Title: A Passive Design Solution to Optimize Thermal Comfort in a Scrap Metal Factory in a

Hot-Dry Climate.

Thematic Area 25: Cross-Cutting Issues in Sustainable Development Goals (Goal No. 7:
Ensure access to affordable, reliable, sustainable and energy for all)
 Background to the Research

The process of thermoregulation is critical to maintaining thermal equilibrium in human

beings. Human beings are generally in a state of thermal comfort when their core body

temperature is between 36.6°C and 37.1°C (Searl & Crawford, 2012). However, the physical

and mental performance of an individual is affected when the body’s temperature deviates by

±2°C. Firstly, when the core temperature increases, this can result in the onset of increased

blood supply to the skin to reduce temperature (vasodilation). Secondly, there will be onset of

sweating which allows the body to cool more quickly as the sweat evaporates from the skin.

Conversely, when the body is exposed to cold, the response will be for the blood to be pulled

into deeper body areas and if the core temperature decreases for shivering to begin. As a result,

behaviour becomes a factor in this system where either removing clothes or putting clothes on

can either reduce or increase temperature (Searl & Crawford, 2012).

Climate has a major effect on the performance of the building which helps to create a

comfortable setting and impact on reducing its energy consumption (Behbood, Taleghani, &

Heidari, 2013). However, when the climate is characterized by high temperatures such as the

climate of hot-dry zones which is generally about 30°C - 45°C during hamattan with sharp

variations in both diurnal (day/ night) and seasonal (wet/ dry) measures to achieve optimum

indoor thermal comfort is required. Furthermore, increase temperature as a result of smelting

processes in scrap metal plant become contributing factor to optimum thermal comfort.
 Statement of Research Problem

Due to the high amount of heat generated during melting of scrap iron and steel, workers are

exposed to unfavourable thermal conditions, which puts workers’ health at risk and increase

energy consumption. Exposure to ambient temperature above 20 °C while carrying out physical

work can result in an increase in core body temperature. The amount of heat gain will also vary

dependent on the levels of physical work and the requirement to wear protective clothing or

respiratory protection. Furthermore, when employees are exposed to additional heat sources

from the outdoor environment from the sun this can add to the heat loading of the individual

worker.

Objectives of the Research

The study has 3 objectives

1. Assessing the thermal comfort level for scrap metal recycling factory in hot dry climate

using questionnaire and temperature reading equipment.

2. Assessing the thermal conductivity of insulated refractory brick produced from a fired

mixture of kaolin and polystyrene

3. Testing the results in a simulated environment using Autodesk simulation

Computational Fluid dynamics (CFD).

Research Questions

1. What is the thermal comfort of a scrap metal recycling plant in hot dry climate of

Nigeria?

2. What is the thermal conductivity of an insulated refractory brick produced from Kaolin

and waste polystyrene?

 3. How can an insulated refractory brick enhance the thermal performance of a scrap metal

plant in hot-dry climate?

Literature review

Thermoregulation are series of physiological processes which react to changes in ambient

environmental temperature to maintain thermal equilibrium in the human body. The

mechanism that control thermoregulation in the human body is called hypothalamus located in

the brain and the temperature of the blood flowing in this area. Moreover, the hypothalamus is

connected to a number of thermo-sensors within the skin, deeper tissue and the central nervous

system which provide feedback (Searl & Crawford, 2012).

The term ‘thermal comfort’ describes a person’s state of mind in terms of whether they feel too

hot or too cold. However, thermal comfort is very difficult to define as one need to take into

account a range of environmental, work-related and personal factors when deciding what

makes a comfortable workplace temperature (Health and Safety Executive). Furthermore,

Environmental factors (such as humidity and sources of heat in the workplace) combine with

personal factors (such as clothing) and work-related factors (how physically demanding the

work is) to influence ‘thermal comfort’ (Health and Safety Executive). As a result, thermal

comfort is not measured by room temperature, but by the number of employees complaining

of thermal discomfort.

According to (Edwards, 1999) minimisation of waste and recycling offers three benefits: (1)

reduce the demand upon new resources, (2) cut down on transport and production energy costs

(3) use waste which would otherwise be lost to landfill sites (Tam & Tam, 2006). Construction

and demolition (C&D) wastes including demolished concrete (foundations, slabs, columns,
floors, etc.), bricks and masonry, wood and other materials such as dry wall, glass, insulation,

roofing, wire and metal, pipe, rock and soil (Coventry, 1999) constitute a significant

component of the total municipal solid waste.

Although there are many material recycling schemes recommended, actual administering of

(C&D) waste recycling is limited to a few types of solid wastes. According to (Mindess,

Young, & Darwin, 2003), when considering a recyclable material, three major areas need to be

taken into account: (i) economy, (ii) compatibility with other materials (iii) material properties.

From a purely economic point of view, recycling of C&D waste is only attractive when the

recycled product is competitive with natural resources in relation to cost and quantity. Recycled

materials will be more competitive in regions where a shortage of both raw materials and

landfilling sites exists.

Ferrous metal recycling has been highly developed all over the world. It is by far the most

profitable and recyclable material (Tam & Tam, 2006). Table 1 shows the global recycling rate

of metals, iron and steel scored highest among ferrous metals with 47% rate. Moreover, the

demands for ferrous metal have long been well established. Therefore, the applications of the

material had also been well accepted on site.

Table 1 indicates the global recycling rate of different metals (ferrous and non-ferrous).

Metals Global recycling rate %

Aluminium (non-ferrous) 40
Copper (non-ferrous) 38
Iron/Steel (ferrous) 47
Lead (non-ferrous) 47
Nickel (non-ferrous) 34
Zinc (ferrous) 36

The Electric Arc Furnace (EAF), introduced commercially for the melting of iron and steel

scrap in the mid 1960s, accounts for 40% of US steel production. The (EAFs) use electricity
conveyed by graphite electrodes (iarcingi) to melt scrap and can accommodate 100% scrap in

the feed (Madias, 2014). However, (EAFs) depend on high amount of energy to generate the

required amount of heat to melt metal scrap.

Research Methodology

Experimental design

Case Study

Quasi-experimental

Expected Results

The expected result is an optimization of thermal comfort in the design of scrap metal recycling

plant using insulated refractory brick in a hot-dry climate.

Innovation

Refractory brick has been used in high temperature melting furnace due to its ability to resist

heat, however, refractory brick has high thermal conductivity. Several studies have given

refractory brick its porosity by adding fugitive such as polystyrene foam particles, sawdust and

starch (Zivcova, et al., 2009). According to (Shimizu, Matsuura, Furue, & Matsuzak, 2013)

such method only produces porosity of about 60-70%. Proving that a GS (gelation of slurry)

method can produce high porosity of up to 94-98% in alumina refractory brick thereby reducing

its thermal conductivity.

Furthermore, rice husk has also been tested with kaolin and fire clay at ratio 4:1:2 (representing

weight in grams of Kaolin, plastic clay and rice husk respectively) and discovered to perform

satisfactorily in terms of refractoriness, thermal conductivity, modulus of rupture, shrinkage

and bulk density and the effective moisture content (Ugheoke, Onche, & Namessan, 2006).

However, what is not available in literature (to the authors knowledge) is the thermal
conductivity of insulated refractory brick (kaolin and polystyrene). Therefore, this study will

evaluate the thermal conductivity of insulated refractory brick produced from a fired mixture

of kaolin and polystyrene, and to determine the mixing ratio that gives the optimum refractory

characteristics suitable for a scrap metal recycling plant in a hot dry climate.

Estimated budget

Stipends for professional and non-professional personnel: inconclusive

Cost of training of personnel: inconclusive

Permanent equipment: inconclusive

Consumable supplies: inconclusive

Travel: inconclusive

Other expenditures not included under the above categories and indirect costs: inconclusive

Costs of prototype production: inconclusive

References

Bahobail, M. A. (2012). The Mud Additives and Their Effect on Thermal Conductivity of
Adobe Bricks. Journal of Engineering Sciences, 40, 21-34.
Behbood, K. T., Taleghani, M., & Heidari, S. (2013). Energy Efficient Architectural Design
Strategies in Hot-Dry Area of Iran: Kashan. Retrieved August 08, 2019, from
www.brikbase.org: www.brikbase.org/sites/default/files/best2_behbood.pdf
Coventry, S. (1999). The reclaimed and recycled construction materials handbook. London:
Construction Industry Research and Information Association.
Designing Buildings. (2016, May 09). (). Retrieved from : . Retrieved August 08, 2019, from
Designing Buildings Wiki: http://www.designingbuildings.co.uk/wiki/Trombe_wall
Health and Safety Executive. (n.d.). Heat stress. Retrieved August 01, 2019, from
www.hse.gov.uk: http://www.hse.gov.uk/temperature/heatstress/

Research Team

Dr. R. B. Tukur
Kaka Victor David MSc. Architecture (degree in view) Correspondence:

kakavictor264@gmail.com or 08093350045

Micheal Okoh MA Industrial Design (degree in view)