Sand Reclamation for an Aluminum Foundry · PDF fileAFS Sand Casting Conference October 20-22,...

AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA

Sand Reclamation for an

Aluminum Foundry

(Rod Christiansen & Greg Shea)

(Eck Industries)


Definition

• Cleans the sand to a degree sufficient to

allow its re-use in the foundry Molding or

Core making Operations.

• Mechanical Attrition

• Thermal Reclamation

• Blending Thermal w/Mechanical

• New Sand Addition


History of Reclamation at Eck

• Thermal – 2007

• Thermal/Mechanical Blended – 2013

• Phenolic Urethane

• Polyol

• Isoset (SO2)

• Shell


Reasons for Sand

Reclamation

CostReclaimed Sand vs New Sand


Savings

• Thermal Reclaimed

Natural Gas

Maintenance Labor

Supplies & Expenses

Maintenance Supplies

Disposal of Dust

Internal Transporting

• New

Sand Cost

Delivery

Waste Sand Disposal


Savings

• Reclaimed is approximately 1/3 the

cost of our new sand.


Savings

• Additional savings by blending

72% / 28%


Pros of Sand Reclamation Achieve a better (rounded) grain shape.

Better densities

Less surface area for chemicals to coat the sand grains

resulting in easier mixing and reduced chemical costs

Sand grains have been through a thermal expansion phase

Environmental Stewardship


SAND RECLAMATION

EQUIPMENT AT ECK

Gudgeon 3

ton/hr. lump

Reducer


RECLAMATION

EQUIPMENT AT ECK


RECLAMATION

EQUIPMENT AT ECK

3 Ton/Hour

Lump Reducer


RECLAMATION

EQUIPMENT AT ECK

GK – 10 ton/hr.

Lump Reducer


RECLAMATION

EQUIPMENT AT ECK


RECLAMATION

EQUIPMENT AT ECK

Sand Transport

from Lump

reducers and to

waste sand silo


RECLAMATION

EQUIPMENT AT ECK

Brokk used for knockout

of larger molds


RECLAMATION

EQUIPMENT AT ECK

20,000# Mold – Brokk

used for knockout


RECLAMATION

EQUIPMENT AT ECK


RECLAMATION

EQUIPMENT AT ECK

Sand Blending

Gudgeon 3 Ton/Hr.


RECLAMATION

EQUIPMENT AT ECK

4 Burners – 1500 BTU ea.


RECLAMATION

EQUIPMENT AT ECK

Control

Panel

1250 Degrees Critical to Eck


RECLAMATION

EQUIPMENT AT ECK

Cooling Tower


RECLAMATION

EQUIPMENT AT ECK

Sand Classifier

Added when we

started blending


RECLAMATION

EQUIPMENT AT ECK

Sand Blending


RECLAMATION

EQUIPMENT AT ECK


Sand System Eck - Blended

Characteristics:Shape - Rounded

Major Screens – 3.96%

Fines - .21%

Thermal – 72%

Blend – 28%

Density Packed – 111.59#

Density Unpacked – 97.81#

Loss On Ignition - .27%


Sand System Eck

0.05% 0.40%

9.57%

23.98%

31.34%

28.77%

5.42%

0.17% 0.02% 0.01%0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

20 30 40 50 70 100 140 200 270 Pan

Screen Distribution Blended Sand


Sand System Eck

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00%

45.00%

01/08/14 01/29/14 02/19/14 03/12/14 04/02/14 04/23/14 05/14/14 06/04/14 06/25/14 07/16/14 08/06/14 08/27/14

SNB MIXER - MAJOR SCREENS - Blended

40 50 70 100 140


Sand System Eck

0.00

50.00

100.00

150.00

200.00

250.00

01/08/14 02/08/14 03/08/14 04/08/14 05/08/14 06/08/14 07/08/14 08/08/14 09/08/14

SNB MIXER - SURFACE AREA CALCULATION - AVG GFNBlended

Surface Area Avg. Grain Fineness


Sand System Eck

-0.10%

0.00%

0.10%

0.20%

0.30%

0.40%

0.50%

0.60%

01/08/14 02/08/14 03/08/14 04/08/14 05/08/14 06/08/14 07/08/14 08/08/14 09/08/14

SNB MIXER FINES % - 200 + 270 + PAN COMBINED -Blended

FINES 200+270+PAN Linear (FINES 200+270+PAN)


