See Full Document Text
Official Journal EN
of the European Union L series
2024/2974 6.12.2024
COMMISSION IMPLEMENTING DECISION (EU) 2024/2974
of 29 November 2024
establishing the best available techniques (BAT) conclusions, under Directive 2010/75/EU of the
European Parliament and of the Council on industrial emissions, for the smitheries and foundries
industry
(notified under document C(2024) 8322)
(Text with EEA relevance)
THE EUROPEAN COMMISSION,
Having regard to the Treaty on the Functioning of the European Union,
Having regard to Directive 2010/75/EU of the European Parliament and of the Council of 24 November 2010on industrial
emissions (integrated pollution prevention and control)(1), and in particular Article 13(5) thereof,
Whereas:
(1) Best available techniques (BAT) conclusions are the reference for setting permit conditions for installations covered
by Chapter II of Directive 2010/75/EU and competent authorities should set emission limit values which ensure
that, under normal operating conditions, emissions do not exceed the emission levels associated with the best
available techniques as laid down in the BAT conclusions.
(2) In accordance with Article 13(4) of Directive 2010/75/EU, the forum composed of representatives of Member States,
the industries concerned and non-governmental organisations promoting environmental protection, established by
Commission Decision of 16 May 2011(2), provided the Commission on 29 April 2024 with its opinion on the
proposed content of the BAT reference document for the smitheries and foundries industry. That opinion is publicly
available(3).
(3) The BAT conclusions set out in the Annex to this Decision take into account the opinion of the forum on the
proposed content of the BAT reference document. They contain the key elements of the BAT reference document.
(4) The measures provided for in this Decision are in accordance with the opinion of the Committee established by
Article 75(1) of Directive 2010/75/EU,
HAS ADOPTED THIS DECISION:
Article 1
The best available techniques (BAT) conclusions for the smitheries and foundries industry, as set out in the Annex, are
adopted.
(1) OJ L 334, 17.12.2010, p. 17.
(2) Commission Decision of 16 May 2011 establishing a forum for the exchange of information pursuant to Article 13 of
Directive 2010/75/EU on industrial emissions (OJ C 146, 17.5.2011, p. 3).
(3) https://circabc.europa.eu/ui/group/06f33a94-9829-4eee-b187-21bb783a0fbf/library/c66a71e9-ce56-47bb-9bba-6d9c79649eee?
p=1&n=10&sort=created_DESC.
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Article 2
This Decision is addressed to the Member States.
Done at Brussels, 29 November 2024.
For the Commission
Maroš ŠEFČOVIČ
Member of the Commission
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ANNEX
1. Best available techniques (BAT) conclusions for the smitheries and foundries industry
SCOPE
These BAT conclusions concern the following activities specified in Annex I to Directive 2010/75/EU:
2.3. Processing of ferrous metals:
(b) operation of smitheries with hammers the energy of which exceeds 50 kilojoules per hammer, where the
calorific power used exceeds 20 MW.
2.4. Operation of ferrous metal foundries with a production capacity exceeding 20 tonnes per day.
2.5. Processing of non-ferrous metals:
(b) melting, including the alloyage, of non-ferrous metals, including recovered products, and operation of non-
ferrous metal foundries, with a melting capacity exceeding 4 tonnes per day for lead and cadmium or 20
tonnes per day for all other metals.
6.11. Independently operated treatment of waste water not covered by Directive 91/271/EEC(1), provided that the main
pollutant load originates from the activities covered by these BAT conclusions.
These BAT conclusions also cover the following:
— Ferrous metal foundries employing continuous casting processes for the production of grey or nodular iron castings at
or near their final shape.
— Non-ferrous metal foundries using alloyed ingots, scrap, recovered products or liquid metal for the production of
castings at or near their final shape.
— The combined treatment of waste water from different origins, provided that the main pollutant load originates from
the activities covered by these BAT conclusions and that the waste water treatment is not covered by
Directive 91/271/EEC (1).
— The coating of moulds and cores in ferrous and non-ferrous metal foundries.
— The storage, transfer and handling of materials, including the storage and handling of scrap and sand in foundries.
— Combustion processes directly associated with the activities covered by these BAT conclusions provided that the
gaseous products of combustion are put into direct contact with material (such as direct feedstock heating or direct
feedstock drying).
These BAT conclusions do not cover the following:
— The continuous casting of iron and/or steel (i.e. to produce thin slabs, thin strips, and sheets). This is covered by the
BAT conclusions for Iron and Steel Production (IS).
— The production of semi-finished non-ferrous metal products requiring further forming. This is covered by the BAT
conclusions for the Non-Ferrous Metals Industries (NFM).
— The coating of castings. This may be covered by the BAT conclusions for the Surface Treatment Using Organic Solvents
including Wood and Wood Products Preservation with Chemicals.
— Forging presses.
— Waste water from indirect cooling systems. This may be covered by the BAT conclusions for Industrial Cooling
Systems (ICS).
(1) Council Directive 91/271/EEC of 21 May 1991 concerning urban waste-water treatment (OJ L 135, 30.5.1991, p. 40).
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— Rolling mills. This is covered by the BAT conclusions for the Ferrous Metals Processing Industry (FMP).
— On-site combustion plants generating hot gases that are not used for direct contact heating, drying or any other
treatment of objects or materials. These may be covered by the BAT conclusions for Large Combustion Plants (LCP) or
by Directive (EU) 2015/2193 of the European Parliament and of the Council(2).
Other BAT conclusions and reference documents which could be relevant for the activities covered by these BAT
conclusions are the following:
— Surface Treatment of Metals and Plastics (STM);
— Waste Treatment (WT);
— Monitoring of Emissions to Air and Water from IED Installations (ROM);
— Economics and Cross-Media Effects (ECM);
— Emissions from Storage (EFS);
— Energy Efficiency (ENE).
These BAT conclusions apply without prejudice to other relevant legislation, e.g. on the registration, evaluation,
authorisation and restriction of chemicals (REACH), on classification, labelling and packaging of substances and
mixtures (CLP).
(2) Directive (EU) 2015/2193 of the European Parliament and of the Council of 25 November 2015 on the limitation of emissions of
certain pollutants into the air from medium combustion plants (OJ L 313, 28.11.2015, p. 1).
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DEFINITIONS
For the purposes of these BAT conclusions, the following definitions apply:
General terms
Term used Definition
A metal workpiece, produced using a casting process, which is ejected or released out of a
Casting
mould.
Pouring molten metal into the cavity of a mould. The molten metal is subsequently allowed
Casting process
to solidify.
Molten metal is poured into a preheated rotating mould, placed either vertically or
horizontally depending on the product shape. After pouring, the mould rotates around its
Centrifugal casting
central axis creating a centrifugal force which displaces the molten metal towards the
periphery, forcing it to deposit on the walls of the mould.
Channelled emissions Emissions of pollutants into the environment through any kind of duct, pipe, stack, etc.
Scrap metal which meets at least all of the following characteristics:
— free of non-metallic impurities;
— free of galvanised, primed or painted scrap parts;
— free of oil and grease;
— free of explosive can material;
Clean scrap
— free of tool steels, stainless steels or chrome-alloyed steels, except for steel foundries;
— for iron and steel foundries, free of non-ferrous metal scrap parts.
Free means that residual impurities are present at such a low level that they do not adversely
affect the environmental performance (e.g. increased TVOC, PCDD/F and/or heavy metal
emissions) and the operation/safety of the plant.
Curing processes for moulds and cores where the sand binder hardens at ambient
Cold-setting processes temperature. Curing begins immediately after the last component of the sand binder
formulation is introduced in the mix.
Molten metal is poured into a water-cooled die that is open at the bottom or at the side.
Through intensive cooling, the outside of the metal product solidifies while it is slowly
Continuous casting
pulled out of the mould. Subsequently, the product (e.g. bars, tubes, profiles) is cut to the
desired product length.
Continuous measurement Measurement using an automated measuring system permanently installed on site.
Production of cores which can be solid or hollow. Cores are inserted into the mould to
Core-making provide the internal cavities or part of the external shape of the casting before the mould
halves are joined.
Non-channelled emissions to air. Diffuse emissions include both fugitive and non-fugitive
Diffuse emissions
emissions.
Direct discharge Discharge to a receiving water body without further downstream waste water treatment.
Solid substances formed during the melting or holding of metal at the surface of the molten
Dross
metal, e.g. by oxidation with air.
Existing plant A plant that is not a new plant.
Feedstock Any metal input in the smitheries production process.
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General terms
Term used Definition
In foundries, this includes a number of mechanical operations carried out after the casting
process including deburring, abrasive cutting, chiselling, needling, fettling, slide grinding,
Finishing
shot blasting and welding.
In smitheries, this includes fettling, deburring, machining, cutting and chipping.
Flue-gas The exhaust gas exiting a combustion unit.
A deformation and metal-shaping process using heating and hammers (e.g. pneumatic,
Forging
steam-driven, mechanical, electrical, hydraulic).
Moulding technique using a foam pattern made of expanded polymers (e.g. expanded
Full mould process polystyrene) incorporated in chemically bonded sand. The foam pattern is lost upon
pouring. This process is generally used for large castings.
Curing processes for cores where a catalyst or hardener is injected in a gaseous form into the
Gas-hardening processes
core box.
Molten metal is poured directly from a ladle into a die under gravity. After solidification, the
Gravity die-casting
die is opened and the metal workpiece is released.
Mixture of sand, clay (e.g. bentonite) and additives (e.g. coal dust, cereal binders) used for
Green sand
mould making.
Hazardous substances Hazardous substances as defined in point 18 of Article 3 of Directive 2010/75/EU.
A thermal process where castings (in foundries) or workpieces (in smitheries) are heated
Heat treatment
below their melting point to improve their physical properties.
Molten metal is forced under pressure into a sealed mould cavity. It is held in place by a
High-pressure die-casting powerful compressive power until the metal solidifies. After solidification, the die is
opened and the metal workpiece is released.
Curing processes for cores or moulds where the sand binder hardens into a heated core box
Hot-curing processes
or a heated pattern, both made of metal or wood.
Indirect discharge A discharge that is not a direct discharge.
Internal scrap consists of gates, risers, defective castings, and other metal pieces generated
Internal scrap
within the installation.
Ladles used to transfer molten metal from a melting furnace to the casting process are
preheated to a controlled temperature in order to dry the ladle after preparation, to
Ladle preheating
minimise thermal shock and refractory wear during pouring and to reduce temperature
losses of the molten metal.
Liquid metal output The amount of liquid metal produced in the melting furnaces.
Foam patterns of the parts to be cast, made of expanded polymers (e.g. expanded
polystyrene), are produced using automated moulding machines and assembled together
Lost foam casting into clusters. The clusters are subsequently incorporated in unbonded sand. Upon
pouring, the molten metal causes the pyrolysis of the expanded polystyrene and fills the
emptied space.
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General terms
Term used Definition
Molten metal is transferred from an airtight furnace through a riser tube into a metal die.
The molten metal is pushed upwards into the die under low gas pressure. After
Low-pressure die-casting
solidification, the gas pressure is released allowing the still-molten metal in the riser tube
to fall back into the furnace, the die is opened and the casting is released.
A major change in the design or technology of a plant with major adjustments or
Major plant upgrade
replacements of the process and/or abatement technique(s) and associated equipment.
Mass flow The mass of a given substance or parameter which is emitted over a defined period of time.
The production of ferrous or non-ferrous molten metal using furnaces. This also includes
Metal melting melting of, for example, scrap generated on site and heat conservation of molten metal in
holding furnaces.
Making of a mould into which the molten metal will be poured. This also includes the
Moulding
making of patterns.
Mixture composed of silica sand (e.g. 85 %), clay (e.g. 15 %) and water. Generally, no other
Natural sand
additives are added to the mixture.
A plant first permitted at the site of the installation following the publication of these BAT
New plant conclusions or a complete replacement of a plant following the publication of these BAT
conclusions.
Nodular iron Cast iron with carbon in a nodular/spheroidal shape, commonly referred to as ductile iron.
Treatment of molten cast iron with magnesium or with a rare-earth element to change the
Nodularisation
carbon particles into a nodular/spheroidal shape.
Periodic measurement Measurement at specified time intervals using manual or automated methods.
A succession of thermal process steps used to raise the temperature of the feedstock before
Heating/reheating
hammering.
Substances and/or mixtures as defined in Article 3 of Regulation (EC) No 1907/2006 and
Process chemicals used in the process(es). Process chemicals may contain hazardous substances and/or
substances of very high concern.
Steel treatment process to remove carbon (decarburisation) from pig iron (primary refining)
Refining of steel
followed by removal of impurities.
Substance or object generated by the activities covered by the scope of these BAT
Residue
conclusions as waste or by-product.
Sand reuse The process of reusing sand in a foundry after sand reconditioning or reclamation.
Any mechanical operation carried out at the installation to reuse green and/or natural sand.
Sand reconditioning This includes screening, removing tramp metal, separating and removing fines and
oversized agglomerates. The sand is then cooled and sent for storage/reuse.
Any mechanical and/or thermal operation carried out at the installation to reuse chemically
bonded sand or mixed sand. This includes an initial mechanical step (e.g. crushing,
Sand reclamation
screening) followed by mechanical (e.g. grinding wheel, impact drum) and/or thermal (e.g.
fluidised bed, rotary furnaces) processes in order to remove the residual binders.
Areas which need special protection, such as:
— residential areas;
Sensitive receptors
— areas where human activities are carried out (e.g. neighbouring workplaces, schools,
day-care centres, recreational areas, hospitals or nursing homes).
Liquid substances that do not dissolve in liquid metal but separate easily from them and
Slag form a separate layer on the liquid metal because of their lower density. Slag is formed by
the oxidation of non-metallic elements that are present in the metal charge.
Substances meeting the criteria mentioned in Article 57 and included in the Candidate List
Substances of very high con
of Substances of Very High Concern, according to the REACH Regulation ((EC)
cern
No 1907/2006(1)).
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General terms
Term used Definition
Water from precipitation that flows over land or impervious surfaces, such as paved streets,
Surface run-off water
storage areas and rooftops, and does not soak into the ground.
Refining operations in aluminium melting processes which include degassing, grain
refining, and fluxing. Degassing (i.e. removal of dissolved hydrogen using nitrogen) is
Treatment of molten metal
often combined with cleaning (i.e. removal of alkali or alkaline earth metal such as Ca)
using Cl gas.
2
Valid hourly (or half-hourly) An hourly (or half-hourly) average is considered valid when there is no maintenance or
average malfunction of the automated measuring system.
(1) Regulation (EC) No 1907/2006 of the European Parliament and of the Council of 18 December 2006concerning the Registration,
Evaluation, Authorisation and Restriction of Chemicals (REACH), establishing a European Chemicals Agency, amending Directive
1999/45/EC and repealing Council Regulation (EEC) No 793/93 and Commission Regulation (EC) No 1488/94 as well as Council
Directive 76/769/EEC and Commission Directives 91/155/EEC, 93/67/EEC, 93/105/EC and 2000/21/EC (OJ L 396,
30.12.2006, p. 1).
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Pollutants and parameters
Term used Definition
Collective term for derivatives of ammonia in which one or more of the hydrogen atoms has been
Amines
replaced by an alkyl or aryl group.
Adsorbable organically bound halogens, expressed as Cl, include adsorbable organically bound
AOX
chlorine, bromine and iodine.
As The sum of arsenic and its compounds, dissolved or bound to particles, expressed as As.
B[a]P Benzo[a]pyrene.
Biochemical oxygen demand. Amount of oxygen needed for the biochemical oxidation of organic and/
BOD
5 or inorganic matter in 5 (BOD ) days.
5
Cd The sum of cadmium and its compounds, dissolved or bound to particles, expressed as Cd.
Cl Elemental chlorine.
2
CO Carbon monoxide.
Chemical oxygen demand. Amount of oxygen needed for the total chemical oxidation of the organic
COD matter to carbon dioxide using dichromate. COD is an indicator for the mass concentration of
organic compounds.
Cr The sum of chromium and its compounds, dissolved or bound to particles, expressed as Cr.
Cu The sum of copper and its compounds, dissolved or bound to particles, expressed as Cu.
Dust Total particulate matter (in air).
Fe The sum of iron and its compounds, dissolved or bound to particles, expressed as Fe.
HCl Hydrogen chloride.
HF Hydrogen fluoride.
Hg The sum of mercury and its compounds, dissolved or bound to particles, expressed as Hg.
Hydrocarbon oil index. The sum of compounds extractable with a hydrocarbon solvent (including
HOI
long-chain or branched aliphatic, alicyclic, aromatic or alkyl-substituted aromatic hydrocarbons).
Mg Magnesium.
MgO Magnesium oxide.
MgS Magnesium sulphide.
MgSO Magnesium sulphate.
4
Ni The sum of nickel and its compounds, dissolved or bound to particles, expressed as Ni.
NO The sum of nitrogen monoxide (NO) and nitrogen dioxide (NO ), expressed as NO .
X 2 2
PCDD/F Polychlorinated dibenzo-p-dioxins/furans.
Phenol index The sum of phenolic compounds, expressed as phenol concentration and measured according to EN
ISO 14402.
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Pollutants and parameters
Term used Definition
The sum of lead and its compounds, dissolved or bound to particles, expressed as Pb (in water).
Pb
The sum of lead and its compounds, expressed as Pb (in air).
SO Sulphur dioxide.
2
TOC Total organic carbon, expressed as C (in water), includes all organic compounds.
Total suspended solids. Mass concentration of all suspended solids (in water), measured via filtration
TSS
through glass fibre filters and gravimetry.
Total nitrogen Total nitrogen, expressed as N, includes free ammonia and ammonium nitrogen (NH4-N), nitrite
(TN) nitrogen (NO2-N), nitrate nitrogen (NO3-N) and organically bound nitrogen.
TVOC Total volatile organic carbon, expressed as C (in air).
VOC Volatile organic compound as defined in Article 3(45) of Directive 2010/75/EU.
Zn The sum of zinc and its compounds, dissolved or bound to particles, expressed as Zn.
ACRONYMS
For the purposes of these BAT conclusions, the following acronyms apply.
Acronym Definition
CBC Cold blast cupola
CMS Chemicals management system
CMR Carcinogenic, mutagenic or toxic for reproduction.
CMR substance of category 1A as defined in Regulation (EC) No 1272/2008 as amended,
CMR 1A
i.e. carrying the hazard statements H340, H350, H360.
