Electromagnetic Pumps and Flow Meters
 
 

PG SERIES PUMPS

CMI Novacast PG Series Electromagnetic Liquid Metal Pumps

The CMI Novacast PG series electromagnetic pumps are used for transferring molten aluminum or zinc in a controlled and non-turbulent manner for low pressure filling of sand, permanent or semi-permanent molds. The pumps can also be used as a metering device for filling of molds via gravity. CMI Novacast electromagnetic pumps last longer in the furnace, cost less to maintain and operate, and deliver more consistent, precise, and better performance than any other pumps in their class.

As well as manufacturing new pumps from start to finish, CMI Novacast performs pump remanufacturing at its facility in Des Plaines, Illinois.

Both PG series pumps are suitable for most aluminum alloys at temperatures up to 800° C (1472° F). The pumps are immersed in molten metal so that only the top 10mm (3/8") of the top ceramic is above the metal surface. This allows the pump to draw only the cleanest metal from below the surface.

Unlike tilt pouring or automatic ladling, CMI Novacast PG pumps draw the metal from below the surface. This allows for only the cleanest metal, free from dross and other materials floating on the top of the melt. As an added feature, ceramic filters are on the bottom of the pumps to further clean the metal before it enters the pump. This allows the pumps to provide the cleanest possible metal to the molds.

The metal is then delivered to the mold through heated launders. The metal entering the mold is the same temperature as in the furnace. There is no heat loss as compared to ladling. The furnace does not have to be set at a higher temperature to compensate for heat loss during ladling.

The model PG450 pump is the "workhorse" pump being used in many different applications, most of which are low pressure. In low pressure precision sand, the pump provides very quick and precise control of mold filling. Because of its high degree of control and extremely fast response, it can help the low pressure sand foundry to produce castings with a very good surface finish, with minimal penetration and burn-in. Conventional low pressure sand foundries produce about 30 castings per hour, while foundries using the rollover scheme may produce castings at the rate of 70 to 90 per hour, even when the cast weight is 50 kg (110 lbs.) per mold.

For all other metals, contact CMI Novacast.


CMI Novacast PG450 Electromagnetic Liquid Metal Pump

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The PG450 is the larger of the two electromagnetic liquid metal pumps. CMI Novacast's engineers can integrate this high performance pump to fit your foundry system needs.

General Specifications for Aluminum
Head Pressure - Sustained: 87 in., 2.2 m
Head Pressure - Peak: 98 in., 2.5 m
Maximum Flow Rate: 22 lbs./sec, 10 kg./sec
Minimum Well Size: 24 x 20 x 22 in. deep, .6 x .5 x .56 m deep
Power Requirements: 0-14 kW, 380/480 Volts , 50/60 Hz
Furnace Type: Gas or Electric
Cooling Air: System supplied by CMI Novacast


CMI Novacast PG300 Electromagnetic Liquid Metal Pump

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The PG300 is the smaller, compact pump model designed for gravity filling of molds, or to fit a smaller furnace-crucible. Typical molding rates are 180 per hour with poured weights averaging 10-41 kg (22-90 lbs.) per mold, or approximately 2100 kg per hour (4700 lbs. per hour).

General Specifications for Aluminum
Head Pressure - Sustained: 40 in., 1.0 m
Head Pressure - Peak: 48 in., 1.2 m
Maximum Flow Rate: 8.5 lbs./sec, 3.9 kg./sec
Minimum Well Size: 19 x 16 x 20 in. deep, .48 x .4 x .5 m deep
Power Requirements: 0-9 kW, 380/480 Volts , 50/60 Hz
Furnace Type: Gas or Electric
Cooling Air: System supplied by CMI Novacast

 
 
 

LA SERIES PUMPS

CMI Novacast LA Series Electromagnetic Liquid Metal Pumps

CMI Novacast's LA series 3-phase linear annular induction pumps are constructed of stainless steel for pumping metals such as Na, NaK, K, and others. Some metals may require that the pump be made from other materials. The metal flows through the annular space between two concentric tubes, the inner of the two containing a magnetic core, through which the lines of a moving radial magnetic field are looped. The field is developed by a 3-phase stator around the tube. The flow of induced currents is circular, within the annular space, cutting the lines of the field. An axially exerted force then results, moving the liquid metal through the pump. Thermocouples are provided to monitor temperature, and cooling is provided to prevent damage to the components during operations up to 600° C. The absence of moving parts within the pumped liquid eliminates the need for seals and bearings that are found in conventional mechanical pumps, thus minimizing leaks, maintenance, and repairs, and improves reliability.

