Ethiopia 5000t/a Lost Foam Casting Plant

Project Planning and Quotation

TEAMS Engineering

2016/01/05
 TEAMS Engineering

Contents

Preface

1 Plant construction proposal overview

2 Production workshop layout
3 Casting technology and process flow
4 Calculation summary of casting technology and equipment capacity
5 Integrated technical parameters and index of the 5000
Ton/Annual lost foam casting production line
6 Main equipment for lost foam casting
7 Configuration table for equipment
8 Proposed cooperation model for project implement
9 Project implementation schedule
10 Quotation sheet
 TEAMS Engineering

Preface

According to years of rich project experience and in-depth work in Ethiopia, we, TEAMS

Engineering(Beijing) Co., Ltd. have well cognized and fully understood the industrial development

and existing technology status of Ethiopia, therefore, we put forward this Ethiopia lost foam

casting plant project planning which contains the implement plan and initial quotation at the same

time.

Technical plan is based on the following aspects:

 Ethiopia national economic development characteristics and momentum represents good

recently. Product of this plant has good market prospects, while at the same time, with

this production line, we can produce other products.

 Production scale is suitable for the Ethiopia economies scale while it keeps the

characteristic of economic at the same time.

 As the widely adopted and matured advanced technology and equipment, it can meet the

requirement of exporting excellent quality and high reliability of complete sets of

equipment;

 Combining with Ethiopia's current technical level and personnel technical skill, we choose

the most suitable transfer technology and strengthen technical training during the project

cooperation, so that to greatly enhance the technical level in Ethiopia and its independent

production capacity.

 Based on our years of experience in international projects and our high technical level of

project management team, we put forward this feasibility study report and provide the

initial quotation for it.

After careful study and analysis, we put forward this 5000t/annual lost foam casting plant

planning and implementation schedule.

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  Representative products: ZF gearbox shell

 Production capability: 5000 t/a

 Independent factory, demonstrative plan

 The technology and production line are suitable for producing other products

 Casting process: lost foam casting (EPC)

About Lost foam casting technology:

Lost foam casting is a process of combining the model of foam cluster which has the similar

size of the casting parts together, and then coating with fire resistant paint before dry it. It was

buried into dry quartz sand to modeling according to continuous vibrating by casting under the

negative pressure. With the gasification of the foam model, metal liquid occupies the foam model

position, after cooling and solidification, it forms the model. Lost foam casting is one of the most

advanced casting technologies in the world.

Lost foam casting process meets with the general modern foundry trend. Compared with

traditional casting technology, it has incomparable advantages:

 High precision: lost foam casting is a new almost no residual high precision modeling

technology. Without modulo, parting surface, sand core, so that the casting parts do not

have edges, burrs and pattern draft. It reduces the size error caused by a combination of

the cores. Surface roughness can drop down to Ra3.2 to 12.5μm. Casting accuracy can

reach IT7 to IT9;

 Flexible casting: It provides sufficient freedom for model design. We can cast a high

complex casting parts according to c combine foam clusters.

 No traditional core sand: as there is no traditional core sand casting process and

equipment, it largely reduces the quantities of waste caused by core making. It will avoid

uneven casting parts wall caused by the inaccurate size and position of the sand ;

 Clean: no chemical binder; the foam is harmless to the environment in low temperature;

more than 95% sand recycling rate; reduce dust, smoke and noise pollution; greatly
 improved the working environment of the foundry workers and reduced labor intensity;

 Reduce investment and production costs: reduce the weight of the casting blank; low

down machining allowance to 1.5mm to 2mm, greatly reduce the cost of machining;

 Simplified plant design: fixed asset investment can be reduced by 30-40%; area and the

construction area can be reduced by 30-50%; power consumption can be reduced by

10-20%.
 1. Plant construction proposal overview

1.1. Representative product

The following gearbox is the localized ZF gearbox (s6-90) produced in China. It was produced
under the strictly executed Germany ZF company advanced technology and quality standard,
widely used to match the power of 15 ~ 25 tons heavy trucks and 10~12m bus which has
220~350hp drive power. This product meets Ethiopia's technology and product development and it
has a great market prospect.

Product: ZF gearbox housing

Dimension: 500X320X390mm

Blank weight: 72 ± 2kg

Material: HT200

1.2. Working system and Annual work time

Combined with the actual situation in Ethiopia:
Single shift production: 254 days / year, 8 hours / day
Annual work time: 254x8=2032 hours
1.3. Production capability: 5000 t/a
(Equivalent to an annual output of 70000 pieces of a single gearbox shell, or all casting parts
of 50000 ZF transmission)
1.4. Demonstrative casting plant layout
Independent factory area which takes about of 2.6 hactare
1.4.1 General layout:

1.4.2 List of buildings.

 1.4.3 General planning data index:

1.4.4 Bird View：

1.5 Principle of genera layout

According to the general layout principle, factory comprises and the natural conditions of the
region, general layout of plant including production line, office and other facilities. The main
buildings are worship, stock yard, public facilities, gate guard, etc.

1.5.1 Steel structured main workshop. One is 24 meters and another is 21 meters, including
melting, modeling, shaping, cleaning and other main production departments. Lost foam casting
technical characteristics needed to be considered when planning the plant layout. It must meet the
requirements of production, maintenance, transportation and fire protection. Placing different
green plants to different places of the plant to reduce dust, noise and other pollutes, as well as
decorating the room at the same time.
1.5.2 Office facilities includes office buildings, staff canteen and other basic facilities
1.5.3 Public facilities include water supply, power supply, gas & oil supply and others. Power
sub-stations set in the vicinity of the melt shop to provide the power for the whole plant.
1.5.4 Built a big stock yard for the characteristics of the lost foam casting
1.5.5 Separate staff and logistic flow ways, use weighbridge to manage in and out logistic in
warehouse.

