The ratio of boric acid to ramming mass in induction furnaces is usually between 0.

2%
and 5%. The amount of boric acid added depends on the customer's
requirements. Explanation Boric acid A small amount of boric acid is added to ramming
mass to help sinter the crucible lining Sintering Sintering is the process of forming a
dense layer that binds the grains in the lining.
This layer prevents liquid metal from penetrating the lining and erosion.
Boric acid melts at 171°C and separates into boric oxide and water. At 440°C, boric
oxide reacts with the silica in the ramming mass to form a borosilicate melt.
Ramming mass Ramming mass is a heat-resistant aggregate that's used to line
induction furnaces. Ramming mass is made up of granules and powder materials with a
small amount of binder and other ingredients.
The performance of the furnace is directly related to the performance of the lining.
The raw material of silica ramming mass is high quality quartz, mixed with high quality
boric acid. Silica content of its raw material is more than 99%. Generally, we will add 1.5
% to 1.8 % boric acid to premix with quartz, but it can be changed as per customers'
requirements Basic ramming mass, also known as acidic ramming mass, is a refractory
material used in induction furnaces for lining the crucible. It is composed of a mixture of
magnesite and other minerals, such as graphite and aluminum oxide, which are finely
powdered and bound together with a resin or binder.
silica ramming mass is composed of silicon carbide (Sic), silica (SiO2), aluminum oxide
(Al2O3), and iron oxide (Fe2O3). These components make up the majority of the
composition of silica ramming mass. Silica ramming mass is generally produced using a
chemical reaction between carbonaceous material and molten metal.
Acidic Ramming Mass, also known as Silica Ramming Mass or Mix, is used in Coreless
Induction Furnaces, for melting of scrap. High performance Silica Ramming Mixes (also
known as Acidic Ramming Mass in generic terms), designed to minimize erosion in
induction meltingSilica Ramming Mass is basically protection against heat with meting
temperature of around 1700-1800°C while the melting of iron ore or metal is about
1600°C Ramming refers to the compaction of granular materials (mold materials, but
also refractory masses) using a ramming tool. In hand or floor molding (open sand
molding), bentonite-bonded or oil-bound mold sands (see green sand mold, O.B.B.
sand, green sand molding process) are mainly compacted by hand ramming.

Chemical Composition: (%) Al2O3 84 Min MgO 11 Min SIO₂ 0.8 Max Ti O₂ 0.7% max 2.
Grain Size analysis: 7F (≤7mm) 3. Bulk density: 2.7-3.05 gm/cc 4. Operating melting
temp: 1500-1800°C (MAX) Basic ramming mass, also known as acidic ramming mass,
is a refractory material used in induction furnaces for lining the crucible. It is composed
of a mixture of magnesite and other minerals, such as graphite and aluminum oxide,
which are finely powdered and bound together with a resin or bind.
Silica Ramming Mass is basically protection against heat with meting temperature of
around 1700-1800°C. while the melting of iron ore or metal is about 1600°C.What is the
relationship mass and melting point. Out of the compounds having same type of bond
(Covalent bond) the melting point is directly related with molar mass. This is because
the Vander Walls force acting between covalent molecules is directly related with molar
mass. What is affects melting point. Impurity: The addition of impurities to the compound
results in a decrease in melting point. Bonding: The melting point also depends upon
the type of bonding between the compound. The compounds having ionic bonding have
more melting points than compounds having covalent bonding.
The basic lining material for induction furnace is made of refractory materials such as
magnesia, dolomite, and alumina. These materials have high melting points and can
withstand high temperatures, making them ideal for lining the furnace.