CMR substance of category 1B as defined in Regulation (EC) No 1272/2008 as amended,
CMR 1B
i.e. carrying the hazard statements H340, H350, H360.
CMR 2 CMR substance of category 2 as defined in Regulation (EC) No 1272/2008 as
CMR 2
amended, i.e. carrying the hazard statements H341, H351, H361.
DMEA N,N-Dimethylethylamine
EAF Electric arc furnace
EMS Environmental management system
ESP Electrostatic precipitator
HBC Hot blast cupola
HPDC High-pressure die-casting
NFM Non-ferrous metal
OME Operational material efficiency
OTNOC Other than normal operating conditions
TEA Triethylamine
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GENERAL CONSIDERATIONS
Best available techniques
The techniques listed and described in these BAT conclusions are neither prescriptive nor exhaustive. Other techniques may
be used that ensure at least an equivalent level of environmental protection.
Unless otherwise stated, the BAT conclusions are generally applicable.
Emission levels associated with the best available techniques (BAT-AELs) and indicative emission levels for
emissions to air
In foundries, the BAT-AELs and indicative emission levels for emissions to air given in these BAT conclusions refer to
concentrations (mass of emitted substances per volume of waste gas) under the following standard conditions: dry gas at a
temperature of 273,15 K and a pressure of 101,3 kPa, without correction to a reference oxygen level, and expressed in the
unit mg/Nm3 or ng WHO-TEQ/Nm3.
In smitheries, the BAT-AEL and indicative emission level for emissions to air given in these BAT conclusions refer to
concentrations (mass of emitted substances per volume of waste gas) under the following standard conditions: dry gas at a
temperature of 273,15 K and a pressure of 101,3 kPa, corrected at a reference oxygen level of 3 dry vol-% and expressed in
the unit mg/Nm3.
The equation for calculating the emission concentration at the reference oxygen level is:
21 – O
E ¼ R × E
R M
21 – O
M
where: E : emission concentration at the reference oxygen level O ;
R R
O : reference oxygen level in vol-%;
R
E : measured emission concentration;
M
O : measured oxygen level in vol-%.
M
For averaging periods of BAT-AELs and indicative emission levels for channelled emissions to air, the following definitions
apply:
Type of measurement Averaging period Definition
Average over a period of 1 day based on valid hourly or half-hourly
Continuous Daily average
averages.
Average over the sampling Average value of three consecutive samplings/measurements of at
Periodic
period least 30 minutes each(1).
(1) For any parameter where, due to sampling or analytical limitations and/or due to operational conditions (e.g. batch processes),
a 30-minute sampling/measurement and/or an average of three consecutive samplings/measurements is inappropriate, a more
representative sampling/measurement procedure may be employed. For PCDD/F, one sampling period of 6 to 8 hours is used.
When the waste gases of two or more sources (e.g. furnaces) are discharged through a common stack, the BAT-AELs apply
to the combined discharge from the stack.
For the purpose of calculating the mass flows in relation to BAT 12, where waste gases with similar characteristics, e.g.
containing the same (type of) substances/parameters, and discharged through two or more separate stacks could, in the
judgement of the competent authority, be discharged through a common stack, these stacks shall be considered as a single
stack.
Emission levels associated with the best available techniques (BAT-AELs) for emissions to water
The BAT-AELs for emissions to water given in these BAT conclusions refer to concentrations (mass of emitted substances
per volume of water), expressed in mg/l.
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Averaging periods associated with the BAT-AELs refer to either of the following two cases:
— In the case of continuous discharge, daily average values, i.e. 24-hour flow-proportional composite samples.
— In the case of batch discharge, average values over the release duration taken as flow-proportional composite samples,
or, provided that the effluent is appropriately mixed and homogeneous, a spot sample taken before discharge.
Time-proportional composite samples can be used provided that sufficient flow stability is demonstrated. Alternatively,
spot samples may be taken, provided that the effluent is appropriately mixed and homogeneous.
The BAT-AELs apply at the point where the emission leaves the installation.
Other environmental performance levels associated with the best available techniques (BAT-AEPLs) and
indicative levels
BAT-AEPLs for specific energy consumption (foundries)
The BAT-AEPLs for specific energy consumption refer to yearly averages calculated using the following equation:
energy consumption rate
specific energy consumption ¼
activity rate
where:
energy consumption rate: total amount of heat (generated from primary energy sources) and electricity consumed by the
relevant process(es) (melting and holding, ladle preheating) in foundries, expressed in kWh/
year; and
activity rate: total amount of liquid metal output, expressed in t/year.
The energy consumption rate corresponds to the total amount of heat (generated from primary energy sources) and
electricity consumed by all furnaces in the relevant process(es): melting and holding, ladle preheating.
Indicative levels for specific energy consumption (smitheries)
The indicative levels for specific energy consumption refer to yearly averages calculated using the following equation:
energy consumption rate
specific energy consumption ¼
activity rate
where:
energy consumption rate: total amount of heat (generated from primary energy sources) and electricity consumed by the
plant in smitheries, expressed in kWh/year; and
activity rate: total amount of feedstock, expressed in t/year.
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BAT-AEPLs for specific water consumption (foundries)
The BAT-AEPLs for specific water consumption refer to yearly averages calculated using the following equation:
water consumption rate
specific water consumption ¼
activity rate
where:
water consumption rate: total amount of water consumed by the plant excluding:
— recycled and reused water, and
— cooling water used in once-through cooling systems, and
— water for domestic-type usage,
expressed in m3/year; and
activity rate: total amount of liquid metal output, expressed in t/year.
BAT-AEPLs for specific amount of waste sent for disposal (foundries)
The BAT-AEPLs for specific amount of waste sent for disposal refer to yearly averages calculated using the following
equation:
waste disposal rate
specific amount of waste sent for disposal ¼
activity rate
where:
waste disposal rate: total amount of waste sent for disposal, expressed in kg/year; and
activity rate: total amount of liquid metal output, expressed in t/year.
Indicative levels for operational material efficiency (OME) (foundries)
The indicative levels for OME refer to yearly averages expressed as a percentage and calculated using the following equation:
good casting rate
operational material efficiency ðOMEÞ ¼ × 100
activity rate
where:
good casting rate: total amount of final castings produced at the installation without defects, expressed in t/year; and
activity rate: total amount of liquid metal output, expressed in t/year.
BAT-AEPLs for sand reuse (foundries)
The BAT-AEPLs for sand reuse refer to yearly averages expressed as a percentage and calculated using the following
equation:
sand reuse ratio ¼ amount of reused sand × 100
total amount of sand used
where:
amount of reused sand: total amount of reused sand, originating from reconditioning or reclamation, expressed in t/
year; and
total amount of sand used: total amount of sand used, expressed in t/year.
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1.1. General BAT conclusions
1.1.1. Overall environmental performance
BAT 1. In order to improve the overall environmental performance, BAT is to elaborate and implement
an environmental management system (EMS) that incorporates all of the following features:
(i) commitment, leadership, and accountability of the management, including senior management, for the
implementation of an effective EMS;
(ii) an analysis that includes the determination of the organisation’s context, the identification of the needs
and expectations of interested parties, the identification of characteristics of the installation that are
associated with possible risks for the environment as well as of the applicable legal requirements relating
to the environment and human health;
(iii) development of an environmental policy that includes the continuous improvement of the environmental
performance of the installation;
(iv) establishing objectives and performance indicators in relation to significant environmental aspects,
including safeguarding compliance with applicable legal requirements;
(v) planning and implementing the necessary procedures and actions (including corrective and preventive
actions where needed), to achieve the environmental objectives and avoid environmental risks;
(vi) determination of structures, roles and responsibilities in relation to environmental aspects and objectives
and provision of the financial and human resources needed;
(vii) ensuring the necessary competence and awareness of staff whose work may affect the environmental
performance of the installation (e.g. by providing information and training);
(viii) internal and external communication;
(ix) fostering employee involvement in good environmental management practices;
(x) establishing and maintaining a management manual and written procedures to control activities with
significant environmental impact as well as relevant records;
(xi) effective operational planning and process control;
(xii) implementation of appropriate maintenance programmes;
(xiii) emergency preparedness and response protocols, including the prevention and/or mitigation of the
adverse (environmental) impacts of emergency situations;
(xiv) when (re)designing a (new) installation or a part thereof, consideration of its environmental impacts
throughout its life, which includes construction, maintenance, operation and decommissioning;
(xv) implementation of a monitoring and measurement programme; if necessary, information can be found in
the Reference Report on Monitoring of Emissions to Air and Water from IED Installations;
(xvi) application of sectoral benchmarking on a regular basis;
(xvii) periodic independent (as far as practicable) internal auditing and periodic independent external auditing in
order to assess the environmental performance and to determine whether or not the EMS conforms to
planned arrangements and has been properly implemented and maintained;
(xviii) evaluation of causes of nonconformities, implementation of corrective actions in response to
nonconformities, review of the effectiveness of corrective actions, and determination of whether similar
nonconformities exist or could potentially occur;
(xix) periodic review, by senior management, of the EMS and its continuing suitability, adequacy and
effectiveness;
(xx) following and taking into account the development of cleaner techniques.
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Specifically for the smitheries and foundries industry, BAT is also to incorporate the following features in the EMS:
(xxi) an inventory of inputs and outputs (see BAT 2);
(xxii) a chemicals management system (see BAT 3);
(xxiii) a plan for the prevention and control of leaks and spillages (see BAT 4 (a));
(xxiv) an OTNOC management plan (see BAT 5);
(xxv) an energy efficiency plan and audits (see BAT 7 (a));
(xxvi) a water management plan and audits (see BAT 35 (a));
(xxvii) a noise and/or vibration management plan (see BAT 8);
(xxviii) a residues management plan (see BAT 10);
(xxix) an odour management plan for foundries (see BAT 32).
Note
Regulation (EC) No 1221/2009 establishes the European Union eco-management and audit scheme (EMAS), which
is an example of an EMS consistent with this BAT.
Applicability
The level of detail and the degree of formalisation of the EMS will generally be related to the nature, scale and
complexity of the installation, and the range of environmental impacts it may have.
BAT 2. In order to improve the overall environmental performance, BAT is to establish, maintain and
regularly review (including when a significant change occurs) an inventory of inputs and outputs, as part
of the EMS (see BAT 1), that incorporates all of the following features:
(i) information about the production processes, including:
(a) simplified process flow sheets that show the origin of the emissions to air, water and soil;
(b) descriptions of process-integrated techniques and waste water/waste gas treatment techniques to prevent
or reduce emissions, including their performance (e.g. abatement efficiency);
(ii) information about the quantity and characteristics of raw materials (e.g. scrap, feedstock, sand) and fuels
(e.g. coke) used;
(iii) information about water consumption and usage (e.g. flow diagrams and water mass balances);
(iv) information about energy consumption and usage;
(v) information about the characteristics of the waste water streams, such as:
(a) average values and variability of flow, pH, temperature and conductivity;
(b) average concentration and mass flow values of relevant substances/parameters (e.g. total suspended
solids, TOC or COD, hydrocarbon oil index, metals) and their variability;
(vi) information about the quantity and characteristics of the process chemicals used:
(a) the identity and the characteristics of process chemicals, including properties with adverse effects on the
environment and/or human health;
(b) the quantities of process chemicals used and the location of their use;
(vii) information about the characteristics of the waste gas streams, such as:
(a) average values and variability of flow and temperature;
(b) average concentration and mass flow values of relevant substances (e.g. dust, NO , SO , CO, metals) and
X 2
their variability;
(c) presence of other substances that may affect the waste gas treatment system (e.g. oxygen, nitrogen, water
vapour) or installation safety;
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(d) presence of substances classified as CMR 1A, CMR 1B or CMR 2; the presence of such substances may
for example be assessed according to the criteria of Regulation (EC) No 1272/2008 on classification,
labelling and packaging (CLP);
(viii) information about the quantity and characteristics of residues generated.
Applicability
The level of detail and the degree of formalisation of the inventory will generally be related to the nature, scale and
complexity of the plant, and the range of environmental impacts it may have.
BAT 3. In order to improve the overall environmental performance, BAT is to elaborate and implement
a chemicals management system (CMS), as part of the EMS (see BAT 1), that incorporates all of the
following features:
(i) A policy to reduce the consumption of and risks associated with process chemicals, including a procurement
policy to select less harmful process chemicals and their suppliers with the aim of minimising the use of and
risks associated with hazardous substances and substances of very high concern as well as to avoid the
procurement of an excess amount of process chemicals. The selection of process chemicals is based on:
(a) the comparative analysis of their bioeliminability/biodegradability, eco-toxicity and potential to be
released into the environment in order to reduce emissions to the environment;
(b) the characterisation of the risks associated with the process chemicals, based on the chemicals’ hazards
classification, pathways through the plant, potential release and level of exposure;
(c) the potential for recovery and reuse (see BAT 17 (f));
(d) the regular (e.g. annual) analysis of the potential for substitution with the aim to identify potentially new
available and safer alternatives to the use of hazardous substances and substances of very high concern;
this may be achieved by changing process(es) or using other process chemicals with no or lower
environmental impacts (see BAT 11 for foundries);
(e) the anticipatory monitoring of regulatory changes related to hazardous substances and substances of
very high concern, and the safeguarding of compliance with applicable legal requirements.
The inventory of process chemicals (see BAT 2 (vi)) may be used to provide and keep the information needed for the
selection of process chemicals.
(ii) Goals and action plans to avoid or reduce the use of and risks associated with hazardous substances and
substances of very high concern.
(iii) Development and implementation of procedures for the procurement, handling, storage, and use of process
chemicals, disposal of waste containing process chemicals and return of unused process chemicals, to
prevent or reduce emissions to the environment (e.g. see BAT 4).
Applicability
The level of detail and degree of formalisation of the CMS will generally be related to the nature, scale and
complexity of the plant.
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BAT 4. In order to prevent or reduce emissions to soil and groundwater, BAT is to use all of the
techniques given below.
Technique Description Applicability
A plan for the prevention and control of leaks and spillages is
part of the EMS (see BAT 1) and includes, but is not limited to:
— site incident plans for small and large spillages;
— identification of the roles and responsibilities of persons
involved;
— ensuring staff are environmentally aware and trained to
The level of detail
prevent and deal with spillage incidents;
of the plan will
— identification of areas at risk of spillage and/or leaks of
generally be re
Set-up and implementa hazardous materials and substances of very high concern,
lated to the nature,
tion of a plan for the pre and ranking them according to the risk;
a scale and complex
vention and control of — identification of suitable spillage containment and clean-up
ity of the plant, as
leaks and spillages equipment and regularly ensuring it is available, in good
well as to the type
working order and close to points where these incidents
and quantity of li
may occur;
quids used.
— waste management guidelines for dealing with waste arising
from spillage control;
— regular (at least on an annual basis) inspections of storage
and handling areas, testing and calibration of leak detection
equipment and prompt repair of leaks from valves, glands,
flanges, etc.
This includes techniques such as:
— impermeable (for example, cemented) floor for process
Structuring and manage
areas and for scrap/feedstock yards;
ment of process areas and Generally applic
b — separate storage for various types of raw materials, close to
raw material storage able.
the production lines; this can be achieved using, for
areas
example, compartments or boxes in the storage areas,
bunkers.
Production areas and/or areas where process chemicals, residues
or waste are stored or handled are protected against surface run-
Prevention of the con off water. This is achieved by using at least the following
Generally applic
c tamination of surface techniques:
able.
run-off water — drainage channels and/or an outer kerb bund around the
plant;
— roofing with roof guttering of process and/or storage areas.
Surface run-off water from areas that are potentially
Collection of potentially
contaminated is collected separately and only discharged after Generally applic
d contaminated surface
appropriate measures are taken, e.g. monitoring, treatment, able.
run-off water
reuse.
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Technique Description Applicability
This includes the following:
— storage in roofed and ventilated areas with floors
impermeable to the liquids concerned;
— use of oil-tight trays or cellars for hydraulic stations and oil-
or grease-lubricated equipment;
— collection of spilled liquid;
Safe handling and storage — loading/unloading areas for process chemicals, lubricants Generally applic
e
of process chemicals and coatings, etc. are designed and constructed in such a able.
way that potential leaks and spillages are contained and
sent to on-site treatment (see BAT 36) or off-site treatment.
— highly flammable liquids (e.g. methyl formate, TEA, DMEA,
mould coatings containing alcohol) are stored separately
from incompatible substances (e.g. oxidisers) in enclosed
and well-ventilated storage areas.
A set of measures aiming at preventing, or reducing, the
generation of emissions (e.g. regular maintenance and cleaning Generally applic
f Good housekeeping
of equipment, work surfaces, floors and transport routes, and able.
containment as well as rapid clean-up of any spillages).
BAT 5. In order to reduce the frequency of the occurrence of OTNOC and to reduce emissions during
OTNOC, BAT is to set up and implement a risk-based OTNOC management plan as part of the EMS (see
BAT 1) that includes all of the following elements:
(i) identification of potential OTNOC (e.g. failure of equipment critical to the protection of the environment
(‘critical equipment’)), of their root causes and of their potential consequences;
(ii) appropriate design of critical equipment (e.g. off-gas treatment, waste water treatment);
(iii) set-up and implementation of an inspection plan and preventive maintenance programme for critical
equipment (see BAT 1 (xii));
(iv) monitoring (i.e. estimating or, where possible, measuring) and recording of emissions during OTNOC and of
associated circumstances;
(v) periodic assessment of the emissions occurring during OTNOC (e.g. frequency of events, duration, amount
of pollutants emitted) and implementation of corrective actions if necessary;
(vi) regular review and update of the list of identified OTNOC under point i following the periodic assessment of
point (v);
(vii) regular testing of backup systems.
Applicability
The level of detail and degree of formalisation of the OTNOC management plan will generally be related to the
nature, scale and complexity of the plant, and the range of environmental impacts it may have.
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1.1.2. Monitoring
BAT 6. BAT is to monitor at least once every year:
— the consumption of water, energy and materials used, including process chemicals, expressed as a yearly average;
— the amount of waste water generated, expressed as a yearly average;
— the amount of each type of materials recovered, recycled and/or reused, expressed as a yearly average;
— the amount of each type of residues generated and of each type of waste sent for disposal, expressed as a yearly
average.
