RECLAIMED SAND IN FOUNDRIES

David Hughes
Product Manager
Foseco Australia

ABSTRACT
Sand disposal costs are always on the increase and many foundries are reclaiming their sand for
re-use. This paper will look at the different types of reclamation units available and the impact
they can have on reconditioning the sand for re-bonding and the different types of binder systems
that are being reclaimed and their limitations to achieving 100% re-use is reviewed. I will also be
discussing the degrees of compatibility between the different binder systems in use for cores and
moulds being reclaimed together, and the impact different sand types such as chromite, can have
on total sand reclamation.

INTRODUCTION

The function of the reclamation equipment is to take lumps of used foundry sand and process it
back to sand grains which are then suitable for re-bonding without excessive addition rates of
binder and catalyst, in order to achieve adequate mould and core strengths for handling and the
casting process. The casting surface quality must also remain unchanged from new sand. Each
of the binder systems being reclaimed have their limitations for re-use, based on mould and core
strengths achievable and the generation of possible surface casting defects.

RECLAMATION PROCESS

There are three main types of sand reclamation equipment;

1. Dry Attrition;
2. Thermal reclamation; and
3. Wet reclamation. (This will not be covered as this process is not common due to disposal costs
and issues with the water used to the washing the sand)
The most common system used in our region is Dry Attrition, due to lower capital cost and lower
running costs. When compared to thermal and wet reclamation dry attrition units are the most
universal in terms of suitability for a range of binder systems. A typical dry reclamation system
layout is shown in Diagram 1.
For all the reclamation systems above, the initial breaking down of the sand lumps after the
removal of the casting is achieved by vibration to breakdown the bond between each grain of
sand by passing the sand through a rotating drum or vibrating screens. During this process about
5-10% of the binder is potentially removed from the sand grains. The sand should be back to a
suitable sand grain size for re-bonding with minimal agglomerates, these being sand grains still
bonded together. At this point the tramp metal and other materials are removed. After this initial
reclamation process depending on the equipment, the sand will go to a cooler classifier for dust
removal cooling to ambient temperature and classifying to give a suitable sand distribution for re-
bonding. This type of basic reclamation was very common for the reclamation of the furan binder
system and achieved a typical reclamation rate of 90% for a total system. .
The introduction of alkaline phenolic resins; industry desire to increase the rate of reclaimed sand
and rising disposal costs of used sand, extra attrition was included in the process to scrub the sand
grains to remove more of the cured binder system from them.
 Diagram 1. Dry Attrition Layout

These units are in principle, refined hammer mills where the processed sand is fed onto a spinning
disc causing the sand grains to impact with each other and the side walls. A typical example of
an attrition unit is shown in Diagram 2 in conjunction with a cooler classifier. Pneumatic
scrubbing is also used in which air accelerates sand upward to a conical target giving both sand
on sand abrasion and impact with the target wear plate. A typical example of a pneumatic
scrubbing unit is shown in Diagram 3.

Diagram 2. Attrition Unit Diagram 3. Pneumatic Scrubbing

The key factor in terms of the effectiveness of these high attrition unit, is that enough energy is
put into the sand during attrition, and that there is sufficient retention time in the attrition unit for
effective binder removal, without fracturing the sand grains and generating excessive dust and
sand losses. Our testing of sand which has been reclaimed, with and without the high attrition
units, revealed the following results:
1. The LOI for all binder systems can be reduced by 20-40%;
2. Alkalinity or acidity will also be reduced by 15-40%; and
3. There will be excess dust and fines generated which must be removed.
Maintenance of the attrition units is essential, as high LOI, dust, alkalinity and acidity
will have a significant effect on re-bonding strength. An example of this is shown in
Table 1 (Tensile Strength) and Graph 1 (Sieve Screen Analysis). Excess dust on the 90-
micron screen greatly reduced mould strength in a reclaimed alkaline phenolic system.
To show the importance of having effective removal of fines, we have determined the LOI and
alkalinity for each sieve screen, from 250 microns down to the pan for a reclaimed alkaline
phenolic sand system where the fines have not been sufficiently removed. The results in Table 2
reveal that the fines in the system came from the binder that had been scrubbed from the sand
grains. The high alkalinity values are very positive in the alkaline phenolic system due to the
alkaline salts having the biggest impact on re-bonding strengths. The negative is that these fines
should have been removed from the reclaimed sand system.

