IJISET - International Journal of Innovative Science, Engineering & Technology, Vol.

4 Issue 6, June 2017

ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
[Link]

A Review on Effects of Hazards in Foundries to Workers and

Environment

Christopher T. Mgonja (PhD)

Department of Mechanical Engineering, Dar es Salaam Institute of Technology, Dar es Salaam, Tanzania

Abstract that result from bad working conditions which do not meet
The working environment of foundries is hazardous and the requirements of hygiene and environment [6].
characterized by multiple simultaneous chemical, physical and Although many changes have occurred in foundry
mechanical hazards exposure, which would lead to injuries of
foundry workers. Health risks from working in the foundry technology and materials, the basic processes and the
industry include exposure to molten metal fume (foundry fume), associated hazards have remained much the same in many
heat and spray mists. In addition to these hazards; some foundry foundries. Some of the most common causes of injury and
workers work with dusts produced by casting sand, fettlings and illness in these industries are: (i) exposure to silica; (ii)
kiln linings, which contain silica and, when dry, produce silica exposure to mineral wools and fibres; (iii) contact with hot
dust known as respirable crystalline silica (RCS). This paper
provides an overview of foundry industry and hazards, health metal; (iv) fire and explosion (v) extreme temperatures; (vi)
effects and safety measures. It presents the information currently non-ionizing and ionizing radiation; (vii) noise and
available from different published research works and involves vibration; (viii) inhalable agents; (ix) skin contact with
the group of people that can be affected by foundry hazards chemicals [2].
including foundry workers and nearby workers. It further
indicates how the foundry industry contributes to environmental In foundries, metals are extracted and produced from ores
pollution. Through this review, it has been revealed from by various metallurgical processes and processes for
different studies that hazards in foundries are many and very
moulding, melting and castings etc. are accompanied by
dangerous both to foundry workers’ health and to the
environment which eventually affect the wider population.
evolution of heat, noise, dust fines, fly-ash, oxides of
Keywords: Foundry, Health hazards, Workers exposure, Metal Nitrogen, Sulphur and metals. Particulate matters are
fumes, Pollution, Solid waste, waste water, Noise. generated in large quantities when preparing mould core
sands and moulds melting metals, pouring metal, knocking
out poured moulds and loading and unloading raw
1. Introduction materials. Here metals are given a specific shape by metal
castings for various engineering purposes [7]. Gaseous
Foundries are integral part of the history of mankind. matters like gases, vapours, fumes and smoke are produced
Foundries have been known for thousands of years [1]. during melting and pouring operations. The major
Founding is the simplest of all metallurgical processes and pollutants are emitted from various work areas in Foundry
one of the oldest of all industries. Two main procedures i.e. Pattern shop, Sand preparation, moulding and core
are carried out in a foundry: sand moulding and metal making, mould drying and ladle heating, cupola, electric
casting. The casting process consists basically of pouring arc furnace, pouring and mould cooling, knockout, fettling,
liquid metal into a mould containing a socket in the heat treatment etc. [7].
geometry desired for the final part. The processes can be
classified by the type of mould and model and by the force Many people are exposed to common air pollutants in their
or pressure pair used to fill the mould with the liquid metal occupations e.g. smoke, dust, suspended particulate
[2, 3]. matters (SPM), respirable suspended particulate matters
(RSPM), carbon monoxide, sulphur dioxide, oxides of
This industry is diverse in terms of materials and processes, nitrogen (NO x ), hydrocarbons, and heavy metals like Pb,
resulting in occupational exposures to a wide range of Cd, Cr, As, Ni, Zn etc. Their prolonged exposure causes
hazard substances or workplace activities that could cause various health hazards. Heavy metals cause acute and
diseases, injury, ill health or death [4]. Hazard is anything chronic poisoning. The term “heavy metals” refers to any
with the potential to cause harm [5]. It is a danger that metallic element that has a relatively high density and is
toxic or poisonous even at low concentration [8]. Some
includes the whole factors and accompanying occurrences
disastrous episodes have focused attention upon air
which make harm to the human organism, property or
pollution as a health hazard [7].
environment. Very dangerous occur to be the disease risks

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ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
[Link]

