In conjunction with MJAC Midland Joint Advisory Council for Environmental Protection. Present. Advanced Module IV

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1 In conjunction with MJAC Midland Joint Advisory Council for Environmental Protection Established 1928 Present Advanced Seminar IV Taking Legal Action Advanced Module IV Session 2 Introduction to Ferrous Foundries 1

2 Aims SG Note description of a ferrous foundry Environmental Impact Examine BAT for ferrous foundry Briefly review permit document IPPC SG3 January 2006 BAT Review & upgrade requirements Summery of releases Emission Limits Techniques for pollution control process controls, emission control, management, raw materials, waste handling, waste re-use, energy, accidents, noise & vibration, monitoring. 2

3 SG3 - Description Raw Materials Powders/ briquettes; coal dust, limestone, refractory's, fluxes kept undercover / enclosed Sand; - bulk in silo or in bags Scrap metal; - in designated area Liquids; binders, resins, catalysts, oils, fuels in delivery containers or bulk in tanks Release agents & other minor materials; - indoors 3

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5 SG3 Description cont Melting Cupolas; refractory lined vertical steel tube, loaded with coke, iron & limestone, air blasted through to melt iron which is tapped off at base Furnaces; reverberatory, rotary, electric arc & induction. Use gas, oil or electricity to heat & melt the iron. Molten iron tipped from the furnace. Desulphurisation; calcium compounds used to remove sulphur Nodularisation; Magnesium used to form ductile iron 5

6 SG3 Description cont Moulds & cores The sand mould is supported by a wooden or metal pattern, mould normally placed into a mould box & hardened sand cores inserted to represent voids in the finished casting Numerous methods of manufacture using a variety of binders, resins, hardeners & catalysts Moulds are most widely manufactured from greensand, involves damp sand & clay mix to form mould & lined with coal dust Cores, made by cold or hot set sand systems Mould coatings may be applied Chemically bonded sand mould having a core inserted Green sand (which is red!) with pouring hole down to the mould & cores 6

7 SG3 Description cont Casting & Cooling Molten metal is poured into the mould to form the iron casting May be carried out by hand (floor or table cast) or via machine, automatic repetition, spun pipe casting, roll casting Cooling to enable casting to cool sufficiently to be knocked out & handled Small scale hand casting Large scale automated line casting 7

8 SG3 Description cont Knockout Removes the cooled & solidified casting from the sand mould. Knocked out by hand, vibrating table or belt, rotating drum, JCB! Casting is revealed & sand recovered for recycling & reuse. 8

9 Vibrating shakers to break down moulds Releasing casting and sand to conveyor below SG3 Description cont Sand Reclamation Primary Attrition to break down large lumps Screening to remove metal & contaminants Crushed in ball mills or vibrating screens Secondary Thermal treatment Wet scrubbing High energy attrition 9

10 sand vibrating filter plant Thermal abatement plant & stack SG3 Description cont Fettling, dressing & finishing of castings Shot blasting Sawing / cutting Welding Grinding Polishing Machining (Coating) 10

11 Tumble blast, shot fired through holes when door closed & the barrel rotates Hand operated shot blast used in an extracted booth, like a car paint spray booth Fettling benches, will each be provided with a hood & LEV normally served by a bag filter unit Paint spray booth, may be the final finish at the foundry adds value to the finished casting 11

12 Environmental Impact Raw materials (delivery, storage & handling) Air = Particulate Matter Water = Rain water run off from open air storage Land = Spillages Accidents = Spillages Noise = Vehicles, delivery to silos, handling 12

13 Environmental Impact cont Melting Air = Particulate Matter, CO, CO2, NO2,SO2, H2S, HC, PAH, heavy metals, dioxins Water = If used for abatement / cooling requires sludge separation Waste = sludge, slag, refractory, filter plant waste Land = Particulate matter emissions in locality Energy = Fuel usage to power cupola / furnace Accidents = Leakage of CO & particulate matter Noise = Charging, fan, oxy-cutting (100dBA+) Environmental Impact cont Desulphurisation Air = Particulate Matter & local odour Waste = High ph slag which may contain carbide & lime Accidents = Carbide releases acetylene if it gets wet, this is a highly flammable gas! 13

14 Environmental Impact cont Nodularisation Air = dense, white magnesium oxide fume Waste = Slag & magnesium oxide dust Environmental Impact cont Moulds & cores Air = Particulate Matter, solvents & VOC`s (amines, aldehydes & phenolics), combustion gases from ovens, odour (DMEA) & ammonia Waste = Sand, binders, resins & catalyst containers Energy = Fuel for heated systems Accidents = Leakage from containers 14

15 Environmental Impact cont Casting & cooling Air = Particulate Matter from casting, VOC`s & odour from cooling Waste = Sand from moulds & cores, filter waste Accidents = discharge of metal could lead to fires of combustibles Environmental Impact cont Knock out Air = Particulate Matter & VOC`s Land = Waste sand Waste = Waste sand Noise = Significant local noise & vibration 15

16 Environmental Impact cont Sand Reclamation Air = Particulate Matter, VOC`s & products of combustion where thermal reclaim used Water = If wet scrubbing used Waste = Particulate matter from filter plant waste Land = Particulate matter emissions in locality Energy = Fuel usage to power thermal reclaim Accidents = Leakage of CO & particulate matter Noise = Fan, handling, blowing Environmental Impact cont Fettling, dressing & finishing of castings Air = Particulate Matter, fume, & products of combustion where heated processes are used Water = sludge where wet scrubbing used Waste = Particulate matter from filter plant waste Land = Particulate matter emissions in locality Accidents = Particulate matter escape from shot blast & grinding very aggressive emissions Noise = Finishing operations can be very noisy 16

17 BAT for ferrous Foundries Best Available Techniques Sector Guidance is considered to constitute BAT BAT must be used to draw up permits BAT must be judged on a case by case basis but is likely to similar in similar installations SG note is the basis of BAT, but case specific factors also need to be taken account of; I.E configuration, size, location, etc What about an operators financial situation? BAT for ferrous Foundries BAT Continued Any mandatory EU emission limits must be complied with, BAT may be more stringent Bat may be exceeded if required to do so, for example to meet an air quality obligation BAT box example BAT Emissions from nodularisation should be captured and abated where necessary to prevent visible emissions beyond the site boundary 17

18 Introduction to the permit document Front Sheet / cover Local Authority Type of installation Name & Address of installation Legislation Reference Number Signed & Dated Introduction to the permit document Introduction & Description Legislation BAT requirements Date permit becomes active Short description of activities Status log table 18

19 Introduction to the permit document General Conditions The permitted installation table Site boundary Notification of change Management & Administration Improvement Programme Emissions to Air Monitoring emissions to Air Introduction to the permit document Materials Handling Storage, handling Solids & liquids + cleaning up spillages Training & Maintenance & Records Trained staff, maintenance scheduled & record of completion Resource Utilisation Raw materials used & the management of waste products 19