EFFICIENT INDUCTION MELTING PRACTICE This is an older version of technology paper. There
are some changes which will be indicated during the program presentation. All are
aware that the Melting Shop is an important department of any foundry. Now a
days it consists of med. frequency Induction Furnace. This melting shop spends
40% to 60% of casting price. Contribution is from pig iron, scrap, ferroalloys &
electricity. Controlling cost in melting dept is very necessary. Factors which are
controlled by market, like price of raw material (scrap, alloys, electricity, etc.) are
not in the foundrymen’s hand. Foundrymen can control/reduce cost at various
stages. Few of them are as under.
1) Selection of Induction Furnace. (KW rating, capacity of furnace, Hz, etc.)
2) Working hours on induction furnace.
3) Producing more metal in minimum time.
4) Operating furnace on min Kw to minimize M.D. charges.
5) Avoid holding of metal.
6) Minimize chemistry adjustment time.
7) Empty out the Furnace as fast as possible. Refractory Materials Silica (SiO2)
ramming mass, Boric acid (binder), Corundum (Al2O3) and Magnesite (MgO)
1. They have to withstand high temp. retain their strength and also take part in
chemical reaction.
2. Acidic refractories contain high Silica
3. Basic refractories are Magnesite.
4. Acid slags have high silica content and do not react with acidic refractories.
5. Basic slag furnaces viz. for steel are lined with magnesia.
6. Induction furnaces for iron melting are lined with silica ramming mass. It is
mixture of crushed quartzite – silica grains from 0 to 4 mm and 0 to 6 mm and
boric acid as the binder. Special refractory castable are used in the furnace
bottom. The coil is grouted with refractory cement. Magnesite linings are used for
high alloy steels. Fluxes are low melting materials. These mix with sticky, viscous
furnace slags, sand, earth materials, metallic oxides etc. and convert them into
easy flowing slags. Silica Ramming Mass It is made from crushed quartzite. It
should be clean and without any binder. SiO2 should be above 98.5%. It should be
amorphous and be crystalline which can be checked under polarized light. Color
should be snow-white Grain Size The more compact a lining, the greater the
strength and life. The packing density depends upon the p proportion of grains of
different sizes that will give the least open spaces between grains (particles).
Standard Mix Particle Size Sieve Opening Mm Mesh Nos. % Coarse 0.6 and above
+ 20 45 Medium 0.2 65 10 Fine 0.2 150 20 Extra fine Fine - 150 25 Preparing the
Ramming Material The ramming material is dried on a heated tray of sheet metal
at about 120o C. It is then cooled to below 60o C and mixed with boric acid
powder in a concrete mixer. Approximately 0.8 to 1.2% boric acid is used as
binder, for the melting temperature of 1450 to 1550o C. Fig. 1 Ramming Tools Ram
in layers and take care that each layer thickness does not exceed 40 to 50 mm.
Use ramming forks tools only for ramming. When the bottom is rammed, the steel
former is inserted and centered. Then ramming is continued up to the top. To
prevent shifting of the former while ramming a starting block is preferably placed
in. The rammed material is then slowed heated to 1000o C by means of induction
in 6 to 10 hrs. Then the former is melted and charging commences.
Initially use only clean, rust free and small size scrap. Fill up the crucible and
heat liquid metal to sintering temperature. The holding period after sintering is
about 2 hrs. On starting up, take at least 4 to 8 melts continuously without
intermediate cooling. Adequate cooling of the coil by water is of great
importance for prolonging lining life. The outlet water temperature must never
exceed 20o C above room temperature. Once every week on holiday, the
furnace should be emptied. The lining dimension shall be measured and
inspected carefully. This will give an idea about the erosion that has taken place.
Sintering During First Heat after Relining of Induction Furnace. This is very
important operation and has to be done cautiously. Normally the supplier of the
furnace recommends the sintering cycle and should be done as per his
instructions.
While sintering, provide a thermocouple touching to the former and achieve
desired rate of heating. Recommended rate of heating as per furnace size is as
below.
a. 500 C per hour for 15 ton and above furnace
