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Metal Casting Technologies : September 2005
BRIEFINGS to require full implementation of Lock Out, Tag Out procedures for all maintenance tasks, and to identify and make safe (by converting to two-hand operation or guarding) all machines which can be operated by one hand only. Emissions to Air Point source emissions to air are discharged through scrubbers, cyclones and/or bag filter systems and generally meet IFC guidelines for particulate content. In the ferrous foundries, fugitive fumes arise during furnace charging and discharging, from molten metal transfer to casting positions and from mould and core making operations and at Gu'an and the existing camshaft facility during casting solidification and cooling. There is also some degree of uncontrolled particulate emission from the foundries' sand plants, and from knock-out and fettling operations. All fugitive emissions contribute to poor workplace air quality. Asimco will commission environmental audits of its existing operations, and will devise and implement, within a reasonable timescale agreed with IFC, projects to capture and treat to IFC requirements all emissions to air of fume and dust. For the greenfield factory planned for Yizheng, Asimco will lay out the plant to minimise opportunities for fugitive emissions to air, will capture and treat emissions to air of fume and dust and will demonstrate to IFC that the plant layout and fume capture systems minimise air emissions to the extent practical to meet IFC and local requirements. A coke-fired cupola melting furnaces is used at Gu'an, though the new camshaft factory will use electrically heated furnaces. Cupola furnaces have the potential to produce dioxins; the dioxin content of dust captured by air pollution abatement equipment will be measured. If dioxins are found, air emissions, will be monitored and measures taken to reduce dioxin emissions to levels meeting IFC requirements if shown necessary by this further monitoring. Beijing Castings' effluent is discharged to another Asimco company (Tianwei) located on the same manufacturing site, before discharge to the municipal sewer for further treatment meeting local and IFC requirements. Process effluent at the new Yizheng camshaft factory will arise from the machining operations. Process and sanitary waste water will be pre-treated within the plant site, before discharge to the development zone's sewer and treatment system. Solid and hazardous wastes Typical solids process wastes produced by the foundries are spent foundry sand, slag and dust recovered from air pollution control equipment. Spent sand, slag and other solid wastes are disposed to licensed landfill sites. Dust has the potential to contain dioxinsand/or heavy metals; these materials are used in cement manufacture, thus encapsulating potentially hazardous materials. Resource Efficiency Environmental review identified areas in which it appeared that Asimco's use of manufacturing resources including energy could be improved. Asimco and IFC will jointly undertake more detail review of these areas to identify projects in more detail and implement those likely to be cost-effective. PEOPLE Mat James joins A-Squared Mat's career began as an apprentice Moulder with Mason & Cox in 1989. He steadily progressed through various roles up to his appointment as Technical Manager of the foundry (then part of the Hensley group) in 2001. His practical experience is augmented with the addition of Mechanical Engineering studies which resulted in him receiving an Associate Diploma in 2002. Mat will work to progress the metal casting industry understanding and beneficial application of CAE technologies with a focus on Casting Process Simulation and Analysis through the A-Squared suite of services. Mat James MBH Analytical Limited is one of the world's major producers and suppliers of Certified Reference Materials. Materials include those that meet most of the day-to-day calibration needs for chemical and spectrochemical analysis techniques including: XRF OES and ICP spectroscopy as well as photometric, and other "wet" methods. Innov-X Systems designs and manufactures versatile, portable, high performance x-ray fluorescence (XRF) analysers. Applications include: ̇ Positive Materials Identification such as steels, copper nickel alloys, titanium base alloys, precious metals ̇ Quality Assurance, Non-destructive Testing (NDT) ̇ Metals Recycling Sietronics Pty Limited Tel: +61 (0)2 6251 6611 ‚ Fax: +61 (0)2 6251 6659 E-mail: firstname.lastname@example.org Web: http://www.sietronics.com.au/ 18 www.metals.rala.com.au