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Aluminium industry

The right refractory solution for the specific challenges of aluminium plants – from raw material production to recycling.

DCS castables

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The lightest of metals

The primary aluminium production industry extracts metallic aluminium from minerals by supplying a large amount of electrical energy in batteries of electrolysis cells where molten metal is separated. Afterwards aluminium is reprocessed by different factories, which use several type of furnaces for the production of aluminium products or semi-finished products. It is in these remelting stages that modern refractory products are mainly used, while the primary aluminium production relies on refractory bricks.

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    “Energy intensive primary production and secondary cycles with extensive remelting and recycling stages have resulted in several different furnace types and processing facilities. It takes great expertise to offer the correct refractory solution for each of them.”

    Marco Tonidandel
    Business Development Manager

    The corundum challenge

    Aluminium has a strong affinity for oxygen, which leads to different mechanisms of oxidation of molten aluminium alloys.

    The bath surface passivation stops the process at the interface with the furnace atmosphere, but the reaction can proceed at the surface of refractory or in its burden layers. This results in the development of corundum, which can be prevented by the targeted usage of modern refractories.

    Seven Refractories product range contains the right blend of additives to ensure these mechanisms are working correctly. We can support aluminium plants and furnace makers with the choice of the right products, with precise instructions how to realize linings and to reduce the corundum formation or other problematic issues.

    The cycle of aluminium metal processing is complex and made by various types of furnaces which melt, treat, refine, remelt and reprocess aluminium products, semi-finished products and scrap in many steps. The primary aluminium production industry extracts metallic aluminium from minerals. Afterwards aluminium is reprocessed by different factories, which use several type of furnaces for the production of aluminium products or semi-finished products. It is in these remelting stages that modern refractory products are mainly used, while the primary aluminium production relies on refractory bricks.

    Seven DCS Advantages

    Ultra-fast drying procedure: This leads to simplified heating curves, reduced needed time (down up to approximately 30%), with a sensitive increase in the plant average availability due to significant reduction of downtime.

    ✔  Versatility: The product benefits can be enjoyed in the context of different technical applications such as casting, gunning, shot-creting..

    Aluminium Industry And Types Of Equipment

    Seven Refractories can offer solutions for the entire aluminium industry. Products for primary aluminium are mainly shaped products such as fireclay bricks, insulating bricks and alumina bricks, which can be supplied by Seven Refractories in case of need, but are not mentioned here, which focuses on monolithic products.

     

    Refractories for Aluminium

    Aluminium has a strong affinity for oxygen, which leads to different mechanisms of oxidation of molten aluminium alloys. The bath surface passivation stops the process at the interface with the furnace atmosphere, but the reaction can proceed at the surface of refractory or in its burden layers. This results in the development of corundum, which can be prevented by the targeted usage of modern refractories.

     

     

    There are two areas where corundum may form:

    At the bath surface because of direct oxidation 4 Al (melt) + 3 O2 → 2 Al2O3

    In the refractory starting from the liquid contact surface (under the bath level), because of the higher affinity to oxygen of metallic aluminium diffused from the bath into refractory driven by the reaction: 4 Al (diff) + 3 SiO2 → 2 Al2O3 + 3 Si.

    “Corundum formation” occurs at the intersection of refractory lining.
    It consists of a composite rich in aluminium/aluminium oxide, which grows by oxido-reduction.