Frequently Asked Questions - CERAKARB™
Frequently Asked Questions - ENVILUBE™
Frequently Asked Questions - Nanokarb
Frequently Asked Questions - OGSS
Q. I am using Coal/Pitch based product. Can I shift to CERAKARB™ technology?
YES ! CERAKARB™ Technology has been used to replace Coal/Pitch based technology. We will give you an accurate time-line that will help you track when the transition will be complete. We will also tell you before hand how your sand properties will vary even before we start the trial ! Our team will work closely with your foundry to make sure the transition is smooth.
Q. What is the Ash content in CERAKARB™?
"Ash" in a foundry usually refers to material that will fuse with the molten metal. This fuse-able material can cause rejections in your castings. However, in CERAKARB™ technology, we do not have any fuse-able material. But unfortunately, the standard test for Ash in a foundry does not differentiate between fuse-able ash and nano-particles. Hence the standard test of CERAKARB™ reflects an Ash content of around 10% by weight, but this is mainly due to nano-particles.
Q. Does CERAKARB™ soften at elevated temperatures?
CERAKARB™ is engineered to have very good flow-ability even at extreme temperatures. Due to the nano-particles, CERAKARB™ has excellent non-wetting properties that not only improve the surface finish but also greatly improves the flow-ability of the hot sand. This also results in breaking down the lumps during shake-out !
Q. Will there be a build-up of nano-particles in the sand system?
No! These nano-particles are spent forming the barrier between the molten metal and the sand. This manifests itself as a brownish layer on top of the casting after shake-out. CERAKARB™ technology does not alter the permeability of the mould.
Q. How will OGSS™ support CERAKARB™ performance?
OGSS™ is designed to learn from your sand system and foundry practices based on a lot of parameters from sand-metal ratio to the gap between the muller blade and drum. OGSS™, over a period of time, will learn from your foundry and help you get the best output with as little waste as possible.
Q. What is the manufacturing capacity for Nano-technology based carbon additive - CERAKARB™?
We have a state-of-the-art manufacturing facility which is completely automated to produce 3000 MT/month. Click here to see a time lapse video of how we built it.
Q.How does ENVILUBE™ reduce Consumption?
Because of the polar nature of the emulsion, it has better chemical and physical adhesion properties. Because of this adhesive power, small amounts are required to give a lasting performance compared to oil based parting agents. This means that the consumption comes down. Few customers have reported up to 80% reduced consumption compared to Oil based Lubricants.
Q.How does ENVILUBE™ reduce Mould Rejection?
It is well known that the surface stability inversely related to the amount on Lubricant applied. More lubricant applied means lesser surface stability which results in mould breakages and smudging of edges and lettering. Because our reduced consumption, the surface stability increases and hence reduced rejection. Surface finish Rejection rates have come down from 3.1% to 0.5% compared to Oil based Lubricants.
Q.How does ENVILUBE™ reduce Sand Fall Defects?
Oil based lubricants are usually flammable and have a flash point. The mould surface is coated with a thin layer of this flammable lubricant. When molten metal is being poured into the mould, the heat because of radiation causes this flammable lubricant to catch fire. This results in weakening the surface of the mould which comes in contact with the molten metal resulting in sand fall. Because our product is non-flammable and does not have a flash point, the mould surface integrity is maintained even at elevated temperatures thus greatly reducing sand fall defects. Sand fall defects have come down from 2% to 0.5% compared to Oil based Lubricants
Q.How does ENVILUBE™ provide protection against Fire?
The water particles present will evaporate and will not allow the oil to catch fire. Our product does not have a flash point and is non-flammable. Our product works as a fire retardant.
Q. ENVILUBE™ is called as GREEN product. Why?
Reduced oil content means lesser Carbon emissions. Our product does not have any harmful chemical. Enhanced fire safety and trouble free handling. Hence ENVILUBE™ is called as "GREEN Product".
Q. Can Nanokarb be used along with my existing carbon additive?
Yes. Nanokarb can be used even along with your existing carbon additive and you will still get all the benefits of our cutting-edge material science technology.
Q. What is the recommended dosage of Nanokarb when used in conjunction with my current carbon additive?
As a thumb rule, we usually recommend on using a maximum 50% Nanokarb of the total replaced carbon. However, our technical team will audit your sand system before recommending the actual dosage.
