Supplier of alloyed steel castings for the cement and mining industry, incl. centrifugally cast pipes
Körfez Döküm San. ve Tic. A.Ş.
KORFEZ main plant, Dilovası/Kocaeli (TR) · KORFEZ Centrifuge, Dilovası/Kocaeli (TR) · KORFEZ Engineering, Neubeckum (DE)New on Amplifa
About Körfez Döküm
Körfez Döküm (Korfez Foundry) is a Turkish family business founded in 1988, based in Dilovası/Kocaeli, supplying alloyed steel castings for the cement and mining industry. The focus is on heat-resistant as well as wear- and impact-resistant steel castings, manufactured to customer drawings and specifications. The portfolio includes bimetallic castings, composite casting with ceramic inserts and, through the sister company KORFEZ Centrifuge, centrifugally cast pipes in stainless steel and ductile steel for boilers, industrial furnaces and chemical/petrochemical plants. Production encompasses molding, melting lines, heat treatment, machining, surface treatment and assembly with unit weights from 0.5 to 8,000 kg and a capacity of 800 tons per month. With more than 44,000 models in the archive and an export share of 90 percent to more than 80 countries, the company supplies plant manufacturers and operators worldwide; in Neubeckum (Germany) the group also operates KORFEZ Engineering for engineering and system components.
- Site
- Dilovası / Kocaeli, Turkey
- Processes
- Alloyed steel castings (heat resistant, wear and impact resistant), Bimetallic Part Casting (bimetallic hammers for crushers), Composite Casting (composite hammers and vertical mill internals with ceramic inserts), Centrifugal Casting (centrifugal pipes, stainless pipes), Machining, Surface treatment, Assembly, Heat treatment
- Materials
- Plain Carbon steels, Low, medium and high alloy steels, High Chromium/High Nickel heat resistant steels, High Chromium abrasive resistant steels, Ni-Hard type abrasive resistant steels, High Manganese impact resistant steel, High alloy cast iron grades, Bi-Metallic Castings
- Certificates
- ISO 9001:2015, ISO 9001:2015 (TÜV-Nord)
- Founded
- 1988
- Industries
- Cement industry, Mining, Boiler and furnace construction (centrifugally cast pipes), Chemical/petrochemical industry, Waste incineration/incinerator, Plant engineering (coolers, preheaters, kilns, mills, crushers)
- 01
Engineering based on customer drawings and specifications
- 02
Melting and chemical analysis of the melt
- 03
Casting (sand casting, bimetallic and composite casting; centrifugal casting at
- 04
Heat treatment
- 05
Machining
- 06
Surface treatment
- 07
Assembly
- 08
Quality inspection and delivery
- 09
Engineering, plant upgrades and spare parts supply
Materials and Processes
Unalloyed plain carbon steels (Plain Carbon Steels)
Base material for general cast components manufactured to customer drawings.
Low-, medium- and high-alloy steels
Alloyed steel casting grades with a focus on heat, wear and impact resistance for cement and mining.
High-chromium/high-nickel heat-resistant steels
For components in the pyro process such as kilns, coolers and preheaters.
High-chromium wear-resistant steels and Ni-Hard
Abrasion-resistant materials for crusher and mill components.
High-manganese impact-resistant steel
For impact-loaded components such as impact and hammer crushers.
High-alloy cast iron grades
For wear- and heat-loaded castings to customer specification.
Bimetallic castings
Bimetallic hammers with a tough shaft material and a hard, wear-resistant working zone, metallurgically bonded.
Composite casting with ceramic inserts
Composite hammers and vertical mill internals with ceramic inserts in the wear zone on a ductile base material.
Centrifugal casting
Seamless centrifugally cast pipes in stainless steel and ductile steel in desired dimensions and analysis at KORFEZ Centrifuge.
