CPT International 01/2017

cptinternational

The leading technical journal for the
global foundry industry – Das führende Fachmagazin für die
weltweite Gießerei-Industrie

www.giesserei.eu

March

2017

CASTING

PLANT AND TECHNOLOGY

INTERNATIONAL

1

Quality control in modern

core shop operation


Benefit from

Tailor-made

Protectivity

Your experts for welding in the areas of repair, anti-wear and cladding.

Decades of industry experience and application know-how in the areas of repair of cracked material,

anti-wear and cladding, combined with innovative and custom-tailored products, guarantee customers

an increase in the productivity and protection of their components.

voestalpine Böhler Welding

www.voestalpine.com/welding


EDITORIAL

On the path to a

high-tech industry!

Environmental considerations are becoming increasingly important in mold

and core production (among the main subjects covered in this issue) – whether

during the conversion of production to inorganic mold and core binders or,

for example, during the development of environmentally friendly cold box

technologies, about which we again report in this issue. With the further development

of technologies, in particular additive manufacturing, another

technology is now about to break through: 3-D core printing, as offered by

companies such as ExOne from Gersthofen in Germany. During an interview

with Georg Geier, the Foundry Manager of Mahle König in Rankweil in Austria,

CASTING has learnt about the advantages the process offers for regular foundry

operation and how it rates in comparison with traditional core-shooting

(from P. 6).

The composition of mold and core binders is an important lever in reducing

harmful emissions in foundries – but by no means the only one. Our article by

Florian Hartung, Managing Director of the Mannheim-based company Infuser,

presents a sophisticated exhaust air decontamination system that can almost

completely eliminate odor emissions and pollutants in foundries (from

P. 26) and thus have a lasting positive effect on the environment.

As a recycling industry, our sector also sustainably exploits the planet’s resources.

This has so far not been the case regarding energy. This could change with

the technology of the Munich-based company Orcan Energy (from P. 30).

Electricity is generated from waste heat – completing the cycle!

CASTING again offers a wide range of topics in our discipline-rich sector, with

more articles on intelligent automation, efficient fettling, energy-efficient

plants, and the introduction of an automated logistical system for transporting

mold boxes and castings. Technologies make change possible – from a traditional

industry to high-tech production.

Be inspired!

Robert Piterek

e-mail: robert.piterek@bdguss.de

Casting Plant & Technology 1 / 2017 3


FEATURES

INTERVIEW

with Dr. Georg Geier

Core injection vs. 3-D core printing 6

COREMAKING

Boehm, Ralf

Inorganic core binder technology: from Germany to the world 10

Sander, Verena; Neun, Werner

Cast part manufacturer introduces new cold box technology 16

MELTING SHOP

Wamsbach, Roman

Air blowers made up of perfectly harmonized components 20

Cover-Photo:

inspectomation GmbH

Düsseldorfer Str. 20

68219 Mannheim

Tel.: +49 (0)621/80 39 66 -0

Fax: +49 (0)621/80 39 66 -5 55

info@inspectomation.de

www.inspectomation.de

PRESSURE DIE CASTING

Kircher, Mareike

Robot-based and fully automatic – towards Industry 4.0 24

ECO-FRIENDLY PRODUCTION

Hartung, Florian

Patented environmental technology for foundries 26

6 26

In an interview with CASTING Dr. Georg Geier, Technical

Director of the Austrian foundry Mahle König, reports on his

experiences with 3-D printed cores (Photo: ExOne)

The Danish company Infuser has developed a solution that

dramatically re duces contamination by harmful substances

or odors (Photo: Infuser)


CASTING

1 | 2017

PLANT AND TECHNOLOGY

INTERNATIONAL

WASTE HEAT UTILIZATION

Lechner, Julian

Save energy costs: generate electricity from waste heat 30

AUTOMATION

Vehreschild, Michael

Schmiedeberger Gießerei – on the path to the intelligent factory 34

CLEANING, FETTLING & FINISHING

Vehreschild, Michael

Finishing the job 42

PLANNING & ENGINEERING OF FOUNDRY PLANTS

van der Weiden, Huub; Brandt, Maurits



COLUMNS

Editorial 3

News in brief 48

Brochures 56

Fairs and congresses 58

Advertisers´ index 58

Preview / Imprint 59

34


processes. With the new ERP system, the foundry makes a decisive step towards an intelligent factory. And additional investments

in robotics and 3-D printing processes will follow (Photo: Michael Vehreschild)


INTERVIEW

Core injection vs. 3-D core printing

Innovation accelerator in engine construction - Mahle König focuses on 3-D-printed sand cores

from ExOne

Dr. Georg Geier, Foundry Director of

Mahle König in Rankweil, Austria, is convinced

of the great potential of

3-D-printed cores in modern foundries

(Photos: Mahle König/ExOne)

Mahle König, a company based in Rankweil,

Austria, ranks among the world’s

leading manufacturers of components

for high-performance engines in the

fields of leisure, motorcycling, as well as

industrial and heavy-duty applications.

Its strong market position rests primarily

on innovative methods such as 3-D

printing technology from ExOne, a

company based in Gersthofen, Germany.

Even more so, Mahle König applies

this future technology for mass production

of small to medium lot sizes. Its potential,

however, is far from exhausted,

as the technical director Dr. Georg Geier

explains in an interview.

Mahle König introduced 3-D printing

processes very early in the series production

of engines and components.

Does your company consider itself a

pioneer of sorts in this area?

It is certainly fair to say so. In fact, the

use of modern production methods

has always been part of our corporate

philosophy. Since its founding by Carl

König, Mahle König has regarded itself

as a technology driver and innovator.

Nowadays, we are pioneers in our field,

not least because of the close development

partnership with our customers.

rive

from these partnerships?

For two and four-stroke engines, as

well as diesel and gas gensets, partnerships

favor the construction of

numerous products with exceptional

performance, efficient consumption,

and low emissions. In turn, this

relies on the development and production

of cylinders, cylinder heads,

pistons and piston rings from a single

source.

And how about the expertise of the

company and its employees?

That’s no doubt a key factor too. Furthermore,

Mahle König provides an

optimal development environment. In

this respect, we regard the latest technologies

suitable for mass production

as an essential building block to develop

and build innovative engines.

Needless to say, 3-D printing counts

among such technologies.

Are these technologies also a way to

meet challenges generally faced by

the engine construction market - and

by Mahle König in particular?

Absolutely. In the future, global markets

will be influenced by two diametrically

opposing paradigms. On the

one hand, customers are demanding

customized products for their target

groups, that is, products that combine

high performance, quality and

reliability – and this partly in the most

adverse environment of high temperature,

abundant humidity, or dust. On

the other hand, customers expect very

cost-effective, resource-saving, and ever-lighter

engines.

In this situation, what opportunities

arise for suppliers?

Clearly: Growth - that is essential. Today

manufacturers primarily seek extremely

adaptable suppliers, which

lower lead times for larger numbers of

new product options, and do so without

compromising on quality. At issue

here are small and very small series

with increasingly complex and sophisticated

geometries, for which production

technologies constitute a decisive

success factor.

And what role does 3-D printing play

there?

Powerful 3-D printing is one of the

key technologies to retain production

in high-wage countries. For us,

3-D printing of sand cores is also an

opportunity to increase our technological

lead in engine construction, as

well as to further secure a unique mar-

6 Casting Plant & Technology 1 / 2017


ket position for our Austrian production

site through new competences.

Our strengths, therefore, lie in superior

engineering, and the use of intelligent

technologies. Accordingly, we endeavor

to expand long-term benefits in the

intelligent, highly flexible manufacturing

lines, differentiating ourselves

from international competition in doing

so. This we accomplish through

the networked digitizing of the entire

production chain: In prototyping and

product development, but also as regards

the flexibility, quality, and efficiency

of mass production.

tages

of 3-D printing of sand cores

over traditional production processes?

With pleasure. Compared to the classic

production, 3-D printing offers enormous

potential for innovation, both in

development and optimization, as well

as regarding serial production flexibility.

While we cannot yet estimate the

total potential of this technology for a

global, networked digital production,

we already see concrete examples of

the enormous impact of 3-D printing

on all industries and areas. In construction,

for example, 3-D printing affects

process and product quality, as well as

flexibility and production optimization.

Could you provide some concrete examples?

We find a good example in the increasingly

complex geometries required to

build high-performance, ever lighter,

and more fuel-efficient engines.

And improving these demands a corresponding

reduction in manufacturing

tolerances. It is precisely here that

conventional production methods

are reaching their limits. On the other

hand, digital sand core printing allows

representing such complex geometries

Benefits of 3-D printing over core injection

» CAD design: De-composing of complex internal geometries can be omitted,

mold parting design, draft angles and core locks omitted, pressure

strips no longer required

» CAM-tool manufacturing: Core boxes and models no longer required,

assembly jigs unnecessary

» Initial sample: Function test / zeroing eliminated, necessary adjustments

(ventilation etc.) eliminated, binder-dependence eliminates core drying

and finishing, deburring unnecessary, tool changes based on measurement

results unnecessary

» Cost: Lower investment and change costs, no tool maintenance and storage

costs, no tool insurance cost

» Time: Shorter change periods and development times, several tests possible

in one step

» Process safety: Reduction of individual components, elimination of manual

activities (assemblies), lower testing costs

» Productivity: No tool wear, no risk of tool loss, high user friendliness,

without affecting the series, uncomplicated transfer of production from

one to another foundry, simple binder changeover

in a single core instead of a multipart

core package. That means that drafts

become unnecessary, loose parts need

not be considered, and undercuts are

possible. Not to mention that the finishing

process for aluminum die casting

can be omitted if cores are produced

digitally. Expressed otherwise:

there can be no errors in a non-existent

process.


for all batch sizes?

Not yet. At present, 3-D sand printing

is particularly interesting for series

of small to medium batch sizes.

We’re nonetheless still skeptical

when it comes to mass production.

As I said, not yet! We expect that the

process will soon grow its potential by

increasing print speed and a growing

capacity to produce variants and modifications

– also those developed in series.

In the future, therefore, the process

will become a smart alternative to

conventional techniques even for larg-

Sand cores for cylinder heads produced by

Mahle König via 3-D printing. Despite the

high degree of complexity, cores in 3-D

printing can be displayed as single cores

Casting Plant & Technology 1 / 2017 7


INTERVIEW

Finished cylinder heads on a Pallet at

Mahle König

far as we know, only supplier to offer

a market-ready solution for the production

and processing of inorganic

cores based on silicate in 3-D printing,

we can quickly and easily leverage the

technical advantages of this process for

our production. For example, to avoid

gas-related defects in the cast component

and prevent condensation buildup

in the mold, which substantially reduces

cleaning costs. For a die casting

manufacturer like ourselves, there are

convincing arguments to support this

technology.

er series – possibly also in hybrid mode.

Accordingly, we see our current entry

into 3-D sand printing technology as

an investment in the future, because

we can adapt processes to the required

dynamics of the digital industry today.

Could you provide further examples

of the future potential of this technology?

For example, 3-D printing has huge future

potential for research and development.

This technology allows geometries

that were impossible with

conventional processes up to that

point. In turn, this paves way for the

construction of hitherto unthinkable

engines. What is more, the “one-piece

core” offers an ever more precise reproduction

by eliminating the manual

core assembly. This clearly increases

process reliability, while reducing

testing costs and production scrap in

a consistent manner.

Does that affect development and delivery

times?

Absolutely. Today, Mahle König is capable

of notably reducing delivery and

development times by reducing or

eliminating costs and time-consuming

tool processes. Under these conditions,

series-parallel developments

become much more interesting. Of

course, the same applies to the flexible

shaping of variants, small series or

special versions – for example racing

variants of standard motors. Changes

are incorporated in almost real time in

production, given that they are passed

directly as CAD (without tools) information.

There is no risk of damage due

to production errors and tool wear in

this digital production environment.

What about the environmental impact

of the technology? Is this something

your company considers?

Of course. Currently, we 3-D print with

an environmentally friendly binder

system based on silicates. Thus, we

combine the innovative possibilities

of digital core production, with a resource-saving

and especially low-emission

production. Lower odor emissions

are a major advantage over organic

binder systems. For us, this represents

a further and major step towards an

efficient and sustainable production

in Austria. What other reasons made

you choose a silicate binder from Ex-

One? With ExOne, the first and, as

You collaborate with ExOne on 3-D

printing. What was the key factor underlying

this decision?

First and foremost, the good teamwork.

In our view, only close partnership

can deliver strong results. All customers,

in fact, can and should expect

such cooperation from us. And we expect

the same from our service providers.

With ExOne, we found the right

partner.

Are there any other reasons?

In our opinion, ExOne has the most

compelling technology package for

3-D sand printing. Moreover, the company

won us over from the first day

with its deep understanding of our

tasks and products. And there is just

another crucial factor. We seek to make

every process step as environmentally

friendly and emission-free as possible,

especially in such a resource-intensive

process as casting. ExOne supports us

in that respect. The company is the

first and, as far as we know, only supplier

offering a marketable solution for

the production and processing of sand

cores in the program, where a modern,

environmentally neutral binder

is used. Last but not least, digital 3-D

printing with ExOne technology allows

emission reductions during core

drying and casting.

www.exone.com

www.koenig-kg.at

8 Casting Plant & Technology 1 / 2017


COREMAKING

Inorganic core for a cylinder head water jacket (Photos and graphics: Hüttenes-Albertus)

Ralf Boehm, Hüttenes-Albertus Chemische Werke GmbH, Düsseldorf

Inorganic core binder technology:

from Germany to the world

Inorganically produced cores are now widely used in German automotive aluminium foundries.


technology and the environmental and production-related advantages they deliver. Against the

tion

arises as to whether and to what extent this technology can also gain acceptance in other

countries and continents. Current research and further developments are set to create the pre-


Many developments in the foundry industry

have their origin in Germany –

driven primarily by the high demands

of the country’s automotive industry

and ever stricter environmental legislation.

Suppliers of foundry chemical

products make a crucial contribution

to technological progress within the

industry. These developments help, for

example, to make cars lighter and more

economical, and to save resources.

Feed materials themselves are also

optimized with a view to their environmental

compatibility. Thanks to

inorganic binders (IOB), the vision of

emission-free casting has already become

reality in Germany. Meanwhile,

the demand for this technology is also

growing in other parts of the world.

Carbon-free formulation for

emission-free casting

The chemistry of carbon-free compounds

is commonly referred to as

“inorganic”. In foundry chemistry, the

term refers to a particular class of core

binders which, owing to their composition,

are completely different from

the conventional binders based on organic

chemistry. Carbon-free, i.e. inorganic,

formulation enables practically

emission-free casting.

In terms of total volumes, inorganic

binders currently represent a relatively

small proportion of the binders

used around the world. But their

use in foundries has spectacularly increased

in recent years. Various German

automotive manufacturers, as

well as some large foundry companies,

have successfully established inorganic

chemistry in their serial production

( and 2).

Replicating success stories

Thanks to continuous innovation,

doubts about the efficiency and cost

effectiveness of inorganic binder sys-

10 Casting Plant & Technology 1 / 2017


tems could be dispelled in recent years.

Success stories are setting precedents

and are being shared among foundries

around the world. Many well-known,

globally positioned foundries are now

turning to “inorganic binders” and investigating

the feasibility of changing

their technology.

In other major industrial countries,

too, rising energy costs and a growing

awareness of environmental issues

have triggered a rethink in the foundry

industry. Stricter emission standards

are also becoming a driver for product

and process innovations in Asia, for example.

In pursuit of sustainable production

processes and better working

conditions, there has been increased

interest in core production processes

other than the organic processes,

which have so far dominated.

The sales volume of inorganic binder systems has grown strongly over the

last 10 years

Clear environmental,


The principle of core production using

Hüttenes-Albertus’ inorganic

binder system is based on water glass;

however, it is far superior to the water

glass binders of the past. The inorganic

Cordis binder is a modified silicate

solution mixed with core sand and the

additive Anorgit. In heated core boxes,

this mixture is cured to form a three-dimensional

cross-linked matrix, which

gives the sand core its strength. In addition,

the cores are gassed with air,

heated to 130 °C. The water in the

cores changes into the gas phase and

is expelled. The curing process involves

only heat and the elimination of the

water solvent.

As no combustion products are generated

during curing, there are no emissions,

i.e. no fumes, no BTX or BTEX,

no amines, no odours. Carbon dioxide

emissions are also greatly reduced.

Moreover, there are no condensate deposits

on the mold, which extends the

useful life of the tool. Due to the endothermic

behaviour of inorganically

bound cores, the material properties

can also be precisely controlled in

the aluminium casting. HA’s inorganic

core process allows the production of

high-quality cast parts and the ability

to create complex core geometries – as

well as outstanding cast quality. Inorganic

cores – also uncoated – are used

for cast surfaces, which are on par with

those produced by organic processes,

and sometimes even better.

In addition to environmental and

production-related benefits, the sys-

Europe

Asia

7.000.000

400.000

Quantity [kg]

Quantity [kg]

Rest

~ 100.000 kg

America

500.000

Quantity [kg]

Figure 2: Use of inorganic binder systems worldwide

Casting Plant & Technology 1 / 2017 11


COREMAKING

Subpolar Zone

Moderate Zone

Figure 3: Climatic conditions play a role in

the use of inorganic binder systems: Moderate

zone – relative humidity avg. 70 %;

Subtropic – relative humidity up to 90 %;

Tropic – relative humidity up to 100 %

Figure 4: Storage trials in the climate chamber

tem also makes economic sense. On

the one hand, a shift to inorganic core

production requires investment in new

production technology. On the other

hand, it also enables cost savings: emissions

are avoided which eliminates the

need for investment in extraction and

air purification equipment. Since the

inorganic process does not cause condensation,

cleaning costs of the cast

tools and the consumption of foundry

auxiliaries are reduced. The extended

service life of the tools brings additional

cost advantages.

Working conditions during inorganic

core production are also significantly

improved because there is no odour

nuisance during the core production

and casting processes. As there is no

Subtropic

Tropic

Subtropic

Moderate Zone

need for extraction at the core machine

and the casting table, the noise

load is equally reduced. As experience

shows, foundry employees who have

worked in inorganic core manufacturing

do not want to return to an area

where organic binders are used.

Challenge: Storage stability

under humid and warm

conditions

Even though inorganic binders have

now matured to the stage where they

are able to deliver stable, high-quality results,

their development is by no means

at an end. Foundry specialists and chemists

at Hüttenes-Albertus have been working

intensively over the last few years to

further improve the products.

In order to enable their use in Asian

countries, a particular challenge must

be tackled: storage stability under humid

and warm conditions (Figure 3).

By their very nature, cores based on

water glass tend to take up moisture

from the air, which is due to the hydrophilic

properties of inorganically

bound cores. They seek equilibrium

with the relative ambient humidity

and/or ambient temperature.

This means, that in the case of high

humidity and high temperatures, curing

is partially reversible; the cores

may lose their strength and be easily

destroyed. One way to prevent this is

to use air-conditioned storage rooms

which are adjusted to a humidity of

30 – 50 %. However, these types of

storage spaces are not always available.

Possible solutions

» Air-conditioning throughout the

foundry

» Separate, air-conditioned core storage

areas

» Monitoring of critical areas

» Production process adapted to climatic

conditions

» Minimal core storage by employing

line production

» Optimizing binder systems

Inorganic cores guaranteeing storage

stability even in difficult climatic conditions

are therefore prerequisite for inorganic

technology to be a viable alternative

in countries such as China, Japan

or Mexico. With this aim in mind, HA

has spent the last few years working intensively

on the further development of

the Cordis binder and Anorgit additives.

To this end, HA’s scientists are developing

sound ideas and solutions,

which are then extensively tested under

laboratory conditions. Possible new

product formulations are tested on trial

cores stored in the climatic chamber

at a variety of defined temperatures and

atmospheric conditions (Figure 4).

12 Casting Plant & Technology 1 / 2017


CASTING TECHNOLOGY

BEYOND TOMORROW

Are you

READY

for the next step?

Say yes, and enjoy a bright future!

Position yourself for the future with a reliable partner with tailor-made services. Our products and solutions are

second to none. Together we‘ll ensure your long-term requirements are met with regard to the environment, technology,

and process costs.

ASK Chemicals experts look forward to hearing from you:

Phone: +49 211 71103-0

E-mail: info@ask-chemicals.com

www.ask-chemicals.com/beyondtomorrow


COREMAKING

350

Tensile Strength [N/cm²]

300

250

200

150

100

50

0

Final strength 3 hours 2 days 4 days 5 days

Cordis System 2003 360 180 140 70 0

Cordis System 2010 360 240 180 160 80

Cordis System 2016 360 320 290 260 210

Figure 5: Storage stability of various product generations

The results provide important parameters

for the foundry supplier and

its customers. When a possible solution

has been found, internal casting experiments

are carried out to check whether

a new modification is fit for practical

use. Only then a small batch test is performed,

followed by a large batch test

and, eventually, introduction to a customer’s

serial production. In this way,

new product generations are created in

the field of inorganic chemistry, which

further optimize the performance properties

of emission-free binder systems

step by step. It has thus been possible to

achieve a significantly better cross-linking

between additive and binder compared

to earlier product generations.

Special additives in the binder specifically

influence the hydrophilic character

of the cores, increasing their resistance

to elevated air humidity. Cores

made with the latest generation of the

inorganic binder system can be stored

for four to five days at 30 °C and 70 %

relative humidity without any significant

impairment of strength (Figure 5).

In addition to the selection of binders

and additives, there are further parameters

in foundry operation which can be

used to influence the storage stability of

the cores. An important factor is, for example,

the thickness of the core shell:

the thicker the shell, the more stable

the core is in storage. The formation of

the shell, which plays an important role

in determining its final strength, can be

specifically controlled via the temperature

and the dwell time in the core box.

The choice of the sand also has an impact

on the storage stability. Sand with

a smaller grain size has a higher capillary

action and there-fore draws water

more easily into the core (Figure 6).

Conclusion

The fundamental feasibility of the inorganic

chemistry has now also been

Core box temperature and dwell

time influence the thickness of

the core shell. The thicker the

shell, the more stable the core in

storage.

Sand with smaller grain size

has a stronger capillary action

and therefore draws water

more easily into the core

High humidity or dew point

differences promote the

accumulation of water on the

sand core

Special compounds of the

Cordis binder and the Anorgit

additives improve the core´s

storage stability

Figure 6: Contributing factors to storage stability

14 Casting Plant & Technology 1 / 2017


Core storage

stability

Core decomposition

Cycle

times

Sand adhesion

No-bake systems for

iron alloys

Gas bubbles

Inorganic systems

for iron alloys

Core compaction/

flowability

Robot

handling

Inorganic systems

for 3D printing

Figure 7: Innovation potential of the inorganic core binder technology

proven in Asia. It is already being successfully

used at major international

foundries in China and Japan.

Looking at the progress that has been

made in the field of inorganic binder systems

over the past decade and projecting

them into the future, the field looks

promising. Development is also progressing

to the extent that interest in this technology

is growing in other countries.

There continues to be a high level of innovation

potential. In addition to storage

stability, various other properties are

being further optimized and additional

fields of application are being developed.

Through constant research and development,

the boundaries still in force today

are progressively being shifted (Figure 7).

www.huettenes-albertus.com

Competence in

Shot Blast Technology

We offer a complete service in surface preparation technology,

not just as machine designers and manufacturers.

Our emphasis is on providing reliable service on:

• Wear and Spare Parts

• Repair and (remote) maintenance

• Inspection and process advice

• Machine upgrades and performance

enhancement

• Upgraded used machines

AGTOS

Gesellschaft für technische Oberflächensysteme mbH

Gutenbergstraße 14 · D-48282 Emsdetten

Tel. +49(0)2572 96026-0 · info@agtos.de

www.agtos.com

151-11/13-4c-GB

Casting Plant & Technology 1 / 2017 15


COREMAKING

Verena Sander and Werner Neun, ASK Chemicals , Hilden, and Michael Poetzsch, Düker GmbH, Laufach

Cast part manufacturer introduces

new cold box technology

By omitting materials subject to the labeling requirement in part 1 cold-box resin, Düker GmbH

from Laufach can achieve an impressive reduction in emissions

The Düker iron foundry pursues a sustainable corporate policy (Photos: ASK Chemicals)

Emission and workplace exposure limit

values represent major challenges for

foundries, and are becoming increasingly

important due to every stricter statutory

regulations. In particular, compliance

with emission guidelines is

essential in safeguarding company sites,

and is now of equal significance as technical

and economic issues.

Modern foundries such as Düker from

Laufach, Germany, pursue a sustainable

corporate policy in which the three pillars

cost-effectiveness, social responsibility

and environmental protection are accorded

equal importance. The example

shows how the use of the new Ecocure

Blue technology supports environmental

protection and occupational health

and safety, while facilitating efficient,

highly productive core production.

The medium-sized company, Düker,

is regarded as one of the leading manufacturers

of valve bodies and pressure

pipe formed parts for drinking water

and gas supply as well as of pipes and

formed pieces for drainage technology

(Figure 1). The company’s expertise

starts with the design phase and

extends across simulation, model construction,

casting and processing right

up to coating. Düker also produces

enameled components and pipes with

high acid resistance for plant construction

in the chemical and pharmaceutical

industry.

A further business field is jobbing

casting, where the focus is on producing

parts for robotics, the mechanical

engineering industry and the railway

industry. Based in Laufach, in Bavaria,

the company sees itself as a pioneer

in its sector and always aims at developing

new products and solutions for

its customers. One example of this is

the series production of a mixed crystal

ferritic cast iron, which only recently

was listed in DIN EN 1563 as a new

material group. Düker has been working

intensively with this new material

since 2012 and has been producing

it, in series production, since 2014.

Düker’s customers are thus offered new

opportunities to optimize components

with improved machinability.

The company subjects its products to

the very highest quality standards and

introduced a modern quality management

system in accordance with DIN

EN ISO 9001 as far back as 1993. The

company’s commitment to ecological

and social issues is made clear by its use

of important management systems.

Düker operates a certified environmental

management system in accordance

with DIN EN ISO 14001 and an

energy management system in accordance

with DIN EN ISO 50001, complemented

by a certified occupational

health and safety management system

in accordance with BS OHSAS 18001.

Emissions in the casting process

Solvents and highly volatile materials,

which are contained in the cold box

binder system, are classified as potentially

harmful to the environment and

to employee health. The new cold box

technology platform from ASK Chemicals

GmbH, Hilden, Germany, Ecocure

Blue, now allows foundries, in the cold

box part 1, to completely avoid using

ingredients which are subject to compulsory

labeling, and to considerably

reduce BTX emissions, particularly

benzene. One of the first users of this

technology is Düker. The Ecocure Blue

High Efficiency (HE) systems combine

16 Casting Plant & Technology 1 / 2017


economic and environmental advantages

throughout the entire process,

without compromising, when it comes

to reactivity, strength and the casting

result.

Most air pollutants, in foundries,

arise during casting. A large part of the

solvents evaporate from the core and

mold, due to the high temperatures

involved as well as residual monomers

such as phenol, formaldehyde and

other low molecular weight polymers.

Subsequently the polyurethane polymer

chains thermally decompose due

to the available oxygen in the mold

cavity, and within the mold and cores

themselves, i.e. combustion. Then as

the oxygen is largely consumed partial

thermal decomposition occurs known

as pyrolysis. This results in products

which include BTX (benzene, toluene

and xylene), CO and NOx, as well as

many other pollutants.

The developments over the past

few years have aimed specifically at

preventing solvent emissions during

core production, or at least discharging

them in a managed manner. “At

the same time, it was and is necessary

to take into consideration the growing

and future demands placed on the

whole foundry process when making

specific modifications to the binder

system,” declares Pierre-Henri Vacelet,

Market Manager for the binder

division at ASK Chemicals. The catalyst

consumption and the amine gassing

time are also important factors relating

to both the environmental and

economic performance. Also during

recent developments in binders, a primary

focus was placed on attempting

to influence the odor and/or the BTX

substances that are released within the

process.


also lowering the binder

quantity

Due to stricter regulations, which prescribe

a drastic reduction in phenol

emissions from 2020 onwards, Düker

has been attempting, since 2013, to

lower the level of all highly volatile aromatic

materials, like phenol and other

aromatics like BTX, and to change

the processes accordingly. “At that

Figure 1: Düker produces valve bodies and pressure pipe formed parts for drinking water

and gas supply as well as pipes and formed pieces for drainage technology

Figure 2: Michael Poetzsch is very happy with the reduction in emissions that Düker

achieved by changing the cold box binder system

time, in our search for support, we approached

ASK Chemicals as an innovation

and technology partner, to help

reduce the benzene emissions during

casting, in particular, at our production

site in Laufach,” reports Michael

Poetzsch, foundry manager at Düker

(Figure 2). The initial approach was

one where the binder content of the

cold box cores was reduced as far as

possible (without compromising the

technical or quality-related properties

of the core, or the quality of the cast

part), and the emissions are thus low-

Casting Plant & Technology 1 / 2017 17


COREMAKING

ered. An initial success was achieved

through the use of the cold box “High

Efficiency” system Ecocure HE from

ASK Chemicals, which was incorporated

into series production in 2014.

