GREEN SAND RECLAMATION a necessity for …...GREEN SAND RECLAMATION a necessity for sustainability...
Transcript of GREEN SAND RECLAMATION a necessity for …...GREEN SAND RECLAMATION a necessity for sustainability...
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GREEN SAND RECLAMATION
a necessity for sustainability
Manish Kothari
Managing Director,
Rhino Machines Pvt Ltd
Manufactured in India under License from FATA Aluminum
Presented at:
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Foundry Technology
Skill Development
Data Acquisition & Analytics on
Cloud
Finance, Strategy & Risk
Management
Lean Management
Women’s Ethnic Wear
BRINGING THE SUSTAINABLE CO-OPERATIVE CULTURE OF “AMUL” FROM ANAND
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3
From Darkness to Light
From Noise to Sound
From Waste to Money
Our Commitmentwww.rhinomachines.net
Ecoflex
Multiflex
Reclaim
Sand
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THE OBJECTIVE
Environment
• Conserving Natural Resources
• Reduce Industrial Waste Dumping
• Reduce CO2 Emissions
• Reduce Fuel Usage
Economics
• Reduce the cost of managing silica sand
• Consistency in Sand Quality directly affecting casting rejections
• Saving in Additives
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ENVIRONMENTAL CONCERNS
Sand Mining
Depletion of Natural
Resources lead to
Environmental Issues
@ 400 kms
110 Million kgs
Every 1 kg of casting = 1 kg of sand
10 Mill MT of Casting Shipped = 10 Mill MT of Sand Transported
165 Million kgs 220 Million kgs
@ 600 kms @ 800 kms
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ECONOMIC CONCERNS
GREEN SAND FOR MOULDING SAND
Landed Cost of Sand
Rs 3,500/MT
or
200 AED /MT
Estimated Saving in Direct Cost
Rs 2,000/MT
Or
AED 110/MT
For 30% usage of Moulding Sand
Sustainability impact
Rs 6 Billion or
AED 330 Million
Coal Dust & Bentonite Reuse in Reclaimed
Sand
Estimated Saving
50% reduction in additions in the Mixer
For 30% usage of Moulding Sand
Sustainability impact
Rs 6 Billion or
AED 330 Million
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ECONOMIC CONCERNS
CORES PRODUCTION IN GREEN SAND
FOUNDRY
Landed Cost of Sand
Rs 4,000/MT
or
225 AED /MT
Estimated Saving in Direct Cost
Rs 1,600/MT
Or
AED 90/MT
For 50% usage of Moulding Sand
Sustainability impact
Rs 8 Billion or
AED 440 Million
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CHALLENGES FOR
NEW SILICA SAND IN FOUNDRIES
New Silica Sand
Technical Aspects
Consistent AFS & Sieve Distribution
Silica Sand Purity
Grain Shape
Commercial Aspects
Vulnerability to transport costs
Seasonal availability issues
Mining restrictions to protect natural resources
Solid waste management
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GENERAL ANALYSIS OF
GREEN SAND FOUNDRIES…SILICA SAND USAGE
Cast Iron Block & Head Foundry
•Core Sand : ~ 1 kg new sand/kg of casting
•Moulding Sand – new sand addition near to zero
•Combination of Cold Box & Shell Sand Processes
Cast Iron Tractor Casting Foundry
•Core Sand : ~ 0.2 to 0.4 kg sand/kg of casting
•Moulding Sand : ~ 1-2% of Prepared Sand
Automotive Casting
•Core Sand : ~ 0.1 to 0.3 kg sand/kg of casting
•Moulding Sand : ~ 2-3% of Prepared Sand
Engineering, Manhole Cover, and similar non cored castings
•Moulding Sand : ~ 3-5% of Prepared Sand
•Core Sand : ~ < 0.1 kg sand/kg of casting
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COMPLETE SOLUTIONS FOR
GREEN SAND PROCESS
S2
S1
S3
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TYPICAL S1 PLANT CONFIGURATION
Sand Dryer
Feeding Belt
ConveyorHigh Pressure Blower with AccousticEnclosure
Reclaimed Sand
Storage
Sand Scrubber & DedusterWith Feed
Hopper
Dust Collection Cyclone & Bag Filter
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2.5 T/HR CAPACITY
GREEN SAND RECLAMATION FOR CORES
BU
CK
ET
ELE
VA
TOR
BELT
CO
NV
EY
OR
SC
REW
FE
ED
ER 2 C
ELL
MEC
HA
NIC
AL
SC
RU
BB
ER
1 C
ELL
MEC
HA
NIC
AL
SC
RU
BB
ER
BU
CK
ET
ELE
VA
TOR
SA
ND
DR
IER
THER
MA
L
REC
LAM
ATI
ON
FU
RN
AC
E
STO
RA
GE
SIL
O
VIB
RA
TOR
Y
SC
REEN
CO
MP
LETE
REC
LAIM
ED
GR
EEN
SA
ND
SIL
O W
ITH
LOA
D C
ELL
Floor Space
30 M x 12 M
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SOLUTIONS FOR
GREEN SAND PROCESS – MOULDING SAND
S1
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SOLUTIONS FOR
GREEN SAND PROCESS – BROKEN/REJECT CORE
S2
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SOLUTIONS FOR
GREEN SAND PROCESS – CORE SAND
S3
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GREEN SAND FOUNDRY SOLUTIONS FROM RHINO
www.rhinomachines.net
We thank you for your
Patient hearing
&
Metalworld for this
opportunity
Our partnerships & associates
• Energy & Consumption Data Analytics on
Cloud
• Swiss Skill Development for foundries
• Lean Manufacturing Solutions
• Centre for Manufacturing Excellence with
MSME
• Turnkey Process & Project Support