Bradken Kilburn SA 2006 Report

Anotec Pty Limited

Report: NR/6179 Odour Assessment

INTRODUCTION INTRODUCTION METEOROLOGICAL DATA ASSESSMENT METHODOLOGY OLFACTOMETRY ASSESSMENT METHODOLOGY OLFACTOMETRY PART 1 OFF -SITE ASSESSMENT (KILBURN & SURROUNDS) RESULTS SECTOR 8 SECTOR 7 SECTOR 6 SECTOR 5 SECTOR 4 SECTOR 3 SECTOR 2 SECTOR 1 PART 2 ON-SITE ASSESSMENT (BRADKEN PLANT KILBURN SA) RESULTS OBSERVATION & COMMENTS BRADKEN ON-SITE ASSESSMENT OBSERVATION & COMMENTS BRADKEN ON-SITE ASSESSMENT 17 MAY 2006 RECOMMENDATIONS CONCLUSION

2 2 5 6 7 8 14 14 16 18 20 22 25 28 30 32 34 34 35 35 41 45

Bradken Resources Pty Ltd Kilburn Plant (SA)

Bradken Ref: 21603

Anotec Pty Limited


INTRODUCTIONBradken Adelaide, Kilburn S.A (Bradken Resources Pty Ltd), herein referred to as Bradken is located at 80 Cromwell Road, Kilburn S.A. 5084.

Figure 1. Bradken Resources Pty Ltd, Kilburn Plant Location

Bradken commissioned Anotec Pty Limited (herein referred to as Anotec) to conduct an odour assessment using real-time olfactometry (The Nasal Ranger) to determine odour levels in and around Bradken and the Kilburn surrounds. Bradken is situated in a mixed industrial / residential area. Frontage to the property is Cromwell Road. South of Bradken, on Cromwell Road and directly opposite is a large oval and the South Australian Canine Association. North of Bradken is a council depot. There are various factories operating in and around Blackburn Rd and Inwood Avenue. The purpose of this report is to assess and report on any odours that emanate from the Bradken plant and their impact on the community. Assessment is divided into two (2) parts. Part 1 being Off-Site (also referred to as surrounds) and Part 2 being On-Site (also referred to as Bradken). The first part was


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conducted up to a 2 kilometre radius of the plant. Sampling locations are indicated below. The area assessed was divided into 8 (eight) sectors and each sector is represented as a coloured sphere.

Figure 2. Off Site Sampling Locations

Eight sectors were then assessed a total of three times and divided into sections for reporting purposes. That is: Section 1 refers to sampling conducted between 6.30 am 10.45 am Section 2 refers to sampling conducted between 2.40 6.25 pm Section 3 refers to sampling conducted between 8.30 pm 12.30 am All sampling was conducted downwind. Although there were a large number of sampling points, light traffic conditions assured that each sector was adequately assessed before moving on.


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The second part was conducted at the Bradken site shown below.

Figure 3. Onsite Sampling Locations

Bradken seem genuinely committed in reducing and/or eliminating any odours from their day to day operations. It was clear on the day of the assessment that Bradken are in the midst of making improvements to the site by way of upgrading buildings and equipment. Assessment of Bradken and Surrounds was conducted 17 & 18 May 2006 Representative(s) present on day: Bradken Kilburn Plant Mr. John Farden..(08) 8262 7378 Anotec Pty Limited Mrs. Victoria Zavras .. (02) 9700 1222


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METEOROLOGICAL DATARainfall Week ending 17 May 2006


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Weather Conditions 5 am Station Temp(0C) Humidity (%) 50 60 Wind Direction NE S Wind Speed (km/h) 7 Calm Wind Pressure Rainfall Gust (hPa) (mm) (km/h) 7 1027.5 0.0 Calm 1027.4 0.00

Adelaide 11 Airport Parafield 9 Airport

10.30 am Station Temp(0C) Humidity (%) 55 73 Wind Wind Direction Speed (km/h) N 11 SW 6 Wind Pressure Rainfall Gust (hPa) (mm) (km/h) 11 1027.5 0.0 6 1027.4 0.00

