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Odourless casting - Odour and hazardous emission abatement of foundries

LIFE10 ENV/FI/000059


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Contact details:

Project Manager: Markku TAPOLA
Tel: 00358405002055
Email: markku.tapola@meehanite.org



Project description:

Background

Foundries make metal castings from both ferrous and non-ferrous alloys. Metals are turned into components by melting the metal, pouring it into a mould, and then removing the mould material, or casting. The most commonly used metals are aluminium and cast iron, although steel, magnesium, copper, tin, zinc and other metals can also be used. Most foundries are operated by small and medium size enterprises (SMEs). There are some 4000 ferrous and non-ferrous foundries in Europe with a combined workforce of around 290 000 employees. The casting process typically leads to emissions of odorous and hazardous gases, which originate from the following: melting shops, especially cupola furnaces but also induction furnaces; moulding shops during the pouring and mould cooling stages; core making, especially the ‘hot box’ system and core curing ovens; sand reclamation; and die casting (metal mould) of aluminium foundries.


Objectives

The 'Odourless casting' project aimed to address problems related to air pollution by odorous and hazardous emissions from foundry processes. The goal was to define odorous and hazardous emissions in typical aluminium, steel and iron foundries and to demonstrate technically and economically feasible emission abatement techniques for wide-scale implementation. Specific objectives focused on:

  • Minimising hazardous and odorous emissions from different foundry processes by 80-90% (in comparison with the industry baseline) at pilot foundries by applying the best feasible exhaust air cleaning systems;
  • Defining the most harmful compounds and odorous concentrations in iron, steel and metal foundries in order to treat them in the most efficient way;
  • Defining the odour emission balances of typical foundry processes and pilot foundries as a whole;
  • Carrying out feasibility studies as pilot tests at foundries to minimise emissions using standardised chemical compound specifications and olfactometric analyses;
  • Calculating total annual cost estimates for the full-scale technologies; and
  • Publishing a design and instruction guide on how to apply cleaning systems for different foundry processes.

  • Results

    Project outcomes have provided the foundries with essential information about how to tackle current odour emissions, as well as new knowhow concerning the most odorous process units and applicable abatement technologies with cost calculations.

    Based on the project measurements, eight odour and hazardous emission balance measurements were carried out and reported to each pilot foundry to help them reduce future odour problems. In addition the project provided foundries with feasibility results about tested abatement technologies for odour abatement in different foundry types and process units.

    The project was able to demonstrate how hazardous and odorous emissions from different foundry processes could be reduced by 80-90% at pilot foundries by applying the best feasible exhaust air cleaning systems. In the case that the 8 pilot foundries fully implement the tested abatement systems, they would be able to reduce the emission of around 11 million kg of noxious compounds.. Such a reduction would create a healthier working environment for foundry employees and people living in the vicinity of these emission sources (as odours can cause sensibilisation and long-term health effects).

    Results were lower however from the adsorption piloting (Action 14) tests where odour reduction efficiency was calculated only to about 54%. This occurred because of the low odour concentration in raw gas. Relevant information for system suppliers of the existing chemicals and the efficiency of abatement technologies was gained and evaluated for future applications.

    Success was also achieved in the project’s aim to define the most harmful compounds and odorous concentrations in iron, steel and metal foundries and treat them in the most efficient way. Other useful findings confirmed the odour emission balances of typical foundry processes and pilot foundries as a whole.

    Feasibility studies were used as pilot tests for the foundries to minimise emissions using standardised chemical compound specifications and olfactometric analyses. Total annual cost estimates for the full-scale technologies were also calculated.

    Dissemination materials included the publication of a design and instruction guide on how to apply cleaning systems for different foundry processes. Information was made available on potentially harmful odour emissions in ferrous and non-ferrous foundry processes. Data on the performance and cleaning efficiency of the tested abatement techniques in different odour-emitting foundry processes was another useful project result.

    From a policy perspective, the project findings concerning reducing and eliminating emissions make contributions the EU VOC Directive and national/regional/local requirements regarding air quality. Project results also can be used in developing further the BAT/BREF documents for the foundry industry. The next BREF note review will be able to rely on the demonstrated results of this project and environmental authorities will be able to refer to the demonstrated abatement systems of this project when dealing with the foundry permit process.

