Characterization of Fine Particulate Emissions from Casting Processes

Figures & data

Figure 1 Schematic of the casting process and sampling location in the Research Foundry at Technikon, LLC (McClellan, CA).

Figure 2 Schematic of the Desert Research Institute (DRI, Reno, NV) Source Dilution Sampling System.

TABLE 1 Daily test conditions for comparisons of the dilution sampling method and U.S. Environmental Protection Agency (EPA) Modified Method 201A (Conditional Test Method 040)/202 sampling train from the Research Foundry at Technikon, LLC (McClellan, CA) from February 25–27, 2004

Date	Start time	End time	Dilution sampling run	Modified EPA Method 201A and 202 train	Sample time (second)	Duct flowrate (scfm)	Cast Wt. (lb)	Binder Wt. (lb)
2/25/04	9:50	10:35	Run 2	GA-2A	2160	253	122.0	5.93
2/26/04	9:00	10:20	Run 3	GA-3A&3B	4500	236	120.6	5.68
2/26/04	15:05	16:24	Run 4	GA-3C	4500	239	95.6	5.91
2/27/04	11:30	12:50	Run 5	GA-4A&4B	4500	233	120.9	5.71
2/27/04	13:52	15:08	Run 6	GA-4A&4B	4500	237	122.0	5.94

TABLE 2 PM_2.5 mass concentrations determined by filter sampler and electronic low-pressure impactor (ELPI) with DRI source dilution sampling system (similar to U.S. Environmental Protection Agency [EPA] Conditional Test Method 039)

DRI dilution sampling run	Volume (m^3) at STP*	Average dilution air ratio	In-stack PM2.5 mass cone. (mg/m^3) by filter	Average PM2.5 mass concentration (mg/m^3) measured by filter	Average PM2.5 mass concentration (mg/m^3) measured by ELPI	Ratio of PM2.5 between ELPI and filter sample	Fraction of PM2.5 from pouring/cooling**
2	1.47	26.25	25.8	0.99	0.72	0.73	NA
3	3.26	31.81	65.6	2.05	1.84	0.90	0.267
4	3.32	44.00	35.6	0.81	0.77	0.95	0.200
5	3.07	42.10	100.9	2.40	1.84	0.77	0.153
6	3.04	60.30	66.9	1.11	0.87	0.78	0.179

TABLE 3 Emission factors of PM_2.5 chemical species from the foundry process (4-on irregular gear No-Bake^® molds). No weighing factors for metal oxides and organic carbon are applied

