Commission Implementing Decision (EU) 2024/2974 of 29 November 2024 establishing the best available techniques (BAT) conclusions, under Directive 2010/75/EU of the European Parliament and of the Council on industrial emissions, for the smitheries and foundries industry (notified under document C(2024) 8322) (Text with EEA relevance)

Regulation (EC) No 1221/2009 establishes the European Union eco-management and audit scheme (EMAS), which is an example of an EMS consistent with this BAT.

The level of detail and the degree of formalisation of the EMS will generally be related to the nature, scale and complexity of the installation, and the range of environmental impacts it may have.

The level of detail and the degree of formalisation of the inventory will generally be related to the nature, scale and complexity of the plant, and the range of environmental impacts it may have.

The level of detail and degree of formalisation of the CMS will generally be related to the nature, scale and complexity of the plant.

The level of detail and degree of formalisation of the OTNOC management plan will generally be related to the nature, scale and complexity of the plant, and the range of environmental impacts it may have.

Monitoring preferentially includes direct measurements. Calculations or recording, e.g. using suitable meters or invoices, can also be used. The monitoring is broken down to the most appropriate level (e.g. to process or plant level) and considers any significant changes in the process or plant.

The applicability is restricted to cases where a noise and/or vibration nuisance at sensitive receptors is expected and/or has been substantiated.

A residues management plan is part of the EMS (see BAT 1) and comprises a set of measures aiming to:

1. minimise the generation of residues;

2. optimise the reuse, recycling and/or recovery of residues; and

3. ensure the proper disposal of waste.

The residues management plan may be integrated in the overall residues management plan of a larger installation (e.g. surface treatment activities).

The level of detail and the degree of formalisation of the residues management plan will generally be related to the nature, scale and complexity of the plant.

BAT 11. In order to prevent or reduce the use of hazardous substances and substances of very high concern in moulding and core-making with chemically bonded sand, BAT is to use alternative substances which are non- or less hazardous.

1.2.1.2.1. Monitoring of emissions to air

1.2.1.2.2. Monitoring of emissions to water

BAT 14. In order to increase energy efficiency, BAT is to use all of the techniques (a) to (f), and an appropriate combination of the techniques (g) to (n) given below.

Further sector-specific techniques to increase energy efficiency are given in Sections 1.2.2.1 and 1.2.4.1 of these BAT conclusions.

The associated monitoring is given in BAT 6.

1.2.1.4.1. Storage and handling of residues, packaging and unused process chemicals

1.2.1.4.2. Operational material efficiency in the casting process

1.2.1.4.3. Reduction of material consumption

1.2.1.4.4. Sand reuse

1.2.1.4.5. Reduction of generated residues and of waste sent for disposal

BAT 21. In order to prevent or, where that is not practicable, to reduce diffuse emissions to air, BAT is to use all of the techniques given below.

Further process-specific techniques to prevent or reduce diffuse emissions are given in BAT 24, BAT 26, BAT 27, BAT 28, BAT 29, BAT 30, BAT 31, BAT 38, BAT 39, BAT 40, BAT 41 and BAT 43.

BAT 22. In order to facilitate the recovery of materials and the reduction of channelled emissions to air, as well as to increase energy efficiency, BAT is to combine waste gas streams with similar characteristics, thus minimising the number of emission points.

BAT 23. In order to prevent or reduce emissions to air from metal melting, BAT is to use either electricity generated from fossil-free energy sources in combination with techniques (a) to (e), or techniques (a) to (e) and an appropriate combination of the techniques (f) to (i) given below.

The BAT-AELs for metal melting are given:

• in Table 1.18 for cast iron foundries;

• in Table 1.20 for steel foundries;

• in Table 1.22 for NFM foundries.

BAT 24. In order to prevent or reduce emissions to air from heat treatment, BAT is to use either electricity generated from fossil-free energy sources in combination with techniques (a) and (d), or all of the techniques given below.

The associated monitoring is given in BAT 12.

BAT 25. In order to prevent or reduce emissions to air from moulding using lost moulds and core-making, BAT is to:

• use an appropriate combination of the techniques (a) to (c) given below in the case of moulding with clay-bonded sand;

• use either technique (d), (e) or (f) and an appropriate combination of the techniques (g) to (k) given below, in the case of moulding and core-making with chemically bonded sand;

• use technique (l) given below for selecting the coatings applied to moulds and cores.

