Refractories

• Coreless Induction Furnace Linings
• Primary and Secondary Melting of Metals
• Channel Induction Furnace Linings
• Castables
• Cement
• Pre-Shaped

Crucibles

• Fire Assay
• Frit Melting
• Iso-Pressed
• One-Shot Liners
• Vibro-Cast

Bottom Pour Systems

• Multicast
• Unibore
• Unibore Autopour

Gas Diffusers

Capital Refractories are now able to offer an extensive series of gas diffuser products for the treatment of melts across a range hot metal industries.

Gas purging homogenises the melt and can contribute to the purification of the alloy. Homogenisation aims for equalisation of the analysis and temperature of the metal in the vessel. Gas purging can effect rapid distribution and dissolution of alloying and deoxidising agents and quick adjustment of casting temperature can be achieved. Reduction of deleterious gas content and separation of non - metallic inclusions, with subsequent improvement in metal quality resulting from their elimination from the melt.

All Capital Refractories gas diffusers are supplied to suit the customers' requirements with respect to the metal casings and gas feed pipe work, the choice of these being dictated by the application, this being particularly important in aluminium melt applications if there is the possibility of chlorine being used as a purging gas.

• Selection
• Crucible Gas Diffuser
• Case Studies
• Competition Comparison

Ancillaries

• Chamotte (Refracoarse)
• Earth Leakage Electrodes (Spiders)
• Fibre Products
• Furnace Formers
• Insulation Material
• Investment Casting Materials
• Pouring Cups
• Mica
• Temperature Measurement
• Vibration Equipment
• Wash Coats

Binder

• SQG NO BAKE FURAN RESIN
• SULFONIC ACID HARDENER
• New Types Low Sulphur Hardeners for furan resin
• P-TOLUENE SULFONIC ACID
• A+B COMPUTER CONTROLLED HARDENER REGULATOR
• JF SERIES OF ALKALINE PHENOLIC RESINS
• NP SERIES PHENOLIC URETHANE NO-BAKE RESIN
• GP COLD BOX RESIN
• SQJ610 CO2 CURED ALKALINE PHENOLIC RESIN
• FR SERIES HOT BOX RESIN
• HC SERIES HARDENER FOR HOT BOX RESIN

Auxiliary Material

• BA-01 SERIES OF MOULD & CORE ADHESIVE
• QA-01 SERIES OF CLEANING AGENT
• RELEASE AGENTS FOR NO-BAKE SYSTEM
• MOULD & CORE ADHESIVE FOR HOT BOX SHELL-CORE
• RELEASE AGENTS FOR HOT BOX & SHELL-CORE
• RELEASE AGENTS FOR COLD BOX RESIN

Metallurgy Material

• SQI-K SERIES OF INOCULANT BLOCK IN MOLD
• THERMOLAN? METALLURGICAL QUALITY PREDICTION SYSTEM
• SLAG REMOVER
• RECARBURIZER
• SQC SERIES OF VERMICULIZER
• SQI SERIES OF INOCULANTS
• SQN SERIES OF MAGNESIUM ALLOY NODULIZERS

Foundry Coatings

• WET POWDER COATINGS
• FQ & FS SERIES SPECIALIZED COATINGS
• FS WATER BASED REFRACTORY COATINGS
• FQ ALCOHOL BASED REFRACTORY COATINGS

Riser Sleeves

• ECD BREAKER CORE
• EA EXOTHERMIC-INSULATING AGENT
• FPS SERIES DIRECT POUR SLEEVES
• FE700 SERIES EXOTHERMIC SLEEVES
• FI200 SERIES INSULATING SLEEVES
• FM100 SERIES EXOTHERMIC-INSULATING SLEEVES
• FT200 SERIES INSULATING SLEEVES
• FT800 SERIES INSULATING SLEEVES(HI-CHROMITE IRON SPECIALLY)
• FT100(III)SERIES INSULATING RISER SLEEVES(HI-MANGANESE STEEL SPECIALLY)
• INSULATING FLEXIBLE BOARD
• FT400 SERIES INSULATING SLEEVES
• FT300 SERIES INSULATING RISER SLEEVES
• FT500 SERIES INSULATING RISER SLEEVES

