CAST HOUSE MANAGEMENT
How much hot metal is tapped out in a particular
cast depends on
The angle of the drill
The diameter of the drill
The tap hole length
Quality of mudgun clay
Mobility of hearth
Accumulation of metal and slag since the last closed
dry
Production of metal and slag during casting
Duration of casting
CASTING PHILOSOPHY
Casting rate matching the production rate
To achieve a casting duration above 100%
If not the knock out time not to exceed 20
minutes
TAP HOLE LENGTH
1. Ideal length is 1.5 to 3.0 meters depending on
length.
2. Mushroom inside the furnace adjacent to tap
hole box should be strong.
3. Lance opening of casting should be avoided
4. Eccentric drill bit must not be used
5. Quality of mudgun clay to match
requirements
CHRACTERISTICS OF MUDGUN CLAY
High melting point.
High corrosion resistant
High erosion resistant
Quick setting property
Easily flowable
Easily compressable
Easily drillable
Easy to handle
DESIGN OF MUDGUN CLAY
Blast furnace pressure
Capacity of drilling machine
Capacity of mudgun
Quality of metal and slag produced
OTHER IMPORTANT POINTS
While low silicon hot metal erodes the clay faster,
high alumina slag corrodes it faster.
The dehydrated tar used as bonding material in
the mudgun clay should have a melting point of
above 100 degree centigrade, so that the void
created by any steam and volatile matter on
heating is occupied by the molten tar. The tar
used is hygroscopic in nature and picks up
atmospheric moisture, especially during monsoon.
It is because of this reason; the mudgun is always
kept hot before closing the cast.
MAIN TROUGH
It is the place where the liquid iron and slag are
received and separated. More the duration of stay
of the liquids in the main through, better is the
separation. Because of this reason, the longer and
wider main through are in use. The depth of the
main through is limited to the performance of
refractories used under load.
The thickness of the shell can be 10mm to 20mm
and normally the slope of the working layer is
maintained at 1%.
TYPICAL REFRACTORY DESIGN
A layer of Ceramic fiber boards on the shell of the
trough.
Two layers of 45% Al2O3 super duty brick linings on
the board at sides and bottom
A layer of high alumina castable above the bricks
as safety lining
A layer of Tixotrophic castable above the safety
lining as working layer
MAINTENANCE OF CAST HOUSE RUNNERS
Use of water on castables is totally
prohibited as it weakens the refractories.
Monitoring the thermal profile by inserting
thermocouples at different places within
the safety lining of Main Trough can
correctly predict the maturity. Also, any
breakout can be avoided.
MAINTENANCE OF CAST HOSUE RUNNERS
The cast house runners are kept with refractory
lined covers and subjected to a de-dusting system
to achieve the following objectives:-
Pollution free working atmosphere
Clean cast house
Less drop in Hot Metal Temperature
Less thermal shock to refractories
A metal pool is always maintained in Tilting
Runners to minimize erosion of the bottom by
allowing metal to strike on metal.
