Examining sand Reclamation Technology.By selecting the appropriate sand reclamation system for your operation, your foundry can reduce raw material costs and improve the bottom line.
Deciding to reclaim your sand is only the first step. When focusing on specific equipment for your operation, many different variables loom, such as system type, dimensions and capacity. To make the decision process easier, modern casting offers the following detailed guide of the various thermal and mechanical sand reclamation systems available. In addition, recent installation information is provided to demonstrate the effectiveness of the systems in operation.
An important fact to remember is that the information supplied is only one model of equipment; additional models and system types may be available from the manufacturer. In addition, the machine-specific information was provided by the manufacturer through a survey.
Rotary Lump Crusher/Sand Reclaimer
Didion International, Inc.
Riverside Industrial Centre
7000 West Geneva Geneva, canton and city, Switzerland
Geneva (jənē`və), Fr. Genève, canton (1990 pop. 373,019), 109 sq mi (282 sq km), SW Switzerland, surrounding the southwest tip of the Lake of Geneva. Drive St. Peters, Missouri 63376
Contact: Mike Didion.
System type: Mechanical.
Drum dimensions: Ranging from 4 x 16 ft to 6 x 30 ft.
Capacity: 1-40 tons/hr.
Key attributes: A serrated-tooth lining offers wear resistance while breaking down large sand lumps and separating metallics from the sand. Automatic recirculation Noun 1. recirculation - circulation again
circulation - the spread or transmission of something (as news or money) to a wider group or area of lumps provides additional scrubbing and higher output percentages, while integral sand screening and fines removal classifies the sand with extremely low cubic ft/mm requirements.
In operation: Vibratory vibratory /vi·bra·to·ry/ (vi´brah-tor?e) vibrating or causing vibration.
vibrating or causing vibration; vibritile. feed conveyors send large sand lumps into the reclaimer. High profile flights screw the lumps forward where they enter the dual chamber attrition section and are reduced to less than 0.375 in. The tramp metal is separated out. The sand then passes through tapered holes in the cast lining to an outer chamber where screening and primary classification occurs. Remaining large chunks automatically are recirculated into the feed conveyor for another pass through the machine. The binder and fines then are removed to a baghouse, leaving only reclaimed sand.
Foundry data: Betz Industries is a nobake molding gray and ductile iron Ductile iron, also called ductile cast iron or nodular cast iron, is a type of cast iron invented in 1943 by Keith Millis. While most varieties of cast iron are brittle, ductile iron is much more ductile, as the name implies. foundry located in Grand Rapids, Michigan “Grand Rapids” redirects here. For other uses, see Grand Rapids (disambiguation).
Grand Rapids is a city in the U.S. state of Michigan. As of the 2000 census, the city population was 197,800. . It produces 12 tons of castings/hr for precision automotive dies, patterns and machine beds for the automotive and heavy industries.
Case history: In 1984, Betz Industries purchased a rotary sand reclaimer to begin nobake sand reclamation, and used it in conjunction with pneumatic scrubbers. After learning that the reclaimed sand was acceptable without using the secondary scrubbers, the company employed only the reclaimer, saving on energy, operation and maintenance costs. When Betz Industries expanded in 1999 (doubling the size of its foundry), it installed two new sand reclaimers, increasing production of reclaimed sand to 130 tons/hr. The company now reclaims 97% of its nobake sand, disposing only 3% dust. Reclaiming sand saves the company $4190.40/ hr. "The proven performance and excellent savings is why we continue to use rotary reclamation equipment. Its design is efficient (1 hp/ton) and requires little maintenance,"
R-Series Mechanical Reclamation Systems
Palmer Manufacturing & Supply, Inc.
18 Bechtle Avenue Springfield, Ohio Springfield is a city in the U.S. state of Ohio and the county seat of Clark CountyGR6. The municipality is located in southwestern Ohio and is situated on the Mad River and Buck Creek, approximately 45 miles (72 km) west of Columbus and 25 miles (40 45504
Contact: Jack Palmer or Lee White.
System type: Mechanical.
