DEPARTMENT OF METALLURGICAL ENGINEERING

GOVERNMENT COLLEGE OF ENGINEERING, SALEM-11

“First review”

“30/03/2022”

“ANALYZE AND RECYLCE OF SAND BY USING

THERMAL RECLAMATION METHOD FOR
EFFECTIVE CORE MAKING”
Presented by: Project Guide:
1861056 UMASANKAR M Dr. B. ANANDAVEL
1961L03 MURALIDHARAN S Assistant professor,
1961L06 THAMARAIKANNAN M Metallurgical Department
 CONTENT
 Introduction
 Sand analysis
 Operation layout
 Thermal reclamation method
 Core making
 Reference
 INTRODUCTION
• The green sand molding is one of the traditional
ways of molding techniques usually employed for
producing castings in foundry.
• Silica sand is one of the type of sand that mostly
used in foundry.
• The main focus of our project is to make an
attempt on the analysis of the silica sand and
how we can effectively recycle the return sand by
thermal reclamation method for core making.
• Here the silica sand properties is analyzed
according to AFS standard for mold making.
• After the completion of molding process, the
casting is separated from sand.
• This sand is known as return sand.
• For recycling the return sand, by send this sand to
thermal reclamation unit for removing resin,
binder and another volatile matters at 850֯C to
obtain reusable sand properties.
 SAND ANALYSIS
SAND PREPARATION FOR MOULD:
 Silica sand
 Bentonite
 Coal dust
 Moisture
 Return sand
 Reclamation sand
Moulding sand per batch:
 New silica sand (10-20 kg) depends on return sand
 Bentonite ( 7-10 kg) depends on return sand
 Coal dust ( 5-7 kg)
 Moisture ( 15-20 litres) depends on return sand
 Return sand ( 1350 kg)
 Reclamation sand ( 20 kg)
Testing of molding sand properties:
• Moisture test
• Compactability test
• Green compression strength
• Permeability
• Wet tensile strength
• Shatter index
• Friability
• Mouldability
OPERATION LAYOUT
THERMAL RECLAMATION METHOD
• The thermal reclamation process enables the
removal of binder residue from sand particles to
return the sand to its original form.
• In most cases, quality of the sand is better than
the purchased new sand.
• The thermally reclaimed sand can be recycled for
reuse in future casting production helping to
reduce waste disposal and new raw material
costs.
• Analysis shows that the cost of thermal
reclamation compared with the purchase and
disposal of new sand can offer saving of up to
50%.
• Return sand:
 no bake sand
(Sand from core)
Shell sand
(Sand from casting mold)
• First, shell sand and no bake sand is send to sand
hooper in thermal reclamation unit.
• Sand is sieved and separated in sieve shaker.
• Casting iron particles is removed from sand in
magnetic separator.
• After removing unwanted particles from sand,
the sand is heated in range of 850֯C to remove
the chemical substance like resin, binder and
additives.
• Then the sand is send to heat exchanger unit
where heat is slightly reduced by air conditioner.
• Shell sand and no bake sand is send to cooler to
reduce the temperate to 33֯C.
• This cooler unit consist of coil based structure
where the coolant is sent inside the coil. The
surrounding sand cooled because of heat
transfer.
• After completion of cooling, the sand is send to
sand storage for reuse in core making.
 CORE MAKING
• A core is a device used in casting and molding
processes to produce internal cavities and
reentrant angles (an interior angle that is greater
than 180°).
• The core is normally a disposable item that is
destroyed to get it out of the piece.
• They are most commonly used in sand casting,
but are also used in die casting and injection
molding.
• Materials required to make cores:
1. Core sand- silica sand-(10 to 20 kg)
2. Bentonite clay- (7 to 10 kg) according to return sand
3. Pulverized coal- (5 to 7 kg)
4. Resin oil.
• Core making process:
1. First, Core pattern is selected according to the
required design and attached into the machine.
2. After acquired the molding for core, the sand is
compressed into the mold in with the addition of
amine gas.
3. Because of amine gas, the core sand is hardened
and the core is removed from mold.
4. To improve surface finish, core is immersed
into toyomet liquid and heated in oven
around 235֯C for 45min.
5. Finally, core is manufactured for mold
assembly.
REFERENCE
• Industrial Data collected from Aquasub
Engineering, Thudiyalur, Coimbatore.
• https://en.m.Wikipedia.org/wiki/casting
• https://www.harrisoncastings.com/
capabilities/thermal-sand-reclamation/