Climate changes have a negative influence on water and automobile parts, textile parts, corrosion resistance parts,
food production but, on the other hand, they are necessary marine parts, impellers, clamps and connectors, over-head
for human existence. Sustainable development is the basic conductors etc. [13]. Non-ferrous castings are fast
approach to the environment in modern times. Energy consuming items and the area of application for these items
consumption and environmental issues with climate are vast. Due to certain inherent advantages of mechanical
changes are global problems, and industry influencing it is and chemical properties, the use of non-ferrous castings is
the foundry industry [4, 9]. The foundry industry can increasing day by day. The consumption of these items is
negatively impact the environment through its use of by Automobile Industries, machine manufacturing
thermal processes and mineral additives. Managing its industries, textile industries, electrical industries and so on
environmental footprint is therefore related mainly to acid [13]. Fig. 1 presents a general foundry process fluxogram
gases and the recycling of mineral waste [4]. There are [10].
relatively permanent earth atmosphere components: O 2 , N 2 ,
CO 2 , H 2 O and other gases. However, emissions of
pollutants of anthropogenic origin may drastically change
proportions at the local and global level [4, 9]. The climate
changes influence the food production, water quality, and
pollution and it is necessary to develop an adequate
strategy for protection [9].

2. Foundry Industry
Foundries melt ferrous and non-ferrous metals and alloys
and reshape them into products at or near their finished
shape through the pouring and solidification of the molten
metal or alloy into a mould. The foundry industry is a
differentiated and diverse industry. It consists of a wide
range of installations, from small to very large; each with a
combination of technologies and unit operations selected
to suit the input, size of series and types of product
produced in the specific installation. The organisation
within the sector is based on the type of metal input, with
the main distinction being made between ferrous and non-
ferrous foundries. The casting of metal is an ancient
activity, dating back to more than 3000 BC [10].

Steel industry plays an important role in the

industrialization and development of a country, as it has
the input within all manufacturing sectors. However, one Fig. 1 The foundry process
of the most important problems encountered in steel
foundries throughout the world is the management of the
dusts produced during melting [11]. Ferrous metals 3. Foundry Hazards, Effects and Control
foundries require metal of controlled composition and Measures
temperature, supplied at a rate sufficient to match the
varying demands of the moulding line. The metallic charge Major hazards in the foundry industry are: Working in
to be melted consists usually of foundry returns, iron heat; hazardous chemicals (incorporating hazardous
scraps, steel scraps and pig iron with alloying additions substances and dangerous goods); airborne contaminants;
such as ferrosilicon [12]. manual tasks; noise; vibration; molten metal; plant and
machinery and electricity [3, 14].
The castings of metals and alloys of copper, zinc, tin,
aluminium, lead etc. come under the group of non-ferrous 3.1 Heat Exposure
castings. Some of the prominent alloy castings are Brass,
Bronze, Aluminium Bronze, Gun Metal etc. These castings High temperatures and direct infrared (IR) radiation are
are used for various purposes like bearing, bushes, common hazards in foundries [15]. Where the body is

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ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
[Link]

