PHILOSOPHY

It is now being globally recognized that in the present situation concerning environmental problems, it would seem wise to argue that no part or sector of society should be excluded from consideration in an attempt to identify problems and to seek improvements. Additionally, it is also being realized that the neo-classical microeconomics based on the specific premise that the human being is purely an economic entity and organizations are purely profit maximizing entities needs an alternative based on the premise that individuals are responsible actors and business operations affect Nature and Environment. This alternative is the basis of integration of the mistakenly divorced disciplines of Ecology/Environment/Science &Technology/ Ethics and Economics. This integration eventually leads to the conclusion that there is no value-free science/technology in relation to environmental and developmental issues. Once this is accepted, the subsequent step is to identify/clarify the values latent to the particular discipline. In the present scenario ecological sustainability is a value of paramount and primary importance. In particular, the need of the day is (1) to understand any business in terms of the broader perspective of efficiency than merely from that of cost-revenue or monitory reductionism and (2) to understand that cooperation-as opposed to competition and conflict/confrontation-can be both rational and socially necessary.

PHILOSOPHY

Until one is committed there is hesitancy, the chance to draw back, always ineffectiveness. Concerning all acts of initiative (and creation), there is one elementary truth, the ignorance of which kills countless ideas and splendid plans: that the moment one commits oneself, then providence moves in to, all sorts of things occur to help one that would never otherwise have occurred. A whole stream of events issues from the decision, raising in ones favor all manner of unforeseen incidents and meetings and material assistance, which no man could have dreamt would come his way. I have learned a deep respect for one of Goethes couplets: Whatever you can do, or dream, begin it. Boldness has genius, power and magic in it. W.H. Murray (The Scottish Himalayan Expedition)

EMISSION POINTS IN TYPICAL IRON FOUNDRY

THE STRATEGY

CONTROL OF AIR POLLUTION SHOULD BE CONSIDERED AS PER MELTING METHODS, SAND HANDLING, TYPES OF MOLTEN METAL AND OTHER MATERIALS, & CLEANING AND FINISHING OF CASTINGS. AIR POLLUTION CHARACTERISTICS ARE AFFECTED BY A NUMBER OF FACTORS: TYPE OF MELTING UNIT, MATERIAL HANDLING AND HOODING SYSTEMS & EMISSION CONTROL SYSTEMS. AIR POLLUTION PROBLEM THEN BECOMES ONE OF CAPTURING (SMOKE, DUST,FUMES) AT THE SOURCE AND CONVEYING THESE CONTAMINANTS TO SUITABLE CONTROL DEVICES.

EMISSION CHARACTERIZATION:MOLD & CORE MAKING AND MELTING

MOLD AND CORE MAKING: PARTICULATES FROM SAND PREPARATION, MOLD CORE FORMING & CURING. ADDITIONALLY, VOCs, CO & PARTICULATES DURING CORE & MOLD CURING/DRYING. MELTING: MELTING PROCESS BEGINS WITH HANDLING OF CHARGE MATERIALS. EMISSIONS FROM HANDLING ARE FUGITIVE PARTICULATES GENERATED FROM RECEIVING, UNLOADING, STORAGE & CONVEYING OPERATIONS. SCRAP PREPARATION & PREHEATING EMITS FUMES, ORGANICS, CO, COARSE PARTICULATES. SCRAP DEGREASING (WITH SOLVENTS) EMITS VOCs.

EMISSION CHARACTERIZATION: INDUCTION AND ARC MELTING

INDUCTION & ARC MELTING: HIGH CONCENTRATIONS OF FURNACE EMISSIONS OCCUR DURING CHARGING, BACK-CHARGING, ALLOYING, SLAG REMOVAL, AND TAPPING OPERATIONS. THERS INCLUDE PARTICULATES (METAL OXIDES) & POSSIBLE ORGANICS, DEPENDING ON SCRAP QUALITY AND PRETREATMENT.TYPICAL DUST LOADING FROM EAF: 5- 10 KG PER TON MELTED. EIF EMITS PARTICULATES AT ONE TENTH OF THIS VALUE.

