Economics and Efficiency in Sand Reclamation

Transcription

1 Economics and Efficiency in Sand Reclamation MCTS Colloquium Dr. Hartmut Polzin TU Freiberg Jens Müller-Späth G U T Seite 1

2 content about G U T Nobake Sand Reclamation in general Plant Capacity Design - less can be more Sand Transportation proper Plant Engineering required Automatisation and Energy Saving low hanging fruits Chromite Separation good example on cost savings Seite // GUT GmbH, HMS

3 our name is our program G = Giesserei = Foundry U = Umwelt = Environment T = Technik = Technology ABCDEF Seite 3 certified quality according DIN EN ISO 9001: // GUT GmbH, HMS

4 Our topic: foundry sand Consulting, Engineering, Equipment and Service for No-Bake Foundries Seite // G U T GmbH, JMS

5 Engineered solution fit to purpose G U T from consulting and engineering to a turn-key plant we design your success Seite // G U T GmbH, JMS

6 Extract foundry machinery Pneumatic Sand and Dust Conveyors Vibratory Lump crushers Sand cooler heater - classifiers Shake-out Devices Sand Separation Plants (Chromite out of Silica) Sand Reclamation (mechanical, pneumatical) Seite 6 Nobake Moulding Lines // G U T GmbH, JMS

7 Extract from reference list more than 100 plants and many other valued customers Seite // GUT GmbH, HMS

8 Our location in Germany and our plants worldwide Seite // G U T GmbH, JMS

9 content about G U T Nobake Sand Reclamation in general Plant Capacity Design - less can be more Sand Transportation proper Plant Engineering required Automatisation and Energy Saving low hanging fruits Chromite Separation good example on cost savings Seite // GUT GmbH, HMS

10 Quality parameters of reclaimed foundry sand low dust content constant sand temperature preferably only sand no others always similar grain size distribution L.O.I. constant and preferably low similar surface structure of sand grains constant sand quality reproducible processes high quality moulds and cores Seite // GUT GmbH, HMS

11 Reclamation technologies reclaim only as much as necessary not as much as possible! = L.O.I. reduction made from machines standard sand recovery pneumatical reclamation secondary attrition thermal reclamation L.O.I loss of sand investment sand costs Seite // GUT GmbH, HMS

12 Miracle sand reclamation system origin: sorry we donnot have but good systems for various applications Seite // GUT GmbH, HMS

13 Shake out 3 D Engineering Seite // GUT GmbH, JMS

14 Shake out with sound isolating cabin Seite // GUT GmbH, HMS

15 Shake out Seite // GUT GmbH, HMS

16 in case shake out grid is to small!!! Seite // GUT GmbH, JMS

17 CRKS: function Seite // GUT GmbH, HMS

18 CRKS Temperatur [ C] Temperaturmessung - CRKS Zeit [min] T-Sand [ C] T-Wasser,ein [ C] T-kompr.Luft [ C] T-Wasser,aus [ C] T-Umgeb [ C] Seite // G U T GmbH, JMS

19 Sandbehandlungsstationen. Entstauben, kühlen oder erwärmen. Seite // G U T GmbH, JMS

20 Plant Capacity Design high capacity areas everywhere where labour is involved! (ideally machines are faster than workers) x silo 1 hot used sand ~150 ton sand + lumps dosing chute Dedusting Sand inlet ~125 C Cooling Sand inlet ~28 C silo 2 hot sand ~20 ton Silo 3 mag. fraction ~20 ton 86 chromite Loading by Bobcat capacity: 10 t/h storage silo 5 new recl. chromite chromite 75t 25t Storage silo 4 reclaimed silica ~200 ton mix chrom. 10t reclaimed silica 60t 106 new sililca 10t 139 storage silo ton new silica 1 Load max. 20 tons x control cabinet 155 lump crusher coarse impurities grain hopper 74 mag. fraction hopper recl. silica chromite separation step 1 75 Big Bag new chrom. SF 6 SF 7 blending 132 SF double arm mixer 148 SF Shake Out 6 12 SF SF 5 SF 4 78 silica sand storage molding mixer station new silica sand supply 16 hopper Vibrating chute hopper Fe SBF1 SBF2 capacity: 30 t/h Seite 20 lower capacity areas machines runs 24 hours in automatic mode less capacity, but storage hoppers required to balance different requirements during a working day lower investment costs lower energy consumption // G U T GmbH, JMS

