Environmental Code of Practice for integrated steel mills: appendix B

Appendix B: Methodologies for the Calculation of Environmental Performance Indicators

• B.1 Methodology for Calculation of Particulate Emissions from Sinter Plants (Recommendation RI103)
• B.2 Methodology for Calculation of Particulate Emissions from Blast Furnaces (Recommendation RI103)
• B.3 Methodology for Calculation of Particulate Emissions from Basic Oxygen Furnaces (Recommendation RI103)
• B.4 Methodology for Calculation of Particulate Emissions from Electric Arc Furnaces (Recommendation RI103)
• B.5 Methodology for Calculation of Total Suspended Solids Discharges from Integrated Steel Mills (Recommendation RI122)
• B.6 Methodology for Calculation of Water Use/Recycle for Integrated Steel Mills (Recommendation RI124)

B.1 Methodology for Calculation of Particulate Emissions from Sinter Plants (Recommendation RI103)

• The Indicator should be based on sinter produced.
  
• The following particulate sources should be included in the Indicator:
  • particulate emissions from the sinter plant stack;
  • particulate emissions from the cooling, crushing and screening, handling and transport of sinter product, and the handling and transport of raw materials and waste materials; and
  • fugitive particulate emissions that are not collected by the emission control systems.
    
• All emission testing should be carried out downstream of the emission control devices.
  
• Measurement of the particulate emissions from the sinter plant stack and other emission control device(s) should be carried out in a manner that is consistent with the emission testing methodology referred to in Recommendation RI102.
  
• Testing should be carried out during normal operations, i.e., upset or malfunction conditions should be excluded.
  
• The particulate emission discharge from the emission control devices should be calculated in accordance with the formula:
  (SPs × Fp × Δt) + ∑(Eo × Fo × Δt) = Ed
  where:
  • SPs is the sinter plant stack particulate concentration;
  • Fp is the sinter plant stack gas flow at standard conditions;
  • Eo is the other emission control system particulate emission concentrations (as applicable);
  • Fo is the other emission control system gas flows at standard conditions;
  • Δt is the duration of the selected production period;
  • ∑(Eo × Fo × Δt) is the sum of the discharges of other emission control devices; and
  • Ed is the total particulate emissions discharged from the control devices for the selected production period.
    
• The calculation of fugitive particulate emissions from sintering operations and sinter cooling, crushing, and handling operations should be based on fugitive emission factors that are widely used in the industry (e.g., EPA AP 42) for each of the sinter plant operations and the estimated capture efficiency of the emission collection systems. Fugitive particulate emissions should be calculated in accordance with the formula:
  ∑[Ef × (1 - Sc)] × Δt = Fep
  where:
  • Ef is the fugitive particulate emission factor for the operation;
  • Sc is the emission control system estimated capture efficiency;
  • Δt is the duration of the selected production period; and
  • Fep is the fugitive particulate emission discharge to the atmosphere for the duration of the selected production period.
    
• The mass emission factor should be calculated for the selected production period in accordance with the formula:
  (Ed + Fep) / Sp = MEF
  where:
  • Sp is the sinter production; and
  • MEF is the mass factor for the selected production period.
    
• The Environmental Performance Indicator is the average of the mass emission factors for three selected production periods.

B.2 Methodology for Calculation of Particulate Emissions from Blast Furnaces (Recommendation RI103)

• The Indicator should be based on liquid iron produced (iron tapped into hot metal car and pig casting).
  
• The following particulate sources should be included in the Indicator:
  • particulate emissions from the cast house including iron tapping, slag tapping, and iron and slag runners;
  • particulate emissions from hot metal treatment at the blast furnace (e.g., de-sulphurization);
  • particulate emissions from slag crushing, screening, granulating, and pelletizing; and
  • fugitive emissions from the above ironmaking operations.
    
• All emission testing should be carried out downstream of the emission control devices.
  
