Casting machines combining Value with Technology

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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.
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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

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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 clients labs and plants

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Advanced Technology

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

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Laboratory test procedure

• Test fixture simulates conditions on the
  casting machine

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Laboratory test procedure

• Test moulds equipped with thermocouples to
  record temperatures

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Laboratory test procedure

• Test fixture simulates pouring into moulds on
  the casting machine

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Laboratory test procedure

• Test fixture simulates water cooling on the
  casting machine

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Laboratory test procedure

• Test fixture simulates discharge on the
  casting machine

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Laboratory test procedure

• Discharged product collected for tests

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Laboratory test procedure

• Mould temperature data is captured under
  various time and cooling cycles

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Recent laboratory tests

• 2003 HC Ferromanganese test
  program
• Confirmed mould temperature cycling for
  slab and ingot shapes
• Confirmed controlled breakage on discharge

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Recent laboratory tests

• 2004 Charge Chrome test program
• Confirmed mould temperature cycling for
  slabs
• Confirmed product breakage on discharge

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Recent laboratory tests

• 2004 Charge Chrome test program

Slowly air-cooled slab 200x200x25 does not
fracture at discharge
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Recent laboratory tests

• 2004 Charge Chrome test program

Rapidly quenched slab 200x200x25 fractures well
at discharge
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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

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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

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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

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Mould temperature cyclingPeak above critical
temperature
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Mould temperature cyclingPeak below critical
temperature
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Advanced Technology

• Field verification of lab tests

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Advanced Technology

• Closed loop water system

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Advanced Technology

• Mould wash application system

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Heavy Duty Construction

• Heavy drive gear

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Heavy Duty Construction

• Rugged Take-up Bearings

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Heavy Duty Construction

• Heavy duty manganese steel chain

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Heavy Duty Construction

• Chain with quick-change feature andflexible
  mounting

Rotation
Expand Contract
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Heavy Duty Construction

• Swivel discharge chute

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Heavy Duty Construction

• Rugged Hydraulic Ladle Tilters

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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

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Machines with International Acceptance

• Argentina
• Australia
• Brazil
• Colombia
• Canada
• Dominican Republic

• Iceland
• Mexico
• Norway
• Saudi Arabia
• South Africa
• USA

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Engineering Partners over the years

• Arthur G. McKee
• Bechtel Corp.
• Brown Root
• Cia. Projectos Brasilieros
• Davy-Minenco
• Dravo Corp.
• Elkem Technology
• Greenblatt Hutton CC

• Hatch Associates
• Hatch et Associés
• Koppers Co.
• Kværner E C
• McDowell-Wellman
• Thomson van Eck
• Voest Alpine
• USS Engrs.

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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 PID
Detail on next slide
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Mould Wash PID Detail
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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

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Special features

• Fine control of pouring rate
• Automatic mould wash purging
• Linkage to plant DCS system
• Proven control programs
• Automatic mould wash mixing
• Simplified operators controls

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

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Wide Product Experience

• Pig Iron Casting Machine Iscor Steel

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Wide Product Experience

• Small shape casters for ferroalloys and aluminium

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Wide Product Experience

• Ferroalloy
• Slab Casters

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Wide Product Experience

• Aluminium ingot casting lines

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Recent Installations

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

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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)

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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.

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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 Economys machines
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For more information, visit us on the web
at www.economyindustrial.comemail
edeniston_at_EconomyIndustrial.com