Anotec - Foundries Overview

ANOTEC PTY LIMITED
PO BOX 292
BOTANY NSW 1455
TEL: (02) 9700 1222 FAX: (02) 9700 1771
FREECALL AUSTRALIAWIDE: 1-800-636-877 (1-800-ODOURS)
Odours - An Overview
BEST AVAILABLE TECHNOLOGY- POLLUTION
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© Anotec Pty Limited. COMMERCIAL-IN-CONFIDENCE
SECTION 1 – ........................................................................................................... 5
WHO & WHAT ARE ANOTEC? ............................................................................... 5
Introduction .............................................................................................................. 6
Odour Control Technologies ..................................................................................... 7
Anotec – Mode of Action........................................................................................... 7
Engineered misting................................................................................................... 9
Testing of Anotec Odour Control............................................................................. 10
SECTION 2 – ......................................................................................................... 11
ODOUR COMPLAINTS? WHAT COMPLAINTS? .................................................. 11
Understanding Odours ........................................................................................... 12
Odour Complaints .................................................................................................. 13
What is a nuisance? ............................................................................................... 14
SECTION 3 – ......................................................................................................... 16
SO, FOUNDRIES POLLUTE, NOW WHAT? .......................................................... 16
Benefits Of Control................................................................................................. 18
Controls on emissions of particulates...................................................................... 18
Controls on emissions of volatile organic compounds (VOCs) ................................. 18
Practical Emission Reduction Measures ................................................................. 19
Assessing the impact of odours .............................................................................. 20
Odour Measurement Methodologies ....................................................................... 20
Process (emission)-based Assessments................................................................. 21
Monitoring and Predictive Modelling Assessments .................................................. 21
Community-based Assessments............................................................................. 21
Assessment based on process emissions ............................................................... 21
Dispersion modelling .............................................................................................. 22
Assessment of Community Exposure...................................................................... 23
Complaint Records................................................................................................. 24
Attitude surveys ..................................................................................................... 25
Extent of an Odour Problem ................................................................................... 25
Identify the sources ................................................................................................ 26
Odour Impact Assessments.................................................................................... 26
Measuring Odours.................................................................................................. 27
Practical Considerations......................................................................................... 27
Subjectivity............................................................................................................. 27
Variability ............................................................................................................... 27
Concentration in ambient air ................................................................................... 27
Use of surrogate substances for monitoring ............................................................ 28
Summary of Odour Measurement Methodologies:................................................... 28
Chemical Techniques............................................................................................. 29
Sensory Techniques............................................................................................... 31
Preventing and Reducing Emissions....................................................................... 33
An Odour Control Strategy ..................................................................................... 33
General considerations........................................................................................... 33
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SECTION 4 – ......................................................................................................... 34
FOUNDRIES – HEY! WHAT GOES ON THERE?................................................... 34
Summary of a foundry’s activities............................................................................ 35
Processes .............................................................................................................. 35
Air Quality Management ......................................................................................... 35
Emission sources ................................................................................................... 36
Mould & Core Preparation ...................................................................................... 37
Casting Moulding or Pouring................................................................................... 37
Casting Practices ................................................................................................... 38
Static Sand Casting................................................................................................ 38
Pipe Casting .......................................................................................................... 38
Roll Casting ........................................................................................................... 38
Knockout & reclamation.......................................................................................... 38
Fettling, dressing or finishing of castings................................................................. 39
Fettling................................................................................................................... 39
SECTION 5 – ......................................................................................................... 40
GIVING FOUNDRIES THE BAT ............................................................................. 40
Fumes evolved from current foundry processes ...................................................... 41
Preparation of cores and moulds ............................................................................ 42
Environmental Impact............................................................................................. 42
BAT for Preparation of cores and moulds................................................................ 42
CASTING, POURING & MOULDING ...................................................................... 43
BAT for Casting, pouring & moulding ...................................................................... 43
KNOCK OUT AND RECLAMATION........................................................................ 44
BAT for Knockout................................................................................................... 44
SAND RECLAMATION........................................................................................... 45
Environmental Impacts........................................................................................... 45
BAT for sand reclamation ....................................................................................... 45
DRESSING OR FINISHING OF CASTINGS ........................................................... 46
BAT for dressing and finishing castings................................................................... 46
WASTE HANDLING ............................................................................................... 47
BAT for waste handling .......................................................................................... 47
CONTROL OF POINT SOURCE EMISSIONS TO AIR ............................................ 48
DECOMMISSIONING OR CLOSURE OF A FOUNDRY .......................................... 48
SECTION 6 – ......................................................................................................... 49
SO? FOUNDRIES SMELL – WHERE DOES ANOTEC FIT IN?.............................. 49
Anotec Procedures................................................................................................. 50
ODOUR EVALUATION, ASSESSMENT & ANALYSIS PROCEDURES ................... 50
CASE STUDY: TYCO WATER - QLD .................................................................... 52
INTRODUCTION.................................................................................................... 52
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Background............................................................................................................ 52
Evaluation of the following took place ..................................................................... 52
Validity and Source of Results ................................................................................ 52
TESTING ............................................................................................................... 54
RESULTS .............................................................................................................. 55
OBSERVATIONS ................................................................................................... 55
CONCLUSION ....................................................................................................... 56
CALCULATED ODOUR UNITS .............................................................................. 56
FIGURES
Figure 1 Tyco Water set up: Anotec Odour Control nozzles..................................... 67
TABLES
Table 1. Odour Control Technologies.................................................................. ……7
Table 2 Emissions from foundry processes .............................................................. 41
Table 3 Environmental Impact: Preparation of Cores & Moulds................................. 42
Table 4 Environmental Impact: Casting, pouring & moulding .................................... 43
Table 5 Environmental Impact: Knockout ................................................................. 44
Table 6 Environmental Impact: Sand reclamation..................................................... 45
Table 7 Environmental Impact: Dressing & Finishing castings .................................. 46
Table 8 Environmental Impact: Waste handling........................................................ 47
Table 9 Tyco Water GC/MS results.......................................................................... 58
Table 10 Tyco Water Vs Anotec Treatment removal Efficiency ................................. 58
CHARTS
Chart 1 Sum of Concentration levels – Odours Vs Anotec ....................................... 59
Chart 2 : Ethanol Vs Anotec..................................................................................... 60
Chart 3 Acetone Vs Anotec ..................................................................................... 60
Chart 4 Methyl Acetate Vs Anotec ........................................................................... 61
Chart 5 Toluene Vs Anotec..................................................................................... 61
Chart 6 m,p-xylenes Vs Anotec............................................................................... 62
Chart 7 Benzene Vs Anotec..................................................................................... 62
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SECTION 1 –
WHO & WHAT ARE ANOTEC?
5
Introduction
Anotec Pty Ltd are an Environmental To date, in the absence of an
Consultant firm (Odours and Australian Standard dealing
Sanitation) involved in Odour Testing specifically with the method of odour
and Odour Control formulations for control to be implemented in each
optimum Removal Efficiency as well industry, Anotec Pty Limited have
as being committed members of the researched and developed proven
Clean Air Society of Australia and methods that will ensure the
New Zealand. Validity and significant reduction and / or
effectiveness of our testing and any elimination of most volatile organic
odour control device has been compounds (VOCs) identified.
determined via qualitative and
quantitative methods conducted by Anotec Pty Limited deals solely with
ANSTO, Environmental Science Odour Issues. This means that
Program at Lucas Heights and the Anotec odour control formulations
University of New South Wales are implemented where chemical
foundry odours
respectively. analysis has identified the chemical
components in a malodorous stream
The product recommended for to be present in low concentrations,
effective control of fugitive emissions well within the allowable TLV, but,
from foundry operations (ferrous & synergistically constitute an odour
non-ferrous) is Anotec 0307. nuisance as evidenced by
community complaints or via the use
Anotec 0307 is a scientifically of an olfactometer. With reference to
developed technology formulated the latter, these odours are
specifically to control and treat perceptible but harmless – they tend
malodours, a range that includes to be annoying rather than
products for cleaning surfaces detrimental to the community or the
effectively every time without relying environment. Chemical Issues arise
on strong perfumes and harsh when the emissions exceed the
chemicals. allowable threshold limits and are
therefore deemed as a toxic
Anotec is an Australian technology chemical emission. Anotec Pty
supplied nationally and exported Limited does not recommend any
worldwide. Premium quality odour control for Chemical Issues as
formulations have been supplied and the treatment required in these
been available for Industrial, cases may involve structural
Commercial and Domestic changes to the building, specialist
Applications since 1991. engineering to improve the
performance of the existing
operation, re-assessment of raw
materials used, manufacturing
processes etc.
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Of course, there is no such thing as formulated odour control solutions
a broad-spectrum odour control for a wide variety of industries
product. However, Anotec Pty including the commercial and
Limited have researched and domestic sectors.
Odour Control Technologies
The various methods to control odours include those presented in the following
table. Selection of control alternatives is very source-and odour-type-specific.
Also, the point(s) of effectiveness monitoring, such as stack emission, plant
property line, or other locations, should be determined.
Odour Control Technologies
Method Process
Source control Replace or modify operating systems
Absorption Capture by water or other fluids
Adsorption Capture by activated carbon
Biological Oxidation by micro-organisms
Chemical Oxidation of odour components
Condensation Cooling of odorous steam
Containment Hold or retain for treatment
Counteraction Diminished in presence of another odour
Dilution Dispersion below threshold levels
Incineration Combustion of odour agent
Masking Superimpose a fragrance
Table 1. Odour Control Technologies

By combining chemical, counteraction, condensation, adsorption and absorption
technologies (not necessarily in that order), Anotec have formulated, developed,
scientifically evaluated and successfully marketed the product identified as
Anotec 0307. Anotec 0307 and its mode of action are discussed further on in
this document.
Anotec – Mode of Action

Anotec 0307 is formulated as a confined or stack emissions, the
hyper-concentrated solution. In the hyper-concentrate is diluted with
case of odour profiling, Anotec 0307 water. The water component used is
is used in this form as an additive to an integral part of the overall
treat and control odours in a liquid performance of the Anotec 0307
mix. When treatment calls for formulation.
atomisation, whether it is for fugitive,
© Anotec Pty Limited. COMMERCIAL-IN-CONFIDENCE 7

