By Peter R. Whiteley
From the eighth Australasian convention on Aluminium Casthouse expertise in Brisbane, Australia, September 14-17, 2003
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We seem to have exchanged the typical corundum growth problems for a consumable lining, which slowly wears away. C. castable? Practical experience suggests there is no clear winner and there are many factors, which affect the choice varying from personal preference to availability. C. C. 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.
Currently it is envisaged that each of the product lines will be managed as independent businesses with a "product manager" assuming full responsibility for each product center. Plant logistics remain to be unexplored territory at the planned production levels and a project is currently under way to ensure that potential bottlenecks are timorously predetermined and addressed. Bayside will continue to rationalize the plant, especially auxiliary equipment to continue to drive down conversion cost and increase throughput.
Castables the conventional castables only found limited use as a metal contact refractory. The calcium aluminate binder shows no corundum reaction and does offer some protection to the grog, however eventually some grog is exposed so corundum growth is inevitable. Apart from this the main problems with conventional castables is their lack of strength and this is a particular disadvantage in furnaces, which are regularly cooled and 52 heated. The high thermal expansion of aluminum means that any residual metal left in cracks in the lining literally tears the castable apart as the furnace cools.
Aluminium Cast House Technology VIII by Peter R. Whiteley