เกจวัดแรงดันแก๊สอาร์กอน down element turnaround time while enhancing quality and decreasing waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the revolutionary development enables the corporate to produce more elements at a time – and extra quickly. This will help in meeting growing customer demand, whereas also decreasing rework and wastage.
“As part of our Project Vuka, this new plant allows us to solid multiple small components per batch quite than just one at a time,” says Smith. “We can also scale back our knock-out occasions from days to simply a few hours.”

The state-of-the-art services allow Weir Minerals Africa to forged high chrome elements weighing as much as 250 kg. There are two phases to the model new process, he explains, which uses polystyrene to create moulds. The first phase is the polystyrene moulding process, which happens after the polystyrene beads have been expanded. The second section is where the ramming, pouring and demoulding takes place.
In contrast to the standard moulding line – where resin and catalyst are used to bind sand – the Replicast Plant uses silica sand of 30-35 AFS grade along with the polystyrene mould, he says. The system entails a vacuum bin, from which all the air is eliminated to compress the sand.
“The absence of resin and catalyst – in addition to having no clamping course of – leads to much less scrap being produced, and subsequently brings operational financial savings,” he says. “The high quality of castings can also be raised, with a better surface end and fewer defects.”

He notes that the geometrical stability of elements is improved, as there’s much less fettling of the finished product thereby decreasing dimensional variation between the identical components. This in flip contributes to the reliability of the equipment using those components. He says the foundry may also realise important environmental advantages on account of utilizing no chemical compounds in the sand.
“This new plant aligns well with our company sustainability targets, guaranteeing that our processes usually are not only compliant however continuously cut back our environmental impression,” says Smith. “Our new moulding systems be certain that fewer gases are emitted through the casting course of, and there are zero emissions of dangerous substances similar to benzene.”

The new technology can also be resulting in less frequent disposal of silica sand, and the sand itself is more environmentally friendly because it incorporates no resin or acid.
“A remarkable side of creating this new plant was the fact that it was carried out with our native skills and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this expertise, and the logistical challenges created by the pandemic, it was efficiently implemented on time and inside budget.”

The plant includes greater than sixteen,000 particular person elements, and uses over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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