When the furnace structure and building materials are optimized to improve or design the furnace, the appropriate energy-saving furnace type should be selected according to the production process requirements, so as to improve the mechanization degree and energy utilization rate. At present, the energy-saving door and window measures are to use circular furnace instead of square furnace. The circular furnace has no dead corner like the square furnace, so the materials can be evenly radiated by the furnace wall and furnace gas. Because the outer surface area of the same volume of round furnace is smaller than that of square furnace, the heat dissipation of furnace wall is reduced, which has certain energy saving effect.
Permanent magnet stirring can not only reduce energy consumption by 20% ~ 30%, but also reduce metal burning loss by 3% ~ 5%. Although the permanent magnet stirring technology has been studied for a long time, it is still in practical application in recent years. Although some domestic manufacturers have also adopted the permanent magnet stirring technology, they all adopt the side mounted type. However, its defects such as large floor area and large investment limit the popularization and application of the side mounted permanent magnet stirring device. High temperature air combustion technology. High temperature air combustion technology is a combustion technology developed in 47hot working technology 2013, Vol.42, no.590s. High temperature air combustion technology can make air preheating temperature reach 95% of flue gas temperature, furnace temperature uniformity ≤ 5 ℃ and combustion thermal efficiency can reach 80% through regenerative flue gas recovery device. This technology has the advantages of high efficiency and energy saving, environmental protection, good combustion stability, large combustion area, wide fuel adaptability, easy combustion control, low equipment investment and long furnace life.
However, there are still some problems in the high temperature air combustion technology, such as the quantitative relationship between the thermal parameters and the design structure, the optimization of the control system and the regulating system, the relationship between the gas quality and the regenerator, the improvement of the life of the regenerator and the regenerative heating furnace, etc., which need to be further explored and improved. Oxygen enriched combustion technology. Oxygen enriched combustion technology can reduce the heat loss of flue gas, increase the flame temperature, prolong the life of furnace, increase the output of furnace, reduce the size of equipment, clean production, and facilitate the comprehensive utilization and storage of CO2 and SO2. However, the increase of oxygen content in oxygen enriched combustion leads to the sharp rise of temperature and the increase of NOx, which is one of the factors that restrict the oxygen enriched combustion technology from entering into more fields.
Regenerative regenerative burner energy-saving technology combines combustion system and waste heat recovery system organically, preheat combustion supporting air temperature to 80% - 90% of flue gas temperature, so that the final exhaust flue gas temperature is reduced to 150-250 ℃, and the waste heat recovery utilization rate is about 70%. It significantly reduces the fuel consumption of aluminum melting furnace, and the average energy saving is 16.3 kg standard coal / T aluminum material. Ma Jianguo  obtained good heat storage performance and remarkable energy saving effect by using SiO2, Al2O3, SiC and heat-resistant cast iron composite prepared in regenerative aluminum melting furnace. At present, most of flue gas waste heat recovery is aimed at high-temperature flue gas. Due to technical and economic reasons, the waste heat utilization of medium and low-temperature flue gas, which also accounts for half of the total flue gas waste heat, is rarely used. Therefore, the research and application of waste heat recovery and utilization of medium and low temperature flue gas should be paid great attention to.
The results show that the length of conductive water-cooled cables should be appropriately shortened, the number of water-cooled cables should be increased, and the cross-sectional area of conductive cables should be reasonably increased to ensure a certain thickness of furnace lining, so as to reduce the distance between the inner wall of induction coil and the furnace wall under the premise of withstanding the erosion and erosion of molten aluminum. The above measures can significantly reduce the energy consumption of medium frequency induction heating aluminum melting furnace, which is an effective way to save energy and reduce consumption. New technology new process permanent magnet stirring energy saving technology. Permanent magnet stirring refers to the non-contact stirring of aluminum melt through the magnetic field generated by permanent magnet. It has the advantages of no pollution of aluminum melt, good mixing uniformity, no stirring dead angle, continuous operation and high production efficiency.