US3646987A - Method for reducing pollution in foundries - Google Patents
Method for reducing pollution in foundries Download PDFInfo
- Publication number
- US3646987A US3646987A US866716A US3646987DA US3646987A US 3646987 A US3646987 A US 3646987A US 866716 A US866716 A US 866716A US 3646987D A US3646987D A US 3646987DA US 3646987 A US3646987 A US 3646987A
- Authority
- US
- United States
- Prior art keywords
- sand
- metal ratio
- metal
- weight
- foundry
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 title claims abstract description 32
- 239000004576 sand Substances 0.000 claims abstract description 155
- 239000002184 metal Substances 0.000 claims abstract description 94
- 229910052751 metal Inorganic materials 0.000 claims abstract description 94
- 238000000465 moulding Methods 0.000 claims abstract description 9
- 238000005266 casting Methods 0.000 claims abstract description 7
- 239000000654 additive Substances 0.000 claims description 12
- 239000000203 mixture Substances 0.000 claims description 9
- 238000001816 cooling Methods 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 6
- 230000000996 additive effect Effects 0.000 claims description 4
- 229910001060 Gray iron Inorganic materials 0.000 claims description 2
- 239000000440 bentonite Substances 0.000 claims description 2
- 229910000278 bentonite Inorganic materials 0.000 claims description 2
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 2
- 239000000428 dust Substances 0.000 abstract description 4
- 238000003915 air pollution Methods 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 235000010980 cellulose Nutrition 0.000 description 1
- 235000013339 cereals Nutrition 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011280 coal tar Substances 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- -1 ferrous metals Chemical class 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000005058 metal casting Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
- B22C5/08—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by sprinkling, cooling, or drying
Definitions
- One of the principal sources of pollution in a foundry is from sand which has been used in the molding operation. After the molding, the sand molds and the castings. are separated and the sand is reclaimed for reuse. During at least a part of this reclaimation process the sand is hot. Consequently, a great deal of dust is expelled into the atmosphere. A large part of this dust occurs at the shakeout since this is the point at which the sand is at its hottest temperature before the next molding operation. As the sand is conveyed from the shakeout additional pollution occurs.
- foundries have utilized various types of devices. An idea of how sizeable the market for such devices is can be gleaned from an examination of the foundry periodicals. Such periodicals also present a reliable indicator for how serious the problem is, some even dedicating entire sections of each issue to the problems and supposed solutions.
- the amount of sand used to form a mold is usually expressed as a function of the amount of metal to be poured into it. This relationship is called the sand to metal ratio.
- sufficient sand can be used for the mold to give a sand to metal ratio of from 3 to l to to 1. While these ratios are frequently used, others are often times used too.
- a common ratio used is a ratio of about 6 to 1. That is, a mold is formed which consists of 6 pounds of sand for each pound of metal to be cast.
- Foundry sand is, of course, not sand alone but contains additional constituents such as clays and/or carbons and/or other additives and/or temper water.
- Carbons in common use are powdered coal, coal tar, pitch, asphalt, graphite and coke.
- Other additives can be added such as celluloses, cereal binders, etc.
- new sand and/or clays and/or carbons can be added to the used sand to replace the portion of the original sand which has been made unuseable.
- Temper water is also frequently added in minor amounts.
- the following is a typicaltable which shows the amount of additives which usually must be added after the batch of sand has-been used. This table is for ferrous metals other than steel. Other data for nonferrous metals, steel and ductile metals is known to those in the foundry industry.
- lutants expelled from hot foundry sand can be very substantially reduced if enough relatively cool sand is added to the hot sand so that a sand to metal ratio of l2/l or greater is obtained.
- the relatively cool sand is added at or near the shakeout since this is the point at which this type of air pollution begins.
- the relatively cool sand could be added later but then all of the benefits of this process would not be obtained. It also may be desirable to add at the shakeout whatever additives are to be added to reconstitute the new sand. Additions at such point also serve to reduce air pollution.
- a foundry process for cooling foundry sand and for reducing foundry pollution which comprises mulling used sand to provide a quantity of sand of at least as great as 12 times the weight of the metal to be cast, said used sand derived from a later step in the process,
- molds from a minor portion of the mulled mixture, said molds each having a weight of at least three times the weight of the material to be cast,
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
Description
Claims (8)
- 2. The foundry process of claim 1 wherein the molds have a weight of about four times the weight of the material to be cast and the weight of the major portion is at least 16 times the weight of the metal to be cast.
- 3. The process of claim 1 wherein minor amounts of additives are added to the used sand.
- 4. The process of claim 1 wherein the temperature of said major portion is less than 90* F.
- 5. A foundry process for cooling foundry sand and for reducing foundry pollution which comprises mulling used sand to provide a quantity of sand of at least as great as 12 times the weight of the metal to be cast, said used sand derived from a later step in the process, forming molds from a minor portion of the mulled mixture, said molds each having a weight of at least three times the weight of the material to be cast, retaining the major portion of foundry sand for the later cooling of said minor portion, casting metal in the molds, separating the metal from said molds, cooling said used sand by mixing with it at the shakeout or immediately adjacent thereto said major portion of sand whereby the mixture has a temperature of below 120* F., and returning the minor and major portions of sand to the aforesaid mulling step.
- 6. The foundry process of claim 5 wherein the molds have a weight of about four times the weight of the material to be cast and the weight of the major portion is at least 16 times the weight of the metal cast.
- 7. The foundry process of claim 6 wherein minor amounts of additives are added to the mixture of the major and minor portions of sand.
- 8. The foundry process of claim 6 wherein the temperature of said major portion is less than 90* F.