2 Production workshop layout (following figure)

冷却 水池 白模烘干 白模烘干 白模烘干 一涂烘干

成型机 成型机 成型机
1 #molding
成型机 成型机
2 #molding
成型机
3 #molding 4 #molding 5 #molding 6#molding machine machine machine machine machine machine

预发→成型→白模烘干→粘接组合→涂刷→一次涂刷烘干→涂 刷→二次涂刷烘干→涂刷→三次涂刷烘干与储
三涂烘干、储存 三涂烘干、储存 三涂烘干、储存
模型方向 model direction 三涂烘干、储存 二涂烘干 二

造型区 modeling area

铸件吊装方向 casting hoisting direction

 Modeling and sand treatment area layout:：

131415 16

1 3 4 5 6 7 8 9 10 11121718 19 20 22 23 21 24 25

造型区 modeling area 2120

浇注区 casting area

17 14 1 2 5 6 7 8 9 14 10 11 12 22 23

3．Casting technology and process flow

3.1 Lost foam casting technology
 Pre-expanding: expandable beads (made of such as polystyrene, polymathic methacrylate and
their copolymers) are stored in cold low temperature. 1 set of 25-30kg/h foaming machine
which is heated by steam and can automatically and intermittently work is needed to expand
the beads (diameter 0.3mm) for backup. Steam valves and components are all imported. The
foaming machine is suitable for beads made by EPS, PMMA and other polymer materials.
 Size of molding machine template: 1000x1200mm, horizontal modeling. Time and pressure of
filling, steam heating, cooling, modeling and other parameters can be adjusted and controlled.
In order to facilitate the modeling, the main mould in the lower position is required to be
stable and the upper mould is dynamically moving.
 6 hours is needed for single model; 12 hours for combined model drying which contains twice
dip coatings and twice dryings; 6 hours for bound model compensate paint drying. Steam
heating oven is used to dry while the temperature and humidity are adjustable. Models and
bound models can be dried on trolley type oven. Trolley cars are used to put and transport
multi-layered single mode, combined model and bound model;
 Using adhesive machine to stick the models together and with artificially dip coating. In the
 process of operation, it needs to strengthen the model, accurate model size and inspect the
coating performance. Hoe melt adhesive need to be bought from market in advance;
 Coating technology is the most important procedure of lost foam casting. Both high and low
speed barrels coating mixers are optional to mix the paint. At the beginning, the painter can be
bought from market. As the mass production, producing the coating is also considerable.
 The production of the qualified bound module for the storage and delivery to modeling line
 Diagram of casting process:
Steam, cooling water, compressed air
Model

Expandable beads Pre-expanding Bead ripening Modeling machine



Twice painting Stick the foam models Modeling time

Twice drying Assembly runner Paint compensation Drying Conveying to the modeling line

3.2 lost foam casting process

 According to the characteristics of gearbox house, 1400x1100x900 (high) mm of the sand box
size is chosen for the production line of the modeling. 4 pieces of castings parts are arranged
in each case, while 10 boxes are produced within one hour;
 The core equipment of lost foam casting process is the vibrating table. A good vibration table’s
vibration frequency, amplitude and time of vibration, vibration acceleration can be adjusted
according to change the parameters. Sand can be filled and compacted to the model well
accordingly to ensure the bound model will not be deformed and damaged.
 Lost foam casting line can be arranged by either closed loop wiring or open wiring. Molding,
adding sand, vibrating, pouring, cooling, sand shakeout and other processes can be completed
at the modelling line. The molding line is composed of horizontal vibration platform, sand box,
transport vehicle, push and buffer cylinder, side roll group, positioning device, hydraulic
station, hydraulic pipe system, electric control system, turning machine and vacuum system.
Cooling time for casing parts is 60 minutes. After cooling, the model and sand are conveyed to
 sand shakeout planks, model and sand are separated there through vibrating.
 PLC distributed control system is used in production line, which can be controlled both
automatically and manually. Computer screen displays and alarms fault when monitoring
 Shower type sand adding machine is used to add sand evenly so that the sand flow will has
tender impact to the bound model. Manually low down the model.
 Use 1 ton casting ladle to carry the melted metal liquid and weigh it by digital electronic
weighing hook, and then transport the casting ladle to pouring station by crane. Set up a set of
vacuum device to achieve negative pressure pouring, after that, cool it for 15-20 minutes in
negative pressure state.
 Process flow chart of lost foam casting process

Put bound models in modeling shelf

Add sand Empty sand box

Lower the bound model in the sand box

Add sand again Vibrate and compact

Lower the pouring cup

Pouring

Cooling

Turn over the sand box

Sand shakeout

Magnetic separation, screening, cooling Used sandModel Convey to cleaning department

