SAND,SANDADDITIVES,SAND

PROPERTIES,and

SAND

RECLAMATION
Prof.Dr.AltanTurkeli
MSE432
Foundry

Technology
SANDADDITIVES

Casting Sand
SAND(SiO2)
CLAYS(Bentonite..)
WATER
CELLULOSE(Wood

flour,Cob

flour..)
OILCHEMICALS(Sodaash,Polymers.)
REFRACTORIES(Alumina,Silica

flour)
SOLUBLES(Corn

flour,Corn

sugar)
Flow

Chart

ofaMetalCasting

System
SAND
SAND
Casting

Sands
Silica

Sands
Zircon
Olivine
Chromite
Aluminum

Silicates
Silica

Sands
Mostgreensandmoldsconsistofsilicasands

bondedwithabentonitewatermixture.(The

termgreenmeansthatthe

mold,whichis

temperedwithwater,isnotdriedorbaked.)

Thecomposition,size,sizedistribution,purity,

andshapeof

thesandareimportanttothe

successofthemold

makingoperation.
Sandsaresometimesreferredtoasnaturalor

synthetic.
Natural

or

Synthetic
Naturalsandscontainenoughnaturallyoccurringclays

thatthey

canbemixedwithwaterandusedforsand

molding.
Syntheticsandshavebeenwashedtoremoveclayand

other

impurities,carefullyscreenedandclassifiedto

giveadesiredsizedistribution,andthenreblended

withclaysandother

materialstoproducean

optimizedsandforthecastingbeingproduced.
Becauseofthedemandsofmodernhighpressure

moldingmachinesandthenecessitytoexerciseclose

controlovereveryaspectofcastingproduction,most

foundriesuse

only

synthetic

sands.
Composition
Foundrysandsarecomposedalmostentirely

ofsilica(SiO2)intheformofquartz.Some

impuritiesmay

bepresent,suchasilmenite

(FeOTiO2),magnetite(Fe3O4),orolivine,

whichiscomposedofmagnesiumandferrous

orthosilicate

[(Mg,Fe)SiO4].Silicasandisused

primarilybecauseitisreadilyavailableand

inexpensive.
Quartzundergoesaseriesofcrystallographic

transitionsasitisheated.Thefirst,at573C,

isaccompaniedby

expansion,whichcan

causemoldspalling.Above870C,quartz

transformstotridymite,andthesandmay

actuallycontractuponheating.Atstillhigher

temperatures(>1470C),tridymite

transformstocristobalite.
ShapeandDistributionofSandGrains
Thesize,sizedistribution,andshapeofthesand

grainsareimportantin

controllingthequalityofthe

mold.Mostmoldaggregatesaremixturesofnew

sandandreclaimedsand,whichcontain

notonly

reclaimedmoldingsandbutalsocoresands.In

determiningthesize,shape,anddistributionofthe

sandgrains,it

isimportanttorealizethatthegrain

shapecontributestotheamountofsandsurface

areaandthatthegrainsize

distributioncontrolsthe

permeabilityofthemold.
Asthesandsurfaceareaincreases,theamountofbonding

material(normallyclayandwater)mustincreaseifthesandis

tobeproperlybonded.Thus,achangeinsurfacearea,

perhapsduetoachangeinsandshapeorthepercentageof

core

sandbeingreclaimed,willresultinacorresponding

changeintheamountofbondrequired.
Roundedgrainshavealowsurfaceareatovolumeratioand

arethereforepreferredformakingcoresbecausethey

require

theleastamountofbinder.However,whentheyarerecycled

intothemoldingsandsystem,theirshapecanbea

disadvantageifthemoldingsystemnormallyusesahigh

percentageofclayandwatertofacilitaterapid,automatic

molding.Thisisbecauseroundedgrainsrequirelessbinder

thantherestofthesystemsand.
Angularsandshavethegreatestsurfacearea(exceptforsands

thatfractureeasilyandproducealargepercentageofsmall

grainsandfines)andthereforerequiremoremulling,bond,

andmoisture.Theangularityofasandincreaseswithuse

becausethesandisbrokendownbythermalandmechanical

shock.
Theporosityofthemoldcontrolsitspermeability,whichisthe

abilityofthemoldtoallowgasesgeneratedduring

pouringto

escapethroughthemold.Thehighestporositywillresultfrom

grainsthatareallapproximatelythesamesize.
Asthesizedistributionbroadens,therearemoregrainsthat