b. 1000 C per hour from 5 to 15-ton
c. 1500 C per hour from 1 to 5-ton
d. 2000 C per hour below 1 ton There should be continuous heating without any
interruptions during sintering.
Typical Cross Section of Induction Furnace Lining Problem - Solving Check List A
check-list of twenty questions is given for particularly baffling problems. If these
steps are systematically followed the problem can, in most cases, be solved.
1. If this is a one-off failure, then repeat everything with personal attention to
details and in the situation, best possible melting practices.
2. If a repeat failure, is it in one shell only? Give it thorough maintenance and a
clean working area. Remember that any activities close by could affect
performance. If failure occurred in several shells, then ask yourself what is
common to them all, e.g. cooling water system (when did your de-scale etc.),
type of charge and additives etc. Sometimes improvements can have a negative
effect, e.g. higher carbon from improved coke may aggravate a super-heat-erosion
problem.
3. May be the problem started with a new source or batch of ramming mass.
Personally check material in stores to ensure that the first-in-first-out is followed.
4. Check stock card, location and condition of binder, additives, charge materials
etc. If any item suggests that short cuts may have been taken then stock out.
5. Personally watch drying and mixing operation (preferable adding dye),
positioning of former, placing of material in furnaces (esp. bottom corner) and
ramming etc. and calculate rammed density. Have there been any changes in tools
used, personnel, supervision or procedures?
6. Is drying-out below 1000 C and warm-up to 8000 C sufficiently slow? Keep them
sticks handy (temperature indicating crayons etc.) How was it done in the past?
7. At melt-down, is bath level brought up quickly enough? Is final temperature
held long enough and high enough? Cross check your thermocouple or pyrometer.
Compare log readings with earlier successful runs.
8. In Case of Mains Frequency Furnace, operate at 66 to 80% heel for first 4 days
or first several heats without shut down to sinter the lining fully. For single shift
operation, keep furnace full of starting blocks on low tap to maintain temperature
above 8000 C at all times till lining sinter zone is strong enough to withstand
cooling. The best lining is made during the first week of its life. Was the failed
lining shut down too soon may be for a holiday etc.
9. Start with several melts of good clean charge Use special feedstock if
necessary. What was used previously to achieve successful campaigns?
10. Switch to normal charging and melting pattern. Refresh your memory again as
to what was charged, how much and how. Observe stirring action. Any changes in
source, cleanliness or storage policy for charge materials?
11. Look out for delays in metal analysis or adjustment, ladles coming late to
furnace etc. Superheating is the single biggest enemy of lining life.
 12. Think about melt additions or slag modifiers. What brand, quality or purity,
how weighed and added, at what bath temperature or heel level, in what
sequence, how long before tapping? Ask again - any recent changes? Beware of
additions of which you do not know the composition.
13. Ask about previous (and observe present) slag generation and slag removal
practices. Be observant. Does anything look or behave differently?
14. Ask about recent overhaul or replacement of furnace or control equipment,
back up refractories or electricals, etc.? (Changes in thermal conductivity or back
up bricks, or cooling water temperatures can have far reaching effects on hot
face temperatures and erosion resistance.)
15. Any changes in shift operation, weekend policy, power saving power cut or
power failure management.
16. Consider the human angle, any changes in workmen or supervisors? Are there
inter-personal relationships in incentives or overtime, in maintenance personnel
or stores staff, in management style or expectations, in pricing or relationships
with suppliers?
17. Think about the working climate in the melting shop. Do you value and reward
consistent, systematic work habits or is it a case of them always ‘firefighting’
coping with crises, handling emergencies, under pressure to keep up with forever
changing demands or disorganized work habits in the casting shop. It is hard to
