Table 4. Percent Change From Conventional Baseline When Using AO-HAC Baghouse Dust Baghouse Plus Green Sand


Total System (including upstream)


molding, pouring, cooling and shakeout.


In pilot-scale production,


reclaimed sand was clean enough to use as core sand. When used in a full-scale demonstration, reclaimed sand cores produced castings of equal or better quality than when using cores from pristine commer- cial sand. Te AO-HAC system can reclaim 85% of normally disposed green sand. Based on this perfor- mance data and the synergistic effects of AO-HAC relative to an advanced oxidation-blackwater clarifier system, the life cycle and cost comparisons in Table 4 show that the AO-HAC system, even when used for baghouse dust only, can significantly reduce VOC production.


Innovations for Implementation The most significant cost,


energy and material savings occur when metalcasting facilities adopt


Energy Fossil


Non-fossil Emissions


Greenhouse gas Criteria pollutants Particulates VOCs


Foundry Facility


Materials New sand


Phenolic resin Clay


Seacoal Cereal


Soda ash


Coke, pig iron, scrap, other Home scrap


VOCs – pouring, cooling, shakeout Costs


Energy Labor


Materials


Other costs Total


Projected Payback (in years)


-0.6 -0.7 -2.9 -1.1 -1.5 0.4


-0.6 -0.7 -6.9 -1.3 -3


0.3


-4.4 -0.7 -38 -38 -38 -38


-0.7 -8.6


-41.4 -85


-0.7 -50 -50 -50 -50


-0.7 -8.6


-41.4


-1.2 -0.6


-12.4 -24.1


-1.7 -0.6


-50.6 -24.1


-0.6 -0.6


-0.6 -0.6


March 2014 MODERN CASTING | 51


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