New 8th China Gold & Precious Metals Summit 2013 · 2013. 12. 11. · 5-6 December , 2013 8 th China Gold & Precious Metals Summit 2013 Contents of the document: 1. Who is IECO Keeps

5-6 December , 2013 8th China Gold & Precious Metals Summit 2013

8th China Gold & Precious Metals Summit 2013

The use of the casting system for the production of Gold and Silver bars

Borghi Alessandro, IECO Keeps On Improving Srl

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Contents of the document:

1 Who is IECO Keeps On Improving Srl1. Who is IECO Keeps On Improving Srl

2. What furnaces are

3. Purposes of the process

4. Disadvantages of the traditional pouring system

5. Research and development of the process

6 Conformity of the bars to the standard Rules6. Conformity of the bars to the standard Rules

7. Surface appearance of the Gold and Silver bars

8. Safe use for humans and the environment (“Green Technology”)

9. Description of a furnace

10. Benefits of the process

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1. WHO IS IECO KEEPS ON IMPROVING SRL


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2. WHAT FLAMELESS TUNNEL® FURNACES ARE


furnace for the production of gold and silver bars

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3 PURPOSES OF THE


• The creation of an innovative process for the production of Gold and Silver barsdevoid of the typical drawbacks of the traditional pouring plants, which

3. PURPOSES OF THE PROCESS

produces Gold and Silver bars in conformity with worldwide rules(LBMA, GOST, CME, DGCX, LPPM, SHFE, TOCOM, ETC);

• Produces Gold and Silver bars with flat and bright surface without additionalmachining;machining;

• The creation of a safe plant for the workers and for the environment (“GreenTechnology”);

• No weight lost;No weight lost;

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4. DISADVANTAGES OF THE TRADITIONAL POURING SYSTEM


‐ Elevated electricity consumption

‐ Elevated heat loss

‐ Loss of precious metal

‐ Elevated need for specialised labour

‐ Elevated accident risk for operators

‐ Environmental impact

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4. Disadvantages of the “traditional melting and pouring system”4 1 Elevated electricity consumption


4.1 Elevated electricity consumption

B B B

A B B 4.1.1

The crucible is only half‐filled with the molten metal (see ref. B

y (“A”)

4.1.2A great deal of heat is lost upwards from the crucible mouth (see ref “B”)mouth (see ref. B )

C 4.1.3(

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The ingot moulds must be pre‐heated in a muffle furnace (see ref. “C”)

4. Disadvantages of the “traditional melting and pouring system”4 1 Elevated electricity consumption cont


4.1 Elevated electricity consumption ‐ cont.

4.1.4Powerful extraction systems must be kept running throughout the entire process

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4. Disadvantages of the “traditional melting and pouring system”4 2 Elevated heat loss


4.2 Elevated heat loss

A 4.2.1Th ibl f l i ( f “A”)

B The crucible stays open for a long time (see ref. “A”)

4.2.1Naked flames must be used continuously to:

C Naked flames must be used continuously to:

‐ keep the sprue hot (see ref. “B”)

‐ keep the ingot surfaces hot during the solidification stage (see ref. “C”)

D g ( )

‐ pre‐heat the ingot mould used for the next pouring operation(see ref. “D”)

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4. Disadvantages of the “traditional melting and pouring system”4 3 Loss of precious metal


4.3 Loss of precious metal

With the “traditional melting and pouring” system, metal is lost during the end‐of‐melt stage due to absorption in the crucible; further losses are caused by uncontrolled splashing of metal during the degassing stage and when pouring the molten metal from the crucible into the ingot mould.

4.4 Elevated need for specialised labour

In the “traditional melting and pouring system” many stages are manuallycommanded and controlled by the operator.

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As a result, a specialised operator must constantly tend the system, together with a second operator during the more delicate processing stages.