Initially, when the malodorous instance from a power plant, being
molecules comes into contact with absorbed into water and falling as
the Anotec 0307 droplets, physical rain. Both of these acids are
adsorption takes place which is extremely water-soluble. Hydrogen
caused mainly by electrostatic sulphide and many of the other
forces. Therefore adsorbents are odorous gases produced by sewage
characterised first by surface treatment are, on the other hand,
properties such as surface area and only slightly so. Anotec 0307
polarity. enhances this effect by using the
tandem effect of one surfactant on
Gas molecules locked up in a solute another to achieve what can be
do not smell. Anotec 0307 as a termed as a hydrophile-lipophile
surfactant induced absorption balance that is not chemically nor pH
technology, also incorporating the selective, but is extremely effective
principles of counteraction and in promoting the absorption of many
condensation, achieves different compounds. It is the opinion
unprecedented results in the removal of the company that Anotec 0307
of odorous gases from an airstream. alters the solubility of compounds it
comes into contact with by having its
Anotec 0307 succeeds by employing hydrophilic end in the water and its
engineering and chemistry that hydrophobic end in the air. This can
works with nature. To further increase the absorbency of the water
explain, an easily identifiable droplets by a factor of approximately
analogy to describe this principle is 500,000. Immediately the droplets
well demonstrated by the are formed, they can simultaneously
phenomenon of acid rain where the absorb acidic, alkaline and neutral
result of components of sulphur odorous gases, effectively locking up
dioxide and oxides of nitrogen, for the offending odour molecules.
When diluted according to the type of application, Anotec 0307 uses the kinetic
laws of matter to trap the gas molecules in two different ways:
1. Energy is transferred from the normally hotter gas phase to the

colder droplets when they meet, this reduces their kinetic energy.
2. The laws of mechanics, which apply to the collisions of molecules,
indicate that the molecules will have the same kinetic energy, a
function of mass and velocity.
Therefore, at a particular temperature, a heavy molecule moves more slowly than

a light molecule, because, as mass increases velocity decreases. When a VOC
or gas pollutant molecule collides with an Anotec 0307 droplet (molecules in a
liquid state), it meets a mass millions of times its own, and is absorbed to form a
solute.
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Engineered misting.
Achieving the correct droplet size is malodorous molecule such as
fundamental to the efficiency of Skatoles, which has a strong faecal
Anotec 0307. As with other odour odour and is found in beetroot with a
control technologies such as molecular weight of 131.17, is still
scrubbing or an extraction system, to very small by comparison. When the
achieve the maximum extraction rate gas molecules collide with the
it is extremely important to have the Anotec 0307 droplets they are
largest practical surface area or captured and at this stage
interface area in relationship to the counteraction and dissociation of the
mass or volume of the agent. For the malodour takes place, and at the
same volume there are 216 x 50- same time, forming a solute. As the
micron water droplets for one 300- absorbent droplets become
micron droplet, and a 600% increase saturated, they become denser and
in surface area and efficiency. A litre drop to the ground where they are
of water misted at 50 microns degraded by the natural bacteria
produces some 426 million droplets. present.
Multiply this figure by the number of Anotec commissions the use of

litres per minute times the number of specialist engineers involved in
minutes of operation per day and developing and manufacturing odour
some very large numbers result. control spray application devices /
Compared with conventional equipment which are engineered and
scrubbing techniques, when one programmed to deliver the Anotec
appreciates this remarkable increase 0307 in a mist appropriate to a
in physical area available for particular problem. Similarly, once
absorbing gases by correctly chemical fingerprinting results are
engineered misting, it is then easier received, the concentration of the
to understand how, with the further proprietary surfactant blend in the
benefit of no back pressure, Anotec Anotec 0307 formulation is
0307 can reduce resource and matched to the type and strength
energy requirements by 90% and do of the malodorous gases. It is
an effective and efficient job. most effectively delivered at the
point of emission.
The mass of the water absorbent is
huge in comparison to a gas. There are, however, limitations. A
Consider the size of malodorous stable gas such as pure methane is
molecules. Hydrogen Sulphide, for not absorbed and, as Anotec 0307
example, has an atomic mass of requires water; high temperatures
34.08; this means that it is less than need to be controlled to prevent
1,000,000,000th of the size of a 50 evaporation.
micron droplet. Even a very big
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Tests have revealed that the solute after treatment, although no longer Anotec
0307, is non-toxic and can be emitted to atmosphere where it will fall and
biodegrade naturally using bacteria present in the surrounding environment, thus
avoiding the costs normally associated with the disposal of spent filters and
chemicals.
Testing of Anotec Odour Control
Evaluation of the Anotec Odour Korea and Ch2MHill to mention a

Control technology has been carried few.
out by numerous organisations such
as Australia’s ANSTO Environmental Anotec’s engineers have been
Science Program (ongoing), The continuing throughout the last three
University of New South Wales years to innovate and develop
Australia, Odour Science & further application devices for this
Engineering USA, Korea Heavy technology. Once such device is the
Industries Corp Korea, Dow Corning Cirrus Misting System engineered
New Zealand, Samsung Corporation and manufactured in Australia.
In summary:
An important part of the Anotec 0307 is that it has within its formulation the
unique ability to alter the properties of the water droplets it is mixed in to absorb,
significantly reduce or remove odours in an airstream. This technology is
extremely beneficial where extraction, filtering and scrubbing systems are not
economically feasible or impossible to apply.
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SECTION 2 –
ODOUR COMPLAINTS? WHAT COMPLAINTS?
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Understanding Odours
Odours, once considered simply an more than just annoying. They claim
inconvenience to sectors such as the that such odours diminish their
foundry industry, now threaten the comfort, quality of life, and property
survival of some operations. The values.
future clearly demands that
operators and producers learn to There are practical limits to what
understand and manage odours producers can do. Some odour is
more effectively, and better unavoidable in certain foundry
appreciate community concerns. related operations. Producers argue
that they have as much right to the
This document serves the purpose of air as the newcomers, and since
assisting operators, managers and they were there first, they should be
the community in understanding that allowed to continue doing their work
an issue of such complexity does not in the same fashion. After all, odour
subscribe to the one-size-fits-all was not an issue until the residents
solution. (or more of them) began to live near
them.
Resolving odour issues requires
creative solutions that are both Odour problems often arise from a
highly effective as well as equitable. lack of understanding and tolerance
Key to this process is the from both sides. Differences in the
development of mutual perceptions of odours play a role too.
understanding for both operators and Due to odour detection and
neighbours. Anotec’s hope is that the evaluation varying among
information in this document will individuals, one person cannot
promote a broader understanding so determine whether a smell is
that business owners can deal offensive for an entire population. A
effectively with odours while person whose livelihood depends on
maintaining profitable and metal casting and has been working
sustainable operations. around a certain smell for years may
not regard the odour as offensive. It
The rise in odour nuisance is important to realise that people
complaints has occurred, in part, due tend to adjust to smells over time. A
to the demand for housing and person acclimatised to a particular
migration of people into an area that smell doesn't even notice a routine
was once predominantly an odour while a new resident will
“industrial zone”. Once there, the become immediately aware of a
residents complain that odours are smell.
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Odour Complaints
All complaints registered by the general public are dealt with seriously and with
the genuine intention of implementing the most effective mitigation program
available. Odour complaints are more common when the humidity is high and the
air is still or when the prevailing breezes carry odours toward populated areas.
When the air is still, odours may flow down slopes much as water does. It has
been established during discussions with the consultants on various projects that
odours emanating from foundries, including deliveries from trucks and waste
disposal of spent sand has lead to complaints. For this reason, site selection and
control of a large area surrounding foundry operations to minimise close
proximity of downwind neighbours are of utmost importance. Perception of
nuisance odours at a given distance from a confinement facility is less common
with “normal” foundry operations and approach to this problem needs careful
attention. In this early planning stage for deciding upon the best implementation
of odour control techniques, it would be pertinent to investigate any set
regulations for separation distances as applied to “normal” foundry operations.
Odour problems often occur when an existing

foundry facility dramatically increases the size Odour problems often
of the operation. Perhaps the most difficult arise from a lack of
situation occurs when a new large-scale
foundry operation moves into an area where it
understanding from
had not previously existed. These situations both sides of the
require the highest degree of odour emission issue
control.
The general community views odours as strictly a nuisance. A foundry

worker or trainer however sees odours as an unavoidable consequence of
their livelihood. In order to live as neighbours, each side must first
acknowledge the other’s point of view. Neighbours need to be more
tolerant of the odours from foundries and related activities. However,
foundry operators must take decisive action as well. There are ways to limit
odours escaping from production operations, and reasonable control
measures need to be employed.
Addressing this issue requires that Foundry operators are also given
operators better understand the guidance on selecting the most
generation, behaviour, and appropriate options for their
management of odours. This operations. The ultimate goal is to
document, compiled from many promote a better understanding of
sources, provides an overview of odour generation and control
odours and their management in strategies and, in turn, enhance the
foundry operations. Emphasis is sustainability of metal casting
given to providing up to date operations at the industrial-
information on the range of residential interface.
approaches to odour control.
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Foundry (ferrous and non-ferrous) overview of current administrative
odour emissions are becoming a approaches to manage nuisance
contentious issue in some areas, complaints and examines how the
spurring increased efforts to address courts have handled odour complaint
the problem. Virtually all suits. The section concludes with a
administrative initiatives aimed at recommended method for
addressing the problem have been responding to and resolving foundry
at the state and local level. Upon odour complaints that has been
request, Anotec can supply literature particularly successful in parts of
on the section that provides an Australia.
Summary:
Odour nuisance from an industrial process may occur as a result of a single

odorant or more commonly, particular for metal casting facilities, from the
generation of a mixture of odorous compounds. The generation and control of
odours is rapidly becoming a key concern for local residents, regulators and
developers with regard to the foundry industry.
What is a nuisance?
When common law was first developed, an overriding principle was that a
landowner had the right to use and enjoy his land as he wished. The concept of
nuisance had no legal basis. With time it became obvious that neighbouring
landowners might choose incompatible property uses. The use of land by one
landowner can clearly conflict with the responsibility not to interfere with
another’s right to enjoy his own property. Nuisance laws attempts to solve this
conflict with the concept of “reasonableness”. An unreasonable interference with
a person’s right to enjoy their property is now legally a nuisance. The rules
governing unreasonable interference are similar in most countries. (Sweeten and
Levi, 1996).
There are two basic types of nuisance lawsuits, a

