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Process Flow for Typical Green Sand Foundry

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

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Process Flow for Typical Green Sand Foundry

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

  2. sand and binder sand-binder mixing PM metal scrap, alloys, flux core forming PM core curing VOC, HAP HC, CO PM, CO, VOC, HAP, MOx mold & core assembly scrap preparation cooling water PM mold pouring, cooling PM, NOx, CO, SO2 metal melting mold making sand slag, dross removal sand renewal shakeout PM riser cutoff & gate removal acidic wastewater PM, HAP, VOC scrap metal, abrasives PM PM, VOC slag, drossspent RM waste sand, metals cleaning, finishing, coating wastewater with solvents, oils sludge QA / shipping inputvapor wasteaqueous wastesolid waste rejects, packing material Materials Flow for Typical Green Sand Foundry

  3. sand-binder mixing core forming 1.2-3.5 MJ/kg saleable casting core curing mold & core assembly scrap preparation mold pouring, cooling 0.7 MJ/kg metal melting mold making slag, dross removal sand renewal shakeout Melting (MJ/kg) Cupola 6.7 Coke 1.3 Electricity 1.9 Natural Gas 0.1 Oxygen Electric melting 5.0-5.6 Induction 5.0-6.0 Electric Arc 6.0-9.2 Reverb Fuel fired melting 2.1-7.9 Crucible 2.9-5.8 Reverb riser cutoff & gate removal 1.2 MJ/kg cleaning, finishing, coating QA / shipping Energy Requirements for Typical Green Sand Foundry

  4. 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…

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