Throughout the casting process, the die spray, which contains oils and phenols, becomes contaminated with oils and heavy metals as in comes in contact with the aluminum and die halves. But the company implemented a multi-step process to recycle die spray in its die casting operations. By recycling both water and raw die spray material, the new system will allow almost unlimited manufacturing expansion while eliminating environmental impact on local waterways. Installed new precast trenches around each machine with removable covers to make cleaning easier while preventing dirt from contaminating the die spray further. Designed custom-fit catch pans for each machine to keep die spray separate from other oils and dirt.
Pipes direct the die spray to the trenches and oil to a separate holding area.
Installed a Koch Membrane Ultrafilter to process the mixture, separating the oil, die spray and water. Smaller water molecules pass through the membrane while larger oil and die spray molecules are trapped and returned to the processing tank. Finally, the fluid is passed though a carbon filter to remove phenols. Although the water from the ultrafilter is clean enough to put down the sewer, the company decided to recycle the water separated by the ultrafilter by mixing it with the raw die release to create die spray. Since every gallon of raw die spray must be mixed with 40 gallons of water, the project is significant.