ALUMINIUM CHINA 2016

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Congratulations to the successful ALUMINIUM CHINA EXHIBITION, which held in Jul 12th – 14th in shanghai.aluminiumchina 2016

ALUMINIUM CHINA is a quite important promotion event which ZHENGJIANG INSERTEC FOUNDRY takes part every year,  and certanly it is also a big and wide-influenced exhibition of the non-ferrous industry.aluminium china 2016

During the three days, everyone plays and indispensablee role.

There is no doubt that the success of the exhibition can not take away from the efforts made by whole team!! hope that brings more huge benefits for ZHENJIANG INSERTEC FOUNDRY SUPPLIES- ZIFS.

FENAF 2015

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FENAF 2015 is a Conference and exhibition for the foundry industry. It is a bianual  fair. The seventh time that INSERTEC exhibited at this fair (since 2003); but is our  first time like INSERTEC REFRACTORY DO Brazil LTDA.FENAF 2015

The market situation is of general uncertainty. All are waiting for a recovery, but few companies dare to make new investments. There is not a clear tendency in  2015, even though we are forecast to close some projects before year’s end.

ITACOLUMITAS

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Itacolumitas are special sandstones which reach this unexpected flexibility due to special interlocking of its grains, coming from its geological growth. Name comes from the Brazilian country of Itacolumia, Minas Gerais, where it was firstly identified.  This strange elastic behavior developed by nature, has been focused by scientists of different areas due to, for example, potential application of itacolumite inspired microstructures, to develop flexible concretes capable to resist, in terms of its own flexibility, vibration coming from earthquakes.

UNITECR 2015

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Two members of INSERTEC R&D Team will attend the most important worldwide Congres on refractories,  UNITECR  (TEchnical Conference on Refractories).Event board is composed by main refractories associations, GRA (Germany), TARJ (japón), ACERS (US & Canadá), ALAFAR (Latin-América), and recently CCS  from (China), PRE  from (UE) and IRMA from (India).

Its celebration every two years takes place in America, Europa and Asia, alternatively. After last congress in Victoria, Canada in 2013, Vienna has been selected as place for current event.

Auckland-20130912-00991

From 15th to 18th of September.

ECERS 2015

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The 14th international conference organized by the European Ceramic Society, ECERS 2015, ECERS 2015, took place in Toledo (Spain), last week.

The even was divided in eight different topics covering all the specialties involving traditional and technical ceramics.  In spite of the weight of refractory business inside ceramic industry, refractory topic was attended for many people.ecers roberto

INSERTEC , was invited to present a “Keynote” so our R&D Manager, Roberto Caballero, presented a review about refractory solutions for aluminium confinement, very welcome by the audience. Regarding the whole event, more than 800 scientists, technicians and professionals met in Toledo.

NEW MATERIALS FOR TOP CAP

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Pagina_Pricipal_Refractarios_ACERODuring the process of  furnaces loading, the linning in the crown area supports strong blows;  in manual or mechanical loading.

This problem is the cause of the development of this new range of products; whose main characteristics is the high mechanical resistance. Also presented during the fusion process, an excellent performance to the thermal shock, avoiding cracks in this upper part of the furnace.

Product range is a follows:

Casting Steel & Aluminium:

– TOP-TAG

– TOP-AL

For the CAP furnaces melting Iron:

– TOP-COR

WHAT IS PLASMA?

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ESTADOSEquipo Plasma 3D Without going any further, the Sun is, in itself, a gigantic plasma, full of atoms of Hydrogen and Helium that have lost totally or partially their electrons as a result of the extremely High temperaturas generated inside (they estimate that the temperatura of the Sun is approximately 6000ºC in surface and some 15 million degrees centrigados in  its interior.

However,To get a Plasma, it is not necessary to apply such high temperatures,  in fact with a candle and a match we have enough; the orange-coloured Corona that we sometimes  see in the flame of the candle is the result of dissociation and ionization of the air molecules and plasma in low density and temperatura.

Finally, If we look arround, it is posible to find more tan one element formed of plasma. Also we can find plasma generated naturally as lightning in a storm, or the sun, man has created artificial plasma with different purposes: in  medicine, industrial aplications such welding, plasma cutting…etc. Even, most of us have at home fluorescent lamps or televisions based on plasma thechnology.

