THESCHAEFERGROUP.COM FURNACE DIVISION REFRACTORY SALES & SERVICE DIVISION DELTA CONTROL DIVISION
2 | THESCHAEFERGROUP.COM About Us Frank W. Schaefer, Inc (FWS) started business as a refractory contractor in 1930, and began designing and manufacturing industrial furnaces in 1945. In the early 1970’s, FWS’s aluminum furnace business grew large enough that it became necessary to form two divisions within the company: A Refractory Sales and Service Division and an Industrial Furnace Division. In 1998, the Industrial Furnace Division was separated from FWS, Inc to form a new company, Schaefer Furnaces, Inc (SFI). A combining of these two related companies took place in late 2002, forming The Schaefer Group, Inc. Two strong traditions are recombined, with the FWS Division providing exceptional refractory sales and service work and the SFI Division providing the best aluminum furnaces and molten metal delivery systems available. Today, no other aluminum furnace builder has more experience than Schaefer Furnaces in the systems approach to high quality aluminum delivery. The Schaefer Group, Inc. provides turn-key service; from design, to construction and installation, to complete technical support and maintenance.
100% PROUDLY MADE IN THE USA | 3 Table of Contents Custom Designed Furnaces and Systems......................................4 Electric Aluminum Melting Furnaces...............................................................................................4 Ultra-Low Energy (Gas/Electric) Holding Furnaces..................................................................5 Gas, Oil, or Propane Aluminum Furnaces......................................................................................6 High Performing Stack/Tower Melters............................................................................................8 Molten Metal Launder Systems..........................................................................................................9 Dry Hearth Furnaces..............................................................................................................................9 Low Pressure Die Casting Systems..................................................................................................10 Filtration Systems....................................................................................................................................11 Degassing Systems.................................................................................................................................11 Crucible Pot-type Furnaces................................................................................................................12 Transfer Ladles & Ladle Heaters........................................................................................................13 Schaefer Shield.........................................................................................................................................14 Fluxes...........................................................................................................................................................14 Refractory........................................................................................... 15 Furnace Parts & Linings........................................................................................................................16 Kilns & Ovens............................................................................................................................................17 Fluxes...........................................................................................................................................................17 Refractory Contracting & Materials..................................................................................................18 Refractory Specialty Products...........................................................................................................18 Training, Consulting & Other Services.............................................................................................20 Systems Integration & Service....................................................21 PLC & HMI Programming......................................................................................................................21 Systems Engineering & Analysis........................................................................................................22 Quality Control Systems.......................................................................................................................22 SCADA Design and Implementation................................................................................................23 Hardware Sales.........................................................................................................................................23
4 | THESCHAEFERGROUP.COM Custom Designed Furnaces and Systems Since 1970, The Schaefer Group has developed custom aluminum furnaces for die casting, permanent mold and sand foundries. We specialize in electric, gas, and propane as well as combination fuel furnaces for melting, holding and transfer. We also custom design launder systems, crucibles, filtration and degassing systems. Our re-line and repair services can retrofit existing furnaces as well. We have probably custom designed more molten metal delivery systems than anyone else in the world. Over 50 years of experience makes Schaefer Furnaces the experts in Profitably Casting Your Bottom Line! Electric Aluminum Melting Furnaces The Schaefer Group developed the world’s first electric reverbatory (wet bath) furnace in 1974 and the rest is history. This furnace is now the industry’s first choice for low cost production of clean molten aluminum. Our highly efficient electric reverberatory melting furnaces provide the best quality metal from ingot or scrap. And, they have an extremely low metal melt loss and are easy to operate and maintain. Melt loss is so low with this furnace (often less than 1%) that those savings alone typically provides a one year (or less) return on investment! ADVANTAGES: • Excellent Metal Quality — no combustion means no metal gassing and a conservatively-sized tranquil bath eliminates oxide-creating metal turbulence. • Melting — silicon carbide resistance elements transfer radiant heat to the work load to melt metal with only 0.20 to 0.23 KWH per pound. You can even melt efficiently from a cold start. A full-proportioning control system delivers accurate energy flow. • Melt loss — typically less than 1%. • Cleaner heat — means a cleaner work space. • Sustainability — no output of hot fuel gasses to heat up the environment means reduced carbon footprint.
