The following case histories describe typical foundry consultancy projects that have been successfully completed by CMPT.
FOUNDRY CASE HISTORIES:
Foundry had significant problems with the inductor in a channel furnace clogging. As a result of this clogging, the refractory was superheated resulting in damage, increased maintenance costs and reduced life of inductor. By analysis of the slag and metal and observation of melting and holding process, a practice was implemented that resulted in improved inductor life and corresponding cost reduction. The major changes were reduction of powerful oxide formers in the metal and improved slag chemistry.
Foundry was an iron casting producer with little experience making steel. Castings exhibited porosity defects. Review of the defects and of the melting and pouring practice determined that defects were as a result of insufficient deoxidation. The melting and pouring practices were modified and the defects eliminated. CMPT played a major part in the successful production of these steel castings.
Phosphorus and sulphur are typically not desired in steel however are always present. Practices for removing phosphorus and sulphur to acceptable levels have been successfully implemented at steel foundries.