 3.3 Sand treatment
 When turnover the sand box, the sand fall into the water cooling container and then moves to
the screening conveyor.
 The screening conveyor screens and transports the sand. It picks out large pieces of debris and
particles of iron from the casting sand, at the same time it removes the dust and cools it by air.
During screening and conveying, slag lifting machine can automatically lift the waste residue at
the conveyor and put it into the slag bucket;
 Cast sand came across the chain bucket type elevator will be conveyed into the powder
screening assembly. After removal of a large number of large dust particles, the sand will be
cleaned in the sand collector and be cooled in the horizontal cooling machine;
 Horizontal cooling machine is one of the main equipment for sand cooling. The casting sand
moves to the chain hoist after be cooled and then transported to the sand temperature
regulator.
 After filled up, material position detection device mounted at the sand temperature regulator
will feedback the signal to all the conveying equipment at the front stage to stop filling sand.
The whole procedure is full automatization without manual operation.
 There mounted a cooling unit at the sand temperature regulator. After three times of
sand cooling, it can meet the sand temperature requirement of less than 50℃.
 The sand will be put into the chain bucket elevator after coming out from the sand
temperature regulator, and then conveyed to three sand storage hoppers. Shower type sand
adding machine is mounted at the lower end of the hopper which can fill sand into the sand
box tenderly in each position. Sand particles are dispersed to avoid impact and manage to the
model. After filling the sand, the sand treatment process is finished.
 Dust removal device is arranged in the sand treatment system. Air flow control valve is also
mounted to places the dust is not often produced, the air suction channel can be turned on
and off according to the actual situation.
 When it need to fill up the system with new sand, the sand will be feed by falling sand
vibration in the magnetic separation;
 Sand treatment and modeling line using the same set of PLC centralized control system;

 Process flow chart:

 Shakeout Water cooling container
Bucket type elevator
vibrating
table
Screenin
g
Sand Bucket type elevator
conveyor temperature
regulator
Horizontal Cooling machine Bucket type elevator

Shower type Modeling

Belt conveyor sand adding
line
machine

3.4 Melting process

 Pig iron, scrap steel, waste casting are stored in daily consumption warehouse; after surface
cleaning at the cleaning drum of daily consumption warehouse, pouring cup will be stored in
the daily consumption warehouse.
 1 sets of 2Ton medium frequency induction furnace (double furnace body, dual power supply)
and 1 sets of 1ton medium frequency induction electric furnace (double furnace body, double
power supply), according to the high temperature, we get the high quality iron liquid;
 According to the ingredients, the iron will be conveyed to the weighing by the microcomputer
iron distribution scale and then been put into the feeding container and moved to the furnace
by electric flat car in front.
 Use crane to lift the feeding container in front of the furnace and then pour the materials to
the medium frequency induction furnace. Turn on the electric furnace to melt;
 The iron liquid comes from the medium frequency induction furnace will be transport to
pouring area in the casting ladle by crane. Crane Bridge mounted with electronic hook weigh
which can accurately weigh the quantity of the iron liquid casting ladle.
 In quick analysis lab, using the vacuum direct reading spectrometer to control and adjust the
chemical composition of the liquid iron rapidly, to ensure the quality of molten iron;
 Configure the crushing mill, casting ladle, baking facilities,
 The melting process flow diagram:
 Pig iron Steel Chip block Return scrap
scra
p

Electric magnetic suction disc

Feeding device

Alloy
Electric flat car

Crane Platform balance

Medium frequency furnace

Hot metal ladle

Bridge crane pouring

3.5. Cleaning process

 Cleaning is the last procedure in casting process. For massive production factories, most of
the processing machineries are special equipment which has higher requirement for casting
parts dimension, cavity cleanliness and surface roughness. Therefore, it must be equipped
with highly efficient cleaning equipment to compose the cleaning line to finish the pouring
cup cleaning, surface cleaning, final finishing, anti-rust treatment processes, etc. Lost foam

casting parts has no sand core. Compare to traditional casting, it has no process of burr so
that grinding workload reduced correspondingly.
 Shakeout sand after casting will be transported to municipal castings stacking area in
barrels with a forklift.
 In the ground casting stacking area, use hydraulic casting machine to removal pouring cup.
 Use continuous sling shot blasting cleaning machine to clean it up.
 In the manual cleaning bench with portable grinders and other tools to clean up the
remaining part of riser and local sand part.
 Second time for cleaning.
 All casting part needs anti-rust treatment. After the treatment, the casting parts shall be
hung on the suspension chain.
 The cleaning process flow chart

