Furnace linings for foundries

Most steel foundries melt scrap in coreless induction furnaces. In larger steel foundries, electric arc furnaces may also be used.

Primary lining

KELLUNDITE high purity alumina spinel forming, dry-vibration refractory materials are designed for lining coreless induction furnaces melting steel alloys.

Capping material

KELLUNDITE 97CAP is a high alumina spinel forming dry topping material that ensures a seamless transition of the refractory without joint.

BLU-RAM are ready-to-use high alumina chemically bonded plastic materials.

Spout material

• BLU-RAM phosphate bonded plastic
• CRITERION low cement castable

Long campaign cupolas are the principal melting unit of most modern automobile and pipe foundries worldwide.

TRIAD Z 189 is a no cement castable based on high purity alumina aggregates enriched with SiC & Graphite. It does not contain dangerous metallic additives that can lead to Hydrogen Generation and potential explosion risk. The TRIAD Z 189 castable is designed for use in long campaign cupolas in the lower portion including the well, syphon, and taphole areas where most erosion occurs due to constant contact with high temperature iron and slag. Find out more

RAMWELL linings are an alumina based range of pitch-free, clay bonded, graphitised ramming material containing between 10% and 20% silicon carbide.

HYDRA-MAX linings are a range of ultra-low cement bonded castables based on fused and calcined alumina, containing between 15 and 55% silicon carbide and graphite. HYDRA-MAX refractories are pitch-free versions.

ULTRAGUN SC linings is a high performance gunning materials containing silicon carbide.

The final choice of products is determined by whether the furnace is a “lined” or “liningless” cupola and by operating conditions in order to improve

• lining performance
• slag resistance
• speed of installation
• dry-out time
• resistance to sculling
• metal cleanliness
• lining security

INSURAL precast furnace lining system

Traditional furnace lining systems involving the application of wet refractory mixes typically require time-consuming dry-out and sintering operations prior to metal charging. In addition to significant furnace downtime, such lining systems also typically lead to hydrogen pick-up in the aluminium melt for the initial period following furnace installation.

The INSURAL furnace lining system, combining highly insulating and durable components, is the ideal solution for today’s aluminium melting operations. A dry, preformed engineered lining system.

Benefits include:

• No sintering or dry-out program
• Reduced furnace downtime
• Lower energy costs
• Improved melt quality
• Greatly reduced hydrogen evolution on start-up - rapid achievement of target melt density
• Low corundum growth - easy to clean and maintain

Foseco supplies a full range of consumable ceramic products for dosing furnaces, produced in a variety of INSURAL technical grades as well as other ceramic materials, for example:

• Filling funnels
• Dosing tubes
• Launders
• Thermocouple and Heating Element Sheaths

Traditional cast linings

Dosing and low-pressure furnaces are usually small and the cast furnace bath is done in a single pour. The bath linings can be cast in TRIAD AL or ALUGARD castable.

Many furnaces use crucibles to hold aluminium. The main advantage is that the crucible can be easily changed and casting can commence immediately, without the need for prolonged drying of the furnace linings and reducing the risk of hydrogen pick-up. Crucibles also ensure that the aluminium is uniformly heated through the crucible wall by electric resistance heating. Foseco offer a wide range of crucibles for all types of furnaces.