WASTE

AUDIT STUDY

THERMAL METAL
WORKING INDUSTRY
PREPARED FOR

ALTERNATIVE TECHNOLOGY DIVISION

TOXIC SUBSTANCES CONTROL PROGRP
CALIFORNIA DEPARTMENT OF
HEALTH SERVICES

PREPARED BY

JACOBS ENGINEERING GROUP INC.

PASADENA, CALIFORNIA
DECEMBER 1990

ABSTRACT

This report presents the results of Jacobs Engineering Groups waste audit study of the
thermal metal working industry. The goal of this study was to identify waste reduction
techniques available to the industry.
The report focuses on source reduction, recycling, and treatment methods for
businesses performing thermal metal working with specific focus on casting and heat
treating. The processes examined include melting, mold and core making, shakeout,
and case hardening by means of thermal and/or chemical methods. Support
operations which may be found at thermal metal working businesses, but have been
explored in previous studies, include machining operations, metal parts cleaning and
stripping, metal surface treatment and plating, and paint application.
Three thermal metal working plants were surveyed as part of the project: a ferrous metal
foundry, a heat treating plant and a non-ferrous foundry. Waste reduction and
treatment techniques were identified and analyzed based on the information collected
during these surveys, as well as from detailed literature review and discussions with
industry representatives. The results include a waste reduction assessment format for
generators to perform their own waste reduction opportunities assessments. Source
reduction techniques, recycling and resource recovery techniques appear to offer high
promise of minimizing waste generation.
A waste reduction Index was developed for use by foundries to measure waste
reduction effectiveness. The index compensates for variation in production activity.
Examples are developed here for brass foundry sand waste, iron foundry sand waste,
and iron foundry baghouse waste.

.
i

ACKNOWLEDGEMENTS

Jacobs Engineering Group Inc. would like to acknowledge the efforts of Mr. Benjamin
Fries, Mr. Bal Lee, and Mr. Eric Workman of the Alternative Technology Division and
various individuals at the cooperating thermal metal working firms for their assistance in
this study.
The Jacobs project manager for this study was Dr. Michael Meltzer. The principal
author and investigator was Dr. Maria Zdunkiewicz. Mr. Carl Fromm and Mr. Michael
Callahan provided quality assurance and control.
This report was submitted in fulfillment of Contract No. 88-TO326 by Jacobs Engineering
Group Inc. pursuant to a contract between Jacobs and the Department of Health
Services. Work for this Final Report was completed as of December 1990.

ii

DISCLAIMER

The statements and conclusions of this report are those of the Contractor and not
necessarily those of the State of California. The mention of commercial products, their
source, or their use in connection with material reported herein is not to be construed
as either an actual or implied endorsement of such products.

CONTRACTORS DISCLAIMER

This report was prepared by Jacobs Engineering Group Inc. as an account of work
performed for The State of California DeDartment of Health Services (client). Neither
Jacobs Engineering Group Inc., nor any persons acting on its behalf; (a) makes any
warranty or representation, expressed or implied, with respect to the accuracy,
completeness or usefulness of the information contained in this report, or that the use
of any information, cost estimate apparatus, method, or process disclosed in this report
may not infringe privately owned rights; or (b) assumes any liabilities with respect to the
use of, or damage resulting from the use of, any information, cost estimate, apparatus,
method, or process disclosed in this report, including consequential or other indirect or
contingent liabilities whether due to the negligence of Jacobs Engineering Group Inc. or
otherwise. Any person, entity or .third party using this report or its contents or relying
thereon does so at Its own risk and does hereby release, defend and indemnify Jacobs
Engineering Group Inc. from and against any liability, cost or expense such person,
e n t i or third party may incur as a resuit of said use, or reliance.

REGULATORY CAVEAT

All text pertaining to law and regulations contained within this report are provided for
general information only. That information is not reliable for use as a legal reference.
The generator must contact the appropriate legal sources and regulatory authorities for
up-to-date regulatory requirements, and their interpretation and implementation.

CONTRACTS

Contract No. 88-TO326 provided $27,000 to prepare this report. No subcontractors

were involved in its preparation.

iii

CONTENTS
Page
i
ii
iii
iii
iii
iii

ABSTRACT
ACKNOWLEDGEMENTS
DISCLAIMER
CONTRACTORS DISCLAIMER
REGULATORY CAVEAT
CONTRACTS

1 .O

2.0

SUMMARY AND CONCLUSIONS

1-1

1 .I
12
1.3
1.4
1.5

1-1
1 -2
1-2
1 -2
1-6

2.6
2.7

3.5

5.2

2-3
2-3
2-3

3-1
3-1
3-1

3-2
3-2

4-1

Environmental Benefits
Program Requirement
The Waste Minimization Opportunity Assessment

REGULATORY ASPECTS

5.1

2-1
2-1
2-2
2-2

3-1

Study Purpose
Industry Overview
Project Approach
Focus
Forging, Tempering, and Rolling

WASTE REDUCTION PROGRAMS

4.1
4.2
4.3
5.0

Metal Casting
Heat Treating
Waste Reduction Alternatives Assessment A - Non-Ferrous Foundry
Waste Reduction Alternatives Assessment B Heating Treating Plant
Waste ReductionAlternatives Assessment C Ductile and Gray
Iron Foundry
Regulations
Advancing Technology

INTRODUCTION

3.1
3.2
3.3
3.4
4.0

2-1

RECOMMENDATIONS

2.1
2.2
2.3
2.4
2.5

3.0

Regulatory Aspects
Waste Streams and Reduction Measures
Waste Reduction Economics
Waste Reduction Assessment Format
Waste Reduction Index

4-1
4-1
4-2
5-1

Regulatory Caveat
Laws, Regulatlons and Ordinances
5.2.1 Land Disposal Restrictions (Existing and Proposed)
5.2.1 .I Treatment Standards for Foundry Sand
5.2.1.2 Treatment Standards for Solid Wastes with Metals
5.2.1.3 Proposed Treatment Standards for Eaghouse Waste
and Gas Scrubber Waste

.
iv

5-1
5-1
5-1
5-2
5-3
5-6

CONTENTS (continued)
Page

5.2.2 Waste Storage

5.2.3 Waste Transport
5.2.4 Waste Reduction
6.0

5-6

5-7
5-7

WASTE REDUCTIONAND TREATMENT ALTERNATIVES

FOR THE METAL CASTING INDUSTRY

6.1
6.2

6.3

6.4

6-1

Description of Hazardous Waste Generation Processes

6-1
Input Materials and Hazardous Waste Characterization
6-6
6.2.1 Input Material Characterization
6-6
6-6
6.2.1.1 Mold and Core Materials
6-8
6.2.1.2 Melting Materlals (Furnace Charge)
6.2.1.3 Blast Cleaning Materials
6-9
6-9
6.2.1.4 Cleaning Solutions and Coating Materials
6.2.1.5 Oils
6-9
6-9
6.2.2 Hazardous Waste Characterization
6.2.2.1 Spent Foundry Sand
6-1 1
6-13
6.2.2.2 Cleaning Room Wastes
6-13
6.2.2.3 Dust Collector and Scrubber Wastes
6-13
6.2.2.4 Slag Wastes
6.2.2.5 Miscellaneous Wastes
6-1 4
Waste Reduction and Treatment Options for Baghouse Dust
and Scrubber Wastes
6-14
6-1 4
6.3.1 Source Reduction
6-14
6.3.1.I Alter Raw Materials
6-1 4
6.3.1.2 Install Induction Furnace
6-1 4
6.3.2 Recycling
6-1 5
6.3.2.1 Recycle to the Original Process
6.3.2.2 Recycle Outside of the Original Production Process 6-1 5
6-17
6.3.2.3 Recycle to Cement Manufacturer
6.3.3 Treatment
6-1 7
6.3.3.1 Cement-Based Chemical Stabilization
6-17
6.3.3.2 Lime/Pouolan-BasedChemical Stabilization
6-18
6-1 8
6.3.3.3 Chemical Reduction
6.3.3.4 Solubility Control
6-1 8
6.3.3.5 Polysllicate Treatment at the Cupola Furnace Stack 6-1 8
6-18
6.3.3.6 Sulphating Process for Zinc In EAF Dust
6.3.3.7 Thermoplastic Binding
6-19
6-1 9
6.3.3.8 Encapsulation
Waste Reduction and Treatment Options for Hazardous Slags
6-19
6-1 9
6.4.1 Source Reduction
6-1 9
6.4.1.I Alter Feed Stock
6-19
6.4.1.2 Alter Desulfuriiation Agent
6-20
6.4.1.3Alter Product Requirements
6.4.1.4 Improve Process Control
6-20
6-20
6.4.2 Recycling
6.4.2.1 Recycle to Process
6-20
6-20
6.4.2.2 Recycle to Other Process Lines
6.4.3 Treatment
6-21

CONTENTS (continued)
Page

6.5

6.4.3.1 Mixing of Treated Desulfurization Slag with

Furnace Dust
6.4.3.2 Improved Treatment Methods
Waste Reduction and Treatment Options for Spent Casting Sands
6.5.1
Source Reduction
6.5.1.1 Material Substitution
6.5.1.2 Waste Segregation
Recycling
6.5.2
6.5.2.1 Screening and Separation of Metal from Sand
6.5.2.2 The PMET Process Metal and Sand Reclamation
6.5.2.3 Sand Reclamation by Wet WashinglScrubbing
6.5.2.4 Sand Reclamation by Dly Scrubbing/Attrition
6.5.2.5 Thermal Reclamation of Sand
6.5.2.6 Reuse of Detoxifiedllmmobllird Sand as
Ingot Molds
6.5.2.7 Use of Sands as a Construction Material
6.5.3
Treatment of Sand
6.5.3.1 Sodium SilicatelLime Immobilization
(Furness Process)
6.5.3.2 Sodium SilicatelPozzalimeor Portland
Cement Immobilization (Trezek Process)

7.0

WASTE REDUCTION AND TREATMENT ALTERNATIVES FOR HEAT

TREATING INDUSTRY
7.1

7.2

7.3

Description of Hazardous Waste Generation Processes

7.1.1
Furnace Operation
7.1.1.1 Heat Treating Other Than Case Hardening
7.1.1.2 Case Hardening
7.1.2
Quenching
7.1.3
Descaling
Parts Cleaning and Surface Coating
7.1.4
Hazardous Waste Characterization
Case Hardening Baths and Salt Pots
7.2.1
7.2.2
Quenching Wastes
7.2.3
Parts Cleaning and Coating
Waste Reduction and Treatment Options for Case
Hardening Baths and Salt Pots
7.3.1
Source Reduction
7.3.1.1 Alter Raw Materials (Bath Composition)
7.3.1.2 Clean All Work Placed in the Bath
7.3.1.3 Use Graphite Cover on the Surface of a
Cyanide Bath
7.3.1.4 Dry Work Completely Prior to Liquid
Case Hardening (Safety)
7.3.1.5 Remove Impurities (Sludges)
7.3.1.6 Minimize Dragout
7.3.1.7 Replace Pot Lining

vi

6-21
6-21
6-22
6-22
6-22
6-22
6-23
6-23
6-24
6-24
6-26
6-26
6-27
6-28
6-28
6-28
6-29
7-1
7-1
7-1
7-1
7-2
7-3
7-3
7-3
7-4
7-4
7-0
7-9
7-9
7-9
7-9
7-10
7-10
7-10
7-10
7-10
7-11

CONTENTS (continued)
Page
Treatment
7.3.2.1 Chemical Treatment
7.3.2.2 ElectrochemicalTreatment
Waste Reduction and Treatment Options for Quenchant Wastes
7.4.1 Source Reduction
7.4.1 .I Minimize Dragout of Molten Salts
7.4.1.2 Minimize Dragout of Quenchant
7.4.1.3 Temperature Control of Oil Quenchant System
7.4.1.4 Use Modlfied Systems
7.4.2 Recycling
7.4.2.1 Desludging
7.4.2.2 Dewatering of Quenching Oil
7.4.2.3 Ultrafiltration of Water-Polymer Quenchants
7.4.3 Treatment
7.4.3.1 Water and Brine Bath Quenchants
7.4.3.2 Quenching Oil Dragout

7.3.2

7.4

8.0

9.0

Introduction
Approach
WRI for the Thermal Metal Working Industry

9.2

8-1
8-1
8-2
9-1

WASTE REDUCTION ECONOMICS

9.1

10.0

8-1

WASTE REDUCTION INDEX

8.1
8.2
8.3

7-11
7-11
7-12
7-13
7-13
7-13
7-13
7-13
7-14
7-14
7-14
7-15
7-15
7-15
7-15
7-15

9-1
9-2

Low Capital Cost Measures

Capital Investment

10-1

REFERENCES

vii

TABLES
Table -1

Waste Reduction and Treatment Alternatives for the

Metal Casting Industry

1-3

Table 2

Waste Reduction and Treatment Alternatives for the

Heat Treating Industry

1-5

Table 5-1

Achievable BDAT Concentrations

5-2

Table 5-2

EPAs Treatment Standards for Some Metal - Containing

Federal "Listed"Wastes

5-4

Table 5-3

Proposed Treatment Standards for Non-RCRA Solid

Wastes with Metals

5-5

Table 5-4

ProposedTreatment Standards for Baghouse Waste

5-6

Table 6-1

Typical Composition of Refractories

Table 7-1

Operating Composition of Liquid Carburizing Baths

7-5

Table 7-2

Compositions and Properties of Sodium Cyanide Mixtures for

Cyaniding Baths

7-7

Table 9-1

Example Cost Information

9-4

6-10

FIGURES

Figure 6-1

Simplified Flow Diagram of the Basic Operations for

Producing a Steel Casting

6-2

Figure 6-2

Primary Sources of Waste Sand

6-12

Figure 6-3

Simplified.Process Flow Diagram for the PMET Sand

Treatment Process

6-25

Figure A-I

Foundry Flow Diagram

A-7

Figure A-2

Air Pollution Control Equipment, Molding and Coremaking

Operations

A-0

Figure B-1

Simplified Flow Diagram for Heat Treating Process at Plant B

6-2

Figure C-I

Foundry Melt Process Schematic

c-3

Figure C-2

Plant C Sand System Process Schematic

c-7

viii

APPENDICES
Page
A.

WASTE REDUCTION ALTERNATIVES ASSESSMENT

FOR PLANT A

A.l
A.2
A.3
A.4
B.

C.

Process Description
Foundly Waste Streams
Present Waste Reduction and Treatment Practices
Future Waste Reduction Alternatives:
Sand Reclamation and Detoxification Systems

A-1

A-1
A- 1
A-2
A-5

WASTE REDUCTION ALTERNATIVES ASSESSMENT

FOR PLANT B

B-1

B.1
8.2
8.3
8.4
8.5

B-1
B-1
8-3
0-4
8-5

Austenitizing
Quenching
Tempering
Sandblasting
Plating and Stripping

WASTE REDUCTION ALTERNATIVES ASSESSMENT

FOR PLANT C
c.1

c.2
c.3

c.4
c.5
C.6
c.7

Melting
Process Description and Input Materials
C.l.l
c.1.2 Waste Streams'
C.1.3
Waste Reduction
Coremaking
Process Description and Input Materials
C.2.1
C.2.2
Waste Streams
C.2.3
Waste Reduction
Mold Making
Process Description and Input Material
C.3.1
Waste Streams
C.3.2
C.3.3
Waste Reduction
Pouring
Shakeout
Process Description.
C.5.1
. Input
. Materials, and Waste Streams
(2.5.2
Waste Reduction
Surface Cleaning
Heat Treating

c-1
c-1
c-1
c-2
C-4
c-5
c-5
C-6
C-6
C-6
C-6
C-6
C-8
C-8
C-8
C-8
C-8
c-9
c-9

D.

WASTE REDUCTIONASSESSMENT FORMAT

Table of Contents

D-1
D-1

E.

STATUTES AND REGULATIONSAFFECTING

HAZARDOUS WASTE GENERATORS
Table of Contents

E-1
E-1

F.

ORDER FORM FOR HAZARDOUSWASTE CONTROL

G.

LAWS AND REGULATIONS

F-1

TOXIC SUBSTANCES CONTROL DIVISION

G-1

ix

APPENDICES (Continued)

Page
H.

CALIFORNIA REGIONAL WATER QUALITY

CONTROL BOARDS

I.

FEDERAL AND STATE AGENCIES

J.

ACRONYMS

J-1

K.

WASTE REDUCTION INDEX

K-1

H-1
1-1

SECTION 1.0

SUMMARY AND

CONCLUSIONS

This study identifies and describes waste reduction measures appropriate for California thermal
metal working industries. It presents a procedure for assessing a plants processes and
improving its waste management system.
The study focuses primarily on source reduction measures, secondarily on recycling techniques,
and finally on treatment methods appropriate to thermal metal working plants and processes.
This report concentrates on the casting and heat treating industry. These processes are
responsible for most of the waste generation from thermal metal operations in California. They
require waste reductlon measures different from those described for fabricated metal and metal
finishing industries.
Effective waste reduction reduces environmental risk, and includes both technology-based
strategies and organizational and management changes within a plant. Creating successful
programs involves: 1) careful planning and organization in order to bring management and
other groups within the plant together in an effective way; 2) an accurate means of analyzing
the companys waste streams, assessing its needs, and selecting appropriate waste reduction
measures; 3) selection of realistic, achievable goals; and 4) a means of implementing the
program through obtaining the necessary funding and firm support of management, and
assembling a waste reduction team that has the technical know-how to make the project a
success.
1.1

REGULATORY ASPECTS

The federal, state, and local ordinances and regulations that influence hazardous waste
management In the California thermal metal working industry include:
0
0
0
0
0
0
0
0

Resource Conservation and Recovery Act (RCRA) prohibitions on land disposal

of untreated waste
State of California Hazardous Waste Reduction and Management Review Act
Superfund Amendments and Reauthorization Act (SARA) Title 3,which include
emergency planning and community right to know requirements
State right-to-know legislation
State land disposal restrictions and standards for generators, transporters, and
owners or operators of treatment, storage, or disposal (TSD) facilities
Discharge requirements set by local Publicly Owned Treatment Works ( P O N S )
Federal regulations governingwastewater discharges and pretreatment standards
Clean Water Act control measures for wastewater discharges.

1-1

1.2

WASTE STREAMS AND REDUCTION MEASURES

The major hazardous waste streams from the casting industry include baghouse and/or
scrubber wastes associated with the control of air emissions from the furnace, hazardous slags
generated during the melting and treatment operation of certain metals, and spent casting
sands which can no longer be reused. Waste reduction measures include options such as
segregating metal contaminants from the spent casting sands, recycling metal wastes back into
the process, and reusing sands for molding purpose. Specific source reduction, recycling, and
treatment methods are summarized in Table 1-1 for each hazardous waste category.
The major hazardous waste streams from the heat treating industry include cyanide-containing
waste generated in liquid carburizing, cyaniding, and nitriding; spent quenchants and dragout
wastes, coating wastes related to selective carburizing or nitriding; and wastes from parts
cleaning operations. The source reduction, recycling and treatment options for these wastes
are presented in Table 1-2. Effective options include altering process chemicals and minimizing
drag-in and dragout losses of chemicals. Waste reduction measures for parts cleaning and
coating wastes can be found in the DHS Waste Audit Study on the Fabricated Metal Products
Industry (August 1989) and the USEPA report on Waste Reduction in Parts Cleaning Operations
(1989).
The focus of this study did not include examination of forging, tempering, and rolling processes
because the hazardous wastes generated from them and waste reduction alternatives are
covered under operations already examined in this report.
1.3

WASTE REDUCTION ECONOMICS

Cost savings associated with many waste reduction measures provide strong arguments for
their use. Typical benefits include reduction or avoidance of: 1) treatment, storage, and
disposal fees; 2) transportation costs; 3)raw material costs; 4) insurance and liability costs; and
5) excessive operating costs resulting from inefficient processes. For this study, assessments
were made of three plants a ferrous foundry, a heat treating plant and a nonferrous foundry.
The assessments revealed the monetary and environmental benefits that can be derived from
implementing waste reduction. Reductions in waste volumes and landfill disposal costs were
measured for the ferrous foundry. Recycling of hazardous slag and baghouse dust from the
heat resistant alloy production line, where induction furnaces are employed, to a cupola furnace
producing gray iron reduced disposal costs by approximately $17,000 per year.

Reduction in waste volumes were also measured for the non-ferrous foundry. Reclamation of
metals at brass foundry by use of an existing ballmill system allowed the company to save
$157,000.
1.4

WASTE REDUCTION ASSESSMENT FORMAT

The format provided in Appendix D can help plant staff to identify the waste reduction measures
most appropriate for their thermal metal working processes, as well as providing them with
procedures for estimating the profitability of such methods, and for implementing them.

1-2

TaDle 1-1
WASTE REDUCTION AND TREATMENT
ALTERNATIVES FOR THE METAL CASTING INDUSTRY

Waste Stream

Baghouse Dust and

Scrubber Wastes

Alternative

Alter raw materials

Use induction furnace
Recycle to original process
Recycle outside of original process (pyrometallurgical
methods, rotary kiln technology, electrothermic shaft
furnace, llll zinc oxide enrichment)
Recycle to cement manufacturer
Cement-based chemical stabilization
Umelpouolan-based chemical stabilization
Chemical reduction
Precipitation using magnesium hydroxide (solubility
control)
Polysilicate treatment at the cupola furnace stack
Sulphating process for zinc in EAF dust
Thermoplastic binding
Encapsulation

'

Hazardous Slags

Method*

Alter feed stock

Alter desulfurization agent
Alter product requirements
Improve process control

Reference

SR
SR
R

Stephens 1988
USEPA 1985. Danielson1973

Morris 1985, Chaubal 1982,

Kellogg 1966, Krishnan 1982
and 1983, Miyashita 1976,
Bounds 1983
Kelly 1989, AFS 1989

T
T
T

Stephen 1984

T
T
T
T
T

Turpin 1985, Edige 1989

Appendix C
Chaubal1982
USEPA, 1988
Chaubal 1982

SR
SR
SR
SR

Stephens 1988
Stephens 1988
Stephens 1988
Stephens 1988

SR = Source Reduction
R = Recycling
T =Treatment

Table 1-1 (Continued)

WASTE REDUCTION AND TREATMENT
ALTERNATIVES FOR THE METAL CASTING INDUSTRY

Waste Stream

Spent Casting Sands

b.

Alternative

Method'

Reference

Recycle to process
Recycle to other process line
Mix treated desulfurization slag with furnace dust
Improve treatment methods (desulfurization
slag quench reactor)

R
R
T

Stephens 1988
Appendix C
Stephens 1988

Vondracek 1988,
Stephens 1988

Alter raw sand

Recycle to other process lines
Use as a construction material
Segregate shot blast from sand waste
Reuse as ingot molds
Detoxify with sodium silicate
Screen sand to remove metal
Reclaim metals in mineral acid leaching
followed by metal recovery process
Reclaim sand by wet washlnglscrubbing
Reclaim sand by dry scrubbinglattriiion
Reclaim sand thermally
Sodium silicatenime (Furness) process
Sodium silicatelpouolime (rlezek)
process

SR
R
R
R
R
T
R
R

DHS 1989
Stephens 1988
Smith 1982
DHS 1989
DHS 1989
DHS 1989
DHS 1989
HazTech News 1988

SR = Source reduction
R = Recycling
T = Treatment

R
R
R
T
T

Table 1-2
WASTE REDUCTION AND TREATMENT
ALTERNATIVES FOR THE HEAT TREATING INDUSTRY

Waste Stream
Spent Baths and
Salt Pots From
Case Hardening

-L

rh
Quenchant Waste

SR = Source reduction
R = Recycling
T
= Treatment

Alternative

Method*

Use noncyanide bath

Avoid bath contamination (clean all work placed in the bath)
Use graphite cover made of artificial graphite powders
Dry work completely prior to liquid case hardening
Increase longevity of molten bath by periodic removal of sludges
Minimize dragout
Replace pot lining (use modified basic brick instead of
ceramic material)
Chemical treatment of cyanide wastewaters with low cyanide
content
Electrochemical treatment of cyanide wastewater
with high cyanide contents (> 200ppm)

SR
SR
SR
SR
SR
SR
SR

Minimize dragout of molten salt

Minimize dragout of oil used as quenchant
Control temperature in oil quenching system
Use modified quenchants
Filter oil and recycfe to the original process
Dewater oil by draining, evaporation, or centrifuge separation
Employ ultrafiltration for water soluble polymer quenchants
Chemicaf treatment of cyanides in spent aqueous and brine
quenchants
Recover oil in oll/water separator for off-site recycling

SR
SR
SR
SR
R
R
R

Reference
ASM 1981

DHS 1989

T
T

T
T

DHS 1989

ASM 1981

1.5

WASTE REDUCTION INDEX

A waste reduction Index (WRI) was developed for use by foundries to measure the effectiveness
of implementing a waste reduction program. The index compensates for variation in productive
activity. It can be applied to a specific waste stream, or to a combination of waste streams.
The WRI uses a baseline period from which it can be measured over successive intervals Of
time. WRls are developed here for the following waste streams:
0

brass foundry hazardous sand waste

iron foundry hazardous sand waste

iron foundry baghouse waste

1-6

SECTION 2.0
RECOMMENDATIONS

In order to achieve maximal reduction of environmental risk, industrial efforts should follow the
waste reduction hierarchy of strategies. This entails first identifying and implementing all source
reduction techniques appropriate to the plant's processes, then implementing recycling
methods, and finally, in order to manage the waste streams that remain, using treatment
techniques.
The investigation of waste reduction measures should be started by developing a flowchart
showing the various waste stream generation points and establishing the relationships between
different operations throughout the entire process. As a next step, a thorough analytical study
is recommended to quantify the metallic content in each wastestream if It is not known. It is
recommended to focus on waste currently being manifested to landfills (see Section 5.0 for
regulatory constraints) since these wastes usually represent the most expensive waste
management problems.
In order to assess a plant's waste management needs, and to identify the opportunities that
exist for waste reduction, It is recommended that plant staff use the procedure detailed in
Appendix D of this report. The procedure focuses on the different industrial processes within
a plant, and provides a method for identifying promising waste reduction techniques. The
Industrial processes examined in this report include metal casting and heat treating.
21

METALCASTING

The main recommendations for reducing metal casting waste in ferrous foundries are to control
the quality of scrap metal used for casting, replace electric arc or cupola furnaces by induction
furnaces, and recycle slag and/or furnace dust from pollution control equipment back to the
original process or to another process line. For example, slag from electric arc furnaces
employed in the production of heat resistant alloy can be added to the feed at cupola furnaces
producing gray iron.
The main recommendationsfor reducing metal casting waste in nonferrous brass foundries are
to: 1) segregate spent nonhazardous foundry sand from shot blasting and grinding dust, 2)
detoxify hazardous sand, 3)reuse stabilized and detoxified sand in production of Ingot molds,
and 4) reclaim metals from metallic rich waste streams. Metallic rich streams include
wheelabrator baghouse waste and furnace dust with high zinc contents. Reclamation can be
by either physical separation such as screening and/or mineral acid leaching. This generates
nonhazardous sand and metallics for use as a furnace feed or for off-site sale.
2.2

HEATTREATING

Source reduction methods that are very effective for heat treating operations include input
material control, careful examination of parts drainage and dragout removal of chemicals from
cyanide bearing baths and quenching media, thorough drying of workpieces to prevent
spattering from high temperature baths, and extension of bath lifetimes through impurity

removal. Recycling of spent process bath solutions, rinsing, filtration, evaporation, desludging
and other separation techniques are also very effective methods for reducing waste streams
from carburizing, cyaniding, nitriding, quenching, and selective case hardening operations.
These and other options are elaborated upon in section 7.0.

2.3

WASTE REDUCTION ALTERNATIVES ASSESSMENT A NON-FERROUS FOUNDRY

This foundry manufactures brass plumbing fiures, using scrap car radiators as raw materials.
Waste streams include raw slag, spent casting sands, waste casting metal, floor sweepings,
furnace fumes and airborne dust from molding operations.
Floor sweepings are returned to the furnace. Crushing and screening operations are employed
to remove and reuse the metal contents of solidified slag and spent foundry sand. Slag dust
from these operations is sent to smelters for further metal recovery. Waste foundry sand is also
sent out for recovery of Its remaining metal content. Metal reclamation strategies have proved
to be cost effective, generally paying for themselves within two years.
Aluminum materials are strictly segregated from process streams, because they can "poison"
the brass. Zinc oxide fumes from furnaces are collected in baghouses, and used offsite as an
additive for fertilizer manufacturing. Airborne dust from sand molds is collected by hydrofilters
employing wet scrubbers and cyclone separators. Reclaimed sand is used again in the
molding process.
2.4

WASTE REDUCTION ALIERNATlVES ASSESSMENT B

- HEAT TREATING PLANT

The plant in this study uses three basic quenching media: oil, water, and a mixture of
nitritelnitrate molten salts. Implementation of dragout minimization techniques would reduce
both the cost of make-up quenching oil or molten salts media and waste handling cost. The
extending of quenching oil life by proper temperature conditioning would prevent formation of
carbonaceous contaminations and would reduce subsequent VeatmenVhandling cost. The
dragout from oil baths is collected in clarifiers and sent for off-site recycling. On-site recycling
such as gravity oil/water separation and subsequent mechanicalnhermal conditioning could
bring input material savings and reduced haulage expense.
The plant electroplates some metal workpieces to render them impervious to the carburizing
atmosphere in the furnace. Segregation of spent cleaning solutions from plating wastes could
reduce the quantity of wastewater to be treated and subsequently the quantity of sludge cake
generated for off-site disposal at a Class I landfill.
Plant B is currently investigating the possibility for off-site copper recovery from the sludge by
providing the sludge to copper recyclers in Utah, Nevada, and Arizona. However, a minimum
metal content in the wastestream is specified as an acceptance criterion. Waste segregation
could play an important role in increasing the copper contents in the cake by treating
concentrated spent plating solutions rather than a dilute stream commingled with low-metal
content cleaning solutions.

2-2

2.5

WASTE REDUCTION ALTERNATIVES ASSESSMENT C DUCTILE AND GRAY IRON

FOUNDRY

This foundry employs one cupola furnace in a gray iron production line. Since July 1988, Plant
C has been recycling the hazardous slag from electric induction furnaces in the heat resistant
alloy production line by charging the slag to the cupola furnace. This operation separates the
metal from the slag, rendering the slag nonhazardous.
At present, experiments are being carried out on the detoxification of residuals from the cyclone
scrubber, part of the cupola furnace pollution control system. Silicate treatment technology is
being employed to immobilize lead, zinc, cadmium and other heavy metals carried over with
the gases and particulates from the stack. A sodium nitratehydrated lime solution Immobilizes
these elements in the quench zone of the stack at temperatures above 1,300"F. This process
has been shown to reduce the nonfixated zinc and cadmium content to desired levels. The
plant is presently working on Improving the efficiency of lead fixation.
The hazardous sand from dust collection in heat resistant alloy production line is segregated
from other foundry non-hazardous sand and is recycled as a feed component to the cupola
furnace.
2.6

REGULATIONS

Hazardous waste, worker health and safety, and other environmental and safety requirements
change continually at the state, federal, and local level. The generator must keep up-to-date
on these changes, and also must maintain flexibility regarding its waste management options
to accommodate such changes.
2.7

ADVANCING TECHNOLOGY

The generator should keep abreast of improved technology in hazardous waste reduction and
management. Information sources include trade journals, chemical and equipment suppliers,
equipment expositions, conferences, and industry association newsletters. Advancing
technology can provide the generator with cost-effective alternatives for Improved operations
that can lead to less waste generation and greater competitive advantage.

2-3

SECTION 3.0
INTRODUCTION
3.1

STUDY PURPOSE

The purpose of this study is twofold: to investigate waste reduction methods currently used
in thermal metal working industries and to develop a set of worksheets to be used by plant
staff to identify opportunities to reduce waste.
3.2

INDUSTRY OVERVIEW

Thermal metal working industries are categorized as follows under the Standard Industrial
Classification (SIC) System:
0

332, 336: foundries, casting

3398: metal heat treating

346: forgings, stampings

3493, 3495: springs

331, 335: rolling, drawing, extruding, finishing

According to 3for California, published by the U.S. Department

of Commerce, Bureau of the Census, there were 279 nonferrous foundries (SIC 336), 96 iron
and steel foundries (SIC 332), 116 establishments under SIC 339 categoty (heat treating,
grinding), 114 establishments under SIC 331, 105 under SIC 335, and 493 under SIC 346.
3.3

PROJECT APPROACH

This study analyzes: 1) source reductiontechniques that allow thermal metal working industries
to minimize or prevent hazardous waste generation within their industrial processes; 2) recycling
techniques that convert potential waste streams into usable process materials; and 3) treatment
techniques that render remaining wastes less hazardous.
Source reduction methodologies that prevent or minimize generation of hazardous waste at its
point of origin receive the primary focus in this report, because it is these techniques that are
widely considered to be the most promising for reducing adverse impacts of hazardous wastes
on the environment (SA6 1988, EPA 1988). Ffecycllng methods are treated as next in
importance. Both source reduction and recycling reduce the quantity of hazardous waste
escaping from the industrial process where it is generated. Finally, treatment methods are
discussed for reducing the environmental impact of wastes that do escape the process.
This report examines waste reduction applicable to a large segment of the thermal metal
working industry. Cross index information has been developed on types of operations and

3-1

relevant hazardous wastes generated by the thermal metal working industry versus waste
reduction and treatment techniques that have been already developed in previous DHS and
EPA Waste Audit Studies. it was found that the metal casting and heat treating industry
generate the most thermal metal Industry-specific wastes that are totally different from those
that have already been studied.
3.4

FOCUS

This report focuses on processes associated with thermal metal working. From the business
patterns data reported in Section 3.2,and from examination of the waste streams of the
different industrial processes listed &I Section 3.2, it appears that the processes that are both
common in California, and generate significant hazardous wastes are:
Ferrous foundry processes
Nonferrous foundry processes
Heat treating.

...

The study does not include examination of the primary metal industry, which is practically
nonexistent in California. The establishments registered in California under primary metal SIC
codes were found during this study to function as interstate product exchange sales offices and
do not represent hazardous waste generators under the SIC codes of interest to this study.
The report does not address processes altering the surfaces of metal workpieces to prepare
them for assembly into the finished products. These processes are covered in detail in the
following Waste Audit Study reports, which are available from the DHS Alternative Technology
Division:

1.
2.

3.
4.
5.

6.
7.

3.5

Waste Audit Study: Automotive Paint Shops

Waste Audit Study: Metal Finishing Industries
Waste Audit Study: Fabricated Metal Products Industry
Waste Audit Study: Precious Metal Products and Recycling
Guide to Solvent Waste Reduction Alternatives, Final Report and Symposium
Proceedings
Guide to Oil Waste ManagementAlternatives, Final Report and Symposium Proceedings
Reducing Californias Metal Bearing Waste Streams, Final Report and Symposium
Proceedings.

FORGING, TEMPERING AND ROLLING

Forging, tempering, and rolling processes were not included as separate sections in this report
because any significant hazardous waste streams generated appear to be covered under
operations already examined in the report (for instance, quench oils are covered in Section 7.0).

.
3-2

SECTION 4.0
INDUSTRIAL WASTE REDUCTION PROGRAMS

4.1

ENVIRONMENTAL BENEFITS

The benefits of waste reduction can be understood in terms of environmental risk reduction.
Risk reduction is the lessening of potential dangers to human health and the environment. It
includes both technology-based strategies, and those that involve organizational and
management changes within a company. The latter includes better worker training programs
or segregation of waste streams. Whatever methods are used, waste reduction programs can
benefit the environment by:

4.2

preventing the generation of wastes, residues, and contaminants that, If released,

could pose a threat;

recycling and reusing wastes by feeding them back as raw materials into
industrial processes.
?

PROGRAM REQUIREMENT

There is a continuum of activities that individual workers, groups of workers within a plant, and
the plant as a whole can engage in to reduce health and environmental risks. But in order for
these activities to take place, an effective organized risk reduction program is essential.
To create a successful program, attention must be paid to the following steps:
0

0
0
0

Planning and Organization

Assessment of Needs
Selection of Attainable Goals
Implementation

Because a waste reduction program impacts many functional groups within a plant, the
planning and organizational phase of the program needs to bring these groups together in an
effective way. Although the complexity of the program depends on the size and waste
problems of the plant, it is critical to have a strong management commitment to support the
program. The potential benefits from a serious waste reduction program that often convince
management to lend their support include economic advantages, improved regulatory
compliance, reduction in liabiliies associated with generation and disposal of hazardous waste,
improved public image, and reduced environmental impact (USEPA 1988).
Assessment of a companys waste reduction needs includes examining the content and volume
of hazardous waste streams it generates, and the processes or operations that generate them.
The object of this step is to prioritize the needs of the company, based on environmental risk,
liability, and economic criteria.

4-1

The assessment phase also includes identification of waste reduction methodologies that
appear promising for solving the particular problems of the plant. Once the origins and causes
of waste generation are understood, it is possible to identify possible ways to minimize waste
in the assessed areas. Many of the ideas and knowledge on how to do this can come from
plant staff with hands-on knowledge of the company's operations. This Is supplemented
through use of the technical literature and contacts with trade associations, state and local
environmental agencies, consultants and equipment vendors.
Selection of the program's goals Is done through analysis of the technical and economic
feaslblllty of the waste reduction options Identified. Technical evaluation determines whether
a proposed option is possible to Implement (i.e., is the necessary equipment and/or expertise
available), and whether it will work in a specific application. Economic analysis is conducted
using standard measures of profitability such as payback period, return on investment and net
present value.
Successful Implementationof waste reduction methodologies depends on several factors, most
notably obtaining the necessary funding. Waste reduction is generally accompanied by process
efficiency improvements and cost reductions. Nevertheless, the company's capital resources
may be tied up elsewhere. 11 is essential to know the level within an organization that has
approval for capital projects, and to have a team that can present the financial, technical and
environmental benefits in such a manner as to sell the project to management.
4.3

THE WASTE REDUCTION OPPORTUNITY ASSESSMENT

In order to aid companies and other organizations in creating effective waste reduction
programs, the Environmental Protection Agency has developed a recommended procedure for
identifying and implementing source reduction and recycling applications that includes the
steps discussed In the previous section. The agency has published a detailed EPA Manual for
Waste Reduction Omortunity Assessments (1968) that outlines this procedure in depth. The
manual employs a series of worksheets that guide plant engineers or other staff personnel
through the methods for evaluating promising waste reduction strategies. The manual also
includes methodologies for analyzing the feasibility of potential options on economic and
technical bases as well. An extensive opportunity assessment is a valuable, effective tool for
choosing the best waste reduction strategies for a particular plant.

4-2

SECTION 5.0
REGULATORY ASPECTS
5.1

REGULATORY CAVEAT

All text pertaining to laws and regulations contained within this report are provided for general
information only. The information provided here is not reliable for use as a legal reference.
The generator must contact the appropriate legal sources and regulatory authorities for up-todate regulatory requirements, and their Interpretation and implementation.
5.2

LAWS, REGULATIONS AND ORDINANCES

A variety of federal, state, and local laws, regulations and ordinances influence hazardous waste
management and waste reduction in the thermal metal working industry. These include: the
Federal Resource Conservation and Recovery Act (RCRA) and its amendments, which prohibit
land disposal of untreated hazardous wastes; the State of Californias land disposal restrictions
and standards set for generators, transporters, and owners or operators of treatment, storage,
or disposal (TSD) facilities; the Federal Clean Water Act, which requires water quality control
for wastewaters discharged to surface waters or municipal sewers; and the State of California
Hazardous Waste Reduction and Management Review Act of 1989 (known as Senate Bill No.
14, signed into law on October 1, 1989). Appendix E identifies major environmental regulatory
requirements that affect hazardous waste generators. This section summarizes existing and
proposed land disposal restrictions and new waste reduction rquirements that affect the thermal
metal working Industty.
5.2.1

Land Disposal Restrictions lExistina and ProDosed)

To facilitate the movement away from land disposal and to spark development of alternative
methods for managing hazardous waste, the State of California passed a number of laws and
regulations restricting land disposal and emphasizing alternative management methods. These
restrictions have caused increases in waste disposal costs, since the restricted wastes now
require some form of treatment prior to land disposal. These increased waste disposal costs
are viewed as a driving force for the thermal metal working industry to implement waste
reduction technologies.
The State of Californias original restrictions prohibited the land disposal of: liquids containing
cyanide, certain metals, certain acids, PCBs; and liquids and solids containing halogenated
organics (California Code of Regulations (CCR) 566900 et seq). The regulations specify the
waste concentrations and schedule of restrictions. The State of Californias most recent Land
Disposal Restrictions, described in the Hazardous Waste Management Act of 1986 expand the
original restrictions by prohibiting land disposal of all untreated hazardous wastes in California.
The Hazardous Waste Management Act of 1986 required the California Department of Health
Services to prohibit the land disposal of all untreated hazardous waste on or before May 8,
1990 and to specify the standards or treatment levels for treating hazardous waste prior to land
disposal. The summary of the proposed treatment standards that would affect the thermal

..
5-1

metal working industry is presented below.

5.2.1.1

Treatment Standards for Foundry Sand

RCRA Waste
If waste foundry sand Is a RCFIA waste (hazardous according to Federal criteria) it is subject
only to applicable Federal land disposal restrictions (40CFR Part 268). The Federal treatment
standards were promulgated on May 8, 1990 with a 9O-day extension. The sand may be
considered hazardous according to the federal criteria if it contains any of the eight metals
identified in 40 CFR I 261.24 above the federal thresholds or exhibits any other hazardous
characteristics pursuant to 40 CFR Part 261, Subpart C.

Non-RCRA Waste
Waste foundry sand is hazardous by State standards if it exhibits the characteristics delineated
in CCR Title 22,Article 11.
The following treatment standards have been developed for metal levels in non-RCRA
hazardous waste foundry sand. The prohibition date for land disposal of untreated non-RCRA
hazardous waste foundry sand is January 1, 1991.
Table 5-1
Treatment Standards for Non-RCRA Hazardous Waste Foundry Sand
Waste Extraction Test (WET)
mg/L
Copper
Lead
Zinc
Cadmium
Nickel

200

30
250
1.o

20

The treatment standards for waste foundry sand are based on sand reclamation and metal
recovery used in conjunction with chemical stabilization applied to the unrecoverable waste
fraction. Generators will be required to meet the treatment standards before disposing of the
waste to the land. Wastes managed by methods other than land disposal are not subject to
the treatment standard.
A waste that meets its treatment standards may be disposed of in a land disposal facility. If
untreated waste meets the standards, then It does not have to be further treated prior to
disposal. If a waste does require treatment, any technology may be used-not necessarily the
Best Demonstrated Available Technology (BDAT).

.
5-2

To determine if a waste meets the treatment standards, representative samples must be tested
by a certified hazardous waste testing laboratory using the California Waste Extraction Test
( W q procedure as described in CCR 566700. Representative samples are defined as
exhibiting average properties of the whole waste (EPA 1985).
if a sample of waste foundry sand contains hazardous concentrations of contaminants other
than the five metals included in these treatment standards, the waste will also be subject to
appropriate treatment standards for solids with metals, solids with organics, aqueous wastes
with metals, and/or aqueous wastes with organics. Standards tor solid wastes with metals are
given below as an example.
5.21.2 Treatment Standards for Solld Wastes with Metals

RCRA Solid Wastes with Metals

RCRA solid wastes with metals include "characteristic" wastes (D wastes) and "iisted" wastes
(K and F wastes). The characteristic wastes are those containing any of the eight RCRA metals
above the extractable concentrations (EP Toxicity levels) identified in 40 CFR Part 261.24.
Although the EP levels are numerically the same as California's STLC levels in Section 66699
Titie 22,CCR, California's extraction procedure is more aggressive than EPA's. Therefore some
wastes containing the eight metals are hazardous only in California.
EPA treatment standards for some "listed" metal-bearing wastes are given in Table 5-2;Foil
waste is generated from metal heat treating operations. The Federal standards for these
wastes are based on the Toxicity Characteristics Leaching Procedure (TCLP).
Non-RCRA Solid Wastes with Metals
Non-RCRA solid wastes with metals are those solid wastes containing metal compounds that
are not regulated by EPA as hazardous wastes.
It has been proposed that non-EPA-regulated metal-containing solid wastes other than the
waste generated from air pollution control equipment, auto shredder waste, foundry sand,
incinerator ash and sulfur sludge be subjected to the treatment standards in Table 5-3.
Wastes containing EPA-regulated metals may become non-RCRA wastes if the concentrations
of extractable metals are below the EP toxicity limits but exceed the STLC levels using the
WET test or the TTLC levels. Non-RCM standards are based on the California Waste
Extraction Test (WET) procedure.

..
5-3

..

Table 5-2

EPA's Treatment Standards for Some Metal-Containing Federal "Llsted"Wastes

TCLP, max. ppm
FOO6
sludge

KO46
sludge

KO61
dust

KO62
sludge

KO71
sludges

KO86
ash

KIOI 8K102

KO48-KO52

ash (lowAs)

ash

KO01
sludge

KO22

Foil

ash

sludge

Sb
As
0a
Be

0.066

0.14

Cr. total
co
cu

5.2

5.2

0.094

Pb

0.51

0.24

0.37

cd

0.004

0.066

0.066

Cr"
~r''

0.094

5.2

0.37

0.51

1.7

5.2

5.2

0.51

0.51

0.025

Hg

Mo

NI
Se
Ag

0.32

0.32

0.072

Th
V
Zn
CN. total
CN; amenaMe

0.32

0.048
0.025

0.32

0.072

110
9.1

m:

KO62 and KO71 sludges did not need stablllzatbn because of very low TCLP values of raw wastes (metal sulfdes)

Data Source:

Federal Register, Volume 53, No. 159, August 17. 1988.

0.32

Table 5-3
Proposed Treatment Standards for Non-RCRA Solid Wastes with Metals
Propased Treatment

standards
Metals

STLC, m a l

Arsenic
Barium
Cadmium
Chromium (VI)
Lead
Mercury
Selenium
Silver
Antimony
Beryllium
Chromium (Ill)
Cobalt
Copper
Molybdenum

5.0
100.0
1.o
5.0
5.0
0.2
1.o
5.0
15.0
0.75
560.0
80.0
25.0
350.0
20.0
7.0
24.0

Nickel
Thallium
Vanadium
Zinc

WET, mSn, merage

15.0
100.0
1.o
5.0
67.0
0.2
1.o
5.0
15.0
0.75
560.0
80.0
230.0
350.0
20.0
7.0
24.0
250.0

250.0

5-5

5.2.1.3

Proposed Treatment Standards for Baghouse Waste and Gas Scrubber Waste.

Treatment standards are proposed for the California Waste Code (CWC) 591 that is designated
for baghouse waste. Baghouse waste refers to the dust that is collected in a baghouse or
other dry air pollution control devices. Baghouse waste is being divided for the purposes of
the proposed treatment standard into baghouse waste from sources other than foundries and
baghouse waste from foundries.
The non-RCFM hazardous wastes include fly ash, bottom ash, retort ash, baghouse waste and
gas scrubber waste that contain any of the metals or metal compounds listed in Section
66699(b), Tile 22, California Code of Regulations (CCR), if any of the metals exceed the criteria
given in Section 66699(a), Tile 22, CCR. The proposed treatment standards for non-RCRA
baghouse waste are summarized in Table 5-4.
Table 5 4
PROPOSED TREATMENT STANDARDS FOR BAGHOUSE WASTE

Metals
Arsenic
Cadmium
Copper
Lead
Nickel
Selenium
Vanadium
Zinc

From Foundries
WET, mg/l

Other Sources
WET, mgll

350

15
1
40

70

20

20
1

20
1

24
250

24
250

15
1

Hazardous wastes that are RCRA wastes are only subject to the Federal land disposal
restrictions (40 CFR Part 268) unless the RCRA waste is mixed with a non-RCRA waste. EPA
established treatment standards for RCRA characteristic wastes on May 8, 1990.
5.2.2

Waste Storaae

Many of Californias hazardous waste storage requirements, including permits, training,

contingency plans, and record keeping, apply to businesses that store hazardous wastes in
tanks or containers (e.g. drums) for longer than 90 days on-site. The time period for calculating
the S w a y period begins when the business has accumulated 100 kilograms of hazardous
waste or one kilogram of extremely hazardous waste or acutely hazardous waste. The
exception to this is if the business generates more than the above-specified quantities during

5-6

any calendar month. Then, the time period begins when any amount of hazardous waste first
begins to accumulate in that month (25123.3 CHSC).
Waste quantities below the levels mentioned above are not subject to the 90-day accumulation
time limit. If sufficient waste reduction measures are implemented, businesses that are small
quantity generators might take a long time to reach the 90-day accumulation limit. Therefore,
these accumulation time limits may encourage waste reduction for many businesses.

5.2.3

Waste Transoort

Small quantities of wastes are usually accumulated in drums. Waste transport fees are typically
based on the number of drums to be picked up. Often shipments of fewer than 10 to 15 55gallon drums are charged a higher transport rate. Smaller thermal metal working businesses
that are not permitted storage facilities and, thereby avoid the 90-day accumulation time limit
may be exposed to high waste management costs. It may not appear to be in the interest
of these businesses to implement waste reduction measures.
Other statutory requirements that have become a priority are the federal Superfund
Amendments and Reauthorization Act (SARA) emergency planning and community right-toknow requirements, as well as State of California citizens right-to-know legislation. The state
law requires local governments to implement programs to regulate hazardous materials storage
(Chapter 6.95, Div. 20,CHSC). These regulatory programs may affect facilities in two ways:
(1) compliance with the local programs will often require capital investments to upgrade the
facilities and will require time for the facilities to develop their permit applications and
hazardous materials management plans; and (2) since the local programs permit fees are
based on the types and quantities of hazardous materials stored at facilities, decisions on
source segregation and batch treatment of wastes, and the storage and use of hazardous
materials will be influenced by these local programs. The impact of item (1) above may be a
reduction in the capital and time that facilities are able to allocate to implementing waste
reduction. On the other hand, because of the additional public scrutiny, there is added
incentive to implement source reduction and recycling techniques that can reduce the quantities
of hazardous materials present at the facilities, and thus, the associated liabilities as well.
Source reduction techniques that might be especially encouraged by the right-to-know
legislation are material substitutions that replace hazardous chemicals with nonhazardous ones
which are able to perform the same functions. Item (2) above could also both discourage and
encourage waste reduction. Segregation of materials and batch treatment may require
additional storage tanks. This could increase storage permit fees and exposure to liability
costs due to spills or other releases. Alternatively, storage permit fees may encourage facilities
to reduce their material inventories and waste generation to minimize their permit costs.
5.2.4

Waste Reduction

On October 1,1989, Senate Bill No. 14 sponsored by Senator Roberti was signed into law by
Governor Deukmejan. This law emphasizes prevention of generation of hazardous waste
through source reduction methods that include changing input materials, process modifications,
operational improvements and product reformulation. The bill stresses source reduction
approaches over more traditional waste management approaches such as recycling and
detoxification by treatment.

5-7

The following is a summary of key SB14 requirements:

1.

Every generator in the state responsible for more than 12,000 kg of hazardous waste
routinely generated in a calendar year (or 12 kg/year of extremely hazardous waste) will
be required to conduct and document a source reduction evaluation review and prepare
a souce reduction plan by September 1, 1991 and every four years thereafter.

2.

The reviews will list the types and quantities for all major hazardous waste streams 0.0,
those greater than 5% of total volume) which are generated routinely. Feasible source
reduction measures for each listed hazardous waste stream will be identified and
characterized including the rationale for either adoption or rejection. The plans will set
forth the implementation timetable.

3.

Waste management performance reports must be prepared by September 1,1991, and

every four years thereafter. The reports will document the assessment of the effects
of each hazardous waste management measure implemented on waste generation and
will also address contributing external factors, such as changes in business activity,
waste classification and natural phenomena.

4.

All reviews, plans and performance reports must be certified by a registered professional
engineer or other qualified professional.

5.

All reviews, plans and performance reports can be requested by the administering
agency. Failure to comply with such request within 30 days may result in enforcement
actions and the fine of $1,OOO per day of violation.

6.

Confidential business Information will be protected from public disclosure.

The source reduction evaluation review and plan conducted and completed for each site shall
include:
1.

Identification of all routinely generated hazardous waste streams which result from
ongoing processes or operations that have a yearly volume exceeding 5% of the total
yearly volume of hazardous or extremely hazardous waste generated at the site.

2.

For each hazardous waste stream:

'

a.

estimate of the quantii of hazardous waste generated

b.

evaluation of potentially viable source reduction approaches available to the

generator including:

1)
2)

3)
4)

Input material changes

Operational improvements
Production process changes
Product reformulation

5-8

3.

Specification of and rationale for technically feasible and economically practicable

source reduction measures which will be implemented by the generator with respect to
each hazardous waste stream identified

4.

Full documentation of any statement explaining the generators rationalefor rejecting any
available source reduction approach

5.

Evaluation and quantification of the effects of the chosen source reduction method on
emissions and discharges to air, water or land

6.

Timetable for making reasonable and measurable progress towards implementation of

the selected source reduction measures.

7.

Review and certification by a professionalengineer or by an environmental assessor who

has demonstrated expertise in hazardous waste management.

..
59

SECTION 6.0
WASTE REDUCTION AND TREATMENT
ALTERNATIVES FOR THE METAL CASTING INDUSTRY
6.1

DESCRIPTION OF HAZARDOUS WASTE GENERATION PROCESSES

The majority of hazardous wastes generated by the metal casting industry are from foundry
operations. Foundries range in size from small job shops to the large manufacturingplants that
turn out thousands of tons of castings each day. Most California foundries fall in the small to
medium size range, and many are jobbing foundries (as opposed to captive suppliers).
Generation of hazardous wastes is directly related to the type of material melted (pig iron, steel,
brass or aluminum), and depends on the types of molds and cores used as well the as
technology employed. Although there may be differences in certain plants, basic foundry
operations typically include: patternmaking, molding, core making, melting, pouring and
cleaning. In California, the metal casting industry is based on the use of secondary (recycled)
metals. In addition to foundries, many plants engaged in metal fabrication do their own casting.
Figure 6-1 presents a simplified flow diagram of the basic operations for producing a sand
casting. The process begins with the patternmaking. A pattern is a specially made model of
the component to be produced, and is used for generating molds. Generally, sand is placed
around the pattern and, in the case of clay-bonded sand, rammed to the desired hardness.
In the case of chemical binders, the mold is chemically hardened after light manual or machine
compaction. Molds are usually produced in two halves so that the pattern can be easily
removed. When these two halves are reassembled, a cavity remains inside the mold in the
shape of the pattern.
Internal passageways within a casting are formed by the use of cores. Cores are parts made
of sand and binder that are sufficiently hard and strong to be inserted in a mold. Thus, the
cores shape the interior of a casting, which cannot be shaped by the pattern itself. The
patternmaker supplies core boxes for the production of precisely dimensioned cores. These
core boxes are filled with specially bonded core sand and compacted much like the mold itself.
Cores are placed in the drag, .or bottom section of the mold, and the mold is then closed by
placing the cope, or top section, over the drag. Mold closing completes the production of the
mold, into which the molten metal is then poured.
Casting production begins with melting of the metal. Molten metal is then tapped from the
melting furnace into a ladie for pouring into the mold cavity, where it is allowed to solidify within
the space defined by the sand mold and cores. Cupola furnaces, electric arc furnaces (EAFs),
hearth (reverberatory), crucible, and induction furnaces are all typical in the industry, and are
described below:

61

Figure 6-1

SIMPLIFIED FLOW DIAGRAM OF THE BASIC

OPERATIONS FOR PRODUCING A STEEL CASTING

6-2

n e cuoola furnace Is the oldest furnace used in the metal casting industry (patented
in 1794). It is still employed for the production of ferrous metals such as gray iron.
It Is a fixed bed cylindrical shaft furnace where alternate layers of metal along with
replacement coke are charged at the top. The metal is melted by direct contact with
the countercurrent flow of hot gases from the coke combustion. The molten metal
collects In the well, where It Is discharged for use by intermittent tapping or by
continuous flow. Conventional cupolas are lined with refractory to protect the shell
against abrasion, heat, and oxidation. The lining thickness ranges from 4.5 to 12
inches. The most commonly used lining is fireclay brick, or block. As the heat
progresses, the refractory lining in the melting zone is progressively fluxed away by
the high temperature and oxidizing atmosphere. Spent lining is a significant source of
wastes generated by foundries. This material is usually disposed of as non-hazardous
wastes.
The cupola fumace Is generally equipped with an emission control system. The two
most common types of collection are the high-energy wet scrubber and the dry
baghouse. High quality foundry grade coke is used as a fuel source. The amount of
coke in the charge usually falls in a range of 8 to 16% of the metal charge. In cupola
fumaces (see Figure C-1 in Appendix C), coke in the metal feed is used as a source
of fuel. The burning of the coke is Intensified by the blowing of oxygen enriched air
through nozzles.
Flectric arc fumaces are used by ferrous foundries and steel mills. Heat supplied to
the fumace during melting Is provided by an electrical arc established from three carbon
or graphite electrodes. The fumace is lined with refractories that deteriorate during the
foundry process, thereby generating some of the slag. The slag is a protective
nonmetallic residue resulting from the mutual dissolution of flux. Flux is used to remove
undesirable substances such as sand, ash, or dirt and nonmetallic impurities. The slag
serves to protect the molten metal from the air and to extract certain impurities.
Depending upon the type of melting, fireclay, alumina, silica, or other types of
refractories are used. The removed slag is a waste.
Along with metal scrap and shop retums (such as heads, gates, and casting scrap), a
carbon raiser (carbon rich scrap) and lime or limestone are added to the furnace charge.
Fume and dust collection equipment at the electric arc furnace is required to control air
emissions.
hduction fumaces have gradually become the most widely used means for melting iron
and, increasingly, nonferrous alloys. This furnace has excellent metallurgical control
coupled with a relatively pollution-free operation. Induction furnaces are available in a
wide range of sizes. Coreless units having a capacity of a few pounds are favored by
the precision cast metal producers. Large coreless units range up to 75 tons powered
at 21,000 KW. In a coreless furnace, the refractory-lined crucible is completely
surrounded by a water-cooled copper coil. Channel type units have with the coil
surrounding a small appendage of the unit called an inductor. They have been built
with a capacity of over 200 tons powered at 4,000 KW per inductor.

..
6-3

Induction furnaces are alternating current electric furnaces. The primary conductor is
a coil. It generates a secondary current by electromagnetic inductionthat develops heat
within the metal charge. Typically used refractories are oxides of silica (SO,), which
is classified as an acid, alumina (A120J, classified as neutral, and magnesia (MgO)
classified as a basic material. Silica Is the clear choice in iron melting because it does
not readily react with the acid slag typically produced In high-silica iron. Alumina is the
usual choice for aluminum melting furnaces.
Reverberatow fhearth) and crucible furnaces are widely used furnaces for batch melting
of nonferrous metals such as aluminum, copper, zinc, and magnesium. In a crucible
furnace, the molten metal is contained In a pot-shaped shell (crucible). Electric heaters
or fuel-fired burners outside the shell generate the heat that passes through the shell
to the molten metal. In many metal-melting operations, slag or dross buildup develops
at the metal surface line and heavy unmelted slush residue collects on the bottom. Both
of these residues shorten crucible life and must be removed and either recycled or
managed as wastes.
Regardless of the type of furnace employed, the melting operations are similar. Recycled scrap
metal along with fluxing agents are charged to the furnace for melting. Inside the furnace,
fluxing agents help to remove nonmetallic impurities such as sulfur from the melt. The mixture
of fluxing agent and impurities, known as slag, floats on the surface of the molten metal and
protects it from oxidation. In some operations, degassing of the metal is performed either
under vacuum or by purging with inert gas such as nitrogen or argon. The object of degassing
is to remove oxygen from the metal.
Once the molten metal has been treated to achieve the desired properties, lt is poured into a
mold or cast. Casting materials may include silica sands, chromite sands, heat-cured furan,
or phenolic resins, or many other heat resistant materials. These materials are often mixed with
a clay or organic resin binder and pressed around a pattern of the part. When cured, the
pattern is removed, leaving a cavity In the sand mold. In some casting operations, the pattern
remains inside the mold and is burned out by the molten metal. Once the poured metal has
solidified and cooled, the casting is shaken out of the mold, and the risers and gates are
removed. Risers (also called Veeders") are shapes that are attached to the casting to provide
a liquid-metal resewoir and control solidification. Metal in the risers is needed to compensate
for the shrinkage that occurs during cooling and solidification. Gates are the channels through
which liquid metal flows into the mold cavity proper. Heat treatment, cleaning, finishing, and
inspection are usually the final steps in producing a sand casting.
After casting, the metal part is very often subjected to blast cleaning so as to remove any
casting sand, metal flash, or oxide. Blast cleaning of castings is a process in which abrasive
particles, usually steel shot or grit are propelled at high velocity to impact the casting surface
and thereby forcefully remove surface contaminants. For aluminum castings, the process is
often used to provide a uniform cosmetic finish in addition to merely cleaning the workpiece.
This is especially true of engine components such as heads and manifolds. Cast components
sometimes require special surface characteristics such as resistance to deterioration or an
appealing appearance. This is achieved by coating of castings. The most important
prerequisite of any coating process is cleaning of the surface.

6-4

The choice of cleaning process depends not only on the types of soil to be removed but also
on the characteristics of the coating to be applied. The cleaning process must leave the
surface in a condition that is compatible with the coating process. For example, If a casting
is to be treated with phosphate and then painted, the cleaning process must remove all oils
and oxide scale because these Inhibit good phosphating.

If castings are heat treated before they are coated, the choice of heat treatment conditions can
influence the properties of the coating, particularly a metallic or conversion coating. In most
cases, heat treatment should be done in an atmosphere that is not oxidizing. Oxides and
silicates formed during heat treating must be removed before most coating processes.
Molten salt baths are used for cleaning complex interior passages in castings. in one
electrolytic, molten salt cleaning process, the electrode potential is changed so that the salt
bath is alternately oxidilng and reducing. Scale and graphite are easily removed with reducing
and oxidizing baths, respectively. Molten salt baths are fast compared to other nonmechanical
methods, but castings may crack if they are still hot when salt residues are rinsed off with
water.
Pickling in an acid bath is usually done prior to hot dip coating or electroplating. Overpickling
should be avoided because a graphite smudge can be formed on the surface. Cast iron
contains silicon; therefore, a film of silica can form on the surface as a result of heavy pickling.
This can be avoided by adding hydrofluoric acid to the pickling bath. Special safety and
environmental protection regulations must be met when using pickling.
Chemical cleaning is different from pickling because, in chemical cleaning, the cleaners attack
only the surface contaminants, not the Iron substrate. Many chemical cleaners are proprietary
formulations, but in general they are alkaline solutions, organic solvents, or emulsifiers. Alkaline
cleaners must penetrate contaminants and wet the surface in order to be effective.
Organic solvents that were commonly used in the past Include naphtha, benzene, methanol,
toluene, and carbon tetrachloride. These have been largely replaced by chlorinated solvents,
such as those used for vapor degreasing. Solvents effectively remove lubricants, cutting oils,
and coolants, but are ineffective against such inorganic compounds as oxides or salts.
Emulsion cleaners are solvents combined with surfactants; they disperse contaminants and
solids by emulsification. Emulsion cleaners are most effective against heavy oils, greases,
slushes, and solids entrained in hydrocarbon films. They are relatively ineffective against
adherent solids such as oxide scale.
After wet cleaning, short-term rust prevention is accomplished by the use of an alkaline rinse.
This can be followed by mineral oils, solvents combined with inhibitors and film formers,
emulsions of petroleum-base coatings and water, and waxes.
The following coating operations are used:
0
0

0
0

electroplating
hot dip coatings
hard facing
thermal sprayed metals and ceramics

6-5

0
0

0
0
0

diffusion coatings
conversion coatings
porcelain enamelling
organic coatings
fused dry-resin coatings

Waste reduction and treatment options for these processes have already been investigated
the reader is referred to the DHS studies listed in Section 3.4.
6.2

INPUT MATERIALS AND HAZARDOUS WASTE CHARAClERlZATlON

The major wastes generated in the casting process include baghouse and/or scrubber wastes
associated with the control of air emissions from the furnace, hazardous slags produced during
the melting and treatment operation of certain metals, and spent casting sands which can no
longer be reused. Metal for melting and sand for core and mold materials are the major input
materials of foundries, while product and waste materials make up the output.
6.2.1

lnmt Material Characterization

The major input materials at foundries consist of the following basic components:

6.2.1.1

Core and mold materials such as sand, binders and additives

Furnace charge (e.g., metal scrap), refractories, fuels, fluxes, electrodes

Other materials such as grinding wheels, shot, abrasives

Oil for forklifts, hydraulics, machines.

Mold and Core Materials

The refractory molds used in casting consist of a particulate refractory material (sand) that is
bonded together to hold its shape during pouring. The most common type of molding process
is green sand molding. The term 'green" means that the mold which is tempered with water
is not dried or baked. Green sand is composed of four major materials - sand, clay,
carbonaceous material, and water. The sand constitutes 85 to 95 percent of the green sand
mixture. Most often the sand is inert silica, but olivine (green colored) and zircon sand are also
used. Approximately 4 to 10 percent of the mixture is made up of some sort of clay, such as
western or southern bentonite, and fire clay. The clay acts as a binder for the green sand,
providing strength and plasticity. Carbonaceous materials make up 2 to 10 percent of the
green sand mixture. Carbon is added to the mold to provide a reducing atmosphere and a gas
film during pouring that protects against oxidation of the metal. Some of the more common
carbonaceous materials include sea coal (a finely ground bituminous coal), cereal (ground corn
starch), proprietary petroleum products, and wood flour. The final additives of green sand are
water, which activates the clay binder and is usually added in small percentages (2 to 5
percent), and cellulose, which controls sand expansion and water content.

6-6

The second type of sand molding process is based on resin binders that include:
0

Furan acid catalyzed no-bake binders. Furfuryl alcohol is the basic raw material.
The binders can be modified with urea, formaldehyde, and phenol. Phosphoric
acids are used as catalysts. The amount of furan ranges between 0.0 to 2.0 wt%
based on sand weight. Acid catalyst levels vary between 20 to 50% based on
the weight of binder.

These are formed in a

Phenolic acid catalyzed no-bake binders.
phenoilformaldehyde condensation reaction. Strong sulfuric acids are used as
catalysts.

Estercured alkaline phenolic no-bake binders. These are formed with a twopart binder system consisting of a water-soluble alkaline phenolic resin and liquid
ester co-reactants. Typically 1.5 to 2.0% binder based on sand weight and 20
to 25% co-reactant based on the resin are used to coat washed and dried silica
sand in most core and molding operations.

Silicate/ester-catalyzed no-bake binders. Sodium silicate binder and a liquid

organic ester (glycerol diacetate and triacetate or ethylene glycol diacetate) that
functions as hardening agent are used.

Oil urethane no-bake resins that are three component systems consisting of part
A, an alkyd oil type resin; Part 6, a liquid amine/metallic catalyst; and Part C,
a polymeric methyl di-Isocyanate.

The phenolic urethane no-bake (PUN) binder.

The polyol-isocyanatesystem (mainly for aluminum, magnesium, and other iightalloy foundries). The nonferrous binders are similar to PUN system consisting
of Part I (a phenol formaldehyde resin dissolved in a special blend of solvents)
Part II (a polymeric MDI-type isocyanate in solvents), and Part 111 (an amine
catalyst)

Alumina-phosphate no-baked binder. This consists of an acidic, water soluble

alumina-phosphate liquid binder and a free flowing powdered metal oxide
hardener.

Novoiac shell-molding binders. Phenol-formaldehydenovolac resins and lubricant

(calcium stearate in the quantity of 4 to 6% of resin weight) is used as a crosslinking agent.

Hot box binders. The resins are classified as furan or phenolic types. The furan
types contain furfuryl alcohol, the phenolic types are based on phenol, and the
furan-modified has both. Both chloride and nitrate catalysts are used. The
binders contain urea and formaldehyde.

6-7

Warm box binders. These consist of furfuryl alcohol type resin that is formulated
for a nitrogen content less than 2.5%. Copper salts of aromatic sulfonic acids
in an aqueous methanol solution are used as catalyst.

The third type of sand molding process is based on unbonded sand molds using a polystyrene
foam pattern imbedded in loose unbonded traditional sand. The foam pattern left in the sand
mold is decomposed by molten metal.
Core sands are used to produce internal cavities within a casting. The core sands are
composed of mixtures of sand with small percentages of a binder. Cores must posses the
characteristics of strength, hardness, and collapsibility. Often the cores must be removed within
a casting through a small orifice and therefore the sand must collapse after the casting
solidifies.
The sand base material for core sands is typically silica sand. Olivine and zircon sands have
also been used when specifications require core sands with higher fusion points or densities.
Binder materials used to hold the individual grains of sand together vary considerably in
composition and binding properties. Oil binders and synthetic binders are most common. Oil
binders are combinations of oils from vegetable andlor animal extractions and petrochemicals.
Typical synthetic resin binders include phenolics, phenolformaldehyde, urea-formaldehyde, ureaformaldehydeflurfuryl alcohol, phenolic-isocyanate, and alkyd isocyanate. Their composition is
very similar to molding sand binders.
Core sand binders will either partially or completely degrade when exposed to the heat of the
molten metal during the pouring operation. Once loose, sand that has had its binder fully
degraded is often mixed with molding sand for recycling or can be recycled back into the core
sand process. Partially decomposed core sands which are removed during the shakeout
process and contain only partially degraded binder are called core butts. The core butts can
be crushed and recycled back into the molding sand process, or may be taken directly to the
landfill for disposal along with broken or offspec cores and core room sweepings. The molding
sand and the core sand wastes might account for 66 to 88 percent of the total waste generated
by ferrous foundries.
6.2.1.2

Melting Materials (Furnace Charge)

The metallics charge to the furnace varies depending on the type of cast to be produced. In
California, the metal casting industry is based on the use of secondary (recycled) metals. As
an example, in a basic steel making operation, a typical metallic charge may consist of 30 to
50% shop retums such as heads, gates, and casting scrap and 50 to 70% purchase scrap.
The metal charge to cupolas in ferrous foundry typically consists of foundry returns such as
gates, runners, and internally generated scrap castings that usually constitute 30 to 50% of the
pouring weight; pig iron, which is considered a premium charge material; cast iron scrap; and
steel scrap.

6-8

Nonferrous foundries are dlfferent from ferrous foundries in that they generally melt ingots from
a scrap metal recycling facility. The ingots are much more consistent in metallurgy than typical
ferrous scrap.
Refractories are the materials that can withstand high temperatures. They are used to line
furnaces and metal pouring ladles. The three essential types of refractories are acid, basic, and
neutral. Table 6-1 presents typical compositions of refractories. The refractories are subject
to deterioration during the foundry process and, therefore, must be replaced occasionally.

Fuels are used in certain types of furnaces.

In cupola furnaces, petroleum coke is used. In

reverberatory furnaces, fuel oil or fuel gas can be used.

