Life cycle assessment in ferrous foundry industry

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2013

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Yiğit, Çisem

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Foundries are most widely facilities all around the world, producing high amounts of castings. In this study, environmental impact of metal foundries was investigated toward a life cycle assessment (LCA) goal. Studies were conducted in two foundry plants in order to collect the inventory data. The difference between the plants regarding their processes was the application of secondary sand reclamation (SSR) in Plant 2. Application of SSR is indicated as a ―best available technique-BAT‖ in the Reference Document for Foundries and Smitheries published by Integrated Pollution Prevention and Control (IPPC) Breau. In order to exhibit SSR‘s environmental effects during its whole life cycle, firstly, environmental impact of conventional casting was evalauated by using LCA. Then, environmental impact of casting with SSR was assessed to see what if the SSR facility is applied after casting for Plant 1. The results of these two scenario (with and without SSR) were compared. In this framework, one ton of metal melted and one ton of mould and core production selected as functional units. The boundaries of the study selected as from cradle to grave for foundry processes, cradle to gate 2 for foundry products. SimaPro LCA software was used during calculations and impact assessment was conducted by using Impact 2002+ method. Additionally, several production scenarios (SSR magnetic seperation efficiency, amount of burned sand during molten metal pouring and different products) were analysed and compared to each other. Results showed that; among the sub-processes one ton metal melting has the highest environmental impact due to its high energy demand because of the production of inputs (e.g. pig iron and steel production) and energy required for melting the metal. For core and mould production, among the process without SSR and six scenarios with SSR, the process without SSR showed the lowest environmental impact. This was explained by the high energy demand of SSR. Also, it was investigated that phenol-resorcinol formaldeyhde resin production is the significant contributor of environmental impact during core and mould production. This study revealed that; application of SSR which is indicated as BAT in the literature, has more environmental effect in life cycle view.

Subject Keywords

Foundries, Metal castings, Sand, Foundry, Persistent pollutants.

URI

http://etd.lib.metu.edu.tr/upload/12615559/index.pdf
https://hdl.handle.net/11511/22302

Collections

Graduate School of Natural and Applied Sciences, Thesis

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Citation Formats

Ç. Yiğit, “Life cycle assessment in ferrous foundry industry,” M.S. - Master of Science, Middle East Technical University, 2013.