During the planned two-week shutdown, the follow- ing needed to happen: • Empty and relocate two large sand silos from the west side of the plant to the south side. The foundation and elevated platform were ready.


• Commission the magnetic separator and process the stored shakeout sand from trials through the magnetic separator.


• Debug the heater/coolers and pneumatic transport system.


• After the sand silos were empty, the ineffective inverted, partial cone anti-segregation device was replaced with the inverted, full cone version. The silo relocation and magnetic separator commissioning proceeded smoothly, meeting the April 2014 goal, a year after the initial planning meeting.


Assessing the Installation


After the project was complete, voestalpine Nortak asked itself some straightforward questions: How is the new system working? How is it being controlled? Since start up, production goals have been achieved and the project has exceeded budgeted cost savings. Te goal is to keep sand usage at or below the business plan with a new chromite sand addition rate of 12%, including new chromite cores. Currently, patterns are being faced with a blend of 9.6% new and 90.4% reclaimed chromite and backed with a blend of 11% new and 89% reclaimed silica. Current stable binder addition rate is 1% for both facing and backing sand. Acid levels vary between 25-45%, depending on resin and blending technique. Revised Wash and Application Practices:Sporadic


surface quality issues were discovered with the olivine/ magnesite wash on the 90/10 reclaimed chromite/new chromite facing sand. Te olivine/magnesite coating had been used successfully on the new olivine sand facing in the old sand system. voestalpine Nortrak tried a magnesia (MgO) coating, which improved surface quality as mea- sured by substantially reduced cleaning times. In addition the following controls were implemented: • Baume control was shelved in favor of weight per volume measurement.


• Results from flowcoating are more consistent using the weight per volume method. If temperature biasing is added, engineers expect variability will be reduced again.


• Mold wash penetration is on the order of 0.1-0.125 in. from flowcoating with a surface layer of 0.01-0.015 in.


• Mold wash pooling can occur if care is not taken to inspect every mold and brush or blow down drips and puddles


• Because of the change to the MgO wash, the pH of the heat treat quench water has gone up to 10pH or more. As a result, castings have a bluish color com- ing out of the quench with little surface rusting. It is not known yet if the high pH quench water has long-term implications.


铬时ડ测。ડલוગґे，斗料满装机重起过通。装安 醛酚化֡酯ङ来Խђ间期фҠ֨，砂落ङ砂硅 铁矿砂 树脂橄榄ी砂 硅砂生фিИӣ开，Օљ通过新ङӒ却 吨料ѓ ङ方Ї֘ख़ӣ选्ङ新йѹӱ送运，וગख़ӣ 硅砂Ӈ生系统ङҼ键部ӣ。 砂矿铁铬是֘ख़ӣ选्。И ：成完要需ҁ工面Ј，间期机ҠյДङӦઋ֨


安新重，侧南ӱ搬侧西Դ工ђ并ѓ料砂型םЗД空清 ș 。ױוӕ需Ֆ平架高չׂ֪ङѓ料。装


输ѓ料ङ砂落存ҥђ砂型ङ验ડ把，֘ख़ӣ选्装安 ș 。֘ख़ӣ选्ӱ送


。统系送输动气չ֘却Ӓ ș લડ加热 ș 型砂料ѓ清空ե，Җ立放置，安装्选ӣख़装置，Ӈ 顺ي进ડલङ֘ख़ӣ选्չ迁搬ङѓ料。Խז部Ҷ ઋ步初੧Р֨是就Э，标ऩङ月 ӯ，完成д 年 Ӧѫઑ一年ե。


果效ੇ،Ѳ੪


п一дӟ提己ਘث՛ҸQGXZXU4联钢奥，ե成完ऩ项 Ӳ控ੴѾײ是它;ङҁ工Ѿײ是统系ङ新：题问ङ单এ ङ; 成过超经已ऩ项，现实经已标ऩф生，ե੧运וગ


本预算ङऩ标。项ऩऩ标是砂ङ҅用ґ持或ѺйЏ务ઋ Ӧ，գ时新ङ铬铁矿砂加ҵ比҆О ％，包括ਯ砂҅用 量。ऩӹ，造型И面砂҅用 ％ङ新砂混合 ％ङ Ӈ生铬铁矿砂，ਅ砂҅用 ％ङ新砂混合 ％ङӇ生硅 ％ ֨定६҆比加添剂ৈড，砂ਅչ砂面括包，ӹऩ。砂 ％Ф间，ՈӐй树脂չ混合水平。 ֨量խङ酸。 Ӈ生铬铁矿砂չ ं用҅֨：ҁ操用҅料涂订ғ 新铬铁矿砂О面砂，橄榄ी 菱镁矿涂料时，零星ङ


੮面ૅ量问题ੴՇ现。橄榄ी 菱镁矿涂料已成功应用й 氧用҅ડغ՛ҸQGXZXU4联钢奥。统系砂ी榄橄新ङ来Խ 理清صӗ幅ם量ૅ面੮ङ进改过通，料涂）5M3（镁化 ：ҁ工ӧЈ੧进要需，י此。间时 。量重॥ѽ量测О改，їՈੴӲ控چ২波 ș ș ђ流涂ৈ果र，҅用ѽ॥重量法得ӱङৈ果更一ਚ。 ӗ次Ӈر性ՊՕङ望٥٤३工，ր影ङچ温Ї加果ײ 。ص


约םچ透渗料涂ङ型铸 ș 约


。تਸ਼


料涂生фИ型铸֨ѫਈՕ、型铸З每查检意注Љ果ײ ș 。象现॥ׄ


Ї经已қ.Vङ池水火淬理ה热，料涂镁化氧换更О֜ ș June 2016 FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 51 چԼك流涂，تਸ਼


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