Calculations based on a one tonne ladle preheatedwith gasol have shown an alarming pollution of theatmosphere.• A 1 tonne ladle on preheat for 6 hours per day will

consume 14500 kg of gasol in one year (based on235 days)

• This one ladle will cost over 12000 € to preheat. • The preheating of this ladle will generate 43000 kg

of carbon dioxide in one year• This quantity of CO2 generated is equivalent to the

pollution of a full 40 tonne truck running for 20000 km

Energy is a major factor in the management of ladlecosts. An assessment in a Scandinavian foundry hasshown energy accounts for over 50% of these costs.

Costs for Lip pour and Bottom pour ladles inScandinavian foundries.

Lip Pour

Bottom Pour

Preheating/HoldingMaintenanceMaterialsInstallationWrecking

Preheating/HoldingStopper/NozleMaintenanceMaterialsInstallation/Wrecking

Roslagsgjuteriet AB conventionally used drum ladles giving the benefits of size and good weight distributionwhatever the weight of molten iron in the ladle. A major problem was the time and cost associated with ladle,maintenance, repairing and relining the ladle. A complete reline would take more than a week.Roslagsgjuteriet AB have changed their ladle technology to a lip pour ladle lined with KALTEK ISO. The ladlelining can now be replaced in a couple of hours. The highly insulating properties of KALTEK ISO and the greatlyreduced need of energy for drying and preheating haveprovided many benefits: • More castings can be poured from the ladle due to

the improved temperature control• Tap temperatures have been reduced by 20-30 °C• Reduced scrap due to cold pouring• Repair to the ladle lining has been almost eliminated.

The complete lining is replaced on a more regular basis• Reduced Gasol usage and reduced CO2 pollutionas

shown on the sheetCastable

Gasol Co2

20.000

40.000

60.000

80.000

100.000

0

27.120

81.230

2.8148.428

KALTEKGasol Co2

Kilo

gra

esm

m

Annual Gasol Consumption andCarbon Dioxide Generation

90% reductionof CO2 emmissions

Teil5 Engl 01.06.2007 13:19 Uhr Seite 1

ENERGY NEWS? Gas costs up by 35%

? Electricity costs up by 30%

? Do you still preheat ladles and pouring systems

? Are you still using excessive superheat to achieve the correct temperature at the point of casting

? Would you like to reduce your carbon footprint

If the answers to any of the above is yes, then theFoseco range of KALTEK metal transfer systems maywell offer a viable way of:

✔Reducing energy use

✔Maintaining liquid metal temperature

✔Reducing the need for superheated metal

✔Suitable for all ferrous metals and a range of transfer applications ranging from ladles to holding and pouring units.

Foseco (FS) Limited, Drayton Manor Business Park, Tamworth, Staffordshire, England B78 3TL

Tel +44 (0)1827 289999 Fax +44 (0)1827 250806www.foseco.co.uk

? Gas costs up by 35%

? Electricity costs up by 30%

? Do you still preheat ladles and pouring systems

? Are you still using excessive superheat to achieve the correct temperature at the point of casting

? Would you like to reduce your carbon footprint

If the answers to any of the above is yes, then theFoseco range of KALTEK metal transfer systems maywell offer a viable way of:

✔Reducing energy use

✔Maintaining liquid metal temperature

✔Reducing the need for superheated metal

✔Suitable for all ferrous metals and a range of transfer applications ranging from ladles to holding and pouring units.

Committed to Foundries

Energy news Engl 01.06.2007 12:56 Uhr Seite 1

FTJ November 2006 289

The 2005-2006 benchmark report, published by NUS Consulting Group, reveals some interesting developments in the world’s electricity industry as all 14 countries surveyed had shown an increase in pricing. As much of the world community has embraced the concept of deregulating electricity supplies, the increase in pricing demonstrates that competitive markets can be volatile as they are susceptible to numerous factors including rising world oil prices.

