Standardized toolkit for identification and quantification of mercury releases

Production of recycled metals ("secondary" metal production)

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5.6Production of recycled metals ("secondary" metal production)

Table 5 185 Production of recycled metals: sub-categories with main pathways of releases of mercury and recommended inventory approach

Chapter	Sub-category	Air	Water	Land	Product	Waste/ residue	Main inventory approach
5.6.1	Production of recycled mercury ("secondary production)	X	X	X	X	X	PS
5.6.2	Production of recycled ferrous metals (iron and steel)	X	x	x		x	PS
5.6.3	Production of other recycled metals	X	x	x		x	PS

Notes: PS = Point source by point source approach; OW = National/overview approach;
X - Release pathway expected to be predominant for the sub-category;
x - Additional release pathways to be considered, depending on specific source and national situation.

5.6.1Production of recycled mercury ("secondary production”)

5.6.1.1Sub-category description

There are two basic types of secondary mercury production: recovery of liquid mercury from dismantled equipment and mercury recovery from scrap products using extractive processes. In the USA (and probably many other countries), the total quantity of mercury recovered as liquid mercury is much greater than that recovered by extractive processes. Three areas that comprise a large proportion of the liquid mercury recovery globally are: 1) dismantling of chlor-alkali facilities; 2) recovery from mercury meters used in natural gas pipelines; and 3) recovery from manometers, thermometers, and other equipment. In each of these processes, the liquid mercury is drained from the dismantled equipment into containers. The second type of production involves the processing of scrapped mercury-added products and industrial wastes and sludges using thermal or chemical extractive processes (US EPA, 1997a and COWI, 2002). (For a description of the processes, see US EPA, 1997a).
The same recycling plants described in above paragraph may also be engaged in recovering of mercury from mineral residuals from mining and primary processing of zinc or other metals, and sludge from pre-distribution cleaning of natural gas. These activities are often called by-product mercury recovery, as opposed to post consumer recycling. When quantifying national mercury cycling, this distinction is useful, and if data exist on this split this information could be reported in the inventory documentation.
Note that mercury recycling may be an import source of mercury to the economy of countries where such facilities exist. Received and refined mercury from these sources is brought back into the global mercury trade cycle. Mercury recycling activities are often economically favoured by governments to encourage collection and treatment of this type of hazardous waste (COWI, 2002)
In some countries mercury recycling activities contribute substantially to mercury market supplies, while other countries do not currently have domestic recycling plants. Some of these countries without recycling programs may export parts of their waste with high mercury concentrations to recycling facilities abroad (COWI, 2002).

5.6.1.2Main factors determining mercury releases and mercury outputs

Table 5 186 Main releases and receiving media from production of recycled mercury (secondary production)

Phase of life cycle	Air	Water	Land	General waste	Sector specific treatment/ disposal
Recovery of liquid mercury	X	X	X	x	X
Extraction of mercury from scrap products	X	X	X	x	X
By-product mercury recovery	X	X	X	x	X

Notes: X- Release pathway expected to be predominant for the sub-category;
x - Additional release pathways to be considered, depending on specific source and national situation.

Mercury recycling/recovery activities may lead to substantial releases of mercury to the atmosphere, to aquatic and terrestrial environments. The amounts lost depend very much on how carefully the process releases are managed. Processing facilities may be equipped with release reduction devices with the potential to reduce direct releases of pollutants to the atmosphere as well as to aquatic and terrestrial environments. As in other sectors, release reduction technology yields additional solid or fluid residues, which also have to be managed to prevent or reduce additional releases (COWI, 2002).
In the USA (and probably many other countries) information on the performance of specific emission control measures is very limited and site specific. If a scrubber is used mercury vapour or droplets in the exhaust gas may be captured in the spray. Concentrations in the workroom air due to mercury vapour emissions (such as from the hot retort process) may be reduced by the following methods: containment, local exhaust ventilation, dilution ventilation, isolation, and/or personal protective equipment. Vapour emissions due to mercury transfer during the distillation or filling stages may be reduced by containment, ventilation (local exhaust or ventilation), or temperature control (US EPA, 1997a).

