Keeping scrap yard sand/dirt to a minimum and away from the charge bucket will provide not only energy benefits, but also reductions in potential fugitive dust and the dust collec- tion required to capture it.


The same principles can be applied to the non-ferrous found- ry. Returns entering a gas melting furnace should be as clean as possible. Ingots should be introduced into the bath direct- ly and not placed on the hearth and allowed to oxidize.


Other Areas for Savings


The maintenance of insulation on all heated ductwork keeps process heat where it belongs. In the winter months, heat leakage might be considered acceptable as a supple-


mental building heat source, but in the summer, it adds to the plant temperature load and will need to be exhausted from the plant. Perform regular inspections on all duct- work and calculate the heat losses. In almost every case, the value of insulating ductwork and piping will be recov- ered quickly.


Cores/Binder Systems


Corerooms are particularly good candidates for im- proving your greenness. The U.S. Environmental Pro- tection Agency (EPA) is required to regulate hazard- ous air pollutants (HAP) from major sources including foundries under the Clean Air Act of 1990. The Casting Emissions Reduction Program (CERP) was created to


Figure 6a. Sheared scrap can contain 5-8% of non-metallics. It takes 1.7-2 times the energy to melt slag than iron.


Figure 6b. Shredded scrap can reduce energy by 15-20%.


(a)


(b)


(c)


(d) Figure 7. a) Sprue drum, b) shake out blast, c) outside media drum, d) inside media drum. International Journal of Metalcasting/Summer 10 13


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