These pumps are designed principally for use in liquid-metal-cooled reactor plants where liquid lithium, sodium, potassium, or sodium-potassium alloys are pumped. Other metallic and non-metallic liquids of sufficiently high electrical conductivity, such as mercury or molten aluminum, lead, and bismuth may also be pumped in non-nuclear applications.

For all other metals, contact CMI Novacast.


CMI Novacast LA500 Electromagnetic Liquid Metal Pump

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LA500 Specifications for Sodium
Max delivery (m3/h): 140
Max temp (°C): 600
ΔP (bars): 4
Max pressure in pipe (rel. bars): 15
N.P.S.H. (bars abs.): 1.0


CMI Novacast LA200 Electromagnetic Liquid Metal Pump

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LA200 Specifications for Sodium
Max delivery (m3/h): 12
Max temp (°C): 600
ΔP (bars): 3
Max pressure in pipe (rel. bars): 15
N.P.S.H. (bars abs.): 0.8


CMI Novacast LA125 Electromagnetic Liquid Metal Pump

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LA125 Specifications for Sodium
Max delivery (m3/h): 4
Max temp (°C): 600
ΔP (bars): 1.3
Max pressure in pipe (rel. bars): 15
N.P.S.H. (bars abs.): 0.7


Other CMI Novacast LA Series Electromagnetic Liquid Metal Pump Specifications

LA400 Specifications for Sodium
Max delivery (m3/h): 50
Max temp (°C): 600
ΔP (bars): 5
Max pressure in pipe (rel. bars): 15
N.P.S.H. (bars abs.): 0.8

LA150 Specifications for Sodium
Max delivery (m3/h): 8
Max temp (°C): 600
ΔP (bars): 1.5
Max pressure in pipe (rel. bars): 15
N.P.S.H. (bars abs.): 0.9

LA300 Specifications for Sodium
Max delivery (m3/h): 25
Max temp (°C): 600
ΔP (bars): 5
Max pressure in pipe (rel. bars): 20
N.P.S.H. (bars abs.): 0.8

 
 

CA SERIES PUMPS

CMI Novacast CA Series Electromagnetic Liquid Metal Pumps

The CMI Novacast CA series of electromagnetic pumps are typically made of stainless steel. Force is imparted to the metal in the pump according to the Left Hand Rule for motors, where if there is a current carrying conductor that is in a magnetic field, the conductor experiences a force which is perpendicular to the flow of current and the magnetic flux.

The metal flows through a straight pipe which is partially flattened over part of its length, where the faces of an electromagnet are placed (keeping the gap between the pole faces small). There are also electrical connections to the side of the pipe in this same area that introduce an electrical current flow into the molten metal. The electrical current flows across the flattened section while the magnetic flux passes through the flattened section at right angles to the current flow, and this produces a force on the metal that is at right angles to the current and magnetic flux. These pumps may operate on direct current or (more frequently) alternating current. When operated with alternating current, the direction of the flow of electricity in the metal changes every half-cycle, and since the electromagnets are also powered by the same alternating current the magnetic field also changes direction every half-cycle, so the force on the metal pulsates but is always in the same direction. These pumps are generally convection cooled, although if the pumped metal temperature is quite high, supplemental cooling may be required.


 CMI Novacast CA15 Electromagnetic Liquid Metal Pump

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CA15 Specifications for Sodium
Frequency: 60 Hz
Voltage: 0-240
Amperage: 0-35
Max temperature: 600° C
Max pressure: 10 bar
Max flow rate at 3 bar: 1.2 kg/sec

 
 

FLOW METERS

CMI Novacast FS Series Electromagnetic Liquid Metal Flow Meters

The CMI Novacast contactless electromagnetic flow meter operates by measuring the amount of distortion in a magnetic field that is caused by movement of a conductor within that magnetic field. The effect is similar to what is called "armature reaction" in certain electric motors and generators. To achieve this, permanent magnets are set near the moving material. The moving material may or may not be contained within a pipe or conduit. The amount of shift of the magnetic field is measured in the direction of movement of the measured material which corresponds to the flow velocity of the material. The measured signal is then used to drive an indicator calibrated into the unit of measurement necessary.

Flow meters can be built for almost any size pipes from small to over 10 inches in diameter. For large size pipe specifications, contact CMI Novacast.