achieve a predictable lining life under these conditions.
18. Write down a list of all changes observed, however minor. Often, seeing a
combination of three or four items on the list will give a clue to the problem.
Writing down the observations also helps logical thinking and may remind you of
aspects not checked.
19. Having decided what is the most likely reason for failure, correct that by
changing, as far as possible, only one variable at a time. If you make too many
changes, and results are erratic, cause and effect will elude you. But if you can
learn from your experience or mistakes, progress and improvements are sure to
follow.
20. Remember, you know your own operations best. You can help yourself (with
honest questions and honest answers) far better than any outside “expert” can.
Medium Frequency Induction Furnaces Mains frequency is 50 cycles per second
(Hz) whereas medium frequency can be defined in the range of 100 Hz to 2000 Hz.
Main frequency furnaces have better stirring effect but need continuous running
with some molten metal heel. Melting is relatively slow as power density is lower.
The mains frequency furnace was commercially established during 1950-1960.
However, due to the above disadvantages and with the commercialization of
medium frequency furnaces during 1970-1980 off late the mains frequency
furnaces are not popular and instead the use of medium frequency furnaces is
increasing tremendously. At present there are more than 2000 medium frequency
furnaces in use in India
Medium frequency furnaces offer the following direct advantages over
conventional mains frequency furnaces.
1. Require less power to achieve the same liquid metal output, i.e. lower kwh/ton
of melting. There is saving in electric power to the tune of about 50 kwh/ton.
2. There is no necessity to keep molten metal (heel) in the furnace to run the
furnace continuously. Thus, no overnight holding power costs.
3. We can pump in more KW per ton of metal. Therefore, one can use smaller
capacity furnace, with lesser space requirement and shorter furnace relining time.
4. Variable power control gives accurate melting and holding temperature.
5. Shorter cold lining melt time and no necessity of starting blocks.
6. We can completely empty the furnace, hence there is no mixing of one grade of
metal with other grade.
The stirring depends upon power input, capacity of the furnace and the frequency
by the following formulae.
h – Height of molten metal above horizontal level.
d – Lined diameter of the furnace.
k – Constant which is 5 for cast iron.
From the above formula, it will be observed that the stirring increases as the
power input is increased. It reduces as the capacity of the furnace is increased
viz. after wearing of lining. It also reduces as the frequency is increased.
I have observed that even if h/d is lower than 0.1 foundrymen are successfully
using medium frequency furnaces for melting of Cast Iron and S. G. Iron. Modern
Techniques for Longer and Economical Induction Furnaces Lining Preamble One of
the most important things in a foundry is to have a reliable friend and a well
working and flexible melting induction furnace. I call the furnace “she” as she
blushes when you heat her up. She is the most important part in your foundry, she
acts independently and often based on feelings, she is wonderful in full action and
she rewards you plentifully if you treat her honestly and with respect. Without
molten metal of correct analysis at correct time with sufficient volume, no
sophisticated foundry can survive in the long run. The furnaces must run
continuously with as few problems as possible at as low cost as ever possible.
Choice of Correct Material For coreless induction furnace you can choose among
the following lining materials depending on the alloy to be melted: SiO2 (Silica or
Quartzite) Al2O3 (Alumina) MgO (Magnesite.
For normal grey iron or basic iron for ductile or malleable iron quartzite is the
best. No other material can compare with the behavior of silica in that
environment. Also melting unalloyed steels as well as copper and brass will give
very good results. However as always, the right supplier and the correct quality
must be chosen with care, Silica (quartz or quartzite) can be found everywhere.
Unfortunately, I do find foundries all around using cheap local quartz and thereby
jeopardizing the safety of the furnace and the workmen. For alloyed steels the
