KALTEK ISO lining systems are the latest addition to the KALTEK range of ladle lining systems. The portfolio of performed one-peace linings, board systems and castable power means that optimal lining systems can be developed to meet your molten metal transfer needs.

KALTEK ladle systems provide benefits in improved foundry processes, increased process control and enhance productivity. Combining efficient insulation with refractory stability, KALTEK systems assist in improving metal cleanliness whilst lowering energy, cleaning, upgrading and scrap costs. Ladle preparation times are reduced and preheating costs minimized. Metal temperature variation during pouring is reduced and casting quality increased.

Finally, KALTEK ladle lining systems improve the overall work environment by reducing noise, and radiant heat in the melting area.

Typically 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.

KALTEK 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 manufactured with improved temperature control significantly reduces scrap and upgrading costs.

The 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 comfortable 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 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, reinspection, 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.

The 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 temperaturerelated 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.

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.

There 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.

Whether melting iron or steel, KALTEK ladle lining systems deliver benefits that can improve your bottom line. These include:

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