Footprint: 9 x 18 ft.
Capacity: 1-10 tons/hr.
Key attributes: The system features an attrition mill with dust hood, feed elevator, screener, surge hopper, flow control valve A flow control valve regulates the flow or pressure of a fluid. Control valves normally respond to signals generated by independent devices such as flow meters or temperature gauges. Control valves are normally fitted with actuators and positioners. , classifier and discharge level control.
In operation: The top-loading attrition mill uses a dual-screen agglomeration ag·glom·er·a·tion
1. The act or process of gathering into a mass.
2. A confused or jumbled mass: reduction system comprised of two perforated steel plates. The first is located in the bottom of the mill in the primary chamber and permits only loose sand and small lumps to feed into the secondary chamber. The second screen is located at the discharge flange flange (flanj) a projecting border or edge; in dentistry, that part of the denture base which extends from around the embedded teeth to the border of the denture.
1. of the secondary chamber and the discharge housing and allows only grain-size sand to exit. The feed elevator transfers reclaimed sand from the discharge of the attrition mill to the top of the screener hopper where a high-frequency pneumatic vibrator vibrator /vi·bra·tor/ (vi´bra-tor) an instrument for producing vibrations.
an apparatus used in vibratory treatment. mounted to the screener segregates compound grains. The sand then is fed through the flow control valve to regulate the sand flow into the classifier body so that fines extraction efficiency is constant. After the fines extraction, the reclaimed sand is ready for use.
Foundry data: Midland Manufacturing Co., a producer of copper-based components in Fort Worth, Texas Fort Worth is the fifth-largest city in the state of Texas, 18th-largest city in the United States, and voted one of "America’s Most Livable Communities. purchased a R-3 Reclaimer in January 2000.
Case history: Midland has converted many of its green sand jobs and tooling to nobake mold boxes as a result of the purchase of a complete nobake molding system in January 2000. The result with the molds is a high sand-to-metal ratio. Coupling this fact with the alloys it pours, Midland is faced with a difficult process to minimize loss-on-ignition (LOI LOI Letter of Indemnity (international trade and carriage business)
LOI Letter Of Intent
LOI Loss On Ignition
LOI Letter of Inquiry
LOI Lack Of Information
LOI Lack of Interest
LOI Letter of Invitation
LOI List Of Items ) sand properties. Without additional process changes or equipment, Midland has controlled its LOI, keeping it less than 2% with minimal new sand additions. Further trimming of sand usage per mold, increase of fluidization Fluidization
The processing technique employing a suspension or fluidization of small solid particles in a vertically rising stream of fluid—usually gas—so that fluid and solid come into intimate contact. and dust collection in the classifier, and reductions in binder usage all have contributed to Midland's LOI being on a consistent down slope. Midland is on track to attain a consistent LOI of 1% within the next six months using only mechanical reclamation.
Calcifire Thermal Reclamation System
Dependable Foundry Equipment Co.
P.O. Box 3210
12505 S.W. Herman Road
Tualatin, Oregon Tualatin (IPA: tu ɔ lə tn̩) is a city that is a southwestern suburb of Portland, Oregon, United States. 97062
Contact: Bill Zachary.
System type: Thermal.
Footprint: 7 ft 6 in. x 14 ft 7 in.
Capacity: 0.5-5 tons/hr.
Key attributes: A direct-fired fuel bed chamber introduces sand from the top and provides full fluidization wall-towall. It works on both chemically-bonded and clay-bonded sand.
In operation: The binder material combusts in the fluid bed chamber as air and natural gas are introduced through distributor tubes. Heat-resistant steel and ceramic fiber insulation eliminate the need for refractory linings and allow the peak temperature to be reached quickly. Sand flow through the fluid bed easily is regulated for desired effectiveness, resulting in reclaimed sand that is ready to use.
Foundry data: Buddy Bar Casting, Inc., South Gate, California South Gate is a city in Los Angeles County, California, United States. It is part of the Gateway Cities region of southeastern Los Angeles County. In 2005 the city had an estimated total population of 103,547. , is an aluminum foundry that specializes in high performance aftermarket automotive components including engine blocks and cylinder heads.
