Organic Moulding Sands for Production of Large-Size Castings

Recently, significant changes in the European foundry industry have led to a decline in heavy steel castings production, particularly for applications in the metallurgical, cement, and energy sectors. This has created challenges in moulding technology for heavy castings, which require extended solidification and cooling times. The industry predominantly utilizes sands with organic binders due to their beneficial properties, including strength and ease of reclamation. However, these materials pose environmental concerns, primarily due to emissions during the casting process. This research examines potential solutions to minimize the environmental impact of organic binder sands by employing formulations that reduce free furfuryl alcohol and sulphur-containing hardeners. Additionally, the study evaluates the feasibility of using alkyd binders as an alternative to traditional furfuryl binders, aiming to maintain high technological performance while decreasing ecological harm. The findings suggest that modifications in binder chemistry can enhance operational efficiency and mitigate adverse effects on the environment, thus supporting the production of large-size castings in a more sustainable manner.