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Metal Casting Technologies : December 2010
Trust your most complex cores to INCAST ®. The ideal combination of geometry, density and particle size distribution, INCAST improves critical core ma ing and casting properties including binder utilization, permeability and dimensional stability. igher strength cores, better surface finish and increased efficiency and yield are the INCAST advantages. These sands are engineered for the metalcaster. Optimize Core Performance For more information and availability: ContactUs@metalcaster.com CORE AND MOULDING SANDS ® INCAST is a trademar . All rights reserved. ©2009 ® metal melted it is not clear if furnace energy is the main CO2 source. In order to reduce carbon footprint it would be useful to identify and quantify the key activities in primary cast houses which emit CO2. The main objective of this study was to examine and determine possibilities for reducing environmental impact of primary aluminium cast house operations within the constrained opportunities of meeting societal demands for aluminium products. This paper evaluates the carbon footprint of aluminium casting operations based on a LCA (life cycle analysis) activity based approach for two "typical" primary smelter cast house layouts. Case 1 - is of a simple plant producing 500,000tpa of aluminium 23 kg remelt ingot in pure and Al-Si alloy. Case 2 is of a more complex plant producing 300,000 tpa of extrusion alloys, and 200,000 tpa of rolling slab alloys (Table 1). The work described in the paper is conducted following the international framework for life cycle assessment . Goals and scope of LCA study The main goals of the presented LCA study are: identification of processes, materials and systems that are major contributors to environmental impact (GHG Green House Gas emissions) and compare environmental performance of two different cases under consideration. This comparison is also extended to determine the major contributors of GHG emissions from cast house operations. The study includes only operations within the cast house plants and recycling of dross and transportation of dross between them. The impact categories that have been selected to report the study are global warming potential (GWP) that deals with the emission of GHG emissions and energy consumption due to their importance for the aluminium industry. The life cycle impact and any comparison is expressed in terms of annual operation for each cast house and on a per tonne basis. Product system, system boundaries and assumptions For case 1, the assumed layout is 8 holding furnaces feeding 4 ingot casting conveyors (Figure 1). Liquid metal is delivered from the reduction cells to the furnaces. For the production of Al-7% Si alloy ingots silicon is added to the furnace. The Al-Si alloy product is assumed to be degassed with argon and filtered inline.