unable to lose heat fast enough through the evaporative chemicals can create different hazards including fires or
cooling process to maintain a steady core body explosions as well as short and long term effects on
temperature, it begins to experience physiological heat specific organs of the body. Prolonged exposure to
strain with different illnesses depending on the degree of hazardous chemicals may result in the following health
heat stress [14, 16]. effects: headaches; nausea; fatigue; irritant or allergic
dermatitis; asthma; bronchitis; chemical burns; irritation of
Potential health effects for persons under increasing the nose, eyes and respiratory tract; adverse effects on the
levels of heat stress include: discomfort; heat fainting; central nervous system and other bodily systems, including
heat stroke; prickly heat; irritability, dehydration; reduced the lungs, kidneys and liver [3, 14, 21]. Work activities
concentration or attention; heat rash; reduced tolerance to that are not essential should be eliminated wherever
chemicals and noise exposure; heat cramps; heat practical. For example: use a physical process to clean an
exhaustion; Heat cramps, heat exhaustion and heat stroke object (e.g. ultra-sound) instead of using a chemical
are the most serious forms of heat illnesses. Heat stroke is process; use clips, clamps or bolt instead of adhesives;
a life threatening condition and may result in permanent purchase supplies of a material in a ready-cut and sized
damage to the heart, kidneys and brain. The effects of heat form rather than carrying out a dust producing cutting
stress are most likely to increase during the hot season [14, process on site, the area should be well ventilated [14, 21].
16]. Exposure of the skin to strong IR may lead to local
thermal effects and even serious burns, especially if the 3.3 Airborne Contaminants
exposure covers the whole body [17]. Eliminating
situations that could lead to heat related illnesses is the This is a contaminant in the form of a fume, mist, gas,
best form of control strategy. This can be done by: vapour or dust, and includes microorganisms. Significant
eliminating unnecessary sources of radiant heat; concentrations of airborne contaminants (e.g. gases,
eliminating sources of water vapour in the workplace (i.e. vapours, fumes and dusts) may be encountered in all facets
leaks from steam valves, evaporation of water from wet of foundry operations. Metal fumes are formed by the
floors, etc.) [14, 16]. Where exposure to heat cannot be evaporation, condensation, and oxidation of metals in air.
prevented or reduced by any other form of control, all These contaminants may be encountered in many areas
exposed persons must be provided with PPE. PPE may be including pattern making, core making, mould making,
used in addition to other control measures. The PPE are: furnace, fettling and sand plant sections. Hence, in
eye wear, such as ultra-violet glasses and radiant energy foundries furnace tenders, melters, casters, ladlemen,
reflective face shields; non-flammable and heat reflective pourers, and crane operators are exposed to the smoke and
clothing and equipment; water cooled bodysuits/vests and fumes during melting [14, 22]. In foundries, airborne
other equipment; protective gloves and footwear- contaminants may be released by, or generated from: the
Metatarsal safety shoe with Heat resistant soles [14, 15, 18, handling of scrap - receiving, unloading, storage and
19,]. conveying; scrap preparation using heat and solvent
degreasers - carbon monoxide; the melting process -
3.2 Hazardous Chemicals carbon monoxide, sulphur dioxide, nitrogen oxides,
chloride and fluoride compounds; the treatment and
Hazardous chemicals (which incorporate hazardous inoculation of molten metal before pouring; core and
substances, dangerous goods and combustible liquids) are mould making processes during sand reclamation, sand
widely used in the foundry industry. The Regulation also preparation and sand mixing; mould and core forming
requires manufacturers or importers of a hazardous processes including core baking and mould drying from
chemical to prepare a Safety Data Sheet (SDS) for each additives, binders and catalysts; cooling of casts causing
hazardous chemical dealt with and for suppliers to provide decomposition of organic binders; casting knockout and
a current SDS to any person that is likely to use or be shake-out; and fettling [3, 14, 23, 24,].
affected by the hazardous chemical. Hazardous chemicals
common to the foundry industry include: amines; benzene; Health Effects of Airborne contaminants: Other gases
hexachloroethane; ammonia; epoxy resins; formaldehyde; may indicate their presence by various irritating effects
furfuryl alcohol; isocyanates; mould release paints; such as respiratory irritation, coughing, asthma, acidic taste
protective coatings; phenol; crystalline silica etc. [3, 14, 20] and eye irritation. The inhalation of wood dusts causes a
slowing of dust clearance and alteration to the structure of
Health Effects of Hazardous Chemicals: Hazardous the mucous membrane lining of the nasal cavity. This may
chemicals can enter the body through inhalation, skin be accompanied by the risk of cancer of the nasal cavity
contact or by accidental ingestion. Different hazardous and sinuses. Some wood dusts also act as sensitisers that

