M/S PEACOCK ENGINEERING (INDIA) EQPTS.

(Manufacturers of metal handling Plants & Equipments in India)

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Pig Casting Machine

PEIE Design, Engineering, Manufacture, Shop-test, Supply, Erection & commissioning 2nd generation Pig iron Casting Machines in TPM methodology with following customer delighting features.

 

PCM TYPE :  Mobile roller Wheel Single Strand

Year of commissioning : 2012

Product data-sheet & Process to achieve 25 TPH casting

TYPE :

Mobile roller Wheel       Single Strand

Mobile roller DoubleStrand

Fixed Roller Single Strand

Fixed Roller DoubleStrand.

Casting Metal Range :

10000 to 18000 C

yes

yes

yes

Productivity (Ton/Hour)

30

60

30

60

Lubrication System :

Splash

Splash

Centralized

Centralized

Rollers :

With Bearing or bushing

yes

yes

yes

Control System :

PLC , VVVF or LPBS

yes

yes yes

Pig Knocker :

Mechanical

yes

yes yes

Mould Heaters :

With heaters or Without

yes yes yes

Mould Coating :

Lime & Graphite Agitator with Spray System

yes yes yes

Water Circuit :

Spray and optimized recirculation

yes yes

yes

Chute Liners :

Wear resistant steel, bottom Rail

yes

yes

yes

Chain Linkage :

Adjustable

yes yes yes

Mould Overflow :

Default

yes

yes yes

Components : 

Standard interchangeable.

yes yes yes

Environmental Aspects 

With Fume Hood or Without

yes yes yes

Specification :

PEIE-25-M1 (34, 43 as on)

PEIE-X-M2

PEIE-X-F1

PEIE-X-F2

Mass of Iron Block

5 or 10 kgs.

yes yes yes

Distance between Head-Tail Wheel

25 or 34 meter and above.

yes yes yes

Inclined Angle of Chain Belt

7-15 0

yes yes yes

Diameter of Rotary Wheel (MM)

1385 mm

yes 1974 yes

Speed of Chain Belt (MM/MIN)

1 – 12 m/min

yes yes yes

Motor, 960 R.P.M.

15 KW to 30 KW

yes*2

yes yes

Gear Reducer

400:1

yes yes yes

Mould

C.I. or Cast Steel IS:3038-92 Gr IV

yes yes yes

Total Weight of Equipment

56 ton

112 ton

72 ton

140 ton

Total Weight of Structure

27 Ton

48 Ton

later

later

 

TECHNICAL SPECIFICATION OF SUCCESS STORY

Type

Mobile roller Wheel Single Strand

1 no

Material

Liquid metal

Temperature

Pig Iron and  Ferro alloy

1000-1800 deg C at pouring point

Capacity

500 tones / day

@ 8 to 12 hours/day

 

Speed

1 – 12 Meter / min

 

Length of the machine

42.70

 

Slope

7.9 degree

Area covered (approx.)

 

180 M2

Product mass

No. of Iron block Casting per Mould

Wt. of each Pig

4 per Mould

 10 kg

Ladle Capacity

Trunion mounting lip pouring

12 – 8 MT of Hot Metal

Control

VVFD

 

Voltage

440 +/- 10%, 50 Hz. +/- 5%, 3 phase

 

Power Consumption

Drive Strand

Lime Sprayer

Lime milk agitation       

Cent. Grease lubrication

Requirement of utilities

30 KW x 1000 rpm AC Motor

5.5 KW x 1440 rpm AC Motor

3.7 KW x 1440 rpm AC Motor

No

15 KW x 1440 rpm AC Motor

Time required

to cast 12 T ladle at different speed

12 – 15 min

cooling of casting block in Strand

Time for air

Time for water

2 min.

4 min

Total Weight of Machine

 

96,000 kgs (approx.)

Drive

Sprocket. Center

34.70 M

 

Chain pitch (mm)

540

 

Details of Gearbox and coupling

Helical & Gear type

 

Gear Ratio

1/400

Mould

Weight ratio of casting / mould

1 / 3

 

No. of Moulds per strand

269

 

Weight of heaviest part in kg    

3500

 

Temp. of casting at discharge end

180 deg C

Launder

Fabricated, anchor welded,

refractory details

G.A drawing PEIE-34-M1-X

Lime & graphite Spray

Lime milk preparation and spray arrangement

G.A drawing PEIE-34-M1-X

 

Lime spray pumps

5.5 KW 20m3/hr @ 10 kg/cm2 Creative Slurry pumps

 

Lime agitator

3.7 KW 15 rpm 6” blade (S.S 304 ) agitator with vertical geared motor

Roller arrangement details

ᶲ 200 mm Forged with collar , hardened

GA Drawing

Pig knocking device details

Mechanical cam driven rotating wheels strikes on 1st & 3rd pocket of mould

GA Drawing

 

Grizzly details

Standard

Details of chute for stickers

Wear resistant steel, bottom Rail

Fabrication drawing

 

Detail of splashing guard and trolley

Not applicable

 

Details of strand tightening device

GA Drawing

Material of construction

 

Sprocket

Moulds

Chain links

Rollers 

Splash guards  

Chute liners

Sprocket shaft

: IS : 2707 Gr.II

: Cast Steel IS 3038-92 Gr IV

: IS : 1030

: Carbon Steel

: MS

: Mn steel and Rail

: C45

water spray

water spray nozzles by dia 100 perforated header anti gravity

GA drawing

Lubrication

Automatic splash droplet to moving parts

GA drawing

Structural

Structural column, support  ISMB 250

Rail 90 lb

Drive base built up, gussets pedestal , platform, runners, M.S. 8, 12, 16 mm

Tie bracing ISA 150

Walkway grating 25X6 ms flats,

Hand railing dia 40 ERW ms

9662 kg

6066 kg

9000 kg

 

1500 kg

2500 kg

350 M

De-noise arrangement

to piglet with chain and Deflector

GA Drawing

Pollution under control

Monitor truss & Steam and Fume hood

Fabrication & GA Drawing

Painting terms

Standard

Equipment: Synthetic Enamel,

Structural.: Primer

 

GENERAL PROCESS DESCRIPTION

Tapped molten metal filled PEIE-Ladle shall be placed in position of PEIE-Ladle-stand to match it’s Trunion with Ladle Tilting arm.

 

.Hot metal shall be poured on C.S. Mould of Pig casting Machine through PEIE-Hot-metal-runner  when tilting of ladle by action of winch or overhead crane.

An inclined chain conveyor having a set of overlapping Moulds fixed between a pair of chain Link carries set of rollers which moves over Rail.

 

A set of sprockets on either side of the PCM one of which is driven (idle/Tail-sprocket) and the other is driving/ Head sprocket are mounted on technological structure.

The VVVF drive AC motor coupled(Pin-bush) to a multistage Helical reduction gear box, the output shaft of which is connected through Geared coupling to the driving sprocket shaft supported at the ends by bearing.

 

After travelling the distance of metal for solidification time , the formatted Pigs shall be fed into water quenching by PEIE-water-spray-Twin-Header

The Pig Knocker facilitates to strike the pigs at discharge end which fall down to direct Dumper through a Pig-Discharge-Chute

 

Lime spray(Graphite powder mixed) coating shall be done on return moulds ~1.2 specific gravity to remove stickiness of pig  .

Wear resistant Slurry Lime pump shall be used for spray and recirculation

S.S-304 Blade  vertically Agitator mixes the lime slurry into concrete lime mixing tank

 

Water spraying and  recirculated  circuit tank hold minimum 100 m3 of water and the clear water pumps shall be used for cooling purpose of Pig.

Spillage collecting Tray contains sand to easy removal of spillage if.

 

A slow speed pouring of Ladle winch shall be provided for ease of operation.