NFR: 2.C.2 Ferroalloys production SNAP: Ferroalloys ISIC: Version Guidebook 2009

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1 2.C.2 Ferrallys prductin Categry Title NFR: 2.C.2 Ferrallys prductin SNAP: Ferrallys ISIC: Versin Guidebk 2009 Crdinatr Jeren Kuenen EMEP/EEA emissin inventry guidebk

2 2.C.2 Ferrallys prductin Cntents 1 Overview Descriptin f surces Prcess descriptin Techniques Emissins and cntrls Methds Chice f methd Tier 1 default apprach Tier 2 technlgy-specific apprach Tier 3 emissin mdelling and use f facility data Data quality References Pint f enquiry...7 EMEP/EEA emissin inventry guidebk

3 2.C.2 Ferrallys prductin 1 Overview Ferrallys are master allys cntaining irn and ne r mre nn-ferrus metals as allying elements. The ferrallys are usually classified in tw grups: bulk ferrallys (prduced in large quantities in electric arc furnaces), and special ferrallys (prduced in smaller quantities, but with grwing imprtance). Bulk ferrallys are used in steel making and steel r irn fundries exclusively, while the use f special ferrallys is far mre varied. In ttal, 86.7 % f the ferrallys prduced are used in the steel industry (Eurpean Cmmissin, 2001). Emissins frm the prductin f ferrallys are nt cnsidered significant, since the cntributin t the ttal natinal emissins is thught t be insignificant, i.e. less than 1 % f the natinal emissins f any pllutant. Hwever, this versin f the Guidebk des prvide default emissin factrs fr this surce categry. The present chapter prvides a very simple prcess descriptin and a Tier 1 apprach t estimate emissins frm this surce categry. 2 Descriptin f surces 2.1 Prcess descriptin Prductin f ferrallys generally invlves the use f electric arc furnaces and reactin crucibles int which natural prducts (e.g. quartz, lime, varius res, wd etc.) with relatively fluctuating physical cmpsitins are laded. Due t this, the main envirnmental impact f prducing ferrallys is the emissin f dust and fumes frm the smelting prcesses. 2.2 Techniques Depending n the raw material that is used (primary r secndary raw material) the prductin f ferrallys can be carried ut as a primary r secndary prcess. The principal chemistry f bth prcesses is shwn in Figure 2.1. EMEP/EEA emissin inventry guidebk

4 2.C.2 Ferrallys prductin Oxidic metal re Irn re / scrap Reductant Primary Prductin Prcess Ferr-ally Reductant xide Slag Fuel Irn scrap Metal scrap Secndary Prductin Prcess Ferr-ally Figure 2.1 Simplified prcess scheme fr primary (tp left) and secndary (bttm right) prductin f ferrallys The primary prcess can be either carb-thermic f metall-thermic reductin f xidic res r cncentrates. In the carb-thermic reductin (the mst imprtant prcess), carbn in the frm f cke (metallurgical cke), cal r charcal is used as the reducing agent. When a blast furnace is used, cke is als needed as an energy surce. T accunt fr this, the prcess scheme als cntains a fuel input and cmbustin emissins utput. Metall-thermic reductin is mainly carried ut with either silicn r aluminium as the reducing agent. 2.3 Emissins and cntrls Dust emissins als ccur frm strage, handling (chapter 2.C.5.e) and the pre-treatment f raw materials where fugitive dust emissins play an imprtant rle. Depending n the raw material and the prcess used, ther emissins t air are sulphur dixide (SO 2 ), nitrgen xides (NO x ), carbn mnxide (CO), carbn dixide (CO 2 ), plycyclic armatic hydrcarbns (PAHs), vlatile rganic cmpunds (VOCs) and vlatile metals. The frmatin f dixins in the cmbustin zne and in the cling part f the ff-gas treatment system may be pssible. Heavy metals are carried int the prcess as trace elements in the raw material. Part f the heavy metals will escape as metal vapur. This prcess depends heavily n the type f ferrally prduced and the temperature f the smelting prcess. A lt f infrmatin n the prcesses and techniques used in the prductin f ferrallys can be fund in the Best Available Techniques Reference (BREF) dcument n nn-ferrus metal industries (Eurpean Cmmissin, 2001). EMEP/EEA emissin inventry guidebk

