As part of their company vision and commitment to a sustainable future, Eurac Poole (a member of the MAT Foundry Group) investigated how they could become a more environmentally friendly foundry. Greensand reclamation was identified as a high priority to becoming more sustainable. So, they turned to Omega Sinto Foundry Machinery Ltd for the answer. A journey which led to the awarding of a Highly Commended in the Innovation category at the 2024 Best of British Casting Awards.
Successful trials were undertaken at Omega Sinto’s pilot plant, which demonstrated the potential benefits of implementing a secondary sand reclamation system, specifically using Omega Sinto’s patented USR green sand back-to-core shop reclamation system.
This system allows Eurac to take their waste greensand from the moulding line and, by a series of mechanical scrubbers and fluidised beds, remove the residual clay and volatiles. This process conditions the sand, making it suitable for reuse within their core shop. By reclaiming their greensand, Eurac can replace up to seventy per cent of the sand used in their cores, significantly reducing their need for new sand by up to five thousand tons per year, and the associated dumping costs.
Eurac has tailored their use of reclaimed sand in their cores with different sand ratios in their brake disc cores and up to seventy per cent reclaim in specific geometry cores. The primary factor in the percentage of reclaimed is the geometry of the product. For producing brake disc cores, the larger airgap castings and therefore greater massed cores, are more suitable for seventy per cent reclaim sand.
BACKGROUND
Although not new, the USR sand reclamation system has been predominantly used for chemically bonded sand. This is the first UK installation to use this equipment for recycling waste greensand back into the coreshop.
Used greensand is collected from the moulding line after the casting process. This sand contains clay (both active and dead), coal dust and other additives; elements that must be removed.
The collected sand is transported to the reclamation system using a primary reclamation system, in this case an Omega Sinto BD unit which is suitable to handle, break down and screen greensand with its typically higher moisture content.
Once the sand is broken down it is pneumatically conveyed to the USRs. The sand enters the USR, which scrubs the sand grains against each other and internal surfaces under controlled settings. After a series of three scrubbing cells, this process scrubs the clay both active and dead, coal dust and other impurities away from the sand grains as well as conditioning the sand grain to a more rounded/sub rounded grain shape.
After processing, the sand is cooled and classified ensuring only suitable sand grains are retained for reuse, removing any remaining dust and fines from the processed sand
The reclaimed sand is then used to produce new cores, replacing a significant portion of new sand requirements.
ORIGINALITY AND UNIQUENESS
The Omega Sinto USR green sand back-to-core shop reclamation system stands out due to several unique and original features, making it an effective solution in the foundry industry.
Dual-purpose scrubbing
The system uses mechanical scrubbing techniques that remove impurities and clay and condition the sand for reuse. This reduces the need for additional processing steps such as thermal or wet reclamation techniques.
Controlled scrubbing
The scrubbing units are designed to apply just the right amount of force, effectively cleaning the sand without breaking down the grains, this maintains the integrity and quality of the sand particles.
Direct reuse in core shop
Unlike traditional systems that may reclaim sand for general use, the USR system specifically conditions the sand for reuse in the core shop. This targeted approach ensures that the reclaimed sand meets the requirements of core making.
Environmental benefits
The reduction in new sand usage, along with decreased disposal needs highlights the system’s comprehensive approach to environmental sustainability.
Eurac Poole’s decision to invest in the system following the successful trials underscores its practical benefits and originality in addressing both economic and environmental challenges in the foundry industry.
CHALLENGES AND BREAKTHROUGHS
Implementing a greensand reclamation system in a foundry comes with several challenges. The USR reclamation system addresses and overcomes these challenges, making it a suitable solution for the industry.
Effective reclamation
Removing active clay, coal dust and other impurities from used sand without damaging the sand grains is difficult.
The USR system provides a solution as it applies precise force to scrub the sand grains against each other and internal surfaces. This process effectively removes impurities while preserving the integrity of the sand particles, ensuring high quality reclaimed sand.
Maintaining sand quality
Reclaimed sand must meet correct testing criteria for maximum reuse in core making. A reduction in LOI, conductivity, dust and fines control must be maintained.
As the USR has a fully adjustable set up, the sand is scrubbed enough to meet these test requirements without damaging the sand grain. Also, using classification systems incorporated within the USR and a separate cooling and classification system to effectively screen the sand ensures that only suitable sand grains are retained. These processes remove fine particles and dust, producing sand that meets the requirements for core making.
