Monolithic Concept foundry Solutionsrevicol.com.co/wp-content/uploads/2018/11/Calderys_Foundry.pdf · Monolithic concept solutions for Ferrous Foundry Channel Holding Furnaces The

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Monolithic Concept Solutions

ferrous foundry

FOUNDRYINDUSTRY

�Monolithic concept solutions for Ferrous Foundry

Innovative Refractory Solutions and Concepts for the Ferrous Foundry Industry

Calderys has been well established in

the global foundry market for more

than half a century. By combining

all our products, knowledge and

experiences, we are able to offer

a comprehensive set of refractory

solutions and concepts for ALL

segments of the Ferrous Foundry

Industry, from the initial design to

thermal calculations, lining profiles and

ultimate installation services.

We have a comprehensive monolithic

product portfolio that has been

specifically designed for the Ferrous

Foundry market. In addition, we supply

a wide range of pre-cast shapes,

including cupola slag/drain/tap tubes,

channel spout blocks, ladles, convertor

plates, CIF push plugs/ring blocks as

well as purging plugs, nozzles, lances

and burner blocks.

Furthermore, our dedicated Research

and Development team has a

program that ensures the continual

improvements in the performance of

our products and in the way that they

can be installed and sintered/dried.

Our worldwide presence and local

experience allows us to propose the

most suitable cost effective and

technical solutions that will contribute

to our customer’s productivity and

efficiency.

� Monolithic concept solutions for Ferrous Foundry

Hearth

CASTABLe

CALDE™ CAST G 7 P

CALDE™ CAST G UC 52S40



CALDE™ CAST G UC 70S20 ED


CALDE™ CAST G UT 62S30

RAMMeD LINING

CALDE™ RAM G B 55S20



CALDE™ RAM G C 65S20

Manhole / Tuyere protection

RAMMeD LINING

CALDE™ PLAST G C 65S20





Syphon Box

CASTABLe

CALDE™ CAST G 7 P




RAMMeD LINING



Runner

CASTABLe

CALDE™ CAST G 7 P

CALDE™ CAST G UB 68S18


RAMMeD LINING



Liningless Long Campaign Cupolas


Lined Long Campaign Cupolas

Melting Zone

CASTABLe

CALDE™ CAST 40 TR

CALDE™ CAST G 7 P


GUNNING MATeRIAL

CALDE™ GUN G C 75S10

CALDE™ GUN G M 33 GSP

Charging Zone

GUNNING MATeRIAL

CALDE™ GUN F 55 CO

CALDE™ GUN F 56 CO

Stack

CASTABLe

CALDE™ CAST LA 60 Z

CALDE™ CAST LZ 106

GUNNING MATeRIAL

CALDE™ GUN M 32


Spout

CASTABLe

CALDE™ CAST 1560

CALDE™ CAST MB 80

CALDE™ FLOW AZ

RAMMING

CALDE™ PLAST 85 S

PReFAB.

Alternatively: prefabricated shape

Coil grout

GROUTING

CALDE™ PATCH C 90

CALDE™ STIX T 90 G1

Coreless Induction Furnaces

have been a major primary melting unit

in the ferrous foundry industry for

many years.

The demands placed on the refractory

lining are varied and sometimes very

complex, bringing very different sets

of circumstances that can affect the

performance of the refractory lining,

including:

• Thermal Shock

• Lining Wear

• Gas Penetration

• Slag Build up.

Thermal Shock

• The constant thermal cycling

of the refractory lining.

Lining Wear

• Erosion due to the physical

movement of the liquid metal.

• Corrosion due to the aggressive

chemistry of the metal and /or slag.

Gas Penetration

• The unwanted movement of gasses

through the refractory lining such as

carbon monoxide, zinc vapour and

steam

Slag Build up

• The deposition of oxides on the

refractory lining.

You will find in the following pages of

this brochure the products that can be

considered for each area of a Coreless

Induction Furnace depending on the

operational conditions.

