These "green" pellets are first dried then heated in a kiln to temperatures between 1200 and 1370°C to bind the small particles, and finally cooled. Con- trol of moisture content of the pellets is very important to ensure strength. Normal moisture content runs between 10.0 and 10.25 percent. The pellets are conveyed through a weight meter to storage. The three most important pelletizing systems are the traveling-grate (updraft and/ 2 or downdraft) system, the shaft furnace system, and the grate kiln system. 2. Input materials - Magnetite taconites are concentrated and agglom- erated at several locations in Minnesota. Tables B-2 and B-3, Appendix B give a typical analysis of taconite concentrates charged to pelletizer and composition of pellets produced. 3. Operating Parameters - Temperatures of 1200 to 1370°C are main- tained at atmospheric pressure. 4. Utilities - Electricity, water and fuel (gas or oil) are required. As an illustration on a magnetic taconite plant, the heat requirement o for pelletizing is 137,400 kilocalories per metric ton of pellets, similar processing of hematite requires twice the kilocalories of mag- A netic taconite per metric ton of pellets. Added to these heat require- ments 94 kWh of electric power per metric ton of pellets (80,900 kilo- calories) is required for mining, crushing and concentrating.3 Table 13 gives the energy consumption (according to the process evaluation group of the U.S. Bureau of Mines) at a typical magnetic taconite pi ant.^ 32 ------- Table 13. ENERGY CONSUMPTION FOR PROCESSES AT A 2 MILLION TPY MAGNETIC TACONITE PLANT3 Process Mining Crushing Concentrating Pelletizing Overall utiliti< . Total Percent of tota energy Electric power, % 7 7 67 15 ?s 4 100 1 39 Energy consumption, % natural gas - - - 88 12 100 61 Both 2 3 26 60 9 100 100 Total consumption, kilocalories/ton of pellets is 256,000 5. Waste Streams - Since the concentrates received at pelletizing plants are usually moist, dust emissions from handling are minimal problem. Pelletizing is usually done at the mine site. Particu- late emissions are similar to those from sintering plants (Process 4). i Table 14 shows the particle size distribution of uncontrolled emissions.' Table 14. PARTICLE SIZE DISTRIBUTION Percent weight 1 4 15 5 75 Size, microns <2 2-10 10 - 30 30 - 50 >150 6. EPA Source Classification Code -None exists. 33 ------- References - Kirk-Othmer. Iron. In: Encyclopedia of Chemical Technology, Volume 12, New York, John Wiley & Sons, Inc., 1968. Iron Ores. In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsyl- vania, U.S. Steel Company, 1971. p. 225-226. Target: New Technology to Improve Economics of Iron Ore Beneficiation. Engineering and Mining Journal. 175:65-68, December 1974. North American Iron Ore: Launching a Rescue Mission for a Steel Short Economy. The Editors, Engineering and Mining Journal. 83-85, November 1974. Goldberg, A.J. A Survey of Emissions and Controls for Hazar- dous and Other Pollutants. Environmental Protection Agency, Washington, D.C. Publication Number R4-73-021. February 1973. p. 69-75. 34 ------- ORE PREPARATION PROCESS NO. 6 Moduli zi.ng 1. Function - In the nodulizing process ore fines are heated in an oil- or gas-fired rotary kiln. The material moves through the kiln and is agglomerated into lumps by rolling of the charge at temperatures near the fusion point of 1260 to 1370°C.1 The ore balls form nodules, which are then discharged and cooled. Nodulizing has no commercial acceptance. (Although nodules appear satisfactory for open-hearth use, they are not acceptable as an agglomerate for good blast-furnace per- formance largely because of their nonuniform size and inferior reduc- ibility.3) 2. Input materials - Nodulizing is not as sensitive to feed moisture 2 and particle size as compared to pelletizing. Table 15 gives the hour- ly input rates to nodulizing kiln (results of 1953 tests) at Extaca's 2 nodulzing plant using magnitite ore. Table B-4, Appendix B gives chemical analysis of nodulized product from Taconite concentrate. Table 15. HOURLY INPUT AND OUTPUT RATES FROM NODULIZING KILN AT EXTACA Material Quantity, tons*/hr Average feed rate 48.2 Limestone content in feed 1.9 Coal consumed 2.9 Average nodule production rate 46.5 3. Operating Parameters - Table 16 gives typical operating statistics for nodulizing at the plant referred to inTablel5 . * Metric tons (1000 kg) 35 ------- Table 16. TYPICAL NODULIZING PROCESS OPERATING TEMPERATURES, °C Optimum nodulizing temperature High-silica ore 1260-1300 Low-silica ore 1345-1370 Magnetite 1260-1290 Temperature of nodules discharged 20-150 from cooler 4. Utilities - Fuel consumption during nodulizing ranges from 0.56 to 3 1.1 million kilocalories per ton of product. Table 17 gives heat and power requirements for producing nodules. (The data in Tables 15, 16 2 and 17 are for the same plant). Table 17. NODULIZING ENERGY REQUIREMENTS, PER KILOGRAM OF NODULES Fuel consumption, calories per kilogram of nodules: For low-silica ore 668,830 For magnetite 512,790 Power requirements, kWh per kilogram of nodules 0.018 5. Waste Streams - No data are available on emissions from nodulzing processes. The emissions should be lower than those from sintering (See Process Q). 6. EPA Source Classification Code - Nqne exists, 7. References - 1. Kirk-Othmer. Iron, In: Encyclopedia of Chemical Technology, Volume 12, New York, John Wiley & Sons, Inc., 1968, p. 1-21. 2. Benett, R.L., R.E. Hagen, and M.V. Mielke. Nodulizing Iron Ore and Concentrates at Extaca. Mining Engineering. 6:32-38, January 1954. 3. Iron Ores. In: The Making, Shaping and Treating of Steel, Ninth Edition. McGannon, H.E. (ed,), Pittsburgh, Pennsyl- vania, U.S. Steel Company, 1971, p. 226. 36 ------- ORE,.PREPARATION PROCESS NO. 7 Briquetting 1, Function - In the briquetting process, ore fines are mixed with a binder and formed into compact masses between two rotating rolls. In hot-ore briquetting process, minus 1/4 inch hematite, ore fines are heated to between 870° and 1040°C, and then briquetted while hot in a r\ double-roll briquetting press at loads of 45 to 55 tons.* 2. Input Materials - Binder substances used are the same as in sinter- ing for cold briquetting, whereas no binder is used in hot briquetting. 3. Operating Parameters - Temperatures in the process range from 650 to 980°C for cold briquetting.1 4. Utilities - External heat is needed. Data on quantities and type of fuel are not available. Electricity is also required. 5. Waste Streams - Data are not available on emissions from briquetting, The emissions should be lower than those from the sintering process, because the mass of material is not heated to as high a temperature as in sintering. 6. EPA Source Classification - None exists. 7. References - 1. Kirk-Othmer. Iron. In: Encyclopedia of Chemical Technology, Volume 12, New York, John Wiley & Sons, Inc., 1968. p. 1-21. 2. Iron Ores. In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.), Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 226-227. * Metric Tons (1000 kg) 37 ------- COKE PRODUCTION Coke production is an integral part of major iron and steel oper- ations. Coke is charged to the blast furnaces to provide the heat and carbon required for smelting and reducing the iron ore. Since approxi- mately 466 kilograms of coke fs required for every ton of iron produced in blast furnaces, the coke plants process thousands of tons of coal a day into coke and coke by-products. Coke is manufactured by the by- product method in enclosed slot-type ovens. The Beehive process is being phased out because the by-product method is much more efficient and produces less pollution. Many iron and steel companies coke coal obtained from their own mines. In 1974, 91.6 percent of the coke used in the industry was produced at coke plants operated by iron and steel manufacturers. Table B-5, Appendix B presents data on coke and coal products produced in 1974 (See Table C-5, Appendix C, for production data on captive mines of the steel industry). Figure 2 shows the processes of the coke plant which are described in this section. These processes are: 8. Coal mining and transportation 9. Coal preparation 10. Charging of coke ovens 11. Coking 12. Pushing and quenching 13. Coke handling and tar condensation 38 ------- MATER HATER V to MINING AND 1* TRANSPORTATION g| 1 / BENE- \ COAL PREPARATION 1 »4 FICIATED' I * 91 \ COAL / COAL CHARGING I , TO OVEN jjjjr* COKING 13 [FUEL AIR COKE u » 2S?lifiND -* C"KE HANDLING IJwnulinti jj " u OVEN GAS FOR BY-PRODUCTS Y GASEOUS EMISSIONS RECOVERY AND COMBUSTION (SEE FIGURE 3} $ LIQUID WASTE 9 SOLID HASTE Figure 2. COKE PRODUCTION ------- COKE PRODUCTION PROCESS NO. 8 Coal Muring and Transportation ! Function - Coal is basically mined by three methods: 1) strip (sur- face) mining, 2} underground (deep) mining, and 3) auger mining. The methods are dictated mostly by geological conditions. Strip mining is generally practiced only when the coal seam lies close to the earth's. surface. The two most wodely used underground mining methods are room and pillar and longwall. Auger mining is relatively inexpensive and is reported to recover 60 to 65 percent of the coal in the part of the bed where it is used. After mining the coal is broken into lumps suit- able for hauling to the surface by electric locomotives, or in increas- ing number of mines, by conveyor belts. In most underground mines, low, flat loading machines gather the loose coal onto shuttle cars. In open- pit or surface mining, th« coal is gathered up by large power shovels and is loaded usually on trucks for hauling to the cleaning plant or rail transportation. The run of mine coal is delivered to the cleaning facilities where the coal is separated from coarse rock and slate by the use of a scalper or breaker or crusher, then screened and sized. Depending upon other impurities and cleaning desired, the coal is further treated by heavy media washing, diester tables, froth flotation and drying. The sized coal can be mixed for direct shipment or is stroed in piles before being transported to the coke plant by trucks, rail or barge. 2. Input Materials - In 1974, iron and steel industry's blast furnaces consumed 81,420,000 tons* of bituminous and 403,000 tons* of anthracite 2 coal. In its natural state coal contains impurities such as sulfur, clay, rock slate, and other inorganic materials. Mining processes add more impurities in the form of mine rock, dirt, tramp iron, and wood. 3. Operating Parameters - Mining is done at ambient conditions. 4- Utilities - Energy is needed for mining equipment in the form of electricity, water and fuel. * Metric tons (1000 kg) 40 ------- 5- Waste Streams - Among the major environmental problems in coal mines are methane in coal beds and coal dust in the atmosphere of mines; both present health and safety problems in mining operations. Open coal stockpiles exposed to the weather are responsible for signi- ficant dust emissions. Airborne coal dusts are hazardous itn. potential for explosion. Reclamation of strip mined lands, drainage of acid mine waters, coal cleaning, and soltd waste disposal are other en- 3 vironmental problems. The nature of acid mine water varies from site 4 to site. Several typical mine water analyses are listed in Table 18. Solid refuse from coal mining consists mainly of insoluble coal, bone, calcite, gypsum, clay, pyrite, or marcacite and overburden. 6. EPA Classification Code * None exists. 7. References - 1. A Dictionary of Mining, Mineral, and Related Terms. Thrush, P.W. and Staff of Bureau of Mines, (ed.). U.S. Department of Interior, 1968. 2. Coke and Coal Chemicals in 1974 (Preliminary release of informa- tion pending publication of Bureau of Mines Minerals Yearbook), Mineral Industry Surveys, U.S. Department of Interior, Bureau of Mines. Washington, D.C. November 1975. 3. Hunter, T. W. Bituminous Coal and Lignite, Minerals Facts and Problems, Bureau of Mines. Washington, D.C., U.S. Government Printing Office, 1970. 4. Girard, L. "Operation Yellowboy." (Unpublished report pre- pared by Dorr Oliver, Inc., for the Coal Research Dept. of Mines and Minerals Industries, Commonwealth of Pennsylvania, 1965.) 5. Lucas, J. R. and D. R. Maneval. Plant Waste Contaminants. In: Coal Preparation. W. L. Midd Series, Leonar, J. W. and D. R. Mitchell, (eds.). New York, American Institute Mining, Metallurgical and Petroleum Engineers, Inc. 1968. 41 ------- Table 18. CHEMICAL ANALYSES OF WATER AT DIFFERENT MINE SITES' Sample pH, field pH, Lab Iron, ppm Total iron, field ferrous lab Total iron, lab Acidity, ppm CaCCL free total Alkalinity, ppm CaC03 Manganese, ppm Silicon dioxide, ppm Aluminum, ppm Calcium, ppm Magnesium, ppm Potassium, ppm Sodium, ppm Chlorine, ppm Sulfate, ppm Copper, ppm A 4.3 3.20 486 454 463 20 850 0 16 35 24 335 0 0 4.0 15 1867 0.3 B 2.9 2.65 828 733 1348 45 5820 0 70 81 595 1263 16 0 2590 2010 12838 0.7 C 4.4 3.65 17 0.5 1.3 15 86 0 10 4 13 89 0 0 4.0 36 301 0.2 Different samples from different locations. 42 ------- COKE PRODUCTION PROCESS NO. 9 Coal Preparation 1. Function ^- Preparation involves the breaking, screening, pulver- izing, blending, and mixing of the coal. Incoming metallurgical coal from the mine is brought to a breaker building at the coke plant. The breaker is provided to remove the refuse from the coal and break up frozen lumps in winter. The coal is then screened. The coarse coal flows to a rotary crusher and final pulverizing is done in the fine-coal system. Low-and high-volatile coals are pulverized separately, and coals of different volatilities are usually blended to improve the chemical and physical properties of the coke and to control the pressure on the oven walls developed during carbonization. To further increase the uni- formity and quality of coals to be fed to coke ovens, their bulk density is controlled. If the bulk density of the coal is below specification, oil is added; if the bulk density of the coal is above specification, water is added. The coals are then conveyed to coke oven battery coal- storage bins. 2. Input Materials - Bituminous coals of high-volutile coal is usually blended with either or both medium- and low-volatile coals to provide charge for the coke ovens. Coals of low ash content, low sulfur content, and suitable coking properties are used. A major protion of the pulver- ized and blended coal (typically 70 percent) is in particles smaller then 0.49 centimeter. Table 19 gives an analysis of typical coke to be charged to an oven. Table 19. ANALYSIS OF A TYPICAL COKE OVEN CHARGE, DRY BASIS Constituents % Water 4.0 Volatile matter 31.4 Fixed carbon 63.4 Ash 5.2 Sulfur 0.76 Phosphorus 0.008 43 ------- Open stockpiles of coal may reach a height of 30 meters and cover up to 500'thousand sq meters. 3. Operating Parameters - Coal preparation operations are carried out at ambient conditions. 4. Utilities - Electrical power is needed for coal preparation equip- ment. 5- Waste Streams - Coal dust is emitted from crushing, screening, storage, reclaiming, conveying, and bin loading operations. Particulate emissions increase as surface moisture in the coal decreases. Emissions are on the order of 5 kilograms per year per ton* of material stored. Particle sizes released to the air average well below 0.1 millimeter, 4 and suspended fractions are in the range of 1 to 10 microns. About 2 to 5 grams of coal are lost for every kilogram of coal received (dry basis). Much of this loss occurs by rainout of fines from storage piles and by wir.j during outdoor handling and storage. About 20 percent of the total loss of coal occurs as dust from the pulverizing and blending operations. The solids concentration in plant waters usually ranges between 30 and 110 grams per liter but may reach 200 grams. Fine coal and mineral particles such as clays remain suspended in most plant waters. These particles vary in size from 28-mesh to colloidal dimensions; most can be eliminated by thickeners, cyclones, A and filters. Some of the trace elements contained in the emissions are beryllium, selenium, arsenic, lead, cadmium, strontium, titanium, potas- sium, and sulfur. 6. EPA Source Classification - Coal crushing and handling - 3-03-003-07. 7. References - 1. Manufacturing of Metallurgical Coke and Recovery of Coal Chemicals. In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 104-116. 2. Kirk-Othmer. Carbonization. In: Encyclopedia of Chemical Technology, Volume 4. John Wiley and Sons, Inc., New York. 1968. * Metric ton (1000 kg) 44 ------- 3. Varga, J. Jr., and H. W. Lownie. Sources of Air Pollution In: Final Technological Report on A Systems Analysis Study of the Integrated Iron and Steel Industry. Battelle Memorial Institute, Columbus, Ohio. May 1969. 4. Barnes, T. M., A. O. Hoffman, and H. W. Lownie. Evaluation of Process Alternatives to Improve Control of Air Pollution from Production of Coke. Battelle Memorial Institute. Columbus, Ohio, January 31, 1970. 5. 1974, Keystone Coal Industry Manual. New York, Mining Infor- mation Services of The McGraw Hill Publications, 1974. 45 ------- COKE PRODUCTION PROCESS NO. 10 . Charging of Coke Ovens 1. Function - Prepared coals are carried from the coke-oven battery coal-storajge bins to the coke oyens in larry cars with three to five hoppers matching the openings for coal charging in each oven. All modern by-product coke ovens are designed to take a definite volume of coal per charge. Two types of larry cars are used: the gravity discharge larry, and the mechanically unloaded larry. Charging is accomplished through openings in the top of the coke oven. To prevent escape of the gases from the oven during charging, gas-cleaning devices ( mechanical or ven- turi scrubbers) have been installed on the larry cars. A steam-jet aspi- rator is used in most plants to draw gases from the space above the charged coal into a gas collecting main. Some newer batteries use pipeline charging, for preheated coal. 2. Input Materials - A specified volume of coal, typically 16 to 20 tons,* is charged to the oven for each coking operation. Bethlehem Steel Corporation, Burns Harbor, Indiana, has a charging capacity of 39.4 cu. o meter (1,391 cu. ft. or approximately 35 tons) per oven. 3. Operating Parameters - Prepared coal is charged at ambient condi- tions. 4. Utilities - Energy is needed for material transportation and for preheating when done. Quantitative data is not available. 5. Waste Streams - The analytical properties of the coal have no appar- o ent significance on the quantities of emission during charging. Dust is evolved when the larry car is filled with coal and weighed. Charging the coal to ovens results in some smoke. Under the conditions of charging some of the hydrocarbons contained in coal are directly volatilized (an- thracene, phenanthrene, and naphthalene). Some coals break down to yield methane and lighter aromatic compound such as benzene. Some emit hydro- gen and are rapidly coked to graphite. Small, porous globules of coke carbon (coke ball) are sometimes emitted in the charging g^ses. The Metric ton (1QOQ kg) ------- gases contain some nitrogen, carbon monoxide, carbon dioxide, hydrogen, 4 methane, and steam. Charging coal into the oven accounts for 6Q to 70 percent of total emissions from oven batteries. Unsubstituted polynu- clear aromatics constitute up to 3 percent of the collected volatiles or 4 to 6 percent of the benzenersoluble portion of the collected volatiles c emitted during the charging operation, Table 20 gives the conditions to which larry car operators are 3 exposed inside the operator'^ cab and this provides an indication of pollutant concentrations in this area. Currently, the following methods are in use for the reduction of charging smoke: 1) external collection and cleaning of gases from the larry car, 2) collection of gases in a gas collecting system, with standard larry car charging, 3) "staggered" charging which consists of charging each oven port separately under negative pressure, and 4) pipe line charging. Table 20. TIME-WEIGHTED AVERAGE CONCENTRATIONS OF GASES INSIDE THE LARRY CAR (BASED ON 8-HOUR WORK DAY) Substance Quantity Coal tar pitch 0.2 mg/m SOp 5.0 ppm H2S 10.0 ppm CO 50.0 ppm Emissions from oven charging contain on the order of 0.75 kilogram particulate, 0.02 kilogram SO^, 0.6 kilogram carbon monoxide, 2.5 kilogram hydrocarbons, 0.03 kilogram NO and 0.02 kilogram ammonia, per ton coal fi charged. 6. EPA Source Classification Code - 3-03-003-02. 7. References - 1. Manufacture of Metallurgical Coke and Recovery of Coal Chemicals. In: The Making, Shaping, and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 118-128. 47 ------- 2. Coal and Coke. In: Watkins Cyclopedia of the Steel Industry, Twelfth Edition, Pittsburgh, Pennsylvania, Steel Publication, Inc. 1969. p, 46t 3. Stoltz, J. H. Coke Charging Pollution Control Demonstration. Environmental Protection Agency, Contract No. CPA 70-162. March 1974. 4. Barnes, T. M., A. 0. Hoffman, and H. W. Lownie. A Final Report on Evaluation of Process Alternatives to Improve Control of Air Pollution From Production of Coke. Battelle Memorial Institute, Columbus, Ohio. May 1969. 5. Smith, W. M. Evaluation of Coke Oven Emissions. Air Pollution Control Association. (Presented at the Annual Meeting, 63rd, St. Louis, Mo. June 14-18, 1970.) 6. Iron and Steel Mills. In: Compilation of Air Pollution Emis- sion Factors. Environmental Protection Agency, Research Triangle Park, N.C. Contract Number CPA-22-69-119. April 1973. 