In-depth survey report: evaluation of and recommendations for control technology in gray-iron foundry shake-out at Eljer Plumbingware, shake-out number three, Salem, Ohio, report no. EPHB-245-11a.
Eljer Plumbingware, Inc. in Salem, Ohio is a gray iron foundry, which has a history of overexposures to silica and carbon monoxide. The most difficult operation from an exposure control point of view is the shake-out of bath tub castings, which occurs at shakeout number three since the 1970's, this operation has either been out of compliance or the workers have been in respirators, despite the cardiovascular demands of the job. This situation has continued despite the costly installation of the current ventilation system. Due to these past difficulties, a new design approach has been employed the supplementation of classical ventilation design techniques with a type of numerical modeling called computational fluid dynamics (CFD). With the modeling of various ventilation design options for shake-out number three, ideas can be tested quickly and economically. After more than fifty simulations using CFD and many conversations with representatives of the ventilation consulting company that was hired to design and install a new system, a ventilation expert and former NIOSH employee, and the Eljer plant engineer, promising results have emerged. A systematic process of combining elements of the existing system, the consulting firm's proposed design, and innovations from brainstorming sessions resulted in some informed design options.