Testing Procedures For Raw Materials And System Sand For Green Sand Moulding& a vl 3 OouUkUDB QGUUUUUOUUVEDY vv VUUUUUUU UUs Sand testing flow chart For silica sand RECEIPT OF THE SILICA SAND COLLECTION OF THE RANDOM SAMPLES DRY THE SAND ¥ SINTERING * Y SIEVE y Ae rarmanee |B ]| Aiea [Sten || fee Si02% CONTENT REFRACTORINESS. NUMBER “ ACCEPTED / REJECTED PROPERTIES PREFERABLE VALUE SILICA 98% Min SINTERING POINT. 15$0 ~ 1700°C AFS No.(CORE) 40 ~ 50 AFS AFS No. (MOULD) 60-70 AFS CLAY 2% Max. ‘ACID DEMAND VALUE _[5.5- 6.5e5 | SIEVE DISTRIBUTION 3/4 SIEVE (Min 80%) & INEACH SIEVE 15%eUuUUUHY vuvuuJUs uw oe woe uUUuUuUWveUYU UeHUKU UG @ 19 SIEVE ANALYSIS OF SILICA SAND SCOPE ‘TO DETERMINE THE AFS NO. OF RAW SILICA SAND. SIGINIFICANCE OF THE TEST. Fineness of the foundry sand is determine by the size and distribution of its particles. ‘The size and distribution of the sand grains have an important bearing on the physical properties that may be developed in foundry sands, such as strength , permeability and workability at optimum moisture. It also has an effect on the cost of sand preparation because it influences the amount of bonding material required to produce desired properties. In addition, fineness of the sand can have an influence on the surface finish of castings. A given distribution of silica grains is characterized by i) average grain size i degree of uniformity and distribution coefficient Average grain size is defined as the size of silicon grains corresponding to 50 percentage passage on the plot of percentage passage is sieve size. Degree of uniformity is defined as the difference in the values of sand passage for 4/3 average grain size and 2/3 average grain size. Distribution coefficient is defined as the ratio of grain size For 75 percent passage to grain size for 25 percent passage. RAW MATERIAL : 50 grams of dried silica sand. EQUIPMENT: i) Oven / Infra-red lamp for drying sand il) Sieve shaker with a set of standard sieves itt) Laboratory balance to read minimum of 0.1 gram.UUYUEOBYUUWUWHW UG uuuUud vu uvuad veueuduYy u 2 A oath en ERA OSA PROCEDURE: ‘Take 50 grams of dried silicon sand , place the sample on the top most sieve of the standard series in a sieve shaken. Shake the sieves of the for 15 minutes. Remove the set of sieves from the shaker. Starting from the upper most sieve, invert it on a piece of hard surface paper and brush the sieve surface with the wire brush. Light tapping of the sieve sides with the brush will also facilitate through cleaning of the sieve. Record the weight of the material retained on each sieve. Percentage retained on each sieve is expressed as the percentage passage through the given sieve and is then plotted as a function of sieve size. ‘The three parameters, defined above, and characterizing the distribution of sand grains, are computed from this plot. TEST REPORT WEIGHT SIEVE SIZE | RETAINED bbe MULTIPLE aN a EACH WEIGHT TACTOR | PRODUCTS MICRONS) i RETAINED 3350. = = 3 = 1700, = = 3 i 350 88 0.96 10, 4.80. 600 2.53 3.06 20 30.60 ‘25 10.94 21.88 30. 328.20 300 8.40 16.80 40 336.00. 212 1756 35.12 30 878.00 150 Tat 14.22 70 497.70. 106. 2.52 5.04 100 252.00 75 035 0.70 200. 70.00 33 0.07 O14 270 21.00 PAN ~ = 300 : TOTAL 9.96 99.93 243830 AFSNo.: 243830 =48.81 49.96é Go vYwovuwevuvd vu Ue ar vuUuUUUKbHEEBEG Ye GS UE Ute Ue Saas dah dee tahdcada TOTAL CLAY IN SILICA SAND SCOPE. To find out clay percentage in raw silica sand. RAW MATERIALS : 7 1) 10 grams of dried silica sand . 2) sodium hydroxide 3% EQUIPMENT : 1). Siphon apparatus 2) Glass cylinder ~ | litre PROMEDURE : 1) Approximately 750 mi of distilled or demincralised water containing, 5 ml of sodium hydroxide which acts as. the deflocculating agent, are boiled gently in an evaporating basin of about 10 in diameter. 2) 10 grams of sample from the silica sand , previously dried at 100-1055 degree, is weighed out. 3) The sample is added to the boiling water and boiled for a period of 10 minutes. 4) The sand/water mixture is allowed to cool and then transferred to a suitably straight sided glass cylinder. The cylinder has a mark suitably inscribed which is 6 inch above the inside base of the cylinder. 5) Extra water is added to the cylinder to adjust the level to this 6 inch mark. 6) The sand/water mixturo is stirred with the glass or metal rod and then allowed to settle during a period of exactly 10 minutes. 7) Using a siphon tube bent to a suitable shape, the water/clay suspensics- is Femoved down to a level of | inch above the base of the cylinder. 8) The cylinder is refilled with water to the 6 inch mark, stirred again and allowed to settle for exactly 10 minutes. The siphon ‘procedun: is then repeated down to the 1 inch level. 9) This procedure is repeated until a 5 minutes settling period gives perfectly clear water in the upper 5 inch. 10) After siphoning, the remaining sand and water are retumed to the original evaporating dish and allowed to settle for 2 minutes before excess water is poured carefully away without losing any granular particles. 11) The residue is dried to constant weight at 100 — 105 degree Celsius. 