Description
Monitoring preferentially includes direct measurements. Calculations or recording, e.g. using suitable meters or
invoices, can also be used. The monitoring is broken down to the most appropriate level (e.g. to process or plant
level) and considers any significant changes in the process or plant.
1.1.3. Energy efficiency
BAT 7. In order to increase the overall energy efficiency of the plant, BAT is to use all of the techniques
given below.
Technique Description Applicability
Management techniques
An energy efficiency plan is part of the EMS (see BAT 1) and entails
defining and monitoring the specific energy consumption of the
activity/processes (e.g. kWh/t liquid metal), setting objectives in
terms of energy efficiency and implementing actions to achieve
these objectives.
Energy efficiency Audits (also part of the EMS, see BAT 1) are carried out at least once
a.
plan and audits every year to ensure that the objectives of the energy efficiency plan
are met and the audits recommendations are followed up and The level of detail of the
implemented. energy efficiency plan,
The energy efficiency plan may be integrated in the overall energy of the audits and of the
efficiency plan of a larger installation (e.g. surface treatment balance record will gen
activities). erally be related to the
nature, scale and com
Drawing up an energy balance record once every year which plexity of the plant and
provides a breakdown of the energy consumption and generation the types of energy
(including energy export) by the type of energy source, for example: sources used.
— energy consumption: electricity, natural gas, renewable energy,
Energy balance re imported heat and/or cooling;
b.
cord — energy generation: electricity and/or steam.
This includes:
— definition of the energy boundaries of the processes;
— information on energy consumption in terms of delivered
energy;
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Technique Description Applicability
— information on energy exported from the plant;
— energy flow information (e.g. Sankey diagrams or energy
balances) showing how the energy is used throughout the
processes.
Process and equipment selection and optimisation
This includes techniques such as:
— burner maintenance and control;
— energy-efficient motors;
— energy-efficient lighting;
Use of general en
— optimising steam and compressed air distribution systems;
c. ergy-saving tech Generally applicable.
— regular inspection and maintenance of the steam distribution
niques
systems to prevent or reduce steam leaks;
— process control systems;
— variable speed drives;
— optimising air conditioning and building heating.
Further sector-specific techniques to increase energy efficiency are given in Sections 1.2.1.3, 1.2.2.1, 1.2.4.1
and 1.3.1 of these BAT conclusions.
1.1.4. Noise and vibrations
BAT 8. In order to prevent or, where that is not practicable, to reduce emissions of noise and vibrations,
BAT is to set up, implement and regularly review a noise and/or vibration management plan, as part of the
EMS (see BAT 1), that includes all of the following elements:
— a protocol containing appropriate actions and timelines;
— a protocol for monitoring emissions of noise and/or vibrations;
— a protocol for responding to identified noise and vibration events, e.g. managing complaints and/or taking
corrective actions;
— a noise and/or vibration reduction programme designed to identify the source(s), to measure/estimate noise and/
or vibration exposure, to characterise the contributions of the sources and to implement prevention and/or
reduction measures.
Applicability
The applicability is restricted to cases where a noise and/or vibration nuisance at sensitive receptors is expected and/
or has been substantiated.
BAT 9. In order to prevent or, where that is not practicable, to reduce noise emissions, BAT is to use one
or a combination of the techniques given below.
Technique Description Applicability
For existing plants, the reloca
Appropriate lo
Increasing the distance between the emitter and the receiver, by tion of equipment and open
cation of equip
a. using buildings as noise screens and by relocating equipment ings of the buildings may not
ment and build
and/or building openings. be applicable due to a lack of
ings
space and/or excessive costs.
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Technique Description Applicability
These include at least the following:
— inspection and maintenance of equipment;
— closing of doors and windows of enclosed areas, if possible,
or use of self-closing doors;
— equipment operation by experienced staff;
Operational
b. — avoidance of noisy activities at night, if possible;
measures
— provisions for noise control, during production and main
Generally applicable.
tenance activities, transport and handling of feedstock and
materials, e.g. reducing the number of material transfer
operations, reducing the height from which pieces fall on
to hard surfaces.
Low-noise This includes direct drive motors; low-noise compressors,
c.
equipment pumps and fans; low-noise transportation equipment.
This includes techniques such as:
— use of noise reducers;
— use of acoustic insulation of equipment;
Applicability to existing plants
Noise control — enclosure of noisy equipment and processes (e.g. unload
d. may be restricted by a lack of
equipment ing of raw materials, hammering, compressors, fans,
space.
shake-out, finishing);
— use of building materials with high sound insulation prop
erties (e.g. for walls, roofs, windows, doors).
Only applicable to existing
plants, as the design of new
plants should make this techni
Inserting obstacles between emitters and receivers (e.g. protec
e. Noise abatement que unnecessary. For existing
tion walls, embankments).
plants, the insertion of obsta
cles may not be applicable due
to a lack of space.
1.1.5. Residues
BAT 10. In order to increase material efficiency and reduce the amount of waste sent for disposal, BAT is
to set up, implement and regularly review a residues management plan.
Description
A residues management plan is part of the EMS (see BAT 1) and comprises a set of measures aiming to:
I. minimise the generation of residues;
II. optimise the reuse, recycling and/or recovery of residues; and
III. ensure the proper disposal of waste.
The residues management plan may be integrated in the overall residues management plan of a larger installation
(e.g. surface treatment activities).
Applicability
The level of detail and the degree of formalisation of the residues management plan will generally be related to the
nature, scale and complexity of the plant.
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1.2. BAT conclusions for foundries
The BAT conclusions in this section do not apply to cadmium, titanium and precious metal foundries, as well as bell and art
casting.
1.2.1. General BAT conclusions for foundries
The BAT conclusions in this section apply in addition to the general BAT conclusions given in Section 1.1.
1.2.1.1. Hazardous substances and substances of very high concern
BAT 11. In order to prevent or reduce the use of hazardous substances and substances of very high
concern in moulding and core-making with chemically bonded sand, BAT is to use alternative substances
which are non- or less hazardous.
Description
Hazardous substances and substances of very high concern used in moulding and core-making are substituted by
non-hazardous substances or – when this is not feasible – by less hazardous substances, by using for example:
— aliphatic organic (instead of aromatic) binders in moulding and core-making (see BAT 25 (d), (e) and (f));
— non-aromatic solvents for cold-box core-making (see BAT 25 (j));
— inorganic binders in moulding and core-making (see BAT 25 (d), (e) and (f));
— water-based coatings in moulding and core-making (see BAT 25 (l)).
1.2.1.2. Monitoring of emissions
1.2.1.2.1. Monitoring of emissions to air
BAT 12. BAT is to monitor channelled emissions to air with at least the frequency given below, and in
accordance with EN standards. If EN standards are not available, BAT is to use ISO, national or other
international standards that ensure the provision of data of an equivalent scientific quality.
Minimum Monitoring
Foundry/furnace
Substance/Parameter Process(es)/source(s) Standard(s) monitoring associated
type
frequency(1) with
Moulding using lost No EN
Amines moulds and core- All standard BAT 26
making(2) available
Moulding using lost
moulds and core- Once every BAT 26
making(3) year
No EN
Benzene All standard
Casting, cooling and shake-
available
out using lost moulds
BAT 27
including full mould
process(3)
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Minimum Monitoring
Foundry/furnace
Substance/Parameter Process(es)/source(s) Standard(s) monitoring associated
type
frequency(1) with
No EN
Once every
B[a]P Metal melting(4) Cast iron standard -
year
available
Heat treatment(5) All BAT 24
Cast iron: CBC,
Once every
Carbon monoxide (CO) HBC and rotary EN 15058 BAT 38
year
furnaces
Metal melting
NFM(5) BAT 43
Once every
Heat treatment(4) BAT 24
year
All
BAT 38
Once every
Metal melting BAT 40
year(6)
BAT 43
Nodularisation(9) Cast iron BAT 39
Refining Steel BAT 41
Moulding using lost
All BAT 26
moulds and core-making
EN
Dust
13284-1(7)(8)
Casting, cooling and shake-
out using lost moulds
All BAT 27
including full mould
process Once every
year
Finishing All BAT 30
Cast iron and
Lost foam casting BAT 28
NFM
Casting in permanent
All BAT 29
moulds
Sand reuse All BAT 31
Moulding using lost Once every
BAT 26
moulds and core-making year
EN standard
Formaldehyde(4) All under
Casting, cooling and shake-
development
out using lost moulds Once every
BAT 27
including full mould year
process
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Minimum Monitoring
Foundry/furnace
Substance/Parameter Process(es)/source(s) Standard(s) monitoring associated
type
frequency(1) with
Cast iron: CBC,
HBC and rotary BAT 38
furnaces(4)
Gaseous chlorides Metal melting EN 1911
Aluminium(4) BAT 43
Once every
year
Cast iron: CBC,
HBC and rotary BAT 38
EN standard
furnaces(4)
Gaseous fluorides Metal melting under
development
Aluminium BAT 43
Casting, cooling and shake-
out using lost moulds Once every
All -
including full mould year
process(4)
Cadmium
and its
Once every
compounds Metal melting All -
year
Once every
Finishing(4) All -
year
Casting, cooling and shake-
out using lost moulds Once every
All -
including full mould year
process(4)
Chromium
and its
Metals compounds Metal melting(4) All EN 14385 Once every -
year
Once every
Finishing(4) All -
year
Casting, cooling and shake-
out using lost moulds Once every
All -
including full mould year
process(4)
Nickel and its
compounds
Once every
Metal melting(4) All -
year
Once every
Finishing(4) All -
year
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Minimum Monitoring
Foundry/furnace
Substance/Parameter Process(es)/source(s) Standard(s) monitoring associated
type
frequency(1) with
Casting, cooling and shake-
out using lost moulds Once every
All -
including full mould year
process(4)
Cast iron: CBC
BAT 38
and HBC(4) Once every
Lead and its Metal melting
year
compounds
NFM(10) BAT 43
Casting in permanent Once every
Lead BAT 29
moulds year
Once every
Finishing(4) All -
year
Zinc and its Once every
Metal melting(4) All -
compounds year
Heat treatment(5) All BAT 24
Thermal sand
regeneration, except for
sand originating from the
cold-box process(5)
All BAT 31
Thermal regeneration of
Nitrogen oxides (NO ) EN 14792
X sand originating from the
cold-box process
Cast iron:
CBC, HBC and Once every BAT 38
Metal melting rotary furnaces year
NFM(5) BAT 43
Cast iron: CBC,
HBC and rotary BAT 38
furnaces
EN 1948-1,
PCDD/F Metal melting Cast iron: EN 1948-2,
BAT 38
Induction(4) EN 1948-3
BAT 40
Steel and NFM(4)
BAT 43
Moulding using lost
moulds and core- BAT 26
making(11)
No EN
Once every
Phenol All standard
Casting, cooling and shake- year
available
out using lost moulds
BAT 27
including full mould
process(11)
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Minimum Monitoring
Foundry/furnace
Substance/Parameter Process(es)/source(s) Standard(s) monitoring associated
type
frequency(1) with
Thermal regeneration of
sand in which sulphonic
All BAT 31
acid catalysts have been
used
Sulphur dioxide (SO ) EN 14791
2 Cast iron:
CBC, HBC and BAT 38
rotary furnaces
Metal melting
NFM(5)(12) BAT 43
Moulding using lost
BAT 26
moulds and core-making
Lost foam, casting Once every BAT 28
year
All
Casting, cooling and shake-
out using lost moulds EN 12619
BAT 27
including full mould
process
Total volatile
organic carbon (TVOC)
Sand reuse BAT 31
Cast iron BAT 38
Metal melting
Steel and NFM(4) -
Casting in permanent
All(4) BAT 29
moulds(13)
(1) To the extent possible, the measurements are carried out at the highest expected emission state under normal operating conditions.
(2) The monitoring only applies in the cold-box process when amines are used.
(3) The monitoring only applies when aromatic binders/chemicals are used or when the full mould process is used.
(4) The monitoring only applies when the substance/parameter concerned is identified as relevant in the waste gas stream based on the
inventory of inputs and outputs mentioned in BAT 2.
(5) The monitoring does not apply when only electricity is used.
(6) For any stack associated with a cupola furnace and with a dust mass flow > 0,5 kg/h, continuous monitoring applies.
(7) If measurements are continuous, the following generic EN standards apply instead: EN 15267-1, EN 15267-2, EN 15267-3, and EN
14181.
(8) If measurements are continuous, EN 13284-2 also applies.
(9) The monitoring does not apply when BAT 39 (a) is used.
(10) The monitoring only applies to lead foundries or to other NFM foundries using lead as an alloying element.
(11) The monitoring only applies when phenolic-based binder systems are used.
(12) The monitoring does not apply when only natural gas is used.
(13) The monitoring only applies when cores with chemically bonded sand are used.
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1.2.1.2.2. Monitoring of emissions to water
BAT 13. BAT is to monitor emissions to water with at least the frequency given below, and in accordance
with EN standards. If EN standards are not available, BAT is to use ISO, national or other international
standards that ensure the provision of data of an equivalent scientific quality.
Minimum
Monitoring
Substance/parameter Process Standard(s) monitoring
associated with
frequency(1)
Waste water from
Adsorbable organically bound halogens
wet scrubbing of EN ISO 9562
(AOX)(2)
cupola off-gases
Various EN standards
Biochemical oxygen demand (BOD )(3) available (e.g. EN
5
1899-1, EN ISO 5815)
No EN standard
Chemical oxygen demand (COD)(3)(4)
available
Hydrocarbon oil index (HOI)(2) EN ISO 9377-2
Arsenic (As)(2)
Cadmium (Cd)(2)
Chromium (Cr)(2)
Die-casting, off-
gas treatment (e.g. Various EN standards
Copper (Cu)(2)
wet scrubbing), available (e.g. EN ISO
finishing, heat 11885, EN ISO 15586, Once every 3
Iron (Fe)(2) BAT 36
Metals/ treatment, EN ISO 17294-2) months(3)
metalloids contaminated
Lead (Pb)(2)
surface run-off
water, direct
Nickel (Ni)(2)
cooling, wet sand
regeneration and
Zinc (Zn)(2)
cupola furnace
slag granulation.
Various EN standards
Mercury (Hg)(2) available (e.g. EN ISO
12846, EN ISO 17852)
Phenol index(5) EN ISO 14402
Various EN standards
available (e.g. EN
Total nitrogen (TN)(3)
12260, EN ISO
11905-1)
Total organic carbon (TOC)(3)(4) EN 1484
Total suspended solids (TSS)(3) EN 872
(1) In the case of batch discharge less frequent than the minimum monitoring frequency, monitoring is carried out once per batch.
(2) The monitoring only applies when the substance/parameter is identified as relevant in the waste water stream based on the inventory
of inputs and outputs mentioned in BAT 2.
(3) In the case of an indirect discharge, the minimum monitoring frequency may be reduced to once every 6 months if the downstream
waste water treatment plant is designed and equipped appropriately to abate the pollutants concerned.
(4) Either COD or TOC is monitored. TOC monitoring is the preferred option because it does not rely on the use of very toxic
compounds.
(5) The monitoring only applies when phenolic binding systems are used.
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1.2.1.3. Energy efficiency
BAT 14. In order to increase energy efficiency, BAT is to use all of the techniques (a) to (f), and an
appropriate combination of the techniques (g) to (n) given below.
Technique Description Applicability
Design and operation
Only applicable to new
Selection of an energy-effi
a. See Section 1.4.1. plants and/or major plant
cient type of furnace
upgrades.
Techniques for maximis
b. ing the thermal efficiency See Section 1.4.1. Generally applicable.
of furnaces
Furnace automation and
c. See Section 1.4.1. Generally applicable.
control
d.. Use of clean scrap See Section 1.4.1. Generally applicable.
Improving casting yield
e. and decreasing scrap gen See Section 1.4.1. Generally applicable.
eration
This includes all of the following elements:
— use of clean preheated ladles;
— keeping closed lids on ladles to preserve heat;
— use of energy-efficient techniques for preheating la Applicability may be re
Reducing energy losses/ dles (e.g. flameless microporous burners or oxy-fuel stricted in the case of big
f. improving ladle preheating burners); ladles (e.g. > 2 t) and bottom
practices — use of large (as practically possible) ladles fitted with pouring ladles due to design
heat-retaining covers; constraints.
— minimising the molten metal transfer from one la
dle to another;
— transferring the molten metal as quickly as possible.
Applicability to existing
plants may be restricted by
g. Oxy-fuel combustion See Section 1.4.1. furnace design and the need
for a minimum waste gas
flow.
Use of medium-frequency
Use of medium-frequency (250 Hz) induction furnaces
h. power in induction fur Generally applicable.
instead of mains frequency (50 Hz) furnaces.
naces
This includes all of the following measures:
— applying an appropriate system maintenance to re
duce leaks;
— efficient monitoring of operating parameters such
Compressed air system op
i. as flow, temperature and pressure; Generally applicable.
timisation
— minimising the pressure drops;
— applying efficient load management;
— reducing the inlet air temperature;
— using an efficient compressor control system.
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Technique Description Applicability
May not be applicable to
continuous casting pro
Use of microwave drying ovens (e.g. with a frequency of
cesses or to the production
Microwave drying of cores 2 450 Hz) for drying cores coated with water-based
j. of large castings, or when
for water-based coatings coatings (see BAT 21 (e)), resulting in rapid and homo
cores are made of reclaimed
geneous drying of the entire core surface.
sand containing traces of
carbon.
Heat recovery techniques
Only applicable to shaft fur
Scrap is preheated by recovering the heat from hot flue-
Scrap preheating using re naces in non-ferrous metal
k. gases which are redirected to come into contact with the
covered heat foundries and to EAFs in
charge.
steel foundries.
Waste heat from hot off-gases is recovered (e.g. through
heat exchangers) and reused on site or off site (e.g. in
thermal oil/hot water/heating circuits, for steam genera
tion or for preheating of combustion air (see technique
(m)). This may include the following:
— Excess heat from cupola hot off-gases is used for
example for steam production, thermal oil heating,
water heating.
Applicability may be re
Heat recovery from off- — Excess heat from the furnace cooling system is used
l. stricted by the lack of a sui
gases generated in furnaces for example for drying of raw material, space heat
table heat demand.
ing, water heating.
— In fuel-fired furnaces in aluminium foundries, ex
cess heat is used for example for heating the pre
mises and/or the water for the casting cleaning fa
cility.
— Low-grade heat is converted into electricity using
high-molecular-weight fluids by using the Organic
Rankine Cycle (ORC).