In Europe, all surveyed countries, with the exception of Germany, experienced double-digit increases in the price of electricity. While rising world petroleum prices are mainly to blame, the increases were also connected to the application of new environmental or ‘green’ taxes on electricity purchases. The European community continues to embrace the concept of market liberalisation in terms of electricity sales, but with prices at historic highs, one can only wonder what impact this situation will have on both the overall political and economic landscape.

In North America, Canada remains one of the lowest cost surveyed countries; however, where deregulation has been enacted, the markets have been extremely volatile. In Ontario, it has been announced that all coal-fired generation is to be decommissioned by 2007 and consumers are being warned that certain subsidies cannot continue. This announcement, coupled with lingering questions concerning the province’s nuclear power plants, has forward prices going ever higher.

In the United States, average prices grew by a hefty 10.9% with many questioning the benefits of

market deregulation. Interestingly, those states that have opened their electricity markets to ‘customer choice’ are experiencing some of the highest increases in pricing after years of relative stability. Americans already experiencing ‘sticker shock’ at the gas pumps are now starting to see the full effect escalating oil prices will have on their monthly electric bills.

Given these developments around the world, medium to large business

consumers of electricity can no longer afford to ignore the realities of the market. With fleeting opportunities for savings and the cold reality of ever-higher prices, each consumer must take an active role when it comes to their electricity purchases.

AustraliaElectricity prices rose for the second year in a row increasing by some 2.8%. However, Australia is the only surveyed country reflecting a net decrease in electricity pricing over the past five years. Basslink, the undersea cable link between Victoria and Tasmania, was completed and is currently undergoing testing. Once fully operational, Tasmania should join the country’s electricity market and adopt retail competition. Supplier mergers should continue in the future with electricity pricing increasing.

BelgiumBelgium’s electricity prices rose by an average of 14% over the past year - well above the country’s inflation rate of 1.7%. Over the past five years, electricity prices have risen by a little over 24%. Electricity prices closely follow developments in the Netherlands, in particular the ENDEX and APX energy exchanges. With electricity prices at all time highs, Electrabel is aggressively pushing its

customers to sign long-term supply agreements with some extending out as far as 2010. Electricity prices should continue their upward spiral over the next 12 months.

CanadaThe average price of electricity in Canada rose by 5.5% over the past year mainly attributable to market increases in Ontario and Alberta. Currently, Ontario and Alberta are the only provinces to have deregulated their electricity markets. All signs point to further increases in prices as consumers are being warned by government and suppliers alike that the time has come to pay for the ‘true cost’ of generating electricity.

DenmarkElectricity prices in Denmark grew by a dramatic 39% over the past year pushing the country to the highest price surveyed country. This increase was mainly due to the country’s reliance on high cost wind power for electricity production as well as the introduction of the European emission trading system over the past year. An unusually long and cold winter has also influenced pricing as most of the country relies on electricity for heating purposes. In conjunction with their counterparts in Finland, Norway and Sweden, Danish grid operators continue to strive for more harmony amongst themselves in the transmission of electricity in the Nordic market.

The Global price of energy

The following international surveys are based on reports prepared by the NUS Consulting Group’s (www.nusconsulting.com) international power reports and

cost surveys for electricity and gas.

Energy

290 FTJ November 2006

FinlandThe average price of electricity in

Finland grew by an alarming 42.2% over the past 12 months while national consumption of electricity declined by nearly 2.5% over the same time period. Finland has completely liberalised or deregulated its electricity market. The future price of electricity is largely dependent upon the price of oil and, as such, NUS foresees prices increasing over the next 12 months.

FranceTariff pricing remained flat over the past year with market-based pricing increasing by 48%. Over the past five years, when compared to 2001 tariff pricing, market-based electricity prices reflected an increase of more than 75%. The average survey price and increase in France is reflective of the liberalised or deregulated market. However, with regulated tariff pricing far below actual market prices, only approximately 10% of consumers opt for deregulated supplies. Regulated pricing should experience relatively small increases by year-end with deregulated pricing increasing along with world oil prices.

GermanyThe average price of electricity in Germany grew by some 7.5% over the past year with its five-year trend increasing by nearly 50%. The market is completely liberalised or deregulated with electricity prices being primarily influenced by the European Electricity Exchange (EEX) as well as the introduction of surcharges/taxes on CO2 emissions which is currently causing upward pressure on electricity prices. Electricity prices are likely to increase well above the rate of inflation over the next 12 months.

ItalyAlthough being dethroned from its position of having the highest electricity price in the survey, Italy witnessed its electricity prices increase by 14.9% over the past year. The five-year trend in electricity pricing saw an increase of 21.1%. The price spike over the past year is mainly attributable to sharp increases in gas pricing which was triggered by shortages. High prices are having an effect on consumption wherein electricity usage from 2004 has only increased by 1.3%, thus limiting national economic growth.

The introduction of newly constructed power stations should help meet the country’s demand for electricity as well as spur competition amongst the suppliers.

The NetherlandsElectricity prices in the Netherlands grew by over 27% from 1 April, 2005 with the five-year trend seeing prices rise by more than 40%. Electricity prices are mainly influenced by the ENDEX and APX energy exchanges. Smaller Dutch suppliers are being targeted for takeover by larger foreign electricity suppliers seeking to gain a toehold in Holland.

South AfricaThe average price of electricity in South Africa grew by a modest 2.8% over the 2005/2006 period, however, most municipalities will be increasing their tariff rates in June 2006. Over a five-year period, electricity prices have risen by slightly over 25%. Demand for electricity is quickly outweighing supply and could have adverse effects on the country’s economy.

SpainThe average price of electricity in Spain grew by 15.5% over the past year with its five-year trend showing a dramatic increase of 39.3%. Consumers negotiating their supplies in the deregulated market have recently had to accept increases of up to 30%. Prices should continue to increase over the next 12 months.

SwedenLike its Nordic counterparts, Swedish electricity prices grew by 39.1% over the past year with a five year trend of slightly over 77%. The country’s largest supplier continues to be government-owned Vattenfall with privately held Fortum being the second largest supplier. High electricity prices were mainly blamed on the country’s long winter and stored volumes of water in the dams falling below capacity.

United KingdomThe average survey price of electricity grew by an alarming 41.4% over the past year with an 80.7% increase in pricing since 2001. The rapid rise in electricity pricing is mainly attributable to the increase in gas charges, as over 40% of all UK power stations are gas fired. The increase in energy prices is

also being blamed on the last winter season, which was originally forecast to be one of the coldest on record. Although this did not transpire, the forecast alone was enough to push up prices. Over the past year, the country’s Department of Trade and Industry began to assess the ‘High Distribution Levy’ which equates to an additional charge of 0.013 pence per kWh on each customer’s billings. With any drop in pricing unlikely in the near future, NUS expects a continued upward trend in UK electricity pricing.

The picture for gasThis year’s benchmark report, published by NUS Consulting Group, reveals not so surprising developments in the world’s gas industry as 13 of the 14 countries surveyed showed an increase in pricing mostly resulting from the rapid rise in world oil prices. Canada was the only country reporting decreased gas pricing, however, this was mainly attributable to very significant decreases surveyed in one province. As much of the world community has embraced the concept of deregulating gas supplies, the overall increase in pricing demonstrates that competitive markets can be volatile.

All European countries, with the exception of Denmark, underwent double-digit increases in gas pricing during the preceding 12 months. While Denmark only experienced modest increases over the past year, the country still retains its position as the most expensive country in terms of gas pricing. Each country reported similar reasons for the increase with gas prices closely shadowing world oil prices since September 2005. The emphasis in Europe appears to be expanding their current gas infrastructure as well as securing more reliable supplies and storage systems in the future.

In North America, Canada reported modest decreases in natural gas pricing. However, these overall decreases belie the fact that consumers in Ontario and Quebec experienced increases over the past year as natural gas pricing in Alberta underwent a significant downturn. Average prices in the United States jumped between 17 to 27% over the survey period. The primary cause of these increases was related to the major hurricanes in the Gulf of Mexico, which severely damaged critical US supplies. Recent news is that natural gas pricing

Energy

FTJ November 2006 291

has been softening as supplies have been on the rise and related oil prices are declining.

