Foundry Provider

Facilities, Expertise, and Advanced Product Technology

The RENO Team has a long history of supplying iron foundries with high-quality refractory products, ladles, tear-out and reline services, and pre-cast specialty items. Foundries that take advantage of our scientifically advanced products enjoy higher profits through increased production, scrap reductions, energy savings, or ergonomic benefits, versus the standard purchasing goals for reduced item costs. We are pleased to raise the standard for our offerings with our newest and most advanced refractory technology, RENO ElectroCast™, and our Mastermelt DE-OX Product Line.

Cupola Furnaces

RENO has set the standards for long running cupola campaigns. These furnaces melt high ratios of steel and iron scrap along with digesting many contaminants. Each zone requires special attention. For example, a ductile pipe plant will require combustion and a melt zone refractory much different than furnaces melting automotive castings.

RENO is recognized as the industry leader for cupola refractory technology. We employ our USA Patented Shot-Crete “RENO Jet Cast TM,” and our USA Patented No-Cement Gunning Method, “RENO NC Gun TM”, for the majority of the refractory linings used in the high production cupola furnaces throughout North America.

Well (Wall & Floor Safety/Hot Face/Maintenance)

4.5” Arch Brick (walls) Straights (floors) x 70% Low Iron Brick
RENO ElectroCast 316 SiC
RENO NC Gun 6044
RENO Jet Cast NC SiC
RENO Gun BTW

Combustion & Melt Zones (Ductile Pipe Plant)

RENO ElectroCast SP-92, Cast and Dried or Pre-Cast Design Ductile Pipe Plant Hottest temperatures, and exposure to High amounts of Ferrous Oxides in the slag, similar to a steel melting furnace

Cupola Furnace applications

RENO Electrocast 70
RENO Electrocast 70
RENO Electrocast SB
RENO Electrocast™ 99
RENO Electrocast™ 16 Sic

Automotive Casting

RENO ElectroCast 390 SiC / ElectroShot 390 SiC, The extra high thermal conductivity conveys corrosive heat into the shell while the silicon carbide resists the slag and metal mixtures

Maintenance

RENO NC Gun 90, RENO Gun SP-92, Ductile Pipe
RENO NC Gun 6044 HT, Automotive Castings

Pre-Heat and Charge Zone

RENO ElectroCast SB, cast and dried or (Pre-Cast Design Preferred) Many Cupolas use bauxite containing products, 85% Brick, etc. Over time the high iron contents contained in bauxite will allow carbon monoxide to exfoliate the grains and the refractory is destroyed from the inside of the structure.

RENO ElectroShot 1170 if the installation method dictates a shot-crete installation.

Combustion Chambers

RENO Jet Cast Super Abrade 60 and RENO Lite Gun 40 RENO was the first company to provide shot-crete, this is our premium low cement, alkali resistant product for extreme thermal cycling conditions. RENO Lite Gun 40 insulates the steel shell and helps reduce the damage from the numerous cycles and thermal shock, as the insulation allows the hot-face refractory to cool at a slower pace than it does without insulation, and it is very easy to install.

Cross Over Ducts

RENO ElectroShot SIL 1199
This application must be tight and stable, our new All Silica based refractroy can tolerate the temperature swings easily and remain slick in service due to the extremely low pore size openings. Silica is a very good insulation mineral to keep the steel cool.

Cupola Bottom

The cupola bottom requires refractory products that match the length of the campaign. RENO Bottom Sand is used for short campaigns as a bottom door covering insulation. RENO Cupola Bottom Ram is installed over the RENO Bottom Sand, for a refractory cap. For some plants, they extend the campaign to six months, in these circumstances, RENO Rock BTW Ram is installed over the top of the RENO Cupola Bottom Ram; no Bottom Sand is used for these long campaigns due to the thermal expansion and contraction characteristics of silica.

Tap Hole

Pre-Cast Block made with RENO ElectroCast 316 SiC
RENO ElectroCoat Vapor Shield is used as a surface treatment inside the tap-hole cavity
RENO Rock BTW Plastic rammed around to seal the block

Many cupolas start up with an open tap-hole. This super-hot blast air can oxidize the carbon containing surfaces of castables or resin bonded plastics, and shorten the tap-hole’s useful life. RENO’s new ElectroCoat Vapor Shield Technology seals the porosity with almost zero permeability which shields the carbon inside the refractory from the hot blast air at start up. This small step can provide much longer performance time.

Front Slagging Trough

RENO NC 90 SiC castable as the safety lining next to the steel shell
RENO ElectroCast 316 SiC as the hot face working lining

The front trough hot face must experience and resist 100% of the molten iron and slag produced in the cupola. The most extreme wear is experienced at the cut-line, the metal/slag mixture as this is the most corrosive portion of the layered bath. Velocity and temperatures can affect the wear rates, as well as the metals / alloys / limestone mixtures charged into the cupola. While we cannot control the operational factors, we can offer general rules that can impact the refractory performances; these are: Shape, Safety Lining Selection, and Hot Face Refractroy Selection.

Shape

The trough’s hot-face surface can benefit from slowing the velocity of the slag swirling against the slag dam, and circulating back and out of the side cut exit channel.   It is imperative to keep the slag chute free and open which reduces the total quantity of slag carried in the trough.   Another action that can be done is to reduce the sidewall thickness at the top of the trough to form a V-Shape.  This will provide a wider pool which will reduce the height of the slag bath.   By using the refractory products selected, this can be safely done in steps, until the pool is enlarged as much as possible.   The wider opening also helps when patching as it gives more space if ramming a plastic patch, etc.

