Integrated “1+2”Molten Aluminum Supply System for Two 9,200T Die Casting Cells

Project Overview

Denova developed an integrated “1+2”molten aluminum supply system for Doli Technology’s large-scale integrated die casting production at its Changzhou manufacturing base.

The system was specifically designed to support two 9,200T ultra-large die casting cells and consists of:

● 1 x DMFS 6000-12000 Melting Furnace

● 2 x DDI 6100 Dosing Furnaces

By integrating melting, holding, molten aluminum treatment, transfer, and precision dosing, the system provides a stable and continuous molten aluminum supply for large-scale die casting production.

Key Project Data

• 2 x 9,200Tultra-large die casting cells
• 6 t/hmelting capacity
• 12 tmelting furnace holding capacity
• 2 x 6 tdosing furnace holding capacity
• 1+2integrated system configuration

Engineering Requirements

Large-scale integrated die casting requires continuous and highly coordinated molten aluminum supply.

For this project, the system needed to support two ultra-large die casting cells simultaneously while maintaining stable molten aluminum quality, temperature, and supply continuity.

The customer also required a high level of automation to reduce manual handling and enable efficient coordination between the melting and dosing processes.

Our Solution

Denova developed a “1+2”system configuration, combining one tower melting furnace with two dosing furnaces positioned on both sides of the die casting cells.

The DMFS 6000-12000 melting furnace integrates melting, holding, molten aluminum treatment, and transfer functions, with a melting capacity of 6 tons per hour and a holding capacity of up to 12 tons.

Two DDI 6100 dosing furnaces, each with a 6-ton holding capacity, provide stable and precise molten aluminum supply to the two 9,200T die casting cells.

An automatic rotary launder system connects the melting furnace with the two dosing furnaces. Based on production demand, the system automatically directs treated molten aluminum to the required die casting unit.

When a dosing furnace detects insufficient molten aluminum, the control system automatically sends a signal to the transfer pump, enabling molten aluminum to be delivered through the launder system without manual intervention.

This coordinated automation enables the complete molten aluminum supply process to operate with significantly reduced manual handling and supports highly efficient die casting island operation.

Project Value

By integrating melting, treatment, transfer, holding, and dosing into one coordinated system, the solution provides a reliable molten aluminum supply platform for two ultra-large die casting cells.

The project demonstrates Denova’s capabilities in Mega Casting applications, intelligent molten aluminum management, automated transfer, and integrated thermal system engineering, supporting more efficient and highly automated large-scale aluminum die casting production.

Related products