• Measurement of the particulate emissions from the emission control device(s) should be carried out in a manner that is consistent with the emission testing methodology referred to in Recommendation RI102.
  
• Emission testing should be carried out during normal operations, i.e., upset or malfunction conditions should be excluded.
  
• The particulate emission discharge from the emission control devices should be calculated in accordance with the formula:
  (P × Fp + S × Fs) × Δt) = Ed
  where:
  • P is the primary emission control system particulate emission concentration;
  • Fp is the primary emission control system gas flow at standard condition;
  • S is the secondary emission control system particulate emission concentration where applicable;
  • Fs is the secondary emission control system gas flow at standard condition;
  • Δt is the duration of the selected production period;
  • Ed is the total particulate emissions discharged from the control devices for the selected production period.
    
  ∑(P × Fp × Δt) = Ed
  where:
  • P is the emission control system particulate emission concentration;
  • Fp is the emission control system gas flow at standard conditions;
  • Δt is the duration of the selected production period;
  • ∑(P × Fp × Δt) is the sum of the discharges from the emission control systems; and
  • Ed is the total particulate emissions discharged from the control devices for the selected production period.
    
• The calculation of fugitive particulate emissions from the ironmaking operations should be based on fugitive emission factors that are widely used in the industry (e.g., EPA AP 42) for each phase of the operations and the estimated capture efficiency of the emission collection systems. Fugitive particulate emissions should be calculated in accordance with the formula:
  ∑(Ef × (1 - Sc) × Δt = Fep
  where:
  • Ef is the fugitive particulate emission factors for the various ironmaking operations;
  • Sc is the emission collection system esitmated capture efficiency;
  • Δt is the duration of the selected production period; and
  • Fep is the fugitive particulate emission discharge to the atmosphere.
    
• The mass emission factor should be calculated for the duration of the selected production period in accordance with the formula:
  (Ed +Fep) / Sp = MEF
  where:
  • Sp is the liquid iron production; and
  • MEF is the mass emission factor for the selected production period.
    
• The Environmental Performance Indicator is the average of the mass emission factors for three selected production periods.

B.3 Methodology for Calculation of Particulate Emissions from Basic Oxygen Furnaces (Recommendation RI103)

• The Indicator should be based on liquid steel produced (steel tapped into ladle, not including liquid heel).
  
• The following particulate sources should be included in the Indicator:
  • primary particulate emissions from the BOF operations including charging, melting, and refining;
  • fugitive particulate emissions from the BOF operations that are collected by the secondary emission control system;
  • fugitive particulate emissions that are not collected by the secondary emission control system, including tapping and slagging;
  • particulate emissions from the hot metal (iron) transfer, ladle metallurgy, vacuum degassing, and continuous casting; and
  • particulate emissions from the flux handling and injection systems.
    
• All emission testing should be carried out downstream of the emission control devices.
  
• Measurement of the particulate emissions from the emission control device(s) should be carried out in a manner that is consistent with the emission testing methodology referred to in Recommendation RI102.
  
• Emission testing should be carried out during normal operations, i.e., upset or malfunction conditions should be excluded.
  
• The particulate emission discharge from the emission control device(s) for the primary and secondary systems for one production cycle (one heat of steel) should be calculated in accordance with the formula:
  (P × Fp + S × Fs) × Δt = Ed
  where:
  • P is the primary emission control system particulate emission concentration;
  • Fp is the primary emission control system gas flow at standard conditions;
  • S is the secondary emission control system particulate emission concentration where applicable;
  • Fs is the secondary emission control system gas flow at standard conditions;
  • Δt is the duration of the selected production period, and
  • Ed is the total particulate emissions discharged from the control devices for the selected production period.
    
