PRIMARY METALS

Solutions

• Alumina

  Rake Drive System

  The MECFOR Rake Drive System comes with two main components: a drive mechanism and an HPU that activate four planetary speed reducers. This rake drive system can be used in the processing industry as well as in all areas where very low rotation speed systems are required. It complements our range of heavy-duty equipment, ensuring efficient operations.
   
  Benefits

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

  

  Descaling Robotic Arm

  A common aspect of alumina production is the decrease in capacity as residue and scale build up 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. Descaling operations often delay or limit production due to the required downtime for maintenance, resulting in reduction of available tank volume and lost production.

   

  Over the past 25 years, MECFOR has designed, manufactured, and commissioned a variety of descaling robotic arms for various tank designs, dramatically improving working conditions and reducing downtime.. Our goal is to increase safety and efficiency for our clients. We are convinced that our custom descaling robotic arm can achieve these objectives for your facility.

  

  

  

  
  
• Carbon Plant System

  Anode Handling and Cleaning Systems

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

  The Anode Handling and Cleaning System is central to every modern smelter carbon operation. This system integrates the Green Anode Plant, the Bake Furnace, and the rodding shop, providing green and baked anode storage to buffer the different processing speeds of each of the carbon plant’s processes. EPIQ Machinery’s experience in providing 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, manage the flow of anodes to optimize the processing of 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 complete with 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)

  Our Anode Splitters separate anodes that are stuck together due to anode baking process issues:

  • Capacity of up to 120 anode per hour
  • 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 system prior to baked anode cleaning systems

   

  

  The MECFOR Anode Slot Cutting Machine (ASCM) features:

  • Proven cycle time of 60 anodes/hour
  • Capable of cutting slots up to 450mm deep
  • Proven extra-long life of the blade cutters, each individually replaceable
  • Extensive experience with more than 30,000,000 slotted anodes over the last decades
  • Trouble-free operation and excellent feedback from customers
  • Optional Remote access for troubleshooting increasing responsiveness
  • Dust collection hopper designed to capture carbon dust at the source, providing a clear view of the operation through windows and minimizing carbon dust escape from the machine enclosure
  • Sturdy frames of the ASCM, along with precise control of saw rotation and anode displacement, ensuring great stability during operation, preventing unwanted vibrations that cause premature wear or damages to the saw blades
  • Easy and safe maintenance access

  

  

  P&F Conveyor

  The Power & Free (P&F) Conveyor is designed to move rod assemblies and anode assemblies from one station to the next in the rod shop, facilitating an efficient assembly line process. This conveyor system includes a P&F by-pass to separate new anode production from butt processing and recycling, offering great flexibility during start-up operations. Our P&F Conveyor system integrates seamlessly with our Anode Handling and Cleaning Systems, ensuring smooth operations.

  

  Anode Stacking Crane

  The anode stacking crane is designed to be installed in the anode storage building located next to the rodding shop. It is used for picking up sets of anodes from roller conveyor and transferring them to another conveyor, storage areas, or back from the storage area to the roller conveyors. This crane system is an integral part of our Heavy-Duty Material Handling Systems for Rodding Shops.

  

  
  
• 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 worldwide, EPIQ has gained extensive knowledge and expertise in this critical task, which was historically done by hand. This experience has led to the development of proven ramming procedures and parameters that offer incomparable compaction results. BROCHOT Pot Ramming Machines are suitable for hot, warm, or cold paste ramming and offer many benefits:

  • 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)
  • User-friendly HMI Interface display along with remote-controlled operations
  • ‘Plug and play’ designed equipment for quicker on-site installation, minimizing impact on production
  • Easy access to components for simplified 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

  The Anode Raising Beam is 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 transitioning from a manual steered hauler to a fully automated one
  • A compact vehicle that is 100% electric driven with battery power
  • Operates in harsh environments (e g.: strong magnetic fields, dust, and wide range of temperatures)
  • Reduced emissions with a fully electric solution
  • Reduced maintenance since there is no diesel motor
  • A dedicated service team that stays close to its installed base with knowledgeable technicians and spare parts availability
  • Ability to ensure 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 are possible.

