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CIRP 98 (2021) 181–186
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28th CIRP Conference on Life Cycle Engineering
28th CIRP Conference on Life Cycle Engineering
Environmental impacts assessment during sand casting of Aluminium
Environmental
LM04 product: impacts
28th Aassessment
CIRP Design case of Indian
Conference, during sand
Maymanufacturing
2018, casting
Nantes, France of Aluminium
industry
LM04 Ankitproduct: 1
Yadav , Anbesh A case of Indian
Jamwal 1*
, Rajeev manufacturing 1
Agrawal , Anil Kumar industry 2

A newDepartment
methodology
1
Ankit
of Yadav
Mechanical to1, analyze
Anbesh
Engineering, theInstitute
Malaviya Jamwal
National functional
1*
, Rajeev andMarg,
Agrawal
of Technology, J.L.N.
1physical architecture
, Anil
Jaipur, Kumar
2
Rajasthan-302017 (India) of
existing products
of Mechanicalfor an assembly oriented product
J.L.N. Marg, family identification
2
Guildhall School of Business and Law, London Metropolitan University, London, UK
1
Department Engineering, Malaviya National Institute of Technology, Jaipur, Rajasthan-302017 (India)
2
Guildhall School of Business and Law, London Metropolitan University, London, UK
* Corresponding author: anveshjamwal73@gmail.com
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
* Corresponding author: anveshjamwal73@gmail.com
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
Abstract
At present environmental pollution is the major problem that is drastically affecting human health and worsening the climatic conditions
worldwide. Manufacturing industries are now working towards cleaner production to reduce the pollution level and other hazardous emissions
At present environmental pollution is the major problem that is drastically affecting human health and worsening the climatic conditions
emitted from manufacturing industries during manufacturing processes. In the present study Life cycle assessment tool is used to compute the
worldwide. Manufacturing industries are now working towards cleaner production to reduce the pollution level and other hazardous emissions
Abstract
total environmental impact of the sand casting process during its manufacturing phase and also different available scenarios have been
emitted from manufacturing industries during manufacturing processes. In the present study Life cycle assessment tool is used to compute the
compared to find the best one. Aluminum alloy-LM04 is used in the present study having good casting characteristics and a wide range of
In today’s
total business environment,
environmental impact of the the sand
trendcasting
towardsprocess
more product
during variety and customization
its manufacturing is unbroken.
phase and Due toavailable
also different this development,
scenarios thehaveneed of
been
applications in different engineering sectors. The case study is carried out in the Indian additive manufacturing industry located in the Southern
agile and reconfigurable
compared to find the best production
one. Aluminumsystemsalloy-LM04
emerged to is cope
usedwith various
in the products
present study and product
having goodfamilies. To design and and
casting characteristics optimize
a wide production
range of
region of
systems as India.
well asThis study considers
to choose the optimal gate to gate
product analysisproduct
matches, which analysis
considersmethods
the manufacturing phase
Indeed,ofmost
the aluminum product. Theaim result
applications in different engineering sectors. The case study is carried out in the Indianare needed.
additive manufacturing of the known
industry located methods
in the Southern to
calculated
analyze a includes
product or raw
one material,
product solid
family on waste,
the energy
physical consumption,
level. Different and
product air emission
families, during
however, maythe manufacturing
differ largely in phase.
terms of Also,
the different
number and
region of India. This study considers gate to gate analysis which considers the manufacturing phase of the aluminum product. The result
environmental
nature impact factors
of components. areimpedes
Thismaterial,
fact calculated inefficient
the study. GABI software versionof9emission
is used in this studyfamily
for the combinations
analysis purpose. It isproduction
found that
calculated includes raw solid an
waste, energycomparison
consumption,and choice
and air appropriate product
during the manufacturing for Also,
phase. the different
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to studied
changes in electricity source in additive manufacturing industries result in about a 40 % reduction in emissions. Also, out of four cluster
environmental impact factors are calculated in the study. GABI software version 9 is used in this study for the analysis purpose. It is found that
electricity
these productssources
in newhydropower source isproduct
assembly oriented found families
be the best
for fit
thefor manufacturing
optimization industries.
of existing About
assembly 91 and
lines % ofthesolid wasteofcan
creation be reduced
future by the
reconfigurable
changes in electricity source in additive manufacturing industries result in about a 40 % reduction in emissions. Also, out of four studied
assembly systems.
reuse of sand. Based on
Combining allDatum Flow Chain,
the available scenario theresult
physical
67 % structure
reduction of in
theemissions.
products is analyzed. Functional subassemblies are identified, and
aelectricity
functionalsources
analysis hydropower
is performed. source is founda be
Moreover, the best
hybrid fit for manufacturing
functional industries. About
and physical architecture 91 % of solid
graph (HyFPAG) waste
is the can be
output reduced
which by the
depicts the
reuse of
similarity sand. Combining
between product all the
familiesavailable scenario
by providing result 67 % reduction in emissions.
© 2020 The Authors, Published by Elsevier B.V. design support to both, production system planners and product designers. An illustrative
example
© 2021
This of
The
is an a Authors.
opennail-clipper is used
accessPublished
article underto explain
by the CC the
Elsevier B.V.proposedlicense
BY-NC-ND methodology. An industrial case study on two product families of steering columns of
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
© 2020
This is The
thyssenkrupp
an Authors,
open access Published
article by
under Elsevier
the CC B.V.
Peer review under the responsibility of the scientific committee of the 28th CIRP of
Presta France is then carried out to give
BY-NC-ND a first industrial
license evaluation the proposed approach.
(https://creativecommons.org/licenses/by-nc-nd/4.0)
Conference on Life Cycle Engineering.
©This
2017is an
Theopen
Peer-review access
under
Authors. article under
responsibility
Published the CC
byofElsevier BY-NC-ND
scientific
B.V. committee license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
of the 28th CIRP Conference on Life Cycle Engineering.
Peer reviewLife
Peer-review
Keywords: under
under
cyclethe responsibility
responsibility
assessment; of manufacturing;
of the
additive the scientific
scientific committee
committee
aluminum; of 28th
of the
sand the 28th
CIRP
casting; CIRP Conference
Design
environmental on Life
Conference
impacts; 2018.
India.Cycle Engineering.

