Econmy Industrial 2004A

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Casting machines combining Value with Technology EconoTech Casting Machines (Left click or page down to advance to next slide)

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CASTING MACHINE SCHEMATIC VIEW

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From 5 tons per hour

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10 tons per hour

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20 tons per hour

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100 tons per hour

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to over 200 tons per hour and everything in between.

Casting machines with a long tradition of reliability: 

Casting machines with a long tradition of reliability 1914 Pittsburgh Coal Washer Co. Built first pig casting machine in USA 1940 Bollinger Corp. Built machines for war plants around the world Over 80% of merchant pig iron produced in USA on its machines 1976 Economy Industrial Corp. MiniCaster Ferro Caster Alumi Caster Ongoing product development

Continuing Product Improvement: 

Continuing Product Improvement Through research Computer analysis Lab testing at Center for Iron andamp; Steel Research at Carnegie-Mellon Univ. Tests in client’s labs and plants Through development Ongoing internal design improvement Learning from our customers Being open to suggestions

Advanced Technology: 

Advanced Technology Patented Process Control to improve mould life by optimizing: Mould Mass Ratios Water Cooling Efficiency Cooling Time Mould Coating

Laboratory test procedure: 

Laboratory test procedure Test fixture simulates conditions on the casting machine

Laboratory test procedure: 

Laboratory test procedure Test moulds equipped with thermocouples to record temperatures

Laboratory test procedure: 

Laboratory test procedure Test fixture simulates pouring into moulds on the casting machine:

Laboratory test procedure: 

Laboratory test procedure Test fixture simulates water cooling on the casting machine:

Laboratory test procedure: 

Laboratory test procedure Test fixture simulates discharge on the casting machine:

Laboratory test procedure: 

Laboratory test procedure Discharged product collected for tests

Laboratory test procedure: 

Laboratory test procedure Mould temperature data is captured under various time and cooling cycles

Recent laboratory tests: 

Recent laboratory tests 2003 – HC Ferromanganese test program Confirmed mould temperature cycling for slab and ingot shapes Confirmed controlled breakage on discharge

Recent laboratory tests: 

Recent laboratory tests 2004 – Charge Chrome test program Confirmed mould temperature cycling for slabs Confirmed product breakage on discharge

Recent laboratory tests: 

Recent laboratory tests 2004 – Charge Chrome test program Slowly air-cooled slab 200x200x25 does not fracture at discharge

Recent laboratory tests: 

Recent laboratory tests 2004 – Charge Chrome test program Rapidly quenched slab 200x200x25 fractures well at discharge

Current pending patents: 

Current pending patents Process and method for casting high-carbon ferrochrome on continuous casting machines Device and process for producing moulds for casting machines to extend life by controlling crack propagation

Advanced Technology: 

Advanced Technology Patented Process Control to improve mould life by optimizing process design parameters: Mould design Air and water cooling times Water cooling efficiency Mould wash application

Technology to reduce mould replacement cost – The highest single cost factor in casting machine operations: 

Technology to reduce mould replacement cost – The highest single cost factor in casting machine operations Control of mould peak temperature is essential Cooling cycle time Mould/metal mass ratio Water cooling application Mould wash material andamp; application

Mould temperature cyclingPeak above critical temperature: 

Mould temperature cycling Peak above critical temperature

Mould temperature cyclingPeak below critical temperature: 

Mould temperature cycling Peak below critical temperature

Advanced Technology: 

Advanced Technology Field verification of lab tests

Advanced Technology: 

Advanced Technology Closed loop water system:

Advanced Technology: 

Advanced Technology Mould wash application system

Heavy Duty Construction: 

Heavy Duty Construction Heavy drive gear

Heavy Duty Construction: 

Heavy Duty Construction Rugged Take-up Bearings

Heavy Duty Construction: 

Heavy Duty Construction Heavy duty manganese steel chain

Heavy Duty Construction: 

Heavy Duty Construction Chain with quick-change feature and flexible mounting Rotation Expand andamp; Contract

Heavy Duty Construction: 

