The Treatment of Iron-Containing Foundry Dusts with the Aim of Their Recycling and Their Effect on the Properties of Cast Iron

The foundry industry is an industry with a large production of waste. One such type of waste is fine-grained to dust-like waste, depending on the stage of the foundry process in which it is generated. As part of this research, dust samples were collected from three Slovak foundries producing castings from gray iron, ductile iron, and steel. The aim of the experiments was to recycle iron from dust materials in the foundry process. Based on the chemical composition of the dust, samples with the highest iron content were selected and added to the charge of the electric induction furnace (EIF). Since it was not possible to add dust material directly into the EIF, the dust was modified by pelletizing and briquetting using three types of binders selected according to the foundries’ requirements. Pellets were prepared using dust from only one type of foundry waste and were used as part of the charge in the EIF. In the case of briquetting, different binder contents in the briquette mixture were tested to evaluate their effect on the strength and disintegration of the briquettes. Based on the foundries’ requirements that the binder had to be low-cost and that we had to not contaminate the melt (thus requiring a minimal amount), not affect the furnace operation, and not degrade the properties of the produced cast iron, briquettes with the best properties were selected and used as part of the charge for cast iron production. Samples of the cast iron produced this way were taken for chemical analysis, and specimens were prepared for tensile strength testing. The results showed that the use of briquettes, in limited amounts, did not have a negative impact on the chemical composition of the cast iron, the melting process, or its tensile strength.