Driving down element turnaround time whereas bettering quality and lowering waste is being achieved at Weir Minerals Africa’s exciting new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the progressive development permits the company to supply extra components at a time – and more rapidly. This will assist in assembly rising buyer demand, while additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant permits us to cast multiple small elements per batch rather than just one at a time,” says Smith. “ เกจวัดแรงดันเชื้อเพลิง can also cut back our knock-out instances from days to simply a few hours.”
The state-of-the-art facilities allow Weir Minerals Africa to cast high chrome elements weighing up to 250 kg. There are two phases to the model new course of, he explains, which uses polystyrene to create moulds. The first part 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 distinction to the standard moulding line – the place 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 involves a vacuum bin, from which all the air is removed to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping process – results in less scrap being produced, and therefore brings operational savings,” he says. “The quality of castings can additionally be raised, with a better surface end and fewer defects.”
He notes that the geometrical stability of components is improved, as there may be much less fettling of the completed product thereby lowering dimensional variation between the identical components. This in flip contributes to the reliability of the tools using these components. He says the foundry may also realise significant environmental advantages because of utilizing no chemical substances in the sand.
“This new plant aligns nicely with our company sustainability objectives, making certain that our processes aren’t solely compliant however continuously scale back our environmental influence,” says Smith. “Our new moulding systems make certain that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances similar to benzene.”
The new technology can be resulting in much less frequent disposal of silica sand, and the sand itself is more environmentally pleasant as it accommodates no resin or acid.
“A remarkable facet of developing this new plant was the fact that it was done with our native abilities and largely during the COVID-19 lockdowns,” he says. “Despite the novelty of this know-how, and the logistical challenges created by the pandemic, it was successfully implemented on time and inside price range.”
The plant includes greater than 16,000 individual elements, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of metal.