MELTING CASTING KNOW-HOW. World class melting technology. meltingsolutions.co.uk

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Hugo Beasley
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1 World class melting technology meltingsolutions.co.uk

Melting Solutions have unrivalled capability in the supply of efficient melting equipment, for the processing of all types of aluminium and aluminium scrap melting applications.

From stand alone equipment to full melting plants, we offer industry leading expertise, covering the whole spectrum of casthouse operation from scrap preparation, melting, alloying and casting.

This brochure is intended to give our customer an overview of our extensive capabilities in supply of equipment and services within the aluminium processing and recycling foundries.

2 Melting Solutions have unrivalled capability in the supply of efficient melting equipment, for the processing of all types of aluminium and aluminium scrap melting applications. Our professional and capable team complements our tradition of exceptional engineering quality, combined with unrivalled in-depth process knowledge in the production of aluminium alloys. From stand alone equipment to full melting plants, we offer industry leading expertise, covering the whole spectrum of casthouse operation from scrap preparation, melting, alloying and casting. Our know how extends to support in terms of full operator training, environmental compliance and first class installation services. This brochure is intended to give our customer an overview of our extensive capabilities in supply of equipment and services within the aluminium processing and recycling foundries. Charging Machines These are purpose built equipment tailored to the furnace type and capacity including: + Stationary vibratory charging machines + Mobile vibratory charging machines + Side loading or scissor lift. 2 Ingot casting All types and capacities of melting furnaces, tilting and stationary: SEE PaGE 6 for details + Ingot casting lines; horizontal or inclined ingots up to 25kg + Di-ox products such as cubes, stars and bars. + Granule casting tables. + Ingot stacking lines with robotic packing for high capacity production. SCRAP PRePaRATION Some scrap grades require pretreatment prior to melting to obtain the best metal yields and ensuring environmental compliance. Equipment supplied can include: + Swarf dryers + Scrap delacquering line.

furnaces, tilting and stationary: + Tilt Rotary +

Chamber closed well + Side well + Sloping hearth

Holding Alloying FURNACES All types and capacities of

stationary reverberatory type holding furnaces +

3 meltingsolutions.co.uk MELTING FURNACES All types and capacities of melting furnaces, tilting and stationary: + Tilt Rotary + Reverberatory wet, dry hearth and combination + Twin Chamber closed well + Side well + Sloping hearth de-ironing furnaces + Crucible furnaces. Holding Alloying FURNACES All types and capacities of melting furnaces, tilting and stationary: + Tilting and stationary reverberatory type holding furnaces + Transfer and ladle furnaces. Metal technologies + Electro magnetic bath circulation + Porous plug metal treatment + Metal filtration. 3

4 FILTER PLANT ROBOT STACKING INKJET BARCODING AUTO WEIGH & BANDING HOLDING ALLOYING FURNACE 4 Casting machine POROUS PLUGS

5 meltingsolutions.co.uk Integrated melting plant HOOD ENCLOSURE TILT ROTARY FURNACE CHARGING MACHINE Copyright

Ingot Casting machine Ingot Casting Machines are built to customer product specification and production rate. Metal pouring is via a starwheel.

These machines include moulds manufactured in ductile iron to give an excellent life span. Our design ensures that a minimal gap exists between the moulds as they pass the pouring point.

The SWAN-NECK INGOT CASTING MACHINE Horizontal swan-neck machine for high production rates of 15T per hour and more. Tray cooling system.

6 Ingot Casting machine Ingot Casting Machines are built to customer product specification and production rate. Metal pouring is via a starwheel. The Low Dross Starwheel Pouring System gives double outlets into each mould and produces a high quality, flash free ingot at high production rates. These machines include moulds manufactured in ductile iron to give an excellent life span. Our design ensures that a minimal gap exists between the moulds as they pass the pouring point. This gap does not increase as the moulds rotate around the head and tail shaft sprockets, thus preventing product from getting between the moulds and jamming or damaging the machine. The SWAN-NECK INGOT CASTING MACHINE Horizontal swan-neck machine for high production rates of 15T per hour and more. Tray cooling system. Swan-neck casting machines are partly horizontal to include the cooling water tank, which extracts heat from the underside of the ingot moulds. The cooling water is circulated from a reservoir, pumped into the cooling tank where the ingots are cooled and is then recycled. The DE-OX MACHINE De-ox product shapes include: cubes, cones, pyramids, dabs and half balls. Pouring is usually by pouring tray with synchronous rocking action delivered by cam and gear-box. Cooling can also be via water sprayed on the back of the moulds. Examples of product are: 6 + Pyramids 250 to 350 gm, 90 to 120 gm, 30 to 70 gm. Half balls 250 to 350 gm. + Cones 90 to 120 gm, 30 to 70 gm + Cones 4 to 6 ounce (US market) + Truncated Cones 4 to 6 ounce. (US market) + 1 Kg notch bars, 2 Kg notch bars + 5 lb notch bars (US market) + 5 Kg Dumpy Ingot + 1 Kg Stars

meltingsolutions.co.uk AUTOMATED INGOT STACKING LINES Ingot Casting and Stacking Machines using a robot give automated production from molten metal at the start and bundles of ingot at the end.

The function of the Cooling and Arranging Conveyor is primarily to prepare rows of ingot ready for the robot gripper to transport and stack on the Bundle Conveyor.

If cooled, the ingots may be ink jet printed with barcodes, the bundles can be automatically strapped and weighed before leaving the Bundle Conveyor.

7 meltingsolutions.co.uk AUTOMATED INGOT STACKING LINES Ingot Casting and Stacking Machines using a robot give automated production from molten metal at the start and bundles of ingot at the end. These machines have four basic elements; Ingot Casting Machine, Cooling, Arranging Conveyor, Robot and Ingot Bundle Conveyor. The function of the Cooling and Arranging Conveyor is primarily to prepare rows of ingot ready for the robot gripper to transport and stack on the Bundle Conveyor. Ingots are stacked hot from the end of the Ingot Casting Machine (250 C 300 C) or after passing through a cooling zone. If cooled, the ingots may be ink jet printed with barcodes, the bundles can be automatically strapped and weighed before leaving the Bundle Conveyor. SOW CASTING Carousel Sow Casting Machines can be used to produce Sows of up to one metric tonne. Typical size is 500kg to 1000kg. The Carousel Sow Casting Machine The power controlled carousel is indexed, passing through a pre-heating station, a pouring station and a sow lifting station. The indexing is controlled and smooth to allow continual movement of the molten metal. The sow moulds are pre-heated before pouring commences to ensure gradual cooling of the molten metal. Once the pre-heat is complete the sows are positioned to commence pouring. The furnace begins pouring and the carousel rotates when the sows are filled. After pouring is complete the sows are allowed to cool. Finally, the sows are removed by the crane leaving the moulds in place. Casting and Dross Moulds Supply of all types and sizes of cast iron and cast steel sow moulds in a range of capacities including low profile sow moulds. Manufacture of dump moulds for dross and slag cooling. 7

Operator Training We offer packages to suit customer requirements for in depth operator training to support Melting Solutions equipment. Projects we have successfully concluded cover a wide scope.

8 Operator Training We offer packages to suit customer requirements for in depth operator training to support Melting Solutions equipment. Projects we have successfully concluded cover a wide scope. This can be pre delivery training where selected operators can travel to Melting Solutions existing customer facilities for supervised training. This is particularly successful for novice operators, thereby gaining a feel for the foundry environment as well as specialist teaching on specified furnaces. Longer term we offer in depth operator training under production conditions, often using a team of trainers to cover alternating shift patterns. This type of support is generally over two or three months. Training covers all aspects of the foundry including; + Safety in the foundry environment. + Awareness of environmental compliance. + Scrap selection and charge make up. + Melting furnace operation and techniques. + Dross and slag handling. + Alloying in the holding furnace or ladle. + Metal treatment. + Sampling and the laboratory. + Use of spectrographs. + Metal casting and production of ingots. Consultancy services In certain cases a Consultancy Project can be an extremely important and cost effective solution. This can take many forms and can cover a wide terms of reference, but generally consultancy reports deal with the underlying feasibility and assessment of a new project. Melting Solutions Interpower Induction Ltd t/a Melting Solutions 250 Lichfield Road, Brownhills, West Midlands, WS8 6LH United Kingdom T: +44 (0) F: +44 (0) E: sales@meltingsolutions.co.uk meltingsolutions.co.uk For example a consultancy assignment can be used to compare and contrast different types of technologies and melting equipment to determine the most beneficial and cost effective solution. We have in house expertise to offer unbiased and objective advice drawing from many years experience and numerous previous consultancy projects already undertaken for a wide range of clients worldwide.

Tilting Rotary Furnace World Class Melting Technology

Tilting Rotary Furnace World Class Melting Technology The Tilt Rotary Furnace Melting Solutions offer the TR range of advanced Tilting Rotary Furnaces available in capacities from 1-21.5 tonnes aluminium