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MCTS Colloquium 2011 27 October 2011, Johannesburg Adrie El Mohamadi Project Leader

MCTS Colloquium 2011 27 October 2011, Johannesburg Adrie El Mohamadi Project Leader. “A collective approach towards green foundries in South Africa” Moving towards green foundries in South Africa. Foundry waste sand NOT W ASTE NOT USED RATHER Spent foundry sand.

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MCTS Colloquium 2011 27 October 2011, Johannesburg Adrie El Mohamadi Project Leader

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  1. MCTS Colloquium 2011 27 October 2011, Johannesburg Adrie El Mohamadi Project Leader “A collective approach towards green foundries in South Africa” Moving towards green foundries in South Africa

  2. Foundry waste sand NOT WASTE NOT USED RATHER Spent foundry sand 1. Setting the context

  3. Colloquium 2009: • Major joint problem raised by companies was the irregular manner in which foundry spent sand is regulated in SA - • Exorbitantcosts to dispose of spent foundry sand • No facility to assist with process • Industry not willing to uniteto deal with the problem

  4. Waste management in South Africa is regulated under the National Environmental Management: Waste Act 2008. The Waste Act is supported by the National Waste Classification and Management Regulations, the Standard for Assessment of Waste for Landfill Disposal, and the National Standard for the Disposal of Waste to Landfill, These are all currently in draft form. Regulatory context

  5. Regulatory context - continued Current bottleneck is that foundry sand is classified as hazardous waste according to the Minimum Requirements for the Handling, Classification and Disposal of Hazardous Waste “Minimum Requirements”

  6. South Africa is applying the leaching test: Toxicity Characteristic Leaching Procedure (TCLP), however the problem is that other than the international standards SA included elements Al, Fe and Mn to the list • These macro elements would leach from inorganic materials under the acidic conditions of the TCLP test.  • On this basis, many materials are classified incorrectly as hazardous • Even virgin garden soil was demonstrated to be hazardous in a test case submitted by concerned academics • These elements are highly abundant in natural soils and are very important since they produce oxides. • Only under extremely low pH conditions do they present a phytotoxicity issue • In the US comparisons are made between foundry sand and soils.

  7. Cost to foundries • In the United Kingdom foundry waste sand, qualifies under the lower rate tax, which is £2.50 =$4.10 per tonne (FTJ, 2011) • In South Africa general waste disposal is about R250=$34.00 per tonne • Problem is not only the cost but the inconsistency of applying this regulation

  8. February 2011; a Foundry Waste management working group was initiated • April 2011; an external consultant was appointed to do tests on 4 green sand foundries spent sand • Chemical Analysis • Interpretation of the analysis • Documents for submission at Department of Environment • Sept 2011; received results of the above, stating that • “Overall, spent foundry • sand should be regarded as inert, rather than low-risk waste” 2. Taking action

  9. Give feedback to 4 foundries; on the results of their sand • Next few weeks; set up a meeting with Department of Environment • Influence regulation; engage America and Germany in this • Start working on alternative uses of spent foundry sand 3. Way forward

  10. German Recycling of spentsands, dust and slags in • Road construction • Cement production • Landfill liner • Backfilling

  11. Recycling of spent sands, dust and slags • Recycling of used sands and slags Road construction, (limit values in Germany)

  12. Recycling of spent sands, dust and slags • Recycling of used sands and quartz dust Cement production, (limit values of the cement industry)

  13. Recycling of spent sands, dust and slags • Landfill: road construction, landfill liner, (limit values in Germany)

  14. Recycling of spent sands,dust and slags • Recycling of dust and used sands Backfilling in mines, (Limit values (not regarding salt mines) in Germany)

  15. 3. Summary • These has been progress since 2009 • Bottleneck – legislation • Draw on international experience • Develop a reliable publicly owned testing facility • Start working on alternative uses for spent foundry sand • Government, Academia, Industry and Research to joint hands

  16. Adrie El MohamadiProject LeaderNFTN012 841 2127082 902 4083adrie.elmohamadi@nftn.co.zawww.nftn.co.za

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