Coreless Induction Furnaces


Upper & lower support rings

CASTABLe

CALDE™ CAST 1560

CALDE™ CAST UB

Top cap

CASTABLe


PATCHING MATeRIAL

CALDE™ PATCH PB 82 U

Hot face lining

IRON - DVM

SILICA MIX

SILICA MIX 4

SILICA MIX 5

SILICA MIX 7

SILICA MIX Q

SILICA MIX QVF

SILICA MIX Z

STeeL - DVM

CALDE™ MIX SC 76 M12



Pusher block

CASTABLe

CALDE™ CAST 1560

CALDE™ CAST UB

Hot face repair

IRON

CALDE™ PATCH HQ 22 U




CALDE™ STIX 151

STeeL

CALDE™ PATCH HC 80 M


CALDE™ PATCH PT 88 R

Safety lining

INSULATION

Ceramic fibre board /Combifoil

Coreless Induction Furnaces Iron-Steel

Cover

CALDE™ CAST F 60 G10

CALDE™ CAST F 65

Safety lining

CASTABLe

CALDE™ FLOW LA 58 Z


Channel Holding Furnaces

The need for higher productivity and lower

costs has placed increasing demands on the

refractory lining. Due to various stresses

placed on the refractory lining, new materials

and designs had to be developed to offer the

best lining solutions to our customers.

Main stresses in a holding furnaces are the

following:

erosion mainly in the inlet spout where the

iron flows with a very high speed especially

if the melt is fed into the furnace by using

big transfer ladles.

Design solutions and very abrasion resistant

refractories are needed.

Corrosion occures in the slag line of the

vessel and in the lower part of the inlet

spout if aggressive slag is transferred into

the channel holder or if too much oxygen is

entering the furnace.

An aggressive slag can be formed by certain

desulphurisation methods or by galvanised

steel scrap used in the primary melting unit.

Highly corrosion resistant refractories have to

be selected together with intelligent design

solutions for the inlet spout area.

Overheating of the inductor throat lining is

the result of slag build up in the upper part

of the inductor throught. The heat exchange

between the inductor and the upper vessel

can be significantly reduced.

Refractories with a high slag sticking

resistance are needed.

You will find in the following pages of

this brochure the products that can be

considered for each area of a channel holding

or pouring furnace.

The best refractory solution for your

application has to be discussed with our

technical sales team.


