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Cadmium and Cadmium Compounds

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Cadmium and Cadmium Compounds Locating and Estimating Air Emissions From Sources of Cadmium and Cadmium Compounds U. S. Environmental Protection Agency Office of Air and Radiation Office of Air Quality Planning and Standards Locating and Estimating Air Emissions From Sources of Cadmium and Cadmium Compounds Prepared for: Anne Pope Office of Air Quality Planning and Standards Technical Support Division U. S. Environmental Protection Agency Research Triangle Park, N.C. 27711 Prepared by: Midwest Research Institute 401 Harrison Oaks Boulevard, Suite 350 Cary, North Carolina 27513 TABLE OF CONTENTS Section Page 1 PURPOSE OF DOCUMENT ..................1-1 REFERENCES ....................1-4 2 OVERVIEW OF DOCUMENT CONTENTS .............2-1 3 BACKGROUND.......................3-1 NATURE OF POLLUTANT ................3-1 OVERVIEW OF PRODUCTION, USE, AND EMISSIONS ....3-4 Production..................3-4 Use.....................3-6 Emissions ..................3-6 REFERENCES ................... 3-13 4 EMISSIONS FROM CADMIUM PRODUCTION ...........4-1 CADMIUM REFINING AND CADMIUM OXIDE PRODUCTION ...4-1 Process Description .............4-3 Emissions and Controls ............4-6 CADMIUM PIGMENTS PRODUCTION ........... 4-11 Process Description ............ 4-14 Emissions and Controls ........... 4-19 CADMIUM STABILIZERS PRODUCTION ......... 4-20 Process Description ............ 4-22 Emission and Controls ........... 4-24 OTHER CADMIUM COMPOUND PRODUCTION ........ 4-25 Process Descriptions ............ 4-25 Emissions and Controls ........... 4-29 REFERENCES ................... 4-32 5 EMISSIONS FROM MAJOR USES OF CADMIUM ..........5-1 CADMIUM ELECTROPLATING ..............5-1 Process Description .............5-2 Emission Control ...............5-6 Emissions ..................5-7 SECONDARY BATTERY MANUFACTURE ...........5-7 Process Description .............5-9 Emission Control Measures ......... 5-13 Emissions ................. 5-13 CADMIUM STABILIZERS FOR PLASTICS ........ 5-14 Process Description ............ 5-16 Emission Control Measures ......... 5-17 Emissions ................. 5-18 CADMIUM PIGMENTS IN PLASTICS .......... 5-18 Process Description ............ 5-20 Emission Control Measures ......... 5-22 Emissions ................. 5-22 REFERENCES ................... 5-23 iii TABLE OF CONTENTS (continued) 6 EMISSIONS FROM COMBUSTION SOURCES ...........6-1 COAL COMBUSTION..................6-5 Coal Characteristics .............6-6 Process Description ............ 6-10 Emission Control Measures ......... 6-15 Emissions ................. 6-16 FUEL OIL COMBUSTION ............... 6-20 Fuel Oil Characteristics .......... 6-22 Process Description ............ 6-23 Emission Control Measures ......... 6-27 Emissions ................. 6-28 NATURAL GAS COMBUSTION ............. 6-33 Natural Gas Characteristics ........ 6-33 Process Description ............ 6-34 Emission Control Measures ......... 6-34 Emissions ................. 6-34 WOOD COMBUSTION................. 6-35 Process Description ............ 6-35 Emission Control Measures ......... 6-37 Emissions ................. 6-39 MUNICIPAL WASTE COMBUSTION ........... 6-40 Municipal Solid Waste Characteristics . 6-42 Process Description ............ 6-42 Emission Control Measures ......... 6-48 Emissions ................. 6-50 SEWAGE SLUDGE INCINERATORS ........... 6-51 Process Description ............ 6-54 Emission Control Measures ......... 6-58 Emissions ................. 6-59 MEDICAL WASTE INCINERATION ........... 6-61 Process Description ............ 6-62 Emission Control Measures ......... 6-67 Emissions ................. 6-68 REFERENCES ................... 6-75 7 EMISSIONS FROM NONFERROUS SMELTING/REFINING ......7-1 PRIMARY LEAD SMELTING ...............7-1 Process Description .............7-2 Emission Control Measures ..........7-4 Emissions ..................7-5 PRIMARY COPPER SMELTING ..............7-7 Process Description .............7-8 Emission Control Measures ......... 7-13 Emissions ................. 7-14 PRIMARY ZINC SMELTING AND REFINING ....... 7-15 Process Description - Electrolytic ..... 7-17 Process Description--Pyrometallurgical (Electrothermic) ............. 7-22 Emission Control Measures ......... 7-23 Emissions ................. 7-24 iv TABLE OF CONTENTS (continued) SECONDARY COPPER SMELTING AND REFINING ..... 7-25 Process Description ............ 7-26 Emission Control Measures ......... 7-31 Emissions ................. 7-33 SECONDARY ZINC RECOVERY FROM METALLIC SCRAP . 7-34 Process Description ............ 7-34 Emission Control Measures ......... 7-39 Emissions ................. 7-41 SECONDARY ZINC RECOVERY FROM STEEL PRODUCTION . 7-41 Process Description ............ 7-43 Emission Control Measures ......... 7-48 Emissions ................. 