Pig Casting Machine
PEIE Design, Engineering, Manufacture, Shop-test, Supply, Erection & commissioning 2nd generation Pig iron Casting Machines in TPM methodology with following customer delighting features. |
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PCM TYPE : Mobile roller Wheel Single Strand Year of commissioning : 2012 |
Product data-sheet & Process to achieve 25 TPH casting
TYPE : |
Mobile roller Wheel Single Strand |
Mobile roller DoubleStrand |
Fixed Roller Single Strand |
Fixed Roller DoubleStrand. |
Casting Metal Range : |
10000 to 18000 C |
yes | yes |
yes |
Productivity (Ton/Hour) |
30 |
60 |
30 |
60 |
Lubrication System : |
Splash |
Splash |
Centralized |
Centralized |
Rollers : |
With Bearing or bushing |
yes |
yes | yes |
Control System : |
PLC , VVVF or LPBS |
yes | yes | yes |
Pig Knocker : |
Mechanical |
yes | yes | yes |
Mould Heaters : |
With heaters or Without | yes | yes | yes |
Mould Coating : |
Lime & Graphite Agitator with Spray System | yes | yes | yes |
Water Circuit : |
Spray and optimized recirculation | yes | yes |
yes |
Chute Liners : |
Wear resistant steel, bottom Rail |
yes | yes |
yes |
Chain Linkage : |
Adjustable | yes | yes | yes |
Mould Overflow : |
Default |
yes | yes | yes |
Components : |
Standard interchangeable. | yes | yes | yes |
Environmental Aspects |
With Fume Hood or Without | yes | yes | yes |
Specification : |
PEIE-25-M1 (34, 43 as on) |
PEIE-X-M2 |
PEIE-X-F1 |
PEIE-X-F2 |
Mass of Iron Block |
5 or 10 kgs. | yes | yes | yes |
Distance between Head-Tail Wheel |
25 or 34 meter and above. | yes | yes | yes |
Inclined Angle of Chain Belt |
7-15 0 | yes | yes | yes |
Diameter of Rotary Wheel (MM) |
1385 mm | yes | 1974 | yes |
Speed of Chain Belt (MM/MIN) |
1 – 12 m/min | yes | yes | yes |
Motor, 960 R.P.M. |
15 KW to 30 KW |
yes*2 | yes | yes |
Gear Reducer |
400:1 | yes | yes | yes |
Mould |
C.I. or Cast Steel IS:3038-92 Gr IV | yes | yes | yes |
Total Weight of Equipment |
56 ton |
112 ton |
72 ton |
140 ton |
Total Weight of Structure |
27 Ton |
48 Ton |
later |
later |
TECHNICAL SPECIFICATION OF SUCCESS STORY |
Type |
Mobile roller Wheel Single Strand |
1 no |
Material |
Liquid metal Temperature |
Pig Iron and Ferro alloy 1000-1800 deg C at pouring point |
Capacity |
500 tones / day |
@ 8 to 12 hours/day |
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Speed |
1 – 12 Meter / min |
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Length of the machine |
42.70 |
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Slope |
7.9 degree |
Area covered (approx.) |
|
180 M2 |
Product mass |
No. of Iron block Casting per Mould Wt. of each Pig |
4 per Mould 10 kg |
Ladle Capacity |
Trunion mounting lip pouring |
12 – 8 MT of Hot Metal |
Control |
VVFD |
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Voltage |
440 +/- 10%, 50 Hz. +/- 5%, 3 phase |
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Power Consumption |
Drive Strand Lime Sprayer Lime milk agitation Cent. Grease lubrication Requirement of utilities |
30 KW x 1000 rpm AC Motor 5.5 KW x 1440 rpm AC Motor 3.7 KW x 1440 rpm AC Motor No 15 KW x 1440 rpm AC Motor |
Time required |
to cast 12 T ladle at different speed |
12 – 15 min |
cooling of casting block in Strand |
Time for air Time for water |
2 min. 4 min |
Total Weight of Machine |
|
96,000 kgs (approx.) |
Drive |
Sprocket. Center |
34.70 M |
|
Chain pitch (mm) |
540 |
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Details of Gearbox and coupling |
Helical & Gear type |
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Gear Ratio |
1/400 |
Mould |
Weight ratio of casting / mould |
1 / 3 |
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No. of Moulds per strand |
269 |
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Weight of heaviest part in kg |
3500 |
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Temp. of casting at discharge end |
180 deg C |
Launder |
Fabricated, anchor welded, refractory details |