private nuisance claim filed by a single
neighbour, or a public nuisance claim filed by a
group of people such as the residents of a
subdivision.
A nuisance lawsuit will not succeed in most
jurisdictions unless that complaining party
(the plaintiff) can demonstrate one or more of the
following (Fershtman, 1999):
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1. The action in question was carried out in a wrongful or unreasonable
manner, for example, a legitimate activity in an unsuitable location;
2. The action resulted in substantial harm to the plaintiff or his property; or
3. The action materially impeded the use and enjoyment of the plaintiff’s
property.
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SECTION 3 –
SO, FOUNDRIES POLLUTE, NOW WHAT?
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Many foundry processes result in the generation of significant emissions of
particulates and volatile organic compounds (VOCs). This document outlines the
processes where such pollutants may be emitted, the potential environmental
impact of the emissions and suggested BATNEEC (Best Available Technology
Not Entailing Excessive Costs) or BAT (Best Available Technology). This
document was prepared and intended as a reference guide for foundry operators
involved in the preparation or implementation of an Odour Mitigation Program or
Environmental Quality System.
The importance of preventing and minimising pollution has increased

progressively throughout the 20th century.
Particulates, including smoke, dust and fume, have always been a major
constituent of air pollution, although the control of such pollutants has improved
enormously following the imposition of a wide range of regulatory controls on
industrial, domestic and traffic sources.
The reasons why such pollutants require control are as follows:
Particles may be inhaled by people or animals, leading to respiratory and other

diseases, and, in some cases, are believed to be responsible for premature
deaths. Deposition of particles can interfere with the rate of photosynthesis in
plants, and also their rate of gas exchange. Dust deposition can cause local
damage and nuisance, including soiling of buildings, abrasion to building fabric,
damage to vehicle finishes, and nuisance to people.
Volatile organic compounds, or VOCs, are a large class of carbon-containing

compounds, which vary in their effects on human health and the environment.
They are under considerable scrutiny internationally, and it is understood that
work is being coordinated between countries to reduce emission levels.
Currently, the main concern about VOC pollution relates to its contribution to the
formation of ozone at ground level. Ozone is an aggressive ground level pollutant
that is formed by a reaction between VOCs and nitrogen oxides in the presence
of sunlight. In addition, some VOC emissions can cause odour nuisance to the
localities around a foundry. The most notorious substance in this respect is the
amine used to catalyse phenolic urethane cores. Breakdown products from the
casting of moulds made with phenol-based chemical binders have also been
implicated in some cases.
Other organic compound emissions are of concern due to their toxic effects on
humans and animals (eg dioxins) or their contribution to global warming (eg
chlorofluorocarbons).
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Benefits Of Control
Good control of pollution from foundry processes not only enables companies to
comply with legislative requirements, but also:
° prevents nuisance to neighbours
° improves the internal work atmosphere and reduces risks to worker

health
° minimise the environmental impact of the operations
° improves the company image.
Controls on emissions of particulates

The general requirement is to prevent any releases of persistently visible
emissions, where persistent is defined as continuous and/or trailing past the
process boundary. Where particulate generation is significant, control of such
emissions can only be achieved by capture and abatement. However, where only
clean charge materials are melted and the method of melting is electric or gas,
some melting operations may not require capture or abatement.
Controls on emissions of volatile organic compounds (VOCs)
VOCs are considered to be the source of significant environmental problems, in

the past, it was not considered cost-effective to capture or abate the VOCs
produced from most foundry processes. One of the main sources in foundries is
the casting process, and, in jobbing foundries in particular, containment of such
emissions was deemed impractical. Anotec Pty Ltd found that where containment
and capture is possible, e.g. at shake-out or cooling, the cost of abatement is
reduced significantly as treatment of fugitive emission, although possible, is
considered excessive relative to the concentration of VOCs emitted.
Emission limits for VOCs have been set for two foundry processes that we are
aware of:
1. investment shelling processes and
2. Thermal sand reclamation plants.
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Investigations show that the application of a VOC limit to solvent-based
investment shelling is deemed appropriate as there are alternative water-based
shelling systems available that have been widely adopted within the industry.
Most thermal sand reclamation plants are gas-fired, and some VOCs will be
emitted as a result of the process of burning off the binder resin. However,
provided that the plant is operated correctly, including good temperature control
and burner maintenance, emissions should be easily controllable to below 20
mg/ m-3.
Practical Emission Reduction Measures
There is usually more than one way of eliminating or reducing emissions of

particulates and VOCs, and it does not always have to involve abatement, which
is the 'end of pipe' solution. Some alternative 'cleaner technologies' are shown
below.
Process Cleaner technology/method of improved control

General Good materials management to avoid losses and
releases to air
Mould coating Water-based coatings
Investment shelling Water-based shelling system
Melting Use of clean scrap. Replacement of oil-fired
furnaces with gas or electric furnaces
Calcium silicate ladle Wire injection
additions to steel
Magnesium treatment of Use of tundish cover, in-mould treatment or flow
ductile iron through treatment box
Casting painting Water-based coatings
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Assessing the impact of odours
The aim of an odour impact assessment should be some or all of the following:
° to predict the exposure of sensitive receptors to odour and to apply a

test of acceptability in some form. This could relate to new or existing
plant
° to indicate the amount of abatement (or additional abatement) required
° to look at trends – improvement or worsening performance over a

period of time
° to determine compliance with a Permit condition, and
° investigating complaints.
Where an existing installation has a history of odour complaints and obvious

problems, a detailed odour assessment as part of the odour investigation should
be conducted.
If odour impact has never been also be considered - under what

systematically assessed before, the operating conditions are odour
starting point should be a simple emissions worst? Meteorological
walk over survey of the foundry conditions can also affect odour
during normal operations. A simple exposure at receptors and it is useful
screening assessment should to walk around beyond the foundry’s
provide a clear indication of whether boundary under the most adverse
any potentially significant odour conditions - light winds / stable
sources exist and whether further conditions - to see if odour is
more detailed assessment is detectable.
required. The “worst case” should
Odour Measurement Methodologies

Odour impact methodologies can be broadly classified into two main “types”
based upon whether emissions at source can be measured or estimated or,
where this information is not available, the effect at receptors has to be
assessed:
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Process (emission)-based Assessments
Monitoring and Predictive Modelling Assessments:
These estimate the “footprint” of effect of the activity by mathematical modelling

of actual or estimated/predicted emissions:
° Olfactometry: such as The Odour Unit’s Dynamic Olfactometry
° Mathematical atmospheric dispersion modelling.
Assessments based upon measurements around the source and/or conditions in

the community (where measurement of emissions at source is not feasible)
Community-based Assessments:
Those that use information collected at the receptor(s), based on the opinions
and judgement of those exposed, to estimate the extent of the footprint and the
magnitude of the exposure. There are two sub-sets:
1. Assessment of community response
° complaint histories (based on past and present experiences)
° attitude surveys (based on past exposures)
° population panels (on-going assessment of the current situation)
° assessing the extent and magnitude of the exposure in the community
° field judges/panels
2. Odour mapping
Assessment based on process emissions
Emissions can be measured or predicted by:
° collecting and analysing odour samples
21
° using emission factors
° using mass balance data
° comparison to a similar operation.
Dispersion modelling
Where the odour emission rate from a source is known by measurement, or can
be estimated, the odour concentration in the vicinity can be predicted by means
of dispersion modelling.
A dispersion model attempts to describe the effects of atmospheric turbulence on

the emission(s) as they undergo dilution and dispersion in the surrounding
environment. Concentration is one of the factors that determine the impact of a
given odour on sensitive receptors.
The modelling of odour is still a developing field when compared to other

pollutants. A range of different models have been used for odour modelling and
have a number of common features, but there are differences in the way that
data is dealt with between the older Gaussian models and the new generation
model such as AUSPLUME.
To visualise the extent of odour impact it is useful to produce contour plots

showing odour concentrations around the source or highlighting where
concentrations exceed the appropriate exposure benchmark which relates to
acceptability.
In some cases it will not be possible to measure or to predict emissions at the

source in any meaningful way. The emission points may not be well defined – for
example there may be a number of fugitive release points, or the emission rate
may vary a lot from day to day or hour to hour. It is possible to measure the
emission from area sources, but only if the surface is homogeneous.
In such cases an assessment may Or, where emissions are not too
be based upon: variable:
° the reaction of the people ° measurements taken in a

exposed to the odour pattern around the source -
emission odour mapping
22
Assessment of Community Exposure
There are a number of situations where an assessment of the community
exposure or response might be required:
° to substantiate complaints or identify/confirm a source
° to provide a correlation between community response and certain

processes or activities
° to determine the extent of the area, the “footprint”, over which an odour
problem is occurring.
Assessment of the extent of community exposure can be approached in two

ways:
1. by gauging the magnitude of the community response
° public attitude surveys (based on past exposures) population
° panels & odour diaries (on-going assessment of current situation).
° complaint records (which are based on past and current experiences)
2. by assessing the magnitude of the exposure
° analysis of ambient air samples
° using field panel tests or field judges.
23
Complaint Records
Odour complaints are widely used as
indicators of the existence of an Such records do not however
odour problem and the severity of provide an ongoing picture of the
the problem. However, it is not general underlying level of
certain how accurately the number of dissatisfaction, neither is it sufficient
odour-related complaints accurately to rely on the number of complaints
reflects the general level of alone to act as an indicator of
annoyance in the community and regulatory compliance. A reduction in
how complaints can best be used in the number of complaints can, over a
support of an investigation. period of time (which will allow
meteorological variation to be taken
Complaints are a good indicator of into account), demonstrate that there
an incident such as an accidental has been an improvement following
release or the sudden onset of a new changes to a process or installation
source of annoyance. The resulting of abatement equipment. A reduction
complaints can be used for in complaints may, however, occur
investigative purposes; to identify the because people get used to the
source and to map out the extent of odour, or get fed up with lack of
the affected area from which some improvement and do not bother to
estimate of the odour emission rate report any more.
can be made.
In order to maximise the benefit of a complaint record, good quality data are
essential. Whilst there is no standard methodology for collecting complaint data,
it is suggested that the following should be recorded:
° location where odour was detected
° date
° time
° duration (or frequency of recurrence)
° a description of the odour – what does it smell like
° weather conditions at the time, particularly wind direction
° a description of any visible activity occurring at the time.
24
Where possible it is often useful to not only record odour incidents, but also
record odour impact at regular intervals during the day. This is likely to record
many occasions of “no odour”, but can provide a very useful data set for
identification of sources when analysed along with wind direction data. This is the
basis of an “odour diary” as implemented by Anotec Pty Limited. Once odour
diaries have been distributed a Freecall number is issued (1800-ODOURS,
1-800 636 877) and all calls are logged.
Whilst differentiation may not be an issue, in a locality with a number of potential

sources it is helpful to be able to characterise the odour, i.e. “it smells like….”,
rather than “it smells horrible”.
Attitude surveys (public opinion surveys) - measuring the degree of

annoyance.
This form of survey involves interviewing on a single occasion a selected sample

of the population about their past experiences. Interviews can be conducted in
person, by telephone or by questionnaire designed to conceal the primary
interest in odour-related annoyance. This form of questioning, together with
modelling of odour emissions, forms the basis of the dose-effect studies
conducted overseas.
The survey must be designed and the results interpreted by specialists to avoid
inadvertent bias and to give a representative picture a sufficiently large sample
must be recruited. The cost will therefore be relatively high, although it will give
an installation-specific confirmation of whether emissions lie within the band of
acceptability for that particular population. It must also be remembered that the
record will comprise a cumulative perception and individual incidents will
probably be lost, as will any variation in the level of annoyance over time.
However, if executed effectively it will give a more unbiased picture than if relying
on complaints alone.
Extent of an Odour Problem

