短流程炼钢技术突破：中频炉耐火材料如何决定绿色炼钢的成本与效率Breakthrough in Short-Process Steelmaking Technology: How Refractory Materials for Induction Furnaces Determine the Cost and Efficiency of Green Steel making

根据我国的政策要求，到年底电炉钢产量占比需提升至15%（发改产业〔2025〕38号），这一目标让短流程炼钢成为行业焦点。与传统长流程相比，短流程炼钢省去焦化、烧结等高污染环节，吨钢碳排放可降低1.5吨，节能降碳效果显著。但在实际生产中，不少企业却面临中频炉炉衬寿命短、更换频繁的难题——某不锈钢企业15吨中频炉采用传统碱性捣打料每月需更换2次炉衬，改用河南中工耐公司HD-95刚玉尖晶石干式捣打料后，炉衬平均寿命提升至108次，年减少更换18次。河南宏达炉业作为我国级专精特新"小巨人"企业，为短流程炼钢提供关键材料支撑。

According to my country's policy requirements, the proportion of electric arc furnace steel production must be increased to 15% by the end of the year (NDRC Industry [2025] No. 38). This goal has made short-process steelmaking a focus of the industry. Compared with the traditional long process, short-process steelmaking eliminates high-pollution processes such as coking and sintering, reducing carbon emissions per ton of steel by 1.5 tons, resulting in significant energy conservation and carbon reduction. However, in actual production, many enterprises face the problem of short furnace lining life and frequent replacement in medium-frequency furnaces. For example, a stainless steel company's 15-ton medium-frequency furnace using traditional alkaline ramming material required lining replacement twice a month. After switching to HD-95 corundum spinel dry ramming material from Henan Zhonggong Nai Company, the average lining life increased to 108 cycles, reducing replacements by 18 times per year. Henan Hongda Furnace Industry, as a national-level specialized and innovative "little giant" enterprise, provides key material support for short-process steelmaking.

短流程炼钢的核心：中频炉与连铸连轧的协同创新

The core of short-process steelmaking: synergistic innovation between intermediate frequency furnaces and continuous casting and rolling.

短流程炼钢的革命性在于"废钢→钢水→成材"的紧凑工艺。以河钢石钢公司为例，其双竖井废钢预热直流电弧炉可将废钢温度提升至600-800℃，配合连铸连轧技术，从钢水到成材仅需传统工艺1/4时间。这种工艺不仅减少75%污染物排放，还能灵活调整产量应对市场波动——当建筑钢材需求激增时，可快速切换生产螺纹钢；汽车制造业订单增加时，又能转产高强度结构钢。

The revolutionary aspect of short-process steelmaking lies in its compact "scrap steel → molten steel → finished product" process. Taking Hebei Iron & Steel Shijiazhuang Iron & Steel Co., Ltd. as an example, its dual-shaft scrap preheating DC electric arc furnace can raise the temperature of scrap steel to 600-800℃. Combined with continuous casting and rolling technology, the process from molten steel to finished product takes only 1/4 of the time of traditional processes. This process not only reduces pollutant emissions by 75%, but also allows for flexible adjustments to production to cope with market fluctuations—when the demand for construction steel surges, it can quickly switch to producing rebar; when orders from the automotive manufacturing industry increase, it can switch to producing high-strength structural steel.

连铸连轧技术进一步放大了短流程优势。德国西马克CMT®工艺将连铸机与轧机直接连接，省去传统加热炉环节，吨钢转化成本降低20欧元。我国沙钢集团采用的ESP无头带钢技术，更是将800米生产线压缩至1/16，生产0.7mm超薄带钢的能耗仅为传统工艺的1/6。但这一切生产的前提，是中频炉能稳定提供高质量钢水，而炉衬耐火材料正是其中的"咽喉"部件。

Continuous casting and rolling technology further amplifies the advantages of short-process production. SMS CMT® technology in Germany directly connects the continuous casting machine and the rolling mill, eliminating the traditional heating furnace step and reducing the conversion cost per ton of steel by €20. my country's Shagang Group's ESP headless strip steel technology further reduces the 800-meter production line to 1/16th of its original length, and the energy consumption for producing 0.7mm ultra-thin strip steel is only 1/6 of that of traditional processes. However, all of this production relies on the induction furnace's ability to stably supply high-quality molten steel, and the furnace lining refractory material is the crucial component in this process.