Preheating of combustion
m. See Section 1.4.1. Generally applicable.
air
Waste heat from the induction furnace cooling system is
Waste heat utilisation in in
n. recovered using heat exchangers for drying raw materi Generally applicable.
duction furnaces
als (e.g. scrap), space heating or hot water supply.
Further sector-specific techniques to increase energy efficiency are given in Sections 1.2.2.1 and 1.2.4.1 of these BAT
conclusions.
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Table 1.1
BAT-associated environmental performance levels (BAT-AEPLs) for specific energy consumption in cast iron
foundries
BAT-AEPL
Process – Furnace type Unit
(Yearly average)
Melting and holding – Cold blast cupola 900– 1 750
Melting and holding – Hot blast cupola 900– 1 500
Melting and holding – Induction kWh/t of liquid metal 600– 1 200
Melting and holding – Rotary 800– 950
Ladle preheating 50– 150(1)
(1) For foundries producing large castings, the upper end of the BAT-AEPL range may be higher and up to 200 kWh/t of liquid metal.
Table 1.2
BAT-associated environmental performance levels (BAT-AEPLs) for specific energy consumption in steel
foundries
BAT-AEPL
Process – Furnace type Unit
(Yearly average)
Melting – (EAF/induction) 600– 1 200
kWh/t of liquid metal
Ladle preheating 100– 300
Table 1.3
BAT-associated environmental performance levels (BAT-AEPLs) for specific energy consumption in aluminium
foundries
BAT-AEPL
Process Unit
(Yearly average)
Melting and holding kWh/t of liquid metal 600– 2 000
The associated monitoring is given in BAT 6.
1.2.1.4. Material efficiency
1.2.1.4.1. Storage and handling of residues, packaging and unused process chemicals
BAT 15. In order to prevent or reduce the environmental risk associated with the storage and handling of
residues, packaging and unused process chemicals and to facilitate their reuse and/or recycling, BAT is to
use all of the techniques given below.
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Technique Description
This includes the following:
— Fabric filter dust is stored on impermeable surfaces, in enclosed areas and in closed
Appropriate storage
containers/bags.
a. of various residue
— Other residue types (e.g. slag, dross, spent furnace refractory linings) are stored
types
separately from each other on impermeable surfaces in covered areas protected from
surface run-off water.
Reuse of internal Reuse of internal scrap directly or after treatment. The degree of reuse of internal scrap
b.
scrap depends on its content of impurities.
Process chemicals packaging is selected to facilitate its complete emptying (e.g. considering
Reuse/recycling of the size of the packaging aperture or the nature of the packaging material). After emptying,
c.
packaging the packaging is reused, returned to the supplier or sent for material recycling. Preferably,
process chemicals are stored in large containers.
Return of unused pro Unused process chemicals (i.e. which remain in their original containers) are returned to their
d.
cess chemicals suppliers.
1.2.1.4.2. Operational material efficiency in the casting process
BAT 16. In order to increase material efficiency in the casting process, BAT is to use either technique (a)
or technique (a) in combination with one or both of the techniques (b) and (c) given below.
Technique Description
Improving casting yield and
a. decreasing scrap genera See Section 1.4.2
tion
Use of computer-aided si
A computer simulation system is used to optimise the casting, pouring and solidification
b. mulation for casting, pour
process, to minimise the number of defective castings and increase foundry productivity.
ing and solidification
Production of light-weight Use of topology optimisation (i.e. casting simulation by means of algorithms and
c. castings using topology op computer programs) to reduce the product mass while meeting the product
timisation performance requirements.
Table 1.4
Indicative levels for operational material efficiency
Indicative levels
Foundry type Unit
(Yearly average)
Cast iron foundries 50– 97(1)(2)
Steel foundries 50– 100(1)(2)
NFM foundries (all types except HPDC) – Pb % 50– 97,5(1)
NFM foundries (all types except HPDC) – metals other than Pb 50– 98(1)
NFM foundries (HPDC) 60– 97(1)
(1) The lower end of the range is typically associated with the production of complex casting shapes due, for example, to the high
number of cores and/or risers/feeders used.
(2) The upper end of the range is typically associated with centrifugal casting.
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The associated monitoring is given in BAT 6.
1.2.1.4.3. Reduction of material consumption
BAT 17. In order to reduce material (e.g. chemicals, binders) consumption, BAT is to use an appropriate
combination of the techniques given below.
Technique Description Applicability
Techniques for aluminium high-pressure die-casting
Separate spraying of release
a. See Section 1.4.2. Generally applicable.
agent and water
Measures to minimise the consumption of release
agent and water include:
— use of an automated spraying system;
— optimisation of the release agent’s dilution
Minimisation of release agent factor;
b. Generally applicable.
and water consumption — application of in-die cooling;
— closed-mould application of release agent;
— measuring the consumption of release agents;
— measuring the die surface temperature to in
dicate hotspots in the die.
Techniques for processes using chemically bonded sand and core-making
Optimisation of binder and re
c. See Section 1.4.2. Generally applicable.
sin consumption
Production parameters of the various product
Minimisation of mould and types are stored in an electronic database that al
d. Generally applicable.
core sand losses lows easy changeover to new products with mini
mised losses in time and materials.
Use of best practices for cold-
e. See Section 1.4.2. Generally applicable.
setting processes
When acid washing is used (e.g. using sulphuric
acid) to treat the cold-box off-gases, amine sulphate Applicability may be re
Recovery of amines from acid
f. is formed. The amines are recovered from the treat stricted due to safety consid
scrubbing water
ment of amine sulphate using sodium hydroxide. erations (explosion hazard).
This may take place on site or off site.
Use of best practices for gas-
g. See Section 1.4.2. Generally applicable.
hardening processes
Applicability of the lost
foam casting process to ex
isting plants may be re
Alternative moulding/core-making processes stricted due to the required
Applying alternative mould using no or a reduced amount of binders include: infrastructure modifica
h.
ing/core-making processes — lost foam casting process; tions. Applicability of va
— vacuum moulding. cuum moulding may be re
stricted in the case of large
moulding boxes (e.g. above
1,5 m × 1,5 m).
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1.2.1.4.4. Sand reuse
BAT 18. In order to reduce the consumption of new sand and the generation of spent sand from sand
reuse in the lost mould casting process, BAT is to use one or an appropriate combination of the
techniques given below.
Technique Description Applicability
The green sand reconditioning process is controlled by a
computer system to optimise raw material consumption
Optimised recondi
a. and green sand reuse, e.g. cooling (evaporative or fluidised Generally applicable.
tioning of green sand
bed), addition of binders and additives, moistening, mixing,
quality control.
Green sand reconditioning in aluminium foundries is car
Low-waste green sand ried out using a scanner for identifying impurities in green
b. Generally applicable.
reconditioning sand based on brightness/colour. These impurities are sepa
rated from green sand using an air blast pulse.
Preparation of clay-
bonded sand by va
c. See BAT 25 (b). Generally applicable.
cuum mixing and cool
ing
Mechanical reclama Mechanical techniques (e.g. breaking of lumps, segregation
May not be applicable to si
d. tion of cold-setting of sand fractions) using crushers or mills are used to reclaim
licate-bonded sand.
sand cold-setting sand.
Cold mechanical recla
mation of clay-bonded
Use of a rotating grinding wheel to remove clay layers and
e. or chemically bonded Generally applicable.
chemical binders from used sand grains.
sand using a grinding
wheel
Use of an impact drum with a spinning internal axis,
equipped with small blades, for abrasive cleaning of sand
Cold mechanical recla
grains. When applied on a mixture of bentonite and chemi
f. mation of sand using Generally applicable.
cally bonded sand, a preliminary magnetic separation is car
an impact drum
ried out to remove parts with magnetic properties from the
green sand.
Cold reclamation of Removal of binders from the sand grains using abrasion and
g. sand using a pneumatic impact. The kinetic energy is provided by a compressed air Generally applicable.
system stream.
Use of heat to burn binders and contaminants contained in
chemically bonded and mixed sand. This is combined with May not be applicable in the
Thermal reclamation an initial mechanical pretreatment to bring the sand to the case of used sand containing
h.
of sand correct grain size and remove any metallic contaminant. In residues from inorganic
the case of mixed sand, the share of chemically bonded sand binders.
should be high enough.
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Technique Description Applicability
After pretreatment (sieving, magnetic separation) and dry May not be applicable for
Combined reclama ing, sand is mechanically or pneumatically cleaned to re core sands containing acidic
tion (mechanical-ther move part of the binder. In the thermal step, organic con binders (because it may alter
i. mal-mechanical) for stituents are burned and inorganic constituents are bentonite characteristics) or
mixed organic-bento transferred to the dust or burned onto the grains. In a final in the case of water glass
nite sands mechanical treatment, these grain layers are removed me (because it may alter green
chanically or pneumatically and discarded as dust. sand characteristics).
After pouring and solidification, moulds/casting units are
loaded into the furnace. When the units reach a temperature
Combined sand recla
> 420 °C, the binders are burnt, the cores/moulds disinte
mation and heat treat
j. grate, and the castings undergo heat treatment. The sand Generally applicable.
ment of aluminium
falls to the bottom of the furnace for final cleaning in a
castings
heated fluidised bed. After cooling, the sand is reused in
the core sand mixer without further treatment.
Sand is mixed with water to produce a sludge. The removal
Wet reclamation for of grain-bound binder residues is performed through inten
k. green sand, silicate- or sive inter-particle rubbing of the sand grains. The binders Generally applicable.
CO -bonded sands are released into the wash water. The washed sand is dried,
2
screened and finally cooled.
Reclamation of so
Sand is heated to make the silicate layer brittle before the use
dium silicate sand
l. of a pneumatic system (see technique (g)). The reclaimed Generally applicable.
(water glass) using a
sand is cooled before reuse.
pneumatic system
Sand resulting from broken/faulty cores, and excess sand
Internal reuse of core
from the core-making machines (after hardening in a speci
m. sand (cold-box or fur Generally applicable.
fic unit), are fed to a breaking unit. The resulting sand is
an-acid binders)
mixed with new sand for the production of new cores.
Dust is collected through the exhaust filtration from the
Reuse of dust from the shake-out installation and from the dosing and handling
n. green sand circuit in stations for dry green sand. The collected dust (containing Generally applicable.
mould making active binder compounds) can be recycled into the green
sand circuit.
Table 1.5
BAT-associated environmental performance levels (BAT-AEPLs) for sand reuse
BAT-AEPL(1)
Foundry type Unit
(Yearly average)
Cast iron foundries > 90
Steel foundries % > 80
NFM foundries(2) > 90
(1) The BAT-AEPLs may not apply when the quantity of used sand is lower than 10 000t/year.
(2) The BAT-AEPL may not apply in aluminium die casting foundries when water glass is used.
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The associated monitoring is given in BAT 6.
1.2.1.4.5. Reduction of generated residues and of waste sent for disposal
BAT 19. In order to reduce the amount of residues generated in metal melting and to reduce the amount
of waste sent for disposal, BAT is to use all of the techniques given below.
Technique Description
Techniques for all furnace types
Slag forming can be minimised by in-process measures, such as:
— using clean scrap;
— using a lower metal temperature (as close as possible to the theoretical melting
point);
— avoiding high temperature peaks;
Minimisation of slag — preventing extended holding of molten metal in the melting furnace or using a
a.
forming separate holding furnace;
— making adequate use of fluxes;
— making adequate choice of the furnace refractory lining;
— applying water cooling of the furnace walls to avoid the wear of the furnace
refractory lining;
— liquid aluminium skimming.
Mechanical pretreatment
of slag / dross / filter dust / See Section 1.4.2.
b.
spent refractory linings to This may also take place off site.
facilitate recycling
Techniques for cupola furnaces
Adjustment of the slag
c. See Section 1.4.2.
acidity/basicity
Coke breeze generated during handling, transport and charging of coke is collected (e.g.
Collection and recycling
d. by using collection systems below conveyor belts and/or charging points) and recycled
of coke breeze
in the process (injected into the cupola furnace or used for recarburisation).
Recycling of filter dust in
Cupola filter dust is partially re-injected into the cupola furnace in order to increase the
e. cupola furnaces using
zinc content in the dust, up to a level that allows Zn recovery (> 18 %).
zinc-containing scraps
Techniques for EAFs
Collected dry filter dust, usually after pretreatment (e.g. by pelletising or briquetting), is
Recycling of filter dust in
f. recycled in the furnace to enable the recovery of the metallic content of the dust. The
the EAF
inorganic content is transferred to the slag.
BAT 20. In order to reduce the amount of waste sent for disposal, BAT is to prioritise off-site recycling
and/or other recovery over disposal for spent sand, undersize sand, slags, refractory linings and collected
filter dust (e.g. fabric filter dust).
Description
Off-site recycling and/or other recovery have priority over disposal for spent sand, undersize sand, slags, refractory
linings and filter dust. Spent sand, undersize sand, slags and refractory linings can be:
— recycled, e.g. in road construction, building materials (such as cement, bricks, tiles);
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— recovered, e.g. filling of mining cavities, landfill construction (such as roads on landfills and permanent covers).
Filter dust can be externally recycled, e.g. in metallurgy, sand fabrication, the construction sector.
Applicability
Recycling and/or other recovery may be restricted by the physico-chemical properties of the residue (e.g. organic/
metal content, granulometry).
It may not be applicable in the case of absence of a suitable third-party demand for recycling and/or recovery.
Table 1.6
BAT-associated environmental performance levels (BAT-AEPLs) for waste sent for disposal
BAT-AEPL(1)
(Yearly average)
Waste type Unit
NFM foundries Cast iron foundries Steel foundries
Slag 0– 50 0– 50(2) 0– 50(2)
Dross 0– 30 0– 30 0– 30
kg/t of liquid metal
Filter dust 0– 5 0– 60 0– 10
Spent furnace refractory
0– 5 0– 20(3) 0– 20
linings
(1) The BAT-AEPL may not apply in the absence of a suitable third-party demand for recycling and/or recovery.
(2) For steel or cast iron foundries operating EAFs, the upper end of the BAT-AEPL range may be higher and up to 100 kg/t of liquid
metal due to increased slag formation during the metallurgical treatment.
(3) For cast iron foundries operating CBC, the upper end of the BAT-AEPL range may be higher and up to 100 kg/t of liquid metal.
The associated monitoring is given in BAT 6.
1.2.1.5. Diffuse emissions to air
BAT 21. In order to prevent or, where that is not practicable, to reduce diffuse emissions to air, BAT is to
use all of the techniques given below.
Technique Description Applicability
Covering the delivery
equipment (contain Cargo space of transport vehicles and delivery equip
a. Generally applicable.
ers) and the cargo space ment (containers) are covered (e.g. with tarpaulins).
of transport vehicles
Cleaning roads and Roads as well as the wheels of transport vehicles are
b. transport vehicle regularly cleaned, e.g. by using mobile vacuum sys Generally applicable.
wheels tems, water lagoons.
Materials are transferred using conveyor systems, e.g.
Using closed con
c. closed conveyors, pneumatic conveying. Material Generally applicable.
veyors
drops are minimised.
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Technique Description Applicability
Vacuum cleaning of May not be applicable in areas
The moulding and casting process areas in sand
d. moulding and casting where the sand has a technical or
moulding foundries are regularly vacuum-cleaned.
process areas safety-related function.
Applicability may be restricted in
the case of large or complex cast
ing shapes because of difficulties
Substitution of alco for circulation of the drying air.
hol-based coatings Not applicable to water-glass-
e. See Section 1.4.3.
with water-based coat bonded sands, the magnesium
ings casting process, vacuum mould
ing or the production of manga
nese steel castings with MgO coat
ing.
This includes the following:
— Minimising the generation of emissions from
quenching baths by using water-based polymer
solutions (e.g. containing polyvinylpyrrolidone
or polyalkylene glycol).
Control of emissions — Collecting emissions from quenching baths (espe
f. Generally applicable.
from quenching baths cially from oil quenching baths) as close as possi
ble to the emission source, using roof ventilation,
extraction domes or edge extractors. Extracted off-
gases may be treated, e.g. by using an ESP (see
Section 1.4.3).
— Use of tempered water as quenching media.
This includes the following:
— Extraction as close as possible to the source of
diffuse emissions (e.g. dust, fumes) from transfer
processes such as furnace charging/tapping using
Control of emission
hoods for example. The extracted off-gases are
g. from transfer opera Generally applicable.
treated using for example fabric filter, wet scrub
tions in metal melting
bing.
— Minimisation of diffuse emissions from liquid me
tal transfer through launders using covers for ex
ample.
Further process-specific techniques to prevent or reduce diffuse emissions are given in BAT 24, BAT 26, BAT 27,
BAT 28, BAT 29, BAT 30, BAT 31, BAT 38, BAT 39, BAT 40, BAT 41 and BAT 43.
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1.2.1.6. Channelled emissions to air
BAT 22. In order to facilitate the recovery of materials and the reduction of channelled emissions to air,
as well as to increase energy efficiency, BAT is to combine waste gas streams with similar characteristics,
thus minimising the number of emission points.
Description
The combined treatment of waste gases with similar characteristics ensures more effective and efficient treatment
compared to the separate treatment of individual waste gas streams. The combination of waste gases is carried out
considering plant safety (e.g. avoiding concentrations close to the lower/upper explosive limit), technical (e.g.
compatibility of the individual waste gas streams, concentration of the substances concerned), environmental (e.g.
maximising recovery of materials or pollutant abatement) and economic factors (e.g. distance between different
production units). Care is taken that the combination of waste gases does not lead to the dilution of emissions.
1.2.1.7. Emissions to air from thermal processes
BAT 23. In order to prevent or reduce emissions to air from metal melting, BAT is to use either electricity
generated from fossil-free energy sources in combination with techniques (a) to (e), or techniques (a) to (e)
and an appropriate combination of the techniques (f) to (i) given below.
Technique Description Applicability
General techniques
Selection of an appropriate The selection of an appro
furnace type and maximisa priate furnace type is only
a. See Section 4.4.1
tion of the thermal efficiency applicable to new plants
of furnaces and major plant upgrades.
b. Use of clean scrap See Section 1.4.1 Generally applicable.
