sandbinder mixing core forming core curing mold core

sand-binder mixing core forming core curing mold & core assembly scrap preparation mold making mold pouring, cooling metal melting sand renewal shakeout slag, dross removal riser cutoff & gate removal cleaning, finishing, coating QA / shipping Process Flow for Typical Green Sand Foundry

sand binder sand-binder mixing PM core forming PM core curing PM PM, CO, VOC, HAP, MOx mold & core assembly mold pouring, cooling mold making sand renewal metal scrap, alloys, flux VOC, HAP HC, CO scrap preparation cooling water PM, NOx, CO, SO 2 metal melting slag, dross removal shakeout PM acidic wastewater PM, HAP, VOC waste sand, metals sludge input vapor waste aqueous waste solid waste riser cutoff & gate removal cleaning, finishing, coating PM scrap metal, abrasives PM, VOC wastewater with solvents, oils QA / shipping rejects, packing material Materials Flow for Typical Green Sand Foundry slag, dross spent RM

sand-binder mixing core forming 1. 0 -3. 0 M BTU/ton saleable casting core curing mold & core assembly mold making mold pouring, cooling sand renewal shakeout Cupola melting 5. 8 Coke 1. 1 Electricity 1. 6 Natural Gas 0. 1 Oxygen Electric melting 4. 3 -4. 8 Induction 4. 3 -5. 2 Electric Arc 5. 2 -7. 9 Reverb Fuel fired melting 1. 8 -6. 8 Crucible 2. 5 -5. 0 Reverb riser cutoff & gate removal cleaning, finishing, coating scrap preparation 0. 6 M BTU/ton metal melting slag, dross removal 1. 0 M BTU/ton QA / shipping Energy Requirements for Typical Green Sand Foundry

Relevant Federal Legislation • • • Resource Conservation and Recovery Act – ID of solid and hazardous wastes – standards for generators of hazardous waste – land disposal restriction – used oil management standards – underground storage tanks – boilers and industrial furnaces Comprehensive Environmental Response, Compensation Liability Act Emergency Planning and Community Right-to-Know Act Clean Water Act Safe Drinking Water Act Toxic Substances Control Act Clean Air Act • Toxic Release Inventory (TRI) • – required of 654 of 2800 -odd foundries in 1995 – “TRI applies to companies that utilize 25, 000 pounds of the approximately 600 designated chemicals or 28 chemical categories specified in the regulations, or uses more than 10, 000 pounds of any designated chemical or category” • State and local legislation…