The article presents the directions of foundry waste management, mainly used for spent foundry sands (SFS) and dust after the reclamation of this waste. An important aspect of environmental protection in foundry production is the reduction of the amount of generated waste as a result of SFS regeneration. The advantage is the reuse of waste, which reduces the costs of raw materials purchase and environmental fees for landfilling. Non -recycled spent foundry sands can be used in other industries. SFS is most often used in road and construction industries as well as inert material in closed mines (Smoluchowska and Zgut 2005; Bany-Kowalska 2006). An interesting direction of using SFS is its application in gardening and agriculture. The article presents the advantages and disadvantages of such use. It was found that spent foundry sands can be useful for the production of soil mixtures for many agricultural and horticultural applications. Due to the possibility of environmental pollution with heavy metals and organic compounds, such an application is recommended for the so-called green sands, i.e. SFS with mineral binders. In addition, an innovative solution for the energy use of dusts after spent foundry sands reclamation with organic binders has been discussed and proposed by some researchers. It was shown that dust from reclaimed SFS with organic binders can be used as an alternative fuel and raw material in cement kilns, due to the high percentage of organic substances which determine their calorific value and silica.
The article discusses the problem of the supply of a by-product, which is synthetic gypsum produced as a result of flue gas desulphurization in conventional power plants. The state of production and forecast for the future are presented. Currently, synthetic gypsum is almost entirely used as a raw material in the gypsum products plant located in the immediate vicinity of the power plant. Since the mid-1990s, in Poland, an increase in the production of synthetic gypsum associated with the construction of a flue gas desulphurization installation in Polish conventional power plants has been observed. In the near future, the upward trend will continue in connection with the construction of new coal units in power plants. Significant surpluses of this raw material will appear on the market, which will not be used on an ongoing basis in the production of gypsum components. However, due to the EU’s restrictive policy towards energy based on coal and lignite, within the next few decades, the share of conventional power plants in energy production will be gradually reduced. As a consequence, the supply of synthetic gypsum will also gradually decrease. Therefore, it is advisable to properly store the surplus of this raw material so that it can be used in the future. Taking this into account, it is already necessary to prepare methods for storing the expected surpluses of synthetic gypsum. For this purpose, post-mining open pits are particularly suitable, especially in mines of rock raw materials. The article proposes a legal path enabling the post-mining open pits to be transformed into a anthropogenic gypsum deposit.
The problem related to the management of post reclamation dusts generated in the reclamation process of waste moulding sands with organic binders is presented in the hereby paper. Waste materials generated in this process are products hazardous for the environment and should be utilised. The prototype stand for the utilisation of this dangerous material in its co-burning with coal was developed and patented in AGH in Krakow. The stand was installed in one of the domestic casting houses. As the utilisation result the transformed waste product is obtained and its management in the production of ceramic materials constitutes the subject of the presented publication.
“Wartowice” tailings pond was closed in 1989, resulting in 232,4 ha tailings pile requiring reclamation. The major problem is heavy metals presence and poor nutrient conditions and physicochemical structure of soil which disturbs the plants development. In order to assess the real condition of studied area the complete biological characteristic has been done. The physicochemical conditions were assessed altogether with phytosociological, microbiological and toxicological studies of deposits. We recorded only 27 species of vascular plants belonging to 15 families on the tailings pond of which 5 belong to Rosaceae, 4 to Asteraceae and 3 to Poaceae and Saliceae. Species inhabiting the tailings depended on their dispersal capacity, metal tolerance and rhizome strategy. Microbiological analyses revealed the low number of bacteria and fungi on the tailings pond, apart from the small uplift area where the plants were indentified. Bacteria identified on the tailings pond were classified to 8 genera. The low number of bacteria suggests the lack of nutrients which affects the development of soil microflora. Toxicity tests showed that post-flotation sludge is not toxic to microorganisms because of its high pH. Some plants, such as lucerne could even influence positively the microorganisms development what has been proved in our studies. The tailings toxicity was higher towards producers, where Secale cereale appeared to be the most sensitive species. Amendment with topsoil from adjacent areas can influence positively the phytotoxic properties of tailings and enrich them into native seeds.
