PROJECT OBJECTIVES AND ACTIVITIES

Green Casting LIFE project aims to demonstrate the technical and environmental feasibility of using inorganic binders, instead of traditional organic ones, in ferrous foundries.

Objectives

• To successfully use inorganic binder systems on an industrial scale in 6 flagship ferrous foundries, including necessary equipment investments, in five European countries.
• To develop tailor-made inorganic binder systems solutions for iron and steel foundries, in cooperation with the flagship foundries.
• To demonstrate different type of sand reclamation methods for inorganic binder system sands (thermal, mechanical and wet methods).
• To enhance the replication potential by
• contacting 200 and interviewing 100 potential ferrous foundries.
• guiding and testing inorganic binders in 15 selected follower pilot foundries in Europe.
• providing new results and experiences for the preparation of the Reference Document on Best Available Techniques in the Smitheries and Foundries Industry (BREF document).
• To ensure an efficient communication and dissemination of the project activities.
• To arrange training workshops in six partner countries for potential follower pilot foundries and other relevant stakeholders.

 Expected results

• Experiences and know-how from six flagship foundries for implementing inorganic binders in their production.
• Step-by-step implementation plans for flagship foundries for the full-scale implementation of inorganic binders.
• Emission reductions after changing from organic binder systems to inorganic binder systems:
  • To reduce total hazardous airborne emissions by 80-95% (VOC, SO2, NOx, Particulate Matters…) in the production lines using inorganic binders compared.
  • To create a healthier environment for the workers by improving indoor air quality in foundries by 70 (CO, VOC, PM, formaldehyde, phenols…).
  • To reduce the harmful substances in waste sand by 80-90% (DOC, phenols, fluoride, BTEX concentrations)
  • To decrease the amount of waste sand to be landfilled by 90% in the partner foundries.
  • After 5 years from the end of the project 300 ferrous foundries in EU are expected to change from current organic to inorganic binder systems.

Total budget: 7 162 398 €
EU contribution (60%): 4 297 432 €
Duration: 09/2022-02/2026

Global gathering in Deyang

The 75th World Foundry Congress, held in Deyang, China, from September 25 to 30, 2024, gathered around 1,500 experts and industry leaders from over 30 countries under the patronage of the World Foundry Organization (WFO). Recognized as the leading global event for the foundry and metallurgical sectors, this year’s Congress focused on “Development of Foundry,” highlighting cutting-edge advancements and encouraging international cooperation. With a wide range of presentations, poster sessions, and exhibitions, the event served as a pivotal meeting ground for innovation and networking.

Polish Contributions to Sustainable Foundry Practices at the Congress

Notably, the Polish delegation was one of the largest from Europe, highlighting Poland’s active role in the industry.

The Polish representatives made a substantial impact in the program of the 75th World Foundry Congress. During the opening ceremony, Professor Rafał Dańko, Vice-Rector of AGH University, delivered a plenary speech titled “Getting Closer To Green Casting Foundry – Sustainable Development.” His presentation focused on the “Green Casting Life” project, implemented in our foundry, which centers on introducing eco-friendly solutions in foundries, including the use of inorganic binder systems.

Dr. hab. Eng. Angelika Kmita, Professor at AGH, also presented her work in a talk titled “Eco-Friendly Casting by Using Innovative Inorganic Binder Systems (IIBs),” discussing efforts to reduce industrial emissions, also as part of the “Green Casting Life” initiative. Her presentation was recognized with the Best Youth Paper Award, underscoring Poland’s contributions to promoting sustainability in the foundry industry.