ACETARC Engineering

Foundry Ladles

Introduction

Acetarc Engineering is an ISO9001 registered company specialising in the design and manufacture of all types of foundry ladles plus associated equipment. We bring over 35 years of experience to build you the very best equipment. A range of Heavy-duty products that are manufactured by crasmen engineers using proven methods and techniques. Our symbol is the WORKHORSE; solid, reliable and enduring. Our full design & manufacturing capabilities enable us to provide tailor-made and cost effective solutions for your foundry ladle requirements; from initial consultation, through to final design and manufacturing.

Transfer & casting ladles Treatment ladles for the production of ductile (S.G.) Iron Porous plug ladles for desulphurising processes Teapot spout ladles Boom pouring ladles Lip-axis pouring ladles Drum & U shaped ladles Aluminium tapping ladles
Geared ladles are available with capacities of up to 40,000Kg (88,000lb) Un-geared ladles are available with capacities up to 100,000Kg (220,000lb). Geared ladles can be supplied with either manual or motorised gearbox rotation. In addition to foundry ladles we also design and manufacture the following equipment:

Ladle pre-heaters Crucible handling equipment Furnace charging equipment Monorail & crane systems Foundry handling equipment

Important Facts Concerning Acetarc Foundry Ladles

Acetarc ladles are made to order. This means that we can fine-tune the design to suit your specific requirements. Acetarc ladles are manufactured as right hand pour unless otherwise specified. Ladles are classed as right hand pour when the ladle pouring spout is at the operators right, as the operator stands facing the gearbox. Acetarc ladles are supplied without refractory linings. The supply and fiing of all refractory and lining materials is the responsibility of the client. Acetarc are happy to quote for the supply of a steel re-usable lining former to match a specific ladle. The more information you can give us, the more accurate we can interpret your requirements. It will greatly assist us if you can supply the following details concerning the ladle you wish to purchase:

Working capacity of the ladle Type of metal that the ladle is to be used with. Type & purpose of the ladle (i.e. casting, transport, treatment) Lining allowance required. Pouring type. (Lip-pour, boom pour, teapot spout or lip axis etc). Gearing required. (un-geared, manual gearbox or motorised rotation). Right hand or le hand pour. Any special features (Cover, low headroom, liing bail, detachable base section etc). How the ladle is to be handled. (Overhead crane or monorail, forkli truck, dedicated
handler or special tilting frame etc).

Typical Sizes For Standard Lip Pour Ladles (Cast Iron)

The heavy-duty ladle design is shown below but the dimensions given are also applicable for the Westminster medium duty ladle designs. Side and base lining thicknesses are suggested allowances and should not be taken as binding. When the ladle is fied with the suggested lining allowance and filled to the given freeboard level, the ladle will have the working capacity given when filled with molten cast iron having a density of 6643Kg per cubic metre.

CAPACITY: Kg 250 400 500 610 750 1000 1250 1500 1750 2000 2500 3000 3500 4000 5000 6000 7000 8000 10000

A 445 495 610 635 710 740 790 850 890 950 1040 1090 1125 1160 1220 1320 1390 1480 1560

B 355 420 535 560 635 660 685 770 785 850 915 940 990 1020 1066 1160 1240 1300 1425

C 460 570 610 635 710 740 790 850 890 950 1040 1090 1090 1160 1220 1320 1390 1480 1560

D 480 590 630 655 730 750 810 870 915 965 1060 1115 1145 1185 1245 1345 1420 1510 1590

E 962 1102 1107 1140 1245 1290 1485 1495 1650 1880 1940 2032 2050 2085 2145 2470 2530 2630 2770

F 260 286 345 410 420 450 482 495 510 550 620 640 660 680 710 755 795 850 890

G 1089 1147 1355 1395 1405 1455 1545 1570 1710 1830 1890 1935 1990 2000 2100 2310 2310 2406 2550

H 395 425 508 535 535 560 605 615 735 750 760 770 790 800 850 915 915 960 1040

I 673 702 827 840 855 880 920 935 975 1080 1130 1145 1200 1170 1221 1380 1380 1427 1475

J 305 305 460 460 460 460 600 600 600 750 750 750 750 750 750 900 900 900 900

SIDE Lining 45 50 60 65 65 65 75 75 75 90 95 95 95 100 100 100 110 120 125

BOTTOM Lining 45 50 60 65 65 65 75 75 75 100 100 100 100 100 100 100 110 125 130

FREEBOARD 75 75 75 75 75 75 100 100 100 100 125 125 125 125 150 150 150 178 178

Please note that the dimensions given are offered for guidance only and should not be taken as binding. If you do not see the required capacity or have special requirements, we are happy to adjust the ladle sizes to suit your specific needs. Capacities are in Kilograms. Dimensions are in Millimetres and subject to change.

