Need Silica Help????
Is the new Silica Exposure standard looming over your foundry?
I think many foundries thought this ruling would just go away. The trouble is it didn't and likely won't. So, the new silica exposure standards go into effect this June. Have you taken steps to get ready? Are you ready? Or are you way behind? We can help.
Silver Bullet Material?
Del Sol offers a material that may be a silver bullet against the silica standard. Seems a bit overstated, but let's give this a shot. Del Sol distributes for Carbo Ceramics. Carbo has the potential to eliminate silica from your sand system. So, the very best way to get through a silica exposure test, is not to have silica on site. Carbo is a replacement core and mold media that contains no silica. It is a perfect 3 screen sand. It is chemically inert. It can be used in greensand or airset or cold box….
Greensand - We have looked into ways to replace silica mold sand with Carbo Ceramics. For iron shops running greensand, the ultimate goal would be to replace silica with Carbo. You would need to reclaim greensand overage (from added new sand cores) in order to cost justify this. We have developed a reclamation method to take greensand back to your core room in order to close the sand loop and drastically reduce new sand purchases. This allows you to run more expensive materials yet still run at a lower cost. We use a combination of thermal sand reclamation (discussed more later) with mechanical and quite a bit of dust collection.
Airset / No Bake - This one is easy but does require thermal sand reclamation. Basically, you would install a thermal reclaimer that is sized to replace your current new sand requirement. Once this is done, ceramic media simply replaces your current silica sand system. This can be done either in a bulk conversion (all at once), or by attrition in your dust collectors. Carbo Ceramics material drastically outlasts silica sand, olivene alternatives, and alumina alternatives due to extremely strong and hard wearing properties. You can simply buy Carbo for your core sand or makeup sand requirements and let it slowly fill your tanks. The only trouble with this is you will still monitor for silica while you are going through the conversion. In a bulk conversion, silica is gone along with the inspections, reporting, insurance issues, etc.
Thermal Sand Reclamation
For anyone looking to replace silica with a non-silica product, your material costs / ton when purchased will be higher. The trick is to not buy as much material. Thermal sand reclamation allows this to happen. If it is for greensand, our goal is to very seriously dry the clays on the sand in order to be able to remove them mechanically. For chemically bonded sands, we are simply burning off the resins (a pretty easy thing to do).
Del Sol represents Enviroair Thermal Reclaimers. These units are durable, very cost effective per ton (normally $5-6 / ton for airset operations), and simply to operate. The controls on these units are thorough which insures proper temperature controls to insure complete thermal reclamation. No fluidizing beds are used reduced dust collection cfm and also reducing gas usage (about 1/3 of other units).
Del Sol can help you with the complete thermal reclamation system including pneumatic transporters, silos, etcetera.
So, if silica is looming over your head and you would like a solution, contact us and we will get to work right away.
Need Silica Help????