BatchPilot furnace weighing system for increasing casthouse productivity and production gets major IT upgrade

A top-selling furnace weighing system from Aluminium Casthouse Technologies (ACT) is embracing the advance of Industry 4.0 with a major IT upgrade.

The BatchPilot, an innovative technology used in casthouses worldwide to accurately measure furnace liquid metal weight and determine exactly what is wanted aluminium and unwanted dross, is now installed with the latest Siemens S7 central processing unit and software for an even more accurate online process data logging and more user-friendly smart screens.

The upgrade of the Batchpilot system will, ultimately, allow customers to achieve greater gains in productivity, leading to even higher production levels at a time when the London Metal Exchange is rising sharply.

Knowing the correct weight of metal in the furnace is crucial to ensure slabs are consistently cast to the precise length ordered by the customer. The BatchPilot means casthouses don’t have to rely on visual estimates of furnace heel weight, which are notoriously unreliable, often leading to short casts, overfilling of the furnace or potentially restricting the number of slabs cast, all hugely wasteful.

Bringing an overall increase of more than 15% in production without the need to install new capacity, the system is an invaluable addition to the casthouse and this IT upgrade embraces the spirit of Industry 4.0, making operations even more efficient and improving the user experience.

The BatchPilot uses unique technology for the accurate electronic measurement of furnace heel weights and transfer weights and is based on the principle of measuring changes in the furnace hydraulic cylinder pressure with furnace tilt angle. This allows precise measurement of furnace liquid metal weight, heel weight and dross build up.

Increasing ‘right first time’ batching, other benefits include increased number of ingots per cast, elimination of short casts, increase in yield due to reduction in overlength casting and energy savings due to reduced furnace waiting times.

Easily fitted to existing furnaces without interruption of production, it is a simple, fully automated, retro fitted device that is fully integrated into the batching process.

In terms of return on investment, with prevailing premiums, the payback time for a BatchPilot fitted on a 70MT furnace is less than three months due to the productivity gains it brings.

Crucially, the system – which has successfully been in production usage for over 10 years with fifty five units installed in casthouses around the world - can be tailored and customised to individual customer needs.

ACT is owned and managed by the Courtenay family, also shareholders and directors in aluminium grain refiner producer MQP. MQP’s parent company is Sitong Group, one of the largest producers of master alloys in the world and manufacturer of MQP’s high efficiency Optifine grain refiner.

As well as the BatchPilot, ACT provides the aluminium industry with a range of well-established casthouse products including Refinal fused fluxes and Casiflux environmentally-friendly launder coatings, together with comprehensive back-up support through distributors, agents and technical personnel.