One of plasma application that interest us, consists of casting units heating based on the technology of high power HPTP, thermal plasma consits in taking advantage of the heat of a plasma arc,  and it is  a consequence of the ionization of plasmagen gas between a graphite (the cathode) electrode and the metal, which is electrically connected to another electrode (called anode).  The electric current flows throught the gas ionizing it, being abble to reach temperaturas up of 10.000ºC in the core of arc.

The generation of plasma is obtained by generating potencial difference between the two electrodes, so that it produces a reaction chain that ionize the plasmagen gas giving rise to plasma arc.

http://www.iltplasma.com/es/

 

NEXT EVENTS

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Firstly please allow us to express gratitude of the continued support from your side. We have the honor to inform you that INSERTEC is going to take part in the exhibitions as listed below:

  • METAL + METALLURGY CHINA2015 – NECC (Shangai) Mar. 31 – Apr.3 (Hall: 1 International zone – Stand:1M40)
  • ALUMINIUM CHINA 2015 – Shangai New Intl´l Expo Centre Jul.8 – 10 (Hall: N1 – Stand: 1L30)

exhibition invitation

METAL CHINA

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ZHENJIANG INSERTEC took part in the main metallurgy exhibition organized in P.R. china- METAL CHINA 2015, from 31st March to 3rd of April.

Different factors has affected that the exhibition was poor from the point of view of visitors/contacts, specially from overseas:

– Move location from Beijing to Shangai.metal china 2015

– New Venue still under construction.

– Year of GIFA.

ZIFS conclusion has been – good enough to be thinking on the Chinese ferrous Market; then we will take part again in Beijing 2016

EVOLUTION OF GLOBAL ECONOMY

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According to IMF, the growth forecast for the world´s economy was 3.3% in 2014.

The global growth projection for 2015 is 3,8%. Chinese President Xi Jinping said China´s will maintain strong. China´s groos domestic product growth rate is expected over 7 percent in 2015.

According to Oxford, the US economy to do well in 2015 with about 3% growth driven in part, by manufacturing momentum and rising employment, some of which is reaching decade highs.

Europe, The oxford Economics predicts growth of a little over 1% in 2015. Oxford Economics sees India as the strongest of the BRIC countries in 2015. Good growth numbers of 5.6% are expected, driven by the election of a pro-business government.

 

STEEL PRODUCTION IN 2014

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The world Steel Association forecasts that global apparent steel use increased by 3.1% to 1527 Mt in 2014 following growth of 3.6% in 2013. In 2015, it is forecast that world steel demand will grow further by 3.3%and will reach 1576 Mt.

If we analyze the table detailed below;  we see that Asia is the leading producer of steel, only China has a production of 822,7 tons while in 2014 has had a slight descents(de 49,7% in 2013 and during 2014 it was a 49,5% ).

The European Union is the second zone in the classification  where Germany is the leading producer. In 2014 has a production was 169 M.Ton. This represents an increase of 1.7%; increases in production in Germany and France and falls in Spain and Italy.

In short, the global steel demand recovery continues but growth is stabilising at a lower rate with continued volatility and uncertainly leading to a challenging environment for steel companies.

Production fell in the CIS, in Ukraine only  fell  17%.

In India, steel demand was expected to grow by 3.3% to 76.2Mt in 2014, following 3.8% growth in 2013. Despite uncertainties relating to the impact of upcoming elections steel demand is projected to grow by 4.5% in 2015.

In North America, crude steel production increased 2%, however in South America shrank 1.4%, since the sharp decline in Brazil, Venezuela and Chile were offset with increases in Argentina, Colombia and Peru.

In Central and South America, apparent steel use was projected to grow by 3.4% to 50.9Mt in 2014 down from 4.3% in 2013.This is forecast to slow further to 2.7% in 2015 due to contraction in Argentina and a sharp slowdown in Chile.

