18.02.2011
Our Cokeless Cupola offers all advantages of a high-duty, economic and environmental melting unit! At a tapping temperature of 1400°C the gas consumption per ton liquid iron is approx. 50 Nm³/hour (approx. 530 kWh).
Scrap iron, return scrap, pig iron, steel scrap as well as slag-forming constituent are used as charge material. According to requirements the liquid iron is subsequently poured or the required temperature and analyses is adjusted in a crucible induction furnace. Half the metallurgical battle of the furnace is the low sulphur content of the molten basic iron with approx. 0,01 %!
The furnace is equipped with modern gas burners to assure constant melting conditions. Each of the burners has their own gas-, air- and oxygen valves for exact control of the burner capacity. Furthermore the melting capacity is simply to adopt the particularly requirements.
Another advantage of the cokeless cupola furnace is the extreme low output of C0², SOx and N0x. The dust emissions with 1,5 kg per ton liquid iron is well below the emissions of the coke-fired furnaces.
As a result of the construction there is also the possibility to rework existing cupola furnaces from coke to natural gas to keep the investment costs low.
08.02.2011
Today a whole range of quality products can be manufactured cost-effectively using the centrifugal casting procedure, and further applications can be found. A distinction can be made between horizontal and vertical centrifugal casting. The most common procedures are the hot mould casting process and the mould spinning in a water bath (de Lavaud procedure).
A foundry's productivity depends on the selection of the appropriate production method. Under certain circumstances, automated centrifugal casting as a supplement or a substitute for mould casting can create the necessary conditions to secure a foundry's competitiveness. Centrifugal casting is one of the casting procedures with permanent moulds. Special fire-proof ceramic materials or coatings, mostly on a silicate base, serve as a separating and insulating layer between the mould and the casting material.
Typical centrifugal casting products are 6 m pressure pipes with a wide diameter range in ductile cast iron and 3 m drainage pipes in gray cast iron. The demand for high-quality cylinder liners in the automobile industry is growing. The focus is not only on the casting quality – for this goes without saying for such a highly strained motor component. The desire is also to do with as little machining allowance on the casting as possible, for machining is expensive! In order to reduce the vehicle weight, motor blocks are also made of aluminum. The gray cast iron cylinder liners required for this application are left un-machined on the outside. These rough cast iron liners are inserted into the mould and cast with liquid aluminum to form the motor block. The dimensions and surfaces of the liners are subject to tight tolerances; in the centrifugal production process these required values must be adjustable and reproducible for large quantities. Apart from the application of the centrifugal casting process for the production of pipes and liners made of steel and iron materials, the advantages of this procedure are also used by non-ferrous casting plants as a supplement to mould and continuous casting. Numerous copper alloys are being processed. Particularly the physical properties establish the supremacy of centrifugal casting.
In foundries for the production of rotation-symmetrical castings, any considerations regarding quality improvement, capacity increase, replacement investments or cost reduction programs should include the possibility of switching from common casting procedures such as sand mould casting to alternative procedures such as the centrifugal casting.
For the client to be able to fulfill the market requirements, it is necessary to develop, plan and construct tailor-made plants. Maximum productivity, shorter transit times and the adherence to reproducible quality are only some of these requirements. The conditions for this are, among other things, computer-controlled and monitored work sequences with the corresponding flexibility as well as efficient mould exchanges and the possibility of the simultaneous use of different moulds with similar pipe and liner dimensions.
The following advantages of an automated centrifugal casting plant should be taken into account:
- high process safety due to automation
- low energy requirement
- high recovery rate, i.e. hardly any returns
- low rejects rate up to only 1%
- minimum staff required
- minor machining allowance
- low costs for rest material disposal
08.02.2011
We manufacture centrifugal casting moulds in different dimension and material, if required with internal shape. We have also systems with insert carrier and insert mould.
18.02.2011
The main part of today's work is the individual and standard-compliant projection and assembly of control systems, measuring systems and power control systems as well as power distribution for requirements in the industry and building engineering including assembling, commissioning and service.
This range of services refers not only to the complex tasks within Düker, but other small and medium-sized companies also benefit from our services and our long-time experience.
Use our services and benefit from the following advantages:
Technical consulting
Focussed projection
Conforming to standards
Cost-efficient
Ergonomic and modern in design
International standards
Certified as per ISO-9001
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