Characterization of Fine Particulate Emissions from Casting Processes

Fine particle (PM_2.5) emission rates and compositions from gray iron metal casting foundry were characterized for No-Bake molds poured at the Research Foundry located at Technikon, LLC (McClellan, CA). For each mold, PM_2.5 was collected for chemical analysis, and particle size distributions were measured by an Electrical Low Pressure Impactor (ELPI) to understand PM emissions during different part of the casting process. Molds prepared with phenolic urethane binders were poured with Class 30 gray cast iron at 1,427–1,480°C. PM_2.5 was collected from the pouring, cooling, and shakeout processes for each mold. Most of the PM_2.5 mass emitted from these processes was composed of carbonaceous compounds, including 37–67% organic carbon (OC) and 17–30% elemental carbon (EC). Oxides of aluminum (Al), silicon (Si), calcium (Ca), and iron (Fe) constituted 8–20% of PM_2.5 mass, and trace elements (e.g., K, Ti, Mn, Cu, Zn, and Pb) contributed 3–6%. Chemical abundances in PM were different between pouring and shakeout for each discrete mold. PM_2.5 mass emissions from pouring were 15–25% of the total from each discrete mold. Ultrafine particles (< 0.1 μm) contributed less than 1% of PM_2.5 mass, but nearly all of the particle numbers. Different mechanisms for pouring and shakeout result in variations in chemical abundances and particle size distributions. The highest PM_2.5 mass and number concentrations were observed when shakeout started. PM_2.5 size distributions in mass concentration during shakeout contained particles in the tail of coarse particles (1.6–2.5 μm) and a vapor condensation mode (0.65–1.6 μm). Flame conditions, vaporization, thermal decomposition of organic materials, and the variability of mold breakup during shakeout affect PM emission rates. A detailed chemical speciation for size-segregated PM samples at different process points needs to be conducted at full-scale foundries to obtain emission factors and source profiles applicable to emission inventories, source receptor modeling, and implementation of emission standards.