The cumulative results of investigations of the possibility of using the reclaimed materials after the mechanical, thermal or mechanical-thermal reclamation for making cores by means of the blowing method in the alkaline CO2 technology, are presented in the paper. Three kinds of spent sands: with furfuryl resin, bentonite and alkaline phenolic resin, obtained from the foundry, were subjected to three kinds of reclamation: mechanical, thermal and combined mechanical-thermal, applying for this aim adequate experimental devices. The obtained reclaims were assessed with regard to the degree of the matrix liberation from the determined binding material. Reclaims of moulding sands with binders of the form of resin were assessed with regard to ignition loss values and pH reaction, while reclaims of moulding sands with bentonite with regard to the residual clay content and pH value. In all cases the results of the performed sieve analyses were estimated and the average characteristic diameter dl was determined. The reclaimed matrix was applied as a full substitute of the fresh high-silica sand in typical procedures of preparing core sands used for making shaped samples for bending strength investigations, Rg u .
The aim of this study was to investigate the possible use of geoinformatics tools and generally available geodata for mapping land cover/use on the reclaimed areas. The choice of subject was dictated by the growing number of such areas and the related problem of their restoration. Modern technology, including GIS, photogrammetry and remote sensing are relevant in assessing the reclamation effects and monitoring of changes taking place on such sites. The LULC classes mapping, supported with thorough knowledge of the operator, is useful tool for the proper reclamation process evaluation. The study was performed for two post-mine sites: reclaimed external spoil heap of the sulfur mine Machów and areas after exploitation of sulfur mine Jeziórko, which are located in the Tarnobrzeski district. The research materials consisted of aerial orthophotos, which were the basis of on-screen vectorization; LANDSAT satellite images, which were used in the pixel and object based classification; and the CORINE Land Cover database as a general reference to the global maps of land cover and land use.
The paper, especially dealt with problems of reclamation of used furan sand, carried out in new, vibratory sand reclamation unit REGMAS developed by researches from AGH-University of Science and Technology, Faculty of Foundry Engineering in Cracow (Poland). Functional characteristics of reclamation unit as well as the results of reclamation of used sand with furfuryl resin are discussed in the paper. The quality of reclaim was tested by means of the LOI and pH value, dust content in the reclaim and at least by the the quality of the castings produced in moulds prepared with the use of reclaimed matrix.
Presented are results of a research on usability of an innovative reclamation process of microwave-hardened moulding sands containing water-glass, combined with activation of binder. After each subsequent stage of reclamation, quality of the reclaimed material was determined on the grounds of measurements of permeability and results of screen analysis. The reclaimed material was next used again to prepare new moulding sand. The sandmix based on high-silica sand prepared with water-glass grade 145, was subject to the following cyclical treatment operations: mixing components, consolidation, microwave hardening, cooling, heating the mould up to 800 °C, cooling to ambient temperature, mechanical reclamation dry and wet. It was found that the used-up and reclaimed sandmix containing water-glass is susceptible to the applied activation process of thermally reacted film of binder and, in addition, it maintains good quality and technological properties of high-silica base. Observations of surfaces of reclaimed high-silica grains with activated film of reacted inorganic binder were carried-out using a scanning microscope. Thanks to properly selected reclamation parameters, the high-silica base can be reused even five times, thus reducing demand for fresh aggregate and inorganic binder.
The results of mechanical reclamation of waste moulding sands with furfuryl resin and activators of new generation are presented. The aim of the research described in this study was to determine what effect the addition of reclaim obtained in the process of dry mechanical reclamation could have on the properties of furan sands. The sand supplied by one of the domestic foundries was after the initial reclamation subjected to a two-step proper reclamation process. The following tests were carried out on the obtained reclaim: pH, S and N content, loss on ignition and comprehensive sieve analysis. The obtained reclaim was next used as a component of moulding sands with furfuryl resin, wherein it formed 50% and 80% of the base moulding material, respectively. The strength properties of the ready sand mixtures (bending strength Rg u and tensile strength Rm u ) were determined after the hardening time of 0.5, 1, 2, 4 and 24 hours.