Crude steel production – December 2014
The figures below are in thousand tonnes.
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total
European Union (28) 14.603 13.871 15.449 14.288 14.973 14.376 13.840 12.129 14.223 14.714 14.210 12.457 169.243
Other Europe 3.075 2.908 3.072 2.834 3.208 3.117 2.995 3.100 3.087 2.909 2.978 2.910 36.194
CIS (6) 8.817 8.295 9.203 9.014 9.681 9.217 9.247 8.601 8.078 8.253 8.261 8.422 105.089
North America 10.136 9.494 10.356 9.812 10.229 10.067 10.463 10.618 10.119 10.243 9.740 9.977 121.247
Africa 1.328 1.287 1.280 1.342 1.229 1.419 1.273 1.397 985 1.286 1.353 1.399 15.579
Middle East 2.047 2.185 2.345 2.461 2.490 2.339 2.247 2.250 2.335 2.490 2.476 2.393 28.059
Asia 93.004 84.104 95.434 92.726 95.153 93.202 92.337 92.830 91.397 91.904 87.264 92.095 1.110.860
Oceania 416 469 489 413 437 455 514 419 503 514 390 470 5.488
Total 65 countries 137.061 126.035 141.586 136.680 141.206 137.823 136.831 135.209 134.559 136.401 130.337 133.712 1.636.960
estimated
This dates are of  65 countries, they for approximately 98% of total world crude steel production in 2013.
Annual total figures include revisions not shown on a monthly basis.

SELF-FLOWING REFRACTORIES

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CUCHARASSelf-flowing refractory castables have been used in refractory market for more than 20 years. Their capability to reach maximum density without vibration have covered some appliications in which classic consolidation techniques has not easy implementation. Extension of self-flow as general castable configuration have been limited by necessary extra addition of finer raw materials which makes self-flow matrixes more reactive than vibrate equivalents.

Recently, RSI have developed a new concept of self-flowing castables with same matrix structure of vibrate materials. Their pure self-compacting behavior links maximum PRESS3performance with the most friendly installation. This new family has been named BERELOC and covers form standard high alumina compositions like BERELOC-82 especially developed for CIF coil protection ,BERELOC 60 Z; excellent resistance to chemical attacl by acid slag, for Pressurized Pouring Furnaces and transport ladles in Iron foundries.

METAL MADRID 2014

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7th Edition of METALMADRID., It was 29th and 30th of  October.Foto Standmetal madrid (2 de 2)

300 companies were present with the 220 stand, occupied more than 8000 m2.

52% more participation than  in the last edition.

Mention the celebration of 3 technical conferences: COMPOSITE, MOLD & TRATER.Conferencia TraterDay (1 de 2)

Our colleague Jorge Almeida participated in trater, about heat treatment.

ALUMINIUM CHINA

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ZENJIANG Insertec, took part one year more in ALUMINIUM CHINA Exhibition in Shanghai from 9th to 11th of July.aluminium-china-2014 ALUMINIUM CHINA

During those three days, some of the main Chinese customers visited the booth as well as other important international companies.

Due to the success with the received, Zhenjiang INSERTEC has already booked the space for the new edition in 2015.

71st. WORLD FOUNDRY CONGRESS

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WFO President Vinod Kapur spoke of the “systematic sea-change” in the industry and said: “Now is the time to respond in terms of the search for new products and process taking into account sustainnability and the moral obligation to be envirommentally conscious”.1240396_426462884131815_1873240478_n20140519_125546

Held every two years, the  WFC provides essential knowledge and gives participants the opportunity to share experience and network.

We were participating in what has undoubtedly been the most important event for the world´s foundry in our country.

28 BIEMH.- International Machine-Tool Exhibition

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28th edition of the biennial of machine tool, it has become one of the most important fairs in the sector in Europe. Professionals from 57 countries have been able to check the quality of machines, accesories, components and industrial equipment in the halls.biehm2014

INSERTEC, as the last years, has presented our  latest products  in the heat treatment sector.

The balance has been positive with numerous visits, Customers and potential customers, recovering the good feeelings of the past.

INSERTEC, LORAMENDI and TECNALIA create a new company to boost the foundry sector

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ILT Plasma Technologies will improve foundry quality, energy performance and productivity of the facilities through an innovative heating system

Basauri, 2 April 2014. In Europe, the iron foundry sector has an annual turnover above wfo10,000 million Euros per annum, according to the data of the World Foundry Organization. In this context, ILT Plasma Technologies SL was created; a new technology-based company seeking to improve foundry quality, energy performance and productivity of the facilities through a high-power thermal plasma heating system. This new company is formed by INSERTEC and LORAMENDI, two industrial partners with a large experience in the sector, and the TECNALIA Applied Research Centre.

The technology developed by TECNALIA, which has been called PLASMAPOUR®, is a casting unit heating system based on High Power Thermal Plasma technology (HPTP). After 15 years of research, it is one of the main innovations in the iron foundry sector worldwide.

