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METAL CASTING
Project Fact Sheet
NON-INCINERATION TREATMENT TO REDUCE
SIMPLE TREATMENT SYSTEMS CAN BE A COST EFFECTIVE
TECHNIQUE TO REDUCE EMISSIONS IN GREEN SAND FOUNDRIES BENEFITS
Btu in 2010.
BENZENE AND VOC EMISSIONS
• Estimated energy savings of 0.85 trillion
• AO/AO-UWAP processing, a low
energy alternative, compared to
conventional incineration techniques
currently employed.
• Have the potential to reduce one-third of
casting industry VOC emissions.
• Improves molding system performance.
APPLICATIONS
The results of this project could be applied in
green sand foundries throughout the casting
industry and could replace current
incineration techniques for emission control.
Sand casting remains the dominant casting
method used in the U.S. today. Therefore
the potential application is widespread.
Cost-effective non-incineration techniques will significantly reduce volatile
organic carbon (VOC) and benzene emissions from green sand foundries.
Increasingly, green sand foundries must reduce benzene and VOC emissions
during pouring, cooling, and shakeout. Conventional incineration systems to treat
stack gases are costly to operate and difficult to maintain. Alternative pollution
treatment methods are needed to comply with air quality requirements. Full-scale
plant trials at green sand foundries have shown that simple, non-incineration
advanced oxidation (AO) treatment systems or a combination of AO with
underwater plasma (AO-UWAP) treatment can greatly reduce emissions. In AO
and AO-UWAP treatment systems, wet collector sludge, or sand system
baghouse dust is passed through a water slurry that has been preconditioned
with ozone, hydrogen peroxide, and sonification/plasma treatment.
Pennsylvania State University and industry partners are evaluating the use of
AO, and AO with an underwater plasma, as a green sand "additive". AO can be
added to a foundry's green sand system wherever water is. In production, before
water or black water slurries are added to the sand, they are treated with small
amounts of AO combined with an ultrasonic treatment. It is believed that AO
treatment cleans the clay, allowing them to be more easily activated. AO has the
potential to activate the seacoal causing the mold to absorb VOCs. Hazardous
pollutants and VOCs are oxidized within the green sand mold, and the amount of
clay and seacoal required in the mold are reduced. Smoke and odor emitted
during cooling and shakeout can be reduced significantly.
REDUCING FOUNDRY EMISSIONS
Test results in green sand foundries
have been positive. Emissions and
sand requirements in participating
foundries have been reduced significantly.
Advanced oxidation processing has reduced smoke, odor and emissions in
foundries.
OFFICE OF INDUSTRIAL TECHNOLOGIES
ENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY
Project Description
Goal: The goal of this research is to understand and further develop cost-effective nonincineration
techniques that will significantly reduce VOC emissions from foundries.
Progress and Milestones
This three year project began in October 1998. Specific tasks include:
• Controlled Foundry Trials - These trials are evaluating the sand system and
environmental performance of advanced oxidant (AO) green sand systems using AO
additions, AO additions with black water collectors, and AO additions with dust reactivation
for bond recovery.
• Laboratory Testing - Pennsylvania State University Metal Casting Laboratory benchscale
tests are being conducted to further understand AO-green sand system
interactions and their effects on sand system performance and emissions.
• Analytical Studies - Analytical studies will be performed to evaluate AO-green sand
reactions and reaction kinetics.
• Technology Transfer - Results will be communicated through the AFS Casting
Congress and future AFS Environmental Affairs Conferences. Results are also
being disseminated through individual AFS Technical Committees and through the
trade press.
Results to date have been positive. At the Neenah Foundry, AO technology has
reduced sand system bond usage by 15 percent with an associated reduction in
emissions from cooling and shakeout. At International Truck & Engine's Waukesha
plant, stack tests conducted in 1999 showed a 56 percent reduction in benzene per
tone of iron poured and a 74 percent reduction of VOCs (including benzene) per tone of
iron poured. Tests have also demonstrated that CO emissions have been reduced by
10 percent as a direct result of sand system optimization. Significant cost reductions
have been achieved at both foundries due to reductions in sand system clay (bond)
requirements.
PROJECT PARTNERS
Pennsylvania State University
University Park, PA
American Foundry Society
Des Plaines, IL
Furness-Newburge, Inc.
Versailles, KY
Grede Foundries, Inc.
Reedsburg, WI
International Truck and Engine Corp.
Waukesha, WI
Neenah Foundry Company
Neenah, WI
Wheeland Foundry
Chattanooga, TN
FOR ADDITIONAL INFORMATION,
PLEASE CONTACT:
Harvey Wong
Office of Industrial Technologies
Phone: (202) 586-9235
Fax: (202) 586-6507
[email-masked]
http://www.oit.doe.gov/IOF/metalcast/
Please send any comments,
questions, or suggestions to
[email-masked].
Visit our home page at
www.oit.doe.gov
Office of Industrial Technologies
Energy Efficiency
and Renewable Energy
U.S. Department of Energy
Washington, D.C. 20585
January 2001