correct choice would be Al2O3 in the shape of corundum (brown, white),
Al2O3/MgO material should be used. If the furnaces are melting continuously and
if the melting temperatures are very high (17000) MgO should be used. Fig. 3
Volumetric Expansion of Different Lining Materials The expansion diagram gives a
simple answer to why SiO2 behaves so well in the coreless furnaces. After initial
transformation at 5730 C of silica to quartz with a volume expansion of around
1.4% no further changes will occur except if the chosen quartzite is transformed
to cristobalite. This could be a disaster and is one of the reasons why correct
supplier must be chosen. A supplier taking full responsibility and having the
technical knowledge and back up. Deletion Of Asbestos Sheets The preparation of
the coil cement is of great importance not only to protect the coil but also to give
a correct build-up of the total lining. The coil cement should not just be a normal
cement but must be of a “soft quality” composed of a fine-grained matrix. The coil
grout shall at as a slipping plane and must not have any coarse grains that might
damage the sensitive copper coils. The preparation and repair must be carefully
carried through and no rough surface must be allowed as well as no thicker and
thicker build-up can or should be approved. This must be dried before installing
the lining. Between the coil grout and the lining no insulating material should be
used. In case pull or push put techniques for lining removal are used provide taper
in the coil coating. All use of asbestos should be avoided in coreless furnaces.
Those foundries still using this material are actually paying money to achieve
shorter lining lives. Asbestos between the coil cement and the lining gives you the
following disadvantages.
1. Dangerous for the health.
2. Time consuming installation.
3. Additional cost for material.
4. Shorter lining life as cooling effect will be reduced.
5. Less security as lining will be sintered all through.
6. More frequent coil problems sintered lining will lift coil upwards.
7. More difficult breaking out of lining as lining has no powder layer.
The influence of bricks and/or insulating fiber between quartzite dry lining
material and coil cement in a coreless furnace. To be able to judge the influence of
bricks and ceramic insulating blanket between the coil cement and the dry
quartzite lining material in a coreless furnace, the following calculation and
assumptions have been made. Lining Thickness – total 198 mm Metal
temperature – 15000 C Temperature inside coil cement (towards center) 1000 C
Value Kcal/m.h. 0C For sintered quartzite 1.20 For semi-sintered quartzite 0.95 For
powder quartzite 0.60 For fiber blanket 0.03 For asbestos 0.13 The following
alternatives have been checked 1. 15000 C 170 20 4 4 1000 C T1 T2 T3 T4 T5 2.
15000 C 198 1000 C S SS P T1 T2 T3 T5 3. 15000 C 195 3 (Fiber) 1000 C T1 T2 T3 T4
T5 S = Sintered (30%) SS = Semi-Sintered (30%) P = Powder (40%) Alternative T1 T2
T3 T4 T5 QkW/M2 1 1500 550 468 - 100 7.1 2 1500 1224 909 - 100 8
Comments By using one single fiber blanket (3mm) instead of bricks (20 mm) and
asbestos (2 x 4mm), the energy loss through the wall will be reduced. However,
the temperature will be high enough to create a semi-sintered material all the way
out to the fiber, which certainly is a risk factor for cracks and break-through. By
using bricks and asbestos the quartzite material will be hard all through and the
expansion movement within the silica can lift the bricks and will most certainly
penetrate into joints between the bricks and thereby open up the possibilities of a
material penetration. By using quartzite only, at least 25% of the lining will be in
powder form, which will itself act as a slipping plane and a self-healing area. The
slightly increased heat loses are negligible compared to the heat losses from an
uncovered furnace. The Q value for the molten iron surface is 800Kw/m2 (100x).
Recommendation Based upon above calculations and experience all over the
world, I strongly advise everybody using dry quartzite materials in coreless
induction furnaces with a well-prepared coil cement, to delete all kinds of
insulating material between the quartzite lining and the coil cement. In case of no
coil cement I would recommend a layer of mica sheet (0.5 mm) between the coil
