ENVIRONMENT

BUSINESS: 327 PRACTICES


TOPIC:

Initiative

Investment in state-of-the art antipollution systems for steel strapping production.

Investment in state-of-the art antipollution systems for steel strapping production.
SUBMITTED FROM:

Μ.Ι.ΜΑΙΛΛΗΣ ΜΟΝΟΠΡΟΣΩΠΗ Α.Ε.Β.Ε

With over 40 years of operation, “Maillis Metals Solutions” is a major player in the European steel strapping business with the largest Vertical Integrated manufacturing facility in Europe. Offering a comprehensive product portfolio along with engineering support, we cover a wide spectrum of application requirements in more than 1200 customers worldwide.   

https://www.maillis.com/en/brands/maillis-metals-solutions



Objective Action

Investment and installation of state-of-the antipollution systems towards the reduction of air emissions and waste water, with a subsequent saving of natural resources. 

 

Target Audience

The program is addressed to the employees of the company but also to the external stakeholders (customers, partners, local community, control authorities) and confirms the company's commitment to the continuous improvement of its environmental management systems and performance, the protection of the environment and the pollution prevention.

 

Duration

The units were installed eight (8) years ago and are constantly being optimized.


Description

Company is highly environmentally conscious. A key investment for the plant at Inofyta, Greece, has been the installation of state-of-the art antipollution systems. These include new filters (trapping of dust particles on the surface of the bag filters with automatic calcium oxide injection system) in all four steel strap production lines combined with a regenerative thermal oxidizer (RTO) system, new dust filters in the two heat treatment lines and a new water treatment unit combined with two evaporators.  

Waste gases from four metal strap production lines after dry dedusting (bag filters), collected by pipeline and routed to the RTO (Regenerative Thermal Oxidiser) system. RTO is considered the most efficient technology for removing VOCs from gas streams. Operating at temperatures from 750 to 850 oC turning Volatile Organic Compounds (VOCs) in Carbon Dioxide and Water vapor. The use of combustion heat of the VOCs gives thermal efficiency of over 95%. This minimizes the requirement for fuel use, and in many cases the RTO operates auto thermally without any fuel.
The waste water facility installed in our plant is designed to treat waste water to the finest level of clean water. It contains a chemical pretreatment step selected to precipitate sulfates, heavy metals & bivalent metallic contaminants. The concentrated waste slurry is dewatered in a filter press to produce a 25-40% solids cake which is used as an additive to the bricks industry. The water with the residual solids flows to the microfiltration - reverse osmosis system and the produced permeate water with the low TDS content is used in our facilities. The concentrated salt solution from the reverse osmosis system goes to the evaporator system which creates a stream of clean distillate water for further usage and a stream of concentrated slurry for future disposal.

The environmental system has helped to reduce waste; in particular we have achieved a zero liquid waste system for the pickling process, minimum water consumption and air emissions much lower than the minimum acceptable limits of EU regulations. 


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Impact on Society

By using RTO equipment we reduced gas consumption by about 80% compared to the amount we would need to burn VOC’s, with a corresponding reduction in direct greenhouse gas emissions and at the same time eliminated the emission of Volatile Organic Compounds (VOCs).


 

 

We zeroed the disposal of treated liquid waste to the environment and at the same time saved over 300,000 m3 of pumped drilling water the last eight (8) years.



Initiative Location

Steel strap production factory at Inofyta Viotias, Greece.


Working with Organization

Cooperation with specialized partners and technical companies providing equipment for the treatment of liquid waste and air emissions.


Workers Participation

For the implementation of the program were participated the Engineers of the Technical Department as well as the technical team from Production and Environmental Management Departments.


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Benefits for Οrganization

The installation of the anti-pollution systems has contributed not only to the drastic reduction of the generated waste but also in minimizing the consumption of natural resources (e.g. water) using the minimum required energy.

Specifically:

Prior to the modernization of the wastewater treatment equipment, the maximum consumption of fresh water (drilling) for the needs of the production process amounted to 204 m3/d (67320 m3/y). After the completion of the system’s improvement, the treated water is recycled in the production process by 86%, resulting in the reduction of the pumped amount of water from the existing drilling by 44% (114 m3/ d).

The air emissions of the four steel strapping production lines enter the Regenerative Thermal Oxidizer (RTO) system with a VOCs concentration of approximately 1000 mg/Nm3 and exit with a concentration of <50mg/Nm3 (half hour average).




Connection with Global Goals







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