Modern investigation methods and equipment for the quality estimation of the moulding sands matrices with organic binders, in their circulation process, are presented in the paper. These methods, utilising the special equipment combined with the authors investigation methods developed in the Faculty of Foundry Engineering, AGH the University of Science and Technology, allow for the better estimation of the matrix quality. Moulding sands systems with organic binders require an in-depth approach to factors deciding on the matrix technological suitability as well as on their environmental impact. Into modern methods allowing for the better assessment of the matrix quality belongs the grain size analysis of the reclaimed material performed by means of the laser diffraction and also the estimation of the moulding sand gas evolution rate and identification of the emitted gases and their BTEX group gases content, since they are specially hazardous from the point of view of the Occupational Safety and Health.
The paper presents the idea of the integrated recycling system of used moulding sands with organic resins. A combination of the method of forecasting averaged ignition loss values of moulding sands after casting and defining the range of necessary matrix reclamation treatments in order to obtain its full recycling constitutes the basics of this process. The results of own investigations, allowing to combine ignition loss values of spent moulding sands after casting knocking out with amounts of dusts generated during the mechanical reclamation treatment of such sands, were utilized in the system.
The study was conducted in the area of the impact of sulfur mine in Jeziórko. The aim of the study was to assess changes in pH, cation exchange capacity and content of available phosphorus, potassium and magnesium after 6 years of conducting remediation. In the experiment (plots with an area of 15 m2) degraded soil was rehabilitating by post-floating lime and compost from sewage sludge, sewage sludge and ash from combined heat and power (CHP). Composts at a dose of dry matter 180 t · ha-1 (6%), were determined in accordance with Minister of the Environment Regulation from 2001, applied the following options: control (only native soil limed), compost from municipal sewage sludge, sewage sludge compost (80%) and ash (20%), compost from sewage sludge (70%) and ash (30%). The reclaimed plots were sown with mixture of rehabilitation grass. Single de-acidification, land fertilization and a further 6-year extensive (without fertilization) use had a different influence on the properties of the native soilless substratum. Irrespective of the reclamation manner, after six years land use in the upper layers, observed increase in the average content of available phosphorus, available potassium content does not changed significantly but recorded a tenfold decrease in the content of available magnesium.
Mining activity influence on the environment belongs to the most negative industrial influences. Land subsidence can be a consequence of many geotectonic processes as well as due to anthropogenic interference with rock massif in part or whole landscape. Mine subsidence on the surface can be a result of many deep underground mining activities. The presented study offers the theory to the specific case of the deformation vectors solution in a case of disruption of the data homogeneity of the geodetic network structure in the monitoring station during periodical measurements in mine subsidence. The theory of the specific solution of the deformation vector was developed for the mine subsidence at the Košice-Bankov abandoned magnesite mine near the city of Košice in east Slovakia. The outputs from the deformation survey were implemented into Geographic Information System (GIS) applications to a process of gradual reclamation of whole mining landscape around the magnesite mine. After completion of the mining operations and liquidation of the mine company it was necessary to determine the exact edges of the Košice-Bankov mine subsidence with the zones of residual ground motion in order to implement a comprehensive reclamation of the devastated mining landscape. Requirement of knowledge about stability of the former mine subsidence was necessary for starting the reclamation works. Outputs from the presented specific solutions of the deformation vectors confirmed the multi-year stability of the mine subsidence in the area of interest. Some numerical and graphical results from the deformation vectors survey in the Košice-Bankov abandoned magnesite mine are presented. The obtained results were transformed into GIS for the needs of the self-government of the city of Košice to the implementation of the reclamation works in the Košice-Bankov mining area.