中频炉耐火材料的技术密码：从材料选择到性能突破

The Technological Secrets of Refractory Materials for Medium Frequency Furnaces: From Material Selection to Performance Breakthroughs

中频炉炉衬处于极端服役环境：内侧是1600℃钢水的剧烈冲刷和电磁搅拌，外侧是水冷线圈造成的巨大温差。洛阳某有限公司的技术资料显示，59%的炉衬损坏源于炉渣侵蚀，32%来自热震开裂。这要求耐火材料必须同时具备四大核心性能：耐火度≥1700℃（GB/T 7322-2025）、荷重软化点＞1650℃（GB/T 5989-2025）、热震稳定性≥20次（1100℃水冷循环，GB/T 30873-2025）、常温耐压强度＞50MPa（GB/T 5072-2025）。

The lining of an intermediate frequency furnace operates under extreme conditions: the inner side is subjected to intense scouring and electromagnetic stirring by molten steel at 1600℃, while the outer side is affected by the significant temperature difference caused by water-cooled coils. Technical data from  one of Luo yang  Furnace Materials Co., Ltd. shows that 59% of lining damage originates from slag erosion, and 32% from thermal shock cracking. This necessitates that refractory materials simultaneously possess four core properties: refractoriness ≥1700℃ (GB/T 7322-2025), softening point under load >1650℃ (GB/T 5989-2025), thermal shock stability ≥20 cycles (1100℃ water-cooled cycle, GB/T 30873-2025), and room temperature compressive strength >50MPa (GB/T 5072-2025).

酸性炉衬以石英砂为主要原料，成本仅800元/吨，适合小型铸铁炉，但在1500℃以上会出现二次相变导致体积膨胀，使用寿命通常不超过50炉次。碱性炉衬采用氧化镁（MgO）材料，耐火度接近2800℃，抗碱性炉渣能力突出，但膨胀系数大易开裂。而中工耐研发的HD-95刚玉尖晶石中性炉衬，通过电熔白刚玉（Al₂O₃≥95%）与镁铝尖晶石（MgO·Al₂O₃）复合，既解决酸性炉衬寿命短问题，又克服碱性材料脆性缺陷，在不锈钢304#熔炼中表现尤为出色。

Acidic furnace linings, primarily made of quartz sand, cost only 800 yuan/ton and are suitable for small cast iron furnaces. However, they undergo secondary phase transformations above 1500℃, leading to volume expansion, and their service life typically does not exceed 50 heats. Basic furnace linings, using magnesium oxide (MgO), have a refractoriness close to 2800℃ and excellent resistance to alkaline slag, but their large expansion coefficient makes them prone to cracking. In contrast, Sino Furnace Industry's HD-95 corundum spinel neutral furnace lining, a composite of fused white corundum (Al₂O₃≥95%) and magnesium aluminum spinel (MgO·Al₂O₃), solves the problem of short service life in acidic linings while overcoming the brittleness of basic materials, exhibiting particularly outstanding performance in the smelting of 304# stainless steel.

中工耐的技术突围：从实验室到产业化的创新实践

Sino's Technological Breakthrough: Innovative Practices from Laboratory to Industrialization

走进中工耐位于郑州的研发中心，扫描电镜下的HD-95刚玉尖晶石显微结构清晰可见——白色刚玉颗粒被灰色尖晶石相紧密包裹，形成三维网格结构。这种微观结构使材料在高温下仍保持2.8g/cm³的高密度，抗折强度达8MPa（1450℃，GB/T 3002-2025）。公司技术总监王工介绍："我们通过添加3%尖晶石微粉，使材料热膨胀系数从8×10⁻⁶/℃降至5.5×10⁻⁶/℃，可以解决热震开裂难题。"

Stepping into the R&D center of SIR in Zhengzhou, the microstructure of HD-95 corundum spinel is clearly visible under a scanning electron microscope—white corundum particles are tightly wrapped by gray spinel phases, forming a three-dimensional network structure. This microstructure allows the material to maintain a high density of 2.8 g/cm³ even at high temperatures, with a flexural strength of 8 MPa (1450℃, GB/T 3002-2025). Wang, the company's technical director, explained, "By adding 3% spinel powder, we reduced the material's coefficient of thermal expansion from 8×10⁻⁶/℃ to 5.5×10⁻⁶/℃, thus solving the problem of thermal shock cracking."

这种技术突破源于持续研发投入。作为专注耐火材料的企业，中工耐每年将营收的7%用于研发，与郑州大学材料学院共建"特种耐火材料联合实验室"，累计获得9项发明技术。其主导产品氧化球团回转窑用耐火材料国内市场占有率超53%，参与制定《中频感应炉用干式捣打料》（YB/T 4878-2025）行业标准。在某大型不锈钢企业的对比试验中，宏达HD-95刚玉尖晶石捣打料炉衬平均侵蚀速率仅0.6mm/炉，比某进口品牌（1.0mm/炉）降低40%。

This technological breakthrough stems from continuous investment in research and development. As a company specializing in refractory materials, SIR  Refractory allocates 7% of its annual revenue to R&D, and has jointly established a "Special Refractory Materials Joint Laboratory" with the School of Materials Science and Engineering at Zhengzhou University, accumulating nine invention patents. Its leading product, refractory materials for rotary kilns used in oxidized pelletizing, holds over 53% of the domestic market share, and it participated in the formulation of the industry standard "Dry Ramming Material for Medium Frequency Induction Furnaces" (YB/T 4878-2025). In a comparative test conducted by a large stainless steel company, the average erosion rate of Hongda HD-95 corundum spinel ramming material furnace lining was only 0.6 mm/furnace, 40% lower than that of an imported brand (1.0 mm/furnace).

