JP4679931B2 - Recycled sand production method - Google Patents
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本発明は鋳型から回収された回収砂からの再生砂の製造方法及びそれにより得られた再生砂を用いた鋳型の製造方法に関する。 The present invention relates to a method for producing reclaimed sand from recovered sand collected from a mold and a method for producing a mold using reclaimed sand obtained thereby.
一方、鋳型に用いた鋳物砂は、鋳型を粉砕（型ばらし）して得た回収砂に再生処理を施して再利用されることがある。回収砂の再生方法には、古くより湿式再生法、加熱式再生法、乾式再生法等各種の方法が提案され、実施されている。 On the other hand, the foundry sand used for the mold may be reused by subjecting the recovered sand obtained by crushing the mold (removing the mold) to a regeneration process. Various methods such as a wet regeneration method, a heating regeneration method, and a dry regeneration method have been proposed and practiced as a method for regenerating recovered sand.
しかしながら、湿式再生法では汚水処理装置を必要とし、そのために設備費がかかり、又再生費もかさむ。また再生処理後は砂を乾燥させる必要もある。更には加熱式再生法では燃焼設備、空冷設備を必要とし、またダイオキシン類などを含む排ガスの揮散が問題となる。乾式再生法では、遠心力を利用して砂粒間に摩擦を与え砂粒表面に付着している粘結剤等を除く方法が現在一般的に普及している。しかしながら、この方法では、再生効率を高めようとすると、砂の破砕、細粒化などにより歩留まりが低下し、回収砂１トン当たりの動力原単位も大となる。また細粒骨材に対しては再生処理が困難で、更には最近多用されるようになってきた耐火性粒状人工骨材に対しては、再生処理後も鋳型強度が向上しない場合があった。 However, the wet regeneration method requires a sewage treatment apparatus, which incurs equipment costs and increases regeneration costs. It is also necessary to dry the sand after the regeneration process. Furthermore, the heating regeneration method requires combustion facilities and air cooling facilities, and volatilization of exhaust gas containing dioxins becomes a problem. In the dry regeneration method, a method in which a centrifugal force is used to cause friction between sand particles and remove a binder or the like adhering to the surface of the sand particles is now widely used. However, in this method, if the regeneration efficiency is to be increased, the yield decreases due to sand crushing, fine graining, etc., and the power unit per ton of recovered sand increases. In addition, it is difficult to regenerate fine-grained aggregates. Furthermore, for fire-resistant granular artificial aggregates that have recently been used frequently, the mold strength may not improve even after reclaiming. .
こうした背景から、鋳物砂の再生方法の改善について種々の提案がなされている。例えば、特許文献１には、１００℃以上に加熱された水と接触させる工程を有する回収鋳物砂の再生方法が提案されている。
特許文献１は、不純物の除去率が高く鋳物品質及び鋳型強度が向上できるとされているが、回収鋳物砂を高温、高圧するため、設備面での制約がある。また、処理後の冷却を水と接触した状態で行うのが現状であり、再生処理後の乾燥工程も必要となる。このため、こうした効果が簡易に得られる方法とは言い難い。 In Patent Document 1, it is said that the removal rate of impurities is high and the casting quality and mold strength can be improved. However, since the recovered foundry sand is heated to a high temperature and a high pressure, there is a restriction in terms of equipment. Moreover, under the present circumstances, the cooling after a process is performed in the state which contacted water, and the drying process after a regeneration process is also needed. For this reason, it is hard to say that this effect can be easily obtained.
本発明は、不純物の除去率が高く鋳物品質及び鋳型強度が向上できる、より簡易な再生砂の製造方法を提供することを目的とする。更に本発明は、砂の破砕や細粒化が起こらず、歩留まりが向上する再生砂の製造方法を提供することを目的とする。 An object of the present invention is to provide a simpler method for producing reclaimed sand that has a high impurity removal rate and can improve casting quality and mold strength. Furthermore, an object of the present invention is to provide a method for producing reclaimed sand that does not cause sand crushing or fine granulation and improves the yield.
