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WEIR MINERALS APPLIES CASTING INNOVATION AT ISANDO PLANT

Driving down element turnaround time while improving quality and reducing waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant manager at Weir Minerals Africa’s Isando facility, highlights that the progressive improvement enables the corporate to supply more components at a time – and more quickly. เกจอาร์กอน will help in assembly rising buyer demand, while additionally reducing rework and wastage.
“As part of our Project Vuka, this new plant allows us to cast multiple small elements per batch quite than simply one by one,” says Smith. “We can also cut back our knock-out instances from days to just a couple of hours.”
The state-of-the-art facilities allow Weir Minerals Africa to cast high chrome parts weighing up to 250 kg. There are two phases to the new course of, he explains, which makes use of polystyrene to create moulds. The first section is the polystyrene moulding course of, which occurs after the polystyrene beads have been expanded. The second section is where the ramming, pouring and demoulding takes place.
In contrast 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 removed to compress the sand.
“The absence of resin and catalyst – as well as having no clamping process – results in much less scrap being produced, and therefore brings operational financial savings,” he says. “The quality of castings can be raised, with a better floor end and fewer defects.”
He notes that the geometrical stability of parts is improved, as there’s much less fettling of the completed product thereby lowering dimensional variation between the same components. This in flip contributes to the reliability of the equipment using these elements. He says the foundry will also realise significant environmental benefits as a end result of utilizing no chemical compounds in the sand.
“This new plant aligns well with our company sustainability objectives, ensuring that our processes aren’t solely compliant but repeatedly reduce our environmental impact,” says Smith. “Our new moulding methods make certain that fewer gases are emitted during the casting process, and there are zero emissions of dangerous substances similar to benzene.”
The new know-how can also be leading to much less frequent disposal of silica sand, and the sand itself is more environmentally friendly as it contains no resin or acid.
เกจวัดแรงดันน้ำ of creating this new plant was the reality that it was carried out with our local abilities and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this technology, and the logistical challenges created by the pandemic, it was successfully carried out on time and within finances.”
The plant includes greater than 16,000 particular person elements, and makes use of over 1,900 m of cabling, 300 m of water piping and fifty five tons of steel.
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