Heavily Loaded Areas in Aluminum Melting Furnaces and Possible Refractory Solutions

Due to the trend to modern melting and recycling furnace technologies, the requirements for the refractories in the Aluminum Casthouse are increasing constantly. The operating temperatures have increased and the chemical attack is more intense. Especially in the areas of the belly band, ramp slope and sill the established lining concepts have reached their limits. The previously well-proven anti-wetting agents of wear-lining material decomposes earlier and the concrete infiltrates with liquid Aluminum. We have responded to these challenges by developing a novel monolithic wear lining refractory with an inorganic binder and a very effective anti-wetting agent. This special additive is highly temperature stable and thus still effective at increased process temperatures. By using the novel material, the life time of the refractory lining was increased significantly. This paper shares theoretical aspects of the refractory technology as well as practical experience and results of the collaborative work with Trimet Aluminum SE.