I built a foundry using the Charcoal Foundry book by David Gingery. Great book, it walks you through building the furnace, making the green sand, building the flasks, making all the tools you will need, and explains how to use all of it.
Here is a video of my foundry running on a charcoal and coal mix (trying to get the higher temps needed to melt brass):
https://youtu.be/J_IMRPQhM28
Yeah, huge clouds of smoke (breathing anthracite smoke really hurts), shooting sparks, having to get the fuel burning, having to load the messy fuel, having to empty the messy ashes, as the fuel burns and settles it can dump your crucible inside the furnace, etc... It can be a pain, but it is also very exciting!
But yeah, my next aluminum casting furnace will be propane or electric...