The advantages of such technology are the following: it allows to work in casting temperatures that would be impossible using conventional equipment; improved energy performance, both in the casting unit as in the rest of the facility; improved productivity of the facilities, due to an increase in line availability, reduction of rejections and a better panel performance; and improved foundry metallurgical grade.

The activity of ILT Plasma Technologies will focus on the manufacturing, adaptation, commercialisation and implementation of plasma facilities in the foundry sector, with an estimated global potential market of 1,600 million Euros. The new company will be located in Basauri (Bizkaia) and foresees an annual turnover of 2.4 million Euros from the fourth year since its creation. You may reach ILT Plasma Technologies on: www.iltplasma.com and info@iltplasma.com.

The creation of this new technology-based company, at a time of economic difficulty, proves that the Basque industry is active and committed to the future and the creation of economic activity, showing its commitment to collaboration, innovation and technology.

BEAZ, a Public Company belonging to the Economic Development Department of the Bizkaia Provincial Council, participated in its start-up, seeking to contribute to the growth of the economic activity and the creation of jobs.

About LORAMENDI

The company was founded in 1973 in Vitoria and became a part of the Mondragon Group. It is a global benchmark in foundry equipment, supplying comprehensive solutions in the field of the manufacturing and assembly of sand cores and vertical moulding lines. Its main markets are Germany, China, USA, Mexico and India and has sales offices and post-sale services in these markets.

Its main clients are first-line globalised suppliers from the block and cylinder heads of the car industry, brake discs and safety systems manufactured in iron and aluminium. The average turnover stands at approximately 60 million Euros, of which 90% are exports. It has a staff of 160 people in Vitoria and 60 in its subsidiaries, who have a clear mission of contributing to the technological development of its clients and provide an excellent post-sale service on a global level.

 www.loramendi.com

About INSERTEC

The company was founded in Bilbao in 1980, and is devoted to the supply of Industrial Furnaces and Refractory Products. INSERTEC designs and manufactures solutions in the field of materials engineering and science for metal processing (mainly iron, steel and aluminium): from melting to casting and final thermal treatment.

 In the ’90s it began its internationalisation process, which resulted in a significant network of subsidiaries (Mexico, Italy, Brazil and China), agents and distributors. The sales from this activity have reached 75% of total sales.

www.insertec.biz

About TECNALIA

TECNALIA Research & Innovation is the first Private Applied Research Centre in Spain and one of the most important centres in Europe; with 1,400 experts, from over 30 different nationalities, focusing on transforming knowledge into GDP to improve people’s quality of life, by creating business opportunities for companies.

Inspiring Business is a synthesis of two concepts that go hand in hand: imagining and making it come true. TECNALIA’s differential value.

In order to value TECNALIA’S own R&D and favour a comprehensive management of the life-cycle of the innovative technological assets so as to maximise their impact on society and obtain a greater return for commercialisation, TECNALIA VENTURES, S.L., a 100% TECNALIA company with a relevant role in the acceleration of the incubation process of ILT Plasma Technologies, was established in 2013.

www.tecnalia.com

 

WFO CONGRESS BILBAO

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INSERTEC will participate as Bronze sponsor in World Foundry Congress, which takes place at Bilbao (19 – 21 of May), we will be proud of your participation!!.

http://www.71stwfc.com

Sponsor_bronce1240396_426462884131815_1873240478_n

The Tabira Foundry Institute, the World Foundry Organization and IK4-Azterlan would like to invite you to participate in the 71st World Foundry Congress that will take place in Bilbao (Spain), from May 19th-21st 2014.

For many years, the foundry industry has played a determining role in the economic and social development of civilizations. Contemporary demands and requirements from current society drive and inspire experts in the search for new technological advances. The different activities gathered within the Congress and the International Foundry Exhibition will represent an extraordinary opportunity to exchange technical knowledge and to build personal and professional relationships with the common goal of a prosperous and sustainable future. This international event will take place in the city of Bilbao. A living metropolis, where the different historical, industrial and economical trends are reflected in its magnificent architectural styles. Always open to visitors and ready to share its extensive cultural offerings, well recognized gastronomy and sincere hospitality.

We look forward to seeing you in Bilbao in 2014.

Yours sincerely,

The Organizing Committee of the 71st World Foundry Congress

BROWN FUSED ALUMINA

Chinese government is pushing all industrial sectors to decrease drastically pollution levels. Actions, from dust filters and on-line controls to activity shut-down, have been stressing all industrial sectors, including refractory industrial mineral producers.

