2008 Sector Performance Report - US Environmental Protection ...

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Table 1 presents the top TRI-reported chemicals emitted to air by the sector based on three indicators. Each indicator provides data that environmental managers, trade associations, or government agencies might use in considering sector-based environmental management strategies. 1) Absolute Pounds Reported. Xylene and aluminum were the highest-ranking chemicals based on the pounds of each chemical emitted to air in 2005. 2) Percentage of Toxicity Score. The top chemical based on Toxicity Scores was manganese, which has a high toxicity weight and was emitted in large quantities. Chromium and diisocyanates were emitted in smaller quantities but are among the chemicals with the highest toxicity weights. 3) Number of Facilities Reporting. Lead was the most frequently reported chemical, with more than half the facilities in the sector filing TRI reports for air emissions of lead. Table 1 Top TRI Air Emissions 2005 Chemical Absolute Pounds Reported 1 Percentage of Toxicity Score Number of Facilities Reporting 2 Aluminum 356,000 3 1% 49 Benzene 4 243,000
Every facility discharging process wastewater directly to waterways must apply for a National Pollutant Discharge Elimination System permit. The permits typically set numeric limits on specific pollutants and include monitoring and reporting requirements. For metal casters, regulated pollutants and the associated limits vary depending on the type of casting operation (aluminum, copper, zinc, or ferrous casting), but most facilities are regulated in their discharges of copper, lead, zinc, and total suspended solids (TSS). 12 In 2005, 236 facilities reported water discharges of TRI chemicals totaling 68,500 lbs. 13 This represented a decline of 52% since 1996. 14 Facilities with materials exposed to precipitation also are regulated for stormwater runoff, usually under a general permit providing sector-specific limits. Depending on the type of foundry, stormwater requirements for metal casting facilities may include effluent limits on copper, zinc, iron, aluminum, and TSS. Waste Generation and Management Waste management is another key environmental issue for Metal Casting facilities. Metal casting wastes fall into four main categories: sand, slag, dust, and other. The sand used to create molds and cores accounts for a large portion of the waste generated at foundries. 15 The high-quality sand required for casting is expensive, so foundries reuse sand to the extent possible. Sand that no longer can be used by iron or steel foundries is often landfilled or beneficially reused. Slag, which can make up about 25% of a foundry’s solid waste stream, is a glassy mass with a complex chemical structure. Slag is composed of metal oxides from the melting process, melted refractories, sand, coke ash (if coke is used), and other materials. Large quantities of slag are generated from iron foundries using cupola furnaces. During casting, some metal is converted to dust or fumes and collected by pollution control equipment such as baghouses, electrostatic precipitators, or wet scrubbers. Some processes for making cores require strongly acidic or basic substances for scrubbing the off gases and can generate sludges or liquors. These sludges or liquors are typically pHcontrolled prior to discharge to the sewer system. Hazardous Waste Management Both ferrous and nonferrous facilities generate hazardous waste, including hazardous waste from finishing operations. Ferrous facilities generate hazardous wastes mostly from pollution control equipment, especially from melting furnaces. Nonferrous facilities tend to produce hazardous wastes as foundry sand contaminated with heavy metals. About 2% of all spent foundry sand is hazardous. Casting sands used in the production of brass or bronze castings may also exhibit toxicity characteristics for lead or cadmium, making them a hazardous waste. In 2005, 170 facilities reported to EPA’s National Biennial RCRA Hazardous Waste Report (BR) generating 30,000 tons of hazardous waste. Wastes captured by air pollution control equipment were the largest source of hazardous waste. Facilities reported managing 28,000 tons of hazardous waste in 2005, most of which was managed through destruction or treatment. 16 2008 SECTOR PERFORMANCE REPORT Metal Casting 75
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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
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equires 32% more energy per ton of
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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 76 and 77: Metal Casting 1 AT A GLANCE 1996-20
Page 78 and 79: using a cupola furnace can dehumidi
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
Page 126 and 127: Cement Manufacturing 1. Facilities:
Page 128 and 129: 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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