Q. What is VOC?
Volatile organic compounds (VOCs) are organic chemicals that have a high vapor pressure at ordinary room temperature. Their high vapor pressure results from a low boiling point, which causes large numbers of molecules to evaporate or sublimate from the liquid or solid form of the compound and enter the surrounding air, a trait known as volatility. Some VOCs are dangerous to human health or cause harm to the environment. Anthropogenic VOCs are regulated by law, especially indoors, where concentrations are the highest. Harmful VOCs typically are not acutely toxic, but have compounding long-term health effects. Because the concentrations are usually low and the symptoms slow to develop, research into VOCs and their effects is difficult.
Compared to conventional technology products like coal dust, Nanokarb has drastically reduced VOCs
Q. What is Halogen remediation?
The halogens are a group in the periodic table consisting of five chemically related elements: fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At). The name "halogen" means "salt-producing". When halogens react with metals they produce a wide range of salts, including calcium fluoride, sodium chloride (common table salt), silver bromide and potassium iodide. Halogens are invariably present in the Sand (usually in trace amount). However, over a period of time, this tends to build up and react with the molten metal causing rejections.
Our engineered Nanokarb has the capability to remediate the effects of halogens by forming intermediate complex compounds that does not react with the metal.
Q. What is the Sulphur content in Nanokarb?
The contribution of Sulphur from Nanokarb is < 0.1%.
Q. What is the size of particles in Nanokarb?
The biggest aggregate size in Nanokarb is 1400 microns.
Q. What is the VM% in Nanokarb?
Standard Volatile Matter test for Nanokarb will reflect a value of around 7% with a max of 10%.
Q. How will low temperature volatiles affect my sand performance?
Low temperature volatiles, as suggested, burns away at low temperatures. These will catch fire by just the radiation heat of the liquid metal. This will result in the bentonite losing its strength and automatically the mould stability decreases leading to sand fall and sand inclusion.
Q. How is Nanokarb engineered?
Nanokarb is probably the only engineered carbon for green sand. This is engineered by a patented process involving high pressure and temperature to alter the properties of carbon at a molecular level.
Q. Is there a timeline by which we can expect to see results of Nanokarb?
Yes! We will predict exactly how you sand parameters will change even before you start using Nanokarb. We will give you checkpoints during the transition so that you can track the progress of the transition.
Q. Each foundry is different. How can one tool / product cater to all the different casting manufacturers?
Yes. Each foundry is different, but the underlying science behind it is universal. With our cutting-edge material science technology and advanced data analysis algorithms, we have created products and tools that will help your foundry achieve precision sand control.
Q. Why are foundries facing rejections even with all parameters in the control range?
Currently, foundries are relying on Statistical Process Controls for maintaining the parameter values in the system. However, this process does not consider many mutual dependencies existing amongst parameters. This leads to rejections even when all parameters are in the control range.
Q. Is SPC the right methodology for evaluating parameter thresholds in the sand system?
No. The basic assumption in SPC is that the variables are independent and identically distributed. However, data in the foundry is not independent or mutually exclusive. Also, foundry data has a time series effect, where the changes in the system do not reflect immediately. Hence, using SPC in a foundry setting would be misleading.
Q. Why OGSS?
OGSS is a software tool built to enable data-driven decision making. It recognizes the interdependencies that exists among the different sand system parameters. It uses mathematical transformations on the data to give each data point a uniqueness that will help analyze the correlations between dependent data points. This helps in differentiating between anomalies and outliers.
Q. What is a digital twin?
OGSS will serve as a digital replica of your foundry conditions, processes and systems. With this digital twin, you will be able to simulate conditions by varying parameter values and analyzing impact before implanting it in your foundry.
OGSS continuously learns and updates itself from multiple sources to represent near real-time status or working condition.
Q. How long will it take for OGSS to start predicting?
OGSS predictions depend on the quality of data, frequency and number of data points available. Missing data points will lead to skewed results which will hamper predictions. Depending on your data quality, it will take anywhere between 3 months to 1 year for the tool to learn from your data and begin predictions.
Q. How accurate will the OGSS predictions be?
OGSS predictions are up-to 99.6% accurate