Iron & Steel 1 AT A GLANCE 1996-2005 Iron & Steel Mills Integrated Mills Mini Mills 119 facilities 153,711 employees 122 107,474 2% 30% 95.5 million metric tons of iron & steel produced 94.9 million less than 1% 62 Iron & Steel <strong>2008</strong> SECTOR PERFORMANCE REPORT
Latest <strong>Environmental</strong> Statistics 2 Energy Use: 1.5 quadrillion Btu Emissions of Criteria Air Pollutants: 755,000 tons Releases of Chemicals <strong>Report</strong>ed to TRI: 263.9 million lbs. air emissions: 3.7 million lbs. Water Discharges: 2.9 million lbs. Waste Disposals: 257.0 million lbs. Recycling, Energy Recovery, or Treatment: 462 million lbs. Hazardous Waste Generated: 1.4 million tons Hazardous Waste Managed: 1.3 million tons The data discussed in this report are drawn from multiple public and private sources. See the Data Guide and the Data Sources, Methodologies, and Considerations chapter for important information and qualifications about how data are generated, synthesized, and presented. Profile The Iron & Steel sector manufactures steel used in products such as vehicles, appliances, machinery, and equipment, and in other sectors. The Construction sector uses more than 22% of steel shipments. 3 The sector includes facilities that produce carbon steel. As noted in the chapter, some data sets define the sector more broadly, to include facilities producing stainless and specialty steels, facilities producing coke for steel production and other uses, and facilities using steel to make new products. NAICS code 331111, for example, also includes facilities making primary metal products, in addition to steel. 4 Data from the U.S. Geological Survey, used to portray the trend in total number of facilities, also include facilities making stainless and specialty steels. Integrated mills produce steel from iron ore using a blast furnace, which consumes carbon, primarily in the form of coke, to convert iron ore to molten iron, known as “pig iron.” A basic oxygen furnace (BOF) then converts the pig iron, along with up to 30% steel scrap, into refined steel. Steelmakers also rely on coal, natural gas, and other fuels and raw materials, in combination with iron, to produce steel. Electric arc furnaces (EAFs) melt steel scrap, along with limited amounts of other iron-bearing materials, to produce new steel. Because scrap can contain a wider range and higher percentage of contaminants, EAF steel requires additional refining to produce some grades of steel that are still made almost exclusively by integrated mills. Steelmakers continue to build new mills using EAFs (also known as mini-mills) and to modernize existing mills, increasing capacity and efficiency while reducing manhours and energy needed per ton of steel produced. Energy Use Significant amounts of energy are required to convert iron ore and scrap to steel. Still, the sector’s energy use per Figure 1 Fuel Use for Energy 2002 Total: 1.5 quadrillion Btu Natural Gas 27% Net Electricity 13% Coal 2% Other 22% Coke and Breeze 36% Note: 1. Other is net steam (the sum of purchases, generation from renewables, and net transfers), and other energy that respondents indicated was used to produce heat and power. 2. Net electricity is an estimation of purchased power and power generation onsite. Source: U.S. Department of Energy <strong>2008</strong> SECTOR PERFORMANCE REPORT Iron & Steel 63
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2008 Sector Performance rePort
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table of Contents i Preface 1 Execu
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Key to our work is collaboration wi
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Energy Use The eight sectors for wh
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Sector Data Side by Side The follow
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TRI Air Emissions Across Sectors 19
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TRI Waste Management Across Sectors
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This report relies upon a variety o
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data Sources, Methodologies, and CO
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Facilities described above must rep
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Data Processing RSEI calculates tox
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• Section 6.2: Transfers to other
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Cement Manufacturing 1. Facilities:
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12. Charles Heizenroth, EPA, person
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Forest Products 1. Facilities: Cens
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40. Includes direct discharges to w
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Public Data Release (PDR) (includes
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Advancing Port Sustainability, Janu