CA2121047C

CA2121047C - Heat treatment of metal castings and in-furnace sand reclamation

Info

Publication number: CA2121047C
Application number: CA002121047A
Authority: CA
Inventors: Scott P. Crafton
Original assignee: Consolidated Engineering Co Inc
Current assignee: Consolidated Engineering Co Inc
Priority date: 1992-08-13
Filing date: 1993-01-27
Publication date: 1998-01-06
Anticipated expiration: 2013-01-27
Also published as: BR9305607A; ES2114039T3; AU3594693A; AU677774B2; EP0612276B1; CA2121047A1; KR100263975B1; EP0612276A1; ES2114039T5; JP2849213B2; EP0612276B2; CN1097662A; JPH11129055A; EP0612276A4; CN1090066C; DE69318000T2; WO1994004297A1; JPH07506299A; DE69318000D1; MX9302659A

Abstract

32 The method and apparatus for reclaiming substantially pure sand from a heat treating furnace (19); wherein a casting with sand core and/or sand mold, comprising sand bound by a combustible binder, attached thereto is introduced into the heat treating furnace (19); or, wherein portions of sand core and/or sand mold that are not attached to a casting are introduced into the heat treating furnace (19). Wherein, the reclaiming within the furnace (19) is carried out, in part, by a fluidizer (40) that promotes binder combustion by one or more process of agitating, heating, and oxygenating. Wherein the characteristics of the reclaimed sand (25) are selectively controlled by controlling the dwell time of the sand (25) within the heat treating furnace (19).

Description

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IIEA'I' l'llEA'rMEiJ'r OF ME'r1\1, CASTINGS AND IN-FUi~N/I~CE S~\ND
n EC L~MI~` 1 ON
: , . ~ `:, : -CROSS-REFEI~ENCES To RELA~l~ED APPLIcA~rIoNs Tl~ l s appllcatlon I R a cont3~ atlorl-ln-part oE
ai~pllcatloll Serial No. 07/705,626, f3.1ed May 24, 1991. ~;.. 1~ .:
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i3ACKGllOUlJD OF TIIE INVENTlON . .;:
'I'lle E~resent Invelltioll relates general.3y to tlle llel~l of lleat treatlny metal castlngs and tlle fleld of eeclalmlllg sand from sancl cores and sand mo).ds used to ;.
m~ke metal cast3ngs.
Generally, prlor art metllods and apparatus requlre .:. ~ :
30 tllat t:~lo or tllree dlst31lctly separate steps be taken ir~
order to lleat treat a metal castlng formed by a ;.
perlllallellt mold or sand mold wltll a sand core, and reclalm sufflc3.ellLIy p~lre sand from tlle sand mold or ~ :
sand core. ~I~lle ~resent 3nvelltioll allows for lleat - ~ ~

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t~:eatll~g and reclamatloll o~ sllf~lc le~ y ~ure sal7d 3.,l a single step.
lletllocls anc3 appara-us Eor man~lEactur3ng metal. `
castirlgs are ~ell kno~ Molds an(l cores are used to 5 dlsE)lace mol~ell mater3al so tllat wllell tlle moIten mater1al ls solicli~ied, a cas~ll)g Is formed î;llat ~:~
L~etlects tlle ~ea~nres oE tlle moîd allcl core. Molds llave ~ ~.
tl~e exterlor rea~ures o~ tlle castlng ~ormed on tl)e lnterlor walls of tlle mold and cores llave tlle Inter30r features of tlle castlng formed on tl)e exterlor surEace ..
of tlle core. Ille cores are typ3.cal1y ma(ie from san(3 ~.
wllereas tlle mok3s are somet1mes mac3e Erom sand. Sand nol(ls and cores are typlcall.y pre-mo1(1ed from a ml.xture :
of sand and a combtlstlbIe bIllder. For sImplIcIty, sand 15 mokls and san(l cores are referred to llereafl:er as slmL)ly sand cores. : .;.;
ln accordallce ~ltll some of tlle pr30r art, once tlle castlng 3.s formed, Lllree dlstlllctly dlfferent steps are carrled out ln order to lleat treat tlle metaI castlng 20 and reclaIm suffIcIently pure san(3 from tlle sand core.
'l'l)e flrst step separates portlons of sarld core from tl)e castlng. 'rhe san(i core ls typlcally separated from tlle cast1ng by one or a comb1nat10ll of mealls. For examp1e, sand may be clllseIed away from tl)e cast1ng or tlle 25 castlng may be pllys1cally sllaken to break-up tl)e sand core ancl remove tlle sand. Once î:lle sand ls removed lirom tlle castlng, tlle second anc3 tlllrd steps are casrled out. In tl)ls typlcal, tllree-step prlor art, tlle order ln wll1cl~ tlle second and tll3rd steps are takell ~

3() ls not 3niportal)t, s1nce tlle sand has already been ~-seE)arated from tlle cast3ng. 'I`lle second step conslsts oE lleat treatlng tlle castIng. 'I`lle castlng 3.s typlcally lleat treated lf it ls deslrable to strengtllen or harderl .~ .
tlle castlng. rl~e tllIrd step consIsts of purlfylng tlle 35 sancl tllat ~as seE)arated ~rom tlle castlng. l~lle 2 ~ 7 purlrlcatlon processes 3s typlcally carrled out ~y one or a comblnatioll oE means. ~ ese may 1nc1ude burnillg tlle l)lnder tllat coats tlle sancl abrading tlle sand and passlng portiolls oE tlle sand tllrougll screens. lt ls 5 lmportant tllat ~lle reclaimed .sand be sufflc1el-t1y pure in or(3er ~or It to l~e properly reused 1ll tlle constructloll oE new san(l cores. It Is also llelpflll If tl~e r.ec.lalmecl sar~d ls roullclecl at least: to some (Jegree so as to asslst .In ~lle castll~g of smootll surfaces and 10 to asslst ln good bondlllg of tlie sand gra1ns w1l1ch causes strong cores. 'I'l~erefore portlons oE salld may ~
be re-subJected to reclalmlng processes unt11 ~ :
suE3.clently pure san(J 3s reclalmed.
'I'lle purlty of tl~e reclalllled sand can be measured ~n .`~
lS terms of tl~e gualltlty oE ullbllrned blnder. ~ e less unl)urrled blnder tl~e more pure tlle sand. Wlli1e seeklllg .: .;;
lncreased pur1ty some sand Is reduced to "E1nes". ; ~:-`
Flnes l.s tlle term used for sand partlcles sma11er tl~an a speclfl.ed slze. Flnes are so small tllat tlley requlre 20 excess1ve amo~lllts of blnder. l'llese two measures .
(pllrll:y and El.nes) generally oppose each otller 1n tllat tlle Illgller tlle meastlre oE one tlle lower tlle measure of t:lle otller. It ls lmportant to balance tllese measures;
tllereEore lt ls lmportallt tllat tlle sand reclalmSng :.
25 processes be capable oE controll1ng tllese measures.
In accordance wltll the present Inventor's prev1Ous ~ :
invellt.lon dlsclosure of U.S. appllcatlon Serlal No. .
07/705 626 only one step need be taken ln order to Ileat treat metal castlngs formed by sand cores and 30 recla1m sand from l:lle sand cores. 'I'llls ls carrled out by lntrodllclllg tlle castlngs wltll tlle sand cores ~ ~ -attaclled thereto illtO a furnace witll an oxygenated atmospllere tllal: ls lleated l:o al: least tlle combllst1Orl ~ ~:
temperatllre oE tlle sand core blnder materlal. 'I`llls 3S causes combustion of some of tlle b1nder of ~lle sand . .

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core ~ icl~ comL7inatlon witll otller means ca~ses tlle sand core to seE7arate rrom tl)e castlrlg ~ e system d1sclosecl ln appllcatloll Serlal rlO. 07/705 626 promoles more blrlder com~7lls~1OIl ~llal) ls req~llred to separate tl~e ~ -5 sal~d core Erom tlle castlr1g. 'I`l~e systen~ dlsclosed 11l appllcatlon Serial No. 07/7~)5,626 ejects sand Erom tl~e fllrl1ace In a stlEllclel~tly i)tlre sLate ror some `' ~ ~ ' applications; l~lt, tl~at system ls I~Ot capat>le of comb~lsLlng a stlEllclellt amol~llt oL bll~der (or otller~lse 10 processlng tlle sand core) so as to rencier sand l:l~at ls suEElcielltIy pure for certalll o~ller appllcatlons ~Iso, tl~at system cloes I~Ot make provlslons for varylng ~-tl~e cl~aracterlstics of tl~e reclalmed sand; no selective control over san~l roul~dl~ess amount of flnes, or amoul~t of unburlled 171llcler ln tl~e reclalmecl sand ls posslble. ~' rl'llerefore, tlle sand reclalmed using tlle metl~od and apparatus dlsclosed ln appllcatlon Serlal No.
07~705,626 may req~llre fllrtl~er processlng In order to obtaln salld tl~at ls sllEElclelltly pure for certaln appllcatlons or sal1cl llat llas certaln cllaracterlstlcs.
'l'llereEore, prevlous sand reclalmlllg systems are llll~erently lnefEiclellt In tllat tl~ey requlre at least a two step process, carrled o~t ln two separate venues ~y separate speclallzed eg~llpmel1t, 11~ orc3er to l~eat t:reat a mel:al castll~g formed ~7y a sal1d core and reclalm ~`
s~lE~3clelltly p~re sancl from tlle sal~d core Tllere ls a l~eec3, tl~ereEore, Eor a more efElclent metl~od, and assoclated apE7aratus, tl~at allows Eor more efflclellt l~ea- treatmerlt, sand core removal, arld' ~ `
reclamatlol1 oE suEficien~ly pure sal1d from tl~e sanc3 core sullMl~ny - OE TIIE IilVE~ N
srleEly clescribe~l tlle presel~t ll~vel~tlon provldes an lmproved metllocl al~cl apparatus for lleat treatlng -- 2 ~ ~ ~ o L~ 7 metal castIngs tl~at are manufactured usIng sand cores and for reclaimillg salld irom ~l~e sand cores. More speclflcally tlle presellt lllventloll provldes an lmproved metllo~ arld apparatlls for coI~.ecting san~
wltl~ln a l~eat treatll~g Eurl~ace purlEyillg tlle sand and `'"Yi~
e)ecting tlle sand from ~lle furllace. 'I'lle presel~t :.
ll~vel~Llon cal~ reclalm sand tl~at ls more pure tllan tllat typically extracLe(J from lleat t.reatillg furnaces. 'I'l~e metllod arld aE~paratus o~ tlle I~resellt illve~ lon also alIo~s lor selectlve colltrol over tl~e amount of bl.nder ~
and filles 1n ~lle salld e)ected frolll tlle furllace.
'I'lle preferred embo(lilllent of tlle presellt lnventlor lncllldes assoclated witll a fur~lace apparatus for . .
agltatlng sand -llicll llas beell collected witl~3n tlle furnace. In tl~e preferred embodimerlt tllls agltatlor apparatus utillzes E-ressurlze(l air to accompIi.sl~ the ` `~
agltatll~g ful~ction tllrougl~ a process oE "Eluldlzatlorl" ;~;
arlcl sllall be reterred l:o llerelll as a fluldlzer. ~rl~15 fluldlzatlon E~rocess passes alr from a pressurlzed source tllrougll sand collected ln tlle Furllace causlng portlorls of tlle salld to be suspellded an(3 act 11ke a ' .
turbulellt 1uld. 'I~lle fluldizer ln con'iullctl.on wll~
otller componel~ts lrl tlle Eurnace causes tlle blnder portlon of sand cores to sufflclently combu9t wll:l~ln tlle ~url~ace so tllat s~lEElcl.elltly ~ure sand ls reclaJ.med. lll tllls embodlmellt tlle sand cores from wlllcll iblllder is comi~usted are attaclled to tlle castlrlgs tllat are trallsE-orted lnto tlle furnace. 1~ preferred ` ~;
furllace embodllllent alld some of tlle elemellts wltllln the ~urllace are clisclosed lrl appllcation Serial No. : .~
07/705 626. 'I'lle Eluidlzer al~d some oE (:lle elemellts ~` ``
assoclated witll it are dlsclosed for tlle f.lrst l:~.me Ir tllls appllcatlorl.
~ e Elul<lizer oE tlle prelerred enll~oclllllent of tlle preserlt Irlvelltiorl causes tlle El-lldlzatlorl of sand tllat .;.;,. ~ ,;, L'~

.. .~ 6 llas collec~ed t/iLllin tlle Eurllace llopper. Ille f1ulcliz1ng causes portions of sancl ~o al)rac~e agalnst one anotller allcl 1n at least orle em~ocl3merlt to also abrade agalnst a metal targel 311 a mallller tilat e~tposes tlle l)lnder. I~lle exposed blnder tllen cc)ml~usts. Ille process ls repeal:ed ulltll a sufEiciellt amollnt oE l~.lncler llas l~eel~ coml)~lst ed ~o sat i s ry tlle user as to tlle pllr3 ty : : .
o f t ll e s a nd .
In tlIe preferred eml~odJIllellt of tlle present lnvenl:1Orl tlle fIul-llzer adds oxygen ~o tlle Eurllace :
l~op p er so as to promote l)i ncler coml)ust1OIl . In one preferred emL~o(lilllellt of tlle presellt invelltl.oll tlle .
f 1uldlzer ls s~lpE~lle(l ~Jltll prelleated alr from a secondary ~leat source so as to furL~Ier promote binder combu s t 1 OIl ~ I n a n a 1 te rna te p re f e r r ed embod 1men t, t lle alr of tlle Eluldi.zer 1s not pre- lleated. In accordance w1tlI one aspect of tlle present 1nvenLlon, mu1t1p1e f.luldlzers are employed and 1n sucll emL~od1merlt : ~:
appropl l.ate f luiclizer emt~od3lllents are cllosen and selectlvel.y placed along a mult3.~ 1e zone~i furnace. : `
l`lle present lnvent1On Eurtller 1ncludes metllods and apparatus for dlscl~arging reclalmed sand from tlle :.
furnace. In tl~e preterred embod~ ent of tlle present .
Invelltlon, tl~1s dlscllarglng 1s control led so as to control tl~e volume of sand contallIed 1n tl~e furnace. . :
Il~1s afEects l:lle amount of t1me tl~at sand ls sul~)ected : :
to l~lle fluldlzlng tlllls effect3ng a control over tl~e ~ ..
cllaracterlst1cs of tlle recla1mecl sand.
~n alternaLe emL)odl.lllellt of Llle present 1nvellt1 30 1nclucles a supE)lelllerltal sand reclamatlon un1t ( tlle SSRU ). Tl~e supplelllelltal sand rec.l.amat1On unlt, wlllcl fllnct1OIls ln con)llllctlo~ 1l tlle f~lrnace lleat source and ln con~unct~oll W1~1l tl~e f1u1dlzer ancl otl~er compolIellts ln tlle furllace provl.cles su~p1elllelItal 3S reclamatJon of sand l-rev3OIlsly recla3me(3 from casl:1.ng 2~
.

