Analysis of total metals in waste molding and core sands from ferrous and non-ferrous foundries.
Waste molding and core sands from the foundry industry are successfully being used around the world in geotechnical and soil-related applications. Although waste foundry sands (WFSs) are generally not hazardous in nature, relevant data is currently not available in Argentina. This study aimed to quantify metals in waste molding and core sands from foundries using a variety of metal-binder combinations. Metal concentrations in WFSs were compared to those in virgin silica sands (VSSs), surface soils and soil guidance levels. A total analysis for Ag, Al, Ba, Be, Cd, Co, Cr, Cu, Fe, Mg, Mn, Mo, Ni, Pb, Sb, Te, Tl, V, and Zn was conducted on 96 WFSs and 14 VSSs collected from 17 small and medium-sized foundries. The majority of WFSs analyzed, regardless of metal cast and binder type, contained metal concentrations similar to those found in VSSs and native soils. In several cases where alkyd urethane binder was used, Co and Pb concentrations were elevated in the waste sands. Elevated Cr, Mo, Ni, and Tl concentrations associated with VSSs should not be an issue since these metals are bound within the silica sand matrix. Because of the naturally low metal concentrations found in most WFSs examined in this study, they should not be considered hazardous waste, thus making them available for encapsulated and unencapsulated beneficial use applications.
A novel use of calcium aluminate cements for recycling waste foundry sand (WFS)
Abstract The recycling of WFS in calcium aluminate cement mortars at high level of replacement (50%) was studied. Consistency and setting time were measured in fresh mortars. Two different curing conditions were used, the second one with the aim of enhancing the formation of stable cubic calcium aluminate hydrates. Compressive strength, pore size distribution and SEM examination were carried out to assess the effectiveness of CAC matrix in the recycling of WFS. The effect of the incorporation of a polymeric admixture – a chitosan derivative – was also explored. Leaching studies on hardened mortars of three target pollutants of the WFS (toxic metals Pb, Cr and Zn) were also done to evaluate their immobilization. By comparison with OPC mortars, the use of CAC showed several advantages, improving the compressive strength and the toxic metal retention.
Evaluation of volatile hydrocarbon emission characteristics of carbonaceous additives in green sand foundries.
This research studied a relative comparison of the hydrocarbon emissions during pyrolysis of four carbonaceous additives that can be used in green sand foundries. These included a highly volatile bituminous coal, anthracite, lignite, and cellulose. Analytic pyrolysis was conducted to simulate the heating conditions that the carbonaceous additives would experience during metal pouring. Specifically, the samples were flash pyrolyzed in a Curie-point pyrolyzer at 920 degrees C with a heating rate of about 3000 degrees C/sec. This simulated some key features of the fast heating conditions that the carbonaceous additives would experience at the metal-mold interface when molten metal is poured into green sand molds. The samples were also pyrolyzed in a thermogravimetric analyzer (TGA) from ambient temperature to 1000 degrees C with a heating rate of 20 degrees C/min; and this simulated key features of the slow heating conditions that the carbonaceous additives would experience within the bulk of green sand molds that is further away from the metal-mold interface. Hydrocarbon emissions from flash pyrolysis were analyzed with GC-FID, while those from TGA pyrolysis were monitored with mass spectroscopy and GC-FID. The anthracite exhibited very low volatile hydrocarbons during both flash pyrolysis and TGA pyrolysis. The cellulose released less hydrocarbons than bituminous coal or lignite in TGA pyrolysis, but more hydrocarbons than those two during flash pyrolysis. This means that cellulose can release sufficient volatile hydrocarbons at the intensely heated molten metal-mold interface where they are most desired for ensuring casting quality, but much less within the bulk of the mold where they are undesirable. This characteristic of cellulose offers an important opportunity for green sand foundries to diminish their hazardous air pollutant (HAP) emissions.