Gregory Miskinis
Reclamation of Green and Core Sands for return to the Core Room Gregory Miskinis Waupaca Foundry, Inc.
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Industrial Sands Used for Iron Metalcasting • Wisconsin sourced sands (GFN 60) U.S. Mesh 50 70 100 140
Specification (%) 15 - 23 24 - 32 32 - 42 7 - 13
• Over 300,000 tons used annually for Waupaca’s Wisconsin facilities AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Justification • Beneficial Reuse • Hedge against industrial competition • Reduction of Core Sand Additives • Contribution to Zero Landfill
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Beneficial Reuse Flowable Fill
Embankment Fill
Gravel Pit Reclamation
Road Construction
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Industrial Competition • Fracking – Over 1.2 million wells to date • Volatile Sand Market – affecting both price and availability
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Reduction of Core Sand Additives • Anti-Veining Additives • Specialty Sands
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Contribution to Zero-Landfill
Waste Sand’s Former Home AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Where to Start?
• Plant 1 waste sands are a mixture of green sand and Phenolic Urethane Cold Box, Furan Warm Box and Shell Core Sands
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Where to Start?
• Plant 2 waste sand is a mixture of green sand and Phenolic Urethane Cold Box Core Sand
• Plant 3 waste sand is a mixture of green sand and Furan Warm Box Core Sand AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Process Flow Diagram
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Input Material to 1st Stage Mechanical • Rotary sand Cooler Shot
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Input Materials
Spent Green and Core Sands AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
First Stage Mechanical
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand after 1st Stage
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Thermal Reclaim Furnace
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand after 2nd Stage Thermal Treatment
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
3rd Stage (Final) Mechanical
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand after 3rd Stage Mechanical Treatment
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Things to Remember • Operating parameters for the reclamation system are adjusted according to output grain fineness, pH and ADV values – examine inputs and outputs
• The core binder system used will determine the most economical operating temperature of the thermal stage
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Things to Remember • Waste stream complexity will drive the selection of any reclamation system
• Operating costs/savings are dependent on the unique operations of each foundry
It depends! AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
For additional information, please contact: • • • • • •
Gregory Miskinis 1955 Brunner Drive, Waupaca, WI 54981 Phone: 715-258-6611 Fax: 715-258-9268 [email protected] www.waupacafoundry.com
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Industrial Sands Used for Iron Metalcasting • Wisconsin sourced sands (GFN 60) U.S. Mesh 50 70 100 140
Specification (%) 15 - 23 24 - 32 32 - 42 7 - 13
• Over 300,000 tons used annually for Waupaca’s Wisconsin facilities AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Justification • Beneficial Reuse • Hedge against industrial competition • Reduction of Core Sand Additives • Contribution to Zero Landfill
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Beneficial Reuse Flowable Fill
Embankment Fill
Gravel Pit Reclamation
Road Construction
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Industrial Competition • Fracking – Over 1.2 million wells to date • Volatile Sand Market – affecting both price and availability
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Reduction of Core Sand Additives • Anti-Veining Additives • Specialty Sands
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Contribution to Zero-Landfill
Waste Sand’s Former Home AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Where to Start?
• Plant 1 waste sands are a mixture of green sand and Phenolic Urethane Cold Box, Furan Warm Box and Shell Core Sands
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Where to Start?
• Plant 2 waste sand is a mixture of green sand and Phenolic Urethane Cold Box Core Sand
• Plant 3 waste sand is a mixture of green sand and Furan Warm Box Core Sand AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Process Flow Diagram
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Input Material to 1st Stage Mechanical • Rotary sand Cooler Shot
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Input Materials
Spent Green and Core Sands AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
First Stage Mechanical
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand after 1st Stage
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Thermal Reclaim Furnace
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand after 2nd Stage Thermal Treatment
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
3rd Stage (Final) Mechanical
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Sand after 3rd Stage Mechanical Treatment
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Things to Remember • Operating parameters for the reclamation system are adjusted according to output grain fineness, pH and ADV values – examine inputs and outputs
• The core binder system used will determine the most economical operating temperature of the thermal stage
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
Things to Remember • Waste stream complexity will drive the selection of any reclamation system
• Operating costs/savings are dependent on the unique operations of each foundry
It depends! AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
For additional information, please contact: • • • • • •
Gregory Miskinis 1955 Brunner Drive, Waupaca, WI 54981 Phone: 715-258-6611 Fax: 715-258-9268 [email protected] www.waupacafoundry.com
AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA
