Refractory Solutions For Aluminium
Refractory Solutionsfor Aluminiumwww.capital-refractories.com
ContentsRefractory Solutionsfor AluminiumCapital Refractories has been manufacturingand supplying high quality refractories andtechnical ceramics to metal melting and otherheat processing industries for over 60 years.During this time, we have extended our coverageworldwide with sales offices or distributors inover 40 countries. Capital has 300 staff at ninesites in the UK, US, mainland Europe, China andIndia.Capital supplies a comprehensive range ofrefractory solutions to the aluminium industryand other heat using industries. Our servicesinclude production and supply of furnace liningsand consumable products, refractory engineering,installation and product development.Capital’s philosophy is: Technical support and customer service Capital has over 50 technical and sales staffwho visit our customers in every industrialcountry in the world to give assistance andtraining to maximise the performance andbenefits of our products.We pride ourselves with our hands-onapproach to problem solving - we getinvolved and stay involved. Product development - Capital spends 10% ofprofits on R&D resulting in over 30% of currentsales being in new products developed inthe last four years - a higher proportion thanattained in some ‘high tech’ industries.Continuous improvement - we recognisethat our Quality Assurance Systems are thebackbone of our company; Capital was one ofthe first in the industry to be certifiedto ISO9001 (previously to BS5750) andparts of the company which supply to theaerospace sector are certified to the moredemanding AS9100 aerospace standard. Inaddition to this we use other continuousimprovement methodologies, for example,Lean Manufacturing.02–03Contents and Introduction10-11Gas Diffusers04-05Reverberatory Furnaces12Refractory Engineering06Rotary Furnaces13Refractory Installation07Tilt Rotary Speed-Line Big Block System14-15Metal Transfer08Tower (Stack) Melters16-17Precast Shapes09Bail Out, Dosing Furnace18-21Product Detailsand Induction Furnace Linings22-24ContactsIt is this commitment, ambition and enthusiasm toour markets, our customers and our people thatmakes Capital a world class company inevery sense.Developing Solutions with our CustomersCapital offers an extensive range of refractoryproducts and services for the aluminium industry,including products for primary, secondary andfoundry customers. Our products have been developed in closecooperation with our customers and haveundergone rigorous testing. Many of ourproducts are approved by Pechiney(now part of Rio Tinto Alcan) and by Alcoa. Capital products for the aluminiumindustry include: An extensive choice of castable refractoriesfor the lining of melting and holdingfurnaces Ladles, launders and filter boxes etc Precast shapes for furnace lining and metaltransfer Dry vibration products for inductionfurnace linings Gas diffusers for degassing and melthomogenisationRepair materials including rapid fire phosphatebonded castables and plasticsProtective washcoats and ancillary items suchas tap out cones, mica and thermocouple tubesOur team of experienced engineers and authorisedinstallers can install and repair your furnace liningsor offer on site supervision and advice as required.Capital’s product range is constantly evolvingto meet new challenges. We can also supply arange of complimentary products for a completeinstallation package including dense and insulatingfirebrick, calcium silicate and microporousinsulating board, mortars and ceramic or metallicanchors.Please contact your local Capital representative forassistance in selecting the correct combination ofmaterials for your specific application.02Refractory Solutions for Aluminium03