Safety Lining 33% of Thickness

Our safety lining, RENO NC 90 SiC, is a 90% containing silicon carbide, no-cement castable. This product is key as it has the highest thermal conductivity to rapidly transfer the heat away from the hot-face. Faster heat sinks, will slow the corrosion at the surface and extend wear rates.

Hot Face Refractory 67% Thickness

The hot face must exhibit high hot strengths to resist the metal and slag rubbing against the sides, as well as the temperatures of the corrosive mixtures. At the cut line, you will see a concave line as if the bath is eating away in a “C-Shape.” Many factors are at play such as miniature explosions of lighting created by the electrical static electricity generated by the passing iron on the grounded refractory. These miniature storms are pushing gases into the refractory structure – this is why the cut line extends above the metal / slag line. These hot dirty gases are the reason; they are being forced into the surface when these electrical charges take place. The only effective way to combat this is to seal the permeability of the refractroy structure and prevent these gases from penetrating the structure. RENO’s new scientific breakthrough in refractory bonding technology, RENO ElectroCast, has produced products unknown to science before now, with almost zero permeability, and extremely high hot strengths. These new characteristics provide the longest lasting refractroy for cupola trough campaigns.

Vertical Channel Furnaces

Refractory performance is critical for these furnaces, holding or melting iron. The following products have extended the performance life due to their ability to withstand thermal cycling, slag removal and increased production rates. Coupled with our Mastermelt DE-OX, energy savings, due to free flowing inductor loops, carbon and silicon losses are eliminated and reduced slag volumes are setting new operational standards.

Throat & Floor

RENO NC 908
While cleaning, the oxygen lance can damage silicon carbide bearing refractory below metal line. This product contains zero carbon, for safer conditions

Insulation and Safety

Floor: ½” Marinite Board, + 3” of 70% Brick
Throats: ¼” Microtherm Overstitch Panels, folded under the brick work

Channel Holding Furnace applications

Insulation Lining
RENO Electrocast™ 16 SiC
Insulation and Safety Lining
Insulation and Safety Lining
RENO Electrocast™ 10 SiC

Walls

Insulation and Safety: RENO Coat It AL on Steel Walls, prevents carbon transfer
4.5” Super Duty Brick, arch type for tight construction
1.5 inches of BNZ 2600° F IFB for Insulation RENO MO Super 3 Mortar. New Insulation-design, reduces energy consumption while providing a true safety liner. The freeze plane is well in front of the brick safety lining.

Hot Face: RENO ElectroCast 316 SiC, and RENO ElectroCast 310 SiC
RENO’s new advanced electro-bonded technology is used for designing the hot-face refractory compositions with super low permeability, and extremely high hot strengths. The attributes contribute to the long-lasting performance and clean interior walls which increases iron melting efficiencies, and reduces electrical power consumption. “Savings for electricity and increased production easily make the refractory cost of no consequence; thus, we provide free refractories when thinking of the cost to savings benefits.”

Roof

Insulation and Anchors: 85% Phos Anchor Brick, and ½ Inch Marinite Board
Hot Face: RENO NC 60 with 3% HCA Fibers

Spouts

Hot Face: RENO ElectroCast 10 SiC
Surface Treatment: RENO ElectroCoat 75 SiC

Mastermelt Additive

Ductile Iron Base: Mastermelt DE-OX D-1
Gray Iron Base: Mastermelt De-OX

These additives are used to eliminate the oxygen molecules contained in the molten iron. These oxygen molecules are extremely hyper-reactive, and combine in a fraction of time to form spinel formations such as calcium oxide, magnesium oxide, and other tramp element combinations. Since the loop is circulating the metal and the water cooled bushings create a strong thermal gradient to keep the refractory from melting away, these spinel formations readily stick to the inside of the inductor loops, and form crusts. These crusts reduce the interior cross sectional areas and thus reduce the amounts of electrical current used for conduction and the melting rates slow, while energy consumption soars. Many plant incorporate a cleaning method known as super heating. This is an uncontrolled event and is used to literally melt away the interior crusts. While it is expensive, it is also dangerous for the refractory compositions making up the loop channels. With Mastermelt DE-OX for GRAY IRON, and Mastermelt DE-OX D-1 for DUCTILE BASED IRON, (Low Sulfur) provides the foundry melt managers with a tool to clean away the buildups and restore the conductance ratios back to nominal states. This new technique is made possible by the science of the Mastermelt TECHNOLOGY.

Another benefit is the change in the slag consistency as the glassy like sticky mess is converted to dry lumps that is easily removed.

Coreless Induction Melting Furnaces

RENO Sil 0.6 and RENO Sil 1.0

RENO’s proprietary Pure Silica Refractory is not made from the traditional low cost quartz found in most competitors’ products. Our product is made from Silica Rock with much smaller crystals that can tolerate rapid heating and cooling for longer performance life, especially true with the higher powered medium frequency furnaces producing ductile based iron.

Cover (Insulation and Anchors/Hot Face/Surface Treatment)

85% Phos Anchor Brick, and ½ Inch Marinite Board
RENO NC 60 with 3% HCA Fibers
RENO ElectroCoat 75 SiC

Spouts (Hot Face/Surface Treatment)

Pre-cast made from RENO ElectroCast 370 & 3% HCA Fibers
RENO ElectroCoat 75 SiC

Lower Rings

RENO ElectroCast 399
The higher alumina tabular product will transfer the heat faster from the lower walls and floor, and provide additional lining life to the most troublesome areas

Walls and Floor

RENO Sil 0.6 for the Floor and Lower Walls
RENO Sil 1.0 for the Upper Walls and Top Cap

Ductile Treatment Ladle

RENO ElectroCoat SP and RENO ElectroCast 310 SiC

Ductile treating ladles are used for transforming gray iron into nodular or ductile iron. The Magnesia Ferro-Silicon alloys used in this process liberate free magnesia and calcium which rapidly builds on the wall surfaces, requiring heavy cleaning. With RENO’s ElectroCoat SP, the castable surface is protected from the magnesia / lime mixtures, and stays clean. This feature allows the ladle to stay in service longer which reduces the cleaning cycles, which saves labor and repair products.

Hot Face / Surface Treatment

RENO ElectroCoat SP
Magnesia Fade is a common problem throughout the ductile iron making industry. If one examines the slag adhearances, the compositions are mainly magnesia + calcium + silica; the alloys used for nucleating the carbon flakes into spheres for ductile iron. The magnesia is attracted to silica which is inherent in most refractory products. RENO has taken our new Electro technology and produced a near zero permeable structure surface treatment that contains zero silica and thus inhibits the magnesia transfer. Rather than the sometimes used magnesia lightweight air-setting products, that have little strength, our RENO ElectroCoat SP is robust and strong to resist the violent reactions during inoculation treatments.

Castable Lining

RENO ElectroCast 310 SiC
Another major technology first is RENO’s Synthesized Mineral Forsterite in combination with our Electro Technology. This product is a high alumina / high density castable refractory that contains silicon carbide. The shear rugged and brute toughness combined with its thermal cycle tolerance allows the RENO ElectroCast 310 SiC ladle lining to provide many times the normal performance life as compared to competitive low cement products.

Safety Interior Steel Surface Treatment

RENO Coat It AL, Pevents Carbon Transfer

Benefits

  • Reduced Cleaning Labor
  • Decreases Safety and Workers’ Compensation Claims
  • Increased Production and Higher Quality as the interior remains a stable size for Accurate Alloy Additions

Insulation

2800° F, IFB Brick Split / RENO MO Super 3 Mortar

Top Compression Cap

It is imperative to keep the castable working lining in compression to avoid horizontal cracking. This can be accomplished by incorporating:

3/8” diameter x # 304 V-Anchors x length of approximately 80% of thickness, welded on 6-inch centers
4 ~ 6-Inch top-cap of RENO Cast 70 KH, mixed with 10% of #446 x ¾” Steel Fibers.
This economical solution adds a robust in the field thrust plate barrier to keep the ladle in compression which eliminates cracks and increases refractory life.

This economical solution adds a robust in the field thrust plate barrier to keep the ladle in compression which eliminates cracks and increases refractory life.

Porous Plug, De-Sulphurization Ladles — “Bubbling Pots”

RENO Refractories, Inc. is proud of our world-leading no-cement nano-bonded colloidal silica products.

RENO NC Nano-Tech Technology

All of our NC products provide properties that are unmatched, by any other refractory supplier; these are:

  • Low Permeability
  • Resists Penetrations
  • Super High Hot Strengths
  • Impact Resistance
  • Pore Sizes are 2-3 Microns
  • Molten Slags do not Wet the Structure
  • Abrasion Values below 6 CC Loss
  • Lasts Longer with High Turbulence

Hot Face/Surface Treatment

RENO ElectroCoat SiC
RENO has taken the new Electro technology and produced a near zero permeable structure surface treatment that contains high levels of Silicon Carbide. RENO ElectroCoat SP is robust and strong to resist the violent reactions during inoculation treatments.

Castable Lining

RENO NC 6059 CA
RENO uses the strength of an all bauxite product with silicon carbide to further increase thermal shock resistance and reduce surface corrosions form the high levels of lime and spar fluxes.

Floor

RENO NC 60L
This material is strong enough to withstand the turbulence within the iron while bubbling and making additions, but is easy to remove to replace the porous plugs.

Safety Steel Surface Treatment

RENO Coat It AL, Prevents Carbon Transfer

Insulation

2800 °F IFB Brick Split / RENO MO Super 3 Mortar

Top Cap

It is imperative to keep the castable working lining in compression to avoid horizontal cracking; this can be accomplished by incorporating:

3/8” diameter x # 304 V-Anchors welded every 6-inches apart
4 ~ 6-Inch top-cap of RENO Cast 70 KH, mixed with 10%
of #446 x ¾” Steel Fibers.

This economical solution adds a robust in the field thrust plate barrier to keep the ladle in compression which eliminates cracks and increase life

Ductile Iron Pour Pressure Furnace

Increased Production, and Reduced Cleaning

While in service, the magnesia and calcium carried over from the alloys used in the inoculation process, tends to create a viscous slag layer that can build up on the walls and throat areas. These adherences are very difficult to remove, requiring dangerous hot work to be done on a regular basis. These cleaning activities, reduces valuable production time.

Our super low permeable refractory products, used in many auto-pour and pressure pour furnaces have greatly increased the production time intervals between these cleaning activities, and have lessened the time required to perform the actual cleaning, and increased the refractory life.

Competitive Low Cement Products display a pore size of 20-30 microns.
Our no-cement, NC products using the sol-gel binder system display pores of 1-2 microns.
RENO ElectroCast Products only exhibit pores of 0.5 ~ 0.1 microns!