  

  

  

  
  
• Industrial Hauling Solutions

  Industrial Hauling Solutions (MTA & MTC)

  As a leader in the North American market, MECFOR MTA/MTC Haulers provide safe transportation of anode 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 operator teams will be able to drive with ease in the pot rooms. The expertise in magnetic field shielding developed by our engineers specialists makes EPIQ haulers safe and reliable.

   

  The MTA/MTC family of vehicles is an excellent choice for standardizing your vehicle fleet. Since they are articulated, it is possible to attach the tractor to a range of trailers designed to transport anodes, molten metal crucible, transvider, tilters, and metal transfer by pressurization. This articulation allows a tight turning radius compared to a rigid frame transporter. 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 transfer by pressurization trailer (MMTP).

   

  The MTA/MTC tractor models are powered by a diesel engine that complies with new industry standards and is coupled to a hydrostatic transmission. This setup offers constant torque with unlimited speed variation on the front axle. The comfortable operator’s environment offers unmatched visibility, safety and precise controls to maximize productivity. The operator will appreciate the easy-to-use electro-proportional joystick and seat rotation, as well as the control modules that enable both front and rear driving ensuring driving front vision at all times. The vehicle is also equipped with controllers 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
  • Sturdy and durable components

   

  Many options and technologies can be offered to meet your specific needs. The MTA/MTC haulers are sturdy, ensuring a long and reliable life cycle time. Contact EPIQ Machinery experts to build the best hauler fleet and see how your operations can be optimized with our Heavy-Duty Industrial Transporters.

  Anode Haulers

  

  

  

  

  

  

  

  Crucible Haulers

  

  

  

  

  

  

  

  

  

  Crucible Tilting

  

  

  

  

  

  

  Molten Metal Transfer by Pressurization (MMTP)

  

  

  

  Molten Metal Transport – MYT

  

  

  

  

  

  Bath Tapping Vehicle (BTV), model MVR-MAC

  MECFOR vehicles are specially built to operate in harsh working environments of aluminium 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, ensuring quick and continuous response without using the overhead crane, and providing greater process flexibility. A good bath balance increases the Faraday current efficiency (cell stability) and reduces the amount of iron content in the aluminum by maintaining the bath under the anode rod level.

   

  MECFOR’s BTV picks up a crucible containing molten bath from a table or 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:

  • 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
  • Additional technologies are available as options – 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 if most smelter operations could be done using a multifunctional vehicle coupled with dedicated tools? Imagine a multifunctional vehicle, such as MECFOR MVR model , with smart tools could help standardize processes while reducing maintenance costs.

   

  For several years, EPIQ Machinery has been offering a concept of great versatility. This concept is called: “Smart Casthouse solution”, where an MVR model vehicle operates as many tools as needed with a hydraulic coupling. This system is part of our Heavy-Duty Material Industrial Handling Systems for Aluminium Smelters.

   

  Easy, fast and efficient

  With 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 set of tools, which can be interchanged in less than thirty seconds, also reduce maintenance costs, increase uptime and minimize energy loss associated with the smelter process. This improvement enhances the quality of the metal and ensures 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 include, 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. As an OEM Aluminium Mobile Equipment Supplier, EPIQ Machinery ensures that each solution meets your specific needs.

   

  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 an aluminium 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. In addition, thanks to the option of double steering of the vehicle, the operator keeps driving with a front vision even with an heavy load. As vision of the operator is essential, MECFOR offers a MVR model with a lifting cab for installations were furnace sills are high.

   

  Contingency

  Using two multifunctional vehicles, MVR or MVA, with a series of interchangeable tools offers the flexibility to carry out all the smelter operations using either vehicle. Reliability engineers will appreciate the optimized use of the vehicle and the long life of the sturdy tools, exceeding industry averages.

   

  Cost reduction

  Smelter operations are performed more quickly, enhancing production efficiency by reducing execution time while maintaining the quality of the cast metal. The availability of optimized tools in the smelter is essential for achieving these improvements.

   

  Increased productivity

  Smelters using MECFOR QuicKonnect technology benefit from a quick return on investment while improving the safety of their workers. Increased productivity is achieved 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. Moreover, Our Mecfor Mobile Equipment, part of our comprehensive product lineup, ensures robust and reliable operations tailored to the specific needs of modern smelters.

