Foundry Insulation
The working temperature of many processes in the foundry is usually over 1430°C (2606℉), which is a severe challenge for the casting foundry factory or foundry worker.
There are many processes in the metal casting process that use high temperature to melt the metal and pour it into the mold. These processes involve intense and continuous high temperatures and cannot have moisture. When water encounters any active surface at this high temperature, it will immediately expand to 1,600 times its original volume. Moisture is the enemy of industrial furnaces, because even slightly damp metal can cause intense hot steam explosions with potentially catastrophic consequences.
In this extreme environment, the foundry industry has countless factors that can create potentially dangerous conditions for fires. In addition to uncontrolled fires, the safety of personnel and equipment caused by metal splashing and high temperatures is also critical.
So in the final analysis, the safety precautions of the foundry can be started from three directions: environmental safety, equipment safety, and personnel safety.
Environmental Safety: Thermal Management And Insulation
High-temperature equipment such as furnaces, pipelines and heat exchange equipment usually have an operating temperature of 1000℃ (1832.000℉), and can even reach 1540℃ (2804℉). Therefore, thermal management and insulation measures should be included in the beginning of equipment design and maintained throughout the equipment life cycle. The temperature and heat distribution of the working environment can be effectively controlled through technical means, while thermal insulation materials can be used to prevent the ineffective transfer of heat.
Proper thermal management and insulation can reduce energy waste, improve energy efficiency, and reduce safety hazards caused by high temperatures, such as heat stress and equipment overheating.
In foundry insulation and furnace insulation, the most commonly used insulation materials include mineral fibers such as rock wool and glass wool. The thermal conductivity of these insulation materials is usually between 0.035 and 0.040 W/m·K, and they can withstand temperatures up to 1000°C. The standard thickness of rock wool board is 100mm, with a thermal conductivity of 0.034 W/m·K, suitable for hot surface temperatures ranging from -50°C to 650°C.
Equipment Safety: Insulation And Furnace Protection
For equipment that generates high temperatures, foundry crucibles or melting furnaces and heat treatment furnaces will use insulation materials to cover the equipment, thermal insulation to reduce heat loss, and special design and maintenance of high-temperature furnaces to prevent furnace damage and improve operational safety.
Foundry crucibles use refractory bricks and ceramic fibers. The fire resistance limit of refractory bricks is usually between 1350°C and 1750°C, and the thermal stability of ceramic fiberboards can reach 1260°C. At the same time, the thermal conductivity of refractory bricks is about 1.3 W/m·K, and the thermal conductivity of ceramic fiberboards is 0.12 W/m·K. It can well isolate the impact of high temperatures.
At the same time, in terms of foundry safety, thermal insulation design should be carried out when the equipment is installed, and the inspection of furnace protection should be included in the equipment cycle inspection.
Personnel Safety: Protective Equipment And Safety Training
Safety in any industry is inseparable from personnel safety, especially in the foundry industry, which is full of molten metal, flames, and high temperatures. Therefore, in terms of personnel safety, protective equipment and safety training should be combined.
New employees must undergo safety training before joining the company, and all employees receive at least one complete safety training refresher every year to improve their awareness of potential hazards and their ability to respond.
At the same time, in all work areas, especially those exposed to high temperatures, chemicals or mechanical equipment, protective equipment can directly prevent or reduce accidental injuries.
A full set of protective equipment includes heat-resistant gloves made of aluminum foil fiberglass fabric and Kevlar fabric (temperature resistant up to 500°C), heat-resistant clothing (temperature resistant up to 1000°C), safety glasses and masks.
These equipment need to have excellent thermal resistance and wear resistance, and safety glasses must comply with ANSI Z87.1 standards to ensure sufficient impact resistance and transparency.