Building on the knowledge that free

monomers arise within fractions of a

second after casting due to vaporization,

and, subsequently BTX and NOx

emissions arise as the casting phase

continues, ASK Chemicals developed

this “High Efficiency” binder technology

as far back as 2008. Its high performance

allows the binder quantity to be

reduced for the same core performance.

“The mechanical properties of the sand

cores which were produced with these

HE systems were comparable with those

of conventional products, despite the

reduction in binder. The increase in reactivity

led to a considerable increase

in initial strength, which made it possible

to conduct the remaining processing

steps safely within a shorter time,”

states Vacelet. The resulting amine saving

is also reflected in the odor as well as

the lower material costs and a less pronounced

tendency towards sticking. As

a consequence of its success, the Ecocure

technology has undergone constant

further development.

In order to further investigate the influence

of the composition of the binding

agent on the composition of emissions,

ASK Chemicals has made particular use

of its own “Hoodstack” casting emissions

capture and analysis method in

recent years, in addition to other methods.

This analysis, in conjunction with

ASK Chemical’s development foundries,

makes it possible to provide real casting

emission evidence of volatile organic

compounds, carbon monoxide, carbon

dioxide, gaseous nitrogen- and sulfur-based

emissions as well as to quantify

lead based compounds.

Figure 3: Employee reaction was very positive with regard to the odor which was perceived

as less pronounced than in the previous systems

Figure 4: Düker produces most of its core product range with the new binder Ecocure Blue

No more ingredients subject

to compulsory labeling in part

1 binder

A systematic reduction in the free

monomer content, particularly the free

phenol, initially took second place as

the development of such a solution was

extremely complex and needed modification

of the existing production systems.

Together with Düker, these modifications

were implemented from June

2015 onwards. Just a few months later,

in September of the same year, ASK

Chemicals presented initial laboratory

prototypes, and in early 2016, the results

of the final developments. The final

outcome was the cold box technology,

Ecocure Blue, based on ultra-low

free phenol resin. All catalysts available

on the market, the usual sand qualities

as well as numerous sand additives can

be used with this binder. With the exception

of Di Basic Ester (DBE) and only

in Germany, Ecocure Blue does not

contain any components that have to

be mentioned due to their workplace

exposure limit value. Only the part 2

of the cold box formulation is unavoidably

based on isocyanate, which must

be declared. “Part 1 of the new cold box

binder no longer bears any hazardous

substance symbols. This is a huge relief

for us regarding the transportation

and storage of the binder. However, it is

first and foremost a clear advantage for

occupational health and safety and an

18 Casting Plant & Technology 1 / 2017


Reduction in cold-box binder quantities

100

80

60

40

20

0

100 %

Conventional cold-box binder EC 30 HE 2/60 HE 22LF EC 30 Blue/EC 60 Blue

important signal for our employees,”

emphasizes Poetzsch. With the Ecocure

Blue system, the odor is less noticeable

to employees compared to the previous

system and this system can be classified

as workplace-friendly thanks to its low

hazard composition (Figure 3).

Developed for iron and steel casting,

the system is also suitable for the

production of hydraulic components,

turbochargers, brake disks and engine

blocks. Düker, in Laufach, uses the

Ecocure Blue technology to produce

the majority of its core product range,

from parts with filigree geometries

weighing just a few grams up to molded

cores weighing 100 kg (Figure 4).

The use of the Ecocure Blue platform

makes it possible to lower the

85 %

Figure 5: Reduction in cold box binder quantities

Benzene emssions in %

100

80

60

40

20

0

100 %

54,28 %

78 %

33,33 %

05.10.11 15.07.16 02.08.16

Ø Measurement results old series EC 30 HE 2/60 HE 22LF EC 30 Blue/EC 60 Blue

Figure 6: Progression of the benzene emissions

emissions throughout the entire process

from core production and casting,

right up to demolding – without

having to forego the advantages of the

original high-efficiency technology

with its ability to systematically optimize

low binder additions with high

initial strengths. “This is of the greatest

significance, particularly in light of the

fact that the cycle times are required to

get shorter, the cast parts and geometries

more complex, and the walls ever

thinner,” confirms Poetzsch. The Ecocure

Blue solution thus combines productivity-increasing

factors such as

very good mechanical strengths, an excellent

reactivity and outstanding casting

results with increased environmental

and health and safety protection.

Benzene emissions in the air

lowered by 66 %

By means of a long-term analysis, conducted

over four months followed by

the introduction for series production,

Düker showed that a binder reduction

of 7 % was possible, even compared

with the efficient Ecocure HE technology

(Figure 5). Compared with a conventional

solution still in use in 2014,

the addition of binder was reduced by

22 %. Through the use of the new Ecocure

Blue technology, the BTX emission

concentrations were lowered across the

board, and in particular those of the

benzene emissions during the casting

process, by 66 %. These measurement

results were provided from an independent

measurement institute that

was commissioned to conduct the BTX

measurements (Figure 6). In addition, a

34 % reduction in BTX emissions from

the green sand/used sand was observed

compared to the previous system.

“It is important to us to discharge as

few emissions as possible into our environment

and to make products as

odor-neutral as possible. In addition to

smaller tests conducted by ourselves,

we also had long-term tests conducted

by an independent institute, from the

start of binder evaluations,” summarizes

Poetzsch. The current emission limit

value of 5 mg/m³ of air was complied

with (thanks to the new binder), while

the previous system was slightly above

this limit. By optimizing the Ecocure

Blue system to the sand quality used, a

binder reduction was achieved so the

overall impacts on costs were neutral,

if not lower. So that this latest technology

does not necessarily raise the costs

of the sand mix.

“The new binder meets all our expectations

regarding the core sand system’s

strength properties and the cast

part quality that results from this. We

are very happy with the result. The introduction

of the new binder can thus

be regarded as a long-term conversion

across the entire line as we can

produce high-value cast parts reliably

and cost-effectively in this way,” says

Poetzsch happily.

www.ask-chemicals.com

Casting Plant & Technology 1 / 2017 19


MELTING SHOP

Roman Wamsbach, Saarbrücken

Air blowers made up of perfectly

harmonized components

Modern drive solution saves energy in foundry furnace operation

Siemens rendered support already during the project planning phase: With the Siemens

“SinaSave” energy-saving tool it was possible to precisely determine which mo-


Roman Wamsbach

The foundry Neue Halberg-Guss, based

in Saarbrücken, Germany, makes highgrade

cast iron cylinder crankcases, cylinder

heads and crankshafts for the passenger

and utility vehicle industry. At

that foundry, two large air blowers have

recently been upgraded adopting a holistic

approach referred to as “Integrated

Drive Systems”. The installation of perfectly

harmonized motor and frequency

converter technology has provided significant

advantages such as simplified

engineering and high energy efficiency.

“Molding the future” is not only a

smart marketing slogan of Neue Halberg-Guss.

It is also part of the strategy

and it is lived in the everyday work at

the foundry, which was established in

1756. Every day, the 1,500 employees

at the Saarbrücken works, which is laid

out for an annual capacity of 180,000 t

of iron, process large quantities of

high-grade input materials – producing

a 1,500 °C hot melt which is cast

into components for spark ignition

and diesel engines. The core of all casting

and processing operations is the

18-meters-high cupola. By no means

may this furnace fail unplanned. This

would bring all downstream processes

– that is the entire production chain –

to a halt within a few hours. Michael

Steuer, Head of Electric Maintenance at

Neue Halberg-Guss, explains: “We listen

very carefully to our maintenance

experts. Therefore we see the need to

regularly upgrade our equipment in order

to improve availability, efficiency,

economy and last but not least environmental

awareness.”

New drive solution saves

largely on energy

An example of such a project was the

retrofit of two radial blowers at the

cupola. Having a diameter of about

1,200 mm, these redundantly arranged

blowers supply up to 24,000 m³ (stp) of

air per hour each, to keep the melting

process running. Each of the frequency-controlled

motors has a maximum

power rating of 325 kW. An important

objective of the upgrade was to increase

energy efficiency, as the works has been

certified according to ISO 50001 since

2012. “With each modernization measure

we want to become even better every

time not only in terms of availability

but also in terms of energy efficiency

and economy,” says Marcel Junk, Manager

Energy at the Saarbrücken works

(Figure 1).

This was the reason why those responsible

at the foundry for the retrofit

project decided in favour of a drive

solution from Siemens, Munich, Germany,

which would consist entirely

of perfectly harmonized components.

According to the “Integrated

Drive Systems” (IDS) strategy adopted

by Siemens, the Simotics FD (Flexible

Duty) motors and the Sinamics

G120P frequency converters have

been optimally combined to form a

drive system that meets the requirements

of efficiency class IES2 according

to EN50598-2. With an output

voltage higher than 97 % of the input

voltage, the capacity of the connected

motor is extremely efficiently used.

The retrofit has achieved an up to 10 %

reduction in electricity costs, last but

not least due to the fact that the electric

motors alone have a 5 % higher efficiency

than the previously installed

fan engines, namely 98 % versus 93 %.

20 Casting Plant & Technology 1 / 2017


Figure 1:





Figure 2:-




engineering

Energy savings are also achieved, for

example, by the adjustable Eco-Mode

of the frequency converters. By reducing

the magnetization in the partial-load

range via special parameter

settings, voltage-dependent core losses

can be reduced. This results in substantial

savings on electricity costs. It

would even be possible to completely

switch off the frequency converter and

switch it quickly back in as required via

remote control using the standardized

ProfiEnergy communications profile.

Optimal coordination between the

Simotics FD motor and the Sinamics

G120P Cabinet converter is effected

quasi “at the touch of a button”,

using the Starter Tool integrated into

the Step 7 programming software

( Figure 3). Via a unique motor identification

code, the control parameters

in the converter are automatically

adjusted to the motor. This results in

higher efficiency and less noise generation.

Dirk Rau (Figure 4), master electrician

and SPS technician at the Neue

Halberg-Guss foundry: ”More or less,

all you need to do to parameterize the

system is to select the components in

use.”

Furthermore, the Sinamics G120P

Cabinet frequency converter also allows

the pressure tappings in the air

ducts to be directly connected to the

corresponding inputs at the frequency

converter. By integrating Proportion-Integral-Derivative

(PID) controllers, a dynamic

and autarkic subsystem is established.

This subsystem does not require

any programming in the higher-level

Programable Logic Controller (PLC)

and does not unnecessarily use computing

capacity. All these features are in

line with the IDS strategy, according to

which everything from the layout of the

drive train through to the control level

is perfectly harmonized. “The perfect

coordination of the entire drive system

was one of the reasons why the cupola

had to be shut down for only three days

to have the new equipment installed,”

says Michael Steuer.

Exact dimensioning ensures

short payback periods

During the process of dimensioning

the motor, the technical experts at Saarbrücken

found that it would be possible

to go for a smaller motor size. The Siemens’

energy saving tool “SinaSave” allowed

to reliably determine which motor

would provide the greatest cost and

energy saving potential, while achieving

the specified capacity. From the research

it eventually emerged that the

Sinamics G120P Cabinet frequency converter

with a power rating of 315 kW

and the AC asynchronous motor FD

High Efficiency with a shaft height of

315 mm and a power rating of 325 kW

would be the best suited combination.

Compared to the previously used motors

with a shaft height of 355 mm, the

lower shaft height would achieve more

favourable values in terms of moment

of inertia, moving mass, efficiency, etc.

“This shows how important it is to carry

out retrofits at certain intervals. The

program calculates the payback periods

of such investments,” adds Wamsbach.

At the same time, the availability

could be substantially increased as a

result of the retrofit. While in the past

the two redundant drive units could

only be operated separately, there

is now the possibility of individual

switch-overs. This means that motors

1 and 2 can alternately be supplied by

frequency converters 1 or 2. This provides

the important advantage that

by capturing the operating hours under

maintenance aspects the load distribution

over the various components

can be optimized.

Casting Plant & Technology 1 / 2017 21


MELTING SHOP

Figure 3: -

-


count

all systems components

Figure 4: Dirk Rau, master electrician and SPS technician at the Neue





A very interesting feature of the Simotics

FD motors is their modular design,

which provides a high degree of flexibility

to cater to most different applications.

While in case of the cupola in Saarbrücken

regular ventilation is sufficient,

it would also have been possible to supply

- or even retrofit - the motors with a

separate ventilation or water cooling system.

Especially under the harsh conditions

prevailing in the foundry, having

interior cooling fins provides the advantage

that they will not be contaminated

during standstills by substances contained

in the ambient air.


operation

“We monitor both, the coil temperature

and the bearing temperature of the motors,”

explains Dirk Rau. Thus any variations

during operation are immediately

detected and can be eliminated without

delay. Moreover, the motors are thus

designed that used lubricant can be removed

without opening the bearing

bushes. In other words: With the right

drive concept in place, initial damage can

be systematically prevented. For thermal

processes of this type, i.e. those that cannot

be simply stopped, safety and availability

must be given top priority.

Energy consumption, the values of

which are transmitted by the PLC via

OPC interface to the works-wide energy

management system, is of equally great

importance. The energy-saving effect of

the new air blower even becomes obvious

at the transformer that feeds the

blowers: the value of kilowatts per ton

of liquid iron has markedly improved

since the new equipment was installed.

Marcel Junk comments: “In spite of, or

even because of the high connected

load in our works every single measure

to save energy deserves attention.”

This is the reason why the maintenance

team is already considering other

modernization measures, namely

at the more than two dozens of cooling

water pumps with connected loads

between 18.5 and 45 kW. Also for this

application, Siemens offers a complete

drive-technological package within its

“Integrated Drive Systems” range of

solutions, namely, the Simotics synchronous

reluctance motors developed

exclusively for converter operation.

Their outstanding feature is the high efficiency

they achieve in the partial load

range. Here they combine the advantages

of conventional AC asynchronous

motors with those of synchronous motors,

namely low investment costs and

extremely energy-efficient operation.

The first step of a plant modernization

process following the “Integrated

Drive Systems” approach has been

successfully completed. The perfectly

harmonized drive system supplied

by Siemens, consisting of a Sinamics

G120P Cabinet frequency converter

and Simotics FD AC asynchronous

motor, has proved to be highly reliable

and energy-efficient day in, day out. It

has definitely passed the acid test at

the Neue Halberg-Guss foundry.


» Sinamics G120P converters and

Simotics FD motors are a perfectly

harmonized IES2drive system with

very low system losses in line with

EN50598-2

» Autarkic drive system with integrated

control functions

» Determination of the optimal combination

of motor and converter by

means of the SinaSave energy efficiency

tool

» Easy commissioning and optimal coordination

of the control para meters

of the motor and the converter via

the Motor Identifier of the Starter

Tool

» Support of the standardized Profi-

Energy profile for demand-based,

energy-efficient operation.

www.siemens.de/starter

www.siemens.de/sinasave

22 Casting Plant & Technology 1 / 2017


PRESSURE DIE CASTING

Aluminum structural components are ground, polished, deburred, milled and riveted on the production line from SHL (Photos: SHL AG)

Mareike Kircher, Marketing, SHL AG, Böttingen

Robot-based and fully automatic –

towards Industry 4.0

Cars are getting lighter because during their production steel is increasingly being replaced by lighter

materials, such as aluminum. SHL AG, in Böttingen, Germany, has responded to this change by

developing a plant that grinds, deburrs and then machines aluminum structural components – fully

automatically in a robot-assisted continuous process. In the role of general contractor, SHL has de-


The increasing use of light materials

is a challenge for process technology.

The processing of aluminum structural

components with complex geometries

is demanding; the requirements

regarding surface quality are high. Robot-based

solutions that carry out processing

steps automatically are advantageous

here. The processes become

leaner and users save time and money.

SHL has exploited its more than 30

years of experience in aluminum processing

to develop the production line, offering

an important element for networked

production within the context of Industry

4.0. Structural components, such as

suspension strut pillars, are sanded, deburred

and measured fully automatically

with the help of industrial robots. This is

followed by machining involving drilling

and milling. The parts are also aligned, inspected

and riveted. “This takes place in

a continuous process. As a general contractor,

we offer customers services from

a single source with defined contact persons,”

explains SHL Project Manager Daniel

Welte. Several production runs have already

been successfully carried out at the

company headquarters in Böttingen.

The belt sanding units developed by

SHL offer users optimum grinding results

consistently and with reasonable

consumables costs. A TÜV test report

underlines the efficiency of SHL’s solutions

– especially those for grinding

aluminum. SHL can design and set up

24 Casting Plant & Technology 1 / 2017


Figure 1: Thorsten Schuler, PLC expert at SHL (left) and application engineer Gebhard Weber

have already completed several production runs at the company headquarters in Böttingen

entire large lines without any problem

in its new 3,000 m² hall for application

technology. The company currently

delivers plant and grinding expertise

from Böttingen to all major foundries.

Processing in the production line starts

with input of the aluminum structural

components on a heat treatment rack.

An employee scans a data matrix code

and the MES system then enables the

“Grinding” process. The part is laid on a

loading table from which Robot Number

One grips the components and moves

them, one after another, to two SHL

FRS 250/450 free belt and contact wheel

grinding machines. These use SHL retrofitting

spindles, contact wheels and SHL

grinding attachments. Then the robot

approaches with the deburring unit and

completes internal processing. It uses a

direct handshake to pass the component

on to Robot Number Two which processes

the exterior using the same machine

arrangement as in the first step. The part

is then inserted in the SHL blow-off airlock,

where remaining dust is removed

by means of air pressure.

On completion, the component is

passed on to a handling robot with a

data matrix code-scanner. The next step

is determined on the basis of the code.

If any problems arise during the grinding

process (for example a drop in air

pressure or a broken belt) Robot Number

Three removes the part via a not-inorder

belt. “If no problems are reported

by the system the components are inserted

in the straightening unit and appropriately

positioned,” explains Daniel

Welte. If there are any discrepancies

here, the component is also removed via

a separate belt, realigned and inserted

again using so-called sequence part control.

Only then does the robot start the

CNC machine for the milling process.

Distortion is monitored here because

considerable forces are exerted

on components during milling. If this

reports “in order”, Robot Number Four

inserts two rivet bolts – whose correct

sit is inspected by force/displacement

measurements. The part must be reworked

if there are deviations from the

predefined norm. If everything is in order

the robot removes the part and lays

it on a belt. The process is finished. The

plant is ready for the next component.

With this production line, SHL has developed

an automated solution with a

higher-ranking PLC that communicates

with customer-specific MES systems.

This gives customers the advantage that

processes can be tested under real conditions

at the SHL site in Böttingen (Figure

1). “This simplifies integration in

the user’s new production system and

enables a rapid start of operation,” says

Daniel Welte. The automation specialist

believes that this innovation from SHL

will offer considerable savings potentials

for automotive suppliers and foundries.

www.shl-automatisierung.de

Pneumatic conveying

technology

For dry, free-flowing,

abrasive and abrasion

-sensitive material

Core sand preparation

technology

For organic and inorganic

processes, turn-key systems

including sand, binder

and additive dosing

and core sand distribution

Reclamation

technology

Reclamation systems for

no-bake sand and core sand,

CLUSTREG for inorganically

bonded core sands

KLEIN Anlagenbau AG

Konrad-Adenauer-Straße 200

57572 Niederfischbach

Fon +49 2734 501 301

Fax +49 2734 501 327

info@klein-ag.de

www.klein-ag.de

Casting Plant & Technology 1 / 2017 25


ECO-FRIENDLY PRODUCTION

Florian Hartung, Managing Director of Infuser Deutschland GmbH, Mannheim

Patented environmental technology

for foundries

Castings, or the components made from them, are indispensable for many everyday products.

More than 80,000 employees used high-tech processes in foundries in Germany to achieve sales

of about 13.8 billion euros in 2015, making this an important economic sector. But it is the focus

of particular attention and under great pressure – not only in this country – due to increasingly

stringent limit values in environmental standards. Together with the University of Copenhagen,

Infuser – a company based in the Danish capital – has developed innovative solutions that

enable foundries to economically reduce contamination by pollutants and odorous substances

by up to 99.99 %

Casting on the casting line of a mold plant. High concentrations of formaldehyde,

VOCs and BTEX are generated in this area, and can be increasingly effectively removed

by improving environmental technology (Photos: Infuser)

Pollutants and other problematic materials

are generated at various points

in the production process. The use of

binder systems leads to the creation

of further pollutants, such as amines,

methyl formate, phenols, formaldehyde,

other volatile organic compounds

(VOCs), as well as benzene, toluene,

ethylbenzene and xylene (BETX),

which can pose a risk to health and the

environment. Apart from the expected

lowering of various limit values when

Germany’s Technical Instructions on

Air Quality Control (TA Luft) is amended,

reducing these emissions is particularly

important for companies for reasons

of health and safety at work.

The atmospheric and chemical

cleaning processes upon which the

Climatic exhaust air decontamination

system is based achieve high purification

levels energy-efficiently for all

VOCs and odorous pollutants in foundries.

During tests carried out with pilot

plants, for example, between 85 and

97 % of BTEX, up to 99.99 % of amines

and up to 95 % of total hydrocarbons

were removed from the exhaust air. The

system can be individually adjusted to

the pollutants generated in particular

processes and adapted to production

fluctuations, saving energy.

In addition to scrubbers, filters or regenerative

afterburning, the Climatic

system represents an efficient alternative

for treating exhaust air. The technology

offers foundries extremely flexible

planning because it can remove

VOCs from the exhaust air at the various

workstations (Figure 1). During the

modification, expansion or construction

of foundries – from whom authorities

expect coherent emissions concepts

– this exhaust air decontamination system

opens up varied and completely new

opportunities for companies. This is because

the decontamination of differing

volume flows with individual pollutant

loads can be carried out either centrally

in a single system or separately, directly

26 Casting Plant & Technology 1 / 2017


at their source, when exhaust air flows

and ventilation plants are completely

redesigned, re-planned and reconstructed.

The cost-effectiveness of the entire

exhaust air decontamination system can

be optimized with skillful planning. The

overall design of foundries can be made

more space-saving by using Climatic as

the main exhaust air decontamination

system. With its compact dimensions

and low space requirement, the system

can be installed directly at the emission’s

source – as a decentralized exhaust air

solution ( Figure 2).

As the topic of odorant pollution is

becoming increasingly important, hall

ventilation is receiving attention. The

Climatic system is used to economically

and efficiently free halls from odors

and pollutants, even if air flows with differing

pollutant loads are combined.

Areas of application: hall exhaust

air, core store, mold production

plant – high-volume


The hall exhaust air in the core shop, as

well as in the core store or the mold production

plant for example, have comparatively

low amine and VOC pollutant

levels, though they represent a not

inconsiderable odor load and health risk

for employees. The standard version of

Store

the Climatic system is used here because

it is ideally suited for removing relatively

low pollutant concentrations from

high-volume flows with comparatively

low energy consumption. Thus in a current

pilot project in a foundry in the German

state of Baden-Württemberg about

50 x 106 odor units/hour of pollutants

could be removed from 40,000 m³/h of

hall exhaust air during decontamination

of the core store, equivalent to a purification

performance of 80 % (Figures 3,

4 and 5).

Areas of application: coreshooting

plant, core drying

furnace and casting line –


pollu tant loads

The Gas Enhanced Catalysis (GEC)

Climatic system is available for volume

flows with high loads. It is based

Mold construction

Core store

plant

Core drying

furnace

on the standard Climatic system but

– depending on the type and level of

pollutants – is expanded and even partially

replaced by a low-energy catalyst.

This uses excess ozone from the standard

system for further reactions, and

thus for further improved purification

performance with low energy costs.

The system’s main area of use is for the

exhaust air of the core-shooting machines,

drying furnace and mold production

plant because high concentrations

of amines, formaldehyde, VOCs,

BTEX and odors are generated here.

Area of application: upstream

connection before existing


By combining the standard Climatic system

with existing active carbon filters,

the VOCs contained in the outgoing exhaust

gas (exhaust gas flowing outdoors)

Core-shooting

Melting plant

Core shop

Mold assembly

1

Pattern-making

2

1 - Climatic Standard

Hall exhaust air – high volume

flows with low pollution load

(amines, formaldehyde, VOCs,

BTEX)

Furnace 1 Furnace 2

Paint shop

Fettling shop

Quality assurance

Furnace 3

Casting line

2

Cooling line

2 - GEC Climate system

Volume flows with high pollution

load. High concentration of

amines, formaldehyde, VOCs,

BTEX and odors

3 - Hot Ozone Climatic system

For preventing condensation in

exhaust air pipes caused by

long-chain oils and fats

Figure 1: Optimized areas of use of Climatic solutions in the production process of a typical foundry

Casting Plant & Technology 1 / 2017 27


ECO-FRIENDLY PRODUCTION

Figure 2: Delivery of one module of a decentralized GEC Climatic system

The exhaust air from casting lines and

core drying furnaces contains longchain

oils and fats from the solvents

used at the foundry. These are very

quickly deposited in the exhaust air

pipes and lead to their sooting. They

also pose a high fire risk due to their

easy flammability. The Hot Ozone Climatic

system is used here. The structure

of these oils and fats is changed

by installing a honeycombed catalyst

in the exhaust air pipe and precisely

injecting extremely pure ozone so that

they can no longer be deposited in the

pipes as condensation. The same effect

is shown at the nozzles and filters

of the regenerative thermal oxidation

(RTO) system, which also becomes

considerably less fatty, substantially

lengthening cleaning and maintenance

intervals. An electrostatic precipitator

or amine scrubber can also

be utilized without the efficiency impairment

that used to occur.

Figure 3: Installed central Climatic system

can be reduced by up to 95 % under normal

operating conditions before it even

reaches the active carbon filter. The socalled

photo-active carbon system is a

solution for controlling emissions that

allows the operating costs of active carbon

filter plants to be reduced by up to

80 %. The system can be combined with

existing active carbon filters or installed

with a new active carbon filter module. It

also has a simple monitoring and control

system that adapts the energy consumption

of the decontamination plant to the

level of pollution, particularly advantageous

for production sites with variable

peak emission values.

Areas of application: exhaust

air pipes on casting lines

and core drying furnaces –

prevent ing the formation of

condensation

The technology – a patented

method for decontaminating

exhaust air

Infuser developed the new patented

method for decontaminating exhaust

air jointly with the University of Copenhagen,

Denmark. The technology

in the compact reactor accelerates the

natural cleaning process of the earth’s

atmosphere by a factor of one hundred

thousand. The so-called atmospheric

photochemical process requires considerably

less energy than conventional

methods because it is based on natural

chemical reactions. The system’s

modular design offers practical advantages,

whereby each module fulfils a

special function in the decontamination

process.

The polluted air is passed through

the individual modules and thereby

exposed to water vapor, atmospheric

reagents in a variety of stages, and ultraviolet

radiation. This process converts

gaseous pollutants to solids, and

the resultant particles can be dealt with

using an electrostatic filter. Foundries

can use the system to remove up to

99.99 % of all amines, methyl formate,

phenols, formaldehyde and BTEX, as

well as the entire hydrocarbon content

from the exhaust air.

28 Casting Plant & Technology 1 / 2017


Figure 4: Commissioning of a Climatic system

Figure 5: Infuser employee installing a Climatic pilot plant

Setting environmental

standards

The modular system provides efficient,

energy- and cost-optimized solutions because

the modules used are designed for

the desired emissions control at defined

areas of use. The plant can completely

replace conventional filter and decontamination

equipment. It can, however,

also be installed upstream of existing

filters in order to increase overall purification

performance whilst reducing the

running costs of the existing technology

(such as active carbon or scrubbers).

The plant’s control system continuously

measures the level of pollution

of the air and adapts the purification

performance accordingly, further reducing

energy and general operating

costs compared to other processes.

The energy required for ventilation

throughout the foundry can also be

reduced by using this system, for example

through shorter duct sections

when utilizing decentralized Climatic

plants or because of lower pressure

loss in the exhaust air system due to

the lack of a conventional static filter.

The system fundamentally decontaminates

with a very low pressure loss by

carrying out purification in the gaseous

phase.

Foundries can use the system to meet

environmental standards cost-effectively

and ensure cleaner air in the production

sites, as well as in the exhaust and

outgoing air – with very low requirements

for consumables or hazardous

chemicals and with little or no waste materials.

The system offers a wide range of

applications for the various process steps

in the works so that companies can take

the foundry’s individual structural and

departmental demands into account on

the basis of tailor-made concepts.

www.infuser.eu/de

THE MILLENNIUM EVENT

THE ALUSPECIALIST’S MEETING

10 TH ALUMINIUM WORLD CONGRESS

6 TH INTERNATIONAL ICEB CONFERENCE

ALONG WITH 21-24 JUNE 2017

THREE EVENTS IN ONE:

THE STRENGTH OF SYNERGY AND THE POWER OF INNOVATION

20 - 24 June 2017

PalaExpoCongress - VeronaFiere

Verona - Italy

Conferences, Poster Session, Social Events

www.aluminium2000.com

INTERALL

International Aluminium Publications

Event organized by:

Interall Srl: Via Gino Marinuzzi- 38 - 41122 Modena - Italy - Tel. +39-059-282390 - Fax +39-059-280462

aluminium2000@interall.it - www.aluminium2000.com

ICEB Organizing Committee at University of Bologna: www.ice-b.net

CONGRESS

Main subjects (but not limited to):

CONFERENCE TOPICS

Markets & strategies, alloys billets & related equipment, Rolling technology,

architecture & special uses, transport & automotive industry, anodizing,

coating, nano technology, automation, measuring, testing & quality techniques,

advanced applications & research, environmental protection & recycling, waste

water treatment, foundry, casting & die casting.

ICEB Session & Extrusion: Process sustainability, process management, process

monitoring, plant & process, process simulation, product quality, alloys, dies,

new processes.

EVENT HIGHLIGHTS

120 highly specialized technical papers, expected 500 delegates from 55

different countries, 4 parallel sessions running throughout the 3 days event,

Social Program for all participants, Sponsorship opportunities.

Ofcial language: ENGLISH


WASTE HEAT UTILIZATION

Julian Lechner, Manager Business Development, Orcan Energy, Munich

Save energy costs: generate

electricity from waste heat




“Process heat makes up about twothirds

of indpustrial total final energy

consumption, and is thus industry’s

most energy-intensive field of application

by far” [1]. Even after exhausting

potential heat utilization, there

are still unused waste heat potentials

in the megawatt per site range. This is

also the case in the foundry industry,

where there are still large waste heat

flows, e.g. in the exhaust gas of melting

furnaces, despite the application

of new technologies for utilizing heat.

The Organic Rankine Cycle:

a thermodynamic circulatory

process

ORC technology is not new: the process

was named after the Scottish physicist

and engineer William John Macquorn

Rankine, who developed the basis for

this technology as long ago as the 19th

century. The fundamental principle of

ORC technology is the same as that of a

steam power process: the Organic Rankine

Cycle is a thermodynamic circulatory

process (Figure 1). A heat flow is

passed over a heat exchanger and vaporizes

a working medium. The vapor

is under pressure and drives an expansion

machine that uses a generator to

produce electricity. The electricity thus

generated is either used directly on site

or is fed into the power grid. A condenser

cools the medium, liquefies it

and feeds it back into the vaporization

process. Waste heat sources with lower

temperatures (as found, for example, in

industrial processes and with motors)

can be recovered in the Organic Rankine

Cycle by using a medium with a

lower boiling point than, say, water.

Industrial use of an ORC plant in Germany (Photos: Orcan Energy)

The ePack: a compact ORC

module for recovering waste

heat

One example of a new generation of

ORC plants in serial production is

the ePack developed by Orcan Energy,

Munich (Figure 2). No larger than

two wardrobes, at the design point the

ePack requires an input of 200 -

400 kW of thermal energy at a temperature

of from at least 80 °C to more

than 850 °C. The net nominal output

of an ePack is 20 - 25 kW of electricity.

All internal consumers required to

run the ePack – such as pumps, ventilation

(cooling), and power electronics

– have already been deducted from

the gross generated electricity. Because

several ePacks can be coupled to

form so-called stacks, greater quantities

of waste heat can also be optimally

recovered. Thus ePacks can convert

heat sources with several megawatts of

waste heat into electricity.

The stack structure also offers a decisive

advantage in the case of dynamic

heat sources: modules can be switched

on and off highly flexibly, depending

on how much waste heat is present.

This is supported by the large partload

capacity of the individual modules,

allowing fluctuating heat sources

(e.g. batch processes) to be recovered.

The ePacks are serially produced at

the FLEX works in Althofen, Austria.

Proven industrial components from

respected suppliers are used in the

ePack. This leads to the system’s high

level of reliability, demonstrated by the

more than 35 commercial plants in operation

(in Germany, the UK, Italy and

Belgium) with more than 350,000 operating

hours. The low maintenance requirement

due to the use of standard

30 Casting Plant & Technology 1 / 2017


Figure 1: How the ePack works

components in the ePack keeps operating

costs low and allows easy planning.

Production is not impaired by malfunctions

or maintenance of the ePacks because

they operate autonomously and

have no influence on the heat-generating

production process. The ePack uses

an organic medium that is neither inflammable

nor poisonous.

Installation is very easy because all

the components of the ORC system

are contained in the compact modules:

the heat is supplied to the ePack via a

standard interface (hot water), and the

electricity generated is fed directly into

the electricity grid via a cable. In addition

to German certification for feeding

into low-voltage networks (according

to VDE-AR-N 4105), there is also a

certificate for German medium voltage.

Apart from electricity, an ePack

can also supply usable heat, e.g. in the

form of hot water for heating buildings.

Because the ePack provides cooling capacity,

coolers can be switched off – depending

on the process step – further

reducing electricity consumption.

Application examples

The range of applications of the ePacks

is very wide due to the system’s scalability:

basically, ePacks can be used

wherever hot waste gas is released,

process heat is left over, or a heat flow

needs active cooling (e.g. through heat

exchangers).

Application example: the ceramics industry

Conrad Liphard & Söhne GmbH in

Großalmerode has been improving its

energy efficiency through the use of ePacks

since 2015. The company’s roughly

80 employees produce bricks for industrial

furnaces and tiled stoves, as

well as technical ceramics for high-performance

turbines. A lot of waste heat

is generated, particularly by the ceramic

furnaces. Two ePacks with an electrical

power totaling 40 kW have been in-

Figure 2: The ePack uses proven industrial

components from respected suppliers

Casting Plant & Technology 1 / 2017 31


WASTE HEAT UTILIZATION

Figure 3: Several more megawatts of thermal

energy can often be exploited when

ePacks are installed as a stack

stalled at a waste heat source in order

to exploit it. The ePack modules can

be operated individually or together.

The ePacks enable the generation of

more than 320,000 kWh of electricity

per year from the waste heat of one

ceramic furnace. This leads to annual

cost savings of more than 50,000 euros

for purchasing electricity. As a result,

the initial investment in the ePacks

and installation was amortized within

a few years.

Application example: a foundry

Large amounts of waste heat are released

in foundries. The heat is often

already reused in other process areas,

CellaCast

Expert for precise

optical temperature

measurement

for process analysis and control

info@keller-msr.de

www.keller-msr.com/pyrometer

32 Casting Plant & Technology 1 / 2017


ut mostly more heat is available than

can be utilized. The use of ORC technology

is suitable here because it converts

the heat into a more valuable

form of energy – electricity. For example,

about half of the waste heat in

the flue gas of a melting furnace (cupola

furnace) is often reused in a recuperator.

Many more megawatts of

thermal energy are available, however,

but they are often wasted in electricity-powered

cooling plants. With

a stack of seven ePacks (see stack of 5

modules, ) 2.5 MW can be converted

into electricity from thermal

energy. They can thus generate about

1,200 MWh of CO 2

-neutral electricity

every year, reducing CO 2

emissions by

about 700 tonnes per year. Using the

heat (e.g. for heating buildings) after

the ePack saves another approximately

500 tonnes of CO 2

emissions per year .

This significantly increases the energy

efficiency of the entire plant.

Cost-effectiveness

The advantages for foundries of converting

waste heat to electricity lie, above all,

in cost reduction through self-generation.

In addition, in view of an increasingly

environmentally aware clientele,

the reduction of a company’s ecological

footprint is an advantage for positioning

and brand communication. The amortization

time of two to five years for an ePack

is very low compared to other solutions

for recovering waste heat. A new

program launched by Germany’s Federal

Ministry for Economic Affairs and

Energy and the KfW bank (KfW 294) –

Deutschland macht’s effizient (Germany

Does It Efficiently) – supports companies

in the conversion of waste heat

to electricity using ePacks. This further

improves cost-effectiveness.

Summary

Foundries already use different means

to use energy and raw materials as economical

and environmentally friendly

as possible. Conversion of waste heat

to electricity with ORC technology is

an important component in these optimization

processes. The ePack from

Orcan is tried and tested, and ready

for use. It is serially produced by Orcan

Energy in high unit numbers, offers

flexible use, and is both low-maintenance

and cost-efficient through the

use of proven industrial components.

The path for new efficiency projects in

foundries is free – through the innovative

and reliable ORC-systems from Orcan

Energy (ePack).

References:

www.cpt-international.com

www.orcan-energy.com

YOUR PARTNER

FOR TURNKEY PROJECTS

in no-bake moulding shops for:

• moulding lines

• continuous mixers

• mechanical and thermal reclamations

• chromite separations

Smooth pneumatic conveying system for:


QUALITY

MADE IN GERMANY

FAT Förder- und Anlagentechnik GmbH www.f-a-t.de


Michael Vehreschild, Kleve

Schmiedeberger Gießerei – on the

path to the intelligent factory

Schmiedeberger Gießerei is attentive and on the ball. The company has invested about 6.5 mil-

-


-

-



34 Casting Plant & Technology 1 / 2017


The fathers, and even grandfathers,

of some of the present workforce were

employed at Schmiedeberger Gießerei,

a tradition of which the two Managing

Directors, Holger Kappelt and Andreas

Mannschatz, are well aware – the company

in Dippoldiswalde, Germany,

wants to remain a dependable resource

for the local population. Despite major

investments in efficiency and modernization

the changes have not become

a nightmare for the personnel

– on the contrary. Because the bottom

line is that sales have risen because capacity

has grown and there is a greater

depth of production. Schmiedeberger

Gießerei has made itself fit for the future

by making brave investments.

The foundry has its ear

to the ground

Those who do not listen to the market

could very soon lose out. So Schmiedeberger

Gießerei listens very closely:

ever-greater numbers of non-core

components are being produced outside

Western Europe for price reasons.

On the other hand, the foundry’s

customers increasingly demand

more complex and core-intensive

casting contours in order to achieve

smaller component sizes. A case for

the Schmiedeberger Gießerei. “This

opens up potentials for us because we

can support customers during this design

phase and bring our expertise to

bear,” underlines Holger Kappelt. The

second important part of his diagnosis

was that capacity had to be increased.

So the company invested in a new

sand preparation plant. The old plant

could only produce one type of sand

for both available molding plants.

“This meant compromising and the

need to coordinate box occupancy,”

reports Kappelt. The new plant now

provides separate supplies for Molding

Plants 1 and 2, with the particular

molding sand optimally adjusted. Performance

per shift has increased and

casting quality is higher.

Increased depth of production

The foundry took another step in the

direction of the future with its new

Casting Plant & Technology 1 / 2017 35


AUTOMATION


Trainee Marcel Kühnel on the core-set


core production center, consisting of

an 80-liter core shooter, a wash tank

and a core drying chamber. “We now

produce cores for the production of internal

structures in the castings which

in the past we often had to buy in,”

says Kappelt, not without pride. This

increases the depth of production,

lowers costs in the long term and “we

can react quicker to fluctuations in demand.

This, too, means an even higher

level of delivery reliability for our customers.”

When discussing efficiency one also

has to talk about energy consumption,

and preferably take action. A new

compressor station now provides the

compressed air supply for core-making,

mold production and the fettling

shop. The waste heat is used to heat the

building. Efficient, no question. Moreover,

the costs of the energy-intensive

processes are lower now thanks to the

greater efficiency of the new technology

– a win-win situation for the company.

Communication at a new level

The new ERP system is another milestone

that, by 2016, will have completely

replaced the old system that

was developed by the foundry itself.

“Communication and data transmission

will be on a new level,” according

to Kappelt. The entire business process

will be linked – from sales, through purchasing

and production, to logistics –

whereby all operational processes will

be controlled. “Firstly, this optimizes

our planning processes. Secondly, we

shorten the throughput times of casting

production through the use of various

feedback points.”

For example, the transport personnel

use a tablet PC installed on the

fork-lift truck to take over the quantity

of components that has been passed

on to the next department. “The foreman

of this department can therefore

immediately see where the parts

currently are and how many of them

there are,” explains Kappelt. The number

of intermediate stores is thus minimized

and part throughput is accelerated.

“For the customers this results

in shorter delivery times, greater planning

security, and a high level of cost

transparency.”



Material stocks are optimized

The sales management can now provide

customers with online information

on the production status at any

time. “As our system is networked

with those of our business partners

and customers, the requirement figures

can also be read out from the customer

system.” Any change, for example,

to the material requirement or

order volumes within a project is immediately

visible for all involved, and

they can react appropriately. The Purchasing

Department can therefore op-

36 Casting Plant & Technology 1 / 2017


timize stocks. Is this already Industry

4.0? “If by Industry 4.0 one means better

organization and control of the entire

value-creation chain then we are

on our way towards it,” says Kappelt.

The new ERP solution is one step in

this direction, and networks the individual

production stages. What is not

yet reality, however, is the intelligent

linking of machines that autonomously

react to one another. Some areas of

the company, such as the mold plant,

are of course automated. But a complete

automation of the foundry has

not yet taken place because the individual

batch sizes are too small.

Start in the direction of

Industry 4.0

But: “This system is a starting shot in

the direction of Industry 4.0.” What is

certain for Schmiedeberger Gießerei is

that the digitalization of industry and

the networking of processes will become

the norm in coming years, even

if “it will be a while yet.” Whatever the

case, what will probably not take too

much longer is investments in robotics.

“This will come next,” explains

Managing Director Andreas Mannschatz.

The use of robots is of interest

for standardized processes, for example

in the fettling shop, mold plant

or core production center, where it is

a relevant technology that will gain



Focus already on robotics and

3-D printing

The foundry is also focusing on 3-D

print technology. It can be used to

obtain prototypes more quickly, and

in importance, particularly given demographic

developments. “My aim

is to start doing something about robots

from 2018,” according to Mannschatz.

-





Casting Plant & Technology 1 / 2017 37


AUTOMATION

changes are easier to implement. Prototypes

have had to be purchased up

to now, but this could change. “We are

considering investing here,” though

this does not make much sense at the

moment because of the costs. The

company has already been putting

out feelers regarding robotics and

3-D print technology for some time

now. Students at the nearby Freiberg

University of Mining and Technology

have been examining these technologies

as part of their courses. The

foundry provides the university with

suggestions for the curriculum. And

the students, in turn, gain practical

work experience at the company in

Schmiedeberg. “After their studies,

engineers who have been trained at

the university bring their expertise

to us, a very advantageous situation

for both sides. This is why we do not

have a shortage of specialist personnel

at present,” stresses Kappelt, a situation

that some foundries can only

dream of.

www.schmie-guss.de

Setting the course for

the future

Schmiedeberger Gießerei is making

large investments, thinking creatively

and imaginatively and, via

its collaboration with the university,

preparing itself against an overall

business situation in which many

foundries are still suffering from the

generally poor economic conditions

and major overcapacities. “Against

this background, competitive and

price pressures are rising in our sector,”

Kappelt sums up. At the same

time, customers are demanding costs

transparency and there is a trend towards

ever-shorter delivery windows

and just-in-time deliveries. “This creates

fresh challenges for production

planning.” Despite the environment

being difficult, Holger Kappelt and

Andreas Mannschatz seem relaxed

– and they have every reason to be:

they have set the course for the future.


Managing Director Andreas Mannschatz

-


-


38 Casting Plant & Technology 1 / 2017


5 th International

Cupola Conference

June 22 and 23, 2017 at CCS Saarbrücken

Programme Survey

Pictures: Küttner, Fritz Winter

NEW

Online Registration:

www.cupolaconference.com

Venue:

CCS Congress Centrum Saar

Hafenstraße 12, 66111 Saarbrücken

Host:

Bundesverband der Deutschen Gießerei-Industrie (BDG)

Further Information:

Bundesverband der Deutschen Gießerei-Industrie (BDG)

Simone Bednareck

Phone: +49 (0)211/68 71-338

E-Mail: simone.bednareck@bdguss.de

Registration:

VDG-Akademie, VDG Verein Deutscher

Giessereifachleute e.V.

Hansaallee 203, 40549 Düsseldorf

Phone: +49 (0)211/68 71-362 (Andrea Kirsch)

Phone: +49 (0)211/68 71-335 (Corinna Knöpken)

E-Mail: info@vdg-akademie.de


1 ST DAY PROGRAMME

SESSION 1 ENERGY, WASTE HEAT RECOVERY

AND STORAGE

Chairman: Hans Jaan Rachner, Küttner GmbH, Essen

09:00 Opening

Dr. Christian Wilhelm, BDG, Düsseldorf

09:10 Energy streams analysis and comparison for

cupola melt shop operations and oxygen use

Dr. Thomas Niehoff, Linde AG, Unterschleißheim

09:35 Energetical optimization of crude gas cooling

of hot-blast cupola plants

Frank Wondra, Herp Gießereitechnik GmbH, Freudenberg

10:00 Dual Media High Temperature Thermal Storage

for Industrial Waste Heat Recovery

Richard Gurtner, ZAE Bayern, Garching

10:30 Coffee Break

11:00 High efficient and economic use of cupola waste

heat

Rainer Schnur, DeVeTec GmbH, Sankt Ingbert

11:25 Energy efficiency improvement and cost savings

through electricity generation from waste

heat

Julian Lechner, Orcan Energy AG, München

11:50 Modernisation of wind blowers saves energy

Roman Wamsbach, Siemens AG, Nürnberg

12:15 20 Years Cokeless Cupola – Retrospective and

Outlook

Dr. Ralf Jennes, Küttner GmbH, Essen

12:30 Lunch

SESSION 2 ENVIRONMENT, SUSTAINABLE

CHARGE MATERIALS AND RECYCLING

Chairman: Dr. Dirk Radebach, Fritz Winter Eisengießerei GmbH

& Co.KG, Stadtallendorf

14:00 Cupola and Climate Protection – a Contradiction

in Terms?

Elke Radtke, BDG, Düsseldorf

14:25 Development of New Bio-Energy Technology

And Its Verification Test

Dr. Tamio Ida, Kindai University, Osaka (JP)

14:50 The use of biogeneous carbon carriers in iron

and steel industries to improve the environmental

balance

Prof. Dr.-Ing. Saulo H. Freitas Seabra da Rocha*,

Tina Steinmetzger, Hochschule R West Bottrop; Dr.

Dirk Radebach, Jörg Billasch, Fritz Winter Eisengießerei

GmbH & Co.KG, Stadtallendorf

15:15 Coffee Break

15:40 The Battery Recycling Process

Valentin Barad*, Jean Pierre Garnier, Fiday Gestion,

Chassey les Scey (F)

16:05 SiC bricks in the cupola

Guido Horn*, Scholz Rohstoffe GmbH & Co.KG,

Duisburg; Dr. Dirk Radebach, Fritz Winter Eisengießerei

GmbH & Co.KG, Stadtallendorf

16:30 End of Session

17:00 Bus Depart at CCS

18:00 Guided tours of World Heritage Site Völklinger

Hütte (ancient integrated steel plant)

19:00 Foundrymens‘ Night

2 ND DAY PROGRAMME

SESSION 3 SUSTAINABLE CHARGE MATERI-

ALS, OPERATION

Chairman: Mehmet Ucur, Eisenwerk Brühl GmbH, Brühl

09:00 How important are CRI and CSR for foundry

coke and cupola performance?

Maria A. Diez, INCAR-CSIC, Oviedo (ES)

09:25 Influence of foundry pig iron on cast iron molten

in the cupola

Mathias Lueben, Georg Fischer GmbH, Singen

Pictures: Fotoschlick - Fotolia, Blickfang - Fotolia,

Peter Fuchs - Fotolia, Petair - Fotolia


Programme Survey

5 th International Cupola Conference

09:50 The use of carbon dust as reduction agent for

the production of foundry pig iron in the blast

furnace

Dr. Carsten Hillmann*, Rolf Emunds, Christian Köhler,

DK Recycling und Roheisen GmbH, Duisburg

10:15 Coffee Break

10:45 Comparison of Steel Scraps for Cupola and Induction

Furnace –Properties, Requirements

and Availability

Mehmet Ucur, Eisenwerk Brühl GmbH, Brühl

11:10 High Performance Castable Refractories for

Cupola Applications

Paul Stancer*, Vesuvius UK; Jerome Drevin, Foseco

FR; Dave Smith, Foseco USA

11:35 Implementation of Cooling Technology in Cupolas

Angelo Petrocelli*, Pete Satre, Allied Mineral Products,

Columbus/OH (USA)

12:00 Lunch

SESSION 4 OPERATION AND PROCESS OPTI-

MIZATION

Chairman: Andreas Kleinert, Georg Fischer GmbH, Mettmann

13:00 Improvement of operating time of the slag riser

in the siphon of a hot blast cupola

Dr. Wilhelm Eitel*, DWE, Ratingen; Andreas Kleinert,

Georg Fischer GmbH, Mettmann

Dr. Erwin Dötsch, Dr. Marco Rische, ABP Induction

Systems GmbH, Dortmund

15:10 Industry 4.0 Process Control and Traceability

for the Cast Iron Foundry Industry

Steve Dawson*, A. Denis, SinterCast AB, Katrineholm

(SE)

15:35 Planning and Optimization of Casting and Transport

Processes – Overall Process from Liquid

Iron Storage through Transport to Pouring

Thomas Voss, Induga GmbH & Co.KG, Lammersdorf;

Dr. Dietmar Trauzeddel, Otto Junker GmbH,

Lammersdorf

16:00 Final discussion, Summary

Dr. Ingo Steller, BDG, Düsseldorf

Programme Committee:

Mehmet Ucur, Eisenwerk Brühl GmbH

Dr. Dirk Radebach, Fritz Winter Eisengießerei GmbH & Co. KG

Andreas Kleinert, Georg Fischer GmbH

Hans-Jaan Rachner, Küttner GmbH & Co. KG

Dr. Christian Wilhelm, BDG Bundesverband der Deutschen

Gießerei-Industrie

Dr. Ingo Steller, BDG Bundesverband der Deutschen Gießerei-

Industrie

13:25 Change from atmospheric to pressurized siphon

Sergio Magri, Fonderia di Torbole (IT)

13:50 Data-driven cupola control

Prof. Johannes Gottschling*, D. Verlage, Univ. Duisburg-Essen;

Prof. Dierk Hartmann, HS Kempten;

Andreas Nissen, L. Schnier, M.Busch GmbH &

Co.KG, Bestwig

14:15 Coffee Break

14.45 Storage of cupola base iron in channel induction

furnaces

Robert Greibig*, Georg Fischer GmbH, Singen;

Picture: CCS

* Speaker


CLEANING, FETTLING & FINISHING

Michael Vehreschild, Kleve

Finishing the job

The Basibüyük corporate group on expansion course

The employees of the Basibüyük Group,

based in Mülheim-Kärlich, Germany,

are always on the road – to wherever

their services are required. On-site at

the foundry they then give the castings

a good finish. The Basibüyük Group has

long recognized the trend at foundries

to outsource the machining of castings.

“This is the future,” says Managing Director

Gökhan Basibüyük. Success has

proved him right. Within six years the

number of employees has doubled to

500 – and is still rising. The Basibüyük

corporate group is based in one of Germany’s

largest industrial estates, the

Mülheim-Kärlich Business Park, and

the foundry’s deployments are coordinated

from here. And because time is

money, foundries often get in touch because

they need help at short notice to

machine castings. No problem for the

team around company founder Mahmut

Basibüyük and his son Gökhan,

both of whom are Managing Directors

of the family-run company. “We drive

out to the customer with our employees

and get the job done on-site at the

foundry (Figure 1),” explains the junior

executive. Whereby the employees

take their own tools with them and

a foreman from Basibüyük provides onsite

leadership of the team.

Basibüyük Holding is a family company with company founder Mahmut Basibüyük

(centre) and his sons Gökhan (right) and Ismail (Photos: Basibüyük Holding)

Final inspection is also

a matter of trust

The machining of castings is also placed

in the hands of the Basibüyük Group

when a foundry is overstretched. “We

can always fill in when required.” For

this purpose, the company has a fettling

shop on its own grounds in Mülheim-Kärlich,

in which up to 60 personnel

are working through orders.

The grinding and blasting is carried out

here if a foundry has insufficient capacity

to machine the castings themselves.

And the qualification of all the Group’s

own employees is guaranteed because

Figure 1: On the road to the customer –

Basibüyük employees carry out the machining

of castings on-site

they can receive additional training in

its own fettling shop.

85 % of the Basibüyük Group’s work

is on the basis of works contracts and

15 % involves leasing personnel to the

Figure 2: The Basibüyük Group of companies

has also invested in an additional

blasting plant

foundries. Whereby the foundries pass

on the entire machining of castings –

including final inspection – to the company,

which has been in existence for

almost 30 years. “Of course, trust in our

42 Casting Plant & Technology 1 / 2017


1987 – when everything started

Mahmut Basibüyük founded “Basibüyük Metall- und

Kunststoffbearbeitung” in 1987 – initially with five employees.

Over the years several new companies followed.

Finally, the three companies – FP Foundry Personal

GmbH, BM Gussbearbeitung GmbH und S.G.G. Gussbearbeitung

& Gießereiservice GmbH – were allied under the

aegis of Basibüyük Holding GmbH in Mülheim-Kärlich

in 2015 in order to further consolidate and strengthen

their position on the market. The subsidiaries have specialized

in typical foundry activities and have customers

throughout Europe. Diesel and ship’s engines, wind turbines,

gas and steam turbines, turbochargers, pumps and

armatures, pipe tools and components from the automotive

industry are examples of the workpieces processed.

The headquarters of the family-run company is located

in Mülheim-Kärlich. There are branches and bureaus

in German cities like Stadtallendorf, Enkenbach-Alsenborn,

Krauschwitz, Torgelow, Rheine and Sainscheid.

The group currently has 500 employees.

All good reasons for celebrating the company’s 30-year

existence this year on a large scale – all its customers will

be invited to the party.

abilities is essential for the final inspection

of castings,” stresses Gökhan Basibüyük.

And his team is indeed trusted.

Better cost control

with works contracts

The need for services such as those offered

by the Basibüyük Group has been

rising for years. The reasons for outsourcing

the machining of castings can also

be found in the foundries themselves.

“They are increasingly concentrating on

their core business,” says Gökhan Basibüyük.

Work processes become more efficient

for the customers. The foundries

can thus prevent the risk that wages for

machining continue even during downturns.

From the point of view of the

foundries, the works contracts with Basibüyük

allow better control of costs, and

the foundries can become more flexible.

A glance in the fettling shop hall in

Mülheim-Kärlich shows that there is a

lot to be done: a ship’s cylinder block

with 20 cylinders is waiting to be processed;

truck parts are being blasted,

and one employee is carrying out fine

tuning during the final inspection of

an engine housing. The team works on

parts made of cast iron, cast iron with

lamellar graphite, or aluminum. Parts

may have very different dimensions.

They range from small components to

large two-tonne castings.

Growing markets: increased

capacities

There are hardly any castings that the

company does not process. The car and

truck industry, as well as wind power,

are particularly “strongly growing markets”

at Basibüyük at present. A trend

that the Group takes into account.

The company’s own hall has been expanded

because the number of orders

is rising “to increase our capacities for

cleaning work,” explains Gökhan Basibüyük.

The company has invested in an

additional blasting plant (Figure 2) and

purchased 120 endoscopes. New trucks

are also lined up in the company’s own

fleet, new cooperation partners have

been found, and bureaus founded, for

example, in the eastern part of Germany.

Made in Germany

The distances covered are often considerable

– the Group has customers

throughout Germany, as well as in

Austria, Switzerland and the Netherlands.

The company, certified according

to ISO 9001:2008 and BS OHSAS

18001, also focuses on diversity when

it comes to its employees – who come

from throughout Europe. “All nationalities

are welcome,” says Basibüyük not

without pride. Multicultural? Happily.

But it is, he stresses, a German company

and offers work “Made in Germany”.

The personnel also seem to feel

good: they are covered by social insurance

and appreciate the informal atmosphere.

“We are here for the people.”

And this also applies for the region

around Mülheim-Kärlich, where the

company has repeatedly been involved

in social initiatives, for example donating

to the Elterninitiative krebskranker

Kinder in Koblenz e.V. (a parent’s

initiative for children in Koblenz with

Figure 3: The company has its own fettling

shop in Mülheim-Kärlich, in which

up to 60 employees work through orders

cancer) – though the company does

not really want to make a fuss about it.

New enquiries and new

products

But in all modesty it can be assumed

that the Basibüyük Group will expand

further. “We have many new enquiries,”

reveals Gökhan Basibüyük.

New projects, particularly in largescale

casting, are coming up. And the

company will soon increase its workforce.

So the expansion process is by no

means over yet. Foundries increasingly

want to get the job finished by Basibüyük

(Figure 3).

www.basibueyuek-holding.de

Casting Plant & Technology 1 / 2017 43


PLANNING & ENGINEERING OF FOUNDRY PLANTS

Aerial view of the Linde plant in Weilbach. With a workforce of 157, the plant produces around 180 counterweights for forklift

trucks every day. The production volume is around 50,000 t per year (Photo: Linde)

Huub van der Weiden and Maurits Brandt, Gemco Engineers, Eindhoven



The site of Linde Material Handling in Weilbach, Germany, has a long history. Founded originally

as “Eisenwerk Weilbach” in 1822, Linde AG took over the foundry in 1975, celebrating its

fortieth anniversary in 2015. The manufacturing programme encompasses counterweights for

the electric and combustion engine counterbalanced trucks of Linde which are assembled at the

Aschaffenburg based plant of Linde. The foundry commissioned the Dutch engineering service

provider Gemco Engineers from Eindhoven in 2014 to improve the working conditions and

hand ling at the shake-out station, to reduce sand spillage inside and outside the foundry as well

as to extend the cooling time in the mold

The foundry produces some 50,000 t

per year of various counterweights

( ) on a semi-automatic nobake

flask molding line with flask sizes

up to 2,600 x 1,800 x 800/800 mm

and castings weighing several thousands

of kilograms. For some time,

Linde had already been seriously considering

to upgrade the facility by optimizing

working conditions, and the

possibility of a capacity increase.