The quarrying industry is changing the local landscape, forming deep open pits and spoil heaps in close proximity to them, especially lignite mines. The impact can include toxic soil material (low pH, heavy metals, oxidations etc.) which is the basis for further reclamation and afforestation. Forests that stand on spoil heaps have very different growth conditions because of the relief (slope, aspect, wind and rainfall shadows, supply of solar energy, etc.) and type of soil that is deposited. Airborne laser scanning (ALS) technology deliver point clouds (XYZ) and derivatives as raster height models (DTM, DSM, nDSM=CHM) which allow the reception of selected 2D and 3D forest parameters (e.g. height, base of the crown, cover, density, volume, biomass, etc). The automation of ALS point cloud processing and integrating the results into GIS helps forest managers to take appropriate decisions on silvicultural treatments in areas with failed plantations (toxic soil, droughts on south-facing slopes; landslides, etc.) or as regular maintenance. The ISOK country-wide project ongoing in Poland will soon deliver ALS point cloud data which can be successfully used for the monitoring and management of many thousands of hectares of destroyed post-industrial areas which according to the law, have to be afforested and transferred back to the State Forest.
One of the purposes of the application of chemically modified inorganic binders is to improve knocking out properties and the related reclamability with previously used in foundry inorganic binder (water glass), which allowing the use of ecological binders for casting nonferrous metals. Good knocking out properties of the sands is directly related to the waste sands reclamability, which is a necessary condition of effective waste management. Reclamation of moulding and core sands is a fundamental and effective way to manage waste on site at the foundry, in accordance with the Environmental Guidelines. Therefore, studies of reclamation of waste moulding and core sands with new types of inorganic binders (developed within the framework of the project) were carried out. These studies allowed to determine the degree of recovery of useful, material, what the reclaimed sand is, and the degree of its use in the production process. The article presents these results of investigation. They are a part of broader research programme executed under the project POIG.01.01.02-00- 015/09 "Advanced materials and technologies".
The results of investigations of the granulation process of foundry dusts generated in the dry mechanical reclamation process of used sands, where furan resins were binders are presented in the paper. Investigations concerned producing of granules of the determined dimensions and strength parameters. Granules were formed from the dusts mixture consisting in 50 mass% of dusts obtained after the reclamation of the furane sands and in 50 mass % of dusts from sands with bentonite. Dusts from the bentonite sands with water were used as a binder allowing the granulation of after reclamation dusts from the furane sands. The following parameters of the ready final product were determined: moisture content (W), shatter test of granules (Wz) performed directly after the granulation process and after 1, 3, 5, 10 days and nights of seasoning, water-resistance of granules after 24 hours of being immersed in water, surface porosity ep and volumetric porosity ev. In addition the shatter test and water-resistance of granulate dried at a temperature of 105oC were determined. Investigations were performed at the bowl angle of inclination 45o, for three rotational speeds of the bowl being: 10, 15, 20 rpm. For the speed of 10 rpm the granulation tests of dusts mixture after the preliminary mixing in the roller mixer and with the addition of water-glass in the amount of 2% in relation to the amount of dust were carried out. The obtained results indicate that the granulator allows to obtain granules from dusts originated from the reclamations of moulding sands with the furane resin with an addition of dusts from the bentonite sands processing plants.
The results of the efficiency of the primary reclamation process as well as the influence of the used sand temperature and other process parameters on it are presented in this paper. A separate stand realized on a reduced scale was built, which is an analogous process of the primary reclamation treatment of spent foundry sands. The used sands were introduced to the crushing process in an agglomerated form in the way typically used in industrial devices. The primary reclamation process was realized on a set of four horizontal sieves with decreasing mesh clearances while maintaining their geometrical dimensions applied in the Regmas industrial device. The model system consists of a vibratory drive mounted on the table, allowing us to control the supply frequency of the vibratory motors within a range of 40-60 Hz as well as the computer system for measuring the vibration parameters and drive power. The used sand on the quartz matrix with the KALTHARZ U404 resin and 100T3 hardener was used in our investigations. The used sand was prepared under the following conditions: cubic-shaped elements made of the applied furan sand was compacted by vibrations then hardened and subjected to heating under controlled conditions (as a “simulation” of the overheating process taking place in the mold after pouring). Time functions of the crushing and sieving process in dependence of the overheating degree of the reference sand samples (100°, 200°, and 300°C) were investigated at various table vibration frequencies and feed loads of the sieve set. The relative index of the crushing ability was determined.
