INSURAL* Furnace Lining System - Pre-formed highly insulating refractory lining for aluminium furnace applications

Traditional furnace lining systems involving the application of wet refractory mixes typically require time-consuming dry-out and sintering operations prior to metal charging. In addition to significant furnace downtime, such lining systems also typically lead to hydrogen pick-up in the aluminium melt for the initial period following furnace installation.

The INSURAL Furnace Lining System, combining highly insulating and durable components, is the ideal solution for today’s aluminium melting operations. A dry, preformed engineered lining system - Ready-to-Use!

Benefits include:

• No sintering or dry-out program
• Reduced furnace downtime
• Lower energy costs
• Improved melt quality
• Greatly reduced hydrogen evolution on start-up - rapid achievement of target melt density.
• Low corundum growth - easy to clean and maintain

Whereas traditional refractory furnace linings require a gradual temperature ramp up over a period of days, the INSURAL lining system can be heated directly to the normal operating temperature. A 48-hour holding time is recommended before melt charging.

With an INSURAL installation, the desired density index of the melt can be achieved much sooner as the dry lining does not evolve hydrogen gas into the melt. The advantage is a faster integration of the furnace into the production process. Production flexibility and capacity is improved and the production of high-quality castings can be scheduled without restriction.

Installation can be carried out either on-site or at a recommended 3rd party installer. All necessary components are delivered ready for installation. For each furnace type, the individual INSURAL components have been designed to fi t exactly into the steel shell. Some backing materials can be reused in subsequent liner installations.

The exceptional insulating properties of the INSURAL Furnace Lining System ensures that the thermal output is at a low level throughout the service life of the lining - ensuring lower energy costs, reduced carbon footprint, and excellent lining life. Compared to monolithic lining systems, up to 17% energy savings can be achieved.

The installation of a traditional monolithic lining and the sintering and pre-heating of the furnace can take up to 2 weeks. As the INSURAL lining needs no sintering and only 2 days of pre-heating; the downtime of the furnace is drastically reduced.

The existing portfolio of INSURAL linings covers a wide range of the most popular furnace types. Since each INSURAL component is carefully designed for each furnace type, the dimensional accuracy of the finished lining is assured.

Foseco supplies a full range of consumable ceramic products for dosing furnaces, produced in a variety of INSURAL technical grades as well as other ceramic materials, for example:

• Filling funnels
• Dosing tubes
• Launders
• Thermocouple and Heating Element Sheaths