4. Disadvantages of the “traditional melting and pouring system”4 5 Inconstant quality of bars high reject percentage


4.5 Inconstant quality of bars, high reject percentage

DendritesShrinkage during

solidification

Metallographic structure of the cross-section of part of a gold ingot, produced by melting and pouring the metal into an ingot mould.

Gas porosity

SEM analysis of the segregation zone in a metal

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produced by melting and pouring it into an ingot mould.

4. Disadvantages of the “traditional melting and pouring system”4 5 Inconstant quality of bars high reject percentage


4.5 Inconstant quality of bars, high reject percentage

DendritesPipe Shrinkage

lines

400 Oz Au bar1000 Oz Ag bar -

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Kilobar

4. Disadvantages of the “traditional melting and pouring system”4 6 Elevated accident risk for operators


4.6 Elevated accident risk for operators

4.6.1Naked flames must be continuously used in the “traditional melting and pouring” system and, moreover, there is an enormous loss of heat and fumes. Operators therefore constantly run the risk of suffering scalds and burns and of breathing unhealthy air and must wear protective equipment, such as aprons, gloves, masks, helmets, visors, etc.

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4. Disadvantages of the “traditional melting and pouring system”4 6 Elevated accident risk for operators cont


4.6 Elevated accident risk for operators ‐ cont.

4.6.2In the “traditional melting and pouring system”, the top of the crucible and the incandescent metal in the ingot moulds release an enormous amount of heat and infrared rays into the surrounding area creating aamount of heat and infrared rays into the surrounding area, creating a dangerous environment with elevated temperatures and infrared brightness; operators are consequently subject to psychological and physical risks

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4. Disadvantages of the “traditional melting and pouring system”4 7 Environmental impact


4.7 Environmental impact

4.7.1The fumes must be extracted and filtered, and the heat must be reducedin order to prevent environmental problems.

4 7 2

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4.7.2The increased consumption of electricity raises theamount of CO2 (carbon dioxide) released into theenvironment by power stations

5. Research and development of the process


400 Oz Au Good Delivery Bar produced with a furnace

161000 Oz Ag Good Delivery Bar produced with a furnace

6. SURFACE APPEARANCE OF THE GOOD DELIVERY BARS


Some photographs of the surface appearance of Good Delivery bars produced using

the process are shown below

400 Oz Au Good Delivery Bar as it stands just coming out from furnace. N.B.: no polishing or brushing treatments have been done on the surface.

400 Oz Au Good Delivery Bar:400 Oz Au Good Delivery Bar: top surface - other view

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6. Surface appearance of the Good Delivery Bars


Lower and side views of a 400 Oz Au Good Delivery Bar just come out from the without any otherthe without any other treatment

400 Oz Au Good Delivery Bar: lower surface

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400 Oz Au Good Delivery Bar: details of edges and corners

6. Surface appearance of the Kilobars


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Kilobar Bars produced with a furnace



1000 Oz Ag Good Delivery Bar produced with a furnace.From the ingot as it is, just come out of the furnace, the top surface has been polished for only 15 secondsby hand with common “Pre Impregnated Wadding for Silver Polishing” to remove the slight shadows on the

surface. The side surfaces haven’t been treated and are as just come out of the furnace.

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Lower and side surfaces of a 1000 oz Ag Good Delivery Bar just come out from the furnace, without any further treatment



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15 Kg Ag Bar produced with a IECO KOIfurnace, without any further treatment

7. SAFE USE FOR HUMANS AND THE ENVIRONMENT


(“GREEN TECHNOLOGY”)

OK OK

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OK

8. DESCRIPTION OF A FURNACE


FLAMELESS TUNNEL®

Melting Furnace

Solidification AreaCooling Area

Unloading Area

Loading Area

The system here introduced is worldwide patented by IECO Keeps On Improving, thephrase “Flameless Tunnel®” is a registeredtrademark by IECO Keeps On Improving.