48 ------- COKE PRODUCTION PROCESS NO. 11 Coking ! Function' - Coke is the residue of destructive distillation of coal. Coal is heated tn the coke ovens (with no air in the oven) by adjacent chambers or flues using; 1) some of the gas recovered from the coking operation, 2) cleaned blast-furnace gas, or 3) a mixture of coke-oven and blast-furnace gases. The reduction starts at the side walls and con- tinues toward the center, when it reaches the center all the coal in the oven is converted to coke. The end doors are opened and a ram then pushes the incandescent coke out of the oven through a coke guide and into the quenching car. The oven is generally left open for several minutes to burn off the carbon collected on the roof around the charging holes. A typical coke oven is 9.1 to 13.1 meters long, 1.8 to 4.3 meters high, and 28 to 56 centimeters wide. Some newer units are 15.2 meters long and 6.6 meters high and 46 centimeters wide. The coke oven operates with a coke conversion factor of approximately 70 percent depending upon the type of coal carbonized, carbonization, temperature and method of coal- chemical recovery. The newer ovens have capacities of 34 tons or more of coal per oven. Coke ovens are constructed in gourps and called bat- teries. At some plants, a battery contains more than 100 ovens. Coking time requires approximately 17 hours but newer refractory techniques are permitting coking to take place in 14-5 hours or less. During carbonization, about 20 to 35 percent by weight of the ini- tial charge of coal is evolved as mixed gases and vapors. The gas con- taining volatile matter sent to the collecting main through an opening at the top of the oven. Table 21 gives the coke and coke chemical yields from one net ton* of coking coal. 2. Input Materials - Feed to the coke oven is prepared coal and com- bustion gas. Approximately 35 percent of the coal gas produced is returned to the oven. o 3. Operating Parameters - Carbonization temperature is about 1150°C. * Metric tons (1000 kg) 49 ------- Table 21. TYPICAL YIELDS FROM ONE TON OF COKING COAL Blast-furnace coke Coke breeze Coke-oven gas Tar Ammonium sulphate Ammonia liquor Light oil 544 - 634 kg 45 - 91 kg 270 - 325 m3 30 - 45 liters 9 - 13kg 57 - 132 liters 9 - 15 liters 50 ------- Heat input to the coke oven at a temperature of 1350°C is 690,000 kcal/ton (2,780,000 Btu/ton) of coal. Stack and radiation losses are 131,000 kcal/ton (527,000 Btu/ton) of coal, i.e. 19 percent losses.3 4. Utilities - Overall heat requirement for coal carbonization amounts to 560 to 640 kcal/kg (1000 to 1150 Btu's per pound) of coal.2 5. Haste Streams - Emissions of gas and dust are released; 1) when the oven ports are opened to charge the coal (Process 10), 2) during the coking by leakage through doors and ports, and 3) when the hot coke is pushed from the oven (Process 12). Several investigators report the presence of suspected carcinogenic hydrocarbons (i.e. polycyclic or polynuclear aromatic hydrocarbons) in coke oven smoke. Prominent among these is benzo(a)pyrene. Table 22 gives emission factors for coking and coke oven pushing or discharging. A complete list of chemicals present in coke oven off- gases is given in Table E-6, Appendix E. 6. EPA Source Classification Code - 3-03-003-03 - oven pushing. 7. References - 1. Manufacture of Metallurgical Coke and Recovery of Coal Chemicals. In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania. U.S. Steel Company. 1971. p. 105-177. 2. Kirk-Othmer. Carbonization. In: Encyclopedia of Chemical Technology, Volume 4, Wiley and Sons, Inc., New York, 1966. p. 400-423. 3. Roland Kemmetmueller, Pres. American Wagner - Biro Co., Inc. Pittsburgh, Pennsylvania, Iron and Steel Engineer. October 1973. 4. Boyland, E. Polycyclic Hydrocarbons, British Medical Bulletin, 202, 1964. 5. Iron and Steel Mills, In: Compilation of Air Pollution Emission Factors, Environmental Protection Agency, Research Triangle Park, N.C. Contract Number. CPA-22-69-119. April 1973. 51 ------- Table 22.. EMISSION FACTORS FOR COKING AND COKE OVEN PUSHING Pollutant Participate CO HCa N02 Ammonia Coking cycle Discharging (kg/ton* of coal charged) 0.05 0.3 0.75 0.005 0.03 0.3 0.035 0.1 0.05 Expressed as methane. * Metric ton (1000 kg) 52 ------- COKE PRODUCTION PROCESS NO, 12 Pushing and Quenching 1. Function - Red-hot coke from the oven is pushed into a quenching car and taken to a quenching station, where a water spray system of water cools the coke. Although a dry quenching method is available, and is used exclusively in Russia, all but one or two plants in the U.S. use wet quenching principally for economic and operating reasons. The usual practice is to achieve an average moisture content of 2 1/2 percent in the metallurgical coke after screening, 2. Input Materials - All the coke product from coke ovens is quenched. 3. Operating Parameters - Ambient conditions are maintained. 4. Utilities - Approximately 15 to 20 percent of quench spray water is evaporated in quenching and increasing the moisture content of the quench 2 coke, and the remainder recirculated. The amount of water for evaporation 2 and moisture content to the coke is about 500 liters per ton*. Electri- city is used by pumps and transferring equipment. 5. Waste Streams - Pushing emissions vary with the degree of coking. Well-coked coal will smoke very little when pushed into the quench car, while poorly coked "green" coke will cause excessive smoke. Particulate emissions for pushing operations were presented in Table 22 and amount 4 to about 0.3 kg/ton of coal charged. At one plant 21.5 percent of the particulate from pushing operations was larger than 74 microns. The distribution of those particle less than 13.5 microns in size is shown in Table 23.5 Baffles have been installed near the top of Some quenching station stacks to minimize carryover of entrained dust and water droplets out of the top of the stacks by the steam generated in quenching. Most of the solids, in the form of coke breeze, are either used within the plant or sold. Table 24 gives a screen analysis of the particulates generated at the quench of one coke plant. Table 25 gives an average analysis of quench water samples. The average weight of particulates emitted during a 2-minute quench cycle at one plant was calculated to be 2.7 kilograms. Metric ton (1000 kg) 53 ------- Table 23. PARTICLE SIZE DISTRIBUTION FOR COKE OVEN EMISSION SAMPLE DURING TYPICAL PUSH AT MAJOR NORTHWEST INDIANA STEEL CO. Size, microns 13.5 8.6 5.6 4.0 2.5 1.3 0.8 0.5 % by weight of total sample collected on plates 31.3 27.7 12.3 9.1 7.3 7.3 3.8 1.0 4*-5 fo.S I*. 5 il.t 11. ( H.« These emissions could be reduced to less then 0.4 kilogram by installation of baffles.6 The volume of the contaminated wastewater averages about 335 to 335 liters per ton of coke. Analysis of coke wash water at one plant showed that the suspended solids exceeded 350 ppm and chloroform-extractable g materials exceeded 260 ppm. Table E-7, Appendix E, gives a complete list of chemicals potentially present in the emissions from quenching and direct cooling. 6. EPA Source Classification Code - 3-03-003-04. 7. References - 1. Manufacture of Metallurgical Coke and Recovery of Coal Chemicals. In: The Making, Shaping and Treating of Steel. Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 130. 2. Ess, T.J. The Modern Coke Plant. Iron and Steel Engineer. C3-C36. January 1948. 3. Gollmar, H.A. Coke and Gas Industry. Industrial Engineering Chemistry. 39:596-601. 1947. 4. Iron and Steel Mills, In: Compilation of Air Pollution Emission Factors, Environmental Protection Agency, Research Triangle Park N.C. Contract Number, CPA-22-69-119. April 1973 54 ------- Table 24. SCREEN ANALYSIS OF QUENCH-TOWER PARTICIPATES Screen size Mesh 6 16 30 50 100 200 -200 Microns 3327 1167 589 298 147 74 -74 Weight Retained 0 1 9 35 39 13 3 Dercent Cumulative 0 1 10 45 84 97 100 Table 25. AVERAGE ANALYSIS OF QUENCH WATER SAMPLES Contaminants Phenols Sul fates Chlorides Total ammonia Cyanides Total solids Concentration, ppm 776 1066 1954 2517 98 5214 55 ------- 5. Yost, K.J., et al. Purdue University. The Environmental Flow of Cadmium and Other Trace Elements: Volume 1. National Science Foundation. PB-229478. June 30, 1973. 6. Barnes, T. M., A. 0. Hoffman, and H. W. Lownie. A Final Report on Evaluation of Process Alternatives to Improve Con- trol of Air Pollution from Production of Coke. Battelle Memorial Institute, Columbus, Ohio. May 1969. 7. Results of analysis of a series of quench water samples by 1) Allegheny County Bureau of Air Pollution Control, 2) U.S. Steel Clairton works, 3) Pennsylvania Department of Health - Division of Sanitary Engineering, 4) The University of Pitts- burgh - Department of Occupational Health. 8. Kozar, R. S. Environmental Pollution Control. Blast Furance and Steel Plant. 598, August 1970. 56 ------- COKE PRODUCTION PROCESS NO. 13 Coke Handling ]' Function -The quench car brings the quenched coke to the coke warf, where it is dumped in a thin layer for drying and for detection of unquenched coke (by visual inspection), Unquenched coke is sprayed with water. When cool, the coke is fed onto a conveyor belt and transferred to a screening station for separation into sizes. Tables B-6,and B-?7, Appen- dix B give typical sizes and properties of coke produced in the screening and separation step. 2. Input Materials - Quenched coke is fed to the coke wharf, and con- veyed to crushers, and then to storage. 3. Operating Parameters - Coke is cooled under ambient conditions. 4. Utilities - Electricity for the quench car, conveyor drives, crushers and screens. Water for additional quenching is used as required. 5. Waste Streams - Coke dust may be released at the transfer points or in mechanical operations such as screening. Size of particulates released to air is well below 0.1 millimeter, and the suspended fractions are in the range of 1 to 10 microns. Coke handling losses are typically 2 less then 0.01 percent. 6. EPA Source Classification Code - None exists. 7. References - ._ 1. Manufacture of Metallic Coke and Recovery of Coal Chemicals. In: The Making, Shaping, and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, 1971. p. 133- 134. 2. Barnes, T.M., A.O. Hoffman, and H.W. Lownie. A Final Report on Evaluation of Process Alternatives to Improve Control of Air Pollution from Production of Coke. Battelle Memorial Institute, Columbus, Ohio. May 1969. 57 ------- COKE BY-PRODUCTS RECOVERY Although most coke-oven plants in the United States are equipped to process tar and light oil, the extent to which an individual plant produces the various products depends upon economic conditions and size of the plant. Figure 3 shows the coke by-products recovery segments. The processes described in the following section are: Primary cooling/reheating Tar decanting Recovery of phenol Distillation of ammonia Ammonia absorption Crystallization and filter drying Light oil recovery Fractionation and refining of light oils Table B-8, Appendix B, presents yields and analysis of products of coking and recovery processes. 58 ------- wu-os m en MMXIIA RECOVERED FIION AWONIA STILL (om.v IN USE OF SWIDIRECTU PSOCESS) 1 1 * MtWNI* ABSORPTION It sunnic Kit /PTOOUCTS\ ">f | II6KT Oltl mntmnsN Figure 3. Coke by-products recovery. 9 GASEOUS EMISSIONS ^LIQUID WASTES <> SOLID WASTES ------- COKE PRODUCTION PROCESS NO. 14 Primary Cooling/Reheating 1. Function < The hot gases resulting from carbonization leave the coke oven through a standpipe into a collecting main. The gases and vapors are sprayed with weak liquor (flushing liquor) to reduce the temperature and volume. As a result of this cooling, most of the tar is condensed and is decanted along with the unevaporated flushing liquor into an adjacent tank. The coke oven gas and uncondensed vapors are passed from the collect- ing main to either a direct or indirect primary cooler for further cooling. As the gas cools, tar and ammonia liquor are condensed. This mixture of condensed liquor flows to the decanter (Process 15). The gas, with a small amount of resulting tar fog, then passes through a steam-driven centrifu- gal gas exhauster, which .emoves some of the remaining tar fog and passes the gas to an electrostatic precipitator. In the precipitator, the final traces of tar are removed. The gas is treated in a reheater where its temperature is raised and then passes through an ammonia scrubber (Process 18). The collected tar is added to the decanter (Process 15). Depending on the sulfur content of the coal used in the ovens, the coke oven gas may contain 9 to 17 grams hydrogen sulfide per cubic meter. Some plants partially or completely strip the sulfur compounds from the 2 coke gas. 2. Input Materials - The gas formed in coking may be usied as fuel or further treated. The quantities treated in primary coolers depend on the demand for by-products. The input gas analysis to the cooler is about 50 percent hydrogen, 27 percent methane and the remaining 23 percent ethane, benzene, CO,,, CO, 02 and Np. 3. Operating Parameters - A slightly reduced pressure is maintained in the collecting main to prevent loss of the gases. The weak ammonia spray reduces the temperature of gas from 600°C to about 100°C. The tempera- ture of the gases is dropped to 30°C in the cooler and raised to 60°C in the reheater. Pressure varies from 30 cm. water below atmospheric pres- 60 ------- sure to a discharge pressure of 1.8 kilograms per square centimeter.3 A precipitator is placed either before or after the exhauster to collect condensed organic droplets. 4. Ut i1it ies - The heat transferred from the hot gases to the cold liquor is recovered by indirect heat exchange with circulating water. Energy is required for operating the exhauster, electrostatic precipita*- tor and reheater, 5. Waste Streams - Some parti.culate is evolved through leaks in the equipment, 6. EPA Source Classification Code - None exists. 7. References - 1. Kirk-Othmer. Carbonization. In: Encyclopedia of Chemical Technology, Volume 4, New York, Wiley & Sons, Inc., 1968, p. 400-423. 2. Sollmar, H.A. Coke and Gas Industry. Industrial Engineering Chemistry. 39:596-601. 1947. 3. Griswold, J. Chemical Engineering Series, Fuels, Combustion, and Furnaces. McGraw Hill Book Company, Inc. 1946. 61 ------- BY-PRODUCTS RECOVERY PROCESS NO. 15 Tar Decanting 1, Function - The tar condensed in the collecting main is decanted along with the unevaporated flushing liquor into an adjacent tank where tar settles to the bottom and leaves through a valve into the tar decan- ter. The flushing liquor is passed to settling tanks. The ammonia liquor condensed in the primary coolers, together with the tar removed by the exhauster and precipitator, is also added to the tar decanter where the tar is separated from the weak ammonia liquor by decantation. Part of weak ammonia liquor is pumped back to the collecting main sprays, another part is passed to the cooling coils of the primary cooler, and the remainder is sent to an ammonia still. From the crude tar collector in the decanter, pitch sludge settles to the bottom and is mechanically raked out for disposal, usually by burning as fuel, Settled crude tar is sent to a separate plant for secondary processing by distillation, where naphthalene is obtained as the main product. The yields of tar vary among plants with the kind of coals car- bonized and the carbonizing temperatures. The yield in 1972 averaged 45 kilograms of tar per ton of coal. Generally from 4 to 5 percent by weight of the coal carbonized is recovered as tar. The relative quan- tities of tar tapped depend upon a number of economic factors, such as availability and current market for tar and tar distillate. Crude tar contains a large number of chemical compounds. One source includes 348 compounds that have been identified in tar. Some of the large plants recover a number of tar derivatives, including creosote oil, cresylic acid, cresols, naphthalene, phenol, pyridine, and medium and hard pitch. Table B- 9, Appendix B, presents the composition of coke oven tar. 2. Input Materials - Weak ammonia liquor and condensed tar from the collecting main, the exhauster, and the precipitator are the feed to the decanter. The input liquor contains from 1 to 5 grams suspended solids and dissolved tarry compounds including phenols and tar acids (expressed o as phenols) per liter. 62 ------- 3. Operating Parameters - Ambient. 4. Utilities - None required, 5. Waste Stream - Pitch sludge is a waste stream if not burned as fuel. There is some odor at the decanter. Ammonia and organic fumes are strong at the sumps where decanted liquor and other flush liquor is collected for recycling to the collecting main sprays. 6. EPA Source Classification Code - None exists. 7. References - 1. Sheridan, E. T. Coke and Coal Chemicals. In: Minerals Year- book, Volume I and II, Bureau of Mines, Washington, D.C., U.S. Government Printing Office, 1972. 2. Ammonia and Ammonium Salts, Chapter 10. In: Coal, Coke, and Coal Chemicals, Chemical Engineering Series, New York, McGraw- Hill Co., Inc., 1950. p. 309. 3. Varga, J. Jr., and H. W. Lownie. Final Technological Report on A Systems Analysis Study of the Integrated Iron and Steel Industry. Battelle Memorial Institute, Columbus, Ohio. May 1969. 63 ------- BY-PRODUCTS RECOVERY PROCESS NO. ]_6 Phenol Recovery 1. Function - Two processes are available to recover phenol, the vapor- recirculation process and the solvent extraction process. In the solvent extraction process weak ammonia liquor recovered with the volatile products of coal carbonization is contacted countercurrently in a scrubber with benzene or light oil to remove phenol (phenols are more soluble in benzene or light oil than in water). The weak ammonia liquor and light oil flows are maintained in the ratio of approximately 1.25 oil to 1.0 liquor. The phenol-free liquor flows to a storage tank for further processing (Ammonia Still, Process -U). The phenolized benzene or light oil is washed with caustic soda in a tower. After a week or two, the caustic in the light oil caustic washer is saturated with sodium phenolate, which is drained into a carbola+-e concentrator. The sodium carbolate in the concentrator is boiled to remove entrained solvent and moisture. It is then neutralized with carbon dioxide to liberate crude phenols and phenol 2 homologues. The vapor-recirculation method is operated in conjunction with the ammonia still. Ammonia is removed from the weak liquor in the "free leg" (See Ammonia Still, Process 17) of the ammonia still. So-called "free" ammonia and acidic gases (HLS, CO^ and HCN) and a minimum amount of phenol are removed in this step. The ammonia liquor leaving the base of the free leg is transferred to the dephenolizing unit where phenols are removed by vaporization with steam followed by extraction with caustic soda. Phenols are recovered from the sodium phenolate solution. The dephenolized liquor is transferred to the "fixed" led of the ammonia still. 2. Input Materials - Weak ammonia liquor, benzene or light oil, caustic soda and carbon dioxide or sulfuric acid are inputs to the solvent extraction process. In the vapor-recirculation process weak liquor from the free leg of the ammonia still is treated with steam and caustic soda. The 2 input ammonia liquor contains 0.5 to 3.0 grams phenol per liter. The pH of the liquor should be within a range of 6.5 to 9.0 for optimum 64 ------- o dephenolization. A phenol removal efficiency of 95 to 98 percent is achieved. 3. Operating Parameters - The solvent extraction process is carried at ambient conditions. The vapor-recirculation process is conducted at 100°C. 4. Utilities - Electricity is required for pumping. 5- Waste Stream - Particulate may be emitted. The scrubber and washer create some wastewater that must be treated. 6. EPA Source Classification Code - None exists. 7. References - 1. Carbone, W.E. Phenol Recovery From By-Product Coke Wastes. Sewage and Industrial Wastes. 22:200-205. February 1950. 2. Manuafacture of Metallurgical Coke and Recovery of Coal Chemicals. In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H. E. (ed.). Pittsburgh, Pennsylvania. U.S. Steel Company, 1971.- 3. Heller, A.N. et al. Some Factors in the Selection of Phenol Recovery Process. (Proceedings of Twelfth Industrial Waste Conference. Purdue University. May 14, 1957). p. 103-122. 65 ------- BY-PRODUCTS RECOVERY PROCESS NO. 17 Ammonia Still 1. Function - Ammonia is transferred to the vapor phase from aqueous solution by distillation and treatment with alkali. The ammonia present in weak liquor is in two forms classified as "free" and "fixed". The free ammonia is that which is readily dissociated by heat, such as ammonium carbonates, sulfides and cyanides. The fixed ammonia requires the presence of strong alkali to effect displacement of the ammonia from the compound in which it is present; examples include ammonium chloride, thiocyanate, ferrocyanide, sulfate. In the ammonia still "free" ammonia and acidic gases are removed by passing weak ammonia liquor down through a column over a series of plates equipped with bubble caps and overflow pipes. The liquor is heated by an upward flow of steam which vaporizes ammonia and volatile acidic gases. The vapors leave the top of the "free leg" of the ammonia still and pass to the dephlegmator. In the dephlegmator the vapors are partially cooled and excess water is removed and returned to the still. The vapors leaving the still consist of 10 to 25 percent ammonia. Most of the balance is water vapor with some acidic gases and neutral oils. Liquor leaving the "free leg" of the ammonia still may be sent to the dephenolizing unit if the weak liquor was not dephenolized by solvent extraction before being fed to the ammonia still. Weak liquor from which phenols and "free" ammonia have been removed will be treated with "milk of lime" (calcium hydroxide solution). The calcium hydroxide reacts with fixed ammonium salts, primarily ammonium chloride, according to the following reaction. 2NH4C1 + Ca(OH)2 + heat -> 2NH3 + 2H20 + CaC12 The ammonia is stripped from the solution by steam in a process similar to that used to remove free ammonia from the original weak liquor. The vapors leaving the ammonia still are added to the gas stream in the semidirect process and sent to Ammonia Absorption (Process 26). Alternatively, concentrated ammonia liquor may be produced. If concentrated liquor is produced the acidic gases are separated by scrubbing the vapors from the 66 ------- still with an alkali. The organic matter is separated by condensation and washing with organic solvents or with solid absorbents. Table B-10, Appendix B, gives an analysis of crude liquor from one plant. 2. Input Materials - Weak ammonia liquor is treated in the ammonia still. The quantities of ammonical liquor and its composition depend on the carbon- ization temperature, moisture content and chemical make-up of the coal 1 O Q charged. Table 26 gives analysis of weak ammonia liquor from three plants. '' Table 26. ANALYSES OF WEAK AMMONIA LIQUOR FROM THREE PLANTS (grams per liter) Composition Ammonia, total free fixed6 Sulfide as H2S Carbonate as C02 Thiosulphates as Cyanides as HCN Sulphates as H2S204 Total Sulphur as S Total phenols Tar material Chemical oxygen demand Biochemical oxygen demand, 5-day Oils Thiocyanates Plant Aa 6.54 3.35 3.19 Plant Ba 7.06 0.138 0.81 Plant Cb 5.6 0.29 1.10 0.03 0.17 0.82 2360 ppm Trace Estimated0 4.8 0.05 2.7 12.4 10.2 1.2 0.8 Reference 1. Reference 2, analysis of liquor before phenol removal. Reference 3, analysis of liquor before phenol removal. Ammonium carbonate, bicarbonate, sulfide, cyanide and carbamate. Ammonium chloride, thiocyanate, ferrocyanide, thiosulfate and sulfate, 67 ------- Milk of lime used contains about 40 grams of lime per liter of solution. From 1 to 1.25 kilograms lime are consumed per ton* of coal. carbonized. Yields of ammonia produced by carbonizing coal in by-product coke * 4 plants range from 2.5 to 3.0 kilograms per ton . 