• The calculation of fugitive particulate emissions from the BOF operations should be based on a fugitive emission factor that is widely used in the industry (e.g., EPA AP 42) for each phase of the operations and the estimated capture efficiency of the secondary emission collection system. Fugitive particulate emissions should be calculated in accordance with the formula:
  [Ef × (1 - Sc)] × Δt = Fe
  where:
  • Ef is the fugitive particulate emission factors for the BOF operation;
  • Sc is the secondary emission collection system esitmated capture efficiency;
  • Δt is the duration of one production cycle (one heat of steel); and
  • Fe is the fugitive particulate emission discharge to the atmosphere.
    
• The calculation of particulate emissions from the particulate emission control devices for other operations should be based on testing of the emission control devices. The formula that should be used is:
  > ∑(Flp × Ff1 × Δt) = Fle
  where:
  • Flp is the control device particulate concentration;
  • Ff1 is the control device gas flow at standard conditions;
  • Δt is the duration of the production cycle;
  • ∑(Flp × Ff1 × Δt) is the sum of the particulate discharges from the emission control devices; and
  • Fle is the total particulate emissions discharged from the emission control devices for one production cycle (one heat of steel).
    
• The mass emission factor for a heat of steel should be calculated for one production cycle (one heat of steel) in accordance with the formula:
  (Ed + Fe + Fle) / Sp = MEF
  where:
  • Sp is the liquid steel production; and
  • MEF is the mass emission factor for one heat.
    
• The Environmental Performance Indicator is the average of the mass emission factors for three production cycles.

B.4 Methodology for Calculation of Particulate Emissions from Electric Arc Furnaces (Recommendation RI103)

• The Indicator should be based on liquid steel produced (steel tapped into ladle, not including liquid heel).
  
• The following particulate sources should be included in the Indicator:
  • primary particulate emissions from the electric arc furnace operations including charging, melting, and refining;
  • fugitive particulate emissions from the above electric arc furnace operations that are collected by the secondary emission control system;
  • fugitive particulate emissions that are not collected by the secondary emission control system, including tapping and slagging;
  • particulate emissions from ladle metallurgy, vacuum degassing, and continuous casting; and
  • particulate emissions from the flux handling and injection systems.
    
• All emission testing should be carried out downstream of the emission control devices.
  
• Measurement of the particulate emissions from the electric arc furnace emission control device(s) should be carried out in a manner that is consistent with the emission testing methodology referred to in Recommendation RN101.
  
• Testing should be carried out during normal operations, i.e., upset or malfunction conditions should be excluded.
  
• The particulate emission discharge from the emission control device(s) for the primary and secondary systems for one production cycle (one heat of steel) should be calculated in accordance with the formula:
  (P × Fp + S × Fs) × Δt = Ed
  where:
  • P is the primary emission control system particulate emission concentration;
  • Fp is the primary emission control system gas flow at standard conditions;
  • S is the secondary emission control system emission particulate concentration where applicable;
  • Fs is the secondary emission control system gas flow at standard conditions;
  • Δt is the duration of the selected production heat cycle, and
  • Ed is the total particulate emissions discharged from the control devices for the production heat cycle.
    
• The calculation of fugitive particulate emissions from the electric arc furnace operations should be based on a fugitive emission factor that is widely used in the industry (e.g., EPA AP 42) for each phase of the operations and the estimated capture efficiency of the secondary emission collection system. Fugitive particulate emissions should be calculated in accordance with the formula:
  [Ef × (1 - Sc)] × Δt = Fe
  where:
  • Ef is the fugitive particulate emission factors for the electric arc furnace operation;
  • Sc is the secondary emission collection system esitmated capture efficiency;
  • Δt is the duration of the production heat cycle; and
  • Fe is the fugitive particulate emission discharge to the atmosphere.
    
