Introduction to Wire Injection system

Cored Wire Injection:

The Minex History of Wire Feeder is over 30 years, in the field of Steel & foundry industries. Over 400 installations have been commissioned during these years from the smallest for below 1 MT Ladle to extra-large one with Four Strand capability. Minex has installed over 90% of the Wire Feeder facilities in this country and many of them are repeat orders, project start-ups along with metallurgical support. Minex expertise in cored wire and injection systems enables us to offer complete turnkey solutions for cored wire technology implementation.

Today Minex is the largest manufacturer of cored wire feeders in the continent. Minex provides total expertise and customer support for cored wire application.

In addition to this Minex is the only supplier of the entire range of Cored Wire Feeders, Metallurgical Cored Wire and other alloying solution, now extended to Aluminium Industry as well.

In profound collaboration with our customers, we made every feeder better than the previous one and so far introduced over 8 different models of Feeder from compact single Strand to Four Strand one.

MINEX has developed during years a vast experience in transferring the operational know-how even to new companies without any Wire Injection experience and helping them to reach the most demanding metallurgical parameters rapidly.

Wire Feeder Product Range:

  • Rod Feeder for Aluminium Industries
  • Single Strand Wire Feeder
  • Two Strand Wire Feeder for Steel Foundry
  • Two Strand Wire Feeder for Steel Plant
  • Four Strand Wire Feeder for Steel Plant
  • Vertical Wire Straighteners for Pure Ca wire injection in Steel Plants
  • Vertical Magnesium Wire Injection System for SG Foundries & DI Pipe industries.
  • Customised Guide Systems.
  • Customised Rear Guide systems.
  • Auxillary systems
  • Control systems with high level of Automations
  • Aluminium Industries
  • Steel Industries
  • Foundry Industries
  • Turnkey Service

Aluminium Industries

Minex Rod Feeder is capable of feeding one or two rods, with a nominal diameter of 9.5mm – 10mm, into the molten aluminium stream in the launder for continuous grain refinement. TiBAl bobbin coils are housed on vertical or horizontal uncoiler stands for smooth feeding of the rod.

Rod Feeder’s is designed with a single motor and gearbox for continuous operations of the system. TiBAlRod is guided in and out of the unit by antifriction guides for positive non-slip feed. The feeder’s needle bearings are sealed for life. The Guide roll bearings on the inlet ensure smooth operation which result in low friction and guides the rod properly. The geared motor is foot mounted with a coupling and connected to the drive shaft for ease of maintenance.

The motor is mounted with external forced cooling fan run independently by a separate motor to ensure proper cooling of the main motor during continuous operations. Encoders are provided to ensure closed loop feedback of speed and accurate indications of length of TiBAl rod feeding. Rolls are hardened for long life and can be tensioned against the rod with a pre-tensioned spring provided to each strand. The body and base plate are designed to withstand the high temperatures and continuous operations at the cast house.

The control system housing the AC Drive and other components is enclosed with a force-cool motor with an internal circuit breaker for both the inverter and fan terminal connections to the fan and drive motor. An isolator is fitted at the incoming power. Main power input is from 240 volts AC and transformers are available for other voltage requirements.

Minex Rod Feeder

Model Speed
MRF100 100CPM
MRF200 200CPM
MRF300 300CPM

Features

  • Dual and Single Strand
  • Uncoiler
  • TiBAl 9.5mm Max
  • Designed to operate 72Hrs at a stretch.
  • Rolls are made of high grade steel, HCHCr wear resistant with 62
  • RC and serrated for higher roll life
  • Rate of feed Synchronising with caster speed
  • Speed varying through AC Drives
  • Counters for setting length.
  • Light indicators during feeding.
  • Digital speed indicators.
  • Shaft encoder for accurate rate of feeding
  • Built in alarm systems
  • Power Isolator switches
  • Plug and socket connections

Steel Industries

Minex being a leading partner to the Indian and world Steel Industries byproviding solutions to the industry for over the past 30years. It has been a continuous process of development of various types of cored wire and wire feeding systems at minex to successfully optimise the economy and high quality of secondary steel refining. Minex systems are designed with the futuristic technologies keep in mind the high demands of the steel melt shops. The layouts are customised to suite different projects with the backing of strong Engineering and Application Metallurgy knowledge.