3. Operating Parameters - Vapors leave the top of the still at tem- peratures of 98 to 104°C.5 4. Utilities - About 200 kilograms of steam at 14 kg/sq cm (200 psig) "and 38°C superheat are required in a 2800-ton*-per-day-capacity coke plant. 5. Waste Streams - The waste sludge is alkaline, has brown or red- brown color, and contains about 0.03 gram ammonia and 1.0 gram lime per liter.1'4 The waste volume depends on the amount of steam added, method of recovery, strength of ammonia liquor, and volume of milk of lime added. Approximate wastes produced per ton* of coal carbonized are: 80 liters if only condensed ammonia liquor is charged to the still, and 340 liters if gases are scrubbed with water to collect ammonia and the resultant solution is charged to the still along with condensed ammonia iiquor. The waste produced from the first process amounts to 150 to 160 percent of the original liquor volume and contains 10 to 20 percent by volume of milk of lime. All the fixed ammonium salts of the original liquor are converted to the corresponding calcium compounds, the chloride, sulfate, thiosul- fate, and thiocyanate. Some of the organic matter present in the original liquor is left in the still waste, but the total concentration is greatly reduced and physical conditions altered. Waste contains about 1000 to 2500 parts per million of phenols. ' Analyses of wastes produced from 1 3 ammonia still are presented in Table 27. ' * Metric ton (1000 kg) 68 ------- Table 27. ANALYSES OF WASTE LIQUOR FROM AMMONIA STILLS (grams per liter) Composition Ammonia, total free fixed Alkalinity as CaO PH Chemical oxygen demand Biochemical oxygen demand, 5-day Sulfide as H2S Carbonate as C02 Oils Phenols Cyanides Thiocyanides Plant Aa 0.041 N.A. N.A. 1.57 Plant Ba 0.0034 0. 0034 1.44 0.75 0.37 Estimated 0.3 10.7 6.0 4.2 0.17 1.15 0.025 0.55 Plants referred to in Table 27 Reference 1. Reference 3, phenols are not extracted from the input materials. 6. EPA Source Classification Code - None exists. 7. References - 1. Wilson, Jr. P.J. Ammonical Liquor. Chapter 32. In: Chemistry of Coal Utilization, Volume II, Lawry, H.H. (ed.). New York, John Wiley and Sons, Inc., 1945. p. 1371-1392. 2. Elliott, A.C., and A.J. Lafreniere. Solvent Extraction of Phenolic Compounds from Weak Ammonia Liquor. Waste and Sewage Works. R325-R332, 1964. 3. Fisher, C.W., R.D. Hepner and G.R. Tallon. Koppers Company, Inc., Coke Plant Effluent Treatment Investigations. Blast Furnace Steel Plant. 315-320. May 1970. 69 ------- 4. Ammonia and Ammonium Salts. Chapter 10. In: Coal, Coke and Coal Chemicals, Chemical Engineering Series, Wilson, Jr. P.O., and J.H. Wells, (eds.). New York, McGraw Hill Book Co., 1950. p. 289-333. 5. Manufacture of Metallurgical Coke and Recovery of Coal Chemicals. In: The Making, Shaping, and Treating of Steel, Ninth Edition, McGanhon, H. E. (ed.). Pittsburg, Pennsylvania. U.S. Steel Company, 1971. 6. Ess, T.J. The Modern Coke Plant. In: Iron and Steel Engineer. C3-C36, January 1948. 7. Gollmar, H.A. Coke and Gas Industry. Industrial and Engi- neering Chemistry. 39:596-601. 1947. 70 ------- BY-PRODUCTS RECOVERY PROCESS NO. 18 Ammonia Absorption 1. Function - Ammonia formed during coking is recovered by reaction with sulfuric acid to form ammonium sulfate. Ammonia exists in the gas phase and in aqueous solution in ammonia liquor. The ammonia-containing gas that is scrubbed with dilute sulfuric acid may be: (1) the total vapor, after condensation of tar (direct process), (2) ammonia which has been removed from the gas by scrubbing. with water and then from the scrubber water and dilute ammonia liquor by disillation and treatment with alkali (indirect process), or (3) ammonia removed from the liquor produced during carbonization by distillation and alkali treatment and added to the gas stream (semi-direct process). The semi-direct process is used most extensively at present. The ammonia may be contacted with dilute sulfuric acid nearly saturated with ammonium sul- fate in a spray tower in the Otto or Wilputte processes, or by bubbling the gas through a large tank filled with liquid called a saturator (usually built before 1930). In any case ammonium sulfate crystals precipitate from the saturated ammonium sulfate - sulfuric acid solution and form a slurry. The slurry is sent to a crystallizer (Process 19) to complete the precipitation process and allow crystal growth. In the Otto process pyridine and other tar bases are recovered separately from the ammonia. The gas from the. saturator is sent to the acid separator for removal of any mist carryover, and then to the light oil recovery plant (Process 20). 2. Input Materials - Gases from the electrostatic precipitator and gaseous ammonia from the still are inputs to the process. For one kilogram of ammonia present in the input gases, 2.88 kilograms of sulfuric acid are used. 3. Operating Parameters - The gases enter the absorber at about 55°C. 4- Utilities - The gas-liquid contactor requires electricity for pumping and fans for gas transport. 5. Waste Streams - Some particulate is evolved. 6. EPA Source Classification Code - None exists. 71 ------- 7. References - 1. Ralph Stone and Co., Inc. Forecasts of the Effects of Air and Water Pollution Controls on Solid Waste Generation. Environ- mental Protection Agency. Publication Number PB-238819. December 1974. 2. Manufacture of Metallurgical Coke and Recovery of Coal Chemicals, In: The Making, Shaping, and Treating of Steel, Ninth Edition, McGannon, H. £. (ed.). Pittsburg, Pennsylvania. U.S. Steel Company, 1971. 72 ------- BY-PRODUCTS RECOVERY PROCESS NO. 19 Crystallization and Filter Drying 1. Function - The ammonium sulfate crystals precipitated in the crys- tal! izer accummulate as a slurry in the bottom. The slurry is removed from the crystal!izer and pumped to the slurry tank where the salt settles the liquid overflows and returns to the ammonia absorber. Prom this tank crystal sulfate slurry is fed to centrifugal dryers or a rotary filter dryer. In the rotary filter dryer, the liquor fs removed and hot air, under slight vacuum, dries the sulfate. The liquor is pumped back to the ammonia absorber. Chemically pure ammonium sulfate is a white salt that contains 25.78 percent ammonia. The commercial salt varies in color from white to tan and contains 25.0 to 25.7 percent ammon- ia. The final dried material contains approximately 0.1 percent water. The free acid content of the finished sulfate ranges from 0.05 to 0.3 2 percent by weight. 2. Input Materials - Solution from absorber. 3. Operating Parameters - The hot air to the dryer is maintained under slight vacuum. 4. Utilities - Not available. 5- Waste Stream - A fine mist of sulfuric acid may be evolved. 6. EPA Source Classification Code - None exists. 7. References - 1. Manufacture of Metallurgical Coke and Recovery of Coal Chemicals, In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 168-170. 2, Ammonia and Ammonium Salts. Chapter 10. In: Coal, Coke and Coal Chemicals. Chemical Engineering Series, New York, McGraw-Hill Co., Inc., 1950. 73 ------- BY-PRODUCTS RECOVERY PROCESS NO. 20 Light Oil Recovery 1. Function1- The gases leaving the ammonia absorber at 50 to 60°C are cooled to 20°C in a tower by direct contact with water. The gas is then scrubbed in a tower with petroleum wash oil which removes the light oil from the gas. The gas, free from all by-products, then flows to the gas holder. The wash oil, enriched with 2 to 3 percent light oil, is preheated to a temperature of 100 to 140°C and then distilled with direct steam to remove about 90 percent by volume of light oil. The mixture of light oil and steam passes out the top of the still through separators which remove water, and finally through a condenser to crude storage. The debenzolized wash oil leaving the bottom of the still is cooled and the water and impurities are removed. The oil is recirculated to the gas absorber. The light oil is a clear yellow brown oil containing well over a hundred constituents, most of them in very low concentrations. Princi- pal usable constituents are benzene (60-85%), toulene (6-17%): xylene (1-7%) and solvent naphtha (0.5-3%). Light oil constitutes approximately 1 percent of the coal carbonized. 2. Input Materials - Gas from the absorber, water and petroleum wash oil. Wash oil comsumption may run 0.07 to 0.1 kilogram per ton of coal carbonized, while a circulation rate of 400 to 800 liters per ton of coal carbonized may be used. About 80 grams of steam are used per liter 2 of wash oil in the stripping still. 3. Operating Parameters - Temperature of the gas entering the scrubber is 15 to 30°C. Temperature of the wash oil entering the process is 17 to 32°C. The petroleum wash oil normally used for this absorption pro- cess has a boiling range of 270 to 350°C. 4. Utilities - Approximately 1400 kilograms of steam at 14.0 kg/sq. cm. (200 psig) and 38°C superheat are required for a plant with 2800 tons 2 of coking capacity. 5. Waste Stream - Some particulate is evolved. Liquor containing tar is disposed of, but quantities generated are not available. 6. EPA Source Classification Code - None exists. 74 ------- 7. References - 1. Manufacture of Metallurgical Coke and Recovery of Coal Chemicals. In: The Making, Shaping, and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company. 1971. p. 165-177. 2. Ess. T.J. The Modern Coke Plant. Iron and Steel Engineer. C3-C36, January 194&. 75 ------- BY-PRODUCTS RECOVERY PROCESS NO. 21 Fractionation and Refining of Light Oil 1. Function - Light oil may be sent to a secondary products recovery plant that produces benzene, toluene, xylene and other compounds. The light oil fraction is washed with concentrated sulfuric acid, neutra- lized with an alkali, and fractionated into desired products. Fractionating and refining of light oil is accomplished over a considerable range of temperatures. The light oil charge is heated in a still by gra- dual increase in temperature. At a still temperature of 65°C, a product containing benzene, and some carbon bisulphide is evolved. At 80°C, a product of crude benzene is evolved; at 110°C, crude toluene; at 120 to 140°C, light solvent naphtha; and at 150°C, heavy solvent naphtha. The residue in the still is wash oil and naphthalene, the latter solidifying when cooled. Usually complete fractionation is not carried out; three fractions are more usual. When pure compounds are required the fractions may be redistilled. About 60 percent of the light oil produced is refined at coke plants. The principal products are: benzene, toluene and xylene. The 9 remainder of the light oil is sold to other processors. 2. Input Materials - Light oil. 3. Operating Parameters - Fractionation is carried out at temperatures from 65 to 140°C. 4. Utilities - No data available. 5. Waste Streams - Wastes from refining light oils include acid and alkali after washing light oil with sulfuric acid and caustic soda. Particulate is also emitted. 6. EPA Source Classification Code - None exists. 7. Reference - 1. Ess, T.J. The Modern Coke Plant. Iron and Steel Engineer C3-C36, January 1948. 76 ------- 2. Perch, M., and R.E. Muder. Coal Carbonization and Recovery of Coal Chemicals. In: Riegel's Handbook of Industrial Chemistry, Seventh Edition, New York, Van Nostrand Reinhold, 1974. p. 103-206. 3. Gollmar, H.A. Coke and Gas Industry. Industrial Engineering Chemistry. 39:596-601, May 1947. 77 ------- PIG IRON PRODUCTION. Figure 4 illustrates the pig iron production in a blast furnace, A very limited amount of iron is porduced as sponge iron by another method i ','; , -1.,- ' '" ' -;' "'' ' '- called direct reduction. Due to its limited application, this method is not described in this report. 78 ------- AGGLOMERATED ORE PRODUCT (FIGURE 1) IRON ORE MISC. RETURNS SLAG FLUX FUEL OXYGEN COKE (FIGURE 2) BLAST FURNACE 22 Figure 4. Pig iron porduction. Note: Material handling and storage which is not shown on the flow sheet is required throught pig iron production and has fugitive emissions, liquid waste, and solid waste. 9 GASEOUS EMISSIONS ^ LIQUID WASTES SOLID WASTES ------- PIG IRON PRODUCTION PROCESS NO. 22 Blast Furnace 1. Function - The agglomerated product and ore are stockpiled. In colder climates three to four months supply is stored. From storage, it is moved to surge hoppers at the blast furnace where it is weighed and transferred to the top of the blast furnace by skip hoist or by belt con- veyor. Coke, and limestone used in blast furnaces are not stored near the furnace area in large quantities, and if possible, are consumed dir- ectly as the are received. Charging of the furnace is automatically controlled. The blast furnace reduces the iron ore to produce pig iron. Iron- bearing materials (iron ore, sinter pellets, mill scale, iron or steel scrap), coke, and fluxes (limestone;and others) are charged into the top of the furnace in a fixed pattern of coke to ore to stone. The heated blast air is introduced into the furnace above the hearth line through tuyeres. In some instances fuel oil, powdered coal, natural gas or oxygen is blown into the bottom. The iron ore descends down the furnace and is reduced and melted by the countercurrent flow of hot reducing gases created by the partial combustion of coke. Hot metal from the fur- nace is tapped into torpedo cars and weighed on the hot metal track scale. After the metal is transferred to a charging ladle, a crane transports it to the steelmaking vessel. Molten slag is removed from the furnace through separate tapping holes which are at an higher elevation than the molten iron tap hole. The slag discharged from the blast furnace is col- lected in slag pits or slag timbles. The hot molten pig metal typically contains 4.1 percent C, 0.9 percent Si, 0.026 percent S, 0.296 percent P and 0.35 percent Mn. Analysis of limestone and coke used in blast fur- naces is given in Tables A-4 and A-5, Appendix A. 2. Input Materials - In the United States in 1973, an average of 1.676 tons of metalliferous materials wer consumed in blast furnaces for each 2 ton pig iron produced. Table 28 lists approximate inputs and outputs of one blast furnace. 80 ------- Table 28. EXAMPLE OF BLAST FURNACE MATERIAL BALANCE Material Weight, tons'* INPUTS Iron bearing burden Iron ore Flux sinter Scrap Flux Limestone Gravel Fuel Coke Natural gas Blast Air Moisture OUTPUTS Hot metal Slag Runner scrap Top gas Moisture Dust and sludge 0.3075 1.226 0.099 0.008 0.008 0.514 0.021 (0.027 million liters) 1.639 (1.254 million liters) 0.016 (0.019 million liters) 1.0 0.25 0.006 2.461 (1.8 million liters) 0.079 (0.093 million liters) 0.042 * Metric tons (1000 kg) 81 ------- 3. Operating Parameters - The furnace operates at about 1540°C. Many of the older furnaces operate at top-pressures of about 7030 kgs/sq meter (10 psii). Newer plants operate at top-pressures of 14,060 kgs/sq meter (30 psi) and future furnaces at 42,200 to 49,200 kgs/sq meter (60 to 70 psi).3 4. Utilities - Table 29 shows the daily utility requirements of a typi- 1 4 cal two-furnace plant. ' This blast furnact plant operation consumes an average of 50.7 kilowatt-hours of electricity per ton of pig iron pro- duced. This blast furnace plant requires an average of 429 liters per second per blast furnace for recirculation, make-up and service water. In addition to this amount, 658 liters of water per second per furnace are needed for boiler house, turbine, condenser, and use as potable water. 5. Waste Streams - Particulate emissions from blast furnaces are mini- mal since a high degree of particulate emission control is necessary to keep the stoves (heat exchangers) from plugging. Without controls, about 5 75 kilograms of particulate per ton of product is emitted. Particulates are also emitted during each tap, and these emissions enter the atmos- phers by passing through the sides and roof of the cast house. Blast furnace slips, which create emissions that bypass the control devices, occur occassionally. Table 30 presents composition data for collected fi fi blast furnace dust; Table 31 gives a size analysis of the dust. The collected dust is usually utilized as feed to the sinter machine. Com- position and size distribution of particulates escaping to the atmosphere were not available. About 6 tons* of gases are evolved for every ton of iron produced from the blast furnace. Table 32 gives an analysis of gases produced at one plant. Heating value of the raw gas (produced at the plant mentioned in Table 32) is 800 kilocalories per cubic meter (90 Btu/ft3) and the mois- ture content is 2 percent. The gases leave the furnace with a dust con- centration of 27.5 grams per cubic meter (12 grains per cubic foot). Part of this gas is used for heating purposes. The gases leave the furnace at temperatures of 180 to 280°C. The flow rate of the gases is a function of the coke feed rate. Total gas volume increases linearly with increase of the coke feed rate. * Metric tons (1000 kg) 82 ------- CO co Table 29. UTILITIES REQUIREMENTS OF A SELF-CONTAINED BLAST-FURNACE PLANT WITH TWO FURNACES, PRODUCING A TOTAL OF 3810 NET TONS* OF HOT METAL PER DAYa Utility Recirculating water Make-up water Other service water Water to utilities (boiler house, turbine condensers, etc.) Potable water Coke-oven gas Natural gas for heat Natural gas for heat (3 months) Boiler house fuel Fuel oil Blast-furnace gas Compressed air at 5.6 kgs/sq. .cm. (80 psi) Steam at 14.1 kgs/sq. cm. (200 psi) and 38°C (100°F) superheat AC electricity - purchased DC electricity - own-produced Quantity required daily English 16,012,800 gal. 259,200 gal. 3,326,400 gal. 29,952,000 gal. 72,000 gal. 1,008,000 cu. ft. 172,000 cu. ft. 20,448,000 cu. ft. 172,800 gal. 446,400,000 cu. ft. 1,152,000 cu. ft. 9,600,000 Ib 151,200 kilowatt hours 42,000 kilpwatt hours Metric 60.61 x 10° liters 0.981 x 106 liters 12.59 x 106 liters 113.37 x 106 liters 0,273 x 106 liters 28.55 x 103 cubic meters 4.87 x 103 cubic meters 0.579 x 10 cubic meters 0.654 x 106 liters 12.640 x 10 cubic meters Q 32.63 x 10 cubic meters 4,354,560 kilograms 151,200 kilowatt hours 42,000 kilowatt hours a Volumes of gases refer to 16°C (60°F) and 1 kg/sq. cm. (30 in. Hg), unless otherwise specified. * Metric tons (1000 kg) ------- Table 30. CHEMICAL COMPOSITION OF DRY, BLAST-FURNACE FLUE DUST Component3 Iron Ferrous oxide Silicon dioxide Aluminum oxide Magnesium oxide Calcium oxide Sodium oxide Potassium oxide Zinc oxide Phosphorus Sulfur Manganese Carbon Weight percent Range for several plants 36.5 - 50.3 N.A. 8.9 - 13.4 2.2 - 5.3 0.9 - 1.6 3.8 - 4.5 N.A. N.A. N.A. 0.1 - 0.2 0.2 - 0.4 0.5 - 0.9 3.7 - 13.9 Midwest plant 47.10 11.87 8.17 1.88 0.22 4.10 0.24 1.01 0.60 0.03 N.A. 0.70 N.A. N.A. - not available a Tests on blast furnace scrubber samples from a plant in Midwest Indiana, showed the presence of cadmium 14 ppm.4 84 ------- Table 31. SIZE ANALYSIS OF FLUE DUST FROM U.S. BLAST FURNACES3 Size U.S. series sieve 20 30 40 50 70 100 140 200 -200 Microns 833 589 , 414 295 208 147 104 74 -74 Range, percent 2.5 - 20.2 3.9 - 10.6 7.0 - 11.7 10.7 - 12.4 10.0 - 15.0 10.2 - 16.8 7.7 - 12.5 5.3 - 8.8 15.4 - 22.6 Dust collected in participate control devices. Table 32. ANALYSIS OF FURNACE GAS Constituent co CO CH Percent by volume 15.8 25.6 3.0 85 ------- Dry cyclones, wet scrubbers, and electrostatic precipitators are used for controlling emissions from blast furnaces. Venturi scrubbers or electrostatic precipitators clean blast furnace flue gas to a parti- culate concentration of 0.023 grams per cubic meter.8 Wastewater from the blast furnace plant includes furnace cooling water and scrubber water. The furnace cooling water leaves the furnace and scrubber water. The furnace cooling water leaves the furnace essentially as received except for the heat added. The scrubber water contains mainly ammonia, phenol, cyanide, fluorides, and carbon monoxide. 9 Table 33 shows typical liquid waste emission rates. Slag from the blast furnace is tapped periodically. The slag is handled usually in one of four ways: directly into cinder ladles and conveyed to a dump area or to other nearby processors; granualted; direct- ly to cooling pits; or into lightweight aggreagate. Slag contains sul- fide compounds that are f.-ntted during quenching. Approximately 0.25 of slag are produced for each kg. of pit iron. 6. EPA Source Classification Code - Blast furnace ore charging - 3-03-008-01. Blast furnace agglomerates charging - 3-03-008-02. 7. References - 1. The Manufacturing of Pig Iron. In: The Making, Shaping and Treating of Steel, Ninth Edition. McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 428 2. Reno, H. T. Iron and Steel. In: Minerals Yearbook, Bureau of Mines, Washington, D.C., Government Printing Office, 1973. 3. Uys, J. M., and J. W. Kirkpatrick. The Beneficiation of Raw Materials in the Steel Industry and Its Effects upon Air Pollution Control. Journal of Air Pollution Control Associa- tion, p. 20-27, January 1963. 4. Yost, K.J. et al. Purdue University. Flow of Cadmium and Trace Metals. Volume I. National Science Foundation. Project Number PB-229478. June 30, 1973. 86 ------- Table 33. POLLUTANTS IN WASTEWATER FROM BLAST FURNACE Waste material Suspended solids, kg Phenols, gms/ton Cyanides, gms/ton^ Fluorides, gms/ton Ammonia, gms/ton^ Old planta /tond 28.2 7.8 9.9 16.4 7.8 Typical plant- 22.2 7.3 9.4 15.3 7.3 Advanced plant0 37.9 7.4 9.4 15.3 7.4 a Utilizing older, relatively inefficient processing technology. May have more than one blast furnace with daily capacities of 1000 tons* of iron. c Operating at an advanced technology, has one or more blast fur- naces with daily capacities of 1000* tons or more iron and fully automated with raw materials fed under computer control. d Per metric ton of pig iron product 87 ------- 5. Iron and Steel Mills. In: Compilation of Air Pollution Emission Factors. Environmental Protection Agency. Contract Number CPA-22-69-119. April 1973. p. 7.5-4. 