33RD National Foundry Convention.

Australian Foundry Institute

13-17 October 2002

TECHNICAL PAPER: ENVIRONMENTAL ODOUR MANAGEMENT.

Anotec Pty Ltd
 which has been shown to remove up to 95% of
ENVIRONMENTAL Foundry odours.
ODOUR
MANAGEMENT INTRODUCTION

Victoria Zavras and John Zavras Anotec Odour Control formulations have been
demonstrated to successfully reduce VOC
emissions from sand handling operations, and
Anotec Pty Limited abate odours from core room emissions in iron
casting foundries. Anotec Pty Limited
ABSTRACT proposed a project to integrate two
methodologies whereby odour emissions are
Industrial emissions to atmosphere have collected and then treated. The project was
always been a significant focus of undertaken at a few existing ferrous and non-
environmental regulation since the first Clean ferrous foundries to determine the economic
Air Act of Australia came into force. With feasibility and the effectiveness of the
current concerns about global warming, ozone proposed methodologies in reducing odours
depletion and the respiratory effects of fine and VOCs. The success of the Anotec Odour
particulates, air quality is a central feature of Control formulation for foundries has now
existing Australian legislation. been commercialised and used by foundries
and other industries with similar operations to
Over the last 12 years, Anotec Pty Limited has control VOCs and odours, a common
engaged in investigating and promoting a nuisance.
phased odour abatement program for clients to
proactively address odour concerns on a “step- ANOTEC ODOUR CONTROL –
by-step” basis. Anotec’s approach emphasises THE TECHNOLOGY BEHIND
a prioritisation scheme that promotes cost
management, optimises odour treatment THE TREATMENT
efficiencies, and takes advantage of new
technologies as they are proven and become A bulk of “odour neutralisers” currently
available. marketed has a high concentration of essential
oils. Anotec products are a surfactant induced
One such proven technology is the treatment absorption technology as evidenced from the
of malodours emanating from foundry GC/MS analysis conducted. This is in part
premises using scientifically formulated why the Anotec product is NOT a masking
Anotec odour control solutions as a direct agent as there is a REDUCTION in
result of examining emission sources within components present in odours. Some
the foundry namely cooling down after companies professing to be “odour control
pouring and the introduction of an Anotec specialists” and ''environmentally friendly'' are
odour profiling product as a liquid additive to using essential oils as a technology to treat
combat volatile emissions in binder resins. malodours. The use of essential oils is not
very environmentally friendly when you
Emissions from pouring are usually consider that trees need to be chopped down,
uncontrolled and usually low level in squeezing out the oil and using this oil to
concentration, and it is the purpose of this reduce odours at an industrial site.
paper to introduce the implementation of an
Anotec odour control formulation to be used These claims are old hypothetical technology
with a suitable device to assist in this area in a which results in the waste of natural resources,
cost effective and efficient manner. is extremely expensive and unreliable for
formulating purposes as essential oils have
The paper introduces Anotec Pty. Ltd. as an been proven to be impure, and on occasion of
odour control company that has developed a low quality and not reproducible.
scientifically proven, economical process

1
A cleaner more scientific approach is the use 1. The collection of fumes by enclosing the
of aroma chemicals and surfactant based emission source (in this case the moulds after
technology. The components in the mix are pouring), and sample collection of all of
reliable and all tests conducted by Anotec Pty foundry emissions (VOCs and other
Limited has revealed that there in no chemicals) by identifying the odour producing
''masking'' involved when using state-of-the- components within the complex odorous
art scientific instrumental and wet methods of mixture and then to measure their threshold
analysis. levels and concentration.

