CASE STUDY Foundry: Fonderie VENISSIEUX Rue Pierre COT 69 200 VENISSIEUX, France Objectives: • Reduce labour time and costs • Improve safety and work conditions • Reduce pre-heating time • Improved insulation and temperature control Alloy: ferritic ductile iron 450/10 Ladle size: Tundish cover ladle process Useful capacity 2.3 tonnes Treatment temperature 1480 °C Furnace tapping temperature 1520 °C Ladle installation: • Total weight of KALTEK ISO 60BF = 850 kg • Thickness: from 85 mm to max 120 mm • Installation time: 2 hours • Reaction time: 1 hour • Pre heat: for 1 hour maximum Lifetime of the ladle: 1150 tons treated 500 cycles of FeSiMg treatment 1 day continuous operating followed by cleaning Earlier lining practice: Ramming granular silica/graphite refractory Total weight of lining = 1275 kg Installation time 4 hours Dry-out 9 hours Pre heating 4 hours 750 tons treated Improvements: Installation and ladle cost reduced by 10%: • Installation time halved • Drying time reduced by 8 hours • Pre-heating time reduced by 3 hours • 35% reduction in lining weight • 35% increase in lining lifetime Cost reduction due to improved insulating properties: • 20°C reduction in furnace tapping temperature MELT SHOP REFRACTORIES – IRON 1.2.4 – Nodular iron for automotive castings COMMENT: Editorial policy is to highlight the latest Foseco products and technical developments. However, because of their newness, some developments may not be immediately available in your area. Your local sales organisation will be pleased to advise. No part of this publication may be reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder. © Foseco International Ltd., 2015,*KALTEK and LUBIX are trade marks of the Vesuvius Group, registered in certain countries, used under licence. Steel former for the ladle FOSECO PRODUCTS + KALTEK* ISO 60BF refractory + LUBIX* 33 release agent KEY BENEFITS + Reduced labour cost + Reduced heat loss from the ladle Firing operation ENVIRONMENTAL BENEFITS + Energy savings + CO 2 generated from drying and pre-heating reduced by more than 90% Ladle after ﬁring

Case Study Venissieux France - Foundry 200 VENISSIEUX, France Objectives: • Reduce labour time and costs ... 500 cycles of FeSiMg treatment 1 day continuous operating followed by

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Page 1: Case Study Venissieux France - Foundry 200 VENISSIEUX, France Objectives: • Reduce labour time and costs ... 500 cycles of FeSiMg treatment 1 day continuous operating followed by

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CASESTUDY

Foundry:Fonderie VENISSIEUXRue Pierre COT69 200 VENISSIEUX, France

Objectives:• Reduce labour time and costs• Improve safety and work conditions• Reduce pre-heating time• Improved insulation and

temperature control

Alloy:ferritic ductile iron 450/10

Ladle size:Tundish cover ladle processUseful capacity 2.3 tonnesTreatment temperature 1480 °CFurnace tapping temperature 1520 °C

Ladle installation:• Total weight of KALTEK ISO 60BF =

850 kg• Thickness: from 85 mm to max

120 mm• Installation time: 2 hours• Reaction time: 1 hour• Pre heat: for 1 hour maximum

Lifetime of the ladle:1150 tons treated500 cycles of FeSiMg treatment1 day continuous operating followed bycleaning

Earlier lining practice:Ramming granular silica/graphite refractoryTotal weight of lining = 1275 kgInstallation time 4 hoursDry-out 9 hoursPre heating 4 hours750 tons treated

Improvements:Installation and ladle cost reduced by 10%:• Installation time halved• Drying time reduced by 8 hours• Pre-heating time reduced by 3

hours• 35% reduction in lining weight• 35% increase in lining lifetime

Cost reduction due to improved insulating properties:• 20°C reduction in furnace tapping

temperature

MEL

T SH

REFR

ACTO

RIES

– IR

1.2.4 – Nodular iron for automotive castings

COMMENT: Editorial policy is to highlight the latest Foseco products and technical developments. However, because of their newness, some developments may not be immediately available in your area. Your local sales organisation will be pleased to advise. No part of this publication may be reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder. © Foseco International Ltd., 2015,*KALTEK and LUBIX are trade marks of the Vesuvius Group, registered in certain countries, used under licence.

Steel former for the ladle

FOSECO PRODUCTS

+ KALTEK* ISO 60BF refractory + LUBIX* 33 release agent

KEY BENEFITS

+ Reduced labour cost + Reduced heat loss from the ladle

Firing operation

ENVIRONMENTAL BENEFITS

+ Energy savings + CO2 generated from drying and pre-heating reduced by more than 90%

Ladle after fi ring