8. Description of a furnace


®120KW FLAMELESS TUNNEL® furnace for the production of 1000oz Ag Good Delivery bars

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9. BENEFITS OF THE PROCESS


9.1 Significant reduction of electricity consumption

In a furnace, the metal melts and solidifies inside a tunnel

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9. Benefits of the process9 1 Significant reduction of electricity consumption cont


9.1 Significant reduction of electricity consumption ‐ cont.

POWER CONSUPTION to produce #32 bars 1000oz Ag (~1 ton) in one shift

21252500

840

1500

2000

tion

in kW

h

840

500

1000

cons

umpt

Chart 2 – Comparison of daily cycle electricity consumption

0Traditional Melting & Pouring System FLAMELESS TUNNEL®

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9. Benefits of the process


9.3 Cancellation of the precious metal loss

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9. Benefits of the FLAMELESS TUNNEL® process


9.2 Considerable reduction in radiant and convective heat loss

OKFLAMELESS TUNNEL®


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9. Benefits of the FLAMELESS TUNNEL® process9 3 Significant reduction of rejects due to increased quality of the bars cont


9.3 Significant reduction of rejects due to increased quality of the bars ‐ cont.

400 Oz Au Good Delivery Bar produced with a FLAMELESS TUNNEL® furnace400 Oz Au Good Delivery Bar produced with a furnace

301000 Oz Ag Good Delivery Bar produced with a FLAMELESS TUNNEL® furnace

9. Benefits of the FLAMELESS TUNNEL® process9 3 Significant reduction of rejects due to increased quality of the bars cont


9.3 Significant reduction of rejects due to increased quality of the bars ‐ cont.

Gold Kilobars produced with a FLAMELESS TUNNEL® furnace

3115 Kg Silver Bar produced with a FLAMELESS TUNNEL® furnace



9.4 Major safety for the operators



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9.5 Improvement of the respect for the Environment (“green technology”)

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SUMMARY OF THE ADVANTAGES OF THE FLAMELESS TUNNEL® PROCESS:

‐ Significant reduction of electricity consumption

‐ Considerable reduction in radiant and convective heat loss

‐ Cancellation of the precious metal loss

‐ Significant reduction of the labour time for the production

‐ Significant reduction of rejects due to increased quality of the bars

‐ Speed up production times

‐ Major safety for the operatorsMajor safety for the operators

‐ Improvement of the respect for the Environment (“green technology”)

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CONCLUSIONS


CONCLUSIONS

IS PLEASED TO HAVE PRESENTED:

®FLAMELESS TUNNEL®AN ADVANCED AND NEW PROCESS FOR THE PRODUCTION OF

GOLD & SILVER BARS

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REASONS FOR CHOOSING A FLAMELESS TUNNEL® FURNACE


REASONS FOR CHOOSING A FLAMELESS TUNNEL® FURNACE.

• TO PRODUCE GOLD AND SILVER BARS USING AN INNOVATIVE PROCESSWITHOUT THE TYPICAL PROBLEMS OF THE TRADITIONAL POURING SYSTEM

• TO PRODUCE HIGHER QUALITY GOLD AND SILVER BARS WITH FLAT AND BRIGHTSURFACES WITHOUT THE NEED FOR ADDITIONAL FINISHING PROCESSES

• TO PRODUCE GOLD AND SILVER BARS USING A SYSTEM THAT IS SAFE FOR BOTHOPERATORS AND THE ENVIRONMENT (“GREEN TECHNOLOGY”)

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• NOWEIGHT LOST


THANK YOU!

IECO Keeps On Improving SrlVi M t V 20Via Monte Verena, 20

36022 San Zeno di Cassola (VI)ITALYITALY

tel. +39 0424 259300e-mail: [email protected]

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@http: www.ieco-koi.it

Documents

New 8th China Gold & Precious Metals Summit 2013 · 2013. 12. 11. · 5-6 December , 2013 8 th China Gold & Precious Metals Summit 2013 Contents of the document: 1. Who is IECO Keeps