Notes for conference call to Fred Cannon 10:00am Monday 20 September 2004 814-238-2559 or 814-238-5175 DISCUSSION QUESTIONS *** Major energy/material differences between aluminum and iron casting. To us, they seem to be: Different preferences in melting furnaces Longer time to cool iron Less recycled material in aluminum casting What else? *** About 1/4 of foundries file TRI data with the EPA. How does the TRI reflect real foundry processes? Especially since very few of the foundries have common releases *** Where to get information on energy requirements for major tools, or even just information on the tools? In trying to get from aggregate data to modeling real-world processes. This is a more general question than for just sand-casting *** How to get emissions information that can be compared to dollars of product or tonnes of product *** Future trends in casting technology, business Overseas production Lightweighting of materials? *** How to split up die casting, maybe? High/Medium/Low temperature alloys High/Low pressure and gravity casting *** Waste sand from foundries can be repurposed for concrete. Does it get used this way? Are there other uses? *** Furnaces: How long does the average furnace last? When and why are they replaced? Do older foundries still have older furnaces? Do smaller foundries have older furnaces? Does the age of the foundry correlate with type of furnace, fuel type, or emissions characteristics? NOTES FROM PAPERS Foundry Emissions Effects with an Advanced Oxidation Blackwater System -Reduction of emissions by 20-75% during shakeout and cooling (in VOCs, benzene, methane, ethane. Not in CO or CO2) -Stack emissions generated from molding lines during pouring cooling and shakeout -Alternative is end-of-pipe incineration Emissions Studies at a Test Foundry using an Advanced Oxidation-Clear Water System -Addition of ozone and hydrogen peroxide to sand system tap water with subsequent sonification, added to the green sand in the muller USE OF ADVANCED OXIDATION TECHNOLOGY FOR EMISSIONS AND MATERIALS REDUCTION AT FOUNDRIES -Fed into a "blackwater clarifier" fed into the sand cooler and muller