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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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.”
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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.
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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.
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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 )
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Attrition Scrub Calcine Scrub
Reclamation Process Options
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Reclamation Processes
• Mechanical
• Pneumatic
• Thermal
• Combinations
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Green Sand To Green Sand
Reclamation
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Resin Sand To Resin Sand
Reclamation
Goal – Remove residual binder for rebonding
• remove surface binder
• maintain AFS / GFN & Distribution
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Resin Sand To Resin Sand
Reclamation
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Green Sand to Core Sand
Reclamation
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
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.
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
For additional information, please
contact:
• Dave Silsby
• Simpson Technologies Corp.
• 751 Shoreline Drive, Aurora, IL 60504
• 630-978-0044
• 630-978-0068 (Fax)
• www.simpsongroup.com