A New Generation of ElectromagneticMetal Moving System

BY SOLIOS THERMAL

DATE: 25-April-2013

→Introduction to Solios→Genios Technology→Genios Case Study→Conclusion

Overview

Fives Solios 3

40 employees Equipment supplier Engineering and site services Project management ISO 9001 certified Part of www.fivesgroup.com

SOLIOS THERMAL

1961 20082003

COMPANY PROFILE

→Introduction to Fives Solios→Genios Technology→Genios Case Study→Conclusion

Overview

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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.

GENIOS – WHY?

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Fives Solios

GENIOS – WHAT IS IT?

Genios is a non metal contact EMS device that can be mounted to the side of a furnace

Stirring Mode

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GENIOS – WHAT IS IT?

Casting Mode

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Fully automatic operation in all modes

GENIOS – WHAT IS IT?

System Overview

→Introduction to Fives Solios→Genios Technology→Genios Case Study→Conclusion

Overview

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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.

PLANT DETAILS

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PLANT LAYOUT AT V.C.M

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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

WHY VCM CHOSE THE GENIOS

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STIRRING AT VCM

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AUTOMATIC CAST AT VCM

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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%)

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IMPROVED RELIABILTY AND PRODUCTIVITY

Parameter Mechanical Pump Genios Remarks

Typical consumable part life

500 tonnes / head >5000 tonnes / casting tile

Minimum bath level at end of cast

250mm <100mm With existing hearth levels

Automatic cast rate control

No Yes

Automatic cast start No Yes

Cast interrupt /restart ability

No Yes

Metal level control No Yes +/- 2mm level control with existing launder

configuration

→Introduction to Fives Solios→Genios Technology→Genios Case Study→Conclusion

Overview

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› 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.

Conclusion

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Fives Solios

THANK YOU. Visit Fives Solios at booth number 12