The document discusses thermal sand reclamation, which involves heating used foundry sand to high temperatures to remove binders so that the sand can be reused. It notes the environmental regulations driving sand reclamation and describes the thermal reclamation process, which uses a fluidized bed combustor to heat sand to 600-800°C. The document provides an overview of the reclamation plant setup and equipment involved, including processing systems, filters, storage, and control panels. It discusses advantages like reduced costs and consistent supply compared to using fresh sand. Finally, it presents common questions and answers regarding the reclamation process.

1. THERMAL SAND
RECLAMATION PLANT

2. INTRODUCTION
What is Sand Reclamation ?
 The Sand Reclamation is process of cleaning previously
used sand so it can be reused
Why Sand Reclamation ?
 Due to environmental regulations, the disposal of waste
foundry sand has become one of the most pressing problems for
the foundry.
 In recent years because of the high disposal costs encountered
and difficulty in finding disposal sites.
 Scarcity of New sand due to local authorities are imposing
restrictions in mining. In future, there will be chances of stopping
supplies to save the natural resources.

3.  Thermal Reclamation is the process in which the sand is
heated to a temperature of about 600 to 800 deg. C, in a
specially designed fluidized bed Combustor which is the
main equipment of the thermal reclamation system.
 In the Thermal Reclaimer, the sand grains obtained from
the lump breaker is generally preheated
 And feed into the combustor where it is fluidized by
precisely controlled air flow at desired pressure.
 The fluidized bed also receives LPG gas at controlled
rate which burns in the fluidized bed with oxygen available
in the fluidizing air in the bed. The binder in the sand is
totally burnt and hot reclaimed sand is obtained at the outlet
of the Combustor.
THERMAL RECLMATION BY PROCESS

4. Why Thermal Process…?!
 Thermally Reclaimed sand undergoes lower
thermal expansion causing better mould
stability.
 Thermally reclaimed sand is better than fresh
sand because it is more rounded in shape
causing lesser binder demand as well as can
be used with any chemical binder system in
subsequent cycle.
 Thermally reclaimed sand is better than
mechanically reclaimed sand.

5. Sand Pro-Claimer Plant Drawing
(Only for Green Sand)

6. Thermal Reclamation plant Drawing

7. PROCESS FLOW CHART

9. LIST OF EQUIPMENTS
S.No Equipment Descrepition
1 LUM CRUSHER
2 BELT CONVEYOR WITH MAGNETIC PULLEY
3 OBMS WITH MAGNETIC PULLEY
4 PROCLAIMAER WITH BLOWER
5
PULSE JET DUST BAG FILTER WITH SUPPORTING EQUIPMENT (40 Bags, 7.5Hp Blower)
(FOR PROCLAIMER)
6 BUCKET ELEVATOR - I
7 OVER HEAD VIBRATING SIEVER
8 SAND STORAGE HOPPER (20 MT capacity)
9 SAND FEEDER BELT WITH RAV & MAGNETIC PULLEY
10 BUCKET ELEVATOR - II
11 COMBUSTION FURNACE 2TPH WITH PLC & MCC CONTROL PANEL
12 DIRECT SAND COOLER WITH FLUDIZED BLOWER
13 SAND SIEVER FOR RECLAIM SAND
14 BUCKET ELEVATOR - III
15 RECLAIMED SAND STORAGE HOPPER (20 MT capacity)
16 DUST & FLUE GAS EXHAUST SYSTEM
17
WET SCRUBBER UNIT WITH SUCTION ID FAN WITH CHIMNEY 13 MTS FROM FLOOR
LEVEL WITH PUMP
18 PULSE JET BAG FILTER WITH SUPPORTING EQUIPMENT (60 Bags, 10 Hp Blower)

16. CONTROAL PANEL

17. REQUIREMENTS
 Space Requirement (Shed) - Minimum 25m x10m x 10m
 Outside space - 10m x 10m (For scrubber & Cooling tower)
 Electricity Requirement for Total Plant - 75.00 KW
(Thermal Plant – 61.00 KW + Pro-Claimer – 15.00 KW)
 Labour – 4 Persons/ Shift ( Thermal -2 & Pro-Claimer – 2 )

18.  Conserves Natural Environment and Cost by eliminating Dumping of used
toxic sand .
 Reclaimed sand replaces fresh sand.( Less purchase )
 Drying not required for reclaimed sand and thus cost can be eliminated.
 Uniform Properties & Characteristics.
 Supply will be Consistent & Adequate.
 No Freight charges and Delay.
 No need to have bulk inventory.
 LOI is Max 0.3 % as per your sand
 OEE -85 - 90%,
 Thermal Efficiency- 90 - 95%
 Gas Consumption : 10 to 15 Kgs (This will vary according to the sand)
7 to 10 Kgs ( For Green Sand Thermal running)
 Finally Sand cost would be Cheaper.
Advantages…..

