Metal Manufacturing And Fabrication - US EPA

Metal Manufacturing and Fabrication P2 National Emphasis Area (FY22-23) P2-TRI Fact Sheet EPA adopted six national emphasis areas (NEAs) for the FY 2022/2023 pollution prevention (P2) grant cycle. This fact sheet summarizes environmental and P2 information for one of the NEAs: the metal manufacturing and fabrication sector (NAICS 331 and 332). According to the Census Bureau, this sector includes 58,435 establishments.1 About 7 percent of these establishments (facilities) reported to the Toxics Release Inventory (TRI) for 2020.1 TRI tracks the management of toxic chemicals as reported by U.S. industrial facilities. Annually, facilities report to TRI how much of each chemical is recycled, combusted for energy recovery, treated, and disposed of or otherwise released to the environment. Locations of TRI Metal Manufacturing and Fabrication Facilities, 2020 TRI Quick Facts for 2020 Metal Manufacturing and Fabrication All Sectors Number of TRI Facilities Total Production-Related Waste Managed (lb) Total On-site and Off-site Disposal or Other Releases (lb) Total On-site (lb) Air (lb) Water (lb) Land (lb) Total Off-site (lb) 4,270 21,022 2.9 billion 28.3 billion 299 million 168 million 41.0 million 25.0 million 102 million 131 million 3.0 billion 2.7 billion 550 million 194 million 1.95 billion 348 million EPA encourages facilities to first eliminate the production of waste at its source (source reduction) prior to recycling, energy recovery, treatment, or disposal. The charts below show quantities of TRI chemicals released or otherwise managed as waste by the sector as reported to TRI. P2 technical assistance providers and others may be able to use the information below to identify opportunities that prevent chemical releases through source reduction activities. Information can be explored in more depth at EPA’s TRI P2 Search tool. Metal Manufacturing and Fabrication Waste Management Approaches Total Releases by Media 500 4,000 Millions of Pounds Millions of Pounds 3,500 3,000 2,500 2,000 1,500 1,000 400 300 200 100 500 0 1 1 20 2 1 20 3 1 20 4 1 20 Disposed of or Otherwise Released 5 1 20 6 1 20 Treatment 7 1 20 8 1 20 9 1 20 Energy Recovery 0 2 20 Recycling 0 11 20 12 20 13 20 14 20 15 20 16 20 17 20 19 20 20 20 On-site Air Releases On-site Surface Water Discharges On-site Land Disposal Off-site Disposal or Other Releases For more information on P2 and the EPA’s P2 Program, please contact the P2 Hub at: p2hub@epa.gov or 202-566-0799 or visit www.epa.gov/P2 1 18 20 Data source: 2020 TRI National Analysis data released October 2021; and U.S. Census Bureau, 2017 Economic Census

Metal Manufacturing and Fabrication P2 National Emphasis Area (FY22-23) P2-TRI Fact Sheet The following charts show the TRI chemicals released on site to air and water by facilities in the metal manufacturing and fabrication sector as a whole and for three selected metal manufacturing and fabrication subsectors: Foundries (NAICS 3315); Coating, Engraving, Heat Treating, and Allied Activities (NAICS 3328); and Architectural and Structural Metals Manufacturing (NAICS 3323). In these charts, each metal and its compounds are combined. Metal Manufacturing and Fabrication Releases to Air, 2020 Releases to Water, 2020 41.0 million pounds 25.0 million pounds Certain Glycol Ethers: 18% All Others: 26% Xylene (Mixed Isomers): 4% Nitrate Compounds: 94% All Others: 2% Ammonia: 15% Sulfuric Acid: 5% Carbonyl Sulfide: 6% Chlorine: 8% Sodium Nitrite: 4% n-Butyl Alcohol: 10% Hydrochloric Acid: 8% Foundries Releases to Air, 2020 Releases to Water, 2020 1.6 million pounds Aluminum: 8% Phenol: 9% 23,996 pounds Benzene: 8% Zinc: 43% Toluene: 8% Xylene (Mixed Isomers): 7% Zinc: 11% Ammonia: 7% Copper: 6% All Others: 27% Hydrochloric Acid: 5% Methanol: 4% All Others: 7% Copper: 5% Lead: 7% Manganese: 38% For more information on P2 and the EPA’s P2 Program, please contact the P2 Hub at: p2hub@epa.gov or 202-566-0799 or visit www.epa.gov/P2

