Air Pollution Control Foundries Metal Processing Units May 21, 2025 sazenviro Post in Uncategorized Foundries and metal processing plants are major sources of industrial air pollutants including metallic dust, fine particulates, smoke, acid gases, and VOCs. Efficient foundry air pollution control systems are essential not just for regulatory compliance, but also to ensure worker safety, reduce equipment corrosion, and minimize environmental impact. Whether it’s a furnace fume extraction solution or a dust collector for casting operations, tailored emission control is a must. 2. Pollutant Sources in Foundries and Metal ProcessingContents1 2. Pollutant Sources in Foundries and Metal Processing2 3. Equipment Used in Foundry Emission Control2.1 A. Dry Dust Collectors2.2 B. Wet Scrubbers2.3 C. Cartridge Filters2.4 D. Furnace Fume Extraction Hoods2.5 E. Spark Arrestors and Pre-Filters3 4. Design Guidelines4 5. Industry-Specific Examples5 6. Advantages of Modern Foundry Systems6 7. Limitations & Challenges7 8. Operation and Maintenance8 9. Compliance and Guidelines9 10. Conclusion Source Area Major Pollutants Induction Furnace Metal fumes, fine metallic particulates Cupola Furnace Soot, ash, CO, SOx Casting & Pouring Sand dust, VOCs from binders, resin fumes Shot Blasting & Fettling Abrasive dust, silica Moulding & Core Making Acid fumes, VOCs, phenols Each stage requires a dedicated emissions control system in metal processing. 3. Equipment Used in Foundry Emission Control A. Dry Dust Collectors Baghouse filters for general dust Used downstream of cupola furnaces and fettling shops B. Wet Scrubbers Effective for sticky or oily fumes Used in core making and binder mixing areas C. Cartridge Filters High-efficiency filters for shot blasting operations D. Furnace Fume Extraction Hoods Captures metal fumes right at the melting zone E. Spark Arrestors and Pre-Filters Used to avoid bag filter fires when collecting sparks from furnaces 4. Design Guidelines Design Parameter Typical Range Furnace Hood Suction Volume 5,000 – 50,000 m³/hr Dust Collector Efficiency >99.5% Particle Size to Capture Down to 1 micron Filter Media Type PTFE, Aramid, or Fiberglass Scrubber Liquid pH (if acidic gases) 6.5 – 7.5 A combination of solutions is often required for a robust furnace fume extraction solution. Venturi Scrubber System for Industrial Emissions Fume Extraction System for Laser Cutting and Plasma Operations Industrial Blower for Fume Extraction Wet Scrubber System for VOC Removal in Paint and Coating Industries Air Handling Unit for Industrial Ventilation Mist Collector System for Coolant Fume Extraction Industrial HEPA Filtration System for Cleanroom and Process Air Control Industrial Carbon Filter System for Gas Phase Pollutant Control Fume Extraction System for Aluminum Melting Furnace 5. Industry-Specific Examples Aluminum Foundries: Oxide dust, resin fumes — use wet scrubber + bag filter Steel Foundries: Graphitic dust, iron oxide fumes — use pulse jet baghouses Brass & Copper: Acid gas from melting — use packed bed scrubbers Grey Iron Foundries: Sand dust and metallic ash — use cyclone + bag filter 6. Advantages of Modern Foundry Systems Protects workers from hazardous inhalable dust Reduces neighborhood complaints from fugitive emissions Increases furnace equipment life Meets environmental norms across regions 7. Limitations & Challenges High-temperature gases may require pre-cooling Sticky dust (especially in sand plants) causes clogging High maintenance in corrosive environments Requires space for hoods, ducts, and dust disposal systems 8. Operation and Maintenance Hood alignment and balance checking Bag cleaning and replacement scheduling Duct pressure checks and fan performance tests Sludge handling (in wet scrubbers) 9. Compliance and Guidelines Foundry-specific standards include: CPCB Sector-Specific Guidelines (India) EPA NESHAP Metal Foundries (USA) EU Foundry Emission BAT Norms KSA PME and UAE air quality norms for metal casting 10. Conclusion To ensure clean air and regulatory compliance, an integrated foundry air pollution control system is essential for every metal processing facility. Whether it’s a dust collector for casting operations or a complete furnace fume extraction solution, the system must be tailored to the pollutants generated by each stage of production to form a comprehensive emissions control in metal processing approach.