cores For ex~mple sarld collected from prlor art sl)akers and sancl discllarged Erom l~e trouglls of tlle furnace of serial nullll>er 07/705 626 is reprocessed ~y tlle stlpplemental san(i reclamatlorl Ulllt. 'I`lle ~ ' `~'':
s~lpplenlellta1 san(l reclamatloll un1t lnclllcies a b3n tllat Is o~ltslde oE tlle f~lrnace r~ tllbe ls connected to a t,i,~ oullet al~(J i~asses ill-o Ll~e turl~ace Ille tut)e passes t 1tllin tlie furnace~ ln close proxlmlty to ~;
furl ace l~eaters al~d termlnates tot/ard ~lle lurl)ace llopper CollecLecl sal~ci Is deposlted ll~to ~l~e ~ln wllere It is l~eatecl ~o al~ove tl~e i~lncier coml~lls~lon temperatllre anci exposed ~o an oxygen-rlcl~ atmospl~ere; tll1s causes an 1n1t1al blnder comi~ustlon Ille sand tllell enters tlle tul~e Wll11e passlng tllrollgll tlle tul)e tlle sand ls lleated by tlle fllrnace lleaters and furtller binder combustlorl occurs Wllell tlle sand exlts tlle tul~e lt ~alls Into tl~e furrlace wllere lt Is preferably, furtl~er ` `
purlLled by lle 1n-Eurrlace sand rec1amatlon unlt of tl~e E~ r e s e 11 t i n V e ll t l o ll .
It ls tllerefore an obJect of tlle present Invelltioll to provide an Improved metllod and apparatus ~ `~
for lleat treat1ng castlngs W1~1l san(l core materIa1 a~taclled tl~ereto and rec1alm1ng sand from tlle sand ! :, core materlal 1~llotller o~Ject of tlle present lnvent1OIl ls to provkle an ImE)roved me~llod and apparatlls for removlllg sand core material Erom a castlng an<i rec1almlrl9 sand ~rom tlle san(l core materlal Anotller object of llle present lnventloll ls to provlde a metllo~l and apparatlls for recIaIming wltll~n a Eurrlace san(l from portlons oE sand core tllat are separated Erom castIngs wltllIn tlle f~lrllace Allotller oL~3ect of tlle present lnvellt~oll 1s to provlde a metllod and apparattls ~or ag1tatlng wltl~1n a f~lrnace sand ~l~at Is collected ~lltl~ e Eurllace 2 ~

.
/\notller ob ject of ~lle present lnventiorl Is to prov3de a metllod alld apparatlls for fluldl.zlrlg, wltlllrl A ::
furl~ace, sand Ll~at ls col lected ~ltl~ln tl~e fur~lace . : ;
Allotller ob ject of lle present ~ nventloll ls to ~ .
S provlde a metllocl and apparatus for enllancing : ~:
combustioll, wlt.illll a lleat treatlng furr~ace, oE blrlder tllat coats sand Ll~at Is collec~ed ln tl~e furllace. -~
Allotller ob~ect of tl~e present lrlvelltlon is to provkle a metl~od al~d apparatus for lleatlng, from a 1~ secondal.y source, sanl3 tllat ls col lected wltl~ln a r l~ace . .
t~notller ob lect of tlle present I nverltion ls to provkle a metllo(l and apparatus for provldlng oxygen to :
tlle area ln wlllcll sand ls collected wltllln a furllace.
rlllotller ob ject ol tlle preserlt lnventlorl ls to provlde a metllod and apparatus for rec.lalml.ng sand outslde of tlle Lurllace, and purlfylng tlle reclalmed salld ~lltllln a Eurnace.
Yet anotller obJect of tlle present lrlventlon ls to 2~ provl~le a metllod and apparatus for controlllrlg the amoullt oE tlme tllat sand core materlal ls exposed to sarld reclamatlorl processlllg wltllln a furrlace so tilat tlle cl~aracterlstlcs o~ tl~e reclalmed sand can be control led .
Otller ob~ects, ~eatures arld aclvantages of t)le present lnventlorl wlll become apparent uE~on readlng and understarldlrlg tllls speclflcatloll, taken ln con~(lrlctlon wltll tlle accom~)allylllg drawlllgs ~ONFIO~NTI~l 3() l~RIEF DESCRIPTION OF 'I'IIE DRAWINGS
F`lg. 1 ls a cut-away vlew of a coml~lnatlon lleat treatlng furnace and ln--furrlace sand reclamatloll unlt, 11l accordance witll tlle preferred embodllnel~t of tl~e ~resel~t Invellti01~.

Flg. 2 is a cut-away vlew of selected e1ements of Llle san(3 reclamation unit of Flg. l.
Fig. 3 ls a cut-a--ay top vlew of selected e1ements of tl~e sand reclamaLlon ulllt of Flg. 1, sllo~,-lng some of tl~e e1em2nts (:llat are cut-atlay In FIg. 1.
Fig. 4 Is a cut-away tol~ vie-~ of selected elements of tlle sand reclamatloll unlt oE ~Jg. 1, sllowlng some of tlle elements tllat are cut-a~ay In Flg. l. ;~
Flg. 5 ls a cut-a--ay slde vlew of tlle dlscl)arge -~
valve assembly of Flg. l.
Flg. 6 ls a cut-away top vlew of a portlon of an `;
lll-furl)ace sand reclamat10ll unit, ln accordance wltll an alterllate, preferred emt)odIlnellt of tlle present lnventlon.
Flg. 7 Is a cut-a~ay slde vlew oE a portlon oE tlle apparatus oE Flg. 6.
Flg. 0 ls a cross-sect10na1 vlew of tl~e f1uldlzer concllllt oE Flg. 6, takell a10ng 11ne ~ ~ of Flg, 7.
Flg. 9 ls a slde vlew of an ln-furllace sand ; -~
2~ reclamatloll unlt, ln accordance wltll an a1ternal:e, preferred em~)odimellt oE the present 1nventloll.
Flg. lO ~s a cletailed perspectlve vlew of t~le f1uldlzlll9 rlng of Flg. 9.
Flg. Il Is a cross-sectlonal vlew oE tlle flllldIzlng rlng o~ Flg 9, takell a10ng 11ne 11--11 of Flg. 10.
Flg. 12 Is a cross-sectlonal vlew oE tlle E1uld1zlng rlng oE FIg 9, taken along 11ne 12-12 of F3g. 1~.
I;Ig. 13 ls a cut-away vlew of a portIon of an ln-furllace sand reclamatlon unlt, In accordance wlth an alterllate eml~o~Jiment oE tlle presel~t El~ventloll.
Flg. 14 ls a cut-away vle~ of a mllltl-zolle elllbodllllerlt oE llle lleat treatIng furrlace an(l In-fllrl-lace sand rec1amatloll system, ill accordance wltll tlle present 1 nvelll: ion .

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Fig. 15 Is an lsolated si~e vlew of a s~pplemelltal sand reclamatiol~ u~llt td~lCIl ls part of an alternate embodlmerlt o~ e prese~lt l-lve-ltion.
Flg. 16 is a cut-a-ay side vlew of tlle supplelllental sarld reclamaLlon ulllt oE F3g. 15 moulltet3 on top of ~l~e com~ atlon l~eat treatlng furnace and ln~
Ellrl~aCe sallC~ recl.allla~101~ lt.
F3g. 1'1 ls a cut-away vlew of t])e rec)almer l~o~per of Flg- 15-DE'l'~ILED DES~RIP~'ION OF TIIE PnEFE~RED EMBODlMENT
'I'l~ls sectlon of tlle speclflcatloll conslsts of two parts. 'I'lle flrst part llltroduces components and descrlbes tllelr orlentatlon and lnterconnectlons. 'I'lle second part descrlbes tlle operatlon of the con~ponents : ~
all~ provldes solne examples of accep~able components. '' l~e~errlng now 3l1 greater detail to tlle drawlngs -`
io wlllcl) llke l)umerals represent llke compollents tllrougllout tlle several vlews ~lg. 1 sllows a partlally cut-a~ay vlew of a comblnatlon Ileat treatlng furnace 19 and ln-Eurllace sand reclamatlon ulllt 20 ln accordance wltll tlle preferred em~odlment of tl~e presel~t lnvelltlon.
'I'he Irl-furnace sand reclamatlon ~II.lt 20 Includes a llopper 30 wlllcll l~as a llopper wall 31 and deflrles a llopper lnlet 33 and a llopper outJet 35. ~ portlon of ~`
tllé llopper wall 31 and otller elemellts are cut-away ln Flg. 1 so tllat elements sl~own can be clearly seen. q'lle In furnace san~ reclamatlorl unlt 20 ~urtller lncludes a fluldlz'er 40 guidance tube ~30 abrasion dlsk'90'and a dlscllarge valve assembly 100. 'I'lle fluldJzer 40 ls sllowll passlng tllrougll tlle llopper wall 31. 'l~lle gul~ance tube 80 ls sllo~-n orlented above tlle fluldlzer wlthlrl tlle llopper 30. 'I`lle at~raslon dlsk 90 ls sllown orlented above tlle gul(lance t~lbe 80 ~ltllln tlle llopper 30. 'I'tle 3g dlscllarge valve assembly 100 3s StlOWII conllected to tlle 3 ~

l~opper outlet 35. 11l tl~e preferred embodllllellt of t1)e present lnvelltioll tlle l~opper 30 o~ tl~e in-ftlrnace sand reclamatlon ullil: 20 doubles as tl~e llopper 30 of the lleat treatlllg furllace 19. /~rl aE-proprlate lleat Lreatirlg . -~urnace 19 ls disclosed ln appllcal:lol~ Serlal No. : f~: .
07/705,626. Il~e speclficatioll of ~J.S. patellt appllcatloll Serlal r1o~ 07/705 626 Is llereby lncorporated llereill by reFerellce. Ille di.scllarge valve assembly 100 E-rovldes a patll to tlle outslde of tlle f u rnace .
Fi.g. 2, wlllcll ls a cut-away slde v3ew of selected elemellts oE ~19. 1 sllows tl~e Eluldlzer 40 of tl)e prelerred embodl.mellt of the presellt 3.1lventlon, ln greater detail. Sand 25 ls also sllown, ln represelltati.ve Eorm, collected at tlle l~opper outlet 35.
Ille fluldlzer 40 ls seen as lncludlllg a fluldlzer colldult 41; tlle f1uld.lzer con(iult 41 llas a fluldlzlng en(i 42 tllat ls wltlllll tlle llopper 30 an(i a source end 43 tllat 19 outsl(;ie of tlle llopper 30. 1~ portl.on of tl~e ~ ::
fluldlzer COll~lUI t 4t l~as been c~lt~away to expose a ; .
condult lrlterlor 44 wlllcll ls defllled by the fluidlzlng condul.t 41. I`lle so~lrce end 43 of tlle fluldlzer condult 41 ls sealed by an end plate 47. Ille elld plate 47 ls attaclled to tlle so~lrce end 43 in a mallner tllat would be ullderstood by tllose reasonably skl.lled ln tlle lndustry;
for example, by weldlllg. ~ portlon of tlle end plate 47 19 cut away ln ~19. 2, Lo ful~y expose a l~eater 60.
Ille lleater 60 ls secured throug11 tlle end plate 4? 1l~ a mallller tliat faclll.tates removal for repalr or reE~lacemellt wl.tll a dif~erellt type oi lleater. Ille lleater 60 has an exllaust enci 61 located wll:llln tlle colldult lnterlor 44 an(l.arl lntake end 62 outslde of tl~e fluld.lzer condllit 41. Pressurlzed alr Is supplled lnto tlle llltake encl 62 ol ~l~e l~eater 60 tl~rougl~ an alr llltake 65. 11l Llle pre~erred enlbodlmel~t of tl~e present 7 ~ :
.... ~.
12 ~ ~ ~
. ~ .
1nventiol), tlle l~eater 6() is a lligll pressure gas burner.
In all alternaLe embodinlent of tlle present invention tlle l~eater 60 conslsts of an electrlc llea-ing element. ~ ;~
Otller lleater ~ypes are acceptaL)le.
/~ slgna1 generatillg pressure gauge 70 ls connected to tlle fluldlzer col-dllit 41 by a gauge condlllt 71 lî~ls connectlon ls sllcl~ tl~at Ll~e slgnal generating -~
press~lre gauge 70 is ll~ conlmlllllcatlon wltll t:lle conclult lnterlor 44 ancl can sense tlle pressure wltlllll t:lle flul(llzer conduit 41 r~ slgnal adJIlster 74 3s assoclated wltll tlle slgnal generatlng pressure gauge 70 llle slgnaJ generatll1g pressure gauge 70 1s conllecte(3 to an electrlc pol1er supply by a gauge power cable 72. llle slgnal genèratlrlg pressure gauge 70 1s connected by a slgnal cable 73 to tlle dlscharge valve assemt~1y lO0, wl~lcl~ is not sl~owll 1n Flg. 2.
rlle fluldlzer end 42 of tlle ~luldlzer condult 41 ls turlled upward Irl Flg 2 toward a tlle gu1dance tu~e 80 and tl~e abrasloll dlsk 90. Ille gul(lance tube 80, part oE wlllcll ls cut: away 1n Flg 2, llas a tube wall 81 and de~lnes a tube passage 82. Ille abrasIon dlsk 90, par~ of whlcl~ ls cut a~ay ln Flg. 2, llas dlsk back 92 and a concave cllsk ~ace 91.
Flg. 3 ls a top vlew o~ tlle apE)aratus of Flg. 2 ln greater detall ancl wltll tlle abrasloll dlsk 90 removed. -~:
~s sllowll ln Flg. 3 tlle gul(lance tube ~30 3s connected to tube ~upport rods 85a b wll1cll are connected to the llopper wail 31. rllese connectlolls are ma~e ln a manner as wolll(l be ull(3erstood by tl-ose reasonably skllied 3n ~lle Industry; ~or example ~y wel(31ll9 or bolt1ng. rlle gukiance tube ~() ls pos31 ioned SllCIl tllat. tlle 9Ui.dallCe tube 80 ls oriented above tlle ~luldlzer end 42 of t:lle ~lulclizer col~ it 41 and l:lle tube passage 82 ls 1n-11ne ;~
wltll l:lle condu1t Inl:erior 4q at tlle fluldlzer end 42 ;
.~.

