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want cleaner air? as environmental and health standards increase for the u.s. metalcasting industry, two facilities established methods to improve their in-plant air quality.

by:Trust&Deal Breeding Equipment     2020-02-27
Are you on your melting deck and can\'t see 20 feet.
In front of you?
This is most likely due to smoke and dust emitted from furnaces and molten metals.
There may be some emission collection systems in your casting facility, but they may be too far or too weak to work effectively.
Due to your limited visibility, this can pose a risk to breathing conditions and physical safety.
To avoid this, two metal casting facilities have developed solutions to improve the air quality in casting operations.
This paper details the trials carried out by the two companies in their factories and how the new system provides cleaner air for the working environment.
Keep the smoke cover at Seneca Foundry
Webster City, which has been improved-
Since the medium term, the houses of its cast iron plant have been ventilated
After the 90 s, its president, Kirk mccroo, made air quality a priority for the facility.
Seneca is two of them-
Induction furnaces and furnace covers are also installed.
However, the smoke cover on the top of the head is only 10 feet. (3. 05 m)
Too far from the stove, leaving too much open space for proper ventilation.
In addition, melting operators are often affected by direct furnace emissions.
Improvements were made to reduce excess dust in the workshop, including replacing the wet collector with a new baghouse system and adding a high
Wall exhaust fan in core room to remove heat and miscellaneous gas.
But melting the deck is still a problem.
Limits of exposure are allowed (PELs)
Rarely exceeded, smoke from the stove and transfer barrel increases the transparency of the air, which leads to hazy working conditions.
Seneca looked at the possibility of installing a more efficient smoke cover, but encountered difficulties because the models they saw were either too expensive or too much maintenance was required, or they would not collect all from the stove
The foundry company spent several years trying to determine what worked best for its operations when people developed an idea for their own smokescreen.
This design requires the installation of a \"hood\" and \"pickup box\" on its induction furnace \".
The company has proposed a project that will place a smoke cover during the preheating operation, a tight capture cover on each furnace, and a cover at the transfer point of the inverted deck.
When on the stove, the barrel will be ported internally for forced airflow.
In addition, a supercharged fan and large spark trap box will be added and baghouse will be modified for fire fighting.
Seneca hired a consultant to look into the proposal, which created a prototype air-quality system.
The company\'s factory engineers worked closely with the melting deck operator to develop an all-in-one
The operator believes that the cardboard model of the furnace cover can reduce heat and eliminate the demand for dust masks.
The production personnel outline the model and then weld each cardboard part together with steel.
The upper pass hood is mounted on the furnace cover, so when the furnace cover is closed, the furnace cover collects all the smoke generated in the furnace.
The pickup box installed next to the hood puts all the smoke through the connected 12-in. (30. 48-cm)
A steel suction pipe on a supercharged fan that delivers air to the drop-out box and finally to the bag chamber.
When the furnace cover is opened for charging operation, the loading bucket is set at the top of the furnace, and the picking box will collect all the smoke in the bucket.
The box also acts as a rotating joint so that the airflow does not break when the furnace is tilted to pour.
The prototype was tested with a temporary fan setup.
Airflow and temperature data were collected while the effectiveness of smoke capture was observed.
The similarly designed second stove smoke cover was built on another stove shortly after the first one.
At the same time, the company also tried to install a 52-ft. (15. 9-m)
\"Fresh Air Island\" on the Pour deck \".
This is a roof.
The entrance makeup fan, which draws ambient air from the outside of the building and feeds it into the vent, at the height of the breathing area, it is dispersed along the pouring monorail through eight diffusers, which is 6-7 ft. (1. 8-2. 1 m)
On the ground.
This will allow the pouring personnel to breathe fresh air while working with the barrel.
In addition, 16-for Seneca-in. (40. 64-cm)
Collect the pipes of smoke and carbon monoxide from its charging preheating Station and build a fixed smoke cover at the location where the metal is transferred to the watering bag to collect magnesium to handle the smoke.
The foundry submitted a new application to Iowa.
Modifications to existing aviation licenses.
This new license requires a reduction in the total number of baghouse cfm, airto-
The department approved the new license below 3: 1.
