A nano-ceramic coating sets new quality standards in aluminium smelting
The nano-ceramic release agent was launched on the market by Ceranovis in Germany with the aim of improving process quality and thereby reducing production costs. This proved successful. Many of the large primary aluminium smelters have switched from conventional carbon-based release technology to ceramic technology.
The driver and motivation behind this change was to reduce process and maintenance costs. Rather than applying a release agent permanently or frequently, the ceramic release coating is applied extremely thinly once or twice a month. Just a few kilograms of coating replace tonnes of release agent.
The infrequent, low-volume application prevents layer thickness build-up and thus cleaning processes. When using a semi-permanent nano-ceramic release coating, the casting plants can continue production without any major cleaning or maintenance interruptions until the next mould change, which reduces costs. The changeover also led to an improvement in safety and working conditions. The oil-based separation technology, in particular, causes open flames and heavy smoke. There is always a risk of fire and smoke inhalation incidents. An oil-contaminated workplace poses a variety of risks.
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We have set new quality standards with nano-ceramics.
Prior to Nanocomp's success in ingot casting, carbon-based release agents such as canola oil, graphite or their combinations were the standard release agents. Contact with molten aluminium at 700 degrees Celsius produces reaction products that form a variety of condensates which adhere to the ingot. There is also a suspicion that carbides may form, which could later contaminate cast products. That was state of the art.
All ingots were affected, and so nobody complained. The problem was solved with the introduction of ceramic release coatings. The Nanocomp MI coating is carbon-free. No condensates are formed. The coating, which is only a few micrometres thick, provides excellent release and protection for over 1,500 castings. Contamination of the ingots can be ruled out.
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Clean, residue-free shiny ingots are produced. Pure aluminium is supplied.
The customers of smelting plants are naturally quick to pick up on this. Many of the customers now insist on uncontaminated ingots or demand a price adjustment in the event of contamination, which reduces the ingots' value. Large smelter companies in the Middle East, India, Canada, and Europe are adopting this new technology to improve product quality, reduce cost, enhance safety conditions and protect the environment.
Note: This article has been issued by Volker Hofmann, Ceranovis GmbH and has been published by AL Circle with its original information without any modifications or edits to the core subject/data.
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