FRED S. CANNON, PROFESSOR, PENN STATE (Masters...
Transcript of FRED S. CANNON, PROFESSOR, PENN STATE (Masters...
DIMINISHING CARBON DIOXIDE EMISSIONS AND ENERGY USE IN
FOUNDRIES VIA INNOVATIVE POLLUTION PREVENTION AND
CLEVER CAPITALIZATION OF HEATCLEVER CAPITALIZATION OF HEATFRED S. CANNONFRED S. CANNON, PROFESSOR, PENN STATE
(Masters and Degree of Ad anced Engineer from Stanford)(Masters and Degree of Advanced Engineer from Stanford)
PENN STATE: BOB VOIGT, SRIDHAR KOMARNENI, TIM CONSIDINE FRANK CLEMENTE ANDRE BOEHMANCONSIDINE, FRANK CLEMENTE, ANDRE BOEHMAN
MIT: TIM GUTOWSKI, LEON GLICKSMAN
NEENAH FOUNDRY: FRANK HEADINGTON STEVE LEWALLENNEENAH FOUNDRY: FRANK HEADINGTON, STEVE LEWALLEN, JEFF GOUDZWAARD
FURNESS NEWBURGE: JIM FURNESS
10-YEAR COLLABORATION: PENN STATE NEENAH FOUNDRY MIT STATE, NEENAH FOUNDRY, MIT,
FURNESS-NEWBURGENeenah ‘98: Green Sand Pollutants and Molding Strength. $25,000Neenah 98: Green Sand Pollutants and Molding Strength. $25,000DOE 98-01: Green Sand Non-Incineration treat. of VOCs. $550,000NSF ‘99: Advanced Oxidation Processes for Foundries. $37,000NSF 00-02: Improve Green Sand with Advanced Oxidation.$250,000p ,DOE 01-05: Less Foundry Emissions and Waste with AO. $525,000EPA/NSF 02-05: Less Materials and Pollutants with AO. $375,000CA ARB ‘03: Non-Incineration removal of VOCs, Odors. $300,000DOE 05-06: Anthracite in Green Sand of Foundries. $70,000NSF 05-08: MUSES Materials Flow of Metal Casting. $1,300,000EPA 07-08: Reclaiming Waste Green Sand in Foundries. $35,000N I U 07 08 Ch t i VOC f C Bi d $20 000N. Iowa U 07-08: Characterize VOCs from Core Binders. $20,000NSF 08-09: Foundry Cores with UV-Toughened Collagen. $50,000DOE 08-09: Anthracite fines bindered with Collagen. $95,000
T t l $3 632 000Total $3,632,000
STRATEGIES FOR DIMINISHING ENERGY, CARBON DIOXIDE
ULTIMATELY, USE ENERGY SOURCE THAT USES NO CARBON, IS SUSTAINABLE, NIMBY-FREEIN INTERIM, BE CLEVER TO DIMINISH ENERGY AND CO2 WHILE USING CARBON-BASED ENERGYFOCUS ON CUPOLA FOUNDRY HEREIN
NEENAH FOUNDRY, WI
CARBON DIOXIDE EMISSIONS CONVENTIONAL CUPOLA IRON FOUNDRY
KG CARBON DIOXIDE / TON IRON POURED295 COKE25 NATURAL GAS AND LIMESTONE 75 OFF-SITE COKING & ELECTRIC POWER
145 HEATING: NATUAL GAS AND ELECTRIC30 GREEN SAND, MOLD BINDER30 GREEN SAND, MOLD BINDER30 SHIPPING: SCRAP, GREEN SAND, ETC.