- 9. In a process for making greyiron castings wherein sand molds are formed on the basis of a sand to metal ratio of at least 3 to 1 wherein a larger quantity is used to cool the sand after molding and shakeout, the improvement which is adapted to reduce pollution comprising adding at least one additive member of the group consisting of sand, clays, and carbons to the used sand at the shakeout, or immediately adjacent thereto, the amounts of said additive member added being calculated from the following formula: number of pounds of new sand (A/2000 X B wherein A the number of pounds of used sand and B 100 where the sand to metal ratio is 3/1 75 where the sand to metal ratio is 4/1 60 where the sand to metal ratio is 5/1 50 where the sand to metal ratiO is 6/1 37.5 where the sand to metal ratio is 8/1 30.0 where the sand to metal ratio is 10/1 25.0 where the sand to metal ratio is 12/1 21.4 where the sand to metal ratio is 14/1 18.7 where the sand to metal ratio is 16/1 16.6 where the sand to metal ratio is 18/1 15.0 where the sand to metal ratio is 20/1 number of pounds of bentonite clays A/2000 X C wherein A the number of pounds of used sand and C 18.8 where the sand to metal ratio is 3/1 14.4 where the sand to metal ratio is 4/1 11.3 where the sand to metal ratio is 5/1 9.41 where the sand to metal ratio is 6/1 7.15 where the sand to metal ratio is 8/1 5.65 where the sand to metal ratio is 10/1 4.71 where the sand to metal ratio is 12/1 4.05 where the sand to metal ratio is 14/1 3.60 where the sand to metal ratio is 16/1 3.15 where the sand to metal ratio is 18/1 2.83 where the sand to metal ratio is 20/1 and the number of pounds of carbons A/2000 X D wherein A the number of pounds of used sand and D 16 where the sand to metal ratio is 3/1 11.9 where the sand to metal ratio is 4/1 9.5 where the sand to metal ratio is 5/1 8.0 where the sand to metal ratio is 6/1 6.03 where the sand to metal ratio is 8/1 4.75 where the sand to metal ratio is 10/1 4.0 where the sand to metal ratio is 12/1 3.43 where the sand to metal ratio is 14/1 3.03 where the sand to metal ratio is 16/1 2.66 where the sand to metal ratio is 18/1 2.40 where the sand to metal ratio is 20/1
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US86671669A | 1969-10-15 | 1969-10-15 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US3646987A true US3646987A (en) | 1972-03-07 |
Family
ID=25348242
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US866716A Expired - Lifetime US3646987A (en) | 1969-10-15 | 1969-10-15 | Method for reducing pollution in foundries |
Country Status (1)
| Country | Link |
|---|---|
| US (1) | US3646987A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5259434A (en) * | 1991-03-27 | 1993-11-09 | Alb. Klein Gmbh & Co. Kg | Method of regenerating used foundry sands |
| US6435262B1 (en) | 2001-03-16 | 2002-08-20 | New Ideas, Llc | Foundry sand |
| US20070125264A1 (en) * | 2005-12-01 | 2007-06-07 | New Ideas Engineering, Llc | Foundry sand system |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3461941A (en) * | 1968-03-19 | 1969-08-19 | Joseph S Schumacher | Method of handling and cooling foundry sand |
-
1969
- 1969-10-15 US US866716A patent/US3646987A/en not_active Expired - Lifetime
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3461941A (en) * | 1968-03-19 | 1969-08-19 | Joseph S Schumacher | Method of handling and cooling foundry sand |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5259434A (en) * | 1991-03-27 | 1993-11-09 | Alb. Klein Gmbh & Co. Kg | Method of regenerating used foundry sands |
| US6435262B1 (en) | 2001-03-16 | 2002-08-20 | New Ideas, Llc | Foundry sand |
| US6516863B2 (en) | 2001-03-16 | 2003-02-11 | New Ideas, Llc | Foundry sand |
| US20070125264A1 (en) * | 2005-12-01 | 2007-06-07 | New Ideas Engineering, Llc | Foundry sand system |
| US20070125265A1 (en) * | 2005-12-01 | 2007-06-07 | New Ideas Engineering, Llc | Foundry bond pre-mix, apparatus and methods |
| US20070125508A1 (en) * | 2005-12-01 | 2007-06-07 | New Ideas Engineering, Llc | Foundry bond and sand, apparatus and methods, with accumulator |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: IMC INDUSTRY GROUP INC., 2315 SANDERS ROAD, NORTHB Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:INTERNATIONAL MINERALS & CHEMICALS CORPORATION, A NY. CORP.;REEL/FRAME:004620/0793 Effective date: 19861028 |
|
| AS | Assignment |
Owner name: FIRST NATIONAL BANK OF BOSTON, THE Free format text: SECURITY INTEREST;ASSIGNOR:APPLIED INDUSTRIAL MATERIALS CORPORATION, A CORP OF DE.;REEL/FRAME:004625/0260 Effective date: 19861103 |
|
| AS | Assignment |
Owner name: APPLIED INDUSTRIAL MATERIALS CORPORATION Free format text: MERGER;ASSIGNORS:INDUSTRY ACQUISITION CORP. (MERGED INTO);IMC INDUSTRY GROUP INC. (CHANGED TO);REEL/FRAME:004640/0541 Effective date: 19861103 |
|
| AS | Assignment |
Owner name: APPLIED INDUSTRIAL MATERIALS CORPORATION (FORMERLY Free format text: RELEASED BY SECURED PARTY;ASSIGNOR:FIRST NATIONAL BANK OF BOSTON, THE;REEL/FRAME:005271/0619 Effective date: 19890905 |