Office of Air Quality Planning and Standards Email: chin.conrad@epa.gov

1. U.S. Iron and Steel Foundry Industry Characterization and National Emission Standards for Hazardous Air Pollutants for Iron and Steel Foundries (Major and Area sources)美國鋼鐵鑄造行業描述及其有毒有害空氣污染物排放的標準 (包括主要源和面源標準) Office of Air Quality Planning and Standards Email: chin.conrad@epa.gov Conrad Chin 美國環保局錢啟祥 June 2010 Taiwan

2. U.S. Iron and Steel Foundries Background Information美國鋼鐵鑄造廠背景 • 美國大約有500家鋼鐵鑄造廠 Approximately 500 iron and steel foundries in the US • 大約 100家鑄造廠是”主要”源 About 100 foundries are “major” sources • “主要”源指的是一種有毒空氣污染物的每年排放量是10噸或更多, 或多種有毒空氣污染物的每年總計排放量是25噸或更多。A major source is one that has the potential to emit 10 tons or more per year (tpy) for a single hazardous air pollutant (HAP) or 25 tpy or more for combined HAP • 大約 400家鑄造廠是”面源” About 400 foundries are “area” sources • “面源”是一種有毒空氣污染物的每年排放量在10噸以下，或多種有毒空氣污染物的每年總計排放量在25噸以下。Area sources are those with potential to emit less than 10 tpy for a single HAP or less than 25 tpy for combined HAP

3. 鑄造廠定義 What is a Foundry? • 設施或部分設施用已熔化生鐵,廢鋼,鋼錠,和/或其他形式的鐵和/或鋼。 Facility or portion of facility that melts scrap, ingot, and/or other forms of iron and/or steel. • 然後把所產生的熔化金屬液體倒入砂模中 。震動分模(翻覆砂模取出鑄件)。 Facility pours the resulting molten metal into molds. Mold sand shakeout operations.

4. 金屬鑄造廠（常規污染物排放量每年大於 250噸） 臭氧不合格地區PM2.5的不合格地區

5. 金屬鑄造廠（所有設備） 臭氧不合格地區PM2.5的不合格地區

6. 鑄造空氣污染排放來源 Foundry Emissions Points • 熔煉爐Melting furnaces • 沖天爐（僅用於鑄鐵）Cupolas (used for iron foundries only) • 電弧爐Electric arc furnaces (EAFs) • 感應電爐和廢料預熱器Electric Induction furnaces (EIFs) and scrap pre-heaters • 澆鑄成形 Metal casting • 澆注，冷卻，震動分模Pouring, cooling, shake-out (PCS) • 鑄件砂模, 制芯生產Production of casting molds and cores • 其他方面(廢料處理和打磨, 廢鋼預熱器, 落砂和舊砂再生)Other miscellaneous emission points (scrap handling and finishing operations, scrap pre-heaters, sand reclamation ) • 逸散Fugitive emissions from foundry operations.

7. 排放特色Emission Characteristics • 熔煉爐是有毒金屬污染物（如錳，鉻，鉛和鎳）的主要排放來源Melting furnaces are the primary emissions sources of metal HAP such as Mn, Cr, Pb, and Ni • 這些空氣污染物危害工人和工廠附近的居民的健康 These HAP are known to cause adverse health effects to workers and residents near the foundries • 在美國，許多鑄造廠都在市區In the US, many foundries are located in urban areas • *許多鑄造廠是鉛排放的重要來源Many foundries are known to be significant Pb emitters* • 感應電爐比電弧爐或沖天爐排放污染比較小 EIFs have much lower emissions than EAFs or cupolas • 結果，大約 75％的感應電爐都沒有污染防治設備。Consequently approximately 75% of EIFs are uncontrolled * 美國新國家環境空氣質量標準規定鉛的排放超過一噸要進行監測。 The new lead NAAQS requires minimum of 1 monitor for sources emitting 1 tpy or more

8. 美國大多數鑄造廠在市區 Many US Foundries are in Urban Areas • 最近美國媒體報導許多學校周圍的有毒空氣污染嚴重 A recent USA Today study found elevated levels of air toxics around many schools • 加州伯克利一所學校，距離一所鑄鋼廠只有一英里，排放錳,鎳，鉻和其他重金屬。A school in the Berkeley, CA area is located within a mile of a Pacific Steel Castings facility, which releases manganese, nickel, chromium and other heavy metals

9. 美國今天的專題報告: “空氣污染和美國學校”

10. 典型的鑄鐵廠有毒有害氣體排放概況 Typical Iron Foundry HAP Emission Profile

11. "Other Chemicals" are TRI chemicals which are not classified as CAA Air Toxics. Source: U.S. EPA, TRI, 2003. 2003年鋼鐵鑄造廠空氣排放物 Before Toxicity Weighing 毒性稱重前 有毒金屬污染物13％ 有毒空氣污染物81％ 有機物 85％ 其他化學物質 19％ 其他有毒空氣污染物小於 2％ 11