Integration with existing processes
Integrating a sand reclamation system into an existing foundry operation without causing significant disruptions can be challenging.
However, the USR system is designed for integration with existing moulding lines and core shops. Because this system can be installed as an extension between reclamation and core shops this ensures minimal disruption to ongoing operations.
Economic feasibility
The initial investment and operational costs of a sand reclamation system can be high, making economic feasibility a concern.
By reclaiming up to seventy per cent of the sand used in the cores, the USR system significantly reduces the need for new sand purchases. This leads to substantial cost savings over time, making the initial investment economically feasible. Additionally, lower disposal and haulage costs further enhance the system's economic benefits. Also, with the potential of being able to re-use dust this could add to the reduction in disposal of this material.
ENVIRONMENTAL IMPACT
The environmental and economic benefits of this reclamation system are substantial. By reducing new sand usage, Eurac decreases the need for sand disposal and haulage, leading to lower operational costs. Additionally, the reduction in these processes results in a significant decrease in CO2 emissions associated with each step, contributing to a lower carbon footprint for the foundry. It has been estimated that to mine one tonne of sand, wash, dry and transport it to site costs on average 226kW per tonne which for Eurac equates to a saving of 1,555,146kW/h or a reduction of 462 tonnes of CO2 per annum.
Foundries need to reduce their environmental footprint by minimising waste and CO2 emissions associated with sand usage.
The USR system effectively reclaims and reuses sand, reducing the need for new sand extraction and the associated environmental impact. By decreasing waste sand disposal and transportation, the system significantly lowers CO2 emissions, contributing to a more sustainable foundry operation.
COMMERCIAL OPPORTUNITY AND RELEVANCE
The secondary reclamation system offers substantial commercial opportunities and relevance for the foundry industry. By addressing market demand for sustainable solutions, providing significant cost savings and efficiency improvements, ensuring high quality reclaimed sand, and aligning with global trends and regulations, the system stands out as a valuable and attractive investment. Its adoption can lead to competitive advantages, enhanced operational performance, and a stronger commitment to environmental responsibility, making it highly relevant in the foundry industry.
With mounting environmental concerns and increasing global awareness of environmental issues, there is a growing demand for sustainable industrial practices. Foundries are under pressure to reduce their carbon footprint and manage resources more efficiently. Many regions are implementing stricter environmental regulations that require industries to minimise waste and emissions. The USR system helps foundries comply with these regulations by significantly reducing the need for new sand and lowering CO2 emissions.
Eurac adopted the USR reclamation system to gain a competitive edge by positioning themselves as leaders in sustainable practices. Companies that demonstrate a commitment to sustainability are more likely to attract clients and partners who prioritise environmentally friendly practices. The reclamation system aligns with the principles of the circular economy, promoting resource efficiency and waste reduction, which is vitally important for the foundry sector.
SUMMARY
Global environmental regulations are rapidly tightening, making sustainability a crucial priority for manufacturers and foundries alike. The MAT Foundry Group is committed to enhancing sustainability by actively measuring and reducing its overall emissions to minimise its carbon footprint.
With a long standing dedication to sustainability, the group aims to cut emissions by twenty per cent by 2025 and by fifty per cent by 2040.
Eurac, part of the MAT Foundry Group, has significantly advanced its sustainable practices by using the Omega Sinto USR Sand Reclamation system. This innovation has drastically reduced the need for new sand in the core shop, leading to fewer lorries on the road, less quarrying for new sand, and reduced sand disposal. These efforts collectively lower Eurac’s carbon footprint, demonstrating a strong commitment to a more sustainable process.
For more information visit: www.matfoundrygroup.com/video/sand-reclamation or contact: Omega Sinto Foundry Machinery Ltd, Morley Way, Woodston, Peterborough, Cambridgeshire PE2 7BW, UK. Tel: +44 (0) 1733 232231, email: [email protected] web: www.ofml.net
AT A GLANCE
- Economic Savings – The reduction in new sand purchase and disposal costs translates to direct financial savings for the foundry.
- Environmental Impact – By reclaiming and reusing sand, Eurac minimises the environmental damage caused by sand extraction and disposal.
- Operational Efficiency – The reclamation system streamlines the sand handling process, enhancing overall operational efficiency.
For imagery and tables detailing savings, refer to the full printed February/March 2025 issue of Foundry Trade Journal.