A history of local odour-related complaints will indicate whether offensive odours
are detectable beyond the installation boundary. The Operator or regulatory
authority could also carry out periodic subjective testing (“sniff testing”) to identify
potential problems or to ascertain any pattern to the emissions.
Differentiating between odour emissions arising from neighbouring plants is often

relatively easy. However where odorous processes are located close together
and the nature of emissions is similar more detailed investigation may be
required - community-based subjective assessment and comparison with
detailed process logs may be indicated.
25
“Fingerprinting” of a particular odour is a routine procedure at Anotec using gas
chromatography mass spectroscopy (GC-MS) whereby individual odorous
compounds may be identified from a sample of air collected from a particular
source. This is also a useful tool when formulating any odour control solutions.
Where the source cannot be clearly identified, or the impact needs to be
assessed in more detail, it may be necessary to undertake a more in-depth
investigation.
Identify the sources

Once a particular activity has been identified as the origin of odorous emissions,
specific sources or emission points should be identified. This can often be
accomplished by a systematic “walk-around”. Some source(s) may be
immediately apparent, but it is important to consider associated release points
which may be less obvious - these might be identified by running through
process flow diagrams and mass balance data, i.e. considering all inputs and
outputs.
Odour Impact Assessments

Whilst each assessment will be day/night changes. The impact, in
different and necessarily installation- terms of concentration, of those
specific, there are a number of emissions on receptors will then be
common features which should be predicted by means of dispersion
covered in a well-planned and modelling and the outcome
executed survey. interpreted in terms of the likelihood
of causing annoyance. It is usual to
Unless the assessment is consider both “normal” operation and
deliberately targeted at specific also “worst case”. The frequency
events only, or at defined with which worst case conditions
parameters, there will be a need to arise is also relevant. In some
quantify the emissions in a way assessments the odour will be
which accounts for any cyclical “characterised” in addition to a
variation as well as any seasonal or quantitative assessment.
26
Measuring Odours
Practical Considerations
There are a number of factors that set odorous emissions apart from other
pollutants in terms of the methods which are available for “measurement” and
also the ease of measurement. These include:
Subjectivity
Most odours are mixtures of compounds and knowledge of the chemical

compounds present in a mixture does not necessarily give an indication of the
human response. A subjective view - what it smells like to those who are actually
exposed (i.e. what people may actually complain about) - can be obtained by
using olfactometry and/or characterising the odour. Anotec strongly
recommends the use of this odour measurement technique.
Variability
Seasonal variation in the level of annoyance caused by a particular source is

fairly common. This may relate to differences in the process or the raw materials,
degradation of putrescible materials during hot weather, or it may be simply
because local residents are outside when the weather is better or have the
windows open in summer. Worst case is therefore a valid consideration – and
may be relevant for more than just infrequent odour events; it may occur for a
considerable period of time.
Concentration in ambient air
The collection of meaningful samples of ambient air (e.g. at an affected area in

the community, or at the installation boundary) for assessment by olfactometry is
subject to a number of difficulties. The main problem relates to low concentration
- generally too low for olfactometry - and so it is not commonly undertaken.
Collection of samples for instrumental analysis is sometimes possible but
fluctuation in concentration is often rapid and only direct reading instruments can
give an indication of the exposure profile. A result that is averaged over a long
period is rarely useful as it is the peaks which tend to cause annoyance, even if
very transient. This would not normally be undertaken for routine compliance
monitoring.
27
Use of surrogate substances for monitoring
In some cases it may be possible to set up continuous or frequent monitoring of

surrogates, i.e. a single substance which is representative of the odour
characteristics of the emission. Once the relationship is established, there must
be a linear response to changes in total odour concentration to enable
quantitative information to be obtained. Linearity is rarely maintained across the
whole scale such that a near zero value for the surrogate may still leave a strong
residual odour (this is often found in the waste water or sewage industry).
Sometimes “calibration” values can be established to adjust for systematic non-
linearity.
Summary of Odour Measurement Methodologies:
In general terms odour can be “measured” in terms of:
Analytical (“chemical”) techniques
° Chemical analysis - indirect assessment involving the collection of a

sample which, when analysed, will give the concentration of the various
chemical species present. This includes wet chemistry, as well as
sample collection followed by instrumental analysis by means such as
gas chromatography (GC).
° Direct reading instrumental analysis - provides information on the

concentration of specific chemical species or their concentrations
relative to each other. This includes portable analysers (including
portable GCs and GC-MS) and the “electronic nose”, as well as
colorimetric tubes.
Sensory methods (relating to human response):
° A sensory assessment - which gives an assessment of the physiological

response to a particular mixture - strength, quality, characteristics -
which provides information on the likely population response. This is
obtained by exposing trained individuals to samples of the odorous air,
either in the laboratory or in the field.
28
The following considers the techniques discussed and shows the context within
which their use might be appropriate:
Chemical analysis –
° Gas chromatography and GC-MS,
° Substance-specific wet chemistry methods.
Direct reading instruments -
° Colorimetric tubes,
° The “electronic nose”,
° Portable analysers.
Sensory assessment
° Dynamic Olfactometry,
° Simplified olfactometric screening - “sniff tests”.
Chemical Techniques
Chemical and/or instrumental analysis can provide quantitative (giving a
numerical concentration value) information on the compounds present. This
information may be required for the following reasons:
° to assist in source identification
° determination of compliance with substance-specific emission limits
° profiling changes in emissions during a process cycle to assist in

identifying where process modifications might be made
° to set optimum operating parameters for abatement equipment (for

example reagent strength, determination of breakthrough or exhaustion
point of absorbents or adsorbents).
As discussed, Anotec utilises the services of ANSTO for GC/MS analysis.

Gas Chromatography (GC) is a widely used analytical technique for separating
the components of an odorous air sample for identification and quantification.
The majority of odorous organic species can be identified in this way.
29
The basic steps are:
° sampling - which may involve pre-concentration of a gaseous sample

onto a solid adsorbent or absorption in a reagent
° thermal desorption or solvent extraction
° separation of the components by passing through a GC column
° detection and identification.
There are a variety of detectors available, however the most commonly used for
mixtures of organic compounds is the Flame Ionisation Detector (FID). Anotec’s
use of a gas chromatograph mass spectrometer (GC-MS) is more widely used
for situations where the emission has an unknown composition and for
formulating purposes. Identification of the resulting mass spectrographic pattern
is made with reference to a computer based spectrum library, although
identification of compounds with similar structures and/or masses can be difficult.
Application
The GC-MS is used for “fingerprinting”, i.e. to analyse air samples at the
complainant’s location in order to ascertain the identity and concentration of the
main odorous components. If this information does not allow positive
identification of the source from existing knowledge of the activities carried out,
then sampling of those potential sources using the same technique can enable a
match to be made. Occasionally the odour is found to be a product of more than
one source, overlaid on top of each other. The extent of dilution and the need for
sampling at receptors to coincide with periods of exposure (particularly if they are
brief) can restrict the usefulness of this method. The cost of the instrument and
the expertise required for analysis and subsequent evaluation also limit its use as
a “quick check” method for everyday use. It can however be useful where there is
on-going uncertainty regarding the source and who is responsible.
Disadvantages
° Direct calibration for analysing odours is difficult because the

composition mixture will often be unknown.
° The concentration in ambient air of individual compounds may be below

or close to the lower limit of detection.
° Longer term samples will average out any peaks, although this may be
of secondary importance in source/compound identification.
30
Sensory Techniques
It should be noted that although Anotec favour the use of chemical techniques
based solely on formulating rather than odour measurement, sensory
assessment of odours should not be thought of as less robust or less defensible
than chemical analysis. It has a number of advantages.
A complex mixture of compounds where identification is difficult, and composition

variable, sensory assessment provides the only reliable method of accurately
quantifying the “strength” of odour.
Sensory assessment provides a measure of the total strength of odour which

may be under estimated if just a single component compound is measured.
The sensory impact of a mixture of odorants and non-odorants can only rarely be
predicted from existing knowledge of its component parts.
Sensory data provide a direct link between a particular odour and the human
response to it - this is particularly important when considering annoyance issues.
The most widely used techniques are:
° dynamic dilution olfactometry - “olfactometry”
° simplified olfactometry - also referred to as “sniff tests”
Sensory assessment of odours can similar. A simplified form of

be undertaken at source, close to olfactometry - “Sniff testing” - is a
source or in the community, although very useful method of assessment
increasing dilution and variability that can be undertaken almost
make the collection of meaningful anywhere.
samples for lab-based olfactometry The data obtained from a lab-based
progressively more difficult with olfactometric assessment will be in
increasing distance. It is possible the form of an odour concentration –
however to take the assessment part “dilutions to threshold” or “odour
of the procedure out into the field units”.
with perhaps a mobile laboratory or
Dynamic Dilution Olfactometry
It is Anotec’s opinion that the only reliable form of measuring odour units is by
use of Dynamic Olfactometry. Dynamic Olfactometry involves the step-wise
dilution of a sample of odorous gas with odour-free air and subsequent
presentation to a panel of observers in order to determine the number of dilutions
required for odour to be just perceived by 50% of the members of the panel. The
most commonly used form of olfactometry is “dynamic dilution olfactometry”.
31
Sampling
Determine the sample locations which best meet the purpose of the investigation.
This could entail collection at:
° specific locations on a process order to identify the point at which a

specific odour arises
° a particular processing step or operation
° release points - stacks, ducts, vents, surface emitters
° in a grid pattern across an installation to establish an installation-wide