19. Returns…..!!!
ROI - LESS THAN ONE YEAR
Budget Cost of the (2 TPH) Reclamation Plant
( As per our Drawing)
12000000
1 INVESTMENT COST (PER KG) UOM
Out Put per Day of 2 TPH ( 2 ton * 24 hrs) 48 MT
Our put per Month (48 x 25 Days) 1200 MT
Our Put for 2 Years ( 1200 * 24 months) 28800 MT
Investment cost (12000000 / 24000) / 1000 0.42 INR
Interest on Investment cost (@ 15%) 0.15 INR
TOTAL INVESTMENT COST / KG 0.57
2 RUNNING COST (PER KG)
Electricity Cost per KG (@ Rs.7 per Unit) ( 38 KWH per TON) 0.30 INR
LPG cost per KG (@ Rs.50 per KG) (Consumption - 10-12 KG PER TON) 0.55 INR
Labour (4 labour per Shift @ Rs.400 per Head) 0.1 INR
Plant Maintenance cost 0.05 INR
TOTAL RUNNING COST / KG 1.00
A TOTAL COST ( INVESTMENT & RUNNING) PER KG 1.57 INR
B PRESENT FRESH SILICA SAND COST PER KG 2.75 INR
Less DIFFRENCE COST PER KG (A-B) 1.18 INR
Yearly Tonnage as per above (1200 MT X 12 MONTHS) 14400 MT
SO, COST PER YEAR ( 14400000 KGS X RS.1.18) 17040000 INR
COST PER MONTH 1420000 INR
ROI PERIOD ( 12000000/1420000) 8 Months

20. Q> What type of Sands can be re-claimed in the Machine?
A> Green Sand / Shell Mould Sand / Alpha Set / Furon (No-bake) / Cold Box Sands
Can be reclaimed.
(*Green Sand needed PRO-CLAIMER PLANT Additionally)
Q> How many times the sand can be re-claimed?
A> Sand Can be reclaimed 10 times (Max)
Q> What types / Ranges of Plants are available ?
A> Thermal Process – with a capacity of 0.5 to 5.0 MT / Hr Plants are available.
Q> What type of Combustion?
A> Fluidized Bed Combustion
Q> What are the Fuel can be used in the Thermal sand reclamation Plant?
A> LPG and CNG can be used.
Q> What is the fuel consumption levels?
A> Consumptions are based on the input sand that to be reclaimed*
Level 1 : If the input sand LOI is 2 to 3% - The Consumption per TON would be
LPG – 10 to 13 KG and CNG -14-18 NM3
Level 2 : If the input sand LOI is Belo 2 - The Consumption per TON would be LPG
– 13 to 15 KG and CNG -18-21 NM3
FAQ…..??

21. Q> What is the Cycle time for Sand reclamation?
A> 7 to 10 Minutes (During Continuous Fluidization Process)
Q> What is the Electricity consumption during production?
A>The Electricity Consumption would be 23 KWH (Units) per TON. (46 KWH for 2 TONS)
Q> What will the Loss of Ignition ( LOI) on the sand after reclamation?
A>It would be <0.2%
Q> What ratios we should mix the fresh sand during next production?
A>The Fresh sand need to be added / Mixed in 1:9 ratio (10%)
Q> How many tons reclaimed per hour?
A> Approximately 1.80 MT used sand can be re-Claimed per hour – (In 2 TPH Plant)
Q> How many years ROI will happen and Explain?
A> Maximum Within a Year....(If Plant runs to this 90% efficiency) It is again based on your
sand volumes.
Q> Is the Equipment is Approved by Pollution Control Board?
A> The Process is Approved. The PCB Approval to be obtained for the Plant after Installation
at your end. We can assist in this Area.
FAQ…..??

22. THANK YOU…
M/s.Thiruvapathi Engineering Works,
S.F.No.625/2, Eachanari Chettipalayam Road,
Eachanari (PO),
Coimbatore – 641 021.
TAMIL NADU – INDIA.
Contact Us:
Mr.Kanagaraj - 0091 – 9842234578
Mr.Vijaya Kumar – 0091-9894833344
E-mail: thiruvapathikanakaraj@gmail.com
indosourcing@live.in