How did DUPUY enable a foundry to extract large quantities of silica sand?
Managing Silica Sand in Foundries: Large Volumes and Abrasive Materials
In the foundry industry, silica sand is used in various stages of metal processing, particularly in molding processes.
Handling this material requires special care due to its high density, abrasive nature, and the quantities that must be moved during production.
For an Italian foundry, the primary requirement was to extract large volumes of silica sand within a limited operating timeframe while maintaining an efficient and continuous process.
With a density of approximately 1,500 kg/m³, the sand was particularly difficult to handle. Its tendency to scatter and accumulate in work areas also made collection and cleanup operations more complex.
Another critical factor was the wear and tear on the components in contact with the material. The abrasive action of the sand required a system designed to withstand harsh operating conditions without compromising long-term reliability.
The customer’s goal was therefore to identify a vacuum system capable of handling large quantities of sand, reducing the need for manual labor, and ensuring controlled material handling.
Key Project Data
>90 MINUTES
Suction Time
Just one and a half hours to suction 2.7 m³ of silica sand, within the maximum time limit set by the customer.
4.05 tons
Amount of sand processed per cycle
More than 4 tons of silica sand vacuumed in a single operating cycle, reducing the need for manual handling of the material
COUNTRY
Italy
SECTOR
Steelworks and Foundries
APPLICATION
Industrial Vacuum Cleaning
Vacuuming more than 4 metric tons of silica sand within a limited time frame
The main challenge faced by the customer was the need to handle large quantities of silica sand within a specified time frame.
With a density of 1,500 kg/m³, the 2.7 m³ of sand to be suctioned amounted to approximately 4,050 kg of material. This was a significant quantity, requiring an industrial system capable of delivering high performance even during prolonged operations.
The abrasive nature of the sand posed an additional challenge. The continuous flow of the material through the pipes and collection components could cause wear and tear, making it necessary to use durable components in the areas subject to the most stress.
At the same time, the customer needed to minimize material spillage in the work areas, preventing buildup that would have made cleaning more difficult.
Another challenge involved managing the discharge. Collecting large volumes of sand required a system capable of discharging the material without frequent interruptions in suction.
The customer therefore needed a solution that combined power, abrasion resistance, and operational continuity, while reducing the manual workload for operators.
Reducing downtime and improving the efficiency of silica sand handling
In foundries, handling silica sand can be a particularly demanding task when large quantities of material must be managed in a short amount of time.
For the customer, the main requirement was clear: to complete the removal of 2.7 m³ of sand within a maximum of an hour and a half.
Material handling therefore required a system capable of maintaining a continuous workflow, preventing emptying operations from frequently interrupting the collection process.
Another key consideration was the durability of the components. The high abrasiveness of the sand made it essential to design a configuration capable of withstanding wear in the areas most exposed to the flow of material.
The solution also had to allow operators to easily reach the various collection areas, minimizing manual handling and the scattering of sand in the work area.
The goal was to develop an industrial vacuum system capable of delivering high performance, continuous operation, and greater reliability, even under particularly demanding operating conditions.
DUPUY MHD250 HV: High-Power Industrial Vacuum Cleaner with Continuous Discharge
To meet the foundry’s needs, DUPUY selected the 20-kW MHD250 HV industrial vacuum cleaner, which is specifically configured to handle heavy and highly abrasive materials such as silica sand.
The main unit has been paired with a Ø560 mm industrial separator with a capacity of 200 liters, designed to intercept and collect the vacuumed material before it reaches the vacuum cleaner.
This configuration allows for the handling of large quantities of sand through a dedicated system, keeping the material collection process separate from the main vacuum unit.
One of the distinctive features of the solution is the continuous discharge system with a Ø250 mm rotary valve. This device allows the collected sand to be discharged gradually, minimizing interruptions caused by emptying and ensuring process continuity.
To counteract the wear caused by the flow of sand, the design also includes a Hardox reinforcement plate installed in the areas most exposed to the abrasive action of the material.
The suction point is connected to the system via approximately 15 meters of Ø70 mm flexible tubing, a solution that provides operators with adequate coverage of the work area and greater freedom of movement during operations.
The combination of suction power, material separation, continuous discharge, and reinforced components has made it possible to develop a solution tailored to the foundry’s specific needs.
2.7 m³ of silica sand were vacuumed up in about 90 minutes
The introduction of the DUPUY MHD250 HV has enabled the customer to make the handling of silica sand within the foundry faster, more continuous, and more controlled.
Thanks to the system’s performance, it is possible to extract 2.7 m³ of sand in about one hour and 30 minutes, meeting the required operating time for the application.
The continuous discharge system with a rotary valve helps minimize interruptions related to emptying the material, allowing for a more consistent workflow.
The specialized configuration also helps minimize sand spillage in operational areas and reduces the need for operators to manually perform the most demanding handling tasks.
Finally, the use of reinforced components in areas subject to greater abrasion helps increase the system’s wear resistance and long-term reliability.
The main benefits achieved:
- Suction of 2.7 m³ of silica sand in approximately 90 minutes.
- Handling of over 4 metric tons of material per operating cycle.
- Greater continuity thanks to the rotary valve discharge system.
- Fewer interruptions during unloading.
- Less sand dispersion in work areas.
- Fewer manual handling operations.
- Greater abrasion resistance thanks to Hardox-reinforced components.
- Improved process efficiency and reliability.
The project demonstrates how a properly configured industrial vacuum system can meet the demands of handling heavy and abrasive materials, ensuring high performance even under particularly demanding operating conditions.