METAL CASTING 
Project Fact Sheet 
NON-INCINERATION TREATMENT TO REDUCE 
SIMPLE TREATMENT SYSTEMS CAN BE A COST EFFECTIVE 
TECHNIQUE TO REDUCE EMISSIONS IN GREEN SAND FOUNDRIES BENEFITS 
Btu in 2010.
BENZENE AND VOC EMISSIONS 
• Estimated energy savings of 0.85 trillion 
• AO/AO-UWAP processing, a low 
energy alternative, compared to 
conventional incineration techniques 
currently employed. 
• Have the potential to reduce one-third of 
casting industry VOC emissions. 
• Improves molding system performance. 
APPLICATIONS 
The results of this project could be applied in 
green sand foundries throughout the casting 
industry and could replace current 
incineration techniques for emission control. 
Sand casting remains the dominant casting 
method used in the U.S. today. Therefore 
the potential application is widespread. 
Cost-effective non-incineration techniques will significantly reduce volatile 
organic carbon (VOC) and benzene emissions from green sand foundries. 
Increasingly, green sand foundries must reduce benzene and VOC emissions 
during pouring, cooling, and shakeout. Conventional incineration systems to treat 
stack gases are costly to operate and difficult to maintain. Alternative pollution 
treatment methods are needed to comply with air quality requirements. Full-scale 
plant trials at green sand foundries have shown that simple, non-incineration 
advanced oxidation (AO) treatment systems or a combination of AO with 
underwater plasma (AO-UWAP) treatment can greatly reduce emissions. In AO 
and AO-UWAP treatment systems, wet collector sludge, or sand system 
baghouse dust is passed through a water slurry that has been preconditioned 
with ozone, hydrogen peroxide, and sonification/plasma treatment. 
Pennsylvania State University and industry partners are evaluating the use of 
AO, and AO with an underwater plasma, as a green sand "additive". AO can be 
added to a foundry's green sand system wherever water is. In production, before 
water or black water slurries are added to the sand, they are treated with small 
amounts of AO combined with an ultrasonic treatment. It is believed that AO 
treatment cleans the clay, allowing them to be more easily activated. AO has the 
potential to activate the seacoal causing the mold to absorb VOCs. Hazardous 
pollutants and VOCs are oxidized within the green sand mold, and the amount of 
clay and seacoal required in the mold are reduced. Smoke and odor emitted 
during cooling and shakeout can be reduced significantly. 
REDUCING FOUNDRY EMISSIONS 
Test results in green sand foundries 
have been positive. Emissions and 
sand requirements in participating 
foundries have been reduced significantly. 
Advanced oxidation processing has reduced smoke, odor and emissions in 
foundries. 
OFFICE OF INDUSTRIAL TECHNOLOGIES 
ENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY
Project Description 
Goal: The goal of this research is to understand and further develop cost-effective nonincineration 
techniques that will significantly reduce VOC emissions from foundries. 
Progress and Milestones 
This three year project began in October 1998. Specific tasks include: 
• Controlled Foundry Trials - These trials are evaluating the sand system and 
environmental performance of advanced oxidant (AO) green sand systems using AO 
additions, AO additions with black water collectors, and AO additions with dust reactivation 
for bond recovery. 
• Laboratory Testing - Pennsylvania State University Metal Casting Laboratory benchscale 
tests are being conducted to further understand AO-green sand system 
interactions and their effects on sand system performance and emissions. 
• Analytical Studies - Analytical studies will be performed to evaluate AO-green sand 
reactions and reaction kinetics. 
• Technology Transfer - Results will be communicated through the AFS Casting 
Congress and future AFS Environmental Affairs Conferences. Results are also 
being disseminated through individual AFS Technical Committees and through the 
trade press. 
Results to date have been positive. At the Neenah Foundry, AO technology has 
reduced sand system bond usage by 15 percent with an associated reduction in 
emissions from cooling and shakeout. At International Truck & Engine's Waukesha 
plant, stack tests conducted in 1999 showed a 56 percent reduction in benzene per 
tone of iron poured and a 74 percent reduction of VOCs (including benzene) per tone of 
iron poured. Tests have also demonstrated that CO emissions have been reduced by 
10 percent as a direct result of sand system optimization. Significant cost reductions 
have been achieved at both foundries due to reductions in sand system clay (bond) 
requirements. 
PROJECT PARTNERS 
Pennsylvania State University 
University Park, PA 
American Foundry Society 
Des Plaines, IL 
Furness-Newburge, Inc. 
Versailles, KY 
Grede Foundries, Inc. 
Reedsburg, WI 
International Truck and Engine Corp. 
Waukesha, WI 
Neenah Foundry Company 
Neenah, WI 
Wheeland Foundry 
Chattanooga, TN 
FOR ADDITIONAL INFORMATION, 
PLEASE CONTACT: 
Harvey Wong 
Office of Industrial Technologies 
Phone: (202) 586-9235 
Fax: (202) 586-6507 
Harvey.Wong@ee.doe.gov 
http://www.oit.doe.gov/IOF/metalcast/ 
Please send any comments, 
questions, or suggestions to 
webmaster.oit@ee.doe.gov. 
Visit our home page at 
www.oit.doe.gov 
Office of Industrial Technologies 
Energy Efficiency 
and Renewable Energy 
U.S. Department of Energy 
Washington, D.C. 20585 
January 2001