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AFS Sand Casting ConferenceOctober 20-22, 2014 – Indianapolis, IN USA

Green Sand Additives

and Clays

Stephen L. Neltner

S&B Industrial Minerals N.A.


The Discussion

• The Trends in the Foundry

• Responses of the Suppliers to Those

Trends

• New Developments and Innovative

Ideas from the Suppliers


Increase Durability

More Na Bentonite Use

Less Replenishment

Additional Sourcing

Enhanced Flowability

New Mold “Blowers”

Difficult Geometries

More Metal in the Molds

Shakeout/Collapsibility

Less Sand Carry-Out

Less Spill Sand

Better Working Conditions

Higher Strengths

More Metal in the Mold

Very Narrow Side Walls

Foundry Trends Suppliers’ Responses

Clay Modifiers, Activated Clays, Clay

Blends

More Flowable Sand

Enhanced Densities

Other Sources

Less Emissions

OSHA & EPA Requirements

Different “Carbon” Sources

Sustainable Materials

Rejuvenated Dust

Black Water

Customized Chemical Additives

Better Dispersing

Enhanced Mulling

Enhanced Flowability


Clay Trends• The Heavy Use of the More Durable Clay

(Na Bentonite)/Drivers

– Drum Uses (Aggressive Shakeout)

– Flaskless Molding (No Run Outs)

– Cost Savings (Higher Thermal Stability)

• Activated Clays/Drivers

– Logistics

– Synergistic Affect

– Sourcing

• Rejuvenated Clays/Drivers

– Sourcing


Hot Compression Strength

- Very Low HCS - Low HCS - --

- Rigid/ Not Plastic - Semi-Plastic - Plastic

- Run-Outs

Concerns

Higher HCS

- Dimensional

Concerns


HCS Affects on System Sand

Excessive HCS Low HCS


Lower DCS & HCS on

Shakeout


Activated/Modified Clays

• The Clays Treated to be Converted to Perform

Like Other Clays

• Na Bent converted to Ca Bent Properties

• Ca Bent converted to Na Bent Properties


Activated/Modified Clay (GCS)


Activated/Modified Clay (WTS)


Activated/Modified Clay (HCS)


Activated/Modified Clay (GCS & WTS)


Rejuvenated Clays

• New Technologies to Recover “Wasted” Clays

• Recycling of Clays

• Sustainability


Landfill Numbers


Baseline vs. Rejuvenated Dust

Supplement

10 10 10 10 10 10

10.5

12.5 12.6

6.8

9.4

12.6

6

7

8

9

10

11

12

13

Greencompressive

strength

Wet tensilestrength

Cone jolttoughness

Friability Dry compressionstrength

Green shearstrength

+ 6 %

+ 25 % + 26 %

- 32 %- 6 %

+ 26 %


Carbon Trends• Low Emissions

– Less Overall Quantity of Added Carbon

– Lower Volatile Carbons Use

– Use of Special Carbons


Graphitic Use for Peel

Graphite Graphite Impregnated

Clay


Foundries Experience Increased Density with

Impregnated Bentonite


Emission Reductions

0.00

0.04

0.08

0.12

0.16

Benze

ne

Toluen

e

Xylene

s

Hexan

e

Napht

halen

e

Creso

ls

Ethylb

enze

ne

Pheno

l

Met

hylna

phth

alene

s

Aceta

ldehy

de

Form

aldeh

yde

Selected Target HAPs & VOCs

lb/t

n m

etal

Reference Test FK

Test HE


Coal Supplement

- Coking Substitutes

- Coking WITHOUT the

Carbon Emissions


Special Chemical Trends

- Low Emission Supplement

- Clay Enhancer on Flowability

- Enhanced Mulling


What’s in the Preblend Mix?

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

NaBentonite

CaBentonite

Sea Coal Cellulose Cereal Special

50.50%

21% 23%

4% 0.50% 1%


Formulation with Clay Modifier

0%

10%

20%

30%

40%

50%

60%

70%

Na Bentonite Ca Bentonite Sea Coal CausticizedLignite

Soda Ash

62%

10%

21%

7%0.50%

Typical Formulation with Clay Modifier


Formulation with Activated

Clay

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Activated Clay Sea Coal

82%

18%

Typical Formulation with Activated Blended Clay


The Supplier’s Role

• Innovative Use of New Technologies

– Low Emission “Carbons”

– Activated/Modified Clays

– Reclaimed/Rejuvenated Clays (Dust)

– Customized Chemical Additives


Questions & Answers

green sand additives and clays - amazon web services€¦ · afs sand casting conference october...

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