本発明は、鋳物砂を使用して得られた鋳型を破砕した回収砂を、常圧下で過熱水蒸気と接触させる工程を有する、再生砂の製造方法に関する。 The present invention relates to a method for producing reclaimed sand, comprising a step of contacting recovered sand obtained by crushing a mold obtained by using foundry sand with superheated steam under normal pressure.
また、本発明は、上記本発明の再生砂の製造方法により得られた再生砂を有機系バインダーで硬化させる工程を有する、鋳型の製造方法に関する。 Moreover, this invention relates to the manufacturing method of a casting_mold | template which has the process of hardening the reproduction | regeneration sand obtained by the manufacturing method of the reproduction | regeneration sand of the said invention with an organic type binder.
本発明の再生砂の製造方法によれば、従来の機械的に砂表面を処理する方法に比べ、歩留まりを落とすことなく効率よく残留有機分を除去した鋳物砂を、簡易に得ることができる。また、本発明によって再生された鋳物砂は、鋳物品質及び鋳型強度に優れた鋳型を提供することができる。 According to the method for producing reclaimed sand of the present invention, compared with the conventional method of mechanically treating the sand surface, it is possible to easily obtain foundry sand from which residual organic components have been efficiently removed without decreasing the yield. In addition, the foundry sand regenerated by the present invention can provide a mold excellent in casting quality and mold strength.
本発明では、回収砂（鋳物古砂）を過熱水蒸気と接触させる。回収砂を水蒸気の状態で熱処理するため、処理後の乾燥工程が不要である。また、常圧下で回収砂と過熱水蒸気とを接触させるため、装置も簡易となる。なお、過熱水蒸気とは、約１００℃の水蒸気を常圧のまま更に加熱した気体である。 In the present invention, recovered sand (cast old sand) is brought into contact with superheated steam. Since the recovered sand is heat-treated in the state of water vapor, a drying step after the treatment is unnecessary. Moreover, since the recovered sand and superheated steam are brought into contact with each other under normal pressure, the apparatus is simplified. The superheated steam is a gas obtained by further heating steam at about 100 ° C. with normal pressure.
本発明において、回収砂と過熱水蒸気とを接触させる方法としては、例えばロータリーキルン上部より回収砂を、側面部より過熱水蒸気を導入し、回転させながら回収砂表面に吹き付け連続的に処理する方法や、炭化炉中に投入された回収砂に過熱水蒸気を噴射する方法などが挙げられる。本発明において、回収砂と過熱水蒸気とを接触させる時間は、本発明の効果発現及びエネルギーコストの観点から１０〜１２０分が好ましく、２０〜９０分がより好ましく、３０〜６０分が更に好ましい。 In the present invention, as the method of contacting the recovered sand and superheated steam, for example, the recovered sand from the upper part of the rotary kiln, the superheated steam is introduced from the side surface, and continuously sprayed on the recovered sand surface while rotating, For example, a method of injecting superheated steam onto the recovered sand thrown into the carbonization furnace. In the present invention, the time for contacting the recovered sand and superheated steam is preferably from 10 to 120 minutes, more preferably from 20 to 90 minutes, and even more preferably from 30 to 60 minutes, from the viewpoint of expression of the effect of the present invention and energy cost.
回収砂と過熱水蒸気の接触には、例えば特開２００２−８０８５４号や特開２００４−２０９３１４号に示されている装置を用いることができ、回収砂の再生処理量が多い場合には、前者の装置が好ましく、処理量が少ない場合には後者の装置が好ましい。 For the contact between the recovered sand and superheated steam, for example, an apparatus disclosed in Japanese Patent Application Laid-Open No. 2002-80854 or Japanese Patent Application Laid-Open No. 2004-209314 can be used. An apparatus is preferable, and the latter apparatus is preferable when the amount of processing is small.
このようにして過熱水蒸気処理を行った回収砂を、微粉セパレータにかけ微粉分を取り除き、再生砂として使用する。なお、ここで、回収砂、再生砂とは、「図解 鋳造用語辞典」（社団法人日本鋳造工学会編、２００３年４月２８日、日刊工業新聞社発行）にそれぞれ記載されている通りである。 The recovered sand subjected to the superheated steam treatment in this way is applied to a fine powder separator to remove the fine powder, and used as recycled sand. Here, the recovered sand and the reclaimed sand are as described in “Illustration casting terminology dictionary” (edited by the Japan Foundry Engineering Society, April 28, 2003, published by Nikkan Kogyo Shimbun). .
本発明に用いられる回収砂は、珪砂、ジルコン砂、クロマイト砂、合成ムライト砂やＭｇＯ系の耐火性粒状人工骨材などの鋳物砂に、バインダーを使用して造型した後、解枠（型ばらし）して得られた回収砂ないし余剰砂（以下、合わせて回収砂という）である。また、火炎溶融法にて製造された球状鋳物砂から得られた鋳型からの回収砂を使用することもできる。このような球状鋳物砂は、例えば特開２００４−２０２５７７号に示されるような火炎溶融法により製造される。即ち、Ａｌ2Ｏ3及びＳｉＯ2を主成分とし、Ａｌ2Ｏ3／ＳｉＯ2重量比率が０．９〜１．７、平均粒径が０．０５〜２ｍｍの粉末粒子を出発原料とし、当該粉末粒子を酸素等のキャリアガスに分散させ、下記火炎中で溶融して球状化する。用いる火炎はプロパン、ブタン、メタン、天然液化ガス、ＬＰＧ、重油、灯油、軽油、微粉炭等の燃料を酸素と燃焼させることによって発生させたものや、Ｎ2不活性ガス等を電離させて生じるプラズマジェット火炎などが使用できる。 The recovered sand used in the present invention is made of cast sand such as quartz sand, zircon sand, chromite sand, synthetic mullite sand, MgO-based refractory granular artificial aggregate using a binder, ) Recovered sand or surplus sand (hereinafter collectively referred to as recovered sand). In addition, recovered sand from a mold obtained from spheroidal casting sand produced by a flame melting method can also be used. Such spheroidal sand is produced by a flame melting method as disclosed in Japanese Patent Application Laid-Open No. 2004-202577, for example. That is, powder particles having Al 2 O 3 and SiO 2 as main components, Al 2 O 3 / SiO 2 weight ratio of 0.9 to 1.7, and average particle diameter of 0.05 to 2 mm are used as starting materials, The powder particles are dispersed in a carrier gas such as oxygen, and melted and spheroidized in the following flame. Occurs flame propane, butane, methane, natural liquefied gas, LPG, heavy oil, kerosene, gas oil, and that is generated by burning the fuel oxygen pulverized coal etc., ionizes the N 2 inert gas or the like used Plasma jet flames can be used.
本発明の製造方法は、過熱水蒸気により残存したバインダーを炭化・除去させることにより効果を発現するものであるから、特に有機系バインダーで造型された鋳型から回収された回収砂に好適である。ここで有機系バインダーとしては、フラン樹脂、フェノール樹脂、アルカリフェノール樹脂、シェルモールド法、フェノールウレタン樹脂、エポキシ樹脂、不飽和ポリエステル樹脂やメチレンジアクリルアミド等の不飽和基を有する樹脂、澱粉、ゼラチン、糖類等が挙げられる。 Since the production method of the present invention exhibits an effect by carbonizing and removing the binder remaining with superheated steam, it is particularly suitable for recovered sand recovered from a mold made of an organic binder. Here, as the organic binder, furan resin, phenol resin, alkali phenol resin, shell mold method, phenol urethane resin, epoxy resin, unsaturated polyester resin, resin having an unsaturated group such as methylene diacrylamide, starch, gelatin, Examples include saccharides.
本発明において、過熱水蒸気の温度は、有機バインダーが付着した回収砂の有機分の炭化促進という観点から、３００℃以上が好ましく、更には５００℃以上が好ましい。また、上限温度は特に限定されないが、エネルギーコストの観点から、１２００℃以下が好ましく、１０００℃以下がより好ましい。ここで、過熱水蒸気の温度は、常圧での温度である。なお、本発明において、常圧とは、大気圧をいうが、若干の減圧又は加圧の範囲（例えば０．０５〜０．１５ＭＰａ、好ましくは０．０８〜０．１２ＭＰａの減圧又は加圧）は含むものとし、大気圧が好ましい。 In the present invention, the temperature of the superheated steam is preferably 300 ° C. or higher, more preferably 500 ° C. or higher, from the viewpoint of promoting carbonization of the organic content of the recovered sand to which the organic binder is attached. Moreover, although an upper limit temperature is not specifically limited, From a viewpoint of energy cost, 1200 degrees C or less is preferable and 1000 degrees C or less is more preferable. Here, the temperature of the superheated steam is a temperature at normal pressure. In the present invention, normal pressure refers to atmospheric pressure, but a range of slight pressure reduction or pressurization (for example, 0.05 to 0.15 MPa, preferably 0.08 to 0.12 MPa pressure reduction or pressurization). Is included and atmospheric pressure is preferred.
本発明の再生砂の製造方法は、残存したバインダーを除去するのが困難な耐火性粒状人工骨材に対しても顕著な効果を発現することから、回収砂として、耐火性粒状人工骨材を３０〜１００重量％、更に５０〜１００重量％含有するものを好適に使用することができる。 The method for producing reclaimed sand according to the present invention exhibits a remarkable effect even on refractory granular artificial aggregates in which it is difficult to remove the remaining binder, so that refractory granular artificial aggregates are used as recovered sand. What contains 30-100 weight% and also 50-100 weight% can be used conveniently.
本発明により再生された鋳物砂を用いて鋳型を製造する方法としては、鋳物砂に対して、従来公知の鋳型バインダー、例えば、粘土、水ガラス、シリカゾル、無機塩、エチルシリケート等の無機系バインダー、フラン樹脂、フェノール樹脂、アルカリフェノール樹脂、シェルモールド法、フェノールウレタン樹脂、エポキシ樹脂、不飽和ポリエステル樹脂やメチレンジアクリルアミド等の不飽和基を有する樹脂、澱粉、ゼラチン、糖類等の有機系バインダーを用いて、それぞれ従来公知の硬化方法により鋳型を製造することができる。バインダーは有機系バインダーが好ましい。これらバインダーは、本発明により再生された鋳物砂１００重量部に対して、通常０．０５〜１０重量部添加するのが好適である。また、従来公知のシランカップリング剤、添加剤等を用いても構わない。 As a method for producing a mold using the foundry sand regenerated by the present invention, conventionally known mold binders such as clay, water glass, silica sol, inorganic salt, ethyl silicate and the like are used for the foundry sand. , Furan resin, phenol resin, alkali phenol resin, shell mold method, phenol urethane resin, epoxy resin, unsaturated polyester resin, resins having unsaturated groups such as methylene diacrylamide, organic binders such as starch, gelatin, saccharides, etc. Each can be used to produce a mold by a conventionally known curing method. The binder is preferably an organic binder. These binders are preferably added in an amount of usually 0.05 to 10 parts by weight with respect to 100 parts by weight of foundry sand regenerated according to the present invention. Moreover, you may use a conventionally well-known silane coupling agent, an additive, etc.
珪砂及び尿素変性フラン樹脂を粘結剤に使用して得られた鋳型を破砕した回収砂（珪砂回収砂）、又は、合成ムライト砂及び水溶性アルカリフェノール樹脂を粘結剤に使用して得られた鋳型を破砕した回収砂（合成ムライト回収砂）を、外気の進入を防止できる構造のロータリーキルン方式の処理炉に投入し、回収砂を回転攪拌させながら過熱水蒸気を表１、２に示す条件で供給し、回収砂と接触させた。 It is obtained by using recovered sand (silica sand recovered sand) obtained by crushing a mold obtained by using silica sand and urea-modified furan resin as a binder, or synthetic mullite sand and water-soluble alkali phenol resin as a binder. The recovered sand (synthetic mullite recovered sand) obtained by crushing the cast mold is put into a rotary kiln type processing furnace with a structure that can prevent the outside air from entering, and the superheated steam is rotated under the conditions shown in Tables 1 and 2 while rotating the recovered sand. Feed and contact with recovered sand.
その後、過熱水蒸気処理砂をサイクロン式セパレータにより微粉分を除去し、再生砂（珪砂再生砂又は合成ムライト再生砂）とした。得られた再生砂について、鋳型強度、強熱減量、並びに歩留まりを以下の方法で測定した。結果を表１、２に示す。 Thereafter, fine particles were removed from the superheated steam-treated sand using a cyclone separator to obtain reclaimed sand (silica sand reclaimed sand or synthetic mullite reclaimed sand). With respect to the obtained reclaimed sand, the mold strength, ignition loss, and yield were measured by the following methods. The results are shown in Tables 1 and 2.
（１）鋳型強度
ＪＩＳ Ｚ ２６０１−１９９３により測定した。ただし、尿素変性フラン樹脂を用いた珪砂再生砂については、２５℃×６０％ＲＨ条件下で、「カオーライトナー Ｃ−１４」（花王クエーカー（株）製）を珪砂再生砂１００重量部に対し０．３２重量部添加混練後、「カオーライトナー ３４０Ｂ」（花王クエーカー（株）製）を珪砂再生砂１００重量部に対し０．８重量部添加し混練後、直ちに直径５０ｍｍ×高さ５０ｍｍのテストピースに充填し、２４時間後、圧縮強度（ＭＰａ）を測定した。また、水溶性アルカリフェノール樹脂を用いた合成ムライト再生砂については、「カオーステップ ＱＸ−１４０」（花王クエーカー（株）製）を合成ムライト再生砂１００重量部に対し０．３重量部添加し混練後、「カオーステップ Ｓ−６６０」（花王クエーカー（株）製）を合成ムライト再生砂１００重量部に対し１．５重量部添加し混練後、直ちに直径５０ｍｍ×高さ５０ｍｍのテストピースに充填し、２４時間後、圧縮強度（ＭＰａ）を測定した。
(1) Mold strength Measured according to JIS Z 2601-1993. However, with respect to silica sand regenerated sand using urea-modified furan resin, “Kaorrightner C-14” (manufactured by Kao Quaker Co., Ltd.) was added to 100 parts by weight of silica sand regenerated sand under the condition of 25 ° C. × 60% RH. After adding and kneading 32 parts by weight, a test piece having a diameter of 50 mm and a height of 50 mm was immediately added after adding and mixing 0.8 parts by weight of “Kaolitener 340B” (manufactured by Kao Quaker Co., Ltd.) with respect to 100 parts by weight of silica sand recycled sand. After 24 hours, the compressive strength (MPa) was measured. In addition, for synthetic mullite reclaimed sand using water-soluble alkali phenol resin, 0.3 part by weight of “Kaoru step QX-140” (manufactured by Kao Quaker Co., Ltd.) is added to 100 parts by weight of synthetic mullite reclaimed sand and kneaded. Then, after adding 1.5 parts by weight of “Kao Step S-660” (manufactured by Kao Quaker Co., Ltd.) to 100 parts by weight of synthetic mullite reclaimed sand, it was immediately filled into a test piece having a diameter of 50 mm and a height of 50 mm. After 24 hours, the compressive strength (MPa) was measured.
（２）強熱減量
鋳物砂中に含まれる粘土の結晶水、有機粘結剤や添加剤などの有機物の量であり、ＪＩＳ Ｚ ２６０１−１９９３により測定した。
(2) Loss on ignition It is the amount of organic matter such as crystallization water of clay, organic binder and additive contained in the foundry sand, and was measured according to JIS Z 2601-1993.
（３）歩留まり
再生処理（微粉除去後）前後での砂重量％で求めた。
(3) Yield Yield was determined by sand weight% before and after regeneration treatment (after fine powder removal).
（注）比較例１は、通常の機械的再生処理を想定したものであり、ロータリーリクレーマー（日本鋳造（株）製）のＢ再生条件（弱条件）により１パス処理した。 (Note) In Comparative Example 1, a normal mechanical regeneration process was assumed, and one pass treatment was performed under the B regeneration condition (weak condition) of a rotary reclaimer (manufactured by Nippon Casting Co., Ltd.).
（注）比較例２は、通常の機械的再生処理を想定したものであり、ロータリーリクレーマー（日本鋳造（株）製）のＡ再生条件（強条件）により４パス処理した。 (Note) In Comparative Example 2, a normal mechanical regeneration process was assumed, and a 4-pass process was performed under the A regeneration condition (strong condition) of a rotary reclaimer (manufactured by Nippon Casting Co., Ltd.).
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| JP2009022980A (en) * | 2007-07-19 | 2009-02-05 | Kao Corp | Method for manufacturing mold |
| JP5422193B2 (en) * | 2008-12-17 | 2014-02-19 | 花王株式会社 | Hardener composition and method for producing mold |
| WO2015115231A1 (en) * | 2014-01-28 | 2015-08-06 | 有限会社ウインズテック | Method for removing sand core and apparatus therefor |
| JP6445333B2 (en) * | 2015-01-14 | 2018-12-26 | 旭有機材株式会社 | Recycle method of recovered foundry sand |
| JP6445334B2 (en) * | 2015-01-14 | 2018-12-26 | 旭有機材株式会社 | Recycling of recovered foundry sand |
| JP6728550B2 (en) * | 2016-08-03 | 2020-07-22 | リグナイト株式会社 | Method for removing mold remaining in casting |
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| JP2002178100A (en) * | 2000-12-15 | 2002-06-25 | Toyohashi University Of Technology | Method for reconditioning recovered molding sand |
| JP2004202577A (en) * | 2002-12-09 | 2004-07-22 | Kao Corp | Spherical molding sand |
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| JPS5841135B2 (en) * | 1975-03-26 | 1983-09-09 | 三菱重工業株式会社 | Imonozu Nano Saiseihouhou |
| JPS5288536A (en) * | 1976-01-21 | 1977-07-25 | Hitachi Ltd | Old sand wet reproduction process and device for mold |
| JPS5292823A (en) * | 1976-02-02 | 1977-08-04 | Hitachi Ltd | Old sand cleaning reproduction process |
| JPS5299924A (en) * | 1976-02-18 | 1977-08-22 | Hitachi Ltd | Old sand cleaning reproduction process |
| EP0132493B1 (en) * | 1980-12-16 | 1988-06-15 | Cosworth Research And Development Limited | Apparatus for and method of reclaiming used foundry sand |
| CH681283A5 (en) * | 1990-08-16 | 1993-02-26 | Fischer Ag Georg | |
| JP3160101B2 (en) * | 1992-11-19 | 2001-04-23 | 旭テック株式会社 | Casting sand recycling method |
| JPH06154941A (en) * | 1992-11-20 | 1994-06-03 | Kurimoto Ltd | Reconditioning method for molding sand and production of casting mold |
| JP3162218B2 (en) * | 1992-12-04 | 2001-04-25 | 旭テック株式会社 | Casting sand recycling method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2002178100A (en) * | 2000-12-15 | 2002-06-25 | Toyohashi University Of Technology | Method for reconditioning recovered molding sand |
| JP2004202577A (en) * | 2002-12-09 | 2004-07-22 | Kao Corp | Spherical molding sand |
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