Sand System Eck

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

01/03/14 02/03/14 03/03/14 04/03/14 05/03/14 06/03/14 07/03/14 08/03/14 09/03/14

PER

CEN

TAG

E

SNB MIXER - %LOI - %MOISTURE - Blended

% MOISTURE % LOI Linear (% MOISTURE) Linear (% LOI)


Sand System Eck - Thermal

Characteristics:Shape - Rounded

Major Screens – 3.93%

Fines - .08%

Thermal – 100%

Density Packed – 112.23#

Density Unpacked – 101.04#

Loss On Ignition - .17%

New Sand Density Unpacked - 98.57#

New Sand Density Packed – 112.11#


Sand System Eck

0.01% 0.32%

9.34%

24.14%

32.05%

28.69%

5.05%

0.08% 0.00% 0.00%0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

20 30 40 50 70 100 140 200 270 Pan

Screen Distribution Thermal Sand


Sand System Eck

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00%

04/08/14 04/22/14 05/06/14 05/20/14 06/03/14 06/17/14 07/01/14 07/15/14 07/29/14 08/12/14

SNB - THERMAL RECLAIMER - MAJOR SCREENS -40,50,70,100

40 50 70 100 Linear (40) Linear (50) Linear (70) Linear (100)


Sand System Eck

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

200.00

01/03/14 02/03/14 03/03/14 04/03/14 05/03/14 06/03/14 07/03/14 08/03/14 09/03/14

SNB - THERMAL RECLAIMER - AVG. GFN - SURFACE AREA CALCULATION

AVG. GFN AVG. SURFACE AREA Linear (AVG. GFN) Linear (AVG. SURFACE AREA)


Sand System Eck

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

01/03/14 01/24/14 02/14/14 03/07/14 03/28/14 04/18/14 05/09/14 05/30/14 06/20/14 07/11/14 08/01/14 08/22/14

SNB - THERMAL RECLAIMER -FINES% - 200, 270, PAN

FINES Linear (FINES)


Sand System Eck

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

01/03/14 01/17/14 01/31/14 02/14/14 02/28/14 03/14/14 03/28/14 04/11/14 04/25/14 05/09/14

SNB - THERMAL RECLAIMER -% MOISTURE -%LOI

% MOISTURE % LOI %FINES Linear (% MOISTURE) Linear (% LOI) Linear (%FINES)


Sand System Eck

Chemistry

Fe2O3

(%)

Al2O3

(%) TiO2 (%)CaO (%)

MgO

(%)

Na2O

(%) K2O (%)

SiO2

(%) ADV pH LOI Clay NTU Perm

1/25/12 0.054 0.136 0.013 0.022 0.016 0.003 0.018 99.738 0.9 7.5

7/18/12 0.054 0.128 0.012 0.024 0.014 0.002 0.029 99.738 1.4 7.4

9/27/13 0.061 0.142 0.014 0.027 0.016 -0.001 0.023 99.719 1.2 7.7. 0.014

Sieve

Analysis 20 30 40 50 70 100 140 200 270 PAN GFN

1/25/12 0.0 0.4 11.9 25.3 30.3 26.9 5.0 0.0 0.0 0.0 52.9

7/18/12 0.0 0.2 11.1 26.9 31.4 24.4 5.7 0.2 0.0 0.0 53.0

9/27/13 0.0 0.4 9.7 23.4 30.8 30.0 5.5 0.2 0.0 0.0 54.5

Request your sand supplier check the sand chemistries from

your reclaimed sand to verify there are no changes or trends.


Conclusion

• Sand Quality – monitor everything you can, and as

frequent as you have resource for. Make incremental

changes and measure results before making more changes.

• Reclamation Equipment – it is self destructive, preventive

maintenance is required to maintain consistent sand

quality.

• The blending of the sand was done to reduce cost and

increase capacity without purchasing new sand. It is

working for us, but has to be monitored.

• Utilize your suppliers, for additional testing and a resource

for experience and advice.

Sand Reclamation for an Aluminum Foundry · PDF fileAFS Sand Casting Conference October 20-22,...

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