Life cycle Design

Keywords:Assembly;
Keywords: assessment; additive
method; manufacturing;
Family identificationaluminum; sand casting; environmental impacts; India.

1. Introduction deforestation, use of plastics, and burning of fossil fuels like

coal, these all process lead to the accumulation of carbon
1.1. Introduction
InIntroduction
the last two decades, tenacious rules and policies by the
deforestation,
of the product
content use of plastics,
range
in the atmosphere and and
and characteristicsburningmanufactured
increments inofthefossil fuels like
and/or
concentration
coal, these
assembled all
of carbon indioxide process
this system. lead to
whichInisthis the
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most the of
main challenge
contributing carbon
gas for in
government forced the manufacturing sector industries to
In the toward
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to two decades, tenacious contentwarming
in the
andatmosphere is and
nowincrements in the concentration
moveDue the
sustainable or green rules
fast development inandthepolicies
production domain
[1]. by the
Globallyof modelling
global analysis
[3]. not only to cope with single
government
communication forced
and the manufacturing
an ongoing sector industries to of carbonconstruction
dioxide product
which is theareormost contributing gasto for
most countries introduced new rulestrend of digitization
regarding the quantityand of products,
Globally a limited range
industries existing product
responsible families,
for 40 45
move toward
digitalization, sustainable or green production [1]. Globally global
percent warming
also toofbe able [3].
greenhouse gasandemissions. Metal industries
pollution, newmanufacturing enterprises are
types of environmentally facingmachinery,
friendly important but to analyze to compare products to define
most countries introduced newtorules regarding Globally aconstruction
of waste,Itindustries are responsible for 40 tothis45
challenges
and workplaces in today’s
that willmarket
help the total the
environments:
lower a quantity
continuing
environmental of generate
new product lotfamilies. about
can be24observed
percent of total
that globally,
classical existing
pollution, new types of environmentally friendly machinery, percent of
not onlyfamilies greenhouse
resultsarein regroupedgas
health problems emissions. Metal
but ofalso industries
environmental
pollution.towards
tendency Also, several
reduction conferences
of productaredevelopment
arranged to times solve and
the product in function clients or features.
and workplaces that willproblem, help to lower the onetotal environmental generate
pollutionsaassembly
lot ofdegradation
and waste, about 24The percent of total
primary metalglobally,
industry this
is
environmental-oriented
shortened product lifecycles. In addition, recently there of them
is an is COP
increasing However, oriented[4].
product families are hardly to find.
pollution. Also, several conferences are arranged not only results in health problems but also environmental
25,
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being the same time heldtoin
insolve the
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products differ production.
mainly in two
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The metals and degradation
industry ofthe [4].isThe
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Spain. Now with
competition climate change
competitors action plans
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25, which is a UN climate change conference held in Madrid, composed
iron-based principally of iron,
and non-iron-based steel, and aluminum
[5]. Non-iron-based production.
industries
the planet
which for human survival [2]. An increasingtorate of
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required tomicrosave type
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[5]. Non-iron-based products
product varieties (high-volume to low-volume
2212-8271 © 2020 The Authors, Published by Elsevier B.V. production) [1]. or solitary, already existing product families analyze the
To
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2212-8271
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Life Cycle Engineering.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
production system, it is important to have a precise knowledge comparison of different product families. Addressing this
Peer review under the responsibility of the scientific committee of the 28th CIRP Conference on Life Cycle Engineering.
2212-8271 © 2021 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review
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28th 28thDesign
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on Life Cycle Engineering.
10.1016/j.procir.2021.01.027
182 Ankit Yadav et al. / Procedia CIRP 98 (2021) 181–186
2 Author name / Procedia CIRP 00 (2019) 000–000