7-48 REFERENCES ................... 7-49 8 EMISSIONS FROM MISCELLANEOUS SOURCES ..........8-1 IRON AND STEEL PRODUCTION .............8-1 Process Description .............8-4 Emission Control Measures ......... 8-10 Emissions ................. 8-12 PORTLAND CEMENT MANUFACTURING .......... 8-12 Process Description ............ 8-15 Emission Control Measures ......... 8-18 Emissions ................. 8-20 PHOSPHATE ROCK PROCESSING ............ 8-20 Process Description ............ 8-23 Emission Control Measures ......... 8-25 Emissions ................. 8-26 CARBON BLACK PRODUCTION ............ 8-27 Process Description ............ 8-29 Emission Control Measures ......... 8-31 Emissions ................. 8-31 MOBILE SOURCES ................. 8-32 REFERENCES ................... 8-33 9 SOURCE TEST PROCEDURES .................9-1 INTRODUCTION ...................9-1 MULTIPLE METALS SAMPLING TRAINS ..........9-2 Method 0012-Methodology for the Determin- ation of Metals Emissions in Exhaust Gases from Hazardous Waste Incineration and Similar Combustion Sources .......9-2 Methodology for the Determination of Metals Emissions in Exhaust Gases from Hazardous Waste Incineration and Similar Combustion Sources ..................9-4 CARB Method 436-Determination of Multiple Metals Emissions from Stationary Sources . 9-4 EPA Method 29-Methodology for the v TABLE OF CONTENTS (continued) Determination of Metals Emissions in Exhaust Gases from Incineration and Similar Combustion Sources (Draft) .....9-5 ANALYTICAL METHODS FOR DETERMINATION OF CADMIUM . 9-5 Flame AAS ..................9-6 Graphite Furnace AAS .............9-6 Hydride AA..................9-6 Cold-Vapor AA ................9-7 SUMMARY......................9-7 REFERENCES ....................9-9 APPENDIX A - NATIONWIDE EMISSION ESTIMATES .........A-1 APPENDIX B - SUMMARY OF COMBUSTION SOURCE CADMIUM EMISSION DATA ................B-1 APPENDIX C - PLANT LOCATIONS AND ANNUAL CAPACITIES FOR MISCELLANEOUS EMISSIONS SOURCES .......C-1 vi LIST OF FIGURES Figure Page 3-1 1991 supply and demand for cadmium ...........3-5 3-2 End use pattern of cadmium ...............3-7 4-1 Flow diagram for cadmium refining ...........4-4 4-2 Process flowsheet for the production of cadmium pigments .................. 4-17 4-3 General flowsheet for the production of powdered cadmium stabilizers. ........... 4-23 5-1 Cadmium electroplating process. ............5-4 5-2 Simplified flow diagram for production of sintered plate nickel-cadmium batteries. .......... 5-11 6-1 Distribution of sewage sludge incinerators in the United States ................... 6-53 6-2 Process flow diagram for sludge incineration ..... 6-55 6-3 Major components of an incineration system. ..... 6-64 7-1 Typical primary lead-processing scheme .........7-3 7-2 Typical primary copper-smelting process. ........7-9 7-3 Typical primary zinc-smelting process. ........ 7-18 7-4 Process flow diagram for second-grade copper recovery. .................. 7-28 7-5 Process flow diagram for high-grade brass and bronze alloying. ............. 7-29 7-6 Process flow diagram for secondary zinc processing . 7-36 7-7 Process flow diagram for Waelz kiln process. ..... 7-45 7-8 Process flow diagram for zinc calcine formation. 7-47 8-1 General flow diagram for the iron and steel industry . 8-5 8-2 Process flow diagram of Portland cement manufacturing process ............... 8-16 8-3 Typical flowsheet for processing phosphate rock . 8-24 vii LIST OF FIGURES (continued) 8-4 Process flow diagram for carbon black manufacturing process ............... 8-30 9-1. Typical multiple metals sampling train ........9-3 viii LIST OF TABLES Table Page 3-1 PHYSICAL PROPERTIES OF CADMIUM .............3-2 3-2 SIC CODES OF INDUSTRIES ASSOCIATED WITH CADMIUM EMISSIONS ................. 3-10 3-3 ESTIMATED 1990 NATIONWIDE CADMIUM EMISSIONS FOR SELECTED SOURCE CATEGORIES ............. 3-12 4-1 CADMIUM AND CADMIUM OXIDE PRODUCERS ..........4-2 4-2 INVENTORY OF CADMIUM EMISSION SOURCES AND CONTROLS FOR CADMIUM REFINING PLANTS .........4-7 4-3 PRIMARY ZINC AND CADMIUM PRODUCERS REPORTING CADMIUM EMISSIONS IN THE 1990 TOXIC CHEMICALS RELEASE INVENTORY ................. 4-10 4-4 CADMIUM EMISSION FACTORS FOR CADMIUM REFINING PLANT USING LEAD BLAST FURNACE DUST ........ 4-12 4-5 EMISSION FACTORS FOR CADMIUM AND CADMIUM OXIDE PRODUCTION .................. 4-13 4-6 COMMON CADMIUM PIGMENTS PRODUCED IN 1991 ....... 4-15 4-7 CURRENT CADMIUM PIGMENT PRODUCERS .......... 4-16 4-8 INORGANIC PIGMENTS MANUFACTURERS REPORTING CADMIUM EMISSIONS IN THE 1990 TOXIC CHEMICALS RELEASE INVENTORY ................. 4-21 4-9 MANUFACTURERS OF ORGANIC COMPOUNDS REPORTING CADMIUM EMISSIONS IN THE 1990 TOXIC CHEMICALS RELEASE INVENTORY ................. 4-26 4-10 CADMIUM COMPOUND MANUFACTURERS (OTHER THAN CADMIUM OXIDE, PIGMENTS, AND STABILIZERS) ....
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