Sand Reclamation Techniques

BY:
MUATTAR ZAHID 2014-MM-21
RIDA ARSHAD 2014-MM-19
TANZEELA ANIS
2014-MM-09
SAIMA BIBI
2014-MM-16

Contents
Introduction
Requirements of all sand reclamation systems
Savings to be made from sand reclamation
Basic steps in sand reclamation
Types of sand reclamation process
Dry reclamation process
Wet reclamation process
Thermal reclamation

sand reclamation
WHAT AND WHY?

Sand Casting
Traditional sand casting dominates other casting

processes
Silica sand is most commonly used
This most commonly used process thus produces the
greatest amount of used sand

Disposed-off
Sand
Huge amounts of

used sand is
produced
Around 70% of

used foundry sand

is recoverable
silica sand
A valuable

resource

Sand Reclamation
An alternative solution
Think of used sand as a product, not a waste!
Increasing interest in sand reclamation

Reclamation vs. Reconditioning

Reconditioning

Reclamation

Treats the sand as a mass

Sand produced is not fit to replace new sand
Clay coatings and residues are not removed
Used for purposes other than foundry use

Treats individual sand grains

Restores approximate original quality
Removal of coatings, fines and dust is

achieved

Basic Reasons for Reclamation

Economical

Reduces sand cost including freight, purchase and disposal

costs

Environmental

If not reclaimed, all sand has to be dumped which causes

adverse effects on environment

Technical

Casting results using reclaimed sand can be as good as those of

new sand

requirements of all sand

reclamation systems
W H A T H A S T O BE D O N E ?

Requirements of Sand reclamation

Removal of Lumps and tramp material
Removal of Magnetic and non magnetic metals
Removal of Inert or organic material
Removal of live and dead clay
Grain size of reclaimed sand
Removal of fines
Grain shape of reclaimed sand

savings through sand

reclamation
W H A T C A N W E GE T ?

Savings Made
New sand purchases
Sand disposal cost
Less variation in sand properties
New sand storage can be reduced
Binder or catalyst reduction

basic steps
H O W I T IS D O N E ?

Basic Steps of Sand Reclamation

SHAKE-OUT

CRUSHING

CLASSIFICATION

COOLING

SCRUBBING

Basic Steps of Sand Reclamation

Shake-out
Method of separating the casting from the mold and/or the
sand from the flask

Magnetic Separation
Magnetic overhead separators are required to remove rods,
chills and other magnetic metals

Basic Steps of Sand Reclamation

Crushing

Reduction in sand grain size

Can be achieved by:

Impact
Rubbing action
Compression

Basic Steps of Sand Reclamation

Cooling

Heat is the most potent catalyst in any chemical reaction;

therefore cooling is required in sand reclamation

Scrubbing

Pneumatic

Sand particles are blown towards a hardened plate

Mechanical

Sand particles are thrown by a revolving wheel onto an attrition

surface

Basic Steps of Sand Reclamation

Classification

The reclaimed sand screen analysis should be similar to the

new sand used originally.

types
B A S I C C L A S S I F IC A T I O N

Sand Reclamation Processes

There are three main sand reclamation methods:

Dry reclamation
Wet reclamation
Thermal reclamation

dry reclamation
WHAT AND HOW?

Dry Reclamation
Binder is separated from sand particles through

attrition
Lump breakers are employed
Pneumatic or mechanical scrubbing is provided

Dry Reclamation
Pneumatic Scrubbing

Sand flows down the blast tube due to gravity, air from blower
(placed at the bottom) rises up
Sand grains experience double attrition
Scrubbed sand either moves to next cell (if present) or is kept
within same cell
Degree of cleanliness determined by:

Retention time in cells

Number of cells

Sand exiting final cell should be screened

Dry Reclamation
Mechanical Scrubbing

Two types-horizontal and vertical

Sand is fed into the center of the unit
The impellers throw the sand against the target ring (in case of
horizontal) or plate (in case of vertical)
For additional scrubbing, vertical type units can be installed in
series

