Dust produced by foundries must be controlled to protect workers and the environment. We discuss the problem and Enviro Technology’s monitoring solutions.
Producing cast metal objects has been described as one of the greatest dust-producing activities. Both environmental and health and safety laws apply to foundry dust, with dust monitoring often needed. Here, we’ve put together a quick guide to dust regulations and monitoring solutions for foundries.
Where is dust produced in foundries?
There are multiple sources of dust in foundries:
- Melting processes – The high-temperature furnaces where metals are melted emit particulate matter (dust of a specific size), often containing metal compounds, as well as gases.
- Creation of cores and moulds – Where sand is used to create cores and moulds as part of the casting process, dust will include particles of sand, possibly containing harmful crystalline silica.
- Metal finishing – Metal finishing processes such as shot blasting, grinding, or polishing produce metallic dust.
- Raw material handling – Transportation and mixing of sand and metal charge releases dust. Dust is also produced when used sand is processed.
Some of this dust – typically from the melting processes – is released from the facility. As foundries are covered by the Environmental Permitting (England and Wales) Regulations 2016, their emissions to air are regulated. It is therefore standard practice for foundries to have filtration systems in place to control their dust emissions. Other types of dust are more likely to be found in the ambient workplace, where they pose serious risks to worker health.
Foundry dust emissions to air
Impacts: Once in the environment, foundry dusts can pollute soils and water, which will have knock-on effects on ecosystems. For example, when nematode worms were introduced to soil and dust samples collected from the area around an Italian steel foundry, significant mortality was observed, with the researchers concluding that the samples were “very highly toxic”. Dust pollution may also become a concern for local residents.
Regulation: As mentioned, foundries are regulated facilities, requiring environmental permits under the Environmental Permitting (England and Wales) Regulations 2016 to operate. Emissions to air are regulated and, once issued, the permit will specify conditions that must be met. These might include installation of filtration systems, emissions limits, and emissions monitoring.
Monitoring solution: The Sintrol S200 range is ideal for monitoring foundry dust emissions to air. Placed in ducts and stacks, the Sintrol S201 Dust Guard notifies of possible equipment faults (e.g., bag filter leaks) or deterioration, while the Sintrol S203 Trend Monitor enables continuous dust monitoring, allowing foundry managers to demonstrate compliance with their environmental permit.
Get in touch with Enviro Technology’s Paul Keeling to find out more about our Sintrol products.
If you want support with an environmental permit, contact our Environmental Management team.
Ambient dust in the foundry
Impacts: Foundry sand often contains respirable crystalline silica, a fine form of mineral that can be drawn deep into lungs and cause silicosis, cancer, and chronic obstructive pulmonary disease (COPD). Its estimated that thousands of deaths each year are linked to occupational exposure to silica. Metal dust can also damage the respiratory system, and is an explosion hazard, too.
Regulation: The 2002 Control of Substances Hazardous to Health (COSHH) Regulations stipulate how hazardous substances – including dusts – should be managed in the workplace. COSHH compliance involves a process of risk assessment, exposure prevention and/or control. Workplace air monitoring may also be necessary. This is often guided by Workplace Exposure Limits (WELs), which are concentrations of hazardous substances in air that cannot be safely or legally exceeded. WELs for ferrous foundry dust exist (ferrous metallurgy represents 90% of global metal production).
The UK Health and Safety Executive (HSE) enforce the COSHH Regulations and define WELs. They also have a set of information sheets specifically for foundries.
Cura Terrae’s team of occupational hygiene professionals can assist you with COSHH compliance.
Monitoring solution: The Sintrol DUMO Ambient Air Dust Monitor is our foremost solution for monitoring harmful ambient dust in the workplace. The DUMO’s robust design makes it the ideal choice for harsh foundry environments, and continuous monitoring paired with dust event alarms ensure workers are protected and health and safety requirements are met.
Get in touch with Enviro Technology’s Paul Keeling to find out more about dust monitoring in the workplace.
Our new data management solution: the Dust Cloud
In collaboration with PSI Technologies, Enviro Technology has developed a new solution for managing dust data, making checking equipment, protecting workers, and demonstrating compliance even easier. Unlike simple display units, the Dust Cloud features an integrated processor and data cloud upload, allowing users to remotely view, collate, and visualise their data. Alarm notifications also provide early warning of increases in dust levels.
To learn more about our exciting new product, get in touch with Paul Keeling.
Read more: We discuss certifications in dust monitoring in this blog.
