Casthouse

Casthouse

Unique refractories for unique furnaces!

Almost all casthouse, melting and holding furnaces have one thing in common — each one is unique! That’s why we have developed a comprehensive range of refractory solutions to improve the performance of your unique production.

In furnace linings, the focus is to maintain a stable heat balance throughout the furnace’s lifetime, and keep the isotherm for the freezing point of the metal within the hot face lining to minimize the risk of a breakout of molten metal. We offer a number of flexible, proven solutions — based on bricks, monolithics and prefabricated shapes — that will help you to do this.

Designing the lining is an also a matter of finding the right balance between output volume and the lining’s functional lifetime, the thicker the brick, or castable lining, the longer its life. In addition, identifying the right amount of insulation is an important factor in getting the best solution.

The extreme environment of the holding furnace makes renovation an ongoing process, regardless of the quality of the refractories and their installation. Höganäs Borgestad offers a full maintenance support.

Standard Casthouse materialsProcessing ConditionsSolution
Casthouse
Furnace materials above bath level
Melting / Holding
Hot Face:
HÖGANÄS BORGCAST 51
HÖGANÄS Cast / Gun LC 60
ALEX BRICKS
VIKING 330 BRICKS

Medium Insulation:
HÖGANÄS Insul CC 1.5
BORG 25R

Light Insulation:
HÖGANÄS Insul CC 1.0
SUPERWOOL PLUS BLOCK
Casthouse
Furnace materials below bath level
Melting / HoldingHot Face:
ALSAFE 90 BP (BRICK)
HÖGANÄS Flow LC 75AL (MONOLITHIC/PRECAST)

Safety layer:
HÖGANÄS Gun CC 50 AL

Insulation:
SUPER WOOL BLOCK
FLEXIPOR / WDS HIGH

*Most furnace conditions are unique and we design materials and technical solutions together with our customers for best furnace operations and reduced downtime. Please contact us for more information.

Our special brick for Casthouse hearth is Alsafe 90 BP is a phosphate bonded high alumina brick made with selective raw materials. To achieve desired end properties such as corrosion, infiltration, impact and alkali resistance in aluminum melting and holding furnaces

Alsafe 90 BP from HÖGANÄS BORGESTAD  is tested against the aluminum alloy AA 7278

according to the SINTEF procedure.

Alloy AA 7278:

Si < 0.15 %

Fe < 0.20 %

Cu 1.7 – 2.1 %

Mg 2.7 – 3.0 %

Zn 6.8 – 7.2 %

Cr 0.18-0.22 %

Results:

There was no sign of penetration or reaction between the Alsafe 90 BP and the aluminum alloy.