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Case Study:
Furnace
Type: 7500 kg, 2.6 MW, 90 Hz
coreless induction furnace
Metal Type:
3.5-4% Mg, 95% Al
Previous Refractories:
dry vibratable
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Refractory Failure Mode:
Cracking and finning in the upper 50% of the furnace due to mechanical
abrasion and thermal shock. The cracks appear as randomly spaced
rectangular arrangement. This coreless induction furnace would typically
exhibit a 3 to 4 month lining life. Metal charge includes chips and
blocks. Over time, through thermal cycling, regular hot and cold cleaning
of dross from the refractory sidewalls, and impact from heavy charge, the
lining would crack, eventually developing macro cracks to the point of
metal penetration and failure. FRDV was used to replace the
traditional dry vibratable in the side walls only, due to cost
constraints. In essence, this furnace used a zoned lining.
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FRDV experimental trial results:
The FRDV lining allowed the same furnace to run for 9 months
compared to its previous 3-4 months. After 9 months the lining was
removed for inspection and there was no noted metal penetration into the
lining. This particular customer has continued to use the FRDV
technology with lining life averaging between 7-9 months. This customer
also has control chemistry specifications which include ultra low levels
of iron and therefore monitors chemistry on a regular basis.
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Case Study:
Furnace Type:
20 tonne channel induction
furnace, 6-150 kW water cooled inductors
Metal Type:
zinc
Previous Refractories:
aluminosilicate castables,
fused silica castables
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Refractory Failure Mode:
Cracking after predrying and
cracking during transport of the inductor to the furnace. This channel
induction furnace has been used to melt zinc for over two decades. The
refractories used in the inductor were traditional calcium aluminate low
cement bonded fused silica and aluminosilicate castables. These castables
required a preheat cycle to remove the wooden loop form and the free and
chemically bonded water prior to being put into service. Historically,
these inductors randomly formed hairline cracks either during preheat or
mounting of the inductor. A second issue was the unpredictable life in
the inductor due to finning.
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FRDV experimental trial results:
An alumina-based dry vibratable with non-wetting agents and FRDV
technology was installed in one inductor. There was no cracking upon
preheat or form burnout. The inductor remains in service some 16 months
after being put into service. The regularly monitored metal chemistry
indicates no problems with zinc metal contamination. This customer has
since replaced three other inductors with this FRDV technology with
equal success.
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Fiber Reinforced DRI-VIBE®
Technology for Aluminum Induction Melting
Fiber Reinforced
DRI-VIBE®
Technology for Zinc and Galvalume Induction Melting
Fiber Reinforced
DRI-VIBE®
Technology for Zinc and Galvalume Coating Pots
Allied Mineral Products Inc.
Phone: 614-876-0244 Fax: 614-876-3133
sales@alliedmin.com
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