Case Study: Melt Department Upgrades

Dura-Bar Furnace Charge System

Challenge

For over 40 years, Dura-Bar has been recognized as the industry leader in producing continuous cast iron. In order to meet their increased demand from customers, Dura-Bar embarked on upgrading their furnace / melt system with the latest technology, designed to achieve greater throughput and melt efficiency while utilizing less energy and labor. The system would include two new furnaces to be fed by an automated charge system.

Approach

Dura-Bar currently utilized a General Kinematics automated charge bucket feed system, as well as an automated furnace charge feeder, so when it came time to upgrade their melt deck, they contacted GK for recommendations. The engineering experts at GK worked with Dura-Bar and their furnace manufacturer to create a system layout that both increased their capacity and system performance.

Solution

General Kinematics provided two two-mass vibratory furnace charge feeders operated with an automated control package. The two charge feeders will receive a charge size of approximately 18,000 pounds and transfer to ABP twin IFM-6 furnaces. Feeders are provided with weigh cells on the frame of the carriage allowing for accurate measurement of product both at the loading of the feeders and at the furnace. The unit also incorporates a fume hood which mates to the hooding of the furnace to ensure capture at transfer into the molten bath.

Results

By implementing GK’s charge system, Dura-Bar significantly increased their melt output. The increased output allowed them to meet growing customer demand for their product while saving time by being able to pre-charge the feeders to maintain a continuous melt schedule.

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