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

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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