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