APPENDIX II Detailed Lists of Potential Contaminants at Foundry Sites

APPENDIX II
Detailed Lists of
Potential Contaminants
at
Foundry Sites

Appendix II
1. Potential Contaminants Deposited By Air Emissions from Ferrous Foundry Melting Processes
Emissions from Melting Fuels * Emissions from Charge Materials Metal Treatment
Metals &
Metalloids: Coal Coke I Coal
Contaminants Ferrous Alloy
Oil
Gas
Fluxes Desulphurisation I Nodularisation I Bessemer Process/
gas
in Scrap Constituents
Oxygen Lancing S
Sb L L L T D/T
As L L L P D/T
Ba L L L
Be T T T
Bi P D/T
B P P D/T
Ca D/T P L
Cd L L L T L
Cr L L L T D
Co L L L D
Cu L L L T P D (may be T)
Fe L L L C C C C
Pb L L L T L D
Hg L T? L P T
Mg L L L D/T P C
Mn L L L L L L L
Mo L L L T D
Ni L L L T D
Se L L L
Ti L L P D/T
V L L L T D
Zn L L L T L
OTHER:
Cl & cmpds C C L P? P
PCDD/F L L P
F & cmpds L L L P P P
Na & cmpds P
PAH C C C P L
S & cmpds C C L C T C P
Key: * where used. From late 19 th century, electric melting methods were also in use in UK & are now the predominant technologies.
C: certain, i.e., always expected L: likely P: possible T: trace only D: dependant on alloys under production
Historic processes only, not used in ferrous foundries currently I: Iron foundries only S: Steel foundries only
Page II-i

Appendix II
2. Potential Contaminants Deposited By Air Emissions from other Ferrous Foundry Processes
Casting in Sand Moulds Knockout from Sand Moulds Fettling Sand Reclaim
Phenolic
bonded
Silicate
bonded
Phenolic
bonded
Silicate
bonded
Other
Mould &
Coremaking*
Oilsand
Resin
Shell
Greensand
Greensand
Shotblasting
Greensand
Phenolic
bonded
Metals & Metalloids:
Sb D/T D
Bi D/T D
Cr D D
Co D D
Cu D/T D
Fe C C
Mn L D
Mo D D
Ni D D
V D D
OTHER:
SiO 2 dust P P P C L L L P/T C L L
Zircon dust S #
P P P P D P/T P
Chromite sand dust S P P P P D P/T P
Coaldust I P C D C
Clay dust P C D C
Phenolics on dust C C C P C C
PAH on dust L C C C P C C T P C C
Sulphur & compounds F F F
Key: * Oil-sand, loam & dry sand mould/core making processes involve drying in an oven, which may be gas or oil-fired.
See list 1 for associated contaminants from the fuel use.
C: certain, i.e., always expected L: likely P: possible T: trace only D: dependant on process/alloy F: S-catalysed furans only
# Contains trace amounts of radioactive isotopes
I: Iron foundries only S: Steel foundries only
Silicate
bonded
Page II-ii

Appendix II
3. Potential Contaminants to Land from Foundry Raw Materials Storage,
Handling & Use in Process
PROCESS
AREA
RAW MATERIAL FORM/CONTAINER COMMENTS
PATTERN
SHOP
MOULD &
COREMAKING
MELTING
HEAT
TREATMENT
CASTING
PAINTING
SOLID MATERIALS
Wood & dust
LIQUID MATERIALS
Glues & adhesives Tins, aerosols P: usually small amounts
Paints & Thinners Tins P: usually 0.5 – 200 l sizes
Epoxy resins & hardeners Tins P: usually small amounts
Fibreglass resins
P
SOLID MATERIALS
Silica sand & dust
Zircon sand, flour & dust #
Chromite sand & dust S
Resin shell sand
Clay
Coaldust I
LIQUID MATERIALS
Silos, hoppers,
1-t bags, 50 kg sacks,
open compounds
(internal or extermal)
L
L: normally in bulk
P: usually smaller amounts
P: usually smaller amounts
P
P
P
Glues & adhesives Tins, aerosols L: usually small amounts
Isopropyl alcohol Tins, drums, IBC’s L
IPA-based mould coatings Drums, IBC’s, bulk tanks L: usually contains Zr
Resins & Hardeners * Drums, IBC’s, bulk tanks L
Gas Oil Bulk tanks P: used for curing ovens
Lubricating Oil Drums P: for moulding equipment
SOLID MATERIALS
Silica sand Bags or open compounds P: for pigging of metal
Coke I
C for cupola/blast furnaces
Internal or external
Coal
P for crucible/reverberatory furnaces
storage compounds
Limestone/dolomite
P
Refractory materials Solids & powders in bags C
Calcium carbide I
Sealed drums
CaO/CaF I
P: only present where malleable or
Sodium Carbonate I
Drums, bags
ductile iron were/are made
Metal returns
Bins, compounds, piles
C
Scrap **
(internal or external; on L: may be contaminated with liquids
Pig iron/ingot/bar soil or hardstandings)
L
Ferro-alloys
Solids, pellets, etc. in
L
Other additions
drums or bags
L
Insulating wools Blanket sheets P: may contain RFC’s
LIQUID MATERIALS
Gas Oil Bulk tanks P: where used as melting fuel
Lubricating Oil Drums P: for hydraulic furnace controls
Transformer Oil Drums L: PCB contamination possible
SOLID MATERIALS
Insulating wools Blanket sheets P: may contain RFC’s
LIQUID MATERIALS
Quench oil Bulk tanks (open) P
Chlorinated solvents Drums, tanks P: for degreasing
SOLID MATERIALS
Zinc wire Drums P
Other metals/coatings Powders in drums P
Page II-iii

