increasing their reclaiming efforts in order to use less new sand. While the technology can be expensive, the new eco- nomic reality of the sand market could force a reappraisal of how cost effective it is. Like many metalcasting facilities in the U.S. Mid-


west, ThyssenKrupp Waupaca, Waupaca, Wis., U.S.A., was fine with its sand costs for many years. According to Gregory Miskinis, director of research and pro- cess development, ThyssenKrupp facilities had good, longstanding relationships with their sand suppliers, and land for sand disposal was plentiful and inexpen- sive. As a result, thermal sand reclamation couldn’t be cost-justified. But now the company is a step away from installing a


thermal sand reclamation system in its Waupaca plants. “Planning for the future led us to this point,” Mis- kinis said. “As good as a relationship as you can have with your sand suppliers, they still have to be respon- sible to their shareholders who are asking why they are selling to the foundry when so much can be sold to [the oil and gas industry] at a higher price. We looked at [the market] and knew we needed to protect our future raw material.” According to Miskinis, the potential sand shortage


and increased costs due to increased demand from the fracking industry are making it easier to justify thermal sand reclamation. “It’s the right thing to do, as our CEO says,” Miskinis


said. “And now it has a payback period that is acceptable to our parent company.” ThyssenKrupp Waupaca has selected and engi-


neered a system and plans to purchase the equipment in the first or second quarter of the next fiscal year. As a high volume casting facility, ThyssenKrupp Waupaca plans to run its thermal sand reclamation equipment constantly. The units are designed and built to provide a continuous amount of fresh sand to keep up with production.


Reclamation for All Sizes At Space Castings, the foundry division of Flotech Inc.,


Jacksonville, Fla., the thermal sand reclamation unit runs just 50 hours a week. “We’re not a production foundry that kicks out 6,000 or 7,000 pieces of something,” said Chris Casey, foundry operator. “We do a lot of one-, two- and three-offs.” Although Flotech is not dealing in the same volume of sand as ThyssenKrupp Waupaca, the material’s cost is still critical. According to Casey, available landfills are scarce in Florida and new sand has to be trucked in with a blower unit. His plant was spending $5,000 for 20 tons of sand. “When you are spending $4,500 to $5,500 for a load of


sand, and that’s only a week’s supply, it adds up,” Casey said. “Tere are only so many times you can run mechanically reclaimed sand through [the system]. If you are doing 50%


您的用量”他说。 “从铸造的角度来看，我们将以最大 程度满足。在这种情况下，在我脑海中我们应该做的让 铸造厂更加积极地考虑旧砂再生。“ Jablonski说过，他的许多客户正在不断增加他们砂再 生的能力，以减小新砂的数量。虽然该技术成本比较高， 砂子市场的新的经济现实会迫使我们重新评估成本。 像美国中西部地区的众多铸造厂一样，美国威斯康星 州沃帕卡ThyssenKrupp Waupaca公司这么多年一直 很好地控制了他们的砂子成本 。据负责研究和工艺开发 的主管Gregory Miskinis所说，ThyssenKrupp厂与他 们的砂子供应商有着长期稳定的合作关系。并且处理废 砂的场地曾经很多而且很便宜。 因此，那时候热法再生 砂并不合算。


但是，目前，该公司在其Waupaca的工厂正在安装 一套热法再生砂系统，这个系统即将完工。 “对未来的预期指引我们走到这一步，”Miskinis 说。“尽可能的与你的砂子供应商保持良好的关系，但 是他们需要为他们的股东们负责，他们的股东会质问他 们为什么要将这些本可以以更高的价格出售给石油和天 然气行业的砂子卖给铸造厂。考虑到目前的砂子市场， 我们知道我们需要保护我们未来的原料来源。 “ 据Miskinis所说，由于水压致裂行业对砂子需求增加 导致了砂子潜在短缺和砂成本增加，我们更加看好热法 再生砂 。


“我们的CEO说过，这是正确的做法，”Miskinis 说。“现在我们的母公司可以接受该投资回收期。“ ThyssenKrupp Waupaca公司已经选择并设计了一 套系统，并计划在下一财年的第一或第二季度购置相应 的设备 。 作为一个大的铸造厂，ThyssenKrupp Wau- paca计划连续运行其热法再生系统。该系统的设计和建 造能够保证源源不断地为生产提供新砂。


适合不同规模的再生 对于大型铸件，像位于佛罗里达州杰克逊维尔市


Flotech公司的铸造厂，他们的热法再生系统一星期只 运行50小时。


“我们不是生产6000或7000件的铸造工厂，”铸造 厂经营者Chris Casey说。


“我们做了大量只有1件、2件或者3件的订单。” 虽然Flotech与ThyssenKrupp Waupaca两个工厂处 理的砂子的量不一样，但是材料的成本仍然是至关重要 的。 据Casey所说，现有的垃圾填埋地在佛罗里达州非 常稀缺。新买的砂必须用带有鼓风系统的卡车装运。 他 的工厂为20吨砂子支付了近5000美元 。 “当你花费4,500到5,500美元买一车砂子，而这仅 仅是你一个星期的用量，这意味着什么” Casey说。“


30 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Winter 2012


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