Know your HAPs: with increased regulations for hazardous air pollutant (HAP) emissions, there's an urgent need for HAP factors that can assist iron casting firms in determining their emission levels.When air toxic emission EMISSION, med. jur. The act by which any matter whatever is thrown from the body; thus it is usual to say, emission of urine, emission of semen, &c. 2. regulations became increasingly stringent in the 1990s, the metalcasting industry saw the need to examine hazardous air pollutants pollutants see environmental pollution. (HAPs) at its facilities. Focus was given to the types and quantities of organic HAPs emitted from the pouring, cooling and shakeout Shakeout A situation in which many investors exit their positions, often at a loss, because of uncertainty or recent bad news circulating around a particular security or industry. Notes: During the dotcom boom and bust, numerous shakeouts occurred. (PCS (1) (Personal Communications Services) Refers to wireless services that emerged after the U.S. government auctioned commercial licenses in 1994 and 1995. This radio spectrum in the 1. ) operations in iron casting facilities. This led to the creation of the Casting Emissions emissions npl → émissions fpl emissions npl → Emissionen pl Reduction Program (CERP CERP Continuing Education Recognition Points CERP Comprehensive Everglades Restoration Plan (United States Army Corp of Engineers; South Florida Water Management District, and other Florida state agencies) ), which would evaluate the HAP HAP. An old word which signifies to catch; as, "to hap the rent," to hap the deed poll." Techn. Dict. h.t. emission potential of various mold mold, name for certain multicellular organisms of the various classes of the kingdom Fungi, characteristically having bodies composed of a cottony mycelium. The colors of molds are caused by the spores, which are borne on the mycelium. and coremaking processes and systems. However, several other organizations were conducting similar investigations, which caused the lack of a single source that a casting firm could consult to estimate its PCS HAP emissions. To address this need, the AFS A distributed file system for large, widely dispersed Unix and Windows networks from Transarc Corporation, now part of IBM. It is noted for its ease of administration and expandability and stems from Carnegie-Mellon's Andrew File System. AFS - Andrew File System Air Quality Committee (10-E) formed an emission factor An emission factor can be defined as the average emission rate of a given pollutant for a given source, relative to units of activity. Emission factors can be used to derive estimates of gas emissions (for instance, greenhouse gas emissions) based on the amount of fuel combusted subcommittee sub·com·mit·tee n. A subordinate committee composed of members appointed from a main committee. subcommittee Noun . The sub-committee was tasked with reviewing and summarizing existing emission data while consulting with various sources, including CERP. It was determined that besides the PCS operations, other processes within a facility also can emit TO EMIT. To put out; to send forth, 2. The tenth section of the first article of the constitution, contains various prohibitions, among which is the following: No state shall emit bills of credit. organic HAPs. These other processes, however, are quantified more easily with traditional methods, such as using information in Material Safety Data Sheets (MSDS MSDS Material Safety Data Sheets, see there ), raw materials' "Certificate of Analysis" and purchasing records. Further, inorganic inorganic /in·or·gan·ic/ (in?or-gan´ik) 1. having no organs. 2. not of organic origin. in·or·gan·ic n. 1. HAPs (i.e. metals) emitted from various processes can be calculated from particulate par·tic·u·late adj. Of or occurring in the form of fine particles. n. A particulate substance. particulate composed of separate particles. emission factors or from stack testing results. This article addresses the major findings from the 10-E subcommittee and how they can be applied to iron casting production. Green Sand Molds The majority of the HAP emissions from PCS operations originate o·rig·i·nate v. 1. To bring into being; create. 2. To come into being; start. from the volatilization volatilization /vol·a·til·iza·tion/ (vol?ah-til-i-za´shun) conversion into vapor or gas without chemical change. vol·a·til·i·za·tion n. See evaporation. and/or and/or conj. Used to indicate that either or both of the items connected by it are involved. Usage Note: And/or is widely used in legal and business writing. thermal decomposition For the biological process, see Decomposition. For chemical decomposition in general, see Chemical decomposition. Thermal decomposition is a chemical reaction whereby a chemical substance breaks up into at least two chemical substances when heated. of organic materials present in the mold or cores. Additionally, CERP testing has shown that the quantity of HAPs emitted during PCS operations is directly proportional (Math.) proportional in the order of the terms; increasing or decreasing together, and with a constant ratio; - opposed to See also: Directly to the surface