and quartzite. The advantages are as follows: 7. Less time to install. 8. Less cost of
insulating material. 9. Higher safety margin due to self-healing powder layers. 10.
Less radial pressure on coil. 11. Less risk for break though caused by complete
sintering. 12. Longer lining time
USE OF REUSABLE FORMER TECHNIQUE Features Considerable savings on former
costs, as ramming former is not melted down for sintering, but can be removed
and reused several times. Removable Former A lot of saving can be done by using
a removable former. One and the same former can be used several times. In some
cases, even more than 200 times. Depending on the size of the former each
former will cost Rs. 10,000/- to Rs. 30,000/- It is up to everyone to make his own
calculation how much will be gained. Former design the former must be in one
piece. Slightly tapered, specific shape and detailed dimensions are shown
diameter (mm) Thickness of plate in former (mm) Ø < 800 6 Ø = 800 - 1000 8 Ø >
1000 10 Lining Material Most dry monolithic materials can be used, if the
refractory material being used, has been found to have an even and reliable
quality standard. No special sintering agent or other additions are required. Lining
Procedure, the refractory material can be densified with established techniques
e.g. by former vibrators, hand ramming or internal vibrators. Prior to inserting the
former, coat the outside with a mixture of oil and graphite powder. Keep
oil/graphite film thin. Alternatively cover the surface by 5 mm corrugated
cardboard.
Sintering Procedure for Use of Removable Former. Before former can be removed
the lining must be heated up to approximately 4500 C. Preferably 450 ± 100 C.
Increase temperature by using gas torch and/or coil power. Temperature rise is
about 1000 C per hour. Hold at 4500 C about 1 hour. Control the temperature by
using thermocouples and make sure of even temperature distribution form
bottom to top of crucible. Cool down former to approximately 2000 C with
compressed air. The cooling rate should be as fast, with as much air, as possible.
Time required for cooling is 15-30 minutes depending on furnace size. Raise
temperature to about 4000 C within 1 hour, then from 4000 C to approximately
11000 C as is normally done. Fill the furnace with liquid iron of about 13000 C. If
liquid metal is not available melting should be continued. Raise temperature to
sintering temperature and hold for 1 hour. • Alternatively set starting blocks after
removal of former and raise temperature to about 4000 C within 1 hour, then with
about 1000 C per hour until block starts to melt. Melt block completely and raise
temperature to 14300 C before charging. Charge and fill up furnace keeping
furnace full and raise temperature to sintering temperature and hold for 1 hour.
Storing of Former Clean the former surface and keep the unit in a dry place. Avoid
warping by means of supporting or reinforcement device. Recommended Further
Reading 1. BCIRA Broadsheet 204-2 2. Longer life and cost effectiveness of
Induction Furnace lining for improved profitability using Former Vibrators The
most frequent way of installing induction furnace is to use manpower. This is
unfortunately neither the best nor the cheapest nor the fastest. The installation by
hand ramming can cause a lot of problems as there is always a risk of bad
compaction, torn coil cement of fiber, litter falling down etc. By reducing the time
of installation and by using suitable equipment these problems can be avoided.
INDCROSS makes the installation with one man in one hour which normally takes
8 hours by two or three men. The compaction will be 10-15% better and this will
give a longer lining life. You will, from installation to installation, get the same
compaction and you will not be dependent on human mistakes. The equipment
needs almost no maintenance, just normal care. INDCROSS is produced in India
but the vibrator is imported from Europe. This equipment can be used for
furnaces with diameters between from, 300 to 1500 mm. Furnaces with melting
capacity up to 25 tons are successfully using this equipment. Larger furnaces, rare
in India, must chose a so-called Junker – Bosch type with 3 to 4 legs. This is an
equipment with electrical vibrators. Compared to a pneumatic system in the
INDCROSS. The Junker Bosch type does not give good compaction due to lower
frequency, which gives a knocking effect rather than vibration

