bref foundries essentials to livar - gov.siokolje.arso.gov.si/ippc/uploads/file/bref_foundry_...
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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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 2
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
Contents• The BREF Smitheries and Foundries
• Survey of key topics in the BREF
• Applicability to LIVAR foundry
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 3
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 4
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
Key environmental issues
MeltMoulding &
Casting
Fin.
Sand
WaterWater
EnergyEnergy
Dust Dust DioxinsDioxinsNONOxx, SO, SO22
VOCVOCOil mistOil mist
DustDustAmineAmine
SandSand
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 5
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 6
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 7
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 8
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 9
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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.
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 10
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 11
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
BAT for dust abatement
• 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
Melt Moulding & Casting
Fin.
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 12
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 13
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 14
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
BAT for dust abatement
• 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
Melt Moulding & Casting
Fin.
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 15
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
NODULARISATION
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 16
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
2. Sand regeneration: monosand
Moulding
Primary (mechanical) regeneration
Waste sand
BAT: regeneration ratioBAT: regeneration ratioGreen : 98%98%
New sand
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 17
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
Sand regeneration: mixed sand
Moulding
Primary (mechanical) regeneration
Waste sand
Core making
New sand
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 18
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
Sand regeneration: mixed sand
Moulding
Primary (mechanical) regeneration
Waste sand
Core making
New sand
Secondary regeneration
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 19
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
Sand regeneration: mixed sand
Moulding
Primary (mechanical) regeneration
Waste sand
Core making
New sandRe-use
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 20
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 21
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
3. Coating of sand cores/moulds• Good metal surface appearance• No metal penetration• Reduces finishing
•• AlcoholAlcohol--basedbased
or
WaterWater--basedbased
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 22
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 23
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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?
Karl Vrancken, STEVITO, Mol
Ljubljana, 06 -08 March 2006
Activity 6: Training on the application procedureMission 6.1: Using BREF in application procedure 24
EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)
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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