StrikoWestofen’s engineers completely replaced the lining in the StrikoMelter’s melting and holding chambers. They also updated the control cabinet, and the aluminum scrap pump. A new charging unit increased operational reliability and made a considerable contribution to the efficiency and performance of the whole system.
Producing around 100,000 wheel hubs every month, this foundry operates a total of 48 die casting lines. 10 aluminium lines are served by a StrikoMelter CombiMelter MHCM II-N 7000/3000/800 G-eg.
After a pause in production, the foundry audited its equipment before restarting the lines. After six years of constant service, its StrikoMelter required some expert attention to regain its full performance potential.
The StrikoMelter’s furnace lining was in particular need of attention. Wear to furnace linings is unavoidable: all melting and dosing furnaces require regular relining to maintain correct operation and maximise energy efficiency. Because this work must be carried out correctly and the OEM knows the equipment better than anyone, this foundry sent the melter to StrikoWestofen’s facility in Changzhou.
Repair and upgrading boost efficiency and make operation easier
“Poorly executed relining shortens the service life of the equipment, reduces the melting capacity and increases its energy consumption by up to 30%,” says Bell Wang, Senior Service & After Sales Manager for StrikoWestofen Asia. “By using the correct combination of materials and achieving exactly the right internal geometry, relining can achieve energy efficiency comparable to new machines at a fraction of the cost. But you also need experts who can recognise when other components need repair, replacement or upgrading too.”
Additionally, upgrading the furnace with a laser monitoring system means shaft filling level is now always at the optimum for maximum waste heat recovery, which minimises fuel consumption and metal loss while preventing damage to the furnace.
“The laser monitoring system constantly checks the filling level in the shaft when closed and during filling,” says Bell Wang. “This improves energy efficiency and makes operation much easier for the customer as they do not need to keep checking the fill level is correct.”
Expert maintenance cuts energy consumption by 15%
After the maintenance and testing, the StrikoMelter went straight back into production. Due to the improved insulation of the new lining and the other renovations, they found energy consumption per ton of aluminium melted had dropped by 15%.
“More and more aluminum foundries are realising that repairing and upgrading existing equipment is worthwhile,” says Bell Wang. “As the OEM, we have different relining options and are often able to retrofit our latest technologies to give substantial increases in performance and efficiency.”