Sand Fines No Fines

hr 10 17
1 hr 17 31
4 hr 19 47
24 hr 38 72
Resin % 1.6% 1.6%
AFS 52 48
LOI % 0.37 0.31
Alkalinity % 3.66 3.28
Table 1. Tensile Strength Comparison (psi) Comparing Reclaimed Sands

Chart 1. Recalaimed Sand Sieve Analysis

50
45
40
35
% Retained

30
25
No Fines
20
Fines
15
10
5
0
1000 710 500 355 250 212 180 150 125 90 63 <63

Sieve size microns

Sieve ums % Retained LOI% Alkalinity %

1000 0 Base sand analysis
710 0.10 Sand AFS 66
500 1.72 LOI 1.14%
355 11.31 Alkalinity 18.1%
250 34.15 0.56 13.89
212 22.92
180 12.03 0.78 7.20
150 9.59
125 4.01 0.89 16.66
90 3.27 1.27 45.13
63 1.10 1.90 72.61
<63 0.37 3.60 79.73
Table 2. LOI and Alkalinity Levels from Different Sieve Screens
Thermal reclamation has been used for many years for the reclamation of organic based binder
systems to try and achieve 95-100%. Most foundries divert 10-30% of the sand from the attrition
unit through a thermal reclamation unit. The sand is heated to 600-720C, which removes all the
organic component of the binder by combustion. When burning these binders from the sand
grains, pollution in the form of a gas/smoke is generated, and many thermal plants will re-use
these gases to reduce the energy required for combustion. A typical example of a thermal
reclamation unit is shown in Diagram 4. After the combustion process, there is usually a two
stage cooling process, to bring sand back to ambient temperature. After thermal treatment the
sand should have an LOI less than 0.3%; an acid value below 1%, and an alkalinity of less than
2%. Thermal reclamation of the alkaline phenolic systems requires that the reclaimed sand must
be pre-treated with an inhibitor to prevent sand fusion during the calcining stage. The fusion
occurs because alkaline salts have been being carried over onto the silica sand grains, fluxing
with temperature and forming a glass phase.

Diagram 4. Thermal Reclamation Unit

BINDERS AND RECLAMATION

All of the current binder systems being used can be reclaimed to varying levels and include the
following:
1. Acid set furane;
2. Alkaline ester set phenolic; and
3. Phenolic urethane self set.

1. ACID SET FURAN

Furan resins are selected today based on nitrogen content, water content and the fufuryl alcohol
content can vary from 30%-95%. The acids used to cure the furan resins have also changed from
the original phosphoric, phosphoric/sulphuric acid blends. However these types of acids are still
used especially the phosphoric acid, which has the lowest fume emission due to being sulphur
free. The phosphoric/sulphuric blends have declined in use, as the fumes from the sulphuric acid
are very unpleasant. Both these acids are inorganic and do not break down during the casting
process, and will build up in the reclaimed sand. The phosphates produce poor mould strengths;
reduce refractory properties of the sand and possibly cause phosphorus pickup in the molten
metal,.causing a pitted casting surface finish. Acids most commonly used today are Xylene
sulphonic acid XSA, and para Toluene sulphonic acid PTSA. These acids can be blended
together to produce a rapid through cure. Both these acids are organic and well suited for
reclamation, as they will partially decompose during the casting process. Low levels of sulphuric
acid in the catalyst will help to minimise the build up of sulphur in reclaimed sand, which
can promote hot tearing in steel castings, and the rim zone effect in ductile iron, where the casting
surface reverts back to grey iron. Low sulphur also reduces the sulphur dioxide emission during
casting.
Compared to other self-set resin systems the furan process has one of the best levels of
reclamation, which can be as high as 95%. This will depend on the nitrogen content of the furan
resin being used, and the alloys being cast. For grey iron castings the nitrogen content of the
reclaimed sand is 0.15% max. and for steel castings 0.01% max. In general, the LOI should be
2.5% max.