Fluxes and flocculants are used to facilitate

removal of Inert materials composed of metal

oxides, melted refractories, sand, coke ash, and other materials. Typical fluxes include
limestone, fluorspar, and soda ash. Silica is also an example of a typical flocculant. In some
cases, desulfurization agents, such as calcium carbide, may also be added to the melting ladle
to produce ductile iron.
6.2.1.3 Blast Cleaning Materials

In cleaning castings, steel shot is typically used, sometimes a shot and grit mixture is used.
In the past, chilled iron grit and malleable abrasives were used. Today, practically all the shot
and grit used is high-carbon cast steel that is heat treated and drawn to give a desired
tempered microstructure and hardness. Some parts undergo a sandblasting. A proper
abrasion-resistant sand is used.
6.2.1.4

Cleaning Solutions and Coating Materials

Molten salt baths, pickling acids, alkaline solutions, organic solvents, and emulsifiers are the
basic materials used in cleaning operations. Plating solutions, molten metal baths, alloys,
powdered metals, volatilized metal or metal salt, phosphate coatings, porcelain enamels, and
organic coatings are used in the coating Industry. The reader is referred to the DHS studies
listed in Section 3.4 for more information.
6.2.1.5

Oils

Hydraulic oils for forklifts, hydraulics, and lube oils for machines are used by the metal casting
industry. The reader is referred to the "Guide to Oil Waste Management Alternatives, Final
Report and Symposiums Proceedings" (see Section 3.4 of this report).
6.2.2

Hazardous Waste Characterization

Foundries manufacture product castings that are sold.

following wastes:

The manufacture generates the

Spent system sand from molding and core making operations and used core
sand not returned to the system sand (sweepings, core butts)
Cleaning room wastes: particulates, abrasives, shots

6-9

Flreclay
Super duty
Medium duty
Semi silica

49-56
57-70
72-80

4044
25-38
18%

1.5-2.5
1.3-2.1
1.0-1.5

4147
3137

2.0-2.8
2.03.3

11-15
7.5-9
1834
0.2-1.0

47.5-52.5
57.5-62.5
67.572.5
77.5-82.5
89.91
60-78
98-99.5

95-97
94-97

0.150.35
0.45-1.20

2.5-4.0
4.0-7.0
1.03.0

Alumlna type (high)

50%

60%
, 70%
,8096

'90%
Mullite
Corundum

20-26

3.04.0
3.04.0
0.40.8
0.53.1
Trace

-_
_-_
-_

304.0

3.04.0
3.04.0
3.04.0
1.0-2.0
1.03.0
0.3-1.0

0.3-2.2
03-2.2

0.02-0.10
0.10-0.30

11-17
0.3-7.0
0.2-1.0

1.0-2.0
0.5-1.0
0.04.6

Slllca type
Silica super duty
Conventional

2.53.5
1.83.5

Bask type

3.0-6.0
Chrome
0.7-1.0
Magnesite
Magnesite high periclase 0.55.0
Chrome magnesite
44

15-34
0.3-1.5
0.2-1.0
16-27

1.03.5
0.5-1.5
0.7-1.5

14-19
85-93
92-98
27-53

o
o
o
o
6.2.2.1

Dust collector wastes and scrubber wastes

Slag
Miscellaneous wastes such as waste oil from forklifts and hydraulics, empty
drums of binder, etc.
Deteriorated refractories.

Spent Foundry Sand

Much foundry waste is spent sand used in coremaking, molding, and shakeout operation.
Most foundries reuse some portion of their foundry sand; in many cases most of the sand is
reused. However, some new sand and binder are typically added to the used sand to maintain
the molding properties and enhance casting quality. Although some sand is lost to spills and
shakeout, an additional amount of sand must often be removed so the system can
accommodate the new sand that must be added. This amount of removed sand, combined
with the sand lost to spills, shakeout, and sand not reused becomes the waste sand. Figure
6-2 illustrates the primary sources of waste sand.
Waste materials generated produced from the molding sand are oflen the dusts or sludges that
are collected as part of the air pollution control system located over the molding and shakeout
operations. They can also be in the form of large clumps that are screened out of the molding
sand recycle system or as sand that has been cleaned from the castings.
Core sand binders either partially or completely degrade when exposed to the heat of the
molten metal during the pouring operation. Once loose, sand that has had its binder fully
degraded is often mixed with molding sand for recycling or can be recycled back into the core
sand process. Partially decomposed core sands which are removed during the shakeout
process and contain only partially degraded binder are called core butts. The core butts can
be crushed and recycled back into the molding sand process, or may be taken directly to the
landfill for disposal along with broken or offspec cores and core room sweepings. The molding
sand and the core sand wastes might account for 66 to 88 percent of the total waste generated
by ferrous foundries.
Foundries casting copper-based alloys (brass or bronze foundries) in particular, generate
hazardous waste sand contaminated with cadmium, lead, copper, nickel, and zinc, oflen in high
total and extractable concentrations.
Some core-making processes use strongly acidic or basic substances for scrubbing the offgases from the core-making process. In the free radical cure (FRC) process In coremaking,
acrylic-epoxy binders are cured using an organic hydroperoxide and SO, gas. A wet scrubbing
unit is used to absorb SO, gas. A 5 to 10% solution of sodium hydroxide at a pH of 8 to 14
provides efficient neutralization of the SO, and prevents the by-product (sodium sulfite) from
precipitating out of solution. Usually, pH controlled sludges are discharged to the sewer
system as non-hazardous wastes. If not properly treated, they may be classified as hazardous
corrosive waste.

6-1 1

Figure 6-2
PRIMARY SOURCES OF WASTE SAND

.
+
l

a d e!

PP P

6.22.2

Cleanlng Room Wastes

Cleaning room wastes that are ultimately disposed in the landfill include: used grinding wheels,
spent shot, floor sweepings, and dust from the cleaning room dust collectors. These wastes
become hazardous If heavy metals exceed STLC' concentrations.

6.2.2.3

Dust Collector and Scrubber Wastes

During the melting process, a small percentage of each charge is converted to dust or fume
and collected by means of baghouses or wet scrubbers. Depending on the types of metal
being melted, this dust will contain varying amounts of zinc, lead, nickel, cadmium, and
chromium. Carbon-steel dusts tend to be high in zinc and lead due to the use of galvanized
scrap while stalnless steel dusts are high in nickel and chrome. The emission control dusts
from gray Iron melting process indicate high lead concentrations. This occurs because the
melting point of gray iron is approximately 28OO"F, whereas the melting point for lead is only
about 62CPF (Oman 1988). As the metal is melted, the lead tends to volatilize and concentrate
in the residual solid particulates collected by either the baghouse or wet dust collection
emission control system. Dusts associated with nonferrous metal production may include
copper, aluminum, lead, tin, and zinc. While most steel dust is encapsulated and disposed of
in a permitted landfill, many of the nonferrous dusts are often sent to a recycler for recovery
of metal.
6.2.2.4

Slag Wastes

Slag is a fairly complex, relatively inert glassy mass with a complex chemical structure. It is
composed of metal oxides resulting from oxidation of metal during the melting process, melted
refractories, sand, coke ash (If coke Is used), and other materials. Slags may be conditioned
by fluxes to facilitate removal from the furnace. They protect the molten metal from the air and
extract Impuritles present In the melted scrap metal.
Non-recydable slag containing high concentrations of nickel, zinc, copper, cadmium or other
toxic metals must be disposed of as hazardous waste if metal concentrations exceed STLC'
limits. Examples are some slags from cupola and induction furnaces in gray iron and alloy
production. These contain significant amounts of certain heavy metals such as lead, cadmium,
and chromium. They may be classified as hazardous wastes due to higher than STLC
concentrations.

To reduce the sulfur content of Iron, some foundries use calcium carbide desulfurization
process in the production of ductile iron. The calcium carbide desulfurization slag generated
by this process may be classified as a reactive waste.

STLC-Soluble Threshold Umit Concentration (per California Code of Regulations, Title

22 regulations).

6-13

6.2.2.5

Miscellaneous Wastes

Most foundries generate some miscellaneous wastes that vary greatly in composition but make
up only a small percentage of the total waste that require off-site disposal. They include
welding materials, waste oil from forklifts and hydraulics, empty drums of binder, scrubber lime,
etc.
6.3

WASTE REDUCTION AND TREATMENT OPTIONS FOR BAGHOUSE DUST AND

SCRUBBER WASTES

Waste reduction options are presented below in the categories of source reduction and
recycling separately. Treatment options are covered in separate subsections following the
source reduction and recycling options below.
6.3.1

Source Reduction

6.3.1.1 Alter Raw Materials

The predominant source of lead and cadmium in baghouse dust or scrubber sludge is the
scrap metal used for casting. To reduce the level of these contaminants, one must identify
the incoming source and arrange to acquire charge material which contains lower
concentrations. A charge modification program at a large foundry was successful in reducing
the lead and cadmium levels in dust collector waste to below EP-Toxicity values (Stephens
1988). Due to the higher cost of high grade scrap and the difficully of obtaining a reliable and
continuous source, most foundries are not able to economically employ this method.
As an example, brass foundries often melt alloys containing 6 to 8% lead while in gray iron
foundries lead Is a tramp metal and may be found at levels very near or slightly below the
detection level in the incoming scrap. Therefore, while a gray iron foundry may be able to
reduce levels of lead in their emission control residual through purchase of a higher grade of
scrap, a brass foundry could not achieve the same reduction unless it produced a different
alloy with a lower lead content.
6.3.1.2 Install Induction Furnace

Induction furnaces offer certain advantages over electric arc or cupola furnaces. An induction
furnace emits 75 percent less dust and fumes, due to the less turbulent nature of the heating
employed inside the fumace. When coupled with the use of relatiiely clean scrap material, the
need for emission control equipment may be avoided. For more information on induction
furnaces, refer to USEPA (1985),and Danielson (1973).
6.3.2

Recvcling

The most promising wastestream for recycling is waste generated in the form of dust in electric
arc furnaces. The dust is collected in baghouses. It typically contains heavy metals such as
lead, cadmium and zinc which makes the dust a hazardous waste. The dust produced from
steel mills and the electric arc furnace dust is a RCRA waste listed as Ko61, and is currently
subject to the land disposal restrictions. A similar dust stream is produced from steel foundries

.
6-14

and, although not listed as an RCRA waste, it is a hazardous waste due to metal toxicity
characteristics. This section is focused on recycling/recovery of heavy metals from carbon steel,
electric arc furnace dust.
6.3.21 Recycle to the Orlglnal Process

Electric arc furnaces (EAFs) generate 1 to 296 of the charge into dust or fume (Chaubal 1982).
If the zinc and lead levels of the metal dust are relatively low, return of the dust to the furnace
for recovery of base metals (iron, chrome, or nickel) is often feasible. This method may be
employed with dusts generated by the production of stainless or alloy steels. But it is mostly
impractical for handling dusts associated with carbon steel production because of the use of
galvanized metal scrap. In the production of carbon steels from galvanized scrap, recovered
dusts tend to be high in zinc.
Many methods have been proposed for fluedust recycling, Including direct zinc recovery. A
good survey of recycling strategies is given by Morris (1985). Most recovery options require
the zinc content of the dust to be at least 15%, and preferably 20% for the operation to be
economical. Zinc content can be increased by returning the dust to the furnace from which
it Is generated. If the dust is injected into the furnace after the charge of scrap metal is melted,
temperatures are high enough for most of the heavy metals to fume off. This results in high
dnc content In the dust collected by the scrubbers, electrostatic precipitation systems, and/or
baghouses.

6.3.22 Recycle Outside of the Original Production Process

Reuse outside of the original process can be accomplished by reclaiming the zinc, lead and
cadmium which have concentrated in the emission control residuals. The feasibility of such
reclamation largely depends on the cost of dust treatment and disposal, concentration of metals
within the residual, the cost of recovering the metals, and the market price for the metals.
While recycling of these materials outside the original production process has been done in the
nonferrous foundry industry (Le., brass foundry), its application within gray iron foundries is
extremely limited. Some foundries have also pursued marketing of the furnace dust as input
to brick manufacturing and other consumer product applications, but consumer product liability
concern8 have limited this option. The following recovery methods are described below:
pyrometallurgical, rotary kiln, electrothermic shaft furnace, and IlTRl zinc oxide enrichment.
Other promising processes for zinc recovery are examined in Morris (1985).
Pvrometalluraical Methods
Pyrometallurgical methods for metals recovery are based on the reduction and volatilization of
zinc, lead, cadmium, and other components of EAF dust. The chemistry of these processes
can be found In Kellogg (1966). A reducing environment favors zinc and cadmium oxide
vaporiition and removal, while an oxidizing environment favors removal of lead by oxide
vaporization. Thus, lead is preferentially removed through roasting in air, while the other metals
are removed through roastkg under reducing conditions (Dressel 1974).

..
6-15

Rotarv Kiln Technolooy

Zinc removal using the rotary (or Waelz) kiln appears to be a promising strategy, partly because
as other materials containing zinc (Morris 1985). This
process can simultaneously reduce ferrous iron oxide to solid iron, as well as lead and zinc
oxide to their metallic forms, using a reducing atmosphere such as carbon monoxide and
hydrogen. New Jersey Zinc has successfully operated a Waelz kiln process to produce zinc
(Krishnan 1983). Rotary kilns have the advantage of having been used worldwide on many
types of zinccontaining materials, and thus their operating conditions and costs are well
documented (Krishnan 1982). The biggest disadvantage of the rotary kiln is that it must be
fairly large to be economically and thermally efficient. Also, chlorine in the EAF dust must be
removed through washing or roasting before metallic zinc can be produced.
it can handle a variety of dusts, as well

The electrothermic shaft furnace can extract zinc from a feed containing at least 40% of the
metal. Typically, agglomerated EAF dust is mixed with other feed to attain this percentage.
St. Joe Minerals operates a zinc smelter in Monaca, Pennsylvania using five electrothermic shaft
furnaces, and Japan also operates one at its Onohama refinery (Miyashita 1976). Bounds
(1983) presents a description of the St. Joe process. The electrothermic furnace has the
advantage that zinc is recovered in its metallic form, from which a very salable Prime Western
Grade can be made.
IlTRI Zinc Oxide Enrichment

IlTR Is involved in developing a technology for recycling of the dust by direct reduction of the
oxides using pure hydrogen at a temperature range of 1000 to 11OWC in which the iron oxide
is reduced in its reaction with hydrogen to iron and water (AFS 1989). The reduction of zinc
oxide during its reactlon with hydrogen requires recycling of hydrogen to the furnace In a
second pass.
The reduction of zinc oxide produces zinc vapors and steam at 1OOO-11oW: that are removed
from the fumace and subjected to an oxidation step wherein the zinc reaction with water
produces zinc oxide, and the hydrogen is recovered and recycled. The zinc oxide produced
is separated in a baghouse. The hydrogen containing the steam is further treated for steam
condensation, and then the hydrogen is ready for recycling into the furnace.

For this project IlTRl performed some lab scale experiments using dust containing 35 to 40%
iron. In some experiments, the sponge iron contained 58% iron and separated ZnO contained
56% zinc. The cadmium and lead were below EP toxci@
' '
text criteria. Produced ZnO can be
used as a crude zinc oxide product for further upgrading. This method of electric arc dust
recycling having proved technically feasible, a preliminary design was developed for a prototype
system with a capacity of 2.5 tons of dust charged to the furnace in a single batch. The
treatment cost was estimated at $159 per ton of dust.

.
6-16

6.3.2.3

Recycle to Cement Manufacturer

Silica based baghouse dust material from the foundry sand system and cupola furnace
generated by the Blackhawk Foundry and Machine Company (Davenport, Iowa) Is used as a
raw material by the Davenport Cement Company (Kelly 1989; AFS 1989). At present,
approximately a hundred cubic yards of material a day is sent to the Davenport Cement
Company. The dust is sent into a primary crusher and then preblended with other components
and transferred to a kiln operation. It is envisioned that baghouse dusts may constitute 5 to
10 percent of the raw material used by cement manufacturers in the near future.

6.3.3

Treatment

Many different chemical treatment systems have been developed to reduce the leachability of
lead and cadmium compounds in flue dust, These systems usually rely on chemical
stabilization, adsorption, chemical reduction, pH control, or polysllicate immobilization.

In chemical stabilization heavy metals are chemically immobilized. This technology is

successfully employed for stabilization of ferrous and non-ferrous foundry baghouse wastes.
It is reported that this method can be successfully used for stabilizing scrubber waste.
By adding stabilization agents and other chemicals to a waste, leachability of metals is reduced.
It is accomplished by the formation of a lattice structure and/or chemical bonds that bind the
metals to the solid matrix and, thereby, limit the amount of metal constituents that can be
leached when water or mild acid solution comes into contact with the waste material.
The Chemical Waste Management, Inc., Kettleman Hills facility, disposes of treated wastes at
a Class I landfill and as of mid 1990 charges the following fees for stabilizing and disposal of
the solid waste with metals:
Bulk waste: $215/ton
Drummed waste: $430/ton

6.3.3.1 Cement-Based Chemical Stabilization

Portland cement used in this treatment is a mixture of powdered oxides of calcium, silica,
aluminum, and iron. The oxides are produced by calcination of materials rich in calcium and
silica, such as limestone and clay, at high temDeratures (255042730F) in a rotary kiln.
When the anhydrous cement powder is mixed with water, hydration occurs and the cement
begins to set. Generated calcium silicate hydrate, called tobermorite gel, is the main cementing
component of concrete. The aggregate (solid waste) should be completely covered by the gel
and there should not be any void space in the waste cement mixture. Calcium hydroxide and
gypsum are additional products that are formed. The stabilization takes several hours but most
structural strength is developed within about one month.
Contaminants present in the waste include hydroxides and carbonates of various heavy metals.
These are incorporated into the interstices of the cement matrix. The high pH of the cement
mixture tends to keep metals in the form of insoluble hydroxide and carbonate salts.

..
6-17

6.3.3.2 Ume/Pozzolan-Based Chemlcal Stabilization

Pozzolan, which contains finely divided noncrystalline silica fly ash, Is a material that is not
cementitious in Itself but becomes so upon the addition of lime. The appropriate weight ratios
of waste to stabilizing agent and other additives are established empirically by conducting a
series of laboratory tests. The ratlo of water to stabking agent impacts the strength and
leaching characteristics of the stabilized material. Its structural strength must satisfy the
requirement of the existing federal landfill criteria as given In 40 CFR 264. Unconfined
compressive strength above 50 pounds per square Inch are characteristic of chemically
stabilized wastes.

6.3.3.3 Chemlcal Reduction

Chemical reduction employing the use of metallic iron has been successful in reducing the
leachability of lead to below EP-Toxicity levels. Adding a 5 percent by weight dose of iron
filings to cupola furnace scrubber sludge, for instance, reduced lead leaching from 28.6 mg/l
to less than 0.1 mg/l (Stephens 1984).

6.3.3.4 Solubllity Control

Solubility control involves controlling the pH of the waste solution so metals will not be soluble
when exposed to acidic conditions. Systems which control pH normally employ slaked lime,
Ca(OH),, to precipitate lead and cadmium as Insoluble hydroxides. A potential problem with
this method is that when excess lime Is used, creating a high pH environment, lead can
resolubilize. To avoid this problem, the use of magnesium hydroxide, Mg(OH),, to precipitate
lead has been suggested (Turpin 1985). Magnesium hydroxide provides a buffering effect so
that the potential of dissolving lead at high pH is avoided. Magnesium hydroxide is
considerably more expensive than Ca(OH), (Egide 1989). In some applications, costs might
prove prohibitive for substitution of Ca(OH), with Mg(OH),.

6.3.3.5 Polyslllcate Treatment at the Cupola Furnace Stack

Polysilicate treatment technology is under current evaluation for immobilization of heavy metals
such as Pb, Zn and Cd that are carried over with flue gases and particulates from the stack
of cupola furnace at the gray iron production line. A solution of 17.5% sodium silicate is
injected into the stack zone at 13ooDF. Hydrated lime is added to activate the sodium silicate
reaction at high temperature. Soluble metals were found below STLC levels for zinc and
cadmium. The lead concentration was decreased significantly (refer to Section C.13 in
Appendix C for details).

6.3.3.6 Sulphating Process for Zinc In EAF Dust

The zinc content of EAF dust can be removed by sulphating, using iron sulfate derived from
pickle liquor residue, a waste product in some steelmaking processes, , as the main ingredient
(Chaubal 1982). Almost 95% of the contained zinc can be converted into water leachable
ZnSO,. A low-zinc iron oxide which can be recycled is also produced.

6-18

6.3.3.7 Thermoplastic Bindlng

The use of a thermoplastic binder, such as asphalt, can be used to bind the waste components
into a solidified, impermeable matrix. A thermoplastic is an organic polymer that Is fluid at high
temperatures but behaves as a solid at ambient temperatures. This method is not widely used.
6.3.3.8 Encapsulation

Vitrification (glassification) is used for some RCRA F006 metal sludges (refer to US EPA, May
1988 for more information). In this process, the waste is incorporated into molten glass and
the mixture is allowed to cool.
6.4

WASTE REDUCTION AND TREATMENT OPTIONS FOR HAZARDOUS SLAGS

In the production of ductile iron, it is often necessary to add a desulfurizing agent in the melt
because the input (charge) materials contain excessive amounts of sulfur. One desulfurization
agent commonly used is solid calcium carbide (CaC,). Based on investigations by Taiballa et
el. (1976), calcium carbide is thought to decompose to calcium and graphite. The calcium
carbide desulfurization slag is generally removed from the molten iron in the ladle and placed
into a hopper. For adequate sulfur removal, calcium carbide must be added in slight excess.
Therefore, the slag contains both Cas and CaC,. Since an excess of CaC, is employed to
ensure removal of the sulfur, the resulting slag must be handled as a reactive waste. The slag
might also be hazardous due to higher than STLC concentrations of heavy metals.
Treatment of this material normally consists of converting the carbide to acetylene and calcium
hydroxide by reacting with water (Stolzenburg 1985). Problems with this method include
handling of a potentially explosive waste material, generation of a wastewater stream which
contains sulfides (due to calcium sulfide in the slag) and many other toxic compounds, and the
liberation of arsine, phosphine, and other toxic materials in the off-gas.
6.4.1

Source Reduction

6.4.1.1 Alter Feed Stock

One way to reduce the need for using calcium carbide is to reduce the amount of high sulfur
scrap employed in the casting. This method is commonly used in the steel industry where a
higher grade of scrap is required. While this method is effective, the ability to obtain a steady
supply of high grade scrap varies considerably and the economics usually favor a different
solution (Stephens 1988).
6.4.1.2 Alter Desulfurization Agent

To eliminate the use of calcium carbide, several major foundries have investigated the use of
alternative desulfurization agents (Stephens 1988). One proprietary process employs calcium
oxide, calcium fluoride, and two other materials. The foundry reported that not only was the
quality of their iron satisfactory, but that the overall process was economically better than
carbide desulfurization.

6-1 9

6.4.1.3 Alter Product Requirements

Quite often, the specifications of a product are based not on the requirements of that product
but on what is achievable in practice. When total sulfur removal is required, it is not
uncommon that 20 to 30 percent excess carbide is employed. The excess carbide then ends
up as slag and creates a large disposal problem. If the iron were desulfurized only to the
extent actually needed, much of this waste could be reduced or eliminated (Stephens 1988).
6.4.1.4

Improve Process Control

In an attempt to reduce calcium carbide usage, and hence waste production, improved process
controls are being developed which utilize different ways of introducing the material Into the
molten metal (Stephens 1988). Very fine granules, coated granules, and solid rods of calcium
carbide have been investigated as ways of controlling the reaction more closely. Information
regarding this option can probably best be obtained from calcium carbide suppliers or
manufacturers.
6.4.2

Recvcllng

6.4.2.1

Recycle to Process

Due to the fact that calcium carbide slag is often removed from the metal by skimming, it is not
uncommon to find large amounts of iron mixed in with the slag. Depending on the means of
removal, this metal will either be in the form of large blocks or as small granules. To reduce
metal losses, some foundries sort through the slag and remove pieces of metal for remelting.
Other foundries have investigated recharging the entire mass to the remelting furnace (Stephens
1988). Inside the furnace, calcium hydroxide forms in the slag as the recycled calcium carbide
either removes additional sulfur or is directly oxidized. While this method has been successful,
much work still remains to be done. For example, it is not known if the calcium sulfide stays
with the slag or if the sulfur is emitted in the flue gas. Initial tests indicate that the sulfur does
not concentrate in the metal so that product quality is not affected.
6.4.2.2

Recycle to Other Process Unes

Hazardous slag from electric induction furnaces (where low carbon steel charge is carburized
and Ni, Mo, and Cr metals are added) that is hazardous due to high nickel and chromium
concentrations can be recycled as a feed to cupola furnaces (gray iron production line). The
induction furnace slag plays the role of a scavenger of trace metals from the cupola slag, (see
Section C.1.3 in Appendix C). The resulting cupola slag may be rendered a nonhazardous
waste.

6-20

6.4.3

Treatment

6.4.3.1

Mixing of Treated Desulfurization Slag with Furnace Dust

Foundries that generate furnace dusts that are hazardous due to lead and cadmium content
have found that by carefully mlxing the dusts with water-treated calcium carbide desulfurization
slag (which contains calcium hydroxide), they may be rendered nonhazardous. Great care
must be taken with this method since at high pH levels the lead may leach out. In addition,
the effect of other hazardous materials in the dust and slag may still render this waste
hazardous (Stephens 1988).
6.4.3.2 Improved Treatment Methods

The state-of-the-art methods of spraying or Immersingthe desulfurizationslag in water have the

potential to cause difficult air emissions and industrial hygiene problems. Several foundry
companies and research groups have evaluated three basic types of reactors for treatment of
calcium carbide desulfurization slag.
The first, a reactor system involving immersion of the slag in water, is a more controlled version
of the methods commonly used by foundries at this time. The British Cast Iron Research
Association has done work on this type of reactor over the past 10 years and has developed
prototypes for systems to introduce the slag Into water (Vondracek 1989).
A second type of reactor involves thermal destruction of the calcium carbide. At about 1500F,
both calcium carbide and acetylene are thermally oxidized. Therefore, a system such as a
rotary kiln could be used for thermal destruction of the reactivity characteristics. An additional
benefit of thermal destruction is that it will effectively deal with potential sulfide reactivity
problems. Large chunks of metal often included in the desulfurization slag tend to be a
problem for many types of thermal units. Concern over air emissions and cost are other
hurdles to the use of thermal systems for calcium carbide desulfurization slag. Some effort
has been made to use the latent heat of the slag (the slag generally runs from 2,600 to 2900F
when It is generated) by introducing a small flow of oxygen into the very hot slag. Little serious
experimentation has been done with this method. The system involves a different process than
what has been used in the past and may require specially trained personnel.
A third treatment method Involves chemical reactions. The calcium carbide, the acetylene, the
other potential offgases, and the sulfide are reacted through the use of strong oxidizing agents,
such as potassium permanganate and hydrogen peroxide. These chemicals have been shown
to be effective In reducing offgases and in eliminating sulfide reactivity when introduced to the
water that is used to treat the slag. However, the chemical doses for achieving all of those
goals are very high, and full-scale systems would be very costly.

Other approaches to treating reactive desulfurization slag include treatment of the waste in a
tank rather than in a waste pile. The tanks, generally constructed with three vertical sides and
a ramped floor on the fourth side, first involved placing the waste and spraying water into it.
Later versions have involved deeper tanks with flat floors that will allow placing hoppers of slag
in the bottom of the tanks and immersing them in water by a combination of spraying and
flooding. Experiments have shown that if the slag can be rapidly covered by water, as little

..
6-21

as one foot of water over the slag surface will act as a scrubber and many of the gases,
including acetylene, arsine, and phosphine, will largely be dissolved in the water. Chemical
oxidants such as potassium permanganate or hydrogen peroxide can be added to the water
to oxidize dissolved species. The foundry must be concerned about releasing large quantities
of flammable and toxic gases as well as sulfides in their wastewater influent to the plant's
wastewater treatment system or to the sanitary sewer because the gases can be liberated
again. Before utilizing this method the facility should investigate how the resulting wastewater
stream will be handled and the regulations affecting its handling.
Other treatment systems consist of utilizing a reactor for the neutrallzatlon process, employing
a rotary kiln to thermally destroy the calcium carbide and acetylene, and the oxldation of the
slag by introducing small amounts of oxygen into the molten material. At this writing, technical
problems associated with these methods have prevented their use, and more research needs
to be done.
6.5

WASTE REDUCTION AND TREATMENT OPTIONS FOR SPENT CASTING SANDS

In most foundries, casting sands are recycled internally until they can no longer be used for
casting. At that time, many of the sands, such as those from iron foundries, are landfilled as
nonhazardous waste. Casting sands used in the production of brass castings may be
contaminated with lead, cadmium, zinc and copper and must be disposed of as hazardous
waste. Methods which can be employed to reduce the toxicity or volume of these wastes are
discussed below.
6.5.1

Source Reduction

6.5.1.1

Materlal Substitution

In a DHS study (1989) it was found that olivine sand seemed to be more difficult to detoxlfy
with sodium silicate and calcium oxide treatment than silica sand. Two foundries reported that
the olivine sand was hazardous due to nickel exceeding state regulatory limits when the raw
sand was tested. Foundries should test their incoming olivine sand and/or use a substitute
sand with a lower nickel content.
6.5.1.2

Waste Segregation

The most recent study (DHS 1989) concludes that a substantial amount of sand contamination
comes from shot blast dust being mixed in wkh the waste sand. This practice should be
discouraged in favor of separation of shot blast dust (a hazardous waste stream) from
nonhazardous spent foundry system sand.
A brass foundry melting approximately 1 million pounds of metal per month has reduced the
overall amount of sand being discarded from approximately 39.5 tons per month to 19.5 tons
per month by implementation of the following waste segregation steps:
1.

Replumbing the dust collector ducting on the casting metal gate cutoff saws to collect
brass chips for easier recycling; these chips were previously swept up with the waste
sand and discarded

6-22

2.

Replumbing the dust collector ducting on the ball mill to recycle the process dust

3.

Installing a new baghouse on the sand system to separate the sand system dust from
the furnace dust

4.

Installing a new screening system on the main molding sand system surge hopper to
continuously clean metal from the sand system

5.

Installation of a magnetic separation system on the shotblast system to allow the metal
dust to be recycled

6.

Changing the core sand knockout procedure to keep this sand, which has been tested
non-hazardous, from being mixed in with system sand prior to disposal

7.

Installing a new screening system on the ball mill to improve metal removal efficiency

8.

Detoxification of sand that remains unusable due to sue reclassification after thermal
sand reclamation.

6.5.2

Recvcllng

6.5.2.1 Screenlng and Separation of Metal from Sand

Most brass foundries currently screen used sand before reusing the sand, some employing
several different screen types and vibrating mechanisms to break down large masses of sand
mixed with metal chips. Coarse screens are used to remove large chunks of metal and core
butts. The larger metal pieces collected in the screen are usually remelted in the furnace.
Increasingly fine screens remove additional metal particles and help to classify the sand before
it is molded. Some foundries remelt these smaller metal particles; other foundries sell this
portion to metal reclaimers. The metal recovered during the screening process is often mixed
with coarser sand components or has sand adhering to it, so remelting these pieces in the
furnace generates large amounts of slag, especially when the smaller particles are remelted.
It was determined (DHS 1989) that the smallest screen opening size that appeared practical
was 0.0331 inch with the majority of the recyclable metal being retained on a screen with
0.0469 inch opening size. In one brass foundry an auger feed rotary screen was designed and
built at a cost of $7,396resulting in a net gain of $31,OOO.

The Chicago Faucet Co. a small red brass foundry, reports a successful metal reclamation
measure (AFS 1989). According to this report the material generated from the sand screening
system Is recycled in a ball mill. All the furnace skims, floor spills, slags, core butts and tramp
metal from screening is dumped Into a vibrator which feeds a rotating ballmlll that pulverizes
all materials and breaks them down into very small particles that are discharged out the bottom
on to a vibrating trough. This trough feeds an elevator that discharges into a receiving hopper.
One of the key items is a vlbrating screen that serves a double purpose. Sand and slag that
has been pulverized pass through the screen and come out of the bottom into a hopper. What
gets recycled goes through an impactor and back across the vibrating screen. After this

6-23

process operates for a very short period of time, clean metallics are left, more than 95% of
which can be returned to the furnace. The baghouse from the ballmill contains 14% copper
metallics, which is a wastestream. Out of 97,000 Ibs processed, 37,000 Ibs of brass was
recovered. Previously, most of thls material was sold to a recycler and/or disposed of in a
landfill.

6.5.2.2 The PMET Process Metal and Sand Reclamation

The PMET (the Pittsburgh Mineral Environmental Technology) process is based on a sand
strategy directed to achieve two goals:
1.

To produce a clean sand for recycle to the system or for disposal. The clean sand
must meet not only todays EP leach regulations, but also the new rules and test
procedures that will become the regulations of the future.

2.

To produce recyclable/marketable metal by-products. The heavy metal contaminants

are recovered as metal products which can be sold rather than disposed Of.

The process, shown in Figure 6-3, consists of two stages (AES 1989). First the sand is
processed to physically remove as much of the brass metal as possible. This material has
relatively high value, and constitutes from one-half to two-thirds of the heavy metals in the sand.
The physical separation processes employed include gravity, size, and magnetic separation
units. The second stage of the process removes the heavy metals found in the fines and the
coatings from the sand. The chemical process consists of mineral acid leaching followed by
metal recovery.
The chemical treatment step decreases the EP or TCLP lead values 50 to 500 times below the
present regulatory thresholds. There is a bleed stream In the chemical process, which
generates material that must be disposed of. However, this is not a hazardous waste, and
depending on how the system is operated, it may have salable value.
6.5.2.3

Sand Reclamation by Wet WashingIScrubbing

The cores of large castings can be removed by high-velocity jets of water. In the process the
cores are broken down into grains, and some binder Is removed. Excess molding sand can
be added and washed simultaneously. If the shakeout system is dry, the sand is charged
into an agitator system where the solid contht is held between 25 and 35%. Excess molding
sand may be blended with the core knockout material. A similar system uses intensive
scrubbing with a solids content of 75 to 80% and units in series. This latter method is superior
because of closer and more frequent grain-to-grain contact. After washing, the sand is
classified and may be used either wet (naturally drained to 4 to 5% moisture) and added to a
system sand, dried for cores, or used for facing sand. Facing sand mixes derive their name
from the fact that they are used in limited quantities against the face of the pattern or core box.
They have properties usually different from those of the back-up or system sand and contain
additives not otherwise present. Facing sands are designed to perform special functions, such
as providing higher green strength for lifting deep pockets, higher deformation for limited draft
patterns, and special carbons that enhance skin drying.

.
6-24

Figure 6-3
SIMPLIFIED PROCESS FLOW DIAGRAM FOR THE
PMET SAND TREATMENT PROCESS

r1

6-25

6.5.2.4 Sand Reclamation by Dry ScrubblnglAttrition

This method is widely used, and there is a large variety of equipment available in price ranges
and capacities adaptable to most binder systems and foundry capacities. Dry scrubbing may
be divided into pneumatic, mechanical, and combined thermal-calcininghhermaldry scrubbing
systems.
In pneumatic scrubbing, grains of sand are agitated in streams of air normally confined in
vertical steel tubes called cells. The grains of sand are propelled upward and rub and impact
each other, thus removing the binder. In some systems, grains are impacted against a steel
target. Banks of tubes may be used depending on the capacity and degree of cleanliness
desired. Retention time can be regulated, and fines are removed through dust collectors.
In mechanical scrubbing, the equipment available offers foundrymen a number of techniques
for consideration. An impeller may be used to accelerate the sand grains at a controlled
velocity in a horizontal or vertical plane against a metal plate. The sand grains impact each
other and metal targets, thereby removing the binder. The speed of rotation has some control
on impact energy. The binder and fines are removed by exhaust systems, and screen analysis
is controlled by air gates and/or air wash separators. Additional equipment options include:

6.5.2.5

A variety of drum types with internal baffles, impactors, and disintegrators to

reduce lumps to grains and to remove binder

Vibrating screens with a series of decks for reducing lumps to grains, with
recirculating features and removal of dust and fines

Shot-blast cleaning equipment that may be incorporated with other specially

designed units to form a complete casting cleaninghand reclamation unit

Vibro-energy systems that use synchronous and diametric vibration, Separation

of the binder from the sand grains is caused by frictional and compressive
forces.

Thermal Reclamation of Sand

Most foundries employ recycling of core and mold sands; however, these materials eventually

lose their basic characteristics, and the portions of these materials no longer suitable for use
are then disposed of in a landfill. In the reclamation of chemically or resin bonded sands, the
system employed must be able to break the bond between the resin and sand and remove the
fines that are generated. The systems most commonly employed are wet washing and
scrubbing for silicate bonded sands, or dry scrubbinglattrition and thermal (rotary drum or
fluidized bed) systems for resin bonded sands.
The reclamation of clay-bonded molding sand (green sand) has been practiced in Japan for
the past 20 years and is currently being adopted in the United States (ASM 1988). Wet
reclamation systems were employed in the 1950's for handling clay-bonded system sands, but
they are no longer utilized. Specific thermal reclamation case studies are summarized in
"Thermal Reclamation" by David V. Silsby (AFS 1989). A typical system reclaiming chemically
bonded sand for reuse in coreroom and molding operations consists of a lump reduction

6-26

System and metal removal, both magnetic and nonmagnetic (metals must be removed before
going into thermal reclamation), a particle classifier, a sand cooler, dust collection system and
thermal scrubber (two bed reactor). There are open sand systems and closed sand systems
discussed for reclamation of no-bake sands, clay bonded sands and sand containing
wheelabrator and ball mill waste.
Thermal-Calcinln~ermal-DrvScrubbinq systems offer the best reclamation for the organic and
clay-bonded systems. Sand grain surfaces are not smooth; they have numerous crevices and
indentations. The application of heat with sufficient oxygen oxidizes the binders or burns them
off. In attrition, only because there is not contact in the crevices, the binder remains. Heat
offers the simplest method of reducing the encrusted grains of molding sand to pure grains.
Both horizontal and vertical rotary kiln and fluidized bed systems are available.

