Brick Manufacturing Using Foundry Sand as Partial Replacement for Fly-ash

Abstract

The foundry is an industrial sector where various iron, scrap steel, and ferroalloys are melted down in arc furnaces or cupolas, shaped in sand, ceramic, or metal moulds, and the cast, steel, nodular, and tempered foundry products needed in industry are produced as raw or processed materials. Especially in establishments such as factories and workshops that produce parts of the automotive, construction, and machine and in steel industry, foundry sand is used to mould foundry products (iron-steel industry and aluminium- and copper-based alloys).Foundry sand is used to prepare metal foundry moulds. For 1 ton of production, 4-5 tons of sand is required. This ratio may be changed based on the type of the metal that needs to be casted, part size, and moulding technique. Sands that contain more than 90% of silica and 7–15% clay (bentonite or kaolinite clay) and have a sintering temperature of over 1500°C are defined as foundry sands. Foundry sand disposal is a herculean task for the industrial sector in today’s scenario. In order to overcome this problem to some extent, it is required to convert it into some useful products. Hence, this project gains its importance for the effective utilization of foundry sand into foundry sand bricks.