Real cases of application of non-stick aluminium castables in aluminium refining industry
As a high-performance refractory material in the aluminium industry, non-stick aluminium castables are widely used for their excellent resistance to aluminium water erosion, non-aluminium ash production and long service life. The following is a real case of application of non-stick aluminium castables in aluminium refining industry.
Background
A large aluminium processing plant decided to upgrade the refractory material of its aluminium melting furnace in order to improve production efficiency, reduce production cost and improve the quality of aluminium alloy products. Traditional refractory materials reacted easily with the aluminium liquid during use, generating aluminium ash and impurities, which not only contaminated the aluminium liquid, but also shortened the service life of the refractory materials. Therefore, the plant decided to use non-stick aluminium castables to replace the traditional refractory materials.
Application process
1、Material selection: The plant chose the non-stick aluminium castable which is mainly made of special high alumina bauxite aggregate, adding α-Al₂O₃ micro-powder, brown corundum fines and a special additive, and using pure calcium aluminate cement as the binding agent. This kind of castable has the characteristics of high strength and high resistance to aluminium water permeability.
2、Construction and installation: In the key parts of the aluminium melting furnace, such as furnace wall, furnace bottom, degassing box, flow channel and flow outlet, the installation of non-stick aluminium castables was carried out in accordance with the professional construction specifications and requirements. During the construction process, the proportioning, mixing, pouring and maintenance of the castables were strictly controlled to ensure the quality and performance of the castables.
3、Performance test: After the installation was completed, a comprehensive performance test was carried out on the aluminium melting furnace. The test results show that the non-stick aluminium castable has excellent resistance to aluminium water erosion, does not produce aluminium ash, and has a significantly longer service life than traditional refractory materials.
Application effects
1、Improvement of production efficiency: Due to the excellent anti-aluminium water erosion resistance of the non-stick aluminium castables, the reaction between the aluminium liquid and the refractory material is reduced, thus improving the production efficiency of the aluminium melting furnace.
2、Production cost reduction: non-stick aluminium castables have a long service life, reducing the frequency and cost of replacing refractory materials. At the same time, because it does not produce aluminium ash, it also reduces the loss of aluminium ingots and cleaning costs.
3、Improve the quality of aluminium alloy products: The use of non-stick aluminium castables reduces the impurities in the aluminium liquid and improves the purity and quality of aluminium alloy products.
4、Environmentally friendly: the application of non-stick aluminium castables reduces the generation of aluminium ash, which is conducive to environmental protection and sustainable development.
Case Summary
The practice of replacing traditional refractory materials with non-stick aluminium castables in this large-scale aluminium processing plant shows that non-stick aluminium castables have a wide range of application prospects in the aluminium refining industry. It not only improves production efficiency and reduces production costs, but also improves the quality and environmental friendliness of aluminium alloy products. This successful case provides useful reference and inspiration for other aluminium processing plants, and promotes the technological progress and sustainable development of aluminium refining industry.