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INSURAL furnace lining system for aluminium foundries saves energy and reduces downtime

Foseco has developed a new, insulating lining system for use in dosing and low-pressure furnaces in aluminium foundries. The system, based on Foseco’s INSURAL range of non-wetting and insulating refractories, offers numerous benefits to the foundryman.

The adoption of energy efficient furnaces in aluminium foundries is widely regarded as best-in-class. However, the efficiency of these furnaces is often undermined by the choice of refractory lining. Foseco is now able to supply a new, multi-part and highly insulating lining made of INSURAL. The lining, which is delivered ready to install, combines energy savings in combination with long service life and resistance to oxide build-up.As the majority of the lining system is made of pre-cast INSURAL shapes, the installation can be completed in just three days, either by the foundry or by a refractory installation company.Unlike traditional linings, no sintering is necessary! The furnace just needs to be pre-heated and maintained at working temperature for 48 hours. It is then ready for service.The INSURAL furnace lining system is completely dry. As a consequence, hydrogen pick-up from a new lining system is negligible and the melt density index goal can be achieved within a very short period following installation. Furnace downtime is dramatically reduced and the risk of increased scrap avoided. Due to the inherent non-wetting behaviour of the lining system, corundum growth is minimal and cleaning of the furnace simplified.

The target: Fast turnaround. The solution: Dry installation of INSURAL precast, insulating shapes. The benefits are:

  • No sintering required
  • Significant energy savings
  • Extremely low corundum growth
  • Improved melt quality
  • Reduced hydrogen level after commissioning
  • Reduction of energy peaks
  • Can be installed on or off-site
  • Minimised downtime
  • Immediate achievement of a constant density
  • Easy to clean

Contact: Paul Jeffs, UK technical manager, email: [email protected]