Total emissions and indoor air quality measurements of pilot foundries

Emissions were measured from pilot foundries representing different moulding agents (organic binders; Alphaset phenol sand system and inorganic binders; water glass as an old type of inorganic binder and new modified inorganic binders available in the market.

The results indicate the total contamination load of ventilation in different process stages using different bonding agencies. That for, the annual mass flow rates were measured and defined referring to the actual appearance and assessments executed at an annual level. There are several odorous emission sources in foundries. Typically, the emission origin is from the processes of melting, core making, casting, cooling line,  shake out and sand reclamation. Based on the results, the processes with the highest harmful substances were defined.

Total emissions and indoor air qualities were measured

• Stainless steel foundry using organic phenolic binder system (Karhula)
• Iron foundry using organic phenolic binder system (URV) (excluding the indoor air quality measurement
• Iron foundry using organic phenolic binder system and two inorganic binder systems were also tested and emission measured (Valumehaanika)
• Steel foundry using old type of inorganic binder, water glass (Stavanger Steel)
• Aluminium foundry using new type inorganic binder system, Cordis (KSMCasting).

As a comparison, small scale chamber tests with different inorganic binders were carried out in Karhula and URV foundries. The aim was to demonstrate the expected emission reduction when exchanging to inorganic binder.

Detailed emission and indoor air quality reports of each foundry can be found below.
B2A Results of emission and indoor air measurements of organic and inorganic binder system test casts in Valumehaanika foundry in Estonia
B2B Results of indoor air quality and occupational hygiene measurements in organic binder system Karhula in Finland
B2C Results of total emission measurements in organic binder system Karhula Foundry in Finland
B2D Results of total emission measurements in organic binder system pilot foundry in URV foundry in Finland