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Casting plants for aluminum

Casting
Leading technology in the aluminium casthouse

The SMS group company Hertwich Engineering designs, supplies, constructs, and commissions machinery and equipment for the aluminum industry worldwide. It focuses particularly on aluminum casthouses, supplying:

1. Horizontal casting plants for ingots, busbars, and billets
2. Vertical casting plants for extrusion and forging billets
3. Open mold ingot casters (air & water cooled)

Horizontal, vertical or open-mold casting? Each of these methods has its merits for different applications

Horizontal casting plants

Very different products can be manufactured on horizontal casting machines, which is why they are also referred to as "universal casters". They are ideal for the production of:
 

  • Foundry alloy ingots
  • T-bars
  • Busbars and anode rods
  • Extrusion billets
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Foundry alloy ingot caster

The melt passes without any turbulence from the furnace to the tundish of the casting machine. Then it travels through the transition tubes into the mold entirely shielded from the atmosphere. That means no oxides can form and enter the ingot.

T-bars emerging from the moulds T-bars emerging from the moulds T-bars emerging from the moulds T-bars emerging from the moulds

T-bar caster

Currently, these plants produce T-bars (850 x 300 mm) containing up to 11% silicon at a maximum output of 17 tph. The T-bars from our HDCs meet the highest customer demands.

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Busbar & anode rod caster

Frequently, primary aluminum producers initially purchase an HDC plant to manufacture busbars for potline construction. Extra-special here is that these plants are also designed for later conversion to foundry products.

Extrusion billets emerging from the moulds Extrusion billets emerging from the moulds Extrusion billets emerging from the moulds Extrusion billets emerging from the moulds

Cast billets

Continuous cast billets can be produced economically on a Hertwich compact remelting line. This concept is particularly suitable for annual capacities between 10,000 and 60,000 tons.

Vertical casting plants

Hertwich also offers vertical casting plants (VDC – Vertical Direct Chill). These are based on a proprietary design. Several plants for casting billets for extrusion and forging as well as rolling slabs have already been put into operation. Hertwich VDC casting systems are equipped with internally guided ceramic-coated casting cylinders and are compatible with all major casting tool brands.

Some outstanding features:

  •     design as single and double VDC caster possible
  •     version-controlled management of casting recipes for continuous quality optimization
  •     active guidance of the operators
  •     fully automatic casting start-up to eliminate subjective operator influences; this leads to constant product quality and improved safety
  •     log tracking system of downstream inspection equipment enables identification of defective molds
  •     operator-friendly diagnostic system for improved maintenance efficiency


Compact-type remelt plants for long profile scrap and VDC casting

A VDC caster, together with a tiltable casting furnace, can also be used as a compact-type remelt plant for long profile scrap. Many extrusion operators choose this type of furnace to remelt clean profile scrap up to 7 meters long at rates of about 3 tons per hour.

Plant Layout

1) Charging and skimming machine

2) Melting furnace

3) Charging well

4) Casting furnaces

5) VDC casting machine

6) Accumulator

7) Continuous homogenizer

8) Cooling station

9) Billet saw

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Open-mold ingot casting

You don’t just get water-cooled ingot casters from Hertwich. We also offer you an air-cooled version. It comes with several improvements and provides an attractive alternative. Common to both types are excellent efficiency, reliability, and product quality.

The casting launder used by Hertwich instead of a casting wheel reduces the cascading effect. That significantly cuts dross formation. It also ensures more uniform ingot height. You choose the downstream packing stations you want, including stacking, strapping, weighing, or marking equipment. All these are available in automated or manual versions. Simply enter your recipe, and the automated casting start ensures perfect safety and operator friendliness.

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Water-cooled ingot caster

In countries with a hot climate, water cooling is vital to achieve the desired production rate. Open-mold ingot casters are traditionally water cooled as a cheap and simple way to solidify liquid metal.

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Air-cooled ingot caster

You can also freeze and cool ingots exclusively with air.
Here are your benefits compared with water cooling:

  • Better ingot quality
  • No shrink holes or cavities, hazard-free remelting
  • No hydrogen pick-up
  • Less wear, longer mold service life
  • Less maintenance
  • No foundation pit
  • No water infrastructure
  • Additional primary cooling of filled molds, secondary cooling of ingots in a paternoster-type cooling tower

Contact

SMSgroup Deubler, Elke

Elke Deubler

Hertwich Engineering GmbH
Prof. Weinberger-Straße 6
5280 Braunau am Inn
Austria

Phone : +43 7722 806 112

SMSgroup Wimroither, Günther

Günther Wimroither

Hertwich Engineering GmbH
Prof. Weinberger-Straße 6
5280 Braunau am Inn
Austria

Phone : +43 7722 806 -112

SMSgroup Oberweger, Thomas

Thomas Oberweger

Hertwich Engineering GmbH
Prof. Weinberger-Straße 6
5280 Braunau am Inn
Austria

Phone : +43 7722 806 112