12) The loss in weight of the sample determined by re-weighing is expressed as a percentage of the original weight of sample, this giving the clay grade percentage.Gu uu & GOUUOUUOHKBLOYE HUG UU Vudu e ue vu Q ACID DEMAND VALUE SCOPE ‘To find out acid demand value in raw silica sand SIGNIFICANCE Sands containing traces of alkaline reacting materials. viz lime stone, chalk or dolomite will affect the effectiveness of acid catalysts added to resin sand mixtures in No-bake sands. If this materials are reacted with acidic activators, then a partion of the catalyst is no longer available for the requirement of resin. There fore, in some cases, it may be necessary to adjust the catalyst by extra amount, to maintain the ratc of strength development. So it becomes essential to measure the acid requirements of the sand. As tho acid demand increases, the acidity requirements of the catalyst system also increases, RAW MATERIALS : 1) 50 grams of dried sand 2) 0. NHCL 3) 0.5 NH2S04 4) Distilled water EQUIPMENT : 1) Laboratory stirrer 2) 50 ml burette 3) 10 ml pipette 4) 250 ml beaker 5) Glass rod PROCEDURE : 1) Weigh accurately 50 grams of dried sand 2 Add 50 ce of distilled water 3) Add 50 ce of 0.1 N hydro chloric acid or 0.5 N sulphuric acid 4) Stir for 20 minutes vigorously in a laboratory stirrer and let it set for 2 hours, so that alkaline materials will react with the acid. 5) Back titrate the solution to neatralise exeoss HCL or H2SO4 with 0. IN NaOH To determine the original amount of HCL OR H2SO4 that has been used in the reaction with the alkaline materials gaGUbUOoOUUUOULEUUBEYE ee] UHUWUeEVNUeue uv vu ut ar a EXAMPLE Original amount of 0.1NHCL = 50ce. Used in back titration of 0.1 N NaOH = 45cc ‘Materials reacted = 30-45 =5ce Acid Demand Value = (blank — mixer reacting) x std. HCL x 100 Wtof sand. A eeeeee ADV less than 6 cc of 0.1 N HCL / 100 grams of sand is preferred.wo GuUdGd wus y ud Gud Vudu uu G JuUUUHe a wewubutu DETERMINATION OF SiO; CONTEN SCOPE TO : DETERMINATION OF SILICA IN SILICA SAND BY THE GRAVIMETRIC METHOD. Significance : Higher the si02 contact they heigher will be the refractoriness. Reagents Sodium Carbonste - Solid Dilute Hydrochloric Acid ‘Concentrated Sulphuric Acid ~ sp gr. 1.84 [Confirming to IS : 266-1961 Specification for Sulphuric Acid. Hydrofluoric Acid — 40 Percent Fasion Mixture ~ Mix 6 g of enhyrous sodium carbonate with 4 g of anhydrous potassium carbonate in & mortar. Concentrated Hydrochloric Acid — Sp gr 1.16 (conforming to JS : 265-1950 Specification for Hydrochloric Acid. Procedure Weigh exactly 0.5¢ of the test sample into a platinum crucible and fuse with 3 to 4 g of sodium carbonate, gently at first and finally at 1 000°C for at east half an hour. Cool the melt and extract with about 75 to 100 inlof difste hydrochloric acid in a beaker or a porcelain dish, Set the contents for drying and baking at 110 10115°C. After baking, cool and digest the contents of the beaker with about 50 ml of dilute hydrochloric ‘acid by boiling and filtering, Transfer thoroughly al the residue from the beaker tothe filter and wash the filter and the residue by hot water til free from chloride Collect the filtrate and washings in a S00-ml beaker and preserve the solution, ‘ignite the paper and the residue in a platinum crucible at 950 to 1000%e and weigh. Moisten the residue swith afew drops of concentrated sulphuric acid and add about 10 ml of hydrofluori acid. Evaporate to pH Value 17 94 9.5 to 10.0 6.0 to 10.0 2 ‘Swelling Index 18.2 16.7 17.0 less then 8.0 ‘Gel Index 35 20 > Total base Exchange Capacity 3 (milli-equivalent Per 100 grams) 91 6 96 to 112 96to1l4 ? Na /Ca ratio 237 0.76 3 Sintering Range (°C) 975-1025 1075 - 1125 > |Green Compression Str. with > 10% Bentonite & 4% Water (gm/cm*) 700 700 (Green Compression Str. with 2 5% Bentonite & 2.5% Water (gem?) - 665 no > Dry Compression Strength (gm/cm’) - - 8750 4900 > > Chemical Analysis (%) ‘Typical Value| Typical value | Typical value Range > Silica (SiO) 45.9 454 64.7 56-59 > ‘Alumina (Al,03) 172 18.3 208 18-21 ° Iron Oxide (Fe:0s, FeO) 86 19 28 5.49.0 > Magnesia (MgO) 38 23 23 30-3300 > Lime (C20) 22 2.0 0.5 12-35 > ‘Soda (Na,O) 25 06 24 03-0.5 ° Potash (K,O) OS ‘Traces o4 0.64-0.75 > Titanium Oxide (TiO2) 08 20 04 ° Loss on Ignition 19 2 — ° NOTE: kutch Sodium base bentonite needs approx. 3.0% more addition to get the same Green > Compression Strength obtainable from Wyoming bentonite(both tempered to the same moisture%) 2 ’« o ew PULL EEL PuUMELEUUUUUUVUUUUDUUUEE ee See eee SPECIFICATION AND TESTS OF BENTONITE Bentonite should be dry powder, free from lumps, sand and other foreign materials. Ground and fine powder with minimum 95% passing through 200 mesh( ie. 75 micron) US Sieve, moisture content 12% Max. and pH value between 8 and 10. 1) Gelling Time:- It guides to know what shall be the mulling time to take the full advantage of swelling capacity of bentonite. When gelling time is more and sand is mulled for lesser time it shall consume higher percentage of bentonite, and when this sand is in hoppers bentonite shall swell and sand will become dry. Gelling time should be instant (upto 10Secs.). Higher time means more time for batch preparation. Test Procedure ‘Add 2.5 Grams of bentonite powder into a graduated test tube with 25ce distilled water, Shake the contents of the test tube thoroughly for 2 minutes. After shaking for 2 minutes, the test tube is allowed to rest in a vertical position, The minimum rest period, checked after every 10 seconds required by the contents to form a gel (ie. to refuse falling down when the test tube is inverted) is the gelling time. Sodium base bentonites develop thick gel formation within the shortest time due to their inherent Swelling properties. Calcium base bentonites are non-swelling type, hence the gel formed will Be more fluid. By the addition of sodium carbonate swelling properties can be enhanced up to a limit. But excess soda addition causes the clay particles to coagulate. 