For example, if we look at rosemary oil, the 2. The above assists Anotec in providing a
chemical make up includes components such basis for calculating odour control alternatives
as geraniol, citronella and pine. Different after housekeeping and other pollution control
batches of oils from different parts of the methods have been assessed.
world have these components at different
concentrations. There is no consistency in the 3. At the time of testing there was no need to
raw product being used by formulators. determine the strength or presence of an odour
via olfactometric means as the project
Carbon chain lengths are important to organic undertaken by Anotec was community
molecules. The shorter the length of the chain, complaint driven.
the more volatile the molecule is. These
carbon chains are in a liquid dispersion. 4. Testing for the strength of the odours
recorded were not economically viable at the
The ability of a liquid to carry material in time and it was suggested that a trial of an
suspension is a function of minute electrical Anotec odour control formulation be assessed
charges. As the electro-negative charge for its removal efficiency once identification
increases, more material can be carried in and concentration levels of the VOCs and
suspension. As the charge decreases, the other chemicals emitted from the area were
particles move closer to each other and the determined. Anotec’s strong recommendation
liquid is able to carry less material. There is a was to trial an Anotec formulation developed
point where the ability to carry material in based on chemical fingerprinting of odour
suspension is exceeded, and particles begin to samples collected at each foundry.
clump together with the heavier particles
materials dropping out of the liquid and 5. Once the general composition of the
coagulating. foundry odours are established Anotec
conducted analytical tests using the odour
ANOTEC ODOUR CONTROL – control formulation derived from the chemical
fingerprint of the raw odours emitted.
FOUNDRIES
In the year 2000 Anotec adopted the
6. The objectives include determining the
BATNEEC Policy (Best Available
amount and kind of substance that could
Technology Not Entailing Excessive Costs) to
effectively reduce or eliminate the odours
ensure that its clients are secure in the
within a confined unit, the degree of dilution
knowledge that all goods and services
by ventilation or outside dispersal which
provided are effective, efficient and
would be needed to dilute a given odour from
economical.
a source, the amount or percentage of odorants
that must be removed from a space by
It should be noted that Anotec Pty Limited are
methods such as the application of an Anotec
the suppliers of Anotec Odour Control
Odour Control Product (OCPs, or 0307) or to
Products developed by examining scientific
lower the concentration of the odorants below
data extrapolated from chemical analysis of
the known perceptible threshold. Subjective
composition and concentration levels of
methods in determining the odours are
chemical constituents identified within an
important but unnecessary for Anotec to
odorous mix.
engage in formulating an odour control
solution. However, Anotec have suggested

2
that another form of subjective testing be used This is true for both qualitative and
by requesting that the residents located in the quantitative methods of odour analysis. The
vicinity of the foundry complete Odour composition of an odour can range from a
Diaries or contribute to an Odour Detection single chemical compound to a complex
Register. mixture of compounds. The components of the
odour will often dictate the method of
The points outlined above need to be sampling. Therefore, insight as to which
addressed with all foundries looking at viable compounds or type of compounds may be
odour mitigation programs and was contributing to the odour is desirable. Without
determined to be of benefit to Anotec and all this, a sampling method that can handle a
the parties involved and/or concerned about broad range of compounds would be
foundry odours as it gave a clear indication of necessary.
what is occurring at the foundry based on
analysis of the said foundry site rather than Several aspects should be considered when
relying on the results of tests conducted in choosing an appropriate sampling method. The
other foundries using other formulations. physical and chemical properties of the
odorant will often determine which sampling
ANOTEC ODOUR method is desirable. Some of these properties
are the polarity, volatility, and stability of the
ASSESSMENT chemical compounds associated with the
odour. To analyse the sample accurately, the
VOCs are not a category of substances but a
composition of the odorant(s) must remain
grouping of a wide range of organic chemical
intact during sample collection. Condensation,
compounds to simplify reporting when these
adsorption, or permeation of the odorous
are present in ambient air or emissions. Many
compounds through the walls of the collection
substances (eg natural gas) could strictly be
system can cause errors. For example, the
classified as VOCs, but the term is reserved to
boiling point of a chemical component in the
characterise the presence of substances in
odorous mix is
polluted air (i.e. the term generally refers to
109 0 C, which means it is a liquid at ambient
the vapours or gases given off by the
temperature. This physical property greatly
compounds rather than the liquid phase of the
influences the chemical component emissions
compounds).
and measurement. Elevated temperatures will
dramatically increase this component’s
Effective management of odorous emissions
emissions. When measuring compounds with
requires a systematic method for odour
high boiling points, it is important not to use
assessment and sampling. This can involve a
sampling techniques that allow the sample to
perceptual response method, an analytical
cool before it enters the analytical detector.
instrument approach, or a process that uses
elements of both approaches. Anotec usually
The ability to detect, identify, and quantify
recommends the latter. Regardless of how
odours from foundries (such as during the
specific odorants are determined (chemically
cooling down of casts after pouring) is an
or via perception), managing odorous
essential tool in the assessment of odours and
emissions and alleviating odour nuisance
in the development of prevention and
remains the desired end result of odour
mitigation treatments. If there is some
evaluations and assessments conducted.
correlation between the concentration of
odorants found by an analytical method and
The need for odour sample collection is most
the odour itself, then this tool is most useful.
likely to occur in the case of a well established
and continuing facility that has been unable to
Upon assessing foundries, it is generally
resolve odour emissions. In this case, the
understood that the major production
foundry operators sought an analytical
operations in the foundry are raw material
approach upon which to base a remediation
handling and preparation, metal melting,
program. The proper collection of air samples
mould & core production, and casting and
containing odorous compounds is essential for
finishing. Anotec have determined that there
accurate analysis of the source of the odour.
are potential odour sources in all these areas

