Lightweight refractory linings

Lightweight refractory linings: a key to greater energy efficiency and lower emissions in the forging industry

Lowering pollutant emissions, optimizing energy consumption – like many other industrial sectors, the steel and metal industry faces the challenge of reducing both its energy use and environmental impact. Refractory linings are a decisive factor in the performance and energy footprint of high-temperature furnaces. The internationally operating refractory manufacturer RATH is increasingly focusing on lightweight refractory linings – including a newly developed, non-classified polycrystalline high-temperature insulation wool that has already demonstrated strong performance in the steel and metal industry.

The push to reduce the carbon footprint by improving energy efficiency and cutting emissions – while also lowering costs – is driving greater demand for lightweight refractory linings.

“Especially in energy-intensive high-temperature processes, which are typical of the steel and metal industry, lightweight linings represent a forward-looking alternative or a complement to conventional linings,” notes Richard Jäger, RATH, Head of Sales Metals & Fuels, Chemicals and Energy.

He explains the advantages: “The lower heat capacity of lightweight refractory materials results in superior insulation performance. This significantly reduces heat loss through furnace walls and ceilings. In addition, their lower mass allows for shorter heating-up and cooling-down cycles. Another compelling benefit is the simplified installation process and reduced labor required for maintenance, repairs, and replacements".

Non-classified polycrystalline high-temperature wool: maximum service life and highly efficient thermal insulation

Innovative high-temperature wool products are playing an increasingly important role in lightweight refractory linings. Driven by a longstanding commitment to innovation, RATH has consistently led the advancement of high-temperature insulation materials through intensive in-house research and development. Among the latest innovations is a product that provides optimal support for the steel and metal industry when it comes to meeting both economic and environmental challenges: ALTRA® 1500C – a further development of the proven polycrystalline wool of the ALTRA® brand and the latest all-rounder in the series.

“With ALTRA® 1500C, RATH has developed a genuine alternative to other high-temperature wool products: it offers all the advantages of polycrystalline fibers, but is more cost-effective,” explains Richard Jäger.

This newly developed, non-classified polycrystalline high-temperature insulation wool is optimized for use at temperatures up to 1500 °C and is available in both blanket and module form.

“In addition to its excellent cost-efficiency, its standout benefits include maximum service life and outstanding thermal insulation performance,” he adds.

Moreover, ALTRA® 1500C is fully compatible with other proven grades in the ALTRA® family – ALTRA® 72, for applications involving exceptionally high temperatures, and ALTRA® 97, when high chemical resistance is required.

ALTRA® 1500C: Successful application in steel and metal companies

ALTRA® 1500C opens up new possibilities for the steel and metal industry. Thanks to its carefully engineered physical properties, this high-temperature wool offers excellent energy efficiency and serves as an ideal complement to commonly used refractory products such as bricks and castables. ALTRA® 1500C is especially well suited for applications involving rapid heating and cooling cycles and is available in various densities and dimensions.

ALTRA® 1500C has already proven its value in the steel and metal industry through its successful use at several companies in Germany and Austria, where it has been applied in a variety of furnace types, including bogie hearth forging furnaces, chamber forging furnaces, rolling mill furnaces, and walking beam or rotary hearth furnaces. The lightweight yet highly durable ALTRA® 1500C modules, which are easy to handle and install, were successfully used, for example, in the delivery of the ceiling of a chamber forging furnace.

Lightweight refractory linings