ProserviceTech develops a tailor-made solution with each customer, based on the available budget, space/layout, cycle time, existing equipment, energy consumption targets and simulations to look for the most efficient method of drying.
We supply static batch ovens, continuous/tunnel ovens, rotary table ovens, ovens dedicated to single core-shooters, drying panels for big moulds with furan/no-bake moulding and vertical ovens. These are just some of our possible solutions for a foundry.
Cores drying: ProserviceTech’s approach
Drying all the water out of the coating is a crucial and a necessary operation to avoid any casting defects. For some suppliers “drying” simply means blowing hot air into a chamber, for ProserviceTech it means the following:
• Evaluation for harnessing any existing “free of charge” heat energy sources already present in the foundry (such as hot water from compressor cooling systems or cooling oil from a cupola furnace, etc.), developing hybrid solutions: for example by using the heat energy recovered from furnace cooling oil and, if insufficient, by adding heat generated from gas burners or electrical elements;
• 3D simulation to optimize the hot air flow and minimize the energy for convection air drying
• Complete review and analysis of your process from the beginning, looking for the best possible and most cost-effective engineering solution
• Support for the critical transition from alcohol-based to water-based coating
• Developing the best and most cost-effective solution to generate the required thermal power: by utilizing gas burners and heat exchangers or by electrical resistor elements strategically placed within the drying chamber
• Extracting as much heat energy from the system, before it is released to the atmosphere
• Dynamic control of wet exhaust air by continuously taking real-time measurements of the moisture content within the drying oven. Most suppliers only control the air temperature and not the moisture content. They constantly release a fixed quantity of wet exhaust air, thus wasting energy and money. In fact, the moisture content of the air will vary with the quantity of cores and ambient conditions. ProserviceTech ovens adapt accordingly to the moisture content of the exhausted air.
• Use of the lowest possible drying temperature (Usually < 140°C) to maintain the highest possible core strength and efficiency of the binder.
• Engineering of complete lines for lost foam patterns (up to 5m) including handling, conveying and flow coating of the patterns.
Drying of big moulds on hand moulding lines
Do you have large moulds or cores and a standard drying oven is not large enough? Or are they coated with alcohol-based coating and are you looking for a simple solution to transition to the water-based coating, without investing huge space and money?
ProserviceTech has developed a “pallet type” drying DTP (Drying Travelling Panels) oven, suitable for this application. The pallets can be stored along a wall or be transported on wheels or even by forklift/crane to a location near the moulds and cores. Using DTP, drying can be completed within 1-3 hours, rather than days as required by natural evaporation drying at room temperature, thereby controlling the penetration of water/coating into the sand.