2008 Sector Performance Report - US Environmental Protection ...

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Metal Casting 1 AT A GLANCE 1996-2005 2,822 facilities 2,266 20% 222,513 employees 166,591 25% $14 million tons ferrous and nonferrous shipments $14.2 million 1% 70 Metal Casting 2008 SECTOR PERFORMANCE REPORT
Latest Environmental Statistics 2 Energy Use: 157 trillion Btu Emissions of Criteria Air Pollutants: 75,000 tons Releases of Chemicals Reported to TRI: 49.6 million lbs. air emissions: 3.8 million lbs. Water Discharges: 68,500 lbs. Waste Disposals: 45.7 million lbs. Recycling, Energy Recovery, or Treatment: 127.5 million lbs. Hazardous Waste Generated: 30,000 tons Hazardous Waste Managed: 28,000 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 Metal Casting sector includes establishments that pour molten ferrous metals (iron and steel) or nonferrous metals under high pressure into molds to manufacture castings. 3 Ferrous metal casting includes those castings made with grey iron, ductile iron, malleable iron, and steel. Each 2008 SECTOR PERFORMANCE REPORT type of iron contains different elements that affect its characteristics. Nonferrous castings are predominantly aluminum but might also be brass, bronze, zinc, magnesium, and titanium. More than 90% of all manufactured goods in the United States contain cast metal components. 4 These includes engine blocks, transmission housings, and suspension parts for cars and trucks; undercarriages of farm and construction equipment; and pipes and valves for plumbing fixtures and boilers. U.S. casting operations are now mostly small businesses, with 80% of facilities employing 100 people or fewer. Energy Use In 2002, the Metal Casting sector consumed 157 trillion Btu. 5 The major furnaces that casting operations use are cupola (used primarily for ferrous metal casting), electric, reverberatory, and crucible furnaces. Heating and melting these various metals consumes large amounts of energy, accounting for 72% of the sector’s total energy use, according to U.S. Department of Energy (DOE) estimates. Mold and core making account for 7% of the sector’s energy use, and finishing accounts for 6%. 6 During molding, foundries use energy for transporting materials, mechanical mixing, and making molds and cores. As shown in Figure 1, the sector is heavily dependent on natural gas and purchased electricity, making up 48% and 34%, respectively, of the sector’s fuel inputs for energy in 2002. Coke, the primary fuel for cupola furnaces, was the third largest energy source, at 15%. 7 A DOE report on the sector identified several energy-saving opportunities. Casting operations using iron induction can automate furnace temperature and power controls to prevent overshooting temperature settings, and can minimize the time that the lid is open while melting or holding iron. Operations Figure 1 Fuel Use for Energy 2002 Total: 157 trillion Btu Coke and Breeze 15% Net Electricity Coal 34% 1% Liquified Petroleum Gas and Natural Gas Liquids 1% Distillate Fuel Oil Natural Gas 1% 48% Note: Net electricity is an estimation of purchased power and power generation onsite. Source: U.S. Department of Energy Metal Casting 71
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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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TABLE 3 Economic Activity Data for
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Presentation of TRI Air Emissions D
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Presentation 500,000,000 of TRI Was
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Cement Manufacturing 1 AT A GLANCE
Page 26 and 27: equires 32% more energy per ton of
Page 28 and 29: Summing the Toxicity Scores for all
Page 30 and 31: l t , r t i t i Figure 3 Cement Kil
Page 32 and 33: ChemiCal manufaCturing 1 AT A GLANC
Page 34 and 35: Chemical facilities purchase electr
Page 36 and 37: conservatively assumes that chemica
Page 38 and 39: Balanced Water Use at BASF Supply U
Page 40 and 41: Waste Management Reported to TRI In
Page 42 and 43: Colleges & universities 1 AT A GLAN
Page 44 and 45: Criteria Air Pollutants Most CAP em
Page 46 and 47: Construction 1 AT A GLANCE 1996-200
Page 48 and 49: Figure 1 Fuel Use for Energy 2002 E
Page 50 and 51: Figure 4 Trends in Construction and
Page 52 and 53: Food & Beverage Manufacturing 1 AT
Page 54 and 55: Figure 2 Air Emissions Reported to
Page 56 and 57: associations, or government agencie
Page 58 and 59: disposed or released to air or wate
Page 60 and 61: Forest Products 1 AT A GLANCE 1996-
Page 62 and 63: 2002 the manufacture of wood produc
Page 64 and 65: emission controls to the pulping, p
Page 66 and 67: Water discharges became a major foc
Page 68 and 69: Iron & Steel 1 AT A GLANCE 1996-200
Page 70 and 71: ton of steel shipped improved over
Page 72 and 73: existing, high-toxicity weighting f
Page 74 and 75: water that has been reused. Typical
Page 78 and 79: using a cupola furnace can dehumidi
Page 80 and 81: Table 1 presents the top TRI-report
Page 82 and 83: Waste Management Reported to TRI hi
Page 84 and 85: Oil & Gas AT A GLANCE 1996-2005 1,2
Page 86 and 87: equipment helps recover the gas. In
Page 88 and 89: The most widely used EOR technique
Page 90 and 91: Petroleum refining Latest Environme
Page 92 and 93: Figure 2 Al TRI HA s Air Emissions
Page 94 and 95: energy technologies, and improving
Page 96 and 97: Paint & Coatings 1 AT A GLANCE 1996
Page 98 and 99: Figure 1 Air Emissions Reported to
Page 100 and 101: Owned Treatment Works, but may also
Page 102 and 103: Ports 1 AT A GLANCE 2005: 360 publi
Page 104 and 105: Increasing Use of Solar Power The P
Page 106 and 107: developing retrofit and replacement
Page 108 and 109: “invasive” if they are capable
Page 110 and 111: shipbuilding & ship repair 1 AT A G
Page 112 and 113: of marine coatings. CAPs and GHGs a
Page 114 and 115: Table 1 Top TRI Air Emissions 2005
Page 116 and 117: Shipyards’ stormwater runoff is t
Page 118 and 119: data Sources, Methodologies, and CO
Page 120 and 121: Facilities described above must rep
Page 122 and 123: Data Processing RSEI calculates tox
Page 124 and 125: • 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
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