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MXC – the Technology of Today

MXC – the Technology of Today. Presented by: Mr. Renzo Cappelletto , Fondarc , France Mr. Manish Kothari, Rhino Machines, India. Why MXC.

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MXC – the Technology of Today

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  1. MXC – the Technology of Today Presented by: Mr. RenzoCappelletto, Fondarc, France Mr. Manish Kothari, Rhino Machines, India

  2. Why MXC • The need to produce castings of improved quality, amongst other things, requires reducing the disadvantages related to hot sand, quite simply by cooling it. • For that, traditionally the foundries install a cooler between the shakeout and the storage of sand into the silos.   • By installing in the circuit an additional machine - the cooler- and its accessories, the sand-preparation plant becomes more complicated and thus more expensive to install and to use it. • Our long experience of the phenomena generated during mixing led us to join together in the same machine the cooler and the mixer. • This new machine, mixer-cooler, is produced under the name of Maxcool - Series MXC.

  3. Why MXC • This made it possible to return to extremely simple and economic concepts of sand-preparation plant as well to the installation as in industrial exploitation. • The results obtained in various foundries as well in Europe as in Asia or Latin America, show clearly than the sand is not only well cooled but also that it is prepared better, which is an important advantage for the quality of the moulding and thus of the castings produced . •  This new concept of ultra compact sand plant generates very important economies on all the levels: • the surface and the volume of building for the sand plant are reduced, • the entire investment for the sand plant is reduced, • the rejects related to sand are reduced, • consumption of additives are reduced, • consumption of energy is reduced.

  4. The MXC - Process • It is an evolution of our mixers ROTOMAX allowing us to enjoy the great benefits of variable speeds in different stages necessary for cooling and mixing sand. •  Compared with our conventional mixers, we have added a diffuser in the center of the tank, pipes of air injection near the tools and a centrifugal fan with variable speed. • Being a batch machine, all parameters are measured easily and accurately: • Weight of sand and additives • Temperature of sand at mixer input • Sand temperature at the outlet of mixer • Power Consumed by the mixing tools • Sand Compactability • Green Compressive Strength (GCS) just before emptying the mixer  • From all above measurements, and also from previous results, we calculate the exact amount of water and time required for cooling. Thus, the cycle is exactly tailored to the needs of sand to be treated.

  5. The MXC - Pictorial View

  6. The MXC – Compact Sand Plant

  7. The MXC – Comparison for 50 T/hr Plant - POWER

  8. The MXC – Comparison for 50 T/hr Plant - SAVINGS

  9. MXC 20 Performance in Indian Conditions Customer : M/s Godawri Spherocast, Ambala, Haryana, India.

  10. MXC- GodawriSpherocast Existing Plant Objectives Control Sand Temperature Reduce Sand Related Rejections Increase Sand Consistency Implement without Disturbing Existing Plant and Production

  11. MXC- GodawriSpherocast Existing Plant Plant Layout Change Before MXC After MXC

  12. MXC- GodawriSpherocast Existing Plant – Performance

  13. Photographs of Installation in Existing BMD 15 T/hr Sand Plant at Godawri Spherocast, Ambala

  14. Photographs of Installation in Existing BMD 15 T/hr Sand Plant at Godawri Spherocast, Ambala

  15. MXC- Godawri Spherocast Existing Plant – Performance

  16. MXC- Upgradation of Plant in India Results Achieved Prepared Sand Temperature Input Sand from 20 to 75 °C Output Sand 32-36 °C at 38 °C Ambient Sand Consistency – Compactibility on Moulding Machine +/- 2 points System Sand Properties Controlled Dead Clay %age within limits New Sand Addition Substantial Reduction due to Removal of Dead Clay Bentonite Addition Reduced from 1.0% addition to 0.6% addition. 40% reduction in consumption of Bentonite Power Consumption Overall Power Consumed reduced and optimized SurfaceFinish Velvet Touch Sand produced improved the surface finish substantially

  17. MXCConclusions The results obtained by casting and savings arising from it. • Show clearly that this new concept of mixer-cooler provides solutions economically and environmentally attractive to both new projects for existing sand plants where it can replace very easily the existing mixer. • This new solution provides a sand always Cool and with optimal Temperature regardless of the input variations and conditions

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