INSERTEC Blog EN

  • The world is watching us

    "The world is watching us. It's time to act. With this slogan, the COP25 climate summit started on Monday in Madrid. In his inaugural speech, its new president, Carolina Schmidt Zaldívar, stressed the importance of a real commitment of political institutions and the need for a faster, fairer and more inclusive climate transition.

    2020 must be the year in which the industrial sector takes an active part in achieving new environmental objectives, such as the control of waste, the use of recycled raw materials or energy efficiency. Internal processes also have to change, recycling has to be imposed in the working methodology.

    In the case of aluminium, the importance of recycling is significant since, in addition to helping to protect the environment, it involves savings in energy and raw materials.

    Already in 2007, an article published in Interempresas stressed that "by recycling scrap metal, water pollution, air pollution and mining waste are significantly reduced by 70%. Likewise, obtaining recycled aluminum reduces air pollution by 95%, saves 90% of the energy consumed in processing and contributes to the lower use of electrical energy, compared to the processing of virgin materials.

    One of the main advantages of aluminum is that it can be re-melted without losing its physico-chemical characteristics; it is a product framed in a process of almost infinite use/recycling/use. In addition, the waste generated by recycling operations does not pose any risk to the environment when treated properly. Finally, it should be remembered that "the recycling of one tonne of aluminium will lead to the non-use of 5 tonnes of bauxite. In this way it helps in the recovery of the natural resources that we have on the planet.

    SOURCES:

    ps://www.eitb.eus/es/noticias/internacional/detalle/6857857/cumbre-mundial-clima-cop25-es-paises-participan-objetivo/

    https://www.interempresas.net/MetalMecanica/Articulos/19655-La-importancia-del-reciclado-del-metal.html

    https://www.inspiraction.org/cambio-climatico/reciclaje/material-reciclado/aluminio

    Translated with www.DeepL.com/Translator (free version)

  • Newsletter - November 2019

    Our newsletter is now available

    WINTER  SHUTDOWN

    Good time to check the furnaces,periodic maintenance is the best prevention.
    HOW TO KEEP A REVERBERATORY FURNACE CLEAN
     
    From the design of the installations to the control of the temperature and the choice of refractories, we offer you some tips to ensure the optimal maintenance of your reverberatory furnace.
    CORUNDUM GROWTH
     
    Initially quite easy to remove, corundum is losing its original flexibility until it becomes a dense and hard material. Do you know why it has a direct impact on energy consumption?

    PLASTIGUN

    New concept for the repair of refractory linings

    New range of refractories for plastic gunite. Resistance, limited chemical reactions, rapid... +Info


    We will be in:

    EUROGUSS 2020

    We invite you to participate with us  us at Euroguss 2020, which will take place from 14-16 January in Nuremberg, Germany.
    Location of our stand: Hall 7/7-542
    +Info

    BAUXAL PROYECT 

     
    WORK BEGINS ON PAVAL REFINING PROTOTYP
     
    La The pre-industrial refining facility of Paval with a capacity of 500 tons/year of Refinal has started during the month of October, as planned in the project's schedule.
    The construction period has been estimated at 7 months, with completion scheduled for April 30, 2020.
     
     

  • Tips for the maintenance of Reverberatory furnace.

    The main advice is periodic maintenance. They are the best prevention.

    With this in mind, there are three main points that will help us.

    Design of the furnace.

    lhttps://www.insertec-store.es/hornos-industriales/hornos-reciclado-de-aluminio/fusion-chatarras/reverbero-con-pozo-lateral.html

    It has direct consequences in the simplicity of maintenance, so we have to take into account:

    • Improvements based on the optimization and efficiency of the operation of the furnace.
    • Easy/comfortable access to all cleaning areas.

    Temperature control:

    • Controlling the excess of temperature has a direct influence on the increase of the useful life and the performance of the installation, as well as on the quality of the metal.
    • Do not prolong the stay of the liquid metal in the furnace once it is ready to pour or transfer.

    Refractory selection.

