Melting furnaces - Concepts


Single-chamber melting & casting furnaces

Heating system:

Cold-air gas burners are commonly used in casting furnaces. However, to achieve the lowest energy consumption (<600kWh/ton), regenerative burners with honeycomb ceramic elements have proved highly effective. Regulated flue gas flaps or flue gas fans adjust the furnace atmosphere to create a slightly positive pressure.

Accessories:

Optional extras include side wells or electromagnetic liquid metal pumps for fitting to the furnace wall. Also available are electromagnetic stirrers that ensure uniform temperature distribution and help dissolve the alloying elements. Furthermore, there are special systems for inserting gas lances into the melt.

Furnace capacity: 10 - 120 tons
Melting rate: 1 - 15 tons/hour

Single-chamber melting & casting furnaces 3D-image

Universal rotary tilting furnaces

(URTF)

Combined with integrated oxygen lances and permanent CO measurement, this furnace type ensures extra-low specific gas consumption.

If you add an integrated post-combustion system, your HE-URTF will comply with even the strictest European emission standards. Today, most URTF operate with the standard low-salt process. They achieve an optimum metal yield with a salt factor of 0.2 - 0.5. Yet there is a greener alternative - because the salt-free AluRec® process saves money and completely avoids hazardous salt slag.

Universal rotary tilting furnaces image

Chip remelting plants

Core characteristics:

  • Chips are charged continuously and heated to some 400 °C in seconds. This evaporates both hydrocarbons and moisture.
  • Dryer and melting furnace functions combined in one process to thermally reclaim organic components
  • Hot swarf goes directly into the melting process. That avoids further oxidation or moisture pick-up.
  • Electromagnetic liquid-metal pump for quick, vigorous submersion of the charged material and continuous melt bath agitation

Your benefits:

  • Melting capacity 2 to 5 tons per hour or 40 to 100 tons per day
  • Very low specific energy consumption (< 550 kWh/ton including drying) due to LOW-NOx regenerative burner systems, yet extremely low NOx emissions
  • Practically no melt loss (< 1 %) for high metal recovery
  • Low manpower for operation and maintenance
  • Good metal quality of the melt (low oxide and hydrogen content)
  • Compliance with even the strictest environmental standards
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Chip remelting plants image
Chip remelting plants image
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