Ultrasonic Separation of Foundry Sand Binder
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Solution Overview
Problem
Conventional methods for recycling waste foundry sand are inefficient and costly, requiring high-temperature treatments that consume large amounts of fuel and result in greenhouse gas emissions, and surface treatments that damage the sand, reducing recovery rates and increasing operating expenses.
Innovation Solution
A separation system using ultrasonic waves to induce interface separation between the foundry sand and the binder, with an ultrasonic surface treatment apparatus that generates air bubbles to crack and remove the binder, accompanied by a dehumidifying dryer and grinding apparatus to optimize the recycling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature treatment is performed to oxidize the binder, then the binder can be removed from the waste foundry sand, but large amounts of fuel are required and greenhouse gases are released
Solution Approach 1:
The patent replaces the thermal field (high-temperature oxidation) with an ultrasonic field to remove the binder. The ultrasonic waves generate cavitation and mechanical vibration that physically separate the binder from the sand particles, eliminating the need for high-temperature treatment and associated fuel consumption and greenhouse gas emissions.
Solution Approach 2:
The patent changes the removal mechanism from thermal/chemical (oxidation at high temperature) to physical (ultrasonic vibration and cavitation). By changing the energy form and interaction mechanism, the binder removal is achieved without requiring high temperature, thus reducing fuel consumption and environmental harm.
2Reliability
If impact surface treatment is used to separate the binder, then the binder can be removed from the waste foundry sand, but the waste foundry sand is crushed and excessive atomization occurs, reducing the recovery rate
Solution Approach 1:
The patent uses ultrasonic vibration to gently separate the binder from the sand particles. The ultrasonic waves create oscillating mechanical vibrations that loosen and separate the binder without applying the harsh impact forces that cause sand crushing and atomization, thereby maintaining sand particle integrity and improving recovery rate.
Solution Approach 2:
The patent replaces the mechanical impact treatment with ultrasonic vibration. This substitution allows for binder removal through gentle oscillatory motion and cavitation effects rather than violent impact, preventing sand particle damage and maintaining high recovery rates.
3Reliability
If grinding surface treatment is used to separate the binder, then the binder can be removed from the waste foundry sand, but the waste foundry sand is crushed and excessive atomization occurs, reducing the recovery rate
Solution Approach 1:
The patent employs ultrasonic vibration to separate the binder through gentle oscillatory motion and cavitation, avoiding the harsh grinding action that causes sand crushing and atomization. This vibration-based approach maintains sand particle integrity and significantly improves recovery rate.
Solution Approach 2:
The patent substitutes the mechanical grinding process with ultrasonic vibration. This replacement enables binder removal through non-invasive oscillatory forces and cavitation effects, preventing the crushing and atomization that occur during grinding, thus maintaining high sand recovery rates.
4Reliability
If conventional surface treatment processes are used to remove the binder, then the binder can be separated from the waste foundry sand, but the operating expenses are significant and the process takes a long time
Solution Approach 1:
The patent uses ultrasonic vibration to rapidly separate the binder from the sand particles. The high-frequency oscillations and cavitation effects work simultaneously across all particles, dramatically reducing the processing time compared to conventional sequential impact and grinding treatments.
Solution Approach 2:
The patent replaces time-consuming conventional mechanical treatments with ultrasonic vibration. The ultrasonic field acts on all particles simultaneously through cavitation and vibration, achieving binder removal much faster than sequential impact and grinding operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Minimizes the number of surface treatment processes, reduces recycling costs, and enhances the recovery rate of waste foundry sand by effectively separating the binder without the need for expensive heat treatments, while minimizing environmental impact.
Implementation Method 1
an ultrasonic device mounted therein to apply ultrasonic waves to the mixture of waste foundry sand and water
Implementation Method 2
generate air bubbles on the critical surface between the waste foundry sand and a binder and in gap(s) of the binder
Implementation Method 3
On ore more cracks in the binder are then formed by impact energy generated when the air bubbles collapse
Implementation Method 4
a dehumidifying dryer, which dehumidifies the mixture of waste foundry sand and water discharged from the ultrasonic surface treatment apparatus, and which dries the waste foundry sand
Implementation Method 5
the waste foundry sand is dried by supplying air heated by an electric heater or the like
Data Source
AI summary
The present invention provides a separation system for a waste foundry sand binder using ultrasonic waves, which can minimize the number of surface treatment processes by inducing interface separation between a foundry sand and a binder, and which further optimizes the working process and reduces the recycling cost of waste foundry sand.