100% PROUDLY MADE IN THE USA | 5 FOR: This versatile furnace meets the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. OPERATION & MAINTENANCE: • Low maintenance requirements — highest uptime operation on the market. • Low metal melt loss • No EPA permits required • Quiet operation ADDITIONAL CONSIDERATIONS: • Filtration, degassing, circulation, transfer methods OPTIONS: • Alarm thermocouples • Premium lining materials • Super insulated linings • SCADA control data collection • Filtration • Degassing • Electric meters Ultra-Low Energy (Gas/Electric) Holding Furnaces ELECTRIC HOLDING FURNACES A 2,000 pound (907.2 kg) Schaefer electric holding furnace will maintain a temperature of 1,300 degrees Fahrenheit (704.4 degrees Celsius) for only 3 KW/hr (2,581.2 kcal/hr) with well covers. Similar savings can be achieved with all capacities ranging from 1,500 (680.4 kg) to 30,000 pounds (13607.77 kg). GAS HOLDING FURNACES A 2,000 pound (907.2 kg) Schaefer gas holding furnace will maintain a temperature of 1,300 degrees Fahrenheit (705 degrees Celsius) with 50 to 60 CF gas/hr (12,660-to-15,120 kcal/hr). We can also supply a dual energy option that lets you convert between electricity and gas to use the lowest cost source. We offer a choice of ni-chrome or silicon carbide heating elements. Ni-chrome lets you use a lower-cost control system; silicon carbide handles higher watt loads for more compact furnaces. ADVANTAGES: • Efficient holding of temperatures at low cost. • Easily cleaned. • Very little pick up of hydrogen in our gas fired units. • Full proportioning controls means we connect more than you will ever need, but use only what it takes to maintain temperature!
6 | THESCHAEFERGROUP.COM FOR: This versatile furnace meet the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. OPERATION & MAINTENANCE: • Lining — select either monolithic or board lining systems. Our rugged, thermally efficient, non-wetting lining allows us to place the hot metal well anywhere specified. And we can make it square or rectangular, straight or offset at special angles, even with sloped ends for robot ladling and other automation equipment. The lining also helps keep the casing temperature low. OPTIONS: • Power-operated tilt lid allows cleaning of the furnace in less than 10 minutes. • Full-proportioning with solid-state microprocessor controls and specially-designed heating elements with a proven record of superior service life can be easily added. • Alarm thermocouples • Filtration • Degassing with T Wands • Molten Metal Circulation • Inoculation • Rotary Degassing Gas, Oil, or Propane Aluminum Furnaces For fuel efficiency like no other; gas, oil or propane aluminum furnaces by The Schaefer Group hit the mark. Typical melting efficiency, based on 100% cold charging with an exterior charge well, is 1,500 BTU of gas per pound (378 kcal/0.4536 kg) of metal in a Schaefer furnace radiant roof-fired reverb. Whatever the fuel, this is only 1,500 BTU per pound (378 kcal/0.4536 kg). And, if you preheat at least 50% of the metal charged in the form of ingot or sows, the number drops to 1,200 BTU of gas per pound (302.4 kcal/0.4536 kg). Batch-type melting reverbs are also available with the latest in high velocity burners.