Given these developments around the world, medium to large business consumers of natural gas cannot afford to ignore the realities of the market. With fleeting opportunities for savings and the cold reality of ever-higher prices, each consumer must take an active role when it comes to their natural gas purchases.

AustraliaAustralian gas prices rose by approximately 4% over the past year equalling the country’s annual Consumer Price Index (CPI). Australia accounts for an estimated 8% of the world’s total known natural gas reserves equalling 123 years of domestic supply at current production levels. Currently, of the 3.5 million natural gas consumers in Australia, only 105,000 are in the commercial/industrial sector with the rest being domestic households. Natural gas supplies will be supplemented in 2009 by a pipeline currently under construction from Papua New Guinea. Once completed, the $3.5 billion project will supplement declining reserves from the Cooper Basin. Pricing in the coming years should remain stable showing increases commensurate with inflation.

BelgiumAverage gas prices in Belgium jumped by nearly 28% over the past 12 months as world oil prices increased. Gas competition in the country has basically ground to a halt since the announcement of merger plans between Suez (owner of Electrabel and Distrigas)

and Gaz de France (owner of Luminus). New proposals have been presented recently to the EU designed to increase competition in the Belgium market. As of this writing, the EU has yet to act on these proposals. Gas prices will generally follow the world oil market and as prices have been weakening in this commodity, gas prices should come down slightly over the next 12 months.

CanadaAverage natural gas prices in Canada declined over the past year between two to nearly 13% depending upon usage classification category. The average decline was mainly attributable to significant price decreases in Alberta with both Ontario and Quebec reporting modest increases over the past year. As new pipelines are being introduced into the North American market connecting gas fields in the Alaska and Northwest Territories, the NUS report anticipates further easing of natural gas pricing over the next 12 months.

DenmarkThe average price of gas in Denmark rose by nearly 6 to 8.5% over the past year depending upon usage category. The increases were mainly attributable to rising world oil prices as gas prices are linked to this commodity. As oil prices have eased over the past month and the short-term outlook confirms steady pricing, Danish natural gas prices should ease over the next year.

FinlandNatural gas prices in Finland grew by an average of nearly 16 to 20% depending upon survey usage category. While the increases over the past year were

significant, Finland does boast of some of the lowest gas prices in Europe. Finland is one of the few EU member states to rely on just one supplier for its natural gas – Russian energy giant OAO Gazprom. In 2005, an agreement was reached extending Russian gas exports to Finland through 2025. Prices should roll back at modest levels over the next year as world oil prices fall back below the $70 per barrel level.

FranceAverage natural gas prices in France grew significantly over the past 12 months ranging from nearly 21 to 31% over 2005 pricing. The rapid increase in world oil prices was mostly to blame for the increases. Gas supplies in France are deregulated, however, consumers can continue to purchase their gas requirements in the regulated market. Deregulated prices are indexed to the world oil market and are reviewed each quarter. Regulated supply prices are reviewed by the Ministry of Industry upon the request of Gaz de France (GDF). The report sees gas prices remaining stable over the next year as oil prices have come off their high, easing back to the low $60 per barrel range.

GermanyAverage German gas pricing rose between 14% to a little over 20% depending upon usage classification. The gas market is very volatile and increases of 10 to 15% over the next year are quite possible.

ItalyAverage gas prices in Italy rose by nearly 20% across all surveyed categories as world oil prices topped $54 per barrel in 2005 and exceeded $70 per barrel during the first six months of 2006. Also contributing to the increases were transportation costs as these charges slightly rose due to a new levy being imposed favouring interruptible supplies. In 2005, 84.8% of the gas sold in Italy was imported, while 13.9% came from domestic production. A scant 1.3% was acquired from storage facilities. In the short term, the regulated market should see increased pricing reflecting previous world oil prices as the deregulated market will experience lower prices. Over the next year, however, very little change in gas pricing is foreseen.

