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This paper describes the development of an inorganic alternative to coal or coal replacement for bentonite bonded molds (greensand molding) and the realization in an operating foundry. Through a time period of 1.5 years, Componenta Foundry changed in many steps from a classical green sand system to a coal free system, based on ENVIBOND developed in the GO-APIC project and further development as an S&B project. At Componenta Foundry, the percentage of casting defects or scrap did not increase. There was a tendency of an increase in stress (scabbing) defects and of a decrease in penetration defects. Benzene emission is reduced by 40%, odor emission has lower values (not statistically proven). Visible is less smoke in the foundry, especially at the cooling line. The benefits for health and emissions are clearly seen.
This paper describes the development of an inorganic alternative to coal or coal replacement for bentonite bonded molds (greensand molding) and the realization in an operating foundry. Through a time period of 1.5 years, Componenta Foundry changed in many steps from a classical green sand system to a coal free system, based on ENVIBOND developed in the GO-APIC project and further development as an S & B project. At Component a Foundry, the percentage of casting defects or scrap did not increase. There was a tendency of an increase in stress (scabbing Benzene emission is reduced by penetration by 40%, odor emission has lower values (not grippeable). Visible is less smoke in the foundry, especially at the cooling line. The benefits for health and emissions are clearly seen.