Case history: Buddy Bar recently installed a I ton/hr system. The foundry thermally reclaims sand from phenolic phe·no·lic
Of, relating to, containing, or derived from phenol.
Any of various synthetic thermosetting resins, obtained by the reaction of phenols with simple aldehydes and used as adhesives. urethane urethane (yoor´ithān´),
n ethyl carbamate used as an anesthetic agent for laboratory animals, formerly used as a hypnotic in humans. bonded nobake molds. The reclaimed sand includes a percentage of shell cores. Bill Fell, president of Buddy Bar Casting, said he expects to reclaim virtually 100% of the spent sand from the mold and core processes and reduce sand disposal to a small fraction of the current level. In addition to savings in new sand purchases and reduced disposal costs, the foundry expects to achieve thermal stabilization of sand grains to minimize or totally eliminate certain dimensional defects experienced with new sand.
TF-3000 Thermfire Thermal Sand Reclamation System
Gudgeon Thermfire International, Inc.
420 Neptune Crescent
London, Ontario, Canada N6M lAl
Contact: Brent Gudgeon.
System type: Thermal.
Dimensions: 13 ft 8 in. x 8 ft x 15 ft lOin loin (loin) the part of the back between the thorax and pelvis.
The part of the body on either side of the spinal column between the ribs and the pelvis. .
Capacity: 1.5 tons/hr.
Key attributes: The reclamation is performed entirely in one machine and can reach working temperature for processing sand from a cold start in 25 mm. The system features two sources of heat recovery, making it thermally efficient and minimizing natural gas usage.
In operation: The sand feeds into the calcining chamber and is elevated to a temperature of 1300F (704C) using an indirect firing method that allows for lower operating temperatures. The temperature is controlled by a thermocouple that feeds data to the PLC, which controls the motorized mo·tor·ize
tr.v. mo·tor·ized, mo·tor·iz·ing, mo·tor·iz·es
1. To equip with a motor.
2. To supply with motor-driven vehicles.
3. To provide with automobiles. valves in the gas supply lines. Direct spark ignition and flame rods on the burners detect flames when burning the gas mixture. The thermally reclaimed sand passes over a weir from the calcining chamber into the sand transfer box, which moves the sand to the cooling bed below. The sand temperature is reduced to 8SF (29C) on discharge as fluidizing air travels through it to dissipate the heat.
Foundry data: Arrow Aluminum Castings Co., Avon Lake, Ohio Avon Lake is a city in Lorain County, Ohio, United States. The population was 18,145 at the 2000 census. Geography
Avon Lake is located at (41.501595, -82.006309). , casts aluminum components using nobake molding and shell and coldbox coremaking.
Case history: Arrow desired a sand reclamation system and made its choice based on the recommendations of other foundries. Its reclamation system produces sand that meets or surpasses the quality of new sand. Closing the loop on buying and dumping sand also has allowed Arrow to purchase better quality sand, improving its entire molding process.
PXC PXC Photonic Cross-Connect (Nortel)
PXC Premium Noise-Cancelling (headphones)
PXC Pacific Xtreme Combat
PXC Pirate Core (music genre)
PXC Pdf Exchange Compact Thermal Sand Reclamation Unit Vulcan Engineering Co.
One Vulcan Drive Helena Industrial Park
P.O. Box 307
Helena, Alabama Helena is a city in Shelby County, Alabama, United States. At the 2000 census the population was 10,296. It has the eighth lowest crime rate per population in the U.S. Helena has two grocery stores. The city also has a McDonalds and a Backyard Burger. 35080
Contact: Kevin Crawford Kevin Crawford is a flute, tin whistle and bodhrán player. Born on 1967-12-06 in Birmingham, England to Irish parents who immigrated from Miltown Malbay, County Clare. He later moved to West Clare to improve his music and become more exposed to traditional Irish music. .
System type: Thermal.
Dimensions: l7 ft x 9 ft 3 in. x l7 ft 10 in.
