Charging chamber of an aluminium melting furnace renewed
30 % lower energy costs – through a targeted overhaul of the charging chamber
Initial situation
On an aluminium melting furnace, the lining of the charging chamber had deteriorated badly after intensive continuous operation. The thermal insulation was weakened, resulting in increased energy consumption and a noticeably reduced melting capacity. The customer commissioned SBS Refractory Service with a comprehensive overhaul to bring the plant back to optimum performance.
Scope of services
- Damage analysis and survey of the charging chamber
- Complete dismantling of the worn lining
- Rebuild with matched refractory materials
- Optimisation of the thermal insulation
- Controlled heat-up and handover to production
Project data
The task
The lining of the charging chamber was worn over a large area and had to be completely renewed
The overhaul was to take place during a planned shutdown – within a tightly limited time window
The new materials had to be matched precisely to the thermal and chemical loads of the charging area
At the same time, energy losses were to be sustainably reduced through improved insulation
The SBS approach
Following a detailed damage analysis, our team developed an optimised lining concept for the charging chamber. The worn lining was completely dismantled and all residues professionally removed.
The new brick lining was built up using highly durable refractory materials matched both thermally and chemically to the requirements of the aluminium melting process. Particular attention was paid to optimising the thermal insulation in the charging area.
Once the work was complete, the furnace was heated up under controlled conditions and handed over to production. The results were immediately reflected in the operating figures.
Charging chamber of an aluminium melting furnace renewed in pictures
Freshly lined charging chamber – optimised for maximum energy efficiency
Highly durable refractory materials for the charging area
Measurable results
The key figures of the “Charging chamber of an aluminium melting furnace renewed” project
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