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Charge optimization and correction for modern foundries

Charge optimization and correction for modern foundries. Melt-IQ. Do you want to:. create a charge optimization with an exact target analysis?. calculate the exact necessary weight of each material?. Work with liquid heel using it´s exact chemical composition?.

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Charge optimization and correction for modern foundries

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  1. Charge optimization and correctionfor modern foundries Melt-IQ

  2. Do you want to: • create a charge optimization with an exact target analysis? • calculate the exact necessary weight of each material? • Work with liquid heel using it´s exact chemical composition? • Consider melting loss and/or pick up for up to 22 elements ? • minimize/maximize the content of return? • Do all this at minimal costs?

  3. ...do you have to take all these points into consideration? Or... With Melt-IQ you can do it!

  4. Melt-IQ assists you during the melting process and avoids costly corrections. So a lot of time and energy is not wasted during a shift! • Melt up to one charge more per day! • With Melt-IQ you can get rid of old diagrams at the furnace! Melt-IQ knows and uses the chemical composition of all your charge materials • Melt-IQ automatically creates a charge log and keeps track of stocks. • The charge log is easy.to use by the furnace operaters

  5. Melt-IQ charge optimization and correction gives you all these possibilities…

  6. Goal analysis are defined... This is the optimization screen, developed for a cost conscious head of the foundry. Here you define your targets. ....using the charge optimization screen

  7. With precise instructions... Here you define which elements are to be used for the goal analysis.

  8. In this example: C has to be 3,77% and Si exactly 1,20% and Mn exactly 0,24%

  9. Here you keep and change your optimization results

  10. In the marked fields you enter the precision of the optimization and below the quantity of the charge in kg as well as additional instructions about pick up and melting loss and min and max limits for chemical elements.

  11. Here you find information about the composition of this charge. From the window Visible elements you can select more elements or entry fields. The will be transferred automatically into the window below.

  12. Results Composition of this charge in kg and % before optimization..

  13. And after optimization -8,4%!

  14. Melt-IQ And now imagine: A charge consisting of 15 different charge materials. Each material consists of up to 22 chemical elements. For 13 elements you need exactly the % values indicated in the goal analysis. For 5 chemical elements a minimum value has to be respected. And for 2 elements a maximum value. The quantity needed is exactly 2500 kg. A heel of 550kg with it's own chemical composition has to be used. 7 elements have a melting loss defined, 5 a pick up. A percentage of at least 5 % pig iron is necessary. Melt-IQ finds the most cost efficient solution in a fraction of a second.

  15. Melt-IQ The Charge Log

  16. This screen shows the working instructions for the furnace operator. All charging actions are registered in this window. Melt-IQ saves charge numbers, time, and used quantities of materials of each charge.

  17. Based on charge optimizations established earlier a working instruction for a specific charge is shown and will be executed by the operator. .

  18. The operator keys in the actual weight he gets from the crane weigher

  19. The chemical composition of the charge is shown here. Values out of tolerance are marked in red.

  20. Used quantities are automatically deducted from stock Costly corrections are reduced to a minimum

  21. Melt-IQ Costs & Charge Analysis

  22. A wide variety of statistics show: The use of each charge material by furnace, sum in kg, as costs.

  23. Furnace statistics show for a definable period of time: The consumption of each charge material by recipe, as sum in kg, costs and power consumption.

  24. Thank you for your attention! Melt-IQ

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