: ... , ,- .,,:

Fig 4 is a top vlew oE tlle apparatlls of Flg. 2 in greal:er detail~ ]n I~ig 4 ~lle ilsk lace 91 oE tl~e al~raslon dlsk 90 ls orlented to~-ar I tlle E]~lldlzer end 42 an i is tl~ereEore nol: seen ts seen 1n Flgs. 2 alld 5 4 tlle abras1OIl d~sk 90 ls conllectecl to dlsk su-7port cables 95 wlllcll are attaclled to tlle lloE~E-er wall 31.
Ille cables 95 llave a disk elld 96, a llook end 97, alcl a turnbuckle 98 ~iisposed bet-/eell tlle dlsk end 96 and lle ... . .
Ilook end 97. ille dlsk ends 96 of ~lle cables 95 are 10 atl:aclled to Ll~e abrasloll dlsk 917 ln a manner tl~at wou1d be llnderstoo ~ l-y tllose reasonably skllled 1n l:lle lndustry; for example, by weldlng or bo1t1ng. Il~e llook end 97 o eacll cable 95 ls at:tacl~ed to tlle lnner lloE~per wall 31 by an eyellook 99; tlle llook encis 97 are l~ooked 15 to eyellooks 99. Ille eyellooks 99 are connected to tl~e lloE)per ~al1 31 in a manller tllat wou1d be understood i~y tllose reasonabiy skl1led 1n the 1ndllstry; for example, by we1dlrlg or boltlrlg~ Illere are a plurallty of eyellooks 99, eacll of wl~lcl~ 1s or1ented so t~lat tlle 20 l~elgllt Oe tlle aijraslon dlsk 90 above t~le flui~lzer elld 42 ls capable of belng ad)usted, as w111 be explalned below ll~e ~luldlzer encl 42 condu1t lnl:erlor 44, and gl~ldallce tube 80 are nol: seell ~1l F1g. 4 because they are conceale(l ~y tlle abras1On dlsk 90.
F19. 5 ls a cut-away slde v1ew of l:lle dlscllarge valve assembly sllo~ln 1n Flg. 1. rl~e cllscllarge valve ~-assembly 100 lllcllldes a doub1e dulllp valve 110 and a F)neumatlc valve operator l3(l Ille dollb1e dump valve 110 llas a valve inlet 111 and a valve outlet 112. Tl~e ~ -valve lnlet Ill ls conllectecl to tlle llopper outlet 35 (see Flg. 1) ln a mallller tllat ~ou1d be ullderstood by tllose reasonaL7ly skilled ln tlle lndustry; for example, by weldlng or ~oltlng. Ille valve outlet 112 ls located outslde of tl~e lleat treatlng Eurl-ace 19 sucl tllat tlle double dullip valve 110 ~rovlcles a paLII from ~ iLIIlll tlle ~, .,~.,~. ..
:.

-:~

! .

l~o~per 30 to tlle outside o~ e ~urllace 19. ~ port~on ~ `
of tl~e clouble dulllp valve 110 ls cut away ln Flg. 5 to expose a Elrst disk 116, a second (3lsk 117, a flrst seat 118, al~d a secolul seat 119. 'I'l~e pnellmatlc valve operator 130 is corlnected to l:l~e double d~lmp valve 110, Jll a mal~ler tllat ls ullderstood by tll-ose reasonably skllled ln tlle art, sucll tllat tlle pneumat3c valve operator 130 coll~rols l:l~e operatloll oE tl,e doll~le clump valve 110. ~I~lle pneumal:lc valve opera~or 130 Is connected to a pllellmatic supply llne 131 and tl~e slgnal cable 73. 11~ al~ alternate embodlmel~t of l:l~e l~resent ll~vel~tlon, tl~e pneumatlc valve operator 130 ls replaced wltll an electric, rnotorlzed valve operator; l~ydraullc valve operator; or some otl~er type oE valve operator.
Flg. 6 alld ~lg. 7 show an alternate, preferred embodlmellt of tl)e present 1nventloll. ~19. 6 ls a cut-away top vle- of portior7s of t)~e present lnventlon ln accordallce wltl~ tlle alterllate embodlmellt. 'I'hlg all:erllal:e elnl)odllllel~t cloes not lllclude tl~e guldance t~lbe 2~ ~() or abraslol~ dlsk 90. 'I'l~ls alternate embodlment does Lncl(lde a flul(3izer 40' wl~icl~ ls somewl~at slmllar to tl~e fluldlzer 40 of tl~e preterred embo(llmel1t. ~owever, ~:lle flul(llzer 40' llas a fluldlzer condult 41' tl~at spllts il~tO tllree fl~lldlzer condults 41'a,b,c, each of wlllcl~ pass tllrougl~ tlle l~opper wall 31. 'I`lle fluldlzer condlllts 41'a,b,c orlgil~ate from a col~dult l~eader 55.
e condult l~eader 55 orlglnates from tl~e source end 43 o~ tl~e fluldlzer con(lu3t 41'. ~lso, Ll~e flul(llzer ends . , ~ ,.
43'a,1),c are sealed ln a manner l:l~at would be ;~
3(1 understood by tllose reasonably skllled ln tl~e 3ndusl;ry;
for example, w3tl~ a l~lug 50. 1\lso, as ls 3ndlcated l~y ~:f F19. 7, wl~lcl~ ls a slde vlew of tl~e fluldizer 40' sl~owll~g a portioll of tlle l~opper 30, eacl~ fJuldlzer ~;
conduit 41'a,b,c ~lefll~es a plurallty of fluldlzll~g l~oles 51 tl~at are oriented toward tl~e l~opper outlet 35.

; ~'Y~

;

(In Fig. 7 t lo of tl~e flulclizer condults 41 b c are concealed by one ot tlle flulclizer corlllllts 41`a.) 8 is a cross-sectlonal vlew taken along llne 8 - 8 ~n Fig. 7; only olle ~lul llzer colld llt 41 a ls sl~own for 5 sim~]lclLy; ~le otller collduits ~l b c belng slmllarly constructed. ~s seen In Flg. ~ tlle fl 1~(3iZlllg l~oles are ln commulli(atlol) witl~ tl~e conc~tllt interlor 44 .
I~lso 11l tlle eml)oclilnellt sl~own ln Flgs. 7 and ~ tl~e flul(llzlllg l~oles ~1 are space~i llnearly ancl raclially along tl~e portion of tlle flul llzer conclllt 41 a tllat ~ -faces tlle 11opper outlet 35. ~referably tlle angle between tlle cellter-llnes 52 deflned by t Jo fluldlzlng lloles 51 that are radlally pos3tlolled wltll respect to one anotl~er is nlllety degrees. In alternate 15 eml)odlmellts oE tlle presellt lnventloll, tlle fluldlzillg lloles 51 are spaçed ln a dlfEerent manl er.
I~llotller all:ernate embodlnlellt of t11e present ~ ;
lnventloll wlllcl~ ls not sllo ~n ls slml~ar to tlle `-prevlous~y dlsclosed alternate embodlmellt of Flgs. 6-8, 2U except tllat tlle flllldlzer conclult 40 spllts lnto slx fl~lldlzer condults. Illree of tl~e slx fluidlzer condults penetrate one furllace llopper 30 and tlle otller tllree oE the slx fluldlzer cond~llts pelletrate a dlfferent furllace llopper 30. l~ctually tllere are a varlety of alternate embodlments of tl~e present lnvelltloll tl~at are varlatlons upon tllose ~ust dlsclosed. I~ltllougll not sllo~ln ln F~gs. 6 and 7~ tlle slgnal generatlng pressure gauge 70, ~ltll all of lts ` ~" `
assoclated elemellts, ls lncludecl ln tllese alternate embodllllellts of tlle presellt lnvelltioll.
F`lg. 9 sllows an alternate, preferred embodlmellt of tlle present ~nvelltlorl wlllcll does not lnclude tlle guldance tube ~0 or tlle abraslon dlsk 90. In tllls alternate embodllllellt a fluldlzlllg rlng 1~0 ls disposed betweell tlle llopper ou~:let 35 ancl l:lle valve lnlet 111.
. .:

' :

2~

~rl~e Illlidlzirlg ring l~o ls collnected to tl~e llo~per o~ltlet 35 an(l ~lle valve Jnle~: 111 ln a manrler tllat would be understood by tllose reasonably skllled In tlle Industry; lor e~.3mple by wel<llng or boltlng. ~lso sllown in F39. 9 is a fluidlzer cond~llt 41''. Tlle fl~ldlzer concl~lit 41'' de~ es a con(llllt Interlor 4~'' (not: sllot1n). ~1~11e flui~Jlzer condult ~I~' llas a flukllzlng end 42'' wl~lcll Is conllecte(3 to l:lle fluldlzing r31l9 14~ an(3 a source encl 43~ lto wlllcll ~ -pressllrlzed alr ls supplled.
Flg. 10 ls a detailed perspectlve vlew of tlle fluldlz31lg rlng 14~ of Flg 9. 'I'lle fluidlzlng rlng 14~) lncludes a llollow ring frame 141 wlllcl~ deflnes a rlng lnterlor 142 (see Flg. Il). Tlle fl~lldizlng ring 140 boullds an open area 145 tllat ls ln communlcatlon wltl) s;
tl~e rlng lnterlor 142 by way of a plurallty of Cluldlzlng l~oles 146 tl~at are deflned by tlle rlng frame 141. Only two of tlle Eluldlzlllg lloles are labeled ln Flg. 10 lor slm~llclty. Tlle rlng frame 141 fur~ller deflnes a collC31l1t connectlon Ilole 147. q`lie rlng frame 141 ls connected at tlle condult connector hole 147 to tl~e fluldlzlng end 42'' of tlle ~lllldlzer condult 41'' sucll tllat tlle condult lnterlor 44'' Is ln communlcatlon `
~rltll tl~e rlng lnterlor 142. 'I`llls connectlon ls made ln a manner tl~at would be understood by tllose reasonably :: .
slcllled ln tlle lndustry; for example by weldlng.
Flg. 11 ls a cross-sectlonal vlew taken along llne ll - 11 ln Flg. 10. Flg. Il sl~ows tlle rlng lnter30r 142. Flg. 12 ls a cross sectlonal vlew taken along -31) llne 12 - 12 in Flg. Il. Flg 12 sllows one of tlle plurallty of tluldlzlng lloles 146 deflned by tlle r3.ng frame 141. 'I'l~e fluldizlng lloles 146 are angled steeply enougll so tllat portlons of sand core wlllcll pass tl~rough tlle open area 145 defllled by tlle rlng frame 141 cannot V ~,~

...... ~
17 :.

easlly mlgra~:e up~ tllrougll tl~e fluldlzlng lloies 146 --~
lnto tl~e rlng lnterlor 142. ~ :
ln an alternate embodlmellt of tl~e present lnvel)tlon no signal generatlllg pressure ga~lge 70 ls S Inclucled. /~s sllowrl ln i-lg. 13 wl~lcl~ ls a cut-away .~ ~ -view, I:l~is al~.ernate embo~llment oE tlle present i.nventlon lncludes slgnal generatlng sensors 170a b c tllat are mo~1n~e(l wiLI~ll) tlle llopper 30 to tl~e l~opper wall 31. 'I'l~e sensors 170a b c are moullted sucl~ tl~at ..
tlley detect a precletermllled level of sand core ln tlle ~ ~ -llopper 3(). Eacl) slgnal generatlng sensor 17~a b c is connected by signal cable ~3' to tlle ~llscllarge valve assemt71y 100 ~not silowll ln Flg. 13). 7~ selector 171 ls assoclated Witll tl~e slgnal generat3.ng sensors 170a b c.
1ll tlle preferred embo~l~ment of tl~ls alternate embodlmellt the slgllal generatlng sensors 170a b c are electr.ic probes.
F~g. 14 sllows a multl-zolle embodlmellt of tlle presellt lnvelltl.on wlllch lncludes a multl-zone furnace 211 employlllg several embodlmellts oi-. tl~e ln-furnace sand reclamation ulllt 20. ~\ll exampl.e of furnace 211 Is dlsclose(i ln appllcatlon Serlal No. 07/705,626. I~s dlsclosecl ln Fig. 14 llereoE, the furnace 2ll lncludes~
a work cilamber 21S; zones 216A 11; furnace lleaters 218; ~-a pre-lleat cl~amber 224; a f~lrnace lnput door 225; a ~ ~ :
furllace upper end 226; a Eurllace dlscharge door 227 a ~ .. -furnace lower end 22~; a roi.ler l~eartl~ 234; rollers ..
236; baskets 240, Eor transportlng castlngs; axlal. Eans ; ;~ -244; a ftlrnace top 24S; screens 252; bafEles 253; a sal~d conveyor 259; and a central collectlon bln 260.
~or a clear ~Inderstalldlllg of tlle furllace 211, pl.ease refer to appllcatloll Serl.al l~o. 07/705 626, wlllcll llas .
been lncorporated lnto tllls speclilcatlon. Tlle furnace ~.
211 furtller includes lloppers 30 and dlscharge valve 3S assenlblles 1()0. Zones 216r\,B are equlpped wltll tlle ;:;
:^
~ .

