Horizontal Ladle Repair Machines

monocon monocator mobile

Monocon design, manufacture, install and commission a range of mobile and stationary, standardised and customised machines for vertical and horizontal ladle repair.

The “Monocator-Mobile“ has been designed using existing known “Monocon Technology” to provide an effective system for the maintenance and repair of horizontal steel making ladles. The ladles are repaired in a horizontal orientation and the system has been designed to reduce conventional refractory repair regimes by maintaining all areas of the ladle with a little and often and targeted approach to ladle lining refractory management. Please see our Monocator-Mobile literature for full information.

The “Monocator-Mobile” offers radio controlled ladle lining repair to all areas in the ladle and is capable of hot lining maintenance. It considerably increase the life of the base Refractories and consists of the following components; “Monocator-Mobile” machine, Material Feed System, Control system, Water System and Radio Control Joystick.

Design Features

Monocon horizontal ladle repair machines 1

Monocator-Mobile Design Features

Radio controlled joystick application of gunning material to the slagline, sidewalls of the ladle as well as the ladle bottom and specific areas of interest such as the well blocks, Impact Pad areas.
Lightweight, user friendly joystick.
Consistent material application.
Extremely maneuverable due to the use of hydraulically powered “tracks”.
Integral Material Feed System.
Integral Bulk Hopper - 3 Tonnes.
Bulk Hopper outlet has butterfly valve.
Storage Chamber.
Material feed Gun.

Operational Benefits

$Monocon refractory hopper 1$ Monocator-Mobile Operational Benefits

All hydraulics are mounted on a single compact base frame
Accurate and easy positioning of the machine for aligning to the ladle.
Increased Productivity
Reduced Ladle turnaround time.
Reduced refractory costs.
Reduced refractory maintenance downtime.
Increased Ladle lining campaign lives.
Increased Ladle availability.
Refractory application exactly where needed - NO WASTE
Programmed maintenance - large selection of pre-programmed patches can be selected and sprayed automatically.
All areas can be maintained.
Constant monitoring of the system status i.e. maintenance, fault diagnosis.
Monocon technical and service back-up.

Monocon EAF monocator control panel

Safety Benefits

Monocator-Mobile Safety Benefits

Monocon EAF remote control

The radio controller functionality ensures that the operator is positioned remotely from the application / heat source and moving machinery.
Emergency Shut-off
No crane required during maintenance

Monocon provide a multitude of safety interlock facilities to enable safe use of the equipment. These interlocks are incorporated into the PLC operation. Safety systems are to be determined with customer but will typically include; Monocator Movement, Ladle Geometry, Emergency Stops and Low Pressure. The Monocator-Mobile can be arranged to perform agreed movements in response to specific Ladle repair events.

Technical Features

Monocator-Mobile Technical Features

The “Monocator - Mobile “has the following axes of movement;

Left and Right Track
Slew: 180⁰
Raise/Lower: 1100mm to 3000mm
Tilt: (+15⁰ - Horizontal - 15⁰)
Beam Telescope: 6 metres
Rotate: Continuous 360⁰
Nozzle: 180⁰

All axes listed are powered from an on board hydraulic power pack driven by a diesel engine. The unit comprises of;

10kw Diesel Engine and Piston Pump
Bell Housing and Flexible Drive Coupling
Hydraulic Reservoir and Filtration System
Tank Accessories

The machine is a fabricated mild steel construction with access covers where necessary.

The Electrical Control System will typically consist of the following:

PLC Panel - typical supply; 220/110V single phase
Control Console - typical supply; 220/110V single phase
Inverter Panel - typical supply; 415V, 3 Phase, 50 Hz
Wireless Radio Controlled Joystick
PLC based Electrical control panel: Standard is Mitsubishi PLC. (Other options are available)

Integral Material Feed System: 2.0 cubic metres Bulk Hopper, with 6 Barg Pressure Vessel and material Delivery of 5.0 cubic metres/hour (max)
Integral Weigh System: Display quantity of dry material, Optional Load Cells on Feed System. Digital Display on Control Panel
Integral Water system: 200 Litres capacity, Multi-stage pump with control valve, digital flow meter and temperature control.

Onsite Services Required

Electrical: - 415V, 3 PH, 63A
Pneumatic:-90 PSI (6 bar), 8m3/min Maximum, 50mm Bore Supply
Water: - City Water Supply
Diesel fuel for Vehicle Diesel engine
All services are to be provided in close proximity to the material feed system

Supply Options

Moncator-Mobile Supply Options

The Monocator-Mobile can be configured and/or customised to suit the clients requirements.
All surfaces can be painted in accordance with the customer specification

Dual Material Feed Systems - The machine can be supplied with two feed systems (either Pressure vessel or Rotary Gun) which will allow easy change of the spray material for different areas of the ladle as required.

Alternate PLC Panel options are available such as an Allen Bradley unit with Ethernet/IP protocol or Siemens PLC with Profinet.
UPS - mains power spike/failure protection

$Monocon refractory hopper system$ Pneumatically operated Hopper lid to prevent the ingress of foreign bodies.
Load Cells on the Hopper System

Extended Machine Warranty option subject to having a Monocon Annual machine Maintenance Contract in place.

Please contact our UK technical team for further information.