Filter

• FCF-2 FOAM CERAMIC FILTER FOR IRON CASTINGS
• FCF-3 FOAM CERAMIC FILTER FOR ALUMINUM CASTINGS
• FCF-4 FOAM CERAMIC CAST-HOUSE
• FCF-1Z ZIRCONIA FOAM CERAMIC FILTER
• ZIRCONIA FILTER CUP FOR STEEL CASTINGS
• NIRVANA? CERAMIC FOAM FILTER FOR LARGE CASTING
• CHF PRESSED CERAMIC FILTERS
• FILTER CLOTH

Ceramic Ball Sand

• CERAMIC BALL SAND

Pouring System

• POURING SOCKET
• POURING CUP
• FILTRATION CONNECTION
• CERAMIC POURING TUBES
• CONNECTION TUBES
• REDUCING INGATE

Risers and Application Technology

• THERMO risers
• POINT risers
• ECO risers
• DUPLO risers
• Compacting risers
• Exothermic/Insulating sleeves
• Special products
• Qualities

Ceracat +

Foundry Consumables

• Adhesives
• Mould Sealants
• Release Agents
• Coatings
• Core Filler
• Sand Binders
• Core Vent
• Exothermic Sleeves
• Silicon Carbide Filters

Specialist Ceramics

No restriction on shape or size

Economic for small and medium production runs

Low tooling costs

Excellent physical properties in terms of thermal shock, high strength, chemical and abrasion resistance

Consistancy

Please refer to the case studies below to learn more about this technology and its capabilities
Case studies of Breaker Ring, Whirl Gate and Ceramic Basin

Holloware

Non Ferrous

• OBB Sand
• Nilscrap
• Die Coatings
• Ladle Coating
• Release Agents
• Adhesives

Low Alloy Steels

Longwear Certified Air Melt Ingots - Alloy Cross Reference Index - Carbon, Low Alloy Steel & Tool Steel

Stainless / Duplex Alloys

Longwear Certified Air Melt Ingots - Alloy Cross Reference Index - Stainless & Duplex Steel

Nickel Based Alloys

Cobalt Based Alloys

Longwear Certified Air Melt Ingots - Alloy Cross Reference Index - Nickel Based Alloys

In addition to the above Specifications we can offer manufacturing to Customer individual requirements and specifications including Toll Melting and re-melting. Longwear Alloys Ltd assumes no liability for errors or ommissions. In relationship to the information contained in this document.

bemalitt Filze

bemalitt Filze SK

bemalitt Dichtstreifen Rollen SK

bemalitt NF-Streifen SK

bemalitt Matten-/Rollen

Rotary Media Drums

Forget shakeouts, call them rollouts. The DIDION Rotary Media Drum® has revolutionized the whole vibratory shakeout process. Now in use in 42 countries, the patented dual chamber design of the machine accomplishes many tasks in one easy step.

• First, it separates green sand from core sand and dramatically improves sand conditions.
  
  
• Second, it screens the sand, eliminating the need to buy and maintain more equipment.
  
  
• Third, it produces cleaner castings, greatly reducing shot blast time and reducing labor in the knockout and finishing departments.
  
  
• Fourth, it cools the castings enough to handle with gloves.
  
  
• And finally, it eliminates phone calls from irate neighbors claiming they just lost another family heirloom due to vibrations from your foundry.

The DIDION Rotary Media Drum® comes in ten standard sizes, or can be built specifically to your requirements. It is ideally suited for high speed, high pressure, flaskless molding systems. It can handle no-bake and shell moulding and will clean brass, bronze, ductile, gray, malleable, and steel castings.

Installation is a breeze - no pits or special foundations. Its efficient design has proven to reduce maintenance costs for many customers and it eliminates air-borne silica dust from sand carryover for a cleaner, safer environment. It also eliminates stress problems and white caps in your coffee mug. So, next shut down or long weekend, remember... the only thing shaking in your foundry will be our competition. Forget shake, forget rattle, think roll.

