Eco-Friendly Inorganic Binders: A Key Alternative for Reducing Harmful Emissions in Molding and Core-Making Technologies.

Many years of foundry practice and much more accurate analytical methods have shown that sands with organic binders, in addition to their many technological advantages, pose risks associated with the emission of many compounds, including harmful ones (e.g., formaldehyde, phenol, benzene, polycyclic aromatic hydrocarbons, and sulfur), arising during the pouring of liquid casting alloys into molds, their cooling, and knock-out. The aim of this research is to demonstrate the potential benefits of adopting inorganic binders in European iron foundries. This will improve the environmental and working conditions by introducing cleaner and more ecological production methods, while also ranking the tested binders studied in terms of their harmful content. The article pays special attention to the analysis of seven innovative inorganic binders and one organic binder, acting as a reference for emissions of gases from the BTEX (benzene, toluene, ethylbenzene, and xylenes) and PAHs (polycyclic aromatic hydrocarbons) groups and other compounds such as phenol, formaldehyde, and isocyanates (MDI and TDI) generated during the mold pouring process with liquid metals. The knowledge gained will, for the first time, enrich the database needed to update the Reference Document on The Best Available Techniques for the Smitheries and Foundries Industry (SF BREF).

Research on the Release of Dangerous Compounds from the BTEX and PAHs Groups in Industrial Casting Conditions.

The assessment of the harmfulness of moulding and core sands is mainly based on investigations of compositions of gases emitted by liquid casting alloys during the mould pouring. The results of investigations of moulding sands obtained under industrial conditions are presented in this paper. A unique research stand was designed and built for this aim. It allowed us to determine emissions of gases at individual stages of casting a mass up to 50 kg. This approach enables simulation of foundry conditions. Moulding sands bound by organic binders (phenol-formaldehyde; furan), inorganic binders and green sand, were subjected to investigations. The composition of gases that evolved during the individual stages, pouring, cooling and knocking out, was tested each time, and the contents of Polycyclic Aromatic Hydrocarbons (PAHs) and benzene, toluene, ethylbenzene, and xylenes (BETX) were analysed. Investigations indicated that the emission of gases from sands with inorganic binders is negligible when compared with the emission of gases from sands with organic binders. The emission of gases from green sand is placed in the middle of the scale. As an example: the sand with furan resin emitted 84 mg of BTEX (in recalculation for 1 kg of sand) while from sands with inorganic binders there was a maximum of 2.2 mg (for 1 kg of sand). In the case of sands with inorganic binders, MI and MC sands indicated comparable and very low emissions of gases from the PAHs group, at the level of 0.018 mg and 0.019 mg for 1 kg of sand, respectively. The higher emission of PAHs from MG sand is the result of its different way of hardening (a binder was of an organic character) than of sands MI and MC.

Environmental Impact of the Reclaimed Sand Addition to Molding Sand with Furan and Phenol-Formaldehyde Resin-A Comparison.

Increasingly strict regulations, as well as an increased public awareness, are forcing industry, including the foundry industry, to develop new binders for molding sands, which, while being more environmentally friendly, would simultaneously ensure a high quality of castings. Until recently, binders based on synthetic resins were considered to be such binders. However, more accurate investigations indicated that such molding sands subjected to high temperatures of liquid metal generated several harmful, even dangerous substances (carcinogenic and/or mutagenic) from the benzene, toluene, ethylbenzene and xylenes (BTEX) and polycyclic aromatic hydrocarbons groups (PAHs). An assessment of the most widely used molding sands technologies at present with organic binders (synthetic resins) from the no-bake group (furan no-bake and phenolic-ester no-bake) and their harmfulness to the environment and work conditions is presented in this paper. In the first stage of this research, gases (from the BTEX and PAHs groups) emitted when the tested molds were poured with liquid cast iron at 1350 °C were measured (according to the authors' own method). The second stage consisted of measuring the emission of gases released by binders subjected to pyrolysis (the so-called flash pyrolysis), which simulated the effects occurring on the boundary: liquid metal/molding sand. The gases emitted from the tested binders indicated that, in both cases, the emission of harmful and dangerous substances (e.g., benzene) occurs, but, of the given binder systems, this emission was lower for the phenolic-ester no-bake binder. The obtained emission factors of BTEX substances show higher values for furan resin compared to formaldehyde resin; for example, the concentration of benzene per 1 kg of binder for furan no-bake (FNB) was 40,158 mg, while, for phenol-formaldehyde no-bake (PFNB), it was much lower, 30,911 mg. Thus, this system was more environmentally friendly.