Adelaide 15.6 Airport Parafield 13.9 Airport

The weather for Adelaide was fine with some high cloud, mild with light winds. UV Index: 3 [Moderate]


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ASSESSMENT METHODOLOGY OLFACTOMETRY

The Nasal Ranger Field Olfactometer, a nasal organoleptic instrument, directly measures and quantifies odour strength in the ambient air using the Operating Principle of mixing odorous ambient air with odour-free filtered air in discrete volume ratios. The discrete volume ratios are called Dilution-to-Threshold ratios (D/T ratios). Field olfactometry is a cost effective means to quantify odour strength in terms of Dilution-to-Threshold (D/T) ratios. To date, Anotec believe this is the most effective and accurate instrument that can confidently measure odour strength at specific locations around a facilitys property line and within the community real time. 1Odour filter for odour-free dilution air Nasal Mask

Figure 5. The Nasal Ranger Figure 4. Dilution to Threshold Dial

1

Information from Operations Manual Nasal Ranger (St. Croix Sensory 2005)


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Anotec Pty Limited


Part 1 Off-Site Assessment (Kilburn & Surrounds)


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In order to get a clearer indication of whether Bradken is the major contributor to any odour issues in the Kilburn area, Anotec conducted field olfactometry analysis in streets (i) enroute to Cromwell Rd (Bradken); and (ii) in predetermined areas plotted to encompass up to a 2 km radius from Bradken. Sampling Locations (working from farthest point away from Bradken)

Sector 8 (up to 1.5 km radius) Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Location Acorn Rd White & Kenworth Grand Junction Whittington Darlington Leslie Hazel Forrest Deakin Audrey Trigg Manuel Hopetoun (Prospect end) Hopetoun (Churchill end) Naweena Pambula Myuna Indama Rosberg Churchill (north


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Report: NR/6179 Odour Assessment Sector 7 (up to 1 km radius) Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Location Acorn (Cavan end) Waldaree Grand Junction Preston Sheffield Marmion Sylvia Lionel Hughes Stone Gladstone Brooklyn Gladstone (near Churchill) Naweena Streiff

Sector 6 (up to 800 m radius) Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Location Churchill Baulderstone Prospect Dover Crawford Anson Marmion Houston Leslie Lionel Denver Way Carroll Garland Hawkesbury Streiff


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Report: NR/6179 Odour Assessment Sector 5 (up to 700 m radius) Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Location Rumble Commercial Baulderstone Prospect Dover Anson Marmion Houston Leslie Lionel Denver Brooklyn Carroll Garland Hawkesbury Streiff

Sector 4 (up to 600 m radius) Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Location Churchill Baulderstone Cambridge Anson Tudor Lorne Owen Brunswick Severn Dee William Albert George Bank Garland Grand Junction Churchill (dead end)


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Report: NR/6179 Odour Assessment Sector 3 (up to 500 m radius) Sample 1 2 3 4 5 6 7 8 9 10 11 Location Grand Junction Prospect Cromwell Solent Nelson Goodman Stevens Breynard Goodman Churchill Mill

Sector 2 (up to 300 m radius) Sample 1 2 3 4 5 6 7 Location Mill Marmion Nelson Stevens Montgomery Cromwell Inwood

Sector 1 (up to 100 m radius) Sample 1 2 3 Location Blackburn Foote Cromwell


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The following pages show odour units (D/T) recorded and documented for the mentioned Sectors. The graphs compare each Section (time of sampling) within each sector. Included on the graphs is a blue segmented line:

This line represents 7 OU (D/T). Results (OU D/T) plotted on the line means that there is a potential for an odour nuisance in that area. Any result plotted above this line means that odour nuisance / annoyance exist in that area.

Results registering 4 OU means that the odour is within perceptible range and the alleged offender should be addressing this as soon as possible. Anotecs experience has been that areas with a 4 OU (D/T) do not generally report an odour but are aware of it and can live with it. 2 OU D/T in any given area means that there are no reportable odours in that area and can be deemed as background. 15 OU (D/T) and above is meant to alert the operator or alleged contributor to any odours that odour mitigation measure must be put in place as soon as possible. 30 OU and 60 OU require odour control immediately as these values will prompt odour complaints.