The rotarv drum system has been In use since the 1950s for the reclamation of shell and
chemically bonded sands. The direct-fired rotary drum is a refractory-lined steel drum that is
mounted on casters. The feed end is elevated to allow the sand to flow freely through the
unit. The burners can be at either end of the unit with direct flame impingement on the
cascading sand; flow can be either with the flow of solids or counter to it.
In indirect-fired units, the drum is mounted on casters in the horizontal position and is
surrounded by refractory insulation. Burners line the side of the drum, with the flames in direct
contact with the metal drum. The feed end is elevated to allow the sand to flow freely through
the unit, and In some cases flights (paddles connected by chains) are welded to the inside to
assist material flow.
The MuItiDle-HearthFurnaceNerticalShaft Furnace consists of circular refractory hearths placed
one above the other and enclosed in a refractory-lined steel shell. A vertical rotating shaft
through the center of the furnace is equipped with aircooled alloy arms containing rabble
blades (plows) that stir the sand and move it in a spiral path across each hearth.
Sand is repeatedly moved outward drum the center of a given hearth to the periphery, where
it drops through holes to the next hearth. This action gives excellent contact between sand
grains and the heated gases. Material is fed into the top of the fumace. It makes its way to
the bottom in a zigzag fashion, while the hot gases rise countercurrently, burning the organic
material and calcining clay, If one or both are present. Discharge of reclaimed sand can be
directly from the bottom hearth Into a tube cooler, or other cooling methods may be used. The
units are best suited to large tonnages, that is, five tons or more.
6.5.2.6

Reuse of Detoxified/lmmobllized Sand as Ingot Molds

Hazardous foundry sand can be solidified and reused as ingot molds, If it is mixed with
materials such as calcium and sodium silicate. This stabilization process can reduce the
leachability of heavy metals in the sand to values in compliance with California regulations (refer
to section 6.5.3).
Actual detoxification of the waste sand is accomplished by mixing the various sodium silicate
mixtures with the sand in standard sand mixers already used by the foundry industry, The
waste sand is recycled in a mold faced with new sand at the mold - metal interface. Molten

-.
6-27

metal is poured into this mold, allowed to solidify and removed from the recycled detoxified
sand, classified as non-toxic per California standards. It was found that almost all costs of
detoxification can be offset by metal recovery and/or prevention of the metal being lost into the
sand. This method allowed a brasslbronze foundry to reuse 80% of their sand while at the
same time the process control requirements on the reclamation equipment were reduced.
In one foundry the molding sand (once separated from the casting) was transported by an end
loader to a vibratory crushing mill where the sand lumps were reduced to individual grains
screened for desired size and primary metal contamination, air washed for undersize sand grain
removal and then elevated Into a storage silo for cooling prior to reuse. The sand requiring
detoxification was the overflow from the reclaim air wash system captured in a dust collector.
An existing core mixer (muller) was used to make ingot molds from the overflow sand with
addition of sodium silicate and calcium oxide utilizing a facing/backing sand scenario. These
molds were then used to pig (empty) the ladles of molten metal when necessary for process
control, thereby continuing to recycle this sand in-house prior to discarding.
Another brass foundry using approximately 39 tons of sand per month has Installed a sand
drying system with ball-milling and three stages of screening, cooling and reclassifying
processes in order to reclaim up to 85% of the sand and up to 16% of metal from the sand.
The sand not reusable due to the reclassification operations of the reclamation system is to be
detoxified in a batch type mixer and then reused as backing sand in an ingot mold.
6.5.2.7

Use of Sands as a Construction Material

Nonhazardous foundry wastes have been constructively used in municipal waste landfills as a
supplement for daily earth cover (Smith 1982). This practice has received greater scrutiny
recently because of regulatory and public concerns over the mixing of industrial and municipal
wastes and fears of pollution problems that could result. An alternative that has been
successfully implemented Is the use of selected foundry wastes for both final cover and as a
topsoil substitute for foundry landfills. A different option is the use of foundry sands and other
wastes for construction fill (Smith 1982).
The suitability of these options depends on the physical and chemical nature of the waste, the
amount of waste to be handled, local market conditions for the waste, and all federal, state,
and local regulations regarding its handling, storage, and disposal. In addition, some foundries
have explored using foundry sand in road beds, asphalt and cement manufacture, making
certain that these options are not considered "use in a manner constituting disposal."
6.5.3

Treatment of Sand

6.5.3.1

Sodium Slllcate/Ume Immobilization (Furness Process)

The presence of heavy metals in foundry sand renders that sand hazardous waste. This
problem is most common in brass foundries. In the DHS study (1989), spent foundry sand was
detoxified with calcium oxide material (Calsifix) and sodium silicate (WC-7). Calsifix and WC7 are products produced by J.B. DeVenne Inc. and available in California through that

6-28

company's distributor, Custom Chemical Formulators, Inc. (4630 Cecilia Street, Cudahy, CA
90201).
In a brassbronze foundry pouring castings for their own in-house use, the following procedure
was determined for detoxifying overflow sand from the reclaim air wash system, captured in a
dust collector in quantities of 500 to 1,000 Ibs dally:
0

Add to an existing core mixer (muller) 150 Ibs of dry waste sand and 30 Ibs
Calsifix-1
Start mixer and blend for six minutes
With the mixer running add approximately 30 Ibs of water to pre-wet the calcium.
Add 30 Ibs of WC-7
Continue mixing while gel forms (10 to 20 seconds is a normal reaction time)
Discharge sand into an ingot mold as backing for a mold faced with new nobake sand
Allow mold to cure for a minimum of 24 hours before stripping pattern
Air dry and/or torch dry the facing sand to avoid an explosive reaction

Total concentrations of acid extractable metals before treatment and in citrate extract after
treatment are shown below:
Metal
Pb
cu
Zn
6.5.3.2

Before
Treatment (ug/g)

1,900
16,000
490

After
Treatment (mg/L)
0.6
5.1
9.9

Sodium SilicatelPorzallme or Portland Cement lmmobllhtion (Trezek Process)

This process is very similar to the Furness process discussed above. Instead of calcium oxide
(lime), poualime or Portland cement are used as reagents. The percentage of reduction can
be as high as 83% for copper, 98% for lead and > 99% for zinc with Portland cement and
potassium silicate reagents.

6-29

SECTION 7.0
WASTE REDUCTION AND TREATMENT
ALTERNATIVES FOR THE HEAT TREATING INDUSTRY
7.1

DESCRIPTION OF HAZARDOUS WASTE GENERATION PROCESSES

Heat treating refers to any of the heating and cooling operations that are performed on metal
workpieces for the purpose of changing the mechanical properties, the metallurgical structure
or the residual stress state of the metal product. Heat treating includes a wide spectrum of
specific processes, such as stress-relief treating, normalizing, annealing, austenitizing,
tempering, hardening, martempering, austempering, quenching, cold treating, etc. Annealing,
as an example, Involves a heating to and holding at a suitable temperature followed by cooling
at an appropriate rate, primarily for softening of metallic material. Steels may be annealed to
facilitate cold working or machining to improve mechanical or electrical properties or to promote
dimensional stability. Annealing of grey iron is performed to soften it and/or to minimize or
eliminate massive eutectic carbides, thus improving I t s machinability.
7.1.1

Furnace Omration

7.1.1.1

Heat Treating Other Than Case Hardening

Heat treating Is performed in either conventional furnaces, salt baths or fluidized-bed furnaces.
In conventional furnace operation, the workpiece is loaded to the furnace either manually or
automatically. The basic furnace consists of an insulated chamber with an external reinforced
steel shell, a heating system for the chamber and one or more access doors to the heated
chamber. Heating systems are direct-fired or indirect heated. With direct-fired furnace
equipment, work being processed is directly exposed to the products of combustion, generally
referred to as flue products. Gas-fired and oil-fired equipment is the most common in heat
treating industry. Indirect heating is performed in electrically heated furnaces and radiant-tubeheated furnaces with either gas-fired tubes, oil-fired tubes, or electrically heated tubes. The
heating Operations e.g., stress-relief, normalizing, annealing, austenitizing, tempering,
martempering, and austempering do not generate hazardous wastes. The off-gases are vented
to the atmosphere. Refractory materials (furnace lining) are the only wastes generated
periodically that are disposed of as non-hazardous wastes. To obtain better thermal control
and more rapid heating rates, salt bath furnaces are commonly used.

In the fluidized bed furnace, a bed of dry, finely divided particles, typically aluminum oxide, is
made to behave like a liquid by passing gas up through the bed. The turbulent motion and
rapid circulation of the particles in the furnace provide a heat-transfer rates comparable with
those of conventional salt-bath equipment. The parts to be treated are submerged in a bed
of fine solid particles held in suspension by an upward flow of gas. Heat input to a fluidized
bed can be achieved by:
o

Internal-Resistance-Heated Bed: the gas and particles are heated by suitably

sheathed internal-resistance-heated elements as silicon carbide

7-1

External-Resistance-HeatedBed: fluidized bed contained in a heat-resisting pot

is heated by external resistance elements

Direct-Resistance-HeatedBed: an electrically conducting material such as carbon

powder or silicon carbide is employed as the bed material

External-Combustion-Heated Bed: a fluidized bed, contained in a heat-resisting

pot, is heated by external gas firing

Submerged-Combustion-Fluidized Bed: the combustion products pass directly

through the mass to be heated

Internal-Combustion Gas-Fired Bed: an air/gas mixture is used for fluidization

and ignited in the bed, generating heat by internal combustion.

Drag-out losses of the fluidized bed particles that are removed by agitation, bouncing, and gas
blowing can be minimized by water spraying. Recovered particles can then be reused after
being dried, sieved, and returned to the bed.
7.1.1.2

Case Hardening

One process that generates major hazardous waste streams in the heat treating industry is
case hardening. Steel case hardening processes are performed to supply an adequate quantity
of carbon or nitrogen for absorption and diffusion into the steel. These processes are carried
out in either gas-phase furnaces or in salt-bath furnaces that are essentially similar in design
to furnaces used for other heat treating processes. The case hardening performed in liquid
media is the major source of hazardous wastes.
The salt baths in liquid carburizing, nitriding, and cyaniding processes are considered to be
hazardous wastes when spent. Typical baths contain molten sodium, potassium cyanide, and
cyanate salts. In liquid carburizing, nitriding, and cyaniding, the parts are held at an
appropriate high temperature in a molten salt. Afier the workpiece is heat treated, it undergoes
quenching. The quenching media becomes contaminatedwith cyanide used in case hardening
and must be disposed of as hazardous waste. Spent quenching oil or wastewater generated
in the cyanide heat treating cycle (liquid carburizing or cyaniding) becomes hazardous waste
due to cyanide salts transferred to the oil bath or water bath as a result of dragout. Gas
carburizing burns natural gas In a sealed furnace as a source of carbon and produces no
hazardous wastes. Gas nitriding employs ammonia gas to supply the nltrogen and produces
no solid hazardous waste as well.
Some case hardening processes require source materials from which carbon and nitrogen
can be generated. After the case hardening is completed, these source materials frequently
become hazardous wastes. For instance, pack carburizing uses solid pack materials such as
coke or charcoal as a source of carbon. Spent packing must be disposed of as hazardous
wastes.

7-2

7.1.2

Quenching

After the workpiece is heat treated in the furnace it very often undergoes a quenching process.
Quenching, an example of a cooling operation in metal heat treating, is generally accomplished
by immersion of a hot workpiece in water, oil, polymer solution, or molten salt, although forced
air is sometimes used. Another method includes spray quenching by applying streams of
quenching liquid at high pressure up to 120 psi to local areas of the workpiece. Fog
quenching, the application of a fine fog or mist of liquid droplets and the gas carrier as cooling
agents, is also used. Gas quenching is used to provide a cooling rate that is faster than that
obtained in still air and slower than that obtained in oil.
A complete quenching system consists of a work tank or machines, facilities for handling the
parts quenched, quenching medium, equipment for agitation, coolers, heaters, pumps and
strainers or filters, quenchant supply tank, equipment for ventilation and for protection against
hazards and equipment for automatic removal of scale from tanks. Quenching is a significant
source of hazardous wastes generated in the heat treating industry. The wastes consist of
spent quenching media in the form of spent baths and wastewater generated during washing
of quenched workpieces.
7.1.3

Descaling

The intense heat used causes an oxide scale to form on the surfaces of the workpieces.
Before further processing can take place, this is usually removed by abrasive cleaning
(sandblasting) or by pickling methods. The workpiece is immersed in a hot acid bath (usually
sulfuric, nitric or hydrochloric acid) in order to clean the surface of all impurities. The acid
dissolves the metal oxide and ferric oxide rust and scale. The workpiece is then rinsed in
water to remove the acid and in some cases is bathed in oil or another special coating.
7.1.4

Parts Cleanlna and Surface Coating

In addition to the above hazardous waste sources, supportive operations in heat treating
process such as parts cleaning or surface coating generate additional hazardous waste.
Plating, as an example, is performed to prevent carburizing or nitriding of a metal workpiece
or its selected parts during the heating cycle. Plated deposits of bronze or copper are the
most common stop-off coatings. Nickel (including electroless nickel), chrome, and silver are
effective also but their higher cost restricts their use to special applications. When the
application does not permit the retention of any protective plate on the finished part after heat
treating, selection of the coating is important from the standpoint of subsequent stripping.
Copper and silver are the easiest to strip; bronze is more difficult. Nickel is very difficult to
remove without detrimentally affecting the part. Therefore, copper plating is most widely used.
Parts cleaning operations are of great concern in plating and case hardening processes. In
liquid nitriding processes, for example, all workpieces placed in the bath should be thoroughly
cleaned and free of surface oxide, entrapped sand, oil and grease, metal particles, etc. The
purpose is to obtain satisfactory nitriding and to protect the bath from contamination. Either
acid pickling or abrasive cleaning is recommended prior to nitriding. Most parts are
successfully nitrided immediately after vapor degreasing. However, some machine finishing

..
7-3

processes such as buffing, finish grinding, lapping and burnishing may produce surfaces that
retard nitriding and result in uneven case depth and distortion even after cleaning.
There are two methods by which the surfaces of parts finished by such methods may be
successfully conditioned before nitriding. One method consists ofvapor degreasing parts and
then abrasive cleaning them with aluminum oxide grit immediately prior to nitriding (residual
grit must be brushed off before parts are loaded into furnace). The second method is to apply
a light phosphate coating. One procedure for applying such a coating is:
0
0
0

degreasing
rinsing in cold water (1/2 to 1 min)
dipping in oxalic acid bath (10 to 30 sec) (0.16 Ib of oxalic acid per one gallon
of water)
rinsing in cold water (112 to 1 min)
rinsing in warm water (150 to 18OOF) (2/1 to 1 min)
treating in phosphate solution at 18BF for 4 min. (0.75 Ib/gal)
rinsing in cold water for 1 min
rinsing in warm water for 1 min
blow drying
storing in clean container until loaded in nitriding furnaces.

The baths should be maintained at appropriate acid strength, therefore they must be constantly
replaced and disposed of as hazardous waste or treated on-site. Due to the fact that waste
reduction and treatment options for these processes have been developed, this study is limited
to short review of these processes. The reader is referred to the following DHS study, Waste
Audit Study on Fabricated Metal Products Industry (August 1989), and an EPA report on Waste
Reduction in Parts Cleaning Operations (1989).
7.2

HAZARDOUS WASTE CHARACTERIZATION

The major wastes generated in the heat treating industry include spent cyanide-containing baths
used in liquid carburizing, cyaniding, and nitriding, spent quenchants, wastewater generated
in parts cleaning operations prior to and after heat treatment, spent abrasive media used in
parts cleaning operations, refractory material used as lining in furnaces, spent cyanide solutions
from salt baths, and coating wastes related to heat treating in selective carburizing or nitriding.
The following sections characterize waste from case hardening baths and pots, quenchant
baths, and parts cleaning and coating operations.
7.2.1

Case Hardenlna Baths and Salt Pots

Significant hazardous waste streams are generated in heat treating operations where cyanidecontaining baths are used. These baths are used in liquid carburizing, cyaniding, and nitriding
processes that are classified as steel case hardening processes. Table 7-1 presents an
operating composition of liquid carburizing baths. They consist Of molten salts of sodium
cyanide, barium chloride, potassium chloride, sodium chloride, sodium carbonate, sodium
cyanate, salts of other alkaline earth metals, and accelerators. Both low-temperature and hightemperature baths are supplied in different cyanide concentrations to satisfy individual

7-4

Table 7-1
Operatlng Composition of Liquid Carburizing Baths

~~

Composition of Bath, %

Constituent

Sodium cyanide
Barium chloride
Salts of other alkaline
earth metals(b)
Potassium chloride
Sodium chloride
Sodium carbonate
Accelerators other than
those involving compounds
of alkaline earth metals(c)
Sodium cyanate
Density of molten salt

(a)
(b)
(c)

Light case,
low temperature
845 to 900%
(1550 to 165OoF)

Deep case,
high temperature
900 to 955QC
(1650 to 1750F)

10 to 23

6 to 16
30 to %(a)

0 to 10
0 to 25

0 to 10
0 to 20
0 to 20
30 max

20 to 40
30 max
0 to 5
1.0 max
7760 kglm3 at 900C
(1 10 lb/f13at 1650F)

0 to 2
0.5 max

2000 kg/m3at 925C

(125 Ib/ft3at 17OBF)

Proprietary barium chloride-free deep-case baths are available.

Calcium and strontium chlorides have been employed. Calcium chloride Is more effective,
but its hygroscopic nature has limited its use.
Among these accelerators are manganese dioxide, boron oxide, sodium fluoride and
sodium pyrophosphate.

7-5

requirements of carburizing activity (carbon potential) within the limitations of manual dragout
and replenishment.
Table 7-2presents compositions and properties of sodium cyanide mixtures used in cyaniding
processes that produce a file-hard, wear-resistant surface on ferrous parts. A sodium cyanide
mixture such as grade 30 in Table 7-2,containing 30% NaCN, 40% Na,CO,
and 30% HCI, is
generally used for cyaniding on a production basis. This mixture is preferable to any of the
other compositions given In Table 7-2. The inert salts of sodium chloride and sodium
carbonate are added to cyanide to provide fluidity and to control the melting points of all
mixtures.
Another process, liquid nitriding, is performed in a molten salt bath composed of a typical
mixture of sodium and potassium salts, The sodium salts, which comprise 60 to 70% (by
weight) of the total mixture, consist of 96.5% NaCN, 2.5% Na,CO, and 0.5% NaCNO. The
potassium salts, 30 to 40% (by weight) of the mixture, consist of 96% KCN, 0.6% SCO,, 0.75%
KCNO and 0.5% KCI. With aging, the cyanide content of the bath decreases, and the cyanate
and carbonate contents increase. The cyanate content in all nitriding baths is responsible for
the nitriding action, and the ratio of cyanide to cyanate is critical.
Cyanide-containing baths used in liquid carburizing, cyaniding and nitriding processes undergo
an aging process that generates undesirable products of oxidation. Aging contributes to
decreasing of the cyanide content of the bath and to increasing the cyanate and carbonate
contents. In a low-temperature cyanide-type bath, several reactions occur simultaneously
depending on bath composition to produce the following various end products and
intermediates: carbon (C), alkali carbonate (Na,CO, or SCO ), nitrogen (N, or 2N), carbon
monoxide (CO), carbon dioxide (CO,), cyanamide (Na,CN, or baCN,) and cyanate (NaCNO).
Two of the major reactions believed to occur in the operating bath are the "cyanamide shift"
and the formation of cyanate:

2 NaCN e-> Na,CN,

and either

2 NaCN
or
NaCN

+C

+ 0, -+ 2 NaNCO

+ CO,

c-> NaNCO + CO

Reactions that influence cyanate contents proceed as follows:

NaNCO iC -> NaCN + CO
and either
4 NaNCO + 2 0,-> 2 Na2C03 + 2 CO + 4 N
or
4 NaNCO + 4 CO, --->2 Na2C0, + 6 CO + 4 N

(4)

(5)
(6)

Reactions (5) and (6) deplete the activity of the bath and lead to an eventual loss of the bath.
Oxidation products in the bath media promote unfavorable temperature gradients. In liquid
nitriding, the carbonate content is kept below 25%. Carbonate content is usually lowered by
cooling the bath to 850 O F and allowing precipitated salt to settle to the bottom of the salt pot.
Another contaminant that forms in the bath is a complex sodium ferrocyanide Na,Fe(CN), that

..
7-6

Table 7-2
Compositions and Properties of Sodium
Cyanide Mixtures for Cyaniding Baths

Constituent

or Property

Composition, %
Sodium cyanide
Sodium carbonate
Sodium chloride
Melting point, "C("F)
Specific gravity
At 25"C(75"F)
At 860"C(1580"F)

(a)
(b)

Grade
75(b)
45(b)

30(b)

97
2.3
Trace

75
3.5
21.5

45.3
37.0
17.7

30.0
40.0
30.0

560
(1040)

590
(1095)

570
(1060)

625
(1155)

1.50
1.10

1.60
1.25

1B O
1.40

2.09
1.54

96-98(a)

Appearance: white crystalline solid. This grade also contains 0.5% sodium cyanate
(NaNCO) and 0.2% sodium hydroxide (NaOH); sodium sulfide (Na,S) content, nil.
Appearance: white granular mixture.

7-7

is removed by holding the bath at 1200OF for about two hours to settle out the compound inthe
form of sludge. In normal bath maintenance routines, sludge collected at the bottom of the
pot is removed on a daily basis. lt is usually spooned from the bottom by means of a
perforated ladle. This sludge must be disposed of or treated as hazardous waste. In liquid
carburizing, sludge is removed while the fumace is stili at idling temperature. The eiectrodes
of internally heated furnaces are scraped clean. In parallel with depletion of bath media,
corrosion of a bath pot takes place. To minimize corrosion of the pot at the air-salt interface,
salts are completely changed every three or four months because replacement of salt is usually
far more economical than replacement of the pot. A graphite cover that is used to maintain
bath composition and reduce surface heat losses of a cyanide bath might promote corrosion
of parts if it contained sulfur.
7.2.2

Quenchlna Wastes

Quenching is an integral part of liquid carburizing, cyaniding, and nitriding processes. When
the surface of the steel absorbs a sufficient quantity of carbon and nitrogen or one of them
(depending on the process requirements) from a hot molten salt bath, then the part is
quenched in mineral oil, paraffin-base oil, water or brine to develop a hard surface layer.
Cyanide salts dragged out on the part from heat treating contaminate the quenching bath,
rendering it a hazardous waste when spent.
The quenching process may employ one of the following media: water, aqueous brine
solutions, caustic solutions, oils, polymer solutions, molten salts, molten metals, or gases, (still
or moving). The selection of the quenchant depends primarily on the hardenabilii of the steel,
surface and core hardness requirements, and the amount of allowable distortion.
Water, 3-5% caustic solutions, and brine (510% sodium chloride) are the quenchants most
commonly used for carbon steel. A water soluble polymer is sometimes used to modify the
quenching rate of a water quench. Oil quenching is less drastic than water quenching and
produces less distortion. Commonly-used quenchants are mineral oils fortified with nonsaponifiable additives that increase their quenching characteristics and lengthen their useful life.
Nitrate-nitrite salt quench baths are compatible with cyanide as well as non-cyanide liquid
carburizing baths. However, parts should never be transferred directly from a carburizing bath
containing more than 5% cyanide to a nitrate-nitrite quench bath, because this will result in a
violent reaction and may cause an explosion.
Hazardous wastes are generated in the following forms:
(1)

(2)
(3)

Residue (salt sludge) from oil baths used for quenching of cyanided and liquid
carburized and nitrided parts
Spent water and brine quenchants used for cyanided, liquid carburized and nitrided
parts
Quenching process dragout wastes from other than case hardening processes.

Another source of hazardous waste is the quenchant media washing operation. Dragout in the
form of oil is removed from the part by hot water washing. Dragout refers to the excess liquid
quenchant that adheres to the workpiece from the quenching bath. Oil is one of the most

7-8

commonly-used quenchants in the heat treating industry, therefore the quantity of waste oil that
needs to be handled as a hazardous waste cannot be neglected.
7.2.3

Parts Cleanlna and Coating

Additional sources of hazardous waste in the heat treating industry are parts cleaning and
coating operations. Parts cleaning is performed prior to some heat treatment operations, or
prior to coating or in post heat treating operations. Solvent cleaning, aqueous cleaning and
abrasive cleaning wastes are generated for disposal and/or treatment. A detailed analysis of
waste reduction options is given in the DHS Study (August 1989).
The most popular coating operation is copper plating (See Section 7.1). The hazardous wastes
generated in this process are identical to metal finishing industry wastes. For more information
on types of hazardous waste generated in plating operations the, reader is referred to DHS
Waste Audit Study on Fabricated Metal Products Industry (August 1989).
7.3

WASTE REDUCTION AND TREATMENT OPTIONS FOR CASE HARDENING BATHS

AND SALT POTS

Oxidation products In the cyanide-containing bath media, which is continuously used in case
hardening processes (liquid carburizing, cyaniding, and nitriding), deplete the activity of the bath
which becomes hazardous waste. Oxidation products form a hazardous sludge that Is removed
frequently (in some operations on a daily basis) from the bottom of the pot while the furnace
is still at idling temperature. Pots or work-holding fixtures that are in contact with case
hardening media undergo corrosion and must be disposed of as hazardous waste every few
months to every few years depending upon service.
7.3.1

Source Reduction

7.3.1 .l Alter Raw Materials (Bath Composition)

In typical liquid carburizing and nitriding processes, molten salts of sodium or potassium
cyanides at concentrations of 30% wt and higher are commonly used by the industry. Liquid
carburizing can be accomplished in a noncyanide bath containing a special grade of carbon
instead of cyanide as the source of carbon. In this bath, carbon particles are dispersed in the
molten salt of carbonates by mechanical agitation, which is achieved by means of one or more
simple propeller stirrers that occupy a small fraction of the bath. The chemical reaction is not
fully understood, but is thought to involve adsorption of carbon monoxide or carbon particles.
The carbon monoxide is generated by reaction between the carbon and carbonates, which are
major ingredients of the molten salt (ASM 1981).
The adsorbed carbon monoxide is presumed to react with steel surfaces much as in gas or
pack carburizing. The case depths and carbon gradients produced are in the same range as
for high temperature cyanide-type baths, but there is no nitrogen in the case. Temperatures
above 1750F produce more rapid carbon penetration and do not adversely affect non-cyanide
salts, because no cyanide is present to break down and cause carbon scum or frothing.
Equipment deterioration is the chief factor that limits operating temperature. Parts that are
slowly cooled following non-cyanide carburization are more easily machined than parts slowly

7-9

cooled following cyanide carburization because of the absence of nitrogen in noncyanidecarburized cases.
The increased cost of detoxification of cyanide-containing effluents have led to development
of a low cyanide salt bath for nitrocarburizing treatments. In one patented process, it confers
sulfur, nitrogen, and presumably carbon and oxygen to surfaces of ferrous materials. The
process is unique in that lithium salts are incorporated in the bath composition. Cyanide is
held to very low levels: 0.1 to 0.5%. Sulfur species present in the bath at concentrations of 2
to 10 ppm, cause sulfidation to occur simultaneously with nitriding.
Another low-cyanide alternative is similar to the one previously described but does not contain
sulfur. Melon, an organic polymer, is used for bath regeneration. When water quenching is
employed, the low level of cyanide permits easier detoxification. Alternatively, quenching into
a caustic-nitrate salt bath at 500 to 795OF may be used for cyanidehyanate destruction.
7.3.1.2

Clean All Work Placed in the Bath

To protect the bath from external contamination and to obtain satisfactory case hardening, all
work placed in the bath should be thoroughly cleaned and free of scale, oxide, entrapped
sand, core material, metal particles and oil and grease. Either acid pickling, abrasive cleaning
with aluminum oxide grit, light phosphate coating or simple vapor degreasing is employed (see
Section 7.1).
7.3.1.3 Use Graphite Cover on the Surface of a Cyanide Bath

To help maintain bath composition and to prolong its lifetime a graphite cover should be
employed on the surface of a cyanide bath. Artificial graphite powders, free of impurities and
sulfur, are best. Natural graphite has a higher ash content that introduces impurities into the
bath which can be a problem particularly at low operating temperatures. Furthermore, natural
graphite that contains sulfur causes corrosion of parts. Uncovered baths are exposed to
carbonate which adversely affects bath life and pot life (enhanced corrosion).
7.3.1.4 Dry Work Completely Prior to Liquid Case Hardening (Safety)

Losses of bath by spattering during contact with workpieces are avoided when the workpiece
is completely dry. Even the slight amount of moisture that may be deposited on parts and
fixtures as a result of atmospheric humidity win cause spatter at contact with molten salt.
7.3.1.5 Remove Impurities (Sludges)

The method that has been successfully used to increase the longevity of molten baths is
periodic cleaning. Carbonates, the main oxidation products, are readily removed by cooling
the bath to 850 O F and allowing the precipitated salt to settle to the bottom of the salt pot.
Perforated ladles can be used to spoon sludge from the bottom.

7-10

7.3.1.6 Minimize Dragout

Dragout refers to the excess bath media that adheres to the workpiece surface and that is
carried out of the media upon withdrawal of the workpiece from the bath. Dragout can be
minimized by implementation of the following techniques:

Substituting racks for tray type work-holding fixtures. Tray-type fixtures carry
more bath media upon withdrawal from the bath media than a rack does, and
drainage of the dragout is more difficult with trays

Reducing the speed of withdrawal of workpieces from the bath and allowing
ample drainage time. The faster the workpiece is removed from the bath, the
higher the dragout will be: the workpiece should be removed as slowly and as
smoothly as possible; ample time should be allowed for draining the media back
to the tank

Proper positioning of the workpiece on the plating rack. The optimal position
of any object to minimize dragout is best determined experimentally, although
the following guidelines were found to be effective:

orient the surface as close to vertical as possible

rack with the longer dimension of the workpiece horizontal
- rack with the lower edge tilted from the horizontal so that the runoff is from
a corner rather than an entire edge.
7.3.1.7

Replace Pot Lining

Submerged-electrodefurnaces will give many years of service in both cyanide and noncyanide
operation when ceramic pots are replaced by a modified basic brick.
7.3.2

Treatmenl

Solid cyanide wastes removed in the form of solid salt from pots must be dissolved in alkaline
water (pH >IO) before it can be treated. A tank of suitable capacity equipped with a coarse
screen set well above the bottom is used to facilitate solution of the solid material. The tank
should also have an agitator.
7.3.2.1

Chemical Treatment

The simplest treatment consists of oxidizing the cyanide in an alkaline solution to which is
added either chlorine gas or its equivalent in the form of a hypochlorite compound, such as
sodium or calcium hypochlorite (bleaching powder). The choice between gas or powder
depends on both the availability of facilities and experienced personnel for handling the
oxidizing agents, and on economics. For small quantities of cyanide solutions, it may be more
practical to use a hypochlorite compound than to use chlorine gas.
Depending on the oxidizing agent employed, several reactions take place when cyanide is
converted into a disposable form. One reaction with chlorine gas is as follows:
c

7-11

2 NaCN

+ 4 NaOH + 2 CI, + 2 HO,

---> (NH,),CO,

+ Na2C0, + 4 NaCl

This reaction indicates that, for each kilogram (2.2 Ib) of sodium cyanide, 1.42 kg (3.13 ib) of
chlorine gas and 1.6 kg (3.5 Ib) of sodium hydroxide are required. Because of probable side
reactions, however, practical experience indicates an actual requirement of slightly more than
2 kg (4.4 Ib) of chlorine for each kilogram of sodium cyanide present in the waste solution.
When a hypochlorite compound is used, the amount of powder required may be estimated on
the basis of available chlorine content in the compound.

When cyanide wastes are to be treated with chlorine gas, the cyanide content must first be
determined and the proper amount of caustic added. The gas is then introduced slowly while
the temperature of the solution is kept below 50% (12OOF). If a sodium hypochlorite solution
is used, it Is only necessary that sufficient caustic be added to raise the pH of the cyanide
solution above 8.5. The reaction between cyanide and the oxidizing agent should continue
until a slight excess of chlorine is present in the solution. This can be determined by testing
with starch iodide paper or with a solution of potassium iodide and starch. Both the iodide
paper and the starch solution will turn blue in the presence of free chlorine.

7.3.2.2 Electrochemical Treatment

Although chemical treatment may be entirely adequate to meet local regulations, a recently
developed electrochemical process destroys free cyanide with efficiency and economy superior
to those of the chemical conversion processes. In the electrochemical process, cyanide wastes
in aqueous solution are circulated through an electrochemical reactor. Within the reactor, an
applied potential oxidizes the free cyanide and cyanate according to the reactions:
2 CN

+ 8OH->

2C0,

2 CNO- + 4 OH--> 2 CO,

+ N, + 4 HO, + 1 0 e
+ N, + 2 HO, + 6 e

Free cyanide and cyanate are converted to the nontoxic gases carbon dioxide and nitrogen,
which are allowed to escape freely from the vented storage tank into which the reacted solution
is circulated. The electrochemical process is most effective at high cyanide-ion concentrations.
With continual recirculation between storage tank and reactor, cyanide can be reduced to 1
ppm or less in about 100 to 150 hours. By combining electrochemical and chemical
treatments, effective treatment can usually be achieved at minimum cost. Electrochemical
removal is used to reduce cyanide concentration to about 200 ppm, and then chemical
treatment is used to complete the oxidation. Electrochemical treatment offers the following
advantages:

o
o
o

The process uses only electricity - no chemicals are required.

Cost per unit weight of cyanide treated is low. depending only on the cost of
electricity (about 6.6 kW-h/kg, or 3 kW-h/lb of free CN).
Capital investment is relatively low.

7-12

o
o
o

The process is simple to control, requiring only periodic determination of cyanide

concentration.
There are no toxic or otherwise harmful reaction products.
Upon reaching a concentration of I ppm cyanide, the oxidized effluent usually
may be drained directly into a sewer.
The process also can be used to convert nitrite into nitrate.

The only significant disadvantage is that the process is time-consuming when levels of cyanide
below 200 ppm must be achieved. Increasing the number of reactors decreases process times.
7.4

WASTE REDUCTION AND TREATMENT OPTIONS FOR OUENCHANT WASTES

Quenching media used in heat treating processes become hazardous wastes when exposed
to metal workpieces contaminated with hazardous residues. Cyanide-containing heat treating
bath contents are introduced to the quenching media in the form of dragout residue left on a
workpiece after nitriding, carburizing, or cyaniding process is completed. Sodium or potassium
cyanide salts form either insoluble residue while in contact with mineral oil quenchant or
dissolve in aqueous base quenchant (water or 3-5% caustic solution) which becomes
hazardous waste.
7.4.1

Source Reduction

7.4.1.1

Minimize Dragout of Molten Salts

Liquid carburizing, cyaniding, and nitriding salts do not dissolve in, or combine with mineral
quenching oils. Salt sludge must be removed periodically either by mechanical means or by
filtering through screens.
Salt quench baths also require desiudging of contaminants. Carryover of molten salts into
brine quench tanks needs to be controlled so as not to exceed 10% of salt concentration.
Source reduction measures for dragout of molten salts are discussed in Section 7.3.1.5.
7.4.1.2 Minimize Dragout of Quenchant

The same waste reduction measures identified for molten salt dragout apply to the reduction
of dragout of quenchant. When quenching oil is used, mechanical removal of surface oil from
the workpiece by applying forced air to blow-off oil from the work surface is efficient.
7.4.1.3 Temperature Control of Oil Ouenchant System

As quenching proceeds, heat is removed from the workpieces and the temperature of the
quenching oil rises. At high uncontrolled temperatures oil degradation or oxidation occurs.
Carbonaceous deposits on quenched parts (sludging) are symptoms of oil breakdown. This
effect might change the cooling rate of the media, causing rejects of treated workpieces. in
addition, carbonaceous deposits are objectionable because they are difficult and costly to
remove. To minimize the quantity of spent oil baths, a cooling system should be installed as
a protection from undesired oil transformations caused by high temperatures.