Appendix II
PROCESS
AREA
CASTING
PAINTING
ANCILLARY
OPERATIONS
RAW MATERIAL FORM/CONTAINER COMMENTS
LIQUID MATERIALS
Paints
Thinners
LIQUID MATERIALS
Tins, drums, IBCs
P: most common solvents are xylene,
white spirit, toluene, MEK
Diesel Bulk tanks L: for forklift trucks
Petrol Bulk tanks P: for vehicle refueling
Lubricating & hydraulic oils Tins, drums
L: equipment & vehicle maintenance;
foundry plant, machining operations
PCB containing oils
In equipment
L: capacitors in electric motors,
fluorescent lights, hydraulic
equipment & process heating plant
Solvent based products Tins, aerosols, tanks P: used in non-destructive testing
Coolants & cutting fluids Drums, IBCs, bulk tanks P: Machining operations
Biocides
Drums, tanks
L: for control of cooling systems
P: use for control of machining fluids
Corrosion inhibitors
Drums, tanks, tins
L: for control of cooling systems
P: use on finished castings
Key:
C: certain L: likely P: possible RFCs: Refractory ceramic fibres
I: Iron foundries only S: Steel foundries only
* See detailed list 3(a) below ** See detailed list 3(b) below
# Contains trace amounts of radioactive isotopes
A free flowing sand pre-coated with a phenol formaldehyde novolak resin, which contains a
hexamine curing agent. Process first introduced in 1950’s.
PCBs can also be found in large booster vacuum pumps installed between 1960 & 1970, as well as
in some imported ring jet pumps
May include chlorinated products
Page II-iv