2) Methylene Blue test Take into a 250ce conical flask 5 grams of clay free new dry sand and 0.5 gram of dried bentonite, Add to this $0cc distilled water. Stirr the contents in a magnetic stirrer to disperse bentonite thoroughly. Boil the contents of the flask for one minute and cool to room temperature. Add 3cc of prepared Tetrasodium Pyrophosphate solution and shake the flask well. Titrate against standard Methylene Blue solution stirring the contents of the flask thoroughly in the magnetic stirrer for 30 seconds after every addition of MB solution. A glass rod is dipped into the blue mixture inside the flask and one drop of the liquid is placed on Whatman No.1 filter paper. Till the end point is reached only a blue circle will appear on the filter paper. Continue the titration with an increment of 2ce of MB, stirring the conical flask contents each time, till a greenish blue halo or ‘sunburst’ pattem will appear around the blue circle. This means that the end point has been reached. After the first appearance of this halo pattem shake the contents of the flask ‘once again for 2 minutes and repeat the drop test to ensure that the same halo is repeated, indicating that the end point is reached. Record the volume of the methylene blue (MB) solution consumed to produce the greenish bluc halo and calculate the MBB absorption as illustrated below: ‘Titration reading on the burette (cc) x 3.74 x 2 = mg of Methylene Blue per gm bentonite.weevewuvvuese s « wow veereuUUUHUUUH YW UUese Instead of Tetrasodium Pyrophosphate, 2.5cc of 0.5 N Sulphuric Acid solution can also be used in the conical flask before starting titration. But nowadays Tetrasodim Pyrophosphate only is widely used. 3) SWELLING CAPACITY :- It shows the property of hydration and swelling of bentonite. Green strength of the sand and dry strength of the sand shall depend on this quality. It shall show the compactability properties of green sand. Higher the swelling capacity higher the compactability. It also shows whether it is Na’ bentonite are Calcium. Higher capacity means Na* bentonite. Test Procedure: Weigh 2 grams of dried bentonite sample Take 100 ml of distilled water in 100 mil graduated measuring cylinder. To this water spray bentonite in very small quantities at a time. When the whole 2 grams of bentonite has been transferred to measuring cylinder, allow to stand for 24 hours. Then measure the volume of the bentonite settled at the bottom of the water column in the measuring cylinder. This volume is the swelling capacity of the bentonite sample. 4) GEL INDEX: ‘This test will describe the gelling characteristics of the bentonite. This shall give temper water-holding capacity of bentonite. Bentonite with high gel index shall retain moisture for long time, Moulding sand will retain moisture for long time and will retain ‘green properties for longer time. And also gives clean stripping and edge retaintion. ‘Test Procedure: Weigh accurately the following: 1.4 grams of dried bentonite, 2. 0.2 grams of Magnesium Oxide (AR quality). 3. 2.6 grams of Aluminium Oxide (AR quality). Thoroughly mix the above three and transfer it to a stoppered 100ml-measuring cylinder having 50m of distilled water. Shake the mixer thoroughly for 5 ~ 10min. Add further water to read 100ml add shake vigorously for 1hour. Allow the contents of the measuring cylinder to stand for 24 hours. Measure the volume of the supematant liquid and subtract it from 100ml, This will give the gel index value of the bentonite in percentage. 5) SWELLING INDEX: Swelling index corresponds to the grams of H,O present in one gram of bentonite in a thixotropic gel. It shows the consumption of bentonite to achieve the same green strength along with water holding capacity. Higher the swelling index lesser the consumption of bentonite and higher the GCS. GoetevoueuuuunuvnvuvuuvuUuUuUy a Test Procedure: Add 0.2 g, 0.25g, 0.3g, 0.35g, 0.4g, 0.58, 0.6g, 0.78, 0.8g, 0.9g and 1.0g of dried bentonite sample in different duly marked test tubes of } 1Smm x 125mm having 10ml of distilled water in each test tube. Shake the mixer well of each test tube to ensure full dispersion of bentonite. Keep the test tubes for 24 hours for full swell. The suspended ‘material with proper ratio will not flow out of test tube when gentle tilted to 45° and shall remains still for atleast one minute. The swelling index is the ratio of water (1Oml) to minimum weight of bentonite (g) at which the suspension just fails to flow. 10ml of water ‘Wt. Of bentonite(g) ‘Swelling Index = It is an approximate measure of the limit of hydration. 6) DETERMINATION OF pH VALUE:- pH value of bentonite, provides with an insight of the nature and extent of the exchangeable cations present in the clay mineral. It has no direct bearing on sand properties. It only speaks the alkalinity of the bentonite. ‘Test Procedure: Take 2 grams of the dried bentonite. Add 100ml of distilled water(pH = 7.0) and tix it thoroughly. Determine the pH of suspension by means of a suitable pH meter using glass electrode. The pH value can also be determined by dipping a pH paper inside the suspension and the colour obtained can be matched with the pH standard. 7) DETERMINATION OF LIQUID LIMIT The liquid limit of a bentonite, determined with the special device, is the water ‘content in a bentonite slurry which will provide enough plasticity to close a prescribed groove in 25 blows. Procedure Determination of water content (W20) of bentonite requiring less than 20 blows to close the groove. Accurately weigh 30 grams out of dried bentonite and split into four approximately equal parts. Thoroughly mix for 90 seconds a quarter portion(7.5g) of the bentonite with exactly 100ml of distilled water at room temperature in a plastic beaker. ‘Add approximately half of the second quarter (3.75 g) and mix for 90 seconds. Remove any dry bentonite adherring to the beaker wall and add to the slunry and remix for 90 seconds. The consistency of the slurry may be too thin at this stage (indicated by previous experience) and if so, carefully add more bentonite in small amounts to give a suitable consistency, following the prescribed procedure. Following the 90 seconds mixing cycle, promptly add the slurry to the cup with a spatula, A good contact between the slurry required is indicated by the line scribed on the inner surface of the cup. Smooth the shurry until it is level with the line at all points. This. step, probably more than any other, will affect the reproducibility of the tgst. Make a groove with the scriber, (see note A). Remove all the bentonite remaining oa the scriberCCUCEULUUUEUYUHYUEYUUVUL YY HoOKUHOHHHDUVEs and retum it to the beaker. Turn the crank at a rate about | or 2 revolutions per seconds, counting the blows necessary to close the groove for a distance of 13 cm. If the number of blows is between 1 and 8, carefully add 1 to 3 spatulas of bentonite and repeat the 90 second mixing procedure. Then again determine the nurnber of blows needed to close the groove as described above. Note the number of blows and if it is between 9 and 20 repeat until the number is constant within + 2 blows, Following each sequence, return as much of the slurry as possible to the beaker. Clean the cup with a dampened cloth and dry thoroughly. ‘After a constant reading of +2 blows is obtained (in the range of 9 to 20 blows), the weight of remaining unmixed bentonite is determined. Subtract this weight from the original 30 grams of bentonite to determine the number of grams of bentonite added to the 100ml of water. This value is ‘B” in the equation. Return the sturry into the beaker. W+P-B/100 W20 5 on menennn neve X 100 B-P-B/L00 ‘Where =~ W20 = Water content for (9 to 20 blows) W = Weight of water used = 100 g. B = Weight of bentonite added in g P+ =Moisture content of bentonite in percent Determination of water content (W40) of bentonite requiring 30 ~ 40 blows 10 close the groove. Carefully add 1 to 3 more spatulas of bentonite to the slurry in the beaker. Experience with the particular bentonite being testing will indicate the amount required. Repeat the 90 seconds mixing procedure and determine the number of blows necessary to close the groove as described above. The number of blows required should be in the range of 30 - 40. Repeat the operation until the number is constant within + 2 blows and note the number. Determine the weight of bentonite remaining and subtract this weight from the original 30 g of clay to determine the total weight of bentonite added to the water. Determine the water content W40 of this more viscous mixture by means of the above equation. Determine the liquid limit (WL) — Plot on semi-logarithmic paper the water content W20 and W20 against the corresponding number of blows. The number of blows is plotted on the logarithmic scale(ordinate). Connect the two points with connecting the points W20 and W40 corresponds to the liquid limit. NOTE A ~ The seriber supports should be adjusted to so that the scriber lightly touches the bottom of the cup, the paper groove being one which exposes the bottom of the cup through-out its length. Adjustment of the cup to provide the required one centimeter clearance between the bottom of the cup at its highest position and the striking, base should be done frequently taking care that the seriber is not off centre, thus striking the cup unevenly.SUN YES vu uu Q ? aU cu NOTE B - The closing of the groove shall be taken as the point at which the bottom of the groove joins to over the exposed portion of the cup for 13 cm along the length o the groove. The groove should not be expected to close entirely, that is along its entire length of its full depth. Only 13 cm closes over so that the cup bottom cannot be seen. NOTE C ~ By this time approximately 14 g of the original 30 g have been used. 8) DETERMINATION OF MOISTURE PERCENTAGE:- It only guides the mechanically held water level of bentonite, It has no relation ship with the quality of clay. ‘Test Procedure: ‘Take 5 grams of bentonite in a watch class and weigh the bentonite along with the watch class. Let the value be A. Keep the watch class inside the oven maintained at ‘a temperature of 105 * 5°C for 10 minutes. Then cool the watch class to room temperature. Reweigh the watch class and let the value be B. Then the moisture percentage of bentonite is calculated as given below. Moisture % =A-B «100 a NOTE: Percentage of Moisture is also done by using Infra-red moisture tester as an altemate method.epee a yee ey ancl cry tes geen as laa eps leet ase ach cee ea psecwo ue UdEDS Oo” Quu"e Uu a) Ot ou (a oO ee a a 2 a COAL DUST SUBSTITUTE FLOW CHART RANDOM SAMPLE, COLLECTION FROM VARIOUS. BAGS AND MIX TOGETHER Votatie | [ asi LOSS ON matrer || content | | IGNITION pee eee pee eg Low . Lp) LUSTROUS* ‘TEMPERATURE CARBON VOLATILE pee ee ee HH >| RESULTS TO BE MONITORED with | PREFERABLE VALUE PROPERTIES: PERFERABLE VALUE vw 60% Ma “ASHE 4% Max LOI 96% Min. FC 36% Min. TUS CARBON 120-25 LOW TEMP. VMi—[25~303 > uo Ou a oreerdgot ud g DETERMINATION OF VOLATILE MATTER IN COAL DUST SCOPE: This determination covers the test method for volatile matter content generated by the product. APPARATUS: L.Weight balance-lab. 2.Dry silica crucible with lid 3.MufMe furnace @925225 °c temperature. 4.Stop watch, S.Desicator. 6.Crucible sand, METHOD OF TEST: 1, Weigh an empty dry silica crucible note the weighed reading, 2.Take 1 gm of product to be tested along with the crucible, note the weighed reading as wr. 3.Keep the crucible along with sample close it with the lid and place it on the crucible stand and keep inside the muffle furnace @925 +25°C at heat zone for exactly 7 (seven) ‘minutes, 4.Remove the crucible along with the stand and transfer it to the desiccators for cooling. S.After 15 to 20 minutes cooling, weigh the crucible along with the ignited sample without lid for the loss in weight, noted the weighted reading as “WI”. 6. Also check for constant weigh by keeping the crucible with ignited sample for another 15 minutes duration inside muffle, cool it and weigh as ‘WI’. 7.Caclulate the volatile matter content % as follows. ‘Volatile matter content % =(W — WI)x100 For example. W=23.500, WI=23.350 Volatile matter content %=(23.500-23.350)x100 =0.150x100=15. CONDITIONS: | Check for lab balance for zero setting before weighing. 2.Always ensure dry silica crucible. 3.Keep the lid in tight with crucible during igniting. wn DETERMINATION OF ASH CONTENT IN COAL DUST SCOPE: ‘This determination covers the test method for Ash content generated by the product. APPARATUS: 1. Weight balance-lab. 2.Dry silica crucible with lid. 3.Muflle furnace @925#25 °c temperature. 4 Stop watch. ‘SDesicator. 6.Crucible sand. METHOD OF TEST: 1.Weigh an empty dry silica crucible note the weighed reading. 2.Weigh 1 gm of product to be tested along with the crucible, note the weighed reading as wr. 3.Keep the crucible along with sample and place it on the crucible stand and keep inside the muffle furnace @925 425°C at heat zone for exactly 2 (two minutes. 4.Remove the crucible along with the stand and transfer it to the desicators for cooling, 5.After 15 to 20 minutes cooling, weigh the crucible along with the ignited sample for the loss in weight, noted the weighted reading as ‘W1”. 6. Also check for constant weight, by keeping the crucible with ignited sample for another 15 minutes duration inside muffle, cool it and weigh as “W1”. 7.Caclulate the Ash content % as follows. Ash content % =(W — W1)x100 For example. W=23.500, W1=23.450 Volatile matter content %=(23.500-23.450)x100 =0.050x100=5. CONDITIONS: 1.Check for lab balance for zero setting before weighing. 2.Always ensure dry silica crucible. 3.Keep crucible without lid during igniting.tcecuetd cuucues uy VvuUuUuVvYVUuvunve vd wee ee eeaoved ove % Hil daicennelaiah Asnieis Pian inh ase LOSS ON IGNITION IN COAL DUST DETERMINATION OF ‘After finding the percentage of ASD» the percentage of “oss on ign! caloulatd as follows. of LOl= 100-% of ASH DETERMINATION OF FIXED CARBON IN COAL DUST ‘after finding the percentage oF THe perventage of Ash he percentage of “loss on ignition” is calealatd a Follows 100(06VM#+ % ASH) = FIXED CARBON.ceueeueueouuunuvueunduuUvuuUuUvsd Ww DETERMINATION OF LUSTROUS CARBON IN COAL DUST SCOPE: ‘This determination covers the test method for Lustrous carbon generated by the product. APPARATU: 1.Weight balance-lab. 2.Dry quartz sintered lustrous carbon tube apparatus with cover. 3.Muffle furnace @87545 °c temperature. 4.Stop watch, 5.Desicator. 6-Lustrous carbon apparatus stand, 7.Glass wool. . METHOD OF TEST: 1. Weigh an empty dry quartz lustrous carbon tube apparatus packed with mineral glass wool along with the cover ; note the weighed reading as “W’. 2.Weigh 0.200gm of product to be tested and transfer it to the bend tube cover of the lustrous carbon apparatus and close it air tightly with a wire. 3.Keep the apparatus closed with the bend tube cover along with the sample careful so that sample at the end of the bend tub cover is downward placed and docs not tilt and keep inside the mufile furnace @ 875 + 5°c at heat zone for exactly 3 (three) minutes. 4.Remove the L.C. apparatus from the furnace and place it on the stand and transfer it to the desiccators for cooling. S.Afler 15 to 20 minutes cooling, weigh the L.C apparatus tube only for increase in weight without cover, note the weighed reading as ‘W1*, 6Caclulate the Lustrous carbon content % as follows, Lustrous carbon content% =(W1 — W)x500 For example, W=101.500, WI=101.500 Lustrous carbon content %=(101.550-101.500)x500 =0.050x500=25. CONDITIONS: | Check for lab balance for zero setting before weighing, 2.Ensure the lid tightly with tube L.C apparatus during igniting. 