PRIMARY METALS

Solutions

• Alumina

  Rake Drive System

  MECFOR Rake Drive System comes with two main components: a drive mechanism and a HPU that activate four planetary speed reducers. This rake drive system may be used in the processing industry as well as in all areas where very low rotation speed systems are used.

  Benefits

  • Sturdy design and manufacturing;
  • Reliability of rotating mechanism;
  • Prevents material from building up on the walls of large tanks;
  • Powerful planetary; and
  • Constancy of movement.

  

  Descaling Robotic Arm

  A common aspect of alumina production is that capacity decreases as residue and scale build inside production vessels. Whether it’s on a digester’s shell or a thickener’s wall, significant scale builds up during multiple refining tasks, impacting tanks, vessels and pipes. Furthermore, descaling operations often delay or limit operations because of the required downtime to perform the maintenance of removing this residue, resulting in reduction of available tank volume and lost production.

   

  Over the past 25 years, MECFOR designs, manufactures, and commissions a variety of descaling robotic arms for various tank design that dramatically improved working conditions and reduced downtime, keeping facilities online and producing revenue. Our goal is to increase safety and efficiency for our clients. We are convinced that custom descaling robotic arm can achieve these things for your facility.

  

  

  

  
  
• Carbon Plant System

  Anode Handling and Cleaning Systems

  Material handling systems for carbon anodes for global supply to smelters.

  At the heart of every modern smelter carbon operation is the anode handling and cleaning system. This system ties together the Green Anode Plant, the Bake Furnace, the rodding shop and provides green and baked anode storage to buffer the different processing speeds of each of the carbon plant’s processes. EPIQ Machinery experience in the provision of these systems to the world’s largest and most automated carbon plants makes us the ideal supply partner. These systems need to be rugged for the harsh environment and at the same time, need to manage the flow of anodes in such a way as to optimize the processing off all the key anode forming, baking and rodding operations.

   

  Our systems include the following state of the art equipment and systems:

  • Anode handling elevators/lowerators (vertical conveyor)
  • Furnace tending crane delivery and reception carts
  • Upender / downenders
  • Turntables
  • Central pull bar conveyors
  • Heavy Duty Chain and Roller Conveyors
  • Upenders and down enders
  • Baked anode separators (for the case where anodes get fused together during the baking process)
  • Anode Cleaning Machines c/w stub hole cleaning and machining
  • Dust and Packing coke collection and recovery including dilute phase and dense phase conveyance.
  • Core Drill (sampling) Stations for taking samples for quality verification
  • Dust collection
  • Anode inspection stations
  • Anode Storage and retrieval cranes
  • Anode Management systems including plant wide SCADA

  

  

  

  

  

  

  

  

  

  

  

  

  Video gallery

  • Metals carbon anode cleaning machine

  Bake Furnace Maintenance

  As an accessory to EPIQ Machinery world leading anode handling and cleaning systems, we offer all the required anode bake furnace maintenance tools including:

  • Furnace wall building machine
  • Furnace wall removal / tear out grabs (under the hook)
  • Wall straightener
  • Flue Wall Brushing Machine
  • Anode Grabs
  • Spreader Bars for handling and storing replacement flue walls
  • Flue wall maintenance platforms – elevator type

  

  

  Anode Splitters (separating station)

  Separates Anodes which are stuck together due to anode baking process issues:

  • Up to 120 anode per hour capacity
  • Custom tailored to anode shape and technology
  • Rugged simple design ensures long life
  • Heavy-duty welded construction
  • Heavy-duty hydraulic cylinder provides separating force
  • Integrated with anode handling prior to baked anode cleaning

   

  

  MECFOR Anode Slot Cutting Machine (ASCM)

  • Proven cycle time of 60 anodes/hour;
  • Up to 450mm deep slots;
  • Proven extra-long life of the blade cutters. Each cutter is individually replaceable;
  • In-depth knowledge in ASCM: more than 30,000,000 anodes slotted over the last decades;
  • Trouble-free operation and excellent feedback from customers;
  • Optional Remote access for troubleshooting is available for increased responsiveness;
  • Dust collection hopper designed so that carbon dust generated during the cut is captured at source, allowing for a clear view of the operation through the windows and letting negligible amounts of carbon dust escaping from the machine enclosure;
  • Sturdy frames of the ASCM along with precise control of saw rotation and anode displacement give a great stability to the operation preventing unwanted vibrations that cause premature wear or damages to the saw blades;
  • Easy and safe maintenance accesses.

  

  

  P&F Conveyor

  To move rod assemblies / anode assemblies from one station to the next in the rod shop in an assembly line manner. A Power & Free by-pass to separate new anode production from butt processing / recycling is also included. This feature provides great flexibility during start-up operations.