Capacity: 0.25-1 ton/hr.
Key attributes: Compact design allows smaller foundries with limited space constraints to have sand reclamation equipment. The dead bed area of the sand reclamation system uses the sand itself to protect the low thermal mass Thermal mass, in the most general sense, is any mass that absorbs and holds heat. In the architectural sense, it is any mass that absorbs and stores heat during sunny periods when the heat is not desirable in the living space of a building, and then releases the heat during ceramic fiber insulation from the direct mechanical abrasion of the fluidized sand, eliminating the need for metal containment tanks within the furnace.
In operation: Sand enters the fluid bed heat exchanger heat exchanger
Any of several devices that transfer heat from a hot to a cold fluid. In many engineering applications, one fluid needs to be heated and another cooled, a requirement economically accomplished by a heat exchanger. and travels a circuitous cir·cu·i·tous
Being or taking a roundabout, lengthy course: took a circuitous route to avoid the accident site. path around the internal stainless steel stainless steel: see steel.
Any of a family of alloy steels usually containing 10–30% chromium. The presence of chromium, together with low carbon content, gives remarkable resistance to corrosion and heat. tubes. Half of the furnace fluidization air is passed through these tubes and heated to approximately 930F (449C). It then is passed to the furnace via the pre-heat manifold. Hot sand then follows the circuitous path around the tubes with spiral wound fins. Cooling water passes through the tubes in a counter-flow path to cool the sand down to 18F (8C) above wet bulb temperature.
Foundry data: Integra Castings, Manitoba, Canada, is a gray and ductile iron foundry that uses nobake molds to produce manufacturing and agricultural castings from 100-500 lb.
Case history: Integra installed the thermal reclamation system in 1996, having previously used a mechanical system. Since installing the system, sand costs have decreased and the foundry is creating better quality castings--the reclaimed sand causes less veining vein·ing
Distribution or arrangement of veins or veinlike markings. and burning, making a better finish.
General Kinematics kinematics: see dynamics.
Branch of physics concerned with the geometrically possible motion of a body or system of bodies, without consideration of the forces involved. Corp.
777 Lake Zurich For the lake and village in the U.S., see .
Lake Zurich (Alemannic: Zürisee; German: Zürichsee) is a lake in Switzerland, extending southeast of the town of Zürich. It is also known as Lake Zürich and Lake of Zürich. Rd.
Barrington, Illinois Barrington is a village in Cook County, Illinois and Lake County, Illinois. The population was 10,168 at the 2000 census. Barrington is part of the greater Chicago metropolitan area. 60010
Contact: Bill Clark.
System type: Mechanical.
Footprint: 10 x 10 ft.
Capacity: 20-30 tons/hr.
Key attributes: The system is a 2-mass natural frequency unit designed for efficient heat removal with ambient air during lump reduction. After initial startup, energy only is required to overcome frictional losses as lumps and sand tumble in a fluid mass.
In operation: The unit's curved drum chamber works in tandem Adv. 1. in tandem - one behind the other; "ride tandem on a bicycle built for two"; "riding horses down the path in tandem"
tandem with vibratory motion to enhance tumbling action and attrition. A large curved screen area speeds up the reduction of nobake lumps to original grain size. Tramp metal is discharged through a pneumatically actuated side gate. Aspecially-designed air bag system tilts one end of the unit a few degrees to promote flow during the trash" unloading cycle.
Foundry data: U.S. filter Castalloy Div.'s steel foundry in Waukesha, Wisconsin Waukesha [ˈwɑkəˌʃɑ] is a city in and the county seat of Waukesha CountyGR6, Wisconsin, United States. As of the 2000 census, Waukesha had a total population of 64,826. uses nobake and shell molding and shell, coldbox and hotbox hot·box
An axle or journal box, as on a railway car, that has become overheated by excessive friction.
Noun 1. hotbox - a journal bearing (as of a railroad car) that has overheated coremaking to produce manufacturing equipment.