Although there are still some obstacles that need to be overcome, seneca has been successful in implementing prototype cleaning
The air system goes into daily operation.
Fumehoods allows the melting deck operator to work in cooler temperatures and cleaner air.
The level of silica and dust on the deck is much lower than that of PEL, and the opacity of the plant is significantly improved.
Although some redesign is required to warm up the smoke cover to improve efficiency, and the melting operator now has additional tasks every week to remove the stove cover, the staff acknowledged, the improvement of air quality is worth the extra work.
Push and pull like seneca and Rochester metal products
I\'m Rochester, Ind.
Find it necessary to reconfigure its emissions-
Ability to capture.
This is to achieve a country.
Qualified air permit.
Indiana, 2003.
Environmental Management (IDEM)
Stack test for Rochester Air
Capture system, found to be insufficient due to non-compliance with the mandatory 100% capture efficiency.
Plants have two pulses.
Jet dust collector (
One at 30,000 cfm and the other at 50,000 cfm)and a side-
Draft canopy emissionscapture system.
But this creates a problem for Rochester as its narrow melting deck with Monorail and conveyor belts seems to be detrimental to the effective aircapture.
For example, near the steel outlet area, the ladle monorail will be on the side
Side ventilation canopy from the inlet of the dust collector and when charging-
Draft canopy entrance captures very little emissions from the opening of the facility
Top bucket.
As a result, Rochester staff are trying to improve their emissions
Capture operation of several trialsand-
Wrong technology.
It needs to determine a way to clean the surrounding air.
Ton induction cooker, two pre-heating, two 10-
Ton charging crane.
One way is to use 30-36-in. (76. 2-91. 44-cm)
The floor fan that pushes the melt discharge into the side-
Ventilated canopy cover, because the canopy used to require only 30,000 cfm compared to the required 200,000 cfm.
But the fan caused the worker to be hit by a foreign body and still did not control the discharge during charging.
Another way to improve air quality is to reduce negative pressure.
To this end, Rochester turned off six 20,000 roof fans to reduce the low pressure.
Unfortunately, this creates excessive heat conditions for the pouring deck operator.
The company has also looked at the tight capture hood of the stove and barrel, but the idea does not take into account the discharge of the faucet, and the barrel needs to be changed.
Then Rochester discovered the theory of pushing.
Pull ventilation. The push-
Rafa requires a certain amount of air to be pushed from the side of the furnace to the center of the furnace.
Then the air is pulled sideways-
Suck the canopy into the inlet of the dust collector.
This is through two 12-in. (30. 48 cm)
Diameter push head, each push head has 25 nozzles, the size is from 0. 75-1 in. (1. 9-2. 54 cm)in diameter.
Each push header is 2,000-
The Blower is located at 7ft. (2. 1 m)
Above the stove.
During the charging process, 1,200 of a pause
The cfm blower located on the crane trolley provides additional push to the sidedraft canopy.
This blower includes 18 1. 5-in. (3. 81-cm)
In order to direct the airflow like a knife to the canopy, the nozzle.
By doing so, Rochester gets a melting deck with cleaner air and better visibility.
The main advantages of push-
The pull system is that it covers all emissions from charging to melting to tapping and does not cause any changes to the charging system.
Unfortunately, the operating system requires 25,000 cfm per furnace to meet the standard and is still easy to cross
Air flow on deck floor.
Currently Rochester is developing a design for a covered charging bucket and coordinating an emissions-
Upgrade the capture project with possible melting capabilities.
Although push-
The Pull method improves the clean air capacity of the plant, and he is working on the option of a completely closed capture system that can save operating costs while maintaining good air quality.
This paper is adapted from a presentation at the AFS Conference on Environment, Health and safety held in August. 21-
2005 in Dearborn, Michigan
Author Phil strokowhn is a factory engineer at Seneca foundry.
Webster, Iowa
Andrew Murdoch is an environmental and project engineer at Rochester metal products.
I\'m Rochester, Ind.
For more information on \"history is the key to future environmental, health and safety issues,\" K.
Bauer, modern casting, October. 2004, p. 35-38.
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