  

  Anode Stacking Crane

  The anode stacking crane is to be installed in the anode storage building located next to the rodding shop for picking up set of anodes on a roller conveyor and transfer them to another conveyor or to storage areas or to transfer set of anodes from the storage area to roller conveyors.

  

  
  
• Rodding Shop

  Hooking / Unhooking

  

  Anode Repair Shop

  

  Carbon Breaking and Stripping Machine

  

  Iron Tromel

  

  Pins Black Wash and Drying-station

  

  Butt Shot Blasting Machine

  

  Stem Brushing Machine

  

  Rodding Bench

  

  

  
  
• Electrolysis

  Pot Ramming Machine (PRM)

  With over 130 Pot Ramming Machines (PRM) in operation all around the world, EPIQ has gained knowledge and expertise in this critical task, historically done by hand. From this situation results the setting of proven ramming procedures and parameters offering incomparable compaction results.

  Either for hot, warm or cold paste ramming, EPIQ BROCHOT machines will bring:

  • Improvement of the quality of the joints making them more uniform thanks to the variety of tooling heads available (compatible with pneumatic or electrical PRM);
  • Friendly-user HMI Interface display along with remote-controlled operations;
  • Plug and play’ designed equipment, for quicker installation on-site that minimizes impact on production;
  • Easy access to components to simplify maintenance.

  COMPACTION TECHNOLOGY BY VIBRATION HAS BEEN SHOWN TO BE THE MOST EFFECTIVE ONE OVER TIME, EVEN FOR SMALL JOINTS BY APPLYING PASTE VERTICALLY ON THE CATHODE FACE.

  • No edging effect during ramming compare to a compacting wheel;
  • No jamming of the paste on EPIQ BROCHOT PRM tools;
  • Compaction results are perfectly reproducible by setting strength, frequency and time of the ramming sequence

  

  

  Anode Raising Beam

  Used to lift the busbar when it reaches the lower end of its stroke. The lifting beam is formed by two longitudinal girders linked between them. It is guided by one square shape profile beam guided by means of rollers.

  

  
  
• Electric Crucible Hauler

  NEW | EPIQ DTA e-CTV 18T Electric Hauler

  • Semi autonomous human operated AGV-ready vehicle, the e-CTV is a perfect model for a transition from a manual steered driven to fully automated hauler;
  • A compact vehicle 100% electric driven with battery power;
  • Operating in harsh environments (e g.: strong magnetic fields, dust, and wide range of temperatures)
  • Reduced emissions with fully electric solution
  • Reduced maintenance as there is no diesel motor
  • A service team dedicated in staying close to its installed base with knowledgeable technicians and spare parts availability
  • Ability to make sure the solution meets your requirements if needed based on specifics of your plant

  Semi-automatic guidance I Operator’s assistance

  Activated by a button, the automatic crucible pick-up mode allows the operator to release the joystick and let the hauler finds its right position under the crucible stand. Multiple positioning schemes possible.

  

  

  

  
  
• Industrial Hauling Solutions

  Industrial Hauling Solutions (MTA & MTC)

  Leader on the North American market, EPIQ Mecfor MTA/MTC Haulers provide safe transportation of anode and/or molten metal. Several models are available to accommodate the operations and space constraints of aluminum smelters. From the MTC30 (narrow model) to MTC50 (wide model), your operators’ teams will be able to drive with ease in the pot rooms. The expertise of magnetic field shielding developed by our product specialists makes EPIQ haulers safe and reliable.

   

  The MTA/MTC family of vehicles is one of the best choices when it comes to standardizing the vehicle fleet. Since they are articulated, it is possible to attach the tractors with a range of trailers: anodes, metal, transvider, tipper, and metal transfer by pressurization. Also, the articulation allows tight turning radius in comparison with a rigid carrier. The swapping of trailers provides contingency that limits unplanned stops and maximizes equipment availability. Adding to the flexibility, the MTC tractor is adapted to work with the molten metal pressurized transfer trailer (MMTP).

   

  The MTA/MTC is powered by a diesel engine complying with new industry standards and is coupled to a hydrostatic transmission. Thus, the machine offers constant torque with unlimited speed variation on the front axle. The comfortable operator’s environment offers unmatched visibility, safety and state-of-the-art controls to maximize productivity. The operator will appreciate the easy-to-use of electro proportional joystick and seat rotation, as well as the control modules that enable both front and rear driving and vision. The vehicle is also equipped with a Sauer-Danfoss controller that gathers and stores vital operational and diagnostic information.

