A busy UK foundry has vastly improved the efficiency of its melting capabilities and notably reduced melt time following a modernisation of existing equipment inspired by proven supplier technology.
With a growing order book and to meet constant demand, the furnaces at The Stockton Casting Company Ltd are in operation every day – they are the beating heart of the foundry. However, the need for improved efficiency, more detailed data for analysis and the ongoing quest for decarbonisation had outstretched the two out-dated Radyne workhorses. A solution was needed – one that would enable a swift change without too much disruption to production.
Foundry manager Richie Waters explains: “We have always enjoyed a high level of investment at the company as the owners understand the importance of ensuring we have the best equipment and facilities, but the melt shop was lagging behind. It’s a difficult decision to upgrade the furnaces as they are in constant use, but we needed to improve our efficiency.”
Having investigated several options, the decision became clear – work with a trusted partner, which led to a problem solving exercise with Inductotherm Europe Ltd. “Whilst another furnace supplier or a larger furnace could have been a possibility, Stockton Casting wanted to keep two furnaces,” says Inductotherm area sales manager Tim Redding. “We needed to put our heads together and find a solution to give Stockton greater production prospects.”
From the beginning the objective was clear – a financially viable solution which can melt quicker, cleaner and with greater ease. This is quite a tall order when trying to achieve this by utilising existing third party equipment, but that is not a new “ask” for the world leading induction melting specialists. “We are used to working with customers who need to upgrade older third party equipment. It is always challenging because you are trying to match the latest high efficiency equipment to something existing that may not have been designed to be upgraded or future proofed, but we have experience in this and would rather work with the customers to find a solution that matches their expectations.”
EXCEPTIONAL PERFORMANCE
Following collaborative working to ascertain the most practicable option, Stockton Casting opted for a 750kw 1000hz Dual-Trak®inverter to replace the two older Radyne inverters. Tim Redding explains: “Similar kW but outstrips performance and reliability.”
The installation also included a new HV transformer to replace the existing two, plus coupling the existing two 1-ton Radyne furnaces with a new busbar network and water-cooling manifolds.
“This new installation basically made one transformer and inverter redundant, with the new Dual-Trak able to handle the existing and potential production requirements,” says Tim Redding.
The now “fit for purpose” outcome is a transformative solution for the north-east based foundry. Richie Waters says it has revolutionised the melt shop and been a success from start to finish. “It is night and day to what we had and we are over the moon,” he told Foundry Trade Journal. “Taking the old inverters out and working with the existing furnace bodies, which were originally installed in the late nineties, meant minimal disruption to our production schedules. We shut off the old furnaces and got one of the new ones up and running in just about a month, including installation of the transformer, water pump and upgrading the power supply.”
TRANSFORMATIVE WORKING
Perhaps the greatest challenge was the amount of civils involved in the project, including the ducting and pipework, which had been shoehorned into a tiny space behind the furnaces. Richie Waters says this was particularly impressive. “It is vitally important that the pipework and of course the water, be handled by experts. Inductotherm did a cracking job of this, and the new Dual-Trak has transformed what was a tight space into a much more pleasant place to be. It is neat and tidy and much more in keeping with what we are about. We have doubled up on the busbars offering extra efficiency and we were delighted to work with Inductotherm’s sister company Emsco for the installation work.
“We have so much data at our fingertips now and can see what power we are using and how efficient we are instantly. Early indications are that we are using less power, the system is cheaper to run and it is quicker to melt – everything we asked for. That is with us just using the one furnace so far, the second furnace will be up and running soon, then we will see the true value of the Dual-Trak function.”
TEAMWORK
Tim Redding says working with enthusiastic and driven people like Richie Waters and his colleagues has been a true highlight. “It was a really interesting and enjoyable experience to get this equipment in place, basically involving a lot of planning and teamwork in advance. What Inductotherm is experienced in is helping people to understand what furnaces they need, bespoke solutions to make the working environment better and the melting process more efficient to refresh their business. We have an increasing number of technical options and can mix and match successfully SCR or IGBT whichever suits – we have a long track record in that. To be honest, a lot of efficiency issues are to do with layout and it might be something that a company hasn’t thought about. For example, the busbars – if that layout is correct and the footprint is lowered, you can make significant savings, otherwise you are losing in this area on every melt you undertake. This is important when considering the energy credentials in each casting. There is a substantial increase in the data available from the new equipment to help foundry personnel make informed decisions.
“At Stockton Casting the furnaces will now be working in partnership rather than as individual furnaces, which is why we are looking forward to recommissioning the second existing furnace in the coming weeks to really show the equipment’s true performance.
“Next year’s plan then is to replace both furnaces completely, to further advance performance and robustness of the installation.”
With space at a premium, profit margins often squeezed and environmental targets to meet, it is becoming increasingly important to highlight bottlenecks on the shopfloor and find solutions to maximise effectiveness.
Richie Waters spells it out: “It is a win at all levels. We’ve already outlined the improvements in energy efficiency and the working environment, but this upgrade also means freeing time for the furnacemen, so there are health and safety improvements but it also frees up personnel for other duties. It’s been a revelation for us, and we are delighted with the results so far.”
Contact: Tim Redding, Inductotherm Europe Ltd, Tel: +44 (0) 1905 791106, email: [email protected] web: www.inductotherm.co.uk