Table 4. Percent Change From Conventional Baseline When Using AO-HAC Baghouse Dust Total System (including upstream)
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
Baghouse Plus Green Sand
These formed anthracite bricks were used in a
full-scale cupola facility in Pennsylvania. This trial employed four tons of bricks formed with biomateri- als, with 25% substitution of the bricks for coke for a half day. The bricks remained intact during rough handling when charged into the cupola and were still intact as they descended to the tuyere windows, where temperatures reached 3,000F (1,550C). During this brick substitution, the total carbon charged into the furnace (i.e., carbon in the coke plus bricks) decreased 6%, while maintaining a constant melt tempera- ture, more favorable CO/CO2 ratio and a favorable olive-green slag color that indicated suitably reduced conditions for metallic iron formation. The carbon content of the iron product remained constant, while the iron maintained acceptable levels of silicon, sulfur and other trace metals. The demonstrations main- tained the iron product quality. The more effective energy release could diminish
natural gas requirements in metalcasting facilities that inject supplemental natural gas into the cupola. The anthracite bricks must be dried at 248F (120C), which requires considerably less energy than coking coke at 1,652-1,832F (900-1,000C) for 26-30 hours. This study estimates the impacts of two variations
of coke replacement: 20% and 50% replacement of coke with anthracite bricks. In light of the energy consumed when making coke, the coal-related life
炭的替代物。在投入冲天炉的粗糙搬运过程中、下 降到温度高达3000℉（1550℃）的风口部位时， 团块仍保持完好无损。用团块的代替期间，装入炉 中的总碳量（即焦炭和团块中的碳）减少6%，且 保持一个恒定的熔炼温度，良好的CO / CO2比和 橄榄绿色的炉渣，表明适当地降低了铸铁的形成条 件。铸铁产品的碳含量保持不变，且铸铁中的硅、 硫和其他微量金属的含量都适当。试验保持了铸铁 产品的质量。
由于更加有效的能量释放，向冲天炉中补充喷 射天然气的企业，可减少其对天然气的需求。无烟 煤团块必须在248℉（120℃）下进行干燥，与在 1,652-1,832℉(900-1,000摄氏度)下焦化26-30小时 的焦炭相比，所需的能量要少的多。 该研究评估了焦炭替代物的两个变量的影响：无 烟煤团块替代20%和50%的焦炭，使用20%的焦炭 替代物和50%的焦炭替代物时，与焦炭相关的生产 活动范围中能量的消耗，分别减少0.6%和 1.5%（ 见表3）。空气排放物指数降低，温室气体和挥发性 有机化合物大幅减少。
June 2014
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 53
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