	Emission factor (lb species/ton metal)					Emission factor (lb species/lb binder)
Run number	Run 2	Run 3	Run 4	Run 5	Run 6	Run 2	Run 3	Run 4	Run 5	Run 6
Mass	2.41 E−01	1.20E+00	8.35E−01	1.83E+00	1.22E+00	2.48E−03	1.28E−02	6.76E−03	1.93E−02	1.25E−02
Ammonia gas (AC)	3.44E−03	2.73E−02	2.64E−02	2.51E−02	3.86E−02	3.54E−05	2.90E−04	2.14E−04	2.65E−04	3.96E−04
Carbon on backup filter by IMPROVE protocol
OC1 backup	2.45E−03	6.82E−03	9.41E−03	6.45E−03	1.31E−02	2.52E−05	7.24E−05	7.61E−05	6.83E−05	1.34E−04
OC2 backup	2.42E−03	7.37E−03	9.87E−03	9.55E−03	1.32E−02	2.49E−05	7.83E−05	7.98E−05	1.01E−04	1.36E−04
OC3 backup	2.40E−03	4.27E−03	5.89E−03	6.51E−03	8.90E−03	2.47E−05	4.53E−05	4.76E−05	6.89E−05	9.14E−05
OC4 backup	4.94E−04	2.03E−03	2.58E−03	3.62E−03	5.52E−03	5.08E−06	2.15E−05	2.09E−05	3.83E−05	5.67E−05
OPC backup	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00
OC backup	7.76E−03	2.09E−02	2.84E−02	2.85E−02	4.46E−02	7.98E−05	2.22E−04	2.30E−04	3.02E−04	4.58E−04
EC1 backup	3.21E−04	2.34E−03	3.01E−03	4.59E−03	6.88E−03	3.30E−06	2.48E−05	2.44E−05	4.86E−05	7.07E−05
EC2 backup	2.47E−04	1.13E−03	2.08E−03	1.83E−03	3.88E−03	2.54E−06	1.20E−05	1.68E−05	1.94E−05	3.98E−05
EC3 backup	0.00E+00	0.00E+00	0.00E+00	0.00E+00	4.42E−04	0.00E+00	0.00E+00	0.00E+00	0.00E+00	4.54E−06
EC backup	5.68E−04	3.03E−03	4.45E−03	4.05E−03	7.29E−03	5.84E−06	3.22E−05	3.60E−05	4.29E−05	7.49E−05
TC backup	8.33E−03	2.40E−02	3.28E−02	3.26E−02	5.19E−02	8.57E−05	2.54E−04	2.66E−04	3.45E−04	5.33E−04
Inorganic ions by IC/AC
Cl−	3.49E−04	6.97E−03	5.44E−03	1.94E−02	1.45E−02	3.59E−06	7.40E−05	4.40E−05	2.05E−04	1.49E−04
NO3 ^−	1.03E−04	3.35E−04	3.97E−04	6.06E−04	9.07E−04	1.06E−06	3.56E−06	3.21 E−06	6.41 E−06	9.32E−06
SO4 ^−	8.77E−04	2.65E−03	1.66E−03	3.51E−03	2.61E−03	9.02E−06	2.81E−05	1.35E−05	3.72E−05	2.68E−05
NH4 ^+	2.74E−04	1.20E−03	6.52E−04	7.14E−03	4.16E−03	2.82E−06	1.27E−05	5.28E−06	7.56E−05	4.27E−05
Carbon on front filter by IMPROVE protocol
OC1	4.72E−03	9.25E−02	4.14E−02	5.46E−02	5.85E−02	4.86E−05	9.82E−04	3.35E−04	5.78E−04	6.01E−04
OC2	7.60E−03	8.64E−02	4.54E−02	6.32E−02	5.46E−02	7.82E−05	9.17E−04	3.67E−04	6.69E−04	5.61E−04
OC3	7.86E−03	6.05E−02	3.02E−02	3.90E−02	3.63E−02	8.08E−05	6.43E−04	2.44E−04	4.13E−04	3.73E−04
OC4	4.38E−03	3.22E−02	3.47E−02	4.42E−02	4.66E−02	4.50E−05	3.41 E−04	2.81E−04	4.68E−04	4.78E−04
OPC	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00
OC	2.83E−02	5.24E−01	3.03E−01	5.20E−01	6.26E−01	2.91 E−04	5.57E−03	2.45E−03	5.50E−03	6.42E−03
EC1	5.14E−02	4.22E−01	2.79E−01	6.77E−01	4.56E−01	5.29E−04	4.48E−03	2.25E−03	7.16E−03	4.68E−03
EC2	9.31 E−03	2.83E−02	2.99E−02	1.85E−01	2.50E−01	9.58E−05	3.01 E−04	2.42E−04	1.96E−03	2.56E−03
EC3	1.08E−03	1.43E−03	1.60E−03	4.44E−03	2.42E−03	1.11E−05	1.52E−05	1.29E−05	4.70E−05	2.49E−05
EC4	5.80E−02	1.99E−01	1.59E−01	5.47E−01	2.78E−01	5.97E−04	2.11E−03	1.28E−03	5.80E−03	2.86E−03
TC	8.63E−02	7.23E−01	4.62E−01	1.07E+00	9.04E−01	8.88E−04	7.68E−03	3.73E−03	1.13E−02	9.28E−03
Elements by XRF
Al	0.00E+00	3.88E−03	2.92E−03	1.64E−03	2.86E−03	0.00E+00	4.11E−05	2.36E−05	1.74E−05	2.94E−05
Si	1.20E−02	6.00E−02	6.00E−02	4.08E−02	4.47E−02	1.24E−04	6.37E−04	4.85E−04	4.32E−04	4.59E−04
P	0.00E+00	0.00E+00	9.46E−05	0.00E+00	6.12E−04	0.00E+00	0.00E+00	7.65E−07	0.00E+00	6.28E−06
S	5.50E−04	1.11E−03	7.52E−04	3.86E−04	6.07E−04	5.66E−06	1.18E−05	6.08E−06	4.09E−06	6.23E−06
