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A New Generation of Electromagnetic Metal Moving System BY SOLIOS THERMAL DATE: 25-April-2013

A New Generation of Electromagnetic Metal Moving System BY SOLIOS THERMAL DATE: 25-April-2013. Introduction to Solios Genios Technology Genios Case Study Conclusion. Overview. 1961. 2003. 2008. COMPANY PROFILE. SOLIOS THERMAL. 40 employees Equipment supplier

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A New Generation of Electromagnetic Metal Moving System BY SOLIOS THERMAL DATE: 25-April-2013

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  1. A NewGeneration of Electromagnetic MetalMoving System BY SOLIOS THERMAL DATE: 25-April-2013

  2. Introduction to Solios Genios Technology Genios Case Study Conclusion Overview

  3. 1961 • 2003 • 2008 COMPANY PROFILE SOLIOS THERMAL • 40 employees • Equipment supplier • Engineering and site services • Project management • ISO 9001 certified • Part of www.fivesgroup.com Fives Solios

  4. Introduction to Fives Solios Genios Technology Genios Case Study Conclusion Overview

  5. GENIOS – WHY? • A requirement in the market place! • A device that could be easily introduced to existing furnaces as well as new installations. • Be able to offer a unique capability; to transfer and cast molten aluminium from the same device. • Need a device that is safe to use and reduce the exposure of the operators to the hot metal areas. • To be able to bring all the benefits of EMS stirring to the furnace. • Cycle reduction. • Energy efficiency. • Less operator intervention. • Metal temperature and composition homogeneity • Present benefits in terms of maintenance issues and cost • Be cost effective against conventional solutions. 5 Fives Solios

  6. GENIOS – WHAT IS IT? • Genios is a non metal contact EMS devicethatcanbemounted to the side of a furnace • Stirring Mode Fives Solios

  7. GENIOS – WHAT IS IT? • Casting Mode 7 Fives Solios

  8. GENIOS – WHAT IS IT? • Fully automatic operation in all modes • System Overview Fives Solios

  9. Introduction to Fives Solios Genios Technology Genios Case Study Conclusion Overview

  10. PLANT DETAILS • Large secondary aluminium producer (120000t/a) based in Italy. • Casting furnace is a conventional regenerative burner fired static type. • 70Tonne nominal capacity with typical bath depth of 1000mm. • Charged with predominantly molten metal from various melting furnaces. • Used to feed a dedicated belt type continuous casting machine. • Casting Machine production rate is between12 and 20 Te/hour of Si alloys. • Previous method of transfer by mechanical graphite pump. Fives Solios

  11. PLANT LAYOUT AT V.C.M Fives Solios

  12. WHY VCM CHOSE THE GENIOS • Serious issues with safety and operation using electromagnetic pumps (50Hz) and mechanical metal moving systems previously installed on this process line. • Attracted by “double option” capability to stir & cast with the same unit. • Wanted better safety afforded by operating at lower frequencies than are available with comparative EM systems. • Strong interface between bath and inductor. • Integrity of furnace not compromised by removal of inductor. • Potential operating & maintenance savings • Wanted to maintain a consistent metal quality Fives Solios

  13. STIRRING AT VCM 13 Fives Solios

  14. AUTOMATIC CAST AT VCM Fives Solios

  15. BENEFITS ACHIEVED AT VCM • Significant gain over safety levels experienced with the previous metal moving systems installed on this furnace. Reduced operator intervention due to auto start & good metal flow regulation. • Improved quality – better chemical & temperature homogeneity throughout cast (rejects reduced by order of 15%) • Reduced dross formation (approx.10%) Fives Solios

  16. IMPROVED RELIABILTY AND PRODUCTIVITY Fives Solios

  17. Introduction to Fives Solios Genios Technology Genios Case Study Conclusion Overview

  18. Conclusion • Can be easily introduced to existing furnaces as well as new installations. • Yes, achieved due to it’s side mounting and modular design. • Be able to stir and cast molten aluminium from the same device. • Yes, controlled casting up to 20te/hr to the client ingot casting machine. • The device has to be safe to use and reduce the exposure of the operators to the hot metal areas. • Improved safety due to less operator intervention – push button operation; operation stops when the device is turned off . • Benefits of EMS stirring to the furnace. • Yes, improvements in metal recovery, improved chemical & temperature homogeneity. The Genios resulted in improved furnace efficiency due to less tasks required with the furnace door open and improved production times. • Present benefits in terms of maintenance issues and cost. • Yes much improved life cycle compared to previous technology used, less down time with improved operability which also offsets costs. • Be cost effective against conventional solutions. • Yes, competitive against other EMS solutions, and requires simple modification to existing furnaces and cast house infrastructure. Offers improved maintenance costs when compared to metal contact devices. 18 Fives Solios

  19. THANK YOU. • VisitFives Solios atboothnumber 12 Fives Solios

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