Sand Reclamation Overview Reclaimed Sand That Performs As Well As – Or Better Than – New Sand.
David Silsby SIMPSON TECHNOLOGIES CORPORATION
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Reconditioning vs. Reclamation As Defined By the AFS 4S Committee on Sand Reclamation and Reuse
Reconditioning: “is sand that has received some degree of cleaning work, but not enough to make the sand suitable as a new sand replacement.”
Reclamation: “is the physical, chemical or thermal treatment of a refractory aggregate to allow reuse without significantly lowering the original properties.”
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Reclaim Process Options •
Alternative Reuse
•
Green Sand to Green Sand
•
Chemical Bonded Sand as Green Sand Addition
•
Chemical Bonded Sand as New Sand Addition
•
Clay Bonded Sand as New Sand Replacement
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
System Cost Considerations •
New Sand Purchase Price. ( Delivered )
•
Sand Disposal Cost. ( All Fees assoc. )
•
Utilities Cost.
•
Price of System. ( Purchase & Install )
•
Reclamation System Maintenance Cost.
•
Associated Labor Cost.
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Equipment Selection Factors •
Sand tonnage required.
•
Sand cleanliness required.
•
Clays, Additives, Chemical Binders used.
•
Sand to Metal Ratio’s.
•
New Sand to Reclaimed ratio desired.
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
System Requirements / Objectives •
Remove sand lumps & tramp metal.
•
Remove non-magnetic/magnetic metal.
•
Reduce inert & organic material.
•
Reduce Bentonite levels. ( MB / AFS )
•
Reduce binder levels. ( LOI, ADV, pH )
•
Consistent fines removal. ( - 200 Mesh )
•
Maintain New Sand analysis. (AFS/GFN )
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Reclamation Process Flow 1. Mold Shake-Out 2.
Tramp Metal Removal
3.
Sand Lump Reduction
4.
Metal Removal
5.
Sand Scrubbing
6.
Sand Cooling (if required)
7.
Classification
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Attrition Unit
Screen Magnetic Separator
Sand Storage
Reclaimer
Reduce to 1/8”
Non Metallic
Remove Tramp
Below 100F 120F (If Required)
Sand Screen
Sand Cooler (if required)
Remove Shot
Sized for Operation Anti-Segregation
Sand for System
Transporter
Pro-Claim
Sand Storage
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Reclamation Process Options
Attrition
Scrub
Calcine
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Scrub
Reclamation Processes •
Mechanical
•
Pneumatic
•
Thermal
•
Combinations
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Green Sand to Green Sand Reclamation GOAL – Replace new sand addition to molding sand •
Bypass 10% to 20% system sand
•
Remove AFS Clay and LOI materials
•
Minimize MB Clay removal
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Reclamation Laboratory Test Results Test No.FL060201 Simpson Technologies Laboratory EvenFlo Pneumatic Reclaimer
Sample A A-1
A-2
6" 2000 1.25
6" 1500 1.25
Batch Number Nozzle Gap Setting Scrub Rate (lb/hr/cell) Plenum Negative
Sample Locations AFS/GFN Loss on Ignition (LOI) % AFS Clay % Methylene Blue Clay % LOI Reduction AFS Clay Reduction M.B. Clay Reduction
As Rec. Sand
Sand
Cyclone
Sand
Cyclone
53.07 5.53 12.00 10.00
56.76 3.37 8.40 7.00
158.14 10.14
56.62 2.84 6.80 6.10
170.43 10.58
39.06% 30.00% 30.00%
48.64% 43.33% 39.00%
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Green Sand To Green Sand Reclamation 25 TPD Cores
PRODUCTION
3.12 TPD Lost Sand
15.0 TPD Scalping's
Land Fill
64 TPD
Reclaim System 162.88 TPD .82 TPD Clay
Backing Muller 163.70 TPD
7.52 TPD Sand 2.08 TPD Clay 54.40
TPD
Facing Mix Muller
1.90 TPD Clay
56.30 TPD
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Green Sand To Green Sand Reclamation
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Resin Sand To Resin Sand Reclamation Goal – Remove residual binder for rebonding • remove surface binder • maintain AFS / GFN & Distribution
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Resin Sand To Resin Sand Reclamation
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Variable Name
Data
Equipment Type
4-Cell Reclaimer
Horsepower
150
Labor Cost
$
Hours of Daily Operation
16
Cost per Kilowatt Hour
$0.06447
Tons Processed Parts
50.00
10 # Required
Life in Hrs.
HP per man hour hrs./day /KWH TPH Cost Each
Cost/Ton
Blast Tube
4
1000
$
295.00
$
0.118
Targets
4
5000
$
410.00
$
0.033
Miscellaneous
1
2000
$
2,500.00
$
0.125
Labor
Man Hrs.
Replace Blast Tubes
0.5
each
$
0.010
Replace Targets
0.5
each
$
0.002
Daily Misc. Maintenance
0.5
/day
$
0.156
Blower Drive Motor
$
0.721
Reclaimer Contribution to Operating Costs
$
1.165
Electrical Power
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Green Sand to Core Sand Reclamation
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
ABSTRACT (1983) Pneumatic scrubbing of green sand systems has been in use for over 50 years. Whether the scrubbed sand is used to maintain the purity level of the system or to make facing sand, the residual active clay can be reused. At present the majority of green sand foundries are disposing of sand that is predominantly molding sand, yet the majority of their new sand goes into core or nobake usage. Molding sands with high clay levels are difficult to reclaim by any dry methods. If the sand is calcined first, we achieve three benefits: removal of a high percentage of organic binders; deactivation of all clays; and a partial removal of clay. Data from a number of calcine + pneumatic scrubbing runs were presented both as to physical properties of the sands as well as rebond data. All rebonding was run at 100% reclaimed sand and at the same binder and catalyst level as in the new sand runs. The use of thermal plus pneumatic scrubbing was and still is a viable method of reclaiming molding sand for reuse in core and nobake work. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
For additional information, please contact: • • • • • • •
Dave Silsby Simpson Technologies Corp. 751 Shoreline Drive, Aurora, IL 60504 630-978-0044 630-978-0068 (Fax)
[email protected] www.simpsongroup.com
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA