Was bedeutet Regenerierung von Formstoff?

Regenerierung bezeichnet die Aufbereitung von gebrauchtem Formsand, sodass er erneut im Gießprozess eingesetzt werden kann. Ziel ist es, die Eigenschaften von Neusand möglichst wieder zu erreichen.

Welche Vorteile hat recycelter PUROLiT-Sand?

Recycelter PUROLiT-Sand senkt Materialkosten, reduziert Abfallmengen und verbessert die Umweltbilanz der Gießerei, ohne die Prozesssicherheit zu beeinträchtigen.

Welche Regenerierverfahren gibt es?

In der Praxis werden vor allem mechanische und thermische Regenerierverfahren eingesetzt, je nach Qualitätsanforderung und Anwendungsbereich.

Ist regenerierter Sand genauso gut wie Neusand?

In vielen Anwendungen erreicht regenerierter PUROLiT-Sand nahezu die Eigenschaften von Neusand und kann diesen teilweise vollständig ersetzen.

Wie oft kann PUROLiT-gebundener Sand regeneriert werden?

Die Anzahl der möglichen Regenerationszyklen hängt von vielen Faktoren ab. Entscheidend sind das verwendete Verfahren und die Prozessführung. In der Praxis sind zahlreiche Umläufe möglich, sodass in einem kontinuierlichen Betrieb häufig nur ein geringer Neusandanteil von wenigen Prozent erforderlich ist, um die Formstoffmenge konstant zu halten.

Recycling

Recycling in foundries: Regenerability of PUROLiT-bonded moulding sand

Recycling plays a central role in modern foundries, as moulding sand is used in large quantities and incurs considerable costs and, particularly when furan or phenolic resin binders are used, also causes significant environmental pollution. For many years now, the recyclability of moulding sand has therefore been playing an increasingly important role as an economic and ecological factor.
PUROLiT-bonded moulding sand is designed so that it can be regenerated both mechanically and thermally and then be reused. This significantly reduces raw material consumption, disposal costs and emissions.

Why recycling moulding sand is important in foundries

Foundries generate large quantities of used sand every day. Without processing and regeneration, this sand would have to be disposed of and replaced with new sand. This leads to high costs, additional transport expenses and unnecessary environmental pollution.
Regenerating the moulding sand enables a closed material cycle, which conserves resources and improves the economic efficiency of the foundry process.

Comparison of the flexural strength of mechanically regenerated PUROLiT used sand and new sand

What does regenerability mean in relation to PUROLiT-bonded sand?

Regenerability describes the ability of a moulding material to be reprocessed and reused after the casting process.
PUROLiT-bonded sand is characterised by the fact that the binder can be easily removed from the grains and the sand then achieves almost the same properties as new sand. This enables a high proportion of regenerated material to be used in moulding and core making.

Mechanical and thermal regeneration compared

Mechanical regeneration

Mechanical regeneration removes adhesions and binder residues through friction and impact.
This method is energy-efficient and particularly suitable for the continuous processing of large quantities of sand.

Thermal regeneration

Thermal regeneration burns organic components at high temperatures.
The result is particularly clean sand with excellent properties for high performance casting applications.

We were able to investigate and verify this correlation in a series of tests conducted in collaboration with the Foundry Institute at TU Bergakademie Freiberg. The results confirm the technical suitability of the PUROLiT system in terms of regenerability and process stability in foundry operations.

Influence of PUROLiT core sand on clay-bonded green sand circulation systems in foundries

Landfilling and environmental aspects

Used moulding and core sand containing PUROLiT can be disposed of much more cost-effectively, as relevant parameters such as phenol index, DOC and aromatics are significantly reduced compared to used sand from conventional binders.
While used sand containing classic phenol or furan resins is usually classified as landfill class 2, PUROLiT-bound used sand can be classified as landfill class 0 or 1, depending on the amount of binder used. This underlines the environmentally friendly approach throughout the entire process chain.

Technical advantages of regenerated PUROLiT sand

Regenerated PUROLiT sand can compete directly with new sand in many applications.
The most important advantages include:

Consistent moulding sand quality
Stable bending strength
Reduced material costs
Lower demand for new sand
Improved environmental balance of the entire process

FAQ:

What does regeneration of moulding sand mean?

Regeneration refers to the processing of used moulding sand so that it can be reused in the casting process. The aim is to restore the properties of new sand as far as possible.

What are the advantages of recycled PUROLiT sand?

Recycled PUROLiT sand lowers material costs, reduces waste and improves the foundry’s environmental balance without compromising process reliability.

What regeneration methods are available?

In practice, mechanical and thermal regeneration methods are primarily used, depending on the quality requirements and casting process.

Is regenerated sand as good as new sand?

In many applications, regenerated PUROLiT sand almost matches the properties of new sand and can sometimes replace it completely.

How often can PUROLiT-bonded sand be regenerated?

The number of possible regeneration cycles depends on many factors. The process used and the exact process control play a particularly important role here. In practice, a large number of cycles are possible, so that in continuous operation, ideally only a few percent of new sand needs to be added to keep the amount of moulding sand constant.

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