Pressure Pour Furnace applications

Throat & Floor

RENO NC 908
While cleaning, the oxygen lance can damage silicon carbide bearing refractory below metal line. This product contains zero carbon, for safer conditions

Insulation & Safety

Floor: ½” Marinite Board, + 3” of 70% Brick
Throats: ¼” Microtherm Overstitch Panels, folded under the brick work

Roof

Insulation and Anchors: 85% Phos Anchor Brick, and ½ Inch Marinite Board
Hot Face: RENO NC 60 with 3% HCA Fibers

Spouts

Hot Face: RENO ElectroCast 310 SiC
Surface Treatment: RENO ElectroCoat SP

Walls

Insulation and Safety:

RENO Coat It AL on Steel Walls, prevents carbon transfer
4.5” Super Duty Brick, arch type for tight construction
1.5 inches of BNZ 2600° F IFB for Insulation
RENO MO Super 3 Mortar

Hot Face:

RENO ElectroCast 310 SiC
Cleaning is made easy and less frequent. The freeze plane is well in front of the brick safety lining.

Pouring Boxes, with Stopper Rods

RENO NC 6059 Coarse, RENO ElectroCoat 75 SiC, RENO NC 908

Pouring Boxes are a constant source of maintenance, as the indexing molds require even and consistent filling via a nozzle and stopper rod assembly. RENO provides the longest casting solutions with our novel pre-cast Nozzles which dispenses the metal in a constant clean flow rates that do not require the continuous stoppage of the molding lines in order to clean, “ROD-OUT” the nozzles. RENO’s innovative designs allow the interior surfaces to run cleaner and longer for reduced change out sequences, which provides more castings and lower costs.

Pouring Box applications

Hot Face/Surface Treatment

RENO ElectroCoat 75 SiC is a robust, near zero permeability, ceramic coating that resists oxidation. This new surface will: extend the on-line performance time without buildups, greatly lessen the cleaning time, and allows the castable working lining to last many times longer.

Castable Lining

RENO NC 6059 Coarse
This rugged refractory castable is engineered to tolerate extreme thermal cycling, very small pore sizes, which reduce adherences, and easy dry-out characteristics.

Precast Nozzles

RENO leads the industry with clean metal dispensing, with pour-box nozzles fabricated with RENO NC 908. This is our calcium free product that is virtually pure alumina and chrome oxide enhanced for clean and dependable mold filling. At the end of the day, the extra molds filled, adds profits for the foundry operation.

Insulation

2800° F, IFB Brick Split / RENO MO Super 3 Mortar

Safety Steel Surface Treatment

RENO Coat It AL
To prevent Carbon Transfer should molten iron touch the steel shell, which weakens the steel and is the major cause of run-outs, apply this ceramic layer of protection.

Top Cap

It is imperative to keep the castable working lining in compression to avoid horizontal cracking; this can be accomplished by incorporating:

3/8” diameter x # 304 V-Anchors welded on 6-inch centers x a length of approximately 80% of the total lining thickness
4 ~ 6-Inch top-cap of RENO Cast 70 KH, mixed with 10%
#446 x ¾” Steel Fibers.

This economical solution can be cast along with castable but the high volume of steel fibers adds a robust, in the field thrust plate barrier to keep the ladle in compression which eliminates cracks and increases life.

Gray Iron Transfer Ladles

RENO ElectroCast 370 and RENO ElectroCoat 75 SiC

Grey Iron Transfer Ladles will perform longer and provide lower turnaround maintenance costs when utilizing these advanced refractory products.

Hot Face/Surface Treatment

RENO ElectroCoat 75 SiC is a robust, near zero permeability, ceramic coating that resists oxidation. This new surface will: extend the on-line performance time without buildups, greatly lessen the cleaning time, and allows the castable working lining to last many times longer.

Gray Iron Transfer Ladles applications

Castable Lining

RENO ElectroCast 370
This super refractroy is engineered to tolerate thermal cycling and has all the advantages listed for our Electro Castables, such as extremely small pore sizes, and very low permeability, to resist adherences, and very high hot strengths, to combat erosion.

Insulation

2800° F, IFB Brick Split / RENO MO Super 3 Mortar

Safety Surface Treatment

RENO Coat It AL
To prevent Carbon Transfer should molten iron touch the steel shell, which weakens the steel and is the major cause of run-outs, apply this ceramic layer of protection.

Top Cap

It is imperative to keep the castable working lining in compression to avoid horizontal cracking; this can be accomplished by incorporating:

3/8” diameter x # 304 V-Anchors welded on 6-inch centers x a length of approximately 80% of the total lining thickness
4 ~ 6-Inch top-cap of RENO Cast 70 KH, mixed with 10%
#446 x ¾” Steel Fibers.

This economical solution can be cast along with castable but the high volume of steel fibers adds a robust, in the field thrust plate barrier to keep the ladle in compression which eliminates cracks and increases life.

Side Charge Cupola and Trough applications

Cupola — 360° Gas Offtake w/ Trough applications

  • RENO Electrocast 70
  • RENO Electrocast SB
  • RENO Electrocast™ 99
  • RENO Electrocast™ 16 Sic

Cupola Furnaces

RENO has set the standards for long running cupola campaigns. These furnaces melt high ratios of steel and iron scrap along with digesting many contaminants. Each zone requires special attention. For example, a ductile pipe plant will require combustion and a melt zone refractory much different than furnaces melting automotive castings.

RENO is recognized as the industry leader for cupola refractory technology. We employ our USA Patented Shot-Crete “RENO Jet Cast TM,” and our USA Patented No-Cement Gunning Method, “RENO NC Gun TM”, for the majority of the refractory linings used in the high production cupola furnaces throughout North America.