7 ~ q ~, ~
,.., ~ .~ ,~ - .

tluldlzer 40 (see Figs. 1 2, 3 and 4) guldance tube 1~0 an(l abraslon dlsk 60. llle pre-lleat cllarl!ber and Zone 216E are equlpped ~llt1l tlle ~luldlzer 40' ~see Flgs. 6, 7, ancl 8), and Zones 216~,G,II are equ3pped ~ -witll tlle flui(lizer ~0~ ~ (see Figs. 9, 10, 11, and 12) .
Sand 25 ls sllo~-n, ln represental:lve form collected at t 11 e llopE)e r ou t t e t 35.
Fig . 15 sllows a supplelnelltal sancl reclamatloll unl t ~ .
180 wlllcll ls ~act oE an alternal:e embod1mellt of tlle 10 present invent3On. ~ e supplemelltal sand reclalmlng unlt 180 lnclIlcles a reclalmer l~opper 181 wlllcl~ l~as a reclalmer lnlel ]82, a reclaimer outlel: 183, ancl a reclallller wal 1 184 . 'I'lle supplemelltal san(3 reclamat3on unll: 180 EllrLller lnc1lltles a d1scllarger 190 tllat llas a 15 dlscllarger lnlet 191 an(l a dlscllarger outlet 192. In `
the preferred, alternate embodiment, tl~e dlscllarger 19û
ls a screw auger. llle dlscllarger ln1et l9I ls ~ ~ ;
connected to tlle llopper outlet 183 ln a manner tl)at ~;
~ould be understood by tllose reasonably skllIed ln tlle `~
20 lndustry; for example by weldlllg or boltlng. I`lle supplemental sand reclamatlon unlt 180 furtller lncludes a clellvery l:u~e 195 tllat deflnes a tube lnterlor l99.
I`lle dellvery (:~lbe 195 also llas a tube lnlet 196, a tube outlet 197, allcl an oxygell s~lpply llne 19~3 tllat 19 ln 25 communlcatloll ~/ltll tl)e tube lnterlor 199. Tlle tul~e lnlet 196 ls connected to tlle dlscharger out1et 192 ln a manrler tllat wollld be understood by tllose reasonably skllled ln tlle lncltlstry; for example by weldlng or l~olt3rlcj.
Flg. 16 ls a cut-away vlew o~ tlle supplemelltal sand reclalllatloll ulllt 180 of Flg. lS mounl:ed on top of tlle comblllatlon l~eat treat~ng ~urllace 19 and in-furnace sand reclamatioll ulllt 20 ln accordallce wltll an all.erllate embo lilllellt o~ tlle presellt lnvelltlon. rl~e 35 reclalmer llopper 181 and dlscllarger 190 are located -~

. 7 , outslde oE tlle lleat trea~lng r~lrnace 19. 'rl~e dellvery tube 195 penetrates ttle l~eat treatlng furllace 19 anci ls in close proximlty to u--tube urllace lleaters 21~'. Tl)e tube outlet 197 ls oriel~ted to~rard tlle llopper .lnlet 33.
S Flg. 17 J.s a cu~:-a~ay vlew of tlle rec1almer llopper l~l of Flg. 15. ~ port~on of Llle reclalmer wall 1~4 Is cut-away to sl~o~/ a reclailller interlor 105 tllat ls dei'lnecl by tlle reclaimer wall 1~34. Incl.llded w1tll1n tlle reclalmer lnterlor lB5 are lleaters 1~6, oxygen supp11ers 1~7 and a level lndlcator 188. q'lle recI.almer llopper 181 also lnclllcles a recycle ex~)aust duct lB9 tl~at exllausts lrtto t~e ~eat treat~ng furnace 19 and a bagl~ouse exllaust duct 198. C~ `l! ID~iJ I !iJ,l .~ .
0P l~_'l'lON
Referrlng back to F'lgs. 1 and l~l, as tl~e castlng, wi.tll sancl core attacl~ed tllereto, ls acted upon ln accordance wltl~ e metllocl and apparatus cllsclosecl ln ~:'' ` ~.':~;
appl1cat1On Serlal No. 07/705,626, port1Ons oE sand and . .- '.
20 sand core fall tllrougll the llopper lnlet 33 and sand col lec~:s wltlllll tlle llot~per 30 toward tlle llopper outlet.
BeEore a defllled level of sand accumulates ln the . ' :"' '':' llopper 30, tlle flrst dlsk 116 and second dlsk 117 wltlll.n tlle doul~.le d(lmp valve 110 are ma1nta1ned In ':`~ ~
contact wltll tlle flrst seat 110 ancl seconcl seat 119, ~ ' ' respecl:ively. 'l'l~erefore, as portlons of sand and sand core contlllue t:o fall tllrougll tlle llopper 1nlet 33, tlle level of sand core wi.tlllil tlle llopper 30 lncreases.
Flgs. 1, 2, 3, ancl 4 cllsclose tlle flirst,'pr'eEerred ';
embodllllellt of îlle present lnvellt1Oll. Tlle equlplnent and process tllat are at tlle lleart of tlle flrst, preferred ~-enlboclllllent are referred to as "lllgll temperature ~luldlzatlon wl~ll a target". In tll1s embodlmellt, pressurized alr ls supplied tllrougl- tlle alr lntake 65. ~' Oxygenated ancl lleated exllaust frolll tl~e lleater 60 - ' . ,,;, ' :, 2 ~ 7 cliscllarges Erom tlle Eluldlzer en l 42 of tile f)lll(llzer condult 41. I\s tlle levet oE sand rlses at ove tlle level ~;
oE tlle fluld~zer end 42 EI~Ildlzat~orl beglns; tlle ;
oxygenated a ld l~eated exl~aust El(lldlzes port~ons of san l core lllat are al)ove L11e lltli lIzer en l 42. qllat ~-is tlle exllaust: passes up tllrougll tlle sand caus3llg tlle san(J to be s lspel1ded an(l act llke a ~lrb lIellt fluI(I.
llle Elllldlzatlon flrtller propels portions of sand tl~rougll tlle guIdarlce tube passage ~2 wllere tlle trajectory of ~lle entrailed portions oE sand Is orlentecl towarcl tlle dlsk iace 9l of ~lle abrasIon dlsk 9(). PortIons of sand contact tlle abraslon dlsk 90 ancl ~ E
Eall l)ack towal-d tlle iluldIzer en l 12 wllere tlley are furtller EIuIclized. llle portlons of sand tllat are fluldlzed abracle agaIrlst each otller and tlle d~sk face `~
91. llle abraslon caused by tllis process knocks away -~
asll tllat Is adllered to tlle sand. IIIIs exposes ullburned bIIlder and tlllls promotes blnder comb~lstIon. In addItloll to promotlr1g blnder combllstIon by exposIng ullburnecd bIllder tlle EluIdIzer 40 promotes combustIon by providlng a llot and oxygenate l envIrolllllel1t. rl~us tl~e exposed l~lnder combusts to promote purIfIcatIol~ o~ ~.
tlle sand reclaImecd Erom tlle sand core. SInce tlle l)lgl temperature Eluidlzatlon wlth a target lncorporates a varlety oE tecllnlq~les to recIalm sand (wlllcl1 IncIude at least fluldlzatloll fluIdIzatlol1 In combInatIo wItll an abrasloll dlsk heatIng to promote combustIon an(l oxyqenatll1g to promote combust~oll) It llas a relatlvely 11191l capaclty as compared tlle processes re~erred to below. -~
Some alternate embodIIllellts of tlle present Invent.lon olle of wllIcll Is sllown ln Flgs. 6 7 and are reEerred ~o as llot fIIlIdIzatIon . llot fl~lldlzatIon <loes not propel port:lolls of sand core toward a ta~gel:. Ilowever IIOt fluidlzaLion ~s ,.

otllerwlse similar to "llot flul(ilzatlorl wltl~ a targeL".
Pressurized alr ls sul)plie~ Lllrougll tlle alr irltake 65.
Oxygenated an(l lleated exi~ausL from tlle lleater 60 discl~arges from tlle fluldlzer l~oles 51. ~s tl~e level 5 of sand approacl~es tl~e level of tlle flllidlz~llg lloles 51 fluidlzatiorl beglrls. Fluidlzatloll ls promoted and el~llanced by Llle placemellt ancl or1.elltatlol~ oE tlle -~ .:
Ell1ldizlllg lloles 51. 'll~e portlol~s of sar,d tl~at are ~luldlzed al)racle agairlst each otl~er. ~rlle abraslon 10 caused by tl~ls process knocks away asll Lllat is adllerec1 to the sand. 'l'l~ls exposes ur~l)urnec1 bi.nder and tl~ll5 promotes bln(3er coml~l1stlor~ addltlon to prornotlng blr,der combus~ion l)y exposlng unburned t)lnder, tlle fluldlzer 40' promotes combustlon by provldlng a llot .~ .
and oxygenate~l envlronlllellt. 'l~lnls tlle exposed l~ der ~
colnbusts to promote pllrlflcatlorl oE tl~e sand reclalmed . . ~ .
frorn tl~e sand core. Slnce "l~ot f1uldlzatlon" does not l~t11lze a target, lt does not typlcall.y cause as mucll. ~
abraslon as "llot fluldlzatloll wltll a target". l'ln1s, .: :
"llot fluldlzat iOII" typlcally exposes less blllder tllan and therefore causes ].ess combustloll tl~an "I)ot L.luldlzatloll wltll a target". 'I~llereEore, "llot ~luldlzatlorl" typlcall.y llas less capaclty tllan "llot Elukllzatloll wltll a target". 'rlnls, "llot fluldlzatlon wltll a target" ls used wllere relatlvely large portlons o~ sand and salld core fall tllrougll tl~e llopper lnlet 33 and "llot Elul.dizatloll" ls used wllere relatlvely moderate port:l.ons of sand and sand core fall tllrougl~ :
tlle llopper lnlet 33.
Otller alternate embodllllellts of tlle present lllverltlon, olle of t~lllCIl ls sllown ln F`lgs. 9, 10, ll, and 12, are referred to as "cool fluldlzatloll". "Cool L.luldlzatlorl" ls somewllat slmllar to "llot E1uldlzatlon"
except tllat lt does not lncorporate l~eatll~g.
Pressllrlzed ai.r ls supplled to tlle source end 43'' o~

2 ~
--~ 22 :. . - , :
tl)e fl~ lzer cor~dllit: 41~ e pressurlzed alr passes Into tlle rl~lg interlor 142 by ~ay of tl~e fluldlzer end -;
~2 o~ tlle f Illldlzer condult 41'' and tlle condlllt connectloll llole 1~7. IIIe pressurlze~l alr tllen escapes 5 from tlle Eluldlzlllg rlng 140 tllrougll tlle fluldlælng lloles Iq6. ~s tlle level oE san(3 rlses above the ,: ~ : -fluldizlllg l~oles 146 fl~ lzatlon begllls. T~e I
portlons of salld tllal: are flul(31zed ai~ra(le agalnst eacil otller. 'I'lle aE~rasloll ca~lsed l)y Lll~s ~rocess knocks away li7 asll tllat ls adllered to l:lle sand. ri'llis exposes urlburned blllder and tlnls promotes b~nder combllstlon. Ir~
addltlon to promotlng bll~der combustlorl by exposlng ullbllrl)ed bln<ier tlle flllldlzer 40'~ promotes combustlon 17y provldlng aclded oxygen to tlle environment (t11e tleat necessary for combllstloll ls provlde(l by tlle lleat treatlng furnace 19). 'l'llus tlle exposed l)lnder combllsts to promote purlflcatlol~ of tlle sand reclalmed Erom tlle sand core. Slnce "cool fluldlzatlon" does not add lleat to promote combustloll, lt does not typically ca~lse as mucll coml)llstloll as "llot fluldlæatlon".
'I'l~erefore "cool flllidlzatlon" typlcally has less capaclty tllan "l~ot fluldlzatlon". 'l')lus "cool `~
Eluldlzatloll" ls ~Ised wllere relatlvely small portlons of relatlvely clean sancl fall tllrougll the llopper lnlet ` ' -~33. "Cool fluldlzatlon" ln ad<lltlon to reclalmlng s~nd, cools portlorls of sand before tlley pass tllrougl tlle double domp valve 110. 'I'llls protects t~le double ~lulllp valve 110 from lleat related stress an(l straln and allows for tlle tlse oE a less expenslve dol~ble dump valve 110. ~ ' t~s specl[led al>ove tlle dlfferent embodlmellts of tlle present lnvelltloll llave dif~erent capacltles. I~s speclfled ln appllcatloll Serlal No. 07/705 626 dlfferent zones 2l6 (see Flg. 14) witllln a contlnuous-process Eurnace 211 llave dlEferellt capacltles for r~ f~ 7 ~`