  	Technique	Description	Applicability
  Techniques for moulding with clay-bonded sand (green sand)
  a.	Use of best practices for green sand moulding	This includes techniques such as: precise addition of the required quantity of key components (e.g. clay, water, coal dust or other additives) to restore the chemical properties of the returned green sand; regular testing (e.g. daily) of the green sand properties (e.g. moisture, green strength, compactability, permeability, loss on ignition, volatile content).	Generally applicable.
  b.	Preparation of clay-bonded sand by vacuum mixing and cooling	Mixing and cooling processes are combined into a single process step by operating the sand mixer under reduced pressure, which results in cooling by the controlled vaporisation of the water.	Generally applicable.
  c.	Substitution of coal dust	Coal dust is replaced by additives such as graphite, coke flour and zeolites, resulting in significantly lower diffuse emissions during the casting process.	Applicability may be restricted by operational constraints (e.g. less efficient shake-out or occurrence of casting defects).
  Techniques for prevention of emissions in moulding and core-making with chemically bonded sand
  d.	Selection of a low-emission cold-setting binder system	A cold-setting binder system generating low emissions of formaldehyde, phenol, furfuryl alcohol, isocyanates, etc. is selected. This includes the use of: no-bake furan resins with low furfuryl alcohol content (e.g. less than 40 wt-%) for production of iron castings for example; no-bake phenol/furan systems with a low-sulphur acid catalyst for production of steel castings for example; aliphatic organic binders based for example on aliphatic polyalcohols (instead of aromatic organic binders) for production of iron, steel, aluminium or magnesium castings, etc.; inorganic geopolymers based on polysialates (for production of grey iron, aluminium and steel castings, etc.); ester silicate (for production of medium and large steel castings, etc.); alkyd oil (e.g. for single castings or small batch production in steel foundries); resol-ester (e.g. for lighter alloys in small or medium production); cement (for production of very large castings for example).	Applicability may be restricted due to product specifications.
  e.	Selection of a low-emission gas curing binder system	A gas curing binder system generating low emissions of amines, benzene, formaldehyde, phenol, isocyanates, etc. is selected. This includes the use of: inorganic binders, e.g. sodium silicate (water glass), hardened using CO2 or organic esters, for example in aluminium die-casting; inorganic geopolymers based on polysialates cured with CO2 (for production of grey iron, aluminium, steel castings, etc.); aliphatic organic binders based for example on aliphatic polyalcohols (instead of aromatic organic binders) for production of iron, steel, aluminium or magnesium castings, etc.; phenolic urethane binders with very low free phenol and formaldehyde content (for production of iron and steel castings, etc.); phenolic urethane binders with reduced amounts of solvents (for production of iron and steel castings, etc.).	Applicability may be restricted due to product specifications.
  f.	Selection of a low-emission hot-curing binder system	A hot-curing binder system generating low emissions of formaldehyde, phenol, furfuryl alcohol, benzene, isocyanates, etc. is selected. This includes the use of: inorganic binders such as geopolymers based on polysialates; inorganic binders cured using a warm-box process without phenol, formaldehyde and isocyanates (for preparing aluminium castings with complex shapes for example); aliphatic polyurethane warm box binders (used as an alternative to the cold box process).	Applicability may be restricted due to product specifications.
  General techniques for moulding and core-making with chemically bonded sand
  g.	Optimisation of binder and resin consumption	See Section 1.4.3.	Generally applicable.
  h.	Use of best practices for cold-setting processes	See Section 1.4.3.	Generally applicable.
  i.	Use of best practices for gas-hardening processes	See Section 1.4.3.	Generally applicable.
  j.	Use of non-aromatic solvents for cold-box core production	Non-aromatic solvents are used that are based either on protein or animal fat (e.g. fatty acid methyl esters of vegetable oil) or on silicate esters in order to reduce emissions of VOCs (e.g. benzene, toluene).	Generally applicable.
  k.	Use of best practices for hot-curing processes	Several hot-curing processes may be used and a series of measures are in place to optimise each process including for the following: Hot-box process: Curing is carried out within the optimum temperature range (e.g. 220 °C to 300 °C). Cores are usually precoated using water-based coatings to prevent burns at the core surface which may result in brittleness during pouring. Core blowers and the area around them are well ventilated and exhausted to capture the formaldehyde liberated during curing efficiently. Warm-box process: Curing is carried out at a lower optimum temperature range than the hot-box process (e.g. 150 °C to 190 °C), resulting in lower emissions and energy consumption than the hot-box process. Shell (Croning): Precoated sands with a phenol-formaldehyde resin are bound using hexamethylenetetramine that decomposes at 160 °C, releasing formaldehyde, necessary for cross-linking the resin, and ammonia. The curing and/or core blower area is well ventilated and exhausted to capture the ammonia and formaldehyde liberated during curing efficiently.	Generally applicable.
  Techniques related to the coatings applied to moulds and cores
  l.	Substitution of alcohol-based coatings with water-based coatings	See Section 1.4.3.	Applicability may be restricted in the case of large or complex casting shapes because of difficulties for circulation of the drying air. Not applicable to water glass-bonded sands, the magnesium casting process, vacuum moulding or the production of manganese steel castings with MgO coating.

