examining sand reclamation technology.

by:AIRWOLF     2020-06-15
By choosing the right sand recovery system for your operation, your foundry can reduce the cost of raw materials and increase profits.
Deciding to recycle your sand is only the first step.
When you focus on specific equipment for your operation, there are many different variable looms such as system type, size and capacity.
To make the decision-making process easier, modern casting provides detailed guidelines for the following various thermal and mechanical sand recovery systems.
In addition, the latest installation information is provided to prove the effectiveness of the system in operation.
An important fact to keep in mind is that the information provided is only one model of the device;
Additional models and system types may be provided by the manufacturer.
Also, the machine-
The manufacturer provided specific information through the investigation.
Dididion International, Inc. rotary block crusher/sand taking Machine
Riverside Industrial Center 7000 West Geneva Avenue
63376 Tel: 636/278-Peters, Missouri
8700 Fax: 636/278-
3155 Email: info @ dididion.
Website: www. didion.
Contact: Mike dididion.
System Type: mechanical.
Drum size: ranging from 4x16 feet to 6x30 feet. Capacity: 1-40 tons/hr.
Key attributes: jagged-
The tooth liner provides wear resistance while breaking down large sand blocks and separating the metal from the sand.
The automatic recycling of the block provides additional washing and a higher output percentage, while the overall sand screen and fine removal classify the sand with extremely low cubic feet/MM requirements.
In operation: the vibrating feeding conveyor sends large sand blocks into the refunding machine.
The high-profile flight will screw forward the block that enters the wear section of the double chamber and reduce it to less than 0. 375 in.
The metal of the Tramp is separated.
The sand then passes through the cone holes on the cast lining and enters the external chamber where screening and primary classification occur.
The remaining large pieces are automatically cycled into the feed conveyor in order to pass through the machine again.
The adhesive and fine are then transferred to the bag house, leaving only recycled sand.
Installation Information casting data: Betz Industries is a nobake formed gray iron foundry in Grand Rapids, Michigan.
It produces 12 tons of castings/hours for precision automotive molds, molds and machine tools for cars and heavy industries.
Case history: In 1984, Betz Industries purchased a rotary sand removal machine to start the nobake sand recovery and use it with a pneumatic washer.
After learning that sand can be recovered without a secondary scrubber, the company only uses a refunding machine, saving energy, operating and maintenance costs.
When the Betz industry expanded in 1999 (
Double the size of its foundry)
Two new sand removal machines have been installed to increase the output of recycled sand to 130 tons/hour.
The company now recycles 97% of the nobake sand and only handles 3% of the dust.
Recycling sand saved the company $4190. 40/ hr.
\"Proven performance and excellent savings are the reasons why we continue to use rotary recycling equipment.
Its design is effective (1 hp/ton)
\"And maintenance is almost unnecessary,\" R-
Mechanical recovery system series Palmer Manufacturing & Supply Co. , Ltd.
45504 Tel: 800/457-18 Baker\'s drive, Springfield, Ohio
5456 Fax: 937/323-
2709 Email: Sales @ palmermfg.
Website: www. palmermfg.
Contact: Jack Palmer or Lee White.
System Type: mechanical.
Floor area: 9x18 ft. Capacity: 1-10 tons/hr.
Key attributes: the system has Wear grinding with dust cover, feed lift, ironing board, surge Hopper, flow control valve, Grader and discharge level control.
Running: Top-
Double for loading wear Mill
A screen reunion reduction system consisting of two perforated steel plates.
The first is located at the bottom of the mill in the primary chamber, allowing only loose sand and small pieces to enter the secondary chamber.
The second screen is located at the discharge flange of the secondary chamber and the discharge chamber, allowing grain only-
The size of the sand to exit.
The feeding elevator transfers the recovered sand from the discharge of the worn-out mill to the top of the screening Hopper, in which it is high
The frequency pneumatic vibrator installed on the filter isolate the composite particles.
Then, the sand is fed into the classifier body through the flow control valve to adjust the sand flow into the classifier body, thus keeping the fine extraction efficiency unchanged.
After extracting fine sand, the recovered fine sand can be used.