Insulating lining

Ceramic fiber board

Safety lining

GUNNING

CALDE™ GUN M 32

BRICK

Super duty fire bricks

Wall & bottom insulating lining

GUNNING

CALDE™ CAST MW 140 C/G

BRICK

Light fire bricks

Spout & upper door

CASTABLe

CALDE™ CAST G LC 80S5

CALDE™ CAST LT 94 SP

CALDE™ CAST T 96

CALDE™ CAST UB

CALDE™ CAST UT 86 S

CALDE™ CAST UT 94

Hot face lining

CASTABLe


CALDE™ CAST LT 98 L

CALDE™ CAST T 96

CALDE™ CAST UB

CALDE™ CAST UT 94

Channel Holding Furnaces Lining with Castable

10 Monolithic concept solutions for Ferrous Foundry

Hot face lining

DVM

CALDE™ MIX BC 90 Z R

CALDE™ MIX BT 98

CALDE™ MIX SA 68 S

CALDE™ MIX SC 88 S R

Spout & upper door

CASTABLe

CALDE™ CAST G LC 80S5


CALDE™ CAST T 96

CALDE™ CAST UB


CALDE™ CAST UT 94

Wall & bottom insulating lining

BRICK

Light fire bricks

Channel Holding Furnaces Lining with DVm

Insulating lining

Ceramic fiber board

Safety lining

BRICK


11Monolithic concept solutions for Ferrous Foundry

Channel Holding Furnaces Covers

Hot face lining

CASTABLe

CALDE™ CAST F 65

CALDE™ CAST T 94

Topping

1 LAYeR

CALDE™ MAG COAT G 93

2 LAYeR

CALDE™ PATCH SC 88

CALDE™ PATCH SC 90

� LAYeR

CALDE™ PATCH OZ 96

Lining

DVM

CALDE™ MIX M S 86 BTI

CALDE™ MIX SC 86 NTI

Insulation layer

Ceramic fibre board

Insulation

CALDE™ CAST LW 134 CO C/G

CALDE™ GUN MW 130

Anchors

Ceramic Hanger bricks

Steel anchors

Insulation layer

Ceramic fibre paper

Channel Holding Furnaces Inductors

12 Monolithic concept solutions for Ferrous Foundry

Vessel hot face lining

CASTABLe


CALDE™ CAST LT 98 L

CALDE™ CAST T 96

CALDE™ CAST UB

DVM (not for inlet and outlet)

CALDE™ MIX BB 84

CALDE™ MIX BC 90 Z R

CALDE™ MIX BT 98

CALDE™ MIX SA 88 S R

CALDE™ MIX SC 68 S

Solutions for channel holding/pouring furnace repair

VeSSeL COLD RePAIR

CALDE™ CAST AF 470

CALDE™ FLOW LB 85

CALDE™ FLOW MA 92

INDUCTOR FLANGe RePAIR

CALDE™ TROWEL HC 90 U

Vessel safety lining

GUNNING

CALDE™ GUN M 32

Brick


Insulation plate

Ceramic fibre board

Channel Pouring Furnaces

Vessel insulating lining

GUNNING


Brick

Light fire bricks

Cover insulating lining

GUNNING

CALDE™ CAST LW 134 CO C/G

Cover hot face lining

CASTABLe

CALDE™ CAST F 65

CALDE™ CAST T 94

1�Monolithic concept solutions for Ferrous Foundry

Receivers

Vessel hot face lining

RAMMING


CASTABLe


CALDE™ CAST LX 58

CALDE™ CAST UB


Cover hot face

CASTABLe

CALDE™ CAST LM 70

CALDE™ CAST LX 50

CALDE™ CAST UB

Vessel / cover insulating lining

GUNNING


Insulation

Insulation plate

1� Monolithic concept solutions for Ferrous Foundry

Hot face lining

CASTABLe

CALDE™ CAST LX 58

RAMMING

CALDE™ RAM PF 55

Hot face lining - Iron

CASTABLe

CALDE™ CAST LB 84 G10

CALDE™ CAST LX 58


CALDE™ CAST UB

CALDE™ FLOW AZ

CALDE™ FLOW LA 52 Z

CALDE™ FLOW LM 80

ramming

CALDE™ RAM PF 55

Repair/maintenance

PATCHING/COATING

CALDE™ GUN B 55 M


CALDE™ STIX F 55 G3

CALDE™ STIX M 65 G3

Segment

Prefabricated shape

Treatment Vessels (GF Converter)

Vessel insulating lining

Prefabricated shape

Hot face lining - Steel

CASTABLe

CALDE™ CAST T 94

CALDE™ FLOW MA 92

Insulation

Insulation plate

Iron & Steel Transport, Pouring & Treatment Ladles

D1

D2

H

1�Monolithic concept solutions for Ferrous Foundry

Gas Purging Plugs

Type* D1 (mm)

D2 (mm)

H (mm)

Vol. (dm3)

SP �000/1�0 72 128 130 1.05

SP �000 59 128 165 1.18

SP �000 59 182 278 3.45

SP ��00 100 182 270 4.33

SP ��00/1�0 135 182 160 3.28

*Further types on request

All plugs are available with: a) direct porosity with slots or with ring channelb) non-direct porosity in quality “CALDe™ RAM LT ��“

Product name main component

Binding system

max. grain size

Chemical analysis (wt %) material required

(t/m3)

Permanent linear change (%)

CCS (N/mm2)

