Heating Furnace Regenerative Balls: High-Efficiency Energy-Saving Solutions

Heating Furnace Regenerative Ball Retrofit 

4.1 Project Overview
- Client: A large domestic steel enterprise with an annual steel output of over 5 million tons.

- Furnace Type: 150t walking-beam reheating furnace (original regenerator used honeycomb ceramics).

- Problems Faced: Low heat exchange efficiency, frequent honeycomb ceramic blockage and cracking, high fuel consumption, and frequent maintenance—resulting in high operating costs and production downtime.

- Solution Provided by us: Customized high-performance corundum-mullite regenerative balls (Φ20-Φ30mm, Al₂O₃ > 90%), plus full engineering services including design, installation, and commissioning.

2 Technical Parameters Comparison

Project Results & Economic Benefits

After retrofitting withours regenerative balls, the steel plant achieved remarkable energy-saving and efficiency gains, with measurable economic benefits:
1. Energy Savings: Furnace fuel consumption decreased by 12-15%, saving approximately 8,500 tons of standard coal annually—directly reducing fuel costs by millions of yuan.

2. Efficiency Boost: Air preheating temperature increased from 850°C to 1050°C, raising the furnace’s thermal efficiency to 92% and improving production efficiency.

3. Maintenance Reduction: Annual maintenance frequency was cut by 70%, downtime reduced by 30 days, and labor costs lowered by 60%.

4. Emission Reduction: Flue gas outlet temperature dropped from 350°C to 130°C, reducing CO₂ emissions by ~22,000 tons/year—helping the enterprise meet environmental standards.

.Quality Improvement: More uniform furnace temperature reduced steel billet oxidation loss by 0.8%, enhancing product yield and quality.

Total Annual Economic Benefit: Over ¥12 million, with the investment payback period of less than 8 months—proving thatours regenerative ball solutions are a high-return investment for industrial enterprises.

Heating Furnace Regenerative Balls Selection Guide (SEO Focus: Practical Guide)
Choosing the right heating furnace regenerative balls is critical to achieving optimal energy savings and efficiency. Below is a professional selection guide from our Furnace Industry, based on decades of industry experience:

1 Material Selection Based on Furnace Temperature

- 1200-1350°C: High-alumina mullite (Al₂O₃ 70-85%)—cost-effective for medium-temperature heating furnaces (e.g., non-ferrous metal smelting furnaces).

- 1350-1500°C: Corundum-mullite (Al₂O₃ > 90%)—ideal for high-temperature steel reheating furnaces, as used inours steel plant case.

- >1500°C: High-purity alumina (Al₂O₃ > 95%)—for ultra-high-temperature special furnaces (e.g., ceramic sintering furnaces).

2 Size Selection

- Small balls (Φ15-Φ25mm): Larger surface area, higher heat exchange efficiency but higher pressure drop—suitable for small/medium-sized heating furnaces.

- Medium balls (Φ25-Φ40mm): Balanced efficiency and pressure drop—most widely used in large heating furnaces (e.g., 150t walking-beam furnaces).

- Large balls (Φ40-Φ60mm): Lower pressure drop, slightly lower efficiency—for furnaces with strict airflow resistance requirements.

3 Key Quality Indicators to Consider

When selecting heating furnace regenerative balls, focus on these core quality indicators (our’s standards as a benchmark):

- Bulk density > 3.0 g/cm³ (ensures high heat capacity).

- Apparent porosity < 20% (reduces thermal conductivity loss).

- Cold crushing strength > 80 MPa (high mechanical strength, resistance to wear).

- Reheating linear change rate < 0.5% (excellent dimensional stability, no deformation at high temperatures).

Conclusion (SEO Focus: Call to Action + Keyword Summary)

Heating furnace regenerative balls are essential components for industrial furnace energy saving and emission reduction, offering high efficiency, stability, and economic benefits. As the industrial sector moves toward green and low-carbon development, upgrading to high-quality regenerative balls has become a necessary measure for enterprises to reduce costs and improve competitiveness.

our Furnace Industry’s successful steel plant retrofit case proves that customized, high-performance regenerative balls can deliver significant energy savings and economic returns. With professional R&D, precision manufacturing, and full lifecycle services, our is a trusted partner for enterprises seeking heating furnace regenerative ball solutions.

If you’re looking to upgrade your heating furnace’s regenerative system, reduce fuel costs, and improve efficiency, contact us today for a customized solution tailored to your needs.