aresmallenoughtofillthespacesbetweenlargegrains.As

grainsbreakdownthroughrepeatedrecycling,therearemore

andmoreofthesmallergrains,andtheporosityofthemold

decreases.
However,iftheporosityofthemoldistoogreat,metalmay

penetratethesandgrainsandcauseaburnindefect.
Therefore,itisnecessarytobalancethebasesand

distributionandcontinuetoscreenthesandandusedust

collectors

duringrecyclingtoremovefinesandtodetermine

theproperbondaddition.
Most

foundries

intheUnitedStatesusethe

American

Foundrymens'Society(AFS)grainfinenessnumberasa

generalindicationofsandfineness.TheAFSgrain

fineness

numberofsandisapproximatelythenumberofopeningsper

inchofagivensievethatwouldjustpassthe

sampleifits

grainswereofuniformsize,thatis,theweightedaverageof

thesizesofgrainsinthesample.Itis

approximately

proportionaltothesurfaceareaperunitweightofsand

exclusiveofclay.
Zircon
Zirconiszirconiumsilicate(ZrSiO4).Itishighlyrefractoryand

possessesexcellentfoundrycharacteristics.Its

primary

advantagesareaverylowthermalexpansion,highthermal

conductivityandbulkdensity(whichgivesita

chillingrate

aboutfourtimesthatofquartz),andverylowreactivitywith

moltenmetal.Zirconrequireslessbinderthan

othersands

becauseitsgrainsarerounded.Theveryhighdimensional

andthermalstabilitiesexhibitedbyzirconarethe

reasonsitis

widelyusedinsteelfoundriesandinvestmentfoundries

makinghightemperaturealloycomponents.
Olivine
Olivineminerals(socalledbecauseoftheircharacteristic

greencolor)areasolidsolutionofforsterite

(Mg2SiO4)and

fayalite

(Fe2SiO4).Theirphysicalpropertiesvarywiththeir

chemicalcompositions;therefore,thecompositionofthe

olivineusedmustbespecifiedtocontrolthereproducibilityof

thesandmixture.Caremustbetakentocalcine

theolivine

sandbeforeusetodecomposetheserpentinecontent,which

containswater.
Thespecificheatofolivineissimilartothatofsilica,butits

thermalexpansionisfarless.Therefore,olivineis

usedfor

steelcastingtocontrolmolddimensions.Olivineissomewhat

lessdurablethansilica,anditisanangular

sand.
Chromite
Chromite

(FeCr2O4),ablack,angularsand,ishighlyrefractory

andchemicallyunreactive,andithasgoodthermal

stability

andexcellentchillingproperties.However,ithastwicethe

thermalexpansionofzirconsand,anditoften

contains

hydrousimpuritiesthatcausepinholing

andgasdefectsin

castings.Itisnecessarytospecifythecalciumoxide

(CaO)and

silicondioxide(SiO2)limitsinchromite

sandtoavoidsintering

reactionsandreactionswithmoltenmetalthat

cause

burnin.
Aluminum

Silicates
Aluminumsilicate(Al2SiO5)occursinthreecommonforms:

kyanite,sillimanite,andandalusite.Allbreakdownathigh

temperaturestoformmullite

andsilica.Therefore,aluminum

silicatesforfoundryuseareproducedbycalcining

these

minerals.Dependingonthesinteringcycle,thesilicamaybe

presentascristobalite

orasamorphoussilica.The

grainsare

highlyangular.Thesematerialshavehighrefractoriness,low

thermalexpansion,andhighresistancetothermal

shock.

Theyarewidelyusedinprecisioninvestmentfoundries,often

incombinationwithzircon.
Bulk

density

=The

mass

ofpowdered

or

granulated

solid

material

per

unit

ofvolume
SANDADDITIVES

Water
Water
H

2

0
SANDADDITIVES

Clays
Clays
Bentonite,Southern

(CaBentonite)
Bentonite,Western(NaBentonite)
Fireclay
KaolinClay
Themostcommonclaysusedinbondinggreensandmolds

arebentonites,whichareformsofmontmorillonite

or

hydratedaluminumsilicate.Montmorillonite

isbuiltupof

alternating

tetrahedra

ofsiliconatomssurroundedbyoxygen

atoms,andaluminumatomssurroundedbyoxygenatoms,as

showninFig.1.Thisisalayeredstructure,anditproduces

clayparticlesthatareflatplates.Waterisadsorbedonthe

surfacesoftheseplates,andthiscausesbentonite

toexpand

in

thepresenceofwaterandtocontractwhendried.
SANDADDITIVESClays
SANDADDITIVESClays
SANDADDITIVESClays
Fireclay
Fireclayconsistsessentiallyofkaolinite,ahydrousaluminum

