Foundry Dust - Alternative Additive for Green Sand Mixtures

Authors

  • Š. Kielar VSB - Technical University of Ostrava, Czech Republic
  • M. Weider TU Bergakademie Freiberg, Foundry Institute, Germany
  • M. Szucki TU Bergakademie Freiberg, Foundry Institute, Germany
  • M. Bašistová VSB - Technical University of Ostrava, Czech Republic
  • M. Bašistová VSB - Technical University of Ostrava, Czech Republic https://orcid.org/0000-0002-8518-275X
  • P. Lichy VSB - Technical University of Ostrava, Czech Republic

DOI:

https://doi.org/10.24425/afe.2026.157992

Abstract

Foundry dust is a significant component of the waste produced by the foundry industry worldwide. This waste is generated during mould making, melting, casting and discharging of moulds, where dust particles are released and subsequently captured by filters. Like most foundry waste, foundry dust usually ends up in landfills. However, this method of waste management faces problems related to environmental and economic requirements, especially in view of tightening legislation. It is important to point out that foundry dust contains components that could be reused in the production of foundry mixtures. The aim of this study is to evaluate the possible positive and negative effects of two foundry dust samples on the quality of the green sand mixtures. Basic analyses include the chemical composition of the leachate in aqueous solution and the granulometric composition of the dust particles. Furthermore, the properties of other ingredients for the preparation of green sand mixtures will be characterized. The study serves as a starting point for future research in the reuse of foundry dust in green sand mixtures, thus contributing to the sustainability of industrial processes.

References

[1] Sabour, M.R., Derhamjani, G., Akbari, M. & Hatami, A.M. (2021). Global trends and status in waste foundry sand management research during the years 1971-2020: a systematic analysis. Environmental Science and Pollution Research. 28(28), 37312-37321. https://doi.org/10.1007/s11356-021-13251-8. DOI: https://doi.org/10.1007/s11356-021-13251-8

[2] European Foundry Federation. (2024). The European foundry industry at a glance. Retrieved October 15, 2025, from https://eff-eu.org/statistics/

[3] EnviroAir. (n.d.). Foundry sand and waste foundry sand (WFS) management solutions. Retrieved July 21, 2025, from https://www.enviroair.net/foundry-sand-and-waste-foundry-sand-wfs-management-solutions/

[4] Ahmad, J., Zhou, Z., Martínez-García, R., Vatin, N.I., de-Prado-Gil, J. & El-Shorbagy, M.A. (2022). Waste foundry sand in concrete production instead of natural river sand: A review. Materials. 15(7), 2365, 1-20. https://doi.org/10.3390/ma15072365. DOI: https://doi.org/10.3390/ma15072365

[5] European Commission. (2020). Circular economy action plan. Retrieved July 21, 2025 from https://environment.ec.europa.eu/strategy/circular-economy-action-plan

[6] European Parliament & Council. (2018). Directive (EU) 2018/850 of 30 May 2018 amending Directive 1999/31/EC on the landfill of waste. Official Journal of the European Union. Retrieved July 21, 2025 from https://data.europa.eu/eli/dir/2018/850/oj/eng

[7] Bhardwaj, B. & Kumar, P. (2017). Waste foundry sand in concrete: A review. Construction and Building Materials, 156, 661-674. https://doi.org/10.1016/j.conbuildmat.2017.09.010. DOI: https://doi.org/10.1016/j.conbuildmat.2017.09.010

[8] Aguiar, I., Cunha, S. & Aguiar, J. (2024). Application of foundry wastes in eco-efficient construction materials: a review. Applied Sciences. 15(1), 10, 1-35. https://doi.org/10.3390/app15010010. DOI: https://doi.org/10.3390/app15010010

[9] Dyer, P.P. & de Lima, M.G. (2022). Waste foundry sand in hot mix asphalt: A review. Construction and Building Materials. 359, 129342, 1-25. https://doi.org/10.1016/j.conbuildmat.2022.129342. DOI: https://doi.org/10.1016/j.conbuildmat.2022.129342

