23kg Remelt Ingot Productivity, the aspects of Mould Life and Heat Transfer

Water-cooled casting conveyors are essential in the aluminium industry for producing the 23kg remelt ingot. As industry trends push for increased ingot casting rates beyond the historical threshold of twenty tonnes per hour, it is imperative to re-evaluate the conventional water cooling systems and mould life. This paper aims to analyze the characteristics of water cooling systems and the factors leading to mould failures. A detailed examination of the variables influencing ingot solidification, mould stress, and subsequent failures is discussed, highlighting the correlation between increased casting rates, modified cooling flow, and changes in casting practices, which have adversely affected mould longevity. The findings reveal that mould failures are closely linked to the quality of the ingot moulds, the increased temperatures during casting, and the adjustments in cooling water flow. The study ultimately suggests potential future research directions to enhance the mould performance and adapt the industry standards as the demand for higher casting rates progresses. This analysis is based on process assessments and observations documented during operational upgrades at Tomago Aluminium, providing valuable insights for future developments in ingot production.