silicatethatisusuallycombinedwithbentonites

inmolding

sand.Itishighlyrefractory,buthaslowplasticity.Itimproves

thehotstrengthofthemoldandallowsthewatercontent

to

bevariedovergreaterranges.Becauseofitshighhot

strengthpotential,itisusedforlargecastings.Itisalsoused

to

improvesieveanalysisbycreatingfineswheneverthe

systemdoesnothaveanoptimumwidesievedistributionof

the

basesand.However,becauseofitslowdurability,itsuse

isgenerallylimited.Inaddition,theneedforfireclaycan

usuallybeeliminatedthroughclosecontrolofsandmixesand

materials.
SANDADDITIVESClays
SANDADDITIVESClays
Sand

Properties
Green

Compression

Strength
Dry

Compression

Strength
HotCompression

Strength
Moisture

(water)
Permeability
Flowability
Refractoriness
Thermal

Stability
Collapsibility
Produces

good

casting

finish
Mold

Hardness
Deformation
Isreusable
Remove

heat

from

the

cooling

casting
GENERALPROPERTIESOFMOLDINGSANDS
Fromageneralviewpoint,themoldingsandmust

bereadilymoldableandproducedefectfree

castingsifitistoqualifyasagoodone.Certain

specificpropertieshavebeenidentified,and

testingproceduresadaptedfortheirquantitative

description.
TheAFS"FoundrySandHandbook"
1

setsforth

thestandardconditionsoftestingthesand

properties.Thosepropertiesofmostobvious

importanceinclude:
GENERALPROPERTIESOFMOLDINGSANDS
1.

Greenstrength.Thegreensand,afterwater

hasbeenmixedintoit,must

haveadequate

strengthandplasticityformakingandhandling

ofthemold.
2.

Drystrength.Asacastingispoured,sand

adjacenttothehotmetal

quicklylosesitswater

assteam.Thedrysandmusthavestrengthto

resisterosion,andalsothemetallostatic

pressureofthemoltenmetal,or

elsethemold

mayenlarge.
GENERALPROPERTIESOFMOLDINGSANDS
3.

Hotstrength.Afterthemoisturehasevaporated,

thesandmayberequiredtopossessstrengthat

someelevatedtemperature,above100
o
C.

Metallostatic

pressureoftheliquidmetalbearing

againstthemoldwalls

maycausemold

enlargement,orifthemetalisstillflowing,erosion,

cracks,

orbreakagemayoccurunlessthesand

possessesadequatehotstrength.
4.

Permeability.Heatfromthecastingcausesa

greensandmoldtoevolve

agreatdealofsteam

andothergases.Themoldmustbepermeable,i.e.

porous,topermitthegasestopassoff,orthe

castingwillcontaingasholes.
GENERALPROPERTIESOFMOLDINGSANDS
5.Thermalstability.Heatfromthecastingcauses

rapidexpansionofthe

sandsurfaceatthemold

metalinterface.Themoldsurfacemaythen

crack,buckle,orflakeoff(scab)unlessthemolding

sandisrelatively

stabledimensionallyunderrapid

heating.
6.Refractoriness.Higherpouringtemperatures,

suchasthoseforferrous

alloysat2400to3200F,

requiregreaterrefractorinessofthesand.Low

pouringtemperaturemetals,forexample,

aluminum,pouredat1300F,

donotrequireahigh

degreeofrefractorinessfromthesand.
GENERALPROPERTIESOFMOLDINGSANDS
7.

Flowability.Thesandshouldrespondtomolding

processes.
8.

Producesgoodcastingfinish.
9.

Collapsibility.Heatedsandwhichbecomeshardand

rocklikeisdifficult

toremovefromthecastingandmay

causethecontractingmetaltotear

orcrack.
10.

Isreusable.
11.

Offerseaseofsandpreparationandcontrol.
12.

