Foundry Industry

Robust treatment of foundry wastewater

Foundry operations (sand molding, core making, shakeout, fettling, die-casting support) generate wastewater with high suspended solids (sand fines, slag), oil and grease, metals, binders/resins (phenolic, furan), pigments, and water–glycol mixtures from cooling or hydraulic circuits.
Deepflow delivers modular, integrated systems that stabilize the flow, remove solids and oil, and concentrate dissolved loads for reuse or compliant discharge.

For large flow rates (e.g., rinsing, floor wash, cooling loops), PFET polymer-film evaporators provide energy-efficient concentration. Their plastic heat exchangers are highly resistant to aggressive species and scaling, ideal for foundry wash waters. For more concentrated streams, Aevya vacuum evaporators deliver clear distillate with minimal chemical use.

Sustainable, compliant, and easy to run

Our solutions couple RaeX chemical-physical steps (pH control, coagulation/flocculation, oil removal) with Seltra membranes (UF/RO) and Aevya / PFET evaporation to achieve:

· Stable compliance with limits on SS, oils, COD, and metals

· Significant volume reduction and lower disposal costs

· Closed-loop reuse of distillate for washing or cooling make-up

· Compact skid-mounted systems with automated operation

· Optional construction in Super Duplex 2507 or Titanium Grade 2 for corrosive media

Typical wastewater types

Shakeout / sand handling wash water (high SS, fines, pigments)
Core making & mold wash rinses (binders/resins, color)
Cutting/fettling washdown (oily solids, metals)
Water–ethylene glycol from cooling/hydraulic circuits
Die-casting line rinses and release-agent wash (if present)
Floor/equipment cleaning and stormwater from foundry areas

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Process flow

1. Equalization & screening → buffer tank, grit removal

2. RaeX pretreatment → pH control, coagulation/flocculation, oil–water separation

3. Solid polishing → sedimentation/DAF and Seltra UF for fine solids & emulsions

4. Evaporation & concentration

o PFET for high-volume foundry rinses and water–glycol streams

o Aevya for medium/high-strength mixed effluents

5. Seltra RO (optional) → distillate polishing for high-quality reuse

6. Sludge management → RedGan low-temperature drying

7. Distillate destination → reuse in washing/cooling or compliant discharge

Your advantages at a glance

Handles sand fines, oils, binders, metals, water–glycol reliably
High recovery and up to 95% volume reduction of wastewater
PFET optimized for large flows with aggressive chemistry
Lower chemical consumption and maintenance
Modular, automated skids for fast retrofit and expansion

Recommended products

DEP – PFET polymer film evaporator
DES – Single-effect, steam/waste heat
DEH – Single-effect, heat pump
DE2H – Multi-effect, heat pump
DE2S – Multi-effect, steam/waste heat
DJY – Chemical dosing skid
DPFR – Pipe flocculation reactor skid
DUF-Ultrafiltration (UF) systems
DRO-Reverse Osmosis (RO) systems
DYS – Horizontal dryer with scraper, steam/hot water

Q&A

Q

Can RaeX automatically adjust chemical dosing based on real-time water changes?

A

Yes. Advanced RaeX systems use pH, conductivity, and turbidity sensors with PLC control to adjust reagent dosing dynamically.

Q

How is clarification efficiency evaluated?

A

It is assessed through turbidity, total suspended solids (TSS), floc quality, and retention time — by comparing inlet and outlet performance.
Q

How should flocculant or reagent solutions be stored to maintain stability?

A

They should be kept in sealed containers, at stable temperature, away from light, and at consistent concentration to prevent degradation.

Q

How often should deep chemical cleaning be performed compared to routine CIP?

A

When standard CIP cannot restore performance or solids removal efficiency, a stronger chemical regeneration should be carried out.
Q

How should polymers be mixed to optimize particle binding?

A

Begin with vigorous mixing to disperse the polymer, followed by gentle agitation to promote floc growth — the “bridging” principle.

Q

How does temperature influence floc formation?

A

Higher temperature accelerates reaction kinetics but may reduce floc stability and adsorption performance.