The investigation results of the reclamation of spent moulding sands with furfuryl resin are presented in this paper. The reclamation process was performed in the secondary reclamation chamber of the REGMAS 1.5 vibratory reclaimer. 70 kg portions of moulding sands, previously subjected to the primary reclamation and dedusting, were used. The secondary reclamation was performed in two stages: the first consisted of determining the reclaimer intensity at various reclamation times (5 min, 10 min and 15 min) and various electrovibrator frequencies (40 Hz, 50 Hz and 60 Hz), the second consisted of determining the influence of additional crushing elements on the intensity of processes.
The investigation results of the influence of the selected parameters of the thermal reclaimer operations on the temperature changes in the combustion chamber and the process energy consumption, are presented in the hereby paper. The analysis of the heat treatment was performed with the application of a fresh foundry sand, since it was assumed that the dominating energy part was used for the grain matrix heating and due to that, the energy used for burning small amounts of organic binder remained on sand grains could be omitted. Thermal treatment processes performed under various conditions were analysed from the point of view of a gas consumption and temperatures obtained in the experimental reclaimer. The recorded data allowed to point out the parameters having essential influence on the process of the quartz matrix heating in the combustion chamber as a gas consumption function.
One of the biggest problems for sand casting foundries must be the waste produced from disposable molds. Stricter environmental regulations make it harder to dispose of waste sand, so a truly competitive foundry does no longer only make great products, but also concentrates on a sustainable casting process. While methods for repurposing waste foundry sand are still limited, the internal circulation of such sands proves significant possibilities. This paper will focus on thermal reclamation of foundry sands in a special rotating drum furnace in a central facility to serve several foundries. Thermal reclamation is a process for handling foundry sands in elevated temperatures to combust unwanted substances from reusable base sand. The introduction focuses on background of the Finnish foundry business, the most common sand systems in Finland and their reclaim properties. The experimental part features presentation of the new reclamation plant process and the conducted test runs. The samples collected from each test run have been laboratory tested to assure proper sand quality. The results of this work showed that the reclamation of alkaline phenolic no-bake sands was excellent. Reclamation of green sands did not provide satisfactory results as expected and the reclamation of furan no-bake sands provided mixed results, as the raw material was imperfect to begin with. The most important result of this work is still the successful initiation of a centralized thermal reclamation plant, with the ability to reclaim sands of several foundries. With this all of industrial symbiosis, circular economy and sustainability advanced in Finland, and the future development of this plant provides even further opportunities and a possibility to spread the ideas on a global scale.
For the reason of environmental problems connected with the use of furan binders, attention is increasingly being paid to self-setting mixtures using alkali resols. A resol binder stabilized with KOH, NaOH is hardened by liquid esters with the formation of alkaline salts. The increase of their concentration affects the shortening of the mixture bench life, it also decreases strength, increases abrasive wear to moulds and cores, and results in uneconomical dilution of the reclaim with expensive new base sand. The length of life (bench life) of mixtures plays an important role in the manufacture of huge and voluminous moulds and cores in self-setting mixtures. This study aims at analyzing the function of reactive alkaline salts in the reclaim, monitors the consequences of its thermal exposure on the properties of selfsetting mixtures, and deals with development of methods evaluating its qualities.