Bradken Ref: 21603

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ResultsSector 8Location Acorn White Grand Junction Whittington Darlington Leslie Hazel Forrest Deakin Audrey Trigg Manuel Hopetoun Hopetoun Naweena Pambula Myuna Indama Rosberg Churchill Section 1(6.30 am 10.45 am)

Section 2(2.40 pm 6.25 pm)

Section 3(8.30 pm -12.30 am)

OU (D/T) 4 2 4 2 4 4 2 1 2 2 1 1 2 1 4 4 2 7 7 2

OU (D/T) 4 2 4 2 4 4 2 1 2 2 1 1 2 1 4 4 2 7 7 2

OU (D/T) 4 2 2 2 4 2 2 2 2 1 1 1 1 1 2 4 2 7 4 2

Sector 8 - Odour Assessment (Kilburn Surrounds)8

7

6

Odour Units (D/T)

5 Section 1 Section 2 Section 3

4

3

2

1

0W G ra hi te nd Ju nc tio W n hi tti ng to n Da r li ng to n Le sl ie Tr ig g M an ue l Ho pe to un Ho pe to un N aw ee na Pa m bu la M yu na In da m a Ro sb er g Ch ur ch ill Ha ze l Fo rre st D ea kin Au dr ey Ac or n

Sampling Location


Bradken Ref: 21603

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Observation & Comments: Sector 8

Sector 8 was observed to have a predominantly waste or putrescibles waste type odour. There were no foundry-like odours identified in this area. Depicted above are the areas that recorded 7 OU (D/T) that Anotec believe are not as a result of Bradken operations. Naweena Road, approximately 1.3 km west of Bradken, had a hot metal and molten plastic odour detected. Anotec do not believe that the odours detected are from Bradken. The wind was blowing from a predominantly north easterly direction which indicates that there is the possibility of an odour contributor north east of Indama St and Rosberg Rd. Sector 8, as assessed in three sections, reveals that Bradken is not a contributor to any odours in this area and that the odours detected are lingering and reminiscent of a waste depot or landfill-type operation.


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Sector 5Location Rumble Commercial Baulderstone Prospect Dover Anson Marmion Houston Leslie Lionel Denver Brooklyn Carroll Garland Hawkesbury Streiff Section 1(6.30 am 10.45 am)


Section 3(8.30 pm -12.30 am)

OU (D/T) 7 4 4 7 7 4 2 2 1 1 1 1 1 1 1 4

OU (D/T) 7 4 4 4 7 2 1 2 1 1 1 1 1 1 1 7

OU (D/T) 7 4 4 4 4 2 1 2 1 1 1 1 1 1 1 4


7

6

Odour Units (D/T)


4

3

2

1

0Ru m bl e Co m m er ci al Ba ul de rs to ne Pr os pe ct Br oo kly n Ho us to n ro ll G ar la nd An so n Li on el De nv er Do ve r ar m io n Le sli e ry Ha wk es bu Ca r St re iff

M

Sampling Location


Bradken Ref: 21603

Anotec Pty Limited



Sector 5 was very much like Sector 6 in that odours were predominantly those of waste handling activities and a hot metallic odour. Any potential for odour in this Sector, Anotec believe, is not attributable to Bradken and Anotec recommend that further studies in this area be conducted or considered. The sampling locations Anotec believe should be further assessed as Rumble Rd, Prospect Rd and Dover St. These areas have a lingering odour that does not seem to dissipate. This could mean that the odours pool there all the time and the community are desensitised or it could mean that there is a continual odour source that deposits the odours in those areas. In any case, further investigation is recommended. It is Anotecs opinion that Bradken do not have an odour impact in areas assessed for Sector 5.


