Eco-Friendly Granule Covering Agent | Dust & Caking Control

1. Superior Thermal Insulation

It creates a low-density, highly effective thermal barrier, dramatically reducing heat loss from the molten metal surface. This preserves the superheat, reduces energy consumption for reheating, and ensures consistent temperature for casting processes.

2. Oxidation & Contamination Prevention

The protective layer prevents atmospheric oxygen from reacting with the molten metal, minimizing the formation of undesirable oxides. It also has the capacity to absorb and trap non-metallic inclusions, effectively cleaning the metal and improving the final product's mechanical properties.

3. Environmental and Safety Champion

Composed of inert, non-toxic minerals, our granular agent eliminates the smoke and hazardous dust associated with traditional materials. This significantly improves air quality, reduces cleaning costs, and enhances worker safety.

Step 1: Raw Material Selection

We source premium-grade volcanic glass (perlite) and silicate minerals. Each batch undergoes rigorous testing (X-ray fluorescence - XRF) to verify its chemical composition and purity, ensuring it meets our strict internal standards.

Step 2: High-Temperature Expansion

The raw material is fed into a vertical furnace and flash-heated to over 900°C (1650°F). This causes the trapped water molecules within the mineral to turn to steam, expanding the granules up to 20 times their original volume, creating a lightweight, multi-cellular structure essential for insulation.

Step 3: Granulation & Precision Sizing

The expanded material is then cooled and passed through a series of screens and classifiers. This step ensures a consistent, dust-free granular product with a precise particle size distribution tailored to the customer's application (e.g., ladle vs. tundish).

Step 4: Surface Modification

For specific applications, granules undergo a proprietary surface coating process. This can enhance their flowability, increase their melting point, or add components that actively refine the molten metal by absorbing specific impurities like sulfur.

Step 5: Rigorous Quality Control

Final product samples are tested for bulk density, moisture content, and thermal performance according to ASTM C518 standards. Only batches that pass all quality checks are approved for packaging in moisture-proof, heavy-duty bags for shipment.

Service Life & Industries

Our covering agent is a consumable product, applied per heat or casting sequence. It is designed for single-use to ensure maximum purity. Key industries include Steelmaking, Iron & Aluminum Foundries, Specialty Alloy Production, and Petrochemical equipment manufacturing.

Steel Ladle Insulation

Challenge: Significant temperature drop during transport from the furnace to the caster, requiring costly superheating.

Solution: A 2-3 inch layer of our agent is added to the ladle after tapping. It spreads instantly, forming a highly insulating barrier. This can reduce temperature loss from 2-3°C/minute to less than 1°C/minute, saving energy and improving casting conditions.

Tundish Covering in Continuous Casting

Challenge: Maintaining a stable temperature in the tundish is critical for consistent steel quality and preventing nozzle clogging.

Solution: Our agent provides a stable, liquid slag layer in the tundish. This not only insulates but also absorbs alumina and other inclusions rising from the steel, acting as a final refining step before solidification and ensuring a cleaner final product.

Foundry & Non-Ferrous Applications

Challenge: Foundries handling iron, aluminum, and copper alloys need to prevent gas pickup and dross formation, which cause casting defects.

Solution: A customized, low-density version of our agent is used. It prevents oxidation and dross formation on the melt surface in holding furnaces and crucibles, leading to higher metal yield and improved surface finish on castings.

Particle Size Adjustment

We can modify the granule size to optimize spreadability in large ladles or to provide a more compact layer in smaller tundishes.

Density & Expansion Ratio

For applications requiring a thicker, fluffier layer, we can increase the expansion ratio. For processes sensitive to gas, a denser granule can be supplied.

Compositional Modification

We can add specific fluxing agents or refining components to the granule's surface to help manage slag chemistry or remove targeted impurities from your specific metal grade.