Clays
Green Sand Additives and Clays Stephen L. Neltner S&B Industrial Minerals N.A.
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
The Discussion • The Trends in the Foundry • Responses of the Suppliers to Those Trends
• New Developments and Innovative Ideas from the Suppliers
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Foundry Trends Increase Durability
More Na Bentonite Use Less Replenishment
Suppliers’ Responses Clay Modifiers, Activated Clays, Clay Blends More Flowable Sand
Additional Sourcing
Enhanced Densities
Enhanced Flowability
Other Sources
New Mold “Blowers”
Less Emissions
Difficult Geometries
OSHA & EPA Requirements
More Metal in the Molds
Different “Carbon” Sources Sustainable Materials
Shakeout/Collapsibility Less Sand Carry-Out
Rejuvenated Dust
Less Spill Sand
Black Water
Better Working Conditions
Customized Chemical Additives Better Dispersing
Higher Strengths More Metal in the Mold
Enhanced Mulling
Very Narrow Side Walls
Enhanced Flowability
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Clay Trends • The Heavy Use of the More Durable Clay (Na Bentonite)/Drivers – Drum Uses (Aggressive Shakeout) – Flaskless Molding (No Run Outs) – Cost Savings (Higher Thermal Stability)
• Activated Clays/Drivers – Logistics – Synergistic Affect – Sourcing
• Rejuvenated Clays/Drivers – Sourcing AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Hot Compression Strength
- Very Low HCS - Low HCS - Higher -- HCS - Rigid/ Not Plastic - Semi-Plastic - Plastic - Dimensional - Run-Outs Concerns Concerns
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
HCS Affects on System Sand Excessive HCS
Low HCS
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Lower DCS & HCS on Shakeout
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clays • The Clays Treated to be Converted to Perform Like Other Clays • Na Bent converted to Ca Bent Properties • Ca Bent converted to Na Bent Properties
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (GCS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (WTS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (HCS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (GCS & WTS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Rejuvenated Clays • New Technologies to Recover “Wasted” Clays
• Recycling of Clays • Sustainability
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Landfill Numbers
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Baseline vs. Rejuvenated Dust Supplement 13 12.6
12.5
12
+ 25 %
12.6 + 26 %
+ 26 %
11 +6%
10.5
10 10
- 32 %
10
10
10
-6%
10
10 9.4
9 8 7 6.8 6 Green compressive strength
Wet tensile strength
Cone jolt toughness
Friability
Dry compression strength
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Green shear strength
Carbon Trends • Low Emissions – Less Overall Quantity of Added Carbon – Lower Volatile Carbons Use – Use of Special Carbons
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Graphitic Use for Peel
Graphite
Graphite Impregnated Clay
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Foundries Experience Increased Density with Impregnated Bentonite
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Emission Reductions 0.16 Reference Test FK Test HE
0.08
0.04
e
Fo
rm
ald
eh
yd
de de hy
es eta l
Ac
Me
thy
lna
ph
tha len
en ol Ph
lbe
nz e
ne
ols Et
hy
Cr es
len e tha
ph
xa ne
Na
He
ne s Xy le
ne lue To
nz e
ne
0.00
Be
lb/tn metal
0.12
Selected Target HAPs & VOCs
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Coal Supplement - Coking Substitutes - Coking WITHOUT the Carbon Emissions
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Special Chemical Trends - Low Emission Supplement - Clay Enhancer on Flowability - Enhanced Mulling
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
What’s in the Preblend Mix? 60.00% 50.00% 40.00% 30.00%
50.50%
20.00% 10.00%
0.00%
21%
23% 4%
Na Ca Sea Coal Cellulose Bentonite Bentonite
0.50% Cereal
1% Special
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Formulation with Clay Modifier Typical Formulation with Clay Modifier 70%
60% 50% 40% 30%
62%
20% 10%
21% 10%
7%
0% Na Bentonite Ca Bentonite
Sea Coal
Causticized Lignite
0.50% Soda Ash
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Formulation with Activated Clay Typical Formulation with Activated Blended Clay
90% 80%
82%
70% 60% 50% 40% 30%
18%
20% 10% 0%
Activated Clay
Sea Coal
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
The Supplier’s Role • Innovative Use of New Technologies – Low Emission “Carbons” – Activated/Modified Clays
– Reclaimed/Rejuvenated Clays (Dust) – Customized Chemical Additives
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Questions & Answers