Bradken Ref: 21603

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Sector 4Location Churchill Baulderstone Cambridge Anson Tudor Lorne Owen Brunswick Severn Dee William Albert George Bank Garland Grand Junction Churchill Section 1(6.30 am 10.45 am)


Section 3(8.30 pm -12.30 am)

OU (D/T) 7 4 7 7 4 4 2 4 4 2 4 4 2 4 4 7 7

OU (D/T) 4 2 4 4 2 2 1 1 1 1 2 2 1 2 2 7 4

OU (D/T) 4 2 4 4 2 2 1 1 1 1 2 2 1 2 2 4 7


7

6

Odour Units (D/T)


4

3

2

1

0Tu do r O we n Br un sw ick Ba nk Ch ur ch Ba ill ul de rs to ne Ca m br id ge G ar la nd n Ch ur ch ill An so n ne W illi am er t G eo rg e Se ve rn De e Ju nc tio Lo r Al b

Sampling Locations


G ra nd

Bradken Ref: 21603

Anotec Pty Limited


Observation & Comments: Sector 4 - PART 1

North West and North East of Bradken in Sector 4 we found that the odours were predominantly those of waste and hot metal type not associated with the Bradken plant. When assessing these odours we must take into account the wind direction and speed as the results thus far show that high level odours detected North West, north and north east of Bradken originate from that direction as the wind was blowing from the North. The following page shows the Sampling Locations in Sector 4, south of the Bradken site.


Bradken Ref: 21603

Anotec Pty Limited


Observation & Comments: Sector 4 PART 2

As we moved south of Bradken the farthest point being approximately 700 metres from Bradken, Anotec detected odours reminiscent of a foundry, and believe these originated from the Bradken Plant. Levels detected were between 2 and 4 OU (D/T) in all Sections of the Sector assessed. Anotec believe that residents and the community alike would easily associate these odours with Bradken. The levels recorded, in Anotecs opinion, do not constitute an odour nuisance but are within perceptible and identifiable range which may affect sensitive people in the area. Therefore, when there is a northerly wind, we believe that odours from Bradken may start to be perceived or recognised in areas to the south, south west and south east of the plant.


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Sector 3Location Grand Junction Prospect Cromwell Solent Nelson Goodman Stevens Breynard Goodman Churchill Mill Section 1(6.30 am 10.45 am)


Section 3(8.30 pm -12.30 am)

OU (D/T) 15 15 7 4 7 7 7 4 4 4 7

OU (D/T) 7 15 7 2 4 7 7 2 2 4 4

OU (D/T) 7 7 7 2 4 7 7 2 2 4 4


14

12

Odour Units (D/T)


8

6

4

2

0 Grand Junction Prospect Cromwell Solent Nelson Goodman Stevens Breynard Goodman Churchill Mill

Sampling Locations


Bradken Ref: 21603

Anotec Pty Limited



Sector 3 confirms the findings of the preceding Sectors assessed. Odours to the north of Bradken do not seem to be originating from the Bradken plant. This is due mainly to the metallic and waste (compost?) type odours detected in these sampling locations. When compared to the other Sectors we see that the odour levels (D/T) get weaker as we get close to the Bradken Site. Of concern is Grand Junction Road where the levels reached 15 OU (D/T) and the absence of any foundry odours. Admittedly there was a characteristic metal like odour. However, the metal type smell was not reminiscent of the Bradken site and leads Anotec to believe that there may be other foundries or business that deals with metal work.


Bradken Ref: 21603

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As we got closer to Bradken, odours were easily recognised as being from the foundry and the levels in OU (D/T) increased. In the areas marked above for Sector 3, the levels detected are interpreted as being within the potential to create an odour nuisance. This means that the odours may be perceived and reported upon. Assessment during the Sections within the Sectors also revealed that the odours may be transient and recurring based on Bradkens activities and wind direction. Odours in this area should be addressed as soon as possible.


Bradken Ref: 21603

Anotec Pty Limited


Sector 2

Location Mill Marmion Nelson Stevens Montgomery Cromwell Inwood

Section 1(6.30 am 10.45 am)


Section 3(8.30 pm -12.30 am)

OU (D/T) 4 7 7 7 7 10 7

OU (D/T) 4 15 7 7 4 7 7

OU (D/T) 1 7 4 4 4 7 4


14

12

Odour Units (D/T)