Case history: Through an increase in casting capacity, Castalloy had outgrown its existing reclamation system. Sand lump reclamation had become a bottleneck. The foundry investigated several options, but many required extensive changes in process flow to accommodate an increase in the space required for an upgraded system. In the end, the foundry decided on a Vibra Mill Drum that could be installed in the existing area and only required slight modifications to conveyers. This system improved capacity from 5-6 tons! hr to 9-11 tons/hr and keeps pace with the furnace's melt capacity. Installation took three days.
GMD (company) GMD - Full name: "GMD - Forschungszentrum Informationstechnik GmbH" (German National Research Center for Information Technology).
Before April 1995, GMD stood for "Gesellschaft für Mathematik und Datenverarbeitung" - National Research Center for Computer Science, Thermo-Scrubber Thermal Sand Reclaimer
GMD Environmental Services The various combinations of scientific, technical, and advisory activities (including modification processes, i.e., the influence of manmade and natural factors) required to acquire, produce, and supply information on the past, present, and future states of space, atmospheric,
P.O. Box 11375
Fort Worth, Texas 76110
Contact: Jerry Reier.
System type: Thermal.
Footprint: 15 x 20 x 35 ft.
Capacity: 1 ton/hr.
Key attributes: The system uses close-coupled fluid beds that provide calcining and pre-cooling on a continuous basis by hot air scrubbing and gravity transfer without moving parts Moving parts are the components of a device that undergo continuous or frequent motion, most commonly rotation. "Parts" only include the mechanical components which does not include fuel, or any other gas or liquid. .
In operation: Sand is fed into a surge bin and then into the reclamation system. Calcining heat is added via the fossil fuel fossil fuel: see energy, sources of; fuel.
Any of a class of materials of biologic origin occurring within the Earth's crust that can be used as a source of energy. Fossil fuels include coal, petroleum, and natural gas. combustion system into the fluid bed at a temperature from 1350-1650F (732-899C). Supplemental fuel is fired in the firebox below the calcining chamber, eliminating coking and ensuring a consistent temperature in the calcining bed. The sand leaves the chamber by flowing over a weir, then travels through the transfer duct by gravity into the pre-cool chamber. There it is cooled with ambient air to a discharge temperature from 700-850F (371-454C).
Foundry data: Gregg Industries, Inc.,
El Monte, California
El Monte is a city in Los Angeles County, California, United States. The city's slogan is "the end of the Santa Fe Trail" and "Welcome to Friendly El Monte. , a green sand foundry, has been using the reclamation system since 1992.
Case history: Gregg Industries reclaims its excess sand and core butts to a condition equal to or better than the new sand. Return and excess sand is continually processed through the system. Clay-bonded sand from the molding operation and broken shell core butts can be processed together in any combination, producing usable sand. Much of this reclaimed sand is shell coated for use in its core room, while the rest is used as additions in the preparation of molding sand (Founding) a kind of sand containing clay, used in making molds.
See also: Molding . The foundry no longer buys coated sand and purchases only a small amount of new sand to replace that lost through normal attrition. It estimates that without reclaiming excess sand, disposal costs would be $500,000 annually.
Fata Aluminum, Inc.
37654 Amrhein Rd.
Livonia, Michigan Livonia is a city located in the northwest part of Wayne County in the U.S. state of Michigan. As of the 2000 census, the city had a total population of 100,545, making it the eighth largest in the state. 48150
Contact: Brian Ginnard.
System type: Thermal regeneration.
Dimensions: Ranging from 16 ft 5 in. x 32 ft 10 in. x 37 ft 9 in. to 24 ft 8 in. x 49 ft 3 in. x41 ft.
Capacity: 3-12 tons/hr.
Key Attributes: This system can be used to reclaim both resin-bonded and green sand. The reclaimed sand can be reused throughout all types of molding and coremaking. The system runs automatically without the need for an operator.
