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Contenu archivé le 2022-12-27

ENERGY SAVING INNOVATION IN AN EXISTING ALUMINIUM SCRAP MELTING SYSTEM

Objectif

To demonstrate that an existing scrap aluminium melting system can be improved to use less energy, generate less pollution and as a result achieve a better yield.

The project comprises three features:
1. a recycling of exhaust fumes to preheat the aluminium scrap in order to save energy and increase the throughput.
2. a molten metal recirculation system to save energy and do away with the need to use molten salt to prevent oxidation
3. a continuous homogenising system saving energy and improving the metallurgical properties of the aluminium.

1. The preheating of scrap aluminium using the otherwise wasted exhaust fumes takes place in separate preheating furnaces.
Each furnace consists of two compartments, one to preheat dirty, painted and oiled scrap and one to preheat clean scrap. Gases from the preheating steps are then burned to eliminate pollution in an after-burner and can be recycled again.
The preheating furnace body is made out of steel plates, reinforced with profiles and lined with refractory material, with in- and outlets for the hot gases. These are built so that the flow staysturbulent at all times in order to increase the heat transfer to the charge. The whole system is to be controlled by an extended pressure control system.
2. The system will use molten metal to heat the scrap by contact rather than heat conductivity and convection. The molten metal will be recirculated by a pump and requires a low temperature than otherwise. The absence of molten salt also diminishes the dross and therefore increases the yield.
This metal recirculating system consists of a well which is built on to existing melting furnace, in contact with both the heating chamber and the melting chamber by means of ducts in the wall. It is fitted with a commercially available pump.
3. To obtain an homogenous metal matrix the aluminium has to be kept at a temperature just below the melting point for a certain time. Unlike in existing systems where billets are charged batchwise in the furnace with heat-wasting support pieces and heatwasting openings of the furnace, in this system billets are charged separately depending on shape and homogenising requirements.This is electronically controlled. Heat is provided by a jet heating system.
Total cost is estimated at Hfl. 2.8 million. Energy saving 800 TOE for
10,000 t/production. Metal saving: 190 t.
This system should be easily applicable to other scrap aluminium melting systems.

Appel à propositions

Data not available

Régime de financement

DEM - Demonstration contracts

Coordinateur

HENGEMOLEN ENGINEERING
Contribution de l’UE
Aucune donnée
Adresse
P.O. BOX 38
6620 AA DREUMEL
Pays-Bas

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Coût total
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