CPT International 02/2019

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SPECIAL: GIFA 2019 ZPF GMBH New furnace plant enables simultaneous melting of aluminium chips and ingots Due to the different shapes of ingots, return material and aluminium chips, different furnace types were previously required for melting the respective material. However, separate plants for the different types of material do not pay off for die casting foundries with too low volumes of aluminium chips or return material, so that only ingots are molten down. ZPF GmbH, Siegelsbach, Germany, have now developed a melting furnace which is qualified for melting down aluminium chips as well as recycling material and ingots – a sustainable utilization of the system is thus always ensured. The plant is equipped with an automatic charging system and is able to melt up to 500 kg raw material per hour, for example 250 kg aluminium chips and 250 kg ingots. The new melting furnace technology will be presented for the very first time at this year‘s GIFA with an exhibit. Production by-products such as scrap material and runner systems or even aluminium chips are usually collected and recycled externally in most foundries, as they cannot be returned directly to the melting process for economic reasons. This results in high costs for storage and transport, and the logistical effort should not be underestimated. “Until now, our aluminium melting furnaces were only designed for charging with unmixed material; a material mix of ingots and recirculation aluminium parts was previously only possible to a limited extent due to the desired boundary parameters such as melting loss and melting rate“, reports Sven- Olaf Sauke, head of R & D at ZPF GmbH. “For some foundries, a pure chip furnace is uneconomic, since the metal-cutting share in the cast product is often too low.“ ZPF has taken this market need as an opportunity to develop a new technology for melting furnaces enabling the simultaneous melting of chips, ingots or return material while still keeping the melting loss values at an extremely low level. This offers companies greater flexibility in the recycling process and new opportunities to optimize the melting process. For an optimal constructive design “Since there are two different shapes in the case of chips and ingots, we first had to choose the main variant“, reports Sven-Olaf Sauke, head of R & D at ZPF GmbH. “For our prototype, we opted for chips as the main material and designed the furnace as a heel melter (Graphics: ZPF GmbH). of the new furnace, simulations were used in the course of development to be able to assess the basic system behaviour. In addition, power and exhaust gas measurements were carried out under foundry conditions which were used to determine the functional parameters. “The decisive factor for us was the optimum melting of the metal and the required temperature control in the furnace,“ explains Sauke. “In addition to energy consumption, numerous other factors that strongly influence the melting result play a role here in a modern furnace system - for example the quality of the raw material and the melting loss. For practical implementation, ZPF analysed the data collected and determined the parameters required for simultaneous melting of chips and other aluminium materials. Based on these results, a prototype with the new technology was implemented. The melting furnace has dimensions of 575 cm x 380 cm x 445 cm (L x W x H) at an empty weight of approximately 28 tons. It is dimensioned for a maximum throughput of 500 kg/h in total. The furnace system is extended by an automatic charging unit. This modular unit is designed in such a way that different types of material can be loaded according to customer requirements. “For the simultaneous melting of different material forms in one furnace, the first step is to determine the leading material variant,“ Sauke says. “For our prototype, we opted for aluminium chips as the main material and therefore designed the furnace as a heel melter. As a result, the chips can be molten down in combination with return material, return wheels or ingots“. Which variant is added to the chips can be selected by the operator. The only important thing is to pay attention to the optimum quantity ratio between chips and secondary material in order to achieve optimum melting performance. The new system will be presented at this year‘s GIFA in Düsseldorf. “We will be demonstrating the new system technology using a furnace at our trade fair stand. This gives us the opportunity to present the innovations to interested users in a detailed and practical manner,“ explains Sauke. Hall 10, Stand F59 www.zpf-gmbh.de 60