include the production of copper, aluminum, lead, zinc, etc. 2.1 Life Cycle Assessment:
The main operations of the basic metals industry in India are
mining of ores, refining of the ore, casting, alloying, sheet, According to ISO 14044:2006, which specifies guidelines and
and rolling into foils. India's basic metals industry is one of regulations of life cycle assessment (LCA) is an
the many booming industries in India. The aluminum industry internationally standardized tool [6]. It consists of four
is classified under the red category in India. Red category phases, first is to define the goal and scope means system
means the industries with more than 60 pollution index score boundary and level of details that are required for the next
[12]. More and more efficient and technologically advanced phases. Second is inventory analysis means to collect all the
methods improved the production processes and in turn, the data required to achieve the goal. After this third one is the
output of the industry increased along with the quality of the life cycle impact assessment (LCIA) to assess the
products [13-15]. More studies are required to find emissions environmental significance and finally the interpretation
during these production processes, also how to reduce the phase in which life cycle inventory (LCI) and LCIA are
emissions and what are the alternate solutions possible for that summarized to conclude, any recommendation and to make a
production process, which help to lower the emissions also decision regarding the results [7].
cost-friendly for the industries. The goal of this study was to analyze the environmental
This study is focused on the aluminum product which is impact of the aluminum sand casting process. And to find
produced by the sand casting approach and total alternative solutions that will produce fewer emissions with
environmental impacts are calculated during its the same quality of the final product along with an optimal
manufacturing phase using GABI software. Factors that are cost. Alternative options chosen here for change practical
calculated include Global warming potential, Acidification scenario include energy consumption from other sources,
Potential, Eutrophication Potential, Ozone depletion potential, reduction in materials, waste recycling, and their
Human toxicity potential, and photochemical ozone creation combinations. Here LCA is performed on the manufacturing
potential. LCA quantifies all these factors during the phase excluding the raw material extraction and use phase this
manufacturing process, it is a systematic tool to compute all is a gate-to-gate approach in which input is raw materials and
emissions, effects on human health, total raw material the final product is output. Figure 2 represents the system
consumption, and energy required during the life cycle of a boundary chosen for the aluminum sand casting process
product or process. which consists manufacturing phase. Also, the functional unit
considered here is one unit of final product weighting 0.24 kg,
1.1 Sand casting: so the data collected are concerning one unit of the final
product. Figure 1 includes the final product produced by the
A metal casting process using sand as the mold material. sand casting process.
Firstly molten metal is poured into the cavity and allowed to
cool after this mold is broken to remove the casting, and
finally, some finishing processes and heat treatment are
performed for better quality and dimension control of the final
product. About 70 percent of metal casting products are
produced by a sand casting process. Aluminum products can
be made by all of the processes used for casting metal, mostly
sand casting is used to make complex shape products.
Aluminum casting products hold a wide range of applications
in automobiles such as in ships, aircraft, and spacecraft. Wide
varieties of aluminum casting alloys provide good strength,
good corrosion resistance, and other special properties.
Around 8 percent of aluminum casting is used in construction
industries. Sand casting is a powerful and versatile method for
the manufacturing of intricate shape products. This technique
requires continuous improvement and development to reduce Figure 1: Final product for this research
environmental pollution and to satisfy user needs without so
much increment in the cost of production. GABI software version 9.1 is used for this life cycle
assessment study (PE international 2013). The method used is
CML 2001, and impact categories selected for study are –
Global warming potential (GWP), acidification potential
2. Methodology
(AP), eutrophication potential (EP), photochemical ozone
creation potential (POCP), and ozone depletion potential
This section includes the methodology followed during this
(ODP).
research work. In this section all the data are collected which
are required to achieve the goal. Also different available
modifications in sand casting process are considered.
Modifications are considered to find the best one in term of
lower environmental emissions. Overall this section provides
the material and energy flow requirement for each alternative
considered in this research work that will help to find the final
emission levels.
 Ankit Yadav et al. / Procedia CIRP 98 (2021) 181–186 183
Author name / Procedia CIRP 00 (2019) 000–000 3

operations according to alternatives.

