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
.
We discuss waste, fuels, and air quality with Prof. Czesława Rosik-Dulewska from the PAS Institute of Environmental Engineering and the Department of Land Protection at the University of Opole.
There are two methods to produce primary copper: hydrometallurgical and pyrometallurgical. Copper concentrates, from which copper
matte is melted, constitute the charge at melting primary copper in the pyrometallurgical process. This process consists of a few stages, of
which the basic ones are roasting and smelting. Smelting process may be bath and flash. Slag from copper production, on the end of
process contain less 0,8%. It is treat as a waste or used other field, but only in a few friction. The slag amount for waste management or
storage equaled 11 741 – 16 011 million tons in 2011. This is a serious ecological problem. The following slags were investigated: slag
originated from the primary copper production process in the flash furnace of the Outtokumpuja Company in HM Głogów 2 (Sample S2):
the same slag after the copper removal performed according the up to now technology (Sample S1): slag originated from the primary
copper production process in the flash furnace of the Outtokumpuja Company in HM Głogów 2, after the copper removal performed
according the new technology (Sample S3). In practice, all tested slags satisfy the allowance criteria of storing on the dumping grounds of
wastes other than hazardous and neutral.
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.
The substrates to biogas production in anaerobic digestion, except plant materials, can also be animal feces and manure. It should be highlighted that Poland is one of leaders in the European Union in animal breeding. However, there is no precise data in the literature on the potential of biogas production from animal feces in this country. The aim of the paper was to analyze the biogas production potential from manure in Poland. The aim of work included anaerobic digestion research following materials: cow manure, pig manure, poultry manure and sheep manure. In the next step, based on the obtained results of the biogas yield, energy potential calculations were made. The methane yield for the investigated feedstock materials in the batch culture technology was performed following the internal procedures developed based on the adapted standards, i.e. DIN 38 414-S8 and VDI 4630. Animal wastes were obtained from the Agricultural Experimental Stations of Poznan University of Life Sciences (Poznan, Poland). On a base of achieved results it was concluded that tested substrates have a high energy potential (approx. 28.52 GWh of electricity). The largest potential for electricity production was found in chicken manure (about 13.86 GWh) and cow manure (about 12.35 GWh). It was also shown which regions of Poland have the best chance for development of agriculture biogas plants (Wielkopolskie and Mazowieckie voivodships) and where the potential is the least (Lubuskie and Opolskie voivodeships).
Theory and practice of environmental protection in the case of foundries in Europe and Asia
• Experience resulting from the cooperation with the foundries in a few European countries, China and India
• Phenomena and factors affecting the pollution of the natural environment and the implementation of measures aiming at the
environmental protection
Every specialist dealing with foundry processes and their impact on environmental pollution must have encountered in their professional
careers numerous situations in which the theory of environmental protection confronts the stark reality. The discrepancy between theory
and practice can particularly be noticed in foundry engineering in developing countries where the contrasts between different countries and
casting plants are extremely striking. The comparison of working conditions in European and Asian foundries provides a vast scope for
further observations and analyses. Environmental protection seems not only a concern of manufacturers of castings, but also of their
customers whose opinion exerts a significant influence on both the acceptability of working conditions and on the approach to
environmental pollution adopted in metal casting industry.
The article presents a number of examples of various outlooks on environmental issues in foundries manufacturing a wide range of cast
steel and cast iron castings, where different technologies and production processes are applied.
Mechanical reclamation process of spent moulding sands generate large amounts dusts containing mainly rubbed spent binding agents and quartz dust. The amounts of post-reclamation dusts, depending of the reclamation system efficiency and reclaim dedusting system, can reach 5 -10% in relation to the total reclaimed moulding sand. This dust due to the high content of the organic substances is a threat to the environment and therefore requires the storage on landfills specially adapted for this type of waste. On the other hand, the presence of organic substances causes that these dusts have relatively high energy values that could be used. However, at present there is no coherent, environmentally friendly concept for the management of this type of dust. The paper presents the results of tests of thermal utilization the dusts (as a source of energy) were carried out at AGH University of Science and Technology. Thermal utilization of dusts was carried out in the co-burning with carbon carriers process or in individual burning (Patent PL 227878 B1 and patent application PL - 411 902).
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.
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.
Plastic rocks can creep, therefore the knowledge of the rheological properties of the drilled formations is an important element of the drilling process and when choosing borehole designs. These properties of plastic formations also influence the way in which appropriate drilling technology and drilling mud properties are selected. The article presents the effect of basic rheological parameters of salt from the Fore-Sudetic Monocline deposit on the drilling of boreholes in the mining area of KGHM Polska Miedź, which in the future can be used as a good drilling practice to improve the safety and efficiency of drilling.
