bref foundries essentials to livar - gov.siokolje.arso.gov.si/ippc/uploads/file/bref_foundry_...

Karl Vrancken, STEVITO, Mol

Ljubljana, 06 -08 March 2006

Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 1

EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)

BREF Foundries Essentials to LIVAR

Karl VranckenProject manager BAT Centre VITO

Formerly EIPPCB





Contents• The BREF Smitheries and Foundries

• Survey of key topics in the BREF

• Applicability to LIVAR foundry





Melting- ferrous- non-ferrous

Metal treatment

Permanent mouldmaintenance

Lost mould making- sand mould- sand core

- pattern- lost model

Manual mouldingMoulding machine

Pouring / Shooting

Cooling

Shake-out/Take-outSand preparation

Sand regenerationFinishing

Scrap, ingots, sand, chemicals, patterns, dies

Finished casting— : metal— : sand— : metal— : sand





Key environmental issues

MeltMoulding &

Casting

Fin.

Sand

WaterWater

EnergyEnergy

Dust Dust DioxinsDioxinsNONOxx, SO, SO22

VOCVOCOil mistOil mist

DustDustAmineAmine

SandSand





Key environmental issues• Reduction of emissions

–– DustDust: off-gas capture and treatment–– VOC: VOC: use of coatings and binders

• Efficient use of energy and materials–– HeatHeat recovery

• Waste reduction–– SandSand re-use and regeneration





LIVAR foundry

BAT for FoundriesGeneric BAT

Materials, finishing, noise, water, fugitive emissions, EMS, decommissioningGeneric BATGeneric BAT

Materials, finishing, noise, water, fugitive emissions, EMS, decommissioning

Ferrous metal melting• Furnace operation• Residues• Emissions

Ferrous metal meltingFerrous metal melting• Furnace operation• Residues• Emissions

Non-ferrous metal melting• Furnace operation (Al, Mg)• Emissions

NonNon--ferrous metal meltingferrous metal melting• Furnace operation (Al, Mg)• Emissions

Lost mould casting• Sand preparation• Sand regeneration & re-use• Emissions

Lost mould castingLost mould casting• Sand preparation• Sand regeneration & re-use• Emissions

Permanent mould casting• Coating & cooling• Used sand management

Permanent mould castingPermanent mould casting• Coating & cooling• Used sand management





Pollution prevention and control

BAT examples:BAT examples:1. Off-gas collection and cleaning 2. Sand regeneration and re-use3. Coatings water- or alcohol-based





1. Off-gas collection and cleaning• Capture

– Prevents fugitive emissions• Dedusting

– Wet or dry• BAT Associated Emission Level

•• Solutions depend on process stepSolutions depend on process step•• Each has its own BAT AELEach has its own BAT AEL





BAT for dust abatement

• Abrasive cutting, shot blasting & fettling

• Wet or DryDry dedusting

BAT AEL: 5 5 –– 20 mg/Nm³20 mg/Nm³

Melt Moulding & Casting

Fin.






• Enclose unit operations and provide exhaust extraction on pouring and cooling line

• Wet or Dry dedusting of shake-out off-gasBAT AEL: 5 5 –– 20 mg/Nm³20 mg/Nm³


Fin.





Core making• Chemically-bonded sand:

– Minimise binder and resin consumption– Evacuate gases from preparation,

handling, holding

– Cold-box: Treat evacuated gases to amine emissions< 5 mg/Nm³






• Cupola, rotary furnaces: Wet or Dry dedusting• Induction, EAF, nodularisation: Lid or hood, dry

dedusting

BAT AEL Ferrous: 5 5 –– 20 mg/Nm³20 mg/Nm³


Fin.





NODULARISATION





2. Sand regeneration: monosand

Moulding

Primary (mechanical) regeneration

Waste sand

BAT: regeneration ratioBAT: regeneration ratioGreen : 98%98%

New sand





Sand regeneration: mixed sand

Moulding


Waste sand

Core making

New sand






Moulding


Waste sand

Core making

New sand

Secondary regeneration






Moulding


Waste sand

Core making

New sandRe-use





BAT for sand regeneration

• Minimise sand for disposal, through strategy of regenerationregeneration and/and/oror rere--useuse of chemically-bonded sand

• BAT regeneration levels for each regenerationtechnique





3. Coating of sand cores/moulds• Good metal surface appearance• No metal penetration• Reduces finishing

•• AlcoholAlcohol--basedbased

or

WaterWater--basedbased





Coating of sand cores•• Alcohol:Alcohol:

– VOC emission upon application, shake-out

– Easy application and drying

– Higher price

•• Water:Water:– Lower VOC emissions

– Drying lines and furnace needed

– Lower shelf-life





BAT for Coating of sand cores•• WaterWater

– Medium and large series, except

•• AlcoholAlcohol– Big/complex cores– Water-glass– Mg– Mn-steel with MgO

- Small-scale- Large-scale jobbing

Further reduction through binder solvents?Further reduction through binder solvents?





Conclusions• Focus on

– capture and treatment of emissions– In-process reduction of VOC-emission– Sand management

• LIVAR foundry on its way to implementation

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