   

  Customers appreciate:

  • Reliability and efficiency;
  • The interchangeability of the different types of trailer to be coupled to the tractor;
  • The safety, comfort and ergonomics of the operator’s cabin;
  • Easy and quick access to components for maintenance works;
  • Driving forward at all times while the operator is keeping an ergonomic position, and;
  • Sturdy and durable components.

   

  Finally, many options and technologies can be offered in options to meet your specific needs. The MTA/MTC haulers are sturdy ensuring a long and reliable life cycle time. Contact EPIQ Mecfor experts; he will work with you to build the best hauler fleet and see how your operations can be optimized.

  Anode Haulers

  

  

  

  

  

  

  

  Crucible Haulers

  

  

  

  

  

  

  

  

  

  Crucible Tilting

  

  

  

  

  

  

  Molten Metal Transfer by Pressurization (MMTP)

  

  

  

  Molten Metal Transport – MYT

  

  

  

  

  

  Bath Tapping Vehicle (BTV), model MVR-MAC

  EPIQ MECFOR vehicles are specially built to operate in harsh working environments of aluminum smelters. Productivity, flexibility, ergonomics, ease of maintenance, visibility and safety are some of the criteria used in our design.

   

  The BTV vehicle is used to perform bath balancing operation, to ensure quick and continuous response (without using the overhead crane) and to ensure greater process flexibility. A good bath balance increases the Faraday current efficiency (cell stability) and reduces the amount of iron content in the aluminium by maintaining the bath under the anode rod level.

   

  EPIQ MECFOR’s BTV picks up a crucible, containing molten bath, from a table or from the floor. Only few seconds are required to load a crucible without the operator leaving the cabin. The grip is secured by manual lock. The vertical movement of the crucible is ensured by the robust mast (forklift) and the heavy duty “C” frame.

   

  The Bath Tapping Vehicle (BTV) also offers other features:

  • Protection against magnetic fields and alumina dust
  • High accuracy real-time weighing system
  • Compliance with maximum floor loading capacity of recent aluminum smelters
  • Unobstructed view during pouring/siphoning
  • Driving forward at all times during transport
  • Other technologies are available in option – contact us for more information.

  

  

  

  

  

  Mecfor Tow Tractor – MTT

  

  

  
  
• Smart Casthouse Solutions

  Today, with the production capacities in place, smelter operations need to be done faster and more efficiently than ever before. What would happen if, as much as possible, operators could avoid manual operations? What would happen if most smelter operations could be done using a multifunctional vehicle coupled with dedicated tools? What if a multifunctional vehicle, such as EPIQ Mecfor MVR or MVA, with smart tools could help standardizing processes while reducing maintenance costs?

   

  For several years, EPIQ Mecfor has been offering a concept of great versatility. This concept is called: “Smart Casthouse solution”, where an MVR or MVA operates as many tools as needed with a hydraulic coupling.

   

  Easy, fast and efficient

  With EPIQ Mecfor Smart Casthouse solution, the number of dedicated vehicles required for furnace charging, tending, and skimming operations can be significantly reduced. The multifunctional vehicle and its tools, which can be interchanged in less than thirty seconds, also reduce maintenance costs, increase uptime and energy loss associated with the smelter process. This, while improving the quality of the metal and ensuring the safety of operations.
  Through a hydraulic connection, Mecfor’s QuicKonnect system operates a wide variety of modular tools that perform specialized and dedicated tasks including furnace skimming, cleaning, scrap loading, alloying and stirring. The types of tools currently available are, but are not limited to: loading clamps, fork rotators, scrap pusher tool system, dump bucket, scrapers, combs and skimming tools, all are firmly and securely connected.

   

  Hydraulic power opens a wide range of possibilities for the development of tools that better fit to the realities of today’s modern smelters. Complete cycle in a smelter can be carried out by the operator using a single vehicle without having to leave the comfort of his air-conditioned cabin. The fenestration of the cabin is designed so that the visibility of the operator is optimum with a full panoramic view at all times. In addition, thanks to the option of double steering of the vehicle, it is possible to drive from front, even with a load.

   

  Contingency

  The use of two multifunctional vehicles, MVR or MVA, with a series of interchangeable tools offers the great flexibility of being able to carry out all the smelter operations using one vehicle or the other. Reliability engineers will be pleased to see that the use of the vehicle is optimized and that the sturdy tools have a very long life from the industry average.

   

  Cost reduction

  Since smelter operations are performed quicker, the efficiency of the production is based on the reduction of the execution time while maintaining the quality of the cast metal. The availability of optimized tools in the smelter is essential.

