Metal Foundry Industry

The metal foundry industry can be divided into two sectors: ferrous and nonfer-rous. Ferrous foundries cast iron and steel products, while nonferrous foundries cast a variety of other metals such as aluminum, copper, zinc, lead, tin, and nickel. More than 75 percent of products by volume are ferrous. Although non-ferrous industries use the same basic molding and casting techniques, byproducts can be different from those produced from ferrous industries.

The casting of metal in foundries is one of the oldest and largest recycling industries in the world. Metal foundries exist everywhere worldwide to produce different products such as valves, pipe fittings, pipe accessories used in water, and wastewater networks made out of cast iron, copper, or aluminum through metal foundry using sand-molding technology. Many other components in engines, pumps, blowers, compressors, and so on can also be produced in metal foundries. The sand molding technology consists of the following processes:"/>
FIGURE 1.27 Bonded marble with antique stone finish 10 inches H (25 cm) (Source:

1. Sand and mold preparation. The sand is first mixed with a hardening material, like bentonite slurry for example, inside the sand preparation mixers. After that the sand molds are formed and are placed on the production line

2. Melting. The main types of metals are used in metal foundry: iron, aluminum, and copper. Other metal can also be used according to requests, such as zinc, aluminum alloy, copper alloy, and so on. A large quantity of slag, which is about 20 to 25 percent of the melted material, comes out from the melting process. The utilization of slag will be discussed with details in the next section.

3. Pouring. The end metal product is then poured into the moulds and left to cool and gain its strength. Then the moulds are untied to get the product from.

4. Cleaning and Inspection. All the products are gathered for inspection and quality assurance. Some of those are rejected and sent back to the furnace for remelting, and others are approved and cleaned. However, there is a huge quantity of wasted sand that creates a disaster to the company and surrounding environment, if it is left without use.

5. Product final preparation phase. The products are sent to workshops for cutting, making holes, and trimming. This process results in many metal wastes that are then delivered again to the furnaces for remelting.

6. Assembly and examination phase. After all the products are prepared, they are assembled according to the specifications, and then their mechanical properties are tested.

7. Finishing and storage phase. The final product is then painted by spraying it either with bitumen or epoxy in a controlled outdoor area. After the product is painted, it is stored in its final shape.

Renewable Energy Eco Friendly

Renewable Energy Eco Friendly

Renewable energy is energy that is generated from sunlight, rain, tides, geothermal heat and wind. These sources are naturally and constantly replenished, which is why they are deemed as renewable.

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