Rotary Sand / Casting Separators

Poured molds are delivered into the intake end of the rotary drum. As the molds tumble through the drum, the sand is separated from the casting, crushed to grain size, and dissipated through apertures in the lining to the outer chamber, where it is conveyed to the sand discharge point. The cleaned castings travel to the casting discharge end of the drum, where they exit and move to the next stage of processing in the cleaning room. The tumbling action in the DIDION crushes sand lumps, removes core butts, and empties sand pockets. The apertures in the patented lining act as a rotary screen to prevent tramp metal, core butts, and other foreign material from entering the sand system. Moreover, the sand is homogenized and uniform in temperature, since cooler sand from molds entering the DIDION is constantly mixed with hotter sand as it passes through the lining into the sand chamber. This allows for better sand control at the muller.

Durability

The rugged, unitized construction of the DIDION is designed with dependability and simplicity in mind. Wear and tear, along with energy consumption, have been reduced to a minimum. All component parts are standard items which may be purchased through local sources or from DIDION International Inc. The liner segments are wear-resistant, alloyed ductile iron designed for long life and may be replaced either individually or as a complete lining, according to installation requirements. The DIDION provides increased reliability and production time for the foundry as a result of the design simplicity of the drum. The DIDION Rotary Sand Casting Separator is a low maintenance piece of equipment with approximately eight hours per year required for regular servicing.

Adaptability

The DIDION is designed for use in any type of molding system-from conventional to automatic. The configuration of the lining is specifically designed for each installation in order to provide the most efficient separation of sand and castings, while minimizing excess tumbling of the castings. Standard sand discharge locations at either end of the unit provide easy installation into new or existing foundry systems. A custom-designed intermediate sand discharge (located at almost any point along the drum) will allow sand to be discharged onto existing sand return conveyors.

Rotary Lump Crusher / Sand Reclaimers

Dealing with spent sand has always been a challenge for foundries, but with environmental regulations getting more stringent all the time, reclaiming one's sand is becoming much more critical to success than ever.

The DIDION Rotary Lump Crusher / Sand Reclaimer represents the most efficient and reliable foundry sand reclaimer in the industry. It is environmentally friendly and has the lowest operating cost, per ton, worldwide. It crushes, scrubs, separates, screens and classifies large mold lumps into reusable grain size sand while automatically discharging tramp metal and debris.

Standard models process lumps from 2 to 50 tons per hour either in batches or continuously and the versatile design allows sand to be discharged at either end. Custom machines can also be built to accommodate specific applications.

The DIDION's extra heavy duty construction saves on maintenance and reduces downtime while its efficient design minimizes utility costs and dust. Plus, since no operator is required, extra labor savings can be enjoyed. With an optional variable jet burner, one can even reclaim wet, outside and dump sand as well.

Installation is simple as the DIDION Lump Crusher / Sand Reclaimer requires no pits or special foundations.

Rotary Sand Screens

Without a doubt, the DIDION Rotary Sand Screen is the most economical, efficient and reliable machine on the market.

No other piece of equipment can blend, condition, and remove core butts and tramp metal from return sand in one easy step.

• DIDION's revolutionary internal sand distribution system utilizes 100% of the screen area.
• Adapts to numerous feeding applications due to its unique open-end design.
• Easy to maintain due to its extra heavy duty design and off-the-shelf components.
• Easy to install - just set it down and turn it on - no special foundations required.

Rotary Sand Blending / Cooling Drums

These machines blend, cool, condition, screen, and classify green return sand efficiently to improve the sand system and increase production. You'll reduce scrap and cleaning costs with lower sand temperature and superior sand conditioning. Integral sand screening eliminates down stream screening equipment. Low energy consumption, low CFM requirements, minimum installation time and low operating cost increases profitability. Machine sizes range from 25 to 750 tons per hour of green sand.

• Reduces scrap and cleaning costs due to lower sand temperature and improved sand conditions.
• Provides more uniform sand to muller, improving muller efficiency and consistency of sand conditions.
• Rugged, durable construction requires minimum maintenance.
• Open end design with no center shaft allows for easy loading by feeder or chute.
• Simple, smooth drive system does not generate high frequency vibrations, thus eliminates the need for special foundations and large spare parts inventories.
• Precision laser alignment of the main support bearings allows the drum to run level, thus eliminates thrust loads and minimizes wear.
• Lifter bars and helical flights improve sand conditions by blending and mixing the sand.
• Integral sand screen.
• All drive components are standard, off-the-shelf items that are easily accessible.
• Dust is contained within the machine.
• Low horsepower, low CFM requirements, minimum installation requirements and low operating costs are cost saving features.
• Easily adapted to programmed automatic control.

Rotary Dross / Slag Metal Reclaimers

Dross & Slag Metal Reclamation Systems

DIDION Rotary Dross / Slag Metal Reclaimers liberate and reclaim valuable metallics from large slag & dross chunks using a patented design. The machine features a Dynamically Isolated Articulated Concentric Crusher with serrated teeth that provides a positive action for reducing large chunks. The material is first screened in an aggressive attrition chamber through an extra heavy-duty cast alloyed wear-resistant liner which is two inches thick for long life. The material is tumbled again in the Star Chamber and then enters the final screening system where the slag & dross is separated and air classified from the reclaimed metal.

Metal Reclamation & Slag Recycling

The DIDION Rotary Dross / Slag Metal Reclaimers are being used to reclaim metal from dross, slag, salt cake, skimmings, spillage, and pot liner in the following materials:

• Aluminum
• Brass
• Bronze
• Copper
• Iron
• Nickel
• Steel/Stainless
• Specialty Alloys

Features & Benefits

• Patented design crushes, cleans, separates, and screens to reclaim valuable metals from slag, dross, salt cake, skimmings, spillage, and pot liner.
• Rotary tumble action provides excellent slag & dross reduction and separation for cleaner metallics and a cleaner melt.
• Positive crushing action with patented crushing roller to break down very hard lumps, yielding higher output.
• Dynamic Suspension System directs the energy of the crushing roller into the material, not the machine, utilizing an innovative isolation design.
• Attrition chamber utilizes serrated tooth lifters and high tumbling action, separating the slag & dross to liberate.
• Automatic recirculation of screen overs provides additional crushing for higher output.
• Extra Heavy Duty Design for 24/7 continuous operations.
• Precision laser alignment of main support bearings for minimum wear.
• Simple one point hookup of ductwork to supplied flanged opening.
• Automatic discharge of clean metal out the discharge end.
• Very efficient air wash for maximum dust separation.
• Very simple foundation requirements for minimal installation cost.
• Low operating cost with no compressed air or other additional energy sources required.
• Patented segmented cast wear liners provide lower noise, much better wear resistance, and ease of replacement.
• Standard drive components with easy access.
• Variable retention time for various materials to be processed/cleaned.

Rotary Sprue Mills

High rotary tumble action crushes core butts and cleans the sand off gates, runners, and sprue. Melting efficiency is increased with clean and condensed melting stock. The sand is recovered and slag handling and disposal costs are greatly reduced as well. The machine eliminates shot blasting of the melt returns and can process large mold/core lumps. Additional savings include the elimination of the cleaning room bottleneck as well as the need for expensive jaw crushers.

DIDION Rotary Separator / Sprue Mills require less energy, less maintenance on shot blast equipment, and install easily. By keeping the sand in the sand system, the machines also significantly reduce clean up costs and keep ones foundry much cleaner.

Rotary Carbon Separator / Thimble Cleaners

DIDION Rotary Carbon Separator / Thimble Cleaners utilize a highly efficient tumbling action for thorough cleaning of carbon from cast iron thimbles, including recesses for a cleaner melt. The patented design with segmented alloyed wear-liners provide lower noise, much better wear resistance, and ease of replacement. Cost savings include the elimination of shot blasting altogether, saving equipment, shot consumption, wear parts, maintenance time, floor space, and labor costs. The machine also serves as a horizontal storage silo with fully automatic feed of thimbles to reduce labor costs.

• Highly efficient tumbling action for thorough cleaning of carbon from cast iron thimbles, including recesses, for a cleaner melt.
• Cost savings include the elimination of shot blasting altogether, saving shot consumption and wear parts with less equipment, less floor space, less maintenance, less energy and less labor to increase efficiency and profitability.
• Simple, smooth drive system with very low energy consumption and low maintenance.
• Precision laser alignment of main support bearings for minimum wear.
• Reduced noise levels and dust escape due to containment in the drum.
• Very low dust collection CFM due to small open area.
• Very simple foundation requirements for minimal installation cost.
• Patented design with segmented cast wear liners provide lower noise, much better wear resistance, and ease of replacement.
• Simple adjustment of compression ring to maintain tightness of liner segments.
• Standard drive components.
• Ease of access to bearings and drive components.