[10] Sgarlata, C., Ariza-Tarazona, M. C., Paradisi, E., Siligardi, C., & Lancellotti, I. (2023). Use of foundry sands in the production of ceramic and geopolymers for sustainable construction materials. Applied Sciences. 13(8), 5166, 1-12. https://doi.org/10.3390/app13085166. DOI: https://doi.org/10.3390/app13085166

[11] Hunger, L., Durjagina, A., Pentz, G., Krampitz, T., Weider, M., Lieberwirth, H., Szucki, M. & Wolf, G. (2025), Untersuchungen zur Aufbereitung von gießerei-altsand-regenerierstäuben mittels abweiseradsichter. Chemie Ingenieur Technik. 97, 964-973. (in German). DOI: https://doi.org/10.1002/cite.70028

[12] Fedorko, P., Pribulova, A., Futas, P., Pokusova, M., Petrik, J., Blasko, P., Brzeziński, M. & Łucarz, M. (2025). The treatment of iron-containing foundry dusts with the aim of their recycling and their effect on the properties of cast iron. Metals. 15(2), 214, 1-23. https://doi.org/10.3390/met15020214. DOI: https://doi.org/10.3390/met15020214

[13] Gong, X., Hu, S., Liu, X., Yang, M., Jiang, W. & Fan, Z. (2023). Flotation separation of coal dust from foundry dust enhanced by pre-soaking assisted mechanical stirring. Journal of Environmental Management. 339, 117899, 1-9. https://doi.org/10.1016/j.jenvman.2023.117899. DOI: https://doi.org/10.1016/j.jenvman.2023.117899

[14] Pribulová, A., Futaš, P., Rosová, A., Demeter, P. & Baricová, D. (2013). Influence of foundry dust on moulding mixtures quality. Metalurgija. 52(1), 51-54.

[15] Holtzer, M. & Bobrowski, A. (2010). Assessment of harmfulness of green sand with additions of dust from dry dedusting. Archives of Foundry Engineering. 10(3), 193-198. ISSN (1897-3310).

[16] Bobrowski, A., Grabowska, B., Żymankowska-Kumon, S. & Kurleto-Kozioł, Ż. (2016). Physico-chemical and environmental characterisation of the dust from dry dedusting of the green sand. Archives of Foundry Engineering. 16(4), 33-36. DOI: 10.1515/afe-2016-0079. DOI: https://doi.org/10.1515/afe-2016-0079

[17] Kemppainen, J., Gallegos, I., Krieg, A. S., Gissinger, J. R., Wise, K. E., Kowalik, M., King, J.A., Gowtham, S., van Duin, A. & Odegard, G. M. (2023). Evolution of glassy carbon derived from pyrolysis of furan resin. ACS Applied Engineering Materials. 1(10), 2555-2566. https://doi.org/10.1021/acsaenm.3c00360. DOI: https://doi.org/10.1021/acsaenm.3c00360

[18] Anca, D., Chisamera, M., Stan, S., Stan, I. & Riposan, I. (2020). Sulfur and oxygen effects on high-Si ductile iron casting skin formation. Coatings. 10(7), 618, 1-15. https://doi.org/10.3390/coatings10070618. DOI: https://doi.org/10.3390/coatings10070618

[19] Ministry of the Environment, Czech Republic. (2021). Decree No. 273/2021 Coll., on details of waste management. Retrieved October 10, 225, from https://www.e-sbirka.cz/sb/2021/273?zalozka=text#ppc_2

[20] European Parliament & Council of the European Union. (2008). Directive 2008/98/EC of the European Parliament and of the Council of 19 November 2008 on waste and repealing certain Directives. Official Journal of the European Union, L 312, 3–30.

[21] Ji, S., Wan, L. & Fan, Z. (2001). The toxic compounds and leaching characteristics of spent foundry sands. Water, Air, and Soil Pollution. 132(3), 347-364. https://doi.org/10.1023/A:1013207000046. DOI: https://doi.org/10.1023/A:1013207000046

Downloads

Published

2026-07-13

How to Cite

Kielar, Š., et al. “Foundry Dust - Alternative Additive for Green Sand Mixtures”. Archives of Foundry Engineering, vol. 26, no. 2, July 2026, pp. 83-89, doi:10.24425/afe.2026.157992.

Issue

Section

Articles

Similar Articles

1 2 > >> 

You may also start an advanced similarity search for this article.