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Metallurgical Sector
Presented by:Eng. Wafaa IsmailECO Energy Efficiency Coordinator
Cleaner Production in EgyptCase Study
in
ECO/ FEIEnvironmental Compliance Office/Federation of Egyptian Industries
About the Office
ECO at a Glance
The “Environmental Compliance Office - ECO” wasestablished in accordance with article 3 ofPresidential Decree no. 64 of 2001 with the aim ofpresenting services to the industry concerningenvironment and the techniques of CleanerProductionThe Office functions as a link between donoragencies and FEI membersECO achieved sustainability and self-funding; it iscurrently established as a special business unit ofthe FEI acting as the focal point for CP andenvironmental consultancy
ECO Mission and GoalsPromoting the sustainable application of CleanerProduction (CP) and Energy Efficiency (EE) in orderto increase the productivity of Egyptian industry and
reduce risks to people and the environmentBy aiming for the following goals:
to encourage industry's compliance withenvironmental legislationto promote environmental investments by offeringsoft loansto improve the occupational health and safetysituation in enterprisesto create production and export opportunities forour clients
ECO ActivitiesSupply soft loans for environmental projects (L.E. 40million have been disbursed for CP implementationin 37 industry enterprises)Provide technical environmental consultancies in CPapplications (384 technical and environmentalstudies have been conducted)Organize training sessions and study tours (687participants have been trained in CP related issues,40 factory owners have participated in five studytours abroad)Organize and hold awareness-raising campaigns andactivities to improve environmental performance offacilities (15 workshops covering related issues havebeen organized)
Scope of WorkSME (small and medium enterprises)Five industry sectors:�Engineering�Metallurgy�Food�Textile�Chemical
One cross-cutting energy-efficiency sector tosupplement energy-efficiency projects in all sectors,and to assess energy conservation and CDM projectsSupport woman- and child-labor, gender, and OHSissues
Technical ServicesCP and EMS assessment in SME(providing no- and low-costsolutions)Qualification for funds and softloans for implementation of CPand BAT, assistance inequipment specification andselection, as well asimplementationPerformance of EIA and energyreview, ER issuanceConductance of environmentalmeasurements (ambient andwork environments)Training-needs assessments formiddle management andtechniciansQualification for variousmanagement systems
Funding Services: The Revolving FundFund value of DKK 69million to financeprojects ofenvironmental andeconomic benefitsMaximum loan value atL.E. 3 million payableat monthly installmentsover a five-year period(including a one-yeargrace-period)Soft loans at an interestrate of 2.5% perannum
Vision
Including all industrial sectors in the scopeof workTargeting small and micro enterprisesIncluding large, highly polluting enterprisesExpanding the Energy-Efficiency Sector,especially in the fields of renewable energy,CDM, and Energy Efficiency andConservation in large enterprises
Case StudyCP Application in a Metallurgy
Sector Enterprise
The Factory in LinesSector: MetallurgyFounded: 1952Products: cast tapsand valvesSites: 2 sites (oldfactory and new siteunder construction)
Location ConsiderationsSome neighboringresidential buildingsborder the factoryincreases thedanger ofenvironmentalimpacts on thesurroundingenvironment
Item 42 in Egyptian Environmental Law
I.e.:The use of coal shall be prohibited in urbanregions and near the dwelling zones.
Processes
Melting and casting of iron productsMachiningAssemblyTesting
Raw Materials
Scrap and pig ironScrap copper and aluminum
Energy Sources
Coke in cupola furnacesGas oil in the copper furnaceElectricity in induction furnace
Gaseous Emissions – Sources:Melting
Gaseous Emissions – Sources:Magnesium Treatment
Gaseous Emissions – Sources:Casting
Gaseous Emissions – Sources:Shake-Out
Gaseous Emissions – Sources:Painting
Gaseous Emissions - Conclusion
No emissions treatment systeminstalled in factory
While dust collection system is installedin some areas within the old factory, itdoes not cover all emissions
Solid Wastes – Sources:Molding Spoilage
Solid Wastes – Sources:Slag (+ 25% out-of-furnace melted material)
Solid Wastes – Sources:Machining Workshop Operations (chips)
Solid Wastes – Sources:Rejects and Metal Wastes
OHS IssuesDust and emissions in workplace
OHS Issues (cont.)High temperatures around meltingfurnaces
OHS Issues (cont.)