area of the casting. Thus, the greater the surface area, the greater the emissions. Tables A, B and C relate to PCS HAP emissions from green sand molds or cored green sand molds. Table A is to be used for castings made from green sand molds using seacoal as the only carbonaceous car·bo·na·ceous adj. Consisting of, containing, relating to, or yielding carbon. carbonaceous Adjective of, resembling, or containing carbon Adj. 1. additive additive In foods, any of various chemical substances added to produce desirable effects. Additives include such substances as artificial or natural colourings and flavourings; stabilizers, emulsifiers, and thickeners; preservatives and humectants (moisture-retainers); and . Table B provides "core only" HAP emission factors for different coremaking binder binder: see combine. An earlier Microsoft Office workbook file that let users combine related documents from different Office applications. The documents could be viewed, saved, opened, e-mailed and printed as a group. systems. Investigations done at CERP have shown that the HAP emissions from cores can be added numerically nu·mer·i·cal also nu·mer·ic adj. 1. Of or relating to a number or series of numbers: numerical order. 2. Designating number or a number: a numerical symbol. to the HAP emissions from sand molds to arrive at total core/mold package emissions. For example, the emissions from a test of a noncored green sand mold can be added to the values of a test on a core component to provide an accurate estimate of HAP emissions from a green sand mold containing that core. This relationship is particularly strong when the PCS emission data for the core component is collected while it is contained in a mold that is devoid de·void adj. Completely lacking; destitute or empty: a novel devoid of wit and inventiveness. [Middle English, past participle of devoiden, of any organic materials. Table C lists the combined core/mold HAP emission factors for three different core/mold combinations based on actual emission testing of cored green sand molds. These factors, combining core and sand mold emissions, may be used if the process specification for an individual metalcasting facility matches those specified in the table. The emission factors listed represent emissions from specific types of core and mold materials at formulations stated in the emission tests. Emission factors for molding sand (Founding) a kind of sand containing clay, used in making molds. See also: Molding and core mixes, where the levels of organic binders or carbonaceous additives are different from those stated in Table C, can be estimated by assuming a direct linear relationship. In other words Adv. 1. in other words - otherwise stated; "in other words, we are broke" put differently , if a green sand line actually runs a 4% loss on ignition Loss on Ignition is a test used in inorganic analytical chemistry, particularly in the analysis of minerals. It consists of strongly heating ("igniting") a sample of the material at a specified temperature, allowing volatile substances to escape, until its mass ceases to change. (LOI LOI Letter of Indemnity (international trade and carriage business) LOI Letter Of Intent LOI Loss On Ignition LOI Letter of Inquiry LOI Lack Of Information LOI Lack of Interest LOI Letter of Invitation LOI List Of Items ), its emission factor can be estimated as 80% of the emission factor provided in Table C, which represents a percent LOI (i.e. 100 x 4%/5%). This same relationship holds true for core binder emissions. It should be noted that in addition to the variability in emission factors due to the level of carbonaceous additives (in this case, seacoal), differences in the volatility of different additives can introduce additional and sometimes unpredictable variability in emissions. Nobake Molding HAP emission factors for typical nobake molding processes--phenolic urethane urethane (yoor´ithān´), n ethyl carbamate used as an anesthetic agent for laboratory animals, formerly used as a hypnotic in humans. , furan furan: see furfural. and ester-cured phenolic resin Noun 1. phenolic resin - a thermosetting resin phenolic, phenoplast synthetic resin - a resin having a polymeric structure; especially a resin in the raw state; used chiefly in plastics systems--are listed in Table D, with phenolic phe·no·lic adj. Of, relating to, containing, or derived from phenol. n. Any of various synthetic thermosetting resins, obtained by the reaction of phenols with simple aldehydes and used as adhesives. urethane being the most commonly used. The HAP emission factors for phenolic urethane nobake binder systems can exhibit a high level of variability as this binder system often is formulated for·mu·late tr.v. for·mu·lat·ed, for·mu·lat·ing, for·mu·lates 1. a. To state as or reduce to a formula. b. To express in systematic terms or concepts. c. to meet specific casting quality requirements and therefore can have different emission characteristics and tensile strengths tensile strength Ratio of the maximum load a material can support without fracture when being stretched to the original area of a cross section of the material. When stresses less than the tensile strength are removed, a material completely or partially returns to its . The furan and ester-cured nobake emission factors listed are typical of these processes; however, these binders generally are not interchangeable in·ter·change·a·ble adj. That can be interchanged: interchangeable items of clothing; interchangeable automotive parts. in with the phenolic urethane systems. Additional Processes Some casting processes, such as permanent mold and centrifugal casting Centrifugal casting or rotocasting is a casting technique which has application across a wide range of industrial and artistic applications:
Table E lists an emission factor for the lost foam casting (LFC LFC Liverpool Football Club LFC Lake Forest College (Lake Forest, IL) LFC Level of Free Convection (meteorology) LFC Large Format Camera LFC Load Frequency Control ) process. This emission factor is the only currently published emission factor for the LFC process. The mold and coremaking, mixing and storage HAP emissions for phenolic urethane binders measured under controlled process conditions at CERP are listed in Table F. Contrary to Tables A-E A-E, AE above-elbow; see under amputation. , Table F does not evaluate PCS processes. The emission factors provided do not include any triethylamine Tri`eth`yl`am´ine n. 1. (Chem.) A tertiary amine analogous to trimethylamine. catalyst catalyst, substance that can cause a change in the rate of a chemical reaction without itself being consumed in the reaction; the changing of the reaction rate by use of a catalyst is called catalysis. HAP emissions. By referencing these tables, metalcasting firms can gain general guidance on organic HAP emission factors for PCS operations and for some mold and coremaking processes. A firm, however, cannot use the tables solely to determine if it emits a large amount of HAPs. All emission sources within a facility must be considered in developing a comprehensive HAP inventory for regulatory reg·u·late tr.v. reg·u·lat·ed, reg·u·lat·ing, reg·u·lates 1. To control or direct according to rule, principle, or law. 2. purposes. The emission factors in the tables are applicable to the process conditions listed in the referenced documents. If process conditions are different, the emission factors provided in the attached tables should be adjusted accordingly to account for the differences. However, if the process conditions are significantly different, the emission factors in the tables may not provide an accurate estimate--even after making the adjustment--and therefore should not be used. The full text of the recommendations and future updates can be found at www.afsinc.org/mact/. It is posted under "Organic Hazardous Air Pollution Emission Factors for Iron Foundries." Applying the Data to Your Operation After reviewing the tables, it's it's 1. Contraction of it is. 2. Contraction of it has. See Usage Note at its. it's it is or it has it's be ~have best to investigate how the data pertains to several casting situations in determining the HAP levels. Green Sand PCS HAP Emission Factor Situation--The average casting poured does not use a core and does not have thin or finned finned adj. Having a fin, fins, or finlike parts. Often used in combination: single-finned; multifinned. sections. Solution--Choose the average surface area HAP emission factor of 0.213 lbs./ton of iron poured (Table A, first row). Look at the process specification in Table A and the referenced report and determine if you run a 5% LOI with a 100% seacoal sand formulation formulation /for·mu·la·tion/ (for?mu-la´shun) the act or product of formulating. American Law Institute Formulation . If so, then use this HAP emission factor. If you use higher or lower LOI level, adjust the HAP emission factor accordingly using a direct linear relationship. If carbonaceous additives (other than or in addition to seacoal) are used, this HAP emission factor is not applicable and other sources of emission factors should be sought. Cored Green Sand Mold PCS HAP Emission Factor Situation--The average casting is poured in a green sand mold made with 5% LOI sand containing seacoal, does not have thin or finned sections, and uses a modern phenolic urethane core at 1.1% binder level. Solution--Use the average surface area green sand mold HAP emission factor of 0.213 lbs./ton of iron poured to represent the green sand mold emissions (Table A, first row). Use the newer technology phenolic urethane core emission factor of 0.368 lbs./ton of iron (Table B, second row). As shown in Table B, the process specification for this test is 1.75% binder level. At 1.1% binder level the core emissions are estimated to be 0.368 x (1.1/1.75) = 0.231 lbs./ton. The total HAP emissions from this mold/core package then would be 0.213 + 0.231 = 0.444 lbs./ton of iron poured. Cored Green Sand Mold PCS HAP Emission Factor Situation--The casting poured is a four-cylinder engine block in a green sand mold made with 5% LOI sand containing seacoal, with an older technology phenolic urethane resin-coated sand core at 1.75% binder level. Solution--This situation is a direct match with the combined mold and core HAP emission factor test listed in Table C as 0.643 lbs./ton of iron poured.
Table A. Green Sand Mold Emissions (PCS)
Emission Factor
(lbs. HAPs/
Process Conditions tons of metal)
Average surface area green
sand parts with seacoal as
the only carbonaceous
additive 0.213
Very high surface area green
sand parts with seacoal as
the only carbonaceous
additive; allow for thin
cross sections 0.378
CERP Test Number,
Publication/Revision
Process Conditions Date and Process Description
Average surface area green 1256-1311 DQ, 4/26/2001--Green
sand parts with seacoal as sand test using only seacoal
the only carbonaceous at 5% LOI and sodium silicate
additive (inorganic) step block cores.
Very high surface area green 1256-1231DE, 7/30/2003--CERP
sand parts with seacoal as production metalcasting
the only carbonaceous facility test with seacoal
additive; allow for thin at 5% LOI and star pattern;
cross sections no cores
Table B. Core Emissions (PCS)
Emission Factor
(lbs. HAPs/tons
Process Conditions of metal)
Old technology phenolic
urethane coldbox (PUCB)
cores; this emission factor
is representative of an
older binder system
requiring high core binder
levels 0.397
Newer technology PUCB cores;
this emission factor is
representative of a newer
technology binder system
capable of low binder levels 0.368
Alkaline phenol ic/
C[0.sub.2]-coated cores 0.122
Phenolic novolac
(shell) cores 0.295
Phenolic hotbox cores 0.061
Furan warmbox cores 0.050
Oil sand cores TBD
Use for core emissions of a 0
green sand mold with no core
Process Conditions CERP Test Number,
Publication/Revision
Date and Process Description
Old technology phenolic 1409-125FB, 7/1/2003--Phenolic
urethane coldbox (PUCB) urethane step block core
cores; this emission factor emission test at 1.75% binder
is representative of an level
older binder system
requiring high core binder
levels
1256-11GSA.3 CM, 12/15/2000--
Newer technology PUCB cores; Phenolic urethane step block
this emission factor is core emission test at 1.75%
representative of a newer binder level; this binder
technology binder system system is capable of running
capable of low binder levels at much lower than 1.75%
binder levels
Alkaline phenol ic/ GE, 8/1/2004--Coated alkaline
C[0.sub.2]-coated cores phenolic cores at 2% binder
(CERP is finalizing this
report)
Phenolic novolac 1410-177FU 9/1/2004--Uncoated
(shell) cores cores at 3% resin level
Phenolic hotbox cores GH, 10/1/2004--Step block
cores at 1.2% binder level
(CERP is finalizing this
report)
Furan warmbox cores GJ-Furan warmbox step block
cores (CERP is finalizing
this report)
Oil sand cores
M-Oil sand step block cores
(CERP is finalizing this
report)
Use for core emissions of a Core emissions not in
green sand mold with no core coreless mold; use zero
Table C. Cored Green Sand Mold Emissions (PCS)
Emission Factor
(lbs. HAPs/tons
Process Conditions of metal)
Complicated castings with a
high phenolic urethane core
content using seacoal as the
only green sand carbonaceous
additive; the emission
factor is representative of
a very high emitting green
sand cored mold package with
an older phenolic urethane
core binder at a high binder
level 0.643
An average casting with an
older phenolic urethane core
binder system at high binder
levels and seacoal as the
only carbonaceous additive 0.5424
Emission factor used by the
U.S. EPA in the MACT
Background Document to
represent the average green
sand metalcasting facility
HAP emissions; the emission
factor is a composite of
different systems but
primarily heavy-cored
castings using furan hotbox
cores 0.285
Process Conditions CERP Test Number,
Publication/Revision
Date and Process Description
Complicated castings with a 1256-122DD, 4/10/2003--A CERP
high phenolic urethane core production metalcasting
content using seacoal as the facility test producing
only green sand carbonaceous engine block castings. Green
additive; the emission Green sand mix used seacoal
factor is representative of as carbonaceous additive
a very high emitting green at a 5% L01; core package
sand cored mold package with used an older technology
an older phenolic urethane phenolic urethane binder
core binder at a high binder at 1.75% binder level
level
An average casting with an 0001-003, 11/11/1999--An
older phenolic urethane core emission test using seacoal
binder system at high binder as the only carbonaceous
levels and seacoal as the additive at 5% L01; and step
