Foundry Sand Processing Lines & Total Plant Solutions
System Overview
This program provides a complete casting sand treatment production line and overall plant planning, covering the core systems of old sand recovery, regeneration treatment, quality control and intelligent control. Through scientific process design and reliable equipment configuration, it realizes efficient recycling of foundry sand, significantly reduces the consumption of new sand and processing costs, and meets the stability, economy and environmental protection requirements of modern foundry sand processing system.
Detailed process flow of the whole plant
Old sand recycling and pretreatment section
After casting, the old sand is evenly fed into the vibrating crusher through the vibrating feeder, which effectively crushes the large sand mass to a particle size of less than 10mm; the crushed material is transferred to the multi-layer vibrating screen through the belt conveyor to carry out the preliminary screening, separating out the larger impurities such as metal debris, flying edge burrs, etc.; in the process of screening, the ferrous impurities are removed through the multi-stage magnetic separator, including the magnetic metal debris and casting residues, providing clean raw materials for the subsequent regeneration treatment. Provide clean raw materials for subsequent regeneration treatment.
Sand regeneration core section
After pre-treatment, the old sand enters the mechanical regeneration system, which effectively removes the binder coating film on the surface of sand grains through the high-speed rotation of the countercurrent regeneration machine and the intense friction between the sand grains; in the process of regeneration, the regeneration process, coupled with the wind sorting device, utilizes the principle of air separation to separate the fine dust and the failing binder from the sand grains; after the regeneration of sand into the cooling system, the sand temperature is lowered to 50°C or below from 150°C or above through the combination of the countercurrent cooling and the air-cooling process. The sand temperature is reduced from 150°C to below 50°C by a combination of counter-current cooling and air-cooling to ensure that the sand meets the requirements of the molding station.
Precise quality control section
The cooled sand enters the quality control system, which monitors the particle size distribution of the sand in real time through the online particle size detector, and automatically adjusts the sand replenishment quantity and grading ratio according to the detection results; equipped with precise moisture control system, the moisture of the sand is stably controlled within the process requirements through the linkage of microwave moisture meter and automatic spraying device; the appropriate amount of binder and auxiliary materials are added according to the requirements of the molding and the uniformity of each component is ensured through the continuous sand mixing machine. The sand mixer ensures the uniform mixing of each component.
Sand circulation and storage management section
The qualified sand is transported to the sand storage warehouse through pneumatic conveying system, which is equipped with material level monitoring and automatic replenishment device; the molding station obtains the required sand through automated quantitative feeding system to realize accurate distribution; the system is equipped with online quality monitoring point to monitor the key indexes such as compactness and permeability of the sand in real time to ensure the stable and reliable quality of the sand.
Core advantages of the whole plant system
Efficient recycling system
Adopting the advanced process combining mechanical regeneration and wind power sorting, the system significantly reduces the cost of purchasing new sand and waste disposal; through scientific control of sand gradation, the reuse rate of old sand is maximized under the premise of guaranteeing the quality of castings.
Quality Stability Guarantee System
A quality monitoring system is established from the recycling of used sand to the use of molding. Through online inspection and automatic adjustment devices, the key parameters such as particle size distribution, moisture content and binder ratio of the sand are under stable control, providing a reliable guarantee for the consistency of casting quality.
Energy-saving and environmental protection design concept
The system adopts closed design and is equipped with efficient centralized dust removal system; the waste heat in the cooling process is recovered and utilized through heat exchange technology, which reduces the energy consumption of the system; the equipment adopts low-noise models and adopts effective vibration isolation measures to ensure that the noise at the plant boundary meets the standard.
Whole plant planning and professional configuration
Functional area scientific planning
The raw material recovery area is set at the entrance of the workshop, which is convenient for the collection and transfer of old sand; the regeneration processing area concentrates on the core regeneration equipment to ensure the consistency of the process; the quality control area is close to the molding section, which shortens the conveying distance of the qualified sand; the control system is independently set up, which provides a good working environment for the operators.
Perfect configuration of environmental protection system
The dust removal system adopts the combination of bag duster and cyclone duster, with the dust removal efficiency reaching more than 99.5%; the water recycling system realizes zero discharge of production waste water; the noise control system ensures that the working environment complies with the occupational health standards through comprehensive measures such as acoustic isolation, muffling and acoustic absorption.
Through mature technology, reliable equipment configuration and perfect control system, this program provides economical and practical overall solution of sand treatment for foundry enterprises, significantly reduces the production cost under the premise of guaranteeing the quality of castings, and realizes the green, high-efficiency and sustainable foundry production mode.
