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Baghouse dust, which typically contains 20 to 30% clay, is slurried with water.  Intense acoustic energy then blasts apart the silica and clay particles.  After that, a clarifier can gravity separate the lighter clay and coal from the silica fines.  The advanced oxidant treated slurry is then pumped to all the sand system moisture addition points.  Control of green sand system fines is achieved through variable removal of the silica from the clarifier.  Foundries employing the Sonoperoxone ® Blackwater system have reported 35 to 40% reductions in their bond usage [3,4,6].

As of June 1, 2004, four Sonoperoxone ® Blackwater Systems are operating in four different foundries in the United States. Two more, one in Canada and one in the U.S., have been constructed and are scheduled to start up during the summer of 2004 in two additional foundries.