Foundry is a metal casting industry. They are casted into shapes by melting into liquid and pouring into moulds. The commonly processed metals are aluminum and cast iron along other metals like brass, bronze, steel, magnesium etc. parts of different sizes and shapes can be obtained in this process. India is considered as the world’s third largest manufacturer of crude steel. The Indian steel sector has a major role in contributing to the country’s manufacturing outcome. Remarkable entrepreneurship and significant economic importance along with the globalization of the technological sectors has made it favorable for the country’s government to stand high in merit.
The modern steel industry has emerged from small batch production to advanced technologies. The locations of the steel canneries depended on the availability of the raw materials and sometimes they were even imported or exported if had in abundance.
The direct reduction of the iron ore derives a product called direct reduced iron or sponge iron. They have the same contents as in pig iron and can be used as feedstock for furnaces in the mini mills. Sponge irons, if left unprotected, it can lead to rusting and even catch fire.
Every steel plant or sponge iron canneries have their own industrial releases that can be hazardous. Along with toxic wastes they even have other factors which stand on the way as the issues and they have to be entertained properly. Some of the problems can be high investment rates, unadvanced technologies, low production capability etc.
Air pollution and their treatments are one of the major issues in such industries. The large scale furnaces release large amount of light weighted particles. The casting takes place by melting the iron/steel into liquid and pouring them into moulds which have cavities of desired shapes. They are then broken and mended into desired shapes. The polishing and shaping of the casts forms dust in large amount.
Thus treatment of these unwanted dust particles has to be carried out as they cause big environmental problems. Weak infrastructural facilities and lack of advanced technologies are the other factors causing air pollution. For example in sponge iron foundries the direct reduction process is done using a reduction gas, which is made up of carbon monoxide and hydrogen. Thus the vaporized carbon monoxide and released dust particles produces hazardous air pollution.
Complications with the Present System
The current steel arsenals are having a tough time, controlling of the emission of fine particulates. They are not able to remove the particulates and recover the free air. The material chemistry is the second problem. The chemical composition corrodes the system and affects the whole operation. Moisture clogging and acidity are the other factors that reduce the life span and efficiency of the system.
Remedies to Dust Hazards
Effective housekeeping techniques and unique atmospheric condition contribute to active dust control plans. Proper enclosure maintenance and good repair state should be followed. Necessary accumulation of dust control equipments should be implemented.
Frequent dust deposit removal from exposed pipes and machinery are the points to keep in mind. Dust separation and dust collection are equally important. One should know the cause of dust formation, the characteristics of the dust and the source of dust emission so that they can apply the dust control system based on the factor that causes dust and hazardous release.
Time to time inspection, exhaust ventilation and dumping mechanisms are the factors that result in the complete control over the dust hazard.