Currently for use with aluminum, zinc, sodium, mercury, and magnesium. For all other metals, contact CMI Novacast.

ADVANTAGES

No moving parts
No contact with measured liquid metal
Continuous operation at liquid metal temperatures over 1000° C
Can be used on virtually any size pipe or conduit
Low power consumption
Welded or flanged connected to existing piping
High accuracy +/- 2% or better (optional)


CMI Novacast FS365HA Electromagnetic Liquid Metal Flow Meter

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FS365HA Specifications for Sodium
Max temperature: 600° C
Max pressure: 10 bar
Max flow rate: 365 liter/min
OD of flow pipe: 114.3 mm
ID of flow pipe: 102.3 mm
Output signal: 4-20 mA


CMI Novacast FS15 Electromagnetic Liquid Metal Flow Meter

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FS15 Specifications for Sodium
Max temperature: 600° C
Max pressure: 10 bar
Max flow rate: 1300 cc/sec
OD of flow pipe: 12.7 mm
ID of flow pipe: 10.2 mm
Output signal: 4-20 mA


CMI Novacast FS10NA Electromagnetic Liquid Metal Flow Meter

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FS10NA Specifications for Sodium
Max temperature: 600° C
Max system pressure: 15 bar
Flow rate: 15.0 gpm
OD of flow pipe: 48.26 mm
ID of flow pipe: 40.89 mm
Output signal: 0-5 mV


CMI Novacast FS02NA Electromagnetic Liquid Metal Flow Meter

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FS02NA Specifications for Sodium
Max temperature: 600° C
Max system pressure: 15 bar
Flow rate: 5.0 gpm
OD of flow pipe: 19.05 mm
ID of flow pipe: 15.75 mm
Output signal: 0-5 mV

 
 

PG SERIES SYSTEMS

CMI Novacast PG Series Electromagnetic Liquid Metal Pump System Components

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The drawing above shows a typical CMI Novacast electromagnetic pump system for aluminum and zinc. CMI Novacast can engineer a system to meet your specific needs. Components included in a standard PG series system are listed below.

For all other metals, contact CMI Novacast.


Two CMI Novacast PG450 or PG300 Electromagnetic Liquid Metal Pumps

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Pump Support (simple, non-motorized) is also included. This device is to be bolted onto or near the existing furnace. It locates the pump in the furnace well. Special motorized version is also available at extra cost.


CMI Novacast Heated Launder

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Launder systems are electrically heated and controlled by thermocouples. All parts that come in contact with the molten metal are made using special silicon-carbide ceramic, which has a long history of providing excellent service. Since the launders are electrically heated, there is very little or no heat loss from the furnace to the mold. This minimizes the need for super-heating of the metal in the furnace, and further improves metal quality and reduces costs.

The metal moves up from the pump through a short unheated section and then enters an 85 degree elbow which is connected to a horizontal section. The horizontal section is at a 5 degree incline, which allows the launder to be self-draining when the pump is shut down. The horizontal section is then attached to the mouthpiece.

There are several different mouthpieces available depending on your needs, such as roll over, direct low-pressure, tundish, gravity, or double low-pressure (i.e. two molds in one press). Special mouthpieces can be designed according to your individual needs.

Since the launder carries a large volume of metal every week, it is important to clean it every week. In most cases, a spare is heated one day in advance and put into service, while the other one is cleaned and re-gasketed. The launder transport cart makes this changeover fast and easy.

CMI Novacast heated launders come in two sizes:
45 mm I.D. system has standard horizontal lengths of 580 mm and 1000 mm
60 mm I.D. system has standard horizontal lengths of 667 mm and 1000 mm


CMI Novacast PG Series Control System

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The control system is critical to the proper operation of the pump system. The control system stores all of the operating parameters for each casting job. In some gravity-pour applications, this can amount to many hundreds of "fill profiles." Each fill profile is stored on an industrial PC and is downloaded to the PLC at the beginning of each job run. Programming of fill parameters is performed by an authorized master operator. But any authorized operator can download fill profiles at any time. Typical fill profiles consist of up to 16 segments of specified time of a specified power. As the profile runs, the pump power is varied according to the programmed fill profile. Since the pump has no moving parts, the only inertia in the system is that of the moving metal itself. This means that the pump delivery pressure can be changed almost instantly to meet the requirements of the casting. Numerous safeguards are standard in the control system to meet safety standards throughout the world. Control systems can also be provided with the capability to report to external systems for such things as SPC and other managerial data systems.

