Cost effectiveness of abatement options for emissions control in Egyptian iron foundries

This study focuses on an evaluation of the cost effectiveness of abatement options for controlling emissions in existing iron foundries in Egypt. It is expected that such a study will enable decision by identifying concrete measures for abating total solid emissions (TSP). The structure of iron foundries in the country have been surveyed and the variant types of furnaces, the TSP emission level without any abatement options and data of the annual turnover of these foundries have been obtained. Possible market based instruments (MBI) options that might encourage these firms to seek the most efficient control measures have also been examined. Different abatement options such as updating burner design, switching heavy fuel oil to kerosene or natural gas, installing cleaning systems and/or updating the process technology were tested in terms of emission level and the overall turnover. The effect of installing different cleaning systems such as wet scrubbers and filter bags on the running cost of abating TSP was also investigated. Results obtained reveal that crucible (CrF) and short rotary (SRF) furnaces are the most numerous types of plants in Egypt. The concentration of TSP emissions exceeds the standards as specified in Law. Poor quality scrap input adversely affects the operation of the furnace, and impairs product quality and causes excessive TSP emissions. TSP emissions per ton of cast iron produced are relatively low for induction furnaces (EIFs), (about 0.04 kg) and very high in the dirtier technologies, particularly CrF and SRF, (29.95 and 32.2 kg, respectively). Cost analysis shows that the cost of abating one ton of TSP emitted amounts to 3000–5000 L.E and this cost represents a high percentage of turnover to plants abating emissions. A program for technical assistance and training would help iron foundries solving difficulties in reducing TSP emissions and encourage them to implement and operate effective pollution control measures. The work suggests structural changes such as: updating equipment; design of furnaces and cleaning of dirty scrap before use. Unification of small foundries in larger plants may provide funding to successfully abate TSP emissions. Financial support or assistance for pollution abatement by firms have had no impact so far. This is because such help has little effect on operating costs. In this context, a proposal for relocating iron foundries in new industrial areas seems to be immaterial if plants move without implementing acceptable abating options.