Foundry Sand: A Recipe for Beneficial Use Mike Lenahan, Resource Recovery Corp. Dan Oman, RMT, Inc. Midwest Industrial By-Products Beneficial Use Summit August 19-20, 2002 Chicago, IL Foundry Sand: A Recipe for Foundry Sand: A Recipe for Beneficial Use Beneficial Use Mike Lenahan, Resource Recovery Corp. Mike Lenahan, Resource Recovery Corp. Dan Oman, RMT, Inc. Dan Oman, RMT, Inc. Midwest Industrial By-Products Beneficial Use Summit Midwest Industrial By-Products Beneficial Use Summit August 19-20, 2002 Chicago, IL August 19-20, 2002 Chicago, IL
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Foundry Sand: A Recipe forBeneficial Use
Mike Lenahan, Resource Recovery Corp.Dan Oman, RMT, Inc.
Midwest Industrial By-Products Beneficial Use SummitAugust 19-20, 2002 Chicago, IL
Foundry Sand: A Recipe forFoundry Sand: A Recipe forBeneficial UseBeneficial Use
Mike Lenahan, Resource Recovery Corp.Mike Lenahan, Resource Recovery Corp.Dan Oman, RMT, Inc.Dan Oman, RMT, Inc.
Midwest Industrial By-Products Beneficial Use SummitMidwest Industrial By-Products Beneficial Use SummitAugust 19-20, 2002 Chicago, ILAugust 19-20, 2002 Chicago, IL
OutlineOutlineOutline! Profile of the Foundry Industry
! Foundry By-Products
! Opportunities for Beneficial Use
! Conclusions
Profile of the Foundry IndustryProfile of the Foundry IndustryProfile of the Foundry Industry! 2,800 Operating Foundries
– 1,000 Ferrous Foundries
– 1,800 Nonferrous Foundries
! Employ more than 220,000 people
! 80% are small operations (less than 100employees)
! $27 Billion in shipments in 2001
! Operating at 76% of capacitySource: AFS
Profile of the Foundry IndustryProfile of the Foundry IndustryProfile of the Foundry Industry! What is a metal casting?
– A casting is a metal part formed by pouring moltenmetal into a sand mold or metal die. The mold or dieis comprised of two halves that, when mated together,form a cavity into which the molten metal is poured.The mold or die form the external surface of thecasting. If an internal cavity is required in the casting,a core is placed inside the mold cavity.
After the metal solidifies, the mold is broken, the coresremoved and the part is readied for finishingoperations. The sand is then remolded and usedagain. Source: AFS
Profile of the Foundry IndustryProfile of the Foundry IndustryProfile of the Foundry IndustryFerrous Metals Non Ferrous MetalsCast Iron Cast Aluminum Gray Iron Cast Copper Alloy Ductile Iron Brass Malleable Iron Bronze Compacted Graphite Iron ZincCast Steel Magnesium Carbon & Low Alloy Titanium
Corrosion Resistant Nickel Heat Resistant Cobalt Manganese Tin
Source: AFS
Profile of the Foundry IndustryProfile of the Foundry IndustryProfile of the Foundry Industry
39%
30%
14%
9%5%
1%
2%
Gray Iron
Ductile Iron
Aluminum
SteelCopper
Malleable Iron
Other
Casting Shipment Mix for 2001
Source: AFS / Stratecast, Inc.
Profile of the Foundry IndustryProfile of the Foundry IndustryProfile of the Foundry Industry
15%
8%
11%
11%
6%
12%
6%
4%5%
3%
Top Ten Foundry States for 2001
Other States - 19%Source: AFS / Stratecast, Inc.
Profile of the Foundry IndustryProfile of the Foundry IndustryProfile of the Foundry Industry
33%
15%
6%6%
5%
5%
4%
3%
3%
3%
17%
Cars & Light Trucks
Pipe & Fittings
Construction / Mining / Oil FieldRailroad
Internal Combustion Engines
Valves
Farm Machinery
Special Industry Machinery
Municipal
Pumps & Compressors
Other
Major Casting End - Use Markets for 2001
Source: AFS / Stratecast, Inc.
Profile of the Foundry IndustryProfile of the Foundry IndustryProfile of the Foundry Industry! 1980’s
– Recession, Increased Regulation, etc.
– 1,000 foundries close (3,000 plant level)
! 1990’s– Strong Economy, Growth in Automotive Industry