BAT 26. In order to reduce emissions to air from moulding using lost moulds and core-making, BAT is to:

• use an appropriate combination of the techniques given in BAT 25;

• collect the emissions using technique (a);

• treat the off-gases using one or a combination of the techniques (b) to (f) given below.

  	Technique	Description	Applicability
  Collection of emissions
  a.	Extraction of emissions generated from moulding and/or core-making as close as possible to the emission source	See Section 1.4.3.	Applicability may be restricted in the case of moulding in cast iron and steel foundries producing large castings.
  Off-gas treatment
  b.	Fabric filter	See Section 1.4.3.	Generally applicable.
  c.	Wet scrubbing	See Section 1.4.3.	Generally applicable.
  d.	Adsorption	See Section 1.4.3.	Generally applicable.
  e.	Thermal oxidation	See Section 1.4.3.	Applicability may be restricted where the energy demand is excessive due to the low concentration of the compound(s) concerned in the process off-gases. Applicability of recuperative and regenerative thermal oxidation to existing plants may be restricted by design and/or operational constraints.
  f.	Catalytic oxidation	See Section 1.4.3.	Applicability may be restricted by the presence of catalyst poisons in the waste gases or where the energy demand is excessive due to the low concentration of the compound(s) concerned in the process off-gases.

  Table 1.8

  BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, amines, benzene, formaldehyde, phenol and TVOC from moulding using lost moulds and core-making

  Substance/Parameter	Unit	BAT-AEL (Daily average or average over the sampling period)
  Dust	mg/Nm3	1 – 5
  Amines		< 0,5 – 2,5 (1)
  Benzene		< 1 – 2 (2)
  Formaldehyde		< 1 – 2 (3)
  Phenol		< 1 – 2 (4)
  TVOC	mg C/Nm3	15 – 50 (5)

The associated monitoring is given in ΒΑΤ 12.

BAT 27. In order to reduce emissions to air from casting, cooling and shake-out processes in foundries using lost moulds including the full mould process, BAT is to:

• collect the emissions by using technique (a);

• treat the off-gases using one or a combination of the techniques (b) to (h) given below.

  Technique		Description	Applicability
  Collection of emissions
  a.	Extraction of emissions generated during the casting, cooling and shake-out processes as close as possible to the emission source	Emissions generated during the casting (especially emissions from pouring), cooling and shake-out processes are appropriately extracted. For the casting and cooling processes, this includes: restricting the pouring process to a fixed area or position to facilitate the capture of emissions using ventilators and enclosure (e.g. in serial pouring); enclosure of pouring and cooling lines. For the shake-out process, this includes: use of ventilator panels situated on both sides and at the rear of the shaker; use of enclosed units equipped with roof openings or removable covers (e.g. doghouse); installation of an extraction point situated underneath the shaker in the sand collection box.	Applicability may be restricted in the case of cast iron and steel foundries producing large castings.
  Off-gas treatment
  b.	Cyclone	See Section 1.4.3.	Generally applicable.
  c.	Fabric filter	See Section 1.4.3.	Generally applicable.
  d.	Wet scrubbing	See Section 1.4.3.	Generally applicable.
  e.	Adsorption	See Section 1.4.3.	Generally applicable.
  f.	Biofilter	The off-gas stream is passed through a bed of organic material (such as peat, heather, compost, root, tree bark, softwood and different combinations) or some inert material (such as clay, activated carbon, and polyurethane), where it is biologically oxidised by naturally occurring microorganisms into carbon dioxide, water, inorganic salts and biomass. The biofilter is sensitive to dust, high temperatures and high variations in the off-gas composition. Supplementary nutrient feeding may be needed.	Only applicable to the treatment of biodegradable compounds.
  g.	Thermal oxidation	See Section 1.4.3.	Applicability of recuperative and regenerative thermal oxidation to existing plants may be restricted by design and/or operational constraints. Applicability may be restricted where the energy demand is excessive due to the low concentration of the compound(s) concerned in the process off-gases
  h.	Catalytic oxidation	See Section 1.4.3.	Applicability may be restricted by the presence of catalyst poisons in the waste gases or where the energy demand is excessive due to the low concentration of the compound(s) concerned in the process off-gases.