.
7-13

7.4.1.4

Use Modified Materials

To minimize distortion of oil quenchant at high temperatures (up to 350 OF), mineral oil is
fortified with non-saponifiable additives that increase its quenching effectiveness and lengthen
its useful life.
7.4.2

Recvclinq

7.4.2.1

Desludging

The lifetime of quenching oil can be prolonged by filtering the oil and recycling it to the original
process. The following contaminants should be removed frequently:

o
o
o

carbonaceous materials which may be products of oil oxidation or carbon fallout

encountered in protective-atmosphere installation
scale (metal oxides)
sand and other insoluble solids
precipitated salts from case hardening baths

The solids can be best removed by appropriate bypass filters. The most commonly used
filtering media are mineral-wool and cellulose types that must be replaced and disposed of as
hazardous wastes once their filtering ability has been exhausted.
Clay filtering media are more expensive than the above types but can be reused after
exhaustion by suitable regeneration. The regeneration will not remove scale or sand. Clay
media should be carefully selected when fast quenching oils are to be filtered because it is
possible to remove the additives along with the undesirable carbonaceous materials.
Magnetic filters or traps and strainers are useful in removing scale and other foreign materials.
These types of filters can be easily cleaned and returned to service. They are especially helpful
for preventing premature filter clogging and for protecting pumps.

In continuous oil quenching, recycling of oil is performed in the system consisting of the
following components:
o

o
o

Quenchant storage-supply tanks and pumps

Coolers and heaters to maintain the temperature of the quenchant in desired
range
Filter in the system to minimize free carbon and other foreign elements
Agitation of the quenchant to obtain uniform quenching and minimize distortion.
Oil is usually agitated by propellers or impeller-type pumps. Compressed air is
never used for agitation to avoid oil foaming problems.

When molten salts precipitate in the oil bath, periodic desludging is necessary. Screens are
usually placed in front of the lines leading to pumps to prevent entry of sludge. The buildup
of chlorides carried over from cyanide containing baths into nitrate-nitrite quenchants is
undesirable. When chloride is allowed to settle to the bottom of the quench area provided for

7-14

gravity separation, the chlorides can be collected in sludge pans. Periodically, either the pans
are removed or the bottoms of the pans are manually desludged.
Some designs employ continuous filtration of chlorides as the suspended crystals pass through
filter baskets. The operator removes the baskets periodically to dump the collected chlorides
and then returns them to the furnace. Another technique involves continuous filtering out of
higher-melting-point salts by pumping the contaminated quench salt through a filter maintained
at a lower temperature. The contaminants are deposited on a wire-mesh-basket, and the
usable salts are returned to the quench tank.
7.4.2.2

Dewatering of Quenching Oil

Water in quenching oils causes not only nonuniform or insufficient hardness of the work, but
also creates heavy foaming and increased fire hazard. Water can be removed from an oil bath
o
o
o

raising the temperature above the boiling point of water (evaporation)

allowing the water to settle and draining it off, and
passing the bath through a centrifuge.

Used quenching oils may sometimes emulsify the water content. Such water-containing oils
cannot be treated by draining method.
7.4.2.3

Ultrafiltration of Water-Polymer Quenchants

Water is commonly used for quenching of carbon steel. A water soluble polymer is sometimes
used to modify the quenching rate of a water quench. If water quenchant is used with a liquid
carburizing line, continuous salt removal by ultrafiltration can be employed (ASM, 1981). The
polymers may be precipitated by salt carried into the quench if ultrafiltration is not used.
7.4.3

Treatment

7.4.3.1

Water and Brine Bath Quenchants

Although a limited amount of dissolved salt increases the efficiency of a water quench bath,
amounts in excess of 10% retard the quenching rate. Controlled addition of fresh water to
the bath, together with a continuous overflow, 'serves to keep the salt concentration at an
acceptably low level. The overflow is usually collected in a special reservoir and treated prior
to discharge to the sewer system. Salt dragout, carried over to water baths from cyanidebased heat treating operations, renders this quenchant a hazardous waste when spent.
Treatment methods for cyanide contaminated wastewater are discussed in Section 7.3.2.1.
7.4.3.2 Quenching Oil Dragout

Power spray washers using hot water are commonly used for oil quenched parts. Waste oil
after gravity separation in oilhater separator is usually sent off-site to oil recyclers. Oil
quenched parts that were previously carburized or nitrided in molten cyanide containing salt
baths are also cleaned by using power washers with hot water or with emulsion cleaners.

7-15

Cleaning Is first performed by soaking parts in hot water to float off the oil and remove the
soluble salts. The parts are then transferred to a hot agitated dilute alkaline cleaner having
high sequestering properties. Silicated cleaners and those containing carbonates or
phosphates are not used because of the formation of insoluble barium compounds in the
presence of barium-containing salts. If a white, powdery overlay of barium carbonate remains
on the part, it is removed (following removal of all cyanides) by immersion in a dilute solution
of acetic acid, The oily wastewater from the first soak is treated in a system consisting of an
oil/water separator, and a cyanide destruct system as described previously. Separated oil is
disposed of off-site as hazardous waste.

7-16

SECTION 8.0
WASTE REDUCTION INDEX
8.1

INTRODUCTION

The waste reduction index (WRI) is an indicator of the degree of waste reduction being
achieved by a particular company. It is based on a comparison of waste generation rates
before and after implementation of waste reduction program. Details are in Appendix K.
The WRI compensates for variation in production levels over an interval of time. This is an
advantage over using the gross amount of waste generated (Illinois ENR, 1989). The WRI does
not necessarily encompass all of the hazardous waste streams of a generator, nor does it
accommodate other important variables. However, if Q and W are carefully selected, the WRI
can, with qualification, be a useful measure of waste reduction effectiveness.
To develop Its WRI, a company would select a measure of productive activity (a)that is closely
related to a selected measure of waste generation ON). Both Q and W must be easily
quantifiable. Examples of Q might be units of production, or of raw materials use. W would
usually be units of waste generation. A baseline time period is chosen, and 0, and W, are
quantified over that baseline.
After a specified time interval, usually 1 month to 1 year, Q and W are again so quantified. A
formula relating the Q and W values is used to calculate the WRI.
8.2

APPROACH

A WRI can be calculated either for a particular waste stream (WRIJ or for all the hazardous
wastes of a company (WRIJ. The company must select whichever approach is appropriate for
properly monitoring the success of its waste reduction program.

The WRI is determined as follows:

0

Select Q, which must be an easily quantifiable measure of productive activity that

relates to waste generation. For example, Q selected for the brass foundry is
tons/year of brass plumbing fixture production.

Select the waste stream for which W will be measured. Ideally a waste stream
selected is one which would be significantly reduced by a generators waste
reduction program. Thus the resulting WRI would be a parameter that is a good
measure of the success of the program. For example, the W selected for the
brass foundry is the tons/year of hazardous foundry sand generated by the
process.

Obtain the quantified values of Q and W. Calculate W/Q, the hazardous waste
generation per unit of activity. The W/Q so calculated for the baseline is defined
as WJQ,.

8-1

Implement the waste reduction program. After a specified time interval (I month
to 1 year), quantify W and Q again, calculate a new W/Q.

The WRI is defined as:

WRI=1

- w/Q
WJQ,

8.3

Subsequent WRls can be calculated after comparable future time intervals to

measure the progress of the waste reduction program. When the ideal of zero
hazardous waste generation is achieved, WRI will equal 1.

WRI FOR THE THERMAL METAL WORKING INDUSTRY

To calculate a waste reduction index (WRI), a measure of productive activity (a)and a quantity
measure ON) of waste typical of the industry are needed. The waste quantity measure W
should represent a stream that can be significantly changed due to application of waste
reduction measures.
Foundries were focused on for the development of a WRI for the thermal metal industry. Data
from both a brass and an iron foundry were used. The measure of productive activity, Q,
selected Is the tons of metal product manufactured on annual basis. The representative waste
stream selected is the hazardous foundry sand, because this is an inherent by product of
typical foundry operations, and is amenable to waste reduction strategies.
Other waste streams generated by foundries include raw slag, waste casting metal, floor
sweeping, and baghowe wastes. Raw slag and waste casting metal are already largely
recycled at many foundries, and data on quantities generated were not available at the
foundries examined. Floor sweepings are more indicative of housekeeping procedures than
basic waste generating industrial processes. Baghouse dusts are conglomerations of many
processes, and might be suitable as a composite index.
Appendices A and C describe studies of a brass and iron foundry, respectively. Appendix
concerns heat treating operations, therefore the data from it were not used in the WRI.
The WRI for the brass foundry is calculated as follows:
Qb=

5500 tons/year brass plumbing fixture production

W,=

3OOO tonslyear hazardous foundry sand

WdQ,=

0.55

WRI

1-

w!a
0.55

The WRI for the iron foundry is calculated as follows:

100 tons/day of scrap metal is melted, and it is assumed that 90 tons of product
are casted per day. The cupola furnace operates 3 to 4 days per week, or an
average of 182 days per year. Thus, approximately 16,400 tons/year of iron
products are produced.
16,400 tons/year of iron products

Q,=

There are 400 tons of foundry sands generated monthly, or 4800 tons annually.
4800 tons hazardous foundry sand

Wb=

--

WJQ, =
WRI

0.29
1-

w/Q
0.29

Also calculated is a WRI for the iron foundry based on baghouse wastes, which average 1250
Ib/week, or 32.5 tonslyear.

w,

WJQ, =

32.5

tonshear

o.Ocn0

8-3

SECTION 9.0
WASTE REDUCTION ECONOMICS

The cost savings associated with many waste reduction measures are strong incentives for
their implementation. Less waste means cost savings from the following sources:
0

0
0

Reduced hazardous waste management costs. This includes onsite and offsite
treatment, storage, disposal and recycling facility (TS.DR) fees; state fees and
taxes on generators; transportation costs; permitting, reporting, and
recordkeeping costs.
Raw material cost savings. Minimizing waste translates into less raw materials
required per unit of product.
Insurance and liability savings. This includes reduced liability for eventual
remedial clean-up of TSDR facilities, There is also less liability when workplace
safety is Improved.
Operating cost savings from product quality control. This results from the
reduced cost of scrap, rework, rejects, and quality control inspections.

Utilities and overhead costs also can often be reduced through waste reduction, although at
times, implementation of such measures can increase these costs. Converting from a cyanide
to a noncyanide bath in liquid carburizing, for instance, can eliminate the operating cost of
treatment of cyanides including chemicals, labor, utilities. Installing a magnetic separation
system on the shotblast system to recycle the metal dust, however, can increase electricity
cost.
9.1

LOW CAPITAL COST MEASURES

As mentioned above, many waste reduction measures involve little or no capital cost. Improved
operating practices can result in reduced waste management costs and reduced raw materials
costs. In the example below, recovery of metallics from foundry wastes reduced raw material
cost. Separating metallics from molding sand allowed reuse of sand. This yielded reduction
of landfill disposal cost.
One small red brass foundry recycles all waste streams generated from the sand screening
system and all furnace skims, floor spills, slags, core butts, and tramp metal. The recycling
is performed in an existing ball mill system that pulverizes all material and breaks it down into
very small particles that are discharged onto a vibrating trough. This trough feeds an elevator
that discharges into a receiving hopper. The hopper feeds a vibrating screen. Metallics and
large particles go across the top of the screen and are recycled back to the hopper after
passing through an impactor.
After short startup period of operation, the hopper contains clean metallics (95% plus) which
can be returned back to the furnace. Data below represent three typical loads that were
processed through the ballmill:

9-1

Gross
Wt. Ibs.

Material

Pounds
Metal
Recovery

Percent
Metal
Recovery

Left-Over
Waste Lbs

Percent
Copper
in Waste

Spills
Slag
Shakeout
Screening
Baghouse

23,882
35,462
22,177
15,390

15,732
11,767
6,954
3,265

65.9
33.2
31.4
21.2

8,150
23,695
15,223
12,125
1,771

21.6
23.3
1.7
4.6
14.5

TOTAL

96,911

37,718

30.9

60,964

13.7

Direct metal recovery for remelt at 38.9 weight percent recovery was equal to 193,000 Ibs on
an annual basis. This gave savings of $154,400 based on $0.80 a pound for ingot that is
produced out of this melt. Freight charges were equal to $5,760. The processing fees were
equal to $24,850. Processing fees include analytical testing fees of wastestreams and operating
costs for processing of 496,100 Ibs of miscellaneous wastes as shown above. The leftover
waste, containing 13.7 wt % of copper, can be sold for 31 cents a pound or $93,960. Before
recycling, the company used to sell this material, gross weight with core butts and sand for 12
cents a pound which included the grinding dust. Previous scrap sale profits were equal to
$59,537 per year.
The project did not involve any capital cost because an existing ballmill system was used. The
annual financial gain was equal to:

$154,000

+ $93,960 - $59,537 - $24,850 - $5,760 = $157,613

This same foundry has reduced by 39 percent landfill disposal costs of spent molding sand as
a result of recycling used sand and reducing the amount of new sand added to the system.
This foundry is pouring somewhere between 18 and 20,OOO pounds a day and adding about
300 pounds of new molding sand. Direct savings of $20,340 were achieved by landfill waste
reduction from 391 tons per year to 238 tons per year.
9.2

CAPITAL INVESTMENT

While substantial economic benefits can ofteh be realized from waste reduction measures
requiring no capital expenditures, there are many other measures that do require capital
investment, but result in large reductions in operating expenses that soon pay back the
investment. One example of this is provided below.

At present the foundry generates 2O

, OO tons per year of spent hazardous sand. The
concentration of lead exceeds the EP toxicity limit. The lead bearing brass flakes in molding
sand account for approximately 0.51% of the weight. Disposal costs in the piant vicinity are
typically in the $200 $250/ton range and are constantly rising. Based on an average disposal
cost of $225/ton, the foundry spends $450,OOO/year on landfill disposal of sand. Installed
capital costs for the equipment is estimated at $500,000. Changes in capital expenses
associated with the waste reduction easure are detailed in Table 6-1 in Worksheet 17c.

9-2

Changes in operating expenses associated with this measure are detailed in Table 8-1, in
Worksheets 17d and 17e. Utilities will increase due to additional electrical expenses. These
are estimated at $10,000 per year. Additional reagents will be used to leach out metals from
sand resulting in expenses of $30,000 a year. Labor and maintenance expenses will be
increased by $50,000 a year (Worksheet 17e). Estimated land disposal cost savings, estimated
at $225 a ton, will be equal to $450,000 (Worksheet 17d). Recovered sand will be recycled
partially into the system that will yield savings of $20,000 a year.

The payback period for installing the new system, calculated on Worksheet 18, is 16 months.
Added to this short payback period are reduction of future liabilities and elimination of
uncertainty concerning waste management trends. It appears that installation of a metal
leaching and recovery system will be a very good investment if the system works as predicted.

9-3

TABLE 9-1
EXAMPLE COST INFORMATION

9-4

Waste Mlnimlzatlon A 8 0 8 w r " t

Plant

prepared BY
Checked By

Date

S h e e t 1 of

Proj. No.

COST INFORMATION

6 Paw

- of -

CAPITAL COSTS Include all costs as appropriate.

TOTALS

0Purchased Process Equipment

Price (fob factory)
Taxes, trelght, hmrance
Dellvered equipment cost
Prlce lor lnttlal Spare Pam inventory

0Estlmated Materlals Cost

Plplng
Electrical
Instruments
StNClUfal

InsuiatIonlPlplng

0Estimated Costs for Utlllty Connectlons and New Utlllty Systems

Electrlctty
Steam
Coollng Water
Process Water
Refrlgeratlon
Fuel (Gas or 011)
Plant Alr
Inert Gas
Estlmated Costs for AUdltlon8l Equlpment
Storage 111 Material Handling

LaboratorylAnalytlcal
Other
Stte Preparation

(Demolltlon, slte clearlng, etc.)

0EatlmatedInstallationCosts
Vendor
Contractor
In-house Staff

9- 5

Waste Mlnlmlretlon Assessment

Plant

prepared By
Checked By

Date

S h e e t 1 of _fi Page

Proj. No.
WORKSHEET

- of

COST INFORMATION
(mminuaQ

TOTALS

CAPITAL COSTS (Cont.)

Englneerlng and Procurement Costs (In-house 8 outslde)
Planning
Englneerlng
Procurement
Consultants

17Start-up costs
Vendor
Contractor

In-house

0Tralnlng Costs
0Permitting costs
Fees
IkhOUse staff coots

0lnltlal Charge of Catalystsand Chemlcals

0Working Capltal (Raw Materials, Product, Inventory,Materials and Supplies (not elsewhere specnied)].
Item W1

item
Item #3
Item IW

0EstlmatedSalvage Value (Ifany)

9-6

Waste Minlmlzatlon Assessment

Plant

Prepared By
Checked By

Date

S h e e t 3 of &- Page

Proj. No.

WORKSHEET

CAPITAL COST SUMMARY

..
9-7

- of

Plant

Waste Mlnlmlzatlon Assessment

Checked By
S h e e t 4 of 6 Page - of

Proj. No.

Date

COST INFORMATION

prepared B~

(oonlimuq

I
I

u Estlmated Decrease(or Increase)In Utllltles

utlllty

Total Decrease (or Increase)

Decrease (or Increase) In Quantity

UnHper tlnu

UnH Cost
t per una

Rofrlgeratlon
Fuel (Gas or 011)

Plant Alr
Inert Air

INCREMENTALOPERATING COSTS

BASIS FOR COSTS

Materlals

- me
Include all relevant operating savings. Estimate these costs on an increa1basis (Le., as decreases or increases over existing costs).

Annual-

L?

Quarterly

-Monthly -Dally -Other-

Unlt Cost
S per unit

Reduction In Quantlty

Unlts per tlme

Decrease In Cost
S per tlme

Waste Mlnlmlzatlon Assessment

Plant

prepared gY

Checked By

Date

S h e e t 5 of 6 Page

Proj. No.

COST INFORMATION

- of

0 EstlmatedDecrease(or Increase)In Anclllsry Chemlcais

Untt Cost
L par unit

CatalyWChomlcal

Total Decrease (or incroaw)

t par time

hcroaaa (or increase) In Ouanttty

UnH par t h

d30,OOO

Estimated Decrease (or Increase)in Operatlng Costs end Malntenance Labor COSS
(Indude cost f supewlsion, beneflts and bur en).
c/o, 000)
/j4meM e c u g ; I r u e c w w

