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Project title

Reduction at Source of Fugitive Emissions Incorporating Flux Chemical Recycling and Heat Recovery

Primary Funding Agency

Environmental Protection Agency

Co-Funding Organisation(s)

n/a

Lead Organisation

Waterford Metal Industries Ltd.

Lead Applicant

Patrick Sheridan

Project Abstract

This galvanising company will change the production process to convert from dry fluxing to hot wet fluxing with chemical recycling.Aspects of the new production process include:Continuous recycling of flux treatment to reduce dross formation;Product for galvanising will be pre-cleaned to prevent contamination of the recycling process;Hot dry product will reduce zinc consumption by reducing oxide formation at source with less skimmings and fume;Engineered furnace flue gas heat recovery will be introduced andAll pre-treatment processes will take place in enclosed spaces.Environmental benefits:The source of fugitive emissions arising from vaporised flux and water will be reduced;Galvanising mud from dirty incoming product will no longer cause fume or skimmings formation on the zinc pot surface;There will be a reduction in zinc contamination of all aspects of the process;There will be downstream savings in chemicals and energy used in recycling lesser quantities of skimmimgs and dross;Heat recovery will reduce carbon dioxide emissions;Reduced energy and water consumption over conventional wet fluxing andNo new emissions to sewer.Economic benefits:There will be reduced chemical costs as it is anticipated that there will be less waste of flux due to more precise application;There will be reduced energy costs arising from heat recovery;Zinc consumption will be reduced. It is expected that the greatest economic benefits will be achieved on lower zinc waste;The new process will provide the opportunity to improve quality and consistency of product. This will also reduce re-work andThere will be an improvement in safety aspects of the operation.

Grant Approved

�100,000.03

Research Hub

Cleaner Production - Green Enterprise - Innovation and Demonstration

Research Theme

n/a

Start Date

n/a

Initial Projected Completion Date

n/a