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Cincinnati, OH, United States

Piccone T.J.,United States Steel Corporation | McClymonds M.,S and B Industrial Minerals | Hashimoto K.H.,S and B Industrial Minerals
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2013

The effect of hydrogen in liquid steel on mold heat transfer at the Rounds Caster at United States Steel Corporation's Fairfield Works was investigated. The results were examined for periods of constant casting speed by grade. Mold heat removal rate was plotted against measured hydrogen concentration for different grades at various casting speeds. It was found that there was no obvious effect of hydrogen on heat removal, unlike the results of prior slab caster studies. The difference between the rounds and slab casters is thought to be related to differences in the compositions and properties of the mold fluxes used. Source


Grefhorst C.,S and B Industrial Minerals | Podobed O.,S and B Industrial Minerals | Lafay V.,S and B Industrial Minerals | Tilch W.,Technische University
China Foundry | Year: 2010

This paper describes the development of an inorganic alternative to coal or coal replacement for bentonite bonded molds (greensand molding) and the realization in an operating foundry. Through a time period of 1.5 years, Componenta Foundry changed in many steps from a classical green sand system to a coal free system, based on ENVIBOND ® developed in the GO-APIC project and further development as an S&B project. At Componenta Foundry, the percentage of casting defects or scrap did not increase. There was a tendency of an increase in stress (scabbing) defects and of a decrease in penetration defects. Benzene emission is reduced by 40%, odor emission has lower values (not statistically proven). Visible is less smoke in the foundry, especially at the cooling line. The benefits for health and emissions are clearly seen. Source


Grefhorst C.,S and B Industrial Minerals | Podobed O.,S and B Industrial Minerals | Lafay V.,S and B Industrial Minerals | Tilch W.,TU Bergakademie Freiberg
Zhuzao/Foundry | Year: 2010

This paper describes the development of an inorganic alternative to coal or coal replacement for bentonite bonded molds (greensand molding) and the realization in an operating foundry. The result show that the coal free green sand system was adopted, and this contributes to rawmaterial, waste, energy reduction and improvement of working and environmental situations. Source


Grefhorst C.,S and B Industrial Minerals | Bohnke S.,S and B Industrial Minerals | LaFay V.,S and B Industrial Minerals | Richardson N.,S and B Industrial Minerals
71st World Foundry Congress: Advanced Sustainable Foundry, WFC 2014 | Year: 2014

High casting quality demand, larger parts, thinner parts, more cores and higher productivity have made greensand casting process complex and increased greensand requirements. To meet today's requirements bentonite must be fast in preparation (muller / mixer), durable (low consumption), apply high green- and hot strength (no broken molds) and good mold break down (shake out) after casting. Each foundry installation and process is different so there is not one excellent bentonite for all foundries. Bentonite, possible modification and additives must be customized. Bentonite is a very complex mineral and the relationship between compositions and binding properties is not always a scientific explanation. At the end of a day suppliers and foundries are interested in molding properties. Bentonites are as different as foundry requirements and by blending bentonite often a good composition can be created. Often blending bentonites is not economic for logistical reasons and bentonites can be modified to achieve better foundry performance. The modification can be completed during bentonite processing or/and by blending / addition of other products. We diversify between blending in additives and bentonite modification, what means there is an impact on the bentonite structure. Modified bentonite can provide improved dispersability, flowability, higher green- and hot strength, less requirement of coal addition and lower bentonite consumption. These effects contribute to sustainable production in terms of casting quality, low consumption and less impact on environment. Copyright 2014 World Foundry Organization. Source


LaFay V.,S and B Industrial Minerals | Grefhorst C.,S and B Industrial Minerals | Richardson N.,S and B Industrial Minerals | Pine M.,S and B Industrial Minerals | And 2 more authors.
71st World Foundry Congress: Advanced Sustainable Foundry, WFC 2014 | Year: 2014

Today's era of ever tightening environmental regulations governing air quality and foundry waste management coupled with increasing raw material prices, transportation, and disposal costs present a challenging obsticle for the future of the metalcasting industry. There is a strong, new movement in foundry management that values sustainablity and material recovery from waste streams. These foundry waste streams still contain viable elements that are lost among the other undesired constituents. A new and innovative process aims to eliminate and aleve these environmental pressures to increase foundry efficiencies, reduce waste, and the costs associated with disposal without sacrificing casting quality. The waste materials from foundry green sand systems can now be turned into a valuable new resource. This innovative new process recovers the bentonite, carbons, and bonded green sand from the waste streams of a foundry and makes them available for reintroduction. All can be made available to improve molding sand properties and improve molding sand performance. The reintroduced bentonite and carbon can replace an equivalent or more of powder bond added to a foundry green sand system. The bentonite exhibits improved molding sand properties because the wet bentonite recovered has an excellent dispersibility. The bonded molding sand grains are provided with a uniform layer of binder and organics that result in an improved casting surface quality. This dispersion results in outstanding mold compaction and shape stability of the prepared molds. The packing density and mold strength are kept at a uniformly high level. Even complex contours with high mold shape can be improved resulting in scrap reduction and improved casting efficiency. Copyright 2014 World Foundry Organization. Source

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