• The calculation of particulate emissions from the particulate emission control devices for other operations should be based on testing of the emission control devices. The formula that should be used is:
  ∑(Flp × Ff1 × Δt) = Fle
  where:
  • Flp is the control device particulate concentration;
  • Ff1 is the control device gas flow at standard conditions;
  • Δt is the duration of the production cycle;
  • ∑(Flp × Ff1 × Δt) is the sum of the particulate discharges from the emission control devices; and
  • Fle is the total particulate emissions discharged from the flux emission control devices for the duration of the production heat cycle.
    
• The mass emission factor for a heat of steel should be calculated for a complete production cycle of a heat of steel in accordance with the formula:
  (Ed + Fe + Fle) / Sp = MEF
  where:
  • Sp is the liquid steel production; and
  • MEF is the mass emission factor for the production of one heat of steel.
    
• The Environmental Performance Indicator is the average of the mass emission factors for three production cycles.

B.5 Methodology for Calculation of Total Suspended Solids Discharges from Integrated Steel Mills (Recommendation RI122)

• The Indicator should be based on liquid steel produced (steel tapped into ladle, not including liquid heel).
  
• Wastewater from the following discharge sources should be included in the Indicator:
  • Sinter plant operations;
  • cokemaking operations including by-product plant;
  • ironmaking operations;
  • steelmaking operations including ladle metallurgy operations, vacuum degassing and continuous casting;
  • hot forming operations;
  • cold forming and finishing operations including cleaning, pickling, and coating;
  • direct cooling;
  • environmental control operations; and
  • service activities (e.g., maintenance and steam generation).
    
• All wastewater discharges to receiving water bodies should be included (non-contact cooling water not included). Wastewater discharges to municipal treatment facilities that meet the municipal wastewater quality requirements should not be included.
  
• Wastewater sampling and analyses should be carried out in a manner that is consistent with the methodology referred to in Recommendation RI121 and is downstream of the wastewater treatment facilities where applicable.
  
• Wastewater flow measurement should be carried out in a manner that is consistent with the methodology referred to in Recommendation RI124 and is downstream of the wastewater treatment facilities where applicable.
  
• The total suspended solids measurement for the Indicator should be based on a 30-day average.
  
• The total suspended solids discharge should be calculated by the formula:
  ∑(TSS × Fw × Δt) / Sp = Ti
  where:
  • TSS is the total suspended solids concentration;
  • Fw is the flow of each wastewater discharge;
  • Δt is the elapsed time of the measurement period (e.g., 30 days);
  • ∑(TSS × Fw × Δt) is the sum of the total suspended solids discharges;
  • Sp is the liquit steel production for the measurement period; and
  • Ti is the total suspended solids Environmental Performance Indicator.

B.6 Methodology for Calculation of Water Use/Recycle for Integrated Steel Mills (Recommendation RI124)

• Sources of wastewater discharges should include those resulting from direct-contact cooling, environmental control operations, all production operations including sintering, cokemaking, ironmaking, steelmaking, hot forming, cold forming, finishing, and service activities (e.g., maintenance and steam generation).
  
• Wastewater discharges should include discharges to receiving water bodies and to municipal treatment facilities.
  
• Water use on the basis of a once-through system should be calculated based on flow measurements or engineering calculations for all uses.
  
• Wastewater discharge on the basis of actual cascading and re-circulation should be calculated based on discharge flow measurements, engineering calculations, or engineering estimates.
  
• Flow measurements should be carried out in a manner that is consistent with the methodology referred to in Recommendation RI124 for the operating units and downstream of the wastewater treatment facilities.
  
• The recycle rate should be calculated in accordance with the following general principles and formula:
  • Once-through flow is measured, calculated, or estimated for the following activities:
    • Direct-contact cooling flow + process water flow + potable water flow = total once-through water flow or TWF.
  • Actual water discharge flow is measured, calculated, or estimated for the following activities:
    • Direct-contact cooling discharge flow + process water discharge flow + potable water discharge flow = total wastewater discharge flow or TWD.
  • The recycle rate is then:
    (TWF - TWD) / TWF = Wr
    where:
    • Wr is the water recycle rate.