Professional Documents
Culture Documents
Environmental, Health, and Safety Guidelines Foundries
Environmental, Health, and Safety Guidelines Foundries
FOUNDRIES
WORLD BANK GROUP
Applicability
The EHS Guidelines for Foundries include information relevant
to foundry projects and facilities casting ferrous (iron and steel)
and nonferrous (primarily aluminum, copper, zinc, lead, tin,
nickel, magnesium, and titanium) metals. Nonferrous metals are
cast in combinations with each other or in combination with
more than forty other elements to make a wide range of
nonferrous alloys. These guidelines address sand casting,
including the preparation and regeneration of molding sand, and
the high- and low-pressure die casting of aluminum, zinc, and
magnesium. In addition to these processes, this document
includes consideration of Disamatic (DISA) technology. It does
not cover further processing of the semifinished products. This
document is organized according to the following sections:
Environmental
1.1
management techniques;
Air emissions
Solid waste
Wastewater
amount of particulate matter (e.g. coke, fly ash, silica, rust and
Noise
Air Emissions
following:
Nitrogen Oxides
Nitrogen oxides (NOX) emissions are caused by high furnace
temperature and the oxidation of nitrogen. Techniques to
prevent and control the generation of NOx are addressed in the
General EHS Guidelines. Emission reduction can be achieved
through primary process modification measures and secondary
end-of-pipe abatement techniques. Pollution prevention and
control techniques include the following:
Sulfur Oxides
3 EC BREF (2005)
4 Ibid.
5 Ibid.
melting.
Carbon Monoxide
The most significant sources of carbon monoxide (CO) are off-
emitted when sand molds and cores come into contact with the
6 EC BREF (2005)
7 Ibid.
in fabric filters;
Metals
Metal emissions should be controlled during the melting and
casting processes. Metal emissions may be emitted through
spent amines;
water-based coating;
or silicate esters) in core box production;
8 EC BREF (2005)
(kWh/t) metal charge for ferrous metals and from 400 to 1200
Solid Waste
Sand Waste
use. Sand wastes from brass and bronze foundries are often
combustion controls;
the following11:
the
sand.)
Sludge Treatment
(e.g. chromium, lead, zinc, and nickel) and oil and grease. A
landfills.
Slag Wastes
melted refractories, sand, and coke ash (if coke is used). Fluxes
may also be added to help remove the slag from the furnace.
Slag may be hazardous if it contains lead, cadmium, or
Decommissioning Waste
the following:
Wastewater
suspended solids.13
document.
followed by filtering;
Store scrap and other materials (e.g. coal and coke) under
the
Guidelines.
Pave process areas, segregate contaminated and noncontaminated stormwater, and implement spill control
Physical hazards
Radiation
Respiratory hazards
Electrical hazards
Noise
Burial hazards
unit.
Physical Hazards
Noise
1.2
procedures, including:
Contact with hot metal or hot water may result in severe burns.
of center of gravity);
following:
operations;
Product Handling
Exposure to Radiation
Workers may be exposed to gamma rays and related ionizing
radiation exposure risks. The following techniques may be used
to limit the worker exposure risk:
10
melting shop;
process;
wooden and sand dusts, which are present in the molding shop.
In the former, workers are exposed to iron oxide, and silica dust
following:
which may contain heavy metals, and wood dust, which may
the following:
enclosed;
11
Noise
Electrical Hazards
Workers may be exposed to electrical hazards due to the
presence of heavy-duty electrical equipment throughout
foundries. Recommendations to prevent and control exposure to
electrical hazards are provided in the General EHS Guidelines.
Entrapment
Workers creating sand molds are exposed to risk of entrapment
1.3
2.0
2.1
Environment
the iron.
12
Units
Particulate Matter
mg/Nm 3
mg/Nm 3
NOX
mg/Nm3
SO2
mg/Nm 3
VOC
mg/Nm 3
PCDD/F
CO
mg/Nm 3
environmental assessment.
Amines
Chlorine
Pb, Cd and their compounds
Ni, Co, Cr, Sn and their
compounds
Cu and their compounds
Chloride
Fluoride
H2S
mg/Nm 3
mg/Nm 3
mg/Nm 3
Units
mg/L
mg/L
C
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L (as N)
mg/L (as F)
mg/L
kg/t
Guideline Value
6-9
35
10
3a
125
1
0.01
0.5
0.5
0.2
0.5
0.5
2
5
5
5
0.02b
NOTES:
a At the edge of a scientifically established mixing zone which takes into
account ambient water quality, receiving water use, potential receptors and
assimilative capacity
b Aluminum smelting and casting
ng TEQ/ Nm 3
Guideline Value
20(2)
50(3)
5
400(4)
120(5)
150(6)
400(8)
50(9)
120(7)
20(10)
30
150(11)
0.1
200(12)
150(13)
5(14)
5(15)
1-2(16)
mg/Nm 3
mg/Nm
mg/Nm 3
mg/Nm 3
ppm v/v
5-20(17)
5(18)
5(19)
5
NOTES:
1. References conditions for limits. For combustion gases: dry, temperature
273K (0C), pressure 101.3 kPa (1 atmosphere), oxygen content 3% dry for
liquid and gaseous fuels, 6% dry for solid fuels. For non-combustion gases: no
correction for water vapor or oxygen content, temperature 273K (0C),
pressure 101.3 kPa (1 atmosphere).