Al2O

3SiO

2mgO

CALDE™ CAST 41 Tabular Alumina Hydraulic 6 96 0.1 2.82 -0.1

(1200°C)+0.2

(1600°C)60

(1200°C)65

(1600°C)

CALDE™ CAST LT 90 SP G8Tabular

Alumina/ Spinel

Hydraulic 8 92 0.1 5 3.2 +0.1 (1200°C)

-0.15 (1600°C)

140 (1200°C)

200 (1600°C)

CALDE™ CAST LT 96 SPTabular

Alumina/ Spinel

Hydraulic 6 96 0.1 2.2 3.25 0 (1200°C)

-0.25 (1600°C)

140 (1200°C)

200 (1600°C)

CALDE™ CAST TL 95 SPTabular

Alumina/ Spinel

Hydraulic 6 96 0.1 2.2 3.15 -0.1 (1200°C)

-0.1 (1600°C)

80 (1200°C)

160 (1600°C)

CALDE™ RAM LT 98 (porous) Tabular Alumina Hydraulic 1 97 0.2 2.65 +0.05

(1300°C)+0.1

(1600°C)40

(1300°C)75

(1600°C)

1�

Technical Data

Monolithic concept solutions for Ferrous Foundry

Product name Main component Max. recomm. temp. (°C)

Chemical analysis (wt %) Material required

(t/m3)Al2O

�SiO

2MgO SiC ZrO

2

CASTABLeS

CALDE™ CAST LW 134 CO C/G Chamotte/Perlite 1340 42 46 - - - 0,95 (cast)

