How to Boost Thermal Efficiency in the Aluminum Industry with Nano/Microporous Insulation Boards?

1. Energy Efficiency and Space Optimization with Nano /Microporous Insulation Boards in Aluminum Industry Equipment

Nano microporous insulation boards, composed of nano-silica with suitable additives, exhibit high-efficiency insulation properties through a special dry pressing process. Their unique nanomaterial structure and additive synergy effectively suppress heat conduction, convection, and radiation across different temperature ranges. In most cases, these boards outperform traditional insulation materials like lightweight insulating bricks, mineral wool, calcium silicate, and ceramic fibers, with the thermal conductivity of nano microporous insulation even lower than that of static air (see Figure 1). These boards offer exceptional insulation while being environmentally friendly, safe, efficient, and durable

In the aluminum industry, we recommend FB-950 and FB- 800 products for applications up to 1000°C and 850°C, respectively.

2. Application Examples of Nano/Microporous Insulation Boards in the Aluminum Industry:

2.1 Application in Aluminum Melting Furnace

Aluminum melting furnaces are crucial components in the aluminum industry, ensuring optimal temperature distribution to maintain a uniform liquid state. The refractory insulation system is vital for correct temperature control in these furnaces

FB-950 or FB-800 flexible boards can be used to reduce heat loss, improve product quality, and lower operating costs. The FB-800 variant is fully coated with aluminum foil to prevent performance degradation caused by moisture absorption from the casting material

Advantages:

• 50% reduction in thickness compared to ceramic fiber boards, resulting in a 9°C temperature decrease.
• 30% reduction in heat loss compared to ceramic fiber boards of the same thickness, leading to a 15°C decrease in cold face temperature.
• Lower heat loss improves product quality and extends the furnace's lifespan.
• FB-950 or FB-800 products can be easily cut and installed on-site using standard tools and techniques.

2.2 Application in Aluminum Transfer Ladles

Efficient transportation of molten aluminum between factories is crucial for the aluminum processing industry. Transfer ladles using road transport help achieve this efficiently. 800 provides a solution to reduce heat loss, increase capacity, and lower operating costs. The 800 material, completely enveloped in aluminum foil, prevents performance degradation due to moisture absorption from the casting material.

Advantages:

• Heat loss equivalent to an 18 cm mineral wool board for a 5 cm 800 board.
• Increased capacity of the ladle, reducing operating costs.
• Maintains the existing furnace shape, reducing heat loss and saving energy.
• 800 can be cut and installed quickly and easily on-site.

2.3 Application in Aluminum Troughs for Molten Aluminum Flow

To transfer molten aluminum from the melter to the casting facility, aluminum processors use troughs to distribute the melted aluminum and eliminate bubbles, thereby enhancing processing quality. To prevent the "freezing" of molten aluminum and maintain consistency in the distribution system, an insulation system is required to preserve the temperature of the melt. The temperature of the aluminum melt is approximately 750°C. Additionally, the use of insulating materials minimizes heat loss in the trough, reducing the risk of overheating the molten aluminum

The cross-sectional diagram (Figure 5) of the application of FB-800C in the aluminum trough is shown below. Figure 7 Schematic of FB-800C Application in Aluminum Troughs FB-800C can be utilized for this purpose. Its thickness is determined based on the specific configuration and dimensions of the lining. FB-800C is entirely covered with aluminum foil to prevent performance degradation caused by moisture absorption from the casting material. The FB-800C material can be bonded to the lining of the trough using high-temperature adhesive.

Advantages:

• 4 cm reduction in insulation thickness compared to calcium silicate board.
• 43% reduction in cold face temperature compared to a similar thickness of calcium silicate board.
• 67% reduction in heat loss compared to a similar thickness of calcium silicate board, improving product quality and extending the trough's lifespan.
• FB-800C can be cut and installed on-site using standard tools and techniques.

2.4 Application in Aluminum Electrolytic Cells

Proper insulation of electrolytic cells is crucial for reducing energy consumption and maintaining thermal balance in the aluminum smelting process. 950 boards are used to insulate the sidewalls of electrolytic cells, providing effective thermal resistance in a challenging environment.

Given the complex structure and operating conditions of electrolytic cells, a comprehensive design and calculation approach is required to determine a suitable insulation solution. The insulation requirement includes moderate insulation at the bottom, reinforced insulation around the waistline above the cathode steel rod, and enhanced insulation at the four corners.

For additional details on specific configurations and dimensions, FB-950 boards are ideal for this application due to their ability to provide efficient insulation in confined spaces.

These applications showcase the versatility and efficiency of nano microporous insulation boards in the aluminum industry, offering energy savings, enhanced product quality, and extended equipment lifespan.

If you have further inquiries or need assistance with your specific requirements, please do not hesitate to contact me: esther.zhang@firebirdref.com Thank you for your reading.