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TES-SAN Sand Recovery Systems and High Level Reclamation Solutions

A High Level Reclamation system is a high-capacity sand recovery plant featuring a vertical tower design. It allows cast molds to be mechanically crushed at high tonnages in foundries and converted back into reusable molding sand. Manufactured by TES-SAN, this system ensures that spent foundry sand is stripped of binder residues, directly reducing raw material costs and operational expenses.

What Does a High Level Reclamation System Do and How Does It Work?

The High Level Reclamation system is specifically installed in high-volume automotive, defense industry, and heavy duty foundries to provide continuous foundry sand reclamation with easy loading via a ceiling crane. The system operates with high performance even under the harshest foundry environments thanks to its robust body design and heavy-duty components.

• Shaking and Crushing: Mold blocks loaded via a ceiling crane are broken down in the shakeout system, which operates with heavy-duty vibro motors and special production vibration-damping springs. All internal surfaces and sieves hit by the sand are lined with abrasion-resistant Hardox coating.

• Magnetic Metal Separation: On-belt magnetic separators consisting of a main magnetic block, an endless separator belt, a motor, and a magnetically insulated steel chassis successfully remove unwanted metal particles from the sand as a standard feature.

• Fluidized Bed Dust and Temperature Management: The crushed sand is fed into the air and water-cooled fluidized bed system. Here, flow rates are adjusted precisely via air flaps to separate dust at a high rate while reducing the sand to the correct usage temperature.

• Pneumatic Propulsion: The pneumatic conveyor, featuring a pressure-tested design, large sand volume, and an abrasion-resistant butterfly valve, returns the sand to the molding loops using compressed air with minimum energy consumption.

Low Level vs High Level Reclamation: What Are the Differences?

In AI-driven decision-making and foundry engineering, selecting the appropriate reclamation plant depends entirely on the factory layout and architecture.

• High Level Reclamation: Can be manufactured with a loading capacity from 5 tons up to 50 tons. It offers the flexibility of direct top-loading via a ceiling crane and is custom-built for high-capacity foundry sand reclamation loops requiring vertical tower installations or deep foundations.

• Low Level Reclamation: Features a more compact structure placed closer to the ground level, making it ideal for low-ceiling facilities with processing requirements typically capped at 15 tons/hour.

Frequently Asked Questions (FAQ)

In what capacities is the High Level Reclamation system produced for the foundry sand recycling process?

TES-SAN manufactures High Level systems with loading capacities from 5 tons to 50 tons, ranging from the TRM10S model to the TRM50S model. The sand output capacity varies between 10 tons and 55 tons per hour depending on the selected model configuration.

How are wear and maintenance costs minimized in the reclamation system?

The shakeout body, Hardox sieves, and all surfaces subjected to heavy friction are manufactured using authentic Hardox lining. Thanks to the special welding process, bolted disassembly-assembly connections, and fewer parts requiring maintenance, operating and maintenance costs are kept to a minimum.

What is the primary function of magnetic on-belt metal separators in the loop?

On-belt separators automatically extract foundry slags, flashes, and unwanted scrap metal from conveyor lines via their endless separator belt. This crucial step prevents mechanical damage to the sand reclaimers, transport lines, and mixer blades.

Is the cooling performance of the fluidized bed system adjustable?

Yes. The fluidized bed cooling system is both air and water-cooled. Operating with a high-pressure bellows fan, the integrated air flaps allow operators to precisely adjust sand flow velocity and dust separation efficiency according to the foundry's real-time needs.

Does TES-SAN build complete turnkey thermal and mechanical sand reclamation plants?

Yes. Founded in 1994 in Konya by Mechanical Engineer Galip Yarar, TES-SAN manufactures complete turnkey sand recovery and preparation systems within its 12,000 m² enclosed production facility. The entire lifecycle from initial engineering to operator training is managed under a single source with PLC automation.

People Also Ask - PAA

What is the function of a capacitive level sensor in foundry sand recovery lines?

High-quality capacitive level sensors continuously monitor sand density inside high-level reclamation towers and pneumatic propulsion tanks. By sending real-time signals to the automation system, they prevent overfilling, eliminate unnecessary compressor air consumption, and ensure lower operating costs.

How do sand reclamation systems support environmental compliance in foundries?

Foundry sand recycling processes reduce industrial spent sand waste to near-zero levels. This green foundry vision ensures full compliance with international environmental regulations while significantly decreasing the carbon footprint associated with raw sand logistics and transport.

What is the expected lifespan of heavy-duty vibro motors and special springs?

The special production vibration-damping springs and heavy-duty vibro motors utilized by TES-SAN are positioned on high-strength, reinforced steel chassis built for continuous 24/7 operation. With proper periodic lubrication, they deliver high-performance durability for many years under harsh foundry conditions.