    Further information on the project can be found in the project's layman report and After-LIFE Communication Plan (see "Read more" section).


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Environmental issues addressed:

Themes

Air & Noise - Air pollutants
Environmental management - Cleaner technologies
Risk management - Pollution control
Risk management - Industrial risks - Hazardous substances
Industry-Production - Metal industry


Keywords

emission reduction‚  air pollution‚  odour nuisance‚  metal products industry‚  hazardous substance


Natura 2000 sites

Not applicable


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Beneficiaries:

Coordinator Uudenkaupungin Rautavalimo Oy (Meehanite Technology Oy)
Type of organisation SME Small and medium sized enterprise
Description Uudenkaupungin Rautavalimo Oy (URV), a supplier of iron castings to pulp and paper machine manufacturers, is the parent company of Meehanite Technology Oy, a consultancy providing expertise in metals casting technology and environmental engineering.
Partners AX Consulting Ltd, Finland Institute für Giessereitechnik GmbH, Germany Swerea SWECAST AB, Sweden REINLUFT Umwelttechnik Ingenieurgesellschaft mbH, Germany Chemisch Thermische Prozesstechnik GmbH, Germany Dantherm GmbH, Germany

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Project reference LIFE10 ENV/FI/000059
Duration 01-OCT-2011 to 30-SEP -2014
Total budget 1,568,123.00 €
EU contribution 768,311.00 €
Project location Burgenland(Österreich) Niederösterreich(Österreich) Wien(Österreich) Kärnten(Österreich) Steiermark(Österreich) Oberösterreich(Österreich) Salzburg(Österreich) Tirol(Österreich) Vorarlberg(Österreich) Schleswig-Holstein(Deutschland) Hamburg(Deutschland) Niedersachsen(Deutschland) Bremen(Deutschland) Nordrhein-Westfalen(Deutschland) Hessen(Deutschland) Rheinland-Pfalz(Deutschland) Baden-Württemberg(Deutschland) Bayern(Deutschland) Saarland(Deutschland) Berlin(Deutschland) Brandenburg(Deutschland) Mecklenburg-Vorpommern(Deutschland) Sachsen(Deutschland) Sachsen-Anhalt(Deutschland) Thüringen(Deutschland) Uusimaa(Finland Suomi) Varsinais-Suomi(Finland Suomi) Satakunta(Finland Suomi) Häme(Finland Suomi) Pirkanmaa(Finland Suomi) Päijät-Häme(Finland Suomi) Kymenlaakso(Finland Suomi) Etelä-Karjala(Finland Suomi) Etelä-Savo(Finland Suomi) Pohjois-Savo(Finland Suomi) Pohjois-Karjala(Finland Suomi) Kainuu(Finland Suomi) Keski-Suomi(Finland Suomi) Etelä-Pohjanmaa(Finland Suomi) Vaasan rannikkoseutu(Finland Suomi) Keski-Pohjanmaa(Finland Suomi) Pohjois-Pohjanmaa(Finland Suomi) Lappi(Finland Suomi) Ahvenanmaa/Åland(Finland Suomi) Baltic Sea Suomi (SF)(Finland Suomi) Groningen(Nederland) Friesland(Nederland) Drenthe(Nederland) Overijssel(Nederland) Gelderland(Nederland) Flevoland(Nederland) Noord-Brabant(Nederland) Limburg(Nederland) Utrecht(Nederland) Noord-Holland(Nederland) Zuid-Holland(Nederland) Zeeland(Nederland) Stockholm(Sverige) Östra Mellansverige(Sverige) Småland med Öarna(Sverige) Sydsverige(Sverige) Västsverige(Sverige) Norra Mellansverige(Sverige) Mellersta Norrland(Sverige) Övre Norrland(Sverige) Baltic Sea Sverige (S)(Sverige)

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Read more:

Brochure Odorless Casting Leaflet (4.12MB)
Poster "Odour and hazardous emission abatement of foundri ...
Project web site Project's website
Publication: After-LIFE Communication Plan After-LIFE Communication Plan
Publication: Layman report Layman report
Publication: Technical report Project's Final technical report

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Project description   Environmental issues   Beneficiaries   Administrative data   Read more   Print   PDF version