In Operation: For chemically-bonded sand, a screw conveyor carries a metered amount of sand into a cylindrical calcination calcination (kăl'sənā`shən), in metallurgy, process of heating solid material to drive off volatile chemically combined components, e.g., carbon dioxide. It is sometimes a step in the extraction of metals from ores. chamber with insulated walls and a stainless steel base plate. The base plate features fluidization nozzles placed together with gas feed pipes on the same axis. Air and gas are mixed together inside a combustion chamber Combustion chamber
The space at the head end of an internal combustion engine cylinder where most of the combustion takes place. See Combustion . Sand flow from the combustion chamber to the pre-cooler is vale-controlled. The pre-cooler consists of two fluidizing beds connected by valves. A concurrent flow of air passes through the sand, cooling the sand to 572F (300C) while recovering 932F (500CD of heat energy. The sand then passes into the final cooler, which is composed of a fluid bed chamber equipped with a circulating water tube nest. After exiting from the final cooler, the sand passes over a vibratory screen that eliminates any remaining impurities. The process for green sand reclamation is similar.
Foundry data: Three Teksid Aluminum Foundries, two in Sylacauga, Alabama Sylacauga is a city in Talladega County, Alabama, United States. At the 2000 census the population was 12,616.
The first documented case of an object from outer space hitting a person happened in Sylacauga. and one in Dickson, Tennessee Dickson is a city in Dickson County, Tennessee, United States. The population was 12,244 at the 2000 census. Geography
Dickson is located at (36.071485, -87.374539)GR1. use the Hot-Rec systems.
Case history: The Sylacauga plants each have a 12 tons/hr system that processes silica sand used in lost foam casting. These systems were ramped up in the last few months. The Dickson plant uses a 6 tons/ hr system for reclaiming coldbox cores used in semi-permanent mold casting.
RSR RSR Regular sinus rhythm, see there 5-1 Rotary Sand Reclaimer
Roberts Sinto Corp.
3001 West Main Street
P.O. Box 40760
Lansing, Michigan “Lansing” redirects here. For other uses, see Lansing (disambiguation).
Lansing is the capital city of the U.S. state of Michigan, and the state's sixth largest city. 48901
Contact: Roger Hayes.
System type: Rotary mechanical.
Footprint: 4 ft 6 in. x 9 ft.
Capacity: 3.3 tons/hr.
Key attributes: The reclaimer has low capital and operating costs operating costs npl → gastos mpl operacionales but high throughput efficiency. One hundred percent of the reclaimed sand from the system is able to be reused in nobake molding. During operation, the system forces sand grains to scrub against each other, increasing reclamation efficiency.
In operation: The system receives shakeout sand into a receiver hopper. The sand then passes at a rated throughput into the rotary reclaimer cell. Fines are removed in a fluid bed classifier before the sand is sent to a surge silo. A transporter delivers reclaimed sand to a day hopper for use in molding and coremaking.
Foundry data: Schlumberger Industries, a phenolic urethane nobake shop in Tallassee, Alabama Tallassee is a city that is divided between Elmore County and Tallapoosa County, Alabama, United States. At the 2000 census the population was 4,934. It is home to a major hydroelectric power plant at Thurlow Dam operated by Alabama Power Company. .
Case history: Schlumberger was looking for Looking for
In the context of general equities, this describing a buy interest in which a dealer is asked to offer stock, often involving a capital commitment. Antithesis of in touch with. a reclamation system to reduce the sand disposal costs for its copper-base casting facility. The foundry wanted to reclaim the largest percentage of its 85 GFN GFN Gone for Now
GFN Gay Financial Network
GFN Good For Nothing
GFN Glass Filled Nylon
GFN Group-Forming Network
GFN Grand Forks, North Dakota (border patrol sector)
GFN Goodbye for Now
GFN Global Futures Network silica sand possible, so efficiency of the reclamation system was critical. The foundry purchased an RSR 5-1 Rotary Reclamation System. The system included bucket elevators, the reclamation equipment and touch screen controls, surge storage, and a pneumatic transporter to bring reclaimed sand to the core room hoppers. "Before the reclaimer, we were hauling our waste sand out behind the plant," said Dave Patton, foundry manager. "Using the reclamation system, we are retaining 100% of our recycled sand. We are working 10-hr shifts, four days a week and are recycling more than 12 tons of sand/day." During the first two months of operation, the 10-hr for the reclaimed sand remained below 1% with a system throughput at 90% efficiency.
