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 chemical vapours may result in workplace hazards, or complications with EPA emission licensing requirements. Capturing the emissions allows them to be vented using a stack, which provides improved dispersion and assists with meeting licensing requirements.

Using CFD modelling the onsite facilities can be represented virtually and modelled to allow an appropriate, efficient capture system to be tailored to the problem, minimising emissions and workplace hazards whilst minimising the need to over engineer the capture system, which in turn reduces energy usage and costs. Two examples of these facilities we have modelled are shown in the video.

Comparison of CFD fugitive emission modelling to onsite emissions

Figure 1: CFD model of casting emissions (left) compared to onsite photograph of the same process (right).

In the case study shown in the accompanying image, Synergetics was asked to provide engineering recommendations to achieve 99% capture efficiency for fume emissions from an iron scrap melting, alloying and casting facility. On-site measurements and observations were carefully recorded and the data analysed to characterize the emissions from the melting furnaces, transfer and charging operations. This was then used as the basis for creation of the virtual environment for computational fluid dynamics modelling of these processes and assessment of hooding options. The initial modelling enables a better understanding of distribution of the emission plume, and the conditions responsible for it. Following modelling, preferred options were selected in consultation with the client to meet 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.