CASTING INNOVATIONS
Furnace Retrofit Boosts Melting Capacity for Alabama Iron Caster Two coreless induction furnaces
at the Grede Holdings LLC facility in Brewton, Ala., recently turned 40 years old. But thanks to a recent project between Grede and ABP In- duction Systems, North Brunswick, N.J., the pair is hardly showing any signs of age. A retrofitting operation in 2014 has boosted overall output, while keeping downtime service interruptions at a minimum. Following the 2010 merger between
Citation Corp. and Grede, the Brewton facility began working with new iron alloys on its two vertically parted mold- ing lines. Te two nine-ton furnaces were dedicated to a single molding line, but struggled to keep up with increased demand for a new ductile iron alloy. Kenny Roley, foundry manager, Grede-Brewton, initially explored the possibility of installing new furnaces, but spatial requirements, investment limitations and production demands made that option a difficult proposition. Grede-Brewton contacted ABP
Induction to discuss possible incre- mental improvements for its melting operations. “Many metalcasters are not aware of how dramatically productivity can
9-ton furnaces in 2014, making improvements to all aspects of the melting system, including: • Upgraded 5,000 KW, 180 Hz power supply.
• New water cooling system utiliz- ing a triplex pump-stand with back-up pump.
• Power supply loop with de-inon- izer system.
• Increased insulation spacing be- tween turns for greater resistance to arcing between turns.
• New coils to accommodate the higher power level that were built with a larger copper profile to increase strength and rigidity. Tese improvements were in-
The power supply inverter was installed to allow for easy access for maintenance.
be improved with an existing older furnace,” said Daniel Green, technical director, ABP Induction. “Te cost of retrofitting an older system is much less than installing a new furnace, primarily because the foundation, decking structure, and furnace body can be saved.” ABP and Grede-Brewton agreed on a plan to retrofit the first of the
stalled during the facility’s scheduled shutdown in December 2014. Com- munication between Grede-Brewton’s maintenance team, ABP’s engineers and the installation contractors led to a relatively smooth conversation, which started on time with no signifi- cant hiccups. “Te project started with equip-
ment placement, followed by plumb- ing and cabling which were done simultaneously,” Green said. “Te real action began when the service engi- neer started to commission the system. Te installation was first thoroughly checked, followed by a series of tests with power on. In the end, the transi- tion was seamless.” Grede-Brewton, which produces
approximately 60,000 tons of ductile iron castings annually, has already begun planning to update the second nine-ton furnace in the near future. Te ability to remain competitive by increasing capacity, all while minimiz- ing investment, has proven valuable to the casting facility, no matter the age of its melting equipment. “Induction furnaces are designed to last a lifetime, if properly main- tained,” Green said. “During that lifespan, technology evolves and improvements can reduce labor and maintenance cost and increase pro- ductivity and sustainability.”
The newly updated nine-ton induction furnace has boosted Grede’s Brewton, Ala., melting output. 44 | MODERN CASTING December 2015
Tis article is based on work from Daniel Green and Tim Herring, ABP Induction Systems, North Brunswick, N.J.
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