6. Varga, J. Jr., and H. W. Lownie. Final Technological Report on A Systems Analysis Study of the Integrated Iron and Steel Industry. Battelle Memorial Institute, Columbus, Ohio. May 1969. 7. Labee, C. J. Steel Making at Weirton. Iron and Steel Engineer. October 1969. 8. Bramer, H. C. Pollution Control in the Steel Industry. Environmental Science and Technology. 1004-1008, October 1971 9. Industrial Waste Profiles No. 1 - Blast Furnace and Steel Mills. Volume III. The Cost of Clean Water. Federal Water Pollution Control Administration. FWPCA Contract Number 14- 12-98. September 28, 1967. p. 55. 88 ------- STEEL PRODUCTION Pig iron is refined into steel in furnaces by reducing the level of impurities, carbon content, and adding alloying compounds. Modern steelmaking processes utilize a large percentage of steel scrap in addi- tion to molten pig iron and various alloying compounds. Molten steel from the furnaces is usually teemed tnto ingot molds for further process- ing. The ingots are then subjected to roughing and finishing operations. Figure 5 illustrates the processes of steel manufacturing. The three basic types of steel furnaces are in use: electric, open- hearth, and basic oxygen. A significant number of open-hearth and elec- tric furnaces also incorporate oxygen lancing because it permits higher production rates. The four majon phases of furnace operations are charg- ing, meltdown, refining, and teeming. Atmospheric emissions vary substantially among these phases of fur- nace operation and are increased by the use of oxygen lancing. From the standpoint of potentially hazardous emissions, however, the composition of furnace emissions is primarily a function of the grade of steel being produced (i.e., the amount and type of alloying compounds charged to the furnace) and the scrap metal charge. Tables F-l through F-3, Appendix F give details of types and numbers of steel furnaces and their capacities in the United States. 89 ------- r (MTMB: TW. IMC. CMKM»«nc« win r*a lIKJ-URt «.lf»I15 wi^lfcs KU» Figure 5, Steel production 9 GASEOUS EMISSIONS ^ LIQUID WASTES A SW.ID HASTES ------- STEEL PRODUCTION PROCESS NO. 23 Electric Furnace 1. Function - Two types of electric furnaces, the arc furnace and the induction furnace, are used to produce steel. The arc furnace is used to produce high-alloy steels, as well as a considerable amount of mild steel. The induction furnace produces primarily speciality and high alloy steels with no real emission problems and therefore is omitted in the re- mainder of this report. Cranes with special designed drop-bottom buckets are used to charge raw materials and alloying materials into the furnace. Charging is done usually through the swing-out roof of the arc furnace. Some units are charged through their doors or openings or via a chute. Practically all modern arc furnaces for steel making are top-charged. At the time of charg- ing, the electrodes are moved out of the way. After charging of the molten metal, light and heavy scrap, alloying material, and fluxes, the furnace roof is returned to close the arc furnace and the electrodes are lowered 2 to about 2.5 centimeters above the charge. Many times a bank is built in front of the arc furnace doors with refractory material (dolomite) to form a dam that keeps molten metal from slopping out of the doors. As current is applied through the electrodes, the charge is melted. Oxi- dation occurs in varying degrees, from the time molten metal begins to form, until l;he entire charge is in solution. During this period phos- phorus, silicon, manganese, carbon, and other materials are oxidized. Slagging commences to form and is carefully controlled throughout the operation. Oxygen lancing is often used to increase production rates. At the end of the process, the electrodes are raised. In taping, depend- ing on the type of furnace, fixed or tilting, the tap hole is opened or the furnace is tilted so that the steel is tapped from the furnace into a ladle. Slagging practice varies from shop to shop. Slag removal may be done prior to tapping, during, or at the end of the tap. A crane moves the ladle either to the pouring platform, where the steel is poured into molds, 2 or to continuous casting, or to a vacuum-degassing station, or to a gas- 91 ------- eous decarburization vessel (ADD). 2. Input Materials - Table 34 gives production data for a particular 3 electric furnace shop. Because of their current-carrying capacity, graphite electrodes are used almost exclusively in electric steelmaking furnaces. 3. Operating Parameters - The charge is tapped at 1570°C, but if vacuum degassing or other processes follow the tapping temperature could be as much as 100°C higher. Table 35 gives operating data of a particular 3 electric furnace shop. The furnace operates at essentially atmospheric pressure. 4. Utilities - The utilities required vary considerably depending on a number of factors: practice; furnace size; product grade; vacuum de- gassing or other processes following. Table 35 gives the power require- 3 ments for a particular e^ctric furnace. Depending on furnace efficiency, and hot metal practice, electric furnace requires about 247 to 375 kilo- 5 2 watt-hours of power per ton of steel produced. Approximately 50 to 75 liters of cooling water per second is required.' 5. Waste Streams - Particulate emissions from electric furnaces con- sist primarily of oxides of iron, manganese, aluminum, calcium, magnesium and silicon. Tables 36 and 37 present typical data on composition of 4 emissions from some electric furnaces. Many new electric furnace instal- lations use baghouses for controlling emissions. Table 38 gives parti- C -7 o cle size distribution of emissions from an electric-arc furnace. The uncontrolled particulate emission rate is approximately 4.6 kilograms per metric ton of metal without oxygen lancing and about 5.5 kilograms per ton of metal produced with oxygen lancing. Other emissions inclu'de gaseous fluorides at 0.006 kilogram per ton* arid particulate fluoride g at 0.119 kilogram per ton* of metal produced. ! Depending upon the amount of pig iron used in the charge, about 9 Q kilograms of carbon monixide gas is emitted per ton* of metal produced. The gases generated during the meltdown and refining steps of furnace Metric ton (1000 kg) 92 - ------- Table 34. PRODUCTION DATA FOR A PARTICULAR ELECTRIC FURNACE SHOP Charge, kg Hot metal charge Total charge Burnt lime Raw limestone Number of charges Net ingot per heat Percent hot metal Percent yield Practice Cold charge 0 181,400 3,600 6,000 3 164,835 0 90.4 35% hot metal 63,500 181,400 3,600 6,400 2 161,387 34.8 88.5 50% hot metal 90,700 181,400 3,600 6,400 1 159,845 49.8 87.7 TABLE 35. OPERATING DATA FOR A PARTICULAR ELECTRIC FURNACE SHOP Practice Charge kWh per heat 02 per heat, liters kWh per net ingot 02 per net ingot, liters Tap to tap hr per heat Ingot tons per tap to tap hr Number of heats per roof Number of heats per side wall Kilograms electrodes per net ingot tons (metric) Cold charge 75,000 3,346,000 375 18,400 4.58 36.02 90 105 4.76 35% hot metal 53,100 3,158,000 263 17,800 3.58 45.09 70 95 4.13 50% hot metal 48,000 4,769,000 247 27,100 3.17 50.44 60 90 4.13 93 ------- Table 36. CHEMICAL COMPOSITION OF ELECTRIC FURNACE DUSTS (percent by weight) Element or Compound FeO Fe2°3 Cr203 MnO NiO PbO ZnO Si02 A1203 CaO MgO S P C Alkalies Sample designation A 4.2 35.04 0.00 12.10 0.30 N.A. N.A. 8.80 12.90 14.90 7.90 0.26 0.10 2.30 1.20 B N.A. 50.55 0.56 12.22 N.A. N.A. N.A. 5.76 5.85 2.60 7.78 tr 0.28 N.A. 4.76 C N.A. 52.62 0.00 5.34 tr 3.47 8.87 6.78 2.55 6.72 3.49 0.59 N.A. N.A. N.A. D N.A. 52.05 0.15 1.29-2.58 tr 0.81-1.08 1.24-2.48 3.85 14.61 1.40-4.20 1.66-4-98 N.A. N.A. N.A. N.A. E N.A. 50.05 13.87 N.A. 3.18 N.A. N.A. 5.50 N.A. 9.80 6.64 N.A. N.A. N.A. 2.50 F 4 - 10 19 - 44 0-12 3-12 0-3 0-4 0-44 2 - 9 1 - 13 5-22 2-15 0 - 1 0 - 1 2 - 4 1 - 11 Note: N.A. - not available, tr - trace Sample A - Single 20-ton furnace. Plant specializing in tool and die steels. Sample B - Representative sample from plant with four 75-ton and two 200-ton furnaces producing low-alloy and stainless steels, Sample C - Single 100-ton furnace producing low-alloy steels for plate. Sample D - Single 100-ton furnace producing low-alloy steels for plate. Sample E - Single 70-ton furnace producing stainless steel. Sample F - Representative samples from multiple-furnace shop. Furnaces vary in size from 4 to 200 ton producing low- alloy and stainless steels. 94 ------- Table 37. CHANGES IN COMPOSITION OF ELECTRIC FURNACE DUST DURING A SINGLE HEAT Product Melting Ore oxidation Oxygen lancing Refining Composition, weiqht percent Fe203 56.75 66.00 65.37 26.60 Cr203 1.32 1.32 0.86 0.53 MnO 10.15 5.81 9.17 6.70 Si02 9.77 0.76 2.42 tr CaO 3.39 6.30 3.10 35.22 MgO 0.16 0.67 1.83 2.72 A1203 0.31 0.17 0.14 0.45 P2°5 0.60 0.59 0.76 0.55 so2 2.08 6.00 1.84 7.55 Table 38. PARTICLE SIZE DISTRIBUTION OF EMISSIONS FROM A PARTICULAR ELECTRIC-ARC FURNACE (percent by weight) Size, microns 0-3 0-5 3 - 11 5-10 n - 25 10 - 20 >25 20 - 44 >44 Reference 9 71.9 8.3 6.0 7.5 6.3 10 67.9 6.8 9.8 9.0 6.5 11 18 64 7 n 95 ------- operation are collected at temperatures ranging from 650 to 980°C. As stated earlier, emission composition is dependent upon the type of steel produced and composition of the charge. Some spilling may occur when the slag is transferred to slag pro- cessing operations. Particulate collected in the emission control systems is sometimes recycled to the sintering operation (much of it not recyclable because of zinc contamination). Water pollution is not a problem unless a scrubber is used, at which time high solid loadings are encountered. Occasionally, extremely high contents of suspended solids, on the order of 5000 ppm, may be present in the cooling water. 6. EPA Source Classification - Electric-arc furnace with lancing - 3-03-009-04. Electric-arc furnace without lancing - 3-03-009-05. 7. References - 1. Yard, E. M., and P. D. Nyajust. Open-Hearths Replaced by Electric Furnaces. Iron and Steel Engineer. 72-75, July 1967. 2. Electric Furnace Steelmaking. In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H. E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 549- 583. 3. Rankin, W. M. Electric Furnace Steel Production, Houston Works, Armco Steel Corp. Journal of Metals 104-107, May 1968. 4. Varga, J. Jr., and H. W. Lownie. Final Technological Report on a Systems Analysis Study of the Integrated Iron and Steel Industry. Battelle Memorial Institute, Columbus, Ohio. May 1969. 5. Bramer, H.E. Pollution Control in the Steel Industry. Environmental Science and Technology. 1004-1008, October 1971. 6. Coulter, R. S. Smoke, Dust, Fumes Closely Controlled in Electric Furnaces. Iron Age. January 14, 1954. 7 Erickson, E. 0. Electric Furnaces Steel Proceedings. 11: 156-160 (1953). 96 ------- 8. Dok, H. Journal of Air Pollution Control Association. 5:23- 26 (1955). 9. Iron and Steel Mills. In: Compilation of Air Pollutant Emission Factors. Environmental Protection Agency, Research Triangle Park, N.C. Contract Number CPA-22-69-119. April 1973. p. 7.5-5. 10. Brough, J. R., and W. A. Carter. Air Pollution Control of an Electric Furnace Steel Making Shop. Journal of Air Pollution Control Association. 167-171, March 1972. 11. Miller, J. R. Impurities in Iron Ore, 1004-1008, Battelle Memorial Laboratories, Columbus, Ohio. 97 ------- STEEL PRODUCTION PROCESS NO. 24 Open-Hearth Furnace 1. Function - Open-hearth furnaces accounted for 26.4 percent of steel production in 1973. Although oxygen lancing is widely used to increase open hearth production rates, electric furnaces and basic oxygen furnaces (EOF) are currently preferred. An open-hearth furnace can produce 30 to 60 tons* of steel per hour compared with 300 or more tons* of steel per hour in a BOF. The feed, consisting of limestone, light and heavy scrap, and normal- ly molten pig iron, is charged to the reverberatory furnace and heated. Cold pig iron is used when molten pig iron is not available. In normal practice a predetermined quantity of iron ore is charged to provide low- cost iron units and oxygen for controlling the carbon content of the bath when the charge is melted. Silica, manganese, phosphorus, and sul- fur impurities are oxidized and form into slag. The oxidized forms of chromium, vanadium, aluminum, titanium, tungsten, columbium, and zinc may also be present in the slag. The elements that may be present, such as copper, nickel, molybdenum, cobalt, tin, and arsenic are held in the iron because iron would have to be completely oxidized before these ele- ments could be removed by oxidation. Some carbon in the charge is con- verted to carbon monoxide. Calcination of limestone produces carbon dioxide. When the molten steel bath is analytical at the grade of steel required, the molten contents of the furnace are tapped through the tap hole into the steel ladles. The alloying, recarbonizing, and deoxidizing materials are added to the molten metal before the slag starts flowing. The molten metal is poured into ingot molds for the particular final 2 product. Slag is tapped into slag pots. 2. Input Materials - Limestone, scrap, pig iron, molten iron, oxygen and alloying, recarbonizing and deoxidizing agents are used. The amounts of hot metal (molten pig iron) and scrap in the charge vary depending on availability of metal and scrap. The amount of iron ore charged in- * Metric tons (1000 kg) 98 ------- creases with the amount of molten iron used. Limestone varies from 5 to 8 percent of the metallic charge. Oxygen consumption ranges from 6,000 to 12,000 liters per ton* during oxygen lancing, with corresponding saving in tap to tap time of 10 to 25 percent and a decrease in fuel 2 consumption of 18 to 35 percent using oxygen roof lances. 3. Operating Parameters - The finishing temperature of steel in an open-hearth steel furnace is about 1595°C, varying according to com- 2 position and grade of steel. The time required for charging and 3 melting down of the scrap ranges from 2 to 4 hours. 4. Utilities - Heat is usually supplied by combustion of fuel oil.natur- al gas, tar, or combinations of these. Table 39 gives a typical heat 2 balance of modern open-hearth furnace. About 21,000 liters of water per ton of finished steel is used at open-hearth furnace plants; most of it is for indirect cooling. The furnace consumes about 8 kWh of elec- 2 tricity per ton* of ingot produced. Table 39. HEAT BALANCE OF A MODERN OPEN-HEARTH FURNACE, kcal/ton* OF STEEL Heat input Heat supplied to the furnace by the combustion of fuel Heat originating by chemical re- actions in the bath Total Quantity 890,000 110,000 1,000,000 Heat output Sensible heat lost in stack gases Heat absorbed and utilized for plant use. Heat actually used to make steel Heat lost by radia- tion, escape of hot gases through doors etc., through system. Quantity 150,000 267,000 250,000 333,000 1,000,000 * Metric ton (1000 kg) 99 ------- 5. Waste Streams - Emissions from each open-hearth furnace depend upon the furnace operation and type of charge in each furnace; and may vary during the cycle and from cycle to cycle. Emissions from open- hearth operations include particulates anf fluorides. Fluoride emission rates depend on the fluorspar content of the fluxes. Uncontrolled par- ticulate emissions from a furnace without oxygen lancing are about 4.2 kilograms per ton of product; with oxygen lancing, emissions range from 4.7 to 11.0 kilograms per ton*. These emissions include 50 grams of gaseous fluoride and 15 grams of particulate fluorides per ton of pro- duct. Tests conducted at major northwest Indiana steel plant showed a particulate concentration of 0.204 grams per cubic meter in a stack gas with a flow rate of 742 cubic meters per minute. The flow rates of gases range from 300 to 2100 cubic meters per minute. Gas temperatures range from 240 to 980°C; gases must be cooled before entering air pollution control equipment. Table 40 presents typical dust loadings of gas flow at different Q times of the meltdown. Table 40. PARTICULATE EMISSION - UNCONTROLLED Function Meltdown Hot melt addition Lime boil Oxygen lancing Refining Gas flow rate, cu meter/sec 28 30 31 - 30 Dust loading, grams/cu meter 1.78 4.30 6.18 Up to 11 0.48 Table 4] gives particle size distribution from open-hearth furnaces and Table 42 presents data on chemical composition of particulate emissions. ' * Metric ton (1000 kg) 100 ------- Table 41. PARTICLE SIZE DISTRIBUTION OF EMISSIONS FROM OPEN-HEARTH FURNACES (percent) <5y 50 46 50-55 5-10y 22 25-30 10-20y Balance 17 15-20 >20u Few 15 Bal According to one Russian report, gases from steelmaking open-hearth furnaces contain very small amounts of carcinogens due to the high 12 temperature occuring in the furnace. Electrostatic precipitators (98% removal efficiency) are the prin- cipal choice for emission control, although venturi scrubbers and bag- 12 houses (99% removal efficiency) are also used. About 8.5 to 10 kilograms of solid waste (dust collected in solid forms) per ton* of steel are generated. Depending on the amount of other metals present, such as zinc, this dust may be discarded or re- turned for sintering. The only potential water pollution source occurs when a scrubber is used to control emissions. The other source of waste water is the blowdown from the waste heat boiler if used. 6. EPA Source Classification Code - Open-hearth with oxygen lancing - 3-03-009-01. Open-hearth without oxygen lancing - 3-03-009-02. 7. References - ^ * 1. Reno, H. T. Iron and Steel. In: Minerals Yearbook, Bureau of Mines. (Preprint from the 1973) Washington, D.C., U.S. Government Printing Office, 1973. 2. The Making, Shaping and Treating of Steel, Ninth Edition. McGannon, H. E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 525, 534, 635. * Metric tons (1000 kg) 101 ------- Table 42. CHEMICAL COMPOSITION OF OPEN-HEARTH PARTICIPATE EMISSIONS, OXYGEN LANCING (percent by weight) Element or Compound Fe2°3 FeO Total Fe Si02 A1203 CaO MgO MnO Mn CuO Cu ZnO Zn PbO Pb Sn02 Cr Ni P2°5 P S Alkalies U.S. Steel Corp. Edgar Thomson 89.07 1.87 63.70 0.89 0.52 0.85 n.a. 0.63 n.a. n.a. n.a. n.a. 1.70 n.a. 0.50 n.a. n.a. n.a. 0.47 n.a. 0.40 1.41 Homestead 88.70 3.17 n.a. 0.92 0.67 1.06 0.39 0.61 n.a. 0.14 n.a. 0.72 n.a. n.a. n.a. n.a. n.a. n.a. 1.18 n.a. 0.92 n.a. Steel Co. of Canada Hilton Works n.a. n.a. 63.5 - 68.0 1.16 - 1.56 0.15 - 0.44 0.68 - 1.06 0.32 - 0.44 n.a. 0.43 - 0.55 n.a. 0.11 - 0.16 0.26 - 2.04 n.a. n.a. 0.50 - 0.95 n.a. 0.06 - 0.11 0.03 - 0.05 n.a. 0.06 - 0.12 0.34 - 0.70 0.56 - 1.71 United Kingdom United Steel Co. 88.5 2.2 n.a. 0.4 0.4 0.9 1.5 n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. 0.3 1.4 n.a. Germany Dillingen 79.65 0.31 55.90 0.47 0.52 0.88 1.86 0.61 n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a. 1.52 n.a. 2.69 2.72 U.S. plant9 n.a. n.a. 59.40 2.00 0.48 1.85 1.12 n.a. 0.28 n.a. 0.08 n.a. 0 - 3.0 n.a. n.a. n.a. n.a. 0.07 n.a. 0.15 2.78 2.88 n.a. - data not available aAverage for U.S. Plant. ------- 3. Midwest Research, Inc. Particulate Pollutant System Study. Volume III. Handbook of Emission Properties. Contract Number CPA-22-59-104. May 1971. 4. Bramer, H. C. Iron and Steel. Chapter 14. In: Industrial Waste Water Control, Chemical Technology, A Series of Mono- graphs. - Volume 2, Gurnham, C. F. (ed.). New York, Academic Press. 1965. 5. Iron and Steel Mills. In: Compilation of Air Pollutant Emission Factors. Environmental Protection Agency, Research Triangle Park, N.C. Contract Number CPA-22-69-119. April 1973. p. 7.5-4. 6. Yost, K. 0. et al. Purdue University. The Environmental Flow of Cadmium and Other Trace Metals: Volume 1. National Science Foundation. Publication Number PB-229 478. June 30, 1973. 7. Engineering Science, Inc. Exhaust Gases from Combustion and Industrial Processes. Washington, D.C., October 1971. 8. Varga, J. Jr., and H. W. Lownie. Source of Air Pollution. In: Final Technological Report on A System Analysis Study of the Integrated Iron and Steel Industry, Battelle Memorial In- stitute, Columbus, Ohio. Contract Number PH 22-68-65. De- partment of Health, Education, and Welfare. May 15, 1969. V-ll p. 9. Bishop, C. A. Some Experience with Air Pollution Abatement In the Steel Industry. Blast Furnace Steel Plant. 40:1448-1453, December 1952. 10. Bishop, C. A., W. W. Campbell, D. L. Hunter, and M. W. Light- ner. Successful Cleaning of Open-Hearth Exhaust Gas with a High-Energy Venturi Scrubber. Journal of Air Pollution Con- trol Association. February 1961. 11. Schneider, R. L. Engineering, Operation and Maintenance of Electrostatic Precipitators on Open-Hearth Furnaces. Journal of Air Pollution Control Association. 83-87, August 1963. 12, Shapritsky, V. N. Zashchita Atmosfery ot Zagryazneniya natserogennymi Veshchestvami. Controlling Atmospheric Car- cinogenics. Text in Russian. Stal., No. 10:961-963, 1972. 13. Wai den Research Corporation. Systems Study of Conventional Combustion Sources in the Iron and Steel Industry. Environ- mental Protection Agency. April 1973. 14. Ralth Stone and Co., Inc. Forecasts of the Air and Water Pol- lution Controls on Solid Waste Generation. Environmental Protection Agency. PB No. 238 819. December 1974. 103 ------- STEEL PRODUCTION PROCESS NO. 25 Basic Oxygen Furnace 1. Function - The basic oxygen process-BO F, (as well as moderation processes Kaldo or Q-BOF) is being used increasingly because of its high production rates, simplicity and efficiency of operation. The BOF is predominant. Molten iron from the blast furnaces is brought to the basic oxygen furnace shop in railroad submarine ladle cars and steel scrap is brought in by both rail and truck. Fluxes such as burnt lime, limestone, burnt dolomite and fluorspar are handled by conveyor. A furnace charge could be scrap (30%), molten iron (70%), and fluxes. Oxygen is introduced through a water cooled lance and is blown onto the charge under pressure generally from 9.84 to 12.66 kg/cm. The process converts the hot metal into steel by oxidation of carbon, phosphorus, silicon, sulfur, and other impurities in the iron. The steel is tapped into a teeming ladle and alloying materials are added. The slag is tapped into slag pots. The overhead crane removes the teeming ladle from the transfer car and the molten steel is teemed into ingot molds, or if continuous casting follows the teeming, the ladle is brought to the continuous casting aisle and located over the tundish and teemed; or to the vacuum degasser for removal of hydrogen and oxygen gases in the molten steel. The slag pot receives the slag from the BQF and is moved to the slag dump yard. 2. Input Materials - Molten iron, scrap, fluxes, oxygen and alloying agents are used. A hot metal to scrap ratio of 3.4 to 1 has been used, but varies from shop to shop dependent on availability of hot metal or scrap. Basically, the iron contains 0.2 to 2.0 percent silicon, 0.4 to 2.5 percent manganese, and up to 0.4 percent phosphorus. 