8

6

4

2

0 Mill Marmion Nelson Stevens Sampling Locations Montgomery Cromwell Inwood


Bradken Ref: 21603

Anotec Pty Limited



Sector 2 assessment revealed that the odours seem to be coming from the Bradken plant. Of interest was a peculiar plastic type smell at Inwood Avenue. The plastic smell could be detected in addition to the Bradken odours in Cromwell Rd and Montgomery Rd. Overall, Anotec believe that the odours detected in Sector 2 are easily identifiable as being from Bradken. Having said this, further investigation is recommended to trace or identify the source of the plastic type odour in the areas mentioned. There was some confusion with Sector 2 as there was also another unidentified source of odour the smell can best be described as hot metal and not those Anotec usually associates with foundry operations. Again, it may be pertinent to seek out the source of this odour. As a suggestion, Anotec believe that if there is another contributor to odours in the area identified as Sector 2, it may be having an additive effect on whatever is being emitted from Bradken maybe enhancing or exacerbating the odours confusing the observer in incorrectly identifying Bradken as the sole contributor.


Bradken Ref: 21603

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Sector 1

Location Blackburn Foote Cromwell

Section 1(6.30 am 10.45 am)


Section 3(8.30 pm -12.30 am)

OU (D/T) 15 15 15

OU (D/T) 15 7 15

OU (D/T) 7 7 15


14

12

Odour Units (D/T)


8

6

4

2

0 Blackburn Foote Sampling Locations Cromwell


Bradken Ref: 21603

Anotec Pty Limited



It is clear from the assessment conducted in Sector 1 for all Sections that the odour detected are identified as Bradken odours. Once again, Anotec detected a faint plastic type odour along with the Bradken foundry smells. It is clear from the levels detected that odours from Bradken must be addressed to prevent odour annoyance in and around the site. It is recommended that the source of the plastic type odour also be investigated at is seems to be having a cumulative effect on odours perceived in the area. The odours were quite strong along Cromwell Rd and of interest were that they were detected in approximately 20 minute intervals. This leads Anotec to believe that the odours here dissipate quite quickly and there is no pooling of odours in the area. In light of this, Anotec feel that there may be numerous odour complaints from the one area due to the transient yet continual nature of the odour emissions from the site in Cromwell Road.


Bradken Ref: 21603

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Part 2 On-Site Assessment (Bradken Plant Kilburn SA)


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On-Site evaluation involved an initial walk-through where Mr. Farden pointed out and identified what he perceived to be Bradkens principle odour sources. Prior to turning into Cromwell Road from Churchill Road, Anotec noted that the area seemed hazy. Travelling along Cromwell Road Anotec observed and recorded a distinctive foundry odour along Cromwell Road leading up to the main gate of the Bradken premises. Directly opposite Bradken, on Cromwell Road is a large oval and what is identified as the South Australian Canine Association. The assessment in this part includes sampling locations along Cromwell Road to include the oval and SA Canine Association (SACA), Nelson St (and cul-desacs), Marmion Avenue (over the fence line, west of the site, outside Residence Number 114) and outside Residence Number 65 in Tyne Avenue. Areas on-site assessed with the Nasal Ranger are indicated below:

The shaded area was not assessed.


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Sample 1 2 3 4 5 6 7 8 9 10 11 12 13

Location Scrap handling Area Furnace Pouring Floor Sand Stockpile Area Knock-Out Area Outside Knock-Out Area 1 Outside Knock-Out Area 2 Outside Aftercast Area Inside Aftercast Area 1 Inside Aftercast Area 2 Outside Main Office Building Bradken Car Parking Area Cromwell Rd, SA Canine Assoc.

Results**Sampling was conducted in duplicate no less than 15 minutes apart.

Odour Assessment - On Site: Bradken Kilburn SA70

60

50 Odour Units (D/T)

40

Samples 7 OU

30

20

10

0


1 -O ut Ar id ea e 2 Af te rc In as si d tA e re Af a te rc as In tA si d re e a Af O 1 te ut rc si as de tA M re ai n a O 2 ffi Br ce ad ke Bu n ild C in ar g Pa rk in C g ro Ar m ea we ll R d (S AC A) O ut sSampling Locations