Metal Manufacturing and Fabrication P2 National Emphasis Area (FY22-23) P2-TRI Fact Sheet Coating, Engraving, and Heat Treating Releases to Air, 2020 Releases to Water, 2020 2.5 million pounds Certain Glycol Ethers: 14% 78 thousand pounds n-Butyl Alcohol: 9% Ammonia: 8% Xylene (Mixed Isomers): 15% Toluene: 7% Nitrate Compounds: 80% All Others: 2% 1,2,4Trimethylbenzene: 7% Zinc: 6% All Others: 24% Zinc: 18% 1-Bromopropane: 6% Nitric Acid: 5% Architectural and Structural Metals Manufacturing Releases to Air, 2020 Releases to Water, 2020 1.4 million pounds 1,065 pounds Manganese: 52% Certain Glycol Ethers: 41% Xylene (Mixed Isomers): 18% Aluminum Oxide: 2% Copper: 2% Lead: 3% All Others: 13% n-Butyl Alcohol: 10% Dimethyl Phthalate: 2% Toluene: 7% Styrene: 3% 1,2,4-Trimethylbenzene: 6% Chromium: 4% Nickel: 8% Zinc: 31% For more information on P2 and the EPA’s P2 Program, please contact the P2 Hub at: p2hub@epa.gov or 202-566-0799 or visit www.epa.gov/P2

Metal Manufacturing and Fabrication P2 National Emphasis Area (FY22-23) P2-TRI Fact Sheet P2 Activities Reported to TRI The figures below illustrate the source reduction activities reported to TRI by facilities in the subsectors comprising the metal manufacturing and fabrication sector for 2016 - 2020. In the bar chart, the number of source reduction activities reported for each metal and its compounds are combined. Metal Manufacturing and Fabrication, 2016-2020 200 100 un er Co m po m te tra For more information on P2 and the EPA’s P2 Program, please contact the P2 Hub at: p2hub@epa.gov or 202-566-0799 or visit www.epa.gov/P2 ds s) rs he Ni Xy le ne in (M ix ed ol yc Gl Iso c tri rta Process Modifications Inventory Control Product Modifications Surface Preparation and Finishing Ce Good Operating Practices Spill and Leak Prevention Raw Material Modifications Cleaning and Degreasing Et Ac id nc Zi Ni ne se er ga pp an M iu m ro Ch 18% el 0 m 6% 300 Co 48% 400 ck 7% 500 Ni 8% 600 ad 7% Le 4% 3% Source Reduction Activities by Chemical Source Reduction Activities Source Reduction Activities

Metal Manufacturing and Fabrication P2 National Emphasis Area (FY22-23) P2-TRI Fact Sheet P2 Opportunities Examples of P2 achievements in the metal manufacturing and fabrication sectors identified from published sources are listed below. For information on additional P2 opportunities, see EPA’s P2 Resources Search tool and the TRI Pollution Prevention Search tool. Some of the sources below link to non-EPA web sites. EPA cannot attest to the accuracy of non-EPA sources and providing links to a non-EPA source is not an endorsement by EPA of the source or the information it contains. Reducing scrap metal. In metal fabrication, using materials more efficiently can result in reduced scrap metal generation. For example, facilities have revised dimensions of raw material purchases to more closely match the dimensions of cut pieces, reducing scrap during production. Others have implemented nesting software programs to improve parts yield from raw materials. The article, Metal Fabrication Design Practices that Reduce Scrap, describes a product modification that leveraged nesting practices for cutting sheet metal. The TRI Pollution Prevention Search tool includes numerous examples of facilities reporting scrap metal reductions after implementing nesting software when ordering or preparing materials. Extending the lifetime of coolant fluids. Coolant fluids might constitute the largest waste stream generated as a by-product of regular machining operations. Metal and oil contamination can be prevented by installing equipment such as bag and cartridge filters, centrifuges, or settling tanks to physically separate and remove contaminants. For facilities where this equipment was previously installed, improving maintenance might increase equipment efficiency and result in further P2. Coolant Maintenance for Machining Operations describes proper coolant selection and best practices in extending coolant life by minimizing contamination and improving usage monitoring. Monitoring plating bath concentrations and proper removal processes. Plating baths are a major source of wastes within metal fabrication facilities. Plating processes often involve heavy metals, strong acids and bases, and other hazardous chemicals that create hazardous work environments and waste. To prevent pollution, facilities have installed chemical concentration monitoring equipment that detects when plating chemicals must be added or replaced. Proper removal and transfer techniques also extend bath life by reducing contamination or loss of chemicals. The University of Minnesota Technical Assistance Program (MnTAP) describes dragout reduction, concentration control, and alternative plating solutions to help facilities maximize the lifetime and efficiency of plating baths. EPA’s P2 Metal Finishing fact sheet provides more information specific to P2 strategies for metal finishing operating including extending bath life, optimizing rinse tanks, and reducing water use. For more information on P2 and the EPA’s P2 Program, please contact the P2 Hub at: p2hub@epa.gov or 202-566-0799 or visit www.epa.gov/P2

Metal Manufacturing and Fabrication P2 National Emphasis Area (F22-23) P2-TRI Fact Sheet EPA adopted six national emphasis areas (NEAs) for the FY 2022/2023 pollution prevention (P2) grant cycle. This fact sheet summarizes environmental and P2 information for one of the NEAs: the metal manufacturing and fabrication sector (NAICS 331 and 332 .