By Peter R. Whiteley

From the eighth Australasian convention on Aluminium Casthouse know-how in Brisbane, Australia, September 14-17, 2003

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Extra info for Aluminium Cast House Technology VIII

Example text

Apart from above, it was around US$ 14 per litre, about 10 times the cost of existing oil being used for lubrication in casting. 4 per litre. The graphite ring life with this casting oil was about 200 castings. This oil was a hydraulic oil (HLP-32 of M/s IOC) which had a mineral oil base with some additives. The additives in mineral oil lead to choking of graphite rings. It was therefore decided to use a vegetable oil (double filtered rapeseed oil). This oil gave a better finish of billets due to better lubricating properties but at the same time graphite ring choking problem aggravated.

A thermal and structural analysis was thus required to evaluate the structural implications of using a castable lining. The analysis began with a finite element analysis of the current furnace configuration with cold face temperatures as measured on site. The same analysis was then repeated on the furnace with the new refractory configuration and larger aluminum mass. Cold face temperatures, as supplied by the refractory supplier, were used as input for this analysis. The tilt cylinder forces for each configuration were also calculated.

1. Fig. 1. Casting ring life Water Quality Improvement A balanced water treatment programme was developed with help of M/s Ion Exchange which incorporated the addition of following water treatment chemicals. Chemical Purpose Indion 5653 Scale inhibitor & fouling control. This is used to avoid any scaling inside the moulds, in-line water filter and the pipe lines Indion 9106 Anodic corrosion inhibitor. Indion 9024 Cathodic corrosion inhibitor. Equal amount of cationic and anionic corrosion inhibitors are added, to avoid any deterioration in cooling efficiency of water.

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