Primary control measures to minimise PCDD/F emissions
Maximisation of the off-
In cupola furnaces, the temperature of the post-combus
gases’ residence time and op
tion chamber is optimised (T > 850 °C) and continuously
c. timisation of the tempera
monitored while the off-gases’ residence time is maxi
ture in the post-combustion
mised (> 2 s).
chamber in cupola furnaces
The off-gas is cooled rapidly from temperatures above
400 °C to below 250 °C before dust abatement to prevent
d. Rapid off-gas cooling the de novo synthesis of PCDD/F. This is achieved by ap Generally applicable.
propriate design of the furnace and/or the use of a quench
system.
The build-up of dust along the cooling trajectory of the
off-gases is minimised, especially in the heat exchangers,
Minimising dust build-up in
e. e.g. by using vertical exchanger tubes, efficient internal
heat exchangers
cleaning of the exchanger tubes, high-temperature
de-dusting.
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Technique Description Applicability
Techniques for reducing the generation of NO and SO emissions
X 2
Applicable within the con
straints associated with the
Use of a fuel or a combina
Fuels with a low NO formation potential include natural availability of different
f. tion of fuels with low NO X
X gas and liquefied petroleum gas. types of fuel, which may
formation potential
be impacted by the energy
policy of the Member State.
Applicable within the con
straints associated with the
Use of a fuel or a combina
Fuels with low sulphur content include natural gas and availability of different
g. tion of fuels with low sul
liquefied petroleum gas. types of fuel, which may
phur content
be impacted by the energy
policy of the Member State.
Applicability to existing
plants may be restricted
h. Low-NO burners See Section 1.4.3.
X by furnace design and/or
operational constraints.
Applicability to existing
plants may be restricted
i. Oxy-fuel combustion See Section 1.4.3. by furnace design and the
need for a minimum waste
gas flow.
The BAT-AELs for metal melting are given:
— in Table 1.18 for cast iron foundries;
— in Table 1.20 for steel foundries;
— in Table 1.22 for NFM foundries.
BAT 24. In order to prevent or reduce emissions to air from heat treatment, BAT is to use either
electricity generated from fossil-free energy sources in combination with techniques (a) and (d), or all of
the techniques given below.
Technique Description Applicability
General techniques
Selection of an appropriate
furnace type and maximisa Only applicable to new plants and major
a. See Section 1.4.3
tion of the thermal effi plant upgrades.
ciency of furnaces
Techniques for reducing the generation of NO emissions
X
Applicable within the constraints asso
Use of a fuel or a combina Fuels with a low NO formation potential
X ciated with the availability of different
b. tion of fuels with low NO include natural gas and liquefied petroleum
X types of fuel, which may be impacted
formation potential gas.
by the energy policy of the Member State.
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Technique Description Applicability
Applicability to existing plants may be
c. Low-NO burners See Section 1.4.3. restricted by furnace design and/or op
X
erational constraints.
Collection of emissions
Off-gases from heat treatment furnaces
(e.g. annealing, ageing, normalising, aus
Off-gas extraction as close
tempering) are extracted using hoods or
d. as possible to the emission Generally applicable.
cover extraction. The collected emissions
source
may be treated using techniques such as
fabric filters.
Table 1.7
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust and NO and indicative
X
emission level for channelled emissions to air of CO from heat treatment
BAT-AEL Indicative emission level
Substance/Parameter Unit (Daily average or average over the (Daily average or average over the
sampling period) sampling period)
Dust 1 – 5(1) No indicative level
NO mg/Nm3 20 – 120(2)(3) No indicative level
X
CO No BAT-AEL 10 – 100(3)
(1) The BAT-AEL only applies when the substance/parameter concerned is identified as relevant in the waste gas streams based on the
inventory of inputs and outputs mentioned in BAT 2.
(2) In the case of heat treatment over 1 000°C (e.g. for the production of malleable iron), the upper end of the BAT-AEL range may be
higher and up to 300 mg/Nm3.
(3) The BAT-AEL and indicative emission level do not apply in the case of furnaces using only electric energy (e.g. resistance).
The associated monitoring is given in BAT 12.
1.2.1.8. Emissions to air from moulding using lost moulds and core-making
BAT 25. In order to prevent or reduce emissions to air from moulding using lost moulds and core-
making, BAT is to:
— use an appropriate combination of the techniques (a) to (c) given below in the case of moulding with clay-bonded sand;
— use either technique (d), (e) or (f) and an appropriate combination of the techniques (g) to (k) given below, in the case of
moulding and core-making with chemically bonded sand;
— use technique (l) given below for selecting the coatings applied to moulds and cores.
Technique Description Applicability
Techniques for moulding with clay-bonded sand (green sand)
This includes techniques such as:
Use of best prac
— precise addition of the required quantity of key components (e.g.
a. tices for green Generally applicable.
clay, water, coal dust or other additives) to restore the chemical
sand moulding
properties of the returned green sand;
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Technique Description Applicability
— regular testing (e.g. daily) of the green sand properties (e.g.
moisture, green strength, compactability, permeability, loss on
ignition, volatile content).
Preparation of
clay-bonded Mixing and cooling processes are combined into a single process step
b. sand by vacuum by operating the sand mixer under reduced pressure, which results in Generally applicable.
mixing and cool cooling by the controlled vaporisation of the water.
ing
Applicability may be re
stricted by operational
Coal dust is replaced by additives such as graphite, coke flour and
Substitution of constraints (e.g. less effi
c. zeolites, resulting in significantly lower diffuse emissions during the
coal dust cient shake-out or oc
casting process.
currence of casting de
fects).
Techniques for prevention of emissions in moulding and core-making with chemically bonded sand
A cold-setting binder system generating low emissions of
formaldehyde, phenol, furfuryl alcohol, isocyanates, etc. is selected.
This includes the use of:
— no-bake furan resins with low furfuryl alcohol content (e.g. less
than 40 wt-%) for production of iron castings for example;
— no-bake phenol/furan systems with a low-sulphur acid catalyst
for production of steel castings for example;
— aliphatic organic binders based for example on aliphatic
Selection of a polyalcohols (instead of aromatic organic binders) for
Applicability may be re
low-emission production of iron, steel, aluminium or magnesium
d. stricted due to product
cold-setting bin castings, etc.;
specifications.
der system — inorganic geopolymers based on polysialates (for production of
grey iron, aluminium and steel castings, etc.);
— ester silicate (for production of medium and large steel
castings, etc.);
— alkyd oil (e.g. for single castings or small batch production in
steel foundries);
— resol-ester (e.g. for lighter alloys in small or medium
production);
— cement (for production of very large castings for example).
A gas curing binder system generating low emissions of amines,
benzene, formaldehyde, phenol, isocyanates, etc. is selected. This
includes the use of:
— inorganic binders, e.g. sodium silicate (water glass), hardened
using CO or organic esters, for example in aluminium die-
2
casting;
Selection of a
— inorganic geopolymers based on polysialates cured with CO Applicability may be re
low-emission 2
e. (for production of grey iron, aluminium, steel castings, etc.); stricted due to product
gas curing bin
— aliphatic organic binders based for example on aliphatic specifications.
der system
polyalcohols (instead of aromatic organic binders) for
production of iron, steel, aluminium or magnesium
castings, etc.;
— phenolic urethane binders with very low free phenol and
formaldehyde content (for production of iron and steel
castings, etc.);
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Technique Description Applicability
— phenolic urethane binders with reduced amounts of solvents
(for production of iron and steel castings, etc.).
A hot-curing binder system generating low emissions of
formaldehyde, phenol, furfuryl alcohol, benzene, isocyanates, etc. is
selected. This includes the use of:
Selection of a
— inorganic binders such as geopolymers based on polysialates; Applicability may be re
low-emission
f. — inorganic binders cured using a warm-box process without stricted due to product
hot-curing bin
phenol, formaldehyde and isocyanates (for preparing specifications.
der system
aluminium castings with complex shapes for example);
— aliphatic polyurethane warm box binders (used as an alternative
to the cold box process).
General techniques for moulding and core-making with chemically bonded sand
Optimisation of
g. binder and resin See Section 1.4.3. Generally applicable.
consumption
Use of best prac
tices for cold-
h. See Section 1.4.3. Generally applicable.
setting pro
cesses
Use of best prac
tices for gas-
i. See Section 1.4.3. Generally applicable.
hardening pro
cesses
Use of non-aro
Non-aromatic solvents are used that are based either on protein or
matic solvents
j. animal fat (e.g. fatty acid methyl esters of vegetable oil) or on silicate Generally applicable.
for cold-box
esters in order to reduce emissions of VOCs (e.g. benzene, toluene).
core production
Several hot-curing processes may be used and a series of measures
are in place to optimise each process including for the following:
Hot-box process:
— Curing is carried out within the optimum temperature range
(e.g. 220 °C to 300 °C).
— Cores are usually precoated using water-based coatings to
prevent burns at the core surface which may result in
Use of best prac
brittleness during pouring.
k. tices for hot-cur Generally applicable.
— Core blowers and the area around them are well ventilated and
ing processes
exhausted to capture the formaldehyde liberated during curing
efficiently.
Warm-box process:
— Curing is carried out at a lower optimum temperature range
than the hot-box process (e.g. 150 °C to 190 °C), resulting in
lower emissions and energy consumption than the hot-box
process.
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Technique Description Applicability
Shell (Croning):
— Precoated sands with a phenol-formaldehyde resin are bound
using hexamethylenetetramine that decomposes at 160 °C,
releasing formaldehyde, necessary for cross-linking the resin,
and ammonia.
The curing and/or core blower area is well ventilated and exhausted
to capture the ammonia and formaldehyde liberated during curing
efficiently.
Techniques related to the coatings applied to moulds and cores
Applicability may be re
stricted in the case of
large or complex casting
shapes because of diffi
Substitution of culties for circulation of
alcohol-based the drying air.
l. coatings with See Section 1.4.3. Not applicable to water
water-based glass-bonded sands, the
coatings magnesium casting pro
cess, vacuum moulding
or the production of
manganese steel cast
ings with MgO coating.
BAT 26. In order to reduce emissions to air from moulding using lost moulds and core-making, BAT is to:
— use an appropriate combination of the techniques given in BAT 25;
— collect the emissions using technique (a);
— treat the off-gases using one or a combination of the techniques (b) to (f) given below.
Technique Description Applicability
Collection of emissions
Extraction of emis
sions generated
from moulding
Applicability may be restricted in the case of moulding in cast iron
a. and/or core-making See Section 1.4.3.
and steel foundries producing large castings.
as close as possible
to the emission
source
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Technique Description Applicability
Off-gas treatment
b. Fabric filter See Section 1.4.3. Generally applicable.
c. Wet scrubbing See Section 1.4.3. Generally applicable.
d. Adsorption See Section 1.4.3. Generally applicable.
Applicability may be restricted where the energy demand is excessive
due to the low concentration of the compound(s) concerned in the
e. Thermal oxidation See Section 1.4.3. process off-gases. Applicability of recuperative and regenerative
thermal oxidation to existing plants may be restricted by design
and/or operational constraints.
Applicability may be restricted by the presence of catalyst poisons in
the waste gases or where the energy demand is excessive due to the
f. Catalytic oxidation See Section 1.4.3.
low concentration of the compound(s) concerned in the process off-
gases.
Table 1.8
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, amines, benzene,
formaldehyde, phenol and TVOC from moulding using lost moulds and core-making
BAT-AEL
Substance/Parameter Unit
(Daily average or average over the sampling period)
Dust 1– 5
Amines < 0,5– 2,5(1)
Benzene mg/Nm3 < 1– 2(2)
Formaldehyde < 1– 2(3)
Phenol < 1– 2(4)
TVOC mg C/Nm3 15– 50(5)
(a) organic binder systems generating low or no emissions of substances classified as CMR 1A, CMR 1B or CMR 2 (see
techniques (d), (e) and/or (f) in BAT 25) are used in core-making;
(b) one or both of the following conditions are met:
— thermal or catalytic oxidation is not applicable,
— substitution with water-based coatings is not applicable.
(1) The BAT-AEL only applies in the cold-box process when amines are used.
(2) The BAT-AEL only applies when aromatic binders/chemicals are used.
(3) The BAT-AEL only applies when the substance concerned is identified as relevant in the waste gas streams based on the inventory of
inputs and outputs mentioned in BAT 2.
(4) The BAT-AEL only applies when phenolic-based binder systems are used.
(5) In the case of core-making, the upper end of the BAT-AEL range may be higher and up to 100 mg C/Nm3 if both of the following
conditions (a) and (b) are met:
The associated monitoring is given in ΒΑΤ 12.
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1.2.1.9. Emissions to air from casting, cooling and shake-out processes in foundries using lost moulds including the full mould
process
BAT 27. In order to reduce emissions to air from casting, cooling and shake-out processes in foundries
using lost moulds including the full mould process, BAT is to:
— collect the emissions by using technique (a);
— treat the off-gases using one or a combination of the techniques (b) to (h) given below.
Technique Description Applicability
Collection of emissions
Emissions generated during the casting (especially emissions from
pouring), cooling and shake-out processes are appropriately
extracted.
For the casting and cooling processes, this includes:
Extraction of
— restricting the pouring process to a fixed area or position to
emissions gener
facilitate the capture of emissions using ventilators and
ated during the Applicability may be re
enclosure (e.g. in serial pouring);
casting, cooling stricted in the case of cast
a. — enclosure of pouring and cooling lines.
and shake-out iron and steel foundries
For the shake-out process, this includes:
processes as close producing large castings.
— use of ventilator panels situated on both sides and at the rear of
as possible to the
the shaker;
emission source
— use of enclosed units equipped with roof openings or
removable covers (e.g. doghouse);
— installation of an extraction point situated underneath the
shaker in the sand collection box.
Off-gas treatment
b. Cyclone See Section 1.4.3. Generally applicable.
c. Fabric filter See Section 1.4.3. Generally applicable.
d. Wet scrubbing See Section 1.4.3. Generally applicable.
e. Adsorption See Section 1.4.3. Generally applicable.
The off-gas stream is passed through a bed of organic material (such
as peat, heather, compost, root, tree bark, softwood and different
combinations) or some inert material (such as clay, activated
Only applicable to the
carbon, and polyurethane), where it is biologically oxidised by
f. Biofilter treatment of biodegrad
naturally occurring microorganisms into carbon dioxide, water,
able compounds.
inorganic salts and biomass. The biofilter is sensitive to dust, high
temperatures and high variations in the off-gas composition.
Supplementary nutrient feeding may be needed.
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Technique Description Applicability
Applicability of recup
erative and regenerative
thermal oxidation to ex
isting plants may be re
stricted by design and/or
operational constraints.
Thermal oxida
g. See Section 1.4.3. Applicability may be re
tion
stricted where the energy
demand is excessive due
to the low concentration
of the compound(s) con
cerned in the process off-
gases
Applicability may be re
stricted by the presence
of catalyst poisons in
the waste gases or where
Catalytic oxida
h. See Section 1.4.3. the energy demand is ex
tion
cessive due to the low
concentration of the
compound(s) concerned
in the process off-gases.
Table 1.9
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, benzene, formaldehyde,
phenol and TVOC from casting, cooling and shake-out processes in foundries using lost moulds including the full
mould process
BAT-AEL
Substance/Parameter Unit (Daily average or average over the sampling
period)
Dust 1– 5
Benzene < 1– 2(1)
mg/Nm3
Formaldehyde < 1– 2(2)
Phenol < 1– 2(3)
TVOC mg C/Nm3 15– 50(4)
(1) The BAT-AEL only applies when aromatic binders/chemicals are used or when the full mould process is used.
(2) The BAT-AEL only applies when the substance concerned is identified as relevant in the waste gas streams based on the inventory of
inputs and outputs mentioned in BAT 2.
(3) The BAT-AEL only applies when phenolic-based binder systems are used in moulding and/or core-making.
(4) The upper end of the BAT-AEL range may be higher and up to 100 mg C/Nm3 when organic binder systems generating low or no
emissions of substances classified as CMR 1A, CMR 1B or CMR 2 (see techniques (d), (e) and/or (f) in BAT 25) are used in core-
making.
The associated monitoring is given in BAT 12.
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1.2.1.10. Emissions to air from lost foam casting
BAT 28. In order to reduce dust and TVOC emissions to air from lost foam casting, BAT is to collect the
emissions using technique (a) and to treat the off-gases by using an appropriate combination of the
techniques (b) to (d) given below.
Technique Description Applicability
Collection of emissions
Extraction of emis
sions generated from In the lost foam casting processes, emissions from the pyro
a. lost foam casting as lysis of the expanded polymer during pouring and shake-out Generally applicable.
close as possible to are extracted using, for example an enclosure or a hood.
the emission source
Off-gas treatment
b. Fabric filter See Section 1.4.3. Generally applicable.
c. Wet scrubbing See Section 1.4.3. Generally applicable.
Applicability of recupera
tive and regenerative ther
mal oxidation to existing
plants may be restricted by
design and/or operational
constraints. Applicability
d. Thermal oxidation See Section 1.4.3.
may be restricted where
the energy demand is exces
sive due to the low concen
tration of the compound(s)
concerned in the process
off-gases.
Table 1.10
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust and TVOC from lost foam
casting
BAT-AEL
Parameter Unit (Daily average or average over the sampling
period)
Dust mg/Nm3 1– 5
TVOC mg C/Nm3 15– 50(1)
(1) The upper end of the BAT-AEL range may be higher and up to 100 mg C/Nm3 if the TVOC abatement efficiency of the waste gas
treatment system is > 95 %.
The associated monitoring is given in BAT 12.
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1.2.1.11. Emissions to air from the casting process in foundries using permanent moulds
BAT 29 In order to prevent or reduce emissions to air from the casting process in foundries using
permanent moulds, BAT is to:
— prevent the generation of emissions by using one or a combination of the techniques (a) to (e);
— collect the emissions by using technique (f);
— treat the off-gases by using one or a combination of the techniques (g) to (j) given below.
Technique Description Applicability
Prevention of emissions
This includes techniques such as
General techniques for — selection of an appropriate lubricant to prevent castings
a. gravity and low-pres surface defects;
sure die-casting — optimised lubricant preparation and application to
avoid excessive use.
This includes techniques such as:
— proper lubrication of the die and plungers using water-
based emulsions of silicone oils, ester oils, synthetic
General techniques for
waxes for example;
b. high-pressure die-cast
— minimisation of the release agent and water consump
ing
tion by optimising the spraying process, e.g. use of mi
cro-spraying for application of release agents (see also
ΒΑΤ 17 (b)).
