European Funds drive industry
We have obtained funding from the European Union under the European Funds for Małopolska 2021–2027 programme for the implementation of the project entitled:
“New technology for the production of modular ladles for lead refining with step-change increased service life, together with an innovative method of sealing and leak-tightness control.”
Project number: | FEMP.01.01-IP.01-1681/24 |
| Programme: | |
| Priority: | European Funds for Research, Development and Entrepreneurship |
| Measure: | Enterprise Research and Development Projects |
Project Objective:
Development and implementation of new solutions in the design and construction of lead ladles
Development and implementation of a new method for leak-tightness control
Development and implementation of a sealing technology to achieve a synergy effect
Increasing the service life of the ladles by at least 50%
A natural assumption is also that the manufacturing and refurbishment costs should not be higher, but rather significantly lower.
The project is based on three levels of innovation:
Research issues to be addressed:
Stage 1 In Progress
Industrial research on an innovative two-module casting design for lead ladles, as well as on sealing and leak-tightness control technology.
- Development of the concept for dividing the modular ladle casting
- Development of the modular casting design and performance of the necessary thermal load simulations, as well as static and fatigue analyses
- Development of an effective method for ladle sealing and leak-tightness control
Stage 2 Industrial Research on the Development of a New Ladle Manufacturing Technology Based on the Adopted Design and Material Assumptions
- Development of mould and moulding sand technology dedicated to two-module castings
- Development of metal and charge technology
- Development of pouring technology
- Development of knockout, cleaning and finishing technology
- Design and manufacture of 3S moulding box models
- Design and construction of a ladle sealing and leak-tightness testing station
- Production of test castings and acquisition of used castings
Stage 3 Experimental Development Work – Verification of Industrial Research Results Obtained in Tasks 1–2. Validation of the technology under real operating conditions and production of test castings.
- Manufacture of prototype castings
- Performance of sealing and leak-tightness testing procedures on prototype castings at the inspection station
- Application of a sealing coating to acquired castings after the first phase of operation and leak-tightness inspection at the testing station
Stage 4 Pre-Implementation Work – Preparatory Activities for Implementing the Results of Industrial Research and Experimental Development into Krakodlew S.A.’s Own Business Operations.
- Development of implementation guidelines
- Quality control of products ready for implementation
- Commercialization activities and market analysis related to introducing the project’s innovative results to the market
- Filing of a patent application and activities related to industrial property protection
Project Effects / Results
The project will result in both product and process innovations on a global scale:
Modular casting design (product innovation)
Casting leak-tightness testing method using 3D image analysis and machine learning (process innovation)
Pressure-based ladle sealing method (process innovation)
Target Groups
The innovativeness of the new products will attract companies requiring durable, high-temperature-resistant castings with extended service life during operation. The offer is particularly targeted at metallurgical plants that use ladles for lead smelting from ores and recycling. Global analyses indicate a continuous increase in demand for cast iron production, as well as a steadily growing role of foundry technology as a method for manufacturing metal products.
The implementation of the new product developed within the project will contribute to the overall development of the Polish economy, its modernization, and improved competitiveness in the international market.
We have extensive experience in carrying out targeted research projects successfully implemented into our own operations. We continuously develop our technology, generating measurable economic and functional benefits.
The project is co-financed by the European Union under the European Funds for Małopolska programme.
Project value: 12 990 881,94 PLN
Funding amount: 8 313 089,32 PLN
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