A New Generation of Electromagnetic
Metal Moving System
BY SOLIOS THERMAL
DATE: 25-April-2013
Overview
→Introduction
to Solios
→Genios Technology
→Genios Case Study
→Conclusion

COMPANY PROFILE
SOLIOS THERMAL
1961
Fives Solios
2003

40 employees

Equipment supplier

Engineering and site services

Project management

ISO 9001 certified

Part of www.fivesgroup.com
3
2008
Overview
→Introduction
to Fives Solios
→Genios Technology
→Genios Case Study
→Conclusion

GENIOS – WHY?

A requirement in the market place!
›
›
›
›
›
›
Fives Solios
A device that could be easily introduced to existing furnaces as well as
new installations.
Be able to offer a unique capability; to transfer and cast molten
aluminium from the same device.
Need a device that is safe to use and reduce the exposure of the
operators to the hot metal areas.
To be able to bring all the benefits of EMS stirring to the furnace.
›
›
›
›
Cycle reduction.
Energy efficiency.
Less operator intervention.
Metal temperature and composition homogeneity
Present benefits in terms of maintenance issues and cost
Be cost effective against conventional solutions.
5
5
GENIOS – WHAT IS IT?
Genios is a non metal contact EMS device that can be mounted to the side of a furnace
Stirring Mode
Fives Solios
GENIOS – WHAT IS IT?
Casting Mode
Fives Solios
7
GENIOS – WHAT IS IT?

System Overview
Fives Solios
Fully automatic
operation in all modes
Overview
→Introduction
to Fives Solios
→Genios Technology
→Genios Case Study
→Conclusion

PLANT DETAILS
Large secondary aluminium producer (120000t/a) based in Italy.
Casting furnace is a conventional regenerative burner fired static type.
70Tonne nominal capacity with typical bath depth of 1000mm.
Charged with predominantly molten metal from various melting furnaces.
Used to feed a dedicated belt type continuous casting machine.
Casting Machine production rate is between12 and 20 Te/hour of Si alloys.
Previous method of transfer by mechanical graphite pump.
Fives Solios
10
PLANT LAYOUT AT V.C.M
Fives Solios
11
WHY VCM CHOSE THE GENIOS
Serious issues with safety and operation using electromagnetic
pumps (50Hz) and mechanical metal moving systems previously
installed on this process line.
Attracted by “double option” capability to stir & cast with the same
unit.
Wanted better safety afforded by operating at lower frequencies
than are available with comparative EM systems.
Strong interface between bath and inductor.
Integrity of furnace not compromised by removal of inductor.
Potential operating & maintenance savings
Wanted to maintain a consistent metal quality
Fives Solios
12
STIRRING AT VCM
Fives Solios
13
AUTOMATIC CAST AT VCM
Fives Solios
14
BENEFITS ACHIEVED AT VCM
Significant gain over safety levels experienced with the previous metal moving
systems installed on this furnace. Reduced operator intervention due to auto start &
good metal flow regulation.
Improved quality – better chemical & temperature homogeneity throughout cast
(rejects reduced by order of 15%)
Reduced dross formation (approx.10%)
Fives Solios
15
IMPROVED RELIABILTY AND PRODUCTIVITY
Parameter
Mechanical Pump
Genios
Typical consumable part
life
500 tonnes / head
>5000 tonnes / casting
tile
250mm
<100mm
Automatic cast rate
control
Automatic cast start
No
Yes
No
Yes
Cast interrupt /restart
ability
No
Yes
Metal level control
No
Yes
Minimum bath level at
end of cast
Fives Solios
16
Remarks
With existing hearth
levels
+/- 2mm level control with
existing launder
configuration
Overview
→Introduction
to Fives Solios
→Genios Technology
→Genios Case Study
→Conclusion

Conclusion
›
Can be easily introduced to existing furnaces as well as new installations.
›
Be able to stir and cast molten aluminium from the same device.
›
The device has to be safe to use and reduce the exposure of the operators to the hot metal
areas.
›
›
›
Fives Solios
Yes, achieved due to it’s side mounting and modular design.
Yes, controlled casting up to 20te/hr to the client ingot casting machine.
Improved safety due to less operator intervention – push button operation; operation stops
when the device is turned off .
›
Benefits of EMS stirring to the furnace.
›
Present benefits in terms of maintenance issues and cost.
›
Be cost effective against conventional solutions.
›
›
›
Yes, improvements in metal recovery, improved chemical & temperature homogeneity. The
Genios resulted in improved furnace efficiency due to less tasks required with the furnace door
open and improved production times.
Yes much improved life cycle compared to previous technology used, less down time with
improved operability which also offsets costs.
Yes, competitive against other EMS solutions, and requires simple modification to existing
furnaces and cast house infrastructure. Offers improved maintenance costs when compared to
metal contact devices.
18
18
THANK YOU.

Fives Solios
Visit Fives Solios at booth number 12