mechanical, 50% new, your costs are really going to start to go up.” Casey suggests a few considerations for metalcasters—
particularly smaller volume shops—that are performing a cost-benefit analysis of thermal sand reclamation: 1. Size of the unit. 2. Energy costs. 3. New sand costs. 4. Disposal and haul-away costs. In April 2008, Flotech upgraded its thermal sand
reclamation to a 1-ton/hour unit. Te system reclaims more than 99% of its sand, with the remainder lost to production and in fines, according to Casey. “Disposal cost is one of the easiest areas to realize
your savings,” he said. “Our disposal costs have been reduced to negligible. Plus, what we do have to haul away is now just sand to be dumped and not a hazard- ous material.” Casey said the return on investment for the unit is expected to be three years. Energy costs have increased for the gas-fired unit, but Casey is satisfied with the fuel efficiency. New sand and disposal costs have been cut dramatically. TyssenKrupp Waupaca is taking a different approach
to running its thermal reclamation system. It plans to keep it in operation constantly, so it had to size the system to match production. “We wanted a size that would provide the needs for
our coreroom but also allow autonomous operation on nonproduction weekends and allow the sand to accu- mulate but not give us a mountain,” Miskinis said. “We went with a system that processes 3 tons/hour but is designed so that we could easily double it in the same location if needed.” When TyssenKrupp Waupaca was researching thermal
sand reclamation, one of its main concerns was the quality of the sand after processing. “We wanted to find out the potential harm to the sand
and compare it to the cost of purchasing new virgin sand and landfilling the end product,” Miskinis said. ThyssenKrupp Waupaca asked a thermal sand recla-
mation equipment supplier to run its sand through the system the metalcaster would be using. The sand then was sent to the company’s resin suppliers for testing. ThyssenKrupp Waupaca also performed in-house testing. “We wanted to know if we’d have something better
or worse,” Miskinis said. “In our case, we found there might be an advantage to thermally reclaiming for dimensional stability.” If TyssenKrupp Waupaca is able to lower distortion in
its coremaking material, it can reduce the amount of addi- tives used to combat distortion-related defects. “Looking at the sheer amount of money spent on those
additives, reducing that by 50% would be a big win for us,” Miskinis said. ■ To receive this digital magazine in the future, go to
www.globalcastingmagazine.com.
有很多次机会，你可以依葫芦画瓢的运行该系统从而砂 再生。 如果你只回收50％，50％用新砂，你的成本真 地开始往上走。“
在执行热法再生的成本效益分析时，Casey给出了一 些对于铸造厂而言，特别是小工厂需要考虑的地方， 装置的大小 。 能耗费用。 新砂成本。
处置和运走成本。
据Casey所说， 2008年4月，Flotech升级了他的热 法再生砂装置，使处理能力提升到1吨/小时。 该系统能 回收超过99％砂子，余下的不到1%损失在生产中或者 变成了细粉，
“处理费用是其中一种最简单的方面来实现你的节 约，”他说。“我们的处理成本已经降低到可以忽略不 计。另外，现在我们需要运走的只是需要倾倒的砂子， 而不是有害物质。
Casey介绍，该装置的投资回报时间预计为三年。对 于燃气单元来说能耗费用会上升，但Casey对他的燃料 效率仍感到满意。 毕竟，新砂和旧砂处理成本已经大 大降低。
ThyssenKrupp Waupaca公司正在采取不同的方式 运行其热法再生系统。他们计划保持它连续运行，所以 必须调整系统大小与生产过程配合。
“我们需要有一个大小合适的处理系统，该系统不仅 能满足我们砂芯车间的需求，而且能够在非生产性的周 末进行自主操作，让多于的砂子堆积起来，但又不会堆 积如山，”Miskinis介绍。“我们需要有个处理能力为 3吨/小时的处理系统，但是它的设计能使我们在需要的 时候可以很容易地在同一位置使它的处理能力加倍。“ 当ThyssenKrupp Waupaca公司调查热法再生时， 其主要关注之一是砂子处理后的质量。
“我们希望找出该方法对砂子的潜在的危害以及与购 买新砂和填埋最终产品的成本进行比较，Miskinis说。 ThyssenKrupp Waupaca要求热法再生设备供应商 用砂处理系统处理它的砂子。随后处理后的砂子被送往 该公司的树脂供应商处进行检测。 ThyssenKrupp Waupaca也进行了内部检测。 “我们想知道，我们是不是会有一些有好或坏的结 果，”Miskinis说。“就我们而言，我们发现热法再生 其中一个可能的优势是它的尺寸稳定性。 “ 如果hyssenKrupp Waupaca公司能够减小制芯材料的 变形，就可以减少用于抑制变形及其相关缺陷的添加剂 量的用量。
“从花在这些添加剂上的钱的绝对数量来看，减少 50％添加剂的用量，对我们来说这将是一个巨大的成 功，”Miskinis说。 ■
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Winter 2012
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