Smart Cooler

The SMART Sand Cooler is designed to continuously cool, homogenize, and condition return moulding sand to the required temperature and moisture levels before it is reused in the moulding process. The system combines controlled water addition, intensive mixing, and fluidized airflow to achieve consistent sand properties and reliable process performance. Cooling is accomplished through evaporative cooling, where a controlled quantity of water is added to the sand and the resulting water vapour is continuously removed by the process air, enabling efficient heat transfer and uniform conditioning.

The main cooling chamber consists of two counter-rotating mixing shafts, each fitted with four specially designed mixing blades. These blades continuously convey the sand from the inlet to the outlet while simultaneously providing intensive mixing to ensure uniform distribution of temperature and moisture throughout the sand mass. The counter-rotating action promotes continuous back-mixing, breaks up agglomerates, and maintains the sand in a loose, permeable condition, allowing every sand grain to be uniformly conditioned.

As the sand moves through the chamber, a precisely controlled water distribution system introduces the required quantity of water based on the thermal condition of the incoming sand. The continuous agitation provided by the mixing blades ensures rapid and uniform wetting of the sand, while a dedicated fluidization blower supplies process air through the sand bed. This airflow enhances evaporation, removes moisture-laden air from the chamber, and maximizes cooling efficiency by carrying away the latent heat released during evaporation.

The counter-rotating mixing shafts are driven by a single electric motor through a double-drive arrangement comprising two gear units. Power is transmitted via a fluid coupling which provides smooth starting, overload protection, and reliable torque transmission, ensuring dependable operation and extended equipment life.

A self-adjusting discharge door automatically regulates the sand retention level within the cooler, maintaining a balance between the incoming and outgoing sand flow. The discharge door allows precise control of the discharge rate and ensures consistent residence time for effective cooling and conditioning.

The SMART Sand Cooler is equipped with temperature and moisture sensors that continuously monitor the condition of the incoming and conditioned sand. The fully automated control system ensures continuous operation, consistent sand quality, reduced operator intervention, and optimum process efficiency.