Energy

292 FTJ November 2006

The NetherlandsGas prices in the Netherlands rose on average by more than 26% over the past year. The Netherlands has traditionally been one of the more expensive countries in Europe in terms of gas costs being rivalled only by Denmark and Germany. Little change in pricing over the next year is foreseen as competition remains sluggish, despite the entry of new suppliers in the Dutch market.

South AfricaAverage gas prices in South Africa rose over 20% during the past 12 months as the country’s supplier, Sasol Gas, links its market rates to international oil prices. South Africa is not a deregulated market in terms of gas sales although the commodity is not widely used. Only certain niché industries (steel, petrochemical etc.) find an absolute need for this particular commodity. The National Electricity Regulator or NER has been transformed into the National Energy Regulator assuming additional responsibilities in the gas market. The move is widely seen reflecting the country’s growing reliance on gas supplies. While international oil prices will largely influence pricing in the gas market, the added variable will be what actions the NER takes now that it has been charged in regulating the gas market.

SpainAverage gas prices rose by between 27 to nearly 30% over the past year

although Spain remains the least expensive European country in terms of this commodity. Government legislation was introduced in 2006, forcing much of the country’s largest gas consumers from the regulated market to the deregulated one. Many large consumers remained in the regulated market as it offered more price assurances and less volatility. As a result of this legislation, an estimated 80% of Spain’s gas is supplied in the free or deregulated market. As gas is relatively inexpensive in Spain compared to other European markets and with demand for this commodity increasing, the report sees gas prices rising over the next year.

SwedenAverage gas prices in Sweden increased by between 26 to nearly 30% over the past 12 months. Like most other European countries, the Swedish gas market is deregulated, currently, over 2,600 companies choosing among seven gas suppliers. In 2005, natural gas accounted for only 2% of the country’s total energy requirements, the NUS report foreseeing gas pricing holding steady over the next year with the possibility of a slight decrease.

United KingdomWhile this year’s gas price increases have not been as high as those witnessed in 2005, the increases over the past year have been between 26 to nearly 28% across the board. A fire in Centrica’s Rough Storage in mid-February worried the markets with short

term pricing increasing dramatically and long term contracts also seeing an upward effect. Concerns continue regarding the UK’s largest storage facility with reports on the damage being worse than first thought. The upcoming winter demand continues to remain a concern although the 2005/2006 winter season was much milder than originally predicted. New gas interconnectors between the UK and Europe are on schedule and near completion, the NUS report claims that current levels of gas pricing are sustainable. However, further increases may be subdued with the current decline in world oil prices.

United StatesAverage natural gas prices rose significantly in the United States over the past 12 months, the increases ranging between 17 to over 27% depending upon survey category. The rise in natural gas prices was mainly attributable to hurricanes Katrina and Rita which caused widespread damage to production facilities located throughout the Gulf of Mexico region. The hurricanes also damaged critical transportation infrastructure leading to all-time historic highs in natural gas pricing. With most production facilities back on line from the devastating hurricanes of 2005 and spot prices softening with news of increased supplies, prices should decrease over the next year.

Energy

This article has been re-printed from the Foundry Trade Journal, November 2006 with the kind permission of the Institute of Cast Metals Engineers,

www.icme.org.uk

Calculations based on a one tonne ladle preheatedwith gasol have shown an alarming pollution of theatmosphere.• A 1 tonne ladle on preheat for 6 hours per day will

consume 14500 kg of gasol in one year (based on235 days)

• This one ladle will cost over 12000 € to preheat. • The preheating of this ladle will generate 43000 kg

of carbon dioxide in one year• This quantity of CO2 generated is equivalent to the

pollution of a full 40 tonne truck running for 20000 km

Energy is a major factor in the management of ladlecosts. An assessment in a Scandinavian foundry hasshown energy accounts for over 50% of these costs.

Costs for Lip pour and Bottom pour ladles inScandinavian foundries.

