Foundries

A unique package solution

Höganäs Borgestad offers foundries a unique package solution that includes all necessary materials and installation. Our long experience makes us one of the Nordic region’s leading supplier to the foundry industry.

With increasing demands for cost-effective refractory solutions, we continuously develop products and concepts to meet customer requirements and desires:

• Increased lining life
• Reduced production losses
• Effective and economical linings
• Reduced energy costs
• Reduced installation time
• Improved repair techniques

Induction Furnaces (CIF)

This is the most used furnace for the foundry industry. The furnace is used to produce many different alloys; e.g. gray iron, ductile graphite iron, steel, copper and aluminum alloys.

The stirring effect of a CIF oven makes it an ideal unit for alloy manufacturing. The atmosphere can be controlled, thus the metallurgical losses can be minimized. The industry is currently investing in rapid melting mid-range CIF heaters.

Höganäs Borgestad and Sibelco have a cooperation and extensive experience with refractory linings for CIF furnaces. We can offer a complete installation with monolithic insert which includes all heat-resistant materials for the furnace (melt lining, prefabricated block, coil cement, lid, laundersystem, etc.) for many different adaptations and operating conditions.

In the foundry industry, our FinMix is; Dry Vibratable Mixes (DVMs), based on our unique Finnish microcrystalline quartz, have become standard for CIF ovens. We can also offer neutral and basic DVMs, adapted to different melting processes.

Höganäs Borgestad has a great focus, and attention to, the installation process and has developed special installation equipment together with our suppliers.

Channel –type Induction furnaces

There are several types of induction heated channel – type furnaces, depending on the alloy to be produced, for example:

• Holding furnace
• Melting furnace
• Casting Furnaces
• Continuous casting

The main type of furnaces are holding and casting furnaces. The capacity of tunnels can hold up to 150 tons of iron. Refractory lining can reach a service interval of 5 years, with replacement of the induction lining at shorter intervals. Casting furnaces, processed with air or nitrogen, can process units with weight up to 20 tons, but 5 to 10 tons are the most common. The most common adaptations are for melting ductile iron and gray iron.

Channel- type furnaces can be used for melting, heat storage and casting of copper.

The inductor is the critical component of a Channel- type furnaces since it is the heating element throughout the furnace. For furnaces intended for both iron and copper smelting, the inductor must be single or double loop, or core free.

The chemistry of various alloys, and the increasing demands on production volumes, have affected the development of our products and concepts.

Höganäs Borgestad concept for lining channel furnaces is based on knowledge and references from a long collaboration with leading foundries. This knowledge is not only based on refractory materials. We can offer solutions for all furnaces with a complete product area consisting of safe, neutral and basic products from castables, gunning materials, self-flowing, dry vib. and vibration materials. Furthermore, we offer expertise to the actual melting process, and of course the installation and maintenance of furnace linings. Refractory material and knowledge are available for all types of iron and copper melting processes.

Crucibles / Ladles

The crucibles are primarily used for transporting liquid metal from furnace to mold (ductile iron is often treated in the ladle). Accuracy in the execution and operation of the ladle is important regardless of whether it is a ladle only for transportation or also for the treatment of ductile iron.

Höganäs Borgestad can offer a complete range of products and solutions for all alloys and applications. Focus on heat loss and lower energy consumption. With a focus on the importance of labor costs, an efficient and reliable ladle lining can provide significant savings.

Different solutions for different needs

Selection of refractory for ladles depends on several parameters; ladle size, shape, alloy, operating temperatures and practice, and of course metallurgical process. Höganäs Borgestad can therefore deliver a wide range of solutions.

Bricks in Ladles

Ladles  can be lined with refractory bricks or refractory castables. In most cases we recommend Bricks as the products are pre dried, and therefore provide a more stable end result. Castables  are easier to install, but must have controlled drying and heating.

We can offer:

• Chamotte bricks with 40% Al₂O₃
• Aluminum oxide bricks with 70% Al₂O₃