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Abstract

Due to the presence of harmful substances in resins those mould sands may be hazardous to the natural environment and workers. The general assessment of harmfulness of sands used for molds and cores encompasses 2 basic points: emission of hazardous substances during processes of preparing sands, pouring mold with liquid metals (high temperatures), cooling and shaking-out; possibility of washing out hazardous substances from used sands to the environment, during storage or economic use outside foundries. We present the results of research on the emission of BTEX compounds from mould sands with phenolic resins during pouring liquid metal of different temperature (cast iron and Al alloy). The research was conducted according to the original method prepared by the authors, which has been used for years in cooperation with various foundries (Poland, abroad).
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Authors and Affiliations

St.M. Dobosz
J. Jakubski
K. Major-Gabryś
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Abstract

Due to the presence of harmful substances in resins those mould sands may be hazardous to the natural environment and workers. The general assessment of harmfulness of sands used for molds and cores encompasses 2 basic points: emission of hazardous substances during processes of preparing sands, pouring mold with liquid metals (high temperatures), cooling and shaking-out; possibility of washing out hazardous substances from used sands to the environment, during storage or economic use outside foundries. We present the results of research on the emission of BTEX compounds from mould sands with phenolic resins during pouring liquid metal of different temperature (cast iron and Al alloy). The research was conducted according to the original method prepared by the authors, which has been used for years in cooperation with various foundries (Poland, abroad).
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Authors and Affiliations

M. Holtzer
R. Dańko
S. Żymankowska-Kumon
A. Bobrowski
J. Kolczyk
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Abstract

In foundry, metal casting can be done with various methods. One of the most important methods preferred around the world is sand casting. Ester curable alkaline phenolic resins have produced to make sand molds by No-bake systems. They must have specific properties to make sand casting efficient and reliable. Production of these resins depends on some fossil raw-materials like phenol. To investigate more sustainable and green resin synthesis method, lots experiment have been done by substitution of phenol with renewable alternative phenolic materials like resorcinol, lignosulphonates and tannic acid and its derivatives. Different properties of resins were produced with competitive performance with the market product, ÇKE Alfanol A 72 No-Bake Resin. Without loss of performance, calcium lignosulfonate was used in polymer synthesis at the rate of 15% instead of phenol. On the other hand, the reaction in which lignin and resorcinol were combined instead of phenol by reducing it by 25% gave better results in terms of mechanical and thermal properties. Thermal properties were investigated for resorcinol and lignin modified resins by using TGA-DSC and mechanical performance of cured sand core sample were tested by Simpson Sand Strength Testing Machine as compression strength as N/cm2.. After laboratory testing casting performance of new resins are compared with two different companies’ resins in steal casting demo. Experimental results were matched with casting trail and no defect was detected.
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Bibliography

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[25] Mocek, J. (2019). Multiparameter Assessment of the Gas Forming Tendency of Foundry Sands with Alkyd Resins. Archives of Foundry Engineering. 19(2), 41-48. DOI: 10.24425/afe.2019.127114.
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Authors and Affiliations

A.E. Güvendik
1
K. Ay
2

  1. Çukurova Kimya Endüstrisi A.Ş., Turkey
  2. Manisa Celal Bayar University, Turkey
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Abstract

The method of the ongoing assessment of the reclaim quality originating from the mechanical reclamation is described in this paper. In the process, the triboelectric system of measuring amounts of dust in the dedusting part of a reclamation device was applied. Based on the online measurements of the amounts of dust generated in the spent sand-reclamation process and the post-process determinations of the ignition losses and granular structures of the removed dust, the proper work parameters of the experimental reclaimer were selected. The allowable value of the ignition losses as well as the main fraction of the reclaimed matrix being similar to fresh sand was assumed as the main criteria of the positive assessment of the process. Within the presented investigations, a periodically operating device for rotor-mechanical reclamation was developed. The possibility of changing the intensity and time of the reclamation treatment as well as the triboelectric system of the dust-amount measuring were applied in this device. Tests were performed for the spent moulding sand with phenol-resol resin Carbophen 5692 hardened by CO2. This sand represents the moulding sand group with a less harmful influence on the surroundings for which the recovery of the quartz matrix utilising the reclamation requires stricter control of the parameters of the reclamation process and reclaim quality.
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Bibliography

[1] Boenisch, D. (1991, March). Reclamation of spent sands containing bentonite. Guidelines for an economical leading to minimized waste. Giesserei 77, nr 19, 1990. In and AFS International Sand Reclamation Conference, Conference Proceedings, Novi/MI (p. 211).
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[5] Łucarz, M. & Dereń, M. (2017). Conditions of thermal reclamation process realization on a sample of spent moulding sand from an aluminum alloy foundry plant. Archives of Foundry Engineering. 17(2), 197-201.
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[11] Vijayakumar, S., Srinivasan, M.V. & Govindaraju, M. (2021). Reduction of waste in furan molding process from cast iron foundry. Materials Today: Proceedings. 46, 5032-5035.
[12] Wang, J.N. & Fan, Z.T. (2010). 'Freezing–mechanical'reclamation of used sodium silicate sands. International Journal of Cast Metals Research. 23(5), 257-263.
[13] Wang, L.C., Jiang, W.M., Gong, X.L., Liu, F.C. & Fan, Z.T. (2019). Recycling water glass from wet reclamation sewage of waste sodium silicate-bonded sand. China Foundry. 16(3), 198-203.
[14] Cruz, N., Briens, C. & Berruti, F. (2009). Green sand reclamation using a fluidized bed with an attrition nozzle. Resources, Conservation and Recycling. 54(1), 45-52.
[15] Dungan, R.S., Huwe, J. & Chaney, R.L. (2009). Concentrations of PCDD/PCDFs and PCBs in spent foundry sands. Chemosphere. 75(9), 1232-1235.
[16] Zitian, F., Fuchu, L., Wei, L. & Guona, L. (2014). A new low-cost method of reclaiming mixed foundry waste sand based on wet-thermal composite reclamation. China Foundry. 11(5).
[17] Ghormley, S., Williams, R. & Dvorak, B. (2020). Foundry Sand Source Reduction Options: Life Cycle Assessment Evaluation. Environments. 7(9), 66.
[18] Holtzer, M. & Kmita, A. (2020). Mold and Core Sands in Metalcasting: Chemistry and Ecology. Sustainable Development. Springer, Cham.

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Authors and Affiliations

R. Dańko
1
A. Pietrzak
1
D. Gruszka
1

  1. AGH University of Science and Technology, Department of Foundry, ul. Reymonta 23, 30-059 Kraków, Poland

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