Castingparts Sling shot Grinding Anti-rust treatment

after cooling blasting machine

Second time cleaning Casting parts warehouse

4. Calculation summary of casting technology and equipment capacity

 Production capability: output of the gearbox house 5000T annually, weight 72kg, then the
annual output is 5000 x 1000 / 72=69445 piece;
 Annual work time 2400 hours; hours production 69445/2032=34 piece, included 5%
waste, then 35.7 pieces / hour;
 Casting production per hour: 5000 t / 254 days/ 8 hours =2.46t, as 5% of scrap and 10%
pouring cup, required hot metal amount 246 * 1.15=2.83t each hour; One set of 2T
medium frequency induction furnace and one set of 1ton of intermediate frequency
induction furnace can meet production needs. Use 2 sets of electric furnaces is intended
to produce different other parts at same time;
 According to the size of the casting part, sand box size is 1400 * 1100 * 900mm, each box
placed 4 pieces of castings, It produce 40 pieces every hour which can meet the
requirements of the production capability.
 Sand quantity per hour: 1.4 x 1.1 x 0.9 x 10 (box) =13.86 m³. According to a pearl sand
vibration compaction density: ρ=2.0tons / m³. Sand needs to be treated are 27.72 (tons)
every hour. Sand handling system will be 30t/h processing capacity;
 Cooling sand processing capacity: 30 tons/hour, sand temperature after treatment is
≤50℃;
  The sand supporting closed cooling tower, cooling water circulation: 100m³/h
 According to the number of sand box and casting weight, negative pressure system
suction quantity: 35m³/min;
 Foam beads consumption: annual production of 5000000kg castings parts, each kilogram
of foam beads can produce s 300kg casting parts, total of bead amount of a years is : 5
000000÷300 ＝ 16667 （ kg ） ， amount of beads every hours is: 16667÷2032÷0.8 ＝
10.2（kg）
 Pre-expander: 25kg/h electric steam pre-expanding machine (EPS) can meet the
requirements of production;
 Molding machine: 1000mm * 1200mm selection and 1200mm * 1500mm molding
machine, each mold can produce one model. Productivity ~15 piece/h. Annual modulus
is 69445 x 1.05 x 2=145835 piece, take 15% waste into account, the actual annual model
pieces is: 145835 x 1.15=167710 piece. Number of molding machine is
167710÷2302÷15=5.5 sets. Say, 6 sets.

5. Integrated technical parameters and index of the 5000 Ton/Annual lost

foam casting production line
 Production capability: more than 5000T/ years
(Meet the production capability requirements);
 Sand processing capacity: ≥20T/;
 The dust content: ≤0.2%
 Sand recovery rate: ≥95%
 Sand temperature: ≤50℃
 Noise: ≤85dB（A）
 Dust emission index: ≤50mg/m3
 6. Main equipment for lost foam casting

No. Equipment Image example

2T Medium frequency furnace

The capacity is 2T, two fire
doors, one for standby

Composition: a high voltage

switch cabinet, a 1500KVA
rectifier transformer, a
1250AKW intermediate
frequency power supply
cabinet, two 2.0 tons of
aluminum shell furnace body,
two 531 gear box, a tilt furnace
operation, water dispenser
1 etc., intermediate frequency
power supply with cooling
water exchanger, furnace body
with water pool and the open
type cooling tower cooling
method

Electric pre-foaming
machine(EPS)
Model：ROYF-I
Capacity: 25~30kg/h，
using power 5KW
simultaneously in actual
operation

2
No. Equipment Image example

Bottom type automatic

turnover box machine
Model：ROFX-Ⅲ（01）
with hydraulic station,
hydraulic oil and hydraulic
cylinder
3

Hydraulic molding machine

Model：ROCX-Ⅱ
1000×1200mm、
1200×1500mm
PLC touch screen control

4
No. Equipment Image example

Horizontal cooling machine

Model：ROWL-Ⅱ（01）
Capacity:30t/h;
Power: 15KW;
water cooling and air
cooling, FM operating
5

Sand temperature regulator

ROST-Ⅰ(01)
Capacity ≥20T/H；
Cooling area 640 ㎡；
Circulating water 30T/H；
Water pressure0.2～0.4Mpa；
water cooling and temperature
regulation, capilary water way
cooling

Sandbox
ROSX-Ⅲ Size：
1400x1100X900

7
No. Equipment Image example

Airbag vibrating table

Model：ROZS-Ⅲ（01）
Size：1900X1300X925
Operation weight：5T;
Power: 5KW,
Exciting force：50000N
airbag,clamping,promotion
8 and demotion,FM
automatic alarm for
breakdown

Chain bucket type elevator

Model：ROLT-Ⅰ-9.5
Capacity：≥30t/h
Hopper running speed：
1.4m/s; Power: 5.5KW
Hopper width：250mm

Negative pressure assembling

unit
Model：ROFY-35A
Maximum pumping capacity：
35m³/min;
Power:55KW；
Includes two vacuum pumps ,
a gas water separator, a surge
10
tank, a wet dust collector, a
water tank, pipeline etc.
2BE253 pump head
No. Equipment Image example

Bag type dust remover

Model：ROCC-96-6
Filter area：250m²；
Sand treatment air
volume：41472m3/h
with 1m³ air storage tank

11

Shot blasting machine and

dust removal
Maximum size of the pendant:
Ф800×1400MM
Shot diameter: 1-2mm ,
Load weight:: about700kg
Power：40Kw
Air volume： 8300m3/h
Consists of a hook, two shot
12 blasting machine, a separator ,
a screw conveyor and a lifting
machine

Casting spray paint line

Catenary suspension type,
through continuous, the whole
line includes: suspension
conveyor, blowing room,
water screen spray room,
13 electric drying room.
Total power: 57.5kw

20 / 36
 7. Configuration table for equipment

Configuration table for equipment

Power(u Power-k
No. Name Model Specification Quantity
nit)KW W Brief introduction

