MODERNIZATION OF LARGE HEAT-TREATMENT FURNACES
V. V. Kurnosov,
I. I. Shakhov,
A. A. Dorozhkin,
N. N. Kalinina,
and Yu. I. Povelitsa
Translated from Novye Ogneupory, No. 3, pp. 146 – 148, March, 2012.
Original article submitted January 19, 2012.
Pre-lined modular blocks of a fibrous refractory, panel assemblies, and modern recuperative burners were re
cently installed in the heating system of large heat-treatment furnaces undergoing upgrades at the OAO
“ZiO-Podol’sk.” These changes are making it possible to rapidly heat and cool the products being treated, re
duce the consumption of natural gas by 25 – 30%, and carry out the heating operation with a uniformity of
2 – 5°C throughout the designated temperature range.
Keywords: heat-treatment furnaces, modular blocks, refractory fiber, recuperative burners, panel assemblies.
Despite the significant slowdown in the development of
new building technologies - including the design and con-
struction of high-temperature furnaces for various industries
— projects that are making qualitative upgrades to existing
production facilities are still going forward thanks to the ac-
cumulated scientific and technical expertise of pioneers in
the construction industry. For example, in 2003 the OAA
“ZiO-Podol’sk” was faced with the problem of performing a
planned overhaul of a car-bottom heat-treatment furnace
(hearth dimensions 5.7 ´ 14.0 m, height from the floor to the
roof of the furnace 3.0 m) that was used to heat-treat metal
structures and products employed in the construction of nu
clear power plants.
In light of the high operating costs of the furnace and the
short length of time that it had been able to operate before
needing repair, it was decided to broaden the scope of the
overhaul and fully modernize the unit to make the heat treat
ment of the metal structures and products more uniform. The
plant also wanted to reduce the furnace’s consumption of
natural gas and shorten the period of time needed for its re
These objectives were met by an affiliate of the OAO
“Teploproekt” — the NPP “Teploograzhdenie” — working
with the Metal Heat Treatment Department of the MISiS
(Moscow State Institute of Steel and Alloys) and the OAO
“ZiO-Podol’sk.” These organizations proposed using modern
low-inertia fibrous materials for the lining and installing
burners with improved combustion dynamics. Inspections
which Teploograzhdenie carried out on the structural mem-
bers and lining of the furnace showed that the furnace’s
frame (the columns and the shell — the skin) were in satis-
factory condition and could continue to be used if the stan-
dard refractory-brick lining were replaced by a lightweight
lining composed of refractory fibers.
In accordance with the modernization plan that was
drawn up, the fireclay-brick lining of the furnace walls
(Fig. 1) was replaced by a lining comprised of modular
blocks of a fibrous refractory . The arched roof of the fur
nace (which was also made of fireclay brick) was replaced
by a flat roof composed of panels lined beforehand with
modular blocks of the fiber-based refractory . These
blocks and the metal structures of the roof panels were made
Refractories and Industrial Ceramics Vol. 53, No. 2, July, 2012
1083-4877/12/05302-0101 © 2012 Springer Science+Business Media, Inc.
This study was conducted within the framework of Russian-Fed
eration Government Resolution No. 218 from 09.04.2010.
Moscow State Institute of Steel and Alloys, Moscow, Russia.
”Teploograzhdenie” OOO, Aprelevka, Moscow Oblast, Russia.
”ZiO-Podol’sk” OAO, Podolsk, Moscow Oblast, Russia.
Fig. 1. Lining of the heat-treatment furnace before modernization.