600 TOTAL FOR CUPOLA FOUNDRY
STRATEGIES FOR LESS ENERGY, CO2% Δ STRATEGY% Δ STRATEGY15 RECIRCULATE H2 AND CO FROM CUPOLA5 REPLACE SOME COKE WITH ANTHRACITE
13 REPLACE SOME COKE WITH NATURAL GAS12 IMPROVE CASTING YIELD VIA HOLLOW RISERS5 RECLAIM GREEN SAND VIA HYDROACOUSTIC5 C G S O COUS C
CLEANING4 LESS VOCS, SCRAP: ADVANCE OXIDATION,
CLEAN BINDERSCLEAN BINDERS20 INDOORS: RE-USE LOW-VOC AIR, SO DON’T
HEAT NEW AIR5 CAPTURE CO2 ON POROUS CARBONS, ASH, ETC
60-80% TOTALS (CUMULATIVE SUM)45 60% TOTALS (COMPOUNDED SUM)45-60% TOTALS (COMPOUNDED SUM)
FOUNDRY SCHEMATIC: MELTING METAL
REPLACE COKE WITH 10-20% NATURAL GAS PLUS OXYGEN; AND 10-20% ANTHRACITE;
ONLY 2 US SUPPLIERS OF COKEWHEN USING COKE MUST HEAT TWICEWHEN USING COKE, MUST HEAT TWICEWITH NATURAL GAS:CH ( IV VALENCE) TO CO (+IV VAL)CH4 (-IV VALENCE) TO CO2 (+IV VAL)MORE ENERGY / CO2 THAN WITH COKE:C (0 ) O CO ( )C (0 VAL) TO CO2 (+IV VAL)WHEN USE CH4 +O2, LESS GAS FLOW UPWARD THROUGH CUPOLA THAN WITHUPWARD THROUGH CUPOLA THAN WITH COKE PLUS AIR; SO BURN MORE H2 AND CO DEEP IN CUPOLACO DEEP IN CUPOLA
CONVENTIONALLY, 35% OF COKE ENERGY IN EXHAUST H AND COENERGY IN EXHAUST H2 AND CO
OPTION A: CONVERT H2 AND CO TOOPTION A: CONVERT H2 AND CO TO POWER VIA OFF-GAS GENERATORB: RECLAIM HEAT DURINGB: RECLAIM HEAT DURING AFTERBURNING FOR INDOOR AIR, MAKING IN SITU POROUSMAKING IN-SITU POROUS CARBONSC RECIRCULATE OFF GAS BACKC: RECIRCULATE OFF-GAS BACK THROUGH CUPOLA TUYERES
GREEN SAND MOLD, METAL POURING ENHANCED BY ADVANCED OXIDATION ENHANCED BY ADVANCED OXIDATION
FOUNDRY WITH SONOPEROXONE SYSTEMTMBLACK WATER (BW)
RECIRCULATION
PLASMA - SILICA
CLAYCAPTURE AND
EXHAUSTAIR
SONO-PEROXONETM
CLARIFIER
DUSTSETTLING
RECYCLE
EXHAUST
BAG HOUSE
FINES
BWWASTE SILICA
DUST
SANDCOOLER
METAL POURINGAND COOLING
MOLDING
EXHAUSTDUST AND
VOCS
SAND MIXER/MULLER
CASTPRODUCT
MOLDING
SHAKEOUT
PRODUCT
RECIRCULATED SAND
MAKE-UP SAND, BOND, WATER
METAL POURING: 40-60% OF MELTED METAL SOLIDIFIES IN
ACCESS-WAY RISERS, ETC.INCREASE PRODUCT YIELD BY EMPLOYING HOLLOW RISERS, ETC.,10-25% LESS ENERGY, CARBON DIOXIDEDIOXIDEULTRASONICS ALSO CREATES STRONGER IRONSTRONGER IRON
LESS IMPORT OF COLD AIR FROM OUTSIDE BY RECIRCULATING
TREATED INDOOR AIR
ALLOW 15-20% LESS ENERGY AND CO2
DURING NORTHERN WINTERS, INDOOR AIR HEATING ACCOUNTS FOR 35-45% OF ENERGY AND CO2
O C C S OTO RECIRCULATE AIR, MUST REMOVE VOCS AND CO, SO WORKERS CAN BREATHE THE AIRBREATHE THE AIRPOLLUTION PREVENTION BY ADVANCED OXIDATION LOW-EMISSION BINDERSOXIDATION, LOW-EMISSION BINDERS, REUSED GREEN SAND
ADVANCED OXIDATION TREATMENT OF BAG HOUSE
DUST / WATER SLURRYBLACKWATER MIXED WITH GREEN SAND. GREEN SAND MAKES THE MOLD THAT MOLTEN METAL IS POURED INTOMOLTEN METAL IS POURED INTOGREENSAND: 85% SILICA SAND, 8% MB CLAY, 4-5% LOI COAL, 2% WATERNEED CARBON IN MOLD TO DRIVE CNEED CARBON IN MOLD TO DRIVE C INTO IRON, AND PREVENT OXIDATIONAO DIMINISHES VOCS BY 30-70% CLAYAO DIMINISHES VOCS BY 30 70%, CLAY AND COAL USE BY 25-35%, AND SCRAP BY 30-50%
BLACK WATER SYSTEM; NEENAH AND 20+ OTHER FOUNDRY LINESAND 20+ OTHER FOUNDRY LINES
Clear view of iron being pou~370 feet from camera
Greensand molds being pushed into shakeout cYOU CAN SEE THE LIGHT AT THE END OF THE TUNNEL
Dust feed from new baghouses
Dust mixer and acoustic systemDust mixer and acoustic system
5000 gallon system retained from replaced wet dust collecting system
EMISSIONS AT NEENAH: WITH AO (SOLID) VS. NO AO (HOLLOW)AO (SOLID) VS. NO AO (HOLLOW)
EFFECT OF ADVANCED OXIDATION:R l Ti T t R ltReal Time Test Results Pouring,
Cooling & Shakeout in Production FoundryStars Pattern - Tap vs A/O
45
30
35
40
15
20
25
ppm Tap
A/O
0
5
10
1 177 353 529 705 881 1057 1233 1409 1585 17611 177 353 529 705 881 1057 1233 1409 1585 1761
Time, sec
WITH AO (WGS), CONDITION GREEN SAND CARBON SO IT HOSTS LESS HAPS BUT CARBON SO IT HOSTS LESS HAPS, BUT
RETAINS CASTING QUALITYBenzene - WGS & Composite
0.005
0.006WGSComposite
0.004
ent (
nA)
0.002
0.003
Ion
Cur
re
0.001
00 100 200 300 400 500 600 700 800 900 1000
Temperature (oC)
WITH AO (WGS), MAINTAIN CO2 AND CO BLANKETS BETWEEN METAL AND CO BLANKETS BETWEEN METAL AND
MOLD, WHICH IS NEEDEDCO2 - WGS & Composite2 p
2.5
3
WGSComposite
2
ent (
nA)
Composite
1
1.5
Ion
Cur
re
0.5
00 100 200 300 400 500 600 700 800 900 1000
Temperature (oC)
TGA-MS / FLASH PYROLYSIS: CELLULOSE BIOMASS RELEASE FEWER VOCS CO IN BIOMASS RELEASE FEWER VOCS, CO2 IN
MOLD (FIRST GENERATION CO2).
50
60
h Py
ro.