2. Particulate matter emissions where toxic metals are present
3. Particulate matter emissions where toxic metals are not present
4. Ferrous metal melting. Maximum emissions level considered on BAT base
and based on cokeless cupola furnaces
5. Non-ferrous metal melting (shaft furnaces)
6. From thermal sand reclamation systems/regeneration units
7. Maximum emissions level considered on BAT base and based on cold blast
cupola furnaces
8. Non-ferrous metal melting (shaft furnaces)
9. Ferrous metal melting (cupola furnaces)
10. Non-ferrous metal melting (shaft furnaces)
11. Ferrous metal melting (EAFs). Cupola furnaces may have higher emission
levels (up to 1,000 mg/N3)
12. Non-ferrous metal melting (shaft furnaces)
13. Cold box molding and core making shop
14. Non-ferrous metal melting (aluminum)
15. Thermal sand reclamation systems and solvent based investment foundry
coating, shelling, and setting operation
16. Higher value applicable to non-ferrous metal foundries from scrap
17. Higher value applicable to copper and its alloy producing processes
18. Furnace emissions where chloride flux is used
19. Furnace emissions where fluoride flux is used
13
Environmental Monitoring
sources.
2.2
14
15
Available at:
http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDAR
DS&p_id=9992
17 Available at: http://europe.osha.eu.int/good_practice/risks/ds/oel/
18 Available at: http://www.bls.gov/iif/ and
http://www.hse.gov.uk/statistics/index.htm
19 Accredited professionals may include Certified Industrial Hygienists,
Registered Occupational Hygienists, or Certified Safety Professionals or their
equivalent.
16
14
3.0
UK DEFRA. 2004. Secretarys State Guidance for Iron, Steel and Non-Ferrous
Metal Process. Process Guidance Note 2/4 (04). London: DEFRA. Available at
http://www.defra.gov.uk/environment/airquality/LAPC/pgnotes/
UK DEFRA. 2004. Secretarys State Guidance for Metal Decontamination
Processes. Process Guidance Note 2/9 (04). London: DEFRA. Available at
http://www.defra.gov.uk/environment/airquality/LAPC/pgnotes/
UK DEFRA. 2004. Secretarys State Guidance for Processes Melting and
Producing Aluminium and its Alloys. Process Guidance Note 2/6a (04). London:
DEFRA. Available at
http://www.defra.gov.uk/environment/airquality/LAPC/pgnotes/
UK DEFRA. 2004. Secretarys State Guidance for Zinc and Zinc Alloy
Processes. Process Guidance Note 2/7 (04). London: DEFRA. Available at
Available at http://www.defra.gov.uk/environment/airquality/LAPC/pgnotes/
UK Environmental Agency. 2001. Integrated Pollution Prevention and Control
(IPPC) Interim Guidance for the Ferrous Foundries Sector. Sector Guidance
Note IPPC S2.03. Bristol: Environment Agency.
UK Environment Agency. 2002. Integrated Pollution Prevention and Control
(IPPC) Technical Guidance for Non-Ferrous Metals and the Production of
Carbon and Graphite. Version 1: January 2002. Sector Guidance Note IPPC
S2.03. Bristol: Environment Agency. Available at http://www.environmentagency.gov.uk/business/444304/444369/673298/nfm/?version=1&lang=_e
United States (US) Environmental Protection Agency (EPA). 1995. Profile of the
Nonferrous Metals Industry. EPA Office of Compliance Sector Note Book
Project. EPA/310-R-95-010. Washington, DC: US EPA. Available at
http://www.epa.gov/compliance/resources/publications/assistance/sectors/noteb
ooks/nonferrous.html
US EPA. 1998. Profile of the Metal Casting Industry. EPA Office of Compliance
Sector Note Book Project. EPA/310-R-97-004. Washington, DC: US EPA.