  Table 1.9

  BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, benzene, formaldehyde, phenol and TVOC from casting, cooling and shake-out processes in foundries using lost moulds including the full mould process

  Substance/Parameter	Unit	BAT-AEL (Daily average or average over the sampling period)
  Dust	mg/Nm3	1 – 5
  Benzene		< 1 – 2 (1)
  Formaldehyde		< 1 – 2 (2)
  Phenol		< 1 – 2 (3)
  TVOC	mg C/Nm3	15 – 50 (4)

The associated monitoring is given in BAT 12.

BAT 28. In order to reduce dust and TVOC emissions to air from lost foam casting, BAT is to collect the emissions using technique (a) and to treat the off-gases by using an appropriate combination of the techniques (b) to (d) given below.

The associated monitoring is given in BAT 12.

BAT 29 In order to prevent or reduce emissions to air from the casting process in foundries using permanent moulds, BAT is to:

• prevent the generation of emissions by using one or a combination of the techniques (a) to (e);

• collect the emissions by using technique (f);

• treat the off-gases by using one or a combination of the techniques (g) to (j) given below.

  Technique		Description	Applicability
  Prevention of emissions
  a.	General techniques for gravity and low-pressure die-casting	This includes techniques such as selection of an appropriate lubricant to prevent castings surface defects; optimised lubricant preparation and application to avoid excessive use.	Generally applicable.
  b.	General techniques for high-pressure die-casting	This includes techniques such as: proper lubrication of the die and plungers using water-based emulsions of silicone oils, ester oils, synthetic waxes for example; minimisation of the release agent and water consumption by optimising the spraying process, e.g. use of micro-spraying for application of release agents (see also ΒΑΤ 17 (b)).
  c.	Optimisation of process parameters for centrifugal and continuous casting	In centrifugal casting, important process parameters such as mould rotation, pouring temperature and mould preheating temperature are optimised (e.g. using flow simulation) to reduce the number of defects and minimise emissions. In continuous casting, the casting rate, casting temperature and cooling rate are optimised to minimise emissions and reduce the amount of water consumed for cooling while reaching the required product specification.
  d.	Separate spraying of release agent and water in high-pressure die-casting	See Section 1.4.2.
  e.	Use of water-free release agents in high-pressure die-casting	Water-free release agents (e.g. in a powdered form) are applied to the die using electrostatic deposition.
  Collection of emissions
  f.	Extraction of emissions generated from the casting process as close as possible to the emission source	Emissions generated from the casting process including high-pressure/low-pressure/gravity die-casting, centrifugal and continuous casting are extracted using enclosures or extraction hoods.	Generally applicable.
  Off-gas treatment
  g.	Fabric filter	See Section 1.4.3.	Generally applicable.
  h.	Wet scrubbing	See Section 1.4.3.
  i.	Electrostatic precipitator	See Section 1.4.3.
  j.	Thermal oxidation	See Section 1.4.3.	Applicability of recuperative and regenerative thermal oxidation to existing plants may be restricted by design and/or operational constraints. Applicability may be restricted where the energy demand is excessive due to the low concentration of the compound(s) concerned in the process off-gases.

  Table 1.11

  BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust, TVOC and lead from the casting process in foundries using permanent moulds

  Substance/Parameter	Unit	BAT-AELs (Daily average or average over the sampling period)
  Dust	mg/Nm3	1 – 5
  Pb		0,05 – 0,1 (1)
  TVOC	mg C/Nm3	2 – 30 (2) (3)

The associated monitoring is given in BAT 12.

BAT 30. In order to reduce dust emissions to air from finishing, BAT is to collect the emissions using technique (a) and to treat the off-gases by using one or a combination of the techniques (b) to (d) given below.

The associated monitoring is given in BAT 12.

BAT 31. In order to reduce emissions to air from sand reuse, BAT is to:

• in the case of thermal sand regeneration, use either electricity generated from fossil-free energy sources or both of the techniques (a) and (b);

• collect the emissions using technique (c);

• treat the off-gases by using one or an appropriate combination of the techniques (d) to (g) given below.

