Framework for LCA Analysis of the Introduction of Inorganic Binders in Ferrous Foundries

European foundries are undergoing a significant environmental transition following the issuance of the new BREF (BAT Reference Document) for the sector, which came into effect in 2025. This document imposes stricter limits on atmospheric emissions, resource consumption, and waste production, encouraging the adoption of the Best Available Techniques (BAT). Among these, inorganic binders emerge as a promising solution to reduce harmful emissions in the foundry industry. However, despite their proven environmental benefits and increasing use in the production of non-ferrous metal castings, their application in ferrous foundries remains limited, mainly due to the economic and operational uncertainties perceived by companies. Additionally, there is still no strong consensus on the actual environmental benefits of implementing this new technological process. Various concerns have emerged, such as the potential increase in pollutants during core blowing or the challenges associated with the recovery of core sand after the casting has been removed from the mold. This study arises from the gap in available information, both in scientific literature and in industrial know-how, by proposing a structured framework for Life Cycle Assessment (LCA) applied to the introduction of inorganic binders in ferrous foundries. Based on ISO 14040 guidelines and the ILCD framework recommendations, the developed model enables the assessment of environmental impact throughout the entire production cycle, considering raw materials, the core blowing process, energy consumption, emissions, and the management of recovered materials. Moreover, the framework integrates a comparative analysis between conventional and innovative production processes, supported by literature data and insights from industry experts. The proposed approach aims to provide companies with a quantitative tool to support strategic decision-making and enhance the sustainability of their operations. The expected results will contribute to bridging the existing knowledge gap on the adoption of inorganic binders in ferrous foundries, facilitating the transition towards lower environmental impact solutions.