Abstract: A scrap material recycling apparatus includes a feeder, a shredder and a separator, the feeder and the shredder mutually coupled, and the shredder and separator mutually coupled. The feeder includes a means for compressing a quantity of scrap material and means for advancing the scrap material to the shredder. The shredder includes a grate assembly and a rotor, the rotor having a plurality of cutting means, the rotor mechanically rotated to reduce the scrap material. The separator separates the reduced scrap material by fractional composition. The recycling apparatus may be configured so as to be a transportable system, thereby allowing such system to be relocated at or near scrap material stockpile locations.

Abstract: A scrap material recycling apparatus includes a feeder, a shredder and a separator, the feeder and the shredder mutually coupled, and the shredder and separator mutually coupled. The feeder includes a means for compressing a quantity of scrap material and means for advancing the scrap material to the shredder. The shredder includes a grate assembly and a rotor, the rotor having a plurality of cutting means, the rotor mechanically rotated to reduce the scrap material. The separator separates the reduced scrap material by fractional composition. The recycling apparatus may be configured so as to be a transportable system, thereby allowing such system to be relocated at or near scrap material stockpile locations.

Abstract: A scrap material recycling apparatus includes a feeder, a shredder and a separator, the feeder and the shredder mutually coupled, and the shredder and separator mutually coupled. The feeder includes a means for compressing a quantity of scrap material and means for advancing the scrap material to the shredder. The shredder includes a grate assembly and a rotor, the rotor having a plurality of cutting means, the rotor mechanically rotated to reduce the scrap material. The separator separates the reduced scrap material by fractional composition. The recycling apparatus may be configured so as to be a transportable system, thereby allowing such system to be relocated at or near scrap material stockpile locations.

Abstract: A scrap material recycling apparatus includes a feeder, a shredder and a separator, the feeder and the shredder mutually coupled, and the shredder and separator mutually coupled. The feeder includes a means for compressing a quantity of scrap material and means for advancing the scrap material to the shredder. The shredder includes a rotor having a plurality of cutting means, the rotor mechanically rotated to reduce the scrap material. The separator separates the reduced scrap material by fractional composition. The recycling apparatus may be part of a system further incorporating additional components, such as conveyors and/or dust extraction devices. The recycling apparatus may be further adapted so as to be a transportable system, thereby allowing such system to be relocated at or near scrap material stockpile locations.

Abstract: An integrated metal processing facility in which molten metal is poured into a series of molds at a pouring station to form metal castings, which are then transferred to a heat treatment line. Prior to introduction of the castings into a heat treatment station of the heat treatment line, the castings are subjected to heating sufficient to arrest cooling of the castings at or above a process control temperature for the metal thereof.

Abstract: A scrap material recycling apparatus includes a feeder, a shredder and a separator, the feeder and the shredder mutually coupled, and the shredder and separator mutually coupled. The feeder includes a means for compressing a quantity of scrap material and means for advancing the scrap material to the shredder. The shredder includes a rotor having a plurality of cutting means, the rotor mechanically rotated to reduce the scrap material. The separator separates the reduced scrap material by fractional composition. The recycling apparatus may be part of a system further incorporating additional components, such as conveyors and/or dust extraction devices. The recycling apparatus may be further adapted so as to be a transportable system, thereby allowing such system to be relocated at or near scrap material stockpile locations.

Abstract: A system for reclaiming sand from a casting process includes a chamber having an inlet, an outlet, and a plurality of baffles defining a circuitous path for the sand therebetween, a heating element for providing heat to the chamber, and a fluidizing distributor for directing the sand through the chamber. A method of reclaiming waste sand also is provided.

Abstract: A system and method for forming and heat treating a metal casting are provided.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply fluid to the castings for heat treating the castings and degrading the sand cores for removal from the castings.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.

Abstract: A system for combustion and removal of residual carbon within fly ash particles in which the fly ash particles are fed into an array of process units for combustion. The fly ash particles are subjected to heat and motive air such that as the fly ash particles pass through the particulate bed, they are heated to a sufficient temperature to cause the combustion of the residual carbon within the particles. The fly ash particles thereafter are conveyed in a dilute phase for further combustion through the reactor chamber away from the particulate bed and exhausted to an ash capture. The fly ash is then separated from the exhaust air that conveys the ash in its dilute phase with the air being further exhausted and the captured fly ash particles being fed to a feed accumulator for re-injection to the reactor chamber or discharge for further processing.

Abstract: An integrated metal processing facility in which molten metal is poured into a series of molds at a pouring station to form metal castings, which are then transferred to a heat treatment line. Prior to introduction of the castings into a heat treatment station of the heat treatment line, the castings are subjected to heating sufficient to arrest cooling of the castings at or above a process control temperature for the metal thereof.

Abstract: A system for combustion and removal of residual carbon within fly ash particles in which the fly ash particles are fed into an array of process units for combustion. The fly ash particles are subjected to heat and motive air such that as the fly ash particles pass through the particulate bed, they are heated to a sufficient temperature to cause the combustion of the residual carbon within the particles. The fly ash particles thereafter are conveyed in a dilute phase for further combustion through the reactor chamber away from the particulate bed and exhausted to an ash capture. The fly ash is then separated from the exhaust air that conveys the ash in its dilute phase with the air being further exhausted and the captured fly ash particles being fed to a feed accumulator for re-injection to the reactor chamber or discharge for further processing.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply fluid to the castings for heat treating the castings and degrading the sand cores for removal from the castings.

Abstract: A method and system of processing castings is provided in which one or more castings are deposited into a mobile furnace and moved from one station to another of a multi-station casting processing system. The interior of the mobile furnace is heated so as to maintain the temperature of the casting within a desired range of temperatures. The multi-station casting processing system may include a casting machine, a fluidized bed and a quench tank. The method may include transferring a casting into the mobile furnace and moving the furnace from one station to another.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: A single furnace system integrates, in combination, two or more distinct heating environments (which in the preferred embodiments include a conduction heating environment and a convection heating environment) integrated such that the multiple environments define a continuous heating chamber through which a moving workpiece (such as a casting) transitions from one heating environment to the other without being exposed to the atmosphere. In accordance with the preferred methods, the transitioning of the casting from one environment to the other is accomplished with no meaningful change in temperature.

Abstract: A single furnace system integrates, in combination, two or more distinct heating environments (which in the preferred embodiments include a conduction heating environment and a convection heating environment) integrated such that the multiple environments define a continuous heating chamber through which a moving workpiece (such as a casting) transitions from one heating environment to the other without being exposed to the atmosphere. In accordance with the preferred methods, the transitioning of the casting from one environment to the other is accomplished with no meaningful change in temperature.