“map”
° at, or close to, the installation boundary
° in the community (although the dilution of the sample can be

prohibitive).
In certain circumstances emissions from point sources have to be measured from

ventilation grilles (typical of general building ventilation) or roof stacks. If this
occurs, gas samples are collected from a point as far into the duct as possible to
exclude ingress of clean air which would artificially dilute the sample.
Samples collected from area (surface) sources usually give a true representation
of the emission provided that any variability across the surface is taken into
account. The most common surface source requiring odour measurement is a
biofilter and when monitoring it is recommended that samples are taken:
(a) close to the inlet of the bed
(b) along the retaining walls, and
(c) at the centre of the bed.
At each location a velocity measurement should be made to ensure that there is

gas flow. For example, in Singapore and the UK newer biofilters are designed
with a cover and release to atmosphere via a stack, where samples can be
taken.
32
Preventing and Reducing Emissions
Ideally, or rather realistically, measures for preventing or reducing odour need to
be considered on an operation by operation basis.
Emphasis should be on:
° good process design or redesign.
° Utilising “clean technology”, i.e. design the problem out rather than relying on
“end-of-pipe” technology
° to clean up afterwards
° good operating and management practice backed up by an environmental

management system
An Odour Control Strategy

An odour control strategy should aim gas stream and the source type.
to prevent odour from being Specialist advice should be sought
generated, but where this is not and/or trials undertaken to determine
practicable, the rate of odour the suitability and efficiency of a
generation should be minimised and particular option prior to committing
end-of-pipe abatement considered, capital expenditure.
as appropriate to the nature of the
General considerations
A reduction in the volume of gas to be treated can reduce abatement costs
considerably.
For each potential treatment technique consider the nature and strength of the
residual odour after treatment - will subsequent dispersion in the atmosphere
cause annoyance and will it meet required acceptable limit or EPA condition?
Does the chosen technology have the ability to deal with fluctuations in input
stream (where appropriate)?
Equipment must be appropriately sized - it should be able to deal with existing

maximum throughput plus any envisaged expansion, but over-sized plant is a
waste of money.
A separate document outlining abatement techniques and appropriateness of use in various industries is available upon
request.
33
SECTION 4 –
FOUNDRIES – HEY! WHAT GOES ON THERE?
34
Summary of a foundry’s activities
Processes
Following are aspects of processes that take place within a foundry (excluding
melting and refining) and considered to be “foundry” operations, namely
operations that occur after the melt has been tapped from the furnace:
° Storage and handling of raw materials (only those associated with the
following foundry operations)
° launders
° desulphurisation of molten iron in ladles
° nodularisation of SG iron in ladles
° preparation of moulds and cores
° casting, pouring or moulding
° knocking out
° fettling, dressing or finishing of castings
° sand reclamation
° waste handling and recycling facilities
Air Quality Management
The potential for air pollution is a major problem associated with foundries.
Potentially significant pollutants are:
° particulate matter;
° nitrogen oxides;
° carbon oxides;
35
° iron and its oxides;
° heavy metals;
° ammonia;
° VOCs including formaldehyde, phenols and esters, and
° Dioxins, where dirty scrap is used
Many of these pollutants are malodorous.
Emission sources.
Dust and fume from refining in ladles may include:
a) from desulphurisation of molten iron in ladles – magnesium oxide or
calcium oxide, carbon monoxide and carbon dioxide
b) from nodularisation of SG iron in ladles – magnesium oxide (in large
quantities).
Preparation of moulds and cores gives rise to dust from sand handling and gases
from any resin, hardener and catalyst used (the binder system) and their
reactions during mixing and curing. The different binder systems give rise to
different emissions, but the main types emit two or more of the following gases:
ammonia, hydrogen sulphide, sulphur dioxide, methyl diisocyanate, phenol,
formaldehyde and a range of other VOCs including amines and esters.
Mould and core storage areas may have high concentrations of VOCs such as
triethylamine (TEA) and dimethyethylamine (DMA), which exude from the cores.
Casting, pouring, moulding and knocking out give rise to emissions relating to the
pyrolisation of the moulds. They include all of those mentioned above for the
preparation of moulds and cores, as well as carbon monoxide, carbon dioxide
and some PAHs such as cresols and xylenol that are malodorous.
Fettling, dressing or finishing give rise to particulate matter and some fume if
techniques involving heat are used. In particular, metallic dusts from shot blasting
operations are highly aggressive and damaging to paintwork.
Sand reclamation gives rise to dust from mechanical reclamation and fume from
thermal reclamation. (An aqueous stream is created by wet reclamation
techniques.)
36
Mould & Core Preparation
The most important issues from mould and core preparation and storage are as
follows:
° Odour;
° Dust from sand handling;
° Resin handling;
° VOC emissions including amines, aldehydes and phenol;
° Emissions of oxides of carbon;
° Fume;
° Leaks of gases being used as a gassing agent in certain mould and

core making processes, such as sulphur dioxide;
° Leaks of gases being used as catalysts, such as triethylamine

(TEA) and dimethyethylamine (DMEA). Both gases have
unpleasant odours. These gases exude from the cores in storage;
° Emissions of ammonia arising from the thermal decomposition of

hexamethylene tetramine which is a catalyst used in the shell
process;
° Particulate emissions.
Casting Moulding or Pouring
Fume generated during casting arises from two sources. Fine iron oxide is
generated at the surface of the molten metal as it is poured, and the organic
products are expelled from the mould as the resins and binders decompose. The
former only occurs as the metal is being poured, whilst smoke and fumes caused
by decomposition of the binder will continue to be evolved as the mould cools.
37
Casting Practices
where it solidifies. The mould is
Static Sand Casting stopped and the casting withdrawn.
This is the simplest technique

whereby the sand moulds are Roll Casting
arranged on the shop floor and filled
from a ladle. The castings are then This can be carried out centrifugally
left to solidify. It is generally or statically. In the centrifugal system
impracticable to have fixed extraction the vertical mould is placed in a
hoods and ductwork in the casting machine and spun at high speed
area. In more automated foundries while the hot metal is bottom poured
the moulds may be moved by into it. Some time after filling, the
conveyor into the pouring position mould is lifted from the machine, and
where local extraction can be is left for several days before
employed. stripping. Fume extraction is normal
on the machine although not in the
cooling pit. In the static system the
Pipe Casting mould is mounted vertically and
bottom poured from the ladle. It
Pipe casting is carried out by pouring remains stationary while it cools and
hot metal from a ladle, via a tundish solidifies. Typically no fume
and runner into the rapidly rotating extraction is required.
horizontal mould. The metal is forced
out on to the inner cooling surface
Knockout & reclamation
Knocking out or stripping is the practice of removing the casting from the mould.
Smaller castings may be removed from the casting box manually or by use of a
vibrating table which dislodges the casting from the box and allows any sand to
fall through the open surface of the table. Dust from these operations is usually
collected and cleaned by bag filters. Large moulds will be broken up and castings
removed in-situ, using an overhead crane or bucket excavator. Although large
quantities of dust may be generated, local extraction and filtration is impractical.
Pipes are removed from their rotary moulds by mechanical means. The sand
from the knocking-out area is excavated, normally by mechanical digger and is
either recycled or disposed of to landfill.
During knockout the mould is broken open and the surface area from which
organic compounds may be liberated is significantly increased. Pyrolysis
products adsorbed onto the resin coated sand, such as phenols for example,
volatilise, and are emitted to the foundry atmosphere. Formaldehyde will be
38
present in the knockout section as it exists in the resin binder. Dust is emitted on
which organic compounds may be adsorbed.
Fettling, dressing or finishing of castings
Fettling
After the castings have cooled they are subjected to a number of finishing
processes in order to obtain the final finish required for the product. These
operations, some of which are referred to as fettling or dressing include:-
° Cleaning by shot blasting or other means to remove core and mould

materials and scale.
° Removal of excess metal such as feeder heads, runner or gating

systems and any other superfluous metal.
° Removal of blemishes and defects.
° Smoothing over of welded parts, areas from which metal has been cut,
and any other rough areas on the surface of the casting, generally is
grinding.
Fettling is generally achieved by flame cutting, grinding or chiselling, and usually

results in the generation of dust and fume. Small items may be finished by
grinding in tumbling drums together with ceramic chips. This is usually carried out
in water to which surfactants may be added. In the case of pipes the internal
surface is dressed by extending a rotating grinding wheel or burr the full length of
the pipe. Another method uses an electric arc to selectively remelt unwanted
small areas of the casting.
39
SECTION 5 –
GIVING FOUNDRIES THE BAT

Fumes evolved from current foundry processes
System Name and Binder Setting Method Fumes during Mixing and Fumes during Casting
Constituents Setting
GREEN SAND
Clay Pressure Dust Carbon oxides
Coal dust or substitute Aromatics (inc polycyclics)
Water Nitro aromatics
SHELL SAND
Phenol Heat Formaldehyde Carbon oxides
Formaldehyde (Novalak) Ammonia Phenols
Resin Phenol Ammonia
Aromatics Aldehydes
Aromatics (inc polycylics)
ALKALI PHENOLIC
Alkaline phenol’
Formaldehyde resin
Self-Setting, eg. Alphaset Cold set with esters Formaldehyde Carbon oxides
Phenol Formaldehyde
Esters Phenol
Gas hardened with methyl Aromatics
Gas hardened eg. Betaset formate vapour Formaldehyde
Phenol
Methyl formate
PHENOLIC URETHANE Carbon oxides
Gas hardened eg. Cold box, isocure Amine vapour Solvents Nitrogen oxides
Isocyanate Monoisocyanates
Amine Formaldehyde
Self Setting Phenol
Self set with substituted Solvents Aromatics
pyridine Isocyanates Anilines
Napthalenes
Ammonia
FURANE
Combination resins of: Cold set with acids Formaldehyde Carbon oxides
Phenol Phenol Phenol
Urea Furfuryl alcohol Formaldehyde
Furfuryl alcohol Hydrogen sulphide Aromatics
Formaldehyde Sulfur dioxide Sulphur dioxide
Acid mists Ammonia
Aniline
HOT BOX Carbon oxides
Combination of resins: Heat Formaldehyde Nitrogen oxides
Phenol Acids Formaldehyde
Urea Furfuryl alcohol Phenol
Furfuryl alcohol Phenol Aromatics
Formaldehyde Aniline
Ammonia
OIL SAND
Linseed oil and starch Heat Acrolein Carbon oxides
Complex organics Butadiene
Ketones
Acrolein
CO2 process
Sodium silicate Gas hardened with CO2 None Carbon oxides
gas
SILICATE ESTER
Self set Cold set with esters Esters Carbon oxides
Sodium silicate Alkanes
Acetone
Acetic acid
Acrolein
Table 2 Emissions from foundry processes

Preparation of cores and moulds
Green Sand Method
Shell Sand Method
Cold Setting Techniques
Mould Coating
Oil Sand Process

