12.4 Ferroalloy Production 12.4.1 General Ferroalloy is an alloy of iron with some element other than carbon.

Ferroalloy is used to physically introduce or "carry" that element into molten metal, usually during steel manufacture. In practice, the term ferroalloy is used to include any alloys that introduce reactive elements or alloy systems, such as nickel and cobalt-based aluminum systems. Silicon metal is consumed in the aluminum industry as an alloying agent and in the chemical industry as a raw material in silicon-based chemical manufacturing. The ferroalloy industry is associated with the iron and steel industries, its largest customers. Ferroalloys impart distinctive qualities to steel and cast iron and serve important functions during iron and steel production cycles. The principal ferroalloys are those of chromium, manganese, and silicon. Chromium provides corrosion resistance to stainless steels. Manganese is essential to counteract the harmful effects of sulfur in the production of virtually all steels and cast iron. Silicon is used primarily for deoxidation in steel and as an alloying agent in cast iron. Boron, cobalt, columbium, copper, molybdenum, nickel, phosphorus, titanium, tungsten, vanadium, zirconium, and the rare earths impart specific characteristics and are usually added as ferroalloys. United States ferroalloy production in 1989 was approximately 894,000 megagrams (Mg) (985,000 tons), substantially less than shipments in 1975 of approximately 1,603,000 megagrams (1,770,000 tons). In 1989, ferroalloys were produced in the U. S. by 28 companies, although 5 of those produced only ferrophosphorous as a byproduct of elemental phosphorous production. 12.4.2 Process Description A typical ferroalloy plant is illustrated in Figure 12.4-1. A variety of furnace types, including submerged electric arc furnaces, exothermic (metallothermic) reaction furnaces, and electrolytic cells can be used to produce ferroalloys. Furnace descriptions and their ferroalloy products are given in Table 12.4-1. 12.4.2.1 Submerged Electric Arc Process In most cases, the submerged electric arc furnace produces the desired product directly. It may produce an intermediate product that is subsequently used in additional processing methods. The submerged arc process is a reduction smelting operation. The reactants consist of metallic ores (ferrous oxides, silicon oxides, manganese oxides, chrome oxides, etc.) and a carbon-source reducing agent, usually in the form of coke, charcoal, high- and low-volatility coal, or wood chips. Limestone may also be added as a flux material. Raw materials are crushed, sized, and, in some cases, dried, and then conveyed to a mix house for weighing and blending. Conveyors, buckets, skip hoists, or cars transport the processed material to hoppers above the furnace. The mix is then gravity-fed through a feed chute either continuously or intermittently, as needed. At high temperatures in the reaction zone, the carbon source reacts with metal oxides to form carbon monoxide and to reduce the ores to base metal. A typical reaction producing ferrosilicon is shown below: Fe2O3 2 SiO2 7 C 2 FeSi 7 CO (1)

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12.4-2 EMISSION FACTORS

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Figure 12.4-1. Typical ferroalloy production process. (Source Classification Code in parentheses.)

Table 12.4-1. FERROALLOY PROCESSES AND RESPECTIVE PRODUCT GROUPS Process Submerged arc furnacea Product Silvery iron (15-22% Si) Ferrosilicon (50% Si) Ferrosilicon (65-75% Si) Silicon metal Silicon/manganese/zirconium (SMZ) High carbon (HC) ferromanganese Siliconmanganese HC ferrochrome Ferrochrome/silicon FeSi (90% Si)

Exothermicb Silicon reduction

Low carbon (LC) ferrochrome, LC ferromanganese, medium carbon (MC) ferromanganese Chromium metal, ferrotitanium, ferrocolumbium, ferovanadium Ferromolybdenum, ferrotungsten Chromium metal, manganese metal LC ferrochrome Ferrotitanium

Aluminum Reduction

Mixed aluminothermal/silicothermal Electrolyticc Vacuum furnaced Induction furnacee

c
d e

Process by which metal is smelted in a refractory-lined cup-shaped steel shell by submerged graphite electrodes. Process by which molten charge material is reduced, in exothermic reaction, by addition of silicon, aluminum, or a combination of the 2. Process by which simple ions of a metal, usually chromium or manganese in an electrolyte, are plated on cathodes by direct low-voltage current. Process by which carbon is removed from solid-state high-carbon ferrochrome within vacuum furnaces maintained at temperatures near melting point of alloy. Process that converts electrical energy into heat, without electrodes, to melt metal charges in a cup or drum-shaped vessel.

Smelting in an electric arc furnace is accomplished by conversion of electrical energy to heat. An alternating current applied to the electrodes causes current to flow through the charge between the electrode tips. This provides a reaction zone at temperatures up to 2000C (3632F). The tip of each electrode changes polarity continuously as the alternating current flows between the tips. To maintain a uniform electric load, electrode depth is continuously varied automatically by mechanical or hydraulic means.