G.A drawing PEIE-34-M1-X |
Lime & graphite Spray |
Lime milk preparation and spray arrangement |
G.A drawing PEIE-34-M1-X |
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Lime spray pumps |
5.5 KW 20m3/hr @ 10 kg/cm2 Creative Slurry pumps |
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Lime agitator |
3.7 KW 15 rpm 6” blade (S.S 304 ) agitator with vertical geared motor |
Roller arrangement details |
ᶲ 200 mm Forged with collar , hardened |
GA Drawing |
Pig knocking device details |
Mechanical cam driven rotating wheels strikes on 1st & 3rd pocket of mould |
GA Drawing |
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Grizzly details |
Standard |
Details of chute for stickers |
Wear resistant steel, bottom Rail |
Fabrication drawing |
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Detail of splashing guard and trolley |
Not applicable |
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Details of strand tightening device |
GA Drawing |
Material of construction
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Sprocket Moulds Chain links Rollers Splash guards Chute liners Sprocket shaft |
: IS : 2707 Gr.II : Cast Steel IS 3038-92 Gr IV : IS : 1030 : Carbon Steel : MS : Mn steel and Rail : C45 |
water spray |
water spray nozzles by dia 100 perforated header anti gravity |
GA drawing |
Lubrication |
Automatic splash droplet to moving parts |
GA drawing |
Structural |
Structural column, support ISMB 250 Rail 90 lb Drive base built up, gussets pedestal , platform, runners, M.S. 8, 12, 16 mm Tie bracing ISA 150 Walkway grating 25X6 ms flats, Hand railing dia 40 ERW ms |
9662 kg 6066 kg 9000 kg
1500 kg 2500 kg 350 M |
De-noise arrangement |
to piglet with chain and Deflector |
GA Drawing |
Pollution under control |
Monitor truss & Steam and Fume hood |
Fabrication & GA Drawing |
Painting terms |
Standard |
Equipment: Synthetic Enamel, Structural.: Primer |
GENERAL PROCESS DESCRIPTION |
Tapped molten metal filled PEIE-Ladle shall be placed in position of PEIE-Ladle-stand to match it’s Trunion with Ladle Tilting arm. |
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.Hot metal shall be poured on C.S. Mould of Pig casting Machine through PEIE-Hot-metal-runner when tilting of ladle by action of winch or overhead crane. |
An inclined chain conveyor having a set of overlapping Moulds fixed between a pair of chain Link carries set of rollers which moves over Rail. |
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A set of sprockets on either side of the PCM one of which is driven (idle/Tail-sprocket) and the other is driving/ Head sprocket are mounted on technological structure. |
The VVVF drive AC motor coupled(Pin-bush) to a multistage Helical reduction gear box, the output shaft of which is connected through Geared coupling to the driving sprocket shaft supported at the ends by bearing. |
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After travelling the distance of metal for solidification time , the formatted Pigs shall be fed into water quenching by PEIE-water-spray-Twin-Header |
The Pig Knocker facilitates to strike the pigs at discharge end which fall down to direct Dumper through a Pig-Discharge-Chute |
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Lime spray(Graphite powder mixed) coating shall be done on return moulds ~1.2 specific gravity to remove stickiness of pig . Wear resistant Slurry Lime pump shall be used for spray and recirculation |
S.S-304 Blade vertically Agitator mixes the lime slurry into concrete lime mixing tank |
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Water spraying and recirculated circuit tank hold minimum 100 m3 of water and the clear water pumps shall be used for cooling purpose of Pig. |
Spillage collecting Tray contains sand to easy removal of spillage if. |
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A slow speed pouring of Ladle winch shall be provided for ease of operation. |