Pattern Release & Carriers
Environmental Impact
Water Not significant
Land Not significant
Air The most important issues from mould and core preparation and
storage are as follows:
Odour; the sources of which are the gases mentioned below
Dust from sand handling
Resin handling
VOC emissions including amines, aldehydes and phenol;
Emissions of oxides of carbon
Fume;
Leaks of gases being used as a gassing agent in certain mould and
core making processes, such as sulphur dioxide;
Leaks from gases being used as catalysts, such as triethylamine and
dimethylethylamine. Both gases have unpleasant odours. These
gases exude from the cores in storage;
Emissions of ammonia arising from the thermal decomposition of
hexamethylene tetramine which is a catalyst used in the shell process;
Particulate emissions.
Waste Choice of binder system affects potential for recycling and recovery.
Energy Not significant
Accidents Mixing and blending problems can impact upon recovery
Noise Not significant
Table 3 Environmental Impact: Preparation of Cores & Moulds
BAT for Preparation of cores and moulds
Minimise consumption of binder Where gas-fired heating systems are

chemicals through good process used (resin shell or oil sand), particular
control. attention should be given to good
Control amine emissions from gasses housekeeping and maintenance of
phenolic urethane systems where burner systems.
necessary for control of odour Solvent-based mould coatings should
nuisance, using techniques such as be torched off as soon as it is safe to
chemical scrubbing, Anotec systems or do so after application.
an effective incineration method.
In most cases, scrap moulds and cores should be avoided. If avoidance is not
should be segregated from other waste possible, non-chlorinated solvents
to facilitate reclamation. should be employed and the amount
Use of carrier organic solvents for used should be minimised.
pattern release agents or elsewhere
CASTING, POURING & MOULDING

Static Sand Casting
Pipe Casting
Roll Casting
Land Not significant
Air Fume
Waste Slag
Accidents Not significant
Table 4 Environmental Impact: Casting, pouring & moulding
BAT for Casting, pouring & moulding

For certain types of casting operation, eg. Green sand and automotive casting
foundries, and where a relatively large number of similar castings are being
manufactured, BT will normally include the use of a fixed pouring station with the
moulds moving past on a conveyor belt system. Where possible, moulds should be
totally enclosed or fully enclosed casting machines used. This will enable all the
casting fume to be extracted efficiently and treated. Where there are significant fumes
emitted after pouring then the conveyor should be enclosed and extracted.
For large items such as rolls, machine too, beds etc, it may be necessary to carry the
hot metal in a ladle to mould in a casting pit or casting bay. Here a movable or
extendable extraction hood connected to fixed arrestment plant installed in the most
advantageous position to collect casting fume should be considered.
Where suction hoods are used, there should be placed as close to the sources of the
fume as possible to reduce dilution of the fumes caused by large volumes of air being
drawn into the hoods. Suction hoods should not hinder process operations or
compromise safety; considerations should be given to push-pull systems to improve
efficiency.

Part of the improvement programme to update operations should be a quantitative
assessment of the emissions so that a further improvement programme can be
established to reduce them if possible within the BAT considerations. This is
particularly important where an odour problem has occurred.
KNOCK OUT AND RECLAMATION


Land Contaminated sand
Air During knockout the mould is broken open and the surface from
which organic compounds may be liberated is significantly
increased. Pyrolysis products adsorbed onto the resin coated
sand, such as phenols for example, volatise, and are emitted to
the foundry atmosphere. Formaldehyde will be present in the
knock out section as it exists in the resin binder. Dust emitted on
which organic compounds may be adsorbed.
Waste Contaminated sand
Noise Many parts of the machine are very noisy and require acoustic
shelters for worker protection. Standard noise protection
measures should be taken to minimise disturbance in the local
neighbourhood.
Table 5 Environmental Impact: Knockout
BAT for Knockout
Cooling of the mould before knockout reduces the mass of organic released.
Knockout area should be enclosed and connected to arrestment plant. Knockout
should not be done by hand. Fixed vacuum cleaning system around the knockout
area.

SAND RECLAMATION
Environmental Impacts

Land Contaminated sand, fugitive dust
Air Fume, products of combustion
Waste Contaminated sand
Energy Afterburners are significant energy users,
and temperature settings should be the
minimum compatible with acceptable
emissions control
Noise Many parts of the machine are very noisy
and require acoustic shelters for worker
protection. Standard noise protection
measures should be taken to minimise
disturbance in the local neighbourhood.
Table 6 Environmental Impact: Sand reclamation
BAT for sand reclamation
The main control issues are:

Use of afterburner by bag filtration of the waste gases when thermal reclamation used;
Effective and reliable temperature control systems on the afterburner.

DRESSING OR FINISHING OF CASTINGS
Water Sludge where wet techniques are used

Land Fugitive dust
Air Dust and fume
Waste Collected dust
Noise Many of these processes are very noisy and require acoustic
shelters for worker protection. Standard noise protection
measures should be taken to minimise disturbance in the local
neighbourhood.
Table 7 Environmental Impact: Dressing & Finishing castings
BAT for dressing and finishing castings

Containment and extraction
Effective means of detection for filter failure

WASTE HANDLING
The most important issues from waste handling and recycling facilities are as follows:
Slag from ladles

Collected dust
Collected sludge
Refractory waste

Land Slag, contaminated sand
Air Fume
Waste Slag
Table 8 Environmental Impact: Waste handling
BAT for waste handling
The main control issues are:

Water efficiency techniques should be employed
Waste should be recovered

CONTROL OF POINT SOURCE EMISSIONS TO AIR
Steam Plume Elimination: Releases from wet scrubber vents should not be hot
enough to avoid visible plume formation in the vicinity of the vent. This is to prevent
the condensation or adsorption of environmentally harmful substances by the
condensing water vapour. Exhaust gases from a wet scrubber can be heated by the
use of waste heat to raise the temperature of the exhaust gases and prevent
immediate condensation on the exit from the vent. This procedure also aids the
thermal buoyancy of the plume.
DECOMMISSIONING OR CLOSURE OF A FOUNDRY

A site closure plan should be maintained to demonstrate that, in its current state, the
installation can be decommissioned to avoid any pollution risk and return the site of
operation to a satisfactory state. The plan should be kept updated as material
changes occur. Common sense should be used in the level of detail, since the
circumstances at closure will affect the final plans.
However, even at an early stage, the closure plan should include:
° either the removal or the flushing out of pipelines and vessels where
appropriate and their complete emptying of any potentially harmful contents;
° plans of all underground pipes and vessels;
° the method and resource necessary for the clearing of lagoons;
° the method of ensuring that any on-site landfills can meet the equivalent of
surrender conditions;
° the removal of asbestos or other potentially harmful materials unless agreed

that it is reasonable to leave such liabilities to future owners;
° methods of dismantling buildings and other structures,
° the protection of surface and groundwater at construction and demolition-

sites;
° testing of the soil to ascertain the degree of any pollution caused by the
activities and the need for any remediation to return the site to a satisfactory
state as defined by the initial site report.
Recommendations for Odour Abatement and Best Available Technologies for the
various processes within foundries are available upon request. The data is extensive
and all requests must be in writing.
SECTION 6 –
SO? FOUNDRIES SMELL – WHERE DOES ANOTEC FIT IN?
49
Included in this document is an example of an assessment and our comments and
procedures are outlined therein. It should be noted that all documents submitted are
to be treated as confidential and are not for publication. Please use these documents
as a reference guide only.
Anotec Procedures
Briefly – recommendations prior to any assessment (where applicable):
At this stage, we recommend that a visit is arranged so that Anotec personnel can
conduct an odour assessment and audit.
Anotec strongly recommend that during the course of any scientific analysis that
Dynamic Olfactometry is conducted. Experts in this field are The Odour Unit, Mr.
Terry Schulz.
Assess ventilation and investigate whether air supply into the building is adequate.
Collect data relating to odour complaints from residents.
ODOUR EVALUATION, ASSESSMENT & ANALYSIS

PROCEDURES
° A Site Assessment Survey/Questionnaire is filled in by the enquiring

company and returned to Anotec Laboratory Services.
° A visit to the site is then organised. Anotec personnel will use

organoleptic (physical method / smell) methods to determine the hedonic
tone of the odour in the first instance to identify the source and type of
odour. If odour source and type are determined at this stage a
recommendation will be made to the client for treatment or for further
investigation. If odours are undetermined, it may be applicable at this time
to establish appropriate sampling sites. In some cases photographs of
site sampling areas are taken for inclusion in report.
° In the case of high level odour emissions a collection of gaseous samples

is performed. Not less than two samples are collected.
° Wet Chemistry methods are used to determine preliminary results of

specific chemical components (usually the predominant odour perceived)
and gas samples are sent to the Australian Nuclear Science and
Technology Organisation for the breakdown of the gaseous mixture.
Analysis takes place well within 24 hours of collection.
50
° Once analysis is complete, results are deciphered and recorded by
Anotec Pty Ltd technical staff and a draft report is prepared.
° Upon all results recorded a report is submitted to the enquiring company

along with any recommendations.
Informational:
The services provided by our company are solely to identify the composition of the
odours/gas and to determine the concentrations in the air at that particular time. It is
advisable that collection of gas samples be at the “worst” time in the day or night or
manufacturing processes.
Identification and concentration of odorous components (VOCs) enable Anotec to

determine the best possible solution or recommendations.
Analysis of the site does not always mean the implementation of odour control
equipment. In some cases recommendation for cover or extra housekeeping may
curb the problem.
Experience with foundry odour emissions have revealed that odour emissions,
although within detectable limits are well within acceptable threshold limits for
exposure. This means that the odour chemical concentrations identified do not pose a
chemical or toxic issue. Therefore, foundry odours, in our experience, constitute an
odour nuisance rather than a health issue.
51
CASE STUDY: TYCO WATER - QLD
CONFIDENTIAL – NOT FOR PUBLICATION OR GENERAL DISTRIBUTION
INTRODUCTION
Background
Anotec Pty Limited was commissioned to evaluate, identify and treat any
malodours being emitted from the Tyco Water Foundry located in QLD using an
Anotec odour control formulation.
Evaluation of the following took place:
(a) Perceived odour sources: mould cooling down area and exhaust stack.
(b) Chemical odour and concentration of components in raw odour emitted
from stack and cooling shed.
(c) Effect of product ANOTEC 0307 on malodours emitted.
(d) Performance of installed odour control application equipment for product
ANOTEC 0307.
Validity and Source of Results
All results herein were obtained by Dr David Stone, of the Environmental

