By Peter R. Whiteley
From the eighth Australasian convention on Aluminium Casthouse expertise in Brisbane, Australia, September 14-17, 2003
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Castable in the ramps and sills. The most commonly used castables in the market is as follows: Material Bond type Hydraulic Max. service temperature 1400 C Refractoriness °C (Seger cone) 1785 (35) Bulk density kg/m3 2820 Albond/ Calcined bauxite Alcast extra HS/bauxite Mideast calcined bauxite Plasram/ bauxite Hydraulic 1400 C 1650 (29) 2900 Hydraulic 1500 C 1750 (34) 2560 Chemical 1700 C 1790 (36) 2750 53 Typical Aluminum Furnace Lining Design Considerations During the 1960's "freeze plains" were the basis of good design for all below metal level refractory linings.
C. castables, used in different areas of aluminum furnaces including bauxite, high alumina, zircon, silicon carbide, mullite, and fused silica. All of them show corundum growth eventually if the conditions are severe enough. So what conditions promote corundum growth? Essentially there are two major factors which affect the rate of corundum growth: (1) Metal/furnace temperature. (2) Type of alloy. It is a general rule that the rate of chemical reactions is increased as temperature is increased and the corundum reaction is no exception.
50% marks in each cast is given against final inspection. The conformance level for each cast is then calculated and is linked with the performance of shift incharges. Quality Improvement Projects Many quality improvement projects were under taken by Strategic Quality Maintenance committee to solve chronic problems and to improve the conformance levels. Few of the major projects undertaken are listed below : Casting oil development for billet casting The recommended casting oil could not be procured due to its non-availability in India and consumption being very small, making it difficult to import.
Aluminium Cast House Technology VIII by Peter R. Whiteley