Thermal Reclamation Systems used for Resin Sand

The casting industry is a major contributor to the global economy, producing a wide range of metal components used in various applications. One of the most common materials used in the casting process is resin sand, a mixture of sand and resin that is used to create molds and cores for metal castings. While resin sand offers good dimensional accuracy, allows for complex shapes, and provides a consistent finish, it also generates significant amounts of waste. This waste includes used resin sand, which needs to be disposed of. This is where thermal reclamation systems come in - they offer a sustainable solution for recovering high-quality sand and minimizing waste.

What is Resin Sand?

Resin sand is a mixture of high-quality silica sand and synthetic resin, typically phenolic or furan, that is used to create molds and cores for metal castings. The sand serves as the primary structural component of the mold or core, while the resin acts as a bonding agent that holds the sand together. The sand-resin mixture is compacted around a pattern, which is a replica of the final product, to create a mold or core. Once the metal is poured into the mold and solidified, the sand is removed from the mold, leaving the final metal component.

The sand used in resin sand casting is typically high-quality silica sand that has been specially washed and dried to remove impurities and ensure uniform particle size. The synthetic resin used in the sand mixture is chosen for its ability to bond the sand particles together and provide the necessary strength and stability for the mold or core.

The Problem with Resin Sand Waste

While resin sand offers many advantages for the casting process, it also generates significant amounts of waste. In traditional sand casting processes, used resin sand is often sent to landfills, which can be costly and have negative environmental impacts. In addition, the process of manufacturing new resin sand requires a significant amount of energy and resources, which further adds to the environmental impact of the casting process.

The Solution: Thermal Reclamation Systems

Thermal reclamation systems offer a sustainable alternative for recovering and reusing used resin sand. The thermal reclamation process involves heating the used resin sand to high temperatures in a controlled environment, which causes the resin to break down and the sand to be cleaned and reactivated. The result is high-quality sand that can be reused in the casting process, thus minimizing waste and reducing costs.

Thermal reclamation systems offer several benefits for the casting industry, including:

• Recovering High-Quality Sand: One of the key benefits of thermal reclamation systems is their ability to recover high-quality sand. The process of thermal reclamation ensures that the sand is thoroughly cleaned and reactivated, resulting in sand with properties that are comparable to new sand. This means that casting companies can reduce their reliance on new sand and save on costs, while also minimizing waste.
• Minimizing Environmental Impact: Another benefit of thermal reclamation systems is that they help to minimize the environmental impact of the casting process. By recovering used resin sand, thermal reclamation systems reduce the amount of waste sent to landfills, which helps to conserve natural resources and reduce greenhouse gas emissions. In addition, the use of recycled sand reduces the need for new sand production, which further reduces the environmental impact of the casting process.
• Reducing Costs: Thermal reclamation systems can help casting companies save on costs by reducing their reliance on new sand and minimizing waste. By recovering high-quality sand, casting companies can reduce the amount of new sand they need to purchase, which can lead to significant cost savings. In addition, the use of recycled sand can help casting companies reduce waste

China Clay: White Magic!

China clay, also known as kaolin, is a type of soft white clay that is commonly used in the resin sand thermal reclamation process. China clay is valued for its ability to act as a binding agent in the thermal reclamation process, helping to enhance the properties of the reclaimed sand.

In the thermal reclamation process, the used resin sand is first heated to high temperatures to break down the resin and release the sand particles. After the sand has been cleaned and reactivated, it is mixed with a binder to form new sand. This binder can be a variety of materials, including china clay.

China clay is a popular choice for use as a binder in the thermal reclamation process due to its unique properties. It has a high melting point, which makes it ideal for use in high-temperature environments. It is also highly plastic, meaning that it can be easily molded and shaped, making it a good choice for use in molding and core-making processes.

In addition to its binding properties, china clay also offers several other benefits for the thermal reclamation process. For example, it can help to improve the flowability and compressibility of the sand, which can lead to improved casting quality. It can also help to reduce the amount of water needed in the sand mixture, which can further improve casting quality and reduce costs.

China clay is a valuable component in the thermal reclamation process, helping to enhance the properties of the reclaimed sand and improve the quality of the final casting product.

What is the content of China Clay?

The primary content of china clay, also known as kaolin, is a mineral called kaolinite, which is a hydrated aluminum silicate. Other minerals that can be present in china clay include quartz, feldspar, and mica.

The exact composition of china clay can vary depending on factors such as the location where it is mined and the processing methods used. However, on average, china clay typically contains around 40-50% kaolinite, 20-30% quartz, 10-25% feldspar, and 1-5% mica.

In addition to these minerals, china clay can also contain trace amounts of other elements and compounds, such as iron, titanium, and calcium. These impurities can have an impact on the properties of the china clay and may need to be carefully controlled during processing to ensure that the clay meets the desired specifications for use in the resin sand thermal reclamation process or other applications.

The content of china clay can vary, but it is primarily composed of kaolinite, with smaller amounts of other minerals and trace elements.

Photo: FAT F?rder- und Anlagentechnik GmbH Thermal Reclamation System