**** Note of Meeting

Transcription

1 EUROPEAN COMMISSION DIRECTORATE-GENERAL JRC JOINT RESEARCH CENTRE Institute for Prospective Technological Studies (Seville) Technologies for Sustainable Development European IPPC Bureau Sevilla, 01 July 1999 Foundries_twg1_report TWG 1 SMITHERIES AND FOUNDRIES SEVILLE, 15 TO 16 APRIL 1999 **** Note of Meeting Introduction 1. The Technical Working Group (TWG) for the Smitheries and Foundries industry sector is organised for the purposes of information exchange under Article 16.2 of the Council Directive 96/61/EC concerning Integrated Pollution Prevention and Control (IPPC). Each TWG is set up according to the work-plan ratified by the IPPC BAT information exchange forum (IEF). 2. On 15 th to 16 th April 1999, the EIPPCB, part of the Joint Research Centre s Institute for Prospective Technological Studies (IPTS) organised the first meeting in Seville. Mr. Don Litten chaired the meeting, which was attended by 26 experts from Member State Authorities (Luxembourg was not represented at the meeting), Commission Services (DGXI), Industrial Organisations (notably CAEF, CTIF and VDMA) and an Environmental Non Government Organisation. World Trade Center, Isla de la Cartuja s/n, E Seville - Spain Telephone: direct line (+34-95) , switchboard Fax: Internet: eippcb@jrc.es;

2 3. The agenda for the meeting comprised an introduction of EIPPCB, DGXI and TWG members; a discussion on the scope of industry within the sector; discussion on the main environmental issues arising within the sector; some detailed discussion on some of the main issues. The meeting concluded by outlining the forward work plan. 4. Following his welcoming speech Mr Litten emphasised that the purpose of TWGs is to debate matters on a sector specific technical level with a view to the content of any proposed BAT reference document (BREF) and not to debate wider issues which should be referred to the IEF. 5. Mr Wicks (DGXI) outlined the IPPC Directive and its aims and he stressed that it was a system of licensing to improve management and control. He also outlined operators obligations, the interface of IPPC and BAT and the implications for the BREF Notes. Scope of work 6. The TWG agreed that Smitheries and Forges are the same process. There are two thresholds, hammer energy and calorific power, for forges and both must be exceeded to fall under the description of section 2.3.(b) in Annex I to the IPPC Directive. TWG Members thought that there were probably no installations of forges and job forges that exceeded both thresholds. TWG Members will establish whether there are any forges in existence that exceed both thresholds and report to EIPPCB within four weeks. If no such forges are identified within that time then they would be excluded from the BREF at this time. DGXI, however intimated that the thresholds may be considered further while reviewing the Directive. (Remark: no forges exceeding both thresholds were reported.) 7. For ferrous foundries the TWG agreed that daily production capacity (section2.4 Annex I) is defined as the production of Good Castings and that the capacity is based on the theoretical capacity if the foundry was operated for 24 hours provided it was capable of being operated in that way. Individual cases, such as the production of a large casting over a long period or where a foundry was not permitted to operate for 24 hours were seen as specific to the permitting process and not affecting the work of the TWG. Nevertheless the TWG could provide some advice that could be used by industry and permitters latter. 8. Malleable iron casting will be dealt with as part of the ductile iron casting. 9. For non-ferrous foundries the melting capacity for 2.5 b) Installations should be the aggregate plated capacity of the furnaces at an installation and that the hourly rate multiplied by 24 would be used if appropriate. The melting stages for non-ferrous metal foundries that use secondary raw materials are covered by the work of the Nonferrous Metals TWG. 10. The TWG advised that titanium, special alloys and precious metal foundries were below the threshold. It was likely that there were no cadmium foundries. Members were asked to identify any cadmium foundries exceeding the daily capacity of 4 t/d. The casting of lead grids for battery production would not mean that the remainder of 2

3 battery production was included. It was emphasised that a stamping process was now commonly carried out to produce grids and that this method may be environmentally better. (Remark: no indication of cadmium foundries exceeding 4 t/d (section 2.5 (b)) 11. The TWG agreed that foundries can be characterised for the work on the basis of: - the metal, the technique for core making, the way the moulds are filled, the degree of automation and size. The sub-division of these stages was agreed. The metal groups would include their alloys. 12. The TWG agreed that bell casting, art casting and investment casting were excluded as they were below the threshold. It was also agreed that investment casting was a high cost, high technology process and was not an alternative to other casting methods. 13. The TWG noted that continuous casting is included in the Iron and Steel and Nonferrous metal work. 14. The TWG agreed that the production stages outlined by EIPPCB were relevant. Scope of work Relevant production steps that have been identified Melting and Metal Treatment Core Production Mould Production Moulding Material Preparation Pouring and Cooling Shake-out Cleaning and Fettling Heat Treatment The upstream and down stream boundaries were defined and it was agreed that wood and metal working techniques to produce patterns would not be included and that varnishing and painting of products would also not be covered. 15. The TWG agreed that mould material preparation (a) was part of the production process and that used sand preparation (b) was part of the environmental measures. 3