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A typical submerged electric arc furnace design is depicted in Figure 12.4-2. The lower part of the submerged electric arc furnace is composed of a cylindrical steel shell with a flat bottom or hearth. The interior of the shell is lined with 2 or more layers of carbon blocks. The furnace shell may be water-cooled to protect it from the heat of the process. A water-cooled cover and fume collection hood are mounted over the furnace shell. Normally, 3 carbon electrodes arranged in a triangular formation extend through the cover and into the furnace shell opening. Prebaked or selfbaking (Soderberg) electrodes ranging from 76 to over 100 cm (30 to over 40 inches) in diameter are typically used. Raw materials are sometimes charged to the furnace through feed chutes from above the furnace. The surface of the furnace charge, which contains both molten material and unconverted charge during operation, is typically maintained near the top of the furnace shell. The lower ends of the electrodes are maintained at about 0.9 to 1.5 meters (3 to 5 feet) below the charge surface. Threephase electric current arcs from electrode to electrode, passing through the charge material. The charge material melts and reacts to form the desired product as the electric energy is converted into heat. The carbonaceous material in the furnace charge reacts with oxygen in the metal oxides of the charge and reduces them to base metals. The reactions produce large quantities of carbon monoxide (CO) that passes upward through the furnace charge. The molten metal and slag are removed (tapped) through 1 or more tap holes extending through the furnace shell at the hearth level. Feed materials may be charged continuously or intermittently. Power is applied continuously. Tapping can be intermittent or continuous based on production rate of the furnace. Submerged electric arc furnaces are of 2 basic types, open and covered. Most of the submerged electric arc furnaces in the U. S. are open furnaces. Open furnaces have a fume collection hood at least 1 meter (3.3 feet) above the top of the furnace shell. Moveable panels or screens are sometimes used to reduce the open area between the furnace and hood, and to improve emissions capture efficiency. Carbon monoxide rising through the furnace charge burns in the area between the charge surface and the capture hood. This substantially increases the volume of gas the containment system must handle. Additionally, the vigorous open combustion process entrains finer material in the charge. Fabric filters are typically used to control emissions from open furnaces. Covered furnaces may have a water-cooled steel cover that fits closely to the furnace shell. The objective of covered furnaces is to reduce air infiltration into the furnace gases, which reduces combustion of that gas. This reduces the volume of gas requiring collection and treatment. The cover has holes for the charge and electrodes to pass through. Covered furnaces that partially close these hood openings with charge material are referred to as "mix-sealed" or "semi-enclosed furnaces". Although these covered furnaces significantly reduce air infiltration, some combustion still occurs under the furnace cover. Covered furnaces that have mechanical seals around the electrodes and sealing compounds around the outer edges are referred to as "sealed" or "totally closed". These furnaces have little, if any, air infiltration and undercover combustion. Water leaks from the cover into the furnace must be minimized as this leads to excessive gas production and unstable furnace operation. Products prone to highly variable releases of process gases are typically not made in covered furnaces for safety reasons. As the degree of enclosure increases, less gas is produced for capture by the hood system and the concentration of carbon monoxide in the furnace gas increases. Wet scrubbers are used to control emissions from covered furnaces. The scrubbed, high carbon monoxide content gas may be used within the plant or flared. The molten alloy and slag that accumulate on the furnace hearth are removed at 1 to 5-hour intervals through the tap hole. Tapping typically lasts 10 to 15 minutes. Tap holes are opened with pellet shot from a gun, by drilling, or by oxygen lancing. The molten metal and slag flow from the tap hole into a carbon-lined trough, then into a carbon-lined runner that directs the metal and slag into a reaction ladle, ingot molds, or chills. (Chills are low, flat iron or steel pans that provide rapid

12.4-4

EMISSION FACTORS

(Reformatted 1/95)

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Figure 12.4-2. Typical submerged arc furnace design.