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ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
[Link]

may manifest itself as a skin rash, inflammation or as an monitoring to ensure airborne contaminants do not exceed
asthmatic condition. The inhalation of heavy metal dusts the exposure standard; training in safe work practices [14]
may produce diverse health effects depending on the and use and maintenance of personal protective equipment.
specific metal dust involved. For example: iron dust may Personal protective equipment that can be used in the
accumulate in the lungs and cause siderosis; aluminium control of airborne contaminants includes: face and eye
dust irritates the respiratory system and may result in protection; respiratory protection appropriate to the
chronic non-specific lung disease; beryllium dust irritates contaminant; respirators with organic vapour filters for
the lungs and may result in tracheobronchitis, pneumonitis organic vapours [14, 18].
and beryllosis, and may also be a possible carcinogen; lead
dust results in systemic poison effects; manganese dust 3.4 Manual Tasks
irritates the lungs and may have a chronic effect on the
nervous system; nickel dust irritates the respiratory tract This is a task that requires a person to lift, lower, push, pull,
and some nickel exposures may result in lung or nasal carry or otherwise move, hold or restrain any person.
cancer [14, 23, 15]. Manual working is a major source of hazards and problems
for industrial workers worldwide. Tasks which are
Respirable crystalline silica (RCS) dust presents one of the performed manually constitute a considerable proportion
greatest risks to the health of foundry workers. Fine silica of work done in industries around the globe, especially in
dust is produced in foundries by the rubbing, abrading or developing areas. Manual carrying is defined as the
mechanical action on quartz and which is primarily unaided moving of objects, often combined with twisted
composed of crystalline silica. The major foundry and awkward postures, contributing to musculo-skeletal
operations which produce RCS dust are mould and core disorders (MSDs) [27, 28, 29, 30]. These tasks are part of
making, shakeout, cleaning of castings, furnace and ladle nearly all work done by workers. They include any activity
repair, sand reclamation and sand preparation. The where workers grasp, manipulate, carry, move (lift, lower,
principal health effect associated with silica dust is push, pull), hold or restrain a load. Workers in most areas
silicosis, which is stiffening and scarring of the lungs. within a foundry would perform manual tasks. The areas
Silicosis is a chronic disease, and usually takes a number that involve frequent performance of manual tasks include
of years for the symptoms to appear. It results in increasing pattern and core making, moulding, fettling shops, stores
shortness of breath, coughing and chest pain. The effects and dispatch, inspection and surface coating area [14].
are irreversible, and lead to degeneration in the person’s
health, invariably resulting in the premature death of the Health Effects of Manual Tasks: Over a period of time,
worker. Silica is also now classed by the International damage to the low back, upper back or shoulder can
Agency for Research on Cancer as an occupational gradually build up through: frequent lifting with the back
carcinogen, where excessive exposures can lead to bent or twisted, or pushing/pulling loads; working in a
irreversible lung cancer [14, 23, 25, 26]. fixed position with the back bent, continuous sitting or
standing, or driving vehicles for long periods; repetitive
There are a number of control options that can be used work with the hand or arm, and having to grip tools or
alone, or in combination, to prevent or minimise exposure loads tightly; working with the neck, shoulders and arms in
to the risk. The risks from airborne contaminants may be a fixed position (e.g. using tools and handling heavy loads).
controlled by substituting a hazardous process or material Manual handling risks may be removed by redesigning
for a safer one. For example: using wet (with caution for equipment or work practices; reduce the amount of force
recycled sands) or vacuum methods or brushes to remove required to carry out the tasks by utilising conveyor system,
loose dust or sand in the mould making process rather than hoists, cranes or forklift trucks, trolley systems and
compressed air to minimise dust creation and using position tasks at comfortable working height.
chromite sand instead of silica sand. Engineering controls Administrative controls involve task specific training;
may involve the use of plant or processes which: minimise work organisation; preventive maintenance programme [14]
the generation of a contaminant; suppress or contain a and personal protective equipment (PPE). To prevent a
contaminant; limit the area of contamination [14, 20]. decrease in work efficiency or an increase in injury
Administrative controls largely involve the development potential, consider the following: Clothing which restricts
and training of workers in safe work practices and the ability to move freely should not be worn; when gloves
procedures that should be used in combination with other have to be worn provide different sizes so the right size
control measures for airborne contaminants. For example: can be selected and cover only the area of the hand
use of continuous monitoring devices to monitor the levels necessary to protect the worker; provide knee protectors
of carbon monoxide in the work area; systematic

