Non - ferrous metals industry

1. Great potential for energy saving and equipment development of aluminum industry in China

China not only has become the world's primary aluminum industry country, and has become a primary power, 2012 annual output of about more than 20000kt, accounting for about 44.4% of the world's total output, with the transition to the industrial base aluminum industrial power. But at the same time, China's aluminum industry also has low capacity utilization, high energy consumption and emissions. But compared with the world aluminum industry, China's aluminum industry in the global allocation of resources, industrial concentration, technical equipment, product competitiveness, technological innovation and other aspects of the larger gap. In the event of energy saving and emission reduction of the aluminum industry, a new emerging nano heat insulating material.

2. Energy saving and space effect of nano microporous insulation board in aluminum industry

Nano porous insulation board is the use of nano silicon dioxide, adding appropriate additives, through the special process of direct compression molding of high pressure insulation material.

Due to the synergistic comprehensive effect of its special nano porous structure and various additives, used in the different temperature range to maximize the inhibition of heat conduction and convection and radiation, makes the material is much better than that of all other traditional insulation materials, such as light heat insulation brick, mineral wool, calcium silicate and ceramic fiber, the temperature in most in the range of thermal conductivity of nano microporous insulation panel is even lower than the thermal conductivity of the static air (Figure 1).

Due to its superior insulation performance, the application can be the same thickness of the insulation layer to obtain lower wall temperature to save energy; or in a thin insulating layer thickness, in a relatively limited space place play an excellent heat preservation effect. At the same time, nano porous insulation board is a kind of green environmental protection material. Not harmful to environment and human, material waste and emissions in the production process, it will not be like other traditional insulation materials in the production process that consumes a lot of energy and easy to cause damage to the production staff.

To sum up, the nano porous insulation board is a super heat insulation, ultra-thin thickness and super environmental protection of new insulation materials.

Fig. 1 Comparison of the thermal conductivity of the main thermal insulation materials at different temperatures

In the application of the aluminum industry we can provide HT-1000 and MT-800 products, respectively, apply to 1000 degrees C and 800 degrees below the use of C. For details, please refer to our product specification or sales engineer.

3. An example of the application of nanoporous insulation board in aluminum industry:

3.1 Application of aluminum melting furnace

In the aluminum industry, aluminum melting furnace is an important part of the production process. These furnaces need to maintain the optimum melt temperature distribution in order to maintain a homogeneous liquid. This uniformity ensures the quality of the end product. It is very important to ensure the proper temperature control in aluminum melting furnace.

MT-800 or MT-800 flexible boards can be used for this purpose to reduce heat loss, improve product quality and reduce operating costs. Please wrap the MT-800 completely to prevent moisture absorption. MT-800 material can be adhered to the inside of the bag with high temperature adhesive. With traditional insulation materials (glass wool, mineral wool and ceramic fibers) compared to aluminum melting furnace, using nano microporous insulation board can save space, or save energy.

Advantage：

- with a ceramic fiber board, the thickness can be reduced by 50% and the temperature is reduced by a factor of 9.
- Compared with ceramic fiber board - with the same thickness, 30% reduction in heat loss, reduce the surface temperature of 15 DEG C
- Lower heat loss can improve product quality and prolong the service life of the furnace
- MT800 can be cut and installed on site using standard tools and techniques.

3.2 Application of aluminum water transport package

Aluminum processing industry is expected to have a high degree of flexibility and low production costs. Many aluminum producers will melt through the aluminum water delivery system of aluminum in water this efficient transfer between factories. The efficient transport of aluminum melt can be achieved by the transfer package of road transport. In China, the current trend is gradually concentrated to the aluminum casting factory around electrolytic aluminum factory, the factory water by aluminum electrolytic aluminum plant, avoid the waste of energy consumption to the melting process of ingot after cooling, directly processed products.

The temperature of molten aluminum is about 750 C...

Figure 4 aluminum water transfer package

MT-800 Solution

The interface of the liner system (Figure 5) is as follows:

- cladding
- 5 cm MT-800 insulation board
- 2.5 cm ceramic fiber board
- 11 cm high alumina brick
- Aluminum melt

Figure 5 Schematic diagram of the application of MT-800 in aluminum water transfer package

MT-800 Can be used for this purpose. According to the specific configuration and size of the package to determine its thickness. Please wrap the MT-800 completely to prevent moisture absorption. MT-800 material can be adhered to the inside of the bag with high temperature adhesive.

Advantage：

- MT-800 board -5 cm of the heat loss is equivalent to only 18 cm mineral wool board heat loss
- increase the capacity of the package, reduce operating costs.
- maintain existing furnace type, reduce heat loss and save energy.
- MT-800 can be cut and installed quickly and easily in the field.

3.3 Application of aluminum water trough

In order to transfer molten aluminum from the melt to the casting facility, the aluminum processing industry uses a runner to distribute the molten aluminum and remove the bubbles to improve the machining quality. In order to avoid the "freezing" of molten aluminum and the consistency of flow in the distribution system, it is necessary to cooperate with the insulation system to keep the temperature of the melt. The temperature of molten aluminum is about 750. In addition, the heat loss of the runner can be minimized by using the insulating material, and the overheating of the aluminum melt can be reduced.

Figure 6 aluminum flow tank

Section MT-800 is applied to the trough (Figure 7).

Figure 7  The application of MT-800 of aluminum water tank

MT-800 can be used for this purpose. According to the specific configuration and size of the package to determine its thickness. Please wrap the MT-800 completely to prevent moisture absorption. MT-800 material can be adhered to the inside of the bag with high temperature adhesive.

Advantage：

- heat insulation thickness reduced by 4 cm
- reducing the thickness can increase the capacity of the runner system
- calcium silicate plate with the same thickness, reduce the surface temperature of 43%
- Compared with the same thickness of calcium silicate board, the heat loss is reduced by 67%, which can improve the product quality and prolong the service life of the runner
- MT-800 can be used in the field of standard tools and techniques for cutting installation.

3.4 Application of electrolytic cell

The slot voltage of the new cathode structure is generally 3.70-3.75V, which is about 0.3V lower than that of the conventional cell. If the slot voltage is reduced by 0.3V, it is equivalent to a reduction of 13% of the electrical energy used in the resistance of the new cathode structure. At this time, a new cathode structure from the heat from the heat balance system, must be correspondingly reduced by about 13% in order to maintain the heat balance required for normal production in normal temperature electrolysis. Therefore, it is very important to reduce the energy consumption and maintain the heat balance of the cell.

Figure 8 electrolytic aluminum electrolytic cell, using HT-1000 insulation board

Due to the restriction of the design of electrolytic cell structure, a side wall assembly space heat insulation material is 10-12mm, tight end position of the space is only about 15mm, and the heat insulation temperature is 950-960 DEG C, using both from the geometry scale or in the working conditions are very suitable for nano microporous insulation material. The use of nano microporous insulation board, clearly made to reduce power consumption and improve the current density, voltage using stable etc..

However, the structure and the operating conditions of the electrolyzer are relatively complex, and the reasonable design scheme should be determined through comprehensive design and calculation. The general requirement of thermal insulation is now at the bottom of the groove of moderate heat preservation; the side of the electrolytic cell should not be too warm, strengthen insulation in electrolytic cell cathode steel bar below the bottom above the girdle shaped lining; but in the electrolytic cell four corners of the need to strengthen heat preservation.