Rautomead Limited

Rautomead Limited

Rautomead LimitedPO Box 100Dundee DD1 9QY Scotland Registered Office: Nobel Road

Wester Gourdie Industrial Estate

t. (44) 1382 622341 Dundee DD2 4UH, Scotland

f. (44) 1382 622941 Incorporated in Scotland No. 152367

Continuous Casting Technology

www.rautomead.com VAT Reg. No. GB 658 2549 03 Advanced Metals Technology 

Rautomead Limited

Introduction to Rautomead

Rautomead Limited

Rautomead LimitedDundee Scotland

Founded 1978

Sir Michael NairnChairman

Brian Frame MDappointed 2008

Employees = 50

No Machines Sold = 337First 1978

Of these :-

No Vertical Upwards = 76First 1995 (Patent expired 1990)

Rautomead Limited

Rautomead – Nobel Road Factory

Rautomead Limited

Rautomead – Nobel Road Factory

Rautomead Limited

Rautomead – Unit 7A Nobel Road Factory

Rautomead Limited

Rautomead – Unit 7A Nobel Road Factory

Rautomead Limited

RS3000 – 8mm Cu-OF Redraw Rod

Rautomead Limited

RS3000/Mg – 30mm CuMg for HS Railway Contact Wire

Rautomead Limited

RS2500 – 8mm 65:356 Redraw Rod for EDM Wire

Rautomead Limited

RS1000 – Brass for Cold Heading

Rautomead Limited

RT850 – Hollow Bronze Billet for Pump Bearings

Rautomead Limited

RX1100 – 70mm Zinc Billet for Extrusion (Wheel Weights)

Rautomead Limited

RMJ/H025

RMT200

RMJ/V005

RVSIII Tilt

Rautomead Limited

5000 – 10000 Tonnes/Year

Rautomead Limited

Rautomead Furnace Technology for

Continuous Casting

Rautomead Limited

Rautomead Furnace Technology

Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-

•Containment (Crucible & Valve)

•Casting (Dies and Packers)

•Heating (Low Voltage resistance heating elements).

Rautomead Limited

Rautomead Furnace Technology

Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-

•Containment (Crucible & Valve)

•Casting (Dies and Packers)

•Heating (Low Voltage resistance heating elements).

Rautomead Limited

Rautomead Furnace Technology

Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-

•Containment (Crucible & Valve)

•Casting (Dies and Packers)

•Heating (Low Voltage resistance heating elements).

Rautomead Limited

Rautomead Brass Wire Continuous Casting Machines

Rautomead Limited

Rautomead Brass & Alloy Wire Rod Machine Installations by Country

Sodick Japan RS2500 8.0mm 2012

Jia Bao Taiwan RS 2500 8.0mm 2006

Sodick Japan RS 1000 8.0mm 2006

Alecosa Spain RS 2500 8.0mm 2005

Kaohsiung Taiwan RS 1000 8 & 20 2003

Outokumpu Finland RS 1000 20mm 2001

Sundwiger Germany RS 2500 20mm 1998

Rautomead Limited

RS2500 CONTINUOUS CASTING TECHNOLOGY FOR BRASSES, BRONZES & ALLOYED COPPERS

• Up to 6,000 tonnes per year• 8 strand production• 8.0 – 30mm diameter• Holding & Casting Furnace (2500 kg

capacity)• - to be fed with pre-alloyed liquid metal• Graphite Crucible Technology• Electric Resistance Heating• Touchscreen Controls• Comprehensive Alarm System• PLC Controlled Coil Formation• Coil Weight: 2500 - 4000kgs • Coiler Model 0800: max. 12.7mm dia.• Coiler Model 0832: max. 30mm dia.• Options: remote plant monitoring

End Use Applications include:-EDM Machining Wire-Brass Wires-Bronze Wires

Services Required:-Primary Melting Equipment & Launder Transfer-240 kVA Mains Power-Diesel Generator & UPS-Secondary Water Cooling; Emergency Water -Nitrogen Gas (5 ppm O2)- Dust Extraction

Rautomead Limited

RS2500 Layout

Rautomead Limited

RS2500 - 8 Strand 8mm Casting 65:35 Brass fro EDM Wire

Rautomead Limited

RS2500 - 8 Strand 8mm Casting 65:35 Brass fro EDM Wire

Rautomead Limited

RS2500 - 8mm 65:35 Brass Supercoolers

Rautomead Limited

RS2500 - 8mm 65:35 Brass Supercoolers

Rautomead Limited

SUPERCOOLER TOOLING ASSEMBLY

SECONDARY COOLING

WATERINLET

WATEROUTLET

COOLINGWATER CHANNELS

THERMALINSULATION

CERAMICHOT END CAP

GRAPHITECASTING INSERT

COPPER ALLOYPRIMARY COOLER

Rautomead Limited

VERTICAL CASTING SYSTEM

OPTIC SENSORS

IMMERSION THERMOCOUPLE

FLOATASSEMBLY

GRAPHITE FLAKE

MOLTENBRASS

WATER COOLINGSERVICES

SUPERCOOLERTOOLING

ASSEMBLY

CONSTANT IMMERSION

Rautomead Limited

RS2500

Rautomead Limited

RS250 Withdrawal Options

Re-Start Motor Shaft

Individual Raise/LowerSupercooler

Rautomead Limited

RS2500 – Liquid Feed from Pre-Melter

The Brass must first be alloyed, tested and adjusted before pouring into the casting furnace.