100% PROUDLY MADE IN THE USA | 7 ADVANTAGES: • Clean Metal — non-wetting refractory linings will not contaminate the metal. • Excellent Temperature Control — Filtration is optional. • Clean Furnace — all blind corners are eliminated and door jambs are tangent with the walls for full accessibility. A clean-out-door provides easy access to the hearth and allows easy clean-up of the furnace bottom or to skim the bath. • Liquid Metal Deliveries — Schaefer reverbs can be engineered with large holding capacities that offer enough “draw-down” capability to accept molten metal delivery. • Regeneration & Recuperation (explained under Operation & Maintenance) — improve melting efficiency even more by preheating the ambient air and metal through a combination of pre-heat hearths, regeneration and recuperation. Melt rates of 950-to-1,000 BTU/lb (239.4-to-252 kcal/0.4536 kg) can be obtained with the right combination of equipment. FOR: This versatile furnace meets the needs of a variety of metal casters, high and low pressure die casters, permanent mold, sand, investment and lost foam foundries around the world. OPERATION & MAINTENANCE: • Low Maintenance — Schaefer furnaces seldom need much attention. Anchored, monolithic linings are custom built to meet specific needs, and all furnace sections are completely accessible for easy maintenance. • Very high efficiencies — can be achieved by sows and ingot bars, followed by the circulation of molten aluminum in the metal bath. Circulation (stirring) of the entire bath is accomplished by pumping metal through a charge well, followed by: – Recuperation — combustion air is preheated by the flue gases in a non-contact recuperator, resulting in noticeably lower fuel usage — normally up to 15% increase in melting efficiency with 700 degrees Fahrenheit (371 degrees Celsius) pre-heated combustion air. – Regeneration — cycles the full temperature products of combustion through efficient heat storage beds. Combustion air passing through these beds is raised up to 600 degrees Celsius, delivering 30 to 35% better melting efficiency than with standard radiant roof-fired reverbs. Schaefer was the first aluminum furnace manufacturer to apply this advanced procedure. ADDITIONAL CONSIDERATIONS: • Filtration, degassing, circulation, transfer methods OPTIONS: Circulation wells and molten metal pumps provide rapid heat transfer from the furnace to the pump and charge wells and back again. This is particularly effective when melting chips from machining operations as circulation breaks the surface tension, pulls the chips down into the melt immediately and keeps the bath homogenized. The Schaefer furnace design uniquely minimizes heat loss.
8 | THESCHAEFERGROUP.COM High Performing Stack/Tower Melters Over the years, we have been asked to provide our customers with Stack Melters. In order to do so, we needed to resolve the reliability issues associated with current stack melter designs. For the past several years, we have been developing a Stack Melter that would exceed our customer’s melting expectations and our high reliability standards and are now pleased to bring this to market. SMALL MELTERS • Including small in-cell melters from 200 lb/hr to 2,500 lb/hr LARGE MELTERS • Including large central melt furnaces up to 30,000 lb/hr SIGNIFICANT STACK MELTER ADVANTAGES: • Reduce Metal Lost — higher yields up to 98% • Simple Operation — easier to maintain • Compact — uses 1/3 of conventional space • Reduce Energy — savings up to 25% • Environmental Friendly — less exhaust, chips & scattering OUR CUSTOMERS WILL BENEFIT FROM THIS PARTNERSHIP MANY WAYS: • All Stack Melters will be built in the US in our Ohio production facility using the Sanken Sangyo design • Materials and components will be sourced from our current US suppliers • Installation will be managed entirely by The Schaefer Group • Service & Support will be managed entirely by The Schaefer Group • The Stack Melter will be a Schaefer furnace — The Schaefer Group will be responsible for the performance of the furnace. PARTNERSHIP The Schaefer Group has formed a partnership with Sanken Sangyo of Japan, the inventor of the Stack / Tower Melter since 1965. In this partnership, The Schaefer Group will manage entire production of these melters in our stateof-the-art facility in Dayton, Ohio. Sanken Sangyo has literally thousands of these melters in operation around the world, making them the global leader in the design and production of Stack Melters. We are proud to announce our complete line of Stack / Tower Melters designed to melt scrap, ingots, chips, degas/filtrate and more.
100% PROUDLY MADE IN THE USA | 9 Molten Metal Launder Systems The most technically advanced way to deliver molten aluminum from melting furnaces to holders and die casting machines is in a heated launder system. A launder minimizes turbulence and oxides in the molten metal and because the metal flows in a quiet stream to the holding furnace, it eliminates transfer labor and monorails, fork trucks, and bull ladles. It automatically delivers the exact amount of metal you need — on-time and at temperature. Launder systems aren’t the answer for everyone. They must be carefully considered because they can reduce the flexibility of your plant layout. But they can be very cost-effective in the right application. We have both the technology and the creative designs to meet your needs. Our launders are well sealed, highly insulated and easy to clean. ADVANTAGES: • Metal quality — ensured through minimized turbulence and oxides. • Highly insulated — to maintain temperature. • Easy to clean. • Reduces the need for transfer equipment. • Reduces manpower and fork lift maintenance. • Save ½ of 1% in metal melt loss caused by turbulent transfers into and from transfer ladles. FOR: This versatile launder system meets the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. Dry Hearth Furnaces We design Dry Hearth furnaces to melt aluminum ingot and large billet; no gassing or contamination by the lining means that metal purity remains high. Impurities and the oxide skin stay on the hearth as only molten aluminum enters the hold zone. CASE STUDY: • Low fuel consumption — a modest 2.0 CF of gas per pound (504 kcal/0.4536 kg) of melted aluminum, thanks to the highly efficient radiant roof; this number drops even further with high momentum burners. A twozone control offers the closest temperature control possible. • Easy to Clean — charge and clean-out doors are tangent with the side walls for quick cleaning access. A double hinged or full width clean-out door provides easy and complete access to the hold zone. FOR: This versatile furnace meets the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world.
10 | THESCHAEFERGROUP.COM Low Pressure Die Casting Systems Schaefer’s Low Pressure Die Casting System (LPCS) is the latest in a long line of innovations. This system offers you the highest quality aluminum casting technology with the speed of conventional die casting. The most technically advanced low pressure casting system provides turbulence-free fill through the mold bottom. This system uses the Schaefer Valve for non-turbulent transfer from a continuous Schaefer furnace (melted with utmost efficiency, degassed, filtered, at the exact temperature, at the exact time) supplying the LPCS. This Low Pressure Casting System features: • Central melter • Molten aluminum filtration-degassing system • Electric heated launder • Schaefer Valve • Low pressure casting furnace ADVANTAGES: • Highest Integrity Casting — no turbulence in the molten aluminum transfer and casting process means better castings. • Cleaner Metal — comes from no turbulence in the entire molten metal transfer process (elimination of oxides or gas entrainment). • Maximize Production Time — by continuous on-line furnace and casting equipment. • Reliable and low maintenance equipment — continuous production means no more production disruptions to just refill it. • Uninterrupted Production — via a large molten metal reservoir capacity in the delivery system. FOR: This versatile furnace meets the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. OPERATION & MAINTENANCE: Low maintenance — change-out time on movable valve part is quick and easy (20-30 minutes).
100% PROUDLY MADE IN THE USA | 11 Filtration Systems High quality aluminum is often selected for critical cast parts used in aircraft, automotive, and computer industries, as these growing markets require better quality, greater strength, and improved machineability. Filtration systems are powerful tools used to filter out inclusions, which reduces flaws, voids, and brittle planes of fracture. While reducing inclusions, the metal acquires increased fluidity, greater strength and ductility, improved machineability and better surface finish. All of those benefits lead to reduced tool wear, fewer rejects and less rework. Schaefer is a pioneer in the design and installation of metal cleaning systems. We use a variety of filtration media, each chosen to meet a specific need. Our filtration solutions include filter plates, filter tubes, filter beds and sparging gases. The basic Schaefer concept connects a highly efficient wet bath reverberatory melting furnace with a specially designed filter furnace. The reverberatory furnace provides low melt loss and high volume whereas the filter furnace delivers high quality, clean metal with very close and stable temperature control. Both furnace types can operate on the energy source preferred. ADVANTAGES: • Reduce Hydrogen — to eliminate impurities to produce clean metal. • Reduce Porosity — to make stronger parts. • Reduce Inclusions — to make better surfaces. FOR: We provide filtration systems for a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. Degassing Systems High quality aluminum is often selected for critical cast parts used in aircraft, automotive, and computer industries, as these growing markets require better quality, greater strength, and improved machineability. Degassing systems are powerful tools used to filter out inclusions, which reduces flaws, voids, and brittle planes of fracture. While reducing inclusions, the metal acquires increased fluidity, greater strength and ductility, improved machineability and better surface finish. All of those benefits lead to reduced tool wear, fewer rejects and less rework.