Appendix II
3(a) Mould & Coremaking Resins, Hardeners & Catalysts
BINDER
SYSTEM
FIRST
USE
SETTING
METHODS
RESIN CONSTITUENTS
HARDENER/CATALYST
CONSTITUENTS
Alkaline
phenolic *
1984/5
Self-set,
gassed
Aqueous alkaline K or Na-based
phenol formaldehyde resin; can
contain methanol
Self-set: organic esters
Gassed: methyl formate or CO 2
Alkyd
urethane
1960’s Self-set
Part 1: drying oil modified alkyd
(polyester)
Part 2: polyisocyanate
Cobalt naphthenate (commonly
incorporated in Part 1)
Ecolotec 1990’s Gassed Alkaline phenolic resin CO 2
SO 2 cured
epoxy resin
1983 Gassed
Modified epoxy resin mixed with
an organic hydroperoxide; a
furan version (from 1975) is also
available
Sulphur dioxide gas
Free radical 1990’s Gassed
Furan * 1958 Self-set
Unsaturated urethane oligomers
& acrylic monomers, with an
organic peroxide
Urea formaldehyde (UF), phenol
formaldehyde (PF) & furfuryl
alcohol (FA) resin mixtures
Sulphur dioxide gas
Para-toluene, xylene or benzene
sulphonic acids, sulphuric acids &
phosphoric acid, or mixtures.
Hotbox 1960 Heat
Methylal
cured
phenolic resin
mid-
1980’s
Gassed
Phenolic (PF) and urea furan (UF)
resins
Phenolic resin
No-bake oils 1950’s Self-set Esterfied or alkyd oil
Oil sand **
Phenolic
urethane *
Pre-
1900
1968-
70
Polidox 1980’s
Heat
Self-set,
gassed
Self-set,
gassed
Resin shell * 1950 Heat
Ammonium chloride, urea & acid
salts
Methylal vapour with a toluene
sulphonic acid catalyst
Sodium perborate or polymeric
isocyanate
Modified vegetable oils & dextrin emulsions
Part 1: phenol formaldehyde
resin in ester/aromatic
hydrocarbon solvents
Part 2: Isocyanate, e.g., MDI
Self-set: liquid tertiary amine,
e.g., phenylpropylpyridine
Gassed: dimethylethylamine or
triethylamine
Sodium polyacrylate Alkaline powder & CO 2
Mostly supplied as dry coated
sand, but phenol novolak resin
liquid in methanol, shellacs,
waxes (if sand coated at foundry)
hexamine
Silicate * 1952
Self-set,
gassed
Sodium silicate solutions
containing SiO 2 and Na 2 O in
varying proportions
Self-set: organic esters
Gassed: CO 2
Warm box 1978 Heat Furan resins
Copper salts or inorganic salts of
sulphonic acid
* most common current systems ** commonly used historically for core making
Note: The term “self-set” is used to describe systems that cure at room temperature after the resin
and liquid hardener are mixed together with the sand.
Page II-v

Appendix II
3 (b) Contamination Potential of Pig Iron & Ferro Alloys
MATERIAL/FORM
POTENTIAL ENVIRONMENTAL IMPACTS
STORAGE ISSUES
MELTING
Pig Iron – solid “pigs”
Ferro Alloys – supplied as lumps,
granules, or powders
Ferro Boron
Ferro Molybdenum
Ferro Niobium
Ferro Titanium
Ferro Vanadium
Ferro Silico Chrome
Ferro Silicon Alloys
Ferro Tungsten
High Carbon Ferro Chrome
Low Carbon Ferro Chrome
Other Ferro Alloys – supplied as
lumps, granules, or powders
Ferro Manganese
Ferro Silicon Zirconium
Ferro Phosphorus
Ferro Silicon
Ferro Sulphur
Magnesium Ferro Silicon
None
Materials are stable, inert and insoluble
in supplied form.
Spillage, particularly of powders, could
result in localised metals contamination
of the ground surface, but leaching into
groundwater is improbable.
Spillages should be prevented from
entering drains and watercourses.
As above, with specific hazards listed
below
Exposure to air can result in formation
of manganese carbide, which reacts
with water to give explosive gases
including hydrogen.
Slightly soluble in water, some leaching
into groundwater following spillage is
possible.
Contact with moisture can result in
evolution of arsine, phosphine, or
hydrogen. Forms corrosive solution on
contact with acids.
Contact with moisture can result in
evolution of hydrogen, arsine or
phosphine
Soluble in acids, which can result in
release of H 2 S gas.
Slightly soluble in water, some leaching
into groundwater following spillage is
possible. Contact with moisture can
result in evolution of hydrogen, arsine
or phosphine
Will contribute to Fe/Mn
releases
Will contribute small amounts
to air emissions, depending on
melting/boiling point
properties, but is added to melt
by methods that ensure
maximum recovery in the metal
being produced.
Thermal decomposition
produces SO x and H 2 S gases.
Page II-vi

