Furnace Technology Argon Purging
Furnace Technology Argon Purging
Furnace Technology Argon Purging
induction furnace
with liquid metal.
Capable of delivering small volumes of purging gas in a
controllable manner.
Compatibility with the Capital Refractories range of lining
Grant Cullen from Capital Refractories materials in the sintered state.
Ltd explains how the company has its Able to operate for the life of the induction furnace lining.
Ease of installation and operation.
gas diffuser technology for the induction
Cost effective.
furnace products in use throughout the Safe.
world following its initial trials just over
two years ago. From this programme a range of gas diffusers was
developed for use with a range of induction furnaces from
at a given temperature, is to using the hypothesis that all the porosity of the infiltration depth between
measure deformation and castable is located in the matrix, and that 100% of the two cycles will reduce the
flow temperature using hot the porosity is infiltrated by slag. Refractoriness thickness of the slag infiltrated
microscopy. is estimated reading liquidus temperature of this layer spalling at each cycle
Ranking of slag capability composition and phases present at 1600C in a due to the different thermal
to infiltrate castable (ranking ternary phase diagram, especially the amount of expansion coefficient of the
of viscosity) can also be fine- solid phase remaining. infiltrated area.
tuned taking into account Ranking of castables will thus be done This can be achieved by
potential slag modifications considering the highest percentage of solid phase selecting a castable with a
during infiltration of remaining and the highest solidus temperature. low Re and also by a castable
refractory (modification due containing additives that will
to temperature decrease Chemical compatibility of the system strongly increase the viscosity
against infiltration depth or (slag matrix) of the penetrating slag
chemical composition changes The first rough ranking of the compatibility
after dissolution in the first
due to refractory component permitted from the refractoriness evaluation can
millimeters of slag penetration.
dissolution). be fine-tuned by taking into consideration rules of
In the case of an acidic slag,
Testing modified slags (for further slag oxides (as Fe or Mn oxides) or alkali,
these additives can be SiO2
or special addition in castables (MgO from A.M
example those containing and Cr2O3, but not MgO from
spinel, Cr203 for example).
increased amount of manganese Al2O3.MgO spinel, which would
This fine-tuning can be achieved using
oxides or SiO2, MgO, Cr2O3 decrease penetrating slag
basics information from binary phase diagrams
etc gives an initial first idea viscosity, and thus increase
as eutectic temperature (when existing) and
about slag viscosity changes penetration speed.
saturation composition of a given refractory
that can results from process
compound (MgO, Cr2O3 etc) into the considered
modification. Examples of these Cupolas under the
slag component. The highest compatibility will
include increase of manganese spotlight
be considered for systems having the highest
oxides level in slag due to In the paper Cupola melting
eutectic temperature and the lowest saturation
changes of quality melted or and coke consumption Dr M
concentration.
from dissolution of refractory Lemperle from Kttner GmbH &
compound (SiO2, MgO or Cr2O3
Acidity and basicity of slags and castables Co. KG, Germany, said that the
from castable additives) during
Another easy way to rank castables against given coke consumption of cupolas
slag penetration.
slag, or to fine-tune first ranking established from has been a frequently discussed
previous methods involves calculating the acidity issue, higher coke rates
Characteristics and or basicity index using the relationship (2) (basicity resulting in both a lower melt
parameters on system index) applied to slag and to refractory matrix. rate and higher costs.
castable plus slag B = ([CaO]+[MgO]+[FeO]+[MnO])/([SiO2]+[TiO2]+[P2O5])
In the past, research work
has focused on the properties
Simplified formula : B = ([CaO]+[MgO])/[SiO2]
As previously mentioned, of the different coke grades
(2)
gap to saturation Cs-C is an employed, today every operator
The ranking of castables would thus be carried
important parameter describing agreeing that coarse foundry
out by considering the closest indexes and
the system (refractory: slag) coke combined with low
avoiding as much as possible using the most basic
and governing the speed of reactivity shows best results.
castables for high acidic slags and reverse.
dissolution. Nevertheless Unfortunately, such an ideal
this parameter is difficult coke is not always available, at
to access without powerful Conclusions least not reasonably priced.
thermodynamical calculation This forced foundrymen to
tools, and anyway only Applying these simples comparison methods, and employ cheaper alternative
describes the behavior for example the simplest one from the last point, fuels instead of foundry coke,
of individual refractory can help avoid wrong and devastating selection as blast furnace coke, anthracite,
components and not the global Al2O3.MgO spinel-containing products (basic) for form coke and even natural
refractory behavior. Thus application involving high acidic slags. gas having been employed to
several more easily accessible If associated with a minimum knowledge of replace part of the expensive
characteristics of the systems degradation mechanisms in furnace and foundry foundry coke. All these
(refractory:slag) are listed practice, these simples methods can allow the fine- alternative fuels, however,
below, that can be considered tuning of a castable selection or help find the route could not really offer smooth
as providing a global picture to refractory performances improvement. operation or economy.
of the chemical compatibility For example, a focus on castable infiltration In many cases it was reported
of the systems, and thus a first resistance, especially infiltration speed, will be the that the lower price of the
way of ranking castables. solution for solving the problem of high wear due alternative fuel was used up
to lining spalling resulting from rapid infiltration by a higher consumption.
Refractoriness of the associated with thermal cycling. Furthermore, there are many
system (slag-matrix) In such a case, thermal cycling resulting from other influences on the coke
The composition of this the process cannot be improved as a foundry rate, which are not always
system can be approximated process parameter. But reducing the slag understood and considered.
Mobile charging devices are used for feeding effected by means of a crane magnet or an
attached charging container incorporating a bottom
melting furnaces, especially induction units for dump flap.
iron as well as for rotary-type furnaces used in Noise level considerations
secondary aluminium melting plants. An increasingly important aspect is the noise
level reduction during charging and operation
A unit designed for an aluminium rotary furnace A charging machine suitable for an induction furnace
installation
M
The chute is highly stressed due to anual oil fired crucible furnaces are available as lift
the highly dynamic bending moments outs up to 235kg of copper; bale-outs up to 600kg of
resulting from the extensive thermal aluminium and 500kg of copper; central axis tilters up to
load as well as un-calculable loads 300kg of copper and hydraulic tilting lip pour furnaces to
arising from collisions caused by the 600kg aluminium or 1500kg of copper.
rotation of the furnace with non- The general description and sizes of these can be found in
smelted aluminium compressed bales. pdf form at www.morganmms.com under library, furnaces,
The endurance strength in the chute data sheets.
area can be significantly influenced They are capable of melting a wide range of metals and
by the design engineer who has to alloys from zinc, aluminium, copper based alloys, through to
maximise the structural strength iron.
without increasing the weight. The Morgan manual oil burner system has the advantage
Furthermore, the application of high- of simplicity, tolerance to a wide range of fuel oils, and can
quality, heat-resistant material offers a raise temperatures high enough to melt iron to 1450C. The
favourable effect. only supply requirements are gravity supply of oil in the
As the materials do not melt as viscosity range of 25-40 seconds Redwood 1, with a head of
quickly as demanded, the travelling three metres and an electrical supply sufficient to operate the
gear of the machine is temporary combustion air fan motor, typically 3kW. Heavy fuel oils can
used to feed the furnace by powerful also be used in conjunction with fuel line heating to reduce
backwards and forwards movements their viscosity to the operating range.
with additional aluminium bales. The The simple, robust controls are all manually adjusted to
installation of an all-wheel driven give fast melting or holding and they require little or no
travelling gear has been well proven in maintenance, other than routine cleaning.
this mode of operation.
The consideration of an exhaust For further detailed information contact:
cover to reduce the dust and smoke Morganite Molten Metal Systems. Tel: +44 (0) 1905 728200.
emissions is more complicated
than that for a crucible furnace.
Nevertheless, it is possible to install Furnace Technology in India
an efficient multi-gap exhaust device
in the front section of the bin. The latest advances in melting technology will be covered at the
The electrical control is executed, 68th World Foundry Congress to be held in Chennai, India in
depending on customer needs, using February 2008.
the conventional relay technique There will be a wide ranging mix of technical debate, backed-
or the PLC. The execution of power up with visits to some of the leading lights of the metal casting
supply must be paid particular industry in India.
attention as it can be provided using a Technical papers covering the latest furnace design and
spring-loaded cable reel, a trail cable developments will give delegates a comprehensive overview
or an energy chain. The spring-loaded of the on-going improvements in the supply of quality melting
cable reel is often chosen due to its technology.
stability. The 68th World Foundry Congress will be held at the Chennai
Jst GmbH; Trade Centre, Chennai, India from 7-10 February 2008.
Tel: (+49) 2590 98208 202; The full programme of technical papers, works visits, social and
Fax: (+49) 2590 98101; partners programme is now available at www.wfcindia08.com or
email: [email protected] from the Institute of Indian Foundrymen.
www.joest.com email: [email protected]