Why Sand Reclamation?
Reclaiming Resources at Sivyer Steel Corporation
Tonya Burgess Director, Quality Assurance/Regulatory Compliance Sivyer Steel Corporation Bettendorf, IA 52722 AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation DEFINITION: Sand reclamation is defined as the physical, chemical or thermal treatment of a refractory aggregate to allow reuse without significantly lowering it’s original properties.
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation Attributes • In reclamation, the important part is the removal of accumulated coatings from around the sand grain and removal of dust, fines and other impurities that make the sand undesirable and unusable. • Every foundry faces processing an adequate supply of sand which has the properties to meet the many requirements imposed on it in molding and core making. Then the volume of sand required presents a major handling problem. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation Attributes • Grain shape, screen analysis, chemical characteristics, as well as thermal characteristics, must be uniform to get uniform properties in sand mixes. • Geographical location makes a difference. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation Attributes • With the ultimate goal of any reclamation system is to reuse as much sand as possible, Sivyer Steel utilizes both mechanical and thermal reclamation. • Sivyer Steel reclaims about 75% of the sand we use, conservatively. – We have demonstrated effectiveness in removing chemical binders from the individual sand grains and making the sand available for reuse in the foundry through our reclamation activities at Sivyer Steel. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Why Sand Reclamation? • At Sivyer, there were three reasons: – Technologically Sound – Environmentally Sound – Economically Sound
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Technologically Sound • The quantity of some catalyst and binders may be able to be reduced by using reclaimed sand. – Sivyer Steel uses Alphaset* and Alphacure* for our ester cured phenolic no-bake molding process. • Using the binders and resins we’ve chosen has allowed us to improve casting quality by reducing shrinkage defects and improving surface finish. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sivyer Steel Molding Process • 100% air set molding utilizing Alphaset binders • Flasks and flaskless lines • Max size: 140” 140” – - 22,000 lbs net weight • Min size: 30” x 48” – -50 lbs net weight
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Technologically Sound • Sand lab testing is conducted, monitored and recorded for reclaimed (both mechanically and thermally) sands for pH, LOI and Sieve Analysis. • We have better dimensional control produced with reclaimed sand due to lower grain expansion caused by repeated heating and cooling of silica sand grains. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
pH Test Results Thermally Reclaimed
Mechanically Reclaimed
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
LOI Test Results Dry Thermally Reclaimed
Dry Mechanically Reclaimed
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sieve Analysis Test Results Thermally Reclaimed
Mechanically Reclaimed
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Environmentally Sound • Disposal costs of large quantities of sand into the ground is extremely difficult.
• Federal, State and Local regulatory agencies want to know what chemicals are in the sand and how much of it will leach into the ground. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Environmental Requirements • • • • • • • • •
Construction Permit Dust Collection Stack Testing Opacity Inspection Emission Limits Maintenance and Inspections O&M Plan PM/PM10 Monitoring and Reporting Record sand Limits on Binders, Resin and Catalyst • VOC/HAP Calculations/Records/Reporting • Maintenance of MSDS AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Economically Sound • Reducing costs in foundries, as with any company, is paramount and sand has large costs associated with it including purchase cost, freight cost, unloading costs, transporting costs once it’s in the foundry and of course, disposal costs which might include dumping costs. • The cost of sand continues to rise
• Reclaiming our sand has helped reduce some of these costs AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Summary • Sand Reclamation at Sivyer Steel – Reduce new sand consumption – Improved sand expansion characteristics – Improved casting quality – Reduced environmental impact – Reduced disposal costs – Reduced costs
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Tonya Burgess Director, Quality Assurance/Regulatory Compliance Sivyer Steel Corporation Bettendorf, IA 52722 AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation DEFINITION: Sand reclamation is defined as the physical, chemical or thermal treatment of a refractory aggregate to allow reuse without significantly lowering it’s original properties.
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation Attributes • In reclamation, the important part is the removal of accumulated coatings from around the sand grain and removal of dust, fines and other impurities that make the sand undesirable and unusable. • Every foundry faces processing an adequate supply of sand which has the properties to meet the many requirements imposed on it in molding and core making. Then the volume of sand required presents a major handling problem. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation Attributes • Grain shape, screen analysis, chemical characteristics, as well as thermal characteristics, must be uniform to get uniform properties in sand mixes. • Geographical location makes a difference. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation Attributes • With the ultimate goal of any reclamation system is to reuse as much sand as possible, Sivyer Steel utilizes both mechanical and thermal reclamation. • Sivyer Steel reclaims about 75% of the sand we use, conservatively. – We have demonstrated effectiveness in removing chemical binders from the individual sand grains and making the sand available for reuse in the foundry through our reclamation activities at Sivyer Steel. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Why Sand Reclamation? • At Sivyer, there were three reasons: – Technologically Sound – Environmentally Sound – Economically Sound
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Technologically Sound • The quantity of some catalyst and binders may be able to be reduced by using reclaimed sand. – Sivyer Steel uses Alphaset* and Alphacure* for our ester cured phenolic no-bake molding process. • Using the binders and resins we’ve chosen has allowed us to improve casting quality by reducing shrinkage defects and improving surface finish. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sivyer Steel Molding Process • 100% air set molding utilizing Alphaset binders • Flasks and flaskless lines • Max size: 140” 140” – - 22,000 lbs net weight • Min size: 30” x 48” – -50 lbs net weight
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Technologically Sound • Sand lab testing is conducted, monitored and recorded for reclaimed (both mechanically and thermally) sands for pH, LOI and Sieve Analysis. • We have better dimensional control produced with reclaimed sand due to lower grain expansion caused by repeated heating and cooling of silica sand grains. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
pH Test Results Thermally Reclaimed
Mechanically Reclaimed
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
LOI Test Results Dry Thermally Reclaimed
Dry Mechanically Reclaimed
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sieve Analysis Test Results Thermally Reclaimed
Mechanically Reclaimed
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Environmentally Sound • Disposal costs of large quantities of sand into the ground is extremely difficult.
• Federal, State and Local regulatory agencies want to know what chemicals are in the sand and how much of it will leach into the ground. AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Environmental Requirements • • • • • • • • •
Construction Permit Dust Collection Stack Testing Opacity Inspection Emission Limits Maintenance and Inspections O&M Plan PM/PM10 Monitoring and Reporting Record sand Limits on Binders, Resin and Catalyst • VOC/HAP Calculations/Records/Reporting • Maintenance of MSDS AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Economically Sound • Reducing costs in foundries, as with any company, is paramount and sand has large costs associated with it including purchase cost, freight cost, unloading costs, transporting costs once it’s in the foundry and of course, disposal costs which might include dumping costs. • The cost of sand continues to rise
• Reclaiming our sand has helped reduce some of these costs AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Summary • Sand Reclamation at Sivyer Steel – Reduce new sand consumption – Improved sand expansion characteristics – Improved casting quality – Reduced environmental impact – Reduced disposal costs – Reduced costs
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