Rotary Dryers

After we designed the best dryer available, we also made sure that it was safe (OSHA approved); efficient (open end design for easy loading); economical (low horsepower, low CFM requirements); dependable (laser aligned to minimize wear).

You see, the DIDION Rotary Dryer is totally reliable technology for drying a full range (and sizes) of materials. Uniquely designed to provide optimum product exposure to incoming heated air, it also maintains temperature uniformity with a variable Jet burner.

What's more, our unique design ensures:

• Minimum installation
• Rugged, durable construction
• Low maintenance
• Improved efficiency with dust and heat containment
• Drive system minimizes vibration
• Drive components standard, off-the-shelf items
• Automatic control with adaptable programming

Rotary Coating Drums

• Rotary tumble action for more thorough coating and draining of parts, including pockets.
• Simple, smooth drive system with no high frequency vibration to produce high loads and rapid wear.
• Very low drive horsepower.
• Precision laser alignment of main support bearings.
• If fume collection is required at all, very low CFM due to small open area.
• No special foundation requirements for minimal installation cost.
• Fully automatic feed of parts, reducing labor costs.
• Patented segmented cast ductile iron liners provide lower noise, much better wear resistance, and ease of replacement.
• Drive components are standard, off-the-shelf items that are easily accessible.
• Variable speed drive to suit parts and coating characteristics.
• Completely self-contained unit.

Core-Shooting Machines

 Besides single units, complete, fully automated core shops can also be provided including sand storage, binder dosing, mixing and core handling.

The KLANN Core Shooters are characterised by:

• high, reproducible core quality by provision of complete core shops incl. sand processing and transport
• short cycle times, short set-up time and high production rates by optimised design and process steps
• high availability with long maintenance cycles
• compact design with small foot point, no foundation hole necessary
• easy accessible for core box change and maintenance purposes.

The following core shooter designs are available:

• Standard Core Shooters with core table for the production of cores in vertical and horizontal separated core boxes up to 60 Litres.
• Core Belters for the high quantity production of cores up to 15 Litres.
• Multi-station core shooters for the use with different core boxes in one machine.
• Core shooters in custom design.

All core shooters can be supplied as core shooting stations with an integrated sand processing unit.

Sand Processing

Core Sand Treatment

Core Sand Mixer

The KLANN Core Sand Mixers are compact batch mixers with a high productivity, which are offered in a varity of volumes. The sand removal is executed by tilting of the mixer drum. This design has no flaps or slides which could plugg or block. The arrangement of the mixer tools and the design of the drum bottom ensure intensive mixing with low power consumption.

The mixers are available with volumetric or gravimetric dosing devices.

Sand Deduster/Cooler

The quality of core sand is dependant on the binder and the processing equipment, but the quality of raw sand and temperature are also crucial. Dust particles in the sand not only decreases the gassing capacity of the core but also consumes more binder due to the high specific surface. To separate the dust from the sand KLANN provides fluidised bed separators, which can also be used to cool or heat raw sand to optimum temperatures in the range of 20 - 30 °C.

Core Fraction Recycling Unit

To avoid deposit costs for core residues Klann developed a special recycling unit which recovers the sand in different process steps. After grinding of the agglomerates, the impurities are separated by screening and the dust fraction is taken out by air flow separation. After this recycling process up to 10 % of the raw sand feed can be replaced by this recycled core-sand.

Bulk Material Transport

Bulk Material Transport and Storage

Crab Rail Systems for Core-Sand Transport

To achieve maximum core quality KLANN offers a special crab rail conveyor system for the transport of core-sand mixture. This systems is specially adapted to the core production as it offers a smooth transport with minimum air contact. This batch transport system allows to supply several core-shooting machines with core sand over a long horizontal and vertical distance without requiring much space. It can also easily be adapted to installation in existing facilities. more...

Pneumatic Conveyors

KLANN offers pneumatic transport units for the transport of raw sand from the silo storage to the intermediate feed bin. These units operate smoothly and at low pressure of 2 - 3 bar which results in low wear and low operation costs as compared to standard 4 - 6 bar units.

Raw Material Storage

Supply of complete silo installations, starting from silo-truck pneumatic unloading and going to material discharge, including the necessary instruments and filter units.