Ⅰ Complete sets of equipment, production lines

Equipment of white area

electric pre-foaming ROYF-Ⅰ using power 5KW simultaneously

1 25-30kg/h 1 9.2 9.2
machine(EPS) in actual operation

2 material storage hopper ROSH-Ⅰ 3m³ 1 0 0 match with electric pre-foaming

machine

3 ROCX-Ⅱ 1000X1200 4 3 12 PLC touch screen control

hydraulic molding machine

4 ROCX-Ⅱ 1200X1500 2 4 8 PLC touch screen control

hydraulic molding machine

5 material feeding system ROSL-Ⅰ 1 3 3

ROJB-Ⅰ
6 coating blender (01) 100kg/(barrel) 1 1.5 1.5
with control box

ROQG-Ⅰ with high density plate; without glass

7 1200X1200 1 0.1 0.1
model cutting machine （01） plate

Sub-total 33.8

The auxiliary equipment of white area

steam boiler (by customer) 2T/h,0.6MPa 1 Burn oil

steam storage surge tank(by 3.0m³，

1 0.7MPa 1
customer)

steam pipe

2.4m³/min，
air compressor(screw) 1 15 15
0.7MPa
air compression & storage 3m³，0.7MPa
2 1 0 0
surge tank

air compression pipe

50m³/h，32m 1 7.5 7.5 centrifugal water pump
water supply pump

3 cooling pipe

water supply tank without 3.0m³，

0.5MPa 1 0 0
tower
 Configuration table for equipment
Power(u Power-k
No. Name Model Specification Quantity
nit)KW W Brief introduction

open type cooling tower 50m³/h 1

4 electric power system air switch, electric cable and so on

Sub-total 22.5

The auxiliary equipment of yellow area

1 11
drying room and steam pipe

white model cutting and

2 1
bond tool bag

3 1 0 Bottom wheel can move

coating brushing groove

the upper table surface is high density

4 2400X1200 1 0
model assembling platform plate; customer can make it.

The universal wheel can be adjusted

5 72 0
drying shelf and disassembly.

ROJR-Ⅰ electric heating; one fan blows for

6 drying heater (01) 11 9 99
single layer

temperature and humidity

7 11 0.1 1.1 with fan
automatic control system

Sub-total 100.1

The equipments and facilitiesof black area and sand processing equipment

bottom type automatic ROFX-Ⅲ with hydraulic station, hydraulic oil

1 1 11 11
turnover box machine （01） and hydraulic cylinder

ROCZ-Ⅰ Sand box

2 dust removal cover 1
about 1400

water cooling & sand ROLS-Ⅱ 2500X2274X model sand collection and
3 1 0 0
shakeout machine 1000 transportation; water cooling

pneumatic sand shakeout ROWK-

4 2 0.02 0.04
device Ⅰ（02） large horizontal cooler

sieving,transportation, removing
ROSF-Ⅲ 4000X1300X dust, wind cooling（10 mesh sieving
5 screening conveyor 1 5.15 5.15
1200 plate）
 Configuration table for equipment
Power(u Power-k
No. Name Model Specification Quantity
nit)KW W Brief introduction

6 slag lifting machine ROTZ-Ⅰ 1 0.5 0.5 slags and iron beans are lifted out of
ground
ROLT-Ⅰ 1100X460X7
7 chain bucket type elevator -7.5 1 5.5 5.5
500 automatic alarm for breakdown

RORS-Ⅱ 1350X720X7
8 powder screening assembly 1 0 0 screen sand and soot particle
20

ROWL-Ⅱ 8200X2000X water cooling and air cooling, FM

9 horizontal cooling machine 1 15 15
（01） 2250 operating

ROLT-Ⅰ 1100X460X9
10 chain bucket type elevator -9.5 1 5.5 5.5
500 automatic alarm for breakdown

ROST-Ⅰ water cooling and temperature

2000X2000X
11 sand temperature regulator (01) 1 0 0 regulation, capilary water way
6000
cooling

ROLT-Ⅰ 1100X460X9
12 chain bucket type elevator -9.0 1 5.5 5.5
000 automatic alarm for breakdown

ROPD-Ⅰ Central
belt widthB=650, three-roller V type
13 belt conveyor distance 1 5.5 5.5
（03） conveying material by belt
L=21500

ROPD-Ⅰ Central
belt widthB=650, three-roller V type
14 belt conveyor distance 1 4 4
（01） conveying material by belt
L=8700

15 plough type unloader ROXL-Ⅰ 2 0.1 0.2

distribute material to each bucket

sand storage hopper for ROSD-Ⅰ 3500X2500X

16 3 0 0
modeling 5000 single bucket

material level detecting ROLW-Ⅰ

17 6 0.05 0.3
device material level control

shower type sand adding ROYJ-Ⅰ

18 3 0.01 0.03
machine

ROSX-Ⅲ 1400X1100X
19 47 0 0
sandbox 900 with walking wheel

ROZS-Ⅲ 1900X1300X airbag,clamping,promotion and

20 airbag vibrating table 2 5 10
（01） 925 demotion,FM

airbag vibrating table ROZS-Ⅲ 1900X1300X airbag,clamping,promotion and

B 1 1.8 1.8
（bottom sand） 925 demotion

ROFY-35
22 negative pressure 35m3/min 2 55 110 2BE253 pump head
A
assembling unit
 Configuration table for equipment
Power(u Power-k
No. Name Model Specification Quantity
nit)KW W Brief introduction

negative pressure automatic ROFY-Ⅲ

23 10 0.06 0.6
butt-joint device with control box

ROCC-96
24 bag type dust remover 41472m3/h 1 55 55 match 1m³ air storage tank
-6

25 sandbox operation vehicle ROYZ-Ⅰ 3 2.2 6.6

sandbox hydraulic pushing ROYT-Ⅰ match with 11KW hydraulic station,

26 5 0 0
device （01） friction coefficient 0.18

27 hydraulic station ROYY-Ⅰ 1 11 11

with hydraulic oil

fixed position clamping RODW-

28 14 0.01 0.14
device Ⅰ(01) for railway

turnover box machine ROAK-Ⅰ

29 1 0 0 PLC touch screen control
control cabinet

ROZK-Ⅰ 600X400X20
30 1 0 0
vibrating table control 0 bottom sand
cabinet
ROZK-Ⅱ 600X400X20
2 0 0 FM
0
negative pressure ROFK-Ⅰ
32 assembling units control (01) 1
since lotus-root reduction voltage start
cabinet