3
(some quite visible). The significant requires the collection of raw odour samples.
contributor of odours at the test sites was the The raw odour samples were collected from
cooling down of the casting stage. directly above the casting line, not exceeding
one meter and in the plume of the gaseous
The assessment revealed that, ideally, fugitive emission.
emissions should be controlled by evacuation
through a retrofitted capture hood using a During the assessment and collection of raw
suppression technique such as an Anotec odour samples, it was determined that the
misting system/gas cleaner. Emissions emissions from the cooling moulds escalated
controlled by hoods and an evacuation in concentration levels between approximately
treatment system should then, ideally, be 25 – 45 minutes after pouring.
vented via a vent stack. The basic concept of
this suppression technique is to prevent the The Anotec formulation developed was based
formation of pollutants by excluding ambient on the “peak” concentration levels detected
air contact with the molten surfaces. The during raw odour sampling.
system was to be constructed with an
evacuated runner cover system and the local Once formulated, the Anotec odour control
hooding to be ducted via the said vent stack. solution was tested on-site. Raw Odour results
during the tests were also included to
VOC (Volatile Organic Compounds) determine the removal efficiency of the
emissions result from core baking and occur formulation based on the emissions on that day
during mould drying. Emissions from pouring and not on the emissions analysed for
consist of fumes, VOCs, and particulates from formulating purposes.
the mould and core materials when contacted
by the molten steel. As the mould cools, It should also be noted that the initial raw
emissions continue. odour samples were collected prior the
construction of an enclosure for the casting
As mentioned, emissions from pouring are line. It was also noted that the concentration
usually uncontrolled and usually low level in levels of the raw odour in the treatment
concentration, and it is the purpose of this assessment were somewhat higher due to lack
paper to introduce the implementation of an of dilution with the ambient air and
Anotec odour control device to assist in this confinement within the constructed enclosure.
area.
The application or testing unit was specially
The odour assessment conducted revealed the designed based on Anotec’s specifications to
need to emphasis that, ideally, all emission ensure that the Anotec formulation is
control techniques should involve an emission effectively applied in direct contact with the
capture system to ensure effective and malodorous emission. To save on the hardship
efficient treatment with the recommended of using literally hundreds of metres of
Anotec formulation and deodorising system. stainless steel pipe work, Anotec
recommended the use of this unit. The model
ODOUR TESTING & RESULTS available can hold up to ten nozzles. It
employs a multiple vane, positive
The initial step in assessing and formulating displacement pump which can have the
for an odour control solution involved the discharge pressure adjusted from 4 -14 bar.
collection of “raw odour” samples. The Elastomeric construction for pump, tank and
significance of the raw odour results is two- solenoid valve is Viton. The control system
fold. One, to determine whether the emissions incorporates a microprocessor with non-
from the casting line after pouring are posing a volatile memory in case of power failure. The
chemical, odour or both issue and two, to microprocessor programs were easily altered
formulate an odour control solution to on site by simply downloading from a laptop
significantly reduce or eliminate the computer the necessary program applicable to
concentration levels detected in the the testing site.
malodorous emission. Testing at all foundries