<4G, 000

IrkC/eAu#

&Of
~

~~~

>

0 Esllmated Decrease (or Increase)In Operatingand MalntenanceSupplles and Costs.

0 Estlmated Decrease (or Increase)In Insuranceand LlabllrtyCosts (explain).

0 Estlmated Decrease
D!C?UM
O

d sad

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INCREMENTAL REVENUES
Estlmated incremental Revenues fmm an increase (or Decrease) In Pmductlon or Marketable
~pprodocts(exptaln).

9-9

Waste MlnlmlzetlonAssessment

Plant
Date

Proj. No.

1
1
.
1
WORKSHEET

COST INFORMATION
(WntlnW*

prepared BY
Checked By
S h e e t 6 of -6-

Page

- of

INCREMENTALOPERATING COST AND REVENUE SUMMARY (ANNUAL BASIS)

Operatlng CostlRevenue item

Decrease In Dlsposal Cost
Decrease In Raw Materlals Cost
Decrease (or Increase) In Utllltles Cost
Decrease (or Increase) In Catalysts and Chemlcals
Decrease (or Increase) In 0 & M Labor Costs
Decrease (or Increase) In 0 & M SupplleS Costs
Decrease (or Increase) In lnourancelLlabllltlesCosts
Decrease (or Increase) In Other Operatlng Costs
IncrementalRevenues from Increased(Decreased) Productlon
IncrementalRevenues from Marketable By-Droducts
_ .
Net Operatlng Cost Savlngs

5 per year

9x0,GO@
c lo, COG?

< 30,GOO)
< 40,ooo>
< 10;GOO >
a,
000
I

9-:o

Waste MlnlmlzatlonAssessment

Plant

Date

Checked By
S h e e t L of 1Paw

Pro]. No.

WORKSHEET

Prepared By

)PROFITABILITY WORKSHEET # 1
Cash Flow For NPV, IRR

Total Capltal Investment ($) (from Worksheet 15c)

50@,
, 000

Annual Net Operatlng Cost Savlngs (5 per year) (from Worksheet 151)
Payback Perlod (In years) =

- of -

Total Capltal Investment

Annual Net Operatlng cost Savlngs

3~0,000

- /. 3 y w r P /6~7hc/%,

Is the cost of thls pmjea worth tho bneflte It otters your company? (as Ilsta on worksheet 171)

1
9-11

SECTION 10.0
REFERENCES

AFS. August 1989. "Proceedings: 2nd Annual Environmental Affairs Conference". American
Foundrvmen's Societv. Inc., Illinois.
ASM. 1981. Metals Handbook, Ninth Edition Volume 4: Heat Treating. American Society of
Metals International, Metals Park, OH.
ASM. 1988. Metals Handbook. Ninth Edition Volume 15: Casting. American Society of Metals
International, Metals Park, OH.
Bounds, C.O. August 1983. The Modernization of the Monaca Electrothermic Zinc Smelter."
Journal of Metals. pp. 30-36.
Brunauer S.and L. Copeland. 1964. "The Chemistry of Concrete". Scientific American, pp. 8192.
Chaubai, P.C., OKeefe, T.J., and Morris, A.E. 1982. Sulphation and Removal Of Zinc from
Electric Steelmaking Furnace Flue Dusts." Ironmakina and steelmaking. Vol. 9, No. 6.
pp. 258-266.
Cullinane J., Brika M., and Francinques N. 1987. "An Assessment of Materials that Interfere
with Stabilization/Solidification Processes". U.S. Armv Corm Enaineers Watetway
Experiment Station. Vicksburg, MS.
Danielson, J. A., ed. May 1973. Air Pollution Enaineerina Manual. 2nd Edition. EPA Wice
of Air Quality Planning and Standards. Research Triangle Park, NC. Publication No.
AP-40.
DHS. February 1989. Detoxifvina Foundrv Sand. California Department of Health Services,
Toxic Substances Control Division, Alternative Technology Section. Prepared by
California Cast Metals Association. Contract No. 86-TO106.

DHS. August 1989. Waste Audit Studv Fabricated Metal Products Industry. Prepared by
Jacobs Enginnering Group, Pasadena, CA.
DHS. November 1989. Technical SUP DO^^ Document: Treatment Standards for Foundrv Sand.
Department of Health Services, Sacramento, CA.
Dressei, W. M., Barnard, P. G., and Fine, M. M. "Removal of Lead and Zinc and the Production
of Pre-Reduced Pellets from Iron and Steelmaking Wastes." Bureau of Mines RI 7927.
Illinois

ENR. August 1989. Alternatives for Measuring Hazardous Waste Reduction, Draft
Report, Hazardous Waste Research and Information Center, Illinois Department of
Energy and Natural Resources, Savoy, II. Contract Number HWRlC M9-067.

HazTECH News. September 8, 1988. "A Process for Treating Lead-Contaminated Sand from
Brass and Bronze Foundries." HazTECH News.
Kelley, K.P. October 1989. "Foundrymen Iron the Search for Effective Treatment Methods."
HAZMAT World, p.16.
Kellogg, H.H. May 1966. Vaporization Chemistry in Extractive Metallurgy." Trans. TMSAIME.
Vol. 236, pp. 602-15.
August 1983. "Recovery of Heavy Metals from Steelmaking Dust."
EnvironmentalProaress.
Vol. 2, No. 3.

Krishnan, E. R.

Krishnan, R. April 1982. Technical Assistance to the Missouri Department of Natural

Resources-Heaw Metal Recvcling. Penco Environmental Report, Contract No. 68-016007.
Miyashlta, T. 1976. "Recovery of Zinc from Steelmaking Dust."
Technoloav. Proceedinas of Joint MMIJ-AIME Meeting. Vol. 2, pp. 622-9. AIME, New
York, NY.
Morris, A. E., Cole, E. R., Neumeier, L. A., and OKeefe, T. J. December 1985. Treatment
Options for Carbon Steel Electric Arc Furnace Dust." Proceedinas-Electric Furnace
Steelmakina Conference.
Nagle, D. L., Stanforth , R. R. Duranceau, P. E., and Kunes, T. P. 1983. "Treatment of
Hazardous Foundry Melting Furnace Dust and Sludges." American Foundwmen's
Societv Transactions. 91:715:720. American Foundrymen's Society, DesPlaines, Illinois.
Oman, D. E. March 1988. The Application of Mass Balance Techniques in the Foundry
Industry." Presented at the National Research Council Board of Environmental Studies
vWorkshoD. Washington, DC.
Oman, D. E. 1988a. "Waste Minimization in the Foundry Industry." USEPA/Journal of the Air
Pollution Control Association Series Waste Minimization, Vol. 38, No. &; 732-940.
Smith, M. E., Stephens, W.A., and Kunes, T.P. May 1982. "Making Your Foundry's Waste Work
for You: Constructive Use and Reclamation." Modern Castinq.
Stephens, W. A., Oman, D. F., and Stolzenburg, T. R. September 1988. Waste Minimization
Options for the Ferrous Foundrv Industry. RMT, Inc. Madison, WI.
Stephens, W. A,, Stolzenburg, T.R., Stranforth, R. R., and Etzel, J. E. May 1984. "Use of Iron
to Render Sludge from Ferrous Foundry Melting Furnace Emission Control Waste
Nonhazardous." Presented at the 39th Annual Purdue Industrial Waste Conference.
West Lafayette, Indiana.
Stolzenburg, T. A., et al. May 1985. "Analyses and Treatment of Reactive Waste: A Case

10-2

Study in the Ductile Iron Foundry Industry."

Transactions. West Layfayette, Indiana.
Taub, S. 1986. "Fixation/Stabilization Techniques for Hazardous Waste". 79th Annual Meetinq
of APCA. MinneaDolis, MN.
Turpin, P. D., et al. 1985. "Methods to Treat EP-Toxic Foundry Wastes and Wastewaters."
American Foundrymen's Societv Transactions. 93:737-740. American Foundrymen's
Society. DesPlaines, Illinois.
USEPA. May 1988. "BDAT Background Document for FOO6". Office of Solid Waste.
USEPA. September 1985.
v $
Point and Area Sources, Fourth Edition. EPA, Research Triangle Park, NC. Publication
No. AP-42. Also include Supplement A to this publication, October 1986.
USEPA. 1986. "Prohibition on the Placement of Bulk Liquid Hazardous Waste in Landfills".
Statutorv lnteroretive Guidance. EPN530-SW-86416.
Vondracek, J.E. September 1989. "Ferrous Foundry Waste Minimization Options." Presented
at California Department of Health Services SvmDosium on Metal Waste Manaaement
Atternatives. Pasadena, CA.

10-3

APPENDICES

APPENDIX A
WASTE REDUCTION ALTERNATIVES ASSESSMENT FOR PLANT A

Plant A is a brass foundry (SIC 3432) which manufactures cast brass plumbing fixtures. The
foundry was built in 1971. Input copper, lead, tin and zinc for brass manufacturing operations
come mainly from recycled automobile radiators.
A.l

PROCESS DESCRIPTION

The foundry manufactures 10 to 12 million Ib/yr of brass plumbing fixtures. A "semi-red leaded
brass" alloy is used, consisting of 79% copper, 12% zinc, 7% lead, and 2% tin. Eighty percent
of the new feed materials come from used radiators; the remainder is from Mexican-made
ingots. The ingots are frequently out of spec, but are bought in order to keep a second
source of materials available.
Channel-type induction furnaces are used in the foundry. Each furnace is heated to 21 OOOF.
There are two furnace lines, only one of which is in use at present. Each line consists of three
450 KW, 10,000 Ib capacity melting furnaces arranged in parallel, which feed into a 450 KW,
30,000 Ib holding furnace. The holding furnace's function, besides storing the melted metal
until it is ready to be poured, is to help homogenize the melt. Output from the holding furnace
goes into a 17,000 Ib pouring furnace, which is equipped with 50 KW and 200 KW inductors.
The pouring furnace is a sealed vessel with a positive air pressure that is used to propel molten
metal from furnace to mold. Molten metal is poured into silica sand molds on a moving mold
car conveyor. The pour ranges from 15 to 25 Ib, depending on the type of castings made.
Cooling time is 18 minutes.
The molds use fine (#130) silica sands. The sands are shipped from quarries in Nevada by
railroad. The sand is initially white, but develops a black color due to high temperature
operations. Clay, cornflour and wood flour are added during mold making.
Coarse (#55 and M O O ) sands are used for the mold core. Coarse sand is required in order
to allow gas to escape. Linseed oil is added as a binder, kerosene is added to prevent the
core from sticking to the metal, and cornflour is added to give the core strength before it is
baked.
A.2

FOUNDRY WASTE STREAMS

Hazardous waste streams from foundry operations include:

0
0
0
0

Raw slag
Foundry sand
Waste casting metal
Floor sweepings

A-1

0
0
0

Furnace fumes
Non-furnace baghouse wastes
Airborne dust from molding operations
A.3 PRESENT WASTE REDUCTION

AND TREATMENT PRACTICES

Most present waste reduction efforts center around reclaiming metal and sand. While many
foundries do this to some extent, Plant A's multistage efforts far surpass those of the norm.
Plant A is a high production foundry that must generate as liile metal waste as possible to
remain profitable. Because of the land ban, and the waste management costs that result from
it, Plant A has also been making increased efforts in recent years to reduce the size of its
waste streams. Its present practices in this regard are documented below.
A.3.1

Raw Slag

Raw slag from the furnaces is hazardous due to the metals it contains. It is sent to a ballmill
after solidifying, which uses cascading steel balls to crush the chunks of slag. It is then sent
through an 8 mesh (8 wires per inch) screen as depicted in Figure A-1. Oversized metal grains
caught by the screen are returned .to the furnaces for remelting. The undersized stream,
consisting of metal and slag, goes to a 20 mesh screen. Again, the oversized metal caught
is remelted, while the undersized stream is routed to a 40 mesh screen. Oversized metal
caught by this screen is not easily remelted. Fine metal particles with oxide layers on their
surfaces tend to float on the molten slag in the furnace, and not melt. Because of this, the 40
mesh metal stream is sent to an offsite metal reclaimer.
The undersized stream that passed through the 40 mesh screen is termed "slag dust", and is
sent to an off-site smelter. Metal extracted during smelting is made into ingots, which are
bought back by the foundry.
A.3.2

Foundrv Sand

Foundry sands are subjected to a series of separation operations for reclaiming both sand and
metal (Figure A-1). A series of screens passes only the fine sands that are suitable for
recycling to molding operations. The oversized stream is termed "raw core butt", and consists
of chunks and grains of coarse core sand, as well as metal. This stream is sent through
vibrating screens. The oversized stream goes to a ballmill that crushes the core sand chunks,
and then through an 8 mesh screen. The oversized "ballmill metal" stream is then sent to a
magnetic separator. Any ferrous metals present are removed and sent to an off-site reclaimer.
The nonferrous stream is remelted in the furnace.
The undersized stream that passes through the 8 mesh screen goes to a 20 mesh screen.
Oversized ballmill metal is remelted. Undersized "dust" until recently was categorized as

.A-2

hazardous or nonhazardous according to its metal content. Because of the new land disposal
restrictions, all of the dust is treated as hazardous. It is presently sent to Chemical Waste
Management's Kettlemen Hills facility for stabilization and landfiiling. This service costs $300
per ton of waste.
Plant A generates 3000 tons per year of foundry sand dust. Section A.3 discusses strategies
that the foundry is investigating for reducing the size and management costs of this stream.
A.3.3

Waste Castlna Metal

Over half of the metal poured into a mold is not a useful part of the casting itself, and needs
to be separated from the casting and remelted. The channel made in the sand, for instance,
that allows metal to pour into the mold fills up with metal that Is not in itself a part of the
casting. The top of this filled channel is conical in shape, and called a sprue head.
Underneath is a filled cylindrical channel called a riser. Underneath the riser are more
extraneous pieces of metal, called runners and gates. The term "gates" is also used generically
to refer to all of the nonuseful parts of the casting.
Most of the gate material breaks off from the casting during shakeout, and Is separated on the
"sorting and breakoff conveyor" by plant personnel, and sent back to the furnace (Figure A1). Castings are sent to the wheelabrator, which is a blasting cabinet using steel shot to clean
the casting surface. After this, the castings are inspected. Rejects not meeting plant standards
are sent for a secondary inspection. The purpose of this is to determine the mechanism that
generated a substandard casting. This data is communicated to line foremen, so that methods
can be found to reduce rejects in the future. This second level of inspection is not typical of
most plants, and is an important part of Plant A's waste reduction program. Although most
of the metal in a reject casting can be recycled, some metal and sand finds its way into the
waste stream.
Good castings are sent to the cutoff and grinding room, where superfluous metal is removed
and sent to the furnace. Next the castings go through a wheelabrator and then to the
polishing shop for additional cleaning. Operators inspect the castings as they are working on
them, and send rejects that were missed in the previous inspections to the furnace. The
machine shop operators also examine castings they are working on, and send rejects, plus
borings and fines to the furnace. Castings that pass these inspections go to the plating shop
for a surface coating. The castings receive another inspection by the operators handling them.
Castings rejected because of bad plating are stripped and replated. if the defect is in the
casting itself, it is sent to the furnace. Finally, the castings are sent to the assembly
department. Even at this stage, some rejects are identified and sent back to the furnace or
plating department.
A.3.4

Floor Sweednas

Metallic floor sweepings from the furnace area are sent back to the furnaces for remelting. The
metal reclamation methods described above significantly reduce the plant's waste and its

A-3

operating costs. The financial benefit of internal metal recycling has been shown to be roughly
three times that of sending metal to an offsite reclaimer.
A.3.5

Furnace Fumes

Fumes rich in zinc oxide from the metal melted in the furnaces are collected by baghouses.
The foundry has two 63,000 CFM baghouses(one for each furnace line), although only one has
been in use in recent years. While sales volume has gone up, the amount of metal feed to the
furnaces has been reduced, due to greater process efficiency. Each baghouse contains 6
sections of bags, which are periodically shaken. The baghouse dust is collected in fiberglass
sacks, and sold to a fertilizer manufacturer. This company reacts the zinc fraction in the dust
with sulfuric acid to produce zinc sulfate and uses it as an additive for almond tree fertilizer.
A.3.6

Non-Furnace Bauhouse Wastes

Plant A has several other baghouse wastestreams besides furnace fumes (Figure A-2). Airborne
dust from the wheelabrator blast cleaning machines is trapped in a 20,000 CFM baghouse, and
then sent to Kettlemen Hills to be disposed of as a hazardous waste. Dust from cutoff and
grinding operations is very high in metal content, and is remelted. It was noted earlier that
small particles do not remelt easily iftheir surfaces are oxidized. The dust from the cutoff and
grinding department is not oxidized, however, and thus can be sent to the furnaces.
Airborne dust from coremaking operations is collected in a 3500 CFM baghouse, while dust
from the sand storage silos is trapped in a small 600 CFM baghouse. These dusts, which were
originally clean sand, are sent to sanitary landfills to be disposed of as nonhazardous waste.
A.3.7

Airborne Dust from Moldina ODerations

The airborne dust from sand molding operations is potentially hazardous due to its metal
content, and because of Total Suspended Particulate (TSP) regulations under the Clean Air Act.
Airborne dust from the sand molds is collected by another air emission control system -- a
"hydrofilter", that includes a wet scrubber and cyclone separators (Figure A-2). Dust laden air
is passed through venturi rods and into the scrubber. Clean air is vented, after going through
demist vanes. Liquids are fed into a settling tank, and "mud settles out with the aid of
polyelectrolytes, onto a conveyer system called a "sludge drag", at the bottom of the tank.
The sludge drag conveyer transports mud up an incline and out of the tank, and dumps the
mud in a hopper. The mud is reused for making molds. Clean water from the settling tank
goes back to the scrubber.
A.3.8

Feed Materials Control

Stringent measures are taken to prevent aluminum from getting into the process streams. Soda
cans for instance, are prohibited in the foundry area. This is because a 0.001% aluminum
content will "poison" the brass, and cause leaks in the fixtures manufactured from it.

A-4

A.4 FUTURE WASTE REDUCTION ALTERNATIVES:

SAND RECLAMATION AND DETOXIFICATION SYSTEMS

Plant A has been paying high waste management costs for its spent sands, especially since
the hazardous waste land disposal restrictions (land ban) have taken effect. Plant A generates
3000 tons per year of sand wastes. Until the land ban took effect, 1000 tons were considered
hazardous, and disposed of at Kettlemen Hills at a cost of $200/ton, or $200,00O/yr. The
remainder was disposed of in a sanitary landfill at a cost of $50/ton, or $1 00,000. These costs
cover transportation, disposal and taxes.
Since the land ban has taken effect, the entire 3000 ton annual waste stream is treated as
hazardous, and sent to Kettlemen Hills. Fixation of the metal content is required before
landfilling, and brings the total cost of waste management to $300 per ton, or $900,000
annually.
To reduce these costs, Plant A is examining sand reclamation and detoxifying options that it
hopes to implement within one year. The options are described below.
A.4.1

Thermal Sand Reclamation Svstem

Plant A is planning to install a 170OOF thermo-calcining reclaimer furnace, to which all waste
sands generated in the plant will be added. The furnace will burn off the organic contaminants
on the sands over a two hour cycle. The sand will then be transferred to a pneumatic scrubber
that uses a high velocity air stream to smash the sand against a plate. This operation helps
to separate the fines that cannot be recycled from the reusable portion of the sands. The
separation process will be completed in a cyclone scrubber. Eighty per cent of the sand
wastes are expected to be reclaimed, and reused for mold and coremaking. The fines, made
up of shattered pieces of sand and clay, as well as a metal fraction, will comprise the other
20% of the stream.
The cost of this option is $600,000. Plant A has already applied to SCAQMD for an operating
permit.
A.4.2

Detoxification of Fines

Plant A is examining two systems as candidates for detoxifying the fines. The first is a thermal
process developed by Ceramic Bonding, Inc. of Mountain View, California. It involves mixing
of the fines with an alumina-silicate clay material, and firing the mixture at approximately 2oooOF.
A ceramic material is produced in which the hazardous metals are physically and chemically
bonded to the alumina-silicate matrix. The material has shown excellent resistance to acid
leaching, even under extreme pH conditions. The ceramic material can either be disposed of
as nonhazardous in a sanitary landfill, or can possibly be marketed as a light weight
construction aggregate. The suitability of this material for construction should be properly
researched. As fill, it may be resistant to leaching, according to the tests mentioned. However
as aggregate for concrete, the abrasion during ready-mix preparation may rupture the ceramic

A-5

particle surface that hinders leaching. There may be other unknowns.

Plant A is also examining an ambient temperature fixation process developed by Thorne
Environmental that employs a cement and silicates mixture. This process also has performed
well in acid leaching resistance tests. Both systems are exceptional in that they appear to
reliably fixate copper in the sands, which many other methodologies are not able to do.
The payback period for the combination thermal sand reclamation system and detoxification
system appears to be approximately one year.

A-6

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APPENDIX B
WASTE REDUCTION ALTERNATIVES ASSESSMENT
FOR PLANT B

Plant B is a commercial heat treating plant (SIC 3398) designed for handling ferrous and
nonferrous metal workpieces. The plant employs 140 workers and was established in 1940.
Stainless steel, carbon steel, aluminum, and titanium alloys are heat treated at the plant.
Machined parts ranging in weight from a few pounds up to twenty tons are delivered for heat
treating from numerous suppliers.
This waste reduction assessment focuses on ferrous metal heat treating, which comprises the
major share of the plant's business. Figure B-1 presents a simplified block flow diagram for
heat treating of ferrous metals, and includes the following operations:
austenitizing
quenching
tempering
sandblasting
aqueous parts cleaning
electroplating
stripping
testing
air cooling
Waste reduction measures are included in the descriptions of each of these processes.

B.l

AUSlENmZlNG

Process DescriDtion
Austenitizing is performed in vertical gas-fired Gantry type furnaces in a batch mode. The
largest parts (mlssile parts) weigh up to 20 tons and are treated in a special furnace. It has
a walking-beam construction consisting of two sets of support rails: one stationary and the
other movable. The austenitizing process Is performed by heating the part to 1625F for
approximately 2.5 hours and subsequently holding the part at this temperature for another 2.5
hours. The temperature is controlled with a thermocouple sensor. The temperature and
holding time are the most critical parameters in the austenitizing process. Excessively high
austenitizing temperatures or abnormally long holding times may result in distortion, abnormal
grain growth, loss of ductibillty, and low strength. Underheating may result in low hardness
and low wear resistance. Gas-fired radiant-tube-heating is used in this process. This method
of heating protects the work chamber from the products of natural gas combustion.
Gas-fired furnaces generate a flue gas that is emitted directly to the atmosphere. City water
is used for cooling of the pit that gives an access to the walking-beam construction furnace.
Due to the fact that a workpiece is processed without direct contact with the furnace refractory

.,
B-1

Figure B-I
SIMPLIFIED FLOW DIAGRAM FOR HEAT TREATING PROCESS AT PLANT B

I
-b AuSTEN~TIZING

1 Spent Alkaline and Acidlc Cleaner

2 spent Sand
3 MiscellaneousWaste: Rinse Water
With Copper Cyanide from Plating
Operation
4 spent Water Quenchant
5 Spent Molten Salts Quenchant
6 Waste Oil
7 Furnace Refractory Liner
spent Stripping Solution and
8
Rinsewater
g Cooling
- Waste Water
10 Furnace Refractory Liners (Bricks,
Ceramics)

QUENCHING

-b

TEMPERING

AIR COOLING

7
STRIPPING
I

material, no metal oxides or other contaminants are transferred to the water that evaporates
from the pit. Thus, the water does not become hazardous waste. The refractory linings of the
furnaces were changed once in the past 40 years from asbestos to a fiberglass type of
material. There are no hazardous wastes generated on a continuous basis from this process.
Substitution of a nonhazardous lining in furnaces was the only waste reduction measure
employed so far In this process. Smaller workpieces are treated in stationary gas-fired Gantry
type furnaces that generate the same type of non-hazardous wastes as described above.
8.2

QUENCHING

Workpieces can be quenched in one of three separate sumps filled with oil, water and molten
salt media. The largest metal workpieces from walking-beam furnaces are quenched in a
sump filled with molten salts of potassium and sodium nitrates. Metal parts are transferred to
the sump with an overhead crane, After the quenching is completed, the workpieces with their
sait residues are returned to the furnace for a tempering process.
Most carbon steel workpieces are quenched in oil at temperatures from 75 to 14BF. Some
stainless steel parts are quenched in the water at ambient temperature. if the same operation
was performed with carbon steel part, it would break due to the very drastic quenching
environment. Other ferrous alloys are quenched in a molten salt bath at approximately 40CPF.
AIi parts quenched in oil are transported by crane to a hot water wash station located in the
vicinity of the wastewater treatment facility. Oily water wastes are generated from this washing.
8.2.1

lnmt Materials and Waste Streams

The molten sait quenchant consists of potassium nitrate and sodium nitrate mixed in the
proportion of 1:l. Make-up salts are periodically added to the bath to maintain the required
volume of quenching media. Since 1971,the molten salt media has not been changed or
disposed of. There has been no need to remove settleable solids since then.
Mineral oil is used as another quenchant. The waste oil is collected in an underground clarifier
at a water wash station and removed periodically by a contractor for off-site recycling. An
average truckload contains approximately 5% oil and 95% wastewater. Plant B generates
about 4,300gallons of waste oil every 6 to 7 months.
Water is used as the quenchant where drastic quenching does not result in excessive distortion
or cracking of the workpiece. The water quenching sump is very rarely used, and no need for
cleaning of this sump has been experienced in the last several years.
6.2.2

Waste Reduction

The forthcoming California state regulations in this area will be a strong driving force for the
plant to institute a waste reduction plan. Source reduction measures for quenchant waste
could include:
o

Substitution of conventional quenching oil for less viscous fasf quenching oil
(a mineral oil blend containing proprietary additives) resulting in decreased
dragout of oil on workpieces, and consequently lowering oil consumption

..
8-3

Use of an air blower for mechanical removal of quenchant from the surface of
a workpiece

Increasing drainage time of workpieces

Recycling of quench oil baths could also minimize waste oil generation and could be achieved
by mechanical and/or thermal conditioning to remove the following contaminants:

o
o
o
o
o

Scale
Carbonaceous sludges that are products of oil oxidation.
Other insoluble solids, such as sand
Water
Soluble compounds, such as carbon dioxide removed in thermal conditioning.

Contaminants can be removed by filtering, evaporation or draining. Solids can best be

removed by appropriate bypass filters. The choice of filtering medium for removing solids is
important. The most commonly used filtering media are the mineral-wool and cellulose, which
must be replaced after their filtering ability has been exhausted. Clay filtering media are more
expensive than the above types but can be regenerated and reused after exhaustion. However,
regeneration will not remove scale or sand. Clay media should be carefully selected when
fast quenching oils are to be filtered, because it is possible to remove necessary additives in
the oil along with undesirable carbonaceous materials.
Magnetic filters, traps and strainers are useful in removing scale and other foreign materials.
These types of filters can be easily cleaned and returned to service. They are especially helpful
for preventing premature filter clogging and for protecting pumps.
Water can be removed by filtering or centrifuging, but these methods are expensive and are
rarely used. Usually, bulk water is removed by draining and suspended water is removed by
heating. Carbon dioxide is also removed by heating.
The waste oil collected in underground clarifiers is sent for off-site recycling. On-site recycling
such as gravity oil/water separation and subsequent mechanicalfihhennal conditioning might be
considered for future quench oil recovery,
8.3

TEMPERING

Tempering of steels is performed by reheating the workpiece after quenching to obtain specific
values of mechanical properties (e.g. ductility and toughness) and to relieve quenching stresses
and ensure dimensional stability. Metal parts, after being quenched, undergo tempering in gasfired furnaces with forced air atmospheres and temperatures from 700 to 1400F. The flue gas
is vented to the atmosphere. There are no hazardous wastes generated in this process.
8.4

SANDBLASTING

Sandblasting at Plant B is performed indoors In four sandblasting booths. There is one

baghouse to collect particulates from all of the these systems. Twenty-five tons a month of
sand is supplied to the location. Spent sand is disposed of off-site by the sand supplier.

B.4.1

Waste Reduction

Future measures for reducing the quantity of spent sand might include:
0

Recycling of silica-based dust.

It is reported (Kelley 1989) that Biackhawk Foundry and Machine Co. (Davenport, Iowa) have
supplied their silica - based dust material to the Davenport Cement Co. for reuse. It was
concluded that 5 to 10 percent of the raw material used by cement companies may be wastes.

Detoxification of hazardous sand (if generated and confirmed by analysis) with

sodium silicate and calcium oxide technology by means of stabilization (refer to
DHS Study on "Detoxifying Foundry Sand", February 1989).

Reducing the usage of raw sand by optimization of feed control system.

8.5

PLATING AND STRIPPING

Plating is employed for some parts that must be protected by a coating that is impervious to
the carburizing atmosphere in the furnace. Copper plating is widely used for this purpose
because lt Is relatively easy to apply, machinable, noncontaminating to furnace atmospheres,
and amenable to stripping by immersing a part in a stripping solution. Most, if not all, of the
copper plate may be removed in the course of subsequent machining operations.
Copper electrostriking operations are performed on some steel and other ferrous alloy
workpieces to optimize the copper electroplating process, which is performed prior to
austenitizing. After this, a metal part typically undergoes austenthing, molten salt quenching,
tempering, air cooling, stripping, sandblasting, and testing.

The following unit operations are performed at the electroplating/stripping site:

o
o
o
o
o

o
o
B.5.1

Alkaline cleaning
Rinsing with tap water
Acid cleaning
Rinsing with tap water
Striking
Electroplating
Stripping

InDut Materials and Waste Streams

Input materials include alkaline cleaner, weak acid solution, copper cyanide baths for striking
and plating, copper stripping solution. Alkaline cleaner is employed to remove soil from metal
parts and acidic cleaner is used to remove dust and scale.

..
B-5

All except acidic wastes, are collected for batch treatment in a 6,500 gallon tank. One strip
tank (1,200 gallons) is emptied every 1 to 1.5 months. The total q u a n t i of hazardous wastes
generated at this site is equal to approximately 6,500 gallons every three months.
8.5.2

Waste Reduction

On a volume basis, contaminated rinsewater accounts for the majority of plating process waste.
Rinsewater is used to wash off the dragout from a workpiece after it Is removed from a bath.
By minimizing the amount of dragout carried from a plating or cleaning bath to a rinsing bath,
a smaller amount of water is needed to rinse off the workpiece. As a result, less of the plating
solution constituents leave the process, which ultimately produces savings in raw materials and
treatmenVdisposa1 costs.
Dragout minimization techniques that can be employed include:
o

Reducing the speed of withdrawal of workpiece from solution and allowing ample
drainage time. Usually, 30 seconds allows most of the drag out to drain back
to the tank.

Use of surfactants.

Wetting agents have been used to lower the surface tension of plating solutions.
Applied in only small amounts, wetting agents can lower solution surface tension
enough to reduce dragout out by up to 50% (USEPA 1981). Only nonionic wetting
agents, which will not be degraded by electrolysis in the plating bath, should be
employed.
o

Proper positioning of the workpiece on the plating rack

Proper positioning of the workpiece on a rack facilitates the dripping of the drag out
back into the bath. The position of any object which will minimize the cany-over of
dragout is best determined experimentally, although the following guidelines are found
to be effective:

Orient the surface as close to vertical as possible

Rack with the longer dimension of the workpiece horizontal
Rack with the lower edge tilted from the horizontal so that the runoff is from a
corner rather than an entire edge

For regularly shaped parts that do not contain oddly-shaped objects, fog or spray nozzles can
be employed for rinsing contaminants from the surface. A fog nozzle uses water and air
pressure to produce a fine mist. Less water is used than with a conventional spray nozzle.
It is possible to use a fog nozzle directly over a heated plating bath to rinse the workpiece.
This allows for simultaneous rinsing and replenishment of the evaporated losses from the tank.
Spent cleaning solutions might be disposable as nonhazardous wastes If they are kept
segregated from plating wastes and neutralized.

.
8-6

Another promising waste reduction measure is the replacement of cyanide plating solutions
with cyanide-free pyrophosphate copper plating solutions.

B.5.3

Wastewater Treatment

Sodium hypochlorite solution is used for batch treatment of wastewater in order to oxidize the
cyanides at alkaline conditions. Treated water is sampled and analyzed for cyanide
concentration. Wastewater with high copper contents are then pH-adjusted for optimum
Cu(OH), precipitation, and pumped to a plate and frame type filter press. Filtrate is discharged
to the sewer system. Sludge is disposed of off-site in quantities 6-7 drums (500 Ibs each)
every 2-3months as hazardous wastes at a Class I landfill.
Plant B Is currently investigating the possibility for off-site copper recovery from the sludge.
One option would be to contract these sludges with copper recyclers including U.S. Pollution
Control, Inc., in Utah, World Resource Company in Arizona, ETICAM in Nevada, or Cyprus
Miami Mining Corporation In Arizona. Some recyclers specify minimum metal contents in the
sludge cake and a minimum tonnage per year for the wastes to be accepted for reclamation.
Refer to the Waste Audit Study on Fabricated Metal Products Industry (DHS 1989) for more
information on waste reduction measures for plating operations.

0-7

APPENDIX C
WASTE REDUCTION ALTERNATIVES
ASSESSMENT FOR PLANT C
Plant C is an iron foundry (SIC 3321) established in 1946. It manufactures gray, ductile, and
alloy iron castings from scrap iron including scrap engines. Plant C typically employs 155
workers, although this number can fluctuate up to 320 employees. Daily consumption of scrap
metal is estimated at approximately 100 tons/day. There are 800 tons of wastes generated a
month for off-site disposal, including approximately 400 tons of foundry sand and at least 300
tons of refractory material that are disposed of as nonhazardous waste. The balance consists
of hazardous wastes generated in form of dust and sludge from air emission control systems.
The iron casting process at Plant C consists of the following operations:
1.
2.
3.
4.
5.
6.

scrap metal melting

core making
molding and core setting
pouring of molten metal
shakeout
casting cleaning (grinding, blasting, cleaning)

Some ductile iron castings undergo annealing, a heat treating operation. The foundry produces
castings by pouring molten metal into molds consisting of molding sand and core sand. Once
the casting has cooled and hardened, it is separated from the mold and core materials in the
shakeout process. The castings are cleaned, inspected, and then shipped for delivery.
C.l
C.l.l

MELTING

Process Description and Input Materials

The foundry employs two types of furnaces for melting scrap metal, five induction furnaces and
one cupola furnace.
System No. 1 consists of two "Ni-resist" electric induction furnaces at Plant C for production
of heat resistant alloy. In these, low carbon steel charge is carburized to increase its carbon
content and nickel, molybdenum, and chromium metals are added. The product castings from
these furnaces are classified as heat resistant iron based alloys. Total charge to the system
is equal to 100 tons per year.
System No. 2 consists of three large induction furnaces with holding capacities of 9, 3.5 and
3.5 tons for production of ductile iron. The feed to this system consists of scrap steel, pig
iron returns, granular carbon, silica, and magnesium alloy. The charge is heated electrically
to 2.90OOF.
The cupola furnace at Plant C is used for melting of motor blocks. The furnace operates 3 to
4 days a week, 9 hours a day, and has been in operation since 1947 (one of the oldest pieces
of equipment at the foundry). It is used for production of gray iron castings.
,-

c-I

Figure C-1 presents a material flow diagram for the cupola melting operation. As illustrated on
this figure, materials input to the melting operation include scrap metal such as engine blocks,
fluxes, coke, and refractory material.
Fluxes inClUd8 limestone, fluorspar and soda ash. These are used as conditioners for slag
formed in the melted charge to facilitate its removal from the furnace.
The coke Is used as a source of fuel for the cupola. Refractory material that can withstand
high temperatures is used to line the furnace. The refractory material is subject to deterioration
during the foundry process and therefore must be replaced periodically.
C.1.2

Waste Streams

Induction Furnaces
The off-gases from the induction furnaces in System No. 2 (ductile iron production) are vented
to the atmosphere. Furnace refractory material is disposed of off-site as non-hazardous waste.
Furnace slag is also disposed of as non hazardous material.
The off-gases from two Ni-resist induction furnaces in System No. 1 (heat resistant alloy
production) are vented to the atmosphere. The slag generated in the melting process in these
furnaces is classified as hazardous waste due to heavy metal toxicity characteristics (high nickel
and chromium concentrations). As estimated, there are 1-2 tons of hazardous slag waste
generated annually. Furnace refractory material from the Ni-resist furnaces is disposed of as
non hazardous waste.
Cupola Furnace

Wastes generated in cupola melting operations (see Figure C-1) include:

o
o
o
o

dust and sludge from emissions control system

slag
bottom drop and sweepings
spent refractories

The major wastestream from the melting operation is refractory lining. Quantities of more than
300 tons a month are generated. All of the wastes except refractory linings generated in this
process are classified as hazardous wastes.

Emission control residuals are generated at the rate of 1,OOO to 1,500 Ibs per week. They
exceed toxicity characteristics for lead, and zinc primarily. Gray iron is melted at approximately
2,700OF. The melting points for toxic metals in the fumace is much lower. Lead, for example,
melts at 62OOF. As the metal feed is melted, the lead, zinc, and cadmium tend to volatilize and
are collected by the emission control system. Emissions from cupola furnaces are controlled
by a cyclone scrubber that removes large particulates, and the baghouse, which separates
fines.

c-2

Flgure C-1
FOUNDRY MELT PROCESS SCHEMATIC
STACK EMISSIONS

FUGITIVE
EMISSIONS

BAGHOUSE

CYCLONE
SCRUBBER

I
I
I

HAZARDOUS
DUST

\-/------n
,

QUENCH UNIT

REFRACTORIES

------CUPOLA

NON-HAZARDOUS

---------

COKE

FLUX

METAL

/
LEOWD
METAL FLOW LINE

-------

NOKMETAL FLOW LINE

WASTE R O W LINE

cuwu
WASTE OENERATION
WASTE MATERIALS

NEWMATERIALS
INTERMEDIATE PRODUCT

C3

C.1.3

Waste Reduction

Plant C has implemented two successful waste reduction measures that include:
o
o

on-site recycling of slag from two Ni-resisr induction furnaces, and

detoxification of residuals in the cupola furnace emission control system.

As of July 1988, Plant C has been recycling the slag from two Ni-resist electric induction
