How long does a refractory lining last in an aluminium melting furnace?

The service life depends on the furnace type, feed material and operating regime. For tilting rotary furnaces with salt slag, 8–18 months are typical, while holding furnaces achieve 3–5 years. Through optimum material selection and regular maintenance, we maximise the service life for your specific conditions.

Which refractory materials are suitable for contact with aluminium salt slag?

For areas exposed to salt slag, we use special non-wetting materials, including aluminium titanate-containing castables and phosphate-bonded high-alumina castables. These withstand the chemical attack of the salt slag considerably better than conventional fireclay linings.

Can repairs be carried out while production is running?

Partial repairs to individual furnace zones are often possible in hot condition – for example the replacement of door blocks or the repair of the tap-out launder. Extensive work on the hearth or roof requires a furnace shutdown, which we reduce to a minimum.

How can the energy efficiency of our aluminium furnaces be improved?

An optimised multi-layer insulation structure can reduce heat losses by 15–30 %. We analyse the current condition of your insulation using thermography and develop a tailor-made insulation concept that pays for itself within a short time through energy savings.

Maximum service life in aluminium melting

Aluminium & Non-Ferrous Metals

The aluminium industry places the highest demands on refractory linings: aggressive salt slags, mechanical stress from charging and cyclic thermal loading. We know the specific challenges of every furnace type and offer tailor-made solutions for maximum service life at minimum energy cost.

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200+

Aluminium furnaces relined

35+

Years of industry experience

900 °C

Max. operating temperature

98%

On-time completion

Industry expertise

Refractory construction for Aluminium & Non-Ferrous Metals

The aluminium industry processes millions of tonnes of primary and secondary aluminium every year under extreme conditions. Aggressive salt slags, cyclic thermal loading and mechanical abrasion from charging operations place the highest demands on the refractory lining. An optimised lining is decisive for energy efficiency, metal yield and plant availability.

SBS Refractory Service has been a reliable partner to the aluminium industry for more than three decades. We know the specific requirements of every furnace type – from the tilting rotary melting furnace and the dosing furnace to the soaking pit furnace. Our manufacturer-independent material selection guarantees that the optimum refractory concept is used for every application.

Whether a complete relining during a planned shutdown or an emergency repair after an unplanned outage – our experienced installation team works on schedule and in close coordination with your production. In this way we minimise downtime and sustainably secure the profitability of your melting processes.

Typical challenges

Aggressive salt slags chemically attack the lining and significantly shorten its service life
Cyclic thermal loading from frequent heat-up and cool-down cycles leads to crack formation
Mechanical abrasion when charging scrap and ingots damages the furnace hearth
Aluminium penetration into the refractory lining causes spalling of the lining layers
High energy costs due to inadequate insulation and heat losses

Furnace types