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cooling of the molten metal.) After tapping is completed, the furnace is resealed by inserting a carbon paste plug into the tap hole. Chemistry adjustments may be necessary after furnace smelting to achieve a specified product. Ladle treatment reactions are batch processes and may include metal and alloy additions. During tapping, and/or in the reaction ladle, slag is skimmed from the surface of the molten metal. It can be disposed of in landfills, sold as road ballast, or used as a raw material in a furnace or reaction ladle to produce a chemically related ferroalloy product. After cooling and solidifying, the large ferroalloy castings may be broken with drop weights or hammers. The broken ferroalloy pieces are then crushed, screened (sized), and stored in bins until shipment. In some instances, the alloys are stored in lump form in inventories prior to sizing for shipping. 12.4.2.2 Exothermic (Metallothermic) Process The exothermic process is generally used to produce high-grade alloys with low-carbon content. The intermediate molten alloy used in the process may come directly from a submerged electric arc furnace or from another type of heating device. Silicon or aluminum combines with oxygen in the molten alloy, resulting in a sharp temperature rise and strong agitation of the molten bath. Low- and medium-carbon content ferrochromium (FeCr) and ferromanganese (FeMn) are produced by silicon reduction. Aluminum reduction is used to produce chromium metal, ferrotitanium, ferrovanadium, and ferrocolumbium. Mixed alumino/silico thermal processing is used for producing ferromolybdenum and ferrotungsten. Although aluminum is more expensive than carbon or silicon, the products are purer. Low-carbon (LC) ferrochromium is typically produced by fusing chromium ore and lime in a furnace. A specified amount is then placed in a ladle (ladle No. 1). A known amount of an intermediate grade ferrochromesilicon is then added to the ladle. The reaction is extremely exothermic and liberates chromium from its ore, producing LC ferrochromium and a calcium silicate slag. This slag, which still contains recoverable chromium oxide, is reacted in a second ladle (ladle No. 2) with molten high-carbon ferrochromesilicon to produce the intermediategrade ferrochromesilicon. Exothermic processes are generally carried out in open vessels and may have emissions similar to the submerged arc process for short periods while the reduction is occurring. 12.4.2.3 Electrolytic Processes Electrolytic processes are used to produce high-purity manganese and chromium. As of 1989, there were 2 ferroalloy facilities using electrolytic processes. Manganese may be produced by the electrolysis of an electrolyte extracted from manganese ore or manganese-bearing ferroalloy slag. Manganese ores contain close to 50 percent manganese; furnace slag normally contains about 10 percent manganese. The process has 5 steps: (1) roasting the ore to convert it to manganese oxide (MnO), (2) leaching the roasted ore with sulfuric acid (H2SO4) to solubilize manganese, (3) neutralization and filtration to remove iron and aluminum hydroxides, (4) purifying the leach liquor by treatment with sulfide and filtration to remove a wide variety of metals, and (5) electrolysis. Electrolytic chromium is generally produced from high-carbon ferrochromium. A large volume of hydrogen gas is produced by dissolving the alloy in sulfuric acid. The leachate is treated with ammonium sulfate and conditioned to remove ferrous ammonium sulfate and produce a chromealum for feed to the electrolysis cells. The electrolysis cells are well ventilated to reduce ambient hydrogen and hexavalent chromium concentrations in the cell rooms.

12.4-6

EMISSION FACTORS

(Reformatted 1/95)

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12.4.3 Emissions And Controls Particulate is generated from several activities during ferroalloy production, including raw material handling, smelting, tapping, and product handling. Organic materials are generated almost exclusively from the smelting operation. The furnaces are the largest potential sources of particulate and organic emissions. The emission factors are given in Tables 12.4-2 and 12.4-3. Size-specific emission factors for submerged arc ferroalloy furnaces are given in Tables 12.4-4 and 12.4-5. Particulate emissions from electric arc furnaces in the form of fumes account for an estimated 94 percent of the total particulate emissions in the ferroalloy industry. Large amounts of carbon monoxide and organic materials also are emitted by submerged electric arc furnaces. Carbon monoxide is formed as a byproduct of the chemical reaction between oxygen in the metal oxides of the charge and carbon contained in the reducing agent (coke, coal, etc.). Reduction gases containing organic compounds and carbon monoxide continuously rise from the high-temperature reaction zone, entraining fine particles and fume precursors. The mass weight of carbon monoxide produced sometimes exceeds that of the metallic product. The heat-induced fume consists of oxides of the products being produced and carbon from the reducing agent. The fume is enriched by silicon dioxide, calcium oxide, and magnesium oxide, if present in the charge. In an open electric arc furnace, virtually all carbon monoxide and much of the organic matter burns with induced air at the furnace top. The remaining fume, captured by hooding about 1 meter above the furnace, is directed to a gas cleaning device. Fabric filters are used to control emissions from 85 percent of the open furnaces in the U. S. Scrubbers are used on 13 percent of the furnaces, and electrostatic precipitators on 2 percent. Two emission capture systems, not usually connected to the same gas cleaning device, are necessary for covered furnaces. A primary capture system withdraws gases from beneath the furnace cover. A secondary system captures fumes released around the electrode seals and during tapping. Scrubbers are used almost exclusively to control exhaust gases from sealed furnaces. The scrubbers capture a substantial percentage of the organic emissions, which are much greater for covered furnaces than open furnaces. The gas from sealed and mix-sealed furnaces is usually flared at the exhaust of the scrubber. The carbon monoxide-rich gas is sometimes used as a fuel in kilns and sintering machines. The efficiency of flares for the control of carbon monoxide and the reduction of VOCs has been estimated to be greater than 98 percent. A gas heating reduction of organic and carbon monoxide emissions is 98 percent efficient. Tapping operations also generate fumes. Tapping is intermittent and is usually conducted during 10 to 20 percent of the furnace operating time. Some fumes originate from the carbon lip liner, but most are a result of induced heat transfer from the molten metal or slag as it contacts the runners, ladles, casting beds, and ambient air. Some plants capture these emissions to varying degrees with a main canopy hood. Other plants employ separate tapping hoods ducted to either the furnace emission control device or a separate control device. Emission factors for tapping emissions are unavailable due to lack of data. After furnace tapping is completed, a reaction ladle may be used to adjust the metallurgy by chlorination, oxidation, gas mixing, and slag metal reactions. Ladle reactions are an intermittent process, and emissions have not been quantified. Reaction ladle emissions are often captured by the tapping emissions control system.

