Sand Reclamation Overview - afsinc.s3.amazonaws.com€¦ · AFS Sand Casting Conference October...

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

Sand Reclamation

Overview

Reclaimed Sand That Performs As Well As – Or

Better Than – New Sand.

David Silsby

SIMPSON TECHNOLOGIES CORPORATION


Reconditioning vs. ReclamationAs Defined By the AFS 4S Committee on Sand Reclamation and Reuse

Reclamation: “is the

physical, chemical or thermal

treatment of a refractory

aggregate to allow reuse

without significantly lowering

the original properties.”

Reconditioning: “is sand that

has received some degree of

cleaning work, but not

enough to make the sand

suitable as a new sand

replacement.”


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


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.


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.


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 )


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


Reduce to -

1/8”

Remove

Tramp

Remove Shot

Sized for

Operation

Anti-Segregation

Pro-Claim

Attrition Unit

Screen

Magnetic

Separator

Sand Storage

Reclaimer

Non Metallic

Below 100F -

120F (If

Required)

Sand for System

Sand Screen

Sand Cooler

(if required)

Transporter

Sand Storage


Attrition Scrub Calcine Scrub

Reclamation Process Options


Reclamation Processes

• Mechanical

• Pneumatic

• Thermal

• Combinations


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


Batch Number

Nozzle Gap Setting

Scrub Rate (lb/hr/cell)

Plenum Negative

Sample Locations Sand Cyclone Sand Cyclone

AFS/GFN 53.07 56.76 158.14 56.62 170.43

Loss on Ignition (LOI) % 5.53 3.37 10.14 2.84 10.58

AFS Clay % 12.00 8.40 6.80

Methylene Blue Clay % 10.00 7.00 6.10

LOI Reduction 39.06% 48.64%

AFS Clay Reduction 30.00% 43.33%

M.B. Clay Reduction 30.00% 39.00%

As Rec.

Sand

A-1 A-2

1.25 1.25

6" 6"

2000 1500

Simpson Technologies Laboratory EvenFlo Pneumatic Reclaimer

Sample A

Reclamation Laboratory Test Results

Test No.FL060201


3.12 TPD Lost Sand

1.90 TPD

Clay

PRODUCTION

Land Fill

Reclaim

System

Backing

MullerFacing

Mix Muller

25 TPD Cores

64 TPD

162.88 TPD

.82 TPD

Clay

7.52 TPD Sand

2.08 TPD Clay

56.30 TPD163.70 TPD

54.40 TPD

15.0 TPD Scalping's

Green Sand To Green Sand

Reclamation


Green Sand To Green Sand

Reclamation


Resin Sand To Resin Sand

Reclamation

Goal – Remove residual binder for rebonding

• remove surface binder

• maintain AFS / GFN & Distribution


Resin Sand To Resin Sand

Reclamation


Variable Name Data

Equipment Type 4-Cell Reclaimer

Horsepower 150 HP

Labor Cost $ 50.00 per man hour

Hours of Daily Operation 16 hrs./day

Cost per Kilowatt Hour $0.06447 /KWH

Tons Processed 10 TPH

Parts # Required Life in Hrs. 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

Electrical Power

Blower Drive Motor $ 0.721

Reclaimer Contribution to Operating Costs $ 1.165


Green Sand to Core Sand

Reclamation


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.


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

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