Well (Wall & Floor Safety/Hot Face/Maintenance)

4.5” Arch Brick (walls) Straights (floors) x 70% Low Iron Brick
RENO ElectroCast 16 SiC
RENO NC Gun 6044

Combustion & Melt Zones (Ductile Pipe Plant)

RENO ElectroCast SP-92, Cast and Dried or Pre-Cast Design, Hottest temperatures, and exposure to High amounts of Ferrous Oxides in the slag, similar to a steel melting furnace

Automotive Casting

RENO ElectroCast / ElectroShot 90 SiC, The extra high thermal conductivity conveys corrosive heat into the shell while the silicon carbide resists the slag and metal mixtures

Maintenance

RENO NC Gun 90, RENO Gun SP-92, Ductile Pipe
RENO NC Gun 6044 HT, Automotive Castings

Pre-Heat and Charge Zone

RENO ElectroCast SB, cast and dried or (Pre-Cast Design Preferred) Many Cupolas use bauxite containing products, 85% Brick, etc. Over time the high iron contents contained in bauxite will allow carbon monoxide to exfoliate the grains. The refractory is destroyed from the inside of the structure.

RENO ElectroShot 1170 if the installation method dictates a shot-crete installation.

Combustion Chambers

RENO Jet Cast Super Abrade 60 and RENO Lite Gun 40 RENO was the first company to provide shot-crete, this is our premium low cement, alkali resistant product for extreme thermal cycling conditions. RENO Lite Gun 40 insulates and is very easy to install.

Cross Over Ducts

RENO ElectroShot SIL 99
This application must be tight and stable, our new All Silica based refractroy can tolerate the temperature swings easily and remain slick in service due to the extremely low pore size openings.

Tap Hole

Pre-Cast Block made with RENO ElectroCast 16 SiC
RENO ElectroCoat Vapor Shield is used as a surface treatment inside the tap-hole cavity
RENO Rock BTW Plastic rammed around to seal the block

Many cupolas start up with an open tap-hole. This super-hot blast air can oxidize the carbon containing surfaces of castables or resin bonded plastics, and shorten the tap-hole’s useful life. RENO’s new ElectroCoat Vapor Shield Technology seals the porosity with almost zero permeability which shields the carbon inside the refractory from the hot blast air at start up. This small step can provide much longer performance time.

Front Slagging Trough

RENO NC 90 SiC castable as the safety lining next to the steel shell
RENO ElectroCast 16 SiC as the hot face working lining

The front trough hot face must experience and resist 100% of the molten iron and slag produced in the cupola. The most extreme wear is experienced at the cut-line, the metal/slag mixture is the most corrosive portion of the layered bath. Velocity and temperatures can affect the wear rates, as well as the metals, alloys, and limestone mixtures charged into the cupola. While we cannot control the operational factors, we can offer general rules that can impact the refractory’s performance; these are: Shape, Safety Lining Selection, and Hot Face Refractory Selection.

Shape

The troughs hot-face surface can benefit from slowing the velocity of the slag swirling against the slag dam, and circulating back and out of the side cut exit channel. It is imperative to keep the slag chute free and open, which reduces the total quantity of slag carried in the trough. Another action that can be done is to reduce the sidewall thickness at the top of the trough to form a V-Shape. This will provide a wider pool which will reduce the height of the slag bath. By using the refractory products selected, this can be safely done in steps, until the pool is enlarged as much as possible. The wider opening also helps when patching as it gives more space if ramming a plastic patch, etc.

Safety Lining 33% of Thickness

Our safety lining, RENO NC 90 SiC, is a 90% containing silicon carbide, no-cement castable. This product is key as it has the highest thermal conductivity to rapidly transfer the heat away from the hot-face. Faster heat sinks, will slow the corrosion at the surface and extend wear rates.

Hot Face Refractory 67% Thickness

The hot face must exhibit high hot strengths to resist the metal and slag rubbing against the sides, as well as the temperatures of the corrosive mixtures. At the cut line, you will see a concave line, as if the bath is eating away in a “C-Shape.” Many factors are at play, such as miniature explosions of lighting created by the electrical static electricity generated by the passing iron on the grounded refractory. These miniature storms are pushing gases into the refractory structure – this is why the cut line extends above the metal / slag line. These hot dirty gases are the reason; they are being forced into the surface when these electrical charges take place. The only effective way to combat this is to seal the permeability of the refractory structure and prevent these gases from penetrating the structure. RENO’s new scientific breakthrough in refractory bonding technology, RENO ElectroCast, has produced products unknown to science before now, with almost zero permeability, and extremely high hot strengths, these new characteristics provide the longest lasting refractory for cupola trough campaigns.

New Advanced Technologies:

RENO ElectroCast™ Technology

  • Almost Zero Permeability
  • No Alkali or Iron Oxide Penetrations
  • Super High Hot Strengths
  • Impact Resistance
  • Pore Sizes below 1-micron
  • Molten Slags do not Wet the Structure
  • Abrasion Values below 3 CC Loss
  • Lasts Longer with High Volume Charging
  • Lower Modulus of Elasticity
  • Resists Thermal Cycling Damage

Mastermelt DE-OX

When Mastermelt DE-OX is injected through the tuyeres, iron oxide inside the cupola is eliminated. The oxidizing waste for carbon and silicon losses disappear. Temperature, chemistry and production controls are now achievable with a much more efficient furnace. The overwhelming savings are realized with coke and silicon savings.

Channel Holding Furnace applications

  • RENO Electrocast™ 10 SiC
  • Surface Treatment
  • RENO 75 SiC
  • Insulation Lining
  • RENO NC 60 w/ 3% HCA Fibers
  • RENO Electrocast™ 16 SiC
  • Insulation and Safety Lining

Channel Induction Furnaces

Refractory performance is critical for these furnaces, holding or melting iron. The following products have extended the performance life due to their ability to withstand thermal cycling, slag removal, and increased production rates. Coupled with our Mastermelt DE-OX, these products will create massive energy savings, due to free flowing inductor loops, carbon and silicon losses that are eliminated, and reduced slag volumes that are setting new operational standards.

