Project Overview
White corundum, fused alumina and mullite are the core abrasives and refractories used in grinding media, refractory bricks and high-temperature linings. Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. supplied the white corundum arc furnace system for an 800,000-ton-per-year project in Shandong province.
Equipment Specification
| Item | Specification |
|---|---|
| Model | BGYL-2000kVA white corundum arc furnace system |
| Application | White corundum, fused corundum, mullite and refractory materials |
| Furnace form | Fixed furnace with water-cooled roof and skirt |
| Charging | Top charging |
| Cooling | External spray water cooling on the shell wall |
Construction Sequence
- Equipment arrival and inspection - shell, roof, electrode lifting system and electrical components received and checked against packing lists
- Electrode lifting system installation - masts, hydraulic cylinders and conductive arms aligned to design tolerance
- Water-cooled roof installation - roof segments assembled, sealed and pressure tested
- Shell and skirt assembly - shell wall erected, external spray cooling ring installed and flow tested
- Electrical and control - transformer connection, short network, instrument and interlock commissioning
- Smelting trial - first heats run to verify melt-down rate, bath temperature and product quality
Process Advantages
The fixed-furnace configuration with water-cooled roof and external spray cooling gives the plant a low-cost, low-maintenance furnace that is well suited to continuous corundum campaigns. Top charging keeps the charge centred and reduces shell hot spots, while the spray-cooled wall maintains a protective slag skull that extends campaign life. Because corundum smelting is energy intensive, the electrical design targets a high power factor and balanced three-phase operation to reduce specific energy consumption per tonne.
Project Result
The furnace line is now operating in the customer's 800,000-ton white corundum plant. Chengda provided full installation drawings, commissioning procedures and operator training, and continues to support the customer with spare parts and technical service.
Support After Start-up
Chengda provided commissioning engineers, operating procedures, water pressure test records and a spare parts list, and continues to support the plant with replacement components and process advice as the furnace moves through successive campaigns.
Energy and Consumable Efficiency
Corundum smelting is dominated by electricity cost, so the furnace design focuses on high power factor, short power-on time per heat and minimal heat loss through the water-cooled roof. Electrode consumption is controlled by stable impedance regulation, and the spray-cooled shell keeps a protective lining skull that reduces refractory wear.
Since start-up the plant has used the furnace across multiple corundum grades, adjusting charge composition and power profile without hardware changes.