which included a system with a separa- tion unit, a system using a furan binder and a system with a separation unit and thermal reclamation. Te com- parison included a look at the required equipment for each system. Voestalpine Nortrak decided on
a chromite silica system with furan binder. When employing a basic oliv- ine sand system, the furan acid binder system cannot be applied. In nobake sand molding, however, furan binder is the most commonly used binder system, which is also true within the voestalpine group. Furan combines good binding properties with superior regeneration rates over other binder systems. Nortrak saw that quartz sand would be the most economical molding material, but because of its poor thermal physical qualities and the inevitable quartz inversion of silica sand, it cannot be applied for fac- ing sand for steel castings. Although relatively expensive, chromite sand
provides excellent facing sand quali- ties and is lightly magnetic. Te latter quality enables the use of the more cost effective silica sand as backing sand, because the chromite sand can be separated from the return sand. In this way, it can be reclaimed and reused as facing sand with minimum addition of new chromite sand to compensate for losses. Te study showed that a chromite silica system would be the most cost efficient system.
Expanding in Phases In order to minimize interference
with ongoing operations, voestalpine Nortrak decided to split the realization of the project in three phases: Phase 1: Installation, which is cur- rently under way, and testing of the new sand system.
Phase 2: Implementation of process changes, additional equip- ment, changing foundry logistics, etc.
Phase 3: Improve scrap handling system. The structure of the physical building expansion was completed in August. The expansion plan is projected to be completed in stages through September 2014 (Fig. 3). Te project will require an esti-
mated investment of approximately $6,820,000, as follows: Phase 1: $1,850,000 for the sand system.
Phase 2: $4,530,000 for molding and finishing.
Phase 3: $440,000 for the scrap han- dling system.
Despite the economically uncer- tain times, voestalpine Nortrak’s Decatur facility has demonstrated a continued growth trend over the years by providing quality track- work to the rail industry. With the upgrade and capacity expansion of the facility, the company can con- tinue to stay on that track for years to come.
October 2013 MODERN CASTING | 29
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