Heavy Duty Construction Swivel discharge chute

Heavy Duty Construction: 

Heavy Duty Construction Rugged Hydraulic Ladle Tilters

Heavy Duty Construction: 

Heavy Duty Construction Stationary Roller Chain Design also available with: Automatic Roller Lubrication Available Manganese Steel Bushes in Steel Links Reduced friction and power requirements

Machines with International Acceptance: 

Machines with International Acceptance Argentina Australia Brazil Colombia Canada Dominican Republic Iceland Mexico Norway Saudi Arabia South Africa USA

Engineering Partners over the years: 

Engineering Partners over the years Arthur G. McKee Bechtel Corp. Brown andamp; Root Cia. Projectos Brasilieros Davy-Minenco Dravo Corp. Elkem Technology Greenblatt andamp; Hutton CC Hatch Associates Hatch et Associés Koppers Co. Kværner E andamp; C McDowell-Wellman Thomson van Eck Voest Alpine USS Engrs.

Sensible Automation: 

Sensible Automation Reduces manpower Automates water cooling Automates mould coating Flushes and purges mould wash Interlocks ladle tilter and caster Provides safety Interlocks With fail-safe design philosophy

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Simplified Pandamp;ID Detail on next slide

Slide41: 

Mould Wash Pandamp;ID Detail

Value Oriented Design: 

Value Oriented Design Automation and interlocks reduce staffing Improved yield increases output Proprietary process design increases mould life Reduced maintenance cost from longer life Computerized design library for design efficiency

Special features: 

Special features Fine control of pouring rate Automatic mould wash purging Linkage to plant DCS system Proven control programs Automatic mould wash mixing Simplified operator’s controls

HMI OPERATOR’S CONTROL: 

HMI OPERATOR’S CONTROL

HMI SCREEN: 

HMI SCREEN

HMI SCREEN: 

HMI SCREEN

Mould Wash System: 

Mould Wash System BULK BAG UNLOADER/FEEDER PREMIX TANK MAIN MIX TANK SPRAY BASIN VALVE PANEL VIBRATING SCREEN AUTOMATED MOULD WASH SYSTEM

Wide Product Experience: 

Wide Product Experience Pig Iron Casters Aluminum Casters Ingots DeOx Cones Ferroalloy casters Armor Plate Casters for U.S. Navy Brass andamp; Bronze Ingot Casters Stainless Steel Ingot Casters

Wide Product Experience: 

Wide Product Experience Pig Iron Casting Machine – Iscor Steel

Wide Product Experience: 

Wide Product Experience Small shape casters for ferroalloys and aluminium

Wide Product Experience: 

Wide Product Experience Ferroalloy Slab Casters

Wide Product Experience: 

Wide Product Experience Aluminium ingot casting lines

Recent Installations: 

Recent Installations Ticor-SA Empangeni (Kumba Hvy. Minerals) First Cast 60 tph Pig Iron Casting Machine

Other Recent Installations: 

Other Recent Installations ANGLO PLATINUM POLOKWANE 70 tph Nickel Matte Casting Machine (Eliminates discharge of acid from granulation) ELKEM METALS CANADA 20 tph Mg Ferrosilicon Casting Machine (Earlier installation at Bjoelvefossen made them the world leader in foundry inoculants) HIsmelt DIRECT REDUCTION – Australia Dual 125 tph Pig Iron Casting Machines (Economy also supplied casting machine for pilot plant)

YOU are also our partner: 

YOU are also our partner You know your alloys best You know your plant operations You know your workforce Together, we can reach the best solution at the lowest total cost.

The best TOTAL VALUE solution: 

The best TOTAL VALUE solution State-of-the-Art Technology Local Content Competitive Capital Cost Low Operating Cost Low Maintenance Cost Proven Reliability with many installations in plants where 100% of the total production is cast on Economy’s machines

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For more information, visit us on the web at www.economyindustrial.com email econind@aol.com Represented in Southern Africa by Redwing Technologies www.redwingtech.co.za +27-11-467-0014