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12.4-8
Productb FeSi (50%) (SCC 3-03-006-01) FeSi (75%) (SCC 3-03-006-02)

Table 12.4-2 (Metric Units). EMISSION FACTORS FOR PARTICULATE FROM SUBMERGED ARC FERROALLOY FURNACESa
Particulate Emission Factors Uncontrolledc 35 46 EMISSION FACTOR RATING B E Particulate Emission Factors Controlledc 0.9 0.24 4.5 4.0 ND ND 16 0.24 0.8 0.25 ND
x,y

Furnace Type Opene,f,g Covered

Control Deviced Baghousee,f Scrubber High energy Low energy Scrubberh,j Low energy ND ND Baghousen,p Baghouseq,r h,s Scrubber High energy
h,j

EMISSION FACTOR RATING B E E E NA NA B B E C NA C C C

Openk Coveredh,j

158 103 282 436 14

E E E B B

EMISSION FACTORS
(Reformatted 1/95)

FeSi (90%) (SCC 3-03-006-03) Si metal (98%) (SCC 3-03-006-04) FeMn (80%) (SCC 3-03-006-06)

Open

Openn,p Open
q,r

FeMn (1% Si) (SCC 3-03-007-01)

Covered

h,t

6 37 78 96

E E C C

Scrubber High energyh,s,w ND ESP

Sealedu,v FeCr (high carbon) (SCC 3-03-006-07) SiMn (SCC 3-03-006-05) Open
x,y

1.2 2.1 0.15

Openz,aa Sealed

Scrubberaa,bb Scrubberv,w High energy

Emission factors are expressed as kg of pollutant/Mg alloy produced. Factors are for main furnace dust collection system before and after control device. Where other emissions, such as leaks or tapping, are included or quantified separately, such is noted. Particulate sources not included: raw material handling, storage, and preparation; and product crushing, screening, handling, and packaging. SCC = Source Classification Code. ND = no data. NA = not applicable. b Percentages are of the main alloying agent in product.

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Table 12.4-2 (cont.).

d e f g h j k m n p q r s t u v w x y z aa bb

In most source testing, fugitive emissions are not measured or collected. Where tapping emissions are controlled by primary system, their contribution to total emissions could not be determined. Fugitive emissions may vary greatly among sources, with furnace and collection system design and operating practices. Low-energy scrubbers are those with P < 20 inches of H2O; high-energy with P > 20 inches of H2O. Includes fumes captured by tapping hood (efficiency estimated at near 100%). References 4,10,21. Factor is average of 3 sources, fugitive emissions not included. Fugitive emissions at 1 source measured an additional 10.5 kg/Mg alloy, or 2.7 kg/MW-hr. References 4,10. Does not include emissions from tapping or mix seal leaks. References 25-26. Reference 23. Estimated 60% of tapping emissions captured by control system (escaped fugitive emissions not included in factor). References 10,13. Estimated 50% of tapping emissions captured by control system (escaped fugitive emissions not included in factor). References 4,10,12. Includes fumes only from primary control system. Includes tapping fumes and mix seal leak fugitive emissions. Fugitive emissions measured at 33% of total uncontrollable emissions. Assumes tapping fumes not included in emission factor. Reference 14. Does not include tapping or fugitive emissions. Tapping emissions included. References 2,15-17. Factor is average of 2 test series. Tests at 1 source included fugitive emissions (3.4% of total uncontrolled emissions). Second test insufficient to determine if fugitive emissions were included in total. References 2,18-19. Factors developed from 2 scrubber controlled sources, 1 operated at P = 47-57 inches of H2O, the other at unspecified P. Uncontrolled tapping operations emissions are 2.1 kg/Mg alloy.

