1. riser cutoff & gate removal
sand-binder mixing
core forming
core curing
mold & core assembly
scrap preparation
mold pouring, cooling
mold making
metal melting
slag, dross removal
sand renewal
shakeout
riser cutoff & gate removal
cleaning, finishing, coating
QA / shipping
Process Flow for Typical Green Sand Foundry

2. metal scrap, alloys, flux
sand and binder
sand-binder mixing PM
metal scrap, alloys, flux
core forming PM
core curing
VOC, HAP
HC, CO
PM, CO, VOC, HAP, MOx
mold & core assembly
cooling water
scrap preparation PM
mold pouring, cooling
PM, NOx, CO, SO2
mold making
metal melting
sand
slag, dross removal
sand renewal
shakeout PM
acidic wastewater
PM, HAP, VOC
riser cutoff & gate removal
scrap metal, abrasives PM
PM, VOC
slag, dross spent RM
waste sand, metals
cleaning, finishing, coating
wastewater with solvents, oils
sludge
QA / shipping
input vapor waste aqueous waste solid waste
rejects, packing material
Materials Flow for Typical Green Sand Foundry

3. 1.0-3.0M BTU/ton saleable casting
sand-binder mixing
core forming
M BTU/ton saleable casting
core curing
mold & core assembly
scrap preparation
mold pouring, cooling
0.6 M BTU/ton
mold making
metal melting
slag, dross removal
sand renewal
shakeout
Cupola melting
5.8 Coke
1.1 Electricity
1.6 Natural Gas
0.1 Oxygen
Electric melting
Induction
Electric Arc
Reverb
Fuel fired melting Crucible
Reverb
riser cutoff & gate removal
1.0 M BTU/ton
cleaning, finishing, coating
QA / shipping
Energy Requirements for Typical Green Sand Foundry

4. Relevant Federal Legislation
Resource Conservation and Recovery Act
ID of solid and hazardous wastes
standards for generators of hazardous waste
land disposal restriction
used oil management standards
underground storage tanks
boilers and industrial furnaces
Comprehensive Environmental Response, Compensation Liability Act
Emergency Planning and Community Right-to-Know Act
Clean Water Act
Safe Drinking Water Act
Toxic Substances Control Act
Clean Air Act
Toxic Release Inventory (TRI)
required of 654 of 2800-odd foundries in 1995
“TRI applies to companies that utilize 25,000 pounds of the approximately 600 designated chemicals or 28 chemical categories specified in the regulations, or uses more than 10,000 pounds of any designated chemical or category”
State and local legislation…