Empowering foundry sustainability: interview with Weir Minerals
13 Jun 2023
If you mention environmental sustainability, most will think first about efforts to reduce carbon emissions. But this is only one of the environmental challenges that face the global foundry industry. Another key element is the reduction of waste as part of efforts to promote beneficial re-use of resources, with hazardous waste streams a particular target.
“Switching to more environmentally-friendly consumables – binders and resins, sleeves, hot toppings – is a major focus for us as we work to reduce our environmental footprint by reducing the amount we send to landfill,” explained Darren Preece, foundry technical manager at Weir Minerals’ Artarmon foundry in Sydney, Australia.
“As part of these efforts, we are looking to reduce the amount of fluorides in our sand waste streams to create a less hazardous material that can be re-used in other sectors, such as for asphalt production in the construction industry,” said Preece, who was speaking at the Foseco stand during GIFA 2023.
Weir Minerals are a global supplier of engineered processing solutions for mining and mineral processing applications. The company has produced iron castings at Artarmon since 1969. The foundry utilizes a furane-based sand system to produce parts ranging from 5 kg to 19 tonne as-cast, mainly in high-chromium irons.
Going fluoride free
According to Preece, Foseco has been “instrumental” in this process, supplying Weir Minerals with fluoride-free hot toppings. Artarmon is also planning to implement fluoride-free sleeves in its process. Available in all standard FEEDEX geometries, the Foseco range of FEEDEX FEF and KALMINEX 2000 FF sleeves significantly reduce fluoride emissions and fluoride-containing waste, as well as delivering much lower VOC emissions than market alternatives.
“We expect the fluoride-free sleeves to be a game-changer for us in terms of reducing the fluoride content of our waste sand, and so changing where that waste stream ends up,” continued Preece. “This obviously has a valuable environmental impact; there is also a financial benefit, as our waste sand will no longer be subject to expensive disposal costs.”
“Our fluoride free sleeves are a key milestone on the sustainability journey,” said John Sutherland, International Marketing Services Manager at Foseco. “With our FEEDEX FEF, KALMINEX 2000 FF, and KALMINEX SD products, we now offer a comprehensive range of feeding systems that are either fluoride emission-free or fluoride free, supporting customers as they seek to reduce the use of hazardous materials in their foundries.” Find out more about FEEDEX FEF sleeves
A journey into innovation
Attending GIFA may have required travelling half way around the world. But for Preece it was an important journey to make. “We are a long way from anywhere in Australia! So it is great to have the opportunity to come and get a broader picture of what is available and how we could implement it at Artarmon to improve our operation and product quality.”
Preece already had his eye on some other of Foseco’s latest innovations, notably the HOLLOTEX shroud. Combining the benefits of filtration and shrouding technologies, the shroud facilitates the pouring of large castings, quickly and effectively, without the turbulence that traditionally causes oxide inclusions. “I already have a product in mind, which we are starting to produce patterns for now, where the shroud would be ideal,” said Preece.
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