Removesheatfromthecoolingcasting.
Thislistbynomeansincludesallthepropertieswhich

mightbedesirable.Obviously,themostimportant

characteristicofamoldingsandisthatitfacilitatethe

economicproductionofgoodcastings.
Sand

Properties
Sand

Properties
Sand

Properties
Sand

Properties
Sand

Properties
Sand

Properties
SANDADDITIVES
Clays
Water
Carbons
Cellulose
OilChemicals
Refrakteries
StarchesSolubles

(Niata)
SANDADDITIVES

Clays
Clays
Bentonite,Southern

(CaBentonite)
Bentonite,Western(NaBentonite)
Fireclay
KaolinClay
SANDADDITIVESClays
SANDADDITIVESClays
SANDADDITIVESClays
SANDADDITIVESClays
SANDADDITIVES

Water
Water
H

2

0
SANDADDITIVES

Carbons
Carbons
Asphalt
Gilsonite

(akind

ofasphalt)
Graphite
Lamp

Black

(lambaisi)
Lignite

(brown

coal)
Pitch,Coal

Tar(zift,kmrkatran)
Seacoal

(pulverized

coal)
Carbonisaddedtothemoldtoprovideareducingatmosphere

andagasfilmduring

pouringthatprotectsagainstoxidationof

themetalandreducesburnin.
Carboncanbeaddedintheformofseacoal

(finelyground

bituminouscoal),asphalt,gilsonite

(anaturallyoccurring

asphaltite),orproprietarypetroleumproducts.
Seacoal

changestocokeathightemperaturesexpandingthree

timesasitdoesso;thisactionfillsvoidsatthemold/metal

interface.Toomuchcarboninthemoldgivessmoke,fumes,and

gasdefects,andtheuseofasphaltproductsmustbe

controlled

closelybecausetheiroverusewaterproofsthesand.
Theadditionofcarbonaceousmaterialswillgiveimproved

surfacefinishtocastings.Bestresultsareachievedwithsuch

materialsasseacoal

andpitch,whichvolatilizeanddeposita

pyrolytic

(lustrous)carbonlayeronsandatthecasting

surface.
SANDADDITIVESCarbons
SANDADDITIVESCarbons
SANDADDITIVESCarbons
SANDADDITIVESCarbons
SANDADDITIVESCarbons
SANDADDITIVESCarbons
SANDADDITIVESCarbons
SANDADDITIVES

Cellulose
Cellulose
Cob

Flour

(msrunu)
Furfural

Residue

(liquid

aldehyde)
Oat

Hulls

(yulafkabuu)
Walnut

Shell

Flour

(eviz

kabuuunu)
Wood

Flour
Celluloseisaddedtocontrolsandexpansionandtobroaden

theallowablewatercontentrange.Itisusuallyaddedinthe

formofwoodflour,ornut

shells.
Cellulosereduceshotcompressivestrengthandprovidesgood

collapsibility,thusimprovingshakeout.
Athightemperatures,itformssoot(anamorphousformof

carbon),which

depositsatthemold/metalinterfaceand

resistswettingbymetalorslags.
Italsoimprovestheflowability

ofthesand

duringmolding.

Excessiveamountsgeneratesmokeandfumesandcancause

gasdefects.Inaddition,ifpresentwhenthe

claycontentdrops

toolow,defectssuchascuts,washes,andmoldinclusionswill

occurinthecastings.
SANDADDITIVESCellulose
SANDADDITIVESCellulose
SANDADDITIVESCellulose
SANDADDITIVESCellulose
SANDADDITIVESCellulose
SANDADDITIVES

OilsChemicals
OilsChemicals
Asphalt

Emulsion
Asphaltic

Oils
Kerosene

(gazya)
SodaAsh
Wetting

Agent
SANDADDITIVESOilsChemicals
SANDADDITIVESOilsChemicals
SANDADDITIVESOilsChemicals
SANDADDITIVESOilsChemicals
SANDADDITIVESOilsChemicals
SANDADDITIVESOilsChemicals
SANDADDITIVES

Refractories(otherthanclays)
Refractories(otherthanclays)
Alumina
ChromiteFlour
FlyAsh
IronOxide
OlivineFlour
SilicaFlour
StauroliteFlour
ZirconFlour
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVES

StarchesSolubles(Cereals)
Solubles
BranFlour(kepekunu)
BritishGum
CornFlour
Dextrin
LigninSulfate
Molasses(pekmez melas)
SodiumSilicate
WheatFlour
Theyincludecornflour,dextrine,andotherstarches,are

adhesivewhenwettedandthereforeactasabinder.
Theystiffenthesandandimproveitsabilitytodrawdeep

pockets.However,useofcerealsmakesshakeoutmore

difficult,andexcessivequantitiesmakethesandtoughand

cancausethesandtoformballsinthemuller.Because

cereals

arevolatile,theycancausegasdefectsincastingsif

usedimproperly.
SANDADDITIVESStarchesSolubles
SANDADDITIVESStarchesSolubles
SANDADDITIVESStarchesSolubles
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESRefractories(otherthanclays)
SANDADDITIVESStarchesSolubles
SANDADDITIVESStarchesSolubles
SANDADDITIVESStarchesSolubles
SandReclamation
Theeconomicsofafoundryoperationrequire

sandreclamationtoreducethecosts

associatedwithnewsandandthecosts

of

landfilluse,andtoreducetheproblems

associatedwiththecontrolof

environmentallyundesirablecontaminantsin

the

discardedsand.
Inaddition,tangibleoperationaladvantagesresultfromsand

reclamation.Thesebeginwiththeabilitytoselectthebest

sandforthecastingprocess,knowingthatmostofitwillbe

reclaimedduringoperation.Inaddition,theuseofreclaimed

sandreducesthenumberofvariablesthatmustbecontrolled,

andprovidesoperationalconsistencyoveraperiodoftime.
Sandgrainshapeanddistributionandbindersystembonding

aremoreuniform,thusreducingsanddefects.Aproperly

designedsandreclamationsystembeginswithgreensandand

convertsittoaproductverysimilartonewsand.Figure5

showstheappearanceofsandbeforecasting,aftermolding,

andafterreclamation.
Sandreclamationbeginswiththeremovaloftrampand

foreignmaterials,suchascorerods,metalspills,slag,and

paper,

andthedisintegrationoflumpsofsand.Thenorganic

andinorganicbindersareremovedbyattrition(scrubbing)

and/or

thermalmethods.Deadclayisremovedasfines.The

sandisthenbroughtuptospecificationbytheadditionof

newsand,

clay,andothersandadditives.
Sandreclamationsystemsmustbeselectedwithregardto

theircost,thespecificationsforthesystemsand,system

capacity,compatibilitywiththesandsystem,metalbeing

poured,andcoremixesbeingused.Itisimportantforthe

foundrytohaveaclearunderstandingofitsneedsinsand

reclamationbeforecallinginvendors.Avarietyof

reclamation

systemsaredescribedbelow.
WetWashing/Scrubbing
Thecoresoflargecastingscanberemovedbyhighvelocity

jetsofwater.Intheprocess,

thecoresarebrokendowninto

grains,andsomebinderisremoved.Excessmoldingsandcan

beaddedandwashed

simultaneously.Iftheshakeoutsystem

isdry,thesandischargedintoanagitatorsystemwherethe

solidcontentisheld

between25and35%.Excessmolding

sandmaybeblendedwiththecoreknockoutmaterial.A

similarsystemuses

intensivescrubbingwithasolidscontent

of75to80%andunitsinseries.
Thislattermethodissuperiorbecauseofcloser

andmore

frequentgraintograincontact.Afterwashing,thesandis

classifiedandmaybeusedeitherwet(naturally

drainedto4to

5%moisture)andaddedtoasystemsand,driedforcores,or

usedforfacingsand.
Facingsandmixes

derivetheirnamefromthefactthatthey

areusedinlimitedquantitiesagainstthefaceofthepatternor

corebox.

They

havepropertiesusuallydifferentfromthoseof

thebackuporsystemsandandcontainadditivesnototherwise

present.

Facingsandsaredesignedtoperformspecial

functions,suchasprovidinghighergreenstrengthforlifting

deeppockets,

higherdeformationforlimiteddraftpatterns,

andspecialcarbonsthatenhanceskindrying.
Thewetsystemhaslimitationsinthatonlyaportionofthe

binder,clay,andcarbonisremoved.Theproduct,however,

isexcellentforuseasamakeupsandinsystems.
DryScrubbing/Attrition
Thismethodiswidelyused,andthereisalargevarietyof

equipmentavailableinprice

rangesandcapacitiesadaptable

tomostbindersystemsandfoundrycapacities.Dryscrubbing

maybedividedinto

pneumatic,mechanical,andcombined

thermalcalcining/thermaldryscrubbingsystems
Inpneumaticscrubbing
Inpneumaticscrubbing,grainsofsandareagitatedin