Installation Information casting data: Midland manufacturing
Copper producer
Fort worth, Texas, purchased R-based Components-
January 2000 3 sets of refunding machine.
Case History: Thanks to the purchase of a complete nobake molding system in January 2000, Midland has converted many of its green sand work and tools into a nobake mold box.
The result of the mold is high sand-to-metal ratio.
Combining this fact with the alloy it injects, Midland faces a difficult process to minimize losseson-ignition (LOI)
Sand properties.
In the absence of additional process changes or equipment, Midland has control over LOI, which remains below 2% with minimal new sand addition.
Further trimming the amount of sand used for each mold, increasing the flow and dust collection of the classifier, and reducing the amount of adhesive used, all contribute to the consistent downhill of the LOI in Midland.
Midland is expected to get 1% LOI in the next six months with only mechanical recycling.
Reliable casting equipment for calcifiire heat recovery systemP. O.
Box 3210 12505W.
Tel: 97062 Hermann Road, tualating, Oregon-503/692-
Fax 5552: 503/692.
4477 mail: Sales @ dfrc
Website: www. dfrc.
Contact: Bill Zachary.
System Type: Hot.
Floor area: 7 feet 6. x 14 ft 7 in. Capacity: 0. 5-5 tons/hr.
Key attributes: direct-
The burning fuel bed room introduces sand from the top and provides a full-flow Walltowall.
It works in both chemistry. Bonding and claybonded sand.
In operation: when air and natural gas are introduced through the distributor tube, the adhesive material in the fluid bed chamber burns. Heat-
Refractory steel and ceramic fiber insulation eliminates the need for a refractory lining and allows for rapid peak temperatures.
In order to achieve the desired effect, it is easy to adjust the flow of sand flowing through the fluid bed, resulting in recycled sand available for use.
Installation Information casting data: Buddy bar casting company
South Gate, California is an aluminum foundry specializing in the production of high-performance after-sales automotive components including engine blocks and cylinder heads.
Case History: Buddy Bar recently installed an I ton/hr system.
The foundry heat recovered sand from the phenol polyurethane bonded nobake mold.
The recovered sand includes a certain percentage of the shell core.
Bill fall, President of buddy bar casting, said he expects to recover almost 100% of the waste sand from the mold and core processes and reduce sand treatment to a fraction of the current level.
In addition to saving on the purchase of new sand and reducing the cost of disposal, The Foundry also hopes to achieve thermal stability of sand grains to minimize or completely eliminate certain size defects that occur in new sandTF-
3000 Thermfire hot old sand regeneration system pivot Thermfire International Co. , Ltd.
Neptune 420 Crescent London N6M Lal, Ontario, Canada Tel: 519/451-
5320 Fax: 519/453-
8753, Email: brentg @ shaft head. on.
Ca website: www. gudgeon. on.
Contact: Brent Gooden
System Type: Hot.
Size: 13 ft 8 in.
X 8ft x 15ft Ridge. Capacity: 1. 5 tons/hr.
Key attributes: recycling is carried out entirely on one machine, and the working temperature of the sand can be reached from the cold start of 25mm.
The system has two sources of heat recovery that give it thermal efficiency and minimize the use of natural gas.
In operation: The sand enters the calcining chamber and is raised to a temperature of 136f (704C)
Indirect ignition methods that allow lower operating temperatures are used.
The temperature is controlled by the thermocouple, which provides the data to the PLC, which controls the electric valve in the gas supply line.
The direct spark ignition on the burner and the flame Rod detect the flame when burning the gas mixture.
The heat-recovered sand crosses the Weir from the calcining chamber into the sand conveying box, moving the sand to the cooling bed below.
Reduce the sand temperature to 8SF (29C)
Discharge when streaming air passes through it to dissipate heat.
Installation Information casting data: Arrow aluminum casting company
Lake Avon, Ohio uses nobake to form, Shell and cold box core cast aluminum parts.
Case History: Arrow wishes to have a sand filling system and has made the choice based on the advice of other foundry.
The sand produced by its recycling system reaches or exceeds the quality of the new sand.
Closing the cycle of buying and dumping sand also allows Arrow to purchase better quality sand, improving the whole molding process.
