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Key outcomes:

  • 99% capture efficiency achieved
  • Workplace health and safety risks mitigated

Fugitive emissions are a common issue with many industrial process, especially in casting. High-temperature emissions from vapourising water, or other chemicals may result in workplace hazards, or complications with EPA emission licensing requirements. Capturing the emissions allows venting through a stack, which improves dispersion and helps meet licensing requirements.

The video showcases two examples of how computational fluid dynamics (CFD) modeling can virtually represent onsite facilities. This enables the design of an efficient capture system to minimize emissions and workplace hazards. This approach also reduces the need for over-engineering the capture system, leading to lower energy usage and costs.

A side by side image showing a CFD model of a plume of fugitive emissions escaping from casting machine, together with a photo of a similar plume in the factory.

Figure 1: CFD model of casting emissions (left) compared to onsite photograph of the same process (right).
The accompanying image displays a case study where Synergetics was tasked with providing engineering recommendations to attain a 99% capture efficiency for fume emissions at an iron scrap melting, alloying, and casting facility. The team conducted meticulous on-site measurements and observations to characterize the emissions from various operations, such as melting furnaces, transfer, and charging. This provided a foundation for creating a virtual environment to conduct CFD modelling of the processes and evaluate hooding options. The initial modelling facilitated a better comprehension of the distribution of the fugitive emissions plume and the underlying conditions.

After conducting the modelling, the team collaborated with the client to choose the preferred options that aligned with their management and production objectives. These options were fine tuned to fit the modelled plume shape, and tested using the CFD model. Finally the optimised extraction system was implemented and the objective of 99% fume capture efficiency was successfully achieved.


For more extraction and ventilation modelling see our sector page.