Client Challenge

• Structural Instability: Alumina-silicate beams showed creep deformation after 500 hours of operation, leading to furnace misalignment and product defects.
• Thermal Conductivity Issues: Poor heat resistance of conventional materials required excessive energy input, increasing operational costs by 20%.
• Short Lifespan: Frequent replacements (every 6–8 months) disrupted production schedules and raised maintenance costs.

• Inability to maintain structural integrity in extreme thermal cycles.
• High energy consumption due to inefficient heat management.
• High lifecycle costs from material degradation.

Kegu Solution

Technical Innovations

1. Custom Design for Furnace Architecture
   • Dimensions: 100mm × 100mm × 2000mm, optimized for load-bearing in large-scale furnaces.
   • Surface Treatment: Micro-textured finish to enhance bonding with refractory coatings.
2. Superior Thermal-Mechanical Performance
   • Service Temperature: Stable up to 1650°C (200°C higher than traditional refractory beams).
   • Bending Strength: 580 MPa (30% higher than alumina-silicate), tested via 4-point bend testing.
   • Thermal Conductivity: 120 W/m·K, enabling uniform heat distribution and reducing energy consumption by 15%.
3. Advanced Manufacturing Traceability
   • Raw Materials: 99.6% pure SiC powder (ISO 9001-certified supply chain).
   • Production Process: 2150°C vacuum sintering for 15 hours, with real-time monitoring of oxygen content (<100 ppm).
   • Quality Assurance:
     • Internal: Non-destructive testing (ultrasonic flaw detection).
     • External: Certified by TÜV Rheinland for compliance with EN 993-1 (refractory materials standards).

Logistical & Service Support

• Modular Packaging: Custom crating to prevent damage during cross-border shipping (10,000 km transit tested).
• Technical Collaboration: Joint simulation using ANSYS to optimize beam placement in client’s furnace designs.
• Warranty: 24-month performance guarantee, with free replacement with structural failure within scope.

Outcome

1. Operational Reliability
   • Service Life Extended to 3+ Years: 4–6x longer than previous materials, reducing replacement frequency.
   • Energy Savings: 15% reduction in power consumption, aligning with EU’s Green Deal objectives.
2. Cost Efficiency
   • Lifecycle Cost Reduction: Total cost of ownership (TCO) decreased by 45% due to fewer replacements and lower energy use.
   • Production Uptime: 99.5% operational stability, eliminating unplanned shutdowns for beam maintenance.
3. Market Differentiation
   • The client’s furnaces featuring Kegu SiC beams gained CE Certification for high-temperature performance.
   • Order inquiries from automotive heat treatment clients increased by 250% within 18 months.

Key Data Comparison