furnaces by charging the slag to the cupola fumace.
This slag from Ni-resist furnaces plays the role of scavenger of trace metal elements from the
cupola furnace charge. The cupola slag has become a nonhazardous waste since most toxic
metals are scavenged from the slag. Forty cubic yards (3-4tons) of slag a month is sent for
application at equestrian trails.
Full scale experiments on detoxffication of residuals from the cyclone scrubber are in progress.
Silicate treatment technology is being employed to immobilize heavy metals (Pb, Zn, Cd and
other elements) carried over with flue gases and particulates from the stack of the cupola
furnace. A 12.5% sodium silicate solution is injected at the rate of 1.5 GPM into the treatment
spray nozzle section in the quench zone In the stack, where the temperature exceeds 13OWF.
Hydrated lime is also added. The chemical costs for this process are estimated at $200 a day.

The total concentration ranges of heavy metals In the wet scrubber residuals before treatment
are:
Zn: 500
P b 605
Cd: 0.8

1,595
6,085
7.5

mglkg
mg/kg
mg/kg

The Waste Extraction Test (WW results after 48 hours of extraction per r i l e 22 regulations
varied as follows on silicate treated materials:
Zn: 0.3
Pb: 20.1
Cd:

44
230
c 0.1

mg/L
mg1L
mg/L

The STLC regulatory limits for metals are as follows:

Zn:
Pb:
Cd:

250
5
1.0

mg/L
mg/L
mg/L

STLC
Soluble Threshold Limit Concentration
Regulations, Title 22, Section 66699.

C-4

as defined in California Code of

It was found that the stack temperature is a critical parameter in the silicate treatment process.
Efficiency of treatment increases when temperatures are above 13OOOF. The cupola furnace
stack temperature is unfortunately not stable through the process. This results in variance in
the efficiency of particulate treatment. The plant is currently attempting to improve this system.
Other possible waste reduction measures under consideration for potential implementation are
as follows:
o

Off-site recycling to an Arizona smelter of lead containing wastes. The smelter

would pick up the material for the cost of $250 per ton.

Internal recycling by combination of furnace dust with sand for reuse in mold
making process. Detoxification of sand with sodium silicate and calcium oxide
technology followed by formation of a mold with detoxified sand as backing and
new sand facing of the mold-metal interface are presented in the DHS study
Detoxifvina Foundry Sand (1989).
C.2 CORE MAKING

C.2.1

Process DescriDtion and Input Materials

Core making involves coating a refractory material (silica sand) with binder compacting the
coated sand into the desired shape and then curing (hardening) the compacted mass so that
it can be handled.
Cores are used to produce internal cavities within a casting. The cores are composed of silica
sands with small percentages of organic binders. Oil binders and synthetic resin types are used
at Plant C. Oil binders are vegetable oils. Resin binders include phenolics and phenolformaldehydes. Cores must possess the characteristics of strength, hardness, and collapsibility.
Often the cores are removed within a casting through a small orifice and therefore sand must
collapse after the casting solidifies.
The following processes of core making are employed at Plant C:
1.

2.
3.

Shell core process (heat cured process)

SO, core process (cold box process)
Core oil process (oven bake heat-cured process)

In the shell core Drocess, precoated shell sand is used. The precoated binder is a synthetic
phenol-formaldehyde type of resin. A gas-fired shell core machine is used to form cores at
45OOF. This process requires the core box to be heated (350to 55OOF) prior to introduction
of the prepared sand.

s,

In the
core Drocess, the sand is mixed with binder and catalyst. The SO, gas activates
the catalyst to bind the sand. This cold-cured process utilizes sulfur dioxide gas that is forced
through the compacted sand mixture to cure the core.

..
c-5

In the oven bake core Drocess, the sand is mixed with vegetable oil and ferrous oxide. The
core box is filled normally with the material and cores are baked in oven at 405OF.
C.2.2

Waste Streams

The excess of sulfur dioxide used in the SO, coremaking process is controlled by the caustic
soda scrubber. 50% make up solution of NaOH is used to replenish the scrubber. There are
approximately 155 gallons of scrubber wastes generated daily that are discharged to the
sanitary sewer system at controlled pH range.
Additional waste streams are handled as follows:
o
o

o
C.2.3

Shell core machine off-gases are vented to the atmosphere.

The core oven gases are combusted in an afterburner.
Solid core wastes are blended with foundry sand and disposed of off-site as
nonhazardous waste.

Waste Reduction

Please see Section (2.5.2.

C.3 MOLD MAKING
C.3.1

Process DescriDtion and InDu! Material

The foundry sand system process schematic is shown in Figure C-2. Molding sand is
compacted around a pattern of the casting that is to be produced. The green sand is used
at Plant C to form molds. The phrase green sand refers to the fact that the medium has been
tempered with water added to activate clay/water bonds in green sand molds.
Green sand is prepared from four major materials:
o
o
o
o

green sand mixture (85-95%) - inert silica

bentonite clay .(4-10%)
carbonaceous material (2-10%)
water (2-5%)

Sand, clay, water, and carbonaceous materials are charged into the mixing device. These
devices are called either mullers or mixers. There are three mullers at Plant C to prepare the
feed for mold making and core setting equipment. The following techniques are employed:
copying/dragging, squeezing and automatic moldmaking.
C.3.2

Waste Streams

Waste streams generated in the molding process are in the form of dusts and sludges that
have been collected in the air pollution control system. Large sand clumps are also formed

C-6

Fi ure C-2
PLANT c SAND S Y S ~ E M
PROCESS SCHEMATIC

t
4-

c-7

that are screened out of the molding sand recycle systems or that are cleaned from the
castings (see Figure (3-2).
C.3.3

Waste Reduction

Molding sand is reclaimed in the system shown in Figure C-2. There are no hazardous wastes
generated in mold making operation. Foundry spent sand is disposed of off-site as
nonhazardous waste.
C.4 POURING

The molten metal Is transported to the pouring area in a transfer ladle, where it is poured into
the pouring ladle and into the molds. The poured molds are allowed to cool and then the
solidified coatings are removed from the mold, rough cleaned of mold material, and allowed
to cool until the cast metal is cold enough to handle. The smoke emllted is exhausted to the
atmosphere. The "sweepings" generated in the pouring process are mixed with foundry sand
and disposed off-site as nonhazardous waste.
C.5 SHAKEOUT
C.5.1

The shakeout process is performed to separate sand from the casting. Sand that has had its
binder fully degraded in the pouring process is mixed with molding sand for recycling. The
core butts (partially decomposed core sands) are crushed and recycled back into the molding
sand process or they are taken directly to the landfill for disposal along with broken or offspec cores and core recovery sweepings. The molding and core sand wastes account for
about 50% of the total waste generated by the foundry (Plant C). The company pays $100,000
a year for sand disposal. The air emission control system consists of four baghouses to collect
the foundry sand. The majority of foundry sand is classified and disposed of off-site as
nonhazardous waste. The sand from System No. 2 with three large induction furnaces is
classified as a hazardous material due to high Zn concentrations. There are 200 ibs/week of
hazardous foundry sand generated in System No. 2 particulate collection equipment.
C.5.2

Waste Reduction

Since 1988, the hazardous sand from System No. 2 is segregated from other foundry spent
sand and is recycled as a feed component to the cupola furnace in the quantity of 1,500 ibs.
per week. This sand becomes a component of the cupola furnace slag and is sold for filling
of equestrian trails. The company would need to spend $250 per ton for hauling this sand to
a smelter in Arizona if the above specified waste reduction measure was not employed.

C-8

C.6 SURFACE CLEANING

Polishing wheels are used for cleaning of castings. The baghouse dust wastes are mixed with
foundry sand and disposed of off-site as nonhazardous wastes.
C.7 HEAT TREATING

Some ductile iron workpieces undergo an annealing process. Annealing is a heat treating
operation. Workpieces are heated to 155BF for six hours and held at this temperature
followed by cooling at an appropriate rate, primarily for softening of metallic materials. The
entire annealing cycle takes from 18 to 24 hours.
Three direct fired (natural gas fired) three box type furnaces operate in batch mode. There are
no hazardous wastes generated in this process. Refractory furnace lining is the only waste
generated periodically at this location and is disposed of as nonhazardous waste.

c-9

APPENDIX D
WASTE REDUCTIONASSESSMENT FORMAT

The following format provides a procedure that can be followed by plant personnel to
identify the hazardous wastes generated and promising methods for reducing them.
This assessment procedure can be of considerable help in analyzing and improving a
plant's waste management system.

Worksheet

1.

Plant Description

2.

Process Identification

3.

Waste Reduction Program Organization

4.

Input Materials Summary

5.

Material Storage and Dispensing Practices

6.

Process Flow Diagram

7.

Process Information

8.

Documentation Available

9.

Products Summary

IO.

Waste Stream identification

11.

Individual Waste Stream Generation and Characterization

12.

Waste Stream Summary

13.

Waste Reduction Options

14.

Option Description

15.

Options Evaluation by Weighted Sum Method

16.

Technical Feasibility

17.

Cost Information

18.

Profitability Worksheet #1

19.

Profitability Worksheet #2

20.

Waste Reduction Index

'

D-1

Waste MlnlmlzatlonA t ~ s s "

Plan1

Checked By
S h e e t 1 of

Proj. No.

Date

Prepared By

1Page - of

PLANT DESCRIPTION
J

,Finn:
Plant:
Department:
Alee:

S t m t Address:
cry:

State/zIP Cod.:
Telephona: (

Major Products:

SIC codes:

EPA Generator Numbers:

Major Unlt or:
product or:
Opemtlonr:

PlantEqulpmont AW:

k W A U . I I D I YCUI

'lant

Waste Mlnlmlzatlon AsaersmeM

Prepared BY

Checked By
)ate

WORKSHEET

(21

~~

Proj. No.

S h e e t 1 of

L Page - of

I PROCESS IDENTlFlCATfON I

I
I

Plant

Waste Mlnlmlzatlon A s m a s
~

Prepared By
Checked By

Date

Sheet 1
.of

Proj. No.

WORKSHEET

FUNCTION
Program Manager
Plant Program Coordinator

1- Page - of -

WASTE MINIMIZATION

NAME

LOCATION

(sketch)

TELEPHONE NO.

Plant

Waste MinimizationAssesMlent

Prepared By
Check By

Date

I WORKSHEFT

Proj. No.

Sheet J- of

1
.Page - of -

INPUT MATERIALS SUMMARY

1
Saeam No.

Streao.

Streao.

Plant

W s p t e M i i Assessment

PreparedBy
Check By

Date

Proj. No.

sheet 1of

MATERIAL STORAGE AND

DISPENSING PRACTICES

1
I

D-6

1Page - of -

Checked By

late

Proj. No.

S h e e t 1 of

PROCESS FLOW DIAGRAM

1Page - of -

Plant

'

Waste Mlnlmlzatlon Assessment

Proj. No.

Date

--

prepared By
CheckedBy
Sheet
of ~ 5 - Page

- of

PROCESS INFORMATION
i

Worksheet 7 contains sectlons on the following lndustrlal processes that generate hazardous waste:
Castlng Operations
Heat Treatlng Operations
Metal Parts Cleanlng & Stripping
Metal Surface Treatment & Platlng OperatlOnS
Other:
~-~
~

Complete the appropriate sectlons of worksheet that correspond to processes practlced In your plant.
1. CASTING OPERATIONS

Descrlptlon of furnace and operation performed:

ldentlflcatlon number:
Type of metals melted:
Addltlves used:
Is feed batch or continuous?:
Size or rate of feed:
Method of feed:
Method of slag removal:
Type of refractory:
Replacement frequency of refractory:
Type of emlsslon controls employed:
Type and amount of sand used per year:
Type and amount of blnder used per year:
Number of castlngs per year:

Of the sand used, what percent is recycled:

What percent ends up as dust:

What type of emlsslon contml devices are employed:
For heat-cured or reactlve blnders, are emlsslons other than Uust produced?

D-8

Waste Minlmizatlon Assessment

Plant
Date

prepared By
Checked By
S h e e t 2 of & Page - of -

Proj. No.

1
m
WORKSHEET

con nue

2. HEAT TREATING OPERATIONS

Foreach
Type of system:
Size of system:
Amount of hazardous material present:
Replacement frequency of material:
Type of hazardous materials used:
Emission controls employed:
Method of waste disposal:
Type of quenching fiuidlmethod:
Replacement frequency of quench bath:
How dlsposedlhandled:

3. METAL PARTS CLEANING AND STRIPPING

Are Solvents used for cleaning purposes?

ifso, which of the foiiowlng are employed?
Vapor Degreaser
Spray Chamber
Covered Solvent Cold Cleaning Tank

0
0Uncovered Solvent Cold Cleanlng Tank

0Rag Wlpedown
Brush Scrubbing

0 Other

Technlaue(include number & size)

How are spent solvents managed?

Biodegradable; dlspose of In sewer
Recycled onslte
c]Recycled offsite

0Treated or Incineratedonslte
0Treated or Incineratedoffsite
0Other

Annual CostsFor onslte recycling, Is residue hazardous?

How are used rags disposed of?
Annual Costs:

.,
0-9

AnnualUsaoe

Waste Mlnlmlzatlon Assessment

Plant
Date

Prepared By
Checked BY
Sheet L of 6 Page - of -

Proj. No.

- PROCESS INFORMATION

3. METAL PARTS CLEANiNGS AND STRIPPING (continued)

Are cleansers, strippers, surfactants and detergents used in the plant?

Types of aqueous cleaners used:

0Alkaline surfactant cleaner

0Alkaline detergent cleaner

0Alkaline stripper

0Acid cleanser
0Acid stripper
process ~eau,muw

0Spray Chamber

0Sink
[7 Rag wiping

Air-sparged bath
Agitated bath

Brush
-(include

number 8 size)

AnnualUSaae

How are spent cleaners managed?

0Biodegradable; dispose of in sewer

0Transported offslte
Treated onslte
Annual Costs:

Annual Costs:
Descrlbe abrasive cleaning and stripping techniques used (e.g.. blastingboxes, buffing machines,etc.):

n-i n

Plant

Date

Waste Minimization Assessment

Sheet&

Proj. No.

IxI
WORKSHEET

Prepared By
I Checked
By

of

3-

Page

- of

PROCESS INFORMATION
(continued)

3. METAL PARTS CLEANING AND STRIPPING (continued)

How are wastes from abraslves techniques managed (e.g.. dust, worn discs, etc.):

Annual Costs:
Annual Costs:

ADDlicatlon

Size of Rlnse Bath

Continvous
QLalL"

Iemn

Are spray rlnse techniques used within the plant?

Describe spray rinse operations:

is the spray rinsing done in combination with or instead of immersion rinslng?

Are spent stlii rinses used as makeups for the process baths?
is counter-current rinsing employed at the plant?

Describe how It is used (Give the number of tanks in each counter-current series, the flow rates and
the process chemicals rinsed from the workpieces.):

Water use rate for entire plant rinsing operations:

is deionized water or reverse-osmosisfiltered water used for rinsinglcieaning? Where?
is air sparging or mechanical agltatlon used in the rinse baths?
List which technlque is used in which bath:

0-11

Waste MlnlmlzatlonAssessment

Plant

prepared BY

Checked By

Date

S h e e t L of 3- Page

Proj. No.

WORKSHEET

- of

PROCESS INFORMATION
(conlinuod)

3. METAL PARTS CLEANING AND STRIPPING (contlnued)

Is the spent water recycled or reclaimed?

0settled
0filtered
0chemically classlfled
is the spent water treated onsite?
is the recycling or treatment residue hazardous?

If yes, how Is It managed?

Waste minimization opportunlties In metal parts cleaning and strlpplng:
Potential waste mlnlmlzatlon savlngs of process materlals and waste management Costs:
Comments:

4.

METAL SURFACE TREATMENT AND PLATING OPERATIONS

Description of tanks functon:
ldentlflcation number:

She:
Composition of process solutlon:
Temperature:
Work volume (square feet of workpiece surface per week):
Quantity of makeup chemicals added per week:
What chemicals are added?:
How much of the makup volume Is due to replenlshlng dragout?:
Replenishing evaporative losses?

Is delonlzed or reverse-osmosis flitered water used In the process baths?

D-I 2

Waste Minlmlzatlon Assessment

Plant

prepared B~
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S h e e t 6 of L Page - of -

Proi. No.

Date

PROCESS INFORMATION
(continued)

4. METAL SURFACE TREATMENT AND PLATING OPERATIONS (contlnued)

Are dragout reduction technlques employed?

Which ones?
~

What Is the dump schedule for the process tank?

is the process line manual or automatlc?
is rack or barrel plating employed In the tank?
What Is the productlon rate of the tank (in 11. of workplece surface area per week)?
Are baths alr sparged or mechanically agltated?
Are personnel trained to throughiy drain workpieces above baths before moving them to another bath?
Are they periodically retrained?
Are there spaces between process baths and their rlnse tanks that allow chemlcals to drlp on the floor?
Are process baths filtered to remove particulates?
5.

MISCELLANEOUS
Are any metal oxide wastes generated In weidlng or solderlng Operations In your plant?
Note: If SO, they must be managed as hazardous waste.
Are any hazardous fluxes used In welding or soldering operations?
How are the above wastes managed?

6.

OTHER PROCESSES THAT GENERATE HAZARDOUS WASTE

Process

Potentlal Source Reduction and Recycling Opportunities:

D-13

Plant

Wane Mlnlmlzatlon Assessment

Prepared BY

Checked BY

Date

Proj. No.

S h e e t 1 of

Page

- of -

Wane Minimization Assessment

Plant

Prepared BY

Checked By

Date

S h e e t 1 of

Pmj. No.

191
WORKSHEET

PRODUCTS SUMMARY

f_

Page

- of -

amam numbam, if applicable, should corrrrpond to tho- urrd on procarr llow diagrams.

F a W A U !e
a ucm

D-15

Waste Mlnlmlzatlon Assessment

Plant
Date

Proj. No.

WORKSHEET

Prepared By
Checked BY
S h e e t 1 of 1 Page - of

WASTE STREAM IDENTIFICATION

1. Check the waste streams below that are generated In the plant.

PROCESS

wsIuM

Castlng

Baghouae Dust

Heat Treatlng

Slags
Spent Sands
Combustlon Emlsslons

0
0

Process Baths

ci

Spllls & Leaks

Quenchlng Flulds
Emlsslon Control Dust &Vapor
Solvents
Alkallne Wastes
ACld wastes

Metal Parts Cleanlng and Strlpplng

Abraslves
Waste Water
Alr Emlsslons

Other:

0
0
0

0
0
0

0
0
0

Spent Bath Solutlons

Surface Treatment and Plating

Flltet Waste
Rinse Water

Spllls and Leaks

Solld waste
Alr Emlsslons
Other:

..
D-16

0
0
0

-[I3U

Waste Minimization Assessment

Plant

Prepared By
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Sheet 1 of

Proj. No.

Date

WORKSHEET

1 Page

- of

WASTE STREAM IDENTIFICATION

(wntlnued)

Other Processes

Leftover Raw Materlals

Other Process Wastes
Types:

Pollutlon Control Residues

Waste Management Resldues
Other:

0
0
0
0
0
0
0
0
0

Waste MlnlmlzWlonAssessment

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Proj. No.

Date
WORKSHEET

& Page - of

INDIVIDUAL WASTE STREAM

GENERATION AND CHARACEREANON
r

1.

Stream Number

Waste Stream NamollD:

Process UnlVOperatlon
2.

Waste Characterlstlcs(attach addltlonal sheets with compositlon data, as n-arary.)

gas
llquld
UsoOUd
mlxedpbre

3.

Waste Leaves Process as:

0 alr emlsslon 0waste m e r c]rolldwaste 0hazardouswaste

4.

Waste
Generation Is:
-

U contlnuws

0 Periodic

bngth Of pried:

spomdlc (Irregular OCCUmW)

0non-recurrent
5.

What Determlnrs it To Be A Waste?

0Chrmlcnl Analysle
0ProcessTypo
0I n d u s t r y W
0EPA Ctmmlclls ~1st
6.

What Could Ellmlnatr mls Waste Generation?

0Improved operations

I3 Material substitutions

0Other:
7.

Generation Rate

Annual

~ b per
s year
Ibs per
Ibs per

Maximum
Average
Frequency
Batch SI=

batchesper

average

range
L U N I U u t O l l . MGl

WaSto Mlnlmlzatlon Al.errsment

Plant

Date

Checked By
S h e e t L of

Proj. No.
WORKSHEET

prepared By

4 Page - of -

INDIVIDUAL WASTE STREAM

GENERATION AND CHARACTERIZATION

Waste Stream
8.

Waste OrlgbdSources
Flll out thls worksheet to ldentlty ths orlgln of the waate. if the waste is a mlxture of waste
for each of the lndhrldual WSt@StmmS.
Is the waste mked wfth other wastes?
Yes
NO
Is waste wgregatlon posalble?
Yes
No

rtrsSmr, fUI Out a *set

0
0

0
0

If yes, what can be segregated from it?

I1 no, why not?

How Is the waste generated?

0Fonnatlon and removal of an undeslrable byproduct compound

Removalof an unconverted Input materlal

0Depletionof a key component (e.g.,

0Equlpment clesnlng waste

drag.out)

Obsolete Input matertal

0Spoiled batch and productlon fun

Spill or leak cleanup

c]Evaporatlve loss

0Breathlng 01ventlng losses

0Other:

D-1 9

F a W A I h l O l l b YGllN

Waste Mlnlmlzatlon Assessment

Plant

Date

prepared By
Checked By
Sheet & of

Proj. No.

jTJ

WORKSHEET

7.

Page

- of

INDIVIDUAL WASTE STREAM

GENERATION AND CHARACTERIZATION

Management Method
Leaves rlte In

0 bulk
0 roil off blns
0 55 911 dNmS
0 other (deacrlbe)

Dlsposal Fruqwncy
Appllcabk Regulations'

Regulatory ClasslflcatloIF
~

cl onslte
0 wmmerclal TSDR
0 own TSDR
0 other (deacrlbo)

0 offsite

cl dlnct uWWII
0 combusted for energy contrnt
0 ndktllled
0 other (describe)
Reclaimed materbl mturnrd lo rlte?
Yes
NO
usodbyotlwrs

mldur ylrld
HOW

IS
the rorldue managed?

Note' llst federal, state 6 local regubtlonr, (e.g., RCRA, TSCA, etc.)
Note* llst ponlnmt m~ulatoryclasslflcatlon (eg., RCRA Llstrd KO11 waste, etc.)
TSDR Tnatmont, Storage, DlSpoMl or Rlcycllng FaClllty

D-20

C".LUI*,*-,n,,c

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Treatment

prepared BY
Checked By
S h e e t 4 of

Page

- of -

bloioglcai

0oxldatlon/reductlon
0incineration
0pH adjustment
0precipitation
soildificatlonlstablli~tion

0other (describe)

Whlch 11 al dir,

el is Involved In management of the wane or Its residue?

0bndflii
(I3 pond

0lagoon
0deep weii
0ocean
0Other (describe)
What Is tha projected date for phaslng out this disposal practice?

Costs as of

(quarter and year)

Waste MinimizationA s u m e n t

Plant

prepared By

Checked By

S h e e t 1 of

Pmj. NO.

WORKSHEET

~~

IWASTE STREAM SUMMARY I

1Page - 01

Coat of Dlsposal
U n l Cost (S per:
Overall (per year)

-Method of ManagemenP
~

Prlortty Rating Crfterla'

mttlng(~)

Rwt.
al'

RXW

mtlng(~)

mtingvt)

RXW

R ~ W

Regulatory Compliance
TreatmenVDlsposal Cost
Potentlal Llablllty
Waste Qusntlty Generated
Waste Hazard

I.

Safety Hazard

Mlnlmlzatlon Potentlal
Potential to Remove Bottlenrdc
Potential By-product Recovery

Sum of Prlorlty Ratlng Scores

Prlorlty Rank
Not.*:

1.

3.
4.

URxW

URxW

XRxW

Strum numbsrs, If.ppuUbk, should cornspond to thow u s 4 on procoSS flow dhgmnu.

For u m p k , unltuy hndflll, h.urdous wn.1.lsnd(ill, 0nr;lt. ncyck, inclrwr.tlon, .tc.
Flat. u c h strum In uch 0.1.gory on a scab hwn 0 (m)
to 10 (hlgh). Th. h l g k th.W aulgnod to a
wasts stream, th. mora of a pot.nt*l problun It Is, and th. hlghsr ths prlornv II should bs g h n tor
ImplamonUUon wn.1. Nduetlon mUsuroa
A wry Important crltarlm for your plant would rooohm a wdght of 10, a n h W y unlmpoNnt crltwla mlght bs
glwn a wdght of 2 ar 3.

D-22

F e w Y * U u l A l P YCllM

Waste Mlnlmlzatlon Assessment

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Checked By
S h e e t 1 of L Page - of -

Proj. No.

Date

WORKSHEET

Prepared BY

WASTE MINIMIZATION OPTIONS

Source reductlon and recycling options for each industrial process are ilsted below (and discussed In detail
earlier in this report). Select those that appear most promislng for your plant, and enter these on Worksheet 13.
Remember that source reduction options frequently offer both environmental and economlc advantages over

recycll ng

DPTloNS (Check those that appear promising for your plant.)

PROCESS
Casting Operations

Source Reductlon:
Alter raw materlal
Convert to inductlon furnace
Use alternate desuifurizatlon agent

Alter product speclficatlon

improve process control
Keep waste segregated
Recycilng:
Charge dust to furnace
Employ pyrometaliurglcai recovery
Employ rotary klln technology
Employ electrothennlc shaft process
Employ ITTRI process

Sell dust to cement plant

Screen metal from sand
Employ the PMET process
Employ wet washingkcrubbing
Employ dry scrubbing/attrition
,

Employ thermal reclamation

Reuse treated sand

Sell sand as flli materlal

D-23

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Waste Minlmizatlon Assessment

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S h e e t 2 of

Proj. No.

m
WORKSHEET

. --

WASTE MINIMIZATION OPTIONS

4 Page - of __

I
I

(continued)

PROCESS
Heat Treatlng

-(Check

those that appear promising for your plant.)

Source Reduction:
Alter raw material
Clean parts before treatment
Use graphite cover on cyanlde bath
~ r work
y before case hardening
Periodlcaily clean baths
Minimize dragout
Replace pot lining
Control temperature of quench bath
Recycling:
Desludge quenchant oll baths
Dewater quenchant oil baths
Ultrafliter water polymer baths

Metal Parts Cleaning and Stripping

Source Reduction:
General Operating Procedures
Process controls
Operator training
Dralnage technlques
Storage and dlstribution measures
Other
Solvents
Vapor degreaser use
Covered immerslon tanks
Dralnboard installation
Other
Material Substltution

0
0
0
0
0
0
0
0
0
0

Plant

Waste Minimization Assessment

Prepared BY
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Date

S h e e t L of A- Page

Proj. No.

Metal Parts Cleaning and Stripping

- of

Source Reduction (continued):

Aqueous Cleaners
l a n k lids

0
0

Other

Sludge removal

Abrasives
Use of water-based binders
Liquid spray abraslves
Precieaning of workpiece
Other

r-

0
0
0
0

Recycling:
Solvents
Filtration
Distillation

0
0

Abrasives
Reusable blasting media
Other
Metal Surface Treatment and Plating

Source Reductlon:
Bath Solution Waste Reduction
Dragout, spill and leak reduction

Use of ndrinse coating

0
0
0
0
0
0
0
0
U
0

Other

Efflclent drainage
Viscosity and surface tenslon control
Other
Flltration
Solution monitoring and control
Rinse System Design
Still rinse design
Counter current rinsing
Efficient drainage

D-25

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Waste Minimization Assessment

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'

Date

Proj. No.

WORKSHEET

Sheet&

of 4 Page - of

WASTE MINIMIZATION OPTIONS

(Continued)

Metal Sullace Treatment and Plating

Source Reduction (COntlflUed):

Product Substitution
Cadmium piatlng alternatives
Chromlum plating alternatives
Cyanide bath alternatives
Immiscible rlnse

0
0
0
0

Other
Recycling:
Process bath recycling
Rinsewater'recycling
Other
Other Processes

Source Reductlon:

17

0
0

0
0

Recycilng:

Good Operating Practices

Material Handling improvements

Waste stream segregation

Loss prevention practices

0
0

Preventive and corrective maintenance

Personnel Practices and Training
Management inltiatlves
Employee training
Employee incentives
Procedural Measures
Documentatlonand tracking
Storage

0
0

D-26

Waste Mlnlmlzatlon Assessment

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Date

Sheet 1_ of

Proj. No.

m
WORKSHEET

Page

- of -

OPTION DESCRIPTION

Waste Mlnlmlzatlon option name:

Brlefly descrlbe the optlon and how it mlght be of ure In and benetil your plant.

Waste Stream(s) Affected:

input Materiai(s) Affected:
~

Product(s) Affected:
lndlcate Typo:

c]Source RMuctfon
- Equlnment-RelateUChange

- PenOnnel/ProcedureRelated Change
- Mateflals43elated' Change

Date:

Orlglnally proposed by:

Revlewed by:
Approved for Study?

Date:

Yes

no,

by:

.-

Reason for Acceptance or Rejection

D-27

F o , W A U Y l O l l YCOaa

Waste Minlmlzallon Assessment

Plant

Dale

Prepared By

Proc. UniVOper.

Checked By

Pmi. No.

S h e e t 1 of

1 Page - of -

OPTIONS EVALUATION BY
WEIGHTED SUM METHOD

Crlterla
RxW

__Sum 01 Welghled Aallngs

(w X R)

__._-

optlon Ranklng
Feasibility Analysls Scheduled for (Date)

Economlc Anafysls Scheduled lor

I
F01WLh.IOI3

UCUW

Waste Mlnimlratlon Assessment

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prepared BY
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Date

Sheet

Proi. No.

WORKSHEET

16a

L of

Page

- of

TECHNICAL FEASIBILITY

WM Optlon Descrlptlon
1. Nature of WM Optlon

Equlpment-Related

0 Penonnel/PmCedure-Related
0 Materials-Related
2.

If the optlon appears technlcally feaolble, state your rationale for thls.

UNO. If yes, comlnue wlth thlr

Is further analy8ls mqulnd? U Y e a

worksheet. If not, rklp to worksheet 15.

3. Equlpment Related Optlon

YE3
Equipment avallable commerclalty?
Demonstrated commerclally?
In rlmllar appllcmlon?
Successfully?

blQ

0
0
0
0

o
n

Descrlbo closest Indudrlal maloo

oescr~brmmur ot Qevebpment

~rorprctlveVendor

Worklng Inatallstlon(8)

Contlct Penan(s)

A k a attach fllled out phone conversation notes, Installgng vlslt report, etC.

Dme contacted

Waste Mlnlmlzatlon A.ro.oment

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Page

- of

WM Optlon Deserlptlon
3. Equipment-Related Optlon (comlnued)

Performance lnformatlon requlred (descflbe parameters):

Scaleup Information requlrrd (descflbe):

Tertlng Required:
Scale:
Obench
Testunltavallable?

om
0

pllot
yea

u
n
o

no

Ton parameters (Ibt)

Number Of trSt NnS:

Amount of matorfal(s) nqulnd:
Testing lo k conductd:

:-

PlanVPmduct Constralnts:
Space Requirements
Porslble locations onslte:

-A

- -....... -.-."...-

Waste Mlnlmlzatlon Assessment

lanf

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ate

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r-J
WORKSHEET

VM Optlon Descrlptlon
1.

Equipment-RelatedOptlon (contlnued)
Utlllty Requlrements:
Electric Power

Volts (AC or DC)

Process Water

Flow

Coollng Water

Soum (tap water, demlnerallrrd, etc.)

Flow
Pressure

kW
Pressure

Temp. In

Temp. Out

CoolanVHeat Tranrlrr Fluld

Steam

Fuel

Temp. In

Tmp. Out

DW
PrOSSUun

Temp.

DutV

Flow

TYP.

Flow
OW

Plant A t

Flow

Inert Gas

Flow

Estlmated dellvety tlme (after award 01 coMraCt)

Estimated Installation time
Installatlon dates
Estlmated productlon domtlmo
Wlll productlon be o t h e m l r rffacted? Exptaln the etfect and Impact on productlon.

Will the product quallty be affected? Exphln the effect on quallty.

Checked By

Date

S h e e t 4 of

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1
7 1
-

TECHNICAL FEASIBILITY

Page

- of

Optlon Descrlptlon

3. Equlpmenl-Related Optlon (contlnued)

Will modiflcatlonsto work flow or productlon procedures be requlred? Explaln.

Rate or Frequency
of Replacement

ltem

SuppLr, Address

Does the optlon m n t govammrnt and company safety and health mqulnments?

0 yes 0 NO

Is .qulpment

Explain

r w k a 8nd 1rchnM u.IM8nca Included? Explaln

-

What warrantlei or parbnnance guamntoes are offered?

Prepared sY

Waste MinimiratlonAssessment

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Sheet & of

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m I
WORKSHEET

TECHNICAL FEASIBILITY

& Page

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WM Option Descrlption

3. Equipment-RelatedOptlon (contlnued)

Describe any addltlonai storage or material handling mquinments.

Descrlbe any addltlonai laboratory or anaiytlcal requlrements.

4.

PemonneUProcedure.Reiated Changes
Affected DepartmentsIAreas

training Requirements

Operating instmion Changes. Dercrlbe responslbb departments.

5.

Materlais-RelatedChanges (Note: If substantialchanges In qulpmant am required, then handle the

yap
tiQ
optlon as an equlpment-related om.)
Has the new material been demonrtratrd commerclaily?
in a similar appllcatlon?
Successlully?

Describe closest appiicatlon.

n .a.a

0
0
0

0
0

.c..

IO,&

yc

Iym

I Checked By
Date

Proj. NO.
WORKSHEET

16f

S h e e t 6 of 6-

Page

WM Optlon Descrlptlon
5.

Materlals-Related Changes (contlnued)

Affected DepanmentslAfeas

~~

Wlll pmductlon be affected? Explain the eflect and Impact on production.

Wlll product quallty b aflected? Explaln the effect and the Impact on product quality.

Wlll addltlonrl storage. hlridllng or other ancillary qulpmem k requlnd? Explain.

~~

Dllcrlb. m
y tralnlng or pncodure changes that am npulnd.

~~

Decribe any material testlng program that wlll be nqulnd.

- of - I

Waste Minlmizatlon Assessment

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Date

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Checked By
Sheet 1_ of

Proj. No.
WORKSHEET

Page

- Of -

COST INFORMATION

WM Option Descrlptlon

TOTALS

CAPITAL COSTS Include all costs as appropriate.

Purchased Process Equipment
Prlce (fob factory)
Taxes, lrelght, Insurance
Delivered equlpment cost
Prlce for inltlal Spare Parts inventory
Estimated Materials Cost
Plplng
Electrical
Instruments
Structural
lnsuiatlon/Plplng
Estimated Costs for Utillty Connections and New Utliity Systems
Electriclty
Steam
Cooling Water
Process Water
Refrlgeratlon
Fuel (Gas or Oil)
Plant Air
inen Gas
Estimated Costs for Addltional Equipment
Storage & Material Handling
Laboratory/AnaiyticaI
Other

0Site Preparation
(Demolltlon, site clearing, etc.)
Estimated instaliatlon Costs
Vendor
Contractor
In-house Staff

Waste Mlnlmlzatlon Assessment

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WORKSHEET

prepared BY
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- of

COST INFORMATION

TOTALS

CAPITAL COSTS (Cont.)

0Englneerlng and Procurement Costs (In-house 81outslde)

Plannlng
Englneerlng
Procurement
Consultants

0start-up costs
Vendor
Contractor
In-house

0Tralnlng Costs
0Permining costs
Fees
In-house Staff Costs

0lnltlal Charge of Catalysts and Chemicals

Item #l
Item #2

0Working Capital [Raw Materials. Product, Inventoty, Materials and Supplies (not elsewhere specified)].
Item #1

Item #2
Item #3
Item #4

0Estlmated Salvage Value (If any)

Waste Mlnlmlzatlon Assessment

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I WORKSHEET I

17c

prepared By

CAPITAL COST SUMMARY

Salvaae Value

D-37

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I WORKSHEET I

17d

Estlmated Decrease (or increase) In Utilities

utility

~ o t abi e r e a r (or Increase)

$ per time

Decrease (or Increase) in Quantity

Unit coat
$per unit

Unt per time

Electricity

Steam
Cooiino
- Prowse

Process Water
Rehlgeratlon
Fuoi p a s or 011)
Plant Air

Inert Air

INCREMENTALOPERATING COSTS

BASIS FOR COSTS

I
I

Include all relevant operating savings. Estimatethese costs on an incremental basis (Le., as decreases or increases over existing costs).

Annual-

Quarterly

-Monthly -Daily -Other-

Estimated Disposal Cost Saving

Decrease In TSDF Fees

Decrease in State Fees and Taxes

Decrease in Transportation Costs
Decrease In Onslte Treatment and Handling
Decrease in Penltting, Reporting and Recordkeeplng
Total Decrease in Dlsposal Costs

Estimated Decrease In Raw Materials Consumption

b

Mterials

1
I

I
I

U n t Cost
$ per unit

Reduction in Quantity
Unlts per time

Waste Minimization Assessment

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Sheet 5 of

Proj. No.
WORKSHEET

6 Page - of -

COST INFORMATION
(eontinuad)

Estlmated Decrease (or Increase) in Anclilary Chemicals

I
I

CatalystlChemicai

$ per unit

Decrease (or increase) in Quantity

Unit per time

Total Decrease (or increase)

t per time

c] Estimated Decrease (or increase) in Operating Costs and Maintenance Labor Costs
(Include cost of supervision, benefits and burden).

[7

Estimated Decrease (or Increase) In Operating and Malntenance Supplles end Costs.

0 Estlmated Decrease (or increase) in Insuranceand Liability Costs (explain).

c] Estlmated Decrease (or Increase) in Other Operatlng Costs (expialn).
INCREMENTAL REVENUES
Estlmated Incremental Revenues from an Increase (or Decrease) In Production or Marketable
By-products (explain).

c]

..
D-39

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1-

COST INFORMATION

Operating CostlRevenue Hem

S h e e t 6 of

6 Page - of -

5 per year

Decrease in Disposal Cost

Decrease in Raw Materials Cost
Decrease (or increase) in Utilities Cost
Decrease (or increase) in Catalystsand Chemicals
DeCr8iwe(or increase) in 0 & M Labor Costs
Decrease (or increase) In 0 & M Supplies Costs
Decrease (or increase) in insurancelLiabiiities Costs
Decrease (or increase) in Other Operating Costs
incremental Revenues from increased (Decreased) Production
Incremental Revenues from Marketable By-products
Net Operating Cost Savings

FOmWMA 128 MCill87

1 Plant

Waste MlnimkationAssessment

prepared By
Checked 0 y

Date

Sheet L of

Proj. No.

WORKSHEET

PROFITABILITY WORKSHEET # 1
Cash Flow For NPV, IRR

Total Capital investment ($) (from Worksheet 15c)

Annual Net Operating Cost Savings ($ per year) (from Worksheet 151)
Payback Perlod (in years)

Total Capital investment

Annual Net Operating Cost SaVlngS

,.

1Page - of -

waste Mlnlmlzatlon Assessment

Plant

Prepared By

Checked By

Dare

S h e e t i of _L Page

Proj. No.

m
WORKSHEET

- of -

PROFITABILITY WORKSHEET #2
CASH FLOW FOR NPV, IRR

0pontlng1Yoar

Conm.

Llno

0 CIshFlow

li.0000

10.0524 ~0.907010.6636 10.8227 10.7835 10.7462 lO.nO7 10.6768

P PWSOfIt VJIW Of WDh now'

0 No! Promnt Valua (NPW

1-

Prom! Wor!h*

6%dkount)

0.8284 0.)513 0.6630 0.6200 0.5645 0.5132 0.4665

0.7561 0.6575 0.5716 0.4972 0.4323 0.3750 0.3269

(15% dl.eOUnt)

,0.(1944 0.5787 0.4623 0.4019 0.3340 0.2791 0.2326

10.04oO )0.5120 )0.4006 10.3277 10.2621 (0.2007 10.1678

Adjust tablo as n o u w r y Itho antlclpstod p r o m N h Is h IO than or mora than 8 ywr

SIIvao. valu. Includoo scmp wluo of oqulpmont plua r h if worklng a p b l mlnw dome
Iltlonmots.
3. Tho Workshsat Io u u d for akulatlng an aftertax cash flow. For protox a s h flow, um an Income tu n t 0 of 0%.
4 Tho prownt valuo of tho cash flow Is oqusl to tho c u h flow mulplhd by tho prount Worth factor.
5 Tho not promnt wluo Io tho oum of tho promnt valuo of tho cash Row fol !hat year and 8II of tho promadlng years.
w h m n Io yooro and r Is tho discount rata.
6 Tho formula tor the promnt worth 1aMor Io
1
(1+r)"
7 Tho Intarnal rate of rotum (IRR) Is tha dlrcount rate (r) th.1 rowlts In o net prosent value of zero overtha Ilfa of the
1
2

-.-I.&

a
,
.

S".WILh.

101s YC.8ll.8

II
I

Waste MinimizationAssessment

Plant

Prepared By
Checked By

Date

Proj. No.

(WORKSHEET7

m I

Sheet 1 of 1 Page-of-

WRI

Calculation

Type of Foundry:

Baseline annual production rate (QJ in tons/year of metal product:

Waste stream measured:

Baseline waste quantity (WJ in tons/yr:

Waste reduction measures implemented:

Annual production rate after waste reduction implemented (Q):

Annual waste generation after waste reduction implemented 0:

WRI =

W/Q
- =
wb/Qb

APPENDIX E

STATUTES AND REGULATIONS

AFFECTING HAZARDOUS WASTE GENERATORS

APPENDIX E
STATUTES AND REGULATIONS AFFECTING
HAZARDOUS WASTE GENERATORS
CONTENTS

. . . . . . . . . . . . . . . . . . . . . Paqe
E-2
Generator Standasds . . . . . . . . . . . . . . . . . E-2
E.2.1
Determination of Waste Classification . . . . . E-2
E.2.2
EPA Identification Number . . . . . . . . . . . E-3
E.2.3
Uniform Hazardous Waste Manifest . . . . . . . E-3
E.2.4
Reports . . . . . . . . . . . . . . . . . . . .
E-4
E.2.5
Packaging. Labeling and Marking Requirements . E-4
Recyclable Hazardous Wastes . . . . . . . . . . . . . E-4
High BTU Wastes . . . . . . . . . . . . . . . . . . . E-4
% a b Packs88 . . . . . . . . . . . . . . . . . . . . .
E-4

Subject
E.l Introduction
E.2

E.3
E.4
E.5
E.6

E.7
E.8
E.9

. . . E-5
E.5.1
Federal Clean Water Act . . . . . . . . . . . . E-5
E.5.2
Federal Occupational Safety and Health Act . . . E-5
E.5.3
California Proposition 65 . . . . . . . . . . . E-5
Solvent Wastes: Land Disposal Restriction . . . . . . E-6
Other State and Federal Statutes and Regulations

Summaries of Pertinent Statutes. Regulations and

Ordinances

. . . . . . . . . . . . . . . . . . . . . . E-6
Regulatory Agencies and Information . . . . . . . . . E-6
TABLES

E-1
E-2
E-3
E-4
E-5

. . . . . . . . . . . . . E-7
Restricted Hazardous Wastes . . . . . . . . . . . . . . E-8
Solvent-Containing Hazardous Wastes for Which Land
Disposal Restrictions Were Proposed by EPA . . . . . . E-9
Summary of General Requirements . . . . . . . . . . . E-11
Selected Codes and Regulations Relevant to
Hazardous Waste Generation and Management . . . . . . E-13
Recyclable Hazardous Wastes

..
E-1

October 19, 1988

APPENDIX E
STATUTES AND REGULATIONS AFFECTING HAZARDOUS
WASTE GENERATORS

E.l

Introduction

California generators, transporters and treatment, storage and/or

disposal facility operators must comply with laws for handling
hazardous materials and wastes. The California Department of
Health Services (DHS) is the state agency responsible for
controlling and monitoring hazardous waste management. This
appendix will discuss some of the federal, state, and local laws,
regulations and ordinances that apply to generation,
transportation, treatment, storage, and/or disposal of hazardous
waste.
Summaries of relevant requirements appear in Tables E-4 and E-5.
Persons involved in regulated activities should become familiar
with the requirements. If needed, additional help can be obtained
from the agencies listed elsewhere in this report. Contact those
sources for details and updated information.
E.2

Generator Standards

Article 6, Chapter 30, Division 4, Title 22, California Code of