Appendix II
4. Potential Contaminants to Land from Ferrous Foundry Wastes
A variety of wastes are generated during the foundry process. The quality of waste management also
varies considerably around the modern industry and poor management was common in the past.
Where sufficient space was available, waste may have been deposited directly on the property, in a
company landfill, or left around on an ad hoc basis, inside or outside of buildings. Most companies
now have some designated storage areas, although bunding of empty drums, etc. is still unusual.
Note that the key for this table refers to whether the process will generate these wastes or not.
Whether the wastes or associated residues may still be present at a site or not will depend entirely on
waste management practices over the years. Any of the waste streams listed may also contain other
materials, e.g., discarded gloves, packaging wastes, etc., depending on the extent of segregation
practised/not practised at the site.
Key to Whether Waste is Generated by the Process: C: certain L: likely P: possible
PROCESS
AREA
WASTE CONTAMINANTS COMMENTS
ALL AREAS
SOLID MATERIALS
LIQUID MATERIALS
SOLID MATERIALS
Any form as received may be disposed of due to damage, spillage,
etc. Dusts from processing & use of materials may also be present,
e.g., sand dust, wood dust. Packaging wastes of all types are also
found.
Any materials arriving on site may eventually end up as waste. Full
containers of resins, paints, oils, etc. may be discarded if the
material becomes off spec, or is no longer required. Partially filled
or “empty” containers will be generated as waste from many areas.
Historically, there is a high potential that such wastes were poorly
managed & spillage or leaks into soil may be expected.
Waste mixed sand
Mixer scrapings
Floor sweepings
Scrap moulds/cores
Uncured resins
Cured resins
C: May or may not be segregated.
Materials tend to be high in
leachable phenolics, aromatics, etc.
depending on the binder system.
Silo filter dust
Material dependant, e.g.,
SiO 2 dust if silica sand
C: where filtration used
Cast/knocked out sand
(largest foundry waste by
volume)
Sand dust, residual binders,
PAH, fine metallic drops from
alloys
C: leachate levels considerably
lower than for uncast sands due to
burn out. pH varies (2.5-12)
SAND
SYSTEM
WASTES
ABATEMENT WASTES
Dusts/sludge – knockout
Greensand plants (in past,
usually wet plants)
Chemically bonded sand
reclamation (usually dry)
SiO 2 & binder residues
(greensand or chemical)
SiO 2 , clay & coal dusts
SiO 2 (or Zircon) & resin rich
dusts
C: plants can be wet or dry, which
can affect likely spillage patterns &
control issues
(Dry bag filtration is now the
predominant type)
Thermal sand reclaim (dry) SiO 2 dusts (or Zircon) C
LIQUID WASTES
See comments under All Areas
Scrubber liquor
Amine, spent phosphoric or
sulphuric acid and amine,
sulphates/phosphates
P: where gas-cured urethane
systems are in use
Page II-vii

Appendix II
PROCESS
AREA
WASTE CONTAMINANTS COMMENTS
MELTING
FETTLING
ANCILLARY
OPERATIONS
SOLID MATERIALS
Cupola Bottom Ash Coke dust, metals C: if cupola melting used
Clinker
Sintered limestone with iron
oxides
C: if blast furnace used
Melting slag
CaO/ MgO, metals, sulphur
C: Variety of types (e.g., air-cooled,
water granulated) & form differs
according to the melting furnace.
Physically unstable if oxides are not
fully hydrated; S where present may
be leachable.
Desulphurisation slag
CaO / Ca carbide residues,
high sulphur, v. alkaline – pH
12-13
P: Physically & chemically unstable
until oxide/carbide is fully
hydrated/reacted.
Refractories from furnaces Can be alkaline, although
& ladles
largely inert
C
Refractories from
nodularisation treatment
Mg nitride – v. reactive,
produces ammonia in
P
ladles
contact with water/moisture
Cr-containing refractory
Cr – leachable
P
waste
Hot toppings/exothermics Metals L
ABATEMENT WASTES
Melting sludge (wet plant)
Melting dusts (dry plant)
LIQUID MATERIALS
Melting Abatement Slurries
SOLID MATERIALS
Spent metallic blasting
media
Grinding wheels
ABATEMENT WASTES
Shotblast dust
Fettling sludge (wet plant)
Fettling dusts (dry plant)
Arc air (dry)
SOLID MATERIALS
Insulating materials/heat
treatment furnace linings
Asbestos
LIQUID MATERIALS
Metals - see Table 1; S
& cmpds, PAH, dioxins, other
organic residues also
possible.
Coke dust – only if used
As above
Fe
Mainly alumino-silicate
materials
SiO 2 dust, Fe & alloy
constituents
Mainly alloy constituents
Refractory ceramic fibres
Asbestos fibres
P: handling of wet slurries (e.g.,
dewatering) can result in
considerable localised spillage
P: dry dusts are prone to wind
blowing if not properly contained &
can be more widely distributed
P: may be handled/treated in a
settling pond or lagoon on site
L
L
L
C: plants can be wet or dry, which
can affect likely spillage patterns &
control issues
Dry plants now predominate
P
L: Building waste, maintenance
activities, protective gloves
Waste oils Many contain PCBs/PAH L
Waste coolants Tramp oil, surfactants, etc. C: if machining undertaken
Page II-viii