Sand Reclamation for an Aluminum Foundry

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Leslie Turner
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1 Sand Reclamation for an Aluminum Foundry (Rod Christiansen & Greg Shea) (Eck Industries)

2 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

3 History of Reclamation at Eck Thermal 2007 Thermal/Mechanical Blended 2013 Phenolic Urethane Polyol Isoset (SO2) Shell

4 Reasons for Sand Reclamation Cost Reclaimed Sand vs New Sand

5 Savings Thermal Reclaimed Natural Gas Maintenance Labor Supplies & Expenses Maintenance Supplies Disposal of Dust Internal Transporting New Sand Cost Delivery Waste Sand Disposal

6 Savings Reclaimed is approximately 1/3 the cost of our new sand.

7 Savings Additional savings by blending 72% / 28%

8 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

9 SAND RECLAMATION EQUIPMENT AT ECK Gudgeon 3 ton/hr. lump Reducer

10 RECLAMATION EQUIPMENT AT ECK

11 RECLAMATION EQUIPMENT AT ECK 3 Ton/Hour Lump Reducer

12 RECLAMATION EQUIPMENT AT ECK GK 10 ton/hr. Lump Reducer

13 RECLAMATION EQUIPMENT AT ECK

14 RECLAMATION EQUIPMENT AT ECK Sand Transport from Lump reducers and to waste sand silo

15 RECLAMATION EQUIPMENT AT ECK Brokk used for knockout of larger molds

16 RECLAMATION EQUIPMENT AT ECK 20,000# Mold Brokk used for knockout

17 RECLAMATION EQUIPMENT AT ECK

18 RECLAMATION EQUIPMENT AT ECK

19 RECLAMATION EQUIPMENT AT ECK

20 RECLAMATION EQUIPMENT AT ECK Gudgeon 3 Ton/Hr. Sand Blending

21 RECLAMATION EQUIPMENT AT ECK 4 Burners 1500 BTU ea.

22 RECLAMATION EQUIPMENT AT ECK 1250 Degrees Critical to Eck Control Panel

23 RECLAMATION EQUIPMENT AT ECK Cooling Tower

24 RECLAMATION EQUIPMENT AT ECK Sand Classifier Added when we started blending

25 RECLAMATION EQUIPMENT AT ECK Sand Blending

26 RECLAMATION EQUIPMENT AT ECK

27 Sand System Eck - Blended Characteristics: Shape - Rounded Major Screens 3.96% Fines -.21% Thermal 72% Blend 28% Density Packed # Density Unpacked 97.81# Loss On Ignition -.27%

28 Sand System Eck 35.00% Screen Distribution Blended Sand 30.00% 31.34% 28.77% 25.00% 23.98% 20.00% 15.00% 10.00% 9.57% 5.00% 0.00% 5.42% 0.05% 0.40% 0.17% 0.02% 0.01% Pan

29 Sand System Eck 45.00% SNB MIXER - MAJOR SCREENS - Blended 40.00% 35.00% 30.00% 25.00% 20.00% 15.00% 10.00% 5.00% 0.00% 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/

30 Sand System Eck SNB MIXER - SURFACE AREA CALCULATION - AVG GFN Blended /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 Surface Area Avg. Grain Fineness

31 Sand System Eck 0.60% 0.50% SNB MIXER FINES % PAN COMBINED - Blended 0.40% 0.30% 0.20% 0.10% 0.00% 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/ % FINES PAN Linear (FINES PAN)

32 PERCENTAGE Sand System Eck 0.45 SNB MIXER - %LOI - %MOISTURE - Blended /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 % MOISTURE % LOI Linear (% MOISTURE) Linear (% LOI)

33 Sand System Eck - Thermal Characteristics: Shape - Rounded Major Screens 3.93% Fines -.08% Thermal 100% Density Packed # Density Unpacked # Loss On Ignition -.17% New Sand Density Unpacked # New Sand Density Packed #

34 Sand System Eck 35.00% 30.00% Screen Distribution Thermal Sand 32.05% 28.69% 25.00% 24.14% 20.00% 15.00% 10.00% 9.34% 5.00% 0.00% 5.05% 0.01% 0.32% 0.08% 0.00% 0.00% Pan

35 Sand System Eck 40.00% SNB - THERMAL RECLAIMER - MAJOR SCREENS - 40,50,70, % 30.00% 25.00% 20.00% 15.00% 10.00% 5.00% 0.00% 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/ Linear (40) Linear (50) Linear (70) Linear (100)

36 Sand System Eck SNB - THERMAL RECLAIMER - AVG. GFN - SURFACE AREA CALCULATION /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 AVG. GFN AVG. SURFACE AREA Linear (AVG. GFN) Linear (AVG. SURFACE AREA)

37 Sand System Eck 0.25% SNB - THERMAL RECLAIMER -FINES% - 200, 270, PAN 0.20% 0.15% 0.10% 0.05% 0.00% 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 FINES Linear (FINES)

38 Sand System Eck 0.40 SNB - THERMAL RECLAIMER -% MOISTURE -%LOI /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 % MOISTURE % LOI %FINES Linear (% MOISTURE) Linear (% LOI) Linear (%FINES)

39 Sand System Eck Request your sand supplier check the sand chemistries from your reclaimed sand to verify there are no changes or trends. Chemistry Fe2O3 (%) Al2O3 (%) TiO2 (%)CaO (%) MgO (%) Na2O (%) K2O (%) 1/25/ /18/ SiO2 (%) ADV ph LOI Clay NTU Perm 9/27/ Sieve Analysis PAN GFN 1/25/ /18/ /27/

40 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.

HIGH-LEVEL SAND RECLAMATION FOR SODIUM SILICATE AND ALKALINE PHENOLIC-BASED SANDS

SANDS & BINDERS HIGH-LEVEL SAND RECLAMATION FOR SODIUM SILICATE AND ALKALINE PHENOLIC-BASED SANDS Mark Fenyes Omega Foundry Machinery Ltd ABSTRACT Historically due to the chemical nature of these two binders