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Metal Casting Technologies : December 2006
Originally, the reclaimed sand was further processed in pneumatic scrubbers until it was later determined that the quality of the reclaimed sand from the DIDION Rotary Reclaimer was actually acceptable before the secondary scrubbers. "This discovery resulted in substantial savings in energy, operational and maintenance costs. The new system uses 300 less H.P. with double the production of the previous system." said John Keener, foundry engineer of Betz. Recently Betz Industries underwent a major expansion that doubled the size of their foundry. The new 200,000 sq.ft. addition included the installation of two (2) new DIDION Model LC-40 Mark 5 Rotary Lump Crusher/Sand Reclaimers, which process 90 TPH of Furan bonded sand. This, coupled with the existing production totals 130 tons per hour of reclaimed sand, which makes Betz the largest reclamation plant per hour of chemically bonded sand in the USA. "Building on the experience from the original plant, the new expansion did not include any secondary scrubbers behind the DIDIONS. The dust collection and maintenance requirements were reduced by 90%. The DIDION equipment crushes our large lumps, scrubs, screens and classifies the sand, and automatically separates the tramp metal. Today, we are reclaiming all of our sand through the DIDIONS at a 97% yield. We no longer dispose of any sand, only 3% dust." said Keener. Large sand lumps are charged into the Rotary Lump Crusher/Sand Reclaimers by vibratory feed conveyors. Upon entering the machine, high profile flights screw the lumps forward in an expansion chamber designed to relieve the feed conveyor. The lumps then enter the dual chamber attrition section where the lumps are reduced to minus 3/8" and the tramp metal is separated. The sand then passes through tapered holes in the wear resistant cast lining and is conveyed back toward the intake end in an outer chamber where screening and primary classification occurs. The oversized agglomerations from the final screen are automatically recirculated back into the feed conveyor for another pass through the machine. The binder and fines are removed through an opening at the top of the screen housing to a baghouse. Dust Collection requirements are low (8,000 CFM) per machine due to the closed environment of the drum. The machine rotates on laser aligned bearings for precision tracking and longevity. "The proven performance and excellent savings ($4,190.40/Hour) is why we continue to use DIDION Rotary Reclamation Equipment. Their patented design is very efficient (1 HP/Ton) and requires very little maintenance." said Keener. The continuous development at DIDION has provided BETZ Industries with their fifth generation rotary machines, which have new serrated liners as well as an internal recirculation system, yielding increased capacity and higher efficiencies. "We currently reclaim up to 130 tons per hour, so higher efficiency is very important to us," concludes Keener. For more information, please contact: 7000 West Geneva Drive Saint Peters, Missouri 63376, U.S.A. Tel: 636/278-8700 Fax: 636/278-3155 E-mail: email@example.com Web Site: www.didion.com Machined foam pattern. Castings made with reclaimed sands. Betz Administrative Offices. METAL Casting Technologies December 2006 37