We are working on the complete revamping of two large reverberatory furnaces located in a major primary aluminum smelter in France. The project not only includes the complete lining of the furnace, but also the installation of regenerative burners, an ideal option for achieving high environmental benefits.
Reverberatory furnaces: What does revamping involve?
Revamping involves the comprehensive modernization of the furnace, with the aim of increasing plant efficiency without the need for major structural changes or the purchase of new equipment. It is based on operations such as
- 3D scanning of plants and equipment
- CFD simulations (ANSYS)
- Thermal analysis of the equipment
- Maintenance of the equipment
- Maintenance of the refractory lining
- Updating to regulations
- etc
Key benefits of revamping reverberatory furnaces
Lower energy consumption: improving the refractory, sealing thermal leaks, and optimizing gas flow reduce losses. When combined with heat recovery, as we are doing in our project by installing regenerative burners, the overall savings in fuel consumption can be very significant.
Greater thermal uniformity and process quality: correct chamber geometry and optimized flame direction reduce thermal gradients in the bath and reduce rejects/waste.
Less oxidation/burn-off and better metallurgical performance: less excess air and atmosphere control will reduce metal losses and alloying element volatilization.
Refractory longevity and fewer shutdowns: selecting suitable materials and designs for sensitive points (burners, load threshold) reduces the frequency of repairs. Insertec has lining solutions for these interventions.
In conclusion
A well-planned technical revamping allows a reverberatory furnace to be converted into a significantly more efficient, cleaner, and competitive unit, especially if regenerative burners are installed.
According to industry literature and project experience, it is reasonable to expect consumption reductions of 35–50% in correctly sized installations, with associated improvements in emissions and process quality.
If you are interested in learning more about our latest reverberatory furnace revamping project, please do not hesitate to contact our technical team: insertec@insertec.biz.