Cl	4.70E−04	1.04E−02	7.02E−03	1.57E−02	1.08E−02	4.83E−06	1.10E−04	5.68E−05	1.67E−04	1.11E−04
K	1.29E−04	6.33E−03	5.64E−03	6.30E−03	6.29E−03	1.32E−06	6.72E−05	4.56E−05	6.66E−05	6.46E−05
Ca	2.94E−04	2.30E−03	2.05E−03	2.42E−03	2.19E−03	3.02E−06	2.44E−05	1.66E−05	2.57E−05	2.25E−05
Ti	0.00E+00	1.59E−04	1.48E−04	5.61 E−05	0.00E+00	0.00E+00	1.69E−06	1.20E−06	5.93E−07	0.00E+00
Va	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00	0.00E+00
Cr	1.19E−04	2.09E−04	1.54E−04	1.84E−04	8.32E−05	1.22E−06	2.22E−06	1.24E−06	1.95E−06	8.54E−07
Mn	2.76E−02	3.67E−02	4.02E−02	7.01E−02	2.15E−02	2.84E−04	3.90E−04	3.25E−04	7.42E−04	2.21E−04
Fe	3.02E−02	4.66E−02	2.54E−02	4.56E−02	2.79E−02	3.11E−04	4.95E−04	2.05E−04	4.83E−04	2.86E−04
Co	5.12E−05	9.29E−05	6.54E−05	5.67E−05	5.24E−05	5.27E−07	9.86E−07	5.29E−07	6.00E−07	5.38E−07
Ni	9.53E−05	9.25E−05	4.68E−05	8.18E−05	5.70E−05	9.81E−07	9.82E−07	3.78E−07	8.66E−07	5.85E−07
Cu	2.52E−03	2.46E−03	1.99E−03	4.05E−03	1.47E−03	2.59E−05	2.61 E−05	1.61 E−05	4.29E−05	1.51E−05
Zn	2.41E−03	3.20E−03	1.74E−03	5.15E−03	1.30E−03	2.48E−05	3.39E−05	1.40E−05	5.45E−05	1.33E−05
Ga	0.00E+00	0.00E+00	0.00E+00	3.16E−05	0.00E+00	0.00E+00	0.00E+00	0.00E+00	3.35E−07	0.00E+00
As	1.99E−05	2.10E−05	7.99E−06	0.00E+00	5.46E−06	2.05E−07	2.23E−07	6.46E−08	0.00E+00	5.61E−08
Se	0.00E+00	0.00E+00	0.00E+00	3.09E−06	0.00E+00	0.00E+00	0.00E+00	0.00E+00	3.27E−08	0.00E+00
Br	0.00E+00	3.12E−05	2.55E−05	2.13E−06	1.23E−05	0.00E+00	3.31E−07	2.06E−07	2.25E−08	1.26E−07
Rb	1.33E−06	2.30E−05	2.40E−05	1.57E−05	1.55E−05	1.36E−08	2.44E−07	1.94E−07	1.66E−07	1.59E−07
Sr	3.15E−06	3.32E−05	2.50E−05	1.37E−05	1.46E−05	3.24E−08	3.53E−07	2.02E−07	1.45E−07	1.50E−07
Yt	5.79E−07	1.15E−05	1.02E−05	1.02E−05	0.00E+00	5.96E−09	1.22E−07	8.27E−08	1.08E−07	0.00E+00
Zr	1.47E−06	1.14E−05	1.36E−05	9.87E−06	1.60E−05	1.52E−08	1.21E−07	1.10E−07	1.04E−07	1.65E−07
Mo	3.05E−05	3.13E−05	0.00E+00	3.75E−05	0.00E+00	3.14E−07	3.32E−07	0.00E+00	3.97E−07	0.00E+00
Pd	0.00E+00	0.00E+00	0.00E+00	0.00E+00	1.46E−05	0.00E+00	0.00E+00	0.00E+00	0.00E+00	1.50E−07
Ag	7.28E−05	7.64E−05	5.47E−05	3.91E−05	2.86E−05	7.49E−07	8.12E−07	4.42E−07	4.14E−07	2.94E−07
Cd	2.50E−06	2.31E−06	2.16E−05	0.00E+00	5.43E−06	2.57E−08	2.45E−08	1.75E−07	0.00E+00	5.57E−08
In	0.00E+00	1.15E−05	5.62E−06	0.00E+00	0.00E+00	0.00E+00	1.23E−07	4.55E−08	0.00E+00	0.00E+00
Sn	2.29E−04	2.27E−04	1.78E−04	2.10E−04	1.20E−04	2.35E−06	2.41E−06	1.44E−06	2.23E−06	1.24E−06
Sb	8.06E−05	2.42E−05	1.38E−04	0.00E+00	1.87E−04	8.29E−07	2.57E−07	1.12E−06	0.00E+00	1.92E−06
Ba	1.09E−04	1.29E−04	0.00E+00	2.16E−04	2.85E−04	1.12E−06	1.37E−06	0.00E+00	2.29E−06	2.93E−06
La	0.00E+00	0.00E+00	1.84E−04	2.15E−04	2.91E−04	0.00E+00	0.00E+00	1.49E−06	2.28E−06	2.99E−06
Au	0.00E+00	0.00E+00	0.00E+00	7.30E−06	0.00E+00	0.00E+00	0.00E+00	0.00E+00	7.73E−08	0.00E+00
Hg	1.54E−05	1.66E−05	0.00E+00	1.17E−05	4.64E−06	1.58E−07	1.76E−07	0.00E+00	1.24E−07	4.76E−08
Ti	2.43E−06	3.86E−06	0.00E+00	0.00E+00	0.00E+00	2.50E−08	4.10E−08	0.00E+00	0.00E+00	0.00E+00
Pb	3.07E−04	2.76E−04	4.60E−05	2.55E−04	5.27E−05	3.16E−06	2.93E−06	3.72E−07	2.70E−06	5.41E−07
Ur	0.00E+00	0.00E+00	1.10E−05	8.46E−06	6.80E−06	0.00E+00	0.00E+00	8.90E−08	8.96E−08	6.98E−08
Sum of species	1.64E−01	9.01E−01	6.13E−01	1.27E+00	1.03E+00	1.69E−03	9.57E−03	4.95E−03	1.35E−02	1.06E−02