loosenirlg sancl core from castlngs. Tllerefore lt ls necessary to reclalm more sand In some zones 216 an~
less Erom otllers. In accordance wltll one multl-zone embocilmellt of tlle present Inventloll as stlown ln Fig.
14 lligl~er capacity embo~llments of tl~e in-~urnace sancl reclama~lon ~ 20 (for example F~lqs. I - 4) are employecl ln 1~191~ capAcity zones 216r~ B; modera~:e capaclty embo(lilllents of tlle In-fllrllace sand reclamatlon ~ ~ ' unlt 2() (for example Flgs. 6 - ~) are employed ln tlle pre-lleat cllanll~er 224 arld mocierate capaclty zones 216E;
al)d lower capaclty eml~o ilmellts of ti~e In-furnace sand reclamatlon ulllt 20 (for example ~Igs. 9 - 12) are employed ln iower capaclty zones 216F G,ll of the furrlace 211. 13kewlse lt Is preEerred to employ l~lgl~er capaclty embodlmellts of tlle presel)t inventlon ln Illgller capaclty batcl~-t:ype fllrnaces an(l lower capaclty embodllllellts of tl~e present lnvelltlon ln lower capaclty ba tcll - type f u rnaces . ~' Irl several embodllllellts of tlle present invent1on tlle slgllal generatlng pressure gauge 70 and tlle eguipment assoclated wltll lt serves to provlde posltlve control over tlle level and tllereEore the volume of san(l tllat accumuJates wltllln tJ)e hopper 30 (reEer to ~lgs. 2 and 9J. I~s portlons of sand cootlr)ue 2S to Eall tllrougll tlle llopper lnlet 33 I:l)e level of sand wltllln tlle llopper 30 ~ncreases. ~s tlle level lrlcrease~
tllere ls more reslstallce to tlle flow of alr from tlle Eluldlzer en(i of tlle colldult 42 and tlle back-pressure lrl tlle fluldizer conclult 41 lncreases. 'I'lle slgnal adjuster 74 assoclal:e(l wltl) tl)e slgnal generatillg pressure gauge 70 ls set SIIC11 tllat wl~en a certall- back-pressure ls cietecte i witllin Llle condtllt lnterlor 44 by tlle slgnal generatlllg pressure gauge 70 a "Illgll level"
slgnal ls generated. 'rlle pneumatlc valve operator 140 recelves tlle "lligll level" slgnal by way oE tlle slgnal :~ .' ,.",~

l;r~ ~

cable 73. Wllile tlle pneulllatlc valve operator 140 ;
recelves tlle slgnaI lt operltes tlle doub]e dump valve 120. I`he dollble dump valve ~20 ls operated sucll tl~at~
tlle ~Irst dlsk 126 and seco~ld dlsk 127 alternately move away from and tllen return to tl~e first seat 118 and ` `~
second seat 119 respectlvely. l~l~i.s operatlon ls sucl tllat w)llle t~le ~irst d~sk 116 ls not ln contacl: wll:l~
tl~e flrst seat 118 tlle second dlsk 117 ls In corltact wltll tlle secorld seat 119 arld vlsa-versa Tl~us, whlle tl~e double dump valve 110 ls operatlng and sand ls 1owlng Irom wltllln tl1e llopper 3t) to outslde of tl~e lleat lreatlng furnace 19 l~y way of tl~e double dump valve 110 back~pressure ls malntalned at tlle hopper ollî;let 35 sucl~ at fluldlzatlon ls not dlsrupted. It ls lmportant tllat back-pressure ls malntalned at tlle `
llopper outlet 35 because tlle pressurlzed alr tl~at ls belng supplled tl~roug~ tl~e fluldlzer condult 41 wlll l:ake tl~e patl~ of ]east reslstance. If botl~ the flrst dlsk IIG anci l:lle second dlsk 117 w1~ere off of tl~elr seats arld tl~ere was a level of sand wlthln the hopper, tlle paLII of least reslstance would be tl~rougl~ tl~e doubled ~lump valve 11() to tl~e atlllospllere outslde of tlle furnace. l`llerelore tlle pressurlzed air would flow ~ rougl~ t~e dollble dump valve 110 ratller tl~an forclng ` ~;
lts way up ~llrougll tl~e sand accumulated 1~ tl~e l~opper.
In an al~ernate embodllller~t of tl~e presenl: Inventlol1, tlle doul~le dulllp valve 110 ls replaced wltl~ a star valve or screw auger or anotl~er type of devlce tl~at performs a dlscllargll~g and a seallng functlol-.
In alternate embodlmellts of tlle present lnventlon slgllal generatlllg sensors 170 mo-lllted to Llle llopper wall 31 (see 1 19. 13) serve to provlde posltlve control over tl~e level and tllerefore tlle volume of sand tllat acculllulates wltllln tl~e hopper 3(). In one embo(lllllellt tlle signal generatlllg sensors 171) cons~st of -2 ~ L ~ ~ 6 eIectrlc capacital~ce probes ~o electr3c capacltance probe Is moullted to tlle llopper wal.1 at eactl posltlon tl)at corresponcls to a Ievel at wi~lcll It 15 deslred to .:
operate tlle do~lble c3ump valve llO. 'rlle partlcu~ar 5 level at wllicll tlle double dump valve wlll operate ls establlslled by operatlng tlle selector 171 wlllcll estaL)llslles wl,icl~ e]ecLric E)robe Is control.llrlg. r~S
tlle level oE sand lrlcreases and comes In~o contact wI~
tlle controlllllg electrlc probe, a "lligl~ leve1" slgllal .:~
10 Is generatèd. 'I'lle plleumatlc valve operator 140 recelves tlle "Illgl~ level" slgllal by way of the s1gnal cable 73'. ~lllen tlle pneulllatlc valve operator 140 :
recelves ~lle s3gnal 3.t operates tlle double dump valve 110 as l.s dlsclosed a~ove.
1'lle cllaracterlstlcs of reclalmed sand are ~ .
controlled by controlllng tlle dwell tlme of portlons of sand wltllltl tlle llopper 30. 1'lle longer tlle dwell tlme, tlle lollger tlle amo~ t ol tlme Lllat tlle portlolls of sand are fluld1zed. Wllen portJons oE blnder coated sand are Eluldlzed for a relatlvely longer perlod of t3.me, l.ess blnder ls col)talned ln tl~e reclalmed sand but more flnes ar.e contallled ln tlle reclalmed sand. Wllen portlons oE blllder coated ~and are fluld3.zed for a relat.lvely sllorter perlod of tlnle, more blllder ls contalned ln tlle reclalmed sand but less flnes are contalllecl ln tlle reclalmed sant3. ~I'lle dwell tlme ls corltroll.ed by controlllng tlle volunle of sand tllat 3.s allowe(3 to accullllllate ln tlle llopper 30. 'l~lle greater ~
the volume oE san(l allowed to accumulate ln tlle llopper ..
30, tlle greater tlle dwe]l tlme (assum3.1lg a constallt Illput of san(3). Tlle volume of salld tllat ls a110wed to accumulate 11l tlle llopper 30 ls sel.ected by ad)ustJ.rlg ~.
tlle slgnaI adJuster 7~ 3n tl)e one dlsclosed E-referred . . ::
emL)od.illlellt oE tlle present lnvelltloll or by ad3ustlng tlle selector 171 11l tlle second dlsclosed eml:)odllllel t of l:lle . ~, .

. . .

- 2 1 ~ 7 ~ `

present lnve~tlol~. In tl~e embodllnellt wlllcll lncl.udes tl~e slgllal genera~:lrlg pressure gauge 10, a iarger volume of sall<l acc~lm~llates 11l tlle llopper 30 ~/llen t~le sl.gnal ad.~uster 74 ls ad.~usted so tl~at tl~e slgnal .
generating ~,ressure gauge 70 emlts a "Illgll level"
signal at a lligller pressure. ~\ smaller volume of sand acc~ln~llates il~ tl~e l~ol-per 30 wl~er~ tlle slgllal ad)llster 7~ ls ad)usted so Lllat tl~e slgnal generating pressure gauge 70 em~ts a "1~1911 level" slgnal at a lower pressure. ln tl~e embodlment wlllcll lncludes slgnal ~ -generatlng sel-sors 170 a larger or small.er volume oE
sand ls allowed to accumulate 11~ tlle llopper 30 by ~ :
adJustlng tlle selector 171 to select tl~e slgnal generatlng setlsor 170 tllat ls mourlted at tlle level tl~at corresporlds to tlle deslred volume.
r~eEerrlng back to Flgs. 2 and 4 tlle cllaracterlstlcs of tlle reclalmed sand are also controlled, ln tlle preferred embodllllent of tlle present lnverltlorl, by ad~ustlllg Llle llelgllt of the abraslon dlsk 90 above tlle fl.uldlzer end 42 oE tlle flul.dlzer cond~llt 41. 'I'l~e lle~gllt ls ad3usted by loosenlng tlle turnl7uckles 98, ullllooklllg tlle llook el~ds 97 Erom tlle eyellooks 99 llooklng tlle llook ends 97 to tlle approprlate eyellooks 99 and tiglltenlng tlle turnbuckles 9~. 'I'llese components can be accessed by enterlrlg l:lle llopper 30 throllgll tlle Eurnace 19 or tllrougll trap doors 11l tlle llopper wall 31. Generally wl~en tlle llelgllt of tlle abraslon dlsk 90 is decreased more abraslon occurs because proE~eLled portlons of sal~d ImE~act tl~e abraslon dlsk 90 wltll more force; tllereEore less blnder ls . ~ .
contallled ln tlle reclalmed sand al~d more Ei~les are :
colltainecl ln tlle reclaimed sand. Generally wl~ell the llelgllt l.s lllcreased less al~rasl.oll occurs t~ecause propelled portions of sand lmpact the abrasion dl.sk 90 ~lltl~ less force; tllerefore, more blllder ls contalned ln ;~ ~.

.' ~ ., .

. :,, -- 2 1 2 ~ 7 tlle reclaimeci sarld and less flnes are contallled ln tlle recla~med sallcl.
Re~errlllg back to Flgs. 15-17 tl~e supplemel-ta1 sand rec1amatiol~ ul~lt 180 1s used In coll3ullct10r~ wlLI
5 tlle fluidlzer 40 and otller comE~ollent:s 1n tlle l-eat treating Eurllace 19 to furtller purlty sand tllat has already beel~ reclalmed by some otller process and î:o rec1aim sand trom portions of saucl core init1a1ly reclalmed by allotller process. Tlle port10ns of sand ~ -~
core and coatecl sand tllat are illtrodllced lnto tlle supplemelltal sand reclamatlon url1t 180 are not adllered to castlngs. For example only 1f a core was accldently molded Into tlle ~rong sllape such tllat lt cou1~ not be used for castlng lt cou1d be cruslled ànd lS tlle portlons tllereof could be Introduced 1llto the supp1emenl:a1 sand reclamat10ll un1t 1~0. Portlons of sàlld core and coated sand are Illtroduced lnto tlle supplelllellta1 sand rec1amatloll un1t 1~0 tllrougll the reclalmer lnlel: 1~2. ~ e )leaters 186 and oxygen supp11ers 181 mallltalll an atlllospllere wltllin tlle rec1almer 1llterlor 185 tllat callses s~me of tl~e b1nder assoclated ~itll the 1ntroduced sand and portlons salld core to combust: sucl~ tl~at sand ls recla1med ~lt~ln tlle reclalrner lloEper 181. 1`1le reclalmed sand ls transferred from tlle reclalmer l~opper 181 to tlle dellvery tube 195 by tlle d1scllarger 19V. 'rlle san<l ~1tll1n the dellvery tube 19S 1s drawll by gravlty from tlle tube llllet 196 to~ard tlle tube outlet 191. ~I~lle sand In tl~e dellvery tube 195 ls lleated due to tlle fact tllat tlle delIvery tube 195 ls ln close proxlmlty to u~
tube furnace l~eaters 218'. 'I'lle sand ln tlle dellvery tube 195 ls also exposed to oxygen tl~at 1s supp11ed tl~rougl~ tlle oxygen supply 11ne 198. 'I'herefore at ~-least some exposed blnder tllat passes tllrougll tlle ~ ~
dellvery tube 195 1s combusted~ ~s sand passes from ~ t' ~ ' :, .

-~ ~
: 2 1~

tlle tut)e out.l~t 197 it ~alls Into tlle llopper 3() wl~Qre lt ls furtller purlEled by 1uidlzatloll, as ls dlscussed above. : :
'Ille embociimellts oE tl~e presellt Invelltlon carl be ~ :
5 collstructed from a vari.e~y of materials and Include a varlety oE com~)ollellts. rlle tollowlng ls o~ereci for exan.ple only. Ille lloE~l~er 30, guldance tube ~o, ancl abraslon dlsk COU I d be made out o~ varlous abraslol~
reslstal~t alloys. More speciflcally, tl~e l~opper 30 arld guldance tut)e ûO could be made out of 4130, 414() or 1~20 steel, aocl tlle abraslol- dlsk 90 cou:ld be made out :
of a cast 1~3gll mangallese alloy. ~IIle fluldi.zlng rlng 140 could be constructe(3 of r,36 structural steel square tubIng. The 1119ll pressure burner, wlllcll serves as t~le . 15 lleater 60 ln ol~e embocllment of tl~e ~resent invenLlon, could be an Ecl.lpse brand. 'I'lle slgnal generatlng pressure gauge 70 couki be a Dwyer brand pl~otoelectrlc gauge. 'l'lle electrlc capacltance probes, tllat serve as tlle sIgrlal generatlng serlsors 170 In one eml)odlment of 20 tlle present Invelltloll, and tlle level lndlcator 188 could be an Endress llauser bralld, LSC 1110 Series caE~acltance probe. r~ low voltage Is applled to tllese ~)robes, and wl~en tl~e probe comes i.nto contact wltll some . ~.
materlal (Eor example salld) currellt ~lo~Js lnto tlle 25 materlal and tlle probe senses tlle current flow. Tlle double dump valve 110 coulci be a Nl-llard and nlckel cllrome alloy Illgll temperature doubi.e dump valve made by l~lattco Corporatloll. 'Ille Fluldlzer conc3ult 41 can be constructed from stalnless steel. 'l'lle lleater 1~6 could ; ..
be a Natlonal bralld slllcon carblde l~eatl~lg element.
Wllereas tl~ls lllventloll llas been descrlbeci ln ~-detall wltll partlcular reference to preferred . :~
emL~odllllellts and alterllate embodlmerlts tllereof"t wlll be understood tllat varlatlons and modlflcatlons can be e~Eected wltllln l:lle splrlt ancl scope of tlle invelltloll, `
'~ ' .

