Casting machines combining Value with Technology EconoTech Castin

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

2. CASTING MACHINE SCHEMATIC VIEW

3. From 5 tons per hour

4. 10 tons per hour

5. 20 tons per hour

6. 100 tons per hour

7. to over 200 tons per hour and everything in between.

8. 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 worldOver 80% of merchant pig iron produced in USA on its machines • 1976 Economy Industrial Corp. • MiniCaster • Ferro Caster • Alumi Caster • Ongoing product development

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

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

11. Laboratory test procedure Test fixture simulates conditions on the casting machine

12. Laboratory test procedure Test moulds equipped with thermocouples to record temperatures

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

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

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

16. Laboratory test procedure Discharged product collected for tests

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

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

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

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

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

22. 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

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

24. 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 & application

25. Mould temperature cyclingPeak above critical temperature

26. Mould temperature cyclingPeak below critical temperature

27. Advanced Technology Field verification of lab tests

28. Advanced Technology Closed loop water system:

29. Advanced Technology Mould wash application system

30. Heavy Duty Construction • Heavy drive gear

31. Heavy Duty Construction • Rugged Take-up Bearings

32. Heavy Duty Construction • Heavy duty manganese steel chain

33. Heavy Duty Construction • Chain with quick-change feature andflexible mounting Rotation Expand & Contract

34. Heavy Duty Construction • Swivel discharge chute

35. Heavy Duty Construction • Rugged Hydraulic Ladle Tilters

36. 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

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

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

39. 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

40. Simplified P&ID Detail on next slide

41. Mould Wash P&ID Detail

42. 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

43. 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

44. HMI OPERATOR’S CONTROL

45. HMI SCREEN

46. HMI SCREEN

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

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

49. Wide Product Experience • Pig Iron Casting Machine – Iscor Steel

50. Wide Product Experience Small shape casters for ferroalloys and aluminium