4
The Testing Unit
The unit is encased in a 2mm powder coated
steel weather, vermin and vandal proof
lockable enclosure. The suction lift of the
pump should not exceed 1.6 metres and the
static discharge head does not exceed 20
metres.
Microprocessor commands pump start.
The solenoid will open, releasing pressurised
liquid to nozzles
There is pressure relief by-pass that maintains
the system pressure while pump is operating.
The solenoid closes, pump turns off, and
pressure relief solenoid opens eliminating
spray line pressure allowing the control unit to
only operate when needed, reducing running
costs. In the case of power failure there is an
in-built battery backup to maintain program
integrity.
A programmable asymmetric recycler controls
the operation of a solenoid valve, which will
release an amount of Anotec 0307, determined
to most effectively neutralise the malodour, to
the spray nozzle.

The
Application / Testing Unit

The Application Nozzle

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 RAW ODOUR (MAJOR ODOUR CONTRIBUTORS)

Component 10 20 45
(ppb) minutes minutes minutes

2-butanone 389 326 802

acetone 22 38 95.4
benzene 1897 26432 14396
ethanol 81.7 26.9 598.4
hexane 87 103.1 311.9
m- and p-xylene 42.6 98.2 701
methanol 626 253.8 1954.5
methyl formate 192 1.6 1985.9
o-xylene 1.2 0.5 3.6
toluene 190.5 2185 4339

RAW ODOUR AND TREATMENT WITH ANOTEC FORMULATION

Component Raw Odour Treated Odour (ppb)

2-butanone 956.2 43
acetone 103.8 12
benzene 38349 400
ethanol 2585 53.3
hexane 412.5 49.5
m- and p-xylene 902.8 30
methanol 2385 93
methyl formate 1659.2 87
o-xylene 5.9 0
toluene 3862 39.2

The results show that the chemical determined for all foundries assessed during
components identified in all samples collected raw odour sampling. Having said this, the
of the odorous emissions from the casting line following should be noted:
are directly attributable to the chemical make-
up of the moulds. The concentration levels recorded where from
within the enclosure and were not indicative of
Initially, due to the extremely high the odours exiting the stack. Any fugitive
temperatures, any VOCs would have been odours escaping from the foundry are not
partially combusted yielding a low attributable to the casting line after treatment
concentration level at 10 minutes. Therefore, it but were directly linked to other processes
can be surmised that there are no obvious taking place within the foundry.
odours emanating from the casting line One nozzle was used in the trial to examine a
immediately after pouring has been completed. “worst case scenario” using the Anotec 0307
formulation and get a better understanding of
The results also show that the concentration the effects one nozzle would have on the stack
levels of the compounds identified were within emissions. The removal efficiency using
perceptible limits and are suitable for Anotec 0307 for foundry emissions is between
treatment using an Anotec odour control 80 -95%. Dispersion of emissions via the stack
formulation and that any toxic emissions are should be looked at further. This will also
not enduring and are below the acceptable have a significant affect on the emissions
threshold limit. The latter was also exiting the building (dilution). Anotec believe

6
that the trial was successful in reducing the
concentration levels of each of the components The Anotec formulation was applied via the
identified within the collection unit. misting system whereby it scrubbed the
That the results show that, logically, if was a malodorous air stream to render it non-
significant reduction in the chemical volatile, significantly reduced in intensity
components then it is safe to assume that the and/or eliminated.
chemical odours were also significantly
reduced. After treatment with the Anotec It is evident based on these results that Anotec
formulation, any emissions from the works by counteraction neutralisation, as
stack/ducts will not constitute an odour quoted from the Odour Control Waste Water
nuisance within the community. Further Facilities Manual of Practice No. 22
investigation may need to be conducted to "...Neutralisation by counteraction is achieved
design an odour management program for when no resultant odour, pleasant or
foundries that includes the successful unpleasant, is sensed." Anotec also utilises
collection of emissions from within the site for current techniques as discussed in the manual
effective and economical treatment via two or that was prepared by the Task Force on Odour
three exit points. Control under the direction of the Facilities
Fugitive odours are the main contributor to the Development Committee and Technical
odour complaints registered with local council Practice Committee.
or regulatory authorities. Once these issues
have been addressed Anotec believe that the Olfactometry conducted using Anotec
foundry industry will be in a better position to formulations on malodours has revealed that
assure the community of compliance with any there is no increase in raw odour units after
regulations pertaining to odour emissions. treatment and GC/MS analysis supports this as
Total time taken to conduct the project in each the chemical components of the odorous mix
foundry was approximately 3 – 5 hours. are significantly reduced.

