Driving down element turnaround time while enhancing high quality and lowering waste is being achieved at Weir Minerals Africa’s thrilling new Replicast Plant in Isando, Gauteng.
Umar Smith, plant supervisor at Weir Minerals Africa’s Isando facility, highlights that the revolutionary improvement allows the corporate to produce more elements at a time – and extra rapidly. This will help in meeting growing customer demand, whereas additionally lowering rework and wastage.
“As part of our Project Vuka, this new plant allows us to forged multiple small elements per batch rather than simply one by one,” says Smith. “We can also reduce our knock-out occasions from days to simply a couple of hours.”

The state-of-the-art amenities enable Weir Minerals Africa to cast excessive chrome elements weighing as much as 250 kg. There are two phases to the model new course of, he explains, which uses polystyrene to create moulds. The first part is the polystyrene moulding process, which happens after the polystyrene beads have been expanded. pressure gauge is the place the ramming, pouring and demoulding takes place.
In distinction to the standard moulding line – the place resin and catalyst are used to bind sand – the Replicast Plant uses silica sand of 30-35 AFS grade along with the polystyrene mould, he says. The system involves a vacuum bin, from which all of the air is eliminated to compress the sand.
“The absence of resin and catalyst – as nicely as having no clamping process – results in much less scrap being produced, and therefore brings operational financial savings,” he says. “The high quality of castings is also raised, with a greater floor end and fewer defects.”

He notes that the geometrical stability of components is improved, as there is much less fettling of the finished product thereby reducing dimensional variation between the same parts. This in flip contributes to the reliability of the equipment using these components. He says the foundry may even realise vital environmental benefits as a result of utilizing no chemical substances within the sand.
“This new plant aligns well with our corporate sustainability goals, guaranteeing that our processes aren’t solely compliant but repeatedly scale back our environmental influence,” says Smith. “Our new moulding systems ensure that fewer gases are emitted during the casting course of, and there are zero emissions of dangerous substances corresponding to benzene.”

The new technology can be leading to less frequent disposal of silica sand, and the sand itself is extra environmentally pleasant because it accommodates no resin or acid.
“A exceptional side of developing this new plant was the reality that it was carried out with our native expertise and largely through the COVID-19 lockdowns,” he says. “Despite the novelty of this technology, and the logistical challenges created by the pandemic, it was efficiently applied on time and inside finances.”

The plant consists of more than sixteen,000 particular person parts, and makes use of over 1,900 m of cabling, 300 m of water piping and 55 tons of steel.

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