Waste Management in Foundries: The Reuse of Spent Foundry Sand in Compost Production—State of the Art and a Feasibility Study

Abstract

The management of spent foundry sand (SFS) presents environmental and operational challenges for foundries. According to the European Union, European foundries generate approximately 9 million tonnes of SFS annually, mainly from the production of ferrous castings (iron and steel). Nowadays, around 25% of the spent foundry sand in Europe is recycled for specific applications, primarily in the cement industry. However, the presence of chemical residues limits the application of this solution. A possible alternative for reusing the spent foundry sand is its employment as a raw material in the production of compost. Studies in the literature indicate that the amount of chemical residue present in the sand can be reduced through the composting process, making the final product suitable for different purposes. However, information about the implementation of this technology in industrial contexts is lacking. To address this issue, this paper proposes a techno-economic analysis to assess the feasibility of composting SFS on a large scale, using information gathered during the testing phase of the Green Foundry LIFE project. This project explored the reuse of sand from organic and inorganic binder processes to create compost for construction purposes, which allowed for the final product. Since the new BREF (Best Available Techniques Reference Document) introduced by the European Union at the start of 2025 recommends composting SFS as a way to reduce solid waste from foundries, this initial study can represent practical guidance for both researchers and companies evaluating the adoption of this technology.