Reverberatory Furnace LiningsAREALower SidewallHearthSubhearthSill and RampDoorAbove and right, a lining designedand installed by CapitalRefractoriesTaphole BlockRepair MaterialsWashcoatPRODUCTDESCRIPTIONCapiral 85High duty materialCapiral 105SRStandard duty materialCapiral 90Very high abrasion resistanceCapiral 85High duty materialCapiral 105SRStandard duty materialCapiral 35 C/GChamotte based barrier materialCapiral LWAMedium weight barrier materialCapiral LWBLightweight barrier materialCapiral S40FFVery high resistance to thermal shock and abrasionCapiral 90Very high abrasion resistanceCapiral 85High duty materialCapiral M60Improve thermal shock resistanceCapiral 105SRStandard duty materialCapiral LWAMedium weight castableCapiral SC70Extreme erosion resistanceCapiral S40 FFHigh resistance to thermal shock and erosionCapiral 85High duty materialPBond 85Two component phosphate bonded repair castableWashcoat 222Alumina based washcoat with non-wetting propertiesZircon WashcoatZircon based washcoatReverberatory Furnace LiningsAREARoofRoof InsulationUpper SidewallFlux Line04PRODUCTDESCRIPTIONCapiral 105SRStandard roof materialCapiral M60Improve thermal shock resistanceCapiral 40Medium density materialPencrete 124GMGeneral purpose insulating castablePencrete 15/40GMLow density insulating castableCapiral 85High density abrasion resistant materialCapiral 105SRStandard duty applicationsCapiral M60Improved thermal shock resistanceCapflow 1730FFResistant to high temperaturesCapiral 85High duty materialCapiral 105SRStandard duty materialwww.capital-refractories.comRefractory Solutions for Aluminium05
REFRACTORIES for ALUMINIUMTilt Rotary Speed-Line Big Block SystemOur experts providecustomised big block3D CAD designs forany tilt rotary furnace.Speed-LineBig Block SolutionsWe have theadvantage of not onlybeing able to offer afull service, but alsothat we manufacture, enabling fasterinstallations.Our experts can help you through the wholeprocess, from design right through to the fullrotary block installation.We’re leading the way in design and engineeringin rotary furnace precast.Pictured top left, graphic designs show one ofour latest European installations; top right, ourfirst American installation.Rotary Furnace LiningsAREABarrelDoorRepair Materials06Advantages of Using Precast BlocksPRODUCTDESCRIPTIONCaprax 50HDHigh strength flint clay castableCaprax 1750LCFHigh strength bauxite based castableCapiral M60High duty mullite based castablePBond 85Two component phosphate bonded repair castablePBond Solo 60Single component phosphate bonded repair castablewww.capital-refractories.com Reduced installation timeIncrease in campaign life by up to 50%Mixing blocks can be included to reducemelt times and salt usageReduced preheat/dryout timeUnlimited shelf lifeCan be installed in extreme hot or coldconditionsOffers the possibility of increased insulation and reduced heat lossReduction in furnace lining thicknessallowing increase in capacityMaterial ‘zoning’. High wear areas in thebarrel can have higher specification materialsor the addition of steel fibresEasy localised repair of high wear areasReduced labour required compared withstandard casting practiceRefractory Solutions for Aluminium07
