REDUCTION OF HARMFUL SUBSTANCES EMISSIONS DURING THE MANUFACTURE OF CAST STRUCTURES WITH NON-METALLIC FILLER
DOI:
https://doi.org/10.15407/plit2026.02.031Keywords:
lost-foam casting, cast structure with non-metallic filler, emissions of harmful substances, methodology for determining emissions of harmful substancesAbstract
The paper examines the relationship between emission reduction and the manufacture of light- weight cast structures with non-metallic filler in comparison with monolithic ones when using the technological process of lost-foam casting (LFC). An algorithm of the methodology for determining emissions of harmful substances for a given volume of production in the LFC process has been developed, which consists of determining the sources of emissions and specific emissions of pol- lutants from technological sources by sections and processes; calculating the need for cleaning and capture equipment; calculation of gross emissions of harmful substances by sections and processes; determination of maximum single emissions for the design or selection of cleaning and capture equipment; calculation of total gross emissions per year by type of pollutants; determination of the amount of possible emissions and waste released into the atmosphere, taking into account purification, capture and neutralization. According to the developed and improved methodology, the types of emissions of harmful substances were determined by sections and, using reference data and formulas, gross and total emissions of harmful substances were calculated with an annual production volume of 1,000 tons of gray iron castings by lost-foam casting when melting in induction furnaces with a capacity of 1 ton. For comparison, a variant of the manufactured cast structure with a non-metallic filler (liquid glass mixture) is presented and it has been calculated that the formation of harmful substances depends on the technological process and specifically, on the consumption of liquid metal. When manufacturing cast structures reinforced with a non-metallic filler, with the same production volume in terms of the number of castings, the amount of emissions is reduced by at least 50% due to the decrease in casting weight, and accordingly, the consumption of electricity and charge materials is reduced.
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