in ferrous foundry industry

in ferrous foundry industry

F e r r o u s Foundry Industry Requirements Ferrous foundries process a wide range of alloys for a variety of applications which all share a similar purpose: to melt and cast a metal in order to give it new shape and properties. Foundries keep envolving as they are driven by their downstream applications. Among them the automotive industry is by far the main and most important market. The foundry equipment has therefore evolved to support the needs of the automotive industry as well as other applications. Aside from the technological aspects of foundry applications, the main drivers of change, innovation, and improvement of foundry equipment are also reduction of emissions, increased efficiency and flexibility.

O u r solutions Seven Refractories has developed a full range of refractories to cover all needs of the foundry industry. Furthermore Seven Refractories is committed to support new market trends, especially those benefiting the environment and efficiency. Among the different products for foundry users, no cement chemical bond refractories are indispensable for the most demanding applications. They are monolithics based on a non-hydraulic bonding system which allows for higher permeability to gases and therefore much faster dry out. As crystallized water and low melting phases (CaO-SiO-AlO) are eliminated from the matrix, no cement chemical bond refractories also show superior high temperature properties. Our solutions for Cupola furnace Coreless induction furnace (CIF) Channel induction furnace Press-pouring fournace Channel inductors Coreless automatic press-pouring furnace Cover Rotary furnace Ladle No cement refractories should be considered in any refractory application with urgent need of and restart of operation or whenever it is difficult to perform a proper dry out. Aside from products, Seven Refractories is committed to offer the right technical and economical solution. Our R&D is available for the continuous improvement ad fine tuning of products to match the specific needs of the customers process. For example, we can run dedicated slag corrosion cup tests for our customers to forecast the behaviour of materials in working conditions as close as possible to the production process. Cup tests

. Cupola furnace Cupola furnaces have been the primary if not the only melting equipment used in foundries for a long time. They can remelt pig iron and scrap to produce different types of cast iron. As coke is burnt to generate heat it also generates relevant emissions to the atmosphere. In recent times considerable efforts have been made towards emission reduction or at least a rethinking of its usage in modern foundries. 7 Usage of cupola In terms of refractory linings, there are mainly philosophies: long campaign or daily cupola. Daily linings are mainly acid ramming masses that can be easily wreaked out and substituted, partially or totally, every day. In a long campaign cupolas linings are made of alumina based refractories that are adapted to the different zones. These can normally be operated one or two weeks before relining. Further developments are unlined cupolas where melting zone and stack have a water cooled shell which does not require refractories and can be operated for several weeks. 9 8 Long campaign Daily lining Charging zone gunning mix, regular castable gunning mix, regular castable abrasion, CO resitance Stack gunning mix, low cement castable gunning mix, low cement castable abrasion, thermal shock, CO resitance Melting zone SiC+ C castable or gunning mix, low cement castable Silica ramming or gunnig mix liquid metal corrosion, CO resitance Tuyere zone SiC+ C ramming mix Silica ramming mix thermal shock, metal corrosion, CO resistance Hearth SiC+ C castable, SiC+ C ramming mix Silica ramming mix liquid metal corrosion Siphon SiC+ C castable, SiC+ C ramming mix Silica ramming mix liquid metal corrosion 7 8 9 Structural components Tuyere Tubes

Launder of cupola furnace Products for long campaigns Seven Cast 0 RM Seven Cast 7 NB 0 Y -0 Seven Cast 7 NR 0 Y Seven Cast 98 NR Seven Cast 7 UB Seven Cast 7 UB Seven Cast 77 UX Seven Cast 70 UX Seven Cast UR Seven Gun 0 KH PLAST Seven Gun 8 NX - Seven Gun 70 NB Seven Gun 7 NB Seven Ram KX Seven Ram KX Seven Ram KX 0 X Seven Plast AKB charging zone stack stack melting zone melting zone, hearth, syphon box, runner melting zone, hearth, syphon box hearth, runner hearth, runner, syphon box hearth, syphon box charging zone stack melting zone melting zone hearth, runner, syphon box, tuyere zone hearth, syphon box, tuyere zone hearth, syphon box, tuyere zone tuyere zone Products for daily lining Seven Cast 0 RM Seven Cast 0 NM Seven Ram 8 K SIL Seven Ram 80 K SIL 0 V Seven Ram 7 K SIL 0 X Seven Gun 88 K SIL Seven Gun 0 NM Seven Gun 0 RM charging zone stack melting zone, tuyere zone tuyere zone, hearth hearth, syphon box melting zone stack charging zone No cement products for fast dry out Seven Cast 770 CB LCS Seven Cast 7 CB LCS melting zone, hearth, syphon box, runner melting zone, hearth, syphon box, runner