5.6.1.3Discussion of mercury inputs

Table 5 187 Overview of activity rate data and mercury input factor types needed to estimate releases from production of recycled mercury ("secondary production")

Process type	Activity rate data needed	Mercury input factor
Recovery of post-consumer mercury	Amounts of produced mercury	g mercury released per metric ton of produced mercury

5.6.1.4Examples of mercury in releases and wastes/residues

During extraction of mercury from waste materials, emissions may vary considerably from one type of process to another. Emissions may potentially occur from the following sources: retort or furnace operations, distillation, and discharge to the atmosphere from the charcoal filters. The major mercury emission sources are due to condenser exhaust and vapour emissions that occur during unloading of the retort chamber. Mercury emissions also can occur in the filling area when the flask overflows and during the bottling process. One company in the USA (Mercury Refining Company) reported results from two emission test studies conducted in 1994 and 1995 that showed average mercury emissions of 0.85 kg per metric tons of mercury recovered (MRC, 1997, as cited in US EPA, 1997a). In 1973, emission factors were estimated to be 20 kg per metric tons of mercury processed due to uncontrolled emissions over the entire process (Anderson, 1973, as cited in US EPA, 1997a).
In the USA, mercury release data were reported in the 1994 Toxics Release Inventory (TRI) for 2 facilities (which use extractive processes). One facility reported mercury emissions to the atmosphere of 116 kg for 1994, and the other facility reported 9 kg mercury emitted to atmosphere for 1994. Plants that focus mainly on obtaining liquid mercury from old equipment (and that do not use the extractive process) are expected to have lower emissions.
In the USA in 1996, an estimated 446 metric tons of mercury was recycled from industrial scrap. The recycling is estimated to have accounted for approximately 0.4 metric tons of mercury emissions in 1995 (US EPA, 1997b). Major sources of recycled mercury include dental amalgams, scrap mercury from instrument and electrical manufacturers (lamps and switches), wastes and sludges from research laboratories and electrolytic refining plants, and mercury batteries.
Weight of processed mercury containing waste and weight of the commercial mercury recovered from the waste in a Russian mercury recycling facility is shown in the table below. The facility employs a tubular rotary oven for the recovery. The oven is a metal cylinder body with the diameter 1.6 m and the length 14 m, installed at a gradient of 3-4 and lined with refractory bricks. The total reported mercury release from the process was 120 kg broken down into 52 kg with off-gas, 65 kg with waste water, 3 kg with cinders, and 0.5 kg unaccounted losses. The average emission to air from the process was 2 kg/metric ton mercury processed whereas the release to wastewater corresponds to and 2.5 kg per metric tons mercury processed. The previous years the releases were significantly higher and the mercury emission to air decreased from 1999 to 2001 for 20 g/metric ton processed mercury to 2 g/metric ton. During the same period the releases to water increased from 0.5 - 2.5 g/metric ton processed mercury.

Table 5 188 Processing of mercury-containing waste at a recycling facility in Russia in 2001 (Lassen et al., 2004)

Type of waste	Weight of waste, kg	Commercial Hg, kg
Catalyst, sorbent, sludge (from VCM production)	244,312	9,793
Unconditioned mercury	16,113	16,097
Mercury lamps	20,610	7
Mercury-containing devices	1,784	131
Luminophor concentrate	23,700	78
Other (galvanic elements, mercury-contaminated construction waste and soils, proper production waste, etc.)	54,800	343
Total	361,319	26,449

5.6.1.5Input factors and output distribution factors

Based on the information compiled above by Lassen et al. (2004) describing one facility in Russia, the following preliminary default mercury release factors are suggested for use in cases where source specific data are not available. It is emphasized that use of these data on other facilities is of course associated with substantial uncertainty, and must be considered indicative only. Because these default factors are based on a very limited data base, they should be considered preliminary and subject to revisions.
The primary purpose of using these default factors is to get a first impression of whether the sub-category is a significant mercury release source in the country. Usually release estimates would have to be refined further (after calculation with default factors) before any far reaching action is taken based on the release estimates.

Table 5 189 Specific reported outputs and output distribution factors for a recycling facility in Russia (Lassen et al., 2004)

	*Specific reported outputs 1**	Output distribution factors - Share of outputs	Specific release factors
	Kg/year	Unit less	Kg Hg release/metric ton Hg totally released (as reported)
Hg produced	26449	0.995	-
Air releases	52	0.002	2,0
Waste water releases	65	0.002	2,4
Sector specific waste disposal (Cinders - solid residues)	3	0.0001	0.1
Sector specific treatment/disposal (unaccounted losses)	0,5	0.00002	0.02
Sum of reported outputs	26569,5	1	-

Notes: *1 Data from Lassen et al. (2004) describing one facility in Russia. The use of these data on other
facilities is associated with substantial uncertainty, and must be considered indicative only.

Links to other mercury sources estimation - The mercury inputs to waste treatment sub-categories can be qualified through the quantification of mercury inputs to society with products and materials, as described in sections 5.1 to 5.6. Beware of double-counting of mercury outputs when developing the mercury inventory. Note that mercury inputs to recycling facilities may include mercury waste imported from abroad.

