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.

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.

rotativo medioambiente

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

Contact with us

 

PROJECTS, summer 2015

During July and August 2015, INSERTEC has been undertaken more than 60 pojects of maintenance Refractory linings. The local market is still predominantly but we have had an increase of projects in the rest of Europe. To carry out these projects, e have counted with the support of a team of more than 50 people displaced in customer, INSERTEC staff and business partners.newsep2015

They have been working in Automatic Pouring system,Melting towers, induction furnaces, Reverberatory furnaces, Channel furnaces, Cupola ..etc making all of these installation on date, according to the commitments entered with customers.

By sectors, Iron and Aluminium casting have been the strongest; but we have also had the opportunity to work in other sectors with new developments.

Another point to emphasize, within the development of these projects is the participation of our subsidiaries staff, Technical and Comercial in this case from Brazil (INSERTEC REFRACTARIOS DU BRASIL) and China (ZHENJIANG INSERTEC FOUNDRY) giving us the opportunity to share knowledge and experiences in various maintenance projects of refractories in the projects mentioned.

 

NEW MATERIALS FOR TOP CAP

Featured

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

FERROCHROME PRICE GO UP

Ferrochrome price is expected to go up in US, China, India, Europe and Japan, do to the tight supply. Is an essential alloy in the production of stainless steel. US, China, European Union and Japan has no chrome ore production or significant reserves.

China overtook South Africa to become the largest producer of Ferrochrome worldwide. The demand for chromium metal is expected to rise by more than 10% in 2015 do to growing demand in stainless steel industry.Resultado de imagen de ferrocromo

Nearly all of the Ferrochrome produced in China relies on imported chrome. From 2004 to 2015, China´s production of high carbon Ferrochrome increased by nearly 10 times, this production till cannot meet domestic demand. China consumed 5.7 million tonnes of Ferrochrome in 2014 and is estimated near 6 million tones in 2015.

Chrome ore has no substitute. Add it to carbon steel in the form of Ferrochrome and the steel becomes stainless steel corrosion resistant, mechanically strong, heat resistant, hard wearing, shiny and glamorous.

Stainless steel is used everywhere in modern life from nuclear reactors, pipes, medical equipments, railroad, airplane and thousands other applications.

 

EVOLUTION OF GLOBAL ECONOMY

Featured

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

Featured

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

Featured

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.

COURSE “APPLICATION COMPLEX SYSTEMS”

During the first week of October, 2nd edition of the technical course ” Application of the complex systems engineering in the designing of refractory castables and precast cyted_curso_2014shapes” took place in Madrid. This training course, supported by the Ibero-American Programme for Science, Technology and Development (CYTED), joined a qualified qroup of teachers from different countries including relevant researchers in refractories, like Prof. Victor Pandolfelli from UFSCar, Brazil. In this cast, RSI R&D Manager presented two lectures about precast shapes and refractories for aluminium industry.

https://es-es.facebook.com/CYTED

https://www.facebook.com/senacyt/posts/499579456848319

 

WHY do we use the Quartzite as a Refractory material?

Silicon oxide is the natural oxide most abundant in the Earth crust. It is high melting point, 1763ºC for pure oxide, and it is softening point closed to melting temperature, allow it is application as high performance refractory material. For this combination of low cost and high refractoriness, quartzite based refractories were widely applied for many years during the 60´s and 70´s of last century.CUARCITA

Steelmaking refining and allotropic tensions during heating hysteresis limited its application to some specialrefractory solutions.  Today, only coke batteries as quartzite fired bricks and iron and steel foundry with coreless induction furnaces as dry mixes, have survived.  Some other special applications like acid resistant castables are partially based in natural quartzites.mina sostenible 2

The best refractory solution is defined by the most cost effective selection of refractory recipe without transformation so if comply technical requirements, cost effectiveeness will be achieved.

INSERTEC, Reorganizes the industrial activity.

We are pleased to confirm that INGENIERIA Y SERVICIOS TECNICOS,S.A. “INSERTEC”, has proceeded to a reorganization of the activities: Furnaces & Refractory Production; forming two new companies:Logo IST - Es

INDUSTRIAL FURNACES INSERTEC, S.L.U.

&

REFRACTORY SOLUTIONS INSERTEC, S.L.U.

It responds practically to our natural activities division. We are convinced that the new created structures shall provide a better results maintaining all of our services.

This new reorganzation will be operative since the first of July.

We appreciate your cooperation and understanding.

 

 

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

Featured

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

 

The production of steel in Spain grows

The production of crude steel in spain registered a positive growth in 2013 after falss suffered in 2011 & 2012.

Spanish steelworks produced a total of 13.8 M. Ton.; un increase of 1.5% over the previous year, according to reviewed the Union´s iron and steel companies in Spain UNESID.

The Association notes a change of trend that began in May 2013 and picked up momentum the last months of the year.ACERIA

Spanish Mills produced 12% more in December 2013 which in the same month the previous year. However, the production is kept at a level similar to the one registered in 1997.

UNESID also notes that the continuos country suffering the high costs of electricity, in fact spanish steelworks pay electricity costs higher than their competitors inside and outside the EU.

ISO 9001:2008 & OHSAS 18001

During last year 2013 our effort has been focused on the development and implementation of a Safety and Health Management System according to the specification OHSAS 18001: 2007.calidad
Last 5th and 6th of March, 2014 Insertec had the Integrated Quality (ISO 9001:2008) and Safety (OHSAS 18001) Management System certification audit.

We have achieved the objective set, which shows the commitment of the company in all aspects of safety and compliance with the applicable legal requirements.

 

 

NEW DEVELOPMENTS

For six months, two students in their final year Bachelor´s Degree in Chemical imagesEngineering from the UPV, developed two projects in the INSERTEC´s R&D Department, with  two products  for FERROUS and ALUMINUM foundry applications:

  1. A refractory castable with high performance and ultra-fast drying capability.
  2. A metal-ceramic composite for refractory precast-shapes manufacturing.

Enhanced products have achieved the objectives mainly thanks to students work, led by INSERTEC´s Head of laboratory (José Ramón Echabe).Products performance have been tested in real applications.ccooThe success of the initiative has strengthened between  INSERTEC & UPV, we hope that next colaboration will be as successeful as the first one.

Logo IST - Es