In 2012 Gemco was asked to perform

a study for the improvement of

the hand l ing of the flasks and castings

as well as improvement of the sand reclamation,

along with the feasibility of

a capacity increase. With this study a

complete technical report was established,

defining all the required measures

to be taken for the building as well

as utilities in order to achieve the intended

works optimization. A capacity

increase proved not to be required. However,

for Linde, the result of the study

marked the initiation of a program for

the upgrade of working and environmental

conditions in order to assure a

sustainable future for the foundry.

For Gemco, a follow-up on this study

came in 2014 when it received the inquiry

for engineering assistance with

different topics related to working

climate conditions, handling at the

shake-out, sand spillage inside and

outside the foundry and increasing

of in-mold cooling time. Linde had

originally considered these issues as

separate topics with corresponding

separate solutions from separate suppliers,

and for Gemco apparently separate

engineering assistance projects.

Gemco took another approach by bundling

the separate issues and looking

for an integral concept addressing all

the issues of casting and flask han-

44 Casting Plant & Technology 1 / 2017


Ready counterweight for a forklift

truck. The stackers are assembled in

Aschaffenburg (Photos: Kitty Eman/Gemco)

dling around the shake-out, spillage,

and working climate.

Analysis identified that in order to effectively

address and solve the main issues,

logistic changes had to be carried

out. Operations in that foundry department

included handling of the specialsized

and very heavy castings and the

enormous flasks in the shake-out area

where the flasks – cope and drag – were

first taken apart and emptied on the

shake-out and then transported away.

The various operations required crane

and forklift movements in a relatively

tight area (). It also caused sand

spillage both inside in the handling areas

and in the outside cooling area. Furthermore,

the combined operations

also impacted the air quality in the adjacent

halls.


Gemco proposed an integrated concept,

incorporating an automated logistics

system for the complete casting

and flask transport to and from

the hall, and a specifically designed

manipulator for the separation of the

flasks and castings. Within the new logistics,

it was also taken into account

that the various dedicated – non-standard

– equipment and installation, required

being foundry-proof and well

maintainable for efficient operations

in designated areas. This one integrated

concept provided for a solution

that encompassed an upgrade of

the working conditions and air quality

as well as safer and more efficient

transport and handling of flasks and

Logistics around shake-out area prior to upgrade

Casting Plant & Technology 1 / 2017 45


PLANNING & ENGINEERING OF FOUNDRY PLANTS

Logistics in the integrated concept, with automated conveyors and transport car, as well as manipulator for operations in

the shake-out area, and additional cooling lines and mechanized molding logistics

castings in the shake-out area. Moreover,

a specially designed lifting and

tilting table alongside the shake-out

would significantly increase direct

sand recuperation, consequently reducing

sand loss and spillage both inside

and outside. The operator, safely

at work inside the air-conditioned and

noise-insulated cabin of the manipulator,

would be the only worker in the

hall, in a position to control and overview

all movements in that area. The

concept further included the extension

of in-mold cooling places and a

significant change in the molding logistics,

and even provided for the future

possibility to implement forced

casting-cooling lines in direct connection

to the shot-blaster in order

to eliminate the necessity for outside

cooling ( ).The concept was

presented with a budget and realization

planning.

Linde approved the concept and calculated

investment costs and the project

was made part of a foundry-wide

program focusing on best working and

environmental conditions. Other projects

to be realized during 2014-2016 –

some of which by Linde – included a

new coke storage bunker, a new sand

mixer and the change from alcohol to

water coating necessitating a big mold

drying oven.


The project was carried out from 2014

to 2016 with Gemco as the engineering

and project management partner

closely cooperating with the Linde personnel

in charge. In the process several

hurdles needed to be taken. Detailing

of the project was challenged by

the very limited space in the existing

foundry, the realization of very complex

and heavy foundations in an old

building and the fact that production

could not be discontinued outside the

planned holidays. The other challenge

was that controls for the new system

had to be included in the existing overall

plant control.

The complex circumstances and

the requirement of continuing production

demanded that the realization

be planned and performed in

multiple stages. In 2015 in-mold cooling

lines were added and the core logistics

to the molding line were considerably

modified. The manual core

This specially developed manipulator

separates molds and castings. In

the foreground: Martin Severing (l.), Project

Manager/Head of Engineering Counterweights,

and Klemens Raub (r.), Plant

Manager Linde Weilbach, with Maurits

Brandt, Gemco Engineers

46 Casting Plant & Technology 1 / 2017


Automatic roller conveyor system for the shake-out station. Up to 25 t of mold boxes can be transported here

transport to the molding line was replaced

by a compact mechanized system

comprising conveyors and elevators.

Then, during the 2015 Christmas

holidays, the foundation for the manipulator

(safe working load 11,000 kg)

had to be carried out and completed.

This was quite an undertaking due the

fact that the manipulator is mounted

right at the edge of a deep pit.

Starting 2016, several modifications

in the hall were planned by Gemco

and Linde in order to prepare the large

overhaul which was to take place in the

summer of 2016. Preparation encompassed

the relocation, and sometimes

the removal, of several control cabinets,

mechanical structures, doors,

walls and certain utility systems.

Again, this was all carried out outside

production hours, without compromising

working procedures. On the

weekends before the summer holidays

the main equipment contractors, for

the manipulator () and for the

logistics systems (rolling conveyors,

), started installation of their

equipment. During the summer holidays

the large part of the installation

took place consisting of several conveyors

for full flasks – weighing up to

25 tons –, castings and empty flasks,

and a special lifting and tilting table

next to the shake-out () from

Shake-out station with a special lifting and tilting table from which the manipulator

picks up molds and mold boxes

which the manipulator takes the flasks

and the castings. Also several noise

dampening structures and a complete

network of dust extraction and fresh

air supply was installed. At the same

time Linde conducted the installation

of the new mold drying oven and sand

mixer.

Prior to the installation the operator(s)

assigned to work in this revamped

working environment were

trained to handle flasks and castings

with the manipulator and get used to

the completely new logistics and communication

procedures.

After three very intensive weeks

during the summer holidays the

foundry was ready to ramp up production

while Linde, Gemco and the suppliers,

always in close cooperation, addressed

the complex start-up related to

the tailor-made equipment and high

level of automation. A good concept

and outstanding teamwork made for

a successfully completed project. The

Weilbach site is ready for a sustainable

future.


Casting Plant & Technology 1 / 2017 47


NEWS

ITALPRESSE-GAUSS


Italpresse of America is opening a new

site in Zeeland, Michigan, USA, which,

alongside the longstanding Italpresse

Mexican site, will be supporting the

North American market, offering customer

care and after-sales service.

Set up as a logistic center for sales, service

support and spare parts distribution,

the new location will be serving

the North American Market with a view

to consolidating the presence of the Italian

company in the area: a key goal for

Italpresse-Gauss after the success of the

growth path pursued over the past

years.

The new site is coordinated by Scott

Burkett, incumbent Vice-President of

Italpresse of America Inc., with the cooperation

of Joey Saucedo, US Service

Manager, who will be supporting customers

as regards spare parts, service

requests and other such needs.

“Over the last few years,” commented

Carlo Scalmana, CEO of Italpresse Industrie

and Gauss Automazione, Capriano

Del Colle, Italy, “we have grown on

the US market and the opening of this

new site will strengthen our presence in

the USA, injecting it with a new lease of

energy and opening up exciting prospects

with our streamlined sales force

and after-sales service. The market is recovering

admirably in the USA and we

want to be a major part of it.”

Check out our Casting Workshops

in Monterrey and Queretaro, Mexico,

May 2017!

More information: workshop-mexico.kurtzersa.com

Highest Efficiency by

Multiple Cavity Dies

Kurtz Foundry Machines stand for technological

lead and highest efficiency in

the production of castings.

Our low-pressure die casting machines

and trimming presses bring huge productivity

increases while maintaining

reliability and ensuring perfect quality.

Double your Productivity while

Casting Aluminum Parts!

Alongside with the longstanding Italpresse Mexican site the new location in Zeeland,

Michigan, USA, will support the business of the company on the North American market

(Photo: Italpresse).

The inauguration of the new site is

consistent with the global orientation

strategy pursued over the last few years

by Italpresse-Gauss Group in its quest

to be present on all the main markets

and with its commitment to grow

whilst continuing to offer the same

high quality and service standards

everywhere.

Today, Italpresse-Gauss Group is active

across 3 continents and controls a network

of fully-owned sites and sales agents

as well as its own headquarters in Italy.



GEMCO


Low-pressure casting

machine with furnace

shuttle system

Trimming press

Brembo, Curno, Italy, has awarded Gemco

Engineers, Eindhoven, The Netherlands,

the contract to design and realize

a greenfield foundry in Monterrey, Mexico.

The foundry will produce 100,000 t

of liquid metal and will be operational

end of 2017. Brembo has selected Gemco

because of the experience in the realization

of new foundries for the automotive

industry. An investment of

100 million US-Dollar (94 million euros)

is necessary to realize the foundry.


48 Casting Plant & Technology 1 / 2017


After a deep analysis of industrial trends, graphical

features and technologies, a team of engineers led by

Andrea Pezzoli, Technical Director of Italpresse Industrie,

Capriano del Colle, Italy, drew up an innovative

tool with the aim of improving the human-machine

interface.

Starting from the analysis of the state-of-art Industrial

Supervision Technology, the team focused on

aspects of the storage and use of data, and in 2015

they created HMe, a system with a user-friendly interface

but, at the same time, a powerful tool for the

real-time storage and analysis of massive amount of

data.

The first step was reaching the target of “situational

awareness”, through accurate and smart data visualization

in efficient dashboards.

HMe is built on the Windows system, it can be

therefore easily installed with all the connectivity capabilities

offered by the Microsoft operating system,

with the chance to embrace the concept of Smart

Factory based on cloud computing servers.

An ‘Avant-guard’ vision of Industry 4.0, an innovative

project that was presented with a further development

at Euroguss 2016 Exhibition of last January:

the concept of Smart Factory requires a Smart

Working System, for this reason Italpresse improved

the graphical interface of HMe, with less strong colors

and better position of the icons in order to focus

the user’s attention only on useful information, and

set up an important innovation called by Italpresse

“Remote Experience” with the aim to integrate the

peripheral devices management in a single machine

control panel.

HMe can be the only interface between the user

and the whole die casting process, and can also offer

an easy remote access to ensure the control of the

machine from any mobile device.

The “Remote Experience” enables a significant improvement

of the connectivity which will be in the

next future the basis for important developments related

to the storage and management of the Big Data

by using Cloud Technologies.

The new HMe is based on Wonderware technology,

the global leading brand by Schneider Electric,

Rueil-Malmaison, France, for industrial software.

The technology platform provided by Wonderware

allows an easy integration of the monitoring of peripheral

devices, enabling the supervision of the

whole process directly from a single control panel.

05 – 08 JUNE

2017

MOSCOW

LITMASH

worldwide

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METALLURGY

INTERNATIONAL FOUNDRY TECHNOLOGY,

SUPPLIES AND CASTINGS TRADE FAIR

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PROCESSES AND METAL PRODUCTS TRADE FAIR

powered by

The Bright World of Metals

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NEWS



Giant casting cooler from Küttner-Schwingtechnik for the foundry M.Busch in Bestwig,

Germany (Photo: Küttner)

Küttner Group, Essen, Germany, has expanded

its global foundry platform by

adding two new companies for vibrating

and molding equipment which perfectly

complete the key activity of Küttner. Each

company has a traditional and high tech

expertise in its field – with all necessary

competences for the design, fabrication/

assembly, installation and commissioning

services. The companies will be integrated

in the field of sales, project development

and later realization but will

remain independent with its own management.

This strategic expansion enables

Küttner to provide entire green sand

molding foundries, from melting, sand

preparation via molding up to shake out,

castings cooling and conveying.

Küttner has been building material

handling systems for foundries using vibrating

equipment from various partners

for 70 years. During the past few years

Küttner, in cooperation with the Austrian

vibrating equipment manufacturer

IFE, Waidhofen an der Ybbs, has built and

installed a new generation of all relevant

foundry machines like electronic controlled

shake-outs, castings cooler and

other special machines. As result of this

successful cooperation IFE and Küttner

have established Küttner Schwingtechnik,

a new joint organization with offices

in Essen, Germany, and Waidhofen,

Austria. The Waidhofen operation uses

the existing infrastructure and capabilities

for design and fabrication of tailor

made foundry equipment and services.

Küttner has also become a major

shareholder of Savelli Technolgies

which was founded by Francesco Savelli

and his partners Boldi, Botticini, Gilberti

and Tura. Savelli Technologies

S.r.L. has hired the most experienced

employees of the old Savelli S.p.A. enabling

the team to design, build, install

and start-up complete molding plants.

Savelli Technologies is based in Brescia,

Italy, with modern offices located in Tre

Torri building and an own assembly, spare

parts and service shop. In its first year

Savelli Technologies was already been

awarded with orders from Russia, Korea

and Poland for new generation molding

and green sand preparation equipment.





Linn High Term, Eschenfelden, Germany,

one of the leading manufacturers of

industrial and lab furnaces since 1969

has developed the fast laboratory furnaces

VMK (up to 1800 °C) and VMK-S/

Vac (up to 1200 °C). They are suitable

for brazing, annealing, ashing, tempering,

sintering, reducing, pyrolysis etc.

The stainless steel housings for corrosive

environment, easy operation and

fast heating- and cooling cycles are special

features of these series. Fiber insulation

is used for lab- and high temperature

furnaces (VMK); a heat resistant

gas-tight muffle insert (1.4841/Inconel)

and a water cooled door flange enable

protective gas- and or vacuum operation

(VMK-Vac) in case of protective

gas/vacuum furnaces (VMK-S).

Linn standard laboratory furnaces are

available in sizes 1 – 25 l, 0.6 – 5.0 kW.

A wide range of options offers many

customer specific solutions, e.g. protective

gas operation of up to 1100 °C possible

in case of the illustrated special

version.

Furthermore possible: after burning,

gas feeding, burning-off device and

flame supervision, safety package for

H 2

-operation, gas ventilation, fast cooling,

gas re-cooling, cooling trap in gas

outlet.


ConviTec

Vibration machines and conveying technology

Project planning – Manufacturing - Service

www.convitec.net · 069 / 84 84 89 7- 0

The Fast laboratory

furnace VMK-

135-S by Linn High

Therm (Photo:

Linn High Therm).

50 Casting Plant & Technology 1 / 2017


Reichmann Casting Finishing, Weißenhorn,

Germany, again confirmed its expertise

in fettling. For a German steel

foundry, a plane grinder was developed

by taking into account the customer

wishes. This machine offers a unique

selling proposition in the sector regarding

the abrasion performance.

