Didion® rotary sprue crusher/cleaner with Conveyor Dynamics vibratory feed conveyor.

Crushing and Cleaning Sprue Increases Melt Efficiency

Jan. 17, 2017
Customized rotary system condenses gates, runners, and replaces high-maintenance processes that do not separate sand, debris Customized for aggressive action Boosting energy savings

Foundries worldwide are learning the value of crushing and cleaning embedded sand from gates, runners, and sprue, before charging into their induction furnaces. The Didion® Rotary Sprue Crusher/Cleaner crushes “gangly” sprue for easier handling and provides a better, denser charge for melting. In the same action, sand lumps are reduced to keep them out of the furnaces.

This rotary drum system has been customized for aggressive action to condense the gates and runners, and it replaces the expensive, high-maintenance jaw crushing systems that do not separate the sand, rust, and debris. The equipment can reduce five tote boxes of gangly ductile iron sprue down to two and a half boxes, creating a 50% reduction; for gray iron, the reduction is up to a 75%.

Before: dirty, difficult-to-handle ductile iron sprue with sand lumps. After: clean and condensed ductile iron runners and sprue, ready for remelting.

In addition to crushing, the machinery performs sand separation and metal cleaning, eliminating the need for shot blasting melt returns and thereby reducing shot blast maintenance and shot consumption. Foundries use this cleaning action as the pig iron, scrap, and returns are all processed in the Didion system to ensure sand, rust, and dirt are removed for a clean charge. The cleaner melt stock boosts energy savings by significantly increasing melting efficiency. As a result, the foundry has less slag, less slag handling, and lower slag disposal costs.

Further advantages to the crusher/cleaner system include:
•  A machined base with precision laser alignment, which prolongs service life;
•  Reduced silica dust emissions due to containment in the drum for a cleaner and safer workplace;
•  A fully automatic feed of pig iron, scrap, and returns; and
•  A patented, wear-resistant lining for long life and easy replacement.

This patented system has the lowest operating and maintenance cost of any comparable equipment set-up now available.
Learn more at www.didion.com