In centrifugal casting, important process parameters such as
Generally applicable.
mould rotation, pouring temperature and mould preheating
Optimisation of pro temperature are optimised (e.g. using flow simulation) to re
cess parameters for duce the number of defects and minimise emissions.
c.
centrifugal and contin In continuous casting, the casting rate, casting temperature
uous casting and cooling rate are optimised to minimise emissions and
reduce the amount of water consumed for cooling while
reaching the required product specification.
Separate spraying of re
lease agent and water in
d. See Section 1.4.2.
high-pressure die-cast
ing
Use of water-free re
Water-free release agents (e.g. in a powdered form) are ap
e. lease agents in high-
plied to the die using electrostatic deposition.
pressure die-casting
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Technique Description Applicability
Collection of emissions
Extraction of emissions
Emissions generated from the casting process including
generated from the
high-pressure/low-pressure/gravity die-casting, centrifugal
f. casting process as close Generally applicable.
and continuous casting are extracted using enclosures or ex
as possible to the emis
traction hoods.
sion source
Off-gas treatment
g. Fabric filter See Section 1.4.3.
h. Wet scrubbing See Section 1.4.3.
Generally applicable.
Electrostatic precipita
i. See Section 1.4.3.
tor
Applicability of recupera
tive and regenerative ther
mal oxidation to existing
plants may be restricted
by design and/or opera
tional constraints. Ap
j. Thermal oxidation See Section 1.4.3. plicability may be re
stricted where the energy
demand is excessive due
to the low concentration
of the compound(s) con
cerned in the process off-
gases.
Table 1.11
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, TVOC and lead from the
casting process in foundries using permanent moulds
BAT-AELs
Substance/Parameter Unit (Daily average or average over the sampling
period)
Dust 1– 5
mg/Nm3
Pb 0,05– 0,1(1)
TVOC mg C/Nm3 2– 30(2)(3)
(1) The BAT-AEL only applies to lead foundries.
(2) The BAT-AEL only applies when TVOC is identified as relevant in the waste gas streams based on the inventory of inputs and outputs
mentioned in BAT 2.
(3) The BAT-AEL only applies when cores with chemically bonded sand are used.
The associated monitoring is given in BAT 12.
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1.2.1.12. Emissions to air from finishing
BAT 30. In order to reduce dust emissions to air from finishing, BAT is to collect the emissions using
technique (a) and to treat the off-gases by using one or a combination of the techniques (b) to (d) given
below.
Technique Description
Collection of emissions
Emissions generated from finishing operations, such as deburring, abrasive cutting, fettling,
Extraction of
slide grinding, shot blasting, welding, chiselling, needling, are appropriately extracted using,
emissions gener
e.g.:
ated from finish
a. — enclosure of the finishing process area;
ing as close as pos
— roof ventilation or dome-shaped roofs;
sible to the
— rigid or adjustable extraction hoods;
emission source
— extraction arms.
Off-gas treatment
b. Cyclone See Section 1.4.3.
c. Fabric filter See Section 1.4.3.
d. Wet scrubbing See Section 1.4.3.
Table 1.12
BAT-associated emission level (BAT-AEL) for channelled emissions to air of dust from finishing
BAT-AEL
Parameter Unit (Daily average or average over the sampling
period)
Dust mg/Nm3 1– 5
The associated monitoring is given in BAT 12.
1.2.1.13. Emissions to air from sand reuse
BAT 31. In order to reduce emissions to air from sand reuse, BAT is to:
— in the case of thermal sand regeneration, use either electricity generated from fossil-free energy sources or both
of the techniques (a) and (b);
— collect the emissions using technique (c);
— treat the off-gases by using one or an appropriate combination of the techniques (d) to (g) given below.
Technique Description Applicability
Techniques for reducing the generation of emissions
Use of a fuel or a
Applicable within the constraints associated
combination of Fuels with a low NO formation potential
X with the availability of different types of fuel,
a. fuels with low include natural gas and liquefied petroleum
which may be impacted by the energy policy of
NO formation gas.
X the Member State.
potential
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Technique Description Applicability
Use of a fuel or a Applicable within the constraints associated
combination of Fuels with low sulphur content include nat with the availability of different types of fuel,
b.
fuels with low sul ural gas and liquefied petroleum gas. which may be impacted by the energy policy of
phur content the Member State.
Collection of emissions
Extraction of Emissions generated from sand reclamation
emissions gener are extracted using an enclosure or a hood
ated from sand re for example. This includes extraction of the
c. Generally applicable.
use as close as pos flue-gases generated from fluidised bed fur
sible to the naces, rotary kilns or hearth furnaces, etc.
emission source used in thermal sand regeneration.
Off-gas treatment
d. Cyclone See Section 1.4.3.
e. Fabric filter See Section 1.4.3. Generally applicable.
f. Wet scrubbing See Section 1.4.3.
Applicability of recuperative and regenerative
thermal oxidation to existing plants may be re
stricted by design and/or operational constraints.
Thermal oxida
g. See Section 1.4.3. Applicability may be restricted where the energy
tion
demand is excessive due to the low concentra
tion of the compound(s) concerned in the pro
cess off-gases.
Table 1.13
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust and TVOC from sand reuse
BAT-AEL
Substance/Parameter Unit
(Daily average or average over the sampling period)
Dust mg/Nm3 1– 5
TVOC mg C/Nm3 5– 20(1)
(1) The upper end of the BAT-AEL range may be higher and up to 50 mg C/Nm3 with a high share of core sand in sand reuse.
Table 1.14
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of NO and SO from sand reuse
X 2
BAT-AEL
Substance/Parameter Process Unit (Daily average or average over
the sampling period)
Thermal regeneration of sand originating from the
NO 50– 140
x cold-box process
mg/Nm3
Thermal regeneration of sand in which sulphonic
SO 10– 100
2 acid catalysts have been used
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The associated monitoring is given in BAT 12.
1.2.1.14. Odour
BAT 32. In order to prevent or, where that is not practicable, to reduce odour emissions, BAT is to set up,
implement and regularly review an odour management plan, as part of the environmental management
system (see BAT 1), that includes all of the following elements:
— A protocol containing appropriate actions and timelines.
— A protocol for conducting odour monitoring as set out in BAT 33. The protocol may be complemented by
measurement/estimation of odour exposure or estimation of odour impact.
— A protocol for response to identified odour incidents, e.g. managing complaints and/or taking corrective
actions.
— An odour prevention and reduction programme designed to identify the source(s); to measure/estimate odour
exposure; to characterise the contributions of the sources; and to implement prevention and/or reduction
measures.
Applicability
The applicability is restricted to cases where an odour nuisance at sensitive receptors is expected and/or has been
substantiated.
BAT 33. BAT is to periodically perform odour monitoring.
Description
Odour can be monitored using the following:
— EN standards (e.g. dynamic olfactometry according to EN 13725 in order to determine the odour
concentration and/or EN 16841-1 or -2 in order to determine the odour exposure).
— Alternative methods (e.g. estimation of odour impact) for which no EN standards are available. In such a case,
ISO, national or other international standards that ensure the provision of data of an equivalent scientific
quality can be used.
The monitoring frequency is determined in the odour management plan (see BAT 32).
Applicability
The applicability is restricted to cases where an odour nuisance at sensitive receptors is expected and/or has been
substantiated.
BAT 34. In order to prevent or, where that is not practicable, to reduce odour emissions, BAT is to use all
of the techniques given below.
Technique Description Applicability
Applicability of water-based coatings
This includes techniques such as:
may be restricted due to the type of
— the use of water-based coatings (see
Substitution of chemicals raw material or product specifications
BAT 25 (l));
a. containing alcohol-based (e.g. big moulds/cores, water glass
— the use of alternative solvents in
or aromatic solvents bonded sands, Mg castings, produc
cold-box core-making (see BAT
tion of manganese steel with MgO
25 (h)).
coating).
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Technique Description Applicability
Off-gases containing amines, generated
Collection and treatment
from the gassing of cold-box cores are
of amine emissions from
b. extracted and treated using for example
the cold-box core-making
wet scrubbing, a biofilter, thermal or cat
process
alytic oxidation (see BAT 26).
Off-gases containing VOCs, generated Generally applicable.
Collection and treatment from the preparation of chemically
of VOC emissions from bonded sand, pouring, cooling and
c. chemically bonded sand shake-out are extracted and treated using
preparation, pouring, for example wet scrubbing, a biofilter,
cooling and shake-out thermal or catalytic oxidation (see BAT
26).
1.2.1.15. Water consumption and waste water generation
BAT 35. In order to optimise water consumption and to reduce the volume of waste water generated as
well as to improve water recyclability, BAT is to use both techniques (a) and (b), and an appropriate
combination of the techniques (c) to (g) given below.
Technique Description Applicability
A water management plan and audits are part of the
EMS (see BAT 1) and include:
— flow diagrams and water mass balances of the
plant as part of the inventory of inputs and outputs
The level of detail of the
mentioned in BAT 2;
water management plan
— establishment of water efficiency objectives;
Water management and audits will generally
a. — implementation of water optimisation techniques
plan and audits be related to the nature,
(e.g. control of water usage, reuse/recycling, detec
scale and complexity of
tion and repair of leaks).
the plant.
Audits are carried out at least once every year to ensure
that the objectives of the water management plan are
met and the audit recommendations are followed-up
and implemented.
Applicability to existing
Segregation of water plants may be restricted
b. See Section 1.4.4.
streams by the layout of the water
collection system.
The degree of water reuse
and/or recycling is limited
Water streams (e.g. process water, effluents from wet
by the water balance of the
Water reuse and/or re scrubbing, cooling water) are reused and/or recycled in
c. plant, the content of im
cycling closed or semi-closed circuits, if necessary after treat
purities and/or the char
ment (see BAT 36).
acteristics of the water
streams.
Prevention of waste
water generation from
d. See BAT 4 (b). Generally applicable.
process and storage
areas
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Technique Description Applicability
Use of dry dedusting This includes techniques such as fabric filters and dry
e. Generally applicable.
systems ESPs (see Section 1.4.3).
Separate spraying of
release agent and
f. See Section 1.4.2. Generally applicable.
water in high-pressure
die-casting
Applicability may be re
stricted by the physico-
Use of waste heat for
When waste heat is available on a continuous basis, it chemical properties of
g. the evaporation of
can be used to evaporate waste water. the pollutants present in
waste water
the waste water that can
be emitted into the air.
Table 1.15
BAT-associated environmental performance levels (BAT-AEPLs) for specific water consumption
BAT-AEPL
Foundry type Unit
(Yearly average)
Cast iron foundries
Steel foundries 0,5– 4
m3/t of liquid
metal
Non-ferrous metal foundries (all types except HPDC)
Non-ferrous metal HPDC foundries 0,5– 7
The associated monitoring is given in BAT 6.
1.2.1.16. Emissions to water
BAT 36. In order to reduce emissions to water, BAT is to treat waste water using an appropriate
combination of the techniques given below.
Technique(1) Typical pollutants targeted
Preliminary, primary and general treatment, e.g.
a. Equalisation All pollutants
b. Neutralisation Acids, alkalis
Physical separation through for example screens, sieves, grit
c. separators, grease separators, hydrocyclones, oil-water se Gross solids, suspended solids, oil/grease
parators or primary settlement tanks
Physico-chemical treatment, e.g.
Adsorbable dissolved non-biodegradable or inhibitory
d. Adsorption
pollutants, e.g. hydrocarbons, mercury, AOX
Precipitable dissolved non-biodegradable or inhibitory
e. Chemical precipitation
pollutants, e.g. metals, fluoride
f. Evaporation Soluble contaminants, e.g. salts
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Technique(1) Typical pollutants targeted
Biological treatment, e.g.
g. Activated sludge process
Biodegradable organic compounds
h. Membrane bioreactor
Solids removal, e.g.
i. Coagulation and flocculation Suspended solids and particulate-bound metals
Suspended solids and particulate-bound metals or
j. Sedimentation
non-biodegradable or inhibitory pollutants
Filtration, e.g. sand filtration, microfiltration, ultrafiltration,
k.
reverse osmosis
Suspended solids and particulate-bound metals
l. Flotation
(1) The descriptions of the techniques are given in Section 1.4.4.
Table 1.16
BAT-associated emission levels (BAT-AELs) for direct discharges
Substance/Parameter Unit BAT-AEL(1) Origin of waste water stream(s)
Adsorbable organically bound halogens Wet scrubbing of cupola off-gases
0,1– 1
(AOX)(2)
Chemical oxygen demand (COD)(3) 25– 120
Total organic carbon (TOC)(3) 8– 40
Total suspended solids (TSS) 5– 25
Hydrocarbon oil index (HOI)(2) 0,1– 5
Copper (Cu)(2) 0,1– 0,4 Die-casting, off-gas treatment (e.g. wet
mg/l
scrubbing), finishing, heat treatment,
Chromium (Cr)(2) 0,1– 0,2 contaminated surface run-off water,
direct cooling, wet sand regeneration and
Metals Lead (Pb)(2) 0,1– 0,3 cupola furnace slag granulation.
Nickel (Ni)(2) 0,1– 0,5
Zinc (Zn)(2) 0,5– 2
Phenol index 0,05– 0,5(4)
Total nitrogen (TN)(2) 1– 20
(1) The averaging periods are defined in the General considerations.
(2) The BAT-AELs only apply when the substance/parameter concerned is identified as relevant in the waste water stream based on the
inventory of inputs and outputs mentioned in BAT 2.
(3) Either the BAT-AEL for COD or the BAT-AEL for TOC applies. The BAT-AEL for TOC is the preferred option because TOC
monitoring does not rely on the use of very toxic compounds.
(4) The BAT-AEL only applies when phenolic binding systems are used.
The associated monitoring is given in BAT 13.
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Table 1.17
BAT-associated emission levels (BAT-AELs) for indirect discharges
Substance/Parameter Unit BAT-AEL(1)(2) Origin of waste water stream(s)
Adsorbable organically bound halo Wet scrubbing of cupola off-gases
0,1– 1
gens (AOX) (3)
Hydrocarbon oil index (HOI)(3) 0,1– 5
Copper (Cu)(3) 0,1– 0,4
Chromium (Cr)(3) 0,1– 0,2 Die-casting, off-gas treatment (e.g. wet
mg/l
scrubbing), finishing, heat treatment,
Metals Lead (Pb)(3) 0,1– 0,3 contaminated surface run-off water,
direct cooling, wet sand regeneration
Nickel (Ni)(3) 0,1– 0,5 and cupola furnace slag granulation.
Zinc (Zn)(3) 0,5– 2
Phenol index 0,05– 0,5(4)
(1) The averaging periods are defined in the general considerations.
(2) The BAT-AELs may not apply if the downstream waste water treatment plant is designed and equipped appropriately to abate the
pollutants concerned, provided this does not lead to a higher level of pollution in the environment.
(3) The BAT-AELs only apply when the substance/parameter concerned is identified as relevant in the waste water stream based on the
inventory of inputs and outputs mentioned in ΒΑΤ 2.
(4) The BAT-AEL only applies when phenolic binding systems are used.
The associated monitoring is given in BAT 13.
1.2.2. BAT conclusions for cast iron foundries
The BAT conclusions in this section apply in addition to the general BAT conclusions given in Sections 1.1 and 1.2.1.
1.2.2.1. Energy efficiency
BAT 37. In order to increase energy efficiency in metal melting, BAT is to use an appropriate
combination of the techniques given below.
Technique Description Applicability
Only applicable to new
plants and major plant
Increase of shaft upgrades.
a. height in CBC fur See Section 1.4.1. Applicability to existing
naces plants may be restricted
by building and other
structural constraints.
Oxygen enrich
b. ment of the com See Section 1.4.1. Generally applicable.
bustion air
Minimal blast
c. shut-off periods See Section 1.4.1. Generally applicable.
for HBC furnaces
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Technique Description Applicability
Long-campaign
d. See Section 1.4.1. Generally applicable.
cupola
Post-combustion
e. See Section 1.4.1. Generally applicable.
of off-gases
The BAT-AEPLs for specific energy consumption are given in BAT 14.
1.2.2.2. Emissions to air from thermal processes
1.2.2.2.1. Emissions to air from metal melting
BAT 38. In order to prevent or reduce emissions to air from metal melting, BAT is to:
— use an appropriate combination of process-integrated techniques (a) to (e) in the case of cupola furnaces;
— collect the emissions using technique (f);
— treat the extracted off-gases using one or an appropriate combination of the techniques (g) to (l) given below.
Technique Description Applicability
Process-integrated techniques for cupola furnaces
Coke is purchased based on important quality specifications (e.g.
Control of coke
a. fixed carbon, ash, volatile matter, sulphur and moisture content,
quality
mean size diameter) which are systematically controlled before use.
Generally applicable.
Adjustment of
b. the slag acidity/ See Section 1.4.3.
basicity
Only applicable to new
plants and major plant
Increase of shaft upgrades.
c. height in CBC fur See Section 1.4.1. Applicability to existing
naces plants may be restricted
by building and other
structural constraints.
Oxygen enrich
d. ment of the com See Section 1.4.3. Generally applicable.
bustion air
Long-campaign
e. See Section 1.4.1. Generally applicable.
cupola
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Technique Description Applicability
Collection of emissions
In cupola furnaces, the off-gases are extracted either:
— above the charge-hole offtake at the end of the cupola stack
using ductwork and a downstream fan; or
— below the charge-hole offtake using an annular ring.
After extraction, the off-gases are cooled for example using:
— long ducts to decrease the temperature by natural convection;
— air/gas or oil/gas heat exchangers;
— water quenching.
For induction furnaces, off-gases are extracted, for example using:
Off-gas extrac — hood extraction (e.g. canopy or side-draught hoods);
tion as close as — lip extraction;
f. Generally applicable.
possible to the — cover extraction.
emission source
For rotary furnaces, off-gases are extracted, for example using hood
extraction.
For EAFs, off-gases are extracted, for example using:
— roof-mounted hood extraction;
— canopy or side-draught hoods;
— partial furnace enclosures (mobile or fixed) mounted around
the furnace and tapping area;
— total furnace enclosure using a complete room enclosure
around the furnace and tapping area equipped with a
moveable roof for charging/tapping operations.
Off-gas treatment
Post-combustion
g. See Section 1.4.3. Generally applicable.
of off-gases
h. Cyclone See Section 1.4.3. Generally applicable.
i. Adsorption See Section 1.4.3. Generally applicable.
