Project Name: Energy-saving Renovation Project with Ceramic Fiber Board Lining for Heat Treatment Furnace at Ukrainian Steel Group
Location: Dnipropetrovsk Oblast, Ukraine
Construction Period: 2024
Products Used: SUNTHERM Ceramic Fiber Boards (High-Alumina Type, Standard Type)
Quantity Used: Approximately 860 cubic meters
Application Areas: Furnace door, observation ports, hot air duct lining, and expansion joint insulation sealing of the heat treatment furnace.

✅ Project Background
The steel group is a major supplier of special steel in Eastern Europe. Its roller hearth heat treatment furnace operates long-term in a high-temperature environment of 1200°C. The original refractory materials had the following issues:
1. Significant heat loss: High surface temperature of the furnace body, leading to severe energy waste.
2. Poor resistance to airflow erosion: Lining materials in the furnace door and ducts were prone to wear, requiring frequent maintenance.
3. Inadequate sealing: Heat leakage in observation ports and expansion joints affected temperature uniformity and production safety.
The client aimed to achieve the following through the renovation:
4. Reduce the surface temperature of the furnace and decrease gas consumption.
5. Enhance the erosion resistance and sealing of materials to extend service life.
6. Reduce maintenance frequency and lower production costs.

✨ SUNTHERM Solution
1. Targeted Material Selection Design:

• Furnace door area: High-alumina ceramic fiber boards (density 220 kg/m³, temperature resistance 1260°C) were used, offering excellent thermal shock resistance and mechanical strength.
• Observation ports and duct lining: Standard ceramic fiber boards (density 130 kg/m³, temperature resistance 1000°C) were employed, balancing insulation and observation needs.
• Expansion joint sealing: A composite structure of custom-shaped fiber boards and ceramic fiber blankets ensured high-temperature sealing.

2. Special Installation Techniques:

• Mortise-and-tenon splicing combined with high-temperature adhesive enabled seamless installation, preventing thermal bridging.
• Stainless steel wire mesh was added to the hot face to enhance erosion resistance (referencing flue construction methods).
• Key areas adopted double-layer staggered paving to further improve sealing and stability.

3. Rapid Construction Solution:

• All boards were pre-processed, allowing for "Lego-style" modular assembly on-site, reducing field cutting by 75%.
• Special suction cup tools assisted installation, improving efficiency and preventing board damage.

✅ Project Results

1. Significant Energy Savings:
Annual natural gas savings of 180,000 m³, reducing carbon emissions by approximately 380 tons, and lowering energy costs by 15%.
2. Improved Production Efficiency:
Furnace temperature uniformity increased by 12%, product heating quality stabilized, and the defect rate decreased by 5%.
3. Enhanced Safety and Reliability:

• The working environment temperature dropped to within European safety standards (≤40°C ambient temperature).
• After 12 months of continuous operation, inspection showed no board detachment or structural damage.

★ Project Summary
This case demonstrates the applicability of SUNTHERM ceramic fiber boards in the harsh industrial environments of Eastern Europe. Through customized material design (e.g., high-alumina formulation for erosion resistance), innovative installation techniques (e.g., mortise-and-tenon sealing with wire mesh protection), and rapid construction solutions, the project successfully addressed the client's pain points regarding energy consumption, maintenance, and safety. The Ukrainian client highly appreciated this solution and plans to promote its use in other heat treatment production lines within the group.