12.4-10
Productb FeSi (50%) (SCC 3-03-006-01) FeSi (75%) (SCC 3-03-006-02)

Table 12.4-3 (English Units). EMISSION FACTORS FOR PARTICULATE FROM SUBMERGED ARC FERROALLOY FURNACESa
Particulate Emission factors Uncontrolledc 70 92 EMISSION FACTOR RATING B E Particulate Emission factors Controlledc 1.8 0.48 9.0 8.0 ND ND 32 0.48 1.6 0.5 ND 2.3
aa,bb

Furnace Type Opene,f,g Coveredh

Control Deviced Baghousee,f Scrubberh,j High energy Low energy Scrubberh,j Low energy ND ND Baghouse
n,p

EMISSION FACTOR RATING B E E E NA NA B B E C NA C C C

Openk Coveredh,j

316 206 564 872 28

E E E B B

EMISSION FACTORS
(Reformatted 1/95)

FeSi (90%) (SCC 3-03-006-03) Si metal (98%) (SCC 3-03-006-04) FeMn (80%) (SCC 3-03-006-06)

Openm Open
n,p

Openq,r

Baghouseq,r Scrubberh,s High energy Scrubber High energyh,s,w ND ESPx,y Scrubber

FeMn (1% Si) (SCC 3-03-007-01)

Coveredh,t Sealedu,v

12 74 157 192

E E C C

FeCr (high carbon) (SCC 3-03-006-07) SiMn (SCC 3-03-006-05)

Openx,y Open
z,aa

4.2 0.30

Sealed a

Scrubberv,w High energy

Emission factors expressed as lb of pollutant/ton of Alloy produced. Factors are for main furnace dust collection system before and after control device. Where other emissions, such as leaks or tapping, are included or quantified separately, such is noted. Particulate sources not included: raw material handling, storage, and preparation; and product crushing, screening, handling, and packaging. SCC = Source Classification Code. ND = no data. NA = not applicable. b Percentages are of the main alloying agent in product.

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Table 12.4-3 (cont.).

d e f g h j k m n p q r s t u v w x y z aa bb

In most source testing, fugitive emissions are not measured or collected. Where tapping emissions are controlled by primary system, their contribution to total emissions could not be determined. Fugitive emissions may vary greatly among sources, with furnace and collection system design and operating practices. Low-energy scrubbers are those with P < 20 inches of H2O; high-energy with P > 20 inches of H2O. Includes fumes captured by tapping hood (efficiency estimated at near 100%). References 4,10,21. Factor is average of 3 sources, fugitive emissions not included. Fugitive emissions at 1 source measured an additional 21 lb/ton alloy, or 5.9 lb/MW-hr. References 4,10. Does not include emissions from tapping or mix seal leaks. References 25-26. Reference 23. Estimated 60% of tapping emissions captured by control system (escaped fugitive emissions not included in factor). References 10,13. Estimated 50% of tapping emissions captured by control system (escaped fugitive emissions not included in factor). References 4,10,12. Includes fumes only from primary control system. Includes tapping fumes and mix seal leak fugitive emissions. Fugitive emissions measured at 33% of total uncontrollable emissions. Assumes tapping fumes not included in emission factor. Reference 14. Does not include tapping or fugitive emissions. Tapping emissions included. References 2,15-17. Factor is average of 2 test series. Tests at 1 source included fugitive emissions (3.4% of total uncontrolled emissions). Second test insufficient to determine if fugitive emissions were included in total. References 2,18-19. Factors developed from 2 scrubber controlled sources, 1 operated at P = 47-57 inches of H2O, the other at unspecified P. Uncontrolled tapping operations emissions are 4.2 lb/ton alloy.

Table 12.4-4 (Metric Units). SIZE-SPECIFIC EMISSION FACTORS FOR SUBMERGED ARC FERROALLOY FURNACES Cumulative Mass Emission Factor (kg/Mg alloy) 16 18 19 20 21 22 23 24 35 0.28 0.35 0.40 0.49 0.57 0.65 0.72 0.77 0.90 4 7 8 9 10 12 13 14 14 0.048 0.070 0.085 0.120 0.160 0.200 0.220 0.235 0.240

Product 50% FeSi Open furnace (SCC 3-03-006-01)

Control Device Noneb,c

Particle (m) 0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d 0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00

Sizea

Cumulative Mass % Stated Size 45 50 53 57 61 63 66 69 100 31 39 44 54 63 72 80 85 100 30 46 52 62 72 86 96 97 100 20 30 35 49 67 83 92 97 100

EMISSION FACTOR RATING B

Baghouse

80% FeMn Open furnace (SCC 3-03-006-06)

Nonee,f

0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d 0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d

Baghousee

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EMISSION FACTORS

(Reformatted 1/95)

