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    • Laboratory Casting Plant
    Launder convection heating unit
    30.07.2018
    • customized solutions

    Laboratory Casting Plant based on semicontinuous casting unit for manufacturing of rolling ingots and extrusion billets

    The unit was designed and manufactured for a laboratory based at the Siberian Federal University for the development of processes and technology of semi-continuous casting of rolling ingots and extrusion billets. Features of the unit are the ability to melt a solid charge and prepare melts of given chemical composition in a rotary resistance stirrer and simulation of real production conditions.

    Task:

    • Автоматизируемые процессы/системы: система подачи воды в кристаллизатор литейной машины, механизм подъема/опускания литейной платформы, а также системы нагрева и поворота наклонного миксера
    • Manufacturing of a casting unit on the basis of the UPNL casting machine, two crucible rotary furnaces PPI-0.16 and a rotary resistance holder
    • The work included automation of the processes in accordance with the documentation developed by our specialists
    • Automated processes/systems: system of water supply to the mold of the casting machine, mechanism of casting platform raising/lowering, and heating and turning systems of the tilting holder

    Customer:

    FSAEI HE Siberian State University, Krasnoyarsk

    Project Year:

    2018

    Problems prior to implementation:

    • Crucible furnaces PPI-0,16 do not function
    • Holder of small-capacity and insufficient functions
    • Outdated casting platform control system
    • Lack of automated water supply to the caisson
    • Lack of a single working platform and launders
    • Localized control systems without integration into the main PLC

    Key features:

    Resistance holder:

    • Temperature of heaters 800-900°С
    • Capacity of molten aluminum bath 100 kg.
    • Maximum angle of holder rotation 29°С
    • Separate control of the heating power of each of three zones of silicon carbide heaters
    • Electromechanical lift drive

    Control cabinet:

    • Total power 31 kW
    • PID controller
    • Thyristor power control
    • Cabinet 1200х600х300 mm
    • Degree of protection – IP65

    Launder:

    • Refractory Concrete Cartridges
    • 95 mm deep trays
    • Four sliding valves

    Jib crane:

    • Load capacity 250 kg
    • length of jib up to 3 m
    • The manual rotary actuator of the jib
    • Lifting speed – up to 8 m/min

    Ventilation:

    • Volume of vented gases up to 2700 m3/hour
    • Material of the duct – galvanized steel

    Result:

     Reduction of ingot crop ends to three times

     Heat losses of the melt during start-up decreased down to 0.5°C/m

     Fast warming-up of concrete cartridges within 1.5–2 hours

     Flexible heating control

    Easy maintenance and good maintainability

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