5 2.C.2 Ferrallys prductin This chapter nly cvers the prcess emissins frm ferrallys prductin. The cmbustinrelated emissins are addressed in chapter 1.A.2.b. Nte that n specific ferrallys cmbustinrelated emissin factrs (EFs) are prvided in 1.A.2.b. It is assumed that cmbustin is similar fr all metal prductin. 3 Methds This sectin prvides default emissin factrs fr this surce categry. Since it is nly a minr surce f emissins, nly Tier 1 default emissin factrs are prvided. 3.1 Chice f methd Nt applicable, since nly Tier 1 factrs are presented. Hwever, if facility level data are available and these are gd enugh they can als be used. 3.2 Tier 1 default apprach Algrithm The Tier 1 apprach uses the general equatin: E = AR EF (1) pllutant prductin pllutant The Tier 1 emissin factrs assume an averaged r typical technlgy and abatement implementatin in the cuntry and integrate all the different sub-prcesses Default emissin factrs Default emissin factrs are prvided in Table 3.1. The emissin factr fr dust (ttal suspended particulate matter TSP) is based n the Air Pllutin Engineering Manual (Air & Waste Management Assciatin, 1992). Fr mre detailed infrmatin n the dust emissins frm different types f ferrallys and/r the varius prcess steps, please refer t the BREF dcument fr nn-ferrus metal industries (Eurpean Cmmissin, 2001). This dcument als gives mre infrmatin n the emissins riginating frm cmbustin activities (NO x, SO x, VOC and PAH). The emissin factr fr TSP prpsed in the table belw is in the same rder f magnitude as the summatin f all available emissin factrs fr subprcesses in the BREF dcument. Table 3.1 Tier 1 emissin factrs fr surce categry 2.C.2 Ferrallys prductin Tier 1 default emissin factrs Cde Name NFR Surce Categry 2.C.2 Ferrallys prductin Fuel NA Nt applicable Aldrin, Chlrdane, Chlrdecne, Dieldrin, Endrin, Heptachlr, Heptabrm-biphenyl, Mirex, Txaphene, HCH, DDT, PCB, PCP, SCCP Nt estimated NOx, CO, NMVOC, SOx, NH3, PM10, PM2.5, Pb, Cd, Hg, As, Cr, Cu, Ni, Se, Zn, PCDD/F, Benz(a)pyrene, Benz(b)fluranthene, Benz(k)fluranthene, Inden(1,2,3-cd)pyrene, Ttal 4 Pllutant Value Unit 95% cnfidence interval Reference Lwer Upper TSP 1 kg/mg ally prduced Air & Waste (1992) EMEP/EEA emissin inventry guidebk

6 2.C.2 Ferrallys prductin Activity data A lt f infrmatin n prductin statistics (fr varius surce categries) is available frm United Natins statistical yearbks r natinal statistics. Further guidance might als be prvided in the 2006 IPCC Guidelines fr Natinal Greenhuse Gas Inventries (IPCC, 2006). 3.3 Tier 2 technlgy-specific apprach The BREF dcument fr the nn-ferrus metal industry (Eurpean Cmmissin, 2001) distinguishes a number f ferrally types that may be prduced. These are: ferr-chrme: High-carbn ferr-chrme (HC FeCr), cntaining 4 10 % carbn; Medium-carbn ferr-chrme (MC FeCr), cntaining % carbn; Lw-carbn ferr-chrme (LC FeCr), cntaining % carbn; ferr-silicn and silicn allys: Ferr-silicn (FeSi), with a silicn cntent less than 96 %; Si-metal (Si-metal), with a silicn cntent abve 96 %; Silic-calcium (Calcium-silicn), with a silicn cntent f abut % and calcium cntent f %; ferr-manganese and manganese allys: High-carbn ferr-manganese (HC FeMn), with maximum 7.5 % carbn; Medium-carbn ferr-manganese (MC FeMn), with maximum 1.5 % carbn; Lw-carbn ferr-manganese (LC FeMn), with maximum 0.5 % carbn; Silicmanganese (SiMn), with maximum 2 % carbn; Lw-carbn silic-manganese (LC SiMn), with maximum 0.05 % carbn; ferr-nickel (FeNi); ferr-vanadium (FeV); ferr mlybdenum; ferr-tungsten; ferr-titanium; ferr-brn; ferr-nibium. The BREF dcument nly prvides emissin factrs fr certain sub-prcesses fr a number f these ferrally types. Since mst f this infrmatin is incmplete, n generic Tier 2 emissin factrs culd be extracted frm this infrmatin. EMEP/EEA emissin inventry guidebk

7 2.C.2 Ferrallys prductin 3.4 Tier 3 emissin mdelling and use f facility data A lt f specific infrmatin is available in the BREF dcument fr the nn-ferrus metal industries (Eurpean Cmmissin, 2001), in the chapter n ferrallys. This dcument extensively discusses varius types f ferrallys and prcess steps. 4 Data quality There are n specific issues fr this surce categry. 5 References Air & Waste Management Assciatin, Air Pllutin Engineering Manual. Bunicre, A.J. and Davis, W.T. (eds). ISBN Van Nstrand Reinhld, NY. Eurpean Cmmissin, Integrated Pllutin Preventin and Cntrl (IPPC), Reference Dcument n Best Available Techniques (BREF) in the Nn-Ferrus Metal Industries. December IPCC, IPCC Guidelines fr Natinal Greenhuse Gas Inventries. Prepared by the Natinal Greenhuse Gas Inventries Prgramme, Egglestn H.S., Buendia L., Miwa K., Ngara T. and Tanabe K. (eds). IGES, Japan. 6 Pint f enquiry Enquiries cncerning this chapter shuld be directed t the relevant leader(s) f the Task Frce n Emissin Inventries and Prjectin s expert panel n Cmbustin and Industry. Please refer t the TFEIP website ( fr the cntact details f the current expert panel leaders. EMEP/EEA emissin inventry guidebk