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Table 12.4-4 (cont.). Cumulative Mass Emission Factor (kg/Mg alloy) 249 292 305 327 349 375 397 414 436 7.8 8.5 10.2 12.2 13.9 15.4 15.8 16.0 15 28 47 49 59 67 71 78 0.40 0.56 0.80 0.96 1.03 1.08 1.2 C

Product Si Metalg Open furnace (SCC 3-03-006-04)

Control Device Noneh

Particle Sizea (m) 0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d 1.00 1.25 2.50 6.00 10.00 15.00 20.00

Cumulative Mass % Stated Size 57 67 70 75 80 86 91 95 100 49 53 64 76 87 96 99 100 19 36 60 63k 76 88k 91 100 33 47 67 80 86 90 100

EMISSION FACTOR RATING B

Baghouse

FeCr (HC) Open furnace (SCC 3-03-006-07)

Noneb,j

0.5 1.0 2.0 2.5 4.0 6.0 10.0 d 0.5 1.0 2.0 2.5 4.0 6.0 10.0 d

ESP

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Table 12.4-4 (cont.). Cumulative Mass Emission Factor (kg/Mg alloy) 27 42 58 62 73 82 92k 96 1.18 1.68 2.02 2.08 2.09 2.10k 2.1

Product SiMn Open furnace (SCC 3-03-006-05)

Control Device Noneb,m

Particle Sizea (m) 0.5 1.0 2.0 2.5 4.0 6.0 10.0 d 0.5 1.0 2.0 2.5 4.0 6.0 10.0

Cumulative Mass % Stated Size 28 44 60 65 76 85 96k 100 56 80 96 99 99.5 99.9k 100

EMISSION FACTOR RATING C

Scrubberm,n

a b c d e f g h j k m n

Aerodynamic diameter, based on Task Group On Lung Dynamics definition. Particle density = 1 g/cm3. Includes tapping emissions. References 4,10,21. Total particulate, based on Method 5 total catch (see Tables 12.4-2 and 12.4-3). Includes tapping fumes (estimated capture efficiency 50%). References 4,10,12. References 10,13. Includes tapping fumes (estimated capture efficiency 60%). References 1,15-17. Interpolated data. References 2,18-19. Primary emission control system only, without tapping emissions.

12.4-14

EMISSION FACTORS

(Reformatted 1/95)

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Table 12.4-5 (English Units). SIZE-SPECIFIC EMISSION FACTORS FOR SUBMERGED ARC FERROALLOY FURNACES Cumulative Mass Emission Factor (lb/ton alloy) 32 35 37 40 43 44 46 48 70 0.56 0.70 0.80 1.0 1.1 1.3 1.4 1.5 1.8 8 13 15 17 20 24 26 27 28 0.10 0.14 0.17 0.24 0.32 0.40 0.44 0.47 0.48

Product 50% FeSi Open furnace (SCC 3-03-006-01)

Control Device Noneb,c

Particle (m)

Sizea

Cumulative Mass % Stated Size 45 50 53 57 61 63 66 69 100 31 39 44 54 63 72 80 85 100 30 46 52 62 72 86 96 97 100 20 30 35 49 67 83 92 97 100

EMISSION FACTOR RATING B

0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d 0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00

Baghouse

80% FeMn Open furnace (SCC 3-03-006-06)

Nonee,f

0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d 0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d

Baghousee

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Table 12.4-5 (cont.). Cumulative Mass Emission Factor (lb/ton alloy) 497 584 610 654 698 750 794 828 872 15.7 17.0 20.5 24.3 28.0 31.0 31.7 32.0 30 57 94 99 119 138 143 157 0.76 1.08 1.54 1.84 1.98 2.07 2.3

Product Si Metalg Open Furnace (SCC 3-03-006-04)

Control Device Noneh

Particle Sizea (m) 0.63 1.00 1.25 2.50 6.00 10.00 15.00 20.00 d 1.00 1.25 2.50 6.00 10.00 15.00 20.00

Cumulative Mass % Stated Size 57 67 70 75 80 86 91 95 100 49 53 64 76 87 96 99 100 19 36 60 63k 76 88k 91 100 33 47 67 80 86 90 100

EMISSION FACTOR RATING B

Baghouse

FeCr (HC) Open furnace (SCC 3-03-006-07)

Noneb,j

0.5 1.0 2.0 2.5 4.0 6.0 10.0 d 0.5 1.0 2.0 2.5 4.0 6.0 10.0 d

ESP

12.4-16

EMISSION FACTORS

(Reformatted 1/95)

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Table 12.4-5 (cont.). Cumulative Mass Emission Factor (lb/ton alloy) 54 84 115 125 146 163 177k 192 2.36 3.34 4.03 4.16 4.18 4.20k 4.3

