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1

Ecological Aspects of the Performed Thermal Reclamation

Łucarz M.

Archives of Metallurgy and Materials

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2015

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Vol. 60, iss. 1

329--333

EN

The thermal analysis results of the selected group of binders and the thermal reclamation of one spent moulding sand with organic binder, are presented in the paper. The reclaiming process of the quartz matrix was performed on the basis of the own method of selecting the reclamation temperature. Taking into account thermogravimetric (TG) analysis results of the binder, the temperature range - required for performing the efficient reclamation of spent moulding sand containing this binder - was indicated. In order to confirm the assumptions, the thermal reclamation operations were carried out at a temperature similar to the determined on the TG basis and - for comparisons - at lower and higher temperatures. During the reclamation operation the reclaim samples were taken for the loss on ignition testing, aimed at the determination of the process efficiency. Temperature in the reclaimer chamber and gas consumptions were also recorded. On the bases of the thermal analyses, loss on ignition, gas consumption and temperatures of the reclaimed moulding sand bed the recommendations for the realisation of the thermal reclamation were given. These recommendations will allow a better, than currently available, process control in an aspect of decreasing the pyrolysis effect and limiting the emission of substances harmful for the environment.

PL

W publikacji przedstawiono wyniki badań analizy termicznej wybranej grupy spoiw i regeneracji termicznej jednej zużytej masy ze spoiwem organicznym. Proces odzysku osnowy kwarcowej przeprowadzono w oparciu o sformułowany własny sposób doboru temperatury regeneracji. Na podstawie zrealizowanych badań analizy termograwimetrycznej (TG) spoiwa wskazano zakres temperatury, wymaganej do przeprowadzenia skutecznej regeneracji termicznej masy zużytej z jego udziałem. W celu potwierdzania przyjętych założeń wykonano zabiegi regeneracji termicznej w temperaturze zbliżonej do wyznaczonej na podstawie TG oraz dla porównania w niższej i wyższej temperaturze. W trakcie trwania zabiegu regeneracji pobierano próbki regeneratu do badania strat prażenia, w celu określenia skuteczności działania procesu. Podczas regeneracji rejestrowano temperaturę w komorze regeneratora oraz zużycie gazu. Na podstawie zestawienia analiz termicznych, strat prażenia, zużycia gazu oraz temperatury złoża regenerowanej masy podano wytyczne do realizacji regeneracji termicznej, w warunkach pełniejszej niż dotychczas kontroli procesu w aspekcie zmniejszenia zjawiska pirolizy i emisji związków szkodliwych do otoczenia.

2

Influence of Thermal Reclamation Temperature on the Strength of the Moulding Sand Made of the Reclaim in the Hot-box Technology

Łucarz M., Grabowska B.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 1 spec.

131--135

EN

The results of the thermal reclamation investigations of the spent moulding sand with the Ekotec 35 binder, are presented in the paper. The reclamation process of the quartz matrix was carried out on the basis of the author's own method of selecting the reclamation temperature. On the bases of the performed thermo-gravimetric analysis of the binder the temperature range required for the efficient thermal reclamation was indicated. In order to confirm the assumption the thermal reclamations were performed at a temperature determined by the TG and - for comparisons - at a lower and higher temperature. During the reclamation process samples of the reclaim were taken for testing ignition losses in order to determine the process efficiency. The correctness of the assumed method of selecting the temperature range of the thermal reclamation of spent moulding sand with the Ekotec 35 binder was confirmed.

3

Determination of Parameters of the Moulding Sand Reclamation Process, on the Thermal Analysis Bases

Łucarz M., Grabowska B., Grabowski G.

Archives of Metallurgy and Materials

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2014

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Vol. 59, iss. 3

1023--1027

EN

For the practical and functional reasons the investigation of the thermal decomposition process is of an essential meaning in relation to the thermal stabilisation of materials and obtaining for them the desired thermal properties. On the other side, thermal tests are carried out in order to identify degradation mechanisms, which is important in the environment protection context, including materials reuse. The cycle of investigations in which thermal TG-DTA methods were applied as supplementary ones for the works on the optimisation of the thermal reclamation process is presented in the hereby paper. The thermal reclamation process as a utilisation method of spent moulding and core sands is more costly than other reclamation methods, but in the majority of cases it simultaneously provides the best cleaning of mineral matrices from organic binders. Thus, the application of the thermal analysis methods (TG-DTA), by determining the temperature range within which a degradation followed by a destruction of bounded organic binders in moulding sands, can contribute to the optimisation of the thermal reclamation process and to the limiting its realisation costs.

PL

Ze względów praktycznych i użytkowych zbadanie procesu degradacji termicznej ma podstawowe znaczenie w odniesieniu do problemu procesu stabilizowania termicznego materiałów i otrzymywania dla nich pożądanych właściwości termicznych. Z drugiej strony badania termiczne prowadzi się w celu rozpoznania mechanizmów ich degradacji, co ma też znaczenie w kontekście ochrony środowiska, w tym ich powtórnego wykorzystania materiałowego. W publikacji przedstawiono cykl badań, w którym zastosowano metody termiczne (TG-DTA) w uzupełnieniu do prowadzonych prac nad optymalizacją procesu regeneracji termicznej. Proces regeneracji termicznej jako sposób utylizacji zużytych mas formierskich i rdzeniowych w stosunku do innych rodzajów regeneracji zużytych mas jest bardziej kosztowny, ale jednocześnie dający w większości przypadków najlepsze oczyszczenie osnowy mineralnej ze spoiw organicznych. Stąd zastosowanie metod analizy termicznej (TG-DTA), poprzez określenie zakresu temperatury, w którym dochodzi do degradacji, a następnie destrukcji związanych spoiw organicznych w masie, może przyczynić się do optymalizacji procesu regeneracji termicznej i zmniejszenia kosztów jego realizacji.