21 Level control unit Level control unit Plant Capacity Design L.O.I. box 3.000m³/h ~ mm Silo 2 used sand ~2x20 t Silo 1 hot sand silo L.O.I. box sand and lumps pre-cooling 3.000m³/h ~200 t 1.000m³/h 1.000m³/h Silo 3 pre-cooled reclaim sand ~100t Silo 4 pre-cooled reclaim sand ~100t 500m³/h dosing chute 1.000m³/h 2.000m³/h lump crusher 1 500m³/h dosing chute 1.000m³/h 2.000m³/h lump crusher 2 end cooling end cooling and dedusting and dedusting Silo 3 Silo 3 Silo 4 Silo 4 4 x 3.100m³/h CRKS-1 CRKS-2 CRKS-3 CRKS-4 =12.400m³/h hopper m³/h shakeout, size: x 3.900mm max. load: 15 tons average temp: 150 C 4.000m³/h 3.300m³/h over belt magnet ± 0, m³/h PC4 waste 500/ m³/h impurities Group B impurities 500m³/h PC5 waste 500/ m³/h main cabinet PC6 850/125 PC7 PC8 850/ /125 4 x 750m³/h =3.000m³/h PC9 850/125 ± 0,000 larger storage hoppers but significant less equipment 1.300m³/h L.O.I. box L.O.I. box vibrating feeder 1.000m³/h hopper iron parts 3.000m³/h ~ mm 3.000m³/h Silo 2 used sand ~2x20 t ~ mm ~ mm PCB PCB PCB x PCB 250/125 3 x 400m³/h = 1.200m³/h Silo 1 hot sand silo sand and lumps ~200 t 1.000m³/h Silo 4 pre-cooled reclaim sand ~100t Potential savings on: Investment costs Filter plant capacity Water re-cooling plant capacity Air compressor capacity m³/h hopper shakeout, size: x 3.900mm max. load: 15 tons average temp: 150 C 4.000m³/h 3.300m³/h over belt magnet 1.300m³/h ± 0, m³/h dosing chute 1.000m³/h 2.000m³/h lump crusher 1 500m³/h PC4 waste 500/ impurities m³/h Group B main cabinet end cooling and dedusting Silo 4 Silo 4 CRKS-3 CRKS-4 PC8 PC9 850/ /125 4 x 750m³/h =3.000m³/h ± 0,000 vibrating feeder 1.000m³/h hopper iron parts ~ mm PCB PCB PCB x PCB 250/125 3 x 400m³/h = 1.200m³/h Seite // G U T GmbH, JMS

22 Economical Plant Capacity Design saves investment costs (less or smaller sand reclamation machinery) saves running/operating cost, because of lower energy consumption less Maintenance costs Examples: filter plant for m³/h instead of m³/h Water Recooling Plant only half size if it can operate 24 instead of 12 hours Seite // G U T GmbH, JMS

23 Sand Transportation, Sand Conveying usually nobake foundries use a huge amount of sand for moulds and cores (in average 4-5 times more than their net casting production, 1 ton casting needs 4-5 tons of sand) usually sand needs to be conveyed several times in between shake out and mixers (from shake out to lump crusher, from lump crusher to cooler, ) Sand transport costs are a considerably portion of total cost for sand reclamation Share on energy cost per ton of reclaimed sand is usually higher than amortisation Foundry layout / Sand reclamation plant layout influences both, economy and efficiency Engineering matters a lot! Seite // GUT GmbH, JMS

24 Sand reclamation plant with chromite separator Seite // G U T GmbH, JMS

25 Sand reclamation and moulding area Seite // G U T GmbH, JMS

26 Secondary Attrition Units are mostly missing in South African Foundries (and also in Germany) increase quality of reclaimed sand are much cheaper on investment and running costs than thermal reclamation needs minimum space needs only very little energy Seite // GUT GmbH, JMS

27 Rotary reclaimer - FKR (Firma Klein) Seite // G U T GmbH, JMS

28 FKR Rotary Sand Reclaimer Seite // GUT GmbH, JMS

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30 Grinding reclaimer: function pot grinding tool sand Seite // GUT GmbH, HMS

