infrequent, occur in steel, iron and nonferrous metalcasting facilities due to several reasons, including: • lack of proper inspection of charge materials for liquids or moisture prior to charging;
• accidental rupture of furnace cooling; • accidental rupture of furnace hydraulic lines; • erroneously charging sealed drums, containers and tubing/ piping containing water or liquid directly into the furnace;
• spilling molten metal or slag into a pit or onto a floor containing water, moisture or other liquids;
• erroneously using wet, cold or rusted tools in the furnace; • furnace bridging; • poor installation of new furnace lining where sintering protocol was not followed;
• poor furnace maintenance; • inadequate drying of ladles after relining; • erroneously allowing uncontrolled water sources in the melt area. However, metalcasting facilities can take precautions
to reduce the risk of molten metal explosions. Following are 21 areas to consider for safe management of potential explosion hazards.
Reduce the possibility of a water/metal explosion by storing scrap material under cover for at least one day, or until thoroughly dry. Inside storage is preferred.
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long before the scrap melts. Pre-heating sealed materials will not prevent this hazard. In fact, the sealed container could explode inside the preheating system. Operator vigilance and charge inspection are the only preventive measures. Sealed material must never be accepted as scrap material or permit- ted in the furnace or pre-heater.
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and moisture before the scrap or alloys enter the furnace bath. Preheating charge materials and tools can help to pre- vent splashing injuries.
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Remote Automatic Charging Systems
Remote automatic charging systems permit the op-
erator to stand a safe distance from the furnace or behind protective barriers during charging.
Charge Dryers and Preheaters
Dryers and pre-heaters maximize the removal of water Material Inspection
Carefully inspect scrap piles, bales and containers for any residual moisture.
Sealed Containers
Containers, including sections of crimped or closed tube or pipe, holding combustible liquids will explode
Charge Specification
Specify charge materials free of liquids and do not ac- cept sealed containers.
Material Storage
液体或者湿气的准确检测；
• 炉冷过程中的意外爆裂; • 熔炼炉液压管的意外爆裂; • 错误地将装有水或者液体的密封的锅筒、容器和管 子直接作为填料放入熔炼炉中；
• 金属液或者矿渣泄露进入含有水、潮气或者其它液 体（如液压系统用液体）的炉底或者地面上；
• 错误地在熔炼炉中使用潮湿的、冷的或者生锈的工具； • 熔炉炉料架桥； • 新炉衬处理不当，没有按照要求进行烧结； • 熔炉保养不好； • 换炉衬后的钢包干燥不充分； • 错误地允许在熔炼区域存在不受控制的水源。 然而，金属铸造厂能够采取预防措施来减少熔融金 属爆炸的威胁。以下是从21个方面考虑的关于潜在爆 炸危险的安全管理措施。
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炉料装填规范
明确要求所装填的炉料没有液体，而且不允许有 密封容器。
原料贮存
通过将废旧炉料覆盖保存至少一天，或者直至完全 干燥来降低发生水/金属爆炸的可能性。推荐采用室
内存储。 原料检验
详细检查废料堆、废料包和容器中是否有残留湿 气（例如液压设备用水或者清洁用水、油等）。
密封容器
含有易燃液体的容器，包括弯曲的或者封闭的管 状零件，会大大先于熔炼废料爆炸。预热密闭原 料并不能防止爆炸。实际上，密封容器能够在预热系统 中爆炸。设备操作员的警觉和填料检查是唯一有效的方 法。密封原料一定不能当做废旧原料在熔炉或者预热系 统中使用。
添加干燥剂和预热设备
干燥剂和预热设备能够在废料或者合金进入炉膛 前最大程度地移除其中的水分和湿气。预热填充 的原料和工具能够防止飞溅造成伤害。
远程自动化填料系统
远程自动化填料系统能够使操作员在填料时站在 离熔炉相对安全的距离或者站在防护装置后面。
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Fall 2011
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