Model 4 Cell Pro-Claim
Simpson Technologies Corp.
751 Shoreline Drive
Aurora, Illinois 60504
Contact: Dave Silsby.
System type: Pneumatic reclaimer.
Dimensions: 21 ft 11.375 in. x 10 ft 11.375 in. x 13 ft 5.25 in.
Capacity: 8-10 tons/hr.
Key attributes: The system uses air as the motivating force and the sand grains as the abrasive body to scrub the sand clean.
In operation: The sand is propelled by air through an inside tube and scrubbed against sand trapped under a target. The sandlair mixture is established in the sand inlet mixing chamber. Agglomerates are disintegrated and the impringement of grains against each other scrubs off binder coatings. The sand curtain is exposed to exhaust air drawn through rectangular openings in an exhaust shroud that surrounds the target. This exhaust air removes the fines as they are created. The sand enters the final dedusting chute to pass through the vibratory classification screen. The reclaimed sand and the refuse are discharged separately.
Foundry data: A green sand foundry casts steel railroad components with sodium silicate cores. The foundry has a production rate of 22 tons of castings/shift and is using sand at a rate of 15 tons/hr.
Case history: This steel foundry was adding 25 tons/day of facing sand to its sand system and removing an equal amount to keep the sand system in balance. The sand removal from the system meant that valuable clay also was removed and sent to disposal. The foundry installed a pneumatic reclamation system with a feed hopper, cyclone and dust collection to improve the disposal situation. The reclaimer has a capacity to process 32,000 tons/year of sand. The reclamation system produces a yield of 85%, reducing disposal to only 15%.
The foundry realized a payback on the reclamation equipment in six months. Factoring in the sand and clay usage reductions, cost of operation, maintenance and other costs associated with the reclamation system, the foundry is saving more than $1800/day through reclamation.
Sand Lion Deep Fluidized Bed
Consolidated Engineering Co.
1971 McCollum Pkwy NW
Kennesaw, Georgia 30144
Contact: Jim Garrett.
System type: Fluidized bed thermal reclaimer.
Dimensions: 200 and 265 cu ft work capacities (depending on system).
Capacity: Starting at 2 tons/hr.
Key attributes: This reclaimer combines several foundry processes into one and has been applied most often to aluminum castings (although ferrous systems are available). In addition to thermally reclaiming sand, the system decores castings without knockout or shakeout. The system also can be equipped with quenching quenching
Rapid cooling, as by immersion in oil or water, of a metal object from the high temperature at which it is shaped. Quenching is usually done to maintain mechanical properties that would be lost with slow cooling. equipment for heat treatment.
In operation: The process begins as the castings with molds and/or cores intact are immersed in a heated bed of fluidized sand. The heat and oxygen present in the bed de-bond the molds and cores (which can be made with any thermally reclaimable binders). The sand is thermally reclaimed in the bed and cleaned sand overflows from a discharge spout.
Thermpak Reclamation System Castec, Inc.
1462 Delberts Drive
Monongahela, Pennsylvania 15063
Contact: Ron Parker. System type: Thermal.
Dimensions: 20 x 12 x 10 ft.
Capacity: 18 tons/day.
Key attributes: The post reclaimer increases throughput capacity and greatly improves operating efficiency. The system doesn't have moving parts in heat zones or use castable refractory.
In operation: The heat exchanger preheats the fluidizing air by utilizing the heat in the exhaust from the calciner. The fluidizing air then acts on the sand, which enters the post reclaimer. The sand cooler receives reclaimed sand from the post reclaimer and cools it to within 5 degrees of ambient air temperature.
Foundry data: Flotech, Inc., a nobake foundry in Jacksonville, Florida, installed a system in 1998.
Case history: Flotech purchased the system for its overall compactness and cost/results ratio. By installing the sand reclamation system, Flotech reduced overall sand purchases by 75%, resulting in a savings of $50,000/yr.