3.Check for muffle temperature @ 875°. 4,Ensure that the sample it kept for only 3 minutes. 5. Weigh only the quartz L.C apparatus without bend tube cover. *"GREEN SAND TESTING FLOW CHART “SAMPLE COLLECTION FROM WC HOPPER Ges, ess, PERMEA ‘ocs BILITY ‘compact ‘ABILITY ‘wouLD ABILITY Loa tHe sano ‘RESULTS TOBE [MONITERED WITH PREFERABLE VALUE oe ‘SIEVE ANALYSIS. wencor) [eae EAD CLAY tor Peet EEL SL Et ee [RESOLISTOSE] MONITERED Wir PREFERABLE VALUE [CONVENTIONAL HOULEING PREESURE MOULONG——] PROPERTIES PREFERABLE VALUE. erequency [PREFERABLE VALUE ‘ADJUSTED UNTIL A CCOMPAGTABILITY OF 40% 12% 8 mosstunt 30-35 ONCE ANHOUR, ‘OPTANED ‘ocs 1000 1900gmen2 |» ONCE AN HOUR 1S amen? 7 oss 909-400 gen ONCE ANHOUR, TBgemien? -625gnen2 PERMEASILITY 1202150 [ONCE AN HOUR 200 [COMPACTABILITY 40-45% [ONCE AN HOUR 65.00 MOULOABILITY ‘ONCE AN HOUR 280 SHATTER INDEX ‘ABOVE 80 [ONCE AN HOUR 205 SIEVE ANALYSIS ONGE A DAY, AESNO 50:60 ONCE A DAY 0.70 0.1448 TO 0 2083-4 SIEVES 0.144 TO 022MM 9-4 SIEVES ‘ora Size SIEVE | FOR 80% GRAINS HAS TO RETAIN FOR 00% GRAINS HAS TO RETA DISTRIBUTION ‘ON ADWUSENT SIEVE ON ADJUSENT SIEVE TOTAL CLAY $2 MAK [ONCE ADAY sea ACTIVE CLAY 00% ONGEA DAY, 10% EAD CLAY MAK. ONCE ADAY NA Lot 45.55% ONGEA DAY, 55-65 Se ONGEADAY ‘STRENGTH 2 200qmien2 > 200qmiema SPALLING STRENGTH > s00grmien2 ONCE A DAY > s00gvone WET TENSE STRENGTH > 20qmieme SeeAe > 2oyovena ‘RY COMPRESSION x STRENGTH > Sglena eae sige? HOT COMPRESSION ONCE A DAY STRENGTH > s0igiom2 | > 10/em2 ww. 35-45%, “pucenDAY—| 5552 3 3 ? 3 UUUULUUVUHUSVOeUVda” tT Lette eee eee rtoecee Uecuuournt isl GREEN SAND TESTING PROCEDURE 4. Moisture: % of Moisture is seen by using Infra Red Moisture balance. Open the lamp housing and clean the sample pan and rest it on the needle provided at the center. Rotate the scale, adjusting the knob provided at the right and side of the balance, until the 0% mark coincides with the index. Now the pointer (Red needle) is just above the index. Carefully distribute the sand sample evenly over the sample pan ‘until the red needle comes to zero mark. To avoid volatile matter of the sand cover the sample pan with 50 mesh sieve which is provided separately. Then lower the lamp housing and tum the Auto transformer controller to 70-100. Now the Infra red lamp is working. Watch the thermometer reading, attached to the equipment, reaching to 110°c. Maintain the temperature at 110°c for 2-3 minutes by adjusting the Autotransformer controller. ‘Switch off the Infra red lamp, by rotating the autotransformer controller in anti clockwise direction until zero is reached. Now adjust the knob to bring the red needle to coincide with the index mark. Note down the scale reading, This is the percentage of moisture present in the sand sample 2. Green Compression Strength: The required amount of sieved sand (150 grams) is weighed and transferred into 50mm dia & 120 mm height cylindrical tube and 3 standard ram strokes are givon in the sand rammer in order to obtain a 2" x 2" dia specimen. The weight of the sand is adjusted to obtain this dimension and the specimen is taken out by using stripper post. Place the specimen in the sand strength machine using the appropriate accessories so that the plain surface of the ‘specimen touches against the circular pads. Rotate the wheel in clockwise direction uniformly until the specimen breaks. Take the Green Compression Strength reading on the scale provided from where the specimen breaks. The strength is measured in grms/Crr’.CELOCULOEUUYUUEUUYVUUEUYHU GoeOUHHHEHOUwY 4 3. Compactability: Take full level of sieved moulding sand in the 50mm dia & 100mm height cylindrical tube and give 3 rams by using the sand rammer, Measure the depth of the tube using a scale from where the specimen's plain end just touches zero mark oF the scale. The height of the depth is measured in millimeters and is expressed as compactability Number in percentage. 4, Permeability: Before operating permeability meter check the dropping time of the drum from 0-2000cc. The time should be (30 2 Sec.) See that the 2000ce air drum is floating at "0" mark when it is fioating over the water. Then the specimen tube is closed tightly over the orifice, water column in the Manometer should show 10mm.Take weighed and sieved moulding sand in 50mm dia & 420mm height specimen tube and give 3 rams by using sand rammer.Now the specimen is inverted and fixed tightly over the 1.5mm orifice in the permeability meter and let the air drum down from Occ to 2000cc by opening the valve. While the drum is dropping, note down the manometer reading This manometer reading is converted into Permeability Number by using the calculation. The calculated chart is fixed in the Permeability meter. Permeability is measured as mere number. 