ACETARC Engineering

Foundry Ladles

Acetarc Engineering is an ISO9001 registered company specialising in the design and manufacture of all types of foundry ladles plus associated equipment.

We bring over 35 years of experience to build you the very best equipment.

A range of Heavy-duty products that are manufactured by cra�smen engineers using proven methods and techniques. Our symbol is the WORKHORSE; solid, reliable and enduring.

Our full design & manufacturing capabilities enable us to provide tailor-made and cost effective solutions for your foundry ladle requirements; from initial consultation, through to final design and manufacturing.

• Transfer & casting ladles • Treatment ladles for the production of ductile (S.G.) Iron • Porous plug ladles for desulphurising processes • Teapot spout ladles • Bo�om pouring ladles • Lip-axis pouring ladles • Drum & U shaped ladles • Aluminium tapping ladles

Geared ladles are available with capacities of up to 40,000Kg (88,000lb)

Un-geared ladles are available with capacities up to 100,000Kg (220,000lb).

Geared ladles can be supplied with either manual or motorised gearbox rotation.

In addition to foundry ladles we also design and manufacture the following equipment:

• Ladle pre-heaters • Crucible handling equipment • Furnace charging equipment • Monorail & crane systems • Foundry handling equipment

Introduction

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Introduction

Acetarc ladles are made to order. This means that we can fine-tune the design to suit your specific requirements.

Acetarc ladles are manufactured as right hand pour unless otherwise specified. Ladles are classed as right hand pour when the ladle pouring spout is at the operator’s right, as the operator stands facing the gearbox.

Acetarc ladles are supplied without refractory linings. The supply and fi�ing of all refractory and lining materials is the responsibility of the client.

Acetarc are happy to quote for the supply of a steel re-usable lining former to match a specific ladle.

The more information you can give us, the more accurate we can interpret your requirements.It will greatly assist us if you can supply the following details concerning the ladle you wish to purchase:

Working capacity of the ladle

Type of metal that the ladle is to be used with.

Type & purpose of the ladle (i.e. casting, transport, treatment)

Lining allowance required.

Pouring type. (Lip-pour, bo�om pour, teapot spout or lip axis etc).

Gearing required. (un-geared, manual gearbox or motorised rotation).

Right hand or le� hand pour.

Any special features (Cover, low headroom, li�ing bail, detachable base section etc).

How the ladle is to be handled. (Overhead crane or monorail, forkli� truck, dedicated handler or special tilting frame etc).

Important Facts Concerning Acetarc Foundry Ladles

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Typical Sizes For Standard Lip Pour Ladles (Cast Iron)

CAPACITY:Kg ØA ØB C D E F G H I ØJ SIDE

LiningBOTTOMLining FREEBOARD

250 445 355 460 480 962 260 1089 395 673 305 45 45 75400 495 420 570 590 1102 286 1147 425 702 305 50 50 75500 610 535 610 630 1107 345 1355 508 827 460 60 60 75610 635 560 635 655 1140 410 1395 535 840 460 65 65 75750 710 635 710 730 1245 420 1405 535 855 460 65 65 75

1000 740 660 740 750 1290 450 1455 560 880 460 65 65 751250 790 685 790 810 1485 482 1545 605 920 600 75 75 1001500 850 770 850 870 1495 495 1570 615 935 600 75 75 1001750 890 785 890 915 1650 510 1710 735 975 600 75 75 1002000 950 850 950 965 1880 550 1830 750 1080 750 90 100 1002500 1040 915 1040 1060 1940 620 1890 760 1130 750 95 100 1253000 1090 940 1090 1115 2032 640 1935 770 1145 750 95 100 1253500 1125 990 1090 1145 2050 660 1990 790 1200 750 95 100 1254000 1160 1020 1160 1185 2085 680 2000 800 1170 750 100 100 1255000 1220 1066 1220 1245 2145 710 2100 850 1221 750 100 100 1506000 1320 1160 1320 1345 2470 755 2310 915 1380 900 100 100 1507000 1390 1240 1390 1420 2530 795 2310 915 1380 900 110 110 1508000 1480 1300 1480 1510 2630 850 2406 960 1427 900 120 125 178

10000 1560 1425 1560 1590 2770 890 2550 1040 1475 900 125 130 178

Please note that the dimensions given are offered for guidance only and should not be taken as binding. If you do not see the required capacity or have special requirements, we are happy to adjust the ladle sizes to suit your specific needs.

Capacities are in Kilograms. Dimensions are in Millimetres and subject to change.

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The heavy-duty ladle design is shown below but the dimensions given are also applicable for the Westminster medium duty ladle designs.

Side and base lining thicknesses are suggested allowances and should not be taken as binding.

When the ladle is fi�ed with the suggested lining allowance and filled to the given freeboard level, the ladle will have the working capacity given when filled with molten cast iron having a density of 6643Kg per cubic metre.

Acetarc ladles shells are designed to take into account modern refractory linings. The working capacity of the ladle is therefore quoted for a given metal density, the lining thickness (sidewalls and base) plus a freeboard (distance between the top of the molten metal and the top of the ladle).

If any of the above factors alter, the working capacity of the ladle will correspondingly change as well. If the suggested lining allowances do not meet with your specifications, the Ladle shell size can be adjusted to take into account special refractory lining requirements. ladles shells can be increased in size to accommodate thicker linings without compromising either the ladle capacity or the freeboard.

Special pre-formed refractory liners for ferrous and non-ferrous ladles.Acetarc ladle shells can also be manufactured to accommodate the pre-formed ladle linings supplied by specialist refractory companies. Contact our office for further details.

Ladles should never be filled to the brim to achieve the required capacity.

Ladles are designed to have a minimum freeboard in accordance with British and European standards. Treatment and porous plug ladles are offered with an extended freeboard to take into account the reaction.

The trunnion positionThe trunnion position for a ladle is located in line with the British Standard for foundry ladles.

The trunnions are located so that the ladle is balanced on the trunnions when the ladle is filled to its working capacity.

The trunnions position is calculated by taking into account all relevant factors such as:

• Lining thicknesses • Metal capacity, and density • Freeboard

Plus any special features that are a�ached to the ladle body such as; covers, fork pockets, extended spouts etc.

The ladle shell is either line bored or has the trunnions fi�ed using special jigs to ensure that the trunnions are correctly aligned.

Ladle Shell, Lining Allowances, Freeboard and Capacity

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In addition to the standard manually operated gearing, Acetarc Workhorse ladles can be fi�ed with a motorized gear assembly for the rotation of the ladle. The ladle construction is identical for both the manual and motorized ladle options. The ladle is usually fi�ed with an electric gearmotor but other options such as pneumatic powered gear motors can also be fi�ed.

The Motorized Tilting Arrangement.The ladle tilting arrangement consists of a motor gear unit and an Acetarc gearbox linked, via a quick release clutch assembly, to give a double reduction gearing resulting in high torque with a low output speed. The gear unit is protected by a steel splashguard enclosure.

The ladle gearing allows the ladle to be rotated in both directions at a nominal fixed speed. The required speed of rotation is normally discussed with the client and is chosen to give a full to empty (vertical rotated around to horizontal) of usually 20-40 seconds depending on the application.

When the clutch is released, the two drives are disengaged; the ladle can then be fi�ed with a handwheel and rotated manually. The Acetarc gearbox fi�ed to the ladle is the same size on the manually rotated ladles as it is on the motorised ladles.

The Torque Limiter (electric motor drive).As standard, in addition to the clutch arrangement, the electric drive motorised gearing assembly is fi�ed with a torque limiter.

This is designed to act as a fail-safe device in the event that the load on the gearing becomes excessive due to some outside influence. For example the ladle fouling on a static object whilst being rotated.

In the event of an overload, the torque limiter will automatically disengage the two gear units. This means that even if the operator does not fully appreciate the situation and continues try to rotate the ladle, the gearing will not suffer damage. To re-engage the torque limiter, the motor drive need only be rotated in the opposite direction.

Control Equipment for Electric Motor Drive LadlesUnless otherwise stated in a specific quotation, all Acetarc electric drive motorized ladles are supplied to the customer without control equipment.

It is the customer’s responsibility to fit suitable control equipment for the safe and efficient operation of this equipment. However, if the customer wishes Acetarc Engineering to supply the control equipment, we would be happy to offer a quotation following full consultation with the customer.

Acetarc Ladles Fitted With Motorized Gearing For Powered Rotation.

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Pneumatic Drive LadlesWhere required, ladles can be fi�ed with pneumatic motor drive units.

Pneumatic motor drives are ideal for hazardous or hostile environments and offer a number of advantages over standard electric motor drive ladles.

• The ladle rotation speed can be adjusted, between maximum and minimum speeds, using flow regulators mounted on the ladle.

• If the motor stalls, due to an overload situation, the motor will not be damaged.

• Smooth starting, does not impose shock loading on the other gear drive components.

• Unaffected by and will not generate electrical interference.

• Pneumatic drive ladles are supplied with forward and reverse controls, a filter regulator lubricator unit, flow regulators and a quick release airline connection as standard.

Acetarc Ladles Fitted With Motorized Gearing For Powered Rotation (Cont.)

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(Photograph le�): shows part of a shipment of twenty motorized tun-dish treatment ladles supplied to the Victaulic group, USA.

Acetarc later supplied the same type of ladle to the new Victaulic foundry in Poland

The WORKHORSE range of foundry ladles are the result of over thirty-five years of experience in the design and manufacture of heavy-duty ladles for all foundry applications. Manufactured in a range of standard rated capacities, starting at 100Kg and going up to 40 tonnes (cast iron) for geared ladles, the WORKHORSE ladle is designed for continuous and trouble free service over long periods. Where there are special factors to be considered, the modular design of the WORKHORSE ladle allows individual ladles to be designed to suit a customer’s specific requirements both quickly and with minimum extra cost.

The WORKHORSE ladle designs form the basis for the following main types of foundry ladle:

• Casting or transfer ladles; either fi�ed with lip pour spouts, extended spouts or teapot spouts. • Bo�om pouring ladles. • Ductile iron (S.G. Iron) treatment ladles.

WORKHORSE Heavy-duty Foundry Ladles

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The main features of the WORKHORSE heavy-duty ladle are as follows;

The Ladle shell is tapered for increased strength and rigidity, with reinforcing bands top and bo�om in addition the centre band. Depending on the size of the ladle shell, extra reinforcement is added to the ladle shell by the addition of under-straps. The complete assembly is of fully welded construction.

The Main Features Of The WORKHORSE

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The standard WORKHORSE ladle design incorporates AIR VENTED BOLT ON TRUNNIONS and the mounting assembly for the trunnions is stepped off the shell to give a free flow of air behind the trunnions. This reduces the heat transference from the ladle shell to the gearing.

The bolt-on trunnion design allows the li�ing assembly and gearing to be removed far more easily than a conventional design and also enables the trunnions to be easily replaced in the event of wear or damage.

The trunnions rotate in large flexible roller bearings, located in cast iron housings. This type of bearing minimises the effort required to rotate the ladle and, unlike the plain bearings o�en used by other manufacturers, .is less prone to tramp metal pick-up that can cause scoring or seizure of the trunnion.

The sidearms are of laminated construction to give a strong and rigid assembly whilst minimising the weight. They are machined to accept the li�ing bail assembly, which consists of two steel channel sections and a li�ing hook.

All ladles are load tested on the calculated gross li�ing load as standard, prior to shipping the Ladle.

Certificates are supplied with the ladle.

From simple open top deep treatment ladles, using the sandwich process, through to complete treatment stations with batch feed additives hoppers, weighing and PLC control, Acetarc Engineering can offer a wide range of solutions for the safe and efficient production of ductile (S.G.) iron.

Open Top Deep Treatment LadlesCharacterised by their tall body with a small diameter, the ladle shell incorporates an extended freeboard to contain the reaction.

The basic design can be adapted to give: • Wire feed ladles • Plunging ladles • Porous plug desulphurising ladles

Tun Dish & Teapot Spout Covered Treatment Ladles Acetarc Engineering can offer several covered treatment ladle designs, including loose tun-dish; fixed tun-dish, sliding tun-dish and teapot spout treatment ladles. These ladle designs offer considerable improvement in performance for li�le additional capital cost when compared to open top deep treatment ladles using the sandwich method.

The main advantages are: • Increased magnesium recovery, o�en allowing a reduction in the amount of additives used. • Fume and glare reduction, leading to a be�er working environment and removing the need for costly fume extraction. • A more consistent treatment process. • Reduced temperature losses. • Reduced slag and dross generated.

Leading to a be�er and consistent quality of castings.

Covered treatment ladles can be supplied with optional extras such as spare ladle bo�om sections.

Where a ladle has a bolt-on section such as the spout or base, the flanges are made from heavy-duty steel with extensive gusseting for increased stiffness. The flanges are jig drilled to ensure interchange ability.

Ladles can also be fi�ed with loose base plates so that the complete shell lining can be removed using a hydraulic ram assembly.

Treatment Ladles For The Production Of Ductile (S.G.) Iron

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The treatment process is the same as a conventional tun-dish ladle but the sliding tun-dish addresses some of the problems associated with the handling of the tun-dish lid. The ladle is based on the WORKHORSE ladle design and has extended sidearms with an inner li�ing bail that can move up and down.

The tun-dish cover is a�ached to the inner li�ing bail so that when the ladle is li�ed up, the tun-dish cover is also raised up and when the ladle is placed on the ground; the tun-dish cover is lowered down.

The tun-dish must always be raised before the ladle is rotated. When the ladle is being rotated, it handles the same as a similar sized conventional ladle.

Lining FormersWe can supply re-usable lining formers especially designed to complement the treatment ladles. The lining formers are manufactured in steel plate and can be supplied in pieces to assist with the fi�ing and removal of the former. This also enables base sections to be fi�ed with linings independently of the main body.

Sliding Tun-Dish Treatment Ladle

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The Workhorse & Essex heavy-duty ladle designs can be fi�ed with a bo�om pour gear assembly for slag free tapping of the metal from the base of the ladle.

Bo�om pour gear ladles incorporate a number of modifications to the basic heavy-duty ladle design: The ladle is fi�ed with a detachable nozzle box in the base of the ladle.

The ladle has three feet added to the base of the ladle, to give clearance on the nozzle box.

The ladle shell sizes are adjusted to ensure that the working capacity is maintained, even when the displacement of the stopper rod refractory sleeve is taken into account.

The stopper rod and nozzle box are usually designed to suit Vesuvius Refractories but can be made to suit other manufacturer’s equipment on request.

The articulated bo�om pour gear can have the operating lever set to be used over a 180� degree radius and is also fi�ed with locking bars to keep the stopper rod closed whilst the ladle is being transported.

On larger ladles two bo�om pour gear assemblies can be fi�ed if required.

Contact our design office for ladle size and specification details.

Heavy-Duty Drum and U Shape LadlesDrum & U-shaped ladles can be supplied for capacities up to and including 10,000Kg (22,000lb) C.I. and are normally based on our heavy-duty designs with shells fabricated from heavy steel plate with reinforcing straps etc.

Vee bails can be fi�ed on the smaller ladles on request.

Motorized gearing options are available for powered rotation.

Both end plates on the drum ladles can be unbolted and removed, to aid in the relining process.

The ladles can be supplied with various spout arrangements, including offset and central positioned spouts. Single or double spouts can also be fi�ed.

The filling slot can be fi�ed with a swing aside or pull back cover for maximum heat retention.

Bottom Pour Ladles

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All Acetarc geared ladles are fi�ed with the appropriately sized gearbox to give safe and efficient control of the rotation of the ladle. The gearbox is a proven worm & wheel design with all moving parts rotating in bearings, with either oil or grease lubrication, for maximum life with minimum effort.

The gearbox is not bolted directly to the sidearm, but is instead fi�ed with a drive plate that engages with a drive peg that is a�ached to the ladle sidearm.

This method of mounting the gearbox reduces wear on the gears and leaves them unaffected by crane vibration.

Gearbox Spare PartsGearbox spare parts are normally ex-stock and can be dispatched within 24 hours of an order being placed. The gearbox should be able to be identified by either the ladle badge, usually located on the li�ing bail, and/or the number cast into the gearbox front cover. If these are either missing or damaged, measuring the gearcase outside diameter can identify the gearbox. Alternatively, if the gearbox is stripped down, the gearbox can be identified by the diameter, and no. of teeth, of the wormwheel. It is also always useful to give the ladle shell size and rated capacity. If in doubt contact the office.

The following diagram gives a schematic view of the typical Acetarc gearbox (sizes 1 to 4). Further details are given in the ladle manual and parts lists for specific gearboxes can be forwarded on request.

The Acetarc Oilbath Gearbox

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For additional security, the No. 3 & No.4 gearbox has the worm wheel fi�ed to the trunnion sha� using both a parallel key and a cone-clamping device.

Available in sizes up to 4000Kg (8800lb) capacity (C.I.), the Westminster type ladle is designed for foundries who require several capacities with economy, quality, and short runs in mind, but who also require a robust ladle of dependable service. The ladle is ideal for aluminium foundries, and the ladle shell can be made to accommodate either standard castable refractory linings, pre-cast liners or a crucible liner etc.

The ladle is fi�ed with the same range of gearboxes as the Acetarc heavy-duty ladles.

The taper shell is of an all welded construction, rolled from steel plate and the bo�om plate is driven in and welded inside and out.

The trunnions rotate in replaceable cast iron bushes and the li�ing bail is made from solid rectangular section with back-to-back top channels. Vee bails are also available if required.

The ladle can also be fi�ed with a cover to reduce heat losses and protect the operator.

Please contact the design office for further details.

The Westminster Medium Duty Geared Crane Ladle

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Westminster ladle with Vee bail and teapot spout

Many of our foundry ladles are specially designed and manufactured to meet a foundry’s specific requirements. We are always happy to discuss your ladle applications and offer advice based on our long experience of providing molten metal handling solutions.

Special Ladle Applications

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Top le�: Lip-Axis ladle for pouring cast iron.

Bo�om le�: The un-geared crane ladles shown above were designed and built in accordance with A.I.S.E. 9 and used a detachable li�ing bail for handling the ladles.

Top right: Vacuum Tapping ladle for transporting aluminium.

Bo�om right: Lip-Axis ladle for transferring and pouring 1000kg aluminium complete with man riding cab, installed with a dedicated monorail system. The Lip-axis ladle uses hydraulic rams for tilting the ladle, which can also be raised 1500mm.

Look for the sign of the

WORKHORSE

Special Pouring Units•

Crucible Handling Equipment•

Monorail & Crane Systems•

Furnace Charging Equipment•

Foundry Handling Equipment•

Ladle Pre-Heaters

Workhorse Foundry Ladles

Acetarc Engineering Co. Ltd.Atley Works Dalton Lane Keighley West Yorkshire BD21 4HT

T: +44 (0) 1535 607323 F: +44 (0) 1535 602522 E: sales@acetarc.co.ukwww.acetarc.co.uk

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