CALDE™ CAST MW 140 C/G Insulating Chamotte 1400 42 43,6 - - - 1,3

CALDE™ CAST 1560 Andalusite 1650 59 36 - - - 2,5

CALDE™ CAST 40 TR Tabular Alumina 1820 95 0,1 - - - 2,67

CALDE™ CAST AF 470 Andalusite 1650 70 24 - - - 2,61

CALDE™ CAST F 60 G10 High Alumina 1500 62 30 - - - 2,25

CALDE™ CAST F 65 Chamotte 1650 65 30 - - - 2,35

CALDE™ CAST G 7 P* Corundum 1650 72 2,5 - 19,5 - 3,1

CALDE™ CAST G LC 80S5* Corundum 1650 78 6,3 - 4,9 - 3

CALDE™ CAST G UB 68S18* Bauxite/ Corundum 1650 68 6,7 - 18,6 - 2,95

CALDE™ CAST G UC 52S40* Corundum 1650 52 3,4 - 39 - 3

CALDE™ CAST G UC 60S30* Corundum 1650 62 3 - 29 - 3,1

CALDE™ CAST G UC 65S25 Corundum 1650 66,5 - - 24,3 - 2,9

CALDE™ CAST G UC 70S20 ED Corundum 1650 72 2,5 - 19,5 - 3,1

CALDE™ CAST G UC 75S15 Corundum 1650 75 3 - 14,5 - 3,1

CALDE™ CAST G UT 62S30* Tabular Alumina 1650 63 1,5 - 32 - 2,95

CALDE™ CAST LA 60 Z Andalusite 1650 57,5 29,7 - - 9,6 2,8

CALDE™ CAST LB 65 Bauxite 1600 67 28 - - - 2,5

CALDE™ CAST LM 70 High Alumina 1650 70 26 - - - 2,51

CALDE™ CAST LT 94 SP Tabular Alumina/ Spinel 1850 92,5 - 5,3 - - 3,15

CALDE™ CAST LT 98 L Tabular Alumina 1850 98 0,2 - - - 3,2

CALDE™ CAST LX 50 Chamotte 1520 52 43 - - - 2,42

CALDE™ CAST LX 58 Andalusite 1650 57 38 - - - 2,53

CALDE™ CAST LZ 106 Zircon 1600 29 24 - - 43 3,25

CALDE™ CAST MB 80 Bauxite/ Corundum 1600 83 11 - - - 2,69

CALDE™ CAST T 94 Tabular Alumina 1800 94 0,2 - - - 2,75

CALDE™ CAST T 96 Tabular Alumina 1750 96 0,1 - - - 2,85

CALDE™ CAST UB Bauxite 1680 84,3 11,5 - - - 3

CALDE™ CAST UT 86 S Tabular Alumina 1800 86,1 6 - - - 3,15

CALDE™ CAST UT 94 Tabular Alumina 1800 93 6 - - - 3,15

* Hydrogen release product

1�

Technical Data




(t/m3)Al2O

�SiO

2MgO SiC ZrO

2

SeLF FLOW CASTABLeS

CALDE™ FLOW AZ Andalusite 1650 59 28,4 - - 9,6 2,8

CALDE™ FLOW LA 52 Z Andalusite 1700 52 28 - - 17 2,85

CALDE™ FLOW LA 58 Z* Andalusite 1650 59 - - - 9,6 2,7

CALDE™ FLOW LB 85 Bauxite 1600 84,5 9,5 - - - 2,8

CALDE™ FLOW LM 80 Tabular Alumina 1750 76 20 - - - 2,7

CALDE™ FLOW MA 92 Tabular Alumina/ Spinel 1850 92 0,6 5,4 - - 2,9

CALDE™ FLOW UT 80 SZ* Tabular Alumina 1700 80 7 - 9,3 - 2,85

GUNNING PRODUCTS

CALDE™ GUN B 55 M Bauxite/Magnesia 1500 52 18 24 - - 2,5

CALDE™ GUN F 55 CO Chamotte 1500 55 35 - - - 2,3

CALDE™ GUN F 56 CO High Alumina 1450 56,5 33,5 - - - 2,4

CALDE™ GUN G B 70S10 Bauxite 1650 69,5 - - 9,6 - 2,3

CALDE™ GUN G C 75S10 Corundum 1750 76 4,9 - 9,6 - 2,5

CALDE™ GUN G LC 70S20 Corundum 1650 68,5 - - 19,1 - 2,7

CALDE™ GUN G M 33 GSP Bauxite 1650 62,5 7,8 - 19,2 - 2,3

CALDE™ GUN M 32 Bauxite 1650 79,5 13,4 - - - 2,75

CALDE™ GUN MW 130 Insulating Chamotte 1300 36,5 44 - - - 1,3

COATING PRODUCTS

CALDE™ MAG COAT G 93 Magnesia 1600 0,8 4,7 92,5 - - 2,42

DVM’s

CALDE™ MIX BB 84 Bauxite 1750 84 11 - - - 2,8

CALDE™ MIX BC 88 S Corundum 1670 87,5 4,6 - 5 - 3,05

CALDE™ MIX BC 90 Z R Corundum 1650 89,5 2,5 - - 3 3

CALDE™ MIX BT 98 Tabular Alumina 1700 98 0,2 - - - 3

CALDE™ MIX M S 86 BTI Magnesia 1700 12 1,5 84 - - 2,8

CALDE™ MIX SA 68 S Andalusite 1670 67 29 - 2 - 2,6

CALDE™ MIX SC 76 M12 Corundum/ Magnesia 1750 76 - 22 - - 2,85