5, Total Clay: Percentage of total clay is done by two ways. {@) By using 25 Micron Test Sieve: Weigh accurately 50 grams of dried moulding sand in a 25 Micron Test Sieve. Keep the sieve under tap water. Open the ‘water with a slow speed and wash the sand.Now all the clay will pass through the sieve. Wash the sand well until the water passing through the sieve becomes clear. Take 10 grams of NaOH pellets in a 250 mi beaker. Add 15- 20m! distilled water and dissolve well,veCleUFUUUUUUUUuUuVUdD dU Houde deve 103, Now pour the NaOH solution over the moulding sand to remove the clay sticking on the sand. Again wash well in tap water until all the NaOH solution goes out. Keep the test sieve on the Muffie furnace to dry the sand. After 1 Hour take the sieve and cool to room temperature. Take the weight of clay free sand. From the weight the percentage of total clay is calculated as follows: % of Total Clay = Weight of sample taken - Weight of Clay free sand_x 100 50 (b) By using Clay washer: Weigh accurately 10 grams (A) of dried moulding sand. Put the sand into the glass jar provided. Fill up the glass jar with distilled water upto the 150 mm mark. Add 10ml of (3%) NaOH solution. Keep the jar on the jar holder. Let the solution stirr for 8-10 mts.by switching on the button provided. ‘Allow the sand to settle for 1 minute. Syphon out the muddy water, using the syphon provided upto the 25mm mark. Again add 10 ml of NaOH solution and refill the glass jar with water upto 150 mm. Stirr for 5 minutes. Allow to settle the sand for 1 minute and syphon out the water upto 25mm mark Repeat the procedure until we get a clear solution (ie. Free of Clay).Filter the washed sand with water through No.41 Filter. Dry the sample along with the filter paper in the Drier. Cool the sample to room temperature and take the weight of clay free sand (B). % of Total Clay = A-B_ x 100 A A= Weight of sample taken. = Weight of Clay free sand. G. Active Clay: Preparation of Standard 0.01 M Methylene Blue solution: Dissolve 3.199 grams of Methylene Blue powder in about 400 ml of distilled water and keep it over night. Next day make upvyvuuvUvVVUVu ve VUuVGdli SF eee Vode guvyu - > - the solution to 1 litre with distilled water using standard measuring flask. The concentration of this solution is 0.01 M. Weigh accurately 5 grams of dried Silica sand and 0.4 grams of Bentonite in a 250 ml beaker. Add 50 mlof distilled water and shake well with a stirer. Warm the solution Put a magnetic rod into the solution. Place the beaker on the Magnetic Stirrer equipment and allow it to stirr for 1/2 Hour. Titrate the solution against standard 0.01 M Methylene Blue solution after adding 4-5 drops of (0.5 N) H2SO4. The end point is the getting of Green hallow with blue ring at the center when a drop of titrated solution is brought into contact with a filter paper. Note down the titrated value of Methylene Blue observed. Since 0.4 gram of Bentonité with 5 grams of Silica Sand is an 8% Bentonite mixture the factor of Methylene Blue is calculated as follows’ Factor = ——_8___________ Volume of Methylene Blue consumed Now weigh accurately § grams of dried moulding sand in a 250 ml beaker. Add 50 ml of distilled water. Warm the solution by stirring, Puta Magnetic rod into the solution and stirr the solution to 1/2 Hour by placing the beaker on the Magnetic Stirrer. Now titrate the solution after adding 4-5 drops of (0.5N) H2SO, against 0.01 M Standard methylene Blue solution by taking the end point as said above. Note down the titrated value of Methylene Blue solution. Calculation: % of Active Clay = Volume of Methylene Blue consumed x Factor. 7. Volatile Matter: Take 1 gram of dried moulding sand in a Volatile Matter crucible. Add 1 or 2 drops of Benzene. Close the crucible with a lid. Place the crucible in a Silica crucible so as to avoid direct contact of heat. Place the crucible inside the Muffie Fumace maintained at a temperature of 920°c + 5°c exactly for 7 minutes. Remove the crucible. Cool it to room temperature and reweigh,% Volatile Matter = Loss in weight x100 41 8. Loss on Ignition: Take 5 grams of dried moulding sand in a Silica crucible. Place the crucible inside the Muffle Fumace maintained at a temperature of 920°c + 5°c and keep it for 4 Hours. After that remove the crucible, cool and weigh the sand again. 2 2 3 2» = Calculation: 2 2 > 3 2 = Loss in weight = Initial Weight - Final Weight > % of LOI= Lossin Weight x 100 3 5 3 > 2 > > > 2 > 2 2 ° > 2 2 - 2 -METHYLENE BLUE TEST COMPARISON GUIDE FOR END POINT HALOS Use this guide as a reference when testing for the MB. requirement foundry molding sands, bentonites, and pre-blended additives. START Prepare the sample and test for halo. When following AFS test procedures, itis recommended that 4 or 5 dots be used to reach a good halo as. illustrated below. WEAK HALO. Stir two minutes more without adding MB. solution, If halo disappears, add another ml. of MB. solution. Test again for halo after stirring GOOD HALO MB, end point reached. Stir for two more minutes. If halo remains, record the number of milliliters of MB. solution required to get a good halo NO HALO Continue to add MB. solution in one ml. increments until a halo appears. OVER TITRATION Excess M.B. solution added to the sample. If the + halo is the rsult of the first test dot, start test over. @ @ e UevyvYV YN VMN Vv Ve UUV ee eee ee wee Ce oe le tobeLICA PR¢ ‘THE SALIENT POINTS IN THE TESTING METHOD OOLITIC MEASUREMENTS Determination of quartz. content and degree of oolitisation by phosphoric acid digestion method, 1) Take 100 grams of representative sand sample, Dry and riddle through 30 mesh USS sieve, so that big lumps etc, are avoided . in the regular manner, perform clay wash test on this 100 grams sample and find the AFS clay percentage. 