3. Operating Parameters - The BOF process is exothermic and no additional heat is required. Refining occurs at approximately 2000°C at atmospheric pressure. 4- Utilities - Steelmaking with the basic oxygen furnace may require only 50 minutes, compared to 8 to 12 hours for the open-hearth furnace 104 ------- with the same tonnage. Electricity is required for the oxygen plant, vent gas fans, conveyors, furnace tilt mechanism, and other equip- ment. 5- Waste Streams - Particulate emission rates are so high that all basic oxygen units utilize high-efficiency particulate control devices. About 23 kilograms of particulate are produced per ton* of product, and about 0.1 kilogram of gaseous fluorides per ton.* Most of the furnace emissions are controlled by either venturi scrubbers of electrostatic precipitators.2 Table 43 gives the chemical composition of dust of three basic oxygen furnaces.3 The dust particles oxidize further outside the furnace vessels and produce fine red dust, whose size distribution is given in Table 44. Operation of basic oxygen furnaces may cause emission of flaking black material called "kish". Kish forms spontaneously whenever hot metal with carbon content greater than 4.5 percent is cooled below the liquid temperature. This results in the formation of solid Fe~C, which j- -5 is unstable and decomposes into graphite and iron. Usually the kish is formed when the hot metal is transferred into and out of the ladle. Gas effluents ranging from 944,000 to 570,000 liters/sec are emitted from the basic oxygen furnace at temperatures between 1600 and 1900°C. These gases carry 140 kilograms or more of oxide dust per minute. Most of the dust is very finely divided, the particles ranging in size from 0.1 to 1 micron.6 About 20 to 30 kilograms of Fe203 are ordinarily collected per ton of steel produced. Table 45 gives the calculated composition of gases leaving the furnace on the basis that Q there is 100 percent of blown oxygen converted to carbon monoxtde. Treatment of wastewaters from steelmaking by the basic oxygen process requires use of chemical coagulants or similar methods, which seldom can remove all particulate matter. Magnetic agglomeration has q proved to be particularly effective in treating BOF wastewaters.' 6. EPA Source Classification Code - BOF General - 3-03-009-03. * Metric tons (1000 kg) 105 ------- Table 43. CHEMICAL COMPOSITION OF BASIC OXYGEN FURNACE STEELMAKING DUST FROM THREE U.S. PLANTS, WEIGHT PERCENT Element or compound FeO Fe2°3 Fe Mn304 Mn Si02 A1203 CaO MgO S P P2°5 Cu Zn Typical 1.5 90.0 N.A. 4.4 N.A. 1.25 0.2 0.4 0.05 N.A. N.A. 0.03 N.A. N.A. BOF dust from U.S. plants N.A. 80.00 N.A. N.A. 0.35 2.00 0.15 5.10 1.10 0.12 0.10 N.A. 0.04 trace N.A. - N.A. 56.0 N.A. 1.2 1.9 0.4 3.1 N.A. 0.09 0.2 N.A. 0.03 1.93a N.A. N.A. 57.68 N.A. 1.54 1.29 0.13 3.59 0.63 0.12 0.09 N.A. N.A. 4.80a Note: N.A. - data not available The high zinc content in the dust is due to the use of galvani/ed steel scrap in the BOF charge. 106 ------- Table 44. PARTICLE SIZE DISTRIBUTION OF RED DUST FROM BASIC OXYGEN FURNACES Size of particle Smaller than 400 mesh From 140 to 400 mesh From 40 to 140 mesh Larger than 40 mesh Percent 74 10 15 1 About 40 percent of dust is smaller than 5 microns and 20 percent is less than 2 microns. Table 45. CALCULATED GAS COMPOSITION FOR 91-TON BOF BLOWN AT 6000 LITERS/SEC. (12,000 SCFM) 02 RATE FOR 20 MINUTES CO co2 °2 N2 Total Converter emissions Total heat kg 5,400 1,300 - - 6,700 1 i ters 456,000 167,000 - - 623,000 Peak rate £/sec 11,300 0 - - 11,300 Peak gas flow rates after combustion, A/ sec (Std.) Tight hood (10% com- bustion) 10,000 11,300 0 2,100 23,400 Open hood (20% excess air) 0 11,300 1,100 . 25,600 38,000 Metric tons 107 ------- 7. References - 1. The Pneumatic Steelmaking Processes. In: The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H. E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. p. 473- 497. 2. Iron and Steel Mills. In: Compilation of Air Pollution Emission Factors. Environmental Protection Agency Contract Number CPA-22-69-119. April 1973. p. 7.5-5. 3. Varga, J. Jr., and H. W. Lownie. Emission Characteristics. Appendix C. In: Final Technological Report on A Systems Analysis Study of the Integrated Iron and Steel Industry, Battelle Memorial Institute, Columbus, Ohio. Contract Number PH-22-68-65. Department of Health, Education and Welfare. May 15, 1969. C-78 p. 4. Henschen, H. C. Wet vs Dry Gas Cleaning in the Steel Industry. Journal of Air Pollution Control Association, p. 338-342, May, 1968. 5. Haltgram, R. Fundamentals of Physical Metallurgy, New York, Prentice Hall, 1952. 6. Parker, C, M. BOP Air Cleaning Experiences. Journal of the Air Pollution Control Association. August 1966. p. 446-448. 7. Wheeler, D. H. The Iron and Steel Industry. In: Proceedings of the Electrostatic Precipitator Symposium. Sponsored by the Division of Process Control Engineering, Air Pollution Control Office, Environmental Protection Agency. February 23-25, 1971. 8. Industrial Gas Cleaning Institute, Inc. Air Pollution Control Technology and Costs in Nine Selected Areas. Environmental Protection Agency, Contract No. 68-02-0301. September 1972. 9. Bramer, H. C. Pollution Control in the Steel Industry. Environmental Science and Technology. 1004-1008, October 1971. 108 ------- STEEL PRODUCTION PROCESS NO. 26 Vacuum Degassing 1. Function - In the steelmaking process the liquid steel may absorb gases, particularly hydrogen, from the atmosphere and from raw materials. Oxygen and nitrogen combine with alloying elements to form oxides, cyano- nitride, or nitride compounds. All of these impurities are partially removed by vacuum degassing, which is done by three methods: stream degassing, circulation degassing, and ladle degassing. The effective- ness of any vacuum degassing process depends upon the surface area of liquid steel exposed to low pressure. Because the degassing operation reduces the temperature of liquid steel, it is necessary to carry out the operation at temperatures higher than the normal tapping temperature. The molten degassed steel is either continuously cast into slabs or billets or is cast into ingots for subsequent forming. 2. Input Material - Molten steel is the only input material. Alloying additives are added after degassing. 3. Operating Parameters - In the stream degassing method the tank is evacuated to a absolute pressure of 0.05 to 0.500 nm Hg. In this method the liquid steel is tapped with 10 to 55°C superheat. In the induction stirred ladle degassing method the liquid steel, with 21 to 66°C superheat is exposed to pressures ranging from 0.075 to 0.200 mm Hg, depending upon the grade of steel. The steel to be degassed by the recirculation degassing method is superheated from 20 to 80°C above the tapping temperature and the pressure in the vessel gradually decreases to the range of 300 to 600 microns. 4. Utilities - No data available. 5. Waste Streams - About 5 kilograms of particulate are emitted from degassing a 100-ton* heat (charge). Composition of the dust that settles in the vacuum chamber depends on the alloying elements in the steel and their respective vapor pressures. Analysis of dust generated during vacuum degassing, and analysis of the metal in the laddie after treatment are given in Table 46. * Metric tons (1000 kg) 109 ------- Table 46; DUST AND f^ETAL ANALYSES FOR VACUUM-TREATED STEELS Material Steel in ladle Dust Steel in ladle Dust Elements, weight C 0.33 1.66 0.33 1.69 Mn 0.73 46.30 0.83 47.70 Si 0.25 1.63 0.26 1.40 Ni 2.86 0.38 0.17 0.13 Cr 0.99 0.36 1.01 0.38 aercent V 0.22 0.01 0.23 0.04 Mo 0.53 0.03 1.21 0.09 Cu 0.17 1.60 0.14 1.20 Fe 17.60 15.50 The composition of off-gases from stream degassing, which varies with grade of steel and extent of the vacuum treatment, can range from 18 to 50 percent carbon monoxide, 20 to 70 percent hydrogen, negligible amounts to 30 percent wate, 1 to 20 percent oxygen, 15 to 75 percent nitrogen, and 1 to 6 percent carbon dioxide. The composition of off-gases from recir- culation degassing is up ^o 80 percent carbon monoxide, up to 20 percent 2 carbon dioxide, and up to 15 percent hydrogen. 6. EPA Source Classification Code - None exists. 7. References - 1. The Making, Shaping and Treating of Steel. Ninth Edition. McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company. 1971. 2. Varga, J. Jr., and H. W. Lownie. Emission Characteristics. Appendix C. In: Final Technological Report on A Systems Analysis Study of the Integrated Iron and Steel Industry. Battelle Memorial Institute, Columbus, Ohio. Contract Number PH-22-68-65. Department of Health, Education and -Welfare. May 1969. C97-C121 p. 110 ------- STEEL PRODUCTION PROCESS NO. 27 Continuous Casting or Ingot Castings^ 1. Function - The molten steel (degassed or not) either is cast contin- uously into products of the desired shape or is cast into ingots for sub- sequent forming. In continuous casting process a laddie of steel is brought and posi- tioned over the tundish which is over the water cooled copper mold. The laddie nozzle is opened and the tundish is filled with molten steel to the desired depth. Then the tundish nozzles are opened to permit molten steel to enter the molds. The casted strand passes through a cooling chamber, straightening mechanism, and cutting device where it is cut into the desired lengths. In conventional ingot making the molten steel is tapped into a refrac- tory lined steel laddie. The laddie is moved by an overhead crane to a pouring platform where the steel is then teamed into a series of molds of the desired dimensions. Alloying materials and deoxidizers may be added during the tapping of the charge or in the molds. The steel solidifies in each of the molds to form a casting called ingot. 2. Input Materials - Molten steel. 3. Operating Parameters - None exists. 4. Utilities - No data available. 5. Waste Streams - Continuous casting and ingot making contributes very little to air pollution. 6. EPA Source Classification Code - None exists. 7. References - 1. The Making, Shaping and Treating of Steel. Ninth Edition. McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company. 1971. Ill ------- STEEL PRODUCTION PROCESS NO. 28 Rolling and Shaping 1- Function - The temperature of steel ingots are raised in a soaking pit furnace to prepare it for hot working (rolling). In the furnace the steel is heated until it is plastic enough for rolling to desired shape. After the ingots are rolled into billets, blooms, or slabs, they are cooled and inspected. Surface defects are removed by grinding, chipping, peeling, or scarfing. Reheating furnaces are used for raising tempera- ture of slabs, blooms, or billets for rolling into sheets, coils, or other shapes. 2. Material of construction - Ingots. 3. Operating Parameters - Soaking pits may have a hearth area of 10 to 30 square meters. Hearth areas of reheating furnaces range from a few square meters to 400 square meters. The normal temperature range for heating ingots is betwee.i 1180 and 1340°C. 4- Utilities - Furnaces are fired with either blast furnace gas, coke- oven gas, natural gas, fuel oil or a mixture. Consumption of fuel per ton* of steel varies from approximately 111,100 to 555,600 kilocalories, depending on the temperature of the charged steel. Water consumption in rolling or shaping operations ranges from 7600 to 26,500 liters per 7 1 2 minute. Table 47 indicates the range of power consumption in rolling or shaping mills. 5. Waste Streams - Data is not available on the emissions that occur during charging and removing of ingots, or during firing. Particulate emissions are considered to be negligible, unless the pits are fired with fuel other than gas. During breakdown of the ingots by rolling into billets, blooms, or slabs, there can be some emission of steam, which is confined in the building. Grinding and chipping generate particulates which are confined in a building adjacent to this area. Airborne particles released fram scarfing are extremely fine. 112 ------- Table 47- POWER CONSUMPTION IN ROLLING OR SHAPING MILLS** Operating unit kWh consumed per ton* of product Blooming mill Slabbing mill Plate mill Merchant mills Wide strip mill 13 5, based on blooms 10-12, based on slabs 30-40, based on plates 40-80, based on product 45-65, based on product * Metric tons (1000 kg) ** Covers the power used by the main drive motors, and does not include that used for auxiliaries such as table, fan, etc. 113 ------- Loss of metal is from 3 to 6 percent in scarfing of billets, up to 2.5 percent in scarfing of slabs, and up to 7 percent for blooms. Losses of gas in scarfing of slabs range from 0.46 to 10 grams per cubic meter. Many scarfing operations control particulate emissions with fabric fil- ters. ' Emissions during reheating of steel billets and slabs are mistures of carbon monoxide, carbon dioxide, nitrogen and moisture from the com- 3 bustion of natural gas. 4 Typical large rolling mill wastes are shown in Table 48. Table 48. QUANTITIES OF SOLID AND WATER WASTE FROM TYPICAL ROLLING MILL (IRON AND STEEL INDUSTRY) Mill Slab Hot-strip Blooming 30" billet 21" billet Hot scarfer Solids load, kg/ton* of product from each processing 15.00 25.00 9.50 14.60 14.60 25.00 Waste water, £/ton* 3,000 25,000 10,000 6,000 6,000 5,000 The steel mill wash waters may contain from 1000 to 2000 milligrams suspended solids per liter. The metal composition of suspended solids c roughly reflects the furnace charge. Most scale and oil produced in rolling mills are recovered in crude settling chambers called scale pits. 6. EPA Source Classification Code - None exists. Finishing/Soaking Pits - 3-03-009-11. 7. References - 1. The Making, Shaping and Treating of Steel. Ninth Edition. McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. 114 ------- 2. Bramer, H.C. Iron and Steel. Chapter 14. In: Industrial Waste Water Control, Chemical Technology, A Series of Mono- graphs - Volume 2, New York, Academic Press, 1965. 3. Varga, L. Jr., and H. W. Lownie. Final Technological Report on A Systems Analysis Study of the Integrated Iron and Steel Industry, Gurnham, C.F. (ed.). Battelle Memorial Institute, Columbus, Ohio. May 1969. 4. Industrial Waste Profiles No. 1 - Blast Furnace and Steel Mills. Volume III. In: The Cost of Clean Water. Federal Water Pollution Control Administration. FWPCA Contract Number 14-12-98. September 28, 1967. 5. Sittig, M. Iron. In: Pollutant Removal Handbook. New Jersey, Noyes Data Corporation, 1973. p. 251-257. 6. Bramer, H. C. Pollution Control in the Steel Industry. Environmental Science and Technology. 1004-1008, October 1971. 115 ------- STEEL PRODUCTION PROCESS NO. 29 Acid Treatment (Pickling) 1. Function - The oxidized surface of the hot-rolled steel is cleaned by acid treatment (pickling) in preparation for cold rolling. The metal is then rinsed with water to remove the bulk of the contaminants from the pickled product. 2. Input Materials - Sulfuric acid or hydrochloric acid is used for pickling. Consumption of acid varies over a wide range from a low of about 0.5 kilogram per ton* to a high of about 25 kilograms per ton*. The volume of water used for rinsing is in the range of about 200 to o 400 liters per ton* of steel pickled. 3. Operating Parameters - No data available. 4. Utilities - No data available. 5- Waste Streams - Acid fumes occur during pickling.3 Water discharge from the pickling operation generally includes spent strong pickle liquor and the acidic rinse water, which must be neutralized before it can be safely discharged. An estimated 150,000 tons of pollutants are expected from pickling processes in 1975. A typical pickling process produces waste water containing 2.25 kilograms of free acid and 8.4 kilograms of combined acid per ton* of ingot. Iron concentration in waste pickle liqour is about 70,000 milli- grams per liter. Spent pickling solutions and acid rinse waters differ widely in quantity, composition, and concentration. Acid rinse waters have the same relative proportions of iron salts and free acid pickling solution, but are much more diluted. 10 to 15 percent of acid used in pickling is discharged in rinse waters. Spent sulfuric acid pickling solutions contain free acid, ferrous sulfate, undissolved scale and dirt, and trace metals. Spent sulfate pickling solutions are discharged at 30 to 90°C. Pickling tanks emit pungent and corrosive mist and vapor. Potential liquid waste streams, other than spent pickle liquor, are suspended particles of waterborne scale, lubricating oil, and pick- ling rinse water. * Metric tons (1000 kg) 116 ------- Strong pickle liquors and rinse waters are often neutralized with lime. Sludge resulting from lime neutralization of spent pickle liquor is a principal solid waste problem. Lagoons filled with the material, which never dries, constitute a major problem at many mills. 6. EPA Source Classification Code - Finishing/Pickling - 3-03-009-10 7. References - 1. The Making, Shaping and Treating of Steel. Ninth Edition. McGannon, H.E. (ed.), Pittsburgh, Pennsylvania, U.S. Steel Company, 1971. 2. Kemmer, F.N. Pollution Control in the Steel Industry. In: Industrial Pollution Control Handbook, Lund, H.F. (ed.). New York, McGraw-Hill Book Company, 1971. p. 16. 3. Varga, L. Jr., and H.W. Lownie. Final Technological Report on a Systems Analysis Study of the Integrated Iron and Steel Industry, Furnham, C.F. (ed.). Battelle, Memorial Institute, Columbus, Ohio. May 1969. 4. Ralph Stone and Company, Inc. Forecasts of the Effects of Air and Water Pollution Controls on Solid Waste Generation. National Environmental Research Center. Publication Number PB-238-219. December 1974. 5. Sittig, M. Iron. In: Pollutant Removal Handbook. New Jersey, Noyes Data Corporation, 1973. p. 251-257. 6. Bramer, H.C. Iron and Steel. Chapter 14. In: Industrial Waste Water Control, Chemical Technology, A Series of Mono- graphs - Volume 2, New York, Academic Press, 1965. 7. Bramer, H.C. Pollution Control in the Steel Industry. Environmental Science and Technology. 1004-1008, October 1971. 117 ------- STEEL PRODUCTION PROCESS NO. 30 Finishing 1. Function - Finishing operations primarily consist of treating the semifinished steel products of costs, plates, billets, blooms by hot or cold working and processing to the final form. Some of the sheet and tin finishing operations are: tempering, tin plating, galvanizing, chrome plating, coating, polishing, continuous annealing. Other finishing oper- ations concern tube or pipe mills, bars, wires, and rails; and their treatment. Treatment may include rolling, piercing, reheating, welding, pickling, washing and plating. 2. Input Materials - Steel is the primary input material. 3. Operation Parameters - No data available. 4. Utilities - Some power requirements are 95 to 110 kWh per ton* for 5 stand cold reduction mill, 42 kWh per ton* for tinning operations and 33 kWh per ton for sheet-mill galvanizing. 5. Waste Streams - Solid waste is evolved from internally generated scrap and as a result of tank cleanouts or precipitates from wastewater treatments. Scrap is essentially all reused, but can result in waste* water treatments. Essentially all scrap is reused, but can result in wastewater problems in reclaiming operations.. Emulsified'oil from cold 2 rolling presents a difficult wastewater treatment problem. New tin plating plants produce an estimated 0.073 liters of wastewater, 0.032 kilograms of chromium and 0.008 kilograms of tin per ton* of steel ingot. Galvanizing plants are estimated to produce 0.018 lite'rs of wastewater q containing 0.0013 kilograms of zinc per ton* of steel ingot. 6. EPA Source Classification Data - Finishing/other - 3-03-009-20. 7. References - 1. The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H.E. (ed.). Pittsburgh, Pennsylvania, U.S. Steel Company, 1971 2. Kulujian, N.J. Compliance Status Evaluation of Iron and Steel Facilities in New York. PEDCo-Environmental Specialists, Inc. Contract Number 68-02-1321. Environmental Protection Agency. April 1975. * Metric ton (1000 kg) 113 ------- 2. Bramer, H. C. Pollution Control in the Steel Industry. Environmental Science and Technology. 1004-1008, October 1971. 3. Industrial Waste Profiles No. 1 - Blast Furnace and Steel Mills. Volume III. The Cost of Clean Water. Federal Water Pollution Control Administration. FWPCA Contract Number 14- 12-98. September 28, 1967. 119 ------- APPENDIX A RAW MATERIALS 121 ------- Table A-l. IRON ORE MINED IN THE UNITED STATES 1 Di stri ct Type of ore Approximate percent of total tonnage mined Lake Superior Birmingham, Alabama Chattanooga, Tennessee Adirondack, Northern New York Northern new Jersey and South Eastern New York Lone Star, Texas Iron Mountain, Missouri Vulcan, California Cornwall, Pennsylvania Sunrise, Wyoming Iron County, Utah Hematite Hematite brown Brown Magnetite Magnetite Hematite Brown Magnetite Carbonate 48 7 1 4 1 122 ------- Table A-2. CONSUMPTION OF MATERIALS OTHER THAN IRON ORE IN IRON AND STEEL INDUSTRY - 19732 Major material Fluorspar Limestone Lime Other fluxes Oxygen Coal: In production of coke In production of steam0 Other purposes Quantity 0.561 million tons 21.80 million tons* 7.080 million tons* 0.820 million tons* 6092. billion liters* 77.64 million tons* 3.81 million tons 0.53 million tons* Includes coal consumed in generating electric power. ^Metric tons (1000 kg) 123 ------- Table A-3. ORIGIN OF COAL RECIEVED BY COKE-OVEN PLANTS IN THE UNITED STATES IN 1974 BY PRODUCING STATE AND VOLATILE CONTENT3'3 Source of coal Al abama Arkansas Colorado 111 inois Kentucky Maryland New Mexico Ohio Oaklahoma Pennsylvania Tennessee Utah Virginia West Virginia Total Volatile content High 2,488 », 1 ,554 4,035 14,564 - 925 41 165 18,588 169 1,863 1,744 14,262 60,398 Medium 3,955 - 399 - - - - - 175 1,103 - - 1,065 2,886 9,583 Low - 178 486 - *»< 7 - - 3 5,172 - - 1,748 9,558 17,152 Total 6,443 178 2,439 4,035 14,564 7 925 41 343 24,363 169 1,863 4,557 26,706 87,133 Volitile matter on moisture - free basis; high-volatile - over 31 percent; medium-volatile - 22 to 31 percent; and low-vplatile - 14 to 22~percent. Cumulative of individual county production in the state 124 ------- Table A-4. ANALYSIS OF LIMESTONE FROM COLUMBUS, OHIO Constituent Si09 2 A1203 CaO MgO P S Percent 0.06 0.04 30.83 22.27 - 0.020 125 ------- APPENDIX B INDUSTRY PRODUCTS 127 ------- Table B-l. AVERAGE GRADE OF SINTER PRODUCED IN 1968 NORTHEASTERN IRON ORES (Wt, %, DRY BASIS}5 Fe P Si02 Mn CaO MgO Benson sinter Benson Non- Bessemer sinter Port Henry sinter 63.91 0.026 5.47 0.30 3.02 1.39 0.26 O.Q.3Q 62.60 0.199 4.31 0.16 2.74 1.28 0.26, 0.030 66.17 0.14G 3.94 ! 