Firstly i apologise for taking so long in replying. i was out visiting customers in diff cities so i couldnt get back to u guys.
OddDuck, on 05 February 2010 - 03:40 PM, said:
Rambo, does the stock that you are heating directly contact the floor of the furnace? Do you get scale or flux on it? At those temps iron itself is a pretty good flux and will help to break down the brick that the floor is made of. You may have to switch to a castable, possibly something magnesia based, think how they line crucibles and ladles and such in a steel works. The chemistry of the furnace atmosphere may be the part of the problem. The floor should be the coolest part of the furnace, so the temp rating may not be the problem. Is the damage to the door arch mechanical damage, say bumping stock into it? You might have to go with a harder brick in that location.
With all that said, there are some parts of the furnace that are probably going to have to be considered as "consumable", and will have to be replaced on a regular basis. I'm sure that the life can be extended between repairs, but nothing's perfect. If I were you, I would really analize what is causing the damage first, mechanical or chemical, and go from there.
yes ure rite.. it IS mechanical wear and tear. while loading of the stock in the furnace, the workers do bump the arc columns and the floor while placing the material inside. that isnt something that can be avoided a lot i guess cause of the sheer bulk of the raw material piece. still, i was thinking maybe i should go for some sort of ceramic fibre lining on the arc columns which would act as a cushion maybe?? but what kinda material mesh would be able to handle the temperature of the furnace to hold the fibre in place? a normal iron mesh would melt in seconds and let the fibre covering the columns fall in a heap.
welder19, on 05 February 2010 - 09:18 PM, said:
I would switch to a different mfg or go with a high temp castable.
That's a BIG forge!
welder19
lol well that depends actually. i know of my competitors having even bigger ones.
forgemaster, on 08 February 2010 - 02:09 AM, said:
Have taken some photos.
I am having problems getting these to load, so I will try to load some more later tonight.
Basically these show our door with the water filled/cooled rim around it.
The pipes coming down through the hood, with heavy air hose to make a flexible connection to allow the door to go up and down.
The cooling tank outside, this is above the level of the door.
We use Plicast 60LC (LEB70544) for our furnace floor a castable refractory, we purchase it from a company called Vesuvius Australia. the product sheet gives it as "a low cement, high alumina castable with excellent strengths and outstanding abrasion resistance.
If you are using bricks on the floor which way are you laying them, sides flats or on end. On end is the better way to lay them.
thanks for the upload forgemaster. hmm i also use a high alumina castable which is called IS-8 grade refractory brick. any idea how that compares with the one ure using?
my dad tells me that we've tried the water idea a few years back and it failed. could have been the design. the real prob is the sheet of cast iron which is covering the sides of the doors. at times the flame comes out through the sides and burns the place there, despite our putting heavier plates, its still something we need to repair regularly... maybe once in 2 months or so. in trying to think of a way that makes the door fit better in the furnace so that it fits tighter. its a door which is lifted open and close by a pulley system
1
furnace0001.jpg 47.36K
278 downloads 
