KLEIN Anlagenbau AG

For more than four decades foundry equipment and pneumatic conveying systems made by KLEIN have a proven worldwide reputation. As a competent partner in the area of foundry and construction material industries as well as public rail transport KLEIN offers its customers consultation, planning and construction of either turnkey systems or single plant components. In our own planning department and workshops, we design and construct the systems which are later installed and started-up at our customers' site.

KLEIN systems are operated worldwide. About 50 - 70 % of our products are exported:

Our product range:

Pneumatic Conveying Systems
KLEIN supplies conveying systems for the transport of dry, pourable, abrasive and sensitive bulk material.

Reclamation of Used Foundry Sands
By means of these system used foundry no-bake sands can be crushed, cooled and de-dusted resulting in a sand quality which can again be employed as mold and core sand.

Core Sand Mixers
For the core shops of foundries, KLEIN supplies complete systems ranging from the sand handling, the sand dosing, the sand mixing process, the dosing of binders to the distribution of the prepared core sand.

Sand filling Systems for Rail Vehicles
With these systems the brake sand boxes of rail vehicles can be refilled. Following the principle of pneumatic conveying, sand is transported from storage silos via sanding stations into the brake sand boxes of the rail vehicles.

KLEIN also supplies brake sand scattering systems type Buran to be integrated into the rail vehicle.

Operating efficiency and economic aspects must be the main characteristics of modern core sand mixers. KLEIN engineers developed core sand mixers that meet these demands. More than 1300 core sand mixers supplied world wide are proof of our customers' trust in KLEIN technology.

KLEIN core sand mixers are suited for any kind of core manufacturing process. KLEIN design and manufacture complete solutions ranging from the sand storage, the heating/cooling, the dosing, the binder supply, the binder dosing, the core sand distribution to the automation, the logging of operating data and the visualization.

KLEIN binder dosing equipment type BDG

KLEIN bellow dosing equipment was particularly developed for use with chemical binders for foundry sands. The design is simple and robust.

Principle components:

stainless steel bellows, welded flange connections on both ends, the seals do not come into contact with any binder, operated by normal compressed air, suction spring-actuated

Features:

volumetric dosing independent of binder viscosityguaranteed repetitive accuracy +/- 0.5 %The bellow dosing equipment is absolutely maintenance-free.The desired dosing volume is easily adjustable by:
a) manually infinitely adjustable set screw
b) selection of two binder quantities using selector switches
c) infinite adjustment of dosed quantity

Binder dosing and distribution systems

Custom-made binder storage systems (storage tanks, container, pumping stations etc.) and supply systems for day tanks, core sand mixers etc. for all current binder systems can be designed and manufactured.

Operating efficiency and economic aspects must be the main characteristics of modern core sand mixers. KLEIN engineers developed core sand mixers that meet these demands. More than 1300 core sand mixers supplied world wide are proof of our customers' trust in KLEIN technology.
 
KLEIN core sand mixers are suited for any kind of core manufacturing process. KLEIN design and manufacture complete solutions ranging from the sand storage, the heating/cooling, the dosing, the binder supply, the binder dosing, the core sand distribution to the automation, the logging of operating data and the visualization.

State of the art core production demands mixers with optimum mixing intensity, high mixing performance, low binder consumption as well as low cleaning and maintenance requirements.

The KLEIN STATORMIX combines the best of the reliable KLEIN core sand mixers.

Here is what makes the STATORMIX stand out:

high mixing intensity
mixing rate matched to the core demand
partial batches can be processed without loss in quality
minimum adherance of residues to the mixer interior
triple stage cleaning concept
freely accessible mixer interior
lowest wear
only negligible sand residues in the mixer after discharge
low energy consumption
no heating up of the sand
no loss of solvents
optimized for inorganic binders

STATORMIX Facts

The core sand mixer STATORMIX, with its vertical mixing drum, employs a proven and efficient mixing technique that ensures high quality, thorough mixing of the sand. This high mixing efficiency is achieved by forcing the sand through two mixing chambers separated by a 'stator'.

The special technology used in the manufacture of the mixer interior results in highly abrasion-resistant mixer lining and mixing tools with exceptionally long life expectancy even in three-shift operation. The lining segments as well as the mixing tools can be replaced individually.

The hinged mixer front cover can be opened and moved to the side making the complete mixing drum freely accessible.

The mixing tools can be removed after releasing a bolt. Once removed, they can easily be cleaned outside of the mixer such as in a blasting chamber.

After the mixing cycle is finished, the sand is completely discharged from the mixer. Almost no sand remains in the mixing drum. Different batches of sand can thus be treated in sequence without mixing up the different kinds.

Self cleaning mechanism

Thanks to the shape of the mixing tool each spot in the mixing drum is reached and thus kept clean.Two integral air nozzle systems remove sand residues from the interior surfaces of the mixing drum and the rotating mixing tools.After each mixing cycle, eventual adherences can be removed from the mixing drum and the mixing tools by cleaning dry sand.

Sand conditioner CST:

The purpose of the sand conditioner is to cool or heat silica sand.

Fluid-Bed Cooler-Sifter

The FKS fluid-bed cooler-sifter is an installation for the treatment of dry silica sand. The sand is cooled down to processing temperature and thoroughly dedusted to reach an excellent quality level

The FKS is particularly distinguished by:

simple and reliable operation, a compact design, an energy-saving economic concept

Design

The fluid-bed cooler-sifter is fitted with baffle-plates arranged at right angles to the longitudinal walls of the housing and forcing the sand to flow alternately over and under the plates. The resulting spaces, the so-called chambers, house the heat exchangers through which cooling water is circulated. The bottom of the housing is permeable to air but not to sand.

Functioning

While hot sand is fed into the FKS through the inlet, air produced by a fan is blown through its air-permeable bottom. This procedure fluidizes the sand, allowing it to flow freely and to behave like a liquid in communicating tubes. The fluid bed is filled to a controlled maximum level before the sand leaves the FKS again at the discharge end. While the sand flows through the individual chambers it passes along and is cooled by the integrated heat exchangers. At the outlet, a thermostat monitors the sand outlet temperature. In the course of this process, the dust contained in the sand is expelled by the fluidizing air.

The dust is then evacuated into the dust separation filter through a dust gas line.

Reclamation technology - Reflux Cooler

The reflux cooler is especially suitable for granular free flowing bulk materials, as it is a contact cooler. The material to be cooled slowly flows along the water cooled cooling faces in counter current fashion. Water does not of course come into contact with the bulk material.

The special design of the contact areas between the cooling segments and the cooling spirals ensures that a high degree of heat exchange is achieved. A constant temperature of the cooled bulk material is achieved by automatically controlling the flow of cooling water.

The special design of the contact areas between the cooling segments and the cooling spirals ensures that a high degree of heat exchange is achieved. A constant temperature of the cooled bulk material is achieved by automatically controlling the flow of cooling water.

The reflux cooler can also be used to heat free flowing bulk material.

Operation of the reflux cooler

Single-stage cooling

The material to be cooled runs out of a hopper via a charging box (1) and a sieve (3) into the cooling packet (4). Below the cooling packet there is a stationary part (5) and below it is the adjustable part of the dosage closure (6). This closure is adjusted depending on the required cooling capacity and it ensures that the material will pass through the cooling packet (4) equally distributed over the whole cross section of the cooler and at the prescribed speed. The material passing through is collected in the discharging hopper (7). Between the cooling packet (4) and the dosage closure (5) a thermostat (8) is installed which regulates the temperature of the bulk material via the cooling-water control valve (9). The contacting thermometer (10) only reacts if the max. required temperature of the cooled bulk material is exceeded. In this case the cooler outlet is closed and/or an optical or acoustic sign is given.

Double-stage cooling

In this case the cooling packet is provided with water by two separate cooling water circuits.
By means of a special circuit of water the peak temperatures of the bulk material are cooled down. The second water circuit with its regulation operates just like the one-stage cooling.
However, an indicating thermometer substitutes the contacting thermometer.

