Case Studies

CR3 is committed to working on research projects that offer members and industry solutions they can use.  Our goal is to be part of a sustainable future.  We work on taking the waste from one process and utilizing it in another, establishing a closed-loop system, emulating nature … creating an environment where nothing is wasted.


Recycling Green Sand Foundry Baghouse Dust

Green Sand Foundry Baghouse Dust

Opportunity

Sand casting is the least expensive of all casting processes for producing rough metal parts. However, foundry waste from sand casting is estimated at 10 to 15 tons … all of which goes into landfills.

Research Goals

  • Develop an efficient process to liberate reusable products from green sand foundry dust.
  • Reduce the costs of buying binders (glue-like materials added to a sand mold to bond sand particles together).
  • Improve disposal of remaining materials.

Results You Can Use

  • Created a hydrocyclone process that eliminates the harsh chemicals associated with the recovery of clay and sea coal.
  • Improved disposal methods of non-reusable waste, as well as recycling binders.
  • Expected to reclaim as much as one million tons (approximately 80 percent) of clay and sea coal that might otherwise go into landfills.

Rare Earth Recovery from Phosphor Dust

Rare Earth REcovery from Phosphor Dust

Opportunity

Global demand for rare earths metals is critical for high tech products and manufacturing processes. It is essential that we stop importing them and instead recycle them from secondary sources, like phosphor dust from spent fluorescent lamps.

Research Goals

  • Develop an efficient, economical and industrially feasible flow sheet to recover mixed rare earth oxides from phosphor in spent lamps.
  • Provide technology to recycle high value rare earths and reclaim tons of phosphor dust so they don’t go into landfills.

Results You Can Use

  • Reduced dependence on China’s exports, which accounts for 95 percent of global rare earth supply.
  • Stablized effects on price, supply and quality of rare earth oxides.
  • Breaching the technology gap for recycling other rare earth-based materials.

Automated Sortation of High Value Metallic Scrap (Fine Particles)

Automated Sortation of High Value Metallic Scrap

Opportunity

Millions of tons of nonferrous metals are discarded and not reused yearly. Recent developments in spectroscopic technology have opened the door for high-speed automated metal sortation and recovery – especially for high valued precious metals – which helps to eliminate disposal problems.

Research Goals

  • Develop a viable method to feed scrap particles of high value materials onto a conveyer belt with improved sensing and ejection.
  • Design a processing method to feed a monolayer of fine particle scrap (3-7 mm) in a controlled fashion in sync with the kinetics of sensing technology.

Results You Can Use

  • Developed and beta tested a continuous rotary feeder (CRF).
  • CRF enables feeding of metallic scrap particles 3-7 mm in size in a controlled fashion allowing for feed rate, particle size and distance between scrap particles laying in a monolayer.
  • Recovered high value metal scrap, reduced waste and reused none-renewable material resources.