Event Background

The foundry industry is interested in developing applications that would allow the re-use of spent foundry sand and spent investment casting shell material. The latter in particular is generally inert and has good properties for use in construction for instance. Many foundries do reclaim sand for re-use but this is not possible in all cases. Sand and shell still go to landfill,adding cost to the foundry and traffic on the roads.

Changes in technology mean that it has become easier and more economically viable to recover and re-use foundry sand within the foundry process but there are still foundries who are not able to recover their sand for a variety of technical, economic and logistical reasons and there is still waste sand generated from the process that goes to landfill. Likewise spent shell, typically alumina, fused silica and zircon, is not typically reused.

This workshop, organised by BEIS, Innovate UK, Cast Metals Federation and KTN, will engage with a cross-sector, multi-disciplinary group representing the materials (including ceramics, glass, cement, geopolymers), manufacturing, infrastructure, art & craft and design communities.

At the workshop, the group will explore innovative concepts for the greater re-use of foundry casting sand and spent investment-casting shell for applications and processes currently not served by the foundries. The following opportunities will be explored:

The development of applications for re-use of spent foundry sand and spent investment casting shell material, for example in large infrastructure projects, for art & craft objects, as secondary raw materials for additive manufacturing, etc.
Increasing resource and energy efficiency and reducing the use of raw materials within the foundry industry (improving environmental impact)
Reducing the volume of waste sent to landfill (improving environmental impact)
Reducing costs for the UK foundry industry (through process efficiency andincreased reuse of sand/shell)

Input is sought from:

Industrialists (technical, environmental, business development and strategy) from micro to multinational businesses with an interest in innovation
Foundries and suppliers of materials and equipment to the foundry and casting industry who have an interest in increasing resource efficiency
Academics and research professionals in Universities, Institutes, RTOs etc. with an interest in research and innovation applicable to circular economy and product and process development
Key local innovation ecosystem players such as LEPs, particularly in areas where foundries are located.
Regulatory bodies such as Environment Agency, WRAP
Other Government Departments, Agencies and organisations: Defra, Highways Agency, Mineral Products Association, Construction Product Association, SAMSA (plus projects such as HS2, Crossrail)

Link to Clean Growth Strategy: an increase in re-use and reclamation levels would help the UK meet its objectives within the clean growth strategy by contributing to the circular economy and increasing resource efficiency. The project will contribute towards transforming one of the UK’s foundation industries.

Programme

9.30: Arrival / Refreshments / Networking

10.30: Welcome & Introductions

10.35: Setting the Scene:-

• Keynote address: Circular economy/Resource efficiency in the UK (BEIS/UKRI)

• Re-use and reclamation in the UK Foundry industry - the size of the opportunity (CMF)

An overview of greensand and chemically bonded sand use and re-use (CMF)
Investment casting ceramic shell materials – what they are and what happens now (CMF)
Q&A

11.30: Coffee break / networking

11.50: Group A discussion – Identifying the opportunities and limitations for re-use of sand

12.30: Group B discussion – Identifying the opportunities for re-use of investment casting shell ceramics

13.10: Lunch and networking

14.00: Group A Feedback – identified opportunities and limitations for increasing sand re-use

14.15: Group B feedback - identified opportunities and limitations for increasing shell re-use

14.30: Group discussions (A & B) – Addressing the opportunities and threats for sand and for shell

15.00: Group feedback

15.15: Coffee break / networking

15.45: Summary and next steps

16.30: Close

Re-use of Foundry Sand and Spent Investment Casting Shell Innovation Workshop