LEVENT ÖNCEL

Sustainability Activities Carried Out in Gedik Kaynak

Abstract

The production of welding electrodes, welding wires, and submerged arc welding flux is an energy-intensive industrial activity due to its high-temperature processes, high electricity consumption, and continuous production structure. In line with increasing global carbon neutrality targets and sustainable production approaches, increasing energy efficiency, using renewable energy, and effectively managing resources are critically important in such industrial facilities. At Gedik Kaynak A.Ş., we implement a holistic sustainability approach in our welding electrode, welding wire, and submerged arc welding flux production facility, incorporating renewable energy integration, waste heat recovery, and water management practices.

Within the facility, approximately 36% of annual electricity consumption is met through a rooftop solar power system (SPP), depending on the season. This application contributes to reducing indirect carbon emissions by decreasing the amount of electricity drawn from the grid. To improve water efficiency, rainwater collected from the factory roof surfaces is stored and recovered for non-process industrial uses. This reduces freshwater consumption and improves the facility’s water footprint.

In addition to the use of renewable energy, various waste heat recovery systems have been implemented at the facility. The hot air released during the operation of compressors used in compressed air systems is utilized in water heating systems, minimizing energy losses. The heat from the flue gases of natural gas-fired furnaces is recovered and used in auxiliary processes, thus reducing fuel consumption and overall energy requirements. Furthermore, all waste from the process is recycled and reintroduced into the economy. Investment projects have also been initiated for the regeneration of chemicals used in gas shielded welding wire production, as part of efforts to reduce waste and carbon emissions and strengthen environmental sustainability.

A holistic evaluation of these applications demonstrates that in facilities producing metal-based consumables such as welding electrodes and welding wires, it is possible to increase energy efficiency, reduce greenhouse gas emissions, and protect natural resources without compromising production quality.

Biography

He graduated from Middle East Technical University in 1988 with a degree in Chemical Engineering and subsequently completed his master’s degree in Geological Engineering at Mersin University.

He began his professional career as a plant engineer at Berdan Tekstil A.Ş. and, after one year, spent 25 years at Çimsa Çimento A.Ş. in various positions. He subsequently held senior management positions at Denizli Cement and Adana Cement, both part of the Oyak Cement group, for five years. During this period, he led various initiatives focused on increasing the use of alternative low-carbon fuels and raw materials, as well as the commissioning of facilities that enhance both efficiency and sustainability through energy recovery from waste heat.

Following his senior management role at Kümaş A.Ş., another Oyak subsidiary, he is currently serving as Operations Director at Gedik Kaynak A.Ş.