12 | THESCHAEFERGROUP.COM Schaefer is a pioneer in the design and installation of degassing solutions. Our degassing solutions include porous plus technology, rotary sparging gas nozzles and degassing lances. ADVANTAGES: • Reduce Hydrogen — to eliminate impurities to produce clean metal. • Reduce Porosity — to make stronger parts. • Reduce Inclusions — to make better surfaces. FOR: Schaefer provides degassing systems for a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. Crucible Pot-type Furnaces Electric crucibles are used for melting or holding and are popular furnaces as they deliver exceptional efficiency. Completely covered, they use only 0.20 to 0.25 KW/hr per lb to melt cold metal and just 3 to 4 KW/hr to hold 1,000 lbs of molten aluminum at 1,220 degrees Fahrenheit. A built-in leak detector sounds an alarm if the silicon carbide crucible should ever leak. Electric crucibles use less energy than channeltype induction furnaces, and they provide more accurate temperature control. Both manual and power-operated tilt-type versions are also available. Crucible furnaces are very compact and only require a small space to operate, and are a perfect companion in a complete Schaefer system of furnaces for a die casting, permanent mold or sand foundries. Gas, oil or propane crucible, or pot-type furnaces are available with many of the same features as the electric models: ceramic fiber lining, exceptional long life, compactness, comfort, low maintenance and easy installation. Gas models require only 3 CF of gas (3,000 BTU) or less per pound of metal melted. Our unique single or double fossil fuel firing and fluing capabilities provide great performance. Close temperature control, rapid melting and leak detectors are all features that enhance the cost efficiencies of these furnaces. ADVANTAGES: • High Temperature Ceramic Fiber Lining — for walls, floor and top provide excellent insulation, low heat storage, and means it is cool to work near. It cannot be thermal shocked, which means it can rapidly be brought online or taken offline. • Quiet operation • Solid-state Controls — reliable, fullproportioning control system continuously meters in only the amount of power required at any given time. • Easy Installation and Maintenance — easily connect the straight resistive electrical load in either single or three phase primary electric service. • Long Service Life — depending on the ratio of melting to hold time, the silicon carbide crucible will outlast those in gas and oil-fired furnaces. The heavy duty electrical resistance heating elements usually deliver one to five years of service, and the lining will last even longer.
100% PROUDLY MADE IN THE USA | 13 FOR: This versatile furnace meet the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. OPERATION & MAINTENANCE: Quick changeover as the crucible can be replaced in 1-2 hours while the furnace remains in place. Transfer Ladles & Ladle Heaters Our powered transfer ladles and ladle heaters can make light work of your foundry transport operations. We can provide custom ladles designed to fit specific needs with a range of: power options, barrel designs, single or multiple spout designs, and transport options. Schaefer’s Heatflow Program is designed to show energy cost savings using a specialized flexliner that will: • Ensure lower metal temperature loss during transport • Reduce thermal head temperatures necessary in aluminum melt furnaces • Reduce time and energy requirements to attain metal temperature in the holding furnaces • Reduce lining maintenance by reducing thermal spalling The powered transfer ladles shown are just a couple of the many designs available from Schaefer. We can provide standard ladle sizes including: 1,000 lb (453.6 kg), 1,500 lb (680.4kg), or 2,000 lb (907.2 kg) holding capacities of molten aluminum, or we can custom build a ladle for aluminum, zinc, or other metal transport. We can provide a variety of forklifts, truck transporters or monorails to carry molten metal transfer ladles, with open tops and single or double pour spouts. ADVANTAGES: • Rugged designs — for a long production life. • Designed with simplicity — for easy operation. • Heavy-duty construction — long lasting in a production environment. LADLE PRE-HEATERS Schaefer ladle pre-heaters are designed according to the size of the ladle and the alloy you are heating. Steel requires a higher input versus aluminum. • Typical burner ratings range: 100,000BTU’s to 1,750,000 BTU’s • Regulated gas supply: ½ lb to 1lb • Air supply required to tilt the burner into the ladle: regulated at 60 p.s.i. at 10 c.f.m. • Power supply: 120V AC @ 30 amps FOR: This versatile furnace meet the needs of a variety of metal casters, high and low pressure die casters, and permanent mold, sand, investment and lost foam foundries around the world. OPTIONS: • Power options • Barrel designs • Single or multiple spout designs • Transport options
