The selection of furnace construction and sintering processes should ensure that a reasonable three-layer structure is obtained after lining sintering, with the initial thickness of the sintered layer, semi-sintered layer, and buffer layer each accounting for approximately 1/3. This is an essential condition for achieving a long service life of the furnace lining and ensuring safe production. A longer lining life means lower electricity consumption per furnace construction cycle.
① Changing the operating conditions of the medium-frequency induction furnace to improve lining service life and reduce energy consumption.
At high temperatures, the crucible reaction occurs in the furnace lining, where the SiO₂ in the lining is reduced by the carbon in the molten iron, rapidly corroding the lining. Chemical reactions caused by different slags also contribute to lining corrosion. Longer exposure to high temperatures intensifies these reactions, reducing the lining's service life. Therefore, increasing the power of the medium-frequency induction furnace to shorten the melting time can effectively extend the lining's service life and thus save energy and reduce costs.
② Choosing a neutral lining.
Recent research shows that neutral linings (high-alumina refractory materials) are widely used in the melting of various ferrous and non-ferrous metals and their alloys, especially suitable for the diverse and high-quality requirements of the precision casting industry. They have good thermal stability, high refractoriness (up to over 1800°C), significantly extending furnace life and greatly reducing maintenance and construction costs. Furthermore, it eliminates the health hazards of quartz sand dust. Based on an annual production of 380 tons of alloy steel, using a neutral lining can save thousands of dollars annually in material and maintenance costs compared to an acidic lining.
