rF{'[IIE

fv{ATTEIt

OF:

PETITION

OF

HORSEflEE

I}

RESOT

RCE

DEVELOPMEi-iT

CCIi}IPAN.!'.

Ii{C. FCIR

AIi

ADJUSTED

STAFIDAfrD

UNDER

55

TLL.

ADIvl.

CODE 720.131(c)

(-'L

f-

fl

i.i'

S O

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L-E

BEFORE

T*IE

TLLINOIS

PGLLU-fION

COFiTROL

BOARD

S[p

r

il

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(Adjustcd

Standard

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RCILA)

TO

raTlcF

otr

Fil.rNC

Dorothy

M,

Gunn,

Clerk

petcr

Orlinsky

ILLINOIS

POLLUTIOI'i

Assisranr

Counsel

COI'ITROL BOARD

Division

of

Leeal

Counsel

i00

Wesr

Itandolph

Streer

--

I

l0'

Fk-,or

Ii-t.lN0lS

fNirtROI;}\,IENTAL

(-)hicago,

IL 6060i

PROTECTION

AGENCY

l70l

S.

Firsr

Avenuc,

Suiie

600

Maywood,

IL 60153

Robert

Lawley.

Chief

Legal

Counsel

ILI-II{OIS

DEPARTME\]

OF

N,\]'L'R

.\L

RESOUI(CES

524

S Second

Street

Springfield,

IL 62101

Piease

take

notice

that

on Fridar'.

September

10, 1999,

ive

hand

delivcrecl

to

r6e

Cllerk

of the Poliurion

C-'onrrol Boarci

HORSEHE,\D

RESoURCE

DEVELOPN{ENT

COL{PANY,

INC

'S

REPI-Y

TO TIIE

RESPO\SE

OF

THE

ILLINOIS

ENVIRON\{ENTAL

PROI'ECTIO};

AGEI{C\'.

a

copy

c{'which

is

attached

herero

alcl

serveC

upon

you

Respect

fi.rl

h'

subrnitted.

HORS

EHEAD

RI]SOLTRCE

DEVELOPI\,IENT

John N

Moore

LAW

OFFICF.S

OF JOH:{

N

\{OOITE

200 North

LaSalle

Street

Sirite 2200

Chicago. IL.

60601-

1095

(3

r:) 782-9503

TTIIS FILING

IS

SUB}TITTED

ON RNCYCLED

PAPER

---

_:

-'

BEFORE

THE

ILLfNCIIS

FOLLU?'ION

IN

'IIiE

TIAT"TER

OF:

PETITIOn"

OF

HORSEIIOAD

RESOIjRCC

)

DEYELOP]IIEHT

CON,TPAN}',

INC.

FOR

AN

)

AD.'LIS'I'ED

STANT}ARD

TTF{DETT 35

ILL.

A

Dst.

rJOl)}l

7

Za.r

31(e\

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(Adjusted

Standard

-

)

RCRA)

)

IIOR,SETi

EAD

RT]SOURCE

DCVELOPI\IEN

T

cofttpANy,

INC.'S

REPLY

TO

-t.I{E

RESpOI\Stl

Pursuant

to i5

Ill

Adrn

Code

106 114(b),

petitioner

Horsehead

Resource

Develcprnent

Con"lpant',

lnc

(HRD).

throu.gh

its

atrorneys,

hereb\.

replies

to

rhe Illirrois

Environnretttal

Protectitttt

.'\gencr"s (lllinois

EPA)

Response

tr)

petiticn

for

Ad.iustcd

Staridard

filed

on Auqust

21.

i999

(Response)

HRD's

Petirion

tbr

an Acijusred

Stantlar<!

(HRD

Petitiorr;

requests

an

adjusted

standarci

tor

crude

zinc

oxide

(CZO)

produced

fropr

the

recycling

of

electric

arc Flrnace

clusr

and snraller

(iuantiries

of

oiher zi:ic-bearirrg

hazardous

and

nolt-h:tz-arclous

wastc

t'eedstccks

In

its respo:rse.

Illinois

EpA

agrer'<J

thar

I'iRD's

Petition

satisfies

tlrc

applicable

reqularon

crircria in

is

Ill r\dnr

Codc

720

l3l(c)

and

recorttntended

tlrat

the Board

granr

rhe

adjustecl

stan,larrl.

assurning

that

HRD

satistactorilv

responds

to

two queslions

ancl

presenls

supponing

evi6e,nce

at

hearing

FIRD

agrees rvith

the analvses

and recornnienclaticrrs

irr

Iilinois

EpA's

Responsc.

and

ans\\'ers lllinr-ris

EP.'\'s

t\vo

questions

in

this

Replr

In

par-ticular,

I-iRL)

co,)curs

$,ith

lllinois

EP,\

tlrat

the

Board's

recentlt'-granted

adjusrecl

standard

foi

i3ig

Rr'er

Zinc

Corproration's

(BRZ)

zinc

oride

nraterial

has

"stronq

precederrtial

value."

and

rh't

the

relie

Iobtained

bv-

BRZ

is

"r'irtuallv

the

sanre

as the relief

souglii

bv

HRD

"

Resporrse

at

---

4

{+ittngl4g

?@nc

Corporation

for att

Adju-sted

Stattdard-UMellJ

Ill.