PXC compact hot sand recovery unit of Vulcan Engineering Co. , Ltd.
Helena industrial park P. O.
Helena, Alabama 307 mailbox 35080 Tel: 205/663-
0732 Fax: 205/663-
9103 mailbox: Sales @ vulcangroup
Website: www. vulcangroup.
Contact: Kevin Crawford
System Type: Hot.
Size: l 7 ft x 9 ft 3 in. x l7 ft 10 in. Capacity: 0. 25-1 ton/hr.
Key properties: compact design allows small foundry with limited space to own sand filling equipment.
The dead bed area of the sand filling system uses the sand itself to protect the ceramic fiber insulation material of low thermal quality from direct mechanical wear of flowing sand, eliminating the need for a metal safety tank inside the furnace.
In operation: sand enters the fluid bed heat exchanger and takes a roundabout path around the inner stainless steel pipe.
Half of the circulating air of the furnace passes through these tubes and is heated to about 930F (449C).
Then it goes through pre-heat manifold.
Then, the hot sand goes along the roundabout path around the tube with a spiral winding fin.
Cooling water through the tube in the counter-
Flow path of cooling sand to 18F (8C)
Wet ball temperature above.
Installation Information casting data: Integra casting in Manitoba, Canada is a gray and cast iron foundry using a nobake mold from 100-500 lb.
Case History: Integra installed the heat recovery system in 1996 and used the mechanical system before.
Since the installation of the system, the cost of sand has been reduced and the foundry is producing better quality castings-
Recycled sand reduces texture and burns to get a better finish. Vibra-
Grinding drum general sports company
No. 777 Lake Road
Barrington, Bar state 60010 Tel: 847/381-
Fax 2240: 847/381.
1376 mail: mail @ general kinematics.
Website: www.
General Sports.
Contact: Bill Clark
System Type: mechanical.
Floor area: 10x10 ft. Capacity: 20-30 tons/hr.
Key attribute: System is 2-
The quality intrinsic frequency unit is designed to use ambient air for efficient heat dissipation during mass reduction.
After the initial start-up, only energy is needed to overcome the friction loss caused by the block and sand roll in the fluid mass.
In operation: the curved drum chamber of the unit works with vibration movement to enhance rolling action and wear.
A large curved screen area speeds up the reduction of the nobake block to the original granularity.
The Tramp metal is discharged through the pneumatic side door. Aspecially-
The designed airbag system tilts one end of the unit several degrees to facilitate the flow in the garbage unloading cycle.
Installation Information casting data: United StatesS.
Filter the Castalloy partition.
The steel foundry in wauha ha, Wisconsin uses nobake and shell molding and shell, box and hotbox cores to produce manufacturing equipment.
Case History: The casting alloy has surpassed the existing recycling system by increasing the casting capacity.
Sand Filling has become a bottleneck.
The foundry has studied several options, but many of them require extensive changes to the process flow to accommodate the increased space needed to upgrade the system.
Finally, the foundry decided to install a vibrating mill drum in the existing area, only minor modifications to the conveyor belt were required.
The system will capacity from 5-6 tons! hr to 9-
11 tons/hour and keep in sync with the melting capacity of the furnace.
It took three days to installGMD Thermo-
GMD Environmental Services company scrubber hot sand feederO.
Fort worth, Texas 11375 box 76110 Tel: 800/725-
2463 Fax: 817/923-
0035 mail: geraldr @ gmdenv
Website: ww. gmdenv.
Contact: Jerry Reier.
System Type: Hot.
Floor area: 15x20x35.
Capacity: 1 ton/hour.
Key properties: The system uses close-
Coupled Fluid bed with calcining and pre-burn is available
Continuous cooling through hot air washing and gravity transfer without moving parts.
In operation: The sand is sent into the surge bin and then into the recycling system.
At a temperature of 1350-, Calcining heat is added to the fluid bed through the fossil fuel combustion system1650F (732-899C).
The supplemental fuel is burned in a fire box under the calcining bed, eliminating coking and ensuring that the calcining bed temperature is consistent.
The sand flows through the weir to leave the chamber, and then through gravity through the transmission pipe into the pre-cool chamber.
There it cools with ambient air from 700-850F (371-454C).