From EU refractory industry point of view, there are two minerals strongly affected due to the European dependency in Chinese import. Those minerals, classified as ‘non critical’ but achieving criticism in terms of risk of supply, are bauxite and magnesite.oxido-de-aluminio-marron-alumina-bulto-por-25-kilos

In a first step, refractory magnesites, like DBM and FM, as well as refractory grade bauxite and BFA are directly affected by Chinese lack of production with shortage and exorbitant prices. In a second step, the price of alumina-based specialties like tabular or calcined alumina or refractory cement, will suffer a significant increasing, opening a period of uncertainty.

 

http://www.anfre.com/henan-enforces-mass-brown-fused-alumina-shutdown-from-november/

 

ILT-PLASMA- 9 th. FOUNDRY forum

ILT-PLASMA ,  will delve into the key parameters for a correct application of high power thermal plasma in nodular iron casting, achieving optimal thermal values without any degradation of the metallurgical quality of the metal.TUNDISH

It will both based their explanations on trials carried out by laboratories of recognised prestige in the industrial experience of companies in the sector.

01-06-17 mercado aisatico apuesta ILT

RENEW THE CERTIFICATION ISO 9001:2015 y OSHAS 18001:2007

We have the pleasure to inform you that REFRACTORY SOLUTIONS INSERTEC has renewed the certification of management systems: quality management system, according to the new standard ISO 9001: 2015 and system of health and occupational safety, OHSAS 18001: 2007 standard, both granted by Lloyd’s Register Quality Assurance accredited certification body.ISO_Página_1

The maturity of our management system encouraged us to implement the requirements of the new version of ISO 9001: 2015, ahead of the deadline.

The obtained certifications confirm the good performance of REFRACTORY SOLUTIONS INSERTEC and recognized the maturity and effectiveness of its management system, at the same time that ratifies its commitment to continuous improvement according to the demands of the market and stakeholders.

Through these certifications is internationally recognized the effort and dedication of the staff of REFRACTORY SOLUTIONS INSERTEC for offering effective solutions to the needs of their customers.

SOUTH AFRICAN METAL CASTING CONFERENCE 15th to 19 th March 2017

South African Metal casting conference  15th to 19th March 2017 in conjunction with :

SAIF (South African Institute of Foundrymen), WFO (World Foundry Organisation), MCTC (Materials Castings Technology Centre), NFTN (National Foundry Technology Network), AFSA (Aluminium Federation South Africa).web_logo

The conference was well organised in a hotel complex close to Johannesburg Airport, and it was estimated that more than 200 visitors attended the event.

As with similar conferences there was a small gathering area where informal and networking meetings could be held between conference papers. This area also included several booths by foundry service and supply companies from around the globe.

Insertec Refractory Solutions had an attendance by Mr. Victor Mendoza, Andrew Fowler and Mark Preece to evaluate the market conditions, potential future development strategies and several key contacts were made in connection with this during the event as well as information gathering from select conference papers.

It was evident that the South African Foundry market was looking forward to expansion with Government backed policies for investment and localisation meaning a determined effort for existing and investing companies to source all of their needs within South Africa as opposed to imports. This being said  the market has some real potential for Insertec Refractory Solutions as an importer and following this initial visit work is on-going to establish a working structure to exploit these potentials and develop a local service supply route.

INSERTEC-IFEX 2017


IFEX 2017 .- 13th INTERNATIONAL EXHIBITION ON FOUNDRY TECHNOLOGY, EQUIPMENT SERVICES & SUPLIES.
3rd to 5th February 2017 in conjunction with: 65th Indian Foundry Congress, IIF (Institute of Indian Foundrymen)

The event was held at the Eco Park, Kolkata where there was high investments being made to change the traditional image of India and portray a new ecological image with many green areas, lakes and social family gathering zones. The IFEX had in excess of 150 exhibitors across 2 halls and the IIF Congress present 44 technical papers.IFEX 2017

Although Kolkata as an event venue for the IFEX historically has not been considered the best due to its westerly position, it was decided by Insertec Refractory Solutions that a suitable opportunity to join with Nickunj Eximp Entp Pvt Ltd existed to promote their new relations to the market and so a booth was taken. Insertec Refractory Solutions had an attendance by Mr.  Andrew Fowler and for Nickunj Mr. Manohar Pai, Sameer Parekh. K. P. Chandrabose. The decision was a good one since all of our main competition were present (booth and visitors) as well as key OEM’s and they all took the time to investigate Insertec’s presence and focus into the Indian market.

