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AFS Sand Casting Conference October 20-22, 2014 – Indianapolis, IN USA The Process of Sand Reclamation Charles Tim Storey President IMF North America
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
The Process of Sand
Reclamation
Charles Tim Storey
President
IMF North America
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Green Sand to N.B. Core Sand
Reclamation
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Conversion of Waste Streams
• Broken & scrap cores
• Sand from box change / head
• Cold box, warm box, & shell
• Return green sand from shake out
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Waste Stream from Green Sand
Molding
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
200 Ton – Bulk Sand Storage
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Receiving Hopper, Lump Crusher,
Bucket Elevator, 1st Mech. Scrubber
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Pneumatic Scrubber Working
Diagram
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Dust Collector for Mech. Scrubber
Closed Loop Water Cooler
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Thermal System Components
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Thermal Furnace &
Fluidized Bed Cooler
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Fluidized Bed Sand Cooler
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Thermal Unit & Heat Recovery
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Furnace Nozzles
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Air & Gas Injection
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Thermal Furnace - Fluidized Bed
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
High Temperature Dust Collector
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Electrical Control Panel
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Visual Sand Results
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Historical Reclaim Data
Foundry #1
Sand to Reclaim Sand to Plant Percent
2012 –
6 Mos 2014 26,067 20,679 79%
Foundry #2
Sand to Reclaim Sand to Plant Percent
July 2013 -
July 2014 16,578 13,700 83%
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Return to Reclaim Comparison
Return Reclaimed
AFS – GFN 63.3 63.6
# SCREENS (40,50,70, 100, 140) 5 5
L.O.I. 7.03% 0.06%
pH 9.8 9.2
ADV @ pH 7 19.4 3.9
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Historic Cost / Ton
Natural Gas $3.53 / ton
Electricity $4.20 / ton
Maintenance $1.90 / ton
Total Operating Cost $9.63 / ton
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Cost Reduction Features• Reclaimed sand ~= $ 9.63 / ton
• New sand (Delivered) $ 60.00 / ton
• Reduction of sand disposal cost ~= $ 15.00 / ton
• Cost reduction ~= $ 65.00 / ton
• Reduction / Elimination of Expansion Additive
• Active bentonite in fines from 1st mechanical scrubber
can be added back into green sand bond
• Reclaimed sand - better than new reduce resin % to
achieve same tensile
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Green Sand to Core Sand
Reclaim Units in USA
• Union Foundry 6 MTPM
• Waupaca #2 2 MTPH
• Waupaca #5 8 MTPH
• Columbus Foundry 8 MTPH
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Casting
75% Reclaim / 25% New
AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Casting Sectioned for
Inspection