REFRACTORIES for ALUMINIUMTower (Stack) Melter LiningsBail Out and Dosing Furnace LiningsAREARoofSidewall and BaseRepairsWashcoatsAREATower (Stack)Melt ZoneHolding AreaRoof and UpperSidewallRoof InsulationLower SidewallSubhearthRepair Materials08PRODUCTDESCRIPTIONCaprax 1750LCFHigh impact and abrasion resistance for upper towerCapiral 85High duty applicationCapflow 1730ALFor high temperature areasCapiral 85High duty materialCapiral M60Improve thermal shock resistanceCapiral 105SRStandard duty materialPencrete 124GMGeneral purpose insulating castablePencrete 15/40Low density insulating castableCapiral 85High duty materialPRODUCTDESCRIPTIONCapiral 40Medium density materialCapiral 105SRStandard duty materialCapiral 85High duty materialCapiral 105SRStandard duty materialCapiral 40Medium density materialPBond 85Two component phosphate bonded repair castableWashcoat 222Alumina based washcoat with non-wetting propertiesZircon WashcoatZircon based washcoatInduction Furnace LiningsAREAPRODUCTTop CapCapram 90High alumina plasticCorvibe 90Fused alumina based for long lifeCorvibe 90 FRXSteel fibre reinforced lining for long lifeFor high temperature melting such asmasteralloysMain LiningDESCRIPTIONCapiral 105SRStandard duty materialCRL 65Capiral 35C/GChamotte based barrier materialC65 LSMullite forming with aluminium non-wetting additivesCapiral LWAMedium weight barrier materialCapirax D11High alumina plastic or puttyCapiral LWBLightweight barrier materialWashcoat 222Alumina based washcoat with non-wetting propertiesZircon WashcoatZircon based washcoatPBond 85Two component phosphate bonded repair tsRefractory Solutions for Aluminium09
REFRACTORIES for ALUMINIUMGas Diffusers for AluminiumCapital has over 15 years experience in theproduction of gas diffusers for aluminiumtreatment. Our extensive range of products hasbeen successfully used in melting and holdingfurnaces, ladles and degassing units.Capital gas diffusers have been shown toconsistently improve metal quality priorto casting and are considered to have lowinstallation costs. Melt homogenisation isimproved with respect to both temperature andchemistry.The gas typically used is either argon or nitrogen.However, for removing light metals such asmagnesium and calcium, chlorine is often utilisedthrough specially designed diffusers.BENEFITS OF GAS DIFFUSERS INCLUDE: Reduced hydrogen content in the melt resulting in fewer casting defects Reduction of oxide inclusions Improved melt homogeneity Improved separation of dross and metal resulting in lower metal loss Elimination of manual stirring Improved melt rate and efficiency in melting furnaces giving energy savings Environmentally friendly compared with other gas systems Reduction of light metal contamination Cost-effective over time compared with rotary systems Low y Solutions for Aluminium11
REFRACTORIES for ALUMINIUMRefractory EngineeringMolar SupraCapiral 35C/GOur installation team can offer a full turnkeyservice or offer training and supervision tolocal installation teams/ the customer’s ownmaintenance team.Capiral 175Our engineering and installations team haveover 30 years experience in the design andinstallation of refractory linings for aluminiumcustomers which helps us give the optimumsolution for new builds, relines and repairs. Oursolutions include monolithic, big block, brickor hybrid designs tailored to the customers’needs.Calcium Silicate 1000Capital can offer a fully engineered refractorysolution for your furnace linings. We useadvanced software for 3D design and thermalmodelling.Refractory InstallationRefractory Services, as part of the CapitalRefractories Ltd group, is here to offer fullturnkey solutions for furnace refractoryinstallations.Whatever the job, and whatever the location, orinstallation, we have a team of experts on hand24/7 to make sure targets are met and the workis done on time.If you have any queries, please do not hesitate tocontact us. We are more than happy to give youany guidance you may need.Above and right, examples of projects ourrefractory services team have completed12www.capital-refractories.comRefractory Solutions for Aluminium13