Lip Pour

Bottom Pour

Preheating/HoldingMaintenanceMaterialsInstallationWrecking

Preheating/HoldingStopper/NozleMaintenanceMaterialsInstallation/Wrecking

Roslagsgjuteriet AB conventionally used drum ladles giving the benefits of size and good weight distributionwhatever the weight of molten iron in the ladle. A major problem was the time and cost associated with ladle,maintenance, repairing and relining the ladle. A complete reline would take more than a week.Roslagsgjuteriet AB have changed their ladle technology to a lip pour ladle lined with KALTEK ISO. The ladlelining can now be replaced in a couple of hours. The highly insulating properties of KALTEK ISO and the greatlyreduced need of energy for drying and preheating haveprovided many benefits: • More castings can be poured from the ladle due to

the improved temperature control• Tap temperatures have been reduced by 20-30 °C• Reduced scrap due to cold pouring• Repair to the ladle lining has been almost eliminated.

The complete lining is replaced on a more regular basis• Reduced Gasol usage and reduced CO2 pollutionas

shown on the sheetCastable

Gasol Co2

20.000

40.000

60.000

80.000

100.000

0

27.120

81.230

2.8148.428

KALTEKGasol Co2

Kilo

gra

esm

m

Annual Gasol Consumption andCarbon Dioxide Generation

90% reductionof CO2 emmissions

Teil5 Engl 01.06.2007 13:19 Uhr Seite 1

E N E R G Y S A V I N G , C L E A N P R A C T I C E , R A P I D R E L I N E . . .

........................................................Improved productivity

.....................................................

...................................................

.................................................

Improved metallurgical control

Reduced labour cost /Lower energy cost

Safer /cleaner workingenvironment

K A L T E K *L A D L E L I N I N G S YS T E M S F O R H A N D L I N G M O LT E N M E TA L S

...................................................

.................................................Excellent insulatingproperties

Improved molten metaltemperature control

KALTEK ISOsystem

3

KALTEK shank system

S S E S F O R H A N D L I N G M O L T E N M E T A L S

Energy savings and moreTypically 60-70% of foundry energy costs

relate to the melting, holding and pouring

of the metal. The insulating properties of

Kaltek provide energy savings through the

potential for lower tapping and holding

temperatures. The KALTEK ladle lining

systems generally need no preheat, so

energy costs associated with gas-fired or

electric preheaters are virtually eliminated.

Reduced tapping and holding temperatures

also allow furnace refractories and

electrodes to last longer.

Improved ladle preparation andcleaning room productivityKALTEK ladle lining systems minimise ladle

turnaround time. Ladles with KALTEK

systems can usually be taken out of service,

relined, and returned in less than one hour,

without the need for labour intensive slag

removal and refractory maintenance, this

allows for a possible reduction the number

of ladles used in the foundry. In addition,

lower tap temperatures in batch pouring

operations reduce tap-to-tap times.

Productivity gains in the cleaning room

resulting from cleaner castings manufac-

tured with improved temperature control

significantly reduces scrap and upgrading

costs.

Improved work environmentThe KALTEK ladle lining systems offer unique

environmental and ergonomic advantages

in the melting and pouring areas. Lower

ladle shell temperatures allow ladle

operators to reline and return ladles to the

melting area more quickly, without the

labour-intensive and dusty chipping and

hammering operations required to maintain

conventional refractories. Reducing the

time for which aggressive tools such as

pneumatic chisels have to be used reduces

the risk of injury and conditions such as

“Vibration White Finger”.

Eliminating extensive ladle preheating

reduces noise and provides a more comfor-

table working environment in and around

the pouring area. Safety is also improved

as gas burners and other heating devices

are not left unattended for several hours.

KALTEK Shank System 90% Alumina Cast Lining

Ladle Shell Surface TemperatureKALTEK Lining vs. 90% Alumina Cast Lining

440

385

330

275

220

165

110

55

0

Tem

pera

ture

°C

Time (hours)5:0

0 AM

7:00 A

M

9:00 A

M

11:00

AM

1:00 P

M

3:00 P

M

5:00 P

M

7:00 P

M

9:00 P

M

11:00

PM

Insulating propertiesof KALTEK systems

4

F O R I M P R O V E D C A S T I N G Q U

K A L T E K L A D L E L I N I N G S Y S T E M S

Improved metal cleanlinessKALTEK linings can be replaced quickly and

frequently to maximize ladle and metal

cleanliness. Risks associated from ladle

contamination with other alloys can be

eliminated. Costs and the problems

associated with inclusion defects such as

scrap, upgrading, re-heat treatment, re-

inspection, excessive work in progress and

late delivery can be reduced. Single-life for

batch processes offers the ultimate in metal

cleanliness. Multi-life linings also provide

consistently cleaner metal to the mould for

improved casting quality.

