Imerys Usa, Inc.

Imerys Minerals Usa, Inc.

Victor Lafay

Jeremy Tibbs

Brian Burns

Felicia Daniels

Compositions useful for foundry processes such as green sandcasting are discussed. The compositions may include ball clay, bentonite, and a carbonaceous material. The ball clay may include leonardite and/or causticized lignite, e.g., as a portion of the natural ball clay deposit. The composition may further include sand, such that the resulting mixture may be formed into a green sand mold for use in casting molded articles. Incorporation of ball clay materials in the compositions may help to improve the quality of the casted article.

Compositions and methods of use thereof in sandcasting

A method of forming a dry molding sand additive may include recovering a non-sand fraction from a foundry waste material and adding the non-sand fraction to a dry molding sand additive formulation to form a dry molding sand additive. Adding the non-sand fraction to the dry molding sand additive formulation may reduce the amount of fresh clay and carbon to produce the dry molding sand additive. A method of forming a molding sand additive may include recovering a waste molding sand additive composition having a clay or carbon content differing from a desired clay and carbon content, recycling the waste molding sand additive as a raw material in production of a fresh molding sand additive, and adjusting the amount of fresh clay or carbon added during production of the fresh molding sand additive to achieve the desired clay and carbon content.

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Cincinnati, OH, United States of America

Victor Lafay