Green Sand Additives and Clays

Transcription

1 Green Sand Additives and Clays Stephen L. Neltner S&B Industrial Minerals N.A.

2 The Discussion The Trends in the Foundry Responses of the Suppliers to Those Trends New Developments and Innovative Ideas from the Suppliers

3 Foundry Trends Suppliers Responses Increase Durability More Na Bentonite Use Less Replenishment Additional Sourcing Enhanced Flowability New Mold Blowers Difficult Geometries More Metal in the Molds Shakeout/Collapsibility Less Sand Carry-Out Less Spill Sand Better Working Conditions Higher Strengths More Metal in the Mold Very Narrow Side Walls Clay Modifiers, Activated Clays, Clay Blends More Flowable Sand Enhanced Densities Other Sources Less Emissions OSHA & EPA Requirements Different Carbon Sources Sustainable Materials Rejuvenated Dust Black Water Customized Chemical Additives Better Dispersing Enhanced Mulling Enhanced Flowability

4 Clay Trends The Heavy Use of the More Durable Clay (Na Bentonite)/Drivers Drum Uses (Aggressive Shakeout) Flaskless Molding (No Run Outs) Cost Savings (Higher Thermal Stability) Activated Clays/Drivers Logistics Synergistic Affect Sourcing Rejuvenated Clays/Drivers Sourcing

5 Hot Compression Strength - Very Low HCS - Low HCS - -- Higher HCS - Rigid/ Not Plastic - Semi-Plastic - Plastic - Run-Outs - Dimensional Concerns Concerns

6 HCS Affects on System Sand Excessive HCS Low HCS

7 Lower DCS & HCS on Shakeout

8 Activated/Modified Clays The Clays Treated to be Converted to Perform Like Other Clays Na Bent converted to Ca Bent Properties Ca Bent converted to Na Bent Properties

9 Activated/Modified Clay (GCS)

10 Activated/Modified Clay (WTS)

11 Activated/Modified Clay (HCS)

12 Activated/Modified Clay (GCS & WTS)

13 Rejuvenated Clays New Technologies to Recover Wasted Clays Recycling of Clays Sustainability

14 Landfill Numbers

15 Baseline vs. Rejuvenated Dust Supplement % + 26 % + 26 % + 6 % - 6 % % Green compressive strength Wet tensile strength Cone jolt toughness 6.8 Friability Dry compression strength Green shear strength

16 Low Emissions Carbon Trends Less Overall Quantity of Added Carbon Lower Volatile Carbons Use Use of Special Carbons

17 Graphitic Use for Peel Graphite Graphite Impregnated Clay

18 Foundries Experience Increased Density with Impregnated Bentonite

19 Emission Reductions Reference Test FK Test HE lb/tn metal Benzene Toluene Xylenes Hexane Naphthalene Cresols Ethylbenzene Phenol Methylnaphthalenes Acetaldehyde Formaldehyde Selected Target HAPs & VOCs

20 Coal Supplement - Coking Substitutes - Coking WITHOUT the Carbon Emissions

21 Special Chemical Trends - Low Emission Supplement - Clay Enhancer on Flowability - Enhanced Mulling

22 What s in the Preblend Mix? 60.00% 50.00% 40.00% 30.00% 50.50% 20.00% 10.00% 21% 23% 0.00% Na Bentonite Ca Bentonite 4% 0.50% 1% Sea Coal Cellulose Cereal Special

23 Formulation with Clay Modifier Typical Formulation with Clay Modifier 70% 60% 50% 40% 30% 62% 20% 10% 0% 10% 21% 7% Na Bentonite Ca Bentonite Sea Coal Causticized Lignite 0.50% Soda Ash

24 Formulation with Activated Clay Typical Formulation with Activated Blended Clay 90% 80% 82% 70% 60% 50% 40% 30% 20% 18% 10% 0% Activated Clay Sea Coal

25 The Supplier s Role Innovative Use of New Technologies Low Emission Carbons Activated/Modified Clays Reclaimed/Rejuvenated Clays (Dust) Customized Chemical Additives

26 Questions & Answers