2 9 . ~ ~ :

as descrlbed l~ereir) l~eEore arld as deflrleci ln tl)e a ppe l~d e d c 1 a I ms We C l a l m ~

~'~ ,~.;,'.'',; ,

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. An apparatus for heat treating a casting with sand core, comprising sand bound by a combustible binder, attached thereto and for reclaiming sand from the sand core, said apparatus comprising: a furnace for receiving the casting therewithin;
furnace heating means for heating said furnace to a temperature sufficient to loosen portions of sand core from the casting, while the casting is in said furnace; and means for reclaiming, within said furnace, sand from loosened portions of sand core, wherein said means for reclaiming includes, at least, a collection means for collecting loosened portions of sand core within said furnace, and a fluidizer so positioned and so constructed to fluidize, within said furnace, the collected portions of sand core.

2. The apparatus of Claim 1, further comprising a supplemental sand reclamation assembly operatively upstream of said furnace and including, at least, a reclaimer hopper, located outside of said furnace and defining a hollow reclaimer interior, wherein said reclaimer hopper includes, at least, a reclaimer inlet, through which portions of sand core are deposited into the reclaimer interior, and a reclaimer outlet, from which partially reclaimed portions of sand core pass out of said reclaimer interior, means for partially reclaiming portions of sand core within the reclaimer interior, and discharge means, connected to said reclaimer outlet, for ejecting partially reclaimed portions of sand core into said furnace such that the partially reclaimed portions of sand core are subjected to said means for reclaiming within said furnace.

3. The apparatus of Claim 1, wherein said fluidizer includes, at least, a source of pressurized gas, and a fluidizer conduit which defines a hollow conduit interior, wherein said fluidizer conduit extends from a first end that is in communication with said source of pressurized gas and terminates at a second end in a manner that causes the collected portions of sand core to be fluidized within said furnace.

4. The apparatus of Claim 3, further comprising a fluidizing ring connected to said second end of said fluidizer conduit, wherein said fluidizing ring includes, at least, a ring frame at least partially bounding a central open area and defining, a hollow ring interior in communication with the conduit interior of said fluidizer conduit, and a plurality of fluidizing portals communicating between the central open area and the ring interior.

5. The apparatus of Claim 3, wherein, said fluidizer further includes, at least, a heater for heating loosened portions of sand core to a temperature above the combustion temperature of the binder of the loosened portions of sand core, and said source of pressurized air includes, at least, a source of oxygen, whereby binder of loosened portions of sand core is combusted.

6. The apparatus of Claim 3, wherein said furnace heating means includes, at least, means for heating loosened portions of sand core that are within said furnace to above the combustion temperature of the binder of the loosened portions of sand core, and said source of pressurized air includes, at least, a source of oxygen, whereby binder of loosened portions of sand core is combusted.

7. The apparatus of Claim 6, wherein said means for reclaiming further includes, at least, an abrasion disc within said furnace, wherein said fluidizer and said abrasion disk are constructed and oriented such that loosened portions of sand core are propelled by said fluidizer toward said abrasion disk such that loosened portions of sand core contact said abrasion disk in a manner that contributes to the reclaiming of sand.

8. The apparatus of Claim 3, further comprising: discharge means for discharging reclaimed sand from said furnace, and regulating means for controlling the discharging operation of said discharge means such that the length of time that collected portions of sand core are subjected to said fluidizer is automatically controlled to control the amount of fines and the amount of binder that are included with the reclaimed sand discharged from said furnace.

9. The apparatus of Claim 8, wherein said discharge means includes, at least, a double-dump valve.

10. The apparatus of Claim 8, wherein, said furnace includes, at least, a furnace upper portion, and a furnace lower portion, and said collection means includes, at least, a hopper including, at least, a hopper inlet defining an opening in the furnace lower portion that is oriented such that loosened portions of sand core fall into said hopper inlet, a hopper outlet defining an opening below said hopper inlet, and a hopper wall connecting said hopper inlet to said hopper outlet such that a hopper interior is defined and a passage exists through the hopper interior from said hopper inlet to said hopper outlet, wherein said hopper wall is angled such that, under the force of gravity, the portions of sand core that fall into said hopper inlet are collected within the hopper interior and tend to accumulate toward said hopper outlet, and said discharge means is connected to said hopper outlet.

11. The apparatus of Claim 10, wherein said discharge means includes, at least, a discharge duct having a duct first end, a duct second end, and a duct side-wall that defines a duct passage therethrough, wherein the duct passage first end is connected to said hopper outlet and said duct second end is located outside of said furnace such that reclaimed sand passes from the hopper interior, through said duct, and is discharged from said furnace, an operator means for selectively controlling the passage of portions of sand core through the duct passage, and means for maintaining a seal at said hopper outlet such that fluidization is not disrupted while reclaimed sand is discharged from said furnace.

12. The apparatus of Claim 10, wherein said fluidizer conduit penetrates said hopper wall and said second end of said fluidizer conduit is located within the hopper interior near said hopper outlet such that collected portions of sand core are fluidized within the hopper interior.

13. The apparatus of Claim 10, further comprising a fluidizing ring connected to said second end of said fluidizer conduit, wherein, said fluidizing ring includes, at least, a ring frame at least partially bounding a central open area and defining, a hollow ring interior in communication with the conduit interior of said fluidizer conduit, and a plurality of fluidizing portals communicating between the central open area and the ring interior, and said fluidizing ring fluidizes the portions of sand core that fall into said hopper inlet and tend to accumulate toward said hopper outlet.

14. The apparatus of Claim 13, wherein, said fluidizing ring is disposed between said hopper outlet and said discharge means such that portions of sand core pass from said hopper outlet, through the central open area defined by said ring frame of said fluidizing ring, and into said discharge means, and said fluidizing portals are angled steeply enough so that portions of sand core which pass through the central open area cannot easily migrate up, through the fluidizing portals into the ring interior.

15. The apparatus of Claim 10, wherein, said regulating means includes, at least, measurement means for determining the amount of portions of sand core collected within the hopper interior, and signal means for generating a signal when said measurement means determines that a predetermined amount of portions of sand core is within the hopper interior, and said discharge means is responsive to said signal of said signal means to effect discharge of portions of sand core, wherein portions of sand core pass from the hopper interior and are discharged from said furnace.

16. The apparatus of Claim 15, wherein, said fluidizer interacts with the collected portions of sand core within the hopper interior to define a back-pressure in the conduit interior of said fluidizer conduit, wherein the back-pressure increases as the depth of the collected portions of sand core within the hopper interior increases, said measurement means includes, at least, a gauge in communication with the conduit interior for determining the back-pressure, and said signal means generates a signal when the back-pressure reaches a predetermined level, whereby a specified amount of portions of sand core is maintained within the hopper interior.

17. The apparatus of Claim 16, wherein said signal means includes, at least, a signal adjustment means for selectively specifying the back-pressure at which said signal means generates said signal, whereby the amount of portions of sand core that collect within the hopper interior is selectively controlled, whereby the length of time that portions of sand core remain in the hopper interior and are subjected to said fluidizer is selectively controlled, whereby the amount of binder and fines contained with the reclaimed sand discharged from said furnace is selectively controlled.

18. The apparatus of Claim 15, wherein said measurement means includes, at least, a sensor mounted to said hopper wall at a predetermined height above said hopper outlet, wherein said signal means generates a signal when the collected portions of sand core in the hopper interior define a level of portions of sand core that is at or above said height of said sensor.

19. The apparatus of Claim 15, wherein said measurement means includes, at least, a plurality of sensors mounted to said hopper wall, each sensor of said plurality of sensors being at a different one of a plurality of predetermined heights above said hopper outlet, wherein each of said plurality of predetermined heights corresponds to a desired amount of portions of sand core in the hopper interior, and said signal means further includes, at least, selector means for selectively specifying one sensor of said plurality of sensors as controlling, wherein, as the level of portions of sand core in the hopper interior increases and portions of sand core contact said sensor of said plurality of sensors that is controlling, said signal means generates said signal, whereby the amount of portions of sand core that collect within the hopper interior is selectively controlled, whereby the length of time that portions of sand core remain in the hopper interior and are subjected to said fluidizer is selectively controlled, whereby the amount of binder and fines contained with the reclaimed sand discharged from said furnace is selectively controlled.

20. An apparatus for heat treating a casting and reclaiming sand from portions of sand core, comprising sand bound by a combustible binder, said apparatus comprising: a furnace for receiving a casting therewithin; furnace heating means for heating said furnace; furnace reclaiming means for reclaiming portions of sand core within said furnace; and a supplemental sand reclamation assembly operatively upstream of said furnace reclaiming means and including, at least, a reclaimer hopper, located outside of said furnace, defining a reclaimer interior and including, at least, a reclaimer inlet, through which portions of sand core are deposited into the reclaimer interior, and a reclaimer outlet, from which partially reclaimed portions of sand core pass out of the reclaimer interior, means for partially reclaiming portions of sand core within the reclaimer interior, and discharge means, connected to said reclaimer outlet, for ejecting partially reclaimed portions of sand core into said furnace such that the partially reclaimed portions of sand core are subjected to said furnace reclaiming means within said furnace.

21. The apparatus of Claim 20, wherein said means for partially reclaiming portions of sand core within the reclaimer interior of said supplemental sand reclamation assembly includes, at least, means for heating portions of sand core within the reclaimer interior to above the combustion temperature of the binder of the portions of sand core, and means for oxygenating the reclaimer interior, whereby binder of portions of sand core is combusted.

22. The apparatus of Claim 20, wherein said furnace reclaiming means for reclaiming portions of sand core within said furnace includes, at least, a fluidizer.

23. The apparatus of Claim 20, further comprising, at least, a screw auger disposed between said discharge means and said reclaimer outlet, a baghouse exhaust duct in communication with the reclaimer interior for eliminating airborne particles from the reclaimer interior, and a recycle exhaust duct in communication with the reclaimer interior for exhausting heat from said supplemental sand reclamation assembly to said furnace.

24. A method for heat treating a casting with sand core, comprising sand bound by a combustible binder, attached thereto, and for reclaiming sand from the sand core, said method comprising the following steps: introducing the casting into a furnace; heating the furnace such that portions of sand core are loosened from the casting while the casting is in the furnace;
and reclaiming, within the furnace, sand of loosened portions of sand core, wherein said step of reclaiming includes, at least, collecting loosened portions of sand core within the furnace, and fluidizing in an oxygenated atmosphere within the furnace the collected portions of sand core.

25. The method of Claim 24, wherein, said step of reclaiming further includes, at least, heating loosened portions of sand core to above the combustion temperature of the binder, and said step of fluidizing includes, at least, the steps of exposing loosened portions of sand core to an oxygenated atmosphere and abrading combustion by-products off of loosened portions of sand core, whereby binder of loosened portions of sand core is exposed to the oxygenated atmosphere, whereby binder of loosened portions of sand core is combusted.

26. The method of Claim 25, wherein said step of abrading includes, at least, the step of causing loosened portions of sand core to abrade against loosened portions of sand core.

27. The method of Claim 25, wherein said step of abrading includes, at least, the step of causing loosened portions of sand core to abrade against an abrasion disk.

28. The method of Claim 24, wherein said step of fluidizing includes, at least, causing loosened portions of sand core to be suspended and act like a turbulent fluid.

29. The method of Claim 24, wherein said step of fluidizing includes, at least, exposing loosened portions of sand core to an oxygenated atmosphere.

30. The method of Claim 24, wherein said step of fluidizing includes, at least, exposing loosened portions of the sand core to an oxygenated atmosphere.

31. The method of Claim 30, wherein said step of reclaiming further includes, at least, heating the loosened portions of sand core that are exposed to an oxygenated atmosphere to above the combustion temperature of the binder, whereby binder of portions of sand core is combusted.

32. The method of Claim 24, further comprising the following steps: discharging reclaimed sand from the furnace; and selectively controlling the intensity of said reclaiming;
whereby the amount of fines and the amount of binder that are included with the reclaimed sand discharged from the furnace are selectively controlled.

33. The method of Claim 32, wherein said step of reclaiming further includes, at least, abrading portions of sand core, and said step of selectively controlling the intensity of said reclaiming includes, at least, selectively controlling the intensity of abrading.

34. The method of Claim 32, wherein, said step of reclaiming further includes, at least, propelling portions of sand core from a first location along a path, and providing an abrasion disk within the path at a distance from the first location, whereby the propelled portions of sand core abrade against the abrasion disk, and said step of selectively controlling the intensity of said reclaiming includes, at least, the step of varying the distance between the abrasion disk and the first location from which portions of sand core are propelled.

35. The method of Claim 24, further comprising the following steps: discharging reclaimed sand from the furnace; and regulating the duration of said reclaiming, whereby the amount of fines and the amount of binder that are included with the reclaimed sand discharged from the furnace are selectively controlled.

36. The method of Claim 35, wherein, said step of reclaiming further includes, at least, heating loosened portions of sand core to above the combustion temperature of the binder, said step of fluidizing includes, at least exposing heated portions of sand core to an oxygenated atmosphere, whereby binder of portions of sand core is combusted, and said step of regulating the duration of said reclaiming includes, at least, regulating said discharging to automatically control the amount of time that portions of sand core are contained in the furnace and therefor the amount of time that portions of sand core are subjected to said step of reclaiming, whereby the amount of fines and the amount of binder that are included with the reclaimed sand discharged from the furnace are selectively controlled.

37. The method of Claim 36, wherein said step of regulating said discharging includes, at least, the step of automatically controlling the quantity of portions of sand core contained in the furnace.

38. The method of Claim 36, wherein said step of regulating the discharging includes, at least, the steps of, determining the quantity portions of sand core collected in the furnace, and initiating said step of discharging when a predetermined quantity of portions of sand core is collected in the furnace, discontinuing said step of discharging when less than the predetermined quantity of portions of sand core is collected in the furnace.

39. A method for heat treating a casting with sand core attached thereto and for reclaiming sand from portions of sand core, comprising sand bound by a combustible binder, said method comprising the following steps: introducing the casting into a furnace; heating the furnace including, at least, the steps of loosening portions of sand core from the casting while the casting is in the furnace; introducing unattached portions of sand core into the furnace, wherein the unattached portions of sand core are not attached to the casting; and reclaiming, within the furnace, sand of loosened portions of sand core and sand of unattached portions of sand core, wherein said step of reclaiming includes, at least, collecting the portions of sand core within the furnace, and fluidizing in an oxygenated atmosphere within the furnace the collected portions of sand core.