Ladle Shell, Lining Allowances, Freeboard and Capacity

Acetarc ladles shells are designed to take into account modern refractory linings. The working capacity of the ladle is therefore quoted for a given metal density, the lining thickness (sidewalls and base) plus a freeboard (distance between the top of the molten metal and the top of the ladle). If any of the above factors alter, the working capacity of the ladle will correspondingly change as well. If the suggested lining allowances do not meet with your specifications, the Ladle shell size can be adjusted to take into account special refractory lining requirements. ladles shells can be increased in size to accommodate thicker linings without compromising either the ladle capacity or the freeboard.

Special pre-formed refractory liners for ferrous and non-ferrous ladles.

Acetarc ladle shells can also be manufactured to accommodate the pre-formed ladle linings supplied by specialist refractory companies. Contact our office for further details. Ladles should never be filled to the brim to achieve the required capacity. Ladles are designed to have a minimum freeboard in accordance with British and European standards. Treatment and porous plug ladles are offered with an extended freeboard to take into account the reaction.

The trunnion position

The trunnion position for a ladle is located in line with the British Standard for foundry ladles. The trunnions are located so that the ladle is balanced on the trunnions when the ladle is filled to its working capacity. The trunnions position is calculated by taking into account all relevant factors such as:

Lining thicknesses Metal capacity, and density Freeboard

Plus any special features that are aached to the ladle body such as; covers, fork pockets, extended spouts etc. The ladle shell is either line bored or has the trunnions fied using special jigs to ensure that the trunnions are correctly aligned.

Acetarc Ladles Fitted With Motorized Gearing For Powered Rotation.

In addition to the standard manually operated gearing, Acetarc Workhorse ladles can be fied with a motorized gear assembly for the rotation of the ladle. The ladle construction is identical for both the manual and motorized ladle options. The ladle is usually fied with an electric gearmotor but other options such as pneumatic powered gear motors can also be fied.

The Motorized Tilting Arrangement.

The ladle tilting arrangement consists of a motor gear unit and an Acetarc gearbox linked, via a quick release clutch assembly, to give a double reduction gearing resulting in high torque with a low output speed. The gear unit is protected by a steel splashguard enclosure. The ladle gearing allows the ladle to be rotated in both directions at a nominal fixed speed. The required speed of rotation is normally discussed with the client and is chosen to give a full to empty (vertical rotated around to horizontal) of usually 20-40 seconds depending on the application. When the clutch is released, the two drives are disengaged; the ladle can then be fied with a handwheel and rotated manually. The Acetarc gearbox fied to the ladle is the same size on the manually rotated ladles as it is on the motorised ladles.

The Torque Limiter (electric motor drive).

As standard, in addition to the clutch arrangement, the electric drive motorised gearing assembly is fied with a torque limiter. This is designed to act as a fail-safe device in the event that the load on the gearing becomes excessive due to some outside influence. For example the ladle fouling on a static object whilst being rotated. In the event of an overload, the torque limiter will automatically disengage the two gear units. This means that even if the operator does not fully appreciate the situation and continues try to rotate the ladle, the gearing will not suffer damage. To re-engage the torque limiter, the motor drive need only be rotated in the opposite direction.

Control Equipment for Electric Motor Drive Ladles

Unless otherwise stated in a specific quotation, all Acetarc electric drive motorized ladles are supplied to the customer without control equipment. It is the customers responsibility to fit suitable control equipment for the safe and efficient operation of this equipment. However, if the customer wishes Acetarc Engineering to supply the control equipment, we would be happy to offer a quotation following full consultation with the customer.

Acetarc Ladles Fitted With Motorized Gearing For Powered Rotation (Cont.)

(Photograph le): shows part of a shipment of twenty motorized tun-dish treatment ladles supplied to the Victaulic group, USA. Acetarc later supplied the same type of ladle to the new Victaulic foundry in Poland

Pneumatic Drive Ladles

Where required, ladles can be fied with pneumatic motor drive units. Pneumatic motor drives are ideal for hazardous or hostile environments and offer a number of advantages over standard electric motor drive ladles.

The ladle rotation speed can be adjusted, between maximum and minimum speeds, using flow regulators mounted on the ladle. If the motor stalls, due to an overload situation, the motor will not be damaged. Smooth starting, does not impose shock loading on the other gear drive components. Unaffected by and will not generate electrical interference. Pneumatic drive ladles are supplied with forward and reverse controls, a filter regulator lubricator unit, flow regulators and a quick release airline connection as standard.