14 | THESCHAEFERGROUP.COM Schaefer Shield Schaefer Shield is a proprietary coating material that cleans the most difficult molten aluminum maintenance applications. Dross and oxide buildup are easily removed with a scoop. No more hammering (and damaging) refractory linings or tools. Steel or refractory can be coated with two different mixes. Use Schaefer Shield for ease of cleaning molten aluminum from: • Furnace Cleaning Tools • Immersible Door Blades • Ladle Cups • Launders (periodic and continuous) • Pouring Boxes • Pump Components • Thermocouple Protection Tubes • Transfer Ladles • Troughs • Tundishes ADVANTAGES: • Reduces labor — cleaning linings is easy and fast. • Reduces damage to refractory linings — remove buildup by simply scraping. SPECS: Available in 5 gallon pails Fluxes SGI FLUX BENEFITS • Reduced Melt Loss • Reduction of Inclusions • Improved Fluidity • Improved Melt Efficiency • Less Furnace Cleaning Time • Lower Hydrogen
100% PROUDLY MADE IN THE USA | 15 Refractory The Refractory Sales & Service Division (FWS,Inc.) has solid experience and proven engineering capabilities that have earned us the reputation of being first in quality refractory contracting services since 1930. From a basic furnace reline to a major design modification or custom fabricated parts, FWS has the expertise to get the job done on time and within budget. FWS has been rebuilding, relining and modifying industrial furnaces and other thermal equipment for over 85 years. We use state-of-the-art materials to ensure a quality job on all our projects, and stand behind our workmanship. Not only do we have the know-how to cost-effectively reline, or repair your furnace; our design capabilities allow us countless ways to improve thermal efficiency and save you precious energy costs. Contact us for refractory reline, repair services, training and materials. FWS, Inc. concentrates on supplying high quality refractories to all industries. We stock a variety of refractory materials including ceramic fiber, monolithic refractories, dense & insulating firebrick, mortars & coatings mixers, block insulation, anchors, and furnace parts. Whether it’s a minor repair or a complete refractory installation, you can count on us to provide the highest quality workmanship in the industry.
16 | THESCHAEFERGROUP.COM Furnace Parts & Linings FWS also stocks a wide variety of furnace parts for all types of aluminum melting, holding and laundering applications. From thermocouples to crucible bowls, we can get you out of trouble fast. FWS houses an extensive inventory of furnace parts for immediate delivery: • Thermocouple Parts and Assemblies • Industrial Control Components • Silicon Carbide Heating Elements • Burner Parts and Assemblies • Tap Out & Drain Blocks and Cast Iron Plugs COMBUSTION SYSTEM — BURNERS, BURNER BLOCKS, REGULATORS, VALVES & BLOWERS • Electrical Components — Heating Elements, Terminal Tubes, Straps & Clamps • Control Panels — Controllers, Transformers, SCR’s & Spang Units • Auxiliary Items — Crucible Bowls, Filtration, Degassers, Drain Blocks & Thermocouples • Specialty Products — Standard configurations or cast shapes • Schaefer Shield • Door Relines and Door Blades • Well Covers • Pier Blocks and Base Blocks • Ladle Linings • Burner Blocks — we provide custom burner blocks in 72 Hours!
100% PROUDLY MADE IN THE USA | 17 Kilns & Ovens Brick or fiber lined kilns are our specialty. Retrofit ceramic fiber linings over brick or replacing brick, repairs and new construction. We can provide high temperature mortars, wear ceramic brick and mortars, acid resistant brick as well as high alumina and insulating firebrick. Fluxes SGI FLUX BENEFITS • Reduced Melt Loss • Reduction of Inclusions • Improved Fluidity • Improved Melt Efficiency • Less Furnace Cleaning Time • Lower Hydrogen FLUX TRAINING The Schaefer Group can provide the proper SGI Flux recommendation for your application, as well as the proper techniques and training of your furnace tenders. Furnace operators that have been properly trained and given the correct flux and tools to use will reduce the time needed to clean the furnace as well as reduce the damage to the refractory lining. FURNACE TOOLS Contact a Schaefer Group representative for a complete list of tools available to properly maintain your furnace.