40. The method of Claim 39, further comprising the following steps, prior to said step of introducing unattached portions:
heating the unattached portions of sand core to above the combustion temperature of the binder; and exposing the heated unattached portions of sand core to an oxygenated atmosphere;
whereby binder of the unattached portions of sand core is combusted.

41. An apparatus for heat treating a casting with sand core, comprising sand bound by a combustible binder, attached thereto, and for reclaiming sand from the sand core, said apparatus comprising: a furnace for receiving the casting therewithin; a furnace heating means for heating said furnace such that portions of sand core are loosened and fall from the casting while the casting is in said furnace; a reclaiming means for reclaiming, within said furnace, sand of loosened portions of sand core, wherein said means for reclaiming includes, at least, a means for contemporaneously exposing loosened portions of sand core to an oxygenated atmosphere and agitating the loosened portions of sand core; collection means disposed within said furnace for collecting the loosened portions of sand core such that collected portions of sand core have a high probability of being recurrently acted on by said reclaiming means; discharge means for discharging reclaimed sand from said furnace; and regulating means for controlling the discharging operation of said discharge means such that the length of time that collected portions of sand core are subjected to said reclaiming means is automatically controlled to sufficiently reclaim sand within said furnace to a state reusable for cores.

42. The apparatus of Claim 41, wherein, said furnace includes, at least, a furnace upper portion, and a furnace lower portion, said collection means includes, at least, a hopper including, at least, a hopper inlet defining an opening in the furnace lower portion that is oriented such that the loosened portions of sand core fall into said hopper inlet, a hopper outlet defining an opening below said hopper inlet, and a hopper wall connecting said hopper inlet to said hopper outlet such that a hopper interior is defined and a passage exists through said hopper interior from said hopper inlet to said hopper outlet, wherein said hopper wall is angled such that, under the force of gravity, the collected portions of sand core tend to accumulate toward said hopper outlet, said discharge means is connected to said hopper outlet, said regulating means includes, at least, measurement means for determining the amount of collected portions of sand core within said hopper interior, and signal means for generating a signal when said measurement means determines that a predetermined amount of collected portions of sand core are within said hopper interior, and said discharge means is responsive to said signal of said signal means to effect discharge of the reclaimed sand, wherein the reclaimed sand passes from said hopper interior and is discharged from said furnace.

43. A method for heat treating a casting having a sand core and reclaiming sand from the sand core, the sand core comprising sand particles bound together by a binder material, the sand core defining a cavity within the casting, and the method comprising steps of: introducing the casting, with at least a portion of the sand core therein, into a furnace;
heating the furnace to a temperature in excess of the combustion temperature of the binder material; containing the casting, with the at least a portion of the sand core therein, within the heated furnace; combusting binder material of at least a portion of the sand core disposed within the casting, whereby portions of the sand core are loosened and fall from the cavity of the casting while the casting is within the furnace; collecting the portions of the sand core which fall from the casting; fluidizing the collected portions of the sand core within a flow of air such that sand is at least partially reclaimed from the collected portions of the sand core, wherein the flow of air is directed into the furnace, and wherein the flow of air is oxygenated and contributes to the creation of an oxygenated atmosphere within the furnace, which oxygenated atmosphere facilitates, at least in part, the combusting step; and conveying the at least partially reclaimed sand away from the furnace.

44. The method of Claim 43, wherein the collecting step and the fluidizing step are carried out within the furnace.

45. The method of Claim 43, wherein the flow of air is cool, and wherein the method further comprises a step of cooling the at least partially reclaimed sand with the flow of air.

46. The method of Claim 43, further comprising a step of heating the flow of air to above the combustion temperature of the binder material whereby the fluidizing step includes a steps of combusting binder material of the fluidized portions of the sand core, and whereby the fluidizing step contributes to the heating of the furnace.

47. The method of Claim 43, wherein the step of fluidizing includes steps of exposing the collected portions of the sand core to an oxygenated atmosphere, and heating the collected portions of the sand core to above the combustion temperature of the binder, whereby binder material of the collected portions of the sand core is combusted.

48. The method of Claim 47, further comprising a step of regulating the duration of the fluidizing step, whereby the amount of fines and the amount of binder material that are included with the at least partially reclaimed sand conveyed away from the furnace are selectively controlled.

49. The method of Claim 47, wherein the step of fluidizing causes the collected portions of the sand core to be suspended and act like a turbulent fluid.

50. The method of Claim 49, wherein the step of fluidizing further includes a step of abrading combustion by-products off of the collected portions of the sand core, whereby binder material combustion is enhanced.

51. The method of claim 43, wherein the collecting step includes a step collecting the fallen portions of the sand core to define a bed of the collected portions of the sand core, and wherein the fluidizing step includes a step of fluidizing the bed of the collected portions of the sand core.

52. The method of Claim 51, wherein the step of fluidizing further includes a step of heating the bed of the collected portions of the sand core to above the combustion temperature of the binder, whereby binder material of the bed of the collected portions of the sand core is combusted.

53. The method of Claim 51, wherein the collecting step and the fluidizing step are carried out within the furnace.

54. A method for heat treating a casting having a sand core and reclaiming sand from the sand core, the sand core comprising sand particles bound together by a binder material, the sand core defining a cavity within the casting, and the method comprising steps of: introducing the casting, with at least a portion of the sand core therein, into a furnace system, wherein the furnace system defines a heat treating region, and a reclaiming region disposed below the heat treating region and in heat and gaseous communication with the heat treating region, wherein the furnace system includes a support assembly for supporting the casting within the heat treating region, and wherein the introducing step includes a step of placing the casting upon the support assembly; heat treating the casting while the casting is disposed within the heat treating region; dislodging portions of the sand core from the casting while the casting is disposed within the heat treating region, wherein the dislodging step includes a step of combusting binder material of the portion of the sand core;
causing the dislodged portions of the sand core to fall from the casting and the support assembly into the reclaiming region; reclaiming, at least partially and within the reclaiming region, sand from the fallen portions of the sand core, wherein the reclaiming step includes a step of further combusting binder material of the fallen portions of the sand core, wherein the further combusting step includes a step of agitating the fallen portions of sand core while retaining them within an oxygenated atmosphere; and conveying the reclaimed sand away from the furnace system, thereby accomplishing heat treatment, core removal, and at least partial sand reclamation in an integrated process associated with a single furnace system.

55. The method of Claim 54, wherein the heat treating region and the reclaiming region are both disposed within a single furnace.

56. The method of Claim 54, wherein the further combusting step includes a step of fluidizing the fallen portions of the sand core, and wherein the fluidizing step includes the agitating step.

57. The method of Claim 54, wherein the method further comprises a step of maintaining the released sand core portions in a heated state during the time between the dislodging step and the reclaiming step.

58. The method of Claim 54, wherein the step of reclaiming is carried out prior to any activity intended to substantially cool the dislodged portions of the sand core.

59. The method of Claim 54, wherein the heat treating region and the reclaiming region are vertically aligned.

60. The method of Claim 54, wherein the dislodged portions of the sand core free fall from casting and the support assembly into the reclaiming region.

61. The method of Claim 54, wherein the reclaiming step further includes steps of collecting the fallen portions of the sand core within the reclaiming region to define a bed of fallen portions of the sand core, and fluidizing the bed of the fallen portions of the sand core, wherein the fluidizing step includes the agitating step.

62. The method of Claim 61, wherein the step of reclaiming is carried out prior to any activity intended to substantially cool the dislodged portions of the sand core, and wherein the heat treating region and the reclaiming region are both disposed within a single furnace.

63. The method of Claim 54, wherein the combusting step of the dislodging step includes a step of exposing the casting and at least a portion of the sand core therein to an oxygenated and heated atmosphere, and wherein the further combusting step further includes a step of suspending, within the oxygenated and heated atmosphere, at least some of the fallen portions of the sand core.

64. The method of Claim 63, wherein the further combusting step includes a step of fluidizing at least some of the fallen portions of the sand core, wherein the fluidizing step includes the suspending step and the agitating step.

65. The method of Claim 63, wherein the suspending step includes steps of providing a screen disposed beneath the casting and the support assembly, suspending on the screen fallen portions of the sand core which are larger than apertures defined by the screen, to allow further combustion of binder material therefrom, and releasing the suspended portions of the sand core subsequent to the combustion of binder material therefrom.

66. The method of Claim 65, wherein the released portions of the sand core are subjected to the agitating step.

67. The method of Claim 54, wherein the further combusting step of the reclaiming step further includes a step of suspending, within an oxygenated and heated atmosphere, at least some of the fallen portions of the sand core such that binder material is combusted from the suspended portions of the sand core, and wherein the combusting step of the dislodging step includes a step of exposing the casting and at least a portion of the sand core therein to the oxygenated and heated atmosphere.

68. The method of Claim 64, wherein the further combusting step includes a step of fluidizing at least some of the fallen portions of the sand core, and wherein the fluidizing step includes the suspending step and the agitating step.

69. The method of Claim 67, wherein the suspending step includes steps of providing a screen disposed beneath the casting and the support assembly, suspending on the screen fallen portions of the sand core which are larger than apertures defined by the screen, to allow further combustion of binder material therefrom, and releasing the suspended portions of the sand core subsequent to the combustion of binder material therefrom.

70. The method of Claim 69, wherein the released portions of the sand core are subjected to the agitating step.

71. The method of Claim 54, wherein the further combusting step of the reclaiming step further includes a step of suspending, within an oxygenated atmosphere, at least some of the portions of the sand core which have fallen from the casting and the support assembly such that binder material is combusted from the suspended portions of the sand core.

72. The method of Claim 71, wherein the further combusting step includes a step of fluidizing at least some of the fallen portions of the sand core, wherein the fluidizing step includes the suspending step and the agitating step.

73. The method of Claim 71, wherein the suspending step includes steps of providing a screen disposed beneath the casting and the support assembly, suspending on the screen fallen portions of the sand core which are larger than apertures defined by the screen, to allow further combustion of binder material therefrom, and releasing the suspended portions of the sand core subsequent to the combustion of binder material therefrom.

74. The method of Claim 73, wherein the suspending step includes steps of providing a screen disposed beneath the casting and the support assembly, suspending on the screen fallen portions of the sand core which are larger than apertures defined by the screen, to allow further combustion of binder material therefrom, releasing the portions of the sand core suspended upon the screen subsequent to the combustion of binder material therefrom, and fluidizing the released portions of the sand core.

75. The method of Claim 71, wherein the heat treating region and the reclaiming region are both disposed within a single furnace.

76. The method of Claim 71, wherein the step of suspending is carried out prior to any activity that substantially cools the released sand core portions.

77. The method of Claim 71, wherein the combusting step of the dislodging step includes a step of exposing the casting and at least a portion of the sand core therein to the oxygenated atmosphere.

78. The method of Claim 71, wherein the support assembly includes a roller hearth assembly, wherein the introducing step includes steps of placing the casting into a basket, and placing the basket, with the casting therein, upon the roller hearth assembly, and wherein the dislodged portions of the sand core fall from the casting, the basket, and the roller hearth assembly prior to the suspending step.

79. A method for heat treating a casting having a sand core and reclaiming sand from the sand core, the sand core comprising sand particles bound together by a binder material, the sand core defining a cavity within the casting, and the method comprising steps of: providing an oxygenated atmosphere;
heating the oxygenated atmosphere to a temperature in excess of the combustion temperature of the binder material; introducing the casting, with at least a portion of the sand core therein, into a furnace, wherein the furnace includes a support assembly for supporting the casting within the furnace, wherein the introducing step includes a step of placing the casting upon the support assembly, wherein the casting is exposed within the furnace to the oxygenated and heated atmosphere to permit binder material to combust, and wherein portions of the sand core are loosened from and fall from the cavity of the casting and the support assembly while the casting is within the furnace; collecting, distant from the casting and the support assembly, the portions of the sand core which fall from the support assembly prior to the binder material being combusted therefrom; maintaining the collected portions of the sand core within the oxygenated atmosphere to combust binder material from the collected portions of the sand core, wherein the maintaining step includes a step of agitating the collected portions of the sand core while retaining them within the oxygenated atmosphere, whereby sand is at least partially reclaimed from the collected portions of the sand core; and conveying the at least partially reclaimed sand away from the furnace.

80. The method of Claim 79, wherein the maintaining step further includes a step of suspending the collected portions of the sand core within the oxygenated atmosphere.

81. The method of Claim 80, wherein the suspending step includes steps of providing a screen disposed beneath the casting and the support assembly, suspending on the screen fallen portions of the sand core which are larger than apertures defined by the screen, to allow further combustion of binder material therefrom, and releasing the suspended portions of the sand core subsequent to the combustion of binder material therefrom.

82. The method of Claim 80, wherein the steps of suspending and agitating are carried out within the furnace.

83. The method of Claim 80, wherein the steps of suspending and agitating comprise a step of fluidizing the collected portions of the sand core within the oxygenated atmosphere.

84. The method of Claim 82, wherein the method further comprises steps of providing a screen disposed beneath the casting and the support assembly, suspending on the screen fallen portions of the sand core which are larger than apertures defined by the screen, to allow further combustion of binder material therefrom, and releasing the suspended portions of the sand core subsequent to the combustion of binder material therefrom.

85. The method of Claim 83, wherein the step of fluidizing the collected portions of the sand core is carried out within the furnace.

86. The method of Claim 82, wherein the furnace defines a plurality of zones that are spatially displaced from one another, and wherein the method further comprises a step of conveying the casting along a path through the plurality of zones.

