New Cross-Feeder Refractory

Technology
Alan Sale, Pyrotek
The Ideal Cross-Feeder
Strong and Hard
Low thermal expansion
Low thermal conductivity
High resistance to molten aluminium attack
Current Materials
Thermal conductivity vs. Material life
Current Materials
Dense material = longer life, less
insulating
Lighter material = less life, more
insulating
25,000 MT
25,000 MT
The Ideal Cross-Feeder
Introducing TITANTM Refractory
Strong and Hard
Low thermal expansion
Low thermal conductivity
High resistance to molten aluminium attack
TITANTM Cross-feeder
Function
1. Reduce molten metal heat loss at cast start and
run
2. Reduce heat transfer into the steel table
3. Reduce maintenance between drops and in the
mold room
Reduce metal temperature loss
Reduce heat transfer
Reduce Maintenance
TITANTM Crossfeeder
WHY IS TITAN UNIQUE?
It is a true composite refractory
featuring a hard hot face backed with
a unique insulating body
TitanTM Cross-Feeder
PyroformHP vs. TITANTM
Properties Pyroform
HP
TITAN
Heat sink, C
P
, BTU/lb F 19.5 17.0
Thermal conductivity,
BTU-in/ft
2
/hr/ F
1.55 1.46
Thermal expansion,
in/in/ F x 10 E
-6
1.60 1.30
Cross-Feeder Insulation Comparison
Wagstaff cross-feeder temperature comparison
0
100
200
300
400
500
600
0 12 24 36 48 52 58 64 70 76
Insural 140 Pyroform PC Titan
T
e
m
p
e
r
a
t
u
r
e
,

F
Casting time, minutes
End of Cast
Thermocouple Placement
Benefits of TitanTM Cross-Feeders
Better insulating
Lower maintenance
Greater energy savings
Design advantages
Benefits of TitanTM Cross-Feeders
Better insulating
Reduce cast start defects due to
temperature loss
Uniform temperature distribution
across the table
Less refractory and mold table
maintenance
Better Insulating
Average 1% gain in pit yield due to
reduction of cast start defects
Benefits of TitanTM Cross-Feeders
Lower Maintenance
Between drop maintenance
Refractory maintenance between
casting campaigns
Refractory life
Benefits of TitanTM Cross-Feeders
Greater energy savings
Possible to reduce furnace temperature
Energy Savings with TitanTM
Titan Crossfeeder
Holding furnace - Gas cost savings
Furnace size, thousand lb 125000
Natural gas cost, $/thousand cubic feet $10
Temperature decrease in F using FS RFM/ WolliteX-feeder 15
Calculated energy to reach 1337 F
(1)
58540625
Calculated energy to reach the lower casting temperature 58118750
Calculated energy difference =Delta Q/furnace load 421875
Number of cast/year based 6 cast/day and 325 working days 1950
Total energy difference in BTU 822656250
Natural gas energy in BTU/ cf 1080
Calculated natural gas volume @ 50% efficiency inmcf 1522
Calculated annual cost saving/furnace $15,000
(1) Q=Cp
Al
x furnace weight x temperature +latent heat of fusion
Benefits of TitanTM Cross-Feeders
Design advantages
All geometry shapes and designs
Possible to eliminate joints
Multiple hot face materials available
Summary
TITAN
TM
Refractory
COST EFFECTIVE ADDS VALUE
Reduce temperature cast start defects
Reduce between drop maintenance
Reduce refractory maintenance
Longer refractory life
Unlimited geometric designs
Multiple mold position modules