Reining in Costs, Controlling Emissions
Innovations in binders, coke replacements and advanced oxidation may decrease consumption and boost efficiency in ductile iron casting facilities.
BY ROSE TORIELLI, FRED CANNON, ROBERT VOIGT, TIMOTHY CONSIDINE, JAMES FURNESS, JOHN FOX, JEFF GOUDZWAARD AND HE HUANG 控制成本，控制排放
在粘结剂、焦炭替代物和先进氧化技术方面的创新，可以为球墨铸铁件生产企业 降耗提效。造型线，在大型铸件市场中占有一席之地。
作者：Rose ToRielli, FRed Cannon, RobeRT VoigT, TimoThy Considine, James FuRness, John Fox, JeFF goudzwaaRd and he huang
industry faces worldwide competition for low cost, high- grade iron and steel scrap amid ever tightening air quality standards. Technological innovation involving raw materials is essential, because they represent one of the largest produc- tion costs for many facilities. Additionally, while conventional end-of-pipe emission
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controls can add substantially to capital investment and operating costs, innovations aimed at emission sources can reduce costs. Tese advancements also may reduce emissions of volatile organic compounds (VOCs) and enable compli- ance with increasingly stringent U.S. Environmental Protec- tion Agency standards. A team of university researchers, development entrepre- neurs and metalcasting personnel has been pursuing sus- tainable technologies for the metalcasting industry, with a particular focus on cast iron. Te researchers have developed three major innovations: 1. The replacement of phenolic urethane core binders with binders composed of hydrolyzed collagen, alkali silicates and other additives can cut VOC pollution by two-thirds.
2. The replacement of conventional metallurgical coke in cupolas with anthracite fines formed into bricks with hydrolyzed collagen, lignin and other additives burn as fast as coke while producing 35-40% more energy per volume.
3. An application of advanced oxidants and hydroacoustic cavitation to spent green sand and baghouse dust restores the binding activity of the clay and cleans the sand. This process reduces costs by decreasing clay, coal and sand consumption, while also diminishing air pollution from VOCs and hazardous air pollutants. Tis study evaluates the flow of energy and materials
n 2012, gray and ductile iron castings represented 68% of the total casting tonnage in the U.S., the world’s third largest producer of gray iron castings and second largest of ductile iron. Te American metalcasting
012年，美国灰铸铁件和球墨铸铁件占铸件总产 量的68%，分别是世界第三大灰铸铁件和第二大 球墨铸铁件生产国。在大气质量标准日益严格的 条件下，美国铸造行业面临着低成本、优质废钢铁的全 球争夺。在很多企业生产成本中，原材料都占有最大的 份额，因此，原材料方面的技术创新是至关重要的。 此外，在管道终端控制排放的传统方法可能大幅度地 增大投资和运营成本，而针对排放源的技术创新可以降 低成本。这方面的进步还可以减少挥发性有机化合物的 排放，能适应日益严格的美国环境保护署的环保标准。 一个由大学科研人员、关心研发工作的企业家和铸造 工作人员组成的团队已经开始探索铸造行业的可持续发 展技术，其中一个重点是铸铁。科研人员已研发了三项 主要的创新：
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1.用由水解胶原、碱性硅酸盐和其他添加剂组配的粘结 剂代替酚醛尿烷砂芯粘结剂，挥发性有机化合物的排 放可减少2/3。
2. 用无烟煤颗粒与水解胶原、木浆胶和其他添加剂制成 的团块代替冲天炉用的冶金焦炭，燃烧速度与焦炭 一样，但是，每单位体积燃料产生的能量比原来多 35-40%。
3. 对于用过的粘土湿型砂和袋式除尘器收集的粉尘，应 用新型氧化剂和水声空化技术，可恢复粘土的粘结作 用，并可清洁砂粒。该工艺通过减少粘土、煤和砂子 的用量以降低成本，同时也减轻了挥发性有机化合物 和有害气体造成的空气污染。
这一研究评估了铸铁企业的能源和材料流程，以更好 地理解目前在行业实施的近商品化的可持续发展技术的
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION June 2014
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