The feeders can be used for wire injection in ladle, ladle furnace, VD/VOD, continuous casting, Tundish and induction furnace. The feeders offered are.

Model:

Single Strand
Two Strand
Four Strand
Six Strand wire feeder under development

Speed range

50MPM, 150MPM, 300MPM, 400MPM

Wire Diameter

6mm - 21mm

Features:

  • Single to Four Strands
  • Variable Speed through AC/DC Drives
  • Three sets of roll in each strand with internal guides.
  • Rolls are manufactured from HCHCr material for longer life.
  • Accuracy of injection +/- 0.5mtrs on the total length fed at speeds of 400MPM.
  • Individual Strand Pressure regulation system.
  • Level 2 Automation
  • Wire Less remote operations of the system.
  • Coil Data Management and Wire Recovery Management system.
  • Capabilities of remote diagnostics of the system
  • Customised Front and Rear Guide System
  • Auxiliary Support System
  • Reliable performance of the Feeder due to its rugged design and workmanship.
  • Consistence and repeatability backed with excellent customer support.
  • Easy operation and maintenance free system.

Customised Guide Systems:

  • FixedGuide Pipe
  • SwivelGuide Pipe System with motorised or pneumatic actuations
  • Telescopic Guide Pipe System with motorised or pneumatic actuations.
  • Customised rear guide system for ensuring safety of the personnel’s.

Foundry Industries

Minex being a partner to the iron and steel industry in the Wire Injection Technology has been able to support the foundries with Magnesium Cored Wire technology by treating metals with cored wires economically and environmental friendly.

Minex has been successful in providing solutions with Cored Wire to achieve the desired sperodising and economical benefits over other processes in foundries. The quantities required for injection is automatically calculated by the system with the integration automation of inputs of Melt weight, temperature of melt and chemistry.

Application:

  • Magnesium treatment of iron
  • Combined Desulphurisation and Spherodisation of cupola melted iron.
  • Highly consistent and No risk of human error
  • Improved Metallurgical results achieved by precise addition of Mg Cored Wire resulting in close control of the residual Mg in the iron.(+/- 5gm of total addition)
  • Topping up of the Magnesium in a pouring furnace.
  • Combined Spherodisation and Inoculation in the pouring ladle.
  • Reduced manpower requirements.
  • Small capital investment when compared to Convertor process.
  • Harmless to the environment as emission can be controlled and drawn off easily by connecting to the existing FES of the plant.
  • Clean & Easy handling
  • No loss of material as it is in a coil form.
  • Safe use of hazardous materials

Watch Video

Model:

Single Strand vertical feeder
Two Strand vertical feeder

Speed range

50MPM, 80MPM, 150MPM, 300MPM

Injection System:

  • Single to Two Strand Feeder
  • Variable Speed through AC/DC Drives
  • Three sets of roll in each strand with internal guides.
  • Rolls are manufactured from HCHCr material for longer life.
  • Accuracy of injection +/- 0.2mtrs on the total length fed at speeds of 150MPM.
  • Individual Strand Pressure regulation system.
  • Wire Less remote operations of the system.
  • Coil Data Management and Wire Recovery Management system.
  • Capabilities of remote diagnostics of the system
  • Customised Front and Rear Guide System
  • Auxiliary Support System
  • Reliable performance of the Feeder due to its rugged design and workmanship.
  • Consistence and repeatability backed with excellent customer support.
  • Easy operation and maintenance free system.

Customised Turnkey supply of Magnesium Wire Injection System which includes:

  • Treatment Ladle
  • Ladle Transfer Car with load cell for weighment of Metal.
  • Injection station structures.
  • Ladle Roof Coverwith motorised or pneumatic actuation system.
  • Integration of Melt weight, Temperature and Chemical analysis for automatic calculation of Wire Weight.
  • Application Metallurgy support to ensure the Magnesium Wire Injection process is established.

Turnkey Service

Minex combines its expertise and experience in metallurgy with sound engineering process to deliver turnkey solutions for cored wire injection into steel to produce superior materials.

  • Process Study.
  • Metallurgical Formulation.
  • Layout Design.
  • Machine Customisation.
  • Automation
  • Supervision of Erection.
  • Trials (Cold & Hot) & Commissioning.
  • Intensive Training (Metallurgical & Wire Injection System.)
  • Operations & Maintenance Support.
  • Review & Improvement.