in conjunction with

02/02/2012

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In conjunction with

Present

MJAC Midland Joint Advisory Council for

Environmental Protection

Established 1928

Advanced Seminar IV Taking Legal

Action

Advanced Module IV

Session 2

Introduction to Ferrous Foundries

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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.

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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

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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

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• 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

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• 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

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• 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.

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Vibrating shakers to break

down moulds

Releasing casting and

sand to conveyor below


• 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

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sand vibrating filter plant

Thermal abatement

plant & stack


• Fettling, dressing & finishing of castings

– Shot blasting

– Sawing / cutting

– Welding

– Grinding

– Polishing

– Machining

– (Coating)

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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

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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

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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+)


• 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!

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• Nodularisation

Air = dense, white magnesium oxide fume

Waste = Slag & magnesium oxide dust


• 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

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• 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


• Knock out

Air = Particulate Matter & VOC`s

Land = Waste sand

Waste = Waste sand

Noise = Significant local noise & vibration

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• 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


Energy = Fuel usage to power thermal reclaim

Accidents = Leakage of CO & particulate matter

Noise = Fan, handling, blowing


• 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


Accidents = Particulate matter escape from shot

blast & grinding – very aggressive emissions

Noise = Finishing operations can be very noisy

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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

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Introduction to the permit document

• Front Sheet / cover

– Local Authority

– Type of installation

– Name & Address of installation

– Legislation

– Reference Number

– Signed & Dated


• Introduction & Description

– Legislation

– BAT requirements

– Date permit becomes active

– Short description of activities

– Status log table

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• General Conditions

– The permitted installation table

– Site boundary

– Notification of change

– Management & Administration

– Improvement Programme

• Emissions to Air

• Monitoring emissions to Air


• 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

in conjunction with

Documents