Mining and Metallurgical Casting

Mining and Metallurgical Casting

Mining and metallurgical casting is the production of metal items designed to work under heavy loads, abrasive wear, corrosion, and extreme temperatures typical of the mining and metallurgical industry. Main purpose:

• Production of wear-resistant parts for crushing and grinding equipment.
• Manufacture of components for conveyor systems and ore transport.
• Production of liner plates, armor plates, and other protective elements.
• Manufacture of parts for metallurgical furnaces, ladles, and molds.
• Production of working elements for earthmoving machinery and mining equipment. Key technical characteristics of mining and metallurgical casting:
• Material: High-manganese steel, chromium iron, alloy steels, heat-resistant alloys, special bronzes, and nickel alloys.
• Casting method: Sand casting, investment casting, chill casting, centrifugal casting, die casting. The choice of method depends on the complexity of the item, the required precision, and the material properties.
• Size and shape: From small, high-precision parts to large liner plates and equipment housings.
• Surface quality: Can range from a rough, as-cast surface to machined for high precision and smoothness.
• Strength and durability: Exceptional strength, hardness, and wear resistance, ensuring a long service life in aggressive environments.
• Weather resistance: High resistance to abrasive wear, impact loads, corrosion, thermal cycling, and high temperatures. Additional characteristics (typical for sand casting):
• Molding sand moisture content: 3⁠-⁠5% (depending on the mix).
• Gas permeability: 80⁠-⁠150 units (to ensure gas is vented).
• Compressive strength: 0.5⁠-⁠1.0 kg/cm² (to hold shape during pouring). Production capabilities: Type of production: Modern Technologies mini-plant Casting method:
• Lost foam casting (LFC) - provides high precision and minimal machining allowance, reduces molding material consumption.
• V-process (vacuum sealed molding) - a cost-effective, environmentally friendly technology that produces high-precision castings with excellent surface quality, reduces molding material costs. Floor area: From 300 m² Output: From 500 tonnes of finished products a year. Wholesale price in Kazakhstan - from $3/kg and up Margin - 25⁠-⁠55% (depends on item complexity, material, and volumes). Kazakhstan market price (approximate benchmarks): By kilogram:
• High-manganese steel (e.g., Hadfield) - from $3/kg to $7/kg (depending on complexity and processing).
• Chromium iron (wear-resistant) - from $2.4/kg to $5.6/kg.
• Alloy steels for liners - from $3.6/kg to $8/kg. By unit price (finished products, examples):
• Mill liner (high-manganese steel) - from $100/pc to $1,000/pc (depending on size and weight).
• Wear-resistant crusher liner plate - from $60/pc to $600/pc.
• Grate bar (cast iron) - from $40/pc to $300/pc. Price depends on the material grade, geometric complexity, dimensions, weight of the item, order volume, and required surface finish/processing.