AnthraciteS C l
30
40
V/F
lash
%)
. Sea CoalLigniteCellulose
20
30
ro. H
CV
HC
V (% Cellulose
0
10
GA
Pyr
C1-C5 C6-C16TG
WITH COLLAGEN
BINDERBINDER RATHER
THAN PHENOLICPHENOLIC URETHANE
BINDER; GENERATEGENERATE FAR LESS
VOCS, CO2; BUT 2;
NEED ENHANCED STRENGTH
WITH UV
RECLAIMING GREEN SAND BY HYDROACOUSTIC CAVITATION, HYDROACOUSTIC CAVITATION,
ULTRASONICS-AOCONVENTIONALLY, SAND GRAINS ,ACCUMULATE “RAINCOAT” OF RECONDENSED CARBONWITH HYDROACOUSTICS BLAST THISWITH HYDROACOUSTICS, BLAST THIS CARBON OFF, THEN THE SAND GRAINS CAN BE REUSEDALSO RELEASED CARBON CAN BE REUSEDALSO, RELEASED CARBON CAN BE REUSED; AND THIS CARBON SOURCE RELEASES LESS HAPS, WHILE MAINTAINING CASTING QUALITY5-10 FEWER TRUCKLOADS / DAY SAND IN AND OUTALSO CLEAN HEAT EXCHANGE TUBE WITHALSO, CLEAN HEAT EXCHANGE TUBE WITH AO
HYDROACOUSTIC ULTRASONICS-AO SAND RECLAMATIONAO SAND RECLAMATION
REMOVE CARBON COAT
BEFORE TMT AFTER
RECLAIMED SAND: QUALITY CASTING; RETAIN TENSILE STRENGTHRETAIN TENSILE STRENGTH
250
With Anti-Veining Additive
150
200
h (p
si)
100ns
ile S
tren
gt
50
Te
00% 20% 40% 60% 80% 100%
Percent Reclaimed Sand
WITH WASTE HEAT FROM CUPOLA, PRODUCE IN-SITU
POROUS CARBON (FOR NO COST)ADSORB VOCS SO AIR CAN BE RECIRCULATEDFULL-SCALE TRIAL: PAC REMOVED 1/3 OF VOCS WITH <0.5 SEC RETENTION TIME BEFORE BAG HOUSE CLOTHAMINATED POROUS CARBON TO CAPTURE CO2, CO (?)
IN-SITU POROUS CARBONS MADE VIA PYROLYSIS SO ROBUST OVER BROAD PYROLYSIS, SO ROBUST OVER BROAD
RANGE OF TIME, TEMP (KISS)
/g) 0 .1 2
0 .1 4
lum
e (m
L/
0 .0 8
0 .1 0
u. P
ore
Vo
0 .0 4
0 .0 6 0 m in6 0 m in1 5 m in3 0 m in7 5 i
Cum
u
0 .0 0
0 .0 2 7 .5 m in
P o r e W id th (A )1 1 0 1 0 0 1 0 0 0
SORB CO2 IN-SITU INTO SORB CO2 IN-SITU INTO AMINATED POROUS CARBONS
WITH AMINE FUNCTIONALITY ON POROUS CARBON, WET CO2 SORBS TO 10-30% MASS RATIO; PUFF OFF AT HIGHER PARTIAL PRESSURES, THENSORB CO ONTO FLY ASH CUPOLASORB CO2 ONTO FLY ASH, CUPOLA EXHAUST PARTICLES, MAGNESIUM SILICATESSILICATESUSE CARBONATED INORGANICS FOR BUILDING AGGREGATEBUILDING AGGREGATE
SUMMARY LOWER ENERGY AND CARBON DIOXIDECARBON DIOXIDE
% Δ STRATEGY15 RECIRCULATE H2 AND CO FROM CUPOLA5 REPLACE SOME COKE WITH ANTHRACITE5 REPLACE SOME COKE WITH ANTHRACITE
13 REPLACE SOME COKE WITH NATURAL GAS12 IMPROVE CASTING YIELD VIA HOLLOW RISERS5 RECLAIM GREEN SAND VIA HYDROACOUSTIC
CLEANING4 LESS VOCS SCRAP: ADVANCE OXIDATION4 LESS VOCS, SCRAP: ADVANCE OXIDATION,
CLEAN BINDERS20 INDOORS: RE-USE LOW-VOC AIR, SO DON’T
HEAT NEW AIRHEAT NEW AIR5 CAPTURE CO2 ON POROUS CARBONS, ASH, ETC
60-80% TOTALS (CUMULATIVE SUM)( )45-60% TOTALS (COMPOUNDED SUM)