Installation Information casting data: Greg Industrial
A green sand plant in El Monte, California, has been using recycling systems since 1992.
Case History: Gregg Industries recycles excess sand and core ass to conditions equal or better than new sand.
Return and excess sand are continuously processed through the system. Clay-
The bonded sand generated by the molding operation and the cracked shell core head can be processed together in any combination to produce the available sand.
Most of this recycled sand is a shell coating for its core room, while the rest is used as an additive in the preparation of molded sand.
The foundry no longer buys coated sand and only buys a small amount of new sand to replace the loss caused by normal wear.
It is estimated that if excess sand is not recovered, the cost of disposal will reach $500,000 per year. Hot-
Rec Fata aluminum
37654 Am Rhine Road
Livonia, Michigan 48150 Tel: 734/953-
5700 Fax: 734/953-
5701 mail: ginnard @ fata-alum.
Website: www. fataaluminum.
Contact: Brian Ginnard.
System Type: heat regeneration.
Size: 5 from 16. x 32 ft 10 in. x 37 ft 9 in. to 24 ft 8 in. x 49 ft 3 in. x41 ft. Capacity: 3-12 tons/hr.
Key properties: this system can be used to recover resin-
The sand is bonded and green.
Recycled sand can be reused in all types of molding and core making processes.
The system runs automatically without an operator.
In operation: for chemistry-
Bonded sand is a screw conveyor that puts the measured amount of abrasive belt into a cylindrical roasting chamber with an insulating wall and a stainless steel substrate.
The substrate has a flow nozzle, which is placed together with the gas feed pipe on the same axis.
Air and gas are mixed together in the combustion chamber.
Sand flow from combustion chamber to pre-combustion chambercooler is vale-controlled. The pre-
The cooler consists of two fluidized beds connected through the valve.
The air flows through the sand at the same time, cooling the sand to 57f (300C)
932F at recovery (
500CD of thermal energy.
The sand then enters the final cooler, which consists of a fluid bed room equipped with a circulating water pipe nest.
After leaving the final cooler, the sand passes through a vibrating screen, eliminating any remaining impurities.
The process of recycling green sand is similar.
Installation Information casting data: Three Teksid Aluminum Foundry, two in Sylacauga, Alabama, one in Dixon, TennesseeRec systems.
Case History: each plant in the Sylacauga plant has a 12 ton/hour system to handle the silica sand used in foam casting.
These systems have increased over the past few months.
Dickson plant uses 6 tons/hour system recycling for half
Permanent casting mold. RSR 5-
Roberts Sinto\'s 1 rotary sand-taking Machine
3001 West StreetO.
Michigan Lansing 40760 mailbox 48901 Tel: 800/748-
0348 Fax: 517/371-
4930 Email: info @ robertssinto.
Website: www. robertssinto.
Contact: Roger Hayes
System Type: rotating machinery.
Floor area: 4 feet 6. x 9 ft. Capacity: 3. 3 tons/hr.
Key attributes: low capital and operating costs for refunding, but high throughput efficiency.
100% of the sand recovered by the system can be reused in nobake molding.
During the operation, the system forces sand particles to scrub each other and improves the recovery efficiency.
In operation: The system receives the settled sand into the receiving Hopper.
The sand then enters the rotary feeder pool at rated throughput.
Before the sand is sent to the surge bin, the fine is removed in the fluid bed grader.
The transport vehicle transports the recovered sand into the daily Hopper for molding and core making.
Installation Information casting data: Schlumberger Industries, a phenol-containing polyurethane nobake store in tallaasi, Alabama.
Case History: Schlumberger is looking for a recycling system to reduce sand treatment costs for copper
Infrastructure foundry facilities.
The foundry wants to recover the maximum possible percentage of its 85 GFN silicon sand, so the efficiency of the recycling system is critical.
The foundry purchased RSR 5-
1 Rotary recycling system.
The system includes bucket hoists, recycling equipment and touch screen controls, surge storage, and pneumatic transport vehicles that bring recycled sand to the hopper in the core room.
\"We were dragging our scrap sand behind the factory before refunding,\" said Dave Barton, foundry manager . \".
