Refractory Design for Optimizing Your Forge Furnace Operations
In the 2021 Forging Business Outlook survey, 35.9% of Executives and decision-makers in the industry reported that they invested in furnaces and/or heating systems in 2020. This was the largest category of capital asset investment across the board.
To ensure you’re investing wisely, this 3-part series breaks down the important features of an optimal forge furnace design. To ensure you’re investing wisely, this 3-part series breaks down the important features of an optimal forge furnace design:
How your forging operations go into considering the forge structure and style (Chapter 1)
Determining your refractory lining design specifications (Chapter 2: this article)
Considerations for Optimizing Your Combustion Design (Chapter 3)
Chapter 2: Determining Your Refractory Design Specifications
If your furnace is the bottleneck of your forging operations, it may be time to consider investing in a new forge furnace or retrofitting an old one to maximize throughput on your production line.
In both cases, the design of your refractory lining is not to be overlooked.
Refractory Design for Optimizing Your Forge Operations
It is the ability of the refractory lining to withstand the harsh operating environment that determines the overall life of a furnace. The high temperatures inside the furnace and the variation in temperature when it opens and closes can damage the refractory lining. Depending on the furnace's purpose, chemical exposure to slag, as well as mechanical abrasion, can also cause damage. In reality, it's nearly impossible to find a single refractory composition that can handle all of these variables at a reasonable price. Refractory linings can be replaced, but you want to postpone this expense for as long as possible.
Refractory Fiber Combination Module
Thermal shock can cause a high-strength refractory with abrasion resistance to crack under extreme temperature fluctuations. In spite of thermal shock, refractory materials can still corrode when exposed to chemicals. To ensure the longest life of the refractory, it is often necessary to balance the properties of different zones. Refractory used near the door where temperatures fluctuate drastically will be different from that used on the roof and sidewalls. There is a lot of work involved in finding the right combination for the right price.
Ramp up Your Forge Throughput with our Technical Refractory Expertise
Ranging from the combustion system to the car that carries the steel, there are hundreds of considerations if you want a system that increases profitability. Not only that, but the system should be designed and built to last for decades, with minimal maintenance, allowing you to support the demands of a growing customer base.
A new furnace (or even a retrofit) is a huge capital expense. Choose a supplier that understands your business, has the technical expertise required to support your equipment and production needs, and can ensure maximum return on your investment.
Looking to Reignite Your Forge Operations in 2023?
Call us at (814) 838-9638 for budgetary numbers to help with planning for the year ahead.