LINING VIBRATOR/PNEUMATIC VIBRATOR
In the realm of induction furnaces, the lining plays a critical role in ensuring optimal performance. The lining, typically made of a suitable ramming mass, directly impacts furnace stability, output efficiency, and metallurgical control. The choice of lining methodology depends on various factors such as furnace capacity, design, and the type of metal being melted. Lawatherm Furnace Pvt Ltd introduces a range of advanced lining vibrators designed to
streamline the lining process and enhance furnace performance.
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2/3/5/6 ARM LINING VIBRATOR
For side lining preparation, Lawatherm offers versatile 2/3/5/6 Arm Lining Vibrators. These vibrators feature multiple arm configurations along with a central air divider. The equipment automatically rotates inside the former, leveraging the angle of impact to facilitate uniform lining application. With an operation time of 1-2 hours, these vibrators ensure efficient and consistent lining across various furnace configurations.
BOTTOM LINING VIBRATOR
Lawatherm’s Bottom Lining Vibrator is engineered to facilitate efficient bottom lining procedures. Equipped with a pneumatic vibrator, the bottom vibrator unit allows for the ramming of dry refractory material in approximately 50 minutes, ensuring perfect compaction and a level bottom surface. This expedited process results in improved furnace stability and operational efficiency.
Basic Introduction
In induction furnaces working face of the main crucible is lined with a suitable ramming mass. Furnace performance is directly related to the lining performance. Well-stabilized lining results in smooth working of the furnace, optimum output, and better metallurgical control. The lining practice best suited to a particular foundry will depend upon the furnace capacity and design, the metal being melted output etc.
Requirement Of A Proper Lining:
Lawatherm emphasizes the importance of a proper lining characterized by thermal resilience, chemical compatibility with molten metal, structural integrity, erosion resistance, and optimal electrical efficiency. The lining should also be easy to install, repairable, and possess low thermal and electrical conductivity. Adhering to these requirements ensures prolonged furnace lifespan and enhanced operational performance.
- Thermal characteristics: it should withstand the stresses developed by the thermal cycle in operation.
- It should be chemically insert to the metal being melted: chemical inertness to molten metal can be achieved by using acid lining for acid slag & basic lining for basic slag.
- It should have enough structural strength to withstand operating conditions.
- The thickness of refractory lining must be such as to ensure good electrical efficiency and thick enough to counter the risk of unexpected failure and major damage to the coil.
- It should have high erosion resistance.
- It should have low thermal & electrical conductivity.
- It should have proper hardening characteristic.
- It should have easy installation procedure.
- It should be easily repairable, economical & posses ease of knocking/removal.
Comparison Manual Lining V/s Lining Using Vibrator
Basic Lining Procedure
| S.No | Manual Lining | Lining Using Lining Vibrator |
|---|---|---|
|
1 |
Erratic and shorter lining life |
Consistent and enhanced lining life |
|
2 |
Unpredictable production |
Predictable and increased total output tonnage
|
|
3 |
Density of Lining is not uniform |
Density of lining is uniform throughout the shell |
|
4 |
Lining thickness is not uniform around the former |
Lining thickness is absolutely uniform around the former |
|
5 |
Refractory material in the tapered Section of the former is not
completely deaerated leading to non-uniform erosion of lining
and problems like elephant foot & leakage |
Material in the tapered section of the former is completely dense achieving max. & uniform compaction. Thus erosion is uniform in the tapered section eliminating any possibility of elephant foot & leakage due to weak lining. |
|
6 |
Refractory material in the tapered Section of the former is not
completely deaerated leading to non-uniform erosion of lining
and problems like elephant foot & leakage
|
Material in the tapered section of the former is completely
dense achieving max. & uniform compaction. Thus erosion
is uniform in the tapered section eliminating any possibility
of elephant foot & leakage due to weak lining. |
|
7 |
Labor Intensive |
One skilled and one semi-skilled person can perform the whole lining
|
|
8 |
Lots of hazardous silica & dust in the air |
Pollution free |
|
9 |
Takes long hours to line the furnace from start to finish |
Whole process of lining is completed in 3-4 hours |
|
10 |
Hassles due to human component like attitude, error & fatigue. |
Smooth and hassle free operation |
Bottom Lining
Ramming mass is poured into the bottom and leveled before initiating the ramming process with the Bottom Lining Vibrator. Successive layers are added until the desired level of compaction is achieved.
- Pour the ramming mass in the bottom to the extent and level the ramming mass.
- Start the ramming with bottom lining vibrator. Continue ramming till layer becomes hard. Keep on introducing layers of proper thickness and repeat the process till required level is attained.
- Care has to be exercised not to allow antenna rod to bend during bottom lining installation.