4 Scope of work Green sand cycle New sand (for coreless casting) Cores (new sand) Mould making Mould material preparation (binder addition, mixing, humidity adjustment) a Sand overflow Shake out Sand loss with casting Used sand preparation: (Lump crushing,cooling, metal removal b Sand reclamation and regeneration were agreed to mean the same thing and it was agreed to use the term regeneration. The definition: "Sand regeneration are measures (mechanical, pneumatic, thermal, wet) that aim at removing the spent binder layers from the sand corn." was agreed. It was also agreed to use the term off-site re-use to refer to the utilisation of foundry sand in various ways. The terms used in the glossary will be checked to ensure that the meanings are consistent following translation, the TWG Members will advise. General BREF outline 16. The structure of the BREF was outlined and was discussed. Outline of the BREF-document Preface Executive summary 1. General Information 2. Applied processes and techniques 3.Emission and consumption levels 4.Techniques to consider in the determination of BAT 5.Best available techniques (BAT) 6. Emerging Techniques 7. Conclusions and recommendations Annexes 4

5 It was emphasised that EIPPCB is not writing a permit and that issues such as life cycle analysis may be examined in other fora. Information Requirements for Chapters 1 to The reports available to EIPPC Bureau at the moment on information needed for chapters 1 to 3 do not cover all countries or or all parts of the sector, especially nonferrous metal data is weak. Some reports are partly outdated. Information required from the TWG Chapter 1 except Panorama 97 no specific reports on these general information 4-5 reports contain information we need, but the problem is: - only for parts of the sector - not all countries - different years, partly outdated Information is needed Information required from the TWG Chapter 2 vast number of reports describing applied processes and techniques a bit weak on non-ferrous metal part especially more information is needed on metal treatment what we need are some good flow-sheets, diagrams etc. to explain processes Information is needed 5

6 Information required from the TWG Chapter 3 almost all reports available, contain bits of the emission and consumption data we need but not for all activities we cover in the BREF (the non-ferrous part is again a weak spot) not enough to give a full picture we need a full list of input material (especially melt treatment and chemically bounded sand Information is needed The Information requirements of EIPPCB were outlined and agreed. 18. Data provided on inputs to and outputs from the processes should be consistent in terms of units and expression (e.g. products, casting sizes). The work of the TWG will involve the collection of data on Process Inputs and Outputs together with data on costs. It was agreed that the data should include references of the source, technical basis and time frame. 19. Sweden can provide a comparison of data on the basis concentration and mass per tonne of liquid metal. Noise data was not included and is difficult to define. 20. Reports were promised during the meeting. English language reports were preferred but other reports can be read or translated. The following reports and data will be sent to EIPPCB and are available or in preparation. Report Country Language Guidance book on foundries Netherlands Dutch Foundries study report Belgium Flemish BAT document Spain Spanish Ancillary process guidance note United Kingdom English Report on chemically bound sand United Kingdom English Research studies Germany German Report on foundry sand Finland Finnish Life cycle analysis for lost foam Netherlands Dutch casting Solvent free coatings Netherlands Dutch 6

7 Environmental key issues 21. EIPPCB identified key issues in all of the foundry stages. For convenience, these stages were defined as Raw Materials Handling and Storage; Melting Furnaces and Metal Treatment; Waste Gas Scrubbing and Foundry Processes (Moulding and Core Making etc). The key issues included Emissions to all Environmental Media; Consumption of Energy and Raw Materials; Other Environmental Issues (such as noise, vibration, heat and odour); Other Factors (such as training, management, process control, decommissioning and emerging and transferable technology). 22. Arising from the group discussion, a number of comments were made on the main issues tabled by the bureau. The issues were presented as overhead slides that were provided for the Members. Key Issues for Foundries (melting and metal treatment) Raw material storage Scrap Yard Dust Waste water (surface water run-off, oil, grease, etc.) Key Issues for Foundries (melting and metal treatment) Melting Furnaces and Metal Treatment Dust / Metal content in dust (Pb, Zn, Sn, Cd, Ni, Cr, spec. non-ferrous metals, high alloy steel) Emissions from combustion of fuel (NOx, SO 2, CO/CO 2 ) Other air pollutants (dioxin, HF, H 2 S) Waste from gas cleaning (dust/sludge) Energy consumption/energy efficiency Slag Dross (spec. non-ferrous metals) 7

8 Key Issues for Foundries (melting and metal treatment) Waste gas scrubbing Waste water (solids, cyanide, heavy metals (partly dissolved), sulphate, AOX) Key Issues for Foundries (mould and core production etc.) Raw Material Handling and Sand Preparation Dust Key Issues for Foundries (mould and core production etc.) Moulding with Clay Bonded Sand Dust 8

9 Key Issues for Foundries (mould and core production etc.) Moulding / Coremaking with Chemically Bonded Sand Dust Organic air pollutants (amine, formaldehyde, phenol, VOC) Inorganic air pollutants (SO 2, ammonia, hydrogen cyanide) Odour Waste sand (not thermally affected, mould/core-breaks) Key Issues for Foundries (pouring and cooling) Pouring and Cooling Combustion products (from pre-heating of pouring ladles) Gaseous Emissions (thermal degradation/volatilisation, chemical compounds from binder or blacking, vaporisation of expendable pattern) Odour Key Issues for Foundries (shake out) Shake-out and Cooling of Castings Dust from shake-out Gaseous Emissions (continued thermal degradation/volatilisation) Waste foundry sand (clay bonded, chemically bonded, mixed sand) 9

