15 inch aluminium melt filtration unit
23.07.2018
Alloying bar feed unit
20.07.2018The project is an integrated turnkey solution for transfer, filtration and casting of rolling ingots. The technical solutions are based on the most effective and proven achievements of the company in the field of electric heating.
Task:
Automation of the mold tray installation/removal, melt transfer from the stirrer to the casting machine with minimal heat loss, and filtration from non-metallic inclusions.
Customer:
JSC RUSAL Krasnoyarsk, Casthouse 2
Project Year:
2018
Problems prior to implementation:
- application of asbothermosilicate plates and ceramic cardboard for lining
- bad start-up of casting through a ceramic foam filter
- great content of titanium diborides due to the small length of a launder
- non-automated heating and metal distribution processes
Key Features:
- Mold tray on a sliding electromechanical platform
An automated electromechanical sliding platform for two types of mold trays – for 2 and 4 ingots
Mold tray pre-heating system – 4 arch cover 10 kW each
Possible pre-heating of dosing sleeves
Mold tray hydraulic lifting system integrated into the casting table
- 20″ filtering box with combined heating system
Filtering box ceramic foam filter 20″ with combined heating system -convective system power is 30 kW
infrared system power is 25 kW
Warming-up time of a foam ceramic filter up to 650°C – 40 minutes
Protection of heaters against splashes of melt, protection against overheating and lack of air
Electromechanical drive for the lifting of the filtering box cover
- Launder with electric heating system
The heating system of fixed launder – 6 arch covers 10 kW each
Length of launder – 11 m
The range of consumption – 8 -21 t/h
Pneumatic slide valves with manual control – 3 pcs
- Control system
SIEMENS PLC control system
Thyristor control based on noise-immune thyristor control units BUT-3U
Result:
The process of the mold tray installation and removal from the casting machine is automated
The mold tray heating system is installed on a sliding platform and allows to warm-up not only cartridges, valves and sleeves
Start-up of casting through the CFF is performed quickly and without the participation of a founder
The level of heat loss during casting is not more than 1 s/m
Titanium diboride level is reduced to a minimum required level
Expanded opportunities for the production of new types of ingots