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ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
[Link]

for work involving kneeling to reduce stress on the knee (8 Hz to 1 kHz). Foundry workers may be subject to
[14, 18]. whole-body vibration during shake out processes, sand-
slinging and from forklift truck, conveyor, overhead crane,
3.5 Noise pneumatic ramming operations and jolt-squeeze machines.
Hand-arm vibrations occur when using hand-held power
Hazardous noise is unwanted sound that may damage a grinders, chippers and other pneumatic tools [14, 33].
person’s hearing. The amount of damage caused by noise
depends on the total amount of energy received over time. Health effects of vibration: Vibration disease may
This means as noise becomes louder, it causes damage in develop after several years of exposure and result from
less time. In the foundry industry, hazardous noise levels either whole body vibration or segmental (hand arm)
are produced in many operations. The noise created by vibration. The main effects of whole-body vibration
foundry machinery is complex due to the wide variety of include: blood pressure and heart problems; nervous
noise sources and whether it is constant or intermittent. disorders; stomach problems; joint and spine damage,
These noise sources include: machinery used in pattern influence on speech, shortness of breath, chest pain. The
making; moulding machinery; core-making machinery; factors that influence the effect of vibration on the hand
furnaces; shake-out and knockout of castings; machinery and wrist include: vibration frequency; level of insulation;
used in tumbling, grinding and cleaning of castings; duration of exposure etc. The symptoms include: blanching
fettling and dressing of castings [14, 15, 31, 32]. and numbness in the fingers (white finger disease);
decreased sensitivity to touch, temperature and pain; loss
Health Effects of Noise include: temporary threshold shift of muscular control and discomfort and/or pain in the
which occurs immediately after exposure to high noise joints, such as the wrists, elbows and shoulders. [14, 34]
levels, condition may last for minutes to hours; noise The control measures of vibrations are: tools with
induced hearing loss that occurs from long term exposure vibration dampers should be used. They should weigh as
to high noise levels, irreversible; tinnitus which is ringing little as possible to reduce muscular effort and have
in the ears that sometimes accompanies noise induced handgrips that do not involve twisting the hand away from
hearing loss; acoustic trauma resulting from explosions or a normal position while using the tool [14, 35]; Machinery
extremely loud impulsive noise which may destroy the cilia must be designed and constructed in such a way that risks
hair cells and ear structure. In addition high noise levels resulting from vibrations produced by the machinery are
may cause difficulties in verbal communication and in reduced to the lowest level [34]. Administrative controls
hearing warning signals or emergency commands. The involve the development of safe work practices and
following control measures are listed in order of the most procedures like labelling equipment to warn workers of
effective way of managing risks from noise: elimination by: potential hazards; avoiding prolonged use of vibrating
replacing the machine or its operation with a quieter equipment etc. [14, 35]. Where exposure to vibration
alternative with equal or better efficiency; replacing noisy cannot be prevented or reduced by any other form of
machinery with newer equipment designed to operate at control, PPE should be provided like: protective gloves
lower noise levels; correcting the specific noise source by and provision of vibration absorbing materials [14, 18].
design changes (e.g. replacing metal components with
plastic). The engineering noise control measures for 3.7 Molten Metal
managing noise levels are treatment of: the source; the
noise transmission path and treatment at the receiver. Molten metal is a major hazard in foundry melting and
Administrative control measures include: Sign posting pouring areas. Workers, who perform tasks with or near
noisy areas; providing quiet rest areas for food and rest molten metal, may come into contact with metal splashes
breaks; limiting the time workers spend in noisy areas by and be exposed to electromagnetic radiation. Extreme
moving them to quiet work areas before their daily noise caution must be taken to prevent metal and metal slag from
exposure levels are exceeded etc. [14, 31, 33]. Workers coming into contact with water or moisture, as this may
should be supplied with personal hearing protectors as ear result in an explosive reaction or ejection of molten metal
plugs; ear muffs and ear caps [14, 18, 25, 20]. with catastrophic consequences. Electromagnetic radiation
is emitted from molten metal in the furnaces and pouring
3.6 Vibration areas. Foundry workers are mainly exposed to infrared and
ultraviolet (UV) radiation [14].
Exposure to noise in industry is often accompanied by
exposure to vibration which is classified as: whole body Health effects of molten metal: Serious burns may result
vibration (1 to 80 Hz), or hand-arm or segmental vibration from splashes of molten metal and radiant heat at any time