The control panel incorporates controls for automatically compensating for variations in metal level in the holding furnace. This is especially important in gravity casting applications since a very small change in metal level in the launder tube can have a dramatic effect on flow rate. Low-pressure casting is not nearly as sensitive to variations in metal level in the furnace, because the flow rate is not very dependent on how high the metal is in the mold. The control panel also monitors and controls the temperatures in the launder system, and will prohibit operation if the temperature is not within specified limits.

The PG series controls are user-friendly where hands-on command capability is desired. Under rigorous production conditions, a computer or programmable controller can drive the pump. Without operator intervention, complex mold fill parameters, difficult or impossible to execute manually, are easily and uniformly achieved in real-time. To ensure that process commands are accurately met, an optional closed-loop feed-back circuit is available.

The exacting molten metal delivery and tight process control assures maximum casting quality and uniformity, minimal cycle downtime, greatly reduced manpower needs, and fewer scrap castings. The result is significantly improved bottom-line performance.

General Specifications:
Precision pump controls
Launder temperature controls
Pump cooling temperature control


CMI Novacast Pump Cooling System

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The CMI Novacast electromagnetic liquid metal pump is an electrical device which contains special coils that are designed to operate at temperatures much higher than almost any other coil made today. There are, however, limits as to how hot the coils may operate, and the laminations which make up the pole pieces also have a maximum temperature limit. In order to keep the temperature of these items below their maximum, a special pump cooling system is provided. This system consists of one (or two for redundancy) special blower and a control package. The control package contains the temperature monitoring and control devices to ensure the safety of the pump electricals.

The cooling system also provides self-sealing for small leaks in the pump. As a result of the cooling of the internal areas of the pump, a "freeze-plane" is developed in the ceramic walls of the pump. If a small crack occurs in the ceramic wall, the metal that penetrates that crack will reach a point inside the wall where the metal temperature is below solidus, and the leak is temporarily sealed. As a result of the "self-sealing" of small leaks, the pump life is greatly extended compared to pumps that do not have this freeze-plane feature.

The controls keep the internal pump temperature constant, which minimizes thermal cycling of the ceramics, improving their longevity.

Specifications:
PG-450: 5.5kva max. 380-480V 50/60Hz 3Ph.
PG-300: 2.2kva max. 380-480V 50/60Hz 3Ph.


CMI Novacast Pump Preheat Oven

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CMI Novacast electromagnetic liquid metal pumps are made of hygroscopic ceramics (they will absorb moisture from the air), therefore it is critical to remove all moisture from the pump and heat the pump to the proper temperature prior to immersion in the molten metal. Failure to fully preheat the pump may result in: thermal shock to the pump, introduction of hydrogen gas into the metal, or freezing of metal inside the pump. The pump preheat oven is designed to raise the pump temperature at a controlled rate, which further enhances the removal of moisture from the pump. Since there are electrical coils inside the pump, it is also required to cool the inside of the pump. The preheat oven incorporates a variable speed cooling blower for this purpose. This cooling blower further aids the removal of moisture and helps to maintain a fixed internal pump temperature. The preheat oven is portable and may be plugged into any standard welding outlet with 3 phase power.

General Specifications:
Power: 0 - 13 kilowatts, 480 volts
Heating: Electrical resistance


CMI Novacast Filter (SiC) and Flotation Disk

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Since the metal inlet on the pumps is on the bottom, it is very easy to apply filtration. The filter of choice is placed on top of the ceramic float. Then the preheated pump is lowered onto the filter and float, forcing both below the bath surface. The buoyancy of the flotation disk forces the filter against the bottom of the pump, and the guides on the float keep the filter and float from sliding out from under the pump. All of the metal entering the pump is filtered, ensuring delivery of the highest quality metal to your castings. Flotation disks and filters need to be preheated before use to remove all moisture.

Metal filtration offers many benefits to the foundry including:
Reduction in oxide inclusions in the casting
Reduced scrap rate
Reduction in finishing tool wear
Improved metal fluidity and castability
Improved surface finish

Expected Life: Nominal of 100,000 pounds of aluminum


CMI Novacast Filter and Float Preheat Oven

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Preheating the metal filter and flotation disk is required before placement into the molten metal. The filter and float preheat oven heats the pair up to bath temperatures to avoid thermal shock and to remove all moisture from the ceramics.


CMI Novacast Pump Cool Down Box

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This device is to be used after the pump is removed from the holding furnace. It slows heat loss from the pump, which extends the life of the ceramics.