SAND MIXER EFFICIENCY ACCORDING TO WENNINGER FORMULA

Efficiency % = Working Bentonite x 100 =

Available Bentonite

GCS = Green compression strength

C = Compactability
M = Moisture
SSU SSU SSU
Compactability GCS Moisture
4-Nov 39 1800 3.4

Mixer efficiency %
Lower than 60%
60% - 65%
65% - 70%
Higher than 70%
Remark: 65% - 67%
67% - 70%

1 psi=70,24gr/cm2
Active bentonite = Working bentonite + Latent bentonite

Sand mixer efficiency is in function of: return sand temperature and moisture, mixing cycle, mixer maintenance

Remark: Available bentonite must be approximately same than Active bentonite, but available bentonite calculated with W
is not exactly the same value than active bentonite calculated with methylene blue test
Woking bentonite depend of mixer efficiency and mixing cycle time.
Logically higher working bentonite for same available bentonite, better mixer efficiency

Return Sand Moisture has to be 1.8-2% (when entering to the sand mixer), and is aprox 1,2%

Mixer Cycle Time 120 sec

Door open 10
Charge 5
Dry Mixing 7 sec
Moisture check
Wet Mixing 93 sec 66%
Descharge 20 sec
Door close 5
Total 140
Available Sand
1 mould weight match plate 70.0 kg
Mould dimmension Height - mm 400 mm
Mould dimmension Width - mm 500 mm
1mm Thickness Moulded Sand Weight (ƥ̵=1,5 kg/dm³) 0.300 kg
mould thickness average 250 mm
moulds/hour average 200 m/h
1 h
neccesary sand tons/hour 15.00 tons

Available Sand
1 mould weight match plate 1000.0 kg
Mould dimmension Height - mm 1200 mm
Mould dimmension Width - mm 1000 mm
1mm Thickness Moulded Sand Weight (ƥ̵=1,5 kg/dm³) 1.800 kg
mould thickness average 500 mm
moulds/hour average 20 m/h
1 h
neccesary sand tons/hour 18.00 tons

Available Sand
1 mould weight match plate 113.0 kg
Mould dimmension Height - mm 520 mm
Mould dimmension Width - mm 520 mm
1mm Thickness Moulded Sand Weight (ƥ̵=1,5 kg/dm³) 0.406 kg
mould thickness average 300 mm
moulds/hour average 75 m/h
1 h
neccesary sand tons/hour 9.13 tons

1 mould weight match plate 420.0 kg

Mould dimmension Height - mm 700 mm
Mould dimmension Width - mm 800 mm
1mm Thickness Moulded Sand Weight (ƥ̵=1,5 kg/dm³) 0.840 kg
mould thickness average 500 mm
moulds/hour average 62.5 m/h
1 h
neccesary sand tons/hour 26.25 tons

Return sand in the silos (silos are common for both lines)
Return sand (bentonite) needs some time to absorb the water that is introduced in the sand cooler
If there is not enough return sand, the sand caracteristics go down
if there is not enough return sand, the sand temperature go up
Return sand moisture should be 1.8-2%
Minimum should be 2 hours of production=
There are in the silos 3.3 Hours
 Bentonite
Sand batch Kg
0,21747 x GCS 650 7
132,1 - C x 100 %
1,316 x M + 1,4934 x GCS
1000
gr/cm2
%
%
D/F J/F
Efficiency % RESULT %MEB C/M (12+-1) %MEB/M (2,6-3,0) Additives recomendations in the mixe
58.70 BAD 10 11.47 2.94

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In 18h: XX kg of core

BAD we rest 0,5% of broken cores

LOW we consider 95% of core sand recove
NORMAL-GOOD %new sand added(((added cores-brok
VERY GOOD
NORMAL
GOOD

onite calculated with W. formula

 Mixer capacity koyo - EIRICH

Mixer batch 650 kg

Cycle time 140 sec
Batchs/hour 25.71b/h
Hours 1h
Avail. Sand Tons/Hour 16.7 tons

Available sand/hour 16.71 tons

11.4% extra capacity
Mixer capacity belloi - DISA

Mixer batch 800 kg

Cycle time 140 sec
Batchs/hour 25.71b/h
Hours 1h
Avail. Sand Tons/Hour 20.6 tons

Available sand/hour 20.57 tons

14.3% extra capacity
Mixer capacity arpa - DISA

Mixer batch 800 kg

Cycle time 140 sec
Batchs/hour 25.71b/h
Hours 1h
Avail. Sand Tons/Hour 20.6 tons

Available sand/hour 20.57 tons

125.4% extra capacity

REQUIRED MIXER CAPACITY

42.13 37.29

SHORT 4.84

85.0 Tons
140 tons
 Bentonite Coal New sand Fines (<0,5%) Water (1,5-2,1)
% Kg % Kg Cores % Kg % L
1.08% 3 0.46% 0 0.00% 0.00% 0 0.00% ?
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mendations in the mixer: according to the excel sheet for calculations

ed: 120 batches: kgr = > 16714.286 prepared sand kg

added cores kg

f broken cores 0 added cores-broken cores kg

% of core sand recovery 0 added cores-broken cores-core sand rec
ded(((added cores-broken cores)*core sand recovery)/prepared sand) 0.00%
Water (1,5-2,1) %
%
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oken cores kg
oken cores-core sand recovery kg