  Technique		Description	Applicability
  Techniques for reducing the generation of emissions
  a.	Use of a fuel or a combination of fuels with low NOX formation potential	Fuels with a low NOX formation potential include natural gas and liquefied petroleum gas.	Applicable within the constraints associated with the availability of different types of fuel, which may be impacted by the energy policy of the Member State.
  b.	Use of a fuel or a combination of fuels with low sulphur content	Fuels with low sulphur content include natural gas and liquefied petroleum gas.	Applicable within the constraints associated with the availability of different types of fuel, which may be impacted by the energy policy of the Member State.
  Collection of emissions
  c.	Extraction of emissions generated from sand reuse as close as possible to the emission source	Emissions generated from sand reclamation are extracted using an enclosure or a hood for example. This includes extraction of the flue-gases generated from fluidised bed furnaces, rotary kilns or hearth furnaces, etc. used in thermal sand regeneration.	Generally applicable.
  Off-gas treatment
  d.	Cyclone	See Section 1.4.3.	Generally applicable.
  e.	Fabric filter	See Section 1.4.3.
  f.	Wet scrubbing	See Section 1.4.3.
  g.	Thermal oxidation	See Section 1.4.3.	Applicability of recuperative and regenerative thermal oxidation to existing plants may be restricted by design and/or operational constraints. Applicability may be restricted where the energy demand is excessive due to the low concentration of the compound(s) concerned in the process off-gases.

  Table 1.13

  BAT-associated emission levels (BAT-AELs) for channelled emissions to air of dust and TVOC from sand reuse

  Substance/Parameter	Unit	BAT-AEL (Daily average or average over the sampling period)
  Dust	mg/Nm3	1 – 5
  TVOC	mg C/Nm3	5 – 20 (1)

  Table 1.14

  BAT-associated emission levels (BAT-AELs) for channelled emissions to air of NOX and SO2 from sand reuse

  Substance/Parameter	Process	Unit	BAT-AEL (Daily average or average over the sampling period)
  NOx	Thermal regeneration of sand originating from the cold-box process	mg/Nm3	50 – 140
  SO2	Thermal regeneration of sand in which sulphonic acid catalysts have been used		10 – 100

The associated monitoring is given in BAT 12.

BAT 32. In order to prevent or, where that is not practicable, to reduce odour emissions, BAT is to set up, implement and regularly review an odour management plan, as part of the environmental management system (see BAT 1), that includes all of the following elements:

• A protocol containing appropriate actions and timelines.

• A protocol for conducting odour monitoring as set out in BAT 33. The protocol may be complemented by measurement/estimation of odour exposure or estimation of odour impact.

• A protocol for response to identified odour incidents, e.g. managing complaints and/or taking corrective actions.

• An odour prevention and reduction programme designed to identify the source(s); to measure/estimate odour exposure; to characterise the contributions of the sources; and to implement prevention and/or reduction measures.

BAT 33. BAT is to periodically perform odour monitoring.

BAT 34. In order to prevent or, where that is not practicable, to reduce odour emissions, BAT is to use all of the techniques given below.

BAT 35. In order to optimise water consumption and to reduce the volume of waste water generated as well as to improve water recyclability, BAT is to use both techniques (a) and (b), and an appropriate combination of the techniques (c) to (g) given below.

The associated monitoring is given in BAT 6.

BAT 36. In order to reduce emissions to water, BAT is to treat waste water using an appropriate combination of the techniques given below.

The associated monitoring is given in BAT 13.

The associated monitoring is given in BAT 13.

BAT 37. In order to increase energy efficiency in metal melting, BAT is to use an appropriate combination of the techniques given below.

The BAT-AEPLs for specific energy consumption are given in BAT 14.

1.2.2.2.1. Emissions to air from metal melting

1.2.2.2.2. Emissions to air from the nodularisation of cast iron

1.2.3.1.1. Emissions to air from metal melting

1.2.3.1.2. Emissions to air from steel refining

BAT 42. In order to increase energy efficiency in metal melting, BAT is to use one of the techniques given below.

The BAT-AEPLs for specific energy consumption are given in BAT 14.

1.2.4.2.1. Emissions to air from metal melting

BAT 44. It is not BAT to use chlorine gas for molten aluminium treatment (degassing/cleaning).

BAT 45. In order to prevent emissions of substances with a high global warming potential from the protection of molten metal in magnesium melting, BAT is to use oxidation control agents with a low global warming potential.

Vibration-reducing and insulating techniques for hammering equipment include the installation of vibration-damping components, e.g. layered elastomeric isolators or viscous spring isolators below the anvil, spring casings below the hammer foundation.

Only applicable to new plants and/or major plant upgrades.

BAT 50. In order to prevent or reduce diffuse emissions to air, BAT is to use both of the techniques given below.

BAT 51. In order to prevent or reduce NOX emissions to air from heating, reheating and heat treatment while limiting CO emissions, BAT is to use either electricity generated from fossil-free energy sources or an appropriate combination of the techniques given below.

The associated monitoring is given in BAT 48.