Introduction

Ebonex bone ash is obtained by calcinating degelatinized bone up to a temperature of approximately 1100°C. Afterwards, the bone ash is cooled and milled (minimum of 95% through a 325 mesh size sieve).

Initially, Ebonex bone ash has been developed as a basic element in the porcelain industry, especially for the manufacturing of bone china, but due to its outstanding characteristics, it soon turned out to be most suitable for casting of refined copper, copper alloy and aluminum.

The expansion of bone ash in the aluminum industry is of such nature, that it forms a substantial part of Direct Chill casting of ingots and billets. Bone ash has a direct influence in improving the casting quality, because of the following intrinsical benefits:

• Has excellent non-wetting properties
• Is chemically inert and free of organic matters
• Has very high heat transfer resistance
• Increases the life expectancy of refractory and equipment

Application

Ebonex Bone Ash can be used as a protective coating on:

• Ladles, launders, troughs, tundishes, etc., made from fused silica
• Ceramic fiber, calcium silicate, castable, etc.
• All metal equipment and tools exposed to molten metal such as metal ladles, sow moulds, ingot moulds, metal troughs, etc.
• Floor areas around mould stations, furnaces and ladles.

Protective Coating

1. SUSPENSION FORM

   In order to determine the appropriate solid level for your application in a quick and easy way, it is preferable to set up a Baume Range with a Baume Gauge or hydrometer. The surface temperature will indicate the Baume to use:

   • Warm surface   →   lower Baume (15-25)
   • Cold surface     →   higher Baume (25-40)

   A proper mixing is obtained by moderate mechanical (150-600 RPM) or air agitation. Most coatings, which are mixed in the foundry, are being used with water as a diluent

   Put half of the required water together with all the coating powder in the mixing tank. Then add enough water to get a good mixing action. Continue mixing until lump free and uniform consistency is obtained. Do not vortex the coating suspension in order to avoid air entrainment. Adjust level of the water until the used Baume is reached. End mixing when the coating is discharged.

   Ebonex Bone Ash can be applied by spray gun directly from the mixing tank or by dipping the mould.

2. POWDER FORM

   Ebonex Bone Ash prevents the metal from coming in contact with the refractory. A layer is built up by rubbing bone ash directly in the refractory. After each pour, a minimal maintenance is required to make sure that the trough lining is still covered.

   Ebonex Bone Ash have proved to be an excellent seal for seams and cracks in refractory lining.

   Ebonex Bone Ash enables an easy clean up of the metal spills by sprinkling the powder on the floor areas.

   Ebonex Bone Ash is a non-wetting powder with unique characteristics as a coating.

   1. High Thermal Stability
        Very high deformation temperature
        Low weight loss up to 1480°C (2700°F)
   2. Excellent Coating
        Uniform coating
        Free of runs, drips, blotches, and teardrops
        Good adhesion to metal
        Prevents mould erosion
        Brush marks and streaks minimized
   3. Easy to Use
        Available as powder
        No multi-component segregation possible
        Easy and fast mixed with water
        Easy to wash off
   4. Application Versatility
        Applicable by spray gun, brush or dipping the mould
        Compatible with refractory based coatings