Use Of Electric Vibrator If at present 41 man-days are required for relining of

furnace. With electric vibrator, about 16 man-days will be sufficient. Thus, savings
of 25 man-days i.e. 25 x 235 = 5975 Rs. per lining or for 12 linings in a year, annual
savings = Rs. 71,700 Reusable former savings = 12 x 9500 = 11, 400/-
2) Important Key Control areas during operation of Induction Furnaces
Introduction: A furnace is like a human stomach, especially for a metallurgical
industry. It is ever so hungry for energy (i.e. food). And its right function
commands that its various operational parameters are holistically optimized such
that not only the impacting factors are understandable, but also actively
controlled from that perspective it is imperative that a great furnace operation
encompasses a complete recourse to one and all of the following factors viz

i. process technology
ii) instrumentation and control,
iii) end-users’ behavior and attitude
iv) economies of scale,
v) changes and
vi) governmental policies. For right operation for energy and environmental
quality (pollution) efficiency (OQEEE) many suggestions are in vogue, which are
based on a broad framework of experimental and theoretical knowledge and are
tailor made for specific instances, depending upon the practices or circumstances
prevalent at the systems level. These suggestions mainly revolve on housekeeping
and retrofitting, providing generally end of pipe solutions unless design
modifications are considered relevant. It has been the general experience that a
minimum 25% decrease in the cost of fuel or energy can be achieved, the moment
these simple suggestions are applied to with faith and maintenance of the spirit
of energy conservation. Similar are the results of each endeavor for environmental
quality upgradation, whether they involve monitoring of exhaust quality, or
installation of secondary or tertiary equipment/instruments or input control.
Consequent improvement in product quality and environmental quality are
corroborations of the energy efficiency improvement exercise and accrue to the
industry as a bonus. This bonus has a pious implication (i.e. deliberate fall out),
facilitating all round cost reduction. Rightly so, in a Foundry operation, where the
energy in melting exceeds 60% of the overall energy expenditure and percentile
increase would impair the QEEE Dynamics (Quality, Energy and Environment
Efficiency) of the plant. Fig. 7 Some Typical Wear Pattern of Lining Concluding
Remarks the Metallurgical quality of a casting is a function of judicious melting
and casting procedure, namely the heat delivery and withdrawal. The design of
heating equipment is important from the Energy point of view. Right installation
of lining, sintering and correct way of melting will give you better life of lining.
EFFICIENT INDUCTION MELTING PRACTICE DO'S & DON'TS Few important points
to be noted by foundrymen while operating Induction Furnace are as follows.
DON'T & DO'S
1) Do not operate furnace at lower Power than rated power. Always draw full
power during melting and try to finish melting as early as possible. Pumping lower
power means increasing melting time, thereby increasing losses & power
consumption. DON'T & DO’S
2) Never allow any limit to appear. This will reduce power. Select proper scrap
combination to avoid any limit appearing on Panel. Too heavy scrap will show
excess charge limit where as too light scrap will show Voltage Limit. DON'T & DO’S
3) Do not leave furnace open during melting. Make use of Lid or any cover of
ceramic blanket to avoid /minimise Radiation Losses. DON’T & DO’S
4) Do not increase bottom lining or side wall thickness of Lining for any reason.
Increasing lining thickness has more disadvantages & very less advantages.
Increasing thickness means
reducing Volume of the melt,
Increasing the possibility of running furnace at Voltage Limit, this will increase
melting time & power consumption. DON'T & DO’S
5) Do not allow anyone to work under furnace. If at all any one wants to do some
maintenance work, lift the furnace, give some mechanical support or hold by EOT
Crane then only allow to work. DON'T & DO’S
6) Ensure 3 mm holes on former, every 150/200 mm spacing, holes are to be
provided on melt out former. Hole Dia should not be more than 3 mm. DON'T &
DO’S
7) Do not allow empty furnace to cool very slow. It is benefitable to do rapid
cooling of empty furnace. This gives more No of cracks with lower depth; where
as slow cooling generates less no of cracks having more depth. It preferable to
have lower depth of cracks. DON'T & DO’S
8) Do not make cold start heat too slow. If you have ensured forced air cooling on
empty furnace, Cold start time can be reduced. It should take 20% longer time
than standard melt cycle. DON'T & DO’S
9) Never remove worn out lining without witnessing. Always measure the left-over
thickness of bottom & side lining. Uniform erosion up to 50% is safe and
permissible. Observe for the powder portion near coil. DON'T & DO’S
10) Not necessary to use asbestos or mica. Asbestos restricts the water cooling of
ramming mass. Powder portion thickness near the coil is reduced. This reduces
the safety of coil. DON'T & DO’S
11) Do not make Coil cementing thickness more. Coil Coating thickness 3 to 5 mm
for smaller furnaces, 5 to 8 mm for bigger furnaces. DON'T & DO’S
12) Never use blunt ramming tools for lining. Ensure spikes are sharp pointed,
with taper of 50 mm on 18 mm round bar. DON'T & DO’S
13) While performing lining, do not exceed each layer more than 50 to 60 mm.
Compaction will be better with sharp tools & layer not more than 50 mm. Do not
use flat rammers during side lining. This will give real monolithic lining. DON'T &
DO'S
14) Never pay electricity Bill without studying carefully. Find out about Demand
charges, Power Factor, Penalties & Incentive. Analise & take corrective action &
pay the bill
preparation of scrap materials for charge materials" would typically detail the
process of sorting, cleaning, and sizing scrap metal to ensure it is suitable for
use as a charge material in a smelting or remelting furnace, including steps
like: identifying scrap types, separating incompatible materials, removing
contaminants like paint or plastic, cutting scrap to appropriate sizes, and
potentially preheating depending on the metal and furnace type; aiming to
optimize the quality and consistency of the melt for the desired final product.
Key points covered in such
 Scrap Sorting:
 Visual inspection to identify different metal types (ferrous, non-
ferrous, alloys).
  Magnetic separation to separate ferrous metals from non-ferrous.
 Density separation to separate metals based on their weight.
Color sorting for specific alloys.
 Cleaning and Pre-treatment:
 Removal of non-metallic contaminants (plastics, rubber, paint, etc.)
through manual cleaning, chemical stripping, or mechanical
processes.
 Degreasing to remove oil and grease
Cutting or shearing scrap into manageable sizes depending on
furnace requirements.
 Scrap Analysis:
Chemical analysis to determine the composition of the scrap mix,
ensuring it meets the desired specifications for the final product.
 Charge Preparation:
 Proportioning different scrap types to achieve the desired chemical
composition in the melt.
Considering the addition of fluxing agents to facilitate slag removal

