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 Reverberating aluminum smelting and holding furnaces

When designing the lining of reverberating furnaces and mixers, it is necessary to take into consideration the specifics of the service of refractories and the properties of molten aluminum. In particular, a barrier layer is to be provided in the lining of the contact surface of the molten with refractories. The main function of the barrier layer is to prevent invasion of the molten in the heat insulation layer. If there is no barrier layer, the metal-impregnated hearth is a monolith that is hard to remove during disassembly operations.

The lining of reverberating smelting furnaces and mixers are of multi-layer type. It may contain protective, working, barrier, heat insulation layers.  

The lining design of the roof, hearth, basin walls and walls above the metal level vary. The wall thickness of reverberating furnaces and mixers does not normally exceed 450 mm; the hearth—600 mm; the barrier layer—from 80 to 120 mm.

Various elements of the lining of reverberating furnaces and mixers may be provided by using the following four techniques:

  • made of molded and pre-baked products (bricks or blocks);
  • ramming mixtures with further drying and commissioning for the required operation mode;
  • refractory concretes using section casting in the framework with further drying and commissioning for the required operation mode;
  • installation of pre-fabricated panels, either signle-layer, or sandwich-type, containing the working or heat insulation layers, which were cast and were subject to heat treatment outside furnaces.

Our lining systems guarantee quick and easy installation, good heat insulation, and overall savings on power costs.

The wide range of heat insulation materials allows us to perform successful repairs on reverberating furnaces of aluminum melting and exposure.

The furnace basin lining is multi-layered:

  • calcium silicate slab CERABOARD SILICATE 1000;
  • insulation concretes CERALIT LWCAST CR27060 G, CERALIT LWCAST CR40059 G;
  • barrier layer CERALIT STICK CI46050;
  • working layer CERALIT CAST BL80130 B.

The furnace wall lining above the metal layer is multi-layered: 

  • calcium silicate slab CERABOARD SILICATE 1000.
  • insulation concrete CERALIT LWCAST CR40059 G;
  • working layer concrete CERALIT CAST AL58007.

The lining of the baffle, framework, and burner unit areas is multi-layered:

  • calcium silicate slab CERABOARD SILICATE 1000.
  • insulation concrete CERALIT LWCAST CR40059 G;
  • working layer concrete CERALIT CAST KL79047.

The furnace roof lining is multi-layered:

  • insulation layer: ceramic fiber CERAWOOL, insulation concrete CERALIT LWCAST VR32026.
  • working layer: concrete CERALIT CAST AL58007.

The lining of the gas duct, recuperator, and chimney stack are made of various lightweight gunned castables, as well as insulation fire-clay grog concretes.