automatic butt-joint control ROJK-Ⅰ

33 2 0 0
cabinet butt-joint

sand processing control ROLK-Ⅰ

34 (03) 1 0 0
cabinet PLC Touching screen

5000 tons production line ROXK-Ⅰ

35 operation main control (02) 1 0 0 PLC touch screen
cabinet

pouring position absorb

36 10
dust cover

37 1 15 15
water-bath dust remover

38 tail gas treatment device 1

39 Sub-total 268.36

The axiliary parts and facilities of black area

 Configuration table for equipment
Power(u Power-k
No. Name Model Specification Quantity
nit)KW W Brief introduction

main dust removal pipe; branch

1 dust removal pipe
pipe

ROFT-Ⅰ
-2 diameter φ200 2 0.1

Air volume adjustment ROFT-Ⅰ

2 -3 diameter φ200 6 0.1
valve
ROFT-Ⅰ
-4 diameter φ200 2 0.1

sand storage bucket ladder, elevator

ladder ladder, pit ladder, dust removal
machine ladder
sand storage bucket guardrail,
elevator guardrail, pit(hole under
guardrail groud)guardrail, dust removal
guardrail

sand shakeout device cover plate,

vibrating table cover plate, pit (line
cover
groove ) cover plate,negative pressure
3 plate
steel structure automatic butt-joint cover plate

screening conveyor chute, elevator

chute chute

maintenan sand storage hopper platform; dust

ce removal machine platform; elevator
platform platform

surroudin
g sand shakeout surrounding blocking
blocking

It connects negative pressure unit and

4 negative pressure automatic butt-joint
negative pressure pipe
steel pipe, flange, elbow and so on.

100m³/h 1 5.7 5.7

cooling tower closed type cooling

5 centrifuga 100m³/h，32m 1 15 15
cooling water pump l pump

cooling water pipes all kinds of pipe and valve

3.2m³/min，
air compressor 0.7MPa 1 18.5 18.5
screw type

6 1m³ 1
air storage tank

air pipe all kinds of pipe and valve

 Configuration table for equipment
Power(u Power-k
No. Name Model Specification Quantity
nit)KW W Brief introduction

24# sandbox walking rail; operation

8
steel rail 300m vehicle rail

9 electric system air switch, electric cable

Sub-total 39.2

Cleaning and machining workshop

shot blasting machine and

1 2 40 80
dust removal double hook

2 2 5
cutting grinding machine

3 3T 1 0
forklift

4 1piece 57.5
spray paint line

Sub-total 142.5

Melting workshop

1 1T 1 800 800 two furnace mouth,one for spare,one

medium frequency furnace
for us

2 2T 1 1200 1200 two furnace mouth,one for spare,one

medium frequency furnace
for use

3 100m³/h 2 5.7 11.4 Used for electric furnace and cooling

cooling tower
for cabinet

4 1T 2
cast iron ladle adjustable

5 1
spectrum analyzer five elements
6 Round cleaning roller Q118 1 7.5 7.5
7 crushing mill C258A 1 7.5 7.5
Gn=6t,S=143
8 Electric flat car KPD-6-1
5mm
1 2.8 2.8

9 Baking device 1
Sub-total 2029.2

Lifting transportation equipment

Gn=5t,S=22.5
The electromagnetic, hook
.5m,H=10m, 1 37 37
bridge crane level A6
Gn=3t,S=22.5
Electric single girder crane 2 7.9 15.8
.5m,H=10m,
 Configuration table for equipment
Power(u Power-k
No. Name Model Specification Quantity
nit)KW W Brief introduction
level A6

Gn=3t,S=19.5
Electric single girder crane ,H=10m, level 2 7.9 15.8
A6
Sub-total 68.6

Total 2704.26 (Kw)

8. Proposed cooperation model for project implement

Proposed project implementation cooperation model

№. Content Remarks
1 Design (plant, civil engineering, plant area)
Complete sets of equipment, production line
2
supply
Full set of equipment, production line installation
3
and commissioning
TEAMS
4 Trial production and technical training
Engineering
(Beijing) 5 Complete sets of tooling
Co., Ltd. Technology products, smelting,
foaming, coating;
6 Technical transfer
Ethiopia raw material substitution
and certification scheme
The production of sand, iron scrap, except raw
7
materials (by 0.5 years)
 TEAMS Engineering

9. Project implementation schedule

Schedule 1 - Suggested total duration is round about 20 months (Based on civil works undertaked by METEC)
Y7 Y8
标识号 任务名称 M69 M70 M71 M72 M73 M74 M75 M76 M77 M78 M79 M80 M81 M82 M83 M84 M85 M86 M87 M88 M89 M90 M91 M92 M93 M94 M95
1 1 - Suggested total duration is round about 20 months (Base on civil works undertaked by METEC)Schedule 1 - Suggested total duration is round about 20 months (Base on civil works undertaked by METEC)
Schedule
Sign contract & become effective
2 Sign contract & become effective

3 Design Design

4 Engineering design
Engineering design
5 Non-standard production line & equipment Non-standard production line & equipment