\"Using the recycling system, we will keep 100% of recycled sand.
We are working.
Human resources shift, recycling more than 12 tons of sand every Thursday day.
\"In the first two months of the operation, 10-
Human resources for sand recycling remain below 1% and system throughput reaches 90%.
Model 4 Cell Pro-
Claims Simpson technology
751 Aurora coastline Avenue, Illinois 60504 Tel: 630/978-
0044 Fax: 630/978-
0068 Email: simpsontech.
Website: www. simpsontech.
Contact: Dave Silsby.
System Type: pneumatic feeder.
Size: 21 11. 375 in. x 10 ft 11. 375 in. x 13 ft 5. 25 in. Capacity: 8-10 tons/hr.
Key attributes: the system uses air as the driving force and sand as the grinding body to scrub the sand.
In operation: The sand is pushed by air through the inner tube and scrubbed the sand trapped under the target.
A mixture of sand holes was established in the sand mixing chamber.
The reunion is broken down and the particles collide with each other to grind off the adhesive coating.
The sand curtain is exposed to the exhaust gas sucked through a rectangular opening in the exhaust hood surrounding the target.
This exhaust air clears the fine when a fine is generated.
Sand enters the final dust removal trough through a vibrating grading screen.
Separate the recovered sand from the garbage.
Installation Information casting data: a green sand casting device for casting railway components with sodium silicon core.
The foundry produces 22 tons of casting/shift and uses sand at a rate of 15 tons/hour.
Case History: The steel foundry added 25 tons/day of facing sand to its sand system and removed the same amount of sand system to keep the sand system balanced.
Removing sand from the system means precious clay is also removed and sent for disposal.
In order to improve the disposal situation, the foundry has installed a pneumatic recovery system with feed hopper, Cyclone cylinder and dust collector.
The Reaper can handle 32,000 tons of sand per year.
The output of the reclamation system is 85% and the processing output is only 15%.
The Foundry achieved a return on recycling equipment within six months.
Taking into account the reduction in sand and clay usage, operating costs, maintenance costs and other costs associated with the recycling system, the foundry saves more than $1800 per day through recycling.
Shashi deep fluidized bed Joint Engineering Co. , Ltd.
Tel: 1971-30144 McCollum Pkwy northwest Kennesaw, Georgia 800/486
6836 Fax: 770/422-
6968 mail: mktg @ cec-intl.
Website: www. cec-intl.
Contact: Jim Garrett
Type of system: fluidized bed heat refunding machine.
Size: 200 and 265 cu ft working capacity (
Depending on the system).
Capacity: starting from 2 tons/hour.
Key attributes: the refunding machine combines several casting processes into one, most often applied to aluminum castings (
Iron system though).
In addition to heat recovery sand, the system dehydrate the castings without knockout or settling.
The system can also be equipped with heat treatment quenching equipment.
In operation: The process begins when the mold and/or the core-intact castings are immersed in the heated bed of the quicksand.
Heat and oxygen in the bed
Mold and core (
Can be made with any heat recovery adhesive).
The sand is heat recovered on the bed, and clean sand spills from the discharge mouth.
Castpak recycling system Castec, Inc.
1462 15063 mononga hilard Bez Avenue, Pennsylvania Tel: 724/258-
8700 Fax: 724/258-
8793 Email: sales @ castecinc.
Website: www. castecinc.
Contact: Ron Parker
System Type: Hot.
Size: 20x12x10 ft.
Capacity: 18 tons/day.
Key attribute: the throughput of the rear Reaper is increased, and the operation efficiency is greatly improved.
The system does not move parts in the hot zone and does not use poured refractory materials.
In operation: the heat exchanger uses the heat discharged from the calcin furnace to preheat the convection air.
Then streaming air acts on the sand of the refunding machine after entering.
The sand cooler receives the recovered sand from the rear Reaper and cools it to less than 5 degrees of ambient air temperature.
Installation Information casting data: Flotech, Inc.
A nobake foundry in Jacksonville, Florida installed a system in 1998.
Case History: Flotech purchased the system for its overall tightness and cost/result ratio.
By installing the sand filling system, Flotech reduced its total sand production by 75% and saved $50,000 a year.
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