For Reclaimed Sand Or Ceramic Material That Performs As Well As – Or Better Than – New
In today’s competitive market you can’t afford to miss the savings and technical advantages available from reclamation. With the Simpson Pro-Claim® you can pneumatically reclaim your chemical or bentonite bonded ceramic, silica or non-silica sand for as little as $1.00 per ton.
Sand or ceramic is the largest foundry process waste, typically constituting about 70% of total waste volume. Environmentally it is becoming increasingly more difficult to dispose of these great quantities of waste sand or ceramic into a landfill. But waste is not the only challenge related to spent foundry sand. Replacing that sand with an adequate amount of new sand in order to maintain consistent properties can become quite costly.
By reclaiming your sand or ceramic material with the Simpson Pro-Claim or Simpson Even-Flo you will be able to:
Fortunately, most foundry sands and ceramic materials are reclaimable and can be effectively reused. Hundreds of foundries around the world are already using the Simpson sand reclamation equipment to significantly lower their production costs, improve the quality of their castings and reduce their disposal cost.
The Benefits of Pneumatic Reclamation
The Simpson reclaimers operate on the principle of pneumatic scrubbing. They are compact, easy to install, operate continuously, and do not require an operator or frequent maintenance. The throughput is easily adjusted to obtain the desired level of binder removal. No moving parts are in contact with the sand or ceramic which significantly minimizes wear and maintenance costs. In the reclaimers the sand grains or ceramic materials abrade against themselves efficiently removing the residual binders. Compared to thermal reclamation which typically ranges from $6.00-$8.00+ per ton the Pro-Claim, at approximately $1.00 per ton, is a much more cost efficient solution requiring no additional post processing such as screening or cooling and no additional permitting is required.
Simpson Technologies first introduced the concept of pneumatic sand reclamation in the 1950s. The current Simpson reclaimers are the result of over 70 years of continuous research and practical field experience in sand reclamation systems. Over 500 foundries around the world have relied on Simpson sand reclamation equipment to cost effectively reclaim their sand or ceramic.
Test your sand or ceramic material before making a purchase decision
Simpson understands that no two foundries are exactly the same in their combination of sand, binder and operating conditions. The Simpson Technologies Performance Laboratory will test your foundry’s sand or ceramic and select the optimum reclaimer for your particular system requirements. Before making a purchase decision, we will also provide you with a full analysis of the results and invite you to attend the test to see first-hand the benefits offered by pneumatic reclamation. To learn more about our testing program you can watch a video on it here. While watching the video you will also learn why Manufacturers Brass and Aluminum Foundry (MBAF) found the testing program beneficial and how they went from testing to implementation. The test results from the Simpson testing facility were achieved upon the start-up of the model 2-Cell Pro-Claim at MBAF.
STEP 1 – The Pro-Claim inlet permits direct connection to a gravity feed from your storage bin, providing simple, continuous operation.
STEP 2 – The turbine type blower introduces air into a common plenum, providing even air dispersion among the cells. The air accelerates through a nozzle at the bottom of each blast tube to the optimum air/sand mixture for your application.
STEP 3 – Propelled by air, sand or ceramic is accelerated at a controlled rate up through a blast tube to a conical target. The Pro-Claim blast tubes typically require minimal maintenance, but when maintenance is required, the design makes tube removal easily accomplished through individual cell access doors.
STEP 4 – Sand or ceramic accelerated through the blast tubes is scrubbed against sand and trapped under the conical target. Since scrubbing is accomplished by sand-to sand contact, maintenance and replacement of wear parts are greatly reduced.
STEP 5 – As the sand or ceramic curtain falls from the target area it is exposed to exhaust air drawn through a shroud surrounding the target. Residual binder and excess fines scrubbed off the sand grains are removed to dust collection. This controls Loss on Ignition (LOI) and maintains the original sand screen distribution
STEP 6 – The Pro-Claim throughput is controlled by a series of adjustable deflector plates between the cells. A controlled amount of the sand is recirculated into the same cell and the remainder is diverted to the next cell. If needed, for more intensive scrubbing the sand can be retained in each cell longer. This controls the degree of cleanliness of the reclaimed sand without needing to recycle the sand through the entire unit. The reclamation process is repeated through as many successive cells as needed, depending on your specific application.
STEP 7 – When the sand or ceramic emerges from the last cell, excess fines are removed in a final dedusting chute. A vibratory classification screen separates and discharges refuse through a horizontal opening, and reclaimed sand enters a discharge hopper below.
Simpson Performance Laboratory Test Program
“Testing prior to installing the machine was extensive. When we finally installed… it was amazing that we used the same settings that they did in the lab.”
-Butch Pacula, Foundry Manager, MBAF
No two foundries are exactly the same in their combination of sand, binder and operating conditions. As a result, the only way to properly determine the performance and expected payback of reclamation is to conduct a test using your foundry’s sand prior to buying a system.
Click on the video to watch an actual test conducted in the Performance Lab. Then, hear how the settings from the test compared to the settings and performance after installation.
“Their technical expertise is second to none in the industry…”
– Geary Smith, Vice President of Operations
Foundry: Brass and Aluminum
Casting: Jobbing Foundry
Molding processes: Sinto FBO and Jolt Squeeze
Mixer: Simpson Mix-Muller (Batch Muller)
Controller: Simpson Hartley
Reclaimer: Simpson 2-Cell Pro-Claim
“The overall reason we wanted to do this is basically to keep the sand that we purchase within the building, minimize if at all possible anything that we throw away and give us the quality for our customers. From an environmental standpoint our carbon footprint needed to be better.” – Foundry Manager
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