12. 2003 年鋼鐵鑄造廠空氣污染物 After Toxicity Weighing (Risk Drivers) 毒性稱重之後（風險驅動） 有毒金屬 98％ 有毒空氣污染物93％ 其他化學物質 7％ 有機物 2％ 12

13. 熔爐污染排放控制Furnace Controls • 熔鐵爐 Cupolas • 大部分裝有袋式集塵器或濕洗滌塔 Mostly equipped with baghouses or wet scrubbers • 電弧爐 Electric arc furnaces (EAFs) • 大部分裝有袋式集塵器 Mostly equipped with baghouses • 感應電爐 Electric induction furnaces (EIFs) • 部分裝有袋式集塵器或濕洗滌塔 Some are equipped with baghouses or wet scrubbers • 許多是沒有排放控制設備 Many are uncaptured and uncontrolled • 袋式集塵器室是粒狀污染物或金屬空氣污染物的最好控制技術。 A baghouse is the best available control technology for PM or metal HAP emissions for all three types of furnaces • 控制粒狀污染物是通常代替控制金屬空氣污染物的方法 Control of PM is often used as a surrogate for control of metal HAP

14. 對非熔爐來源的排放控制Controls for Non-furnace Sources • 用火炬以控制從熔鐵爐排放的揮發性有機物 Afterburners for cupolas (VOC) • 用於酚醛聚氨酯冷盒系統的三乙胺除塵器（三乙胺排放物） Triethylamine (TEA) scrubbers for phenolic urethane coldbox systems (TEA emissions)

15. 美國鑄造行業空氣污染物排放標準制定歷史History of US Regulations on Foundries • 美國環保署已經發布了三個關於鑄造廠空氣污染物的排放標準。US EPA has issued three air toxic regulations on foundries • 鋼鐵鑄造廠主要源參照條款 5E號（2004年4月公布)Subpart 5E for major iron and steel foundries (April 2004) • 鋼鐵鑄造廠面源參照條款 5Z（2007年12月公布)Subpart 5Z for area iron and steel foundries (December 2007) • 鋁,銅和其他有色金屬鑄造廠面源參照條款 6Z（2009年6月公布)Subpart 6Z for area source aluminum, copper, and other nonferrous foundries (June 2009) • 主要源的排放標準需在法規公佈日8年後進行殘餘風險評估（預期 2012年）Major source regulations are required to conduct the residual risk reviews eight years after promulgation (due 2012) • 主要和面源的排放標準都需在公佈日起每八年進行一次技術評估。Both major and area source regulations are required to conduct the technology reviews every eight years after promulgation

16. 鑄造廠已制定的排放標準及法規遵守日期 Completed Foundry Regulations and Compliance Dates

17. 鑄造廠主要源排放標準需求Major Source Foundry MACT(EEEEE) Requirements • 原廢料檢測或證明Scrap inspection or certification • 熔爐和澆注之粒狀污染物或金屬空氣污染物的排放限制PM or metallic HAP limits for melt furnaces and pouring operations. • 廠房逸散不透光率控制在20％或以下Facility fugitive emission limit of 20% opacity. • 針對廢料預加熱器揮發性有機物排放限制VOC limits for scrap pre-heaters. • 冷芯盒造型制芯線三乙胺限制TEA scrubber limits • 工作習慣Work practices • 原廢料檢測 (不含氯塑料, 機油濾清器等)/汽車汞開關拆除Scrap inspections/mercury switches removal • 排放捕獲效率Capture efficiency • 監督,測試,記錄和報告需求Compliance monitoring, testing, recordkeeping and reporting. • 運行及維護,啟動,停止,故障處理O&M Plan, Startup Shutdown and Malfunction Plans.

18. 排放限制標準或工作運行管制 Emissions Limit or Work Practice Standard for Regulated Sources * 1 gr = 64.8 mg; 1dscf = 0.0283m3; 1 gr/dscf = 2288 mg/m3

19. 排放限制標準或工作運行管制轉成公制Emissions Limit or Work Practice Standard for Regulated Sources Converted to Metric System

20. 排放限制標準或工作運行管制Emissions Limit or Work Practice Standard for Regulated Sources (Cont’d) * 需要捕獲系統 Requires capture system

21. 排放限制標準或工作運行管制Emissions Limit or Work Practice Standard for Regulated Sources (Cont’d) 21 * 需要捕獲系統 Requires capture system

