The beginning of a new era
The melt shop has been producing ductile materials since 2008 by winding in magnesium filled wire. Because we are a historically evolved company, the process could only be used with compromises. We have been concerned for many years with the sum of the many small drawbacks started from the converters to the process control of the molten metal to be cast in the casting furnaces. Through countless trial tests it then became clear with which measures the treatment process can become more uniform and predictable.
A concept on how we can prepare ourselves for the future at Gienanth was developed in close cooperation with suppliers. We were able to take the last decisive step during the course of the capacity expansion for the Disa 14 by designing a second wire-spooling cabin, which, in conjunction with the test evaluations, enabled us to eliminate most of the previous compromises. This system enabled us to test and optimize the possible weakpoints of this design.
In March 2016, the first orders for the wire treatment project were placed. During the extensive renovation phase, we were able to supply the casting process with treated molten metal without any production loss through disciplined scheduling. I would like to take this opportunity to thank all those involved for this top performance.
The most important milestones during the conversion phase involved raising the ASEA 1 and 3 holding furnaces, converting the iron channel of the cupola furnace, customizing the core shop, modernizing and expanding the IT infrastructure, and finally installing wire treatment cabins with automated bulk material dosing.
Since November 7, 2016, all ductile materials are being manufactured via the three linked wire spooling cabins in conjunction with automatic bulk material dosing. On this day, the era of the +GF+ converter was ended at Gienanth and replaced completely by the new automized process.
It turns out that Gienanth has made the right decision. The expected positive effects for the production have been fulfilled and yet other positive aspects have developed. Remaining work is currently being carried out on the system and software. This will result in alleviating the daily routine of the employees working in the melt shop particularly with regard to the process documentation. For this reason, it is important that all colleagues remain curious and continue to develop themselves further in the team.