2) From the washed AFS clay sand sample, take 50 grams and conduct the sieve analysis test, note down the fines content below 140 mesh from this analysis as “Eee 3) Calcine the washed sand at 925 degree centigrade for 3 hours or so around $0 ‘grams sample to be taken for calcination. Also find out the LOT of this washed and washed and calcined sample, call it “WC” 4) From the washed and calcined sand sample (fom 3), take around 12-13 grams of representative sample, slightly moistened to avoid segregation. Dry and then weigh accurately 10 grams sample. Place this 10 grams sample in to a 600 ml beaker. Pour in to the beaker 200 ml of concentrated (85%) phosphoric acid. Less acid should not be used. Acid should be added once only. 5) Boil the sample at about 300 degree Celsius for about an hour or a little longer. After the evaporation of water in the acid, digestion the beaker is allowed to coal for about 15 to 20 minutes, Then the excess acid is decanted by tilting cautiously, taking care not to spill out any sand grains. Precautions : do not pour either , ‘water or cold acid into the hot acid. Warm acid after cooling should not be poured in water.) 6) After decanting, cooling is continued, till the beaker reaches below 100 degree Celsius. Then the beaker is filled with hot water with stiring action and allow to stand for 5 minutes. The excess water is siphoned off, and the process of filling , standing and siphoning off is repeated 3 or 4 times. Then the quartz residue in the beaker is rinsed in to a paper filter, washed and dried. The sand can also be washed through a 25 microns sieve. The weight loss afler the phosphoric acid digestion directly corresponds to the degree of ovlitization, Aficr the phosphoric acid digestion, when all the ooltic coatings have been removed, the left over material residue in soluble quartz. Call this as “Q”. This Q value is from the washed and calcined original sand sample after phosphoric acid digestion, Now, this value should be corrected in to the figure “Q” ic. quartz, content of the original dried sand sample in the unwashed condition, 7) Assuming this “Q” is 72% then the quartz content of the original unwashed and dried sand can be calculated thus.3 3 9 >? ? VUUUUGDULUEUBUUOGUYDwE Wh Y @ & “a -o Ubu EY CALCULATIONS Quartz content“q” = 100 — (fines content “FC” + LOI of washed and calcined sand “WC")x “O” 100 where “Q” is the insoluble quartz grain residue after phosphoric acid digestion = quartz content of the washed and calcined sand. Example, Q 2% FC 14% we a% Hence, Quartz content “Q” = 100-(14+4)x 72 = 59% 1003 & yey NV YU YU UY UE EF VE eVE Ve Ue U > > > Pe eee eer wt CLEANLINESS FACTOR 1) Find out the oolitics percentage by the phosphoric acid method. 2) From the AFS clay washed and calcined sand sample, put it in a mortar and crush. Then boil the sand sample by adding 4 to 5 globules of NaOH crystals. After cooling, perform regular clay wash test again. Then residual sand is dried and the difference in weight is recorded as percentage of but clay 3) True clay is obtained by subtracting the burnt clay percentage (from item-2) from Ist AFS clay washed sample. 4) The burnt clay washed sample from item —2 is again crushed in a mortar to free the sand from magnetic materials ic. FeO & Fe203 and then spread on a piece of paper and a feeble magnet is run over the spread out sample. Weigh the collecied iron particles on the magnet and record the percentage weight picked up by the magnet with the original sample weight taken for the clay wash. SILICA = 100+ Oolitics — (LOI+ AFS clay + Magnetic materials) FLUX = Total AFS clay ~ (Active clay + Oolitics) ((MB active clay from the original Ist representative sample) Cleanliness factor = Silica Silica + Flux + Magnetic materials Cleantiness factor of 90 and above is considered good. Some foundries consider oolitics as bumt clay fines. Hence they take the sand sample, perform the AFS clay wash, calcine the washed sand sample at 925 degree Celsius for 2 hours or so and sieve analyse the resultant sample through the finest mesh available i¢.270 or 300 mesh U.S.sieve taking care not to split out any sand ‘grains The percentage retained on pan is as Oolitic. White conducting the SILICA programme, if the result is above 85% (Quatrz content), then the sand becomes similar to new facing sand. If the silica level of an iron foundry sand increases to this range, the moisture requirements of the unit sand system will change and the sand may not be suitable for high production automatic moulding lines these sands will dry out quickly and require close control Silica content, conducted by silica programe test, in the range above 70% and below 85% is considered good for Grey iron, Malleable iron and S.G.iron moulding sands Each foundry should establish this values after regular systematic tests conducted by well trained staffS over a period of time with R&D approach and fix the norms initially, this tests to be conducted once in @ week and thereafter fortnightly.MERON aoureuooaugevWOBGUGUUuDoUoUUUWUUUY ACKNOWLEDGEMENT Mr.P.Arul Mozhi Devan, Manager-Production of M/S Aquasub Engineering, Foundry div-II,Coimbatore:1 7,kindly acknowledge the valuable opportunity given by the IIF,Coimbatore Chapter & Mr.Shankar Raman. T also take immense pleasure in thanking the my Management and Mr.N.Purushottama,General Manager, in particular for the motivation and encouragement given. BIBLIOGRAPHY 1.Mould and Core Making materials-Dr.H.Md.Roshan. 2.Sand Practice-Krishnamurthy. 3.AFS Transactions. 4.Disa application manuals.