1.22 1.16 0.26 128 ------- Table B-2. TYPICAL TACONITE CONCENTRATE PRODUCT ANALYSIS Composition Fe Si02 CaO MgO A12°3 Mn Percentage 64.55 9.2 0.53 0.67 0.55 0.22 129 ------- Table B-3. COMPOSITIONS OF PELLETS PRODUCED IN 1968, (Wt. %, DRY Minntae pellets Reserve pellets Erie pellets Eveleth pellets Birch Lake3 pellets Cornwel 1 pellets Morgantown pellets ( Grace Mine) Fe 65.12 62. 56 63.91 65,39 62.48 64.92 65.83 P 0.011 0.028 0.012 0.012 0.023 0.006 0,010 Si02 5.50 8.76 7.22 5.50 9.00 3.30 3.18 Mn 0.16 0.27 0.23 0.14 0.22 0,08 0,08 A12°3 0,42 0.47 0.31 0.29 0.54 1.50 0.61 CaO 0.25 0.44 0.19 0.50 0.90 0.55 MgO 0.59 0.51 0.30 0.65 1.50 1.54 S 0.002 0.009 Q.OQ9 Pellets produced from concentrates originated with magnetic taeonites. 130 ------- Table B-4. CHEMICAL ANALYSIS OF NODULIZED PRODUCT, AVERAGE3'7 Composition Moisture Fe Si02 Mn P CaO Percent 0.12 62.99 7.33 0.29 0.020 2.44 Taconite concentrate is used as input to the kiln. 131 ------- Table B-5. SUMMARY OF THE COKE INDUSTRY IN THE UNITED STATES IN 19748 Material Quantity Coke produced: At merchant plants At furnace plants Total Coke breeze produced Coal carbonized: Bituminous Anthracite Average yield of coke of total coal carbonized, % Coke used in blast furnaces Coke breeze used in agglomerating plants Coal chemical materials producted: Crude tar Ammonia Crude light oil Gas 4,632,000 tons 50,466,000 tons* 55,865,000a tons* 4,621,000 tons* 81,420,000 tons* 403,000 tons* 68.28 51,200,000 tons* 1,334,000 2,564,137,000 liters 519,000 tons* 822,920,000 27,392,000 x 106liters a About 1-4 percent of this amount is produced in beehive ovens. * Metric tons (1000 kg) 132 ------- Table B-6. TYPICAL SIZES OF COKE Variety of Coke Size, cm Foundry Blast furnace Breeze Various sizes, >8 8 x 0.75 through 1.9 133 ------- Table B-7. TYPICAL PROPERTIES OF COKE9 Moisture, % 2 Volatile matter, % 0.5-2 Fixed carbon, % 87 - 91 Ash, % 5-9 Heating value, 7050 - 7350 kcal/kg 134 ------- Table B- 9. COMPOSITION OF HIGH-TEMPERATURE12 COKE-OVEN TARa Percent by weight Liquor 1.6-5.8 Benzol 0.1-0.3 Toluol 0.1-0.4 Xylol 0.1-0.5 Total tar acids (phenols, cresols, xylenols) 2.0-3.9 Total tar bases (pyridine, picolines, quinolines) 1.4-2.0 Naptha (coumarone, indene) 0.4-2.0 Crude naphthalene 7.7-11.7 Methyl naphthalene oil 2.1-2.9 Biphenyl oil 0.9-1.5 Acenaphthene oil 1.4-2.8 Fluorene oil (fluorene, diphenyl oxide) 1.9-3.6 Anthracene-heavy oil (anthracene, phenanthrene, carbazole) 9.6-12.3 Pitch 60.2-64.2 Distillation losses 0.9-2.8 a Ranges of composition of five typical tars from "The Coal Tar Data Book." The Coal Tar Research Association, 2nd Ed., Section Al, 2-4, 1965. 136 ------- Table B-8. YIELDS AND ANALYSES OF PRODUCTS OF CARBONIZATION PROCESS 10,11 Product Coke Gas Ammonia Tar Liquor Light oils Cyanogen Carbon disulphide Hydrogen sulphide Constituent Ash Carbon Hydrogen Sulphur Nitrogen Totals C02 CO CH4 C2H4 N2 H2 02 Totals Hydrogen Nitrogen Totals Carbon Hydrogen Oxygen Totals Moisture Oxygen Hydrogen Totals C6H6 (Equivalent) C2N2 cs2 H2S Percent of coal by weight 7.210 61.711 0.469 0.683 0.270 70.343 1.042 3.154 7.468 1.529 0.385 1.366 0.717 15.661 0.040 0.183 0.223 4.687 0.327 0.436 5.450 3.310 3.107 0.388 6.805 1.102 0.078 0.013 0.325 Analysis percent of product by weight 10.24 87.76 0.66 0.96 0.38 100.00 6.66 20.14 47.69 9.76 2.46 8.72 4.57 100.00 17.9 82.1 100.0 86.0 6.0 8.0 100.0 48.70 45.60 5.70 100.0 100.0 100.0 100.0 100.0 Yield kg per ton* 72.10 617.12 4.69 6.83 2.70 703.44 10.42 31.54 74.68 15.29 3.85 13.66 7.17 156.61 0.40 1.83 2.23 46.87 3.27 4.36 54.50 33.10 31.07 3.88 68.05 11.02 0.78 0.13 3.25 * Metric ton (1000 kg) 135 ------- Table B-10. ANALYSIS OF CRUDE AMMONIA LIQUOR13 Specific gravity 1.1055 Ammonia, total, percent 22.47 free, percent 22.20 Pyridine, grams per liter 2.79 Sulfides as H2$, grams per liter 53.3 Organic matter, cc N/50 KMnO, 103,300 per liter 137 ------- APPENDIX C COMPANIES 139 ------- Table C-l. IRON AND STEEL PRODUCING FACILITIES 14 Company - Plant AUn Hood Steel Coke and Chemical Plant Blast Furnaces Ivy Rock Plant Allegheny Ludlum Ind., Inc. Allegheny Ludlum Steel Corp. Dunkirk & Watery! let Works AJax Forging & Casting Co. New Hartford Works Location Conshohocken, Pa. Swede! and, Pa. Swedeland, Pa. Ivy Rock, Pa. Pittsburgh, Pa. Dunkirk & Water* vliet, Pa. Ferndale & Detroit Michigan New Hartford, N.Y. No. Of agglomerating facilities 3 No. of blast furnaces 2 Type of furnace Basic Oxygen Hot bla^t cupola Basic On furnace Electric Arc Vacuum reduction Electric Arc Vacuum melt Induction Vacuum Melt electrode A.O.D. Vessel Electric Arc Induction Vacuum Melt Induction Consumable electrode Steel producing No. of furnaces 2 1 2 5 1 4 1 7 1 2 6 5 8 Steel grade Carbon, low alloy Iron Alloy Alloy & stain- less Refining stainless Carbon, alloy, & stainless, Stainless Alloy & Stainless Stainless Alloy Alloy Specialty steels Specialty Steels Size 1 Coke tons*/heat production 150 55/hr 80 80 (2) 70 (2) 55 (1) 80 25 (2) 15 1 2 (1) 1/5 or 1 1/2 to 11 25 1 & 4 1/4 to 2 '!(!) 0.5-2.5(3) 5 Yes - ! *Metric ton (1000 kg) ------- Table C-l(continued). IRON MID STEEL PRODUCING FACILITIES 14 Company - Plant American Compressed Steel CQCGU Araco Steel Corporation Ashland Works Butler Plant Hamilton Plant Houston Works Kansas City Works Mlddletown Works Sand Springs Works Baltimore Works Torrance Plant Location Cincinnati, Ohio Etlwanda, Ca. Mlddletown, Ohio Ashland, Ky. Butler, Pa. Hamilton, Ohio Houston, Texas Kansas City, Mo. Mlddletown. Ohio Sand Springs, Okla. Baltimore, Md. Torrance, Ca. No. of agglomerating facilities 1 1 No. of blast furnaces 2 2 1 1 Type of furnace Electric Arc Electric Arc Basic 02 Electric Arc Electric Arc Electric Arc Basic Open Hearth Basic 0? Electric Arc Electric Arc Vacuum Arc Re- melt Ar-Og Reactor Electric Arc Steel PH No. of furnaces 1 3 2 3 6 4 6 2 2 3 2 1 2 jductlon Steel grade Carbon Carbon, Alloy Carbon, Alloy Carbon, alloy stainless Carbon, alloy Carbon, Alloy Carbon Carbon Carbon Size tons*/heat 6 15 & 18 180 165 117 (2) 175 (4) 125 (2) 150 (2) 310 200 70 Super-alloy, 25 (2) stainless 40.0 (1) Superalloy, stainless 10 Superalloy, 20/40 stainless Carbon, alloy, stainless 22.5 (1) 10.0 (1) Coke production yes yes yes Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES 14 ro 8 No. of strands. * Metric tons (1000 kg) Company - Plant Atlantic Steel Company Babcock i Mil cox Co. Bethlehem Steel Corp. Bethlehem Plant Steel ton Plant Sparrows Point Plant Lackawanna Plant Johnstown Plant Location Atlanta, Ga. Beaver Falls, Pa. Bethlehem, Pa. Bethlehem, Pa. Steel ton, Pa. Sparrows Pt. Md. Lackawanna, N.Y. No. of agglomerating facilities 4a 6a 6? Z* No. of blast furnaces 4 10 6 4 Type of furnace Electric Arc Electric Arc Argon Oxygen Electroslag remelt Basic oxygen Electric Arc Electric Arc Open hearth furnaces Basic 82 Basic open hearth Basic oxygen Basic open hearth Steel pro No. of furnaces 2 9 1 2 6 5 7 2 8 3 8 iduction Steel grade Carbon Carbon, alloy stainless Stainless Stainless & high alloy Carbon, alloy Alloy Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy Carbon , alloy Carbon, alloy Size tons*/heat 85 2S (2 50 (2 75 (2 100 (3 25 "3 270 7 (I) 28 (1) 50 (4) 5 0) 15 (1 150 (3.) 420 220 190 (3) 190 (5) 300 180 Coke production Yes Yes Yes Yes ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES 14 fa CO Conpany - Plant Burns Harbor Plant Los Angeles Plant Seattle Plant Norgantown Plant Border Steel Rolling Hills, Inc. Borg-Uarner Corporation Chicago Heights Works New Castle Works Braeburn Alloy Steel Dlv. Braeburn Works Cabot Corporation Machinery Division at Pampa Location Westchester Twsp., Ind. Los Angeles, Ca. Seattle, Wash. Morgan town, Pa. El Paso, Texas Chicago, 111. Chicago Hts, 111. New Castle, Ind. Braeburn, Pa. Braeburn, Pa. Boston, Mass. Pampa, Texas No. of agglomerating facilities 6 1 No. of blast furnaces 2 3 Type of furnace Basic oxygen Electric Arc Electric Arc Electric Arc Electric Arc Electric Arc Electric Arc Vacuum consumable electrode arc remelt Electric Arc Steel production No. of furnaces 2 3 2 2 2 4 2 1 1 Steel grade Carbon, alloy Carbon, alloy Carbon, alloy Carbon, low alloy Carbon Carbon, alloy stainless Carbon, alloy Alloy Size tons*/heat 300 75(1) 100 (2) 120 25 30 9 (2) 12 (2) 10 11 10 Coke production Yes * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES 14 Company - Plant Cameron Iron Works, Inc. Carpenter Technology Corp. Carpenter Steel 01 v. - Reading Bridgeport Plant Ceco Corp. (The) Letnont Works H11 ton Works Birmingham Works Location Houston, Texas Reading, Pa. Reading, Pa. Bridgeport, Conn, Chicago, 111. Lemon t, 111. Hilton, Pa. Birmingham, Ala. No. of agglomerating facilities No. of blast furnaces Type of furnace Electric Arc Vacuum Induction Vacuum consumable Electric Arc Vacuum Induction Consumable elect. Steel production No. of furnaces 1 2 20 5 2 10 Electroslag remelt 2 Argon-oxygen decai Electric Arc Ar - Og Decarb. Electric Arc Electric Arc Electric Arc b. 1 2 1 3 3 2 Steel grade Carbon, alloy Specialty alloys Specialty alloys Alloy, stainless Alloy, stainless Alloy, stainless Alloy, stainless Alloy, stainless Alloy, .stainless Alloy, stainless Carbon Carbon Carbon, high strength, low alloy Size tons*/heat 60 25 & 60 16 - 34 14 7.5 (1) 7.5 (1) 2.5 (2) iffi 15 15 42 50 30 20 14 Coke .production * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES14 Company - Plant CF & I Steel Corporation Pueblo Plant Roebllng Plant Columbia Tool Steel Co. Chicago Heights Works Continental Steel Corp. Kokomo Works Copperweld Corporation Copperweld Specialty Steel Co. Crucible Inc. (subsidiary Colt industries) Alloy Division Stainless Steel D1v. Location Pueblo, Colo. Pueblo, Colo. Roebllng, N.J. Chicago Hts, 111. Chicago Hts. 111. Kokomo, Ind. Kokomo, Ind. Pittsburgh, Pa. Warren, Ohio Pittsburgh, Pa. Midland, Pa. Midland, Pa. No. of agglomerating facilities 1 No. of blast furnaces 4 2 Type of furnace Basic oxygen Electric Arc Electric Arc Electric Arc Electric Arc Electric Arc Top oxygen Top oxygen converters Electric Arc ADD Refining Electrode vacuum Steel production Ho. of furnaces 2 1 3 2 2 7 2 5 1 9 Steel grade Carbon, alloy Carbon, alloy Carbon Tool stee Carbon Carbon, alloy Carbon, alloy Carbon, alloy, stainless Stainless Alloy, stainless Size tons*/ heat 118 120 43 1 5 (1) 8 (1) 175 45 (3) 75 (4) 100 75 (4) 25 (1) 100 10 (4) 2.5 (1) 10 (2) 4 (1) 2.5 (1) Coke production Yes Yes * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES14 Conpany - Plant Specialty Metals Dlv. Cyclops Corporation Empire Detroit Steel Div. (Mansfield Plant) Portsmouth Division Bridgeville Plant Location Syracuse, N.Y. Pittsburgh, Pa. Mansfield, Ohio Portsmouth, Ohio BridgevUle, Pa. No. of agglomerating facilities No. of blast furnaces 2 Type of furnace Curved-mold cont. Electric Arc Electric Inductloi Vacuum melting Induction Vacuum melting electrode arc remeltlng Basic open hearth Electric Arc ADD Refining vessel Basic open hearth Electric Arc Vacuum arc remelt Vacuum Induction Electroslag re- fining Steel production No. of furnaces 1 5 i 1 5 2 1 5 3 2 1 1 Steel grade Stainless Carbon, alloy, stainless Carbon , alloy, stainless Alloy, stainless Alloy, stainless Carbon, alloy Carbon, alloy, stainless Alloy, stainless Carbon Stainless & spedalt Specialty grades Specialty grades Specialty grades Size tons*/heat 100 35 (1) 15 (4) 1 1.5 10 170 100 100 320 40 (1) X 20 (2) 6 1.7 4 Coke production Yes * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES14 Company - Plant Donner-Hanna Coke Corp. Eastern Stainless Steel Co. Baltimore Works Electralloy Corp. 011 City Works Elliott Bros. Steel Co. Florida Steel Corp. Tamps Works Indiantown Works Croft Works Location Buffalo, N.Y. Baltimore, Md. Baltimore, Md. New York, N.Y. Oil City, Pa. New Castle, Pa. Tampa, Fla. Tampa, Fla Indianatown, Fla. Croft, N.C. No. of agglomerating facilities * No. of blast furnaces Type of furnace Electric Induc- tion Electric arc Electric Arc Ar-Oj vessel Vacuum Induction Electric Induction Gas fired Electric Arc Electric Arc Electric Arc Steel production No. of furnaces 2 3 1 2 1 2 2 3 2 2 Steel grade Alloy & stainless Alloy & stainless Carbon Carbon Carbon Size tons* /heat 3 1/4 15 50 f! 35 20 30 3 .75 .25 18 50 20 25 35 i) i) 11 i) i) ii 30 (1) 35 (1) 25 30 !! Coke production Yes * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES CO Company - Plant Ford Motor Company Rouge Works Georgetown Steel Corp. Harrlsburg Steel Co. (Dlv. of Ha r sco Corp.) Harrlsburg Works Hawaiian Western Steel limited Ewa Works Heppenstall Company Nldvale - Heppenstall Co. Industrial Products Group Coke Plant Chattanooga Dlv. Location Dearborn, Mich. Dearborn, Mich. Georgetown, S.C. Harrisburg, Pa. Harrlsburg, Pa. Ewa, Hawaii Pittsburgh Philadelphia, Pa. Woodward, Ala. Woodward, Ala. Chattanooga, Tern. No. of agglomerating facilities . No. of blast furnaces 3 Type of furnace Basic oxygen Electric Arc Basic open hearth Electric Arc Electric Arc Vacuum electrode Steel production No. of furnaces 2 3 3 1 3 3 Steel grade Carbon, alloy Carbon Carbon, alloy Carbon Carbon, alloy, stainless Carbon, alloy, stainless Size tons*/heat 240 65 50 15 40 (1 80 (1 140 (1 5 (2) 55 (1) Coke production Yes Yes Yes * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES14 Company - Plant Inland Steel Co. Indiana Harbor Works Inter lake Incorporated Chicago Plant Erie Plant Toledo Plant R1verda1e Station Works Wilder Works International Harvester Co. South Chicago Works Iowa Steel Mill, Inc. Wilton Works ITT Harper, Inc. Norton Grove Works Location Chicago, 111. East Chicago, 111. Chicago, 111. South Chicago, 111. Erie, Pa. Toledo, Ohio Chicago, 111. Wilder, Ky. Chicago, 111. S. Chicago, 111. Wilton, Iowa Morton Grove, 111. No. of agglomerating facilities 1 1 No. of blast furnaces 8 2 1 2 3 Type of furnace Bask open hearth Basic oxygen Electric arc Basic oxygen Electric Arc Basic oxygen Electric Electric Arc Electric Induction Steel Ho. of furnaces 19 4 2 2 3 2 1 2 1 production Steel grade Carbon, alloy Carbon, alloy Carbon, alloy Carbon Carbon, alloy Carbon, alloy Stainless Stainless Size tons*/heat 210 (12) 335 (7) 255 (2) 210 (2) 120 75 85 130 , 10 (1) 4 (1) 1 Coke production Yes Yes Yes Yes Yes -p. vo * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES Company - Plant Jessop Steel Company Washington Works Green River Steel - Owensboro Works Jones * Laugh! in Steel Corp. Aliquippa Works Division Pittsburgh Works Division Location Washington, Pa. Washington, Pa. Owensboro, Ky. Pittsburgh, Pa. Aliquippa, Pa. Pittsburgh, Pa. No. of agglomerating facilities 1 No. of blast furnaces 5 4 Type of furnace Electric Arc Electric induction Electric induction vacuum melt Electric induction emit Ar - 0-2 vessel Electric Arc Basic oxygen Basic open hearth Electric Arc Steel No. Of furnaces 4 1 1 2 1 2 3 6 1 production Steel grade Carbon, stainless alloy tool steel Carbon & alloy tool steel Carbon & alloy tool steel Carbon & alloy tool steel Stainless Carbon, alloy stainless Carbon, high strength, alloy Carbon, high strength & alloy Carbon, alloy stainless Size tonstheat 16 (1) 14 (2) 8 (1) 1/2 1 2 1/2 20 60 207 340 2 Coke production ~ Yes Yes en * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES1 Company - Plant Cleveland (fork's D1v. Warren Works Jorgensen Co., Earle M. Seattle Works Joslyn Stainless Steels Fort Wayne Works Judson Steel Corp. Emeryville Works Kaiser Steel Corp. Fontana Works Location Cleveland, Ohio Warren, Rich. Seattle, Hash. Seattle, Htsh. Ft. Hayne, Ind. Emeryville, Ca. Emeryville, Ca. Oakland, Ca. Fontana, C*. No. of agglomerating facilities 1 2 No. of blast furnaces 2 4 Type of furnace Basic oxygen Electric arc Electric arc A.O. vessel Electric arc Electric arc A.O.D. vessel Electric arc Basic open hearth Steel production No. of furnaces 2 2 5 1 2 3 1 1 8 Steel grade Carbon, high strength Carbon, high strength Alloy, stainless Stainless Carbon, alloy, stainless Stainless Stainless Carbon Carbon & alloy Size tons*/heat 220 170 60 70 40 20 (1) 17 (2) 17 45 225 Coke production Yes * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES14 en ro Company - Plant Fontana Works Kentucky Electric Steel Co. Coal ton Works Keystone Consolidated Ind., Inc. Peoria Works Liclede Steel Co. Alton Works tone Star Steel Company Lone Star Works Lukens Steel Company Coatesville Works Marathon Letourneau Co. Longvlew Works Harathon Steel Company Tenpe Works Location Ashland, fy. Coal ton, Ky. Peoria, 111. St. Louis, Mo. Alton, 111. Dallas, Texas Lone Star, Tex. Coatesville, Pa. Coatesville, Pa. Longvlew, Tex. Longview, Tex. Tempe, Ariz. Tempe, Ariz. No. of agglomerating facilities - No. of blast furnaces 1 Type of furnace L-D Oxygen Electric arc Electric arc Electric arc Basic open hearth Basic open hearth Electric arc Electric-arc Electric Arc Steel No. of furnaces 3 3 2 2 5 6 4 2 3 D reduction Steel grade Carbon & alloy '., Carbon Carbon Carbon Carbon, alloy Carbon , alloy Carbon, alloy Carbon, alloy Size tons*/heat 120 15 170 225 250 145 150 (2) 100 (2) 25 20 Coke production Yes j : j I * Metric tons (1000 kg) ------- Table C-l (continued). IRON AND STEEL PRODUCING FACILITIES 14 Company - Plant NcLouth Steel Corporation Mesta Machine Company West Homestead Plant New Castle Plant Mississippi Steel Dlv. of Magna Corporation National Forge Company Irvine Works Erie Plant National Steel Corp. Blast Furnace Dlv. Location Detroit, Mich. Pittsburgh, Pa. Nest Homestead, Pa. New Castle, Pa. Jackson, Miss. Irvine, Pa. Irvine, Pa. Erie, Pa. Pittsburgh, Pa. River Rouge, Mich. No. of agglomerating facilities 1 No. of blast furnaces 2 4 Type of furnace Electric Arc Basic oxygen Acid open hearth Acid open hearth Electric Arc Electric Arc Electric Arc Steel production No. of furnaces 2 5 4 4 3 2 3 Steel grade Carbon , stainless Carbon, stainless Carbon, alloy Carbon, alloy Carbon Carbon, alloy, stainless Carbon, alloy, stainless Size tons*/heat 200 120 40 (1) 50 (1) 125 (2) 35 (1) 50 (2) 100 (1) 14 (2) 35 (1) 20 (1) 45(1) 35 (1) 75 (2) Coke production Yes en CO * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES1 Company - Plant Ecorse Works Weirton Plant Granite City Works New Jersey Steel & Structural Corporation North Star Steel Company Ramsey County Works Northwest Steel Rolling Mills, inc. Kent Works Northwestern Steel and Wire Company Sterling Works Oregon Steel Mills Front Avenue Plant Rlvergate Plant \ Pacific States Steel Corp. Location Detroit, M1ch. Weirton, W. Va. Granite City, 111. Sayrevllle, N.J. Ramsey County, M1nr Kent, Washington Sterling, 111. Sterling, 111. Portland, Oregon Union City, Ca. No. of agglomerating facilities 2 1 . No. of blast furnaces 4 2 Type of furnace Basic oxygen Electric Arc Basic oxygen Basic o,.ygen Electric Arc Electric Arc Electric Arc Electric Arc Electric Arc Electric Arc Basic open hearth Steel production No. of furnaces 4 2 2 2 2 2 2 3 3 2 4 Steel grade Carbon, alloy Carbon, alloy Carbon Carbon Carbon Carbon, alloy Carbon Carbon Carbon 8 low alloy Carbon & low alloy Carbon, alloy Size cons*/heat 200 (2) 300 (2) 150 335 220 65 60 35 150 (1) 250 1) 400 (1) 23 75 150 Coke production Yes Yes en * Metric tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES 14 Company - Plant Phoenix Steel Corp. J Plate Division Structural & Tube Oiv. Porter Company, Ind., H.K. Conners Steel Div. - Conners Works ' Nest Virginia Works Republic Steel Corp. Youngstown Works Warren Works Mass ill on Works Canton Works Location Claymont, Del. Claymont, Del. Phoenixville, Pa. Pittsburgh, Pa. Birmingham, Ala. Huntington, W. Va. Cleveland, Ohio Youngstown, Ohio Warren & Niles, Ohic Hassillon, Ohio Canton, Ohio to. of agglomerating facilities 1 No. of blast furnaces 3 1 1 Type of furnace Electric Arc Basic open hearth Electric arc Electric arc Basix oxygen Electric Arc Electric Arc Vacuum melt electrode Steel production No. of furnaces 2 4 2 2 2 2 9 8 Steel grade Carbon, alloy, stainless Carbon, alloy Carbon Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy, stainless Alloy, stainless & special steels Size tons*/heat 150 150 30 30 150 185 80 (5) 200 (4) 5 to 10 Coke production Yes Yes Yes en tn * Metric Tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES 14 Company - Plant Cleveland District Buffalo Works South Chicago Works Gulf steel Works Thomas Works Finkl & Sons Co., A. Roblin Steel Company Dunkirk Works Sharon Steel Corp. Steel Division Location Cleveland, Ohio Buffalo, N.Y. South Chicago, 111 . Gadsden, Ala. Chicago, 111 N. Tonawanda, N.Y. Dunkirk, N.Y. Sharon, Pa. Sharon, Pa. Ho. of agglomerating facilities 1 1 No. of blast furnaces 5 2 1 2 2 Type Of furnace Basic oxygen Basic open hearth Basic oxygen Basic open hearth Electric Arc Basic oxygen Electric Arc Electric Arc Electric Arc Basic oxygen (L-D) Basic oxygen Electric Arc Steel production Mo. of furnaces 2 4 2 4 3 2 2 2 2 1 2 2 Steel grade Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy Carbon , alloy Carbon, alloy Carbon, alloy Alloy, stainless Size tons*/heat 220 400 100 250 150 150 185 65 25 150 150 110 Coke production Yes Yes Yes Yes en * Metric Tons (1000 kg) ------- Table C-1 (continued). IRON AND STEEL PRODUCING FACILITIES 14 Company - Plant Fairmont Coke Division Coke Plant Shenango Incorporated Neville Plant Sharpsville Plant Simonds Steel Division Lockport Works Soule' Steel Company Carson Works Southwest Steel Rolling Mils Los Angeles Works Standard Steel Burnham Works Location Fairmont, W. VA. Temple ton, Pa. Pittsburgh, Pa. Neville Island, Pa. Sharpsville, Pa. Lockport, N.Y. Lockport, N.Y. San Francisco, Ca. Carson, Ca. Los Angeles, Ca. Los Angeles, Ca. Burnham, Pa. Burnham, Pa, No. of agglomerating facilities No. of blast furnaces 2 1 Type of furnace Electric Arc Electric induction Consumable electrode Electric Arc Electric Arc Basic elec- tric arc Acid elec- tric arc Steel Droduction No. of furnaces 3 2 3 2 2 2 2 Steel grade Carbon, alloy, stainless Alloy Alloy Carbon Carbon Carbon, alloy, stainless Carbon, alloy Size tons*/heat X 15 1 (1) 600 Ibs (1) 5 15 21 (1) 22 (1) 40 (1) 18 (1) 45 (1) .70 (1) Coke production Yes Yes Yes Yes i en -vl * Metric Tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES 14 . ..mi.............. -=-==========» i ',',.