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ApplicationSanhe has accumulated hundreds of successful engineering cases across industries such as cement, electrolytic aluminum, new energy EV, energy storage ESS, and other high-temperature industrial sectors.
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Aluminum Electrolysis Cell
In modern electrolytic aluminum production, the thermal balance and structural stability of the pot are directly related to energy consumption and pot life. As a high-performance inorganic refractory material, Sanhe vermiculite board has become a key functional layer in the cathode structure of electrolytic aluminum pots due to its high-temperature resistance, low thermal conductivity, and excellent resistance to fluoride corrosion.
I. Core Application Scenarios of Vermiculite Boards in Electrolytic Aluminum Pots
1. Bottom Thermal Insulation and Anti-Penetration
Vermiculite boards are laid under the cathode carbon blocks, forming an efficient thermal insulation barrier. They effectively prevent heat from conducting downwards to the pot shell, while simultaneously inhibiting the penetration of cryolite-alumina molten salt and fluorides into the bottom concrete. This stabilizes the furnace bottom pressure drop and protects the pot foundation.
2. Side Wall Thermal Insulation
Whether attached to the inner or outer side of the pot wall, vermiculite boards significantly reduce the surface temperature of the pot shell, minimize lateral heat loss, and optimize the transverse thermal field distribution of the electrolytic cell.
3. Joint Sealing and Buffering
Filling vermiculite boards at pot body joints, openings, and around cathode steel bars provides an excellent seal, preventing air ingress and electrolyte leakage. The material's inherent micro-elasticity effectively absorbs thermal stress during the drastic temperature fluctuations of pot start-up and shutdown, preventing cracking in the insulation layer.
II. Key Performance Parameters (Technical Specifications)
High-Temperature Resistance: Melting point up to 1370-1400°C, with a maximum long-term service temperature reaching 1200℃, fully adaptable to the harsh 950-970℃ operating conditions of electrolytic aluminum pots.
Insulation Efficiency: Thermal conductivity as low as 0.04 – 0.13 W/(m·K) (typically between 0.04-0.06 W/(m·K) under standard conditions), offering insulation performance far superior to traditional refractory materials.
Corrosion Resistance & Anti-Penetration: Exhibits excellent resistance to molten fluoride salts and cryolite, effectively blocking electrolyte penetration and protecting the underlying structure of the insulation layer.
Mechanical Properties: Compressive strength ranges from approximately 0.3–10 MPa, with density controlled between 500–1200 kg/m³. This ensures a certain load-bearing capacity while maintaining lightweight insulation characteristics.
Safety & Environmental Protection: Class A non-combustible material, non-toxic and harmless, complying with high-temperature industrial safety standards.
III. Project Application Outcomes (Data Cases)
Practice demonstrates that using vermiculite boards yields significant economic benefits for enterprises:
Energy Saving & Consumption Reduction: In a specific 500 kA series electrolytic cell, after applying an 80 mm thick vermiculite insulation layer, the pot voltage was reduced by approximately 30 mV translating to a decrease in DC power consumption per ton of aluminum of about 100 kWh.
Extended Service Life: Using vermiculite anti-penetration boards under the cathode carbon blocks effectively inhibits expansion caused by sodium ion and electrolyte penetration. This keeps the furnace bottom pressure drop stable and significantly extends the pot maintenance cycle.
IV. Key Points for Selection and Construction Technology
To ensure vermiculite boards perform optimally, the following points require attention during design and construction:
1. Scientific Material Selection: Recommended thickness for the pot bottom and side walls is 50–100 mm. Recommended density range is 600–1000 kg/m³ to achieve optimal insulation while ensuring strength.
2. Composite Structure Design: A composite structure is typically adopted, consisting of an inner "refractory layer (resisting wash)" + middle "vermiculite board layer (thermal insulation)" + outer "sealing plate/steel plate". Each layer has a specific function, working synergistically.
3. Precise Installation: Laying must be done with staggered joints, filling gaps with specialized high-temperature resistant sealant or refractory mortar. Reinforce sealing at corners and openings to strictly prevent "thermal bridge" effects.
4. Hot Anchoring: In high-temperature areas exceeding 600°C, high-temperature resistant alloy anchors should be used for fixation to prevent material displacement during long-term operation.
5. Quality Control: Conduct spot checks on density, compressive strength, and thermal conductivity before material acceptance. Strictly inspect flatness and joint density during construction to ensure project quality.
Strong corrosive environment, material aging damage, poor thermal insulation, short service life.
Corrosion-resistant Vermiculite board.
Stable insulation performance, anti-corrosion and long service life for cell side and bottom lining.
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Contact Information
Luoyang Sanhe New Material Technology Co., Ltd.
Address: No.26 Anshangwei Road, Shangcheng Strt., Yanshi District, Luoyang, Henan, China
Main Products: SH400 nano insulation board, corrosion-resistant vermiculite insulation board, battery insulation pads
Phone: +86-15138766787
Email: irenewang@lyshxcl.com
Nantong Zhongbao Energy Saving Technology Co., Ltd.
Address: High-tech Zone, Hai'an City, Jiangsu Province
Main Products: SH950 and SH1150 nano insulation boards
Yanshi Subsidiary
Address: Goushi Town, Yanshi District, Luoyang City
Main Products: SH550 nano insulation board
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Empowering global high-temperature industries with energy-efficient thermal insulation solutions
HUATAO GROUP
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No.26 Anshangwei Road, Shangcheng Strt., Yanshi District, Luoyang, Henan, China
Email: irenewang@lyshxcl.com
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