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Meeting 2017 TMS Annual Meeting & Exhibition
Symposium Cast Shop Technology
Presentation Title Case Study of Magnetically-Stirred Casting Furnaces at New Zealand Aluminium Smelters Limited
Author(s) Ray Cook, Marcos Varayud, Steve Iijima, Eishin Takahashi
On-Site Speaker (Planned) Ray Cook
Abstract Scope New Zealand Aluminium Smelters Limited (NZAS) supplies the highest purity primary aluminium ingot, high quality extrusion billet and rolling slab products. In 2011 NZAS installed Zmag’s MagStir™ into a 50T casting furnace. MagStir utilizes zPMC™, Zmag Permanent Magnetic Circuit, the world’s first, proprietary permanent magnet-based technology for contactless stirring in the bath. Agitation of casting furnaces during alloying to achieve elemental dissolution and temperature control is the key part of furnace preparation and when performed in an efficient manner, it can give significant savings in fuel and alloying costs and increased throughput. In 2016 NZAS added MagStir to two more casting furnaces and achieved significant improvements in temperature control during all phases of furnace preparation. This paper is a case study on the benefits of stirring in general, specific benefits observed using Zmag's MagStir at NZAS as well as lessons learned in the operation of the systems over 5 years.
Proceedings Inclusion? Planned: Light Metals

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Study on DC Casting Trough/ Launder Design and Material Selection
Application and Results of Oxipyr Diluted Combustion in Aluminum Furnaces
Automation and Optimization of Sow Casting in Alouette
Case Study of Magnetically-Stirred Casting Furnaces at New Zealand Aluminium Smelters Limited
Circulation of Grains during Ingot Casting
Critical Role of Thermal Management during Cast Start-up of DC Casting Process
Effect of Grain Refiners on Aluminum Twin Roll Casting Process
Effect of Magnesium Content on Microstructure and Mechanical Properties of Twin-Roll Cast Aluminum Alloys
Effect of Ultrasonic Processing on a Direct Chill Cast AA6082 Aluminium Alloy
Energy Efficiency Status-quo of UK Foundries: The “Small-Is-Beautiful” Project
Full Size Measurement and Simple Prediction on Macro Segregation of Aluminum Alloys Elements in Industrial DC Casting Slab
Grain Refiner Settlement in the Launder System of Twin Roll Casting and Application of Electromagnetic Stirring
Have Recent Advances in Direct Chill Casting Made Us Less Safe?
Influence of Process Conditions on Segregation Behavior in Twin-Roll Casting of an AlFeSi Alloy
Influence of Sticking on the Roll Topography at Twin-roll Casting of Aluminum Alloys
Material Surface Roughness Change in Twin Roll Casting of Aluminium as Cast Sheet Product
Minimization of Macrosegregation through Jet Erosion of a Continuously Cast Ingot
Modelling and Analysis of a Horizontal Direct Chill Casting Process
Multi-Component High Pressure Die Casting (M-HPDC): Influencing Factors on the Material Temperature during the Joining of Metal-plastic-hybrids
Operational and Economic Impact of Super Vacuum Die Casting Technologies
Optimization of Recovery Efficiency for Briquetted Aluminum Chips up to Briquetting Parameters
Overpressure Due to a Molten Aluminum and Water Explosion in a Casthouse
Peritectic Coupled Growth Solidification - A Review
Radio Frequency Identification (RFID) Technology for the Aluminum Industry
Semi Finished Products Traceability Improvement with Laser Marking
Sequential Gravity Casting in Functionally Graded Aluminum Alloys Development
Shear Induced Grain Refinement of a Continuously Cast Ingot
Structural Integrity Assessment of Pressurized Ladles for Aluminum Smelting
The Evaluation of Hot Dross Processing Systems
Twin-roll Casting of Aluminum-steel Clad Strips: Static and Dynamic Mechanical Properties of the Composite
Ultrasonic Assisted Reduction of Hot-tearing during High-speed DC Casting of 6000 Series Aluminum Alloys
X-Ray Computed Tomographic Investigation of High Pressure Die Castings

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