Table 1: Different available modification in the sand casting

process
Case Scenario Electricity Changes in Recycling or
no. form raw material reuse
1 Basic scenario Grid mix No No

2 Electricity source photovoltaic No No

(only solar)
3 Electricity source wind No No
(only wind)
4 Electricity source Solid No No
(only biomass biomass
solid)
5 Electricity source hydropower No No
(only hydropower)
6 Reduction in resin Grid mix Yes No
consumption
7 Reuse of waste Grid mix Yes Yes
sand
8 Use of scrap Grid mix Yes Yes
Figure 2: System boundary of the aluminum sand casting
process
Although in the big manufacturing sector it’s not possible to
produce the entire electricity requirement from solar only or
wind only, in the small sector it can be possible. In a country
like India which is endowed with vast solar energy potential.
About 5,000 trillion kWh per year energy is incident over
India's land area with most parts receiving 4-7 kWh per sq. m
per day it’s an advantage to have solar power. Here Cases of
electricity are considered to figure out which one is better and
in what amount they affect the emissions. While, today,
domestic coal-based power generation is the cheapest
electricity source, future scenarios suggest that this could well
change [8]. The next case is the reduction of resin and binder
consumption. A lot of research is focused on binder and resin
material. One of them is a comparison of the hydrocarbon
emissions during pyrolysis of four carbonaceous additives that
can be used in green sand foundries. These included highly
volatile bituminous coal, anthracite, lignite, and cellulose. It is
Figure 3: Material and Energy flow diagram found that cellulose offers an important opportunity for green
sand foundries to diminish their hazardous air pollutant
(HAP) emissions [9]. Other cases are related to reducing solid
2.2 Different Alternatives available for sand casting waste by reuse or recycling process. The energy requirement
process: in different stages is shown in Figure 4.
Central Pollution Control Board under the Ministry of
Environment, Forest and Climate Change set the standards in
India to regulate emissions from various sources. The Indian Other
government announced that the country would skip the BS V 9%
norms altogether and adopt BS-VI norms by 2020. Supreme Raw
Finishing material
Court has banned the sale and registration of motor vehicles melting
18%
conforming to the emission standard Bharat Stage IV in the 46%
entire country from 1 April 2020. 51% of pollution is caused Mold
by industrial pollution, 27% by vehicles. These two are the preparation
major contributor to polluting the environment and require 18%
strict action and new techniques to reduce pollution. This Casting
study is focused on reducing industrial emissions. 9%
Alternatives may include changes in energy sources,
reduction in raw materials consumption, and reuse or
recycling of waste. Eight different alternatives are chosen in Figure 4: Energy requirement in different stages
this study based on their technical suitability. Table 1
represents the available scenarios. These are the advancement 3. Results and discussion:
in the basic scenario. All the modifications are performed on
the basic scenario by the addition of different processes and 3.1 Life cycle inventory results:
184 Ankit Yadav et al. / Procedia CIRP 98 (2021) 181–186
4 Author name / Procedia CIRP 00 (2019) 000–000

