Yongyi Refractory × Chinalco Materials: Conquering Molten Aluminum Penetration to Cast Long-Lasting Linings for Non-Ferrous Melting Furnaces
Client: Chinalco Materials
Industry: Non-Ferrous Metallurgy (Aluminum Melting and Holding Furnaces)
Services Provided: Supply of Anti-Penetration Specialty Refractories and Comprehensive Precision Masonry Services for Aluminum Melting Furnaces
Project Background: As the core supply chain platform of the Aluminum Corporation of China (Chinalco), Chinalco Materials provides critical material support for numerous large-scale aluminum deep-processing enterprises. During the aluminum alloy melting and casting stages, the operational efficiency and lining lifespan of melting and holding furnaces directly impact the purity of the molten aluminum and the enterprise’s production costs. Facing the common industry dilemma where traditional linings are easily penetrated by molten aluminum—leading to frequent corundum nodule growth and reduced furnace capacity—Chinalco Materials selected Yongyi, a partner with profound technical expertise in non-ferrous metallurgy refractories, for the major furnace overhauls at their affiliated plants.
Project Challenges: The service environment of an aluminum melting furnace is exceptionally demanding. First, high-temperature molten aluminum has extremely low viscosity, much like “water,” allowing it to easily penetrate deeply through the pores and joints of refractory materials. Second, active elements in the molten aluminum undergo reduction reactions with silica in traditional refractories, forming rock-hard “corundum nodules” (corundum growth) on the furnace walls. This not only contaminates the molten aluminum but also severely damages the lining during cleaning. Lastly, the daily charging of cold aluminum ingots or scrap causes intense mechanical impact and abrasion on the furnace bottom and lower sidewalls. The client urgently required a comprehensive furnace solution that is “non-wetting to aluminum, impact-resistant, and fully sealed.”
Yongyi’s Solution:
Premium Product Supply (Targeted Anti-Penetration and High-Strength Impact Resistance): Addressing the severe conditions of aluminum melting furnaces, Yongyi’s technical team customized a complete “anti-penetration and anti-nodule” product line. For the working layer of the molten bath in direct contact with liquid aluminum, we extensively applied ultra-low cement anti-penetration aluminum castables and anti-penetration high-alumina bricks enhanced with special non-wetting additives. At high temperatures, these materials significantly increase the wetting angle of molten aluminum, achieving a true “non-wetting” effect. This fundamentally cuts off the penetration and reaction pathways of the liquid aluminum, suppressing the formation of corundum nodules. For the furnace bottom and ramp areas subjected to the most severe charging impacts, we selected highly abrasion-resistant dense Silicon Carbide (SiC) bricks and high-strength wear-resistant materials to create an impenetrable bottom armor.
Professional Construction Services (Seamless Monolithic Casting and Dense Joint Management): To counter the extreme penetrability of molten aluminum, Yongyi dispatched a senior furnace masonry team highly proficient in non-ferrous melting furnace construction. For the molten bath area, we prioritized monolithic casting techniques combined with high-frequency vibration to minimize lining joints as much as possible. For areas requiring brickwork, our technicians used high-bonding-strength special fire mud perfectly matched to the brick material, strictly controlling joint widths to under 1.5mm, or even 1mm. This ensured the entire molten bath functioned as a “dense, seamless bathtub,” completely eliminating the risk of molten aluminum seeping through joints and burning through the furnace’s steel shell.
Customer Value & Results: Following the application of Yongyi’s specialty anti-penetration refractories and meticulous construction, the melting furnaces at the affiliated plants were successfully put into operation. After multiple production cycles, the furnace walls and bottom remained exceptionally clean, with almost zero corundum nodule formation. Furnace cleaning has become incredibly easy, significantly reducing labor intensity while greatly protecting the structural integrity of the lining. The purity of the molten aluminum has noticeably improved, and the actual service life of the furnaces has nearly doubled compared to previous campaigns. This has generated incalculable economic benefits and safety guarantees for Chinalco Materials and its downstream processing enterprises.