  

  

  

  

  

  

  

  

  
  
• 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.
  Our expertise includes Handling Systems for Aluminium Casthouse and advanced casting lines, ensuring optimal performance and reliability.

  Extrusion billet batch homogenizing systems

   

  Under the AD line of product, we offer fully automated or semi-automated material handling for extrusion billets, including homogenizing and sawing operations. EPIQ Machinery designs and builds a highly efficient automatic aluminium batch homogenizing build and break down system. One significant advantage we have over our competitors is that our gantry system does not touch the aluminum billets.

  All motions during the transfer of the extrusion billets are made in linear motions, which improves the reliably and positioning of the billet at the transfer point. Our solution ensures:

   

  • Uniform load growth during the homogenizing cycles
  • Linear motions for aluminum 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’s commitment to innovation and excellence in Handling Systems for Aluminium Casthouse positions us as a leading provider in the industry. Additionally, we offer the world’s most automated and productive aluminium extrusion billet sawing and packaging systems, which can be either automatic or semi-automatic. These systems package billets and logs for internal use or customer supply and can be tailored to meet specific packaging needs, demonstrating our dedication to providing comprehensive, high-performance solutions for aluminium production.

   

  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 Banknote 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

  AD brand offers robust systems for receiving Ingots from vertical casting machines, and then cutting 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 part of our comprehensive Handling Systems for Aluminium Casthouse.

   

  AD Slab and T-ingo Sawing Systems are designed for handling vertically direct chill (VDC) cast ingots, our ultra heavy-duty equipment ensures reliability and high uptime, even under heavy loads and occasional operator abuse. Integral to Heavy-Duty Material Handling Systems for Smelters, EPIQ Machinery’s advanced systems enhance productivity and operational efficiency in aluminium casthouses while maintaining high safety and quality standards. These type of systems also 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 labeling systems
  • Automatic stacking, strapping and packing per customer requirements
  • Automatic ultrasonic inspection

  

  

  

  

  Video gallery

  • Metals slab ingot Aluminum Ingot Handling & Sawing System

  Melt Furnace Charging and Tending Machines

  Rail bound aluminum scrap furnace charging car and furnace tending machines.

   

  EPIQ Machinery develops and constructs rail bound scrap furnace charging machines and furnace tending machines for both upgrading existing casthouses and constructing new ones. These systems provides numerous benefits, such as increased throughput, reduced furnace lining damage, the ability to use a higher percentage of scrap, lower gas usage, and improved operator safety.

  

  

  

  Video gallery

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

  Sow Casting Systems

  Under its BROCHOT brand, EPIQ Machinery designs and builds a comprehensive range of sow casting systems, with capacities ranging from 5 to 40 tons per hour, available in both air-cooled and water-cooled versions. These systems can serve as basic backups to more sophisticated casting machines or fully automated with a marking and packing lines, functioning as mission-critical processing lines.

   

  Our systems include:

  • Gantry style cranes for crucible transportation
  • Crucible tilter stations
  • Robotic or dedicated skimming stations
  • Sow mold train or turntable style
  • Sow molds
  • 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 various types of machines 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, labeling

  

  

  

  

  

  

  

  
  
• AGV Solutions

  Since the launch of the AGV TEAM prototype in 2018, North America’s first electric auto-guided Molten Metal hauler, EPIQ Machinery has consistently expanded its range of AGV equipment solutions to serve the global market of primary and secondary aluminum producers.

   

  In the aluminum industry, numerous heavy-load travels are conducted between various sectors such as ladle of molten metal, anodes, coil, ingots, etc. Each travel requires a rigorous analysis of inputs to ensure safe travel in all conditions, whether indoor or outdoor, and in all seasons.

   

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

   

  EPIQ Machinery is committed to guiding aluminium producers towards the shift to Industry 4.0. by offering global material handling system integration into plants. As the AGV market booms, the cooperation between EPIQ Machinery and DTA is timely. The combination of the skills of two major industry leaders will benefit end-user customers. EPIQ machinery is now in great position to offer more automated and integrated custom Heavy-Duty Material Handling Systems to the benefit of Aluminium producers.

   

  Visit our Heavy Duty AGV section for more information.

  
  
• Aftermarket Services

  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 about the range of our Aftermarket services.

  
  
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