6 Tooling and mold

Tooling and mold
7

8 Purchase for standard equipment Purchase for standard equipment

9 No.1 Patch
No.1 Patch
10 No.2 Patch No.2 Patch

11 No.1 Patch No.1 Patch

12

13 Manufacture Manufacture

14 Non-standard equipment Non-standard equipment

15 Tooling & mold

Tooling & mold
16

17 Purchase for utilities system equipment & materials Purchase for utilities system equipment & materials

18

19 Shiping Shiping

20 No.1 Patch No.1 Patch

21 No.2 Patch No.2 Patch

22 No.1 Patch No.1 Patch

23

（ By METEC ）
24
Plant area & civil works Plant area & civil works （ By METEC ）
25 Plant Engineering Plant Engineering

26 Civil Works
Civil Works
27

28 Site jobs of United Engineering (Beijing) Site jobs of United Engineering (Beijing)

29 Utilities system installation and commissioning

Utilities system installation and commissioning
30 Equipment installation and commissioning Equipment installation and commissioning

31 Technical and operational training

Technical and operational training
32 Trial production Trial production

33 Project Final Acceptance Project Final Acceptance

28 / 36
 TEAMS Engineering

10. Quotation sheet

Project quotation summary：
No. Item Price(USD) Remarks

1 Complete sets of equipment, production line 1,784,331.48

Complete sets of equipment, production line
2 installation and commissioning, trial 554,597.29
production and technical training
3 Molds, tools and instruments 85,322.66

4 Technology transfer 127,983.99

A year of consumption,
5 Production of raw and auxiliary materials 274,052.13
partially supply

Total 2,826,287.55

Breakdown price list:

Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

Ⅰ Complete sets of equipment, production lines

Equipment of white area

electric pre-foaming ROYF-Ⅰ 25-30kg/h 1

1 16,381.95
machine(EPS)