Regulations (CCR) details requirements with which all generators of
hazardous waste must ordinarily comply. These requirements include
the following:

- Determine if each generated waste is hazardous.

- Obtain an EPA

Identification Number.

- waste.
Prepare a manifest for all off-site shipments of hazardous
- activities
Prepare and submit biennial reports covering generator
of the previoua year with respect to hazardous
waste.

- hazardous
Comply with requirements for generators who accumulate
wastes outaite, pending off-site shipment within
90

days.

- hazardous
Ship hazardous wartas oif-aite within 90 days or obtain a
waste storage facility permit from DHS and comply
with other requiremente applicable to facility operators.

E-2

October 19, 1988

- with
Ensure that prior to shipment off-site, all wastes conform
DHS and Department of Transportation regulations for
proper packaging, labeling, and marking.

- Equalization
Pay applicable fees to the California State Board
for hazardous wastes generated.

of

The generator is responsible for meeting other requirements that

might not be specified in this appendix.
E.2.1

Determination of Waste Classification

The generator of a waste must determine if the waste is hazardous.

To do this, the generator must determine if the waste is specifically listed as a hazardous waste (Article 9, CCR), and/or if it
is a characteristic hazardous waste (ignitable, corrosive, toxic,
reactive) (Article 11, CCR). Certain wastes are also classified as
"extremely hazardous wastes." These are listed in Article 9, CCR
and their characteristics are identified in Article 11, CCR.
E.2.2

EPA Identification Number

Any generator of hazardous waste must obtain from EPA or DHS an EPA
Identification Number. This number must be used on all official
documents involving waste generation, transportation, treatment,
storage, and/or disposal. This number must also appear on all
required reports. A generator shall not offer his hazardous waste
to a transporter or to an operator of a treatment, storage, and/or
disposal facility who does not have an EPA Identification Number.
E.2.3

Uniform Hazardous Waste Manifest ("Manifest")

A generator who offers for transportation a hazardous waste for

treatment, storage and/or disposal off-site must prepare a manifest
before ohipping the waste off-site. The manifest is a multicopied
document that allows the generator and the DHS to track shipments
of hazardous vaste. The manifest also provides the DHS with data
on waste generation throughout the ntate.
The generator must designate on the manifest one facility which is
permitted to handle the vaste described on the manifest. A copy of
each manifest must be nent to the DHS, and another copy must be
maintained by the generator for at least three years.
The manifest includes a vaste minimization certification. "LargeQuantity" generators must certify m...that I have a program in
place to reduce the volume and toxicity of waste generated to the
degree I have determined to be economically practicable...."
(This
language appears as Item 16 on the Uniform Hazardous Waste
Manifest.) "Small-Quantity" generators must certify that they have
made good-faith efforts to minimize waste generation. The
generator must also.certity that he or she has chosen the safest
method of treatment, storage, and/or disposal.
E-3

October 19, 1988

E.2.4

Reports

A generator who ships (currently) 5 tons or more of his hazardous

waste off-site during the calendar year shall prepare and submit a
biennial report to the DHS by March 1 of each even numbered year.
The report covers generator activities with respect to hazardous
wastes during the previous calendar year. A separate report must
be sent annually to the California State Board of Equalization for
taxation purposes.

E.2.5

Packaging, Labeling and Marking Requirements for Generators

Hazardous waste must be packaged in accordance with DHS and

Department of Transportation (DOT) requirements prior to shipment
to a treatment, storage and/or disposal facility. Marking and
labeling must also be in accordance with DOT guidelines. A
hazardous waste label must be affixed to all hazardous waste
containers.
E.3

Recyclable Hazardous Wastes (Recyclable Materials)

If a hazardous waste such as a spent solvent can be recycled and

used on-site, it might be exempt from many of the above listed
requirements, as well as from DHS permit requirements. The
recycling must generally be done continuously without storing the
waste prior to reclamation. The recycled material is not considered a waste. Other conditional exemptions for recycling of
hazardous waste also exist (Section 25143.2, California Health and
Safety Code [CIi&SC]).

The DHSO regulations provide a list of recyclable hazardous wastes

waste is
and suggest methods for recycling them. If a 8*recyclable8*
disposed of, the DHS may require the generator to explain why the
waste was not recycled. The generator must respond. (See Section
25175, CHLSC and Sections 66763 and 66796, CCR).
E.4

High BTU Wastes

By 1990, any hazardous waste that is to be disposed and that has a

heating value greater than 3000 Btu/lb must be incinerated or go
through an equivalent treatment process. Also, in 1990, hazardous
wastes destined or diopoaal and containing volatile organic
compounds in concentrations exceeding standards to be determined by
DHS must be incinerated or be disposed by an equivalent treatment
process.
E.5

Lab Packs

Most laboratory-generated waste is disposed of in lab packs. Lab

packs are steel drums containing small containers of compatible
hazardous wastes. The amall containers in the drum are packaged in
chemical adsorbent. The drum is then sealea and sent to a
E-4

October 19, 1988

hazardous waste landfill. As of July 8, 1989 certain waste
chemicals in lab packs are restricted from landfills. Most of
these are listed in Table E-2.
If a lab pack includes a hazardous waste that contains any of the
elements/compounds at or in excess of any of the limits listed in
Table E-2, it cannot be disposed on land on and after July 8, 1989.
E.6

Other State and Federal Statutes and Regulations

There are many federal statutes and regulations requiring compliance. Many of these federal laws are the same as California laws.
Some of these federal and state laws are discussed below.
E.6.1

Federal Clean Water Act

The Federal Clean Water Act (CWA) mandates the establishment of

pretreatment standards for discharges to npublicly owned treatment
worksgg (POTW). Institutions that are connected to public sewers
must comply with the CWA pretreatment standards. This could result
in not allowing certain compounds down the drain even if diluted
(e.g. formaldehyde cannot be discharged to a POTW even in minute
quantities with abundant dilution).
The CWA has also established the Natibnal Pollutant Discharge
Elimination System (NPDES) program which regulates discharges to
surface waters. The California State Water Resources Control Board
and its 9 regional boards aarry out the NPDES program in
California.
E.6.2

Federal Occupational Safety and Health Act

The Federal Occupational Safety and Health Act (OSHA) and State
occupational safety laws regulate chemical handling on public and
provision requires
private locations. OSHAg8 ggRight-to-Knowgg
employers to train their employees about hazardous substances they
handle. The law applies to paid employees but not necessarily to
other individuals. The OSHA "Right-to-Known provisions (and state
"Right-to-Know" laws) have increased the awareness of chemical
hazards and they have given impetus to the creation of hazardous
waste management programs.
There is currently pending in the California Legislature a bill
called the "Student-Right-To-Know" bill which would require educational institutions to develop a safety program for students who
handle hazardous materials.
E.6.3

California proposition 65

Proposition 65 requires private employers to post warnings for

persons handling carcinogenic compounds, and restricts all
discharges of carcinogenic compounds. This i s a new law that at
E-5

October 19, 1988

preoent does not affect public institutions. However, state
legislation is pending that will require public institutions to
comply.

E.7

solvent Wastes:

Land Disposal Restriction

The 1984 Hazardous and Solid Waste Amendments (HSWA) to RCRA

mandated the November 8, 1986 federal restriction on the land
disposal of halogenated and non-halogenated solvent wastes.
Reatricted solvent wastes are numbered F001-FQ05 as defined in
Section 261.31, Title 40, Code of Paderal Regulations. On
November 7, 1986, EPA announced a conditional extension on the
implementation of the restriction. According to the modified
restriction, solvent wastes were prohibited from land disposal
starting on November 8, 1986, unless one or more of the following
conditions applies:
(1) The generator of the solvent waste is a small quantity
generator of 100-1000 kg/month of hazardous waste.
(2) The waste contains less than 1 percent total of ~ 0 0 1 - ~ 0 0 5

solvent constituents.

(3)

The solvant waste is generated due to cleanup or other remedial action taken under the Comprehensive Environmental
Response, Compensation, and Liability Act (CERCLA) of 1980, as
amended.

However, the solvent wastes listed in Items 1 to 3 above are

restricted from land disposal affective November 8, 1988.
E.8

Summaries of Pertinent Statutes, Regulations and Ordinances

Table E-5 contains a list of federal, state and local statutes,

regulations and ordinances that are relevant to hazardous waste
generators. The list includes requirements for raw material
handling, waste diaposal, air quality control, and discharges to
sewers.
E.9

Regulatory Agencies and Znformation

Appendices C through J identify the ragulatory agencies that may be

contacted with questions on the management o f hazardous wastes.
Appendix P has Form DHS 8400 ( 6 / 8 7 ) . This form can be used to
obtain copies of California hazardous waate control laws and
regulations.

E-6

October 19, 1988

TABLE E-1
RECYCLABLE HAZARDOUS WASTES
0

Commercial chemical products including unused laboratory grade

products.

Solvents, used or contaminated, including:

- perchloroethylene,
Halogenated solvents such as trichloroethane,
methylene dichloride, chloroform, carbon
tetrachloride, and Preons;

- methanol,
Oxygenated solvents, such as acetone, methyl ethyl ketone,
ethanol, butanol, and ethyl acetate: and
- Hydrocarbon
solvents, such as hexanes, Stoddard, benzene,
toluene, xylenes, and paint thinner.
0

Used or unused petroleum products, including motor oils,

hydraulic fluids, cutting lubricants, and fortified weed oils.

Pickling liquor.

Unspent acids, such as hydrochloric, hydrofluoric, nitric,

phosphoric, and sulfuric, in concentrations exceeding 159.

Unspent alkalis, including: hydroxides and carbonates of

sodium, potassium, and calcium: and acetylene sludge.

Unrinsed empty containers of iron or steel used for pesticides

or other hazardous chemicals:

- Pesticide containers; and

- Other hazardous chemical containers.

..
E-7

October 19, 1980

TABLE E-2

RESTRICTED HAZARDOUS WASTES

Concentration Limit
of Restriction
1.

Liquid hazardous wastes containing

free cyanides

2.

Liquid hazardous wastes containing

one or more of the following:

Chromium VI and/or chromium VI compounds

-> 500 mg/liter

-> 100 mg/liter
-> 500 mg/liter

Lead and/or lead compounds

> 500 mg/liter

Arsenic and/or arsenic compounds

Cadmium and/or cadmium compounds

Mercury and/or mercury compounds

Nickel and/or nickel compounds
selenium and/or selenium compounds
Thallium and/or thallium compounds
3.

Liquid hazardous wastes with a pH 188s

than or equal to 2.0

4.

Liquid hazardous wastes containing

polychlorinated biphenyls (PCBs)

5.

Liquid hazardous wastes containing

halogenated organic compounds (i.e.
chlorinat8d solvents)

E-8

-> 2 0 mg/liter
-> 134 mg/liter
-> 100 mg/liter
-> 130 mg/liter
->

50 mg/liter

October 19, 1988

TABLE E-3
SOLVENT-CONTAINING HAZARDOUS WASTES HAVING
EPA LAND DISPOSAL RESTRICTIONS

Waste code

Description

FOOl

The following spent halogenated solvents used in

degreasing: tetrachloroethylene, trichloroethylene,
methylene chloride, 1,1,l-trichloroethane, carbon
tetrachloride, and chlorinated fluorocarbons; spent
solvent mixtures/blends used in degreasing containing, before use, a total of 10 percent or more (by
volume) of one or more of the above halogen solvents
or those solvents listed in F002, F004, and F005:
and still bottom from the recovery of these spent
solvents and spent solvent mixtures.

FOO2

The following spent halogenated solvents:

tetrachloroethane, chlorobenzene 1,1,2-trichloro1,2,2-trifluoroethane, ortho-dichlorobenzene, and
trichlorofluoromethans; all spent solvent mixture/
blends containing before a total of 10 percent or
more (by volume) of one or more of the above
halogenated solvents or those solvents listed in
F o o l , F004, and F005: and still bottoms from the
recovery of these spent solvents and spent solvent
mixtures.

F003

The following spent nonhalogenated solvents: xylene,

acetone, ethyl benzene, ethyl ether, methyl isobutyl
ketone, n-butyl alcohol cyclohexanone, and methanol:
all spent solvent mixtures/blends containing solely
the above spent nonhalogenated solvents: and all
spent 8olvent mixtures/blends containing, before
use, one or more of the above nonhalogen solvents,
and a total of 10 percent or more (by volume) of one
or more of the solvents listed in Fool, F002, F004,
and F005; and still bottom from the recovery of
these spent solvents and spent solvent mixtures.

F004

The following spent nonhalogenates solvents:

cresols and cresylic acid and nitrobenzene; all
spent 8olvent mixtures/blends containing, before
use, a total of 10 percent Or more (by volume) of
one or more of the above nonhalogenated solvents or
those solvents listed in F001, P002, and FOO5; a
still bottoms from the recovery of these spent
solvents and spent solvent mixtures.
E-9

October 19, 1988

TABLE E-3 (continued)

Waste code
PO05

Description
The following spent nonhalogenated solvents:
toluene, methyl ethyl ketone, carbon disulfide,
isobutanol, and pyridine; all spent solvsnt
mixtures/blands containing, beofre use, a total of
10 percent or more (by volume) of one or more oF the
above nonhalogenatod solvents or those solvents
listed in PQQ1, PQQ2, and FQQ4; and still bottoms
from the recovery of these spent solvents and
solvent mixtures.

November 8, 1986 at

4 0 CFR

268.3Q(b).

E-10

October 19, 1988

TABLE E-4
SUMMARY OF GENERAL REQUIREMENTS
ACTIVITY

Waste
Generation

AGENCY

REQUIREPIENT

Shipments of waste must be accompanied

by a minifest.

DHS

Prepare biennial report concerning the

volume of waste generated.

DHS

If wastes are temporarily stored on

site, the generator must comply with
handling procedures, personnel
requirements, etc

DHS, county
hazardous
material
regulators

Generators disposing of "recyclable

wastesu might be asked to provide
justification or not recycling.

DHS

New Process
If the new process or process modifior Process
cation involves treatment of a
Modification; hazardous waste, a treatment, storage
Material
and/or disposal (TSD) permit might be
Substitution necessary. In some cases material
substitution may constitute process
modification.

DHS

Process must comply with fire codes

occupational health requirements.

Local fire
department,
Cal/OSHA

On-site
Treatment

In general, a treatment, storage

and/or disposal facility permit is
required. DHS may grant variances
for activities that'are adequately
rogulatod by other agencies or for
wastes that are insignificantly
hazardous.

DHS

On-site
Recycling

Same as above: however, 8ome on-site

recycling activities are catogorically
exompt from permit requiromontc.

DHS

Of f-site
Recycling

~ommorcial (i.o., off-site) recycling

activities gonerally roquire a TSD
permit.

DHS

commercial recyclers must submit an

annual facility report.

DHS

.-

E-11

October 19, 1988

TABLE E-4 (continued)
SUMMARY OF GENERAL REQUIREMENTS
ACTIVITY

REQUIREMENT
Some resource re cove^ facilities are
eligible for Series *io,
IBl, or 'C'

AGENCY
DHS

resource recovery facility permits in

lieu of TSD permits.
Disposal

In California, several classes of

DHS

hazardous waste are restricted from

land disposal.
A national land disposal restriction
program is being implemented.

EPA

Disposal facilities must have a TSD

permit and comply with technical and
financial regulations.

DHS

Air Pollution
Industrial

All devices emitting air pollutants

must be permitted or exempted.

Local APCD/
AQMD

If changes in equipment or procedures

result in an increase of any pollutant
above a specified level, a permit is
required.

Local APCD/
AQMD

If certain designated toxic air

contaminants are emitted, the
generator must comply with rules
established under the toxic air
contaminant program.

Local APCD/
AQMD

If there is an increase in an
"attainment pollutant" by a
significant apIount (generally
25 to 40 tons/yr), a permit
may be necessary.

EPA Region
IX

Water Pollution
Industrial

Discharge of industrial waste to

sewer requires a sewer permit.

Local sewer
agency

Discharge of waste to land requires

a di8chargc p8t"it.

Regional
Water Qualit]
Control Boarc

Discharge of Vasts to public waters

requires an NPDES permit.

Reg iona1
Water Qualit:
Control Boarc

E-12

TABLE E-5
SELECTED STATUTES, REGULATIONS AND ORDINANCES RELEVANT TO
HAZARDOUS WASTE GENERATION AND MANAGEMENT
Cateqory

Requlation/Rule

Air quality

SCAQMD Rule 442

SBAQMD Rule 317
MBUAPCD Rule 416
BAAQMD Regulation 0 ,
Rule 35
KCAPCD Rule 410
SLOCAPCD Rule 407 H(l)
VAPCD Rule 66

Restrict discharge of
organic materials into
the atmosphere from
equipment in which
solvents are used.

SCAQMD Rule 443

Requires coatings and

solvents to be labeled
to indicate their
photochemical reactivity.

SCAQMD Rule 1113

SBAQMD Rule 323
MBUAPCD Rule 426
BAAQMD Regulation 0 ,
Rule 3
KCAPCD Rule 4 1 0 . 1
SLOCAPCD Rule 407 H(3)

Establish VOC
standards for architectural and specialty
architectural coatings.

SCAQMD Rule 1 1 4 1 . 1

Establish operating
requirements for coatings and inks manufacturing.

BAAQMD Regulation 0 ,
Rule 5

Deals with the storage

of organic liquids.

MBUAPCD Rule 429

KCAPCD Rule 413

Deal with organic

liquid loading.

SBAQMD Rule 322

SOLCAPCD Rule 407 H ( 2 )

Prohibit photochemically reactive metal

surface coating
thinners and reducers.

SBAQMD Rule 324

KCAPCD Rule 4 1 0 . 2
BAAQMD Regulation 0 ,
Rule 39
SLOCAPCD Rule 4 0 7 H(4)

Deal with the disposal and evaporation

of solvents.

DeSCriDtiOn

E-13

Cateqory

Reuulation/Rule

DescriDtion

Solvent
storage

CCR Title 23,

Chapter 3, Subchapter 16

Addresses underground
storage of solvents.

CHLSC Division 20,

Chapter 6.7

Regulates underground
storage of hazardous
substances.

CCR

Title 22,
Div. 4, Ch. 30,
Article 24

Regulates the use

and management of
containers.

CCR Title 22,

Division 4, Chapter
30, Article 6

Sets requirements for

generators of hazardous
wastes including
restrictions on how long
wastes can be accumulated
without the storage
facility being permitted.

CHLSC Section
25123.3

mfinition of 'storage
facility", including
quality and time limits
for qualification as a
storage facility.

CHLSC Division 20
Chapter 6.95

Requires local government

agencies to implement
hazardous mat@rial management programs requiring
local businesses to submit
business plans and
inventories for the storage
and handling of hazardous
materials.

CCR

Title 22,
Division 4,
chapter 30,
section 66470 to
Section 66515

Require generators of
hazardous waste to store,
label, and manifest
hazardous wastes properly.

CCR Title 22,

Division 1,
Chapter 30,
Section 66680

Lists specific elements,

compounds, and generic
materials that are
potentially hazardous
wastes when they are no
longer useful. For
example, nsolventsllare

Hazardous
Materials
and Wastes

E-14

Category

Descrivtion

Requlation/Rule

listed as potentially
hazardous based on the
ignitability criterion.

Wastewater
discharge

40 CFR Part 268

Sets forth federal regulations that restrict the

disposal of spent solvents
and solvent-containing
wastes.

CCR Title 22,

Division 4,
Chapter 30,
Section 66693 to
Section 66723

List the criteria for

determining whether a waste
is considered hazardous or
extremely hazardous, using
criteria for ignitability,
toxicity, corrosivity, and/
or reactivity.

CH&SC Sec. 25100

to Section 25196

Identify penalties for

non-compliance with
hazardous waste control
laws and regulations.

Clean Water Act

32 U.S.C. 1251
et seq.

Water quality control for

waste water disposed in
surface waters, municipal
sewers, and injection well.

Safe Drinking
Water Act.
40 CFR 141

Water quality control or

waste water disposed in
surface waters, municipal
sewers, and injection well.

NPDES regulations
40 CFR 122

Regulations on the
reduction of pollutant
discharges into the waters
of the United States.

CCR Title 23
Subchapter 9

State regulations governing the discharge of waste

waters to surface waters.
Includes provisions or
issuance of permits and
setting effluent
limitations.

Local municipal
codes addressing
discharges to

Discharge requirements set

by local POTWs restricting
the concentrations of pollutants in waste waters
discharged to sanitary
sewers.

POTWS

E-15

Cateqory

Requlation/Rule

Waste
treatment,
recycling,
or disposal

CHhSC Section
25175

Authorizes DHS to provide

a listing o f recyclable
hazardous wastes found by
DHS to be economically and
technically feasible to
recycle. Also authorizes
fee penalties for failure
to do so, as specified.

Title 22, CCR

Section 66796

List for CH&SC Section

25175 provides a list of
recyclable wastes and
suggests methods for
recycling them.

Title 22, CCR

Section 66763
and CH&SC
Section 25175

Specifies method for

CH&SC Section 25175 if
a "recyclable" hazardous
waste is disposed,
authorizes DHS to request
that the generator
explain why the waste was
not recycled. The
generator must respond.
DHS can assess penalties
for failure to comply.

CHLSC, section
25143.2 (b),(C)
and (e)

Exempt recyclable
materials from hazardous
waste control requirements if they meet
certain conditions.

C H S C Section
25180-25196

Specifies penalties for

generator non-compliance
with the regulations.

CH&SC Sections
25180-25196

Specifies penalties for

facilities with permits,
non-compliance with the
regulations.

CHLSC Section
25155.5 (a)

Requires incineration
or equivalent treatment
of hazardous wastes
w i t h greater than
Existing
3000 Btu/lb.
law becomes effective
postponed to 1990.

E-16

Description

Cateqow

Requlation/Rule

Description
Requires incineration
or equivalent treatment
of hazardous wastes
containing volatile
organic compounds in
concentrations exceeding
standards to be
determined by DHS.
Existing law becomes
effective in 1990.

CH&SC Section

25155.5(b)

Prohibits discharge of
any liquid hazardous
waste into a surface
impoundment located
within 1/2 mile of a
potential source of
drinking water.
contains important
exemption provisions.

CHLSC Section
25200.4

Requires annual certification by hazardous waste

generators who operate
onsite TSD facilities
that they have a waste
minimization program in
operation. Further, they
must certify that the
treatment, storage, or
disposal methods minimize
threats to human health
and environment.

CHLSC Section
25202.9

CHLSC Section
25244.4

Requires generators
to submit a report
every two years on
waste reduction status.

CHLSC Section
25179.6

Would prohibit land

disposal of all
untreated hazardous
wastes with specified
exceptions. Effective
1990.

40 CFR Part 165

Recommended procedures
for the disposal and
storage of pesticides
and pesticide
containers.

.-

E-17

Cateqory

Land
disposal

Description

Recmlation/Rule
32A CFR Part 650

Hazardous and toxic

materials management
(bibliography and
tables).

CH&SC Section

specifies land
disposal restrictions.
Lists therein
restricted hazardous
wastes which include
wastes containing
more than 1000 mg/kg
of halogenated
organic compounds.

25122.7 and
Title 22 CcR
Sections 6690066935

Prohibits land disposal of bulk or noncontainerized liquid

hazardous waste or
hazardous waste containing free liquids.

40 cFR Section

264.314 (b)

RCRA Section
3004 (e)(1)

Prohibits land disposal

of most solvents unless
treatment levels (2 ppm
for most constituents)
are met.

40 cFR Section
268.3

Prohibits land disposal

of dilute waste waters
containing solvents
and having 1% or less
total organics.

4 0 cFR Section

Prohibits land disposal

of bulk or noncontainerized liquid
hazardous wastes or
hazardous wastes
containing free liquids.

265.314 and
cCR Title 22,
Div. 4, Ch. 30,
Sec. 67422
General

EPA guidelines and

standards for Paint
formulating industry.

40 CFR Part 446

E-18

Abbreviations :

-- Air
Pollution Control District
Air Quality Management District
-- Bay
Area
British thermal unit
-- California
Code of Regulations
Code of Federal Regulations
Health and Safety Code
-- California
Department of Health Services
Kern County
- Monterey
Bay Unified
National Pollutant Discharge Elimination System
-- Resource
publicly Owned Treatment Works
Conservation and Recovery Act

APCD
AQMD
BA
Btu
CCR
CFR
CHWCDHS
KC
MBU
NPDESPOTW
RCRA
SB
SC
SLOC
TSD
VOC
V

-- Santa
Barbara
South Coast
-- Treatment,
San Luis Obispo County
Storage, or Disposal
-- Volatile
Organic Compounds
Ventura

The generator should contact the appropriate local, state, or federal

authority f o r complete, detailed, and updated regulatory information.
Source:

Jacobs Engineering Group, Inc. 1987; and ESE, 1987.

..
E-19

APPENDIX F
State of Calilomia-Health and Wellare Agency
Department of Health Sewices

TOXIC SUBSTANCES CONTROL PROGRAM

ORDERING CALIFORNIA HAZARDOUS WASTE CONTROL

LAWS AND REGULATIONS
The laws (Chapters 6.5 through 6.98, Division 20, California Health and Safety Code)
were enacted by the Legislature. Recent history indicates that the laws change to
some extent each year, usually effective January first. To keep up to date with the
lam, reorder them each year because no amendment service is available.
The regulations (Chapter 30, Division 4, T i e 22. California Code of Regulations [CCR])
were adopted by the California Department of Health Services (DHS) within the scope
of DHS authority under the laws. The regulations may change at any time during
the year according to specified administrative procedures. Therefore, continuous
amendment service is available by annual subscription, but is useful only in conjunction
with the complete regulations &e., Division 4, T i e 22, CCR).
The laws and regulations are not identical. Therefore, both may be needed to obtain
complete information.
Copies of the hazardous waste control laws administered by DHS may be ordered
from the California Department of General Services, Publications Section. Copies of
the hazardous waste control regulations may be ordered from Bardays Law Publishers.
Addresses and phone numbers for each are below:

LAWS:

Department of General Services, Publications Section

P.O. Box 1015
North Highlands, CA 95660
Phone: (916) 973-3700 (Information only; NO phone orders)

REGULATIONS:

Bardays Law Publishers

File No. 42021. P.O. Box 60000
San Francisco, CA 94160-2021
Phone: (415) 244-6611

See REVERSE side for information and forms to Order both the laws and regulations.

F-1

O e ~ m m ol
t Nuh

S 01 c.Sbma

TOXIC

H d m n d W I t h n *(*y

S . N ~

SUBSTANCES C3NTRCL P R C G a M

ORDER FORM FOR CALIFORNIA HAZARDOUS WASTE CONTROL LAWS

b p i a r of the huordous wase mnml laws adminiuerd by Caidomu D.pamenf of Heakh
amplering me form b l o w and mailing it wrth the aoppliabk paymenr m:

SOnkOS

may be ordoroc by

0 . p M r of GIN^ Sarvic.r. PuMkrrians Sacacn

P.O. Box 1015
Nonh Highlands, CA 95660
PHONE: (916) 913-3700 (InfonnuPn only; NO phone ordam)

1 Pleasasandme
E W C ~ ) of Ifam No. 7540958-101S-6, Huudous Wasa ConWl Law (Chaprors 6.5 6.98.
Division 20. Hem and Wary Coda). alS25.00 per oopy. including pcmgs. taY8S. and hand- slm.

WU dudc 01 mony d e r for h. MPl MI)Mpayabla to: 5-

P. Pbru p h t o r t y p p u r M a i i d d n u and

oi California

number khw. Then sign d

du (h. bm.

ORDER FORM FOR CALIFORNIA HAZARDOUS WASTE CONTROL REGULATIONS

COpiM of the h.rprdous ww m m i rogut.ri01~dmhrktrnd b, U u Witomia D.purmem H d h SaNiOls Ud annual
amendment rNia m y k ordered by omplating (h. bnn kbw .nd maling t dilh th..ppl*pbk p8yment m:

BMjyr l a w pubtirhers
A. No. 42021. PO. Box 6o0(10

5 . n F a . c A 941#)-2021
PHONE: (415) 244-6611 (Phone ard.0 mprd)
DEOCRlPMN

NPE

OROEACODE

PRICE TAX

HINDUNO

TOTAL PRICE

APPENDIX G
TOXIC SUBSTANCES CONTROL DIVISION
REGIONAL OPERATIONS

GA

VII. REOIONAL OPERATIONS MAP:

Rqim 3
1405 N. San Femando BM.
Suke 300
Burbank. CP. 91504
181E) 567-3003

WHERE TO GET HELP:

C A L I F O R N I A STATE AGENCIES

AIR RESOURCES BOAR0

EWERCENCY SERVICES
S p i l l s (24-hour)
Emergency Planning

1102 a S t r e e t
Sacramento, CA 95814

800/8S2-7550
916/427A287

916/322-2990

HEALTH SERVICES
Toxic Substances Control

I n f o n a t ion
EPA I O number
Hanifest
O i l (Used) ReryclinaHazardous Waste
Exchange
Recyc?ing
Transport

LOCAL AGENCIES

AIR QUALITY EIAINTENANCE DISTRICTS

1: Bay Area

2: Lake County
3: b r t h Coast Unfd

4: Northern Sierra
5: Shasta Cotnty
6: South Coast

A151771-6000
.
. . . ...~
707/26?-7000
707/443-3093
916/265-1398
916/225-5674
818/572-6200

HIGHWAY PATROL
Transport

916/327-3310

916/3 24-1781
916/324-1781
916/324-1807
1020 Ninth S t r e e t , 1300
Sacranento, CA 95814
916/322-3330

916/324-1807
916/324-1807
916/324-2430

O i l (Used) Recycling 800/553-2962

Reqional Offices

WATER RCWIJRCfS CONTROL BOARD

901 P S t r e e t
Sacr&ento, CA 95814
916/322-3132

Hater auaiity
vlderground Tanks

916/445-9552
916/324-1262

WATER QUALITYCONTROL 8OARDS

Region 1, TSC
4250 Power Inn Road
Sacranento, CA 95826
(916) 739-3145

Region 1, TSC*
5545 East Shields Avenue
Freano. CA 93721
(209).445-5938

Region 1
Region 2
Region i
Region 4
Re ion 5
?sacranento)
(Fremo)
(Reddim)

Re

ion 6

qSouth Lake Tohoe)

(Victorvilla)
Region 7
Region E
Region 9

Region 2, TSC
5850 Shellmound Blvd, 6390
Berkeley, CA 94608
(415) 540-2043

Region 3, TSC
1405 North Sen Fernando Blvd.
Burbank, CA 91504
(818) 567-3000
Region 4, TSC
245 West Broadway, 1360
Lon Beach, CA 90802
q21.3) 590-.

4868

707/576-2220
415/46&1255
805/549-3147
213/6204460
916/361-5600
2091445-5116
916/ 224-4845
916/54&3481
619/241-6583
619/346-7491
714/7824130
619/265-5114

AIR POLWTIM CONTROL OISTRICTS

209/223-6406
h d 0 r Comty
Wltte county
916/891-2882
Calaveras Comty
209/754-6460
Coluaa County
9161458-5891
E l Dorado Cotnty
916/621-5897
F r R M O County
209/445-3239
Glenn Comty
916/ 9 3 4 4 5 1
7: Crest Basin v l f d 619/872-8211
Imperial Comty
619/3394>14
Kern County
805/861-3682
Kings C o t n t y
209/584-1411
Lasaen County
916/257-8311
M&ra Comty
209/675-7823
Mariposa County
209/966-3689
Mndodno Comty
707/4634354
Merced County
209/385-7391
b d o c Comty
916/233-3939
8: b n t e r e y Boy (hfd 408/442-1135
NDrthern h n m
707/433-5911
916/889-3159
Placer County
916/386-6650
Sacrsnanto C o m t p
San Bernsrdino Cnty 619/243-8200
5.n Oiego Cotnty
619/694-1307
San Joaquin County 209/460-3473
5.n L u i s b i s p o Cnty 805/549-5912
5.nts Barbara County 805/9674872
Siakiyou Cotnty
916/842-8029
St anisl a u s County
209/5254152
916/741-7500
Sutter C o d y
l e h a County
. 916/527-4%4
1ularc comty
209/73F6438
Tuolumne County
209/533-5693
805/654-2667
Ventura C o d y
Yolo-Solano County 916/666-8146
Yub. Comty
916/741-6484

* S u r v e i l l a n c e , enforcement, s i t e
mitigation only.

*Environaental Management Dirt.

p.3

."On

U. 5. OEPARTWNT Of TRANSPORTATIOH

WHERE TO GET HELP:

Information Ibtlinc: 202/366-4488

Southern California: 818-405-7110
Northern California: 916/551-1300

FEDERAL AGENCIES

u.
T h e U. S. E n v i r o n m e n t a l
Protection Agency has written s e v e r a l r e p o r t s which
will help you r e d u c e , r e c y c l e or reuse h a z a r d o u s
waste.

U. S. PUBLIC HEALTH SERVICE

5. COAST CWJU)

National Health Information

National Response Center

800/3364797

800/42*-0802

U. 5. WIROWNTAL PROTECTION AGENCY

You can order t h e following

set f o r $152 f r o m t h e Na-

tional Technical Information

S e r v i c e , Springfield, Virginia. 22161 (703/ 4874650). The order number is
PB87-114328.
Volume 1 is
t h e E x e c u t i v e Summary &
Fact Sheet.
M i n i m i z a t i o n of Hazardous Waste, Vols. 1-5.
You can order t h e following

t h r e e Waste Minimization
Audit R e p o r t s f r o m NTIS.
O r you c a n o r d e r t h e executive summaries from
EPA/ATD/HWERL, 26 West
St. Clair Street, Cincinnati,
Ohio, 45268.

Case Studies o f Corrosive

a n d H e a v y M e t a l Waste
M i n i m i z a t i o n A u d i t at a
S p e c i a l t y Steel Manufactrtring C o m p l e x , (NTIS
PB88-107180/GAR).
.

Case Studies of Minimizat i o n of S o l v e n t Waste

f r o m Parts Cleaning and
f r o m Electronic Capacitor
Manufacturing Operations,
(NTIS PB87-227013).
C a s e Studies of Minimizat i o n of C y a n i d e Wastes
f r o m Electroplating OperPB87ations,
(NTIS
229662).

You'll f i n d EPA (and other)

offices listed to t h e right.

Region 1
John F. Kennedy Building
Boston, MA 02203
617/56 5-371 5

Region 3

Region 2

26 Federal Plaza
New York, NV 10278
212/264-2525

Region 4

841 Chestnut Street

Philadelphia, PA 19107
21 5/597-9800

345 Courtland Street

Atlanta, u\ 30365
4W/3474727

Region 5
230 South Dearborn Street
Chicago, IL 60604
312/35>200

Region 6
1445 Ross AVSNJS
Callas, TX 75202
214/655-6444

Region 7
726 Minnesota Avenue
Kanssa C i t y , KS 66101
913/236-2800

Region 8
999 Eighteenth Street
b n v e r , CO 80202
303/293-1603

Region 9..

Region 10
1200 Sixth Avewe
Seattle. WA 98101
206/442-5810

(see next page)

EPA Hotlines

800/42&9346
RCRA/Suprfmd:
h a l l Business hbudman: 800/368-5088
800/535-O 202
Title 1x1:

f'-

- ;

ENVIRONMENTAL
.--_
".
REGION
9
PHo-N-EDlREc~oR-~--

_.._"._.*

"...^

APPENDIX H

CALIFORNIA REGIONAL. WATER

QUALITY CONTROL BOARDS

STATE WATER RESOURCES CONTROL BOARD

P. 0 . Box 100, Sacramento, CA 95801

CALIFORNIA REGIONAL WATER QUALITY CONTROL BOARDS

NORTH COAST REGION (1)
1440 Guemeville Road
Santa Rosa, CA 95403
(707)576-2220
SAN FRANCISCO BAY REGION (2)
1111 Jackson Street, Rm. 6040
Oakland, CA 94607
(415) 464-1255

CENTRAL COAST REGION (3)

1102-A Laurel Lane
San Luis Obispo, CA 93401
(805) 549-3147
LOS ANGELES REGION (4)
107 South Broadway, Rm. 4027
Los Angeles, CA 90012
(213) 620-4460
CENTRAL VALLEY REGION (5)

F n s m Bmchofficr
3614 East Ashlan Ave.

LAHONTAN REGION (6)

2092 Lake Tahoe Boulevard
P.O.Box9420 .
South Lake Tahoe, CA 95731
(916) 544-3481
VMorvllk Bnnch Office
15371 Bonanza Road
Victorville, CA 92392
(619) 241-6583
COLORADO RNER BASIN
73-271 Hihway 111, Sle. 21
Palm Desert CA 92260
(619) 346-7491
SANTA ANA REGION (8)

SAN DIEGO REGION (0)

9771 Clairemont Mesa Blvd. Ste. B
San Diego, CA 92124
(619)265-5114

H-2

APPENDIX I

FEDERAL AND STATE AGENCIES

FEDERAL AND STATE AGENCIES

Federal
U.S. Environmental Protection Agency

RCRA/Superfund Hotline
Title I11 Hotline
Small Business Ombudsman Hotline

U.S. Department of Transportation

Information Hotline
Southern California (El Monte)
Northern California (Sacramento)

U.S. Coast Cuard/National Response Center

U . S . Public Health Service. National Health

Information Clearinghouse
QShL

Chemical
CHEMTREC
CHEMTREC
National
National

Manufacturers Association
(transportation accidents)
(non-emergencies)
Pesticide Telecom Network 800-858-7378
Animal Poison Control Center

aoo-424-9300
202-aa7-1255
217-333-3611

California Department of Health Sewices

Used Oil Recycling and Roylatory Information
Manifest and EPA Idontification Number Information
Recycling of Hazardous Wasto.
Northern California Soction
North G o u t California Section
Southern California Soction
Frerno D i 8 t r i C t Office
Transportation Unit

916-324-ia07
916-326-17ai
916-324-1807
916-739-3145
415-540-2043
213-620-2380
209-445-593a
916-323-6042

Office of Emergency Sowices

24-Hour Number for Reporting S p i l l s / R e l e a s o r
Hazardous Materials/Emergency Resporue Planniry

uoo-a52-7550
936-427-4287

California State Water Rosources Control Board

Water Quality Division
Underground Tank Program

916-445-9552
916-324-1262

1-2

FEDERAL AND STATE AGENCIES (CONT)

California Waste Management Board

General Informacion on Solid Waste
Used-oil Recycling Center Locations

916-322-3330
800-553-2962

California Highway Patrol/Motor Carrier Section

916-U5-6211

California Local Air Pollution Control Discriccs

Amador County-APCD (Mountain Counties)
Bay Area AQMD (San Francisco Bay Area)
Butte County APCD (Sacramento Valley)
Calaveras County APCD (Mountain Counties)
Colura County APCD (Sacramanco Valley)
El Dorado County APCD (Lake Tahoe and Mountain Counties)
Fresno County APCD (San Joaquin Valley)
Glenn County APCD (Sacramento Valley)
Great Basin Unified APCD (Great Basin Valleys)
Imperial County APCD (Southeast Deserr)
Kern County APCD (San Joaquin Valley and Southeast Desert)
Kings County APCD (San Joaquin Valley)
Lake County AQMD (Lake County)
Lassen County APCD (Northeast Plateau)
Hadera County APCD (San Joaquin Valley)
MaripOSA County APCD (flountain Counties)
Mendocino County APCD (North Coast)
Merced County APCD (San Joaquin Valley)
Modoc County APCD (Northeast PhtOAU)
Montery Bay Unified APCD (North Central Coast)
Mountain Counties Air Basin
North Coast Unified AQHD (North Coast Air Basin)
Northern Sierra AQMD (Mountain Counties A i r Basin)
Northern S o n o m County APCD (North Coast)
Placer County APCD ( k l w Tahoe, Mountain Counties. and Sacramento Valley)
Sacramento County APCD (Sacramento Valley)
San Bernadino County APCD (Southeast Desert)
San Diego County APCD (San Diego)
San Joaquin County APCD (San Joaquin Valley)
San Luis Obispo County APCD (South Central Coast)
Santa Barbara County APCD (South Central Coast)
Shasta County APCD (Northeast Plateau and Sacrunento Valley)
Siskiyou County APCD (Northeast Plateau)
South Coast AQkD (South Coast)
Stanislaus County APCD (San Joaquin Valley)
Sutter County APCD (Sur Joaquin Valley)
Tehama County APCD (Sacramento Valley)
Tulare County APCD (San Joaquin Valloy)
Tuolunme County APCD (nounuin Countla.)
Ventura County APCD (South Central Coast)
Yolo-Solano APCD (Sacramento Valley)
Yuba County APCD (Sacramento Valley)

1-3

APPENDIX J
ACRONYMS

J-1

APPENDIX J
ACRONYMS
AMs
BOD

CAC
CFR
CHSC

co2
CVD
DI
DOHS
EPA, USEPA

GRAS

IE
NPDES
PCE
POTW
RCRA

RP
SAB
SARA

SIC
1,l.l TCA, or TCA
TCE
TSD
TSDR
USC

WM

American Society
Biological Oxygen Demand
California Ad"ative
Code
Code of Federal REgulations
California Health and Safety Code
Carbon Dioxide
Chemical Vapor Deposition
Deionized
California Department of Health SeMces
United States Environmental Protection Agency
Generally Recognized as Safe
Ion Exchange
National Pollution Discharge Elimination System
Perchloroethylene
Publicly Operated Treatment Works
Resource Conservation and Recovery Act
Reverse Osmosis
Science Advisory Board of the EPA
Superfund Amendments and Reauthorization Act
Standard Industrial Classification
1.1.1 Trichloroethane
Trichloroethylene
Treatment, Storage and Disposal Facilities
Treatment, Storage, Disposal, and Recycling Facilities
United States W e
..
waste MlnlmKation

J-2

APPENDIX K

WASTE REDUCllON INDEX

1.

A waste reduction index (WRI) can be calculated for any or all of the following:

a.
b.
c.

for a given segregated hazardous waste, WRI,

for a given generator and location, WRI,
for the industry as a whole, WRI,

2.

Where a generator has only one wastestream, WRI, = WRI,

3.

The WRI used for a generator's waste audit program can be WRI, and/or WRI, as
appropriate.

4.

A WRI as calculated spans a specific time period, such as monthly or quarterly, but no

longer than annually.

5.

WRls can be calculated at the ends of successive time intervals into the future, to
monitor the progress of a generator's waste reduction program over each of these time
intervals.
The intervals can each be monthly, quarterly, annually, biannually, or longer. The
calculated WRls can be plotted over time to compare to the WRls of other generators,
or to compare to the WRls for the industry.

6.

The WRI is calculated as follows:

a.

Select an activity measure, Q, that correlates closely with hazardous waste

generation, W, and that is readily measurable.
Q = measure of productive activily that generates the hazardous waste(s) during

the specified time period. This measure varies with the industry. Examples are:
1.
2.

3.
4.

automotive repairs - labor hours worked

electroplating - electrical power consumption
formulators - gallons of product formulated
photofinishing square feet of film and prints processed

W = quantity of hazardous waste generated during the specified time period.

b.

Set a baseline time period as a reference for the WRI. Usually this is the first
time period In which a reliable value of Q and W are each available. These then
are Q and W.
Then WRI =

w/Q

"''doe

..
K-1

c.

Note that for the baseline period, WRI, = 1.00 by definition.

d.

Note that when the ideal of zero waste generation is reached, WRI = 0.00 by
definition.

K-2