4

Thermal Reclamation Process of the Spent Moulding Sand with the Polymer BioCo2 Binder

Grabowska B., Łucarz M., Kaczmarska K.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 3 spec.

90--94

EN

The results of the thermal reclamation investigations of the spent moulding sand with the polymer BioCo2 binder, are presented in the paper. The reclamation process of the quartz matrix was carried out on the basis of the author's own method of selecting the reclamation temperature. On the bases of the performed thermo-gravimetric analysis of the binder the temperature range required for the efficient thermal reclamation was indicated. In order to confirm the assumption the thermal reclamations were performed at a temperature determined by the TG and - for comparisons - at a lower and higher temperature. During the reclamation process samples of the reclaim were taken for testing ignition losses in order to determine the process efficiency. The correctness of the assumed method of selecting the temperature range of the thermal reclamation of spent moulding sand with the polymer BioCo2 binder was confirmed.

5

Influence of the Thermal Reclamation of the Spent Core Sand Matrix on Its Reuse

Łucarz M.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 1 spec.

27--30

EN

The investigation results of the thermal reclamation of spent core sands made in the hot-box technology are presented in the paper. Energy-consumption of the process was tested by recording the media consumption during the thermal treatment of the determined intensity. Gas demands in dependence of the reclamation process temperatures were compared. During the reclamation process the reclaimed material samples were taken to test ignition losses in order to determine the efficiency of the realised procedures. The influence of the reclamation temperature on the quality of the obtained reclaimed material was checked. The effects of the realised reclamation procedures of the same moulding sand at various temperatures were also assessed on the grounds of strength of moulding sands prepared on the bases of the obtained reclaims. It was found that the process energy-consumption can depend on the expected core sand parameters. The attention was drawn to the fact, that bearing of costs for the thermal reclamation - very often - does not correspond directly with the obtained effects. The thermal reclamation performed very intensively, which corresponds with the costs increase, is not always needed for obtaining the core sand of parameters comparable with the sand made of fresh components.

6

Analysis of the Selected Parameters of the Thermal Reclaimer

Łucarz M.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 4

67--72

EN

The investigation results of the influence of the selected parameters of the thermal reclaimer operations on the temperature changes in the combustion chamber and the process energy consumption, are presented in the hereby paper. The analysis of the heat treatment was performed with the application of a fresh foundry sand, since it was assumed that the dominating energy part was used for the grain matrix heating and due to that, the energy used for burning small amounts of organic binder remained on sand grains could be omitted. Thermal treatment processes performed under various conditions were analysed from the point of view of a gas consumption and temperatures obtained in the experimental reclaimer. The recorded data allowed to point out the parameters having essential influence on the process of the quartz matrix heating in the combustion chamber as a gas consumption function.

7

The influence of the configuration of operating parameters of a machine for thermal reclamation on the efficiency of reclamation process

Łucarz M.

Archives of Metallurgy and Materials

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2013

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Vol. 58, iss. 3

923--926

EN

An experimental machine for thermal reclamation, constructed specifically for the research purposes, enables various ways of regaining sand grains from the used moulding and core sands bound by synthetic resins. The source of heat for the process of burning the used moulding and core sands is provided by three gas burners equipped with automatic ignition devices which control the flame and whose work is individually steered by temperature adjusters. It is extremely important to find an appropriate system of stirring the reclaimed sand in order to create the conditions for fast and even burning of the border of the used synthetic binder. The fluidized floor in the machine for thermal reclamation presented in the paper is divided into three independent sections. Air provided to each section by a blower gets through an electrovalve, whose work is steered by an electronic system which was designed and constructed specifically for the use in machine. The adequately set time adjusters in the controller make the electrovalve open and enable the air to flow to particular sections of the fluidized floor of the reclamation chamber. The process is monitored and the working parameters are recorded electronically. The diverse methods of stirring the reclaimed sand used in the process were analyzed in relation to their influence on temperature fluctuation in the reclamation chamber, the length of reclamation process, the amount of the media needed to obtain the purity of the reclaimed (gas, energy), in order to obtain the reclaimed sand of purity defined in terms of ignition losses.

PL

Doświadczalny regenerator termiczny o specjalnie stworzonej konstrukcji umożliwia realizacje odzysku osnowy kwarcowej z zużytych mas formierskich wiązanych żywicami syntetycznymi w różny sposób. Zródłem ciepła wypalania zużytej masy w urządzeniu są trzy palniki gazowe wyposażone w automaty zapłonowe z kontrolą powstania płomienia, których praca sterowana jest indywidualnie przez regulatory temperatury. Ważna kwestia pracy regeneratora termicznego jest stworzenie odpowiedniego systemu mieszania złoża regenerowanej masy, w celu szybkiego i równomiernego spalania otoczki zużytego spoiwa syntetycznego. Dno fluidalne w prezentowanym doświadczalnym regeneratorze termicznym podzielone jest na trzy niezależne sekcje. Do każdej strefy doprowadzone jest powietrze z dmuchawy przez elektrozawór, którego praca steruje specjalnie zaprojektowany i wykonany układ elektroniczny. Odpowiednio zadeklarowane nastawy czasowe w sterowniku decydują o otwarciu elektrozaworu i przepływie powietrza do określonej strefy dna fluidalnego komory regeneracyjnej. Proces jest w pełni monitorowany, a parametry pracy są zapisywane w pamieci rejestratorów. Zastosowane zróznicowane sposoby mieszania złoza regenerowanej masy analizowano pod względem wpływu: na wahania temperatury w komorze regeneracyjnej, czasu regeneracji, ilosci zużytych mediów (gazu, energii) dla uzyskania regeneratu o określonej czystości określonej stratami prażenia.