The charging well of a melting furnace, recast
Where the charge enters, the shape decides the wear
Initial situation
The charging well is the point at which a melting furnace is fed — and therefore the point where material lands, slides and pushes. It takes mechanical load and thermal shock at the same time, and it is the first zone to recede. On this aluminium melting furnace it had worn back so far that the anchors stood free in the space.
Scope of services
- Charging well
- Monolithic casting
- Anchoring
- Melting chamber
- Door portal
Project data
The task
The well had receded down to the stud pattern; the substrate had to be made sound again before new material made any sense.
A slope that the charge slides across must have no joints and no edges — every step is a point of attack.
Inlet, melting chamber and door portal merge into one another. Three separate repairs would have produced three new seams.
Three weeks lay between inspection and completion — the furnace had to stand still predictably during that time.
The SBS approach
The charging well was broken out completely, the stud pattern checked and supplemented, then recast monolithically — with no joints in the sliding surface.
The slopes run into the melting chamber in rounded transitions. Rounded means: the charge is guided rather than braked, and there is no edge where build-up can take hold.
Melting chamber and door portal were done in the same standstill. That puts the seams where they belong structurally, and not where a repair happened to end.
The surface was closed and floated smooth — a dense face absorbs less melt than a porous one.
The charging well of a melting furnace, recast in pictures
Before: the well has receded down to the stud pattern
After: closed slopes, rounded transitions, no joint in the sliding surface
The melting chamber was done in the same standstill
Door portal: the third zone that belongs in the same standstill
Measurable results
The key figures of the “The charging well of a melting furnace, recast” project
Similar references
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