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Clean , Green and Zero waste discharge
31/01/2014
N.Visvanathan
Managing Partner & CEO
Ammarun Foundries
Coimbatore.
(a) Clean Foundry:

(i) Handling of Raw materials and
Consumables:
Cast iron borings and New silica sand are unloaded by
using electrical unloader.
Ammarun Foundries #2
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Unloading cast iron borings.
1.Unloading cast iron borings.
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Cast iron boring is Unloaded by electrical unloader.
Cast iron boring is Unloaded by electrical unloader.
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(i)Handling of Raw materials and

Consumables:
New silica sand is unloaded by electric unloader.

Consumables:
New silica sand is unloaded by electric unloader.
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Unloading Bentonite & pitch powder in gunny bags.
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Consumables:
If these materials are supplied in jumbo bags ,
handling is easier and pollution is avoided.
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(ii) Moulding Department

Shake outs Provide small dust collectors with good
hood design.
Return sand conveyor belts must be in trenches.
Bucket Elevator Weld the sheets completely
Provide inspection doors properly.
Top of the Bucket elevator seal properly.
(ii) Moulding Department:

Sieve Do not use vibratory sieve.
~Use polygonal Sieve.
~Provide doors properly.
~Use dust collector.
Do not carry sieved return sand in open conveyors.
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Use pipes from bucket elevator to storage hopper.
Use pipes from bucket elevator to storage hopper.
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Cover the storage hopper top properly and provide
breather.
Feed return sand to sand mixers in enclosed conveyor
or bucket elevator system.
Bentonite and pitch powder may be supplied to mixers
by Screw conveyors.
Breathers are used in sand mixers.
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Provide discharge doors properly.
In short , after shake out , dry return sand should
not be visible till converting into prepared sand.
(iii) Melting Department:

Cast iron borings shall be conveyed from
godown to induction furnaces by conveyor belts.
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Provide wet scrubbers or dry filters with proper hoods.
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(iv) Fettling Department:

Floor is spoiled if knocked down castings are
transferred from shake out to fettling area by wheel
barrows.
Use metallic conveyors.
Discharge dust from dust collectors to closed bins by

using a rubber hose.
All must go for low cost mechanization or automation.
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Grinding machines use dust collectors.

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(v) Foundry Building:

Dust sticks to the galvulum or AC sheets if they are provided with slope .
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Foundry Building:
Provide all vertical louvers to avoid dust deposit on sheets.
Foundry Building:
Provide transparent sheets on roof for good day light.
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Foundry Building:
Operating expenditure of pollution control
equipments may be met by reducing rejection
of castings by 0.50%.
Provide transparent sheets in vertical louvers for good day light and
also to avoid dust deposit.
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Provide transparent sheets in vertical louvers for good day light and
also to avoid dust deposit.
(b) Green Foundry:
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Green Foundry:
More than 750 plants are planted.
Used water from hand wash area is filtered and
irrigated to fruit bearing trees and plants.
Many fruit bearing trees and plants are grown.
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Seasonal vegetable plants are also grown.
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Green Foundry:
Treated water from sewage treatment plant is
irrigated to other plants like teak etc.
All Indians may contribute for agricultural products.
All foundry men must contribute for agricultural
products by using used water.
Rain water harvesting system is provided.
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Rain water harvesting system is provided.
(c) Zero waste discharge foundry:

Nothing is waste in this world except the
word Waste.
Ones waste is raw material for somebody
else.
(Sand Reclamation Video).
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Washing type sodium silicate bonded sand reclamation.
Zero waste discharge foundry:

Foundry wastes like slag , used sand and
dust from shot blasting machine are used
for laying roads.
(Road Laying Video).
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Road Laying:
Making Floors.
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Making Floors.
Making paver blocks and fencing stones.
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Making paver blocks and fencing stones.
Making Paver Blocks
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Making Paver Blocks

Area of roads laid at Ammarun Foundries 300 m2.
Area of floors laid at Ammarun Foundries - 850m2.
Paver blocks are made and used.
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Conventional Flooring Concrete
Bottom concrete Cement : River Sand : 1 jelly = 1:5:10
Top Concrete Cement : River Sand : jelly = 1:1.5:3
Foundry Waste Flooring Concrete

Bottom concrete Cement :Black Sand + Dust from Shot Blasting
Machine:1 slag = 1:5:10
Top concrete cement :Black Sand: slag = 1:1.5:3
Foundry Waste Road Concrete

Bottom Concrete 3 thick cement : Black Sand + Dust from shot
blasting Machine : 1slag=1:5:10
Top concrete 6thick Cement : Black Sand + slag quartz : slag =
1:1.5:3

Conventional Paver Block
Cement : quary dust : jelly = 1:2:4
Foundry Waste paver Block and Brick
Cement : Black Sand + slag quartz : slag = 1:4:2
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Bricks are made and used for constructing walls.
Bricks are made and used for constructing walls.
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Planned to manufacture and sell bricks , paver
blocks and fencing stones etc.
I wish to collect all wastes from all foundries in
Coimbatore , make products and sell.
I request one from each foundry centre should
start converting foundry wastes into products and

sell.

Waste papers are sold to ITC industries ,
Coimbatore.
I request all the foundries in India must
take initiative and declare as..
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OURS IS A ZERO WASTE DISCHARGE FOUNDRY
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Clean , Green and Zero waste discharge

(a) Clean Foundry:

Clean , Green and Zero waste discharge

Unloading cast iron borings.

1.Unloading cast iron borings.

Clean , Green and Zero waste discharge

Cast iron boring is Unloaded by electrical unloader.

Cast iron boring is Unloaded by electrical unloader.

Clean , Green and Zero waste discharge

(i)Handling of Raw materials and

(i)Handling of Raw materials and

Clean , Green and Zero waste discharge

Unloading Bentonite & pitch powder in gunny bags.

Unloading Bentonite & pitch powder in gunny bags.

Ammarun Foundries #10

Clean , Green and Zero waste discharge

Unloading Bentonite & pitch powder in gunny bags.

Ammarun Foundries #11

Unloading Bentonite & pitch powder in gunny bags.

Ammarun Foundries #12

Clean , Green and Zero waste discharge

Unloading Bentonite & pitch powder in gunny bags.

Ammarun Foundries #13

(i)Handling of Raw materials and

Ammarun Foundries #14

Clean , Green and Zero waste discharge

(ii) Moulding Department

(ii) Moulding Department:

Ammarun Foundries #16

Clean , Green and Zero waste discharge

Use pipes from bucket elevator to storage hopper.

Ammarun Foundries #17

Use pipes from bucket elevator to storage hopper.

Ammarun Foundries #18

Clean , Green and Zero waste discharge

(ii) Moulding Department

Breathers are used in sand mixers.

Ammarun Foundries #20

Clean , Green and Zero waste discharge

(ii) Moulding Department

Ammarun Foundries #21

(iii) Melting Department:

Ammarun Foundries #22

Clean , Green and Zero waste discharge

(iii) Melting Department:

Ammarun Foundries #23

(iii) Melting Department:

Ammarun Foundries #24

Clean , Green and Zero waste discharge

(iii) Melting Department:

Ammarun Foundries #25

(iii) Melting Department:

Ammarun Foundries #26

Clean , Green and Zero waste discharge

(iv) Fettling Department:

Ammarun Foundries #27

(iv) Fettling Department:

Discharge dust from dust collectors to closed bins by

Ammarun Foundries #28

Clean , Green and Zero waste discharge

(iv) Fettling Department:

Ammarun Foundries #29

(iv) Fettling Department: