THERMAL SAND RECLAMATION PLANT

GO GREEN…

INTRODUCTIONWhat is Sand Reclamation ?

The Sand Reclamation is process of cleaning previously used sand so it can be reused

Why Sand Reclamation ?

Due to environmental regulations, the disposal of waste foundry sand has become one of the most pressing problems for the foundry.

In recent years because of the high disposal costs encountered and difficulty in finding disposal sites.

Scarcity of New sand due to local authorities are imposing restrictions in mining. In future, there will be chances of stopping supplies to save the natural resources.

Thermal Reclamation is the process in which the sand is heated to a temperature of about 600 to 800 deg. C, in a specially designed fluidized bed Combustor which is the main equipment of the thermal reclamation system.

In the Thermal Reclaimer, the sand grains obtained from the lump breaker is generally preheated

And feed into the combustor where it is fluidized by precisely controlled air flow at desired pressure.

The fluidized bed also receives LPG gas at controlled rate which burns in the fluidized bed with oxygen available in the fluidizing air in the bed. The binder in the sand is totally burnt and hot reclaimed sand is obtained at the outlet of the Combustor.

THERMAL RECLMATION BY PROCESS

Why Thermal Process…?!Thermally Reclaimed sand undergoes lower

thermal expansion causing better mould stability.

Thermally reclaimed sand is better than fresh sand because it is more rounded in shape causing lesser binder demand as well as can be used with any chemical binder system in subsequent cycle.

Thermally reclaimed sand is better than mechanically reclaimed sand.

Sand Pro-Claimer Plant Drawing (Only for Green Sand)

Thermal Reclamation plant Drawing

PROCESS FLOW CHART

INPUT SAND & LUMPS FEED THRIUGH BELT COVEYOR

WITH OBMS

SAND ENTER TO PRO CLAIMER

THERMAL SAND RECLAMATION PROCESS FLOW CHART FOR GREEN SAND PROCESS

SAND FEED THROUGH RAV BY BELT CONVEYOR ATTACHED WITH MAGNETIC

PULLEY FEED THROUGH BUCKET ELEVATOR TO SAND PRE HEATER

SAND ELEVATE TO THE OVER HEAD SIEVER AND THE SIEVED SAND STORED IN BUNKER

MAGNETIC PARTICLES BIG & SMALL IRON PIECES WILL REMOVED THROUGH OBMS &

MAGNETIC PULLEY

ABOVE 3mm SIZE GRAIN WILL REMOVED

BENDONITE & DUST WILL REMOVE & COLLECTOD BY DUST BAGS

ABOVE 3mm SIZE GRAIN WILL BE REMOVED

MAGNETIC GRAIN WILL BE REMOVED BY MAGNETIC PULLEY

LUMPS & SAND ENTER INTO LUMP CRUSHER

COOLED SAND ENTER TO SAND SIEVER & ELEVATE THROUGH BUCKET ELEVATOR & STORED IN BUNKER FOR READY PROCESS. FINE DUST WILL BE REMOVED AT

WET SCRUBBER UNIT WITH CHIMNEY & EXHAUST BLOWER

SAND ENTER TO COMBUSTOR (CHAMBER TEMP 500 ° C TO 600 ° C) IT GETS TEMP &

PROCESSED THROUGH FLUDISATION PROCESS

HOT SAND (>600 ° C) ENTER TO SAND COOLER. THERE THE TEMP IS TRANSFER TO WATER COOLED HEAT EXCHANGER AND

PROCESSED THROUGH FLUDISATION PROCESS UPTO 40° C

SAND ENTER IN THE SAND PRE HEATER IT WILL GET UPTO 200 ° C & THEN ENTER TO

COMBUSTOR

FLUE GAS EXHAUST STARTING FROM SAND PRE HEATER

LESS THAN 150 MICRON SAND WILL BE REMOVED AT AIR PRE HEATER

FLUE GAS TEMP IS USE TO FLUDISATION PROCESS THROUGH

AIR PRE HEATER

DUST WILL BE REMOVED BY FIRST & SECOND STAGE CYCLONE

SEPERATORS

LIST OF EQUIPMENTS S.No Equipment Descrepition

1 LUM CRUSHER

2 BELT CONVEYOR WITH MAGNETIC PULLEY

3 OBMS WITH MAGNETIC PULLEY

4 PROCLAIMAER WITH BLOWER

5 PULSE JET DUST BAG FILTER WITH SUPPORTING EQUIPMENT (40 Bags, 7.5Hp Blower) (FOR PROCLAIMER)

6 BUCKET ELEVATOR - I

7 OVER HEAD VIBRATING SIEVER

8 SAND STORAGE HOPPER (20 MT capacity)

9 SAND FEEDER BELT WITH RAV & MAGNETIC PULLEY

10 BUCKET ELEVATOR - II

11 COMBUSTION FURNACE 2TPH WITH PLC & MCC CONTROL PANEL

12 DIRECT SAND COOLER WITH FLUDIZED BLOWER

13 SAND SIEVER FOR RECLAIM SAND

14 BUCKET ELEVATOR - III

15 RECLAIMED SAND STORAGE HOPPER (20 MT capacity)

16 DUST & FLUE GAS EXHAUST SYSTEM

17 WET SCRUBBER UNIT WITH SUCTION ID FAN WITH CHIMNEY 13 MTS FROM FLOOR LEVEL WITH PUMP

18 PULSE JET BAG FILTER WITH SUPPORTING EQUIPMENT (60 Bags, 10 Hp Blower)

LUMP CRUSHER

FLUIDISED FURNACE

SAND COOLER

OVER HEAD SIEVER

FLUE GAS EXHAUST

HOPPER & BUCKET ELEVATOR

CONTROAL PANEL

REQUIREMENTS

Space Requirement (Shed) - Minimum 25m x10m x 10m

Outside space - 10m x 10m (For scrubber & Cooling tower)

Electricity Requirement for Total Plant - 75.00 KW (Thermal Plant – 61.00 KW + Pro-Claimer – 15.00 KW)

Labour – 4 Persons/ Shift ( Thermal -2 & Pro-Claimer – 2 )

Conserves Natural Environment and Cost by eliminating Dumping of used toxic

sand .