87. A method for heat treating a casting having a sand core and reclaiming sand from the sand core, the sand core comprising sand particles bound together by a binder material, the sand core defining a cavity within the casting, and the method comprising steps of: introducing the casting, with at least a portion of the sand core therein, into a furnace;
heating the furnace to a temperature in excess of the combustion temperature of the binder material; containing the casting, with the at least a portion of the sand core therein, within the heated furnace; combusting binder material of at least a portion of the sand core disposed within the casting, whereby portions of the sand core are loosened and fall from the cavity of the casting while the casting is within the furnace; collecting the portions of the sand core which fall from the casting; fluidizing the collected portions of the sand core within a flow of heated gas such that sand is at least partially reclaimed from the collected portions of the sand core, wherein the flow of heated gas is directed into the furnace, and wherein the flow of heated gas contributes to the heating of the furnace; and conveying the at least partially reclaimed sand away from the furnace.

88. The method of Claim 87, wherein the flow of heated gas is oxygenated and contributes to the creation of an oxygenated atmosphere within the furnace, which oxygenated atmosphere facilitates, at least in part, the combusting step.

89. The method of Claim 87, wherein the step of fluidizing the collected portions of the sand core is carried out within the furnace.

90. A method for heat treating a casting having a sand core and reclaiming sand from the sand core, the sand core comprising sand particles bound together by a binder material, the sand core defining a cavity within the casting, and the method comprising steps of: introducing a casting with at least some sand core therein into a furnace, wherein the furnace includes a support assembly for supporting the casting within the furnace, and wherein the introducing step includes a step of placing the casting upon the support assembly; heating the furnace to a temperature sufficient to heat treat the casting and sufficient to combust the binder material of the sand core;
burning binder material of the sand core within the furnace to release sand core portions from the casting, wherein the released sand core portions fall from the cavity of the casting and the support assembly while the casting is within the furnace; reclaiming, at a reclaiming region distant from the casting and the support assembly, at least some sand from portions of the fallen sand core portions, wherein the reclaiming step includes a step of burning binder material of portions of the fallen sand core portions, the burning step including contemporaneous steps of agitating the fallen sand core portions while retaining them in an oxygenated atmosphere, and wherein the reclaiming region and the furnace are proximately located such that heat passes between the reclaiming region and the furnace; and thereafter conveying sand and any attached binder material away from the furnace.

91. The method of Claim 90, wherein gasses are transferred between the reclaiming region and the furnace.

92. The method of Claim 90, wherein the step of reclaiming is carried out prior to any activity intended to substantially cool the released sand core portions.

93. The method of Claim 90, wherein the step of introducing the casting into the furnace is performed prior to any mechanical shaking intended to remove meaningful portions of the sand core, whereby mechanical shaking for core removal is avoided.

94. The method of Claim 90, wherein the reclaiming region is below the support assembly such that the released sand core potions fall, under the force of gravity, from the support assembly to the reclaiming region.

95. The method of Claim 94, wherein the reclaiming region is disposed within the furnace.

96. The method of Claim 90, wherein the reclaiming step includes a step of fluidizing the fallen sand core portions, wherein the fluidizing step includes the contemporaneous steps of agitating and exposing.

97. The method of Claim 96, wherein the reclaiming step further includes a step of collecting a bed of the fallen sand core portions, and wherein the fluidizing step further includes a step of fluidizing the bed of the fallen sand core portions.

98. The method of Claim 97, wherein the collecting step and the fluidizing step are carried out within the furnace.

99. The method of Claim 96, wherein the step of fluidizing further includes a step of heating the fallen sand core portions.

100. The method of Claim 96, wherein the step of fluidizing contributes to the heating of the furnace.

101. The method of Claim 96, further comprising a step of controlling the duration of the fluidizing, whereby the amount of fines and the amount of binder material that are included with the sand conveyed away from the furnace are controlled.

102. A furnace system for heat treating a casting having a sand core and reclaiming sand from the sand core, the sand core comprising sand particles bound together by a binder material, the sand core defining a cavity within the casting, and the furnace system comprising: a heat treating region for receiving the casting therewithin; a support assembly for supporting the casting within the heat treating region; and a heating means for heating said heat treating region to a temperature sufficient to loosen portions of the sand core from the casting while the casting is in said heat treating region; a reclaiming region disposed below said heat treating region and in heat and gaseous communication with said heat treating region, wherein the loosened portions of the sand core fall under the force of gravity from the casting and said support assembly into said reclaiming region; and a fluidizer for fluidizing and reclaiming sand from the fallen portions of the sand core disposed within said reclaiming region.

103. The furnace system of Claim 102, further comprising a conveyer downstream from said reclaiming region for conveying the reclaimed sand away from the reclaiming region.

104. The furnace system of Claim 102, wherein said fluidizer is constructed and arranged to define and fluidize a bed of the fallen portions of the sand core.

105. The furnace system of Claim 102, wherein the furnace system defines a work chamber, wherein said heat treating region and said reclaiming region are both disposed within said work chamber, and wherein said fluidizer is constructed and arranged to define and fluidize, within said work chamber, a bed of the fallen portions of the sand core.

106. The furnace system of Claim 102, wherein said heat treating region and said reclaiming region are vertically aligned.

107. The furnace system of Claim 106, wherein the furnace system defines a work chamber, and wherein said heat treating region and said reclaiming region are both disposed within said work chamber.

108. The furnace system of Claim 106, wherein said furnace system further defines a vertically extending passage between said heat treating region and said reclaiming regionl wherein said passage allows the loosened portions of the sand core to fall substantially vertically from said heat treating region to said reclaiming region, and wherein said passage facilitates said gaseous and heat communication.

109. The furnace system of Claim 102, wherein the furnace system further comprises a hopper defining a hopper interior and including a hopper inlet that is oriented such that the loosened portions of the sand core fall into said hopper inlet and into said hopper interior, and a hopper outlet defining an opening below said hopper inlet, wherein said hopper outlet is constructed and arranged to pass the fallen portions of the sand core from said hopper interior, and wherein said fluidizer is proximate to said hopper outlet.

110. The furnace system of Claim 109, wherein said fluidizer is connected to said hopper proximate to said hopper outlet.

111. The furnace system of Claim 110, wherein said fluidizer is directly connected to said hopper outlet.

112. The furnace system of Claim 110, wherein the furnace system defines a work chamber, and wherein said hopper is at least partially disposed within said work chamber and said hopper outlet is further constructed and arranged to pass the fallen portions of the sand core from said work chamber.

113. The furnace system of Claim 112, wherein said heat treating region and said reclaiming region are vertically aligned.

114. The furnace system of Claim 113, wherein said furnace system further defines a vertically extending passage between said heat treating region and said reclaiming region, wherein said passage allows the loosened portions of the sand core to fall substantially vertically from said heat treating region to said reclaiming region, and wherein said passage facilitates said gaseous and heat communication.

115. The furnace system of Claim 109, wherein said fluidizer includes a source of pressurized gas, and a fluidizer conduit which defines a hollow conduit interior, wherein said fluidizer conduit extends from a first end that is in communication with said source of pressurized gas and terminates at a second end in a manner that causes fluidization of the fallen portions of the sand core.

116. The furnace system of Claim 115, wherein said fluidizer further includes a heater for heating the fallen portions of the sand core to a temperature above the combustion temperature of the binder material of the fallen portions of the sand core, and wherein said source of pressurized gas includes a source of oxygen, whereby binder material of the fallen portions of the sand core is combusted.

117. The furnace system of Claim 115, wherein said fluidizer further includes a fluidizing ring connected to said second end of said fluidizer conduit, wherein said fluidizing ring includes a ring frame at least partially bounding a central open area and defining, a hollow ring interior in communication with the conduit interior of said fluidizer conduit, and a plurality of fluidizing portals communicating between the central open area and the ring interior.

118. The furnace system of Claim 117, wherein said fluidizing ring is disposed such that fallen portions of the sand core pass from said hopper outlet and through said central open area defined by said ring frame, and wherein said fluidizing portals are angled steeply enough so that fallen portions of the sand core which pass through the central open area cannot easily migrate up, through the fluidizing portals into the ring interior.

119. The furnace system of Claim 115, wherein said fluidizer is constructed and arranged to fluidize the fallen portions of the sand core within said hopper interior.

120. The furnace system of Claim 119, wherein the furnace system defines a work chamber and said heat treating region is disposed within said work chamber, wherein the furnace system further comprises a level means for controlling the level of fallen portions of the sand core within said hopper interior, said level means including a measurement means for determining the amount of fallen portions of the sand core within said hopper interior, and a signal means for generating a signal when said measurement means determines that a first amount of fallen portions of the sand core is within said hopper interior, and a discharge means for discharging reclaimed sand from said work chamber, wherein said discharge means is responsive to said signal of said signal means to effect discharge of fallen portions of the sand core, and wherein during said discharge, fallen portions of the sand core pass from said hopper interior and are discharged from said work chamber through said hopper outlet, and wherein the amount of fallen portions of the sand core that collect within said hopper interior is controlled by said level means and said discharge means such that the length of time that fallen portions of the sand core remain in said hopper interior and are subjected to said fluidizer is controlled, whereby the amount of binder material and fines contained with the reclaimed sand discharged from said work chamber is controlled.

121. The furnace system of Claim 120, wherein said fluidizer interacts with the fallen portions of the sand core within said hopper interior to define a back-pressure in said conduit interior of said fluidizer conduit, wherein the back-pressure increases as the depth of the fallen portions of the sand core within said hopper interior increases, wherein said measurement means includes a gauge in communication with said conduit interior for determining the back-pressure, and wherein said signal means generates a signal when the back-pressure reaches a first level, whereby a specified amount of fallen portions of the sand core is maintained within said hopper interior.

122. The furnace system of Claim 120, wherein said signal means includes a signal adjustment means for selectively specifying the back-pressure at which said signal means generates said signal, whereby the amount of fallen portions of the sand core that collect within said hopper interior is selectively controlled, whereby the length of time that fallen portions of the sand core remain in said hopper interior and are subjected to said fluidizer is selectively controlled, whereby the amount of binder material and fines contained with the reclaimed sand discharged from said work chamber is selectively controlled.

123. The furnace system of Claim 120, wherein said measurement means includes a sensor disposed at a height above said hopper outlet, wherein said signal means generates a signal when the fallen portions of the sand core in said hopper interior define a level of fallen portions of the sand core that is at or above said height of said sensor.

124. Furnace system of Claim 120, wherein said measurement means includes a plurality of sensors, wherein each sensor of said plurality of sensors is disposed at a different one of a plurality of different heights above said hopper outlet, wherein each of said plurality of different heights corresponds to a desired amount of fallen portions of the sand core in said hopper interior, and said signal means further includes selector means for selectively specifying one sensor of said plurality of sensors as controlling, wherein, as the level of fallen portions of the sand core in said hopper interior rises to the height of said sensor of said plurality of sensors that is controlling, said signal means generates said signal, whereby the amount of fallen portions of the sand core that collect within said hopper interior is selectively controlled.

125. A method for reclaiming sand from a sand core, the sand core comprising sand particles bound together by a binder material, the sand core defining a cavity within the casting, and the method comprising the steps of: introducing the casting, with at least a portion of the sand core therein, into a furnace; heating the casting and the sand core therein to a temperature in excess of the combustion temperature of the binder material, whereby binder material of the sand core combusts and portions of the sand core are loosened from the cavity of the casting while the casting is within the furnace;
and fluidizing the loosened portions of the sand core within a flow of gas that is directed into the furnace.

126. The method of Claim 125, wherein the method further comprises a step of collecting the loosened portions of the sand core within the furnace, wherein the fluidizing step includes a step of fluidizing the collected portions of sand core, and wherein the method further comprises a step of discharging loosened portions of the sand core from the collected portions of the sand core and the furnace during steps of heating and fluidizing.

127. The method of Claim 125, wherein the flow of gas is oxygenated.

128. The method of Claim 127, wherein the fluidizing step at least partially contributes to the creation of an oxygenated atmosphere within the furnace, which oxygenated atmosphere at least partially facilitates the combustion of the binder material.

129. The method of Claim 127, wherein the method further comprises the steps of: conveying the casting through the furnace, wherein the furnace defines a plurality of zones that are spatially displaced from one another, wherein the conveying step includes a step of sequentially conveying the castings through zones of the plurality of zones, and wherein the distribution of the loosened portions of the sand core material across the plurality of zones is varied; and defining a plurality of beds of loosened portions of sand core, wherein each bed of the plurality of beds defines a level, and wherein the fluidizing step includes a step of fluidizing beds of the plurality of beds; maintaining a first level of loosened portions of sand core material within a first bed of the plurality beds; and maintaining a second level of loosened portions of sand core material within a second bed of the plurality beds, wherein the step of maintaining a first level is independent of the step of maintaining a second level.

130. The method of Claim 127, wherein the method further comprises a step of defining a bed of loosened portions of sand core, and wherein the fluidizing step includes a step of fluidizing the bed of loosened portions of sand core.

131. The method of Claim 130, wherein the bed defines a level, and wherein the method further comprises a step of at least generally maintaining the level.

132. The method of Claim 130, wherein the fluidizing step includes the step of combusting binder material of the bed of loosened portions of sand core, whereby the fluidizing step at least partially reclaims sand from the loosened portions of the sand core.

133. The method of Claim 132, further comprising the step of controlling the fluidizing so that the amount of fines and the amount of binder that are included with the reclaimed sand are controlled.

134. The method of Claim 132, wherein the bed defines a level, and wherein the method further comprises the step of controlling the level so that the amount of fines and the amount of binder that are included with the reclaimed sand are controlled.

135. The method of Claim 130, wherein the method further comprises the steps of: conveying the casting through the furnace, wherein the furnace defines a plurality of zones that are spatially displaced from one another, wherein the conveying step includes a step of sequentially conveying the castings through zones of the plurality of zones, and wherein the distribution of the loosened portions of the sand core material across the plurality of zones is varied; and compensating for the varied distribution of sand core materials.

136. The method of Claim 135, wherein the compensating step includes a step of varying the fluidizing between zones of the plurality of zones.

137. The method of Claim 125, further comprising the steps of:
introducing unattached portions of sand core into the furnace, wherein the unattached portions of sand core are not attached to the casting; and subjecting the unattached portions of sand core to the fluidizing step.

138. The method of any one of Claims 125-137, wherein the fluidizing step is carried out within the furnace.