green sand reclamation a necessity for …...green sand reclamation a necessity for sustainability...
TRANSCRIPT
GREEN SAND RECLAMATION
a necessity for sustainability
Manish Kothari
Managing Director,
Rhino Machines Pvt Ltd
Manufactured in India under License from FATA Aluminum
Presented at:
Foundry Technology
Skill Development
Data Acquisition & Analytics on
Cloud
Finance, Strategy & Risk
Management
Lean Management
Women’s Ethnic Wear
BRINGING THE SUSTAINABLE CO-OPERATIVE CULTURE OF “AMUL” FROM ANAND
3
From Darkness to Light
From Noise to Sound
From Waste to Money
Our Commitmentwww.rhinomachines.net
Ecoflex
Multiflex
Reclaim
Sand
THE OBJECTIVE
Environment
• Conserving Natural Resources
• Reduce Industrial Waste Dumping
• Reduce CO2 Emissions
• Reduce Fuel Usage
Economics
• Reduce the cost of managing silica sand
• Consistency in Sand Quality directly affecting casting rejections
• Saving in Additives
ENVIRONMENTAL CONCERNS
Sand Mining
Depletion of Natural
Resources lead to
Environmental Issues
@ 400 kms
110 Million kgs
Every 1 kg of casting = 1 kg of sand
10 Mill MT of Casting Shipped = 10 Mill MT of Sand Transported
165 Million kgs 220 Million kgs
@ 600 kms @ 800 kms
ECONOMIC CONCERNS
GREEN SAND FOR MOULDING SAND
Landed Cost of Sand
Rs 3,500/MT
or
200 AED /MT
Estimated Saving in Direct Cost
Rs 2,000/MT
Or
AED 110/MT
For 30% usage of Moulding Sand
Sustainability impact
Rs 6 Billion or
AED 330 Million
Coal Dust & Bentonite Reuse in Reclaimed
Sand
Estimated Saving
50% reduction in additions in the Mixer
For 30% usage of Moulding Sand
Sustainability impact
Rs 6 Billion or
AED 330 Million
ECONOMIC CONCERNS
CORES PRODUCTION IN GREEN SAND
FOUNDRY
Landed Cost of Sand
Rs 4,000/MT
or
225 AED /MT
Estimated Saving in Direct Cost
Rs 1,600/MT
Or
AED 90/MT
For 50% usage of Moulding Sand
Sustainability impact
Rs 8 Billion or
AED 440 Million
CHALLENGES FOR
NEW SILICA SAND IN FOUNDRIES
New Silica Sand
Technical Aspects
Consistent AFS & Sieve Distribution
Silica Sand Purity
Grain Shape
Commercial Aspects
Vulnerability to transport costs
Seasonal availability issues
Mining restrictions to protect natural resources
Solid waste management
GENERAL ANALYSIS OF
GREEN SAND FOUNDRIES…SILICA SAND USAGE
Cast Iron Block & Head Foundry
•Core Sand : ~ 1 kg new sand/kg of casting
•Moulding Sand – new sand addition near to zero
•Combination of Cold Box & Shell Sand Processes
Cast Iron Tractor Casting Foundry
•Core Sand : ~ 0.2 to 0.4 kg sand/kg of casting
•Moulding Sand : ~ 1-2% of Prepared Sand
Automotive Casting
•Core Sand : ~ 0.1 to 0.3 kg sand/kg of casting
•Moulding Sand : ~ 2-3% of Prepared Sand
Engineering, Manhole Cover, and similar non cored castings
•Moulding Sand : ~ 3-5% of Prepared Sand
•Core Sand : ~ < 0.1 kg sand/kg of casting
COMPLETE SOLUTIONS FOR
GREEN SAND PROCESS
S2
S1
S3
TYPICAL S1 PLANT CONFIGURATION
Sand Dryer
Feeding Belt
ConveyorHigh Pressure Blower with AccousticEnclosure
Reclaimed Sand
Storage
Sand Scrubber & DedusterWith Feed
Hopper
Dust Collection Cyclone & Bag Filter
2.5 T/HR CAPACITY
GREEN SAND RECLAMATION FOR CORES
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MP
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REC
LAIM
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GR
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SA
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SIL
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LOA
D C
ELL
Floor Space
30 M x 12 M
SOLUTIONS FOR
GREEN SAND PROCESS – MOULDING SAND
S1
SOLUTIONS FOR
GREEN SAND PROCESS – BROKEN/REJECT CORE
S2
SOLUTIONS FOR
GREEN SAND PROCESS – CORE SAND
S3
GREEN SAND FOUNDRY SOLUTIONS FROM RHINO
www.rhinomachines.net
We thank you for your
Patient hearing
&
Metalworld for this
opportunity
Our partnerships & associates
• Energy & Consumption Data Analytics on
Cloud
• Swiss Skill Development for foundries
• Lean Manufacturing Solutions
• Centre for Manufacturing Excellence with
MSME
• Turnkey Process & Project Support