5.6.1.6Source specific main data

The most important source specific data would in this case be:

Specifically measured mercury amounts to all output streams.

5.6.2Production of recycled ferrous metals (iron and steel)

5.6.2.1Sub-category description

Iron and steel are produced from scrap metal, using various high temperature processes. Mercury may be present in recycled metals/materials as a result of presence of natural mercury impurities in the original materials, as well as presence of mercury contamination originating from anthropogenic use of mercury (e.g. mercury switches in cars going to iron/steel recycling).

5.6.2.2Main factors determining mercury releases and mercury outputs

Table 5 190 Main releases and receiving media from production of recycled ferrous metals (iron and steel)

Phase of life cycle	Air	Water	Land	Products	General waste	Sector specific treatment/ disposal
Shredding, storage and smelting	X	x	x		x	x

Notes: X - Release pathway expected to be predominant for the sub-category;
x - Additional release pathways to be considered, depending on specific source and national situation.

Ferrous scrap is processed by different industries and types of facilities and involves various process steps. For example, some automobiles are sent to dismantlers initially and valuable components are removed. The remaining automobile is usually crushed then shipped to a shredder. Some older automobiles are sent directly to the shredders. Other discarded items enter the scrap process at various stages of the processing system. Mercury may be released to air, water or land during various points in the process, including shredding (NJ MTF, 2002) and smelting.

5.6.2.3Discussion of mercury inputs

Table 5 191 Overview of activity rate data and mercury input factor types needed to estimate releases from production of recycled ferrous metals (iron and steel)

Life-cycle phase	Activity rate data needed	Mercury input factor
Shredding, storage and smelting	Numbers of vehicles/appliances recycled annually	Mercury content per vehicle/appliance recycled

The scrap includes recycled metals from discarded motor vehicles and home appliances, and waste metals from demolished building structures. Mercury is present in many items that are included in this scrap. For example, in the USA in the 1990s, about 9 metric tons mercury per year were used in tilt switches (such as trunk lights) and in anti-lock breaking systems (ABS) in automobiles. One study (ECGLU, 2001) estimated that between 155 - 222 metric tons of mercury were in automobiles on the road in the USA in year 2001. Since, the average age of automobiles on the road is about 9 years, and since the vast majority of discarded automobiles become scrap metal, one can estimate that about 10% (or 15 - 22 metric tons) of the mercury in automobiles enters the scrap processing system each year (NJMTF, 2002).
Mercury use in switches has declined roughly about 60 - 80% from the period 1996 to 2000 in the USA. However, the use of mercury in ABS systems has increased by about 130 - 180% over the same period (NJMTF, 2002).
Mercury switches in cars have been substituted earlier in European cars than described for the USA above.
Mercury is also found extensively in gas pressure regulators, switches and flame sensors in appliances that become part of the scrap for iron and steel production (Cain, 2000, as cited in NJ MTF, 2002).
In its 2006 report to the Legislature, the Agency estimated that 43,000 vehicles are discarded annually in Vermont, USA, with the potential of 25,000 individual mercury switches. Each switch contains about one gram of mercury (Vermont ANR, 2008), equalling about 2 grams of mercury per vehicle on average, including vehicles which do not contain mercury switches.
According to Vermont ANR (2008) mercury switches were discontinued from use as follows (presumably for the US market, but may have general relevance): Ford and General Motors, 2003 model year; DaimlerChrysler, late 1990s; and European manufacturers, 1993 model year. Toyota and Honda reportedly never used mercury auto switches in convenience lights or braking systems. Subaru, Nissan, and Mitsubishi had limited use of mercury switches in anti-lock brake sensors.

5.6.2.4Examples of mercury in releases and wastes/residues

In New Jersey, USA, there are 3 facilities that produce steel by melting scrap in electric arc furnaces and 3 facilities that produce cast iron from melting scrap in furnaces called “cupolas.” The total estimated mercury emissions to air from these six facilities is about 0.46 metric tons/year (NJ MTF, 2002), or an average of about 0.076 metric tons/year from each facility. Total mercury emissions to air in the USA for this sub-category was estimated to be about 15.6 metric tons/year based on a study by the Ecology Center (Ecology Center, 2001, as cited in NJ MTF, 2002).
The major pathway of releases is expected to be to air, via stack emissions from the iron and steel facility furnaces (NJ MTF, 2002). Mercury releases to air, land and water may also occur at other points during process, such as during storage, shredding and dismantling activities (NJ MTF, 2002).
However, a mass balance study at one facility estimated that only 31% was released through stack emissions, 49% was in furnace silo dust, 18% was in shredder fluff residues, and 2% emitted during shredding (Cain, 2000, as cited in NJ MTF, 2002).