The booth yielded over 60 recorded visit and potential enquiries most of which requested follow-up visits to their sites for further discussions.

India is a key foundry centre for Insertec Refractory Solutions and is considered the second largest metal producing market Globally and although entering later than most some great opportunities exists and

Insertec are now looking forward to the coming year’s developments.

 

 

The origin of world “Aliron”

Alirón word, term used after attaining a degree by Athletic, originated in the industrial and mining past of Bizkaia.

b_20100123170256_historia_del_aliron_all_iron

In the late nineteenth century is discovered in bilbao, close to the estuary, iron mines with an extraordinary purity of ore.Engineers and managers were essentially British. Then he piecework and payment is made according to the productivity of mine workers. So the salary was proportional to the degree of purity of the mineral extrated. The maximum quality corresponded to all iron (especially iron). that label became “ALIRON”. This originated among miners signs of joy as they were rewarded with extra pay. Then he was associated with football sport, the British engineers had brought to Bilbao.

ALUMINIUM 2016

IMG-20161201-WA0005IMG-20161201-WA0006Fantastic ALUMINIUM 2016 exhibition.

More than 1000 exhibitors from 50 countries and an estimation of 30,000 visitors, a success for the Organization and the Exhibitors.

For INSERTEC, the exhibition has been very positive with many visits, and new contacts and we are grateful to all of them the visit in hopes that we have been able to meet your expectations.

 

ANKIROS 2016

 INSERTEC was in the fair together with our distributor ISTANBUL METALURJI. This year the fair was with uncertainties after the political situation that has recently had Turkey.

Participation was lower but in spite of this, the fair served as a meeting place for smelters and suppliers of cast iron. The foreign presence also decreased comparatively with other editions.ANKIROS

AKDAS again presents itself as largest cast steel in Medium East, being capable of producing unique pieces of more than 150 t.

59th INTERNATIONAL COLLOQUIUM ON REFRACTORIES

INSERTEC R&D has attended the 59th INTERNATIONAL COLLOQUIUM ON REFRACTORIES which took place in Aachen, Germany, last 28th and 29th of September. This event is a meeting of the main suppliers of raw materials and equipment. At same time, most relevant researchers from European countries present last scientific advances on refractories technology.

logo COLLOQUIUM ON REFRACTORIES

This time a significant group of non-EU technicians has been present in added to a group of more than 200 participants. Main research lines were steelmaking, foundry, non-ferrous metallurgy and refractory castables, the latter with many followers.

Education on refractories a topic supported by the German industry has appeared as a relevant one.

 

Link: http://ecref.eu/index.php?id=kolloquium&L=1

 

CUPOLA FURNACES

The dictionary defines a cupola as a domed roof, a gun turret or a vertical cylindrical Furnace to melt metal to further refine it in other furnaces, or to cast it into useful shapes. The editors of Encyclopedia Britannica claim that René-Antoine Ferchault de Réaumur built the first cupola furnace on record, in france, About 1720. Cupola melting is still recognized by some as the most economical melting process if the furnace is operated continuously. A lot of grey iron is still melted and cast by this method.  Improvements in the process over the last 200 years have included the construction of the larger furnaces and the application of the heated air at the tuyeres.  Many foundries however as we shall see have invested in other more modern furnace designs and INSERTEC are able to supply a complete range of  refractory lining products for all.cubilote croquis

Cupolas were traditionally lined with brick but in the last 50 years many of these units and other vertical shaft furnaces have switched to monolithic linings because the quality and availability of monolithic refractories have improved enormously and they are more cost effective when properly engineered and expertly installed.

At the top of the furnace the refractories must resist mechanical and thermal shock while in the lower part of the lining the most important properties are the ability to resist attack from molten metal and slag at elevated temperature. Intermittently operated furnaces are sometimes cleaned and given a protective wash on the hot face each day but continuously operated units must be constructed from premium products for long life and low cost.

INSERTEC, have a complete range of monolithics for the original linings of both ferrous and non ferrous furnaces of all sizes and you are invited to contact us for precise recommendations.

http://www.insertec-store.com/iron-foundry/horno-cubilote.html

For economic and operational reasons many ferrous and nonferrous foundries have more recently invested in crucible and induction furnaces for melting and casting their products.

