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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!