Sites
KORFEZ main plant Dilovası/Kocaeli
TRMain plant: molding, melting lines, heat treatment, machining, administration
- Part weight / size
- 0.5–8,000 kg unit weight
- Lot size
- 800 t/month casting capacity
- Materials
- Unalloyed and alloyed steels, high-alloy cast irons, bimetallic and composite casting
- Molding shop (molding lines)
- Melting lines
- Heat treatment facilities
- Machining machinery
- Spectrometer
KORFEZ Centrifuge Dilovası/Kocaeli
TRCentrifugal casting plant of the sister company for stainless steel and ductile steel pipes (own plant since 2010)
- Materials
- Stainless steel, ductile steels
- Centrifugal casting plant (Centrifugal Casting Factory)
KORFEZ Engineering Neubeckum
DETechnical sales and consulting site; engineering and manufacturing of system components (mill liners,
- Materials
- High-alloy wear- and heat-resistant steel castings
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Alloyed steel castings (heat resistant, wear and impact resistant)Guss | – | – | 0.5 kg – 8,000 kgs | 800 tons monthly | Plain Carbon steels, Low, medium and high alloy steels, High Chromium/High Nickel heat resistant steels, High Chromium and Ni-Hard type abrasive resistant steels, High Manganese impact resistant steel, High alloy cast iron grades |
| Bimetallic Part Casting (bimetallic hammers for crushers)Guss | – | – | – | – | Tough material in shaft, Hard wear resistant material in working area |
| Composite Casting (composite hammers and vertical mill internals with ceramic inserts)Guss | – | – | – | – | Ceramic inserts, Ductile base material |
| Centrifugal Casting (centrifugal pipes, stainless pipes)Guss | – | – | – | – | Stainless steels, Ductile steels |
| MachiningZerspanung | – | – | – | – | Steel castings |
| Surface treatmentOberfläche | – | – | – | – | Steel castings |
| AssemblyMontage | – | – | – | – | – |
| Heat treatmentWärmebehandlung | – | – | – | – | Steel castings |
| Quality control: Chemical Analysis (spectrometer), Dimensional Control, Mechanical Tests (Hardness,Prüfung | – | – | – | – | – |
| Engineering and Supervising / Process Control and Optimization / Equipment Upgrades / Spare PartsEngineering | – | – | – | – | – |
| Ball mill system components design and manufacturing (mill shell linings, mill diaphragms)Engineering | – | – | – | – | High-alloy wear- and heat-resistant steel castings |
6 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Molding lines | – | – | – | – | Dilovası, Kocaeli, Turkey |
| Melting lines | – | – | – | – | Dilovası, Kocaeli, Turkey |
| Heat treatment lines | – | – | – | – | Dilovası, Kocaeli, Turkey |
| Machinery (Machining Factory) | – | – | – | – | Dilovası, Kocaeli, Turkey |
| Spectrometer | – | – | – | – | Dilovası, Kocaeli, Turkey |
| Centrifugal Casting Factory | – | – | – | 2010 | Dilovası, Turkey (3000 m2 facility) |
Additional services
Quality
Quality assurance begins with incoming material inspection and accompanies the entire production process: every melt is checked with the spectrometer, supplemented by dimensional control, mechanical tests (hardness, tensile, bending, impact), microstructure analysis as well as non-destructive testing (ultrasonic, magnetic particle, radiographic, penetrant testing) by certified personnel to EN standards. The quality system is certified to ISO 9001:2015 by TÜV-Nord.
| Evidence | KORFEZ main plant Dilovası/Kocaeli | KORFEZ Centrifuge Dilovası/Kocaeli | KORFEZ Engineering Neubeckum |
|---|---|---|---|
| ISO 9001:2015 (TÜV-Nord) |
History
- 1988
Founding of Korfez Foundry in Turkey.
- 1996
Relocation to the current site in Dilovası (same region).
- 2004
Founding of the sister company KORFEZ Centrifuge for centrifugally cast pipes; knowledge transfer with a German strategic partner.
- 2010
Relocation of KORFEZ Centrifuge to a new 3,000 m² plant.
- 2011
KORFEZ Engineering focused on engineering and manufacturing of system components (mill shell liners, mill diaphragms for ball mills).
- 2023
Trade fair participation at GIFA 2023 / NEWCAST 2023 (booth 14/F23).