Throat & Floor

RENO ElectroCast 99
While cleaning, the oxygen lance can damage silicon carbide bearing refractory below metal line. This product contains zero carbon, for safer conditions

Insulation and Safety

Floor: ½” Marinite Board, + 3” of 70% Brick
Throats: ¼” Microtherm Overstitch Panels, folded under the brick work

Walls

Insulation and Safety: RENO Coat It AL on Steel Walls, prevents carbon transfer
4.5” Super Duty Brick, arch type for tight construction
1.5 inches of BNZ 2600° F IFB for Insulation
RENO MO Super 3 Mortar

Hot Face: RENO ElectroCast 16 SiC
New Insulation-design, reduces energy consumption while providing a true safety liner. The freeze plane is well in front of the brick safety lining.

Roof

Insulation and Anchors: 85% Phos Anchor Brick, and ½ Inch Marinite Board
Hot Face: RENO NC 60 with 3% HCA Fibers

Spouts

Hot Face: RENO ElectroCast 10 SiC
Surface Treatment: RENO ElectroCoat 75 SiC

Mastermelt Additive

Ductile Iron Base: Mastermelt DE-OX D-1
Gray Iron Base: Mastermelt De-OX

Coreless Induction Melting FCE applications

RENO Sil 0.6 and RENO Sil 1.0

RENO’s proprietary Pure Silica Refractory is not made from the traditional low cost quartz found in most competitors’ products. Our product is made from Silica Rock with much smaller crystals that can tolerate rapid heating and cooling for longer performance life, this is especially true with the higher powered, medium frequency furnaces producing ductile based iron.

New RENO ElectroCast™ Technology

These new products provide properties that are unmatched by any other refractory supplier; such as:

  • Almost Zero Permeability
  • No Alkali or Iron Oxide Penetrations
  • Super High Hot Strengths
  • Impact Resistance
  • Pore Sizes below 1-micron
  • Molten Slags do not Wet the Structure
  • Abrasion Values below 3 CC Loss
  • Lasts Longer with High Volume Charging

Cover (Insulation and Anchors/Hot Face/Surface Treatment)

85% Phos Anchor Brick, and ½ Inch Marinite Board
RENO NC 60 with 3% HCA Fibers
RENO ElectroCoat 75 SiC

Spouts (Hot Face/Surface Treatment)

Pre-cast made from RENO ElectroCast 70 & 3% HCA Fibers
RENO ElectroCoat 75 SiC

Lower Rings

RENO ElectroCast 99
The higher alumina tabular product will transfer the heat faster from the lower walls and floor, and provide additional lining life to the most troublesome areas

Walls and Floor

RENO Sil 0.6 for the Floor and Lower Walls
RENO Sil 1.0 for the Upper Walls and Top Cap

Treatment Ladle applications

Ductile Iron Ladles

RENO Refractories, Inc. is proud to announce the arrival of our new Refractory Technology, “RENO ElectroCast™.” When combined with our world-leading no-cement nano-bonded products, Ductile Iron Ladles will perform longer and provide labor savings, as well as lower turnaround maintenance costs for our valued customers.

Refractory Surfaces (Hot Face / Surface Treatment)

RENO ElectroCoat SP
Magnesia Fade is a common problem throughout the ductile iron making industry. If one examines the slag adhearances, the compositions are mainly magnesia + calcium + silica; the alloys used for nucleating the carbon flakes into spheres for ductile. The magnesia is attracted to silica which is inherent in most refractory. RENO has taken the new Electro technology and produced a near zero permeable structure surface treatment that contains zero silica and thus inhibits the magnesia transfer. Rather than the sometimes used magnesia lightweight air-setting products, that have little strength, our RENO ElectroCoat SP is robust and strong enough to resist the violent reactions during inoculation treatments.

Castable Lining

RENO ElectroCast 310 SiC
Another major technology first is RENO’s Synthesized Mineral Forsterite in combination with our Electro Technology. This product is a high alumina / high density castable refractory that contains silicon carbide. The shear rugged and brute toughness combined with its thermal cycle tolerance allows the RENO ElectroCast 310 SiC ladle lining to provide many times the normal performance life as compared to the normal low cement products used.

Safety Surface Treatment

RENO Coat It AL, Pevents Carbon Transfer

Benefits

  • Reduced Cleaning Labor
  • Increases Safety and Workers’ Compensation Claims
  • Increased Production and Higher Quality as the interior remains a stable size for Accurate Additions

Insulation

2800° F, IFB Brick Split / RENO MO Super 3 Mortar

Top Compression Cap

6-Inches of RENO Cast 70 KH / Hi Wire
3/8” # 304 V-Anchors x 60% of ladle thickness, welded every 8-inches apart always produces a cracked lining. This economical solution can be cast along with castable but the high volume of steel fibers adds a robust “in the field” thrust plate barrier to keep the ladle in compression which eliminates cracks and increase life.

Bubbling Pot applications

Porous Plug, De-Sulphurization Ladles — “Bubbling Pots”

RENO Refractories, Inc. is proud of our world-leading no-cement, nano-bonded, colloidal silica products.