This section communicates the life cycle inventory data for all account for 55 % of total installed power capacity by 2030. A
the scenarios. Table 2 provides detailed data on raw material study focused on India's renewable energy resulted that there
consumption, energy, emissions, and solid waste generated can a 74 % reduction in CO2 emissions by 2050 [10].
during all eight scenarios. Emissions to air and freshwater are
shown in percentage for total output. The greatest benefit in 3.2 Environmental impact by different scenarios
terms of solid waste reduction can be achieved by the reuse of This section consists of the result in terms of environmental
waste sand because the major source of solid waste in casting impact (GWP, AP, EP, ODP, FAETP, HTP, POCP) produced
is sand produced during the casting and shakeout process. by each scenario. This section reveals the increment or
91% reduction in solid waste can be achieved by this scenario. decrement in different emissions levels by recycling and reuse
Sand regeneration technique shifts the burden by lowering of waste sand or scrap. It also helps to find out the best
solid waste generation and increasing energy consumption. environmentally friendly source of electricity. Table 3
But it’s a large reduction in solid waste with a small contains the data of environmental impact produced by
increment in energy consumption. Scrap recycling also individual scenarios. GWP produced in the base scenario is 13
reduces the amount of solid waste by 1 to 2 percent; KgCO2, which is the maximum among all the cases. In sand
Aluminium can be infinitely recycled without losing quality casting the major contribution in CO2 emission is given by
also in a lesser time range of eight weeks. Recycling the raw material melting process, here in this case study
aluminum saves up to 95 % of energy as compared to melting is done by using an electric arc furnace means
producing aluminum from raw materials. Recycling one tonne electricity will have a great impact on total emissions results
of aluminum saves up to 9 tonnes of CO2 emissions. will vary according to electricity sources also this can be seen
in the table. Among the four different sources of electricity
Table 2: Inventory data for all the scenarios (wind, solar, biomass, hydropower) best suitable electricity
source for cleaner production is hydropower and wind. Both
Scenarios RMC EC EA EFW SWG sources are producing the almost same level of impact on the
environment. In the future electricity production from
Base scenario 32.904 4.5 0.162 50 32.664 renewable energy source will take lead on fossil fuels because
at the current rates of production fossil fuels will run out in
Electricity (wind) 32.904 4.5 0.0893 50 32.664
future, that’s why these four sources are included in this study
Electricity (solar) 32.904 4.5 0.162 50 32.664 because in the next 15 to 20 years solar or wind will provide a
Electricity (biomass) 32.904 4.5 2.01 48.1 32.664 major contribution in electricity production.
Electricity 32.904 4.5 0.0505 50 32.664
(hydropower) Table 3: Emission data for all scenarios
Reduction in resin 32.854 4.5 0.141 50 32.614
consumption Scenario GWP AP EP ODP FAETP HTTP POCP
Reuse of waste sand 32.904 4.5 0.162 50 2.664
Base scenario 13 0.0879 4.74 4.14 0.0649 26.7 4.84
Scrap recycling 32.904 4.5 0.197 49.9 32.264
Electricity 7.86 0.0279 1.93 8.52 0.0526 25 2
RMC: Raw material consumption (Kg/FU); EC: Energy consumption (wind)
(Kwh/FU); EA: Emissions to air (%); EFW: Emissions to fresh water (%);
Electricity 8.05 0.0287 1.99 109 0.0544 25.1 2.08
SWG: Solid waste generation (Kg/FU)
(solar)
Electricity 8.16 0.0502 5.48 3.45 0.0708 25.6 5.24
and binders are used in the metal casting industry to achieve a (biomass)
good strength mold. Different types of resin and binders are Electricity 7.84 0.0278 1.92 3.38 0.0522 24.9 2
used according to the material to be cast. Different casting (hydropower)
Reduction in 12.9 0.0877 4.71 4.03 0.064 26.7 4.78
materials exhibit distinct HAP emission characteristics and resin
levels. Quantity of HAPs such as cresols benzene, toluene, consumption
naphthalene, and phenol in casting processes can be reduced Reuse of 13 0.0879 4.74 4.14 0.649 26.7 4.84
by using organic resins and chemical binders [11]. For a waste sand
Scrap 9.49 0.0747 3.87 3.6 0.0427 13.5 4.08
foundry having a capacity of 50 units/day, a reduction of 0.1 recycling
kg CO2 per functional unit can be achieved by reducing binder -3
GWP: (Kg CO2 eq.); AP: (Kg SO2 eq.); EP: (*10 ) (Kg Phosphate eq.); ODP:
or resin consumption and it leads to a total reduction of 1680 (*10-14) (Kg R11eq.); FAETP: (Kg DCB eq.); HTTP: (Kg DCB eq.);
kg CO2 annually. To reduce HAPs emissions more POCP(*10-3): (Kg Ethene eq.)
environmentally friendly casting materials should be
developed to replace the conventional materials.
Electricity which is the major source of energy in casting About 40 percent reduction in Kg CO2 eq. can be achieved by
processes has a great impact on the emissions level. In this using wind or hydropower as a source of electricity
research work, four different cases of electricity such as wind, production. Also, a 68 percent reduction in Kg SO2 eq. and a
solar, biomass, and hydropower are considered. Electricity 59 percent reduction in eutrophication potential will be
from wind and hydropower reduces emissions to the air. achieved using wind as an electricity source. Electricity from
Electricity from biomass increases emissions to air and biomass results in a 13 percent increment in eutrophication
reduces emissions to freshwater. Presently in India, most of potential as compared to the base scenario. All over in terms
the electricity is produced from fossil fuel-based power plants, of Kg CO2 emission hydropower and wind are the best
but in the future to achieve the government's ambitious green available sources for electricity production. POCP and HTP
energy targets it is expected that renewable energy will data also signify that hydropower and wind are the best
 Ankit Yadav et al. / Procedia CIRP 98 (2021) 181–186 185
Author name / Procedia CIRP 00 (2019) 000–000 5