Adrn.

Code

72cj i3l(.c)

(Anril

15, l99g),

AS

99-3

(BRZ

Opinion

and

Order),

alnended

May 6. 1999).

HRD's CZO and

BRZ's

zirtc oxirle

n)atel'ial are

vinually

icfr*ntica! in source, conlp-.rsirion.

ancJ

process

suitabiiity.

and

HR,D

has

,Jemonstratecl

compliance

with the regulalon criteria

in 35 ill Adm Code

"l\C

i:i l(c)

in ri manner

similai'to

BRZ fhe remainder of this

Reply

acldresses

Iliinois

EPA's two

questiorrs

l-

C-otttpiusj.n_Jfrlh..Rau'S.&.leJi$

FIRD agrees

rvith Illinois EPA's

$tatenicnt

that

the

pertentages of

zittc,

iron,

and

lead

in zinc

concenlraler

p.r,.rduced

ttom

mired

qre

ar'd

in

C7,O are

wer,v sirnilar

Response at

3. Illinois

EPi esked.

ho.*,eoer,

u'hother

the "highcr

chlorint conterit

Iill

fZO]

poses

any

pollution

conirol

problems

not

inherent

ir.

the

procerrifig

,:i

niiiied

zinc

"1

id In shcn, as explained

below,

the

presence of chlorides

does

not

po5e

iinv

pglluiion

i.:niiol ei';E!€r.ri

o; oih€irfi;e ;mpede the

preee:siag

ef eEO

Direct

Feedstock

fq{ Ziqs

l:q-du-g[Sg

One of CZO

s usc-1

ii a: n direct

teeds(dcfi: {n

zine

llroductifl(t

at ZfA's zinc

production

faciiity

in

Monaca.

Pennsylvania

Sg?

HRD l'etition at

l3-i4 No

separate

salts

removal

step

is neces-san

for

this

irse CZO

is blended

rvith

other

feedstocks

(roasted

nrined

zinc concentrate

and

otlter

low-sulfur

zinc oxides) and

the

cornbined

feedstock

is sintered.

ivhich results irr two

rn-aterials

zinc

sinter and

lead

c.oncentraie

'fhe

salts

pa.rtition

primarilr

lo

the lead concerltrate,

rvhich

serves as a

feedstock

in

another

processing

circuit

at

the iacilitv Incidental salts

in water fiom

that

pr,-rcessine

1

tvhile

HRD

reported the

clenrcntal

presence in

terms of

"chlorine,"

this

elernent is

presenr

in

CZO

as

"ctrlorides"

or

"salts

"

In

the

rentainder of this Reply, I{RD

uses

the

terms

chlorides

or salts

to responC

to illinois

EPA's

questiorrs

')

---

sircuir

are

discharsed

to

*

*"ou,'--.::|lj";:::,"::;-

--:

is

cirarged

to

the

electrothermic

fLrnace

for

the

iinal

step

I

pirectEeElstocbfotcllci4ittg

.

-,-

r^r calcrniug

at

HRr)'s

faciiity

iil

cZo

also

is

usecl

as

a

direct

feedstock

for

cal'

'on

of

the

Palnrerton'

Penns-vivarria

S-es

HRD

Petiticn

at

i5-l-/

IRD

calcines

a

portl

cLo

\npart

for

the

same

reasons

thar.

BRZ

rvashes

ir,;

zinc

oxide

niateriai

Lo-iupsrs

HRD

petition

ar

r5

(caicining

of

cZo

increases

rhe

effrcierrcy

and

rongevity

of

ZcA's

si.tering

product

coriectors)

urb

BR7-

opini.n:nd

order

at

12

(salts

co*ld

conode

BRZ,s

refi'ery

equipment)

calcining

resu*s

in

zinc

calci*e

and

lead

concentratc'

and

further

puriires

the

cZo

bv

removinl-r

the

read

and

saits'

rv'ich

partition

to

the

leail

concenttate

Agairr'

no

acldition"l

pollt'lion

control

nleasures

are

required

The

lead

c-oncentrateisprocessedstanHRDaffiliatefornletalsrecoveryandthesaltsare

dispose<i

of

in

a

perrnitteil

rronhaz..rd'us

underground

injection

rvelr'

The

zinc

calcine

is

sellttoZCA.s.i\4.onaca.Pennrvlvaniafacilitv.whereitissintereclirrcombinationrvit}t

CZO

and

other

zinc

collc€'rl'roleS'

z.

lJilrinrizntiqqoj-Lqss

-....r?pc.

the

potential

tbr

CZo

ioss

lllirrois

EPA

agrees

that

IIRD

satisfactorily

rninimizes

the

pc

duringr.:,":;

;#;;:#-:cperarions

are

e.crosed

antr

controiled

b)'

iilinois

i?u'itt*ttted

ba

gh

ouses'

2-IlrellTlv,tllProcessprcclrrcesnowastesar.rltrt'wastewatefdiscltarges.

j

Atler

production.

