in cast iron facilities to better understand the costs and environmental benefits of sustainable technologies cur- rently under deployment in the industry and those near- ing commercialization. Te potential innovations involve advanced oxidation systems for recycling baghouse dust and green sand, binder technologies that reduce VOCs and replace coke, and binder systems developed from waste products in non-metalcasting processes to replace materials that produce large amounts of VOCs.
A Basis for Comparison A baseline model is necessary to measure the use of
resources, emission profiles and costs related to existing and prospective casting technologies. Tis control model is calibrated for an actual cupola-based iron casting facility in Wisconsin that uses metallurgical coke, conventional green sand molding, no recycling of baghouse dust or sand, and no innovations for releasing sands or clays from their carbon coating. Tis baseline also uses phenolic urethane cores cured with amine gas. Te operation was used to estimate the impact of the various sustainable production technologies. Te life cycle boundaries include major upstream activi- ties that supply inputs to iron casting facilities. Te model accounts for energy, materials, environmental emissions, operating costs and capital costs. Tese metrics are tracked at each intermediate stage of production, including hot metal making, coremaking, green sand molding, pouring, cooling
成本和环境效益。这类前景看好的创新包括袋式除尘器 粉尘和粘土湿型砂回收利用的新型氧化系统，减少挥发 性有机化合物、代替焦炭的粘结剂技术，以及由非金属 铸造工艺中产生的废弃物研发出来的取代产生大量挥发 性有机化合物的材料的粘结剂系统。
比较的基础
为了评估资源的使用、排放情况以及与当前使用的和 预期的铸造工艺相关的成本，需要一个基础性的标样。 该控制标样是就位于威斯康辛州的一个冲天炉铸铁企业 标定的，该企业采用冶金焦炭、传统的粘土湿砂造型工 艺，袋式除尘装置收集的粉尘或废砂不再循环利用，在 脱除旧砂或粘土上的碳质覆盖物方面也没有创新。基础 性标样还使用胺硬化的酚醛尿烷砂芯。用这种作业方式 来评估各种可持续生产技术的效果。
生产活动的范围涉及为铸铁厂提供输入材料的主要 上游生产活动。标样中涵盖了能源、材料、排放物、运 营成本和资本投入。生产中的每一个中间环节对这些数 据进行跟踪，包括热金属的制备、制芯、湿砂造型、浇 注、冷却和落砂。下游的铁制品回收和循环利用没有考 虑在内，因为创新的工艺不影响这些过程。
Fig. 1. The chart shows the baseline input- output boundaries for the conventional cupola iron casting facility used for this analysis.
June 2014
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