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WEIR MINERALS APPLIES CASTING INNOVATION AT ISANDO PLANT

Driving down element turnaround time whereas improving 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 revolutionary growth allows the company to provide more parts at a time – and more rapidly. This will assist in meeting growing customer demand, whereas also decreasing rework and wastage.
“As a half of our Project Vuka, this new plant allows us to forged a number of small parts per batch somewhat than simply separately,” says Smith. “We also can cut back our knock-out instances from days to only a couple of hours.”
The state-of-the-art facilities enable Weir Minerals Africa to forged excessive chrome components weighing as a lot as 250 kg. There are two phases to the new course of, he explains, which makes use of polystyrene to create moulds. The first phase is the polystyrene moulding course of, 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 together with the polystyrene mould, he says. The system involves a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – as properly as having no clamping process – leads to less scrap being produced, and subsequently brings operational savings,” he says. “The quality of castings can also be raised, with a greater surface end and fewer defects.”
He notes that the geometrical stability of components is improved, as there may be less fettling of the finished product thereby reducing dimensional variation between the identical parts. This in turn contributes to the reliability of the tools utilizing these parts. He says the foundry may also realise significant environmental benefits on account of utilizing no chemical compounds within the sand.
“This new plant aligns properly with our corporate sustainability objectives, ensuring that our processes aren’t solely compliant but repeatedly reduce our environmental impression,” says Smith. “ เกรดวัดแรงดัน ensure that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances similar to benzene.”
The new technology is also leading to less frequent disposal of silica sand, and the sand itself is more environmentally friendly as it contains no resin or acid.
“A remarkable aspect of developing this new plant was the fact that it was accomplished with our native abilities and largely during the COVID-19 lockdowns,” he says. “Despite the novelty of this technology, and the logistical challenges created by the pandemic, it was successfully applied on time and inside budget.”
The plant contains greater than sixteen,000 particular person elements, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of metal.
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