Product SiMn Open furnace (SCC 3-05-006-05)

Control Device Noneb,m

Particle Sizea (m) 0.5 1.0 2.0 2.5 4.0 6.0 10.0 d 0.5 1.0 2.0 2.5 4.0 6.0 10.0

Cumulative Mass % Stated Size 28 44 60 65 76 85 96k 100 56 80 96 99 99.5 99.9k 100

EMISSION FACTOR RATING C

Scrubberm,n

a b c d e f g h j k m n

Aerodynamic diameter, based on Task Group On Lung Dynamics definition. Particle density = 1 g/cm3. Includes tapping emissions. References 4,10,21. Total particulate, based on Method 5 total catch (see Tables 12.4-2 and 12.4-3). Includes tapping fumes (estimated capture efficiency 50%). References 4,10,12. References 10,13. Includes tapping fumes (estimated capture efficiency 60%). References 1,15-17. Interpolated data. References 2,18-19. Primary emission control system only, without tapping emissions.

Available data are insufficient to provide emission factors for raw material handling, pretreatment, and product handling. Dust particulate is emitted from raw material handling, storage, and preparation activities (see Figure 12.4-1). These activities include unloading raw materials from delivery vehicles (ship, railway car, or truck), storing raw materials in piles, loading raw materials from storage piles into trucks or gondola cars, and crushing and screening raw materials. Raw materials may be dried before charging in rotary or other types of dryers, and these dryers can generate significant particulate emissions. Dust may also be generated by heavy vehicles used for loading, unloading, and transferring material. Crushing, screening, and storage of the ferroalloy product emit particulate matter in the form of dust. The properties of particulate matter emitted as dust are similar to the natural properties of the ores or alloys from which they originated, ranging in size from 3 to 100 micrometers (m).

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12.4-17

Approximately half of all ferroalloy facilities have some type of control for dust emissions. Dust generated from raw material storage may be controlled in several ways, including sheltering storage piles from the wind with block walls, snow fences, or plastic covers. Occasionally, piles are sprayed with water to prevent airborne dust. Emissions generated by heavy vehicle traffic may be reduced by using a wetting agent or paving the plant yard. Moisture in the raw materials, which may be as high as 20 percent, helps to limit dust emissions from raw material unloading and loading. Dust generated by crushing, sizing, drying, or other pretreatment activities may be controlled by dust collection equipment such as scrubbers, cyclones, or fabric filters. Ferroalloy product crushing and sizing usually require a fabric filter. The raw material emission collection equipment may be connected to the furnace emission control system. For fugitive emissions from open sources, see Section 13.2 of this document. References For Section 12.4 1. F. J. Schottman, "Ferroalloys", 1980 Mineral Facts And Problems, Bureau Of Mines, U. S. Department Of The Interior, Washington, DC, 1980. J. O. Dealy and A. M. Killin, Engineering And Cost Study Of The Ferroalloy Industry, EPA-450/2-74-008, U. S. Environmental Protection Agency, Research Triangle Park, NC, May 1974. Background Information On Standards Of Performance: Electric Submerged Arc Furnaces For Production Of Ferroalloys, Volume I: Proposed Standards, EPA-450/2-74-018a, U. S. Environmental Protection Agency, Research Triangle Park, NC, October 1974. C. W. Westbrook and D. P. Dougherty, Level I Environmental Assessment Of Electric Submerged Arc Furnaces Producing Ferroalloys, EPA-600/2-81-038, U. S. Environmental Protection Agency, Washington, DC, March 1981. F. J. Schottman, "Ferroalloys", Minerals Yearbook, Volume I: Metals And Minerals, Bureau Of Mines, Department Of The Interior, Washington, DC, 1980. S. Beaton and H. Klemm, Inhalable Particulate Field Sampling Program For The Ferroalloy Industry, TR-80-115-G, GCA Corporation, Bedford, MA, November 1980. C. W. Westbrook and D. P. Dougherty, Environmental Impact Of Ferroalloy Production Interim Report: Assessment Of Current Data, Research Triangle Institute, Research Triangle Park, NC, November 1978. K. Wark and C. F. Warner, Air Pollution: Its Origin And Control, Harper And Row, New York, 1981. M. Szabo and R. Gerstle, Operations And Maintenance Of Particulate Control Devices On Selected Steel And Ferroalloy Processes, EPA-600/2-78-037, U. S. Environmental Protection Agency, Washington, DC, March 1978. C. W. Westbrook, Multimedia Environmental Assessment Of Electric Submerged Arc Furnaces Producing Ferroalloys, EPA-600/2-83-092, U. S. Environmental Protection Agency, Washington, DC, September 1983.

2.

3.