WORKHORSE Heavy-duty Foundry Ladles

The WORKHORSE range of foundry ladles are the result of over thirty-five years of experience in the design and manufacture of heavy-duty ladles for all foundry applications. Manufactured in a range of standard rated capacities, starting at 100Kg and going up to 40 tonnes (cast iron) for geared ladles, the WORKHORSE ladle is designed for continuous and trouble free service over long periods. Where there are special factors to be considered, the modular design of the WORKHORSE ladle allows individual ladles to be designed to suit a customers specific requirements both quickly and with minimum extra cost. The WORKHORSE ladle designs form the basis for the following main types of foundry ladle:

Casting or transfer ladles; either fied with lip pour spouts, extended spouts or teapot spouts. Boom pouring ladles. Ductile iron (S.G. Iron) treatment ladles.

The Main Features Of The WORKHORSE

The main features of the WORKHORSE heavy-duty ladle are as follows; The Ladle shell is tapered for increased strength and rigidity, with reinforcing bands top and boom in addition the centre band. Depending on the size of the ladle shell, extra reinforcement is added to the ladle shell by the addition of under-straps. The complete assembly is of fully welded construction.

The standard WORKHORSE ladle design incorporates AIR VENTED BOLT ON TRUNNIONS and the mounting assembly for the trunnions is stepped off the shell to give a free flow of air behind the trunnions. This reduces the heat transference from the ladle shell to the gearing. The bolt-on trunnion design allows the liing assembly and gearing to be removed far more easily than a conventional design and also enables the trunnions to be easily replaced in the event of wear or damage. The trunnions rotate in large flexible roller bearings, located in cast iron housings. This type of bearing minimises the effort required to rotate the ladle and, unlike the plain bearings oen used by other manufacturers, .is less prone to tramp metal pick-up that can cause scoring or seizure of the trunnion. The sidearms are of laminated construction to give a strong and rigid assembly whilst minimising the weight. They are machined to accept the liing bail assembly, which consists of two steel channel sections and a liing hook. All ladles are load tested on the calculated gross liing load as standard, prior to shipping the Ladle. Certificates are supplied with the ladle.

Treatment Ladles For The Production Of Ductile (S.G.) Iron

From simple open top deep treatment ladles, using the sandwich process, through to complete treatment stations with batch feed additives hoppers, weighing and PLC control, Acetarc Engineering can offer a wide range of solutions for the safe and efficient production of ductile (S.G.) iron.

Open Top Deep Treatment Ladles

Characterised by their tall body with a small diameter, the ladle shell incorporates an extended freeboard to contain the reaction. The basic design can be adapted to give:

Wire feed ladles Plunging ladles Porous plug desulphurising ladles

Tun Dish & Teapot Spout Covered Treatment Ladles

Acetarc Engineering can offer several covered treatment ladle designs, including loose tun-dish; fixed tun-dish, sliding tun-dish and teapot spout treatment ladles. These ladle designs offer considerable improvement in performance for lile additional capital cost when compared to open top deep treatment ladles using the sandwich method. The main advantages are: Increased magnesium recovery, oen allowing a reduction in the amount of additives used. Fume and glare reduction, leading to a beer working environment and removing the need for costly fume extraction. A more consistent treatment process. Reduced temperature losses. Reduced slag and dross generated. Leading to a beer and consistent quality of castings. Covered treatment ladles can be supplied with optional extras such as spare ladle boom sections. Where a ladle has a bolt-on section such as the spout or base, the flanges are made from heavy-duty steel with extensive gusseting for increased stiffness. The flanges are jig drilled to ensure interchange ability. Ladles can also be fied with loose base plates so that the complete shell lining can be removed using a hydraulic ram assembly.

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Sliding Tun-Dish Treatment Ladle

The treatment process is the same as a conventional tun-dish ladle but the sliding tun-dish addresses some of the problems associated with the handling of the tun-dish lid. The ladle is based on the WORKHORSE ladle design and has extended sidearms with an inner liing bail that can move up and down. The tun-dish cover is aached to the inner liing bail so that when the ladle is lied up, the tun-dish cover is also raised up and when the ladle is placed on the ground; the tun-dish cover is lowered down. The tun-dish must always be raised before the ladle is rotated. When the ladle is being rotated, it handles the same as a similar sized conventional ladle.

Lining Formers
We can supply re-usable lining formers especially designed to complement the treatment ladles. The lining formers are manufactured in steel plate and can be supplied in pieces to assist with the fiing and removal of the former. This also enables base sections to be fied with linings independently of the main body.