2. ALKAINE ESTER SET PHENOLIC

The reclamation of the ester set alkaline phenolic systems, have improved with the average now
being 75% with a maximum of 85%. This is now possible as a result of improvements, in both
the reclamation equipment, (increased attrition without fracturing the sand grains) and the resins
themselves, developing higher strengths and being able to wet out and coat the reclaimed sand
more efficiently. Photograph 1 shows the porous surface of a sand grain which has been coated
with an alkaline phenolic resin. One of the biggest advantages of using this system has been in
steel casting production as the excellent hot strength, greatly reduces hot tearing on critical steel
castings. The surface finish on all ferrous and non-ferrous castings is also very good. The
limitation in using alkaline phenolic and reclaiming is the build up of alkali salts on the sand grain
surface, as the presence of these salts will ultimately cause a reduction, in re-bonding properties
by:
1. Inhibiting the bonding and cure speeds.
2. The build-up of alkali salts which react with silica sand to form glass like material at
elevated temperatures, and makes the sand grains difficult to wet with the resin when re-
bonding.
3. Alkaline salts impacting on silica sand refractory properties, causing mould distortion
when producing heavy castings, due to pouring pressure and heat. The potential impact
on a reduction in silica sand refractory properties is shown in Photograph 2.
To maintain good mould and core strengths and casting surface finish, the LOI of the reclaimed
sand should be 2.0% maximum, the dust being calculated as the combined % retained on the 90
micron sieve to the pan, being less than 3% total. The alkalinity, which is an indication of the
sodium or potassium build up, should be less than 6%.

3. PHENOLIC URETHANE SELFSET

Phenolic urethane cold set system can be reclaimed up to 95% by dry attrition. It is important to
keep the loss on ignition at 3% maximum as nitrogen will build up in the reclaimed sand which
could cause nitrogen fisher defects. Veining can also occur on cored surfaces and a typical
veining defect is shown in Photograph 3. The other area of concern is the lustrous carbon that is
generated on casting, this can be an advantage with some thin section iron castings, producing an
excellent surface finish without coating. This is also possible with non-ferrous castings. On
larger iron castings with flat surfaces and most steel castings, the lustrous carbon will produce a
poor casting surface finish. To try an eliminate these defects, either an iron oxide up to 3%, or a
proprietary sand additive can be added to the sand. Good quality coating containing iron oxide
can be used to try and protect against these casting surface defects.

A comparison of these binders systems is shown in Table 3, covering both positive and
negative attributes of the binder system from reclaiming sand to producing castings.
 Photograph 1. Reclaimed Sand Grain Showing Porous Surface

Photograph 2. Sand Sinter Defect

ALKALINE PHENOLIC
ATTRIBUTES FURANE
PHENOLIC URETHANE

Reclamation Rates 75 - 85% 90%+ 80 - 90 %

Mainly dry attrition, Both dry attrition and Both dry attrition and
Reclamation some thermal but thermal reclamation thermal reclamation
Equipment additive required to possible at high possible at high
prevent sintering levels levels

Typical Strength at
18 psi Tensile 31 psi Tensile 45 psi Tensile
stripping
Tough / Medium Brittle / High
Mould rigidity Brittle / High Strength
Strength Strength

Pattern Stripping Excellent Good Fair

Resin Water soluble Partial Solvent 2 part

Catalyst Ester Blends Acid Blends Liquid amine

Resin Addition 1.5% up to 1.7% 1.5% down to 1.0% 0.8 to 1.5%

Catalyst 23% 20% up to 50% 50:50 to 55: 45

Bench life strip time
1:3 1:2 1:0.75
ratio
Coatings Water/Alcohol Water / Alcohol Water / Alcohol

Little to none in Can be a real Can be an issue and

Hot Tearing
steel problem lustrous carbon

Disposal Phenol leachable Inert waste MDI and phenol

Little to none in
Hot Tearing Can be a concern Can be a concern
steel

As cast Finish Excellent Good Good

Casting fume Degrading phenol S02 Solvent aromatic

Table 3. Binder System Comparison Guide

 Photograph 3. Veining Defect from Phenolic Urethane Core

CORE SANDS
Foundries considering reclamation or, who are reclaiming, the type of binder that is to be used, or
is being used for the production of cores, has to be considered in regard to compatability with the
moulding binder system in order to give complete reclamation without having to separate out core
sand. The ratio of reclaimed sand to new sand, is usually lower for cores to give a higher surface
strength for handling and longer storage. It is also common for the cores to be in 100% new sand,
which contributes to the new sand addition of the moulding system. The main issue for
compatability between core and mould binder system, is the pH of the different systems effecting
the reclaimed sand. This pH will influence the rate of strength development, the ultimate strength
but in some cases will not bond at all. As a guide, Table 4 shows the most common core and
mould systems being used and their potential compatability,.when the core binder system is
reclaimed with the moulding sand.