-:; Company - Plant Structural Metals, Inc. Sequin Works Teledyne All vac Monroe Works Teledyne Vasco Vanadium Plant - ^=g^^~ Location Sequin, texas Monroe, N.C. Monroe, N.C. tatrobe, Pa. La t robe, Pa. No. Of agglomerating facilities No. of blast furnaces - " ___^__ Type of furnace Vacuum electrode Electric arc Vacuum Induction Vacuum melting electrode ESR melting electrode Electric Induction Electric Induction Electric arc Vacuum melting electrode Steel production No. of furnaces 2 2 3 5 5 2 2 1 2 Steel grade Alloy, stainless, nonferrous alloy Carbon high strength high temp. high strength temp. high strength high temp Carbon, alloy high speed Carbon, alloy high speed Carbon, alloy high speed Carbon alloy high speed mi I'"-!! - i_ -MB- Size tons*/heat 11 (1) 23 (1) 25 10.5 (1) 7.5 1 1.5 (1) 7.5 8 1/20 (1) 1/8 (1) 1/2 (1) 1 (D 1 13 6.5 =r i ," "HLBBeasgaaBe8«a Coke production en oo * Metric Tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES 14 Company - Plant Col on la Plant Tennessee Forging Steel Corp. Harlman Works Kankakee Electric Steel Works Texas Steel Company Tlnken Company (The) Canton Works Union Electric Steel Corp. Carnegie & Harmon Creek Plants Location Monaca, Pa. HarHman, Tenn. Harrlman, Tenn. Kankakee, 111. Ft. Worth, Tex. Canton, Ohio Canton, Ohio Pittsburgh, Pa. Carnegie & Harmon Creek, Pa. No. of agglomerating facilities No. of blast furnaces Type of furnace Vacuum melting electrode Electric arc Electric arc Electric arc Electric arc Electric arc Electric Arc Vacuum melting electrode Electric arc Steel production No. of furnaces 1 1 2 2 3 2 7 1 1 Steel grade Carbon, alloy high speed Carbon, alloy high speed Carbon, alloy Carbon, alloy Carbon, * 1 !«.* i alloy & stainless Carbon Carbon , alloy, stainless Carbon, alloy, stainless Alloy Size cons*/heat 1/10 IS 25 22 8 (1) 19 / 1 \ 12 (1) 3 (1) 25 (1) 30 (1) 140 (2) 110 (4 60 (1) 19 35 Coke production . in Metric Tons (1000 kg) ------- Table C-l(continued). IRON, AND STEEL PRODUCING FACILITIES14 o Company - Plant United States Pipe & Foundry Co. Coke Plant Blast furnace United States Steel Corp. Clairton Works Edgar Thomson-Irvin Works Fairless Works Homestead Works Blast Furnace Homestead Works - Steel Division Johnstown - Canton Works Lorain - Cuyahoga Works Lorain - Cuyahoga Works - Central Fees Location Birmingham, Ala. N. Birmingham, Ala. N. Birmingham, Ala. Pittsburgh, Pa. Clairton, Pa. Braddock, Pa. Fairless Hills, Pa. Rankin, Pa. Homestead, Pa. Johnstown, Pa. Lorain, Ohio . Cleveland. Ohio No. of agglomerating facilities 1 2 1 1 No. of blast furnaces 1 1 5 3 4 5 2 "IF ' ' ~~~*"^"TTff'iff-"- ' ' Type of furnace Basic oxygen Basic open hearth Basic open hearth Electric arc Basic oxygen Steel NO. Of furnaces 2 9 11 3 2 1 J u. i.m.i.ujiM'LJ.|.i. ..u ...... HP ..M . mmm . i - . - production Steel grade Carbon, alloy Carbon, alloy Carbon, alloy Carbon, alloy, stainless Carbon, alloy Tssrftgf" "p i""!]ijma!K Size tons*/heat 220 395 320 30(1) 3 (2) 225 Coke production Yes Yes Yes Yes * Metric Tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES Company - Plant National - Ouquesne Works - McKeesport National - Duquesne Works - Ouquesne Youngstown Works Duluth Works Gary Works South Works Geneva Works Torrance Plant Falrfleld District Works Location Duquesne, Pa. Gary, Ind. S. Chicago, m. Geneva, Utah Torrance, Ca. Ala. No. of agglomerating facilities 1 1 5 1 2 4 No. of blast furnaces 3 4 4 13 8 3 6 Type of furnace Basic oxygen Electric arc Basic open hearth Basic open hearth Basic oxygen Basic oxygen A.O.D. 4 strand billet caster Electric arc Basic open hearth Basic open hearth Basic open 'hearth Steel production No. of furnaces 2 5 14 2 6 3 1 1 1 10 4 9 Steel grade Carbon, alloy Alloy. stainless Carbon, alloy A Carbon, alloy Carbon, alloy Stainless Carbon Stainless Carbon, alloy Carbon, alloy Carbon, alloy Size tons*/heat 215 20 50 85 i) i 3,i 163 215 200 200 90 200 100 340 11 63 340 (4) 230 150 1} Coke production Yes Yes Yes Yes * Metric Tons (1000 kg) ------- Table C-l(continued). IRON AND STEEL PRODUCING FACILITIES ro Company - Plant Texas Works Washington Steel Corp. Fitch Works Wheeling-Pittsburgh Steel Corp. ^^^^^riVWIW*- Steuvenville Plant Honessen Works Witteman Steel Mills Youngstown Sheet & Tube Company Campbell Works Brier Hill Works Indiana Harbor Works Location Bay town, Texas Washington, Pa. Houston, Pa. Pittsburgh, Pa. Steubenville, Ohio Monessen, Pa. Fontana, Ca. Youngstown, Ohio Campbell, Ohio Youngstown, Ohio E. Chicago, Ind. No. of agglomerating facilities 1 1 1 1 No. of blast furnaces 5 2 4 2 4 Type of furnace Basic oxygen Electric a.c Electric arc Basic oxygen Basic oxygen Electric Basic open hearth Basic open hearth Basic open hearth Basic oxygen Steel production No. of furnaces 2 2 2 2 2 1 12 11 8 2 Steel grade Carbon, alloy Carbon, alloy Stainless Carbon Carbon, alloy Carbon Carbon & alloy Carbon & alloy Carbon & alloy carbon & alloy Size tons* /heat 200 200 35 275 200 25 210 175 315 290 Coke production Yes Yes Yes Yes Yes * Metric Tons (1000 kg) ------- Table C-2. DIRECT REDUCTION PLANTS IN OPERATION AND ON ORDER AS OF DECEMBER 1974 15 en Plant - location Armco Steel, Houston, Texas Korf Steel, Georgetown, South Carolina Gilmore Steel, Portland, Oregon HECLA, Casa Grande, Arizona0 Process Armco Midrex Midrex SL/RN Start-up year 1973 1971 1969 1975 Annual rated capacity, tons product per year A 330,000 350,000 300,000 B 65,000 A = In operation. B = On order. c Process residues from calcines Teaching-washing plant into sponge iron for use as precipitant for cement copper production. ------- Table C-3. U.S. IRON ORE PRODUCERS, SALIENT DATA 16 Name of operation/ location Arcturus mine Marble, Minn. Black River Falls mine Black River Falls, Wise Butler Taconite Nashwauk, Minn. Canisteo mine Coleraine, Minn. Cedar City mine Cedar City, Utah Comstock mine Cedar City, Utah Coons Pacific1 Eveleth, Minn. Eagle Mountain mine Eagle Mountain, Calif. Enpire Iron Mining Co. Ishpeming, Mich. 6-ie Mining Co. Hoyt Lakes, Minn. Ownership managing partner under- lined U.S. Steel Inland steel Inland steel Hanna Mininq Wheeling Steel Mesaba-Cliffs National Steel Cleveland Cliffs Utah International CF&I Steel Coons Pacific Kaiser Steel Inland Steel McLouth Steel Cleveland Cliffs International Harvester Bethlehem Steel Youngstown S4T Steel Co. of Canada Interlake Pickands Mather Haul- age (ore) truck , truck truck truck truck truck conv _ truck truck truck, rail Ore mined dtp*)* na 9,000 22,800 29,450 6, OOOs t 4,700nt _ 30,000 45,000 90,000 Ore grade Ore % minerals na hem 33 mag 21.8 mag 38.10 goe hem 39.8 mag, hem 51.92 hem mag hem 34 . hem mag 33 mag 32 mag Cone. Cone. Cone. methods Agglo output grade Cone, (pellet mera- (Itpd)* X methods plants) tion h-m 3,000 67 - mag. sep. pz 7,100 68 - mag. sep. pz 8,100 "j wash, h-m 4, OOOs t 58 h-m, mag. - sep KB _ _ _ 9,500 56-62 wash, jig, h-m, spir 18,000 60 - wash, pz Jig.h-m, mag. sep 16,920 66.5 - mag. sep pz flot siphon 29,600 62.5 - mag. sep pz '74 pro- % grade Pellet Pellets jected final firing (Hpd)* (Itpd)* product - - na na sg 3,000 940,000 64.75 g-k 8,000 2,626,000 66.1 1,200.000 56 - - na na 950,000 51.92 - na - sg 6,500 3,791,000 61 g-k 10,085 4,060,000 64.65 vst 29,100 10,600,000 62.5 Total em- ploy- ees na 239 520 228 na na 57 1,500 827 2,768 * To convert to metric tons per day multiply by 1.016 ------- Table. C-3(cont1nued). U.S. IRON ORE PRODUCERS, SALIENT DATA16 en Ownership managing Name of operation/ partner under- locatlon lined Eveleth Expansion Co. Eveleth, Minn. Eveleth Taconlte Co. Eveleth, Minn. Grace Mine Morgan town, Pa. Gross-Nelson mine Eveleth, Minn. Grovel and mine Randville, Mich. Hill Annex mine Calumet, Minn. Hull Rust mine Hibbing, Minn. Jackson County -Iron. Co.. Black River Falls, Wise. Llnd-Greenway mine Grand Rapids, Minn. Lone Star Steel Co. Lone Star, Texas Armco Steel Steel Co. of Canada Oglebay Norton Dofasco Ford Motor Oglebay Norton Bethlehem Steel Rhude & Fryberger Hanna Mining Jones & Laughlin Rhude & Fryberger Inland Steel Jones & Laughlin Northwest Industries Haul- Ore age mined (ore) (Itpd)* truck na truck, 17,000 rail 1-h-d, 7,025 conv truck 6,000 truck 14,250 truck, 20,000 conv truck 4,000 truck 7,500 * truck 20,000 truck na Ore grade Ore % minerals na na 23.5 mag 41.75 mag, chalc 48 hem 35 hem, mag 36.55 goe, hem, 11m 58 hem 36 mag 30 goe. hem, 11m 26.68 11m, sld Cone. '74 Total Cone. Cone. methods Agglo pro- % grade em- output grade Cone, (pellet mera- Pellet Pellets jected final ploy- (Itpd)* X methods plants) tion firing (Itpd)* (Itpd)* product ees na na na mag.sep pz g-k na na na 5,567 67.12 - mag.sep pz g-k 5,700 2,300,000 64.4 4,900 66.35 - mag.sep pz vst 4,900 1,160,700 65.4 3,600 54 wash, .... 300,000 54 jig. h-m 5,850 61 - mag.sep, pz sg 6,000 2,045,000 63 flot 6,000 59.67 wash, .... 940,000 58 h-m, h-m, eye, splr 3,200 54 wash .... 150,000 54 2,700 67.75 - mag.sep pz sg na 920,000 64.91 5,800 58.70 wash, - ... 918,000 58.70 jig, h-m 3,821 42.10 wash - sn rotary - na 52.60 kilns na 472 815 55 475 200 49 242 170 132 * To convert to metric tons per day multiply by 1.016 ------- Table C-S(continued). U.S. IRON ORE PRODUCERS, SALIENT DATA 16 Name of operation/ location Luck Mining Co. Silver City, N.M. Maclntyre Development Tahawus, N.Y. Mather mine Ishperaing, Mich. ' ' McKinley mine gj McKinley, Minn. Meramec Mining Co. Sullivan, Mo. Hinntac Plant Mt. Iron, Minn. National Steel Pellet Plant Keewatln, Minn. Nevada Barth Corp. Carl in, Nev. Pilot Knob Pellet Co. Ironton, Ho. Pioneer Pellet Plant Ishpesing, Mich. Ownership managing partner under- lined Private N L Industries Republic Steel Bethlehem Steel McLouth Steel Cleveland Cliffs Sharon Steel Jones 8 Laugh! in Bethlehem Steel St. Ooe Minerals U S Steel National Steel Hanna Mining Nevada-Earth Hanna Mining Haul- age (ore) truck truck rail, hoist truck truck, rail, conv truck, rail truck, conv truck conv, Ore mined (Itpd)* 180 5,000 7,300 17,000 8,500 110,000 24,000 1,200 5,979 Ore grade % 43 28 54.69 56.5 45 22 31 60 34.6 Ore minerals hem mag hem, mar goe, hem, Hm mag mag mag hem, mag mag Cone. Cone. output grade (Itpd)* % none 1,000 12,000 5,500 35,000 7,200 none 5,616 - 62.64 60 69 65 67.2 none 65 Granite City Steel 1-h-d Republic Steel Bethlehem Steel McLouth Steel Cleveland Cliffs Sharon Steel hem, inar 4,800 60.75 Cone. methods Agglo Cone, (pellet mera- methods plants) tion - mag, sep wash mag. sep pz flot, fine scr mag. sep pz mag. sep pz mag. sep pz flot h-m none pz '74 pro- Pellet Pellets jected firing (Itpd)* (Itpd)* 40,000 261,000(gt) 1.954,000 2,240,000 vst 4,800 na g-k 35,000 12,500,000 g-k 7,740 2,600,000 105,000 sg 4,080 950,000 g-k 4,616 1,550,000 % grade final product 43 62.64 60.22 60 67 65.3 65.7 60 63.46 61.5 Total em- ploy- ees 11 186 575 245 na 2,940 569 20 435 113 * To convert to metric tons per day multiply by 1.016 ------- Table C-3(continued). U.S. IRON ORE PRODUCERS, SALIENT DATA 16 Name of operation/ location Pi tanner mine Coleraine, Minn, Republic mine Ishpemlng, Mi. Neville mine Chlsholm, Minn. New York Division Star Lake, N.Y. Rana mine Klnney, Minn. Reserve Mining Co. Silver Bay, Minn. Rouchleau group Virginia, Minn. Sherman mine CMsholm, Minn. Sherwood mine Iron River, Mich. Stephens mine Aurora, Mich. Ownership managing partner under- lined U. S. Steel Jones & Laughlin Cleveland Cliffs Wheeling Pitts. International Harvester Pittsburgh Pacific* Jones & ? Laughlin Rhude & Freyberger Republic Steel Annco Steel U.S. Steel U.S. Steel Inland Steel U.S. Steel Haul- age (ore) truck. conv truck truck truck truck truck truck, rail truck, rail rail, conv, hoist truck Ore mined (Itpd)* na 24,200 8,650 9,600 3,600 85,000 na na 1,600 na Ore grade Ore X minerals na hem 36 hem mag na hem 23.2 mag, mar 58 hem 24 mag na hem. lim na hem, 11m 54.7 goe, hem na na Cone. output (Hod)* na Cone. grade na 10,400 65.37 na 2,730 2,400 28,500 na na na na na 66.3 52 64.6 na na na na Cone. Methods Cone, (pellet methods plants) wash, h-m flot, elut wash mag.sep splr wash mag.sep crush. scr, h-m wet scr, h-m - crush, scr '74 Agglo pro- mera- Pellet Pellets jected tion firing (Itpd)* {Itpd)* ... na pz g-k na 2,6)0,000 200.000 sn - - 943,000 100,000 pz sg 29,50010,491,583 ... na - na 385,000 - na I grade final product 59.9 65.2 na 65.2 52 Total em- ploy- ees na 831 226** 509 29 60.76 2,850 58.17 59.18 55 58.10 na na 109 na *To convert to metric tons per day multiply by 1.016 ------- Table C-S(continued). U.S. IRON ORE PRODUCERS, SALIENT DATA 16 CTl CO Name of operation/ location Sunrise mine Sunrise, Wyo. Tilden Mining Co. Ishpeming, H1ch. U S Pipe S Foundry Co. Russcllville, Ala. Whitney mine Nibbing, Minn. Wyoming mine Virginia, Minn. Ownership Managing partner under- lined CFSI Steel Algoma Steel Jones & Laughlin Cleveland Cliffs bteico coal Wheeling Pitts. Sharon Steel Jim Walter Corp. National Steel Hanna Hining Pittsburgh Pacific* Haul- age (ore) rail, conv. hoist truck truck truck, conv truck Ore mined (Itpd)* na 36,800 700 20,300 3.200 Ore grade Ore % minerals nu hem 36 hem 48 goe na goe, hem na hem Cone. Cone. output grade (Itpd)* « 2,400nt 48.99 12,300 1,000 13,500 na 65.61 50+ 52.6 na Cone. methods jig. h-m . h-m, flot wash, h-m h-m Cone. methods Agglo (pellet mera- Pellet Pellets plants) tion firing (Itpd)* flot, pz g-k 11,000 selec- tive floe na * * - '74 pro- jected (Itpd)* 500,000 none na 700,000 175,000 (cone) X grade final product 48.99 65.90 na 52.6 na Total em- ploy- ees 225 618 82 337 226** na - not available hero - hematite h-m - heavy media mag - magnetite mag sep - magnetic separation pz - pelletizing sg - straight gate g-k - grate-kiln goe - goethite wash - washing st - short tons conv - conveyor nt - net tons jig - jigging spir - spirals flot - flotation 1-n-d - load haul dump siphon - siphonsizers vsf - vertical shaft furnace chalc - chalcocite lira - limestone eye - cyclones sid - siderite gt - gross tuns fine scr - fine screening mar - martite elut - elutriation ** - combined total for Neville, Wyoming mines sn - sintering scr - screening wet scr - wet screening floe - flocculation * - leased for U.S. Steel * To convert to metric tons per day multiply by 1.016 ------- Table C-4. MINE AND PLANT EXPANSIONS - IRON AND STEEL INDUSTRY IN USA - 1975 17 Company Bethlehem Steel Cleveland Cliffs Iron Cleveland Cliffs Eveleth Taconite Hibbing Taconite Inland Steel Mitsubishi U.S. Steel National Steel Plant U.S. Steel Sovereigh, In. Krupp Location Cornwall, Pa. Til den, Mi. Empire, Mi. Eveleth, Mn. Hibbing, Mn. Minorca, Mn. Klukwan, Al . Keewatin, Mn. Virginia, Mn. Black Mt. , Az. Project3 co/pp mi/co/pp mi/co/pp co/pp PP co/pp mi/pp PP co/pp mi/pp Capacity planned tpy* 762M 10.2MM 5.4MM 6.1 MM 5.5MM 2.6MM 3.6MM 6.1MM 18.3MM Start 1975 1974 1974 1976 1976 1978 1977 1978 Notes Reopening of plant closed down in mid-1973. Recoverable reserves over 900MM tons of 36% iron ore. Started up in fourth quarter 1974. Possible further expansion. Partners in the expansion are Stelco, Dofasco, Armco Steel . Jointly owned by Bethlehem Steel and Pickands Mather. The co plant to be built by Bechtel and pp by Dravo. Capacity reduced from original 5MM typ of pellets. Deliveries would start 3-1/2 yr after construction starts. NSP is owned by National Steel 85% and Hanna Mining 15%. Tentative agreement for partnership. cr> a Abbreviations: co - concentrator, pp - pellet plant, mi - mine, M - thousands, MM - millions. * Metric Tons (1000 kg) ------- Table C-5. MAJOR CAPTIVE STEEL COAL MINES 18 Controlling company Operating company State Production, metric tons, 1974 1. U.S. Steel Corp. 2. Bethlehem Steel Co. 3. Republic Steel Corp. 4. Jones & Laugh!in Steel Corp. 5. Youngstown Sheet & Tube Co. 6. Inland Steel Co. 7. Kaiser Steel Corp. 8. Armco Steel Corp. 9. Cannelton Industries, Inc. 10. National Steel Corp. 11. Steel Co. of Canada 12. CF & I Steel Corp. U.S. Steel Corp. Bethlehem Mines Corp. Beth-Elkhorn Coal Corp. Republic Steel Corp. Jones & Laughlin Steel Corp. Gateway Coal Co. Olga Coal Co. Buckeye Coal Co. Youngstown Mines Corp. Inland Steel Co. Kaiser Steel Corp. Armco Steel Corp. Big Mountain Coal, Inc. Cannelton Coal Co. (Div. of Algoma Steel Corp.) Maple Meadows Mining Co. National Mines Corp. Pikeville Coal Co. CF & I Steel Corp. Ala., W. Va., Ky., Colo., Pa., Utah Pa., W. Va., Ky. Pa., Ky. Pa. Pa. W. Va. Pa. W. Va. 111. N. M., Utah W. Va. W. Va. W. Va. W. Va. Pa., Ky. Ky. E Colo. 14,865,306 8,995,124 3,111,566 2,676,797 1,639,469 990,758 1,148,662 796,553 419,229 2,239-, 849 1,859,365 1,355,737 414,949 1,761,217 9,504* 1,754,256 720,323 489,655 ------- Table C-5(Continued). MAJOR CAPTIVE STEEL COAL MINES Control 1 i ng company 13. Wheeling-Pittsburgh Steel Corp. 14. Keller Steel Co. Operating company W-P Steel Corp. Buckeye Coal Mining Co. Industrial Mining Co. State W. Va. Ohio Ohio Total Production, metric tons, 1974 397,350 93,379 88,054 45,827,102 4989 TPD capacity. ------- Table C-6. COKE-OVEN PLANTS IN THE UNITED STATES ON DECEMBER 31, 1973^'19 Name and address of company Alabama Alabama Byproduct Corp. P.O. Box 10246 Birmingham, Alabama 35202 Republic Steel Corp. P.O. Box 6778 Cleveland, Ohio 44101 Republic Steel Corp. P.O. Box 6778 Cleveland, Ohio 44101 Empire Coke Co. 2201 First Avenue North Birmingham, Alabama 35203 U.S. Pipe & Foundry Co. 330 First Avenue North Birmingham, Alabama 35202 U.S. Steel Corp. 600 Grant Street Pittsburgh, Pennsylvania 15230 Woodward Iron Co. Division of Mead Corp. Woodward, Alabama 35189 California Kaiser Steel Corp. P.O. Box 217 Fontana, California 92336 Colorado Colorado Fuel & Iron Steel Corp. P.O. Box 316 Pueblo, Colorado 81002 Illinois Granite City Steel Co. P.O. Box 367 Granite City, Illinois 62041 Inter! ake Inc. 135th Street & Perry Avenue Chicago, Illinois 60627 International Harvester Co. 2800 East 106th Street Chicago, Illinois 60617 Location of plant Tarrant Gadsden Thomas Holt Birmingham Falrfleld Woodward Fontana Pueblo Granite City Chicago Chicago Classifi- cation of plant Merchant Furnace Furnace Merchant Furnace Furnace Furnace Furnace Furnace Furnace Furnace Furnace Major uses of coke Captive BF, other Industrial BF BF, foundry, other in- dustrial BF, other Industrial BF, foundry BF BF, foundry, other in- dustrial BF, other Industrial BF BF Commercial sales BF, foundry, other industrial , Foundry, other industrial BF, foundry Other Industrial BF, foundry Foundry, other Industrial - .. BF Coal -chemical materials produced3 1,5,13 1,5,13,14,15,16, 17,19 1,5,13,14,14A,19 1,5,7,13,18 1,5,13,18 1,5,6,12B,13,19A 1,5,13,14,15,16, 17, 19A 3,5,13,18 1,2,3,5,6,12A, 126,13,14,15,16 17,19 1,5,13,18 1,5,13,19 1,5,13 I ro ------- Table c-6(cont1nued). COKE-OVEN PLANTS IN THE UNITED STATES ON DECEMBER 31. 19731'19 Name and address of company Illinois, continued Republic Steel Corp. P.O. Box 6778 Cleveland, Ohio 44101 Indiana Bethlehem Steel Corp. Bethlehem, Pennsylvania 18016 Citizens Gas & Coke Utility 2020 North Meridian Street Indianapolis, Indiana 46202 Indiana Gas & Chemical Corp. 13th & Hulman Streets Terre Haute, Indiana 47802 Inland Steel Co. 30 West Monroe Street Chicago, Illinois 60603 U.S. Steel Corp. 600 Grant Street Pittsburgh, Pennsylvania 15230 Youngs town Sheet & Tube Co. P.O. Box 900 Youngstown, Ohio 44501 Kentucky Allied Chemical Corp. P.O. Box 1013R Morristown, New Jersey 07960 Maryl and Bethlehem Steel Corp. Bethlehem, Pennsylvania 18016 Michigan^ Allied Chemical Corp. P.O. Box 1013R Morristown, New Jersey 07960 Ford Motor Co. The American Road Dearborn, Michigan 48121 Location of plant Chicago Burns Harbor Indianapolis Terre Haute Indiana Harbor . Gary Indiana Harbor Ashland Sparrows Point Detroit Rouge Classifi- cation of plant Furnace Furnace Merchant Merchant Furnace Furnace Furnace Merchant Furnace Merchant Furnace Major uses of coke Captive2 BF, other industrial BF, Other In- dustrial BF BF, other industrial BF, other industrial BF, other Industrial Foundry, other industrial BF, foundry, other In- dustrial Commercial sales BF, foundry, other Industrial Foundry, other industrial BF BF, foundry, other Industrial Other industrial Coal -chemical materials produced^ 1,5,6,13,19A 1,5 5 5,13,14,15,16,17 1,5,7,13 1,5, 6, 12,13, 19A 2,5,13,18 2,5^7,13 1,5,13,14,15,16, 18 5 3,5,13 ------- Table C-6(continued). COKE-OVEN PLANTS IN THE UNITED STATES ON DECEMBER 31, 19731'19 Name and address of company Michigan, continued fireat Lakes Steel Corp. Detroit, Michigan 48229 Minnesota (Coppers Co., Inc. 1000 North Hamllne Avenue St. Paul, Minnesota 55104 U.S. Steel Corp. 600 Grant Street Pittsburgh, Pennsylvania 15230 Missouri Great Lakes Carbon Corp. 299 Park Avenue New York, New York 10017 New York Allied Chemical Corp. P.O. Box 1013R Morris town, New Jersey 07960 Bethlehem Steel Corp. Bethlehem, Pennsylvania 18016 Donner-Hanna Coke Corp. Abby & Mystic Streets Buffalo, New York 14220 Ohio ATrTed Chemical Corp. P.O. Box 1013R Morris town, New Jersey 07960 Armco Steel Corp. Middletown, Ohio 45042 Armco Steel Corp. Middletown, Ohio 45042 Diamond Shamrock Chemical Co. 1100 Superior Avenue Cleveland, Ohio 44115 Empire-Detroit Steel Division Portsmouth, Ohio 45662 Location of plant Zug Island St. Paul Duluth St. Louis Buffalo Lacka wanna Buffalo ' Ironton Hamilton Middletown Raines vi lie Portsmouth Classifi- cation of plant Furnace Merchant Furnace Merchant Merchant Furnace Furnace Merchant Furnace Furnace Merchant Furnace Major uses of coke Captive2 BF BF, other Industrial Foundry, other industrial Foundry, other industrial BF BF, other Industrial Foundry, other Industrial BF BF Other in- dustrial BF, other Industrial Commercial sales BF Foundry, other industrial Other Industrial Foundry, other industrial BF, foundry, other Industrial Other industrial BF, foundry, other industrial Foundry, other industrial Other industrial Foundry, other Industrial Coal -chemical materials produced^ 1,5,8,13 V v 9 *^ 9 v 5 1,5 5 2,5,7,13 1,5,8,13,18 1,5,8,13 2,5,7,13 1,5,13 1,5,8,13, 14, 14A, 15,16,17,18 2,5 5,13 ------- 1 19 Table C-6(continued). COKE-OVEN PLANTS IN THE UNITED STATES ON DECEMBER 31, 1973 ' Name and address of company Ohio, continued Inter! ake Steel Corp. 135th Street & Perry Avenue Rlverdale, Illinois 60627 Republic Steel Corp. P.O. Box 6778 > Cleveland, Ohio 44101 Republic Steel Corp. P.O. Box 6778 Cleveland, Ohio 44101 Republic Steel Corp. P.O. Box 6778 