Core sand mixing technology - Distribution systems

In order to supply several core shooting machines with prepared core sand, different kinds of distribution systems can be employed, depending on the conditions at site:

distribution vehicles on trackssuspended monorail systemsdistribution vehicle with linear actuation

The decision which system to chose depends on the requirements and the conditions at site.

A KLEIN solution for every requirement

From the aspect of ecomomy and environmental protection, used sand reclamation in foundries is of major importance.

From decades of experience in the construction of sand reclamation systems and practice-orientated proceeding, KLEIN can offer a solution for any requirement.

A KLEIN solution for every requirement

From the aspect of ecomomy and environmental protection, used sand reclamation in foundries is of major importance.

From decades of experience in the construction of sand reclamation systems and practice-orientated proceeding, KLEIN can offer a solution for any requirement.

Spiral vibration crusher:

KLEIN spiral vibration crusher combine several functions of a resin-bound sand reclamation plant, such as:

lump crushing
metal and foreign matter separation
sand screening and removal of oversized grains

Advantages

Intensive though careful friction which minimizes wear of the individual silica grains and ensures an excellent sand quality.Compact design.No need for deep pits as the sand is conveyed to the top of the crusher through the outside spiral.Low investments.Low energy consumption.Economic operation.No moving parts in the crusher chamber.

Functioning

The moulding boxes are emptied on a shake-out grid. The crushed sand lumps and the loose sand are fed into the crushing chamber.
The tree-dimensional screwing movement of the spiral crusher guarantees an extremely intensive friction of the sand lumps, but at the same time careful treatment of the sand grains.
Over a screen at the bottom of the crusher the sand gets into the outer spiral.
On a fine-screen segment in the outer spiral, sand and oversize grains are separated and automatically discharged resp. transported upwards for sand delivery. For further treatment of the remaining oversize grains, automatic return is possible.

 

Reclamation unit ROTAREG:

Cold resin bonded sands are mechanically reclaimable. A large proportion of the sand which has been reclaimed using the conventional type of single phase mechanical reclamation unit can be re-used.

The used sand portion of the moulding sand can be considerably increased and the new sand requirement correspondingly reduced by the installation of a second reclamation unit.

Lower new sand costs! Lower dumping costs! Lower transport costs!

The ROTAREG reclamation unit is intended for such applications and is particularly suitable as an addition to existing single phase plants

The reclamation unit ROTAREG consists of the following parts:

centrifugal force cleaner (1)pneumatic conveyor (2)fluid bed screen (3)

Functioning

In the centrifugal force cleaner the incoming sand stream from direction (E) is thrown upwards against the pockets of the stator ring which are filled with sand. The resulting friction of the sand grains against each other causes part of the binder coatings to be rubbed off. The speed of the rotor is chosen so that the sand grains are mainly affected by friction and only slightly by impact. Machine parts which come into contact with the sand are manufactured from materials which have a very good resistance to wear.

The pneumatic conveyor transports the sand from the centrifugal cleaner upwards to the fluid bed screen.

In the fluid bed screen, the particles which were rubbed off are detached from the sand by a rising air flow. The sand enters the screen at (F) and leaves at the discharge point (G) or (H). The fine parts are extracted at point (K) together with the discharged air. A short circuit is prevented by a perforated middle wall (L). If required cooling pipes can be installed in the fluid bed screen.

By alternate use of the two discharge points (G) and (H) it is possible to process the sand once or several times.

KLEIN offer solutions for a variety of applications:

Foundry:used sand - new sand, additives, filter dust

Construction material industry: sand, cement, lime, ready mixtures

Chemical industry: fine dust, granulate material, mixed bulk material

Fertilizer fabrication

Our range of products offers a custom-made solution for almost any kind of application. In our test department conveying tests with demanding bulk material can be carried through.

We plan and manufacture turnkey solutions including process steps such as metering, weighing, exhaust cleaning etc. Complex plant processes are monitored and controlled by the innovative control technique developed by KLEIN engineers.

Following are only some out of a variety of KLEIN pressure vessel conveyors. KLEIN will find a solution for your particular conveying application!