Mold Wash Dryer Provides Energy Savings for Ferrous Foundry.In 1997, American Cast Iron Pipe Co. (ACIPCO ACIPCO American Cast Iron Pipe Company ), a ferrous ferrous (fĕr`əs), iron in the +2 valence state. Containing or having to do with iron. The difference between ferrous and ferric is the number of valence electrons they contain (ferrous contains two and ferric contains three), which caster in Birmingham, Alabama Birmingham (pronounced [ˈbɝmɪŋˌhæm]) is the largest city in the U.S. state of Alabama and is the county seat of Jefferson County. , was looking to improve the performance of its G-Foundry molding line. The decision to switch from a Naphthabased mold mold, name for certain multicellular organisms of the various classes of the kingdom Fungi, characteristically having bodies composed of a cottony mycelium. The colors of molds are caused by the spores, which are borne on the mycelium. coating to a water-based coating already had been made, which would result in annual savings of $11,700. Next, the operating cost of the existing gas-fired oven required examining. ACIPCO already had installed an electric infrared dryer in its D-Foundry in 1996. The Model MW-7290 from ITW/BGK Finishing Systems, Minneapolis, is a stationary-type dryer that operates in an indexing mode. After a mold is positioned under the dryer, the operator manually initiates the drying cycle. When the cycle timer timer, n radiographic timing device that functions as an automatic exposure timer and a switch to control the current to the high-tension transformer and filament transformer. The face of the timer is calibrated in seconds and fractions of seconds. times out, the mold is completely dry and ready for closing. In the first year, a 96% reduction of mold scab rejection was realized, and D-Foundry experienced the best improvement in scrap reduction of all their casting units. ACIPCO believed that the scrap reduction was due not only to mold scab reduction but was directly associated with the improved working environment as well as the production of consistently even-dried and well-dried molds. Part of the justification for replacing the existing gasfired mold-drying oven in C-Foundry was the performance of the new oven. As a result, it estimated saving 19 castings from mold scab defects at $376 each, saving $7144 annually. A similar yet expanded dryer was needed operate in a "dynamic" mode in G-Foundry. Five x 5-ft molds traveled from the wash application station and required drying at a constant rate of 4.4 ft/min. ITW/BCK electric infrared/forced-air mold wash dryers are designed for rapid drying of water-based refractory refractory Material that is not deformed or damaged by high temperatures, used to make crucibles, incinerators, insulation, and furnaces, particularly metallurgical furnaces. coatings on sand molds. The combination of short-wave electric infrared and the forced-air feature provide the high heat source required to quickly vaporize va·por·ize v. To convert or be converted into a vapor. Vaporize To dissolve solid material or convert it into smoke or gas. the water molecules and the air-flow essential to separate the water vapor from the sand surface. The dryers feature instant on/off capabilities, 0-100% adjustable power output, independent lamp zone control and an energy-saving idle mode. A 5 x 20-ft-long inline dynamic dryer was suspended sus·pend v. sus·pend·ed, sus·pend·ing, sus·pends v.tr. 1. To bar for a period from a privilege, office, or position, usually as a punishment: suspend a student from school. above the mold conveyor Conveyor A horizontal, inclined, declined, or vertical machine for moving or transporting bulk materials, packages, or objects in a path predetermined by the design of the device and having points of loading and discharge fixed or selective. , and drying time amounted to 4.5 min. The dryer lamp zones first were divided into a front and back section and then divided into a center and outside zone. When small molds were being processed, only the center zones in each section were activated. When large molds were processed, all four zones were activated. The dynamic dryer operates in an automatic mode. A mold nearing the oven breaks a photo eye positioned in front of the oven, triggering the front section. Molds then are tracked through the oven to trigger the back sections when a mold approaches. When the last mold leaves the oven, the zones shut down in reverse order. During times when the conveyor is not moving and/or no molds are present, the oven trims back to the energy-saving idle mode and is ready to respond instantly when production begins again. ACIPCO anticipated energy savings of $8400 annually over the previous gas-fired oven. When added to the $7144 savings in rejection costs, the numbers justified the oven's replacement. |
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