Reclaimed sand replaces fresh sand.( Less purchase )

Drying not required for reclaimed sand and thus cost can be eliminated.

Uniform Properties & Characteristics.

Supply will be Consistent & Adequate.

No Freight charges and Delay.

No need to have bulk inventory.

LOI is Max 0.3 % as per your sand

OEE -85 - 90%,

Thermal Efficiency- 90 - 95%

Gas Consumption : 10 to 15 Kgs (This will vary according to the sand)

7 to 10 Kgs ( For Green Sand Thermal running)

Finally Sand cost would be Cheaper.

Advantages…..

Returns…..!!!ROI - LESS THAN ONE YEAR

Budget Cost of the (2 TPH) Reclamation Plant ( As per our Drawing) 12000000

1 INVESTMENT COST (PER KG) UOM  Out Put per Day of 2 TPH ( 2 ton * 24 hrs) 48 MT  Our put per Month (48 x 25 Days) 1200 MT  Our Put for 2 Years ( 1200 * 24 months) 28800 MT  Investment cost (12000000 / 24000) / 1000 0.42 INR  Interest on Investment cost (@ 15%) 0.15 INR  TOTAL INVESTMENT COST / KG 0.57     2 RUNNING COST (PER KG)    Electricity Cost per KG (@ Rs.7 per Unit) ( 38 KWH per TON) 0.30 INR  LPG cost per KG (@ Rs.50 per KG) (Consumption - 10-12 KG PER TON) 0.55 INR  Labour (4 labour per Shift @ Rs.400 per Head) 0.1 INR  Plant Maintenance cost 0.05 INR  TOTAL RUNNING COST / KG 1.00     A TOTAL COST ( INVESTMENT & RUNNING) PER KG 1.57 INR   B PRESENT FRESH SILICA SAND COST PER KG 2.75 INR

Less DIFFRENCE COST PER KG (A-B) 1.18 INR  Yearly Tonnage as per above (1200 MT X 12 MONTHS) 14400 MT  SO, COST PER YEAR ( 14400000 KGS X RS.1.18) 17040000 INR  COST PER MONTH 1420000 INR  ROI PERIOD ( 12000000/1420000) 8 Months       

Q> What type of Sands can be re-claimed in the Machine?A> Green Sand / Shell Mould Sand / Alpha Set / Furon (No-bake) / Cold Box

Sands Can be reclaimed. (*Green Sand needed PRO-CLAIMER PLANT Additionally) Q> How many times the sand can be re-claimed?A> Sand Can be reclaimed 10 times (Max)Q> What types / Ranges of Plants are available ?A> Thermal Process – with a capacity of 0.5 to 5.0 MT / Hr Plants are

available.  Q> What type of Combustion? A> Fluidized Bed Combustion Q> What are the Fuel can be used in the Thermal sand

reclamation Plant?A> LPG and CNG can be used.Q> What is the fuel consumption levels? A> Consumptions are based on the input sand that to be reclaimed* Level 1 : If the input sand LOI is 2 to 3% - The Consumption per TON

would be LPG – 10 to 13 KG and CNG -14-18 NM3

Level 2 : If the input sand LOI is Belo 2 - The Consumption per TON would be LPG – 13 to 15 KG and CNG -18-21 NM3

FAQ…..??

Q> What is the Cycle time for Sand reclamation?A> 7 to 10 Minutes (During Continuous Fluidization Process)

Q> What is the Electricity consumption during production?A>The Electricity Consumption would be 23 KWH (Units) per TON. (46 KWH for 2

TONS)

Q> What will the Loss of Ignition ( LOI) on the sand after reclamation?A>It would be <0.2% Q> What ratios we should mix the fresh sand during next production?A>The Fresh sand need to be added / Mixed in 1:9 ratio (10%)

Q> How many tons reclaimed per hour?A> Approximately 1.80 MT used sand can be re-Claimed per hour – (In 2 TPH Plant) Q> How many years ROI will happen and Explain?A> Maximum Within a Year....(If Plant runs to this 90% efficiency) It is again based

on your sand volumes. Q> Is the Equipment is Approved by Pollution Control Board?A> The Process is Approved. The PCB Approval to be obtained for the Plant after

Installation at your end. We can assist in this Area.

FAQ…..??

THANK YOU…M/s.Thiruvapathi Engineering Works,S.F.No.625/2, Eachanari Chettipalayam Road, Eachanari (PO),Coimbatore – 641 021.TAMIL NADU – INDIA.

Contact Us:

Mr.Kanagaraj - 0091 – 9842234578Mr.Vijaya Kumar – 0091-9894833344

E-mail: thiruvapathikanakaraj@gmail.com indosourcing@live.in