rautomead continuous casting technology for brass rod
DESCRIPTION
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines. For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world. Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals www.rautomead.co.uk [email protected]TRANSCRIPT
Rautomead Limited
Rautomead Limited
Rautomead LimitedPO Box 100Dundee DD1 9QY Scotland Registered Office: Nobel Road
Wester Gourdie Industrial Estate
t. (44) 1382 622341 Dundee DD2 4UH, Scotland
f. (44) 1382 622941 Incorporated in Scotland No. 152367
Continuous Casting Technology
www.rautomead.com VAT Reg. No. GB 658 2549 03 Advanced Metals Technology
Rautomead Limited
Introduction to Rautomead
Rautomead Limited
Rautomead LimitedDundee Scotland
Founded 1978
Sir Michael NairnChairman
Brian Frame MDappointed 2008
Employees = 50
No Machines Sold = 337First 1978
Of these :-
No Vertical Upwards = 76First 1995 (Patent expired 1990)
Rautomead Limited
Rautomead – Nobel Road Factory
Rautomead Limited
Rautomead – Nobel Road Factory
Rautomead Limited
Rautomead – Unit 7A Nobel Road Factory
Rautomead Limited
Rautomead – Unit 7A Nobel Road Factory
Rautomead Limited
RS3000 – 8mm Cu-OF Redraw Rod
Rautomead Limited
RS3000/Mg – 30mm CuMg for HS Railway Contact Wire
Rautomead Limited
RS2500 – 8mm 65:356 Redraw Rod for EDM Wire
Rautomead Limited
RS1000 – Brass for Cold Heading
Rautomead Limited
RT850 – Hollow Bronze Billet for Pump Bearings
Rautomead Limited
RX1100 – 70mm Zinc Billet for Extrusion (Wheel Weights)
Rautomead Limited
RMJ/H025
RMT200
RMJ/V005
RVSIII Tilt
Rautomead Limited
5000 – 10000 Tonnes/Year
Rautomead Limited
Rautomead Furnace Technology for
Continuous Casting
Rautomead Limited
Rautomead Furnace Technology
Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-
•Containment (Crucible & Valve)
•Casting (Dies and Packers)
•Heating (Low Voltage resistance heating elements).
Rautomead Limited
Rautomead Furnace Technology
Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-
•Containment (Crucible & Valve)
•Casting (Dies and Packers)
•Heating (Low Voltage resistance heating elements).
Rautomead Limited
Rautomead Furnace Technology
Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-
•Containment (Crucible & Valve)
•Casting (Dies and Packers)
•Heating (Low Voltage resistance heating elements).
Rautomead Limited
Rautomead Brass Wire Continuous Casting Machines
Rautomead Limited
Rautomead Brass & Alloy Wire Rod Machine Installations by Country
Sodick Japan RS2500 8.0mm 2012
Jia Bao Taiwan RS 2500 8.0mm 2006
Sodick Japan RS 1000 8.0mm 2006
Alecosa Spain RS 2500 8.0mm 2005
Kaohsiung Taiwan RS 1000 8 & 20 2003
Outokumpu Finland RS 1000 20mm 2001
Sundwiger Germany RS 2500 20mm 1998
Rautomead Limited
RS2500 CONTINUOUS CASTING TECHNOLOGY FOR BRASSES, BRONZES & ALLOYED COPPERS
• Up to 6,000 tonnes per year• 8 strand production• 8.0 – 30mm diameter• Holding & Casting Furnace (2500 kg
capacity)• - to be fed with pre-alloyed liquid metal• Graphite Crucible Technology• Electric Resistance Heating• Touchscreen Controls• Comprehensive Alarm System• PLC Controlled Coil Formation• Coil Weight: 2500 - 4000kgs • Coiler Model 0800: max. 12.7mm dia.• Coiler Model 0832: max. 30mm dia.• Options: remote plant monitoring
End Use Applications include:-EDM Machining Wire-Brass Wires-Bronze Wires
Services Required:-Primary Melting Equipment & Launder Transfer-240 kVA Mains Power-Diesel Generator & UPS-Secondary Water Cooling; Emergency Water -Nitrogen Gas (5 ppm O2)- Dust Extraction
Rautomead Limited
RS2500 Layout
Rautomead Limited
RS2500 - 8 Strand 8mm Casting 65:35 Brass fro EDM Wire
Rautomead Limited
RS2500 - 8 Strand 8mm Casting 65:35 Brass fro EDM Wire
Rautomead Limited
RS2500 - 8mm 65:35 Brass Supercoolers
Rautomead Limited
RS2500 - 8mm 65:35 Brass Supercoolers
Rautomead Limited
SUPERCOOLER TOOLING ASSEMBLY
SECONDARY COOLING
WATERINLET
WATEROUTLET
COOLINGWATER CHANNELS
THERMALINSULATION
CERAMICHOT END CAP
GRAPHITECASTING INSERT
COPPER ALLOYPRIMARY COOLER
Rautomead Limited
VERTICAL CASTING SYSTEM
OPTIC SENSORS
IMMERSION THERMOCOUPLE
FLOATASSEMBLY
GRAPHITE FLAKE
MOLTENBRASS
WATER COOLINGSERVICES
SUPERCOOLERTOOLING
ASSEMBLY
CONSTANT IMMERSION
Rautomead Limited
RS2500
Rautomead Limited
RS250 Withdrawal Options
Re-Start Motor Shaft
Individual Raise/LowerSupercooler
Rautomead Limited
RS2500 – Liquid Feed from Pre-Melter
The Brass must first be alloyed, tested and adjusted before pouring into the casting furnace.