   

  Increased productivity

  Smelters using Mecfor QuicKonnect technology benefit from a quick return on investment while improving the safety of their workers. Increased productivity passes through a rigorous selection of QuicKonnect tools. Significant savings are achieved by protecting the furnace refractories, thanks to the Furnace Protection System – FPS-  as well as reducing the number of vehicles and simplifying periodic mechanical maintenance. Safety, productivity, cost savings and ergonomics are the main factors taken into account in the design of Mecfor Smart Casthouse Solution.
  For several years, EPIQ Mecfor has been offering a concept of great versatility. This concept is called: “Smart Casthouse solution”, where an MVR or MVA operates as many tools as needed with a hydraulic coupling.

   

  Easy, fast and efficient

  With EPIQ Mecfor Smart Casthouse solution, the number of dedicated vehicles required for furnace charging, tending, and skimming operations can be significantly reduced. The multifunctional vehicle and its tools, which can be interchanged in less than thirty seconds, also reduce maintenance costs, increase uptime and energy loss associated with the smelter process. This, while improving the quality of the metal and ensuring the safety of operations.
  Through a hydraulic connection, Mecfor’s QuicKonnect system operates a wide variety of modular tools that perform specialized and dedicated tasks including furnace skimming, cleaning, scrap loading, alloying and stirring. The types of tools currently available are, but are not limited to: loading clamps, fork rotators, scrap pusher tool system, dump bucket, scrapers, combs and skimming tools, all are firmly and securely connected.

   

  Hydraulic power opens a wide range of possibilities for the development of tools that better fit to the realities of today’s modern smelters. Complete cycle in a smelter can be carried out by the operator using a single vehicle without having to leave the comfort of his air-conditioned cabin. The fenestration of the cabin is designed so that the visibility of the operator is optimum with a full panoramic view at all times. In addition, thanks to the option of double steering of the vehicle, it is possible to drive from front, even with a load.

   

  Contingency

  The use of two multifunctional vehicles, MVR or MVA, with a series of interchangeable tools offers the great flexibility of being able to carry out all the smelter operations using one vehicle or the other. Reliability engineers will be pleased to see that the use of the vehicle is optimized and that the sturdy tools have a very long life from the industry average.

   

  Cost reduction

  Since smelter operations are performed quicker, the efficiency of the production is based on the reduction of the execution time while maintaining the quality of the cast metal. The availability of optimized tools in the smelter is essential.

   

  Increased productivity

  Smelters using Mecfor QuicKonnect technology benefit from a quick return on investment while improving the safety of their workers. Increased productivity passes through a rigorous selection of QuicKonnect tools. Significant savings are achieved by protecting the furnace refractories, thanks to the Furnace Protection System – FPS-  as well as reducing the number of vehicles and simplifying periodic mechanical maintenance. Safety, productivity, cost savings and ergonomics are the main factors taken into account in the design of Mecfor Smart Casthouse Solution.

  

  

  

  

  

  

  

  

  
  
• Casthouse Handling Systems and Casting lines

  EPIQ Machinery engineers and manufactures mission critical material handling and processing systems for world leading primary aluminium smelters and secondary cast houses worldwide.

  Extrusion billet batch homogenizing systems

   

  Fully automated or semi-automated material handling for extrusion billets for homogenizing and on to sawing operations

  EPIQ Machinery designs and builds a highly efficient automatic aluminium batch homogenizing build and break down system.  One advantage we have over our competitors is that our gantry system does not touch the aluminium billets.

  All motions that we make during the transfer of the extrusion billets are made in linear motions. This improves the reliably and position of the billet at the transfer point.

   

  Our solution ensures;

  • uniform load growth during the homogenizing cycles
  • linear motions for aluminium billet transfer – no log rolling
  • robust billet homogenizing furnace spacers to prevent loads from shifting

  

  

  

  

  Video gallery

  • Metals extrusion billet homo load build animation

  Extrusion Billet Sawing and Packaging Systems

  Fully automated or semi-automated material handling for extrusion billets for internal or external supply EPIQ Machinery provides its customers with the worlds most automated and productive aluminium extrusion billet sawing and packaging systems.  Our solutions can be either automatic or semi-automatic and will package the billets and logs for internal use or to supply your customer.  The billets and logs are typically prepared to industrial shipping standards but, we can design the packaging line to meet your specific needs.