RENO NC Nano-Tech Technology

All of our NC products provide properties that are unmatched, by any other refractroy supplier; these are:

  • Low Permeability
  • Resists Penetrations
  • Super High Hot Strengths
  • Impact Resistance
  • Pore Sizes are 2-3 Microns
  • Molten Slags do not Wet the Structure
  • Abrasion Values below 6 CC Loss
  • Lasts Longer with High Turbulence

Hot Face/Surface Treatment

RENO ElectroCoat SiC
RENO has taken the new Electro technology and produced a near zero permeable structure surface treatment that contains high levels of Silicon Carbide. RENO ElectroCoat SP is robust and strong enough to resist the violent reactions during inoculation treatments.

Castable Lining

RENO NC 6059 CA
RENO uses the strength of an all bauxite product with silicon carbide to further increase thermal shock resistance and reduce surface corrosions form the high levels of lime and spar fluxes.

Floor

RENO NC 60 Castable
This is a no-cement product made to last longer. It is easier to remove than the coarse grained wall lining when replacing plugs.

Safety Steel Surface Treatment

RENO Coat It AL, Prevents Carbon Transfer

Insulation

2800 °F IFB Brick Split / RENO MO Super 3 Mortar

Top Cap

6-Inches of RENO Cast 70 KH / Hi Wire
3/8” # 304 V-Anchors x 60% of ladle thickness, welded every 8-inches apart always produces a cracked lining. This economical solution adds a robust “in the field” thrust plate barrier to keep the ladle in compression which eliminates cracks and increase life.

Pressure Pour Furnace applications

Ductile Iron Pour Pressure Furnace

Increased Production, and Reduced Cleaning

While in service, the magnesia and calcium carried over from the alloys used in the inoculation process, tends to create a viscous slag layer that can build up on the walls and throat areas. These adherences are very difficult to remove, requiring dangerous hot work to be done on a regular basis. These cleaning activities, reduces valuable production time.

Our super low permeable refractory products, used in many auto-pour and pressure pour furnaces have greatly increased the production time intervals between these cleaning activities, and have lessened the time required to perform the actual cleaning, and increased the refractory life.

Competitive Low Cement Products display a pore size of 20-30 microns.
Our no-cement, NC products using the sol-gel binder system display pores of 1-2 microns.
RENO ElectroCast Products only exhibit pores of 0.5 ~ 0.1 microns!

Throat & Floor

RENO NC 908
While cleaning, the oxygen lance can damage silicon carbide bearing refractory below metal line. This product contains zero carbon, for safer conditions

Insulation & Safety

Floor: ½” Marinite Board, + 3” of 70% Brick
Throats: ¼” Microtherm Overstitch Panels, folded under the brick work

Roof

Insulation and Anchors: 85% Phos Anchor Brick, and ½ Inch Marinite Board
Hot Face: RENO NC 60 with 3% HCA Fibers

Spouts

Hot Face: RENO ElectroCast 310 SiC
Surface Treatment: RENO ElectroCoat SP

Walls

Insulation and Safety:

RENO Coat It AL on Steel Walls, prevents carbon transfer
4.5” Super Duty Brick, arch type for tight construction
1.5 inches of BNZ 2600° F IFB for Insulation
RENO MO Super 3 Mortar

Hot Face:

RENO ElectroCast 310 SiC
Cleaning is made easy and less frequent. The freeze plane is well in front of the brick safety lining.

Pouring Box applications

Pouring Boxes, with Stopper Rods

RENO NC 6059 Coarse, RENO ElectroCoat 75 SiC, RENO NC 908

Pouring Boxes are a constant source of maintenance, as the indexing molds require even and consistent filling via a nozzle and stopper rod assembly. RENO provides the longest casting solutions with our novel pre-cast Nozzles which dispenses the metal in a constant clean flow rates that do not require the continuous stoppage of the molding lines in order to clean, “ROD-OUT” the nozzles. RENO’s innovative designs allow the interior surfaces to run cleaner and longer for reduced change out sequences, which provides more castings and lower costs.

Hot Face/Surface Treatment

RENO ElectroCoat 75 SiC is a robust, near zero permeability, ceramic coating that resists oxidation. This new surface will: extend the on-line performance time without buildups, greatly lessen the cleaning time, and allows the castable working lining to last many times longer.

Castable Lining

RENO NC 6059 Coarse
This rugged refractory castable is engineered to tolerate extreme thermal cycling, very small pore sizes, which reduce adherences, and easy dry-out characteristics.

Precast Nozzles

RENO leads the industry with clean metal dispensing, with pour-box nozzles fabricated with RENO NC 908. This is our calcium free product that is virtually pure alumina and chrome oxide enhanced for clean and dependable mold filling. At the end of the day, the extra molds filled, adds profits for the foundry operation.

Insulation

2800° F, IFB Brick Split / RENO MO Super 3 Mortar

Safety Steel Surface Treatment

RENO Coat It AL
To prevent Carbon Transfer should molten iron touch the steel shell, which weakens the steel and is the major cause of run-outs, apply this ceramic layer of protection.

Top Cap

It is imperative to keep the castable working lining in compression to avoid horizontal cracking; this can be accomplished by incorporating:

3/8” diameter x # 304 V-Anchors welded on 6-inch centers x a length of approximately 80% of the total lining thickness
4 ~ 6-Inch top-cap of RENO Cast 70 KH, mixed with 10%
#446 x ¾” Steel Fibers.

This economical solution can be cast along with castable but the high volume of steel fibers adds a robust, in the field thrust plate barrier to keep the ladle in compression which eliminates cracks and increases life.

Gray Iron Transfer Ladle applications

Gray Iron Transfer Ladles

RENO ElectroCast 370 and RENO ElectroCoat 75 SiC

Grey Iron Transfer Ladles will perform longer and provide lower turnaround maintenance costs when utilizing these advanced refractory products.