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ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
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in the melting and pouring areas. Sparks from molten metal 3.9 Electricity
may also damage the eyes. Exposure to infrared and UV
radiation may result in eye damage including cataracts. To Electrical risks are risks of death, electric shock or other
control molten metal exposure, barriers and other injury caused directly or indirectly by electricity.
suitable shields, including mobile shields should be used or Electricity can cause death or serious injury. Foundry
installed to protect workers against molten metal splashes workers who may be exposed to the risk of injury from
and electromagnetic radiation; restricting visitors and electricity include those who work with or around
workers from wearing synthetic clothing, including electrical equipment in areas such as the pattern shop,
undergarments when entering the furnace and pouring fettling shop, and the furnace section. The common
areas; keeping melting and pouring areas free of electrical hazards and causes of injury can be broken into
combustible materials and volatile liquids using: heat three broad categories: Electric shock which can cause
resistant protective clothing as footwear, headgear, face injury or death [14, 37]; Table 1 shows the effects of
shields, fire retardant spats, aprons, coats and gaiters; eye current on the human body. Arcing, explosion or fire that
protection with side shields; special UV and infra-red cause burns and Toxic gases causing illness or death.
glasses [14]. There are a number of control measures that can be used
alone, or in combination, to reduce the level of risk of
3.8 Plant and Machinery injury from electricity:

Special care should be taken with plant and machinery Table 1: Effects of current on the human body [38]
used in foundry environments. For example, the elevated
temperature in a foundry creates greater stress on crane
components and may dramatically reduce a crane’s
working life. Continuous vibration of some equipment
results in increased mechanical stress on nuts, bolts, chains
and cables, which may eventually lead to equipment failure.
This in turn may result in major explosions, fires, spills
and burns. Atmospheric particulate matter also increases
wear through contamination of lubricants and ingress to
bearings [14].

Health effects of plant and machinery: Improper

maintenance, repair, guarding and use of plant and
machinery in foundries may result in significant increases Turn off the power: it is not allowed to work on electrical
in the risk of injury to operators and nearby workers. The equipment where there may be a risk of exposed live parts;
injuries are: cuts and lacerations; amputations; foreign removing covers on equipment to access mechanical parts
bodies in eyes; crush injuries; fractures; burns and manual may also expose live electrical parts. Employers have a
handling injuries. To avoid plant and machinery injuries: duty to ensure their business is conducted in a way that is
Redesign can be carried out which involves changing the electrically safe, including that all electrical equipment is
design of the workplace, equipment or work process. It safe. Safety switches and regular maintenance of electrical
involves thinking about ways the work could be done equipment are good ways of controlling electrical safety
differently to make the plant safer such as modifying risk [14, 37, 38].
equipment, combining tasks, changing procedures,
changing the sequence of tasks. Administrative measures
involve: ensuring that purchasing specifications for new 4. Environmental Issues
equipment incorporate all required safety features, for
example, safety devices and guards and “fail safe” design; Today pollution has become big challenge around the
carrying out routine and preventive maintenance programs globe [39]. The major terms of pollution are air pollution,
at regular intervals; PPE should be used as: eye protection; water pollution, soil contamination, plastic pollution. Air
hearing protection; safety helmets, and skin protection - pollution comes from both natural and man-made sources.
gloves, barrier creams [14, 18, 36]. However, globally human made pollutants from production,
combustion, construction, mining, agriculture and welfare
are increasingly significant in the air pollution equation.
Adverse air quality can kill many organisms including
humans. Pollution prevention and waste minimization are

