Green Sand System
PihBond – Pre‑Blended Additives
PihBond is a pre‑blended additive for green sand systems that replaces separate Bentonite and lustrous carbon additions with a single, controlled input to the mixer. It is available in variants tuned for horizontally and vertically parted moulding lines.
Variants & application focus
- PihBond P‑009 – formulated for horizontally parted moulding lines handling a wide mix of castings.
- PihBond P‑045 – tuned for vertically parted lines where moulding speeds and consistency demands are higher.
- Developed to deliver higher mould strengths at lower overall additive usage compared to separate Bentonite + LCA systems.
Typical usage & benefits
- Added directly to the mixer with sand, followed by water as per normal practice.
- Overall additive rates can often be reduced compared to conventional Bentonite + LCA combinations, while maintaining or improving strengths.
- Enhanced casting peel‑off with less sand adherence on the surface when sand control is properly maintained.
- Helps improve consistency in sand properties across different moulding lines and casting mixes.
Note: Exact addition rates and settings depend on your sand system, moulding line, and casting mix. Always validate through controlled trials.
Lustrous Carbon Additive
PihKol – Coal Dust Replacement
PihKol is a potent carbonaceous additive engineered to replace conventional coal dust in green sand moulding. Based on selected low‑ash, high lustrous‑carbon sources, it is designed to build a stable, non‑wetting barrier between metal and mould.
Series & positioning
- PihKol has been developed as a family of lustrous carbon additives with controlled ash and volatile content to suit different foundry requirements.
- Certain variants are tuned for lower addition rates while maintaining the desired surface finish and reducing sand sticking on castings.
- The range is suited for a wide variety of castings—from automotive and pump castings to ductile iron components—where consistent finish is critical.
Typical usage & benefits
- Generally added in small percentages to the mixer as part of the normal sand preparation sequence.
- Helps create a stable lustrous‑carbon layer at the mould–metal interface, leading to better casting surfaces and reduced burn‑on / sand adhesion.
- Lowered tendency for friable sand can support a reduction in sand inclusions when the overall system is properly controlled.
- Can contribute to reduced cleaning and shot‑blasting time thanks to a more uniform casting surface.
Note: Exact grade and dosage selection should be based on your casting mix, base sand and moulding line. Trials under guidance are recommended.
Foundry Grade Coal Dust
Coal Dust for Casting Finish
Goyal Group manufactures coal dust specifically for foundry applications, with tight control on ash, volatile matter and moisture. The product is designed to support good casting finish and collapsibility while addressing common handling and ignition concerns.
Grade overview
- Foundry coal dust is offered in variants with different ash and volatile levels to suit the casting mix and process window.
- Moisture is kept under control using dedicated drying and handling systems to improve consistency in use.
- The product is targeted at foundries that still prefer coal dust based systems or use it alongside other additives.
Typical usage & practical points
- Added to the mixer before water, as part of the dry mix stage, to allow proper dispersion through the sand.
- Supports better casting finish and contributes to improved collapsibility at knockout when balanced with the rest of the sand system.
- Careful storage in covered, dry areas and adherence to recommended stacking practices help minimise safety and quality issues.
Note: Recommended grades and charge rates depend on your sand recipe, section sizes, and environmental objectives.
Calcined Anthracite Recarburiser
Carbolit® – Ultra-Low Impurities
Carbolit® is a premium calcined anthracite recarburiser with 98%+ fixed carbon content. Designed for ductile iron and critical grey iron applications where ultra-low sulphur and phosphorus levels are essential for chemistry control.
Product positioning
- Premium grade recarburiser specifically developed for SG iron (ductile iron) where sulphur and phosphorus must be tightly controlled.
- 98%+ fixed carbon ensures high carbon recovery with minimal additions, reducing total recarburiser consumption.
- Ideal for critical applications including ductile iron crankshafts, windmill parts, and high-grade grey iron components.
- Consistent sizing and screening ensure uniform dissolution behavior across batches.
Typical usage & benefits
- Added to the furnace or ladle depending on melting practice and target carbon levels. Can be used in induction, cupola or electric arc furnaces.
- High fixed-carbon content (98%+) delivers 95%+ recovery rate, meaning less material waste and more predictable chemistry adjustments.
- Ultra-low sulphur and phosphorus levels help maintain cleaner melts, especially critical for nodular iron where sulphur can affect nodularity.
- Proper sizing ensures rapid dissolution without floating or undissolved particles, supporting consistent melt quality.
Note: Addition rates and timing should be optimized based on your base charge composition, furnace type and target grade specifications.
Graphitized Petroleum Coke
Pihcarb® – Rapid Dissolution
Pihcarb® is a graphitized petroleum coke recarburiser with 99%+ carbon purity. Engineered for rapid dissolution in grey iron and select ductile iron melts, preventing chill formation and ensuring consistent carbon levels.
Product characteristics
- Graphitized petroleum coke with 99%+ carbon content, processed to achieve rapid dissolution in molten iron.
- The graphitization process ensures the carbon structure is highly favorable for quick absorption, reducing dissolution time compared to non-graphitized alternatives.
- Particularly effective in grey cast iron applications where preventing chill and maintaining consistent carbon levels is critical for mechanical properties.
- Suitable for grey iron cylinder blocks, machine beds and general engineering castings.
Typical usage & benefits
- Can be added during melting in the furnace or in the ladle, depending on your practice and the required carbon adjustment window.
- Rapid dissolution characteristic means less waiting time for carbon pick-up, supporting tighter process control and faster turnaround.
- Prevents chill formation in thin-walled sections by ensuring carbon is uniformly distributed before pouring.
- Consistent batch quality ensures predictable carbon recovery rates and reduces melt-to-melt variation.
Note: Selection between Pihcarb® and Carbolit® should consider your iron grade, section thickness and sulphur/phosphorus sensitivity.
Foundry Coatings
Prime Kote, Prime Lite , Primesol & Prime Flash
Comprehensive range of water-based and alcohol-based refractory coatings designed for different alloys, binder systems and application methods. From large steel castings to intricate aluminum cores and high-volume automated lines.
Prime Kote
Zircon Water-Based
- High-grade zircon refractory base
- Excellent insulation properties
- Prevents burn-on defects
- Ideal for large steel & SG iron castings
Dip or spray application
Prime Lite
Alcohol-Water Hybrid
- Magnesite + graphite blend
- Fast drying formulation
- Ideal for intricate cores
- Perfect for aluminum & light alloy castings
Dip or spray application
Prime Flash
Quick-Flash Alcohol
- Special refractory blend
- Anti-veining properties
- Automated dipping line compatible
- High-volume green sand foundries
Dip or spray application
Selection & Application Guidance
Selection Factors
- Alloy type (steel, iron, aluminum)
- Binder system and core/mold process
- Application method (dip, spray, brush)
- Drying and handling constraints
Key Benefits
- Reduces burn-on and burn-in defects
- Improves casting surface aesthetics
- Supports easier cleaning and fettling
- Compatible solvents and auxiliaries available
Note: Coating trials should consider application method, drying conditions, venting and film build to achieve repeatable results across production batches.
Choosing the Right Solution
Each product family addresses a specific part of the foundry process. This overview helps position them in your overall green sand and melt strategy.