Improved temperature controlThe KALTEK systems effectively reduce heat

loss through the walls of the ladle achieving

more consistent process temperatures

during pouring. This provides improved

casting quality by reducing temperature-

related defects such as mis-runs, cold laps

and burn-on. Slag defects and related

blowhole defects that result from variations

in metal processing temperatures are also

reduced. The improved temperature control

can allow more casings to be poured from

the ladle while maintaining the pouring

temperature specification.

5

High insulationproperties reduce

energy loss

KALTEK linings canbe replaced quickly

and frequently tomaximise ladle

cleanliness

U A L I T Y

KALTEK providesconsistentlyclean metal tothe mould

The rate of heat loss during holding and

pouring sequences is significantly reduced

by the use of KALTEK lining systems as

compared to conventional refractories. In

turn, outer ladle shell surface temperatures

are consistently lower, creating a safer and

more comfortable work environment.

Rate of Heat Loss from Different Size Ladle Brick Liningcompared with KALTEK

Heat Loss °C/minuteKALTEK Board System

Heat Loss °C/minuteHigh Density Refractory Lining

0

1

2

3

4

5

6

7

0,25 1 2 4 8 15 30

Ladle Weight Tonnes

Tem

pera

ture

°C

Typical Cooling Profile90% Alumina Cast Lining compared with KALTEK

KALTEK Board System 90% Alumina Cast Lining

1360

1370

1380

1390

1400

1410

1420

1430

1440

1590

1430

1270

1115 95

579

563

547

532

0

Weight Remaining in Ladle kg

Tem

pera

ture

°C

6

KALTEK ladle lining systems canbe tailored to meet your needsThere are three main types of KALTEK ladle

lining systems:

KALTEK Board Systems – supplied in board

form, the lining is prefabricated outside of

the ladle and is then positioned in the ladle.

It can be used in the bottom or lip pouring

of both molten iron and steel. The system

is also beneficially applied in pouring boxes

used in automatic or manual high production

lines.

KALTEK Shank systems – supplied as

preformed linings for Lip Pour and T. Pot

ladles. The system is ideally suited for

application in the transfer and pouring of

molten iron and molten steel.

KALTEK ISO – supplied as a dry, castable

powder. The powder is poured between the

ladle shell and a former designed to meet

the specific needs of the foundry. The

powder is ignited to initiate a bonding

reaction, after a short sintering time the

ladle is ready for use.

KALTEK ladle lining systemsadvantagesWhether melting iron or steel, KALTEK ladle

lining systems deliver benefits that can

improve your bottom line. These include:

M A D E T O F I T Y O U R N E E D S

K A L T E K L A D L E L I N I N G S Y S T E M S

KALTEK ISOlining sets

via controlledexothermic

reaction

7

Figure left:Applicationof a KALTEK

Board Systemto a Pouring

Box

Figure right:Lining a

ladle withKALTEK ISO

Figure left andfigure right:

Installation ofa KALTEK shank

Excellent insulating properties

Reduced pouring temperature variability

Reduced taping temperature

Improved furnace refractory life

Reduced radiant heat from the ladle

shell

Improved metallurgical control

Reduced re-oxidation rate

Reduced slag carryover/fewer slag

related inclusions

Improved alloy recovery, reduced fade

Reduced labour cost

Quick and easy assembly

Quick and easy knock out

Lower energy cost

Eliminated or reduced preheat

Reduced taping temperatures

Safer /cleaner working environment

Improved productivity

Significant improvements in ladle

preparation time

Longer pouring runs achievable

Frequent alloy changes can be

accommodated more easily

Reduced defective or scrap product