Calderys

SILICA MIX V for CIF

Refractories Solutions

 

In the foundry industry today, the modern Coreless Induction Furnace (CIF) more often uses a fast batch melting process. This can be a more efficient method of production than the traditional processes since it allows the complete emptying of metal from the furnace, leading to higher production yields.

Traditionally, since a portion of metal (~30 to 50%) was always remaining in the furnace, the CIF would be exposed to high levels of erosion and corrosion. The modern CIF minimizes these stresses, but now with the furnace fully emptying after melting there is more of a thermal cycling process (heating and cooling) which leads to increased thermal shock and thermal aging stress.

For high resistance to thermal shocks in the modern CIF, it is normally recommended to use hybrid refractory products containing fused silica, rather than natural silica. The Calderys R&D team has now developed a cost-effective quartzite refractory that provides added benefits over natural silica products.

Branded as SILICA MIX V, this extension to the SILICA MIX refractory product range provides additional thermal shock resistance beyond natural silica products (such as SILICA MIX 4 / 5 / 7). SILICA MIX V is a dry vibratable ramming mix based on Calderys’ own high quality Swedish Micro-crystalline quartzite that effectively bridges the gap between natural and fused silica to further adapt to modern foundry conditions.

SILICA MIX V can be zoned with other Calderys SILICA MIX products for a complete refractory solution which provides each client with maximum value for the specific power density needs of their furnaces.

Examples of Calderys zoning recommendations for CIF
Examples of Calderys zoning recommendations for CIF
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Benefits of SILICA MIX V:

  • High reliability – Excellent life consistency to give each client peace of mind in planning their production.
  • Cost-effective – Closer to the price range of natural silica products with high thermal shock and aging resistance for the modern CIF which approaches that of fused silica refractories.
  • Low internal stress – The product has a clear internal zone development giving high flexibility and reduced rigidity in the back lining and therefore less likely to crack under stresses vs. natural silica products./li>
  • Excellent mechanical impact resistance – Like all Calderys refractories, this product is designed to be strong and has been tested both in the lab and in the field, with successful installations already in foundries in Sweden and the UK and many other locations preparing for adoption.
  • SILICA MIX V is globally available and ready to be tested.

For more details, please ask your melting partners at Calderys !
SILICA MIX V testing
SILICA MIX V testing
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Inductive sinter
Inductive sinter
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About Calderys India

Our mission is to help you meet your ever-increasing production and productivity targets, whilst protecting the safety of your people and the integrity of your equipment. Our focus is to deliver safe, reliable, and high performing refractory solutions customized to your needs. Our international production and sales facilities allow us to develop and deliver customized solutions based on monolithic and ready shape monolithic refractory materials worldwide in a fast, efficient, and safe manner.

Calderys in India

Calderys in India

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SILICA MIX Unique Expertise

Case studies 01

In the foundry industry, silica based refractories - SILICA MIX - have been well known for many decades as linings for Coreless Induction Furnaces for melting and holding iron.

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International projects involving multiple business units are commonplace at Calderys. This is a fine example of employees utilizing company resources to better serve our customers.

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