Ferrous Melt Shop Highlights
Ferrous Metal Treatment
The FERROLAB V thermal analysis system enable foundries to accurately monitor metallurgical process performance and take immediate corrective action by analysing base and final iron quality. FERROLAB V can be used on the melt deck to minimise variances in base iron by providing the operator information necessary to adjust the characteristics of iron within predetermined process specifications. It provides real time measurement of %Ceq, %C, %Si and the nucleation status of the iron. FERROLAB V can be used at the pouring station to provide real time measurement of the metallurgical quality of the final iron and highlight the possibility for defect formation.
The system is simple to install and has a user-friendly interface and real savings can be achieved from a reduction in scrap rate, and improvements in the quality and consistency of castings. FERROLAB V thermal analysis systems enhance the performance and value of the Metallurgical Solutions portfolio from Foseco.
Flow Control for Iron and Steel Foundries
Foseco will highlight the latest technologies available for controlling the metal flow in steel ladles and autopour iron applications.
We will show alternative steel ladle lining and flow control systems for both cold start and hot start ladle systems.
TRIAD Z lining system is a new generation of castables that bring long lining life. TRIAD Z are no-cement castables with superior hot strength properties and slag resistance. The drying procedure before usage takes half the time compared to conventional low cement castable.
Foseco will show the KALTEK board system for bottom pour ladles, a unique lining system that requires no pre-heating. The KALTEK board system is suitable for ladles up to 25T capacity and more for specific projects. A new generation of KALTEK board multi-life system has been introduced to the market to combine the KALTEK board properties (no pre-heating, metal cleanliness, insulation) with a KALTEK set that can be used up to 5 times and allow thermal cycles and nozzle exchange.
Foseco’s new, VISO isopressed zoned nozzle offers the steel foundry a multi-life nozzle for improved productivity. The zoned nozzle uses a combination of different refractory systems to enhance strength and performance, thereby enabling repeated use of the nozzle in a steel foundry ladle.
Furthermore, we will show the latest flow control technology for grey and ductile iron, especially for unheated pouring boxes. Here, we will show a range of design and refractory combinations to meet the requirements of a variety of autopour applications.
Refractory Linings for Iron and Steel Foundries
Foseco will highlight the latest developments in foundry lining technology including the launch of the TRIAD Z no cement castable range for iron and steel foundry applications.
No cement castable have been available for many years and are attractive for minimising the furnace downtime during the relining process. The recent development of the
TRIAD Z range bring added advantages in terms of superior slag resistance and enhanced hot properties of the castable system.
TRIAD Z can be cast, pumped and shotcreted is now available for most of iron and steel foundry applications such as long campaign cupola melting, channel holding and pouring furnaces as well as iron and steel ladle applications.
On the stand Foseco will present a complete package of lining and purging refractories designed for long life and improved metal cleanliness in coreless induction furnaces melting steel grades. The portfolio consists of high quality KELLUNDITE lining systems suitable for melting a wide range of steel alloys and purge plugs utilising integral earth protection and precise gas flow control systems to ensure safe and optimal operation.
Finally, Foseco will also show a complete package of long-life linings for long campaign cupolas melting iron grades. The cupola portfolio consists of high quality RAMWELL ramming mixes and HYDRA-MAX low cement castable lining systems enriched with silicon carbide and graphite aggregates to improve slag resistance.