全产业链解决方案：从产品到服务的价值延伸

Full industry chain solutions: extending value from products to services

中工耐提供的不止是耐火材料，而是覆盖"炉衬设计-材料供应-施工指导-寿命管理"的全周期服务。针对某镍基合金企业的特殊需求，技术团队现场分析炉渣成分（CaO/SiO₂=1.2），定制出含Cr₂O₃的碱性捣打料，使炉衬寿命从65炉次提升至92炉次。公司还开发智能炉衬监测系统，通过预埋传感器实时监测厚度变化，提前预警更换周期，避免突发性漏炉事故。

SIR Refractory provides more than just refractory materials; it offers a full-cycle service covering "furnace lining design, material supply, construction guidance, and lifespan management." For a nickel-based alloy company with specific needs, the technical team analyzed the slag composition on-site (CaO/SiO₂=1.2) and customized an alkaline ramming mix containing Cr₂O₃, increasing the furnace lining life from 65 heats to 92 heats. The company has also developed an intelligent furnace lining monitoring system that uses pre-embedded sensors to monitor thickness changes in real time, providing early warnings of replacement cycles and preventing sudden furnace leakage accidents.

这种"材料+服务"模式为客户创造显著价值：某汽车零部件企业采用宏达解决方案后，中频炉有效作业率从72%提升至91%，年减少停机损失120万元。产品不仅供应国内宝武、河钢等巨头，还出口至东南亚、欧洲等地区，在越南某钢铁厂的100吨中频炉上，宏达耐火材料已稳定运行8个月，性能媲美欧洲同类产品，价格却低30%。

This "materials + service" model creates significant value for customers: After adopting Hongda's solutions, a certain auto parts company increased the effective operating rate of its intermediate frequency furnace from 72% to 91%, reducing annual downtime losses by 1.2 million yuan. The products are not only supplied to domestic giants such as Baowu and Hebei Iron & Steel, but also exported to Southeast Asia and Europe. In a steel plant in Vietnam, Hongda refractory materials have been operating stably for eight months in a 100-ton intermediate frequency furnace, demonstrating performance comparable to similar European products, but at a price 30% lower.

绿色炼钢的未来：耐火材料技术创新展望

The Future of Green Steelmaking: Prospects for Technological Innovation in Refractory Materials

随着短流程炼钢向"近零碳"目标迈进，耐火材料正朝着更高纯度、更低导热、更长寿命方向发展。中工耐正在研发的纳米复合刚玉材料，通过引入5%ZrO₂纳米颗粒，使材料高温强度再提升25%。同时开发的可循环利用炉衬技术，将用后耐火材料破碎筛分后重新制砖，实现90%资源回收，助力钢铁行业真正实现"绿色制造"。

As short-process steelmaking moves towards the goal of "near-zero carbon," refractory materials are developing towards higher purity, lower thermal conductivity, and longer service life. SIR Furnace Industry is developing a nano-composite corundum material, which, by introducing 5% ZrO₂ nanoparticles, further increases the material's high-temperature strength by 25%. Simultaneously, they are developing a recyclable furnace lining technology that allows used refractory materials to be crushed, screened, and remade into bricks, achieving 90% resource recovery and helping the steel industry truly achieve "green manufacturing."

我国《钢铁行业节能降碳专项行动计划》明确提出，到2025年废钢利用量要达到3亿吨。这意味着更多中频炉将投入运行，而优质耐火材料正是释放短流程潜力的关键。中工耐以25年技术积累，正从"材料供应商"向"低碳冶炼解决方案服务商"转型，其案例印证了一个真理：在钢铁工业绿色转型的赛道上，谁掌握了耐火材料核心技术，谁就能在成本控制和效率提升中占据先机。my country's "Special Action Plan for Energy Conservation and Carbon Reduction in the Steel Industry" clearly states that the utilization of scrap steel should reach 300 million tons by 2025. This means that more induction furnaces will be put into operation, and high-quality refractory materials are the key to unleashing the potential of the short-process smelting method. SIR Furnace Industry, with 25 years of technological accumulation, is transforming from a "material supplier" to a "low-carbon smelting solution provider." Its case proves a truth: in the race for green transformation of the steel industry, whoever masters the core technology of refractory materials will gain an advantage in cost control and efficiency improvement.