Allowance is made for Zinc Losses during transfer of the metal.
Sample preparation and Analysis equipment needs to be near the machine.
Ladle, Mould, Small Lathe & Spectrometer
Rautomead Limited
RS2500 – Premelting Furnace
Rautomead Limited
Pre-Melter Emergency Empty Pit
Rautomead Limited
RS2500 – Feeding Pre-Melter
Rautomead Limited
RS2500 – Feeding Pre-Melter & Transfer Launder
Rautomead Limited
RS2500 – 65:35 Brass for EDM Feedstock
Rautomead Limited
RS2500 – Liquid Feed Launder
Rautomead Limited
RS2500 Fume Extraction
Rautomead Limited
RS2500 Fume Extraction
Rautomead Limited
Rod Breakdown for 8mm Brass
Rautomead Limited
EDM Wire from 8mm Continuous Cast RodTypical Breakdown of sizes42% of finished wire 0.25 and 0.3mm
50% of finished wire 0.2mm2% of finished wire 0.15 and
0.1mm
Rautomead Limited
RS10000 CONTINUOUS CASTING TECHNOLOGY FOR BRASSES, BRONZES & ALLOYED COPPERS
• to 3,000 tonnes per year • 4 strand production• 8.0 – 30mm diameter• Holding & Casting Furnace (1000kg
capacity)• - to be fed with pre-alloyed liquid metal• Graphite Crucible Technology• Electric Resistance Heating• PLC Controlled Coil Formation• Coil Weight: 2500 - 4000kgs • Options:• - plant monitoring for remote viewing of
production data & enhanced technical service support
End Use Applications include:-EDM Machining Wire-Brass Wires-Bronze Wires
Services Required:-Primary Melting Equipment & Launder Transfer-175 kVA Mains Power-Diesel Generator & UPS-Fume Extraction & Filter Secondary Water Cooling; Nitrogen Gas
Rautomead Limited
RS1000 Layout
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
• Launder feed to RS casting machine
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
• Launder feed to RS casting machine
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
RS1000 Casting 8mm
Rautomead Limited
Saikawa Rod Breakdown machine for 8mm Brass
Rautomead Limited
Shaving 8mm Brass Rod for EDM wire
8mm rod must be shaved to remove suface zinc spotting and microcracks common when casting brasses.
Typically 0.3mm off 8mm diameter.
Normal Method is to fit a shave die on inlet to Rod Breakdown
Rautomead Limited
http://www.saikawa.co.jp/eng/index.html
Mr Takashi AizawaExec [email protected]
Alternative is Niehoff
Rautomead Limited
ECONOMIC CASE operating
Investment cost/tonne
Marx Melting furnace € 500,000 € 30
Rautomead Continuous casting € 700,000 € 60 (RS1000)
1 x breakdown drawing 8 – 3mm € 400,000 € 30
1 x intermediate drawing 3 – 1.3mm € 350,000 € 20
5 x fine wire (2 strands 1.3 – 0.2) € 1,000,000€ 30
Ancillaries, services etc € 450,000
Overheads, labour etc etc allow € 100
Investment budget € 3,400,000
operating cost/tonne €270
Rautomead Limited
ECONOMIC CASE ctd
Oct 13, when Copper $ 7,150 / tonne Zinc $ 1,800 / tonne
Market price 0.2mm 60:40 wire € 5.00/ kg (assume)
Metal value: 60:40 brass: 0.6 * 7.15 = $4.29/Kg 0.4 * 1.8 = $ 0.72 /kg
metal: $ 5.01/kg @ $1.0 = €0.73 = € 3.657/kg
plus operating cost per kg € 0.270/kg
Total cost: € 3.927/ kg
Margin per kg = € 5.00 - € 3.927 = € 2.195/kg
Production : 1,500tpyr BENEFIT/YEAR € 1,609,500 million
PAYBACK OF INVESTMENT WITHIN 26MONTHS
Rautomead Limited
Thank You
www.rautomead.com
Rautomead LimitedNobel Road, Wester Gourdie Ind. Est.Dundee DD2 4UHScotland U.K.