5.6.2.5Input factors and output distribution factors

No attempt was made to define default factors for production of recycled iron and steel.
If no specific data are available on the prevalence of mercury switches, etc., in recycled ferrous metal, a first estimate can be formed by using the default input factors selected in Table 5 -192 below (based on the data sets presented in this section). The low end default factors has been set to indicate a low end estimate for the mercury input to the source category (but not the absolute minimum), and the high end factor will result in a high end estimate (but not the absolute maximum possible). The low end input factor is expected to be relevant in countries where switches with mercury has not been used cars and house appliances within the last 10 years, or where switches are generally removed before metal recycling.
Note that the default input factor given only includes mercury switches in vehicles. If mercury components (electric switches, gas thermostats, etc.) have been used in other recycled metal appliances nationally, these must be quantified separately to be included in the inventory.

Table 5 192 Preliminary default input factors for mercury in ferrous metals recycling

Material	Default input factors; g Hg/vehicle; (low end - high end) *1
Per vehicle recycled	0,2 - 2

Notes: *1 Relevance - see text above.

b) Default mercury output distribution factors

Table 5 193: Preliminary default mercury output distribution factors for recycling of ferrous metals

	*Default output distribution factors, share of Hg input1**
	Air	Water	*Land 2**	Products	*General waste 2**	Sector specific treatment/ disposal
None	0.33		0.34		0.33	?

Notes: *1 These default factors are derived one example from the USA, air emissions are likely to be higher in facilities without dust retention filters on the furnace air outlets.
*2 The distribution on land deposition and general waste may likely vary with local conditions and the distribution here is artificial, meant to signal that these may be important output pathways.

c) Links to other mercury sources estimation

For the waste treatment sub-categories it is very important to keep in mind that the mercury content in the waste originates from 1) intentionally used mercury in discarded products and process waste; 2) natural mercury impurities in high volume materials (plastics, paper, etc.) and minerals; and 3) mercury as a human-generated trace pollutant in high volume materials. Note that parts of these mercury inputs may be directed to municipal, hazardous and medical waste.
The mercury releases to the environment and waste deposits from these sub-categories should therefore be seen as a consequence of mercury being present in the products used in society.
Similarly, the estimated mercury inputs to waste treatment sub-categories can be qualified through the quantification of mercury inputs to society with products and materials, as described in sections 5.4 - 5.6. Beware of double-counting of such mercury inputs when developing the mercury inventory.
Note that mercury inputs to incineration from mercury trace concentrations in high volume materials (plastics, metals, etc.) are not quantified individually in this Toolkit.

5.6.2.6Source specific main data

The most important source specific data would in this case be:

Inputs are extremely dependent on the national or regional history of mercury-containing components in especially cars and home appliances. National information on the prevalence/existence of mercury switches in cars (and housing) over the last 10-20 years is a key issue for inventory refinement.
Amount of each type of scrap metal processed; and,
Measured data on emission reduction equipment applied on the source (or similar sources with very similar equipment and operating conditions).

5.6.3Production of other recycled metals

5.6.3.1Sub-category description

In principle aluminium, copper, zinc and other metals which are recycled in most countries, may contain mercury. Mercury inputs to production of recycled non-ferrous metal are largely un-described in the literature. For most metals, the processes involved in their original manufacture indicate that natural mercury impurities in the feed materials do not follow the produced metals to any major degree. Most of the mercury input to non-ferrous metal recycling, if any, would therefore originate from mercury use in other mercury-containing materials or products/components. As for production of recycled steel, the most obvious contributions may likely come from mercury switches, relays, thermostats and similar. Based on background knowledge on mercury use in components and products, non-ferrous metals fed to recycling activities may perhaps generally be less contaminated with mercury than recycled steel.
Aluminum is one recycled metal among others with potential for mercury emissions. Contamination of recycled aluminium and other metals are suspected. Mercury tends to preferentially amalgamate with aluminium rather than ferrous metals, therefore, in the recycled metals stream, mercury contamination may be more associated with aluminium versus ferrous metals. It is possible that facilities that process recycled aluminium using heat release some mercury to air and other media.

5.6.3.2Main factors determining mercury releases and mercury outputs

Table 5 194 Main releases and receiving media during the life-cycle of production of other recycled metals

Phase of life cycle	Air	Water	Land	Products	General waste	Sector specific treatment/ disposal
Production	X	x	x		x	x