Products – Shakespeare Foundry Egypt

List of Possible Clients and Industries

Oil and Gas Industry
Construction
Medical Industry
Automotive
Power Industry
Chemical Plants
Aviation and Aerospace
Industrial Plants
Cement Manufacturers
Nuclear Power
Agriculture
Military

Pipes Manufacturing

Stainless Steel and Carbon Steel Seamless Pipes advantages in the market/ Pipe Specs.
AOD Process for low carbon steel pipes

Stainless Steel and Low Carbon Steel Seamless Pipes advantages

Seamless steel pipes are pipes with round hollow cross sections that do not have seams. They are generally factory-made using hot working steel. One of the advantages of the pipes is its growing preference. Seamless steel pipes can sustain high pressure. Generally, in welded pipes, the points of welds are the weakest for sustaining pressure, in turn damaging the pressure resistance capability of the pipe, welded pipes also cause corrosion from the breaking down of the metal during the welding process. In contrast, seamless pipes are tougher and more pressure resistant.
Seamless steel pipes make it easy to calculate pressure ratings, as there is no need to be concerned about the quality of welding. These pipes are also thinner and lighter than welded pipes, thus making it more cost efficient. Growth in pharmaceutical and chemical & fertilizers industries are increasing their demand for seamless steel pipes. Seamless steel pipes have high resistance to corrosive substances that are transported through it. Fluctuations in the price of crude oil is a restraining factor for the growth of the market.
Carbon steel pipe is highly resistant to shock and vibration making it ideal to transport water and other fluids under roadways. The high-tensile strength in addition to its elasticity and ductility allow carbon steel pipes to be used safely under high-pressure conditions. Under abnormal loads, they will bend, not break.
Low-carbon steel is characterized by a low ratio of carbon to iron. By definition, low-carbon consists of less than 0.30% of
carbon. Also known as mild steel, it costs less to produce than both medium-carbon and high-carbon steel. In addition to its
low cost, low-carbon steel is more pliable, which may improve its effectiveness for certain applications while lowering its
effectiveness for other applications. The most popular industry for this type of pipe is the medical industry as the possible
contamination to anything flowing through the pipes is unacceptable.

Pipe Specifications

Seamless Stainless and Carbon Steel pipes
Diameter of 4-8 inches depending on application
Schedule 20-160 (thickness)

Argon Oxygen Decarburization Process (AOD)

The key feature in the AOD vessel is that oxygen for decarburization is mixed with argon or nitrogen inert gases and injected through submerged tuyeres. This argon dilution minimizes unwanted oxidation of precious elements contained in specialty steels, such as chromium.
AOD is widely used for the production of stainless steels and specialty alloys such as silicon steels, tool steels, nickel -base alloys and cobalt -base alloys. The process is so popular because it combines higher metallic yields with lower material costs. Other benefits include pinpoint accuracy in chemistry control down to 0.01% carbon and lower, rapid desulfurization to less than 0.001%, and lead removal to less than 0.001%. When the end result is a cleaner metal coupled with increased productivity.

Services of Shakespeare Foundry

Manufacturing Capabilities.
Design & Development.

Manufacturing Capabilities. Products for the Cement Industry

By owing more than 2000 pattern of different designs for different products. Shakespeare Foundry Egypt has the
capability to supply the most demanding designs of the following products:

Manufacturing Capabilities: A . Cooler plates patterns and designs

• Grate cooler plates.
• Satellite cooler tube liners and lifters.
• Shakespeare Supertherm cooler plates.
• Grate hard faced cooler plates.

Manufacturing Capabilities: B. Dip Tube patterns and designs

Cyclone Segmented Dip Tubes:

Shakespeare dip tube design.
Others Diptube Designs.

- Manufacturing Capabilities : B. Dip Tube patterns and designs

Manufacturing Capabilities : C. Kiln plates patterns and designs

Nose Ring Segments.
Inlet, outlet and closing part sectors .
Discharge chute.
End Segment for kiln trough.
Tongue plate.
Z plates.

Manufacturing Capabilities : C. Kiln plates

2- Design & Development.

Shakespeare operate Solid Works Computer Aided Design (CAD) software
to simulate and analyze the stresses.
Firstly, we take client 3D product design models and evaluate them for “
design for manufacturing. As part of the technical
support service we offer, we work with the clients to refine and improve
their products to ultimately either reduce manufacturing costs
and/or improve strength and fit for purpose in the products intended
application.
Once our engineers are satisfied that the product can be efficiently cast as per the clients requirements, we then
import the 3D CAD file and to create 3D CAD models of the casting pattern(s). The 3D CAD models of the
pattern(s) are then processed through Computer Aided Manufacturing (CAM) software
to create off-line programs with optimized machine tool cycle times. The machine tool program is then fed to
the CNC robotic, to then commence pattern manufacturing.

- Design & Development : A. Simulation and Analysis:

Identifying customer needs:

Step1: Evaluating problem

Step2: Rule out-process

Step3: Synthesizing the data

Step4: Performing a complete simulation for the process.

Step5: Afford a detailed report for the problem and solution
criteria.

Design & Development : A. Simulation and Analysis:

A. Inner Pipe Simulation:

Analyzing extremely high temperature effect.
Analyzing extremely high Sulphur and
chlorine concentration.
Analyzing different materials and chemical
interactions.
Estimating total life time for the inner pipe.
Estimating wear behavior due to high
temperature air loaded with clinkers and
emissions concentration.