22. 原材料（廢料) 遴選要求Raw Materials (Scrap) Selection Requirements • 只購買和使用認證的金屬錠, 生鐵，或其他不包括廢汽車車身廢料，或廢汽車發動機, 機油濾清器, 鉛成分,汞開關, 塑料, 或有機液體 Foundry should purchase and use certified metal ingots, pig iron, or other materials that do not include automobile body scrap, engine blocks, oil filters, lead components, mercury switches, plastics, or organic liquids. • 鑄造廠也可以按照材料說明書購買廢料 Alternatively, foundry can prepare and operate a written material specifications for the purchase of scrap • 鑄造廠如果使用廢汽車廢料，需要從合格的供應商處購買，保證汞開關已拆除 Foundry using scrap from motor vehicles should purchase from certified providers, certifying the removal of mercury switches

23. 運作和維修要求 Operation and Maintenance Requirements • 建立收集體系的操作限制或參數 Establish operating limits or parameters for capture systems • 建立控制濕洗滌塔的壓降和水流速度運行參數 Establish wet scrubber pressure drop and water flow rate operating parameters for PM control • 建立燃燒設備燃燒帶最低溫度用以控制沖天爐, 廢料預熱器, 或三乙胺冷芯盒模型或制芯線所排放的揮發性有機有害空氣污染物 Establish minimum combustion zone temperature for combustion device to control VOHAP from cupola, scrap preheater, or TEA cold box mold or core making line • 設濕法酸性洗滌塔的最大的pH值用以控制三乙胺Establish maximum pH for wet acid scrubber to control TEA emissions

24. 其他要求 Other Requirements • 捕獲系統每月檢測Monthly inspections of the capture system • (壓力敏感器，節氣閘和節氣閘開關) (pressure sensors, dampers, and damper switches) • 袋式集塵器系統的定期檢測 Periodic inspection of the bag leak detection system (for baghouses) • 每日檢查控制設備操作參數（集塵器和濕式洗滌器） Daily inspection of operating parameters of control devices (baghouses and wet scrubbers) • 監督要求 Monitoring requirements • 性能測試 Performance testing • 通知要求 Notification requirements • 報告要求 Reporting requirements • 記錄保存要求 Record keeping requirements

25. 鑄造廠(面源)的要求（ZZZZZ） Area Source Foundry Requirements (ZZZZZ) • 面源 Area sources • 超過 75％的面源鑄造廠是小規模的 Over 75% of the area source foundries are small businesses • 70％的鑄造廠在市區 70% of the foundries are in urban areas • 大小型鑄造廠 Large and small foundries • 大小型鑄造廠選用不同排放標準 Different standards apply to large and small foundries • 大型鑄造廠(現有源)定義為年金屬熔煉產量大於 2萬噸，或大於 1萬噸(新源)A large foundry has an annual metal melt production greater than 20,000 tons for an existing source or production greater than 10,000 tons for a new source. • 小型鑄造廠 (現有源)定義為年金屬熔煉產量小於 2萬噸，或小於 1萬噸(新源)A small foundry has an annual production less than 20,000 tons for existing source or less than 10,000 tons for a new source.

26. 面源鑄造廠要求Area Source Foundry Requirements (ZZZZZ)- Cont’d • 針對小型鑄造廠的要求 Requirements for small foundries • 污染防治管理 Pollution prevention management practices • 廢料規定和檢測 Scrap specification and inspection • 汞開關移除 Mercury switch removal • 粘結劑規定 Binder formulations • 通知要求 Notification requirements • 記錄保存要求 Record keeping requirements

27. 面源鑄造廠要求Area Source Foundry Requirements (ZZZZZ)- Cont’d • 大型鑄造廠要求 Requirements for large foundries • 污染控制管理 Pollution prevention management practices • 熔爐排放限制 Emission limits for melt furnaces • 每噸金屬熔煉可以排放0.8磅粒狀污染物(現有源標準) 0.8 pounds of PM per ton of metal charged (existing) • 每噸金屬熔煉可以排放0.1磅粒狀污染物(新源標準) 0.1 pounds of PM per ton of metal charged (new) • 逸散 (廠房建築不透光率不超過 20％)Fugitive emissions (20% building opacity) • 監督要求 Monitoring requirements • 性能測試 Performance testing • 通知要求 Notification requirements • 記錄保存要求 Record keeping requirements

28. 環境效益 Environmental Benefits • 估計美國鑄造廠每年排放大約 400噸的有毒金屬空氣污染物 It is estimated the US foundries emit approximately 400 tons of metal HAP per year • 主要和面源規定實現了每年減少 134噸的有毒空氣排放物 The major source and area source rules achieved reductions of 134 tons per year • 有許多鑄造廠在市區 Many of these sources are in urban areas

29. For More Information:Conrad Chin, 919-541-1512, chin.conrad@epa.gov