Crucible furnaces are one of the oldest and also one of the simplest types of melting unit used in a foundry where small batches of low melting point metal or alloys are required.  The charge is placed in a refractory crucible and heated mainly by conduction through the walls of the crucible using gas oil or electricity as the fuel. Most modern foundries however use electric induction furnaces for the efficient melting of both ferrous and non ferrous metals and alloys and these have largely now replaced crucible furnaces especially for elting of high melting point alloys such as cast iron and steel.  Induction furnaces are generally easier to control with regard to temperature and chemistry and better suited to the enviorement.

Written by Eate From U.K.

 

DEVELOPMENT IN CUARSIL RANGE

The metallurgy of iron ever needs faster melting processes. This fact make furnaces with high current density near the periphery of the lining ; for this reason the temperature in this area suffering the effects of overheating and logical sudden cooling of fusion process.

foto horno induccion

When lining has a good resistance to thermal shock will cause cracks, if dosent close, they are  the way of metal infiltration. These metal penetrations can compromise the final performance of all lining.

INSERTEC, have developed a complete range of CUARSIL IS6 PAN, with some improved performance thermomechanical that means, better resistance of the lining to the formation of cracks.

These properties have been got with a very studied particle size of the product and the mix of different qualities of quartzite for get  the optimum mineralogy  of the product.

This new development enables the lining of induction furnace to behave better against sudden changes in temperature, higher demands power from fusion of the furnace and, ultimately, getting to increase the service life of the refractory lining.

http://www.insertec-store.es/contacts

 

 

IDEX Our green furnace

IDEX® System

The IDEX® is designed to give maximum flexibility together with minimum fuel consumption and emissions. It is an indirectly fired rotary kiln for thermal delacquering / drying that removes volatile organic compounds (VOC), such as water coolants, paints, oils, … from the surface of crushed aluminium materials.1-sistema-idex-reciclado-aluminio-e6d04a0210

The system is completed with a postcombustion chamber for the incineration of the hazardous gases generated during the drying/decoating process.

Hot exhausted gases are recirculated to the rotary kiln to eliminate the VOC, without any additional energy supply and so reducing the overall thermal consumption to the minimum.

Final exhausted gases to the atmosphere are innert and comply with the most strict EU enviromental regulations.

ECO-Kiln® System

It is compact system where the postcombustion and drying chamber are in the same rotary kiln.

Benefits of Drying/Decoating

Economical arguments

  • Increase metal yield during melting.
  • Safer melting process, no water.
  • Low Salt / flux usage on melting.
  • Increase melting rate.
  • Increase of scrap value.
  • Firing VOC pollutants reduce overall fuel consumption.

Enviromental arguments

  • Reduce emissions, waste gas controls.
  • Pollution control.
  • Reduce landfil disposal.

BIEMH 2016, In Bilbao

INSERTEC, has been present in the recent edition of 29th BIEMH 2016, held in Bilbao, making promotion of our range of installation for Heat Treatment for diferents sectors as: aeronautical,metallurgical…2016 BEC - INSERTEC 07

The feeling (Particular & general) received from the rest of exhibitors, have been very positive and interesting; from business standpoint, overcome the last economical situation in thee last two editions.

Summary, has met the objectives set before their participation in the event.

See you at the next edition May 2018…..

 

 

MAXION , Brasil

maxion

This week INSERTEC, has participated in the opening of the new plant of MAXION Brazil.

MAXION is a Brazilian capital group manufacturer of wheels steel and aluminium; this company  bought all the plants in the world of a traditional wheel manufacturer ” hayes lemmerz aluminium”; with this expansion they become a global capacity of 60,000,000 wheels/year being 12,000,000 aluminium wheels ,now they are the largest manufacturer of the world.

INSERTEC, has supplied the first Melting Tower MT-3-4000 and it is manufacturing a recycling furnace for scrap of 1500 kg/h, for delivary in October.

METAL-METALLURGY China 2016

With the great efforts done by the internal  teams.Metal China-2016-Juan with Korean distributer

INSERTEC succeded in the METAL-METALLURGY CHINA in May 2016.

This Exhibition is the most important one in Asia, not only for China domestic, but also for other Asian countries. Majority members of the sales and technicians from ZIFS attended the exhibitions.Metal China-2016-1

They met potencial customers and searched for new suppliers there.

Thanks to their contribution, more and more visitors became our friends.  Hope the exhibition can help INSERTEC in better market promotion.