REFRACTORIES for ALUMINIUMMetal TransferCapital offer high quality firedlaunders and ladle liners or a widerange of castable or rammed productsthat can be installed in situ or usedfor repairs.Precast fused silica launderCast in situ launder feeding a precast filter boxPRODUCT14Cast in situ transfer launderDESCRIPTIONCalight 1.4Calcium silicate insulating shapesFused Silica FS65CFused silica shapesFused Silica FS55CSilicon carbide reinforced fused silica shapesFused Silica FS45CSilicon carbide reinforced fused silica shapesTuffmax ML60High fracture toughness composite with mulliteTuffmax SC40High fracture toughness composite with silicon carbideCapiral FSAFused silica castableCapiral FSCFused silica/silicon carbide castableCapiral 105SRHigh alumina non-wetting castableCapiral 85High alumina non-wetting castableCapiral S15Silicon carbide reinforced mullite castableCapiral S40FFSilicon carbide reinforced mullite castableCapiral SC70Silicon carbide castableCast in situ transfer ladlewww.capital-refractories.comRoad transfer ladle designRefractory Solutions for Aluminium15
Precast ShapesCapital produce a wide variety of precastshapes for aluminium ranging from lessthan one kilogram to several tons inweight. Hot tops, control pins and downspouts formetal castingFeed cones and riser tubes for dosingfurnaces and low die pressure castingfurnacesFlue covers, exhaust ports, burner and fluecaps for carbon anode bakingThese can be made from any of our castablerange or from a range of more specialisedprecast materials summarised below. Theseare typically fully fired to remove both free andchemically combined water and to form a trueceramic bond.We can also precast complete linings into yoursteelwork and carry out full preheat beforedelivery to your site.Typical applications include:Typical applications include: Big block construction for reverberatory androtary furnacesLaunders, filter boxes and degassing unitsfor metal distribution and treatmentLadle liners and impact padsCrucibles Launder systemsDegassing and filter unitsDosing furnacesLow pressure die casting furnacesFoundry melting and holding furnacesChip melting unitsArmour Cast nose ring blocksSkim blades stirrers and door surroundsin Armour CastPrecast launder assembly in fusedsilica materialPrecast liner for ALPUR degassing unitProduct DataPHYSICAL PROPERTIESPRODUCT NAMEPHYSICAL PROPERTIESBULK DENSITY( g cm-3)APPARENTPOROSITY ( %)COLD CRUSHINGSTRENGTH (MPa)MODULUS OFRUPTURE (MPa)SiO2Al2O3CaOSiCOthersF5 45CSilicon carbide reinforced fused silica2.2713.263.38.449163266F5 55CFiner fused silica material with silicon carbide2.2616.180.512.855263106F5 65CDense fused silica material2.2212.173.412.165263-6Capiral MLAMullite based non-wetting material2.5117.748.78.531582-9Calight 1.4Calcium silicate insulating material1.3852.68.83.0372331-9Fibre matrix alumina material3.0822.1189610.1964--High fracture toughness alumina material3.1717.020658.22952--†High fracture toughness mullite material2.8115.112446.225643--†High fracture toughness silicon carbide3.0213.317359.7351235Armour Cast AL1Tuffmax AL1†Tuffmax ML60Tuffmax SC40††16CHEMICAL ANALYSIS (%)DESCRIPTIONwww.capital-refractories.comMaterial contains high percentage of refractory steel fibresRefractory Solutions for Aluminium1917
REFRACTORIES for ALUMINIUMProduct DataCastablesPRODUCT NAMEPRINCIPAL RAWMATERIALMAX.SERVICETEMP( C)MAX.GRAINSIZE(mm)Vermiculite10003272111Expanded Clay110052938Insulating Chamotte13001042Insulating Chamotte130010Expanded Clay1200ChamottePERMANENTLINEAR CHANGE(%)CHEMICAL ANALYSIS (%)COLD CRUSHINGSTRENGTH(MPa)BULK DENSITY(kg m-3)DRIED FIRED FIRED110 C 800 C 1000 CDRIED FIRED FIRED110 C 800 C 1000 CTHERMALCONDUCTIVITY,MEAN700 C(W m-1 K-1)APPROXWATERADDITION(%)MgOSiCFIRED800 CFIRED1000 *5474312---0.1-0.11151091002370234023701.86.5Flint 0256025601.86.5Capiral 01.55.5Capiral 801.25.5Capiral 90Fused Aluminate1400*108930.32-- 0.10.0100156257232032903300-4.0Capiral 50-5.5Capiral 165Chamotte 1.85.5Capiral 02.65.0Capiral 29702.25.0Mullite17008652913---0.4 1.1109102922530248024401.71.75Capiral 42CChamotte/Silicon Carbide135010384212-150.0 0.585110902450240024001.31.65Capiral S15Mullite/Silicon 2.01.12Capflow 1730ALBauxite/Silicon .31.06Capiral S40FFSilicon Carbide/Mullite1500840160.41-38-0.3 1.615118786276027502650-2.18Capiral SC70Silicon Carbide14005196-1-67 0.10.051811382640262026008.76.0Capiral FSAFused 6Capiral FSCFused Silica/Silicon Carbide1000516490.13-26-0.1 .41044041272026902730-N/AMullite1650556291----0.2 0.05-43136-23502350-N/ABauxite175010821212---0.2 1.4107150922860287027802.35.5Pencrete 15/40 GMPencrete 124 GMCapiral LWACapiral LWBPencrete LWGM†Capiral 40Caprax 50HD†Capiral 105SRSilcast 65†PBond 85PBond Solo 60Caprax 1750LCF†††Al2O3 SiO2 Fe2O3 CaO†Material does not contain non-wetting agents * Not aluminium contact temperatureProperties are the mean of values determined during routine quality control and therefore do notconstitute a specificationTesting and classification according to BS EN993 and BS EN ISO 192718www.capital-refractories.comRefractory Solutions for Aluminium19
REFRACTORIES for ALUMINIUMDry Vibration LiningsPRODUCT NAMEPRINCIPAL RAWMATERIALSCorvibe 90MAX.GRAINSIZE (mm)CHEMICAL ANALYSIS (%)BONDINGAl2O3SiO2MgOCaOFe2O3BULKDENSITY(kg m-3)OTHERMAX. SERVICETEMP ( C)SustainedShorttermCOMMENTSFused AluminaChemical913--0.4-5285013001400Fused alumina based for long lifeFused AluminaChemical913--0.4-5285013001400Steel fibre reinforced lining for long lifeCRL 65AndalusiteCeramic6829 0.5 0.51-4260016501700Mullite forming, excellent chemical, thermal & impact resistanceCRL 75AndalusiteCeramic7423 0.5 0.51-5260016501720Mullite forming, for mixed meltingC65 LSAndalusiteChemical5936 0.5 0.51-5260013001400Mullite forming with aluminium non-wetting additivesMulliteCeramic5129- 0.51 SiC105260010501400Mullite containing lining for aluminium and copper alloysCorvibe 90 FRX†CRL MASR†Data is without fibresWet Rammables, Patching & MiscellaneousPRODUCTNAMECHEMICAL ANALYSIS (%)Al2O3SiO2Fe2O3ZrO2P205BULKDENSITY,DRIED110 C(kg m-3)TYPEOFSETBacking InsulationPRODUCT NAMEMAX.SERVICETEMP( C)CHEMICAL ANALYSIS (%)BULKDENSITY(kg m-3)THERMALCONDUCTIVITY(W m-1 K-1)Capram 90Alumina180058950.3-52950ChemicalCapram 121-52550ChemicalSupra 50ChemicalCalcium SilicateBoardWashcoat222Microporous Board1000-80--SiC rflex10001060--ZrO2 9130.3--2690HydraulicSuperwool HT paper1300-70-80-22-2100.10.1Silkote 90WFA17001920.30.1-–2510HydraulicBlock 80010001461-17-3200.10.1PBond 85Bauxite1300387461-52640ChemicalPBondSolo CIPALSERVICE GRAINRAWSIZETEMPMATERIALS(mm)( C)www.capital-refractories.comAl2O3 SiO2 Fe2O3 CaO OTHER400 C800 CRefractory Solutions for Aluminium21
Contact DetailsFor supply and additional information aboutTel: 886 2 2367 0154BeneluxCapital Refractories, or if your countryEmail: capital.taiwan@msa.hinet.neis not listed, please contact Capital’s UKThailandheadquarters, see back of brochure forPine-Pacific Corporation Limiteddetails.Tel: 662 705 5900Capital Refractories LimitedTel: 33 680069733Email: cyril.lepelletier@capital-refractories.comCzech RepublicCapital Refractories sroTel: 42 0775 909 466Tel: 42 0734 233 id.slowik@capital-refractories.comDenmarkDanref A/STel: 48 28 89 00Email: od@danref.dkFinlandOy Lux ABTel: 35 8 9 6220550Email: info@lux.fiFranceCapital Refractories LimitedTel: 33 ies.comGermanyCapital Refractories LimitedTel: 33 6 80 06 97 GreeceC. Adamacopo
Refractory Solutions for Aluminium Refractory Installation Refractory Services, as part of the Capital Refractories Ltd group, is here to offer full turnkey solutions for furnace refractory installations. Whatever the job, and whatever the location, or installation, we have a team of exper
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