We heartily thank you for enquiring about our product. We would like to give you an insight into the product that you are going to use to give you optimal performance in your coreless induction furnace. A core less induction furnace works on the principle of melting of metal through conduction of heat generated by circular electrical coil around the furnace. The temperature is elevated gradually to decompose the metal and the impurities are flushed out of the system being lighter in weight which is then manually removed to attain filtered molten metal ready to be casted. This further is tapped in ladles then moved through continuous casting machines to make suitable products for rolling mills.

The acidic silica ramming mass plays an optimal role in this process. Silica ramming mass is basically a proportionate mixture of Quartz/Quartzite graded and blended to homogeneity. The pure stones cleaned and handpicked are crushed in a closed circuit of machines then passed through high gauss magnets to remove free iron induced due to grinding media and then are mixed with utmost care to ascertain appropriate mix to suit furnace requirements.

Silica ramming mass as used by the consumer are of numerous types depending on the basic requirements of the consumer. They vary with factors like, size of furnace, make of furnace, charge mix being used, tapping temperature, coil condition, machine sensitivity, working atmosphere (i.e. dry, damp, humid etc.) and economies.

The silica ramming mass is a generated mixture of quartz/quartzite mixed in proportion to form a monolith body. It is rammed in furnace using manual ramming or electrical rammer for optimal performance. If the product is PRE-MIX (i.e. Boric acid added by the manufacturer) then it is directly rammed or if non-premix is used then it has to be added at the consumer end as per requirement. The proportion of same varies from 0.8 % for slag zones to 1.4% in tapers and bottoms.

The basic use of silica ramming mass is that it starts its matrix formation at a lower temperatures of 200-300 deg.C and completely deforms at around 700-800 deg. C. It has to be assured that the boric used is mixed homogeneously so that the same can percolate to the surface and generate a monolith body up 25% of the exposed surface to the metal. When the temperature is gradually increased the boric acid reacts with the oxygen and silica of the product and flows towards the metal form surface. As the temperature increases in the sintering heat the boric acid reacts with the silica and sinters the front surface and hardens the same to prevent percolation. Appropriate amount of boric acid is to be added so that the optimal sintering takes place. If the boric is less than the sintering in the bottom will be less and there will be high chance of leakage whereas if the boric is more than require then there will be a high probability of GLD.

We manufacture complete range of ramming masses for all kinds of coreless induction furnaces.

The material is hygroscopic in nature so it has to be prevented from direct or indirect contact with moisture and liquid for optimal performance.

The grading may vary from panel to panel depending on the capacity of the furnace.

There persist myths about the purity of silica in quartz and quartzite. And users are normally unclear about usage of quartz or quartzite. Quartzite though impure (relatively less silica 97 to 98%) performs better in high temperature furnaces then purer quartz of 99.5% SiO2. This theory is normally unanswerable by numerous metallurgist and experienced technocrats in this field. Silica though plays a vital role for conduction of heat and prevention of leakage but is not that significant in comparison to the emphasis given by the end user. The matrix formation at the desired temperature and the capability to conduct is the most important criteria to be evaluated for optimal performance.

The best raw material with inhomogeneous mixing and improper application will produce worst results then slightly impure material with proper grain ratio. We suggest our quartzite base mix for high temperature continuous casting systems and quartz mix for smaller pit side pouring systems. The optimal silica in premix is normally 97% + 1% to incorporate the boric acid being used. The base material has silica of specification above but the overall percentage after using boric acid goes down by the proportion of boric being used.

Proper application, storage, usage and numerous factors play a role to give optimal performance of the product. It is hygroscopic in nature so should not be left in open as it absorbs moisture from the system and affect the life of the product. Appropriate and proper ramming further enhances the life of the product. Optimal charge mix with lesser impurities gives optimal results and drastically affects the life of the machines and consumables. We can supervise the initial heats on use of our products to give optimal life on application.