10 Key Issues for Foundries (post casting operations) Finishing and Post Casting Operations Dust (sand, metal particles, abrasives, ) Fumes from thermal separation or welding Key Issues for Foundries (heat treatment) Heat Treatment Combustion products (furnace firing, NOx, etc.) Oil mist from quenching bath Key Issues for Foundries Waste gas scrubbing (e.g. organic bonded core and mould making, pouring cooling, shake-out, fettling) Waste water (amine, phenol, sulphate) 10

11 Last, but not least Issues not discussed yet, but to be addressed in the BREF fugitive emissions accidental releases accidents noise/vibration start up/ de-commissioning The comments below relate to the comments and the amendments that were made. The processes can be affected by the raw materials, feedstock selection is important to prevent down stream problems. It was acknowledged that there have been some cases where secondary raw materials have been contaminated with radioactive isotopes. Member States have their own regulations for these instances. VOCs were likely to be emitted from melting oily scrap and from the use of materials such as HCE (for Al). SF 6 is used for Mg. Odour could also be an issue for melting shops and wet abatement systems. It was agreed to delete sulphate as an issue for wastewater discharge of waste gas treatment. Handling liquids such as phenol means that water pollution and odour were issues for foundry processes. CN was also an issue. The term non-cured sand should be used instead of not thermally affected. Benzene (from black products) and PAHs were key issues for pouring and cooling. Collection of fume and measurement of components was a key issue. Techniques for measurement are available. The use of permanent moulds can contribute to air emissions. Glycols can be emitted from pressure casting. 11

12 Sand regeneration should form a new section under key issues including energy use and efficiency. The term residues will be used as opposed to wastes or by-products. Co-incineration is included in new waste legislation and could affect the use of foundry sand in cement kilns as well as the thermal sand regeneration. Especially on the second aspect concern is expressed by experts who see thermal regeneration endangered by limit values being established for very different waste incineration processes. Fumes from finishing operations (thermal arc) and noise and vibration are issues. Dust reactivity is an issued (shot blast dust, dust from Mg). Case hardening and CN are usually associated with out-sourcing and are excluded from the scope of the BREF. Waste gas scrubbing should be included with Waste Gas Treatment as a general section. De-commissioning experience is not available for IPPC sites but some information is available from some other sites. The key issues are the degree of possible soil contamination (e.g. sand) and the type of chemicals that may be involved. Techniques to Consider in the Determination of BAT This section was included in the papers submitted by EIPPCB prior to the meeting. Specific points were discussed. Preparation of clay bonded sand by vacuum mixing and cooling was thought to be not proven and to be only on an experimental basis. As there was no expert present with specific knowledge on this issue, more information is required. Bio-filters are only at a development stage. Bio-scrubbers are a more proven technique. Lost foam casting techniques are techniques to consider. Solvent free coating techniques are techniques to consider. The cross media aspect of water pollution is an issue. More information required, especially for the description on techniques to consider in the determination of BAT, was summerized by the EIPPCB as follows: 12

13 Information we need Melting and Metal treatment TWG to complete list of measures and provide information, case studies, data etc. more case studies are requested to get a profound set of data feedback and information from other countries on dioxins (measures/techniques)? Information on waste water treatment (equipment, data etc.) Information we need Moulding, core making, casting etc. TWG to complete list of techniques to consider and provide information, case studies, data etc. more case studies and operational data (especially regarding different sand regeneration techniques, capture and abatement of air emissions especially for organics from moulds and cores Information on waste water treatment (equipment, data etc.) Information Systems 23. As part of the whole TWG work, a trial of electronic information exchange is carried out. A presentation was given on the use of the EIPPCB homepage on the Internet and of the facility to use the TWG workspaces for exchanging of information and commenting. The workspace will only be accessible by TWG members. An invitation to join the electronic information exchange trial (get access to the work space) will be sent by to all TWG members who have provided the EIPPCB with an address. Note: Following some requests of TWG members to obtain only electronic messages, the distribution procedure for papers, such as interim reports of the workprogress, summary of comments etc., will be simplified. Information will 13

14 be provided to those registered for the workspace only by means of the workspace. People without workspace registration, but with adress, will obtain information via . Only those who have neither nor workspace access will receive information as fax. TWG members are advised to set workspace preferences so to get the automatic activity reports for the workspace. Draft BREFs will still be send as paper copy to every TWG member, but will also be available (easier and quicker) on the EIPPCB homepage, both within the workspace and on the public side of the web site under activities. It was stressed that the EIPPCB homepage is a valuable public source of up to date information for TWG membership and background listing of material being used in the BREF work. ( Any other business 24. There were no items under this heading. 25. The next TWG meeting will take place towards the end of the BREF preparation when the full draft has been circulated. The meeting will attempt to finalise the draft BREF and to obtain consensus. 14