Dry Reclamation

Breaking
Equipment

Demagnetizing
Equipment

Dry
Reclaiming
Machine

Heating
Equipment

Winnowers

Dry Reclamation
Binder is not removed completely
Dry reclaimed sand can only be used as support

sand
In dry reclamation, the cleaner the sand, the better
its quality (achieved by scrubbing more fiercely and
for a longer time)

Dry Reclamation
In case of clay-bonded sands, sands with very high

clay content is difficult to reclaim by dry reclamation

High wear parts are the impellers, targets and the
tube
Dust collection systems are significant in these
processes

wet reclamation
WHAT AND HOW?

Wet Reclamation
Mainly used for silicate binder systems
Silicate systems are difficult to reclaim by thermal

reclamation
Water dissolves residual binders and frees the sand
particles

Wet Reclamation
Steps

Screening and demagnetization is done

A sand-water slurry is prepared
The slurry is passed through a primary classifier
Wet scrubbing is employed
Slurry is subjected to secondary classification
Dehydration is carried out
Drying

Wet Reclamation

Breaking
Equipment

Dehydrating
Equipment

Demagnetizing
Equipment

Wet
Reclaiming
Machine

Drying
Equipment

Sewage
Disposal
Equipment

Wet Reclamation
Most installations allow 100% reuse of reclaimed

sand
Clay-bonded systems may not be reclaimed through
wet reclamation
Slurry disposal
High running cost

thermal reclamation
WHAT AND HOW?

Thermal Reclamation
Removes all the organic binder and carbonaceous

materials
Expensive process than mechanical attrition process
Quality of reclaimed sand is equal to the new sand
provided that no inorganic material is present

Principle
Combination of mechanical attrition reclamation

and thermal reclamation

Mechanically reclaimed sand is heated to a
temperature of about 800C
Heating takes place in a specially-designed furnace
Sand is fluidised as well as heated
Rubbing of sand against sand takes place

Equipments
Lump Reducer

To reduce the de-moulded sand lump into sand grains

Pneumatic Sand Transporter

To transport the reduced de-moulded sand into the return sand

storage silos

Screw Feeder

Feeds the sand from storage silos to the sand preheating unit

Equipments
Sand Pre-heating Unit

To preheat the incoming return sand by using waste heat in the

flue coming out from the combustor

Air Pre-heater

To extract further heat from the flue

Fluidised Bed Combustor

Preheated sand is fed by screw feeder and fluidised by preheating

air. preheated sand is further heated to 800C by heat provided
through combustion system

Equipments
Dust Extraction System
To remove dust by using suction points at various stages

of reclamation system

Equipments
Skip Hoist

To transport hot reclaimed sand into hot sand silos at the inlet
of the cooler

Fluidised Bed Cooler

To cool the hot reclaimed sand to useable temperature by

means of fluidising air as well as cooling coils

Pneumatic Sand Transporter

Transport the cooled reclaimed sand to the sand storage silos

for reuse

Process of Thermal Reclamation

Electric vs. Gas Fired Reclaimer

Electric Reclaimer

Gas Fired Reclaimer

Do not require large quantity of air as

combustion not take place here

No contamination of sand with products of
combustion

Require large quantity of air for

combustion
Contamination of sand with products of
combustion

Electric vs. Gas Fired Reclaimer

Electric Reclaimer

Gas Fired Reclaimer

Complete reclamation takes place at lower

temperature(500c)
Chances of thermal shock cracking and
heat losses are minimum

Complete reclamation takes place at

higher temperature(800c)
Chances of thermal shock cracking
and heat losses are greater

Advantages of Thermal Reclamation

Lower thermal expansion
Require less amount of binder
Conserves natural resources
Highly energy efficient process
About 80% sand can be recovered

conclusion
TRASH CAN BE TREASURED!

questions

thank you.