Complete overhaul of an aluminium furnace
30 % more capacity, 23 % lower energy consumption – through systematic modernisation
Initial situation
A leaking door frame on an aluminium furnace had initially been classified as purely local damage. Closer analysis by SBS Refractory Service, however, revealed a systemic deterioration: oxygen ingress through the leak was causing increased slag formation, reduced melting capacity and a 30–40 % drop in aluminium yield per melting cycle.
Scope of services
- Systematic damage analysis extending beyond the local defect
- Overhaul of the door frame with new seals
- Renewal of the refractory lining in critical areas
- Revision of the thermal insulation and control systems
- Controlled heat-up and performance documentation
Project data
The task
The leak at the door frame had led to uncontrolled oxygen ingress
Increased slag formation considerably reduced the usable furnace capacity
Aluminium yield had fallen by 30–40 % per melting cycle
Repairing the frame alone would not have solved the systemic problems – an overall modernisation was required
The SBS approach
Instead of simply repairing the door frame, our team carried out a comprehensive system modernisation. In addition to the professional overhaul of the frame, the door seals, control systems and the entire thermal insulation were revised.
The refractory lining was renewed in the critical areas and executed with materials offering improved resistance to slag attack. The furnace geometry was optimised to achieve a more even heat distribution.
After the modernisation was complete, the furnace was heated up under controlled conditions and the operating parameters were documented. The results clearly exceeded the customer's expectations.
Complete overhaul of an aluminium furnace in pictures
Fully modernised aluminium furnace – 30 % more capacity
Renewed lining and optimised sealing systems
Measurable results
The key figures of the “Complete overhaul of an aluminium furnace” project
Similar references
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