The paper presents results of floristic investigation conducted within the territory of post-industrial spoil heaps connected with zinc and lead products manufacturing. The flora of specific technogenic habitats was analyzed with regard to geographical-historical groups and syntaxonomic classification. For each species, the following characteristics were determined: a life form according to the classification of Raunkiaer, means of seed spreading and types of mycorrhiza for each species based on the literature. On the two heaps, a total of 257 species of vascular plants belonging to 59 families were found. Only 92 species occurred on both sites, which is 36% of all plants recorded. The most numerous families are: Asteraceae (45 species) and Poaceae (28 species). Apophytes dominate in the flora of spoil heaps (70.9%). Hemicryptophytes are the most numerous group and therophytes are also abundant. Ruderal (belonging to Artemisietea vulgaris and Stelarietea mediae) and meadow species (belonging to Molino-Arrhenatheretea) dominate on both post-industrial dumps. Xerothermal species (belonging to Festuco-Brometea) are also fairly numerous (6.7%). Their presence is related to the specific habitat conditions. The anemochoric species dominate in the flora of dumps. The high proportion of mycorrhizal plants was recorded. Finally, reclamation interventions which were carried out on the H2 spoil heap are discussed.
The presented in the paper investigations were aimed at the determination of the reclaimed material (obtained in the dry mechanical reclamation process) addition influence on properties of moulding sands with hydrated sodium silicate modified by colloidal suspension of zinc oxide nanoparticles in propanol. Nanoparticles originated from the thermal decomposition of alkaline zinc carbonate, were used. The results of the reclamation of the spent moulding sand with hydrated sodium silicate performed in the AT-2 testing reclaimer are presented in the paper. Both, spent sands from the Floster S technology and from the technology with the modified water-glass were subjected to the reclamation processes. The following determinations of the reclaimed material were performed: pH reaction, acid demand, ignition loss and Na2O content. The obtained reclaim was used as a matrix component of moulding sands with water-glass in the Floster S technology, in which it constituted 60% and 50% of the sand matrix. The strength properties of the prepared moulding sands were determined (bending strength Rg u , tensile strength Rm u ) after samples storing times: 1h, 2h, 4h and 24 hours.
The paper presents an original method of measuring the actual chromite content in the circulating moulding sand of foundry. This type of material is applied for production of moulds. This is the case of foundry which most frequently perform heavy casting in which for the construction of chemical hardening mould is used, both the quartz sand and chromite sand. After the dry reclamation of used moulding sand, both types of sands are mixed in various ratios resulting that in reclaimed sand silos, the layers of varying content of chromite in mixture are observed. For chromite recuperation from the circulating moulding sand there are applied the appropriate installations equipped with separate elements generating locally strong magnetic field. The knowledge of the current ratio of chromite and quartz sand allows to optimize the settings of installation and control of the separation efficiency. The arduous and time-consuming method of determining the content of chromite using bromoform liquid requires operational powers and precautions during using this toxic liquid. It was developed and tested the new, uncomplicated gravimetric laboratory method using powerful permanent magnets (neodymium). The method is used in the production conditions of casting for current inspection of chromite quantity in used sand in reclamation plant.
A technology of sands with water glass hardened by liquid esters is a cheap and ecologic method of producing moulding sands. Due to these advantages, this technology is still very important in several foundry plants for production of heavy iron and steel castings. Reclamation of the mixed moulding and core sands generates significant amounts of dusts, which require further treatments for their reuse. The results of investigations of a pressureless granulation of dusts generated in the dry mechanical reclamation process of the mixture consisting in app. 90 % of moulding sands from the Floster S technology and in 10 % of core sands with phenolic resin resol type, are presented in the hereby paper. Investigations were aimed at obtaining granulates of the determined dimensional and strength parameters. Granules were formed from the mixture of dusts consisting of 75 mass% of dusts after the reclamation of sands mixture and of 25 mass% of dusts from bentonite sands processing plant. Wetted dusts from bentonite sands were used as a binding agent allowing the granulation of after reclamation dusts originated from the mixed sands technology.