Important factors to consider when preparing scrap for charging:
 Metal type and alloy composition: Different metals require specific
cleaning and preparation methods.
 Contaminant levels: Excessive impurities can negatively impact the
quality of the final product.
 Scrap size and shape: Proper sizing ensures efficient melting and
furnace operation.
- Recycling process and furnace technology: The chosen melting process will
influence the optimal scrap preparation steps.
Scrap consists of recyclable materials, usually metals,
left over from product manufacturing and consumption, such a
parts of vehicles,
building supplies, and
surplus materials.
Unlike waste, scrap can have monetary value, especially recovered metals, and
non-metallic materials are also recovered for recycling.
Ferrous metal contains iron and is attracted to magnets, so you can identify it as an
iron alloy if the magnet sticks to the metal. Non-ferrous metal is without iron and is not
attracted to magnets. If a magnet does not stick to a piece of metal, it is a non-
magnetic metal such as brass or aluminum.

Explosive waste includes, but is not limited to, fireworks, commercial

explosives, military explosives, homemade explosive devices, small and
large ammunition and pressurized gas vessels, and cylinders.
Jacob Albert
(000) 320-9942
[email protected]

January 4, 2023

Mr. David Bough

Human Resources Manager
UNICEF
39 Balt Road
San Antonio, TX 38742

Dear Mr. Bough: When I read your ad for a Project Officer position at UNICEF, I was
surprised at the perfect alignment between my qualifications and your
requirements. This led me to explore this opportunity further.

As can be seen on the attached resume, I am exceptionally skilled in performing

project management and support activities. Precisely my qualifications include the
following:

1. Proficient in providing support services, such as report preparation and

resource coordination.
2. Highly skilled in preparing and maintaining project documentation.
3. Knowledge of sourcing, collating, and compiling data to identify emerging
issues.
4. Hands-on experience in tracking and reporting on project progress against
established milestones.
5. Proficient in undertaking research and analysis and identifying trends.
6. Adept at managing and facilitating the flow of essential information among
company members.
7. Well-versed in establishing quantitative staffing models’ strategy owners use
to inform resource requests.
8. Able to provide cross-foundation analytics to senior management.

Apart from the abovementioned qualifications, I can provide operational support to

project staff and consultants. Moreover, I am skilled in implementing procurement
systems and performance management processes. My previous employers
recognized me as a team player with a ‘can-do’ attitude.

It would be a pleasure to meet with you in person so that I can highlight my

suitability for a Project Officer job at UNICEF in detail. I appreciate your
consideration.

Sincerely,

Jacob Albert