18 | THESCHAEFERGROUP.COM Refractory Contracting & Materials REFRACTORY CONTRACTING Whether delivering a total refractory package or providing a turn-key furnace reline or rebuild, you can count on FWS to provide the best… 24 hours a day, 7 days a week. Our combination of engineering capabilities, broad experience and state of the art materials, ensure a quality project. • Full design and engineering capabilities. Turnkey Installations. • High quality refractory materials including premium and energy efficient products. • Skilled workforce with decades of experience in the aluminum industry. • Work performed at your facility or in our shop. Available 24/7. CONTACT US FOR RELINE, REPAIR SERVICES, TRAINING AND MATERIALS FOR: • Boilers • Hot Water Tanks • Incinerators • Iron & Steel REFRACTORY MATERIALS FWS distributes the highest quality refractory materials available, including Thermbond®, Plibrico® and Unifrax®. Not only can we reline your furnaces using any of these fine products, we can utilize any materials you specify including: • Ceramic Fiber Products — Blanket, Board, Paper, Modules & Specialties. • Monolithic Refractories — Dense & Insulating Castable, Plastic, Gunning & Shotcrete. • Firebrick & Mortar — Dense & Insulating Firebrick, High Alumina Mortar & Coating Mixes. • Block Insulation, Ceramic & Stainless Steel Anchors, Precast Shapes. • Other Materials — Concrete Patch Materials, Wear Ceramics, Pre-Krete Corrosion Resistant Linings – Plastics — Gunite and Castable – Mixes, Bonding Agents and Mortars – Dense & Insulating Firebrick and Acid Bricks – Coatings – RCF Blankets and Board – Phoscrete Hot Floor Refractory Specialty Products Burner blocks, wedge blocks, pre-cast launder sections…you name it, FWS can provide it. We have equipped our facilities to provide any cast and baked refractory shape you specify, usually within two days. Standard configurations or cast shapes…FWS provides quick turn-around for all of your critical refractory components: • Door Relines and Door Blades • Well Covers • Pier Blocks and Base Blocks • Ladle Linings BURNER BLOCKS — QUICK! A special service of FWS…Customer Burner Blocks in 72 hours! In most cases, if we already have the information, or if you can provide us with a part or a drawing, we will get a replacement burner block to you within three days.
100% PROUDLY MADE IN THE USA | 19 CUSTOM CERAMIC FIBERBOARDS The Schaefer Group, Inc. offers ceramic boards in a variety of sizes, thicknesses, and fabrications. They provide exceptional strength, insulating qualities, and low off-gassing. Boards can be cut to custom sizes and machined with specialized shaping. SGI maintains a sizeable inventory of stock for immediate shipping. • Calcium Silicate • Non-Wetting • Hot face Refractory • Insulating/Back-up Should you need assistance in tool design, our technical staff can work with you to create the perfect components for your operation. DAMS We produce several dam products for controlling or diverting metal flow, along with skim management to protect metal quality. Our machining technology provides limitless refinement options for your molten flow control needs. PRE-CAST LAUNDER INSERTS The Schaefer Group services the foundry industry with custom pre-cast launder inserts, including design, shell and lining fabrication, and replacement. We work with all refractory manufacturers to provide optimal application specific solutions. CERAMIC PRE-CAST SHAPES We also service the foundry industry with both standard inventory and custom pre-cast components and shapes. These can include runners, funnels, pouring components, covers, and other items. Large intricate custom pieces have firing capabilities up to 2,000°F. FURNACE TOOLS The Schaefer Group offers a wide variety of standard furnace tools including tongs, skimmers, scoops, and ladles. We also manufacture custom tools for your casting process, providing you with a one-stop resource for the items you need to effectively run your operation.
20 | THESCHAEFERGROUP.COM HEAT CONTROL We also offer a variety of fabric products. These are manufactured as seals, gaskets, curtains, and insulating curtains for temperature retention and control, as well as items for metal immersion and filtering. We can also supply various sizes of ceramic fiber blanket, paper and textiles. THERMOCOUPLES AND THERMOCOUPLE PROTECTION TUBES Used for accurate temperature data to manage your melting and casting operations, we have an in-stock inventory for quick delivery. Training, Consulting & Other Services • Training Sessions — Furnace Cleaning & Fluxing, Combustion System Troubleshooting • New Control Panels & Upgrades — HMI & PLC Programming • Combustion System Balancing and Fine Tuning • Refractory Supervision, Heat Flow Analysis, Energy Audits
100% PROUDLY MADE IN THE USA | 21 Systems Integration & Service Delta Control is an experienced systems designer of integrated control systems for industrial furnaces, chemical plants, wastewater treatment plants and any industry that requires a highly engineered system to control operations accurately, reliably and consistently. We design systems from single pumps to elaborate SCADA with PLCs & HMIs. PLC & HMI Programming Growth in Programmable Logic Controllers (PLC) applications have expanded into every type of manufacturing and process control area imaginable. PLCs vary in cost and size from the small control system for individual stand-alone single processes, to the immense plant wide control, with the ability to communicate with every process to monitor, alarm and control. We are constantly expanding our variety of platforms to provide our customers with the most cost effective configurations, and the most flexible installations. Our wide variety of PLC products that we use include complete digital, analog and specialty modules as well as the communications networks required to fit your needs.