only carbonaceous additive block cores made with an
older phenolic urethane
binder system at 1.75%
binder level
Emission factor used by the 0001-002, 2/26/2003--This
U.S. EPA in the MACT CERP Mexico Study represents
Background Document to green sand molds with seacoal
represent the average green at 5% L01 and a combination
sand metalcasting facility of cores but primarily
HAP emissions; the emission phenolic hotboxl; this study
factor is a composite of is quoted as the "general
different systems but medium HAP emission
primarily heavy-cored estimate" in the MACT
castings using furan hotbox Background Document EPA-
cores 453/R-02-013
Table D. Nobake Mold Emissions (PCS)
Emission Factor
(lbs. HAPs/tons
Process Conditions of metal)
A high emitting phenolic
urethane nobake mold package
with high core tensile
strengths 2
An average emitting phenolic
urethane nobake mold package
with average tensile
strengths 1.521
A low emitting phenolic
urethane nobake binder with
low core tensile strengths 1.16
An average furan nobake
mold package 1.08
An ester-cured phenolic
nobake mold package 0.803
Process Conditions CERP Test Number,
Publication/Revision
Date and Process Description
A high emitting phenolic 1256-1211DG, 4/10/2003--
urethane nobake mold package Irregular gear pattern in
with high core tensile phenolic urethane nobake
strengths molds at 1.1% binder level
and high core tensile
strengths
An average emitting phenolic 1410-113FP, 3/1/2004--
urethane nobake mold package Irregular gear pattern in
with average tensile phenolic urethane nobake
strengths molds at 1.1% binder level
and medium core tensile
strengths
A low emitting phenolic 1256-1112DP,--12/l/2003--
urethane nobake binder with Irregular gear pattern
low core tensile strengths in phenolic urethane nobake
molds at 1.1% binder level
and core tensile strengths
An average furan nobake 1256-1115DX, 5/18/2001--
mold package Irregular gear pattern in
furan nobake molds at 1.3%
binder level with irregular
gear castings
An ester-cured phenolic 1256-1116DZ, 6/22/2001--
nobake mold package Irregular gear pattern with
ester-cured phenolic nobake
binder at a 1.1% binder level
Table E. Lost Foam Process Emissions (PCS)
Emission Factor
(lbs. HAPs/tons
Process Conditions of metal)
Lost foam casting process
(LFC) or expandable pattern
process (EPC) 1.02
Process Conditions CERP Test Number,
Publication/Revision
Date and Process Description
Lost foam casting process EPA-453/R-02-013, 12/1/2002--
(LFC) or expandable pattern Emission factor referenced in
process (EPC) EPA MACT background document
("Identification of
Emissions and Solid Waste
Generated from EPC Process,"
AFS, June 4, 1991)
Table F. Mold/Coremaking, Mixing and Storage Emissions
Process Conditions Emission Factor
(lbs. HAPs/tons of metal)
Combined core mixing, core
make and storage emission
factor for an older
technology phenolic
urethane core binder at a
high binder level <0.002
Combined core mixing, core
make and storage emission
factor for a newer
technology phenolic urethane 0.001
core binder at two different <0.074
binder levels
Combined mold sand mixing,
mold making, and storage
emission factor for a new
phenolic urethane nobake
mold package <0.002
Oil sand core curing
(baking) TBD
Process Conditions CERP Test Number,
Publication/Revision
Date and Process Description
Combined core mixing, core 1409-123EQ, 12/9/2002--
make and storage emission Emissions from an older
factor for an older phenolic urethane core
technology phenolic binder at 1.75% binder
urethane core binder at a level; test does not include
high binder level TEA (a HAP); some analytes
below quantitation level.
Combined core mixing, core 1409-111ER, 12/21/2002--
make and storage emission Emissions from a newer
factor for a newer technology phenolic urethane
technology phenolic urethane core binder at 1.2% and
core binder at two different include TEA (a HAP); some
binder levels analytes below quantitation
level.
Combined mold sand mixing, 1409-124EY, 5/29/2003-Nobake
mold making, and storage moldmaking emissions using a
emission factor for a new phenolic urethane binder at
phenolic urethane nobake 1.3% binder level; some
mold package analytes below quantitation
level.
Oil sand core curing Oil sand step block cores
(baking) (CERP is preparing report)
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