The anode baking furnace is a crucial step in primary aluminum production. Correspondingly, the selection of refractory materials is crucial. The refractory solution needs to meet the prolonged high-temperature, strong-oxidizing and high-mechanical stress environment within the furnace. Traditional refractory bricks are highly susceptible to deterioration, collapse or cracking, leading to increased heat loss and energy consumption. To address this industry pain point, Kerui R&D team has independently developed a patented product — refractory bricks for flue wall of anode baking furnace — which has been authorized by the State Intellectual Property Office. This technology has proven to help customers extend furnace life and reduce overall costs.
Anode Baking Furnace Operating Conditions and Refractory Material Requirements
Anode Baking Furnace Structure Introduction
The anode calcination furnace is a key piece of equipment in prebaked anode production. It operates under extreme conditions of continuous high temperatures (up to 1250℃), strong alkali metal vapor erosion, frequent temperature cycles, and high mechanical loads. The furnace consists of the furnace roof, side walls, transverse walls, fire channel walls, bottom plate, combustion system, and annular flue.
Refractory Requirements on Anode Baking Furnace
| Area | Operating Conditions | Requirements for Refractory Materials |
| Furnace top | High-temperature radiation, gas erosion | 1. High temperature resistance above 1300℃; 2. Low thermal conductivity to reduce heat loss; 3. Strong resistance to gas erosion; |
| Furnace wall | Large temperature fluctuations, gas infiltration | 1. Excellent thermal shock resistance (no spalling during thermal cycling); 2. Resistance to molten bitumen and sodium salt erosion; 3. High structural density; |
| Furnace bottom | Mechanical load, high-temperature wear | 1. High temperature compressive strength with ≥30MPa and below 1400℃; 2. Wear and impact resistance; 3. Strong impermeability; |
| Combustion system | Localized high temperature (1400℃+) | 1. Extremely high temperature resistance above 1600℃; 2. Resistance to flame erosion; 3. Good thermal stability; |
| Fluorite and chimney | Low-temperature corrosion, dust erosion | 1. Resistance to low-temperature acidic gas corrosion; 2. Smooth surface to reduce dust accumulation; 3. Low cost and easy construction. |
Kerui Invention Patent for Anode Baking Furnace
The fire channel walls need to withstand severe high temperature impacts and chemical erosion over long periods. While traditional refractory bricks often experience problems such as spalling and cracking. To address these issues, Kerui R&D team independently developed a type of refractory brick and obtained invention patent. This product provides a more reliable and economical solution for customers with anode baking furnace. Here are details about Kerui invention patent for your reference:
- Patent Name: Refractory Bricks for Flue Wall of Anode Baking Furnace (ABF)
- Patent Number: ZL201110087095.1
KERUI refractory bricks for flue walls aim to “extend furnace life and reduce energy consumption.” Through patented formulas and process innovation, they achieve the following performance breakthroughs.
Patented Formula System
Utilizing optimized gradation of high-alumina materials and a composite binder system, ensuring structural stability and preventing cracking at high temperatures.
Superior Thermal Shock Resistance
Verified through thousands of thermal cycling tests, its thermal shock resistance is more than 30% superior to traditional high-alumina bricks.
High-Strength Erosion Resistance
Effectively resists chemical erosion and mechanical wear from high-temperature flue gas and dust, extending the service life of the furnace walls.
Customized Design
Personalized solutions in terms of size, material, and installation methods are provided based on the combustion system, temperature zone distribution and structural requirements of different calcining furnaces.
Customer Benefits to Buy KERUI ABF Refractory Brick
- Significantly extended furnace wall life;
- Delayed furnace shutdown and maintenance cycles to reduce maintenance costs;
- More stable insulation performance to result in more outstanding energy-saving effects;
- Safer and more reliable furnace operation.
KERUI Experience on Anode Baking Furnace Refractory
This product has been granted a national invention patent, further recognizing Kerui’s R&D strength in the field of special refractory materials.
Currently, Kerui complete refractory solutions for anode calcining furnaces have served many large enterprises, including China Aluminum, Nanshan Aluminum, and Iran’s AL-MAHDI Aluminum, providing full-process technical support from material supply and construction guidance to regular follow-up visits with positive customer feedback. You can browse more feedback on Kerui Pinterest.
The independent laboratory help Kerui provide authentic and traceable data assurance. The refractory brick material source, proportion and performance test data of each batch of brick refractory is traceable. The laboratory equipment includes trace element rapid analyzer, re-burning test furnace, cold crushing pressure test machine and so on. These are the basis for Kerui to carry out product upgrades, formula optimization and performance verification.