22 | THESCHAEFERGROUP.COM Whether you are batch processing, continuous monitoring, or closed loop PID for flow, temperature, level or pressure, we have the knowledge and experience to design, install and service the best solution. We specialize in designing and installing new systems as well as designing upgrades to replace older obsolete controls and systems. We routinely add Human Machine Interface (HMI), wireless radio communications, and/or a computer controlled data acquisition (SCADA) for a complete turnkey system that is easy for the operator to manage. Systems Engineering & Analysis Delta Control has 45 years of experience in engineered systems design. Our systems are known for their quality and reliability. Turn-key systems engineered from AutoCAD schematics to the final installation including testing and start-up, and are enhanced by our experienced professionals. We include training your operators to give you peace of mind. Our systems applications include waste water and water pumping control, molten aluminum pouring, heat treating furnaces, aluminum recovery systems, chemical mixing systems and many other process control applications. Whether you need flow, level, temperature, or pressure control, or all of the above, we can assist with putting it all together to provide you with a system that is verifiably accurate and easy to operate. Quality Control Systems Control systems developed by Delta Control consist of: 1. Waste Management systems to monitor and control flow and treatments. 2. Food processing controls that measure and count quantities and flow rates of various products as they move through the manufacturing process. 3. Aluminum melting control systems with PLC and HMI screens to monitor and control all aspects of the melting process including temperature control, metal level, pump speeds and door operations. 4. Chemical plants monitoring of flow and mixing data to ensure the exact quantity and quality of the product. 5. Most importantly, SCADA Design in any application! 24/7/365 Hour Technical Support 937.253.3342
100% PROUDLY MADE IN THE USA | 23 SCADA Design and Implementation Delta Control is a leader in Supervisory Control and Data Acquisition (SCADA) design and the sale, installation, and maintenance of process control equipment. Delta Control Inc. has worked in the industrial sector for a variety of manufacturing or process applications, for many years. Our customers include many private manufacturing groups as well as municipalities. SCADA is the real time exchange of information for the purposes of control, data collection, and integrated management. It improves the visibility of production environments, and ensures product quality, by adapting to rapid changes in the manufacturing processes in order to improve productivity. The data acquisition allows the tracking of runtimes, pump starts, flow totals, temperature profiles and any other process variables necessary for the cost effective maintenance and control of your system. This also allows for the quick identification of problems to reduce the loss of labor, material and energy. A SCADA system gathers information seamlessly to perform smart maintenance routines to reduce downtimes. It also improves the connectivity from the actual process to the operator and supervisor with screens loaded directly on your desktop, displaying the real time data and animated processes. Hardware Sales Delta Control stocks and sells these spare parts for quick delivery: • Resistance Temperature Detectors (RTDs) • Thermocouples • Wire by the foot • Temperature Controllers • Data Recorders • Indicators • Sensors and controllers by many different manufacturers
HEADQUARTERS 1300 Grange Hall Road Dayton, OH 45430-1013 Phone: 937.253.3342 Fax: 937.253.2306 CINCINNATI OFFICE 11310 Tamarco Drive Cincinnati, OH 45242 Phone: 513.489.2420 Fax: 513.489.2494 KNOXVILLE OFFICE 4312 S. Middlebrook Pike Knoxville, TN 37921 Phone: 865.909.9352 Fax: 865.909.9164 TOLEDO OFFICE 29102 Glenwood Road Perrysburg, OH 43551 Phone: 419.897.2883 Fax: 419.897.2886 LOUISVILLE OFFICE 214 Eiler Ave Louisville, KY 40214 Phone: 502.969.3193 Fax: 502.969.2998 get.info@theschaefergroup.com THESCHAEFERGROUP.COM ©2023, The Schaefer Group, Inc. FURNACE DIVISION REFRACTORY SALES & SERVICE DIVISION DELTA CONTROL DIVISION
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