. Coreless induction furnace (CIF) The coreless induction furnace has become the main furnace in modern foundries due to its flexibility, ease of use along with reduced emissions. Size, power and frequency of these furnaces have increased during the years, they can be used both for melting and holding purposes. Silica based linings are dominantly used in to melt iron, while alumina based dry mixes are the most common refractory material in CIF used to melt steel. 8 0 9 7 Shell Top cap dry mix, low cement castable, patching material sintering behavior, liquid metal corrosion Spout low, ultra low cement castable thermal shock, liquid metal corrosion Upper ring and bottom low, ultra low cement castable thermal shock, liquid metal corrosion Working lining dry mix sintering behavior, liquid metal corrosion Safety lining low cement castable thermal shock, liquid metal corrosion 7 Slip plane mica foil 8 Slip plane mica + fiber foil 9 Coil grout trowelling material sticking and sealing behavior Structural components

CIF after lining with silica Products iron Seven Dry 98 CK SIL 08 Seven Dry 98 CK SIL 08 F Seven Dry 9 CK SIL Seven Patch 90 C SIL Seven Trow 80 RX - top cap Steel products Seven Dry 8 KP Seven Dry 8 KW 09 X Seven Dry 8 KB 09 W Seven Dry 8 KR 9 X Seven Dry 90 CKW 0 V Seven Trow 9 RR 08 Z - Seven Trow 9 CR 0 V -0 top cap Common products Seven Cast 0 UD Seven Flow 97 RR -0 Seven Trow 9 RR 08 Z - upper ring, spout, pusher safety lining coil grout No cement products for fast dry out Seven Cast 99 CF LCS Seven Cast 90 CR LCS Seven Cast 9 C SIL safety lining 7

. Channel induction furnace (body) It is the typical furnace used for holding purpose as a buffer between the casting line and the melting (cupola) furnace. The power is induced through the inductor in the bottom around a loop of molten metal, where failures of refractory lining are most likely to occur. The furnace is operated hours per day. Shell Spout low, ultra low, no cement castable resistance against molten metal, strength, thermal shock Pot low, ultra low, no cement castable resistance against molten metal, sintering behavior Pot safety lining regular castable, gunning mix strength, resistance against molten metal Pot insulating bricks, MW insulating castable thermal conductivity, strength Insulation second layer insulating boards thermal conductivity Products Seven Cast 9 UR Seven Cast 8 UX Seven Cast 98 UR Seven Cast 90 UB Seven Cast 9 UR 09 V -0 Seven Cast 9 ND Seven Cast 80 NX 0 V -0 Seven Cast 88 NR 0 W Seven Cast 80 RX 0 V Seven Cast 8 UB Seven Brick KM Sevenlite 0 LI Sevenlite 00 Insulation Fire Brick / Micro porous board Ceramic fiber board No cement products for fast dry out Seven Cast 80 CX LCS Seven Cast 90 CR LCS Seven Cast 7 CB 0 X LCS pot pot pot pot pot spout spout spout spout spout pot safety lining pot pot pot second layer second layer pot pot spout 8

. Press-pouring furnace (body) This evolution of the channel furnace is operated in inert atmosphere and allows for the finest control over temperature and poured volume along with high flexibility. Shell Spouts low, ultra low, no cement castable resistance against molten metal, strength, thermal shock Pot low, ultra low, no cement castable resistance against molten metal, strength Pot safety lining regular castable, gunning mix strength, resistance against molten metal Pot first insulating bricks, MW insulating castable thermal conductivity, strength Insulation boards thermal conductivity Products Seven Cast 9 UR Seven Cast 8 UX Seven Cast 98 UR Seven Cast 9 UR 09 V -0 Seven Cast 88 NR 0 W Seven Gun 8 NX Seven Brick KM Sevenlite 0 LI Sevenlite 00 Insulation Fire Brick / Micro porous board Ceramic fiber board No cement products for fast dry out Seven Cast 80 CX LCS Seven Cast 90 CR LCS pot and spout pot and spout pot pot and spout pot and spout pot safety lining pot safety lining pot pot pot second layer second layer pot and spout pot and spout 9

. Channel inductors COIL > Coil CORE > Core Inductor couplig patching or mouldable mix resistance against molten metal, patching behavior Inductor dry mix sintering behavior, resistance against molten metal Inductor insulating boards density, thermal conductivity Installation of channel inductor Products Seven Dry 8 KW 09 X Seven Dry 8 K MAG X Seven Dry 8 KP Seven Coat 88 CR - Seven Patch C ZIR Seven Cem 99 K CRO Micro porous board Ceramic fiber paper inductor coupling inductor coupling inductor coupling, separating mass 0

