Small scale test casts
The chamber emission tests were carried out in Finland and Poland. Emissions were measured from the moulds made by using organic and inorganic binder systems.
In Finland the emission tests were made by using a closed chamber, where the mould was placed in. The weight of the test casting was about 200 kg and the amount of sand in the mould was also ca. 200 kg. The tests were made in two ferrous foundries: URV and Karhula.
In Poland small scale chamber tests were made in the laboratory foundry of AGH-UST and in the ferrous foundry Hardkop. The weight of the test casting in the AGH-UST laboratory test as about 150 g and the amount of the sand in the mould was also ca. 150 g. The weight of the test casting in Hardkop was ca 23 kg and the amount of sand in the mould was ca. 65 kg.
Conclusions of the chamber tests in Finland
The measured emissions from both inorganic binder moulds are only a fraction (3,8% and 0,8%) compared to the emissions of the organic Alphaset binder mould.
Peaks inorganic binder system uses organic hardener (ester compound). Thus it is understandable that some organic emissions are measured. The recommended amount of the hardener is small, and the emissions are only 3,8% compared to the emissions from organic Alphaset mould.
In Inotec inorganic binder system both binder and hardener should be 100% inorganic, but minor organic emissions were found. There must be some organic matter added to the binder and/or promotor material to improve the technical performance of the binder system.
The emissions from both inorganic binder moulds are so small that a drastic decrease in harmful emissions from the foundries would be obtained by using these inorganic binders instead of organic binders. In addition, improvement in indoor air quality is expected, as well as in the quality of the castings due to the decreased risk of gas porosity.
Conclusions of the chamber tests in Poland
Emissions of PAHs, as well as BTEX in case of moulding sands with organic binders is several dozen higher than the emission of these compounds from moulding sands with inorganic binders. Moulding sands with inorganic binders are characterized by lower harmfulness for the environment and employees than moulding sands with organic binders.
The hardener of inorganic Geopol binder system is organic ester compound, and thus emissions are somewhat higher than with fully inorganic Cordis and Inotec binder systems. But some organic material must have been added to them for technical performance reasons into Cordis and Inotec binders and/or promotors.
More details: Conclusion report of the chamber emission tests in Finland and Poland