Dry powder or a suspension/solution of an alkaline reagent (e.g.
lime or sodium bicarbonate) is introduced and dispersed in the off-
j. Dry scrubbing Generally applicable.
gas stream. The material reacts with the acidic gaseous species (e.g.
SO ) to form a solid which is removed by filtration (e.g. fabric filter).
2
k. Fabric filter See Section 1.4.3. Generally applicable.
l. Wet scrubbing See Section 1.4.3. Generally applicable.
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Table 1.18
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, HCl, HF, NO , PCDD/F, SO ,
X 2
TVOC, lead, and indicative emission level for channelled emissions to air of CO from metal melting
BAT-AEL Indicative emission level
Substance/Parameter Unit Furnace type (Daily average or average over (Daily average or average
the sampling period) over the sampling period)
Induction, rotary,
1– 5
EAF
Dust
CBC, HBC 1– 7(1)
No indicative emission
level
HCl CBC, HBC 10– 30(2)
HF CBC, HBC, rotary
1– 3(2)
furnaces
mg/Nm3
Rotary furnaces No BAT-AEL 10 – 30
CO
CBC, HBC No BAT-AEL 20 – 220
HBC 20–160
NO CBC 20– 70
X
Rotary furnaces 20– 100
CBC, HBC, rotary
< 0,01– 0,08
furnaces
ng WHO-
PCDD/F
TEQ/Nm3
Induction < 0,01– 0,08(3)
No indicative emission
level
HBC 30– 100
SO mg/Nm3 Rotary furnaces 10– 50
2
CBC 50– 150
TVOC mg C/Nm3 All furnace types 5– 30
Pb mg/Nm3 CBC, HBC 0,02– 0,1(3)
(1) For existing HBC plants using wet scrubbing, the upper end of the BAT-AEL range may be higher and up to 12 mg/Nm3 until the next
major upgrade of the cupola.
(2) The lower end of the BAT-AEL range can be achieved by using dry lime injection.
(3) The BAT-AEL only applies when the substance/parameter concerned is identified as relevant in the waste gas stream based on the
inventory of inputs and outputs mentioned in BAT 2.
The associated monitoring is given in BAT 12.
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1.2.2.2.2. Emissions to air from the nodularisation of cast iron
BAT 39. In order to prevent or reduce dust emissions to air from the nodularisation of cast iron, BAT is
to use technique (a) or both of the techniques (b) and (c) given below.
Technique Description
Nodularisation with no
Use of the in-mould process whereby the magnesium alloy is added as a tablet, directly into
a. magnesium oxide
the mould cavity, and the nodularisation reaction takes place during pouring.
emissions
Off-gas extraction as When magnesium oxide emissions are generated from the nodularisation technique used
b. close as possible to the (e.g. sandwich, ductilator), off-gases are extracted as close as possible to the emission
emission source source using a fixed or movable extraction hood.
See Section 1.4.3. The magnesium oxide collected may be reused for the production of
c. Fabric filter
pigments or refractory materials.
Table 1.19
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust from the nodularisation of cast
iron
BAT-AEL(1)
Parameter Unit
(Daily average or average over the sampling period)
Dust mg/Nm3 1– 5
(1) The BAT-AEL does not apply when technique (a) is used.
The associated monitoring is given in BAT 12.
1.2.3. BAT conclusions for steel foundries
The BAT conclusions in this section apply in addition to the general BAT conclusions given in Sections 1.1 and 1.2.1.
1.2.3.1. Emissions to air from thermal processes
1.2.3.1.1. Emissions to air from metal melting
BAT 40. In order to prevent or reduce emissions to air from metal melting, BAT is to use both of the
techniques given below.
Technique Description
Collection of emissions
The off-gases from induction furnaces are extracted, for example using:
— hood extraction (e.g. canopy or side-draught hoods);
— lip extraction;
— cover extraction.
Off-gas extrac
The off-gases from EAFs are extracted, for example using:
tion as close as
a. — partial furnace enclosures (mobile or fixed) mounted around the furnace and tapping
possible to the
area;
emission source
— total furnace enclosure using a complete room enclosure around the furnace and tapping
area equipped with a moveable roof for charging/tapping operations;
— hood extraction (e.g. roof-mounted, canopy or side-draught hoods);
— direct extraction through the fourth hole in the furnace roof.
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Technique Description
Off-gas treatment
b. Fabric filter See Section 1.4.3.
Table 1.20
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust and PCDD/F
BAT-AEL
Parameter Unit (Daily average or average over the sampling
period)
Dust mg/Nm3 1– 5
PCDD/F ng WHO-TEQ / Nm3 < 0,01– 0,08(1)
(1) The BAT-AEL only applies when PCDD/F are identified as relevant in the waste gas stream based on the inventory of inputs and
outputs mentioned in BAT 2.
The associated monitoring is given in BAT 12.
1.2.3.1.2. Emissions to air from steel refining
BAT 41. In order to reduce emissions to air from steel refining, BAT is to use both of the techniques given
below.
Technique Description
Collection of emissions
Off-gas extrac Off-gases from steel refining (e.g. from Argon Oxygen Decarburisation (AOD) or Vacuum
tion as close as Oxygen Decarburisation (VOD) converters) are extracted using for example a direct extraction
a.
possible to the hood or a roof canopy combined with an accelerator stack. Extracted off-gases are treated
emission source using technique (b).
Off-gas treatment
b. Fabric filter See Section 1.4.3.
Table 1.21
BAT-associated emission level (BAT-AEL) for channelled emissions to air of dust from steel refining
BAT-AEL
Parameter Unit (Daily average or average over the sampling
period)
Dust mg/Nm3 1– 5
The associated monitoring is given in BAT 12.
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1.2.4. BAT conclusions for non-ferrous metal foundries
The BAT conclusions in this section apply in addition to the general BAT conclusions given in Sections 1.1 and 1.2.1.
1.2.4.1. Energy efficiency
BAT 42. In order to increase energy efficiency in metal melting, BAT is to use one of the techniques given
below.
Technique Description
A pump is installed on reverberatory furnaces to force the circulation of molten
Molten metal circulation in
a. metal and minimise the temperature gradient throughout the molten bath (from
reverberatory furnaces
top to bottom).
Minimisation of energy
Crucible furnaces are covered using a lid and/or equipped with radiant panel linings
b. losses by radiation in cruci
to minimise energy losses by radiation.
ble furnaces
The BAT-AEPLs for specific energy consumption are given in BAT 14.
1.2.4.2. Emissions to air from thermal processes
1.2.4.2.1. Emissions to air from metal melting
BAT 43. In order to reduce emissions to air from metal melting, BAT is to collect the emissions using
technique (a) and to treat the off-gases using one or a combination of the techniques (b) to (e) given below.
Technique Description
Collection of emissions
Off-gases from shaft, crucible, resistance, reverberatory (hearth-type) and radiant roof furnaces
are extracted using hood extraction (e.g. canopy hoods). The extraction equipment is fitted in
Off-gas extraction such a way that it enables the capture of emissions during pouring.
as close as possi Off-gases from induction furnaces are extracted, for example using:
a.
ble to the emis — hood extraction (e.g. canopy or side-draught hoods);
sion source — lip extraction;
— cover extraction.
Off-gases from rotary furnaces are extracted, for example using hood extraction.
Off-gas treatment
b. Cyclone See Section 1.4.3
c. Dry scrubbing See Section 1.4.3
d. Fabric filter See Section 1.4.3
e. Wet scrubbing See Section 1.4.3
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Table 1.22
BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, HCl, HF, NO , PCDD/Fs, SO ,
X 2
Pb, and indicative emission level for channelled emissions to air of CO, from metal melting
BAT-AEL Indicative emission level
Substance/Parameter Unit (Daily average or average over the (Daily average or average over the
sampling period) sampling period)
Dust 1– 5
HCl 1– 3(1)(6) No indicative emission level
HF mg/Nm3 < 1(1)
CO No BAT-AEL 5– 30(2)(3)
NO 20– 50(4)(5)
X
PCDD/F ng WHO-TEQ/Nm3 < 0,01– 0,08(6)
No indicative emission level
SO < 10(4)(7)
2
mg/Nm3
Pb < 0,02– 0,1(8)
(1) The BAT-AEL only applies to aluminium foundries.
(2) The upper end of the indicative emission level may be higher and up to 70 mg/Nm3 in the case of shaft furnaces.
(3) The indicative emission level does not apply in the case of furnaces using only electric energy (e.g. resistance).
(4) The BAT-AEL does not apply in the case of furnaces using only electric energy (e.g. resistance).
(5) The upper end of the BAT-AEL range may be higher and up to 100 mg/Nm3 in the case of shaft furnaces.
(6) The BAT-AEL only applies when the substance/parameter concerned is identified as relevant in the waste gas stream based on the
inventory of inputs and outputs mentioned in BAT 2.
(7) The BAT-AEL does not apply when only natural gas is used.
(8) The BAT-AEL only applies to lead foundries or to other NFM foundries using lead as an alloying element.
The associated monitoring is given in BAT 12.
1.2.4.3. Emissions to air from the treatment and protection of molten metal
BAT 44. It is not BAT to use chlorine gas for molten aluminium treatment (degassing/cleaning).
BAT 45. In order to prevent emissions of substances with a high global warming potential from the
protection of molten metal in magnesium melting, BAT is to use oxidation control agents with a low
global warming potential.
Description
Suitable oxidation control agents (covering gases) with a low global warming potential include:
— SO ;
2
— gas mixtures of N , CO and/or SO ;
2 2 2
— gas mixtures of argon and SO .
2
The use of SO results in the formation of a protective layer composed of MgSO , MgS and MgO.
2 4
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1.3. BAT conclusions for smitheries
The BAT conclusions in this section apply in addition to the general BAT conclusions given in Section 1.1.
1.3.1. Energy efficiency
BAT 46. In order to increase energy efficiency in heating/reheating and heat treatment, BAT is to use all
the techniques given below.
Technique Description Applicability
This includes techniques such as:
— optimisation of key furnace characteristics (e.g. number and
type of burners, airtightness, furnace insulation using suitable
refractory materials);
— minimisation of heat losses from furnace door openings, e.g.
Only applicable to new
Optimisation of by using several liftable segments instead of one in
a. plants and major plant up
furnace design continuous reheating furnaces;
grades.
— minimisation of the number of feedstock-supporting
structures inside the furnace (e.g. beams, skids) and use of
suitable insulation to reduce the heat losses from water
cooling of the supporting structures in continuous
reheating furnaces.
Furnace automa
b. See Section 1.4.1. Generally applicable.
tion and control
This includes techniques such as:
— ensuring that feedstock heating/reheating target
Optimisation of temperatures are consistently met;
c. feedstock heat — switching off equipment during idle periods; Generally applicable.
ing/reheating — furnace operation optimisation, e.g. furnace capacity
utilisation, correction of the air/fuel ratio, improvement of
insulation.
Applicability to existing
plants may be restricted by
Preheating of
d. See Section 1.4.1. a lack of space for the in
combustion air
stallation of regenerative
burners.
Table 1.23
Indicative level for specific energy consumption at plant level
Indicative level
Sector Unit
(Yearly average)
Smitheries kWh/t of feedstock 1 700– 6 500
The associated monitoring is given in BAT 6.
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1.3.2. Material efficiency
BAT 47. In order to increase the material efficiency and to reduce the quantity of waste sent for disposal,
BAT is to use all of the techniques given below.
Technique Description
a. This includes techniques such as:
— computerised management of processes, e.g. heating/reheating cycles, hammering
sequences;
Process optimisation — selection of an appropriate hammer according to raw material size;
— adjustment of raw material size, either in the forging line (fully automated) or in the
organisational area of the material shearing (manual), in order to minimise the
amount of residues and the number of process operations.
b. This includes techniques such as:
— Use of computer-aided design for optimising forging tools and forging (die)
Optimisation of raw and
geometry in order to reduce the need for forging tests;
auxiliary material con
— selection of an appropriate type of coolant/lubricant forging, e.g. synthetic lubricant
sumption
for closed-die forging, water-based dispersions of graphite;
— systems for collecting and recirculating coolants/lubricants in closed-die forging.
c Recycling of process re Process residues (e.g. metallic residues from the processes of preparation of raw
sidues materials, hammering and finishing; used shot blast media) are recycled and/or reused.
1.3.3. Vibrations
BAT 48. In order to reduce vibrations occurring from the hammering process, BAT is to use vibration-
reducing and insulating techniques.
Description
Vibration-reducing and insulating techniques for hammering equipment include the installation of vibration-
damping components, e.g. layered elastomeric isolators or viscous spring isolators below the anvil, spring casings
below the hammer foundation.
Applicability
Only applicable to new plants and/or major plant upgrades.
1.3.4. Monitoring of emissions to air
BAT 49. BAT is to monitor channelled emissions to air with at least the frequency given below, and in
accordance with EN standards. If EN standards are not available, BAT is to use ISO, national or other
international standards that ensure the provision of data of an equivalent scientific quality.
Minimum monitoring Monitoring associated
Substance/Parameter Specific process Standard(s)
frequency(1) with
Nitrogen oxides (NO ) Heating/reheating,
X EN 14792
heat treatment
Once every year BAT 50
Carbon monoxide (CO) Heating/reheating,
EN 15058
heat treatment
(1) To the extent possible, the measurements are carried out at the highest expected emission state under normal operating conditions.
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1.3.5. Emissions to air
1.3.5.1. Diffuse emissions to air
BAT 50. In order to prevent or reduce diffuse emissions to air, BAT is to use both of the techniques given
below.
Technique Description
This includes techniques such as:
— use of closed bags or drums to handle materials with dispersible or water-
Operational and technical mea
a. soluble components, e.g. auxiliaries;
sures
— minimising transport distances;
— efficient material handling.
Extraction of emissions from Emissions from shot blasting. Extracted off-gases are treated using techniques
b.
shot blasting such as fabric filters.
1.3.5.2. Emissions to air from heating/reheating and heat treatment
BAT 51. In order to prevent or reduce NO emissions to air from heating, reheating and heat treatment
X
while limiting CO emissions, BAT is to use either electricity generated from fossil-free energy sources or
an appropriate combination of the techniques given below.
Technique Description Applicability
Use of a fuel or a combina
Fuels with a low NO formation potential include
a. tion of fuels with low NO X
X natural gas and liquefied petroleum gas.
formation potential
Measures taken to maximise the efficiency of en
ergy conversion in the furnace while minimising
emissions (in particular of CO). This is achieved
by a combination of techniques including good
Generally applicable.
b. Combustion optimisation design of the furnace, optimisation of the tem
perature (e.g. efficient mixing of the fuel and
combustion air) and residence time in the com
bustion zone, and use of furnace automation and
control.
Furnace automation and
c. See Section 1.4.1.
control
Recirculation (external) of part of the flue-gas to
the combustion chamber to replace part of the
fresh combustion air, with the dual effect of low
ering the temperature and limiting the O content
2 Applicability to existing plants may
d. Flue-gas recirculation for nitrogen oxidation, thus limiting the NO
X be restricted by a lack of space.
generation. It implies the supply of flue-gas from
the furnace into the flame to reduce the oxygen
content and therefore the temperature of the
flame.
Applicability to existing plants may
e. Low-NO burners See Section 1.4.3. be restricted by design and/or opera
X
tional constraints.
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Technique Description Applicability
Limiting the air preheating temperature leads to a
decrease of the concentration of NO emissions.
Limiting the temperature X
f. A balance has to be achieved between maximis Generally applicable.
of air preheating
ing heat recovery from the flue-gas and minimis
ing NO emissions.
X
Applicability to existing plants may
be restricted by furnace design and
g. Oxy-fuel combustion See Section 1.4.3.
the need for a minimum waste gas
flow.
Applicability to existing plants may
be restricted by furnace design (i.e.
furnace volume, space for burners,
distance between burners) and the
need for a change of the furnace re
h. Flameless combustion See Section 1.4.3.
fractory lining. Not applicable to fur
naces operating at a temperature
lower than the auto-ignition tem
perature required for flameless com
bustion.
Table 1.24
BAT-associated emission level (BAT-AEL) for channelled emissions to air of NO and indicative emission level for
X
channelled emissions to air of CO
BAT-AEL Indicative emission level
Parameter Unit Process(es) (Daily average or average (Daily average or average over the
over the sampling period) sampling period)
Heating / reheating / heat
NO 100– 250(1) No indicative level
X treatment
mg/Nm3
Heating / reheating / heat
CO No BAT-AEL 10– 100
teatment
(1) The upper end of the BAT-AEL range may be higher and up to 350 mg/Nm3 when recuperative/regenerative burners are used.
The associated monitoring is given in BAT 48.
1.3.6. Water consumption and waste water generation
BAT 52. In order to optimise water consumption and to reduce the volume of waste water generated,
BAT is to use both of the techniques (a) and (b) given below:
Technique Description Applicability
Applicability to existing
Segregation of water plants may be restricted by
a. See Section 1.4.4.
streams the layout of the water col
lection system.
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Technique Description Applicability
The degree of water reuse
and/or recycling is limited
Water streams (e.g. process water, cooling water) are re
Water reuse and/or re by the water balance of the
b. used and/or recycled in closed or semi-closed circuits, if
cycling plant, the content of impu
necessary after treatment.
rities and/or the character
istics of the water streams.
Note: BAT 52 only applies when waste water generation is identified as relevant based on the inventory of inputs and outputs
mentioned in BAT 2.
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1.4. Descriptions of techniques
1.4.1. Techniques to increase energy efficiency
Technique Description
Furnace automation and The heating process is optimised by using a computer system controlling key parameters such as
control furnace and feedstock temperature, the air to fuel ratio and the furnace pressure.
Measures are taken to maximise the efficiency of the casting process and to decrease the
generation of scrap, e.g.:
— optimising melting and pouring operations to reduce, for example, melting losses, excessive
Improving casting yield
pigging, scrap generation rates;
and decreasing scrap
— optimising moulding and core-making to reduce scrap generation resulting from
generation
deficiencies in moulds and cores;
— optimising gating and rising systems;
— using insulated exothermic feeders.
Increase of shaft height Increasing the shaft height in cold blast cupola furnaces enables combustion gases to remain in
in CBC furnaces contact with the charge for longer, resulting in a higher heat transfer.