Science Program at ANSTO Lucas Heights Research Laboratories. Dr Stone
is an expert in his field and has extensive experience identifying chemical
components within a gaseous mix.
2. ODOUR SOURCES EVALUATED

2.1 Time started: 10.10am
AREAS OF COLLECTION:
COOLING SHED
STACK (PART 1)
STACK (PART 2)
SAMPLES COLLECTED FROM PERCEIVED ODOUR

SOURCES
1. RAW ODOUR from Cooling Shed
2. RAW ODOUR from STACK (PART 1) Anotec Fans
Turned Off.
3. RAW ODOUR from STACK (PART 2) ANOTEC 0307
Fans Turned On.
52
COMMENTS: Sample collection was performed in exactly the same way in areas of
perceived odours. In the case of the cooling shed, the sample was taken from directly
above the cooling mould not exceeding 1 metre. The area is enclosed and unaffected
by drafts.
Each sample bag took approximately three minutes to fill.
All samples were taken in duplicate.
SAMPLE # 1 RAW ODOUR – Cooling Shed

SAMPLE # 2 STACK (PART 1) – Fans Off
SAMPLE # 3 STACK (PART 2) – Anotec & Fans On
Sample # 1 – Chemical fingerprinting to show values (ppb) for each constituent within
the Raw Odour mix.
the raw odour mix as it exits the stack. The fans that assist in application of the
Anotec odour control solution were turned off.
the raw odour mix as it mixes with the Anotec odour control solution and exits the
stack. The fans were turned on and the Anotec odour control system was operational
at the time of sample collection.
3. APPARATUS & PROCEDURES

3.1. Laboratory Facilities
All equipment for sampling were used on site. Air samples were subsequently
transported to the ANSTO laboratories at Lucas Heights for chemical analysis
well within 24 hours of collection.
3.2. Apparatus and sample collection
All samples were collected in proprietary air quality sampling bags constructed
of “Tedlar” (Teflon). Sampling line was Teflon. Fittings of sampling drum were
stainless steel, brass or PVC.
3.2.1. Samples were not passed through the pump but were collected by using
a sampling drum to enclose the bags. Evacuation of ambient air from
the drum caused the bags to be filled with the odour samples.
53
3.2.2. A cherry picker was hired for the day to allow sample collection from the
exit point of the stack.
3.2.3. The cooling shed is an enclosed area that significantly reduces the
dispersion of fugitive emission during the cooling down stage. The
cooling shed was chosen as a sampling site as it will represent the
highest concentration of chemical constituents emitted during the cooling
down stage and prior to further dilution as it travels up the vent stack.
3.3 Evaluation procedure/method
3.3.1 Tyco Water’s Mr. Michael Brown was present and conducted sample
collection from the exit point of the stack as it involved climbing into a
cherry picker that was raised up to 20 metres in height. A total of six
samples (duplicates for each sampling site) were collected and labelled
accordingly.
(a) Sample No. 1 – “Raw Odour”, referred to in the results section as

RO, was collected approximately 25 minutes after the pour by
holding the sampling line directly above the visible emission.
(b) Sample No. 2 – “Stack (Part 1)”, referred to in the results as S1,
was collected after checking that the fans and Anotec Odour
Control system servicing the stack were switched off. The
samples were collected from the exit point of the stack.
(c) Sample No. 3 – “Stack (Part 2), herein referred to as S2, was
collected once the fans and Anotec odour control system was
operational in the same manner described in (c).
3.4 The Tedlar bags took approximately three minutes to fill and there was
an interval of about six minutes between collection times.
TESTING
4.1 Chemical Analysis
Testing of all samples was completed well within 24 hours of collection by Dr

David Stone of ANSTO.
4.2 The technique of Thermal desorption GC-MS was employed using the most
advanced equipment currently available in Australia.
4.3 Table 1 represents the chemical odour concentration level detected for each
sampling site.
4.3.1 The first column shows values for each constituent within the raw odour mix.
54
4.3.2 The second column in the table shows the values of each constituent within the
raw odour mix as it exits the exhaust stack leading from the cooling shed. The
fan in this area was switched off.
4.3.3 The third column in the table shows the value of each constituent within the raw
odour mix after it is treated with Anotec 0307, an odour control formulation.
4.3.4 It is self-evident that there was a significant reduction of ppb in the major
components of the raw odour after treatment with Anotec 0307. It is also
interesting to note that residual Anotec 0307 within the stack also reduced the
raw odour concentration levels of odour.
4.3.5 Graph 1 presents the sum of the concentrations of all chemical components
identified for each test performed at each sampling site.
It also shows the effectiveness of the existing spray system when turned on
compared to the system when it is off.
RESULTS
5.1 The results and tables presented herein were comprised by using the data as
submitted by Dr David J M Stone, ANSTO.
5.2 Explanation of results

The author of this report has endeavoured to be as concise and clear as possible.
However, in the event that explanations for any material herewith are required,
please direct all queries to Anotec requesting contact details for Dr David Stone of
ANSTO, Lucas Heights.
5.2.1 Table 1 presents the averaged results of duplicate chemical analysis for the
three odour sources selected, using 3 litre tedlar bags. A small volume of
odour, typically 100ml is used in each case. The concentration of each
component (in ppb) is displayed for the various conditions at each sampling
site.
OBSERVATIONS
6.1 Accuracy
All sample collections were performed in exactly the same way. Methods used
by Dr Stone to determine chemical components and calculations are
reproducible and obtained by using quality precision equipment. The use of
odour standards ensures accurate results.
6.2 There is a vast difference in odour concentrations being emitted from the odour
sources tested.
6.3 The Cooling Shed results show a high concentration of chemical components
ideal for formulating purposes. There is no evidence of a chemical issue in this
55
area. The odour immediately detected, via simple olfactometric means, can be
described as “blackcurrant” that quickly changed to an obnoxious “burnt resin”
type odour. The results in this set are not indicative of the levels detected
outside this area. Due to the enclosure housing the cooling shed there was no
evidence to suggest that emissions during cooling were escaping into the
adjoining building or outside.
6.4 Stack (Part 1) – Fan Off results show a significant reduction in chemical odour
concentration levels. The analysis showed that traces of the Anotec odour
control formulation were present in this set of samples. It should be noted that
the Anotec product is sprayed within the stack in pre-determined intervals. This
is due to the residual effect that the solution has when sprayed into and onto a
surface. The results clearly show that although the fans were switched off, the
Anotec product was still present within the stack. These results are indicative
of what is exiting the stack to atmosphere when the system is turned off for
short periods of time.
6.5 Stack (Part 2) – Fan On results also show a significant reduction in chemical
odour concentration levels. The results show that when the system is
operational odour reduction for this area is at its optimum level.
CONCLUSION
7.1 Based on the testing and subsequent results, we feel that the product ANOTEC
0307 (Tyco Water) would significantly reduce the concentration of odours being
emitted from the exhaust stack leading from the cooling shed if used as
recommended. According to results in this report, as well as preliminary bench
tests performed, ANOTEC 0307 reduces odour concentrations significantly to a
point where there is a low calculated olfactometry number.
7.2 Based on the results of this evaluation, it is our opinion that if ANOTEC 0307 is
atomised into the exhaust stack and used in the testing throughout for each
sample, odour concentrations will be reduced by greater than 80%. Therefore,
emissions treated with the Anotec odour control solution will be extremely low
in odour concentration and will not transverse the boundary causing an odour
nuisance to the general public and/or neighbours.
CALCULATED ODOUR UNITS
A calculation of the chemical odour of each component can be produced

by dividing the concentration of each chemical by its odour threshold.
Odour thresholds were derived from components as determined by
Dynamic Olfactometry at the UNSW CWWT and from odour thresholds is
determined by J.E. Amoore & E. Hautala (Journal of Applied Toxicology).
56
The summation of this type of data is an approximation and guesstimate
only calculating the odour level as would have been determined by Dynamic
Olfactometry. These calculations do not negate the need for conducting
Dynamic Olfactometry at this site.
Unit = chemical odour concentration

Odour threshold
7.3 The Tyco Water Plant is a well kept and efficient facility. It is in our opinion,
based on the results from our testing, that the odour control device installed to
treat odours in the stack is effective in controlling and reducing the malodour.
Issues regarding the possible blocking of nozzles should be addressed and the
system upgraded accordingly.
7.4 A point to consider:
It is in our opinion that the malodour problem experienced from the foundry will
be vastly improved if specifications from Anotec Pty Ltd are met. It is also our
opinion that in the event that any malodours still perceived and documented via
complaints to council or management after the above is in force, may well be
coming from other areas within the foundry that were not assessed in this
evaluation.
7.5 Anotec 0307 conclusively eliminates or significantly reduces the odour

chemical concentration levels of ethanol, acetone, methyl acetate,
toluene, m,p-xylenes and benzene, the major sources of odour
annoyance.
One of the major reasons that the Anotec Odour Control formulation works at
the Tyco Water foundry is directly attributable to Tyco’s excellent Housekeeping
Regime and total awareness of emission points around their foundry. This
coupled with the low level; non-toxic concentration of odour compounds
identified ensures effective odour control of the site. Prior to treatment with
Anotec Odour Control, and upon chemical fingerprinting, it was revealed that
emissions do not pose a health risk to the community. However, the test
results revealed that the emissions analysed posed an odour issue that may
have been evidenced by odour complaints from the community. The Anotec
Odour Control formulation applied has significantly reduced / or eliminated the
odours from that site.
57
Chemical
Component (ppb) RO S1 S2
ethanol 1,829.8 1204.9 106.2
i-propanol 141.4 51.3 24.4
propanol 1.4 0.2 0.2
butanol 184.5 8.4 2.6
acetone 1,165.2 84.4 16.9
2-butanone 6.1 5.1 0.8
3-buten-2-one 2.6 2.3 2.1
methylisobutylketone 1.7 0.1 0.1
ethylacetate 236.5 27.7 7.8
methylacetate 2,598.8 269.4 75.6
benzene 159.4 14.0 3.2
methylhexanes 33.7 0.3 0.3
toluene 1,553.8 209.6 31.3
ethylbenzene 149.9 76.3 17.1
m,p-xylenes 2,770.8 295.8 85.3
o-xylenes 89.9 13.8 4.1
hexane 4.0 3.2 1.9
Table 9 Tyco Water GC/MS results
RE RE RE
(RO + S1) (S1 & S2) (RO + S2)
34.15 91.19 94.2
63.73 52.43 82.7
83.50 18.18 86.5
95.46 69.03 98.6
92.76 80.00 98.6
17.22 84.25 87.0
11.54 8.70 19.2
94.12 94.12 94.1
88.27 71.83 96.7
89.63 71.95 97.1
91.19 77.40 98.0
99.02 7.59 99.1
86.51 85.06 98.0
49.08 77.59 88.6
89.32 71.18 96.9
84.65 69.94 95.4
19.56 40.41 52.1
Table 10 Tyco Water Vs Anotec Treatment removal Efficiency
KEY RO Raw Odour