GIFA 2019 hall 16 / C11 Torque motors – here on an Eirich Intensive Mixer R28 – are an energy saving alternative to asynchronous motors. EIRICH Molding Material as an Opportunity As a specialist in the processing of clay-bonded molding materials, Eirich, Hardheim, Germany, enables foundries to meet ever-increasing demands. The molding material holds opportunities for improving the casting quality. A preparation system from Eirich achieves higher energy efficiency. Optimized and automated processes enable the autonomous preparation of molding material. They are the basis for the Industrial Internet of Things (IIoT). At GIFA 2019, visitors can gather information about groundbreaking EIRICH technology, from which every founder can benefit. The highlights and exhibits presented at the fair include a QualiMaster AT1 of the new generation and an Intensive Mixer R28 with torque motors. The QualiMaster AT1 system is well known and proven as the heart of quality assurance in molding material preparation. The new generation of modular design is available as Eco, Profi or ProfiPlus version. In the Eco version, the inline tester is equipped with a compactability measuring unit. A reporting tool facilitates using it as a stand-alone unit. The Profi version additionally measures compactability and shear strength with deformability. Completely new possibilities are now available with the Quali- Master AT1 ProfiPlus: For the first time, the inline tester also measures springback and gas permeability. Due to its modular design, the AT1 Eco can be upgraded to the AT1 Profi or AT1 ProfiPlus at any time Eirich mixers equipped with torque motors as direct drives achieve a new level of energy efficiency. Energy savings of up to 25 % are a realistic prospect. These motors also have the advantages of lower maintenance requirements and reduced noise emissions. Torque motors are not just a good option for new Eirich mixers; they can also be retrofitted to Eirich mixers in operation without any problems. Another highlight expected at the fair is the prototype of an Evactherm mixer in a new small size. Hall 17, Stand A 38 www.eirich.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 Shockwave Technology CERABITE ® Clean Castings for the efficient removal of residual sand and coatings out of complex castings KLEIN Anlagenbau AG KLEIN Stoßwellentechnik GmbH a subsidiary of KLEIN Anlagenbau AG Obere Hommeswiese 53-57 57258 Freudenberg | Germany Phone +49 27 34 | 501 301 info@klein-group.eu www.klein-ag.de www.stosswellentechnik.de CASTING PLANT & TECHNOLOGY 2/2019 61
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EDITORIAL It’s Showtime! The quad
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CONTENTS CLEANING, FETT LING & FINI
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“Innovations are crucial for succ
Page 9 and 10: YXLON - QUALITY ASSURANCE AND PROCE
Page 11 and 12: the first cores would take place as
Page 13 and 14: After removal, a robot deburrs the
Page 15 and 16: FOUNDRY - A PASSION FROM OUR HEART.
Page 17 and 18: Photos: Klaus Vollrath carried out
Page 19 and 20: Left: Fully automatic plant for hea
Page 21 and 22: ut also the design, joining and pro
Page 23 and 24: Potential solutions in foundry plan
Page 25 and 26: foundry is busy working with eight
Page 27 and 28: the mass finishing system can debur
Page 29 and 30: State of the art Exothermic feeder
Page 31 and 32: Figure 6: GTP Schäfer feeder datab
Page 33 and 34: CASTING Special GIFA 2019 Part 2: O
Page 35 and 36: “Germany is a trade fair country
Page 37 and 38: ment - which will continue to produ
Page 39 and 40: selves about what the exhibitors ar
Page 41 and 42: HÜTTENTAG 2019 Get-Together of the
Page 43 and 44: The Bright World of Metals With the
Page 45 and 46: FOSECO Non ferrous melt shop Insura
Page 47 and 48: IMERYS Kersand and Durandal - the r
Page 49 and 50: dehyde potential. Furthermore, the
Page 51 and 52: BÜRKERT Modular platform for heati
Page 53 and 54: Photo: Foseco Foseco’s new, paten
Page 55 and 56: IDECO Hydrogen Analysis in Aluminum
Page 57 and 58: FOSECO Filtration for iron and stee
Page 59: WHEELABRATOR A new wheel, advanced
Page 63 and 64: act the casting and extends the lif
Page 65 and 66: MASTER EVERY MELT Speed up the prod
Page 67 and 68: Figure 9: A continuous layer of coa
Page 69 and 70: The Kinetic Assembly Structure refl
Page 71 and 72: Production of a 3-D pattern and its
Page 73 and 74: Order Form - NEWSLETTER 2019 NEWSLE
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CPT International 02/2019

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