Figure 1: Sand Flows in the Queensland Foundry Industry

	The Queensland Foundry Industry
N ew Sand Purchased 48,700 tpa		S pent Sand 46,400 tpa
	Sand Lost (< 5% baghouse dust & general loss) 2,300 tpa	L andfill 85% B eneficial Reuse 15%

As depicted in Figure above, the average rate of internal sand reclamation for the Queensland foundry industry as a whole is currently 36%. Based on stated plans by several Queensland foundries, the industry average could potentially increase to 50% within the next two years.

Moving beyond 50% recovery will be relatively difficult. A further 5% may be gained if companies improve the efficiency of the current systems. Further gains will probably only be possible through the greater use of thermal reclamation, by improving moulding techniques to reduce the sand input, by changing to different casting processes or by identifying cost effective methods for sand reclamation at small foundries.

While significant work has already been undertake, most Queensland foundries recognise that there are many opportunities for continuous improvement in terms of by-product minimisation and for improving resource efficiency. Key areas identified by the sector include improved sand reclamation, metal yields, energy efficiency and the beneficial reuse of by-products. All of these opportunities are discussed in further detail in this report.

4.	Make the word combinations by matching the words in columns:

environmental	disposal
solid	management
spent	clean
landfill	metals
noise and	origin
relatively	issues
foundry	wastes
heavy	strategy
beneficial	sand
organic	odour
by-product	reuse
‘end-of-pipe’	processes

5.	Fill each gap with an appropriate word from the list below:

a) non-secured, b) relatively, c) ferrous, d) human, e) heavy, f) solid,

g) costs, h) thermal, i) stated, j) efficiency, k) dust, l) by-product

generated from ___ foundries	large quantities of ___ by-products
waste and ___ streams	sent to ___ landfill
biodegrade ___ quickly	energy ___ programs
increasing ___ of landfill disposal	use of ___ reclamation
baghouse ___ and slag	hazardous to ___ health
the presence of ___ metals	based on ___ plans

6.	Decide whether the following statements are true or false:

1. Wastes generated from ferrous foundries are relatively benign.

2. Most chemical additives used for sand binding can rather easily be decomposed.

3. Waste sand from ferrous foundries is usually sent to secured landfill.

4. The presence of heavy metals in the non-ferrous foundry sands is the reason for their sending to secured landfill.

5. Bag-house dust from ferrous foundries is dark and heavy so it is very harmful for health.

6. Changing energy sources means using bagasse instead of grid power, natural gas instead of propane, electricity instead of diesel.

7.	Match the following English phrases with their Ukrainian equivalents:

considerable efforts	значні зусилля
to minimise the impacts	зменшувати вплив
to monitor emissions	контролювати викиди
generated by the foundry industry	ливарне виробництво
on site waste disposal	ліквідація відходів на місці
relatively benign	відносно безпечний
chemical additives	хімічні добавки
leaching procedure	процес вилуговування
bag-house dust	пил з пиловловлювальної камери
occupational health	гігієна праці
secured landfill	ізольоване захоронення відходів
on-site recovery	локальне відновлення

8.	Translate the following sentences into Ukrainian:

1. The major waste streams of ferrous foundries are sand, bag-house dust and slag.

2. The ferrous foundries hope to achieve 100% reuse for their major waste streams in the nearest future.

3. The volume of material going to landfill is planned to be reduced by 25,000 tonnes per year.

4. Reuse of wastes can reduce the cost of purchasing materials as well as reducing the cost of unnecessary processing, handling and disposal costs.

5. Major foundries seek to minimise waste and maximise resource efficiency.

6. A number of foundries are in the process of installing manual sand reclamation systems or optimising the systems to increase recovery rates.

7. One of the Queensland foundries, using a shell casting process, has recently commenced thermal sand reclamation to recover 100% of its waste sand.

8. There are many opportunities for continuous improvement in terms of by-product minimisation and for improving resource efficiency.

9.	Find antonyms to the following words in the text above:

active		big
inorganic		passive
light		exclude
heavy		maximization
decreasing		short
enlarge		low

10.	Match the participle adjectives on the left with a suitable noun on the right. Use each word only once. Translate the collocations into Ukrainian.

stated	systems
diverted	foundries
presented	methods
disposed	goals
generated	options
improved	rates
increased	costs
installed	sand
located	opportunities
reduced	wastes
limited	material
discussed	ideas

11.	You have found out from the text above that foundries have actively sought to minimise waste and maximise resource efficiency in a number of areas throughout the foundry. Write a short research essay (150-180 words): Energy efficiency programs in metallurgy.

12.	Explain the meaning of phrases below:

1. ‘End-of-pipe’ strategy;

2. On-site sand reclamation;

3. Changing energy sources.

13.	Answer the following questions:

1. What are the impacts of foundry industry on the environment?

2. How can waste materials be disposed?

3. Where is spent foundry sand generated in Queensland disposed?

4. Is it possible to achieve 100% beneficial reuse for the major waste streams?

5. Can you give some examples of waste minimization?

14.

Suppose you are taking part in the international seminar on the ecological problems. Make up a short report on the by-products and wastes generated at the metallurgical works. The following information should be included: general comments on the by-products and wastes generated in metallurgy; characteristics of the by-products and wastes from the point of view of their quantities; relatively benign by-products and wastes; the most dangerous by-products that must be sent to secured landfill.

UNIT 2

CLEANER PRODUCTION

1.	Arrange the following words in three columns according to their meaning:

shot-blast dust, steel, ladle lining, rolls, iron ore, bag-house dust, raw materials, non-ferrous alloys, solid metal charge, steel sheets, spent green sand, used pots, iron and steel scrap, steel bars, flux, fuel, dross, high-strength irons, large-section billets, chips, air emissions.