The process of drilling in plastic rocks may be hindered. Salt is a plastic rock and in the analyzed rock mass it is deposited at a considerable depth. The caprock exerts big loads on it, beside the temperature in the deposit intensifies the rheological properties of the rock. The creep process causes that the borehole contracts, therefore the knowledge about the rheological properties of the drilled rock is very important for establishing the safe time in which the well may remain uncased. The paper is devoted to the influence of basic rheological parameters of salt bed in the Fore-Sudetic Monocline on the process of drilling of a borehole in the area of KGHM Polska Miedź as these data can be used in drilling practice in the future.
This article presents the history of mining for rock raw materials in the Cieszyn area since the beginning of the 20th century. The study assessed the possibility of continuing these activities in relation to the ongoing enlargement of conservation areas. The conflict between mining these deposits and environmental interests was described. The results of the analysis allowed for the identification of potential sites for further exploitation of Godula Sandstone and Cieszyn Limestone. The study used analog and digital data which were subjected to the procedures specific to the GIS (Geographic Information System) methods. The exploitation of Cieszyn Shale and Limestone played an important role in the first half of the 20th century. They were used for the production of lime and cement. However, the importance of these materials decreased gradually due to declining demand and quality. In later years, after the closure of the cement plant in Goleszów, limestone was used only for aggregate production. Natural aggregates and clay raw materials were initially exploited in small excavations based on local needs, and later in an organized manner with documented deposits. At present, mining of these materials has been discontinued. The centuries-old tradition of Godula Sandstone block production was maintained during the last hundred years. In the last decade, their extraction was conducted in the original quarry, as well as several new quarries. Additional resources have been documented at other locations. Because of the nature of the product, such extraction (in small quarries, without the use of blasting agents) does not significantly affect wildlife. Moreover, the locations of current and former mining operations often become tourist attractions. This is evidenced by the fact that the documentation sites are established on the basis of such excavations. Numerous objects of protection established in recent years have led to a major conflict between the exploitation of rock materials and the environment. This prevents development or even the continuation of exploitation. Therefore, in future planning processes, efforts must be made to characterize mineral deposits as a part of nature, requiring protection.
Production waste is one of the major sources of aluminium for recycling. Depending on the waste sources, it can be directly melted in furnaces, pre-cleaned and then melted, or due to the small size of the material (powder or dust) left without remelting. The latter form of waste includes chips formed during mechanical cutting (sawing) of aluminium and its alloys. In this study, this type of chips (with the dimensions not exceeding 1 mm) were melted. The obtained results of laboratory tests have indicated that even chips of such small sizes pressed into cylindrical compacts can be remelted. The high recovery yield (up to 94 %) and degree of metal coalescence (up to 100 %) were achieved via thermal removal of impurities under controlled conditions of a gas atmosphere (argon or/and air), followed with consolidation of chips at a pressure of minimum 170 MPa and melting at 750 oC with NaCl-KCl-Na3AlF6 salt flux.
The work presents the results of examinations concerning the influence of various amounts of home scrap additions on the porosity of
castings made of MgAl9Zn1 alloy. The fraction of home scrap in the metal charge ranged from 0 to 100%. Castings were pressure cast by
means of the hot-chamber pressure die casting machine under the industrial conditions in one of the domestic foundries. Additionally, for
the purpose of comparison, the porosity of specimens cut out directly of the MgAl9Zn1 ingot alloy was also determined. The examinations
consisted in the qualitative assessment of porosity by means of the optical microscopy and its quantitative determination by the method of
weighting specimens in air and in water. It was found during the examination that the porosity of castings decreases with an increase in the
home scrap fraction in the metal charge. The qualitative examinations confirmed the beneficial influence of the increased home scrap
fraction on the porosity of castings. It was concluded that the reusing of home scrap in a foundry can be a good way of reduction of costs
related to the production of pressure castings.
The work presents the results of examinations concerning the influence of various amounts of home scrap additions on the properties of
castings made of MgAl9Zn1 alloy. The fraction of home scrap in the metal charge ranged from 0 to 100%. Castings were pressure cast by
means of the hot-chamber pressure die casting machine under the industrial conditions in one of the domestic foundries. The examinations
consisted in the determination of the following properties: tensile strength Rm, yield strength Rp0.2, and the unit elongation A5, all being
measured during the static tensile test. Also, the hardness measurements were taken by the Brinell method. It was found that the
mechanical properties (mainly the strength properties) are being improved up to the home scrap fraction of 50%. Their values were
increased by about 30% over this range. Further rise in the home scrap content, however, brought a definite decrease in these properties.
The unit elongation A5 exhibited continual decrease with an increase in the home scrap fraction in the metal charge. A large growth of
hardness was noticed for the home scrap fraction increasing up to the value of 50%. Further increasing the home scrap percentage,
however, did not result in a significant rise of the hardness value any more.