Mould Binder Core Binder Compatability Coments

UF/FA furane Cold Box 60% core sand Lusterous carbon
UF/FA furane Alkaline Phenolic MEF 5-10% pH difference effecting strength
UF/FA furane Sodium Silicate C02 5-10% pH difference effecting strength
High level of burn out with hollow
UF/FA furane Shell Sand 60% plus
cores
UF/FA furane Alkaline Phenolic C02 5-10% pH difference effecting strength
pH difference effecting strength and
Esterset Phenolic Cold Box 20-25%
cure times
Reactivity of moulding reducing
Esterset Phenolic Alkaline Phenolic MEF 60% plus
mixed sand bench life
Soda build up reducing refractive
Esterset Phenolic Sodium Silicate C02 30% maximum
properties of moulding sand
High level of burn out with hollow
Esterset Phenolic Shell Sand 60% plus
cores
Reactivity of moulding reducing
Esterset Phenolic Alkaline phenolic C02 60% plus
mixed sand bench life
Lusterous carbon, shorter mixed sand
Urethane Selfset Cold Box 60% core sand
bench life
Alkali content will effect strip time
Urethane Selfset Alkaline Phenolic MEF 10% maximum
and strengths pH difference
Urethane Selfset Sodium Silicate C02 None Will not bond at all
High level of burn out with hollow
Urethane Selfset Shell Sand 60% plus
cores
Alkali content will effect strip time
Urethane Selfset Alkaline phenolic C02 10% maximum
and strengths pH difference
Table 4. Guide to Reclaiming Core and Mould Sand Together
In general sodium silicate is not compatible with many systems except ester set alkaline phenolic
due to the alkaline properties of the system. Where pH is mentioned there is a reaction between
acid and basic which interferes with strengths and rate of cure of the moulding binder system.
Each of the binder systems can be used individually for the production of cores using different
rates of reclaimed sand that would be used for mould making, the decision to use a different core
system is usually based on the following:
1. Productivity in core manufacture
2. Core breakdown after casting
3. Dimensional accuracy of core and casting
4. To reduce or eliminate hot tearing

OTHER REFRACTORY SANDS

It is common for foundries to use zircon, chromite and olivine as facing sand or 100% core sand
for the following reasons:
1. Chromite and zircon for sand fusion and metal penetration.
2. Due to high density both chromite and zircon can be used to chill the metal to influence
metal feed.
3. Thermal stability to eliminating silica sand expansion defects.
4. Silica can react with metallic oxides during casting, thus reducing refractory properties
and producing a fluid slag with a low melting point.
5. Olivine sand is mainly used in the production of manganese steel castings, due to it being
a basic refractory in contact with a basic metal to give the best possible as cast finish.
Table 5 below indicates the chemical analysis and physical properties for each of these speciality
sands.

Zircon Chromite Olivine

Zr02 65% min Cr203 44% min Mg0 49% min
Si02 34% max Fe203 26% max Si02 42% max
Fe203 0.15% max Si02 4% max Fe203 3.0% max
Ti02 0.35% max Ca0 0.5% max Ti02 3.0% max
Al203 2.0% max Al203+Mgo bal Al203 3.0% max
Specific Gravity 4.7 Specific Gravity 4.5 Specific Gravity 3.6
Thermal expansion Thermal expansion Thermal expansion
0.45% 0.6% 1.1%
Table 5 Sand chemical Specification

The amount of chromite and olivine sand, which could be carried over into the reclaimed sand
system should be monitored, as both these sands can lower the refractory properties of the
reclaimed sand system and generate slag and fusion-type casting surface defects. The main
concern is the contamination of the facing sand that is in contact with the molten metal. When
recovering the chromite sand from the reclamation system for re-use, it is critical to keep the free
silica sand content to a max of 3%. The same applies when chromite sand is carried over in the
reclaimed silica sand. When the silica sand particles are in contact with the chromite particles a
reaction occurs during the casting process, which lowers the melting point of the silicate which in
turn destroys the cohesion of the particles and makes their wetability easier and encourages metal
penetration. The issue of silica in contact with chromite must also be considered when selecting a
coating, and its potential to contain free silica.
The reclamation of foundry sand will continue to be an important issue for foundries to minimize
disposal costs, it is also an area that has to be controlled and monitored from sand testing to
regular maintenance on the reclamation equipment, to ensure consistent mould and core strengths
and casting quality.

References
The Foseco Foundrymans Hand Book.
CTI Broadsheet 341.
Warill Engineering.
Influence of the presence of chromite in reclaimed silica sands used in a steel foundry P Poyet
and R Chevriot.
Foseco Australia laboratory results from testing reclaimed sand.