31 New generation basic machine Eirich R12W av. batch size: 420 kg easy accessibility (pan cover and tool can be tipped up completely) automatic central lubrication high energy input into the mix Seite // GUT GmbH, JMS

32 Single line setup capacity: up to 3 t/h Seite // GUT GmbH, JMS

33 Mechanical intensive reclamation Alpha Set Input Sand Seite // G U T GmbH, JMS

34 Mechanical intensive reclamation Alpha Set Sand Reclaimed sand 10 min Seite // G U T GmbH, JMS

35 Results grinding reclaimer 5,00% Glühverlust 4,00% 3,00% 2,00% 1,00% 0,00% Croning-IMP Croning-TAM Bentonit Cold- Box/Bentonit AS REG-6min REG-12min Beta-Set Phenolharz 100,00% Ausbringung 75,00% 50,00% 25,00% 0,00% Croning-IMP Croning-TAM Bentonit Cold- Box/Bentonit AS REG-6min REG-12min Beta-Set Phenolharz Seite // GUT GmbH, HMS

36 Automatisation and Energy Saving on new cars automatic start-stop of the engine has become a standard feature what about Sand Reclamation systems in Foundries? very often many drives have only a simple on/off switch resulting in unnecessary running times Intelligent Plant software switches unnecessary running drives off and re-starts them automatically if required, f.e.: filter and water re-cooling plants can save easy 5-10 % of energy cost of main and auxilliary machinery Seite // GUT GmbH, JMS

37 content about G U T Nobake Sand Reclamation in general Plant Capacity Design - less can be more Sand Transportation proper Plant Engineering required Automatisation and Energy Saving low hanging fruits Chromite Separation good example on cost savings Seite // GUT GmbH, HMS

38 Flowchart Sand Reclamation and Chromite Separation L.O.I reducer Silo 2 used sand Silo 1 CRKS 750 (used sand and small lumps) Bypass Step Silo 4 Storage silo for reclaimed silica Silo 5 65 KHP 73 recl silica chro mite new silica ±0 3 2 waste Dosing device crusher with screen coarse grain 78 waste Step 2-4 MF silica silica Silo 3 recl. chromite Big Bag PC maincabinet Big- Bag blending PC 5 Big- Bag recl. new chrom. chrom hopper Vibrating feeder Overbel t magnet PC2 Chrom. PC 4 89 PC3 91 group E group D2 moulding sand mixer t/h group F 15 group A 18 PC1 Fe Seite 38 group B group C group D // G U T GmbH, JMS Chromite separator = last step in sand reclamation process

39 G U T Chromite separation 4 step technology 4 steps = separation result suits reuse in steel foundries Seite // G U T GmbH, JMS

40 Highlights average recovery rate about 80 % short R.O.I. very low energy consumption more than 50 plants running blend of 80 % reclaimed and 20 % new Chromite recommended for re-use proofed for Furan / Pepset / Alphaset / Phenolic / Alkydic Resins Seite // G U T GmbH, JMS

41 Example: Economic Analysis 1 Example: Chromite Separation Plant Basic Approach: Calculation of average sand costs Boundary Conditions: - Steel Foundry, - Portion of Chromite: 15%, tons of good castings per year, - Sand : Metal Ratio = 4 : 1 Seite // GUT GmbH, HMS

42 Example: Economic Analysis Cost of sand (average per ton) Dumping Costs Running costs for sand reclamation plant 20 /t 10 /t Running costs for chromite separation 2 /t without separation with separation waste new silica reclaimed new chromite Potential Savings: 50 % of total sand costs, or: appr. 20 per ton of sand, or: appr per year Total Sand per year Seite 42 New Sand costs Amount of new sands (without chromite separation) // GUT GmbH, HMS Amount of new sands (with chromite separation) Silica t 35 /t 3 % 3 % Chromite t 170 /t 100 % 20 %

43 Chromite Separator Plant Seite // G U T GmbH, JMS

44 left: ECO-FORM rigth: standard Seite

45 Kontakt specialists for nobake foundries! Obere Hommeswiese Freudenberg Fon: +49 (0) Fax: +49 (0) Seite 45