REFRACTORY JOIN SOLUTIONS

Stable material PLASTIC PATCH is a compressible refractory joint filler, developed for Anode Baking Furnaces, to protect expansion gaps against clogging with packing coke during heat up and operation, and prevent the distortion of flue-walls during thermal cycling. Developed by CIR Laboratory Canada (www.cirlaboratory.com ), PLASTIC PATCH is available worldwide from INSERTEC Furnaces and Refractories (www.insertec.biz).

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Packing coke plays an essential process role in anode baking. However, the infiltration of its finer grains into expansion gaps, particularly those between flue- and end-walls, quickly leads to clogging, increased maintenance cleaning, even flue-wall distortion and eventually increased refractory repair costs. Poorly mortared brick joints, exposed during heat up, also suffer similar infiltration and clogging problems.

PLASTIC PATCH provides a stable and permanent solution to coke grains infiltration. Made from exfoliated vermiculite and fine-grain anhydrous aluminosilicate, and suitable for applications up to 1350c, PLASTIC PATCH adapts to these thermal expansion forces, by maintaining a glassy-phase during heat-up, allowing it to compress under thermal expansion, then heat-set to a hardened finish (1.2g/cm³ at 1200c) to maintain a tight seal.PLASTIC

Unlike conventional ceramic fibre or mortar options, PLASTIC PATCH does not shrink (<2%), or become brittle at temperature, and therefore does not need to be replaced at the end of each cell firing cycle. Occasional light repairs, if necessary, can be skimmed directly onto existing clean product. Both ways, downtime is minimised, and furnace availability is improved.

PLASTIC PATCH is supplied premixed, in cartons, ready for use. If additional flow is needed, up to 5% water can be added. In tight working spaces, its brownish-grey colour allows filled gaps and joints to be easily identified against refractory brickwork. Initial set is after 15 minutes, at +5°c. For larger areas, application can be by pump, or trowel. Finer joints and gaps can be hand-packed as required. Tools can be quickly cleaned with warm water. PLASTIC PATCH is non-corrosive, and does not contain irritants, known physical hazards or carcinogens, however wearing PPE is recommended. Storage should be for up to 12 months.

For the best results on new or larger gaps; PATCH GRIP, LIQUID ANCHOR and SOLID ANCHOR, also from CIR/INSERTEC, are additional products that can be used with PLASTIC PATCH.

 

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.

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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.

 

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.