A new low-cost method of reclaiming mixed foundry waste sand based on wet-thermal composite reclamation

A lot of mixed clay-resin waste sand from large-scale iron foundries is discharged every day; so mixed waste sand reclamation in low cost and high quality has a great realistic significance. In the study to investigate the possibility of reusing two types of waste foundry sands, resin bonded sand and clay bonded sand which came from a Chinese casting factory, a new low-cost reclamation method of the mixed foundry waste sand based on the wet-thermal composite reclamation was proposed. The waste resin bonded sand was first reclaimed by a thermal method and the waste clay bonded sand was reclaimed by a wet method. Then, hot thermal reclaimed sand and the dehydrated wet reclaimed sand were mixed in certain proportions so that the hot thermal reclaimed sand dried the wet reclaimed sand leaving some water. The thermal reclamation efficiency of the waste resin bonded sand was researched at different heat levels. The optimized wet reclamation process of the waste clay bonded sand was achieved by investigating the effects of wet reclamation times, sand-water ratio and pH value on the reclaimed sand characteristics. The composite reclamation cost also was calculated. The research results showed that the properties of the mixed reclaimed sand can satisfy the application requirements of foundries; in which the temperature of the thermal reclamation waste resin bonded sand needs to be about 800 oC, the number of cycles of wet reclamation waste clay bonded sand should reach four to five, the optimal sand-water ratio of wet reclamation is around 1:1.5, and the pH value should be adjusted by adding acid. The mass ratio of hot thermal reclaimed sand to dehydrated wet reclaimed sand is about 1:2.5, and the composite reclaimed sand cost is around 100 yuan RMB per ton.

Discrete particle simulation of mixed sand transport

An Eulerian/Lagrangian numerical simulation is performed on mixed sand transport. Volume averaged Navier-Stokes equations are solved to calculate gas motion, and particle motion is calculated using Newton＇s equation, involving a hard sphere model to describe particle-to-particle and particle-to-wall collisions. The influence of wall characteristics, size distribution of sand particles and boundary layer depth on vertical distribution of sand mass flux and particle mean horizontal velocity is analyzed, suggesting that all these three factors affect sand transport at different levels. In all cases, for small size groups, sand mass flux first increases with height and then decreases while for large size groups, it decreases exponen- tially with height and for middle size groups the behavior is in-between. The mean horizontal velocity for all size groups well fits experimental data, that is, increasing logarithmically with height in the middle height region. Wall characteristics greatly affects particle to wall collision and makes the fiat bed similar to a Gobi surface and the rough bed similar to a sandy surface. Particle size distribution largely affects the sand mass flux and the highest heights they can reach especially for larger particles.