Foundries

Solving condensate issues within the foundry environment

Compressed air is widely used throughout all casting foundries. High variances in temperature across the foundries often mean that significant volumes of condensate (liquid water, or oil / water emulsion) are experienced throughout the compressed system and airlines.

This condensate enters pneumatic equipment, and often leads to equipment failure or unsatisfactory performance. This consequently means refinishing, reworking or even recasting may be required resulting in production downtime or equipment maintenance and repair costs.

Some key examples of challenges faced with water in compressed airlines are noted below:

  • Water in painting or coating lines may prevent the finish from binding to the metal surface. Reworking or surface cleaning is often required to enable re-coating of the metal to a satisfactory finish.Water in painting or coating lines may prevent the finish from binding to the metal surface. Reworking or surface cleaning is often required to enable re-coating of the metal to a satisfactory finish.
  • Water in blow lines used for blowing out moulds will sit on the surface of the sand. This will expand once molten metal comes into contact with it, creating a ‘pit’ or deformation in the face of the casting. Re-casting is often required in this event.
  • Water in airlines feeding pneumatic tools in the fettling shops will cause seal failures and internal corrosion of the tools. Costly repairs or even replacement may be required.
  • CNC milling and grinding machines are very sensitive to water and particles in airlines. It can cause cylinder, valve or actuator failures internally within the machinery. This can result in immediate downtime of the equipment.

Installing an EXPEL filter at point of use protects equipment and stops issues like those above from arising. Correctly positioned, an EXPEL will guarantee that ALL liquids (water, and oil/water emulsion) along with ALL solid contaminants down to 1 micron are effectively removed from the compressed air. This prevents operational downtime and will reduce maintenance and repair costs.

The EXPEL is a completely unique product that combines the roles of both a water separator and a particle filter into one cleanable, reusable unit. This means that one EXPEL can replace up to three conventional style filters.

 

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