Sa nd Kn oc k

Ar ea

Ar ea

Fl oo r

Ha nd lin g

Fu rn ac e

Po ur in g

Sp en t

O

Sc r

Kn oc k

ap

ut Ar ea

Bradken Ref: 21603

Anotec Pty Limited


Observation & Comments Bradken On-Site Assessment 17 May 2006In order to better understand the odour situation at Bradken, Bradken personnel made known to Anotec previous odour assessment undertaken by the SA EPA in 2005 after Anotec completed their assessment. The comments regarding the findings of 17 May 2006 show that Bradken have make significant improvements at the site that have resulted in reduced odour levels. However, the odour levels detected and reported upon also show that Bradken still have work to do in further reducing their odour emissions to achieve their goal of being a good neighbour. Although most of the areas assessed have the potential to create an odour nuisance, Anotec will try and explain the relationship between the on-site results and the off site results. Unlike the off site assessment, we need to discuss each area assessed onsite as part of a whole as each process taking place within the Bradken site has a direct impact on the sampling location assessed. We cannot simply take the results from one area and proceed to plan a treatment as the area assessed is impacted upon by whatever is taking place in the vicinity. Hopefully, Anotec will make this statement clearer as the report progresses. Anotec noted that the Scrap Handling area immediately outside of the furnace area had a high odour level registering 15 OU (D/T). The same odour was detected immediately outside the premises on Cromwell Road, all the way toward Churchill Road (note: there was a north easterly wind blowing). Anotec firmly believes that odours perceived in Cromwell Rd, including the SACA are from this area. It is noted that previous assessment by the SA EPA recorded between 60 and 30 OU (D/T). Anotec believe that the reduction in odour levels at the SACA and Cromwell Rd (from 30 & 60 OU to 7 & 10 OU) is due to the significant upgrade to the process in cooling of the moulds after pour. An exciting development at Bradken is the inclusion of an air curtain that Anotec believe Bradken installed as a capture technology whereby emissions from the cooling moulds are contained within a defined area preventing odour travelling throughout the premises. In Anotecs opinion, what may have happened prior to the inclusion of the air curtain is that emissions from the cooling moulds would travel throughout the building, either exit via various points of egress in the building and / or combine with fumes and odorous emissions from the furnace and exit the roller door. The following diagram may help in explaining this:


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The Cooling of MouldsThe following diagrams are illustrative and indicative only.

Figure 6. (Assumed) BEFORE Air Curtain capture technology

Figure 7. (Assumed) AFTER inclusion of Air Curtain as capture technology

Prior to the air curtain, odorous fumes would travel freely and create an additive effect with fumes and emissions from other operations to create the extremely high odour levels detected off-site by the SA EPA. Anotec believe that the above is a viable explanation to why there is a significant reduction of odours in Cromwell Road and its surrounds.


Bradken Ref: 21603

Anotec Pty Limited


Of significance and importance is that Anotec personnel present on 17 May 2006 personally experienced the effectiveness of the said air curtain. Anotec have been assessing foundries for over 11 years and have never come across an air curtain such as the one at Bradken (Kilburn). The results when sampling inside the air curtain and outside of the air curtain are quite astounding. Anotec believe that this is an exciting, innovative and effective capture technology when addressing certain areas within a foundry. Of course, Anotec are not privy to the costs involved in such technology and we encourage further exploration of air curtains and their possible inclusion in successfully addressing odours from foundries. Results: Sampling Location Outside Cooling mould area (Air curtain ON) Inside Cooling mould area (Air Curtain ON) Outside Within vicinity of Stacks Odour Units (D/T) 15 60 7

The air-curtain is invisible. The cooling moulds are visible and it is only when we pass through the air curtain that we can appreciate the significant reduction of any odours.

60 OU

15 OU

The cooling area is also fitted with an extraction fan extracting the volatile fumes via three stacks exiting the building. Levels detected outside the building in the vicinity of the stacks was 7 OU (D/T). This means that the air curtain in combination with the extraction system and stacks removes >80% of odours in this area


Bradken Ref: 21603

Anotec Pty Limited


The Furnace Heavy plumes were observed escaping the building and into the scrap handling area this has a direct impact on odours perceived outside. The Furnace area is currently under review and upgrading has already started. Construction of an exhaust system is underway photographs were not taken as the construction is not finalised. Anotec believe that once the system is operational fumes and odours from the furnace area will be significantly reduced if not eliminated. This is a significant project and Anotec are interested in seeing the finished installation. It is Anotecs opinion that inclusion of such an exhaust fan will successfully control odours in this area and the necessity of any add-on odour control technology should be considered as a final resort and/or tertiary treatment to any emissions that may pose an odour issue via any stacks to atmosphere. The latter should only be considered once items such as fan capacity, stack height etc have been fully explored and exhausted.