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
The Discussion • The Trends in the Foundry • Responses of the Suppliers to Those Trends
• New Developments and Innovative Ideas from the Suppliers
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Foundry Trends Increase Durability
More Na Bentonite Use Less Replenishment
Suppliers’ Responses Clay Modifiers, Activated Clays, Clay Blends More Flowable Sand
Additional Sourcing
Enhanced Densities
Enhanced Flowability
Other Sources
New Mold “Blowers”
Less Emissions
Difficult Geometries
OSHA & EPA Requirements
More Metal in the Molds
Different “Carbon” Sources Sustainable Materials
Shakeout/Collapsibility Less Sand Carry-Out
Rejuvenated Dust
Less Spill Sand
Black Water
Better Working Conditions
Customized Chemical Additives Better Dispersing
Higher Strengths More Metal in the Mold
Enhanced Mulling
Very Narrow Side Walls
Enhanced Flowability
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Clay Trends • The Heavy Use of the More Durable Clay (Na Bentonite)/Drivers – Drum Uses (Aggressive Shakeout) – Flaskless Molding (No Run Outs) – Cost Savings (Higher Thermal Stability)
• Activated Clays/Drivers – Logistics – Synergistic Affect – Sourcing
• Rejuvenated Clays/Drivers – Sourcing AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Hot Compression Strength
- Very Low HCS - Low HCS - Higher -- HCS - Rigid/ Not Plastic - Semi-Plastic - Plastic - Dimensional - Run-Outs Concerns Concerns
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
HCS Affects on System Sand Excessive HCS
Low HCS
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Lower DCS & HCS on Shakeout
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clays • The Clays Treated to be Converted to Perform Like Other Clays • Na Bent converted to Ca Bent Properties • Ca Bent converted to Na Bent Properties
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (GCS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (WTS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (HCS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Activated/Modified Clay (GCS & WTS)
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Rejuvenated Clays • New Technologies to Recover “Wasted” Clays
• Recycling of Clays • Sustainability
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Landfill Numbers
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Baseline vs. Rejuvenated Dust Supplement 13 12.6
12.5
12
+ 25 %
12.6 + 26 %
+ 26 %
11 +6%
10.5
10 10
- 32 %
10
10
10
-6%
10
10 9.4
9 8 7 6.8 6 Green compressive strength
Wet tensile strength
Cone jolt toughness
Friability
Dry compression strength
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Green shear strength
Carbon Trends • Low Emissions – Less Overall Quantity of Added Carbon – Lower Volatile Carbons Use – Use of Special Carbons
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Graphitic Use for Peel
Graphite
Graphite Impregnated Clay
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Foundries Experience Increased Density with Impregnated Bentonite
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Emission Reductions 0.16 Reference Test FK Test HE
0.08
0.04
e
Fo
rm
ald
eh
yd
de de hy
es eta l
Ac
Me
thy
lna
ph
tha len
en ol Ph
lbe
nz e
ne
ols Et
hy
Cr es
len e tha
ph
xa ne
Na
He
ne s Xy le
ne lue To
nz e
ne
0.00
Be
lb/tn metal
0.12
Selected Target HAPs & VOCs
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Coal Supplement - Coking Substitutes - Coking WITHOUT the Carbon Emissions
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Special Chemical Trends - Low Emission Supplement - Clay Enhancer on Flowability - Enhanced Mulling
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
What’s in the Preblend Mix? 60.00% 50.00% 40.00% 30.00%
50.50%
20.00% 10.00%
0.00%
21%
23% 4%
Na Ca Sea Coal Cellulose Bentonite Bentonite
0.50% Cereal
1% Special
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Formulation with Clay Modifier Typical Formulation with Clay Modifier 70%
60% 50% 40% 30%
62%
20% 10%
21% 10%
7%
0% Na Bentonite Ca Bentonite
Sea Coal
Causticized Lignite
0.50% Soda Ash
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Formulation with Activated Clay Typical Formulation with Activated Blended Clay
90% 80%
82%
70% 60% 50% 40% 30%
18%
20% 10% 0%
Activated Clay
Sea Coal
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
The Supplier’s Role • Innovative Use of New Technologies – Low Emission “Carbons” – Activated/Modified Clays
– Reclaimed/Rejuvenated Clays (Dust) – Customized Chemical Additives
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Questions & Answers
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
