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Metal Casting Technologies : December 2006
BETZ INDUSTRIES Betz Industries in Grand Rapids, Michigan is a modern gray and ductile iron no-bake foundry specializing in large dies, patterns and machine beds for the automotive and heavy machine industries. The plant and offices presently occupy 8 acres under roof. When the owners, brothers Karl and Ken Betz both degreed metallurgists, decided to reclaim their disposal sand, they tested their chemically-bonded lumps at various manufacturers. After careful analysis, they purchased a Rotary Lump Crusher/Sand Reclaimer from DIDION International Inc., St. Peters, MO. Betz Foundry saves $4,190.00 per hour with Didion Rotary Sand Reclaimer Betz's two DIDION Model LC-40 Mark 5 Rotary Lump Crusher/Sand Reclaimers. Economics of Nobake to Nobake Reclamation System GENERAL DESCRIPTION Foundry Type Nobake Gray and Ductile Iron Product Type Precision automotive dies, patterns, and machine beds Production Rate 12 tons of castings/hour Typical Sand-to-Metal Ratio 2:1 Sand System Size 1700 tons Sand Type/Binder 10% Ottuwa, 90% Lake/Furan Sand Usage 130 tons/hour Capacity 130 tph Actual Production 120 tph Yield 97% Reclaimed Sand:New Sand 97:3 Disposal 3% Dust-No Sand Description of Reclamation System Two (2) vibratory feed conveyors, (2) Rotary Lump Crusher/Sand Purchased During Project: Reclaimers, dust collection, distribution panel and installation. ECONOMIC EVALUATION Before Reclamation: Cost of New Sand (per ton) Ottuwa Sand 10% $45.00 x (10%) = $4.50 Lake Sand 90% $20.00 x (90%) = $18.00 Cost of Sand Disposal (per ton) $13.50 Total Cost of Sand (per ton) $36.00 Total Cost of Sand (per hour) $4,320.00 After Reclamation: Savings of Sand (per ton) 97% yield $34.92 Savings of Sand (per hour) $4,190.40 METAL Casting Technologies December 2006 36