   

  These systems are tailored to suit customer production requirements and include:

  • High speed and robust roller conveyors
  • High capacity accumulation conveyors
  • Smooth and quiet 90 degree pick and place transfer devices
  • High speed circular saws or band saws
  • Length gauge stops with integrated programmable pin marking systems
  • Automatic Billets stacking machines
  • Automatic Billet Strapping machines using steel or plastic strapping and having the capability to insert woodrunners
  • Package weighing
  • Saw chip collection
  • Saw chip briquetting
  • Ultrasonic Inspection Stations
  • Level 0 and 1 instrumentation and control systems with option Level 2 SCADA

  

  

  

  

  

  

  

  

  

  

  

  

  Video gallery

  • Metal sawing systems ultrasonic inspection

  Slab and T-ingot Sawing Systems

  Robust systems for receiving Ingots from vertical casting machine and then cutting them and packing them for downstream processing.

   

  For the handling and high speed cutting, marking, and packaging of Slabs, T-Bars, and plates, EPIQ Machinery provides complete automated systems.

   

  These systems are designed for the specific handling of vertically direct chill (VDC) cast ingots. The equipment is ultra heavy duty to assure reliability and high uptime in the face of the heavy loads and occasional operator abuse.

  Systems include:

  • Ingot downenders
  • Roller Conveyors
  • Squaring devices
  • High Speed Circular or Band Sawing Machines
  • Fully integrated weigh stations
  • Automatic pin marking, ink jet marking and labelling systems
  • Automatic stacking, strapping and packing per customer requirements
  • Automatic ultrasonic inspection

  

  

  

  

  Video gallery

  • Metals slab ingot Aluminium Ingot Handling & Sawing System

  Melt Furnace Charging and Tending Machines

  Rail bound aluminium scrap furnace charge car and furnace tending machines.

   

  For both upgrades of existing casthouses and for new cast houses, EPIQ Machinery designs and builds rail bound scrap furnace charging machines and furnace tending machines.  Benefits associated with such charging and tending systems include increased throughput, reduction of damage to the furnace linings, ability to use a greater percentage of scrap, reduction of gas usage, and increased operator safety.

  

  

  

  Video gallery

  • Metals furnace charging rotary furnace charge car R01
  • Metals cast house melt furnace charge car

  Sow Casting Systems

  EPIQ Machinery designs and builds a full range of sow casting systems from 5 to 40 tonne per hour in both air cooled and water cooled versions.  These systems can be very basic and used as a back-up to other more sophisticated casting machines or they can be fully automated with a marking and packing line and used as mission critical processing lines.

   

  Our systems include:

  • Gantry style cranes for crucible transportation
  • Crucible tilter stations
  • Robotic or dedicated skimming stations
  • Sow mould train or turntable style
  • Sow moulds
  • Vacuum de-moulding/ sow extraction machines
  • Secondary water cooling
  • Sow weighing and marking stations
  • Sow stacking
  • Sow accumulation conveyors

  

  

  

  

  Custom Heavy Handling and Packaging Systems

  EPIQ Machinery can custom engineer machines of all types for automatic or semi-automatic material handling operations.

  Examples of such machines are:

  • Ultra heavy duty roller and chain type conveyors
  • Bridge cranes, Gantry Cranes, ASRS Cranes
  • Rail Bound transfer cars – optional battery operation and wireless control
  • Robotic pick and place (up to 1000 kg payloads)
  • Industrial Weighing, marking, labelling

  

  

  

  

  

  

  

  
  
• AGV Solutions

  Following the launch of the AGV TEAM prototype in 2018, the first North American electrical auto guided Molten Metal hauler, EPIQ Machinery has continuously look into offering a wider range of AGV equipment solutions for the global international market of aluminium producers (primary and secondary).

   

  In the aluminium industry, there are many heavy-load travels done between various sectors (ladle of molten metal, anodes, coil, ingots, etc.). Each requiring a rigorous analysis of inputs to ensure safe travel in all conditions, indoor and outdoor, winter and summer.

   

  In 2022, EPIQ Machinery announced a partnership with DTA, the world most advanced manufacturer of auto guided solutions. The goal of EPIQ Machinery teaming with DTA is to bring the AGV technology accessible and in accordance with our clients’ specific needs. EPIQ Machinery will also act as solution integrator and provide after-sale technical support.

   

  EPIQ Machinery wants to embrace the aluminium producers towards the shift to Industry 4.0. by offering global material handling system integration into plants. As the AGV market is booming, the cooperation between EPIQ Machinery and DTA is timely. The combination of the skills of the two equipment manufacturers, leaders in their field, can only benefit end-user customers.

   

  Check out our AGV Solutions page.

  
  
• Aftermarket Services

  Support the Equipment until the end of its useful life

  EPIQ Machinery offers a comprehensive suite of services and solutions designed to provide our customers with unprecedented value and cost savings throughout the life span of equipment and systems. Learn more on our Aftermarket services.

  
  
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