We provide turnkey installation for producing aluminum wire rod through con-tinuously casting and rolling route . Aluminum wire rod rolling mill is available for different wire rod diameter and with capacity ranging from as low as 300 tons per month to 2000 tons per month . Different equipments used for the manufacture of aluminum and alloy wire rod are -

CASTING MACHINE
Suitable to produce EC/CG/Alloy wire rod of 6 mm to 12 mm dia @ 1 to 5 MT/hr. The construction shall be all steel heavy duty fabricated struc-ture with casting mold of 1200 to 1800 mm dia. The machine shall be provided with internal and external cooling system. A suitable drive along with reduction gear box is connected to the casting wheel. An ad-justable Idealer Wheel system with belt tensioning device is fitted on casting wheel. Pneumatic belt press roll system presses the belt on cast-ing wheel. Inner and outer water spray jacket shall be made out of SS 304 material. An internal spray system shall be divided in to compart-ments having individual valve for regulation of flow of water. An outer spray jacket shall be divided in to different compartments having indi-vidual valve for flow control of water. The speed of the casting machine shall be variable between .5 to 4 RPM. The casting machine shall be pro-vided with horizontal pouring system with metal flow control attachment. The casting machine shall be able to deliver metallurgical sound cast bar up to 5 tons per hour for EC grade material and @ 4 tons per hour for 6201 grade alloy material.

A unique design developed by Arihant Engineers is capable to wind aluminum wire rod up to 15 mm diameter and weighing up to 3 tons. Steel industries ap-plication require layer to layer winding of aluminum wire rod for fast injection of wire in to molten steel ladle. Our company has developed complete line for aluminum wire rod coiling machine for perfect layer to layer winding specially for steel plant application. Our several installations are running successfully all over India.

TECHNICAL SPECIFFICATIONS

Twin reel coiler is a rotary turn table coiler. The coiler is mounted in line with the strip rolling mill. This will be equipped with heavy duty reduction gear box with output drive at both ends. The drive will be alternate to individual coiler through clutch brake unit. Once the first coiler completes the winding opera-tion, the complete unit can be turned to 180 degree so that the second coiler will be in line with the rolling mill. This will reduce idle time for winding. The complete unit will consist of coiler unit, gear box, clutch and brake unit, mounting bearing and two sets of expandable collapsible type coiler unit mounted on the common base.

TECHNICAL SPECIFFICATIONS

The equipment consist of steel ring mold different diameter and having a cross section area varying from 300 x20 to 100 x 20 or other thickness is also available as per the requirement of customer . The top off the mold is covered with endless steel belt pressed against the mold with the help of belt pressing roll. Two rows of adjustable type SS nozzles are provided for the cooling of in-ner mold wall. Segment type outer spray with SS nozzles is provided for belt cooling. Metal Tundish with ceramic tip is provided for metal feed in to the mold .guide rollers along with floating guide is provided for the support and guide of strip. The drive to the caster is with drive coupled through double stage reduction gear box. The caster can operate with max speed of 2 rpm and min speed of 0.5 rpm.

Arihant Engineers Ingot Casting machine has been developed to give trouble free production of Aluminum /Lead/Zinc and its alloy. Metal is poured from the furnace in to the casting wheel/Tundish and the system accurately controls the volume of metal in to each mould. The filled moulds travel up the incline, where they are water cooled. As the molds pass around the head sprocket, they invert, allowing the ingots to fall by gravity- assisted by two knock out hammer.

Combining our technical expertise with latest technological development, we offer ingot stacking line work in conjunction with our widest range of ingot casting machine.

Shredding machine

The mono shear type shredders utilize a multi toothed single rotor working against a fixed anvil, the scrap being forced in to the rotor by a controlled hy-draulic pusher. This machine is characterized by lower energy consumption and quieter mode of operation.

Process

Decoating is the process by which paint, ink, paper, plastic and oil are removed from the surface of a material usually metallic, to enhance recyclables. When coated scrap aluminum is melted directly in the furnace there will be substan-tial metal loss that will vary depending on many factors including.

The fixed axis rotary furnace is nothing more than a rotating tube with burner at one end and a flue at other. The furnace operates under negative pressure and draws cold air from outside thus making it virtually impossible to control the atmosphere of the furnace, which is nearly always oxidizing (air rich). This condition makes it necessary to use large amount of salt to protect the charge. The oil consumption is also high because travel length of flue gas is less. The UTRF furnace on the other hand is a closed chamber design having a single en-trance and exit point. The door carries the burner and the flue. The furnace operates under positive pressure and when the burner is firing there is a total absence of outside cold air therefore the furnace can operate with reduced amount of salt flux. Additionally the furnace operates at an angle, the charge is mixed with a similar action that of a concrete mixture. This improves homoge-neity and heat transfer resulting in a very high thermal efficienc

Functional Description

Chips from machining operations are fed into the screw feeder hopper (A). The screw feeder feeds the chips into the rotary hearth (D) at a constant rate. In the rotary hearth, the chips are typically heated to a set point temperature between 800 and 900°F to vaporize the water and oil. Products inside the rotary hearth (D) are indirectly heated. Natural gas fired burners/furnace oil burner to heat the rotary hearth from the outside. These burners are fired into a cavity between the outside of the rotary hearth and in-side of the furnace shell refractory. There is no direct flame impingement on the chips or extreme temperatures that could result in surface oxidation of the chips.

Technical details
It is basically an impact mill unit. The main grinding unit is a fabricated hous-ing. Hardened impact hammers are housed in main grinding unit. The grinder is powered by 10/25/50 HP 2800 RPM electric motor. Due to heavy impact the aluminum dross is ground to fine particle thus leaving aluminum particle and oxide separated from each other. The grinder is connected to cyclone type dust collector. The function of cyclone dust collector is to separate fine dust and heavy particles. A blower is provided to suck the fine particle and send it to the filter bags. The function of filter bag is to collect very fine dross particles from the grounded product. Filter bags are provided at the top to minimize dust pol-lution inside the factory

Single and Double Decker screens are manufactured as per the requirement. The vibratory screen is most suitable to screen Aluminum dross after grinding to get maximum recovery of aluminum from dross different sixes and varieties are available as per the specific need of the customer. An all SS screen fitted in the machine is easily replaceable type. Different mesh sizes are available as per the specific customer requirement.

Aluminum scrap normally contains iron particles if not removed may lead to increase in iron content in the melt which is not desirable different capacities and sizes are available on request.

Special Features
Maintenance of the Press is very easy.
All Spare Parts are easily available.
Rigid construction.
Replacement of parts is easy & less time consuming.
User – Friendly Press.
All parts are of international standards, hence reliability is more.
Very Easy Hydraulic Circuit.

We provide oil centrifuge system for the cleaning of contaminated furnace oil in order to improve burning efficiency of combustion system. Contaminated oil not only reduces burning efficiency of furnace oil but it also increase down time of combustion system. By continuous cleaning of contaminated oil frequent cleaning of burner nozzles can be avoided. In total it improve burning efficiency of furnace oil and reduces down time of combustion system. We can provide oil centrifuge according to our customer specific requirement. We also provide centrifuge to remove moisture from aluminum chips to improve overall recovery of metals from turning and boring scrap.

We can supply different type of rotary furnace of capacity to suit our customer requirement. This can be for aluminum scrap processing or heating of other materials. We can take up tailor made order for the design , engineering and supply of different type of fixed axis rotary furnace as per the specific require-ment .

Hot dross from the furnace is collected in to a pan. The pan is shifted to dross processing machine by forklift/crane. Dross processing machine is a modified version of Universal Tilting Rotary Furnace. The major difference is that the door of the furnace is completely flush with the furnace and the door rotates with the furnace.

When all the dross is charged in to the furnace. The furnace door is attached with the furnace body and is detached with the door Colum. The furnace is ro-tated at a high speed which separate liquid aluminum metal from oxide. After the rotation the furnace tap hole which is located at the front end is open and liquid aluminum is tapped out by tilting the furnace upward. When all liquid metal is removed, the furnace is moved back to its original position and the door is removed from the furnace. Now all residual oxide with minimum amount of trace aluminum is collected in a pan for disposal .

We offer most advanced Zinc melting furnace of capacity ranging from 1 ton to 50 ton. Different variations are possible to suit specific customer requirement.

Our furnaces are available in different variant like box type furnace, hydraulic tilting furnace and small crucible type furnace for the processing of zinc oxide.

Arihant Engineers Ingot Casting machine has been developed to give trouble free production of all type of non ferrous metal and its alloy. Metal is poured from the furnace in to the casting wheel/Tundish and the system accurately controls the volume of metal in to each mould. The filled moulds travel up the incline , where they are water cooled. As the molds pass around the head sprocket , they invert , allowing the ingots to fall by gravity- assisted by two knock out hammer.

Mould type - 25 kg capacity
Mold Dimensions – 600 mm long x 100 mm width x 40Mm height
Number of molds – 60
Mould material – SG cast iron
Mould cooling – Water spray , 9 spray heads, Total water consumption At 2 bar pressure 100 lts per hour
Knock out system – Automatic dual Knock out system
Pouring system – Casting wheel/ Cam operated tundish , Drive off main chain
Drive Motor – 2 HP AC variable frequency drive
Gear box – 750:1 double reduction worm gear
Conveyor chain – 150 mm pitch bolted assembly
Machine inclination – 13 degree
Machine construction – Robust frame fully welded

The equipment shall consist of an MS ring mold of 1200 mm diameter support-ed on a heavy duty fabricated steel base frame. The drive to the ring mold is by variable frequency drive system and motor through double stage reduction gear box . The equipment is essentially a four wheel construction to cover the outer face of the ring mold by an endless steel belt. The caster is provided with inner and outer SS spray nozzle. Each nozzle can be controlled individually for fine setting of solidification pattern of as cast strip. The belt guide rollers are pneumatically operated with pressure control valve to regulate the working pressure between ring mold and belt guide rolls. The width of as cast strip shall be 300 mm with a minimum thickness of 20 mm. The production capacity of the caster shall be 2 tons per hour.
 

We provide complete plant on turnkey basis for the manufacturing of Zinc wire by continuous casting , rolling and wire drawing process .

Process description

Zinc ingots are loaded in to the hydraulic tilting type zinc melting furnace. Mol-ten zinc from the melting furnace is fed to the continuous caster . The cast bar from the caster is passes through tandem rolling mill for size reduction. A round wire of size 5.5 mm is produced by continuous casting and rolling pro-cess. Further size reduction is carried by specially designed wire drawing ma-chine. Wire produced is packed in cardboard drum by drum packer machine.

Technical details

Universal Tilting Rotary Furnace is a new generation of Rota table and tilt able melting furnace for secondary non ferrous metal extraction. This furnace is lat-est of its kind in the world.

A significant advantage claimed for the UTRF is that it can be both rotated and tilted. First of all, the scrap is loaded in to the furnace with the smelting salt and the furnace is locked shut. By firing the burner that is mounted on door the material is heated with the help of air and oil/gas until it reaches melting point. Heating up is considerably faster resulting in saving of energy as well as melt loss. During the whole melting process, the UTRF rotates. This improves the heat transfer rate from the burner to the material, and additionally, the ro-tating movement promotes the separation of liquid metal from the oxide and other impurities. When all the scrap is melted, the burner can be switched off.

After opening the furnace door, the liquid metal can be poured in to the holding furnace or to the other station by tilting the furnace. Through tilting the fur-nace even further the salt cake can be taken out. Using the UTRF enables a very high yield of material to be delivered with very low energy consumption.

If compared with traditional reverbaratory furnace the yield is 2 to 5 % higher and the energy saving is to the tune of 25 to 40 %. Another significant ad-vantage by this furnace is that metal can be recovered efficiently from the dross. This furnace is highly useful in making master alloy as during the whole melting process the furnace rotates resulting in homogenous mixing of other elements in metal.

An specially designed furnace charging machine suitable for charging of lead scrap in to the tilting rotary furnace is made out of heavy duty MS structure. A charging bucket of 500 liter is placed at the rear end of the charging machine. Two sets of 2 HP vibratory motor is mounted on furnace charging machine. Charging nose is made out of 4 mm SS310 plate. Wear resistant plate of 4 mm thickness is provided on charging bucket to reduce wear and tear. The to and fro movement of the charging machine is by traversing mechanism. The charg-ing machine movement is by reduction gear box and driven by rear wheel. A cable drum with 10 meter cable is provided for the charging machine move-ment. Rail line to be provided by the client.