Hot Face/Surface Treatment

RENO ElectroCoat 75 SiC is a robust, near zero permeability, ceramic coating that resists oxidation. This new surface will: extend the on-line performance time without buildups, greatly lessen the cleaning time, and allows the castable working lining to last many times longer.

Castable Lining

RENO ElectroCast 370
This super refractroy is engineered to tolerate thermal cycling and has all the advantages listed for our Electro Castables, such as extremely small pore sizes, and very low permeability, to resist adherences, and very high hot strengths, to combat erosion.

Insulation

2800° F, IFB Brick Split / RENO MO Super 3 Mortar

Safety Surface Treatment

RENO Coat It AL
To prevent Carbon Transfer should molten iron touch the steel shell, which weakens the steel and is the major cause of run-outs, apply this ceramic layer of protection.

Top Cap

It is imperative to keep the castable working lining in compression to avoid horizontal cracking; this can be accomplished by incorporating:

3/8” diameter x # 304 V-Anchors welded on 6-inch centers x a length of approximately 80% of the total lining thickness
4 ~ 6-Inch top-cap of RENO Cast 70 KH, mixed with 10%
#446 x ¾” Steel Fibers.

This economical solution can be cast along with castable but the high volume of steel fibers adds a robust, in the field thrust plate barrier to keep the ladle in compression which eliminates cracks and increases life.

Refractory Products for Foundry Maintenance Applications

RENO Refractories, Inc. provides the iron foundries with easy to work with refractory products used for daily maintenance duties. The long list includes:

RENO Black ICE 2
General silica / carbon, ladle wash that can be spryed or brushed on most refractory surfaces. This product works great as the furnace top rings and other ladle free-board slag-splash applications. Some even spry the outside of the ladle steel shells to prevent molten metal / slag splash adherences.

RENO MO Super 3
Fast and strong air setting super duty mortar, used for installing safety lining brick and insulation brick.

RENO 95 HS Mortar
This heat setting mortar can be used for installing brick with high expansion rates, such as tabular alumina type, and for creating gasket seals between receiver and discharge spouts used in conjunction with ceramic paper, etc. It is recommended as the surface preparation before phosphate bonded plastic repairs, versus the air-set mortars that are bonded with sodium silicate. Sodium sliicates react with the phosphate chemicals in the plastics and may result in improper bonding

RENO ElectroCoat Zinc Shield
This Near Zero Permeability Surface Treatment is used for applying a vapor resistant barrier between the IMF coil-grout, and the hot-face dry vibe refractory, to prevents zinc vapors from re-condensing on the coils

RENO ElectroCoat 75 SiC
The high amounts of silicon carbide resists oxidation and thus provides protection from the corrosion of metal – slag mixtures. This product bonds to steel and extends the useful life for slagging tools many times. The clean slagging tool also reduces the labor required for cleaning furnace and ladle slag layers. This unique product is an invaluable asset for reducing labor costs associated with ladle cleaning.

RENO Putty 55
This user friendly chemical bonded, fine grained plastic / putty like refractory, can be used to form lips, and top-cap rings for slag-splash resistance.

RENO Putty 80 FF
This is a high alumina chemical bonded product that can be used in a variety of patching applications such as ladles, spouts, troughs and any high wear areas. The special particle sizing used makes the patching product crack free for smooth surfaces.

RENO PL 70 P
This is a phosphate bonded mullite plastic used for patching large areas in ladles, spouts, and troughs. Works best when the used and dry refractory surface is clean from dust and debris, then wet- down with a thin layer of RENO Mortar just prior to ramming.

RENO Plastic 85 P
This is a phosphate bonded bauxite plastic used for patching all areas in the foundry, and can many times replace the more expensive 90% products, which are used simply due to the high workability. Applications like the top-cap in the coreless induction melting furnaces are just one of many areas where our 85% alumina, high strength plastic will demonstrate its value.

RENO Plastic 90 P
This is our high purity 90% alumina, phosphate bonded plastic refractory. It is used where high strengths and corrosion resistance are common.

RENO PL 349 CRM
Our tabular alumina phosphate bonded plastic fortified with chrome oxide plastic is used for the most demanding applications such as spout repairs, as well as impact pads, and high wear areas inside the melting furnaces, or areas that require a corrosion resistant refractory.

RENO NC Hot Gun 6044
This is a patching repair gunnite refractory that can be shot over hot surfaces. This is a no-cement, high alumina – silicon carbide refractory composition that applies easily and develops extremely high strengths at use temperatures. Applications include Vertical and Horizontal Induction Furnaces as well as Large Fore-Hearth Ladles where impact streams or slag corrosion gouges the walls and require patching.

RENO Floor Cast
Many high traffic areas around furnaces experience damages from metal or slag spills. These floor areas can be easily repaired with our super strong, high cement content refractory concrete to keep the floor smooth for safe fork-truck operations.

Ceramic Fiber Blanket, Ceramic Insulation Paper, and Sodium Silicate
We stock a variety of ceramic fiber blankets with the one-inch x (8) pound density being the most common. We also have 1/ 8” and ¼” x 2300 ⁰F Ceramic Paper Insulation, and Sodium Silicate for applying these insulation materials.

Microthermal Insulation Panels
RENO provides micro-porous insulation in a quilted glass cloth which we stock in sizes of 24 inches x 36 inches’ x ¼ inch thick. We have successfully used this super insulation in many applications whereas the furnace linings demand steel shell protection or where ladles are not sufficiently thick enough for traditional insulating fire-brick designs. Please discuss with a RENO Technical Engineer before incorporating; it is imperative to calculate the freeze plain designs for safety when considering this super-efficient insulation.

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