The plane grinder PM 6 developed

by Reichmann is constructed to withstand

the demands of the harsh foundry

environment. A high performance

abrasive ring is used to remove risers

and sprues on high-alloyed steel castings.

The grinding process is numerically

controlled and operates automatically.

The sound proof cabin protects

the user effectively from flying sparks

and swarf.

A high abrasion performance in

shortest time is an especially significant

cost advantage when it comes to

hard-to-cut steel castings. For the customer,

which produces steel castings

for construction and agricultural machines,

an outstanding abrasion performance

of up to 5 mm per hub has

been realized. Thus, the customer requirements

could be met with particular

success.

The business sector Casting Finishing

has gathered a long-time experience

and competence in developing

solutions for fettling of steel and iron

castings. Nevertheless, the existing

know-how is continuously improved

to reach further cost reductions in the

future.


Plane grinder PM 6, which was developed

for a German steel foundry

(Photo: Reichmann)

Gleitschlifftechnik | Strahltechnik

more than 100000 solutions

Wir freuen uns auf Ihren Besuch in Hannover!

24.-28.04.2017

Halle 6 | Stand D30

RLWA-BI-02806022016

just one supplier

www.rosler.com

Casting Plant & Technology 1 / 2017 51


Museum of

antique furnaces

NEWS

AGTOS


Privately owned

museum of antique

furnaces sells 95

German artistic

casting furnaces

from 3 centuries,

all functional.

Each furnace is a

piece of art.

Price

negotiable.

AGTOS, Emsdetten, Germany, is presenting a

compact drum shot blast machine type TS 0150

in the „Surface Technology Area“ at the „Industrial

Supply“ show within the “Hanover Messe”

exhibition (24th - 28th April 2017) on the common

VDMA booth in hall 6.

The trend towards delicate production parts

continues. Material savings and new manufacturing

methods require a continual careful

treatment. This is why AGTOS developed a new

series of drum shot blast machines in particular

for the treatment of bulk goods. Apart from a

professional blasting technology, they focus on

a careful treatment of the work pieces.

The blast technology treatment of bulk goods

may have different objectives. Two of the most

common are clean blasting and hardening. It is

important that all parts are treated in the same

way and with the same intensity which frequently

has to be proofed by means of technical

data. AGTOS has the experience to treat bulk

goods reproducibly and identically. The size of

the work pieces varies from a few millimeters up

to compact parts.

With a loading unit drum shot blast machines

are automatically loaded batchwise. For

this, the drum is in loading position and after

the loading process swivels into the blasting position.

The abrasive is thrown into the rotating

drum by means of an AGTOS high performance

turbine. Thanks to the good blending, all of the

work pieces are evenly blasted. After the blasting

process they return into the provided containers

by softly tilting them out of the drum.

While bulk goods can be treated batchwise

in a drum shot blast machine, a continuous

production can be built up by a combination

of several machines. Besides an increase of the

AGTOS drum shot blast machine TS 0150 for

blast technology treatment of bulk goods

(Photo: AGTOS)

capacity by operating additional machines,

non-productive times can be reduced and

downtimes can be balanced for example by

maintenance works.

Reliable procedures are essential for a safe production.

The AGTOS high performance turbines

with their functional one-disc system represent

a maintenance-friendly and powerful

plus of the machines. The optimized construction

saves abrasive, the tool in the blasting technology.

Apart from the proven turbine technology,

the reliable and maintenance-friendly

filter technology is especially worth mentioning.

A differential pressure depending cleaning

of the filter cartridges contributes to the economic

method of operation as well.

Another aspect for the design of this machine

series was the energy efficiency. All drives are

designed according to the latest eco-design

guidelines. Thus, the shot blast machine consumes

a relatively small quantity of energy compared

to conventional machines. This helps to

keep the operation costs to a minimum.




Italian foundry Guido Glisenti, a specialist

provider of ductile iron castings to the automotive

sector, is set to commission a new

CT-6 shotblast machine from Wheelabrator,

Portsmouth, New Hampshire, USA, at its site

in Villa Carcina, Italy.

The new machine replaces a smaller CT-4

from 2002, increasing the maximum size of

castings that can be processed, as well as improving

processing speed and therefore capacity.

Gianluigi Parravicini, Sales Manager at

Wheelabrator, explains: “Guido Glisenti initially

approached us and our Italian agent

ProService about further enhancing casting

quality – to keep in step with ever more demanding

standards in automotive. The new

machine achieves just that. However, with

www.kunstgussofen.com

E-Mail: wulfmonika@gmx.de

52 Casting Plant & Technology 1 / 2017


We Manufacture

80 Models of Borescopes

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you select the right one!

The Italian foundry Guido Glisenti in Villa

Carcina, Italy (Photo: Fonderie Guido Glisenti

S.p.A.)

the move to the larger CT-6, we were also

able to increase capacity and improve

blast operations in a number of ways.”

Centerpiece of all CT machines is a

continuous apron conveyor that reliably

tumbles parts for all-round blast coverage.

The blast wheels are arranged to cover

the width of the apron conveyor,

pointing directly into the ‘apron’, where

the parts are being tumbled along.

The new machine at Guido Glisenti,

with its six powerful U70 x 500 blast

wheels, is designed to fit seamlessly into

the high-end production line.

Despite increased blast power, the

new machine is more energy efficient

and less maintenance-intensive, with

improved process control even at higher

throughput rates.

Gianluigi Parravicini continues: “Guido

Glisenti has started producing castings

with larger diameters, which the new machine

can easily accommodate in addition

to existing part sizes. This gives them

the flexibility they need to efficiently respond

to customer demands – be it a German

car manufacturer or a global leader

in earthmoving equipment.”

Ing. Dalla Bona, CEO at Guido Glisenti,

comments: “Working closely with

Wheelabrator enabled us to position this

larger machine into the available space,

minimizing the need for modifications on

foundation and building. It has been a

pleasure to work with the Wheelabrator

team – they understand our needs, provide

an excellent service and deliver high-quality,

high-performance machines.”

The foundry’s relationship with

Wheelabrator goes back over 25 years, resulting

in mutual understanding and

trust. This close co-operation, in conjunction

with local support from ProService,

made it possible to aim for delivery

and completion of the project within an

ambitious timeframe: the order was received

in September 2016; hand-over of

the machine was in January 2017.


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Void in casting, after

machining, seen with a

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Flash as seen with a

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Video Borescope

High-quality rigid, flexible and video borescopes, at far

lower prices than comparable instruments!

Manufacturers of complex castings now have a fast, affordable

way to improve quality control in their visual inspection process

with Hawkeye ® Pro Borescopes. We stock over 80 models of rigid,

flexible and video borescopes, and accessories. The right scope for

your application can deliver detailed images of sand, voids, flash,

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NEWS

COLD JET

Dry ice blasting expert moves to new technology center

Cold Jet Combi 120H for surface preparation

applications (Photo: Cold Jet)

Cold Jet, one of the leading companies

for dry ice cleaning and production system

solutions, at February 2017 moved

into its new technology center at Weinsheim,

Germany. The new 640 m² building

is constructed on a space of 3000 m².

The building is designed for future expansion

by the possibility of adding

more modules. The new office houses

sales, service, training, marketing and

administration for the regions of Germany,

Austria and Switzerland, allowing

for more synergy. Individual inquiries

and services can now be implemented

faster and more flexibly. Extensive training

opportunities will be possible in the

new building, as well as presenting more

equipment in the future, including the

Combi 120H and a pelletizer 120H for

dry ice production.

In the new competence center, solutions

for process optimization will be

established together with customers

and partners. The goal is to enable

business partners to produce faster,

more economically and produce better

quality. In this way, the cooperation

with the customer will be intensified.

“We are going to set up a demonstration

room in the near future where customer

samples can be tested and

cleaned,” said Dietmar Juchmes, General

Manager of Cold Jet in Germany.

“We also plan to implement an integrated

system, the Combi 120H and a

pelletizer 120H. This enables our customers

to experience dry ice production

and an automated dry ice cleaning

system live, on site. In this way, the

customer can experience how their

production process can lead to further

reduction in downtime, improved

component quality and a faster ROI.”

The Combi 120H is an automated

cleaning and surface preparation solution

that meets both the requirements

of industrial companies for a continuous

cleaning process and also minimizes

consequential costs of machine/

plant cleaning and maintenance. The

Combi 120H combines dry ice pellet

production and dry ice blasting into

one system, able to integrate with a robot.

High-density dry ice pellets are

produced on demand and are always

available on site and in the exact quantity

required. The pelletizer unit automatically

adapts the production of dry

ice pellets to the dry ice consumption,

predefined on the blasting unit. The

system can also be used to produce dry

ice pellets for other applications. It is

fitted with an extra pellet outlet from

where pellets can be produced directly

into an external dry ice container.

“Thanks to new premises, installations,

products and services, we are

now able to meet the requirements of

our demanding global customers even

more professionally,” said Juchmes.

www.coldjet.com

54 Casting Plant & Technology 1 / 2017


Foundries, suppliers and guests from

the UK cast metals industry came together

for the Cast Metals Industry

2016 Awards Dinner in Mid-November

to meet and enjoy each other’s company

and to find out the winners of the

UK Cast Metals Awards.

The flagship “Component of the

Year” award was won by William Cook

Cast Products, Sheffield, for its valve

cage for an engineered valve for the oil

and gas industry. Made from a Cobalt-based

alloy this component brings

castings to a whole new market and

brings benefits to both the foundry

and the customer.

The Company Achievement Award

was won by CastAlum, Welshpool, for

their move from five to six day working,

investment in capital equipment

and people, and growth in manpower

and sales, and the Innovation Award

was won by Hall & Botterill, Leeds, for

their in-house development of a robotic

fettling plant, hydraulics system and

cooling system.

“Through the Cast Metals Industry

Awards we can recognize the many remarkable

developments that are happening

throughout our industry. In

the UK foundry industry we see examples

of innovation, problem solving,

risk taking, investment and ambition

for the future day in and day out. It is

important to give credit to those who

lead the way and these three companies

certainly carry that mindset,” said

Pam Murrell, Chief Executive of the

Cast Metals Federation which organizes

the awards. “Whether the company

is big or small, supplying millions of castings

or one offs, there is so much in the

UK cast metals industry to celebrate,” she

continued.

The UK Component of the Year cast by

William Cook Cast Products

Simon Alexander of William Cook Cast

Products (left) and Peter Radcliffe of

CastAlum congratulate each other on their

awards (Photos: Cast Metals Federation)

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BROCHURES

Cleaning solutions

12 pages, English

This brochure describes the processes and systems offered by Piller Entgrattechnik in the




Information: www.piller-online.com

Hose technology

4 pages, English, German





Information: www.lippmann-gmbh.com

Foundry conveyors

4 pages, English





Information: www.jml-industrie.com

Foundry technologies, equipment and expertise

16 pages, English

A comprehensive company brochure setting out the mission, range of technologies and




Information: www.foseco.com

56 Casting Plant & Technology 1 / 2017


Dry ice technology

4 pages, English





Information: www.icetechworld.com

Heating and cooling devices

6 pages, English

This brochure presents mould heating and cooling devices offered by Thermobiehl Ap




Information: www.thermobiehl.com

Briquetting systems

12 pages, English





Information: www.briquetting.com/foundry

Mixing and conveying equipment

40 pages, English, German






Information: www.f-a-t.de

Casting Plant & Technology 1 / 2017 57


INTERNATIONAL FAIRS AND CONGRESSES

Fairs and Congresses

121. Metalcasting Congress



Hannover Messe



Practical Cupola Seminar



Aluminium Middle East 2017



Metallurgiya - Litmash 2017



Metal + Metallurgy China 2017



Metef 2017



5th International Cupola Conference



ALUMINIUM TWO THOUSAND

Four sessions in a three-day conference

From 20 to 24 June 2017 the Aluminium

Two Thousand-ICEB World Congress

will be held at the PalaExpo Congress,

VeronaFiere in Verona, Italy, following

the successful participation of the past

edition in Florence 2015. After 9 editions,

it has become a important and

irreplaceable meeting point for all operators

working in the aluminum industry.

The synergy with the International

Conference on Extrusion and

Benchmark (ICEB), the biggest event

in Europe related to the recent developments

on Extrusion Technology and

its analysis by FEM simulation, brought

the congress always more in the foreground.

Highly qualified “Aluspecialists” from

companies, universities and associations

come from all over the world to present

tries,

hundreds of delegates and a compre-

-


to a specialized and international audience

the most innovative technologies

and applications in the aluminium field.

The aim of the conference is to join together

technical and scientific experts,

to widespread their knowledge and to

form an international community for

the discussion of the state of the art as

well as future developments in the field

of extrusion and in its most powerful

tool, the numerical simulation.

Also for this 2017 edition the ICEB

conference will keep all its main features,

by merging technical sessions on

the “Latest advances in the extrusion

of light alloys” with the contest “Extrusion

Benchmark” of simulation codes.

Four parallel sessions for three full

days will ensure that all subjects will be

covered in detail. Papers will be reviewed

by the conference scientific

committee, in order to select the most

innovative studies and researches, the

newest industrial applications, and the

most interesting case studies.

www.aluminium2000.com

Advertisers´ Index

Admar Group 53

AGTOS Ges. für technische







EREDI SCABINI SRL 23






Wulf Ofenmuseum 52




INTERALL Srl 29



KLEIN Anlagenbau AG 25


Beteiligungs KG 48

Maschinenfabrik Gustav Eirich


PREVIEW / IMPRINT

Preview of the next issue

Publication date: June 2017

View of the production hall of Matthies Druckguss. The company uses state-of-the-art measuring equipment and,

amongst other things, an ERP system (Photo: Matthies Druckguss)

Selection of topics:

D. Beste: Matthies Druckguss: Tradition and innovation from a single source

The range of services offered by the family-owned company Matthies Druckguss from Rendsburg, Germany, is changing.

Just like the future – ideal conditions for keeping up with the market and proving itself as a pioneer

M. Patalocci: Increasing quality and reducing costs through innovative fettling

The Italian company Q-Design, Lugnano Vicopisano, has developed an innovative robot-based system that allows foundries

– without much prior knowledge in robot programming – to improve castings at low cost

A. Strunz: High-performance tungsten-based materials enable improved casting process

Bayerische Metallwerke GmbH, Dachau, Germany, offers an innovative material for casting tool construction with its

product family Triamet A, a tungsten-based heavy metal alloy that can withstand more frequent temperature changes

Imprint

Publisher:

German Foundry Association

Editor in Chief:

Michael Franken M.A.

Editor:

Robert Piterek M.A.

Editorial Assistant:

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Layout:

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All rights, including those of translation into

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ISSN 0935-7262

Casting Plant & Technology 1 / 2017 59

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