ALUMINIUM, Key in the construction of modern aircraft.

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A combination of lightness, ressitance and high electrical and thermal conductivity, is the property that became a key to Aluminium and its alloys, for the construction of aircraft,  automobiles, or engines, among many other applications. And it is that a given volume of aluminium weighs less than one-third of the same volumen of steel. Unique lighter metals are Lithium, Berylium and Magnesium.avion

On the other hand, only has a 63% of the electrical conductivity of the copper wire of the same thickness, but weighing less than half.  This means that a comparable one of cooper conductivity aluminium wire is thicker, but still lighter.  All of  this has its importance in case of  the transport of electricity of high voltage-700,00 volts or more-longer distance for what, precisely, are used for aluminium conductors.

TILTING ROTARY FURNACES

Due to the considerable savings produced during recycling and to the simplicity of the process, the aluminum started to be recycled a long time ago, and today is a widespread activity, technically solved and profitable, In fact, more than the 75% of the last 100 years produced aluminum is today in use because of the recycling.

Over the past 20 years , Insertec has developed a range of specific products for the aluminum recycling sector, in which we can remark tilting rotary furnaces.

Looking at this type of equipment, the refractory lining is one of the critical points , and where our refractory division provides differentiated and innovative engineering refractory solutions.

The success key in the performance of these solutions is given by the combination of 3 factors:

Design and selection of the more appropiate materials. (zones)

Best Lining design (anchoring way, insulation, thickness and geometry)

Correct installation.rotativos

REFRACTORY ENGINEERING purpose is to get together those 3 factor and INSERTEC, Ingeniería y Servicios Técnicos is able to reach the target giving solutions such as:

 

  • The use of REFRACTORY PRECAST SHAPES à remove the main disadvantages of the use of bricks and monolithic mases, providing all the advantages of each one of them:
    • Manufacturing according to a quality system: (moulds design and manufacturing, mixing, vibration, demoulding, drying and fyring) = Homogeneity in the technical characteristics in all the shape geometry.
    • Specifically designed (materials y geometry) = best behaviour taking into account the requirements of each zone of the installation.
    • The customer receives the shapes just ready for their installation and put in operation. They could be installed by mechanical team with some drawings and assemblying instructions.
    • Installation days and scheduled stops are considerably descreased.
    • There can be spares in the customer or in the manufacturer warehouse, so in case of non scheduled stop of the plant, replacement of the shape and repairing works are reduced at minimum.
    • The characteristics of the shapes are homogeneus and materials and designs the best in each application = increases in the life of the refractory components à less repairing costs (refractory and metallic elements that are protected by the refractory), and less operations inside the furnace.
    • Less operations inside the installation à less exposure of the workers to more occupational hazard (demolitión, equipments and tooling handling in reduced spaces, activities in reduced accesses zones,etc) = Improvement in SAFETY and Health conditions.
    • The possibility of accidents and incidents  decrease due to the minimizing of the number of repairing operations..
    • The increase in the life of the refractory components involve an enviromental and economical improvement due to the less waste creation and its latest management.

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The following picture symolizes all the advantages (technical, economical, safety and enviromental) that are involved in the use of REFRACTORY PRECAST SHAPES.

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How we can optimize the performance of cupola furnace?

cubilote croquisMethods of improving the behavior of cupola:

  • Keep Furnace in optimum regime of operation.Relationship between inyection velocity coke charging & melting velocity (see Junblüth diagram)
  • Avoid excessive temperatures in the casting and reduce overheating.
  • Ensure uniform load: The distribution of metal and coke must be  uniform during charging.
  • Improve the control of charges weight , the inyection flow and metal temperature.
  • Minimize air leaks. Supply the correct amount of air is essential for the proper performace of the cupola. It is necessary to take extra care to prevent leaks and ensure efficent operation of the furnace. These losses are common in the hot wind cupola and take place in the exchanger of heat. As result, oxygen in the nozzles should be injected to compesate lost air.
  • Avoid vaults formation in the cupola. vaults stickings and jams of the load in charging area creates efficency loses during the melting and ocassionally, even in severe cases stop it completely.
  • Improve the Refractory linning. During the melting process,  the wear in the refractory linning modifies the dimensions of it; afecting directly to the performance. For this reason minimizing the attack to the linning , is a way of energy saving. The maintanaince of the linning must be taken carefully.