In the Aluminum industry, refractories must contend with a unique set of challenges, primarily molten aluminum penetration, the growth of corundum (alumina buildup), severe chemical reactions with various aluminum alloys and fluxes, and the effects of thermal shock during charging and tapping. These issues are prevalent across melting, holding, refining, and alloying furnaces, where metal purity and energy efficiency are paramount.
Refractory IntegraSmart’s expertise focuses on selecting and managing non-wetting and infiltration-resistant refractory solutions that prevent metal adhesion, reduce dross formation, and maintain furnace integrity. We advise on specialized alumina-based materials, silicon carbide, and monolithic linings designed for specific zones like hearths, sidewalls, doors, and ramps. Our services encompass design optimization for furnace bottoms and side walls, rigorous material quality inspection, and post-mortem analysis of affected linings to understand and mitigate failure mechanisms. By enhancing refractory performance, we help aluminum producers achieve consistent metal quality, reduce energy consumption, minimize cleaning frequency, and extend furnace availability.
