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TES-SAN Sand Recovery Systems and Thermal Reclamation Solutions

Thermal Reclamation is the most advanced recovery method in foundries where used molding sand is subjected to high temperatures to completely burn off all chemical resin and binder coatings. Integrated by TES-SAN within the scope of global Sand Recovery Systems, this high-tech plant almost entirely eliminates the necessity for new raw sand procurement.

What is Thermal Sand Reclamation and What Are Its Advantages?

Unlike mechanical options, thermal reclamation applies thermal treatment to sand grains, giving them a more stable crystal structure than even brand-new sand. Positioned inside TES-SAN Sand Recovery Systems, this line radically upgrades production efficiency, especially in steel and gray iron foundries.

• Superior Crystal Structure: Since the thermally processed sand grains have completed their thermal expansion, they do not undergo expansion during casting. This boosts dimensional accuracy and prevents chronic defects like gas permeability.
• Additive Optimization: In steel foundries, the system limits or completely eliminates the requirement for expensive iron oxides, zircon, and chromite sands.
• Reduced Finishing Work: Thanks to superior quality sand particles stripped of chemical additives, casting defects like finning are eliminated, meaning castings require far less grinding and welding.

Thermal Reclamation vs Mechanical Reclamation: Which One to Choose?

Choosing the optimal line for your foundry sand preparation depends entirely on your target surface quality and investment budget.

• Thermal Reclamation: Burns away the resin completely with heat. It reduces new sand procurement costs by up to 95% and minimizes landfilling costs. It results in far less odor and smoke in the foundry during pouring operations.
• Mechanical Reclamation: Physically breaks down the binder coating by rubbing sand grains together. It features lower initial acquisition costs but leaves a certain amount of dead clay or resin residue on the grain.

Frequently Asked Questions (FAQ)

By what percentage does the thermal reclamation plant reduce sand acquisition costs?

The TES-SAN thermal reclamation plant purifies used sand by up to 95%, returning it safely to the loop. This minimizes the part of new sand needed, providing up to a 95% reduction in sand acquisition and disposal costs.

What is the quality of sand processed by thermal reclaimers?

Thermally reclaimed sand gains an expanded silica structure that offers better gas permeability and stability than new sand. Since it does not go through expansion during the pour, it delivers high surface finish and low porosity.

Why is thermal sand reclamation critical for high-quality steel casting?

Thermal systems eliminate or restrict the need for expensive structural components like chromite sand and zircon. This dramatically optimizes your long-term foundry sand preparation operational expenses.

Are thermal sand recovery plants environmentally compliant?

Yes. Because chemical binders are safely incinerated at high temperatures under control, the generation of odor and gas during pouring is minimized. This ensures easier environmental compliance and reduces landfill waste.

Does TES-SAN supply turnkey thermal sand recovery plants?

Yes. Founded in 1994 in Konya, TES-SAN manufactures comprehensive foundry equipment and automated Sand Recovery Systems within its 12,000 m² factory. From initial design to operator training, the lifecycle is managed under a single contract.

People Also Ask - PAA

When should foundries integrate a thermal reclaimer into their sand loops?

Thermal reclaimers should be integrated when dealing with high-specification automotive or defense castings where dimensional accuracy is vital, or when raw sand logistics and waste disposal costs create high financial burdens.

How do thermal sand reclaimers impact overall labor and finishing costs?

While initial capital investment is higher than mechanical alternatives, it lowers operational labor by reducing casting defects like burn-in. This leads to a substantial reduction in the welding, grinding, and cleaning phases of castings.

Why does thermal recycling solve gas permeability issues in green sand casting?

Since the resin layers around the sand grains are turned entirely to ash by high heat and evacuated through high-efficiency filter systems, no chemical blockades remain to generate gases during the mold pouring phase.