Publications by Wingra Engineering Staff

 

"Air Toxics Control Alternatives for Iron Foundry Pouring, Cooling and Shakeout Operations"

Steven Klafka, P.E.
Wingra Engineering, S.C.

ABSTRACT

Total suspended particulates (TSP) and volatile organic compounds (VOC) are released during the pouring, cooling and shakeout of iron castings.  Contained in the TSP and VOC emissions are air toxics now receiving greater attention by regulatory agencies.  The TSP emissions can be effectively controlled using fabric filter baghouses and wet scrubbers. The VOC emissions historically have not required control.  Case studies are used to describe the air quality impacts associated with the TSP and VOC emissions.  The use of stacks which are not equipped with obstructions and avoid excessive building downwash effects may be required to comply with the air standards for TSP and air toxics.  The VOC emissions are generated by the degradation and evaporation of organic binders and raw materials contained in the molding sands or core binders.  Potential methods for controlling the VOC emission and associated air toxics include the following: alternative core binder materials; reduced mold organic content; extended/reduced mold cooling time; use of tighter molds; and, add-on control equipment such as regenerative incineration, catalytic incineration, carbon adsorption, and biofiltration. Factors controlling the technical and economic feasibility of each of the potential VOC control methods are discussed.