S1 Stack Part 1 – Fan Off
S2 Stack Part 2 – Fan On
RE Removal Efficiency %
58
SUM OF CONCENTRATION LEVELS
12,000.0
10,000.0
8,000.0
ppb
6,000.0 TOTAL
4,000.0
2,000.0
0.0
RO S1 S2
SAMPLES
Chart 1 Sum of Concentration levels – Odours Vs Anotec
59
Major odour contributors:
Raw Odour Vs Anotec 0307
ethanol
2,000.0
1,800.0
1,600.0
1,400.0
1,200.0
ppb
1,000.0
800.0
600.0
400.0
200.0
0.0
RO S1 S2
Sampling Site
Chart 2 : Ethanol Vs Anotec
acetone
1,400.0
1,200.0
1,000.0
800.0
ppb
600.0
400.0
200.0
0.0
RO S1 S2
Sampling Site
Chart 3 Acetone Vs Anotec
60
methylacetate
3,000.0
2,500.0
2,000.0
ppb
1,500.0
1,000.0
500.0
0.0
RO S1 S2
Sampling Site
Chart 4 Methyl Acetate Vs Anotec
toluene
1,800.0
1,600.0
1,400.0
1,200.0
1,000.0
ppb
800.0
600.0
400.0
200.0
0.0
RO S1 S2
Sampling Site
Chart 5 Toluene Vs Anotec
61
m,p-xylenes
3,000.0
2,500.0
2,000.0
ppb
1,500.0
1,000.0
500.0
0.0
RO S1 S2
Sampling Site
Chart 6 m,p-xylenes Vs Anotec
benzene
180.0
160.0
140.0
120.0
100.0
ppb
80.0
60.0
40.0
20.0
0.0
RO S1 S2
Sampling Site
Chart 7 Benzene Vs Anotec
62
TYCO WATER - RAW ODOUR Vs ANOTEC TREATMENT
2,000.0
1,800.0
1,600.0
1,400.0
1,200.0
ethanol
ppb 1,000.0 i-propanol
propanol
800.0 butanol
acetone
600.0
400.0
200.0
0.0
RO S1 S2
SAMPLES
Graph 1 Raw Odour Vs Anotec (Set 1)
63
3,000.0
2,500.0
2,000.0
2-butanone
3-buten-2-one
ppb 1,500.0
methylisobutylketone
ethylacetate
methylacetate
1,000.0 benzene
500.0
0.0
RO S1 S2
SAMPLES
64
3,000.0
2,500.0
2,000.0
methylhexanes
toluene
ppb 1,500.0
ethylbenzene
m,p-xylenes
o-xylenes
1,000.0 hexane
500.0
0.0
RO S1 S2
SAMPLES
65
3,000.0
2,500.0
2,000.0
ethanol
acetone
ppb 1,500.0
methylacetate
toluene
m,p-xylenes
1,000.0 benzene
500.0
0.0
RO S1 S2
SAMPLES
66
Anotec Odour Control
Nozzles are
introduced into the
stack to effectively
“scrub” odorous
emissions in the
vapour phase
Figure 1 Tyco Water set up: Anotec Odour Control nozzles
67
REFERENCES
References
Abdelrahman Dr. M., (1999) Integrated Industrial Process Sensing and Control
System Applied to and Demonstrated on Cupola Furnaces, Prepared by the
Tennessee Technological University for the Sensors and Controls ’99,
Information Exchange Meeting, May.
Allborg University (1998), The Cosworth Process, Available at:

http://www.iprod.auc.dk/procesdb/cosworth/intro/cosworth.htm (Last accessed,
August 1999).
American Council for an Energy-Efficient Economy Home Page (ACEEE, 1999)

Making Business Sense of Energy Efficiency and Pollution Prevention, The
Integrated Approach: Case Studies Available at:
http://www.aceee.org/p2/p2cases.htm#decatur (Last accessed, August 1999).
Brown, J (1994), Foseco Foundryman’s Handbook, Tenth Edition, Foseco

International Ltd., UK.
Cast Metal Coalition (CMC,1998), Metalcasting Industry Technology Roadmap,

Sponsored by the CMC or the American Foundrymen’s Society, North America
Die Casting Association and Steel Founders’ Society of America, January.

Clegg, A., (1991) Precision Casting Processes, Loughborough University of
Technology, Leicestershire, UK, Pergamon Press, Oxford.
Commonwealth of Australia (CoA, 1985), Australian Ferrous Foundry Industry,

Final Report, Department of Industry, Technology and Commerce in
association with the Metal Trades Industry Association, October.
CRC for Alloy and Solidification Technology (CAST, 1999), Corporate

Homepage, http://mama.minmet.uq.edu.au/cast/service.html (Last accessed,
August 1999).
Dravnieks A, Masurat T, Lamm R A, “Hedonics of Odours and Odour

Descriptors”: in Journal of the Air Pollution Control Association, July 1984, Vol.
34 No. 7, pp 752-755
Durham M., and T. Grimm (1996) SLS and SLA: Different Technologies for
Different Applications, Prepared by Accelerated Technologies, Inc. USA, April.
Environment Agency for England and Wales and Scottish Environment

Protection Agency (SEPA) and the Northern Ireland Environment and Heritage
Service (EHS). IPPC – Horizontal Guidance for Odour 2001.
Environment Canada (1997) Technical Pollution Prevention Guide for
Foundries in the Lower Fraser Basin of British Columbia, Fraser River Action
Plan, Prepared by Kent Engineering Ltd. West Vancouver, B.C. for the
Environmental Protection Fraser Pollution Abatement Office, North Vancouver,
March 1997.
Environmental Technology Best Practice Program (ETBPP, 1995b), Foundry

greensand: use and reclamation, Guide EG5, prepared by Castings
Technology International.
Foundry Online (1999). Moulding and Casting Processes, Available at:

http://www.implog.com/foundry/foundvpr.htm (Last accessed, August 1999).
Foundry Trade Journal (FTJ, 1996b), End-of-pipe abatement or process

change? The case of cupola melting, Vol. 170, Number 3514, January, p 34-38.
Foundry Trade Journal (FTJ, 1997g), How to reduce the impact of foundry
waste arisings, Vol. 171, Number 3531, June, p 242-243.
Foundry Trade Journal (FTJ, 1998o), Smoking can seriously damage your
wealth, Vol. 172, Number 3549, December, p 443-446
Foundry Trade Journal (FTJ, 1999d), Getting the best from binder systems,
Vol. 173, Number 3551, February, p 27-28.
Guidance for the Regulation of Odour at Waste Management Facilities under the
Waste Management Licensing Regulations, July 2001, Version 2.3
Hurst, S (1996) Metal Casting, Appropriate technology in the small foundry,

Intermediate Technology Publications.
Knowlton J and Pearce S, “Handbook of Cosmetic Science and Technology”.
Leonardos G, Kendall D and Bernard N, “Odour threshold determinations of 53

odorant chemicals” JAPCA Volume 19, No 2, 1969.
Queensland Government Environmental Protection Authority (EPA, 1999),

Environmental Guideline: Beneficial re-use of ferrous foundry by-products -
draft guidelines.
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Turk, “Atmospheric gases and vapors” Annals New York Academy of Sciences.

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ANOTEC PTY LIMITED

BEST AVAILABLE TECHNOLOGY- POLLUTION

Odour Control Technologies

Odour Control Technologies

Table 1. Odour Control Technologies

Anotec – Mode of Action

© Anotec Pty Limited. COMMERCIAL-IN-CONFIDENCE 7

1. Energy is transferred from the normally hotter gas phase to the

Therefore, at a particular temperature, a heavy molecule moves more slowly than

Multiply this figure by the number of Anotec commissions the use of

Testing of Anotec Odour Control

Evaluation of the Anotec Odour Korea and Ch2MHill to mention a

Odour problems often occur when an existing

The general community views odours as strictly a nuisance. A foundry

Odour nuisance from an industrial process may occur as a result of a single

There are two basic types of nuisance lawsuits, a

The importance of preventing and minimising pollution has increased

The reasons why such pollutants require control are as follows:

Particles may be inhaled by people or animals, leading to respiratory and other

Volatile organic compounds, or VOCs, are a large class of carbon-containing

° prevents nuisance to neighbours

° improves the internal work atmosphere and reduces risks to worker

° minimise the environmental impact of the operations

° improves the company image.

Controls on emissions of particulates

Controls on emissions of volatile organic compounds (VOCs)

VOCs are considered to be the source of significant environmental problems, in

Practical Emission Reduction Measures

There is usually more than one way of eliminating or reducing emissions of

Process Cleaner technology/method of improved control

° to predict the exposure of sensitive receptors to odour and to apply a

° to indicate the amount of abatement (or additional abatement) required

° to look at trends – improvement or worsening performance over a

° to determine compliance with a Permit condition, and

Where an existing installation has a history of odour complaints and obvious

If odour impact has never been also be considered - under what

Odour Measurement Methodologies

Monitoring and Predictive Modelling Assessments:

These estimate the “footprint” of effect of the activity by mathematical modelling

° Olfactometry: such as The Odour Unit’s Dynamic Olfactometry

° Mathematical atmospheric dispersion modelling.

Assessments based upon measurements around the source and/or conditions in

1. Assessment of community response

° complaint histories (based on past and present experiences)

° attitude surveys (based on past exposures)

° population panels (on-going assessment of the current situation)

° assessing the extent and magnitude of the exposure in the community

Assessment based on process emissions

Emissions can be measured or predicted by:

° collecting and analysing odour samples

° using mass balance data

° comparison to a similar operation.

A dispersion model attempts to describe the effects of atmospheric turbulence on

The modelling of odour is still a developing field when compared to other

To visualise the extent of odour impact it is useful to produce contour plots

In some cases it will not be possible to measure or to predict emissions at the

° the reaction of the people ° measurements taken in a

° to substantiate complaints or identify/confirm a source

° to provide a correlation between community response and certain

Assessment of the extent of community exposure can be approached in two

1. by gauging the magnitude of the community response

° public attitude surveys (based on past exposures) population

° panels & odour diaries (on-going assessment of current situation).

° complaint records (which are based on past and current experiences)