Figure 8. Fumes from the Furnace travel through the open roller door. It is expected that the new exhaust system will successfully capture and disperse these emissions.


Bradken Ref: 21603

Anotec Pty Limited


Aftercast (dressing) Area This area was the one of most concern when addressing the odours inside the building. The levels were >60 OU (D/T). It was noted that all Bradken personnel working in this area adhere quite strictly to PPE requirements. There are atomising nozzles installed along the ceiling / roof line for cooling purposes. Some nozzles were dripping. Anotec suggests that the configuration and positioning of these nozzles be reviewed. The entire area is smoky and hazy and it is reported that this area can get quite hot in the summer or warmer months.

Figure 9. Aftercast / Dressing area. Highest odour levels onsite

The Aftercast or dressing area is within an enclosed building. Although the odour levels were extremely high, levels detected immediately outside were logged in at 15 OU (D/T). This in itself is interesting as there was a metal mantle cooling down outside that could have contributed to the 15 OU (D/T) detected. This leads Anotec to believe that the Aftercast areas nozzle system is successful in cooling down the indoor atmosphere and any odours detected outside are purely fugitive from various exit points in the building. There are three obviously new stacks installed that seem to be effectively dispersing any of the fumes collected within the building to atmosphere. Odours detected by Anotec in the outside area (Sample 8) seemed to be mainly ground level odours (fugitives). Knock Out AreaBradken Resources Pty Ltd Kilburn Plant (SA) Bradken Ref: 21603

Anotec Pty Limited


Knock out activities are conducted directly next to the air-curtained cooling moulds. Visible dust and fumes were observed whilst knocking out. The levels detected here ranged between 7 and 15 OU (D/T). This is interesting in itself as it proves that if cooling of the moulds was conducted outside or near knock out without treatment we would expect the levels to be much higher. The odours from this area are not particularly offensive but can become annoying if exposed for prolonged periods of time. Depending on which way the wind was blowing the fumes would travel along that direction. The knock out area will need review to consider the design of an effective capture technology or treatment to suppress the dust and fumes. There is medium vehicular activity in the area that stirs up dust adding to any odours from the knock out activity. During the assessment Anotec noted that Bradken regularly and frequently utilise a mobile sweeper that suppressed the majority of dust emissions in the area.

Figure 10. Knock out area. Levels of odour were not as high as expected - mainly due to air curtained cooling moulds


Bradken Ref: 21603

Anotec Pty Limited


Identified Hot Spots

These areas, outside, registered 15 OU (D/T) and have the potential to create an odour nuisance in the immediate area outside of the Bradken site.


Bradken Ref: 21603

Anotec Pty Limited


RecommendationsBased on this odour assessment, Anotec believe that Bradken are well on the way to successfully mitigating an odour issues at their Kilburn plant. Most of the odours detected and reported upon are from fugitive sources. Following are Anotecs suggestions and recommendations for areas we believe are directly impacting on odours perceived off site. The furnace area In Anotecs opinion, once the furnaces exhaust system is fully operational, Bradken will not have the level of odours detected at this time. Anotec do not recommend any added technology for this area up until such time that the extraction system is operational and has been assessed for efficacy. It is also Anotecs opinion that the Scrap handling area will no longer pose an odour nuisance issue once the fumes and odours from the furnace are effectively captured and dispersed via ducting and stacks. Having said this, the scrap handling area, due to medium level vehicular activity will stir up dust and fumes that may pose a low level odour issue in the future. It may be worth considering the installation of a perimeter spraying system or similar such as an oscillating fan or hollow bladed fans at the inside boundary of Cromwell Rd to suppress dust and fumes in the future. Conceptual Drawing indicative only

Oscillating Fan


Bradken Ref: 21603

Anotec Pty Limited


The Knock Out Area This area can be further improved by considering the use of vehicle mounted dust & odour suppressing units. The units can be designed to fit on the vehicle and activate when dust & odour creating activities take place. One disadvantage with this may be ensuring that the suppression technique does not cause wetting. Anotec will further investigate the possibility of using air assisted nozzles for this area. Another way to keep dust and fumes in the area for source control is to increase the height of the back wall. Currently there is a mound there. This may also assist with noise levels from the area. Increasing the height of any fences or boundary walls will assist in lessening any visual impact, act as a wind break preventing dust travelling next door, as a noise & odour barrier.


