In the high-energy-consuming production processes of the metallurgical industry, the thermal insulation performance of furnace linings directly impacts energy consumption and production efficiency. Ceramic fiber boards, as highly efficient thermal insulation materials, have demonstrated significant energy-saving effects in metallurgical furnace linings, as validated by actual measurement data, providing a reliable solution for energy conservation and cost reduction in the industry.
In a blast furnace furnace renovation project at a certain steel company, 1400 high-purity ceramic fiber boards were used to replace traditional refractory bricks as thermal insulation lining. Test data showed significant energy-saving effects. Before the renovation, the outer wall temperature of the furnace reached 180°C, resulting in severe heat loss, with natural gas consumption per ton of steel production at 86m³. After installing 100mm-thick ceramic fiber boards, the outer wall temperature of the furnace chamber dropped below 65°C, with heat loss reduced by over 60%. Natural gas consumption per ton of steel decreased to 62m³, achieving an average daily energy savings of 2,400m³ per furnace. Calculated based on annual production capacity, this results in over 3 million yuan in annual energy cost savings. This data validates the energy-saving value achieved by ceramic fiber boards through reduced surface heat loss.
In actual measurements of reverberatory furnaces in non-ferrous metal smelting, the energy-saving advantages of ceramic fiber boards are equally prominent. Before the renovation, the reverberatory furnace used alumina-silica wool insulation, which took 90 minutes to heat the furnace chamber to 1200°C, with significant temperature fluctuations (±30°C). After replacing it with 1600 high-alumina ceramic fiber boards, the furnace chamber heating time was reduced to 65 minutes, with a 28% reduction in energy consumption during the heating phase. Additionally, the low thermal conductivity of ceramic fiber boards improved furnace temperature stability, with fluctuations controlled within ±10°C, reducing energy waste caused by temperature fluctuations. Continuous production tests showed that the reflective furnace using ceramic fiber boards achieved monthly electricity savings of 12,000 kWh, with equipment maintenance intervals extended to twice the original duration.
Actual test data from medium-frequency induction furnaces further demonstrated the energy-saving potential of ceramic fiber boards. At a certain alloy smelting plant, the medium-frequency furnace experienced heat loss from the furnace body, causing the working environment temperature to exceed 40°C, with a power factor of only 0.82. After installing 50mm-thick ceramic fiber boards on the outer side of the furnace lining, the environment temperature dropped to 32°C, the power factor improved to 0.91, and electricity consumption decreased by 15% under the same smelting volume. Additionally, the thermal shock resistance of ceramic fiber boards reduces cracks caused by sudden temperature changes in the furnace lining, extending its service life from 3 months to 6 months and indirectly reducing energy waste caused by shutdowns for maintenance.
These measured data clearly demonstrate that ceramic fiber boards achieve significant energy-saving effects for metallurgical furnace linings by reducing heat loss, improving heating efficiency, and stabilizing furnace temperatures. In the context of the metallurgical industry’s pursuit of green and low-carbon development, the promotion and use of ceramic fiber boards have become an important measure to reduce energy consumption per unit of product and enhance production efficiency.