CALDE™ MIX SC 84 M16 Corundum/ Magnesia 1750 84 - 14 - - 2,85

CALDE™ MIX SC 85 M17 Alumina/ Magnesia 1750 84 0,3 14 - - 2,8

CALDE™ MIX SC 86 NTI Alumina/ Magnesia 1700 86 0,6 10 - - 3

CALDE™ MIX SC 88 S R Corundum 1700 89 9 - - - 3

* Hydrogen release product

1�

Technical Data




(t/m3)Al2O

�SiO

2MgO SiC ZrO

2

PATCHING PRODUCTS

CALDE™ PATCH C 90 Corundum 1500 87 2,5 - - - 2,3

CALDE™ PATCH F 40 Chamotte 1400 38 45,5 - - - 2,2

CALDE™ PATCH HC 80 M Alumina/Magnesia 1600 82 2,3 14 - - 2,65

CALDE™ PATCH HQ 22 U Quartzite 1700 4 93 - - - 2



CALDE™ PATCH OZ 96 Zirconia Oxide 1700 - - - - 96

CALDE™ PATCH PB 82 U Bauxite 1600 82 9 - - - 2,9

CALDE™ PATCH SC 88 Corundum 1600 88 10 - - -

CALDE™ PATCH SC 90 Corundum 1700 89 8,5 - - -

PLASTIC PRODUCTS

CALDE™ PLAST 85 S Bauxite 1700 85 7,4 - - - 2,95

CALDE™ PLAST G C 65S20 Corundum 1650 65 6,5 - 20 - 2,8

RAMMING PRODUCTS

CALDE™ RAM G B 55S20 Bauxite/Silicon Carbide 1600 55 11 - 22 - 2,6

CALDE™ RAM G B 64S10 Bauxite 1700 64,5 8,8 - 9,7 - 2,8

CALDE™ RAM G B 68S15 Bauxite/Corundum 1650 67 7 - 15 - 2,94

CALDE™ RAM G C 65S20 Corundum 1700 63 3,8 - 19,2 - 2,8

CALDE™ RAM LT 98 Tabular Alumina 1850 97 0,2 - - - 2,65

CALDE™ RAM PF 55 Chamotte 1620 60 35 - - - 2,6

STIX PRODUCTS

CALDE™ STIX 151 High Alumina 1550 55 32 - - 3 2,1(TR) 2,45(G)

CALDE™ STIX F 55 G3 Chamotte 1450 54 37 - - - 1,85 (TR)

CALDE™ STIX M 65 G3 High Alumina 1600 67 25 - - - 2,2 (TR) 2,6(G)

CALDE™ STIX T 90 G1 Tabular Alumina 1750 91 3 - - - 2,85 (TR)

TROWeL PRODUCTS

CALDE™ TROWEL G SM 40 Kyanite 1600 41,6 41,6 - - - 2,35

CALDE™ TROWEL HC 90 U Corundum 1600 89 9 - - -

1�

Technical Data


NOTES: CALDERYS does not warrant the accuracy, fitness for purpose or update of any information disclosed herein. The recipient shall refer to instructions and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS. Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed.References, trademarks and specifications of the products may change according to the geographical area to be supplied. Please check the availability of the products with the sales area manager.



(t/m3)Al2O

�SiO

2MgO SiC ZrO

2

DRY SILICA DVM’s

SILICA MIX (for example A 0.8) Quartzite 1580 - 98 - - - 2,1

SILICA MIX 4 (for example A 0.8) Quartzite 1580 - 98 - - - 2,1



SILICA MIX CAP Quartzite 1600 - 96,2 - - - 2,2

SILICA MIX ITP Quartzite 1700 - 96,3 - - - 2,2

SILICA MIX Q 14 Quartzite 1450 - 98 - - - 2

SILICA MIX Q 15 Quartzite 1550 - 98,2 - - - 2



SILICA MIX QVF 14 Quartzite 1450 - 98 - - - 2

SILICA MIX QVF 15 Quartzite 1550 - 98,2 - - - 2



SILICA MIX Z 14 Quartzite 1450 0,6 91,8 - - 6 2,25

SILICA MIX Z 15 Quartzite 1550 0,6 92 - - 6 2,25



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Performance you can trust

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AustrAliA Calderys Australia Pty LtdPh.: +61 (0)2 4272 28 [email protected]

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Documents

Monolithic Concept foundry Solutionsrevicol.com.co/wp-content/uploads/2018/11/Calderys_Foundry.pdf · Monolithic concept solutions for Ferrous Foundry Channel Holding Furnaces The