Figure 3 Process variations of stack temperature (°C), carbon monoxide (CO) concentration (ppm), and total hydrocarbon concentration (THC) (ppm), measured in: (a) Run 3, (b) Run 4, (c) Run 5, and (d) Run 6. (Note that peak stack temperature [°C] in Runs 5 and 6 during shakeout period exceeds 300°C; in Runs 3 and 4 it is ∼ 200°C.)

Figure 4 Process variations of PM_2.5 concentration (4 μg/m³) and number concentrations (particles/cc) measured by ELPI for: (a) Run 3, (b) Run 4, (c) Run 5, and (d) Run 6. (Note that PM_2.5 mass concentrations in Runs 5 and 6 are approximately twice those of Runs 3 and 4, whereas PM_2.5 number concentrations are similar.)

TABLE 4 Average PM_2.5 mass fraction determined by Electrical Low-Pressure Impactor (ELPI)

	PM size range (μm)
Dilution sampling Run	< 0.03	0.03–0.056	0.056–0.1	0.1–0.22	0.22–0.32	0.32–0.59	0.59–0.91	0.91–1.6	1.6–2.5
Run 3	0.0%	0.0%	0.1%	1.0%	7.9%	21.0%	28.7%	22.2%	19.3%
Run 4	0.0%	0.0%	0.2%	1.7%	9.2%	24.8%	24.8%	19.9%	19.6%
Run 5	0.0%	0.0%	0.0%	0.5%	4.9%	15.9%	26.0%	26.3%	26.3%
Run 6	0.0%	0.0%	0.1%	1.1%	7.5%	21.5%	24.0%	22.2%	23.6%

Figure 5 Distribution of calculated in-stack particle mass concentrations (mg/cm³/μm) for: (a) Run 3, (b) Run 4, (c) Run 5, and (d) Run 6.

Figure 6 Distribution of calculated in-stack particle number concentrations (particles/cc/m) for: (a) Run 3, (b) Run 4, (c) Run 5, and (d) Run 6.