. Coreless automatic press-pouring furnace This furnace combines the features of CIF furnaces and channel press the furnace in the same set of equipment. Refractories for this application also meet a compromise of properties. The press pour channel is created inside the refractory lining. 8 9 7 Shell Casting nozzle ultra low cement castable, precast shape liquid metal corrosion, thermal shock Inlet outlet basin regular, low cement and ultra low cement castable liquid metal corrosion, thermal shock Bath and press pour channel dry mix, ramming mix sintering behavior, liquid metal corrosion Bath safety lining self flowing castable patching behavior, resistance to liquid metal Supporting ring low and ultra low cement castable strength, liquid metal corrosion 7 Lower ceramic paper, micro porous board thermal conductivity 8 Upper gunning mix, micro porous thermal conductivity, strength 9 Slip layer mica foil Slip layer mica foil Products: Seven Dry KD 0 V Seven Ram KX 0 X Seven Cast 80 RX 0 V Seven Cast 88 RBX Seven Cast 9 UR Seven Cast 80 UB -0 Seven Cast 0 UD Seven Cast 77 UX Seven Flow 80 NB Seven Flow 8 UX Seven Flow 0 ND 0 W Seven Plast 8 CX - Seven Gun RH CO Seven Gun 7 RH 0 V CO Sevenlite 00 Micro porous board bath and press pour channel bath and press pour channel of inlet outlet basin, cover, supporting rings supporting rings inlet outlet basin inlet outlet basin supporting rings, spout inlet outlet basin inlet outlet basin, bath safety ling inlet outlet basin, bath safety ling, supporting rings, nozzle bath safety lining, inlet outlet basin of inlet outlet basin of inlet outlet basin of inlet outlet basin upper upper and lower

7. Cover Shell Working lining regular, low, ultra low cement castable thermal shock Insulation LW, MW insulating castable thermal conductivity, strength Products Seven Cast 9 ND Seven Cast 0 UD Seven Cast 9 RR Seven Cast NH CO Seven Cast 00 LW Sevenlite 0 LI Sevenlite 00 Ceramic fiber board, special product for improved 8. Rotary furnace This simple furnace has become popular in some countries as a simple alternative to the cupola furnace in order to reduce emissions to the atmosphere, but without using electrical power. Shell Cap Insulation insulating board thermal conductivity Working lining wet ramming mix, gunning mix sintering behavior, resistance to molten metal Rim low, no cement castable, wet ramming mix sintering behavior, resistance to molten metal Products Seven Ram 90 K SIL Seven Gun 88 K SIL Seven Trow 80 RX - Seven Patch 90 C SIL Seven Cast 9 C SIL Ceramic fibre board Micro porous board No cement products for fast dry out Seven Cast 99 CF LCS, rim, rim,

9. Ladle Precast ladle Shell Working lining low, ultra low, no cement castable, self flowing, dry mix resistance to molten metal, strength Insulation insulating board thermal conductivity, strength Products iron Seven Cast 9 ND Seven Cast 0 UD Seven Cast 0 ND Y Seven Flow 0 ND 0 W Seven Flow 0 ND Z Seven Cast 8 UX Products steel Seven Cast 9 UR 09 V -0 Common products Seven Trow 80 RX - Seven Trow 9 RR 08 Z - Seven Plast 8 CX - Seven Trow 0 RM - Micro porous board Ceramic fibre board No cement products for fast dry out Seven Cast 0 CD Y LCS Seven Cast 90 CR LCS Seven Dry KD, special product

S e r v i c e s provided Preliminary study and investigation for the entire project Design and architecture including bill of materials and thermal calculation Full range of products for lining and maintenance Regular, low, ultra-low and no-cement castable Regular and dense low-cement gunning mix Ramming Shotcreting Self flowing Supply of mixer, gunning machines, pump, etc. Training on mixing, gunning and maintenance techniques Training on equipment usage Supervision and monitoring by experienced technicians Global research & development Technical advice by experts Monitoring and targeting of results Slovenia Seven Refractories d.o.o. Poslovna cona Risnik 0, Divača Tel. +8 79 7 0 Ukraine Seven Refractories Ukraine LLC 8-B, st. Rosa Luxemburg 800 Donetsk, Donetsk Region Tel. +8 0 09 0 Austria Seven Refractories GesmbH Landstraßer Hauptstraße 88/7 00 Wien Tel. + 7 0 88 08 Russia Seven Refractories LLC Liteyny prospekt,, liter A, premise 7, office 908 Saint-Petersburg Tel. 0078 7() Fax 0078 7() 0 Germany Seven Refractories Deutschland GmbH Becherstraße 0 07 Düsseldorf Tel. +9 770 Italy Seven Refractories Srl Via Carlo Mussa 8 07 Castellazzo Bormida Tel. +9 0 7 88 8 Kazakhstan Seven Refractories Asia Quarter 08, block 8, Bukhar-Zhirau district 0008 Doskey, Karaganda Tel. +77 0 077 info@sevenrefractories.com www.sevenrefractories.com ISO 900 ISO 00 0-07