EMISSION CHARACTERIZATION: CUPOLA MELTING CUPOLA MELTING: QUANTITY & COMPOSITION OF PARTICULATE EMISSIONS VARY AMONG CUPOLAS, & EVEN AT INTERVALS IN THE SAME CUPOLA. CAUSES INCLUDE CHANGES IN Fe- TO-COKE RATIOS, AIR VOLUMES PER TON MELTED, STACK VELOCITY, & QUALITY OF SCRAP MELTED. WHEN OILY SCRAP IS CHARGED, THE RAW EMISSION POTENTIALLY NOT ONLY WILL BE GREATER IN QUANTITY, BUT CAN BE MUCH MORE VISIBLE. EMISSIONS FROM AN UNCONTROLLED CUPOLA MAY BE IN THE RANGE 7-25 KG PER TON MELTED. 85% OF THE EMISSIONS MAY BE GREATER THAN 10m SIZE. PARTICULATES MAY INCLUDE SOME OR ALL OF THE FOLLOWING MATERIALS: IRON OXIDES, MgO, MANGANESE OXIDES, ZnO, SiO2, CaO, Pb, Cd. GASES & ORGANICS MAY ALSO BE EMITTED (SO2, CO, NOX). THE QUANTITY OF SO2 IS LARGE ENOUGH TO CAUSE SERIOUS CORROSION PROBLEM. THERE ARE A NUMBER OF INSTANCES OF RAPID DETERIORATION OF APCS WHERE CORROSION PROTECTION WSA NOT CONSIDERED. WHEN FLUOROSPAR IS USED AS AN ADDITIVE, THE F DRIVEN OFF CAN CAUSE SERIOUS CORROSION PROBLEM ALONG WITH H2CO3.

EMISSION CHARACTERIZATION: POURING, CASTING & FINISHING PARTICULATES DURING TREATMENT AND INNOCULATION OF MOLTEN Fe, e.g. ADDITION OF Mg TO MOLTEN METAL TO PRODUCE DI CAUSES AN EXTREMELY VOILENT REACTION ACCOMPANIED WITH EMISSION OF Mg OXIDES & METALLOC FUMES, DEPENDING ON METHOD OF TREATMENT. SOME METHODS VIZ. TUNDISH METHOD, RESULT IN SIGNIFICANTLY LOWER EMISSIONS THAN OTHERS. EMISSIONS FROMPOURING CONSIST OF METAL FUMES, CO, ORGANICS & PARTICULATES EVOLVED WHEN THE MOLD AND CORE MATERIALS ARE CONTACTED BY THE MOLTEN METAL. EMISSIONS CONTINUE DURING MOLD COOLING & SHAKEOUT OPERATIONS, THOUGH AT A MUCH LOWER RATE. FINISHING OPERATIONS EMIT PARTICULATES DURING REMOVAL OF BURRS, RISERS, AND SHOTBLASTING OPERATIONS. THESE CONSISTS MAINLY OF Fe, Fe OXIDES & ABRASIVE MEDIA. PAINTING OF CASTINGS LEADS TO EMISSION OF VOCs. PICKILNG OF STEEL CASTING CAUSES HNO3 AND HCl/HF EMISSIONS IN VAPOUR AND LIQUID FORM ALONG WITH HAZARDOUS SOLID WASTE IN THE FORM OF SLUDGE.

EMISSION CHARACTERIZATION
WORK ZONE PATTERN SHOP SAND PREPARATION MOULD AND CORE MAKING MOULD DRYING AND LADLE HEATING CUPOLA EIF POURING AND MOULD COOLING KNOCK OUT FETTLING HEAT TREATMENT SAW DUST FINES SAND, FINES,BINDER DUST, VAPOURS CO, SO2 SO2, CO, UBHC, OXIDES, COKE DUST OXIDES, SMOKE, DUST CO, BINDER FUMES, AND OIL VAPOURS SAND, FINES, DUST, SMOKE VAPOURS DUST (METAL AND SAND) CO, SO2, OIL VAPOURS POLLUTANT CONCENTRATION g/m3 100-150 100-175 50-100,150-200,50-125 LIGHT LIGHT 10, 2, 0.02, 0.002, 200 LIGHT LIGHT, MODERATE, HEAVY 400, HEAVY 150 LIGHT 25

