Continuously reducing our emissions of conducted and non-guided emissions remains a top priority. In recent years, we have taken numerous environmental measures that are now bearing fruit as our emissions have fallen significantly.
The biggest challenge, however, lies in further reducing the non-guided emissions that are mainly caused by blowing dust during internal logistical movements of recycled materials and byproducts.
In 2020, it became clear that even greater vigilance is needed. Although emissions were well below the norm, the average blood lead levels from the spring of 2020 showed a sudden increase, after a historically low average in 2019. Research showed that the increase was caused by a longer period of drought and higher wind speeds combined with children staying at home during the COVID lockdown. This prompted us to take extra action toprevent blowing dust. Thanks to our ongoing projects, which are explained below, the blood lead levels have been showing a downward trend for several years now.
We will continue to invest and work to reduce our emissions as much as possible. An overview of our most important and recent measures on site and in the surrounding neighborhood are available below.
Monthly environmental measurements
Reducing emissions on site
We deploy numerous technical measures to reduce fine particulate matter generated by production processes. Simultaneously, we also tackle dust that is released as a result of our logistics activities, for example when moving recycling materials and transporting them on the site.
Purification plants
In 2024, two additional installations came into operation with the aim of further reducing unguided emissions from two buildings on the site. A tertiary extraction system has been installed at one of the production buildings—the fourth on our site. This is an extraction in addition to the process and hygiene gas extraction. A tertiary extraction system creates slight negative pressure, so that dust can no longer escape from the buildings.
When a dust source is discovered, we immediately look for the cause and possible solutions. In another building, for example, one of the heat exchangers, which cools process gases with pure air, was causing emissions. We installed an extra HEPA filter to prevent the cooled air from going out unpurified. A HEPA filter is a powerful filter that can remove even the finest dust particles.
Lead refinery
A good example of how we combat emissions is the lead refinery that is located close to the Moretusburg district.
Measures against the wind
Wind barometer
Periods of exceptional weather, like longer droughts and higher wind speeds, are becoming more common. Since the beginning of 2021, we have made our production and logistics activities (i.e, the loading and unloading and transport of raw materials on site) dependent on the predicted wind speeds of our wind barometer. It is our responsibility to work sustainably minimizing the impact of our operations and prioritizing the wellbeing of our neighbors.
The wind barometer works with green, orange and red color codes. The usual dust control measures apply to green. In orange, our production activities will continue, but we will take additional dust-reducing measures, or postpone certain activities. In the event of code red, with increased wind speeds or storms, we will stop certain logistics and/or production operations.
This weather-related way of working has consequences for our suppliers and subcontractors. In case of code orange or red, they also have to wait. For example, a ship might have to stay a day longer before it can be unloaded.
Since the first use of the wind barometer in January 2021, we have adjusted our activities more than 110 times.
Windbreaks around warehouses and along the Scheldt
One of the more recent measures is the installation of hundreds of meters of windscreens of six meters high on our site.
The windbreaks are located around our storage facilities for raw materials. At the beginning of 2023, we installed a windbreak of about 220 meters, along the banks of the Scheldt and near the smelter.
We are also installing windscreens near the Blast furnace, also on the banks of the Scheldt.
For example, this helps keep the spread of dust on site and in the vicinity to a minimum when loading and unloading raw materials.
Watering, cleaning and covering
Intensive spraying and misting
A basic measure to limit or prevent blowing dust is spraying and cleaning. The company premises are kept wet every day. This is done by a sprinkler truck and by automated sprinkler systems on both the streets on site and in and around warehouses.
Covered and misted warehouses of 10,000 m2
We store our intermediate products and raw materials in warehouses. For example, since 2021, we have been using two 5,000 square meter halls, both of which are covered with a fireproof tarpaulin.
In the covered storage areas, we use nebulizers that precipitate dust.
All water is collected in our internal sewage system and then purified in our water treatment plant on the site. We put two-thirds of the water back on our site. The other part of the purified water is discharged into the Scheldt.
Read more about our sustainable water management
Searching for dust sources with 3D models and X-ray fluorescence
Thanks to different measurement methods and follow-up action, we now have many dust sources under control. As a result, the emissions of some substances have already reached such a low level that their measurement is hardly possible from a technical point of view.
The major challenge is to detect and control smaller and less obvious dust sources and particulate matter that is difficult to detect or are even invisible. We therefore use the most modern measurement techniques in our search for dust.
The Flemish Institute for Technological Development (VITO) prepared a 3D map of our site, which can be used for 3D visualizations of possible air flows. This gives us a better picture of the different wind directions and speeds on the factory site and detect draught holes where dust may be blowing up.
Another example is the use of X-ray fluorescence. This device directly measures the amount of metals in particulate matter that are released by our activities, or at installations that we did not suspect cause particulate matter. The results of the measurements can be read hourly. The use of this advanced technology and data analysis allows us to identify new and smaller sources of substance more quickly and take appropriate improvement measures.
Preventing and limiting dust
Intensive cleaning
In the Moretusburg district next to our site, we clean the streets every week. The playground and the playground equipment are also regularly and thoroughly cleaned. The footpaths are also cleaned twice a year and more often during the months of July and August, or during prolonged drought.
Neighboring homes
During home renovations, accumulated dust can be released and spread throughout the house. For example, local residents who want to have their attic renovated or an old roller shutter box removed are advised to professionally dust these parts of their homes.
For this free service, you can reach us by email or on our toll-free number 0800 93739.