Side Wall Lining
The former is positioned securely within the furnace, and ramming mass is introduced between the former and coil. The 3 Arm Lining Vibrator is then employed to compact the material until it hardens, ensuring consistent wall thickness.
- Make sure that furnace bottom is leveled.
- Lower the former into furnace making sure it sits flat and level on bottom refractory. Check the surface of former makes contact with earth leakage antenna.
- Set the former in place and position so that the resulting wall thickness will be consistent and concentric with coil.
- After aligning former, introduce ramming mass in the space between former and coil. Now compact it with 3 Arm lining vibrator till it becomes hard.
- Keep on adding ramming mass during 3 Arm lining vibrator movement from down to up.
- After reaching to top layer make the top collar and spout with ramming mass ix with sodium silicate.
3 Arm Lining Vibrator
3 arm lining vibrators are used for side lining preparation, consist 3 vibrator cylinder and one air divider at center of the equipment. It automatically rotates inside the former due to the angle of impact. It will take 1-2 hours for the full operation. There is require 6kg/cm2 Air pressure for smooth operation during the lining
Bottom Lining Vibrator
Bottom Vibrator Unit ramming plate is equipped with one Electric vibrator. Dry refractory is rammed in about 40 min. in one operation, achieving perfect compaction and absolutely even and leveled bottom.
Salient Features
- Lining vibrator is equipped with a control panel by which we can select the vibrator to operate in AUTO MODE.
- Control panel controls the timing and lift of the vibrator through the hoist.
- Contact between former & vibrator is controlled & consistent during vibration
- 3 arm lining vibrator can adjust itself against the taper of the former.
Lining Vibrator
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Arm Lining Vibrator
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Bottom Lining Vibrator
Lorem Ipsum is simply dummy text of the printing and typesetting industry. Lorem Ipsum has been the industry's standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a type specimen book. It has survived not only five centuries, but also the leap into electronic typesetting, remaining essentially unchanged.
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Air Demolition Hammer
Lorem Ipsum is simply dummy text of the printing and typesetting industry. Lorem Ipsum has been the industry's standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a type specimen book. It has survived not only five centuries, but also the leap into electronic typesetting, remaining essentially unchanged.
Salient Features
Lawatherm’s Lining Vibrators are equipped with advanced features to streamline operations:
- Control panel enables operation in AUTO MODE, regulating timing and lift of the vibrator.
- Consistent contact between the former and the vibrator ensures uniform vibration.
- The 3-arm lining Vibrator can adjust itself against the taper of the former, ensuring precise lining application.
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Advantages
- Efficiency: Lawatherm’s Lining Vibrators expedite the lining process, reducing downtime and enhancing overall furnace efficiency.
- Uniformity: By facilitating uniform compaction, these vibrators ensure consistent lining thickness and density, contributing to improved furnace performance.
- Precision: Advanced control features enable precise regulation of vibration parameters, resulting in optimal lining quality and longevity.
Construction
Specifications
- Bottom Lining Vibrator: Equipped with a pneumatic vibrator, capable of ramming dry refractory material in approximately 50 minutes.
- 2/3/5/6 Arm Lining Vibrator: Features multiple arm configurations and a central air divider, suitable for various side lining applications.
Applications
Lawatherm’s Lining Vibrators find application in a wide range of industries utilizing induction furnaces, including steel plants, foundries, and metal casting facilities. These vibrators streamline the lining process, enhancing productivity and operational efficiency.
Installation
Lawatherm provides comprehensive installation guidelines for its Lining Vibrators, ensuring seamless integration into existing furnace setups. Technical support is available to assist with installation and setup procedures, ensuring optimal performance from the outset.
Maintenance
Regular maintenance is essential to prolong the lifespan and performance of Lawatherm’s Lining Vibrators. Periodic inspections, lubrication of moving parts, and prompt resolution of any issues are recommended to ensure continued reliability and efficiency.
Safety Precautions
Lawatherm emphasizes the importance of adhering to safety protocols during the installation, operation, and maintenance of its Lining Vibrators. Users are advised to familiarize themselves with safety guidelines and utilize appropriate personal protective equipment to mitigate risks associated with industrial equipment operation.
Frequently Asked Questions
The operating time varies depending on the specific model and application requirements. However, most vibrators complete the lining process within 1-2 hours.
Yes, Lawatherm’s Lining Vibrators are designed to accommodate a wide range of ramming mass formulations, ensuring versatility and compatibility with various furnace setups.
Regular maintenance, adherence to operating guidelines, and prompt resolution of any issues are essential for ensuring optimal performance and longevity of Lawatherm’s Lining Vibrators.