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key aspects of activity
1)
industrial
furnace
construction
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Innovative
insulating up to 1800 °C for industrial furnace
construction
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Due to
the constantly increasing combustion
temperatures and polluted atmospheres,
industrial furnaces with lining of ceramic fiber
modules are reaching the application limits of
the used fiber modules. In addition, material
wear results in a reduction of wall thickness
which can result in higher exterior wall
temperatures.
Alfatec has developed a rehabilitation system of
vacuumformed, prefired front panels,
which can be installed directly onto the
existing modular wall using ceramic
anchors (applicable up to 1700 °C).
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Depending
on operating temperature and operating
conditions, front panels with different
classification temperatures of up to 1750 °C
are used.
The
advantages:
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Instead of completely new lining with
long shutdown times and high cost, the front
panel system allows for an economically durable
rehabilitation.
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The possibility of being able to select
from different fiber qualities (also bio-soluble
fibers).
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As
a further product group, roller- insulation
required for tunnel furnaces are able to
manufacture and to offer. These formed
parts are manufactured with high
dimensional accuracy for the insulation of
ceramic or water-cooled metal rollers with
a diameter from 20 mm to 150 mm.
Application
examples are all types of heat treatment
furnaces or glass bending furnaces.
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A
further innovation are vacuum-formed fire
bricks for heating coils as well as grooved
panels for permanent application
temperatures of up to 1200 °C. These
formed parts with a density of approx.
0.65 g/cm3 do not show any signs of
brittleness.
The advantages become obvious in
particular, with furnaces where the weight
of the conventional dense (2.0 g/cm3) and
heavy fire bricks/grooved panels is
significantly higher than the fuel
material. Fast heating up and cooling down
with simultaneous energy savings have a
positive result for the operator of the
furnace.
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2)
aluminium
casting
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Wear
resistant formed parts for aluminum foundries
The
quality requirements of components made of aluminum used in the
automotive industry are on the highest level. The Austrian
Alfatec company has further developed vacuum-formed fiber formed
parts and provides the aluminum foundry with insulating and at
the same time wear-resistant products, which can even be used
for die-casting procedures and consequently support a
problem-free casting process. (quality AV 50/75G)
For
example, insulating feed bushes, pouring nozzles
or sub-risers are used for the manufacturing of wheel
rims, without any penetration of aluminum. The insulating
characteristics of these vacuum-formed products is better than
with the known and relatively heavy calcium grades.
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For
the production of aluminum panels, we also use these fiber
grades to manufacture wear-resistant castertips,
which stand out by a high resistance to thermal shocks. |
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As
the only manufacturer in Europe, this company are able to offer
insulating pouring
cups for foundry robots, to replace the heavy cast-iron
cups. The advantages are, on one hand, the low weight (smaller
size of roboter !), and on the other hand the high thermal
insulation properties prevent sticking of a casting skin. This
corrosion, which can be mainly observed with metal cups, does
not occur with fiber cups. The loss of temperature is only
approx. 5 °C. As standard, before delivery a coating is applied
to all casting cups, which is also suitable for very saline
alloys.
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As
a supplement to these product groups, we offer a plastic fiber
compound
(mastic
and other mouldables) for possible repairs, which can also
be used to line complete casting troughs.
For
gluing of wear-resistant formed parts and also for calcium silicate
panels, a sinter glue was developed, whose adherence steadily
increases with rising temperature (600 °C to 1000 °C) and
which is practically a welding connection.
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The material
Alfatherm creates new perspectives for the company.
Apart from the "refractory applications", this new
material also opens up markets for us such as fire
protection technology, which were not accessible to us previously, and
where co-operation with an important company in Germany has already
been established. This year, Alfatec expects the "general approval of
the supervisory construction authority" as a new material and the issue
of a test certificate from the "German Institute for Construction
Technology" in Berlin. Additional advantages are that the material need
not be classified as hazardous material (as in Germany) or special
waste (as in England), doing away with more cost-intensive industrial
protection measures (such as for ceramic fibres with marking
obligation). The cost structure concerning raw materials and
manufacturing process allows the user of Alfatherm to procure these at
economical and competitive prices.
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This new type of product
safeguards the location and the jobs, probably even
creating additional employment! The company is
additionally generating an increase in turnover of 20 %, which was additionally secured by the EU-wide patent.
The innovation service of the Chamber of Commerce of Lower Austria with
its regional technology and innovation offices assists and supports
companies in innovation, technology and co-operation projects.
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Rearrangement
to a new quality management system
Our
company has been successfully certified according to DIN EN ISO 9001
since 1996 in order to convert your idea, as a reliable partner with
high-quality products in the refractory production area, to your fullest
satisfaction.
To ensure that this
standard will apply also to our future business relationship, we have
certified our quality management system
to
the DIN EN ISO 9001:2000 standard successfully in the year 2002, so that
we will be able to pass on a certain head start to you also in this regard.
We will endeavour to
intensify customer relationships in order to strengthen the existing
customer connections and to win new customers.
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We will endeavour to
intensify customer relationships in order to
strengthen the existing customer connections and to
win new customers.
Click to
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