Binder Dosing / Storage

Binder Storage and Dosing

As binder agents used for the core-shooting process have to be stored in accordance with water protection legislation, special considerations must be taken into account for the design of binder storage and dosing facilities. To this end the company KLANN offers variety of storage and dosing equipment, which meet the environmental protection requirements.

Drum Storage

For smaller core shops the binder is mostly delivered in drums, which have to be stored and connected to the dosing equipment. Using a special level gauge device in these drum storages, new binder agents can be ordered in good time.

Container Storage

When using larger quantities of binders in the core shop, containers are used for delivery and storage. Special racks are offered by KLANN for container storage allowing easy exchange and connection. To catch up spillages at the connection points special drawers are installed underneath, which can be easily cleaned. In case of leakages a pan is installed on the rack bottom to catch drips under the complete container volume. The binder is transferred to the dosing station by a sealed double-membrane pump, which is easy accessible.

Binder dosing equipment

In order to assure an exact dosing of the binder components into the mixer special piston pumps are used, these are installed in a cabinet. The set points of the binder volumes can be modified by the PLC. An intermediate reservoir on top of the pumps avoids air suction by the pumps.

Core Handling

Core Handling

Beside a precise handling, the fully automated handling and processing of cores requires peripheric installations offering high reproductibilty.

Robotic Systems

For lifting cores out of the core shooter and further processing special robot systems are offered with multi-functional gripper systems.

Coating Tanks

The automatic processing of cores require special coating tanks with a static level.

Synthetic graphite/Electrode graphite

PRODUCT INFORMATION

APPLICATION

ADVANTAGES OF RANCO® PRODUCTS

Advantages of our synthetic graphite:

• A high degree of purity of at least 99% carbon and the particle morphology guarantee efficient dissolution in the melt.
• Low levels of sulphur and nitrogen
• Positive effect on the germ balance in the formation of nodular graphite (EN-GJS) and support of the inoculating effect against chilling.
• Grain sizes individually adapted to the size of the melting unit

GRAIN SIZE

Calcined Petroleum coke SK

PRODUCT INFORMATION

APPLICATION

ADVANTAGES OF RANCO® PRODUCTS

• High carbon content and low levels of volatile components and ash enable efficient carburisation.
• Customised grain sizes available

GRAIN SIZE

Special graphites & specialty cokes

PRODUCT INFORMATION

APPLICATION

ADVANTAGES OF RANCO® PRODUCTS

Synthetic graphite

• Unique mechanical and thermal properties due to its ordered crystalline structure, improving both performance and comfort
• The heat generated by friction is distributed more evenly over the entire surface of the base or dissipates it into the deeper layers of the base. Hotspots on the lining or the brake disc can therefore be prevented and thermally induced surface deformations reduced, leading to a reduction in noise and vibration and thus increasing comfort.
• Due to its low modulus of elasticity, it has an elasticising effect on the base, which also reduces noise and juddering and lowers wear on the base.

Calcined petroleum coke

• Increases the coefficient of friction and stabilises it over the entire temperature range.
• Helps to reduce unwanted fading and increases braking performance.
• Reduces wear on the brake disc due to the high degree of purity (ash content only 0.2% approx.).
• Reduces vibration and thus noise, which in turn increases comfort.

GRAIN SIZE

Milled Graphite

PRODUCT INFORMATION

APPLICATION

• In lubricating greases as “solid additives”
• In insulating materials for the construction industry
• As a covering agent for copper melts
• In the chemical industry
• In the plastics industry

ADVANTAGES OF RANCO® PRODUCTS

• Excellent lubricity and adhesion
• Corrosion, water and temperature resistance
• Reduction of thermal conductivity in insulating materials
• Acid resistance
• Electric conductivity

GRAIN SIZE

Calcined anthracite

PRODUCT INFORMATION

APPLICATION

GRAIN SIZE

Inoculating carbon

PRODUCT INFORMATION

APPLICATION

ADVANTAGES OF RANCO® PRODUCTS

GRAIN SIZE

Pig Iron – indispensable component in the melt

PRODUCT INFORMATION

APPLICATION

QUALITIES

• Basic pig iron for GJS/GS
• (Semi-)nodular pig iron for GJS and GJV
• Hematite pig iron for GJL