Metallurgical
Engineering
Technology
Group of Industries
The most cost-effective and proven
Melt Additives, Foundry Chemicals & Fluxes
for Foundries…
Mr. C. Natarajan the founder of MET group of Industries is a
qualified and experienced Metallurgist in the field of foundry
industry.
NC Innovations P Ltd, a manufacturing wing of MET Group is a
leading manufacturer of specialty foundry process and finishing
additives for application in the foundry industry which are based on
formulations developed at its in-house R & D division. NC
Innovations is based in Bangalore.
“Providing solutions to the foundries before they have a Problem” is
the company’s motto.
Main focus of products developed by MET Group, has been to ensure
it is eco-friendly, it is recycled and affordable.
One such innovation and development is the Reclamation of Sodium
Silicate bonded CO2 by DETERGENT WASH method.
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
Even though there are many different methods and processes in the market for
Sodium Silicate Bonded sand reclamation, but, there are many disadvantages
and downsides to it, which are listed below:
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Cannot remove100% of the binder from the sand system
Cannot maintain sand grain size, shape and distribution
Still require a complex disposal system
Still require procurement of new sand
High investment cost
High energy to operate
Complex process – detrimental to human health and environment
High maintenance cost
High wear and tear of equipment's
Will result in variation in the sand system to before and after reclamation
process , which will eventually make it un-fit for use in the foundries
Therefore to overcome the above disadvantages and to ensure it is beneficial to
both the user and the environment, MET Group has developed - A 100% sand
reclamation system for Sodium Silicate bonded CO 2 sand by detergent wash method. This
system recycles foundry CO2 sand which otherwise would be a natural waste and hard to
dispose disturbing the environment.
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
CO2 Sand Reclamation System by detergent wash method.
With lot of experiments and through evaluation of various methods available
for the CO2 sand Reclamation, MET Group has finally boiled down to the
detergent wash method which is a fool proof system and will retain the
original sand grain shape, size and distribution.
Advantages of the System:
1. 100% Recycling of sand
2. Conserve resources
3. Low operating cost
4. No Grain Size variation – as seen in other methods of reclamation
5. No harmful or hazardous end products
6. Reduce Pollution
7. No additional disposal cost
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
Existing Methods Of Reclamation
i.
Mechanical Attrition
Attrition using mechanical vibrators/crushers breaks down used sand
lumps into sand grains and part of the fine binder is removed by dust
collector.
Only 60 to 70 % of binder is possible to be removed and balance remain
in the sand system.
ii.
Thermal Treatment and Attrition
Lumps are subjected for breaking in rotary furnace between 400 to
8000 C, when sand particles expand; this helps to break the bond on the
sand grains and simultaneous rubbing peels off the coating from the
sand grains and fines are removed from the sand system.
In this process, the removal of binder may be in the order of 75 to 80%,
and the additional cost of cooling of sand is involved.
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
iii. Detergent Wash Method by MET Group of Industries
The used sand lumps are broken into individual sand grains
through mechanical vibrators During breaking the lumps,
part of the binder becomes fine powder and being removed by the
action of dust collector in the system.
Subsequently, the sand system is treated with detergent (say 4 to 5
% by wt of the sand) to remove the adhered binder to the sand
grains and the treatment will last for 5 minutes.
By this, 100 % removal of binder is possible.
Thus, the sand is free from binder and virtually without wet
condition.
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
System Flow Chart:
Used Sodium
Silicate Sand
(Lumps)
Mechanical
Attrition
Hydraulic
Press
Silicate
Sand –
Individual
grains
Detergent
Aeration
Reclaimed
Sand
Wash
Storage &
Distribution
Pre Process
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
Process
Post Process
System Requirements:
 Power
: ~50 -55 Hp
 Capacity
: 2MT per Hour *
 Plant Size
: 2500 sqft
* The capacity can be increased upto 10 MT, using the same technology and setup
without significant increase in investment.
Cost of the Detergent Wash Method System:
 System Cost
: Rs. 1.25 crore
 Operating Cost : ~ Rs 1,250 per MT *
* taking into account the following: electricity, labour, maintenance, interest on plant
and machinery, consumables and overheads
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
Laboratory Trials On Properties of Reclaimed Sand v/s
New Sand
Sodium Silicate
Addition Used
4%
5%
6%
Reclaimed Sand by
Detergent Wash Method
(Compression Strength)
5.8Kg F/cm2
6.5Kg F/cm2
8.6Kg F/cm2
9Kg F/cm2
10.8Kg F/cm2
11Kg F/cm2
(Compression Strength)
New Sand
The above results shows that the properties of the reclaimed sand is
almost close to the properties of the New sand.
The sand reclaimed by detergent route will be 100 % reusable.
Email : cn@metgroup.co.in
Ph: +91-98864-94441
Website: www.metgroup.co.in
Thank you!
For queries please contact us:
Mr. C. Natarajan
#126, Ballur Cross, Attibele Post, Bangalore Dist 562107
Cell: +91.98864.94441
Email: cn@metgroup.co.in Website: www.metgroup.co.in