Foundry activity start in 1961, since then never fail the share and the commitment that company gave and want to give to territory transformation, from a strictly agricultural zone to a modern industrial/commercial centre.
Le Fonderie del Delta, Company strongly deep-rooted in this area of the lower Polesine (Province of Rovigo), creates new jobs gaining imagine of prestige and reliability acknowledge by important customers of different industrial sectors. The production range is: water pomps - gearmotors - electric motors - breaking units textile machinery - stove production - mechanical industry.
The new iron foundry of the company is reputed ones of the most modern iron foundry in the world, has been not just because it is the latest, but also for the level of technical innovation incorporated. The foundry has been commissioned last year.
Melting requirement is provided from rotary gas melting furnaces, with one intermediary 25 tonnes capacity "DUPLEX" induction furnace allowing the holding and super-heating of cast-irons to produce quality alloys with maximum metallurgical control for pouring at the desired temperature.
Ensures the regular operation of the foundry regardless of the level of mechanisation and automation , since it forms a buffer between the melting and the casting section.
It thus copes with the possibility of breakdowns without affecting the quality or the temperature of the metal.
In the most typical application of the channel induction furnace the customer usually use an holding furnace, from which it takes the iron to pour it into the moulds/flasks of the moulding line that comes after the melting system. The molten metal is conveyed from duplex to the pouring furnace through a special pouring channel, of either fixed or mobile type or by ladles moved on crane or fork-lift as in this case.
The charging and pouring siphons design allows for charging and pouring at the same time. The metal poured in this manner is free from slag because of the tight sealing of the furnace cover avoids air entering, again reducing slag formation from oxidation of the metal. The great advantages are about:
Analysis of the metal poured out from the furnace will be constant, even if the cast iron is held within the furnace for many hours;
The high efficiency of this type of furnace is due to the direct conversion of electrical energy into heat energy.
The unique air cooled quick- interchangeable inductor that forms the channel where is passing the metal is flanged on the side or on the bottom of the furnace body and the heating of the metal inside the channel occurs through internal transfer of heat energy continuously and at maximum possible temperature, the unique limit being the refractory resistance of the lining.
A perfect consistency of metal analysis and temperature is maintained by the harmonization of unavoidable variations in the cast iron coming from the melting furnaces; Eliminates the waste from having to ingot, because it ensures that the iron is at the correct temperature right from the first pour . Also, the tailings residue of the pouring ladle can be recycled into the receiver furnace rather than being poured into ingots; Permits correction of the analysis of the iron through the possible addition of iron alloy and additives, while the melting furnace maintains a feed of standard cast-iron directly through the launder; In this way the receiver furnace can produce special cast-irons for the production of nodular, ductile and compacted grades of iron.
The great flexibility of the system and its adaptability to existing installations, ensures that the DUPLEX receiver furnace respond to the requirements of the most varied production programmes.
It is adaptable to any planned hourly production, temperature variations, accepting various launder systems, direct feeding from cupolas, rotary or electric melting, shift work, idle time, down time, etc.
In the most typical application of the channel induction furnace the customer usually use an holding furnace, from which it takes the iron to pour it into the moulds/flasks of the moulding line that comes after the melting system. In this case, at the end of the melting process, the molten metal is conveyed to the holding furnace through a special pouring channel, of either fixed or mobile type or by ladles.
The customer usually use a pouring furnace to pour metal into the moulds/flasks of the moulding line.
In order to adapt to furnace to varying pouring positions ,the furnace can be moved vertical, lengthwise and perpendicular to the moulding casting line as required when installed with box-less greensand vertical moulding lines . A hydraulic tilting equipment allows the furnace to be completely emptied for changing the alloy also. This furnace is equipped with a special automatic lifting system able to meet the new moulding line requirements of different mould highs.
The ability to pour with the best accuracy and dosing repeatability with constant pouring temperature it is now a result approachable for all foundries that look for getting better quality and improving production.
The pouring control system must obtain together with the maximum exploiting of the production cycle time the maximum quality of the castings under continuous running operation. Pouring out metal by controlling the pressure inside the furnace to maintain the metal level constant and opening the stopper rod according the metal pouring filling mould requirement.
The pouring speed and flow during the mould filling process must always be matched to the intake capacity. For this purpose, FOMET has system, which operate with a "teach-in" program memory or/and in a closed-loop control circuit with CCD camera for moulding the opening of the stopper rod for maintaining constant the level in the pouring cup.
This is achieved having a reliable system that shall permit to avoid losses and over pours of metal.
Several optional equipment has been designed from FOMET for completing the pouring furnace control increasing the process efficiency and its automation; the following optional equipment could be interfaced and integrated in the FOMET furnace pouring control system.
The automatic pouring furnace supplied by FOMET srl, has been equipped with the most technically advanced pouring control system yet seen in foundries, which includes metal level control by laser, and a reactive intelligent video camera system to supervise the control of the dosage of molten iron into the moulding boxes. The furnace is equipped with "smart" automatic inoculation systems for correcting metal composition with in stream inoculation and also with an automatic furnace positioning system.
The FOMET pouring furnace is a channel induction mains frequency type, incorporating a very high level of thermal insulation along with constructional characteristics and "know how" covered by patents. The economical air-cooled induction coil (no water) also facilitates both maintenance, and eventual replacement of the inductor.
Unlike coreless type pressure pouring units where the useful power varies according to the metal level inside the furnace, our super heating capability (useful power) is always available, regardless of the metal level inside the furnace. Moreover the power is managed in a special way to counteract the inclusions and build-up that may occur inside the channel. The need for changing the inductor is planned in advance by simply monitoring the program data efficiency indicator diagram (cosphi operating range). Also the cleaning of the fill and pour siphons is simple, as they are straight and without bottom bends and swan necks for entering into the furnace vessel.
Another big advantage of the induction channel furnace versus the coreless pouring furnace is the good electrical and thermal efficiency, hence leading to low energy consumption in continuous operation.
The pouring furnace is designed for operating with an inert gas pressurizing media, like Nitrogen. The furnace and cover are gastight with an excellent seal without gas leaks. The large refractory thickness used in our design makes a perfect supporting face for the cover sealing ring avoiding the known pressure sealing problems associated with the coreless furnaces.
In processing Nodular iron the treatment methods, which use pure magnesium, are generally to be recommended.
According to customers data initially the gas atmosphere has no effect on the rate of melting loss (Mg fade); however after formation the rate of melting loss (fade) is reduced considerably, thus assuring that the molten metal remain ready for pouring with a sufficient Mg content over the full holding time of 8 hours.
Maintenance operations are simple with the minimum time requirements for maintaining the furnace at best efficiency and the lack of a water-cooling circuit it is a great advantage.
Pouring without slag; the pouring furnace with its siphons and stopper guarantees a pour with no slag and inclusions. This also brings a better quality with reduction of scrap and increase of productivity.
Immediate increase of productivity due to the consistency and repeatability of the pouring cycle. Eliminating of over pours of cast iron on the mould, with almost perfect and uniform filling of the mould will give saving in metal.
Better working environment without heat exposure; without polluted air from emissions and fumes. Saving of manpower necessary for pouring operation; one supervisor is enough to control all the pouring operation. Upgrading critical operation with qualified o personnel
The management interface pouring system of the furnace, also exchanges data with the other associated plant. This continually maintains the maximum efficiency of the entire production processes, while indicating any potential problems requiring maintenance intervention.
Precise control of the poured metal quantity with precise pouring temperature, homogenization of the cast-iron with the best consistency of analysis.
This results in consistent quality of castings with increased in productivity and reduction of foundry returns.
This new installation in Occhiobello, confirms FOMET's position as the leader in the supply of automatic pouring systems, which guarantee high returns for foundries, combined with advanced technology and reliable safety standards..
Other than Le Fonderie del Delta the following companies have chosen FOMET equipment in the last two year time:- Amtek, Disa, Aci-Renault, F.Lli Giovannini, Fonderie Valchienti, Foresti e Suardi, Abloy Oy Diaco, C.M. Smith And Sons, Kumar, Akis, Herz Aramturen , S.A. Cheminees Philippe, Favi, Baylan, Hydro-Vacuum Sa., Brembo etc etc..