streamsofairnormallyconfinedinverticalsteeltubescalled

cells.Thegrainsofsandarepropelledupwardandruband

impacteachother,thusremovingthebinder.Insome

systems,

grainsareimpactedagainstasteeltarget.Banksof

tubesmaybeuseddependingoncapacityanddegreeof

cleanliness

desired.Retentiontimecanberegulated,and

finesareremovedthroughdustcollectors.
Inmechanicalscrubbing
Inmechanicalscrubbing,theequipmentavailableoffers

foundrymenanumberoftechniquesforconsideration.An

impellermaybeusedtoacceleratethesandgrainsata

controlledvelocityinahorizontalorverticalplaneagainsta

metal

plate.Thesandgrainsimpacteachotherandmetal

targets,therebyremovingthebinder.Thespeedofrotation

hassome

controlonimpactenergy.Thebinderandfinesare

removedbyexhaustsystems,andscreenanalysisis

controlledbyair

gatesand/orairwashseparators.
ThermalCalcining/ThermalDry

ScrubbingCombinations
Thesesystemsofferthebestreclamationforthe

organicand

claybondedsystems.Grainsurfacesarenotsmooth;they

havenumerouscrevicesandindentations.The

applicationof

heatwithsufficientoxygenoxidizesthebindersorburns

themoff.Inattrition,onlybecausethereisno

contactinthe

crevices,thebinderremains.Heatoffersthesimplestmethod

ofreducingtheencrustedgrainsofmolding

sandtopure

grains.Bothhorizontalandverticalrotarykilnandfluidized

bedsystemsareavailable.
Inthehorizontalrotarykiln,materialisfedintooneend

(usuallythecoldone)andmovedprogressivelythroughthe

heat

zonebyrotationassistedbybaffles,flights,orother

mechanicalmeans.Somemechanicalscrubbingalsooccurs.

Some

systemsincorporateheatexchangertechnologyto

considerablyreducetheenergyrequired.Thelatest

technologyalso

includesprovisionforrecoveryofmetal

entrainedinthesandandcollectionanddetoxificationofthe

processwastesfor

suitablenonhazardouswastedisposal.
Severalfluidizedbedsystemdesignsareavailable.Someuse

preheatingchambersandhotairrecuperation.Adrying

compartmentmayalsobeadded.Sandisintroducedintothe

top(preheating)chamberofthereactorandisliftedbythe

hotairstreamfrombelowuntilitassumessomeofthe

characteristicsofafluid.Thehotaircomingincontactwith

the

sandgrainsburnstheorganicsandcalcinestheclay.At

thesametime,someattritiontakesplace.Acorrectpressure

differentialmustbemaintainedbetweenthecompartmentsif

morethanoneisusedinordertoensuredownwardflowof

sand;otherwisegravityflowmustbeprovided.Fluidizingisa

verygoodmethodforcoolingsandwhenusingcoolair.
MultipleHearthFurnace/Vertical

ShaftFurnace
Themultiplehearthfurnaceconsistsofcircularrefractory

hearthsplacedoneabovetheotherandenclosedina

refractorylinedsteelshell.Averticalrotatingshaftthrough

the

centerofthefurnaceisequippedwithaircooledalloy

armscontainingrabbleblades(plows)thatstirthesandand

move

itinaspiralpathacrosseachhearth.Alternatehearths

are"in"or"out."Thatis,sandisrepeatedlymovedoutward

from

thecenterofagivenhearthtotheperiphery,whereit

dropsthroughholestothenexthearth.Thisactiongives

excellent

contactbetweensandgrainsandtheheatedgases.
Materialisfedintothetopofthefurnace.Itmakesitswayto

the

bottominazigzagfashion,whilethehotgasesrise

counter

currently,burningtheorganicmaterialandcalcining

clay,if

oneorbotharepresent.Dischargecanbedirectly

fromthebottomhearthintoatubecooler,orothercooling

methods

maybeusedTheunitsarebestsuitedtolarge

tonnages,thatis,fivetonsormore.Theyareextremely

ruggedand

relativelymaintenancefree.
Combinationsofsystems
Combinationsofsystemsmayalsobeused,

forexample,thermalmethodsfollowedbydry

attritionscrubtoremove

calcinedclayfrom

moldingsandorundesirablechemicalsand

oxidesfromcoreprocesses.Also,commercial

centersfor

sandreclamationareinoperation

andmaybeusedbysmallerfoundries.