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.
Some of the early designs used completely aluminium structure was built by a Norway company called BJERRING. They only manufactured 4 prototypes until the Lord Raufoss take the control of the company and tried to transfer the advances developed in the space technology of aluminium frame design in cars and buses.
This project could not be held due to lack of resources and technology ( we are talking of 1930s). The first car manufactured using abodywork and structure entirely of aluminium was the PANHARD DYNA, a prototype made in France in 1954. This vehicle was powered by a two stroke engine, weiged only 629 kgr. and could carry 6 people.
During the period between 1915-1941 many attempts were made to develop new production process of magnesium, especially in Europe. By the urgent need for magnesium created by the threat of the second world war, some of those procedures were employed … Continue reading →
METAFO fair is the largest fair of IRAN. This has been the twelfth edition. In 2014 doubled participation and designated space for the this Fair. FUNDIGEX has participated, on behalf of the ICEX in a grouped stand with Basque companies.INSERTEC, had its own stand.
Since 15 years ago in Iran, The foundry has been growing, espacially the sector of steel and aluminium parts:
The production of casting can be decomposed into:
70% Iron Casting
8% steel parts.
12% are castings of other non-ferrous materials.
70% of Iron castings goes to the automotive sector, which is growing in Iran and moves a significant volume of business.
In 2013, a reduction of iron furnace was located in Galdakao (Bizkaia-Spain). This building,is the largest in Europe, with 5.5 meters tall and 4 wide, this large furnace that was based on the manual work against others later which were helped from the force of the water was really great.
Before the revolution industrial, at the beginning of the 19th century, this metal (Iron) also was very importan in Basque country life. The iron was good, had little phosphorus, for this reason they could manufacture more flexible tools. They obtaining the Iron through these funaces drilled on the slopes. They pouring the mineral into the furnace and with the heat were obtained iron in one side and slag on the other.
Researchers have given them the name of “BASQUE FURNACE”. In fact, compared with other structures, the zone have walls curved – the European are straight- and channel which gives air is located on one side rather than in the center of the bottom.
We consider an interesting news, because we can see that this town has its history very linked to the iron, also seemed a curosity that one of the locations of INSERTEC was in this town.
INSERTEC, in the XIV Congress of according (National Congress of heat treatments and surface), held on the premises of the AIMEN technological Center in O Porriño (Pontevedra) during the days from September 30 to October 1st.
The main objective of our presence, is primarily the promotion of the equipment of the Division of industrial furnaces, mainly for the Sector of the thermal treatment, exposing various roll-upp´s in order to get the public installations supplied by INSERTEC for heat treatment in sectors such as the metallurgical, aeronautical, wind, energy, & automotive.
AIMEN President with Jorge almeida in TRATERMAT 2015
INSERTEC, has developed a new range of plastic products. Comercial name DRYPLAST. The main difference from INSEPLAST range is the use of a dry binder, with this new binder we get these advantages: Manteinance the consistency that needs for working, … Continue reading →
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.
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 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.
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.
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.
Aluminium is a relatively young metal in that two hundred years ago no one knew that it existed. It was not until 1825 that Hans Christian Oersted, professer of phisics at the University of Copenhagen managed to produce the first few milligrams of pure aluminium in his laboratory.
It took a further thirty years after Oersted´s original research effors for H. Saint-Claire Deville to produce a slightly larger sample of the pure metal and this was exhibited as a small bar at the Paris Exhibition of 1855 next to crown jewels of France.
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.
President, Aser Etxebarria (FAGOR) and Marcial alzaga (TEDFUN), made presentation overview about the market and situation of casting in Spain; after this our colleague Victor Mendoza gave a conference about New technology for the linning of holder & dosing furnaces.
General comments about market situation:
Among the partners founders, the forecast is to get an increase of +10.2% (Total 104.955 tons) production in 2015.
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.
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.
If we speak about Sir Isaac Newton, all we go back to our school days and see how relevant is F=m·a, second motion law in our lives.
All we will agree but, if I say any refractory castable, any civil concrete or, in general, any fluid mix would be properly managed through pumping, casting, conveying and so on, thanks to another, basically unknown, Sir Isaac Newton’s law, most of you wouldn’t say what law I am referring.
It says that the shear stress of a fluid is proportional to its shear rate. The proportional factor was called by Newton ‘viscosity’ and its regulation allow us to install our castables, to buy different sauces in the supermarket, to make up our face,…
During 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.