Objective
To demonstrate that an economic energy saving of about 128 TOE/y can be achieved in a 1 t/h light alloy quick melting furnace by adding an adjacent holding cell.
Description : An holding cell is added to the existing melting cell to compensate heat losses of the discontinuous melting batches.
Moreover heat recovery from exhaust gases to pre-heat sequent batches. Air-fumes recuperators are utilized.
Innovative aspects : New desing of furnace and heat circuits.
- Practical speed of melting : 1,230 kg/hL% - Consumption per Ton of metal : 690.90 kWh/t (PCI)L% (includes melting and maintenance as well as the energy needed for reheating the molten metal)L% - Energy efficiency : 55
% Energy consumption has dropped by 53%, compared to the crucible furnaces the customer had been using prior to installation of the Quick Melt Unit. Maintenance cost have been cut by 80%, and the furnace running costs by 33%. Metal wastage is estimated to be under 1%.
Furnace consists in a double-cell or double-chamber construction the main function of which is energy saving by integrating rapid melting, molten batch hoding and combustion products heat recovery.
Further advantages are high quality aluminium avoiding occlusions and with less oxidising effects. Melting rated capacity of the unit is 1,350 kg Aluminium per hour. Melting cell will be fitted with high intensity two operating levels (high-low output) 900 kW burners. A tilt bottom causes the molten metal flow into the holding storage chamber with 4,000 kg capacity. One radiation burner with total output of 700 kW keeps the molten batch conditions.
Owing to fume path and insulation features. achievable specific consumption will be 600 to 700 kWh/t whereas in updated but conventional units raise 1,000 kWh/t. Present average value in Spain, under real operating conditions, keeps near 2,000 kWh/t.
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Coordinator
08002 Barcelona
Spain
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.