Cleveland, Ohio 44101 Republic Steel Corp. P.O. Box 6778 Cleveland, Ohio 44101 Youngstown Sheet & Tube Co. P.O. Box 900 Youngstown, Ohio 44501 U.S. Steel Corp. 600 Grant Street Pittsburgh, Pennsylvania 15230 Pennsylvania Alan Wood Steel Co. Consholocken, Pennsylvania 19428 Bethlehem Steel Corp. Bethlehem, Pennsylvania 18016 Bethlehem Steel Corp. Bethlehem, Pennsylvania 18016 Crucible Steel Corp. P.O. Box 226 Midland, Pennsylvania 15059 Eastern Gas & Fuel Associates 4501 Richmond Street Philadelphia, Pennsylvania 19137 Location of plant miiM>mtt«MiBvm«iiBBH«*«a^Hi^MN Toledo Cleveland Massillon Warren Youngstown Campbel 1 Loral n Swede! and Bethlehem Johnstown Midland Philadelphia Classifi- cation of plant ^^^MttHH^A^^BBMB^Ut Furnace Furnace Furnace \ Furnace ' Furnace Furnace Furnace Furnace - Furnace Furnace Furnace Merchant Major uses of coke 0 Captive* MMM^^HatfMIMMaHH^BVqB^B^^BVMVIV BF BF BF, other Industrial BF BF, other Industrial BF BF BF, other industrial BF, other Industrial BF, other Industrial BF, other industrial Commercial sales ^^Em^lH^^qvVtlMH^HaBMMMHBBflVMMV^^BI BF BF BF BF, foundry, other industrial BF Foundry, other Industrial Coal -chemical materials produced3 ^^^^MBMHHMmBB^IBMMMnNBHHA 1,5,13,14,15,16 1,5,8,13,14,15, 16,17,19 1,5,13 , - 1,5,13,19 1,5,13,14,15, 16,17,19 1,5,13 1,5,13 5,13,14A,17 1,5,13,14,15, 16,18,19 1,5,7,12,13,17, 18 1,5,8,13 5 CJ1 ------- Table C-6(continued). COKE-OVEN PLANTS IN THE UNITED STATES ON DECEMBER 31, 19731'19 Name and address of company Koppers Co., Inc. P.O. Box 739 Erie, Pennsylvania 16512 Jones 8 Laughlin Steel Corp. Aliquippa, Pennsylvania 15001 Jones & Laughlin Steel Corp. 2709 East Carson Street Pittsburgh, Pennsylvania 15203 Wheeling-Pittsburgh Steel Corp. 1134-40 Market Street Wheeling, West Virginia 26003 Shenango Inc. Neville Island Pittsburgh, Pennsylvania 15225 U.S. Steel Corp. 600 Grant Street Pittsburgh, Pennsylvania 15230 U.S. Steel Corp. 600 Grant Street Pittsburgh, Pennsylvania 15230 Tennessee Chattanooga Coke & Chemical Co., Inc. 4800 Central Avenue Chattanoota, Tennessee 37410 Texas Armco Steel Corp. P.O. Box 1367 Houston, Texas 77001 Lone Star Steel Co. P.O. Box 35888 Dallas, Texas 75235 Utah O7 Steel Corp. 600 Grant Street Pittsburgh, Pennsylvania 15230 Location of plant Erie Aliquippa Pittsburgh Monessen Neville Island Clairton Falrless Alton Park Houston Da inger field Geneva Classifi- cation of plant : Merchant Furnace Furnace Furnace Furnace Furnace Furnace Furnace Furnace Furnace Furnace Major uses of coke y Captive BF, other Industrial BF, other Industrial BF BF, foundry BF BF Foundry BF BF, foundry BF, other Industrial Commercial sales BF, foundry, other Industrial * Other Industrial BF, foundry Other Industrial Foundry, other industrial Other industrial Coal -chemical materials produced^ 5 1,5,8,13,14, 14A, 15, 16,17 1,5,8,13 1,5,8,13 1,5,8,13 5,6,6A,9,9A, 10,11,12,126, 13,14,15,16,1 19.19A.21.22 1,5,8,15,19 1,5,13,14,15, 5 1,5,13,14,15, 16,17 1,5,13,14,15, 16,17,19 cr> ------- Table C-6(continued). COKE-OVEN PLANTS IN THE UNITED STATES ON DECEMBER 31, 1973 .1,19 Name and address of company West Virginia National Steel Corp. Weirton, West Virginia 26062 Sharon Steel Corp. P.O. Box 291 Sharon, Pennsylvania 16146 Wheeling-Pittsburgh Steel Corp. 1134-40 Market Street Wheeling, West Virginia 26003 Wisconsin Milwaukee Solvay Coke Division Pickands Mather 311 East Greenfield Avenue Milwaukee, Wisconsin 53204 Location of plant Weirton Fairmont East Steubenvllle Milwaukee Classifi- cation of plant Furnace Furnace Furnace Merchant Major uses of coke Captive2 BF, other Industrial BF BF Commercial sales Other industrial Other Industrial Other industrial BF, foundry, other Industrial Coal -chemical materials produced^ 1,5,7,8,13,18 1,5,13 1,5,7,8,12,13 5 -Residential and commercial heating Included in other Industrial. "Coke transferred to intergrated operations and to affiliated companies. ^Numbers in this column refer to coal-chemical materials produced at coke plants as follows: 1 - Ammonium sulfate. 2 - Ammonia liquor (NH- content). 3 - Diammonium phosphate. 4 - Monoammonium phosphate. 5 - Crude coal tar. 6 - Creosote oil, straight distillate. 6A - Creosote oil, in coal-tar solution. 7 - Crude chemical oil (tar acid oil). 8 - Sodium phenolate or carbolate. 9 - Phenol (industrial grades). 9A - Phenol, all other grades. 10 - Cresols. 11 - Cresylic acid 12 - P1tch-of-tar, soft, (s.p. minus 110°). 12A - P1tch-of-tar, medium {s.p. 110° to 160°F). 12B - Pitch-of-tar, hard (s.p. over 160eF). 13 - Crude light oil. 14 - Benzene, specification grades. 14A - Benzene, other industrial grades. 15 - Toluene, all grades. 16 - Xylene, all grades. 17 - Solvent naphtha, all grades. 18 - Intermediate light oil. 19 - Naphthalene, crude, solidlfing under 74°C. 19A - Naphthalene, crude, solidifying from 74° to 798C. 20 - Pyrldine, crude bases. 20A - Pyridine, refined (2°C). 21 - Picolines. 22 - Sulfur. ------- Table C-7. SUMMARY OF COKE-OVEN OPERATIONS IN THE UNITED STATES IN 1974, BY STATES8 State Alabama California, Colorado, Utah Maryland and New York Illinois Indiana Kentucky, Missouri, Tennessee, Texas Michigan Minnesota and Wisconsin Ohio Pennsylvania West Virginia Total in 1974 Plants in existence Dec. 31 7 3 4 4 6 5 3 3 12 13 3 63 Coal carbonized (thousand tons)* 6,635 4,817 8,448 2,733 12,467 2,537 4,110 1,181 11,764 21,141 4,774 80,607 Yield of coke from coal (percent) 70.49 62.89 68.61 62.45 66.48 67.74 73.08 70.69 68.64 69.31 69.93 68.42 Coke produced (thousand tons)* 4,647 3,012 5,858 1,735 8,231 1,742 2,957 866 8,022 14,808 3,225 55,103 Metric Tons (1000 kg) 178 ------- APPENDIX D ENERGY AND UTILITY REQUIREMENTS 179 ------- Table :D-1. ENERGY CONSUMPTION IN THE STEEL INDUSTRY - 1972 a,20 Major source Coal, tons Natural gas, liters Fuel oil, liters LP gas, liters Electricity, kWh Others Actual consumption 60.78 x 106 10.5 x 1012 5.42 x 106 3.47 x 108 in 4.72 x 10IU Percent 63 21.7 6.7 0.1 5.2 3.3 Total steel production was 120.88 million metric tons. In addition to the coal quantities listed, an additional 11 million metric tons of coal were used by coke ovens and boilers with equiv- alent Btu's transferred to other than steel consumers in the form of electricity, steam and coke oven products. 180 ------- Table D-2. WATER REQUIREMENTS OF THE IRON AND STEEL INDUSTRY - 19643'21' Process/Mill Blast furnace Open hearth furnace Basic oxygen furnace Electric furnaces Hot- roll ing mills and related Cold mills and related Coke plants Sanitary, boilers, etc. Blowers, condensers, etc. Process water, liters per ton* of steel 9,100 33 262 33 15,400 8,700 200 Cooling water, liters per ton of steel 19,000 16,100 1,200 2,100 15,400 - 20,800 8,300 64,200 a Total production of steel was 115.3 million tons. Estimated process water and cooling water reuse were 18.1 and 52.2 percent, respectively. * Metric Tons (1000 kg) 181 ------- APPENDIX E EMISSION DATA 183 ------- Table E-l. QUANTITIES OF POLLUTANTS DISCHARGED FROM IRON AND STEEL INDUSTRY5 BEFORE TREATMENT IN -|97123>24>25>26 (Thousand metric tons) Pollutants Air Pollutants Particulates Ammonia Water Pollutants Suspended solids Ammonia Cyanide Phenol FeS04 H2S04 Sintering 882 - k 470 PROCESS Materials handling 545 - Reduction, blast furnace 4810 - 2464 Steel furnace Open * hearth 296 - 3780a Basic oxygen 1680 - Electric arc 166 - Scarfing 163 * Pickling 458 123 Rolling mill 4578 Coking, by-product 59.2 203 _ 2.84 0.41 2.19 CO a Total for open hearth and basic oxygen. ------- Table E-2. SUMMARY OF WASTE STREAMS (NON-RADIOACTIVE) RELEASED FROM IRON AND INDUSTRY22 (Percent of total) Geographic area New England Mid-Atlantic East North Central West North Central South Atlantic East South Central West South Central Middle West Total metric tons/} Iron manufacturing Waste sludge 0.05 0.05 0.56 0.02 0.12 0.03 0.09 0.05 0.03 r 2,720 Consolidated Steel plant waste 0.02 0.33 0.42 0.02 0.09 0.02 0.03 0.05 0.02 227,000 Coke Plant Raw waste 0.002 0.33 0.41 0.01 0.07 0.02 0.06 0.06 0.02 36,300 185 ------- Table E-3. METAL ANALYSIS OF EMISSION TESTS (CONDUCTED IN 1973) ON VARIOUS PROCESSES AT A MAJOR NORTHWEST STEEL PLANT23 Source test Sinter plant, ESP dust Blast furnace, scrubber sample Open hearth, ESP dust Basic oxygen, scrubber sample Electric furnace, baghouse dust Cadmium ppm 13 14 250 80 580 Lead ppm 320 830 18,000 4,600 32,000 Zinc ppm 820 9,300 157,000 45,000 190,000 186 ------- Table E-4. ANALYSIS OF WASTEWATER DISCHARGE FROM IRON ORE MINING AND CONCENTRATION OPERATIONS AT ONE MILL24 Constituent Lead Phosphorus Arsenic Selenium Copper Iron Manganese Magnesium Zinc Chlorine Sul fates Phenol a Hardness as CaCO PH mg/1 0.014 0.002 0.005 0.005 0.005 0.167 1.94 27.6 0.03 10.9 227.0 0.005 o 287 3 7.0 Table E-5. SOURCES OF MILL WASTEWATER AT RESERVE MINING 28 Source Percent of total flow 1640 liters per second (58 cfs) Approximate suspended solids content, mg/1 Cyclone overflows Primary flotation underflows Regrind flotation underflows Dewatering operations Pellet plant Crusher and dust collection Miscellaneous 17.5 42.0 15.5 14.5 0.5 4.0 6.0 14,000 150,000 40,000 1,000 5,000 187 ------- Table E-6. POTENTIALLY HAZARDOUS EMISSIONS FROM COKE PLANTS26 Status Known present/ known hazardous Known present/ suspected hazardous Chemicals potentially present Emission class Amines Combustion gases Polynuclear Organometal lies Fine particulates Cyanides Acid and anhydrides Amines Carbonyl compounds Polynuclear Sul fur compound-, Specific components a + 6 Naphthyl amine 4-aminobiphenyl Carbon monoxide Pyrene Chrysene Benzo(a)pyrene Benzo(e)pyrene Dibenzo( a, h) -anthracene Di benzo (a ,g )f 1 uorene Nickel carbonyl Tar Soot Hydrogen cyanide Benzoic acid Hydroxybenzoic acid Hydrochloric acid Ammonia Ani line Methyl am" line Formaldehyde Acetaldehyde Paraldehyde Methyl chrysene Benzo(a)anthraceno Dimethyl ben zanthracenes Methyl mercaptan Ethyl mercaptan Phase Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas 188 ------- Table E-6(continued). POTENTIALLY HAZARDOUS EMISSIONS FROM COKE PLANTS26 Status Suspected present/ known hazardous Suspected present/ known hazardous Chemicals potentially present Emission class Trace elements | Specific components Beryl! ium Silver metals and soluble compounds Mercury Vanadium Lead Heterocycl ics Hydrocarbons Phenols Cadmium Antimony Arsenic Barium Pyridine Alkyl pyridine Phenyl pyridine (Mono) Benzofurans Qu incline Alkyl quinoline Al iphatics 01 e fins Benzene Toluene Xylene Alkyl benzenes Phenol o,m,p-cresols Phenyl phenol Alkyl phenols Alkyl cresols Phase Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gar, Gas /"» Gas Gas Gas Gas Gas Gas Gas Gas 189 ------- Table E-6(continued). POTENTIALLY HAZARDOUS EMISSIONS FROM COKE PLANTS26 Status Emission class Chemicals potentially present Specific components Phase Polynuclear Sulfur compounds Trace elements Fine particulates Cyanimides BipTienyl Naphthalene Alkyl naphthalene Phenyl naphthalene Tetralin Methyl tetralin Acenaphtylene Acenaphthene Fluorene Alkyl anthracenes Phenanthrenes Alkyl phenanthrenes Coronene Carbazole Acridine Benzocarbazoles Aklylacridines Benzo(a)anthrone Perylene Hydrogen sulfide Thiophenes Methyl thiophcne Carbon disulFide Carbonyl sulfide Selenium Coke Coal Ammonium cyanide Naphthyl cyanide Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas 190 ------- Table E-7. CHEMICALS POTENTIALLY PRESENT IN EMISSIONS FROM COKE QUENCHING AND DIRECT COOLING OPERATION26 Status Known present/ known hazardous Known present/ suspected hazardous Chemicals potentially present Emission class Amines Combustion gases Phenols Polynuclear Organometallics Fine particulates Cyanides Acid and anhydrides Amines Inorganic salts Carbonyl compounds Heterocyclics Hydrocarbon Specific components a + 0 Napthyl amine 4-aminobiphenyl Carbon monoxide Phenol Pyrene Chrysene Benzo(a)pyrene Benzo(e)pyrene Dibenzo(a,h)anthracene Dibenzo(a,g)fluorene Nickel carbonyl Tar Soot Hydrogen cyanide Benzoic acid Hydro xybenzoic acid Hydrochloric acid Sulfur acid Ammonia Aniline Methyl anilines Ammonia Ammonium sulfate Formaldehyde Acetaldehyde Paraldehyde Pyridine Benzene Toluene Xylene Phase Gas Gas Gas Aqueous Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Aqueous Gas Gas Gas Aqueous Aqueous Gas/Aqueous Gas/Aqueous Gas Aqueous Aqueous Aqueous Aqueous 191 ------- Table E-7 (Continued). CHEMICALS POTENTIALLY PRESENT IN EMISSIONS FROM COKE QUENCHING AND DIRECT COOLING OPERATION26 Status Suspected present/ known hazardous ; i Chemicals potentially present Emission class Phenols Polynuclear Sulfur compounds Trace elements Organometallics Cyanides Heterocyclics Hydrocarbons Phenols Specific components o,m,p-Cresol Methyl chrysenes Benzo(a)anthracene Dimethyl benzanthracene Methyl mercaptan Ethyl mercaptan Thiophenes Beryl 1 i urn Silver metals and soluble compounds Mercury Vanadium Lead Cadmi urn Antimony Arsenic Barium Selenium Nickel carbonyl Hydrogen cyanide Ammonium cyanide Ammonium thiocyanate Pyridine Alkyl pyri dines Phenyl pyri dine (Mono) Benzofurans Quinoline Alkylquinolines Dibenzofuran Alkyl dibenzonfurans Aliphatics Olefins Benzene Tol uene Xyl ene Alkyl benzenes Phenol o,m,p-Cresols Phenyl phenol Xylenols Phase Aqueous Gas Gas Gas Gas Gas Aqueous Gas Gas Gas/Aqueous Gas Gas/Aqueous Gas Gas Gas Gas Aqueous Aqueous Aqueous Aqueous Aqueous Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas ------- Table E-7 (Continued). CHEMICALS POTENTIALLY PRESENT IN EMISSIONS FROM COKE QUENCHING AND DIRECT COOLING OPERATION26 Status Emission class Chemicals potentially present Specific components Phase Polynuclear Sulfur compounds Trace elements Fine particulate: Cyanides Alky! Alkyl phenols cresols Biphenyl Naphthalene Alkyl naphthalenes Phenyl naphthalenes Tetralin Methyl tetralins Acenaphthylene Acenaphthene Fluorene Anthracene Alkyl anthracenes Phenanthrenes Alkyl phenanthrenes Coronene Carbazole Acridine Benzocarbazoles Alkylacridines Benzo(a)anthrone Perylene Hydrogen sulfide Thiophenes Methyl thiophenes Carbon disulfide Carbonyl sulfide Selenium Arsenic (arsenic tri- oxide, sodium arsenate, sodium arsenite) Barium (acetate, chloride, nitrate) Cadmium (chloride, nitrate sulfate) Coke Coal Ammonium cyanide Naphthyl cyanide Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Aqueous Aqueous Aqueous Gas Gas Gas Gas 193 ------- APPENDIX F TYPES AND NUMBERS OF STEEL FURNACES 195 ------- Table F-l . ELECTRIC DIRECT-ARC STEELMAKING FURNACES IN THE UNITED STATES, AS OF JANUARY 1, 197027 Capacity range, net tons* 1 - 5 6-10 11 - 15 16 - 20 21 - 25 26 - 30 31 - 35 36 - 40 41 - 45 46 - 50 51 - 60 61 - 70 71 - 80 si - :o 91 - "1 00 101 - 120 121 - 140 141 - 160 161 - 180 181 - 200 201 - 225 226 - 250 400 Total Number of furnaces 15 17 44 20 19 14 11 6 8 12 12 13 19 7 12 10 3 22 6 10 2 1 1 284 Source: Iron and Steel Works Directory of the United States and Canada, published by American Iron and Steel Institute, New York, N.Y. (1970). * Metric tons (1000 kg) 196 ------- Table F-2. BASIC OPEN-HEARTH FURNACES IN THE UNITED STATES27 (as of January 1, 1970) Rated capacity per heat, net tons* 11 - 30 31 - 50 51 - 70 71 - 90 91 - 110 111 - 130 131 - 150 151 - 170 171 - 190 191-210 211 - 230 231 - 280 281 - 330 331 - 380 381 - 400 401 - 450 451 - 500 501 - 550 551 - 600 Tons* of open-hearth steel produced, thousands of net tons* Percent of total raw steel production Furnaces over 191 -ton* capacity Furnaces under 191 -ton* capacity All types including stationary and filtering type 4 4 2 13 _ 76 33 51 61 39 40 33 28 13 7 1 2 1 60,934 43.2 i 225 183 * Metric tons (1000 kg) 197 ------- Table F-3. BASIC OXYGEN PROCESS STEELMAKING FURNACES IN THE UNITED STATES, CLASSIFIED INTO CAPACITY RANGES27 (As of January 1, 1970) Capacity range, net tons* 51 - 75 76 - 100 101 - 125 126 - 150 151 - 175 176 - 200 201 - 225 226 - 250 251 - 275 276 - 300 301 - 325 326 - 350 Number of furnaces with rated capacities within range 2 8 10 11 _ 15 7 6 4 9 - 2 * Metric Tons (1000 kg) 198 ------- REFERENCES FOR APPENDICES 199 ------- REFERENCES FOR APPENDICES 1. Kirk-Othmer. Iron. In: Encyclopedia of Chemical Technology, Volume 12, New York, John Wiley and Sons, 1968. p. 1-21. 2. Annual Statistical Report. American Iron and Steel Institute - 1973. Washington, D.C. 1974. 3. Coke and Coal Chemicals in 1974. Mineral Industry Surveys, U.S. Department of the Interior, Bureau of Mines. Washington, D.C., November 11, 1975. 4. Labee, C.J. Steel Making at Weirton. Iron and Steel Engineer. W1-W60, October 1969. 5. Aiken, G.E., and et al. Streamlining the North American Toconite Industry. Society of Mining Engineering. October 1973. 6. Lee, Oscar. Taconite Beneficiation comes of Age at Reserve's Babbit Plant. Mining Engineering. 484-488, May 1954. 7. Benett, R.L., R.E. Hagen and M.E. Mielke. Nodulizing Iron Ore and Concentrates at Extaca. Mining Engineering. 6:32-38. Jaunary 1954. 8. Coke anc Coal Chemicals in 1974 (Preliminary release of information pending publication of Bureau of Mines Minerals Yearbook), Mineral Industry Surveys, U.S. Deparment of Interior, Bureau of Mines. Washington, D.C. November 1975. 9. Kirk-Othmer. Carbonization. In: Encyclopedia of Chemical Techno- logy, Volume 4, New York, John Wiley and Sons, Inc., 1968. 10. ESS, T.J. The Modern Coke Plant. Iron and Steel Engineer. C3- C36. January 1948. 11. Light Oil. Chapter 11. In: Coal, Coke and Coal Chemicals. Chemical Engineering Series, Wilson, Jr., P.J. and J.H. Wells. (ed). New York, McGraw-Hill Book Co., 1950. p. 336-337. 12. Perch, M. and R.E. Muder. Coal Carbonization and Recovery, of Coal Chemicals. In: Riegel's Handbook of Industrial Chemistry, Seventh Edition, New York, Van Nostrand Reinhold, 1974. p. 193-206. 200 ------- 13. Wilson, Jr., P.J. and J.H. Wells. Ammonical Liquor. Chapter 23. In: Chemistry of Coal Utilization, Volume II, Larvey, H.H. (ed). New York, John Wiley and Sons, Inc., 1945. p. 1371-1421. 14. Directory of Iron and Steel Works of the United States and Canada. Thirty-third Edition. American Iron and Steel Institute, Washington, D.C. 1974. 15. Kotsch, J.A. and C.J. Lakee, Annual Review 1974. Iron and Steel Engineer, D1-D46, January 1975. 16. Billion Dollar Expansion in U.S. Iron reflects High Demand Forecasts. Engineering and Mining Journal, p. 106-157, November 1974. 17. 1975 E/MJ Survey of Mine and Plant Expansion. Engineering and Mining Journal. 73-78, January 1975. 18. 1974, Keystone Coal Industry Manual. New York, Mining Information Services of the McGraw Hill Publications, 1974. 19. Coke Producers in the United States in 1973. Mineral Industry Surveys, U.S. Department of the Interior, Bureau of Mines. Washing- ton, D.C., September 1974. 20. Mimmick, K.L. The Energy Problems - Where are Our Priorities. Iron and Steel Engineer. 63-65, May 1974. 21. Industrial Waste Profiles No. 1 - Blast Furnace and Steel Mills. Volume III. The Cost of Clean Water. Federal Water Pollution Control Administration. FWPCA Contract Number 14-12-98. September 28, 1967. 22, Office of Solid Waste Management Programs. Hazardous Waste Stream Data. Appendix B. In: Report to Congress, Disposal of Hazardous Wastes, U.S. Environmental Protection Agency, 1974. p. 47-54. 23. Yost, K.J. and et al. Purdue University. Flow of Cadmium and Other Trace Metals. Volume 1. National Science Foundation. Project No. PB-229478. June 30, 1973. 24. Lewis, C.J. Metal-Mining, In: Industrial Waste Water Control, Chemical Technology, A series of Monographs, Volume 2, Gurnham, C.F. (ed). New York, Academic Press, 1965. 25. Baillod, C.R., G.R. Alger, and H.S. Santeford, Jr. Wastewater Resulting from the Beneficiation of Low Grade Iron Ore. Michigan Technological University. (Proceedings of 25th Industrial Waste Conference. Purdue University. Lafayette, Indiana, May 1970). 57 p. 201 ------- 26. Cavanaugh, G, and et al, Potentially Hazardous Emissions from the Extraction and Processing of Coal and Oil, Environmental Protection Agency, Publication No, 650/2-75-038. April 1974. p. 69-77. 27. The Making, Shaping and Treating of Steel, Ninth Edition, McGannon, H.E. (ed). Pittsburgh, Pennsylvania, U.S. Steel Company. 1971. 202 ------- TECHNICAL REPORT DATA (Please read /nttntctions on the reverse bcjorn completing) REPORT NO. ;PA-600/2-77-023x 2. NTIS No. PR 266226/AS 3. RECIPIENT'S ACCESSION'NO. TITLE AND SUBTITLE ndustrial Process Profiles for Environmental Use: Chapter 24. The Iron and Steel Industry 5. REPORT DATE February 1977 6. PERFORMING ORGANIZATION CODE AUTHOR(S) Terry Parsons, Editor 8. PERFORMING ORGANIZATION REPORT NO. 'ERFORMING ORGANIZATION NAME AND ADDRESS Radian Corporation P.O. Box 9948 Austin, Texas 78766 10. PROGRAM ELEMENT NO. 1AB015: ROAP 21AFH-025 11. CONTRACT/GRANT NO. 68-02-1319, Task 34 2. SPONSORING AGENCY NAME AND ADDRESS EPA, Office of Research and Development Industrial Environmental Research Laboratory Research Triangle Park, NC 27711 13. TYPE OF REPORT AND PERIOD COVERED Initial: 8/75-11/76 14. SPONSORING AGENCY CODE EPA/600/13 5. SUPPLEMENTARY NOTES Chapter authors are V.S.Katari and R.W.Gerstle (PEDCo.). IERL- RTP project officer I.A. Jefcoat is no longer with EPA: contact G.Tucker, Mail Drop 63. 919/541-2745. 8. ABSTRACT The catalog was developed to aid in defining the environmental impacts of U.S. indistrial activity. Entries for each industry are in consistent format and form separate chapters of the catalog. The iron and steel industry encompasses a variety of processes for transforming iron ore into fabricated iron and steel products: most Large steel mills operate by-product coke plants that produce metallurgical coke and coke by-products. The industry is divided into five segments: ore preparation, coke production, coke by-products recovery, pig iron production, and steel manufacturing. Five process flow sheets and 30 process descriptions characterize the industry. For ach process description, available data is presented on input materials, operating parameters, utility requirements, and waste streams. Related information, presen- ted as appendices, includes raw materials, company, and product data. 7. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS b.lDENTIFIERS/OPEN ENDED TERMS c. COSATI Field/Group Pollution Industrial Processes Chemical Engineering Iron and Steel Industry Iron Ores Coking Coke Pig Iron Steel Making Process Assessment Environmental Impact 13B 13H 07A 11F 08G 12 D 18. DISTRIBUTION STATEMENT Unlimited 19. SECURITY CLASS (This Report) Unclassified 21. NO. OF PAGES 213 20. SECURITY CLASS (Thispage) Unclassified 22. PRICE EPA Form 2220-1 (9-73) 203 ------- |