Complete relining of an aluminium melting furnace
Every day of shutdown costs money – which is why a relining calls for speed with no compromise on quality.
Initial situation
An aluminium melting furnace was due for a complete relining. Once the old lining had been demolished, the steel shell was cleaned and inspected – from there the lining grew upwards layer by layer. The layer structure, material selection and installation sequence were fixed before the first material entered the furnace; the anchoring system was inspected and supplemented before the lining grew.
Scope of services
- Demolition of the old lining and cleaning of the steel shell
- Inspection and supplementation of the anchoring system
- Floor build-up: insulating layer and brick-laid wear lining
- Wall lining with insulating boards and insulating firebricks
- Monolithic execution of the melting ramp
- Formwork construction for the bath, door openings and arch
- Casting, compaction and curing
- Prefabrication of door lintels and arch elements
Project data
The task
Tight shutdown window – every additional day costs production
The furnace floor carries the melt and has to deliver peak performance both mechanically and thermally
The anchoring has to hold the lining securely under constant thermal cycling
Dross attack and mechanical cleaning at the melting ramp
Refractory castable tolerates no defects at subsequent operating temperatures above 1,000 °C
The SBS approach
Construction phase 1 – start: old lining removed, steel shell cleaned and inspected, anchoring system checked and supplemented
Construction phase 2 – floor: insulating layer of lightweight bricks as a thermal barrier, topped by a dense wear lining laid precisely in bond
Construction phase 3 – walls and ramp: Y anchors and brackets on the steel shell, wall lining of insulating boards and insulating firebricks, melting ramp executed monolithically and therefore seamlessly
Construction phase 4 – formwork and casting: dimensionally accurate formwork for the bath, door openings and arch, individually adapted to the furnace geometry; casting, compacting, curing
Door lintels and arch elements prefabricated in our own workshop – this shortens the shutdown on site
Complete relining of an aluminium melting furnace in pictures
Construction phase 1: old lining removed, steel shell cleaned and inspected
Construction phase 2: insulating layer of lightweight bricks, topped by the dense wear lining laid in bond
Construction phase 3: dimensionally accurate formwork for the bath and door openings
Construction phase 4: wall lining of insulating boards and insulating firebricks, anchors set
Prefabrication in our own workshop – this shortens the shutdown on site
Result: completed chamber with a seamless ramp and cast arch
Measurable results
The key figures of the “Complete relining of an aluminium melting furnace” project
Similar references
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