Masking agents.

The concept of using perfumes to combat

odours is one that has been around for over
thirty years. However, aromatherapy, as it is
called, works very much the same as any
ordinary masking agent. That is, the product
relies heavily on its perfumes to disguise the
perception of a bad odour. In some instances
masking agents have been quite successful in
covering up malodours temporarily. The key
words here are “covering up” and
“temporarily”. Masking agents are not in
themselves harmful but are deemed by Anotec
as being ineffectual in industries where there
are high level concentration of odours and
continuous emissions.

There are applications for masking agents

within the community that have proven to be
quite successful. However these products are
suitable for intermittent and temporary odours.
Masking agents cover one smell with another.
As a result, they must be strong, and may be
Pouring and Sampling almost as objectionable as the foundry odour.
Masking agents are normally used as
vaporised material injected into the air.

7
Masking agents may be prohibitively ranging from a strong to weak variation of the
expensive if used for more than small amounts same product.
of waste. It should also be noted that the
organic chemical composition of most Testing during the trials at the foundries
masking agents makes them susceptible to showed that the chemical make up of most
degradation by the micro organisms emissions are virtually identical. However,
indigenous to manure. Therefore, the odour having said this, the concentration levels are
control capacity of most masking agents may what differed within each sample taken during
be too short lived for practical use in metal raw odour emission collection. Based on all
casting production environments. testing to date, Anotec envisage in the near
future, formulating an odour control product
Of interest during the trials was that the that will be suitable for ferrous and non-
inclusion of a volatile signature to the Anotec ferrous foundries respectively based solely on
formulation did not interfere with the overall raw odour analysis.
results. The Olfactometry conducted did not
show an increase in odour units when applied. The process works on emissions collected and
passed through an exhaust flue. A sample of
the emission is collected and a complete
The approach Anotec has taken towards chemical analysis done of its constituents. On
significantly reducing and/or eliminating the basis of this analysis, Anotec prepare an
odours from processes within the foundry Odour Control Product (OCP) which will react
industry is achievable, economical and most with the chemicals in the emission, reducing
importantly effective. It is definitely the more them to non-odorous, non-toxic residues. The
preferred approach to counteract the odour OCP is introduced into the exhaust stream via
problems when source control is not possible. an atomised spray. Analysis of the exhaust
The various ways to address the problem stream after treatment confirms the
includes facilitating ventilation, the use of effectiveness of the process.
Anotec’s odour control formulations and
effective collection of emissions. To date, The process has been conducted at several
Anotec’s odour control technology although Australian Foundries using portable dosing
quite sophisticated can be effortlessly equipment as well as existing and custom built
implemented without major changes taking equipment on-site. Emissions were collected
place within the foundry or any disruption to from moulding lines which used Phenolic
manufacturing. A variety of specially resin bonded sand. Treatment with Anotec
formulated Anotec products are available to OCP not only reduced the concentration of
dissociate the unique chemical components odour producing chemicals, but also had a
(i.e. the odour properties) in each type of similar effect on substances such as Benzene.
emission identified in various industries. The
usages of such specialised Anotec Anotec have adopted the BATNEEC Policy
formulations are quite common in industrial (Best Available Technology Not Entailing
and commercial applications since the sources Excessive Costs) to ensure that its clients
of odours are more diverse. receive goods and services that are effective,
efficient and economical.
CONCLUSION Anotec Pty.Ltd welcome the opportunity to
There is no such thing as “broad spectrum” discuss the scientific data supporting our claim
odour control. that Anotec odour control successfully treats
foundry malodours. Removal efficiency using
the Anotec Foundry Formulation is on average
Where odour control products are concerned,
> 90%.
it is virtually impossible to control all forms of
odours with the same product. This can only
be achieved if different dilutions of the same
As published and presented at the
product were to be made available – that is,
Australian Foundry Institute National
Convention 2002