Bradken Ref: 21603

Anotec Pty Limited


Cooling Moulds It has been relayed to Anotec that Bradken is in the process of upgrading and refurbishing the whole site. Overall, Bradken seem to be succeeding in addressing the most important areas for odour and dust. The area where the cooling moulds are placed seems to be a new extension t the original building. Any odour control, if necessary would be positioned to treat extracted air from this area. What was not taken into consideration at the time and Anotec may have missed it, was whether the crane in the building has access to the new extension the reason we mention this is because Anotec did not see the method used to transfer the cooling moulds into the new extension. If the moulds are transferred via forklift there will be temporary odours in the area until all moulds have been transferred (unless they are immediately moved upon pouring). In the event that the latter is the case, and, if not already done, Bradken should consider extending the existing crane to effectively transfer the moulds upon completion of pouring. Anotec feel that the current set-up for treating odours and dust from the cooling mould building is at its optimum. When Anotec stepped through the entrance past the air-curtains, the building seemed to be under negative pressure, there was no dust and the extraction system was effectively collecting odorous fumes. Anotec feel this is important because the set-up ensures that there is no dust being extracted along with the fumes and then dispersed to atmosphere.


Bradken Ref: 21603

Anotec Pty Limited


ConclusionOverall Bradken is a well maintained and neat facility. Dust levels are kept to a minimum and control of odours has already begun by way of addressing the cooling of moulds, knock-out and the proposed installation of an extraction system for the furnace area. Until such works are completed Bradken can expect to receive odour complaints from time to time. After Anotec completed their assessment of the Bradken site and Kilburn surrounds, Bradken submitted to Anotec a previous assessment conducted by the SA EPA outlining the impact of various business in the area in relation to odour. This report, identified as Kilburn Odour Study 2005, revealed that Bradken scored high on the list as being a major odour emitter in the area. The results from Anotecs study differ dramatically to that of the SA EPA in that there is a significant reduction in odours recorded in and around the area that can be attributable to Bradken operations. The reason that the results differ is that since 2005 Bradken have made major changes to their buildings, have vastly improved various capture techniques for odour and have significantly upgraded their housekeeping procedures that has resulted in a significant reduction in dust and odour from their site.Comparison Odour Levels 2005 Vs 200670

60

50 Odour Units (D/T)

40 Bradken 30

20

10

0 1 2005 (SA EPA) Sampling Years 2 2006 (Anotec)


Bradken Ref: 21603

Anotec Pty Limited


Based on the Bradken (Cromwell Rd, close to SA Canine Association) results, when compared to Anotecs results we see a significant reduction of 75% in this area.

Although Bradken is still one of a few odour contributors to the Kilburn area, their impact can be measured (depending on wind direction) no further than within a 780 metre radius from the site. There are a few other contributors in the area that remain unidentified by Anotec that can also have a cumulative effect on any odours from Bradken giving the impression that Bradken may be impacting further than the stated 780 metres. Anotec believe further investigation in this area should be conducted. In the event that Bradken require Anotec to assist in the recommendation of any add-on technologies once all other avenues have been exhausted or completed, Anotec would welcome the opportunity in working with Bradken. Finally, as a result of Bradkens upgrading of plant and equipment, effective capture technologies there is an overall (approximate) 56% reduction in odour. This is significant as Bradken have yet to complete their odour mitigation projects around the site. The installation of extraction fans and air-curtains has positively impacted on the overall performance of Bradken and ensures that they are closer in achieving their good neighbour goal.

Victoria Zavras Managing Director


Bradken Ref: 21603

Date post:	14-Nov-2014
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Bradken Kilburn SA 2006 Report

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