    The main objective is to keep the lining stable for as long as possible, protecting the metal structure of the furnace and ensuring the quality of the metal in contact with it.e following factors must be taken into account:

    • Dimensional and capacity requirements of the furnace.
    • Requirements of energy consumption and temperature limitations in boilermaking.
    • Operational parameters (working temperatures, alloy types...)

    Well-designed and selected refractory linings help improve furnace productivity and profitability.

  • PLASTIGUN, a new concept for Aluminium furnaces repairs.

    In addition, Insertec has successfully developed the technology for the gunning of chemically agglomerated dense products.

    First product of this family : PLASTIGUN-85 P
    This product is particularly suitable for fast, quality repairs of aluminium furnaces where rapid commissioning of the unit is required.
    With this high pressure gunning system this is achieved:

    To be able to project as much in cold as in hot.
    The speed of installation is much higher than conventional plastic.
    It can be applied both on old coating, as replacing the entire coating.
    It is not necessary to install moulds.
    The installation and drying times are reduced.


    INSERTEC's offer includes machinery and installation equipment for the application of the material.

  • WINTER SHUT DOWN.-

    The adhered corundum layer is initially soft and can be easily removed, but in later stages the product is dense, hard and difficult to remove during cleaning and can cause mechanical damage to the lining during removal.
    So , it is evident that the accumulation of corundum is one of the main factors influencing energy consumption, because the growth of corundum reduces the capacity of the hearth furnace and the thermal conductivity in walls also its reduces the furnace life due to differential thermal behavior.

    corundum re-growths.

    The growth of corundum requires intensive cleaning of the liner with cleaning fluxes and mechanical tools that cause wear of the hot face liner and consequent loss of heat in the furnace.

    The use of some refractory materials can also help to reduce the formation of corundum; in general, phosphate bonded materials show excellent resistance to aluminium metal penetration and corundum growth.

  • BAUXAL PROJECT- II

    The construction of prototype for Paval refining starts.

    The preindustrial prototype for Paval refining with a Refinal´s capacity of 500tpy has been started during the month of October, as it was expected in the project´s schedule.

    It has been estimated in 7 months the length of the construction, the deadline has been planned the 30th April 2020.

  • RENAULT Bursa Project,

    in Turkey, where INSERTEC has supplied a 2000 kg/hr Fusora Tower and auxiliary equipment .

    (Sleeve Filter, Transport ladles, Preheater and Degasser).

  • FURNACE REPAIRS

    INSERTEC, Put at your disposal an engineering studies; Combination of Refractory castables and precast pieces to rehabilitate and optimize the performance of lining.

    SIFCA technology supposed an excepcional solution reinforcing more critical areas, combining mechanical and refractory properties.

    THERMBOND technology, optimizes and minimizes partial repairs thanks to its properties of chemical adhesion to old lining.

  • NEW ORGANIC BLANKET

    The soluble fibre blanket is manufactured using a unique spinning technology and is made from a mixture of calcium, silica and magnesium which gives the fibre the ability to withstand continuous applications under high temperature conditions of 1300ºC.

    The soluble fibre blanket is flexible and suitable for treatment with refractory lining, thermal insulation and metal transfer.

    Main characteristics:

    • Low thermal conductivity.
    • Resistance to thermal shock
    • Lightweight
    • High tensile strength.
    • Low heat storage.

  • 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.
  • BIG-BLOCKS- Aluminium Solutions

    Ramp and bottom with precast pieces

    Refractory bricks have been used for the lining of reverberatory furnaces. For the installation of these bricks, a large amount of concrete is required, which then has to be dried and takes a long time to lay.
    As an alternative from INSERTEC, we propose the use of the so-called BIG-BLOCKS, (large shaped pieces). By means of these pieces it is possible to carry out the complete installation of the lining.

    ADVANTAGES:

    • Fewer kiln joints than bricks.
    • No drying required.
    • Reduced installation time.
    • Lower maintenance costs.

  • CORUNDUM FORMATION

    Corundum formation and its subsequent destruction of the furnace lining can be a constant worry to the maintenance department. The picture below is all too common of a reality in a typical Aluminium Foundry.

    The following conditions facilitate corundum formation:

    • Excessive free silica in the refractory.