PAINTING

VOC

AIR POLLUTION CONTROL METHODS:PARTICULATE MATTER:WET METHODS WET METHODS INCLUDE LOW AND HIGH ENERGY TYPES. MECHANISM OF COLLECTION IN WET MOTHODS:INERTIAL IMPACTION AND DIRECT INTERCEPTION. THESE ARE USED EITHER SEPARATELY ON IN COMBINATION. FOR A WELL DESIGNED WET SCRUBBER, THE EFFICIENCY IS A FUNCTION OF ENERGY CONSUMED IN THE AIR-WATER CONTACT PROCESS AND IS INDEPENDENT OF THE TYPE. THIS IS THE REASON WHY WELLDESIGNED COLLECTORS OPERATING WITH COMPARABLE PRESSURE DROPS EXHIBIT COMPARABLE PERFORMANCE. ALL COLLECTORS EXHIBIT FRACTIONAL EFFICIENCY CHARACTERISTICS i.e. THEIR EFFICIENCY VARIES DIRECTLY WITH THE SIZE OF THE PARTICLE BEING COLLECTED. GENERALLY, COLLECTORS OPERATING WITH LOW PRESSURE DROPS WILL REMOVE ONLY THE MEDIUM TO COARSE FRACTIONS. COLLECTION OF FINE PARTICULATES REQUIRE INCREASED ENERGY INPUT, WILL BE REFLECTED IN HIGHER PRESSURE DROP. VENTURY SCRUBBER IS THE MOST APPROPRIATE FOR CUPOLA FURNACES. THESE CAN BE DESIGNED TO USE AS LITTLE AS 30lpm H2O/1000 cfm OF SATURATED GAS AT THROAT, WITH A PRESSURE DROP OF 30wc. H2O IS RECIRCULATED AND A BLED FROM THE SYSTEM (@ 4lpm/1000cfm) TO REMOVE COLLECTED DUST AND TREATED AS PER NORMS. THE ADDED ADVANTAGE IS T: CONTROL OF GASES WITH USE OF ALKALINE SCRUBBING MEDIA. THE EFFICIENCY FOR PARTICULATE (MASS MEDIAN SIZE OF 0.5 m) & GAS REMOVAL IS AT LEAST 98%.

AIR POLLUTION CONTROL METHODS:PARTICULATE MATTER:DRY METHODS

COMMONLY USED: BAG FILTERS. WITH THE MASS MEDIAN SIZE OF 0.5m, A COLLECTION EFFICIENCY OF 98% CAN BE ACHIEVED. AS THE FILTERS GETS COATED THE COLLECTION EFFICIENCY AND PRESSURE DROP INCREASES. THIS DROP RESULTS IN SIGNIFICANT REDUCTION OF AIR FLOW AND TO MAINTAIN IT FILTERS MUST BE CLEANED PERIODICALLY MECHANICALLY OR BY PULSED AIR. FABRICS ARE NOE AVAILABLE FOR HOT CORROSIVE ATMOSPHERES SUCH AS CUPOLA EMISSIONS. OPERATING TEMP OD 260C IS NOT UNCOMMON. FREE MOISTURE AND ACID DEW POINT ARE THE WORST ENEMIES IF NO PROVISION IS INCLUDED FOR CONDENSATION OF MOISTURE. FOR REVERSE AIR AND MECHANICALLY CLEANED SYSTEMS AIR-TO-CLOTH RATIO RECOMMENDED IS IN THE RANGE 1.0-2.5 :1. PULSE-JET AND CARTRIDGE COLLECTORS ARE ALSO USED TO COLLECTS POLLUTANTS FROM SAND PREPARATION/CASTING AND CLEANING OPERATIONS. HOWEVER, PROPER AIR-TO-CLOTH RATIOS (MAX 25:1 FOR PULSE-JET AND 1.5:1 FOR CARTRIDGE) ARE RECOMMENDED. FABRIC FILTERS WILL HAVE ONLY MARGINAL RESULTS WITH FURNACE AND INNOCULATION OPERATIONS UNLESS VERY LOW AIR-TO-CLOTH RATIOS ARE EMPLOYED. ADDITIONALLY MOISTURE INTRODUCED WITH COMPRESSED AIR MAY BE SIGNIFICANT AND CAUSE SUSTEM FAILURE.

INFORMATION REQUIRED FOR EFFECTIVE DESIGN

GAS FLOW RATE AND COMPOSITION TEMPERATURE AND DEW POINT ACID DEW POINT HEAT BALANCE AND THERMAL EFFICIENCY MASS BALANCES PARTICLE SIZE DISTRIBUTION SOLID LOADING CHEMICAL AND PHYSICAL PROPERTIES OF PARTICULATES LEGISLATIVE REQUIREMENTS FURNACE DESIGN (SOURCE ASSESSMENT) OPERATING PRACTICES AND VARIATIONS OPERATIN AND MAINTENANCE CAPABILITES

THERMAL EFFICIENCY OF A CUPOLA COKE CONSUMPTION = 121 kg/T MELTED. COKE ANALYSIS: C = 86.6%, H= 1.0%, O= 3.6%, N= 0.7%, S= 1.2%, ASH = 6.9%. GCV = 30.1084 MJ/kg. HEATING RANGE 30C TO 1420C. MEAN CP OF IRON = 0.681 kJ/kg. LATENT HEAT OF FUSION OF IRON = 206.6 kJ/kg. HEAT IN METAL = 1153.19 MJ/T. MELTING EFFICIENCY OF CUPOLA = (1153.19 MJ/T)/(30.1084 MJ/kg x 121kg/T) = 31.65%.