Influence of a Reclaimed Sand Addition to Moulding Sand with Furan Resin on Its Impact on the Environment.

Metalcasting involves having a molten metal poured in a hollow mould to produce metal objects. These moulds are generally made of sand and are chemically bonded, clay-bonded, or even unbounded. There are many binder systems used. Binders based on furfuryl resins constitute currently the highest fraction in the binders no-bake group. Moulding sand, after knocking out the cast, is partially reclaimed, and the remaining part, known as waste foundry sand is used or stored outside the foundry. In this case, the environment hazardous organic compounds and metals can be leached from the moulding sand, thus causing pollution of water and soil. Also during the casting moulds with molten metal, they emit pyrolysis gases containing many different compounds, often dangerous from the BTEX and PAH group, which has adverse impacts on the environment and workers. The article presents the results of research on the impact of the regenerate addition to the moulding sand matrix on emitted gases and the degree of threat to the environment due to leaching of hazardous components. Therefore, for the total assessment of the moulding sands harmfulness, it is necessary to perform investigations concerning the dangerous substances elution into the environment during their management and storage, as well as investigations concerning emissions of hazardous substances (especially from the BTEX and PAHs group) during moulds pouring, cooling, and casting knocking out. Both kinds of investigations indicated that reclaimed sand additions to moulding sands have significantly negative influence on the environment and working conditions.

Determination of PCDDs, PCDFs, PCBs and HCB emissions from the metallurgical sector in Poland.

BACKGROUND: The aim of the project was to measure the actual emissions of PCDD/F, PCBs and HCB from 20 selected metallurgical installations in Poland, in order to update the national inventory of dioxin emission from metallurgical industry for developing a strategy for dioxins and furans emission abatement from the subject facilities (UNEP 2005). METHODS: Sampling methodology used in this work was developed at the Cracow University of Technology because of the complexity of simultaneous sampling and determining PCDFs, PCDDs, PCB and HCB. For the determination a GC-MS/MS system was used. RESULTS AND DISCUSSION: Results from the work indicate that the highest dioxins and PCB concentrations were recorded for iron ore sintering plants at 1.10-1.32 ng total1 TEQ/Nm3 followed by aluminium scrap melting at 0.03-0.66 ng total TEQ/Nm3. The highest HCB concentrations at 613-1491 ng/Nm3 were also recorded fo iron ore sintering plants, whereas at aluminium plants the HCB concentrations were in the range of only 10.1-22.7 ng/Nm3. CONCLUSIONS: The above investigations indicate that secondary aluminium production is the most significant dioxins source, if calculated as emission factor values. However, iron ore sintering plants are operating at much higher production capacity, causing this process to become the major source of dioxins, PCB and HCB pollution to the atmosphere in Poland. RECOMMENDATIONS AND PERSPECTIVES: Based on the performed tests and the environmental reviews of selected plants several recommendations were formulated for the reduction of generation or of emission of these pollutants from iron ore sintering plants, electric arc furnace steel production processes, hot-blast furnace operations, secondary aluminium smelting and primary zinc production from zinc cathodes.

Survey of dioxin sources in the Baltic Region (extended summary).

The present paper summarises the results of the project: 'Survey of Anthropogenic Sources of Dioxins and Furans in the Baltic Region'. As a part of the project, inventories have been carried out in Estonia, Latvia, Lithuania and Poland by applying the toolkit for quantification of dioxin and furan releases developed by UNEP Chemicals. The main route of direct releases to the environment is emission to air. Total emission to air from Poland was estimated at 490 (88-1,300) g I-TEQ/year, whereas the emissions from Estonia, Latvia and Lithuania were estimated as being 14 (2.4-54), 23 (2.6-63) and 17 (2.6-38) g I-TEQ, respectively. In general, the uncertainty on the estimates is very high, and recommendations regarding further development of the inventories have been made, and measures for reducing the releases have been provided.