Life Cycle Analysis of Conventional Manufacturing Techniques: Sand Casting

Abstract

Conventional manufacturing techniques have not been subject to much scrutiny by industrial ecologists to date. Many newer techniques and products draw more attention as they rise quickly from research to global scales, amplifying their environmental consequences. Despite the presence of new technologies and increased overseas production, casting activity continues to have a strong presence in the US, and represents a stable component in the national economy. Data from the US government, US industry groups, and UK mass balance profiles facilitate an understanding of sand casting and comparison across manufacturing processes. The figures in the US and UK are similar in terms of diversity of metals (where the US is 72%, 13%, 10% and the UK 76%, 13%, 8% for iron, aluminum, and steel, respectively), energy per ton of saleable cast metal (10.1 and 9.3 million Btu/ton in the US and UK), and overall emissions, with notable similarities in benzene and particulate emissions. One notable discrepancy is in sand use, where the US sends to waste 0.5 tons of sand per ton of cast metal, whereas the UK sends 0.25 tons to landfill.