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Bottom Pour Ladles

The Workhorse & Essex heavy-duty ladle designs can be fied with a boom pour gear assembly for slag free tapping of the metal from the base of the ladle. Boom pour gear ladles incorporate a number of modifications to the basic heavy-duty ladle design: The ladle is fied with a detachable nozzle box in the base of the ladle. The ladle has three feet added to the base of the ladle, to give clearance on the nozzle box. The ladle shell sizes are adjusted to ensure that the working capacity is maintained, even when the displacement of the stopper rod refractory sleeve is taken into account. The stopper rod and nozzle box are usually designed to suit Vesuvius Refractories but can be made to suit other manufacturers equipment on request. The articulated boom pour gear can have the operating lever set to be used over a 180 degree radius and is also fied with locking bars to keep the stopper rod closed whilst the ladle is being transported. On larger ladles two boom pour gear assemblies can be fied if required. Contact our design office for ladle size and specification details.

Heavy-Duty Drum and U Shape Ladles

Drum & U-shaped ladles can be supplied for capacities up to and including 10,000Kg (22,000lb) C.I. and are normally based on our heavy-duty designs with shells fabricated from heavy steel plate with reinforcing straps etc. Vee bails can be fied on the smaller ladles on request. Motorized gearing options are available for powered rotation. Both end plates on the drum ladles can be unbolted and removed, to aid in the relining process. The ladles can be supplied with various spout arrangements, including offset and central positioned spouts. Single or double spouts can also be fied. The filling slot can be fied with a swing aside or pull back cover for maximum heat retention.

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The Acetarc Oilbath Gearbox

All Acetarc geared ladles are fied with the appropriately sized gearbox to give safe and efficient control of the rotation of the ladle. The gearbox is a proven worm & wheel design with all moving parts rotating in bearings, with either oil or grease lubrication, for maximum life with minimum effort. The gearbox is not bolted directly to the sidearm, but is instead fied with a drive plate that engages with a drive peg that is aached to the ladle sidearm. This method of mounting the gearbox reduces wear on the gears and leaves them unaffected by crane vibration.

Gearbox Spare Parts

Gearbox spare parts are normally ex-stock and can be dispatched within 24 hours of an order being placed. The gearbox should be able to be identified by either the ladle badge, usually located on the liing bail, and/or the number cast into the gearbox front cover. If these are either missing or damaged, measuring the gearcase outside diameter can identify the gearbox. Alternatively, if the gearbox is stripped down, the gearbox can be identified by the diameter, and no. of teeth, of the wormwheel. It is also always useful to give the ladle shell size and rated capacity. If in doubt contact the office. The following diagram gives a schematic view of the typical Acetarc gearbox (sizes 1 to 4). Further details are given in the ladle manual and parts lists for specific gearboxes can be forwarded on request.

For additional security, the No. 3 & No.4 gearbox has the worm wheel fied to the trunnion sha using both a parallel key and a cone-clamping device.

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The Westminster Medium Duty Geared Crane Ladle

Available in sizes up to 4000Kg (8800lb) capacity (C.I.), the Westminster type ladle is designed for foundries who require several capacities with economy, quality, and short runs in mind, but who also require a robust ladle of dependable service. The ladle is ideal for aluminium foundries, and the ladle shell can be made to accommodate either standard castable refractory linings, pre-cast liners or a crucible liner etc. The ladle is fied with the same range of gearboxes as the Acetarc heavy-duty ladles. The taper shell is of an all welded construction, rolled from steel plate and the boom plate is driven in and welded inside and out. The trunnions rotate in replaceable cast iron bushes and the liing bail is made from solid rectangular section with back-to-back top channels. Vee bails are also available if required. The ladle can also be fied with a cover to reduce heat losses and protect the operator. Please contact the design office for further details.

Westminster ladle with Vee bail and teapot spout

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Special Ladle Applications

Many of our foundry ladles are specially designed and manufactured to meet a foundrys specific requirements. We are always happy to discuss your ladle applications and offer advice based on our long experience of providing molten metal handling solutions.

Look for the sign of the

WORKHORSE

Top le: Lip-Axis ladle for pouring cast iron. Boom le: The un-geared crane ladles shown above were designed and built in accordance with A.I.S.E. 9 and used a detachable liing bail for handling the ladles.

Top right: Vacuum Tapping ladle for transporting aluminium. Boom right: Lip-Axis ladle for transferring and pouring 1000kg aluminium complete with man riding cab, installed with a dedicated monorail system. The Lip-axis ladle uses hydraulic rams for tilting the ladle, which can also be raised 1500mm.

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Workhorse Foundry Ladles

Special Pouring Units Crucible Handling Equipment Monorail & Crane Systems Furnace Charging Equipment Foundry Handling Equipment Ladle Pre-Heaters

Acetarc Engineering Co. Ltd. Atley Works Dalton Lane Keighley West Yorkshire BD21 4HT T: +44 (0) 1535 607323 F: +44 (0) 1535 602522 E: sales@acetarc.co.uk www.acetarc.co.uk

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