American Journal of Applied Science and Technology
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VOLUME
Vol.05 Issue01 2025
PAGE NO.
23-25
10.37547/ajast/Volume05Issue01-06
Utilization of aspiration dust and fine waste in foundry
production
Bragina Vera
1
, Dzotova Sayyora
2
1
Associate professor, Tashkent State Technical University named after Islam Karimov, Tashkent, 100095, Uzbekistan;
2
Master student, Tashkent State Technical University named after Islam Karimov, Tashkent, 100095, Uzbekistan;
Received:
25 October 2024;
Accepted:
28 December 2024;
Published:
30 January 2025
Abstract:
Foundry production inevitably generates significant volumes of waste, such as aspiration dust, sludge,
and shavings. These materials present both environmental risks and economic potential due to their content of
valuable metals. This paper examines traditional methods of recycling these wastes, their limitations, and
innovative approaches utilizing rotary tilting furnaces (RTFs). The study includes research findings and practical
case studies that confirm the effectiveness of RTFs in processing complex wastes and integrating them into
production processes.
Keywords:
Aspiration dust, fine waste, rotary tilting furnaces, recycling, environmental sustainability.
Introduction:
Foundry production plays a vital role in
the metallurgical industry, providing materials and
components for machinery, construction, and other
sectors. However, it is inevitably accompanied by the
generation of wastes, such as aspiration dust, sludge,
and shavings. These wastes are produced during
grinding, drilling, and processing of metals. On one
hand, they pose significant environmental risks due to
toxic components. On the other hand, they contain
valuable metals, such as iron, zinc, and lead, making
them an important source of secondary raw materials.
Modern challenges, including stricter environmental
standards and rising raw material costs, demand the
implementation of efficient waste recycling methods.
Traditional approaches, such as briquetting or direct
use of fine waste in smelting furnaces, demonstrate
insufficient effectiveness due to high metal losses, low
energy efficiency, and significant slag generation [1-3].
In this context, rotary tilting furnaces (RTFs) offer an
innovative solution, providing higher energy efficiency,
reduced operational costs, and improved metal
recovery rates [4-6].
MATERIALS AND RESEARCHES
Issues with Traditional Recycling Methods
Briquetting is a process where fine waste materials are
compressed into compact forms for subsequent
smelting. Despite its popularity, this method has
significant limitations. It requires a considerable
amount of energy for drying and compressing fine
waste. The resulting briquettes are fragile and prone to
breakage during transportation and storage. Moreover,
impurities in the briquettes often degrade the quality
of the final product, reducing its commercial value [7].
Direct use of fine waste in smelting furnaces, though
seemingly straightforward, leads to significant metal
losses due to oxidation. Under these conditions, fine
waste particles quickly turn into slag, reducing overall
metal recovery. Additionally, the uneven heating of
fine materials results in defects in the final products,
making them less suitable for industrial applications
[8].
These methods, besides being energy-intensive, have a
significant environmental impact, making them less
attractive under modern sustainability requirements.
Innovative Approaches Using Rotary Tilting Furnaces
Rotary tilting furnaces (RTFs) represent a modern
technology that overcomes the limitations of
traditional methods. The main advantage of RTFs lies in
the creation of a dynamic layer where particles are
evenly heated, ensuring complete melting and
minimizing metal losses.
Another key feature of RTFs is their ability to create a
American Journal of Applied Science and Technology
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American Journal of Applied Science and Technology (ISSN: 2771-2745)
reducing atmosphere within the furnace. This prevents
further oxidation of metals and enhances the quality of
the final product. For example, during the processing of
oxidized waste at the Belarusian Metallurgical Plant,
the use of RTFs achieved an iron recovery rate of 90%,
which is significantly higher than that of traditional
methods [4].
RTFs also effectively handle waste containing oils and
other contaminants. The heat released during the
combustion of these substances is utilized to reduce
energy consumption, making the process more cost-
effective.
Method
Thermal
Efficiency (%)
Energy Consumption
(kWh/t)
Metal Losses
(%)
Fuel
Usage
(m³/t)
Traditional
Furnaces
25
1500
20
20
Rotary Tilting
Furnaces
55
800
5
8
Table 1. Comparison of Thermal Efficiency Between Rotary and Traditional Furnaces
The data presented in the table highlight the significant
advantages of rotary tilting furnaces over traditional
ones. The high thermal efficiency (55% versus 25%)
indicates more effective energy utilization in RTFs,
attributed to uniform heating of materials and
minimized heat loss. This is particularly critical for
enterprises aiming to reduce energy costs and their
carbon footprint.
RTFs exhibit nearly twice the energy efficiency of
traditional furnaces (800 kWh/t versus 1500 kWh/t).
This advantage stems from the ability to utilize heat
generated during the combustion of impurities and the
optimized heat transfer processes.
Metal losses in RTFs amount to only 5%, compared to
20% in traditional furnaces. This is due to the creation
of a reducing atmosphere, which prevents further
oxidation of metals. Specific fuel consumption is also
significantly lower (8 m³/t versus 20 m³/t), reducing
overall production costs.
However, it should be noted that implementing RTFs
requires substantial initial investments in equipment
and the adaptation of technological processes. Despite
this, long-term benefits, such as reduced operational
costs, minimized environmental risks, and improved
product quality, make these furnaces an economically
viable and environmentally sustainable solution for
recycling fine waste in foundry production.
CONCLUSION
Rotary tilting furnaces represent a promising solution
for recycling fine waste generated in foundry
production. They provide high metal recovery rates,
reduced energy consumption, and minimized
environmental risks. In the context of stricter
environmental regulations and rising raw material
costs, the adoption of RTFs becomes a critical element
of sustainable development in the metallurgical
industry.
These technologies not only address the challenges of
recycling complex wastes but also contribute to the
circular economy by ensuring the efficient use of
resources. By integrating RTFs, enterprises can achieve
significant economic and environmental benefits,
paving the way for a more sustainable future in
metallurgy.
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American Journal of Applied Science and Technology (ISSN: 2771-2745)
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