|Steel ladle linings|
The Foseco range of ladle technology and engineered refractory solutions for steel ladles to optimize thermal efficiency, metallurgical quality and cost effectiveness.
KALTEK Insulating Ladle Lining Systems
KALTEK ladle linings offer superb thermal insulation compared to conventional refractory systems. The use of insulating linings allows foundries to adopt a lower tapping or holding temperature practice and to reduce the variation in metal pouring temperatures. This results in improved control of metal chemistry, lower energy consumption, a reduction in furnace refractory consumption, and fewer slag inclusions and temperature-related casting defects.
Reduction in ladle maintenance and direct labor costs for assembly can also be realized through the use of KALTEK ladle linings. Most KALTEK linings can be installed quickly, with minimum training, and without the need for capital investment. The linings can be used for a single heat in batch processes or reused after repeated thermal cycles.
KALTEK insulating ladle linings are available in a variety of forms to meet individual customer requirements:
Preformed Boards Systems
KALTEK board linings are prefabricated outside the ladle and then positioned in the ladle shell. Suitable for bottom, lip and teapot pouring, KALTEK board lining systems are available for ladles up to 45 tons capacity.
Preformed One-Piece Linings Shanks
KALTEK shanks are preformed, one-piece linings for lip pour and teapot ladles ideally suited for the transfer and pouring of molten steel. KALTEK shank linings are available for ladles of up to 1 ton capacity and can last for up to 50 fills.
KALTEK ISO castable powder is bonded by an inorganic exothermic reaction. It is a durable lining system that can be applied in ladles of virtually any size.
The life and performance of KALTEK ISO powders can be further enhanced by the application of KALTEK ISOpatch repair material. Slag and oxide build up can be rapidly and easily removed, prolonging the life of the ladle lining and improving melt cleanliness.
The benefits of using KALTEK insulating ladle linings
Lower tapping and holding temperatures and more consistent pouring temperatures will reduce the risk of temperature related defects. Further, use of KALTEK linings as part of a clean metal practice will lead to fewer slag inclusions.
KALTEK systems are simpler and faster to install than other liner systems and require less maintenance. KALTEK systems are virtually always more economical than alternative practices when production rate and casting quality improvement are taken into account.
KALTEK systems can help reduce the variability a foundry's melt process. A more robust process at lower, more consistent temperatures, is an important tool in the effort to produce superior metallurgical and physical properties in the finished product.
Advantages of the KALTEK system:
• improved metallurgical control;
• a high level of molten metal temperature control;
• reduced labor costs;
• lower energy costs;
• safer, cleaner working environment;
• improved productivity;
• cold start – no need for preheat.
FERRUX APC exothermic/insulating ladle cover powders
Exothermic/insulating ladle cover powders prevent heat loss most effectively. Designed for use directly on the metal in the ladle, before and during casting.
Precast Shapes, Castables and Ramming Mixes
Dense pre-cast refractory linings or segments such as bottoms, lip rings, nozzles, pocket blocks and impact pads.
CRITERION low cement castable
A range of low cement castables, supplied dry for mixing and placement on site, it must be installed behind suitable formwork by internal or external vibration. CRITERION low cement castable is ideally suited as a durable ladle lining for all grades of cast steel.
KALPAK rammable refractory
KALPAK rammable refractory is used to secure nozzles.
KALSEAL/SUREBOND are mortars used for bonding and sealing refractory shapes.
BLU-RAM HS and BLU-RAM HSW ready-to-use phosphate-bonded plastic materials are ideally suited for application as a repair material or for the lining of spouts and small ladles. BLU-RAM HS is moldable version for easy installation without formwork.