Foundry industry is the pillar industry of China’s national economy, but also energy consumption and environmental pollution.
This paper combines the actual work, from the perspective of environmental protection concept, focusing on the application of green casting technology and development strategies for exploration and research.
In recent years, China’s foundry industry has achieved rapid development, but at the same time, in the casting process, it is also easy to bring serious environmental pollution problems, such as air pollution caused by the melting of iron and steel, sand casting caused by dust pollution and exhaust gas pollution, the old sand waste emissions caused by environmental pollution and so on, have seriously damaged the natural environment, a crisis of people’s physical and mental health. Therefore, in order to reduce environmental pollution in the foundry industry, it is necessary to attach great importance to the application of green casting technology and development, in order to improve the production environment of the foundry industry, to achieve green, clean production process, and ultimately to achieve the minimisation of negative environmental effects, as well as the optimal use of resources and energy efficiency of the production goals.
- the application of green casting technology analysis
Green casting technology, refers to castings in the manufacturing process, the use of non-polluting clean technology to meet the high quality, high efficiency, low consumption, low scrap rate of casting production goals.
In recent years, China’s large and medium-sized foundry enterprises, have to green as the guiding ideology, the establishment of a new production model with the natural ecological coordination of cleaner production of an eco-industry to replace the traditional high consumption, heavy pollution of the crude production model, thus greatly improving the overall technical level of China’s foundry industry and fundamentally solve the problem of sustainable development of resources and the environment.
At present, in China’s green casting technology in the application of practice, to prevent pollution and environmental protection as the main starting point, the application of its key technologies, focusing on the following three aspects: First, the casting production process of green transformation; Second, the casting waste recycling and reuse; Third, the casting of the environment of the green transformation.
- casting production process green transformation.China’s casting production process green transformation, the main emphasis on maintaining product quality and cost, try to reduce energy consumption and reduce resource consumption, produce less “three wastes”, and make the waste can achieve good recycling and reuse. In recent years, in China’s non-ferrous metal industry, a new type of production process is generally used to overcome the defects of poor product quality and pollutant emissions in the traditional process, to achieve the green production of products. For example, in the casting material selection, the use of high clean steel, ductile iron, special cast iron, clean aluminium and other new clean materials, to replace the traditional polluting materials: in the casting moulding process, the use of a variety of advanced casting technology such as the use of high-pressure casting, investment casting method, centrifugal casting method, the solid disappearing mould casting (EPS), these casting moulding process not only helps to improve casting Molding quality, but also can significantly reduce the production process of environmental pollution and damage; in the casting process, the active use of computer technology, microelectronics technology, automatic control technology to control and manage the process, in order to achieve the casting production process in the process of quantitative, numerical online monitoring and control, not only reduces the consumption of resources and energy, but also synchronised with the realization of a low rate of scrap and low environmental pollution production goals.
(2) Recycling and reuse of casting waste. Foundry industry due to the specificity of its production, complete zero emission and zero waste is the main direction of its efforts. In production practice, efforts should be made to combine green casting technology, so that the casting production process of waste gas, waste water and waste clean to be comprehensive use, so that waste into treasure, in order to achieve a coordinated development of resources and the environment requirements. For example, in the iron casting process, will produce a large number of slag, the composition of these slag is mainly composed of iron trioxide, calcium oxide, silica and other trace elements constitute a complex mixture. For a long time, the slag has not been fully utilised, only a small amount for burning cement and building materials, and the remaining large amount of slag only to be discarded, resulting in serious social problems and environmental damage.
In recent years, China’s foundry industry attaches great importance to the recovery and reuse of slag, and has gradually mastered a variety of slag processing and treatment methods. For example, the slag can be processed into a new type of wall materials, this material has good thermal insulation, high strength, light weight, but also the current new building materials – an important development direction; or slag processed into a cemented material, can be transported into the hollow area in order to protect the villages, railways, and other surface building safety. In addition, the slag contains iron, aluminium and other metal elements can be fully extracted to obtain good economic and social benefits.
(3) Green transformation of the foundry enterprise environment. At present, China’s large and medium-sized foundry enterprises in addition to strengthening the green transformation of the production process, strengthen the recycling and reuse of waste, but also have to use the green design of the enterprise production environment protection and transformation. Baosteel construction as an example: in recent years, Baosteel Group pays great attention to the protection of the production environment, and through the active implementation of green design and cleaner production, in order to focus on creating a green Baosteel. At present, Baosteel Group is also China’s foundry industry, the first through the 1S014001 environmental certification of enterprises, the greening rate of its plant reached 42.71%, the plant air quality has reached the national standards of scenic spots, but also China’s first national industrial tourism attractions. The greening construction of its plant and the main project planning is basically the same time planning, simultaneous implementation, and according to the production area planted different plants, the use of substances of the principle of mutualism, in order to maximise the absorption of harmful gases, impede the formation of dust, noise, so that the entire plant constitutes a benign green ecological environment.
- Green casting technology development strategy
After more than a decade of continuous development, green casting technology has been in China’s large and medium-sized foundry enterprises have a wide range of popularity and application. But overall, China’s green casting technology research and application results, is still in the primary stage, in the future will still focus on the development of the following directions.
(1) the greening of process design. Green casting production process design, refers to the casting product or casting process through the optimal design to achieve the highest efficiency in the use of resources, minimise the harm to the environment. The green development direction of casting process design mainly includes modular design, computer-aided design, parallel engineering design and other advanced process design theories.
Computer-aided design, for example, it can use advanced computer hardware and software equipment, as well as intelligent expert systems, fuzzy control theory to ultimately achieve the casting production process optimisation and process parameter optimisation.
(2) Intelligent process control. Intelligent is also an important development direction of green casting technology. Especially in recent years, accompanied by neural network technology, fuzzy control technology, image recognition technology and other intelligent technology is gradually mature, coupled with the expert knowledge base, the establishment and application of the method library, a variety of casting production control of the level of intelligence will be further enhanced, in order to better play the role of intelligent control in the production process.
In short, this paper starts from the perspective of environmental protection concept, on the application of green casting technology and development strategy for exploration and research. China’s foundry industry to effectively achieve their own process technology level, to achieve the optimisation and upgrading of industrial structure, we must attach great importance to the application and development of green casting technology, in order to better promote China’s foundry industry as a whole, energy saving, improve energy efficiency, reduce the pollution and destruction of the natural environment.
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