CZo;s

transferrcd

to

railcars

irl

an

enclosec..

presstrrized

sYstent'

arrcl

4otl.'sitetranspoflati:.1^:ffl-.)nttrstcornplyrvithl-.)sDepartmento[

f

'a"'Pottotion

regulatto'"s

---

Respcnse

at 4, While

agreeing

ihar

HRD

minirnizes

rhe porenrial

loss

of

CZO,

Illineis

EPA

suggesterJ

in

its

Response

that

HRD

"address

its

procerJures

lor dealing

rvith

accidental

spiils,

ruptured

baghcuses,

ar

aiher

environmental

concerns

"

Response

at 4

Funciamentaliy..

FlR.b's process

design minimizes

ihe

potentiai

l-or

loss

of

eZC

ns

explained

in

FIRD's

Pe'rition

(pages l-9),

CZO is

managed

eniirely

in

enclcsed

buildings.

contairrers,

and

conveyances,

end tlrerefore

is

protected

from

exposure

to the

outside

environment

Nevertheless,

in

the highly

unlikely

evenr

rhat

a spill

of

CZO

cccuryecl.

HRD

is

fullv

prepared

to respond

quickly

and

effectively

to

prevent

exposure

and recover

the

CZO

F,mplo;r'ees

trained

to

respond

to

emergencies

staff

HRD':i

Chicago

thcilitv

24

hours,

se''uen

days a

r'.'eek

FIP.D implements

a multi-pronged

preventior.l

and respopse

strategy, including

"

Ftnplo,"ee

training

ProsJanls,

o

lnspection

and monitoring

programs,

e

Preventativentaintenanoe;

r

Cornprehensive

housekeeping

progrants;

e

Emergency

equipment.

anci

e

Arrangenlents

witb

appropriate

authorities.

These programs

and

procedures

greatly

minimize

the

possibility

of

a spill

of

CZO

or

other material

If a

spill

of

CZQ

were

to

occur, however,

trainecl t{RD

personnel

rvoulcl

immediately

respond

Io the

spill

Thq

entire

area where

CZO is

managed

is

pavecl

ivith

asuirnii

ul

qiontlHtF,

rrhj'-h

*uul,-l

.t,''igin

;n;,

CJO

ipili

n6d

laiitil;it€i

ieiiiav;l

af

lh€

rnateria!

by

industrial

vacuunt

lntcks. road

srveepers,

and

other

appropriate

containnrent

equipment The

recovered

CZO

ri,ould

be

returned

to

the recvcling

process

---

An accidental

retease due

to

product

collector

bag

failure

also

is unlikely

to

occur'

IIP.D

operates

two

Illinois

EFA-perrrritterl

product

collectars'

each

with

12

contpari.ments.

A 24-hour

opacity

monitor

continuously

nleasures

exit

gases

from

the

product

collectors,

arrd

an alarm

connectecl

to the

monitor

alerts

the

kilrr

operatclr

ii'

opacity

ievels

increase Given

the

large number

of'bags

in

each

compartment,

inciividual

t-ailures are

unlikel.;

to affect

the

rec1,'cling operation

or othenvise

require

an

emergencV

response.

Nevertheless.

if a

product collector

bag

or contpartment

is the suspected

cause

of

a

failurre,

FIRD

imnteciiately

renloves the

affected

unit

frotti service

u'ithout

interruption

to

the

remaining

compartments,

initiates

repairs,

and

rcturns

the

unit to

service.

Thus.

HRD

has

*'ell-designed and

efTective

procedures

lbr

addressing

immediately

any contingencies,

including

those

posited

by

Illinois

EPA,

demonstrating

that CZO

is

handled caiefullv

to

nrinintize

ioss

CONCI,USION

IVI{EREFORE.

for

the

reasons set

fonh above

and

in HRD's

Petition,

which

dernonsrrate

thar

HRD

satisfies

all the criteria

for an

adjusted

standard,

IIP.D respectfully

requests

that

the

Board

grant F{RII

an

adjusted

standard

ior CZO

produced front tlte

rec-vcling

of

electric

arc

filrnace

dust. and

smaller

quantities of

zinc-bearing

hazarcious

and

non-hazardous

u.'aste

feedstor:ks.

Respect

fu I

11,'

submitted.

HORSEHEAD

RESOURCE

DEVELOPIV1ENT

CON{PA}I\'.

D'iC

Br-

ne of

its

Attomeys

---

ffiri#,triffy,rHAL,:R&

U;y;,

;,,

*oF'ffi,t

;#;I

;1'

t

;

[?;'.''

John

N.

ilfoore

3tr"ii[i.f_:,,"!,,,.l.iTJ;.-j,",?*

i;",'iii?:r\,f,ou,'

Date:

Septernber

lA.

j9g9

---

-cERrIFIca

rs

ep

sEn

u,rau

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(r_Ld\D

DELr\/ER\,

*r*"riii'l',,,

T[#.,*];::ffiounse,

,r,,i

|;fr

,rr

Firsr

Avenue

Robert

Larvlev

urrref

Legal

Ctunsei

I"f

i

f"X#*::i',

Reso,,rces

spnn-sfield

il t

lttir*l*#fr

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