photo by F.A. “Swarzędz” sp. z.o.o.
Good practices and investments related to Cleaner Production
Example No. 75
Reduction of atmospheric emissions and heat loss in the company's premises, thanks to the filtration and recuperation system
Company:
Fabryka Armatur “Swarzędz” sp. z o.o.
Industry branch: metallurgical industry
Main products: die forgings, gearbox synchronizer rings, water and heat meter bodies, gas cylinder valves
Resources in question:
- Thermal energy
- Fossil fuels
- Waste
- Emissions into the atmosphere
Cost (implementation of good practice): High
- Electrostatic filtration and ventilation: about PLN 700,000 net (filter unit – about PLN 550,000; filter unit housing – about PLN 85,500; pipeline – about PLN 145,500 net)
- Filtration and ventilation with recuperation – filter unit including piping: about PLN 445,000 net
When the company moved its headquarters to a newly built state-of-the-art hall in 2009, it seemed that the planned rooms and halls would meet production demands for many years. In the forge hall, only one of the presses was a press emitting harmful substances, for which an external air extractor was designed.
However, as production expanded and forging technology changed, more presses appeared, compounding the problem of emissions at the workstations. In addition, in the autumn and winter, with the solutions used (air extraction that directs emissions to the outside), there was a significant loss of heat, compounding heating needs.
However, as production expanded and forging technology changed, more presses appeared, compounding the problem of emissions at the workstations. In addition, in the autumn and winter, with the solutions used (air extraction that directs emissions to the outside), there was a significant loss of heat, compounding heating needs.
Applied solution:
Environmental and social aspects were more important than economic considerations in the selection of this project. Air quality is a key factor in maintaining a hygienic and safe work environment. The use of a filtration system has made it possible, first of all, to eliminate oil mist, fumes, smoke and odors generated during the production process. The forging presses were combined into two lines, each equipped with a separate filtration system – which was related to the characteristics of the materials being processed, the use of different lubricants and the frequency of operation of the presses at these stations. The system used consists of filter modules for the separation of smoke, dust, mist and vapor in forging presses. It has a smart solution in the form of adjusting the speed of the air exhaust for filtration, which is automatically adjusted to the line load (it can reach a maximum capacity of up to 20,000 m3/h). On the line of presses with manual forging, where an aqueous graphite solution is used as a lubricant, a cyclone pre-separator was also designed, to ensure pre-dedusting.
However, the solutions described here could hardly be called Cleaner Production if it were not for the recuperation system used. Dedusted and cleaned air goes to the recuperator and then to the so-called air conditioning unit, from where, after collecting air from outside, it returns to the hall, reducing heat loss (and thus gas consumption) in the autumn and winter months.
However, the solutions described here could hardly be called Cleaner Production if it were not for the recuperation system used. Dedusted and cleaned air goes to the recuperator and then to the so-called air conditioning unit, from where, after collecting air from outside, it returns to the hall, reducing heat loss (and thus gas consumption) in the autumn and winter months.
Obtained benefits and effects of the implementation:
- Reduction in gas consumption for space heating
- Improved indoor air quality, reduced outdoor emissions
- Other benefits of oil mist extraction:
- compliance with the occupational health and safety standards
- minimized health hazards, dry surfaces, less risk of slips and falls
- improved field of vision
- minimized risk of fire spreading
- longer life of machines and tools
Forge hall with visible filtration systems
photo by F.A. “Swarzędz” sp. z.o.o.
Source:
- Report on the Cleaner Production Project No. 48.772, developed within the framework of the Cleaner Production Academy at Fabryka Armatur "Swarzędz" sp. z o.o.: "Reducing emissions of pollutants entering the atmosphere through the use of an integrated air filtration system"
Polish version:
This
material has been subsidized by the National Fund for Environmental
Protection and Water Management. The Polish Cleaner Production Movement
Association is solely responsible for its content.
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