Figure 1. The photo at left shows alkaline phenolic resin molds four hours after pouring. At right are Bangni resin molds 10 minutes after pouring.
图1是邦尼树脂砂型和碱性 酚醛树脂砂型浇注后情况 的对比。
that compared to alkaline phenolic resin sand and furan resin sand, the gas, smoke and odor emitted from Bangni resin sand after pouring are all significantly decreased and working conditions are markedly improved. Figure 1 compares the situation after pouring Bangni resin and alkaline phenolic resin sand molds. Bangni resin sand has good breakdown properties
after pouring. For steel castings, the working conditions at shakeout, fettling and final finishing are significantly
improved. Te health hazard for operators caused by SiO2 dust during fettling also is reduced. Energy saving, emission reduction and sand rec-
lamation cost saving—The statistical data from Wuxi Foundry showed that when using ester-hardened silicate sand, the recycling rate of used sand was 77.5%, and 0.9 metric tons of new sand was consumed for every metric ton of steel castings produced. After changing to Bangni resin sand, the recycling rate of used sand reached 95.4% and, on average, less than 0.2 metric ton of new sand was consumed for every metric ton of steel castings; in addition, discharged waste substances were signifi- cantly reduced. In Tian Qian Heavy Industries Co., Limited, which
produces large steel castings, after changing to Bangni resin sand, no new sand was added for the first 6 months operation and a recycling rate of 94% was achieved. Using Bangni resin sand, the cost of reclamation of recycled
sand is around 30%, compared to water glass (silicate) sand or alkaline phenolic resin sand. When considering the investment cost of hot reclamation equipment, sand cooling after heating and equipment depreciation, the energy and cost savings in used sand reclamation are remarkable.
Comprehensive Production Cost of Steel Castings Cost compared to silicate binder—Although the
price of Bangni resin is much higher than that of sili- cate binder, production experience has shown that when using Bangni resin, the overall cost per metric ton of steel castings is about 6% lower than when using a silicate binder. Te main reasons are the increased recycling rate of used sand, lower cost of reclamation, high efficiency in shakeout and fettling, lower cost of fettling and shorter production cycle. Cost compared to alkaline phenolic resin—Accord- ing to the 2012 statistics of the QINYE Steel Foundry, when using Bangni resin, the comprehensive cost per metric ton of steel castings is about 15% lower than when using alkaline phenolic resin. Among these cost savings, the investment cost of hot reclamation equip- ment, equipment depreciation and operational costs
三．邦尼树脂的应用效果 1、在作业环境和环保方面
• （1）采用邦尼树脂粘结砂，铸型浇注后烟气明显减 少。已投产应用的铸造企业一致认为：与碱性酚醛树 脂、呋喃树脂相比，浇注后由树脂粘结砂散发的刺激 气味与烟气大幅度降低，显著地改善了劳动环境。 （2）邦尼树脂砂浇注后的溃散性好，显著改善了铸 钢件落砂、清理和精整工作的作业条件，尤其是大幅地 降低了铸件清理时SiO2粉尘对环境的污染及对操作者健 康的危害。
2、在节能、减排和降低砂再生成本方面
无锡铸造厂的统计表明，采用酯硬化硅酸盐粘结砂 时，旧砂的回用率只是77.5%，平均每吨铸钢件耗用 新砂约0.9吨。改用邦尼树脂砂后，旧砂的回用率可达 95.4%，平均每吨铸钢件耗用新砂不到0.2吨，显著减少 了废弃物的排放。
生产大型铸钢件的天乾重工公司，采用邦尼树脂粘结 砂后，前六个月未加任何新砂，旧砂回用率为94%。 采用邦尼树脂，除旧砂回用率高以外，每吨回用砂的 砂再生成本大约只是水玻璃砂或碱酚醛树脂砂的30％左 右。如果再考虑热法再生一次性的设备投入的费用、设 备折旧费用及加热后再冷却的费用，邦尼树脂砂在旧砂 再生方面节能和降低成本的效果是十分显著的。
3、铸钢件的综合生产成本
（1）与采用硅酸盐粘结剂的成本对比 虽然邦尼树脂的价格比硅酸盐粘结剂高得多，但无 锡铸造厂实际使用的经验表明，采用邦尼树脂砂，每吨 铸钢件的综合生产成本却比用硅酸盐粘结剂时低6％左 右。其主要原因是旧砂回用率提高、砂再生费用低、铸 件落砂与清理效率高、清理费用低、生产周期缩短等。
（2）与采用碱性酚醛树脂的成本对比
按秦伊铸钢厂2011年的统计，采用邦尼树脂，每吨 铸钢件的综合生产成本比与采用碱性酚醛树脂降低15％
46 |
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION February 2013
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84 |
Page 85 |
Page 86