INSERTEC, Participate in METAL BULETIN Aluminium Recycling Congress in Varsovia, as Event Sponsor as Speaker on it.
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.
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.
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.
It will both based their explanations on trials carried out by laboratories of recognised prestige in the industrial experience of companies in the sector.
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.
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 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).
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.
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.
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.
Alirón word, term used after attaining a degree by Athletic, originated in the industrial and mining past of Bizkaia.
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.
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.
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.
AKDAS again presents itself as largest cast steel in Medium East, being capable of producing unique pieces of more than 150 t.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
It is compact system where the postcombustion and drying chamber are in the same rotary kiln.
Benefits of Drying/Decoating
- 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.
- Reduce emissions, waste gas controls.
- Pollution control.
- Reduce landfil disposal.
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…
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…..
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 succeded in the METAL-METALLURGY CHINA in May 2016.
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.
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.
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.
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)
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.
The following picture symolizes all the advantages (technical, economical, safety and enviromental) that are involved in the use of REFRACTORY PRECAST SHAPES.
- 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.