An abnormally high energy consumption in a rectangular aluminum melting furnace can adversely affect production costs and energy efficiency, and may involve the following system problems:

1. Furnace body structure related

   Furnace lining aging is one of the common causes. As the service life increases, the furnace lining material will wear and crack, and its heat insulation performance will decrease significantly, causing a large amount of heat to be lost to the surrounding environment through the furnace body, resulting in increased energy consumption. In addition, unreasonable furnace body structure design, such as excessively thin furnace walls or insufficient insulation layer thickness, will also cause heat loss to be too rapid, increasing energy consumption.

2. Combustion system problems

   The decline in burner efficiency cannot be ignored. After prolonged use, burner nozzles may become clogged or worn, leading to uneven fuel-air mixing and incomplete combustion. This not only wastes fuel but also prevents the furnace temperature from reaching the set value, requiring more energy to maintain the temperature. Simultaneously, malfunctions in the air supply system, such as fan failure or blocked ducts, can affect the air supply quantity and pressure, thus impacting combustion performance and causing abnormal energy consumption.

3. Waste heat recovery and sealing issues

   A malfunction in the waste heat recovery device of a rectangular aluminum melting furnace flue can affect the secondary utilization of energy. If the device is damaged, blocked, or has reduced heat exchange efficiency, it cannot effectively recover waste heat from the flue gas, resulting in a large amount of heat being discharged with the flue gas and increasing energy waste. In addition, if the furnace door is not sealed tightly, cold air will enter the furnace during the opening and closing of the furnace door or during daily use, while heat will also be lost from the furnace. In order to maintain a stable furnace temperature, more energy needs to be consumed to compensate for the heat loss.

To address the above issues, it is recommended to conduct thermal tests. By using specialized instruments and equipment to detect and analyze various parameters of the rectangular aluminum melting furnace, the specific causes of the abnormally high energy consumption can be accurately identified. In this way, targeted measures can be taken for maintenance and improvement to reduce energy consumption and increase production efficiency.