The cupola furnace is set up for long campaign operation to minimise maintenance and process
changes. This may be achieved by using more resistant furnace refractory linings in the shaft,
Long-campaign cupola
bottom and hearth, by using water cooling of the furnace wall and with water-cooled blasting
pipes penetrating deeper into the furnace shaft.
Minimal blast shut-off Minimisation of blast shut-off periods by programming the schedules of the moulding and
periods for HBC furnaces casting processes to ensure a reasonably constant demand for metal.
Combustion air is replaced fully or partially with pure oxygen. Oxy-fuel combustion can be used
Oxy-fuel combustion
in combination with flameless combustion.
Oxygen enrichment of Oxygen enrichment of the combustion air is realised either directly at the blast supply or
the combustion air through injection of oxygen into the coke bed, or via the tuyères.
Post-combustion of off-
See Section 1.4.3.
gases
Reuse of part of the heat recovered from the combustion flue-gas to preheat the air used in
Preheating of combus combustion. This may be achieved for example by using regenerative or recuperative burners
tion air (see below). A balance has to be achieved between maximising heat recovery from the flue-gas
and minimising NO emissions.
X
Recuperative burners employ different types of recuperators (e.g. heat exchangers with radiation,
Recuperative burner convection, compact or radiant tube designs) to directly recover heat from the flue-gases, which
are then used to preheat the combustion air.
Regenerative burners consist of two burners which are operated alternately and which contain
beds of refractory or ceramic materials. While one burner is in operation, the heat of the flue-
Regenerative burner
gas is absorbed by the refractory or ceramic materials of the other burner and then used to
preheat the combustion air.
Selection of an energy- Furnace energy efficiency is taken into consideration for the furnace selection, e.g. furnaces that
efficient type of furnace allow the preheating and drying of incoming charge prior to the melting zone.
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Technique Description
Measures taken to maximise the efficiency of energy conversion in melting and heat treatment
furnaces while minimising emissions (in particular of dust and CO). This is achieved by
applying a series of process optimisation measures according to the furnace type including
optimisation of the temperature (e.g. efficient mixing of the fuel and combustion air) and
residence time in the combustion zone, and use of furnace automation and control (see above).
Measures for some specific furnaces include the following:
For cupola furnaces:
— optimisation of operational regime;
— avoidance of excess temperature;
— uniform charging;
— minimisation of air losses;
— good lining practice.
For induction furnaces:
— feedstock conditions (e.g. optimum size and density for input materials and scrap);
— closure of furnace lid;
— minimum holding time;
— keeping a liquid heel in the furnace;
— addition of carburisers at the beginning of the melting cycle;
— operation at maximum power input level;
— temperature control to prevent overheating;
— prevention of excessive slag build-up by optimising melting temperatures;
— minimisation and control of the wear of furnace refractory lining;
— when several induction furnaces are in operation, the energy use is optimised through peak
load management.
Techniques for maximis
ing the thermal effi For rotary furnaces:
ciency of furnaces
— use of anthracite and silicon for melt protection;
— adjustment of the continuous or discontinuous speed rotation of the furnace to achieve
maximum heat transfer;
— adjustment of the power and angle of the burner to achieve maximum heat transfer.
For EAFs:
— shorter metal melting and/or treatment times using advanced control methods for example
for the composition and the weight of the charged materials, the temperature of the melt, as
well as by efficient sampling and deslagging methods.
For shaft furnaces:
— choice of the furnace size according to continuous melt demand, to achieve a continuous
melting process;
— keeping the shaft filled with charging material to have optimum heat recovery;
— adapting the shaft design to the designated charging material for an optimum charging
material distribution in the shaft;
— regularly cleaning the furnace;
— independent control of the fuel/air ratio for each gas-fired burner;
— continuous CO or hydrogen monitoring for each row of burners;
— addition of oxygen above the melting zone to provide afterburning in the upper level of the
shaft;
— preheating of the charge using waste heat recovered from the flue-gases.
For reverbatory furnaces:
— preheating of the charge in the case of dry hearth or side-well reverberatory furnaces;
— use of burners with automatic temperature control.
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Technique Description
For crucible furnaces:
— preheating of the crucible prior to charging;
— use of crucibles with high thermal conductivity and thermal shock resistance (e.g. graphite);
— cleaning of crucible walls immediately after emptying to remove slag or dross.
Melting clean scrap prevents the risk of non-metal compounds being taken up by the slag and/or
Use of clean scrap
degrading the furnace or ladle refractory linings.
1.4.2. Techniques to increase material efficiency
Technique Description
Adjustment of the slag acid Use of an appropriate flux (e.g. limestone for acidic and calcium fluoride for basic cupola
ity/basicity operations) to render the slag fluid enough to separate from the iron.
Improving casting yield and
See Section 1.4.1.
decreasing scrap generation
Mechanical pretreatment of
slag / dross / filter dust / spent Generated slag / dross / filter dust / spent refractory linings are pretreated on site, by using
refractory linings to facilitate techniques such as crushing, segregation, granulation, magnetic separation.
recycling
Measures to optimise binder and resin consumption include:
— use of a sand quality which is consistent with the binder system;
— good management of sand storage and sand testing (purity, grain size, shape, moisture);
Optimisation of binder and — temperature control;
resin consumption — mixer maintenance and cleaning;
— checking mould quality (to prevent and if necessary repair moulding defects);
— optimising binder addition process;
— optimising mixer operation.
Water and release agents are applied separately to the mould using an additional row of
Separate spraying of release
nozzles mounted on the spray head. Water is sprayed first, leading to a significant cooling
agent and water in high-pres
of the mould before the application of the release agent, which results in reduced emissions
sure die-casting
and consumption of release agents and water.
Practices include the following (according to the binding system used):
— Temperature control: the temperature of the sand is kept as constant as possible and
low enough to prevent emissions caused by evaporation. For phenolic- and furan-
acid-catalysed, polyurethane and ester silicate systems, the optimum temperature
range is between 15 °C and 25 °C. For resol-ester systems, the optimum temperature
Use of best practices for cold-
range is between 15 °C and 35 °C;
setting processes
— for furan-acid-catalysed systems:
— the content of free (monomer) furfuryl alcohol in the resin is minimised (e.g. less
than 40 wt-%); and
— the sulphur content of the acid catalyst is reduced by substituting a portion of the
sulphonic acid with a strong sulphur-free organic acid.
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Technique Description
Practices include the following (according to the hardening process used):
For phenolic urethane resins (cold-box process):
— the consumption of amines is minimised by optimising the diffusion process within the
core, typically through computer simulation for optimisation of the gas flow;
— the sand temperature is maintained as constant as possible, between 20 °C and 25 °C, to
minimise gassing time and amine consumption;
— the moisture of the sand is maintained below 0,1 % and the gassing and purging air is
dried;
— core boxes are well sealed to allow the amine catalyst gas to be extracted and the cores
are thoroughly purged to prevent amine releases during the storage of cores.
For resol-ester resins:
— the sand temperature is maintained as constant as possible, between 15 °C and 30 °C;
— curing of the alkaline phenolic resin is achieved using methyl formate that is gasified by
Use of best practices for gas-
air typically heated up to 80 °C;
hardening processes
— core boxes and gassing heads are sealed correctly and the venting of the core box
designed to give a slight backpressure so that the curing vapour is held long enough
for the reaction to take place.
For CO -hardened resins (e.g. alkaline phenolic, silicate):
2
— the exact volume of CO gas necessary for curing the resins is used by employing a flow
2
controller and a timer to achieve the best strength and storage time;
— for silicate resins, liquid breakdown agents are employed (e.g. soluble carbohydrates) to
increase gassing speed.
For SO -hardened resins (e.g. phenolic, epoxy/acrylic):
2
— the gassing period is followed by purging with either the same inert gas (e.g. nitrogen)
used for curing or air, to remove the unreacted excess sulphuric dioxide from the sand;
— core boxes are well sealed and the cores are thoroughly purged to prevent gas releases
during the storage of cores.
Use of clean scrap See Section 1.4.1.
1.4.3. Techniques to reduce emissions to air
Technique Description
Adjustment of the slag
See Section 1.4.2.
acidity/basicity
The removal of pollutants from a process off-gas or waste gas stream by retention on a solid
Adsorption surface (activated carbon is typically used as the adsorbent). Adsorption may be regenerative or
non-regenerative.
Abatement technique which oxidises combustible compounds in a waste gas stream with air or
oxygen in a catalyst bed. The catalyst enables oxidation at lower temperatures and in smaller
Catalytic oxidation
equipment compared to thermal oxidation. The typical oxidation temperature is between
200 °C and 600 °C.
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Technique Description
Equipment for the removal of dust from an off-gas stream based on imparting centrifugal forces,
Cyclone usually within a conical chamber. Cyclones are mainly used as a pretreatment before further dust
abatement or abatement of organic compounds. Multicyclones may also be used.
Dry powder or a suspension/solution of an alkaline reagent (e.g. lime or sodium bicarbonate) is
Dry scrubbing introduced and dispersed in the off-gas stream. The material reacts with the acidic gaseous
species (e.g. SO ) to form a solid, which is removed by filtration (e.g. fabric filter).
2
Electrostatic precipitators (ESPs) operate such that particles are charged and separated under the
influence of an electrical field. Electrostatic precipitators are capable of operating under a wide
range of conditions. Abatement efficiency may depend on the number of fields, residence time
Electrostatic precipita (size), and upstream particle removal devices. They generally include between two and five
tor fields, but may contain up to seven fields for the most advanced ESPs. Electrostatic precipitators
can be of the dry or of the wet type depending on the technique used to collect the dust from the
electrodes. Wet ESPs are typically used at the polishing stage to remove residual dust and droplets
after wet scrubbing.
Emissions generated from moulding (including the making of patterns) and/or core-making are
extracted. The extraction system selected depends on the type of moulding/core-making process.
— Natural/green sand moulding:
Off-gases generated in the natural or green sand preparation areas (e.g. transport, sieving,
mixing and cooling) and in the moulding areas, especially during pouring, are extracted. In
the case of automatic moulding machines, appropriate extraction systems are used to
Extraction of emissions collect emissions (e.g. roof extraction). In the case of hand moulding, extraction as close as
generated from mould possible to the emission source is achieved using mobile extraction hoods.
ing and/or core-making
— Cold-setting, gas curing, hot-curing processes:
as close as possible to
the emission source In the case of automatic moulding machines, extraction systems are used to collect emissions
(e.g. fixed extraction hoods, canopy extraction). In the case of hand moulding, extraction as
close as possible to the emission source is realised using mobile extraction hoods.
In the event that mobile hoods cannot be used due to the size of the mould and/or space
restrictions, casting hall extraction is used.
Core shooting machines are enclosed and off-gases are extracted. Extraction is also applied
during checking, handling and storage of freshly made cores (e.g. by using hoods at the
checking table, above the handling and temporary storage areas).
Fabric filters, often referred to as bag filters, are constructed from porous woven or felted fabric
through which gases are passed to remove particles. Fabric filters can be in the form of sheets,
Fabric filter cartridges or bags with a number of the individual fabric filter units housed together in a group.
The use of a fabric filter requires the selection of a fabric suitable for the characteristics of the
waste gas and the maximum operating temperature.
Flameless combustion is achieved by injecting fuel and combustion air separately into the
combustion chamber of the furnace at high velocity to suppress flame formation and reduce the
Flameless combustion formation of thermal NO while creating a more uniform heat distribution throughout the
X
chamber. Flameless combustion can be used in combination with oxy-fuel combustion (see
Section 1.4.1).
Furnace automation
See Section 1.4.1.
and control
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Technique Description
The technique (including ultra-low-NO burners) is based on the principles of reducing peak
X
flame temperatures. The air/fuel mixing reduces the availability of oxygen and reduces the peak
Low-NO burner
X flame temperature, thus retarding the conversion of fuel-bound nitrogen to NO and the
X
formation of thermal NO , while maintaining high combustion efficiency.
X
Optimisation of binder
See Section 1.4.2.
and resin consumption
Oxygen enrichment of
See Section 1.4.1.
the combustion air
Oxy-fuel combustion See Section 1.4.1.
Post-combustion of CO and other organic compounds contained in furnace off-gases is used to
reduce emissions and for heat recovery. The generated heat is recovered with a heat exchanger
and used for blast air preheating or other internal purposes. In HBC furnaces, post-combustion
Post-combustion of off-
takes place in a separate post-combustion chamber preheated by a natural gas burner. In CBC
gases
furnaces, post-combustion takes place directly in the cupola shaft. In rotary furnaces, post-
combustion is carried out using an afterburner installed between the furnace and the heat
exchanger.
Selection of the appropriate furnace type(s) based on the level of emissions and technical criteria,
e.g. type of process such as continuous or batch production, furnace capacity, type of castings,
Selection of an appro
availability of raw materials, flexibility depending on raw materials’ cleanliness and alloy change.
priate furnace type
The energy efficiency of the furnace is also considered (see technique ‘Selection of an energy-
efficient type of furnace’ in Section 1.4.1).
Substitution of alcohol-
Substitution of alcohol-based coatings of moulds and cores with aqueous coatings. Aqueous
based coatings with
coatings are dried in ambient air or using drying ovens.
water-based coatings
Abatement technique which oxidises combustible compounds in a waste gas stream by heating it
with air or oxygen to above its auto-ignition point in a combustion chamber and maintaining it at
a high temperature long enough to complete its combustion to carbon dioxide and water. The
typical combustion temperature is between 800 °C and 1 000°C.
Several types of thermal oxidation are operated:
— Straight thermal oxidation: thermal oxidation without energy recovery from the
combustion.
Thermal oxidation — Recuperative thermal oxidation: thermal oxidation using the heat of the waste gases by
indirect heat transfer.
— Regenerative thermal oxidation: thermal oxidation where the incoming waste gas stream is
heated when passing through a ceramic-packed bed before entering the combustion
chamber. The purified hot gases exit this chamber by passing through one (or more)
ceramic-packed bed(s) (cooled by an incoming waste gas stream in an earlier combustion
cycle). This reheated packed bed then begins a new combustion cycle by preheating a new
incoming waste gas stream.
Use of best practices for
See Section 1.4.2.
cold-setting processes
Use of best practices for
gas-hardening pro See Section 1.4.2.
cesses
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Technique Description
The removal of gaseous or particulate pollutants from a gas stream via mass transfer to a liquid
solvent, often water or an aqueous solution. It may involve a chemical reaction (e.g. in an acid or
Wet scrubbing
alkaline scrubber). In some cases, the compounds may be recovered from the solvent. This
includes venturi scrubbers.
1.4.4. Techniques to reduce emissions to water
Technique Description
In the activated sludge process, the microorganisms are maintained as a suspension in the waste
Activated sludge pro
water and the whole mixture is mechanically aerated. The activated sludge mixture is sent to a
cess
separation facility from which the sludge is recycled to the aeration tank.
The removal of soluble substances (solutes) from the waste water by transferring them to the
Adsorption
surface of solid, highly porous particles (typically activated carbon).
The biological oxidation of dissolved organic pollutants with oxygen using the metabolism of
microorganisms. In the presence of dissolved oxygen, injected as air or pure oxygen, the organic
Aerobic treatment
components are mineralised into carbon dioxide and water or are transformed into other
metabolites and biomass.
The conversion of dissolved pollutants into an insoluble compound by adding chemical
Chemical precipita precipitants. The solid precipitates formed are subsequently separated by sedimentation, air
tion flotation or filtration. If necessary, this may be followed by microfiltration or ultrafiltration.
Multivalent metal ions (e.g. calcium, aluminium, iron) are used for phosphorus precipitation.
The conversion of pollutants by chemical reducing agents into similar but less harmful or
Chemical reduction
hazardous compounds.
Coagulation and flocculation are used to separate suspended solids from waste water and are often
Coagulation and floc carried out in successive steps. Coagulation is carried out by adding coagulants with charges
culation opposite to those of the suspended solids. Flocculation is carried out by adding polymers, so that
collisions of microfloc particles cause them to bond to produce larger flocs.
Balancing of flows and pollutant loads at the inlet of the final waste water treatment by using
Equalisation
central tanks. Equalisation may be decentralised or carried out using other management techniques.
Evaporation of waste water is a distillation process where water is the volatile substance, leaving the
concentrate as bottom residue to be handled (e.g. recycled or disposed of). The aim of this operation
is to reduce the volume of waste water or to concentrate mother liquors. The volatile steam is
collected in a condenser and the condensed water is, if necessary after subsequent treatment,
Evaporation
recycled.
There are many types of evaporators: natural circulation evaporators; short-tube vertical
evaporators; basket-type evaporators; falling film evaporators; agitated thin film evaporators.
Typical pollutants targeted are soluble contaminants (e.g. salts).
The separation of solids from waste water by passing them through a porous medium, e.g. sand
Filtration
filtration, microfiltration and ultrafiltration.
The separation of solid or liquid particles from waste water by attaching them to fine gas bubbles,
Flotation
usually air. The buoyant particles accumulate at the water surface and are collected with skimmers.
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Technique Description
MBR consists of the combination of a membrane process (e.g. microfiltration or ultrafiltration)
Membrane bioreactor with a suspended growth bioreactor. In an MBR system for biological waste water treatment, the
(MBR) secondary clarifier and the tertiary filtration step of a traditional aerated sludge system is replaced
by membrane filtration (the separation of sludge and suspended solids).
Nanofiltration A filtration process in which membranes with pore sizes of approximately 1 nm are used.
The adjustment of the pH of waste water to a neutral level (approximately 7) by the addition of
chemicals. Sodium hydroxide (NaOH) or calcium hydroxide (Ca(OH) ) is generally used to increase
2
Neutralisation the pH, whereas sulphuric acid (H SO ), hydrochloric acid (HCl) or carbon dioxide (CO ) is
2 4 2
generally used to decrease the pH. The precipitation of some substances may occur during
neutralisation.
The separation of gross solids, suspended solids, metal particles from the waste water using for
Physical separation example screens, sieves, grit separators, grease separators, hydrocyclones, oil-water separation or
primary settlement tanks.
A membrane process in which a pressure difference applied between the compartments separated
Reverse osmosis by the membrane causes water to flow from the more concentrated solution to the less
concentrated one.
Sedimentation The separation of suspended particles and suspended material by gravitational settling.
Water streams (e.g. surface run-off water, process water) are collected separately, based on the
Segregation of water
pollutant content and on the required treatment techniques. Waste water streams that can be
streams
recycled without treatment are segregated from waste water streams that require treatment.
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