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Secondary aluminum producers need refractory solutions to respond to the increased demand for high-quality, low-cost and environmentally sound recycled aluminum used in the automotive, transportation, packaging, construction and aerospace industries.

Download: Refractory Solutions for Aluminum Brochure

Secondary Aluminum Solutions

HarbisonWalker International addresses the increased demand for recycled aluminum with advanced solutions that increase production efficiency and service life of your continuous high-temperature operation.

Secondary aluminum production involves aluminum metal that is not refined from aluminum oxide. It includes all aluminum made from melted ingot and all recycled scrap. Secondary aluminum casthouses use a variety of furnace types to melt and refine ingot produced in primary aluminum, as well as various scrap sources such as used beverage containers, recycled sheet, and coil trimmings.

We offer a full portfolio of firebrick linings, including our industry standard ALCOR-32® and DV-38®, as well as monolithic refractory options to perform in the most severe conditions in the secondary aluminum process.

HWI Firebrick Linings and Castables: Key Benefits

  • Thermal shock resistance
  • Consistent thermal reliability
  • High temperature stability and structural integrity
  • Reduced energy consumption
  • Increased production efficiency and service life time
  • High abrasion resistance
  • Resistance to corundum formation
  • Minimal shrinkage at operating temperatures

Featured Secondary Aluminum Products

ARMORTECH 65 AL: A 65% alumina, low cement castable capable of vibration or pump casting. An advanced non-wetting package provides ultimate aluminum resistance, while still offering high hot strengths and excellent abrasion resistance. Available in coarse grain, quick-setting and fast fire, and shotcrete.

DV-38: A high fired 80% alumina, phosphate bonded brick for use in aluminum contact. This brick is ceramically bonded and delivers outstanding impact and abrasion resistance for charging zones, such as the hearth and ramp.

ALCOR-32: This premium aluminum resistant brick has a dual penetration inhibitor to offer top notch resistance to aluminum and chemical attack. Tight sizing control makes sure courses are level to provide excellent wall builders.  Also available in waffle brick for additional wall stability.

GREENGUN®-85 P PLUS: This 85% alumina phosphate bonded material offers the advantages of a gunned lining with the excellent physical properties of plastic refractories. GREENGUN is cement free and offers alkali, thermal shock and abrasion resistance. This advanced material is designed to be installed rapidly, hot or cold, to minimize turnaround time.

ARMORKAST 80 AL ADTECH®: An 80% alumina, low cement castable workhorse. Excellent aluminum resistance and strengths make this a go-to product for many aluminum contact applications. Available in coarse grain for impact and thermal cycling or self-leveling with smooth surface finish.

VERSAFLOW® Family: A robust alumino-silicate product line offering chemistries from 45-80% alumina. These economical products can offer a wide range of properties tailored to your secondary aluminum needs. All 16 products also offer the flexibility to be hand cast or pumped.

THOR® 60 ABR ADTECH®: This 60% silicon carbide based, low cement castable was designed to handle thermal cycling and abrasion needs around furnace doors and trough impact pads. Being naturally aluminum resistant, this product is a great problem solver for tough applications.

Did You Know?

HWI’s ARMORTECH® is the next generation of aluminum resistant refractory castables – delivering ultimate molten aluminum resistance to penetration, reaction and metal pickup needed for secondary aluminum production.

Secondary Aluminum

Product SDS
AL CLEAN A-94 A 95% alumina porous plug English
ALCOR® An 80% alumina, phosphate bonded brick English
ALCOR® 32 An 80% alumina, phosphate bonded brick with an alumina metal penetration inhibitor English
ALCOR® 60 A cured, phosphate bonded high alumina brick, non-wetting to aluminum metal English
ARMORKAST 80AL C ADTECH® An 80% alumina, aluminum resistant, coarse aggregate castable
ARMORLITE® 85AL An aluminum resistant, 85lb/ft3, insulating castable
ARMORTECH 65AL A 65% alumina, aluminum resistant, dense castable
ARMORTECH 65AL C A 65% alumina, aluminum resistant, coarse aggregate castable
ARMORTECH 65AL ON-LINE A 65% alumina, aluminum resistant, fast-curing castable
CLIPPER® DP A super duty fireclay brick
CORAL® BP A burned, phosphate bonded 80% alumina brick
DV-38® An 80% alumina, burned, phosphate bonded brick
EXPRESS® ARMORKAST 80 AL MAX An 80% alumina, aluminum resistant, free flowing castable
GREENGUN®-85 P PLUS An 85% alumina, phosphate bonded gunning plastic
GREENKLEEN®-60 PLUS A 60% alumina, andalusite containing low cement castable
GREENLITE®-45-L AL PLUS A 2500oF rated lightweight castable with resistance to molten aluminum
GREENSET®-85 P An 80% alumina, phosphate bonded mortar
H-W ES CASTABLE C AL A fireclay, aluminum resistant, coarse aggregate castable
HPV®-ESX CASTABLE A fused silica castable designed for thermal shock resistance
KALA® A 50% alumina brick
KALA® HPC CHECKERS A 50% alumina brick
KALAKAST AR® ADTECH® A 60% alumina castable designed for alkali resistance English
KAST-O-LITE® 22 G PLUS A 2200°F rated lightweight gunning mix
KAST-O-LITE® 22 PLUS A 2200°F rated lightweight castable
KAST-O-LITE® 30 LI PLUS a 3000°F, low iron, insulating castable
PLASTECH® 85P STD An 85% alumina, phosphate bonded plastic refractory
UFALA® A 60% alumina brick shape
UFALA® A 60% alumina brick shape
ULTRA-EXPRESS® 70 AL A 70% alumina, free-flowing, ultra-low cement dense castable
ULTRA-GREEN® 45 A 45% alumina, low cement castable
VERSA-TECH 55 AR HS PLUS A low cement, alkali resistant castable
VERSA-TECH MW 55 AR PLUS A low cement, lower density, alkali resistant castable English
VERSAFLOW® 57A PLUS An andalusite containing, low-cement castable
VERSAFLOW® 65/AL C ADTECH® A 65% alumina, low-cement castable
VERSAFLOW® 70 C PLUS A 70% alumina, coarse aggregate, low-cement castable English
VERSAFLOW® 70AL SC PLUS A 70% alumina, low-cement castable with silicon carbide and molten aluminum metal resistance English
VERSAFLOW® 80 C PLUS An 80% alumina, coarse aggregate, low-cement castable

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