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.

Leave a Reply

XHTML: You can use these tags: <a href="" title=""> <abbr title=""> <acronym title=""> <b> <blockquote cite=""> <cite> <code> <del datetime=""> <em> <i> <q cite=""> <s> <strike> <strong>

Related Case Studies

Material Testing

Material Testing: Screening ASR Scrap

A new opportunity for innovation ASR scrap can be a particularly difficult material to screen and separate due to tangled wiring and easily knotted materials. When planning an ASR sorting system for enhanced separation, a current GK customer had an idea of how they would like to improve their system. However, the customer was uncertain […]

Read More
Bottom Ash Conveyor

Covanta Pinellas: A Lasting Impression

Covanta, one of the largest mass-burn facilities in North America, explores their 30-year relationship with General Kinematics. Converting MSW to renewable energy for Pinellas county, Covanta depends on the reliability of their equipment to run without fail. GK’s Bottom Ash Conveyors have been able to provide 95-98% uptime.    Learn more about it in the […]

Read More
Queensland two-mass mining screen installation

Client Case Study: Australia Coal Mine

In 2016, a CPP coal mine site in Australia wanted to handle higher ash seams than the CPP had been designed for. It also was looking to recycle coking coal tailings to produce a thermal product. To achieve this, the mine needed an increased reject screen capacity of up to 1000 tph from their current […]

Read More