4.

5.

6.

7.

8.

9.

10.

12.4-18

EMISSION FACTORS

(Reformatted 1/95)

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11.

S. Gronberg, et al., Ferroalloy Industry Particulate Emissions: Source Category Report, EPA600/7-86-039, U. S. Environmental Protection Agency, Cincinnati, OH, November 1986. T. Epstein, et al., Ferroalloy Furnace Emission Factor Development, Roane Limited, Rockwood, Tennessee, EPA-600/X-85-325, U. S. Environmental Protection Agency, Washington, DC, June 1981. S. Beaton, et al., Ferroalloy Furnace Emission Factor Development, Interlake Inc., Alabama Metallurgical Corp., Selma, Alabama, EPA-600/X-85-324, U. S. Environmental Protection Agency, Washington, DC, May 1981. J. L. Rudolph, et al., Ferroalloy Process Emissions Measurement, EPA-600/2-79-045, U. S. Environmental Protection Agency, Washington, DC, February 1979. Written Communication From Joseph F. Eyrich, Macalloy Corporation, Charleston, SC, to GCA Corporation, Bedford, MA, February 10, 1982, Citing Airco Alloys And Carbide Test R07-7774-000-1, Gilbert Commonwealth, Reading, PA. 1978. Source Test, Airco Alloys And Carbide, Charleston, SC, EMB-71-PC-16(FEA), U. S. Environmental Protection Agency, Research Triangle Park, NC. 1971. Telephone communication between Joseph F. Eyrich, Macalloy Corporation, Charleston, SC, and Evelyn J. Limberakis, GCA Corporation, Bedford, MA. February 23, 1982. Source Test, Chromium Mining And Smelting Corporation, Memphis, TN, EMB-72-PC-05 (FEA), U. S. Environmental Protection Agency, Research Triangle Park, NC. June 1972. Source Test, Union Carbide Corporation, Ferroalloys Division, Marietta, Ohio, EMB-71-PC-12 (FEA), U. S. Environmental Protection Agency, Research Triangle Park, NC. 1971. R. A. Person, "Control Of Emissions From Ferroalloy Furnace Processing", Journal Of Metals, 23(4):17-29, April 1971. S. Gronberg, Ferroalloy Furnace Emission Factor Development Foote Minerals, Graham, W. Virginia, EPA-600/X-85-327, U. S. Environmental Protection Agency, Washington, DC, July 1981. R. W. Gerstle, et al., Review Of Standards Of Performance For New Stationary Air Sources: Ferroalloy Production Facility, EPA-450/3-80-041, U. S. Environmental Protection Agency, Research Triangle Park, NC. December 1980. Air Pollutant Emission Factors, Final Report, APTD-0923, U. S. Environmental Protection Agency, Research Triangle Park, NC. April 1970. Telephone Communication Between Leslie B. Evans, Office Of Air Quality Planning And Standards, U. S. Environmental Protection Agency, Research Triangle Park, NC, And Richard Vacherot, GCA Corporation, Bedford, MA. October 18, 1984. R. Ferrari, "Experiences In Developing An Effective Pollution Control System For A Submerged Arc Ferroalloy Furnace Operation", J. Metals, p. 95-104, April 1968. Metallurgical Industry 12.4-19

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

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26.

Fredriksen and Nestas, Pollution Problems By Electric Furnace Ferroalloy Production, United Nations Economic Commission For Europe, September 1968. A. E. Vandergrift, et al., Particulate Pollutant System StudyMass Emissions, PB-203-128, PB-203-522 And P-203-521, National Technical Information Service, Springfield, VA. May 1971. Control Techniques For Lead Air Emissions, EPA-450/2-77-012, U. S. Environmental Protection Agency, Research Triangle Park, NC. December 1977. W. E. Davis, Emissions Study Of Industrial Sources Of Lead Air Pollutants, 1970, EPA-APTD-1543, W. E. Davis And Associates, Leawood, KS. April 1973. Source Test, Foote Mineral Company, Vancoram Operations, Steubenville, OH, EMB-71-PC-08 (FEA), U. S. Environmental Protection Agency, Research Triangle Park, NC. August 1971. C. R. Neuharth, "Ferroalloys", Minerals Yearbook, Volume I: Metals And Minerals, Bureau Of Mines, Department Of The Interior, Washington, DC, 1989. N. Irving Sox and R. J. Lewis, Sr., Hawleys Condensed Chemical Dictionary, Van Nostrand Reinhold Company, Inc., Eleventh Edition, 1987. Theodore Baumeister, Marks Standard Handbook For Mechanical Engineers, McGraw-Hill, Eighth Edition, 1978.

27.

28.

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30.

31.

32.

33.

12.4-20

EMISSION FACTORS

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