Converting a Sand System


One case study shows how converting a steel casting facility’s olivine sand system to a phenolic-based chromite/silica system required planning, cooperation and tight controls. GENE SWANSIGER AND BLAKE ALBRITTON, VOESTALPINE NORTRAK INC., DECATUR, ILLINOIS


更换砂系ঞ


矿铁铬ׂ脂树醛酚О换转统系砂ी榄橄把ѾײԴ钢铸؟一йҼ是҆案ङ绍介文本 。Ӳ控格Еչҁ合、Ӧઁङ需۱Ճљ，统系砂硅 砂


9='49/-+8 ո (2'1+ '2(8/::54。 +4+-，՚ҷ1'8:854联钢奥٠特ӛ૦ L


ess than five years ago, the mining of olivine sand ceased in the U.S., leaving North American metalcasters looking for alternative sources. Some chose to import olivine sand from Norway, though the increased shipping costs when compared to a


domestic supplier made this an expensive option. For voestalpine Nortrak’s metalcasting facility in Decatur,


Illinois, importing its olivine sand more than doubled in cost, from $140 per ton in 2011 to $280 in 2012. Te facility’s flaskless molding system for manganese steel trackwork cast- ings relied on new olivine facing sand for surface quality and reclaimed olivine/silica backing sand to minimize costs. Plant expansion plans were developed to increase production by nearly 60% in the short-term and 115% in the long-term. voestalpine Nortrak contacted an engineering firm


(GEMCO, Son, Netherlands) that had installed a turnkey casting facility in 2010 for a company site in France. Com- pany officials hoped the project for the Decatur site could be partially paid for with cost savings realized from an improved sand molding system.


ל


约м年ӹ，২国Ҡ止д橄榄ी砂ङ开采， 有。源资ङї替找ج始开Џѣ造铸ङ২北 пѣЏ选择ђ挪威进Ս橄榄ी砂，当然ब


比҅用 国ӄ供应商ङ材料，运输成本ङ增加҅这一选择 较О昂贵。 ，Դ造铸ङ՛ҸQGXZXU4联钢奥ङ١特Ӝ迪州ѤમӯѤ


进Ս橄榄ी砂ङ成本增加д ҕ，ђ ङ ২ҫ 吨 成Ѻ降֪چ限ם最дО。吨 Ї升ӱ 年ङ ২ҫ 本，铸造Դ生ф锰钢铁轨铸ўङ无ঔ造型系统҅用新橄 榄ी砂ҁО面砂，Ӈ生橄榄ी砂 硅砂Оਅ砂。工Դ正ઋ Ӧ扩ҭфਈ，近期ऩ标提高 ，远期提高 。 5)3+-（՛Ҹ३工؟一д系联՛ҸQGXZXU4联钢奥


Ҹ՛，ѹйਾҺফ恩）， 年થҸ՛Оҿ法国ङ铸 ١特Ӝ迪望٥ك理管՛Ҹ。३工装安匙钥сд供提Դ造 来本成ङѺ降৲统系砂型֑改用ӯљՕ用ોӣ部ङऩ项


Table 1. Options for Updated Sand System 更新的砂系ঞ选项


Sand System ֹ६ঞ系砂


Phenolic-based, olivine/silica system, mechanical reclamation (the existing system) 硅砂系统，机械法Ӈ生（现有系统） 砂ी榄橄，ׂ脂树醛酚


Phenolic-based, 100% olivine system, mechanical reclamation 橄榄ी砂系统， 机械法Ӈ生 ，ׂ脂树醛酚


Phenolic-based, 100% olivine system, mechanical and thermal reclamation 橄榄ी砂系统， 机械法չ热法Ӈ生 ，ׂ脂树醛酚


Phenolic-based, chromite/silica system, mechanical reclamation 硅砂系统，机械法Ӈ生 砂矿铁铬，ׂ脂树醛酚


Furan-based, chromite/silica system, mechanical reclamation separation 硅砂系统，机械法Ӈ生，्选ӣख़ 砂矿铁铬，ׂ脂树喃呋


Phenolic-based, chromite/silica, mechanical and thermal reclamation 硅砂系统，机械法չ热法Ӈ生 砂矿铁铬，ׂ脂树醛酚


Reclamation Rate(s) 再生率


Facing 0% Backing 75% 面砂


ਅ砂


Facing 60% Backing 60% 面砂


ਅ砂


Facing 80% Backing 80% 面砂


ਅ砂


Facing 70% Backing 70% 面砂


ਅ砂


Facing 87.5% Backing 87.5% 面砂


ਅ砂


Facing 90% Backing 70% 面砂


ਅ砂 June 2016 FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 47 45% $1,400,000 45% $960,000 110% $780,000 60% 110%


Cost (compared to existing system) ҄用成本Љ现有系ঞ比较


N/A


Investment 投ઞ


Not Applicable 无


Minor ش较


$620,000


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65