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ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
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most desirable than pollution control. The pollution control 2002, 18 states had implemented programs to encourage
devices used commonly are dust collection systems, and regulate the beneficial use of SFSs [44, 45] as an
scrubbers, and sewage treatment, industrial wastewater alternative friendly solid waste disposal. Zanetti and Fiore
treatment, vapour recovery systems and phytoremediation [46] report that in Europe, because of the different rules
[40]. The environmental issues associated with foundries and economic factors that exist in different countries, a
primarily include air emissions, solid waste, wastewater solution that can be valid for the reuse of foundry wastes in
and noise [40]. one country might not be acceptable in another country.
However, a knowledge of the possible solutions could lead
Dust and particulate matters are generated in each of the to choosing modifications that might be acceptable. Silica
process steps with varying levels of mineral oxides, metals sands for foundry products in the different European
(mainly manganese and lead), and metal oxides. Dust countries are commercialised at different prices: in Italy
emissions arise from thermal (e.g. melting furnaces) and the price is about 0.04 €/kg while in Belgium and
chemical / physical processes (e.g. moulding and core Netherlands the same product is sold at about 0.01 €/kg.
production), and mechanical actions (e.g. handling of raw These differences and the landfilling costs justify the
materials, mainly sand, and shaking out and finishing different solutions adopted in European countries for green
processes) [41, 42]. Metal emissions should be controlled moulding sands (recycling or reuse): recycling in Italy, re-
during the melting and casting processes. Metal emissions use as capping for landfills and concrete production in
may be emitted through volitization and condensation of Sweden, re-use for road construction in Belgium and so on.
metals during molten metal pouring into moulds.
Particulates in ferrous foundries may contain heavy metals, The most significant use of water in foundries is in the
such as zinc (mainly if galvanized steel scrap is used), cooling systems of electric furnaces (induction or arc),
cadmium, lead (e.g. from painted scrap), nickel, and cupola furnaces, and in wet dedusting systems. In most
chromium (these last two in alloy steel casting production) foundries, water management involves an internal
depending on the steel grade being produced and scrap recirculation of water resulting in a minimal effluent
used. Particulates associated with nonferrous metal volume. Use of wet dedusting techniques may increase
production may contain copper, aluminum, lead, tin, and water use and consequent disposal management. In core
zinc. The presence of metal in particulate emissions can be making, where scrubbers are used, the scrubbing solutions
especially significant during alloying activities and during from cold-box and hot-box core-making contain
the introduction of additives. For example, the addition of biodegradable amines and phenols. In high-pressure die-
magnesium to molten metal to produce ductile iron may casting, a wastewater stream is formed, which needs
result in a reaction releasing magnesium oxides and treatment to remove organic (e.g. phenol, oil) compounds
metallic fumes. Dust, fumes and particulate emission can before discharge. Wastewater containing metals and
be controlled by using high-efficiency dust abatement suspended solids may be generated if the mould is cooled
techniques [40, 41]. with water. Wastewater with suspended and dissolved
solids and low pH may also be generated if soluble salt
Solid waste streams include sand waste, slag from cores are used. Wastewater may be generated by certain
desulfurization and from melting, dust collected within finishing operations such as quenching and deburring, and
emissions control systems, refractory waste, and scrubber may contain high levels of oil and suspended solids.
liquors and sludges. General techniques to manage the Prevention techniques for effluent streams from foundries
waste generated by foundries include the selection, design include: installation of closed loops for cooling water to
and construction of storage areas for metals, dust waste reduce water consumption and discharge; recycle tumbling
from filters, refractory waste, slag, and sand waste, with water by sedimentation or centrifuging followed by
due consideration of site geological and hydrogeological filtering; store scrap and other materials (e.g. coal and coke)
conditions to prevent potential contamination from under cover and / or in bunded area to limit contamination
potential heavy metal leaching [41]. Disposal by landfill of of storm water and facilitate drainage collection; process
spent sands is becoming an increasing problem as water treatment [41]. Industrial operators must ensure that
legislation is getting tighter and economic as disposal cost waste generated at the premises is not discharged into any
by current practices increases rapidly [43]. According to a waters or onto land where it is reasonably likely to enter
foundry industry survey, approximately 9.4 million tons of any waters (e.g. by seepage, runoff or infiltration) [47].
non-hazardous spent foundry sand (SFS) is generated
annually in the United States. Of this, 28% is beneficially The foundry process generates noise from various sources,
used in construction fill, as a component of concrete and including scrap handling, furnace charging and electric arc
asphalt, in road construction, and/or in soil mixes. As of furnace melting, etc. The recommended noise management

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ISSN (Online) 2348 – 7968 | Impact Factor (2016) – 5.264
[Link]

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