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Re-Use of Waste Foundry Sand

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Re-Use of Waste Foundry Sand. By Shaun Lindfield Safety & Environmental Engineer ... Fettling We fettle/grind approx 110,000 castings per week ready for dispatch. ... – PowerPoint PPT presentation

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Date added: 18 July 2020
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Tags: fettle | foundry | sand | use | waste

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Title: Re-Use of Waste Foundry Sand


1
Re-Use of Waste Foundry Sand By Shaun Lindfield
Safety Environmental Engineer Precision Disc
Castings Ltd
2
Precision Disc Castings Ltd Leading the world in
brake disc technology
Who are we?
We are a cast iron foundry based in Poole, Dorset
that manufactures brake discs for the automotive
industry.
  • Employees 198
  • Turnover 24 million
  • Capacity 50,000 ton castings/year
  • 5-6 million brake disc castings/year
  • 90 ventilated discs 10 solid discs
  • OE Aftermarket Customer base

3
Precision Disc Castings Ltd Leading the world in
brake disc technology
How do we make brake discs?
Melting We melt 1500T per week of scrap
material in 4 medium frequency induction furnaces
_at_ 1,530oc.
4
Precision Disc Castings Ltd Leading the world in
brake disc technology
How do we make brake discs?
Moulding We make approx 65,000 greensand moulds
each week out of sand, clay, coal dust and water
on each of our 2 Disamatic Moulding Lines
5
Precision Disc Castings Ltd Leading the world in
brake disc technology
How do we make brake discs?
Core Making We make approx 105,000 sand cores
per week, using virgin sand (from the Congleton
area in the UK) resin and a catalyst in one of 7
cold box core machines.
6
Precision Disc Castings Ltd Leading the world in
brake disc technology
How do we make brake discs?
Casting We add cores to each mould and then
pour molten metal into the mould using a laser
guided pouring system on our Calamari Holding
Furnaces.
7
Precision Disc Castings Ltd Leading the world in
brake disc technology
How do we make brake discs?
Fettling We fettle/grind approx 110,000
castings per week ready for dispatch.
8
Precision Disc Castings Ltd Leading the world in
brake disc technology
The Problem
All the materials used in the moulding/casting
process can be re-used within our own sand
system, but they cant be re-used for core
making.
Because the material cant be economically
reclaimed for core making we have approx 275
Tonnes of material (equivalent to 105,000 cores
sacrificed in the process) excess in the sand
system each week, which must be removed.
There is also 40 tonnes per week of dust
extraction fines that have to be dumped to
Landfill. A further 100 tonnes per week of
material that is natural spillage from the
moulding lines goes to landfill.
9
Precision Disc Castings Ltd Leading the world in
brake disc technology
The Solution - Past
In 1996/97 PDC formed a partnership with Tarmac
Southern Ltd, which meant that most of the excess
waste greensand would be used by Tarmac
manufacture asphalt.
PDC made modifications to their plant to allow
sand batches to be dumped direct into rigid
lorries rather than onto indirect production line
belts skips. Tarmac also made some
modifications including building a covered
storage bay.
This original partnership meant that PDC would
send the excess greensand to Tarmac for re-use
rather than landfill. This was approx 4,000
tonnes/year and saving 59,000/year.
10
Precision Disc Castings Ltd Leading the world in
brake disc technology
The Solution - Current
PDC and Tarmacs partnership has continued to
flourish since 1997, which has allowed PDC to
provide Tarmac with more material for re-use.
As more material became available, Tarmac
increased the number of sites using PDCs surplus
sand to include three of their South Western
asphalt plants, with a fourth coming online
during 2008.
  • PDC have increased the amount re-used by Tarmac
    by -
  • Installing blow over units from the dust
    extraction plants
  • Installing a Pre-conditioning plant.
  • Installing a Sand Reclamation belt

11
Precision Disc Castings Ltd Leading the world in
brake disc technology
The Solution - Current
By installing these afore mentioned items of
plant PDC have increased the amount of material
re-used by Tarmac from 4,500 Tonnes/year to
12,500 Tonnes/year.
12
Precision Disc Castings Ltd Leading the world in
brake disc technology
The Solution - Current
As a result of this initiative, PDC has managed
to save a significant amount of money as shown
below.
Cost of Re-use 8.75 per tonne Cost of Disposal
in 06/07 14 per tonne 80 transport per
load Cost of Disposal in 07/08 15 per tonne
92 transport per load
Year Tonnes Tarmac Cost Disposal Cost Saving
2006/2007 9,165 80,193 180,681 100,488
2007/2008 12,664 110,810 273,180 162,370
As you can see from the above table PDC saved
162,370 through our partnership with Tarmac in
07/08.
13
Precision Disc Castings Ltd Leading the world in
brake disc technology
The Solution - Future
PDC hopes to further increase the amount of
material re-used internally before eventually
being transferred to Tarmac for re-use in
asphalt.
A pneumatic fines blow over system is currently
being installed, which allow approx another 500
tonnes of material per annum to be re-used.
This will mean that Tarmac will soon be re-using
13,000 tonnes of PDC excess waste greensand
PDC will therefore, re-use/recycle 14,500 tonnes
per annum of the total 17,000 tonnes of waste
generated 86.
14
Precision Disc Castings Ltd Leading the world in
brake disc technology
Summary
PDC and Tarmacs partnership has gone from
strength to strength since its beginnings in
1997. Tarmac originally took 4,500 tonnes/year
in 1997/1998 compared to 12,500 tonnes/year in
2007/2008, giving considerable environmental and
economic benefits to them. This has had a
massive positive impact for PDCs Environmental
Performance, compliance with ISO 14001 and
economy of operation.
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