Green sand reclamation gna phagwara casting clinic 6jan2017

6th Jan 2017

Green Sand Reclamation for Moulding Sand & Core Sand Techo-Commercial Evaluation Presented by: Manish Kothari, Managing Director, Rhino Machines Pvt Ltd, Anand, Gujarat.

At Casting Clinic Whatsapp Group Seminar GNA, Phagwara

Manufactured in India under License from FATA Aluminum

The Objective

Environment Resources • Reduce Industrial

Waste Dumping • Reduce CO2 Emissions

• Reduce Fuel Usage

Sand Reclamation

• Conserving Natural

Economics • Reduce the cost of managing silica sand

• Consistency in Sand Quality directly affecting casting

rejections • Saving in Additives

Environmental concerns Every 1 kg of casting = 1 kg of sand 10 Mill MT of Casting Shipped = 10 Mill MT of Sand Transported

Sand Mining Depletion of Natural Resources lead to Environmental Issues

110 Million kgs

165 Million kgs

@ 400 kms

@ 600 kms

220 Million kgs

@ 800 kms

Solutions for Green Sand Process – Moulding Sand

S1

Actual Usage Data from Dec 2015 to Dec 2016 • Processing Costs @ 1.3 t/hr • Energy – 20 kWh/MT of Reclaimed Sand @ Rs 8.0 = Rs 160/MT

• LPG (To dry incoming sand) – 4.3 kg/MT (with 2-3% Moisture) @ Rs 60 = Rs 258 • Total Cost of Reclaimed Sand = Rs 418/MT

• Net cost of replacement of new sand = 2 x 418 = Rs 836/MT against Rs 1,000 considered in projections)

Techno-Commercial Considerations a typical calculation for Sand in S1 Sand Balance Calculation

Quantity & Economics New Sand MT/ Month

600

New Sand MT/ Day

24

New Sand Cost Rs / MT

3,000

Disposal Cost Rs./ MT

50

Drying & Handling Rs / MT

0

Reclamation Cost Rs/ MT

1,000

Net Saving in Sand Cost Rs/MT

2,050

Reclaimed Sand Usage

75%

Reclaimed Sand MT per Month

450

Saving per Month in Rs.

9,22,500

Present Batch Capacity Return Sand Dead clay RS New Sand kgs Dead Clay NS DC Reduction Dead Clay S1 Net S1 Input to RS Net Dead Clay

100.00 97.00 3.50% 3.00 3.0% 0.50% 40% 2.10%

3.418

With Reclamation (S1) 100.00 94.75 3.50% 0.75 0.75% 0.50% 40% 2.10% 4.50 4.5% 3.415

Estimated Effect on Additives Bentonite Balance

Coal Dust Balance

Batch Capacity Return Sand Active Clay Return Sand

100.00 97.00 7.03% 6.82

With Reclamation (S1) 100.00 94.75 7.03% 6.66

New Sand kgs

3.00 3.0% 0.00% 0.00

24% 5.33% 0

100

Active Clay New Sand

AC Reduction Active Clay S1 Net S1 Input to RS AC Absolute S1 Net Active Clay Bentonite Addition Final Active Clay

Batch Capacity Return Sand LOI Return Sand

100.00 97.00 4.66% 4.52

With Reclamation (S1) 100.00 94.75 4.66% 4.42

0.75 0.75% 0.00% 0.00

New Sand kgs

3.00 3.0% 0.00% 0.00

0.75 0.75% 0.00% 0.00

LOI Reduction LOI S1 Net S1 Input to RS

33% 3.14% 0

0

24% 5.33% 4.50 4.5% 0.24

0

33% 3.14% 4.50 4.5% 0.14

6.832 1 7.83

6.901 0.93 7.83

Net LOI Coal Dust Addition Final LOI

4.530 0.50 5.03

4.557 0.47 5.03

Present

100

LOI New Sand

LOI Absolute S1

Present

Estimated Commercials for Prepared Sand Green Sand - Unit Sand Batch Size

1000.00 Kgs Present Typical Usage

Estimated Usage with S1

Net Materi Prepared Saving in Prepared unit %age als unit Sand Rs per MT kgs/Batch Sand Cost rate/kg additions Weight rate/kg Cost per of Sand per MT Prepared /Batch MT

Consumable

%age additions

Bentonite % of Batch Size

1.00%

10.0

6

Coal Dust % of Batch Size

0.50%

5.0

27

S1 Reclaimed Sand

0.00%

0.0

0.5

New Sand

3.00%

30.0

2.5 Total

60 135 75 270

0.93%

9.3

6

56

4

0.47%

4.7

27

128

7

4.50%

45.0

0.5

23

34

0.75%

7.5

2.5

19

Total

225

45

Solutions for Green Sand Process – Core Sand

S3

Rs 450

+

Rs 1,000

+

Rs 900

=

Rs 2,350

THANKS

Q&A