FOUNDRYINNOVATION

SIMPLIFYING THINGS MEANS PROGRESS

6 WHO WE ARE7 WHAT WE DO8 HOW WE DO9 FIELDS OF ACTION10 FURNACE CHARGING 11 ADDITIVES 12 VIBRANT CHARGER

13 DRYING VIBRANT CHARGER

14 LADLE PRE-HEATERS 15 OXY-GAS AND AIR-GAS HEATERS

16 ENERGETIC MANAGEMENT 7 LABEMASTER

18 TRANSPORT OF LIQUID METAL 19 LADLES 20 AUTOMATIC CRANE HOOK 21 NODULIZATION ADDITIVES

22 AUTOMATIC LADLE CAR

24 PNEUMATIC TRANSPORT 25 PNEUMATIC SAND TRANSPORT

26 LABEHOSE 27 LABEHOSE

28 ELECTRIC ARC FURNACE FOUNDRIES 29 LF-EAF 30 SAMPLING EQUIPMENT 31 DOOR CLEANING LANCES 32 AUTOMATIC ARGON COUPLING 33 APPLICATIONS WITH ROBOTS 34 ELECTRODE REGULATION

35 ELECTRODE CLAMPS

36 SERVICES 37 TELEASSISTANCE 38 GENERAL ASSESSMENTS

TABLE OFCONTENTS

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LABECAST is a highly qualified team of engineers specialized in the foundry sector. LABECAST combines the experience of its founder, Mikel Mendiola, with over 25 years of experience in technical management positions in the foundry world, with the enthusiasm and expertise of a young but very experienced team.

An exceptional human team using the latest technology in the market in an exclusive workshop for control and development of our own products.

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We find solutions to technical problems in the foundry world, based on four basic premises:

THE SAFETY OFTHE PEOPLE WHOPRODUCE IRON.

SAVINGS, ESPECIALLY ENERGETIC ONES.

EFFICIENCY OF ITSPROCESSES.

ENVIRONMENTALCARE.

WHO WE ARE

WHAT WE DO

HOW WE DOThrough the creation of completely new equipment or modernization of existing equipment (REVAMPINGS)Simple equipment, easy to use.Reliable equipment that do not require a lot of maintenance.Equipment designed to suit customer needs.

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FURNACE CHARGING - RAW MATERIAL

LIQUID METAL TRANSPORT - LADLES

PNEUMATIC TRANSPORT-ANTIWEAR HOSES

ENERGETIC EFFICIENCY

ELECTRIC ARCFURNACE FOUNDRIES

HOW WE DO

FIELDS OF ACTION

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FURNACE CHARGING

VIBRANT CHARGER

DRYING VIBRANT CHARGER

AUTOMATIC ADDITIVES DOSING SYSTEM

AUTOMATIC ADDITIVES DOSING SYSTEM

In the foundries it is necessary to add a recipe of ferroalloys in the furnace to achieve a correct chemical composition of the liquid metal.

In order to do that, LABECAST has developed an additives storage system, (LABEADS), which automatically carries out the recipes of these ferro-alloys, quickly and precisely, in permanent contact with the chemical analysis spectrometer.

In addition, communicating this program with the raw material loading crane, it calculates and automatically provides the necessary quantities of additives.

• Robust additive storage silos.• Light indicator and screen warning of minimum

level of additive in the silo.• Quick answer.• Accuracy in the recipe weighting.• Communication with the loading crane to have

an automatic calculation of the recipe.

• Easy to use machine via a touch screen.• Access to all the information, alarms and

historics through the touch screen.• Ease to use, reliability, no maintenance

needed.

The characteristics of the system are:

Advantages:

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VIBRANT CHARGER

LABECAST designs and builds vibrant or continuous furnace chargers.The LABECAST chargers have a large charging bin to facilitate its filling with the scrap yard crane and, at the same time, through vibration or continuous ribbon, they obtain a gradual and controlled charge of scrap to the furnace.

• Valid for induction furnaces and rotating combustion furnaces.

• Robust to resist mechanics and thermal requirements.

• Additive bins integrated in the charger• Possibility of automatically transporting the

additives from the additives system LABEADS to the charger.

• Longitudinal movement from the scrap yard to the furnace with acoustic or light warning for a secure use.

The characteristics of the system are:

• Easy to use machine via a touch screen.• Access to all the information, alarms and

historics through the touch screen.• Reliability, low maintenance needed.

Advantages:

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In cold places where water and ice may accumulate in the scrap, it is dangerous to introduce it directly into the due to the risk of explosions. This is the reason why LABECAST offer the possibility of including drying burners, drying the charge before entering into the furnace, and getting in this way safe charges.

• Combustion burners fitted to LABECAST chargers.

• Work with the aspiration of the furnace – no extra aspiration needed.

• Simultaneous operation of vibration and drying.• Possibility of oxygen-gas combustion-

COMBUSTIBLE SAVING.

• Removal of explosion risk in the charge of the furnace-SAFETY.

• Easy to use machine via touch screen.• Removal of explosion risks in the furnace.• Simplicity, reliability, no maintenance needed.• Low consumption with oxy-gas heating.

The characteristics are:

Advantages:

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DRYING CHARGER

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The ladle heaters have two objectives: to dry the refractory of new ladles and to heat the ladles every time they are about to receive the iron from the furnace.Proper drying requires a certain temperature and a correct pre-heating cycle which allows the penetration of heat into the rear side of the refractory.During the heating process before every heat, the heat application cycle is less strict than in the drying, being the temperature reached on the ladle refractory the most important aspect. The higher this is, the less temperature the liquid metal will lose.

LADLE PRE-HEATERS

OXI-GAS AND AIR GAS HEATERS

OXI-GAS AND AIR GAS HEATERS

Due to the increase in fuel prices and the cost derived from fuel emissions, LABECAST has developed the LABEHEAT heater using oxygen combustion, allowing savings of 40% in fuel consumption, therefore reducing emissions by 40% and eliminating NOx completely.

• Heaters for ladles of treatment.• Heaters for casting ladles with or without

liquid metal.• Easy use of the machine through the touch

screen.• Regulation of the power by stages for a correct

drying.• Possibility of automating the whole cycle

included the security turned on.

• 40% fuel saving.• 40% CO2 reduced emissions.• Reduced dioxin generation (NOx).• No fans required.• The ladle can reach higher temperatures thanks

to a higher temperature of the oxygen flame.• Ease of use, reliability no maintenance needed.

Characteristics:

Advantages:

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ENERGETIC MANAGE-MENT

LABEMASTER

LABEMASTER

Steer your Foundry production having intelligent energetic judgment.LABEMASTER manage the scheduled production to reach a clear target:

Intelligent tool (hardware + software) that:

• Reduce to maximum the electric contracted power.

• Minimize electric consumption, analyzing trends.

• Schedule the Plant production with minimal energetic consumption criterion.

• Create and store historical information about charges and consumptions.

• Is very easy to customize to each particular case.

• Present a very short ROI.

Advantages:

MINIMUMPROCESS STOPPING COST

+ =ENERGETIC COST

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LADLES

NODULIZATION ADDITIVES

LIQUID METAL AUTOMATIC TRANSPORT CARRIAGE

LABEHOOK

LIQUIDMETAL TRANSPORT

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LADLES

LABECAST designs and builds its own ladles for the iron transport with a specific solution for each customer.Following all the required regulations and tests and with an exceptionally robust design specific for the use that they will be exposed to. LABECAST ladles are a safe and efficient solution for de transport of iron in the foundries.

SAFETY! – LABECAST in his search of security for the operators that work in the foundry, includes in its ladles, security systems to make the ladle recover its verticality slowly and in a controlled way in case of any break in the cinematic chain.

The ladles can be:

• Ladles with tap hole.• Ladles for casting by the bottom.• Ladles with or without TUNDISH-COVER.• Ladles for the transport with forklift.• Ladles with electric or pneumatic drive for its

overturning.

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LABEHOOK

The patented LABECAST automatic crane hook is equipped with a magnet on its lower section.

When the magnet is close to the load, it attracts and positions the sling. The user pushes the control button, the hook closes, catches the ring and lifts the load without any additional handling. The system works with cable slings and even bigbags.

Using the new and patented LABECAST automatic hook, you will pick up and release loads remotely, avoiding any handling and travelling.

The LABECAST hook system brings you the safest and most productive working method ever.

The magnet attracts the ring.

Adjusts the lifting hook.

And elevates the load.

HOOK MODEL

WORKING LOAD LIMIT

OPTION

5.000 KG 10.000 KG 20.000 KG

EVO 5 EVO 10 EVO 20

B10-- -- --B20 B20L L L

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SPHEROIDISATION ADDITIVES

En las fundiciones de hierro nodular se hace necesario antes de recibir el caldo, poner en la cuchara el material nodulizante y su cubriente (para retardar la reacción), así como otro tipo de aditivos. Esta operación puede ser automatizada con el sistema de almacenaje y dosificación de aditivos LABEDOS, que automáticamente realiza las recetas de estas ferroaleaciones de una forma rápida y precisa y las vierte en la cuchara de forma apropiada antes de que se cuele el hierro líquido en ella.

Además del sistema de dosificación de aditivos, LABECAST pone a disposición del cliente su experiencia en tecnología TUNDISH COVER para conseguir el máximo rendimiento del magnesio en la reacción de nodulización.

• Robust additive storage silos.• Light indicator of minimum level of additive in

the silo.• Records of recipes.• Quick response.• Accuracy in the recipe weighting.• Controlled spill in the ladle to ensure optimal

reaction.• With or without TUNDISH COVER technology.

• Nodulising material saving.• Process traceability. • Easy to use machine via a touch screen.• Access to all the information, alarms and

historics through the touch screen.• Reliability, no maintenance needed.

The characteristics of the system are:

Advantages:

LIQUID METAL AUTOMATIC TRANSPORT CARRIAGE

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Liquid metal automatic transport carriageNormally in the foundries operators controlled cranes or forklifts are used to transport the liquid metal from the melting furnace to the casting lines. As a consequence there are important problems of productivity and safety for the operators. To solve it, LABECAST has developed a liquid metal automatic transport system LABECAR.

With LABECAR the ladle with the liquid metal goes automatically from the melting furnace, where it receives the liquid metal, to the casting line where it is poured.

• Automate and minimize de cycle time. Remove the operator´s direct intervention during this cycle, increasing Safety in the Production.

• Repeatability and reliability of each cycle.• Remove errors of manipulation.• Plan a more tight production.• Release the crane.• Create and store historical information about

charges and cycles.• It is very easy to customize to each particular case.• It presents an extremely short ROI.

Advantages:

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SAND PNEUMATIC TRANSPORT

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SANDPNEUMATIC TRANSPORT

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SAND PNEUMATIC TRANSPORT

Sand pneumatic transport equipment assures its sealed movement from its reception on the sand storage silos, as well as its return from the demoulding process to the correspondent storage silo. In this way, the environmental and industrial hygiene regulations referred to moulding sands and core shops are guaranteed.

The system is formed by a silo whose dimensions are adjustable according to the client´s needs (from 40 m3 to 100 m3) and a variable pressurized dispenser of between 1000 and 5000 l.

• Automatically adjustable sand flow between 10-90kg/min.

• Silo automatic air cleaning filter. • Pressure/under-pressure safety valve.• Continuous control of the dispenser´s pressure.• Used air flow control.• Anticlog system in the transport line.• Weighing system.• Anti - abrasive curves.

• Sand flow control.• Clean atmosphere in the foundry.• Optimal consumption of compressed air.• Removal of clogs in the transport line.• Good ergonomics, a totally automatic piece of

equipment adapted to the production process.• Ease of use, reliability, low maintenance

needed.

The characteristics of the system are:

Advantages:

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LABEHOSELABEHOSE

LABEHOSE: LABECAST HOSES WITH MAXIMUM RESISTANCE TO ABRASION

PRESSURE HOSE

Applications:

• Sand blasting.• Sand transport.• Cement clicker.• Pulverised coke.• Pulverised coal.• Pulverised lime.

Characteristics:

• Great resistance to abrasion.• Good flexibility, equivalent to a rubber hose for

general use.• Can be used bent.

SUCTION HOSE

Applications:

• Grain (pneumatic transport).• Concrete (pressure injection).• Caustic lime.

Characteristics:

• Fine ceramic grains are used in the thermal coating.

• Great resistance to abrasion.• Good flexibility, equivalent to a rubber hose for

general use.• The internal steel wire spiral prevents the hose

collapsing due to suction.• Appropriate for transport of mineral waste, sands,

ferruginous sands, etc. which are mixed with water by suction and/or discharge.

• If necessary, it is advisable to complete the house using clamps and integrated type connectors paced at the end of the hose.

USEPNEUMATIC

TRANSPORT OF GRAPHITE IN A STEEL PLANT.

JET SHOT IN A FOUNDRY.

TRANSPORTED MATERIAL

Coke (3-5 mm) Iron balls. Diameter: 1-2 mm

TRADITIONAL RUBBER HOSE USEFUL LIFE

1 month 2 months

SPECIAL LABEHOSE HOSE USEFUL LIFE

In use after 10 months (24 hours/day, 25 days/month)

Not affected by abrasion for 10 months.

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ARCFURNACE FOUNDRIES

SAMPLING EQUIPMENT

LF-EAF: ARC FURNACE

AUTOMATIC ARGON COUPLING

DOOR CLEANING LANCES

ELECTRODES REGULATION

ELECTRODE CLAMPS

ROBOT APPLICATIONS

LF-EAF: ARC FURNACE

LABECAST furnaces (EAF) and ladle furnaces (LF) have been designed following the criteria provided by our 25-year experience using similar equipment.

• This criteria only admits simple solutions because we know that complicated solutions are not practical in steel plants.

• Robust criteria in our equipment because we know how difficult and demanding steel manufacturing process is.

• Criteria to design parts which are easily detachable and interchangeable with their spares, such as our clamping devices, because we know how difficult and costly maintenance is during short production stops.

• Resource optimisation and efficiency criteria, such as our low impedance circuits, because we know how important it is to save in the production, due to its large use a lot of resources and energy.

• Criteria of minimum environmental impact, such as our combustion equipment, and addition of chemical energy, because steel production can be very aggressive.

• Criteria of personnel safety, such as our EBT closure, because we know that risk is present in some routine process operations.

Characteristics:

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SAMPLING EQUIPMENT

The LABETEMP manipulator has been developed to take the temperature and sample of the liquid metal for its chemical analysis through the slag door. This is done through the deslagging door and with the furnace powered on at all times. The equipment is fixed to the platform on any side of the door, letting enough space in front of the door when it is not in operation. The process is completely automatic and safety is improved because there is no operator in front of the door.

• Refrigerated lance for improved durability.• Quick lance connection for easy replacement.• Automatic operation from the EAF cab.• Adapted to any type of commercial cartridge.

• Totally safe since there is no operator in front of the door.

• Automatic operation from the EAF cab.• It works while the furnace is on.• Angle and insertion depth repetitiveness

increase the measurement reliability.• Easy maintenance.• Touch screen with historic registers, alarms,

process status, etc.

Characteristics:

Advantages:

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WATER COOLED LANCES

It works on the furnace door to clear slag. It injects oxygen at supersonic speed. The lance is supported and moved by a manipulator fixed to the platform or into another surrounding rigid structure. The set can be placed at a distance on either side of the door. By turning the arm, the lance is positioned over the slag tunnel so that the generated oxygen dart melts the trapped slag.Besides the oxygen lance, the machine can incorporate an additional coal lance for the generation of foaming slag.

• Use of O2 for decarburisation and generation of slag.

• Possibility of an additional coal lance for the generation of slag.

• Remote control from the furnace room or by radio control.

• Robust precise equipment.• Water-refrigerated protection shields to protect

the equipment from radiation and splashes.• Easy removal of lances with quick connections

at the back.• Easy maintenance.

• Quick insertion of lances in the tunnel.• Increased O2 injection time.• Increased productivity.• Repetitive and homogeneous results.• The oxygen speed when coming out of the

nozzle helps quick decarburisation.• The amount of O2 used for the formation of

foaming slag is optimised by injecting it below the slag but on top of the bath.

Characteristics:

Advantages:

AUTOMATIC ARGON COUPLING

Argon stirring aims to homogenise temperature and analyse of the steel bath. The manual connection of the argon hose is a risky job, as the operator needs to get close to a ladle full of liquid metal and is exposed to high temperatures, dirt and furnace slag spills. LABECAST has developed a piece of equipment which carries out this job automatically.

LABARGON has been developed for the quick coupling of argon, in a safe and reliable way and with no maintenance needed. The difference between this equipment and other existing systems on the market is that the cylinder reaches out for the ladle and not the other way round. In other pieces of equipment, the coupling is made while putting the ladle on the moving head. The whole ladle weight touches the joint, so joint consumption is high (up to three times per shift, sometimes).

However, our equipment remains hidden in the moving head until the ladle is positioned and still in it. At that time, the cylinder extends and couples against the plate welded to the ladle. Thus, the joint is untouched and joint consumption is reduced to a minimum.

• No more joint problems.• Quick coupling.• System reliability.• Staff safety.• Easy maintenance.

Advantages:

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ROBOT APPLICATIONS

LABEROB is the adaptation of a conventional 6-axis robot to the steel industry environment to carry out certain tasks automatically and in a versatile way.

• Temperature measuring in any furnace (induction, EAF, LF, etc.).

• Sample taking for quality control.• Other tasks that the process needs.

• Tasks carried out quickly and flexibly.• Operators´ safety, eliminating unpleasant

tasks.• Better process quality, eliminating the

possibility of human error.

Characteristics:

Advantages:

ELECTRODES REGULATION

ELARC is a recently developed electrode regulation which is equipped with the latest electronic components.

• Simple and reliable measurement, mainly at the transformer´s primary voltage.

• High speed calculation and execution of the commands.

• Several logical criteria: Z=k. I=k. W=k.• Special logic for reducing electrode breakages.• Automatic modification of the set points for

correcting deviations.

• Simple installation.• Reports available per heat, per basket,

instantaneous information for the analysis of particular events.

• Much information for taking decisions.• Simple access to the information.• Comfortable change of set points.• ELARC obtains a powerful application with

minimal deviations from the set point, and thus diminishes the radiation index to the refractory and the consumption of electrodes.

• Very competitive price.

Characteristics:

Advantages:

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ELECTRODE CLAMPS

In LABECAST we have designed our own model of electrode clamps which are operating successfully on multiple clients:

• Fast changing of clamps. The replacement of the conductive copper plate consists of loosing and tightening a few screws. In 20 minutes, the operation can be performed.

• Fast change electrode tightening kit. The clamping system (springs, cylinder, etc) is a kit that is extracted and changed all together. All checks, adjustments and repairs of these elements must be carried out in the mechanical shop, not on the ladle furnace. The change can be performed in one hour.

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Advantages:

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SERVICESTELEASSISTANCE

GENERAL ASSESSMENTS

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TELEASSISTANCE

LABECAST offers its clients a helpline service at all its premises to respond rapidly and efficiently to issues arising where the machine has been placed. Whenever the client requires, and never without his consent, the LABECAST technicians will take control of the machine to offer a quick response anywhere in the world.

• Quick response anywhere in the world.• Access to the whole process information for

correct problem diagnostics.• Permission required from the client for the

connection- PRIVACY.

Advantages:

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Our full name is LABECAST Engineering and Services, the word “services” is there for a reason, because we add to our engineering activity some consultancy services which will help those who trust us.

Help to diagnose a problem, to quantify it, to measure times, to analyse bottlenecks, to assess the efficiency of the current processes, or to compare possible alternatives... A myriad of technical organisation fields which we make available to our clients and friends:

• Our experience, after 25 years in the sector.• The impartiality and objectivity achieved by being external agents.• The dedication and time that our clients cannot give to tasks other than those. demanded by all aspects of daily

management.

From there, LABECAST might have finished its relevant work or continue, depending on the client´s specific needs.

We are requested in multiple fields, but the two most in demand are improvement in the use of energy and productivity increase.

To do this, we have developed a detailed methodology which offers a quick and precise response.

GENERAL ASSESSMENTS

1. WE START WITH SOME INFORMATION ABOUT OUR OBJECTIVES.

2. FOLLOWING WITH OUR ANALYSIS TASK AT THE STEEL PLANT.

3. THE ANALYSIS TASK AT LABECAST.

4. AND THE PRESENTATION OF RESULTS AND SOLUTION PROPOSAL.

SIMPLIFYINGTHINGS MEANS PROGRESSPARQUE EMPRESARIAL ZUATZU EDIFICIO EUROPA. 5ª PLANTA LOCAL 220018 DONOSTIA - SAN SEBASTIÁN GIPUZKOA / SPAINTFNO.: +34 943 22 59 85 / FAX: +34 943 22 59 86www.labecast.com / labecast@labecast.com