Allowance is made for Zinc Losses during transfer of the metal.

Sample preparation and Analysis equipment needs to be near the machine.

Ladle, Mould, Small Lathe & Spectrometer

Rautomead Limited

RS2500 – Premelting Furnace

Rautomead Limited

Pre-Melter Emergency Empty Pit

Rautomead Limited

RS2500 – Feeding Pre-Melter

Rautomead Limited

RS2500 – Feeding Pre-Melter & Transfer Launder

Rautomead Limited

RS2500 – 65:35 Brass for EDM Feedstock

Rautomead Limited

RS2500 – Liquid Feed Launder

Rautomead Limited

RS2500 Fume Extraction

Rautomead Limited

RS2500 Fume Extraction

Rautomead Limited

Rod Breakdown for 8mm Brass

Rautomead Limited

EDM Wire from 8mm Continuous Cast RodTypical Breakdown of sizes42% of finished wire 0.25 and 0.3mm

50% of finished wire 0.2mm2% of finished wire 0.15 and

0.1mm

Rautomead Limited

RS10000 CONTINUOUS CASTING TECHNOLOGY FOR BRASSES, BRONZES & ALLOYED COPPERS

• to 3,000 tonnes per year • 4 strand production• 8.0 – 30mm diameter• Holding & Casting Furnace (1000kg

capacity)• - to be fed with pre-alloyed liquid metal• Graphite Crucible Technology• Electric Resistance Heating• PLC Controlled Coil Formation• Coil Weight: 2500 - 4000kgs • Options:• - plant monitoring for remote viewing of

production data & enhanced technical service support

End Use Applications include:-EDM Machining Wire-Brass Wires-Bronze Wires

Services Required:-Primary Melting Equipment & Launder Transfer-175 kVA Mains Power-Diesel Generator & UPS-Fume Extraction & Filter Secondary Water Cooling; Nitrogen Gas

Rautomead Limited

RS1000 Layout

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

• Launder feed to RS casting machine

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

• Launder feed to RS casting machine

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

RS1000 Casting 8mm

Rautomead Limited

Saikawa Rod Breakdown machine for 8mm Brass

Rautomead Limited

Shaving 8mm Brass Rod for EDM wire

8mm rod must be shaved to remove suface zinc spotting and microcracks common when casting brasses.

Typically 0.3mm off 8mm diameter.

Normal Method is to fit a shave die on inlet to Rod Breakdown

Rautomead Limited

http://www.saikawa.co.jp/eng/index.html

Mr Takashi AizawaExec DirectorSaikawaJapanaizawa@saikawa.co.jp

Alternative is Niehoff

Rautomead Limited

ECONOMIC CASE operating

Investment cost/tonne

Marx Melting furnace € 500,000 € 30

Rautomead Continuous casting € 700,000 € 60 (RS1000)

1 x breakdown drawing 8 – 3mm € 400,000 € 30

1 x intermediate drawing 3 – 1.3mm € 350,000 € 20

5 x fine wire (2 strands 1.3 – 0.2) € 1,000,000€ 30

Ancillaries, services etc € 450,000

Overheads, labour etc etc allow € 100

Investment budget € 3,400,000

operating cost/tonne €270

Rautomead Limited

ECONOMIC CASE ctd

Oct 13, when Copper $ 7,150 / tonne Zinc $ 1,800 / tonne

Market price 0.2mm 60:40 wire € 5.00/ kg (assume)

Metal value: 60:40 brass: 0.6 * 7.15 = $4.29/Kg 0.4 * 1.8 = $ 0.72 /kg

metal: $ 5.01/kg @ $1.0 = €0.73 = € 3.657/kg

plus operating cost per kg € 0.270/kg

Total cost: € 3.927/ kg

Margin per kg = € 5.00 - € 3.927 = € 2.195/kg

Production : 1,500tpyr BENEFIT/YEAR € 1,609,500 million

PAYBACK OF INVESTMENT WITHIN 26MONTHS

Rautomead Limited

Thank You

www.rautomead.com

Rautomead LimitedNobel Road, Wester Gourdie Ind. Est.Dundee DD2 4UHScotland U.K.