among the four different sources considered in this study. emission, and energy consumption). In this study, 8 different
cases are compared to find the best one in terms of lower
Results by combining different cases: emissions.
About 40 percent reduction in CO2 emissions can be achieved
Among the eight different cases considered, In this research by using wind or hydropower as a source for electricity
most significant are using wind and hydropower as a source production. The key environmental issue in the sand casting
for electricity production during the sand casting process. But process is a solid waste generation, energy consumption, and
these different cases can be combined to achieve a more emission of hazardous air pollutants (HAPs). Landfilling of
environmentally friendly scenario which results in cleaner solid waste creates the greatest environmental impact. About
production Table 4 consists of 16 different combinations out 91 percent reduction in solid waste can be achieved by solid
of which 16th is the best one in terms of lower emissions. waste recycling.
Scrap recycling results as an environmentally friendly
Table 4: Results by combining different cases practice, because aluminum is an infinity recyclable material.
Recycling aluminum metal leads to a saving of 95 percent
S.No EW ES EB EH RIS RS SR
Kg Kg SO2 energy, as compared to producing aluminum from raw
CO2 eq. materials. Four different sources of electricity (wind, solar,
eq. biomass, hydropower) are considered in this study to find the
1 * * 7.76 0.0277 best one among them, because in the next 10 to 15 years
2 * * 7.86 0.0279 renewable will provide major input in electricity production.
3 * * 4.35 0.0147
4 * * 7.95 0.0285
Overall this research work concluded that using renewable
5 * * 8.05 0.0287
6 * * 4.54 0.0155
sources of energy with some modification in the sand casting
7 * * 8.06 0.0500 process results in a 67 percent reduction in CO2 emissions so
8 * * 8.16 0.0502 renewable energy has a good chance of becoming the energy
9 * * 4.65 0.0370 of choice in the future. LCA methodology was used here to
10 * * 7.74 0.0276 demonstrate the environmental impacts of the sand casting
11 * * 7.84 0.0278 process. LCA methodology proves to be effective in
12 * * 4.33 0.0146 establishing the integrated approach required for informed
13 * * * * 4.25 0.0145 decision-making in cleaner production activities
14 * * * * 4.44 0.0153
15 * * * * 4.55 0.0368 Future work recommendation
16 * * * * 4.23 0.0144
EW: Electricity Wind, ES: Electricity Solar, EB: Electricity In this research work, LCA is done for the manufacturing
Biomass, EH: Electricity hydropower, RIS: Reduction in resin, RS: phase of sand casting means this is a gate to gate approach. In
Reuse of Sand, SR: Scrap recycling the future researchers can work on the cradle to grave analysis
of the sand casting process from raw material extraction to
A cumulative 67 percent reduction in CO2 emission can be end of life. Also, life cycle cost analysis can be performed to
achieved by combining all available scenarios with find out the best scenario in terms of cost-friendly, because
hydropower as an energy source. Table 5 includes the reducing the quantity of pollution may not always be
emission of the base scenario and the best available scenario. sufficient motivation for manufacturing industries. LCC will
help to find out the scenario which is cost-friendly so that the
Table 5: Comparison between the base scenario and best industry can adopt that scenario practically.
available scenario
Acknowledgment
Emission/waste Base Best % Reduction
scenario alternative
GWP 13 4.23 67.46 Author(s) received financial support from TEQIP-III
(Kg CO2 eq.) sponsored project “Exploration of sustainable manufacturing
AP 0.0879 0.0144 83.61 in Indian manufacturing industries” for this research work.
(Kg SO2 eq.) Author(s) are also thankful for the Southern-based additive
Solid waste 32.664 kg 2.664 kg 91.84 manufacturing industry to provide valuable data for this study.

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