REFEREED JOURNAL PAPERSWang, Y.J., F. S. Cannon, M. Salama, J. Goudzwaard, J. C. Furness (2007) Characterization of hydrocarbon emissions from green sand foundry core binders by analytical pyrolysis. Env. Sci and Tech.y g y y y py yFox, J.T., F.S. Cannon, R.C. Voigt, J.C. Furness, P.B. Smith, S.E. Lewallen, J.E. Goudzwaard (2007) Simultaneous Sand, Clay and Coal Reclamation using Induced Particle Collision, Discretionary Settling, and Advanced Oxidation. American Foundry SocietyMilan-Segovia, N., Y.J. Wang, F.S. Cannon, R.C. Voigt, J.C. Furness (2007) Determination of Advanced Oxidants in Aqueous Solutions: Use of Terephthalic Acid Dosimeter for Measurement of OH* Radical P d ti O S i d E i iProduction. Ozone Science and Engineering. Wang, Y.J.; H. Huang F.S. Cannon, R.C. Voigt, S. Komarneni, J.C. Furness (2007) Evaluation of Volatile Hydrocarbon Emission Characteristics of Carbonaceous Additives in Green Sand Foundries. Env. Sci. Tech. 41 pp 2957-2963. Wang, Y.J., F.S. Cannon, R.C. Voigt, S.Komarneni, J.C. Furness (2006) Study on the Effects of Advanced Oxidation on Green Sand Properties via Iron Casting into Green Sand Molds Env Sci Tech 40 pp 3095Oxidation on Green Sand Properties via Iron Casting into Green Sand Molds. Env. Sci. Tech. 40 pp.3095-3101. Wang, Y., F.S. Cannon, S. Komarneni, R.C. Voigt, J. Furness (2005) Mechanisms of Advanced Oxidation Processing on Bentonite Consumption Reduction in Foundries. Environmental Science and Technology. 39 pp.7712-7718. Wang Y F S Cannon D Neill K Crawford R X Voigt J C Furness C R Glowacki (2004) Effects ofWang, Y. , F.S. Cannon, D. Neill, K. Crawford, R.X. Voigt, J.C. Furness, C.R. Glowacki. (2004) Effects of Advanced Oxidation Treatment on Green Sand Properties and Emissions. Foundry Society Trans. V112 No 04-069 p. 635-648. Land, J.D, F.S. Cannon, R.C. Voigt, J. Goudzwaard (2004) Perspectives on Foundry Air Emissions: A Statistical Analysis Approach. American Foundry Society Trans. V112 No 04-040 p. 1075-1081Glowacki, C.R., G.R. Crandell, F.S. Cannon, R.C. Voigt, J.K.Clobes, J.C. Furness, B.A. McComb, S.M. , , , , g , , , ,Knight. (2003) Emissions Studies at a Test Foundry using an Advanced Oxidation-Clear Water System. American Foundry Society Transactions. No. 03-152 (20 pp.). Goudzwaard, J.E., C.M. Kurtti, J.H. Andrews, F.S. Cannon, R.C. Voigt, J.E. Firebaugh, J.C. Furness, D.L. Sipple (2003) Foundry Emmissions Effects with an Advanced Oxidation Blackwater System. American Foundry Society Transactions. No. 03-079 (20 pp) L d J D V i t R C C F S F J C G d d J L bb H (2002) “P f dLand J.D., Voigt R.C., Cannon F.S., Furness, J.C., Goudzwaard, J., Luebben, H. (2002) “Performance and Control of a Green Sand System During the Installation and Operation of an Advanced Oxidation System.” American Foundry Society Transactions, Vol 110, pp. 705-715. Andrews, J., R. Bigge, F. S. Cannon, G. R. Crandell, J. C. Furness, M. Redmann, R. C. Voigt (2000) Advanced Oxidants Offer Opportunities to Improve Mold Properties, Emissions. Modern Casting September; pp 40 43