2 material storage hopper ROSH-Ⅰ 3m³ 1 1,215.85

3 hydraulic molding machine ROCX-Ⅱ 1000X1200 4 47,268.75

4 hydraulic molding machine ROCX-Ⅱ 1200X1500 2 29,393.66

5 material feeding system ROSL-Ⅰ 1 4,692.75

6 coating blender ROJB-Ⅰ(01) 100kg/(barrel) 1 853.23

7 model cutting machine ROQG-Ⅰ（01） 1200X1200 1 1,450.49

Subtotal 101,256.68

29 / 36
 Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

The auxiliary equipment of white area

steam boiler 2T/h,0.6MPa 1

1 steam storage surge tank 3.0m³，0.7MPa 1

steam pipe

2.4m³/min， 1
air compressor(screw)
0.7MPa

air compression & storage surge 3m³，0.7MPa 1

2
tank

air compression pipe 85,322.66

water supply pump 50m³/h，32m 1

cooling pipe

3
water supply tank without tower 3.0m³，0.5MPa 1

open type cooling tower 50m³/h 1

air switch, electric

4 electric power system
cable and so on

Sub-total 85,322.66

The auxiliary equipment of yellow area

1 11 53,966.58
drying room and steam pipe

white model cutting and bond 1

2 490.61
tool bag

3 coating brushing groove 1 234.64

4 model assembling platform 2400X1200 1 234.64

5 drying shelf 72 15,358.08

6 drying heater ROJR-Ⅰ(01) 11 5,396.66

 Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

temperature and humidity 11

7 5,396.66
automatic control system

Sub-total 81,077.87

The equipments and facilitiesof black area and sand processing equipment

bottom type automatic turnover ROFX-Ⅲ（01）

1 1 31,334.75
box machine

ROCZ-Ⅰ Sand box 1

2 dust removal cover 4,692.75
about1400

water cooling & sand shakeout ROLS-Ⅱ 2500X2274X100 1

3 7,465.73
machine 0

4 pneumatic sand shakeout device ROWK-Ⅰ（02） 2 3,839.52

5 screening conveyor ROSF-Ⅲ 4000X1300X1200 1 11,091.95

6 ROTZ-Ⅰ 1 1,215.85
slag lifting machine

7 chain bucket type elevator ROLT-Ⅰ-7.5 1100X460X7500 1 9,150.86

8 powder screening assembly RORS-Ⅱ 1350X720X720 1 1,919.76

9 horizontal cooling machine ROWL-Ⅱ（01） 8200X2000X2250 1 32,550.59

10 chain bucket type elevator ROLT-Ⅰ-9.5 1100X460X9500 1 9,598.80

11 sand temperature regulator ROST-Ⅰ(01) 2000X2000X6000 1 45,796.94

12 chain bucket type elevator ROLT-Ⅰ-9.0 1100X460X9000 1 9,492.15

ROPD-Ⅰ（03） Central distance 1

13 belt conveyor 10,665.33
L=21500

ROPD-Ⅰ（01） Central distance 1

14 belt conveyor 7,465.73
L=8700

15 plough type unloader ROXL-Ⅰ 2 2,431.70

sand storage hopper for ROSD-Ⅰ

16 3500X2500X5000 3 25,340.83
modeling

17 material level detecting device ROLW-Ⅰ 6 5,119.36

31 / 36
 Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

shower type sand adding ROYJ-Ⅰ

18 3 10,878.64
machine

19 sandbox ROSX-Ⅲ 1400X1100X900 47 140,355.77

20 airbag vibrating table ROZS-Ⅲ（01） 1900X1300X925 2 31,356.08

airbag vibrating table（bottom ROZS-ⅢB

21 1900X1300X925 1 14,952.80
sand）

negative pressure assembling ROFY-35A

22 35m3/min 2 38,565.84
unit

negative pressure automatic ROFY-Ⅲ 10

23 9,598.80
butt-joint device

24 bag type dust remover ROCC-96-6 41472m3/h 1 31,996.00

25 sandbox operation vehicle ROYZ-Ⅰ 3 14,462.19

sandbox hydraulic pushing ROYT-Ⅰ（01）

26 5 9,598.80
device

27 hydraulic station ROYY-Ⅰ 1 7,679.04

28 fixed position clamping device RODW-Ⅰ(01) 14 11,945.17

turnover box machine control ROAK-Ⅰ

29 1 2,410.37
cabinet

30 ROZK-Ⅰ 600X400X200 1 1,557.14

vibrating table control cabinet
31 ROZK-Ⅱ 600X400X200 2 4,095.49
negative pressure assembling ROFK-Ⅰ(01)
32 1 2,047.74
units control cabinet

automatic butt-joint control ROJK-Ⅰ

33 2 5,801.94
cabinet

34 sand processing control cabinet ROLK-Ⅰ(03) 1 11,305.25

5000 tons production line ROXK-Ⅰ(02)

35 1 11,731.87
operation main control cabinet

pouring position absorb

36 10 8,532.27
dust cover
 Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

37 water-bath dust remover 1 14,504.85

38 tail gas treatment device 1 57,166.18

39 Sub-total 659,714.83

The axiliary parts and facilities of black area

1 dust removal pipe 10,665.33

ROFT-Ⅰ-2 diameter φ200 2

2 Air volume adjustment valve ROFT-Ⅰ-3 diameter φ200 6 4,202.14

ROFT-Ⅰ-4 diameter φ200 2

ladder
guardrail
cover plate
chute
3 steel structure 13,864.93
maintenance
platform

surrouding
blocking

4 negative pressure pipe 1,279.84

cooling tower 100m³/h 1 31,996.00

5 cooling water pump centrifugal pump 100m³/h，32m 1 1,130.53

cooling water pipes 2,133.07

3.2m³/min， 1
air compressor screw type 8,425.61
0.7MPa

6 air storage tank 1m³ 1 1,706.45

air pipe 1,813.11

7 steel rail 24# 300m 746.57

8 electric system 7,679.04

Sub-total 85,642.62
 Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

Cleaning and machining workshop

shot blasting machine and dust 2

1 49,060.53
removal

2 cutting grinding machine 2 1,279.84

3 forklift 3T 1 10,665.33
4 spray paint line 1piece 119,451.72
Sub-total 180,457.42

Melting workshop

1 medium frequency furnace 1T 1 106,653.32

2 medium frequency furnace 2T 1 149,314.65

3 cooling tower 100m³/h 2 63,991.99

4 cast iron ladle 1T 2 4,266.13

5 spectrum analyzer 1 46,927.46

6 Round cleaning roller Q118 1 17,064.53

7 crushing mill C258A 1 12,798.40
8 Electric flat car KPD-6-1 Gn=6t,S=1435mm 1 20,264.13
9 Baking device 1 3,199.60
Sub-total 424,480.21

Lifting transportation equipment

Gn=5t,S=22.5.5
electromagnetic, hook bridge 1
1 m,H=10m,level 74,657.33
crane
A6
Gn=3t,S=22.5.5
2 Electric single girder crane m,H=10m,level 2 49,060.53
A6
Gn=3t,S=19.5,H
3 Electric single girder crane 2 42,661.33
=10m,level A6
Sub-total 166,379.19

Total 1,784,331.48
" Complete sets of equipment, production line installation and commissioning, trial production and technical
training
 Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

All equipment installation and

commissioning fee: (large
1 554,597.29
machines and local
accommodation is not included)
Ⅲ Molds, tools and instruments

6 sets of lost foam casting die

1 85,322.66
and other tools
Ⅳ Technology transfer

Mainly includes process

technology, mould and tooling
drawings, melting process
technology, beads foam
1 technology, coating technology, 127,983.99
workshop tooling drawings,
which also include seeking
work for substitute material in
Ethiopia
Ⅴ Production of raw and auxiliary materials (according to the production of the first year after the casting
plant, the listed materials such as, sand, iron bulk materials shall buy locally, consider the validity of the material,
partial delivery is suggested

1 EPS raw material 25KG/bag 18T 49,913.76

2 coating RO-HT 25KG/bag 156T 96,499.93

3 tooling for assemble pattern 5,375.33

4 plastic film 1,279.84

5 special glue 25KG/bag 48 bags 10,238.72

6 glue gun 72 pcs 1,842.97

7 Lost foam repair cream 5kg/bucket 60 buckets 2,175.73

8 furnace material grey iron 25KG/bag 24T 9,214.85

9 furnace ladle material grey iron 26KG/bag 12T 14,078.24

10 rare earths 1# ton/ladle 12T 17,149.85

11 slag conclection agent 18T 7,679.04

12 slag cotton 16piece/box 384 boxes 9,010.07

 Quotation for 5000t/a lost foam casting plant
Total price
No. Name Model Specification Quantity
(USD)

thermodetector(one)+temperatur
13 15,358.08
e measuring probe(600)

14 pouring cup 3000 30,716.16

15 Steel shot 3T 3,519.56

Sub-total 274,052.13
General Total 2,826,287.55