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.
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.
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.
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.
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.
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.