Available at
http://www.epa.gov/compliance/resources/publications/assistance/sectors/noteb
ooks/casting.html
United Kingdom (UK) Department for Environmental Food and Rural Affairs
(DEFRA). 2004. Secretarys State Guidance for Copper and Copper Alloy
Processes. Process Guidance Note 2/8 (04). London: DEFRA. Available at
http://www.defra.gov.uk/environment/airquality/LAPC/pgnotes/
US EPA. 2004. Code of Federal Regulations (CFR) Title 40: Protection of the
Environment. Part 63. National Emission Standards for Hazardous Air Pollutants
for Iron and Steel Foundries. Washington, DC: Office of the Federal Register.
Available at http://epa.gov/ttncaaa1/t3/fr_notices/8287founddirfin.pdf
UK DEFRA. 2004. Secretarys State Guidance for Hot and Cold Blast Cupolas
and Rotary Furnaces. Process Guidance Note 2/5 (04). London: DEFRA.
Available at http://www.defra.gov.uk/environment/airquality/LAPC/pgnotes/
UK DEFRA. 2004. Secretarys State Guidance for Furnaces for the Extraction
of Non-Ferrous Metal from Scrap. Process Guidance Note 2/1 (04). London:
DEFRA. Available at
http://www.defra.gov.uk/environment/airquality/LAPC/pgnotes/
15
poured.
Melting Shop
composites.
16
systems.
Cupola Furnaces
foundries. Its use for cast iron production is less common. The
The cupola furnace is the common furnace used for cast iron
the molten metal to flow out through the tapping spout. Opposite
Induction Furnaces
Induction furnaces (IF) are used for melting ferrous and non-
iron and floats on the top of the molten metal protecting it from
level of the sand bed and collected into a ladle and / or a holding
17
fumes.21
carburization.
Shaft Furnaces
combustion gases from the burners are blown over the metal
the melting rate. These furnaces are typically used for small-
Crucible Furnaces
mold.22
Rotary Furnaces
Molding Shop
and US EPA Office of Compliance. 1998. Sector Note Book Project: Profile of
the Metal Casting Industry
22 EC BREF (2001) on the Smitheries and Foundries Industry
the type of metal being cast, the desired shape of the final
23
18
types24:
family;
size, the type of sand used, the production rate, the metal
the sand mold is shaken from the metal parts. Most of the used
uses and needs to be disposed of. For this reason, mold and
prevent rust. Water is used to activate the clay. The mold must
mold. After the mold has dried, the pattern is burned or melted
removed from the metal piece after cooling. Cores are typically
the
the
19
Casting Shop
Since these products may cause health and odor hazards, they
Finishing Shop
All remaining operations necessary to yield a finished product
are conducted in the finishing shop. Depending on the process
used, different steps may be required such as removal of the
running and gatting system, removal of residual molding sand
from the surface and core remains in the casting cavities,
removal of pouring burrs, repair of casting errors, and
preparation of the casting for mechanical post-treatment,
assembly, thermal treatment, and coating.29
The metal piece is cleaned using steel shot, grit, or other
mechanical cleaners to remove any remaining casting sand,
metal flash, or oxide. Flame cut-off devices and air-carbon arc
devices may also be used for this purpose. Small items are
usually ground by tumbling, which is carried out in a rotating or
vibrating drum. This usually involves the addition of water, which
may contain surfactants. Residual refractory material and oxides
are typically removed by sand blasting or steel shot blasting,
which can also be used to provide the casting with a uniform
and improved surface appearance. Welding may be required to
join castings, as well as to repair casting flaws. Chemical
cleaning of castings may be carried out before coating
operations to ensure that the coating will adhere to the metal.
29 Ibid.
20
DISA Technology
Disamatic (DISA) technology is a green sand molding process
designed to automatically build molds and inject the metal. The
DISA molds are produced with the help of a hydraulic press,
improving the production and quality of compacted sand. DISA
allows for various molding configurations, including vertical
molding, horizontal molding, and matchplate molding
technology. The vertical molding configuration is the most
popular configuration since it provides very close tolerance
castings. In this process, the molding chamber is movable and
achieved by two opposite patterns (ram pattern and swing
pattern). This allows the sand blown in the molding chamber to
be compressed and then extracted from the chamber.
DISA technology allows an efficient means of creating a string of
flask-less molds (without rigid metal or wood frame). It is
typically the choice for mass production of close-tolerance iron
castings or aluminum. Environmental aspects related to the
DISA technology are similar to those experienced by other
foundries casting ferrous products in sand molds, but are
normally contained and handled as part of the automated
system.
21
Raw materials
Melting Shop
Metal melting
Molten metal holding
Molten metal treatment
Molding Shop
Mold production
Core production
Casting Shop
Pouring
Cooling
Shaking-out/Taking-out
Metal
recycling
Sand
recovery and
recycling
Finishing Shop
Shot blasting
Grinding
Deburring
Thermal treating
Inspection/testing
Packing
Labeling
Storage
Shipping
22