Sand Reclamation for an Aluminum Foundry · PDF fileAFS Sand Casting Conference October 20-22,...
Transcript of Sand Reclamation for an Aluminum Foundry · PDF fileAFS Sand Casting Conference October 20-22,...
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand Reclamation for an
Aluminum Foundry
(Rod Christiansen & Greg Shea)
(Eck Industries)
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Definition
• Cleans the sand to a degree sufficient to
allow its re-use in the foundry Molding or
Core making Operations.
• Mechanical Attrition
• Thermal Reclamation
• Blending Thermal w/Mechanical
• New Sand Addition
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
History of Reclamation at Eck
• Thermal – 2007
• Thermal/Mechanical Blended – 2013
• Phenolic Urethane
• Polyol
• Isoset (SO2)
• Shell
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Reasons for Sand
Reclamation
CostReclaimed Sand vs New Sand
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Savings
• Thermal Reclaimed
Natural Gas
Maintenance Labor
Supplies & Expenses
Maintenance Supplies
Disposal of Dust
Internal Transporting
• New
Sand Cost
Delivery
Waste Sand Disposal
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Savings
• Reclaimed is approximately 1/3 the
cost of our new sand.
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Savings
• Additional savings by blending
72% / 28%
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Pros of Sand Reclamation Achieve a better (rounded) grain shape.
Better densities
Less surface area for chemicals to coat the sand grains
resulting in easier mixing and reduced chemical costs
Sand grains have been through a thermal expansion phase
Environmental Stewardship
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
SAND RECLAMATION
EQUIPMENT AT ECK
Gudgeon 3
ton/hr. lump
Reducer
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
3 Ton/Hour
Lump Reducer
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
GK – 10 ton/hr.
Lump Reducer
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
Sand Transport
from Lump
reducers and to
waste sand silo
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
Brokk used for knockout
of larger molds
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
20,000# Mold – Brokk
used for knockout
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
Sand Blending
Gudgeon 3 Ton/Hr.
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
4 Burners – 1500 BTU ea.
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
Control
Panel
1250 Degrees Critical to Eck
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
Cooling Tower
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
Sand Classifier
Added when we
started blending
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
Sand Blending
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
RECLAMATION
EQUIPMENT AT ECK
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck - Blended
Characteristics:Shape - Rounded
Major Screens – 3.96%
Fines - .21%
Thermal – 72%
Blend – 28%
Density Packed – 111.59#
Density Unpacked – 97.81#
Loss On Ignition - .27%
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.05% 0.40%
9.57%
23.98%
31.34%
28.77%
5.42%
0.17% 0.02% 0.01%0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
20 30 40 50 70 100 140 200 270 Pan
Screen Distribution Blended Sand
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
40.00%
45.00%
01/08/14 01/29/14 02/19/14 03/12/14 04/02/14 04/23/14 05/14/14 06/04/14 06/25/14 07/16/14 08/06/14 08/27/14
SNB MIXER - MAJOR SCREENS - Blended
40 50 70 100 140
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.00
50.00
100.00
150.00
200.00
250.00
01/08/14 02/08/14 03/08/14 04/08/14 05/08/14 06/08/14 07/08/14 08/08/14 09/08/14
SNB MIXER - SURFACE AREA CALCULATION - AVG GFNBlended
Surface Area Avg. Grain Fineness
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
-0.10%
0.00%
0.10%
0.20%
0.30%
0.40%
0.50%
0.60%
01/08/14 02/08/14 03/08/14 04/08/14 05/08/14 06/08/14 07/08/14 08/08/14 09/08/14
SNB MIXER FINES % - 200 + 270 + PAN COMBINED -Blended
FINES 200+270+PAN Linear (FINES 200+270+PAN)
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
01/03/14 02/03/14 03/03/14 04/03/14 05/03/14 06/03/14 07/03/14 08/03/14 09/03/14
PER
CEN
TAG
E
SNB MIXER - %LOI - %MOISTURE - Blended
% MOISTURE % LOI Linear (% MOISTURE) Linear (% LOI)
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck - Thermal
Characteristics:Shape - Rounded
Major Screens – 3.93%
Fines - .08%
Thermal – 100%
Density Packed – 112.23#
Density Unpacked – 101.04#
Loss On Ignition - .17%
New Sand Density Unpacked - 98.57#
New Sand Density Packed – 112.11#
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.01% 0.32%
9.34%
24.14%
32.05%
28.69%
5.05%
0.08% 0.00% 0.00%0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
20 30 40 50 70 100 140 200 270 Pan
Screen Distribution Thermal Sand
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
40.00%
04/08/14 04/22/14 05/06/14 05/20/14 06/03/14 06/17/14 07/01/14 07/15/14 07/29/14 08/12/14
SNB - THERMAL RECLAIMER - MAJOR SCREENS -40,50,70,100
40 50 70 100 Linear (40) Linear (50) Linear (70) Linear (100)
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
200.00
01/03/14 02/03/14 03/03/14 04/03/14 05/03/14 06/03/14 07/03/14 08/03/14 09/03/14
SNB - THERMAL RECLAIMER - AVG. GFN - SURFACE AREA CALCULATION
AVG. GFN AVG. SURFACE AREA Linear (AVG. GFN) Linear (AVG. SURFACE AREA)
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
01/03/14 01/24/14 02/14/14 03/07/14 03/28/14 04/18/14 05/09/14 05/30/14 06/20/14 07/11/14 08/01/14 08/22/14
SNB - THERMAL RECLAIMER -FINES% - 200, 270, PAN
FINES Linear (FINES)
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
01/03/14 01/17/14 01/31/14 02/14/14 02/28/14 03/14/14 03/28/14 04/11/14 04/25/14 05/09/14
SNB - THERMAL RECLAIMER -% MOISTURE -%LOI
% MOISTURE % LOI %FINES Linear (% MOISTURE) Linear (% LOI) Linear (%FINES)
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Sand System Eck
Chemistry
Fe2O3
(%)
Al2O3
(%) TiO2 (%)CaO (%)
MgO
(%)
Na2O
(%) K2O (%)
SiO2
(%) ADV pH LOI Clay NTU Perm
1/25/12 0.054 0.136 0.013 0.022 0.016 0.003 0.018 99.738 0.9 7.5
7/18/12 0.054 0.128 0.012 0.024 0.014 0.002 0.029 99.738 1.4 7.4
9/27/13 0.061 0.142 0.014 0.027 0.016 -0.001 0.023 99.719 1.2 7.7. 0.014
Sieve
Analysis 20 30 40 50 70 100 140 200 270 PAN GFN
1/25/12 0.0 0.4 11.9 25.3 30.3 26.9 5.0 0.0 0.0 0.0 52.9
7/18/12 0.0 0.2 11.1 26.9 31.4 24.4 5.7 0.2 0.0 0.0 53.0
9/27/13 0.0 0.4 9.7 23.4 30.8 30.0 5.5 0.2 0.0 0.0 54.5
Request your sand supplier check the sand chemistries from
your reclaimed sand to verify there are no changes or trends.
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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA
Conclusion
• Sand Quality – monitor everything you can, and as
frequent as you have resource for. Make incremental
changes and measure results before making more changes.
• Reclamation Equipment – it is self destructive, preventive
maintenance is required to maintain consistent sand
quality.
• The blending of the sand was done to reduce cost and
increase capacity without purchasing new sand. It is
working for us, but has to be monitored.
• Utilize your suppliers, for additional testing and a resource
for experience and advice.