Transcript www.economyindustrial.com

Casting machines
combining Value
with Technology
EconoTech Casting Machines
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CASTING MACHINE SCHEMATIC VIEW
From 5 tons per hour
10 tons per hour
20 tons per hour
100 tons per hour
to over 200 tons per hour
and everything in between.
Casting machines with a
long tradition of reliability
• 1914 Pittsburgh Coal Washer Co.
– Built first pig casting machine in USA
• 1940 Bollinger Corp.
– Built machines for war plants around the world
Over 80% of merchant pig iron produced in USA on its machines
• 1976 Economy Industrial Corp.
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MiniCaster
Ferro Caster
Alumi Caster
Ongoing product development
Continuing Product Improvement
• Through development
– Ongoing internal design improvement
– Learning from our customers
– Being open to suggestions
• Through research
– Computer analysis
– Lab testing at Center for Iron & Steel
Research at Carnegie-Mellon Univ.
– Tests in client’s labs and plants
Advanced Technology
Patented Process Control to
improve mould life by optimizing:
• Mould Mass Ratios
• Water Cooling Efficiency
• Cooling Time
• Mould Coating
Laboratory test procedure
Test fixture simulates conditions on the
casting machine
Laboratory test procedure
Test moulds equipped with thermocouples
to record temperatures
Laboratory test procedure
Test fixture simulates pouring into
moulds on the casting machine:
Laboratory test procedure
Test fixture simulates water cooling on
the casting machine:
Laboratory test procedure
Test fixture simulates discharge on the
casting machine:
Laboratory test procedure
Discharged product collected for tests
Laboratory test procedure
Mould temperature data is captured under
various time and cooling cycles
MT4, TC closer to the melt
300
Temperature, oC
250
200
150
100
50
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0.200
0.400
0.600
0.800
time, hours
1.000
1.200
1.400
1.600
Recent laboratory tests
2003 – HC Ferromanganese test
program
• Confirmed mould temperature
cycling for slab and ingot shapes
• Confirmed controlled breakage on
discharge
Recent laboratory tests
2004 – Charge Chrome test program
• Confirmed mould temperature
cycling for slabs
• Confirmed product breakage on
discharge
Recent laboratory tests
2004 – Charge Chrome test program
Slowly air-cooled
slab 200x200x25
does not fracture at
discharge
Recent laboratory tests
2004 – Charge Chrome test program
Rapidly quenched
slab 200x200x25
fractures well at
discharge
Current pending patents
• Process and method for casting
high-carbon ferrochrome on
continuous casting machines
• Device and process for producing
moulds for casting machines to
extend life by controlling crack
propagation
Advanced Technology
Patented Process Control to
improve mould life by optimizing
process design parameters:
Mould design
Air and water cooling times
Water cooling efficiency
Mould wash application
Technology to reduce mould replacement
cost – The highest single cost factor in
casting machine operations
Control of mould peak temperature
is essential
• Cooling cycle time
• Mould/metal mass ratio
• Water cooling application
• Mould wash material & application
Mould temperature cycling
Peak above critical temperature
Mould temperature cycling
Peak below critical temperature
Advanced Technology
Field verification of lab tests
Advanced Technology
Closed loop water system:
Advanced Technology
Mould wash application system
Heavy Duty Construction
• Heavy drive gear
Heavy Duty Construction
• Rugged Take-up Bearings
Heavy Duty Construction
• Heavy duty manganese steel chain
Heavy Duty Construction
• Chain with quick-change feature and
flexible mounting
Rotation
Expand &
Contract
Heavy Duty Construction
• Swivel discharge chute
Heavy Duty Construction
• Rugged Hydraulic Ladle Tilters
Heavy Duty Construction
Stationary Roller Chain Design also available with:
• Automatic Roller Lubrication Available
• Manganese Steel Bushes in Steel Links
• Reduced friction and power requirements
Machines with International
Acceptance
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Argentina
Australia
Brazil
Colombia
Canada
Dominican Republic
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Iceland
Mexico
Norway
Saudi Arabia
South Africa
USA
Engineering Partners over the years
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Arthur G. McKee
Bechtel Corp.
Brown & Root
Cia. Projectos Brasilieros
Davy-Minenco
Dravo Corp.
Elkem Technology
Greenblatt & Hutton CC
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Hatch Associates
Hatch et Associés
Koppers Co.
Kværner E & C
McDowell-Wellman
Thomson van Eck
Voest Alpine
USS Engrs.
Sensible Automation
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Reduces manpower
Automates water cooling
Automates mould coating
Flushes and purges mould wash
Interlocks ladle tilter and caster
Provides safety Interlocks
With fail-safe design philosophy
Simplified P&ID
Detail on next slide
Mould Wash P&ID Detail
Value Oriented Design
• Automation and interlocks reduce staffing
• Improved yield increases output
• Proprietary process design increases mould life
• Reduced maintenance cost from longer life
• Computerized design library for design efficiency
Special features
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Fine control of pouring rate
Automatic mould wash purging
Linkage to plant DCS system
Proven control programs
Automatic mould wash mixing
Simplified operator’s controls
HMI OPERATOR’S CONTROL
HMI SCREEN
HMI SCREEN
SPRAY BASIN
Mould Wash System
VIBRATING SCREEN
VALVE PANEL
PREMIX TANK
BULK BAG
UNLOADER/FEEDER
AUTOMATED MOULD WASH SYSTEM
MAIN MIX TANK
Wide Product Experience
• Pig Iron Casters
• Aluminum Casters
– Ingots
– DeOx Cones
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Ferroalloy casters
Armor Plate Casters for U.S. Navy
Brass & Bronze Ingot Casters
Stainless Steel Ingot Casters
Wide Product Experience
• Pig Iron Casting Machine – Iscor Steel
Wide Product Experience
Small shape casters for ferroalloys and aluminium
Wide Product Experience
Ferroalloy
Slab Casters
Wide Product Experience
Aluminium ingot casting lines
Recent Installations
Ticor-SA Empangeni (Kumba Hvy. Minerals)
First Cast 60 tph Pig Iron Casting Machine
Other Recent Installations
ANGLO PLATINUM POLOKWANE
70 tph Nickel Matte Casting Machine
(Eliminates discharge of acid from granulation)
ELKEM METALS CANADA
20 tph Mg Ferrosilicon Casting Machine
(Earlier installation at Bjoelvefossen made them the
world leader in foundry inoculants)
HIsmelt DIRECT REDUCTION – Australia
Dual 125 tph Pig Iron Casting Machines
(Economy also supplied casting machine for pilot plant)
YOU are also our partner
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You know your alloys best
You know your plant operations
You know your workforce
Together, we can reach the best
solution at the lowest total cost.
The best TOTAL VALUE solution
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State-of-the-Art Technology
Local Content
Competitive Capital Cost
Low Operating Cost
Low Maintenance Cost
Proven Reliability
with many installations in plants where
100% of the total production is cast on
Economy’s machines
For more information,
visit us on the web at
www.economyindustrial.com
email [email protected]