Personal Protective Equipment (PPE) are notused, exposing workers to accidents
OHS Issues (cont.)Visual danger resulting from the process ofmagnesium treatment in an open area, increasingrisk on workers
OHS Issues – ConclusionsActivities causing hazard are notseparated from other activities
Consequently, workers are exposed toperils from activities not connected
with their work.
The Suggested CP OptionsReplacement of the coke-operated Cupolafurnace by a natural-gas-operated RotaryfurnaceUpgrade of the shakeout and sandpreparation processesUpgrade of the painting areaInstallation of a fume and dust collection andtreatment systemReplacement of the copper crucible with anelectric induction furnace
ECO Case StudySpecifying CP Options
CP Option 1:Replacement of Cupola by Rotary Furnace►Current State:
Co2, SO2 and NOx emissionsExposing workers to perils resulting from meltedmetal diffusion and the fall of some materials out offurnace
►Needed Action:Replacing copula furnaces with rotary furnace withthe possibility of increasing furnaces in the futureProviding solutions to copula furnaces problems witha lower-cost because of its closed design and energyconsumption
CP Option 1: Environmental Benefits
Improving working environmentAchieving compliance with EELReduction of accidentsLower operation cost due to the use ofnatural gasHigher quality of molten productReduced maintenance frequency andincreased melting efficiency
CP Option 1: Environmental Indicators
CO2 Emission Reduction = 647.633 t/y
SO2 Emission Reduction = 24.1056 t/y
PM10 Reduction = 7.6717 t/y
Heavy Metals Reduction = 0.218 t/y
CP Option 1: Economic Aspects
Achieved Savings = 614,748 L.E/ Y
Investment Cost = 1,260,200 L.E
Simple Pay-Back Period = 2 Year
CP Option 2:Development of Shake-Out Process
► Current State:Separation between sand and product takesplace through manual shaking causing sandto fly apart and leading to productivityslowdown; additionally, product is cleaned incasting workshop.
►Needed Action:Making shake-out process an automatic one,taking into consideration the matter of usingfilters and a system for collecting flying dust.
CP Option 2: Environmental BenefitsIncrease productivity
Higher product quality opening exportmarkets
Conservation of raw materials and reductionof waste
Improvement in working and surroundingenvironment
CP Option 2: Environmental Indicators
Reduction of Total Suspended Particulates:TSP Reduction = 0.64 t/y
CP Options 2: Economic Aspects
Achieved Savings = 492,885 L.E/Y
Investment Cost = 913,600 L.E
Simple Pay-Back Period = 1.8 Year
CP Option 3:Development of Painting Area
► Current State:The process of painting products currentlytakes place in an open area with the use ofspray compressor, which leads to wastingmaterials and causes emissions in thesurrounding area.
►Needed Action:Developing painting area through usingpowder based system containing a unitcommitted for collecting emissions and re-using paint leading to reduced costs andimproved environment.
CP Option 3: Environmental Benefits
Reducing painting residue
Improving work and surroundingenvironments
Reducing volatile organic compounds(VOC)
CP Option 3: Economic Aspects
Achieved Savings = 27,500 L.E/M
Investment Cost = 606,500 L.E
Simple Pay back Period= 1.8 Year
By conducting measurements insamples related to implementedoptions as a practical verification of thetheoretical calculations
Follow-Up
ECO – Environmental Compliance Office
Wafaa Ismail, Eng.Energy Efficiency Coordinator- ECO
www.eco-fei.orgPhone: ++20 (0)2 576 88 70Fax: ++20 (0)2 576 17 79Email: wismail@eco-fei.net
… Taking care of our environment, andyour business
Thank you for your time and attention!
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