    • Excessive amounts of sodium, either in the refractories or in the fluxes.

    • Refractory products that do not have any non-wetting agents.

    • Inefficient burner operation carbonizes deposits on the refractory, thus rendering it wettable by molten aluminIum. Carbon deposits would occur if the burners are not runnning properly.

    • Negative furnace pressure, thus aspirating oxygen into the furnace.

    • Excessive temperature, e.g., 850°C plus and it would be worst if burner`s flame beats the lining.

    * Same as above, if electric roof heaters are very close to linings not having good properties against aluminium.

    As you can see by the above points, there are multiple factors that go into corundum formation. We want to make it clear that there is no one factor that will eliminate corundum.

    Also, the formation cannot be solved by refractory selection alone. This helps but we need to go to the root cause.  Aluminium producers must make an analysis and clean the furnaces on a regular basis in order to reduce the chances of  corundum build ups.

    Do not hesitate to contact us if you need further information.

    https://www.insertec-store.es/contacts

  • FENAF 2019

    Our subsidiary in Brazil has once again participated in FENAF, Sao Paulo from 17 to 20 September.

    They were accompanied by Andrés Rubio, director of ILT PLASMA TECHNOLOGIES SL .

    Around 50 companies related to the ferrous and non-ferrous materials foundry sector passed through the stand.

    Both, customers and new customers were interested not only in plasma technology as an innovative heating system, also in the latest innovations presented by INSERTEC Brazil regarding furnaces and refractories.

  • INSERTEC CHINA cumple 15 años 2004/2019

    Nuestra filial está de celebración.

  • SUMMER - Melting Tower

    Some of our customer in Casting Aluminium, taking advantage in summer holidays to setting up their Melting Towers.

    INSERTEC, Put at your disposal an engineering studies; Combination of Refractory castables and precast pieces to rehabilitate and optimize the performance of lining.

    SIFCA technology supposed an excepcional solution reinforcing more critical areas, combining mechanical and refractory properties.

    THERMBOND technology, optimizes and minimizes partial repairs thanks to its properties of chemical adhesion to old lining.

  • THANK YOU for visiting our stand at the GIFA 2019 show!

    We had a successful show and we could not make it with out you

  • Tilting Reverb Melter Aplication Report

    illet Casthouse Melting unit

    Aluminium Tilting Reverb Melter

    MELTING PRODUCTION RATES

     Furnace capacity....................................................12 Ton
    Material to process

    • - 70% Baled or loose clean Window frames & profiles,Occasionally painted or dirty scrap
    • - 30% Primary Ingot bundles
    Melting load ..................................................8.800 kg
    Melting rate ................................................... 6.000 kg/hr
    Bath dimensions ........................... 3.400W x 6.500L mm
    Regenerative Burners natural gas ................... 4.700 kW
    Total cycle time ................................................. 2h20min
    Number daily casting billets ....................... 10 cycles/day
    Logs Productivity (billets Ø7” & Ø9”) .............. 85 ton/day
    Yearly production 330 days/year ................ 28.000 ton/yr

    dedicated Charging Machine, for processing logs 85 ton/day.
    Melting Production rates.

  • INSERTEC, & RENAULT collaboration

    RENAULT – The RENAULT Group has officially started its new manufacturing Plant in Valladolid, devoted to the manufacturing of the last generation of 3 and 4 cylinders blocks.

    INSERTEC, among the collaboration framework reached with the RENAULT Group, which started in 2016 with the supply of several melting and heat treatment furnaces for the new Plant that RENAULT set in Curitiba, Brazil, has already supplied for the new Plant in Valladolid three Meltowers of aluminium and four T5 rotary hearth heat treatment furnaces, based on the latest generation design of our technological partners of Sanken Sangyo, from Japan.

    But the collaboration framework is not yet finished, as there are already additional expansion plans for the Valladolid Plant, as well as another greenfield Plant in Bursa, Turkey, and performance and capacity expansion plans in their traditional Plant of Cleon, France, where INSERTEC will supply additional melting and heat treatment furnaces.

    Oscar Iribarren.-28 de Febrero de 2019

  • 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.

     

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