Abstract
The production of green sand systems in iron foundries can be improved by controlling batch-to-batch mulling energy instead of controlling the mulling time. In this study, sand data from 4 foundries were evaluated before and after the transition from conventional mull-to-time (MTT) to mull-to-energy stable power mulling strategies (MTESP). Unnecessary over-mulling was eliminated with MTESP strategies, which significantly brought down the time by 75%, thus increasing the mulling output. In the process, sand properties were not adversely impacted. However, in terms of scrap, there was a 50% reduction in sand-related scrap after MTESP implementation. This paper evaluates green sand system changes during production foundry transitions from MTT strategies to MTESP strategies to significantly reduce the time, power and cost of mulling. In addition, control strategies to identify the point of stable power during mulling have been evaluated.
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